Disassembly and repair of gearbox 084 (VW Golf 2)

1. Unscrew the oil drain plug with a hex key and drain the oil into a container. Screw the plug back in.

2. Remove the clutch release bearing and shaft.

3. Unscrew and remove the reverse light switch.

4. Temporarily screw two bolts into each drive flange. While holding the flanges in place one by one with a rod, unscrew the fastening bolts 1 (figure 6.2)



Label each flange (right and left), then remove them from the main gear. Drive flanges of different lengths (figure 6.1).



Remove spring 4, support washer 5 and conical ring 6 from the seat of drive flange 2 on the main gear housing and keep them together with the corresponding drive flanges (Fig. 6.2).



5. The drive flange seals can be removed and replaced with new ones if necessary, either immediately or later, after removing the differential mechanism.

This operation can also be performed with the gearbox installed after removing the drive flanges. It should be noted that the right and left seals are different sizes.

6. Loosen and remove the bolts connecting the clutch housing to the main housing. Make sure that all bolts are removed from the clutch housing.

7. Support the gearbox with the clutch housing on top, then use a wooden mallet to separate the clutch housing from the main housing, then set it aside.

8. Remove the magnet that collects sawdust from the groove on the gearbox housing.

9. Remove the differential mechanism from the gearbox.

10. Support the main gearbox housing with the rear cover facing up.

11. Loosen and remove the bolts and the rear bearing cover (photo 6.1). Mark the distance washers of the input and output shaft bearings and then remove them. There is no need to replace the distance washers, as then you will need to adjust the longitudinal clearances of the shafts during installation. Remove the gasket.



12. Using pliers, remove the spring retaining ring from the entrance hall, and then remove the small spacer washer (photo 6.2)




13. Check whether the selector shaft is in a free position, and then use a hex key to unscrew the locking rod together with the bushing washers, springs and locking studs 21 (figure 6.3)

(The original information is posted on the resource vwmanual)



14. Unscrew the 20 bolt with a Phillips-head screwdriver, the reverse gear fork. This bolt is located next to the locking rod holes. The bolt is very tightly clamped, so you will need an impact screwdriver or chisel to remove the bolt.

15. Turn the gearbox housing and remove the slider of the forks of the reverse gear 9 and fork 11. The forks have cutouts at the ends into which the kingpin 10 of the slider 9 fits on one side and the reverse gear 17 on the other side.

16. Then it is necessary to remove the shafts, input 15 and output 43. You can remove two shafts, simultaneously knocking them out through ball bearings 6 and 7.

17. To remove the shafts separately, it is necessary to prepare a special support plate and screw it to the housing so as to make the input shaft immobile (figure 6.4). Place a hex nut M 16 between the shaft lever and the gearbox housing to lock the shaft.



18. Support the gearbox with the ball bearings upwards, and then use a special puller to remove the input shaft bearing from the housing.

19. Remove the special support plate.

20. Using an M16 nut or a piece of wire, hold the selector shaft by bending the spring.

21. Move the input shaft away from the output shaft, and then remove it together with the slider and the 3rd and 4th speed forks from the gearbox. Slightly lift the reverse gear pinion so that the 1st speed gear pinion of the input shaft can pass.

22. Remove the M16 nut or piece of wire used to lock the selector shaft.

23. Using pliers, remove the spring retaining ring from the end of the output shaft and the small spacer washer (photo 6.2).

24. Using a puller, push the output shaft out of the end bearing and simultaneously remove the slider and 1st and 2nd speed forks and the reverse gear pinion. Make sure that the shaft and reverse gear pinion do not jam.

25. Remove the locking rod 21 from the gearbox housing (if there are any left).

26. Using a soft metal punch, knock the input shaft bearing out of the gearbox housing. Mark the input and output shaft bearings.