Input Shaft, Disassembling And Assembling

Special tools and workshop equipment required 

• Bearing Driver - Multiple Use VW244B
• Press Plate VW401
• Press Plate VW402
• Press Piece - Rod VW407
• Press Piece - Multiple Use VW412
• Press Piece - Bushing VW434
• Press Piece - Multiple Use VW454
• Press Piece - Multiple Use VW455
• Press Piece - Multiple Use VW519
• Bearing Installer - Differential Bearing 40-21
• Support Bridge 2011
• Bearing Installer - Wheel Bearing 3345
• Puller - Kukko Quick Action Separating Tool - 22-115mm 17/2
• Inductive Heater VAS6414
• Depth Gauge

Input shaft, disassembling

• The input shaft is removed from the output shaft and the bearing bracket. Refer to GEARS AND SHAFTS, DISASSEMBLING AND ASSEMBLING .
• The bolt inside the input shaft is removed. Refer to Figure .
• If the synchronizer rings are not to be replaced, make sure they are reallocated to their original gear.
• Do not interchange the locking collar for the 3rd and 4th gear with the locking collar for the 5th and 6th gear. Mark the locking collars

-- Remove the 3rd, 4th and 6th gearshift wheels together with the 3rd and 4th gear synchronizer hubs and the inner race/needle bearing.

A  - Separating Tool - 22-115mm, for example Puller - Kukko Quick Action Separating Tool - 22-115mm 17/2

-- Remove the locking ring on the 5th/6th gear synchronizer hub from the input shaft.

-- Remove the 5th and 6th gear synchronizer hub/locking collar with the 5th gear wheel.

-- Expand the 5th gear needle bearing -2- and carefully guide it over the locking ring -1- as well over the splines -3- on the 5th/6th gear synchronizer hub.

-- Remove the locking ring -1-.

-- Press roller bearing off input shaft  .

A  -

Separating Tool - 22-115mm, for example Puller - Kukko Quick Action Separating Tool - 22-115mm 17/2

-- Clean the internal multipoint bolt threads on input shaft from locking compound residue.

Input shaft, assembling

Hook the rounded end of the synchronizer spring -arrow- into the hole in the gear wheel.

-- Install the roller bearing all the way onto the input shaft  .

-- Expand the needle bearing -2- 5th gear wheel and carefully guide over the splines on the 5th/6th gear synchronizer hub -3-. When doing this, do not lay the needle bearing on the collar -arrow- on the input shaft  .

-- If removed, carefully open the new locking ring -1- guide it over the splines on the 5th/6th gear synchronizer hub -3-.

• The locking ring must not be turned by hand in the groove all around the input shaft

-- Install the 5th gear wheel -B-  .

• The gear wheel -B- must not touch the locking ring -A- while it is being turned.
• There must be an even distance -x- between the gear wheel and the locking ring.

Installed position, synchronizer hub with groove -arrow B- :

• The shorter spline -arrow A- above the groove -arrow B- on the synchronizer hub -1- must be facing the 6th gear wheel.

Note the follow when performing the next steps:

-- Insert the input shaft into the hole on the Support Bridge 2011.

-- Place pressing tool in center of warmed components (synchronizer hub and needle bearing inner races).

-- After pressing briefly on components, stop and align pressing tool again at center and press to stop.

-- Install the 5th gear synchronizer ring.

-- Install the heated synchronizer until the stop.

-- Slide the locking collar over the synchronizer hub.

• The synchronizer hub is installed all the way.

-- Determine thickest circlip which can still just be installed and insert it.

The following circlips are available:

Circlip thickness (mm)
2.44	2.47	2.50

-- Install the 6th gear wheel, the needle bearing and the synchronizer ring.

-- Install the thrust washer -A-.

-- Install the heated 3rd gear wheel inner race/needle bearing -B-.

-- Install the 3rd gear wheel, the needle bearing and the synchronizer ring.

• The inside collar -arrow A- on the synchronizer hub -1- faces 4th gear.

-- Place the locking collar for the 3rd and 4th gear on the synchronizer hub.

-- Install the 4th gear wheel, the needle bearing and the synchronizer ring.

-- Install the thrust washer -A-.

-- Install the heated roller sleeve inner race -B-.

-- Then check all selector gears for ease of movement and axial play.

• Gear wheel axial play must be at least 0.15 mm.