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 - 23-

t	Drift sleeve -30 - 100-

t	Thrust piece -T10080-

t	Thrust piece -T10081-

t	Circlip pliers -VW 161 A-

t	Tube -2010-

t	thrust piece -T10083-

t	Washer -T10083/1-

t	Pressure plate -T10084A-

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

t	-4-Counter support -Kukko 22/2-

t	-Fühlerblattlehre-

t	When installing new gear wheels or input shaft, consult technical data and → Electronic parts catalogue „ETKA“.

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 and synchro-hub → Fig..

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

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

q	Pressing on → Fig.

17 -	Needle bearing

q	For 4th gear

q	Renew together with → Item

18 -	Thrust washer

19 -	Inner race for cylindrical roller bearing

q	Pressing off → Fig.

q	Pressing on → Fig.

20 -	Retaining ring

q

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

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 22/2- 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.

Pressing off cylindrical roller bearing inner race –  First remove retaining ring with Circlip pliers -VW 161 A-. –  Press off inner race for cylindrical roller bearing together with thrust washer, synchromeshed gear for 4th gear with needle bearing, locking collar and synchro-hub for 3rd and 4th gears and gear wheel for 3rd gear.

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 gear	1.1…1.7 mm	0.5 mm

Pressing on synchro-hub with locking collar for 3rd and 4th gears

Pressing on sleeve -A- for 4th gear needle bearing –  After pressing on sleeve -A-, fit 4th gear needle bearing, 4th gear synchro-ring with synchromeshed gear and thrust washer.

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 using → Electronic parts catalogue (ETKA). Available retaining rings

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- → Fig.

Insert shim -T10083/1-

Pressing on bearing support –  Heat inner bearing mounting to approx. 100 °C before pressing on.   WARNING Wear protective gloves!

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.