Audi 80/90/Coupe
+ 1.2. Car identification
+ 2. Engines, carburettors
3. Greasing system
+ 4. Cooling system
+ 5. Fuel system
+ 6. An exhaust system
+ 7. Ignition system
- 8. Transmission
8.1.2. A plug - the main cylinder of coupling
8.1.3. Press a coupling disk
8.1.4. Malfunctions of coupling
+ 8.2. A mechanical transmission 012
- 8.3. A mechanical transmission 01А
8.3.2. Removal and transmission installation
8.3.3. Dismantling and transmission assemblage
+ 8.3.4. Differential
8.3.5. A kardannyj shaft
8.3.6. Central карданный the hinge
+ 8.4. An automatic transmission 089
+ 8.5. An automatic transmission 087
8.6. Dismantling and assemblage of automatic transmissions
8.7. The block of valves
+ 8.8. An automatic transmission 097
+ 9. Suspension brackets, wheels
+ 10. Brake system
+ 11. A steering
+ 12. A body, salon
+ 13. A central air
+ 14. An electric equipment
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Transmission in gathering
1. A leading shaft
2. The ball-bearing
3. Carter of coupling
4. Differential
5. Двухрядный a conic roller bearing
6. A gear wheel of 1 th transfer
7. A gear wheel 2nd transfers
8. A gear wheel of 3 transfers
9. A gear wheel of 4th transfer
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10. A gear wheel of 5th transfer
11. A gear wheel of transfer of a backing
12. Carter of a transmission
13. A conic roller bearing
14. Carter of differential
15. A flange a drive
16. Differential
17. A hollow shaft
18. A leading gear wheel |
The mechanism of the main transfer
1. Carter of a transmission
уллотнительное a ring of a flange of a leading shaft – remove by means of tool VW 681, establish (on 5 mm below a surface картера the main transfer) by means of tool VW195
Measure depth of installation сапуна
The plug of a rod of switching: establish by means of the tool 30-205
герметизируйте by means of hermetic AMV188 200 03
2. A lock ring
Mark after removal
3. The directing plug with a sealing ring
4. 35 Н.м.
5. A concave washer
The party with smaller diameter is turned to directing plug (the concave party)
6. The ball-bearing of a leading shaft
7. 10 Н.м.
8. A speedometer sending device
9. Differential
It is possible to remove, without removing картер a transmission
10. A sealing ring
11. A flange of the left semiaxis
Establish by means of VW 295
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12. A lock ring
Always replace
13. 25 Н.м.
14. A cover of the main transfer
Remove уплртнительное a ring by means of tool VW 681
герметизируйте by means of hermetic AMV 188 200 03
15. The lever of a gear change and a shaft casing
16. The lock of 5th transfer and backing transfer
It is possible to replace without removing a transmission
The oblique party of the plastic plug should be turned to a switching shaft
17. A lock ring
Always replace
18. A flange of the right semiaxis
Establish give to drink help VW 295
19. 25 Н.м.
20. A clamping plate
For a multipurpose sending device
21. A multipurpose sending device
22. A socket of connection of a multipurpose sending device |
Dismantling / assemblage
PERFORMANCE ORDER |
1) establish a transmission at the repair stand |
2) merge трансмиссионное oil |
3) remove the lever of deenergizing of coupling and выжимной the coupling bearing |
4) remove directing plug |
5) remove the lock ring established in front of the ball-bearing and measure its thickness |
6) remove the ball-bearing with картера transmissions by means of a stripper |
7) remove the lock ring established behind the ball-bearing and measure its thickness |
8) remove bolts between karterom/a transmission cover (for differential) and uncover together with differential |
9) remove bolts between картером couplings and картером transmissions and remove картер transmissions |
10) remove a multipurpose sending device |
11) remove bolts of a shaft of switching |
12) remove a bolt of the lock and get the lock
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13) remove together the leading shaft, a leading gear wheel, a switching shaft, rods of switching and a switching plug |
14) assemblage is spent upside-down to dismantling, thus pay attention to the following:
– The leading shaft, a leading gear wheel, a switching shaft, rods of switching and a switching plug are established together;
– Lock rings for the ball-bearing on the leader to a shaft should be established on an old place and to be the same thickness |
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The prevention Before installation картера transmissions, check up, that directing plugs have been established in картере transmissions.
Address with a speedometer sending device very accurately. Do not drop it, differently speedometer indications can be not exact.
If it is necessary for you to replace картер the main transfer or a conic roller bearing of a leading gear wheel or a hollow shaft and a deviation r it is not designated on a conic cogwheel, position of installation of a leading gear wheel should be defined before removal картера transmissions (it is necessary to spend measurements of the valid size of a deviation).
The mechanism of a leading shaft
1. A leading shaft
2. A rod of switching Z-ej/of 4th transfers and a switching plug
It is possible to replace a rod of switching or a switching plug separately
3. A switching shaft
4. 40 Н.м.
5. A washer
6. A washer
7. The lock
8. 25 Н.м.
The head inside is turned to safety мехнизму lock springs /
9. Internal draught of switching
Remove a sealing ring of internal draught of switching by means of tool VW 681 and establish заподлицо by means of tool VW 460/2
10. A leading gear wheel with hollow shaft
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11. Carter of a transmission
12. 25 Н.м.
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 1st, 2nd, 5th transfers and transfer of a backing with a switching plug
For assemblage dismantling / remove / establish spring pins
1-oj/2nd transfers it is possible to replace switching plugs separately
Replace a plug of switching of 5th transfer / of transfer of a backing only together with a ring of switching and a switching rod
14. 40 Н.м.
15. A gear wheel of transfer of a backing
16. The needle bearing of transfer of a backing
17. A persistent washer
18. A lock ring |
The cover also can be removed together with differential.
Differential and the mechanism of the main transfer
1. Carter of a transmission
2. The plug
3. A press spring
4. A lock ring
5. The ball-bearing with a flute of a flange of a drive
6. Carter of differential
герметизируйте by means of hermetic AMV188 200 03
7. A lock ring
8. A cap
9. A closing ring
Always replace
Grease before installation
10. A sealing ring of a flange of a drive
Remove by means of tool VW 681
11. A counterbalance
12. A cutting lock ring
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13. A drive flange
Installation is made through an aperture in a cover
Removal: remove a cap
14. 35 Н.м.
38 mm in length
15. 25 Н.м.
42 mm in length
16. A lock ring
Dissolve the ends in the parties for ring removal
Establish together with a drive flange
17. A lock ring
18. The ball-bearing with a flute
19. The needle bearing
20. Differential
Do not assort
Always replace, if it is damaged
Remove after removal of a flange of a drive |
Mechanical transmission – картер, gear wheels, shaft / the Leading shaft – a check point 01А
1. A ring of the synchronizer of 3 transfers
2. A gear wheel of 3 transfers
3. The needle bearing of 3 transfers
4. A leading shaft
5. The needle bearing of a leading shaft
Establish by means of the tool 3096/1
6. Carter of the main transfer
7. A lock ring
If you are going to use the old ball-bearing and a shaft, it is necessary to measure a thickness of an old lock ring and to replace its new the same thickness
8. A lock ring
9. The ball-bearing of a leading shaft
10. Carter of a transmission
11. The plastic plug
12. The needle bearing of a leading shaft
Establish by means of tool VW 295 and VW 295A on depth in 214 mm, measuring from a surface картера
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13. A lock ring
Specify a demanded thickness at replacement of a gear wheel of 5th transfer
14. A gear wheel of 5th transfer
15. The needle bearing of 4th transfer
16. A gear wheel of 4th transfer
17. A ring of the synchronizer of 4th transfer
18. Sliding муфта 3-ej/4th transfers
19. A lock ring
Specify a demanded thickness at replacement of a nave of the synchronizer
20. A nave of synchronizer Z-ej/of 4th transfers
Acting ободок it is turned to a gear wheel of 3 transfers
21. A lock ring
If you are going to use the old ball-bearing and a shaft, it is necessary to measure a thickness of an old lock ring and to replace its new the same thickness |
Lock rings differ on a thickness and diameter and it is necessary to measure them at removal. At gear wheel or shaft replacement it is necessary to measure corresponding lock rings for installation of a ring of a demanded thickness and diameter.
Rings of synchronizers and a synchronizer nave, replacement
Since 26.01.87 rings of synchronizers have started to be issued with new external diameter and the flute on a synchronizer nave has been reduced by 0.6 mm. Do not establish together a nave sliding муфт and rings of synchronizers of the different sizes.
The prevention At replacement of conic roller bearings define position of their installation before removal of a leading gear wheel and a hollow shaft.
Do not damage epiploon edge between conic roller bearings.
Leading gear wheel and hollow shaft – a check point 01А
1. Carter of the main transfer
2. Washer S3
3. Двухрядный a conic roller bearing – an external holder
4. A leading gear wheel
Corresponds to a gear wreath (pair a gear wreath / a leading gear wheel)
At pair replacement a gear wreath / a leading gear wheel adjust installation of a leading gear wheel, and also a hollow shaft and a gear wreath
5. The needle bearing of a hollow shaft
At installation grease with greasing MoS2
6. The needle bearing of a hollow shaft
At installation grease with greasing MoS2
7. Двухрядный a conic roller bearing – an internal holder
After measurement of washers S3 and S4 grease the small bearing with greasing MoS2
8. A lock ring
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9. A hollow shaft
At replacement of a hollow shaft define a necessary thickness of washer S3
At replacement картера the main transfer define a necessary thickness of washer S4
The external holder of the small bearing is established on hollow to a shaft
10. The small needle bearing of 1st transfer
11. The big needle bearing of 1st transfer
12. A gear wheel of 1st transfer
Remove together with a synchronizer nave
13. A ring of the synchronizer of 1st transfer
14. A synchronizer nave 1-oj/2nd transfers
The acting edge is turned to 2nd transfer
15. A lock ring
16. The needle bearing 2nd transfers
17. Sliding муфта 1-oj/2nd transfers |
Leading gear wheel and hollow shaft – a check point 01А
1. A synchronizer ring 2nd transfers
2. A gear wheel 2nd transfers
Establish a spring before gear wheel installation
3. A lock ring
4. A gear wheel of 3rd transfer
The flute is turned to a gear wheel of 4th transfer
5. A lock ring
6. A gear wheel of 4th transfer
The flute is turned to a gear wheel of 3rd transfer
7. A lock ring
8. The needle bearing of 5th transfer
9. A gear wheel of 5th transfer
10. A ring of the synchronizer of 5th transfer
11. A lock ring
12. A nave of the synchronizer of 5th transfer / of transfer of a backing
The acting edge is turned to a gear wheel of 5th transfer
Establish by means of the plug 2010
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13. A lock ring
14. The needle bearing of transfer of a backing
15. Sliding муфта 5th transfer / of transfer of a backing
16. A ring of the synchronizer of transfer of a backing
17. A gear wheel of transfer of a backing
18. A 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. Washer S3
22. A clamping plate
23. A washer
Compensates expansion depending on heating temperature
24. Carter of a transmission |
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