Disassembly
Differential/Clutch Housing Removal
- Mount transmission in repair stand
- Drain transmission oil
- Remove circlip and wave washer
- Attach VW391 to flange with 2 bolts
A = M8 x 30 bolts
- Pull drive flange out
- Before starting repair work (which does not require final drive to be adjusted) mark position of adjusting rings on transmission housing. Measure depth to which they are installed with VW 382/7 and record readings
^ Scribe left side (ring gear side) with one mark (arrow)
^ Scribe right side with two marks
- Remove adjusting rings using VW 381/15
- Remove Clutch housing
NOTE: Cover main shaft splines to prevent damage to oil seal when removing clutch housing.
Rear Main Shaft Removal
- Remove circlip (arrow)
- Push reverse gear backward on splines and screw out main shaft
- Lift out differential
Gear Carrier Removal
NOTE: If bearing and/or transmission housing are replaced, and dimension r is not marked on ring gear, pinion depth must be measured and noted BEFORE gear carrier is removed. Service and Repair-- Differential Adjustments, 091 Transmission
- Use two M8 x 20 bolts to attach VW 457
- Press gear carrier out with VW 296
Gear Carrier Disassembly
- Remove circlip
- Remove shift fork for lst/2nd gear
- Move selector shaft back to neutral
- Remove clamp bolt for 3rd/4th gear shift fork
- Engage 3rd gear, pull selector shaft back until shift fork is free
- Engage 4th gear
- Loosen union nut on relay lever support
- Lift pinion shaft when pressing out and guide it carefully so that gears and needle bearings do not jam and get damaged
- Check 3rd/4th gear for free movement
Clutch Housing Disassembly
- Reference image
Reverse Gear Disassembly
- Reference image
- Remove pinion needle bearing
Gear Carrier Housing Disassembly
- Press out main shaft ball bearing
- Remove pinion needle bearing
CAUTION; Be careful not to damage circlip.
- To remove interlock/detent plunger, tap a 6 mm thread in plug and pull out with bolt (always use new plug)
Gear Shift Housing Disassembly
- To remove plug for rocker lever shaft, tap a 6 mm thread in plug and pull out with bolt (always use new plug)
- - Push rocker lever shaft out of gear shift housing
- Remove selector shaft bushing using pliers to twist out
- Remove selector shaft seal by prying out with a screw driver
Main Shaft Disassembly
- Remove 3rd/4th gear synchronizer by pressing off with 3rd gear
- Remove 3rd/4th gear circlips
Pinion Shaft Disassembly
- Hold 4th gear down with press tool VW 460/3 to compress spring and remove circlip
CAUTION: Spring is under tension.
- Remove 1st gear and synchronizer sleeve/hub
- Press off supporting outer race for tapered roller bearing
- If necessary, press 2nd inner race off separately
- Removing tapered roller bearing 2nd inner race