Audi 80/90/Coupe

since 1986-1991 of release

Repair and car operation


Audi 80/90/Coupe
+ 1.2. Car identification
+ 2. Engines, carburetors
3. Greasing system
+ 4. Cooling system
+ 5. Fuel system
+ 6. Exhaust system
+ 7. Ignition system
- 8. Transmission
   8.1.2. A fork - the main cylinder of coupling
   8.1.3. Press coupling disk
   8.1.4. Malfunctions of coupling
   + 8.2. Mechanical transmission 012
   - 8.3. Mechanical transmission 01А
      8.3.2. Removal and transmission installation
      8.3.3. Dismantling and transmission assembly
      + 8.3.4. Differential
      8.3.5. Driveshaft
      8.3.6. Central kardanny 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. Central air
+ 14. Electric equipment







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8.3.3. Dismantling and transmission assembly
GENERAL INFORMATION

Transmission assembled
1. Leading shaft
2. Ball-bearing
3. Coupling case
4. Differential
5. Dvukhryadny 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
ullotnitelny ring of a flange of a leading shaft – remove by means of the VW 681 tool, establish (on 5 mm lower than a surface of a case of the main transfer) by means of the VW195 tool
measure depth of installation сапуна
plug of a rod of switching: establish by means of the tool 30-205
pressurize by means of hermetic AMV188 200 03
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 smaller diameter is turned to directing plug (the concave party)
6. Ball-bearing of a leading shaft
7. 10 N of m.
8. Speedometer sending device
9. Differential
it is possible to remove, without removing a transmission case
10. Sealing ring
11. Flange of the left semi-axis
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 hermetic
15. Lever of gear shifting and shaft casing
16. Lock of the 5th transfer and backing transfer
it is possible to replace without removing a transmission
the slanted party of the plastic plug should be turned to a switching shaft
17. Lock ring
always replace
18. Flange of the right semi-axis
establish give to drink the help of VW 295
19. 25 N of m.
20. Clamping plate
for the multipurpose sending device
21. Multipurpose sending device
22. I will corrode connections of the multipurpose sending device
Dismantling / assembly
PERFORMANCE ORDER
1) establish a transmission at the repair stand
2) merge transmission oil
3) remove the lever of switching off of coupling and vyzhimny 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 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 a transmission and remove a transmission case
10) remove the multipurpose sending device
11) remove bolts of a shaft of switching

12) remove a bolt of the lock and get the lock
13) remove together a leading shaft, a leading gear wheel, a switching shaft, rods of switching and a switching fork
14) assembly is carried out 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 fork of switching are established together;
      – lock rings for the ball-bearing on the leader should be established to a shaft on an old place and to be the same thickness
Prevention

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

Address with the speedometer sending device very accurately. Do not drop it, differently indications of a speedometer can be not exact.

If it is necessary for you to replace a case of the main transfer or a conic roller bearing of a leading gear wheel or a hollow shaft and a deviation of r it is not designated on a conic cogwheel, it is necessary to define the provision of installation of a leading gear wheel before removal of a case of a transmission (it is necessary to carry out measurements of the valid size of a deviation).

Mechanism of a leading shaft
1. Leading shaft
2. Rod of switching Z-ey/of the 4th transfers and switching fork
it is possible to replace a rod of switching or a fork of switching 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. A leading gear wheel with 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 backing transfer with a switching fork
for dismantling / assembly remove / establish spring pins
1-ой/the 2nd transfers can replace switching forks separately
replace a fork of switching of the 5th transfer / transfer of a backing only together with a ring of switching and a switching rod
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

The cover can be removed 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 flute of a flange of a drive
6. Differential case
pressurize by means of hermetic AMV188 200 03
7. Lock ring
8. Cap
9. A closing ring
always replace
grease before installation
10. Sealing ring of a flange of a 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 in length
15. 25 N of m.
42 mm in length
16. Lock ring
dissolve the ends in the parties for ring removal
establish together with a drive flange
17. Lock ring
18. The ball-bearing with a flute
19. Needle bearing
20. Differential
do not assort
always replace, if it is damaged
remove after removal of a flange of a drive

Mechanical transmission – a case, gear wheels, in bulk / Leader a shaft – a check point 01А

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 a 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 a leading shaft
10. Transmission case
11. Plastic plug
12. Needle bearing of a 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 demanded thickness at replacement of 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-ей/of the 4th transfers
19. Lock ring
specify the demanded thickness at replacement of a nave of the synchronizer
20. Nave of synchronizer Z-ey/of the 4th 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 it is necessary to measure them at removal. At gear wheel or shaft replacement it is necessary to measure the corresponding lock rings for installation of a ring of the demanded thickness and diameter.

Rings of synchronizers and synchronizer nave, replacement

Since 26.01.87 rings of synchronizers started to be issued with 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 sliding couplings and a ring of synchronizers of the different sizes.

Prevention

At replacement of conic roller bearings define the provision 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. Case of the main transfer
2. S3 washer
3. The Dvukhryadny conic roller bearing – an external holder
4. Leading gear wheel
corresponds to a gear wreath (pair gear the wreath / leader a gear wheel)
at pair replacement gear the wreath / leader a gear wheel adjust installation of a leading gear wheel, and also a hollow shaft and a gear wreath
5. Needle bearing of a hollow shaft
at installation grease with Mos2 greasing
6. Needle bearing of a hollow shaft
at installation grease with Mos2 greasing
7. The Dvukhryadny conic roller bearing – an internal holder
after measurement of washers of S3 and S4 grease the small bearing with Mos2 greasing
8. Lock ring
 9. Hollow shaft
at replacement of a hollow shaft define necessary thickness of a washer of S3
at replacement of a case of the main transfer define 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-ой/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-ой/of the 2nd transfer

Leading gear wheel and hollow shaft – a check point 01А

1. Ring of the synchronizer of the 2nd transfer
2. Gear wheel of the 2nd transfer
establish a spring before gear wheel installation
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 transfers
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