Disassembling and Assembling Transmission

Disassembling and assembling transmission

Preliminary work

1. Remove transmission.
2. Use engine support 9589 to secure the transmission on the assembly support.
3. Drain transmission oil.

Disassembling transmission

Removing transmission cover

Overview

1. Remove lid -3- with hexagon socket.
2. Unscrew retaining screw for reverse-gear bearing segment -4- and remove screw and washer -5-.
3. Remove dowel sleeve -6- using internal puller NR.108, striker VW 771/1 and threaded piece VW 771/15.
4. Unscrew fastening screws -7- and remove switching module -8- together with the support -9-.
5. Remove catches. To do this, unscrew hexagon socket head bolts -10- and remove guide cylinder -11-, spring -12- and ball -13- lying underneath.
6. Unscrew fastening screws -14- between transmission cover -15- and transmission housing -16-.
7. Open circlip -A- and remove transmission cover using a rubber hammer if necessary.

Circlip

Removing shift rods

Transmission overview

1. Unscrew reversing light switch -1-.
2. Remove catches for reverse gear. To do this, unscrew hexagon socket head bolts -2- and remove guide cylinder -3-, spring -4- and ball -5- lying underneath.
3. Remove cotter pin -6- between shift rod -7- and shift fork -8- for reverse gear, pull shift rod out of the transmission housing -23- and remove it together with the shift fork.
4. Unscrew fastening screws -9- between bearing segment and oil baffle -10- and between transmission housing and oil baffle and remove oil baffle.
5. Unscrew fastening screw -11- between shift rod for 3rd/4th gear -12- and shift fork for 3rd/4th gear -13- and pull shift rod for 3rd/4th gear out of the transmission housing.
6. Remove cotter pin -6- between shift finger for 5th/6th gear -14- and shift rod for 5th/6th gear -15-.
7. Unscrew fastening screw -11- between shift rod for 5th/6th gear -15- and shift fork for 5th/6th gear -16-.
8. Pull shift rod for 5th/6th gear out of the transmission housing and remove shift mechanism for 5th/6th gear together with shift mechanism for 3rd/4th gear.
9. Unscrew fastening screw -11- between shift rod for 1st/2nd gear -17- and shift fork for 1st/2nd gear -18- and pull shift rod for 1st/2nd gear out of the transmission housing. Make sure to leave the catch for 1st/2nd gear -3 to 5- in place when pulling out the shift rod.
10. Unscrew fastening screw -19- between oil baffle -20- and gear wheel set capsule -21-.
11. Unscrew fastening screws -22- between gear wheel set capsule and transmission housing.
12. Remove sleeves, 2 ea.
13. Remove gear wheel set capsule with shift forks for 1st/2nd gear.

Removing gear wheel set

Overview

1. Lever halfshaft flange -1- out of transmission housing.
2. Unscrew fastening screws -2- for lid -3-.
3. Remove lid using a rubber hammer if necessary and remove differential -4- from the transmission housing.
4. Unscrew fastening screws -5- for retaining bracket -6- and take off retaining bracket.
5. Unscrew fastening screws -7- for tensioning plate.
6. Heat the bearing seat of the output shaft in the transmission housing to approx. 120°C with a hot-air gun.
7. Pull complete gear wheel set out of the transmission housing until the reverse gear shaft -8- can be removed with the bearing segment -9-. At this point, the output shaft is pulled approx. -X = 1.5 cm- out of the transmission housing.

Output shaft protruding out of transmission housing

8. Pull output shaft -10- out of the transmission housing.
9. Take adjusting panel -11- off the output shaft.
10. Pull drive shaft -12- out of the transmission housing.
11. Take bearing for drive shaft -13- off the drive shaft.

Assembling transmission

Installing gear wheel set

Overview

1. Position bearing for drive shaft -13- on drive shaft.

Information
If the transmission housing, lid, differential or output shaft is replaced, the thickness of the adjusting panel must be calculated again.

2. Position adjusting panel -11- on output shaft.
3. Heat the bearing seat of the output shaft in the transmission housing to approx. 120°C with a hot-air gun.
4. Fit output shaft -10- and drive shaft -12- together on the transmission housing -14- so that the output shaft bearing protrudes approx. 2 cm out of the transmission housing.

Output shaft protruding out of transmission housing

X - approx. 2 cm

5. Fit reverse gear shaft -8- with bearing segment -9- on the transmission housing.
6. Insert complete gear wheel set fully into the transmission housing.
7. Fit retaining bracket -6- and screw in fastening screws -5-.

- Tightening torque: 17 Nm (13 ftlb.)

8. Screw in fastening screws -7- for tensioning plate once the transmission housing has cooled down.

9. Insert differential -4- into transmission housing.

Information
Carefully clean all sealing faces prior to assembly to remove all traces of oil, grease and old sealant.
Evenly apply a bead of sealant. If there is an interruption, overlap the end of the interrupted bead when continuing to apply the sealant.

10. Clean the lid -3- and coat with Three Bond 1281.
11. Fit lid and screw in fastening screws -2-.

12. Tap halfshaft flange -1- into the transmission housing using a rubber hammer if necessary.

Installing shift rods

Information
When fitting the shift forks, make sure that the plastic slides are seated correctly.

Overview

1. Position gear wheel set capsule -22- with shift fork for 1st/2nd gear -19- on transmission housing -24- and screw in fastening screws -23-.

2. Fit oil baffle -21- on gear wheel set capsule, coat fastening screw -20- with Loctite 270 and screw it in.

3. Turn transmission and insert catch for 1st/2nd gear -4 to 6- into gear wheel set capsule.
4. Press catch down against the spring force and slide shift rod for 1st/2nd gear -18- through the shift forks and gear wheel set capsule into the transmission housing.
5. Screw in new fastening screw -12- between shift rod for 1st/2nd gear and shift fork for 1st/2nd gear.

6. Position shift fork for 5th/6th gear -17- on gear wheel set.
7. Position shift fork for 3rd/4th gear -14- on gear wheel set and slide shift rod for 3rd/4th gear -13- into the transmission housing.
8. Slide shift rod for 5th/6th gear -16- through the shift fork for 5th/6th gear and the shift finger for 5th/6th gear -15- into the transmission housing.
9. Screw in new fastening screw -12- between shift rod for 5th/6th gear and shift fork for 5th/6th gear.

10. Screw in new fastening screw -12- between shift rod for 3rd/4th gear and shift fork for 3rd/4th gear.

11. Tap in cotter pin -7- between shift finger for 5th/6th gear and shift rod for 5th/6th gear.
12. Fit oil baffle -11- to transmission housing and bearing segment using fastening screws -10-.

13. Position shift fork for reverse gear -9- on gear wheel set and slide shift rod for reverse gear -8- through the shift fork for reverse gear into the transmission housing.
14. Tap in cotter pin -7- between shift fork for reverse gear and shift rod for reverse gear.
15. Fit catch for reverse gear. To do this, insert ball -6-, spring -5- and guide cylinder -4- into the transmission housing, coat thread of hexagon socket head bolt -3- with Three Bond 1281 and screw in hexagon socket head bolt.

16. Fit reversing-light switch.

Installing transmission cover

Information
If the transmission cover or deep-groove ball bearing for the drive shaft is replaced, the thickness of the circlip must be calculated again.

Overview

Information
Carefully clean all sealing faces prior to assembly to remove all traces of oil, grease and old sealant.
Evenly apply a bead of sealant. If there is an interruption, overlap the end of the interrupted bead when continuing to apply the sealant.

1. Clean the transmission cover -15- and transmission housing -16- and coat with Three Bond 1281.
2. Fit transmission cover on transmission housing.
3. Open circlip -A- and slide transmission cover forward as far as it will go on the transmission housing. The circlip must engage in the groove on the deep-groove ball bearing.

Circlip

4. Screw in fastening screws -14- between transmission cover and transmission housing.

5. Fit catch for 3rd/4th gear. To do this, insert ball -13-, spring -12- and guide cylinder -11- into the transmission housing.
6. Coat the thread of the hexagon socket head bolt -10- with Three Bond 1281 and screw in hexagon socket head bolt.

9. Insert dowel sleeve -6- into transmission cover.
10. Screw in retaining screw -4- for bearing segment with washer -5-.

13. Screw in oil drain plug -1- with a new sealing ring -2-.

Subsequent work

1. Install transmission.
2. Fill with transmission oil.