Input Shaft
Input Shaft
=> [ Grooved Ball Bearing Changes ]
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)
Disassembling
- Remove the grooved ball bearing locking ring.
Removing the Grooved Ball Bearing
- Remove the locking ring from the input shaft beforehand.
- Mount the (VW 431) and the (40-105) on the input shaft before mounting the puller.
- Mount the separating tool - B - into the groove in the bearing for the locking ring.
A Puller , for example, (18/1)
B Separating tool 12-75 mm , for example, (Kukko 17/1)
Removing the 5th Gear
A Separating tool 22-115 mm , for example, (Kukko 17/2)
Input Shaft, Assembling
Installing 5th Gear
The groove - arrow - on the gear must face up.
Grooved Ball Bearing Installed Position
The groove for the locking ring faces up - arrow A -. 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 - faces the (VW 412).
- Install the grooved ball bearing securing ring on the input shaft (see next figure).
Determining the Grooved Ball Bearing Locking Ring on the Input Shaft
- 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 Kukko support , for example, (22/2)
B Kukko extractor 30-37 mm , for example, (21/5)
Pressing Cylindrical Roller Bearing Into 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.
Grooved Ball Bearing Changes
From transmission build date 4.10.06 through approximately 1.21.08
A washer above and below the grooved ball bearing seat - item 6 - => [ (Item 6) Grooved Ball Bearing ] .
Above the Bearing Seat:
Below the bearing seat - arrow -:
Slightly Deeper from Transmission Build Date 4.10.06 through Approximately 1.21.08
The grooved ball bearing seat - arrow - is slightly deeper to hold the washer under the bearing - item 6 - => [ (Item 6) Grooved Ball Bearing ] .
Flattened areas on the grooved ball bearing - A - and bearing seat - B - in the transmission housing approximately from transmission build date 2.21.08.
• If the flattened areas are present, do not insert any washers above and below the grooved ball bearing.