Assembly Sequence

5 Speed Manual 02J

Assembly sequence

Disassembling and assembling transmission housing cover, transmission housing, selector mechanism, input shaft, output shaft (pinion shaft), differential and selector forks

Special tools and equipment






- VW 309 Holding plate
- VW 353 Transmission support
- VW 295 Drift
- VW 244 B Driving sleeve
- VAG 1416 Hot air blower or equivalent
- Studs M8 x 100 mm

Disassembling






- Mount transmission on repar stand.
- Drain transmission oil.
- Remove clutch release lever and release bearing.
- Remove guide sleeve.






- Remove transmission housing cover (arrow),






- Remove bolts and 5th gear selector fork (arrows)
- Remove spring for locking elements
- Push operating sleeve over synchronizer hub and takeout locking elements.






- Select 5th (arrow -1-) and 1st gear (arrows -2- and -3-) and remove bolts -A- for synchronizer hub and 5th gear.

Note:
After engaging both gears the input shaft and output shaft are locked and the synchronizer hub and gear cannot turn. Both bolts can then be loosened.

- Remove operating sleeve






- Pull off 5th gear synchronizer-hub 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:
- Position two arm puller and center by turning knob (arrow).
- Heat gear with heat gun VAG 1416 or equivalent and pull off.

Note:

When pulling off the gear ensure that the tool hooks do not bend outward. If necessary tighten the screw at the knob (arrow). After 5th gear has been removed check for damage.






- Remove both flange 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; to do this place selector shaft in neutral position. Then remove bolts (arrows) and pull selector shaft out of transmission housing.

Transmissions From 06.99

- Remove selector shaft with selector mechanism cover; to do this place selector shaft in neutral position. Then remove bolts -arrows- and pull selector shaft out of transmission housing.

Continuation For All Vehicles






- 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 bolts -B-at differe7tial.






- Remove clutch housing to transmission housing bolts -A- from inside clutch housing.

Note:
DO NOT remove nuts -B- for output shaft bearing support.






- Remove transmission housing,

Note:
If necessary carefully pry up all around the housing on the protruding housing flange (arrows) and alternate between sides.

CAUTION!
Do not damage the seating surfaces when removing the transmission housing.






- Remove selector forks -A- together with selector rails.
- Remove bolt for reverse gear selector mechanism -B-.
- Remove nuts for output shaft bearing support.






- Remove reverse gear -A-, input shaft -13- and output shaft -C-from clutch housing in order.
- Remove differential.

Assembling
- Install differential.

Note:






- Always replace O-rings (arrows) for output shaft bearing support.
- The illustration only shows 3 of the 4 O-rings.

- Install input shaft, output shaft and reverse shaft together.
- Tighten nuts for output shaft bearing support.
- Using a tap, clean any remaining fluid in reverse shaft support threads.
- Install reverse shaft support.
- Install reverse gear selector mechanism.






- Installed position of reverse gear
- Install selector forks together with selector rails.






- Thread M8 x 100 mm studs -A- into reverse shaft support so that shaft will be aligned after installing transmission housing.
- Align selector rails.

Note:
The selector segments must be positioned in the grooves on the operating sleeves.

- Install transmission housing.
- Install reverse shaft support bolts (arrow) as follows:






- Insert bolt -a-, remove stud (Illustration V34-2008), insert bolt -lb- and hand tighten.
Tightening sequence:
1 Bolt -a- = 30 Nm (22 ft. lbs.)
2 Bolt -b- = 30 Nm (22 ft. lbs.)






- Align selector mechanism with a screwdriver and install pivot pin for selector forks (arrow).






Install selector shaft as follows:
- Place selector rails in neutral.
- Locate lug (arrow -1-) in recess in transmission housing and position selector shaft so that selector finger (arrow -2-) is inserted in the selector rails.
- Install selector shaft cover.

Installation position of 5th gear






- The circumferential groove (arrow) faces toward transmission housing.






- Drive-on 5th gear.

Checking 5th gear synchronizer ring






- Before installing 5th gear and synchronizer ring press synchronizer ring onto cone of gear and measure gap -a- with feeler gauge.






- Install 5th gear with needle roller hearing
- 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






The pointed teeth of the operating sleeve (arrow -1-) and the high shoulder of the synchronizer hub (arrow -2-) face the transmission housing.
The synchronizer hub mountings (arrow -3-) align with the synchronizer ring cast locking pieces refer to arrows on Illustration N35-0018.

5th gear synchronizer ring with cast locking pieces (arrows)











- Drive-on 5th gear synchronizer hub.

Note:
When driving on make sure the synchronizer ring is free to move.

- Thread-in securing bolts for synchronizer hub and 5th gear but do not tighten.






Installation position of dished spring for gear and 5th gear synchronizer hub securing bolts:
The concave side of the dished springs faces the gear.






- Engage two gears and tighten 5th gear synchronizer hub and gear securing bolts (arrows).
- 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. If 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.