Input shaft, disassembling and assembling input: Notes
Special tools and workshop equipment required
- VW 407 Press tool
- VW 447 H Press plate
- VW 412 Press tool
- VW 422 Tube
- VW 401 Thrust plate
- VW 408 A Press tool
Special tools and workshop equipment required
- VW 421 Tube
- VW 454 Press piece
- VW 447 i Thrust plate
- VW 510 Press piece
- 41-501 Drift sleeve
- 3 - Kukko 17/1 Puller set
NOTE:
- When installing new gears, consult technical data. Refer to Code letters, transmission application, ratios, capacities .
- If the position of the tapered roller bearings is affected when exchanging parts, the input shaft must be re-adjusted. Refer to Adjustment overview
1 - Clutch housing
2 - Tapered roller bearing outer race
- Removing. See Pressing out tapered roller bearing outer race
- Pressing in. See Pressing in tapered roller bearing outer race
3 - Tapered roller bearing inner race
- Pressing off of shaft. See Tapered roller bearing inner race, pressing off
- Pressing on. See Pressing on tapered roller bearing inner race
4 - Input shaft
- Adjusting. Refer to Input shaft, adjusting
5 - 3rd gear
- Shoulder points to 4th gear
- Pressing off. See 5
- Pressing on. See Pressing on 3rd gear wheel
6 - Circlip
- Always replace
7 - 4th gear
- Pressing off with tapered roller bearing outer race and sleeve. See Pressing off 4th gear wheel with tapered roller bearing and sleeve
- Pressing on. See Pressing on 4th gear wheel
- Collar faces to 3rd gear
8 - Tapered roller bearing inner race
- Pressing off with 4th gear wheel and sleeve. See Pressing off 4th gear wheel with tapered roller bearing and sleeve
- Pressing on. See Pressing on tapered roller bearing inner race
9 - Thrust washer
10 - Tapered roller bearing outer race
- Pressing out. See Pressing out tapered roller bearing outer race
- Pressing in. See Pressing in tapered roller bearing outer race
11 - Shim
- Determining thickness; adjusting input shaft: Refer to Input shaft, adjusting
12 - Transmission housing
13 - Sleeve
- For needle roller bearing
- Press off with 4th gear wheel and tapered roller bearing inner race. See Pressing off 4th gear wheel with tapered roller bearing and sleeve
- Pressing on. See Pressing on sleeve for needle roller bearing
- Place thrust washer on before installing (item - 9 Input shaft, disassembling and assembling input )
14 - Needle roller bearing
15 - Selector gear for 5th gear
- Pull off together with 5th gear synchro-hub. Refer to Assembly sequence
16 - 5th gear synchro-ring
- With cast locking pieces. See 12
- Check for wear. Refer to Figure
17 - Spring
- Installation position. See Assembling 5th gear locking collar/synchro-hub
- Changed from transmission build date 05 11 1. Refer to Springs for 5th gear synchro modified from transmission build date 05 11 1
18 - Locking pieces (Qty. 3)
- Installation position. See 5th gear synchronizer
- From transmission build date 05 03 1 locking pieces are installed that are hollow on inside.
19 - 5th gear synchro-hub
- Removing and installing. Refer to Assembly sequence
20 - 5th gear locking collar
- Removing and installing. Refer to Assembly sequence
21 - Dished washer
- Installation position. Refer to Figure
22 - Torx socket head bolt M10, 80 Nm
- Fitted piece on bolt head locates dished spring. Refer to Figure