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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
Specifications
Dismantling gearbox
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
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Electrical
 


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Assembling the gearbox



Installing shaft reverse gear

and - the distance from the end of the shaft reverse gear flange to the transmission housing

The locking mechanism

1 - cork;
2 - the transmission housing;
3 - the plug-holder;
4 - the directing plug;
5 - a spring;
6 - a lining;
7 - the plug;
8 - rod of a plug of switching of 3-4th transfers;
9 - lock pin;
10 - Gear Shift 1-2 second gear;
11 - lock pin;
12 - rod fork reverse gear

The gap between the plug and the reverse gear shift fork 1-2 th gear

1 - fork reverse gear;

2 - a plug of switching 1-2 th gear

PERFORMANCE ORDER
1. Drive shaft reverse gear, the dimension a = 83.3 mm from the end of the shaft to the gearbox flange (see. Fig. Installation of the shaft reverse gear).
2. Press in the bearing 6 (see. Fig. Carter of a transmission) of the secondary shaft in the gearbox housing 22 side closed separator to the crankcase.
3. Insert the locking pin 9 (see. Fig. The locking mechanism) into the hole casing 2 gearbox.
4. Squeeze the shift lever and secure it with a nut M16 6 (see. Fig. Installation of the plaque).
5. Set the rod 14 (see. Fig. Carter gearbox) with shift fork 21 1-2-th transmission, the output shaft 15 and gear 19 reverse.
6. Drive the output shaft 15 to the inner ring of the bearing 6, making sure that the rod 14 shift fork and reverse gear 19 is not jammed.
7. Install shim 5 and the retaining ring 4.
8. Adjust the axial clearance of the secondary shaft, if you replace one of the following parts: clutch, gearbox housing, output shaft or tapered roller bearings of the secondary shaft.
9. Install the retaining ring 4 without shim 5.
10. Measure the gap between the probe locking ring 4 and the inner bearing ring 6.
11. Choose shim 5 in such a way that the gap was 0-0.05 mm.
12. Set the transmission housing the input shaft 17 and a rod 16 with a fork 20 switching 3-4th gear, making sure that the lock pin 9 (see. Fig. The locking mechanism) is between the rods 8 and 10. At the same time lift using the tool (see. Fig. Special tool) gear 19 (see. fig. Carter of a transmission) backing.
13. To establish a special plate (see. Fig. Special plates and Installation of the plaque).
14. Press in the bearing 30 (see. Fig. Carter of a transmission) to lock the closed cage side to the gearbox housing.
15. Install the thrust washer 31 and the retaining ring 32.
16. Adjust axial clearance of input shaft, if you replace one of the following parts: clutch, gearbox housing, the input shaft or tapered roller bearings for input shaft, similar to adjusting the output shaft (see. Pp. 9-11).
17. Remove the special plate.
18. Remove the nut M16 unlocking the shift lever.
19. Insert the lock pin 11 (see. Fig. The locking mechanism).
20. Install the stem 11 (see. Fig. Carter of a transmission) fork reversing the plug 13 and the reverse gear.
21. Turn the stem 11 and enter the plug 13 engages the reverse gear with the gear 19 reverse.
22. Tighten bolt 24 with a washer 23 so that between the plug 13 and the reverse gear shift fork 21 1-2 th gear was the distance a (see. Fig. The gap between the plug and the reverse gear shift fork 1-2 th gear ) equal to 1,3-2,8 mm.
23. Assemble the plug latch 25 (see. Fig. Carter of a transmission) with the spring 26 and the guide sleeve 27 and insert three sets in the transmission housing (see. Fig. The locking mechanism).
24. Install the gaskets 6 and 7 plug wrap.
25. Install the plug 1.
26. Install the shims 3 and 33 (see. Fig. Carter of a transmission), according to earlier made marks.
27. Choose shims 3 and 33, where the replacement of the following parts: clutch housing and gearbox, respectively, primary or secondary shafts and tapered roller bearings shafts. To do this, when fully pressed into the respective bearing indicator to measure the distance between the rear end of the gearbox housing and the outer end of the bearing.
28. Install a new gasket and the cover 2 1.
29. Tighten the screws 34 to 25 Nm.
30. Perform a test of inclusion of transfers, all transfers should be integrated easily and seamlessly.
31. Install the differential assembly.
32. Install the pins.
33. Coat the sealant ?�D3?� surface connection clutch housing and gearbox or a new gasket (depending on configuration).
34. Install the magnet in the clutch housing.
35. Install the shift fork in the neutral position.
36. Connect clutch housing to gearbox housing, while keeping an eye to the finger shaft gear engages the gear lever.
37. Tighten the screws evenly diagonally to 25 Nm.
38. Insert slots in the flanges of the differential bevel gears 2 (see. Fig. Transmission type 084) with semiaxes spacer ring 5, the support washer 4 and the spring 3.
39. Block flanges of semiaxes a screwdriver and tighten bolts 1 to 25 Nm.
40. Install the backup light switch.

The measured distance, mm
The thickness of the washers
0.14 - 0.18
0.45
0.19 - 0.23
0.50
0.24 - 0.28
0.55
0.29 - 0.33
0.60
0.34 - 0.38
0.65
0.39 - 0.43
0.70
0.44 - 0.48
0.75
0.49 - 0.53
0.80
0.54 - 0.58
0.85
0.59 - 0.63
0.90
0.64 - 0.68
0.95
0.69 - 0.73
100
0.75 - 0.79
1.05
0.80 - 0.84
1.10
0.85 - 0.89
1.15
0.90 - 0.94
1.20
0.95 - 0.99
1.25
1.00 - 1.04
1.30




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The gear change mechanism

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