Disassembly and Assembly Sequence

Disassembly and assembly sequence, 02M, 5 and 6 Spd. M/T

Disassembling and assembling transmission housing, selector mechanism, input shaft, output shafts, differential and selector rods

Special tools and equipment:

- VW 309 Holding plate
- VW 313 Support clamp
- VW 353 Transmission support
- 30-21 Sleeve
- T40008 Press piece
- V.A.G 1331 Torque wrench

Disassembling





- Secure transmission to assembly support with bolts (arrows).
- Turn transmission on assembly support with oil drain plug downward.
- Place drip tray underneath.
- Drain transmission oil.





- Remove slave cylinder with release bearing (arrows).
- Put selector shaft in neutral position.





- Remove back-up light switch -1-.
- Remove hex bolts -2- for selector shaft cover plate -A-.
- Carefully pull out cover plate.
- Remove locking bolt -3- for selector shaft gate.
- Remove bolts -4- and press selector shaft cover -B- out of transmission housing.
- Pull selector shaft out of transmission housing.





- Remove both flanged shafts.





- Remove bolts securing transmission housing to clutch housing -A- in area of differential.
- Remove bolts -B- inside clutch housing for securing clutch housing to transmission housing.

Note: The hex bolt (arrow) is located outside the bolting flange. It is installed with a washer.

- Take off transmission housing. If necessary, carefully pry up all around and alternating between sides on protruding flange taking care not to damage sealing surfaces.

For transmissions from build date 06 04 0





- Unscrew locking plate bolt (arrow) (outer race/tapered roller bearing from input shaft).
- Remove locking plate.

Continued for all transmissions





- Swing input shaft in direction of arrow and take off.
- Remove speedometer drive.





- With help of a second technician, remove differential -1-, output shafts -2- and -3-, reverse shaft -4- and selector rods -5- together from clutch housing.
- Drive out input shaft oil seal with sleeve 30-21.

Assembling
- Install differential -1-.
- Install 5th, 6th and reverse gear output shaft -2- together with reverse selector fork, 5th, 6th and reverse gear selector rod -3- and reverse shaft -4-.





- Take 1st-4th gear output shaft -3- with selector rods -5- in right hand as illustrated.
- With left hand, lift differential slightly.
- At same time, have a second technician slightly lift 5th, 6th and reverse gear output shaft together with reverse shaft -4-.
- Insert 1st-4th gear output shaft in direction of arrow.
- Toothing of output shafts and final drive gear/differential must mesh.
- Together with second technician, place shafts in their bearing seats.





- Set input shaft in clutch housing and swing in (arrow).
- Install transmission housing.

For transmissions from build date 06 04 0





- Insert locking plate (arrow) in outer race/tapered roller bearing recess for input shaft.
- Tighten new bolt to tightening torque.

Continued for all vehicles
- Install transmission housing.

Install selector shaft as follows:
- Bring selector rods into neutral position.





- Insert selector shaft -1-.
- Position selector shaft so that shift fingers are inserted in selector rods.
- When doing this, align lower selector shaft bearing (arrow) through drilling for cover plate.
- Bolt cover plate -A- to lower selector shaft bearing -1- with bolt -2-, M8 x 60 mm.
- Hand tighten cover plate -A- by alternately tightening (1/2 turn) bolts (arrows).





- Remove bolt -2- and hand tighten original bolt in its place.
- Install selector shaft cover -B- and tighten hex bolts -4- to prescribed torque.
- Tighten cover plate -A- hex bolts.
- Insert locking bolt -3- for selector shaft gate with locking fluid D 000 600 A2.
- Install switch for back-up light.
- Install both flanged shafts with springs, thrust washers and tapered rings.
- Install speedometer sensor.





- Press in input shaft oil seal.
- Install slave cylinder with release bearing.