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)
• Feeler Gauge
Disassembly
- Remove the grooved ball bearing locking ring.
Removing the Grooved Ball Bearing
- Install the thrust pad 16.5/28 mm dia. (VW 431) and the thrust piece (40-105) on the input shaft before installing the puller.
- Install the separating tool - B - into the groove in the bearing for the locking 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 5th Gear
A Separating tool 22 to 115 mm, for example, Kukko Separating Tool 22-115 mm (17/2)
Assembly
Heat 5th Gear and Install it
The groove - arrow - on the gear must face up.
Grooved Ball Bearing Installed Position
The groove for the locking 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 locking ring and install it on the input shaft. Refer to => [ Selecting the Locking Ring ].
Selecting the Locking Ring
- Insert a 1.86 mm locking ring - A - into the groove in the input shaft and press it upward.
- Measure the gap between the grooved ball bearing - B - and the installed locking ring - A - with a feeler gauge - C -.
- Remove the locking ring used for the measurement.
- Select the locking ring according to the table.
• For the correct locking rings, refer to the Parts Catalog.
The following locking rings are available:
Removing the Cylindrical Roller Bearing from the Clutch Housing
- Compress the cylindrical roller bearing locking 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 the Clutch Housing
- Compress the cylindrical roller bearing locking ring - arrow - with pliers - C - and install it.
- Remove the pliers before the cylindrical roller bearing gets into its installed position. The locking ring must lock into the groove on the clutch housing.