Input Shaft

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
Punch VW 408 A
Thrust Disc VW 412
Thrust Tube VW 454
Thrust Tube VW 455
Sleeve VW 519
Press Tube 2040
Pressure Washer 3074
Kukko Extractor 37-46 mm 21/5
Kukko Puller 65-160 mm 18/1
Kukko Separating Tool 22-75 mm 17/1
Kukko Separating Tool 22-115 mm 17/2
Kukko Support 22/2
Feeler Gauge

Fig 1: Remove the Seal and Remove the Roller Bearing from the Clutch Housing.

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A - Support, for example 22/2

B - Extractor 37-46 mm, for example 21/5

Fig 2: Pressing Cylindrical Roller Bearing into Clutch Housing

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-- Install the roller bearing seal.

Fig 3: Remove the Roller Bearing Inner Race -D-.

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-- Clamp the input shaft in a vise. Use jaw protectors -C-.

A - Puller, for example 18/1

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

NOTE:

The roller bearing inner race can also be removed with the 4th gear. Refer to Fig 4.

Fig 4: Removing 4th Gear Wheel

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4th gear installed position: the high inner collar -arrow- faces the pressing tool.

Fig 5: Installing 4th Gear Wheel

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Fig 6: Removing Roller Bearing Inner Race -A-

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-- Install the locking ring.

Fig 7: Remove the Seal and Remove the Grooved Ball Bearing with the 6th Gear Wheel.

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

-- Remove the locking ring.

Fig 8: Remove the 5th and 6th Gear Synchronizer Hub/Locking Collar with the 5th Gear Wheel.

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Fig 9: Checking 4Th Gear Synchronizer Ring For Wear

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-A- = Brass Synchronizer Ring
Gap dimension -a-	Installed dimension	Wear limit
5th and 6th gear	1.0 to 1.7 mm	0.5 mm

-B- = Steel Synchronizer Ring
Gap dimension -a-	Installed dimension	Wear limit
5th and 6th gear	1.3 to 2.4 mm	0.8 mm

-- Press synchronizer ring onto taper of the gear and measure gap dimension -a- using a feeler gauge.

Fig 10: Checking 4Th Gear Synchro-Ring For Wear

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Fig 11: Disassembling And Assembling 1St And 2Nd As Well As 3Rd And 4Th Gear Locking Collar And Synchro-Hub

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Spring
Locking piece
Locking collar
Synchronizer hub

-- Slide the locking collar over the synchronizer hub.

The notches for the locking pieces on the synchronizer hub and locking collar must line up with each other.

Fig 12: Assembling 1St And 2Nd As Well As 3Rd And 4Th Gear Locking Collar/Synchro-Hub

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The locking collar is pushed over the synchronizer hub.

-- Install the locking pieces and springs offset by 120°. The angled end of the spring must engage into the hollow locking piece.

Fig 13: Identifying Installation Position 3rd And 4th Gear Locking Collar/Synchro-Hub

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The high inner collar of the synchronizer hub -arrow- points to 5th gear.

-- Install the needle bearing.

-- Install the 5th gear, the waved washer and the synchronizer ring.

Fig 14: Pressing On Locking Collar/Synchronizer Hub For 5Th And 6Th Gears

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-- Install the locking ring.

-- Install the needle bearing.

-- Install the 6th gear, the waved washer and the synchronizer ring.

Grooved ball bearing installed position: the groove for the seal points upward -arrow A- and the shoulder -arrow B- must point to the 6th gear.

Fig 15: Installing Grooved Ball Bearing

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