Input Shaft, Disassembling and Assembling

Input shaft, disassembling and assembling




Special tools and equipment
^ VW 401 Thrust plate
^ VW 412 Press tool
^ VW 519 Tube





Note: When installing new gear wheels or the input shaft, consult the technical data.

1. Transmission housing
2. Needle roller bearing
^ For input shaft
^ Pulling out; Refer to Fig. 13
^ Driving in; Refer to Fig. 14
3. Securing clip
^ For needle roller bearing
4. Securing clip
^ For input shaft
5. Thrust washer
6. Needle roller bearing
^ For 4th gear
^ Mark before removing
^ Do not interchange with 3rd gear needle roller bearing
^ Before installing, lubricate with gear oil
7. Selector gear for 4th gear
^ Insert spring before installing
8. 4th gear synchro-ring
^ Checking for wear
9. Locking collar
10. Securing clip
^ If synchronizing hub is replaced, redetermine thickness - Fig.3
^ Installed position: ends align with groove in synchronizing hub
11. 3rd and 4th gear synchronizing hub
^ Pressing off - Fig.4
^ Installation position - Fig.5
^ Pressing on - Fig.6
12. 3rd gear synchro-ring
^ Coated with Molybdenum
^ Checking for wear; Refer to Fig 2
13. Selector gear for 3rd gear
^ Insert spring before installing; Refer to Fig 1
14. Needle roller bearing
^ For 3rd gear
^ Mark before removing
^ Do not interchange with 4th gear needle roller bearing
^ Before installing, lubricate with gear oil
15. Input shaft
16. Spring pin
^ Always replace
^ Drive in when replacing input shaft - Fig. 7
17. Roller bearing
^ For input shaft
^ Pressing out; Refer to Fig. 5
^ Pressing in; Refer to Fig. 6
18. Gear carrier
19. Tapered roller bearing inner race
^ For cylindrical roller bearing
^ Take off and put on by hand
20. Securing clip
21. Thrust washer
^ For 6th gear sliding wheel needle roller bearing
^ Fitting position: Collar facing circlip, smooth thrust surface facing needle bearing
22. Needle roller bearing
^ For 6th gear
^ Before installing, lubricate with gear oil
23. 6th gear wheel
^ Insert spring before installing - Fig.1
^ After installing, check axial clearance with feeler gauge (0.15.0.35 mm)
24. 6th gear synchro-ring
^ Checking for wear - Fig.2
25. 5th and 6th gear synchronizing hub
^ Installed position: Projecting hub facing 5th gear sliding wheel
26. Locking collar
27. 5th gear synchro-ring
^ Checking for wear; Refer to Fig 2
28. Selector gear for 5th gear
^ Insert spring before installing
29. Inner race for needle roller bearing
30. Needle roller bearing
^ For 5th gear
^ Before installing, lubricate with gear oil
31. 1st inner race for 4-point bearing
32. End cover
33. 2nd inner race for 4-point bearing
34. Multi-point socket head bolt





Fig. 1 Inserting spring in sliding wheel
The bent end of the spring (arrow) must be hooked into the hole in the gear wheel.





Fig. 2 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-.
- Calculate average gap.
- Average gap must not be less than 0.5 mm.





Fig. 3 Determining thickness of circlip
- Synchronizing hub pressed to stop
- Determine thickest circlip which will just fit and install.

Note:
^ The gap in the circlip must line up with groove in synchronizing hub.
^ Determine the circlip according to the parts Supplier.





The securing clips shown in the provided table are available.





Fig. 4 Pressing off 3rd and 4th gear synchro hub





Fig. 5 Installed position of locking collar

Oil groove in synchronizing hub (arrow -1-) must line up with oil drilling (arrow -2-) in input shaft





Fig. 6 Pressing on 3rd and 4th gear synchro-hub
- Warm synchronizing hub to about 100°C, put on shaft and press.
- Determine circlip and install; Refer to Fig 3





Fig. 7 Driving spring pin into input shaft
- Insert drift -A-, 9 mm diameter, into oil drilling and drive spring pin -B to stop with drift.