Volkswagen Workshop Service and Repair Manuals

Removing and installing input gear

Special tools and workshop equipment required

t	Thrust plate -VW 402-

t	Press tool -VW 407-

t	Multipurpose tool -VW 771-

t	Thrust plate -30 - 205-

t	Drift sleeve -40 - 21-

t	Thrust plate -40 - 105-

Pinion shaft and differential do not need to be removed.

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

t	Grip -V.A.G 1582/3-

t	Torque wrench -V.A.G 1576-

1 -	Clamping bolt, 250 Nm

q	Engage parking lock to remove or install

q	Use 22 mm socket

q	Before installing clamping bolt, insert needle thrust bearing → Item.

2 -	Dished spring

q	Convex side faces clamping bolt.

3 -

Shim

q	Determining thickness ⇒ Adjusting input gear → Chapter.

4 -	Tapered roller bearing inner race

q	After measuring shim, apply locking fluid -AMV 185 101 A1- and place it on input gear → Fig..

5 -	Tapered roller bearing outer race

q	Drive out with copper drift

q	Drive in with thrust plate -30 - 205-.

q	Insert with locking fluid -AMV 185 101 A1-

6 -	Gearbox housing

7 -	Needle thrust bearing

q	Install with flat side facing input gear.

q	Insert into input gear before installing clamping bolt → Item.

8 -	Tapered roller bearing outer race

q	Drive out with copper drift

q	Drive in with thrust plate -30 - 205- and appropriately long drift.

q	Insert with locking fluid -AMV 185 101 A1-

9 -	Tapered roller bearing inner race

q	Pulling off → Fig.

q	Pressing on → Fig.

q	Insert with locking fluid -AMV 185 101 A1- → Fig.

10 -	Input gear

q	With impulse wheel for driving speed sender -G68-.

q	Number of teeth → Chapter.

q	Adjusting → Chapter

q	If input gear or output gear are damaged, always renew together.

q	Removing → Fig..

q	If input gear is renewed, adjust planet carrier → Chapter

Pulling off tapered roller bearing inner race –  Place thrust plate -40 - 105- on input gear.

Pressing on tapered roller bearing inner race A thrust piece must be placed under the hub of the input gear to avoid damage to the input gear.

Inserting tapered roller bearing inner races –  Before inserting, coat area of bearing seat -arrow- of inner races one after other with locking fluid -AMV 185 101 A1-. If inner races have “lugs”, the “lugs” must engage in each other -arrow-. –  Then install inner races one after another.

Removing input gear –  Insert clamping bolt without dished washer, shim and needle thrust bearing far enough that a gap -a- of 3 mm exists between bolt and tapered roller bearing inner race. –  Carefully drive out input gear using multipurpose tool -VW 771-.