Determining thickness for circlip behind the input shaft ball bearing: Notes

Fig 1: Location Of Rear Circlip For Input Shaft Ball Bearing

Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Install a provisional circlip - arrow  - in rear groove on input shaft.
• Then push ball bearing onto input shaft.

Installation position:

The sealed side of the ball cage faces transmission housing.

Fig 2: Pressing In Ball Bearing

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• Pressing in ball bearing:

Screw replacement stud (M8 and M10) 3114/2 into tapped hole for ball head stud.

Slide thrust plate - A  - of fitting tool T10246 onto input shaft.

Position fitting tool behind splines for clutch plate. Tighten bolts - B  - lightly. The bolts locate in the recess in the thrust plate - A  -.

Press in ball bearing onto stop by tightening bolts alternately (1/2 turn at a time).

Fig 3: Dished Spring, Guide Sleeve And Bolt

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• Install dished spring - 1  -.

Installation position:

The convex side faces guide sleeve - 2  -.

• Install a shrink hose onto input shaft splines.
• Bolt guide sleeve to transmission housing - 2  - with bolts - 3  -.
• Turn the transmission housing so the joint flange for the bearing housing points upward.

• The contact surface must be cleaned to remove sealing paste  .

Fig 4: Measuring From Thrust Washer To Contact Surface Of Housing

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• Place thrust washer - 1  - for 4th and 5th speed selector gears onto input shaft.
• Place a digital depth gauge (e. g. VAS 6087) onto thrust washer and measure the distance to the contact surface of housing. The measuring point on the housing contact surface must be as close to the input shaft as possible.

Specification: distance "a" = 164.14 mm