Disassembling and Assembling

5 Speed Manual 02J





Special Tools
- VW 407 Press tool
- VW 447 H Press plate
- VW 412 Press tool
- VW 422 Tube
- VW 401 Press plate
- VW 408 A Press tool





- VW 454 Press piece
- 41-501 Drift sleeve
- VW 447 i Thrust plate
- VW 510 Press piece

Note:
- When installing new gears, consult technical data.
- If the position of the tapered roller bearings is affected when replacing parts, the input shaft must be re-adjusted. Refer to adjustment overview.





1. Clutch housing
2. Tapered roller bearing outer race
- Removing Fig. 1
- Pressing in Fig. 2
3. Tapered roller bearing inner race
- Drive off input shaft using drift
- Pressing on refer to Fig. 3
4. Input shaft
- Adjusting.
5. 3rd gear
- Shoulder points to 4th gear
- Pressing off refer to Fig. 5
- Pressing on refer to Fig. 6
6. Circlip
- Always replace
7. 4th gear
- Pressing off with tapered roller bearing outer race and sleeve refer to Fig. 4
- Pressing on refer to Fig., 7
- Collar faces to 3rd gear
8. Tapered roller bearing inner race
- Pressing off with 4th gear and sleeve refer to Fig. 4
- Pressing on refer to Fig. 8
9. Thrust washer
10. Tapered roller bearing outer race
- Pressing out refer to Fig. 10
- Pressing in refer to Fig. 11
11. Shim
- Determining thickness.
12. Transmission housing
13. Sleeve
- For needle roller bearing
- Press off with 4th gear and tapered roller bearing inner race refer to Fig. 4
- Pressing on refer to Fig. 9
- Place thrust washer on before installing -9-
14. Needle roller bearing
15. 5th gear
- Pull off together with 5th gear synchronizer hub.
16. 5th gear synchronizer ring





- With cast locking pieces.
- Check for wear.
17. Spring
- Installation position refer to Fig. 13
18. Locking pieces (Qty. 3)
- Installation position refer to Fig. 12
19. 5th gear synchronizer hub
- Removing and installing.
20. 5th gear locking collar
- Removing and installing.
21. Dished washer
- Installation position.
22. Torx socket head bolt M10, 80 Nm
- Fitted piece on bolt head locates dished spring.





Fig. 1 Pressing out tapered roller bearing Outer race





Fig. 2 Pressing in tapered roller bearing outer race





Fig. 3 Pressing on tapered roller bearing inner race





Fig.4 Pressing off 4th gear together with tapered roller bearing and sleeve





Fig. 5 Pressing off 3rd gear





Fig. 6 Pressing on 3rd gear





Fig. 7 Pressing on 4th gear
Shoulder points to 3rd gear.





Fig. 8 Pressing on tapered roller bearing inner race





Fig. 9 Pressing an sleeve for needle roller bearing





Fig. 10 Pressing out tapered roller bearing outer race





Fig. 11 Pressing in tapered roller bearing outer race
- Install together with shim after adjusting input shaft.





Fig. 12 5th gear synchronizer
1. Springs for lock pieces
2. Locking collar With 3 recesses (arrows -A-) for the locking pieces (item -4-)
3. Synchronizer hub
4. Locking pieces installation position: thin extension (arrow -B-) faces pointed teeth of locking collar (item -2-) the





Fig. 13 Assembling 5th gear locking collar/synchronizer hub
- Push locking collar over synchronizer hub.
- Pointed teeth -A- and shoulder -B- of synchronizer hub face in same direction.
- Recesses for locking pieces in locking collar and synchronizer hub must be aligned (Fig. 12)
- Insert locking pieces (installation position: Fig. 12).
- Insert springs offset by 120° underneath lug -C-.
- Angled ends of spring must be directly behind locking pieces (arrows).