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>> Transmission assembly
If adjustment axial люфта primary and secondary shaft and differential was not made, execute adjustment as it is described.
Assembly of a transmission carry out in the following order:
check, that internal and external surfaces of cases of a transmission and coupling were pure;
if it is necessary, replace the plug of a shaft of a starter for what by means of a stripper press from a shaft the old plug and by means of an opravka (a piece of a pipe of suitable diameter) press the new plug and grease it. It is possible to replace the plug, without removing a transmission;
arrange a coupling case so that the party from which coupling is established, appeared below;
grease bearings of differential and establish differential a gear wheel of a drive of a speedometer, in a case;
establish a secondary shaft in a transmission. Check, that on hairpins of fastening of a support of the bearing sealing rings were established, and the flat part of a support was directed to a backing gear wheel;
establish in a transmission primary shaft;
establish into place a kosozuby gear wheel of a backing then establish a backing shaft. Enter teeths of a pryamozuby gear wheel of a backing into gearing with the corresponding gear wheel on secondary to a shaft;
having established forks of inclusion of a reverse gear over a pryamozuby gear wheel of a backing, combine an opening in the holder of a fork with a carving opening in a case and screw the holder of forks a bolt, having tightened it the demanded moment;

Fig. 8.43. Arrangement of screws of fastening of the holder of a shaft of a backing: 1–the cross-section; 2– the longitudinal


establish laying and the holder of a shaft (fig. 8.43) of gear wheels of a backing;
establish the main unit of forks of gear shifting, thus tips of forks should be established in flutes of sliding rings of synchronizers;
temporarily turn out carving hairpin М8х100 in the holder of a shaft of a reverse gear and combine selector plates. Forks of gear shifting should enter into flutes of sliding couplings;
establish a magnet in a nest in a transmission case;
apply a thin film hermetic on interfaced surfaces of cases of a transmission, combine transmission and coupling cases and screw bolts, having tightened them the regulated moment;
after assembly of a case of a transmission establish screws of the holder of a shaft of a backing for what screw at first the cross-section screw 1 (see fig. 8.43 ). turn out the carving hairpin screwed in a case of a transmission, and screw the longitudinal screw 2. Tighten screws in sequence at first the screw 2, and then the screw 1. Togkh-otvertka is for this purpose necessary. Use only new screws;

Fig. 8.44. Installation of the directing plug of the vyzhimny bearing


establish directing plug (fig. 8.44) of the vyzhimny bearing and fix it bolts, having tightened them the demanded moment. At installation of the directing plug of the vyzhimny bearing, it is necessary to establish a new sealing ring;

Fig. 8.45. Alignment of axes of forks by means of a screw-driver and a pin


for alignment of axes of forks (fig. 8.45) and installations of pins of forks of inclusion of transfers establish a screw-driver in a window of a transmission and сориентируйте switching mechanism that it was possible to establish pins;

Fig. 8.46. Installation of a shaft of the mechanism of a choice of transfers: 1–shaft; 2– dredging on the case; 3– ledge


establish a shaft of the mechanism of a choice of transfers (fig. 8.46) in neutral situation and establish a shaft so that the ledge on it took place in dredging on the case. Move a shaft so that the finger of a shaft was established in an opening of levers of forks of inclusion of transfers, and tighten bolts of fastening of a shaft the regulated moment;
establish a cover closing the mechanism of gear shifting and tighten bolts of fastening of a cover the regulated moment;
establish a cover of a shaft of the mechanism of a choice of transfers;
establish a transmission a coupling case down;
establish a conducted gear wheel of the fifth transfer, previously its heating to 100 °C;
establish on primary shaft the needle bearing of a leading gear wheel of the fifth transfer then establish a gear wheel and a ring of blocking of the synchronizer;
establish a spring on a ring of blocking of the synchronizer;

Fig. 8.47. Slanted teeths on the sliding coupling of the synchronizer should be directed to a gear wheel of the 5th transfer


establish a nave of the synchronizer and the sliding coupling of the synchronizer so that slanted teeths on the sliding coupling were directed to a gear wheel of the fifth transfer (fig. 8.47) ;
establish washers on conducted and conducting gear wheels of the fifth transfer and fix them bolts, previously having put on a carving of bolts the means interfering their otverchivaniye. At a tightening of bolts of fastening of gear wheels of the fifth transfer block gear wheels from a provorachivaniye, simultaneous inclusion of the fifth transfer and backing transfer;

Fig. 8.48. Elements of the mechanism of inclusion of the fifth transfer: 1– fork of inclusion of the fifth transfer; 2– lever of moving of a fork of the fifth transfer; 3– spring; 4– synchronizer ring; 5– the sliding coupling of the synchronizer; 6–gear wheel; and – a gap equal of 1,2 mm


establish and adjust the provision of a fork 1 (fig. 8.48) of inclusion of the fifth transfer. Previously establish tips of forks of the fifth transfer to a flute of the sliding coupling of the synchronizer and screw pins of a fork of inclusion of the fifth transfer;

Fig. 8.49. Adjustment of provision of a fork of inclusion of the fifth transfer: And – щупы in the thickness of 1,2 mm; 1–bolt of fastening of the lever. The arrow specified the direction a fork otzhatiya at adjustment


having included the fifth transfer, insert from two opposite sides between the sliding coupling of the synchronizer and a gear wheel of the fifth transfer two щупа in the thickness of 1,2 mm and, having pressed a back part of a fork of inclusion of the fifth transfer in the direction from a transmission case, tighten a bolt of fastening of the lever of moving of a fork of the fifth transfer (fig. 8.49) ;
clear a surface of a case of the transmission, interfaced to a cover of the fifth transfer, establish laying and a cover of the fifth transfer and fix a cover bolts, having tightened them the regulated moment;
establish the block of a drive of a speedometer;
if there is a need, establish new sealing rings of differential;

Fig. 8.50. Installation of new spring lock rings on a drive flange


establish new lock rings on drive flanges, put on working edges of sealing rings of differential a layer of greasing and establish drive flanges in a transmission before accurate fixing them lock rings (fig. 8.50) ;
establish the lever of switching off of coupling and vyzhimny the bearing;
establish a support of fastening of a transmission;
establish an arm of fastening of cables of gear shifting.







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