Volkswagen Type II Transporter 1200 Series Shop Manual page 144

6tl-Transmission and Rear .4xle
TO ASSEMBLE
{1) Thoroughly clean all parts and check for wear or
damage and renew if necessary.
(2) Pack the bearing housing with approximately 70
grams of lithium based grease.
{3) Using a suitable drift, drive the ball bearing into
position.
( 4) Insert the circlip and drift in the oil seal.
(5) Instal the roller bearing outer ring, spacer sieeve
and roller bearing iimer ring.
(6) Insert the outer circlip and, using a suitable drift,
drive in the oil seal.
(7) From inside, drive in the rear wheei shaft and slide
on the spacer ring.
(8) Instal the complete wheel bearing housing as
previously described in the appropriate sectiori.
16. FAULT DI.-'GNOSIS
GEARBOX
l.
Difficult gear change.
2.
3.
4.
Possible cause
(a) Bent or worn gear shift lever.
{b) Faulty gear synchroniser mechanism.
(c) Faulty clutch or dutch release bearing.
{d) Faulty clutch cable adjustment.
Gear clash on changing down.
Possible cause
(a) Faulty clutch or clutch release mechanism.
{b) Faulty synchroniser ring and clutch assemblies.
(c) Broken or incorrect positioning of synchro
retaining springs.
{d) Faulty clutch cable adjustment.
(e) Gearbox lubricating oil too heavy.
Slipping out of gear, (1st and 2nd).
Possible cause
(a) Weak or broken selector shaft detent springs.
{b) Worn pinion shaft sliding gear.
{c) Excessive end float of pinion shaft gears.
(d) Worn main drive or pinion shaft bearings.
(e) Incorrectly adjusted gear shift mechanism.
Slipping out of gear, (3rd and/or top).
Possible cause
(a) Weak or broken selector shaft detent springs.
{b) Worn synchro teeth on 3rd or top speed sleeve.
(c) Excessive end float of main drive shaft gears.
{d) Worn bearings on main drive gear and pinion shafts.
(e) Incorrectly adjusted gear shift mechanism ..
144
Remedy
Check and renew lever.
- Overhaul gearbox.
Check and overhaul clutch and/or renew bearing.
- Renew and/or adjust cable.
Remedy
Overhaul and adjust.
Check and overhaul gearbox, renew components as required.
Overhaul gearbox and renew components as required.
Check and adjust cable.
Drain gear case and rear axle assembly and refill with
correct grade of oil.
Remedy
Renew faulty components.
Check and renew faulty components.
Check and renew faulty thrust washer and shims.
Check and renew worn bearings.
- Check and re·adjust as required.
Remedy
Check and renew faulty components.
Check and renew worn components.
Check and renew thrust
washers~
Check and renew worn bearings.
Check and re·adjust as required.