Input Shaft: Notes
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Special tools and workshop equipment required
- PunchVW 407
- Thrust PadVW 447 H
- Thrust DiscVW 412
- Tube SplitVW 422
- Thrust PlateVW 401
- Thrust PlateVW 402
- PunchVW 408 A
- Tube 28 mm Dia 100 mmVW 421
- Thrust TubeVW 454
- Thrust PadVW 447 i
- Thrust PadVW 510
- Mounting Universal Joint41-501
- Kukko Separating Tool 12-75 mm17/1
- Inductive HeaterVAS 6414
NOTE:
The input shaft must be adjusted because the position of the tapered roller bearing is affected when parts are replaced. Pay attention to the adjustment overview, refer to ADJUSTMENT OVERVIEW .
Replace both tapered roller bearings together.
Wearing safety gloves, warm the bearing inner races, the gears and the synchronizer hubs to approximately 100 °C (212 °F) using the VAS 6414 before installing them.
- Clutch Housing
- Outer Race/Tapered Roller Bearing
- Removing, refer to Removing the Outer Race/Tapered Roller Bearing .
- Installing, refer to Installing the Outer Race/Tapered Roller Bearing .
- Bearing Inner Race/Taper Roller Bearing
- Removing, refer to Removing the Bearing Inner Race/Taper Roller Bearing .
- Installing, refer to Installing the Bearing Inner Race/Taper Roller Bearing .
- Input Shaft
- Adjusting, refer to INPUT SHAFT, ADJUSTING .
- 3rd Gear
- Installed position: The shoulder faces 4th gear.
- Removing, refer to Removing the 3rd Gear .
- Installing, refer to Installing 3rd Gear .
- Lock Ring
- Always replace.
- 4th Gear
- Remove with the bearing inner race/tapered roller bearing and sleeve, refer to Removing the 4th Gear with the Tapered Roller Bearing and Sleeve .
- Installing, refer to Removing the 4th Gear with the Tapered Roller Bearing and Sleeve .
- The shoulder faces 3rd gear.
- Bearing Inner Race/Taper Roller Bearing
- Remove with 4th gear and sleeve, refer to Removing the 4th Gear with the Tapered Roller Bearing and Sleeve .
- Installing, refer to Installing the Bearing Inner Race/Taper Roller Bearing .
- Thrust Washer
- Outer Race/Tapered Roller Bearing
- Removing, refer to Removing the Outer Race/Tapered Roller Bearing .
- Installing, refer to Installing the Outer Race/Tapered Roller Bearing .
- Adjusting Shim
- Determining thickness, refer to INPUT SHAFT, ADJUSTING .
- Transmission Housing
- Sleeve
- For the needle bearing.
- Pressing off with 4th gear drive gear and tapered roller bearing inner race, refer to Removing the 4th Gear with the Tapered Roller Bearing and Sleeve .
- Installing, refer to Pressing on Sleeve for 5th Gear Needle Bearing .
- Mount before installing the thrust washer -item 9-.
- Needle Bearing
- For 5th gear.
- 5th Gear
- 5th Gear Synchronizer Ring
- With cast locking pieces, refer to 5TH GEAR, INSTALLING => 5th Gear Synchronizer Ring with Cast Locking Pieces .
- Checking for wear, refer to 5TH GEAR, INSTALLING => 5th Gear Synchronizer Ring, Checking .
- Spring
- Installed position, refer to Assembling 5th Gear Locking Collar/Synchronizer Hub .
- Offset springs are used as of transmission build date 05 November 2001. Refer to Installation of Offset Springs -A- .
- Locking Pieces
- Quantity: 3
- Installed position, refer to 5th Gear Synchronizer .
- 5th Gear Synchronizer Hub
- Removing individually, refer to TRANSMISSION HOUSING COVER AND 5TH GEAR .
- Remove with the transmission housing. Refer to TRANSMISSION .
- 5th Gear Locking Collar
- Remove with the 5th gear synchronizer hub -item 19-.
- Plate Spring
- Installed position, refer to 5TH GEAR, INSTALLING => Installed Position of Plate Springs for 5th Gear Synchronizer Hub and Drive Gear Bolts .
- Bolt
- See -item 4- TRANSMISSION HOUSING AND 5TH GEAR COVER => Bolt .
- Always replace.
- Holds in position with the adapter on the plate spring bolt head, refer to 5TH GEAR, INSTALLING => Installed Position of Plate Springs for 5th Gear Synchronizer Hub and Drive Gear Bolts .