Input Shaft, Disassembling And Assembling: Notes

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

Special Tools And Workshop Equipment Required

Press Plate :VW401
Press Plate :VW402
Press Piece - Rod :VW407
Press Piece - Multiple Use :VW412
Press Piece - 60mm :VW415A
Press Piece - Shift Rod/Alternator :VW422
Press Piece - Multiple Use - Spacing Sleeve :VW472/2
Press Piece - 42mm :VW516
Press Piece - Multiple Use :30-23
Press Piece - Press Tube :30-100
Press Piece :T10080
Press Piece :T10081
Circlip Pliers :VW161A
Press Piece - Trailing arm :2010
Press Piece - Block :T10083
Press Piece - Block - Washer :T10083/1
Bearing Installer - Bearing Press Plate :T10084A
-1- Puller - Kukko Internal - 28-37mm :Kukko 21/5
-4- Puller - Kukko Counterstay :Kukko 22/1
:Feeler Gauge
Inductive Heater :VAS6414

CAUTION:

This procedure contains mandatory replaceable parts. Refer to component overview(s) prior to starting procedure. See OVERVIEW - INPUT SHAFT

Fig 1: Remove The Roller Bearing From The 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 :22/1

B - Internal Puller 30 to 37 mm, for example, Puller - Kukko Internal - 28-37mm :21/5

Fig 2: Pressing Cylindrical Roller Bearing Into Clutch Housing

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Support the clutch housing with the :VW415A (not illustrated) directly below bearing mount.

-- Compress the cylindrical roller bearing locking ring -arrow- with pliers -A- 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.

Fig 3: Remove The Bearing Mount & Grooved Ball Bearing

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Slide the locking collar for 1st and 2nd gear to 2nd gear.

-- Slide the :T10084A sideways all the way into input shaft.

-- Insert the centering pins in :T10081 into holes in input and output shaft.

Fig 4: Removing Bearing Inner Race For Cylindrical Roller Bearing

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the locking using the :VW161A .

-- Remove the cylindrical roller bearing inner race together with the: thrust washer, 4th gear wheel with needle bearing, 3rd and 4th gear locking collar/synchronizer hub and 3rd gear wheel.