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	Tube -VW 421-

t	Thrust piece -VW 454-

t	Thrust pad -VW 447 i-

t	Thrust pad -VW 510-

t	Drift sleeve -41-501-

t	-3-Splitter -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.

5th gear synchronization 1 -  Springs for lock pieces 2 -  Locking collar with 3 recesses -arrows A- for the locking pieces -item 4- 3 -  Synchro-hub 4 -  Locking pieces - installation position: thin extension -arrow B- faces the pointed teeth of the locking collar -2-

Assembling 5th gear locking collar/synchro-hub –  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.). –  Install springs below shoulder -C- of the locking piece, offset 120°. Installation positions of springs if locking pieces are not hollow: Spring must seat with angled end in front of locking piece -arrows-. Installation positions of springs if locking pieces are hollow: –  Angled end of spring must locate in hollow locking piece (⇒ second figure below).

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 → Fig.).

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-.