Transaxle Disassembly: 4-Speed

NOTE: For 4-Speed Transaxle Disassembly and Reassembly Procedures, refer to Illustration. See Fig 1 .

Fig 1: Sectional View of Transaxle Assembly

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Mount transaxle in holding fixture and drain fluid. Remove clutch release push rod from center of mainshaft and withdraw from bell housing end.
Install support bar (30-211) across mouth of bell housing and install support block between support bar and mainshaft. Tighten bolt of bar to take up clearance between bar and mainshaft. See Fig 2 .

Fig 2: Installation of Mainshaft Support Fixture
Courtesy of VOLKSWAGEN UNITED STATES, INC.
Remove cap, snap ring and spring washer from drive shaft flange. Remove both drive shaft flanges with remover. Remove release bearing cover, pry circlips off release shaft.
Remove release shaft, clutch lever and return spring. Remove release bearing and guide sleeve. Remove 2 mainshaft bearing retaining nut plugs. Remove 3 mainshaft bearing retaining nuts. Remove reverse idler shaft bolt and backup light switch.
Remove selector shaft cover and lock bolt. Set shift forks in neutral position and remove selector shaft and spring with remover (US4463). Remove 2 stud nuts and 12 bolts retaining transmission case to transaxle case. See Fig 3 .

Fig 3: Exploded View of 4-Speed Transaxle case
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Install mounting plate on rear of transmission case and center remover on mainshaft. Separate transmission case from transaxle case. Remove mainshaft bearing retaining screws that fell into case. Remove magnet from transaxle case.
Remove mainshaft bearing shim. Remove 2 "E" clips from shift fork and pull shift fork shaft from housing. Swing shift forks to one side and remove reverse gear and shaft. Remove 4th gear snap ring from pinion shaft. Remove mainshaft assembly and 4th gear on pinion shaft as an assembly.
Remove snap ring, 3rd gear, 2nd gear, 2nd gear needle bearing and race and 2nd gear synchronizer ring. Using a puller, simultaneously remove 1st gear, 1st gear synchronizer ring, 1st-2nd gear synchronizer, 1st gear needle bearing and thrust washer. Remove pinion bearing cover bolts, remove cover and pull pinion shaft out of bore. Lift out differential unit. See Fig 4 .

Fig 4: View of 4-Speed Pinion Shaft Assembly
Courtesy of VOLKSWAGEN UNITED STATES, INC.

NOTE: All gears must be removed from pinion shaft before shaft and differential can be removed from case.