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
- 8.3. Mechanical transmission 01A
8.3.2. Removal and installation of the transmission
8.3.3. Dismantling and assembly of the transmission
+ 8.3.4. Differential
8.3.5. Driveshaft
8.3.6. Central cardan hinge
+ 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
|
Transmission assembled
|
1. Leading shaft
2. Ball-bearing
3. Coupling case
4. Differential
5. Two-row conic roller bearing
6. A gear wheel 1 - oh transfers
7. Gear wheel of the 2nd transfer
8. Gear wheel of the 3rd transfer
9. Gear wheel of the 4th transfer
|
10. Gear wheel of the 5th transfer
11. Gear wheel of transfer of a backing
12. Transmission case
13. Conic roller bearing
14. Differential case
15. Flange drive
16. Differential
17. Hollow shaft
18. Leading gear wheel |
Mechanism of the main transfer
|
1. Transmission case
– remove an ullotnitelny 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 VW195 tool
measure depth of installation of a sapun
switching rod plug: establish by means of the tool 30-205
pressurize by means of AMV188 200 03 sealant
2. Lock ring
mark after removal
3. The directing plug with a sealing ring
4. 35 N. of m.
5. Concave washer
the party with a smaller diameter is turned to the directing plug (the concave party)
6. Ball-bearing of the leading shaft
7. 10 N. of m.
8. Sending device of a speedometer
9. Differential
it is possible to remove, without removing a transmission case
10. Sealing ring
11. Flange of the left half shaft
establish by means of VW 295
|
12. Lock ring
always replace
13. 25 N. of m.
14. Cover of the main transfer
remove an uplrtnitelny ring by means of the VW 681 tool
pressurize by means of AMV 188 200 03 sealant
15. Lever of gear shifting and casing of a shaft
16. 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 has to be turned to a switching shaft
17. Lock ring
always replace
18. Flange of the right half shaft
establish give to drink the help of VW 295
19. 25 N. of m.
20. Clamping plate
for the multi-function sending device
21. Multi-function sending device
22. I will corrode connections of the multi-function sending device |
Dismantling / assembly
| PERFORMANCE ORDER |
| 1) install the transmission at the repair stand |
| 2) merge gearbox oil |
| 3) remove the lever of switching off of coupling and the release bearing of coupling |
| 4) remove the directing plug |
| 5) remove the lock ring established in front of the ball-bearing and measure its thickness |
| 6) remove the ball-bearing from a transmission case by means of a stripper |
| 7) remove the lock ring established behind the ball-bearing and measure its thickness |
| 8) remove bolts between a transmission case / cover (for differential) and uncover together with differential |
| 9) remove bolts between a case of coupling and a case of the transmission and remove a transmission case |
| 10) remove the multi-function sending device |
| 11) remove switching shaft bolts |
|
12) remove a bolt of the lock and get the lock
|
| 13) remove together the leading shaft, the leading gear wheel, a switching shaft, rods of switching and a fork of switching |
14) assembly is carried out upside-down to dismantling, at the same time pay attention to the following:
– the leading shaft, the leading gear wheel, a switching shaft, rods of switching and a fork of switching are established together;
– lock rings for the ball-bearing on the leader to a shaft have to be established on the old place and to be the same thickness |
|
Prevention
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.
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 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 measurements of the valid size of a deviation).
Mechanism of the leading shaft
|
1. Leading shaft
2. Rod of switching Z-ey/of transfers by the 4th and fork of switching
the rod of switching or fork of switching can be replaced separately
3. Switching shaft
4. 40 N. of m.
5. Washer
6. Washer
7. Lock
8. 25 N. of m.
the inside of a head is turned to a safety mekhnizm of the spring / lock
9. 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
10. The leading gear wheel with a hollow shaft
|
11. Transmission case
12. 25 N. of m.
the screw with a head under a face key for fastening of a rod of switching of transfer of a backing
13. A rod of switching of the 1st, 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 of switching of the 5th transfer / transfer of a backing only together with a ring of switching and a rod of switching
14. 40 N. of m.
15. Gear wheel of transfer of a backing
16. Needle bearing of transfer of a backing
17. Persistent washer
18. Lock ring |
It is also possible to uncover together with differential.
Differential and mechanism of the main transfer
|
1. Transmission case
2. Plug
3. Press spring
4. Lock ring
5. The ball-bearing with a drive flange flute
6. Differential case
pressurize by means of AMV188 200 03 sealant
7. Lock ring
8. Cap
9. The closing ring
always replace
grease before installation
10. Sealing ring of a flange of the drive
remove by means of the VW 681 tool
11. Counterbalance
12. Cutting lock ring
|
13. Drive flange
installation is made through an opening in a cover
removal: remove a cap
14. 35 N. of m.
38 mm long
15. 25 N. of m.
42 mm long
16. Lock ring
part the ends in the parties for removal of a ring
establish together with a drive flange
17. Lock ring
18. The ball-bearing with a flute
19. Needle bearing
20. Differential
do not sort
always replace if it is damaged
remove after removal of a flange of the drive |
The mechanical transmission – a case, gear wheels, shaft / Leader a shaft – KPP 01A
|
1. Ring of the synchronizer of the 3rd transfer
2. Gear wheel of the 3rd transfer
3. Needle bearing of the 3rd transfer
4. Leading shaft
5. Needle bearing of the leading shaft
establish by means of the tool 3096/1
6. Case of the main transfer
7. Lock ring
if you are going to use the old ball-bearing and a shaft, it is necessary to measure thickness of an old lock ring and to replace it new the same thickness
8. Lock ring
9. Ball-bearing of the leading shaft
10. Transmission case
11. Plastic plug
12. Needle bearing of the leading shaft
establish by means of the VW 295 and VW 295A tool on depth in 214 mm, measuring from a case surface
|
13. Lock ring
specify the required thickness when replacing a gear wheel of the 5th transfer
14. Gear wheel of the 5th transfer
15. Needle bearing of the 4th transfer
16. Gear wheel of the 4th transfer
17. Ring of the synchronizer of the 4th transfer
18. The sliding coupling 3-ey/of the 4th of transfers
19. Lock ring
specify the required thickness when replacing a nave of the synchronizer
20. Nave of the Z-ey/synchronizer of the 4th of transfers
the acting rim is turned to a gear wheel of the 3rd transfer
21. Lock ring
if you are going to use the old ball-bearing and a shaft, it is necessary to measure thickness of an old lock ring and to replace it new the same thickness |
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.
Rings of synchronizers and nave of the synchronizer, replacement
Since 26.01.87 of a ring of synchronizers began to be issued with a new external diameter and the flute on a nave of the synchronizer was reduced by 0.6 mm. Do not establish together a nave of the sliding couplings and a ring of synchronizers of the different sizes.
Prevention
When replacing conic roller bearings define the provision of their installation before removal of the leading gear wheel and hollow shaft.
Do not damage edge of an epiploon between conic roller bearings.
The leading gear wheel and hollow shaft – KPP 01A
|
1. Case of the main transfer
2. S3 washer
3. A two-row 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. Needle bearing of a hollow shaft
at installation grease with MoS2 lubricant
6. Needle bearing of a hollow shaft
at installation grease with MoS2 lubricant
7. A two-row conic roller bearing – an internal holder
after measurement of washers of S3 and S4 grease the small bearing with MoS2 lubricant
8. Lock ring
|
9. Hollow shaft
when replacing a hollow shaft determine the necessary thickness of a washer of S3
when replacing a case of the main transfer determine the necessary thickness of a washer of S4
the external holder of the small bearing is established on hollow to a shaft
10. Small needle bearing of the 1st transfer
11. Big needle bearing of the 1st transfer
12. Gear wheel of the 1st transfer
remove together with a synchronizer nave
13. Ring of the synchronizer of the 1st transfer
14. Nave of the synchronizer 1-oy/of the 2nd transfer
the acting edge is turned to the 2nd transfer
15. Lock ring
16. Needle bearing of the 2nd transfer
17. The sliding coupling 1-oy/of the 2nd transfer |
The leading gear wheel and hollow shaft – KPP 01A
|
1. Ring of the synchronizer of the 2nd transfer
2. Gear wheel of the 2nd transfer
establish a spring before installation of a gear wheel
3. Lock ring
4. Gear wheel 3-oh transfers
the flute is turned to a gear wheel of the 4th transfer
5. Lock ring
6. Gear wheel of the 4th transfer
the flute is turned to a gear wheel 3-oh of transfer
7. Lock ring
8. Needle bearing of the 5th transfer
9. Gear wheel of the 5th transfer
10. Ring of the synchronizer of the 5th transfer
11. Lock ring
12. Nave of the synchronizer of the 5th transfer / transfer of a backing
the acting edge is turned to a gear wheel of the 5th transfer
establish by means of the plug 2010
|
13. Lock ring
14. Needle bearing of transfer of a backing
15. The sliding coupling of the 5th transfer / transfer of a backing
16. Ring of the synchronizer of transfer of a backing
17. Gear wheel of transfer of a backing
18. Lock ring
establish a lock ring before installation of an internal holder of a conic roller bearing
19. A conic roller bearing – an internal holder
20. A conic roller bearing – an external holder
establish by means of 3062
21. S3 washer
22. Clamping plate
23. Washer
compensates expansion depending on heating temperature
24. Transmission case |
|
|