The assembly of the driven shaft

If necessary, replacement of the driven shaft or a driven shaft bearing is subject to adjustment as described below.

Assembling of the shaft is carried out in sequence, return dismantling. Besides the adjustment it is necessary to pay attention to the following:

The output shaft is shown in Fig. 185) is measured (see below).

- Drive in the tapered roller bearing 28 at the end of the shaft;

- Before the assembly of the shaft to check the synchronizer ring first and second gears for wear. The measurements were performed twice. First, press the inner ring towards the tapered surface of the gear wheel and measured by the contact probe and the clearance (Fig. 187). Allowable clearance (wear limit) of 0.3 mm (the new 0.75-1.25 mm). When you press the second dimension should be made on a synchronizer ring, outer and inner rings in the direction of the conical surface of the gear transmission and a touch trigger probe to measure the gap as well (Fig. 188). Allowable clearance (wear limit) of 0.5 mm (the new 1.2-1.8 mm).

The assembly of the driven shaft should be carried out as follows.

Collect details of the second gear synchronizer as shown in Fig. 189 in the following order:

- To set the inner ring A on the second gear. Bevelled protrusions (arrow 1) are pointing in the direction of the outer ring B;

- Set the outer ring B. The projections (arrow 2) must be in the groove gear transmission (arrow 3);

- Establish a synchronizer ring C. The slots should enter into engagement with the inner ring in a place marked by an arrow 1;

- Set three stopper to hub transmission and sliding sleeve - the hub;

- Installation synchronizer springs used in Fig. 190 and springs set as shown: shift the end of the spring located on the opposite side by 120 ?� relative to the other spring, as shown by the dotted line. It should be remembered that the groove in the sliding sleeve must be turned towards the first transmission.

Collect details of first gear synchronizer in the following order:

- Set the outer ring, as shown in Fig. 191. The protrusions on the inner side is facing the reverse gear pinion A;

- To set the inner ring A, using Fig. 192. Bevelled protrusions (arrow 1) should enter into engagement with the grooves (arrow 2) of the ring in the synchronizer;

- Set top first gear. The grooves in the collar switching gear must enter into engagement with projections on the outer ring of the synchronizer;

- On the electric stove to warm the fourth gear to 120 ?� C and drive shaft, guide him through the gear so that the shoulder is facing the third gear;

- Set both stop ring 24 (see. Fig. 185), and 25. For this purpose, use the special pliers used for repairing water pumps. Set first ring on the shaft, and then enter it into the groove pliers;

- Install gear to third gear 23 oiled needle bearing, and secure it to the other side of the retaining ring 21. Check the secure connection of the ring in the groove;

- Set the second transmission gear 20 with the details of the synchronizer (see. Above installation instructions) on the needle bearing and install assembled synchronizer.

The groove in the sliding sleeve should be turned toward the first gear and reverse gear teeth - towards the second gear. Synchronizer extrude using a press, with the slots in the synchronizer shown on one line with the stoppers;

- Install the shaft first gear defined therein details of the synchronizer (see. Above installation instructions) and needle bearing.

Adjust the output shaft as follows:

- Drive in the clutch outer thrust ring mounting tapered roller bearing using shims thickness of 0.75 mm with the appropriate mandrel or gently beat him;

- Place the assembled input shaft and the transmission housing. Bolts tighten the moment 25 Nm;

- Rotate the shaft several times to the bearing could be earned extra, and set shown in Fig. 193 special tools with dial gauge at the end of the shaft. Set the slip tension indicator, equal to 1.0 mm, and move the arrow indicator to zero;

- To translate the output shaft in the direction indicated by the arrow, and fixed (e.g., 0.30 mm) at the reading pointer indicator. It should be remembered that this operation must be carried out with each new metering as the arrow pointer indicator to its original position will not be returned;

- Based on this measurement to determine the thickness of the shims. For this sum the thickness of the installed washers shown value and pre-tightening. The amount will the thickness desired goals;

Example

The thickness of the installed shims 0,75 mm

The measured value is 0.30 mm

The value of pre-tightening 0.20 mm

The thickness of shims required: 0.75 + 0.30 + 0.20 = 1.25 (mm)

- Again to remove the output shaft, remove the outer ring of the bearing from the crankcase and remove the washer. Washers with a thickness of 0.70 to 1.40 mm, so you can pick up the necessary thickness exactly;

- Remove adjusting thrust washer with a suitable puller (see. Fig. 173) and remove the installed shims thickness of 0.75 mm from the clutch housing;

- Again pressed into the clutch outer mounting thrust ring with the required shims (this time, a thickness of 1.25 mm), set the gearbox housing and tighten the bolts clutch torque 25 Nm;

- Set the output shaft torque sensor and nozzle VW 548 and evenly turn the shaft with a device for measuring the torque (Fig. 194). If you have installed a new tapered roller bearings, the reading should be 80-160 Ncm. At run-bearings torque must be at least 30 Ncm. Prior to monitor bearings must be lubricated with gear oil.