Volkswagen Tiguan Service and Repair Manual: Input Shaft

Overview - Input Shaft

Note

• Warm the toothed gear to approximately 100 ºC (212 ºF) using Inductive Heater -VAS6414-. Wear protective gloves.
• Install all input shaft bearings with transmission fluid.
• Replace grooved ball bearing after removing.

1. Circlip
   • For grooved ball bearing/input shaft
   • Removing and installing.
   • The thickness must be determined again on transmissions with reinforcement measures (⇒ manual transmission 0FB, for CC, Passat, Golf.
2. Transmission Housing
3. Circlip
   • Select when replacing the grooved ball bearing and the input shaft.
4. Grooved Ball Bearing
   • Replace after removing the drive axle
   • Removing.
   • Installation position.
   • Installing.
5. 5th Gear Wheel
   • Available as a replacement part together with the input shaft
   • Removing.
   • Installed position: the surrounding groove -arrow- points toward grooved ball bearing
   • Installing.
6. Input Shaft
   • With 3rd/4th and 6th gear wheel
7. Cylindrical Roller Bearing
   • With circlip
   • Removing.
   • Installing.
   • Installed position: the circlip in bearing points to input shaft
8. Clutch Housing

Input Shaft, Disassembling and Assembling

Special tools and workshop equipment required

• Press Plate -VW401-
• Press Plate -VW402-
• Press Piece - Rod -VW407-
• Press Piece - Rod -VW408A-
• Press Piece - Rod -VW412-
• Press Piece - Multiple Use -VW454-
• Press Piece - Front Control Arm -2040-
• Press Piece - Bushing - 50mm Diameter -VW432-
• Bearing Installer - Multiple Use -32-111-
• Inductive Heater -VAS6414-
• -1-Puller - Kukko Internal - 28-37mm -21/5-
• -3-Puller - Kukko Quick Action Separating Tool - 22-115mm -17/2-
• -4-Puller - Kukko Counterstay -22/2- Feeler Gauge

Input Shaft, Disassembling

• Remove the grooved ball bearing locking ring.

Removing the Grooved Ball Bearing

• Mount the Separating Tool-A- into the groove in the ball bearing for the locking ring.

1. Puller - Kukko Quick Action Separating Tool - 22-115mm -17/2-, for example.

• The grooved ball bearing and 5th gear wheel can also be removed together. To do this, place the Separating Tool-A- as shown in the following illustration under the 5th gear wheel.

Removing the 5th Gear Wheel

1. Puller - Kukko Quick Action Separating Tool - 22-115mm -17/2-, for example

Input Shaft, Assembling

Warming the 5th Gear Wheel and Installing

• The groove -arrow- on the gear wheel must face up.

Grooved Ball Bearing Installation Location and Installing the Grooved Ball Bearing

• Grooved ball bearing installation location: the groove for the circlip faces up -arrow A-. The collar -arrow B- must face the 5th gear wheel.
• Then select the grooved ball bearing locking ring and install it on the input shaft.

Selecting the Locking Ring

• Insert a 1.86 mm locking ring -A- into groove in the input shaft and press it upward.
• Measure the gap between the grooved ball bearing -B- and the installed locking ring -A- with a feeler gauge -C-.
• Remove the locking ring used for the measurement.
• Select the locking ring according to the Table.

Note

Allocate the correct locking rings. Refer to the Parts Catalog.

The following locking rings are available:

Measured Value (mm)	Circlip Thickness (mm)	Axial Play (mm)
0.01 to 0.05	1.86	0.01 to 0.05
0.05 to 0.07	1.89	0.01 to 0.05
0.07 to 0.10	1.92	0.01 to 0.05
0.10 to 0.13	1.95	0.01 to 0.05
0.13 to 0.16	1.98	0.01 to 0.05

Removing the Cylindrical Roller Bearing from the Clutch Housing

• Compress the cylindrical roller bearing locking ring -arrow- with pliers -C- and remove it.

1. Puller - Kukko Counterstay -Kukko 22/2-, for example.
2. Puller - Kukko Internal - 28-37mm -21/5-, for example.

Pressing Cylindrical Roller Bearing into Clutch Housing.

• Compress the cylindrical roller bearing locking ring -arrow- with pliers -C- and install it.
• Remove the pliers before the cylindrical roller bearing gets into its installed position. The locking ring must lock into the groove on the clutch housing.

Input Shaft Seal, Replacing

Special tools and workshop equipment required

• Puller - Crankshaft/Power Steering Seal -T20143/1-
• Seal Installer - Drive Axle -T40008-
• Sealing Grease
• Grease allocation. Refer to the Parts Catalog.

 

• Remove manual transmission.
• Remove the clutch slave cylinder with release bearing
• Pry the input shaft seal out.

Note

Be careful not to damage the contact surface for the seal on the input shaft.

• Fill the space on the new seal between the sealing/dust lip halfway with Sealing Grease.
• Coat the outer circumference of the seal lightly with transmission fluid.

• Install the input shaft seal so that it is flush.
• Install the clutch slave cylinder with release bearing.
• Install manual transmission.