VW Transporter 1600 Owners Workshop Manual: All Volkswagen Transporter 1600 Models with 1584 cc (96.7 cu in) engine 1968-79 (Haynes Manuals)

Citation preview

96030

Q HAYNES

1973

(082)

•

byJH Haynes Member a t the GUlld of MOlt...Ong Writers

and DHStead Models covered: All Volkswagen Transporter 1600 models with 1584 cc (96.7 cu in) engine Ooes not cover the alternative bodies and con versions produced by specialist manufacrurers

ISBN O 85696 660 6

©

Haynes Norlh America, Inc.

1977,1981,1982,1986,1990

Wilh permission lrorn J. H. Haynes & Co. Ltd.

AH rights reserved . No part of this book may be reproduced or transmitted in any form or by any means, electrical or mechanical , including photocopying , recording or by any information storage or retrieval system , withoui permission in writing from the copyright holdar.

Printed in the USA

(BU1-OB2)

Haynes Publishing Group Sparkford Nr Yeovil Somerset BA22 7JJ England Haynes North America, Inc 861 Lawrence Drive Newbury Park California 91320 USA

""~ ....., """ , FGHU

Aclent w;th the synchro sleeve and should be refiued on

a trial and error basis until the two components exhibit the best sliding fit. 53 When fining the springs make sure that they run in opposite directions when viewed from each side of the unit, that they engage fully with the sliding key s and th eir angled ends are located in the hollow key, but on no account have both the angled ends of the two springs engaged in th e same key.

61 With all parts dean and renewed where necessary, assemble the gearbox in the following sequence. Apply oil to each ca mpenent as it is assembled and observe absolute cleanliness. Mainshaft 62 Aeassembly is a reversal of dismantling but note the following points. 63 When fitting 3rd/4th synchro make sure that the groove on the sleeve (arrowed Fig .12.1 31 is towards 4 th gear. Pinion driveshaft 64 When titting the tapered roller bearing, the inner [rack should be heated to 212 0 F (1000 C) in water before titting. 65 Th e combined 1st gear needle bearing inner track and ring nut should be heated in water to 140°F (60 0 e) before fitting to the main shaft but make sure that th e tapered roller bearing track has cooled down first . 66 Using the spec ial tool (VW 2052) tighten the ring nut (still hot) to 145 Ib ft (177 kgf ml. 67 The pinion driveshaft should now be fitted in the transmission case and its turning to rque checked either with a torque wrench or by winding a cord round the shaft splines and attaching its end to a spring balance . Oil the bearing and turn it several times in both directions to settJe the bearin9s. The turning torque for new hearings should be between 6 and 21 kgf cm (5.2 and 18.3 Ibf in) or if the original bearings have been used again, 3 to 7 kgf cm (2.6 to 6 .1 Ibf inl. 68 Once the torque has been checked, remove the driveshaft from the transmission casing and continue reassembly, which is in the reverse order of dismantling. Fit 1st gear and needle bearing, 1st/2nd synchro, 2nd gear and needle bearing, 3rd gear

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6 5 FIG,12.13 COMPONENTS OF THE GEAR CARRIER l

2 3 4 5

Inrermediate se/eetor

6

Stop

lever Bafljo inr

7

Link Se/eetor lever shafr

8 9

eoil springs

10

Intermediate se/eetor lever braeket 3rd/4th se/eetor rad Reverse se/eetor rod tstl2nd se/eetor rad

"

Detent hale p /ug Detent baJ! Detent spring Detent sleeve

12 13 14 15 P/ug 16 Pinion driveshafr needfe

17

18 19 20 21

bearing Mainshafr bearing Lockplate

Clamp sleeve Union nut

22 23 24 25 26

Re/ay shafr braeker

Racker lever Re/ay shafr Re/av shaft braeker Circlip

Racker lever support

~

... II)

208----------------------------------------------------------~

FIG.12 .15 SYNCHRO SIDE TO SIDE SPRING LOCATION

FIG.12.14 3RD/ 4TH SYNCHRO HUB AND SLE EV E

Line on hub must be at bortom (black arrow) when groove on sleeve is uppermosr (wh i te arrowJ

....--.... 3RD/4TH--

O

/

/2ND

O FIG .12 .161 ST / 2ND SYNCHRO HUS AND SLEEVE FIG .12.17 SECTlONAL VIEW OF DETENT/ SEl ECTOR SHAFT ARRANGEMENT SHQWING POSITION OF INTERlOCK PLUNGERS

294b(

FIG .12.18 USING SPECIAL JIG TO SET REVERSE SELECTOR PIN

FIG.12.19 RQC KE R LEVER e aU A L C l EARANCE POINTS

Chapter 12/Supplement

209

Grey

really satisfactory way to set up the selector mechanism is to use the special setting jig VW 294 b. If this cannot be borrowed then this work should be left to your dealer by taking the assembled gesr carrier to him. 86 If the jig is available, fit the gear carrier complete with reverse sliding gear and seleetor tork. 87 Release the balts on the reverse relav shaft braekets and slide the braeket (on the selector pin side of the relay shaft) until the seleetor pin contacts the reverse sliding gear. 88 Now press the opposite bracket against the shaft until all endplay is eliminated. Tighten the bracket balts to a torque of 141bf ft (1.9 kgf mI. 89 Check that the clearance at both ends of the rocker lever is equal. If it is not, release the union nut and rotate the revene lever support as necessarv. Retighten the union nut to 22 Ibf f t

Copper

13.0 kg! mI.

(shouider towards 2nd gearl. circlips, spacer spring, 4th gear (shouider towards spring) and the circlip. but note the following points. 69 Before pressing the lstl2nd synchro onto the driveshaft, fit a new anti-rotation ring.

70 Once 3rd speed gear is fitted. use feeler blades to check the endfloat. This should be between 0.05 and 0.20 mm. Adjust

by using a selective thickness circlip from the following which are available. Try and set the endfloat to the lower tolerance. Thickness (mm)

C%ur of circJip

1.60 1.75 1.90 2.05 2.20 2.30 2.40

Black Blue Brown

Brass Silver

Transmission case 71 Retit the mainshaft and reverse shaft bearings to the trans-

mission ease using new circlips. 72 Fit reverse shaft and reverse driven gear, the latter having the oH grooves towards the needle bearing. If the complete reverse shaft/gear assembly has been removed the n it is simpler to refit completely assembled, including the shaft needle bearing, cirdip and thrust washer. Tap home, using a plastic faced hammer. Gear carrier 73 Fit the seleetor detent balls and springs. 74 Depress the detent balls and springs and fit the seleetor shahs. Make sure that the interlock pins are in position. 75 Drive in new detent plugs. 76 Press the mainshaft bearing inta the gear carrier so that the numbers engraved on the bearing outer track are visible when viewed from outside the carrier. Once the milled edge of the bearing aligns with the recess in the gear carrier, press the semi· circular JockpJate inta the recess. 77 Fit the cirdip and press in the pin ian driveshaft bearing. 78 Fit the damp sleeve, reverse Jever support and the umon nut. Tighten the sleeve to 32 Ibf fl (4.4 kgf mI. 79 laosely fit the reverse gear relay shah and braekets. 80 Fit the selector link bracket and tighten the balts to 18 Ibf ft

(2.5 kg! mI.

90 Adjustment of the 1st/2nd and 3rd/4th seleetor forks is rather more complicated because if the final drive requires resetting due to the installation of new components, then this must be done tirst (see paragraph 110J. 91 Install the gear carrier to the special jig and then hand tighten the special retaining ring at the pinion gear bearing. This ring is supplied as part of the setting jig. 92 Loosen the nut on the reverse lever support and move the support and lever aside. 93 Fit 1 st/2nd seleetor tork to its shaft but leave it tree to slide on the shaft. 94 Reconnect the reverse lever and slightly tighten the union nut on the support. 95 Pull the 1 st/2nd seleetor shaft unt" 2nd gear detent engages. Now slide the svnchro sleeve/tork in the same direction as the shaft was moved until the sleeve slides over the teeth on the baulk ring, and is against 2nd gear. 96 Now centralise the fork in the groove in the synchro sleeve and tighten the tork lock bolt. 97 Turn the mainshaft and select 1st, 2nd and neutral several times and at each gear position check that the fork does not rub against the side of the synchro sleeve groove. If it does, slight readjustment must be carried out. 98 With the gear train in neutral, move the 3rd/4th selector rod until it engages in 3rd gear detent. Adjust the 3rd/4th tork in a sim ilar way to that described tor the 1st/2nd fork. During these adjustments, the mainshaft bearing in the gear carrier must be fully seated.

81 Fit the seleetor !ink and seleetor link shaft. 82 The selector shafts and forks will require adjustment (as described later) once the gear train has been fitted to the carrier. 83 To fit the gear train, mesh together the mainshaft and the pin ian driveshaft. Slip the 3rd/4th seleetor fork anta its shaft and make sure that it si ides freely. Support the ends of the gear shafts and then lower the gear carrier down anta the oppasite end 5 of the shafts. Apply pressure to the inner track of the mainshaft bearing using a tubular distance piece and a press. A heavy hammer may do the job if an assistant is available to guide the pin ian driveshaft inta the carrier and to retain the selector fork anta its shaft. 84 The dished washer and a new circlip must now be titted to the mainshaft. Make sure that the circlip snaps inta its groove against the pressure of the washer and then compress it fully with a pair of pipe grips until it bonoms in its groove. Selector forks . refitting and adjustment 85 Correct setting of the seJector forks is vital for smooth gearchange and minimum wear on the selector components. Basically, what must be achieved is to so adjust the selector forks that when a gear is seleeted, the tork is central in its synchro sleeve groove (or pin in reverse sliding gear groove) without any side pressure to cause the fork to rub against the sides of the groove. A great deal of trial and error work will be needed to achieve this uniess the original components are being refitted and their exact relative positions were marked before dismantling. Where new parts have been fitted, then the on ly

12 FIG.1220 SPECIAL PIN lON BEARING ADJUSTER NUT SUPPllED WITH SELECTOR SETTING JIG

210

Chapter 12/Supplement

99 Adjust the union nut on the reverse rocker lever support

until the support is just fre e to slide in and out of its damp sleeve . 100 Push the reverse (middle) se leetor shaft until ilS circlip cont8cts the face of the gear carrier. Hand tighten the union nut.

101 Without touching its sh ift tor k, press reverse slidi ng gea r towards the gear carrier until th ere is a clearance between the sliding gear and the mainshaft 2nd gear of between 0.020 and 0.039 in (0.50 and 1.00 mm). Tighten the union nut to 22 Ibf Ib 13.0 kgf mI. 102 Disengage reverse gear and select 2nd gear. Check that there is a clearance between the teet h of reverse sl idin g gear and 1stl 2nd gear sleeve. If not, readjust the reverse lever support after releasing the union nut . 103 FinaUy check that the interl ock mechanism is doing its job by on ly aliowing the se lection of one gear at a time. Check that the selector for k lock balts are all tight at 18 Ibf f t (2.5 kgf mI. 104 Stick a new gasket to the fla nge of the transmission case and locate the pin ian driveshaft bearing shims in position (refer to paragraph 110 if th e pinion/crownwheel has yet to be adjustedJ. 105 Insert the gear train inta the casing so that the twelve sided shoulder o f the pin ia n bearing seats in its recess. 106 F it a new reta ining nut and with t he special tool u sed to release il, tighten it to 160 Ibf Ib (21 .8 kgf m J. Release the nut one Quarter o f a turn and retighten to the correct torQue. Stake the nut by means o f its retaining ring . 107 Insert and tighten the balts which hold the gear carrier to the transmissio n case. Work in a diagonal sequence and tighten to a torqueof 141bf ft 11.9 kgf m). 108 To the face of the gear carrier ba lt on the seleetor link and bracket, th e selector link and link shaft. 109 If the gearchange lever housing was overhauled. fit a new bush /oil seal. Fit the ho using to th e gear carrie r making sure that the selector inner lever engages with the ba lljoint o f the link. Fit the securing bolts and tighten to 11 Ibf ft (1.5 kgf mI. Final drive - fitting 110 If the differential has been dismantled or certain compon· ents renewed (see paragraph 127) then it is essentiai that the setting o f the crownwheel and pinion is left to your dealer due to the need for special gauges. Under these circumstances, the jig setting of the selector mechanism (paragrap hs 85 to 103) should b e carried o u t by h im at the same time. 111 Where the differential /final drive has remained undisturbed during the gearbox overhaul operations, then reHt it in the following way. 112 Fit the differential inta the transmission housing so that the crownwhee l and pinion mesh . 113 Fit a new oil seal and O-ring to each of the adjusting rings. 114 Screw in the right-hand adjusting ring (they sh ou Id have been marked L or R before removalI by the exact number of turns recorded at dismantling until its mark is correctly aligned . 115 Centralise th e d iff erential in the transmission housing and screw in the opposite b earin g adjuster ring again to the original depth and stopp in g when the marks on ring and housing are in alignment . Release this ring o ne complete turn until the clutch bellhousing has been fitted . 116 To the right· hand side fit a new spacer, a lockplate seal, the lockplate, the kidney shaped plates and the Phillips screws. 117 Into the open end of t he gearcase , locate t he reverse gear sleeve a nta the end of the mainshaft. 118 Insert the input shaft, without its c ircl ip but with a threaded connecting stud screwed into its end, and pick up the reverse sleeve . Draw the sleeve towards you on the input shaft and screw th e shaft up tight with the mainshaft. Now unscrew il just a fraction (o ne spline) until th e sleeve can be pushed forward fre ely . 119 Fit a new circlip inta the input shaft groove. 120 Using a new joint gasket, bolt th e clutch bellhousing to the front of the transm ission case. Tighten the balts to 14 Ibf ft (1.9 kgf mI.

FIG .1221 REVERSE SlIDING GEAR CLEARANCE (a) TO MAINSHAFT

A

FIG.1222 PINlON DRIVESHAFT NUT STAKING DIAGRAM

A

0 '----"

StiJking tool

o

o o

o FIG .1 223

INTERMEDIATE

SELECTOR

LEVER

ARRANGEMENT 1 Weaker spring

2

Stronger spring

SPRING

211

Chapter 12/Supplement

\3

\5

4

FIG.1224 GEARSHIFT HOUSING COMPONENTS

l

2

Housing Bush

3

Inner selector lever

121 Set the left-hand differentia l bearing adjusting ring to its originally marked position (see paragraph 541 by screwing it in t he turn which it was backed off. 122 Refit the components detailed in paragraph 116. 123 F it the drive fl anges, th e thrust washers and using a piece of tublng, drive on new circlips. 124 Fit new plastic sealing caps to the centres of the drive flanges. 125 Refer to Chapter 4 for details of the clutch release mechanism and retit the components. 126 The gearbox may be filled with oil now or after the unit is fitted in the vehic le. 127 If any of the following components have been renewed then the final drive will require adjusting and settJng up by your VW dealer.

Transmission case Differential tapered roller bearings Pinjon bearing (double tapered roller) Pinion bearing circ/ip Crawnwheel and pinion Differential carrier or cover plate 128 The differential is adjusted in two ways : (il by shims at t he pin ian driveshaft tapered roller bearing to controi the dePth of mesh of the pinian teeth with those of the crownwheel, and (jj) by threaded adjust ing rings at the differential tapered roller bearings. Tightening or releasing the rings has the effect of moving the comp lete differential hOoJsing sideways within the transmission case, agaln altering the meshing depth of the crownwheel and pin ian teeth. 129 Without the special tools and gauges w hich your dealer will have for this work, it is virtually impossible to ca rry out adjustments which w ill not on ly cause noisy operation of the final drive but wil l also rapidly wear the transmission components.

4

Type

091

Spacer

manual gearbox

lubrication

5

(January

Seal

1976 on)

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•

130 Commencing January 1976, this type of gearbox is 'fi lled for life' a nd periodic oil changes are not required. 131 A larger magnet is fitt ed to the drain plug to ensure that the lubricant is kePt free from swarf now that oil chang ing is no longer required.

8

Brak ing system

Disc calipers (Girling type) 1 As from SePtember 1975, Girling disc brake cal ipers are fittad as an alternative to the Teves type. 2 Pads shou ld be inspected regularly a nd renewed if th eir friction material hasworn down to 0.08 in (2.0 mml. 3 To renew the pads, remove the roadwhee l, extract the spring cl ips from the ends of the pins and tap out th e pins with a thin drift. 4 Remove the spring plate and pu ll the pads from the cal iper gripping them with a pair of pliers if necessary. 5 On the back of each pad is an anti-squeal sh im. Nate that the directional arrow points upwards_ 6 In order to accept the new thicker pads, the ca liper pistans will have to be depressed fully inta their cylinder bores. Use a flat bar such as a tyre lever to do this and anticipate a rise in the reservair fluid level by syphoning same fluid out before depressing the pistans. 7 Insert the pads ([dctian lining against th e disc) the antisqueal shims and insert t h e pins and spring clips. B Apply the footbrake hard severa l times to plJsition the pads against the disc. 9 Overhaul of a Girling caliper follows very dosely the operations described in Chapter B, Section 7 for the Teves type. Neve r attempt to release the bal ts which hold the two halves

12

212

Chapter 12/SuppJement

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FIG.1225 GIRLlNG TYPE CALlPER

10

Retaining ring

8

Piston seal Piston

11

Anti-squeaf shim

9

Dust excluder

12

Friction pad

l

Discthub

4

Anti-ratt/e spring

7

2

Caliper body

5

Pad retaining pin

3

BJeed screw

6

Pin securing clip

of the caliper together. If fluid is seen to be leaking from the

joint, renew the caliper complete. 10 Girling and Teves caljpers can be interchanged but o nly in pairs on the same axle.

9

Electrical system

1974 on) - removal and

Master cylinder

Instrument panel (August refitting

11 On later modeis, the master cylinder used in con junctio n with a vacuum servo differs in detail from that used on systems without servo assistance. 12 Overhaul is similar with both types of cy linder.

1 Disconnect the battery. 2 Pull the knobs from the heater and ventilator controi levers . 3 Unscrew the instrument pan el securing 5crews a few turns but do not remove them completely and then reach behind

•

213

2

I

5-

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22 - /

FIG.12.26 BRAKE MASTER CYLINDER IWITHOUT SERVO) l

2 3 4 5 6 7

Stop lamp switch St op lamp switch Sealing plug

8 9

Washer

Cup seal Cup washer

M aster cylinder bodY

10 ll

Secondary piston

Stop b olt Spring Support ring

12 13 14

Piston seal Piston seal Stroke limiting screw

15 16 17 18 19

Stop sleeve Spring

Support ring

20

Washer Cup seal Cup washer

21

Primary piston

22 23 24 25

Cup seal S top washer Dust exclud ing b o o t Circlip

12

214----------------------------------------------------------------~

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