Input shaft, removing and installing

Special tools, testers and auxiliary items required 

Fig 1: Puller T40050

Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Puller T40050

Removing 

• Drain ATF → ATF, draining for ATF flushing process  , pivot transmission in installation position (level),

Fig 2: Removing Bolts

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• Remove bolts - arrows  -.
• Using a plastic mallet, carefully knock input shaft flange cover so that input shaft flange cover loosens itself from seal.

Fig 3: Securing Puller T40050 On Transmission Input Shaft

Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Secure Puller T40050 on transmission input shaft.
• Check Puller T40050 for secure seating on input shaft.

• Circlip must be pushed all the way down.

• Pull input shaft with flange cover and forward clutch on Puller T40050 out of transmission housing - arrow  -.

Fig 4: Identifying Oil Pipe

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Installing 

Install in reverse order of removal, note the following:

• Check wear on transmission components → Transmission components, evaluating wear 
• Clean sealing surfaces on transmission housing and flange cover.

Fig 5: Checking Whether Bushings For Centering Flange Cover On Transmission Housing Are Installed And Seated Securely

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• Check whether bushings - arrows  - for centering flange cover on transmission housing are installed and seated securely.

Fig 6: Checking Condition Of Sealing Ring

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• Check condition of sealing ring - arrow  - , replace if necessary.

• Installation position of oil seal: Sealing lip towards flange cover.

• Place paper gasket in position.

Fig 7: Aligning Clutch Discs Of Reverse Gear Clutch E.G. Using Straight-Edge

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• Align clutch discs of reverse gear clutch e.g. using a straight-edge.

• Splines must stand exactly in a row.

Fig 8: Identifying Oil Pipe

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• Check installation dimension of oil pipe - arrow  - :

• If oil pipe is inserted completely, the dimension from its end to the input shaft is approx. 11.5 mm.

If the dimension is smaller, the oil pipe possibly is damaged as it was pushed in too far and is broken at the end.

If the dimension is larger, it is not pushed in far enough.

• Insert entire input shaft into transmission housing.

Fig 9: Using Back And Forth Rotating Motions On Input Shaft Until Clutch Discs Of Reverse Gear Clutch Have Engaged

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• Use back and forth rotating motions - arrow  - on input shaft until clutch discs of reverse gear clutch have engaged. Raise input shaft slightly when doing this.
• Just before the input shaft is fully in position, rotate it counter-clockwise over the last few millimeters so that it engages in the teeth of the helical intermediate gearing.

Fig 10: Removing Bolts

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• Tighten bolts - arrows  - in diagonal sequence and in stages.
• Fill with ATF → ATF, filling for ATF flushing process .

Torque specification