VW Passat B5

since 1996 release

Repair and operation of the car



Foltsvagen Passat B5
+ Maintenance instruction
+ 1. Maintenance
+ 2. Engines
+ 3. Cooling system
+ 4. Fuel system
+ 5. Engine management
+ 6. Exhaust system
- 7. Transmission
   + 7.1.2. Clutch plate
   + 7.2. Mechanical transmission
   + 7.3. Automatic transmissions
+ 8. Running gear
+ 9. Steering
+ 10. Brake system
+ 11. Body
+ 12. Heating, ventilation
+ 13. Electric equipment






7. Transmission

7.1. Coupling

7.1.1. General information

GENERAL INFORMATION

Coupling

1 – transmission,
2 – a hairpin with a spherical tip,
3 – intermediate element,
4 – dish-shaped spring,
5 – sealing ring,
6 – sealing ring of an entrance shaft of the transmission,
7 – the directing plug of the release bearing,
8 – spring,
9 – coupling switching off lever,
10 – самоконтрящийся bolt,
11 – release bearing,
12 – bolt, 20 Nanometers,
13 – working cylinder of coupling,
14 – pusher,
15 – flywheel,
16 – clutch plate,
17 – press disk,
18 – bolt, 25 Nanometers

Prevention

The spherical tip of a hairpin 2 is greased with lubricant on the basis of a molybdenum disulfide.

Moments of tightening of a hairpin 2:
 – in a transmission case from aluminum alloy of 25 Nanometers,
 – in a transmission case from magnesian alloy of 20 Nanometers.

The convex party of a spring 4 has to be directed to the directing plug.

At installation of a sealing ring 5 it is necessary to use a new sealing ring.

Installation of a sealing ring 6 is made against the stop.

The spring 8 fastens on the coupling switching off lever.

Tightening moments самоконтрящегося bolt 10:
 – to a transmission case from aluminum alloy of 35 Nanometers,
 – to a transmission case from magnesian alloy of 25 Nanometers.

Do not wash out the release bearing 11 in solvent as from it lubricant will be washed up.

The bearing 11 publishing noise at rotation needs to be replaced.

Lubricant on the basis of a molybdenum disulfide is applied on a head of a pusher 14.

If on the car the flywheel 15 consisting of two sections is established, then the clutch plate 16 without springs of a quencher of fluctuations is established.
If the flywheel 15 consists of one detail, then the clutch plate 16 with springs of a quencher of fluctuations is established, and springs have to be from a press disk.

Grease clutch plate vents with the 16th thin layer of G000100 lubricant. The layer of lubricant has to be thin and uniform, otherwise during the coupling work excessive lubricant will be rejected on the working surfaces of coupling that can break its work.

18 you make tightening of bolts gradually and evenly in the diagonal sequence.


Hydraulic drive of coupling

1 – popolnitelny tank of the brake system,
2 – hose,
3 – working pipeline of coupling,
4 – connecting nut, 15 Nanometers,
5 – arm,
6 – coupling pedal,
7 – bolt, 20 Nanometers,
8 – axis,
9 – main cylinder of coupling,
10 – transmission,
11 – working cylinder of coupling,
12 – tutser of pumping.
13 – transmission arm,
14 – bolt, 25 Nanometers,
15 – nut, 2 Nanometers,
16 – laying,
17 – laying

Prevention

At removal of the working cylinder of coupling 11 do not press a coupling pedal.

If the plastic basic ring is installed in the working cylinder of coupling, before installation grease an external surface of a ring. Apply on a pusher head lubricant on the basis of a molybdenum disulfide.

At assembly of the working cylinder of coupling press the piston into the cylinder so that it was possible to screw up a fixing bolt.

The union of pumping 12 unscrews only during removal of air from the hydraulic drive of coupling. During removal of air exclude hit of brake fluid on the transmission from the hydraulic drive of coupling.


Coupling is located between the engine and the transmission and intended for separation and connection of a bent shaft of the engine and a main shaft of the transmission. Coupling is an integral part of transmission for ensuring deduction of the car concerning the road by the included transfer, smooth start-off of the car from the place and gear shifting without noise and risk of damage of details.

At the included coupling i.e. when the pedal of coupling is in the top situation, the dish-shaped spring of the leading part of coupling moves press a clutch plate towards the engine. At the same time the clutch plate supplied with frictional slips is clamped between a press disk and a flywheel, and the torque is transferred from the engine to the transmission. When pressing a pedal of coupling the persistent bearing of coupling moves press a disk back. At the same time the clutch plate then the shaft of the engine and a shaft of the transmission can rotate independently from each other is released.

On all models dry one-disk coupling which consists of a clutch plate, a press disk, a dish-shaped spring, a casing and the press bearing is established.

The clutch plate freely moves on vents of a main shaft of the transmission and is clamped between a flywheel and a press disk by effort which is created by a dish-shaped spring. From two parties of a clutch plate of a priklepana frictional slips. The leading part of a clutch plate connects to a nave through details of a quencher of tortional fluctuations which provides elastic communication between them. The necessity of a quencher of tortional fluctuations is caused by the following.

At sharp change of speed of the movement of the car, arrival on roughness of the road, sharp inclusion of coupling, and also owing to uneven operation of the engine in transmission of the car there are dynamic loadings causing twisting (untwisting) of shaft of transmission. Unevenness of torque of the engine can cause considerable overloads in transmission owing to emergence of tortional fluctuations and a resonance at coincidence of frequencies, the transferred loadings to frequencies of own fluctuations of transmission. Elastic fluctuations of transmission lead not only to emergence of noise in mechanisms and units, but also to dangerous vibrations, and sometimes and to breakages of details when amplitude of fluctuations reaches big size. Energy of tortional fluctuations is absorbed by a quencher.

The release bearing is installed from the forward party of the transmission on the directing plug. Movement of the bearing is made by the coupling switching off lever. Pressing of a pedal of coupling moves the piston in the main cylinder and compresses liquid which on a hose is transferred to the working cylinder of coupling. Under pressure the piston of the working cylinder of coupling moves ся and puts the coupling switching off lever in action. The lever of switching off of coupling moves the release bearing which influences a spring of a press disk and takes away press a disk from a clutch plate. Adjustment of coupling happens automatically.

Depending on a design of the flywheel installed on the engine use ся various clutch plates. If the flywheel consisting of two sections with a spring and the damping system is established, then the clutch plate without springs of a quencher of fluctuations is established. If on the engine the flywheel consisting of one detail is established, then the clutch plate with springs of a quencher of fluctuations (a classical clutch plate) is established.