Volkswagen Golf Mk1 1974-1983
Gearbox maintenance - Volkswagen Golf Mk1 1974-1983
This project started with a simple clutch adjustment. The clutch was engaging very close to the floor, so I decided to adjust the cable. After the adjustment, however, the clutch started slipping. The previous owner had told me that the clu
6/6 phases complete
Project stages
Inspection & Assessment
I removed the gearbox on my own, without using an engine support bar. I used a trolley jack instead. The car was raised quite high and securely supported on jack stands, while metal discs were placed underneath the engine for additional support.
100% complete
- Lift the Car
- Remove the Gearbox
- Remove the Clutch
- Remove the Release Bearing
Service the Gearbox
Since the gearbox was already out of the car, I decided to replace the seals before reinstalling it. The housing was covered in decades of oil and dirt, so cleaning it took considerably longer than expected. I didn't use anything special for the job — just some engine bay cleaner and water from a garden hose, which my neighbor was kind enough to let me use.
100% complete
- Clean the Gearbox
- Replace the Oil Seals
Service the Drive Shafts
After rebuilding the driveshafts, I decided to give them a fresh coat of 3-in-1 metal paint. For cleaning them up, I used a little trick I had seen on TikTok: a strip of sandpaper wrapped around the shaft and pulled back and forth with a piece of rope. By that time, it was already getting quite cold outside, so I improvised a small paint booth out of a cardboard box.
100% complete
- Paint the Drive Shafts
Install the Clutch
The clutch pressure plate and flywheel were installed using new bolts, as specified in the parts catalog. From there, I continued with the reassembly, using the freshly powder-coated mounts. I also made sure not to forget the special washers on the driveshafts.
100% complete
- Service the Drive Shafts at CarFix
- Install the Clutch
- Refurbish the Mounts
Gearbox Installation
After the final assembly, the only thing left to install was the speedometer cable. I decided to test-fit the bolt that was supposed to go there and... dropped it straight inside the gearbox. That was a disaster. I spent the next few days feeling pretty miserable and trying to figure out what to do. Eventually, I bought a borescope and, after quite a bit of struggling, finally managed to retrieve the bolt.
100% complete
- Install the Gearbox
- Install the Starter
- Remove a fallen bolt from the gearbox
- Fill with Gearbox Oil
- Reinstall the Remaining Components
Final Steps
Once everything was back together, I gave the car a proper test drive on the way to its new garage. To be continued...
100% complete
- Take a Test Drive
