Transmission and Clutch Housing Servicing

5 Speed Manual 02J





Special tools
- VW 295 Drift
- VW 295a Adapter
- VW 447 H Press plate
- VW 512 Press disk
- VW 415 A Tube
- VW 454 Press piece





Special Tools And Workshop Equipment Required
- VW 228 B Puller
- VW 222 A Drift
- 3066 Spindle from assembly tool
- 3124 Press piece





1. Transmission housing If replaced adjust input shaft and differential
2. Needle roller bearing
- For output shaft
- Removing refer to Fig. 1
- Installing and securing refer to Fig. 2
3. Oil filler plug, 25 Nm
- Without magnet
4. Shim
- For input shaft
- Adjustment overview.
5. Outer race/taper roller bearing
- For input shaft
- Removing and installing.
- If replaced adjust input shaft.
6. Outer race/taper roller bearing
- For output shaft
- Removing and installing.
- If replaced adjust output shaft.
7. Shim
- For output shaft
- Adjustment overview.
8. Outer race/taper roller bearing
- For input shaft
- Removing and installing.
- If replaced adjust input shaft.
9. Needle bearing
- Removing and installing.
10. Dowell sleeve
- (Qty. 2)
11. Starter bushing
- Pulling out refer to Fig. 5
- Driving in refer to Fig. 6
- Can be replaced without removing transmission
12. Clutch housing
- If replaced: refer to Adjustment overview.
13. Guide sleeve
- With input shaft seal and O-ring
- Driving-out oil seal refer to Fig. 3
- Driving-in oil seal refer to Fig. 4
- Remove guide sleeve to change the oil seal
- If damaged replace guide sleeve and O-ring together
14. Socket head bolt, 20 Nm
- Self-locking
- Always replace
15. Oil seal
- replacing.
16. Sleeve
- For oil seal -15-
- Removing refer to Fig. 7
- Installing refer to Fig. 8
17. Speedometer drive, 30 Nm
18. Oil drain plug, 25 Nm
- Without magnet
19. Outer race/taper roller bearing
- For differential
- Removing and installing.
- If replaced adjust differential.
20. Magnet
- Held in place by housing joint surface
21. Outer race/taper roller bearing
- For differential
- Driving in and out.
- If replaced: Adjust differential.
22. Shim
- For differential
- Adjustment overview.
23. Oil seal
- Replacing.





Fig. 1 Driving out needle roller bearing





Fig. 2 Driving needle roller bearing in onto stop
- Secure needle roller bearing in transmission housing at three points (120° offset) using punch.





Fig. 3 Driving oil seal out of guide sleeve





Fig. 4 Driving oil seal into guide sleeve onto stop





Fig. 5 Pulling out starter bushing





Fig. 6 Driving in starter bushing





Fig. 7 Prying out sleeve using screwdriver





Fig. 8 Pulling sleeve in
A-Screw threaded rod from assembly tool 3066 into differential threaded piece
B-Nut M 12 with washer
- Pull sleeve into stop with thrust piece 3124 by turning on nut -B-.

Note: When transmission is disassembled press sleeve in with thrust piece 3124 onto stop.