TRANSMISION 02G STANDAR

00 - General, Technical data 30 - Clutch 34 - Manual Transmission - Controls, Housing 35 - Manual Transmission - Gears, Shafts 39 - Final drive, Differential - General, Technical data

7UDQVPLVVLRQ�LGHQWLILFDWLRQ Code letters, transmission allocation, ratios, capacities

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7UDQVPLVVLRQ�LGHQWLILFDWLRQ� The manual transmission 02G is installed in

the EuroVan as a 5-speed transmission in conjunction with the 5-cylinder engine.

Applications Page 00-3 .

/RFDWLRQ�RQ�WUDQVPLVVLRQ� Code letters and date of manufacture (arrow 1)

Manual transmission 02G (arrow 2)

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([DPSOH�� AFK 24 08 5

I I I I

I I I I

Code letters

Day Month Year (1995) of

manufacture

Additional data depends on manufacture.

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08.95

$SSOLFDWLRQ� Model (XUR9DQ�� Engine 2.5 L - 75 kW

(100 hp)

Turbo Diesel

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5DWLR��=��=�� Final drive 82 : 21 = 3.905

1st gear 43 : 11 = 3.909

2nd gear 36 : 17 = 2.118

3rd gear 35 : 26 = 1.346

5th gear 35 : 48 = 0.729

6th gear -

Reverse gear 37 : 23 x 23 : 10 =3.700

Speedometer drive 13 : 22 = 0.591

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6SHFLILFDWLRQ� Gear oil G50 SAE 75W90 (synthetic oil)

&OXWFK�FRQWURO� hydraulic

&OXWFK�SODWH�GLDPHWHU� 219 mm

'ULYH�VKDIW�IODQJH�GLDPHWHU�� 108 mm

L2YHUDOO�UDWLR�LQ�WRS�JHDU� 2.847 ��

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Arrows point in direction of travel

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I -

1st gear

II -

2nd gear

III -

3rd gear

IV -

4th gear

V -

5th gear

R -

Reverse gear

A -

Final drive

T -

Speedometer drive

Arrows point in direction of travel

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&DOFXODWLQJ�RYHUDOO�UDWLR��L�� ([DPSOH� � 5th gear Final drive

Drive gear ZG1 = 48 ZA1 = 21

Driven gear ZG2 = 35 ZA2 = 82

i = Z2 : Z1 1)

iG = Gear ratio = ZG2 : ZG1 = 35 : 48 = 0.729

iA = Axle ratio = ZA2 : ZA1 = 82 : 21 = 3.905

ioverall ratio = Total ratio

ioverall ratio = iG x iA = 0.729 x 3.905 = 2.847

1) Z1 = No. of teeth drive gear, Z2 = No. of teeth driven gear

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*HQHUDO�UHSDLU�LQVWUXFWLRQV� To ensure perfect and successful transmission

repairs, the greatest care and cleanliness as well as the use of good and proper tools is essential. Obviously, the basic rules for safety are also applicable during all repair work.

A number of generally valid instructions applicable for the various repair procedures - which were previously repeated a number of times at numerous places in the Repair Manual - are summarized here. They apply to this Repair Manual.

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When installing ensure that the dowel sleeves between the engine and transmission are correctly located.

When changing a transmission fill with gear oil to the lower edge of the filler hole.

Capacities and specifications Page 00-3 .

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Thoroughly clean joint surfaces and apply sealant AMV 188 200 03.

Apply sealant uniformly but not too thick.

Always replace "O-rings".

Radial shaft oil seals -

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- Lightly oil outer edge, fill space between

sealing lips -arrow- with grease.

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- Check transmission oil and top-up if necessary

Specification Page 00-3 .

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Always replace circlips.

Do not overstretch circlips.

Circlips must locate properly in the groove.

Replace spring pins. Installation position: Slot longitudinal to line of force.

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Tighten and loosen bolts and nuts for securing covers and housings in a diagonal sequence.

Especially delicate parts, such as clutch pressure plates, must not be distorted. Loosen and tighten nuts and bolts in stages in a diagonal sequence.

Tightening torques as specified are for

unoiled bolts and nuts.

Always replace self-locking bolts and nuts.

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Install needle bearings with lettered side (thicker metal) towards fitting tool.

Lubricate all transmission bearings with gear oil before installing. Lubricate with special care when measuring turning torque.

Tapered roller bearings installed on one shaft must be replaced as a set. Use bearings from the same manufacturer if possible!

Heat inner tapered roller bearing races to approx. 100 C before pressing on.

Do not interchange outer and inner races of bearings of the same size; bearings are paired.

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Measure shims at several points with a micrometer. Tolerance variations make it possible to find the exact shim thickness required.

Check for burrs and damage.

Only install perfect shims.

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Do not interchange. When reusing always match to same gear.

Check for wear and replace if necessary.

Coat with gear oil before installing.

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Before installing clean and heat on a hot plate to approx. 100 C (212 F).

Temperature can be checked with temperature tester VAG 1558 or equivalent.

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1P��IW�OE� For master cylinder to mounting bracket

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Removing and installing Page 30-11

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Need not be disassembled to remove pedal cluster

Seal to bulkhead with AKD 497 010 04 R 10


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Before removing unbolt steering column and lay to side

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Knock out with drift

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Always replace

For mounting bracket and brake servo to mounting plate

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&OXWFK�SHGDO��UHPRYLQJ�DQG�LQVWDOOLQJ� 5HPRYLQJ� - Separate clutch pedal from master cylinder

Page 30-2 .

- Remove over-center spring Page 30-11 .

- Remove clutch pedal locking clip from pivot pin.

- Drive pivot pin out to right until clutch pedal can be pulled off.

- Remove clutch pedal.

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sequence.

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For master cylinder operating rod


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For master cylinder to mounting bracket

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Bleeding clutch system Page 30-12

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Always replace

Pull onto line/hose connection

Coat with brake fluid before installing

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Removing Fig. 1

Installing: press in by hand


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Pry out with a screwdriver


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Qty. 3

Install on slave cylinder flange

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Bleeding clutch system Page 30-12

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- Guide screwdriver between clip and connecting piece, if necessary turn connecting piece first so that flattened section of connecting piece that is in area of clip is pointing forward.

- Carefully pry clip out and remove.

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5HPRYLQJ� - Remove carpet in area of over-center spring.

- Pry securing clip off with a screwdriver and remove washer.

- Tension over-center spring with clutch pedal

and install retaining clamp 3113A from above.

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- Move clutch pedal onto stop.

- Remove over-center spring together with retaining clamp 3113A.

- Remove over-center spring from retaining

clamp and install.

,QVWDOOLQJ� Installation is performed in the reverse sequence.

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Bleed clutch system using the brake filling and

bleeding appliance VAG1238 B and bleed hose VAG 1238 B/3 or use Fluid Evacuator EZ1 or equivalent.

- Remove insulation tray below engine/transmission.

- Connect pressure hose -C- to brake fluid reservoir.

- Step 1: Connect bleed hose -A- to bleed valve -

B- in engine compartment and open bleed valve.

- Switch on bleeder unit.

- Step 2: Connect bleed hose -A- to bleed valve -

arrow- below transmission and open bleed valve.

- Switch on bleeder unit.

- Step 3: Repeat bleed sequence at bleed valve -B- in engine compartment, illustration N30-0144.

- Depress clutch pedal several times after completion of bleeding process.

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Ensure centering pins are a tight fit

Contact surface for clutch lining must be free of grooves, oil and grease

Removing and installing

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Diameter page 00-3

Installation position: Shorter hub end (arrow) points toward pressure plate

Centering Fig. 1

Lightly grease splines

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Removing and installing Fig. 1

Check ends of diaphragm spring Fig. 2

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Loosen and tighten gradually and diagonally

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- Loosen and tighten bolts gradually and diagonally.

- Reverse position of retainer 3067 when removing.

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Wear up to half the thickness of the diaphragm spring is permitted.

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Double-headed arrow -A- Gear selection movement

Double-headed arrow -B- Gate selection movement

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Removing and installing selector mechanism Page 34-19

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Thread on and off together with boot (item 2 )

When threading on hold boot in position

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Remove and install together with gear shift knob (item 1 )

After installing clip into frame (item 4 )

Installation position Page 34-22 , illustration V34-2980

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Remove and install together with frame (item 4 ) Page 34-19 and Page 34-22

Clip and unclip into frame (item 4 ) Page 34-22 , Fig. 34-2978

Installation position: Inscription ""VORN" (front) points in direction of travel

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Remove and install together with boot (item 3 ) Page 34-19 and Page 34-22

Installation position: Inscription "VORN" (front) -arrow- points in direction of travel Page 34-22 , illustrationV34-2978

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Installation position: Arrow type markings point in direction of travel, lip toward floor plate

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Remove from transmission together with mounting bracket (item 15 )

Removing from gearshift bracket Page 34-20

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Remove from gear shift and relay lever Page 34-20

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Pry out with screwdriver

Installing Fig. 1

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Lever off and press into gear selector lever (item 12 )


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For front selector rod

Press into gear selector lever

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Install so that master spline aligns with selector shaft

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Removing from gate rod Fig. 2

Pressing on Fig. 3

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Removing Fig. 4

Installing Fig. 5

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Transmission side: engage in reverse gear locking unit

Secure to gate rod (item 1 )

Engage onto gear shift housing and hook onto lever

Page 34-15

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Pressing off Fig. 6

Pressing on Fig. 7

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Pressing off Fig. 6

Pressing on Fig. 7

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Installation position:

Press in from smaller shoulder side of center mounting.

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- Remove in direction of arrow.

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EUDFNHW - Coat bushing lightly with MoS2 grease and

carefully press in.

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A - Separating device 5 ... 60 mm, e.g. Kukko 17/0

B - Driver, 6 mm diameter

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Dimension "a" = 78 mm - points to left-hand side of vehicle

Dimension "b" = 80 mm - points to right-hand side of vehicle

The thicker shoulder -arrow- points downward.

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Disassembling and assembling to floor plate Page 34-20

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Pry out with a screwdriver before removing rubber mounting (item 3 )

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Pry out with a screwdriver after removing bushing

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Installation position Page 34-23

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Remove with gear shift

First remove following components: rear selector rod (item 15 ), gate rod (item 20 )

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Loosen to adjust gear selector mechanism and to remove selector and gate rods


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Two part

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Removing and installing to transmission Page 34-19 and Page 34-21

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Hook into lever (item 24 )

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Mounted on bushing (item 18 )

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5HPRYLQJ� - Unclip boot from frame, unscrew and remove

from gearshift together with gear knob Page 34-3 , items 1 and 2 .

- Release frame -a- from gearshift housing -b-

by prying upward in front and rear areas -arrows-.

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- Remove seal from floor plate.

- Unbolt swivel head -arrow 1-.

- Pry front selector rod off transmission selector lever -arrow 2-.

- Unbolt mounting bracket with gate rod -arrow 3-.

- Unclip reverse gear lock cable -arrow 4- from reverse gear locking unit.

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- Remove rear selector rod from relay lever.

- Remove rear selector rod from selector lever.

- After loosening the clamp -arrow- pull gate rod

forward, off gearshift bracket.

- Remove gearshift housing from floor plate.

- Press gear shift bracket together with gear shift forward, so as to guide around fuel tank and then remove downward.

- Guide gate rod with mounting bracket, relay lever and front selector rod out rearward.

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,QVWDOOLQJ� Install in reverse order.

- Guide gear shift housing with gear shift bracket and gear shifter into position from below and secure.

- Guide gate rod into gearshift bracket and slide onto guide pin. First install clamp ( Page 34-20 , illustration V34-2291, arrow).

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- Hook rear selector rod into relay lever, right illustration N34-0391, Page 34-14 .

- Adjust selector mechanism Page 34-23 .

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- Engage lugs -arrow 1- around circumference

of boot into frame.

- Place seal around edge of floor plate.

- Place frame mounting tubes on gearshift housing securing screws -arrow 4- and then press, first front and then rear, fully home.

Inscription "VORN" (front) -arrow 2- points in direction of travel

- Engage frame locking devices -arrow 3- by pressing into gearshift housing cut-outs Page 34-19 , illustration V34-2979.

- Thread on gearshift knob together with boot, holding boot in position.

- Clip boot into frame.

One lug -arrow- on inside of boot is applied on front (direction of travel).

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- Place transmission in neutral position.

- Remove gear shift knob, boot, and boot frame Page 34-19 .

- Loosen nut -arrow-.

The gate rod/gearshift bracket connection must be free to move.

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- Align stop so that grub screw -A- locates in

gearshift depression -arrow-.

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- Install gear shift jig until it sits on stop and

lock by tightening knurled wheel -arrow-.

- Align gate rod free of stress (transmission in neutral) and tighten nut to 20 Nm (15 ft lb).

Page 34-23 , illustration V34-2291, arrow.

- Pull gear lever towards seat, loosen knurled nut and remove jig.

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The gear shift lever must rest in the 3rd/4th gear plane with the transmission in neutral. The lower area of the gearshift must be vertical.

- Operate clutch.

- Select all gears several times. Pay particular attention to operation of reverse gear catch.

Should a gear fail to engage smoothly after repeated selection then continue as follows:

- Engage 1st gear.

- Remove play in selector mechanism by carefully moving gearshift to the left.

��

The distance between gearshift stop and gearshift housing must be approx. 2 mm (dimension "a").

- Repeat adjustment sequence if necessary. Reinstate dimension "a" with 1st gear engaged if necessary.

- Install gear shift knob and covering Page 34-22 .

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7UDQVPLVVLRQ��UHPRYLQJ�DQG�LQVWDOOLQJ��

5HPRYLQJ� - Switch ignition off and disconnect battery

strap (in engine compartment and if equipped, under driver’s side).

5HSDLU�0DQXDO��(OHFWULFDO�(TXLSPHQW��5HSDLU�*URXS��

1RWH� 2EWDLQ�UDGLR�FRGH�IRU�YHKLFOHV�ZLWK�FRGHG�UDGLR�� - Remove radiator grille with trim frame.

5HSDLU�0DQXDO��%RG\�([WHULRU��5HSDLU�*URXS��

- Remove charge air cooler from lock carrier -

arrows- if equipped.

- Fold radiator and lock carrier out forward.

5HSDLU�0DQXDO��%RG\�([WHULRU��5HSDLU�*URXS��

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- Install support frames 3250 with vehicle in

unloaded condition to both sides before the vehicle is raised.

1RWH� 6XSSRUW�IUDPHV��DOORZ�UHPRYDO�RI�OHIW�KDQG�GULYH�VKDIW��LOOXVWUDWLRQ��DQG�OHIW�DQG�ULJKW�KDQG�VKRFN�DEVRUEHU�VWDELOL]HU�EDU�FRXSOLQJ�OLQN� ,QVWDOODWLRQ�SRVLWLRQ�� Support frame bearing surface -arrow A- must be located below the upper control arm -1-.

The V-shaped opening -arrow B- bears on the assembly carrier -2-.

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%UDNHV��6WHHULQJ�P�\��5HSDLU�*URXS��

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- With vehicle standing on wheels loosen left

and right-hand drive shaft/wheel hub bolt and left and right-hand wheel bolts.

- Raise vehicle.

- Remove noise insulation tray below engine/transmission..

Remove left and right-hand drive shafts as follows:

- Remove bolt for left-hand shock absorber/stabilizer bar coupling rod.

- Compress left-hand shock absorber completely.

- Disconnect drive shaft at flange.

- Remove wheel.

- Separate lower wheel bearing housing ball

joint bolted connection. Support ball joint when separating

- Remove drive shaft.

��

- Unbolt flange shaft mounting -A- from

bracket -B- -arrow-.

- Pull right-hand flange shaft -C- out from stub shaft -D-.

- Remove battery ground strap from transmission and mounting bracket.

- Remove all electrical connections from transmission and starter motor.

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- Unscrew speedometer drive shaft cable or remove sensor connector and speedometer sensor.

- If so attached, unfasten electrical wiring from coolant hoses.

- Unfasten coolant lines at starter motor -

arrows- (from expansion tank to water pump).

- Remove wiring harness from lines.

- Remove starter.


��

- Remove front exhaust stop plate.


- Separate front exhaust pipe at catalyst.


- Remove transverse support after removing

bolts on selector mounting bracket -A- and bolt on left-hand transmission support -B-.

Remove selector mechanism from transmission as follows:

- Remove back-up light switch.

- Remove swivel head -arrow 1-.

- Pry front selector rod off transmission selector lever -arrow 2-.

- Unbolt mounting bracket with gate rod -arrow 3-.

- Unclip reverse gear lock cable -arrow 4- from transmission.

- Tie-up selector and gate rods.

��

- Remove clutch mechanism line from transmission, release from transmission support retainer and tie-up.

- Remove auxiliary heater line, if necessary.

- Remove pendulum support after removing

bolts arrows -A- and -B- by pushing up lightly on rear of transmission restriction -arrow C-.

- Remove retaining plate for electrical connectors from crankcase.

- Bolt engine support to block.

��

- Attach auxiliary support 3184/1 for removal

device 3184 into cross panel -arrows-.

- Install removal device 3184 into auxiliary

support 3184/1 and into subframe -A-. Screw spindle -C- into hole on engine mounting.

- Align removal device so that slide -B- is resting against right-hand tube -arrow-.

- Secure removal device to subframe -A- and to auxiliary support 3184/1 by tightening angle plates.

- Relieve subframe loading by raising engine/transmission by means of spindle -C-.

��

- Remove engine/transmission connecting

bolts -arrows- except for bolt -arrow a-. Also remove flywheel small cover plate.

- Remove engine/transmission hex socket-

head bolt -arrow-.

1

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- Support transmission, left, with transmission

jack VAG 1383 A.

A - Trolley jack insert

- Unbolt left-hand transmission support -arrows- on transmission.

- Lower engine using removal device spindle.

- Carefully rock engine/transmission alternately forward and then lower until V-belt pulley almost contacts longitudinal member.

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- Assemble transmission jack VAG 1383A with transmission support 3282, adjustment plate 3282/23 (for "02G" transmission) and support elements as follows:

- Place adjustment plate 3282/23 on transmission support 3282. (Adjustment plate only fits in one position).

- Align arms of transmission support according to holes in adjustment plate.

- Bolt on support elements -A-, as illustrated on

adjustment plate.

- Place transmission jack with transmission

support under vehicle, arrow symbol -B- ( Illustration N34-0363) on adjustment plate points to front of vehicle.

- Align adjustment plate parallel to transmission and lock safety supports on transmission.

- Remove lower engine/transmission securing bolts ( Page 34-33 arrow -A- on illustration N34-0360).

��

- Press transmission off engine and remove cover plate from between engine/transmission.

- Carefully lower transmission and swing out.

- Constantly correct transmission position via transmission jack spindles. Ensure there is sufficient clearance to assembly carrier and removal device 3184.

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GHYLFH�ILWWHG�WKHQ�WKH�IROORZLQJ�PXVW�EH�REVHUYHG��

6FUHZ�VSLQGOH�LQ�RQWR�VWRS��WR�OLIW�RU�ORZHU�WKH�HQJLQH�WUDQVPLVVLRQ�

([HUFLVH�H[WUHPH�FDUH�LQ�WKH�YLFLQLW\�RI�D�KRLVW�

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7UDQVPLVVLRQ��WUDQVSRUWLQJ� Special tool 3336 may be used to transport the

transmission and also when setting up

transmission mount 3282.

- Bolt transmission lifting device 3336 to clutch

housing.

- Set support arm on sliding piece with locking

pin (arrow).

No. of holes visible = 7

- Remove transmission with workshop crane and transmission lifting device 3336.

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,QVWDOOLQJ� Install in reverse order.

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:KHQ�UHSODFLQJ�WUDQVPLVVLRQ�HQVXUH�WKDW�LQWHUPHGLDWH�SODWH�LV�FRUUHFWO\�SRVLWLRQHG�

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- Alternately swing in and raise engine/transmission assembly.

Install engine/transmission mountings stress-free, as follows:

- Before installing bolts to secure left-hand

mounting bracket to body ensure that engine mounting pin and removal device spindle -arrow- are in line.

- Use transmission support VAG 1383 A to

support transmission when guiding transmission mounting bracket.

A - Trolley jack insert

- Tighten rear transmission mounting to torque setting.

- Tighten pendulum support to torque.

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- Install front exhaust pipe to catalyst

5HSDLU�0DQXDO��(QJLQH�0HFKDQLFDO��5HSDLU�*URXS��5HPRYLQJ�DQG�LQVWDOOLQJ�SDUWV�RI�H[KDXVW�V\VWHP�

- Always replace seal between flange shaft and drive shaft, but first remove protective foil before bolting drive shafts to flanges.

5HSDLU�0DQXDO��6XVSHQVLRQ��:KHHOV��%UDNHV��6WHHULQJ�P�\��5HSDLU�*URXS��6HUYLFLQJ�GULYH�VKDIW

- Install starter/wiring.


- Check transmission oil Page 34-44 .

- Adjust gear change mechanism Page 34-23 .

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Transmission to Engine

3RV�� %ROW� 4W\�� 1P��IW�OE�� 11) M 12 x 70 2 80 (59)

2 M 12 x 70 1 80 (59)

3 M 12 x 60 1 80 (59)

4 M 12 x 100 1 80 (59)

5 M 12 x 130 1 80 (59)

6 M 8 x 45 1 25 (18)

72) M 8 x 45 1 25 (18)

1) Additionally for flywheel cover plate

2) Tighten from engine side

Positions A & B = Dowel sleeves

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Front left transmission mounting

Bolts -A- 50 Nm (37 ft lb) + 90

Bolt -B- 30 Nm (22 ft lb)

Bolts -C- 30 Nm (22 ft lb)

Rear transmission mounting

Bolt -A- 80 Nm (59 ft lb) + 90

Bolt -B- 200 Nm (148 ft lb)

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Flange shaft mounting to bracket 25 Nm (18 ft lb)

Clutch mechanism valve unit to

transmission

5 Nm (44 in. lb)

Selector mechanism mounting bracket to transmission

20 Nm (15 ft lb)

Selector mechanism swivel head to transmission

9 Nm (7 ft lb)

Back-up light switch to switch unit 20 Nm (15 ft lb)

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7UDQVPLVVLRQ�RLO��FKHFNLQJ� Gear oil specification Page 00-3

- Remove insulation tray below engine/transmission, if equipped.

- Remove plug -arrow- to check oil.

The oil level is correct when the transmission is full to the lower edge of the filler hole.

- Install plug -arrow-.

:KHQ�ILOOLQJ�ZLWK�QHZ�RLO�QRWH�IROORZLQJ�� - Remove plug (arrow).

- Top up oil to lower edge of filler hole.

- Fit plug (arrow).

7LJKWHQLQJ�WRUTXH� Oil filler plug 25 Nm (18 ft lb)

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Dismantling and assembling reverse gear wheel Page 35-49


�� 2XWSXW�VKDIW Dismantling and assembling Page 35-18

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�� ,QSXW�VKDIW Dismantling and assembling Page 35-1

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Dismantling from clutch housing Page 34-53

Servicing Page 34-60

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Dismantling and assembling from Page Page 34-71

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�� 'LIIHUHQWLDO Dismantling and assembling Page 39-7

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Drive in with synthetic head hammer

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Always renew page 34-59

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Dismantling and assembling from Page Page 34-71


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�� 2XWSXW�VKDIW Dismantling and assembling Page 35-18

�� 6HOHFWRU�URG�ZLWK�VHOHFWRU�IRUN�IRU��UG�DQG��WK�JHDU

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�� ,QSXW�VKDIW Dismantling and assembling Page 35-1

�� 6HDOLQJ�ULQJ� Qty. 4

Always renew

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Bolt to slave cylinder pipe

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Always renew


Qty. 2

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4 nuts for bearing support

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Always renew Page 34-59

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Dismantling and assembling transmission housing, selector mechanism, input shaft, output shaft (pinion shaft), differential and selector rods

'LVDVVHPEOLQJ� - Drain gearbox oil.

- Mount gearbox on repair stand.

- Remove slave cylinder with release bearing (arrows).

- Remove left flange shaft

Screw in M10 x 75 bolts (arrows) alternately.

��

- Remove both bolts (arrows) for the reverse

gear wheel mounting bracket.

- Remove selector mechanism, to do this

place selector shaft in neutral position. Then remove bolts (arrows) and pull selector shaft out from the gearbox housing.

��

- Remove gearbox housing to clutch housing

securing bolts -A- in area of differential.

- Remove bolts -A-, from inside clutch

housing for securing clutch housing to gearbox housing.

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- Take-off gearbox housing, carefully lever up

all round and alternating between sides on the protruding flange (arrows), if necessary, do not damage sealing surfaces.

- When taking off, pull pull rod out from locking unit.

- Swing reverse gear wheel in direction of

arrow -A- and take off.

- Remove guide tube for reverse gear, arrow -B-.

- Remove nuts for output shaft bearing support ( Page 34-55 Item -B-, Illustration N34-0373).

��

- Take off input shaft -A-, output shaft -B- and

selector rods -C- together from clutch housing.

- Remove stub shaft, right (shown here with

gearbox installed).

A - Separating device Kukko 17/0

B - Separating device Kukko 17/1

1 - Bolt M10 x 80 (Qty. 2)

- Turn bolts -1- evenly against separating device -B-.

- Remove speedometer drive.

- Take out differential.

��

$VVHPEOLQJ� - Install differential.

- Install speedometer drive.

- Always renew sealing rings (arrows) for output

shaft bearing support.

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- Install input shaft, output shaft and selector rods together.

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- Tighten nuts for output shaft bearing support.

- Install guide tube for reverse gear.

- Install reverse gear wheel.

��

- Install M8 x 80 mm studs in clutch housing -

arrows-, so that when installing transmission housing stop sleeves are aligned to selector rods.

- Install transmission housing.

- Place selector plates in neutral.

- Install selector mechanism.

- Replace securing rings for flange shaft

and/or stub shaft.

- Using vice clamps, clamp flange shaft or stub shaft in a vice. Press old circlip out from groove with new circlip -A-.

- Drive in left-hand flange shaft as well as right-hand stub shaft with a synthetic head hammer.

- Install slave cylinder with release bearing.

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If replaced: Adjust input shaft, output shaft and differential Page 39-24

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For output shaft

Adjustment overview Page 39-24

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For input shaft

Removing and installing from Page 35-11

If replaced: Adjust input shaft Page 35-13

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For output shaft


If replaced: Adjust output shaft Page 35-42

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For output shaft



For differential


If replaced: Adjust differential Page 39-25

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For differential


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�� /RFNLQJ�XQLW For reverse gear

Removing Fig. 1

Driving in Fig. 2

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Removing Fig. 3


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A - Ball joint splitter (commercial type) e.g. Kukko No. 128/2

B - Hex nut M10

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A - Puller Kukko 204-1

- Tension puller when assembling (arrow) then using a lever under puller, lever stop sleeve out.

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Installing Fig. 1

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Installing Fig. 1


For output shaft


If replaced: Adjust output shaft Page 35-42

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For output shaft


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For input shaft


If replaced: Adjust input shaft Page 35-13

�� 0DJQHW Held in place by housing joint surface

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(Qty. 2)

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Removing Fig. 2

Installing Fig. 3

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Pulling out Fig. 4

Pulling in Fig. 5

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For speedometer


If replaced: Adjustment overview, Page 39-24


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Installation position: Step on internal diameter points to seal


For differential


If replaced: Adjust differential Page 39-25

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- Insert selector rod guide -A- with centralizing shoulder into hole in clutch housing.

- Insert oil pan -B- into housing cut-out next to differential taper roller bearing outer race.

- Secure oil pan and selector rod guide with a hexagon head bolt -C-.

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- Lever oil seal out carefully with a screwdriver.

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RXW

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A - Bonded rubber mounting

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Install so that the master spline aligns with selector shaft

Can be replaced with the selector mechanism installed

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Installing Fig. 2

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For gearbox breather

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:KHQ�LQVWDOOLQJ�QHZ�JHDU�ZKHHOV��FRQVXOW�WHFKQLFDO�GDWD� 3DJH�� ,I�WKH�SRVLWLRQ�RI�WKH�WDSHU�UROOHU�EHDULQJV�LV�DIIHFWHG�ZKHQ�H[FKDQJLQJ�SDUWV��WKH�LQSXW�VKDIW�PXVW�EH�UH�DGMXVWHG��6HH�DGMXVWPHQW�RYHUYLHZ� 3DJH�� &OXWFK�KRXVLQJ

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Pulling out Fig. 1

Pressing in Fig. 2

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Pressing off Fig. 6

Pressing on Fig. 7

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For 3rd gear

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Checking for wear Fig. 8

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Press off with 3rd gear wheel

Fig. 5

Dismantling Fig. 9

Assembling locking collar/synchro-hub Fig. 9 and Fig. 10

Pressing on Fig. 11

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For 4th gear

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Pressing off Fig. 4

Pressing on Fig. 12

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Pulling off Fig. 3

Pressing on Fig. 13


Pulling out Fig. 14

Pressing in Fig. 15

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Installation position Fig. 10

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A - Internal extractor, e.g. Kukko 21/6, 37 ... 46 mm

B - Counter support, e.g. Kukko 22/2


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)LJ�� 6\QFKUR�ULQJ��FKHFNLQJ�IRU�ZHDU - Press synchro-ring onto the gear wheel

cone and measure gap "a" with feeler gauge.

Gap "a" New dimension Wear limit

3rd gear

4th gear

1.0 ... 1.7 mm

1.0 ... 1.7 mm

0.5 mm

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1 - Spring

2 - Locking piece

3 - Locking collar

4 - Synchro-hub

- Slide locking collar over synchro-hub.

The recesses for locking pieces in synchro-hub and locking collar must align.

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The locking collar has been pushed over the synchro-hub.

- Insert locking pieces and install springs 120 off-set. The angled end of the spring must locate in the hollow locking piece.

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SXOOLQJ�RXW�RI�WUDQVPLVVLRQ�KRXVLQJ

A - Internal puller 46 ... 58 mm, e.g. Kukko 21/7


��


SUHVVLQJ�LQWR�WUDQVPLVVLRQ�KRXVLQJ

- Fit shim under outer race.

- Support gearbox housing with press piece 3062 directly below bearing support.

��

,QSXW�VKDIW��DGMXVWLQJ� (Determining thickness of shim for input shaft)

It is only necessary to readjust the input shaft when

Gearbox housing

Clutch housing

Input shaft

or the

Taper roller bearing

is renewed.


- Press taper roller bearing outer race without shim into gearbox housing onto stop, using VW 433.

- Install input shaft in clutch housing and assemble gearbox housing. Tighten hexagon head bolts to 25 Nm and then turn 90 further.

- Fit measuring appliance and D.T.I. in clutch

housing (large taper roller bearing in gearbox housing).

��

- Before taking any measurements rotate input shaft to allow bearing to settle. Set D.T.I. to "O" with 1 mm preload.

1RWH� 7KLV�SUHSDUDWLRQ�LV�WR�EH�UHSHDWHG�IRU�HDFK�

VXEVHTXHQW�PHDVXUHPHQW��RWKHUZLVH�WKH�JDXJH�ZLOO�QRW�UHWXUQ�WR�WKH�VWDUWLQJ�SRVLWLRQ�

- Press input shaft in direction of D.T.I.

- Read off and note play indicated on D.T.I. (example 0.975).

1RWH� '�7�,��GRHV�QRW�UHWXUQ�WR�RULJLQDO�SRVLWLRQ�

- Determine thickness of shim from table Page 35-15 (example 0.875).

- Remove input shaft and pull taper roller bearing outer race out from gearbox housing.

- Press taper roller bearing outer race together with 0.875 shim into gearbox housing using VW 433.

- Assemble gearbox housing and tighten hexagon head bolts to 25 Nm and then turn 90 further.

��

7DEOH�RI�VKLPV� %HDULQJ�SOD\� 6KLP�

0HDVXUHG�YDOXH� �PP��

7KLFNQHVV��PP��

3DUW�1R��

0.695 ... 0.769

0.770 ... 0.794

0.795 ... 0.819

0.650

0.675

0.700

02F 311 391

02F 311 391 A

02F 311 391 B

0.820 ... 0.844

0.845 ... 0.869

0.870 ... 0.894

0.725

0.750

0.775

02F 311 391 C

02F 311 391 D

02F 311 391 E

0.895 ... 0.919

0.920 ... 0.944

0.945 ... 0.969

0.800

0.825

0.850

02F 311 391 F

02F 311 391 G

02F 311 391 H

0.970 ... 0.994

0.995 ... 1.019

1.020 ... 1.044

0.875

0.900

0.925

02F 311 391 J

02F 311 391 K

02F 311 391 L

1.045 ... 1.069

1.070 ... 1.094

1.095 ... 1.119

0.950

0.975

1.000

02F 311 391 M

02F 311 391 N

02F 311 391 P

1.120 ... 1.144

1.145 ... 1.169

1.170 ... 1.194

1.025

1.050

1.075

02F 311 391 Q

02F 311 391 R

02F 311 391 S

1.195 ... 1.219

1.220 ... 1.244

1.245 ... 1.269

1.100

1.125

1.150

02F 311 391 T

02F 311 391 AA

02F 311 391 AB

��

%HDULQJ�SOD\� 6KLP�

0HDVXUHG�YDOXH� �PP��

7KLFNQHVV��PP��

3DUW�1R��

1.270 ... 1.294

1.295 ... 1.319

1.320 ... 1.344

1.175

1.200

1.225

02F 311 391 AC

02F 311 391 AD

02F 311 391 AE

1.345 ... 1.369

1.370 ... 1.394

1.395 ... 1.419

1.250

1.275

0.650 + 0.650 = 1.300

02F 311 391 AF

02F 311 391 AG

02F 311 391 + 391

1.420 ... 1.444

1.445 ... 1.469

1.470 ... 1.494

0.650 + 0.675 = 1.325

0.675 + 0.675 = 1.350

0.675 + 0.700 = 1.375

02F 311 391 + A

02F 311 391 A + A

02F 311 391 A + B

1.495 ... 1.519

1.520 ... 1.544

1.545 ... 1.569

1.570 ... 1.590

0.700 + 0.700 = 1.400

0.700 + 0.725 = 1.425

0.725 + 0.725 = 1.450

0.725 + 0.750 = 1.475

02F 311 391 B + B

02F 311 391 B + C

02F 311 391 C + C

02F 311 391 C + D

��

&KHFNLQJ�PHDVXUHPHQW

- Install measuring appliance and D.T.I.

- Rotate input shaft so that the taper roller bearing settles.

- Press input shaft in direction of arrow.

- Bearing play should be min. 0.04 ... max. 0.12 mm.

1RWH� ,I�WKH�EHDULQJ�FOHDUDQFH�FDQQRW�EH�PHDVXUHG��EXW�LQSXW�VKDIW�SOD\�LV�SHUFHSWLEOH�DQG�WKH�LQSXW�VKDIW�WXUQV�IUHHO\��WKH�DGMXVWPHQW�LV�DFFHSWDEOH�

- Frictional moment (bearing preload) max. 20

Ncm.

A - Commercial torque gauge 0 ... 600 Ncm

B - Extension for 1/2 " square drive socket

��

2XWSXW�VKDIW��GLVDVVHPEOLQJ�DQG�DVVHPEOLQJ��1RWHV�

:KHQ�LQVWDOOLQJ�QHZ�JHDU�ZKHHOV�RU�D�QHZ�RXWSXW�VKDIW�FRQVXOW�WHFKQLFDO�GDWD� 3DJH�� ,I�WKH�RXWSXW�VKDIW�RU�WDSHU�UROOHU�EHDULQJV�KDYH�EHHQ�UHQHZHG�WKHQ�FDUU\�RXW�RXWSXW�VKDIW�DGMXVWPHQW� 3DJH�� +H[�QXW��1P�

��IW�OE��SOXV�� WXUQ��IXUWKHU

4 nuts for bearing support


�� 6KLP�6�


�� 6PDOO�WDSHUHG�UROOHU�EHDULQJ�RXWHU�UDFH

Pulling out Fig. 1

Pressing in Fig. 2

��

�� 6PDOO�WDSHUHG�UROOHU�EHDULQJ�LQQHU�UDFH

Pulling off Fig. 3

Pressing on Fig. 4

�� 2XWSXW�VKDIW Is paired with final drive gear wheel, always renew together as a set

Adjusting Page 35-42

�� /DUJH�WDSHUHG�UROOHU�EHDULQJ�LQQHU�UDFH

Pressing off Fig. 10

Pressing on Fig. 13

�� /DUJH�WDSHUHG�UROOHU�EHDULQJ�RXWHU�UDFH

Pressing out Fig. 11

Pressing in Fig. 12

��

�� 6HDOLQJ�ULQJ

Place sealing rings (Qty. 4) on the bearing support bolts

�� %HDULQJ�VXSSRUW �� 1HHGOH�UROOHU�

EHDULQJ

For 1st gear

�� VW�JHDU�ZKHHO Installation position Fig. 16

�� 6\QFKUR�ULQJ

(1st gear inner ring)


Check lugs for scoring


�� VW�JHDU�RXWHU�ULQJ

Insert in the synchro-ring (item 13 )


Renew if scored

��

�� VW�JHDU�V\QFKUR�ULQJ



�� VW�DQG��QG�JHDU�ORFNLQJ�FROODU�ZLWK�V\QFKUR�KXE

After removing securing clip (item 17 ) pull off over bearing support Fig. 9

Dismantling Fig. 17

Assembling locking collar/synchro hub Fig. 17 and Fig. 18


Pressing on Fig. 20

�� 6HFXULQJ�FOLS

�� QG�JHDU�V\QFKUR�ULQJ


Assemble so that the recesses locate in the locking collar (item 16 ) locking pieces

��

�� 2XWHU�ULQJ

Insert in the synchro-ring (item 18 ), installation position Fig. 21

Renew if scored

�� 6\QFKUR�ULQJ

(Inner ring)


Check lugs for scoring


�� QG�JHDU�ZKHHO Installation position Fig. 23


For 2nd gear

��

�� UG�JHDU�ZKHHO Press off with 2nd gear sliding wheel Fig. 8

Pressing on Fig. 24

Shoulder points to 4th gear

�� WK�JHDU�ZKHHO Pressing off Fig. 7

Pressing on Fig. 25

Shoulder points to 3rd gear

�� &LUFOLS


For 5th gear

�� WK�JHDU�ZKHHO Press off together with locking collar/synchro hub Fig. 6

�� WK�JHDU�V\QFKUR�ULQJ

Check for wear Fig. 26

��

�� WK�DQG�UHYHUVH�JHDU�ORFNLQJ�FROODU�ZLWK�V\QFKUR�KXE

Press off with 5th gear sliding wheel (item 27 ) Fig. 6

Dismantling Fig. 17

Installation position locking collar/synchro-hub Fig. 27

Assembling locking collar/synchro hub Fig. 17 and Fig. 18

Pressing on Fig. 28

�� &LUFOLS

�� 5HYHUVH�JHDU�V\QFKUR�ULQJ

Check for wear Fig. 26


For reverse gear wheel

�� 5HYHUVH�VOLGLQJ�JHDU�ZKHHO

��

�� 7KUXVW�ZDVKHU �� 7DSHUHG�UROOHU�

EHDULQJ�LQQHU�UDFH

Press off with reverse gear wheel Fig. 5

Pressing on Fig. 29


Pulling out Fig. 30

Pressing in Fig. 31

�� 6KLP�6�



��

)LJ�� 6PDOO�WDSHUHG�UROOHU�EHDULQJ�RXWHU�

UDFH��SXOOLQJ�RXW

A - Internal puller 46 ... 58 mm, e.g. Kukko 21/7



SUHVVLQJ�LQ

��

)LJ�� 6PDOO�WDSHUHG�UROOHU�EHDULQJ�LQQHU�

UDFH��SUHVVLQJ�RII - Fit gripping device and tension behind

bearing rollers, then turn bearing and retension gripping device.

)LJ�� 6PDOO�WDSHUHG�UROOHU�EHDULQJ�LQQHU�

UDFH��SUHVVLQJ�RQ

��


SUHVVLQJ�RII - Press off taper roller inner race via reverse

gear wheel.

1RWH� %HIRUH�SUHVVLQJ�RII��VOLGH�ORFNLQJ�FROODU�RYHU�WR��WK�JHDU�

)LJ�� WK�JHDU�DQG�UHYHUVH�JHDU�ORFNLQJ�

FROODU�V\QFKUR�KXE��SUHVVLQJ�RII


After removing securing ring press 2nd gear sliding wheel and locking collar/synchro-hub off together.

��

)LJ�� WK�JHDU�ZKHHO��SUHVVLQJ�RII - First remove securing clip.

)LJ�� UG�JHDU�ZKHHO��SUHVVLQJ�RII - Press off 3rd gear wheel via 2nd gear wheel.

1RWH� %HIRUH�SUHVVLQJ�RII��VOLGH�ORFNLQJ�FROODU�RYHU�WR��VW�JHDU�

��

)LJ�� /RFNLQJ�FROODU�ZLWK�V\QFKUR�KXE��

SXOOLQJ�RII�YLD�EHDULQJ�VXSSRUW

A - Two-arm puller, e.g. Kukko 20/10 with 250 mm reach hooks

1RWH� 5HPRYH�FLUFOLS�EHIRUH�SXOOLQJ�RII�LQGLYLGXDO�FRPSRQHQWV�

)LJ�� /DUJH�WDSHUHG�UROOHU�EHDULQJ�LQQHU�

UDFH��SUHVVLQJ�RII - Before starting press sequence, tension

gripping device V.A.G. 1582/1 onto inner race.

��

)LJ�� /DUJH�WDSHUHG�UROOHU�EHDULQJ�RXWHU�

UDFH��SUHVVLQJ�RXW�IURP�EHDULQJ�VXSSRUW

)LJ�� /DUJH�WDSHUHG�UROOHU�EHDULQJ�RXWHU�

UDFH��SUHVVLQJ�LQWR�EHDULQJ�VXSSRUW

��

)LJ�� /DUJH�WDSHUHG�UROOHU�EHDULQJ�LQQHU�

UDFH��SUHVVLQJ�RQ

1RWH� 3UHVV�SLHFH��VWHS�SRLQWV�WRZDUGV�WDSHU�UROOHU�EHDULQJ�LQQHU�UDFH�

)LJ�� VW�DQG��QG�JHDU�LQQHU�ULQJ��FKHFNLQJ�IRU�ZHDU

- Press inner ring onto gear wheel cone and measure gap "a" with a feeler gauge.

Gap "a" New dimension Wear limit

1st and 2nd gear

0.75 ... 1.25 mm

0.3 mm

��

)LJ�� VW�DQG��QG�JHDU�V\QFKUR�ULQJ��FKHFNLQJ�IRU�ZHDU

- Press synchro-ring, outer-ring and inner-ring onto gear wheel cone and measure gap "a" with feeler gauge.

Gap "a" New dimension

Wear limit

1st and 2nd gear

1.2 ... 1.8 mm 0.5 mm

)LJ�� 2XWHU�ULQJ��LQQHU�ULQJ�DQG��VW�JHDU�V\QFKUR�ULQJ��LQVWDOODWLRQ�SRVLWLRQ

- Place inner ring -A- on 1st gear sliding wheel.

The angled lugs (arrow 1) point towards outer ring -B-.

- Fit outer ring -B-.

The lugs (arrow 2) engage in the sliding wheel recesses (arrow 3).

- Fit synchro-ring -C-.

The grooves (arrow 4) engage in the inner ring -A- lugs (arrow 1).

��

)LJ�� /RFNLQJ�FROODU�DQG�V\QFKUR�KXE��GLVDVVHPEOLQJ�DQG�DVVHPEOLQJ

1 - Spring

2 - Locking collar

3 - Synchro-hub

4 - Locking piece

- Slide locking collar over synchro-hub.

The recesses for locking pieces in synchro-hub and locking collar must align.

)LJ�� /RFNLQJ�FROODU�DQG�V\QFKUR�KXE��DVVHPEOLQJ

The locking collar has been pushed over the synchro-hub.

- Insert locking pieces and install springs 120 off-set. The angled end of the spring must locate in the hollow locking piece.

��

)LJ�� VW�DQG��QG�JHDU�ORFNLQJ�

FROODU�V\QFKUR�KXE��LQVWDOODWLRQ�SRVLWLRQ

The wider shoulder of the synchro-hub (arrow) faces towards 2nd gear.

)LJ�� VW�DQG��QG�JHDU�ORFNLQJ�

FROODU�V\QFKUR�KXE��SUHVVLQJ�RQ

��

)LJ�� QG�JHDU�RXWHU�ULQJ��LQVWDOODWLRQ�

SRVLWLRQ

The lugs (arrows) face to 1st gear -A-

)LJ�� 6\QFKUR�ULQJ��$��LQQHU�ULQJ�IRU�

�QG�JHDU��LQVWDOODWLRQ�SRVLWLRQ

The lugs (arrow 1) locate in the recesses (arrow 2) in the synchro-ring -B-.

��

)LJ�� QG�JHDU�ZKHHO��LQVWDOODWLRQ�

SRVLWLRQ

The higher shoulder -A- faces to 1st gear -B-. The recesses in the shoulder (arrows) locate in the lugs of the outer ring (arrow Fig. 21 )

)LJ�� UG�JHDU�ZKHHO��SUHVVLQJ�RQ

Shoulder points towards 4th gear.

��

)LJ�� WK�JHDU�ZKHHO��SUHVVLQJ�RQ

Shoulder points to 3rd gear.

- Fit securing ring.

)LJ�� 6\QFKUR�ULQJ��FKHFNLQJ�IRU�ZHDU - Press synchro-ring onto the gear wheel

cone and measure gap "a" with feeler gauge.

Gap "a" New dimension

Wear limit

5th gear and reverse gear

1.0 ... 1.7 mm

0.5 mm

��


FROODU�V\QFKUR�KXE��LQVWDOODWLRQ�SRVLWLRQ

The wider synchro hub shoulder with chamfer (arrow) faces towards 5th gear sliding wheel.


FROODU�ZLWK�V\QFKUR�KXE��SUHVVLQJ�RQ

��


SUHVVLQJ�RQ


SXOOLQJ�RXW�IURP�WUDQVPLVVLRQ�KRXVLQJ

A - Internal extractor 37 ... 46 mm, e.g. Kukko 21/6


��


SUHVVLQJ�LQWR�WUDQVPLVVLRQ�KRXVLQJ


- Support gearbox housing with press piece 3062 directly below bearing support.

��

2XWSXW�VKDIW��DGMXVWLQJ� (Determining output shaft shims S1 and S2)

It is necessary to readjust the output shaft when

Final drive

Clutch housing

Gearbox housing

Bearing support

or

Taper roller bearing

have been changed.


6KLP�6��GHWHUPLQLQJ� - Press small taper roller bearing outer race

together with a 0.65 mm thick shim fully into clutch housing Page 35-26 .

- Insert output shaft and tighten bearing support to 25 Nm and then turn 90 further.

��

- Mount D.T.I. (3 mm measuring range) and

"O" with 1 mm preload.

- Move output shaft up and down and recall dial gauge reading (example: 0.30 mm)

1RWH� 'R�QRW�WXUQ�WKH�RXWSXW�VKDIW�ZKLOVW�PHDVXULQJ��RWKHUZLVH�WKH�EHDULQJ�ZLOO�VHWWOH�DQG�D�IDOVH�UHDGLQJ�ZLOO�EH�JLYHQ� 'HWHUPLQLQJ�WKLFNQHVV�RI�VKLP� The specified bearing preload is obtained by adding a constant figure to the reading

obtained: (0.30 mm) and the thickness of the shim installed (0.65 mm).

Example:

Shim installed 0.65 mm

+ Reading 0.30 mm

+ Preload (constant) 0.20 mm

S1 shim thickness 1.15 mm

- Remove output shaft and pull out small

taper roller bearing outer race.

��

The following adjustment shims are available:

6L]H��PP�� 3DUW�1R�� 0.65

0.70

02A 409 210

02A 409 210 A

0.75

0.80

0.85

02A 409 210 B

02A 409 210 C

02A 409 210 D

0.90

0.95

1.00

02A 409 210 E

02A 409 210 F

02A 409 210 G

1.05

1.10

1.15

02A 409 210 H

02A 409 210 J

02A 409 210 K

1.20

1.25

1.30

02A 409 210 L

02A 409 210 M

02A 409 210 N

1.35

1.40

02A 409 210 P

02A 409 210 Q

Varying tolerances make it possible by measuring the shims to obtain the exact shim thickness required.

- Press in small taper roller bearing outer race together with the determined shim (in example 1.15 mm) Page 35-26 .

��

6KLP�6��GHWHUPLQLQJ� - Complete output shaft.

- Insert output shaft without bearing support O ring and tighten bearing support nut to 25 Nm then turn 90 further.

- Attach measuring assembly to 3rd gear wheel.

A - Measuring gauge extension from VW 2066

- Press taper roller bearing outer race with a 0.65 mm shim into gearbox housing onto stop, using 30-26.

- Fit gearbox housing and tighten bolts to torque setting.

- Mount D.T.I. and "0" with 1 mm preload.

A - Measuring gauge extension from VW 2066

1RWHV�

0HDVXULQJ�JDXJH�H[WHQVLRQ�PXVW�EH�DJDLQVW�RXWSXW�VKDIW�PHDVXULQJ�DVVHPEO\�DV�LOOXVWUDWHG�RQ�LOOXVWUDWLRQ�1��

'R�QRW�WXUQ�RXWSXW�VKDIW�ZKHQ�PHDVXULQJ�

��

- Loosen bearing support hexagon nuts -B-

using cross-over sequence until the nuts release the output shaft.

- Read off play on gauge and note reading (example: 0.30 mm)

'HWHUPLQLQJ�WKLFNQHVV�RI�VKLP� The specified bearing preload is obtained by adding to the reading obtained: (0.30 mm) and the thickness of the shim installed (0.65 mm) a preload constant of (0.10 mm).

([DPSOH�

Shim installed 0.65 mm

+ Reading 0.30 mm

+ Preload (constant) 0.10 mm

S2 shim thickness 1.05 mm

��

- Remove gearbox housing and pull taper

roller bearing outer race out from gearbox housing.

- Insert shims of correct thickness, thickest shim first.

The following shims are available:

6L]H��PP�� 3DUW�1R�� 0.65

0.70

0.75

020 311 391 P

020 311 391 Q

020 311 391

0.80

0.85

0.90

020 311 391 A

020 311 391 B

020 311 391 C

0.95

1.00

1.05

020 311 391 D

020 311 391 E

020 311 391 F

1.10

1.15

1.20

020 311 391 G

020 311 391 H

020 311 391 J

1.25

1.30

1.35

020 311 391 K

020 311 391 L

020 311 391 M

1.40

0.70+0.75 = 1.45

0.75+0.75 = 1.50

020 311 391 N

020 311 391 Q/391

020 311 391/391

0.75+0.80 = 1.55 020 311 391/391 A

��

- Press outer race in again.

- Remove output shaft and engage 4th gear using locking collar.

- Insert input shaft together with output shaft. Tighten bearing support nut in clutch housing to 25 Nm and then turn 90 further.

- Install gearbox housing and tighten hexagon head bolts to 25 Nm and then turn 90 further.

&KHFNLQJ�IULFWLRQ�PRPHQW�

A - Commercially available torque gauge 0 ... 600 Ncm


For new taper roller bearings the friction moment must be 130 ... 180 Ncm.

For used taper roller bearings the friction moment must be at least 30 Ncm.

1RWH� /XEULFDWH�EHDULQJV�ZLWK�JHDUER[�RLO�EHIRUH�FKHFNLQJ�IULFWLRQ�PRPHQW�

��

5HYHUVH�JHDU�ZKHHO��UHPRYLQJ�DQG�LQVWDOOLQJ�


�� 6KDIW Press out from mounting (item 6 ) with reverse gear wheel Fig. 1

Pressing in Fig. 2

�� 5HYHUVH�JHDU�ZKHHO


�� 7KUXVW�ZDVKHU

��

�� 5HYHUVH�JHDU�PRXQWLQJ


�� 5HYHUVH�JHDU�JXLGH�WXEH



��

)LJ�� 5HYHUVH�JHDU�ZKHHO��SUHVVLQJ�RXW�

IURP�PRXQWLQJ


)LJ�� 5HYHUVH�JHDU�ZKHHO�VKDIW��

SUHVVLQJ�LQWR�PRXQWLQJ

��

2LO�VHDO�IRU�VWXE�VKDIW�RU�IODQJH�VKDIW��UHPRYLQJ�DQG�LQVWDOOLQJ�

(Gearbox installed)

To renew the left-hand flange shaft or right-hand stub shaft seal the relevant drive shaft must be removed as follows:

- Fit support device 3250 before lifting vehicle.

5HSDLU�0DQXDO��6XVSHQVLRQ��:KHHOV��%UDNHV��6WHHULQJ�P�\��5HSDLU�*URXS��6HUYLFLQJ�IURQW�VXVSHQVLRQ

- Remove hexagon bolt (arrow) for drive

shaft/wheel hub and loosen wheel securing bolts

- Remove noise insulation tray.

- Disconnect drive shaft from flanged shaft.

- Remove wheel.

- Disconnect wheel bearing housing/lower ball

joint bolted connection.

- Remove bolt for shock absorber/anti-roll bar coupling link.

- Press drive shaft out of wheel bearing housing.

��

:KHQ�UHSODFLQJ�OHIW�KDQG�RLO�VHDO�� - Removing drive shaft Page 39-1 .

- Remove flange shaft, to do this screw 2 bolts

-A- in alternatively.

- Always renew flange shaft circlip Page 34-59 .

- Pull flange shaft oil seal out using VW 771

and VW 771/37.

1RWH� 'R�QRW�GDPDJH�RLO�GHIOHFWRU�ULQJ�ZKHQ�SXOOLQJ�RXW�

��

- Drive new seal in onto stop.

- Fill space between seal and dust lip with multi-purpose grease.

- Drive in flange shaft.

- Install drive shaft.

- Check gearbox oil Page 34-44

- Install noise insulation tray.

��

:KHQ�UHSODFLQJ�ULJKW�KDQG�RLO�VHDO�� - Remove drive shaft Page 39-1 .

- Unbolt flange shaft mounting -A- from

bracket -B-.

- Pull right-hand flange shaft -C- out from stub shaft -D-.

- Take O ring out from stub shaft.

- Removing stub shaft.

A - Separating device Kukko 17/0

B - Separating device Kukko 17/1

1 - Bolt M10 x 80 (Qty. 2)

- Turn bolts -1- evenly against separating device -B-.

��

- Lever seal out.

- Drive new seal in onto stop.

- Fill space between seal and dust lip with multi-purpose grease.

- Always renew stub shaft circlip Page 34-59 .

- Drive stub shaft in complete with new circlip and O ring with synthetic head hammer.

1RWH� *UHDVH�VWXE�VKDIW�LQWHUQDO�VSOLQHV�ZLWK�GULYH�VKDIW�JUHDVH�*��

- Install right-hand flange shaft.

- Install drive shaft.

- Check gearbox oil Page 34-44

- Install noise insulation tray.

��

7LJKWHQLQJ�WRUTXH�� Drive shaft to drive flange 80 Nm

Wheel bearing housing to lower ball joint

55 Nm

Hexagon bolt on drive shaft 150 Nm + 90

Flange shaft mounting to bracket

25 Nm

��

'LVPDQWOLQJ�DQG�DVVHPEOLQJ�GLIIHUHQWLDO�1RWHV�

+HDW�WDSHU�UROOHU�EHDULQJ�LQQHU�UDFH�WR�� &�EHIRUH�LQVWDOOLQJ� $OZD\V�UHQHZ�ERWK�WDSHU�UROOHU�EHDULQJV�WRJHWKHU�DV�D�VHW� ,I�GLIIHUHQWLDO�KRXVLQJ��JHDUER[�KRXVLQJ�RU�FOXWFK�KRXVLQJ�WDSHU�UROOHU�EHDULQJV�DUH�UHQHZHG�DGMXVW�GLIIHUHQWLDO� 3DJH�� *HDUER[�

KRXVLQJ

�� 6KLP

For differential


��

�� 7DSHU�UROOHU�EHDULQJ�RXWHU�UDFH

Pulling out Fig. 5

Pressing in Fig. 6

�� 7DSHU�UROOHU�EHDULQJ�LQQHU�UDFH

Pulling off Fig. 3

Pressing on Fig. 4

�� 'LIIHUHQWLDO�KRXVLQJ

With rivetted final drive gear

When renewing final drive gear drill out rivet heads Fig. 7

Attaching final drive gear with bolts Fig. 10

�� 6SHHGRPHWHU�GULYH�JHDU

Fit on differential housing before pressing on inner race

��

�� 7DSHU�UROOHU�EHDULQJ�LQQHU�UDFH

Pulling off Fig. 3

Pressing on Fig. 4

�� 7DSHU�UROOHU�EHDULQJ�RXWHU�UDFH

Pressing out Fig. 1

Pressing in Fig. 2

�� 2LO�GHIOHFWRU�ULQJ

Press out with taper roller bearing outer race (item 8 )

Fig. 1



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Always renew

Insert into stub shaft groove (item 14 )

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For stub shaft


Pressing on Fig. 18

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Grease internal splines with drive shaft grease G 000 603

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Always renew

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Pressing on Fig. 16

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For flange shaft


Pressing on Fig. 14

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Coat with gearbox oil when installing

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Installing Fig. 12

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Installing Fig. 12

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For securing planet pinion axis shaft

Removing and installing Fig. 11

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Always replace

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Rivetted in production

Bolted Fig. 10

Heat to 100 C before installing

Pressing off Fig. 8

Fit to differential housing Fig. 9

Is paired with output shaft, only renew as a set

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Bolt to final drive gear wheel Fig. 10

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B - Internal puller 46...58 mm, e.g. Kukko 21/7

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- First insert oil deflector ring.

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- Before fitting the extractor position press piece 40-105 on differential housing.

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A - Internal puller 56...70 mm, e.g. Kukko 21/8



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- Support gearbox housing with sleeve 30-14 directly below bearing support.

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)LJ�� 5LYHW�KHDGV��GULOOLQJ�RXW�- Drill out rivet heads with 12 mm drill from

countersunk side and knock-out with drift.

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)LJ�� 3UHVVLQJ�RII�ILQDO�GULYH�JHDU - Place thrust piece 40-105 on differential

housing.

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- Use bolts -A- from repair kit to guide final drive gear into position during installation.

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Use special bolts with nuts according to parts catalog.

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- Cover taper roller bearing inner race and speedometer drive gear to avoid possible damage and ingress of metal particles.

- Knock-out spring pin with chisel, inserting chisel into circumferential groove.

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- Knock fully into the differential housing.

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- Lubricate one piece thrust washer with gearbox oil and install.

- Install both sun wheels and secure (e.g. with flange shaft).

- Insert planet wheels turned through 180 and pivot into position.

- Drive planet wheel axle into final position and secure with spring pin.

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- Press new dust plate on until it is flush with shoulder -arrow-.

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RII - Remove circlip on bearing first.

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- Install circlip.

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WR�EH�DGMXVWHG�� Input shaft

Page 35-13

Output shaft

(S1 and S2)

Page 35-42

Differential

Page 39-25

3DUWV� Gearbox housing x x x

UHQHZHG�� Clutch housing x x x

Input shaft x

Output shaft (final drive) x

Differential housing x

Input shaft taper roller bearing

x

Output shaft taper roller bearing

x

Differential taper roller bearing

x

Bearing support x ��

$GMXVWLQJ�GLIIHUHQWLDO� The differential must be adjusted, when

Gearbox housing

Clutch housing

Differential housing

or the

Differential taper roller bearing

have been renewed.

Adjustment overview Page 39-24 .

- Pressing taper roller bearing outer race with oil deflector ring into the clutch housing using thrust piece 2050 Page 39-14 .

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- Pressing taper roller bearing outer race without

shim into the gearbox housing using thrust piece 2050 Page 39-16 .

- Fit differential into clutch housing

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- Fit gearbox housing and tighten 5 bolts to torque setting.

- Mount D.T.I. and "0" with 1 mm preload.

- Move differential up and down and recall play indicated on D.T.I. (Example: 0.70 mm)

A - 60 mm gauge extension

1RWH� 'R�QRW�WXUQ�GLIIHUHQWLDO�ZKHQ�PHDVXULQJ�RWKHUZLVH�WKH�EHDULQJ�ZLOO�VHWWOH�DQG�D�IDOVH�PHDVXUHPHQW�ZLOO�EH�JLYHQ� 'HWHUPLQLQJ�VKLP�WKLFNQHVV� The specified bearing preload is obtained by adding a constant figure (0.40 mm) to the reading obtained.

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Reading 0.70 mm

+ Preload (constant figure) 0.40 mm

Thickness of shim = 1.10 mm

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- Remove gearbox housing and pull taper

roller bearing outer race out from gearbox housing.

- Insert shims of correct thickness, thickest shim first.

The following shims are available:

6L]H��PP�� 3DUW�1R�� 0.65

0.70

0.75

02G 409 210

02G 409 210 A

02G 409 210 B

0.80

0.85

0.90

02G 409 210 C

02G 409 210 D

02G 409 210 E

0.95

1.00

1.05

02G 409 210 F

02G 409 210 G

02G 409 210 H

1.10

1.15

1.20

02G 409 210 J

02G 409 210 K

02G 409 210 L

1.25

1.30

1.35

1.40

02G 409 210 M

02G 409 210 N

02G 409 210 P

02G 409 210 Q

0.70+0.75 = 1.45

0.75+0.75 = 1.50

0.75+0.80 = 1.55

02G 409 210 A + B

02G 409 210 B + B

02G 409 210 B + C

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- Press outer race in again and tighten

gearbox housing to torque setting.

&KHFNLQJ�IULFWLRQ�PRPHQW� A - Commercial torque gauge 0 ... 600 Ncm


- Lubricate taper roller bearing with gear oil.

Friction moment:

New taper roller bearings 120 ... 320 Ncm

Used taper roller bearings at least 30 Ncm.

TRANSMISION 02G STANDAR

Documents

trolley jack

square drive

auxiliary

master spline

synthetic

needie roiier

tapered roiier

remove insulation