Volkswagen Type II Transporter 1200 Series Shop Manual page 92

11-Transmission and Rear Axle
CROWNWHEEL
until the shift plates engage with the slots in the ring.
Keep within the limit of ±.002" in the position of the
clutch gear face in relation to, above or below the end of
the splines on the pinion shaft.
In the event of exceeding the upper or lower tolerance
limit of .002", correct the end play of the assembled parts
on the splined portion of the drive pinion by installing a
shim between the roller bearing and the second speed
clutch gear or by altering the thickness of the shim. It
should be ensured that the parts have to be assembled on
the splined portion of the drive pinion shaft in the correct
order.
{11) Position the fourth speed stop ring on the clutch
gear for the shift plates engaging the slots in the ring.
- 3rd SPEED SYNCHRO GEAR
- 2nd SPEED SYNCHRO GEAR
2nd SPEED SYNCHRO CONE
2nd SPEED SYNCHRO HUB
..- SLIDING GEAR SLEEVE
..._ROLLER BEARING
-PINION
Assembling Drive Pinion Components.
{12) Instal the fourth gear bush, the fourth gear and
the friction washer.
{13) Instal the required thickness of shims on the drive
pinion shaft for correct axial adjustment. Shims with the
thickness of .008" and .0 12" are serviced by the
manufacturers.
(a) When drive pinion assembly parts are being
replaced and which do not affect the axial
adjustment, it is not recommended to alter the
total thickness of the shims to correct meshing of
the drive pinion and ring gear.
(b) If the drive pinion or other parts are being
replaced which can affect the axial adjustment,
again determine the correct amount of shims t~ be
installed. The standard thickness of the total
amount of shims is .0275". Always take into
consideration the plus or minus marking on the
face of the drive pinion.
Example:
Standard thickness of shims . . . . . . . . . . . . . . .0275"
Axial tolerance discrepancy -0.18 mm. This
value is to be raised to the next tenth of
a mm. viz . . . . . . . . . . . . . . . . . . . . . . . . . . .0078"
.Total thickness of shims required . . . . . . . . . . .0196"
Position the double row ball bearing, with machined
channel for fitting the balls, facing towards the drive
pinion nut and press bearing into position .
(14) Renew the lockplate and instal after applying
grease. .
(15) Instal and tighten the drive pinion nut to a torque
of 45ft/lb. '
(16) Check the end play of the 2nd, 3rd and 4th gears.
In each case end play should be .004" to .010".
(17) After checking the axial adjustment of the drive
pinion, bend the tabs on the lock plate and secure the nut.
I
J. DIFFERENTIAl. AND FINAL DRIVE
TO DISMANTLE
(1) As previously described, dismantle the transmission
case and remove the differential and rear axle shafts.
(2) Take out the lock wire and undo the ring gear
securing bolts.
(3) Take off the differential housing cover with rear
92
axle shaft, qifferential side gear and fulcrum plates.
(4) Withdraw the ring gear.
(5) Extract the lock pin from the differential shaft.
(6) Remove the differential pinion shaft ,and pinions.
(7) Remove the rear axle shaft, the differential side
gear and fulcrum plates from the differential housing.