Audi 100/A6
+ 1. Maintenance instruction
+ 2. Maintenance
+ 3. Engines
+ 3.2. Diesel engines
+ 3.3. Removal and partition of engines
+ 4. Cooling system
+ 5. Heating and ventilation
+ 6. Fuel system
+ 7. Exhaust system
+ 8. Systems of start, ignition
- 9. Transmission
+ 9.1.2. Technical characteristics
- 9.2. Mekhnichesky transmission
+ 9.2.2. Technical characteristics
9.2.3. Gear shifting mechanism
9.2.4. Removal and MKPP installation
9.2.5. MKPP partition
9.2.6. Multipurpose switch and switch of lamps of a backing
9.2.7. Speedometer sensor
9.2.8. Epiploons
9.2.9. Evident repair of a transmission 012
+ 9.3. Automatic transmission
+ 10. Brake system
+ 11. Suspension brackets, steering
+ 12. Body
+ 13. Electric equipment
+ 14. Good advice
|
Transmission 012 assembled
|
1. Conic roller bearing
2. Gear wheel of transfer of a backing
3. Gear wheel of the 5th transfer
4. Gear wheel of the 4th transfer
5. Gear wheel of the 3rd transfer
6. Gear wheel of the 2nd transfer
7. Gear wheel of the 1st transfer
|
8. Conic roller bearing
9. Differential
10. Coupling case
11. Ball-bearing
12. Transmission case
13. Leading shaft
14. Block of gear wheels of an intermediate shaft |
Technical characteristics, 5-speed transmission 012
| Code |
AKL/AUF
|
ALP/AAD
|
| |
The 4-cylinder
|
The 5-cylinder
|
| Transfer number: |
| – main transfer |
37:9= 4.111
|
37:10= 3.700
|
| – first transfer |
39:11= 3.545
|
39:11= 3.545
|
| – second transfer |
40:19= 2.105
|
40:19= 2.105
|
| – third transfer |
39:30= 1.300
|
39:30= 1.300
|
| – fourth transfer |
33:35= 0.943
|
35:34= 1.029
|
| – fifth transfer |
30:38= 0.789
|
31:37= 0.838
|
| – backing transfer |
35:10= 3.500
|
35:10= 3.500
|
| Speedometer |
the electronic
|
| Greasing volume |
2,35 liters
|
| Specification |
Transmission G 50 oil (synthetic)
|
| SAE 75 W 90 |
| Coupling drive |
the hydraulic
|
| Diameter of a disk of the coupling of coupling |
210 mm
|
228 mm
|
| Diameter of a flange of a leading shaft |
100 mm
|
108 mm
|
| Speed on the highest transfer at 1000 rpm |
34 km/h
|
36 km/h
|
Prevention
Do not grease the lever mechanism of the lever of gear shifting.
LEVER MECHANISM OF THE LEVER OF GEAR SHIFTING, ADJUSTMENT / CHECK
Transmission
Removal
| PERFORMANCE ORDER |
| 1. Disconnect a wire of the negative plug of the accumulator. |
| 2. Turn off three top bolts of fastening of the engine and a transmission. |
| 3. Disconnect a wire of grounding of a transmission from a check point. |
| 4. Remove the socket of connection of the sending device of a speedometer and the socket of the multipurpose sending device having squeezed clips. |
| 5. Disconnect the socket of connection of the catalytic converter. |
| 6. Remove a protective plate of a case of a transmission. |
| 7. Turn off bolts of fastening of a final collector. |
| 8. Remove a forward exhaust pipe. |
| 9. Remove a back cross-section beam. |
| 10. Disconnect ropes of an automatic tension of seat belts from a transmission. |
| 11. Remove draft of gear shifting. |
| 12. Remove a protective plate of a case of coupling. |
| 13. Remove a protective plate of a leading shaft. |
| 14. Disconnect semi-axes from a transmission. |
| 15. Turn a steering wheel against the stop to the right and fix semi-axes having adhered them to a body. |
| 16. Remove the working cylinder of coupling. |
| 17. Remove an arm of the mechanism of a steering. |
| 18. Establish the engine on a support. |
| 19. Establish a transmission on a support |
| 20. Remove fastening on a back left part of a transmission. |
| 21. Remove forward fastening of the engine. |
| 22. Remove the bottom bolts of fastening of a transmission and the engine. |
| 23. Slowly lower a transmission. |
|
Installation
Installation is made in sequence, return to removal.
At installation pay attention to the following:
– check, that centering plugs were established correctly.
– establish the working cylinder of coupling into place by means of the lever so that the bolt was inserted easily.
Prevention
The bolt for fastening of the working cylinder of coupling has the pointed end for simplification of installation.
Moments of an inhaling of carving connections
| Transmission fastening to the engine: |
| – bolts М8 |
25 N of m.
|
| – bolts М10 |
45 N of m.
|
| – bolts М12 |
65 N of m.
|
| Fastening of a leading shaft to a flange: |
| – М8 |
45 N of m.
|
| – М10 |
80 N of m.
|
TRANSMISSION FASTENING TO THE ENGINE
4-cylinder engine
1= bolt М12 x 70
2= bolt М12 x 85
3= bolt М12 x 100
4= bolt М8 x 15 5-cylinder engine
1= bolt М12 x 70
2= bolt М12 x 80
3= bolt М12 x 90
4= bolt М12 x 100
5= bolt М11 x 120
6= bolt М10 x 50
7= bolt М10 x 40
8= bolt М8 x 40
Arrangement of centering plugs: points And and In
Arrangement of centering plugs: points And and In
Prevention
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).
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.
Mechanism of the main transfer
|
1. Speedometer drive
2. Differkntsial
3. Sealing ring
4. Cover of the main transfer
5. A bolt with a head under a face key – 25 N of m.
6. Lock ring
7. Flange of a leading shaft
8. A bolt with a head under a face key – 35 N of m.
9. The directing plug with a sealing ring
10. Concave washer
11. Lock ring
12. Ball-bearing of a leading shaft
13. Lock ring
14. Speedometer sending device
15. Case of the main transfer
|
16. A bolt with a head under a face key – 10 N of m.
17. I will corrode connections of the mnogofugktsionalny sending device
18. Cover of the channel of the lever of gear shifting
19. Multipurpose sending device
20. A locking film for the multipurpose sending device
21. Bolt of 25 N of m.
22. Lock of the 5th transfer and backing transfer
23. Lock ring |
Prevention
спидометра1 it is possible to replace a drive, without removing a transmission.
The differential 2 can be removed, without removing a transmission case.
Remove a sealing ring 3 by means of the VW 681 tool.
Pressurize a cover of the main transfer 4 by means of AMV 188 200 03 hermetic.
Always replace lock rings 6 and 23.
Establish a flange of a leading shaft by means of the VW 295 tool.
The party of a concave washer 10 with smaller diameter is turned to directing plug (the concave party).
Lock rings 11, 13 mark after removal.
Sealing ring of a flange of a leading shaft – remove by means of the VW 681 tool and establish (on 5 mm lower than a surface of a case of the main transfer) by means of the VW 195 tool.
Case of the main transfer 15: a sealing 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 VW 195 tool. The plug of a rod of switching 3-ей/the 4th transfer – establish by means of the VW 295 and VW 295А tools. Pressurize by means of AMV 188 200 03 hermetic.
Cover of the channel of the lever of gear shifting 18 – tighten a fastening bolt to 20 N of m.
22 it is possible to replace the lock of the 5th transfer and transfer of a backing, without removing a transmission. The slanted party of the plastic plug is turned to a switching shaft. Moment of an inhaling of bolts of fastening: 10 N of m.
Mechanism of a leading shaft
|
1. Internal draft of switching
2. A rod of switching of the 1st, 2nd, 5th transfers and backing transfer with a switching fork
3. A leading gear wheel with hollow shaft
4. Transmission case
5. A bolt with a head under a face key - 25 N of m.
6. A bolt with a head under a face key for an axis of transfer of a backing – 35 N of m.
7. A bolt with a head under a face key – 25 N of m.
8. Lock
9. A bolt with a head under a face key – 40 N of m.
10. Washer
11. Switching shaft |
12. Washer
13. A bolt with a head under a face key
14. Switching rod 3-ей/4th transfers and switching fork
15. Leading shaft
16. Lock ring
17. Washer
18. Gear wheel передачт backing
19. The needle bearing of a conducted gear wheel of transfer заденго a course
20. Persistent washer
|
Prevention
Remove a sealing ring of internal draft of switching 1 by means of the VW 681 tool and establish aflush by means of the VW 460/2 tool. On the established transmission accurately remove a sealing ring by means of a screw-driver and establish by means of the VW 423 tool. In the beginning remove pipes of an exhaust system and draft of gear shifting for receiving an empty seat.
Rod of switching of the 1st, 2nd, 5th transfers and backing transfer with a fork of switching 2 – 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.
Bolt with a head under a face key for an axis of transfer of a backing of 6-35 N of m. The axis of transfer of a backing does not need to be removed for removal of a gear wheel of transfer of a backing.
Bolt with a head under a face key of 7-25 N of m Vnutrennya the party of a head is turned to the safety mechanism of the spring / lock.
The lock 8 establish after installation of a shaft of switching 11 and an internal rod of switching.
Switching rod 3-ей/4th transfers and switching fork: it is possible to replace a rod of switching or a fork of switching separately. Replace the bearing of a rod of switching if it is worn-out.
Removal of bolts of a shaft of switching
|
|
Shooters specified bolts of a shaft of switching. |
Position of the mechanism of gear shifting
|
|
1. A rod of switching of the 5th transfer / transfer of a backing with a switching fork
2. Switching rod 3-ей/4th transfers
3. Switching fork 1-ой/the 2nd transfers
4. Switching shaft
5. Lock
6. Internal rod of switching |
The provision of a leading shaft, leading gear wheel with hollow shaft, rods of switching and вилкок switchings
It is necessary to establish these elements together.
It is possible to establish a shaft of switching and an internal rod of switching later.
Installation of a shaft of switching and internal rod of switching
|
|
And – a switching shaft
In – an internal rod of switching |
| PERFORMANCE ORDER |
| 1. Include the 3rd transfer. |
| 2. Establish a switching shaft. |
| 3. Put an internal rod of switching In sideways on an opening in a case of the main transfer and combine it with an arm nest on a switching shaft. |
| 4. Turn a switching rod inside in the arrow direction (see fig. Installation of a shaft of switching and internal rod of switching). |
|
Removal of the plug of a rod of switching
|
|
Use a hammer and an internal stripper And on 18,5–23,5 mm (for example, 1088 or Kukko 21/3). |
Removal and installation of the bearing of a fork of switching
Removal and oil pan installation
|
|
The arrow specified an oil pan |
| PERFORMANCE ORDER |
| 1. Remove an oil pan by means of a screw-driver. |
| 2. insert an oil pan so deeply into a transmission case that lock uvulas of an oil pan were hooked for grooves in a transmission case. |
| 3. The cup of an oil pan should look up in a transmission case. |
|
Installation of a sealing ring of an internal rod of switching
MECHANICAL TRANSMISSION – THE CASE, GEAR WHEELS, SHAFT
Leading shaft
Leading shaft in assembly
|
1. Transmission case
2. Plastic plug
3. The needle bearing – a leading shaft
4. Lock ring
5. Gear wheel of the 5th transfer
6. The needle bearing – the 4th transfer
7. Gear wheel of the 4th transfer
8. Synchronizer ring
9. The sliding coupling – 3-я/the 4th transfers
10. Lock ring
11. A synchronizer nave – 3-я/the 4th transfers
|
12. Lock ring
13. Lock ring
14. The ball-bearing – a leading shaft
15. Lock ring
16. Case of the main transfer
17. The needle bearing – a leading shaft
18. Leading shaft
19. The needle bearing – the 3rd transfer
20. Gear wheel of the 3rd transfer
21. A synchronizer ring – the 3rd transfer. |
Prevention
Always replace the plastic plug 2. It is absent on the leader to a shaft on which there are lubricant openings for 3-ей/no 4th transfers.
The needle bearing 2 is damaged at removal. Always replace it. Establish it by means of the VW 416В tool on depth in 214 mm, measuring from a case peoverkhnost.
Lock ring 4 – specify the demanded thickness at replacement of a gear wheel of the 5th transfer.
Lock ring 10 – specify the demanded thickness at replacement of a nave of the synchronizer.
Synchronizer 11 nave – the acting rim is turned to a conducted gear wheel of the 3rd transfer.
Lock ring 13 – 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 ring 15 – 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
The needle bearing – a leading shaft. Establish by means of the tool 40-202.
Needle bearing of a leading shaft
Removal of the needle bearing of a leading shaft
Depth of installation of the needle bearing
Depth of installation is measured from bottom edge of a verifying ruler to the upper edge of the bearing.
Ball-bearing
Ball-bearing installation in a case
| PERFORMANCE ORDER |
| 1. Establish a lock ring on a leading shaft. |
| 2. Establish the ball-bearing on a leading shaft against the stop. |
| 3. Establish a persistent heel of the vyzhimny tool 3235 on the ball-bearing. |
| 4. Establish vyzhimny the tool 3235 for shlitsa of a disk of coupling on an entrance shaft. |
| 5. Press on the ball-bearing having twirled two bolts In, established in deepenings of a persistent heel And. |
| 6. Press the bearing against the stop in turn and gradually twisting two bolts. |
|
Prevention
Bolts In should be twisted alternately (for example, on a half of turn for time), differently the ball-bearing can be turned and damaged.
Provision of installation of the ball-bearing: the open party of the plastic case should be turned to directing plug.
Check of a ring of the synchronizer on wear
| PERFORMANCE ORDER |
| 1. Establish a synchronizer ring on the sliding coupling and measure a gap and with the help щупа for measurement of gaps in points And, In and Page. |
| 2. Combine the received values and divide the sum on 3. |
| 3. The received value should not be less, than 0.5 mm. |
|
Installation of the sliding coupling – 3-я/the 4th transfers
|
|
The party with a groove (it is specified by an arrow) is turned to a gear wheel of the 3rd transfer. |
Installation of a spring of the synchronizer
Establish a spring (it is specified by an arrow) in a gear wheel, having established the pointed end of a spring in a groove.
Removal of a gear wheel of the 5th transfer
|
|
And = the demountable device on 22–115 mm, for example, Kukko 17/2. |
Installation of a gear wheel of the 5th transfer
The acting edge is turned to backing transfer. Lubricant channels are turned to the 4th transfer.
Removal / installation of the needle bearing of a leading shaft
|
|
And = a stripper on 22–28 mm, for example, Kukko 11/4
In = VW 771 hammer |
Prevention
Before stripper installation for bearing removal, split / remove the plastic plug if it is established. For installation of the bearing press it by means of VW 416В opravka on depth of 214 mm, measuring from a case surface.
LOCK RINGS
Installation of a lock ring of a gear wheel of the 4th transfer
Define the greatest possible thickness of a lock ring which can be established, and establish it. The lock ring for a gear wheel of the 5th transfer gets out in the same way.
|
THICKNESS OF THE LOCK RING, MM
|
NUMBER
|
| Lock ring 3 (brown)
|
|
2.00
|
902 945.01
|
| Lock ring 4 (dark blue)
|
|
1.90
|
902 944.01
|
|
1.93
|
902 944.02
|
|
1.96
|
902 944.03
|
|
1.99
|
902 944.04
|
|
2.02
|
902 944.05
|
|
2.05
|
902 944.06
|
| Lock ring 5
|
|
1.90
|
902 942.02
|
|
1.93
|
902 942.03
|
|
1.96
|
902 942.04
|
|
1.99
|
902 942.05
|
|
2.02
|
902 942.06
|
Installation site, selection of lock rings
|
|
Lock rings are designated in drawing, they are numbered according to their situation on the leader to a shaft. |
Lock rings 1, 2, 4 and 5 it is necessary to select. The thickness of a lock ring 3 is always constant.
Define necessary thickness of lock rings 1 and 2.
Removal of a nave of the synchronizer 3-ей/of the 4th transfers
|
|
VW 401/VW 402 = persistent heels
32-12= disk
VW 408А = drift
And = a stripper on 22–115 mm, the Kukko 17/2 type |
| PERFORMANCE ORDER |
| 1. Establish the following tools as is shown in drawing. Before installation of a stripper And, press a ring of the synchronizer of the 3rd transfer (it is specified by an arrow) to a gear wheel of the 3rd transfer. |
| 2. Remove a synchronizer nave. |
|
Installation of a nave of the synchronizer 3-ей/of the 4th transfers
Installation of the plastic plug
Establish the plastic plug B together with the needle bearing A.
Prevention
The plastic plug B is established only on the leader to a shaft with lubricant flutes (are specified by an arrow) for 3-ей/the 4th transfers.
Adjustment of a leading shaft
| PERFORMANCE ORDER |
| 1. Fix a leading shaft in a vice with soft laying on sponges |
| |
2. Establish And, a rasporny plate 3167, on the 3rd transfer. |
| 3. Establish a case on a rasporny plate, having put on it a leading gear wheel. |
|
Installation of a lock ring
| PERFORMANCE ORDER |
|
1. Establish a depth gage on a case and measure distance to the bottom flute on a shaft. and = 28,5 mm. |
|
2. Establish a depth gage on a case and measure distance to a ball-bearing installation site. b= 26,8 mm. |
| 3. Define necessary thickness of the bottom lock ring. Size x: x = and - b. x = 28,5 - 26,8 = 1,70 mm. Define necessary thickness of a lock ring (See table 1). |
|
4. Establish a lock ring and the ball-bearing on a shaft by means of an opravka 30–100. |
| 5. Find a lock ring of the biggest thickness which can be inserted. See table 2. |
|
Table 1
|
Size
|
Thickness
|
Number
|
|
1.64-1.71
|
1.69
|
902 941.05
|
|
1.72-1.79
|
1.77
|
902 941.06
|
|
1.80-1.87
|
1.85
|
902 941.07
|
|
1.88-1.95
|
1.93
|
902 941.08
|
|
1.96-2.03
|
2.01
|
902 941.09
|
|
2.04-2.11
|
2.09
|
902 941.10
|
|
2.12-2.19
|
2.17
|
902 941.11
|
|
2.20-2.27
|
2.25
|
902 941.12
|
|
2.28-2.35
|
2.33
|
902 941.13
|
Table 2
|
Thickness (mm)
|
Number
|
|
1.69
|
902 941.05
|
|
1.77
|
902 941.06
|
|
1.85
|
902 941.07
|
|
1.93
|
902 941.08
|
|
2.01
|
902 941.09
|
|
2.09
|
902 941.10
|
|
2.17
|
902 941.11
|
|
2.25
|
902 941.12
|
|
2.33
|
902 941.13
|
Removal of an external holder of a dvukhryadny conic roller bearing
Installation of an external holder of a dvukhryadny conic roller bearing
| PERFORMANCE ORDER |
| 1. Establish a vyzhimny plate of a stripper 3128 under an external holder. |
| 2. establish a level of VW 771/29 and establish a bolt on a transmission case. At a bolt twisting, the external holder acts in film from a case. |
|
Removal of an internal holder of a dvukhryadny conic roller bearing
Prevention
For removal of an internal holder, the external holder And should be established.
Installation of an internal holder of a dvukhryadny conic roller bearing
Leading gear wheel and hollow shaft
|
1. Case of the main transfer
2. S3 washer
3. The Dvukhryadny conic roller bearing – a vneyshy holder
4. Leading gear wheel
5. The Dvukhryadny conic roller bearing – an internal holder
6. Lock ring
7. The needle bearing – the 1st transfer
8. Gear wheel of the first transfer
9. Synchronizer ring-1st transfer
10. A synchronizer nave – 1-ая/the 2nd transfers
11. Lock ring
12. The needle bearing – the 2nd transfer
13. The sliding coupling – the 1st/2nd transfers
14. A synchronizer ring – the 2nd transfer
15. Gear wheel of the 2nd transfer
16. Lock ring
17. Gear wheel of the 3rd transfer
18. Lock ring
19. Gear wheel of the 4th transfer
|
20. Lock ring
21. The needle bearing – the 5th transfer
22. Gear wheel of the 5th transfer
23. A synchronizer ring – the 5th transfer
24. Lock ring
25. A synchronizer nave – the 5th transfer / transfer of a backing
26. Lock ring
27. The needle bearing – backing transfer
28. The sliding coupling – the 5th transfer / transfer of a backing
29. A synchronizer ring – backing transfer
30. Gear wheel of transfer of a backing
31. A conic roller bearing – an internal holder
32. The lock carving plug for an external holder of a conic roller bearing
33. A conic roller bearing – an external holder
34. S4 washer
35. Clamping plate
36. Washer
37. Transmission case |
Prevention
The leading gear wheel 4 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.
The acting edge of a nave of the synchronizer 10 is turned to the 2nd transfer. To remove a nave 10 together with a gear wheel of the 1st transfer. Use persistent plates of VW 401 and VW 402. Establish by means of VW 415А and VW 519 plug opravka.
The flute of a gear wheel 17 is turned to a gear wheel of the 4th transfer.
The edge of a gear wheel 19 is turned to a gear wheel of the 3rd transfer.
The acting edge of a nave 25 is turned to a gear wheel of the 5th transfer. Remove a nave 25 together with a gear wheel of the 5th transfer. Establish by means of the plug 2010.
Installation of the lock carving plug 32 at replacement of an external holder is not required (this plug is necessary only by production).
The washer 36 compensates expansion depending on temperature (heating). For removal drill an opening in a washer and remove by means of the screw.
Installation of a spring of the synchronizer in a gear wheel
Establish a spring (it is specified by an arrow) in a gear wheel, having established the pointed end in a flute.
Check on wear of a ring of the synchronizer
| PERFORMANCE ORDER |
| 1. Press a synchronizer ring to the sliding coupling and measure a gap and with the help щупа for measurement of gaps in points And, In and Page. |
| 2. Combine the received values and divide the sum on 3. |
| 3. The received value should not be less, than 0.5 mm. |
|
Installation of the sliding coupling 1-ой/of the 2nd transfer
The party with a flute should be turned to a gear wheel of the 1st transfer.
Removal of a gear wheel of the 3rd transfer
|
|
And = a stripper on 22–115 mm, the Kukko 17/2 type
|
Installation of a gear wheel of the 3rd transfer
Provision of installation: the flute should be turned to a gear wheel of the 4th transfer.
Removal of a gear wheel of the 4th transfer
Installation of a gear wheel of the 4th transfer
Removal of a nave of the synchronizer
Remove a synchronizer nave together with a gear wheel of the 5th transfer. Use a stripper And on 22–115 mm, the Kukko 17/2 type.
Identification of a ring of the synchronizer
Production of rings with more, than 3 uvulas, was stopped.
Removal of an internal holder of a conic roller bearing
Remove an internal holder together with a gear wheel of transfer of a backing. Use a stripper And on 22–115 mm, the Kukko 17/2 type.
Installation of an internal holder of a conic roller bearing
Installation of the sliding coupling of the 5th transfer / transfer of a backing
|
|
The diagonal strip 1 is turned to a gear wheel of transfer of a backing.
The party with a flute 2 is turned to a gear wheel of the 5th transfer. |
Removal of the lock carving plug
Use a stripper And on 22–115 mm, the Kukko 17/2 type. Installation of the plug is not required at replacement of an external holder (this plug is necessary only by production).
Removal of an external holder of a conic roller bearing
| PERFORMANCE ORDER |
| 1. Twirl a special bolt for removal in a vyzhimny plate (bolt М10 in length of 50 mm, ground off on one end till the diameter М8). |
| 2. Remove a vyzhimny plate and an external holder from a case by means of a hammer |
|
Installation of an external holder of a conic roller bearing
Installation of a lock ring of a conic roller bearing
Find a lock ring of the biggest thickness which can be inserted, and establish it. The necessary thickness of lock rings of a nave of the synchronizer and thickness of lock rings of gear wheels 3-ey/4-oh transfers is defined also, as thickness of a lock ring of a conic roller bearing.
List of lock rings
|
THICKNESS OF THE LOCK RING, MM
|
NUMBER
|
| Lock ring 1
|
|
2.00
|
902 945.01
|
|
2.02
|
902 950.02
|
|
2.04
|
902 950.03
|
|
2.06
|
902 950.04
|
|
2.08
|
902 950.05
|
|
2.10
|
902 950.06
|
| Lock ring 2 (dark blue)
|
|
1.90
|
902 947.01
|
|
1.93
|
902 947.02
|
|
1.96
|
902 947.03
|
|
1.99
|
902 947.04
|
|
2.02
|
902 947.05
|
| Lock ring 3 (dark blue)
|
|
2.50
|
902 947.06
|
|
Lock ring 4
|
|
1.90
|
902 946.02
|
|
1.93
|
902 946.03
|
|
1.96
|
902 946.04
|
|
1.99
|
902 946.05
|
|
2.02
|
902 946.06
|
| Lock ring 5
|
|
1.87
|
902 952.01
|
|
1.90
|
902 952.02
|
|
1.93
|
902 952.03
|
|
1.96
|
902 952.04
|
| Lock ring 6 (brown)
|
|
2.00
|
902 945.01
|
| Lock ring 7 (dark blue)
|
|
1.90
|
902 944.01
|
|
1.93
|
902 944.02
|
|
1.96
|
902 944.03
|
|
1.99
|
902 944.04
|
|
2.02
|
902 944.05
|
|
2.05
|
902 944.06
|
Place installation/selection of lock rings
|
|
Lock rings are numbered according to their situation on the leader to a shaft.
Lock rings 1, 2, 4, 5 and 7 it is necessary to select.
The thickness of lock rings 3 and 6 is always constant. |
Differential assembled
|
1. Differential case
2. Bolt of a gear wreath
3. The big roller bearing – an internal holder
4. Gear wheel of a drive of a speedometer
5. A big roller bearing – an external holder
6. S1 washer
7. Cover
8. Persistent washer
|
9. Satellites
10. Axis of satellites
11. Pin of an axis of satellites
12. Gear wheels of semi-axes
13. Gear wreath
14. A small roller bearing – an internal holder
15. A small roller bearing – an external holder
16. S2 washer |
Prevention
At replacement of the case of differential 1 adjust installation of a gear wreath.
Use bolts 2 only the demanded specification. Tighten them evenly in a diagonal order.
Establish a big roller bearing 3 by means of the VW 295 and VW 551 tools.
Note thickness of a washer 6.
Before installation of a persistent washer 8 grease it with transmission oil.
Remove an axis of satellites 10 by means of a drift after removal of a pin of an axis of satellites.
Pin of an axis of satellites 11 remove by means of a drift.
Gear wreath 13 and a leading gear wheel are adjusted to each other. At pair replacement gear the wreath / leader a gear wheel, carry out adjustment. For installation – heat up to 100 ° With and establish by means of centering pins.
Small roller bearing 14 establish by means of the plug 40-21.
Note thickness of a washer of S2.
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|
