Disassembly

Drive Flange and Differential 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 Cover/Reverse Gear Removal

- Remove cover plate
- Remove shift shaft
- Loosen bolt until relay lever (arrow) can be pulled against housing
- Tighten bolt to lock lever in that position

- Remove retaining ring
- Remove gear shift housing
- Remove reverse gear shift fork and hub
- Remove outer circlip

- Pull off synchronizer hub and reverse gear
^ A = Puller US 1078
- Remove inner circlip, washer and needle bearing
- Remove reverse gear together with needle bearing and washer
- Remove gear carrier housing bolts

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, 091/1 Transmission

- To remove gear carrier attach VW 457 with two M8 x 20 bolts
- Press gear carrier out with VW 296
- Remove shim S3 and record thickness