A4 Mk2
Dismantling and assembling input shaft |
Special tools and workshop equipment required |
t | Drift -VW 295- |
t | Adapter -VW 295 A- |
t | Thrust plate -VW 401- |
t | Thrust plate -VW 402- |
t | Press tool -VW 407- |
t | Press tool -VW 408 A- |
t | Tube -VW 415 A- |
t | Tube -VW 416 B- |
t | Thrust plate -VW 447 i- |
t | Multi-purpose tool -VW 771- |
t | Drift sleeve -30 - 100- |
t | Thrust plate -40 - 105- |
t | Drift -VW 222 A- |
t | Drift -30 - 24- |
t | Extractor -40 - 202- |
t | -1-Internal puller -Kukko 21/4- |
t | -3-Splitter -Kukko 17/2- |
Note
t | When installing new gear wheels or input shaft, consult technical data → Chapter. |
t | The position of tapered roller bearings is affected when renewing ball bearing, gearbox housing or input shaft. In this case the input shaft must be re-adjusted → Chapter. |
1 - | Circlip |
q | Mark |
q | Installation position → Fig. |
q | Determining thickness → Chapter |
2 - | Ball bearing |
q | Removing and installing → Chapter |
3 - | Circlip |
q | Mark |
q | Installation position → Fig. |
q | Determining thickness → Chapter |
4 - | Gearbox housing |
5 - | Needle bearing |
q | Secured with bolt on some gearboxes → Fig. |
q | Driving out → Fig. |
q | Installation position → Fig. |
q | Pressing in → Fig. |
q | Securing → Fig. |
6 - | Input shaft |
q | With oil feed sleeve |
q | Knocking in oil feed sleeve → Fig. |
q | Adjusting → Chapter |
7 - | Needle bearing for 3rd gear |
8 - | 3rd speed selector gear |
9 - | Spring |
q | Insert in 3rd speed selector gear → Fig. |
q | Allocation to selector gear → Electronic parts catalogue |
10 - | Synchro-ring for 3rd gear |
q | Checking for wear → Fig. |
11 - | Circlip |
q | Mark |
q | Installation position → Fig. |
12 - | Synchronising hub for 3rd and 4th gear |
q | Higher shoulder faces towards 3rd gear |
q | Pressing off → Fig. |
q | Pressing on → Fig. |
13 - | Circlip |
q | Mark |
q | Installation position → Fig. |
q | Redetermine thickness if synchronising hub is replaced → Fig. |
14 - | Locking collar for 3rd and 4th gear |
q | Installation position → Fig. |
15 - | Synchro-ring for 4th gear |
q | Checking for wear → Fig. |
16 - | Spring |
q | Insert in 4th speed selector gear → Fig. |
q | Allocation to selector gear → Electronic parts catalogue |
17 - | 4th speed selector gear |
18 - | Needle bearing for 4th gear |
19 - | 5th gear wheel |
q | Pressing off → Fig. |
q | Pressing on → Fig. |
20 - | Circlip |
q | Mark |
q | Installation position → Fig. |
q | If the 5th gear wheel is renewed redetermine thickness → Fig. |
21 - | Roller bearing |
q | Renew |
q | Will be damaged during removal |
q | Pulling out → Fig. |
q | Installation position → Fig. |
q | Driving in → Fig. |
22 - | Sleeve |
q | Made of plastic |
23 - | Gearbox cover |
Note
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Item | Oil feed sleeve dia. | Fitting tool |
A | 14 mm | Drift -VW 222 A- |
B | 16 mm | Drift -30 - 24- |
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Circlip thickness (mm) | ||
1.90 | 1.96 | 2.02 |
1.93 | 1.99 | 2.05 |
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Circlip thickness (mm) | ||
1.90 | 1.96 | 2.02 |
1.93 | 1.99 |
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