Input Shaft, Disassembling and Assembling
Input shaft, disassembling and assembling, 02M, 5 and 6 Spd. M/T
Special tools and equipment:
^ VW 401 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 433 Press piece
^ VW 454 Press piece
^ VW 801 Holding plate
^ VAG 1582 tapered roller bearing puller
^ VAG 1582/7 Grip
^ 1 - Kukko 21/7 Internal puller
^ 3 - Kukko 17/2 Separating device
^ 4 - Kukko 22/2 Counter support
Special tools and equipment:
^ 40-105 Thrust plate
^ 41-501 Drift sleeve
^ 2040 Tube
^ 2050 Thrust piece
^ 3074 Press disc
^ 3161 Extension
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 - Transmission housing
2 - Shim
3 - Tapered roller bearing outer race
^ Pulling out go to Fig. 1
^ Pressing in go to Fig. 2
4 - Circlip
^ Redetermine if tapered roller bearing item 5 or input shaft item 8 are replaced go to Fig. 11
5 - Tapered roller bearing inner race
^ Pulling off go to Fig. 3
^ Pressing on go to Fig. 10
6 - 5th gear
^ Pressing off go to Fig. 4
^ Pressing on go to Fig. 9
7 - 3rd, 4th and 6th gear
^ Pressing off go to Fig. 5
^ Pressing on go to Fig. 7
8 - Input shaft
9 - Tapered roller bearing inner race
^ Pressing off go to Fig. 6
^ Pressing on go to Fig. 8
10 - Tapered roller bearing outer race
^ Pulling out go to Fig. 12
^ Installed position go to Fig. 13
^ Pressing in go to Fig. 14
^ Transmissions from build date 06 04 0 secured with locking plate and bolt
^ Bolt 12 Nm
^ Always replace
11 - Clutch housing
^ Transmissions from 06 04 0, with additional threaded hole and recess for locking plate to secure tapered roller bearing outer race for input shaft, item 10
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 - Vise clamps/vise
- Remove securing clip.
- Before setting up pulling device, set extension 3161 and thrust plate 40-105 on input shaft.
Fig. 4 Pressing off 5th 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
- Determine circlip and install go to Fig. 11.
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 Outer race/tapered roller bearing installation position in clutch housing
Transmissions from build date 06 04 0
The recesses for locking plate (go to Fig. 14) on outer race/tapered roller bearing (arrow -A-) and clutch housing (arrow -B-) must align.
Fig. 14 Pressing in tapered roller bearing outer race
Transmissions from 06 04 0
- After pressing in, check if locking plate -A- can be inserted in recess.
- Before installing and securing locking plate, insert axle shaft.