Volkswagen Workshop Service and Repair Manuals

Dismantling and assembling gearbox housing cover, gearbox housing, selector mechanism, input shaft, output shaft (pinion shaft), differential and selector forks

Dismantling

• ‒ → Mount gearbox on repair stand.
• ‒ Drain gearbox oil.

• ‒ → Remove clutch release lever -A- with release bearing -B-.
• ‒ Remove guide sleeve -C-.

• ‒ → Remove both flanged shafts.
• ‒ Take out flanged shafts along with springs, thrust washers and tapered rings.
• ‒ Unbolt gearbox housing cover and take off along with seal.

• ‒ Screw selector finger onto selector shaft.
• ‒ → Select 5th gear (arrows 1 and 2).

• ‒ → Loosen lock nut (arrow A) below 5th gear fork.
• ‒ Unbolt ball head bolt (arrow B) and remove selector fork together with 5th gear locking collar.

• ‒ Slide locking collar again over synchro-hub.
• ‒ → Remove bolt -A- for 5th gear by selecting 5th (arrow 1) and 2nd gear (arrows 2 and 3).
• ‒ After engaging both gears the input shaft and output shaft are locked, synchro-hub and gear cannot turn. The bolt can now be loosened.
• ‒ Take off 5th gear synchro-hub and take out 2nd gear.

• ‒ → Take off securing ring (arrow) for synchro-hub

• ‒ → Pull off synchro-hub with 5th selector gear.

• A - Two arm puller e.g. Kukko 20/10 with Matra V/170 hooks.

• ‒ → Remove needle roller bearing (arrow).

• ‒ → Pull off 5th gear

• A - Two arm puller e.g. Kukko 20/10 with Matra V/170 hooks.
• B - Hexagon bolt M8 x 15 (13 mm AF).
• Sequence for removing:
  Fit two arm puller and centralize by turning screw (arrow). Heat gear wheel with hot air blower V.A.G 1416 and pull off.

Note:

When pulling off the gear wheel ensure that the hooks do not bend outwards, if necessary tighten screw (arrow). After 5th gear wheel has been removed check for damage.

• ‒ → Squeeze clip together (arrow) and take off.
• ‒ Remove clutch housing securing bolts.
• ‒ Take off clutch housing.
• ‒ Take differential off gearbox housing.

• ‒ → Pull sealing plugs out.

• ‒ → Pull out selector shaft, drive out with a drift if necessary.

• ‒ → Remove spring (arrow) between selector finger -A- and selector console -B-.
• ‒ Remove selector finger -A-.

• ‒ → Remove bolt (arrow) and take out selector console with bush.

• ‒ → Remove reversing light switch -1- and reverse gear securing bolts -2-, -3- and -4-.

• ‒ → Remove 5th gear selector rod -1- and reverse gear selector rod -2- with reverse lever -3-.

• ‒ Turn gearbox in installation position
• ‒ → Press out output shaft with puller -1- e.g. Kukko 18/1. The taper roller bearing outer race -2- is pressed out of the housing when doing this.

• ‒ → Drive out reverse gear shaft -1-.
• ‒ Take out input shaft -5 -, output shaft -4-, 1st and 2nd gear selector rod -3-, 3rd and 4th gear selector rod -6- as well as reverse gear -2- and shaft -1- from gearbox housing.

Assembling

• ‒ Press output shaft taper roller bearing outer race into gearbox housing .
• ‒ → Insert output shaft -3- with 1st and 2nd gear selector rod -4-.
• ‒ Slide reverse gear -1- over shaft -2- and insert shaft.

• ‒ → Lift up reverse gear so that the reverse gear lever can be inserted later.

• ‒ → Lift up output shaft -1- with 1st and 2nd gear selector rod slightly and insert again together with input shaft -3- as well as 3rd and 4th gear selector rod -4-.

Notes:

• ◆ Reverse gear wheel remains lifted with VW 681.
• ◆ Guide input shaft with 3rd and 4th gear past output shaft 4th gear during insertion.

• ‒ → Secure shaft for reverse gear.

• ‒ → Insert reverse gear lever -1- into reverse gear selector rod -2-.
• ‒ Install components, but first insert reverse gear lever into reverse gear.

• ‒ → Secure reverse gear lever (arrow).
• ‒ Remove special tool VW 681 from gearbox housing.

• ‒ → Install 5th gear selector fork -1- and secure.

• ‒ → Bring selector rods -A- into neutral.
• ‒ Install selector console -B- with bush and bolt.
• ‒ Align selector console -B-, to do this insert selector shaft -C- and tighten bolt -arrow-.
• ‒ Remove selector shaft -C- again.

• ‒ → Insert selector finger -1- in selector console -2-.

• ‒ → Insert spring (arrow) between selector finger -1- and selector console -2-.
• ‒ Push selector shaft -3- into selector finger and selector console.

Installation position:

The step points towards input and output shafts.

• ‒ Drive sealing plug -4- in flush.
• ‒ If necessary adjust selector finger and selector sleeve =>
  Page 34-114 .

• ‒ Install differential.
• ‒ Fit gearbox housing.

• ‒ Fit reversing light switch.
• ‒ Install springs, thrust washers, tapered rings and flange shafts. Observe differences between flange shafts.

→ Differences

Installation position of 5th gear

The recess on internal diameter faces gearbox housing.

• ‒ → Knock-on 5th gear.

• ‒ → Screw-in new 5th gear securing bolt -1- with dished spring -2-.

Installation position of dished spring for 5th gear securing bolt:

The outer diameter (concave side) faces 5th gear.

• ‒ Install thrust washer -3- for 5th gear sliding wheel.

Installation position:

Recess on thrust washer internal diameter faces towards needle roller bearing.

• ‒ Heat sleeve -4- for 5th gear needle roller bearing to approx. 100°C on a hot plate then drive on.

• ‒ → Install 5th selector gear -1- with needle roller bearing
• ‒ Install spring (arrow) on 5th gear synchro-ring.
• ‒ Place 5th gear synchro-ring on gear wheel

→ Installation position of 5th gear synchro-hub

The high shoulder of the synchro-hub (dimension -a-) faces towards gearbox housing.

• ‒ → Drive on 5th gear synchro-hub -1- with tool 30-23.

Note:

When driving synchro-hub on ensure synchro-ring is free to move.

The locking piece (arrow) must sit in the synchro-ring recess.

• ‒ Determine new circlip -2-.
• ‒ Determine and insert circlip -the thickest one that just fits in-.

Available circlips

• ‒ Squeeze clip -3- together and insert on 5th gear selector rod.

→ Installation position of 5th gear locking collar

Install teeth points (arrow A) towards 5th selector gear.

• ‒ The marked splines (arrow B) are to be inserted into the recesses on the synchro-hub.

• ‒ → Tighten 5th gear bolt -A-, to do this select 5th (arrow 1) and 2nd gear (arrows 2 and 3).
• ‒ Remove locking collar again.

• ‒ Clean ball stud threads in housing, use an M8x1 thread tap if necessary.
• ‒ Insert locking collar together with 5th gear selector rod.
• ‒ → Turn back lock nut (arrow A) below 5th gear selector rod.
• ‒ Screw in ball headed bolt (arrow B).

Adjusting 5th gear:

Basic setting

• ‒ Coat threads on ball head bolt with locking fluid D 000 600.

• ‒ Turn gearbox to installation position.
• ‒ All selector rods in neutral.
• ‒ Loosen ball head bolt lock nut.
• ‒ → Adjust ball head bolt (arrow) so that the locking collar is flush with the synchro-hub.

Fine adjustment

• ‒ Select 5th gear.

• ‒ → Turn ball head bolt (arrow A) in so far so that there is no axial play in the locking collar groove for 5th gear selector fork.
• ‒ Then turn ball head bolt (arrow A) back so that play can just be felt between locking collar and selector fork (approx.1/8 turn).
• ‒ Lock ball head bolt (arrow A) with lock nut (arrow B) below 5th gear fork to gearbox housing, ensuring that the ball head bolt has not turned.
• ‒ Disengage 5th gear. Locking collar must now be in the neutral position. Synchro-ring must move freely.
• ‒ Fit seal.
• ‒ Fit gearbox housing cover