Contents - Volkspage

Manual transmission 7.3
removal, refitting and
adjustment
2.15 Removing the rear engine mounting
and bracket
2.16a Disconnecting the shift rod coupling
2.16b Removing the shift rod coupling 2.16c Shift rod adapter and bush
16 Remove the screw from the shift rod
coupling and ease the coupling from the rod.
The screw threads are coated with a liquid
locking agent and if difficulty is experienced it
may be necessary to heat up the coupling with
a blowlamp, however take the necessary fire
precautions. If required, remove the coupling
ball from the adapter (see illustrations).
17 Support the transmission on a trolley jack
then withdraw it from the engine keeping it in
a horizontal position until clear of the clutch. If
necessary use a lever to free the transmission
from the locating dowels.
Caution: Do not allow the transmission to
tilt until it the input shaft is clear of the
clutch driven plate, or damage to the plate
may occur.
18 Lower the transmission and remove it
from under the car.
Refitting
19 Refitting is a reversal of removal, but first
smear a little molybdenum disulphide based
grease on the splines of the input shaft, and
make sure the engine rear plate is correctly
located on the dowels. Delay fully tightening
the mounting nuts and bolts until the
transmission is in its normal position. Adjust
the gearchange if necessary (see Section 4).
2 Detach the inner ends of the driveshafts
from the drive flanges with reference to
Chapter 8 and tie the driveshafts to one side.
3 Unscrew the bolt from the centre of each
drive flange using a bar and two temporarily
inserted bolts to hold the flange stationary.
4 Place a container beneath the transmission
then remove the drive flanges and lever out
the old oil seals. Identify the flanges side for
side.
5 Clean the recesses then drive in the new oil
seals using a suitable length of metal tubing.
6 Smear a little grease on the lips of the oil
seals, and insert the drive flanges.
7 Insert the bolts and tighten them to the
specified torque using the bar and bolts to
hold the flanges stationary.
8 Refit the driveshafts with reference to
Chapter 8.
9 Check and if necessary top-up the
transmission oil level then lower the car to the
ground.
Removal
1 Jack up the front of the car and support on
axle stands (see “Jacking and vehicle
support”). Apply the handbrake.
2 With neutral selected, mark the shift rod
and coupling in relation to each other, then
unscrew the coupling clamp and pull out the
shift rod.
3 Working inside the car unscrew the gear
knob and remove the gaiter.
4 Unscrew the nuts from the ball housing
stop plate, and withdraw the complete
gearchange mechanism upwards into the car
(see illustration). Recover the spacers.
5 Dismantle the mechanism as necessary
and examine the components for wear and
damage. Renew those showing signs of wear
or deterioration. Note that the selector rod
bush is in two parts, and both parts are
destroyed when removing the mechanism.
When fitting the new bush, ensure that the
two plastic cups are not pushed apart.
Refitting
6 Lubricate the joints and bearing surfaces
with high-melting-point grease then refit using
a reversal of the removal procedure. If a new
coupling has been fitted it will be necessary to
adjust the coupling position - this is best
carried out by a VW dealer, as a specially
shaped template is required, but if necessary
the method described in the following sub-
Section can be used in an emergency.
Adjustment
7 With the car raised and supported on axle
stands (see “Jacking and vehicle support”),
loosen the shift rod clamp bolt.
8 Have an assistant position the gear lever as
shown (see illustration). Use a twist drill for
dimension (a), and align the lever so that the
reverse gear catch is exactly opposite the
recess in the housing.
9 With the transmission still in neutral, tighten 7
the clamp bolt.
10 Check that all gears can be selected
easily.
1 Jack up the front of the car, support it on
axle stands (see “Jacking and vehicle
support”) and apply the handbrake.