Input shaft of box 084 (VW Golf 2)

1. Using pliers, remove the retaining ring 13 from the end of the input shaft that ends with splines (figure 6.5).



2. Remove the 4th speed gear 12- and needle bearing 11.

The original can be viewed on the portal [www.VWManual.ru]

3. Remove the 4th speed synchronizer ring.

4. Remove the support washer 9, and then, using pliers, remove the safety spring ring 8 of the 3rd and 4th speed synchronizer unit. Do not bend the spring ring too much.

5. Attach the puller under the 3rd speed toothed gear and pull out the toothed gear together with the 3rd and 4th speed synchronizer unit. Then disassemble the unit and remove the 3rd speed synchronizer ring 7.



6. Remove the needle bearing of the 3rd speed gear 5.

7. Clean the elements in kerosene and check them for wear and damage. Check the pinion teeth and needle bearing shafts. If necessary, replace the elements with new ones.

8. Synchronizer unit.

Installation

9. Begin assembly by placing the 3rd speed gear needle bearing on the input shaft. Lubricate it with gearbox oil.

10. Install 3rd speed gear 6.

11. Install the 3rd gear synchronizer ring into the 3rd and 4th gear synchronizer unit so that the synchronizer pieskis are in the ring cutouts. Then press the synchronizer unit onto the shaft splines. If necessary, you can use a metal tube.

Note: Make sure that the groove on the hub is on the 4th speed gear side.

12. Place the safety spring ring 8 into the groove of the shaft, and then put on the spacer washer 9.

13. Place the 4th speed synchronizer ring on the 3rd and 4th speed synchronizer assembly so that the synchronizer crackers are in the cutouts of the ring.

14. Place the 4th speed needle bearing 11 on the shaft, lubricate it with gear oil, and then put on the 4th speed gear 12.

15. Place the safety spring ring 13 in the groove and make sure it is seated correctly.