Volkswagen Golf Variant / Jetta. Manual - part 189

 

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Volkswagen Golf Variant / Jetta. Manual - part 189

 

 

♦ Pressure Plate - VW402-
♦ Thrust Piece - VW431-
♦ Spacer - VW472/2-
♦ Drift - 10-206-
♦ Thrust Piece - 3290/1-
♦ Subframe Support Assem‐

bling Device - 3301-

218

♦ Assembly Mandrel - 10-508-

♦ Tensioner - 2070-

12. Special Tools    

219

1

Input Shaft

⇒ “1.1 Input Shaft, Disassembling and Assembling”, page 220
⇒ “1.2 Input Shaft, Adjusting”, page 226
⇒ “1.3 Input Shaft Seal, Replacing”, page 229

1.1

Input Shaft, Disassembling and Assem‐

bling

Special tools and workshop equipment required
♦ Press Piece - Rod - VW407-
♦ Press Piece - Multiple Use - VW447H-
♦ Press Piece - Rod - VW412-
♦ Press Piece - Shift Rod/Alternator - VW 422-
♦ Press Plate - VW401-
♦ Press Piece - Rod - VW408A-
♦ Press Piece - 28x100mm - VW421-
♦ Press Piece - VW447I-
♦ Press Piece - Multiple Use - VW454-
♦ Press Piece - Multiple Use - VW510-
♦ Press Tube - 41-501-
♦ Puller - Kukko Quick Action Separating Tool - 12-75mm - Kuk‐

ko 17/1-

♦ Press Plate - VW402-
♦ Inductive Heater - VAS6414-

Note

When installing new gear wheels or a new input shaft. Refer to

⇒ “2.3 Codes, Transmission Allocation and Capacities”, page 3

 and Parts Catalog.

The input shaft must be adjusted because the position of the tapered roller bearing is affected when parts

are replaced. Pay attention to the adjustment overview. Refer to 

⇒ “2 Adjustment Overview”, page 262

 .

Replace both tapered roller bearings together.

Wearing safety gloves, warm the bearing inner races, the gear wheels and the synchronizer hubs to ap‐

proximately 100 °C (212 °F) using an Inductive Heater - VAS6414- before installing them.

220

Bearing

❑ Removing. Refer to

⇒ Fig. ““Removing the

Outer Race/Tapered

Roller Bearing”“ ,

page 222

❑ Installing. Refer to

⇒ Fig. ““Installing the

Outer Race/Tapered

Roller Bearing”“ ,

page 223

3 - Bearing Inner Race/Taper

Roller Bearing

❑ Removing. Refer to

⇒ Fig. ““Removing the

Bearing Inner Race/

Taper Roller Bearing”“ ,

page 223

❑ Installing. Refer to

⇒ Fig. ““Installing the

Bearing Inner Race/

Taper Roller Bearing”“ ,

page 223

4 - Input Shaft

❑ Adjusting. Refer to

⇒ “1.2 Input Shaft, Ad‐

justing”, page 226

 .

5 - 3rd Gear Wheel

❑ Installed position: shoul‐

der faces 4th gear

❑ Removing. Refer to

⇒ Fig. ““Removing the

3rd Gear Wheel”“ , page

224

❑ Installing. Refer to 

⇒ Fig. ““Installing 3rd Gear Wheel”“ , page 224

6 - Circlip

❑ Always replace.

7 - 4th Gear Wheel

❑ Removing with the bearing inner race/tapered roller bearing and sleeve. Refer to

⇒ Fig. ““Removing the 4th Gear Wheel with the Tapered Roller Bearing and Sleeve”“ , page 223

❑ Installing. Refer to 

⇒ Fig. ““Removing 4th Gear Wheel”“ , page 224

❑ The shoulder faces 3rd gear

8 - Bearing Inner Race/Taper Roller Bearing

❑ Removing with 4th gear wheel and sleeve. Refer to

⇒ Fig. ““Removing the 4th Gear Wheel with the Tapered Roller Bearing and Sleeve”“ , page 223

❑ Installing. Refer to 

⇒ Fig. ““Installing the Bearing Inner Race/Taper Roller Bearing”“ , page 224

9 - Thrust Washer
10 - Outer Race/Tapered Roller Bearing

❑ Removing. Refer to 

⇒ Fig. ““Installing the Outer Race/Tapered Roller Bearing”“ , page 225

❑ Installing. Refer to 

⇒ Fig. ““Installing the Outer Race/Tapered Roller Bearing”“ , page 225

11 - Shim

❑ Selecting thickness. Refer to 

⇒ “1.2 Input Shaft, Adjusting”, page 226

 .

1. Input Shaft    

221

 

 

 

 

 

 

 

Content   ..  187  188  189  190   ..