5 Speed Manual 02J

5 Speed Manual 02J

Input Shaft, Disassembling And Assembling

Special tools






- VW 407 Punch
- VW 447 H Thrust pad
- VW 412 Thrust disc
- VW 422 Split tube
- VW 401 Thrust plate
- VW 408 A Punch






- VW 454 Thrust tube
- 41-501 Drift sleeve
- VW 447 1 Thrust pad
- VW 510 Thrust pad

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.






1 Clutch Housing
2 Tapered roller bearing outer race
3 Tapered Roller bearing inner Race
- Drive off shaft with drift
4 Input Shaft
5 3rd Gear
- Shoulder points to 4th Gear
6 Circlip
- Always Replace
7 4th Gear
- Pressing off with tapered roller bearing outer race and sleeve
- Collar faces 3rd gear
8 Tapered Roller bearing inner race
- Pressing off with 4th gear and race
9 Thrust Washer
10 Taper Roller Bearing outer race
11 Shim
12 Transmission housing
13 Sleeve
- For needle roller bearing
- Press off with 4th gear and tapered roller bearing inner race Fig 4
- Pressing on refer to Fig. 9
- Place, thrust washer or before installation, (item 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
- Checking 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 operating sleeve
- Removing and installing
21 Dished washer
- Installation position
22 Torx socket-head bolt
- 80 Nm (59 ft. lbs.)
- M10
- 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 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 on sleeve for needle roller bearing






Fig. 10 Pressing out tapered roller bearing outer race






Fig. 11 Pressing in tapered roller bearing outer race






Install with shim after adjusting input shaft.

Fig. 12 5th gear synchronizer






1 Springs for locking pieces
2 Operating sleeve with 3 recesses (arrows -A-) for locking pieces (item 4)
3 Synchronizer hub
4 Locking pieces installation position: thin extension (arrow -B-) faces pointed teeth of operating sleeve (item 2)

Fig. 13 Assembling 5th gear operating sleeve / synchronizer hub






- Push operating sleeve over synchronizer hub.
- Pointed teeth -A- of operating sleeve and shoulder -B- of synchronizer hub face in same direction.
- Recesses for locking pieces in operating sleeve 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-).