Input Shaft

Input Shaft

Special tools, testers and auxiliary items required

• Punch (VW 407)

• Thrust Pad (VW 447 H)

• Thrust Disc (VW 412)

• Tube Split (VW 422)

• Thrust Plate (VW 401)

• Punch (VW 408 A)

• Tube 28 mm Dia. 100 mm (VW 421)

• Thrust Pad (VW 447 i)

• Thrust Tube (VW 454)

• Thrust Pad (VW 510)

• Mounting Universal Joint (41-501)

• Kukko Separating Tool 12-75 mm (17/1)

• Thrust Plate (VW 402)

• Inductive Heat Unit (VAS 6414) or equivalent

Removing the Outer Race/Tapered Roller Bearing





Installing the Outer Race/Tapered Roller Bearing





Removing the Bearing Inner Race/Tapered Roller Bearing





A Separating device 12 to 75 mm Kukko separating tool 12-75 mm (17/1)

Installing the Bearing Inner Race/Tapered Roller Bearing





Removing the 4th Gear with the Tapered Roller Bearing and Sleeve





Removing 3rd Gear





- Remove the lock ring first.

Installing 3rd Gear





Wear safety gloves.

Installed position: The shoulder faces the 4th gear.

Removing 4th Gear





Wear safety gloves.

Installed position: The shoulder faces the 3rd gear.

Installing the Bearing Inner Race/Tapered Roller Bearing





Pressing on the Sleeve for the 5th Gear Needle Bearing





Removing the Outer Race/Tapered Roller Bearing





Installing the Outer Race/Tapered Roller Bearing





- Install with the shim after adjusting the input shaft.

5th Gear Synchronizer Assembly





1. Springs for locking pieces

2. Locking collar with 3 notches - arrow A - for locking pieces - 4 -

3. Synchronizer hub

4. Locking pieces - installed position: the extension - arrow B - faces toward the pointed teeth of the locking collar - item 2 -


5th Gear Locking Collar/Synchronizer Hub Assembly





- Slide the locking collar over the synchronizer hub.

The pointed teeth - A - and the high shoulder - B - on the synchronizer hub face in the same direction. Recesses for locking pieces in locking collar and synchronizer hub must line up (see => [ 5th Gear Synchronizer Assembly ] ).

- Insert the locking pieces (Location: see => [ 5th Gear Synchronizer Assembly ] ).

- Install the springs offset by 120° under the tabs - C -. The angled end of the spring must be positioned in front of the locking pieces - arrows -.

• Note the location of the springs when using locking pieces with hollow interiors, refer to => [ Installing the Springs ].

Installing the Springs





- Insert the locking pieces (Location: see => [ 5th Gear Synchronizer Assembly ] ).

Spring installed position:






- Install the springs 120° offset.

- The angled end - A - of the spring must engage into the hollow locking piece.

It must be located below the tab - B - of the locking pieces.

The offset end always faces away from the synchronizer hub in the - direction of the arrow -.