Workshop Manual. Volkswagen Transporter. Four-wheel drive 5-Speed Manual Gearbox 094 And Final Drive


Workshop Manual. Volkswagen Transporter. Four-wheel drive 5-Speed Manual Gearbox 094 And Final Drive PDF

July 1986. Workshop Manual. Volkswagen Transporter. Four-wheel drive 5-Speed Manual Gearbox 094 And Final Drive.

The manual is divided into separate booklets which can be ordered individually and allocated on the shop floor as required.

This manual is valid for the new Volkswagen Transporter syncro from the start of production. It describes all the operations which require special instructions to ensure satisfactory work.

Layout of booklets

Each booklet has the contents listed according to repair operations and items to make it easier to find the information required. The technical data is followed by a description of the repair operations. Where practical, each operation is preceded by an exploded view which also contains all the main repair instructions. This is supplemented, where necessary, by photographs – which are referred to in the exploded views – giving details of the fitting positions of parts or showing special tools in use. If a definite sequence has to be followed when dismantling and assembling a component, the exploded view is followed by a description of the main steps of the work sequence. Any adjustments required are also explained.

Workshop Bulletins

Workshop bulletins will be allocated to the individual booklets and should be filed at the back of the booklet concerned. To remind you that bulletins have been published, the manual pages should be marked by hand with the bulletin number as explained in the bulletin heading.

Fault finding

All fault finding instructions are given in the appropriate sections.
Instructions on the elimination of current defects are given in the Fault finding handbook ‘.

CONTENTS

TECHNICAL DATA

  • Gearbox identification
  • Front final drive identification
  • Code letters, gearbox allocation, ratios, oil capacities
  • Transmission layout
  • Calculating transmission ratio
  • Instructions regarding performance test, brake test and towing

Repair Instructions

  • Repair Instructions

Clutch

  • Repairing hydraulic clutch control
  • Clutch repairs

Controls, Housing

  • Exploded view, permanent 4WD
  • Exploded view and vacuum pipe layout of selectable 4WD
  • Repairing gear shift mechanism
  • Adjusting gear shift linkage
  • Exploded view, differential lock operation
  • Repairing differential lock mechanism
  • Removing and installing lock controls
  • Repairing differential lock mechanism
  • Removing and installing shift element .
  • Renewing vacuum lines
  • Checking the viscous coupling function
  • Removing and installing manual gearbox
  • Removing and installing front final drive
  • Removing and installing propshaft
  • Renewing propshaft oil seal on front final drive or gearbox
  • Renewing drive flange oil seal on front final drive
  • Dismantling and assembling gearbox
  • Removing and installing clutch housing/differential
  • Removing and installing gear train
  • Dismantling and assembling output shaft housing
  • Dismantling and assembling crosscountry gear housing
  • Dismantling and assembling gear train
  • Repairing clutch housing
  • Repairing housing

Gears, Shafts

  • Gear train, exploded view
  • Dismantling and assembling input shaft
  • Dismantling and assembling gear train pinion

Final Drive, Differential

  • Removing and installing propshaft
  • Renewing propshaft oil seal on front final drive
  • Renewing drive flange oil seal on front final drive
  • Renewing drive flange oil seal
  • Dismantling and assembling differential without differential lock
  • Dismantling and assembling differential with differential lock
  • Adjusting axial play of differential gears
  • Adjusting crown wheel and pinion
  • Adjustment table Finding position of pinion (actual dimension)
  • Adjusting pinion
  • Adjusting crown wheel
  • Front final drive, exploded view
  • Dismantling and assembling front final drive
  • Removing and installing differential
  • Dismantling and assembling final drive casing
  • Dismantling and assembling final drive casing with viscous coupling
  • Dismantling and assembling final drive casing with selectable 4WD
  • Dismantling and assembling front pinion

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Four-wheel drive 5-Speed Manual Gearbox 094 And Final Drive – View Online PDF