Input Shaft

Input Shaft

Special tools, testers and auxiliary items required

• Thrust Plate (VW 401)

• Thrust Plate (VW 402)

• Punch (VW 407)

• Thrust Disc (VW 412)

• Thrust Pad 16.5/28 mm Dia. (VW 431)

• Arbor 50 mm Dia. (VW 432)

• Thrust Tube (VW 454)

• Locking Pin (30-505)

• Thrust Piece (40-105)

• Press Tube (2040)

• Kukko Extractor 30-37 mm (21/5)

• Kukko Puller 65-160 mm (18/1)

• Kukko Separating Tool 12-75 mm (17/1)

• Kukko Separating Tool 22-115 mm (17/2)

• Kukko Support (22/2)

• Inductive Heat Unit (VAS 6414) , or equivalent

• Feeler Gauge

Input Shaft, Disassembling

- Remove the grooved ball bearing lock ring.

Removing the grooved ball bearing





- Mount the thrust pad 16.5/28 mm dia. (VW 431) and the thrust piece (40-105) on the input shaft before mounting the puller.

- Mount the separating tool - B - into the groove in the bearing for the lock ring.

A Puller, for example, Kukko puller 65-160 mm (18/1)
B Separating tool 12 to 75 mm, for example, Kukko separating tool 12-75 mm (17/1)

Removing the 5th gear





A Separating tool 22 to 115 mm, for example, Kukko separating tool 22-115 mm (17/2)

Input Shaft, Assembling

Heat the 5th gear and install it.





The groove - arrow - on the gear must face up.

Grooved ball bearing installed position





The groove for the lock ring faces up - arrow A - and the collar - arrow B - must face the 5th gear.

Installing the grooved ball bearing





Grooved ball bearing with a rubber ring - arrow -

The shoulder - A - on the thrust tube (VW 454) faces the thrust disc (VW 412).

- Select the grooved ball bearing lock ring and install it on the input shaft. Refer to => [ Selecting the lock ring ].

Selecting the lock ring





- Insert a 1.86 mm lock ring - A - into groove in the input shaft and press it upward.

- Measure the gap between the grooved ball bearing - B - and the installed lock ring - A - with a feeler gauge - C -.

- Remove the lock ring used for the measurement.

- Select the lock ring according to the table.

• For the correct lock rings, refer to the Parts Catalog.

The following lock rings are available:






Removing the cylindrical roller bearing from the clutch housing





- Compress the cylindrical roller bearing lock ring - arrow - with pliers - C - and remove it.

A Counter support, for example, Kukko support (22/2)
B Internal puller 30 to 37 mm, for example, Kukko extractor 30-37 mm (21/5)

Pressing the cylindrical roller bearing into clutch housing.





- Compress the cylindrical roller bearing lock ring - arrow - with pliers - C - and install it.

- Remove the pliers before the cylindrical roller bearing gets into its installed position. The lock ring must lock into the groove on the clutch housing.