Disassembly and assembly of the gearbox

Disassembly

Install the gearbox on a stand for disassembly.

Drain the oil from the gearbox housing.

Remove the gearbox rear cover plug by using a large screwdriver to punch a hole in the center of the plug and remove it.

Block the input shaft by placing a lock on the splines for the hub of the clutch disc.

Remove the hex bolt from the rear end of the input shaft.

Loosen the bolts securing the rear cover of the gearbox.

Remove the gearbox rear cover using a bearing puller.

Remove the spring cotter pin from the driver of the 1st and 2nd gear shift fork rod by turning the driver to the left.

Engage 3rd gear by pulling out the shift rod of the 3rd and 4th gear forks.

Turn the gear selector rod to the left and remove it.

Remove the leash from the stem of the fork of 1st and 2nd gears.

Knock out the spring cotter pin from the 5th gear fork, while holding the fork rod with a hammer so as not to damage the hole for the fork rod in the gearbox housing wall.

Using a double-lever puller, remove the connecting part together with the 5th gear, the sliding sleeve and the 5th gear synchronizer cage. At the same time, make sure that the 5th gear engagement fork remains free. Fork stem stays in crankcase (see photo).



Remove the 5th gear needle bearing inner race and thrust washer using two large screwdrivers if necessary.


Engage any gear and block the input shaft with the lock VW 294b1.

Remove the nut from the rear end of the output shaft.

Remove the 5th gear with a double-lever puller (see photo).



Set the shift forks to the neutral position.

Remove the gearbox housing together with the input and output shafts and clamp it in a vise with soft metal pads.

Knock out the spring cotter pin from the shift fork of III and IV gears, while holding the fork rod with a hammer so as not to damage the fork rod socket in the gearbox housing partition.

Pull out the 3rd and 4th gear fork rod until the fork can be removed.

Note. If it is intended to remove the output shaft, fully pull out the 3rd and 4th gear fork rod.

Apply lightly (by 6-8 cm) back output shaft.

Remove input shaft assembly with 3rd and 4th gear fork.

Return fork rods to neutral position.

Knock out the axle and remove the reverse idler gear.

Press output shaft out of gearbox housing.

Warning. When pressing out the secondary shaft, make sure that the shift fork rod of the 1st and 2nd gears does not jam, if necessary, release it by lightly hitting it with a hammer.


Remove the secondary shaft together with the rod and fork of 1st and 2nd gears.

Loosen the differential output shaft bolts, holding them with mandrels.

Loosen the differential cover bolts.

Remove the differential cover using two levers.

Take out the differential.