Contents: Clutch type ↓ Transmission ↓ Four-speed gearbox ↓ Five-speed gearbox (mm) ↓ Tightening torques for threaded…↓
Clutch type
- Engines 1.1/1.3 l - Single disc, with diaphragm spring and adjustable cable drive
- Engines 1.5/1.6/1.8 l - Single-disc, with diaphragm spring, drive disc mounted directly on the crankshaft
- Clutch pedal free travel: 15-20 mm
Transmission
- Standard - four or five speed
- Formel E 1.1/1.3 — 3 + E
- Formel E 1.5 - 4 + E
Four-speed gearbox
- The gap between the synchronizing teeth of the gear and the locking ring of the synchronizer is not less than 0.5 mm
Dimensions of the adjustment shims of the reverse lock (mm)
- Yellow - 2.0
- Shiny - 1.8
- Blue - 1.6
- Brown - 1.4
- Gray - 1.2
- Axial clearance of gears (mm) — 0.15—0.40
Dimensions of secondary shaft thrust washers (mm):
- 084311 154D — 2.83
- 084311 154E — 2.90
- 084 311 164B/164C (production discontinued) — 2.80/3.00
- Axial clearance of primary/secondary shaft (mm) 0—0.05
- Dimensions of small adjustment shim of primary/secondary shaft bearing (mm) — 1.75—2.05 with interval of 0.05 mm
- Dimensions of large adjustment shim of primary/secondary shaft bearing (mm) - 0.45-1.30 with interval of 0.05 mm
Differential Bearing Shims (mm):
- Gasket 1 - 1 mm
- Bearing preload - 0.30 mm
- Gasket 2 - 1.00-2.35 mm with an interval of 0.05 mm
Five-speed gearbox (mm)
- Axial displacement of third gear pinion — 0—0.20
Gear adjusting stop rings (thickness):
- Brown - 2.5
- Black - 2.6
- Brilliant - 2.7
- Copper - 2.8
- Brass - 2.9
- Blue - 3.0
The gap between the synchronizing teeth of the gears and the synchronizer locking ring - on a new gearbox:
- First and second gears - 1.1-1
- Third gear - 1.15-1.75
- Fourth and fifth gears - 1.3-1.9
- Minimum acceptable - 0.5
- Secondary shaft front bearing adjusting shims - 0.65-1.40 with 0.05 mm interval
[View the original on this portal: VWmanual.ru]
Torque required to rotate the secondary shaft:
- New bearings - 50-150 Ncm
- Previously in operation 30 Ncm minimum
Fifth gear locking force:
- On the gear selector lever - 10 kg
- On the gear shift lever - 4 kg
- Dimensions (thickness) of differential bearing adjusting shims: 0.15/0.30/0.60/0.70/0.80/1.0 mm
The value of the torque required to rotate the differential:
- New bearings - 120-350 Ncm
- Previously in operation - 30 Ncm
Tightening torques for threaded connections (kgm)
- Fastening the clutch drive disc to the flywheel (1.1/1.3 l) — 2.5
- Fastening the drive disc to the crankshaft (1.5/1.6/1.8 l) — 7.5
- Fastening the flywheel to the drive disk (1.5/1.6/1.8 l) — 2.0
- Axle Flange Bolt (1.1/1.3L) - 2.5
- Gearbox to engine mount - 5.5
- Fastening the drive shaft to the axle flange - 4.5
- Bolts for fastening the clutch housing to the gearbox housing - 2.5
- Gear Selector Lever Clamp Bolt - 2.0
- Reverse gear lever bolt (four-speed gearbox) — 3.5
- Drain plug - 2.5
- Control and filling hole plug-2.5
- Fastening the left support to the transmission - 2.3
- 5th gear synchronizer hub bolt - 15.3
- Fastening the main gear pinion to the differential housing - 7.2
- Primary shaft bearing retaining plate - 1.5
- Secondary shaft bearing retaining plate - 4.1
- Rear End Cap Bolts - 1.5
- Gear shift lever brackets (posts) - 2.5
- Reverse Light Switch - 2.5
- Gear Shift Sensors - 2.5
- Reverse idler gear axle screws:
- Four-speed gearbox - 2.1
- Five-speed gearbox - 3.0
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