Audi Workshop Service and Repair Manuals

Dismantling and assembling input shaft

Special tools and workshop equipment required

t	Thrust plate -VW 401-

t	Thrust plate -VW 402-

t	Press tool -VW 407-

t	Press tool -VW 412-

t	Press tool -VW 431-

t	Press tool -VW 432-

t	Press tool -VW 454-

t	Mandrel -30 - 505-

t	Thrust plate -40 - 105-

t	Tube -2040-

t	-1- Kukko internal puller 21/5

t	-2- Puller 18/1

t	-3- Splitter 17/1 and 17/2

t	-4- Kukko 22/2 counter-support

Pulling off grooved ball bearing –  Remove circlip on input shaft. –  Before setting up puller, position press tool -VW 431- and thrust plate -40-105- on input shaft. –  Apply splitter -B- at circular slot for circlip 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-

Pressing on 5th gear wheel l  Slot -arrow- on gear wheel must face upwards.

Pressing on grooved ball bearing with rubber ring l  If grooved ball bearing is fitted with a rubber ring -arrow-, press tool -VW 454- must be applied so that shoulder -A- faces towards press tool -VW 412-.

Installation position of grooved ball bearing l  Installation position of grooved ball bearing: Slot for circlip faces upwards -arrow A- and shoulder -arrow B- must face towards 5th gear wheel. –  Then determine thickness of required circlip → Fig. and install circlip.

Determining thickness of circlip –  Install a 1.86 mm thick circlip -A- in slot on input shaft and press circlip upwards. –  Measure gap between grooved ball bearing -B- and fitted circlip -A- using feeler gauge -C-. –  Remove circlip fitted for measurement. –  Select circlip from table; refer to → Electronic parts catalogue for part number. The following circlips are available:

Measured value (mm)	Circlip thickness (mm)	Axial clearance (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 roller bearing out of clutch housing –  When pulling out, compress circlip -arrow- for 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 roller bearing into clutch housing –  When pressing in, compress circlip -arrow- for roller bearing using pliers -A-. –  Remove pliers before roller bearing seats in its final position. l  The circlip must engage in the groove in the clutch housing.