Case: Service and Repair

5 Speed Manual 02J

Transmission Housing And Clutch Housing Servicing

Special tools






- VW 295 Drift
- VW 295a Adapter
- VW 447 H Thrust pad
- VW 512 Thrust pad
- 2040 Tube
- VW 454 Thrust tube






- VW 222 A Drift
- vw 353 Transmission support
- 3066 Spindle from assembly tool
- 3124 Press piece
- VAG 1331 Torque wrench
- 1 - Kukko 21/1 Internal puller
- 4 - Kukko 22/1 Counter-support






1 Transmission housing
- If replaced adjust input shaft and differential.
2 Needle roller bearing
- For output shaft
- Removing
- Installing and securing
3 Oil filler plug
- 25 Nm (18 ft. lbs.)
- Without magnet
4 Outer race/tapered roller bearing
- For output shaft
- Removing and installing
- If replaced adjust output shaft
5 Shim
- For output shaft
- Adjustment overview
6 Shim
- For input shaft
- Adjustment overview
7 Outer race/tapered roller bearing
- For input shaft
- Removing and installing
- If replaced adjust input shaft
8 Outer race/tapered roller bearing
- For input shaft
- Removing and installing
- If replaced adjust input shaft
9 Needle bearing
- Removing and installing
10 Dowel sleeve
- Qty. 2
11 Starter bushing
- Pulling out - Fig. 5
- Driving in - Fig. 6
- Car be replaced without removing transmission
12 Clutch housing
- If replaced, refer to Adjustment overview. Adjustments
13 -Guide sleeve
- With input shaft seal and O-ring
- driving-out oil seal - Fig. 3
- driving-in oil seal - Fig. 4
- Remove guide sleeve to charge oil seal
- If damaged replace guide sleeve and O-ring together
14 Socket-head bolt
- 20 Nm (15 ft. lbs.)
- Self-locking
- Always replace
15 Oil seal
- Replacing.
16 Sleeve
- For oil seal (Item 15)
- Removing refer to Fig, 7
- Installing refer to Fig. 8
17 Speedometer drive
- 30 Nm (22 ft. lbs.)
18 Oil drain plug
- 25 Nm (18 ft. lbs.)
- Without magnet
19 Outer race/tapered roller bearing
- For differential
- Removing and installing.
- If replaced adjust differential.
20 Magnet Held in place by housing joint surface
21 Outer race/tapered roller bearing
- For differential
- Driving in and out.
- If replaced adjust differential.
22 Shim
- For differential
- Adjustment overview
23 Oil seal
- Replacing

Fig. 1 Driving out needle roller bearing.






Fig. 2 Driving needle roller bearing in onto stop






- Secure needle roller bearing in transmission housing at three points (120° offset) with a punch.

Fig. 3 Driving oil seal out of guide sleeve.






Fig. 4 Driving oil seal into guide sleeve onto stop.






Fig. 5 Pulling Out Starter Bushing.






A Internal extractor 12... 14.5 mm, e.g. Kukko2l/1
B Counter support. e.g. Kukko 22/1

Fig. 6 Driving in starter bushing






Fig. 7 Prying out sleeve with screwdriver (arrow)






Fig. 8 Pulling in sleeve






A Spindle from assembly tool 3066 screwed into differential threaded piece
B Nut M12 with washer
- Pull sleeve in onto stop with thrust pad 3124 by turning nut -B-.

Note:
When transmission is disassembled press sleeve in with thrust pad 3724 onto stop.