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
      5.4.3. 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




5.4.3. Transmission assembly

GENERAL INFORMATION

The provision of an opening under a bolt of fastening of a shaft of a gear wheel of a backing

1–an opening under a bolt;

2–backing gear wheel;

3–shaft of a gear wheel of a backing;

X – the size from an opening in a coupling case under a bolt to an opening under a bolt on a shaft of a gear wheel of a backing

PERFORMANCE ORDER
1. To press a new epiploon 5 (see fig. Carter couplings with differential) in the plug 6.
2. To grease a working edge of an epiploon with the 5th transmission oil and to press the plug 6 in a case of the 7th coupling.
3. To establish differential assembled in a coupling case.
4. To establish the right flange of 4 semi-axes with a spring 45, a washer 44 and a rasporny ring 43 in a case of the 7th coupling.
5. To establish a spring washer the 3rd bent party to a flange of 4 semi-axes, a lock ring 2 and a cap 1.
6. To press on a secondary shaft 4 (see fig. Secondary shaft) conic roller bearings 3 and 5.
7. To establish an adjusting washer 1 in a coupling case.
8. Напрессовать an external ring 2 roller conic bearings in a coupling case.
9. To establish a secondary shaft 4 in a coupling case.
10. To establish a plate of the 6th fastening of the bearing and to twirl bolts the 7th moment of 40 N · m.
11. To establish a spring washer the 22nd concave party to the bearing.
12. To check a gap between blocking rings 19 and 17 and gear wheels corresponding to them 20 and 14 (see subsection 5.2.2.1).
13. To grease the needle bearing 21 and to establish it on a secondary shaft 4.
14. To establish a gear wheel 20 1st transfers.
15. To establish blocking ring 19.
16. To heat up a synchronizer nave to temperature 120 ° With and напрессовать the synchronizer 18 on a secondary shaft 4, watching thus that crackers of the synchronizer got to grooves of a blocking ring.
17. To establish a shaft 24 (see fig. Carter couplings with differential) backing gear wheels with a gear wheel of the 27th backing.
18. To establish arms of 36 and 38th fastening of a fork of inclusion of a backing and наживить bolts 37.
19. To establish a fork of the 35th inclusion of a backing and to tighten bolts 37.
20. Напрессовать an internal ring 16 (see fig. Secondary shaft) needle bearing.
21. To establish the needle bearing 15.
22. To establish blocking ring 17, watching thus that crackers of the synchronizer got to grooves of a blocking ring.
23. To establish a gear wheel 14 2nd transfers.
24. To heat up a gear wheel 13 3rd transfers to temperature 120 ° With and напрессовать it on a secondary shaft a ledge towards a gear wheel of the 2nd transfer.
25. To pick up and establish a new lock ring 12. The axial gap between a gear wheel 13 3rd transfers and a lock ring 12 should be absent (the most admissible gap of 0,2 mm). A set of the lock rings delivered in the spare part, thickness from 2,5 to 3 mm (rings of different thickness have the color).
26. To establish primary shaft 32 (see fig. A transmission four-stage type 020) in a case of 1 coupling.
27. To heat up a gear wheel 11 (see fig. A secondary shaft) the 4th transfer to temperature 120 ° With and напрессовать it on a secondary shaft a ledge to the bearing 8.
28. To establish a lock ring 10.
29. To establish a rod of 33 forks of gear shifting in collecting (see fig. A transmission four-stage type 020), having entered at first a fork of switching of the 1-2nd of transfers to a pro-point of the sliding coupling of the synchronizer of the 1-2nd of transfers, then, slightly having raised a rod, to enter a fork of switching of the 3-4th transfers to a pro-point of the sliding coupling of the synchronizer of the 3-4th transfers. Then to enter ползун forks of inclusion of a backing into gearing with a fork of inclusion of a backing.
30. To establish all forks of gear shifting in neutral situation.
31. To turn a shaft 24 (see fig. Carter of coupling with differential) backing gear wheels so that the opening under a bolt occupied a certain situation (see fig. The provision of an opening under a bolt of fastening of a shaft of a gear wheel of a backing) (both distances X should be equal among themselves).
32. To establish a magnet 32 (see fig. Carter couplings with differential) in the coupling case.
33. To establish an adjusting washer 14 (see fig. Primary shaft) if it is required, and the ball bearing 12 in a case of a transmission by acting part of an internal ring towards a gear wheel of the 4th transfer.
34. To establish bolts 1 (see fig. Fastening of the bearing of primary shaft) with special heads and to put the clamps 2 (see fig. Nuts of fastening of the bearing) moment of 15 N · m.
35. To establish new laying between cases if it was on a complete set.
36. To connect a case of a transmission and a coupling case, напрессовав thus on primary shaft the ball bearing being in a case of a transmission.
37. To twirl a bolt 4 (see fig. Nuts of fastening of the bearing) fastenings of a shaft of a gear wheel of a backing by the moment of 20 N · m.
38. To twirl bolts 6 (see fig. Transmission four-stage type 020) moment of 25 N · m.
39. To establish a transmission in neutral situation.
40. To insert a shaft of 22 gear shiftings assembled into a transmission case.
41. To establish a spring 23, a washer 24 and to twirl a cover 25.
42. To establish an antisplash cover 29, the lever 30 of gear shifting and to twirl a nut 31 moment of 50 N · m.
43. To twirl a bolt the 27th moment of 20 N · m.
44. To twirl the switch of light of a backing.
45. To establish directing plug 12 and vyzhimny the bearing 13.
46. To establish the lever of 21 switching off of coupling, having put on its shaft a spring 19 and the lever 18, thus the ends of a spring should rest against a transmission case, and the average part – to be in gearing with the lever 18.
47. To establish lock rings 20.
48. To establish new laying 14, a cover 15 and to twirl bolts the 16th moment of 25 N · m.
49. To establish the left flange of a semi-axis (see subitem 4-5).
50. To grease a pusher 34 and to insert it into primary shaft.
51. To check correctness of inclusion of transfers.

Color of a lock ring
Thickness, mm
The brown
2,5
The black
2,6
Bright
2,7
Cooper
2,8
Yellow copper
2,9
The dark blue
3,0