On today's transmission adventures......

[mcmscott]

Line on the hub goes toward third, line on slider goes toward 4th. That trans spent a lot of time in 3rd gear. It is ok to remove sets of teeth on both 3 and 4. Typically 3rd has almost no wear, your case is different.
_________________
There are no stupid questions, only stupid people,

68 Ghia
67 T-1
65 Notch
02 Mexican beetle
74 Thing
15 Long travel rail
07 Nomad
05 f-250

[balljoint]

Ok i think I figured it out, there is no line on the hub as the manual did state that replacement parts are not marked but did say the chamfer goes on 3rd side....I found the chamfer!
...And the operating sleeve 1mm deep groove toward 4th.

Also no line on hub for meshing so they state to try in different positions for smoothest operation.

I'll press off both hubs, remove the 9 teeth each and swap them so the slightly pitted one ends up on 4th.

1st and 2nd dogs are in pretty good condition.
_________________
It's an ongoing journey, never forget where you came from....

65 rhd Beetle
72 rhd kombi

[balljoint]

Measured up 1st end play, good to go at 0.15mm.

Measured 3rd at 0.33mm so wanna tighten by going at least one circlip size up....maybe two.

Scott can you supply these? No luck at weddle.
_________________
It's an ongoing journey, never forget where you came from....

65 rhd Beetle
72 rhd kombi

[balljoint]

So back to this washer that I found on the pinion shaft.

Its the one in the pic below on the left which Tom also confirmed didn't belong in the location as seen in the pic above.

Still not sure where it goes though as I already had what the manual refers to as a dished washer between the circlip and main shaft bearing, its just that its flat as can be seen below on the right....I'm assuming its the correct dished washer for this location (21)but will have to replace this one as its beat up.

The left wavy washer is 0.5mm thick, ID=30mm, OD=44.5mm
The right washer 2.0mm thick, ID=25.5mm, OD=37mm.


4th gear thrust washer on the MS goes directly up against te bearing right?

So is this left washer just a spare part thrown in there??
Not seeing a location for it anywhere in the diagrams.

_________________
It's an ongoing journey, never forget where you came from....

65 rhd Beetle
72 rhd kombi

[mcmscott]

The washer you show is on the pinion shaft, not the mainshaft. And doesn't belong there either. Get a "too thick" circlip for third and machine the gear to get you to zero clearance

_________________
There are no stupid questions, only stupid people,

68 Ghia
67 T-1
65 Notch
02 Mexican beetle
74 Thing
15 Long travel rail
07 Nomad
05 f-250

[balljoint]

So just to confirm, you saying that the left wavy washer doesn't belong in the transmission at all?

_________________
It's an ongoing journey, never forget where you came from....

65 rhd Beetle
72 rhd kombi

[balljoint]

And of course found this after I made my parts order.

Can't figure out how this happened...maybe lost the TOB retainer clips at some time??
_________________
It's an ongoing journey, never forget where you came from....

65 rhd Beetle
72 rhd kombi

[balljoint]

Finished up the pinion shaft with 3rd down to zero, but this washer/shim is playing (for want of a better word)with my mind!

How i found it, it was riding on the shoulder of 4th and in between the needle bearing in the carrier therefore moving the pinion shaft 0.5mm away from the needle bearing.

I question the competence of the guys who rebuilt it before, but i do not think they would of found a random shim that fits perfectly on the diameter of both the needle bearing and the race out of nowhere and just put it in there. See pics with shim in place.

Is it possible this shim was used by vw to set the pinion shaft in relation to the main shaft?
Or maybe to take up some slack because of not having to use such a thick pinion (S3)shim??
_________________
It's an ongoing journey, never forget where you came from....

65 rhd Beetle
72 rhd kombi

[Kiwi1966]

Its not the shim washer that sits up against the pinion nut?

[mcmscott]

As was said before,,,, that shim DOES NOT BELONG THERE
_________________
There are no stupid questions, only stupid people,

68 Ghia
67 T-1
65 Notch
02 Mexican beetle
74 Thing
15 Long travel rail
07 Nomad
05 f-250

[balljoint]

Got this thing buttoned up, finally!
Had to change the cam plug too as the one it had in there was installed with sealant which was sealing the drain hole also causing a leak. So it took some time having to start the engine on the ground and taking her through a few heat cycles to check for leaks.

Haven't taken her on the hway yet but she feels good so far in all gears...no grinding, jumping out of gear, funny noises or leaks!
Only small hiccups were 4th is kinda knotchy to select, which was happening before as well but would have to play with shifter adjustment some to see if I get it better.

Also the inner bearing spacers were on in the wrong direction so flipped them the correct way. The right side wheel only gets a little hard to turn when the axle nut is tightened down. Will see if with a little driving things would work itself into place.
And of course thanks to the one and only, literally...the man of few words....Scott!

_________________
It's an ongoing journey, never forget where you came from....

65 rhd Beetle
72 rhd kombi