Repair of mechanical transmissions
To repair T4 manual transmissions, you will need a number of special tools and tools.
Before starting a repair, we recommend that you balance your strength and skills with the scope of work, as well as check the availability of appropriate spare parts. Below are some tips for a successful repair. - Gears in case of wear or breakage are recommended to be replaced in pairs, otherwise the life of new parts will be significantly reduced.
- Be sure to include the box code when purchasing. Despite the fact that outwardly the details of all VW boxes are very similar, they differ in the number of teeth, splines (gears, splined shafts), dimensions (which cannot always be determined at a glance), hardness, etc. - because over 27 modifications of five-speed gearboxes have been used
in the nine years of production of the Transporter T4 On fig. 353 shows the arrangement of the gearbox housing. O-rings pos. 9, 16, as well as the input shaft seal pos. 8 are subject to mandatory replacement, replacement of the gasket pos. 11 is recommended depending on her condition.
Rice.
353 Gearbox housing 1 - lower part of the housing, 2, 3 - bushings, 4 - boot, 5 - nut M24x1.5, 6 - magnet, 7 - upper part of the housing, 8 - stuffing box, 9 - O-rings, 10 - filler plug holes, 11 - cover gasket, 12 - cover, 13 - M8x20 bolt, 14 - M7x20 bolt, 15 - extension, 17 - release bearing guide
Adjusting rings (7, see Fig. 354) have a thickness of 0.65 to 1.27 mm in 0.25 mm increments, rings (10) have a thickness of 0.65 to 1.40 in the same increment.
Rice.
354 Mechanical transmission device 1 - input shaft, 2 - oil scraper, 3 - 3rd gear wheel, 4, 22, 47 - retaining rings, 5 - 4th gear wheel, 6 - bearing, 7, 10 - adjusting rings, 8 - washer , 9, 52, 53 - Top-type bolts, 11 - roller bearing, 12 - M8 nut, 13 - sealing ring, 14 - body, 15 - 1st gear thrust ring, 16 - 1st gear gear, 17, 23 - bushings, 18, 24, 26, 31, 41 - synchronizer rings, 19 - 1/2 gear synchronizer, 20 - cracker, 21 - spring, 25 - output ring, 27 - 2nd gear wheel, 28, 36 - thrust rings, 29 - bearing bushing, 30 - 3rd gear gear, 32 - 3rd/4th gear synchronizer, 33 - ring, 35 - 4th gear wheel, 37 - bushing, 38 - 5th gear, 40 - 5th gear wheel, 42 - ring, 43 - synchronizer bushing , 44 - synchronizer slider, 45 - reverse gear shaft, 46 - reverse idle gear, 48 - reverse gear wheel, 49 - thrust bushing, 51 - bracket.
The body (14) is supplied complete with bearing (13).
On fig. 355 shows the arrangement of the gearshift mechanism of a five-speed manual transmission. The lever (10) shifts 1/2 gears, (14) - 3/4 gears, the lever (30) selects the 5th gear, and the reverse gear is engaged by a mechanism consisting of parts (21) and (22). Spring (23) provides some resistance when reverse gear is engaged.
Rice.
355 Gear selection mechanism 1 - selector shaft housing, 2 - oil seal, 3 - bushing, 4 - bolt, 5 - bushing, 6 - ventilation system adapter (breather), 7 - retaining ring, 8 - selector shaft, 9 - M8x25 bolt, 10, 14, 30 - selector lever assembly, 11, 15, 31 - pins, 12 - pin retainers, 13 - bushings, 16 - 1-4 gear carrier, 17 - 5 gear carrier, 18 - lock washer, 19 - carrier reverse gear, 20 - cuff, 21 - reverse gear engagement lever limiter, 22 - reverse gear engagement lever, 23 - springs, 24 - guide, 25 - cover, 26 - axle assembly, 27 - sealing ring, 28, 29 - Torx bolts
Models manufactured after 1996 are distinguished by the absence of a smooth sleeve, which was located in the cover (25) on previous models.