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




5.3.2.1. Primary shaft

GENERAL INFORMATION

Adjustment of primary shaft

1–support;

2–rack;

3–indicator;

4–indicator leg;

5–plate;

6–primary shaft;

7–transmission case

Dismantling

PERFORMANCE ORDER
1. Выпрессовать the conic roller bearing 63 (see fig. Type 085 transmission).
2. To remove the conic roller bearing 49.
3. To remove a basic washer 50.
4. To remove a gear wheel 52 4th transfers, the needle bearing 51 and blocking ring 53.
5. To remove a lock ring 54.
6. To press from primary shaft a gear wheel 60 3rd transfers together with a blocking ring 59 and a synchronizer 56 nave (with the sliding coupling).
7. To remove a lock ring 58.
8. To remove the needle bearing 61.

Assembly

PERFORMANCE ORDER
1. To grease the needle bearing 61 and to establish it on primary shaft 62.
2. To establish a lock ring 58.
3. To check a gap between blocking rings 53 and 59 and gear wheels corresponding to them 52 and 60.
4. To establish on primary shaft the 62nd gear wheel 60 3rd transfers and blocking ring of the 59th synchronizer.
5. Напрессовать the synchronizer 56 in collecting (if the synchronizer understood, see subsection 5.2.2.2) so that the long part шлицов naves was directed towards a gear wheel of the 4th transfer, and crackers of the synchronizer got to grooves of a blocking ring.
6. To establish a lock ring 54.
7. To establish blocking ring 53 synchronizers, watching thus that crackers of the synchronizer got to grooves of a blocking ring.
8. To grease the needle bearing 51 and to establish it on primary shaft 62.
9. To establish a gear wheel 52 4th transfers.
10. To establish a basic washer 50.
11. To establish the conic roller bearing 49.
12. Напрессовать on a shaft the conic roller bearing 63, putting effort to an internal ring of the bearing.

Adjustment of an axial gap of primary shaft
Prevention

Adjustment make after replacement of one of the following details: transmission case, coupling case, primary shaft or conic roller bearings of primary shaft.


PERFORMANCE ORDER
1. Выпрессовать an external ring 3 (see fig. Carter of coupling) the conic roller bearing from a case of 2 couplings.
2. To take out an adjusting washer 4 and to press back a ring 3 bearings.
3. To establish primary shaft, to connect a case of coupling with a case of a transmission and to tighten bolts 14 (see fig. Carter transmissions) the moment of 25 N · m.
4. To turn several times primary shaft that bearings rose into place.
5. To establish a transmission vertically, having directed the shaft end from the 5th transfer up.
6. To establish a support 1 (see fig. Adjustment of primary shaft) with a rack 2 and the indicator 3 on a case of the 7th transmission.
7. To enclose under a leg 4 indicators on primary shaft 6 ground plate 5.
8. To move primary shaft 6 in the axial direction from an emphasis against the stop and to take readings of the indicator.
9. To pick up an adjusting washer of the necessary size depending on size of an axial gap (a difference between indicator indications).
10. To remove the indicator with a rack and a support.
11. To disassemble a case and выпрессовать an external ring of the bearing from a coupling case.
12. To establish in a coupling case the picked-up adjusting washer and to press an external ring of the bearing.
13. To collect a transmission and once again to make check. The axial gap should be within 0,1–0,12 mm.

The measured size of an axial gap, mm
Thickness of an adjusting washer, mm
to 0,68
0,65
0,68-0,75
0,7
0,74-0,78
0,75
0,79-0,83
0,8
0,84-0,88
0,85
0,89-0,93
0,9
0,94-0,98
0,95
0,99-1,03
1,00
1,04-1,08
1,05
1,09-1,13
1,10
1,14-1,18
1,15
1,19-1,23
1,20
1,24-1,28
1,25
1,29-1,33
2 x 0,65
1,34-1,38
0,65 + 0,7
1,39-1,43
2 x 0,7
1,44-1,48
0,7 + 0,75
1,49-1,53
2 x 0,75
1,54-1,58
0,75 + 0,8
1,59-1,63
2 x 0,8
1,63-1,68
0,8 + 0,85
1,69-1,75
2 x 0,85