Volkswagen Workshop Service and Repair Manuals

Dismantling and assembling input shaft, through gearbox date 18 05 3

Special tools and workshop equipment required

t	Pressure plate -VW 401-

t	Pressure plate -VW 402-

t	Press tool -VW 407-

t	Press tool -VW 408 A-

t	Press tool -VW 412-

t	Tube -VW 416 B-

t	Thrust piece -VW 433-

t	Thrust piece -VW 454-

t	Support plate -VW 801-

t	Tapered roller bearing puller -V.A.G 1582/-

t	Adapter -V.A.G 1582/7-

t	Internal puller -1 - Kukko 21/7-

t	Splitter -3 - Kukko 17/2-

t	Counter support -4- Kukko 22/2-

t	Thrust plate -40 - 105-

t	Drift sleeve -41 - 501-

t	Tube -2040-

t	Thrust piece -2050-

t	Thrust pad -3074-

t	Extension -3161-

Note t  If the position of the tapered roller bearings is affected when parts are exchanged, the input shaft must be readjusted. See adjustment overview → Chapter. t  Always renew both tapered roller bearings together as a set.

1 -	Gearbox housing

2 -

Shim

q	Determining thickness → Chapter

3 -	Tapered roller bearing outer race

q	Pulling out → Fig.

q	Pressing in → Fig.

4 -	Retaining ring

q	If tapered roller bearing → Item and input shaft → Item are renewed, redetermine → Fig.

5 -	Tapered roller bearing inner race

q	Pulling off → Fig.

q	Pressing on → Fig.

6 -	Gear wheel for 5th gear

q	Pressing off → Fig.

q	Pressing on → Fig.

7 -	Gear wheel for 3rd, 4th and 6th gears

q	Pressing off → Fig.

q	Pressing on → Fig.

8 -	Input shaft

q	Adjusting → Chapter

9 -	Tapered roller bearing inner race

q	Pressing off → Fig.

q	Pressing on → Fig.

10 -	Tapered roller bearing outer race

q	Pulling out → Fig.

q	Installation position → Fig.

q	Pressing in → Fig.

q	From gearbox date 06 04 0 secured with locking plate and bolt → Fig.

q	Bolt, 12 Nm

q	Always renew

11 -	Clutch housing

q	From gearbox build date 06 04 0 with additional threaded hole and recess for locking plate to secure tapered roller bearing outer race → Item

Pulling tapered roller bearing outer race out of gearbox housing A -  Counter support, e.g. -Kukko 22/2- B -  Internal puller, 46…58 mm, e.g. -Kukko 21/7-

Pressing tapered roller bearing outer race into gearbox housing –  Support gearbox housing with thrust piece -2050- directly below bearing support.

Pulling off tapered roller bearing inner race -A- Vice with jaw protectors –  First remove retaining ring. –  Before setting up pulling device, set extension -3161- and thrust plate -40 - 105- on input shaft.

Pressing off gear wheel for 5th gear A -  Splitter, 22 … 115 mm, e.g. -Kukko 17/2-

Pressing off gear wheel for 3rd, 4th and 6th gears

Pressing off tapered roller bearing inner race A -  Splitter, 22 … 115 mm, e.g. -Kukko 17/2-

Pressing on gear wheel for 3rd, 4th and 6th gears –  Heat gear wheel to about 100 °C. –  Press on gear wheel quickly so that the heat is not immediately transferred to input shaft.

Pressing on tapered roller bearing inner race

Pressing on gear wheel for 5th gear

Pressing on tapered roller bearing inner race –  Determining thickness of retaining ring → Fig..

Determining thickness of retaining ring –  Determine thickest retaining ring which will still fit and install it. –  Determine retaining ring from table. Part number → Electronic parts catalogue (ETKA) Available retaining rings

Thickness (mm)
1.79	1.89	1.98
1.83	1.92
1.86	1.95

Pulling tapered roller bearing outer race out of clutch housing A -  Counter support, e.g. -Kukko 22/2- B -  Internal puller, 46…58 mm, e.g. -Kukko 21/7-

Tapered roller bearing outer race installation position in clutch housing From gearbox date 06 04 0 The recesses for locking plate ( → Fig.) on tapered roller bearing outer race -arrow A- and clutch housing -arrow  B- must align.

From gearbox date 06 04 0: pressing in tapered roller bearing outer race –  After pressing in, check if the locking plate -A- can be inserted in the recess. The locking plate may be inserted only after the input shaft has been installed and tightened.