Longitudinal section of gearbox type 013
Remove the outer race of the front tapered roller bearing of the input shaft, first on the type 013 gearbox by removing the cylindrical pin, and on the type 093 gearbox by unscrewing the hexagon socket head bolt. Press in a new ring if necessary.
Pressing in the outer ring of the rear bearing of the secondary shaft
Removing the locking pin of the inner ring of the front bearing of the secondary shaft to the gearbox type 013
Install the locks and locks of the shift fork rods in the correct position.
Install the secondary shaft with the shift fork of I and II gears in the gearbox housing.
Install the reverse intermediate gear on the axle, then press the axle.
Install the input shaft with the shift fork of III and IV gears into the crankcase.
Bring the rods of the shift fork of I and II gears, as well as the forks of switching on the V gear and reverse gear to the neutral position.
Install the 3rd and 4th gear fork stem with the retainer pre-lubricated with grease, insert the spring cotter pin into the fork while holding the stem with a hammer.
Press on the first inner race of the output shaft rear double row tapered roller bearing.
Pressing on the inner ring of the rear bearing of the secondary shaft
Install the support washer on the input shaft with the protruding part towards the gearbox housing. Heat up to a temperature of about 120°C and install the inner race of the V gear bearing as far as it will go, using drift 30-23 if necessary. With an atom, hold the input shaft.
Installing the support washer of the gear of the 5th gear on the input shaft
Heat up to a temperature of about 120°C and install on the secondary shaft, pushing it to the stop, the gear of the V gear, using, if necessary, a mandrel 30-100. While doing this, hold the output shaft.
Installing the V gear gear on the output shaft
Put the 5th gear on the input shaft together with the hub and the synchronizer sliding sleeve, the needle bearing and the 5th gear fork. Fasten the fork to the stem with a spring cotter pin, while holding the stem with a hammer.
Install the 5th gear synchronizer ring.
Installing the 5th gear synchronizer
Heat up to a temperature of about 120°C and reinstall the 5th gear synchronizer assembly. If necessary, use drift 30-23 to push it up to the stop on the input shaft. At the same time, fix the position of the input shaft.
Install a new gasket and attach the gearbox housing with the primary and secondary shafts installed to the clutch housing. Put the mounting pins in place and tighten the crankcase mounting bolts to a torque of 2.5 kgf·m.
Engage a gear and lock the input shaft with pin 2946/1.
Tighten the nut on the rear end of the output shaft to 10.0 kgf·m and lock it.
Push forward the leash of the fork rod of 1st and 2nd gears and engage the 3rd gear by pulling back the fork rod.
Install the gear selector:
- put the ends of the spring on the stem of the shift fork of III and IV gears;
- slide the lever of the gear selection rod onto the rod of the fork of III and IV gears;
- Align the selector rod and insert it into the guide bushing.
Set the fork stems to the neutral position.
Position when assembling the gearbox of the gear selector rod
Align the holes of the leash and the stem of the fork of I and II gears and insert the spring cotter pin
Install a new gasket and install the rear case cover using an M10 threaded rod.
Tighten the hex bolt at the rear end of the input shaft to 4.5 kgf·m.
Tighten the crankcase rear cover mounting bolts to a torque of 2.5 kgf·m, having previously applied a special VW D3 type glue to their threads.
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