taking 5th gear apart

[rapieper at yahoo.com (Ron Pieper)]

Flip the assembly over from how it appears in the pic.  With a small screwdriver, *carefully* pry off the large steel bushing.  Then the gear slips off and the synchro can be separated (and the retaining clip removed).

To reinstall the large bushing, heat it a bit.  Not red hot though.

Make sure the needle bearing looks good and the plastic retainer is not all melted.

here is how it looks apart:  http://scirocco.dhs.org/cheapassron/P7210130.JPG
without the keys and retaining clips etc. The large steel bushing is on the left.

For reassembly you may also want:


020301215C                5th
gear cover gasket


020311579B                5th
gear lock plate

HTH

Ron



  020301215C


  Gasket



  020301215C


  Gasket



  020301215C


  Gasket


----- Original Message ----
From: Koabi Brooks <koabi.brooks@xxxxxxxxx>
To: Ron Pieper <rapieper@xxxxxxxxx>
Cc: Scirocco List <scirocco-l@xxxxxxxxxxxx>
Sent: Saturday, July 21, 2007 12:46:14 PM
Subject: Re: taking 5th gear apart

http://koabi.lazyslacker.com/photos/gallery2/main.php?g2_view=core.DownloadItem&g2_itemId=7536&g2_serialNumber=2.jpg


to the left is the ring I pulled out.  in the keyway you can see the end of the lower ring that I can't get out.  I want to replace the bronze colored synchro because it looks a bit damaged where the keys pop in - one of the keys was sheared pretty badly.


Also I noticed my 5th gear housing has some surface cracks - should I be concerned?:  

http://koabi.lazyslacker.com/photos/gallery2/main.php?g2_view=core.DownloadItem&g2_itemId=7545&g2_serialNumber=2.jpg

I do have a 5th gear housing from a 9A transmission I believe that looks ok.  The inside of it looks a bit different though.  


On 7/20/07, Ron Pieper <rapieper@xxxxxxxxx> wrote:
I recommend posting a pic.

Also, I'd suggest a whole new 5th gear assy.  I have several to sell reasonably.  What's your ratio?  (Sorry I'm out of 'good' ratios).

Ron

----- Original Message ----

From: Koabi Brooks <koabi.brooks@xxxxxxxxx>
To: Scirocco List <scirocco-l@xxxxxxxxxxxx>
Sent: Friday, July 20, 2007 9:47:21 AM

Subject: taking 5th gear apart


Some of those locking keys that appear to hold 5th and the synchro together
were pretty destroyed when I took my transmission apart.  I am now trying to
separate the synchro but there are two wire clips that seem to be doing

something. The top clip was easy to pull off but the bottom clip I can't
figure out how to get off.  Obviously, if I am approaching this the wrong
way let me know...

thanks
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