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
		General Information
		Engine
		The power supply system
		Coupling
		Transmission
			Refitting
			Four-speed transmission
			A five-speed manual transmission
				Specifications
				Dismantling gearbox
					Primary shaft
					Output shaft
					Differential
				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
		Transmission
		Front-wheel Drive
		A steering
		Suspension
		Brakes
		Body
		Electrical

printable version

Primary shaft

Adjusting input shaft

1 - support;

2 - Front;

3 - Indicator;

4 - leg indicator;

5 - a plate;

6 - the input shaft;

7 - the gearbox housing

Dismantling

PERFORMANCE ORDER

1. Press out the tapered roller bearing 63 (see. Fig. Transmission type 085).

2. Remove the tapered roller bearing 49.

3. Remove the support washer 50.

4. Remove the gear 52 4th gear, the needle bearing 51 and the locking ring 53.

5. Remove the retaining ring 54.

6. To press from a primary shaft gear 60 3rd gear with the locking ring 59 and the synchronizer hub 56 (with a sliding clutch).

7. Remove the retaining ring 58.

8. Remove the needle bearing 61.

Assembly

PERFORMANCE ORDER

1. Grease the needle bearing 61 and set it to the input shaft 62.

2. Install the retaining ring 58.

3. Check the gap between blocking rings 53 and 59 and their associated gears 52 and 60.

4. Set the primary shaft gear 62 60 3rd gear synchronizer ring 59 and the synchronizer.

5. Press on the synchronizer assembly 56 (if the synchronizer understood. See subsection 5.2.2.2) so that the longest part of the splines of the hub has been directed towards a gear wheel of 4th transfer and synchronizer crackers have got to grooves of a blocking ring.

6. Install the retaining ring 54.

7. Install the synchronizer blocking ring 53, watching thus that synchronizer crackers have got to grooves of a blocking ring.

8. Lubricate the needle bearing 51 and set it to the input shaft 62.

9. Install pinion 52 4th gear.

10. Install the thrust washer 50.

11. Install tapered roller bearing 49.

12. Press on the shaft tapered roller bearing 63 by applying a force to the inner ring of the bearing.

Adjusting the axial clearance of the primary shaft

A warning

The adjustment is made after the replacement of one of the following components: gearbox housing, clutch, input shaft or tapered roller bearings of a primary shaft.

PERFORMANCE ORDER

1. Press off the outer ring 3 (see. Fig. Clutch housing) tapered roller bearing from the clutch housing 2.

2. Remove the shim 4 and drive back the bearing ring 3.

3. Set the input shaft to connect the clutch to the transmission case and tighten the bolts 14 (see. Fig. Carter of a transmission) to 25 Nm.

4. Turn several times the input shaft to the bearings into place.

5. Place the gearbox vertically, giving the shaft end from the 5th gear up.

6. Establish a support 1 (see. Fig. Adjustment of the input shaft) with a reception indicator 2 and 3 on the crankcase 7 gearbox.

7. Lay a leg 4 indicators on the input shaft 6 polished plate 5.

8. Move the input shaft 6 to the axial direction from stop to stop and remove the indicator.

9. Choose the right size shim depending on the size of the axial gap (the difference between the readings of the indicator).

10. Remove the display with a reception and support.

11. Dismantle the housing and press out the outer ring of the bearing from the clutch housing.

12. Set the clutch matched shim and press in the outer ring of the bearing.

13. Assemble the gearbox and once again make check. The axial clearance should be between 0.1-0.12 mm.

The measured value of the axial clearance, mm	The thickness of the shim, mm
to 0.68	0.65
0.68 - 0.75	0.7
0.74 - 0.78	0.75
0.79 - 0.83	0.8
0.84 - 0.88	0.85
0.89 - 0.93	0.9
0.94 - 0.98	0.95
0.99 - 1.03	100
1.04 - 1.08	1.05
1.09 - 1.13	1.10
1.14 - 1.18	1.15
1.19 - 1.23	1.20
1.24 - 1.28	1.25
1.29 - 1.33	2 x 0.65
1.34 - 1.38	0.65 0.7
1.39 - 1.43	2 x 0.7
1.44 - 1.48	0.7 0.75
1.49 - 1.53	2 x 0.75
1.54 - 1.58	0.75 0.8
1.59 - 1.63	2 x 0.8
1.63 - 1.68	0.8 0.85
1.69 - 1.75	2 x 0.85

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Dismantling gearbox

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Output shaft