Input shaft, assembly overview: Notes

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Disassembling and assembling input shaft, assembly sequence → Input shaft, disassembling and assembling - assembly sequence

NOTE:

When installing new gears, note technical data → 00 TECHNICAL DATA .
When replacing synchronizer rings, the intermediate ring and synchronizer ring for the respective gear must be replaced together.
Insert all bearings and synchronizer rings on input shaft with transmission fluid.
On transmissions with spring-loaded shifter forks → 3rd/4th gear selector rod with spring-loaded shift fork - arrow - , items 8, 11 to 14, 18 to 21, 25, 28 to 31 and 34 to 37 were changed.

Fig 1: Input Shaft, Assembly Overview

Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Circlip

2 - Grooved ball bearing

Replacing with transmission removed, not disassembled → Input shaft grooved ball bearing, replacing in uninstalled but not disassembled transmission

3 - Transmission housing

4 - Needle bearing

5 - Circlip

Determine thickness → Determine thickness of circlip and shim as follows:

6 - Washer

Determine thickness → Determine thickness of circlip and shim as follows:

7 - Twelve-point nut, 75 Nm

Has left threads

8 - Drive gear for 4th gear

9 - Needle bearing

For 4th gear

10 - Inner race/needle bearing

For 4th gear selector gear

11 - Inner race for 4th gear

Installed location Installation location of synchronizer rings for 3rd to 6th gears
Replace if grooved or scored

12 - Intermediate ring for 4th gear

Installed location Installation location of synchronizer rings for 3rd to 6th gears
Checking for wear Synchronizer rings for 3rd to 6th gears, checking for wear

13 - Synchronizer ring for 4th gear

Installed location Installation location of synchronizer rings for 3rd to 6th gears
Checking for wear Synchronizer rings for 3rd to 6th gears, checking for wear
Replace if grooved or scored

14 - Locking collar for 3rd and 4th gear

Assembling locking collar/synchronizer hub Assembly of locking collar/synchronizer hub for 3rd and 4th gear

15 - Locking piece

Installation position: insert with convex side in locking collar Assembly of locking collar/synchronizer hub for 3rd and 4th gear
Installing locking pieces (qty. 3) Assembly of locking collar/synchronizer hub for 3rd and 4th gear

16 - Thrust plate

Installing thrust pieces (3x) Assembly of locking collar/synchronizer hub for 3rd and 4th gear

17 - Synchronizer hub for 3rd and 4th gears

Pressing off
Pressing on
Installation position: small shoulder on collar faces toward 3rd gear 3rd/4th gear synchronizer hub installation location
Assembling locking collar/synchronizer hub Assembly of locking collar/synchronizer hub for 3rd and 4th gear

18 - Synchronizer ring for 3rd gear

Installed location Installation location of synchronizer rings for 3rd to 6th gears
Checking for wear Synchronizer rings for 3rd to 6th gears, checking for wear
Replace if grooved or scored

19 - Intermediate ring for 3rd gear

Installed location Installation location of synchronizer rings for 3rd to 6th gears
Checking for wear Synchronizer rings for 3rd to 6th gears, checking for wear

20 - Inner race for 3rd gear

Installed location Installation location of synchronizer rings for 3rd to 6th gears
Replace if grooved or scored

21 - Drive gear for 3rd gear

22 - Needle bearing

For 3rd gear

23 - Inner race/needle bearing

For 3rd gear selector gear

24 - Thrust washer

For 3rd and 6th gear selector gears

25 - Selector gear for 6th gear

26 - Needle bearing

For 6th gear

27 - Inner race/needle bearing

For 6th gear selector gear

28 - Inner race for 6th gear

Installed location Installation location of synchronizer rings for 3rd to 6th gears
Replace if grooved or scored

29 - Intermediate ring for 6th gear

Installed location Installation location of synchronizer rings for 3rd to 6th gears
Checking for wear Synchronizer rings for 3rd to 6th gears, checking for wear

30 - Synchronizer ring for 6th gear

Installed location Installation location of synchronizer rings for 3rd to 6th gears
Checking for wear Synchronizer rings for 3rd to 6th gears, checking for wear
Replace if grooved or scored

31 - Locking collar for 5th and 6th gear

Assembling locking collar/synchronizer hub Assembly of locking collar/synchronizer hub for 5th and 6th gear

32 - Synchronizer hub for 5th and 6th gears

Installation position: High inner collar faces 5th gear gear-wheel
Pressing off
Pressing on
Assembling locking collar/synchronizer hub Assembly of locking collar/synchronizer hub for 5th and 6th gear

33 - Thrust plate

Installing thrust pieces (3x) Assembly of locking collar/synchronizer hub for 5th and 6th gear

34 - Synchronizer ring for 5th gear

Installed location Installation location of synchronizer rings for 3rd to 6th gears
Checking for wear Synchronizer rings for 3rd to 6th gears, checking for wear
Replace if grooved or scored

35 - Intermediate ring for 5th gear

Installed location Installation location of synchronizer rings for 3rd to 6th gears
Checking for wear Synchronizer rings for 3rd to 6th gears, checking for wear

36 - Inner race for 5th gear

Installed location Installation location of synchronizer rings for 3rd to 6th gears
Replace if grooved or scored

37 - Drive gear for 5th gear

38 - Needle bearing

For 5th gear

39 - Roller bearing

For input shaft
Do not interchange with hollow shaft roller bearing
Pressing off
Pressing on

40 - Bearing bracket

Roller bearing outer race must not have any radial play in bearing bracket

41 - Input shaft

Differentiation of input shafts Differentiation of input shafts
Change: with additional PTFE washer for 5th gear needle bearing system Differentiation of input shafts

42 - Roller sleeve

For input shaft mounting in transmission cover
Always replace

43 - Transmission cover