, , ,

C-30-108-000/MP-002 - Overhaul Manual

C-30-108-000/MP-002
1986-12-05247 Pages

PDF (7,578 KB)

Canadian Department of National Defence logo
C-30-108-000/MP-002

Overhaul Manual

For Truck, Utility, Light, 4 x 4, Military Design, Iltis Canadian Series
Issued on Authority of the Chief of the Defence Staff
OPI: DSVEM 2
1986-12-05
Canada logo


   The following sections have been extracted from the original CFTO document. For ease of use, some hyperlinks, reformatting, and minor modifications may have been made. English only. Pour la version français, télécharger le document original.


WARNING — All parts on the Iltis Canadian Series are dimensioned in the metric system. During any maintenance procedures, all replacement fasteners must have the same measurement and strength as those removed. (Numbers on the heads of metric bolts and on the surfaces of metric nuts indicate their strength). Mismatched or incorrect fasteners may result in personal injury, damage or malfunction of components. Therefore, fasteners removed from the engine should be saved for re-use in the same location where possible. When fasteners are unsatisfactory for re-use, care should be taken to select a replacement that matches the original.

Part 1 — General Description

Section 1 — General

Scope

1.This manual contains overhaul procedures for the engine, transaxle and rear differential for the Truck, Utility, Light 4×4 Military Design, Iltis Canadian Series at third and fourth line maintenance units. Information on component maintenance and repair is provided in CFTO C-30-108-000/MP-001.

Authority

2.All correspondence concerning this manual should be directed to:
National Defence Headquarters
Ottawa, Canada  K1A OK2
Attention: DSVEM 2

Types of Overhaul

3.Types of information in this manual include removal, disassembly, cleaning, inspection, measurements, repair, adjustments and assembly.

Manual Organization

4.The manual is organized into the following parts:

  1. Part 1 - General Description
  2. Part 2 - Engine
  3. Part 3 - Transaxle
  4. Part 4 - Rear Differential

Section 2 — General Overhaul Procedures

Introduction

1.To perform a major overhaul or other extensive repairs, the complete assembly should be mounted on an overhaul stand and the various assemblies removed.

2.Parts removed from an individual assembly should be kept together to be available for inspection and reassembly to the same assembly. Those items having machined faces, which might be easily damaged by steel or concrete, should be stored on suitable wooden racks or blocks, or on a separate dolly.

3.For inspection, repair and overhaul of all engine components, including the coolant pump, alternator, starter, oil pan and oil pump,carburetor and distributor, refer to "Truck, Utility, Light, 4x4 Military Design, Iltis Canadian Series, Maintenance Manual", CFTO C-30-108-000/MP-001.

4.When a decision to use a new component is made, the following general factors should be considered:

  1. degree of wear of the old component;
  2. time required for reconditioning an old component compared with the cost of a new component;
  3. component deterioration (usually electrical) due to length of service time and operating environment;
  4. hours in service; and
  5. the next overhaul period.

Cleaning

5.General — After each subassembly is removed and disassembled, the individual parts should be cleaned. Thorough cleaning of each part is absolutely necessary before it can be satisfactorily inspected. Before removing any of the subassemblies from the engine (but after removal of the electrical equipment), the exterior of the engine should be thoroughly cleaned.

6.Steam Cleaning — A steam cleaner can be used to remove heavy accumulations of grease and dirt from the exterior of the engine and its subassemblies after removal of the electrical equipment.

7.Solvent Tank Cleaning — A tank of sufficient size to accommodate the largest part that will require cleaning (usually the cylinder block) should be provided and provisions made to heat the cleaning solvent between 82 and 93°C.

8.Fill the tank with a commercial heavy duty solvent and heat between 82 and 93°C. Lower large parts directly into the tank with a hoist. Place small parts in a wire mesh basket and lower them into the tank. Immerse the parts long enough to loosen all grease and dirt.

9.Rinsing Bath — Provide another tank of similar size to the solvent cleaning tank, containing hot water for rinsing the parts.

10.Drying — Parts may be dried with compressed air. However, the heat transferred to the part from the hot tanks will frequently completely dry the parts without the use of compressed air.

11.Machined Surface Cleaning — Make sure that mating surfaces are thoroughly clean and free from such foreign matter as gasket debris.

12.Rust Preventive — If parts are not used immediately after cleaning, dip them in a suitable rust preventive compound. Remove the rust preventive compound before installing the parts.

Inspection

13.The purpose of parts inspection is to deter mine which parts can be used and which must be replaced. Although the overhaul specifications given throughout the manual will aid in determining which parts should be replaced, considerable judgement must be exercised by the inspector.

14.Many service replacement parts are available in various undersizes or oversizes as well as standard sizes. Also, service kits for reconditioning certain parts, and service sets, which include all of the parts necessary to complete a particular repair job, are available.

15.In addition to measuring the used parts after cleaning, parts shall be carefully inspected for cracks, scoring, chipping and other defects.

Assembly

16.Following cleaning and inspection, use new parts as determined by the inspection.

17.Use of proper equipment and tools makes the job progress faster and produces better results. A suitable working space with proper lighting is essential.

18.Keep working space, equipment, tools, assemblies and parts clean at all times. The area where assembly takes place should, if possible, be away from the disassembly and cleaning operation. Any machining operation should be as far as possible from the assembly area.

19.After removal and cleaning, particular attention should be paid to the storage of parts and subassemblies. If there is any doubt as to the cleanliness of stored parts, they should be cleaned before use.

20.All assembly operations and measurements require great care and absolute cleanliness if accurate results are to be obtained.

Work Safety

21.The following safety precautions shall be strictly observed:

  1. When using compressed air to clean a component, use a safe amount. Too high an air pressure could result in personal injury or damage to a component.
  2. Avoid the use of carbon tetrachloride as a cleaning agent because of the harmful vapour that it releases. Use perchlorethylene or trichlorethylene. However, while less toxic than other chlorinated solvents, use these cleaning agents with caution. Be sure the work area is adequately ventilated and use protective gloves, goggles or face shield and apron.
  3. Exercise caution against burns when using oxalic acid to clean the cooling passages of the engine.
  4. Always wear protective gear such as safety glasses, safety shoes and hard hat to provide adequate protection when working under hazardous conditions.
  5. When lifting an assembly, make sure the lifting device is fastened securely. Be sure the item to be lifted does not exceed the capacity of the lifting device.
  6. Use caution when operating power tools.

Part 2 — Engine

Section 1 — Disassembly

Clutch Pressure Plate

1.Removal — Remove the six socket head screws from the clutch pressure plate and pull the pressure plate and clutch disc away from the flywheel.

Flywheel

Figure 2-1-1 — Tool B 183 012 361 Installed
Figure 2-1-1 — Tool B 183 012 361 InstalledClick image to enlarge.

2.Removal — To remove, proceed as follows:

  1. Install tool B 183 012 361 to prevent the flywheel from turning, see Figure 2-1-1, and remove the six cap screws from the flywheel.
  2. Remove the flywheel from the crankshaft.

NOTE — It is not necessary to scribe the flywheel prior to removal. The flywheel will fit onto the crankshaft in one position only.

Intermediate Plate

3.Removal — Remove the intermediate plate and mount the engine on a stand.

Carburetor

4.Removal — To remove, proceed as follows:

  1. Remove the vacuum advance hose.
  2. Remove the four cap screws from the carburetor and remove the carburetor.

Intake Manifold

Figure 2-1-2 — Exhaust Manifold Bracket
Figure 2-1-2 — Exhaust Manifold BracketClick image to enlarge.

5.Removal — To remove, proceed as follows:

  1. Remove the two coolant hoses from the manifold.
  2. Remove the cap screw that secures the intake manifold to the exhaust manifold bracket, see Figure 2-1-2.
  3. Loosen the nut on the exhaust manifold bracket stud. Remove the bracket.
  4. Remove the six socket head cap screws from the manifold and remove the manifold and gasket.

Exhaust Manifold

6.Removal — To remove, proceed as follows:

  1. Remove the eight nuts and flat washers from the manifold.
  2. Remove the manifold and four exhaust gaskets.

Alternator

7.Removal — To remove, proceed as follows:

  1. Prior to removing the drive belts, loosen the coolant pump and crankshaft pulley cap screws.
  2. Remove the alternator adjusting bolt and flat washer and remove the drive belts.
  3. Remove the alternator adjusting arm.
  4. Remove the plug from the timing belt upper cover and, using a 6 mm hex head socket, hold the mounting bolt and remove the nut.
  5. Support the alternator and withdraw the mounting bolt.
  6. Remove the alternator from the bracket.

Coolant Pump

8.Removal — To remove, proceed as follows:

  1. Remove the bolt, nut and lock washer that secure the timing belt lower cover to the coolant pump.
  2. Loosen the hose clamps that secure the two coolant hoses to the pump and disconnect the hoses.
  3. Remove the four cap screws from the coolant pump and remove the pump.

Distributor

Figure 2-1-3 — Distributor Locking Collar
Figure 2-1-3 — Distributor Locking CollarClick image to enlarge.

9.Removal — To remove, proceed as follows:

  1. Disconnect the four spark plug high tension cables from the spark plugs.
  2. Remove the cap screw from the distributor locking collar, see Figure 2-1-3.
  3. Remove the distributor.

Engine Mounting Brackets

10.Removal — Remove the cap screws and washers from the brackets and remove the brackets.

Oil Filter Housing

11.Removal — To remove, proceed as follows:

  1. Using an oil filter wrench, remove the oil filter.
  2. Remove the oil temperature sending unit.
  3. Remove the three socket head screws and flat washers from the oil filter housing and remove the housing and gasket.

Crankshaft Pulley

12.Removal — Remove the four socket head screws from the pulley and remove the pulley.

Timing Belt

Figure 2-1-4 — Intermediate Shaft Seal and Carrier
Figure 2-1-4 — Intermediate Shaft Seal and CarrierClick image to enlarge.

13.Removal — To remove, proceed as follows:

  1. Remove the upper and lower timing belt covers.
  2. Loosen the locking nut on the timing belt tensioner. Turn the tensioner counter-clockwise and remove the timing belt.

Intermediate Shaft and Sprocket

Figure 2-1-5 — Intermediate Shaft
Figure 2-1-5 — Intermediate ShaftClick image to enlarge.

14.Removal — To remove, proceed as follows:

  1. Remove the intermediate shaft sprocket.
  2. Remove the two securing cap screws and remove the intermediate shaft oil seal and seal carrier, see Figure 2-1-4.
  3. Carefully, so as not to damage the bearings with the distributor drive gear or fuel pump eccentric, pull the intermediate shaft from the engine block, see Figure 2-1-5.

Timing Belt Rear Plate

15.Removal — To remove, proceed as follows:

  1. Remove the cap screws from the timing belt rear plate.
  2. Remove the crankshaft timing sprocket.
  3. Remove the cap screw and nut that secure the plate to the front of the engine block and remove the plate and front alternator bracket.

Alternator Bracket (Rear)

16.Removal — Remove the two cap screws and washers from the bracket and remove the bracket.

Valve Cover

17.Removal — To remove, proceed as follows:

  1. Remove the accelerator cable mounting bracket and two spark plug wire securing brackets and washers from the left side of the valve cover.
  2. Remove the cover reinforcement bars from both sides.
  3. Remove the valve cover.
  4. Remove the gasket from the cover.
  5. Remove the rubber half seal from the front camshaft bearing cap.
  6. Remove the rubber seal plug from the rear of the head.

Cylinder Head

Figure 2-1-6 — Cylinder Head Bolt Tightening Sequence
Figure 2-1-6 — Cylinder Head Bolt Tightening SequenceClick image to enlarge.

18.Removal — To remove, proceed as follows:

  1. Starting at the front and rear of the cylinder head and working toward the centre, loosen a little at a time, the cylinder head securing bolts in the reverse sequence to that shown in Figure 2-1-6. Remove the bolts and flat washers.
  2. Remove the cylinder head. If the head will not move, insert the handle of a hammer into an exhaust port and pry the head loose.
  3. Remove the cylinder head gasket and, using either a plastic scraper or solvent, remove the pieces of gasket that are stuck to the cylinder head and engine block. Do not use a metal scraper or wire brush.

Oil Pan and Gasket

19.Removal — To remove, proceed as follows:

  1. Remove the drain plug from the oil pan and drain the oil into a suitable container.
  2. Remove the twenty oil pan securing cap screws and flat washers.
  3. Loosen the oil pan and remove.
  4. Remove the oil pan gasket from the engine block.

Oil Pump

20.Removal — To remove, proceed as follows:

  1. Remove the two cap screws and flat washers from the bottom of the oil pump housing.
  2. Withdraw the oil pump drive shaft from the engine block.

Piston Assemblies

Figure 2-1-7 — Removal of Top Cylinder Ridges
Figure 2-1-7 — Removal of Top Cylinder RidgesClick image to enlarge.

21.Removal — To remove, proceed as follows:

  1. Mark the tops of unmarked pistons with a piston number and an arrow pointing towards the front of the engine, so that the pistons will be reassembled in the same order and direction.
  2. Remove the connecting rod nuts and connecting rod caps.

CAUTION — If the engine block has any top cylinder ridges, remove them with a ridge reamer before removing the pistons, as the piston rings and pistons could be damaged during removal, see Figure 2-1-7.

  1. Using a hammer handle, push the piston/connecting rod assembly away from the crankshaft and through the top of the cylinder.
  2. Immediately after each piston/connecting rod assembly is removed, mark the cylinder number on both the rod cap and the connecting rod, on the intermediate shaft side.

Figure 2-1-8 — Removal of Piston Pin Circlip
Figure 2-1-8 — Removal of Piston Pin CirclipClick image to enlarge.

Figure 2-1-9 — Removal of Piston Pin
Figure 2-1-9 — Removal of Piston PinClick image to enlarge.

22.Disassembly — To disassemble, proceed as follows:

  1. Using needle-nosed pliers or a punch as a lever, remove the piston pin circlips from both ends of each piston pin, see Figure 2-1-8.
  2. Using tool VW 207c, press the pins out and remove the pistons from the connecting rods, see Figure 2-1-9.

NOTE — If the piston pin is difficult to remove, heat the piston in oil to a temperature of 60°C. Correct pin fit should require only a light push to remove the pin from a heated piston.

Crankshaft

Figure 2-1-10 — Front Crankshaft Seal Carrier
Figure 2-1-10 — Front Crankshaft Seal CarrierClick image to enlarge.

23.Removal — To remove, proceed as follows:

  1. Remove the six securing cap screws and washers and remove the rear crankshaft seal carrier.
  2. Remove the three securing cap screws and washers and remove the front crankshaft seal carrier, see Figure 2-1-10.
  3. Remove the securing bolts from the five main bearing caps and remove the caps and bearings.
  4. Remove the crankshaft.

NOTE — The main bearing caps are factory-numbered to ensure correct installation. If the bearings are to be reused, mark the bearing numbers on the backs of the bearing shells as they are removed and note the upper and lower positions. The centre bearing is a flanged thrust bearing.

  1. Remove the bearing shells from the main bearing saddles.

Crankshaft Pilot Bearing

24.Removal — Using extractor 10-202, remove the pilot bearing from the crankshaft.

Block Heater

25.Removal — To remove, proceed as follows:

  1. Loosen and unscrew the heater retaining screw to the limit of its travel.
  2. Withdraw the heater from the frost plug opening of the cylinder block.

Cylinder Head Coolant Outlet Connector (LH Side)

26.Removal — Remove the three capscrews and washers from the cylinder head and remove the connector and gasket.

Cylinder Head Heater Coolant Connector (Rear)

27.Removal — Remove the two capscrews and washers from the cylinder head and remove the connector and gasket. Remove and identify the sending units.

Section 2 — Cleaning and Inspection

Cylinder Block

Figure 2-2-1 — Checking Cylinder Block for Flatness
Figure 2-2-1 — Checking Cylinder Block for FlatnessClick image to enlarge.

1.Flatness Check — To check, proceed as follows:

  1. Ensure the block is clean.
  2. Check the top of the block for flatness through the centre of bores with an accurate straight edge and feeler gauge, see Figure 2-2-1. The surface must not vary more than 0.10 mm longitudinally. If the flatness is not within the above limits, the cylinder block must be resurfaced. The maximum amount that can be cut from an engine block is 0.25 mm. The engine rebuild plate must include the total amount which has been cut from the block.
  3. Check and clean all bolt hole threads and stud threads. Repair as necessary and lubricate.

Figure 2-2-2 — Checking Cylinder Diameter and Degree of Wear
Figure 2-2-2 — Checking Cylinder Diameter and Degree of WearClick image to enlarge.

2.Cylinder Bore — To check, proceed as follows:

  1. Using a cylinder bore gauge, determine the cylinder diameter and degree of wear. Record the readings, see Figure 2-2-2.

NOTE — When checking the cylinder bores, remove the cylinder block from the engine stand, take measurements at three points in each cylinder and at right angles to one another. The first measurement should be made 10 mm from the top. The second measurement should be in the middle of the cylinder, and the third 10 mm from the bottom. Take one set of measurements, first in one direction (e.g., across the width of the engine) and then take a second set of measurements in another direction (e.g., in line with the crankshaft).

  1. Minor variations in cylinder diameter can be corrected by honing. If there is scoring or there are variations of 0.05 mm or more between the measurements in any one cylinder, or a cylinder is worn to more than 0.08 mm over the original or oversized bore, all the cylinders must be rebored and honed to accept the next larger-size piston.

Size Piston Marking Cylnder Bore Honing Diameter
Original Diameter 79.50 mm 79.53 mm
1st Oversize 79.75 mm 79.78 mm
2nd Oversize 80.00 mm 80.03 mm
3rd Oversize 80.50 mm 80.53 mm

Figure 2-2-3 — Cylinder Bore Honing Measurements

  1. Record the largest bore diameter measurement obtained for each cylinder.
  2. Compare these measurements with the honing measurements, see Figure 2-2-3.

NOTE — Rebored cylinders must be honed to obtain a clearance of 0.03 mm between the piston and the cylinder wall.

Figure 2-2-4 — Cylinder Wall Glaze Removed
Figure 2-2-4 — Cylinder Wall Glaze RemovedClick image to enlarge.

  1. Compute the piston clearance between the original pistons and their respective cylinders. Subtract the diameter of the piston, see para. 3, from the maximum diameter of the cylinder.
  2. If the piston clearance exceeds the wear limits, but the cylinders are not worn to a diameter that is 0.04 mm greater than their original or oversize honing measurements, correct the clearance by installing new pistons of the same diameter.
  3. If piston clearance exceeds the wear limits because of cylinder wall wear, the cylinders must be bored and honed to the next oversize measurement and new pistons of the same oversize measurement installed.
  4. If the cylinders have not been rebored, remove the cylinder wall glaze using a (220-grit) hone. Remove the glaze only so that the rings will properly seat. Remove as little metal as possible, see Figure 2-2-4.

Piston Assembly

Figure 2-2-5 — Measurement of Piston Diameter
Figure 2-2-5 — Measurement of Piston DiameterClick image to enlarge.

Figure 2-2-6 — Checking Piston Ring Side Clearance
Figure 2-2-6 — Checking Piston Ring Side ClearanceClick image to enlarge.

3.Pistons and Rings — To check, proceed as follows:

  1. Check the pistons for wear. Measure the diameter of the piston at right angles to the piston pin at a point approximately 10 mm from the lower edge of the piston skirt, see Figure 2-2-5. Compare the measurements obtained with the original piston diameter marked on the piston crown. Comparison will give an indication of the extent to which the piston is worn. Maximum wear is 0.04 mm. However, it can only be determined whether the piston is suitable for reuse by also measuring the cylinder bore.
  2. Using feeler gauges, check the side clearance of all the piston rings, see Figure 2-2-6. Piston ring side clearances should be 0.02 to 0.05 mm with new parts. When installing new rings, ensure the side clearance is not less than specified. The maximum wear limit for old rings is 0.15 mm.
  3. Using a piston ring remover, remove the rings from the pistons. If rings are to be reused, they should be tagged or otherwise identified so that they can be reinstalled in the same order and on the same pistons during reassembly.

NOTE — If rings are to be reused, care must be taken to prevent breakage during removal.

Figure 2-2-7 — Measurement of Ring End Gap
Figure 2-2-7 — Measurement of Ring End GapClick image to enlarge.

  1. Check the ring end gap in the cylinders by pushing each ring about 15 mm into the bottom of the cylinder. Measure the gap in the ring, see Figure 2-2-7. New ring gaps should be 0.30 to 0.45 mm for the compression rings and 0.25 to 0.40 mm for the oil scraper ring. If the gap is too narrow, enlarge it with a file or oil stone. Used rings must not have a ring gap larger than 1.00 mm. When replacing rings, they must be of the same group size as the pistons and cylinders.
  2. If reusing old pistons, clean the ring grooves with a ring groove cleaning tool.

4.Piston Pin — Check the piston pin fit in each connecting rod. If the clearance exceeds 0.04 mm, replace the rod and pin or fit a new pin and rod bushing. Hone the bushing to obtain a clearance of 0.01 to 0.02 mm. Check rod alignment after fitting new bushings.

Crankshaft Assembly

Figure 2-2-8 — Checking Crankshaft Journals for Taper
Figure 2-2-8 — Checking Crankshaft Journals for TaperClick image to enlarge.

Figure 2-2-9 — Checking Crankshaft Journals for Run-Out
Figure 2-2-9 — Checking Crankshaft Journals for Run-OutClick image to enlarge.

Repair Stage Crankshaft Main Journal Diameter Crankshaft Connecting Rod Journal Diameter
Original Diameter 53.978 - 53.958 mm 45.978 - 45.958 mm
Repair Stage 1 53.728 - 53.708 mm 45.728 - 45.708 mm
Repair Stage 2 53.478 - 53.458 mm 45.478 - 45.458 mm
Repair Stage 3 53.228 - 53.208 mm 45.228 - 45.208 mm

Figure 2-2-10 — Crankshaft Repair Stage ChartClick image to enlarge.

5.Crankshaft — To check, proceed as follows:

  1. Using a micrometer, measure the crankshaft main bearing and connecting rod journals. Take measurements at each side of the journal to check for taper, see Figure 2-2-8.
  2. Check eccentricity. Using a micrometer, take two measurements of the journals, one at 90° from the first, or place the crankshaft on “V” blocks and check run-out with a dial indicator, see Figure 2-2-9.
  3. Record the measurements of each journal and compare to Figure 2-2-10.

NOTE — If the journals are rough, scored, tapered, or exceed 0.03 mm out of round, the crankshaft must be replaced or reconditioned to the next repair stage.

Intermediate Shaft Bearings

6.Inspection — If the bearings are worn so that the copper backing shows through the silvery bearing surface, drive the bearings out.

Intake Manifold

7.Inspection — To inspect, proceed as follows:

  1. Using a straight edge, check the mating surfaces of the manifold for distortion. If necessary, surface grind until flat.
  2. Clean around the ports and ensure the mating surfaces are smooth.

Exhaust Manifold

8.Inspection — To inspect, proceed as follows:

  1. Inspect the manifold for cracks.
  2. Using a straight edge, check the mounting surfaces for distortion. If necessary, surface grind until flat.

Flywheel

9.Inspection — To inspect, proceed as follows:

  1. Inspect the flywheel clutch surface for cracks and burns and replace, if necessary.
  2. Inspect the ring gear for broken or chipped teeth and replace, if necessary.

Clutch Disc and Pressure Plate

Figure 2-2-11 — Pressure Plate Distortion Check
Figure 2-2-11 — Pressure Plate Distortion CheckClick image to enlarge.

10.Inspection — To inspect, proceed as follows:

  1. Check the contact surface of the pressure plate for signs of heat and cracks.
  2. Using a straight edge and feeler gauge, inspect the contact surface of the pressure plate for wear and distortion, see Figure 2-2-11. If wear or distortion exceeds 0.30 mm, replace the pressure plate.
  3. Check the pressure plate cover for cracks and ensure the rivets are tight and undamaged. Replace the pressure plate, if necessary.
  4. Check the diaphragm spring fingers at the location of the throw-out bearing contact for scoring and grooving. If score marks exceed 0.30 mm in depth, replace the pressure plate.
  1. Check the friction material of the clutch disc for wear. The minimum allowable distance above the rivet heads is 2.0 mm.
  2. Check the disc for run-out. Measure 2.50 mm from the outer edge of the disc. The maximum allowable run-out is 0.50 mm.
  3. Check the disc for loose or broken rivets and replace, if necessary.

Oil Pan Gasket Surfaces

Figure 2-2-12 — Protrusions on Engine Block
Figure 2-2-12 — Protrusions on Engine BlockClick image to enlarge.

11.Inspection — To inspect, proceed as follows:

  1. Clean the oil pan gasket surface and the gasket surface on the engine block.
  2. File smooth all rough areas on the oil pan gasket surface and the gasket surface on the engine block.

NOTE — New replacement engine blocks may have protrusions which will interfere with the proper positioning of the starter motor, see Figure 2-2-12. These protrusions must be ground off before assembling the engine components.

Section 3 — Assembly

Crankshaft Assembly

Figure 2-3-1 — Crankshaft Assembly

1. Bearing Cap
2. Flanged Thrust Bearing
3. Bearing Shell
4. Crankshaft

Figure 2-3-1 — Crankshaft AssemblyClick image to enlarge.

1.Crankshaft — To assemble and install, see Figure 2-3-1 and proceed as follows:

NOTE — Ensure the crankshaft (4), bearing shells (3), bearing caps (1) and saddles are clean and the anti-rotation tabs engage in the notches in the saddles. The centre bearing is a flanged thrust bearing (2). Ensure that the shells with oil holes are placed in the saddles of the engine block.

  1. Using the original bearings, original-size new bearings, or undersize bearings, depending on the condition of the crankshaft, install the upper bearing shells (with oil holes and lubrication grooves) in the saddles of the engine block.
  2. Place the crankshaft in the block.
  3. Place the lower bearing shells in the bearing caps.
  4. Place a small piece of 0.025 – 0.076 mm Plastigage on each main journal.

NOTE — If checking used bearings or new bearings installed in a high mileage engine, use Plastigage which measures clearances from 0.050 to 0.150 mm.

  1. Install the bearing caps over the journals. Ensure the #1 cap is at the front and all the numbers are facing away from the intermediate shaft.
  2. Install the bearing cap bolts and torque to 35 N•m (25 ft lb).

NOTE — Do not turn the crankshaft.

Figure 2-3-2 — Measurement of Crankshaft Bearing Clearance
Figure 2-3-2 — Measurement of Crankshaft Bearing ClearanceClick image to enlarge.

  1. Remove the bolts and bearing caps.
  2. Using the Plastigage package, measure the bearing clearance as indicated by the squash of the Plastigage, see Figure 2-3-2. The clearance should be 0.03 to 0.08 mm for new bearings. If clearance for used bearings exceeds 0.17 mm, replace the bearings and repeat steps d. through h. If the clearance still exceeds 0.17 mm , replace or recondition the crankshaft.

CAUTION — To prevent damage to the journal, do not scrape off the Plastigage.

Figure 2-3-3 — Measurement of Axial Play
Figure 2-3-3 — Measurement of Axial PlayClick image to enlarge.

Figure 2-3-4 — Front Crankshaft Seal Carrier
Figure 2-3-4 — Front Crankshaft Seal CarrierClick image to enlarge.

  1. Using a cleaning solvent, remove the flattened Plastigage from the journals.
  2. Remove the crankshaft and coat the upper bearing with assembly lubricant.
  3. Reinstall the crankshaft and coat the journals with assembly lubricant.
  4. Coat the bearing caps with lubricant and install them over the journals noting their correct location.
  5. Install the bolts and torque to 65 N•m (47 ft lb).
  6. Tap the crankshaft all the way to the rear of the block.
  7. Insert feeler gauges between the crank throw for No 2 cylinder and the centre main bearing, see Figure 2-3-3. With new parts, axial play should be 0.07 to 0.17 mm. Axial play is excessive if clearance is 0.37 mm or greater. Excessive clearance can usually be corrected by replacing the centre main bearing.
  8. Remove the old seals from the crankshaft seal carriers and clean the carriers of any gasket material.
  9. Install new seals in the carriers so that the seal lips will face in when installed.
  10. Install new gaskets to the carriers and secure the rear carrier to the block with the six cap screws and washers. Torque to 10 N•m (7 ft lb).
  11. Install a new gasket to the front carrier and secure it to the block with the three cap screws. Torque to 10 N•m (7 ft lb). Do not install cap screws in the top and right centre holes as they are for the timing cover cap screws, see Figure 2-3-4.

Piston Assemblies

2.Piston Pin/Connecting Rod — To assemble and install, proceed as follows:

NOTE — If the pistons or connecting rods are replaced, all four must be of the same weight class. Connecting rod weight classes are designated by a number on the rod cap. Pistons and connecting rods come in sets of four. Unmarked pistons must be within 10 grams of the weight of the other pistons.

  1. Install one circlip in one end of the piston pin bore.
  2. Heat the piston in an oil bath to 60°C.
  3. Insert the connecting rod into the piston so that when the arrow on the piston crown is facing the front end of the engine, the marks on the connecting rod will be towards the intermediate shaft side of the engine.
  4. Working quickly, so that the piston does not cool, hand press the piston pin into the piston and through the connecting rod bushing. Seat the pin against the circlip that is already installed and then install the second circlip. Ensure the circlips are fully engaged in their grooves.
  5. Using the ring remover/installer, carefully install the rings in the ring grooves. Install the oil scraper ring first.

NOTE — The top compression ring has a chamfer to the inside top. The second compression ring has a groove to the outside bottom. Both rings must be installed with the word “TOP” towards the piston crown. Install the oil scraper ring and its spring with the lettering towards the piston crown.

Figure 2-3-5 — Position of Ring Gaps
Figure 2-3-5 — Position of Ring GapsClick image to enlarge.

  1. Turn the crankshaft so that No 1 connecting rod journal is at BDC.
  2. Thoroughly lubricate the cylinder walls and piston rings.
  3. Stagger the ring gaps so that the oil scraper ring gap is not over the end of the connecting rod pin and the other two gaps offset 120° to each side of the scraper ring gap, see Figure 2-3-5.
  4. Install the ring compressor over the piston and tighten to fully compress the rings.
  5. Install the connecting rod upper bearing ensuring that the anti-rotation tab engages in the rod.
  6. Install the piston/connecting rod assembly in the cylinder, with the arrow on the piston crown facing toward the front of the engine block until the ring compressor contacts the block.
  7. Using a wooden hammer handle, press the piston into the cylinder until the connecting rod bearing is seated squarely on the crankshaft journal. Ensure that the crankshaft journal is not nicked by the connecting rod studs.
  8. Install the bearing shell into No 1 cap.

NOTE — If checking used bearings or new bearings installed in a high mileage engine, use Plastigage which measures clearances from 0.050 to 0.150 mm.

CAUTION — Do not lay the Plastigage over the oil hole in the journal.

  1. Place a piece of 0.025 - 0.076 mm Plastigage on the bearing journal.
  2. Install the connecting rod cap and torque the nuts to 35 N•m (25 ft lb). Do not turn the crankshaft. Ensure the forged marks or numbers are towards the intermediate shaft.

Figure 2-3-6 — Checking Clearance Between Crankshaft and Connecting Rod Bearing
Figure 2-3-6 — Checking Clearance Between Crankshaft and Connecting Rod BearingClick image to enlarge.

Figure 2-3-7 — Measurement of Connecting Rod Axial Play
Figure 2-3-7 — Measurement of Connecting Rod Axial PlayClick image to enlarge.

  1. Remove the cap and measure the bearing clearance with the Plastigage package, see Figure 2-3-6. With new parts, bearing clearance should be 0.028 to 0.088 mm. With used parts, if clearance is at the wear limit, 0.12 mm or greater, install new bearings and recheck the clearance. If the clearance is still excessive, remove the crankshaft and repair it to the next repair stage, see Figure 2-2-10.
  2. If clearance is within specifications, clean the Plastigage from the journal with solvent, lubricate the bearings and journal.
  3. Reinstall the cap and torque the nuts to 45 N•m (32 ft lb).
  4. Install No 4 piston/connecting rod assembly and perform steps p. to u. inclusive.
  5. Hand turn the crankshaft 180° and install Nos 2 and 3 piston/connecting rod assemblies. Perform steps p. to u. inclusive for each rod assembly.
  6. Using feeler gauges, check the axial play of each rod by pushing the rod as far as possible to one side and inserting the feeler gauges between the opposite side and the journal, see Figure 2-3-7. Maximum clearance is 0.37 mm. If clearance is in excess, replace the connecting rod or crankshaft.

Oil Pump

3.Installation — Install the pump with two cap screws and flat washers and torque to 20 N•m (15 ft lb).

Oil Pan and Gasket

4.Installation — To install, proceed as follows:

  1. Install a new gasket on the engine block.
  2. Install the oil pan.
  3. Install the twenty cap screws and flat washers. The longest cap screw is installed in the left rear corner and requires a copper washer.
  4. Torque all cap screws to 10 N•m (7 ft lb).

5.Installation — To install, proceed as follows:

  1. Ensure the sealing surface, pistons and cylinders are clean and apply engine oil to the cylinder walls.
  2. Install a new cylinder head gasket on the engine block with the word “OBEN” (TOP) facing up.
  3. Ensure the sealing surface of the cylinder head is clean and place the head on the engine block.
  4. Apply an anti-seize compound to the ten cylinder head bolts and washers to prevent seizure to the aluminium head and install the bolts and flat washers.
  5. Tighten the cylinder head bolts following the sequence shown in Figure 2-1-6 and torque the bolts to 30 N•m (22 ft lb).
  6. Torque the cylinder head bolts to 58 N•m (43 ft lb) following the sequence described in step e.
  7. Torque the cylinder head bolts to 75 N•m (55 ft lb) following the sequence described in step e.
  8. After torquing all cylinder head bolts, turn each bolt a further quarter turn following the sequence described in step e. After completing step h., it will not be necessary to torque the bolts a second time after the engine is hot or broken in.
  9. Adjust the valve tappet clearance. When cold, the clearance between the intake valves and camshaft lobes should be 0.15 mm to 0.25 mm. When cold, the clearance between the exhaust valves and camshaft lobes should be 0.35 mm to 0.45 mm.

Alternator Bracket (Rear)

6.Installation — Install the alternator rear bracket on the engine block with two cap screws and lock washers and torque to 20 N•m (15 ft lb).

Timing Belt Rear Plate

7.Installation — To install, proceed as follows:

  1. Install the front alternator bracket and rear plate on the engine block and install the cap screw and washer. Torque the cap screw to 20 N•m (15 ft lb).
  2. Install the stud that secures the top of the bracket and rear plate to the engine block and torque to 20 N•m (15 ft lb).
  3. Install the cap screw and washer that secure the timing belt rear plate to the cylinder head and torque the cap screw to 10 N•m (7 ft lb).

Intermediate Shaft and Sprocket

8.Installation — To install, proceed as follows:

  1. Install new bearings ensuring that the oil hole in the bearing aligns with the oil hole in the block. Use a bearing installer that accurately fits the inside of the bearing.
  2. Coat the bearings and gear with lubricant or grease and install the shaft.
  3. With the lip facing in, install a new seal in the seal carrier, install an “0” ring and secure the carrier to the block. Torque the cap screws to 25 N•m (18 ft lb). Check axial clearance. The maximum clearance is 0.25 mm. Replace the seal carrier or the intermediate shaft to correct excessive clearance.
  4. Install the woodruff key and intermediate shaft sprocket.
  5. Install the cap screw and flat washer and torque to 80 N•m (59 ft lb).

Crankshaft Sprocket

9.Installation — To install, proceed as follows:

  1. Install the crankshaft sprocket.
  2. Install the bolt and flat washer and torque to 80 N•m (59 ft lb).

Timing Belt

Figure 2-3-8 — Camshaft Sprocket Timing Mark
Figure 2-3-8 — Camshaft Sprocket Timing MarkClick image to enlarge.

Figure 2-3-9 — Alignment of Intermediate Sprocket and Crankshaft Pulley
Figure 2-3-9 — Alignment of Intermediate Sprocket and Crankshaft PulleyClick image to enlarge.

10.Installation — To install, proceed as follows:

  1. Turn the camshaft sprocket until the timing mark on the sprocket is even with the tip at the top of the timing belt rear plate, see Figure 2-3-8. Both camshaft lobes of the #1 cylinder must face up at similar angles.
  2. Install the crankshaft pulley with the four cap screws and flat washers. Ensure the indentation in the pulley aligns with the protrusion in the sprocket.
  3. Turn the intermediate sprocket until the punch mark on the sprocket is in line with the “V” mark on the crankshaft pulley, see Figure 2-3-9.
  4. Place the timing belt on the crankshaft, intermediate and camshaft sprockets. Ensure the sprockets do not turn while the belt is installed. Ensure the teeth of the belt are correctly engaged in the sprockets, and all the slack of the timing belt is on the side nearest the timing belt tensioner.
  5. Adjust the timing belt tensioner by turning clockwise until the timing belt has the correct tension and then torque the locking nut to 45 N•m (33 ft lb).

NOTE — The timing belt has the correct tension when it can be turned through 90 degrees only, using the thumb and forefinger at a midpoint between the camshaft and intermediate sprockets, or belt deflection is 15 mm.

  1. Rotate the crankshaft through two complete revolutions. Ensure the timing marks are correctly aligned and recheck timing belt tension.
  2. Remove the crankshaft pulley.
  3. Install the lower timing belt cover and torque the cap screws to 10 N•m (7 ft lb).

Coolant Pump

11.Installation — To install, proceed as follows:

  1. Install a new “O” ring seal in the pump and position the pump on the engine block. Install the four cap screws. The two long cap screws go in the bottom mounting holes. Torque the four cap screws to 20 N•m (15 ft lb).
  2. Install the two coolant hoses to the pump and tighten the hose clamps.
  3. Install the bolt, nut and lock washer that secure the lower timing belt cover to the coolant pump and torque to 10 N•m (7 ft lb).
  4. Install the coolant pump pulley.

Alternator

12.Installation — To install, proceed as follows:

  1. Install the alternator on the mounting bracket and insert the mounting bolt.
  2. Install the nut on the mounting bolt.
  3. Swing down the alternator adjusting arm and loosely install the adjusting bolt and flat washer.

Valve Cover

13.Installation — To install, proceed as follows:

  1. Ensure the top gasket surface of the cylinder head is clean.
  2. Place a new rubber half seal on the front camshaft bearing cap.
  3. Install a new rubber plug at the rear of the cylinder head.
  4. Install a new cover gasket in the valve cover.

Figure 2-3-10 — Valve Cover Reinforcement Bars
Figure 2-3-10 — Valve Cover Reinforcement BarsClick image to enlarge.

  1. Install the cover on the head and install reinforcement bars on both sides, ensuring the flat side of the bar faces toward the valve cover and the pointed end points toward the rear of the engine, see Figure 2-3-10.
  2. Install the timing belt upper cover.
  3. Place the two spark plug wire retaining brackets and washers on the centre left valve cover securing studs.
  4. Place the accelerator cable mounting bracket on the second stud from the front on the left side.
  5. Install a flat washer on both front valve cover securing studs.
  6. Install the eight nuts and torque to 10 N•m (7 ft lb).
  7. Install the plug nut in the timing belt upper cover.

Drive Belts

14.Installation — To install, proceed as follows:

  1. Install the crankshaft pulley. Ensure the indentation on the pulley engages in the protrusion on the crankshaft sprocket and install the cap screws and flat washers. Do not tighten the cap screws at this time.
  2. Install the drive belts and adjust belt deflection to 15 mm.
  3. Torque the crankshaft pulley cap screws to 20 N•m (15 ft lb).
  4. Torque the cap screws for the coolant pump pulley to 20 N•m (15 ft lb).

Oil Filter Housing

15.Installation — To install, proceed as follows:

  1. Install the oil filter housing and a new gasket with three socket head cap screws and flat washers. Torque the screws to 20 N•m (15 ft lb).
  2. Coat the gasket of a new oil filter with clean oil and install the filter by hand. Tighten until the gasket contacts the housing and then turn an additional half turn.
  3. Install the oil temperature sending unit and torque to 10 N•m (7 ft lb).

Distrubitor

16.Installation — To install, proceed as follows:

  1. Unscrew the three screws from the distributor cap and remove the cap.
  2. Turn the rotor and shaft until the rotor pickup contact faces toward the TCI electrical connector socket.

Figure 2-3-11 — Oil Pump Shaft
Figure 2-3-11 — Oil Pump ShaftClick image to enlarge.

  1. Turn the oil pump drive lug so that it will align with the slot in the distributor shaft when the distributor is installed, see Figure 2-3-11.
  2. Ensure that the intermediate sprocket and crankshaft pulley marks are aligned, see Figure 2-3-9. Ensure that the camshaft sprocket timing mark is aligned with the timing belt rear plate, see Figure 2-3-8.
  3. With the TCI electrical connector facing the rear, insert the distributor shaft into the engine block and then turn the distributor rotor shaft until the gears mesh, the oil pump lug enters the distributor and the distributor sits flush on the block.
  4. Install the distributor locking collar and cap screw.
  5. Install the distributor cap.
  6. Connect the four spark plug high tension cables to the distributor cap in clockwise firing order 1-3-4-2. The spark plug terminal that is nearest the rear of the engine block is the #1 spark plug cable terminal.

Engine Mounting Brackets

17.Installation — To install, proceed as follows:

  1. Install the right engine mounting bracket with four cap screws and washers and torque to 25 N•m (18 ft lb).
  2. Install the left engine mounting bracket with three cap screws and washers and torque to 55 N•m (41 ft lb).

Exhaust Manifold

18.Installation — To install, proceed as follows:

  1. Install the manifold and new exhaust gaskets. Ensure the gaskets are correctly positioned with the inner edge towards the block.
  2. Install eight nuts and flat washers and torque to 25 N•m (18 ft lb).

Intake Manifold

19.Installation — To install, proceed as follows:

  1. Install a new gasket on the intake manifold ports and install the manifold.
  2. Install the socket head cap screws and flat washers and torque to 25 N•m (18 ft lb).

NOTE — The two longer cap screws go in the second hole from either end.

  1. Install the cap screw that secures the intake manifold to the exhaust manifold bracket and torque to 20 N•m (15 ft lb).
  2. Torque the nut on the exhaust manifold bracket to 25 N•m (18 ft lb).
  3. Install the coolant hoses. The lower hose goes to the rear of the cylinder head.

Carburetor

20.Installation — To install, proceed as follows:

  1. Ensure the carburetor and intake manifold mounting surfaces are smooth and free of nicks and cuts.
  2. Install the carburetor on the intake manifold, ensuring the side of the carburetor with the air/fuel cutoff valve is nearest the valve cover.
  3. Install the four cap screws, ensuring the ground wire is attached to the cap screw under the air/fuel cutoff valve.
  4. Tighten the four cap screws.
  5. Install the vacuum advance hose.

Intermediate Plate

21.Installation — To install, proceed as follows:

  1. Remove the engine from the stand.
  2. Coat the engine side of the intermediate plate with sealing compound and install the plate.

NOTE — Do not apply Loctite to flywheel cap screws if flywheel is to be removed for installation in engine container.

Flywheel

22.Installation — Apply Loctite 270 or 271 to each cap screw. Install the flywheel and cap screws. Torque the cap screws to 75 N•m (55 ft lb).

Crankshaft Pilot Bearing

23.Installation — To install, proceed as follows:

NOTE — To ensure that the pilot bearing seal is correctly positioned, install the bearing with its lettering facing outwards.

  1. Place a new pilot bearing on the end of the bearing installer tool VW 207C and install the bearing.
  2. Drive the bearing into the crankshaft and remove the bearing installer tool. The bearing should be 1.5 mm inside the end of the crankshaft.

Clutch Disc and Pressure Plate

24.Installation — To install, proceed as follows:

Figure 2-3-12 — Installation of Clutch Assembly
Figure 2-3-12 — Installation of Clutch AssemblyClick image to enlarge.

  1. Insert pilot 10-213 into the clutch disc and then into the flywheel.

NOTE — Clutch disc protrusions go towards the pressure plate.

  1. Install the clutch pressure plate against the flywheel ensuring the indexing pins of the flywheel fit into the indexing holes of the pressure plate, see Figure 2-3-12.
  2. Install the six socket head screws and torque to 25 N•m (18 ft lb) in a diagonal sequence.
  3. Withdraw the clutch disc pilot.

Block Heater

25.Installation — To install, proceed as follows:

NOTE — The V-shaped clamping yoke, which retains the block heater to the cylinder block, is spread wider than the frost plug opening when the retaining screw is tightened during installation. If installing a used heater, the yoke must be in good condition and bent to a slightly narrower V-shape than the frost plug opening. Replace the “0” ring if necessary.

  1. Clean the frost plug opening.
  2. Apply a light coat of grease to the opening. Do not use gasket sealer.
  3. Install the block heater, with its element pointing to 6 o'clock, into the right front frost plug opening of the block. Ensure that the heater is fully seated against the block.
  4. Torque the retaining screw to 190 N•cm (17 in lb).
  5. Verify that the heater is locked in position by attempting to pull it out of the frost plug opening with pliers.

Cylinder Head Coolant Outlet Connector (LH Side)

26.Installation — Place a new gasket on the connector and install it to the cylinder head using the three cap screws and washers. Torque the cap screws to 10 N•m (7 ft lb).

Cylinder Head Heater Coolant Connector (Rear)

27.Installation — Place a new gasket on the connector and install it to the cylinder head using the two cap screws and washers. Torque the cap screws to 10 N•m (7 ft lb). Install the sending units.

Section 4 — Cylinder Head

Camshaft

Figure 2-4-1 — Camshaft Bearing Caps
Figure 2-4-1 — Camshaft Bearing CapsClick image to enlarge.

1.Removal — To remove, proceed as follows:

  1. Remove the timing belt tensioner and lock nut.
  2. Remove the camshaft sprocket cap screw and flat washer.
  3. Remove the sprocket and woodruff key.
  4. Remove the nuts and flat washers from camshaft bearing caps one, three and five and set the caps aside, in order, so that each bearing cap will be reinstalled in the same place, see Figure 2-4-1.
  5. To avoid camshaft distortion, loosen, a little at a time, the four nuts on camshaft bearing caps two and four until the tension is released. Remove the nuts, flat washers and bearing caps, and set the bearing caps aside, in order.
  6. Remove the camshaft from the cylinder head and remove the seal from the front end of the camshaft.

Figure 2-4-2 — Measurement of Camshaft Run-Out
Figure 2-4-2 — Measurement of Camshaft Run-OutClick image to enlarge.

2.Inspection — To inspect, proceed as follows:

  1. Inspect the toes and flats of the camshaft lobes for wear and grooving. Wear and grooves are an indication of engine oil contamination.
  2. Inspect the camshaft bearing surfaces for grooves and replace the camshaft, if necessary.
  3. Place the camshaft bearing surfaces one and five on V-blocks or inverted bearing caps and, using a dial indicator, measure the run-out of the camshaft, see Figure 2-4-2. Replace the camshaft, if the run-out is greater than .01mm.
  4. To measure the camshaft axial clearance, proceed as follows:
  1. Remove the shims and buckettype cam followers from the cylinder head and set aside, in order, so that each will be reinstalled in the same location.

CAUTION — The bearing caps are off centre. If a cap is installed incorrectly, the cap or cylinder head will crack.

Figure 2-4-3 — Measurement of Camshaft Axial Clearance
Figure 2-4-3 — Measurement of Camshaft Axial ClearanceClick image to enlarge.

  1. Install the camshaft and bearing caps one and five and install washers and nuts.
  2. Tap either end of the camshaft so that all the clearance is at one end.
  3. Place a dial indicator, set at zero, at the end of the camshaft with all the clearance and tap the opposite end of the camshaft, see Figure 2-4-3, to eliminate the clearance at the dial indicator end of the camshaft. If the axial clearance is greater than 0.15 mm, install a new camshaft and measure axial clearance. If the clearance is still unacceptable, replace the cylinder head.
  1. To measure camshaft bearing clearance, proceed as follows:

Figure 2-4-4 — Measurement of Camshaft Bearing Clearance
Figure 2-4-4 — Measurement of Camshaft Bearing ClearanceClick image to enlarge.

  1. Install the camshaft and place a small piece of 0.025 - 0.076 mm Plastigage on all five bearing surfaces.
  2. Install the bearing caps, washers, and nuts in their correct positions and torque to 20 N•m (15 ft lb). Do not turn the camshaft.
  3. Remove the bearing caps.
  4. Using the Plastigage package, measure the Plastigage squash, see Figure 2-4-4. The bearing clearance should be 0.02 mm to 0.05 mm. Replace the camshaft if the bearing clearance is greater than 0.05 mm. If the clearance is still unacceptable, replace the cylinder head.

Valves

Figure 2-4-5 — Removal of Valve Keepers
Figure 2-4-5 — Removal of Valve KeepersClick image to enlarge.

Figure 2-4-6 — Valve Assembly

1. Valve Stem
2. Spring Seat
3. Stem Seal
4. Inner Valve Spring
5. Outer Valve Spring
6. Valve Spring Retainer
7. Valve Keepers

Figure 2-4-6 — Valve AssemblyClick image to enlarge.

3.Removal — To remove, proceed as follows:

  1. Using either a plastic scraper or solvent, remove the pieces of gasket that are stuck to the cylinder head. Do not use a metal scraper or wire brush.
  2. Install tool 2036 on the mounting studs of camshaft bearing caps one and five and install four nuts and flat washers, see Figure 2-4-5.
  3. Using compressor tool VW 541/1, compress the valve springs of each valve assembly and remove both halves of each valve keeper from each valve stem and set aside, in order.
  4. Remove the valve spring retainer, the inner and outer springs, stem seal and spring seat from each valve stem and set aside, in order, see Figure 2-4-6.

CAUTION — Damage will occur to the valve guides during valve removal if burrs and roughness are not removed first.

  1. Feel all valve keeper grooves for roughness and, using either a small file, stone, or emery cloth, remove all burrs and roughness before removing the valve from the valve guide in the cylinder head.
  2. Remove the valves from the valve guides and set aside, in order.

Figure 2-4-7 — Cylinder Head Distortion Check
Figure 2-4-7 — Cylinder Head Distortion CheckClick image to enlarge.

Figure 2-4-8 — Measurement of Cylinder Head Thickness
Figure 2-4-8 — Measurement of Cylinder Head ThicknessClick image to enlarge.

Figure 2-4-9 — Measurement of Valve Rocking Play
Figure 2-4-9 — Measurement of Valve Rocking PlayClick image to enlarge.

Figure 2-4-10 — Removal of Valve Guide
Figure 2-4-10 — Removal of Valve GuideClick image to enlarge.

4.Cleaning and Inspection — To clean and inspect, proceed as follows:

  1. Clean the valves with a wire brush.
  2. Using a straight edge and feeler gauge, check the sealing surface of the cylinder head for distortion, see Figure 2-4-7. If the distortion is greater than 0.10 mm, the head must be resurfaced. After resurfacing, the thickness of the head must not be less than 132.55 mm, see Figure 2-4-8.
  3. Remove carbon deposits from the valves, valve guides and intake and exhaust ports.
  4. Using a dial indicator, measure the rocking play at each valve head. Move each valve stem back and forth in its guide and measure the stem movement, see Figure 2-4-9. The stem tip must be flush with the top of the guide. The maximum allowable rocking play of the intake valve stems is 1.00 mm. The maximum allowable rocking play of the exhaust valve stems is 1.30 mm. If the valve exceeds the allowable free play, install a new valve and measure the free play.
  5. If the new valve exceeds the allowable free play, replace the guide. Proceed as follows:
  1. From the combustion side of the cylinder head, press out the guide using tool 10-206, see Figure 2-4-10.

CAUTION — To prevent damage to the valve guide seating collars, do not use more than one ton of pressure after the seating collar contacts the cylinder head as the collar may break off.

Figure 2-4-11 — Reaming Valve Guide
Figure 2-4-11 — Reaming Valve GuideClick image to enlarge.

  1. Lubricate the new guide with oil and press into the cold cylinder head from the camshaft side ensuring the shoulder of the guide firmly contacts the top of the cylinder head.
  2. Ream the valve guide with tool 10-215 to obtain a uniform inside diameter of 8.013 to 8.035 mm, see Figure 2-4-11. Lubricate the reamer with cutting oil while reaming the guide.
  3. Check the diameter of the guide bore with a go/no-go gauge that has a go diameter of 8.013 mm and a no-go diameter of 8.035 mm. The 8.013 mm end of the gauge should enter the guide easily, but it should be impossible to insert the 8.035 mm end into the valve guide.
  1. Grind the intake valves, if necessary, to a 45° angle. The intake valves must have a minimum margin of 0.50 mm, see Figure 2-4-12.

CAUTION — Do not grind exhaust valves. Exhaust valves can be lapped only.

Figure 2-4-12 — Specifications for Inlet Valve, Inlet Valve Seats and Exhaust Valve Seats
Figure 2-4-12 — Specifications for Inlet Valve, Inlet Valve Seats and Exhaust Valve SeatsClick image to enlarge.

Figure 2-4-13 — Valve Spring Compression Test
Figure 2-4-13 — Valve Spring Compression TestClick image to enlarge.

Figure 2-4-14 — Valve Lapping
Figure 2-4-14 — Valve LappingClick image to enlarge.

  1. Inspect the cylinder head for cracks. Replace the cylinder head if any cracks are noted.
  2. Inspect the valve seats for burns and pitting and grind to 45 degrees, if necessary. Intake valve seats should have a maximum width of 2.00 mm and exhaust valve seats a maximum width of 2.40 mm, see Figure 2-4-12. Lessen with a 30° stone.
  3. Using a valve spring tester, test the tension of the springs, see Figure 2-4-13. When the outer springs are compressed to 22.30 mm (7/8 in), the spring pressure should be 43.5 to 48.0 kg (96 to 106 lb). When the inner springs are compressed to 18.30 mm (23/32 in), the spring pressure should be 21.0 to 23.0 kg (46 to 51 lb). Replace valve springs as required.
  4. Place both halves of each valve keeper in the corresponding keeper groove on each valve stem. Rotate the valve while holding the keepers. The valve stem should rotate freely without excessive free play. If a keeper is loose, grind or file the keeper mating surface to make a tighter fit.
  5. Set aside all valve keepers in order.
  6. Lap each valve in its corresponding seat, see Figure 2-4-14.
  7. Clean all valves, stems and seats.
  8. Apply a little Prussian blue to each valve at four points where the valve will contact the seat. Insert the valve stems into their corresponding guides and turn each valve one quarter turn in both directions. Withdraw the valves from the cylinder head and examine the circle of bluing on each valve. If the valves are correctly lapped, there will be a complete circle of bluing on each valve. If a circle is incomplete, lap the valve until a complete circle can be formed.
  9. Clean the bluing from the valves and seats and insert the valve stems into their corresponding guides.
  10. Place a covering over the bottom of the cylinder head so that the valves will not fall out when the cylinder head is turned over.

Figure 2-4-15 — Installation of Valve Stem Seal
Figure 2-4-15 — Installation of Valve Stem SealClick image to enlarge.

5.Installation — To install the valves, proceed as follows:

  1. Place the spring seats over the corresponding valve stems.
  2. Place a plastic sleeve from the seal replacement kit on a valve stem to prevent damage when installing valve stem seals.
  3. Insert the spring end of a seal into valve seal installer tool 10-204, see Figure 2-4-15, and apply a coat of oil to the valve stem.
  4. Push the seal onto the valve stem and remove the plastic sleeve from the valve stem.
  5. Install seals on all valve stems following steps b., c. and d. and install the inner and outer springs and retainers on the corresponding valve stems.
  6. Place bar tool 2036 on the mounting studs of camshaft bearing caps one and five and install four nuts and flat washers.
  7. Using compressor tool VW 541/1, compress each set of valve springs and place both halves of each valve keeper in the corresponding keeper groove on each valve stem.
  8. Remove bar tool 2036.
  9. Tap the top of each valve assembly to ensure the keepers are securely in place.

Figure 2-4-16 — Camshaft Bearing Caps
Figure 2-4-16 — Camshaft Bearing CapsClick image to enlarge.

6.Installation — To install the camshaft, proceed as follows:

  1. Oil the bucket-type cam followers and shims and install on the corresponding valve assemblies.
  2. Clean and lubricate the camshaft bearing cap surfaces of the cylinder head.
  3. Ensure all camshaft lubricating holes in the cylinder head are open.
  4. Lubricate the lip of a new seal and install the seal on the front end of the camshaft with the lip facing toward the rear.
  5. Install the camshaft.
  6. Install bearing caps two and four over the corresponding camshaft bearing surfaces, see Figure 2-4-16. Ensure the bearing caps are correctly positioned.
  1. Install flat washers and nuts on bearing caps two and four and tighten each nut a little at a time. Torque to 20 N•m (15 ft lb).
  2. Install bearing caps one, three and five over the corresponding camshaft bearing surfaces, ensuring the bearing caps are correctly positioned.
  3. Install washers and nuts on bearing caps one, three and five and torque to 20 N•m (15 ft lb).
  4. Install the woodruff key, camshaft sprocket and cap screw. Torque to 80 N•m (59 ft lb).
  5. Install the timing belt tensioner onto the mounting stud and loosely install the locking nut and flat washer.
  6. Adjust the valve tappet clearance. When cold, the clearance between the intake valves and camshaft lobes should be 0.15 mm to 0.25 mm. When cold, the clearance between the exhaust valves and camshaft lobes should be 0.35 mm to 0.45 mm.

Section 5 — Torque Values, Special Tools and Specifications

General

1.Figure 2-5-1 lists the torque values for all components used in Part 2.

2.Figure 2-5-2 lists the special tools used in Part 2.

3.Figure 2-5-3 lists the specifications used in Part 2.


Item
No 		Item or Component Torque
1. Crankshaft Bearings 65 N•m 47 ft lb
2. Crankshaft Seal Carrier (front and rear) 10 N•m 7 ft lb
3. Connecting Rod Caps 45 N•m 32 ft lb
4. Oil Pump 20 N•m 15 ft lb
5. Oil Pan 10 N•m 7 ft lb
6. Cylinder Head (refer to Part 2, Section 3) N•m ft lb
7. Alternator Brackets 20 N•m 15 ft lb
8. Timing Belt Rear Plate and Alternator Bracket 20 N•m 15 ft lb
9. Timing Belt Rear Plate (stud) 20 N•m 15 ft lb
10. Timing Belt Rear Plate (at cylinder head) 10 N•m 7 ft lb
11. Intermediate Shaft Seal Carrier 25 N•m 18 ft lb
12. Intermediate Shaft Sprocket 80 N•m 59 ft lb
13. Crankshaft Spocket 80 N•m 59 ft lb
14. Timing Belt Tensioner 45 N•m 33 ft lb
15. Timing Belt Lower Cover 10 N•m 7 ft lb
16. Coolant Pump 20 N•m 15 ft lb
17. Valve Cover 10 N•m 7 ft lb
18. Crankshaft Pulley 20 N•m 15 ft lb
19. Coolant Pump Pulley 20 N•m 15 ft lb
20. Oil Filter Housing 20 N•m 15 ft lb
21. Oil Temperature Sending Unit 10 N•m 7 ft lb
22. Engine Mounting Bracket (right) 25 N•m 18 ft lb
23. Engine Mounting Bracket (left) 55 N•m 41 ft lb
24. Exhaust Manifold 25 N•m 18 ft lb
25. Intake Manifold 25 N•m 18 ft lb
26. Exhaust Manifold Bracket (cap screw) 20 N•m 15 ft lb
27. Exhaust Manifold Bracket (nut) 25 N•m 18 ft lb
28. Flywheel 75 N•m 55 ft lb
29. Clutch Pressure Plate 25 N•m 18 ft lb
30. Camshaft Bearing Caps 20 N•m 15 ft lb
31. Camshaft Sprocket 80 N•m 59 ft lb
32. Block Heater 190 N•cm 17 in lb
33. Cylinder Head Coolant Outlet Connector (LH Side) 10 N•m 7 ft lb
34. Cylinder Head Heater Coolant Connector (Rear) 10 N•m 7 ft lb

Figure 2-5-1 — Engine Torque Values


Item
No 		Tool No Nomenclature NATO Stock No
1. B 183 012 361 Flywheel holder 5120-21-899-4887
2. VW 207c Drift 5120-12-176-4480
3. 10-213 Centering tool 5120-12-176-1093
4. 2036 Valve mounting device 5120-21-896-7686
5. VW 541/1 Lever-valve spring 5120-21-896-7704
6. 10-206 Driver-valve guide 5120-21-896-7716
7. 10-215 Reamer-valve guide 5110-21-896-7719
8. 10-204 Driver 5120-12-181-6870
9. 10-202 Extractor 5120-12-181-9729

Figure 2-5-2 — Special Tools

Figure Description Measurement
2-2-1 Cylinder block distortion 0.00 - 0.10 mm
na Maximum allowable cylinder block cut to correct distortion 0.25 mm
na Maximum allowable cylinder bore variation 0.05 mm
na Maximum allowable cylinder wear 0.08 mm
na Maximum allowable cylinder wear when fitting new pistons 0.04 mm
na Original piston diameter 79.50 mm
na Piston oversizes + 0.25 + 0.50 + 1.00 mm
na New piston to new cylinder clearance 0.03 mm
2-2-5 Maximum allowable piston wear 0.04 mm
2-2-6 Piston ring side clearance in piston
   New parts
   Wear limit
0.02 - 0.05 mm
0.15 mm
2-2-7 Piston ring end gap
   New compression rings
   New oil rings
   Used rings
0.30 - 0.45 mm
0.25 - 0.40 mm
1.00 mm (Max)
na Piston pin clearance in connecting rod
   New
   Wear limit
0.01 - 0.02 mm
0.04 mm
2-2-8
2-2-9 		Maximum allowable crankshaft journal taper or out-of-round 0.03 mm
2-3-3 Crankshaft axial play
   New
   Wear limit
0.07 - 0.17 mm
0.37 mm
na Crankshaft original diameter
   Main journals
   Connecting rod journals
53.978 - 53.958 mm
45.978 - 45.958 mm
na Standard main and connecting rod journal undersizes – 0.25 – 0.50 – 0.75 mm
2-3-2 Main bearing clearance
   New
   Wear limit
0.03 - 0.08 mm
0.17 mm
2-3-6 Connecting rod bearing clearance
   New
   Wear limit
0.028 - 0.088 mm
0.12 mm
2-3-7 Maximum allowable connecting rod axial play 0.37 mm
2-4-2 Maximum allowable camshaft run-out 0.01 mm
na Maximum allowable camshaft axial play 0.15 mm
na Camshaft bearing clearance 0.02 - 0.05 mm
na Intake valve guide stem diameter 7.97 mm
na Exhaust valve guide stem diameter 7.95 mm
na Intake and exhaust valve guide bore diameter 8.013 - 8.035 mm
2-4-9 Maximum allowable valve rocking play
   Intake
   Exhaust
1.00 mm
1.30 mm
2-4-12 Maximum allowable valve margin
   Intake
   Exhaust
0.50 mm
Do not grind
2-4-12 Valve face angle
   Intake
   Exhaust
45°
Do not grind
2-4-12 Valve seat angle 45°
2-4-12 Valve seat width reduction angle 30°
2-4-12 Intake valve seat width 2.00 mm
2-4-12 Exhaust valve seat width 2.40 mm
2-4-13 Valve spring tension
   Outer spring
   Inner spring
43.5 - 48.0 kg (96 - 106 lb)
21.0 - 23.0 kg (46 - 51 lb)
na Valve clearance-cold
   Intake
   Exhaust
0.15 - 0.25 mm
0.35 - 0.45 mm
2-4-7 Cylinder head distortion 0.00 - 0.10 mm
2-4-8 Minimum allowable cylinder head thickness to correct distortion 132.55 mm
na Maximum allowable intermediate shaft play 0.25 mm
na Timing belt deflection 15 mm
2-2-1 Maximum allowable pressure plate distortion 0.30 mm
na Maximum allowable clutch spring finger grooving 0.30 mm
na Maximum allowable clutch disc run-out 0.50 mm
na Minimum allowable distance above clutch disc facing rivets 2.0 mm

Figure 2-5-2 — Engine Specifications

Part 3 — Transaxle

Section 1 — Disassembly

Transmission

Figure 3-1-1 — Transmisson Assembly

1. Cap
2. Propeller Shaft Flange
3. Transmission Cover
4. Dowel Pin
5. Short Cap Screws
6. Transmission Housing
7. Dowel Pin
8. Short Cap Screws
9. Selector Fork Shaft
10. Spring Pin
11. Flange Securing Nut
12. Pinion Shaft

Figure 3-1-1 — Transmisson AssemblyClick image to enlarge.

Figure 3-1-2 — Removal of Propeller Shaft Drive Flange Nut
Figure 3-1-2 — Removal of Propeller Shaft Drive Flange NutClick image to enlarge.

Figure 3-1-3 — Removal of Propeller Shaft Drive Flange
Figure 3-1-3 — Removal of Propeller Shaft Drive FlangeClick image to enlarge.

1.Removal — To remove, see Figure 3-1-1 and proceed as follows:

  1. Mount the transaxle on a repair stand.
  2. Drain the oil.
  3. Pry the cap (1) from the propeller shaft flange (2).
  4. Straighten the lock on the flange securing nut (11).
  5. Remove the flange securing nut using a 36 mm socket and Matra 3028 to hold the flange, see Figure 3-1-2.
  6. Remove the flange from the pinion shaft (12) using tool VW 391 and a 25 mm open end wrench, see Figure 3-1-3.
  7. Remove the two dowel pins (4), see Figure 3-1-1, from the transmission. cover (3) and transmission housing (6) (top and bottom).
  8. Remove the spring pin (10) of the selector fork shaft (9) for cross-country and reverse gears by driving the pin into the case. The pin can be tapped out later when the cover is removed.
  9. Pull out the shaft (9) for the selector fork.
  10. Remove the ten long cap screws and two short cap screws (5) securing the cover to the transmission housing.
  11. Remove the cover from the transmission housing.
  12. Remove the transmission from the differential housing by removing the two dowel pins (7) and the two securing cap screws (8).

Clutch Release Bearing

Figure 3-1-4 — Clutch Release Bearing and Shaft Assembly

1. Securing Springs
2. Clutch Release Bearing
3. Cap Screw
4. Locking Collar
5. Bushing
6. Guide Sleeve
7. Release Shaft
8. Shaft Stop
9. Release Shaft Spring
10. O-ring
11. Plastic Bushing
12. O-ring
13. Platic Cap
14. Snap Ring
15. Bolt
16. Washer
17. Clutch Lever
18. Washer
19. Nut

Figure 3-1-4 — Clutch Release Bearing and Shaft AssemblyClick image to enlarge.

Figure 3-1-5 — Removal of Clutch Release Shaft Bushing
Figure 3-1-5 — Removal of Clutch Release Shaft BushingClick image to enlarge.

2.Removal — To remove, see Figure 3-1-4 and proceed as follows:

  1. Remove the left and right clutch release bearing securing springs (1) by using a screwdriver to unhook the springs from the fingers on the shaft (7).
  2. Pull the release bearing (2) off the guide sleeve (6).

Clutch Release Bearing Shaft and Seals

3.Removal — To remove, see Figure 3-1-4 and proceed as follows:

  1. Relieve tension on the shaft (7). Using brake spring pliers, grip under the spring and pry the spring (9) to one side using a screwdriver.
  2. Remove the snap ring (14) and pry off the plastic cap (13).
  3. Pry the plastic bushing (11) and “O” ring (12) from the shaft.
  4. Remove the “O” ring from the plastic bushing.
  5. Work the shaft all the way to one side until it is free of the bushing (5). Push the shaft in the opposite direction until the end is clear of the housing and remove the shaft.
  6. Using a small screwdriver, pry the “O” ring (10) out of the housing.
  7. Remove the clutch-shaft stop (8) for access to the bushing.

CAUTION — Ensure the jaws of the extractor do not protrude past the inner edge of the bushing. If the jaws contact the suface of the housing, they will cause damage to the housing.

  1. Insert internal extractor KUKKO 21/3 and tighten the nut.
  2. Insert puller VW 771 through the shaft opening in the housing.
  3. Screw the puller into the bushing puller, using adapter VW 771/15, see Figure 3-1-5.
  4. Remove the bushing.

Starter Bushing

Figure 3-1-6 — Removal of Starter Bushing
Figure 3-1-6 — Removal of Starter BushingClick image to enlarge.

4.Removal — To remove, see Figure 3-1-6 and proceed as follows:

  1. Insert tool 788-14 into the starter bushing.
  2. Install puller KUKKO 22-1.
  3. Remove the bushing from the differential housing.

Two-Wheel Drive and Interlock Levers

Figure 3-1-7 — Two-Wheel Drive and Interlock Lever

1. Interlock Lever
2. Shaft
3. Spring Pin
4. Interlock Shaft Cover
5. Two-Wheel Drive Lever
6. Shaft
7. Bolt and Nut

Figure 3-1-7 — Two-Wheel Drive and Interlock LeverClick image to enlarge.

5.Removal — To remove, see Figure 3-1-7 and proceed as follows:

  1. Remove the bolt and nut (7) securing the two-wheel drive lever (5) to the shaft (6).
  2. Mark the lever and the end of the shaft for reassembly.
  3. Remove the lever.
  4. Remove the interlock lever (1) from the shaft (2) by driving out the spring pin (3).
  5. Remove the lever.
  6. Remove the three socket head cap screws from the interlock shaft cover (4).
  7. Remove the cover.

Left Drive Flange

Figure 3-1-8 — Removal of Drive Flange Centre Bolt
Figure 3-1-8 — Removal of Drive Flange Centre BoltClick image to enlarge.

Figure 3-1-9 — Removal of Left Drive Flange Seal
Figure 3-1-9 — Removal of Left Drive Flange SealClick image to enlarge.

6.Removal — To remove, proceed as follows:

  1. Remove the speedometer driven gear and adapter.
  2. Install two bolts in the drive flange and hold the bolts with a pry bar.
  3. Remove the centre bolt from the drive flange, see Figure 3-1-8.
  4. Pull the drive flange from the housing.
  5. Pull out the seal using extractor hook VW 771/37 and puller tool VW 771, see Figure 3-1-9.

Right Drive Flange

7.Removal — To remove, proceed as follows:

  1. Pierce and pry out the drive flange cover.
  2. Install two bolts in the drive flange and hold the bolts with a bar, see Figure 3-1-8.
  3. Remove the drive flange centre bolt and washer.
  4. Remove the drive flange.
  5. Remove the half shaft and needle bearing from the drive flange.

Differential Flange Assembly

8.Removal — To remove, proceed as follows:

  1. Remove the nine cap screws from the differential flange.
  2. Remove the differential flange assembly.
  3. Remove the spacer and shim.
  4. Remove the crown gear and carrier from the differential housing.

Differential Bearing Races

Figure 3-1-10 — Removal of Pinion Shaft Bearing Race and Shim
Figure 3-1-10 — Removal of Pinion Shaft Bearing Race and ShimClick image to enlarge.

Figure 3-1-11 — Removal of Left Carrier Bearing Race and Shim
Figure 3-1-11 — Removal of Left Carrier Bearing Race and ShimClick image to enlarge.

9.Removal — To remove, proceed as follows:

  1. Remove the pinion shaft bearing race and shim using tool 2050 and puller VW 771, see Figure 3-1-10.
  2. Remove the left carrier bearing race and shims using puller KUKKO 21-7, support tool KUKKO 22-2 and a 27 mm wrench, see Figure 3-1-11.

Figure 3-1-12 — Removal of Input Shaft Needle Bearing
Figure 3-1-12 — Removal of Input Shaft Needle BearingClick image to enlarge.

Input Shaft Needle Bearing

10.Removal — Remove the input shaft needle bearing using extractor KUKKO 21-5 and sliding hammer VW 771, see Figure 3-1-12.

Differential Flange Assembly

Figure 3-1-13 — Differential Flange Assembly

1. Oil Seal
2. Oil Seal
3. Nut, Bolt and Washers
4. Two-wheel Drive Lever
5. Selector Shaft Seal
6. Snap Ring
7. Two-wheel Drive Sending Unit
8. Extension Shaft
9. Detent Plug
10. Seal
11. Spring
12. Detent
13. Differential Flange
14. Selector Shaft
15. Selector Fork
16. Snap Ring
17. Sliding Collar
18. Bearing Race
19. Shim
20. Tubular Key
21. Magnet

Figure 3-1-13 — Differential Flange AssemblyClick image to enlarge.

11.Disassembly — To disassemble, see Figure 3-1-13 and proceed as follows:

  1. Place the differential flange (13) in a vise.
  2. Pry or drive out the two oil seals (1 and 2).
  3. Remove the detent plug (9) and seal (10).
  4. Remove the spring (11) and detent (12).
  5. Remove the two-wheel drive sending unit (7) and extension shaft (8).
  6. Remove the seal (5) from the selector shaft (14).
  7. Remove the snap rings (6 and 16) from the selector shaft.
  8. Remove the shaft (14), selector fork (15) and sliding collar (17).
  9. Remove the bearing race (18) and shims (19) from the housing using a brass drift.
  10. Pull out the tubular key (20) and remove the magnet (21).

Crown Gear and Carrier

Figure 3-1-14 — Crown Gear and Carrier Assembly

1. Shims
2. Side Gears
3. Thrust Washers
4. Pinion Gears
5. Nuts
6. Drive Flange Shim(s)
7. Shaft
8. Carrier
9. Tubular Key
10. Small Carrier Bearing
11. Speedometer Drive Gear
12. Cap Screw
13. Crown Gear
14. Large Carrier Bearing

Figure 3-1-14 — Crown Gear and Carrier AssemblyClick image to enlarge.

Figure 3-1-15 — Removal of Large Carrier Bearing
Figure 3-1-15 — Removal of Large Carrier BearingClick image to enlarge.

Figure 3-1-16 — Removal of Small Carrier Bearing
Figure 3-1-16 — Removal of Small Carrier BearingClick image to enlarge.

Figure 3-1-17 — Removal of Crown Gear from Carrier
Figure 3-1-17 — Removal of Crown Gear from CarrierClick image to enlarge.

12.Disassembly — To disassemble, see Figure 3-1-14 and proceed as follows:

  1. Remove the drive flange shim (6).
  2. Remove the speedometer drive gear (11).
  3. Secure the assembly in a vise.
  4. Remove the large carrier bearing (14) using puller KUKKO 44-2 and tool 40-105. Ensure that the puller fits into the grooves on the carrier, see Figure 3-1-15.
  5. Remove the small carrier bearing (10), see Figure 3-1-14, using puller OTC 1025 and tool 40-105, see Figure 3-1-16.
  6. Remove the ten cap screws (12), see Figure 3-1-14, from the carrier (8).
  7. Drive the crown gear off the carrier, see Figure 3-1-17.
  8. Drive out the tubular key (9), see Figure 3-1-14, that secures the shaft for the pinion gears.
  9. Drive out the shaft (7) for the pinion gears (4) and side gears (2) and remove the two nuts (5).
  10. Remove the pinion gears and thrust washers (3) by turning the gears to the opening.
  11. Remove the side gears and shims (1).

Transmission

Figure 3-1-18 — Reverse and Cross-Country Gear Assembly

1. Shim
2. Thrust Washer
3. Reverse Gear
4. Bushing
5. Needle Bearing
6. Hub
7. Operating Sleeve
8. Selector Fork
9. Bushing
10. Needle Bearing
11. Cross-Country Gear
12. Thrust Washer
13. Pinion Shaft

Figure 3-1-18 — Reverse and Cross-Country Gear AssemblyClick image to enlarge.

Figure 3-1-19 — Transmission Assembly

1. Countershaft
2. Countershaft Needle Bearing
3. Transmission Housing
4. Countershaft Reverse Gear
5. Thrust Washer
6. Bearing Race
7. Bearing
8. Bearing Race
9. Retaining Washer
10. Snap Ring
11. Washer
12. Socket Head Cap Screw
13. Input Shaft
14. Tubular Key
15. 3-4 Selector Fork
16. Pinion Shaft
17. 1-2 Shifter Rod
18. 1-2 Selector Fork
19. Operating Link
20. Cap Screw
21. 3-4 Shifter Rod
22. 3-4 Interlock Pin
23. Cross-Country/Reverse Shifter Rod
24. Cap Screw
25. Support Plate
26. Retaining Washer
27. Socket Head Cap Screw
28. Washer
29. Bearing Race
30. Ball Bearing
31. Bearing Race
32. Roller Bearing

Figure 3-1-19 — Transmission AssemblyClick image to enlarge.

13.Removal — To remove, see Figure 3-1-18 and proceed as follows:

  1. Clamp the transmission in a vise.
  2. Remove the cross-country gear (11) including thrust washer (12), needle bearing (10) and bushing (9).
  3. Remove the selector fork (8).

NOTE — Mark the operating sleeve (7) and hub (6) for identification (if not removed as a unit).

  1. Remove the hub with the operating sleeve.
  2. Remove the needle bearing (5), bushing (4) and reverse gear (3).
  3. Remove the thrust washer (2) and shim (1). The shim is smaller than the thrust washer.
  4. See Figure 3-1-19 and remove the socket head cap screw (27) and washer (28) from the input shaft (13) using a 6 mm hex head driver.

Figure 3-1-20 — First and Second Gear Operating Link
Figure 3-1-20 — First and Second Gear Operating LinkClick image to enlarge.

  1. Remove the operating link for first and second gear by removing the two cap screws and lock washers, see Figure 3-1-20.

Figure 3-1-21 — Gear Dentent Plugs, Plungers and Springs
Figure 3-1-21 — Gear Dentent Plugs, Plungers and SpringsClick image to enlarge.

Figure 3-1-22 — Cap Screw Installed on Input Shaft
Figure 3-1-22 — Cap Screw Installed on Input ShaftClick image to enlarge.

  1. Remove the gear detent plugs, plungers and springs (green), see Figure 3-1-21.
  2. Remove the centre gear detent plug using a 6 mm hex head driver, see Figure 3-1-21.
  3. See Figure 3-1-19 and remove the tubular key (14) from the shifter rod (21) at the selector fork (15) for third and fourth gears.
  4. Remove the cross-country and reverse gear shifter rod (23) ensuring that the third/fourth shifter rod (21) is in the neutral detent position.
  5. Remove the interlock pin (22) from the third and fourth gear shifter rod.
  6. Remove the third and fourth gear shifter rod (21) and selector fork (15) by turning the rod towards the countershaft (1) 90°.
  7. Remove the four cap screws (24) from the support plate (25) and remove the plate.
  8. Remove the retaining washer (26).
  9. Install a support plate M8x20 cap screw fully into the input shaft, see Figure 3-1-22.

Figure 3-1-23 — Support Plate and VW 477h Installed
Figure 3-1-23 — Support Plate and VW 477h InstalledClick image to enlarge.

  1. Install the support plate and tool VW 447h with four M8x35 cap screws, see Figure 3-1-23.
  2. Loosen the cap screw in the centre of the input shaft. This will press the input shaft out of the bearing race (29), see Figure 3-1-19.
  3. Remove the input shaft (13) and bearing race (31).
  4. Remove the support plate and ball bearing (30).
  5. Remove the socket head cap screw (12) and washer (11) from the countershaft (1).

Figure 3-1-24 — Countershaft Snap Ring and Retaining Washer
Figure 3-1-24 — Countershaft Snap Ring and Retaining WasherClick image to enlarge.

  1. Remove the snap ring and retaining washer, see Figure 3-1-24.

Figure 3-1-25 — Removal of Countershaft
Figure 3-1-25 — Removal of CountershaftClick image to enlarge.

  1. Press the countershaft from the races using VW 431 and puller KUKKO 44-2, see Figure 3-1-25.
  2. Remove the bearing (7), races (6 and 8) and thrust washer (5), see Figure 3-1-19.
  3. Remove the countershaft reverse gear (4).
  4. Remove the pinion shaft (16), shifter rod (17) and attached selector fork (18).

Figure 3-1-26 — Interlocking Plungers, Gear Detent Plug and Spring
Figure 3-1-26 — Interlocking Plungers, Gear Detent Plug and SpringClick image to enlarge.

  1. Remove the short and long interlocking plungers and the detent plug and spring (unpainted) from the housing, see Figure 3-1-26.

Figure 3-1-27 — Removal of Countershaft Needle Bearing
Figure 3-1-27 — Removal of Countershaft Needle BearingClick image to enlarge.

  1. Press the countershaft needle bearing out of the transmission housing using tools Matra 30-505 and VW 472/2, see Figure 3-1-27.
  2. Remove the input shaft roller bearing (32) using a brass drift, see Figure 3-1-19.
  3. Tap the pinion bearing race and shims out of the transmission housing using remover VW 447i.

Transmission Cover

Figure 3-1-28 — Transmission Cover Assembly

1. Oil Trap Lock Screw
2. Oil Trap
3. Idler Gear Shaft
4. Shaft Lock Screw
5. Thrust Washer
6. Bearings
7. Idler Gear
8. Thrust Washer
9. Transmission Cover
10. Seal
11. Reverse Light Switch Plug
12. Pinion Shaft Roller Bearing
13. Pinion Shaft Seal-Inner
14. Pinion Shaft Seal-Outer
15. Countershaft Roller Bearing
16. Snap Ring

Figure 3-1-28 — Transmission Cover AssemblyClick image to enlarge.

Figure 3-1-29 — Removal of Countershaft Roller Bearing
Figure 3-1-29 — Removal of Countershaft Roller BearingClick image to enlarge.

Figure 3-1-30 — Removal of Pinion Shaft Roller Bearing
Figure 3-1-30 — Removal of Pinion Shaft Roller BearingClick image to enlarge.

14.Disassembly — To disassemble, see Figure 3-1-28 and proceed as follows:

  1. Remove the lock screw (1) holding the oil trap (2).
  2. Remove the lock screw (4) that locks the idler gear shaft (3).
  3. Remove the idler gear shaft (3) by placing a drift in the hole on the side of the shaft and pulling the shaft from the housing.
  4. Remove the gear (7) and two sets of bearings (6).
  5. Remove the two thrust washers (5 and 8).
  6. Remove the snap ring (16) from the countershaft roller bearing (15).
  7. Remove the countershaft roller bearing using puller HAZET 788-30, see Figure 3-1-29.
  8. Pry the two pinion shaft seals (13 and 14) from the cover (9), see Figure 3-1-28.
  9. Using tool VW 447i and VW 407, press the pinion shaft roller bearing (12) from the cover, see Figure 3-1-30.
  10. Remove the reverse light switch plug (11) and seal (10), see Figure 3-1-28.

Pinion Shaft

Figure 3-1-31 — Pinion Shaft Assembly

1. Pinion Shaft
2. Tapered Roller Bearing
3. Fourth Gear
4. Snap Ring
5. Third Gear
6. Snap Ring
7. Needle Bearing
8. Second Gear
9. Tapered Roller Bearing
10. First Gear
11. Needle Bearing
12. First Gear Synchronizing Ring
13. Snap Ring
14. Synchronizing Unit
15. Second Gear Synchronizing Ring
16. Sleeve
17. Synchronizer Hub

Figure 3-1-31 — Pinion Shaft AssemblyClick image to enlarge.

15.Disassembly — To disassemble, see Figure 3-1-31 and proceed as follows:

  1. Press off the first gear (10) and bearing (9).
  2. Remove the needle bearing (11) for first gear.
  3. Remove the first gear synchronizing ring (12).
  4. Remove the snap ring (13).
  5. Mark the synchronizer hub (17) and sleeve (16) if they are to be separated and remove the synchronizing unit (14).
  6. Remove the second gear synchronizing ring (15).
  7. Remove the second gear (8) and needle bearing (7).
  8. Remove the snap ring (6).
  9. Press off third gear (5).
  10. Remove the snap ring (4).
  11. Press off fourth gear (3).
  12. Press off the tapered roller bearing (2).

Input Shaft

Figure 3-1-32 — Input Shaft Assembly

1. Third Gear Synchronizing Ring
2. Third Gear
3. Needle Bearing
4. Input Shaft
5. Synchronizing Unit
6. Snap Ring
7. Fourth Gear Synchronzing Ring
8. Needle Bearing
9. Fourth Gear
10. Snap Ring
11. Operating Sleeve
12. Synchronizer Hub

Figure 3-1-32 — Input Shaft AssemblyClick image to enlarge.

16.Disassembly — To disassemble, see Figure 3-1-32 and proceed as follows:

  1. Remove the snap ring (10).
  2. Remove fourth gear (9).
  3. Remove the needle bearing (8) for fourth gear.
  4. Remove the synchronizing ring (7) for fourth gear.
  5. Remove the snap ring (6).
  6. Press off the operating sleeve (11) and synchronizer hub (12) with synchronizing ring (1).
  7. Remove third gear (2).
  8. Remove the needle bearing (3) for third gear.

Section 2 — Assembly and Adjustments

General

1.If a complete overhaul of the transaxle is required, do all adjustments and measurements as part of the reassembly procedure. Figure 3-2-60 indicates which adjustments must be done if only certain parts of the transaxle are replaced and a complete overhaul is not required.

2.When choosing new shims for adjustments, measure each shim at several different points with a micrometer. The thickness of available shims is such that it is possible to obtain any desired thickness to within a tolerance of ± 0.04 mm. Ensure new shims are undamaged and free from burrs. Do not install shims that are not in good condition.

Pinion Shaft

Figure 3-2-1 — Installation of Roller Bearing and Fourth Gear
Figure 3-2-1 — Installation of Roller Bearing and Fourth GearClick image to enlarge.

Figure 3-2-2 — Selection of Snap Ring for Fourth Gear
Figure 3-2-2 — Selection of Snap Ring for Fourth GearClick image to enlarge.

Mfg. Part No. NATO Stock No. Thickness (mm)
B 088 311 363 AA — 2.34
B 088 311 363 AC — 2.36
B 088 311 363 AE — 2.38
B 088 311 363 AG — 2.40
B 088 311 363 AJ — 2.42
B 088 311 363 AL — 2.44
B 088 311 363 AN — 2.46
B 088 311 363 AQ — 2.48
B 088 311 363 AS — 2.50

Figure 3-2-3 — Snap Rings For Fourth Gear

Mfg. Part No. NATO Stock No. Thickness (mm)
B 088 311 287 — 1.65
B 088 311 287 A — 1.70
B 088 311 287 B — 1.75

Figure 3-2-4 — Snap Rings For Third Gear

Figure 3-2-5 — Clearance Between Synchronizing Ring and Gear Cone (Second Gear Illustrated)
Figure 3-2-5 — Clearance Between Synchronizing Ring and Gear Cone (Second Gear Illustrated)Click image to enlarge.

Mfg. Part No. NATO Stock No. Thickness (mm)
B 088 311 327 — 1.50
B 088 311 327 A — 1.55
B 088 311 327 B — 1.60

Figure 3-2-6 — Snap Rings For Synchronizing Hub

Figure 3-2-7 — Checking Clearance Between Bearing and First Gear
Figure 3-2-7 — Checking Clearance Between Bearing and First GearClick image to enlarge.

3.Assembly — To assemble, see Figure 3-1-31 and proceed as follows:

  1. Remove all traces of oil and grease from the fourth gear (3) and pinion shaft (1) and heat the gear to 120°C.
  2. Press the roller bearing (2) and fourth gear onto the shaft with the fourth gear shoulder facing towards the third gear, see Figure 3-2-1.
  3. Install the thickest snap ring (4) that will fit into the gap, see Figure 3-2-2. See Figure 3-2-3 for a list of snap rings.
  4. Check the clearance between fourth gear and the snap ring. Clearance should be 0.00 and not exceed 0.02 mm.
  5. Press the third gear (5) onto the shaft so that the third gear shoulder faces towards the second gear (8), see Figure 3-1-31.
  6. Install a snap ring (6).
  7. Check the clearance between third gear and the snap ring. The clearance should be 0.00 and not exceed 0.04 mm.
  8. Adjust the clearance by selecting a suitable snap ring. Keep as near as possible to the lower limit. Figure 3-2-4 lists available snap rings.
  9. Install the second gear needle bearing (7), see Figure 3-1-31.
  10. Install second gear.
  11. Install second gear synchronizing ring (15).
  12. Check the clearance between the synchronizing ring and the second gear cone, see Figure 3-2-5. The gap, when new, is 1.0 to 1.7 mm. The minimum gap is 0.5 mm.
  13. Press on the operating sleeve (16) and synchronizer hub (17) so that the fork groove faces towards first gear (10), see Figure 3-1-31. Ensure the ring grooves and keys are aligned.
  14. Install the snap ring (13).
  15. Check the clearance between the snap ring and the synchronizer hub. Clearance should be 0.00 and not exceed 0.04 mm. Adjust the clearance by selecting a suitable snap ring. Stay as near as possible to the lower limit of clearance. Figure 3-2-6 lists available snap rings.
  16. Install the first gear synchronizing ring (12) ensuring that the ring grooves are aligned with the keys in the hub, see Figure 3-1-31.
  17. Install the needle bearing (11) for first gear and install first gear (10).
  18. Check the clearance between the synchronizing ring and first gear. Clearance should be between 1.00 and 1.70 mm when new. The minimum gap is 0.50 mm.
  19. Install the roller bearing (9) by pressing on with tool VW 454 and VW 401. Check the clearance between the bearing and first gear, see Figure 3-2-7. Clearance should be between 0.10 and 0.40 mm.

Mfg. Part No. NATO Stock No. Thickness (mm)
B 088 311 317 — 1.50
B 088 311 317 B — 1.56
B 088 311 317 C — 1.62

Figure 3-2-8 — Snap Rings For Input Shaft Synchronizing Hub

Input Shaft

4.Assembly — To assemble, see Figure 3-1-32 and proceed as follows:

  1. Install the needle bearing (3) for third gear (2).
  2. Install the third gear (2) with the teeth facing towards second gear.
  3. Install the synchronizing ring (1) for third gear.
  4. Check the clearance between the synchronizing ring and the gear cone, refer to paragraph 3. n.
  5. Press on the operating sleeve (11) and synchronizer hub (12) so that the wide shoulder of the hub faces towards the fourth gear (9). Ensure the cutaway portions on the synchronizer hub are aligned with the keys on the hub.
  6. Install the snap ring (6).
  7. Using a feeler gauge, check the clearance between the hub and the snap ring. Clearance should be between 0.00 and 0.50 mm. Adjust the clearance by selecting a suitable snap ring. Try to keep the clearance towards the lower value. Figure 3-2-8 lists available snap rings.
  8. Check the clearance between the second and third gears. Clearance should be between 0.00 and 0.35 mm.
  9. Install the needle bearing (8) for fourth gear, see Figure 3-1-32.
  10. Install the fourth gear synchronizing ring (7), ensuring that the cutaway portion on the ring aligns with the keys on the synchronizer hub (12).
  11. Install the fourth gear (9) with the gear teeth away from the third gear (2).
  12. Check the clearance between the synchronizing ring and the gear cone, refer to paragraph 3. n.
  13. Install the snap ring (10). There is no clearance adjustment.

Crown Gear and Carrier

Figure 3-2-9 — Installation of Small Carrier Bearing
Figure 3-2-9 — Installation of Small Carrier BearingClick image to enlarge.

5.Assembly — To assemble, see Figure 3-1-14 and proceed as follows:

  1. Mount the carrier (8) in a vise.
  2. Heat the small carrier bearing (10) to about 100°C. Place the bearing on the end of the carrier and press the bearing fully home with tool 40-21, see Figure 3-2-9.
  3. Heat the large carrier bearing (14) to about 100°C. Place the bearing on the end of the carrier and press the bearing fully home with VW 415A and VW 447i, see Figure 3-2-10.
  4. Heat the crown gear (13) to about 100°C and place the crown gear on the carrier. Ensure the bolt holes in the carrier and crown gear are aligned.

CAUTION — To prevent damage, do not torque the cap screws that secure the crown gear to the carrier until the crown gear and carrier have cooled.

Figure 3-2-10 — Installation of Large Carrier Bearing
Figure 3-2-10 — Installation of Large Carrier BearingClick image to enlarge.

  1. Install the ten cap screws (1 2) and torque to 100 N•m (74 ft lb).
  2. Apply hypoid gear oil to the side gears (2) and pinion gears (4).
  3. Install the side gears and shims (1) in the carrier.
  4. Apply a small amount of grease to the pinion gears to hold the thrust washers (3) in place and place a washer on each gear.
  5. Install a pinion gear in each side opening of the carrier and turn the gears until the holes in the gears are aligned with the holes in the carrier for the side gear shaft (7).
  6. Install the top and bottom nuts (5) in the carrier.
  7. Drive in the side gear shaft until the hole in the shaft for the tubular key (9) is aligned with hole in the carrier.
  8. Press the pinion gears outwards, towards the carrier, and check the play of the side gears. If no play of the gears can be felt by hand and the gears turn easily without sticking, it is not necessary to adjust the side gears. The maximum allowable play of the side gears is 0.10 mm. Adjust the side gears if necessary. Proceed as follows:

Mfg. Part No. NATO Stock No. Thickness (mm)
B 011 519 215 — 0.50
B 088 409 249 — 0.60
B 088 409 249 A — 0.70
B 088 409 249 B — 0.80

Figure 3-2-11 — Shims Available for Side Gears

  1. Tap out the side gear shaft.
  2. Remove the pinion gears and thrust washers.
  3. Remove the side gears and shims.
  4. Choose new shims for the side gears so that the play of the side gears is not greater than 0.10 mm. Figure 3-2-11 lists those shims that are available for the side gears.
  5. Repeat steps g. through m.
  1. Tap in the tubular key (9) to secure the side shaft.
  2. Install the speedometer drive gear (11) on the end of the carrier.

Crown Gear and Pinion Adjustments

Figure 3-2-12 — Crown Gear and Pinion Adjustments and Identification Marking (Transaxle)

1 Identification “K 7/37” means Klingelnberg crown wheel/pinion, ratio 7:37.
2 Index number (312) of matched set.
3 Deviation “r” measured against master gauge of special machine used in production. Deviation “r” is always given in 1/100 mm. Example: “25” means r = 0.25 mm.
Ro Length of master gauge used in special test machine. “Ro” = 59.65 mm.
R Actual distance between centre axis of crown wheel and face of pinion with pinion in position for quietest running for this particular matched set.
Vo Hypoid Offset = 12 mm.

Figure 3-2-12 — Crown Gear and Pinion Adjustments and Identification Marking (Transaxle)Click image to enlarge.

6.Careful adjustment of the crown gear and pinion is essential to ensure that the transaxle gives long service and runs silently. During manufacture, the crown gear and pinion are matched and run on special testing machines to ensure a correct mesh pattern and silent running in both directions. The position for quietest running is obtained by moving the pinion axially and lifting the crown gear away from the no-play meshing position to maintain the backlash within the specified tolerances. See Figure 3-2-12 for the adjustments and identification markings of the crown gear and pinion.

Figure 3-2-13 — Location and Identification of Transaxle Adjusting Shims
Figure 3-2-13 — Location and Identification of Transaxle Adjusting ShimsClick image to enlarge.

7.Figure 3-2-13 shows the location of those shims that affect the crown gear and pinion settings. Adjust the crown gear and pinion settings in the following order:

  1. Determine the total shim thickness for the crown gear, S Total (S1 plus S2), to give the specified preload of the differential carrier bearings.
  2. Determine the total shim thickness for the pinion, S Total (S3 plus S4), to give the specified preload of the pinion bearings.
  3. Distribute the total shim thickness for the pinion between S3 and S4 in order that the distance from the centre axis of the crown gear to the face of the pinion corresponds to dimension “R”, see Figure 3-2-12, as determined during manufacture.
  4. Distribute the total shim thickness for the crown gear between S1 and S2 to obtain the specified backlash between the crown gear and pinion.

Bearing Races

Figure 3-2-14 — Installation of Pinion Bearing Race in Differential Housing
Figure 3-2-14 — Installation of Pinion Bearing Race in Differential HousingClick image to enlarge.

Figure 3-2-15 — Installation of Left Carrier Bearing Race
Figure 3-2-15 — Installation of Left Carrier Bearing RaceClick image to enlarge.

Figure 3-2-16 — Installation of Differential Flange Bearing Race
Figure 3-2-16 — Installation of Differential Flange Bearing RaceClick image to enlarge.

Figure 3-2-17 — Installation of Pinion Bearing Race in Transmission Housing
Figure 3-2-17 — Installation of Pinion Bearing Race in Transmission HousingClick image to enlarge.

8.Installation — To install, proceed as follows:

  1. Heat the differential housing or the area around the bearing race for the pinion to 150°C and drive the bearing race into the housing with tools 3062 and VW 295, see Figure 3-2-14. Do not install the adjusting shims at this time. Hold the race in place with the press for one or two minutes until the heat transfer has taken place.

NOTE — The differential housing can be heated with a hot air blower, cleaning equipment, water bath or steam jet. A soft welding flame can also be used but care must be taken to heat the complete area around the bearing race seat as constantly and evenly as possible in order to avoid stress and distortion to the housing.

  1. Drive the bearing race of the left carrier bearing fully home with VW 511 and VW 295, see Figure 3-2-15. Do not install the adjusting shims at this time.
  2. Press the bearing race of the differenttial flange assembly fully home with VW 472/1, see Figure 3-2-16. Do not install the adjusting shims at this time.
  3. Press the bearing race for the pinion into the transmission housing with VW 511, see Figure 3-2-17. Do not install the adjusting shims at this time.

Carrier Bearing Preload Adjustment "S Total" (S1 + S2)

Figure 3-2-18 — Measurement of Carrier Axial Play
Figure 3-2-18 — Measurement of Carrier Axial PlayClick image to enlarge.

9.Adjustment — To adjust, proceed as follows:

  1. Remove the speedometer drive gear and place the carrier in the differential housing ensuring the crown gear teeth are towards the differential flange.
  2. Install the differential flange and eight cap screws. Torque the cap screws to 25 N•m (18 ft lb).
  3. Install VW 387, VW 385/17, a dial gauge and a dial gauge extension that is about 85 mm long, see Figure 3-2-18.
  4. Set the dial gauge to zero.
  5. Move the carrier up as far as it will go and note the reading (example reading: 1.42 mm).
  6. Determine the total shim thickness, S Total, where total shim thickness equals the dial gauge reading plus the preload allowance which is a constant value of 0.50 mm. Note the following example:
Preload allowance (constant value): 0.50 mm
Dial gauge reading (example only): + 1.42 mm
Total shim thickness (S Total): 1.92 mm

Mfg. Part No. NATO Stock No. Thickness (mm)
B 005 409 381 — 0.15
B 005 409 381 A — 0.20
B 005 409 381 B — 0.25
B 005 409 381 C — 0.55
B 005 409 381 D — 0.60
B 005 409 381 E — 0.65
B 005 409 381 F — 0.80
B 005 409 381 G — 1.35
B 005 409 381 H — 1.50
B 005 409 381 J — 1.65

Figure 3-2-19 — Shims For S Total and S2

  1. Remove the differential flange.
  2. Using a brass drift and hammer, tap the bearing race from the differential flange.
  3. Choose shims of the correct thickness from those shims available for S Total and S2 , see Figure 3-2-19.
  4. Install shims in the housing.
  5. Using VW 472/1, press the bearing race fully home.

Carrier Turning Torque Measurement

Figure 3-2-20 — Carrier Turning Torque Measurement
Figure 3-2-20 — Carrier Turning Torque MeasurementClick image to enlarge.

10.Measurement — To measure, proceed as follows:

  1. Lubricate the carrier bearings with hypoid gear oil.
  2. Place the carrier in the housing and install the differential flange and cap screws. Torque the cap screws to 25 N•m (18 ft lb).
  3. Install VW 521/8, VW 521/4 and a torque gauge with a range of 0 to 600 N•cm (0 to 53.1 in lb), see Figure 3-2-20, and measure the turning torque. If new carrier bearings have been installed on the carrier, the turning torque must be at least 250 N•cm (22.1 in lb). If used bearings have been installed, the turning torque must be at least 30 N•cm (2.6 in lb).
  4. Remove the differential flange and crown gear and carrier.
  5. Adjust the pinion.

Pinion Preload Adjustment "S Total" (S3 + S4)

Figure 3-2-21 — Measurement of Pinion Axial Play
Figure 3-2-21 — Measurement of Pinion Axial PlayClick image to enlarge.

11.Adjustment — To adjust, proceed as follows:

  1. Install the pinion bearing races and the preassembled pinion shaft.
  2. Install the transmission housing on the differential housing and torque the cap screws to 25 N•m (18 ft lb).
  3. Install VW 385/17, VW 387, a threaded rod (or VW 294b/3) and a dial gauge, see Figure 3-2-21.
  4. Set the dial gauge to zero.
  5. Move the pinion up as far as it will go and note the dial gauge reading (example reading: 1.30 mm).
  6. Determine the total shim thickness, S Total (S3 + S4), where total shim thickness equals the dial gauge reading plus the preload allowance which is a constant value of 0.30 mm. Note the following example:
Preload allowance (constant value): 0.30 mm
Dial gauge reading (example only): + 1.30 mm
Total shim thickness (S Total): 1.60 mm

Mfg. Part No. NATO Stock No. Thickness (mm)
B 088 311 393 — 0.24
B 088 311 393 A — 0.27
B 088 311 393 B — 0.30
B 088 311 393 C — 0.33
B 088 311 393 D — 0.36
B 088 311 393 E — 0.39
B 088 311 393 F — 0.42
B 088 311 393 G — 0.45
B 088 311 393 H — 0.69
B 088 311 393 J — 0.93
B 088 311 393 K — 1.17
B 088 311 393 L — 1.41

Figure 3-2-22 — Shims For Pinion S Total and S4

  1. Remove the dial gauge and threaded rod from the transmission housing.
  2. Remove the transmission housing and pinion.
  3. Tap the bearing race out of the transmission housing with a brass drift and hammer.
  4. Choose shims of the correct thickness from those shims available for S Total and S4, see Figure 3-2-22, and install the shims, amounting to the total shim thickness, behind the bearing race in the transmission housing.
  5. Press the bearing race into the transmission housing with VW 511.

Pinion Adjustment (S3 and S4)

12.Adjustment — After installing the shims for the pinion preload adjustment, S Total, distribute the S Total between S3 and S4. To adjust, proceed as follows:

Figure 3-2-23 — Universal Measuring Bar
Figure 3-2-23 — Universal Measuring BarClick image to enlarge.

  1. Install the transmission housing on the differential housing and torque the cap screws to 25 N•m (18 ft lb).
  2. Turn the pinion several times in both directions to settle the pinion bearings.
  3. Adjust the setting ring of universal measuring bar VW 385/1 to 50 mm.
  4. See Figure 3-2-23 and assemble the universal measuring bar as follows:
  1. Install dial gauge extension VW 385/15 (9.3 mm) on VW 385/14 and install on measuring bar VW 385/1.
  2. Install the dial gauge fully in the end of the measuring bar. Extract the gauge 1 mm and lock it.
  3. Set the master gauge VW 385/30 to “Ro” which is 59.65 mm, see Figure 3-2-12, and install the gauge on the measuring bar.

Figure 3-2-24 — Universal Measuring Bar Installed in Transaxle
Figure 3-2-24 — Universal Measuring Bar Installed in TransaxleClick image to enlarge.

Mfg. Part No. NATO Stock No. Thickness (mm)
B 088 311 391 — 0.20
B 088 311 391 A — 0.25
B 088 311 391 B — 0.30
B 088 311 391 C — 0.35
B 088 311 391 D — 0.40
B 088 311 391 E — 0.65
B 088 311 391 F — 0.90
B 088 311 391 G — 1.15

Figure 3-2-25 — Shims For S3

  1. Move the adjustable setting ring as far back as it will go.
  2. Install measuring plate VW 385/17 on the end of the pinion.
  3. Remove master gauge VW 385/30 from the measuring bar.
  4. Insert the measuring bar through the differential housing and install the differential flange and four cap screws, see Figure 3-2-24.
  5. Move the second centering disc outward with the adjustable setting ring until the measuring bar will just turn by hand.
  6. Turn the measuring bar until the dial gauge pin contacts the measuring plate on the pinion end face and the dial gauge shows maximum deflection.
  7. Note the counter-clockwise reading in red figures (example reading: 0.46 mm) and calculate the shim thickness for S3, where S3 equals e plus r (“e” is the dial gauge reading at maximum deflection and “r” is the deviation marked on the crown gear, see Figure 3-2-12). Note the following example:
e: 0.46 mm
r: + 0.18 mm
S3: 0.64 mm
  1. See Figure 3-2-25 for a list of shims for S3 and choose shims that will provide the correct thickness.
  2. Determine the thickness of S4 where S4 equals S Total minus S3. Note the following example:
S Total: 1.60 mm
S3: - 0.64 mm
S4: 0.96 mm
  1. See Figure 3-2-22 for a list of shims for S4 and choose shims that will provide the correct thickness.
  2. Remove the differential flange and measuring bar.
  3. Remove the transmission housing and pinion. Tap out the bearing race and preload adjusting shims from the transmission housing.
  4. Install the newly selected S4 shims in the transmission housing and press the bearing race fully home with VW 511.
  5. Remove the bearing race from the differential housing with tool 2050 and VW 771.
  6. Heat the front differential housing or the area around the bearing race for the pinion to 150°C and drive the bearing race and S3 shims into the housing with tool 3062 and VW 295. Hold the race in place for one or two minutes until the heat transfer has taken place.

NOTE — The differential housing can be heated with a hot air blower, cleaning equipment, water bath or steam jet. A soft welding flame can also be used but care must be taken to heat the complete area around the bearing race seat as constantly and evenly as possible in order to avoid stress and distortion to the housing.

  1. Check dimension “r”, see Figure 3-2-12, after installing the pinion adjusting shims:
  1. Install the pinion in the transmission housing.
  2. Install the transmission housing, cover and cap screws. Torque the cap screws to 25 N•m (18 ft lb). Turn the pinion in both directions several times.
  3. Repeat steps c. through k. and note the reading. If the correct shims have been installed, the dial gauge counter-clockwise reading, in red figures, will be the same as deviation “r”, which is marked on the crown gear to within ± 0.04 mm.
  4. Remove the differential flange and measuring bar.

Figure 3-2-26 — Measurement of Pinion Turning Torque
Figure 3-2-26 — Measurement of Pinion Turning TorqueClick image to enlarge.

  1. Remove the transmission cover and housing and lubricate the pinion bearings with hypoid gear oil.
  2. Install the transmission housing and cover and torque the cap screws to 25 N•m (18 ft lb).
  3. Using a torque gauge with a range of 0 to 600 N•cm, measure the turning torque, see Figure 3-2-26. If new pinion bearings have been installed, the pinion turning torque must be 200 to 400 N•cm (17.7 to 35.4 in lb) and for used bearings 30 to 60 N•cm (2.6 to 5.3 in lb).

Crown Gear Backlash Adjustment (S1 and S2)

Figure 3-2-27 — Measurement of Crown Gear Backlash
Figure 3-2-27 — Measurement of Crown Gear BacklashClick image to enlarge.

13.Adjustment — To adjust, proceed as follows:

  1. Place the carrier in the differential housing.
  2. Install the pinion in the transmission housing.
  3. Install the transmission housing and cap screws.
  4. Turn the pinion in both directions to settle the tapered roller bearings.
  5. Install the differential flange and eight cap screws. Torque the cap screws to 25 N•m (18 ft lb).
  6. Install VW 387, VW 388, VW 521/4, VW 521/8 and dial gauge extension VW 382/10, see Figure 3-2-27.
  7. Adjust measuring lever VW 388 to 79 mm.
  8. Turn tool VW 521/4 counter-clockwise and set the dial gauge to zero. j. Without moving the pinion, turn VW 521/4 clockwise and record the reading.
  9. Loosen tool VW 521/4, turn it counterclockwise through 90° and tighten the tool. Do not turn the carrier when turning the tool.
  10. Turn tool VW 521/4 clockwise as far as it will go.
  11. Set the dial gauge to zero, turn the tool counter-clockwise and record the backlash reading.
  12. Repeat steps m. and n. a second and third time and each time record the backlash reading.

NOTE — If the difference between any of the four backlash readings is greater than 0.06 mm, either the crown gear and pinion are not installed correctly, or they are defective. Ensure the crown gear and pinion are installed correctly and, if necessary, install a new crown gear and pinion.

  1. Add the four readings together and divide by four to calculate the average backlash. Note the following example:
First reading: 0.84 mm
Second reading: 0.85 mm
Third reading: 0.84 mm
Fourth reading: + 0.83 mm
Total: 3.36 mm
 
Average backlash = 3.36 ÷ 4 = 0.84 mm
  1. Calculate the shim thickness for S2 where S2 equals S Total minus average backlash plus required final backlash (constant value of 0.15 mm). Note the following example:
S Total: 1.92 mm
Average backlash: - 0.84 mm
1.08 mm
 
Required final backlash: + 0.15 mm
S2: 1.23 mm
  1. Choose shims of the correct thickness for S2. Figure 3-2-19 lists shims for S2.
  2. Calculate the shim thickness for S1 where S1 equals S Total minus S2. Note the following example:
S Total: 1.92 mm
S2: - 1.23 mm
S1: 0.69 mm

Mfg. Part No. NATO Stock No. Thickness (mm)
B 005 409 385 — 0.15
B 005 409 385 A — 0.20
B 005 409 385 B — 0.25
B 005 409 385 C — 0.50
B 005 409 385 D — 0.80
B 005 409 385 E — 1.00
B 005 409 385 F — 1.50

Figure 3-2-28 — Shims For S1 (Transaxle)

  1. Choose shims of correct thickness for S1. Figure 3-2-28 lists shims for S1.
  2. Remove the differential flange and the carrier from the differential housing.
  3. Using a brass drift and hammer, remove the bearing race and shims from the differential flange.
  4. Install the newly selected shims for S2 in the differential flange and press the race into the flange with VW 472/1.
  5. Using a brass drift and hammer, remove the carrier bearing race from the differential housing.
  6. Install the newly selected shims for S1 in the differential housing and drive the bearing race into the housing with VW 295 and VW 511.
  7. Check the crown gear backlash. Proceed as follows:
  1. Place the crown gear and carrier in the differential housing.
  2. Install the differential flange and eight cap screws. Torque the cap screws to 25 N•m (18 ft lb).
  3. Install VW 387, VW 388, VW 521/4, VW 521/8, dial gauge and extension, see Figure 3-2-27.
  4. Repeat steps g. to p. Start the measurement at a different point each time. The backlash must be 0.10 to 0.20 mm each time and the difference between any of the four readings must not be greater than 0.06 mm.
  1. Remove the differential flange.

Drive Flange Adustment (Right Side)

Figure 3-2-29 — Measurement of Drive Flange Shim Thickness
Figure 3-2-29 — Measurement of Drive Flange Shim ThicknessClick image to enlarge.

Dimension “A” mm Shim Thickness (mm) Mfg. Part No. NATO Stock No.
84.55 to 84.85 none — —
84.86 to 85.15 0.30 B 005 409 737 —
85.16 to 85.45 0.60 B 005 409 737 A —
84.46 to 85.80 0.90 B 005 409 737 B —

Figure 3-2-30 — Shims Available For Dimension “A”

14.Adjustment — Between the half shaft gear and spacer, there must be a clearance of 0.20 to 0.50 mm. To adjust the clearance, proceed as follows:

  1. Place the carrier in the differential housing.
  2. Install the differential flange and torque the cap screws to 25 N•m (18 ft lb).
  3. Measure dimension “A” from the inner race of the tapered roller bearing on the carrier to the outer edge of the differential flange, see Figure 3-2-29. Allow for the thickness of the straight edge when measuring.
  4. Choose a shim of the correct thickness for dimension “A”. Figure 3-2-30 lists available shims.
  5. Remove the differential flange.
  6. Remove the carrier from the housing.
  7. Install the shim and spacer against the large carrier bearing.

Spacer Adjustment (Non-Locking Differential)

Figure 3-2-31 — Measurement of Gap Between Half Shaft Gear and Spacer
Figure 3-2-31 — Measurement of Gap Between Half Shaft Gear and SpacerClick image to enlarge.

Gap (mm) Shim Thickness (mm) Mfg. Part No. NATO Stock No.
2.42 to 2.10 none — —
2.09 to 1.80 0.30 B 183 525 293 —
1.79 to 1.50 0.60 B 183 525 293 A —
1.49 to 1.20 0.90 B 183 525 293 B —

Figure 3-2-32 — Shims To Adjust The Drive Flange

15.Adjustment — To adjust, proceed as follows:

  1. Install setting shims in the end of the carrier. One of the shims must be 0.30 mm thick and the two other shims 0.90 mm thick for a total thickness of 2.10 mm.
  2. Install the half shaft, needle bearing, right drive flange, washer and centre bolt and tighten the bolt.
  3. Lift up the drive flange and measure the gap between the half shaft gear and spacer with a feeler gauge, see Figure 3-2-31.
  4. See Figure 3-2-32 and choose a shim that is the correct thickness. More than one shim may be required.
  5. Remove the drive flange, half shaft, needle bearing and setting shims from the carrier.
  6. Install the newly selected shim(s) in the end of the carrier.
  7. Install the half shaft, needle bearing, drive flange, washer and centre bolt and measure the gap between the half shaft gear and spacer. The gap should be 0.20 to 0.50 mm.

Input Shaft Bearing

Figure 3-2-33 — Installation of Input Shaft Bearing
Figure 3-2-33 — Installation of Input Shaft BearingClick image to enlarge.

16.Installation — Press the input shaft bearing into the transmission housing with VW 295 and 30-507, see Figure 3-2-33.

Countershaft Needle Bearing

Figure 3-2-34 — Installation of Countershaft Needle Bearing
Figure 3-2-34 — Installation of Countershaft Needle BearingClick image to enlarge.

17.Installation — Press the needle bearing into the transmission housing with tools 30-505 and 40-503, see Figure 3-2-34.

Transmission

Figure 3-2-35 — Interlock Plunger, Detent and Spring Intalled
Figure 3-2-35 — Interlock Plunger, Detent and Spring IntalledClick image to enlarge.

Groove Width (mm) Snap Ring
Thickness (mm) 		Mfg. Part No. NATO Stock No.
1.86 to 2.04 1.85 N 900 433.0 —
2.05 to 2.16 2.00 N  12 290.2 —

Figure 3-2-36 — Snap Rings For Countershaft

Figure 3-2-37 — Measurement of Gap Between Snap Ring and Bearing
Figure 3-2-37 — Measurement of Gap Between Snap Ring and BearingClick image to enlarge.

Gap (mm) Snap Ring
Thickness (mm) 		Mfg. Part No. NATO Stock No.
1.05 to 1.14 1.00 B 005 311 837 —
1.15 to 1.24 1.10 B 005 311 837 A —
1.25 to 1.34 1.20 B 005 311 837 B —
1.35 to 1.44 1.30 B 005 311 837 C —

Figure 3-2-38 — Retaining Washers for Countershaft

18.Assembly — The outer races and S3 and S4 adjusting shims for the pinion were installed during the pinion adjustment. To assemble, see Figure 3-1-19 and proceed as follows:

  1. Using grease, install the long, interlock plunger in the housing between the opening for the cross-country and reverse gear shifter rod and the opening for the third and fourth gear shifter rod, see Figure 3-2-35.
  2. Install the first and second shifter rod (17) and selector fork (18) on the synchronizing hub of the pinion shaft (16) and insert the pinion shaft and shifter rod into the housing (3).
  3. Install the countershaft reverse gear (4) in the housing. Ensure the shoulder of the gear faces towards the differential end of the housing.
  4. Insert the countershaft (1) into the housing.
  5. Install the thrust washer (5) on the countershaft and press onto the shaft the first inner race (6) for the bearing.
  6. Install the bearing (7). Ensure the groove in the bearing outer race faces towards the differential end of the housing and the groove is aligned with the groove in the housing.
  7. Using tool VW 295A, install the second inner race (8) into place on the countershaft.
  8. Measure the width of the snap ring groove in the housing and choose a snap ring (10) that is the correct thickness. Install the snap ring in the housing. Figure 3-2-36 lists those snap rings that are available.
  9. Measure the gap between the snap ring and bearing (7) and choose a retaining washer (9) that is the correct thickness, see Figure 3-2-37. Figure 3-2-38 lists available washers.
  10. Remove the snap ring and install the newly selected retaining washer and snap ring. Ensure the locking lip of the washer fits into the bearing groove.
  11. Clamp the countershaft in a soft-jawed vise to prevent the shaft from turning and install a washer (11) and socket head cap screw (12) on the end of the shaft. Torque the cap screw to 25 N•m (18 ft lb).
  12. Install the input shaft bearing race (31) on the input shaft (13).
  13. Install the assembled input shaft in the housing.
  14. Install the ball bearing (30) on the end of the input shaft and install the bearing race (29). Ensure the groove in the bearing race aligns with the groove in the housing.
  15. Install the washer (28) and socket head screw (27) and torque to 25 N•m (18 ft lb).
  16. Determine the thickness of the retaining washer (26) for the input shaft:

Figure 3-2-39 — Measurement for Input Shaft Retaining Washer
Figure 3-2-39 — Measurement for Input Shaft Retaining WasherClick image to enlarge.

Dimension “A” (mm) Retaining Washer
Thickness (mm) 		Mfg. Part No. NATO Stock No.
1.05 to 1.14 1.00 B 005 311 837 —
1.15 to 1.24 1.10 B 005 311 837 A —
1.25 to 1.34 1.20 B 005 311 837 B —
1.35 to 1.44 1.30 B 005 311 837 C —

Figure 3-2-40 — Retaining Washers for Dimension “A”

  1. Measure dimension “A” from the transmission housing to the outer race of the input shaft bearing with a depth gauge, see Figure 3-2-39. Ensure the ball bearing is against the roller bearing.
  2. Choose a retaining washer of the correct thickness. Figure 3-2-40 lists those washers that are available. Install the retaining washer ensuring the locking lip of of the washer aligns with the groove in the housing and bearing.
  3. Install the retaining washer, the support plate (25) and four cap screws (24). Torque the cap screws to 25 N•m (18 ft lb).

Figure 3-2-41 — Shifter Rods Installed
Figure 3-2-41 — Shifter Rods InstalledClick image to enlarge.

  1. Using grease, install the short, interlock plunger in the housing between the opening for the first and second gear shifter rod and the opening for third and fourth gear shifter rod.
  2. Install the detent and spring (unpainted) in the opening (centre hole) for the third and fourth gear shifter rod. Ensure the detent faces up.
  3. Install the selector fork (15) for third and fourth gear on the input shaft synchronizing hub.
  4. Insert the shifter rod (21) for third and fourth gears into the centre opening in the housing and through the selector fork. Ensure the 3-4 interlock pin (22) is in the shifter rod.
  5. Insert the cross-country and reverse gear shifter rod (23) into the remaining opening in the housing. Ensure the lug on the rod points towards the countershaft (1). The third and fourth gear shifter rod (21) must be in its neutral detent position.
  6. Install the operating link on the first and second gear shifter rod with cap screws and torque to 15 N•m (7 ft lb), see Figure 3-2-41.
  7. Install the tubular key (14) in the selector fork (15) and shifter rod (21) for third and fourth gear.
  8. Install the gear detent plugs, detents, springs (green) and new washers for the first and second gears and the cross-country and reverse gears.
  9. Install the centre gear detent plug for third and fourth gear.
  10. Determine the thickness for the pinion shaft shim for reverse gear. Proceed as follows:

Figure 3-2-42 — Measurement for Reverse Gear Adjusting Shim
Figure 3-2-42 — Measurement for Reverse Gear Adjusting ShimClick image to enlarge.

Dimension “A” (mm) Thickness (mm) Mfg. Part No. NATO Stock No.
10.20 to 10.30 2.30 B 005 311 395 —
10.30 to 10.40 2.40 B 005 311 395 A —
10.40 to 10.50 2.50 B 005 311 395 B —
10.50 to 10.60 2.60 B 005 311 395 C —
10.60 to 10.70 2.70 B 005 311 395 D —
10.70 to 10.80 2.80 B 005 311 395 E —
10.80 to 10.90 2.90 B 005 311 395 F —
10.90 to 11.00 3.00 B 005 311 395 G —
11.00 to 11.10 3.10 B 005 311 395 H —
11.10 to 11.20 3.20 B 005 311 395 J —

Figure 3-2-43 — Pinion Shaft Adjusting Shims for Reverse Gear

  1. Measure dimension “A” from the transmission housing to the pinion bearing with a depth gauge, see Figure 3-2-42. Ensure the pinion shaft is held in place while measuring.
  2. Select a shim that is the correct thickness. Figure 3-2-43 lists pinion shaft shims for reverse gear.
  3. Install the reverse gear adjusting shim (1) and thrust washer (2) on the pinion shaft, see Figure 3-1-18.
  1. Install the reverse gear (3) on the pinion shaft. Ensure the dog collar faces away from the housing.
  2. Install the reverse gear needle bearing (5) and bushing (4) onto the pinion shaft and into the reverse gear.
  3. Install the hub (6) and sleeve (7) on the pinion shaft. Ensure the flat side of the hub faces away from the housing.
  4. Move all gears into neutral.
  5. Install the selector fork (8) for reverse and cross-country gears on the operating sleeve (7) and the lug of the reverse and cross-country gear selector rod. Ensure the flat side of the fork is nearest the transmission housing.
  6. Install the needle bearing (10) and bushing (9) for the cross-country gear (11) on the pinion shaft.
  7. Install the cross-country gear (11) and thrust washer (12) on the pinion shaft. Ensure the teeth of the gear are towards the selector fork.

Transmission Cover

Figure 3-2-44 — Installation of Pinion Shaft Roller Bearing
Figure 3-2-44 — Installation of Pinion Shaft Roller BearingClick image to enlarge.

Figure 3-2-45 — Installation of Countershaft Roller Bearing
Figure 3-2-45 — Installation of Countershaft Roller BearingClick image to enlarge.

19.Assembly — To assemble, see Figure 3-1-28 and proceed as follows:

  1. Install the reverse warning light switch plug (11) and seal (10).
  2. Press the pinion shaft roller bearing (12) into the cover with VW 447i and VW 407, see Figure 3-2-44.
  3. Install the countershaft roller bearing (15) in the cover with VW 295 and 30-204, see Figure 3-2-45.
  4. Install the snap ring (16) in the cover.
  5. Install the thrust washer (8) with the two flats in the cover. Ensure the tapered shoulder of the washer faces towards the back end of the cover and the flat portion of the washer faces the countershaft bearing (15).
  6. Install the notched thrust washer (5) in the cover. Ensure the notch is towards the oil trap lock screw (4) and the tapered portion of the washer faces towards the front of the cover.
  7. Install the two needle bearings (6) in the idler gear (7) and place the gear in the cover ensuring the angular grooves are towards the flats of the thrust washer (8).
  8. Insert the shaft (3) for the idler gear into the cover and through the bearings. Ensure the screw hole in the shaft is aligned with the screw hole in the transmission cover and the flat portion of the shaft is in line with the flat portion on the bottom of the thrust washer (8). j. Apply sealer to the threads of the shaft lock screw (4) and install the screw. Torque to 25 N•m (18 ft lb).
  9. Install the oil trap (2). Ensure the rounded portion of the trap fits in the groove in the transmission housing and against the idler gear shaft.
  10. Install the oil trap lock screw (1). Ensure the screw fits into the notch in the top thrust washer (5) and torque the screw to 25 N•m (18 ft lb).

Differential Flange Assembly

Figure 3-2-46 — Installation of Selector Shaft Oil Seal
Figure 3-2-46 — Installation of Selector Shaft Oil SealClick image to enlarge.

20.Assembly — The bearing race and S2 shims were installed during the Crown Gear Backlash Adjustment. To assemble, see Figure 3-1-13 and proceed as follows:

  1. Mount the flange (13) in a vise.
  2. Install the magnet (21) on the flange and tap in the tubular key (20).
  3. Install the selector fork (15) on the sliding collar (17). Ensure the shoulder at the top of the fork faces towards the race in the flange and place the fork and collar in the flange.
  4. Insert the selector shaft (14) into the flange (13) from the race side of the flange. Ensure the small, splined end of the shaft enters the flange first.
  5. Install the snap ring (6 and 16) on the end of the selector shaft.
  6. Install a new seal (5) on the end of the selector shaft with the lips of the seal facing in and, using VW 421, drive in the seal until it is flush with the flange, see Figure 3-2-46.
  7. Insert the detent (12) and spring (11) into the flange and install the plug (9) and a new seal (10).
  8. Install the extension shaft (8) and the two-wheel drive sending unit (7).

Clutch Housing Starter Bushing

Figure 3-2-47 — Installation of Clutch Housing Starter Bushing
Figure 3-2-47 — Installation of Clutch Housing Starter BushingClick image to enlarge.

21.Installation — Drive the clutch housing starter bushing into the housing with B 183 012 363, see Figure 3-2-47.

Input Shaft Needle Bearing

Figure 3-2-48 — Installation of Input Shaft Needle Bearing
Figure 3-2-48 — Installation of Input Shaft Needle BearingClick image to enlarge.

22.Installation — Ensure the lettering on the race faces out, away from the differential housing, and drive the bearing into the housing with tools 40-503 and VW 295 until the bearing is flush with the housing, see Figure 3-2-48.

Differential Assembly

Figure 3-2-49 — Installation of Oil Seals in Differential Flange
Figure 3-2-49 — Installation of Oil Seals in Differential FlangeClick image to enlarge.

Figure 3-2-50 — Grease Points for Differential Flange Oil Seals
Figure 3-2-50 — Grease Points for Differential Flange Oil SealsClick image to enlarge.

Figure 3-2-51 — Adjustment of Two-Wheel Drive and Interlock Levers
Figure 3-2-51 — Adjustment of Two-Wheel Drive and Interlock LeversClick image to enlarge.

23.Assembly — To assemble, proceed as follows:

  1. Place the carrier in the differential housing. Ensure the crown gear faces towards the differential flange.
  2. Install the drive flange adjusting shim and spacer on the large carrier bearing.
  3. Apply sealing compound and place the flange on the differential housing.
  4. Install nine cap screws and torque to 25 N•m (18 ft lb).
  5. Install the drive flange shim in the open end of the carrier shaft.
  6. Grease two new oil seals and install the seals one at a time with tool 3025, see Figure 3-2-49. Use end “A” of tool 3025 for the inner seal and end “B” for the outer seal. Ensure the spring side of each seal faces in, towards the shifter fork. Ensure grease is applied to the seals at the points shown in Figure 3-2-50.
  7. Install the half shaft in the carrier. Ensure the splines of the shaft are aligned with the splines of the sliding collar.
  8. Install the needle bearing and drive flange on the half shaft. Ensure the drive flange is engaged in the sliding collar.
  9. Install the washer on the drive flange. Ensure the hole in the washer is engaged on the split pin.
  10. Install the centre bolt and torque it to 25 N•m (18 ft lb).
  11. Apply sealing compound and install the drive flange cover.
  12. Install the interlock shaft (2), see Figure 3-1-7, and cover (4) and secure with three socket head cap screws. Torque the cap screws to 15 N•m (11 ft lb).
  13. Install a new seal on the shaft and install the interlock lever (1) on the shaft, ensuring the lever points down. Tap in a spring pin (3) to secure the lever.
  14. Install the two-wheel drive lever (5) on the selector shaft (6). Ensure the scribe marks on the shaft and lever are aligned.
  15. See Figure 3-2-51 and adjust the interlock and two-wheel drive levers:
  1. Move the interlock lever fully forward.
  2. Move the two-wheel drive lever fully forward.
  3. Measure the distance between the centre points on the levers. The distance should be 102 mm.
  4. If the distance between the centre points is not 102 mm, reposition the two-wheel drive lever on the splines until the measurement is correct.
  5. When the drive lever is in the correct position, install the bolt and washers. Secure with an elastic nut.

Figure 3-2-52 — Installation of Left Drive Flange Oil Seal
Figure 3-2-52 — Installation of Left Drive Flange Oil SealClick image to enlarge.

  1. Install the speedometer drive gear on the end of the carrier nearest the crown gear.
  2. Grease the lip of a new oil seal and install with seal installer 3024. Drive in the seal until the outer end of the seal is 9.00 to 9.50 mm inside the housing, see Figure 3-2-52. Ensure the lip of the seal faces inward. Use end “A” of seal installer 3024.
  3. Install the drive flange by turning it until the splines engage and push the flange home.
  4. Install the centre bolt and torque the bolt to 25 N•m (18 ft lb).
  5. Install the speedometer driven gear and adapter in the differential housing.

Transaxle Input Shaft Oil Seal

24.Removal — To remove, proceed as follows:

  1. Remove the three cap screws securing the locking collar and guide sleeve to the transaxle housing.
  2. Remove the guide sleeve and collar.
  3. Insert a small pry and pry out the seal.

25.Installation — To install, proceed as follows:

Figure 3-2-53 — Installation of Transaxle Shaft Oil Seal
Figure 3-2-53 — Installation of Transaxle Shaft Oil SealClick image to enlarge.

  1. Lubricate the seal with grease.
  2. Install a protective sleeve over the splines to avoid damage to the seal.
  3. Slide the seal over the sleeve, lip side first, and start it squarely into the housing.
  4. Remove the protective sleeve from the splines.
  5. Position seal installer VW 454 and Matra 30-100 against the seal and drive it into the housing, see Figure 3-2-53.

NOTE — Do not grease the guide sleeve.

  1. Install the guide sleeve and locking collar with the three cap screws and torque to 15 N•m (11 ft lb).

Transmission

26.Installation — To install, proceed as follows:

Figure 3-2-54 — Cross-Country Locking Catch
Figure 3-2-54 — Cross-Country Locking CatchClick image to enlarge.

Figure 3-2-55 — Two-Wheel Drive Lever Adjustment
Figure 3-2-55 — Two-Wheel Drive Lever AdjustmentClick image to enlarge.

  1. Ensure the cross-country locking catch is in the correct position to allow the cross-country and reverse shifter rod to engage in the differential housing, see Figure 3-2-54.
  2. Install the assembled transmission on the differential housing and install two dowels and two short cap screws. Torque the cap screws to 25 N•m (18 ft lb).
  3. Place a gasket on the transmission housing and install the cover.
  4. Install two dowels for the transmission cover and housing.
  5. Install the ten long cap screws and torque to 25 N•m (18 ft lb).
  6. Install the two short cap screws and torque to 25 N•m (18 ft lb).
  7. See Figure 3-2-55 and adjust the twowheel drive lever if necessary. Proceed as follows:

Figure 3-2-56 — Installation of Propeller Shaft Drive Flange Oil Seals
Figure 3-2-56 — Installation of Propeller Shaft Drive Flange Oil SealsClick image to enlarge.

  1. Move the interlock lever fully forward.
  2. Move the two-wheel drive lever fully forward.
  3. Measure the distance between the centre points on the levers. The distance should be 102 mm.
  4. If the distance between the centre points is not 102 mm, reposition the two-wheel drive lever on the splines until the measurement is correct.
  5. When the drive lever is in the correct position, install the bolt and washers. Secure with an elastic nut.

Figure 3-2-57 — Grease Points for Propeller Shaft Drive Flange Oil Seals
Figure 3-2-57 — Grease Points for Propeller Shaft Drive Flange Oil SealsClick image to enlarge.

Figure 3-2-58 — Installation of Propeller Shaft Drive Flange
Figure 3-2-58 — Installation of Propeller Shaft Drive FlangeClick image to enlarge.

  1. Insert the shaft for the selector fork into the transmission cover and install a tubular key.
  2. Grease and install two new oil seals (13 and 14), one at a time, with fitting tool 3026, see Figure 3-2-56. Use end “A” of tool 3026 to install the inner seal and end “B” for the outer seal. Ensure the lip of the inner seal faces in and the dust shield lip of the outer seal faces out. Apply plenty of grease to the seals in those areas indicated in Figure 3-2-57.
  3. Install the propeller shaft drive flange with VW 391.
  4. Install the flange securing nut with Matra 3028, see Figure 3-2-58. Torque the nut to 150 N•m (111 ft lb) and lock the nut onto the shaft. The nut can only be used twice.
  5. Install the cap in the propeller shaft drive flange.

Clutch Release Bearing Shaft and Seals

27.Installation — To install, see Figure 3-1-4 and proceed as follows:

Figure 3-2-59 — Installation of Clutch Release Shaft Bushing
Figure 3-2-59 — Installation of Clutch Release Shaft BushingClick image to enlarge.

  1. Place the bushing (5) on VW 295 bushing installer.
  2. Insert the installer through the shaft opening in the housing, see Figure 3-2-59.
  3. Drive home the bushing.
  4. Install the new lightly lubricated “O” ring (10) in the groove in the housing. e. Install a new release shaft stop (8) with the foot facing down.
  5. Lubricate the inside of the shaft bushing (5).
  6. Install the spring (9) on the shaft (7) with the straight end pointing up towards the housing and position the release shaft in the housing.
  7. Insert the end of the shaft into the bushing (5).
  8. Tap the end of the shaft until one arm of the shaft (7) is in line with the groove on the stop.
  9. Tap the arms down as far as they will go.
  10. Lubricate the plastic bushing (11).
  11. With the lug on the bushing facing outwards, fit the lug into the groove in the housing, and tap the bushing all the way into the housing.
  12. Grease a new “O” ring (12). Install the “O” ring on the shaft and push it into the recess in the bushing.
  13. Install the bushing cap (13). Push on the cap until its outer edge seats on the “O” ring (12) on the bushing.
  14. Install the snap ring (14).
  15. Using brake spring pliers and a screwdriver, work the spring (9) towards the middle of the shaft until it is on the lefthand side of the left arm of the shaft. Hook the end of the spring over the left arm of the shaft.

Clutch Release Bearing

28.Installation — To install, see Figure 3-1-4 and proceed as follows:

  1. Slide the bearing (2) over the guide sleeve (6).
  2. Hook the securing springs (1) onto the fingers of the shaft (7). Ensure the springs properly hook behind the fingers.

Adjustments Required for Replaced Parts

29.General — The replacement of certain transaxle components necessitates that adjustments be made, see Figure 3-2-60.

Part Replaced Crown Gear (S1 + S2)
Adjustment 		Pinion (S3 + S4)
Adjustment 		Drive Flange
Adjustment 		Spacer Adjustment
(Non-Locking Differential)
Differential Housing X X X X
Transmission Housing X
Differential Carrier X X X
Pinion Shaft Bearing X
Differential Carrier Bearings X X X
Crown Gear and Pinion X X X X
Differential Flange Assembly X X X
Drive Flange X X

Figure 3-2-60 — Transaxle Adjustment Required for Replaced Parts

Section 3 — Torque Values, Special Tools and Specifications

General

1.Figure 3-3-1 lists the torque values for all components used in Part 3.

2.Figure 3-3-2 lists the special tools used in Part 3.

3.Figure 3-3-3 lists the specifications used in Part 3.


Item or Component N•m ft lb
Crown Gear 100 74
Differential Flange 25 18
Carrier (minimum turning torque with new bearings) 250 N•cm 22.1 in lb
Carrier (minimum turning torque with used bearings) 30 Nc•m 2.6 in lb
Transmission Housing 25 18
Transmission Cover 25 18
Pinion Shaft (turning torque with new bearings) 200 to 400 N•cm 17.7 to 35.4 in lb
Pinion Shaft (turning torque with used bearings) 30 to 60 N•cm 2.6 to 5.3 in lb
Countershaft Cap Screw 25 18
Input Shaft Support Plate 25 18
Input Shaft Cap Screw 25 18
Drive Flanges (left and right) 25 18
Interlock Cover 15 11
Guide Sleeve and Locking Collar 15 11
Oil Trap Screw 25 18
Propeller Shaft Drive Flange Nut 150 111

Figure 3-3-1 — Transaxle Torque Values


Item No. Tool No. Nomenclature NATO Stock No.
1. Matra 3028 Counter holder 5120-12-176-1109
2. VW 391 Extractor 5120-21-896-7696
3. KUKKO 21/3 Extractor-internal 5120-21-896-7680
4. VW 771/1 Sliding hammer 5120-21-896-7698
5. VW 771/15 Threaded piece 5120-21-896-7702
6. 788-14 Internal puller 5120-21-899-4857
7. KUKKO 22-1 Puller —
8. VW 771/37 Extractor hook 5120-21-896-7705
9. 2050 Arbor —
10. KUKKO 21-7 Internal puller —
11. KUKKO 22-2 Puller 5120-21-896-7690
12. KUKKO 21-5 Internal puller —
13. KUKKO 44-2 Puller - two jaw 5120-21-896-7695
14. 40-105 Pressure piece 5120-12-176-1102
15. VW 447h Thrust plate —
16. VW 431 Thrust pad —
17. Matra 30-505 Mandrel 5120-12-176-1104
18. VW 472/2 Distance sleeve —
19. VW 447i Thrust plate —
20. HAZET 788-30 Extractor —
21. VW 407 Punch —
22. VW 454 Pressure piece —
23. VW 401 Thrust plate 5120-12-181-6888
24. 40-21 Sleeve —
25. VW 415A Tube - 60 mm diameter 5120-12-176-1099
26. 3062 Thrust pad —
27. VW 295 Needle bearing drift 5120-21-896-7669
28. VW 511 Thrust pad —
29. VW 472/1 Thrust piece —
30. VW 387 Universal dial gauge bracket 5120-21-896-7697
31. VW 385/17 Measuring plate - 50 mm —
32. VW 521/8 Split Sleeve —
33. VW 521/4 Adaptor - carrier to torque gauge —
34. VW 294b/3 Set of bolts - 4 pieces —
35. VW 385/1 Universal measuring bar —
36. VW 385/15 Dial gauge extension - 9.3 mm —
37. VW 385/30 Universal master gauge —
38. VW 388 Adjustable measuring lever —
39. VW 382/10 Dial gauge extension - flat tip —
40. 30-507 Installing tool —
41. 30-505 Mandrel 5120-12-176-1104
42. 40-503 Installer —
43. VW 295A Attachment for drift 5120-21-896-7670
44. 30-204 Bearing installer —
45. VW 421 Tube - 28 mm diameter —
46. B 183 012 363 Replacer - starter bushing 5120-21-899-4889
47. 3025 Drift 5120-12-176-1107
48. 3024 Drift 5120-12-176-1106
49. Matra 30-100 Driving sleeve 5120-12-194-7010
50. 3026 Drift 5120-12-176-1108

Figure 3-3-2 — Special Tools


Figure Description Measurement
3-2-2 Clearance between fourth gear and snap ring 0.00 - 0.02 mm
na Clearance between third gear and snap ring 0.00 - 0.04 mm
3-2-5 Clearance between synchronizing ring and second gear
- New
- Wear limit
1.00 - 1.70 mm
0.50 mm
3-2-5 Clearance between synchronizing ring and first gear
- New
- Wear limit
1.00 - 1.70 mm
0.50 mm
3-2-7 Clearance between bearing and first gear 0.10 - 0.40 mm
na Clearance between input shaft snap ring and synchronizer hub 0.00 - 0.50 mm
na Clearance between second and third gears 0.00 - 0.35 mm
3-2-5 Clearance between synchronizing ring and third gear
- New
- Wear limit
1.00 - 1.70 mm
0.50 mm
3-2-5 Clearance between synchronizing ring and fourth gear
- New
- Wear limit
1.00 - 1.70 mm
0.50 mm
na Axial play of differential side gears 0.00 - 0.10 mm
na Carrier bearing Preload 0.50 mm
na Pinion bearing preload 0.30 mm
na Crown gear backlash 0.10 - 0.20 mm
na Crown gear backlash deviation 0.06 mm
3-2-31 Clearance between half shaft gear and spacer 0.20 - 0.50 mm
3-2-52 Left drive flange seal installation depth 9.00 - 9.50 mm
3-2-55 Two-wheel drive lever adjustment 102 mm

Figure 3-3-3 — Transaxle Specifications


Part 4 — Rear Differential

Section 1 — Disassembly

Lock Lever

1.Removal — To remove, proceed as follows:

  1. Mount the differential in a vise.
  2. Remove the securing bolt, nut and two flat washers and remove the lock lever.

Drive Flanges (Left and Right Side)

2.Removal — To remove, proceed as follows:

  1. Install two bolts in either the left or right drive flange and, using a bar to prevent the drive flange from turning, remove the centre bolt from the drive flange.
  2. Repeat step a. for the other drive flange.
  3. Pull out both drive flanges from the differential housing.

Differential Flange Assembly

3.Removal — Remove the nine cap screws and the flange assembly.

Figure 4-1-1 — Rear Differential Assembly

1. Centre Bolt
2. Right Drive Flange
3. Drive Flange Oil Seal - RH
4. Filler Plug
5. Differential Housing
6. Breather Hose Fitting
7. Plug
8. Flange Assembly
9. Detent Plug
10. Seal
11. Spring
12. Detent
13. Sending Unit
14. Extension Shaft
15. Snap Ring
16. Selector Shaft
17. Selector Fork
18. Snap Ring
19. Oil Seal
20. Lock Lever
21. Shim(s)
22. Magnet
23. Tubular Key
24. Differential Lock Gear
25. Sliding Collar
26. Inner Drive Flange Oil Seal
27. Outer Drive Flange Oil Seal
28. Left Drive Flange
29. Centre Bolt
30. Crown Gear
31. Pinion Shaft
32. Pinion Shaft Inner Bearing
33. Pinion Shaft Inner Bearing Race
34. Pinion Adjusting Shim(s)
35. Pinion Shaft Inner Bearing
36. Spacer Sleeve
37. Spacer Ring
38. Pinion Shaft Outer Bearing Race
39. Pinion Shaft Outer Bearing
40. Pinion Shaft Nut
41. Propeller Shaft Drive Flange
42. O-Ring
43. Oil Seal - Outer
44. Oil Seal - Inner
45. Crown Gear Adjustng Shim(s)
46. Differential Carrier Bearing Race
47. Differential Carrier Bearing
48. Tubular Key
49. Carrier
50. Shim
51. Pinion Gear
52. Thrust Washer
53. Side Gear
54. Left Drive Flange Shim(s)
55. Nut
56. Cap Screw
57. Differential Carrier Bearing
58. Pin
59. Differential Carrier Bearing Race
60. Crown Adjusting Shim(s)
61. Drain Plug

Figure 4-1-1 — Rear Differential AssemblyClick image to enlarge.

4.Disassembly — To disassemble, see Figure 4-1-1 and proceed as follows:

  1. Mount the assembly in a vise.
  2. Remove the differential lock gear (24).
  3. Pry or drive out both oil seals (26 and 27).
  4. Remove the detent plug (9) and seal (10).
  5. Remove the spring (11) and detent (12).
  6. Remove the differential lock sending unit (13) and extension shaft (14).
  7. Pry the oil seal (19) from the selector shaft (16).
  8. Remove the snap rings (15 and 18) from the selector shaft.
  9. Withdraw the selector shaft from the assembly and remove the selector fork (17) and sliding collar (25).
  10. Using a brass drift and hammer, tap out the outer race (46) and shims (45).
  11. Pull out the tubular key (23) and remove the magnet (22).

Crown Gear and Carrier Assembly

5.Removal — To remove, see Figure 4-1-1 and proceed as follows:

  1. Turn the propeller shaft drive flange (41) until one of the openings in the carrier (49) is in line with the pinion shaft (31).
  2. Tip the end of the carrier up and remove the assembly from the differential housing (5).

6.Disassembly — The disassembly procedure for the crown gear and carrier of the rear differential is the same as the disassembly procedure for the crown gear and carrier of the transaxle. Refer to Part 3, Section 1.

Pinion Shaft

Figure 4-1-2 — Removal of Pinion Shaft Nut
Figure 4-1-2 — Removal of Pinion Shaft NutClick image to enlarge.

Figure 4-1-3 — Removal of Propeller Shaft Drive Flange
Figure 4-1-3 — Removal of Propeller Shaft Drive FlangeClick image to enlarge.

7.Removal — To remove, see Figure 4-1-1 and proceed as follows:

  1. Using a punch and hammer, unlock the collar of the pinion shaft nut (40).
  2. Install tool 3028 on the propeller shaft drive flange (41) and remove the pinion shaft nut, see Figure 4-1-2.
  3. Remove the propeller shaft drive flange. If necessary, use tool VW 391 to remove the flange, see Figure 4-1-3.
  4. Place a block of wood in the differential housing to prevent damage to the pinion and press out the pinion shaft (31).

Figure 4-1-4 — Removal of Inner Bearing from Pinion Shaft
Figure 4-1-4 — Removal of Inner Bearing from Pinion ShaftClick image to enlarge.

Figure 4-1-5 — Removal of Propeller Shaft Drive Flange Oil Seals
Figure 4-1-5 — Removal of Propeller Shaft Drive Flange Oil SealsClick image to enlarge.

Figure 4-1-6 — Removal of Pinion Shaft Outer Race and Spacer Ring
Figure 4-1-6 — Removal of Pinion Shaft Outer Race and Spacer RingClick image to enlarge.

Figure 4-1-7 — Removal of Pinion Shaft Inner Bearing Race and Shims
Figure 4-1-7 — Removal of Pinion Shaft Inner Bearing Race and ShimsClick image to enlarge.

8.Disassembly — To disassemble, see Figure 4-1-1 and proceed as follows:

  1. Remove the “O” ring (42) from the pinion shaft (31).
  2. Using KUKKO 17-1, press inner bearing (32) from the pinion shaft, see Figure 4-1-4.
  3. Using KUKKO 21-7 and KUKKO 22-2, remove the pinion shaft outer bearing race (38) and spacer ring (37), see Figure 4-1-6.
  4. Using a brass drift and hammer, tap out the pinion shaft oil seal (35).
  5. Using Matra 3061 and Matra 30-100, press out the race (33) and shims (34) for the inner bearing, see Figure 4-1-7.

Drive Flange Oil Seal and Carrier Bearing Race (Right Side)

Figure 4-1-8 — Removal of Carrier Bearing Race and Shims
Figure 4-1-8 — Removal of Carrier Bearing Race and ShimsClick image to enlarge.

10.Removal — To remove, see Figure 4-1-1 and proceed as follows:

  1. Using a brass drift and hammer, tap out the drive flange oil seal (3).
  2. Using KUKKO 21-7 and KUKKO 22-2, remove the carrier bearing race (59) and shims (60), see Figure 4-1-8.

Section 2 — Assembly and Adjustments

General

1.If a complete overhaul of the rear differential is required, do all adjustments and measurements as part of the reassembly procedure. Figure 4-2-32 indicates which adjustments must be done if only certain parts of the rear differential have been replaced and a complete overhaul is not required.

2.When choosing new shims for the adjustments, measure each shim at several points with a micrometer. The thickness of available shims is such that it is possible to obtain any desired thickness to within a tolerance of ± 0.04 mm. Ensure new shims are undamaged and free from burrs. Do not install shims that are not in good condition.

Crown Gear and Carrier Assembly

3.Assembly — Assemble the crown gear and carrier. Refer to Part 3, Section 2.

NOTE — A speedometer drive gear is not used in the rear differential assembly.

Bearing Races

Figure 4-2-1 — Installation of Carrier Bearing Race in Differential Flange
Figure 4-2-1 — Installation of Carrier Bearing Race in Differential FlangeClick image to enlarge.

Figure 4-2-2 — Installation of Carrier Bearing Race in Differential Housing
Figure 4-2-2 — Installation of Carrier Bearing Race in Differential HousingClick image to enlarge.

Figure 4-2-3 — Installation of Pinion Shaft Inner Bearing Race in Differential Housing
Figure 4-2-3 — Installation of Pinion Shaft Inner Bearing Race in Differential HousingClick image to enlarge.

Figure 4-2-4 — Installation of Pinion Shaft Oil Seal
Figure 4-2-4 — Installation of Pinion Shaft Oil SealClick image to enlarge.

Figure 4-2-5 — Measurement of Distance Between Housing Bearing Shoulder and Pinion Shaft Seal
Figure 4-2-5 — Measurement of Distance Between Housing Bearing Shoulder and Pinion Shaft SealClick image to enlarge.

Figure 4-2-6 — Installation of Pinion Shaft Outer Bearing Race
Figure 4-2-6 — Installation of Pinion Shaft Outer Bearing RaceClick image to enlarge.

4.Installation — To install, see Figure 4-1-1 and proceed as follows:

  1. Press the carrier bearing race (46) into the differential flange (8) with VW 472/1, see Figure 4-2-1.
  2. Press the carrier bearing race (59) into the differential housing (5) with VW 511 and VW 295, see Figure 4-2-2.
  3. Press the pinion shaft inner bearing race (33) into the differential housing (5) with tools 3062, 2050 and VW 517, see Figure 4-2-3.
  4. Using VW 551, install the pinion shaft oil seal (35), see Figure 4-2-4. Ensure the distance between the housing shoulder of the pinion shaft bearing race and seal is 20 mm, see Figure 4-2-5.
  5. Place the spacer ring (37) in the differential housing (5).
  6. Press in the pinion shaft outer bearing race (38) with VW 517, 30-205 and 3062, see Figure 4-2-6.

Pinion Shaft Inner Bearing

Figure 4-2-7 — Installation of Pinion Shaft Inner Bearing
Figure 4-2-7 — Installation of Pinion Shaft Inner BearingClick image to enlarge.

5.Installation — Heat the pinion shaft bearing (32) to about 120°C, see Figure 4-1-1. Press the bearing onto the pinion shaft (31) with VW 519 and VW 401, see Figure 4-2-7.

Crown Gear and Pinion Adjustments

6.Careful adjustment of the crown gear and pinion is essential to ensure that the differential gives long service and runs silently. During manufacture, the crown gear and pinion are matched and run on special testing machines to ensure correct mesh pattern and silent running in both directions. The position for quietest running is obtained by moving the pinion axially and lifting the crown gear away from the no-play meshing position to maintain the backlash within the specified tolerances.

Figure 4-2-8 — Location and Identification of Crown Gear and Pinion Adjusting Shims (Rear Differential)
Figure 4-2-8 — Location and Identification of Crown Gear and Pinion Adjusting Shims (Rear Differential)Click image to enlarge.

7. Figure 4-2-8 identifies the location of those shims that affect the crown gear and pinion settings. Adjust the crown gear and pinion settings in the following order:

  1. Determine the total shim thickness for the crown gear adjustment, S Total (S1 plus S2), to give the specified preload of the differential carrier bearings.
  2. Determine the thickness of S3, pinion axial adjustment.
  3. Distribute total shim thickness, S Total, between S1 and S2 to obtain the specified backlash between the crown gear and pinion.

Differential Carrier Bearings Preload Adjustment "S Total" (S1 + S2)

Figure 4-2-9 — Measurement of Carrier Axial Play)
Figure 4-2-9 — Measurement of Carrier Axial PlayClick image to enlarge.

8.Adjustment — To adjust, proceed as follows:

  1. Ensure the pinion shaft is removed and the carrier bearing races are installed without the shims.
  2. Place the carrier in the differential housing. Ensure the crown gear is nearest the right side of the housing.
  3. Install the differential flange and eight of the cap screws. Torque the cap screws to 25 N•m (18 ft lb).
  4. Install VW387, VW385/17, a dial gauge and a dial gauge extension that is approximately 85 mm long, see Figure 4-2-9.
  5. Move the carrier up as far as it will go and note the axial play reading (example reading: 1.30 mm).
  6. Determine the total shim thickness, S Total, where total shim thickness equals the dial gauge reading plus the preload requirement which is a constant value of 0.30 mm. Note the following example:
Preload requirement (constant value): 0.30 mm
Dial gauge reading (example only): + 1.30 mm
Total shim thickness (S Total): 1.60 mm

Mfg. Part No. NATO Stock No. Thickness (mm)
B 005 409 381 — 0.15
B 005 409 381 A — 0.20
B 005 409 381 B — 0.25
B 005 409 381 C — 0.55
B 005 409 381 D — 0.60
B 005 409 381 E — 0.65
B 005 409 381 F — 0.80
B 005 409 381 G — 1.35
B 005 409 381 H — 1.50
B 005 409 381 J — 1.65

Figure 4-2-10 — Shims For S Total and S2 (Rear Differential)

  1. Select shims of the correct thickness. Figure 4-2-10 lists available shims.
  2. Remove the differential flange.
  3. Using a brass drift and hammer, tap the carrier bearing race from the differential flange.
  4. Install shims of the correct thickness in the flange.
  5. Using VW 472/1, press the carrier bearing race into the flange.

Carrier Turning Torque Measurement

Figure 4-2-11 — Measurement of Carrier Turning Torque)
Figure 4-2-11 — Measurement of Carrier Turning TorqueClick image to enlarge.

9.Measurement — To measure, proceed as follows:

  1. Lubricate the differential carrier bearings with hypoid gear oil.
  2. Place the crown gear and carrier in the differential housing and install the differential flange. Torque the cap screws to 25 N•m (18 ft lb).
  3. Install VW 521/8, VW 521/4 and a torque gauge with a range of 0 to 600 N•cm, see Figure 4-2-11, and measure the turning torque. If new bearings have been installed, the turning torque must be at least 250 N•cm (22.1 in lb). If used bearings have been installed, the turning torque must be at least 30 N•cm (2.6 in lb).

Pinion Shaft

Figure 4-2-12 — Block of Wood Supporting Pinion)
Figure 4-2-12 — Block of Wood Supporting PinionClick image to enlarge.

Figure 4-2-13 — Installation of Outer Bearing on Pinion Shaft)
Figure 4-2-13 — Installation of Outer Bearing on Pinion ShaftClick image to enlarge.

10.Installation — To install, see Figure 4-1-1 and proceed a follows:

  1. Remove the differential flange (9) and carrier (49).
  2. Place fitting sleeve 3063 on the pinion shaft (31) and insert the shaft into the differential housing (5).
  3. Place a block of wood that is about 5-1/2 inches tall in the differential housing to support the pinion, see Figure 4-2-12.
  4. Heat the pinion shaft outer bearing (39) to about 120°C and install the bearing on the end of the pinion shaft (31).
  5. Drive the bearing fully home with tool 30-100, see Figure 4-2-13.
  6. Install the propeller shaft drive flange (41) and pinion shaft nut (40).
  7. Tighten the pinion shaft nut to obtain a turning torque of 280 to 320 N•cm (24.7 to 28.3 in lb).

Pinion Adjustment (S3)

Figure 4-2-14 — Universal Measuring Bar)
Figure 4-2-14 — Universal Measuring BarClick image to enlarge.

Figure 4-2-15 — Crown Gear and Pinion Adjustments and Identification Markings (Rear Differential)

1 Identification “K 7/37” means Klingelnberg crown wheel/pinion, ratio 7:37.
2 Index number (312) of matched set.
3 Deviation “r” measured against master gauge of special machine used in production. Deviation “r” is always given in 1/100 mm. Example: “25” means r = 0.25 mm.
Ro Length of master gauge used in special test machine. “Ro” = 53.15 mm.
R Actual distance between centre axis of crown wheel and face of pinion with pinion in position for quietest running for quietest running for this particular matched set.
Vo Hypoid Offset = 35 mm.

Figure 4-2-15 — Crown Gear and Pinion Adjustments and Identification Markings (Rear Differential)Click image to enlarge.

Figure 4-2-16 — End Gauge Plate Installed on Pinion
Figure 4-2-16 — End Gauge Plate Installed on PinionClick image to enlarge.

Figure 4-2-17 — Universal Measuring Bar Installed in Rear Differential
Figure 4-2-17 — Universal Measuring Bar Installed in Rear DifferentialClick image to enlarge.

11.Adjustment — To adjust, proceed as follows:

  1. Adjust the setting ring of the universal measuring bar, VW385/1, to 65 mm.
  2. See Figure 4-2-14 and assemble the universal measuring bar as follows:
  1. Install dial gauge extension VW 385/20 (3 mm) on VW 385/14.
  2. Install VW 385/14 on measuring bar VW 385/1.
  3. Install the dial gauge fully in the end of the measuring bar. Extract the gauge 4 mm and lock it.
  4. Set the master gauge VW 385/30 to “Ro”, which is 53.15 mm, see Figure 4-2-15.
  5. Place the master gauge on the measuring bar and set the dial gauge to zero.
  6. Remove master gauge VW 385/30 from the measuring bar.
  1. Move the adjustable centering disc VW 385/3 inward.
  2. Install end gauge plate VW 385/31 on the end of the pinion, see Figure 4-2-16.
  3. Insert measuring bar VW 385/1 through the differential housing and install the differential flange and four cap screws, see Figure 4-2-17. Ensure the dial setting is not disturbed during installation.
  4. Move the second centering disc VW 385/3 outward with the adjustable centering disc until the measuring bar will just turn by hand.
  5. Turn the measuring bar until the dial gauge pin contacts the end gauge plate VW385/31 on the pinion and the dial gauge shows maximum deflection.
  6. Note the counter-clockwise reading (example reading: 1.60 mm).
  7. Calculate the shim thickness for the pinion adjustment, S3, where S3= e - r (“e” is the dial gauge reading at maximum deflection and “r” is the deviation marked on the crown gear, see Figure 4-2-15). Note the following example:
e: 1.60 mm
r: - 0.42 mm
S3: 1.18 mm

Mfg. Part No. NATO Stock No. Thickness (mm)
B 183 525 231 — 0.95
B 183 525 231 A — 1.00
B 183 525 231 B — 1.05
B 183 525 231 C — 1.10
B 183 525 231 D — 1.15
B 183 525 231 E — 1.20
B 183 525 231 F — 1.25
B 183 525 231 G — 1.30
B 183 525 231 H — 1.35
B 183 525 231 J — 1.40
B 183 525 231 K — 1.45
B 183 525 231 L — 1.50
B 183 525 231 M — 1.55

Figure 4-2-18 — Shims For Pinion Adjustment S3

Figure 4-2-19 — Installation of Propeller Shaft Draft Flange Oil Seals
Figure 4-2-19 — Installation of Propeller Shaft Draft Flange Oil SealsClick image to enlarge.

Figure 4-2-20 — Grease Points for Propeller Shaft Drive Flange Oil Seals
Figure 4-2-20 — Grease Points for Propeller Shaft Drive Flange Oil SealsClick image to enlarge.

  1. See Figure 4-2-18 for a list of shims that are available for S3 and choose shims that will provide the correct thickness.
  2. Remove the differential flange, measuring bar and pinion end gauge.
  3. Remove the nut and propeller shaft drive flange and press out the pinion shaft.
  4. Remove the outer bearing.
  5. Remove the inner bearing race with MATRA 3061 and 30-100.
  6. Install the adjusting shims (S3) and bearing race with tools 3062, 2050 and VW 517.
  7. Install the pinion shaft, spacer sleeve, bearing and a rubber “O” ring.
  8. Grease new propeller shaft drive flange seals and drive in the seals, one at a time, with MATRA 3027, see Figure 4-2-19. Use end “A” of MATRA 3027 for the inner oil seal and end “B” for the outer oil seal. Apply grease at the points shown in Figure 4-2-20. Ensure the spring side of each seal faces in towards the crown gear and carrier.

CAUTION — Tighten the pinion shaft nut slowly and check the turning torque frequently. If the turning torque is exceeded, the spacer sleeve must be replaced. If a sleeve has been compressed too much, it is no longer usable.

Figure 4-2-21 — Measure of Pinion Shaft Turning Torque
Figure 4-2-21 — Measure of Pinion Shaft Turning TorqueClick image to enlarge.

  1. Install the propeller shaft drive flange and pinion nut, tighten the pinion nut to obtain a turning torque of 280 to 320 N•cm (24.7 to 28.3 in lb) and lock the collar of the nut, see Figure 4-2-21.
  2. Check dimension “r”, see Figure 4-2-15:
  1. Turn the pinion several times in both directions.
  2. Install the universal measuring bar VW 385/1 and differential flange and check the measurement. If the correct shims have been installed, the dial gauge counterclockwise reading will be the same as deviation “r”, which is marked on the crown gear to within ± 0.04 mm.

Crown Gear Backlash Adjustment (S1 and S2)

Figure 4-2-22 — Crown Gear Backlash Measurement
Figure 4-2-22 — Crown Gear Backlash MeasurementClick image to enlarge.

12.Adjustment — To adjust, proceed as follows:

  1. Install the crown gear and carrier in the differential housing.
  2. Install the differential flange and eight cap screws. Torque the cap screws to 25 N•m (18 ft lb).
  3. Turn the propeller shaft drive flange several times in both directions to seat the carrier bearings.
  4. Install VW 387, VW 388, VW 521/4, VW 521/8, dial gauge and extension VW 382/10, see Figure 4-2-22. Ensure the 6 mm square end of the extension is farthest from VW 521/4.
  5. Adjust measuring lever VW 388 to 79 mm.
  6. Turn the crown gear as far as it will go and set the dial gauge to zero. Turn the crown gear back and read the backlash. Note the reading.
  7. Repeat the measurement another 3 times, turning the crown gear through 90° each time.

NOTE — If the difference between any of the four backlash readings is greater than 0.06 mm, either the crown gear is not installed correctly, or the crown gear and pinion are defective. Ensure the crown gear is installed correctly and, if necessary, install a new crown gear and pinion.

  1. Add the four readings together and divide by four to calculate the average backlash. Note the following example:
First reading: 0.68 mm
Second reading: 0.70 mm
Third reading: 0.70 mm
Fourth reading: + 0.68 mm
Total: 2.76 mm
 
Average backlash = 2.76 ÷ 4 = 0.69 mm
  1. Calculate the shim thickness for S2 where S2 equals S Total minus average backlash plus required final backlash, which is a constant value of 0.15 mm. Note the following example:
S Total: 1.60 mm
Average backlash: - 0.69 mm
0.91 mm
Required final backlash: + 0.15 mm
S2: 1.06 mm
  1. Choose shims of the correct thickness for S2. Figure 4-2-10 lists those shims that are available for S2.
  2. Calculate the shim thickness for S1, where S1 equals S Total minus S2. Note the following exam
S Total: 1.60 mm
S2: - 1.06 mm
S1: 0.54 mm

Mfg. Part No. NATO Stock No. Thickness (mm)
B 018 409 385 — 0.15
B 018 409 385 A — 0.20
B 018 409 385 B — 0.25
B 018 409 385 C — 0.50
B 018 409 385 D — 0.80
B 018 409 385 E — 1.00
B 018 409 385 F — 1.50

Figure 4-2-23 — Shims For S1 (Rear Differential)

  1. Choose shims of the correct thickness for S1. Figure 4-2-23 lists available shims for S1.
  2. Remove the differential flange and the crown gear and carrier from the differential housing.
  3. Using a brass drift and hammer, remove the carrier bearing race and shims from the differential flange.
  4. Place the newly selected shims for S2 in the differential flange and press in the race with VW 472/1.
  5. Using a brass drift and hammer, remove the carrier bearing race from the differential housing.
  6. Place the newly selected shims for S1 in the differential housing and press in the bearing race with VW 295 and VW 511.
  7. Check the crown gear backlash:
  1. Install the carrier in the differential housing.
  2. Install the differential flange and eight cap screws. Torque the cap screws to 25 N•m (18 ft lb).
  3. Install VW 387, VW 388, VW 521/4, VW 521/8, dial gauge and extension, see Figure 4-2-22.
  4. Measure the crown gear backlash four times. Start the measurement at a different point each time. The backlash must be between 0.10 to 0.20 mm each time and the difference between any of the four readings must not be greater than 0.06 mm.
  1. Remove the differential flange.

Drive Flange Adjustment

Figure 4-2-24 — Measurement for Drive Flange Shim Thickness
Figure 4-2-24 — Measurement for Drive Flange Shim ThicknessClick image to enlarge.

Dimension “A” (mm) Thickness (mm) Mfg. Part No. NATO Stock No.
84.55 to 84.85 none — —
84.86 to 85.15 0.30 B 005 409 737 —
85.16 to 85.45 0.60 B 005 409 737 A —
85.46 to 85.80 0.90 B 005 409 737 B —

Figure 4-2-25 — Shims for Dimension “A”

13.Adjustment — Between the drive flange and the differential lock gear, there must be a clearance of 0.20 to 0.50 mm. To adjust the clearance, proceed as follows:

  1. Place the carrier in the differential housing.
  2. Install the differential flange and torque the nine cap screws to 25 N•m (18 ft lb).
  3. Measure dimension “A” from the inner race of the carrier bearing to the outer edge of the differential flange, see Figure 4-2-24. Allow for the thickness of the straight edge when measuring.
  4. Choose a shim of the correct thickness for dimension “a”. Figure 4-2-25 lists those shims that are available.
  5. Remove the cap screw from the differential flange and remove the flange.
  6. Remove the carrier from the differential housing.
  7. Install the shim and differential lock gear on the carrier bearing.

Differential Lock Gear Adjustment

Figure 4-2-26 — Measurement of Gap Between Drive Flange and Lock Gear Shoulder
Figure 4-2-26 — Measurement of Gap Between Drive Flange and Lock Gear ShoulderClick image to enlarge.

Gap (mm) Shim Thickness (mm) Mfg. Part No. NATO Stock No.
2.42 to 2.10 none — —
2.09 to 1.80 0.30 B 183 525 293 —
1.79 to 1.50 0.60 B 183 525 293 A —
1.49 to 1.20 0.90 B 183 525 293 B —

Figure 4-2-27 — Shims to Adjust the Drive Flange

14.Adjustment — To adjust, proceed as follows:

  1. Install setting shims in the end of the carrier. One of the shims must be 0.30 mm thick and the two other shims 0.90 mm thick for a total thickness of 2.10 mm.
  2. Install the left drive flange and centre bolt and tighten the bolt.
  3. Lift up on the nut and side gear in the carrier and measure the gap between the drive flange and the shoulder of the differential lock gear, see Figure 4-2-26.
  4. See Figure 4-2-27 and choose a shim that is the correct thickness. More than one shim may be required.
  5. Remove the drive flange and setting shims from the carrier.
  6. Install the newly selected shims in the end of the carrier.
  7. Install the left drive flange and centre bolt and measure the gap between the drive flange and shoulder of the differential lock gear. The gap should be 0.20 to 0.50 mm.

Differential Flange Assembly

Figure 4-2-28 — Installation of Selector Shaft Oil Seal
Figure 4-2-28 — Installation of Selector Shaft Oil SealClick image to enlarge.

15.Assembly — To assemble, see Figure 4-1-1 and proceed as follows:

  1. Mount the flange (8) in a vise.
  2. Place the magnet (22) on the flange and tap in the tubular key (23).
  3. Place the selector fork (17) on the sliding collar (25) and place the fork and collar in the flange. Ensure the shoulder at the top of the fork faces towards the bearing race in the flange.
  4. Insert the selector shaft (16) into the flange from the bearing race side. Ensure the small splined end of the shaft enters first.
  5. Install the snap rings (15 and 18) on the end of the selector shaft.
  6. Place a new seal (19) on the end of the selector shaft with the lips of the seal facing in and, using VW 421, drive in the seal until it is flush with the flange, see Figure 4-2-28.
  7. Insert the detent (12) and spring (11) into the flange housing and install the plug (9) and seal (10).
  8. Install the extension shaft (14) and differential lock sending unit (13).

16.Installation — To install, see Figure 4-1-1 and proceed as follows:

  1. Apply sealing compound and install the flange assembly (8) on the differential housing (5).
  2. Install the cap screws and torque to 25 N•m (18 ft lb).
  3. Install the differential lock gear (24) on the carrier (49) and into the sliding collar (25). Ensure the shoulder of the gear faces towards the carrier.

Drive Flange Oil Seals (Left Side)

Figure 4-2-29 — Installation of Left Drive Flange Oil Seals
Figure 4-2-29 — Installation of Left Drive Flange Oil SealsClick image to enlarge.

17.Installation — Grease and install two new oil seals with tool 3025, see Figure 4-2-29. Ensure the spring side of each seal faces inward, towards the crown gear and carrier. Use end “A” of tool 3025 to install the inner oil seal and end “B” for the outer oil seal.

Drive Flange (Left Side)

18.Installation — To install, proceed as follows:

  1. Insert the drive flange. Ensure the flange engages in the sliding collar.
  2. Install the centre bolt and torque the bolt to 25 N•m (18 ft lb).

Differential Lock Lever

Figure 4-2-30 — Differential Lock Lever Adjustment
Figure 4-2-30 — Differential Lock Lever AdjustmentClick image to enlarge.

19.Installation — To install, proceed as follows:

  1. Place the differential lock lever on the selector shaft.
  2. Rotate the shaft to the centre detent.
  3. Rotate the drive flange so that two of the bolt holes and the differential flange retaining bolt are in a straight line.
  4. Place a ruler along the vertical line made by the two bolt holes and the edge of the differential flange retaining bolt, and measure the distance from the vertical line to a centre line on the lever, see Figure 4-2-30. The distance from the centre line on the lever to the straight edge of the ruler should be 25 mm. Rotate the lever on the splines in the required direction until the correct measurement is obtained.
  5. Install the securing bolt, flat washers and nut.

Drive Flange Oil Seal (Right Side)

Figure 4-2-31 — Installation of Right Drive Flange Oil Seal
Figure 4-2-31 — Installation of Right Drive Flange Oil SealClick image to enlarge.

20.Installation — Grease and install a new oil seal with tool 3024, see Figure 4-2-31. Ensure the lips of the seal face inward, towards the crown gear and carrier. Use end “A” of tool 3024 to install the seal.

Drive Flange (Right Side)

21.Installation — To install, proceed as follows:

  1. Install the drive flange.
  2. Install the drive flange centre bolt and torque the bolt to 25 N•m (18 ft lb).

Adjustments Required for Replaced Parts

22.General — The replacement of certain rear differential components necessitates that adjustments be made, see Figure 4-2-32.

Part Replaced Crown Gear (S1 + S2)
Adjustment 		Pinion (S3)
Adjustment 		Drive Flange
Adjustment 		Differential Lock Gear
Adjustment
Differential Housing X X X X
Pinion Shaft Bearings X
Differential Carrier Bearings X X X
Crown Gear and Pinion X X X X
Differential Flange Assembly X X X
Drive Flange X X
Differential Carrier X X X

Figure 4-2-32 — Rear Differential Adjustments Required for Replaced Parts

Section 3 — Torque Values, Special Tools and Specifications

General

1. Figure 4-3-1 lists the torque values for all components used in Part 4.

2. Figure 4-3-2 lists the special tools used in Part 4.

3. Figure 4-3-3 lists the specifications used in Part 4.


Item or Component Torque
Differential Flange 25 N•m 18 ft lb
Crown Gear 100 N•m 74 ft lb
Carrier (minimum turning torque with new bearings) 250 N•cm 22.1 in lb
Carrier (minimum turning torque with used bearings) 30 N•cm 2.6 in lb
Pinion Shaft (turning torque) 280 to 320 N•cm 24.7 to 28.3 in lb
Drive Flange (left and right) 25 N•m 18 ft lb

Figure 4-3-1 — Rear Differential Torque Values


Item
No 		Tool No Nomenclature NATO Stock No
1. 3028 Counter holder 5120-12-176-1109
2. VW 391 Extractor —
3. KUKKO 17-1 Separator —
4. VW 771/37 Extractor hook 5120-21-896-7705
5. VW 771 Sliding hammer 5120-21-896-7698
6. KUKKO 21-7 Internal puller —
7. KUKKO 22-2 Puller 5120-21-896-7690
8. Matra 3061 Thrust pad —
9. Matra 30-100 Drving sleeve 5120-12-194-7010
10. VW 472/1 Thrust piece —
11. VW 511 Thrust pad —
12. VW 295 Needle bearing drift 5120-21-896-7669
13. 3062 Thrust pad —
14. 2050 Arbor —
15. VW 517 Threaded spindle —
16. VW 551 Drift Sleeve —
17. 30-205 Pressure plate —
18. VW 519 Tube - 50 mm diameter —
19. VW 401 Thrust plate 5120-12-181-6888
20. VW 387 Universal dial gauge bracket 5120-12-896-7697
21. VW 385/17 End plate - 50 mm —
22. VW 521/8 Split sleeve —
23. VW 521/4 Adaptor - carrier to torque gauge —
24. 3063 Mandrel —
25. VW 385/1 Measuring mandrel —
26. VW 385/20 Dial gauge extension - 3 mm —
27. VW 385/14 Measuring rod - 30 mm —
28. VW 385/30 Universal master gauge —
29. VW 385/3 Centering discs —
30. VW 385/31 End gauge plate —
31. Matra 3027 Drift 5120-12-176-1775
32. VW 388 Adjustable measuring lever —
33. VW 382/10 Dial gauge extension - flat tip —
34. VW 421 Tube - 28 mm diameter —
35. 3025 Drift 5120-12-176-1107
36. 3024 Drift 5120-12-176-1106

Figure 4-3-2 — Special Tools


Figure Description Measurement
4-2-5 Housing bearing shoulder to pinion seal 20 mm
4-2-26 Clearance between drive flange and differential lock gear 0.20 - 0.50 mm
4-2-30 Differential lock lever adjustment 25 mm
na Carrier bearing preload 0.30 mm
na Crown gear backlash 0.10 - 0.20 mm
na Crown gear backlash deviation 0.06 mm
na Axial play of differential side gears 0.00 - 0.10 mm

Figure 4-3-3 — Rear Differential Specifications