Input Shaft, Disassembling and Assembling

Input shaft, disassembling and assembling, 02J, 5 Spd. M/T

Special tools and equipment:

- VW 407 Press tool
- VW 447 H Press plate
- VW 412 Press tool
- VW 422 Tube
- VW 401 Press plate
- VW 408 A Press tool

Special tools and equipment:

- VW 421 Tube
- VW 454 Press piece
- VW 447 i Thrust plate
- VW 510 Press piece
- 41-501 Drift sleeve
- 3 - Kukko 17/1 Separating device





Note:
- When installing new gear wheels, consult technical data.
- If the position of the tapered roller bearings is affected when exchanging parts, the input shaft must be re-adjusted. See adjustment overview

1. Clutch housing
2. Tapered roller bearing outer race
^ Removing go to Fig. 1
^ Pressing in go to Fig. 2

3. Tapered roller bearing inner race
^ Pressing off go to Fig. 3
^ Pressing on go to Fig. 4

4. Input shaft
^ Adjusting

5. 3rd gear wheel
^ Shoulder points to 4th gear
^ Pressing off go to Fig. 5
^ Pressing on go to Fig. 7

6. Circlip
^ Always replace

7. 4th gear wheel
^ Press off with tapered roller bearing inner race and sleeve go to Fig. 5
^ Pressing on go to Fig. 8
^ Collar faces to 3rd gear

8. Tapered roller bearing inner race
^ Pressing off with 4th gear wheel and sleeve go to Fig. 5
^ Pressing on go to Fig. 9

9. Thrust washer
10. Tapered roller bearing outer race
^ Pressing out go to Fig. 11
^ Pressing in go to Fig. 12

11. Shim
^ Determining thickness adjusting input shaft

12. Transmission housing
13. Sleeve
^ For needle roller bearing
^ Press off with 4th gear wheel and tapered roller bearing inner race go to Fig. 5
^ Pressing on go to Fig. 9
^ Place thrust washer on before installing (item 9)

14. Needle roller bearing
15. 5th gear wheel
^ Pull off together with 5th gear synchro-hub

16. 5th gear synchro-ring
^ With cast locking pieces Illustration N35-0018
^ Check for wear

17. Spring
^ Installation position go to Fig. 14
^ From transmission manufacture date November 05 01 the spring was changed

18. Lock pieces (Qty. 3)
^ Installation position go to Fig. 13
^ From transmission manufacture date March 05 01 are lock pieces installed, which are inner hollow

19. 5th gear synchro-hub
20. 5th gear locking collar
21. Dished washer
^ Installation position

22. Torx socket head bolt M10, 80 Nm
^ Installed piece on bolt head locates dished spring





Fig. 1 Pressing out tapered roller bearing outer race





Fig. 2 Pressing in tapered roller bearing outer race





Fig. 3 Pressing off tapered roller bearing inner race
A - Separating device Kukko 17/1





Fig. 4 Pressing on tapered roller bearing inner race





Fig. 5 Pressing off 4th gear wheel with tapered roller bearing and sleeve





Fig. 6 Pressing off 3rd gear wheel





Fig. 7 Pressing on 3rd gear wheel





Fig. 8 Pressing on 4th gear wheel
Shoulder points to 3rd gear.





Fig. 9 Pressing on tapered roller bearing inner race





Fig. 10 Pressing on sleeve for needle roller bearing





Fig. 11 Pressing out tapered roller bearing outer race





Fig. 12 Pressing in tapered roller bearing outer race
- Install with adjusting shim after adjusting input shaft.





Fig. 13 5th gear synchronizer
1 - Springs for lock pieces
2 - Locking collar
With 3 recesses (arrows A) for the locking pieces (item 4)
3 - Synchro-hub
4 - Locking pieces
Installation position: The thin extension (arrow B) faces the pointed teeth of the locking collar (item -2-)





Fig. 14 Assembling 5th gear locking collar/synchro-hub
- Push locking collar over synchro-hub.
- Pointed teeth -A- of the locking collar and shoulder -B- of the syncro-hub face in one direction. The cut outs for the locking piece in the locking collar and the syncro-hub must be in-line with one another (Fig. 13).
- Insert locking pieces (Installation position: Fig. 13).
- Insert springs offset by 120° underneath lug -C-. Angled ends of spring must be directly behind locking pieces (arrows).