Input Shaft Overview: Notes

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Special tools and workshop equipment required

Thrust Plate VW 401
Thrust Plate VW 402
Punch VW 407
Thrust Disc VW 412
Thrust Pad 16.5/28 mm Dia.VW 431
Arbor 50 mm Dia. VW 432
Thrust Tube VW 454
Locking Pin 30-505
Thrust Piece 40-105
Press Tube 2040
Kukko Extractor 30-37 mm 21/5
Kukko Puller 65-160 mm 18/1
Kukko Separating Tool 12-75 mm 17/1
Kukko Separating Tool 22-115 mm 17/2
Kukko Support 22/2
Inductive Heat Unit VAS 6414
Feeler Gauge

NOTE:

Install all input shaft bearings using transmission fluid.

Always replace the grooved ball bearing, in item "Grooved Ball Bearing" in item 6.

Fig 1: Identifying Input Shaft, Disassembling And Assembling Overview

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Locking Ring
- For the grooved ball bearing/input shaft, refer to "Grooved Ball Bearing" in item 6.
- Removing and installing, refer to TRANSMISSION, WITHOUT A SEALING CAP CIRCLIP .
Washer
- Outer circumference = 78.6 mm.
- Only insert with the changed transmission housing (from transmission production date 10 April 2006 through approximately 20 January 2008). Refer to GROOVED BALL BEARING CHANGES .
Transmission Housing
- Adapted in the grooved ball bearing seat area and from transmission build date 10 April 2006 through approximately 20 January 2008. Refer to "Grooved Ball Bearing" in item 6, "Washer" in item 2, "Washer" in item 4 and GROOVED BALL BEARING CHANGES .
- Flattened areas on grooved ball bearing and bearing seat approximately from transmission build date 21 January 2008. Refer to GROOVED BALL BEARING CHANGES .
Washer
- Outer circumference = 85 mm.
- Only insert with the changed transmission housing (from transmission production date 10 April 2006 through approximately 20 January 2008). Refer to GROOVED BALL BEARING CHANGES .
Lock Ring
- Select when replacing the grooved ball bearing and the input shaft. Refer to "Grooved Ball Bearing" in item 6, "Input Shaft" in item 8 and see Fig 7.
Grooved Ball Bearing
- Always replace.
- Removing, refer to Fig 2.
- Installed position, refer to Fig 5.
- Installing, refer to Fig 6.
- Flattened areas on grooved ball bearing and bearing seat approximately from transmission build date 21 January 2008. Refer to Figure.
5th Gear
- Available as a replacement part together with the input shaft.
- Removing, refer to Fig 3.
- Installed position: the surrounding groove -arrow- points toward the grooved ball bearing, refer to "Grooved Ball Bearing" in item 6.
- Installing, refer to Fig 4.
Input Shaft
- With the 3rd/4th and 6th gear.
Cylindrical Roller Bearing
- With locking ring.
- Removing, refer to Fig 8.
- Installing, refer to Fig 9.
- Installed position: the circlip in the bearing points to input shaft.
Clutch Housing

Disassembly

-- Remove the grooved ball bearing locking ring.

Fig 2: Identifying Kukko Tool Assembly To Pull Off Grooved Ball Bearing

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Mount the thrust pad 16.5/28 mm dia. VW 431 and the thrust piece40-105 on the input shaft before mounting the puller.

-- Position the separating tool -B- in the surrounding groove inside the bearing for the locking ring.

A - Puller, for example, kukko puller 65-160 mm 18/1

B - Separating tool 12 to 75 mm, for example, kukko separating tool 12-75 mm 17/1

Fig 3: Identifying Kukko Separating Tool To Press Off 5th-Gear Gear Wheel

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

A - Separating tool 22 to 115 mm, for example, kukko separating tool 22-115 mm 17/2

Assembly

Fig 4: Identifying Tool Assembly To Press On 5th-Gear Gear Wheel

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

The groove -arrow- on the gear must face up.

Fig 5: Identifying Tool Assembly To Press On Grooved Ball Bearing

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

The groove for the locking ring faces up -arrow A- and the collar -arrow B- must face the 5th gear.

Fig 6: Identifying Tool Assembly To Install Grooved Ball Bearing

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Grooved Ball Bearing with a Rubber Ring -arrow-

The shoulder -A- on the thrust tube VW 454 faces the thrust disc VW 412.

-- Select the grooved ball bearing locking ring and install it on the input shaft. Refer to Fig 7.

Fig 7: Identifying Tool To Install Grooved Ball Bearing Securing Ring

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Insert a 1.86 mm locking ring -A- into the groove in the input shaft and press it upward.

-- Measure the gap between the grooved ball bearing -B- and the installed locking ring -A- with a feeler gauge -C-.

-- Remove the locking ring used for the measurement.

-- Select the locking ring according to the table.

NOTE: The following locking rings are available:

Measured Value (mm)	Locking Ring Thickness (mm)	Axial Play (mm)
0.01 ••• 0.05	1.86	0.01 ••• 0.05
0.05 ••• 0.07	1.89	0.01 ••• 0.05
0.07 ••• 0.10	1.92	0.01 ••• 0.05
0.10 ••• 0.13	1.95	0.01 ••• 0.05
0.13 ••• 0.16	1.98	0.01 ••• 0.05

Fig 8: Identifying Tool Assembly To Pull Off Cylindrical Roller Bearing Clutch Housing

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Compress the cylindrical roller bearing locking ring -arrow- with pliers -C- and remove it.

A - Counter-support, for example, kukko support 22/2

B - Internal puller 30 to 37 mm, for example, kukko extractor 30-37 mm 21/5

Fig 9: Identifying Tool Assembly To Press Cylindrical Roller Bearing Into Clutch Housing

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Compress the cylindrical roller bearing locking ring -arrow- with pliers -C- and install it.

-- Remove the pliers before the cylindrical roller bearing gets into its installed position. The locking ring must lock into the groove on the clutch housing.