Audi 80/90/Coupe

Since 1986-1991 of release

Repair and car operation

8.2.3. Removal and transmission installation

THE GENERAL DATA

Transmission 012 in gathering

1. A conic roller bearing 2. A gear wheel of transfer of a backing 3. A gear wheel of 5th transfer 4. A gear wheel of 4th transfer 5. A gear wheel of 3rd transfer 6. A gear wheel 2nd transfers 7. A gear wheel of 1st transfer

8. A conic roller bearing 9. Differential 10. Carter of coupling 11. The ball-bearing 12. Carter of a transmission 13. A leading shaft 14. The block of gear wheels of an intermediate shaft

Transmission fastening to the engine (4-cylinder model)

Centering plugs: points And and In 1 = bolt М12х70 2 = bolt М12х85 3 = bolt М12х100 4 = bolt М8х15

Transmission fastening to the engine (5-cylinder model)

Centering plugs: points And and In 1 = bolt М12х70 2 = bolt М12х80 3 = bolt М12х90 4 = bolt М12х100 5 = bolt М10х120 6 = bolt М10х50 7 = bolt М10х40 8 = bolt М8х40

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 a socket of connection of a sending device of a speedometer and a socket of a multipurpose sending device having squeezed clips 5) disconnect a connection socket каталитического the converter 6) remove a protective plate картера transmissions 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) draught of a gear change 12) a protective plate картера couplings 13) a protective plate of a leading shaft 14) disconnect semiaxes from a transmission 15) turn a steering wheel against the stop to the right and fix semiaxes 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 spent upside-down removals. At installation pay attention to the following:

PERFORMANCE ORDER

1) check up, that centering plugs have been established correctly 2) establish the working cylinder of coupling into place by means of the lever so that the bolt was inserted easily The prevention The bolt for fastening of the working cylinder of coupling has the pointed end for simplification of installation.

The mechanism of the main transfer

1. A speedometer drive It is possible to replace, without removing a transmission 2. Differential It is possible to remove, without removing картер a transmission 3. A sealing ring 4. A cover of the main transfer Remove a sealing ring By means of tool VW 681 герметизируйте by means of hermetic AMV 188 200 03 5. A bolt with a head under a face key – 25 Н.м. 6. A lock ring Always replace 7. A flange of a leading shaft Establish by means of tool VW 295 8. A bolt with a head under a face key – 35 Н.м. 9. The directing plug with a sealing ring 10. A concave washer The party with smaller diameter is turned to directing plug (the concave party) 11. A lock ring Mark after removal 12. The ball-bearing of a leading shaft 13. A lock ring Mark after removal 14. A speedometer sending device 15. Carter of the main transfer Sealing ring of a flange of a leading shaft remove by means of tool VW 681

Establish (on 5 mm below a surface картера the main transfer) by means of tool VW 195 External holder of a conic roller bearing establish by means of tools VW 511 and VW 295 The plug of a rod of switching 3-j/4th transfer establish by means of tools VW 295 and VW 295А герметизируйте by means of hermetic AMV 188 200 03 16. A bolt with a head under a face key – 10 Н.м. 17. A socket of connection of a multipurpose sending device 18. A cover of the channel of the lever of a gear change Tighten a bolt of fastening to 20 Н.м. 19. A multipurpose sending device 20. A locking lath For a multipurpose sending device 21. 25 Н.м. 22. The lock of 5th transfer and backing transfer It is possible to replace, without removing a transmission The oblique party of the plastic plug is turned to a switching shaft The moment of an inhaling of bolts of fastening – 10 Н.м. 23. A lock ring Always replace

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The prevention

If it is necessary for you to replace картер the main transfer or a conic roller bearing ведушей a gear wheel or a hollow shaft and the deviation r is not designated on on a conic cogwheel, position of installation of a leading gear wheel should be defined before removal картера transmissions (it is necessary to spend measurement of the valid size of a deviation).

Before installation картера transmissions, check up, that directing plugs have been established in картере transmissions.

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

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Bolts of a shaft of switching

The gear change mechanism, installation position

1. A rod of switching of 5th transfer / of transfer of a backing with a switching plug 2. A switching rod 3-j/4th transfers 3. A switching plug 1-oj/2nd transfers 4. A switching shaft 5. The lock 6. An internal rod of switching

The leading shaft, leading gear wheel with hollow shaft, rods of switching and a switching plug, installation position

These elements should be established together.

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The prevention

The shaft of switching and internal rod of switching can be established later.

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Shaft of switching and internal rod of switching

Installation

PERFORMANCE ORDER

1) include 3rd transfer 2) establish a shaft of switching And 3) put an internal rod of switching In sideways on an aperture in картере the main transfer and combine it with an arm nest on a switching shaft 4) turn a switching rod inside (in an arrow direction)

The plug of a rod of switching

Removal

PERFORMANCE ORDER

Take advantage of a hammer and an internal stripper And on 18.5–23.5 mm (for example, 1088 or Kukko 21/3)

The bearing of a plug of switching, removal and installation

Маслосборник

PERFORMANCE ORDER

1) remove маслосборник (it is specified by an arrow) by means of a screw-driver 2) insert маслосборник so deeply in картер transmissions that lock uvulas маслосборника were hooked for grooves in картере transmissions 3) the cup маслосборника should look upwards in картере transmissions

Sealing ring of an internal rod of switching

The size and = 1 mm

The needle bearing of a leading shaft, removal

The needle bearing, depth of installation

It is measured from a bottom edge of a verifying ruler to a bearing upper edge The size and = 39.5 mm

The ball-bearing

Installation in картер

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 выжимного the tool 3235 on the ball-bearing 4) establish выжимной the tool 3235 for шлицами a coupling disk 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 by turns and gradually twisting two bolts The prevention Bolts In should be twisted alternately (for example, on a half-turn for time), differently the ball-bearing can be turned and damaged. Position of installation of the ball-bearing: the open party of the plastic case should be turned to directing plug.

Synchronizer spring

Installation

PERFORMANCE ORDER

Establish a spring (it is specified by an arrow) in a gear wheel, having established the pointed end of a spring in a groove

Synchronizer ring

Check

PERFORMANCE ORDER

1) establish a synchronizer ring on sliding муфту and measure a backlash and with the help probeа for measurement of backlashes in points And, In and With 2) combine the received values and divide the sum on 3 3) the received value should not be less, than 0.5 mm

Sliding муфта – 3-ja/4th transfers

The party with a groove (it is specified by an arrow) is turned to a gear wheel of 3 transfers

Gear wheel of 5th transfer

Removal

And = the demountable device on 22–115 mm, such as, for example, Kukko 17/2

Installation

The acting edge is turned to backing transfer; lubricant channels are turned to 4th transfer

The needle bearing of a leading shaft

And = a stripper on 22–28 mm, for example Kukko 21/4 In = hammer VW 771

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The prevention

Before installation of a stripper for bearing removal, split / remove the plastic plug if it is established. For bearing installation, press it with the help оправки VW 416В on depth of 214 mm, measuring from a surface картера.

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Lock rings

Lock ring of a gear wheel of 4th transfer

Removal

PERFORMANCE ORDER

Define the greatest possible thickness of a lock ring which can be established, and establish it The prevention The lock ring for a gear wheel of 5th transfer gets out in the same way.

Installation site selection

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The prevention

Lock rings are numbered according to their position on the leader to a shaft.

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Lock rings 1, 2, 4 and 5 it is necessary to select. The thickness of a lock ring 3 is always constant.

Define a necessary thickness of lock rings 1 and 2.

Lock ring 3 (brown)

THICKNESS OF THE LOCK RING, MM	NUMBER
2.00	902 945.01

Lock ring 4 (dark blue)

THICKNESS OF THE LOCK RING, MM	NUMBER
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

THICKNESS OF THE LOCK RING, MM	NUMBER
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

Synchronizer nave 3-j/4th transfers

Removal

PERFORMANCE ORDER

1) establish following tools as is shown in drawing: VW 401/VW 402 = persistent heels 32 – 12 = a disk VW 408А = выколотка And = a stripper on 22–115 mm, type Kukko 17/2 The prevention Before installation of a stripper And, press a ring of the synchronizer of 3 transfers (it is specified by an arrow) to a gear wheel of 3 transfers. 2) remove a synchronizer nave

Synchronizer nave 3-j/4th transfers, installation

The plastic plug

Installation

PERFORMANCE ORDER

The plastic plug In is established only on the leader to a shaft with lubricant flutes (are specified by an arrow) for 3-ej/4th transfers. Establish the plastic plug In together with the needle bearing And.

Leading shaft

The mechanism of a leading shaft

1. Internal draught of switching Remove a sealing ring of internal draught of switching by means of tool VW 681 and establish заподлицо by means of tool VW 460/2. On the established transmission accurately remove a sealing ring by means of a screw-driver and establish by means of tool VW 423. In the beginning remove pipes of an exhaust system and draught of a gear change for empty seat reception. 2. A switching rod 1st 2nd, 5th transfers and transfer of a backing with a switching plug For assemblage dismantling/, remove / establish spring pins: 1-oj/2nd transfers it is possible to replace switching plugs separately Replace a plug a rekey ния 5th transfer / of transfer of a backing only together with a ring of switching and a switching rod 3. A leading gear wheel with hollow shaft 4. Carter of a transmission 5. A bolt with a head under a face key – 25 Н.м. 6. A bolt with a head under a face key for an axis of transfer of a backing – 35 Н.м. The axis of transfer of a backing does not need to be removed for removal of a gear wheel of transfer of a backing

7. A bolt with a head under a face key – 25 Н.м. The head inside is turned to the safety mechanism of a spring / of the lock 8. The lock Establish after installation of a shaft of switching (11) and internal, a switching rod 9. A bolt with a head under a face key – 40 Н.м. 10. A washer 11. A switching shaft 12. A washer 13. A bolt with a head under a face key 40 – Н.м. 14. A switching rod 3-ej/4th transfers and a switching plug It is possible to replace a rod of switching or a switching plug separately Establish by means of tools VW 295 and VW 295A Replace the bearing of a rod