Input Shaft: Service and Repair
NOTE:
- When installing new gears, consult Applications and ID
- Vehicles with 2.0 liter 85 kW (115 hp) engine: the input shaft incorporates larger dimensions for the following:
^ Splines for clutch disc
^ Input shaft oil seal
^ Front needle bearing
1 Bolt--M17 (Always replace)
- Engage both 5th and reverse to loosen or tighten
- Coat threads with VW D6 locking fluid
- Torque 150 Nm (111 ft lb)
2 Dished washer
3 Operating sleeve/synchronizer hub for 5th gear
- Removing/Installing - 020 Transmission Disassembly - 020 Transmission Assembly
4 Stop ring
- Prevents locking keys from moving out of position
- Removing stop ring
^ Press pipe piece 2010 into synchronizer/stop ring while prying stop ring from synchronizer (stop ring must be fully on pipe piece 2010)
^ Remove stop ring together with pipe piece 2010
- Installing stop ring
^ Install stop ring, together with pipe piece 2010, in synchronizer hub/5th gear, (ribs arrows 1) lock into openings (arrow 2) for locking parts of synchronizer)
^ Remove pipe piece 2010, locking ribs into synchronizer
5 Spring
6 5th gear operating sleeve
- Installation position of 5th gear operating sleeve
^ Slide operating sleeve over synchronizer hub
^ Recesses for locking keys in synchronizer hub and operating sleeve must be aligned
^ Chamfer on teeth (arrow 1) is toward shaft (arrow 2) of 5th gear synchronizer
^ Insert locking keys and install springs at 120° offset. Angled ends of each spring must engage in hollow keys
- Installation position of 5th gear thrust washer
^ The chamfer (arrow) is located opposite the gear
7 Synchronizer hub
8 Locking key
9 Socket-head bolt
10 Deep groove ball bearing
- Removal of deep groove ball bearing
^ 11A = Separator, e.g. Kukko 17/1, 12-75 mm
11 Tension bracket
- Secures deep groove ball bearing
12 4th gear
13 4th gear synchronizer ring
- Checking synchronizer ring for wear
^ Press synchronizer ring onto gear cone and measure gap -a- with feeler gauge
^ New = 1.3-1.9 mm (0.051-0.075 in)
^ Wear limit = 0.5 mm (0.020 in)
14 Circlip (always replace)
- Do not overstretch
- Must seat properly in groove
15 Operating sleeve/synchronizer hub for 3rd/4th gear
- Pressing off operating sleeve and synchronizer hub for 3rd and 4th gear
^ A =Separator, e.g. Kukko 17/1, 12-75 mm
- Identification of 3rd/4th gear synchronizer hub is one of two ways:
^ Continuous circular groove (arrow A) at center (4th gear side)
^ Axial groove on tips of spline teeth (arrow B)
- Assembling 3rd/4th gear operating sleeve and synchronizer hub
^ Slide operating sleeve over synchronizer hub keeping the recesses for locking keys in synchronizer hub and operating sleeve in alignment
^ Insert locking keys and install springs at 120° offset. Angled ends of each spring must engage in hollow keys
- Installation position of 3rd/4th gear operating sleeve and synchronizer hub
^ Operating sleeve and synchronizer hub must be installed with chamfer on inner splines of hub (arrow) toward 3rd gear
- Pressing on 3rd/4th gear operating sleeve and synchronizer hub
16 Operating sleeve
17 Synchronizer hub
18 Locking key
19 Spring
20 Input shaft
- Different diameter for vehicles with 2.0 liter, 85 kW (115 hp) engine
21 Clutch housing
- Bores modified for larger input shaft on vehicles with 2.0 liter, 85 kW(115 hp) engine
22 Input shaft needle bearing - Bell Housing
23 Seal for clutch pushrod
- Removal of seal
^ Can be replaced without disassembling transmission (transmission removed)
- Installation positions of oil seal and bushing
^ A = Seal for clutch pushrod
^ B = Bushing for clutch pushrod
- Installing oil seal
24 Bushing
- Installation positions of oil seal and bushing
^ A = Seal for clutch pushrod
^ B = Bushing for clutch pushrod
- Removal of bushing
^ Can be replaced without disassembling transmission (transmission removed)
- Installation of bushing
^ Drive in until seated on shoulder
25 3rd gear
26 3rd gear synchronizer ring
- Checking ring for wear
^ Friction surface is coated with molybdenum
^ Press synchronizer ring onto gear cone and measure gap -a- with feeler gauge
^ a = New: 1.15-1.75 mm (0.045-0.069 in)
^ a = Wear limit: 0.5 mm (0.020 in)
27 Transmission housing
28 Input shaft shim
- Input shaft adjustment not required
- Original adjustment shim should be reinstalled after repairs
- If no shim was installed, re-assemble without shim
- When bearing or clutch housing/transmission housing is replaced, shim installation is not required
29 Thrust washer
- Installation position
^ The chamfer (arrow) is located opposite the gear
^ After installing 5th gear synchronizer ring (31), place 5th gear (30) on synchronizer hub (7)
30 5th gear
31 5th gear synchronizer ring
- Checking ring for wear
^ Friction surface is coated with molybdenum
^ Press synchronizer ring onto gear cone and measure gap -a- with feeler gauge
^ a = New: 1.3-1.9 mm (0.051-0.075 in)
^ a = Wear limit: 0.5 mm (0.020 in)