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
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Primary shaft
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1–plug;
2–primary shaft;
3–needle bearing;
4–gear wheel of the 3rd transfer;
5–a blocking ring;
6–synchronizer;
7–lock ring;
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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
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1–sealing ring;
2–plug;
3–primary shaft |
The special adaptation for adjustment of primary shaft
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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
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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. |
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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. |
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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 |
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The measured size of an axial gap, mm
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Thickness of an adjusting washer, mm
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0–0,46
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The washer is not required
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0,47-0,75
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0,3
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0,76-1,04
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0,6
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1,05-1,45
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0,6 + 0,3
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