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
+ 6. Transmission
+ 7. Forward drive
+ 8. Steering
+ 9. Suspension brackets
+ 10. Brake system
+ 11. Body
+ 12. Electric equipment



5.3.3. Transmission assembly

GENERAL INFORMATION

Installation of shaft of a transmission

1–backing gear wheel;

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

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

4–secondary shaft;

5–primary shaft;

6–special adaptation

Synchronizer of the 5th transfer

Assembly

PERFORMANCE ORDER
1. To establish a shaft 68 (see fig. Type 085 transmission) backing gear wheels together with a gear wheel of the 67th backing.
2. To establish a fork of switching of the 1-2nd of transfers with a rod in a groove of the sliding coupling of the synchronizer of a secondary shaft.
3. To establish at the same time secondary shaft 4 (see fig. Installation of shaft of a transmission) and a rod of 2 forks of switching of the 1-2nd of transfers, raising thus a backing gear wheel by means of a hook 6 of a wire.
4. To establish a fork of switching of the 3-4th transfers with a rod in a groove of the sliding coupling of the synchronizer of primary shaft.
5. To raise a secondary shaft 4 with a rod 2 and to establish primary shaft with a rod of 3 forks of switching of the 3-4th transfers, raising thus a backing gear wheel by means of a hook 6 of a wire.
6. To twirl the screw 11 (see fig. Internal mechanism of switching of a transmission) fastenings of a shaft of a gear wheel of a backing.
7. To establish a rod 3 (see fig. Removal of a shaft of gear shifting) with a fork of inclusion of a backing.
8. To twirl the screw 10 (see fig. Internal mechanism of switching of a transmission).
9. To establish a rod 2 (see fig. Removal of a shaft of gear shifting) forks of inclusion of the 5th transfer.
10. To twirl a bolt 9 (see fig. Internal mechanism of switching of a transmission).
11. To establish all forks of gear shifting in neutral situation.
12. To establish an arm 4 levers of gear shifting and the plug 3.
13. To twirl a bolt 2.
14. To establish the lever of 1 gear shifting with a spring in an arm 4.
15. To hammer a shaft of the 6th gear shifting and to establish a cap 5 aflush with a surface of a case of a transmission.
16. To establish the connecting plug 8 (see fig. Carter couplings) and to wrap a bolt 9.
17. To adjust mutual position of the lever 1 (see fig. The internal mechanism of switching of a transmission) gear shifting and the connecting plug 8 (see fig. Carter of coupling) (see subsection 5.3.4).
18. To establish into place differential.
19. To establish in a case of the 11th coupling (see fig. Carter transmissions) adjusting pins 10.
20. To grease with hermetic the being interfaced plane of a case of the 11th coupling.
21. To connect a case of the 5th transmission and a case of the 11th coupling.
22. To twirl bolts the 14th moment of 25 N · m.
23. To establish a new epiploon 3 (see fig. Type 085 transmission) in the plug 4, having greased with konsistentny greasing a working edge of an epiploon.

Prevention

Flanges of semi-axes are various among themselves. Diameter of a working edge of an epiploon is on the left side equal 57 mm, and on the right side – 48 mm.


24. To press the plug 4 in a coupling case.
25. To establish a flange of 2 semi-axes with a spring 5, a washer 6 and a rasporny ring 7.
26. To block a semi-axis flange a screw-driver and to twirl a bolt 1 moment of 25 N · m.
27. Напрессовать a gear wheel 64 5th transfers on primary shaft, thus a fillet of a gear wheel it should be directed to the bearing.
28. To establish a washer 27 on a secondary shaft.
29. To grease and напрессовать an internal ring of the needle bearing 26.
30. To establish the needle bearing 26.
31. To establish a gear wheel 25 5th transfers on a secondary shaft, thus a fillet of a gear wheel it should be directed to the bearing.
32. To establish blocking ring 24 synchronizers with a spring 23.
33. Напрессовать a synchronizer 22 nave, thus a fillet of a nave it should be directed to a gear wheel of the 5th transfer, and ledges of a blocking ring – to enter into nave grooves.
34. To establish a lock ring 21.
35. To establish the sliding coupling on the synchronizer nave, thus made narrower shlitsa on the coupling should be directed to a gear wheel of the 5th transfer and should be combined with wider hollows at шлицов naves (see fig. Synchronizer of the 5th transfer).
36. To include the 5th transfer.
37. To include the 2nd transfer by means of the gear shifting lever, having blocked thereby shaft.
38. To twirl a new bolt 66 (see fig. Type 085 transmission) with a spring washer 65 on the end of primary shaft the moment of 40 N · m.
39. To establish all forks of gear shifting in neutral situation.
40. To remove the sliding coupling of the synchronizer of the 5th transfer.
41. To establish the lever 5 (see fig. A fork of inclusion of the 5th transfer) on a rod of a fork of inclusion of the 5th transfer.
42. To establish at the same time a fork of 2 inclusions of the 5th transfer and the sliding coupling 4 synchronizers of the 5th transfer.

Prevention

Since 1986 the new bolt of 1 fastening of a fork of inclusion of the 5th transfer is established. At an old and new bolt a carving different.


43. To establish the plug 3 and to twirl a bolt 1.
44. To turn a bolt 1 until the face surface of the sliding coupling will not appear flush with a face surface of a nave of the synchronizer.
45. To include the 5th transfer.
46. To twirl a bolt 1 so that the fork 2 had no gap in a pro-point of the sliding coupling.
47. To weaken a bolt 1 so that between a fork 2 and a pro-point of the sliding coupling the small gap was formed.
48. To tighten a lock-nut.
49. To establish a cover 1 (see fig. Carter transmissions) transmissions with new laying 4.
50. To twirl bolts the 2nd moment of 8 N · m.