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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
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Refitting
Four-speed transmission
Specifications
Dismantling gearbox
Primary shaft
Output shaft
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Assembling the gearbox
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A five-speed manual transmission
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A five-speed transmission of type 020
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Hit Counter by Digits


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Dismantling gearbox



Transmission type 084

1 - a bolt;
2 - flange half-line;
3 - spring;
4 - washer;
5 - spacer ring;
6 - clutch;
7 - a bolt;
8 - differential;
9 - a lining;
10 - the transmission housing;
11 - a secondary shaft;
12 - a primary shaft;
13 - pin

Transmission housing

1 - Back Cover;
2 - a lining;
3, 33 - a large shim;
4, 32 - a lock ring;
5, 31 - a small shim;
6, 30 - bearing;
7 - the plug;
8 - backup light switch;
9 - differential;
10 - the gear lever;
11 - rod fork backing;
12 - pin rod fork backing;
13 - a plug of inclusion of a backing;
14 - Gear Shift 1-2 second gear;
15 - a secondary shaft;
16 - rod of a plug of switching of 3-4th transfers;
17 - a primary shaft;
18 - a lock ring;
19 - a gear wheel of a backing;
20 - a plug of switching of 3-4th transfers;
21 - a plug of switching 1-2 second gear;
22 - the transmission housing;
23 - washer;
24 - a bolt;
25 - Sleeve-lock;
26 - a spring;
27 - the directing plug;
28 - a lining;
29 - tube clamp;
34 - a bolt

The special plate


Installation of the plaque

1 - a special plate;

2 - the input shaft;

3 - a secondary shaft;

4 - the transmission housing;

5 - the shift lever;

6 - a nut M16


Special tool


PERFORMANCE ORDER
1. Clean the gearbox from dirt and rinse with water, protecting casings from water.
2. Insert into the hole of the flange 2 (see. Fig. Transmission type 084) and the half-line screwdriver to rest at the edge of its casing 6 clutch to lock the flange against rotation.

A warning

Flanges of semiaxes are of different lengths. The length of the left flange is 84.5 mm, and the right - 89.6 mm. It is recommended to label the flange before removal.


3. Unscrew using a ring spanner bolt 1.
4. Remove the flange of 2 semiaxes from the clutch housing using two screwdrivers.
5. Remove the spring 3, washer 4 and the spacer ring 5.
6. Remove the flange half-line with the other gearbox (see. Pp. 2-5).

A warning

Since 1986, the semi-axes instead of flange bolts with hexagon head bolts have been used with cylinder head hexagon.


7. Release the switch 8 (see. Fig. Carter of a transmission) reversing light.
8. Loosen the screws and remove the clutch housing from the transaxle case.
9. Remove the differential 8 (see. Fig. Transmission type 084) assembly from the gearbox housing.
10. Remove the magnet from the clutch housing.
11. Set the plugs 21 and 20 (see. Fig. Carter gearbox) shift into neutral.
12. Remove the three plugs 29 stem retainer gear, remove the pads 28 and remove the guides 27, 26 and spring-sleeve clamps 25.
13. To turn away a stopper 7, and further remove the pins when removing the rods corresponding shift forks.
14. Loosen the screws 34 and remove the back cover 1 gearbox housing.
15. Remove the gasket 2.
16. Remove the adjusting ring 3 and 33, mark them for installation to the respective shafts.
17. Remove the retaining ring 32 of the primary shaft.
18. Remove a small shim 31 and mark it.
19. Remove the bolt securing the plug 13 24 Reverse gear.
20. Remove the stem 11 fork and fork reverse 13 reverse gear.
21. Set on the gearbox casing 8 specific plate (refer to its dimensions. Fig. Special plate) in a defined position (see. Fig. Installation of the plaque), thereby locking the input shaft.
22. Squeeze the lever 5 shift and lock it in position using M16 nuts 6.
23. Compress the rear ball bearing 30 (see. Fig. Carter gearbox) input shaft.
24. Remove the special plate 1 (see. Fig. A special plate).
25. Reject the input shaft 17 (see. Fig. Carter of a transmission), it is disengaged the pinion gear with the output shaft 15, and remove the primary shaft 17 and the rod 16 with a fork 20 switch gears 3-4th, at the same time while raising a special device made of wire (see. fig. A special device), the pinion 19 (see. fig. Carter of a transmission) backing.
26. Remove the nut 6 (see. Fig. Installation of the plaque), stick to the gear lever.
27. Remove the retaining ring 4 (see. Fig. Carter of a transmission) of the secondary shaft.
28. Remove the shim 5, having marked it.
29. To press the bearing of a secondary shaft 6.
30. Remove the retaining ring 18.
31. Remove the secondary shaft 15, the rod 14 with a fork 21 1-2-th switching gears and gear 19 reverse.
32. Remove the clutch mechanism of the clutch housing (see. Section 4.2.1).
33. Remove the seal and press out the roller bearing from the input shaft clutch (if necessary).
34. Press out the roller bearing output shaft of the clutch (if necessary).
35. Unscrew and remove the plug speedometer drive gear.
36. Press out the shaft reverse gear (if needed).




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