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
   - 5.3. Five-speed transmission
      5.3.1. Technical characteristics
      - 5.3.2. Transmission dismantling
         5.3.2.1. Primary shaft
         5.3.2.2. Secondary shaft
         5.3.2.3. Differential
      5.3.3. Transmission assembly
      5.3.4. Position of the lever of gear shifting and connecting plug
      5.3.5. Gear shifting mechanism
   + 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



5.3.2. Transmission dismantling

GENERAL INFORMATION

Transmission case

1–cover;
2–bolt;
3–washer;
4–laying;
5–transmission case;
6–drain stopper;
7–switch of fires of the back
course;
8–stopper;
9–magnet;
10-pin;
11-coupling case;
12-plug;
13-epiploon;
14-bolt;
15-valve

Fork of inclusion of the 5th transfer

1–bolt;

2–fork of inclusion of the 5th transfer;

3–plug;

4–the sliding coupling of the synchronizer of the 5th transfer;

5–lever

Coupling case

1–arm;
2–coupling case;
3–external ring of the roller
conic bearing;
4–adjusting washer;
5–washer;
6–external ring of the roller
conic bearing;
7–adjusting washer;
8–connecting plug;
9–bolt;
10-gear shifting rod;
11-plug;
12-epiploon;
13-external ring of the roller conic bearing;
14-adjusting washer;
15-plug;
16-epiploon;
17-shaft of a drive of a speedometer;
18-carving plug;
19-sealing ring;
20-the directing plug;
21-bolt;
22-Vyzhimny bearing;
23-pin

Internal mechanism of switching of a transmission

1–gear shifting lever;
2–bolt;
3–plug;
4–arm;
5–cap;
6–gear shifting shaft;
7–transmission case;
8–washer;
9–bolt of fastening of a rod of a fork of inclusion of the 5th transfer;
10-screw of fastening of a rod of a fork of inclusion of a backing;
11-screw of fastening of a shaft of an intermediate gear wheel of a backing;
12-rod

Removal of a shaft of gear shifting

1–gear shifting shaft;

2–rod of a fork of inclusion of the 5th transfer;

3–rod of a fork of inclusion of a backing;

4–rod of a fork of switching of the 1-2nd of transfers;

5–rod of a fork of switching of the 3-4th transfers;

6–screw-driver;

7–primary shaft;

8–secondary shaft;

9–transmission case

Dismantling

PERFORMANCE ORDER
1. To clear a transmission of dirt and to wash out water, having protected cases from water hit.
2. To insert into an opening of a flange 2 (see fig. Type 084 transmission) a screw-driver and to rest semi-axes it in edge of a case of the 6th coupling, to block a flange from a provorachivaniye.

Prevention

Flanges of semi-axes have different length. The length of the left flange makes 84,5 mm, and right – 89,6 mm. It is recommended to mark flanges before removal.


3. To unscrew by means of a cap key a bolt 1.
4. To take out a flange of 2 semi-axes from a coupling case by means of two screw-drivers.
5. To remove a spring 3, a washer 4 and a rasporny ring 5.
6. To remove a semi-axis flange on the other side of a transmission (see subitem 2-5).

Prevention

Since 1986 instead of bolts of flanges of semi-axes with a six-sided head bolts with a cylindrical head under a shestigrannik began to be applied.


7. To turn off three bolts 2 (see fig. Carter transmissions).
8. To uncover 1 transmission and laying 4.
9. To include the 5th transfer.
10. To weaken a lock-nut being under a fork 2 (see fig. Fork of inclusion of the 5th transfer).
11. To turn off a bolt 1 and to remove it with the plug 3.
12. To remove at the same time a fork 2 and the sliding coupling 4 synchronizers of the 5th transfer.
13. To establish again as the sliding coupling 4 synchronizers of the 5th transfer.
14. To include the 5th transfer by means of the synchronizer and the 2nd transfer by means of the gear shifting lever, having blocked thus transmission shaft from rotation.
15. To turn off a bolt 66 (see fig. Type 085 transmission).
16. To remove the sliding coupling 4 (see fig. Fork of inclusion of the 5th transfer) synchronizer of the 5th transfer.
17. To remove a lock ring 21 (see fig. Type 085 transmission).
18. To press a gear wheel 25 5th transfers together with the synchronizer 22 a blocking ring 24 and the needle bearing 26.
19. To pick up a basic washer 27 and to remove it together with an internal ring of the needle bearing.
20. To press a gear wheel 64 5th transfers from primary shaft 62.
21. To remove the lever 5 (see fig. A fork of inclusion of the 5th transfer) from a rod of a fork of inclusion of the 5th transfer.
22. To turn off bolts 14 (see fig. Carter transmissions).
23. To separate a case of the 5th transmission and a case of coupling 11.
24. To take out differential.
25. To unscrew the carving plug 18 (see fig. Carter couplings) and to take out a shaft of the 17th drive of a speedometer.
26. To unscrew the switch of light of a backing.

Prevention

If the connecting plug or the internal lever of gear shifting acts in film, at installation it is necessary to execute adjustment.


27. To turn off a bolt 9.
28. To remove the connecting plug 8.
29. To remove a cap 5 (see fig. Internal mechanism of switching of a transmission).
30. To beat out a shaft of the 6th gear shifting.
31. To remove the lever of 1 gear shifting.
32. To turn off a bolt 2 and to take out the plug 3.
33. To remove an arm 4 levers of gear shifting.
34. To unscrew a bolt of the 9th fastening of a rod of a fork of inclusion of the 5th transfer and the screw 10 of fastening of a rod of a fork
backing inclusions.
35. To take out a rod 2 (see fig. Removal of a shaft of gear shifting) forks of inclusion of the 5th transfer and rod of 3 forks of inclusion of a backing.
36. To unscrew the screw 11 (see fig. Internal mechanism of switching of a transmission) fastenings of a shaft of an intermediate gear wheel of a backing.
37. To take out from a transmission case at the same time primary 7 (see fig. Removal of a shaft of gear shifting) and secondary the 8th shaft, a backing gear wheel with shaft and rods of 4 and 5 forks of switching of the 1-2nd and 3-4th transfers.