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 of switching if it is worn out 15. A leading shaft 16. A lock ring 17. A washer 18. A gear wheel of transfer of a backing 19. The needle bearing of a conducted gear wheel of transfer of a backing 20. A persistent washer

Leading shaft in gathering

1. Carter of a transmission 2. The plastic plug Always replace Is absent on the leader to a shaft on which there are lubricant apertures for Z-ej/no 4th transfers 3. The needle bearing – a leading shaft It is damaged at removal Always replace To establish by means of tool VW416V on depth in 214 mm, measuring from a surface картера 4. A lock ring Specify a demanded thickness at replacement of a gear wheel of 5th transfer 5. A gear wheel of 5th transfer 6. Игольчаты the bearing – 4th transfer 7. A gear wheel of 4th transfer 8. A synchronizer ring – 4th transfer 9. Sliding муфта – 3-ja/4th transfers 10. A lock ring Specify a demanded thickness at replacement of a nave of the synchronizer 11. A synchronizer nave – 3-ja/4th transfers, acting ободок it is turned to a conducted gear wheel of 3 transfers

12. A lock ring 13. 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 14. The ball-bearing – a leading shaft 15. 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 16. Carter of the main transfer 17. The needle bearing – a leading shaft Establish by means of the tool 40-202 18. A leading shaft 19. The needle bearing – 3rd transfer 20. A gear wheel of 3 transfers 21. A synchronizer ring – 3rd transfer

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The prevention

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

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Adjustment of a leading shaft

PERFORMANCE ORDER

1) fix a leading shaft in a vice with soft linings on sponges 2) establish And, распорную a plate 3167, on 3rd transfer 3) establish картер on распорную a plate having put on it a leading gear wheel 4) establish глубиномер on картер and measure distance to the bottom flute on a shaft 5) the size and = 28.5 mm 6) establish глубиномер on картер and measure distance to a ball-bearing installation site The size b = 26.8 mm 7) define a necessary thickness of the bottom lock ring The size х х = a – b х = 28.5 mm – 26.8 mm = 1.70 mm 8) define a necessary thickness of a lock ring from the table 9) establish a lock ring and the ball-bearing on a shaft with the help оправки 30-100 10) find a lock ring of the biggest thickness which it is possible to insert (values of a thickness of lock rings are reflected in the table) 11) establish выжимную a plate of a stripper 3128 under an external holder 12) establish lath VW 771/29 and establish a bolt on картер transmissions 13) at a bolt twisting the external holder acts in film with картера

The size	Thickness	Number
1.64 – 1.71	1.69	902 941.05
1.72 – 1.79	1.77	902 941.06
1.80 – 1.87	1.85	902 941.07
1.88 – 1.95	1.9	902 941.08
1.96 – 2.03	2.01	902 941.09
2.04 – 2.11	2.09	902 941.10
2.12 – 2.19	2.17	902 941.11
2.20 – 2.27	2.25	902 941.12
2.28 – 2.35	2.33	902 941.13

Thickness (mm)	Number
1.69	902 941.05
1.77	902 941.06
1.85	902 941.07
1.93	902 941.08
2.01	902 941.09
2.09	902 941.10
2.17	902 941.11
2.25	902 941.12
2.33	902 941.13

Leading gear wheel and hollow shaft

I. Carter of the main transfer 2. Washer S3 3. A decade 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. Двухрядный a conic roller bearing – an internal holder 6. A lock ring 7. The needle bearing – 1st transfer 8. A gear wheel of the first transfer 9. A synchronizer ring – 1st transfer 10. A synchronizer nave – 1-aja/2nd transfers Acting to an edge it is turned to 2nd transfer To remove together with a gear wheel of 1st пepeдачи, use persistent plates VW 401 and VW 402 Establish with the help оправки VW 415А and plugs VW 519 11. A lock ring 12. The needle bearing – 2nd transfers 13. Sliding муфта – 1-aja/2nd transfers 14. A synchronizer ring – 2nd transfer 15. A gear wheel 2nd transfers 16. A lock ring 17. A gear wheel of 3 transfers The flute is turned to a gear wheel of 4th transfer 18. A lock ring 19. A gear wheel of 4th transfer The edge is turned to a gear wheel of 3 transfers 20. A lock ring 21. The needle bearing – 5th transfer 22. A gear wheel of 5th transfer

23. A synchronizer ring – 5th transfer 24. A lock ring 25. A synchronizer nave-5th transfer / backing transfer The acting edge is turned to a gear wheel of 5th transfer Remove together with a gear wheel of 5th transfer Establish by means of the plug 2010 26. A lock ring 27. The needle bearing – backing transfer 28. Sliding муфта – 5th transfer / backing transfer 29. A synchronizer ring – backing transfer 30. A gear wheel of transfer of a backing 31. A conic roller bearing - an internal holder 32. The lock carving plug for an external holder of a conic roller bearing Its installation is not required at replacement of an external holder (this plug is necessary Only by manufacture) 33. A conic roller bearing – an external holder 34. Washer S4 35. A clamping plate 36. The washer compensates expansion depending on temperature (heating) For removal drill an aperture in a washer and remove by means of the screw 37. Carter of a transmission

Installation of an external holder двухрядного a conic roller bearing


Removal of an internal holder двухрядного a conic roller bearing, removal

PERFORMANCE ORDER

For removal of an internal holder the external holder And should be established.

Installation of an internal holder двухрядного a conic roller bearing

Installation of a spring of the synchronizer in a gear wheel

PERFORMANCE ORDER

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

Synchronizer ring, check on deterioration

PERFORMANCE ORDER

Press a synchronizer ring to sliding муфте and measure a backlash and with the help probeа for measurement of backlashes in points And, In and With Combine the received values and divide the sum on 3 The received value should not be less, than 0.5 mm

Installation sliding муфты – 1-aja/2nd transfers

The party with a flute should be turned to a gear wheel of 1st transfer.

Removal of a gear wheel of 3 transfers

And = a stripper on 22–115 mm, type Kukko 17/2

Installation of a gear wheel of 3 transfers

Installation position: the flute should be turned to a gear wheel of 4th transfer.

Removal of a gear wheel of 4th transfer


Installation of a gear wheel of 4th transfer


Removal of a nave of the synchronizer

Remove a synchronizer nave together with a gear wheel of 5th transfer. Use a stripper And on 22–115 mm, type Kukko 17/2.

Identification of a ring of the synchronizer

Manufacture of rings with more than 3 uvulas has been stopped.

Removal of an internal holder of a conic roller bearing

Remove an internal holder together with a gear wheel of transfer of a backing. Use a stripper And on 22–115 mm, type Kukko 17/2.

Installation of an internal holder of a conic roller bearing


Installation sliding муфты – 5th transfer / backing transfer

The diagonal strip 1 is turned to a gear wheel of transfer of a backing. The party with a flute 2 is turned to a gear wheel of 5th transfer.

Removal of the lock carving plug

Use a stripper And on 22–115 mm, type Kukko 17/2. Plug installation is not required at replacement of an external holder. (This plug is necessary only by manufacture.)

Removal of an external holder of a conic roller bearing

PERFORMANCE ORDER

Twirl a special bolt for removal in выжимную a plate. Bolt М10 (length 50 mm), ground off on one end till the diameter М8. Remove выжимную a plate and an external holder with картера by means of a hammer.

Installation of an external holder of a conic roller bearing


Installation of a lock ring of a conic roller bearing

PERFORMANCE ORDER

Find a lock ring of the biggest thickness which can be inserted, and establish it. The necessary thickness of lock rings of a nave of the synchronizer and thickness of lock rings of gear wheels 3-ej/4th transfers is defined also, as a thickness of a lock ring of a conic roller bearing.

Installation site and selection of lock rings

Lock rings are designated in drawing, they are numbered according to their position on the leader to a shaft. Lock rings 1, 2, 4, 5 and 7 it is necessary to select. The thickness of lock rings 3 and 6 is always constant (the Lock ring 3 (dark blue) and the table the Lock ring 6 (brown)) see the table

Lock ring 1

Thickness (mm)	Number
2.00	902 950.01
2.02	902 950.02
2.04	902 950.03
2.06	902 950.04
2.08	902 950.05
2.10	902 950.06

Lock ring 2 (dark blue)

Thickness (mm)	Number
1.90	902 947.01
1.93	902 947.02
1.96	902 947.03
1.99	902 947.04
2.02	902 947.05

Lock ring 3 (dark blue)

Thickness (mm)	Number
2.50	902 947.06

Lock ring 4

Thickness (mm)	Number
1.90	902 946.02
1.93	902 946.03
1.96	902 946.04
1.99	902 946.05
2.02	902 946.06

Lock ring 5

Thickness (mm)	Number
1.87	902 952.01
1.90	902 952.02
1.93	902 952.03
1.96	902 952.04

Lock ring 6 (brown)

Thickness (mm)	Number
2.00	902 945.01

Lock ring 7 (dark blue)

Thickness (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