Gear change box type 020

Basic data transmission of type 020

The main parts of a transmission of type 020 include housing 1 (Fig. 5.49) clutch housing 6 transmission with rear lid 8, the input shaft 3 (Fig. 5.50), the output shaft 13 with gears and synchronizers, the axis of the intermediate reverse gear the main gear 25, 26 and the differential mechanism (Fig. 5.51), a choice of transfers.

Transmission ratio Type 020 models of engines: AAM, 55 kW; ABS, power of 66 kW; and 2E, 85 kW are presented in Tables 5.6, 5.7 and 5.8 respectively.

Adjusting (controlling) the data transmission of type 020

Reference values for checking synchronizer rings

The axial clearance between the synchronizer ring and gear:

ring of the synchronizer of 1st and 2nd gear (new items):

Nominal size, mm 1.1 to 1.7

minimum, to 0.5 mm

ring of the synchronizer of 3rd transfer (new items):

nominal size from 1.15 to 1.75

minimum, to 0.5 mm

synchronizer ring 4th and 5th gear (new items):

Nominal size, mm 1.3 to 1.9

minimum, to 0.5 mm

Data for adjusting the output shaft

Prestress

rolling bearings, 0.2 mm

Thickness adjustment

washers, from 0.65 mm to 1.4

with a pitch of 0.05 mm

Moment of resistance pair of rotation lubricated bearings Nm:

new bearings from 0.5 to 1.5

bearings, used

minimum 0.3

Possible thickness and color of the thrust ring gear 3rd gear: a brown ring - 2.5 mm; black ring - 2.6 mm; brilliant ring - 2.7 mm; copper-colored ring - 2.8 mm; Ring milky - 2.9 mm; blue ring - 3.0 mm.

The data on differential regulation

Prestress

rolling bearings, 0.4 mm

Thickness adjustment

washers, 0.15 mm; 0.3; 0.6; 0.7; 0.8; 10

Moment of resistance pairs

rotation-lubricated bearings

Differential Nm:

new bearings, from 0.5 to 1.5

bearings, used

minimum 0.3

Oil for transmission of type 020

Fuel capacity transaxle case

transmission, when changing the oil, 2.0 l

Oil used: gear, hypoid SAE 80 or SAE 75W90 Standards API - GL4.

Tightening torques

Bolts gearbox to the engine Nm / kg-cm:

M12 80/8

M10 60/6

M6 or M7 10/1

Bolts bearing box

the shift to a body 60/6

Bolts drive shaft

to the flange of the output shaft 45 / 4.5

Bolts connection clutch

and gearbox housing 25 / 2.5

Bolts back cover

to the gearbox housing 25 / 2.5

Bolts return

reverse gear 20 / 2.0

Bolts locking plate

a rolling bearing of a secondary shaft 40 / 4.0

Locking bolt hub 5th gear

to the input shaft 150 / 15.0

Removal and installation of a transmission of type 020

Removing the gearbox type 020 can be performed without removing the engine, the car down. Removing the transmission is necessary for the repair or replacement of the clutch or gearbox.

Transmission is removed from the bottom of the car, so the car must be raised to the appropriate height. Regardless of the method of raising the vehicle is required to substitute under the vehicle frame goats. Besides vehicle jack required to prop up the gearbox.

Removal and installation of a transmission of type 020 made similarly to removal and installation of transmission of type 085.

Dismantling of a transmission of type 020

Dismantling of a transmission of type 020 should be performed with special tools, and the work is done accurately and consistently.

Some of the tools required for complete disassembly, includes pullers to remove the internal and external retaining rings, bearing puller hammer puller set beard, dial gauge and possibly a hydraulic press. In addition to that required large and sturdy bench vise.

During disassembly of the gearbox carefully record how every detail has been installed to facilitate the subsequent assembly and perform it more accurately.

Dismantling the gearbox type 020. The procedure for disassembling the gearbox type 020 is made in the same manner as for the transmission of type 085.

Removal and dismantling of the gearbox input shaft 020 by uncoupling the gearbox from the clutch housing.

Removing the primary shaft spend in the following order:

- Remove the leash fork, which is held by two springs in a floating position (one spring is located in the transmission housing, and the second in the bearing cover);

- Remove the lead from the bearing cover and a full set of forks;

- Remove the retaining ring fourth gear;

- Remove the input shaft with the fourth gear (this gear output shaft).

Detail shot of the primary shaft of a transmission of type 020 shown in Fig. 5.52.

Gearbox output shaft has a thickening in areas splined profile mating with the clutch plate and the front of the needle bearing.

Dismantling of a primary shaft spend in the following order:

- Insert the press stops between the ball bearing 3 (see. Fig. 5.52) and the fourth transmission gear 5 and Xpress bearing from the input shaft 13;

- Insert the press stops at the fourth gear and Xpress with the input shaft fourth gear;

- Remove from a primary shaft the needle bearing 6 and the locking ring 7;

- Remove the retaining ring 8 is used for mounting the synchronizer of the third-fourth gear;

- Insert the press stops at the third gear and synchronizer Xpress 9;

- Remove the locking ring 10 of the third transfer;

- Remove the needle bearing 12 with the input shaft;

- Xpress primary shaft gear 11, third gear;

- At the other end of the primary shaft, remove the sleeve 14;

- Xpress ball bearing from a primary shaft, then remove the needle bearing.

Dismantling of a secondary shaft of a transmission of type 020. Details interfaced with the secondary shaft are shown in Fig. 5.53.

First of all, we should dismantle the whole set of gears:

- Remove the retaining ring 1 (see. Fig. 5.53), the fourth gear output shaft and the gear itself 2. Make sure that the gear was packed up collar;

- Remove the retaining ring 3 (if installed);

- Remove the retaining ring 4 with a third gear transmission;

- Remove from the output shaft 13 of the third gear 5 and 6 of the second gear transmission synchronizer ring 8 and the needle bearing 7;

- Remove the gear 16 reverse with the shaft 14 reverse gears. If necessary emboss shaft bearing housing of a plastic hammer;

- Using the two-armed scraper (fig. 5.54) and the pressing boss VW477h, placed at the end of the secondary shaft, while Xpress gear 10 (see. Fig. 5.53) and the first transmission synchronizer 9 1st and 2nd gears;

- Remove the needle bearing 11 1st gear and thrust washer 12. Note the position of the thrust washer;

- Unscrew the bearing cap bolts to the transmission and remove the bearing cover;

- Remove the output shaft from the bearing housing;

- Xpress turns with the two ends of the output shaft bearings.

When removing the two output shaft bearings may be destroyed if they are pressing. In this case, the cover should be replaced with the ball bearing and the bearing at one end and the outer race mounted in the bearing housing, on the other hand. In the case of these studies will be necessary to re-make adjustment of the backlash of a secondary shaft.

Dismantling-type differential transmission 020. Produced as well as disassembling the differential-type transmission 085 (see. 84).

Verification of parts and assemblies transmission of type 020

Checking parts and assemblies transmission type 020 produced exactly as for the transmission type 085.

Assembling the gearbox type 020

When assembling the transmission of type 020 soak the following recommendations:

- Bearings, rollers, gears, bearing washers and all rubbing surfaces grease gear oil;

- When installing new blocking rings of the synchronizer grind them to the respective tapered surfaces of gears. Total contact area after grinding should be at least 75% of the thread;

- The bearings are pressed only by the mandrels and only those rings that are experiencing land, do not allow transmission of forces pressing through the rolling elements.

Assembling the gearbox input shaft type 020. Carrying on the same assembly of the primary shaft of a transmission of type 085 (see para. 85).

Assemblage of a secondary shaft of a transmission of type 020. The gear 5th gear output shaft is located above the transmission case. The crankcase is a needle bearing.

The gearbox designed for this engine, a number of changes that have affected the construction of a secondary shaft. Diameter was increased fixed gear teeth 4th gear, there is an additional groove on the gear 3 and the second transmission parts for fastening the gear transmission 4 minutes, were increased retaining rings etc. Therefore, when ordering new parts of the secondary shaft should always inform Transm.

In the case of re-use of bearing grease gear oil separators, insert the shaft into the bearing housing and fit the bearing cover. Right turn the cap as Head lock reverse gear should be on the same side as the shaft reverse gear.

If new bearings, then heat them to a temperature of 100 ?� C using an oil bath or hot water, and press them to the secondary shaft. At the same time the inner race of the lower bearing must be securely prop.

After that, the secondary shaft assembly sequence is as follows:

- Check the locking ring and set the details of the synchronizer. Maximum allowable size of the gap when installing the rings of 0.5 mm. The gap between the newly installed parts must be equal to 1.1 - 1.7 mm;

- Mount the secondary shaft 13 (see. Fig. 5.53) thrust washer 12 so that the collar facing the bearing cap;

- Spread on output shaft gear 10 with the first transmission gear oil well lubricated needle bearing 11;

- Heat up to 120 ?� C, the sliding sleeve of the 1st and 2nd gears together with the locking ring 8 and by a length of pipe press them on a secondary shaft. The teeth of the sliding sleeve must be turned to the first gear;

- Set the shaft 14 reverse gear with the gear 16 reverse. If necessary, the shaft can be installed easy blows;

- Press them, or spread on a secondary shaft the inner ring together with the needle bearing 7;

- Push the needle bearing in the gear 6 2nd gear;

- Heat gear 5 3rd gear and with its press-fit end portion of the output shaft. Retaining ring must be established in the slot;

- Measure axial play gear 3rd gear. Usually taking the snap ring and insert it into a groove, and the gear must be firmly pressed. The measurement can be performed using the probe (Fig. 5.55). The results of measurements must be ordered retaining ring size you need. Issued retaining rings of varying thickness: 2.5 mm (chestnut), 2.6 mm (black), 2.7 mm (bright), 2.8 mm (color of copper) 2.9 mm (white) and 3.0 mm (blue);

- Replace the secondary shaft gear April 2 nd transmission collar up and a new lock ring 1. Firmly press it into the slot. The gearbox 2-liter engine sets the second snap ring;

- Press them on the secondary shaft bearing with a recessed groove. A wide bead of the inner ring of the bearing to be converted to the punch press;

- Fit the preload (it can be installed in only one position), and then tighten it to the full;

- Before installing the unit plugs into the hole, insert the spring clutch. It is located in front of the gears;

- Set the fork in the reverse order of removal;

- Align shaft reverse gear, which screw the bolt into the threaded hole of the shaft reverse gear and insert the axle in its guide hole so that the line mentally drawn through the bolt head, held in the middle between two bolt hole on the gearbox (Figure . 5.56). In this position, slide the shaft up to the stop towards the bearing cover;

- Collect the gearbox housing.

Assembling the differential gearbox of type 0 20. Before assembly, lubricate the gear oil differential side gears and satellites.

Assembling the differential transmission of type 020 is similar to the assembly of the differential transmission of type 085

Assembling the gearbox type 020 is the same as the assembly of the gearbox type 085

Adjusting the transmission and differential

Adjustment of transmission and differential should be carried out in the following cases:

- The replacement of the gearbox - regulated differential;

- The replacement of the bearing housing - is governed by the input shaft, output shaft and differential;

- When replacing the clutch - regulated secondary shaft and differential;

- When replacing the differential bearing - regulated differential;

- The replacement pinion and output shaft - regulated output shaft;

- When replacing the differential housing - regulated differential;

- When replacing the bearing of a secondary shaft - regulated output shaft.

Adjusting the primary shaft of a transmission of type 020. A primary shaft of a transmission of type 020 is not required to adjust, but you need to see to it to remove the shim when dismantling the assembly has been re-established.

Adjusting the secondary shaft of a transmission of type 020 is to determine the thickness of the shim located under foreign yoke front bearing shaft.

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??� ???�???�???�?� ???�???�?? ?? ?�???�?�???????? 0,65 ???? ?? ?????�?�???? ?????????????� ???�?�???�?�?????? ?? ?�?�?????�?????????�?� ?????�???????? ???�???????? ???????????????????�;

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??� ?????�?�?????????�?� ?????�?�???�?�???????� ?????????????????�?�?�?????� (????. ??????. 5.57 ). ?????�???? ???????????�?�?????� ?????�?�?????????�?� ???� ?????????????? ???????�?????? ?? ?????�?????�?????�?�?�?????�?? ???�?�????????, ???�?????�?? 1 ????, ?? ?? ???�???? ?????�???�?�?????? ?�?�?�???????????????�?� ???????????�?�????, ???????�?� ?�?�???? ???�???�?�???? ???????????�?�?????� ?????�?�?????????�?� ???� ?????�??;

- Move from the bottom up and down the shaft and follow the indications of the indicator, which may be about 0.30 mm;

- According to the formula S = A + B + C, calculate the thickness of the shim bearing front where

S ??� ?�???�?�?????� ???�?????�???????????�?????? ???�???�?�, ????;

?? ??� ???�?�???�?????� ?????�???????? ???�???�???�?�?�?????? ???�?�?� (???�???�???�???????� ?�???�?�?�?????�), ????;

?� ??� ???�?�???�?????� ?????�?????�?????�?�?�?????????? ???�?�?????�, ????;

?? ??� ?�???�?�?????� ?????�?�?????????�?????? ???�???�?� (???�?�???�?????� ???????�?????????�??), ????.

Example of measurement is as follows.

???????�?? ?�???�?�?????� ?????�?�?????????�?????? ???�???�?� ?? = 0,65 ????, ???�???�???�?????�?? ???�?�???�?????� ?? = 0,30 ????, ???�?�???�?????� ?????�?????�?????�?�?�?????????? ???�?�?????� ?� = 0,20 ????. ???�?�???????�?�?�?�??????, ?�???�?�?????� ???�?????�???????????�?????? ???�???�?� S = 0,65 + 0,30 + 0,20 = 1,15 ????;

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To adjust the tightness of the bearing of a secondary shaft provided shims of different thickness (total of 16 sizes from 0,650 to 1,400 mm and a pitch of 0.05 mm), presented in the Table. 5.4.

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?�?�?????�???????????� ?????�?�?�???�???�???�?�?� ?????????�???? ???�???�???�?� ?�?????� 020

?�?�?????�???????????� ?????�?�?�???�???�???�?�?� ?????????�???? ???�???�???�?� ?�?????� 020 ???????????????�???? ?�?�?? ?�?�, ???�?? ?? ???�?? ?????????�???? ???�???�???�?� ?�?????� 085.

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