Volkswagen Workshop Service and Repair Manuals

Dismantling and assembling input shaft

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	Tube -VW 415 A-

t	Tube -VW 422-

t	Spacer sleeve -VW 472/2-

t	Tube -VW 516-

t	Drift sleeve -30-100-

t	Tube -2010-

t	Thrust piece -3002-

t	Thrust piece -T10080-

t	Thrust piece -T10081-

t	thrust piece -T10083-

t	Washer -T10083/1-

t	Pressure plate -T10084A-

t	-1-Internal puller -Kukko 21/5-

t	-2-Puller -Kukko 18/1-

t	-3-Splitter -Kukko 17/1-

t	-4-Counter support -Kukko 22/1-

t	When installing new gears or new input shaft, refer to → Electronic parts catalogue „ETKA“ and technical data.

t	Install all bearings, synchromeshed gears and synchro-rings on input shaft with gear oil.

t	Do not interchange synchro-rings. When reusing always fit to the original gear.

1 -	Retaining ring

q	Always renew

q	Determining thickness → Anchor

2 -	5th gear locking collar with synchro-hub

q	Removing and installing → Chapter

q	Dismantling → Fig.

q	Assembling 5th gear locking collar/synchro-hub

q	Installation position → Fig.

3 -	Synchro-ring for 5th gear

q	Check for wear → Fig.

4 -	Synchromeshed gear for 5th gear

5 -	Needle bearing

q	For 5th gear

q	Renew together with → Item

6 -

Sleeve

q	For 5th gear needle bearing

q	Renew together with → Item

q	Press off with bearing mounting with deep groove ball bearing → Fig.

q	Pressing on → Fig.

7 -	Gearbox housing

q	Repairing → Chapter.

8 -	Bearing mounting with deep groove ball bearing

q	Renew deep groove ball bearing only together with bearing mounting

q	If bearing mounting is separated from gearbox housing, then mounting must always be renewed.

q	Pressing off → Fig.

q	Pressing on → Anchor

9 -	Input shaft

10 -	Needle bearing

q	For 3rd gear

11 -	Synchromeshed gear for 3rd gear

12 -	Synchro-ring for 3rd gear

q	Check for wear → Fig.

13 -	Locking collar with synchro-hub for 3rd and 4th gear

q	Press off with synchromeshed gear for 3rd gear → Fig.

q	Dismantling → Fig.

q	Installation position, locking collar and synchro-hub → Fig.

q	Assembling → Fig.

q	Pressing on → Fig.

14 -	Synchro-ring for 4th gear

q	Check for wear → Fig.

15 -	Synchromeshed gear for 4th gear

16 -

Sleeve

q	For 4th gear needle bearing

q	Renew together with → Item

q	Removing → Fig.

17 -	Needle bearing

q	For 4th gear

q	Renew together with → Item

18 -	Thrust washer

19 -	Inner race for cylindrical roller bearing

q	Removing → Fig.

q	Pressing on → Fig.

20 -	Retaining ring

q	Always renew

q	Determining thickness → Fig.

21 -	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

22 -	Clutch housing

q	Repairing → Chapter.

23 -

Spring

q	Installation position → Fig.

24 -	3rd and 4th gear locking collar

25 -	3rd and 4th gear synchro-hub

26 -	Locking pieces (Qty. 3)

27 -

Spring

q	Installation position → Fig.

28 -	Locking pieces (Qty. 3)

29 -	Synchro-hub for 5th gear

30 -	Locking collar for 5th gear

31 -

Stop ring

q	Prevents locking pieces from drifting out

q	Removing → Fig.

q	Installing → Fig.

Pulling cylindrical 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 22/1- B -  Internal puller, 30 … 37 mm, e.g. -Kukko 21/5-

Pressing cylindrical roller bearing into clutch housing –  Support gearbox housing with tube -VW 415 A- (not visible in figure) directly below bearing support. –  When pressing in, squeeze together retaining ring -arrow- for cylindrical roller bearing using pliers -A-. –  Remove pliers before cylindrical roller bearing is in installation position. Retaining ring must engage in groove of clutch housing.

Pressing off bearing mounting with deep groove ball bearing –  Slide locking collar for 1st and 2nd gear towards 2nd gear. –  Then slide pressure plate -T10084 A- onto input shaft to stop from side. –  Insert centring pins in thrust piece -T10081- into holes in input and output shafts.

Pulling off sleeve for cylindrical roller bearing with 4th gear synchromeshed gear –  First remove retaining ring. –  Position splitter -B- behind teeth of synchromeshed gear for 4th gear which engage in the other gear wheel (not dog teeth) and tension. A -  Puller, e.g. -Kukko 18/1- B -  Splitter, 12 … 75 mm, e.g. -Kukko 17/1- C -  Protective jaw covers

Pressing off locking collar with synchro-hub for 3rd and 4th gear –  After removing retaining ring, press off 3rd gear synchromeshed gear together with locking collar and synchro-hub.

Dismantling and assembling 3rd and 4th gear locking collar and synchro-hub 1 -  Spring 2 -  Locking collar 3 -  Synchro-hub 4 -  Locking piece –  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 3rd and 4th 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.

Installation position of locking collar with synchro-hub for 3rd and 4th gears Groove on top -arrow- faces 4th gear.

Checking synchro-ring for wear –  Press synchro-ring onto cone of synchromeshed gear and measure gap -a- using feeler gauge.

Gap -a-	Installation dimension	Wear limit
3rd, 4th and 5th gears	1.1…1.7 mm	0.5 mm

Pressing on synchro-hub with locking collar for 3rd and 4th gears Installation position: high inside collar faces 3rd gear synchromeshed gear.

Pressing on inner race -A- for cylindrical roller bearing

Determining thickness of retaining ring –  Insert a 2.0 mm thick retaining ring -A- in groove of input shaft and press upwards -arrow-. –  Measure distance between inner race -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 according to → Electronic parts catalogue „ETKA“. The following retaining rings are available:

Measured value (mm)	Retaining ring thickness (mm)	Axial play (mm)
0.05 … 0.14	2.0	0.05 … 0.15
0.15 … 0.24	2.1	0.05 … 0.15
0.25 … 0.34	2.2	0.05 … 0.15
0.35 … 0.44	2.3	0.05 … 0.15
0.45 … 0.51	2.4	0.05 … 0.10

Press bearing mounting with deep groove ball bearing onto input shaft and output shaft.   Note

t  Due to different spline heights, dimension -a-, output shafts of individual gearboxes have different lengths (shown here with shafts installed). t  To ensure that bearing support is always evenly pressed onto shafts, it is necessary for shafts always to be inserted evenly into thrust block -T10083-. t  If necessary, insert a shim -T10083/1- (3 mm thick) into fitting hole for input shaft → Fig.. t  Therefore, measure dimension -a- of output shaft splines.

Dimension -a- = 30.6 mm

Insert shim -T10083/1- ⇒ next figure.

Insert shim -T10083/1-

Pressing on bearing support –  Heat inner bearing mounting to approx. 100 °C before pressing on.

Pressing on sleeve -A- for 5th gear needle bearing

Removing stop ring –  Unclip hooks -A- of stop ring from synchro-hub using a screwdriver

Dismantling and assembling 5th gear locking collar and synchro-hub 1 -  Spring 2 -  Locking piece 3 -  Synchro-hub installation position: groove on face -arrow A- and wide shoulder -arrow B- must face 5th gear. 4 -  Locking collar 5 -  Stop ring –  Slide locking collar over synchro-hub. Deeper notches -arrow C- for locking pieces in synchro-hub and notches -arrow D- in locking collar must align.

Assembling 5th gear locking collar/synchro-hub 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.

Installing stop ring –  Press on stop ring using tube -2010-. –  Insert stop ring together with tube -2010- into 5th gear synchro-hub/locking collar (observe installation position → Fig.). The hooks -arrow 1- lock in the recess -arrow 2- of the synchro-hub locking pieces. –  Press stop ring downwards until hooks engage.