①When assembling the transmission input shaft, install the locking ring, use special tools VW415A and VW510, install the ball bearing into the transmission case, and press it onto the threaded shaft.
②When replacing the shaft, bearing and synchronizer spline hub, the thickness of all the locking rings on the shaft must be measured and marked one by one. When assembling, replace the locking ring with the same thickness.
③Before installing the third and fourth gears, insert the spring into the gear so that the end with the hook angle enters the hole.
④ When checking the wear of the synchronizer gear, the synchronizer should be placed in the coupling sleeve at an interval of 120. Measure the three positions with a thickness gauge, and the average of the three numbers shall not be less than 0.50mm.
⑤When removing the needle bearing on the input shaft of the transmission, use the special tool 40-202. When installing the needle bearing, the pressing depth should be 39.5mm from the bottom surface of the shell.
⑥ When disassembling the spline hub of the third and fourth gear synchronizer and the fifth gear, use special tools VW408a, VW401, VW402, VW4471 and VW407. The side of the spline hub with a higher inner shoulder faces the third gear.
Gearbox input shaft
②When replacing the shaft, bearing and synchronizer spline hub, the thickness of all the locking rings on the shaft must be measured and marked one by one. When assembling, replace the locking ring with the same thickness.
③Before installing the third and fourth gears, insert the spring into the gear so that the end with the hook angle enters the hole.
④ When checking the wear of the synchronizer gear, the synchronizer should be placed in the coupling sleeve at an interval of 120. Measure the three positions with a thickness gauge, and the average of the three numbers shall not be less than 0.50mm.
⑤When removing the needle bearing on the input shaft of the transmission, use the special tool 40-202. When installing the needle bearing, the pressing depth should be 39.5mm from the bottom surface of the shell.
⑥ When disassembling the spline hub of the third and fourth gear synchronizer and the fifth gear, use special tools VW408a, VW401, VW402, VW4471 and VW407. The side of the spline hub with a higher inner shoulder faces the third gear.
Gearbox input shaft
