Volkswagen Type II Transporter 1200 Series Shop Manual page 123

Transmission and Rear A.xle-42
a.
TB.~NSMISSION
ASSEMBLV
TO REMOVE AND DISMANTLE
(1) Undo the three self-locking nuts and take off the
three double row pinion bearing retainers.
(2) Remove the gearshift housing with the inner shift
lever and take off the shift lever. Using a soft head hammer,
lightly tap the drive pinion until it moves sufficiently
forward to expose the double taper roller bearing circlip.
(3) From the pinion bearing take off the large outer
circlip.
NOTE: Do not over-stretch the circlip. To facilitate
removal, insert a right-an~led screwdriver under the circlip.
Over-stretched eire/ips should be discarded.
( 4) Remove the pinion shims and make a note of the
number and thickness.
(5) Undo the gear carrier securing nuts and remove the
nuts and washers.
(6) Press out the gears using a special tool according to
manufacturers instructions, levering against the end face of
the pinion shaft.
(7) Slacken the union nut for the rocker lever sleeve.
Just swing the reverse gear shaft far enough to facilitate
removal of the shift fork with reverse sliding gear.
(8) Slide the shift forks for the first and second and the
third and fourth gears off the shift rods.
(9) Using circlip pliers, remove the circlip off the main
drive shaft forward end, against the face of the gear carrier.
NOTE: Use care taking out the circlip as the dish washer
below the circlip is under considerable tension and
if
allowed to
fly
off it can cause injury.
(10) Press out the drive shaft and pinion assembly from
the gear carrier, carefully guide the pinion assembly to
avoid damaging the gears.
Installing New Circlip to Retain Main Drive Shaft in Gear Carrier.
123