Checking gearbox parts (VW Golf 3)

Clean all parts thoroughly and dry them by blowing them with compressed air. Check all gears, bearings, and synchronizers for wear and damage. Replace gears of the same gear only in pairs. The main gear pinion and the bevel gear (secondary shaft) must also be replaced as a set.

Check for wear, scratches or other damage to the balls, rollers and separators of all bearings. Check for similar damage to the synchronizers, engagement forks, and sliding clutch grooves.

Replace all seals and snap rings, use new screws, nuts and washers if their appearance is unsatisfactory. In case the transmission parts are intended to be repaired or they are subject to replacement. In the following sections you can find out the procedure for the corresponding section of the transmission.

It should be taken into account that if it is necessary to replace the gearbox housing, the differential and primary shaft must be adjusted.

The clutch release shaft and shift shaft oil seals can be easily replaced. Pry up the corresponding oil seal with a screwdriver and, using a round iron part of a suitable diameter, drive in a new oil seal, lubricating its edges with grease. There is a plug at the end of the sealing ring on the clutch shaft. Drive in the sealing ring until it rests against the flange, and then set the plug aside. This ensures that the sealing ring is positioned at the specified installation depth of 0.8-1.3 mm. Be careful not to damage the sealing rings. Lightly lubricate the sealing edge of the ring.



To replace the secondary shaft needle roller bearing, you will need the special VW 771/15 puller and the VW 771 hammer. A suitable insert, to which the puller can be attached, must be placed inside the needle roller bearing so that it can be grasped from below and knocked out with a hammer.

[The original information is posted on the resource: www.vwmanual.ru]

Replace the primary shaft sealing rings by knocking out the old sealing ring from the inside of the gearbox. Drive in the new sealing ring from the outside until it rests against the outer working ring of the bearing. At the same time, you also need to replace the sheet metal sleeve 9.



To remove the old sleeve, drive it in with a mandrel in the inward direction, then pull it out with pliers. Drive in the new sleeve with a mandrel, avoiding deformation of the sleeve.

The outer working ring of the differential bearing is replaced in a similar manner. Make sure that the adjusting washer does not get lost under the bearing ring. When replacing the bearing, re-adjust the differential. The bearing separator, of course, must be left with the new working ring.