Input Shaft 2, Disassembling And Assembling

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Special tools and workshop equipment required 

• Drive Sleeve:30-20 
• Bearing Installer - Needle Bearing:30-506B 
• Press Plate:VW401 
• Press Plate:VW402 
• Press Piece - Multiple Use:VW412 
• Press Piece - 60mm:VW415A 

Special tools and workshop equipment required 

• Press Piece - Multiple Use:VW447H 
  Fig 1: Press Piece - Multiple Use

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• Inductive Heater:VAS 6414 
  Fig 2: Identifying Heater

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• Puller - Transmission Gears:T10309A 

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• Extracting Tool - Press In Piece:T40413/12 

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• Input shaft 2 removed. Refer to GEAR SET, DISASSEMBLING AND ASSEMBLING .

Disassembling

Pull off the sensor wheel 1 for the input shaft 2.

Fig 3: Remove the Sensor Wheel -1- for the Input Shaft 2

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TIP:

• The Puller - Transmission Gears - Half Shell:T10309/3  -2- cannot be completely closed.

2 -  Puller - Transmission Gears - Half Shell:T10309/3 

3 -  Puller - Transmission Gears:T10309/1 

4 -  Press Piece - Multiple Use:VW447H 

-- Remove the circlip -2-.

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-- Remove the thrust washer -1- and 4th gear assembly -3- with the needle bearing.

Input shaft 2 1, pressing on

Fig 4: Input Shaft 2 -1-, Pressing on

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2 -  Press Piece - Multiple Use:VW412 

3 -  Drive Sleeve:30-20 

4 -  Bearing Installer - Needle Bearing:30-506B 

5 -  Press Plate:VW401 

• All additional components remaining on the Press Plate:VW401  must be secured from falling.

-- When removing the components in the sequence, at the same time pay attention to the installation position. Refer to OVERVIEW - INPUT SHAFT 2 .

Assembling

6th gear wheel inner race 1, installing

Fig 5: 6th Gear Wheel Inner Race -1-, Installing

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3 -  Press Piece - 60mm:VW415A 

4 -  Press Piece - Multiple Use:VW412 

• Beforehand, push on the thrust washer -2-.
• Warm the inner race -1- using the Inductive Heater:VAS 6414  to 100 °C (212 °F).
• Layout of the oil filler hole -arrows- at an offset of approximately 90°.
• Installation position: the lettering on the bearing -1- (thicker wall thickness) points to the Press Piece - 60mm:VW415A  .

-- Press on the needle bearing for the 6th gear assembly -1-, 6th gear assembly -2- and synchronizer ring for 6th gear assembly -3-.

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Synchronizer hub 1, pressing on

Fig 6: Synchronizer Hub -1-, Pressing On

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4 -

Press Piece - 60mm:VW415A 

-- Lift the 6th synchronizer ring -2- with 6th gear assembly -3- slightly, until the anti-twist mechanism -arrow B- of the synchronization is flush with the cut-outs -arrow A- of the synchronizer hub -1-.

• Warm the synchronizer hub -1- using the Inductive Heater:VAS 6414  to 100 °C (212 °F).
• The lettered side of the synchronizer hub points to the Press Piece - 60mm:VW415A  .

-- Insert the three thrust pieces -arrows-.

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-- Push the double-toothed locking collar onto the opening -arrow A- with the lettering facing upward.

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-- Press the tops of the thrust pieces in slightly by hand when installing.

Inner race for 4th gear selector gear 1, pressing on.

Fig 7: Inner Race for 4th Gear Selector Gear -1-, Pressing On

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2 -  Press Piece - 60mm:VW415A 

3 -  Press Piece - Multiple Use:VW412 

• Warm the inner race -1- using the Inductive Heater:VAS 6414  to 100 °C (212 °F).
• Layout of the oil filler hole -arrows- at an offset of approximately 90°.
• Installation position: the lettering on the bearing -1- (thicker wall thickness) points to the Press Piece - 60mm:VW415A  .

-- Pressing on the 4th gear synchronizer ring -1-, needle bearing for 4th gear assembly -2-, 4th gear assembly -3- and 4th gear thrust washer -4-.

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• The anti-twist mechanisms -arrow- of the synchronizer ring -1- must be flush with the cut-outs of the locking collar.

Determine the circlip for the 4th gear assembly

Fig 8: Determining Thickness Of Circlip

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TIP:

• The illustration shows a different component. However, determining the circlip is identical.

-- Determine the thickest (but still usable) circlip and insert it. For the part number, refer to the appropriate Electronic Parts Information.

The following circlips are available:

Press on the sensor wheel 1.

Fig 9: Press on the Sensor Ring -1-

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2 -  Extracting Tool - Press In Piece:T40413/12 

3 -  Press Plate:VW402 

• Installation position: the high collar -arrow- of the sensor wheel points to the Extracting Tool - Press In Piece:T40413/12  .

-- Press on the sensor wheel -1- all the way.