Audi 80/90/Coupe

Since 1986-1991 of release

Repair and car operation

8.3.3. Dismantling and transmission assemblage

THE GENERAL DATA

Transmission in gathering

1. A leading shaft 2. The ball-bearing 3. Carter of coupling 4. Differential 5. Двухрядный a conic roller bearing 6. A gear wheel of 1 th transfer 7. A gear wheel 2nd transfers 8. A gear wheel of 3 transfers 9. A gear wheel of 4th transfer

10. A gear wheel of 5th transfer 11. A gear wheel of transfer of a backing 12. Carter of a transmission 13. A conic roller bearing 14. Carter of differential 15. A flange a drive 16. Differential 17. A hollow shaft 18. A leading gear wheel

The mechanism of the main transfer

1. Carter of a transmission уллотнительное a 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 VW195 Measure depth of installation сапуна The plug of a rod of switching: establish by means of the tool 30-205 герметизируйте by means of hermetic AMV188 200 03 2. A lock ring Mark after removal 3. The directing plug with a sealing ring 4. 35 Н.м. 5. A concave washer The party with smaller diameter is turned to directing plug (the concave party) 6. The ball-bearing of a leading shaft 7. 10 Н.м. 8. A speedometer sending device 9. Differential It is possible to remove, without removing картер a transmission 10. A sealing ring 11. A flange of the left semiaxis Establish by means of VW 295

12. A lock ring Always replace 13. 25 Н.м. 14. A cover of the main transfer Remove уплртнительное a ring by means of tool VW 681 герметизируйте by means of hermetic AMV 188 200 03 15. The lever of a gear change and a shaft casing 16. The lock of 5th transfer and backing transfer It is possible to replace without removing a transmission The oblique party of the plastic plug should be turned to a switching shaft 17. A lock ring Always replace 18. A flange of the right semiaxis Establish give to drink help VW 295 19. 25 Н.м. 20. A clamping plate For a multipurpose sending device 21. A multipurpose sending device 22. A socket of connection of a multipurpose sending device

Dismantling / assemblage

PERFORMANCE ORDER

1) establish a transmission at the repair stand 2) merge трансмиссионное oil 3) remove the lever of deenergizing of coupling and выжимной 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 with картера transmissions by means of a stripper 7) remove the lock ring established behind the ball-bearing and measure its thickness 8) remove bolts between karterom/a transmission cover (for differential) and uncover together with differential 9) remove bolts between картером couplings and картером transmissions and remove картер transmissions 10) remove a multipurpose sending device 11) remove bolts of a shaft of switching 12) remove a bolt of the lock and get the lock 13) remove together the leading shaft, a leading gear wheel, a switching shaft, rods of switching and a switching plug 14) assemblage is spent 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 switching plug are established together;       – Lock rings for the ball-bearing on the leader to a shaft should be established on an old place and to be the same thickness

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The prevention

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.

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

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The mechanism of a leading shaft

1. A leading shaft 2. A rod of switching Z-ej/of 4th transfers and a switching plug It is possible to replace a rod of switching or a switching plug separately 3. A switching shaft 4. 40 Н.м. 5. A washer 6. A washer 7. The lock 8. 25 Н.м. The head inside is turned to safety мехнизму lock springs / 9. 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 10. A leading gear wheel with hollow shaft

11. Carter of a transmission 12. 25 Н.м. 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 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 of switching of 5th transfer / of transfer of a backing only together with a ring of switching and a switching rod 14. 40 Н.м. 15. A gear wheel of transfer of a backing 16. The needle bearing of transfer of a backing 17. A persistent washer 18. A lock ring

The cover also can be removed together with differential.

Differential and the mechanism of the main transfer

1. Carter of a transmission 2. The plug 3. A press spring 4. A lock ring 5. The ball-bearing with a flute of a flange of a drive 6. Carter of differential герметизируйте by means of hermetic AMV188 200 03 7. A lock ring 8. A cap 9. A closing ring Always replace Grease before installation 10. A sealing ring of a flange of a drive Remove by means of tool VW 681 11. A counterbalance 12. A cutting lock ring

13. A drive flange Installation is made through an aperture in a cover Removal: remove a cap 14. 35 Н.м. 38 mm in length 15. 25 Н.м. 42 mm in length 16. A lock ring Dissolve the ends in the parties for ring removal Establish together with a drive flange 17. A lock ring 18. The ball-bearing with a flute 19. The needle bearing 20. Differential Do not assort Always replace, if it is damaged Remove after removal of a flange of a drive

Mechanical transmission – картер, gear wheels, shaft / the Leading shaft – a check point 01А

1. A ring of the synchronizer of 3 transfers 2. A gear wheel of 3 transfers 3. The needle bearing of 3 transfers 4. A leading shaft 5. The needle bearing of a leading shaft Establish by means of the tool 3096/1 6. Carter of the main transfer 7. A lock ring If you are going to use the old ball-bearing and a shaft, it is necessary to measure a thickness of an old lock ring and to replace its new the same thickness 8. A lock ring 9. The ball-bearing of a leading shaft 10. Carter of a transmission 11. The plastic plug 12. The needle bearing of a leading shaft Establish by means of tool VW 295 and VW 295A on depth in 214 mm, measuring from a surface картера

13. A lock ring Specify a demanded thickness at replacement of a gear wheel of 5th transfer 14. A gear wheel of 5th transfer 15. The needle bearing of 4th transfer 16. A gear wheel of 4th transfer 17. A ring of the synchronizer of 4th transfer 18. Sliding муфта 3-ej/4th transfers 19. A lock ring Specify a demanded thickness at replacement of a nave of the synchronizer 20. A nave of synchronizer Z-ej/of 4th transfers Acting ободок it is turned to a gear wheel of 3 transfers 21. A lock ring If you are going to use the old ball-bearing and a shaft, it is necessary to measure a thickness of an old lock ring and to replace its new the same thickness

Lock rings differ on a thickness and diameter and it is necessary to measure them at removal. At gear wheel or shaft replacement it is necessary to measure corresponding lock rings for installation of a ring of a demanded thickness and diameter.

Rings of synchronizers and a synchronizer nave, replacement

Since 26.01.87 rings of synchronizers have started to be issued with new external diameter and the flute on a synchronizer nave has been reduced by 0.6 mm. Do not establish together a nave sliding муфт and rings of synchronizers of the different sizes.

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The prevention

At replacement of conic roller bearings define position of their installation before removal of a leading gear wheel and a hollow shaft.

Do not damage epiploon edge between conic roller bearings.

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Leading gear wheel and hollow shaft – a check point 01А

1. Carter of the main transfer 2. Washer S3 3. Двухрядный a conic roller bearing – an external holder 4. A leading gear wheel Corresponds to a gear wreath (pair a gear wreath / a leading gear wheel) At pair replacement a gear wreath / a leading gear wheel adjust installation of a leading gear wheel, and also a hollow shaft and a gear wreath 5. The needle bearing of a hollow shaft At installation grease with greasing MoS2 6. The needle bearing of a hollow shaft At installation grease with greasing MoS2 7. Двухрядный a conic roller bearing – an internal holder After measurement of washers S3 and S4 grease the small bearing with greasing MoS2 8. A lock ring

9. A hollow shaft At replacement of a hollow shaft define a necessary thickness of washer S3 At replacement картера the main transfer define a necessary thickness of washer S4 The external holder of the small bearing is established on hollow to a shaft 10. The small needle bearing of 1st transfer 11. The big needle bearing of 1st transfer 12. A gear wheel of 1st transfer Remove together with a synchronizer nave 13. A ring of the synchronizer of 1st transfer 14. A synchronizer nave 1-oj/2nd transfers The acting edge is turned to 2nd transfer 15. A lock ring 16. The needle bearing 2nd transfers 17. Sliding муфта 1-oj/2nd transfers

Leading gear wheel and hollow shaft – a check point 01А

1. A synchronizer ring 2nd transfers 2. A gear wheel 2nd transfers Establish a spring before gear wheel installation 3. A lock ring 4. A gear wheel of 3rd transfer The flute is turned to a gear wheel of 4th transfer 5. A lock ring 6. A gear wheel of 4th transfer The flute is turned to a gear wheel of 3rd transfer 7. A lock ring 8. The needle bearing of 5th transfer 9. A gear wheel of 5th transfer 10. A ring of the synchronizer of 5th transfer 11. A lock ring 12. A nave of the synchronizer of 5th transfer / of transfer of a backing The acting edge is turned to a gear wheel of 5th transfer Establish by means of the plug 2010

13. A lock ring 14. The needle bearing of transfer of a backing 15. Sliding муфта 5th transfer / of transfer of a backing 16. A ring of the synchronizer of transfer of a backing 17. A gear wheel of transfer of a backing 18. A 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. Washer S3 22. A clamping plate 23. A washer Compensates expansion depending on heating temperature 24. Carter of a transmission