Volkswagen Type II Transporter 1200 Series Shop Manual page 105

(7) Check the selector forks for wear. The permissible
clearance between the selector forks and the operating
sleeves should be· .Oo4"- .012". Renew any worn parts.
(8) Check the condition of the main drive shaft and
drive pinion and recondition if necessary.
(9) Press the drive pinion and main drive shaft
assemblies into the gear carrier. Position the selector fork
for the third and fourth gears in the operating sleeve
beforehand. The drive pinion should be lifted slightly when
pressing and care should be exercised to ensure that the
selector fork for the third and fourth gears does not get
jammed on the selector shaft. ·
NOTE: It is recommended that while pressing the shaft and
gear assemblies into position, a rubber band should be
placed round the operating sleeve for the first and second
gears and the main drive shaft to hold the drive pinion and
main drive sliilft together.
(10) Instal the first and second speed selector fork.
(II) Attach the .reverse selector fork including the
reverse sliding gear to the reverse lever.
(12) Adjust the selector forks.
TO ADJUST SELECTORFORKS
Correct adjustment of the selector forks should only be
undertaken when a special tool VW294 is available for the
purpose. Since the adjustment of the drive pinion alters the
adjustment of the first and second reverse selector forks,
the adjustment of the drive pinion should be completed
first. It is also to be noted that the ddve pinion and main
drive shaft nuts must be tightened to the prescribed torque,
before adjusting the selector forks.
Transmission and Rear A.xle-24
(I) Clamp the special tool in a vice and position the
transmission with drive pinion shims and gear carrier gasket
on the gear shift testing special tool and attach the gear
carrier with four bolts. .
(2) Attach the drive pini~n ball bearing retainer with
two bolts diagonally opposed to one another and tightened
to a torque of 36 ft/lb.
(3) Fit the special tool crank on the main drive shaft
splines, locking the main drive shaft by the crank handle.
Engage the first or second gear.
(4) Tighten the drive pinion and main drive shaft nuts
to a torque of 87 ft/lb. Slacken off the nuts and again
tighten to a torque of 36 ft/lb.
(5) Set the selector shafts in the neutral
po~ition
and
attach the gearshift housing and shifting haridie. Attaching
the gearshift housing ensures a correct seating of the rrtain
drive shaft ball bearing in the gear carrier.
(6) Set the selector forks for the first and second and
the third and fourth gears so that the forks move freely in
the operating sleeve in neutral position as well
a~
when
different gears are engaged. . · ' .
(7) Set the reverse gear selector f~rk in a position
where the reverse sli\fing gear is in the centre, b~etween the
operating sleeve and the second gear of the main drive
shaft. With the second gear engaged, the reverse gear on the
drive pinion will be properly engaged with the reverse gear.
(8) Tighten the locking screws of the selector forks to a
torque of 18 ft/lb. The reverse lever guide screw should be
tightem;d to a torque of 14ft/lb.
(9) Remove the gearshift housing and take off the
transmission.
II. MAIN DRIVE SHAFT Oil. SEAl.
TO REMOVE
(I) As already described in the appropriate section,
remove the engine.
(2) Remove the clutch release bearing.
(3) Using a suitable tool remove the damaged oil seal
carefully from the transmission case.
105
TO INSTAL
Installation is a reversal of the removal procedure
observing the following points:
(I) Apply a light coating of sealing compound to the
outer periphery of the oil seal. Apply some oil on the rriain
drive shaft and the oil seal lip.
(2) Slide the oil seal on to the main drive shaft and,
using a suitable drift, drive the oil seal into position.
NOTE: Use care when sliding the oil seal on the shaft to
avoid dislodging the spring around the lip.