Volkswagen Workshop Service and Repair Manuals

Dismantling and assembling input shaft

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 412-

t	Thrust piece -VW 431-

t	Thrust piece -VW 432-

t	Thrust piece -VW 454-

t	Thrust piece -30-505-

t	Thrust plate -40-105-

t	Tube -2040-

t	-1-Internal puller -Kukko 21/5-

t	-2-Puller -Kukko 18/1-

t	-3-Splitter -Kukko 17/1-

t	-3-Splitter -Kukko 17/2-

t	-4-Counter support -Kukko 22/2-

Dismantling input shaft. –  Remove retaining ring for deep groove ball bearing.

Pulling off deep groove ball bearing –  First remove retaining ring from input shaft. –  Before setting up pulling device, set thrust piece -VW 431- and thrust plate -40-105- on input shaft. –  Apply splitter -B- to peripheral groove for retaining ring in bearing. A -  Puller, e.g. -Kukko 18/1- B -  Splitter, 12 … 75 mm, e.g. -Kukko 17/1-

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

Pressing on gear wheel for 5th gear Groove -arrow- in gear wheel must face upwards.

Installation position of deep groove ball bearing Groove for retaining ring faces upwards -arrow A- and shoulder -arrow B- must face gear wheel for 5th gear.

Pressing on deep groove ball bearing Deep groove ball bearing with a rubber ring -arrow- Shoulder -A- faces press tool -VW 412-. –  Determine retaining ring for deep groove ball bearing on input shaft (⇒ next Fig.) and install.

Determining retaining ring for deep groove ball bearing on input shaft –  Insert a 1.86 mm thick retaining ring -A- in groove of input shaft and press upwards. –  Measure distance between deep groove ball bearing -B- and installed retaining ring -A- using feeler gauge -C-. –  Remove retaining ring used for measuring purposes. –  Determine retaining ring from table.   Note Allocate retaining rings according to → Electronic parts catalogue „ETKA“. The following retaining rings are available:

Measured value (mm)	Retaining ring thickness (mm)	Axial play (mm)
0.01 … 0.05	1.86	0.01 … 0.05
0.05 … 0.07	1.89	0.01 … 0.05
0.07 … 0.10	1.92	0.01 … 0.05
0.10 … 0.13	1.95	0.01 … 0.05
0.13 … 0.16	1.98	0.01 … 0.05

Pulling cylinder roller bearing out of clutch housing –  When pulling out, squeeze together retaining ring -arrow- of cylindrical roller bearing, using pliers -C-. A -  Counter support, e.g. -Kukko 22/2- B -  Internal puller, 30 … 37 mm, e.g. -Kukko 21/5-

Pressing cylindrical roller bearing into clutch housing –  When pressing in, squeeze together retaining ring -arrow- of cylinder roller bearing, using pliers -A-. –  Remove pliers before cylindrical roller bearing is in installation position. Retaining ring must engage in groove of clutch housing.