Input shaft disassembling and assembling
All parts should be installed dry.
— Mount shaft in vise using special tool P 355 a.
— Follow steps in illustration on following page.
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Transmission input shaft components
1. Collar nut removal: Use special tool P 252 a (41 mm socket) or equivalent.
• Lock by punching collar. See detail A.
2. Roller bearing removal: Press off with special tools VW 401, VW 402, VW 412. When pressing, support under 2nd gear (17).
• Press on with special tools VW 401, VW 454 (press sleeve), VW 407
3. Ball bearing inner race removal: Keep with bearing and other race (6) as matched set.
• Installation: Heat to approx. 120°C (250°F), then press on.
4. Ball bearing
5. Ball bearing flange
6. Ball bearing inner race: same as 3
7. Thrust washer
8. 4th gear: Check synchronizer as described later.
• Installation: If necessary, replace matched gears in pairs only.
9. Needle bearing: Keep with gear and race.
10. Needle bearing race: Keep with gear and bearing. 11.3rd - 4th gear operating sleeve: Check for wear. See detail B.
12. Operating sleeve hub: Check for wear.
13.3rd gear: Check synchronizer as described later.
• Installation: If necessary, replace matched gears in pairs only.
14. Needle bearing: Keep with gear and race.
15. Needle bearing race: Keep with gear and bearing.
16. Thrust washer
17.2nd gear: Replace matched gears in pairs only.
• Installation: Manufacturer's marks face 1 st gear. See de tail C. 18. Spacer
19.1 st gear (integral with shaft)
20. Input shaft
21. Roller bearing removal: Press off with special tool VW 407 and suitable pipe.
• Press on with special tool VW 407 and suitable pipe.
— Always check drive shaft runout after tightening collar nut.
• Remove outer bearing races from transmission case and install them on input shaft.
• Place drive shaft bearings on machinist V-blocks.
• Set dial indicator to measure runout at pilot bearing end of shaft.
Input Shaft Runout
• Maximum runout at pilot bearing end . 0.1 mm (0.004 in.)
A shaft with up to 0.3 mm (0.012 in.) runout can be straightened out cold.
Details
A Stake collar nut to input shaft.
B Check clearance between shift fork and operating sleeve.
Shift Fork Clearance Specification
• Shift fork to operating sleeve.....max 0.5 mm (0.02 in.)
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C Install 2nd gear with manufacturer's marks facing 1st gear.
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1. Roller bearing removal: Use special tools VW 401, VW 412, P 255 a (press sleeve). Press off by supporting under pinion end roller bearing (19).
• Press on with special tools VW 401, VW 412, VW 244 b (installing drift).
2. Thrust washer
3. 1st gear: Check synchronizer as described later.
• Installation: First gear is matched to input shaft. If necessary, both must be replaced together.
4. Needle bearing: Keep with gear and race.
5. Needle bearing race: Keep with gear and bearing.
6. 1 st - 2nd gear operating sleeve: Check for wear. See detail A.
• Installation: Asymmetric teeth and recess face 1 st gear. See detail B.
7. Operating sleeve hub: Check for wear.
8. 2nd gear: Check synchronizer as described later.
• Installation: If necessary, replace matched gears in pairs only.
9. Needle bearing: Keep with gear and race.
10. Needle bearing race: Keep with gear and bearing.
11. Thrust washer
12. 3rd gear installation: Replace matched gears in pairs only.
• Raised collar faces thrust washer. See detail C.
13. Spacer
14.4th gear: Replace matched gears in pairs only.
• Raised collar faces thrust bearing. See detail D.
15. Ball bearing flange
16. Ball bearing inner race removal: Keep with bearing and other race (18) as matched set.
• Installation: Heat to approx. 120°C (250°F), then press on.
17. Ball bearing
18. Ball bearing inner race: same as 16.
19. Roller bearing removal: Use special tools VW 401, VW 412, P 255 a (press sleeve).
• Install with collar of needle case facing gear set.
• Press on with special tools VW 407 and VW 415 a (press sleeve).
20. Pinion shaft
21. Drive pinion gear must match ring gear in differential.
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