Volkswagen Workshop Service and Repair Manuals

Input shaft - dismantle and assemble

Special tools and workshop equipment required

t	Pressure pin -VW 407-

t	Pressure disc -VW 447 H-

t	Pressure disc -VW 412-

t	Tube -VW 422-

t	Plate -VW 401-

t	Plate -VW 402-

t	Pressure pin -VW 408A-

t	Tube -VW 421-

t	Pressure tube -VW 454-

t	Pressure disc -VW 447 i-

t	Bracket -VW 540-

t	Installation collar -41-501-

t	Separating device -KUKKO 17/1-

Note t  When installing new gears, consult technical data → Chapter t  If the position of the taper roller bearings is affected when exchanging parts, the input shaft must be readjusted. See adjustment overview → Chapter

1 -	Clutch housing

2 -	Outer race/taper roller bearing

q	Remove → Fig.

q	Install → Fig.

3 -	Taper roller bearing inner race

q	Remove → Fig.

q	Install → Fig.

4 -	Input shaft

q	Adjust → Chapter

5 -	3rd gear wheel

q	Shoulder points to 4th. gear

q	Remove → Fig.

q	Install → Fig.

6 -

Circlip

q	Always renew

7 -	4th gear wheel

q	Pressing off with taper roller bearing outer race and sleeve → Fig.

q	Install → Fig.

q	Shoulder points to 3rd. gear.

8 -	Taper roller bearing inner race

q	Remove with 4th. gear and sleeve → Fig.

q	Install → Fig.

9 -	Thrust washer

10 -	Outer race/taper roller bearing

q	Remove → Fig.

q	Install → Fig.

11 -	Adjustment shim

q	Determining thickness: adjusting input shaft → Chapter

12 -	Gearbox housing

13 -

Bushing

q	For needle roller bearing.

q	Press off with 4th gear wheel and taper roller bearing inner race → Fig.

q	Install → Fig.

q	Place thrust washer on before installing ( → Item)

14 -	Needle roller bearing

15 -	5th gear wheel

q	Remove together with synchro hub from 5th gear → Chapter

16 -	5nd gear synchro-ring

q	With cast locking pieces → Fig.

q	Check wear → Fig.

17 -

Spring

q	Installation position → Fig.

18 -	Locking pieces (3 units)

q	Installation position → Fig.

19 -	Synchro-hub of the 5th gear

q	Remove and install → Chapter.

20 -	Locking collar of the 5th gear

q	Remove and install → Chapter.

21 -	Spring washer

q	Installation position → Fig.

22 -	M10 Torx screw, 80 Nm

q	Fitted piece on bolt head locates dished spring → Fig.

Press out taper roller bearing outer race

Install taper roller bearing outer race

Press out taper roller bearing inner race A - Separating device -KUKKO 17/1-

Install taper roller bearing inner race

Press off 4th. gear wheel with taper roller bearing and sleeve

Remove the 3rd gear wheel

Install the 3rd gear wheel

Install the 4th gear wheel Shoulder points to 3rd. gear

Install taper roller bearing inner race

Press on sleeve for needle roller bearing

Press out taper roller bearing outer race

Install taper roller bearing outer race –  Install with shim after adjusting input shaft.

Synchro-hub of the 5th gear 1 -  Springs for lock pieces 2 -  Locking collar with 3 recesses -arrows A- for the locking pieces (item 4) 3 -  Synchro-hub 4 -  Cast locking pieces Installation position: the lug -arrow B- points towards the pointed teeth of the locking collar (item. 2)

Assembly of the locking collar/synchro hub of the 5th gear –  Slide locking collar over synchro-hub. Pointed teeth -A- and shoulder -B- of synchro hub face in same direction. The recesses for the locking pieces in locking collar and synchro hub must be aligned ( → Fig.). –  Insert locking pieces (Installation position: → Fig.). –  Insert springs offset by 120° underneath lug -C-. The angled ends of the spring must be directly behind the locking pieces -arrows-.