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



5.4.2.1. Primary shaft

GENERAL INFORMATION

Primary shaft

1–plug;
2–primary shaft;
3–needle bearing;
4–gear wheel of the 3rd transfer;
5–a blocking ring;
6–synchronizer;
7–lock ring;
8–a blocking ring;
9–needle bearing;
10-gear wheel of the 4th transfer;
11-washer;
12-bearing;
13-lock ring;
14-adjusting washer

The plug with a sealing ring of primary shaft

1–sealing ring;

2–plug;

3–primary shaft

The special adaptation for adjustment of primary shaft

1–special arm;
2–carving core;
3–bolt;
4–nut;
5–plug;
6–primary shaft;
7–coupling case

Adjustment of an axial gap of primary shaft

1–primary shaft;

2–gear wheel of the 4th transfer;

3–transmission case;

4–support;

5–indicator;

6–indicator leg;

7–special plug;

8–washer;

and – a measured axial gap

Dismantling

PERFORMANCE ORDER
1. To press the ball bearing 12 (see fig. Primary shaft).
2. To remove a gear wheel 10 4th transfers.
3. To remove the needle bearing 9.
4. To remove blocking ring of the 8th synchronizer.
5. To remove a lock ring 7.
6. To remove the synchronizer 6.
7. To remove blocking ring of the 5th synchronizer.
8. To remove a gear wheel 4 3rd transfers.
9. To remove the needle bearing 3.
10. To check a gap between a pusher of coupling and a sealing ring 1 (see fig. The plug with a sealing ring of primary shaft). If there is a gap, it is necessary to replace a sealing ring 1.
11. Выпрессовать the plug 2 with a sealing ring 1 from primary shaft 3.

Assembly


Prevention

Before assembly to grease all details.


PERFORMANCE ORDER
1. To press the plug 2 and a new sealing ring 1 in primary shaft 3, thus a sealing ring it should be drowned on 0,8–1,3 mm from an end face of primary shaft.
2. To establish the needle bearing 3 (see fig. Primary shaft).
3. To check a gap between blocking rings 5 and 8 and gear wheels corresponding to them 4 and 10 (see subsection 5.2.2.1).
4. To establish a gear wheel 4 3rd transfers.
5. To establish blocking ring 5.
6. To establish the synchronizer a facet on a nave towards a gear wheel of the 3rd transfer, watching thus that crackers of the synchronizer got to grooves of a blocking ring.
7. To establish a lock ring 7.
8. To establish blocking ring 8, watching thus that crackers of the synchronizer got to grooves of a blocking ring.
9. To establish the needle bearing 9.
10. To establish a gear wheel 10 4th transfers.

Adjustment of primary shaft

PERFORMANCE ORDER
1. To establish on a coupling case the special adaptation (see fig. The special adaptation for adjustment of primary shaft). The arm 1 is fastened by bolts 3 to a case of the 7th coupling. On a carving core 2 the nut 4 is wound and the plug 5 resting against primary shaft 6 is put on.
2. Turning a nut 4, to move primary shaft so that between a gear wheel of the 2nd transfer of a secondary shaft and the 3rd transfer of primary shaft the gap of 1 mm (a gap turned out measure shchupy).
3. To block in this situation a nut 4.
4. To establish a washer in thickness of 3,5 mm if there was no washer 11 (see fig. Primary shaft) in this complete set. It is necessary to establish a washer on a shaft with a radial gap.
5. To establish on primary shaft 1 (see fig. Adjustment of an axial gap of primary shaft) special plug 7 (VW549). The plug 7 can be made proceeding from the sizes of the ball bearing, primary shaft and a transmission case.
6. To establish a support 4.
7. To establish the indicator 5 with a leg 6.
8. To move the plug 7 up and down and to take readings of the indicator, having determined by that an axial gap "and".
9. To pick up an adjusting washer from two standard sizes in thickness of 0,3 and 0,6 mm according to the measured size axial a gap

The measured size of an axial gap, mm
Thickness of an adjusting washer, mm
0–0,46
The washer is not required
0,47-0,75
0,3
0,76-1,04
0,6
1,05-1,45
0,6 + 0,3