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.

Synchroniser Disassemble
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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.)

0018922

Pilot Bearing Removal Tool

C Install 2nd gear with manufacturer's marks facing 1st gear.

Bearing Race Sleeve

001$879

Roller Bearing Blocks

0018922

Special Tools

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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