Input Shaft Cover

Input Shaft Cover

Special tools, testers and auxiliary items required

• Seal remover (T40014)

• Pressure stand (T40099)

• Ice spray

• Protective gloves

• Protective glasses

Removing

• Input shaft removed => [ Input Shaft ] Input Shaft.

- Pull oil pipe - arrow - upward and out to avoid damage.





- Check all 8 Bolts - arrows - on Pressure Stand (T40099).





• Bolts must be installed flush to 25 Nm => Assembly instructions for pressure stand (T40099).

- Insert input shaft in pressure stand (T40099).





- Rotate seal ring extractor (T40014) by hand into shaft seal until the tool has a good hold in the shaft seal. Then tighten puller with an open-end wrench.

- You can pull out shaft seal a short distance by screwing in rear screw - arrow -.

- Re-tighten Seal ring extractor (T40014) so that puller engages securely in shaft seal again and continue turning screw to pull out shaft seal.

- Repeat procedure until shaft seal has been pulled out completely.

- Remove input shaft cover circlip - A -.





- Measure and note thickness of removed circlip.

• When installing, circlip must be replaced with a new circlip of same thickness.

- Clean cover sealing surface - arrow -.





CAUTION!
Danger of getting burned

Always wear gloves and eye protection!

- Cool hollow shaft, for example with ice spray, through opening - arrow 1 - for the removed oil pipe - 1 - on the inner bearing seat - arrow 2 -"A" - 2 - (transmission input shaft ball bearing).





• Shaft represented in section here.

• The shaft must be cooled down so that it is easier to press the cover and the bearing "A" - 2 - (transmission input shaft ball bearing) without damaging them.

- Clean surface of pressure stand (T40099).





- Insert input shaft in pressure stand (T40099).

• Input shaft sealing surface must be flush.

• There must be no objects such as cable ties or dirt between input shaft sealing surfaces and surface of pressure stand (T40099).

CAUTION!
Shavings or dirt damage cover sealing surfaces when pressed, cover must then be replaced.

- Also cool shaft from outside - arrow - with ice spray, for example.

• The shaft must be cooled down so that it is easier to press the cover and bearing "A" (transmission input shaft ball bearing) without damaging them.

- Place input shaft together with pressure stand ( T40099) on hydraulic press thrust plate.

• Pressure stand (T40099) should lie on as much surface of hydraulic press as possible.





- Hold shaft from below and at the same time, press shaft out of cover with hydraulic press.

- Place input shaft on assembly tool (T10219/1).





• Ignore screwdriver and arrows.

Installing





- Replace bearing "A" (transmission input shaft ball bearing) in the input shaft cover => [ Bearing A in Input Shaft Cover ] Bearing A in Input Shaft Cover.

- Place input shaft cover on input shaft and press on by hand as far as possible.

- Place input shaft - B - on Thrust plate (VW 401).





CAUTION!
Place input shaft straight and centered under hydraulic press thrust disc; otherwise input shaft can tip to the side when cover is pressed on.

- With hydraulic press, press input shaft cover - A - with Tube (VW 416 B) onto input shaft up to stop.

Input shaft cover circlip, installing

- When installing, circlip - A - must be replaced with a new circlip of same thickness.





• Check for correct circlip seating.

Oil pipe, installing

- Check wear on transmission components.

- Replace O-ring on oil pipe - 2 -.





• The oil pipe is pressed into the input shaft with O-ring - 2 -.

• Oil pipe must engage noticeably, rotor blades - arrow A - on oil pipe must lie completely in input shaft.

- Press oil pipe - arrow - down into input shaft to stop.





• If oil pipe is inserted completely, the dimension from its end to the input shaft is approximately 11.5 mm.

If dimension is smaller, the oil pipe possibly is damaged as it was pushed in too far and is broken at the end.

If dimension is larger, it is not pushed in far enough.

CAUTION!
• Input shaft must not be set down on the projecting oil pipe - arrow - otherwise it will be damaged.

• If the oil pipe is damaged, starting problems or a transmission malfunction will result.