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