Volkswagen Golf ll, Jetta II

1983-1992 of release

Repair and car operation



Volkswagen Golf 2 / Jett 2
+ 1.1. Short technical characteristics of diesel engines
+ 2. Engine
+ 3. Power supply system
+ 4. Coupling
- 5. Transmission
   5.1. Removal and installation
   - 5.2. Four-speed transmission
      5.2.1. Technical characteristics
      - 5.2.2. Transmission dismantling
         5.2.2.1. Primary shaft
         5.2.2.2. Secondary shaft
         5.2.2.3. Synchronizer
         5.2.2.4. Differential
      5.2.3. Transmission assembly
      5.2.4. Gear shifting mechanism
   + 5.3. Five-speed transmission
   + 5.4. Type 020 four-speed transmission
   + 5.5. Type 020 five-speed transmission
   + 5.6. Automatic transmission
+ 6. Transmission
+ 7. Forward drive
+ 8. Steering
+ 9. Suspension brackets
+ 10. Brake system
+ 11. Body
+ 12. Electric equipment



5.2.2.4. Differential

GENERAL INFORMATION

Differential

1–bolt;
2–semi-axis flange;
3–epiploon;
4–plug;
5–spring;
6–washer;
7–rasporny ring;
8–adjusting washer;
9–roller conic bearing;
10-gear wheel of a drive of a speedometer;

11-shaft of a drive of a speedometer;
12-differential case;
13-a conducted gear wheel of the main transfer;
14-separator;
15-conic gear wheel;
16-round nut;
17-axis of satellites;
18-pin;
19-satellite

Differential adjustment

1–transmission case;
2–adjusting washer;
3–roller conic bearing;
4–a conducted gear wheel of the main transfer;
5–roller conic bearing;
6–indicator;

7–plate;
8–coupling case;
9–differential case;
10-bolt;
11-laying

Dismantling

PERFORMANCE ORDER
1. To press internal rings of bearings 9 from both parties of the case of the 12th differential.
2. To press a gear wheel of the 10th drive of a speedometer (without its destruction it is almost impossible to make it).
3. To beat out two pins 18 on an axis of 17 satellites.
4. To beat out an axis of 17 satellites.
5. To beat out conic gear wheels 15 with round nuts 16.
6. To take out a separator 14.
7. Выпрессовать from a case of coupling and a transmission case external rings of bearings of differential.

Prevention

To remove a conducted gear wheel 13 from the case of the 12th differential, the special tool and a certain skill and consequently it is recommended to address in specialized workshops is necessary.



Assembly
Prevention

External and internal rings of bearings of differential are not interchangeable and should be replaced in a set.


PERFORMANCE ORDER
1. To establish a separator 14 in the case of the 12th differential.
2. To establish conic gear wheels of 15 semi-axes and holding them with a hand, to insert flanges of 2 semi-axes.
3. To establish two satellites 19 in cuts of the case of the 12th differential against each other and, turning conic gear wheels of 15 semi-axes, to establish satellites 19 into place.
4. To establish round nuts 16 and, holding them, to insert an axis of 17 satellites.
5. To establish pins 18.
6. Напрессовать new gear wheel of the 10th drive of a speedometer.
7. Напрессовать internal rings of bearings 9, previously their heating to temperature 100 ° Page.
8. To press in a case of coupling and a transmission case external rings of bearings of differential.

Adjustment
Prevention

Adjustment make after replacement at least one of the following details: transmission case, coupling case, case of differential or conic roller bearings of differential.


PERFORMANCE ORDER
1. To establish in a case of 1 transmission an adjusting washer 2 (see fig. Differential adjustment) thickness of 1 mm and to press an external ring of the roller conic bearing 3.
2. To press in a case of the 8th coupling an external ring of the roller conic bearing 5 without an adjusting washer.
3. To establish the case of differential 9 in a case of 1 transmission.
4. To connect a case of the 8th coupling and a case of 1 transmission, having established laying 11 if it was on a complete set.
5. To twirl bolts 10 evenly on a diagonal the moment of 25 N · m.
6. To establish the ground plate 7.
7. To establish the indicator 6 with the extension piece on 30 mm on a universal support.
8. To establish indicator 6 indications on a zero.
9. To move the case of differential 9 several times up and down, having read thus instruments of the indicator and having defined an axial gap.

Prevention

Not to turn differential at measurement. Otherwise bearings will move a little and results of measurement will be incorrect.


10. To calculate thickness of an adjusting washer on a formula: S2 = Sn + 0,3 mm, where S2 – settlement thickness of a demanded adjusting washer, Sn – the measured size of an axial gap.
11. To remove a case of the 8th coupling and выпрессовать an external ring of the bearing 5.
12. To pick up washers of the demanded thickness proceeding from sets delivered in the spare part. The existing sizes: from 1,45 mm to 2,45 mm through each 0,05 mm.
13. To establish the picked-up adjusting washers in a case of coupling and to press an external ring of the roller conic bearing.
14. Further assembly see subsection 5.2.3.