Volkswagen Air-Cooled 1970-1981 Repair Guide

Transaxle Assembly

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REMOVAL & INSTALLATION



See Figures 1 through 8

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Fig. Fig. 1: When installing the driveshafts, make certain to position the attaching bolt spacers and lockwashers in the correct order



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Fig. Fig. 2: To gain access to the shifter rod-to-transaxle coupling, remove the rear seat and remove the access plate hold-down screws



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Fig. Fig. 3: Lift the access plate up and off of the center frame tube



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Fig. Fig. 4: Note that the access plate is secured in place not only by the hold-down screws, but also by these holding flaps



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Fig. Fig. 5: Once the access plate is removed, the shift rod-to-transaxle coupling can be seen



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Fig. Fig. 6: Snip the safety wire off of the retaining bolt ...



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Fig. Fig. 7: ... then remove the 8mm retaining bolt with a wrench or socket



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Fig. Fig. 8: Move the shift rod forward, by moving the shifter handle rearward, to disengage the coupling from the transaxle shift input shaft

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the engine, as described in Engine And Engine Overhaul .
  4.  
  5. Remove the special 12-point socket head screws which secure the driveshafts to the transaxle. Remove the bolts from the transaxle end first and then remove the shafts.
  6.  

It is not necessary to remove the driveshafts entirely from the car if the car does not have to be moved while the transaxle is out.

  1. Disconnect the clutch cable from the clutch lever and remove the clutch cable and its guide tube from the transaxle. Loosen the square head bolt at the shift linkage coupling located near the rear of the transaxle. Slide the coupling off the inner shift lever. There is an access plate under the rear seat to reach the coupling on Type 1 and 3 models. It is necessary to work under the car to reach the coupling on Type 2 models.
  2.  
  3. Label and disconnect the starter wiring.
  4.  
  5. Label and disconnect the back-up light switch wiring.
  6.  
  7. Remove the front transaxle mounting bolts.
  8.  
  9. Support the transaxle with a floor jack and remove the transaxle carrier bolts.
  10.  

1972 and later Type 2's have two upper carrier bolts which also join the engine to the transaxle. The transaxle must be supported when these bolts are removed to prevent damage which could be caused by letting the unit hang.

  1. Carefully lower the jack and remove the transaxle from the car.
  2.  

To install:
  1. Jack the transaxle into position and loosely install the bolts.
  2.  
  3. Tighten the transaxle carrier bolts first, then tighten the front mounting nuts.
  4.  
  5. Install the driveshaft bolts with new lockwashers. The lockwashers should be positioned on the bolt with the convex side toward the screw head.
  6.  
  7. Reconnect the wiring, the clutch cable, and the shift linkage.
  8.  

It may be necessary to align the transaxle so that the driveshaft joints do not rub the frame.

  1. Install the engine.
  2.  

SHIFT LINKAGE ADJUSTMENT



See Figures 9 and 10

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Fig. Fig. 9: Manual transaxle gearshift pattern-the shifter must be depressed to position the transaxle in Reverse



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Fig. Fig. 10: Cross-sectional view of the manual transaxle gear shifter assembly-the shifter is held to the floor by only two 13mm bolts

The Volkswagen shift linkage is not adjustable. When shifting becomes difficult or there is an excessive amount of play in the linkage, check the shifting mechanism for worn parts. Make sure the shift linkage coupling is tightly connected to the inner shift lever located at the rear of the transaxle under a plate below the rear seat on Types 1, 3 and 4. On Type 2 models, Check the setscrew where the front shift rod connects to the center section below the passenger compartment, and the rear setscrew where the linkage goes into the transaxle. Worn parts may be found in the shift lever mechanism and the supports for the linkage rod sometimes wear out.

The gear shift lever can be removed after the front floor mat has been lifted. After the two retaining screws have been removed from the gear shift lever ball housing, the gear shift lever, ball housing, rubber boot, and spring are removed as a unit.


CAUTION
Carefully mark the position of the stop plate and note the position of the turned up ramp at the side of the stop plate. Normally the ramp is turned up and on the right-hand side of the hole.

Installation is the reverse of removal. Lubricate all moving parts with grease. Test the gear shift pattern. If there is difficulty in shifting, adjust the stop plate back and forth in its slotted holes.

 
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