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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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
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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
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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
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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 |
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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
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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
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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
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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
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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
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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 |
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