Contents - Volkspage
Contents - Volkspage
Contents - Volkspage
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Chapter 7<br />
Manual transmission<br />
<strong>Contents</strong><br />
Drive flange oil seals - renewal ............................. .3 Reversing lamp switch - testing, removal and refitting ........... .5<br />
Gearchange mechanism - removal, refitting and adjustment ...... .4 Speedometer drive - removal and refitting ..................... .6<br />
General description ...................................... .1 Transmission - removal and refitting ......................... .2<br />
Degrees of difficulty<br />
Specifications<br />
General<br />
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .<br />
Oil capacity:<br />
4 speed transmission . . . . . . . . . . . . .................<br />
5 speed transmission . . . . . . . . . . . . . . . .................<br />
Oil type/specification . . . . . . . . . . . . . . . . . .................<br />
Transmission codes<br />
4 speed:<br />
Engine code AAU (1.05 litre, 33 kW) . . . . . . . . . . . . . . . . . . . . . . . . .<br />
Engine code AAV (1.3 litre, 40 kW) . . . . . . . . . . . . . . . . . . . . . . . . . .<br />
5 Speed:<br />
Engine code AAU (1.05 litre, 33kW) . . . . . . . . . . . . . . . . . . . . . . . ,<br />
EnginecodeAAV(1.3litre,40kW) . . . . . . . . . . . . . . . . . . . . . . . . . . .<br />
Enginecode3F(1.3litre,55kW) . . . . . . . . . . . . . . . . . . . . . . . . . . . .<br />
EnginecodePY(1.3litre,83kW) . . . . . . . . . . . . . . . . . . . . . . . . . . . .<br />
Torque wrench settings<br />
Transmission to engine:<br />
5 speed transmission . . . . . . . .<br />
4 speed transmission . . . . . . . . .<br />
Gearshift lever lower housing nuts .<br />
Drive flange centre bolts . . . . . . . . .<br />
Selector rod clamp nut . . . . . . . . . .<br />
Bearing cover . . . . . . . . . . . . . . . .<br />
Filler and drain plugs . . . . . . . . . . .<br />
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Transverse mounted, front wheel drive layout with integral transaxle<br />
differential/final drive. 4 or 5 forward speeds,1 reverse speed<br />
2.2 litres<br />
3.1 litres<br />
See end of “weekly checks”<br />
AKV, AKY, CEL, CEN<br />
AKY, CEL<br />
AHZ, AYZ, CEE, CEM<br />
CEG, 8P<br />
AHD, CEH<br />
CEK, ATV<br />
Nm<br />
Ibf ft<br />
. . . . .......... 55 41<br />
. . . . .......... 80 59<br />
. . . . .......... 15 11<br />
. . . . .......... 25 18<br />
. . . . .......... 20 15<br />
. . . .......... 20 15<br />
. . . . .......... 25 18<br />
Description<br />
1 The manual transmission is mounted<br />
transversely in the engine bay, bolted directly<br />
to the engine. This layout has the advantage<br />
of providing the shortest possible drive path<br />
to the front wheels, as well as locating the<br />
transmission in the airflow through engine<br />
bay, optimising cooling. The unit is cased in<br />
aluminium alloy.<br />
2 Drive from the crankshaft is transmitted via<br />
the clutch to the transmission input shaft,<br />
which is splined to accept the clutch driven<br />
plate.<br />
3 All forward gears are fitted with<br />
syncromeshes. When a gear is selected, the<br />
movement of the cabin floor-mounted gear<br />
lever is communicated to the transmission by<br />
a selector rod. This in turn actuates a series of<br />
selector forks inside the transmission which<br />
are slotted onto the synchromesh sleeves.<br />
The sleeves, which are locked to the<br />
transmission shafts but can slide axially by<br />
means of splined hubs, press baulk rings into<br />
contact with the respective gear/pinion. The<br />
coned surfaces between the baulk rings and<br />
the pinion/gear act as a friction clutch, that<br />
progressively matches the speed of the<br />
synchromesh sleeve (and hence the<br />
transmission shaft) with that of the<br />
gear/pinion. The dog teeth on the outside of<br />
the baulk ring prevent the synchromesh<br />
sleeve ring from meshing with the gear/pinion<br />
until their speeds are exactly matched; this<br />
allows gear changes to be carried out<br />
smoothly and greatly reduces the noise and<br />
mechanical wear caused by rapid gear<br />
changes.<br />
4 Drive is transmitted to the differential<br />
crownwheel, which rotates the differential
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