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
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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;
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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;
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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.
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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. |
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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.
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| 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. |
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