Volkswagen Type II Transporter 1200 Series Shop Manual page 126

45-Transmission arid Rear .4xle
FIRST AND SECOND SHIFT ROD
Gear Carrier Showing Rocker Lever Support Adjusting
Union Nut and Clamp Sleeve.
TO ADJUST AXIAL PLAY BETWEEN REVERSE
SLIDING GEAR AND SHIFT FORK
If for any reason the reverse relay shaft and brackets
are removed, adjustment of play between the reverse sliding
gear and shift fork must be carried out by axial movement
of the shaft and brackets as follows:
(1) Using a setting appliance, instal the gear carrier
with reverse gear and shift fork.
(2) Slacken the mounting screws of both brackets.
(3) Slide ·the shift fork side bracket on to the shaft
until it abuts the reverse gear, then tighten the bracket
mounting screws.
(4) Position the other bracket against the end of the
shaft until the shaft is firmly fixed with no play and then
tighten the bracket mounting screws.
(5) Remove the gear carrier from the setting appliance
and assemble the transmission as previously described.
7. SHIFT HOfJSING
TO DISMANTLE
(1) Clamp the shift housing in a vice with soft jaws and
using an adjustable pliers, turn the bush and sealing ring to
remove.
(2) Using a suitable drift, drive out the inner guide
bush.
(3) Unscrew the plug/back-up light switch with washer
and remove the shift housing from the vice.
TO ASSEMBLE
(1) Press in the inner guide bush.
(2) Press in the bush and sealing ring.
NOTE: The bushes are finished to size and, therefore,
reaminl! is not, normally, required. However, if the inner
shift lever tends to be stiff in operation, open the bushes
out from inside the housinK with a (.6023" - .6102")
reamer. Avoid damaging the sealing ring.
(3) Screw in the plug/back-up light switch after fitting
the washer.
8. TRANSMISSION t:;ASE
TO DISMANTLE
(1) Take off the circlip from the reverse drive gear,
press off the gear with levers and·remove the Woodruff key
from the reverse gear shaft. ·
(2) Withdraw reverse gear shaft and thrust washer fr_om
the housing.
· (3) Remove the drive shaft needle bearing circlips.
Using a suitable drift, drive out the needle bearing.
(4) Remove the reverse shaft needle bearing locking
screw. Using a suitable drift, drive out the needle bearing
and sleeve.
126
TO ASSEMBLE
(1) Carefully check the reverse gear shaft, gear and
needle bearing for wear or damage and renew ifnecessary.
(2) Using a suitable drift, drive in the main drive shaft
needle bearing. Insert circlips.
(3) Insert the reverse· shaft spacer sleeve and lock it in
position.
(4) Using a suitable drift, from either side drive in the
needle bearings as far . as the spacer sleeve. Position the
needle bearing with the metal ring towards the spacer
sleeve. Strike bearing on the lettered side only.
· (5) From the. transmission side insert the reverse gear
shaft with thrust washer. Fit the Woodruff key, slide on the
reverse drive gear and instal a new circlip.