5 Speed Manual Gearbox 094 VW Transporter Dec 1982 PDF

,.
f; THE TRANSPORTER WORKSHOP MANUAL CONS'ISTS OF THE FOLLOWING BOOKLETS:
ij ~~;
..
' ..'
MAINTENANCE
Engi~es
Techni cal data
10
13
1.6 LITRE DIESEL ENGINE
R + I engine
Crankshaft group ·
Tightening torques 15 Cylinder head, valve gear
Delivery service ,' 17 Lubrication
Service intervals ~ -. '
19 Cooling
First service 20 Fuel system
I
.....:
...
Standard service
Lubrication service
23
26
Fuel injection system
Exhaust system
Service operations 28 Glow plug system
Identification plate, chassis and
engine numbers 4 SPEED MANUAL GEARBOX 091
Lifting vehicle 30 Clutch
Towing 34 Controls, housing
Safety precautions for transistorized 35 Gears, shafts
ignition systems 39 Final drive, differential
1.6 LITR~ CARBURETOR ENGINE

I 5 SPEED MANUAL GEARBOX 094 Page
10 R +I engine 30 Clutch 5
13 ,Cran.kshaft group • 34 Contro'ls, housing 9
15 Cylinder head, valve gear 35 Gears, shafts 29
17 Lubrication 39 Final drive. differential 40
19 . Cool ing
AUTOMATIC GEARBOX 090
·20 . ·Fuel system
I • 32 Torque converter
·22 Carburetor, control~
26 · E.~ f.lg.ust system:·.·· · 37 Controls, housing
38 Gears 1 hydraulic controls
· ~8 lgn ~tlon system ,.
39 Final drive, differential
- 1.9 LITRE CAR13URETOR .ENGINE
RUNNING GEAR
to R + 1 -'~ngirw · ,
40 Front suspension
l3 · Crankshaft gtoe1p ·
15':, Cylinder heaqr,:valve gear· 42 Rear suspension, drive shafts
17 '
Llibric;a:tion ·.
44 Wheels, tyres, wheel alignment
:. 19 ·· cooli ng ~ •
46 Brakes- mechanism
,_; 20 :-.; Fuel system ~ . 47 Brakes- hydraulics., regulator, servo
1
22 I Carburetor; controls • "
48 Steering
26 ·t Exhaus system BODY REPAIR WORK
28 :~lgnition· system 55 Lid, flaps
t • • '
57 Front doors
. ·' 2.0 LIJ:~~- CARBURETOR ENGINE
58 Rear doors
~0 -~R 1~~'[1~e · 60 ~. Sliding roof
13 .~ .'7~~f~~~group ' 61 Cover
1s_ :.;:. G.yl.fttq·~r'heap, valve gear 63 Bumpers
.1'7 ..~:t<, ,~t>Hea:tion
-'1=9 ~... • ' c6b:1j.n:g 70 Trim panels
72 Seats
20' , \ Fuei ·system ,
..
22 : Carburetor, controls HEATING, VENTILATION
~' ·:· 26 Exhaust system· 80 Heating
~-... :~; ;· 2&,. ._:. lgnitiQ.~ _system 82
,
. . ...:.. ........,...""',..,: •',: Auxiliary heater
\
85 Ventilation
:"':.ft~·· ~{.: O . ~~.IJ~~. LIT~E L JETRONIC ENGINE
~70.; t•. 1 :, R-r .tengine "''~ ELECTRICAL SYSTEM
rJ-1 ..· :· .. :..t.13 ~ Crankshaft group 27 Starter, current supply ,J
,.• ;.- . l1.5 · ;.Cylinder head , valve gear 90 Instruments, radio

· · \7 · Lubrication ..... ;. 92 Windscreen wipers and washer system
•--?· · . . '·~. f~ ' ,, B"ooliQg · .,. ·~ . · ·~. 94
>; ·-
~1fo;:;'t.~
1·
· . ·
2 · · · · · Fuel system .
24 . . L Jetron . ic.syster:n ·
,•
·',
96
Exterior lights
Interior lights, switches
~
... ·.
~ J ,J . ...... .' t l ( .' . 97 Wiring
.. •. , .·if/' -26 ·;. Exhaust system
-;: ~t~ ' :, 28 '.:: . ,lgnltion.s¥stem CURRENT FLOW DIAGRAMS
. _• . f """: _
.. .. .
~ -. Main and additional current
flow diagrams
.. .•.
•. .. I
~ ..
• '
' ...,
VA.G Service.
Workshop Manual
Volkswagen Transporter.
5 Speed Manual Gearbox 094 OOoS~<jjt bl20
December 1982 Edition.

Replaces Workshop Manual Volkswagen Transporter Preliminary Information
October 1982 Edition
The manual is divided into separate booklets dismantling and assembling a component, the
which can be ordered individually and allo- exploded view is followed by a description of
cated on the shop floor as required. the main steps of the work sequence. Any
adjustments requ i red are ~lso explained.
Th is manual is valid for the Transporter with
5 speed manual gearbox 094 from the start of
Workshop Bulletins
production (October 1982). It describes all the
operations which require special instructions Workshop bulleti ns will be allocated to the in-
to ensure satisfactory work. dividual booklets and should be fi led at the
. back of the booklet concerned. To remind you
Layo~t of booklets ... that bulletins have been publ ished, the manual
pages should be marked by hand with the bul-
Each booklet has the contents listed accord ing
letin number as explained in the bulletin head-
to repa ir operations and items to make it easier
ing.
to find the information required. In the repair
operations list, the special tools and workshop
Fault findi,ng
equipment required for each operation are . ;1/j l . -
given. General fault finding instruction , / g1ven m
the workshop manual and in a o ~ to this
The technical data is followed by a description the following fault f ind i ng leaftes have been
of the repair operations. Where practical, each published :
operation is preceded by an exploded view
L-Jetronic engin ·-~
which also contains all the main repair instruc-
Automatic gear~( ·
tions. This is supplemented, where necessary,
Brakes
by photographs- which are referred to in the
exploded views - giving detai ls of the fitting po- Instructions on the elimination of current de-
sitions of parts or showing special tools in use. fects are given in the " Fault find ing hand-.
If a definite sequence has to be fo ll owed when book".
Technical information should always be made available to all foremen ~d mechanics because
compliance with the instructions given is essential to ensure vehicle, roadj(orthiness and safety.In
addition, the normal safety precautions to be observed when working on moter vehicles are al~o
applicable.
VOLKSWAGENWERK AKTIENGESELLSCHAFT · WOLFSBURG I

Contents
REPAIR OPERATIONS AND TOO,LS
Operation Repair Page Special Tools Workshop Equipment

No.
Gearbox identification 1
300167 . . Clutch, bleeding 5 vw 1238/ 1

302019 .. Clutch master cylinder,
removing and installing 5
30 2319 .. All pressure lines,

30 2419 .. Front pressure line,

30 2619 .. Centre pressure line,

30 2719 .. Pressure hose,

302919 .. Rear pressure li ne,

30 3019 .. Clutch operating cylinder,

30 4519 .. Release bearing,

305019 .. Clutch , removing and installing 7 VW215cor3067

10-213
341516 . . Gearshift linkage, adjusting 10
341719 .. Shift rod ,

343519 .. Gearbox, removing and installing 11 vw 785/1 V.A.G 1383
..
}.
..·•.
•"
II ReRair operations and tools

Operation Repair Page Special Tools Workshop
No. Equipment
343537 .. Gearbox, dismantling and 14, 18 VW244b Two-armed extractor

assembling 25, 28 VW296 (commercially available)
VW309 e.g. Kukko 20/10.
VW352
vw 381 / 14, 15
VW382/ 7
VW391
VW401
VW411
VW412
VW454
VW456a
VW457
30-100
Securing gearbox in repair 15 VW309
stand VW352
Input shaft o il seal, 25 VW244b
removing and installing VW454
VW681
Drive flange oil seal, 35 VW391
2051
Gearshift shaft oil seal, 27 VW681
Starter bush, removing and 25 VW222a
installing VW228b
Release shaft bush, removing 5 VW408a Extractor
and installing VW771 18.5 -23.5 mm,
vw 771 / 15 e.g. Ku kko 21 / 3
3540 37 .. Input shaft, dismantling and 30 VW295 Extractor

assembling VW401 18.5- 23.5 mm,
VW407 e.g. Kukko 21 / 3.
VW411 Support
VW412 e.g. Kukko 22/ 2.
VW421
VW456a
30-14
30-100
:!
355019 .. Input shaft oil seal, 25 VW681 _.

removing and installing VW244b
VW454
Repair operations and tools Ill

.·
Contents
Operation Repair Page Special Tools Workshop

No. Equipment
355915 .. Out put shaft, adjusting 53 vw 381/14 Dial gauge 0 - 3 mm

VW385/ 1 Dial gauge extension
vw 385/ 4 approx. 30 mm long
vw 385/ 14
VW385/ 16
VW385/ 17
VW385/ 30
355937 .. Output shaft, d ismantling 34 VW401 Parti ng t ool

and assembling VW408a 12- 115 mm,
VW409 e.g. Ku k ko 17/ 1 + 2
VW41 1 Extract or
VW415a 30 - 37mm
2052 e.g. Ku k ko21 / 5.
Support
e.g. Kuk ko 22/ 2.
30-506b Torque gauge
32-109 (commercially available)
32-111 0- 600Ncm
390915 . . Differential, adjusting 55 VW 381 / 5a, 7, 8, 15 Torque gauge

VW382/ 7, 9 (commercially available)
VW386A 0- 600Ncm
VW387 Dial gauge 0 - 3 mm
390937 .. Differential, dismantling 41 VW 381 / 5a

and assembling VW 38 1/13or 30-45
VW387
VW401
VW402
VW407
VW412
VW 415a
VW442
VW454
VW456a
VW457
VW771
40-21
40-103
2050
2054
392219 .. Drive flange oil seal, 40 VW391

2051
•, .
I' ,
IV Repair operations and tools

Contents
ALPHABETICAL LIST
Page Page
Adjustment table . . . . . . . . . . . . . . . . . . . . 52 Gearshift linkage, repairing . . . . . . . .. . . . 9
Gearshift linkage, adjusting . . . . . . . .. . . . 10
Bearings for input shaft, renewing . . . . . . 30 Gear lever, removing and installing . .. . . . 9
Bearings for differential, renewing . ..... 41 Gear lever, adjusti ng . . . . . . . . . . . . . .. . . . 10
Bea·ring for pinion, renewing . . . . . . . . . . . 34 Gear train, removing and installing/
Bearing housing, repairing . . . . . . . . . . . . 27 dismantling and assembling . . . . . . . . . . . 18
Calculating speed " V" . . . . . . . . . . . . . . . . 4 Input shaft. removing and installing . . . . . 18

Calculating ratios "i" . . . . . . . . . . . . . . . . . 4 Input shaft, dismantling and assembling . · 30
Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Input shaft o il seal, renewing . . . . . . . . . . . 26
Code letters . . . . . . . . . . . . . . . . . . . . . . . . . 2 Identification of gearbox . . . . . . . . . . . . .. 1
Clutch, removing and installing . . . . . . . . . 7
Clutch housing, repairing . . . . . . . . . . . . . . 25 Lim ited slip differential,
Clutch system bleeding . . . . . . . . . . . . . . . 5 dismantl ing and assembling . . . . . . . . . . . 46
Clutch mechanism hydraulic, repairing . . 5
Clutch housing, removing and installing . 14 Mounting gearbox in.repair stand . .. .. . . 15
Clutch pressure lines, removing
and installing . . . . . . . . . . . . . . . . . . . . . . . . 5 Needle bearing for input shaft, renewing . 30
Clutch, repairing . . . . . . . . . . . . . . . . . . . . . 7 Needle bearing for pinion, renewing . . . . . 34
Clutc h master cylinder, removing
and installing . . . . . . . . . . . . . . . . . . . . . . . . 5 Output shaft, removing and installing . . . . 18
Clutch operating cylinder, removing Output shaft, adjusting . . . . . . . . . . . . . . . . 53
and installing . . . . . . . . . . . . . . . . . . . . . . . . 5 Output shaft, dismantling and assembling . 34
Crown wheel, adjusting . . . . . . . . . . . . . . . 55
Crown wheel and pinion, renew ing ... 34, 41 P inion beari ngs, renewing . . .... . ...... 34
Crown wheel and pinion, adjusting . . . . . . 50 Pressure lines/ hoses for clutch,
removing and installing . . . . . . . . . . . . . . . 5
Differential, removing and installing . . . . . 14 Pinion, adjusting . . . . . . . . . . . . . . . . . . . . . 53
Differential, adjusting . . . . . . . . . . . . . . . . . 55 Pinion, removing and installing . . . . . . . . . 18
Differential housing, renewing . . . . . . . ... 41 Pinion, d ismantling and assembling 34
Differential, dismantling
and assembling . .. . . .. . ..... . . ....... 41 Release bearing, removing and installing . 5
Differential bevel gears, renewing ... . . . . 41 Ratios ........... ... . .... . .... . ..... 2
Differential bearings, renewing ... ...... 41
Drive flange oil seal, renewing . . . . . . . . . . 40 Shift rods, removing and installing . . . . . . 9
Sync hro hub and sleeve for 2nd/ 3rd gear,
Exploded view . . . . . . . . . . . . . . . . . . . . . . 29 removing , installing, dismantling
and assem bling . . . . . . . . . . . . . . . . . . . . . . 34
Final drive, adjusting . . . . . . . . . . . . . . . . . 50 Sync hro hub and sleeve for 4th/ 5th gear,
Finding position of pinion removing , installing, d ismantling
(actual tnension) . . . . . . . . . . . . . . . . . . . 52 and assembling .... . ..... . ... . ....... 30
Synchromesh units, repairing . . . . . . . 30, 34
Gearshift shaft oil seal, renewing . . . . . . . 28 Synchronizer ri ngs, wear limits . . . . . . 31 , 37
Gearbox, removing and installing . ... . .. 12 Synchronizer rings, list of . . . . . . . . . . . . . 39
Gearbox, dismantling
and assembling .. . ...... . .. . . 14, 18, 25, 27 Technical data . . . . . . . . . . . . . . . . . . . . . . 2
Gearbox housing, repairing . . . . . . . . . . . . 27 Transmission layout . . . . . . . . . . . . . . . . . . 3
Alphabetical list · V
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Technical data
GEARBOX IDENTIFICATION 5 speed manual gea rbox 094

The 5 speed manual gearbox 094 is instaUed i n
Transporter vehicles in conjunction w ith the
1.9 I carburetor engine and 1.6 I d iesel engine
as an alternative to the 4 speed manual gear-
box.
J.ol-1287
Code letters and date of manufacture

DV 19 08 2
I I I I
Code Day Month Year
letters (82)
of manufacture
Gearbox identification 1
Technical Data
CODE LETTERS, ALLOCATION, GEARBOX RATIOS, OIL CAPACITY
Code letters DV 70 ow 80 ox 90
from : 10.82 10.82 10.82 10.82 10.82 10.82

Manufactured
to:
Manual g.earbox 5 speed manual gearbox 094
Gearbox number 094.1 094.2 094.3
Allocation Model Volkswagen Transporter
Engine 1.91 44kW 1.91 57-60 k;W 1.61 37kW

Diesel
Ratios Final drive 34 : 7 = 4.86 38 : 7 = 5.43

Z2: Z 1 = i
1st gear 37: 9 =4.11
2nd gear 35 : 15 = 2.33
3rd gear 31 : 21 = 1.48
4th gear 57 : 56 = 1.02
5th gear 49 : 64=0.76
Reverse 33 : 9 = 3.67
'
' Oil capacity 3.01 4.01
Specification Hypoid gear oil GL 4 {MIL-L- 2105)

, SAE ,80 or SAE 80- W 90 1
Clutch operation Hydraulic

.
Clutch plate dia. 215mm
Tyres : dynamic roll circumference 1.97m
iove!all in 5th gear .. 3.72 4.16
Speed at n = 2000 rpm 63.57 km/h 56.88 km/h
Remarks
Note:
M220 M 220
M2~~
. '.,~-
M 220 : Limited slip differential ~~
1
) Gearboxes with limited slip differential must only be filled with special oil-see Workshop Bulletin
Special Information No. 22 " Gearbox oils for Volkswagen and Audi vehicles" .
2 Code letters, allocation; gearbox ratios, oil capacity

Technical Data
TRANSMISSION LAYOUT DIRECTION OF MOTION
11Ef5ttR-- -r
~~~c=~
3- - -+- !~Ur\--rv
~-- :m
~--:rr
6-__....- ll--- -!-----4
~--~~~~~~2
Designation Ratios
1 Engine I 1st gear
2 - Clutch II - 2nd gear
3 - Gear train Ill - 3rd gear
4 - Input shaft IV - 4th gear
5 Ou~p~--shaft (pinion) V - 5th gear
6 DifM'r.ential R - Reverse
A Final drive
_.
.;.:
.. Transmission layout 3
·~I J;
. -...
., '\-
~,~ .
Technical data
Calculating ratios "I"

Z1 = Teeth on driving gear Driven
Z2 = Teeth on driven gear Driving gear =
Example 5th gear Final drive
Driving gear: Z G, = 64 ZA1 = 7
Driven gear: ZG2 = 49 ZA2 = 34
Gear ratio Axle ratio " iA" Overall ratio " io..,,u"
ZG2 Z A2
Z G1 ZA1 = ioverall
49 34
49:64 = 0076 34 : 7
@
= 4086
64 7 = 3072
Calculating speed "V" Example:

n
v 0
- -
I overall
0 UA 0 0006 v = 20000
3072
01097 0006° = 63057 km/h
n Engine speed (rpm) With an engine speed of 2000 rpm, speed in 5th
iovra ll = Overall ratio gear is 63057 km/h o
UA Dynamic roll circumference
of tyres (m)
v = Speed (km/h)
Calculating ratios "i"

4 Calculating speed "V"
Clutch 30
REPAIRS TO HYDRAULIC CLUTCH CONTROL Clevis
Adjust so that there is a maximum
Split pin of 0.5 mm play between push rod
renew and piston in master cylinder.
_ _ _ _ _ _ _ Spring pin
Fitting position- Fig. 1
Pin Bleeding clutch
Lubricate w ith Connect brake bleeding appliance
multi-purpose VW 1238/ 1 (see also Bleeding brakes,
grease. Running Gear booklet) . Working
pressure 2-2.5 bar.
Open bleeder valve until brake
fluid issues free of bubbles.
Bushes
Knock out with VW 207,
install flush .
wr~~{j~f:~-----------------------Rubberrtop
)Jr.--------- Clutch pedal
Bracket Note:
When work is required on release
bearing or release shaft, gearbox
must be removed
For work on pedal, remove instrument
Pressure line instrument panel. See booklet
front "Body Repair Work".
Connecting piece , - - - - - Bleeder valve
-------llo'·
Open only for bleeding
purposes, hydraulic system
Pressure line should only be bled with
cnetre bleeding appliance.
Pressure line
rear Retaining screw 15 ~1 m
Clutch operating cylinder secures release shaft.
Install rear screw before
fitting. Gu ide sleeve
Bracket for
operating cylind
I Lubricate metal sleeve with
grease. Do not grease
- plastic sleeve.
15 Nm
Pressure hose
25Nm
Circlip
renew
Release shaft
Lubricate with multi-purpose
grease.
Bush for release shaft Bush

Removing- Fig. 2 ·
Spring Inserting- Fig. 3 .
Insert in retain ing clip
and then fit on shaft Release bearing - - . . . . J
together with release Wipe only, do not wash, lubricate
bearing and clip. 30-072 work ing surfaces with MoS2.
Repairs tc;tydraulic clutch control 5

30 Clutch
Fig. 1 Fitting position for spring pin Fig. 3 Installing bush for release shaft flush.
Spring pin must be located in recess- arrow-
on t)1e side of the bracket.
VW771/15
VW771
Fig. 2 Removing bush for release shaft

A - Extractor 18.5 - 23.5 mm,
e. g. Kukko 21 / 3.
6 Repairs to hydraulic clutch control

,
Clutch 30
w~ g
CLUTCH REPAIRS
Removing, installing and checking clutch
Note:
When work is to be done on clutch,
gearbox must be removed .
Important Important
Clutches with damaged or When replacing engines, gearboxes or clutches, it should be
loose riveted connections ensured that the diameters of release bearing and diaphragm
should be replaced .
spring correspond.
Pressure plate
Removing and installing-
Fig. 1
Flywheel Checking for wear and
Check for firm fit on centering pins, distortion- F igs. 2, 3 and 4
contact surface for clutch lining must
be free of grooves, oil and grease.
i I ( (;
(
r l <:
/!;:
/i<IJ
(I
I ' ,'-
( ', )
\' ') '( ~~ ~~',';''.'I

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0) y!
f ,•· .' ~
!,'
,'
( ( r (. •
•) - .,
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.t
Clutch disc - - - - - - - -
Centering - Fig. 1
Checking lateral runout - Fig. 5
Lubricate splines lightly with Hexagon or socket head screw 25 Nm
Moly-paste or Moly-spray. Loosen and t ighten d iagonally in stages.
Watch installation position, spring
cage points towards pressure plate.
30-092
Clutch repairs t-
Removing , installing and checking clutch 1
30 Clutch
Fig. 1 Removing and installing clutch Fig. 4 Check the contact surface for cracks,
Use holder 3067 instead of VW 215c on Diesel signs of burning and distortion
engine. Inward distortion of pressure plate
Mark position- arrow-. max. 0.3 mm.
.. !J0-033)
Fig. 2 Checking diaphragm spring fingers
Scoring up to 0.3 mm deep is acceptable.
Fig. 5 Checking clutch plate lateral runout

Wear limit: max. 0.5 mm
Measure 2.5 mm from outer edge.
Fig. 3 Check the spring connections between

@Q-0321
... ...
pressure plate and cover for cracks,
tightness of rivets and firm fitting.
Clutches which have damaged or loose rivets
should be renewed.
Clutch repairs
8 Checking pressure plate and disc
Controls, Housing 34
REPAIRING GEAR SHIFT MECHANISM
Adjusting gasr shift linkage- Page 10.
Knob ------ff?"""
- '-"'1
Gear lever
Adjusting - page 10.
B
Bush~
Grub screw -.::::::__
M5x8
Spring
~
~
W@
~v
IAl
I Spring
~Locking pin
@
"0--
@)
~ ~
Gear lever bearing - - - - -- - -----,
Assembling: insert shells in rubber bush, Le,,.. plote ~
press lower ball half into shells (the shoulder
of rubber bush must be upwards), insert
spring and install upper ball half by pressing <5--- Upper ball half
shells apart. Press complete rubber bush
fully into lever plate.
t}- Spring
I
~ Lower ball half
8 f } shells
fl!iiiiJ- Rubber guide

~
[U Iff}- Shift g
~
Spacer
Position : shoulder upwards
Mounting plate
Housing of shift linkage
Repairing gear shift mechanism 9

Important Rear shift rod
Lubricate all . .
with special ~~~~~~~~friction surfaces
art No. AOS 126 00 05 Pin
/1
~ ?.. ~ 0
~ 1ri~ :_ un'/'r
Front bu•h Clip
2s:m
• ]
25N..,. /@
. ./,love<
~
~
Fl" onto goonh .,
/ •h•ft In onl ' t
Front sh•"ft rod

Gearshift shaft
Bush
~· Boot
/ .g} Sol~o"ovw
10 Nm
ing
II
<iP~ ' [j-

ck for lock"mgpm
.
·/ .r- SP<Ing pin
r catch
c~~ ~ ~~~!.:. .
~
Rear bush
I 34-1280 I
~ - .~. "..:--·
, ._,
----
...
34 Controls, Housing
w~ q
Adjusting gearshift linkage
Gearbox must be in neutral.
Place lever on gearbox in vertical position

and push gearshift shaft into the gearbox
until spring pressure is felt.
Align centering holes (arrows) in mounting

block and gear lever bearing .
.·
Loosen clip. The shift rods must move easily.

Remove spare wheel.
Move shift rod to the right into 1st/A gear

plane and move longitudinally until dimen-
sion " a" between reverse gear catch and
the stop on the shift rod is
3.0mm
Measure dimension " a" with a 90° offset
3 mm thick strip of metal.
Important
Gearbox in neutral. Lever on gearbox must
be in vertical position. Gearshift shaft must
be pushed in .
10 .Adjusting gearshift linkage

, 134-8801
Check gap between gear lever and heater

trim with 2nd gear engaged .
Dimension " a" must be at least 15 mm.
If this is not so the gear lever mounting must
be moved to the rear in the dongated holes.
Select all gears and check that they engage
easily and without jamming. Particular care
Allow shift rod to spring back to the left into should be taken to check the effectiveness
2nd/ 3rd gear plane and press sl ightly to the of the reverse gear catch.
right (the plastic bellows must make con-
tact on the right with the housing of shift
linkage- arrow).
Important:
Gearbox in neutral. Lever on gearbox
must be in vertical position. Gearshift
shaft must be pushed in.
Firmly tighten clip in this position.
Adjusting gearshift linkage 11

Removing and Installing gearbox

The gearbox can be removed separately (engine
remains in vehicle).
Removing
Disconnect battery earth strap.
Take out top engine-gearbox bolt and
support for throttle cable.
- Disconnect starter wires.

On vehicles with diesel engine: remove
starter.
Detach right drive shaft from gearbox and
hang it up with a hook.
Note:
Hydraulic line remains connected .
- Remove wire for reversing lights.
-
12 Removing and installing gearbox
.... #., .... .,., --...:,
r
Detach gearshift linkage from gearbox. Lower gearbox at front (by turning back
Support gearbox with gearbox lifter V.A.G spindle of lifter), until it can be pulled from
1383. under the cross member.
Remove lower engine-gearbox bolts.
Pull gearbox off engi ne studs and take it
out.
Installing
To install gearbox, reverse the removal proce-
dure.
Notes:
Clean input shaft splines and lubricate
lightly with Moly-paste or Moly-spray.
Tighten front gearbox mounting last.
Tightening torques:
Gearbox to engine (M10) 30Nm
Drive shaft to gearbox 45Nm
Disconnect earth cable from bodywork.

Detach front gearbox mounting from body.
I ·
Removing and installing gearbox 13

DISMANTLING AND ASSEMBLING GEARBOX Drive f l a n g e - - - - - - - - - - -
Pulling off - Fig. 3 ~
Removing and installing clutch housing/differential Installing - Fig. 8
Note:
Before starting work mount gearbox in Locking plate - - - - - - . ......
repair stand- Fig. 1 and drain oil.
Important Adjusting ring, r i g h t - - - - - - .

Before removing and installing clutch housing, Mark before removing - Fig. 4
protect seal from damage by shaft spline. Removing - Fig. 5
To do this fit a piece of sleeving over the shaft. Installing - Fig. 7
Coat thread with MoS2 grease,
dismantling and assembling- Page 41 .
Oil filter plug

20 Nm
Gearbox housing with-------------~

gear train
Dismantling and assembl ing
gear train - Page 18.
Differential - - - -
..._i..., l
~- Removing - Fig. 6
Before removing: remove
adjusting rings and rear
input shaft, d ismantling' ,
and assembling - Page 41 .
;
-
. , l ($illti6":6 - -
~~~
..
. \..
\~'
·,
---------------Cap
renew
- - - - - - - - - - Circlip
renewing, installing- Fig. 9 .
---------------------- Was~
________ Input shaft, rear

Removing:
Remove circlip, push reverse gear back
and screw shaft out.
Installing:
Screw front and rear shafts together
then release one spline; push reverse gear
on and fit new circlip.
Wath different lengths - Fig. 10.
Hexagon head bolt M 8 x 46

with washer (6)
20 Nm
Reverse gear
Stud---'
Circlip
~ Drain
renew
plug
.. ,. '
Clutch housing
20 ~'m
Before removing: loosen left final
drive adjusting ring to relieve ' - - - - Hexagon head bolt M 8 x 28
preload in gearbox housing. -. •~ with washer (4)
Mark position of adjusting ring -• 20 Nm
beforehand- Fig. 4
.
Repairin .-Rage 25.
. '
lsmantling and assembling gearbox
Removing and installing clutch housing/differential
Controls, f1ousing 34
Fig. 4 Determining and marking position of

adjusting ring
Before starting repair work which does not
require the differential to be adjusted again
afterwards, mark the position (arrow) of the
adjusting rings in the gearbox housing and
measure the depth to which they are screwed
in with VW 382/7 and record the readings.
Make one mark on the left side (crown wheel
Fig. 1 Mounting gearbox in repair stand side) and two marks on right side.
Beforehand: Remove gearshift lever and Beforehand : Remove gearshift lever and
switch for reversing lights. switch for reversing lights.
.· .,
...
Convert g~..rbox holder VW 352 in
accordance with diagram
Fig: 5 Removing adjusting rings •
Fig. 3 Pull drive flange out

A = 2 Screw M 8 x 30 bolts through the slots
into the flange.
.•
Dismantling and assembling gear.bofl
Removing and installing clutc~h houstng/differential 15
Fig. 6 Lift differential out
Fig. 9 Installing circlip

Install washer and circlip.
Press c irclip into groove and ensure that wash- .
er is central.
Fig. 7 Installing adjusting rings

Screw adjusting rings into gearbox housing as
previously marked, and set them to the marks
made when removing and to the depth measured.
Important
Do not tighten the left-hand ring until the
clutch housing has been fitted and the nuts
..
tightened .
Fig. 10 Identification of rear input shaft

Dim. a Dim. b Total
length
1.61 diesel engine 3mm 287mm
1.91 carburetor
engine 27mm 298mm
..
Dismantlin-'\Jind assembling gearbox
16 Rem_Oving and installing clutch housing/different!._al
..·...--.,
. . ......
f . ..' . '.
controfs, Housing ...34
•
DISMANTLING AND ASSEMBLING GEARBOX Remove gear wheel for 1st gear and syn-
Dismantling and assembling gear train chron ization for 1st and reverse gear.
Remove 1st circlip for synchronizer hub.
Dismantling
Remove cover for gearshift shaft, remove
gearshift shaft.
'
~ . Turn out screw until the relay lever-arrow-
can be pulled ag~inst the housing.
Turn •in screw
• • •
by
I
hand and thus lock relay
lever m posrtron.
;;
. ~ -
. ;.1 - ,
f ~
Unscrew retai..ning ring. ~~

·;·~ ...~
. .
. .,
' · ..,...,, j
Unscrew cover for bearing carrier.·
Unscrew selector fork for 1st and reverse
gear.
- ~
Dlsmantllng·and.asSeinb_ling gqJMX
./ Dismantlin~ and assefnf!ft'ing gear train· " .
" .•.
·. ••
.(
3~ ~ontrols, Housing
\
Assembling
30-100
I 35- 691 I
Press out gear train.
Secure VW 457 with two screws M 8 x 20.
Remove shim " S3 " Note thickness.
Remove circlip for input shaft.
VW401
134-13171
Press in input shaft with gearshift rail.
J..._..---- vw 411
Fit pm1on with gearshift rai~. To do this

engage 4th gear.
- Put gearbox into neutral and fit needle be-
aring for pinion.
t.
Press out input shaft with pinion and gear-
shift rails .
- .,.
,...
"-
. -\
Dismantling and a8sembl.lng gearbo~
DismantUf!9 ,al)d, emblmg gear tfam
Tighten retaining ring to 225 Nm, loosen

and then finally tighten to 225 Nm.
Place circlip for input shaft in position.

Lugs on circlip must be under the teeth -
arrow-, notches or raised parts (anti-rota-
tion) grip over the teeth .
Installing gear train / •

" S3 " and new gasket. Align gearshift rails.
Align double hex. of the double roller bear-
ing with recess in gearbox housing ..
Fit gear train onto pinion by hitting with a
plastic hammer. Check free movement . of
parts.
- Secure retaining ring at two points by peen-
ing.
A -self-produced peening tool.
- Screw bearing carrier to gearbox housing-
20Nm.
'
/,_;J IIunantllng and assef!tbllng gearbox

_.1 1\smantling and assembling tear train
..
I
Determining the thickness of thrust washer for Fit thrust washer determined, gear wheel
reverse gear for reverse gear with needle bearing and
2nd circlip.
YVW244b
134-13391
Fit circlip and measure dimension " c ".
Example: 29.1 mm.
Measure dimension " d".
Example: 24.7 mm.
j34- 1305j
Dimension c
- Dimension d - Push on synchromzer hub.
= Adjustment range Fit 1st circlip.
Example: - Fit reverse idler gear with needle bearing
c = 29.1 mm and washers.
- d = 24.7 mm Position: The chamfers on the' teeth tb the
4.4mm cover.
- Fit synchromesh unit for 1st and reverse ge-
ars with selector fork.
Determining thrust washer from table
Position: the molybdenum-coated synchro-
nizer ring to gear wheel for 1st gear.
·Adjustment Part No. Colour
range (mm) - Secure selector fork on gearshift rail. Coat
screw with 06 and tighten to 20 Nm.
3,97 ... 4,19 091 311 379 white Fit gear wheel for 1st gear with needle
bearing.
4 ,20 . . . 4,39 091311379A black
4,40 . . . 4,59 0913113798 green
4,60 . .. 4,90 091311379C

I
red
"\
.-
·~-
Dismantlln§ and assembling gearbox

Dismantling and as~embli ng
' • ;i·
Determining thickness of shim for gear wheel1 st gear
134 - 13381
Adjustment range = a- b Dimension b = >..
. ....""
··,
;~
~ .,f;;r - Measure dimension " x".

Example: x = 77.6 mm
. .... .,
Measure dimension " a"

Example: a= 77.8 mm.
134 -13371
Measure dimension " y"

Example: y = 1.0 mm.
-.
I•
Dismantling and assembli~ gearbox

Dismantling and assembling geartrai.p 23~
..
' .
.34 Controls, Housing
x-y
Example:
b = 77 .6 mm
- 1.0 mm
76.6 mm
Adjustment range = a - b
= 77.8 mm,
- 76.6 m'rn
1.2mm
Determining shim from table.
Adjustment Shim Part No.

range (mm)
0,95 . . . 1,14 0,6 094311379
1 '15 . .. 1,34 0,8 094311379A
1,35 . .. 1,54 1,0 09431"1379 8

. -..
'
1,55 . .. 1,74 1,2 094311379C
1,75 ... 1,94 1,4 0943113790
1,95 ... 2,14 . 1,6 094311379 E
2,15 ... 2,47 1,8 094311 379 F
Fit sh im determined and new gasket.
- · · Fit cover (if necessary, align shaft for reverse

·. idler gear) and t ighten screws to 20 Nm.
Loosen screw for relay lever, push relay
lever in and t ighten screw to 20 Nm.
- . 1A·stall gearshift shaft.
POsition: Slotted side of bracket towards
differential.
Press new oil seal into the profile of the
cover, place cover in position with spring
and tighten screws to 15 Nm.
Fit switch for reversing lights and lever for
gearshift shaft after having removed the
\
gearbox from the repair stand.
...
!
Dismantling and assemblln ile4px
ismantling and assembli_ng geartr.ain .1
·.
DISMANTLING AND ASSEMBLING GEARBOX

Repairing clutch housing
-.
:
Retaining scr·wr-------,
15 Nm ide sleeve
45 Nm Lubricate metal sleeve with MoS2
grease. Do not grease plastic sleeve.
bush
Pull out- Fig. 3
Drive in- Fig. 4
Can be renewed with gearbox
installed.
Operating
cylinder bracket Release shaft
Lubricate with multi-purpose
Release Bush
Removing and .
shaft bush install ing - Page 5.
I
~·
!\-spring
I
- - Retaining clip
Clutch lever
Lightly grease ball
Release bearing • .
\ Do not wash, wipe with.
Circlip dry cloth. ·
renew ' - - - - - Drive shaft oil seal
Pull out - Fig. 1
Drive in - Fig. 2 ·-
Drain plug Fill space between lips w ith
20 Nm multi-purpose grease.
I 35-6971
...... _
....
...
.. •.
-:·. Dismantling and assembling gearbox
~
25 '
Repairing clutch housing
•
34-28 4
Fig. 1
Fig. 3 Removing starter bush
(gearbox Installed)
When gearbox is out, use drift VW 222a to
knock bush out.
Fig. 2 Knocking input oil seal in
Fig. 4 Knocking in starter bush flush
-
Dismantling and assembling gearbox
26 Repairing clutch housing
..
controls, Housing 34
DISMANTLING AND ASSEMBLING GEARBOX
Repairing housing
Cover for bearing carrier - - -
Bearing for pinion

Removing and installing- Page 34.
Gearshift rail bearing

Amoving and installing- Fig. 4.
Bearing shells
Unclip to remove the gearshift
rail.
Gearshift rail
for 1st apd reverse gear
Bearing outer race/needle bearing

for pinion
Removing and installing - Page 34.
·~
..,
..:·
Repairi ng housing 27
- .
Shaft for reverse idler gear
Also secures bearing for input
shaft against torsion . Install such
that the outer race of the
bearing is corered uniformly.
Bearing for input shaft

Pressing in and out- Page 30.
Retaining screw for relay lever
20 Nm
Bearing carrier
Bush
Position : lug to
bearing carrier.
Oil seal
For gearshift shaft.
Removing- Fig . 1
Pressing in - Fig. 2
Can be renewed with
gearbox installed.
Needle bearign for

input shaft Gearshift rail· bearing
Removing and installing - Removing and
Page 30. installing- Fig. 4.
Spring pin
Guides the bracket of Gearbox housing
the gearshift shaft If renewed: adjust
Position: slot of spring pinion to position
pin towards centre of measured befo~e
gearbox. removal (actual
Depth - Fig. 3. dimension), Page 52
Modification- Fig. 3. Adjusting crown wheel,
Page 55.
134-1320 1
.i
,,
..
134-13401
Fig. 1 Pressing out oil seal for gearshift shaft

Fig. 3 Installation depth of spring pin
Beforehand : remove gearshift shaft
Install so that the slot po ints towards the centre
of the gearbox.
Note:
As from assembly date 11 102, this spring pin
is replaced by a pin. The housing surface is
machined. Knock in pin as far as stop.
Fig. 2 Knocking in oil seal for gearshift shaft

Remove wire ring .
Knock in oil seal with 3077.
Re-fit wire ring.
134-13411
Fig. 4 Removing and installing gearshift rail

bearing (
In order to remove, turn gearshift rail bearing
so that the lug (arrow) is above the recess in the
housing. Press out gearshift rail bearing.
.., ... ·.
When installing, align the gearshift rail bearing
to the gearshift rai l.

Repai-ring housing
Gears, Shafts 35
GENERAL VIEW
4th gear--,
1st gear - - - - '
i-
Ciutch housin!
...
General view
·-
--
Gearbox housing
3rd gear
..
2nd gear
, .·
Input shaft
Disma.r\tling and
assembling - Page 30 .
·~·"
...
..
. ... ,.
. . ..
~ .
,r ...
,.
DISMANTLING AND ASSEMBLING INPUT SHAFT
Note:
When installing new gears
or pairs of gears, see
Technical Data, page 2.
Sleeve
Synchronizer hub -----._
Locking key~
Spring
Wire dia. 1.6 mm
Circlip
Position - Fig. 12
Fastening screw for

needle bearing <; N f1
··0
f · •. B:!i.,wc, .
·, ,~~ .!'j ' 0
~~~~ t'J II
~-
i,,
..
•.; Bearing carrier
?.~~s~ ~
0 .
Synchronizer ring for 5th gear
Checking for wear- Fig. 2
~ I '-e '>~ ; - ; """'
Identification - Page 39.
Needle bearing for 5th' gear
Lubricate with gearbox oil before fitting: ...
-
••
)
•• t
>I
•'
35 Gears, Shafts
s~;u.
Needle bea1 iny
Removing - Fig. l!!t I
Installing- Fig. tJ-. ~ .J. t:..r
,1. ~-:; "") •
Circlip
J . - - - Needle bearing
K"Tlocking out- Fig. 8
Knocking in - Fig. 9 .
I
1{
Q\
/)~~
Jr- Gearbox housing
4th gear needle bearing .
Before fitting, lubricate with
gearbox oil.
4th gear wheel
Synchronizer ring for 4th gear ~ .·

Check for wear - Fig. 2
Circlips
for synchronizer hub,
renew.
35-876
-
Gears, Shafts 35
I 35 -8781
Fig. 1 Pressing sleeve and synchronizer hub
off together with 4th gear wheel
Fig. 3
.
Assembling sleeve and synchronizer
hub for 4th and 5th gears
Position: The identification grooves (arrows A
and B) of sleeve and synchronizer hub lie in
opposite positions. The groove of the sleeve-
Arrow B- towards 5th gear wheel.
The grooves- Arrows C- serve to d ~stinguish
between the sleeves for 2nd and 3rd ~ears (one
groove) and 4th and 5th gears (two grooves).
Fig. 2 Checking synchronizer rings

Press rings onto cones of gears and measure
gap " a" with feelers.
Gap " a" New Wear limit
4th+ 5th gears 1.0-1.7 mm 0.5mm
Fig. 4 Assembling sleeve and synchronizer

hub
SHde sleeve over synchronizer hub in any
position.
Fit locking keys and spring with ends offset
120°. The angled end must fit in the hollow
key. ·
Dismantling and assembling input shift
... ..
35 Gears, Shafts
t
l Fig. 7 Pressing input shaft bearing fully into
bearing carrier
Press in so that the milled edge of bearing
aligns with recess in beari ng carrier (arrow).
Fig. 5 Press on sleeve with synchronizer hub

Turn synchronizer ring so that the grooves are
aligned with the locking keys.
Position: The identification groove on the sleeve
(Fig. 3, Arrow B) towards 5th gear wheel.
Fig. 8 Knocking needle bearing out

of gearbox housing
j34 -1329j
.~
Rg. 6 Pressing bearing out of bearing carrier

Beforehand : knock out shaft for reverse idler
gear.
'l- •
..
Oismantl~ng and a•sembllng input shaft

Gears, Shafts 35
Fig. 9 Knocking needle bearing into gearbox Fig. 11 Knocking needle bearing into cover
housing until stop of bearing carrier
Note Tighten securing screw to 5 Nm.
When knocking the needle bearing in, apply
the drift VW 295 on the lettered side of bearing
(thicker metal).
Fig. 12 Fitting position of the circlip

L ugs of circlip must lie below the teeth .
Notches of raised parts (anti - rotation) grip
over the teeth.
·~-.. fig . 10Removing needle bearing from cover
·~ • of bearing carrier
Beforehand unscrew fastening screw.
A = Extractor 18.5 - 23.5 mm , e. g. Kukko 21/3.
B = Support, e. g. Kukko 22/2.
,. •'
:j
Dismantling and assembling input shaft

DISMANTLING AND ASSEMBLING PINION
Note: Synchromesh unit for 1st
When installing new gears or gear pairs, and reverse gear
see Technical Data, Page 2. Position: molybdenum-conted
synchronizer ring towards 1st gear
wheel.
1st circlip
for synchron izer hub
Synchronizer hub for .1s
Shim for 1st gear - - - - - - - . and reverse gear
Determine thickness-
Page 23 2nd circlip
fo r synchron izer
hub.
Bearing for pinion

Removing- Fig. 17
Pressing in- Fig. 18
Needle bearing
Insert with gearbox o~l
1st gear wheel
Sleeve ------------""~
Synchronizer hub - - - - - - - - . . .
Secures the inner race/needle
bearing for 2nd gear
Locking key
Spring
Wire dia. 1.6 mm -
,.
I
Circlip
for synchronizer hub, must
fit properly in groove.
Sleeve/synchronizer hub for - - -- --""'

2nd and Jrd gears
Pr8$~ng off - Fig. 2
Assembling - Figgs. 10 and 11
Pressi f!9 on - Fig. 12
}
" Synchronizer ring for 2nd gear
·,
~
_.. Checking for wear- Fig. 9
Identification - page 39.
.' 2nd gear wheel ----~
-
35 Gears, Shafts
Bearing carrier
Circlip
Thrust washer for gear wheel/ renew, must fit properly in
reverse gear the groove.
Determining thickness - Page 22
Circlip
for 4th gear wheel ·
Renew, must fit properly in
the groove.
Determining thickness- Fig. 14
3rd gear wheel
...
.
,. ~·
~
·.
'
'•••
~
~
Needle bearing 4th gear wheel

Knocking out- Fig . 15 Pressing off- Fig. 1 ·
Pressing in- Fig. 16 Pressing on- Fig. 13
Position : shoulder towards 3rd
'----- Gear wheel for reverse gear gear wheel
\ . . . . . - - - - - Needle bearing 5th gear wheel

Insert with gearbox oil Position: circular groove towards
bearing carrier.
- - - Double roller bearing

Pressing off- Figs. 3 and 4
Fit warm and press home- Fig. 5
If renewed, measure position of
pinion before dismantling
(actual dimension) . See page 52 Shim S3
Checking turning torque- Figs. 7 Note thickness
and 8. · Adjustment table - page 52.
jj Gearbox housing
Washer
Jnner race/needle bearing

1-or 2nd gear
.lossen!ng and tightening - Fig. 6
• s secured against turn ing by a
collar on the synchronizer hub. Pinion
Matched to crown wheel (gear set)
• . If gear set is renewed : adjust pinion
'.leedle bearing and crown wheel, page 50.
=or 2nd gear.
Jil befor~ fitting. 35-881
Dismantling and assembling pinion

Gears, Shafts 35
VW411
Fig. 1Pressing off 4th gear wheel with

3rd gear wheel
l A- Partingtool22-115mm
e. g. Kukko 17/2.
r 135 - 8871
Fig. 3 Pressing double roller bearing off via

outer race
First unscrew inner race/needle bearing -:::_..s ee·
Fig. 6.
•,
Rg. 2 Pressing off sleeve/synchronizer

hub with 2nd gear wheel
A - Parting tool 22- 115 mm
e. g. Kukko 17/2.
Secure parting tool behind coupling teeth of 135-8881
gear wheel.
"' Fig. 4 Pressing off 2nd inner race
A - Parting tool12- 75 mm
I
e. g. Kukko 17/1 .
35 Gears, Shafts
Fig. 7 Checking turning torque of double

roller bearing
A = Normal tor.que gauge (0 - 600 Ncm)
Oil bearing beforehand with hypoid gear oil
and t ighten reta ining ring as specified .
First turn pinion rapidly in both d irections
about 15-20 times, then read the torque while
sti ll turning.
Fig. 5 Heat inner races of bearing to about
100° C, install and press home Test values
Before tightening the needle bearing inner New bearings Used bearings *)
race, allow double roller bearing to cool to
Torque up to 210 Ncm upto70Ncm
room -temperature.
*)After running at least 50 km
..
Fig. 6 Loosening or tightening needle

bearing inner race
Tightening: Heat inner race to about 60° C and
screw on as far as possible by hand.
Place pinion in appliance 2052 and tighten Fig. 8 Check rock
wing bolt lightly. If there is n? ~orque, check for rock i n beari ng
Tighten inner race to 210 Nm and t_hen check at end of pm1on shaft. There must not be any
turning torque of double r~ll.er beanng. det~ctable rock otherwise a new bearing must
be f1tted .
36 Dismantling and assembling pinion

Gears, Shafts 35
Fig. 9 Checking synchronizer rings

Press rings onto cones of gear"s and measure
gap " a" with feelers.
Gap " a " New Werarl imit

2nd + 3rd gears 1.3- 1.9 mm 0.5mm
hub
Slide sleeve over synchronizer hub in any
position.
Insert locking key and install springs with
ends offset 120°. The angled end must fit in
the hollow key.
·-·
135-8891

hub for 2nd and 3rd gears VW401
Fitting position:
Groove- Arrow A- towards 3rd gear wheel.
Synchronizer hub collar (anti-rotation for in-
-ner race/needle bearing) towards 2nd gear
wheel. Turn synchronizer hub so that the old
pressure marks on the hub are opposite a tooth
" gap on the bearing inner race.
·t-t!k..~~....... ~
Groove - Arrow B - serves to distinguish
between the sleeves for and 3rd gears (one Fig. 12 Pressing sleeve/synchronizer hub on
groove) and 4th and 5th gears (two grooves). Turn synchron izer ring so that the grooves
aligr:t w ith key~..
Fitting position: see Fig. 10.
l
Di$mantlit)g and assembling pinion

35 0 , Shafts
Fig. 13 Pressing on 4th gear wheel Fig. 15 Knocking outer race/needle bearing
Fitting position: Shoulder towards 3rd gear out of the bearing carrier
wheel.
30-506b
134-3631
Fig. 14 Adjusting 4th gear wheel axial play Fig. 16Pressing outer race/needle bearing
into bea_ring carrier
Measure the axial play of the 4th gear wheel
with a feeler gauge and adjust it by selecting a VW 447h ca n also be used instead of 30-506b.
suitable ci rclip. The play should be between
0.05 and 0.20 mm with lower limit being pre-
ferred .
The following circlips are available.
Thickness (mm) Part No. Colour

1.60 113 311 382 black
1.75 113 311 383 blue
1.90 113 311 384 brown
2.05 113 311 385 grey
2.20 113 311 386 copper
2.30 113311387 brass
2.40 113 311 388 silver
\ ,,
\
38 Dismantling and assembling pinion

J
Gears, Shafts 35
Identification of synchronizer rings

If the rings are not renewed, they must be put
back into the same places.
Standard fitted synchronizer rings
Fig. 17 Removing bearing from cover of

bearing carrier
Beforehand : Lever off thrust bearing and re-
move radial bearing . This destroys the bearing.
A Extractor 30- 37 mm,
e. g. Kukko 21/5. 2nd gear: Special brass ring sprayed with
B Support e. g. Kukko 22/2. molybdenum, 3 x 6 teeth
Identification: 3 lugs
3rd + 4th gears: Special brass ring sprayed

with molybt:lenum. Full outer toothing.
Fig. 18Pressing complete bearing into

bearing carrier cover
VW 447h can also be used instead of 30-506b.
5th gear: Brass ring 3 x 8 teeth. Identification 3

notches.
Synchronizer rings supplied as replacement

parts
091 311 295 A is supplied as a spare part for ail
gears (standard for 3rd + 4th gears} .
.
Disman!ling C!Pd assembling pinion 39
39 Final Drive, Differential
RENEWING DRIVE FLANGE OIL SEAL Installing

(Gearbox installed)
Renewal of the seal is only justified if there is a
lot of oil on seal and gearbox housing or final
drive cover. A light film of oil on the seal does
not justify renewal. This " weeping " is in fact
desirable from a design po int of view as it helps
to p revent the seal lips from running dry.
Removing
Unscrew socket head bolts of drive shaft,
press drive shaft upwards and hang up with
a wire hook.
Pierce cap in flange with screwdriver and
lever it out.
Drive new seal in fully.

Fill space between lips with multipurpose
grease.
t- ....: Screw on lock plate.
Remove c irclip and pull flange out.

A - Insert 2 M 8 x 30 bolts through the slots
,.._...r into. the flange.
Unscrew lock plate.
Installing the drive flange.
Install washer and circlip. Press circlip into
groove with VW 244b and ensure that washer
is central.
Press a new cap in.
Install drive shaft and tighten socket headt ·
bolts to 45 Nm.
Top up gearbox oi l.
Removing seal.
40 Renewing drive flange oil seal

)
'
..
L!t
Final Drive, Differential 39
DISMANTLING AND ASSEMBLING DIFFERENTIAL
Note:
T
If d ifferent ial bearings are renewed,
adjust crown wheel - page 55
Renew both bearings at same time. -:-- - - - - Adjusting ring
Outer race/bearing
(crown wheel side)
Pressi!,11 out- Fig. 10
Pressing in - Fig. 11.
fftir.ini:11~r--t----- Inner race/bearing

(crown wheel side)
Pressing off - Fig. 4
Crown wheel bolts Pressing on - Fig. 7
Use only correct bolts. Pull all
bolts down first, then tighten
diagonally to 50 Nm. ~U----- Differential cover
Pull off - Fig. 3
Position: Oil holes must be
approx ..9QO offset to pinion
shaft. If renewed, adjust ax ial
play, page 45 and adjust crown
Spacer crown wheel - Page 55.
Measure length - Page 45.
Thrust washers
Differential gears, large Check for cracks and chips.
long shaft in housing, short
shaft in cover. If renewed,
adjust axial play, page 45.
Differential gears, small
Differential housing
If renewed : adjust axial play,
page 45 and crown wheel, page
page 55.
~Crown wheel
~ is matched to pinion
<a (gear set)
• Removing - Fig. 2
Pin Installing - Fig..9
Knock in flush. If gear set is renewed, adjust
pinion and crown wheel,
page 50.
Inner race/bearing
(oppos ite crown wheel)
Press off- Fig. 5 · • -- -- - - - Outer race/bearing
Press on - Fig. 8 (opposite crown-wheel)
Pressing out - Fig. 10
Pressing ih - Fig. 11
Note:
Clamp differential in vice to
dismantle - Fig. 1. I Js- 11sl
Dismantling and assembling differential 41

r 39 Final Drive, Differential
Fig. 1 Clamp differential in vice Fig. 3 Pull cover off differential housing
Use vice clamps.
... it 'A%
,.
Fig. 2 Knock crown wheel off housing Fig. 4 Press inner race/bearing off cover
/ pismantling and assembling differential

;;.-
Fig. 5 Press inner race/bearing off housing Fig. 8 Heat inner race/bearing to about
To do this drill a hole in VW 457 / 1 as in sketch 1~ C, place in position and press h~e
(Fig . 6) if not already done.
. . A. .
.
~
-"' r, t .... .
.
Fig. 6 Drill. additional hole (arrow) in

-VW457/1 .
.' a= 8.0 mm, b = 9.5 mm
Fig. 9 Heat crown wheel to about 100° C and

install.
A - Centering pins (local manufacture)
Important
Clean contact surfaces are essential to ensure
that the crown wheel , differential housing and
cover fit properly. Remove all burrs and pres-
sure marks.
Fig. 7 Heat inner race to about 1 ooo C, place

in position and press home
Dismantling and assembling differential 43

Fig. 10 Pressing outer race/bearing out of

adjusting ring
Fig. 11 Pressing outer race/bearing into

adjusting ring
44 Dismantling and assembling differential

Adjusting axial play of differential gears - Insert sleeve and bolt housing and cover to-
The spacer sleeve ensures that the backlash gether with four M 8 x 20 bolts.
between the bevel gears is adequate even
when there is axial pressure on the differential
side gears. If the housing, the cover, one of the
side gears or the spacer sleeve is replaced, the
length of the spacer sleeve for the new assembly
must be worked out again. 387
134-3991
A- M 10 X 25 bolt ... -.. .

Dial gauge extension :
30- 45 = 76 mm long
Measure the shortest spacer sleeve- Part No. 381/13 = 52 mm long
002 517 241 -with a micrometer and mark the
Install dial gauge (3 mm range) and zero
actual dimension on the sleeve with an electric
with 2 mm preload.
marker or similar device. This sleeve should
then always be used as a measuring sleeve and - Ascertain axial play by moving the side gear
should be kept with the measuring device. up and down (red figures).
Add the measured play and length of sleeve
together. Find this figure in the table under
"x" range to obtain correct sleeve.
"x"range Sleeve length Part No.

31 .87- 31 .95 31 .84 002517241
31 .96 - 32.04 31 .93 002 517 242
32.05-32.13 32.02 002 517 243
32.14- 32.22 32.11 002517244
32.23- 32.33 32.20 002 517 245
Take differential apart, remove measuring

sleeve, fit correct sleeve as determined
above, assemble differential again (without
shaft) and recheck the play.
If the sleeve has been selected correctly the
play should be
from 0.03 to 0.17 mm.
·.
Place side gear (short shaft) and both thrust
washers in the cover, fit clamping sleeve
VW 381 / Sa and clamp bevel gear hard
against the cover.
- . Place side gear (long shaft) in the differenti-
al housing.
Dismantling and assembling differential

Adjusting axial play 45
DISMANTLING AND ASSEMBLING LIMITED SLIP DIFFERENTIAL
Locking effect approx. 45 %
Note:
Gearboxes with limited slip
d ifferent ials must be f illed
with special oil. See W. B.
Special Information No. 22
"Gearbox oils for VW and Audi :'.
+----Differential cover
Mark position on housing -
Fig. 1
Pull ing off- Fig. 2
Pressing on - Fig. 3
Dished washer
Thrust washer
2 .3 mm th ick
Inner spl ined plates

(4)
Finding thickness of plate set- Outer splined plates (4)

Figs. 4 - 9 Find thickness- Figs. 4- 9
Use special o il when assembling
parts.
Differential pinion shafts
Differential gears, small
Removing and installing bearings

and crown wheel, page 41. Differential gears, large
Pressure ring
Spacer
(4)
Differential housing
10 Nm
I Js-120 I
~ 46 Dismantling and anembllng lim ed slip differential

Fig. 1 Marking position of cover and housing

Fig. 3 Pressing cover on
Ensure that marks are al igned.
Determining thickness of plate set

When new parts are installed, the thickness of
the plate set must be determined. This is done '!t,
by measuring the housing , cover and plate set -· ;\..
separately.
134 -388 1
Fig. 2 Pulling cover off housing Fig. 4 Measure housing depth "a"
Example : a = 93.80 mm
Dismantling and assembling limited slip differential 47

ADJUSTING CROWN WHEEL AND PINION

General Instructions
Careful adjustment of crown wheel and pinion is essential to ensure long rear axle service and silent
running . For this reason the crown wheel and pinion are matched during manufacture on special
testing machines to check the contact pattern and silent running in both directions. The position for
the quietest running is obtained by moving the pinion axially with the crown wheel lifted so far out of
the no-play meshing position that the backlash is w ithin the specified tolerance range.
The deviation " r " from master gauge " Ro" used in the special test machines in produciton is
measured and recorded on the outer face of the crown wheel. Each hypoid gear set- pinion and
crown wheel - may only be replaced together.
Crown wheel and pinion marks:
1 2 3
1 2 3
Ro
- R - -Pn - --'
Service gears Production gears
1 The marking " K 738" means a Klingeln- X This detail is not required in production.
berg gear set with a ratio of 7 : 38 teeth. Po - Setting dimension for production.
2 Matching numberofgearset(312).
3 Deviation " r" based on the master Caution
gauge used in the special test machine In production the position of the pinion is de-
in production. The dimension " r " is termined by demension Po (crown wheel
always given in 1/ 100 mm . centre-line to back of pinion head). The mark-
Example : " 25" means that r = 0.25 mm ing of the deviation " r" on the crown wheel
Ro - Length of master gauge used in pro- and the matching number have been discon-
tinued. It is therefore necessary to measure
duction ; " Ro " = 63.00 mm
the position of the pinion before removing it
A Actual dimension between crown wheel when parts which affect the position of the
centre-line and end face of pinion at the pinion are to be replaced. See adjustment
quietest running point for this gear set. table on page 52.
Vo - Hypoid offset = 10 mm
t
Adjusting crown wheel and pinion
50 General instructions
,
I
The gears usually only need readjusting when Practical working sequence for adjustment of
parts which directly influence the adjustment gears:
have been replaced. When fitting new parts, If pinion and crown wheel must be adjusted,
see table on page 52. the following sequence should be observed to
The object of the adjustment is to set the gear ensure rational working :
to the same quiet running position as was
obtained on the special test machine in pro- 1 - Find total screw-in depth "Statal" (S. plus
duction. ~)
The correct bearing preload is obtained
Maximum possible care and cleanliness dur- by measuring the torque required to turn
ing all assembly and measuring operations the crown wheel.
are essential if the results are to be satisfac-
tory. 2 - Adjust pinion (S:l) and check
Adjust position of p inion by placing
shi ms between double roller bearing and
contact su rface on the gearbox housing
so that the dimension from crown wheel
centre-line to pinion end face corre-
sponds as nearly as possible with the fitt-
ing dimension " R" .
3 - Adjust backlash
Divide " Stotal " into S 1 and S 2 so that there
is a specified amount of backlash bet-
ween crown wheel and pinion.
S, = Screw-in depth of adjusting ring

(crown wheel end)
S2= Screw-in depth of adjusting ring
(opposite end)
S3 = Shim for pinion
Adjusting crown wheel and pinion S1

General instructions
ADJUSTMENT TABLE
When working on the final drive, it is only ne- of the transmission have been replaced. The
cessary to adjust the pinion, crown wheel or following table should be noted in order to pre-
both if parts which directly influence the setting vent unnecessary adjustments being carried out.
To be adjusted Pinion (S3) Pinion (S3) Crown wheel

from actual from devi- (S1 and S2)
dimension ation " r"
Part renewed Page 52 Page 53 Page 55
Gearbox housing X X
Adjusting rings for final drive X
D ifferential housing X
Cover for differential housing X
Dif ferential roller bearings X
Double roller bearing for pinion X
Crown wheel and pinion X X
FINDING POSITION OF PINION
This work need only be carried out if deviation

"r" is not given on crown wheel and parts
wh ich affect the pinion position are to be
renewed. These are:
Double roller bearing for pinion
•!f•J and gearbox housing.
Take differential out.

Assemble measuring bar as described on
page 53 and place it in gearbox housing.
- Set universal gauge VW 385/ 30 to Ro =

63,00 mm and place it on bar. Zero d ial gau-
ge (3 mm) with 1 mm preload.
- Measure difference from " Ro " (max. de-
flection, reading red figures). The measured
value equals deviation " r" .
Example: 0.25 mm.
When parts have been renewed , the p1n1on

should be adjusted as described on pages 53
and 54.
The deviation " r" as measured is then used
when determining the thickness of shi m " S 3".
·•
Adjustment table- Finding position of pinion (actual dimension)

' I
J ~
,I '
ADJUSTING PINION
(Adjusting output shaft)
The pinion only needs adjusting as described
here if the gears themselves have been renew-
ed . If other parts which affect the position of
the pinion are to be renewed , the setting must
be measured before dismantling and set to this
dimension on assembly. See page 52 for table
of adjustments.
Assemble pinion up to needle bearing for
1st speed gear wheel , tighten needle
bearing inner race to 210 Nm.
Place measuring plate VW 385/ 17 on end of

pinion.
Place bar in housing and screw 2nd adj ust-
ing ring in until it is also flush with housing.
Move the 2nd centering ring outwards with
the movable setting ring until the bar can
just be turned by hand.
Note
To screw the 2nd ring in a wrench can be
made from a lock plate and a piece of strip
metal, as shown in illustration.
- Install pre-assembled pinion in the gearbox

housing without shim " S3 " . Install retaining
·. ring and tighten to 225 Nm first then back it
off and tighten to 225 Nm again.
Finding dimension "e"
- Screw adjusting ring into gearbox housing
until it is flush with housing.
- Adjust setting ring on measuring bar VW

385/ 1 to dimension " a" .
a= approx. 75 mm
VW385/ 16
VW385~7
Set universal gauge VW 385/ 30 to Ro =

VW385/4 134- 636 1 63.00 mm and place it on the bar. Zero dial
- Assemble bar as shown. Dial gauge exten- gauge (3 mm) with 1 mm preload.
sion VW 385/16 = 12.3 mm long.
Adjusting pinion
Finding dimension " e "
Shims available as parts

Part No. Thickness (mm)
001 311 391 0.15

001 311 392 0.20
001 311 393 0.30
001 311 394 0.40
001 311 395 0.50
001 311 396 0.60
The shim tolerances make it possible to select

any required thickness for " S 3".
Measure shims at several points with a micro-
meter and check them for burrs and damage.
Use only shims which are in good condition.
Turn bar until measuring pin touches plate
on end of pinion and needle deflects to re- Ct:tecking adjustment
turn point. Install p inion with measured shift " S 3" and
The reading is dimension " e".
check the setting.
Example: 0.40 mm.
lfthe shim has been selected correctly, the dial
gauge reading (read anticlockwise, red figu-
Finding thickness of shim "S3"
res) should now show deviation " r" within a
tolerance of ± 0.04 mm.
e Measured figure (max. deflection)

r Deviation (marked on crown wheel in
1/100 mm or found by actual measure-
ment).
Example:
Dial gauge reading " e" 0.40 mm
Deviation " r" marked on
crown wheel + 0.25 mm
...... Thickness of shim "S3" = 0.65 mm
- VW385117
- VW385116
VW385/1
- - VW385/4
· Arrangement of measuring tools for finding dimension "e".
Adjusting pinion
54 Finding dimension " e" and thickness of shim " S 3".
ADJUSTING CROWN WHEEL Fit dial gauge (3 mm) in bar VW 382/7 with
(Adjusting differential) an 18 mm long extension VW 382/9 and
The crown wheel only needs adjusting if zero with 3 mm preload.
adjusting rings Screw adj usti ng ring at crown wheel end i n
gearbox housing with 381 / 15 unti l its upper edge is 0.20 mm
differential housing cover below surface of housing.
differential bearings Screw other ring in w ith VW381/15 unti l the
differential housing or d ifferential is held free of play and without
crown wheel and pinion preload.
have been re new ed . Fit sleeve VW 381 /Sa on crown wheel side
Adjustment table, Page 52. dand lock it w ith hexagon nut.
Turn gearbox so t hat d ifferential is at the
Finding total screw-in depth '' Stotel". top and place bridge VW 381/8 on the dowel
(Adj usti ng beari ng p re load ). pi ns.
Pinion out.
Note!
It is essential to the measurements that the rol-
ler bearing outer races are pressed fully home.
Press home if necessary.
- Install differential complete with crown
wheel in housing. The crown wheel is on the
left.
vw 382/7
vw 381/15 \_vw 3B!J Sa
Arrangement of tools when adjusting bearing preload.

rrT
Adjusting crown wheel
Fi nd ing " S rota•" 55
A = Torque gauge (0- 600 Ncm). Measure provisional depth to which the ad-
Install torque gauge with a 19 mm socket. justing rings are screwed in, "S," and"~"
Turn differential in both directions while (Statal) with the measuring bar VW 382/7.
oiling the bearings with hypoid gearbox oil. Note the readings.
Increase the bearing preload slowly by screw- Mark adjusting rings (arrow) and do not in-
ing in the adjusting ring (opposite end to terchange them.
crown wheel ) with VW 381/15 while turning
the differential rapidly and continue until Note
the specified preload figure is reached. If crown wheel and pinion are being reset,
the pinion adjustment and check should
Adjust as follows: now be carried out (se page 53). Differential
must be removed to do this.
New Used
bearings bearings* Adjusting backlash
Pinion with S3 installed.
Torque 300- 350Ncm 30 - 70Ncm
Install differential and screw in adjusting
* after running at least 50 km . rings on correct sides.
Fit spacer bridge VW 381/8 again. Turn the
differential and at the same time screw the
adj usting rings in until the provisional
screw-in depths, and S2 i obtained again. In
this way, the preload on the bearings wh ich
was obtained by the turn ing torque test is
obtained again. (S total).
t
I
•1
I
-
Adjusting pinion
Finding " 8 1018(
Adjusting backlash
Important
• If the readings obtained vary by more than
0.06 mm from one another, there is something
wrong with the installation of the crown wheel
or the gears themselves. Check al l assembly
operations and renew crown wheel and pinion
if necessary.
Screw adj usting ring at opposite end to

crown wheel out from the provisional
screw-in depth "~" and adjusting ring at
ring gear end in by the same amount. The
position of the adjusting ring at opposite
end to crown wheel must be rectified after
screwing in adjusting ring at crown wheel
end because of t he preload. Keep w ithin a
Install measuring tools.
tolerance of ± 0.01 mm when doing this.
Press bracket VW 381/7 onto two crown
wheel screws as far as it will go. Note
S1 +~must always add up to Stot.l otherwise
the bearing preload has been altered.
Keep adjusting the rings until the backlash

is 0.15-0.25 mm.
Note:
In order to obtain the required backlash quick-
ly, the measured backlash minus 0.20 mm can
be assumed for the 1st setting of adj usting
rings.
Checking backlash.
It must be measured at four points goo apart
and should be
0.15-0.25 mm.
Note
Fix pinion. The ind ividual readings must not differ from
A = M 8 x 125 bolt. one another by more than 0.05 mm.
Turn crown wheel to stop, set dial gauge to
l zero. Turn crown wheel in opposite direc-
tion and read off the backlash. Note the
figure.
Take bracket off.
After turning crown wheel goo each time,
take three more readings.
Adjusting crown wheel

Adjusti[lg backlash 57
..
' .·~
V.A.G Service.
Workshop Bulletin.
Volkswagen Transporter No.9
5 - Speed Man ual Gea r box 094
To be marked in Manual: Decembe r 1982 Ed i t i o n of, o. 88
Pages: 7, 9, 1 0 & WB No . 7
Page
A - Ho~if!ed gear lever bearing 2
• B - Amendments 3' 4
1. Greasin g joints and slidin g surfaces

of select o r mechanism
2. Repairin g clut c h
3. Ad j ustin g bellows at front of rear

selector rod bearing
Printed in Germany
000 . 5 7 26 . 09 . 20
82
A - Modified gear lever bearing
-.From 06.88, there are no location bores

(arrows) in the gea r lever bearing (gear
lever bracket). The modified gear lever
bearing was introduce d gradually .
•
Adjusting the modified g ear lever
bearing
• After loosening the retainin g nuts (not

illustrated), twist gea r lever bearin g
to the ri gh t or left until the retaining
pins on the mountin g plate touch the slots
on the opposite side of the g ear lever
bearing (arrows). Tightening torque of
retaining nuts 10 Nm.
The remainder of the adjusting procedure

.
is to be performed as described in the
Workshop Manual.
Note :
The modified gea r lever bearing can be
installed in veh icles from 10.82.
2
B - Amendments
1 - Greasing of joints and sliding surfaces in selector mechanism
To grease the joints and sliding surfaces in the selector mechanism ~
Molycote _greqse - Part No. G 000 6?2 should be used instead of whit e
solid lubricant paste - Part No. 126 000 005. Before applying the
Molycote grease , the white solid lubricant paste should be removed
from joints and sliding surfaces.
~ 2 - Repairing clutch
Greasin g of gear teeth on drive shaft and clutch plate hub:
The g ear teeth of the clutch plate hub are not to be greased with
Moly lubricant or Moly spray, as previously described in the Work -
shop Manual, but with grease Part No . G 000 100.
- Remove corrosion and abrasion from gear teeth of drive shaft and
clutch hub.
•
- Thinly coat gear teeth with grease •
- Lock drive shaft by selectin g a gear and reseat clutch plate

on drive shaft and check that it can move freely.
- Always remove excess grease to prevent it coming into contact

with the clutch linin g .
000 . 5726.09.20 3
3 - Adjusting bellows at front .of rear selector r:od bearing
The front bellows i~ot attached to the

selector rod with a hose clamp as indi-
cated in Workshop Bulletin No . 7 -
Edition 06.87.
D
The hose clamp is attached to the
selector rod in front of the bellows.
Distance "a" = 60 mm.
4
V.A.G Service.
Workshop Bulletin.
Volkswagen Transporter No. 8
File in booklet:
5 speed manual gearbox 094 of 02.88
December 1982 Edition
Page to be marked: 5
Self-centering release bearing
We have reason to point out that

new release bearingsJ on which
the thrust ring is not centrally
positioned to the housing carrow)J
can still be installed without
giving any cause for concern.
jJ0 -3261
The thrust ring centralises
itself automaticallyJ after the
first operation of the clutch
pedal.
...
82 Printed in Germany 000.5726.08.20

V.A.G Service.
• Workshop Bulletin.
Volkswagen Transporter
File in booklet:
5 speed manual gearbox 094
No.7
of
Ed i tion December 1982
Page to be marked: 06.87
• Modified rear shift rod mounting
From 05.87 a boot is fitted each side of the shift rod mounting
bushJ to prevent the lubricant from being washed out of the
bush .
•
•
1 --
I
~ •
2
•
• 1 - Lever
o Cincorrectly shown on page 9)
2 - Screw M8 x 40
3 Flange on bearing carrier for mounting the support plate

o Fig. 1
4 - Shift rod bush

o With groove for locating the boot
5 - Boot
•
o Adjusting - Fig. 2
5 - Hose clip
o Install so that the front boot is properly located -
Fig. 2
Fig. 1 - Flange on bearing carrier

previous dimension
a= 14.5 mn
Flange on bearing carrier
modified dimension
a = 21 mn
• The flange on the bearing carrier

for mounting the support plate
has been increased to 21.0 mm .
This repositions the shift rod
bush 5.5 mn further foreward .
This prevents the rear boot from
being over compressed and causing
the gear to jump out.
When carrying out repairs the
modified bearing carrier can
be installed from build date
10.82.
000.5726.07.20 3
Fig. 2 - Adjusting the front boot ~
in neutral dimension
a 56 mn
=
arrow points in direction
travel
Note:
The modified shift rod mounting
can be installed with the previous
bearing carrier. To do this fit
a nut M8 x 6.5 - N 011 008 18 -
between flange and the support
•
plate. Use screws M 8 x 40 -
N 010 340 4 -
4
V.A.G Service.
Workshop Bulletin.
File in booklet: 5 speed manual gearbox 094 of 10.86
Page to be marked: December 1982 Edition
Modified circlio
From July 1986 a modified circlip is being installed for the

input shaft ball race.
• A
A - Old circlip
Part No. 091 311 381
B - Nevi c i r c 1i p
Part No. 091 311 381 A
B
!Js-loaol
Note:
The old type circlip will be discontinued once stocks have
~ been exhausted. Until then either type of circlip could be
installed in service. The circlip must always be renewed.
Removing and i nstalling the modified circlip
Removing: Remove circlip using two equal length screwdrivers.
Installing: Press the circliP into the input shaft groove with
a pipe wrench. The markings Carrow) face the reverse
gear splines .
•
V.A.G Service.
Workshop Bulletin.
File in booklet: 4 speed manu a 1 g ear b ox 0 9 4 of 02 .8 6
REPAIRING GEARSHIFT LINKAGE
The white lubricating paste - Part No. A05 126 000 005 previously
used for greasing the joints and friction surfaces on the gear-
shift linkage has been replaced by
Holy grease - Part No. G 000 602 •
• Note:
If the gearshift linkage is to be greased in service with Moly

grease~ the white lubricating paste previously used must be
completely cleaned from joints and friction surfaces first .
•
a 2 Printed in Germany ooo. s 7 2 6 . o5 . 2 o
V.A.G Service.
Workshop Bulletin.
File in booklet: 5 Speed manual gearbox 094 of
Page to be marked: 41 02 / 85
Differential with four pinions
In conjunct i on with the 2.1 litre 82 kW fuel injection engine

the differential has four pinions .•
The changed or new repair operations compared with the

differential with two pinions are dealt with in this bulletin.
The axial play adjustment of the differential gears is not
necessary on the differential with four pinions.
Note:
Code letters, ratios and oil capacities have already been included
in W.B. No. 2

Nr. 4
Workshop Bulletin 5 Speed manual gearbox 094 02/85
Dismantl i ng and assembl i ng different i a l
Thrust washers --------~-----::;;.-........

check for cracks ,-----Pinion
and ch i ps Qty. 4 -
inserting - Fig. 2
Spacer----------------.~
position - Fig. 2 >-----Gears
axial adjustment
Assembly all parts not required
with gear oil
Pinion shaft - long----,

when installing a l ign
hole with housing. ..-----Housing
I"
I
Do not damage thrust
washers.
~~-pinion shaft - -s hort

removing - F i g. 1
S p r i nH'·:~p i n - - - - - - - - - installing - Fig. 2
knock. . in flush
watch position - Fig. 3
Crown w h e e l - - - - - - - - - - '
• • 'r
139-9691
2
Workshop Bulletin 5 Speed manual gearbox 094 02 / 85
• VW411
•
Fig . 1 Pres s short shafts out Fig. 3 Press short shafts
together to one side in together .
after removing long shaft.
Position
The grooves in ends of

shprt shafts must be aligned
with long shaft .
• Fig. 2 Insert pinions with thrust

washers and spacer
- Stick thrust washe rs on with

grease.
Install pinions offset 90°.
- Insert s pacer so that the

larger hole is in line with
long s haft.
- Align long shaft hole with hole

in housing, knock it in and
secure with spring p in .
3
V.A.G Service.
• Workshop Bulletin.
File in booklet: 5 speed manual gearbox 094
No. 3
of 02 / 84
From the start of production to December 1982 a number of

modifications were made to the 5 speed manual gearbox 094 to
improve operation and service life.
To avoid repeat repairs, gearboxes from this production period

should be converted to the December 1982 state when carrying
out repairs.
• This bulletin contains repair instructions and a list of the

necessary service parts for this gearbox, subdivided according
to assembly dates.
Modifications to
- Gearshift shaft . . . . . . . . . . . . . . . . . . . . . . . 2
-Gearshift shaft cover . . . . . . . . . . . . • . . . . 2
- Synchronizer hubs 2nd to

5th gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
• - Shift forks/rails 2nd to

5th gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
List of service parts required . . . . . . . . . • 4
• Printed in Germany 000.5726.03.20 / 82

Workshop Bulletin 5 speed manual gearbox 094 02 / 84
Modifications from Assy. dates 12 10 2, 03 12 2 and 15 12 2
Cover for gearshift shaft r----------large spring

presses gear lever
into 2nd/3rd gear
•
plane
15
~-----up to Assy. date
11 10 2
Spring-----------J
presses gear lever
out of 1st/reverse ""-c---......_- Gearshift shaft
gear plane wit~ small preload
spring
from Assy. date 12 10 2~

Gearshift shaft--------------~
135-9701
Gear lever planelocation altered from Assy. date 12 10 2
The lever plane location of 2nd and 3rd gear by the large spring
and a s mall preloaded s pr i ng in the gear s hift s haft has been
discontinued. The new spring (from 4 speed gearbox 091 / I ) merely
presses the gear lever out of the 1st / reverse gear plane.
Install new ge ars hift s haft and use new spri ng.
The large spring can be installed again in gearbo xes up to

Assy. dat e 11 10 2 so that the d river do es not have to change
his gear s hifting habits.
•
Gearshift shaft cover with guide shoulder from As sy . date 0 3 12 2
Th e cover ·wa s provided wi th a s hould er to locate the s pring

properly. The spring ca n no longer slip out of position when
assembling the parts .
Up to Ass y. date 02 12 2 renew cover and sealing ring.
Gearshift shaft modified from Assy . date 15 1 2 2
The detents for the shift planes in the gearshift shaft were
i mprov e d. Wh e n re pai ri ng gearboxes up to Assy . date 14 12 2
the compl ete gearshift s haft s h o uld b e rene we d.
2
Vol k s wagen Transporter No. 3
Workshop Bulletin 5 s peed manual gearbox 094 02 / 84
Modifi catio n s from Assy . d ates 19 11 2 and 25 11 2
r---- Shift fork/rail

for 4th/5th gears
Bearing
...---- Sleeve/hub
for 4th/5th gears
Shift fork/rail
for 2nd/ 3rd gears
•
Pi nion
Sleeve/hub ------------J
for 2nd/3rd gears 135-971 1
Synchroni zer hub with improved method of

preventing jump i ng out of gear from Assy. date 19 11 2
Th e gear jumping prevention of the synchronizer hubs a nd operating
•
sleeves for 2nd / 3rd gears a nd 4th /5 th gears was improve d .
Th e modifi catio n s cannot b e detected o p tically .
Up to Assy. date 18 11 2 the parts should be renewe d. Only

the improved parts are supplied as service parts.
Shift forks and rails from Assy. date 25 11 2
The shift forks and rails for 2n d / 3rd gears and 4th/5th gears
are we lded as well as riveted. This e nsu res correct location
of the parts to one anot h er .
Up to Assy . d ate 24 11 2 the parts s hould be re n e wed.
3
Work s hop Bullet i n 5 speed manual ge a rbox 09 4 02 / 84
List of service part s required
When repairing a gearbo x , the following new parts may be required

depending on modification state.
•
Th e previous p a rts are not available as service parts.
State Parts required

Designation Part No.
Assy. date depending on state
up to / Gearshift
091 311 534
- shaft
,,~10
,~ 4.e'f r~ m
2
r-
Spring
Synchro hub
091 311 548 B
091 311 241 B

for 2nd / 3rd
l 12 10 2
to - gears
Synchro hub
for 4th / 5th
091 311 301 B
' 18 11 2 gears
r-
from Shift fork 091 311 549 A
for 2nd / 3rd
19 11 2
tq,
24 11 2
-
.......
gears
Shift fork
for 4th / 5h
gears
091 311 559 A
.
~
from Cover for 091 301 232 A
gearshift
shaft
25 11 2
to
-
....... Sealing ring 094 301 278 A
02 12 2
'-...
r-
from Gearshift 091 311 534
03 12 2
to
-
-
shaft
14 12 2
4
V.A.G Service.
Workshop Buletin.
Volkswagen Transporter No. 2*
File in booklet: 5 Speed manual gearbox 094 of
Edition December 1982
Page to be marked: 2 03.88
*Supersedes Workshop Bulletin No. 2 - Edition 10.84
Technical data
4t List of gearboxes
The list of gearboxes showing code letters~ allocation~ ratios

and capacities has been amended and it replaces the list shown
in the Workshop Manual.
New addi tions are gearboxes with code letters ABK~ AGT and
AAR .

Code letters, gearbox allocation, ratios, capacities
5 Speed manual gearbox 094
Code letters DV 70 ow
M anufactured from : 10.82 10 . 82 10.82
to: 1 1. 83 11.83 1 1. 83
Allocation Model Volkswagen Transporter, Caravelle
Engine 1 . 9 ltr . - 41 kW 1.9 ltr . -

44 kW 57 - 60 kW
Ratios Final drive 34 : 7=4 . 857 34: 7=4.857 34: 7=4 . 857
•
Z2 : Z1 = i 37: 9=4 .111 37: 9=4 . 111
1st gear 37: 9=4. 111
2nd gear 35:15=2.333 35:15=2 . 333 35 :15=2.333
3rd gear 31 : 21=1.476 31 :21=1.476 31: 21=1.476
4th gear 57: 56=1. 023 57:56=1.023 57: 56=1. 023
5th gear 49:64=0.765 49:64=0.765 49 : 65=0.765
Reverse gear 33: 9=3 . 666 33 : 9=3.666 33: 9=3 . 666
Speedo drive
Capacity 1) _3_ n .lit.r__e_s_
Specification 2) Gearbox oil GL 4 (Mil-L 2105) SAE 80
Clutch control
Clutch p late dia.
or G 50 SAE 75 W- 90 (Syntheti c oil)
215 mm
hydraulic
215 mm 228 mm
•
Drive Flange dia. 100 mm 100 mm 100 mm
Tyres: Dynamic roll circumference 1.97 m
Overall ratio in top gear 3.72 3.72 3.72

Speed in top gear at 1000 rpm ~2 km/h 32 km/h 32 km/h
(km/ h)
Remarks:
M 220: Differ enti al lock M 220 Strengthened
1) When checking the oil level note gearbox
Workshop Bulletin No. 1 housi ng
2) Gear boxes with di fferential lock
only f i ll wi th gear box oil to Ford
specification M 2 C 104 A.
2
5 Speed .anual gearbox 094
Code letters 80 ox 90
M anufactured from : 10.82 10.82 10.82
to: 11.83 11.83 11 . 83
Allocation Model
Volkswagen Transporter, Caravella
Engine 1.9 ltr . - 1.6 ltr. - 37 kW

57 - 60 kW Diesel
• Ratios Final drive 134: 7=4.857 38: 7=5.428 38: 7=5.428

z2 :z, = i
1st gear 37 : 9=4 .111 37: 9=4.111 37: 9=4.111
2nd gear 35 :15=2 .333 35:15=2.333 35:15=2.333
3rd gear 31:21=1.476 31: 21=1.476 31: 21=1.476
4th gear 57:56=1.023 57:56=1.023 57: 56=1. 023
5th gear 49:64=0.765 49:64=0 .765 49:64=0.765
Reverse gear 33: 9=3.666 33: 9=3.666 33 : 9=3. 666
Speedo drive
Capacity 1) 3.0 ltr. 4.0 ltr. 4.0 ltr.
• Clutch control
Clutch plate dia.
or G 50 SAE 75 W-90 (Synthetic oil)
228 mm
hydraulic
215 mm 215 mm

Speed in top gear at 1000 rpm 32 km/ h 28 km/h 28 km/h
(km/h)
Remarks:
M 220: Differential lock M 220 M 220
1) When checking the oil level Strengthened
note Workshop Bulletin No. 1 gearbox
hous i ng
2) Gearboxes with differential
lock only fi ll with gearbox oil
to Ford specification M 2 C 104 A.
000.5726.02.20 3
5 Spe ed manual gearbox 094
Code letters BH SF BE
Manufactured from: 11. 83 11 . 83 11. 83
to: 7 .84 7 .84 7 .84
Allocation Model
Vo l k s waq e n Tran s po r ter, Carav e lle
Engine 1. 9 ltr . - 41 kW 1.9 ltr . -57 kW

44 kW 63 kW
66 kW
Ratios Final drive 34 : 7=4. 857 34: 7=4 . 857 34 : 7=4 . 857
z2 :z, = i 1st gear 37 : 9=4 <111 37: 9=4 . 111 34: 9=4.111
2nd gear 35:15=2 .333 35:15=2.333 35:15=2 . 333
3rd gear 31 : 21=1. 476 31:21=1.476 31 : 21=1. 476
4th gear 57: 56=1. 023 57 : 56=1. 023 57 : 56=1.023
5th gear 51: 62=0 . 822 51 : 62=0 . 822 51:62=0.822
Reverse gear 33: 9=3. 666 33: 9=3 . 666 33: 9=3.666
Speedo drive
Capacity 1) 3.0 litres
Specification 2) Gear box oil GL 4 (Mil-L 2105) SAE 80
Clutch control
Clutch plate dia.
or G 50 75 W-90 (Synthetic oil)
228 mm
hydra ulic
228 mm 228 mm
•
Tyres: Dynamic roll circumference 1 . 97 m

Speed in top gear at 1000 rpm 30 km/h 30 km/h 30 km/h
(km/h)
Remks: .
M : 01fferential l ock M 220 Strengthened
1) When checkinq the oil level gearbox
note Workshop Bulletin No . 1 housinq
2) Gearboxes with differential lock
onl y fill with gearbox oil t o
Ford specification M 2 C 104 A.
4
Code letters 3P 8L 8K
Manufactured from : 11 .83 11.83 11.83
to: 7 .84 7.84 7.84
Allocation Model
Volkswagen Transporter, Caravelle
Engine 1.9 ltr. - 57 kW 1. 6 ltr . - 37 kW Diesel

63 kW
66 kW
• Ratios Final drive 34: 7=4.857 38 : 7=5.428 38: 7=5.428

Z2 :z, = i
1st gear 37: 9=4.111 37: 9=4.111 37: 9=4.111
2nd gear 35 :15=2.333 35:15=2.333 35:15=2.333
3rd gear 31: 21=1.476 31 : 21=1.476 31:21=1.476
4th gear 57: 56=1. 023 57: 56=1. 023 57: 56=1. 023
5th gear 51:62=0 .822 51:62=0.822 51:62=0.822
Reverse gear 33: 9=3.666 33: 9=3 . 666 33: 9=3.666
Speedo drive
or G 50 SAE 75 W-90 (Synthetic oi l)
Clutch control hydraulic

Clutch plate dia. 228 mm 215 mm 215 mm
Overall ratio in top gear 4.00 4 .47 4.47

(km/h)
Remarks:
note Wor kshop Bullet in No.1 gearbox
2) Gearboxes with differential housing
l ock onl y fill with gearbox
oil to Ford specification
M 2 C 104 A.
cm.S726.o2.20 5
Code letters ABP ABR AAS

Manufactured from : 8.84 8.84 7.84
to:
Engine 1.6 ltr . - 37 kW Diesel 1.6 ltr.-51 kW

1.7 ltr. - 42 kW Diesel Turbo Diesel
Ratios Final drive 33: 6=5 . 500 33: 6=5.500 29: 6=4 .833
•
Z2 :z, = i 37: 9=4.111 37: 9=4.111 37 : 9=4.111
1st gear
2nd gear 35 : 15=2.333 35:15=2 . 333 35:15=2 333
3rd gear 31:21=1.476 31: 21=1.476 31:21=1. 476
4th gear 45: 44= 1. 023 45:44=1 .023 45:44=1.023
5th gear 40:49=0.816 40:49=0 . 816 40:49=0 . 816
Reverse gear 33 : 9:3 ,666 33: 9=3.666 33: 9=3.666
Speedo drive
Capacity 1) 4.0 litres
Specification 2) Gearbox oil GL 4 (Mil- L 2105) SAE 80
Clutch control hydraulic

Clutch plate dia. 215 mm 215 mm 215 mm
Overall ratio in top gear 4.49 4 .49 3.94

(km/h)
Remarks:
note Workshop Bulletin No .1 gearbox
2) Gearboxes with differential housing
lock only fill with gearbox
M 2 C 104 A.
Code letters 3H ABL ABM

Manufactured from : 7.84 7 . 84 7 .84
to:
Engine 1. 6 ltr . -51 kW 1.9 ltr. - 41 kW 1.9 ltr.-54 kW

Turbo-Diesel 44 kW 57 kW
63 kW
66 kW
2.1 ltr.-64 kW
70 kW
• Ratios Final drive 29: 6=4.833 29 ; 6=4.833 29: 6=4.833

Z2 :z, = i 1st gear 37: 9=4 . 111 37 : 9=4.111 37: 9=4 .111
2nd gear 35:15=2 . 333 35 :15=2 . 333 35:15=2.333
3rd gear 31: 21=1.476 31: 21=1.476 31 :21=1 .476
4th gear 45:44=1.023 45 ;44=1 . 023 45:44=1.023
5th gear 40 : 49=0 . 816 40:49=0.816 40 : 49=0.816
Reverse gear 33: 9=3.666 33 : 9=3 . 666 33: 9=3 . 666
Speedo drive
• Clutch control
Clutch plate dia.
215 mm
hydraulic
228 mm 228 mm
Overall ratio in top gear 3.94 3 . 94 3.94

(km/h)
Re~lfs ·
M : · Differential lock Strengthened M 220
gearbox
housing
note Workshop Bulletin No. 1 gearbox
2) Gearboxes with di fferential housing
M 2 C 104 A.
000.5726.02.20 7
Code leners ABN AAP

Manufactured from: 7.84 1.85
to:
Engine 1.9 ltr. - 54 kW 2.1 ltr. - 82 kW

- 57 kW
- 63 kW
- 66 kW
Ratios Final drive 29: 6=4.833 32: 7=4.571

•
Z2 : z, = i 37: 9=4 . 111 37: 9=4.111
1st gear
2nd gear 35 : 15=2.333 35:15=2 . 333
3rd gear 31: 21=1. 476 31: 21=1.476
4th gear 45 :44=1.022 45 :44=1. 022
5th gear 40:49=0.816 40:49=0.816
Reverse gear 33: 9=3.666 33: 9=3.666
Speedo drive
Capacity 1) 3.0 ltr . 3.0 ltr.
Clutch control
Clutch plate dia.
or G 50 SAE 75 W- 90 (Synthetic oil)
228 mm
hydraulic
228 mm
•
Drive Flange dia. 100 mm 100 mm
Tyres: Dynamic roll circumference 1 .97 m
Overall ratio in top gear 3 .94 3.73

Speed in top gear at 1000 rpm 30 km/h 32 km/h
(km/h)
Remarks: Differential with
1) When checking the oil level 4 small bevel gears
note Workshop Bulletin No.1
Strengthened gearbox housing
2) Gearboxes with differential
M 2 C 104 A.
8
5 Speed .anual gearbox 094
Code letters ABK AGT AAR

Manufactured from : 7.87 7 . 85 1.87
to:
Engine
'
1.9 ltr . -44 kW 2.1 ltr.-64kW
70kW
2.1 ltr.-82kW
• Ratios Final drive 29: 6=4.833 29: Fl=4.833 32: 7=4.571

z2 :z, = i
1st gear 37: 9=4.111 37: 9=4.111 37: 9=4.111
2nd gear 35:15=2.333 35:15=2.333 35:15=2 . 333
3rd gear 31:21=1.476 31:21=1.476 31 : 21=1.476
4th gear 45:44=1.022 45 : 44= 1. 022 45:44=1.022
5th gear 40 : 49=0.816 40:49=0.816 40:49=0.816
Reverse gear 33: 9=3.676 33: 9=3.676 33 : 9=3.676
Speedo drive
Capacity 1) 3.0 ltr.
• Clutch control
Clutch plate dia.
228 mm
hydraulic
228 mm 228 mm

(km/h)
Remarks : M 220 Differential M 220

M 220: Differential lock with 4 small
1) When checking the oil level bevel gears
note Workshop Bulletin No . 1
2) Gearboxes with differential Strenqthened ~earbox housing
oil to Ford specificati on
M 2 C 104 A.
(((). 5726. 02. 20 9

...
V.A.G Service. V·A·G

Workshop Buletin.
Volkswagen Transporter No. -
File in booklet: 4 speed manual gearbox 091/1 - Edition 12/82 of 04/83
5 speed manual gearbox 094 - Edition 12/82
Page to be marked:
Correction to text
In the 4 speed manual gearbox 091/1 and 5 speed manual gearbox 094 booklets
there are, in each case, sc::xre printing errors on page 30. Please alter the
lines to the text blocks in the 091/1 booklet as sh::Mn below.
Then cut out the drawing 35-876 an:i stick it on page 30 in the 094 booklet.
This bulletin can then be destroyed.
Bearing carrier
Circlip
renew, must fit properly in
the groove.
Circlip
for 3rd gear wheel
Renew. must fit properly in
groove.
Determine thickness- Fig. 14.
,..J..J~---'< 2nd gear wheel )

'--- -
c
3rd gear wheel
Needle bearing Pressing off - Fig. 1
Driving out - Fig. 15 Pressing on- Fig. 13
Pressing in - Fig. 16. Position: Shoulder towards
(
,_ 2nd gear wheel . - -
4th gear wheel
Position: annular groove towards
bearing carrier .
.e
Printed in Germany 000.5726.99.20/82
Volkswagen Trans}:X)rter
4 speed manual gearbox 091/1
Workshop Bulletin 5 speed manual gearbox 094 04/83
Please cut this drawing out and stick it on page 30 of the 5 speed rranual
gearbox 094 booklet.
Sleeve
Synchronizer hub -----..
Locking key~
Spring
. ®' (:
Wire d ia. 1.6 mm
Circlip I
Position - Fig. 12
Fastening screw for ~ ...~ ~

~lebalring
5Nm
Needle bearing
Removing- Fig. 10
Installing- Fig. 11.
Bearing carrier
Ball bearing
pressing out - Fig. 6
pressing i n - Fig. 7
Checking for wear - Fig. 2
Needle bearing for 5th gear
Lubricate with gearbox oil before fitting.
---------------------------------------------------------------------------------------
2
4 speed manual gearbox 091/1
Workshop Bulletin · 5 speed manual gearbox 094 04/83
Sleeve/hub
for 4th and 5th gears
pressing off- Fig. 1
assesbling - Fig. 3 and 4
Watch position when
pressing on - Fig. 5. Circlip
Needle bearing
I<."Tlocki ng out- Fig. 8
Knocking in- Fig. 9.
4th gear wheel

Check for wear - Fig. 2
·taentification - Page 39.
' - - - - - Circlips
for synchronizer hub,
renew.
35-876
3
V.A.G Service.
Workshop Bulletin.
Volkswagen Transporter No . ....j}.
File in booklet: 5 Speed manual gearbox 094 of o6 / 83
Checking the oil level
The oil capacity has been reduced in order to improve the gear shifting.
For production reasons however the oil filler hole has remained at the
same location. For this reason, the oil level is now approx. 15 mm below
the filler hole.
Wh=n checking the .oil level, one should note that oil may only be poured
in up to a leve 1 which is approx. 15 mn be low the filler hole .
The filling capacities when new are, as shown in the Technical Data
3.0 litres on vehicles with petrol engines and

4.0 litres on vehicles with diesel engines .
• Printed in Germany 000.5726.01.20/82

r... - .... ~ , .·.;. .
·.·
...
·.
..
'''•
.j
..
...
.._. .. :
.·f. I
• ' . J
~
~ ·.
...
·. "
~·
L.~
..
., ••
.;
.,
.
l
,. #" ' .
· ; ·. . "'
,.,...
This publication is intended only for internal use within the V.A.G Organization and is not1o be ·
passed Of.lto any other person or persons.
' ·,,
I
~ 1982 VOLKSWAGENWERK AKTIENGESELLSCHAFT, Wolfsburg
All rights reserved.

:.
000.5381 .61.20 Printed in Germany
' 'IJ..t
r
..
1\ .. I
... . ' ..
.
~,..

5 Speed Manual Gearbox 094 VW Transporter Dec 1982 PDF

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5 Speed Manual Gearbox 094 VW Transporter Dec 1982 PDF

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,.

f; THE TRANSPORTER WORKSHOP MANUAL CONS'ISTS OF THE FOLLOWING BOOKLETS:

1.6 LITR~ CARBURETOR ENGINE

,.• ;.- . l1.5 · ;.Cylinder head , valve gear 90 Instruments, radio

December 1982 Edition.

VOLKSWAGENWERK AKTIENGESELLSCHAFT · WOLFSBURG I

REPAIR OPERATIONS AND TOO,LS

Operation Repair Page Special Tools Workshop Equipment

300167 . . Clutch, bleeding 5 vw 1238/ 1

30 2319 .. All pressure lines,

30 2419 .. Front pressure line,

30 2619 .. Centre pressure line,

30 2719 .. Pressure hose,

302919 .. Rear pressure li ne,

30 3019 .. Clutch operating cylinder,

30 4519 .. Release bearing,

305019 .. Clutch , removing and installing 7 VW215cor3067

341516 . . Gearshift linkage, adjusting 10

341719 .. Shift rod ,

343519 .. Gearbox, removing and installing 11 vw 785/1 V.A.G 1383

II ReRair operations and tools

343537 .. Gearbox, dismantling and 14, 18 VW244b Two-armed extractor

3540 37 .. Input shaft, dismantling and 30 VW295 Extractor

355019 .. Input shaft oil seal, 25 VW681 _.

Repair operations and tools Ill

Operation Repair Page Special Tools Workshop

355915 .. Out put shaft, adjusting 53 vw 381/14 Dial gauge 0 - 3 mm

355937 .. Output shaft, d ismantling 34 VW401 Parti ng t ool

390915 . . Differential, adjusting 55 VW 381 / 5a, 7, 8, 15 Torque gauge

390937 .. Differential, dismantling 41 VW 381 / 5a

392219 .. Drive flange oil seal, 40 VW391

IV Repair operations and tools

Calculating speed " V" . . . . . . . . . . . . . . . . 4 Input shaft. removing and installing . . . . . 18

.. :: .. . ·. -:· ,:- ;__ ,•

GEARBOX IDENTIFICATION 5 speed manual gea rbox 094

Code letters and date of manufacture

CODE LETTERS, ALLOCATION, GEARBOX RATIOS, OIL CAPACITY

from : 10.82 10.82 10.82 10.82 10.82 10.82

Manual g.earbox 5 speed manual gearbox 094

Gearbox number 094.1 094.2 094.3

Allocation Model Volkswagen Transporter

Engine 1.91 44kW 1.91 57-60 k;W 1.61 37kW

Ratios Final drive 34 : 7 = 4.86 38 : 7 = 5.43

2nd gear 35 : 15 = 2.33

3rd gear 31 : 21 = 1.48

4th gear 57 : 56 = 1.02

5th gear 49 : 64=0.76

Specification Hypoid gear oil GL 4 {MIL-L- 2105)

Clutch operation Hydraulic

Tyres : dynamic roll circumference 1.97m

iove!all in 5th gear .. 3.72 4.16

Speed at n = 2000 rpm 63.57 km/h 56.88 km/h

2 Code letters, allocation; gearbox ratios, oil capacity

TRANSMISSION LAYOUT DIRECTION OF MOTION

6-__....- ll--- -!-----4

Calculating ratios "I"

Example 5th gear Final drive

Driving gear: Z G, = 64 ZA1 = 7

Driven gear: ZG2 = 49 ZA2 = 34

Calculating speed "V" Example:

Calculating ratios "i"

Connecting piece , - - - - - Bleeder valve

Bush for release shaft Bush

\' ') '( ',';''.'I