Transmission Housing, Servicing

Transmission housing, servicing, 02X, 6 Spd. M/T AWD

Special tools, testers and auxiliary items required:

^ Drift VW 295
^ Adapter VW 295 A
^ Punch VW 408 A
^ Tube VW 423
^ Slide hammer-complete set VW 771
^ Holding fixture VW 801

Special tools, testers and auxiliary items required:

^ Guide pin 10 - 15
^ Installing tool 40 - 503
^ Torque wrench V.A.G 1331
^ - 1 - Internal puller Kukko 21/2
^ - 4 - Counter-support Kukko 22/2
^ Drift T40085





1 - Transmission housing
^ When replacing: adjust input shaft

2 - Oil seal for selector shaft
^ Replacing with transmission installed
^ Can be replaced with transmission removed (transmission remains assembled)
^ Always replace
^ Pulling out
^ Driving in
^ Use assembly sleeve to install (selector shaft remains installed)

3 - Tapered roller bearing outer race (right-side)
^ For differential
^ If replaced: adjust differential (ring gear)

4 - Shim "S2"
^ Note thickness
^ Table of adjustments

5 - Bush
^ Drive in (for example, with punch VW 408 A when replacing transmission

6 - Magnet
^ Clean

7 - Ball head stud, 25 Nm
^ Grease with MoS2 grease

8 - Oil drain plug, 45 Nm
9 - Oil seal
^ For flange shaft (right-side)
^ Removing and installing

10 - Locking bushing
^ For selector rod for 1st and 2nd gear
^ Removing and installing

11 - Locking bushing
^ For reverse gear selector rod
^ Removing and installing

12 - Ball sleeve
^ For selector rod for 1st and 2nd gear
^ Pulling out
^ Drive in until flush using guide pin 10 - 15

13 - Ball sleeve
^ For selector rod for 3rd and 4th gear
^ Pulling out
^ Drive in until flush using guide pin 10 - 15

14 - Shim "S2" 3
^ Note thickness
^ Table of adjustments

15 - Outer race of double tapered roller bearing
^ For pinion shaft

16 - Bolt, 24 Nm
17 - Needle bearing
^ For input shaft
^ Driving out
^ Driving in

18 - Oil collector
^ With magnet
^ Installation position in transmission housing

19 - Ball sleeve
^ For selector shaft
^ Pulling out
^ Driving in

20 - Cap
^ For transmission breather

21 - Breather tube
^ Drive in onto stop
^ Clip in cap for transmission breather





Pulling out oil seal for selector shaft with transmission disassembled





Installing oil seal - C - with selector shaft installed
- Push assembly sleeve 01E311120 - A - onto selector shaft - B -.





Driving in seal for selector shaft
- Pack space between sealing lip and dust lip half-full with sealing grease G052128A1.
- Lightly oil outer circumference of seal.
- Drive oil seal - arrow - into housing as far as it will go.





Removing and installing locking bushing for selector rod
- Drive out used locking bushing - A - inward into transmission housing.
- Drive in new locking bushing into transmission housing - B - until flush.





Pulling out ball sleeve - C - from transmission housing.
A - Counter-support, e.g. Kukko 22/2
B - Internal puller 14.5 to 18.5 mm, e.g. Kukko 21/2





Driving out input shaft needle bearing from transmission housing
- Remove bolt for securing needle bearing .
- Install adapter VW 295 A with smaller outside diameter into needle bearing.
- Drive out needle bearing with drift VW 295.





Pressing in input shaft needle bearing until limit stop
- Secure needle bearing after pressing in





Securing input shaft needle bearing
- Secure input shaft needle bearing with bolt - 2 -.
- Insert oil collector - 1 - into transmission housing.





Removing selector shaft ball sleeve
- A - Internal puller 14.5 to 18.5 mm, e.g. Kukko 21/2





Driving in ball sleeve for selector shaft
Install ball sleeve so that side with lettering (thicker metal) faces guide pin 10 - 15.
- Drive in ball sleeve until flush.