Input Shaft, Disassembling And Assembling

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 - Rod: VW408A
Press Piece - Multiple Use: VW412
Press Piece - Multiple Use: VW454
Press Piece - Bushing - 50mm Diameter: VW432
Bearing Installer - Multiple Use: 32-111
Inductive Heater: VAS6414
-1- Internal Puller: VAS251611 (Kukko 21-5)
-3- Splitter: VAS251411 (Kukko 17-2)
-4- Counter Support: VAS251623 (Kukko 22/2)
Feeler Gauge

Input Shaft, Disassembling

-- Remove the grooved ball bearing circlip.

Grooved Ball Bearing, Removing

Fig 1: View Of Removing the Grooved Ball Bearing

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Mount the Separating Tool -A- into the groove in the ball bearing for the locking ring.

A - Splitter: VAS251411 (Kukko 17-2)

-- The grooved ball bearing and 5th gear wheel can also be removed together. To do this, place the Separating Tool -A- as shown in the following illustration under the 5th gear wheel.

5th Gear Wheel, Removing

Fig 2: Identifying 5Th-Gear Gear Wheel

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

A - Splitter: VAS251411 (Kukko 17-2)

Input Shaft, Assembling

5th Gear Wheel, Warming and Installing

Fig 3: Identifying 5th Gear, Warm Up and Install

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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

Grooved Ball Bearing Installation Position and Installing Grooved Ball Bearing

Fig 4: View Of Grooved Ball Bearing Installation Location and Grooved Ball Bearing

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Grooved ball bearing installation position: the groove for the circlip faces upward -arrow A-. The collar -arrow B- must face the 5th gear wheel.

-- Then select the grooved ball bearing locking ring and install it on the input shaft. Refer to Fig 5.

Circlip, Determining

Fig 5: Determining Circlip

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Insert a 1.86 mm thick circlip -A- into the input shaft groove and push upward.

-- Use a feeler gauge -C- to measure between the grooved ball bearing -B- and the inserted circlip -A-.

-- Remove the circlip used for the measurement.

-- Select the appropriate circlip according to the table.

NOTE:

Allocate the correct circlips. Refer to the Parts Information.

The following circlips are available:

Measured Value (mm)	Circlip 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

Cylindrical Roller Bearing, Removing from Clutch Housing

Fig 6: Identifying Tool Assembly To Pull Off Cylindrical Roller Bearing Clutch Housing

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Use pliers -C- to press the cylindrical roller bearing circlip -arrow- together during removal.

A - Counter Support: VAS251623 (Kukko 22/2)

B - Internal Puller: VAS251611 (Kukko 21-5)

Cylindrical Roller Bearing, Installing in Clutch Housing

Fig 7: Identifying Tool Assembly To Press Cylindrical Roller Bearing Into Clutch Housing

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Use pliers -A- to press the cylindrical roller bearing circlip -arrow- together during installation.

-- Remove the pliers before the cylindrical roller bearing is in its installation position. The circlip must engage into the clutch housing groove.