Small Nut Reduction Box Disassembly

hazetguy

I finally got around to taking some pics of disassembling a small nut reduction box, showing pullers, process, parts in the right order, that kind of stuff.
While the pics are of a Barndoor reduction box, the process is the same for all small nut reduction boxes. There are only minor differences between the barndoor boxes and later small nut ones, and they are really only in the way the brake backing plate attaches to the outer housing, and those differences will be addressed in the text of the pics. Again, the process is the same.
You can also follow along in your service manual.

There are 23 pics, in numbered disassembly order, in the gallery, under the same heading as this thread. Find them by searching for pics by me, using any of the words in the title of this thread.

Direct link:
http://www.thesamba.com/vw/forum/album_search.php?...isassembly

campingbox · Posted: Wed Nov 01, 2006 6:06 pm Post subject:

Why bother to mark the gears? Won't they constantly change since the gears have different number of teeth?

hazetguy · Posted: Wed Nov 01, 2006 6:11 pm Post subject:

only for directional orientation, so they ride the same way, and the same direction.
i figure they have worn in a certain way to eachother, might as well keep them that way.
obviously it won't matter if they are damaged and need to be replaced, but i like to keep things they way they were matched and rotating, especially gears and bearings (if the bearings are to be reused).

campingbox · Posted: Wed Nov 01, 2006 7:39 pm Post subject:

bbus · Posted: Wed Nov 01, 2006 7:46 pm Post subject:

nice pictures.
why did you use the multi arm type puller in stead of the collet type puller as in the large nut reduction box sequence?

hazetguy · Posted: Wed Nov 01, 2006 8:53 pm Post subject:

i used a different one because everyone has seen the collet type before.
so since there is a thread about different pullers, i thought i would show another type being used.

http://www.thesamba.com/vw/forum/viewtopic.php?t=200751

hazetguy · Posted: Thu Nov 02, 2006 3:41 pm Post subject:

well, wouldn't you know it. i am taking apart another reduction box, and of course, the lower axle does not want to come out easily from the housing.
so the pics have been added to, showing how to remove the lower stub axle and then the bearing that remains in the housing.
they are numbered 20a through 20e.

j.pickens · Posted: Thu Nov 02, 2006 3:44 pm Post subject:

All excellent.
Now I realize I need to get both the 8 jaw and 7 jaw collets for the puller gatorwyatt's getting for me.
Correct?
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hazetguy · Posted: Thu Nov 02, 2006 4:05 pm Post subject:

yes. here is the page from the Baum tool catalog.

http://www.thesamba.com/vw/forum/album_page.php?pic_id=312823

Image may have been reduced in size. Click image to view fullscreen.

Major Woody · Posted: Thu Nov 02, 2006 4:26 pm Post subject:

Really nice job on that pictorial, Jon. We could use more of that kind of stuff in here.

One thing is obvious from looking at that: you have got to have the correct tools!

Big Bill · Posted: Thu Nov 02, 2006 4:34 pm Post subject:

hazetguy, excellent step by step on the RGB bearing removal and the heater box flange, pipe rebuild. I have used a few of your other step by steppers for brake spring replacment, steering box seal replacement and a couple of other repairs. Thanks, when I see one of your repair items I know its always done the right way. Bill


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