Figure 6.22. Input shaft details (Section 7): 1 - Spring clamp; 2 - Washer; 3 - Outer bearing clamp; 4 - Bearing; 5 - Input shaft; 6 - 4th speed synchronizer ring; 7 - Needle bearing.
1. Remove the spring clip and shaft washers.
2. Pull the shaft out of the bearing, but make sure that the support falls on the central race of the bearing. If a puller is used on the outer race, that bearing must be removed and then a new one installed.
3. Remove the needle bearing and then remove the 4th gear synchronizer ring, which may be stuck to the input shaft gear cone.
4. Check the gear teeth for chips or damage, and also check the condition of the bearings for wear.
5. Hold the inner bearing race and insert the input shaft into it. Make sure the bearing groove for the spring clip faces the front end of the shaft.
6. Now you need to install a spring clip of the thickest possible thickness into the shaft groove. However, before doing this, select a washer of a thickness that will ensure a clearance between the bearing and the washer of 0.05 to 0.15 mm. Selecting the correct washer thickness requires trial and error.
Figure 6.23. Measuring the clearance between the washer and the input shaft bearing (Section 7).
7. Lubricate the needle roller bearing and install it in the groove of the input shaft.
8. Install the synchronizer ring onto the gear cone on the input shaft.
(View the original on the website: VWmanual.ru)
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