Assembly Sequence

Assembly sequence, 02J, 5 Spd. M/T

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 Fitting sleeve
- VAG 1416 Hot air blower

Disassembling





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





- Remove transmission housing cover (arrow).





- Remove 5th gear selector fork (arrow)
- Remove spring for locking piece.
- Remove locking collar and take off locking piece.
- Slide locking collar, without selector fork, over syncro-hub again.





- Remove bolts -A- for synchro-hub and 5th gear, to do this select 5th (arrow -1-) and 1st gear (arrows -2- and -3-).
- After engaging both gears input shaft and output shaft are locked, synchro-hub and gear wheel cannot turn. Both bolts can now be loosened.
- Take off locking collar.





- Pull off synchro-hub and 5th gear wheel 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 wheel
- A - Two arm puller e.g. Kukko 20/10 with Matra V/170 hooks.
- B - Hex bolt M10 x 20
- Sequence for removing:
- Install two arm puller and centralize by turning screw (arrow).
- Heat gear wheel with hot air blower VAG 1416 and pull off.

Note: When pulling off the gear wheel make sure that the hooks do not bend outward, if necessary tighten screw (arrow). After 5th gear wheel has been removed check for damage.





- Remove both flange shafts.
- Take out 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 as of 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 and transmission housing to clutch housing securing bolts -B- in area of differential.





- Remove bolts -A-, from inside clutch housing for securing clutch housing to transmission housing.

Note: Do not remove nuts -B- for output shaft bearing support.





- Take off transmission housing, carefully pry up all round and alternating between sides on protruding housing flange (arrows). Be careful not to damage sealing surfaces.





- Remove selector forks -A- together with selector plates.
- Unscrew bolt for selector mechanism for reverse gear -B-.
- Remove nuts for output shaft bearing support (Item -B-, Illustration N34-0060)





- Remove reverse gear -A-, input shaft -B- and output shaft -C- one after other from clutch housing.
- Take out differential.

Assembling
- Install differential.





- Always replace sealing rings (arrows) for output shaft bearing support.

Note: The illustration only shows 3 of the 4 sealing rings.

- Install input shaft, output shaft and reverse shaft together.
- Tighten nuts for output shaft bearing support.
- Clean locking fluid remnants from threads in reverse shaft support (arrow Illustration V34-2293).
- Remnants can be removed using a tap.
- Install reverse shaft support.
- Install selector mechanism/reverse gear.





- Installation position reverse gear
- Install selector forks together with selector plates.





- Screw M 8 x 100 mm studs -A- into reverse shaft support so that shaft is aligned after installing transmission housing.
- Align selector plates.

Note: The selector segments must be positioned in the grooves on the locking collars.





- Install transmission housing.
- Install reverse shaft support bolts (arrow) as follows:
- Insert bolt -a-, remove stud (see Illustration V34-2s008), insert bolt -b- and hand tighten.
Tightening sequence:
1 - Bolt -a- 30 Nm
2 - Bolt -b- 30 Nm





- Install pivot pin (arrow) for selector forks. To do this align selector mechanism with a screwdriver so that relevant pivot pin can be installed.
- Install selector shaft cover





- Install selector shaft as follows:
- Place selector plates in neutral.
- Locate lug (arrow -1-) in recess in transmission housing. Position selector shaft so that selector finger (arrow -2-) is inserted in selector plates.





- Install selector shaft cover.

Installation position 5th gear wheel
- The circumferential groove (arrow) faces to transmission housing.





- Drive on 5th gear wheel.

Checking 5th gear synchro-ring





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





- Install 5th gear wheel with needle roller bearing
- Place 5th gear synchro-ring on gear wheel
- Assembly 5th gear synchro-hub/locking collar before installing.





Installation position 5th gear synchro-hub/locking collar
The pointed teeth of the locking collar (arrow -1-) and the high shoulder of the synchro-hub (arrow -2-) face the transmission housing.
The mountings (arrow -3-) of the syncro-hub are in-line with the cast locking pieces of the syncro-ring (arrows in illustration. N35-0018).





5th gear synchro-ring with cast locking pieces (arrows)





- Drive on 5th gear synchro-hub

Note: When driving make sure synchro-ring is free to move.





- Screw-in securing bolts for synchro-hub and 5th gear wheel.

Installation position of dished spring for gear wheel and 5th gear synchro-hub securing bolts:
The outer diameter (concave side -arrows-) faces 5th gear.





- Engage two gears before tightening 5th gear synchro-hub and gear wheel securing bolts (arrows) (Illustration 34-2613)
- Install 5th gear selector fork.





Adjusting 5th gear:
- Engage 5th gear. Loosen bolt -1-. Press locking collar and selector fork jaws in direction of (arrow), then tighten bolt -1- to 25 Nm.
- Check measurement: It must not be possible to slide a 0.2 mm feeler gauge between locking collar and gear wheel. If necessary repeat adjustment.
- Disengage 5th gear. Locking collar must now be in neutral position. Synchro-ring must move freely.
- Select 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.