Volkswagen Polo 3 with 1994 for 2001 of release.
1. The general data
2. The engine
3. Greasing system
4. Cooling system
5. Systems of injection of fuel
6. Ignition system
7. Coupling
8. A mechanical transmission
8.1. Removal and transmission installation
8.2. Dismantling and check
8.3. Check of details of a transmission
8.4. Transmission assemblage
8.4.1. Assemblage of a conducted shaft
8.4.2. Assemblage of a primary shaft
8.4.3. Definitive assemblage
8.5. Differential
8.6. The gear change mechanism
9. A drive of wheels
10. A steering without the amplifier
11. A steering with the hydraulic amplifier
12. A forward suspension bracket
13. A back suspension bracket
14. Brake system
15. An electric equipment
16. Heating and ventilation system
17. An automatic transmission
18. Appendices


8.4.2. Assemblage of a primary shaft

Fig. 182. Details of a primary shaft: 1 — screw Torx with head М8; 2 — a spring lock ring; 3 — a gear wheel running, fifth transfer; 4 — an adjusting persistent ring of the conic roller bearing; 5 — an internal ring of the conic roller bearing; 6 — картер transmissions; 7 — a primary shaft; 8 — the needle bearing; 9 — a gear wheel of the third transfer; 10 — a ring of the synchronizer of the third transfer; 11, 13 — persistent rings; 12 — муфта a free wheeling with a switching nave; 15 — a gear wheel of the fourth transfer; 16 — the needle bearing; 17 — an adjusting washer; 18 — an internal ring of the conic roller bearing; 19 — a compensatory washer; 20 — an external ring of the conic roller bearing; 21 — картер couplings; 22, 26 — springs of synchronizers; 23 — a switching clamp; 24 — муфта a free wheeling; 25 — a synchronizer nave

If replacement картера transmissions, картера the couplings, the shaft or conic roller bearings the primary shaft is subject to adjustment was spent. Shaft assemblage is spent in sequence, return dismantling, at use fig. 182. Besides adjustment, it is necessary to pay attention to the following the moments:

Fig. 195. Marks of details of the synchronizer of the third/fourth transfer

- To collect the synchronizer 13 it is necessary in sequence, its return dismantling. As it was already mentioned, sliding муфту and an inclusion nave it is impossible разукомплектовывать, to replace them it is necessary in gathering. The big party on length of the gear gearings interrupted with ring bore (the bottom arrow, fig. 195), should be turned towards a gear wheel of inclusion of the fourth transfer. Additional маркировочная ring bore (the top arrow) also should be turned towards the fourth transfer;
- запрессовать on the shaft end the internal ring 8 (fig. 182 see) is necessary under a press an oblique surface of rollers outside;
- To establish a synchronizer ring on a gear wheel of transfer and, as is shown in fig. 196, to measure щупом a backlash and. The backlash (a deterioration limit) makes 0,5 mm (at new 1,3–1,7 mm);

Fig. 196. Backlash measurement between the established ring of the synchronizer and a transfer gear wheel

- To oil the needle bearing 8 (fig. 182 see), to pull it over a shaft and to establish on the bearing a gear wheel 9 third transfers. To establish a ring 10 synchronizers. To establish a persistent ring 11. By means of the special flat-nose pliers used at repair of water pumps to get this ring in ring bore;
- To establish a shaft under a press and запрессовать the synchronizer by means of a pipe piece on a shaft. As ring bore in gear gearing it is not so visible, the correctness control запрессовки should be spent inclusion naves with the help маркировочной the ring bore located on the top party (the top arrow on fig. 195);
- To establish a persistent ring 13 (fig. 182 see) and to insert a ring 14;
- To establish a gear wheel 15 fourth transfers with the needle bearing 16 and an adjusting washer 17 and запрессовать the conic roller bearing 18 on the shaft end.
If any of the above-named details was not replaced, the shaft can be established again. Otherwise to spend following measurements:
- запрессовать an external ring 20 bearings without a compensatory washer 19 against the stop in картер couplings. To insert a power shaft in картер transmissions, to establish картер couplings and to tighten fastening bolts картера the moment 25 Нм;

Fig. 193. The special tool for carrying out of measurements on conducted to a shaft

- To establish on картере specified in fig. 193 the special tool, however the measuring plate should be established this time on the power shaft end. To turn some times a shaft, to provide full self-installation of bearings;
- To establish preliminary on стрелочном the indicator a tension equal of 1,0 mm, and to translate an arrow on zero;
- To wring out a shaft in a direction стрелочного the indicator and to fix the indication (for example, 1,21 mm) стрелочного the indicator. On sale there are washers of a various thickness, on the basis of the measured value it is possible to get the necessary washer. Measurements to spend some times not to be mistaken at assemblage;
- Again to remove a power shaft and to take out an adjusting persistent ring of the bearing, as is shown in fig. 173;

Fig. 173. Removal of an adjusting persistent ring of the conic roller bearing of a primary shaft: And — stripper Kukko 21/5; B — bridge Kukko 22/2

- Again запрессовать a ring of the bearing with a certain compensatory washer (or by two washers depending on result of measurement, in an example it is specified one washer in the thickness of 1,20 mm), again to establish a power shaft and again to plant on fastening bolts картер. Some times to turn a shaft that bearings could be earned extra;
- Repeatedly to spend the specified measurements. At correct adjustment the indication стрелочного the indicator should be now in limits of 0,01-0,12 mm. So, the transmission is adjusted according to the instruction, it can be collected definitively.

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8.4.1. Assemblage of a conducted shaft
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8.4.3. Definitive assemblage