Volkswagen Workshop Service and Repair Manuals

Removing

• ‒ Remove shift fork circlip, pull fork shaft out of bearing housing and swing complete shift fork set to the side.
• ‒ Remove circlip for 4th speed gear/output shaft.
• ‒ Take out complete drive shaft and 4th speed gear/output shaft together.

Installing

• ‒ If the drive shaft has not been dismantled, press ball bearing off =>page 35-5
• ‒ Insert complete drive shaft without ball bearing ( the drive shaft
  is supported by bridge 30-211, adaptor VW 295a and an M 12
  locknut, see =>page 34-40 .

• ‒ Install 4th speed gear on output shaft secure it with circlip.
• ‒ → Locate shift forks in the operating sleeves, press shaft into bearing housing and fit both circlips - arrows-

Removing and installing differential

Remove output shaft gears =>page 35-25 , and bearing cover first.

Removing

• ‒ Remove cap, circlip and washer.
• ‒ → Pulling drive flange off

• A - Screw 2 M 8 x 30 bolts through the elongated holes into
  the flange.

Installing

• ‒ → Fitting drive flange.

• ‒ → Pressing circlip for drive flange into groove.

Mods.:

Selector forks for 1st, 2nd and reverse gear.

• →      1 -     Up to 04 04 6
•      2 -     From 05 04 6

A lug was fitted on the reverse gear fork to operate the reversing light switch (see =>page 34-53 ). Install correct parts.

Up to Assy. date 25 10 8:

•      → 1 -     Fork for 1st and 2nd gear.
•      2 -     Fork for reverse gear.

Side location and stop for 2nd gear by pin in the 1st and 2nd gear fork and slot in reverse fork.

From 26 10 8 - gradual introduction.

•      → 1 -     Fork for 1st and 2nd gear.
•      2 -     Fork for reverse gear.

Side location and stop for 2nd gear by slot in the 1st and 2nd gear fork and lug on the reverse gear fork.

Note:

Do not install old and new parts together.

Reverse gear stop

→ Up to Assembly date 15 06 5: a stop bush was fitted.

→ From 16 06 5:

The stop is on the bearing cover plate.

Repair instructions

When installing a new taper roller bearing

for output shaft (cover with stop) the stop

on the reverse gear shaft should be

removed.

Note:

• ◆ Use self-locking nuts on housing with
  studs.
• ◆ Use bolts on housing without studs.

• Bearing housing
• Output shaft
• Reverse gear stop
• From 03 05 7
• ◆ Stop with plastic cap -arrow- lug 2 mm shorter and with hole to hold cap

Note:

Fit plastic cap only on plate with shorter

lug and hole.

• Up to 09 09 6
• Self-locking nuts and studs in bearing
  housing (interference fit thread).
• 25 Nm

• Bearing cover plate
• From 10 09 6
• M 8 x 45 bolts with serrated
  locking head.
• Part No. N 900.234.01 Normal thread
  in housing.
• 25 Nm and tighten further 90°
• Reinforcement plate
• Dropped form 29 03 7