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
^ V. A. G. 1416 Hot air blower
^ Studs M8 x 100 mm
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 bolts -A- for synchro-hub and 5th gear by selecting 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 cannot turn. Both bolts can now be loosened.
- Pull off synchro-hub and 5th gear and remove together with needle roller bearing.
A - Two arm puller e.g. Kukko 20/10 with Matra V/1 70 hooks.
B - Hex bolt M10 x 20
- Pull off 5th gear
A - Two arm puller e.g. Kukko 20/10 with Matra V/1 70 hooks.
B - Hex bolt M10 x 20
Sequence for removing:
- Fit two arm puller and centralize by turning screw (arrow).
- Heat gear with hot air blower V.A.G 1416 and pull off.
Note: When puffing off the gear ensure that the hooks do not bend outward, if necessary tighten screw (arrow). After 5th gear has been removed check for damage.
- Remove both flange shafts.
- Take out flanged 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
- Place selector shaft in neutral position.
- Pull selector shaft out of the transmission housing.
Transmissions from 05.99
- Remove selector shaft with selector cover
- Place selector shaft in neutral position.
- Remove bolts (arrows) and pull selector shaft out of the transmission housing.
Continued 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, if necessary carefully pry up all around and alternate between sides on protruding housing flange (arrows). Take care 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 (go to Item -B-, Illustration N34-0060)
- Remove reverse gear -A-, input shaft -B- and output shaft -C- one after another from clutch housing.
- Take out differential.
Assembling
- Install differential.
Note:
^ Always replace sealing rings (arrows) for output shaft bearing support.
^ 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 in Illustration V34-2293). Remnants can be removed using a tap.
- Install reverse shaft support.
- Install reverse gear selector mechanism.
Installation position reverse gear
- Install selector forks together with selector plates.
- Screw M8 x 100 mm studs -A- into reverse shaft support so that shaft is aligned after fitting transmission housing.
- Align selector plates.
Note: The selector segments must be positioned in the grooves on the locking collars.
- Fit transmission housing.
Install reverse shaft support bolts (arrow) as follows:.
- Insert bolt -a-, remove stud go to Illustration V34-2008), 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 by aligning 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
The circumferential groove (arrow) faces to transmission housing.
- Drive-on 5th gear.
Checking 5th gear synchro-ring
- Before installing 5th gear and synchro-ring press synchro-ring onto cone of gear and measure gap -a- with a feeler gauge.
- Install 5th gear with needle roller bearing
- Place 5th gear synchro-ring on gear.
- Assemble 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 synchro-hub mountings (arrow -3-) align with the synchro-ring cast locking pieces go to arrows on Illustration N35-0018).
5th gear synchro-ring with cast locking pieces (arrows)
- Drive on 5th gear synchro-hub
Note: When driving on ensure synchro-ring is free to move.
- Screw in securing bolts for synchro-hub and 5th gear.
Installation position of dished spring for gear 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 securing bolts (arrows) go to 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. 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.