Input shaft, disassembling and assembling - assembly sequence: Notes

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Fig 1: Identifying Special Tools - Input Shaft, Disassembling And Assembling - Assembly Sequence (1 Of 2)

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Special tools, testers and auxiliary items required

Thrust plate VW 401
Thrust plate VW 402
Punch VW 412
Tube VW 415 A

Seal driver-frt wheel bearing 30 - 100
Driving sleeve 32 - 109

Fig 2: Identifying Special Tools - Input Shaft, Disassembling And Assembling - Assembly Sequence (2 Of 2)

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Special tools, testers and auxiliary items required

Seal driver-frt wheel bearing 40 - 21
Tube 2040
Guide sleeve 3039
Tube for wheel bearing 3345

Thrust plate T10084 A
Feeler gauge

Special tools, testers and auxiliary items required

Fig 3: Clamp T10306

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Clamp T10306

Fig 4: Wrench T10307

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Wrench T10307

Input shaft, disassembling

With input shaft removed, you must first remove circlip and washer in front of twelve-point nut.

Fig 5: Placing Key T10307 On Twelve-Point Nut

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Place key T10307 on twelve-point nut.
For the following step, the input shaft must be inserted in the clamp T10306 with clutch plate splines and clamped into a vise.

A - Torque wrench

NOTE:

Due to the input shafts center of gravity, it must be supported, e.g. by a second technician.
The twelve-point nut has left threads and it must be turned clockwise to loosen.

Remove twelve-point nut in direction of - arrow -.
Then remove 4th gear selector gear with needle bearing and synchronizer ring.

Fig 6: Pressing Of 3rd, 5th And 6th Gear Selector Gears Together With Synchronizer Hub And Inner Races/Needle Bearings

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Press of 3rd, 5th and 6th gear selector gears together with synchronizer hub and inner races/needle bearings.

NOTE:

Pressing force may be up to 200 kN (20 t).

Fig 7: Placing Bearing Bracket Over Roller Bearing On Input Shaft So That Rollers Are Not Pressed Out Of Bearing Cage

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Place bearing bracket - A - over roller bearing on input shaft so that the rollers are not pressed out of the bearing cage.
Press roller bearing off input shaft.
Clean twelve-point nut threads on input shaft from locking compound residue.

Input shaft, assembling

NOTE:

Clean thread on input shaft.
Lubricate all needle bearings and synchronizer rings with transmission fluid before inserting.
Before pressing needle bearing inner races off, warm to a maximum of 130°C while wearing protective gloves.
Warm synchronizer ring before pressing off to a maximum of 100°C while wearing protective gloves.
Always press roller bearing, needle bearing inner races and synchronizer body to stop so that selector gears have the recommended axial clearance.