Transmission Housing, Servicing

Transmission housing, servicing, 02M, 5 and 6 Spd. M/T

Special tools and equipment:

- VW 407 Press tool
- VW 416 B Tube
- VW 771 Multi-purpose tool
- VW 801 Support plate
- 12-551 Centering mandrel
- 3129 Installation tool

Special tools and equipment

3176 Centering mandrel:

1 - Kukko 21/2 Internal puller
1 - Internal puller Kukko 21/4
4 - Kukko 22/2 Counter support





1. Transmission housing
^ If replaced: adjust input shaft, output shafts and differential

2. Oil seal
^ Always replace

3. Oil drain plug, 30 Nm
^ Always replace

4. Stop sleeves
^ Driving out go to Fig. 1
^ Driving in go to Fig. 2

5. Oil filler plug, 30 Nm
^ Always replace

6. Locking pin
^ Is pressed into gate of selector shaft when adjusting outer selector mechanism
^ Driving out go to Fig. 3
^ Driving in go to Fig. 4

7. Bushing
^ For selector rods
^ Replace each time after removing
^ Driving in go to Fig. 5
^ Installing go to Fig. 6

8. Needle bearing
^ Replace each time after removing
^ Pulling out go to Fig. 7
^ Pressing in go to Fig. 8

9. Shim
^ For input shaft
^ Adjustment overview

10. Outer race/tapered roller bearing
^ If replaced: adjust input shaft

11. Outer race/tapered roller bearing
^ If replaced: adjust 5th, 6th and reverse gear output shaft

12. Shim





13. Outer race/tapered roller bearing
^ If replaced: adjust 1st-4th gear output shaft

14. Shim
^ Adjustment overview

15. Outer race/tapered roller bearing
^ If replaced: adjust differential

16. Shim
^ Adjustment overview

17. Oil seal
^ Replacing





Fig. 1 Driving out stop sleeve





Fig. 2 Driving stop sleeve in onto stop
- Drive stop sleeve in onto stop with 13 mm socket -A- and plastic head hammer.





Fig. 3 Driving out locking pin





Fig. 4 Driving in locking pin -A- onto stop





Fig. 5 Pulling out mounting bushing for selector rod
A - Internal extractor 14.5 to 18.5 mm, e.g. Kukko 21/2
B - Counter support, e.g. Kukko 22/2





Fig. 6 Driving selector rod mounting bushing in flush





Fig. 7 Pulling reverse shaft needle bearing out of transmission housing
A - Internal extractor 23.5 to 30.0 mm, e.g. Kukko 21/4
- Counter support, e.g. Kukko 22/2

Note: The needle bearing is destroyed during removal and must be replaced.





Fig. 8 Pressing needle bearing -A- into transmission housing
- Before pressing in, lay reverse shaft thrust washer -B- on needle bearing.
- Support transmission housing with tube VW 416 B directly below bearing mounting.