Check balls, rollers and cages for all bearings for wear, scratches or other damage. Check for similar damage to synchronizers, shift forks, sliding sleeve grooves.
Replace all o-rings and snap rings, use new screws, nuts and washers if their appearance is unsatisfactory. In the event that gearbox parts are intended to be repaired or they are to be replaced. in the following sections, you can find out the procedure for the corresponding section of the gearbox.
It should be noted that if it is necessary to replace the gearbox housing, the differential and input shaft must be adjusted.
The oil sealing rings of the clutch release shaft and the shift shaft can simply be replaced. Pry off the appropriate oil seal ring with a screwdriver and, using a round iron piece of suitable diameter, drive in a new oil seal ring, lubricating its edges with grease. There is a plug on the clutch shaft at the end of the sealing ring. Drive in the sealing ring. until it rests against the collar, and then set the cork aside. As a result, the sealing ring is positioned at the predetermined installation depth of 0.8-1.3 mm. Be careful not to damage the sealing rings. Lightly grease the sealing lip of the ring.
To replace the needle roller bearing of the secondary shaft, a special removable device VW 771/15 is needed, as well as a hammer VW 771. A suitable insert to which the removable device can be attached must be placed in the inner part of the needle roller bearing in such a way that, clasping it from below, it can be knocked out with a hammer.
Replace the sealing rings of the input shafts by knocking out the old sealing ring from the inside of the gearbox. Drive in a new O-ring from the outside until it rests against the outer working ring of the bearing. In this case, the tin sleeve 9 must also be replaced.
To dismantle the old sleeve, drive it inward with a mandrel, and then pull it out with pliers. Drive in a new sleeve using a mandrel, avoiding deformation of the sleeve.
The outer working ring of the differential bearing is replaced in the same way. Make sure that the shim is not lost under the bearing race. Re-adjust the differential when replacing the bearing. The bearing cage, of course, must be left with the new working ring.
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