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
      5.2.3. 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



5.2.3. Transmission assembly

GENERAL INFORMATION

Installation of a shaft of a gear wheel of a backing

and – distance from an end face of a shaft of a gear wheel of a backing to a flange of a case of a transmission

Blocking mechanism

1–stopper;
2–transmission case;
3–plug clamp;
4–the directing plug;
5–spring;
6–laying;
7–stopper;
8–rod of a fork of switching of the 3-4th transfers;
9–blocking pin;
10-rod of a fork of switching of the 1-2nd of transfers;
11-blocking pin;
12-rod of a fork of inclusion of a backing

Gap between a fork of inclusion of a backing and a fork of switching of the 1-2nd of transfers

1–fork of inclusion of a backing;

2–fork of switching of the 1-2nd of transfers

PERFORMANCE ORDER
1. To press a shaft of a gear wheel of a backing, having sustained the size and = 83,3 mm from a shaft end face to a flange of a case of a transmission (see fig. Installation of a shaft of a gear wheel of a backing).
2. To press the bearing 6 (see fig. Carter transmissions) a secondary shaft in a case of 22 transmissions the party closed by a separator, to a case.
3. To insert a blocking pin 9 (see fig. The blocking mechanism) in an opening of a case of 2 transmissions.
4. To wring out the lever of gear shifting and to block it by means of a nut М16 6 (see fig. Installation of a special plate).
5. To establish a rod 14 (see fig. Carter transmissions) with a fork of 21 switchings of the 1-2nd of transfers, a secondary shaft 15 and a gear wheel of the 19th backing.
6. To press a secondary shaft 15 in an internal ring of the bearing 6, watching that a rod of the 14th fork of gear shifting and a gear wheel of the 19th backing did not jam.
7. To establish an adjusting washer 5 and a lock ring 4.
8. To adjust an axial gap of a secondary shaft if one of the following details was replaced: coupling case, transmission case, secondary shaft or conic roller bearings of a secondary shaft.
9. To establish a lock ring 4 without an adjusting washer 5.
10. To measure shchupy a gap between a lock ring 4 and an internal ring of the bearing 6.
11. To pick up an adjusting washer 5 so that the gap made 0–0,05 mm.
12. To establish in a transmission case primary shaft 17 and a rod 16 with a fork of the 20th switching of the 3-4th transfers, watching, that a blocking pin 9 (see fig. The blocking mechanism) was between rods 8 and 10. Thus to raise by means of the adaptation (see fig. The special adaptation) a gear wheel 19 (see fig. Carter of a transmission) a backing.
13. To establish a special plate (see fig. Special plate and Installation of a special plate).
14. To press the bearing 30 (see fig. Carter transmissions) the party against the stop closed by a separator to a transmission case.
15. To establish an adjusting washer 31 and a lock ring 32.
16. To adjust an axial gap of primary shaft if one of the following details was replaced: a coupling case, a transmission case, primary shaft or conic roller bearings of primary shaft, similar to adjustment of a secondary shaft (see subitem 9-11).
17. To remove a special plate.
18. To remove nut М16, having unblocked the gear shifting lever.
19. To insert a blocking pin 11 (see fig. Blocking mechanism).
20. To establish a rod 11 (see fig. Carter transmissions) forks of inclusion of a backing and a fork of the 13th inclusion of a backing.
21. To turn a rod 11 and to enter into gearing a fork of the 13th inclusion of a backing with a gear wheel of the 19th backing.
22. To twirl a bolt 24 with a washer 23 so that between a fork of the 13th inclusion of a backing and a fork of 21 switchings of the 1-2nd of transfers there was a distance and (see fig. A gap between a fork of inclusion of a backing and a fork of switching of the 1-2nd of transfers), equal 1,3–2,8 mm.
23. To assemble the plug clamp 25 (see fig. Carter transmissions) with a spring 26 and the directing plug 27 and to insert three sets into a transmission case (see fig. Blocking mechanism).
24. To establish laying 6 and to wrap jams 7.
25. To wrap a stopper 1.
26. To establish adjusting washers 3 and 33 (see fig. Carter transmissions) according to earlier made marking.
27. To pick up adjusting washers 3 and 33 if one of the following details was replaced: coupling and transmission cases, respectively primary or secondary shaft and conic roller bearings of shaft. For this purpose it is necessary to measure at completely pressed corresponding bearing by the indicator distance between a back end face of a case of a transmission and an external end face of the bearing.
28. To establish new laying 2 and a cover 1.
29. To twirl bolts the 34th moment of 25 N · m.
30. To make trial inclusions of the transfers, all transfers should join easily and freely.
31. To establish differential assembled.
32. To establish pins.
33. To grease with D3 hermetic of a surface of connection of cases of coupling and a transmission or new laying (depending on a complete set).
34. To establish a magnet in a coupling case.
35. To establish gear shifting forks in neutral situation.
36. To connect a case of coupling with a transmission case, watching thus that the finger of a rod of gear shifting entered into gearing with the gear shifting lever.
37. To twirl bolts evenly on a diagonal the moment of 25 N · m.
38. To insert in a shlitsa of conic gear wheels of differential flanges 2 (see fig. Type 084 transmission) semi-axes with a rasporny ring 5, a basic washer 4 and a spring 3.
39. To block flanges of semi-axes a screw-driver and to twirl bolts 1 moment of 25 N · m.
40. To twirl the switch of light of a backing.

The measured distance, mm
Thickness of a washer
0,14-0,18
0,45
0,19-0,23
0,50
0,24-0,28
0,55
0,29-0,33
0,60
0,34-0,38
0,65
0,39-0,43
0,70
0,44-0,48
0,75
0,49-0,53
0,80
0,54-0,58
0,85
0,59-0,63
0,90
0,64-0,68
0,95
0,69-0,73
1,00
0,75-0,79
1,05
0,80-0,84
1,10
0,85-0,89
1,15
0,90-0,94
1,20
0,95-0,99
1,25
1,00-1,04
1,30