Volkswagen Type II Transporter 1200 Series Shop Manual page 106

25-Transmission and Rear .4xle
12. DRIVE PINION
TO DISMANTLE
(1) Press out the needle bearing inner race and the
fourth gear.
(2) Extract the Woodruff key and remove the spacer
sleeve and shim for the third gear. Take off the second and
third speed gears with the needle bearing and synchroniser
stop ring for the second gear.
(3) Remove the first and second gears, clutch gear with
springs, shifting plates and operating sleeve and dismantle
the unit.
If any difficulty is experienced in removing the clutch
gear by hand, it should be pressed off. However, care
should be exercised to ensure that the shoulder of the ball
bearing does not foul the thrust plate.
( 4) Take off the synchroniser stop ring, the first speed
gear and the ball bearing retainer.
(5) Remove the two shims for the first gear.
(6) Using a special box wrench undo the round mit.
(7) Remove the first gear thrust washer and needle
cage.
(8) Positioning the drive pinion on a press, rembve the
inner race of the needle bearing, first gear thrust washer and
the ball bearing.
TO INSPECT
( 1) Carefully inspect the drive pmwn for wear or
damage and renew, if necessary. As the drive pinion and
ring gear are only serviced in mated pairs, it will be
necessary to renew the pair. Check for the matching
number on both the drive pinion and the ring gear. .
(2) Carefully check condition of the ball bearing and
needle bearing and renew, if necessary.
NOTE: Whenever a drive pinion or a ball bearing is
renewed, the drive pinion and the ring gear must be
re-adjusted.
(3) Carefuily check gears for wear or damage and
renew if necessary.
NOTE: Whenever a gear is renewed its mating gear must
also be renewed. If first and second speed gears are worn or
damaged and replacement is necessary, the main drive shaft
should also be replaced. ·
As from Chassis No. 614456 the number of teeth, and
therefore the ratio, of the third and fourth speed gears have
been altered as follows:
Early models: No. of teeth
Third speed . . . . . . . 29:22
Fourth speed . . . . . . . 24:27
Ratio
1.32:1
0.89:1
Later models: No. of teeth Ratio
Third speed . . . . . . . 28:23 1.22:1
Fourth speed ....... 23:28 0.82:1
The modified gear trains can be identified .by the
groove in the teeth.
( 4) Check the condition
ot
all-synchroniser parts.
(a) Using a suitable wire brush; clean the iriner cone
surface of the stop ring;
(b) Check the clearance between the face on the stop
ring and the clutch teeth of the corresponding gear
(normal .03"1 "). If the wear limit is found to be
reached (.012") the stop ring should be renewed.
·A clutch in poor condition can cause premature
1
wear of the stop rings as also can incorrect
a
i;J;:.
operation of the clutch by .a driver.
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The diameter of the clutch gear conical surface of
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the
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h" beon tncre,.,d
by
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7 20 21
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2nd 5elei:tor fork.
2.
~earing
cone.
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12
130
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33. Lock ScreW for 32.
3. Ball race.
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34. Pinion and shaft.
4. Bolts and lock plate for 10. 35 Woodruff key
5. Bolts and lock plate for 10. 18. Shims. "'
15
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ff1'f~J30,,
10.
Retainer for 6. 23. Needle bearing for 22.
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11. Needle rollers and cage. 24. 3rd speed gear.
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12. Inner race for 11. 25. Concave washer.
..,.-35
13. Thrust washer for 11. 26. Shim for 25.
14. Nut. 27. Spacer sleeve.
15. 1st speed gear. 28. 4th speed gear.
16. Synchro cone. 29. Needle bearing.
17.
1st
ahd 2nd synchro assy. 30. Lock washer.
Exploded View of Drive Pinion and
Shaft
Components.
106