Repair clutch

In Fig. 172 provides details of coupling. When provided work to further disassembly, you should proceed as follows:

- Remove the guide bushing 14 speedometer drive gear and remove speedometer drive gear 15 from the hole;

- Oil seal rings 16 of the drive flange is easy to replace. Remove the old O-ring, using a large screwdriver or pry bar. Housing O-ring 17 when replacing the O-ring must also be replaced. Remove the old cabinet with a screwdriver and press in the new building of the respective mandrel. Drive new sealing ring with a steel rod of appropriate diameter. Space sealing lips lubricated universal grease;

- Clear the oil seal rings 18 of the inner gear lever with a respective mandrel. New O-ring must drive in such a way that it is flush with the end fell crankcase. To remove the internal gear lever must knock sleeve 19 and pull the lever. New molded sleeve 10 mm below the plane of the crankcase;

- Remove the starter shaft bushing 13 corresponding stripper (for example, the special adaptation VW 228b and 204b). The new hub should drive in such a way that its end was located flush. You must first before pressing greased sleeve grease;

- Remove the adjusting ring 3 is tapered thrust roller drive shaft by a suitable puller, as shown in Fig. 173. For this work fit puller Kukko 21/6 bridge Kukko 22/2 with. Remove the shims 4 (see. Fig. 172), which is under mounting thrust ring. Drive in a new setting appropriate thrust ring Tool for fitting, in case of replacement of the bearing is necessary to adjust the drive shaft. The adjustment of the drive shaft to hold well when replacing the gearbox housing and the clutch, as well as of the shaft;

- To remove the installation of the thrust ring 26 tapered roller bearing output shaft also needs a stripper. Remove the shims 25, which is under mounting thrust ring. Drive in a new setting appropriate thrust ring mandrel for pressing, pre-adjusting the output shaft. The last subject to adjustment if the replaced gearbox housing and clutch shaft or bearing;

- To replace the cuff 9 to remove the drive shaft bearing 12 of the clutch 10 and the guide sleeve cuff and pull in the appropriate manner. Drive new seal before installing 2.5 mm less than half gearbox, which is almost all the way. Replace the guide sleeve and tighten the bolts to 20 Nm;

- If you will shoot the connecting plug 21 (after loosening the bolts 22 and remove the inner shaft of the gearshift), adjustment is necessary when installing parts. The same adjustment should be carried out and the replacement of the finger shift, the clutch housing and gearbox, the internal gear lever or stopper 1 (see. Figure 172) for internal gear lever. To adjust the required special tools. The adjustment should be carried out as follows:

- Set the adjusting plate with the mounting bushings on the transmission housing;

- Mounted on the housing with the appropriate dial gauge holder, as shown in

Fig. 174;

- Set the measuring pin of the dial gauge on the reversing guide. Install the pre-tension of 1 mm dial gauge to the measuring pin was under tension;

- Take the left guide to the reverse gear and arrow set dial gauge to zero;

- From the lower side to press the dial gauge in the other direction and read the displayed value. Assume that it is, for example, 0.70 mm;

- To fix the guide in the middle position, i.e. to reduce the value obtained by half and move the transfer rail on the bottom side up until it reaches a value equal to 0.35 mm (one-half). Tighten in this position, the transfer guide bolt 1;

- Transfer shift finger with a special tool VW 709, as shown in

Fig. 175, in the direction reverse and set the measuring gauge 3154/1 (Pos. 1);

- Move the measuring gauge from stop to stop and fix the reading on the pointer indicator. Assume that it is, for example, 0.60 mm. Set the measuring gauge in the middle, that is, the reading is 0.30 mm, and tighten the bolt 1 (

fig. 176);

- Again unscrew the screw using the dial gauge;

- Loosen the bolt 1 (

Fig. 177) so that the coupling sleeve can move freely on the internal gear lever, and set the gear lever to the middle stop;

- Extrude positioning sleeves in the clutch housing and install gauge 3154 on the clutch housing, turning it 180 ?�, so that the shift finger and a coupling sleeve were centered with respect to each other. If necessary, carry out additional adjustments with a screwdriver as shown in

Fig. 178.