Input Shaft

Input Shaft

Special tools, testers and auxiliary items required

• Thrust Plate (VW 401)

• Thrust Plate (VW 402)

• Punch (VW 407)

• Thrust Disc (VW 412)

• Tube 60 mm Dia. (VW 415 A)

• Tube Split (VW 422)

• Sleeve (VW 472/2)

• Tube 42 mm Dia. (VW 516)

• Press Tube (30 - 23)

• Press Tube (30 - 100)

• Thrust Piece (T10080)

• Thrust Piece (T10081)

• Circlip Pliers (VW 161 A)

• Sleeve (2010)

• Thrust Block (T10083)

• Thrust Plate (T10084 A)

• Kukko Extractor 30-37 mm (21/5)

• Kukko Support (22/1)

• (Feeler Gauge)

• Inductive Heater (VAS 6414)

• For more information, refer to => [ Codes Letters, Transmission Allocation and Capacities ] Codes Letters, Transmission Allocation and Capacities and to the Parts Catalog.

• Insert all bearings, selector gears and synchronizer rings on input shaft using transmission fluid.

• Do not exchange synchronizer rings, always allocate to original selector gear when reusing.

• Wearing safety gloves, warm the bearing inner races, the gear wheels and the synchronizer hubs to approximately 100 °C (212 °F) using the (VAS 6414) before installing them.

1 Lock Ring

• Always replace

• Determining thickness, refer to => [ Select a new lock ring. ] Transmission.

2 Locking Collar with 5th Gear Synchronizer Hub

• Removing and installing, refer to => [ Transmission ] Transmission.

• Disassembling.

• Assembling the 5th gear locking collar/synchronizer hub.

• Installed position.

3 5th Gear Synchronizer Ring

• Checking for wear.

4 5th Gear

5 Needle Bearing

• For the 5th gear.

• Replace together with the sleeve - item 6 -.

6 Sleeve

• For the 5th gear needle bearing.

• Replace together with the needle bearing - item 5 -.

• Remove with the bearing mount/grooved ball bearing.

• Installing.

7 Transmission Housing

8 Bearing Mount with Grooved Ball Bearing

• Only replace the grooved ball bearing together with the bearing mount.

• If the bearing mount is removed from the transmission housing, it must always be replaced.

• Removing.

• Installing.

9 Input Shaft

10 Needle Bearing

• For the 3rd gear.

11 3rd Gear

12 3rd Gear Synchronizer Ring

• Checking for wear.

13 Locking Sleeve with Synchronizer Hub for 3rd and 4th Gears

• Removing with the 3rd gear.

• Disassembling.

• Installed position: locking collar/synchronizer hub.

• Assembling.

• Installing.

14 4th Gear Synchronizer Ring

• Checking for wear.

15 4th Gear

16 Sleeve

• For the 4th gear needle bearing.

• Replace together with the needle bearing - item 17 -.

• Removing with the 3rd gear.

• Installing.

17 Needle Bearing

• For the 4th gear.

• Replace together with the sleeve - item 16 -.

18 Thrust Washer

19 Bearing Inner Race for the Roller Bearing

• Removing.

• Installing.

20 Lock Ring

• Determining thickness.

21 Cylindrical Roller Bearing

• With lock ring.

• Removing.

• Installing.

• Installed position: The lock ring inside the bearing faces the input shaft.

22 Clutch Housing

23 Spring

• Installed position.

24 Locking Collar for 3rd and 4th Gear

25 Synchronizer Hub for 3rd and 4th Gear

26 Locking Pieces

• Quantity: 3

27 Spring

• Installed position.

28 Locking Pieces

• Quantity: 3

29 5th Gear Synchronizer Hub

30 5th Gear Locking Collar

31 Stop Ring

• Prevents the locking pieces from moving off.

• Removing.

• Installing.

Removing the Roller Bearing from the Clutch Housing

- Compress the cylindrical roller bearing lock ring - arrow - with pliers - C - and remove it.

A Counter-support, for example, (22/1)
B Internal puller 30 to 37 mm, for example, (21/5)

Pressing the Cylindrical Roller Bearing into the Clutch Housing

- Support the clutch housing using the (VW 415 A) (not illustrated) directly below bearing mount.

- Compress the cylindrical roller bearing lock ring - arrow - with pliers - A - and install it.

- Remove the pliers before the cylindrical roller bearing gets into its installed position. The lock ring must lock into the groove on the clutch housing.

Removing the Bearing Mount and Grooved Ball Bearing

- Slide the locking collar for 1st and 2nd gear to 2nd gear.

- Slide the (T10084 A) sideways all the way into input shaft.

- Insert the centering pins in the (T10081) into the holes in the input and output shaft.

Removing the Bearing Inner Race for the Cylindrical Roller Bearing

- Remove the lock ring using the (VW 161 A).

- Remove the cylindrical roller bearing inner race together with the: thrust washer, 4th gear with needle bearing, 3rd and 4th gear locking collar/synchronizer hub and 3rd gear.

Disassembling and Assembling the Locking Collar and Synchronizer Hub for 3rd/4th Gears

1. Spring

2. Locking collar

3. Synchronizer hub

4. Locking piece

- Slide the locking collar over the synchronizer hub.

The deeper recesses - arrow A - for the locking pieces inside the synchronizer hub and the recesses - arrow B - inside the locking collar must align.

Assembling the Locking Collar/Synchronizer Hub for 3rd and 4th Gears

• The locking collar is pushed over the synchronizer hub.

- Insert the locking pieces in the deep recesses - arrows - and install the springs offset by 120°. The angled end of the spring must engage into the hollow locking piece.

Installed Position: Locking Collar/Synchronizer Hub for 3rd and 4th Gears

The groove on back - arrow - faces toward 4th gear.

Checking the Synchronizer Ring for Wear

- Press the synchronizer ring onto the taper of the gear and measure the gap dimension - a - using a feeler gauge.

Installing the Synchronizer Hub with Locking Collar for 3rd and 4th Gears

Installing the 4th Gear Needle Bearing Sleeve - A -

- Install the 4th gear needle bearing, the 4th gear synchronizer ring and the thrust washer after installing the sleeve - A -

Installing the Bearing Inner Race - A - for the Cylindrical Roller Bearing

Determining the Locking Ring

- Insert a 2.0 mm thick lock ring - A - into groove of input shaft and press upward - arrow -.

- Measure between the bearing inner race - B - and the installed lock ring - A - with a feeler gauge - C -.

- Remove the lock ring used for the measurement.

- Select the lock ring according to the table.

• For the correct lock rings, refer to the Parts Catalog.

Available Lock Rings

Installing the Bearing Mount with Grooved Ball Bearing

- Warm to approximately 100 °C (212 °F) before installing.

CAUTION!
Wear safety gloves.

Installing the 5th Gear Needle Bearing Sleeve - A -.

Removing the Stop Ring

- Unclip the stop ring hook - A - from the synchronizer hub with screwdriver.

Locking Collar and 5th Gear Synchronizer Hub, Disassembling and Assembling

1. Spring

2. Locking piece

3. Synchronizer hub - installed location: Groove on the rear side - arrow A - and wide collar - arrow B - face toward the 5th gear

4. Locking collar

5. Stop ring

- Slide the locking collar over the synchronizer hub.

The deeper recesses - arrow C - for the locking pieces inside the synchronizer hub and the recesses - arrow D - inside the locking collar must align.

Assembling 5th Gear Locking Collar/Synchronizer Hub

- Press the stop ring onto the (2010).

- Insert the stop ring together with the (2010) into the 5th gear synchronizer hub/locking collar (note the installed location, refer to.)

The hooks - arrow 1 - engage in the recesses - arrow 2 - for the synchronizer hub locking pieces.

- Press the stop ring down until the hooks engage.