Input Shaft: Notes

WARNING: This page is about a different variant/trim than selected.

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

Disassembling

-- Remove the grooved ball bearing locking ring.

Removing the Grooved Ball Bearing

Fig 1: Pulling Off Grooved Ball Bearing

Courtesy of VOLKSWAGEN UNITED STATES, INC.

-- Remove the locking ring from the input shaft beforehand.

-- Install the thrust pad 16.5/28 mm dia. VW 431 and the thrust piece 40-105 on the input shaft before installing 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 2: Pressing Off 5th-Gear Gear Wheel

Courtesy of VOLKSWAGEN UNITED STATES, INC.

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

Assembling

Installing 5th Gear

Fig 3: Pressing On 5th-Gear Gear Wheel

Courtesy of VOLKSWAGEN UNITED STATES, INC.

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

Grooved Ball Bearing Installed Position

Fig 4: Pressing On Grooved Ball Bearing

Courtesy of VOLKSWAGEN UNITED STATES, INC.

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

Installing the Grooved Ball Bearing

Fig 5: Installing the Grooved Ball Bearing

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Grooved Ball Bearing with a Rubber Ring -arrow-

The shoulder -A- faces the thrust disc VW 412.

-- Install the grooved ball bearing securing ring on the input shaft (next illustration).

Determining the Grooved Ball Bearing Locking Ring for the Input Shaft

Fig 6: Determining Circlip

Courtesy of VOLKSWAGEN UNITED STATES, INC.

-- Insert a 1.86 mm locking ring -A- into 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.

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 7: Pulling Cylindrical Roller Bearing Off Clutch Housing

Courtesy of VOLKSWAGEN UNITED STATES, 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 8: Pressing Cylindrical Roller Bearing Into Clutch Housing

Courtesy of VOLKSWAGEN UNITED STATES, 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.