VW Passat repair


+ 1. Ekspluatatsiiya of the car
+ 2. Maintenance
+ 3. Engines
+ 4. Cooling system
+ 5. Power supply system
+ 6. Ignition system
+ 7. Coupling
- 8. Transmission
   - 8.1. Mechanical transmission
      8.1.1. General information
      8.1.2. Transmission removal
      8.1.3. Transmission installation
      8.1.4. Transmission dismantling
      8.1.5. Dismantling, check of a condition and assembly of primary shaft
      8.1.6. Secondary shaft
      8.1.7. Backing shaft
      8.1.8. Differential
      8.1.9. Gear shifting mechanism
      8.1.10. Installation axial люфта primary shaft
      8.1.11. Installation axial люфта secondary shaft
      8.1.12. Transmission assembly
      8.1.13. Mechanism of management of a transmission
      8.1.14. Adjustment of the mechanism of gear shifting
      8.1.15. Check of level of oil in a transmission
   + 8.2. Automatic transmission
   + 8.3. Distinctive features of transmission of cars with a full drive of Passat Syncro
+ 9. Drive of forward wheels
+ 10. Suspension brackets
+ 11. Steering
+ 12. Brake system
+ 13. Wheels and tires
+ 14. Systems of heating, ventilation and conditioning
+ 15. Electric equipment
+ 16. Body
+ 17. Electric circuits


Repair B3-B4/Passat B3-B4 Volkswagen Passat>> Transmission>> Mechanical transmission>> Secondary shaft
       NOTE
The details removed from a secondary shaft have in the sequence corresponding to an order of their installation on a shaft — it will facilitate assembly process.

Removal of details from a secondary shaft carry out in the following order:

Fig. 8.21. Secondary shaft and its details: 1–nut; 2–coupling case; 3–washer; 4–cup of the conic bearing; 5–cone of the conic bearing (small); 6–primary shaft; 7–cone of the conic bearing (big); 8–ring; 9–a bearing arm of the bearing; 10-persistent washer; 11-gear wheel of the 1st transfer; 12-needle bearing of a gear wheel of the 1st transfer; 13-ring of the synchronizer of the 1st transfer; 14-nave of the synchronizer 1-y/2-y of transfers; 15-lock ring; 16-ring of the synchronizer of the 2nd transfer; 17-external ring; 18-internal ring of the synchronizer; 19-gear wheel of the 2nd transfer; 20-needle bearing of a gear wheel of the 3rd transfer; 21-persistent washer; 22-plug of the needle bearing; 23-needle bearing of a gear wheel of the 3rd transfer; 24-gear wheel of the 3rd transfer; 25-ring of the synchronizer of the 3rd transfer; 26-nave of the synchronizer 3-y/4-y of transfers; 27-plug of the needle bearing; 28-needle bearing of a gear wheel of the 4th transfer; 29-ring of the synchronizer of the 4th transfer; 30-gear wheel of the 4th transfer; 31-persistent washer; 32-needle bearing; 33-transmission case; 34-basic plug; 35-plug; 36-gear wheel of the 5th transfer; 37-plug; 38-screw


establish a stripper so that its captures densely fixed a gear wheel of the second transfer and remove details from a shaft (fig. 8.21) ;
remove the rotating plug of the needle bearing and a persistent washer;
remove from a shaft a gear wheel of the 4th transfer, the needle bearing and the plug;
remove the synchronizer 3rd and 4th of transfers with rings. Note the provision of a nave — in the subsequent it will help you to establish it correctly;
remove a gear wheel of the 3rd transfer, the needle bearing and the plug;
remove a persistent washer, a gear wheel of the 2nd transfer and the needle bearing;
remove external steel and internal rings of the synchronizer of the 2nd transfer. Mark their arrangement;
take a lock ring;
remove the block of a nave of the synchronizer 1-y/2-y of transfer from a shaft. At removal of the block be careful: try not to damage a synchronizer ring;
remove a ring of the synchronizer of the first transfer, a gear wheel of the first transfer and the needle bearing;
remove a bearing arm together with an external ring of the bearing and a washer;

Fig. 8.22. The bearing support in the zone "and" can be width of 3,8 mm or have the dredging specified by an arrow


for removal of conic bearings from a secondary shaft the special tool is required. In case of need their dismantle address for the help to specialists of specialized service station. For removal of a support of bearings from a shaft it is necessary to use a stripper with two captures, it is necessary to establish a stripper under a bearing support. It is necessary to establish a support of the changed design at which the thickness of a wall is equal 3, 8 mm (fig. 8.22) .

       PREVENTION
At replacement of the conic bearing to obligatory replacement its cone and a cup are subject.

Check of a technical condition of details carry out as follows:
inspect all details removed from a secondary shaft. If it is necessary, replace the damaged or worn-out details;
check a condition of naves of synchronizers. In case of their complete dismantling use a piece of a fabric not to allow loss of small parts;

Fig. 8.23. Check of an internal ring of the synchronizer of the 2nd transfer


Fig. 8.24. Check of an external ring of the synchronizer of the 2nd transfer


check wear of rings of the synchronizer (fig. 8.23 and 8.24) . For this purpose, having arranged a ring on naves, press them to the plug and shchupy measure a gap between an internal surface of a ring and a surface of the plug adjacent to it. If the gap exceeds the specified limit, replace synchronizer rings.
Dismantling and assembly of the synchronizer carry out in the following order:

Fig. 8.25. Absent tooth (it is noted by an arrow) on a ring of the synchronizer of the 1st transfer


Fig. 8.26. An arrangement of dredging (are noted by shooters) in a ring of the synchronizer of the 2nd transfer


for dismantle of the synchronizer designate the provision of a nave in relation to the coupling, and also an arrangement of springs and three blocking crackers labels for their correct installation. Pay attention that the ring of the synchronizer of the first transfer has characteristic — lack of three teeths on a gear surface (fig. 8.25) . The ring of the synchronizer of the second transfer has three dredging for installation of internal lock rings (fig. 8.26) ;

Fig. 8.27. Synchronizer 1 and 2nd of transfers: 1 — a spring; 2 — a cracker; 3 — a synchronizer nave; 4 — the sliding coupling


Fig. 8.28. At installation of the synchronizer 1 and 2nd of transfers wider fillet should be directed to a gear wheel of the 1st transfer


for synchronizer assembly (fig. 8.27) 1-y/2-y of transfers check, that directing cracks for crackers on the sliding coupling and a nave settled down opposite to each other. Wider fillet should be directed on the first transfer (fig. 8.28) . Crackers and springs should be placed through equal intervals (120 °);
for assembly of the synchronizer 3-y/4-y of transfers check, that at plug installation on a nave grooves of a cracker of blocking of a nave and the plug were combined. The Vnutreny surface of a nave having dredging, should be turned to a gear wheel of the first transfer. Crackers and springs should be placed through equal intervals (120 °).
Installation of details on a secondary shaft carry out in the following order:
establish new ring consolidations on racks of a bearing arm of the bearing and establish an arm on a shaft;
establish a thin washer of the bearing a ledge to the bearing;
establish the needle bearing and a gear wheel of the first transfer;
establish a ring of the synchronizer of the 1st transfer;
establish directing plug 1-y/2-y of transfers by a flute to the first gear wheel and впрессуйте it into place a piece of a pipe of suitable diameter;
flat-nose pliers place a lock ring in a flute on a shaft;
establish an external ring of the synchronizer, an intermediate ring and an internal ring of the synchronizer in the operating plug 1-y/2-y of transfers;
establish on a shaft the needle bearing;
establish on a shaft a gear wheel of the 2nd transfer and a persistent washer;
press the plug of the needle bearing of a gear wheel of the 3rd transfer on a shaft by means of a piece of a pipe of suitable diameter;
establish on a shaft the needle bearing;
establish on a shaft a gear wheel of the 3rd transfer;
establish a synchronizer ring on a gear wheel of the 3rd transfer;

Fig. 8.29. The flute on an internal surface of a nave of the synchronizer 3-y/4-y of transfers should be directed to a gear wheel of the 4th transfer


establish the nave block 3-y/4-y transfers, watching orientation (fig. 8.29) ;
press a nave into place a piece of a pipe of suitable diameter, watching thus that its ledges coincided with synchronizer grooves;
establish a ring of the synchronizer of the 4th transfer and the plug of the needle bearing of a gear wheel of the 4th transfer;
establish the needle bearing and a gear wheel of the fourth transfer;
having placed a persistent washer opposite to a gear wheel of the fourth transfer, впрессуйте the plug.