5th gear conversion

["Chris DeLong" <green536@hotmail.com>]

How is this?

Chris DeLong
ICQ#45030867
Seattle, WA USA
'80 16V 'Rocco ragtop
'91 GLi 2.0 16V
'77 Rabbit 16V
'80 'Vert (parting out!)
'61 17 Window type II
'91 Vanagon
'77 Rabbit (for sale Cheap!)


>Did you install that 5th gear yourself, Chris?
>
>Can you explain the process of installing the .71?

All 020 8V trannies will accept this conversion.

1. jack up car
2. remove clutch cable from transmision
2a. loosen locknut on cable adjuster and wind plastic ring into cable 
sheath. Disconnect small metal clip and retainer support on clutch actuator 
arm.
3. support rear of trans.
4. remove 17mm bolts and nuts from rear trans mount
5. remove 6 13mm bolts (trans fluid may leak after this; good time to drain 
and replace fluid with synthetic such as Amsoil)
6. remove TO bearing housing which you just unbolted
6a. be careful not to yank hard on it as you "might" pull the rod that holds 
all the forks out of the trans too far and create a huge project for 
yourself. The rod has a spring attached to it and sits in the TO bearing 
housing.
7. You MUST have a head bolt removal tool (12pt. 12mm ? and a pair of 
circlip pliers for this job (sorry to tell you now if you have gone this far 
;)
8. Remove circlip holding 5th gear on pinion shaft (pay close attention to 
the removal of each part as it MUST go back on in the EXACT same order that 
it was removed)
9. Install head bolt tool into the only obvious hole (5th gear selector hub)
10. set socket wrench to "remove" and insert a rag into the splines to 
prevent movement upon wrenching
11. remove mainshaft 5th gear selector after the bolt is out. You will 
probably have to use a pair of screwdrivers to lever it off if your tranny 
is "tight".
12. Remove the 5th gear on pinion shaft with 5th gear selector.
13. Get new circlip for pinion gear for installation.
14. Installation is the reverse of removal. Be sure to Loctite the big 12pt 
bolt after torquing to spec.


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