Transmission Housing, Assembly Overview
Transmission housing, assembly overview, 02M/02Y, 5 & 6 Speed M/T, AWD
1 - Transmission housing
^ Adjust input shaft, output shafts and differential when replacing Adjustment overview
2 - Cap
^ Removing
^ Driving in
3 - Oil drain plug
^ Note different versions
^ Tighten hex socket bolt to 30 Nm
^ Tighten head socket bolt to 45 Nm
4 - Seal
^ Always replace
5 - Locking bolt for oil filler hole
^ Note different versions
^ Tighten hex socket bolt to 30 Nm
^ Tighten head socket bolt to 45 Nm
6 - Lock elbow
^ For adjustment of shift mechanism
^ Can be replaced with non-disassembled transmission
^ Removing
^ Installed position
^ Driving in
7 - Bearing bushing
^ For shift rods
^ Pulling out
^ Driving in
8 - Lock sleeve
^ Pressing off with transmission disassembled
^ Driving off with non-disassembled transmission
^ Driving in
9 - Needle sleeve
^ For reverse shaft
^ Always replace after removal
^ Pulling out
^ Pressing in
10 - Tapered roller bearing outer race
^ For output shaft for 5th/6th and reverse gear
^ Adjust output shaft for 5th/6th and reverse gear when replacing Output shaft for 5th/6th and reverse gears, adjusting
11 - Adjustment shim
^ For output shaft for 5th/6th and reverse gear
^ List of adjustments Adjustment overview
12 - Tapered roller bearing outer race
^ For output shaft for 1st to 4th gear
^ Adjust output shaft for 1st to 4th gear when replacing Output shaft for 1st to 4th gear, adjusting
13 - Adjustment shim
^ For output shaft for 1st to 4th gear
^ List of adjustments Adjustment overview
14 - Tapered roller bearing outer race
^ For differential
^ Adjust differential when replacing Adjustment overview
15 - Adjustment shim
^ For differential
^ List of adjustments Adjustment overview
16 - Bearing bushing
^ For selector shaft
^ Pulling out
^ Driving in
17 - Sealing plugs
^ Driving out
^ Driving in
18 - Seal
^ For left flanged shaft
Various locking bolts for oil drain hole and oil filler hole
I - Socket head locking bolt, 45 Nm
II - Hex socket locking bolt, 30 Nm
Remove cap
- Knock rubber through in center of cap - A - using a screwdriver - B - and pry off cap in direction of - arrow -.
Driving in cap
- Drive in cap until impact.
Removing lock elbow for selector shaft
- Break off bracket in released position.
- Guide a screwdriver - A - into hole of lock elbow - B -.
- Pull out lock elbow in direction of - arrow -.
Installation position of lock elbow
^ Marking on lock elbow - arrow - must point to slave cylinder connection - 1 -.
^ Angle - a - must be approx. 45°.
Driving in lock elbow for selector shaft
- Drive lock elbow - arrow - for selector shaft in to tool stop.
^ Lock elbow must be released for driving in procedure.
Pulling out bearing bushing for shift rod
A - Internal puller 14.5 to 18.5 mm Kukko 21/2
B - Support Kukko 22/2
Driving in bearing bushing for shift rod to tool stop
- Drive in bearing bushing up to tool stop.
Pressing lock sleeve out of transmission housing
A - Lock sleeve
- Arrange transmission housing on thrust plate VW 401 and thrust plate VW 402 so that alignment bushings in transmission housing are not damaged.
Driving off lock sleeve with non-disassembled transmission
- Remove mounting screw and selector shaft.
- Rotate transmission so that lock sleeve does not fall into transmission.
- Drive out lock sleeve with non-disassembled transmission using guide pin 10-15.
Driving in lock sleeve until tool stop
^ Transmission housing bolted to clutch housing.
- Drive in lock sleeve to tool stop using only drift T10168.
Pulling needle sleeve for reverse shaft off transmission housing
A - Internal puller 23.5 to 30 mm Kukko 21/4
B - Support Kukko 22/2
Note: Needle sleeve is destroyed when removed and must be replaced.
Pressing in needle sleeve into transmission housing
- During pressing sequence, place thrust washer - B - for reverse shaft on needle sleeve - A -.
- Support transmission housing directly beneath bearing mount using tube VW 416 B.
Pulling out bearing bushing for selector shaft
A - Internal puller 14.5 to 18.5 mm Kukko 21/2
Driving in bearing bushing for selector shaft
- Drive in bearing bushing - A - up to tool stop.
Driving out sealing plugs
- Drive sealing plug - 1 - from interior of transmission housing toward outside.
Driving in sealing plug
- Drive in sealing plug - 1 - to dimension - a - approx. 3 mm under lower edge of housing using bearing driver 3264.