Trans Housing, Shaft Mechanism, Input Shaft, Output Shafts, Differential, Bevel Gear Transfer Case, Disassembly/Assembly

Transmission housing, shaft mechanism, input shaft, output shafts (driven shafts), differential, bevel gear transfer case and shift rods (transmission as of approx. 04.2003), disassembling and assembling, 02M/02Y, 5 & 6 Speed M/T, AWD





Special tools, testers and auxiliary items required
^ Holding plate VW 309
^ Holding fixture VW 313
^ Transmission support VW 353
^ Thrust tube VW 455
^ Slide Hammer-Complete Set VW 771
^ Sleeve 30-21





Special tools, testers and auxiliary items required
^ Bracket 30 - 211 A
^ Thrust piece T10042
^ Mandrel T10168
^ Thrust piece T40008
^ Torque wrench V.A.G 1331
^ Heat gun V.A.G 1416

Special tools, testers and auxiliary items required





^ - 1 - Internal extractor Kukko 21/1
^ - 3 - Separating tool Kukko 17/0
^ - 4 - Support Kukko 22/1





^ Old oil collecting and extracting device V.A.G 1782

Disassembling

Vehicles with 4 cylinders Engine:





- Secure transmission to holding fixture using bolts - arrows -.

Vehicles with 6 cylinders Engine:





- Secure transmission to holding fixture using bolts - arrows -.

All:
^ Rotate transmission in assembly stand with oil drain plug downward.
^ Place old oil collecting and extracting device V.A.G 1782 beneath transmission.
^ Remove drain plug and drain gear oil.





^ Remove bolt for right flange shaft using hex extension V.A.G 1669.

Note: Right flanged shaft remains in bevel gear transfer case.

- Remove four connecting bolts (only three depicted in illustration) for bevel gear transfer case/manual transmission - arrows -.
- Press bevel gear transfer case off of manual transmission.





- Remove clutch slave cylinder with release bearing - arrows -.





- Bring selector shaft into idle position.

Note: Make sure that selector shaft is not locked by the lock elbow - arrow -.





- Remove Back-Up Light Switch F4 - item 1 -.
- Remove mounting screw - 2 - and bolts - 3 -.
- Pull out selector shaft - 4 - out of transmission housing.
- Remove flange shaft and stub shaft.





- Remove bolts - B - for securing clutch housing to transmission housing.

Note: Hex bolt - arrow - is located outside of bolting flange. It is installed with a washer.





- Secure input shaft by inserting Thrust tube VW 455 over input shaft onto clutch housing.
- Tension separating tool Kukko 17/0 - item A - behind input shaft splines.
^ Back side of separating tool must contact Thrust tube VW 455 free of play.





- Knock rubber through in center of cap - C - using a screwdriver.
- Remove cap from transmission housing.
A - Support Kukko 22/1
B - Internal puller 8 to 12 mm Kukko 21/01





- When removing securing ring - C - from grooved ball bearing of input shaft/transmission housing, hold one end of securing ring using a screwdriver - A -.
- Pry other end off of securing ring from groove of grooved ball bearing direction of - arrow - using a screwdriver - B -.
- By following with screwdriver - B - continue to pry out securing ring.





- Remove connecting bolts - A - of transmission housing/clutch housing.





- Screw adapter VW 771/40 into threaded hole of transmission housing.
- Heat transmission housing using heat gun V.A.G 1416 in area of bearing seat for grooved ball bearing/input shaft to 100°C for approx. 10 minutes.
- Pull off transmission housing from clutch housing direction of - arrow - using slide hammer VW 771.

Note: If necessary, carefully pry up all around and alternating between sides on protruding flange taking care not to damage sealing surfaces.





- Remove separating tool - A - and thrust tube from input shaft.





^ A 2nd technician is required to remove shafts from clutch housing.
- Lift differential - 1 - using left hand. With the right hand, lift output shaft for 1st to 4th gears together with shift rods - 2 - - arrow A -.
- At the same time, 2nd technician lifts input, reverse and output shaft for 5th/6th gear - 3 - together with shift rods out of clutch housing - arrow B -.

Note: If necessary, differential can be shifted again in clutch housing after lifting shafts.

- Drive in sealing ring for input shaft using sleeve 30-21.





Assembling
- Insert input shaft - 1 -, output shaft for 5th/6th gears - item 2 - together with shift rod - 3 -, shift fork - 4 - and reverse shaft - 5 -.





- Insert differential - 1 -.





- As shown in illustration, take output shaft for 1st to 4th gears - 3 - with shift rods - 4 - in right hand.
- Lift differential slightly using left hand.
- At the same time, 2nd technician slightly lifts input shaft, output shaft for 5th/6th gears and reverse gear - 2 - together with reverse shaft.
- Now, insert output shaft for 1st to 4th gears in direction of - arrow -.
^ Splines of input shaft, output shafts and final drive gear/differential must engage.
- Together with a second technician, displace shafts in their bearing seats.





- Secure bracket 30-211 A for input shaft at clutch housing.

Note: For the sake of illustration, clutch housing is depicted rotated 180°.

- Screw in bolt - A - far enough until input shaft rises slightly.
- Heat transmission housing using heat gun V.A.G 1416 in area of bearing seat for grooved ball bearing/input shaft to 100°C for approx. 10 minutes.
- Install transmission housing.





- Install circlip - 1 - for grooved ball bearing/input shaft.
- Remove bracket 30-211 A for input shaft.





- If lock sleeve for selector shaft has been removed, drive it in using drift T10168 until tool makes contact.
- Turn transmission with opening for selector shaft in assembly stand upward.





- Insert selector shaft - 1 - into lower bearing - 2 - and into shift forks - 3 -.

Note: For better depiction, cap is removed.





- Press selector shaft - 1 - against lock sleeve - 2 - direction of - arrow - and guide downward with shift finger - 3 - through shift forks until stop.
^ Shift cover - 4 - must stand parallel to bolting surface on transmission housing during this.
^ Selector shaft must be able to be moved slightly in selector motion (up- and downward).

Note: If shift cover stands at an angle to bolting surface, selector shaft is not inserted in lower bearing.





- Tighten bolts - 3 - for cover/selector rod - 4 -.
- Screw in mounting screw - 2 -, lock elbow - arrow - must lie outside.
- Install Back-Up Light Switch F4 - item 1 -.
- Install flanged shaft and stub shaft with compression springs, thrust washers and tapered rings.





- Drive in sealing ring for input shaft.
- Install clutch slave cylinder with release bearing.
- Shift into all gears.





- Drive in cap into transmission housing until tool stop using pressure piece T10042.





Install bevel gear transfer case as follows:
- Replace O-ring for sealing of bevel gear transfer case/manual transmission - arrow A - and O-rings for sealing oil supply sleeves -arrows B and C -.
- Lightly oil O-rings when installing.
- Slide on bevel gear transfer case completely on manual transmission, while doing this join splines of input shaft/bevel gear transfer case centrally with connecting sleeve/differential.
- Bring right drive axle splines and differential bevel gear also into alignment, rotate drive flange if necessary.
^ With proper tooth position and central guiding, bevel gear transfer case slips up to stop against manual transmission.

CAUTION! Do not pull bevel gear transfer case with mounting bolts against manual transmission, otherwise bevel gear transfer case is canted and mounting eyelets can break off.





- Install four connecting bolts (only three depicted in illustration) for bevel gear transfer case/manual transmission - arrows -.
- Install conical head bolt for right flanged shaft using socket V.A.G 1669, secure against turning using a drift.