Replacing the secondary shaft

Dismantling of a secondary shaft-type five-speed transmission 02A spend in the following order:

- With the help of rods respective diameters of Xpress clutch outer ring 2 (Fig. 5.86) tapered roller bearing from the outside to the inside;

- Remove from the output shaft 4 of the bearing inner ring 3;

- Remove gear 4th gear with the inner race of tapered roller bearing 8 and 13 of the needle bearing cage;

- Remove gear 3rd gear;

- From the gearbox Xpress conical outer ring 10 of the bearing;

- Remove gear 5th gear and other parts, as described in the partial disassembling the gearbox;

- Remove from the hub 18 of the synchronizer clutch 19, and remove the snap ring 17 and the locking ring 16.

Check the details of the secondary shaft assembly is preceded by a secondary shaft. After dismantling all parts of the secondary shaft rinse thoroughly, dry them, blowing with compressed air, and inspect and make a measuring critical mating surfaces.

In the teeth of the gear should not be chips and nicks, involute tooth surface must be flat, without deep dents. On the lateral surfaces of the teeth, and the ends of the gears should be scuffing. Landing gear surfaces must not be damaged or wear violating alignment details.

Spot the contact between the teeth of the gears in mesh should be extended to the entire working surface of the teeth.

Check for wear and damage in all gears and synchronizers. Gears transmit replace only one of the pair.

Check the condition of seat belts secondary shaft on which the bearings are located. They should not damage or wear.

Slots and grooves shafts also must not have nicks, burrs and wear to provide backlash-free fit coupling hub synchronizers. If there are defects that hinder the assembly of parts without damage, replace the secondary shaft new.

Replace all seal retainer rings. Use new bolts, nuts and washers, if their appearance is not satisfactory.

Check the details of the secondary shaft spend in the following order:

- Fix a secondary shaft in the lathe holders and check the indicator runout of the shaft;

- Place the synchronizer ring 5th gear at the gear 5th gear and press it. With the probe to measure the gap "a" (Fig. 5.87). Its nominal size of 1.1-1.7 mm. The maximum wear of the locking ring is allowed gap size "a" of 0.5 mm;

Output shaft assembly sequence is as follows:

- Replace the secondary shaft gear 3rd gear. Flange gear must be oriented in the direction of gear 4th gear;

- Install the shaft retaining ring;

- Replace the shaft gear 4th gear. Flange gear must be oriented in the direction of gear 3rd gear;

- With a piece of pipe with an outer diameter equal to the inner ring, set the internal conical bearing cage. Do not install using the outer ring of the bearing;

- Set the outer race 2 and 10 (see. Fig. 5.86) bearings;

- The outer ring of the bearing 10 of the conical first set without shim 11;

- Insert the secondary shaft in the clutch housing 1 and slide the top 12 gearbox housing. Bolts tightening crankcase, tighten the moment 25 Nm;

- To measure the axial clearance of the secondary shaft Fit VW353 (Fig. 5.88). Turn a few times a secondary shaft, to set the bearing race, and then expose the initial reading on the dial gauge to 1 mm;

- Shake the secondary shaft in the direction of the arrow (see. Fig. 5.88) and remove the instrument readings. According to the obtained values of the pick shim of this thickness to play a secondary shaft was 0,01-0,09 mm. There are 45 shims of different thicknesses;

- Again, remove the secondary shaft, remove the tapered roller bearing outer race, set a clip matched shim and install the bearing race;

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

- Reinstall special device VW353 and once again measure the axial play. Now its value should be 0.01-0.12 mm.

Replacing the primary shaft of a transmission type 02A. Note that some details had been removed during the partial disassembly of the gearbox.

Dismantling of a primary shaft in the following order:

- Remove the thrust washer 31 (Fig. 5.89), a gear wheel of 4th transfer 30, the needle bearing 28 and the locking ring 29 of the synchronizer of 3rd and 4th transfers;

- Remove the 26 synchronizer of 3rd and 4th transfers with the inner race of the needle bearing 27. To do this, the input shaft in a vise (Fig. 5.90) and squeeze the shaft from a nave of the synchronizer;

- Remove the locking ring 25 (see. Fig. 5.89) and the synchronizer gear 3rd gear 24;

- Remove the needle bearing 23, thrust washer 21 and the needle bearing 20 together with the gear 2nd gear 19;

- Remove the inner 18 and the outer ring of the synchronizer 17 2nd gear and remove the retaining ring 15;

- Remove the synchronizer of 3rd and 4th transfers with the inner race of the needle bearing 22 (Fig. 5.91);

- Remove the locking ring 13 (see. Fig. 5.89) synchronizer, the needle bearing 12 and a gear wheel of 1st transfer 11;

- With the help of the mandrel and the outer race of a stripper remove 4 small tapered roller bearing from the clutch housing (Fig. 5.92);

- Remove from the socket housing 2 (see. Fig. 5.89) Clutch bearing shim 3. The thickness of the washers will need to pick up again, if the result of the replacement parts will change tightness of bearings;

- With the help of a stripper (see. Fig. 5.90) remove first with one end of a primary shaft of the inner ring 5 (see FIG.

Fig. 5.89) of small tapered roller bearing, and then the other end of the input shaft - the inner ring 7 large tapered roller bearing (Fig. 5.93);

- Outer cage large tapered roller bearing is fixed in the flange 9 large tapered roller bearing and replace it should always be together with the flange.

Check details of the input shaft is carried out after disassembling. All parts of the primary shaft rinse thoroughly, dry them, blowing with compressed air, and inspect and make a measuring critical mating surfaces.

In the teeth of the gear should not be chips and nicks, involute tooth surface must be flat, without deep dents. On the lateral surfaces of the teeth, and the ends of the gears should be scuffing. Landing gear surfaces must not be damaged or wear violating alignment details.

Spot the contact between the teeth of the gears in mesh should be extended to the entire working surface of the teeth.

Check for wear and damage in all gears and synchronizers. Gears transmit replace only one of the pair.

Check the condition of seat belts a primary shaft on which the bearings are located. They should not damage or wear.

Slots and grooves of the primary shaft, too, must not have nicks, burrs and wear to provide backlash-free fit coupling hub synchronizers. If there are defects that hinder the assembly of parts without damage, replace the shaft with a new one.

Replace all seal retainer rings. Use new bolts, nuts and washers, if their appearance is not satisfactory.

Check details of the input shaft is performed as follows:

- Locking ring 13, 16, 25 and 29, synchronizers, each at a time, check for wear. Enclose each synchronizer ring in a gear, push it to the gear and measure the gap with a feeler gauge "A" (Fig. 5.94);

- The nominal value of the gap "a" is 1.0 - 1.7 mm. Maximum allowable size of the gap "a" with a maximum wear of the locking ring is 0.5 mm;

- Put on the cone gear 2nd gear synchronizer ring outer part, push it to the gear and measure gap probe "a" (Fig. 5.97). The nominal value of the gap "a" is equal to 1.2-1.8 mm, and the maximum permissible - 0.5 mm;

- Put on the cone gear 2nd gear synchronizer ring interior, push it to the gear and measure gap "a" (Fig. 5.98). The nominal value of the gap "a" is 0.75-1.25 mm, the maximum allowable size of the gap "a" corresponding to the maximum wear of the locking ring is 0.3 mm.

Assembling input shaft is made in the reverse order, taking into account the following:

- If the initial value of a tightness of bearings of a primary shaft has not changed or been adjusted, place thrust washer 3 (see. Fig. 5.89) into the clutch housing and install outer race 4 small tapered roller bearing using the tool VW407 (Fig. 5.99) and VW512 or piece tube of suitable diameter;

- Using the tool VW409 (Fig. 5.100), VW519 and VW402 press them at one end of the primary shaft of the inner ring 5 (see. Fig. 5.89) small tapered roller bearing, and at the other end - the inner ring 7 large tapered roller bearing;

- Generously grease both bearings;

- Flange 9 large tapered roller bearing Fit the shaft with pins down;

- Fit the thrust washer 10. The flange washer must be deployed to the tapered roller bearing;

- The needle bearing 12 plentifully grease, put on the input shaft, and then set it on gear 1st gear 11;

- Wear on the gear blocking ring 13 of the synchronizer of 1st transfer;

- Assemble the synchronizer of 1st and 2nd gear (Fig. 5.101). Grooves crackers must be mounted opposite the slots in the collar. Place bread crumbs and put a spring ring. Bend the ends of the snap ring must be installed in the grooves of crackers and separated by 120 ?�;

- Set the assembly synchronizer (Fig. 5.102) on the primary shaft by means of devices (Fig. 5.103). Flange (arrow, see. Fig. 5.102) and cut the edges of the teeth should be turned to a gear wheel of 1st transfer;

- Wide flange has to be from the 1st gear transmission;

- Set the retaining ring 15 (see. Fig. 5.89);

- Connect the outer and inner part of the synchronizer ring 2nd gear and install it on gear 2nd gear;

- Set the input shaft 22, the inner ring of the needle bearing;

- Well lubricate the needle bearing 20, spread on the sleeve bearing, and then set him gear 2nd gear 19;

- Install thrust washer 21;

- The needle bearing 23 generously lubricate and install the input shaft;

- Push the 3rd gear transmission 24, and tapered gear set 25 of the synchronizer blocking ring;

- Assemble the synchronizer 26 3-4th gear and set using the tool (Fig. 5.104) on the primary shaft;

- Synchronizer assembly 3-4th transmissions must be installed on the shaft so that the chamfer (Fig. 5.105, arrows) splined hole in the hub of the synchronizer faces the 4th gear transmission;

- Replace the shaft locking ring 29 (see. Fig. 5.89) of the synchronizer;

- Set the inner ring on the shaft 27 of the needle bearing. Generously grease and put on the needle bearing inner race 28, and then gear 4th gear thrust washer 30 to 31;

- Set the needle bearing 32 in the transmission housing and zakernite it in three places;

- Insert the primary shaft and flange studs bearing in the clutch housing. Push pins on new sealing rings and on the other hand tightening nuts 30 Nm.

Replacing shaft reverse gear.

When replacing the shaft reverse gear the following guidelines:

- Angular contact ball bearing 2 (Fig. 5.106) and the needle bearing 8 should be replaced after each removal shaft reverse gear. Bearings or removed by a stripper, or under pressure, and adjusted with mandrels or lengths of pipe of appropriate diameter;

- To remove the reverse gear 5, remove the retaining ring 4. When the pinion flange 5 it must be by moving gears 3 reverse;

- Shaft reverse gear assembly is removed from the secondary and primary shaft gearbox.

Replacing the differential transmission of type 02A.

Details of the differential and final drive are shown in Fig. 5.107.

Differential Dismantling spend in the following order:

- Beat out the dowel pin 5 of the differential housing 13;

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- If you had removed the driven gear 14 (see. Fig. 5.107) final drive, then before installing the screw in the support flange differential housing on two opposite places rod (bolt), which will guide the ring gear during its installation;

- Heat the crown wheel to 100 ?� C and place on the differential housing 13 (Fig. 5.109);

- For fixing the ring gear, use new special bolts, nuts and lock washers (catalog number spare parts 171 498 088). After accurate setting of gear in the differential case, tighten the nuts to 70 Nm;

- Push the side gears 3 (see. Fig. 5.107) with a plastic separator 2 and on both sides, insert the output shafts 11;

- Insert the satellites 1 and rotate them through the output shafts so that the holes satellites established coaxially with the hole axis of satellites in the differential housing;

- Carefully hammer the axis of 4 satellites, so as not to damage the separator;

- Align the hole in the axis of satellites with the pin hole in the body and lock the differential pinion gear shaft by inserting a dowel pin 5. Pin deepens as long as it will not install flush with the outer surface of the differential case (Fig. 5.110).

Adjusting the transmission of type 02A

Adjusting input shaft gearbox type 02A. Adjust the tightness of bearings of the input shaft is needed in case the input shaft with the ring gear, clutch or tapered roller bearings were replaced.

Adjusting the input shaft is to determine the thickness of the shim located under foreign yoke front bearing shaft.

Determine the thickness of the shim a special device in the following sequence:

- Invest into the socket at the tapered bearing in the clutch housing 2 (see. Fig. 5.89) 3 shim thickness of 0.65 mm and a press-fit into the socket outer race 4 small tapered roller bearing;

- Insert the primary shaft 6, screw nuts 1 on the studs of the flange 9 large tapered roller bearing and tighten nuts to 30 Nm;

- Set the extender device (Fig. 5.111) on the clutch housing, and secure with universal dial gauge holder to the support mandrel. Feet indicator set on the supporting mandrel with preload of 1 mm, and in this position lock indicator and arrow, set it to zero;

- Move from the bottom up and down the shaft up to the stop and follow the indications of the indicator, which may be about 0.30 mm;

- According to the formula S = A + B + C count thickness shim small tapered roller bearing, wherein:

S - thickness of the shim, mm;

A - the axial displacement of the shaft (measured value), mm;

In - the value of preload mm;

S - thickness of shims (a constant value) mm.

Example of measurement is as follows.

Let the thickness of shims C = 0.65 mm, the measured axial clearance A = 0.30 mm, the amount of preload B = 0.20 mm. Consequently, the thickness of shim S = 0,65 + 0,30 + 0,20 = 1,15 mm;

- After determining the thickness of the shim and remove the input shaft using a mandrel and a stripper (see. Fig. 5.92), remove the outer race of the bearing from the clutch housing;

- Invest in the bearing housing shim thickness equal to the calculated value. Fit the outer ring of the bearing back into the slot and set the input shaft.

To adjust the tightness of the bearing of a primary shaft provided shims of different thickness (total of 45 sizes from 0,650 to 1,750 mm and a pitch of 0.05 mm), presented in the Table. 5.10.

Adjust the differential transmission of type 02A spend in the following order:

- Tapered roller bearing outer race, set the transmission housing without shim 8 (see. Fig. 5.107) and the siege of the differential case;

- Dock the gearbox housing and clutch housing and tighten the screws housings to 25 Nm;

- Set on a transmission measuring device (Fig. 5.112);

- Set the indicator reading 1 mm. Shake the differential case upside-down and remove the indicator;

- The desired initial preload bearing is determined by adding to the measured value a constant value of 0.40 mm.

The resulting addition value is equal to the thickness of the shim (pads).

Example:

measured value - 0.70 mm;

constant - 0.40 mm.

Therefore, shim thickness is 0.70 + 0.40 = 1.10 mm;

- Remove the clutch again. Knock out of the gearbox housing tapered roller bearing outer race. Put in the bearing seat shim thickness required. If the required size is obtained by adding the number of goals, the thickest of which must be laid first. There are washers 16 sizes (from 0.65 to 1.25 mm, in increments of 0.05 mm) that enables selection of a set of washers desired thickness;

- Press in the outer ring of the conical bearing set differential, bolted to the gearbox housing and clutch. If the measurements were performed exactly tightness of bearings must match required.

The selection mechanism Gearing type 02A

The gearbox type 02A conventional rods gear mounted on the type of PPC 085 and 020 are replaced by two rope pull. As a result, reduce the vibration transmitted to the gear lever in the interior of the vehicle. In addition, fluctuations in the power unit have practically no influence on the gearshift and the mechanism does not require maintenance.

All locations of the sliding surfaces treat molybdenum grease.

Disassembly and reassembly mechanism selection Gearing type 02A. Components and parts of the mechanism gear selection shown in Fig. 5.113 and 5.114.

Disassembly of the mechanism gear selection procedure is as follows:

- Remove the bolts 11 (see. Fig. 5.113) bracket 10 light switch reversing lamps;

- Unscrew nut 2 stock management;

- Remove the gear selection lever 15;

- Remove the bolt 20 fastening clamp;

- Pull rod 1 gear selection mechanism;

- To remove the guide bushing 3 break plastic cage and remove the plug.

The assembly mechanism gear selection procedure is as follows:

- Install the new guide sleeve 3;

- Install the O-ring 4;

- Enter stock 1 gear selection mechanism and replace the bolt clamp;

- Set the cover 8 so that the flats on the teeth of the spline fit to the arm off gear;

- Set the gear lever to select 15, and tighten the nut of its fastening torque 25 Nm;

- Set the switch bracket 10 light reversing light.

Replacement cables gear selection mechanism

Replace the cable drive mechanism gear selection can be performed, guided by the figure. 5.115.

When replacing the cables, follow these guidelines:

- 8 wire switching gear should always be installed before installing the cable 7 gear selection;

- 13 rod clamps are always replaced by new ones;

- Grommet 6 should push with the rod;

- Rubber covers 19 and 20 carefully puts on the ropes 7 and 8;

- Only loosen the nut 3 in order to adjust the stroke of cables;

- Fitting bolt 2 cover before installing the graphite lubricant;

- Always replace the nut 4 to the new;

- To remove the clutch slave cylinder, remove the gear change lever 1 without disconnecting with the cable from the lever;

- When assembling the two levers (selection and gear) gear selection mechanism set, as shown in Fig. 5.116;

- A bolt 14 (see. Fig. 5.115) with a flange used for fixing the cable 7 to the selector lever;

- Rubber bushings 11 and 12 have to be removed and installed with a special tool.

If for any reason, the cables are disconnected, after their connection, adjust their length. This requires the installation template. Without a template length of rope can be adjusted only by trial and error.

Adjusting the length of the rope to the template is performed as follows:

- Set the transmission in neutral, the parking brake, tighten;

- Disconnect the tip of the gear lever and remove the boot;

- Loosen the screw 1 (fig. 5.117) and nut 2 so that the cables can move freely in the longitudinal holes of the select lever;

- Inside the car, loosen the screw 1 (fig. 5.118) and the select lever set template 3192;

- Fastening hook pattern hook behind the plate and tighten the nut 2;

- Move the gear selection lever fully to the left (arrow) in this position lock plate bolt pattern 3;

- Now move the select lever to the right until it stops and tighten the bolt 1;

- Fully insert the wedge 3192/1 (Fig. 5.119) between the select lever and bracket light switch reversing lamps. When this lever is to be lifted up;

- In such a position fix both rope to pull the lever. Remove the wedge with the guide rod and the mounting template;

- Fasten the lever boot and install the tip of the lever;

- Turn on all the transmission queue and check the correct operation of the mechanism of a choice of transfers.

Table 5.11 Fault transmission, their causes and remedies