Input Shaft: Service and Repair

Special tools, testers and auxiliary items required:
^ Thrust plate VW401
^ Press toolVW412
^ Tube VW519
^ Feeler gauge

Note: When installing new gears see Technical data.





1. Gearbox housing
^ Servicing
2. Circlip
3. Thrust washer
4. Needle bearing for 4th gear
^ Mark before removing
^ Do not interchange with needle bearing for 3rd gear
^ Oil with gear oil before installing
5. 4th speed sliding gear
^ Before installing, insert spring see Fig. 1
^ After installing, check axial clearance with a feeler gauge (0.15 - 0.35 mm)
6. Synchroring for 4th gear
^ Check for wear
7. Locking collar
^ Paired with synchrohub
^ Mark before removing
8. Circlip
^ Redetermine thickness when replacing synchrohub see Fig. 3
^ Installation position: ends align with groove of synchrohub
9. Synchrohub for 3rd and 4th gear
^ Pressing off see Fig. 4
^ Installation position see Fig. 5
^ Pressing on see Fig. 6
10. Synchroring for 3rd gear
^ Coated with molybdenum
^ Check for wear see Fig. 2
11. 3rd speed sliding gear
^ Before installing, insert spring see Fig. 1
^ After pressing on -item 9-, check axial clearance with a feeler gauge (0.15 - 0.35 mm)
12. Needle bearing for 3rd gear
^ Mark before removing
^ Do not interchange with needle bearing for 4th gear
^ Oil with gear oil before installing
13. Input shaft
14. Spring pin
^ Drive in when replacing input shaft see Fig. 7
15. Bearing plate
^ Servicing
16. Inner race for cylinder roller bearing
^ Take off and fit by hand
17. Circlip
18. Thrust washer for needle bearing for 6th gear
^ Installation position: shoulder towards circlip, smooth contact surface towards needle bearing
19. Needle bearing for 6th gear
^ Oil with gear oil before installing
20. 6th speed sliding gear
^ Before installing, insert spring see Fig. 1
^ After installing, check axial clearance with a feeler gauge (0.15 - 0.35 mm)
21. Synchroring for 6th gear
^ Check for wear see Fig. 2
22. Synchro hub for 5th and 6th gear
^ Pulling off
^ Driving on
^ Installation position: projecting hub towards 5th speed sliding gear
23. Locking collar
^ Paired with synchrohub
^ Mark before removing
24. Synchroring for 5th gear
^ Checking for wear see Fig. 2
25. 5th speed sliding gear
^ Before installing, insert spring see Fig. 1
^ After installing, check axial clearance
26. Inner race for 5th speed sliding gear
^ Pulling off
^ Driving on
27. Needle bearing for 5th gear
^ Oil with gear oil before installing
28. 1st inner race for tapered roller bearing for input shaft
^ Pulling off
^ Driving on
29. End cover
^ Servicing
30. 2nd inner race for tapered roller bearing for input shaft
^ Pulling off
^ Driving on
31. Loosening and tightening





Fig. 1 Inserting spring in sliding gear
- Insert spring (arrow) in sliding gear, hook angled end into hole.





Fig. 2 Checking synchro-ring for wear
- Press synchro-ring into locking collar and measure gap "a" with a feeler gauge at positions -A-, -B- and -C-.
- Add together results and divide by three.
^ The figure calculated must not be less than 0.5 mm





Fig. 3 Re-determining thickness of circlip
- Press synchro-hub onto stop.

Note: Note installation position when pressing on see Fig. 5

- Determine the thickest circlip that can still just be fitted.

Note: The opening of the circlip must align with the groove in the synchro-hub.

- Determine circlip from table. Part No.





Circlips available
- Fit circlip.





Fig. 4 Pressing off synchro-hub for 3rd and 4th gear





Fig. 5 Synchro-hub installation position
^ Oil groove in synchro hub (arrow -1-) must align with oil drilling -arrow 2- in Input shaft





Fig. 6 Pressing on synchro-hub for 3rd and 4th gear
- Heat synchro-hub to approx. 100°C, fit and press home.
- Fit circlip.





Fig. 7 Driving spring pin into input shaft
- Guide a 9 mm diameter drift -A- into oil drilling and drive spring pin -B- in until it touches drift.