Volkswagen Workshop Service and Repair Manuals

Dismantling and assembling input shaft, from gearbox date 19 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 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	Internal puller -1 - Kukko 21/5-

t	Splitter -3 - Kukko 17/1-

t	Splitter -3 - Kukko 17/2-

t	Puller -2 - Kukko 18/1-

t	Counter support -4- Kukko 22/2-

Install all bearings on input shaft with gear oil.

1 -	Retaining ring

2 -

Washer

q	Outer diameter = 78.6 mm

q	May be renewed only in modified gearbox housings. (From gearbox date 10 04 6) → Fig.

q	Allocation of components via → Electronic parts catalogue (ETKA)

3 -	Gearbox housing

q	From gearbox date 10 04 6, modified in vicinity of seat for deep groove ball bearing → Item, washers → Item and → Item, → Fig. and → Fig.

q	Allocation of components via → Electronic parts catalogue (ETKA)

4 -

Washer

q	Outer diameter = 85 mm

q	May be renewed only in modified gearbox housings. (From gearbox date 10 04 6) → Fig.

q	Allocation of components via → Electronic parts catalogue (ETKA)

5 -	Retaining ring

q	If deep groove ball bearing → Item and input shaft → Item are renewed, redetermine → Fig.

6 -	Deep groove ball bearing

q	Always renew

q	Pulling off → Fig.

q	Pressing on → Fig.

7 -	Gear wheel for 5th gear

q	Pressing off → Fig.

q	Installation position: peripheral groove -arrow- faces deep groove ball bearing → Item

q	Pressing on → Fig.

8 -	Input shaft

q	With gear wheels for 3rd, 4th and 6th gears

9 -	Cylindrical roller bearing

q	With retaining ring

q	Pulling out → Fig.

q	Pressing in → Fig.

q	Installation position: retaining ring in bearing faces input shaft

10 -	Clutch housing

From gearbox date 10 04 6, modified in area above deep groove ball bearing To accommodate the washer → Item, the area above the deep groove ball bearing → Item has been machined deeper

Distance above deep groove ball bearing	Dimension „a“
From gearbox date 10 04 6	10.7 mm
Through gearbox date 09 04 6	10 mm

From gearbox date 10 04 6, modified bearing seat for deep groove ball bearing The bearing seat for the deep groove ball bearing → Item has been machined slightly deeper for the washer → Item-arrow-.

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

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

Pressing on deep groove ball bearing Groove for retaining ring faces upwards -arrow A- and shoulder -arrow B- must face gear wheel for 5th gear. –  Determine and install retaining ring → Fig..

Determining thickness of retaining ring –  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 using → 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.