Gearbox assembly (VW Caddy 3)

1. Fix the primary (2) and secondary shafts (1) in the bracket with a radial ball bearing.

2. Install the engagement mechanism (forks) (4) into the annular groove of the gear engagement clutch.

3. Install the reverse gear engagement fork (3).



4. Install the components into the gearbox. Before installing the bracket, ensure that the shift forks are properly seated in the gearbox housing.

5. Install the bracket together with the primary and secondary shafts by pressing it until it clicks into place.

6. Tighten the screw (A) securing the reverse gear shaft (see figure VC 4.046).

7. Remove the pivot pins (B) located on the top side of the gearbox.

8. Install the reversing light switch (C) (see figure VC 4.045).

9. Install the rotation axes (B) located on top of the gearbox housing.

10. To install the gear selection and engagement mechanism (A), set it to the neutral position and tighten the screws (arrows).

11. Using new screws (A), secure the input and output shaft bracket.

12. Tighten the hex nut (B) securing the gear shift mechanism.



13; Install the oil catch can (A) into the cutout (1) and hole (2) of the gearbox housing.





14. Install the oil guide deflector (B) with the magnet installed in it into the gearbox housing.



15. Install the differential (A) (see figure VC 4.043).

16. Secure the clutch housing to the gearbox housing.

17. Install the 5th gear pinion (1) with the protrusion towards the surface of the gearbox housing (arrow).

18. Install the 5th gear synchronizer sleeve with needle bearing.

19. Install the 5th gear synchronizer locking ring.

20. Install the hub with the 5th gear synchronizer sliding sleeve with the thrust washer.



21. Install the 5th gear shift fork (2) and the rotation axis (1) by pressing until it clicks into place in the direction of the arrow.


22. Determine the thickest thrust washers that will fit the primary (3) and secondary (4) shafts. Install new thrust washers (arrow).



23. Secure the gearbox housing cover.

24. Install both flanged shafts together with thrust washers, springs and tapered rings

25. Install the clutch release lever together with the release bearing and guide sleeve.