18)
Insert the fourth gear woodruff key into the drive pinion shaft on models using it. Newer models are splined.
19) Heat in oil both the fourth gear and needle bearing inner race to
approx. 1900 - 2001 (exception - '68 and later splined gear).
20) Slide fourth gear onto pinion shaft with the wide shoulder facing the spacer sleeve or helical spring, depending on model.
21) Usins Vw tool #426 or a
15/16"
deepwell socket, press fourth gear and needle bearing inner race fully into position.
MAIN SHAFT TEARDOWN
(See photo
A135
for parts and identification.)
1) Remove the thrust washer
2) Remove fourth gear
3~
Remove the needle bearing cage
4
Remove synchro
ring..
5)
Support shaft behind third gear and press off the inner needle bearing race, third - fourth gear synchro assembly and third gear.
6~ Remove the third gear needle bearing cage
7 Inspect the third - fourth gear synchro assembly and if necessary disassemble
INSPECT ALL PIECES FOR WEAR
1) Inspect the splined part of
main
shaft for wear, ships, etc,
2) Check the clutch sealing - seating surfaces of the oil seal in the main case. Check the rear mainshaft for scores.
3)
Check rear
main
shaft where it fits into the pilot bushing for rust or bad scoring.
4) Inspect first and second gears.
5)
Inspect needle bearings and surfaces.
6)
Check third and fourth gears for wear.
7)
Put front main shaft between two points and check contact surfaces of third gear needle bearing for run out. Run out should not exceed .006".
8)
Clean inside of synchro rings with wire brush - replace when past w ar Limit. Clearance between the synchro ring tooth and gear should be
.045"
with a wear limit of .024".
ASSEMBLY
Before proceeding note the following:
1) The marks on the hub and *leave of third - fourth gear synchro assembly should coincide
2) The hub is chamfered on the third gear side
3
The groove on the sleeve should be facing fourth gear
4) If the hub or sleeve has to be replaced, they must be replaced as a Pair
5)
Assemble the synchro unit for third and fourth gears. The operating sleeve and the synchro hub are paired and etched for identification to keep backlash at a minimum.
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