Input Shaft

Input Shaft

Special tools, testers and auxiliary items required

• Punch (VW 407)

• Thrust Pad (VW 447 H)

• Thrust Disc (VW 412)

• Tube Split (VW 422)

• Thrust Plate (VW 401)

• Punch (VW 408 A)

• Tube 28 mm Dia. 100 mm (VW 421)

• Thrust Pad (VW 447 i)

• Thrust Tube (VW 454)

• Thrust Pad (VW 510)

• Mounting Universal Joint (41-501)

• Kukko Separating Tool 12-75 mm (17/1)

• Thrust Plate (VW 402)

• Inductive Heat Unit (VAS 6414)

Removing the Outer Race/Tapered Roller Bearing





Installing the Outer Race/Tapered Roller Bearing





Removing the Bearing Inner Race/Taper Roller Bearing





A Separating device 12 to 75 mm Kukko separating tool 12-75 mm (17/1)

Installing the Bearing Inner Race/Taper Roller Bearing





Removing the 4th Gear with the Tapered Roller Bearing and Sleeve





Removing the 3rd Gear





- Remove the lock ring first.

Heat the 3rd Gear and Install It





Wear safety gloves.

Installed position: The shoulder faces 4th gear.

Heat the 4th Gear and Install It





Wear safety gloves.

Installed position: The shoulder faces 3rd gear.

Installing the Bearing Inner Race/Tapered Roller Bearing





Pressing on the Sleeve for the 5th Gear Needle Bearing





Removing the Outer Race/Tapered Roller Bearing





Installing the Outer Race/Tapered Roller Bearing





- Install with a shim after adjusting the input shaft.

5th Gear Synchronizer





1. Springs for the locking pieces

2. Locking collar with 3 notches - arrow A - for the locking pieces - 4 -

3. Synchronizer hub

4. Locking piece installed position: The brace - arrow B - faces toward the pointed teeth of the locking collar- 2 -


Assembling the 5th Gear Locking Collar/Synchronizer Hub





- Slide the locking collar over the synchronizer hub.

The pointed teeth - A - and the shoulder - B - on the synchronizer hub face in the same direction. Recesses for locking pieces in locking collar and synchronizer hub must line up (refer to => [ 5th Gear Synchronizer ] ).

- Insert locking pieces (Location: refer to => [ 5th Gear Synchronizer ] ).

- Install the springs offset by 120° under the tabs - C -. The angled end of the spring must be positioned in front of the locking pieces - arrows -.

• Note the location of the springs when using locking pieces with hollow interiors. Refer to => [ Installation of Offset Springs ].

Installation of Offset Springs





These springs - A - are installed on both sides.

- Springs are only installed in conjunction with hollow locking pieces.

- Insert locking pieces (Location: refer to => [ 5th Gear Synchronizer ] ).

Spring installed position:






- Install the spring offset by 120°.

- Angled end - A - of spring must engage into the hollow locking piece.

It must be located below the tab - B - of the locking pieces.

The offset end always faces away from the synchronizer hub in the - direction of the arrow -.