VW Polo sedan sedan cars are equipped with either a five-speed manual transmission of the 02T modification, or a six-speed automatic transmission of the 09G model.
Rice. 6. Manual transmission Volkswagen Polo sedan
1 – a back cover of a transmission; 2 - drive gear V transmission; 3 - drive gear of the 1st gear; 4 – an intermediate gear wheel of a backing; 5 - reverse drive gear; 6 – a leading gear wheel of the II transfer; 7 – a leading gear wheel of III transfer; 8 - gearshift mechanism manual transmission Volkswagen Polo; 9 - drive gear IV gear; 10 - clutch release bearing; 11 - clutch housing; 12 - primary (drive) shaft; 13 - flange of the semi-axial gear for fastening the drive of the right front wheel; 14 - differential box; 15 - driven gear of the main gear; 16 – side gear flange for fastening the drive of the left front wheel; 17 - gearbox housing; 18 - secondary (driven) shaft
The 02T manual gearbox is a compact 5-speed unit designed for use in VW Polo sedan vehicles with front axle drive. By design, this is a two-shaft gearbox with an additional reverse gear axle.
Helical gears of constant mesh are installed on the input and output shafts. All moving gears are supported by needle bearings. This achieves a high level of fluency.
The reverse gear of the manual transmission Volkswagen Polo sedan is a spur gear. The 1st and 2nd gears are mounted on the output shaft, and the 3rd, 4th and 5th gears are mounted on the input shaft.
The input shaft is supported by a cylindrical roller bearing in the clutch housing (moving mount) and a ball bearing (fixed mount) in the bearing block in the gearbox housing. To reduce weight, the input shaft is drilled from the inside.
The input shaft has a fixed/movable mount. Like the input shaft, it is installed in the gearbox housing of the VW Polo sedan:
- rests on a cylindrical roller bearing (movable mount) in the clutch housing.
– rests on a ball bearing (fixed mount) in the bearing block together with the input shaft bearing.
To reduce weight, the output shaft is drilled from the inside.
The gears of the 1st, 2nd gears and reverse gears are fixedly fixed on the input shaft. The 3rd, 4th and 5th gears are movable and rotate on needle bearings.
The synchronizers of the 3rd, 4th and 5th gears of the Volkswagen Polo sedan gearbox are fixedly fixed to the input shaft on the keys.
After one of the gears is displaced, the corresponding "moving gear" is also fixedly connected to the input shaft. They are held in place by spring rings.
The 3rd, 4th and 5th gears and the 1st/2nd gear synchronizer are fixedly fixed to the output shaft in the direction of rotation by means of small keys.
They are held in place by circlips. The movable 1st and 2nd gears rotate on the output shaft on needle bearings.
A new design feature of the Volkswagen Polo Sedan gearbox is a modular structure. A typical example of a module is a bearing base plate with two ball bearings.
The ball bearings are not installed in the gearbox housing, but on a separate support plate.
The input and output shaft and gear assemblies are installed in the bearing support plate outside of the gearbox housing, so this assembly is easy to install in the gearbox housing.
The two "stationary" ball bearings for the input and output shafts are part of the bearing support plate assembly and are installed with an interference fit.
Ball bearings are held by a figured plate. The shaped plate is welded to the bearing base plate.
Ball bearings have radial seals on both sides to prevent abrasive particles from gear oil from entering the bearings.
The bearing base plate is fitted with a tight-fit glasses-shaped flange into the gearbox housing of a VW Polo sedan sedan and is attached to the housing with six bolts.
1st and 2nd Gear Double-Cone Synchronizers Before the gear on the input shaft engages the synchronizer and the synchronizer cage with the gear on the output shaft, the gears need to rotate "in sync" (be in sync).
Synchronization of rotation is carried out when shifting gears due to the friction of the cone on the gear and on the synchronizer cage.
Increasing the friction surface area of the cone by about a factor of two improves synchronization by about 50%, while the effort required to shift gears is reduced by about half.
This achieves improved smoothness when shifting from 3rd to 2nd gear and from 2nd to 1st gear.
The double-cone synchronizers of each of these gears of the 02T Volkswagen Polo sedan gearbox consist of the following parts:
- synchronizer cone.
– synchronizer ring (internal).
- conical ring.
– synchronizer ring (outer).
The differential forms a single unit with the manual transmission of the Volkswagen Polo sedan. It is mounted on two redesigned tapered roller bearings in the manual transmission housing and clutch housing.
The differential housing is sealed on the outside, at the flanged shafts, with two seals of different diameters. The final drive gear is riveted to the differential case and engages with the output shaft gear.
Engine torque is transmitted to the gearbox through the input shaft. The torque is transmitted by a pair of gears in the engaged gear to the output shaft and from it to the main gear with differential. Thus, the torque and rpm depend on the selected input shaft gears.
Rice. 7. Volkswagen Polo manual transmission control drive
1 - counterweight of the gear lever; 2 – the lever of a gear change; 3 - gear selection lever; 4 – a cable of a gear change; 5 – a cable of a choice of transfers; 6 - thermal screen; 7 – a scene of the lever of a gear change; 8 - ball bearing; 9 - gearbox control lever
External gearshift mechanism gearbox Volkswagen Polo sedan
In order to isolate the shift lever from vibration and vibrations generated by the power drive, the gearbox is equipped with a cable-operated shift mechanism.
The connection between the gear lever (in the passenger compartment) and the gearbox is carried out using two cables.
Two cables transmit the movements of the gear lever for selecting and engaging gears to the gear shift shaft of the VW Polo sedan manual transmission.
The mechanism (selector lever and engagement lever) converts the movement of the two cables into forward and backward movement, as well as into rotational movement of the shift shaft.
There is an angle lever on the cover of the shift mechanism. It allows you to fix the shift shaft in a predetermined position when performing repair work. This detail greatly simplifies the operation of adjusting the cable shift mechanism.
Internal gearshift mechanism manual transmission Volkswagen Polo sedan
The movements of the shift mechanism are transmitted to the gearbox from above. The shift shaft moves in the gear shift cover.
When a gear is selected, it moves in the axial direction, and when a gear is engaged, it rotates. In certain positions, the gear shift shaft is fixed by two spring-loaded balls.
The 1st / 2nd and 3rd / 4th gear forks are mounted on angular contact ball bearings, thanks to this design, the Volkswagen Polo gearbox shift mechanism works easily. The 5th gear fork is mounted on plain bearings.
When a gear is engaged, the guide, and therefore the shift fork, is displaced by the action of the shift pin. The segments of the shift forks are located in the holders of the synchronizers of the corresponding pair of gears.
The movement of the gear selection (left-right) of the gear lever is converted to the movement of the gear selection cable back and forth with the selector lever. The selector lever rotates on an axis.
VW Polo sedan's external transmission mechanism converts the forward and reverse movements of the selector cable into up and down movements of the shift shaft.
The gear selection cable is connected to the transfer lever. The transfer lever is mounted on a hinge on the gearbox housing, it is connected through a slider to the shift shaft.
In the gearbox, during vertical reciprocating movements of the shaft, the corresponding shift finger is directed to the drive of a specific shift fork of the selected gear (1st / 2nd gear; 3rd / 4th gear; 5th / 6th gear or gear reverse).
Reverse gear lock mechanism VW Polo
To protect against accidental engagement of reverse gear, a push-type lock is used. The reverse gear lock mechanism is built into the gear shift housing.
Before selecting and engaging reverse gear, the driver must unlock the lock mechanism.
When you try to engage the reverse gear in the same way as the forward gear, the locking protrusion of the shift lever rests against the detent (part of the shift mechanism housing).
When pressing on the shift lever and overcoming the force of the spring, the lever moves down through the spherical guide of the shift lever, while the locking lug falls below the detent.
During the subsequent movement of the selector for switching reverse gear, the lock does not interfere with movement and the inclusion of reverse gear becomes possible.
The spring pushes the shift lever back to the engaged position and holds it in the reverse gear position.
Adjusting the cable shift mechanism manual transmission VW Polo sedan
Adjusting the cable shift mechanism is simplified by the presence of an angle lever on the shift cover and a shift lever locking pin.
The adjustment procedure always begins with shifting the Volkswagen Polo Sedan gearbox to neutral gear:
Disconnect cables. The locking mechanism on the shift cable and on the select cable moves forward until it stops, then locks by turning to the left. Now you can adjust the length of the cable.
Block shift shaft. An angle lever is installed on the cover of the gearshift mechanism, which allows you to block the gearshift shaft.
To do this, shift the shift shaft down to a position between 1st and 2nd gears. While pushing it down, push the bevel lever towards the selector shaft, then turn it. The angle lever will lock and lock the shift shaft in this position.
Gear lever lock. The shift lever of the Volkswagen Polo sedan gearbox should be moved to the neutral gear position between 1st and 2nd gears.
The shift lever has a lock hole. Through this hole, a locking pin is inserted into the hole under the gear shift housing.
Fixing cables in place. The locking mechanism on the selector cable and shift cable can now be turned to the right again. The spring shifts the locking mechanism to a predetermined position and holds it in place. After that, loosen the angle lever again and remove the locking pin.
The shift lever should now be in neutral between 3rd and 4th gear.
The Volkswagen Polo Sedan is a popular car that has been in production since 1975. For a long time the existence of the brand, 5 generations of the vehicle entered the markets.
Manual Transmission
The Volkswagen Polo Sedan is equipped with five or six-speed manual gearboxes. The transmission is performed according to a two-shaft scheme with synchronized gears. In the manual transmission, the main gear with the differential is combined with a common crankcase.
Types of mechanical transmission repair
The story must begin with the fact that the repair of the Polo Sedan manual transmission can be partial or major. With local restoration, the box is removed, disassembled, washed, defective. Troubleshooting is the process of determining the cause of a breakdown. After troubleshooting, the master will 100% correctly indicate the specific malfunction. Overhaul also involves the complete removal of the unit. Mechanisms:
- fully understood;
- washed;
- Troubleshooting is being carried out, but already completely.
Faulty mechanisms are identified, spare parts that are worn out and do not function are changed.
Causes of failure and problem solving
- In case of spontaneous gear shifting, most likely, the gear shift forks have worn out or the detent spring has broken. The clearance of the synchronizer clutch on the hub can also be increased. Only professional repair of the Volkswagen Polo 1.4 manual transmission, carried out in the service, will help here.
- Shifting is difficult and there is a grinding sound? The reason is incomplete clutch disengagement, malfunction of the gearshift cables, significant weakening of the synchronizer spring, filled oil that does not meet the established requirements. The way to solve the problem is to repair the clutch release drive, remove air from the hydraulic system. You will also need to fill in the oil of the desired brand in order to try to fix the problem by repairing the Volkswagen Polo Sedan manual transmission on your own.
- Do you hear a rattle or vibration in the gearbox? Possible reasons for incorrect functioning are loosening or damage to the engine mounts or manual transmission. The gears may still be worn or damaged, the engine idle adjustment may be disturbed. The solution to the problem is tightening the fasteners or replacing the support. If it is impossible to self-diagnose the operation of the system in 100% of cases, a professional inspection of the car and subsequent repair of the Volkswagen Polo sedan 1.6 manual transmission in the service will be required.
Quality assurance - the help of professional craftsmen
Need an urgent Volkswagen Polo manual transmission repair? Please contact our service, where there is a large warehouse of spare parts with more than 5000 items. During the restoration work, the masters use only the equipment that meets the requirements of the manufacturer. Service specialists have a high level of qualification and extensive experience in the repair of mechanical transmissions.
Do not try to solve the problem yourself, because high-quality repairs are the privilege of professional craftsmen.
Volkswagen Polo sedan (Volkswagen Polo sedan) after entering the market for a number of reasons has become a real bestseller. A well-known brand, modern interior and exterior design, reliable and economical engines, as well as a good level of equipment and safety at an affordable price ensured that the models were in great demand.
Moreover, the budget car, like the more solid models of the brand, also received a choice of transmissions. In addition to the traditional one, the Polo sedan can be installed in any configuration.
Read in this article
Polo sedan automatic transmission
So, as you know, when choosing cars from the budget segment, many motorists tend to purchase the most reliable equipment. At the same time, the key to durable and trouble-free operation of all units is their structural simplicity (a proven and unpretentious engine, manual transmission and a minimum of complex technical equipment).
As for the automatic transmission, in the CIS, motorists consider such a box to be complicated, expensive and unreliable, that is, they are in no hurry to change the mechanics to an automatic one. It is also generally accepted that a car with an automatic transmission consumes more fuel and accelerates worse. There is some truth in this, especially when it comes to old 4-speed automatic transmissions of past generations.
We note right away that today the situation has changed somewhat. First of all, modern automatic transmissions have 5 or more gears, and can also be even more economical than mechanics. Also, actively working electronics and a number of additional functions and automatic transmission modes allow such a box to confidently compete with manual transmissions.
- The Polo Sedan is also no exception, as Volkswagen offers this car with a modern automatic transmission. On the Polo, the sedan is reliable (especially compared to or).
The transmission simply does not have enough factory heat exchanger for cooling. The oil in the automatic transmission gets very hot, especially in the heat when driving around the city. The result is a decrease in pressure, oil starvation, accelerated wear, cranking of the bimetallic bushings of the oil pump and individual elements of the planetary gear set.
Also among the problems of this automatic transmission, the owners note the main pressure regulator in the valve body. A malfunction of this kind leads to the fact that.
When and why you need to change the oil in an automatic transmission. Changing transmission oil in automatic transmission Polo Sedan. Councils and recommendations.
REPAIR OF GEARBOX VOLKSWAGEN Polo 1.0 1.1 1.2 1.4 1.5 1.6 1.8 1.9
MEKHANEVOLKSWAGEN Polo
installation replacement buy all modifications 1.0 1.1 1.2 1.4 1.5 1.6 1.8 1.9
repair and restoration of shafts argon welding of the manual transmission case
Moscow city
Artem 8 965 126 13 83 Vadim 8 925 675 78 75
Full diagnostics of the car during repair - for free!
With a high level of professionalism, extensive experience in the repair of mechanical transmissions, and our own spare parts warehouse, we carry out diagnostics, sale, replacement and repair of all types of manual transmissions for the VOLKSWAGEN Polo car. Repair of boxes begins with the primary, mandatory free diagnostics.
The cost of work during the repair of the VOLKSWAGEN Polo gearbox:
A range of services for the repair of a manual gearbox VOLKSWAGEN Polo:
- consultation by a repairman /by phone free of charge/
- delivery of a car for repair /within Moscow 3,000 rubles. From the Moscow region and other regions of the Russian Federation - by agreement/
- complex diagnostics of the car / determination of the presence of a malfunction of the engine, manual transmission, ABS, brake system; checking the electrical circuits of the car for corrosion, checking the kinematic destruction of the unit, checking the level of transmission oil, checking the performance of the clutch hydraulic system / - free of charge during repairs
- visual inspection, hull integrity check
- checking the transmission oil content for steel, aluminum or bronze chips
- pallet opening /if necessary/
- removal from vehicle
- disassembly, washing of parts and assemblies
- Troubleshooting / the presence of the car owner is mandatory /
- coordination with the car owner of the cost of a complete repair and the date of completion of the repair
- receipt from the warehouse of spare parts / rem. kit, consumables, assemblies/
- repair / argon welding / gearbox housing if necessary
- assembly
- clutch replacement /at the request of the car owner/
- car installation
- transmission oil filling
- output diagnostics and test run of the car
Warranty from 3 to 24 months or 60,000 km. run.
We have a fundremanufactured gearboxes Volkswagen Polo 1.0 1.1 1.2 1.4 1.5 1.6 1.8 1.9 /see article replacement/. If the car owner wishes, we can replace the faulty one with the one taken from the exchange fund, which is often more economically feasible.
Prices for additional work
Spare parts for manual transmission repair:
- economy - from 3,000 to 8,000 rubles. /use, at the request of the car owner, only used parts to reduce the cost of repairs/
- business - from 8,000 to 28,000 rubles. /replace only directly damaged parts in the unit/
- representative - from 28,000 to 60,000 rubles. /replacement, regardless of damage, as a set: oil seals, bearings, needle bearings, synchronizers, stoppers, clutch hub locks - plus directly affected parts/
Own warehouse of spare parts necessary for the repair of mechanical transmissions. Bearings, oil seals, gears, synchronizers, gear couplings, shafts, differentials, manual transmission housings in stock and on order for all brands of cars.
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VOLKSWAGEN Polo gearboxes are repaired in 9 out of 10 cases due to the characteristic noises emitted by the bearing bearings on the gearbox and differential shafts. An example of such a VOLKSWAGEN Polo box in the photos is just below. Three bearing bearings are changed (one each: primary, secondary shaft, differential); new gearbox oil seals (input shaft, differential, gear selection unit), flush the manual gearbox housing with nefras, the inside, to remove steel chips and old gear oil:
The Volkswagen Polo hatchback appeared back in 1975; the lineup already includes 6 generations of the German bestseller. Since 2009, the 5th generation of the hatchback has been produced, the car was offered to customers in a three-door and five-door version. The last update was carried out in the fall of 2017: the manufacturer introduced cars with 65 or 75 hp gasoline engines. with., as well as with a diesel engine with a capacity of 80-95 liters. from. Official deliveries of the model to Russia have been discontinued since 2014.
Features of the gearbox and its problems
In the basic version, a 5-speed manual gearbox is installed on Volkswagen Polo cars; until 2004, the 085th and 020th modifications were installed during assembly. This is a reliable and durable unit, designed for high mileage. It is made according to the classic two-shaft scheme and has synchronized gears. The gearbox and main gear with differential have a common crankcase.
Due to technical features, the box has a number of vulnerabilities, which leads to common malfunctions. For models of the 085th modification, the secondary shaft support bearing has become a weak spot, in addition, the release bearing is often destroyed. Their damage is manifested by a characteristic hum during the movement of the car.
The Volkswagen Polo gearbox is sensitive to a lack of oil or its poor quality: in case of oil starvation, the 5th gear fails in a short time. It is recommended to change the lubricant according to the manufacturer's regulations every 80-100 thousand kilometers traveled. The original VAG G052512A2 API GL4 SAE 75W-80 oil is used for replacement, and more affordable analogues can be selected.
The manufacturer claims that an oil change is not required, since it is filled for the entire life of the engine. However, in practice, it still has to be changed due to natural wear and tear, leakage through worn seals, in addition, a new lubricant is required after each repair with the box disassembled. In our auto repair shop it is offered to purchase the necessary lubricants and consumables.
Signs of manual transmission malfunctions and possible causes of failure
Volkswagen Polo manual transmission repair is rarely required due to the reliability of the unit, however, some factors can significantly accelerate the wear of parts. The gearbox suffers during constant movement with jerks in traffic jams, sudden starts and braking, and movement with overload. It is also negatively affected by oil starvation - a lack of lubrication or the ingress of metal filings into it leads to complete wear of the unit.
The car owner should pay attention to the following signs:
- Extraneous hum when driving. It usually indicates a bearing failure that requires urgent replacement. With their complete destruction, the fragments will fall into the mechanism and lead to even larger breakdowns.
- Difficulties with gear shifting: difficult movement of the lever, the appearance of a metallic crack or crunch. Such symptoms may indicate a breakdown of the shift mechanism or a malfunction of the gears.
- Inability to engage one or more gears. With severe wear of parts, the controllability of the car is disturbed, this reduces traffic safety.
If signs of malfunctions appear, you must immediately contact the workshop: the car cannot be trusted by "garage" masters, unprofessional repairs will lead to additional breakdowns. We offer our customers a profitable cooperation scheme: high-quality repair of the Volkswagen Polo gearbox is guaranteed at low prices.
Repair shop services
We carry out a complete diagnosis of the gearbox and clutch mechanism: the unit is checked in motion, an external inspection is performed to detect damage and oil leakage, and disassembly and troubleshooting are also carried out. A full check allows you to identify the exact causes of malfunctions and make a list of components that need to be replaced. There are two troubleshooting options available:
- Overhaul of "mechanics" with the replacement of all defective parts. To do this, we offer to purchase new and used spare parts, the installation of components takes no more than 2 days. After the task is completed, output diagnostics is performed, confirming the successful completion of the task.
- Sale of a Volkswagen Polo gearbox with a subsequent complete replacement assembly. This option is useful if the mechanism is severely damaged and it would be too costly to replace all defective components. Also, a complete replacement is beneficial for owners of used cars for which it is difficult to find suitable new parts.
We offer to buy a Volkswagen Polo gearbox after a major overhaul: used spare parts are almost as reliable as new ones, as they have been completely restored. Such an exchange will not cost much, we offer our clients in Moscow favorable prices.
What are our advantages?
Our workshop has been carrying out professional repair of transmissions of foreign cars for many years, experienced specialists successfully find a solution for the most difficult tasks. A large selection of new and remanufactured spare parts is always in stock, this allows us to carry out repairs in the shortest possible time. If the car is not running due to transmission failures, we will deliver it to the workshop on our own tow truck free of charge.
To find out the preliminary cost, call our numbers and get advice from experienced specialists. Calls are accepted around the clock, we are always ready to answer your questions. After the repair is completed, a guarantee is provided for a period of six months to two years, depending on the complexity of the breakdown and the parts installed. Take advantage of the favorable terms of cooperation and call us now to book a car for diagnostics!
VOLKSWAGEN Polo gearbox diagram
gearbox input shaft
gearbox output shaft
gear selector (gearbox forks)
differential
The workshop for the repair of gearboxes is ready to perform the following work:
- gearbox replacement and repairVolkswagen Polo
- replacement And repair manual transmission Volkswagen Polo
- replacement And repair checkpoint Volkswagen Polo
- transmission oil change
- replacement clutch Volkswagen Polo
- replacement clutch release bearing Volkswagen Polo
- replacement rear oil seal and crankshaft bearingVolkswagen Polo
- replacement of the input shaft seal and drive sealsVolkswagen Polo
- manual transmission input shaft replacementVolkswagen Polo
- replacement of the secondary shaft of the manual transmissionVolkswagen Polo
- repair backstage checkpoint Volkswagen Polo
- repair ( argon welding) corps manual transmission Volkswagen Polo
- repair of the secondary shaft of the VW Polo gearbox
- replacement of the fifth gear of the manual transmission (without removing the gearbox from the car)Volkswagen Polo
- repair 1 And 2 transmission Volkswagen Polo
- repair 3 And 4 transmission Volkswagen Polo
- repair 5 transmission Volkswagen Polo
- buy checkpointVolkswagen Polo
- buy manual transmissionVolkswagen Polo
- buy box gearVolkswagen Polo
Call us to schedule a manual transmission diagnostic and repair in a transmission repair shop. A preliminary appointment will allow you to find the most convenient solution, we are always ready to meet the wishes of the client.
In our specialized workshops for the repair of gearboxes of VOLKSWAGEN Polo manual transmissions, high-quality maintenance, diagnostics and repair of all types of gearboxes are carried out. We offer an honest service for your repair. Your presence is obligatory at all stages of diagnostics and repair of the VOLKSWAGEN Polo gearbox; all work and accessories are coordinated. The term for the overhaul of the gearbox is from 0.5 to 1 working days (if the necessary parts are available).
We work seven days a week.
Works for us round the clock line advice on the repair of manual transmission gearboxes (8 965 126 13 83) and delivery for repair by tow truck (8 926 167 15 40). A tow truck during the repair of the manual transmission is provided for a fee (within the Moscow Ring Road - 3000, outside the Moscow Ring Road by agreement).
The cost of work during the overhaul of the VOLKSWAGEN Polo gearbox is 10,000 rubles (input and output diagnostics, removal and installation of the gearbox, disassembly and assembly, test drive weekend trip) + cost of components.
Input diagnostics is carried out with the obligatory presence of the owner of the car within 30-40 minutes after removing the gearbox from the car (inspection, disassembly of the manual transmission, washing the inner case of the gearbox from metal chips, disassembly of the shafts).
Removing the gearbox from the car, disassembling and troubleshooting takes place on the day of applying for repairs.
Warranty for the repair of the VOLKSWAGEN Polo gearbox from 1 to 12 months or 60,000 km (set individually for each car - depending on the components during the repair).
Volkswagen Polo sedan cars are equipped with either a five-speed manual transmission mod. 021 or a six-speed automatic transmission mod. 09G.
The mechanical gearbox is made according to a two-shaft scheme with synchronized gears. The gearbox and final drive with differential share a common crankcase. Clutch housing 11 is attached to the front of the gearbox housing. On the back of the crankcase
Manual gearbox: 1 - gearbox rear cover; 2 - drive gear V gear; 3 - drive gear of the 1st gear; 4 - intermediate reverse gear; 5 - reverse drive gear; b - drive gear of the 2nd gear; 7 - drive gear III gear; 8 - gear shift mechanism; 9 - drive gear IV gear; 10 - clutch release bearing; 11 - clutch housing; 12 - primary (drive) shaft; 13 - flange of the semi-axial gear for fastening the drive of the right front wheel; 14 - differential box; 15 - driven gear of the main gear; 16 - side gear flange for fastening the left front wheel drive; 17 - gearbox housing; 18 - secondary (driven) shaft
the gearbox has a stamped steel cover 1.
On the input shaft 12 there are drive gears of I and II gears and reverse gears, made in one piece with the input shaft, and drive gears III,
IV and V gears rotate freely on needle bearings.
The secondary shaft 18 is made together with the drive gear of the main gear, in addition, the driven gears of I and II gears freely rotating on plain bearings are installed on the shaft. driven gears III,
IV and V gears and reverse gears are mounted on splines.
The forward gears are switched on by axial movement of the clutches of two synchronizers HI and III-IV gears mounted on the secondary shaft and primary shafts, respectively, as well as the synchronizer clutch of the V gear mounted on the input shaft. The reverse gear is engaged by engaging the reverse gear 4 with the driven
Gear representing the Secondary shaft. The gearshift mechanism is located inside the gearbox housing.
Outside there are two levers of the mechanism: the shift lever and the gear selector lever.
Manual transmission control drive: 1 - counterweight of the gear lever; 2 - gear lever; 3 - gear selection lever; 4 - shift cable; 5 - gear selection cable; b - thermal screen; 7 - linkage of the gear lever; 8 - ball bearing; 9 - gearbox control lever
The control drive of a manual transmission consists of a link 7 of a gear lever 9 with a ball bearing 8 mounted on the base of the body, two shift cables 4 and gear selection 5, as well as a mechanism located in the gearbox housing. To ensure a clear gear shift, the shift lever 2 of the shift mechanism is made in one piece with a massive counterweight 1. The cables are protected from heating by thermal radiation of the exhaust gas system by a thermal screen 6 installed on the base of the body. The gear selection and shift cables are structurally different from each other and are not interchangeable.
The main gear is made in the form of a pair of cylindrical gears matched according to noise. Torque is transmitted from the driven gear of the final drive to the differential and then to the front wheel drives.
The differential is conical, four-satellite. The tightness of the connection of the vortex hinges of the front wheel drives with the differential gears is ensured by oil seals.
The automatic transmission is arranged according to the traditional planetary circuit with friction braking and is connected to the engine crankshaft through a torque converter. The automatic transmission electronic control system constantly monitors vehicle speed and engine load, eliminates driver error by preventing the driver from shifting up at low speed to avoid engine overload, or downshifting at too high a speed, which eliminates the possibility of exceeding the maximum allowable frequency. rotation of the engine crankshaft. When the vehicle speed decreases, the gears automatically switch to lower gears without the participation of the driver. When the car comes to a complete stop, 1st gear is automatically engaged.
The automatic transmission control algorithm is described in detail in the “Car device”
The automatic transmission consists of a torque converter, pump, planetary gear, multi-disc clutches, multi-disc brakes and a valve block.
The torque converter plays the role of a clutch and serves to smoothly connect the engine and the gearbox mechanism and increase torque when the car starts to move. The torque converter housing is connected to the engine crankshaft through the drive plate and rotates constantly when the engine is running. The internal cavity of the torque converter is filled with a working fluid for automatic transmissions. The engine rotates the torque converter and drives the pump wheel, which creates flows of working fluid in the direction of the turbine wheel. The latter begins to rotate due to the flow of the working fluid created by the pump wheel. With a large difference in the speeds of rotation of the turbine and pump wheels, the reactor changes the direction of the fluid flow, increasing the torque. As the speed difference decreases, it becomes unnecessary and is therefore installed on the overrunning clutch.
The hydraulic control system of the automatic transmission includes a pump, a pressure regulator, an automatic transmission range selection spool valve. auxiliary valves (solenoids), clutches and brakes. A pump located at the front of the gearbox housing pressurizes and supplies fluid to all systems in the gearbox.
Planetary gear sets correspond to the gear set in a manual transmission and serve to change the gear ratio in an automatic transmission when changing gears.
The planetary gearbox of the Ravignier system is a gear train with external and internal gears, which provides various ways of connecting its elements to obtain various gear ratios.
Band brakes are used to temporarily block the elements of the corresponding planetary gear set on the automatic transmission housing.
The automatic transmission control drive is cable-operated, designed on the same principle as the manual transmission control drive, but differs from it in the number and design of parts. The link 4 (Fig. 6.8) of the automatic transmission selector is installed in the same place on the floor tunnel 3 as the manual transmission control lever, and is connected to the control unit on the gearbox 7 with a cable 1.
The differential of an automatic transmission is completely similar in design to the differential of a manual transmission.
Automatic transmission: 1 - main gear housing; 2 - working fluid heat exchanger; 3 - bracket for the left suspension support of the power unit; 4 - selector position sensor; 5 - casing of the torque converter; b - torque converter
Automatic transmission control drive: 1 - transmission control cable; 2 - the handle of the gear selector lever; 3 - floor tunnel; 4 - linkage of the gearbox control selector; 5 - cover of the backstage of the gearbox control selector; b - cable holders; 7 - gearbox
To repair a gearbox, especially an automatic one, a large set of special tools and appropriate training of the performer are required, therefore, this section discusses only the removal and installation of the gearbox, the replacement of its seals, and the repair of the drive. If necessary, have the gearbox repaired by a specialist workshop.