Input Shaft

Special tools and workshop equipment required 

• Punch VW 407
• Thrust Pad VW 447 H
• Press Piece - Multiple Use VW 412
• Tube Split VW 422
• Press Plate VW 401
• Punch VW 408 A
• Tube 28 mm Dia. 100 mm VW 421
• Thrust Pad VW 447 i
• Thrust Tube VW 454
• Thrust Pad VW 510
• Mounting Universal Joint 41-501
• Kukko Separating Tool 12-75 mm 17/1
• Press Plate VW 402
• Hot Air Blower V.A.G. 1416

Fig 1: Identifying Tapered Roller Bearing Outer Race

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Fig 2: Identifying Tapered Roller Bearing Outer Race

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Fig 3: Identifying Inner Race/Tapered Roller Bearing

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A -

Separating device 12 to 75 mm Kukko separating tool 12-75 mm 17/1

Fig 4: Identifying Inner Race/Tapered Roller Bearing

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Fig 5: Identifying 4th Gear With Tapered Roller Bearing And Sleeve Using Special Tools VW407, VW421 & VW401

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Fig 6: Identifying 3rd Gear Using Special Tools VW408A, VW447H & VW401

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-- Remove the lock ring first.

Fig 7: Identifying 3rd Gear Using Special Tools VW408A, VW447H & VW401

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Installed position: the shoulder faces 4th gear.

Fig 8: Identifying 4th Gear Using Special Tools VW 412, VW 454 & VW 401

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Installed position: the shoulder faces 3rd gear.

Fig 9: Identifying Inner Race/Tapered Roller Bearing

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Fig 10: Identifying Sleeve For Needle Bearing

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Fig 11: Identifying Tapered Roller Bearing Outer Race

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Fig 12: Identifying Tapered Roller Bearing Outer Race

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-- Install with a shim after adjusting the input shaft.

Fig 13: Installing 5th Gear Synchronizer

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1. Springs for the locking pieces.
2. Locking collar with three notches -arrow A- for the locking pieces -4-.
3. Synchronizer hub.
4. Locking pieces installed position: the brace -arrow B- faces toward the pointed teeth of the locking collar -2-

Fig 14: Assembling 5th Gear Locking Collar/Synchronizer Hub

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-- Slide the locking collar over the synchronizer hub.

The pointed teeth -A- and the shoulder -B- on the synchronizer hub face in the same direction. Recesses for locking pieces in locking collar and synchronizer hub must line up, refer to Fig 13.

-- Insert locking pieces. Installed position, refer to Fig 13.

-- Install the springs offset by 120° under the tabs -C-. The angled end of the spring must be positioned in front of the locking pieces -arrows-.

Fig 15: Identifying Offset Springs -A- For 5th Gear Synchronization

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These springs -A- are installed on both sides.

-- Springs are only installed in conjunction with hollow locking pieces.

-- Insert locking pieces. For installed position, refer to Fig 13.

Spring Installed Position

Fig 16: Identifying Installation Position Of (Offset) Spring

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-- Install the spring offset by 120°.

-- Angled end -A- of spring must engage into the hollow locking piece.

It must be located below the tab -B- of the locking pieces.

The offset end always faces away from the synchronizer hub in the -direction of the arrow-.