Input Shaft

WARNING: This page is about a different car, the 2014 Volkswagen Tiguan, 2013 Volkswagen Tiguan, and 2012 Volkswagen Tiguan. However, it is still accessible from the selected car via links, so may be relevant.

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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