8.3.3. Dismantling and assembly of the transmission
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
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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 |
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Prevention
Mechanism of the leading shaft
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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
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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
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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
The leading gear wheel and hollow shaft – KPP 01A
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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
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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 |