Transmission And Rear Axle - Volkswagen Type II Transporter 1200 Series Shop Manual

TRANSMISSION AND REAR AXLE
PART I
TWO-PIECE SPLIT TYPE TR .. 4.NSMISSION
CASE
SPEt::IFit::ATIONS
Type . . . . . . . . . . . . . . . . . . 4 speed and reverse,
incorporating rear
axle and
differential in
split type case
Synchromesh ............ . 2nd, 3rd and 4th gears
Gear ratios:
First ............... . 3.60:1
Second .............. .
Third ............... .
Fourth .............. .
Reverse ............. .
Final drive ratios:
Pinion and ring gear
Axle reduction gear
1.88:1
1.23:1
0.82:1
4.62:1
4.43:1
1.40:1
I. DESt::RIPTION
The gearbox, rear axle and engine are combined in the
rear of the vehicle. The rear axle is of the swing half axle
type. The rubber-cushioned transmission case is secured to
the frame at three points. It incorporates the gearbox and
the differential.
The transmission case is of light alloy and in two parts.
It is important that when replacements are necessary, it is
not permissible to fit a single half of the transmission case.
They are machined in pairs to very close limits and in
consequent replacements must be made in pairs.
The gearbox has four speeds forward and one reverse,
which is provided with a stop. Synchromesh is obtained
with the helical 2nd, 3rd and 4th gears, which are in
constant mesh to ensure quiet operation.
The change rod in the frame tunnel links the gearbox
to the gear change lever, which is located on the tunnel
beside the driver's seat. The changing of first and reverse is
effected by sliding gears.
2. REAR .i\XLE ASSEMBLY
TO REMOVE
If it is intended to dismantle the rear axle upon its
removal from the vehicle, loosen the axle shaft nuts and the
wheel boltsbefore lifting the vehicle.
(1) Disconnect the battery earth cable.
(2) Lift
~he
vehicle, support it on stands and remove
the engine.
(3) Remove the rear wheels.
(4) If the rear axle is to be dismantled afterwards clean
the assembly with solvent. · ·
(5) Remove the axle shaft nut and withdraw the brake
drum and oil deflector.
(6) Disconnect the brake line at the rear. Remove the ·
brake shoe return springs, brake shoes, brake levers
and
brake cable brackets. Withdraw the brake cables froni the
back plates.
NOTE: When replacing the rear axle, the brake· cables and
brake drums remain on the axle. Unhook the brake cables
from the brake bar at the frame head and withdraw them
82
from the conduit tube towards the rear. The brake lines
between the back plates and the clamps on the rear axle
tube should be removed.
(7) Remove the bolts at the rear axle shaft bearing
housing:·'
(8) Disconnect the clutch cable from the ciutch
operating shaft lever and withdraw it from the guide plate.
(9) Disconnect the cables from terminals at the starter
motor.
(1 0) Remove the frame end cover plate. Remove the
rear screw of the shiftirig rod coupling and move the
gear change lever ·to withdraw the coupling from the
transmission change rod.
(11) Remove the nuts at the transmission front rubber
cushion.
(12) Remove the two bolts at the transmission carrier.
(13) Withdraw the axle assembly from the rear of the
vehicle, .
NOTE: Take care not to damage the dust sleeves.