Volkswagen Type II Transporter 1200 Series Shop Manual page 100

19-Transmission and Rear Axle
-TRANSMISSION ASSY
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Components of Rear Axle Shaft Tube Attachment.
(8) Instal the reduction gear case bolts and secure the
, cover to the case.
(9) Instal and tighten the rear axle nut to a torque of
220 ft/lb and insert a new split pin.
(10) Fill with 0.44 Imp. pint of recommended gear oil
into the reduction gear case.
(11) Check oil level in transmission and top up, if
necessary.
(12) Bleed the hydraulic system and adjust brake.
S. REAR AXLE TUBE AND SHAFT
TO REMOVE
(1) As previously described, take off the brake drum
and shoes including the wheel cylinder. Undo the retaining
bolts and remove the ball bearing cover and back plate.
Using a suitable puller, extract the outer ball bearing and
remove the reduction gear.
(2) Undo the brake pipe retaining clip and remove the
brake pipe.
(3) Undo the axle tube retainer nuts.
(4) Detach the axle tube with retainer and remove the
gasket and plastic packing.
(5) Extract the differential side gear snap ring.
(6) Withdraw the differential side gear thrust washer
and remove the axle shaft.
(7) From the differential housing, take out the
differential side gear and fulcrum plates:
(8) Remove the lock pin from the reduction gear case.
(9) Slacken the dust excluding sleeve.
(I 0) Position the reduction gear case on a press and,
with the aid of a special tool, press the axle tube out of the
reduction gear case. ·
NOTE: Care should be exercised during the above
operation to avoid damaging the reduction gear case. In the
event of the flange being damaged, the case should be
renewed.
( 11) Slide the dust excluding sleeve off the rear axle ·
tube and take off the tube retainer.
100
TO INSTAL
Installation is a reversal of the removal procedure
observing the following points:
(1) Thoroughly clean the axle tube retainer and
retainer seat on the final drive cover.
. (2) Carefully check the condition of the dust excluding
sleeve and if necessary, renew.
(3) Thoroughly clean, check and oil the seating faces of
the reduction gear case before assembling. Position the case
on a press and with the aid of spacers, press the case into
place.
(4) Check the condition of the rear axle shaft,
differential side gear. and thrust washer and if worn or
damaged, the components should . be r-enewed, but
consideration should be given to the following:
(a) Permissible clearance between the convex sides of
the flat end of the rear axle shaft and the inner
diameter of the differential side gear is from
.0012" to .004".
(b) Rear axle shafts and differential side gears are in
three tolerance groups and bear identifying paint
marks viz: blue, pink and green for guiding correct
mating. Only two tolerance groups are supplied as
spares, ie, blue and pink.
The identification mark on the side gear is
discernible by a paint dot on the recessed face. On
the axle shaft the identification is a ring painted
6" from the flat end.