Disassembling and Assembling
5 Speed Manual 02J
Transmission, Disassembling And Assembling
1. 1st gear
2. 2nd gear
3. 3rd gear
4. 4th gear
5. 5th gear
6. Transmission housing
- Servicing. Refer to Case, M/T.
7. Selector mechanism (Selector forks)
- Disassembling and assembling. Refer to Shift Fork, M/T.
8. Input gear for 1st and reverse gear
9. Input shaft
- Disassembling and assembling. Refer to Input Shaft.
10. Output shaft
- Disassembling and assembling. Refer to Output Shaft, M/T.
11. Differential
- Disassembling and assembling.
12. Clutch housing Servicing.
Assembly Overview
I - Removing and installing cover for transmission housing and 5th gear.
II - Disassembling and assembling transmission housing and shift mechanism.
III - Disassembling and assembling input shaft, output shaft, differential and selector forks.
Transmission Housing And 5Th Gear Cover, Removing And Installing Cover
1. Bolt, 10 Nm (7 ft. lbs.)
- For transmission housing cover
2. Transmission housing cover
Note:
If the transmission cover IS removed and reinstalled with the transmission installed, check oil level as follows:
- Fill with oil up to lower edge of filler hole and install filler plug.
- Start engine, engage gear and allow transmission to turn for approx. 2 minutes.
- Switch off engine and top up transmission oil to lower edge of filler hole again.
3. Gasket
4. Torx socket head bolt M10, 80 Nm (59 ft. lbs.)
- Bolt head holds dished washer in position
5. Dished washer
- Installing. Refer to Case, M/T.
6. Socket head bolt, 25 Nm (18 ft. lbs.) For pivot pin to transmission housing
7. Pivot pin
8. 5th gear selector fork
- Disassembling and assembling
- Adjusting. Refer to Case, M/T.
9. 5th gear operating sleeve
- Installation position.
- Adjusting.
10. Synchronizer hub with 5th gear and synchronizing ring
- Disassembling and assembling
11. Needle roller bearing
12. 5th gear
- Installation position.
Transmission Housing And Selector Mechanism, Removing And Installing
1. Cone head bolt, 25 Nm
2. Flange shaft with spring
- Removing and installing. Refer to Differential, Manual Transaxle.
- Complement.
3. Torx socket head bolt, 30 Nm
- For reverse shaft support
- Self-locking
- Always replace
4. O-ring
- Always replace
5. Pivot pin
6. Bolt, 25 Nm
7. Bolt, 25 Nm
8. Cover plate
9. Transmission housing
- Servicing. Refer to Case, M/T.
10. Clutch housing
- Servicing. Refer to Case, M/T.
11. Bolt, 25 Nm (18 ft. lbs.) plus 90°
12. Selector mechanism
- Disassembling and assembling.
13. Bolt, 25 Nm (18 ft. lbs.)
Input Shaft, Output Shaft (Pinion Shaft), Differential And Selector Forks Removing And Installing
1. Differential
- Disassembling and assembling. Refer to Differential, Manual Transaxle.
2. O-ring
- Qty. 4
- Always replace
3. Output shaft
- Disassembling and assembling.
4. Reverse shaft support
- Disassembling and assembling.
5. Reverse shaft
- Disassembling and assembling.
6. Input shaft
- Disassembling and assembling.
7. Reverse gear selector fork
- Disassembling and assembling.
- Installation position.
8. Torx (R) socket head bolt, 25 Nm
9. Selector mechanism (forks)
- Disassembling and assembling.
10. Clutch housing
- Servicing. Refer to Case, M/T.
11. Nut, 25 Nm plus 90°
- 4 nuts for bearing support
12. Flange shaft with spring
- Removing and installing.
- Assembling.
13. Cone head bolt, 25 Nm
Assembly Sequence
Disassembling and assembling transmission housing cover, transmission housing, selector mechanism input shaft, output shaft (pinion shaft), differential and selector forks
Special Tools
- VW 309 Holding plate
- VW 353 transmission support
- VW 295 Drift
- VW 244 B Installing sleeve
- VAG 1416 Hot air blower, or equivalent
- Studs M8 x 100 mm
Disassembling
- Mount transmission on repair stand.
- Drain transmission oil.
- Remove clutch release lever and release bearing.
- Remove guide sleeve.
- Remove transmission housing cover (arrow).
- Remove 5th gear selector fork (arrow)
- Remove bolts -A- for synchro-hub and 5th gear by selecting 5th (arrow 1) and 1st gear (arrows 2 and 3).
- After engaging both gears input shaft and output shaft are locked, synchro-hub and gear cannot turn. Both bolts can now be loosened.
- Pull off synchronizer hub for 5th gear and remove together with needle roller bearing.
A-Two arm puller e.g. Kukko 20/10 with Matra V/170 hooks.
B-Hex bolt M10 x 20
- Pull off 5th gear.
A-Two arm puller e.g. Kukko 20/10 with Matra V/170 hooks.
B-Hex bolt M10 x 20
Sequence for removing:
- Fit two arm puller and centralize by turning screw (arrow).
- Heat gear using hot air blower V.A.G 1416 or equivalent and pull off.
Note: When pulling off the gear ensure that the hooks do not bend outward, if necessary tighten screw (arrow). After 5th gear has been removed check for damage.
- Remove both flange shafts.
- Take out flanged shafts along with springs, thrust washers and tapered rings.
- Remove both reverse shaft support bracket bolts (arrows).
Transmissions up to 05.99
- Remove selector shaft with selector mechanism cover:
- Place selector shaft in neutral position.
- Pull selector shaft out of the transmission housing.
Transmissions from 05.99
- Place selector shaft in neutral position.
- Remove bolts (arrows) and pull selector shaft out of the transmission housing.
Continued for all vehicles
- Remove bolts (arrows) and pull selector shaft out of transmission housing.
- Remove cover plate -A- and pivot pins -B- from underside of transmission.
- Remove pivot pins -A- on top side of transmission.
- Remove transmission housing to clutch housing securing bolts -B- in area of differential.
- Remove bolts -A-, from inside clutch housing for securing clutch housing to transmission housing.
Note:
- DO NOT remove nuts -B- for output shaft bearing support.
- Take off transmission housing.
- Take-off transmission housing, if necessary carefully pry up all round and alternate between sides on protruding housing flange (arrows). Take care not to damage sealing surfaces.
- Remove selector forks -A- together with selector plates.
- Unscrew bolt for selector mechanism for reverse gear -B-.
- Remove nuts for output shaft bearing support.
- Remove reverse gear -A-, input shaft -B- and output shaft -C- one after the other from clutch housing.
- Take out differential.
Assembling
- Install differential.
Note:
- Always replace sealing rings (arrows) for output shaft bearing support.
- The illustration only shows 3 of the 4 sealing rings.
- Install input shaft, output shaft and reverse shaft together.
- Tighten nuts for output shaft bearing support.
- Clean locking fluid remnants from threads in reverse shaft support. Remnants can be removed using a tap.
- Install reverse shaft support.
- Install reverse gear selector mechanism.
Installed position of reverse gear
- Install selector forks together with selector plates.
- Screw M 8 x 100 mm studs -A- into reverse shaft support so that shaft is aligned after fitting transmission housing.
- Align selector plates.
Note: The selector segments must be positioned in the grooves on the locking collars.
- Fit transmission housing.
Install reverse shaft support bolts (arrow) as follows:
- Insert bolt -a-, remove stud, insert bolt -b- and hand tighten.
Tightening sequence:
1. Bolt -a-: 30 Nm(22 ft. lbs.)
2. Bolt -b-: 30 Nm (22 ft. lbs.)
- Install pivot pin (arrow) for selector forks by aligning selector mechanism with a screwdriver so that relevant pivot pin can be installed.
- Install selector shaft cover
Install selector shaft as follows:
- Place selector plates in neutral.
- Locate lug (arrow -1-) in the recess in transmission housing. Position selector shaft so that selector finger (arrow -2-) is inserted in the selector plates.
- Install selector shaft cover.
Installation position of 5th gear
The circumferential groove (arrow) faces to transmission housing.
- Drive on 5th gear.
Checking 5th gear synchronizer ring
- Before installing 5th gear and synchronizer ring press the synchro-ring onto cone of the gear and measure gap -a- using feeler gauge.
- Install 5th gear together with needle roller bearing.
- Place 5th gear synchronizer ring on gear.
- Assemble 5th gear synchronizer hub/operating sleeve before installing.
Installation position of 5th gear synchronizer hub/operating sleeve
Pointed teeth of operating sleeve (arrow -1-) and high shoulder of synchronizer-hub (arrow -2-) face transmission housing.
Synchronizer-hub mountings (arrow -3-) align with synchronizer-ring cast locking pieces.
5th gear synchronizer ring with cast locking pieces (arrows)
- Drive on 5th gear synchronizer hub.
Note: When driving on ensure synchro-ring is free to move.
- Screw-in securing bolts for synchro-hub and 5th gear.
Installation position of dished spring for gear and 5th gear synchro-hub securing bolts:
The outer diameter (concave side -arrows-) faces 5th gear.
- Engage two gears before tightening 5th gear synchronizer hub and gear securing bolts.
- Install 5th gear selector fork.
Adjusting 5th gear:
- Engage 5th gear.
- Loosen bolt -1 -
- Press operating sleeve and selector fork jaws in direction of arrow, then tighten bolt -1- to 25 Nm (18 ft. lbs.).
- Check measurement: it must not be possible to slide a 0.2 mm feeler gauge between operating sleeve and gear necessary repeat adjustment.
- Disengage 5th gear so that operating sleeve is in neutral position. Synchronizer ring must move freely.
- Check selection of all gears.
- Install transmission housing cover
- Install flange shafts along with springs, thrust washers and tapered rings.
- Install release bearing guide sleeve.
- Install clutch release lever and release bearing. Refer to Clutch, M/T.