Hi all.

Thought I'd jot these down before I fergit.

Some from archives, some from good old BS & T. (wadda great band)

FWIW, I swapped shafts between 2 DK's but kept each gear with its'
corresponding transmission. I assume gears wear to each other.

This is what worked for me. YMMV. Assuming you've read Bentley.....

My cheap circlip pliers *just* reached. Buy/borrow longest you can find.

Gear lifting tool: old screwdriver bent 90*. Tip ~ 1/2" long after
bend. End filed to 45* to get under gear. Rounded edges so gear easier
to turn while tool holding it up.

Smaller light would be more useufl than trouble light. Maybe small
clip on light?

Dental type mirror: REALLY useful. See if gear lifted high enough for
removal (Thanks Scott) and see actually backing off one spline or just
turning both shafts as a unit. (wrong). Made wire clip for mirror and
hung it on case for hands free.

Removal: Positioned cut out on (carrier?) as per Bentley, jockeyed
diff back/forth slightly (in neutral) while lifting gear. This helps
find sweet spot so gear can be lifted high enough. Be gentle. Easy to
jamb gear sleeve against carrier. Lift gear above join where input
shaft and lower splined shaft meet. Put trany in gear once shaft ready
to unscrew from stud.

Backing off one spline: in neutral, screwed input shaft down until it
*just* turned lower shaft, put in gear, backed off one spline, slid
gear down. FWIW, first attempts found me twisting input shaft too
tight to lower part. When in gear attempting to back off the input
shaft on spline, I ended up turning the lower splined shaft which
turned diff binding carrier against sleeve of gear.

Though obvious, after backing off one spline, hold input shaft in
position and turn other gear (idler?) to allow input shaft gear to
slide back down and mesh.

Hope that helps. I have pics. Will post in this thread soon.

Neil.

--
Neil Nicholson '81 VanaJetta 2.0 "Jaco"

http://tubaneil.googlepages.com/

http://groups.google.com/group/vanagons-with-vw-inline-4-cylinder-gas-engines