In detail: do-it-yourself repair of a Volkswagen T2 gearbox from a real master for the site my.housecope.com.
Here are photo reports on repair and detailed documentation on cars:
Volkswagen T2 Type 2 / Volkswagen T2 Type 2 (model code: 211, 214, 215, 216) 1968 - 1979
Volkswagen Type 2 Microbus T2 / Volkswagen T2 Type 2 Microbus (model code: 221, 224, 225, 228) 1968 - 1979
Volkswagen Type 2 Kombi T2 / Volkswagen T2 Type 2 (model code: 231, 234, 235) 1968 - 1979
Volkswagen Type 2 Microbus Deluxe T2 / Volkswagen T2 Type 2 Microbus Deluxe (model code: 241, 244, 245, 246) 1968 - 1979
Volkswagen 1.9L Digijet (63/66 kW) Engines: DH, GW (ger.) Repair of DH, GW engines on Volkswagen Transporter 1983 - 1985
Volkswagen 1.6L 2.0L Engines: CS, CT, CU, CV, CZ (ger.) Repair of CS, CT, CU, CV, CZ engines on Volkswagen Transporter 1981 - 1989
Information on the repair of engines VAG / Engines repair
This engine repair information applies to all VAG vehicles. In order to quickly find the documentation for your engine, simply press Ctrl-F on the keyboard and type the letters of your engine. For example: 2E or BSE (English only!)
Cooling, heating, ventilation and air conditioning system
(Cooling, Heating, Air Conditioning and Climate Control Systems)
Injection and ignition systems
This information on injection systems applies to all VW, Skoda, SEAT, Audi vehicles.
General information on ignition systems
Suitable for many cars VW, Skoda, SEAT, Audi
General information on fuel systems
Suitable for many cars VW, Skoda, SEAT, Audi
General Suspension Information
Suitable for many cars VW, Skoda, SEAT, Audi
Video (click to play). |
Information on the repair of gearboxes VAG / Transmission repair
This gearbox repair information applies to all VAG vehicles.
Volkswagen T2 Station Wagon / Bus 1968 - 1979. Official repair manual (eng.) Factory repair manual. Developer: Volkswagen of America Inc. Published by Robert Bentley. 41 MB., 492 pages.
VW Transporter 1982-1992 (rus.) Repair and maintenance manual for Volkswagen Transporter T2 1982-1992, equipped with 1.6l diesel engines. 1.7L, turbo diesel engines with a working volume of 1.6L, gasoline engines with a working volume of 1.9L, 2.1L. The book examines the methods of repairing VW Transporter cars 1980-1990 (including the all-wheel drive model Syncro), as well as typical malfunctions, their diagnosis and elimination. The design of cars is described in detail, various assembly and disassembly operations, repair and adjustment work on cars are consistently and in detail. 221 p. 103 Mb. VW Bus T2 t2A t2B Volkswagen Vanagon Repair Manual (ger.) Repair manuals. 37 Mb
If you did not find information on your car, look at the cars built on the platform of your car.
With a high degree of probability, the information on repair and maintenance will be suitable for your car as well.
All documentation in English is marked (eng.), In German - (ger.)
For everyone who has a Volkswagen, hands and the desire to do something with them.
For all who has Volkswagen, hands and desire to do something by them.
Current time: 10/18/18, 13:00
Pitman "31.10.08, 16:59 Problems with the gearbox on T2
MAX 2 » 31.10.08, 17:57
RT » 31.10.08, 18:03
Pitman » 31.10.08, 19:46
rimmT3 » 31.10.08, 20:30
busya T3 1.8mono 88g (red and very hardworking))
MULT T3 2.1i 90g (BLUE STAR-Hannover edition but how :-)
MB-123/230-very rare hearse..79)
Teshka78 » 31.10.08, 20:37
VW Multivan 1987 1.9TDI (was)
Vw Multivan 2001 2.5TDI
Pitman » 31.10.08, 22:29
Dmitriy » 31.10.08, 22:43
Pitman » 01.11.08, 09:32
apots » 01.11.08, 12:33
pitmanf2d »16.11.08, 23:46 Re: Problems with the gearbox on T2
Cars change, friends and the forum remain. [my.housecope.com/wp-content/uploads/ext/1209]
Message VladimerT2 »11 Sep 2009, 23:37
Message tereleg 12 Sep 2009, 00:32
Message VladimerT2 "12 Sep 2009, 22:30
Message sergei 61 04 Dec 2009 09:29
Message victorvwv »06 Mar 2011, 13:22
Message dima_danila »19 Mar 2012, 13:25
Message alex120945 »22 Mar 2012, 12:44
The Volkswagen 02T gearbox is extremely compact.
It has 5 gears and is used on front wheel drive vehicles.
The Volkswagen gearbox is a two-shaft design with an additional axle for the reverse gear.
The gears of the primary and secondary shafts are helical with constant mesh.
All carriage gears are on needle bearings, which results in a high smoothness of the movement.
Reverse gears are spur gear.
The inclusion of the 1st and 2nd gears is carried out on the input shaft, the 3rd, 4th and 5th gears - on the secondary shaft.
To engage reverse gear, there is a reverse idler gear on a separate axle between the input and output shafts, which changes the direction of rotation of the output shaft.
All transmissions are synchronized; 1st and 2nd gears are double synchronized.
The torque is transmitted through the pinion of the output shaft (pinion of the final drive) to the driven pinion of the final drive and thus to the differential.
Input shaft bearings: cylindrical roller bearing in the clutch housing (movable fit) and deep groove ball bearing (fixed fit) in the end shield of the gearbox housing.
To reduce the mass of the input shaft, deep longitudinal drilling is made in it.
The primary shaft is made in the form of a block of gears of the 1st and 2nd gears, a reverse gear.
On the input shaft, gears-carriages of the 3rd, 4th and 5th gears are freely installed on needle bearings.
The hubs of the 3rd / 4th and 5th gear synchronizers are rigidly fixed to the splines of the input shaft.
After engaging a gear, the corresponding carriage gear is connected to the input shaft.
The gears-carriages are held on the input shaft by means of circlips.
The checkpoint is the only unit on the Omega, inside which I have not yet climbed. And it so happened that this is the first unit of the Conveyor, which I had to climb into. Actually, this did not come as a surprise to me. It became an unpleasant incident. I knew it was going to happen, but I didn't know when. And I really didn't want to go into the box to prevent it.
It all started with buying a car. At the dealer's site, she behaved perfectly, there were no complaints. But when he drove her home. A hundred kilometers later, an ever-increasing roar was heard from the box, the gears began to be switched on very hard. I was already starting to figure out options for how to take the car in tow to reach home, but a friend we drove with persuaded me to call the dealer and return the car to him to fix the problem. With a creak, but the car was taken. They promised to fix everything.
The next day, the dealer already phoned that everything was in order, everything was working. When I was picking up the car, he said that there was almost no oil in the box, and “I had to replace this one. hammasratas (gear) ”.
The car really behaved remarkably, the gears shifted perfectly, only on the fifth from the very first kilometers a thin whistle appeared. The car was needed all the time, I didn't want to bother with problems at all, and I diligently drove away from myself the idea that gears should actually be replaced in pairs.
The transporter drove, whistled. After 3-4 thousand kilometers, I suddenly noticed a strip of oil flowing to the ground along the inner surface of the right front wheel. I discovered an amazing thing: oil flows from the boot of the inner CV joint through a small neat hole, flows down the drive shaft to the outer CV joint, to the steering knuckle, to the wheel disk and then to the ground. Where did the liquid oil come from in the CV joint? After all, there should only be a grease that does not flow! However, this time too, despite the distinct "transmission" smell of oil, I closed my eyes to it. I just wrapped the boot with electrical tape and secured it with an additional clamp. No more oil flowed out of it.
After 8000 km, the whistle of the fifth gear began to gradually turn into a crackling sound - the “jet plane” was reborn into a “tractor”. But another thousand kilometers passed before. One fine evening, when the fifth gear was turned on, the Transporter jerked, made a loud crunch, and then continued coasting, rattling and clanking. They sailed. What to do? I tried lower gears - they are included. Gently turned around and in first gear "crawled" back to the house, fortunately drove off not far, a couple of kilometers. That's it, now you can't get out. The box is in the bulkhead.
I built such a mega-structure from my universal puller in order to pull out the left wheel drive shaft after (.) I heroically pulled off the “stocking”. Note that the lower half of the gearbox has been removed and that all gears and shift forks remain in the upper half. They are not released by the gear wheel of the main drive, and it, in turn, is held by the flange of the drive of the right wheel.
Finally I pull out the right flange. But again he made a difference with a puller. Everything could be done much easier.
Below is the correct sequence for disassembling the box.
So, we have disassembled the box in detail, washed and cleaned from all sides as much as possible, and even better. Remains of sealant are carefully cleaned off from all parts. The magnet inside the box body is free from dirt and adhering metal shavings. If there is a compressor, it is a good idea to blow out all bottlenecks. If not, flushing the slots and small bearings with a carburetor cleaning fluid in an aerosol can helps a lot. Old oil seals were taken out of their nests and discarded, new ones were purchased. If any bolts are damaged, buy new ones. We also need a transmission sealant and a surface degreaser (acetone).
If the checkpoint was disassembled without problems, then the assembly of its problems will not cause either. However, I would not write the phrase “assembly is the reverse procedure of disassembly”.
The first question that arose before me was how to roll a Transporter onto the overpass with an inoperative engine. I solved this problem with the help of Omega, two towing ropes and a manual winch. For safety reasons, Omega put spacers between the overpass and the rear bumper - so that the overpass does not go forward during the ascent. For this, I hooked the second towing cable not to the front towing eye, but to the Transporter's hitch. In this position, the cable does not press the nose of the car against the overpass, but, on the contrary, even slightly relieves the front axle.
For some reason, looking at the work ahead, you imagine that everything can be done quickly enough. This is this way, this is this way, no problem. And when you take up the instrument. I dragged the transporter onto the overpass on Friday at 18:00 to install the box. He left it on his own only at 6:00 am on Saturday. The result of this night - four dead light bulbs in a carrier, hands smeared to the elbows with oil, mud and brake, and wild delight that I still defeated him!
Volkswagen Transporter model T 2 release from year to year. It is driven from the crankshaft through a helical gear and rotates twice as slowly relative to the crankshaft.
Manuals → Volkswagen → Transporter. The structure and operation of the gearbox. Power is transmitted to the main drive shaft via two gear shafts.
50 advertisements for the sale of Volkswagen T 2 (Transporter) with manual / manual transmission. Announcements Sale Volkswagen T4 (Transporter) cargo.
This box knocked out the second one. When he ruled the stopper, he also disassembled it. The drive and epicyclic gears of the main drive are cylindrical. They can be replaced after removing the cylinder head.
The backstage in Techiki is a misfortune ... it is long, there are many different elements responsible for the normal engagement of gears ... And as often happens after repairs, some masters have patches, they say they are there to support the pants, but as a result, when the car falls into normal hands, it turns out that everything is very sad.
In this article I will describe how I changed the wings, since my gear shifting turned into agony .. I will give a visual diagram of the gear shifting mechanism, and in particular the front part .. do not let down aluminum or some other alloy. Used to direct the flow when the R-1 and gears are engaged. In their absence, it is very difficult to get into the desired gear. So I had them half erased and therefore it was very difficult to turn on the gear.
I welded them with argon and adjusted them to the desired size .. I don't know why, but I had it for a short one, and that's why it fell out and corked the lever. I had to create a new piston only for mm, I don’t remember exactly longer .. I will give a diagram of the rear end mechanism .. Here the situation is much simpler. Wherever the curtain has friction, you need to clean out the dirt and anoint it well.
This boot was completely unstuck and everything was clogged with dirt, which made it very difficult to switch gears. It would be nice to replace it, well, and all the other anthers on the wings - but I have not looked for them anywhere. I just cleaned everything up, smeared it over. We have to do this quite often, since the anthers on the wings are quite weak. I'll have to look for them. After such simple procedures, the transmissions are switched on very easily and pleasantly. Good luck in the repair ... I hope this info will help you ....
Part four: complete disassembly, sandblasting VW T 2.
In this part, the story of the restoration of the 1972 Volkswagen T 2 b minibus continues. All previous articles have described the preparatory steps, and in this article, the beginning of the recovery process.
After purchasing the donor, the next step was to determine where to start the repair. Time passed, summer passed the middle, an inner voice pushed to more active actions.
On reflection, it was decided to start repairs in two directions at the same time:
- to carry out mechanical repair of the chassis, brakes, steering.
Having taken from Alexander the phone number of the masters whom he advised, I immediately phoned them and we agreed to meet on Wednesday morning. On Wednesday, July 24th at 9:30 am, I gave them our copy. After a detailed inspection, to my great happiness, the guys agreed to take our bus for repair! We discussed the cost and timing. According to their forecasts, the body repair of the bus will be at least 6 months. They advised to completely sandblast the bus! To my remarks that the crystal lattice of the metal is changing, electrons are knocked out, etc. etc., they laughed and told me to trust their experience and that everything would be fine. I, in turn, promised to deliver them the "patient" in a day, on Friday, disassembled and sandblasted. On this and said goodbye. On the same day, I began a search for where I could sandblast the bus completely, since I had only two days to search, completely disassemble and sandblast the bus.
There are still pluses in the fact that we live in the XX-I century. I searched Google for “sandblasting” and got enough suggestions to analyze. It only remained to process the received data. After several phone calls, the place for processing the bus was chosen: Konstantin, the owner of the business and the direct executor, very well told how the work on sandblasting is being carried out and politely, which is not unimportant, answered all my questions from an amateur. As a result, I promised to deliver the bus to them on the territory on the street. Wheat (Bogschagovka) on Friday at 9.00. There was only one day left - Thursday for a complete disassembly and search for a tow truck for transportation.
On Thursday, July 25th, having completed all the urgent and planned tasks in the office, at about 2.30 pm, we began to dismantle. It was very hot, but the work was in full swing. Several photos of the bus disassembly.
In this driver's seat, I will have to "steer" for more than two hours. We removed everything that could be removed from the bus: all the wiring, locks, took out all the windows, dismantled the doors. Everything did not always go smoothly, a lot of fasteners rusted. Sometimes it was necessary to use "brute physical force" to overcome resistance. At the German Motors station they dismantled the gearbox and axle shafts.
By half past seven in the evening, the bus was fully prepared for sandblasting.
Another problem was solved a little earlier in the day - a tow truck. One random call provided an answer to the question of how to get the bus for sandblasting, which was about 12 km from our territory. Igor Kuts, my old friend, called, on pressing problems - the purchase of spare parts. During a telephone conversation, I asked Igor if he would advise on where it would be better to order a tow truck. While working as a director at ViDi Automarket, he often has to deal with the transportation of cars due to his duty.To this Igor asked if the bus has brakes, I answer the brake, only on one front right wheel. Igor immediately offered to tow our bus from Lukyanovka to Borschagovka on a "tie"!
Knowing Igor as an amateur - an extreme (we jumped with a parachute and a paraglider) and being himself to some extent a lover of light extreme sports and thrills, I agreed without hesitation for a long time. On this and decided. Thus, the issue of transportation was resolved.
After the bus was disassembled and prepared for further operation, by sandblasting, being in a great mood, we took several photos.
By eight on Thursday evening, we had finished the photo session as well.
Having parked the bus, we put it on the "handbrake", in the literal sense of the word, because the blocks under the front wheels were placed by hand.
The bus stayed overnight at the exit from the territory. The warm night of July 26, without a doubt, was his last night in red! In less than a day, or rather 18 hours later, he will permanently throw off this "red suit" (soil + rust).
The next morning Igor hooked up with his Nissan Navara bus and at exactly 7.00 a start was made for sandblasting. The first meters of the way, adaptation.
We drive up to Pshenichnaya street. The hand on the door is not a sign of relaxation, but a real need to hold the door.
Scheme of the route taken.
They uncoupled the "tractor", the bus was left to wait for its fate. A game of shadows.
Here is the "cockpit" in which I spent 34 minutes. The steering wheel rests on a thin plate that "walks" in all directions. Recaro seat and one pedal - brakes one wheel.
The day before, they forgot to remove the fuel tank, we had to remove it right on the spot, because it cannot be sandblasted.
The condition of the bus is "no makeup". Now, six months later, it’s even scary to see what condition he was in. Is it possible to clean all this differently than sandblasting.
That's it, the "patient" is ready for surgery. The last photo in the "red suit". At 8.28, exactly 12 hours ago, we finished disassembling it and now it is already at the next stage. The whole process of transportation from st. Khokhlov family to st. Pshenichnaya (with a stop for a photo session), as well as removing the tank took 1 hour and 28 minutes. We left the bus and left. There was a working day ahead.
Konstantin (sandblaster) promised that everything would be finished by 15.00. One more task for the current day, in addition to the main job, was to find a tow truck, because after sandblasting, the bus had to be delivered to Brovary, which is about 40 km, and even on Friday at the end of the working week.
The main work that day was in the background, no matter how hard I tried, all thoughts were about the bus. At 11 o'clock in the morning, I decided to take care of the tow truck so that I would be ready to pick up the bus at any moment. As soon as I started calling companies providing tow truck services, fifteen minutes later Igor Kuts called and asked how I plan to deliver the bus to Brovary? I said that I was looking for a tow truck, to which he asked if I wanted to repeat the morning feat? I said that it would be impossible to repeat the same feat on Friday night! Nevertheless, the desire for thrills was already taking over. I asked Igor why he offered me this? (I remembered an excerpt from the series Interns, where Lobanov asked Romanenko if he had forgotten to turn off the iron?). After ten minutes of conversation, the decision was made: from Borschagovka to Brovary we again pull the bus with Navara and this is in Kiev, Friday evening. Even now, that decision seems to me very courageous, to be honest, even somewhat absurd.
At 15.30 Konstantin called and said that in half an hour the bus would be ready! After that call, there was nothing to think about work. Yura Vasilenko and I got together and went for the bus. Half an hour later at 16.02 we were already there!
This is how we saw the bus AFTER... And so he was in 6 hours and 30 minutes BEFORE.
The mood was excellent, it seemed that today we have laid the foundation for an excellent result of the future renovation.
Inspection. Visually, there was a feeling that we had changed the car.
Konstantin was clearly pleased that the customers were satisfied. Together with the body, the accompanying parts were also sandblasted: both parts of the dashboard, bumpers, grilles, sliding door lining.
A casual conversation ensued about the renovation budget. Then I thought that I would "fit" in 15 thousand USD.
View of the "modified", if not the raped interior partition.
They pushed the bus out of the factory by hand.
We began to wait for Igor with Nissan.
In order to pass the time, we took a few souvenir photos.
An autopsy revealed previously unnoticed corrosion effects.
Such a transformation could not but please.
This view on the left is clearly more pleasing to the eye than the photo on the right before processing.
Traces of deep corrosion and handicraft repairs have become even more visible. The number of patches on the body was probably beyond the power of anyone.
"Workplace", after which I had to drive another 40 km along the streets of Kiev at rush hour.
As they say - the expectation of death is worse than death itself. The waiting time for the tug dragged on very slowly.
The son, Dima, also modeled himself as a driver.
Igor arrived at 17.50. His attention was drawn to an abstract drawing of putty and several layers of paint on the doors of the bus.
We hit the bus and were ready to go to Brovary. Even now, six months later, that trip seems insane to me. The start was given at exactly 18.00.
At the start, when we drove through the empty back streets of Borschagovka, it was fun.
We can say that the unused body parts even interfered with the control of the bus.
Standing at a traffic light, the unused parts of the body became larger.
So I informed the tug that everything was in order. I no longer had any other possibilities besides gestures.
When leaving the district, in the direction of Odessa Square, they immediately stuck in a traffic jam.
During the jam, the drivers who were dragging along the neighboring lanes whiled away the time gazing at our rarity. "Especially cultured" were pointing fingers.
The speed was small, everything was fine.
An auto transporter with brand new cars stopped nearby. Someone is just beginning life, and someone has got a chance and is on the way to a second life.
After the congress to Odessa, the traffic jam was left behind. Igor put on the gas, and I barely caught the bus at the entrance to the overpass over Odessa Square, squeezing the steering wheel so that it seemed that water would drip from it.
We passed Vydubychi and I looked at the time for the first time. It was 19.00, exactly one hour on the way.
We are crossing the Dnieper, the flight is normal. It was sunset time and the sun was leaning towards the horizon, you could take off your glasses. Taking them off, I immediately put them back on. Such a large stream of sand and dust at such a low speed! What kind of abrasive flow does the paintwork of a car lend itself to during daily use? I stayed with my glasses on until I arrived at my destination.
Overall, the ride went well. Igor turned on the cruise control at an acceptable speed for me. From time to time I changed my position on the trumpet. The doors were tied this time. All that remained was to hold the steering wheel and brake.
I was already beginning to feel victory over such a test, until a traffic policeman stopped us at the checkpoint between Kiev and Brovary! His claims were not unfounded. He rubbed his hands and invited me to the building for a "conversation." As soon as he began to tell me that I was driving without identification signals - stops, turns, at this time Yura was a little behind on the Passat, drove around our coupling and stopped. The traffic policeman noticed this and began to fuss. I said that it stopped our feet and turns. The traffic policeman really smiled, but did not loosen his grip. To my deep regret, he was absolutely right. I have except those. there was absolutely nothing in the passport: no stops, no turns. Only now I realized that there are not even NUMBERS! I offered to pay the fine on the spot, after which I handed him a receipt with Grushevsky. He grimaced, I said, I can send the bus to the fine area. I immediately reissued the receipt for Shevchenko. After this small incident, we continued our journey, there was just a little bit left.
We turn off the column from Brovarskaya Okruzhnaya.
There were only three hundred meters left and we went in the wrong place, turned into the "field".
I had to deploy the entire column.
After returning to the correct trajectory.
At 20.16 we arrived at the final point. The finish!
According to Google, we drove 45 km, which, together with the pit stop at the traffic police post, took us 2 hours 16 minutes (according to goolge, we had to spend only 48 minutes). However, I think that it is impossible to show the result declared by Google on Friday evening in Kiev. The guys who will restore the bus, seeing that we have dragged the bus in tow, are just "crazy" (I apologize for the French). You, they say, are crazy to pull the bus in tow, for such a distance, without numbers, almost without brakes, and even at rush hour. Feeling pride in the accomplished "feat", Igor and I answered that it was bright. Firstly, pass the strength test yourself, and secondly, go and attract the attention of absolutely all road users to yourself.
They rolled the bus into the box, where he will spend at least nine months! Again the analogy with a new life, but that's exactly what the craftsmen told me: “Six months for bodywork and three months for painting”.
I felt incredible relief. That's when people ask what happiness is, I can answer: “It’s when so many bright events fit in one day.” Returning home, tired, but with a sense of accomplishment, I thought about how amazing and unpredictable our life is. Even on Monday night, the task seemed difficult and difficult to accomplish. There was no ready-made solution. Nevertheless, after 4 days, by Friday, thanks to the accompanying luck and successful coincidence of circumstances, it was resolved.
I sincerely express my gratitude to Alexander Magradze for his support and advice in the matter of sandblasting and bodywork. It was thanks to his competent opinion and sincere commitment that I was able to gain confidence on the way to rebuilding our VW T2 bus.
P.S. I express my deep gratitude to my old friend, Igor, for the help in transporting our bus, as well as for the uncountable number of various emotions that were experienced by all the participants in our motorcade.
Duka Bogdan
Director of AvtoNova-D LLC
13.03.2013
Repairing T4 manual transmissions requires a number of special pullers and tools. Before starting repairs, we recommend that you weigh your strengths and skills against the volume of work, as well as check the availability of appropriate spare parts. Below are some guidelines for a successful repair.
- In case of wear or breakage, gear wheels are recommended to be replaced in pairs, otherwise the service life of new parts will be significantly reduced.
- Be sure to indicate the box code when purchasing. Despite the fact that outwardly the parts of all VW boxes are very similar, they differ in the number of teeth, splines (gear wheels, splined shafts), dimensions (which cannot always be determined at a glance), hardness, etc. - since Over the nine years of production of the Transporter T4 model, more than 27 modifications of five-speed gearboxes have been applied, it is impossible to describe in detail the repair of each modification within the framework of this manual.
In fig. 353 shows the structure of the gearbox housing. O-rings pos. 9, 16, as well as the input shaft oil seal pos. 8 are subject to mandatory replacement, replacement of the gasket pos. 11 - recommended depending on its condition.
Rice. 353 Gearbox housing
1 - lower part of the body, 2, 3 - bushings, 4 - boot, 5 - nut M24x1.5, 6 - magnet, 7 - upper part of the body, 8 - oil seal, 9 - sealing rings, 10 - filler plug, 11 - cover gasket, 12 - cover, 13 - M8x20 bolt, 14 - M7x20 bolt, 15 - extension, 17 - release bearing guide
The adjusting rings (7, see Fig. 354) have a thickness of 0.65 to 1.27 mm in 0.25 mm increments, the rings (10) have a thickness of 0.65 to 1.40 in the same increment.
Rice. 354 Mechanical transmission device
1 - input shaft, 2 - oil scraper clutch, 3 - wheel of 3 gears, 4, 22, 47 - retaining rings, 5 - wheel of 4 gears, 6 - bearing, 7, 10 - adjusting rings, 8 - washer, 9, 52, 53 - bolts of Top type, 11 - roller bearing, 12 - M8 nut, 13 - O-ring, 14 - housing, 15 - thrust ring of 1st gear gear, 16 - 1st gear gear, 17, 23 - bushings, 18, 24, 26 , 31, 41 - synchronizer rings, 19 - 1/2 gear synchronizer, 20 - cracker, 21 - spring, 25 - output ring, 27 - 2nd gear wheel, 28, 36 - thrust rings, 29 - bearing sleeve, 30 - gear 3 gears, 32 - 3/4 gear synchronizer, 33 - ring, 35 - 4th gear wheel, 37 - sleeve, 38 - 5th gear gear, 40 - 5th gear wheel, 42 - ring, 43 - synchronizer sleeve, 44 - synchronizer slide , 45 - reverse gear shaft, 46 - reverse gear wheel, 48 - reverse gear wheel, 49 - thrust sleeve, 51 - bracket.
The housing (14) is supplied complete with the bearing (13).
In fig. 355 shows the structure of the gearshift mechanism of a five-speed manual transmission. Lever (10) shifts 1/2 gear, (14) - 3/4 gear, lever (30) engages 5th gear, and reverse gear is engaged by a mechanism consisting of parts (21) and (22). Spring (23) provides some resistance when engaging reverse gear.
Rice. 355 Gear selection mechanism
1 - selector shaft housing, 2 - oil seal, 3 - bushing, 4 - bolt, 5 - bushing, 6 - ventilation system (breather) adapter, 7 - retaining ring, 8 - selector shaft, 9 - bolt М8х25, 10, 14, 30 - selector levers assembled, 11, 15, 31 - fingers, 12 - finger clamps, 13 - bushings, 16 - carrier of 1-4 gears, 17 - carrier of 5 gears, 18 - lock washer, 19 - carrier of reverse gear, 20 - cuff, 21 - stop lever for engaging reverse gear, 22 - lever for engaging reverse gear, 23 - springs, 24 - guide, 25 - cover, 26 - axle assembly, 27 - O-ring, 28, 29 - type bolts Torx
Models released after 1996 are distinguished by the absence of a smooth bushing, which was located in the lid in previous models (25).
at idle there is some kind of ringing from under the covers, like where the 5th gear then zelensit then disappears, what can it be?
What can be if the box rustles? (T4 synchro)
Hello, the fifth gear on my T4 has disappeared, what could it be, and the rear one is knocking out at least to be repaired?
Hello! On my T4, when changing gear, there is not a big jerk with twitching and knocking, what could be? It feels like the box is unwinding again.
Hello! Due to bearing wear on the secondary shaft, the outer cage cracked and a piece of 3-4 mm broke off from it, which ground and gathered on the magnet. The shafts and gears were not visually damaged, but the satellites had cavities in the form of shells. The indication for disassembling the checkpoint was: the gradually increasing hum of the 5th gear and, closer to disassembly, not a loud but noticeable chatter in the checkpoint when driving in neutral from 40 km / h and below up to a stop. It was also noticed that a sound similar to this chirping occurs at the moment of switching to 3rd gear. From the moment the hum appeared in 5th gear and until disassembly, I drove about 1000 km, by the end of this period I almost did not use the 5th. After replacing 2 bearings of the output shaft, all needle bearings, two small satellites with a plastic insert, all oil seals, troubleshooting the remaining bearings, the gearbox was installed in place - T4 2.5 AJT, gearbox EWB. The rumble in the 5th gear is almost inaudible, but in the 4th it remained as before the repair, but most of all it is annoying the chatter, which did not pass after the repair. What could be its source? Main pair: diff-l - output shaft?
Good day. T4 2.5 TDI 1999 Reverse gear is often turned on with a crunch and sometimes the second one cannot be stuck with neutral. What could be the reason?
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vw t 4 2.5 volkswagen t 4 gearbox repair. analysis without repair, too large losses The main problems when applying for remote work. School of remote work NOVA. Kinesio taping.
The gearbox device is shown in fig. 50.Place the shift forks in neutral. • Heat the place for the bearing in the transmission housing to 40 -.
Fasten the bearing with the shaft in a vise as shown in fig. Install old locking rings on those gears with which they worked before. Reverse gear rod. Retaining ring of the synchronizer hub. First, the outer ring of the double bearing is removed along with the rollers and one of the inner rings, and then the remaining rollers together with the second inner ring.
Everything related to the chassis and gearbox .. Do you need the entire table or a specific gearbox? Or freight with long ones, this is the passenger. Do not confuse yourself and others, it all depends on the size of the engine and the purpose of the car. Manovar wrote: byldozer wrote: DQL broken, I wanted to increase the speed on ABL, but both the table and the other with long fifths. Vitya wrote a: Gena wrote a: The gear ratios must correspond to the power-torque.
As I see, the specialists "hammered" on the topic, but it's a pity. He is a fool, and in Africa the "chief" of the Fool is to teach that to treat the dead! Please tell me to solve the problem. The box was covered, they say the bearing split and broke through the body, the oil left. This car is very necessary. The sites do not indicate the difference between the PPC, the synchro is probably different, I think, and where it can be found.
Tell the teapot, thanks in advance for any information. How long did you drive without oil? We have such devices.
But here there is someone who thinks from those parts of the world really he is “incognito! Try to contact him.
Assistant to the car enthusiast for the repair and operation of VOLKSWAGEN TRANSPORTER T 2. Before starting work, carefully study the step-by-step instructions given in the text of the manual and the illustrations to them.
Volkswagen T 2 Transporter service manual and Volkswagen T 2 Transporter repair manual. release, equipped with gasoline engines working.
Multimedia manual on the device, operation, maintenance and repair of cars Volkswagen Golf 2, Volkswagen Jetta 2. release.
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The VW CARAVELLE is equipped with a four-cylinder water-cooled boxer engine located at the rear of the vehicle. The engine crankcase consists of two parts, which are connected to each other at the level of the crankshaft and camshaft. The four cylinders of the engine are of the same shape and can be replaced separately, if necessary, together with the corresponding pistons. Each pair of cylinders has a common cylinder head made of light metal alloys.
Four valves, one for intake and one for exhaust per cylinder, located in the cylinder head. They can be replaced after removing the cylinder head. Both cylinder heads are perfectly symmetrical. Since not all cylinders are arranged in a row on an engine with an opposed cylinder arrangement, they are numbered starting from the cylinders located on the right side in the direction of travel and then the counting continues from front to back.
The crankshaft is forged from steel and mounted on three main bearings. A fourth, smaller bearing is mounted on the rear end of the shaft between the camshaft drive gear and the large belt pulley. The camshaft is housed in the engine crankcase under the crankshaft and runs in three separated steel bearings with a tin anti-friction alloy running surface.
It is driven from the crankshaft through a helical gear and rotates twice as slowly relative to the crankshaft. Eight hydraulic pushers and pusher rods and four rocker arm levers are used to transfer the travel of the cams to the valves.
Thanks to the installation of hydraulic valve clearance expansion joints, clearance adjustment is not required. The lubrication circuit consists of a gear pump driven by a camshaft, an oil pressure reducing valve, an oil cooler and a hydraulically driven oil switch.
The water pump is mounted on the side of the engine block. It should be noted that the cooling system is filled with antifreeze and alkali-free water throughout the year. The preparation of the flammable air / fuel mixture is carried out by a carburetor or fuel injection device, which are generally maintenance-free.
An ignition spark is generated in a transistor ignition system that maintains a constant ignition timing. The ignition distributor is mounted on the engine block and is driven through a splined connection from the crankshaft.
Warning: The radiator fan can turn on by itself when the engine is stopped and the ignition is off. Due to stagnant heat zones in the engine compartment, this can also happen repeatedly. When working in the engine compartment and a warm engine, be careful and ready to suddenly turn on the radiator fan. Please click here if you are not redirected within a few seconds. Volkswagen Transporter T2 repair and maintenance manual.
Name: Volkswagen Transporter T2 Operation manual, care, maintenance and repair, wiring diagrams. Graduation from the year. Pages in the book:
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