Input gear, removing and installing: Notes

WARNING: This page does not describe the selected car, but rather 20 other vehicles, including the 2007 Volkswagen Golf, 2006 Volkswagen Golf, 2005 Volkswagen Jetta, 2005 Volkswagen Golf, and 2004 Volkswagen Jetta. However, it is still accessible from the selected car via links, so may be relevant.

Special tools and equipment required

Fig 1: Identifying Special Tools - Input Gear, Removing And Installing (1 Of 2)

Courtesy of VOLKSWAGEN UNITED STATES, INC.

VW 402 Thrust plate
VW 407 Press tool
VW 771 Multi-purpose tool
30-205 Thrust plate

40-21 Press tool

Fig 2: Identifying Special Tools - Input Gear, Removing And Installing (2 Of 2)

Courtesy of VOLKSWAGEN UNITED STATES, INC.

40-105 Thrust plate
V.A.G 1582 Tapered roller bearing puller
V.A.G 1582/3 Grip
V.A.G 1576 Torque wrench

NOTE: For transmissions produced from 04.98, the tool for removing the tapered roller bearings in the final drive and differential is VAG 1582/8

NOTE: Drive pinion and differential do not need to be removed.

Fig 3: Exploded View Of Input Gear Components

Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Socket head fastener

250 Nm
Engage parking lock to remove and install
Use 22 mm wrench socket
Before installing socket head fastener insert axial needle bearing (item -7 )

2 - Dished washer

Curved side faces socket head fastener

3 - Shim

Determining thickness. Refer to Adjusting input gear, Input gear, adjusting

4 - Tapered roller bearing inner race

After measuring thickness of shim, fit onto input gear with locking fluid AMV 185 101 A1. See Inserting tapered roller bearing inner race

5 - Tapered roller bearing outer race

Drive out with drift
Drive in with 30-205
Insert with locking fluid AMV 185 101 A1

6 - Transmission housing

7 - Axial needle bearing

Install with flat side facing input gear
Insert into input gear before installing socket head fastener (item -1 )

8 - Tapered roller bearing outer race

Drive out with drift
Drive in with 30-205 and appropriately long drift
Insert with locking fluid AMV 185 101 A1

9 - Tapered roller bearing inner race

Pulling off. See Pulling off tapered roller bearing inner race
Pressing on. See Pressing on tapered roller bearing inner race
Insert with locking fluid AMV 185 101 A1. See Inserting tapered roller bearing inner race

10 - Input gear

With impulse wheel for Vehicle speed sensor -G68-
Number of teeth. Refer to Code letters, application, ratios, equipment
Adjusting. Refer to Input gear, adjusting
If signs of damage exist, always replace input gear and output gear together

Removing. See Removing input gear
If input gear is replaced, adjust planet carrier. Refer to Planet carrier, adjustments .