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 Thrust plate
^ VW 408 A Press tool

Special tools and equipment:

^ VW 454 Press piece
^ 41-501 Drift sleeve
^ VW 447 i Thrust plate
^ VW 510 Press piece





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

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
^ Knock-off the input shaft with a drift
^ Pressing on go to Fig. 3

4 - Input shaft
5 - 3rd gear
^ Shoulder points to 4th gear
^ Pressing off go to Fig. 5
^ Pressing on go to Fig. 6

6 - Circlip
^ Always replace

7 - 4th gear
^ Pressing off with tapered roller bearing outer race and sleeve go to Fig. 4
^ Pressing on go to Fig. 7
^ Collar faces to 3rd gear

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

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

11 - Shim
^ Determining thickness go to adjusting input shaft

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

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





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

17 - Spring
^ Installation position go to Fig. 13

18 - Locking pieces (Qty. 3)
^ Installation position go to Fig. 12

19 - 5th gear synchro-hub
20 - 5th gear locking collar
21 - Dished washer
22 - Torx socket head bolt M10, 80 Nm
^ Fitted 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 on tapered roller bearing inner race





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





Fig. 5 Pressing off 3rd gear





Fig. 6 Pressing on 3rd gear





Fig. 7 Pressing on 4th gear
Shoulder points to 3rd gear.





Fig. 8 Pressing on tapered roller bearing inner race





Fig. 9 Pressing on sleeve for needle roller bearing





Fig. 10 Pressing out tapered roller bearing outer race





Fig. 11 Pressing in tapered roller bearing outer race
- Install with shim after adjusting input shaft.





Fig. 12 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. 13 Assembling 5th gear locking collar/synchro-hub
- Push locking collar over synchro-hub.
Pointed teeth -A- and shoulder -B- of synchro-hub face in same direction. The recesses for the locking pieces in locking collar and synchro-hub must be aligned (Fig. 12).
- Insert locking pieces (installation position: Fig. 12).
- Insert springs offset by 120° underneath tab -C-. Angled ends of spring must be directly behind locking pieces (arrows).