Part 1

Output shaft, disassembling and assembling, 02J, 5 Spd. M/T

Special tools and equipment:

^ VW 407 Press tool
^ VW 412 Press tool
^ VW 512 Press disk
^ VAG 1582 Puller
^ VAG 1582/4 Grip piece
^ VAG 1582/5 Grip piece

Special tools and equipment:

^ VW 402 Thrust plate
^ 32-111 Thrust piece
^ VW 408 A Press tool
^ VW 407 Press tool
^ VW 457 Support rails
^ VW 519 Tube

Special tools and equipment:

^ VW 429 Thrust ring
^ VW 415 A Tube
^ VW 447 H Press plate
^ VW 454 Press piece
^ VW 455 Fitting sleeve
^ 41-501 Drift sleeve





Note:
^ The output shaft is disassembled as follows:

- Position separating device under 2nd gear (item 19) and press off as described in Fig. 5.
- Remove circlip (item 15).
- Position two-arm puller under bearing support (item 9) and pull off locking collar with 1st and 2nd gear synchro-hub as described in Fig. 6.
^ Both tapered roller bearings must be replaced together as a set.

1 - Hex nut, 25 Nm and then turn 90° further
^ 4 nuts for bearing support

2 - Clutch housing
3 - Shim
^ For output shaft

4 - Small tapered roller bearing outer race
^ Removing go to Fig. 1
^ Pressing in go to Fig. 2

5 - Small tapered roller bearing inner race
^ Pulling off go to Fig. 3
^ Pressing on go to Fig. 4

6 - Output shaft
^ Is paired with final drive gear, always replace together as a set

7 - Large tapered roller bearing inner race
^ Pulling off go to Fig. 7
^ Pressing on go to Fig. 8

8 - Sealing ring
^ Place sealing rings (Qty. 4) on bearing support bolts

9 -Bearing support
^ With large tapered roller bearing outer race and bolts
^ Only change outer race together with large tapered roller bearing and bearing support

10 - Thrust washer
^ Shoulder on thrust washer faces tapered roller bearing

11 - 1st selector gear
^ From transmission build date 02 05 0 the synchronization for 1st gear has been modified

12 - Needle roller bearing
^ For 1st gear

13 - 1st gear synchro-ring
^ Checking for wear go to Fig. 9
^ Identification go to Fig. 14
^ From transmission build date 02 05 0 the synchronization for 1st gear has been modified

14 - 1st and 2nd gear locking collar with synchro-hub
^ Pull off with bearing support after removing the circlip (item 15) go to Fig. 6
^ Disassembling go to Fig. 10
^ Assembling locking collar/synchro hub go to Fig. 10 and Fig. 11
^ Installation position go to Fig. 12
^ Pressing on go to Fig. 13
^ From transmission build date 02 05 0 the synchronization for 1st gear has been modified

15 - Securing clip
16 - 2nd gear synchro-ring
^ Identification go to Fig. 14
^ Checking for wear go to Fig. 16
^ Assemble so that the recesses locate in the locking collar (item 14) locking pieces

17 - Outer ring
^ Insert in the synchro-ring (item 16). Installation position go to Fig. 17
^ Replace if scored

18 - Synchro-ring
^ (inner ring)
^ Checking for wear go to Fig. 18
^ Check lugs for scoring
^ Installation position go to Fig. 19

19 - 2nd gear
^ Installation position go to Fig.

20 - Needle roller bearing
^ For 2nd gear

21 - Thrust washer
22 - Sleeve for 3rd gear needle roller bearing
^ Pressing off with 2nd gear go to Fig. 5
^ Pressing on go to Fig. 21

23 - Needle roller bearing
^ For 3rd gear

24 - Selector gear for 3rd gear
25 - 3rd gear synchro-ring
^ Checking for wear go to Fig. 9

26 - Locking collar with 3rd and 4th gear synchro-hub
^ Press off with 2nd gear (item 19) and 3rd gear (item 24) go to Fig. 5
^ Disassembling go to Fig. 22
^ Installation position locking collar/synchro-hub go to Fig. 24
^ Assembling locking collar/synchro-hub go to Fig. 22 and Fig. 23
^ Pressing on go to Fig. 25

27 - Sleeve
^ For needle roller bearing
^ Press off with locking collar and 3rd and 4th gear synchro-hub (item 26) go to Fig. 5
^ Pressing on go to Fig. 26

28 - Needle roller bearing
^ For 4th gear

29 - 4th gear synchro-ring
^ Checking for wear go to Fig. 9

30 - Selector gear for 4th gear
31 - Thrust washer
32 - Needle roller bearing
^ For output shaft

33 - Transmission housing
34 - Sleeve
^ For output shaft needle roller bearing
^ Pressing off go to Fig. 5
^ Pressing on go to Fig. 27

35 - 5th gear
36 - Dished spring
37 - Torx socket head bolt M10, 80 Nm
^ Fitted portion on bolt head holds saucer spring washer in position





Fig. 1 Pulling out small tapered roller bearing outer race
A - Internal extractor 37 to 46 mm, e.g. Kukko 21/6
B - Counter support, e.g. Kukko 22/2





Fig. 2 Pressing in small tapered roller bearing outer race





Fig. 3 Pulling off small tapered roller bearing inner race
A - Vice clamps/vice
- Fit gripping device and tension behind bearing rollers, then turn bearing and retension gripping device.