Disassembly

Drive Flange and Differential Removal





- Remove shift rod lever and backup lights switch
- Drain transmission oil
- Mount transmission in repair stand





- Remove circlip and wave washer
- Attach VW391 to flange with 2 bolts
A = M8 x 30 bolts
- Pull axle 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 differential lock servo
- Drive out shift fork lock servo
- Remove differential lock servo from shift fork





- 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





Low Gear Housing/Gear Carrier Removal





- Remove output housing bolts
- Remove housing

- Remove splined sleeve (arrow)
- Remove cover for reverse idler gear





- Remove bolt (arrow)
- Remove low gear housing bolts





- Rotate transmission 180° (1/2 turn)
- Remove low gear housing along with low gear, needle bearing and shim
- Unbolt shift shaft cover
- Remove shift shaft





- Loosen bolt until relay lever (arrow) pulls against housing
- Tighten bolt by hand to lock lever in that position





- Remove retaining ring
- Remove end shield from housing





- Attach VW 457 with two M B x 20 bolts
- Push out gear carrier
- Remove shim S3 and note thickness





Output Housing Disassembly





- Secure flange with tool 3145 and remove flange nut





- If necessary, pull off flange with a two armed extractor
^ A = two armed extractor of commercial size, e.g. Kukko 44-2





Low Gear Housing Disassembly





- Remove low gear idler shaft
^ A = Puller, e.g. Kukko 22-1
^ B = Reducing thread bolt M5





- Remove reverse gear idler
^ A = Puller, e.g. Kukko 22-1
^ B = Reducing thread bolt M5




- Press off intermediate bearing
- Clamp separation device behind bearing
^ A = Separation device, e.g. Kukko 15-15, Gr. 2





Gear Carrier Disassembly





- Remove low/reverse gear shift fork
- Remove low/reverse gear synchronizer
- Remove synchronizer hub first circlip
- Remove synchronizer hub with control gear
^ A = two armed extractor, e.g. Kukko 20/10
- Remove second circlip, thrust washer and needle bearing
- Remove main shaft circlip





- Press out main shaft with drive pinion and shift rails





Main Shaft Disassembly





- Remove 3rd/4th synchronizer gears by pressing off with 3rd gear





Pinion Shaft Disassembly





- Press off 2nd/3rd gears
^ A = Separation device 22-115 mm, e.g. Kukko 17/2





- Remove 1st gear synchronizer sleeve/hub
^ A = Separation device 22-115 mm, e.g. Kukko 17/2





- Unscrew needle bearing inner race
- Push bearing over outer race





- Remove needle bearing inner race
^ A = Separation device 12-175 mm, e.g. Kukko 17/1