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


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Assembling the gearbox



Installing the fork 5th gear

1 - a bolt;
2 - a nave of the synchronizer;
3 - sliding sleeve of the synchronizer;
4 - a plug of inclusion of 5th transfer;
5 - stock shift forks;
6 - rod fork 5th gear;
7 - the transmission housing;

8 - a bolt;
9 - plate;
10 - the bearing;
and - the distance between the fork 5th gear and the end of the stem fork 5th gear

Installation of the clutch lever return spring

1 - spring;

2 - the lever

PERFORMANCE ORDER
1. Run 1-28 subsection 5.4.3.
2. Run 29 sub-section 5.4.3, the pre-setting spring under the stock shift forks.
3. Run 30-32 sub-section 5.4.3.
4. Install the shim 14 (see. Fig. Primary shaft), if desired (see adjustment. Subsection 5.5.2.1), and the ball bearing 12 in the transmission housing protruding part of the inner ring toward the gear wheel of 4th transfer.
5. Install the mounting plate of the ball bearing and tighten the four bolts 21 (see. Fig. Gear 5th gear).
6. Run 35-38 sub-section 5.4.3.
7. Install the thrust washer 23 (see. Fig. Gear 5th gear).
8. Set the needle bearing 20.
9. Heat the gear 6 5th gear to a temperature of 120 ?� C Press on it to the output shaft so that the groove on the gear facing up.
10. Install the washer 7 and 8 retaining ring.
11. Install the pinion May 19 th transmission synchronizer blocking ring 18 and the synchronizer 5th gear assembly, watching thus that synchronizer crackers have got to grooves of a blocking ring.
12. Set the groove of the sliding sleeve of the synchronizer of 5th transfer fork 10 of inclusion of 5th transfer and wear podsobranny node to the input shaft and the stem plugs gear setting and the sleeve 9 and the retaining plate 1 (see. Fig. Removing fork 5 th transmission).
13. Screw the rod 6 (see. Fig. Installing fork 5th gear) fork 5th gear clockwise to turn on the power plug 4 5th gear so that the rod 6 fork 5th gear spoke of the yoke 4 a distance a = 5 mm.
14. To establish a washer 15 (see. Fig. Gear 5th gear).
15. Lubricate the bolt 14, the composition D6 and tighten its moment of 20 Nm.
16. Run 39-44 sub-section 5.4.3, given that the five-speed gearbox is no slinger plate, and by the shift lever is set O-ring.
17. Tighten the 3 (see. Fig. Gear 5th gear) reverse lockout.
18. Check the inclusion of 5th transfer.
19. Lay a fork emphasis thickness of about 12 mm and drive down the lock plate 1 (see. Fig. Fixing fork 5th gear).
20. Install the rear cover 12 (see. Fig. Transmission five-speed type 020) clutch lever 20, having put on its shaft 13 and spring arm 15 (for the proper installation of the spring, see. Fig. Setting the clutch lever return spring).
21. Install the retaining ring 14 (see. Fig. Transmission five-speed type 020).
22. Install the clutch release bearing 19.
23. Install the rear cover 12 with a new seal 11 on the gearbox housing.
24. Tighten the screws 16 to 25 Nm.
25. Run 49-51 sub-section 5.4.3.




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