Input Shaft, Disassembling and Assembling
Input shaft, disassembling and assembling
Special tools and equipment
^ VW 295 Mandrel
^ VW 295 A Adapter
^ VW 401 Pressure plate
^ VW 402 Pressure plate
^ VW 407 Press tool
^ VW 408 A Press tool
Special tools and workshop equipment required
^ VW 415 A Tubular section
^ VW 416 B Tubular section
^ VW 447 i Thrust pad
^ VW 771 Multi-purpose tool
^ 30-100 Press tube
^ 40-105 Thrust plate
Special tools and workshop equipment required
^ VW 222 A Mandrel
^ 30-24 Mandrel
^ 40-202 Pressing-out element
^ 1 - Kukko 21/4 Internal puller
^ 3 - Kukko 17/2 Separating tool
Note:
^ Observe technical data when installing new gear wheels or the input shaft
^ Replacing components -items 2, 4 and 6 influences the position of the ball bearing. In this case, input shaft must be re-adjusted.
1 - Circlip
^ Mark
^ Installation position - item 1
^ Determining thickness go to Adjusting input shaft
2 - Ball bearing
^ Removing and installing
3 - Circlip
^ Mark
^ Installation position - item 2
^ Determining thickness go to Adjusting input shaft
4 - Transmission housing
5 - Needle bearing
^ Secured with bolt
^ Extracting
^ Installation position
^ Pressing in
6 - Input shaft
^ With oiling sleeve
^ Driving in oiling sleeve
^ Adjusting
7 - Needle bearing for 3rd gear
8 - Sliding gear for 3rd gear
9 - Spring
^ Inserting in 3rd gear sliding gear
^ Assignment to sliding gear
go to Parts catalog
10 - 3rd gear synchro-ring
^ Checking for wear
11 - Circlip
^ Mark
^ Installation position- item 3
12 - 3rd and 4th gear synchro-hub
^ High collar faces 3rd gear
^ Pressing off Fig. 11
^ Pressing on Fig. 1
13 - Circlip
^ Mark
^ Installation position - item 4
^ Re-determine when replacing synchro-hub
14 - 3rd and 4th gear locking collar
^ Installation position
15 - 4th gear synchro-ring
^ Checking for wear
16 - Spring
^ Inserting in 4th gear sliding gear
^ Assignment to sliding gear
go to Parts catalog
17 - 4th gear sliding gear
18 - 4th gear needle bearing
19 - 5th gear wheel Pressing off Pressing on
20 - Circlip
^ Mark
^ Installation position - item 5
^ Re-determine when replacing 5th gear wheel
21 - Roller sleeve
^ Replace
^ Gets damaged on removal
^ Extracting
^ Installation position
^ Driving in
22 - Sleeve
^ Plastic
23 - Transmission cover
Fig. 1 Locking bolt for needle bearing - Unscrew locking bolt -arrow-.:
Note: Bolt is not always installed.
Fig. 2 Extracting needle bearing:
Fig. 3 Installation position of needle bearing:
Dimension -a- from bottom edge of rule to top edge of needle bearing = 39.5 mm
Note: Measure from top edge of rule and subtract height of rule from measured value.
Fig. 4 Pressing in needle bearing:
Fig. 5 Locking bolt for needle bearing:
- If installed, screw in locking bolt and tighten to 25 Nm.
Fig. 6 Driving oiling sleeve into input shaft:
^ Installation position:
Flared edge of oiling sleeve faces driving-in tool
^ Drive-in depth:
3.5 mm below top edge
Fig. 7 Extracting roller sleeve:
A - Internal puller 22 to 28 mm, e.g. Kukko 21/4
- Before installing internal puller, destroy plastic bushing inside roller sleeve.
Fig. 8 Installation position of roller sleeve:
^ Dimension a = 216 mm
Fig. 9 Driving in roller sleeve:
Fig. 10 Pressing out 5th gear wheel:
- Remove circlip before pressing out.
A - Separating tool 22 to 115 mm, e.g. Kukko 17/2
Fig.11 Pressing out 3rd and 4th gear synchro-hub:
- Remove circlip before pressing out.
- Push 3rd gear synchro-ring (arrow) toward sliding gear for 3rd gear, then install separating tool -A-.
A - Separating tool 22 to 115 mm, e.g. Kukko 17/2
Fig. 12 Inserting spring into sliding gear:
Bent end of spring (arrow) must be hooked into hole of sliding gear.
Fig. 13 Checking synchro-ring for wear:
- Push synchro-ring into locking collar and use feeler gauge to measure gap -a- at positions -A-, -B- and -C,
- Add up measured values and divide by 3.
Obtained value must not be lower than 0.5 mm.
Fig. 14 Installation position of circlips:
^ Circlips -1- and -2- secure ball bearing of input shaft.
Determining thickness go to Adjusting input shaft.
^ Circlip -3- secures synchro-hub for 3rd and 4th gear.
Thickness 2.00 mm. Identifiable by: Color brown.
^ Circlip -4- secures synchro-hub for 3rd and 4th gear.
Determining thickness go to Chart.
Identifiable by: Color blue.
^ Circlip -5- secures 5th gear wheel.
Determining thickness go to Chart.
Fig. 15 Determining circlip:
- Determine and install thickest circlip which can still just about be inserted.
- Determine circlip as accurately as possible using chart. Part numbers
go to Parts catalog
Available circlips for 3rd and 4th gear synchro-hub
Available circlips for 5th gear wheel
Fig. 16 Pressing on 3rd and 4th gear synchro-hub:
^ Installation position:
High collar on inside faces 3rd gear
Fig. 17 Installation position of locking collar:
Locking collars with chamfer -A- and locking collars with high shoulder -13are used for assembly.
^ Installation position:
Chamfer -arrow 1 - faces 4th gear
Low shoulder -arrow 2- faces 3rd gear
High shoulder -arrow 3- faces 4th gear
Fig. 18 Pressing on 5th gear wheel:
WARNING: Wear protective gloves.
- Heat 5th gear wheel to approximately 100°C before pressing on.
^ Installation position:
High collar faces reverse gear