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
   - 5.4. Type 020 four-speed transmission
      5.4.1. Technical characteristics
      - 5.4.2. Transmission dismantling
         5.4.2.1. Primary shaft
         5.4.2.2. Secondary shaft
         5.4.2.3. Synchronizer
         5.4.2.4. Differential
      5.4.3. Transmission assembly
      + 5.4.4. Gear shifting mechanism
   + 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




5.4.2. Transmission dismantling

GENERAL INFORMATION

Transmission four-stage type 020

1–coupling case;
2–plug;
3–secondary shaft;
4–adjusting washer;
5–bolt;
6–bolt;
7–semi-axis flange;
8–spring washer;
9–lock ring;
10-cap;
11-transmission case;
12-the directing plug;
13-Vyzhimny bearing;
14-laying;
15-back cover;
16-bolt;
17-bolt;

18-lever;
19-returnable spring;
20-lock ring;
21-lever of switching off of coupling;
22-gear shifting shaft;
23-spring;
24-washer;
25-cover;
26-bolt;
27-bolt;
28-switch of fires of a backing;
29-cover;
30-lever;
31-nut;
32-primary shaft;
33-a rod with gear shifting forks;
34-pusher

Nuts of fastening of the bearing

1–cap;

2–nut;

3–transmission case;

4–bolt of fastening of a shaft of a gear wheel of a backing

Case of coupling with differential

1–cap;
2–lock ring;
3–spring washer;
4–semi-axis flange;
5–epiploon;
6–plug;
7–coupling case;
8–hairpin;
9–adjusting washer;
10-external ring of the roller
conic bearing;
11-nut;
12-washer;
13-separator;
14-lock ring;
15-a conducted gear wheel of the main transfer;
16-lock ring;
17-conic gear wheel;
18-satellite axis;
19-satellite;
20-bolt;
21-axis;
22-roller conic bearing;

23-lock ring;
24-shaft of a gear wheel of a backing;
25-bolt;
26-differential case;
27-backing gear wheel;
28-external ring of the roller conic bearing;
29-adjusting washer;
30-plug;
31-roller conic bearing;
32-magnet;
33-needle bearing;
34-loose leaf;
35-fork of inclusion of a backing;
36, 38 – arms;
37-bolt;
39-adjusting pin;
40-laying;
41-masloslivny stopper;
42-washer;
43-rasporny ring;
44-washer;
45-spring

Fastening of the bearing of primary shaft

1–bolt;

2–bearing;

3–transmission case

PERFORMANCE ORDER
1. To clear a transmission of dirt and to wash out water, having protected cases from hit in water.
2. To take out a pusher 34 (see fig. A transmission four-stage type 020) couplings from primary shaft 32.
3. To remove an arm 19 (see fig. Gear shifting mechanism) gear shifting mechanism.
4. To unscrew the switch 28 (see fig. Transmission four-stage type 020) backing fires.
5. To turn off a bolt 27 fixing a shaft of gear shifting.
6. To unscrew a nut 31.
7. To remove the gear shifting lever 30.
8. To remove an antisplash cover 29.
9. To turn off a cover 25 and to remove it together with a washer 24 and a spring 23.
10. To establish a transmission in neutral situation by means of a shaft of 22 gear shiftings and carefully to beat out it from a transmission case.
11. To unscrew bolts 16.
12. To remove a back cover of the 15th case of a transmission and laying 14.
13. To remove lock rings 20 from a shaft of the lever of 21 switching off of coupling.
14. To remove the lever of 21 switching off of coupling and to take out the lever 18 and a returnable spring 19.
15. To remove vyzhimny the coupling bearing 13.
16. To remove caps 1 (see fig. Nuts of fastening of the bearing) and to unscrew three nuts 2.
17. To turn off a bolt of 4 fastenings of a shaft of a gear wheel of a backing.
18. To remove a cap 1 (see fig. Carter couplings with differential) from the left flange of a semi-axis.
19. To remove a lock ring 2 and a spring washer 3.
20. To remove a flange of 4 semi-axes together with a spring 45, a washer 44 and a rasporny ring 43.
21. To unscrew bolts 6 (see fig. Transmission four-stage type 020).
22. To separate a case of 1 coupling and a case of the 11th transmission.
23. To remove an adjusting washer if is available, and to remove bolts 1 (see fig. Fastening of the bearing of primary shaft) with a special head of fastening of the bearing 2.
24. To take out a magnet 32 (see fig. Carter couplings with differential) from a coupling case.
25. To remove a rod 33 (see fig. A transmission four-stage type 020) with forks of gear shifting and polzuny assembled.
26. To weaken bolts 37 (see fig. Carter couplings with differential) fastenings of arms 36 and the 38th forks of the 35th inclusion of a backing.
27. To remove a fork of the 35th inclusion of a backing.
28. To remove a shaft of 24 gear wheels of a backing together with a gear wheel of the 27th backing.
29. To remove a lock ring 10 (fig. A secondary shaft) from a secondary shaft.
30. To remove a gear wheel 11 4th transfers.
31. To remove primary shaft assembled.
32. To remove a lock ring 12.
33. To press from a secondary shaft at the same time a gear wheel 20 1st transfers, blocking ring 19, the synchronizer 18, blocking ring 17, a gear wheel 14 2nd transfers, the needle bearing 15 with an internal ring 16 and a gear wheel 13 3rd transfers.
34. To remove the needle bearing 21.
35. To remove a washer 22.
36. To unscrew bolts of the 7th plate of the 6th fastening of the bearing 5.
37. To remove a plate of the 6th fastening of the bearing.

Prevention

Internal diameter of a plate 6 carries out a role of an external ring of the bearing 5.


38. To remove a secondary shaft 4.
39. To remove arms 36 and 38 (see fig. Carter couplings with differential) forks of inclusion of a backing.
40. To remove the right flange of a semi-axis (see subitem 18-20).
41. To remove differential.
42. To remove the needle bearing 33 of a case of the 7th coupling.
43. Выпрессовать the plug 6 with an epiploon 5 if it is necessary to replace these details.