Hi all,

I have a spare gearbox kicking around so I thought I will tear it down and generally mess about with it to understand how it works.

I have got as far as taking the diff and fifth gear off, but I'm stuck now.

Is there a guide or expanded diagram anywhere? The search function didn't yield much.

Thanks guys.

Nige has asked me to upload these for him...
Hope they are of use!

Adjusting_differential.doc

Adjusting_input_shaft.doc

Adjusting_output_shaft.doc

Adjustment_overview.doc

Dismantling_and_assembling_differential_drive_gear_wheel.doc

Dismantling_and_assembling_differential.doc

Dismantling_and_assembling_gearbox.doc

Dismantling_and_assembling_input_shaft.doc

Dismantling_and_assembling_output_shaft.doc

Servicing_clutch_housing.doc

Thanks a lot mark, very helpful.

I think if this info was in the faq section it would help a lot of membrs out as its not easy to come by.

Thanks again

Thanks for the very helpful diagrams Mark/Nige, I have been looking everywhere for them and some information on the speedometer drive.

I have a problem with my son's 6N1 gearbox which I hope someone may be able to help me with. He lost gears a few weeks ago and it turned out to be a cracked selector bracket and loose top bolt. I couldn't find anywhere who would part a gearbox to sell me a bracket, so I fixed it with a brass reinforcing plate. The only problem I had was re-fitting it and I had to take off the speedo sensor (357 919 149) to fit the top bolt. I took the sensor off from above and remember seeing the drive, but I replaced it from underneath when I was reconnecting the linkage.

The speedo (and fuel gauge) had stopped working so today I pulled the sensor but there is bugger all connecting it to the gearbox. I can't feel anything that is anywhere close enough to drive it so can anyone suggest what has happened or where it's gone?

Many thanks in anticipation.

Probably fell in if it didn't come out with the sensor? Unless it was broken?

I have a few selector mechanisms here if you want one?

Thanks dixy but my repair to the selector mechanism seems to be holding up. Unfortunately the top bolt has pulled out of the casting again so I'll going to have to tap a larger hole.

However, my biggest problem now is that the MoT is due in ten days and (as of 2012) the speedo is part of the MoT. Although the speedo drive wheel is shown in the differential dismantling/assembling drawing, I cannot find anything about the shaft to the speed sensor. Does anyone know what it looks like or have any information e.g. pictures, part numbers, whether it can be accessed through the sensor hole, etc or have a spare or even let me borrow one?

Many thanks in desperate anticipation.

PS Would a SatNav do as a speedo?

11) 084409187 speedometer drive gear

12) 014409193A guide for pinion

13) 001301131 seal

14) 084409197 speedometer pinion

Thanks Nige. That doesn't look too clever as I can't see the pinion going in from outside. And where the hell has the old one ended up?

Did you remove the metal retainer (no 12) with the sensor? As it sometimes comes out with it.

I have tried on mine to Dee if it will go in, but it doesn't meaning it either broke inside or it came out with the retainer and fell off.

It got through the MoT with SatNav speedo but now the clutch has packed up - I suppose that's the down side of a low mileage, one little old lady owner car. My son's got the box off and the top lug of the selector mechanism is cracked, so we might as well replace the whole lot now it's on the bench. Do you still have some selector mechanisms dixy?

Oh and yes, I now realise that the retainer came out as well as the sensor. And any suggestions on where to get the pinion from? Less than a quid at vwheritage and volkspares but £4 and £8 postage! I may get a couple as if it won't go in without splitting the gearbox, I'm going to try cutting an M16 thread on the teeth and screwing it in.

Tbh I would get a new one. At the price you'd be hard pushed to get a used one for that really. And it's new so will no doubt last longer.

I'm not really sure what you mean, what will you be taping into?

I do have a mechanism I think, but will have to dig it out as I have just recently moved house so all my "collection" is all over the place. What part has cracked exactly?

As with the clutch, generally if I'm planning on keeping the car and don't know the history I would throw a new one in regardless really, because at the very least o know it recent and on these cars they are simple to change and the parts are cheap.

Thanks for the offer dixy but I rang Volksmania last week and they had a gearbox mechanism available this time, so it's all back together with a new clutch and oil. The speedo drive pinion CAN be replaced without cracking open the gearbox but when you chew one up it turns the gearbox oil a funny consistency.

My son (18) is impressed with himself as he's done it all himself. The only problem is he forgot to check the bonnet release mechanism worked before dropping the lid.... does anyone know of an easy way to get to the bonnet catch?

Thew are holes in the front panel but I am not sure if you can. I'm sure there is a way as there is always a plan b built in.

Sure you just smash the grill and unbolt it from there.

A new grill is a minor problem..

Oh yeah, that's what the holes are for :)

Adjusting_differential.doc

Adjusting_input_shaft.doc

Adjusting_output_shaft.doc

Adjustment_overview.doc

Dismantling_and_assembling_differential.doc

Dismantling_and_assembling_differential_drive_gear_wheel.doc

Dismantling_and_assembling_gearbox.doc

Dismantling_and_assembling_gearbox.doc

Dismantling_and_assembling_input_shaft.doc

Dismantling_and_assembling_output_shaft.doc

Servicing_clutch_housing.doc

hopefully here are the replacement links..

Thanks for these guys.