Disassembling and Assembling

Tools














Disassembling and assembling transmission G 86

Note If the 5th and reverse gears stick or catch after adjustment of the gear changing mechanism, before removing and disassembling the transmission first remove the lock for the 5th and reverse gears, inspect it and, if necessary, replace it Instructions for disassembly and assembly

Disassembly

Note The differential does not have to be removed in order to take out the gear set. Removal is necessary only in order to determine which deviation "r" is given on the crown wheel. This deviation is necessary if the transmission housing or tapered roller bearing for the output shaft is replaced.





1. Clamp the transmission in the assembly support using the special tool 9589 or VW 540 and drain off the gear oil.
2. Pull the clutch release lever off the ball journal and remove with the release bearing.





3. Pull the ball bearing for the input shaft out of the transmission housing using the special tools V.A.G. 1582 and V.A.G. 1582/2.





4. Take out the input shaft "A", the output shaft "B", the relay shaft "C", the shift rods "D" and the shift forks "E" together.

Assembly





1. Assemble the input and output shafts with the shift rods and install them together in the transmission housing.
2. Insert the relay shaft and the interior shift rod.
- Engage 3rd gear.
- Insert the relay shaft.





- Position the interior shift rod next to the guide hole of the bearing cover, push the shift finger into the driver of the relay shaft and, by turning the interior shift rod, carefully swivel the latter into the guide hole.
3. Install the switch interlock.
- Push the locking slide to the center position and ensure that no gear is engaged.
- Insert the switch interlock.
- Guide the relay shaft into the switch interlock.
- Tighten the switch interlock with the stipulated tightening torque.
4. Insert the bolts for the relay shaft and tighten them with the stipulated tightening torque.
5. Seal and fit the transmission case cover. When doing so, pay attention to the installation position of the dowel sleeves in the transmission housing.
6. Press in the ball bearing for the input shaft.
- Place the pressure disc - A - of the special tool onto the ball bearing.
- Put the special tool 3235 behind the teeth for the clutch plate on the input shaft and pretension with the two screws - B -. Here, the screws support themselves in the two recesses of the pressure disc.
- Press in the ball bearing as far as it will go by alternately tightening the two screws.





Note Tighten the screws - B - only by 1/2 of a turn each so that the ball bearing is not tilted and thereby damaged.