Volkswagen Type II Transporter 1200 Series Shop Manual page 130

49-Transmist~ion
and. Rear Axle
transmission case · or the drive pinion are replaced,.
re-adjustment of the drive pinion is essential.
(4) Check the pre-load of the double row taper roller
bearing as described in the appropriate section.
(5) Instal the shims which govern the first gear axial
play. Slide into position the first gear with synchroniser
ring and the assembled synchroniser hub and, using
a
feeler
gauge, check the axial play. The play should be between
. 004" and .010" but preferably on the lower side. .
(6) ·Slide into position the second gear synchroniser
ring, second speed gear with the needle bearing and the
third speed gear.
(7) Using a feelergauge, measure the third speed gear
axial play and effect adjustment by selection of a suitable
circlip. The axial play shouid be restricted to between
.004" and .010" but preferably on the lower side in the
range.
1
(8) Instal the spring
sp~cer.
As already described in this
section, heat the needle bearing inner race to approximately
100°C and press it on with the fourth speed gear .
(9)
U~ing
a special circlip pliers, instal a new clip and
ensure that it is properly seated.
12. AD.JUSTMENT OF SH.IFT FORKS
TO ADJUST
To effect proper adjustment of the shift forks a special
setting tool VW294a is necessary. Before commencing
adjustment, ensure that the pinion and the drive shaft must
be positioned exactly as they are when installed in the
transmission case. Fm this purpose, the axial location shims
of the drive pinion must be decided before-hand, and also
positioned in the setting tool. It is also necessary to take
into
co~sideraq.on
the thickness of the paper gasket which
is fitted between !he gear carrier and spacer bolts.
· (1) In the event of it not being possjble to obtain a
special setting tool ·for this iater model transmission with
'
'
certain modifications the earlier model VW294a can be
converted for the purpose. . . · . ·
(2) Position the gear carrier with gasket, pinion, c1rive
shaft and the reverse gear in the special tool and secure the
four nuts of the tool. Slide the selected adjustment shlms
on to the double row taper roller bearing and inser.t the
circlip in the groove. ·
(3) Instal.the clamp flange and uniformly tighten with
two bolts.
(4) Instal the shift forks for the first and second gears
and the third and fourth gears. · ·
NOTE: The sh.ift fork for the first and second gears (larger
fork width) is installed. with the offset towatds the gear
~arrier.
The offset of the third and fourth gear fork is away
from the gear carrier. .
(5) Instal the support with the rocker lever an!l slightly
tighten the union nut: ·· · ·
· (6) Locate the lower shift rod for the first and second
gear in the detent groove for the second gear. Slide the
operating sleeve with fork over the synchronising teeth
until
~t
abuts the second speed gear. Position the shift fork
in the centre of the groove in the operating sleeve and
tighten the clamp screw.
130
NOTE: The shift forks must be so positioned that, when in
the neutral position or when a gear is engaged, they should
not touch the sides or exert any pressure on the sides of the
groove in the operating sleeve_. There must always be some
clearance. ·
(7) While turning the transmission select both gears and
neutral a number of times and, in each position, check the
clearance between the shift fork and the operating sleeve.
The shift fork position can be altered, if necessary, so that
the same clearance exists between the fork and the sleeve
groove with the shift rod in both the end positions. Tighten
the clamp screw to a torque of 18 ft/lb.
· · (8) Locate the upper shift rod for the third and fourth
gears in the detent groove for the third gear. Adjustment of
the shift f9rk for third and fourth gears should. be done as
for the first and second gear.
(9) Tighten the clamp screw to atorque of 18ft/lb.
NOTE: For the adjustment of the third and fourth speed
gears it is important that the ball bearing in the gear ca"ier
is fullY. sea(ed. ·
(10) Push in the centre shift rod for the reverse gear
until it abuts the circlip and then slightly tighten the union
nut of the support for the rocker lever. ,
(11) Before tightening the union nut, press against the
sliditig reverse gear but not against the shift fork, then move
it in the ciirection of the gear carrier so that a clearance of
.0196" - .0393" exists between the reverse gear and the
second speed gear on the drive shaft. lil this position,
tighten the union nut.
NOTE: Ensure that there is no axial play while adjusting
the reverse sliding gear.
(12) Select the reverse gear and check the teeth
engagement on both the sliding reverse gear and on the
operating sleeve. This should be rectified, if necessary.