Input Shaft, Disassembling and Assembling
Input shaft, disassembling and assembling
Special tools and workshop equipment required
^ VW 295 Needle bearing drift
^ VW 295 A Needle bearing drift
^ VW 401 Thrust plate
^ VW 402 Thrust plate
^ VW 407 Punch
^ VW 408 A Punch
Special tools and workshop equipment required
^ VW 415 A Tube
^ VW 416 B Tube
^ VW 447 i Thrust pad
^ VW 771 Slide hammer - complete set
^ 30-100 Press tube
^ 40-105 Thrust piece
Special tools and workshop equipment required
^ VW 222 A Mandrel
^ 30-24 Mandrel
^ 40-202 Press tool
^ 1 - Kukko 21//4 Internal puller
^ 3 - Kukko 17/2 Separating tool
Note:
^ When installing new gears or the input shaft consult technical data
^ If -items 2, 4 or 6 - are replaced the position of the ball bearing will be affected. The input shaft should be re-adjusted.
1 - Circlip
^ Mark
^ Installation position - item 1
^ Determining thickness adjusting input shaft
2 - Ball bearing
^ Removing and installing
3 - Circlip
^ Mark
^ Installation position - item 2
^ Determining thickness adjusting input shaft
4 - Transmission housing
5 - Needle bearing
^ Secured with bolt
^ Driving out
^ Installation position
^ Pressing in
^ Locking
6 - Input shaft
^ With oil feed sleeve
^ Knocking in oil feed sleeve
^ Adjusting
7 - Needle bearing for 3rd gear
^ Mark
8 - 3rd speed sliding gear
9 - Spring
^ Insert in 3rd speed sliding gear
^ Allocation of spring to sliding gear
go to Parts Catalog
10 - Synchro-ring for 3rd gear
^ Check for wear
11 - Circlip
^ Mark
^ Installation position item 3
12 - Synchro-hub for 3rd and 4th gear
^ High collar faces 3rd gear
^ Pressing off
^ Pressing on
13 - Circlip Mark Installation position-item 4 If synchro-hub is replaced re-determine thickness
14 - Locking collar for 3rd and 4th gear
^ Installation position
15 - Synchro-ring for 4th gear
^ Check for wear
16 - Spring
^ Insert in 4th speed sliding gear
^ Allocation of spring to sliding gear
go to Parts Catalog
17 - 4th gear sliding gear
18 - Needle bearing for 4th gear
^ Mark
19 - 5th gear wheel
^ Pressing off
^ Pressing on
20 - Circlip
^ Mark
^ Installation position - item 5
^ If the 5th gear wheel is replaced redetermine thickness
21 - Roller sleeve
^ Replace
^ Will be damaged during removal
^ Pulling out
^ Installation position
^ Tapping in
22 - Sleeve
^ Made of plastic
23 - Transmission cover
^ Apply thin coat of sealing paste AMV 188 001 02 to sealing surfaces
Fig. 1 Remove securing bolt -arrow- for needle bearing:
- Remove securing bolt -arrow-.
Note: Bolt is not installed on all versions.
Fig. 2 Driving out needle bearing:
Fig. 3 Installation position of needle bearing:
Distance -a- from lower edge of straight-edge to upper edge of needle bearing = 39.5 mm
Note: Measure distance from top edge of straight-edge and subtract the width of the straight-edge from the measured distance.
Fig. 4 Pressing in needle bearing:
Fig. 5 Screwing in securing bolt -arrow-:
^ Tighten to 25 Nm
Note: Bolt is not installed on all versions.
Fig. 6 Driving oil feed sleeve into input shaft:
^ Installation position:
Flanged edge on oil feed sleeve faces toward fitting tool
^ Insertion depth:
3.5 mm below top edge
Fig. 7 Pulling out roller sleeve:
A - Internal extractor, e. g. Kukko 21/4, 22... 28 mm
Before installing internal extractor, the plastic sleeve inside the roller sleeve must be destroyed.
Fig. 8 Installation position of roller sleeve:
^ Dimension a = 216 mm
Fig. 9 Driving in roller sleeve:
Fig. 10 Pressing off 5th gear wheel:
- Remove circlip before pressing off.
A - Separating device 22... 115 mm, e.g. Kukko 17/2
Fig.11 Pressing off synchro-hub for 3rd and 4th gear:
- Remove circlip before pressing off.
- Press 3rd gear synchro ring (arrow) toward 3rd gear wheel, then install separating device -A-.
A - Separating device 22... 115 mm, e.g. Kukko 17/2
Fig. 12 Inserting spring in sliding gear:
The bent end of the spring (arrow) must be hooked in the hole in the sliding gear.
Fig. 13 Checking synchro-ring for wear:
- Press synchro-ring into locking collar and measure gap -a- with a feeler gauge at positions -A-, -B- and -C-.
- Add the measured values and divide by 3.
The average value must not be less than 0.5 mm.
Fig. 14 Installation position of circlips:
^ Circlips -1- and -2- secure the input shaft ball bearing Adjusting input shaft.
^ Circlip -3- secures the 3rd and 4th gear synchro-hub.
Thickness 2.00 mm. Identification: Brown color.
^ Circlip -4- secures the 3rd and 4th gear synchro-hub.
Determining thickness table on. Identification: blue color.
^ Circlip -5- secures the 5th gear wheel.
Determining thickness table on.
Fig. 15 Determining thickness of circlip:
- Determine thickest circlip that will just fit and install it.
- Determine circlip as accurately as possible from table. Part numbers
go to Parts Catalog
Available circlips for 3rd and 4th gear synchro-hubs
Available circlips for 5th gear wheel
Fig. 16 Pressing on synchro-hub for 3rd and 4th gear:
^ Installation position:
High inside collar faces 3rd gear
Fig. 17 Installation position of locking collar:
Different types of locking collar are installed: illustration -A-, arrow 1 - with chamfered edge, or illustration -B-, arrow 3- with large shoulder.
^ Installation position:
Chamfered edge -arrow 1 - faces 4th gear
Small shoulder -arrow 2- faces 3rd gear
Large shoulder -arrow 3- faces 4th gear
Fig. 18 Pressing on 5th gear wheel:
WARNING: Wear protective gloves.
- Heat 5th gear wheel to approximately 100°C before pressing on.
^ Installation position:
High collar faces reverse gear