Technical data
11 Gearbox identification
11.1 Gearbox identification
11.2 Code letters, gearbox allocation, ratios, capacities
22 Rear final drive identification
72.1 Rear final drive identification
72.2 Code letters, assembly allocation, ratios, capacities
83 Transmission layout
123.1 Transmission layout
124 Calculating overall ratio "i"
144.1 Calculating overall ratio "i"
145 Notes on performance test, brake test and towing
145.1 Notes on performance test, brake test and towing
146 General repair instructions
146.1 General repair instructions
14Clutch
171 Servicing clutch control
171.1 Servicing clutch control
171.2 Assembly overview - Pedal cluster - Hydraulic clutch control
191.3 Removing and installing clutch pedal - Hydraulic clutch control
221.4 Assembly overview - Hydraulic system
231.5 Removing and installing slave cylinder for vehicles with short front end
261.6 Removing and installing slave cylinder for vehicles with long front end
301.7 Bleeding clutch system
331.8 Assembly overview - Pedal cluster - Mechanical clutch control
341.9 Removing and installing over-centre spring
371.10 Removing and installing clutch pedal - Mechanical clutch control
381.11 Assembly overview - Mechanics
391.12 Removing and installing clutch cable
432 Servicing clutch release mechanism
462.1 Servicing clutch release mechanism
463 Servicing clutch
493.1 Servicing clutch
49Controls, Housing
561 Servicing gear selector mechanism
561.1 Servicing gear selector mechanism
561.2 Installation position of gear selector mechanism
561.3 Removing and installing gear stick housing
581.4 Removing and installing gear stick
611.5 Removing and installing selector and gate rods
641.6 Removing and installing selector mechanism
731.7 Adjusting gear selector mechanism
762 Removing and installing operating elements for differential lock and freewheel
782.1 Removing and installing operating elements for differential lock and freewheel
782.2 Removing and installing valve for operating differential lock and warning light
782.3 Removing and installing actuator for differential lock
792.4 Adjusting differential lock
802.5 Removing and installing actuator for freewheel lock
803 Differential and freewheel pipes and hoses routing diagram
823.1 Differential and freewheel pipes and hoses routing diagram
823.2 Routing diagram for vehicles with petrol engine
833.3 Routing diagram for vehicles with diesel engine
954 Removing and installing gearbox
1044.1 Removing and installing gearbox
1044.2 Differences between Transporter with long and short front end from 01.96
1054.3 Removing and installing gearbox for vehicles with short front end
1064.4 Removing and installing gearbox on vehicles with long front end
1295 Removing and installing bevel box
1465.1 Removing and installing bevel box
1466 Checking oil in manual gearbox with bevel box
1536.1 Checking oil in manual gearbox with bevel box
1537 Dismantling and assembling gearbox
1557.1 Dismantling and assembling gearbox
1557.2 Assembly overview
1557.3 Removing and installing cover for gearbox housing and 5th gear
1567.4 Removing and installing gearbox housing and selector mechanism
1597.5 Removing and installing input shaft, output shaft (pinion shaft), differential and selector forks
1617.6 Assembly sequence
1648 Servicing gearbox housing
1808.1 Servicing gearbox housing
1809 Servicing clutch housing
1849.1 Servicing clutch housing
18410 Dismantling and assembling gearbox selector mechanism
19210.1 Dismantling and assembling gearbox selector mechanism
19211 Dismantling and assembling selector forks
19711.1 Dismantling and assembling selector forks
197Gears, Shafts
2041 Dismantling and assembling input shaft
2041.1 Dismantling and assembling input shaft
2042 Adjusting input shaft
2162.1 Adjusting input shaft
2162.2 Table of adjustment shims
2182.3 Performing measurement check
2203 Dismantling and assembling output shaft (pinion shaft)
2213.1 Dismantling and assembling output shaft (pinion shaft)
2214 Adjusting output shaft
2504.1 Adjusting output shaft
2505 Dismantling and assembling reverse shaft
2535.1 Dismantling and assembling reverse shaft
253Final drive, Differential rear
2591 Removing and installing seal for drive flange or flange shaft
2591.1 Removing and installing seal for drive flange or flange shaft
2591.2 Removing and installing oil seal for left-hand flanged shaft
2591.3 Removing and installing oil seal for right drive flange
2632 Renewing bevel box output flange seal
2672.1 Renewing bevel box output flange seal
2673 Dismantling and assembling differential
2693.1 Dismantling and assembling differential
2694 Adjustment overview
2834.1 Adjustment overview
2835 Adjusting differential
2845.1 Adjusting differential
2846 Dismantling and assembling bevel box
2866.1 Dismantling and assembling bevel box
2866.2 Assembly overview
2876.3 Dismantling and assembling sequence
2957 Adjusting shaft bevel gear and bevel gear (gear set)
3097.1 Adjusting shaft bevel gear and bevel gear (gear set)
3097.2 General notes
3097.3 Adjusting and marking of gear sets
3107.4 Position of shims
3137.5 Adjustment overview (bevel box)
3137.6 Determining shaft bevel gear installation position (actual measurement)
3147.7 Recommended sequence for adjusting gear set
3147.8 Determining shim "S4" thickness when replacing output flange
3157.9 Adjusting shaft bevel gear
3167.10 Adjusting bevel gear
3218 Removing and installing 2-section propshaft
3248.1 Removing and installing 2-section propshaft
3248.2 Removing and installing 2-part propshaft underfloor mountings
3279 Removing and installing 3-section propshaft
3289.1 Removing and installing 3-section propshaft
3289.2 Removing and installing 3-section propshaft underfloor mounting
33110 Servicing 2-section propshaft
33510.1 Servicing 2-section propshaft
33511 Servicing 3-section propshaft
34811.1 Servicing 3-section propshaft
34812 Checking function of viscous coupling
36212.1 Checking function of viscous coupling
36213 Removing and installing viscous coupling
36313.1 Removing and installing viscous coupling
36315 Removing and installing flange shaft or drive flange oil seal (final drive installed)
36615.1 Removing and installing flange shaft or drive flange oil seal (final drive installed)
36615.2 Renewing right-hand flange shaft oil seal
36615.3 Renewing left drive flange seal
36916 Functional check of freewheel
37316.1 Functional check of freewheel
37317 Functional check of freewheel lock
37317.1 Functional check of freewheel lock
37318 Removing and installing rear final drive
37418.1 Removing and installing rear final drive
37419 Checking rear final drive oil
37719.1 Checking rear final drive oil
37720 Dismantling and assembling rear final drive
37820.1 Dismantling and assembling rear final drive
37820.2 Removing and installing viscous coupling and pinion housing
37920.3 Removing and installing differential lock and freewheel lock
38120.4 Removing and installing input shaft bevel gear and differential lock control
38620.5 Assembly sequence
39021 Dismantling and assembling differential and freewheel (assembly overview)
40121.1 Dismantling and assembling differential and freewheel (assembly overview)
40122 Dismantling and assembling differential (assembly sequence)
40522.1 Dismantling and assembling differential (assembly sequence)
40523 Removing and installing freewheel (sequence)
40923.1 Removing and installing freewheel (sequence)
40924 Dismantling and assembling freewheel (sequence)
41024.1 Dismantling and assembling freewheel (sequence)
41025 Servicing shaft bevel gear bearings
41125.1 Servicing shaft bevel gear bearings
41125.2 Assembly overview
41125.3 Assembly sequence
41326 Servicing input shaft bevel gear bearings
41926.1 Servicing input shaft bevel gear bearings
41926.2 Assembly overview
41926.3 Assembly sequence
42727 Dismantling and assembling differential lock controls
43427.1 Dismantling and assembling differential lock controls
43428 Adjusting bevel gear and shaft bevel gear (gear set)
43628.1 Adjusting bevel gear and shaft bevel gear (gear set)
43628.2 General notes
43628.3 Adjusting and marking of gear sets
43628.4 Position of shims
43928.5 Adjustment overview (rear final drive)
43928.6 Determining shaft bevel gear installation position (actual measurement)
44028.7 Recommended sequence for adjusting gear set
44028.8 Adjusting shaft bevel gear
44128.9 Adjusting bevel gear
446