5 & 6 Speed Manual 02M

Input shaft, disassembling and assembling





Special tools and equipment
^ VW401 Thrust plate
^ VW 402 Thrust plate
^ VW 407 Press tool
^ VW 408 A Press tool
^ VW 412 Press tool
^ VW 416 B Tube





Special tools and equipment
^ VW 309 Holding plate
^ VW 353 Transmission support
^ VW 433 Press piece
^ VW 454 Press piece
^ VW 457 Support rails
^ VW 801 Holding plate





Special tools and equipment
^ 40-105 Thrust plate
^ 41-501 Drift sleeve
^ 2040 Tube 2050 Thrust piece
^ 3074 Press disc
^ 3161 Extension





Special tools and equipment
^ 3235 Press
^ V.A.G 1582 Tapered roller bearing puller
^ V.A.G 1582/7 Grip
^ 1-Kukko 21/7 Internal puller
^ 3-Kukko 17/2 Separating device
^ 4-Kukko 22/2 Counter support

Note:

^ When installing new gears, consult technical data, Refer to Manual Transmission/Transaxle, Application and ID.
^ If the position of the tapered roller bearings is affected when exchanging parts, the input shaft must be re-adjusted. See adjustment overview, Refer to Differential, Manual Transaxle,Adjustments, Adjustment Overview





1- Transmission housing
2- Shim
3- Tapered roller bearing outer race
^ Pulling out, Refer to Fig. 1
^ Pressing in, Refer to Fig. 2
4- Circlip
^ Redetermine if tapered roller bearing -item- 5- or input shaft -item 8- are replaced, Refer to Fig. 11
5- Tapered roller bearing inner race
^ Pulling off, Refer to Fig. 3
^ Pressing on, Refer to Fig. 10
6- 5th gear
^ Pressing off, Refer to Fig. 4
^ Pressing on, Refer to Fig. 9
7- 3rd, 4th and 6th gear
^ Pressing off, Refer to Fig. 5
^ Pressing on, Refer to Fig. 7
8- Input shaft
9- Tapered roller bearing inner race
^ Pressing off, Refer to Fig 6
^ Pressing on, Refer to Fig 8
10- Tapered roller bearing outer race
^ Pulling out, Refer to Fig. 12
^ Pressing in, Refer to Fig. 13
11- Clutch housing





Fig. 1 Pressing tapered roller bearing outer race out of transmission housing
^ A - Counter support, e. g. Kukko 22/2
^ B - Internal puller 46 to 58 mm, e.g. Kukko 21/7





Fig. 2 Pressing tapered roller bearing outer race into transmission housing
^ Support transmission housing with press piece 3062 directly below bearing support.





Fig. 3 Pulling off tapered roller bearing inner race
A - Vice clamps/vice
^ Before setting up pulling device, set extension 3161 and thrust plate 40-105 on input shaft.





Fig. 4 Pressing off5th gear
A - Separating device 22 to 115 mm, e.g. Kukko 17/2





Fig. 5 Pressing off 3rd, 4th and 6th gear





Fig. 6 Pressing off tapered roller bearing inner race
A - Separating device 22 to 115 mm, e g. Kukko 17/2





Fig. 7 Pressing on 3rd, 4th and 6th gear
^ Heat gear wheel to about 100°C
^ Press on gear wheel quickly so that heat is not immediately transferred to input shaft.





Fig. 8 Pressing on tapered roller bearing inner race





Fig. 9 Pressing on 5th gear





Fig. 10 Pressing on tapered roller bearing inner race





Fig. 11 Determining thickness of circlip
^ Determine thickest circlip which will just fit and install it.





The following circlips are available:





Fig. 12 Pulling tapered roller bearing outer race out of transmission housing
A - Counter support, e. g. Kukko 22/2
B - Internal puller 46 to 58 mm, e.g. Kukko 21/7





Fig. 13 Pressing in tapered roller bearing outer race