Info

No.

Description

Removing

en: Installing

1

Hex bolt

4

Tighten crosswise to torque of 8 Nm (6 ftlb), and check pump for freedom of movement.

2

Washer

4

3

Cover

1

4

Ball

1

5

Spring

1

6

Gasket

1

Replace, re-determine thickness

7

Holding clip

1

8

Screen

1

9

Impeller

1

10

Circlip

1

11

Drive gear

1

12

Woodruff key

1

13

Impeller

1

14

Bushing

1

Pull out with suitable internal puller

Drive into correct position with suitable mandrel

15

Bushing

1

Pull out with suitable internal puller

Drive into correct position with suitable mandrel

16

Bushing

1

Pull out with suitable internal puller

Drive into correct position with suitable mandrel

17

Bushing

1

Pull out with suitable internal puller

Drive into correct position with suitable mandrel

18

0-ring

1

Replace, coat with transmission oil

19

Side transmission cover

1

DISASSEMBLY AND ASSEMBLY INSTRUCTIONS

Disassembly

1. Note installation position of bushings for re-installation.

2. Set end play of pump to 0.05 + 0.1 mm with suitable paper gasket. Gaskets in thicknesses of 0.15 and 0.20 mm are available.

2. Pull out bushings with suitable internal puller.

Assembly

3. Tighten hex bolts for pump cover to a torque of 8 Nm (6 ftlb), and check pump for ease of motion.

1. Drive bushing into side transmission cover in correct position until stop with suitable mandrel (see sketch).

NG 300

TOOLS

No.

Description

Special Tool

Remarks

1

Circlip pliers

VW 161 a

2

Feeler blade gage

As commonly used

3

Pressing plate

VW 401

4

Pipe section

VW 519

5

Separator

For example, Kukko 15-17 Gr. 1

DISASSEMBLING AND ASSEMBLING INPUT SHAFT

Gang Bolt Torque

No.

Description

Qty.

Removing

Note Wh

Instal1ing

1

Circlip

1

2

Fourth gear

1

End play 0.1 to 0.4 mm

3

Needle bearing

1

Oil with transmission oil

4

Synchromesh ring

1

Check for wear

5

Circlip

1

Re-determine thickness

6

Synchronizer with sliding sleeve for 3rd and 4th gears

1

Press off with 3rd gear wheel

Position correctly, measure end play

a

Sliding sleeve

1

b

Synchronizer

1

c

Spring

2

Position correctly.

d

Locking piece

3

7

Synchromesh ring for 3rd gear

1

Check for wear

8

3rd gear 3. Gang

1

J

Measure end play between 2nd and 3rd gear wheels. Control value 0.1 to 0.39 mm

9

Needle bearing

1

Oil with transmission oil

10

Circlip ring

1

Install only after installation of input shaft

11

Inner race

1

Install only after installation of input shaft

12

Input shaft

1

2. Mount springs with 120° offset. Angled end of spring must engage in hollow lockpiece.

DISASSEMBLY AND ASSEMBLY INSTRUCTIONS

1. Press off sliding sleeve/ synchronizer with 3rd gear wheel.

1. Assemble sliding sleeve and synchronizer for 3rd and 4th gears. It is not necessary to pair in a certain position. However, the wide collar of the hub must face the 4th gear wheel.

3. Press on sliding sleeve and synchronizer in correct position using VW 519. Turn synchromesh ring so that grooves align with locking pieces.

4. Measure end play of synchronizer with a feeler gage blade and adjust by selecting the correct circlip. End play should be between 0 and 0.05 mm. The lower value is preferable.

The following circlips are available:

Replacement Part No.

Thickness (mm)

Note

The wide collar of hub must face 4th gear wheel.

088 311 317 088 311 317 B 088 311 317 C

5. Measure play between 2nd and 3rd gears. Nominal value: 0.1 to 0.39 mm. If this tolerance cannot be reached, recheck adjustment of synchronizer.

Checking Synchro-mesh Rings

1. Clean synchromesh rings and gears.

6. Measure end play on 4th gear. Nominal value: 0.1 to 0.44 mm. If this tolerance can not be reached, recheck adjustment of synchronizer.

Clearance

Distance

Wear Limit

3rd

and

1

.0

to

4th

gear

1

.7

mm

5th

gear

1

.0

to

1

.9

No.

Descri ption

Special Tool

Remarks

1

Support rail

VW 457

2

Pipe section

VW 519

3

Pressing plate

VW 401

4

Feeler blade gage

As commonly used

5

Separator

For example Kukko 15-17 Gr. 1

6

Pressing tool

VW 454

DISASSEMBLING AND ASSEMBLING PINION SHAFT

No.

Description

Installing

1

Tapered roller bearing

1

Press off with VW 457

Replace if necessary. Always replace both bearings at same time.

2

1st gear wheel

1

Check end play.

3

Needle bearing

1

Lubricate with gear oil

4

Synchromesh ring for 1st gear

1

Identification: 1 tooth missing every 3. Friction surfaces coated with molybdenum. Spiral groove. Check for wear.

5

Circlip

1

Re-determine thickness

6

Synchronizer with sliding sleeve for 1st and 2nd gears

1

6a

Sliding sleeve

1

6b

Synchronizer

1

6c

Spring

2

Position correctly

6d

Locking piece

3

i

7

Synchromesh ring for 2nd gear

1

Friction surface coated with molybdenum spiral groove

8

2nd gear wheel

1

9

Needle bearing

1

Lubricate with gear oil

10

Circlip

1

Re-determine thickness

No.

Description

Qty.

Removing

Installing

11

3rd gear wheel

1

Check for wear. Install warm and press on. Large collar faces 2nd gear wheel. Adjust end play.

12

Circlip

1

Thickness always 2.4 mm

13

Circlip

1

Re-determine thickness

14

4th gear wheel

1

Check for wear. Install warm and press on. Large collar faces 3rd gear wheel. Adjust end play.

15

Tapered roller bearing

1

Press off with separator

Replace if necessary. Always replace both bearings at same time.

16

Pinion shaft

1

Check for wear. Paired with ring gear (pinion set). When replacing pinion set, adjust pinion shaft and ring gear.

3. Press off 3rd gear wheel.

DISASSEMBLY AND ASSEMBLY INSTRUCTIONS Note

When replacing tapered roller bearings, determine installed position of pinion shaft (actual location) before removing gearbox.

1. Press off inner race of tapered roller bearing with 1st gear. Use support rails VW 457.

2. Press off sliding sleeve and synchronizer with 2nd gear. Use support rails VW 457.

3. Press off 3rd gear wheel.

4. Press off 4th gear with a separator, for example Kukko 15-17 Gr. 1.

5. Press off inner race for tapered roller bearing with a separator, for example Kukko 15-17 Gr. 1.

1. Heat inner race for tapered roller bearing to approx. 120°C/ 248°F and press it on.

2. Heat gear wheel for 4th gear to approx. 120°C/248°F and press on. The collar must face the 3rd gear wheel.

3. Adjust end play on 4th gear wheel (gear must have cooled off and be pressed against stop).

Measure and install the thickest possible circlip. The end play must not exceed max. 0.03 mm.

The following circlips are available:

Replacement

Thickness

Part No.

(mm)

016 311 363

AA

2.24

016 311 363

AB

2.26

016 311 363

AC

2.28

016 311 363

AD

2.30

016 311 363

AE

2.32

016 311 363

AF

2.34

016 311 363

AG

2.36

016 311 363

AH

2.38

016 311 363

AJ

2.40

4. Press on 3rd gear wheel with collar facing 2nd gear wheel, after installing circlip (arrow) 016 311 363 AJ, 2.4 mm thick.

Note

Perform this adjusting procedure very carefully, as otherwise the service life of the tapered roller bearings will be impaired.

Clean gear and shaft, removing all oil and grease, with a clean gasoline. Heat gear on a hotplate to approx. 120° C/248°F.

Note

Coat molybdenum-coated synchro-mesh rings with an approved transmission oil.

7. Press on sliding sleeve and synchronizer. Turn synchromesh ring so that grooves are aligned with lock pieces.

016 311 287 016 311 287 A 016 311 287 B

6. Assemble sliding sleeve and synchronizer for 1st and 2nd gears. It is not necessary to pair in a certain position. Insert lock pieces and install springs with a 120° offset. Angled end of spring must engage in hollow lock piece.

5. Measure end play on 3rd gear wheel with a feeler gage blade and adjust by using the appropriate circlip. Play should be between 0 and 0.04 mm, with the lower value being preferable.

The following circlips are available:

Replacement Part No.

Thickness (mm)

8. Adjust end play on synchronizer. Measure end play with a feeler gage blade and adjust by selecting the appropriate circlip. Play should be between 0 and 0.04 mm, with the lower value being preferable.

9. Heat inner race for tapered roller bearing to approx. 120°C/ 248°F and press on with VW 454.

The following cirelips are available :

Replacement

Thickness

Part No.

(mm)

016 311 327

1.50

016 311 327

A

1.55

016 311 327

B

1.60

10. Measure play on 1st gear wheel. Play should lie between 0.10 and 0.40 mm. If necessary, check adjustment of synchronizer. Parts must be pressed on up to stop!

Checking Synchro-mesh Rings

1. Clean synchromesh rings and gears.

2. Press dried synchromesh rings onto tapers of gears and measure clearance "a" with a feeler gage blade.

Clearance

New

Distance

Wear

Ii 3 Ii a

Li mi t

1st and

1.0

to

0.5 mm

2nd gears

1.7

mm

REMOVING AND INSTALLING DIFFERENTIAL

Note When:

No.

Description

Qty.

Removing

Installing

1

Seal ring

1

Pull out with VW 681

Install only after installing gear set. Oil sealing lip. Drive 1.5 mm into housing with Special Tool 9178 and suitable pipe section.

2

Threaded sleeve

1

Tightening torque 30 Nm (22 ftlb)

3

Gasket

1

Replace

4

Spring

1

5

Bushing

1

6

Speedometer socket

1

Tightening torque 42 Nm (30 ftlb)

7

Speedometer pinion

1

Oil guide pin

8

Hex bolt

3

Tightening torque 8 Nm (6 ftlb)

9

Lock washer

3

10

Cover

1

Position correctly (manufacturer's mark outwards)

11

Gasket

1

i

Replace

(complete)

1

-

13

Dowel sleeve

2

14

Hex bolt

12

Tightening torque 24 Nm (17.7 ftlb)

Note When:

No.

Description

Qty.

Removing

Installing

15

End plate

1

Coat sealing surface with Curil KIH

16

Allen head bolt

2

Tightening torque 24 Nm (17.7 ftlb)

17

Flange shaft

2

Lubricate shaft

18

Hex bolt with washer

9

Tightening torque 24 Nm (17.7 ftlb)

19

Cover

1

Evenly coat sealing surface with Loctite 573 or 574

20

Differential

1

Remove gearbox before removing differential

Light coat of oil for tapered roller bearings and conical gear teeth

21

Transmission housing

1

If the transmission housing requires replacement and deviation "r" is not given on ring gear, check position of pirn*on shaft prior to removing gearbox (actual distance).

ASSEMBLY AND DISASSEMBLY INSTRUCTIONS

Disassembly

Note

Before removing the differential, the gearbox must be removed.

1. Remove cooling coil.

?.. Unscrew mounting bolt for flange shaft and take off flange shaft, counterholding with a mandrel.

Assembly

1. Tighten mounting bolts for side transmission cover to a torque of 24 Nm (17.7 ftlb).

2. Tighten mounting bolts for flange shaft to a torque of 24 Nm (17.7 ftlb)

2. Unscrew final drive cover mounting bolts and pry off cover with two tire irons.

TOOLS

No.

Description

Special Tool

Remarks

1

Two-arm extractor

As commonly used for example Kukko 44/2

Ù

Pressing tool

VW 40-105

3

Pipe section

VW 40-21

DISASSEMBLING AND ASSEMBLING DIFFERENTIAL

14 12 13 11

14 12 13 11

No.

Description

Removing

sn

Installing

1

Drive gear

1

2

Inner race for large tapered roller bearing

1

Remove with suitable two-arm puller and Special Tool VW 40-105

Heat to approx. 100°C /212°F and press on with Special Tool VW 40-21.

3

Inner race for small tapered roller bearing

1

Remove with suitable two-arm puller and Special Tool g VW 40-105

Heat to approx. 100°C /212°F and press on with Special Tool VW 40-21.

4

Drive gear

1

Install so that position of recess corresponds to position of recess in housing

5

Hex bolt

10

Loosen, then tighten crosswise to torque of 90 Nm (65 ftlb)

6 ;

Ring gear

1

Heat to approx. 120°C /248°F

7

Dowel sleeve

1

Knock in flush

8

Pin

1

Knock in carefully, to avoid damage to thrust washers. Lock with dowel sleeve.

9

Small differential gear

2

10

Thrust washer

2

Check for wear

11

Large differential gear

2

Adjust

12

Nut

2

Note When:

No.

Description

Qty.

Removing

Installing

13

Shim

2

Determine new

thickness

14

Locking pin

1

15

Housing

1

When replacing adjust

ring gear

2. Take ring gear off of housing.

DISASSEMBLY AND ASSEMBLY INSTRUCTIONS Disassembly

1. Clamp differential in a vice and unscrew ring gear bolts. Fit vice with soft jaws.

2. Take ring gear off of housing.

3. Pull off inner races for large and small tapered roller bearings. Use a suitable two-arm extractor and pressing tool VW 40-105.

During assembly, lubricate the following parts with transmission oil: running surfaces of the housing as well as large and small differential gears, and thrust washers.

1. Heat inner races for small and large tapered roller bearings to approx. 100°C/212°F, position, and press on with pipe sections VW 40-21.

2. Install differential gears. Install large differential gears with correct shims. Install small differential gears with 180° offset (hold thrust washers in place with a small amount of grease) and swing in. Align thrust washers with shaft bore, knock in shaft carefully, and lock with a dowel sleeve.

3. Heat ring gear to approx. 120°C/248°F and install. Align bolt holes with each other using centering pins.

A - Centering pins

ADJUSTING DIFFERENTIAL GEARS

1. Install large differential gears with thinnest shims (0.5 mm).

2. Install small differential gears with thrust washers and press in shaft.

Note

4. Adjust play to maximum of 0.10 mm by inserting a shim of the correct thickness.

Note

Adjustment is also correct when no play can be felt but the differential gears still turn easily and without catching.

From this point on be careful not to mix up differential gears and thrust washers.

3. Press small differential gears outwards and check play of large differential gears by hand (arrows).

The following shims are available:

Replacement Part No.

Thickness (mm)

Oil

519

215

0.5

088

409

249

0.6

088

409

249

A

0.7

088

409

249

B

0.8

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