Volkswagen Type II Transporter 1200 Series Shop Manual page 122

41-Transmission and Rear Axle
NOTE: While executing repairs which need re-adjustment
of the taper roller bearing pre-load and the J!ear backlash,
only instal the differential in the first instance to enable the
bearing pre-load to be checked. The oil seals
m~,tst
be
removed from the side covers when pre-load has to be
adjusted.
(3) Using a suitable tool, press the taper roller bearing
outer ~ings into the final drive covers.
(4) Apply oil lightly to the oil seals and press them into
position. Fit new 0 rings.
( S) Instal the left side final drive cover, with shims and
screw on the securing nuts and tighten.
(6) Turn the housing 180° while supporting the
differential and locate it in the left bearing. The right hand
final drive cover and shims can now be installed.
(7) Screw together the front and rear main drive shaft
and then screw back one spline. Slide on the reverse gear
and fit a new circlip.
NOTE: The right main drive cover cap nuts should not be
tightened until the clutch housing has been fitted and
secured with nuts.
(8) Instal the clutch housing with new gasket and
secure with nuts.
(9) Tighten the final drive cover cap nuts.
(10) Insert the spacer rings, slide on the flanges and
instal new circlips. The side gear can be drawn into the
flange splines using a bridge piece across the flange and a
screw in the end of the gear shaft, until the spring ring is
compressed sufficiently for the circlip to be fully seated. .
(II) Drive the new sealing caps into position.
LOCKING NUTS(3)
-TRAN,SMISSION CASE
Pinion Double Row Bearing Retainers and Self Locking
Nuts used on Earlier Models with Shim Adjusted Carrier
· Bearings. ·
TO DISMANTLE
(1) Clamp the differential housing in a suitable vice.
(2) Undo the ring gear mounting bolts and tap the gear
off the housing.
(3) Press the end cover off the differential housing.
( 4) Using a suitable puller, withdravv the taper roller
bearing out of the end cover. ·
(S) Remove the taper roller bearing from the
differential housing in the same manner. .
(6) Drive out the retaining pin and differential shaft
from the differential housing and remove the differential
pinions and thrust washers.
TO ASSEMBLE
(I) Carefully check the differential housing thrust
faces, thrust washers, gears, cover, ring gear and housing for
wear or damage and renew parts where necessary;
(2) Into the differential, insert the differential shaft
and side gear and pinions with thrust washers.
(3) Drive in the shaft, referred to in (2)above, using a
new pin, lock the shaft and peen the housing over the end
of the pin.
(4) Using a container of oil, immerse one of the taper
roller bearings and heat it. to approximately 1 00°C and
immediately place it on the housing and press it firmly into
position. ·
(5) Similarly heat the ring gear and, using two
centering pins,
inst~l
it on the differential
ho~sing.
'·
NOTE: Check the contact faces for· cleanliness which is
most essential and any bum should be remove.d with the
aid of an oil stone.
(6) Similar to (4) above, heat the second taper roller
bearing and press it on 'to the end cover,
~sing
the same
method of installation.
(7) Instal the end cover with the differential shaft and
. side
~ear
and the thrust washer, insert ring gear mounting
bolts with spring washers
~ptd
tighten them diagonally .to a
122
torque of 32ft/lb. · ·
NOTE: The co"ect type of bolts
with
spring washers
should only De used. ·
(8) Check the axial play by turning the differential
gears. Turning the gears by hand they should rotate
smoothly and without any binding. The axial play limit is
.012".