Audi 80/90/Coupe

since 1986-1991 release

Repair and operation of the car



Audi 80/90/Coupe
+ 1.2. Identification of the car
+ 2. Engines, carburetors
3. Lubrication system
+ 4. Cooling system
+ 5. Fuel system
+ 6. Exhaust system
+ 7. System of ignition
- 8. Transmission
   8.1.2. A fork - the main cylinder of coupling
   8.1.3. Press clutch plate
   8.1.4. Malfunctions of coupling
   - 8.2. Mechanical transmission 012
      8.2.2. Lever mechanism of the lever of gear shifting
      8.2.3. Removal and installation of the transmission
      8.2.4. Differential mechanisms
   + 8.3. Mechanical transmission 01A
   + 8.4. Automatic transmission 089
   + 8.5. Automatic transmission 087
   8.6. Dismantling and assembly of automatic transmissions
   8.7. Block of valves
   + 8.8. Automatic transmission 097
+ 9. Suspension brackets, wheels
+ 10. Brake system
+ 11. Steering
+ 12. Body, salon
+ 13. Air conditioning system
+ 14. Electric equipment



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8.2.3. Removal and installation of the transmission

GENERAL INFORMATION

Transmission 012 assembled

1. Conic roller bearing
2. Gear wheel of transfer of a backing
3. Gear wheel of the 5th transfer
4. Gear wheel of the 4th transfer
5. Gear wheel 3-oh transfers
6. Gear wheel of the 2nd transfer
7. Gear wheel of the 1st transfer
8. Conic roller bearing
9. Differential
10. Coupling case
11. Ball-bearing
12. Transmission case
13. Leading shaft
14. Block of gear wheels of an intermediate shaft

Fastening of the transmission to the engine (4-cylinder model)

Centering plugs: points And yes In
1 = M12x70 bolt
2 = M12x85 bolt
3 = M12x100 bolt
4 = M8x15 bolt

Fastening of the transmission to the engine (5-cylinder model)

Centering plugs: points And yes In
1 = M12x70 bolt
2 = M12x80 bolt
3 = M12x90 bolt
4 = M12x100 bolt
5 = M10x120 bolt
6 = M10x50 bolt
7 = M10x40 bolt
8 = M8x40 bolt

Removal

PERFORMANCE ORDER
1) disconnect a wire of the negative plug of the accumulator
2) turn off three top bolts of fastening of the engine and the transmission
3) disconnect a wire of grounding of the transmission from the check point
4) remove the socket of connection of the sending device of a speedometer and the socket of the multi-function sending device having squeezed clips
5) disconnect the socket of connection of the catalytic converter
6) remove a protective plate of a case of the transmission
7) turn off bolts of fastening of a final collector
8) remove a forward exhaust pipe
9) remove a back cross beam
10) disconnect ropes of an automatic tension of seat belts from the transmission
11) draft of gear shifting
12) protective plate of a case of coupling
13) protective plate of the leading shaft
14) disconnect half shafts from the transmission
15) turn a steering wheel against the stop to the right and fix half shafts having tied them to a body
16) remove the working cylinder of coupling
17) remove a steering mechanism arm
18) install the engine on a support
19) install the transmission on a support
20) remove fastening on a back left part of the transmission
21) remove forward fastening of the engine
22) remove the lower bolts of fastening of the transmission and engine
23) slowly lower the transmission

Installation

Installation is carried out upside-down removals. At installation pay attention to the following:

PERFORMANCE ORDER
1) check that centering plugs were installed correctly
2) install the working cylinder of coupling into place by means of the lever so that the bolt was inserted easily

Prevention

The bolt for fastening of the working cylinder of coupling has the pointed end for installation simplification.


Mechanism of the main transfer

1. Speedometer drive
it is possible to replace, without removing the transmission
2. Differential
it is possible to remove, without removing a transmission case
3. Sealing ring
4. Cover of the main transfer
remove a sealing ring
by means of the VW 681 tool
pressurize by means of AMV 188 200 03 sealant
5. A bolt with a head under a face key – 25 N. of m.
6. Lock ring
always replace
7. Flange of the leading shaft
establish by means of the VW 295 tool
8. A bolt with a head under a face key – 35 N. of m.
9. The directing plug with a sealing ring
10. Concave washer
the party with a smaller diameter is turned to the directing plug (the concave party)
11. Lock ring
mark after removal
12. Ball-bearing of the leading shaft
13. Lock ring
mark after removal
14. Sending device of a speedometer
15. Case of the main transfer
remove a sealing ring of a flange of the leading shaft by means of the VW 681 tool
establish (5 mm lower than a surface of a case of the main transfer) by means of the VW 195 tool
establish an external holder of a conic roller bearing by means of the VW 511 and VW 295 tools
3-y/the 4th transfer install the switching rod plug by means of the VW 295 and VW 295A tools
pressurize by means of AMV 188 200 03 sealant
16. A bolt with a head under a face key – 10 N. of m.
17. I will corrode connections of the multi-function sending device
18. Cover of the channel of the lever of gear shifting
tighten a fastening bolt to 20 N. of m.
19. Multi-function sending device
20. The locking level
for the multi-function sending device
21. 25 N. of m.
22. Lock of the 5th transfer and transfer of a backing
it is possible to replace, without removing the transmission
the slanted party of the plastic plug is turned to a switching shaft
the moment of an inhaling of bolts of fastening – 10 N. of m.
23. Lock ring
always replace

Prevention

If you need to replace a case of the main transfer or a conic roller bearing of the leading gear wheel or a hollow shaft and the deviation of r is not designated on on a conic cogwheel, the provision of installation of the leading gear wheel should be defined before removal of a case of the transmission (it is necessary to take measurement of the valid size of a deviation).

Before installation of a case of the transmission, check that the directing plugs were installed in a transmission case.

Handle the sending device of a speedometer very accurately. Do not drop it, otherwise indications of a speedometer can be not exact.


Switching shaft bolts

Gear shifting mechanism, provision of installation

1. A rod of switching of the 5th transfer / transfer of a backing with a switching fork
2. Switching rod 3-y/the 4th transfers
3. Switching fork 1-oy/the 2nd transfers
4. Switching shaft
5. Lock
6. Internal rod of switching

The leading shaft, the leading gear wheel with a hollow shaft, rods of switching and a fork of switching, the provision of installation

These elements should be established together.

Prevention

The shaft of switching and internal rod of switching can be established later.


Shaft of switching and internal rod of switching

Installation

PERFORMANCE ORDER
1) include the 3rd transfer
2) establish a shaft of switching And
3) put an internal rod of switching In sideways on an opening in a case of the main transfer and combine it with an arm nest on a switching shaft
4) turn a switching rod inside (in the direction of an arrow)

Switching rod plug

Removal

PERFORMANCE ORDER
use the hammer and an internal stripper And on 18.5–23.5 mm (for example, 1088 or Kukko 21/3)

Switching fork bearing, removal and installation

Oil pan

PERFORMANCE ORDER
1) remove an oil pan (it is specified by an arrow) by means of the screw-driver
2) insert an oil pan so deeply into a transmission case that lock uvulas of an oil pan were hooked for grooves in a transmission case
3) the cup of an oil pan has to look up in a transmission case

Sealing ring of an internal rod of switching

size and = 1 mm

Needle bearing of the leading shaft, removal

Needle bearing, installation depth

it is measured from bottom edge of a test ruler to the upper edge of the bearing

size and = 39.5 mm

Ball-bearing

Installation in a case

PERFORMANCE ORDER
1) establish a lock ring on the leading shaft
2) install the ball-bearing on the leading shaft against the stop
3) install a persistent heel of the release tool 3235 on the ball-bearing
4) install the release tool 3235 behind clutch plate vents on an entrance shaft
5) press on the ball-bearing having twirled two bolts In established in deepenings of a persistent heel And
6) press the bearing against the stop in turn and gradually twisting two bolts

Prevention

Bolts In should be twisted alternately (for example, half way for time), otherwise the ball-bearing can be turned and damaged.

Provision of installation of the ball-bearing: the open party of the plastic case has to be turned to the directing plug.


Synchronizer spring

Installation

PERFORMANCE ORDER
establish a spring (it is specified by an arrow) in a gear wheel, having established the pointed end of a spring in a groove

Synchronizer ring

Check

PERFORMANCE ORDER
1) install a synchronizer ring on the sliding coupling and measure a gap and by means of the probe for measurement of gaps in points And, In and With
2) put the received values and divide the sum on 3
3) the received value should not be less, than 0.5 mm

The sliding coupling – 3-ya/the 4th transfer

the party with a groove (it is specified by an arrow) is turned to a gear wheel of the 3rd transfer

Gear wheel of the 5th transfer

Removal

And = the removable device on 22–115 mm, such as, for example, Kukko 17/2

Installation

the acting edge is turned to transfer of a backing; lubricant channels are turned to the 4th transfer

Needle bearing of the leading shaft

And = a stripper on 22–28 mm, for example Kukko 21/4

In = VW 771 hammer


Prevention

Before installation of a stripper for removal of the bearing, split / remove the plastic plug if it is established. For installation of the bearing, press it by means of VW 416B mandrel on depth of 214 mm, measuring from a case surface.


Lock rings

Lock ring of a gear wheel of the 4th transfer

Removal

PERFORMANCE ORDER
determine the greatest possible thickness of a lock ring which can be established, and establish it

Prevention

The lock ring for a gear wheel of the 5th transfer is chosen in the same way.


Selection of an installation site


Prevention

Lock rings are numbered according to their situation on the leader to a shaft.


Lock rings 1, 2, 4 and 5 should be selected. Thickness of a lock ring 3 is always constant.

Determine the necessary thickness of lock rings 1 and 2.

Lock ring 3 (brown)

THICKNESS OF THE LOCK RING, MM
NUMBER
2.00
902 945.01

Lock ring 4 (blue)

THICKNESS OF THE LOCK RING, MM
NUMBER
1.90
902 944.01
1.93
902 944.02
1.96
902 944.03
1.99
902 944.04
2.02
902 944.05
2.05
902 944.06

Lock ring 5

THICKNESS OF THE LOCK RING, MM
NUMBER
1.90
902 942.02
1.93
902 942.03
1.96
902 942.04
1.99
902 942.05
2.02
902 942.06

Nave of the synchronizer 3-y/of the 4th of transfers

Removal

PERFORMANCE ORDER
1) install the following tools as shown in the drawing:

VW 401/VW 402 = persistent heels

32 – 12 = disk

VW 408A = drift

And = a stripper on 22–115 mm, the Kukko 17/2 type


Prevention

Before installation of a stripper And, press a ring of the synchronizer of the 3rd transfer (it is specified by an arrow) to a gear wheel of the 3rd transfer.


2) remove a synchronizer nave

Nave of the synchronizer 3-y/of the 4th of transfers, installation

Plastic plug

Installation

PERFORMANCE ORDER
The plastic plug B is installed only on the leader to a shaft with lubricant flutes (are specified by an arrow) for 3-ey/by the 4th transfers.

Install the plastic plug B together with the needle bearing A.

Leading shaft

Mechanism of the leading shaft

1. Internal draft of switching
remove a sealing ring of internal draft of switching by means of the VW 681 tool and establish aflush by means of the VW 460/2 tool. On the installed transmission accurately remove a sealing ring by means of the screw-driver and establish by means of the VW 423 tool. In the beginning remove pipes of the exhaust system and draft of gear shifting for receiving an empty seat.
2. A rod of switching of 1 2nd, 5th transfers and transfer of a backing with a switching fork
for dismantling / assembly, remove / establish spring pins:
switching forks 1-oy/the 2nd transfers can be replaced separately
replace a fork a rekey a niya of the 5th transfer / transfer of a backing only together with a ring of switching and a rod of switching
3. The leading gear wheel with a hollow shaft
4. Transmission case
5. A bolt with a head under a face key – 25 N. of m.
6. A bolt with a head under a face key for an axis of transfer of a backing – 35 N. of m.
the axis of transfer of a backing does not need to be removed for removal of a gear wheel of transfer of a backing
7. A bolt with a head under a face key – 25 N. of m.
the inside of a head is turned to the safety mechanism of the spring / lock
8. Lock
establish after installation of a shaft of switching (11) and internal, a switching rod
9. A bolt with a head under a face key – 40 N. of m.
10. Washer
11. Switching shaft
12. Washer
13. A bolt with a head under a face key 40 – N. of m.
14. Switching rod 3-ey/the 4th transfers and switching fork
the rod of switching or fork of switching can be replaced separately
establish by means of the VW 295 and VW 295A tools
replace the switching rod bearing if it is worn-out
15. Leading shaft
16. Lock ring
17. Washer
18. Gear wheel of transfer of a backing
19. The needle bearing of the conducted gear wheel of transfer of a backing
20. Persistent washer

Leading shaft assembled

1. Transmission case
2. Plastic plug
always replace
is absent on the leader to a shaft on which there are no lubricant openings for Z-ey/of the 4th transfers
3. The needle bearing – the leading shaft
it is damaged at removal
always replace
to establish by means of the VW416B tool on depth in 214 mm, measuring from a case surface
4. Lock ring
specify the required thickness when replacing a gear wheel of the 5th transfer
5. Gear wheel of the 5th transfer
6. Igolchata the bearing – the 4th transfer
7. Gear wheel of the 4th transfer
8. A synchronizer ring – the 4th transfer
9. The sliding coupling – 3-ya/the 4th transfers
10. Lock ring
specify the required thickness when replacing a nave of the synchronizer
11. A synchronizer nave – 3-ya/the 4th transfers, the acting rim it is turned to the conducted gear wheel of the 3rd transfer
12. Lock ring
13. The lock ring if you are going to use the old ball-bearing and a shaft, should be measured thickness of an old lock ring and to replace it new the same thickness
14. The ball-bearing – the leading shaft
15. The lock ring if you are going to use the old ball-bearing and a shaft, should be measured thickness of an old lock ring and to replace it new the same thickness
16. Case of the main transfer
17. The needle bearing – the leading shaft
establish by means of the tool 40-202
18. Leading shaft
19. The needle bearing – the 3rd transfer
20. Gear wheel of the 3rd transfer
21. A synchronizer ring – the 3rd transfer

Prevention

Lock rings differ on thickness and diameter and they should be measured at removal. When replacing a gear wheel or shaft, the corresponding lock rings should be measured for installation of a ring of the required thickness and diameter.


Adjustment of the leading shaft

PERFORMANCE ORDER
1) fix the leading shaft in a vice with soft laying on sponges
2) establish And, an expansion plate 3167, on the 3rd transfer
3) establish a case on an expansion plate having put on it the leading gear wheel
4) establish a depth gage on a case and measure distance to the lower flute on a shaft
5) size and = 28.5 mm
6) establish a depth gage on a case and measure distance to a ball-bearing installation site
size b = 26.8 mm
7) determine the necessary thickness of the lower lock ring
Size x
x = a – b
x = 28.5 mm – 26.8 mm = 1.70 mm
8) determine the necessary thickness of a lock ring from tables
9) establish a lock ring and the ball-bearing on a shaft by means of a mandrel 30-100
10) find a lock ring of the biggest thickness which can be inserted (values of thickness of lock rings are reflected in the table)
11) establish a release plate of a stripper 3128 under an external holder
12) establish a level of VW 771/29 and establish a bolt on a transmission case

13) when twisting a bolt the external holder is removed from a case


Size
Thickness
Number
1.64 – 1.71
1.69
902 941.05
1.72 – 1.79
1.77
902 941.06
1.80 – 1.87
1.85
902 941.07
1.88 – 1.95
1.9
902 941.08
1.96 – 2.03
2.01
902 941.09
2.04 – 2.11
2.09
902 941.10
2.12 – 2.19
2.17
902 941.11
2.20 – 2.27
2.25
902 941.12
2.28 – 2.35
2.33
902 941.13

Thickness (mm)
Number
1.69
902 941.05
1.77
902 941.06
1.85
902 941.07
1.93
902 941.08
2.01
902 941.09
2.09
902 941.10
2.17
902 941.11
2.25
902 941.12
2.33
902 941.13

Leading gear wheel and hollow shaft

I. Case of the main transfer
2. S3 washer
3. A decade conic roller bearing – an external holder
4. Leading gear wheel
corresponds to a gear wreath (couple a gear wreath / leading a gear wheel)
when replacing couple a gear wreath / leading a gear wheel adjust installation of the leading gear wheel, and also hollow shaft and gear wreath
5. A two-row conic roller bearing – an internal holder
6. Lock ring
7. The needle bearing – the 1st transfer
8. Gear wheel of the first transfer
9. A synchronizer ring – the 1st transfer
10. A synchronizer nave – 1-aya/the 2nd transfers
acting to an edge it is turned to the 2nd transfer
to remove together with a gear wheel of the 1st transfer, use persistent plates of VW 401 and VW 402
establish by means of a mandrel of VW 415A and the VW 519 plug
11. Lock ring
12. The needle bearing – the 2nd transfers
13. The sliding coupling – 1-aya/the 2nd transfers
14. A synchronizer ring – the 2nd transfer
15. Gear wheel of the 2nd transfer
16. Lock ring
17. Gear wheel of the 3rd transfer
the flute is turned to a gear wheel of the 4th transfer
18. Lock ring
19. Gear wheel of the 4th transfer
the edge is turned to a gear wheel of the 3rd transfer
20. Lock ring
21. The needle bearing – the 5th transfer
22. Gear wheel of the 5th transfer
23. A synchronizer ring – the 5th transfer
24. Lock ring
25. A synchronizer nave - the 5th transfer / transfer of a backing
the acting edge is turned to a gear wheel of the 5th transfer
remove together with a gear wheel of the 5th transfer
establish by means of the plug 2010
26. Lock ring
27. The needle bearing – transfer of a backing
28. The sliding coupling – the 5th transfer / transfer of a backing
29. A synchronizer ring – transfer of a backing
30. Gear wheel of transfer of a backing
31. A conic roller bearing - an internal holder
32. The lock carving plug for an external holder of a conic roller bearing
its installation is not required when replacing an external holder (this plug is necessary
only by production)
33. A conic roller bearing – an external holder
34. S4 washer
35. Clamping plate
36. The washer compensates expansion depending on temperature (heating)
for removal drill an opening in a washer and remove by means of the screw
37. Transmission case

Installation of an external holder of a two-row conic roller bearing


Removal of an internal holder of a two-row conic roller bearing, removal

PERFORMANCE ORDER
For removal of an internal holder the external holder And has to be established.

Installation of an internal holder of a two-row conic roller bearing

 

Installation of a spring of the synchronizer in a gear wheel

PERFORMANCE ORDER
Establish a spring (it is specified by an arrow) in a gear wheel, having established the pointed end in a flute.

Synchronizer ring, check on wear

PERFORMANCE ORDER
press a synchronizer ring to the sliding coupling and measure a gap and by means of the probe for measurement of gaps in points And, In and With

put the received values and divide the sum on 3

the received value should not be less, than 0.5 mm

Installation of the sliding coupling – 1-aya/the 2nd transfers

The party with a flute has to be turned to a gear wheel of the 1st transfer.

Removal of a gear wheel of the 3rd transfer

And = a stripper on 22–115 mm, the Kukko 17/2 type

Installation of a gear wheel of the 3rd transfer

Provision of installation: the flute has to be turned to a gear wheel of the 4th transfer.

Removal of a gear wheel of the 4th transfer


Installation of a gear wheel of the 4th transfer


Removal of a nave of the synchronizer

Remove a synchronizer nave together with a gear wheel of the 5th transfer.

Use a stripper And on 22–115 mm, the Kukko 17/2 type.


Identification of a ring of the synchronizer
Production of rings with more than 3 uvulas was stopped.

Removal of an internal holder of a conic roller bearing

Remove an internal holder together with a gear wheel of transfer of a backing.

Use a stripper And on 22–115 mm, the Kukko 17/2 type.


Installation of an internal holder of a conic roller bearing


 

Installation of the sliding coupling – the 5th transfer / transfer of a backing

The diagonal strip 1 is turned to a gear wheel of transfer of a backing.

The party with a flute 2 is turned to a gear wheel of the 5th transfer.


Removal of the lock carving plug

Use a stripper And on 22–115 mm, the Kukko 17/2 type.

Installation of the plug is not required when replacing an external holder. (This plug is necessary only by production.)


Removal of an external holder of a conic roller bearing

PERFORMANCE ORDER
Twirl a special bolt for removal in a release plate.

M10 bolt (length of 50 mm) which is ground off on one end to diameter of M8.

Remove a release plate and an external holder from a case by means of the hammer.


Installation of an external holder of a conic roller bearing

 

Installation of a lock ring of a conic roller bearing


PERFORMANCE ORDER
Find a lock ring of the biggest thickness which can be inserted, and establish it.

Necessary thickness of lock rings of a nave of the synchronizer and thickness of lock rings of gear wheels 3-ey/transfers is also defined by the 4th as thickness of a lock ring of a conic roller bearing.


Installation site and selection of lock rings
Lock rings are designated in the drawing, they are numbered according to their situation on the leader to a shaft.

Lock rings 1, 2, 4, 5 and 7 should be selected.

Thickness of lock rings 3 and 6 is always constant (see the table the Lock ring 3 (blue) and the table the Lock ring 6 (brown))

Lock ring 1

Thickness (mm)
Number
2.00
902 950.01
2.02
902 950.02
2.04
902 950.03
2.06
902 950.04
2.08
902 950.05
2.10
902 950.06

Lock ring 2 (blue)

Thickness (mm)
Number
1.90
902 947.01
1.93
902 947.02
1.96
902 947.03
1.99
902 947.04
2.02
902 947.05

Lock ring 3 (blue)

Thickness (mm)
Number
2.50
902 947.06

Lock ring 4
Thickness (mm)
Number
1.90
902 946.02
1.93
902 946.03
1.96
902 946.04
1.99
902 946.05
2.02
902 946.06

Lock ring 5

Thickness (mm)
Number
1.87
902 952.01
1.90
902 952.02
1.93
902 952.03
1.96
902 952.04

Lock ring 6 (brown)

Thickness (mm)
Number
2.00
902 945.01

Lock ring 7 (blue)

Thickness (mm)
Number
1.90
902 944.01
1.93
902 944.02
1.96
902 944.03
1.99
902 944.04
2.02
902 944.05
2.05
902 944.06