REPAIR MAINTENANCE OPERATION OF MOTOR VEHICLES
Volkswagen Golf II, Jetta (from 1983 to 1992, the year of issue)

general info. full specifications. diagnostics. hints. tips. tricks

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Volkswagen
	Golf 2 / Jetta
		General Information
		Engine
		The power supply system
		Coupling
		Transmission
			Refitting
			Four-speed transmission
				Specifications
				Dismantling gearbox
					Primary shaft
					Output shaft
					Synchronizer
					Differential
				Assembling the gearbox
				The gear change mechanism
			A five-speed manual transmission
			The four-speed transmission of type 020
			A five-speed transmission of type 020
			Automatic transmission
		Transmission
		Front-wheel Drive
		A steering
		Suspension
		Brakes
		Body
		Electrical

printable version

Differential

Differential

1 - a bolt;
2 - flange half-line;
3 - gland;
4 - the plug;
5 - a spring;
6 - washer;
7 - spacer ring;
8 - an adjusting washer;
9 - tapered roller bearing;
10 - a gear wheel drive of a speedometer;

11 - speedometer drive shaft;
12 - the differential case;
13 - ring gear;
14 - separator;
15 - bevel gear;
16 - round nut;
17 - an axis of satellites;
18 - pin;
19 - Satellite

Adjusting the differential

1 - gearbox housing;
2 - an adjusting washer;
3 - tapered roller bearing;
4 - ring gear;
5 - tapered roller bearing;
6 - the indicator;

7 - a plate;
8 - clutch;
9 - differential housing;
10 - a bolt;
11 - a lining

Dismantling

PERFORMANCE ORDER

1. Compress the inner bearing ring 9 on both sides of the housing 12 of the differential.

2. Compress the speedometer drive gear 10 (without destroying it is almost impossible to do).

3. Knock out the two pins 18 on the axis 17 satellites.

4. Knock axis 17 satellites.

5. Knock bevel gears 15 to the ring nut 16.

6. Remove the separator 14.

7. Press out of the clutch and the gearbox bearing outer ring of differential.

A warning

To remove the driven gear 13 of the differential casing 12, you need special tools and specific skill, and therefore it is recommended to apply to the specialized workshops.

Assembly

A warning

The outer and inner rings of bearings of differential are not interchangeable and must be replaced in the kit.

PERFORMANCE ORDER

1. Set the separator 14 into the housing 12 of the differential.

2. Install the bevel gear 15 axis and holding their hand, insert flanges 2 axis.

3. Set the two satellites to the recesses 19 of the housing 12 of the differential against each other and rotating the bevel gears 15, spindles, satellites 19 set in place.

4. Set the round nut 16 and holding them, insert an axis 17 satellites.

5. Set pins 18.

6. Press on a new speedometer drive gear 10.

7. Press on the bearing inner ring 9, after heating them to a temperature of 100 ?� C.

8. Drive to the clutch and the gearbox housing differential bearing outer ring.

Adjustment

A warning

The adjustment is made after the replacement of at least one of the following components: gearbox housing, clutch, differential housing or tapered roller bearings differential.

PERFORMANCE ORDER

1. Install the crankcase 1 gearbox shim 2 (see. Fig. Adjusting differential) of 1 mm thickness and press in the outer ring of the roller tapered roller bearing 3.

2. Press in the crankcase 8 clutch outer ring of the roller tapered roller bearing without shim 5.

3. Install the differential carrier 9 into the crankcase 1 transmission.

4. Connect the crankcase and clutch housing 8 1 transmission, the gasket 11 when she was on the set.

5. Tighten the bolts 10 uniformly in diagonally to 25 Nm.

6. Set a polished plate 7.

7. Set the indicator 6 with an extension of 30 mm on a universal stand.

8. Set the indicator 6 to zero.

9. Move the differential case 9 a few times up and down, taking off at the same time indicator and determining the axial clearance.

A warning

Do not turn the differential while measuring. Otherwise bearings budge and the results of the measurement will be incorrect.

10. Calculate the thickness of the shim by the formula: S2 = Sn 0,3 mm, where S2 - design thickness required shim, Sn - the measured value of the axial clearance.

11. Remove the clutch housing 8 and press out the bearing outer ring 5.

12. Choose the desired thickness of the washer on the basis of supplied parts kits. Existing sizes: from 1.45 mm to 2.45 mm by 0.05 mm each.

13. Install selected shim in the clutch housing and press in the outer ring of the roller tapered roller bearing.

14. For further assembly see. Subsection 5.2.3.

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Assembling the gearbox