Gear change box-type 02A

In cars Golf III / Vento also establishes five-speed gearbox of the "02A".

The main parts of a transmission of type 02A include housing 1 (Fig. 5.59), the clutch housing 9 transaxle rear cover 6, the input shaft 1 (Fig. 5.60), the output shaft 2 with gears and synchronizers, the shaft 9 with an intermediate gear wheel course and mechanism (Fig. 5.61), a choice of transfers.

Transmission ratio-type 02A, with the ABF motor model (110 kW) are presented in Table. 5.9.

Fuel capacity of the gearbox housing, while changing oil, 2.0 l

Oil used: gear, hypoid SAE 80 or SAE 75W90 Standards API - GL4.

Oil change intervals - every 30 000 km of run of the car.

transmission to the engine 80 / 8.0

bolts transaxle case

Transmission to the clutch housing 25 / 2.5

then tighten another 90 ?�

bolts back cover

to the gearbox housing 14 / 1.4

bolts of the working cylinder

Clutch 25 / 2.5

Filler plug 30 / 3.0

drain plug 25 / 2.5

Adjusting data

The clearance between the synchronizer ring and gear, mm:

gears for 1st transfer and synchronization

trainer of 3rd and 4th gear from 1.0 to 1.7

for gear 2nd gear from 1.2 to 1.8

for gear 5th gear from 1.1 to 1.7

To limit used 0.5

Transmission Type 02A is fixed on the left side of the engine. Transmission, final drive and differential housed in a common housing (Fig. 5.62). Gears transmission and final drive are lubricated by immersion in a common oil bath.

Fifth gear is placed at the side of the gearbox cover.

Marking 1 (arrow, Fig. 5.63) is knocked out on the gearbox housing, and in the place indicated by the arrow 2 (see. Fig. 5.63) and (arrow, Fig. 5.64) is applied to the type designation of transmission.

To repair the gearbox Special tools and instruments. If you do not have to, do not perform any operation for removal and disassembly, as no special tools will be impossible to properly assemble and install the gearbox in place.

Removing the gearbox type 02A

Removing the gearbox can be performed without removing the engine, the car down. Removing the transmission is necessary for the repair or replacement of the clutch or gearbox.

Transmission is removed from the bottom of the car, so the car must be raised to the appropriate height. Regardless of the method of raising the vehicle is required to substitute under the vehicle frame goats. In addition, the required vehicle jack in order to prop gearbox.

Removing the gearbox in the following order:

- Install and secure the car on the overpass, ramp, lift or pit, or expose the car on the driver's seat, if the work is carried out on the court with a firm, level surface. It should have sufficient space for access to the car from all sides. Apply the parking brake;

- Turn off the engine and remove the ignition key;

- Disconnect the "-" battery terminal;

- Disconnect all electrical transmission wires;

- A diesel engine with turbo charging, disconnect the air nozzles turbochargers;

- Disconnect the gearbox rod gear selection mechanism and remove bracket linkage;

- For vehicles with hydraulic clutch disconnect the select lever and remove it without disconnecting the rod of choice. Remove the bolts and remove clutch slave cylinder. Attach the wire to his body. Hydraulic connections are disconnects;

- In cars with a mechanical drive clutch disconnect draft from the corner of the lever and bracket on the gearbox;

- Disconnect the gearbox flexible shaft drive of a speedometer;

- Remove the bolts of the flange of the left drive shaft and tie up its wire to the body;

- Disconnect the upper crankcase bolts transmission to the engine;

- Remove the three screws 1 (Fig. 5.65) fastenings of an arm of the right support of the power unit to the cushion 2;

- Remove the bolt 1 (fig. 5.66) bracket of the left support of the power unit to the cushion 2. If the car is equipped with power steering system and ABS, access to the bolt 1 is strongly complicated. If necessary, carefully move in the direction of the hydraulic lines for power steering, remove the coolant expansion tank engine, unclip the hose and unscrew the bolt 1 key with extension and universal joint;

- Unscrew nut 2 (Fig. 5.67), the front axle of the power unit;

- Set the engine compartment of the device 10-222A and 10-222A / 1 (Fig. 5.68) and hang it on the engine. In the context of the workshop the engine can be hung on the beam. Some types of engines as they may hurt for suspending the fan housing. In this case, you must remove the radiator;

- Disconnect the electrical wires and remove the starter;

- Remove the front engine mount bracket;

- Power-steering body lean on the pillow front engine mount and attach it;

- Unscrew the anti-vibration load on the beam located under the engine;

- Remove thermofilter internal hinge right drive shaft, if installed;

- Remove the bolts of the flange of the right drive shaft and tie up its wire to the body;

- Slide to the right as much as possible the power unit and lift it slightly;

- Loosen the gearbox support 1 (fig. 5.69), and Bracket 2. Remove the lower bolt 3, which slide to the front of the engine compartment power unit;

- Disconnect the clutch from the engine;

- Substitute for gearbox VAG 1383 special elevator or at least a car jack;

- Remove the lower crankcase bolts transmission to the engine;

- Using the mount wring transmission from the engine, and then remove it. This operation is carried out, together with an assistant;

- Carefully lower the gearbox on the ground.

Installation of transmission of type 02A

Installation of transmission is made in the reverse order of removal, but you must do the following:

- Before installing gearbox, check the technical condition of the clutch;

- Ensure in good clutch release bearing, lubricate it with grease;

- Clean and lubricate the thin slots and neck primary shaft gearbox anti-friction lubricant MoS2 or G 000 100 of the company VW. Keep the excess grease contaminate the friction linings slave drive, and without affecting the clutch. Note that the slave drive to move easily on the input shaft;

- Push the clutch fork in the direction of transmission, and then Lock the mounting rod (Fig. 5.70) or bolt M8?�22. After setting the transmission pin (or bolt) to be removed, and the hole closing plug;

- Check that the dowel pins are installed in the engine block and not to the transmission housing. Otherwise, remove them from the gearbox and place it in the cylinder block;

- Check the position of the intermediate plate of the motor. Intermediate plate should definitely get on the dowel pins of the engine;

- Neatly rewound the input shaft in the clutch;

- All the support of the power unit set without tightening;

- In cars with a mechanical drive of coupling should be at least three times to press the clutch pedal, and move the clutch fork 10 mm in the opposite direction during pabochih progress and check for smooth moves fork;

- Adjust the position of the selector shaft;

- Bolts of a transmission to the engine to tighten the moment 80 Nm;

- Tighten the bolts of support of the engine torque (depending on the design);

- Refit all removed components;

- Check the oil level in the gearbox. The oil must be filled up to the lower edge of the filler hole;

- If necessary, adjust the gearshift;

- Take a test drive on the car with all the options of switching transmission.

Dismantling and transmission assemblage type 02A

Disassembly and assembly of transmission is most easily done on a special stand. If there is such a stand, set the gearbox on a clean work bench with vise. Transmission dismantling should be done with special devices and tools, and the work must be carried out accurately and consistently.

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During disassembly of the gearbox carefully record how every detail has been installed to facilitate the subsequent assembly and perform it more accurately.

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- Remove the bolts fastening the gearbox to the clutch housing and using a plastic hammer, disconnect the gearbox housing. If the gearbox housing is not possible to separate the clutch housing, you can use a removable device VW3042 (see. Fig. 5.28);

- Disconnect the body of the switching mechanism, set the selector shaft to neutral position and remove it together with the body of the mechanism;

- Remove the plug or through the transmission housing, or via the clutch;

- Remove the magnet that is fixed rib transmission housing;

- Remove the clutch driven gear 3 (see. Fig. 5.72) the speedometer;

- Remove the release fork and the release bearing;

- Remove the bolts 30, remove the guide 29 with the gland. Replace the oil seal on the new one. Bybeyte gland secondary shaft of a transmission;

- Remove the bolt 2;

- Using the key-head bolts type of Togh unscrew the bolt 17 and bolts 19 fastening shaft reverse gear.

The assembly partially disassembled gearbox type 02A spend in reverse order. At the same time, follow these guidelines:

- In case of replacement of the support 27 (see. Fig. 5.72), remove old starter shaft bearing using the puller and install with the help of a new mandrel. This operation can also be performed when the transmission is installed in the vehicle;

- In support of the shaft reverse gear screw pin 1 (Fig. 5.78);

- Set forks stocks in line and check whether the foot slip plugs in the grooves of the coupling;

- To interface the gearbox and clutch housing, apply a thin layer of silicone sealant;

- Connect the gearbox housing and clutch, tighten the bolts evenly to 25 Nm;

- Through a hole selector shaft, check whether there are stocks of plugs on the same line;

- The holes (Fig. 5.79, arrow), insert the outside ear plugs. Bolts 8 (see. Fig. 5.72) mounting inserts 11 tighten the moment 25 Nm;

- Screw the bolt 1 (fig. 5.80), and using the pre-installed studs 1 (see. Fig. 5.78), set the support shaft reverse gear. After that, remove the pin and screw the bolt 2 (see. Fig. 5.80). Both the bolt with a wrench type Togh tighten the moment 30 Nm;

- Set the selector shaft. Housing Bolts stem tighten the moment 20 Nm;

- Press-fit the shaft with a gear wheel of 5th transfer;

- Replace the secondary shaft gear 5th gear with needle bearing, synchronizer ring and clutch. The chamfer on the teeth of the coupling should be deployed to gear 5th gear and synchronizer ring grooves on the teeth and the coupling must be aligned (Fig. 5.81, indicated by arrows);

- Insert ear plugs and tighten to 25 N ?� m;

- Fit the hub flange, turn 5th gear and reverse gear and tighten the fixing bolts (see. Fig. 5.73) to 40 N ?� m;

- Include 5th transfer and loosen the screw 1 (Fig. 5.82). Between the clutch and the gear 5th gear in areas "A" and "B", insert two probes 1.2 mm thick. Plugs 5th gear using a screwdriver to push the gear 5th gear and forks, pull the stem in the direction of the arrow. In this position, tighten the bolt 1 to 25 Nm. Synchronizer clutch should now be in the neutral position, this means that the 5th gear must be turned off. Check that the spring locking ring is easily moved;

- Switch on the transmission queue and check the correctness of inclusion of transfers;

- In the guide sleeve 29 (see. Fig. 5.72), install the new oil seal;

- Lubricate the sliding surface of the guide sleeve of graphite or molybdenum-containing lubricant grease, install the guide sleeve with the new O-ring 28 and tighten new bolts 30;

- Set release bearing and release fork. Put the return spring;

- In the gearbox housing set, using mandrel VW2035 (Fig. 5.83), new seals output shafts;

- Insert the output shafts of the differential until it clicks snap rings.

Disassembly of clutch gearbox type 02A.

Components and parts installed in the clutch housing is shown in Fig. 5.84.

When disassembling the clutch, follow these guidelines:

- Remove the differential;

- In the clutch housing, remove the three nuts of the primary shaft and the four nuts (Fig. 5.85, indicated by arrows) fastenings of a secondary shaft and remove the input shaft assembly with the secondary shaft and the shaft of the reverse gear;

- Remove the bracket shaft reverse gear;

- Remove the shaft reverse gear;

- Seals must always be replaced with new ones.