Disassembling and Assembling the Drive Shaft

Disassembling and assembling the drive shaft
Tools





Preliminary work

1. Remove transmission.





2. Tighten the transmission using engine support 9589 or engine and gear support VW 540 at the assembly support.
3. Drain transmission oil.
4. Disassemble the transmission.

Disassembling the drive shaft
Removing drive shaft








Removal instructions for drive shaft

Note: Circlips of different sizes and thicknesses are used. For this reason, the individual circlips must be marked (e.g. with numbers). The thickness of the circlip must be determined again if a directly affected component is replaced.





1. Press off fixed gear wheel for 5th gear -as shown in illustration-.





2. Press synchroniser ring for 3rd gear -Arrow- to the loose gear wheel for 3rd gear.
3. Press off synchronising hub for 3rd and 4th gear -as shown in illustration-.

Assembling the drive shaft
Fitting drive shaft








Assembly instructions for drive shaft

Note: Circlips of different sizes and thicknesses are used. For this reason, the individual circlips must be marked (e.g. with numbers). The thickness of the circlip must be determined again if a directly affected component is replaced.

Note: All transmission parts, particularly synchronisation parts, must always be coated with transmission oil before assembly. Avoid assembling dry parts.

1. Check the synchroniser rings for wear.
^ Push ring into shift sleeve.
^ Measure gap dimension -a- with a feeler gauge in positions -A, B and C-.
^ Add up the measured values and divide by three. The value obtained must not be less than 0.5 mm.









2. Insert the spring into the loose gear wheel so that the angled end engages in the bore.





3. Fit operating sleeve so that the slant -1- is facing 4th gear and the offset side -2- is facing 3rd gear.





4. Determine the circlip for 4th gear. To do this, determine the thickest ring that can still be used.
5. Determine the circlip for 5th gear in the same way as for 4th gear.





6. Heat the synchronising hubs for 3rd and 4th gear to approximately 100°C and press onto the drive shaft. The high collar is facing the loose gear wheel for 3rd gear.





7. Heat the fixed gear wheel for 5th gear to approximately 100°C and press onto the drive shaft. The high collar is facing reverse gear and the oil pockets are facing 4th gear.

Subsequent work

1. Assemble transmission.
2. Fill with transmission oil.
3. Remove transmission from assembly support.
4. Install transmission.