Audi 80/90/Coupe

Since 1986-1991 of release

Repair and car operation



Audi 80/90/Coupe
+ 1.2. Car identification
+ 2. Engines, carburettors
3. Greasing system
+ 4. Cooling system
+ 5. Fuel system
+ 6. An exhaust system
+ 7. Ignition system
- 8. Transmission
   8.1.2. A plug - the main cylinder of coupling
   8.1.3. Press a coupling disk
   8.1.4. Malfunctions of coupling
   + 8.2. A mechanical transmission 012
   - 8.3. A mechanical transmission 01А
      8.3.2. Removal and transmission installation
      8.3.3. Dismantling and transmission assemblage
      + 8.3.4. Differential
      8.3.5. A kardannyj shaft
      8.3.6. Central карданный the hinge
   + 8.4. An automatic transmission 089
   + 8.5. An automatic transmission 087
   8.6. Dismantling and assemblage of automatic transmissions
   8.7. The block of valves
   + 8.8. An automatic transmission 097
+ 9. Suspension brackets, wheels
+ 10. Brake system
+ 11. A steering
+ 12. A body, salon
+ 13. A central air
+ 14. An electric equipment





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

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).


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.


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.


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