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