Transmission Housing and Clutch Housing, Servicing

Transmission housing and clutch housing, servicing, 02J, 5 Spd. M/T

Special tools and equipment:

- VW 295 Drift
- VW 295a Adapter
- VW 447 H Press plate
- VW 512 Press disk
- VW 415 A Tube
- VW 454 Press piece

Special tools and equipment:

^ VW 228 B Puller
^ VW 222 A Drift
^ 3066 Spindle from assembly tool
^ 3124 Press piece





1 - Transmission housing
^ If replaced: adjust input shaft and differential

2 - Needle roller bearing
^ For output shaft
^ Removing go to Fig. 1
^ Installing and securing go to Fig. 2

3 - Oil filler plug, 25 Nm
^ Without magnet

4 - Shim
^ For input shaft

5 - Outer race/tapered roller bearing
^ For input shaft
^ If replaced: Adjust input shaft

6 - Outer race/tapered roller bearing
^ For output shaft

7 - Shim
^ For output shaft

8 - Outer race/tapered roller bearing
^ For input shaft

9 - Needle bearing
10 - Dowel sleeve
^ (Qty. 2)

11 - Starter bushing
^ Pulling out go to Fig. 5
^ Driving in go to Fig. 6
^ Can be replaced without removing transmission

12 - Clutch housing
^ If replaced: go to Adjustment overview

13 - Guide sleeve
^ With input shaft seal and a vulcanized O-ring
^ Driving-out oil seal go to Fig. 3
^ Driving-in oil seal go to Fig. 4
^ Remove guide sleeve to change the oil seal
^ If damaged replace guide sleeve and O-ring together

14 - Socket head bolt, 20 Nm
^ Self-locking
^ Always replace

15 - Oil seal
16 - Sleeve
^ For oil seal (item 15)
^ Removing go to Fig. 7
^ Installing go to Fig. 8

17 - Speedometer drive, 30 Nm
18 - Oil drain plug, 25 Nm
^ 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

23 - Oil seal





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 Drive oil seal into guide sleeve onto stop





Fig. 5 Pulling out starter bushing





Fig. 6 Driving in starter bushing





Fig. 7 Pry out sleeve with screwdriver





Fig. 8 Pulling sleeve in





- Pull sleeve in onto stop with thrust piece 3124 by turning on nut -B-.

Note: When transmission is disassembled press sleeve in with thrust piece 3124 onto stop.