Volkswagen Workshop Service and Repair Manuals

Dismantling and assembling input shaft

Special tools and workshop equipment required

t	Press tool -VW 407-

t	Thrust pad -VW 447 H-

t	Press tool -VW 412-

t	Tube -VW 422-

t	Pressure plate -VW 401-

t	Pressure plate -VW 402-

t	Press tool -VW 408 A-

t	Drift sleeve -41 - 501-

t	Thrust pad -VW 447 i-

t	Drift sleeve -30 - 100-

t	Thrust pad -VW 510-

t	Splitter -3 - Kukko 17/1-

Pressing out tapered roller bearing outer race

Pressing in tapered roller bearing outer race

Pressing off tapered roller bearing inner race A -  Splitter-Kukko 17/1-

Pressing on tapered roller bearing inner race

Pressing off gear wheel for 4th gear with tapered roller bearing and sleeve

Pressing off gear wheel for 3rd gear

Pressing on gear wheel for 3rd gear

Pressing on gear wheel for 4th gear Shoulder faces 3rd gear

Pressing on tapered roller bearing inner race

Pressing on sleeve for needle bearing

Pressing out tapered roller bearing outer race

Pressing in tapered roller bearing outer race –  Install with shim after adjusting input shaft.

Deeper notches in both sides of locking collar for 5th and 6th gears -arrows- from gearbox date 12 06 6

Dimension -a- (6th gear side)	Through gearbox date 11 06 6	From gearbox date 12 06 6
	1.5 mm	1.8 mm

Dimension -b- (5th gear side)	Through gearbox date 11 06 6	From gearbox date 12 06 6
	1.5 mm	2.0 mm

–  Allocate locking collar and synchro-hub for 5th and 6th gears according to → Electronic parts catalogue „ETKA“. Due to the deeper notches, the adjustment procedure for 5th and 6th gears has been changed: –  Adjusting 5th and 6th gears through gearbox manufacture date 11 06 6 → Fig. –  Adjusting 5th and 6th gears from gearbox manufacture date 12 06 6 → Fig.

Dismantling and assembling locking collar and synchro-hub for 5th and 6th gears 1 -  Spring 2 -  Locking piece 3 -  Synchro-hub 4 -  Locking collar –  Slide locking collar over synchro-hub. Deeper notches -arrow A- for locking pieces in synchro-hub and notches -arrow B- in locking collar must align.

Assembling locking collar and synchro-hub for 5th and 6th gears l  Locking collar has been pushed over synchro-hub. –  Insert locking pieces in deeper notches -arrows- and install springs offset 120°. Angled end of spring must locate in hollow locking piece.   Note t  From gearbox date 26 05 8, a wave spring washer is installed below the synchro-ring for 5th gear and above the synchro-ring for 6th gear → Item and → Item. t  In this case, install only locking piece springs without angled ends. (As shown in → Fig. - item 1-)

Installing springs with bent ends -A- These springs are installed on both sides. –  Spring are installed only in conjunction with hollow locking pieces. –  Insert locking pieces.

Installation position of springs –  Install springs offset 120°. –  Angled end -A- of spring must locate in hollow locking piece. It must be located under shoulder -B- of locking piece. Bent ends always face away from synchro-hub -direction of arrow-.