Checking Oil Level Replacing Manual Transmission Oil
Capacity Approx. 2 l hypoid transmission oil SAE 75 W 90 to APl Class GL or MIL-L 2105 B, or SAE 80 to API Class GL 4 or MIL-L 2105. 1. Clean outside of filler and drain plugs, and unscrew. The fluid level in the transmission housings used in production is approx. 6 to 8 mm below the filler neck when 2 liters of transmission oil have been filled in. 2. Drain transmission oil of a car parked on level ground or floor and transmission having operating temperature. 3. Clean filler and drain plugs,...
Removing And Installing Central Tube
When performing operations on the transaxle system that involve rotating or shifting the transaxle tube, always wear leather gloves to avoid injuries 3. Disconnect parking brake cable on parking brake 4. Loosen control cable on bracket and disconnect on accelerator pedal. 5. Press control cable out of rubber guide in firewall and pull out cable forward. Disconnect suspension clamps on engine and front bell housing. 8. Disconnect axle shafts on transmission end and remove rear axle. 9....
Adjusting Differential Gears
1. Install large differential gears with thinnest shims 0.5 mm . 2. Install small differential gears with thrust washers and press in shaft. Do not mix up differential gears and thrust washers from this point on 4. Adjust play to max. 0.10 mm by installing a shim 4. Adjust play to max. 0.10 mm by installing a shim
Bleeding Clutch
The use of a pressure bleeder is recommended. 1. Fill tank with brake fluid to upper edge. Remove restrictor sleeve. Connect bleeder. 2. Switch on bleeder and open bleeder screw on clutch slave cylinder until escaping fluid is without air bubbles. Operate clutch pedal several times during this step. 3. If necessary because of residual air release traver less than 15 mm , unscrew slave cylinder on clutch housing. Push rod against stop in slave cylinder and release again bleeder switched off,...
Removing And Installing Differential
N o t e 1. Torque side transmission cover bolts to 25 Nm Gear carrier must be removed first before removing the differential. 2. Torque flange shaft mounting bolt to 25 Nm 18 ft lb . 1. Unscrew flange shaft mounting bolt and take off flange shaft, while holding with a mandrel. 2. Unscrew final drive cover mounting bolts and pry off cover with two tire irons.
Transmission Identification
Code Letters and Mfg. Date of Transmission Example RH 15 03 2 Code Letters and Mfg. Date of Transmission Example RH 15 03 2
Adjusting Throttle And Control Pressure Cable
The positioning of the throttle to the valves in the transmission is extremely important for perfect transmission operation and unimpaired driving of car. transmission bracket at distance A 29 mm and tighten to torque of 20 Nm. transmission lever completely and secure on transmission lever with securing clip. 3. Set accelerator pedal and cam to neutral position 4. Make sure short cable sleeve fits correctly in firewall. 5. Up to Mod. '85 adjust short cable sleeve on firewall to dimension B 8 mm...
Adjusting Pinion And Ring Gear
Careful adjustment of the drive pinion and ring gear is important to guarantee a long service life and quiet running for the final drive. This is why drive pinions and ring gears are matched during production and checked on special testing machines for the most favorable surface appearance and low noise levels in both directions of rotation. The position of quietest running is determined by moving the drive pinion in an axial direction, keeping the ring gear within specified backlash...
Disassembling And Assembling Pinion Shaft
When replacing tapered roller bearings, check installed position of pinion shaft actual location before removing the gear carrier. 1. Press off inner race of tapered roller bearing with 1st gear. Use Special Tool VW 457. 2. Press off sliding sleeve and synchronizer with 2nd gear. Use Special Tool VW 457. 4. Press off 4th gear with a separator, e. g. Kukko 15 -17 Gr. 1. 1. Heat inner race for tapered roller bearing to about 120 C 250 F and press on. 5. Press off inner race for tapered roller...
Changing Atf And Cleaning Atf Filter Screen
ATF-Dexron II D is no longer red and transparent, but brown and becomes completely black after short operation. New filling with ATF cooler approx. 6.5 liters Oil change approx. 2.8 liters 1. Unscrew oil filler tube at oil sump and filling tank, and drain ATF. 2. Remove oil sump and oil filter screen when ATF stops running out of transmission Oil sump to transmission case 21 Nm Oil filter screen to valve body 4 Nm Car must be parked on level surface and transmission should have operating...
Manual transmission Control Housing
Gearbox, removing and installing Type 016 J and 016 K 34 - 1 Gearbox, removing and installing, Type 016 J and 016 K Mod. 85 2 onward 34 - 4 Checking oil level, replacing transmission oil 34 - 7 Transfer box, removing and installing Type 016 J and 016 K 34 - 9 Transfer box, disassembling and assembling Type 016 J and 016 K 34 - 15 Rear cover, disassembling and assembling Type 016 J and 016 K 34 - 27 End plate. disassembling and assembling Type 016 J and 016 K 34 - 31 Transmission case,...