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I think this was a fairly easy project as far doing
the job goes, we will see how i make out once i run it
and close up the tranny but i dont see any problems
with that, the hard work was done. If your
mechanically inclined and are not afraid of a new
challenge, then go for it =D
This was my first LSD install and i really dont have
much tranny knowledge, but after doing this i feel
much more comfortable with the tranny.
I wrote up these instructions, after i did this job
so it might need some fine tuning =D
**NOTE** becareful when you open up the tranny that
none of the smaller sleeve bearings dont fall out.
01. Drain Transmission oil (this gear oil stinks)
02. Remove output flanges using bolt from tranny case
and put a flat bar behind it to make removal easier
03. Remove (2) bolts from shifter and pull out
carefully.
04. Remove (2) bolts from VW cap on other side and pry
out.
05. Remove fork and throw out bearing from bell
housing.
06. Remove (3) bolts, for the collar around the spline
and pull out.
07. Remove (4) nuts, to the left of the spline.
08. Remove all remaning bolts inside bell housing.
09. Remove all 13mm bolts you see on the outside
holding the case together
10. Turn tranny upside down and let it sit flat so you
can open the 5th gear cover.
11. Remove (5) bolts holding cover and pry open
12. There are (2) bolts one on the right and left,
holding the fork down, remove both bolts and
pull out the fork
13. Now you have 2 gears inside that both need to come
out, in the center of them is an allen bolt
remove the bolts and washers, you will need to
hold the gear from spinning on you, so you will
have to engage the gear. You can do this by
pushing the 3 little clips in on the top of the gear
and pulling the outer ring. Once it is engaged
you can remove the bolt with an impact gun.
14. Now you have the difficult task of removing the
gears, everyone seems to think this is a PITA
But it really aint, first you need to remove that
outer ring, that~Rs in the way, I pulled out the metal
clip at the top and pushed in those 3 lil clips and
slid up the outer ring but be careful that those clips
don~Rt go flying. I then used a small gear puller to
pull the gear, there is a couple of them that you can
pull up by hand, to make it easier I screwed in the
allen bolt that I removed, but not all the way, so I
could give the puller something to center on without
damaging anything. Make sure you put the gear puller
claws under the gear and not holding on to the edge of
the gear, were you might chip it.
15. Now do the same for the next gear next to it.
16. Once you have removed the gears, there is one more
bolt inside the 5th gear area, look inside one of the
holes
17. Now remove the (4) pivots, 2 on the right and 2 on
the left.
18. Now remove the bolt in the middle of the pivots.
19. Now you can crack open the tranny case and lift it
up slowly. The case is glued shut so you will have to
pry it open, once its open it should lift right off,
if it is not lifting straight off, you still have a
bolt somewhere that you have forgotten to remove.
20. Now that the case is opened you will see all the
gears, study this carefully, as you will have to put
all this back together. Remove the large fork
assembly, this will slide out, notice how the arms sit
in the grooves.
21. There is one screw that holds that spring down on
the left hand corner that needs to come out. Remove
and pull the small fork assembly out with spring.
22. You can now begin to remove those small gears,
carefully, that lil assembly will come out just put it
back together, so you now how you took it out for
later.
23. Now you can remove the next gear assembly to your
left.
24. Now you have one more gear assembly left and that
is the large one, just pull em out
25. Now all that is left in the case is the
differential, just lift it out.
26. All that work just to pull that out lol
27. Lift out the what I believe is the ring and pinion
gear, we need to transfer this gear over to the LSD
28. The gear is held in place with solid rivets, these
rivets are not easily removed., some people use and
air hammer to remove them. I used a grinder to
flatten down one side of the rivet and then used a
drill press to drill them out half away, then used a
punch to nail them out.
29. Once you remove all the rivets, you are almost
complete. I then cleaned the gear and brough it over
to the new LSD. The peloquin provides the screws for
this new installation, we no longer use those rivets.
You are now almost complete just have to put
everything back together again.
30. SHIMS <--need to look into this, some people say
the orignals are good enough.
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@gti-vr6