VW T3 TDI gearbox rebuild

VW T3 TDI 5 Speed rebuild

VW T3 5 speed TDI rebuild

VW T3 TDI 5 Speed rebuild

This is one from last week 

Crown and pinion  29/7 teeth equals 4.14 Final Drive ratio  for TDI 

New Factory Bearings and seals 

New Pinion Bearing new FAG 

Lock ring 1st gear inner race  torqued to 210nm

New Mainshaft bearing FAG 

New Mainshaft bearing 002311125a INA R52867

2nd gear

Reconditioned bearing race with new needle bearings,

New 247b syncro ring

Excellent 1/2 syncro hub with new slider 

 New 3rd gear syncro ring 

4th gear oil face down (0,05-0.2 oil gap desired ) 4th gear circlip Brass 2.3mm 0.1 oil gap

New 5th gear oil ring up

New pinion bearing lock ring torqued to 225 nm  and synched

Crown Wheel

 New differential Bearings installed Timken preloaded and run in at 47nm

Excellent used mainshaft 

New 4rd and 5th gear 02A 311 265 D needle bearings installed VW

4th  gear reused

New 5th  gear  

HD weddle 4/5 syncro hub and slider

New 4th and 5th Syncro rings 

New Mainshaft Bearing FAG installed

AJT Mainshaft bearing plate installed

New shift rail bearings installed Rolax

4th gear oiling plate installed

All gears mesh    Yes

New Mainshaft bearing 002311125A installed in main case and circlip

Case re-sleeved for relay lever and relay lever in

New selector shaft bush installed

All case holes tapped and faces cleaned

New paper gasket

Green spacer replaced with red oil gap 0.4mm

Refurbed R gear needle bearings installed (used cage new needles)

Refurbed 1st gear roller bearings installed (used cage new needles)

Good used Syncroniser (no play in rivets ) 

Thrust washer 1.2mm  

Skimmed end case with new pinion bearing 373

Rev idler installed with shortened shaft and skimmed plate.

Refurbed Rev Idler needle bearings installed

All case holes tapped and mating faces cleaned

Oiling plate for Crown wheel installed

New TDI input shaft installed with new circlip

New Bell housing paper gasket  

Clutch fork installed with Weddle HD Bronze bush, new bonze bush in bellhousing, and new circlips. Bell housing modified for Dual mass Flywheel New  inspection cover and plug

New input shaft seal and new INA clutch guide sleeve

New output shaft seals and O rings

New selector Shaft Seal better one with spring gaiter 

Output flanges installed with new circlips and bungs

New ball, washer and Nylock nut  and selector shaft boot and selector ball boot.

Clutch fork (Diesel) installed with new circlip

Rev Housing installed with new O ring and paper gasket

All gears select

One years warranty unlimited mileage

Book yours now  http://vantopia.ie/contact/

This Post Has 2 Comments

  1. MY VW GOLF MK4 TDI AUTOMATIC 2009 GEARBOX BEEN DAMAGED WHILE DRIVING WITH ALL GEARBOX OIL COMING OUT THERE AND THEN ON THE ROAD. BEEN TOLD THAT I NEED A COMPLETE UNIT AND AM LOOKING FOR A REBUILT OR EQUIVALENT. CAN SOMEONE PLEASE ADVISE FROM WHERE CAN I SECURE THIS UNIT.

    1. Not really sure sounds like your gearbox is scrap I would try the local scrapyard for a replacement box hope you get sorted Paul

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