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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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. |
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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. |
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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. |
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