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

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Volkswagen Golf 2 / Jetta
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Golf 2 / Jetta
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Refitting
Four-speed transmission
A five-speed manual transmission
Specifications
Dismantling gearbox
Assembling the gearbox
Position the shift lever and the coupling sleeve
The gear change mechanism
The four-speed transmission of type 020
A five-speed transmission of type 020
Automatic transmission
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Assembling the gearbox



Installing shaft gearbox

1 - a gear wheel of a backing;

2 - 1-2 shift fork rod second gear;

3 - rod of a plug of switching of 3-4th transfers;

4 - secondary shaft;

5 - input shaft;

6 - a special device

The synchronizer of 5th transfer

Assembly

PERFORMANCE ORDER
1. Install the shaft 68 (see. Fig. Transmission type 085) reverse gear with the gear 67 reverse.
2. Install the shift fork 1-2 second gear with the stem into the groove of the sliding sleeve of the synchronizer output shaft.
3. Set the same time the output shaft 4 (see. Fig. Installation of transmission shaft) and stem 1-2 shift fork 2 nd gear, lifting while reverse gear with a hook 6 of the wire.
4. Install the shift fork 3-4th transfers with a rod in the groove of the sliding sleeve of the synchronizer input shaft.
5. Raise the output shaft 4 and rod 2, and set the input shaft with a rod 3 shift fork 3-4th gear, lifting while reverse gear with a hook 6 of the wire.
6. Tighten the screw 11 (see. Fig. The internal mechanism of switching transmission) mounting shaft reverse gear.
7. Install the rod 3 (see. Fig. Removing the shift shaft) with a fork reverse gear.
8. Tighten the screw 10 (see. Fig. The internal mechanism of switching transmission).
9. Install the rod 2 (see. Fig. Removing the shift shaft) fork 5th gear.
10. Tighten the screws 9 (see. Fig. The internal mechanism of switching transmission).
11. Install all the shift fork in the neutral position.
12. Set the bracket 4, the gear lever and bushing 3.
13. Tighten the screws 2.
14. Install the shift lever 1 with a spring into the bracket 4.
15. Hammer gear shaft 6 and 5 to set the cap is flush with the surface of the gearbox housing.
16. Install the coupling sleeve 8 (see. Fig. Clutch housing) and tighten the bolt 9.
17. Set the relative position of the lever 1 (see. Fig. The internal mechanism of switching transmission) shift and coupling sleeve 8 (see. Fig. Carter clutch) (see. Subsection 5.3.4).
18. Replace the differential.
19. Set the clutch housing 11 (see. Fig. Carter of a transmission) dowel pins 10.
20. Lubricate mating sealing plane 11 clutch housing.
21. Connect the crankcase 5 gearbox and the clutch housing 11.
22. Tighten the screws 14 to 25 Nm.
23. Install the new oil seal 3 (see. Fig. Transmission type 085) in the sleeve 4 Grease a working edge of the gland.

A warning

Flanges of semiaxes distinct. The diameter of the working edge of the stuffing box on the left side of 57 mm, and the right side - 48 mm.


24. Drive sleeve 4 in the clutch housing.
25. Install the flange 2 half-line with spring 5, the washer 6 and the spacer ring 7.
26. Block flange half-line with a screwdriver and tighten bolt 1 to 25 Nm.
27. Press on gear 64 5th gear to the input shaft, wherein the gear collar must be directed towards the bearing.
28. Install the washer 27 on the output shaft.
29. Lubricate and Press on the inner ring of the needle bearing 26.
30. Install the needle bearing 26.
31. Set 25 gear 5th gear to the output shaft, wherein the gear collar must be directed towards the bearing.
32. Set the synchronizer blocking ring 24 and spring 23.
33. Press on synchronizer hub 22, wherein hub shoulder should be directed to gear 5th gear and the locking ring projections - enter into the grooves of the hub.
34. Install the retaining ring 21.
35. Install the sliding sleeve on the synchronizer hub, with narrower slots in the sleeve should be directed to a gear wheel of 5th transfer and must be combined with broader depressions at the splines of the hub.
36. Include 5th transfer.
37. Turn 2nd gear using the gear lever, thereby blocking the shafts.
38. Install new bolt 66 (see. Fig. Transmission type 085) with spring washer 65 at the end of the input shaft torque of 40 Nm.
39. Install all the shift fork in the neutral position.
40. Remove the sliding sleeve of the synchronizer of 5th transfer.
41. To establish the lever 5 (see. Fig. Fork for 5th gear) on the stem fork 5th gear.
42. Install the plug 2 at the same time enable the 5th gear sliding sleeve 4 and the synchronizer of 5th transfer.

A warning

Since 1986, installed a new bolt of 1 fastening of a plug of inclusion of 5th transfer. The old and the new bolt thread is different.


43. Install the sleeve 3 and tighten screw 1.
44. Turn the bolt 1 until the end face is not sliding sleeve is flush with the end surface of the synchronizer hub.
45. Include 5th transfer.
46. Tighten bolt 1 so that the plug 2 did not have clearance in the groove of the sliding sleeve.
47. Loosen the bolt 1 so that between the plug 2 and the sliding sleeve groove formed small gap.
48. Tighten the lock nut.
49. Install the cover 1 (see. Fig. Carter of a transmission) gearbox with a new gasket 4.
50. Tighten bolts 2 to 8 Nm.




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