Input Shaft
Input Shaft
Special tools, testers and auxiliary items required
• Thrust plate (VW 401)
• Thrust plate (VW 402)
• Punch (VW 412)
• Tube (VW 415 A)
• Seal driver-front wheel bearing (30 - 100)
• Driving sleeve (32 - 109)
• Seal driver-front wheel bearing (40 - 21)
• Tube (2040)
• Guide sleeve (3039)
• Tube for wheel bearing (3345)
• Thrust plate (T10084 A)
• Feeler gauge
• Clamp (T10306)
• Wrench (T10307)
Disassembling
- With input shaft removed, you must first remove circlip => [ (Item 5) Circlip ] and washer => [ (Item 6) Washer ] in front of twelve-point nut.
- Place key (T10307) on twelve point nut.
- For the following step, the input shaft must be inserted in the clamp (T10306) with clutch plate splines and clamped into a vise.
A Torque wrench
• Due to the input shaft's center of gravity, it must be supported, e.g. by a second technician.
• The twelve point nut has left hand threads and it must be turned clockwise to loosen.
- Remove twelve point nut in direction of - arrow -.
- Then remove 4th gear selector gear with needle bearing and synchronizer ring.
- Press of 3rd, 5th and 6th gear selector gears together with synchronizer hub and inner races/needle bearings.
• Pressing force may be up to 200 kN (20 t).
- Place bearing bracket - A - over roller bearing on input shaft so that the rollers are not pressed out of the bearing cage.
- Press roller bearing off input shaft.
- Clean twelve-point nut threads on input shaft from locking compound residue.
Assembling
• Clean thread on input shaft.
• Lubricate all needle bearings and synchronizer rings with transmission fluid before inserting.
• Before pressing needle bearing inner races off, warm to a maximum of 130 °C while wearing protective gloves.
• Warm synchronizer ring before pressing off to a maximum of 100 °C while wearing protective gloves.
• Always press roller bearing, needle bearing inner races and synchronizer body to stop so that selector gears have the recommended axial clearance.
Synchronizer rings for 3rd to 6th gears, checking for wear
- Check inner race on outer friction surface arrow for scoring or signs of wear, replace if necessary.
- Check synchronizer ring on inner friction surface arrow for scoring or signs of wear, replace if necessary.
- Place inner race, intermediate ring and synchronizer ring on selector gear taper and screw in.
• Screw in means: Turn synchronizer ring approximately one turn while pressing on the ring at the same time.
- Then measure gap - a - with a feeler gauge.
• Replace inner race, intermediate ring and synchronizer ring for the respective gear together.
Installation location of synchronizer rings for 3rd to 6th gears
• If the components are not to be replaced, make sure they are reallocated to their original gear.
- Place inner race - 2 - on sliding gear - 1 -.
- Install intermediate ring - 3 -. Tab - B - must be inserted into recess - A -.
- Insert synchronizer ring - 4 -. Guide tabs - C - through recess - arrow -.
- Press roller bearing onto input shaft to stop, shoulder of tube (VW 415 A) faces toward roller bearing when doing so.
- Insert 5th gear selector gear together with needle bearing and synchronizer ring.
With an input shaft with additional PTFE washer, you must now insert PTFE washer.
Assembly of locking collar/synchronizer hub for 5th and 6th gear
- Slide locking collar - 1 - over synchronizer hub - 2 -.
• Groove - arrow A - on locking collar and high inner shoulder - arrow B - on synchronizer hub must face toward 5th gear selector gear.
• Recesses - arrow C - for thrust pieces - 3 - in synchronizer hub and notches - arrow D - in locking collar must align.
- Then place thrust pieces - 3 - in synchronizer hub and press thrust pieces into notches in locking collar.
Pressing on synchronizer hub with locking collar for 5th and 6th gears
Note the follow when performing the next steps:
• Synchronizer hub installation location: High inner collar faces 5th gear, gear wheel
- Place input shaft in hole in pressure plate ( VW 401).
- Place pressing tool in center of warmed components (synchronizer hub and needle bearing inner races).
- After pressing briefly on components, stop and align pressing tool again at center and press to stop.
• On an input shaft with PTFE washer, washer must be inserted before pressing 5th/6th gear synchronizer hub.
• When pressing, synchronizer ring tabs - arrow 1 - and notches - arrow 2 - on synchronizer hub must align.
Inner race/needle bearing - arrow A - for 6th gear selector gear, pressing on
- Remove 6th gear selector gear - A - together with needle bearing and synchronizer rings.
- Place 3rd and 6th gear selector gears thrust washer - B - on 6th gear selector gear.
Inner race/needle bearing - arrow A - for 3rd gear selector gear, pressing on
- Remove 3rd gear selector gear together with needle bearing and synchronizer ring.
3rd/4th gear synchronizer hub installation location
• Synchronizer hub shoulder - arrow - must face toward 3rd gear selector gear.
Pressing on synchronizer hub for 3rd and 4th gears
• Note installation location of synchronizer hub, refer to => [ 3rd/4th gear synchronizer hub installation location ]
• When pressing on, synchronizer ring tabs and synchronizer hub recesses must align.
3rd/4th gear locking collar installation location
• Groove - arrow - on locking collar must face toward 3rd gear selector gear.
Assembly of locking collar/synchronizer hub for 3rd and 4th gear
• 3rd and 4th gear synchronizer hub is pressed on.
- Coat 3 locking pieces - A - with some grease on convex side - arrow 1 -.
- Insert 3 locking pieces with convex side in recesses in locking collar - B -.
• Note locking collar installation location, refer to => [ 3rd/4th gear locking collar installation location ]
- Then place locking collar over synchronizer hub - C - so that the synchronizer hub recesses - arrow 2 - align with locking pieces.
- Then place thrust pieces - D - in synchronizer hub and press them in direction of - arrow 3 - into recesses in locking collar. When doing so, locking collar must be held in middle position.
Inner race/needle bearing for 4th gear selector gear, pressing on
- Remove 4th gear selector gear together with needle bearing and synchronizer ring.
- Clean threads of twelve point nut that was removed.
- Hand-tighten twelve point nut on input shaft.
- Place key (T10307) on twelve point nut.
- For the following step, the input shaft must be inserted in clamp (T10306) with clutch plate splines and clamped into a vise.
• Due to the input shaft's center of gravity, it must be supported, e.g. by a second technician.
• Twelve point nut has left hand threads and so must be turned counterclockwise to tighten.
A Torque wrench
- Tighten twelve point nut in direction of - arrow - to 75 Nm.
- Check all selector gears for ease of movement and axial play.
• Selector gear axial play must be at least 0.10 mm.
Determine thickness of circlip - 1 - and shim - 2 - as follows:
- Measure a gap of 0.10 mm max. between the shim available as a replacement part and circlips, measured between circlip and shim.
- Check gap with a feeler gauge - 3 -.
• When measuring, circlip - 1 - must be fully seated in groove.
- Determine shim and circlip according to table. For part numbers,
The following circlips are available:
The following shims are available:
- Install shim and circlip.