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MrKrik · Joined: 11 Jun 2006 Posts: 21

Hey guys jstu figred some of oyou must have droped teh gas tank on one of teh early 4 speed cars befroe .. hwo do i get the transmission out so that i can get teh gas tank out.. i have a chilton manual btu tsi little to bno help..

i got teh 6mm hex at "input shaft" throguh that ryubebr boushing off. I took off all the bolts between teh tourque tube adn teh tranny . and i undid the mounts. but ti wount seperate and also the shift likages still go throuh botht eh torurque tube AND the tranny how do i get it apart :|

Ozzie · Posted: Mon Aug 07, 2006 9:24 am Post subject:

Is there a reason to removing the tank?

You have to remove some of the exhaust and the tranny to remove the tank.
Never done it completely as I just lowered the tank enough to replace the lines. If the fuel lines only need replacing check the How-To section
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Porsche 924 1984 (UK import) NA
Its AUTO and its BLACK
Montego Black on black/red
Engineer of Electro/Mechanical Systems Maintenance

MrKrik · Joined: 11 Jun 2006 Posts: 21

the car sat for 16 years .. the tank is sooooo rusty and varnished inside it plugs teh fuel lines up withint minuits after cleaning them. so i ahve to get it cleaned adn lined

Ozzie · Posted: Mon Aug 07, 2006 3:31 pm Post subject:

Ok. not a simple job. Might be easier to replace than repair.
_________________
Porsche 924 1984 (UK import) NA
Its AUTO and its BLACK
Montego Black on black/red
Engineer of Electro/Mechanical Systems Maintenance

MrKrik · Joined: 11 Jun 2006 Posts: 21

im not the one fixign teh tank...

it is onyl rusty inside from old gas.. theya re chargin 100BUCKs to clean it out and make it liek new.. i jsut need to know how to get the damn tranny outa the way

Viking · Joined: 30 Jan 2003 Posts: 107 Location: Oslo, Norway

Now, I'll do something dangerous, I'm going to guess, guess that you have the Audi style manual transmission.

I never even saw a snailshell transmission, which was on the '79 and '80 models, IIRC.

Consider getting a copy of the Haynes manual, it doescribes this better then I can do form memory.

First of all, put the bolts that connect the bellhousing and transmission back in. Also consider to reattach the mountings for safety, because you might have to go back into the bellhousing with your hands, and I don't want to be responsible for you getting hurt.

There are two hexbolts on the piece that is inside the bellhousing. You also need to slide this connecting piece backwards, onto the rod that is part of the transmission. You will then feel the gap between the rods.

I've only ever done the 5 speed Audi transmissions, and getting the shiftlever linkage off is the hard part of the job. You need to remove the shiftlever and the boot that attached to it. Then you need to get the linkage off the lover part of the stickshift. Then remove the rest of the stickshift, you might be able to pop it out, but I unscrew it instead. Remove the bolt that attaches the linkage to the so called "intermediate shift lever", which is the thing that is attached eto the transmission. It should be secured with a piece of wire that you need to cut, and replace when you reinstall the transmission.
Now, you are going to push the linkage down and forwards towards the enginecompartment to get it out of the way in the back, there should be an opening in the foam that you can push it through. It helps to have someone push from the back while someone pushes in the front too.
Now, use a garage jack to support the transmission, undo the mounts and the bolts on the bellhousing.
You should now feel that the transmission is "free", and with some effort you should be able to wiggle it out.

And be careful, the transmission isn't that heavy, but it can still be painful and might hurt you if it falls on you.

Lizard · Posted: Tue Aug 08, 2006 12:41 am Post subject:

he has stated that he has the 4 speed which dictates that he has an audi based tranny.

to remove the gas tank you must obviously remove the tranny and exhaust,
if you cant figure out how to remove the exhaust well I dont think you should even attempt the tranny so I wont explain that.

to remove the tranny you will need sockets and wrenches of the following sizes. 19, 17, 13, 10 (maybe on the 10),

you will also need a VW CV joint allen key, which is refered to as a 12 point 8 mm allen key, or a 8mm triple square.

you will also need I believe a 5mm allen key though it may be a 6mm.

start by undoing the CV bolts, these are the hardest and most likely to strip, I would recommend replacing them with NEW factory style units, can be obtained from local VW dealer. once you have them all off bag the CV joints and use a coat hanger to get them out of the way, next look in the larger bellhousing area at the front of the tranny (where it meets the torque tube) and you will see the coupler which has the two 5mm (or 6mm) allen key bolts, you will have to turn it 180 deg to be able to access the second, remove both bolts entirely and slide the coupler off so that it is only on one of the shafts and not joining the two together.
next go to the top of the tranny and find the two wires for your backup lights and unplug them, then find the shifter linkage and there will be one bolt (either 13mm, or 12mm) and remove it, (it would help to put the car in 4th gear before doing this), once the bolt is removed whack the shift lever forward into third, this may take a couple of tries but the goal is to get the shift rod off the selector lever on the tranny. Next you will want to undo the 4-6 bolts holding the tranny to the torque tube, once these are removed and you will now need a jack, or your chest, and take the weight of the tranny off of the mounts and undo the two mount bolts and then lower the tranny, once the tranny is out the gas tank is very simple and you should be able to figure that out without an issue.

the tranny will weight roughly abit over 100 lbs,
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