Input Shaft

WARNING: This page is about a different car, the 2016 Volkswagen Beetle, 2015 Volkswagen Beetle, 2014 Volkswagen Beetle, and 2013 Volkswagen Beetle. 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
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
Inductive Heat Unit VAS 6414
Feeler Gauge

Disassembly

-- Remove the grooved ball bearing locking ring.

Fig 1: Identifying Grooved Ball Bearing

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Mount the thrust pad 16.5/28 mm dia. VW 431 and the thrust piece 40-105 on the input shaft before installing the puller.

-- Mount the separating tool -B- into the groove in 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: Identifying 5th-Gear Gear Wheel

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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

Assembly

Fig 3: Identifying 5th-Gear Gear Wheel

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

Fig 4: Identifying Grooved Ball Bearing

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

Fig 5: Identifying Tool Assembly To Install Grooved Ball Bearing

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Grooved ball bearing with a rubber ring -arrow-

The shoulder -A- on the thrust tube VW 454 faces the thrust disc VW 412.

-- Select the grooved ball bearing locking ring and install it on the input shaft. Refer to Fig 6.

Fig 6: Determining Circlip

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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

NOTE:

Use the correct locking rings.

The Following Locking Rings Are Available:

Measured Value (mm)	Locking Ring Thickness (mm)	Axial Play (mm)
0.01 to 0.05	1.86	0.01 to 0.05
0.05 to 0.07	1.89	0.01 to 0.05
0.07 to 0.10	1.92	0.01 to 0.05
0.10 to 0.13	1.95	0.01 to 0.05
0.13 to 0.16	1.98	0.01 to 0.05

Fig 7: Identifying Tool Assembly To Pull Off Cylindrical Roller Bearing Clutch Housing

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-- 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: Identifying Tool Assembly To Press Cylindrical Roller Bearing Into Clutch Housing

Courtesy of VOLKSWAGEN GROUP OF AMERICA, 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.