Input Shaft: Assembling

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NOTE:

Lubricate all needle bearings and synchronizer rings with transmission fluid before inserting.

Before pressing needle bearing inner races off, warm to a maximum of 100°C (212°F) while wearing protective gloves.

Warm synchronizer ring before pressing off to a maximum of 100°C (212°F) 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.

Fig 1: Checking Synchronizer Ring For Wear

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-- Check inner race on outer friction surface arrow for scoring or signs of wear; replace if necessary.

-- Check synchronizer ring on inner friction surface arrow for scoring or signs of wear, replace if necessary.

-- Place inner race, intermediate ring and synchronizer ring on selector gear taper and screw in.

NOTE:

Screw in means: Turn synchronizer ring approximately one turn while pressing on the ring at the same time.

-- Then measure the gap dimension -a- with a feeler gauge.

Gap Dimension -a-	Wear Limit
3rd to 6th gears	0.7 mm

NOTE:

Replace inner race, intermediate ring and synchronizer ring for the respective gear together.

Fig 2: Installation Position Of Synchronizer Rings For 1st And 2nd Gear

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NOTE:

If the parts are not to be replaced, make sure they are reallocated to their original gear.

-- Place inner race -2- on selector gear -1-.

-- Install the intermediate ring -3-. The tab -B- must be inserted into the recess -A-.

-- Insert the synchronizer ring -4-. Guide the tabs -C- through the recess -arrow-.

Note the Following when Performing the Next Steps:

-- Place pressing tool in center of warmed components (synchronizer hub and needle bearing inner races).

-- After pressing briefly on components, stop and align pressing tool again at center and press to stop.

When pressing on, synchronizer ring tabs and synchronizer hub recesses must align. Raise the gear wheel with the synchronizer ring a little bit so that it locks into the openings on the synchronizer hub.

-- Place the plate T40213/1 and the adapter T40213/9 on the V.A.G 1290A pressing table.

Fig 3: Installing Driveshaft

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-- Install the driveshaft in the adapter T40213/9.

-- Install the roller bearing all the way onto the input shaft.

-- Insert 5th gear selector gear together with needle bearing and synchronizer ring.

Fig 4: Assembly Of Locking Collar/Synchronizer Hub For 5th And 6th Gear

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-- Slide the locking collar -1- over the synchronizer hub -2-.

The openings -arrow C- for the thrust pieces -3- in the synchronizer hub and the notches -arrow D- in locking collar must be centered over one another.
Installed position: The high inside collar -arrow C- or the notch -arrow D- on the synchronizer hub must face the 5th gear wheel.

-- Then place thrust pieces -3- in synchronizer hub and press thrust pieces into notches -arrow B- in the locking collar.

Fig 5: Pressing on Synchronizer Hub with Locking Collar for 5th and 6th Gears

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Fig 6: Installing the 6th Gear Wheel Inner Race/Needle Bearing -A-

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-- Insert 6th gear selector gear -A- together with needle bearing and synchronizer rings.

Fig 7: Installing 6th Gear Selector Gear

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-- Place the thrust washer -B- on the 6th gear wheel.

-- Inner race/needle bearing -C- for the 3rd gear, pressing on.

-- Insert 3rd gear selector gear together with needle bearing and synchronizer rings.

Fig 8: Installing Locking Pieces -A- in Locking Collar

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-- Coat the 3 locking pieces -A- with some grease on convex side -arrow 1-.

-- Insert 3 locking pieces with the convex side in the openings in the locking collar.

Fig 9: Assembly of Locking Collar/Synchronizer Hub for 3rd and 4th Gear

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Install the 3 locking pieces -4- in the installed position into the locking collar openings -1-, refer to Fig 8.
Synchronizer hub installation location: The notch -arrow B- or the "label" must face the 4th gear wheel.

-- Place the locking collar -1- over the synchronizer hub -2- so that the openings on the synchronizer hub -arrow A- are centered over the installed locking pieces in the locking collar.

-- Then place thrust pieces -3- in synchronizer hub and press thrust pieces into notches -arrow C- in the locking collar.

Fig 10: Installing Synchronizer Hub with Locking Collar for 3rd and 4th Gears

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Fig 11: Inner Race/Needle Bearing for 4th Gear Selector Gear, Pressing On

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-- Insert the 4th gear wheel -A- and the needle bearing and synchronizer rings.

Fig 12: Inserting 4th Gear Wheel

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-- Install the thrust washer -B-.

Check to make sure that the inner race/needle bearing -D- for the 4th gear wheel is higher than the 4th gear wheel itself -A-.

-- Press on the ball bearing -C- until it hits the end stop.

-- Then check all selector gears for ease of movement and axial play.

Selector gear axial play must be at least 0.15 mm.

Determine Shim Thickness -B- as Follows:

Fig 13: Identifying Locking Ring And Shim

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-- Select the thickest - but still installable - shim from those available as replacement parts -B-

After you have selected the shim, the locking ring -A- must lie against the groove.