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
- 2040 Tube
- VW 454 Press piece
Special tools and equipment:
- VW 228 B Extractor
- VW 222 A Drift
- 3066 Spindle from assembly tool
- Oil seal and sleeve are driven out in two pieces:
- 3124 Press piece
- Oil seal and sleeve are driven out in one piece:
- VW 771 Multi-purpose tool
- VW 771/37 Pulling hook
Special tools and equipment
VW 353 Transmission support:
Oil seal and sleeve are driven out in one piece:
- T10148 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, 30 Nm
^ Without magnet
4. Shim
^ For input shaft
^ Adjustment overview
5. Outer race/tapered roller bearing
^ If replaced: Adjust output shaft
6. Outer race/tapered roller bearing
^ If replaced: Adjust input shaft
7. Shim
^ Adjustment overview
8. Outer race/tapered roller bearing
^ If replaced: Adjust input shaft
9. Needle bearing
10. Dowel sleeve
^ (Qty. 2)
11. Starter bushing
^ Not installed in all transmissions
^ Pulling out go to Fig. 5
^ Driving in go to Fig. 6
^ Can be replaced without removing transmission
12. Clutch housing
^ If replaced: 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 oil seal
^ If damaged replace guide sleeve and O-ring together
14. Socket head bolt, 20 Nm
^ Self-locking
^ Always replace
15. Oil seal
^ Replacing with installed transmission
16. Sleeve
^ For oil seal (Item 15)
^ Removing go to Fig. 7
^ Installing go to Fig. 8
17. One piece oil seal and sleeve
^ With damaged oil seal, replace both oil seal and sleeve
^ Removing go to Fig. 9
^ Installing go to Fig. 10
18. Speedometer drive
^ For aluminum tighten to 30 Nm
^ For synthetic material tighten to 10 Nm
19. Oil drain plug, 30 Nm
^ Without magnet
20. Outer race/tapered roller bearing
^ For differential
^ Pressing in and out
^ If replaced: Adjust differential
21. Magnet
^ Held in place by housing joint surface
22. Outer race/tapered roller bearing
^ For differential
^ Pressing in and out
^ If replaced: Adjust differential
23. Shim
^ For differential
^ Adjustment overview
24. 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 Drive oil seal into guide sleeve onto stop.
Fig. 5 Pulling out starter bushing.
- Mounting sequence from extractor VW 228 b
- Turn the nut on the thread of the extractor in direction of tensioning bolt as far as possible.
- Install extractor VW 228 b onto stop.
- Now tighten tensioning bolt until the extractor VW 228 b is tensioned with the bushing.
Fig. 6 Driving bushing for starter in flush.
Fig. 7 Pry sleeve out with a screwdriver (arrow)
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.
Fig. 9 Pulling out sleeve and oil seal
- There is a step in inner diameter from sleeve
- For pulling out sleeve and oil seal, apply the pulling hook VW 771/37 at the back of the step in the sleeve.
- While pulling out press forcibly the pulling hook VW 771/37 into the sleeve.
Fig. 10 Driving in sleeve and oil seal
- Clean the sitting place of oil seal in transmission.
Drive sleeve over press piece T10148 onto stop by turning on nut -B-.
Note: When transmission is disassembled press sleeve in with press piece T10148 onto stop.