Volkswagen Air Cooled 1949-1969 Repair Guide

Understanding the Manual Transaxle


Because of the way an internal combustion engine breathes, it can produce torque, or twisting force, only within a narrow speed range. Most modern, overhead valve pushrod engines must turn at about 2500 rpm to produce their peak torque. By 4500 rpm they are producing so little torque that continued increases in engine speed produce no power increases. The torque peak on overhead camshaft engines is generally much higher, but within a much narrower speed range.

The manual transaxle and clutch are employed to vary the relationship between engine speed and the speed of the wheels so that adequate engine power can be produced under all circumstances. The clutch allows engine torque to be applied to the transaxle input shaft gradually, due to mechanical slippage. Consequently, the vehicle may be started smoothly from a full stop. The transaxle changes the ratio between the rotating speeds of the engine and wheels by the use of gears. The gear ratios allow full engine power to be applied to the wheels during acceleration at low speeds and at highway/passing speeds.

The power is usually transmitted from the input shaft to a mainshaft or output shaft. The gears of the mainshaft mesh with gears on the input shaft, allowing power to be carried from one to the other. All forward gears are in constant mesh and are free from rotating with the shaft unless the synchronizer and clutch are engaged. Shifting from one gear to the next causes one of the gears to be freed from rotating with the shaft and locks another to it. Gears are locked and unlocked by internal dog clutches which slide between the center of the gear and shaft. The forward gears employ synchronizers; friction members which smoothly bring gear and shaft to the same speed before the toothed dog clutches are engaged.

All manual transaxles (covered by this guide) employ four forward speeds and a reverse. All forward speeds have synchromesh engagement. The gears are helical and in constant mesh. Gear selection is accomplished by a floor-mounted lever working through a shift rod contained in the frame tunnel. The final drive pinion and ring gear are also helical cut.