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



5.3.2.2. Secondary shaft

Dismantling

PERFORMANCE ORDER
1. To press from a secondary shaft the 45th gear wheel 30 1st transfers with a blocking ring 32, a basic washer 29 and the conic roller bearing 28 (see fig. Type 085 transmission).
2. To remove the needle bearing 31.
3. To remove a lock ring 33.
4. To press a gear wheel 39 together with a blocking ring 38 and the synchronizer 36.
5. To remove the needle bearing 40.
6. To remove a gear wheel of 41 3rd transfers.
7. To remove lock rings 42 and 43.
8. To remove a gear wheel 44 4th transfers.
9. To press the roller bearing 46.

Assembly

PERFORMANCE ORDER
1. Напрессовать on a secondary shaft 45 conic roller bearing 46, putting efforts to an internal ring of the bearing.
2. To establish a gear wheel 44 4th transfers.
3. To establish lock rings 43 and 42.
4. To establish a gear wheel of 41 3rd transfers.
5. To grease the needle bearing 40 and to establish it on a shaft 45.
6. To check a gap between blocking rings 38 and 32 and gear wheels corresponding to them 39 and 30 (see subsection 5.2.2.1).
7. To establish a gear wheel 39 2nd transfers and blocking ring 38.
8. Напрессовать the synchronizer 36 in collecting (if the synchronizer understood, see subsection 5.2.2.2) so that the pro-point under a fork on the sliding coupling of the synchronizer was directed towards a gear wheel of the 1st transfer, and crackers of the synchronizer got to grooves of a blocking ring.
9. To establish a lock ring 33.
10. To establish blocking ring 32 synchronizers, watching thus that crackers of the synchronizer got to grooves of a blocking ring.
11. To grease the needle bearing 31 and to establish it on a shaft 45.
12. To establish a gear wheel 30 1st transfers.
13. To establish a basic washer 29.
14. Напрессовать the conic roller bearing 28, putting effort to an internal ring of the bearing.

Adjustment of an axial gap of a secondary shaft
Prevention

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


PERFORMANCE ORDER
1. Выпрессовать an external ring 6 (see fig. Carter of coupling) the conic roller bearing from a case of 2 couplings.
2. To remove an adjusting washer 7 and to establish instead of it a washer in thickness of 0,75 mm.
3. To press an external ring of the 6th bearing in a case of 2 couplings.
4. To establish a secondary 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.
5. To check several times a secondary shaft that bearings rose into place.
6. To establish a transmission vertically, having directed the shaft end from the 5th transfer up.
7. 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.
8. To enclose under a leg 4 indicators on a secondary shaft the ground plate 5.
9. To move a secondary shaft in the axial direction from an emphasis against the stop and to take readings of the indicator.
10. To settle an invoice thickness of a demanded adjusting washer on a formula: S= 0,75 + S0 + 0,20, where S – settlement thickness of a demanded adjusting washer, mm, S0 – the measured size of an axial gap, mm.
11. To pick up an adjusting washer of the demanded thickness proceeding from sets delivered in the spare part. Existing standard sizes: from 0,7 mm to 1,4 mm through each 0,05 mm.
12. To remove the indicator with a rack and a support.
13. To disassemble cases and выпрессовать an external ring of the bearing from a coupling case.
14. To remove a washer in thickness of 0,75 mm and to establish the picked-up adjusting washer.
15. To press an external ring of the bearing.
16. To collect a transmission and once again to make check.