Input shaft, disassembling and assembling: Notes
Special tools and equipment
- VW 401 Thrust plate
- VW 412 Thrust tool
- VW 519 Tube
- Feeler gauge
- When installing new gears or the input shaft consult technical data. Refer to Code letters, mechanical unit assignment, transmission ratios, capacities .
1 - Transmission housing
- Servicing. Refer to Transmission housing, servicing
2 - Needle bearing
- For input shaft
- Pulling out. Refer to Pulling needle bearing out of transmission housing
- Driving in. Refer to Driving needle bearing into transmission housing
3 - Circlip
- For needle bearing
4 - Circlip
- For input shaft
5 - Thrust washer
6 - Needle bearing
- For 5th gear
- Mark before removing
- Do not interchange with needle bearing for 3rd gear
- Oil with gear oil before installing
7 - 4th sliding gear
- Before installing, insert spring. See Inserting spring in sliding gear
8 - 4th gear synchro-ring
- Checking for wear. See Checking synchro-ring for wear
9 - Locking collar
- Paired with synchro-hub
- Mark before removing. Refer to Figure
10 - Circlip
- When replacing synchro-hub, re-determine thickness. See Determining thickness of circlip
- Installation position: Ends align with groove of synchro-hub
11 - Synchro-hub for 3rd and 4th gear
- Pressing off. See Pressing off synchro hub for 3rd and 4th gear
- Installation position. See Installation position of synchro-hub
- Pressing on. See Pressing on synchro hub for 3rd and 4th gear
12 - 3rd gear synchro-ring
- Coated with molybdenum
- Checking for wear. See Checking synchro-ring for wear
13 - 3rd sliding gear
- Before installing, insert spring. See Inserting spring in sliding gear
- After pressing on -Item 11 check axial play using feeler gauge (0.15 to 0.35 mm)
14 - Needle bearing
- For 3rd gear
- Mark before removing
- Do not interchange with needle bearing for 4th gear
- Lubricate with gear oil before installing
15 - Input shaft
16 - Spring pin
- Replace
- Drive in when replacing input shaft. See Driving spring sleeve into input shaft
17 - Cylindrical roller bearing
- For input shaft
- Pressing out. Refer to Pressing cylinder roller bearing for input shaft out of bearing plate
- Pressing in. Refer to Pressing cylinder roller bearing for input shaft into bearing plate
18 - Bearing plate
- Servicing. Refer to Bearing plate, servicing
19 - Inner race
- For cylinder roller bearing
- Remove and install by hand
20 - Circlip
21 - Thrust washer
- For needle bearing for 6th sliding gear
- Installation position: Shoulder toward circlip, smooth face contact surface toward needle bearing. Refer to Figure
22 - Needle bearing
- For 6th gear
- Oil with gear oil before installing
23 - 6th sliding gear
- Before installing, insert spring. See Inserting spring in sliding gear
- After installing, check axial play. Refer to Figure
24 - 6th gear synchro-ring
- Checking for wear. See Checking synchro-ring for wear
25 - Synchro-hub for 5th and 6th gear
- Pulling off. Refer to Figure
- Driving on. Refer to Figure
- Installation position: Projecting hub toward 5th sliding gear
26 - Locking collar
- Paired with synchro-hub
- Mark before removing. Refer to Figure
27 - 5th gear synchro-ring
- Checking for wear. See Checking synchro-ring for wear
28 - 5th sliding gear
- Before installing, insert spring. See Inserting spring in sliding gear
- After installing, check axial play. Refer to Assembling
29 - Inner race for needle bearing
30 - Needle bearing
- For 5th gear
- Oil with gear oil before installing
31 - 1st inner race for four-point bearing
32 - End cover
- Servicing. Refer to End cover, servicing
33 - 2nd inner race for ball bearing
34 - Multi-point socket head bolt, 150 Nm