Input Shaft 2, Disassembling And Assembling

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 
• Press Piece - Multiple Use: VW447H 
• Inductive Heater: VAS6414 
• Puller - Transmission Gears: T10309A 
• Extracting Tool: T40413/12 

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

Disassembling

Remove the Sensor Wheel 1 for the Input Shaft 2

Fig 1: 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: T10309A/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 2: 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 3: 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: VAS6414  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 4: Synchronizer Hub -1-, Pressing On

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4 -

Press Piece - 60mm: VW415A 

-- Lift the 6th gear assembly -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: VAS6414  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 5: 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: VAS6414  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 6: 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 Parts Information.

The following circlips are available:

Press on the Sensor Ring 1

Fig 7: Press on the Sensor Ring -1-

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2 -

Extracting Tool: T40413/12 

3 -

Press Plate: VW402 

• Installation position: the high collar -arrow- of the sensor wheel points to the Press Piece - 60mm: VW415A  .

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