Sie sind auf Seite 1von 32

Repair Manual VW 02J gearbox

INA GearBOX

Repair Manual VW 02J gearbox INA GearBOX
Repair Manual VW 02J gearbox INA GearBOX
Repair Manual VW 02J gearbox INA GearBOX
Repair Manual VW 02J gearbox INA GearBOX

Special tools

Special tools Pipe section, 50 mm: • Press fitting of synchronizer body for third/fourth gear. •

Pipe section, 50 mm:

• Press fitting of synchronizer body for third/fourth gear.

• Assembly of support bearing for input and output shaft.

• Part number: 400 0472 10

for input and output shaft. • Part number: 400 0472 10 Press fit sleeve: • Press

Press fit sleeve:

• Press fitting of needle roller bearing sleeve for third gear.

• Part number: 400 0475 10

Shim set

sleeve for third gear. • Part number: 400 0475 10 Shim set Shim set: • Installation

Shim set:

• Installation location: differential tapered roller bearing.

• Outside diameter of 67,9 mm

• Part number: 464 0001 10

• Outside diameter of 67,9 mm • Part number: 464 0001 10 Pipe section, 60 mm:

Pipe section, 60 mm:

• Press fitting of synchronizer body for first/second gear.

• Part number: 400 0473 10

body for first/second gear. • Part number: 400 0473 10 Thrust piece: • Press fitting of

Thrust piece:

• Press fitting of needle roller bearing sleeve for third gear.

• Assembly/disassembly of reverse gear shaft needle roller bearing.

• Part number: 400 0476 10

shaft needle roller bearing. • Part number: 400 0476 10 Shim set: • Installation location: output

Shim set:

• Installation location: output shaft tapered roller bearing.

• Outside diameter of 50,2 mm

• Part number: 464 0002 10

• Outside diameter of 50,2 mm • Part number: 464 0002 10 Drive-in sleeve: • Press

Drive-in sleeve:

• Press fitting of needle roller bearing sleeve for fourth and fifth gear.

• Assembly of support bearing for input and output shaft.

• Part number: 400 0474 10

for input and output shaft. • Part number: 400 0474 10 Shim set: • Installation location:

Shim set:

• Installation location: of input shaft tapered roller bearing.

• Outside diameter of 69.0 mm

• Part number: 464 0003 10

Repair Manual for VW 02J gearbox

• Drain the transmission fluid (arrow).

• Then refit the oil drain plug. Tightening torque of oil drain plug: 25 Nm

• Remove the gearbox from the vehicle in accordance with the vehicle manufacturer specifications.

• Unhook the retaining spring (arrow).

• Remove the release lever and release bearing.

• Remove screws (1) from guiding sleeve.

• Remove the guiding sleeve.

1
1
2
2
3
3

• Loosen the screws on the left and right drive- shaft flanges.

• Completely remove the driveshaft flanges together with pressure spring, thrust washer and conical ring.

Note:

To release, secure the driveshaft flanges with two screws and a tyre lever.

• Remove screws (1) from transmission housing cover.

• Remove transmission cover.

Note:

Clean sealing surfaces.

• Remove screws (1) from bearing journals.

• Remove gear shift fork fifth gear (2).

• Unscrew screws for synchronizer body and toothed gear fifth gear (A).

Note:

To undo the screws, block the transmission. To do this, press selector sleeve fifth gear (1) downwards, push in selector shaft (2) and rotate anti- clockwise (3).

• Return the selector shaft to neutral after loosening the screws.

Note:

For the neutral position, turn selector shaft clockwise until it pops out independently.

4
4
5 4
5
4
6
6
7
7

• Place extractor under speed gear for fifth gear.

• Extract synchronizer package and speed gear from input shaft.

Caution:

Take care when lifting out synchronizer package (selector sleeve, thrust pieces and spring lock washer) to prevent it from falling apart!

• Place extractor underneath toothed gear fifth gear.

• Remove toothed gear fifth gear.

• Unscrew nut (1) from selector mass.

• Remove selector mass.

• Remove screws from selector shaft (arrows).

• Remove selector shaft.

• Remove both bearing journals (1).

8
8
9
9
10
10
11
11

• Remove both bearing journals (1).

• Undo screw on reverse gear (2).

• Remove cover (3).

• Remove screw from reverse gear (arrow).

• Remove screws (1) from transmission housing.

Caution:

Do not unscrew bearing housing retainer nuts (2) of the output shaft.

• Remove screws from transmission housing.

12
12
13
13
14
14
15
15

• Lift off transmission housing.

Caution:

Be careful not to damage the sealing surfaces when doing this.

Note:

Clean sealing surfaces.

• Remove gear shift forks and gear shift rails (1).

• Remove screw from reverse gear actuator (2).

• Remove reverse gear actuator.

• Remove bearing housing retainer nuts (1) from the output shaft.

• Remove reverse gear (1), input shaft (2) and output shaft (3) from the housing.

• Lift out differential (4).

• Remove magnet (5).

16
16
17
17
18
18
19
19

• Pull out reverse gear drawn cup needle roller bearing with open end from housing.

• Pull out engine-side bearing ring for input shaft.

• Pull out engine-side bearing ring for output shaft.

• Remove shim.

• Pull out engine-side bearing ring for differential.

20
20
21
21
22
22
23
23

• Remove flanged shaft seal on the engine side.

• Install new engine-side flanged shaft seal.

Note:

Clean the sealing surface before

Note:

installing the new sealing ring. Adhere to nonverbal mounting instructions 9996006770.

• Pull out transmission-side bearing ring for differential.

• Remove shim.

• Remove drive flange seal on the transmission side.

24
24
25
25
26
26
27
27

• Install new transmission-side flanged shaft seal.

Note:

Clean the sealing surface before installing the new sealing ring.

• Press out transmission-side bearing ring for input shaft together with shim.

• Press out transmission-side bearing ring of output shaft.

• Press out drawn cup needle roller bearing with open end from reverse shaft support.

Note:

Use special tool 400 0476 10.

28
28
29
29
30
30
31
31

• Extract both differential bearings.

• Remove speedometer drive.

• Drive out roll pin in direction of arrow.

• Drive in the new roll pin as far as it will go.

32
32
33
33
34
34
35
35

• Reassemble speedometer drive.

• Press fit new differential bearings on both sides.

Note:

Adhere to nonverbal mounting instructions

9996006760.

• Press fit engine-side bearing ring for differential.

• Press fit transmission-side bearing ring for differential.

Note:

First press fit bearing ring without shim.

36
36
37
37
38
38
39
39

• Press off engine-side bearing of input shaft.

• Press off transmission-side bearing of input shaft together with toothed gear for fourth gear, washer and sleeve.

• Press fit engine-side bearing of input shaft.

Note:

Support bearing when press fitting onto the inner ring.

• Press fit the toothed gear for fourth gear

Note:

The shoulder on the toothed gear must point towards third gear

40
40
41
41
42
42
43
43

• Press fit transmission-side bearing of input shaft.

Note:

Use special tool 400 0474 10.

• Position washer (1).

• Press fit sleeve (2) for needle roller bearing.

Note:

Use special tool 400 0474 10.

• Press fit drawn cup needle roller bearing with open end into reverse shaft support.

• Press off speed gears for second to fourth gears from output shaft together with synchronizer package and sleeve (components 1-17).

Note:

Lift the components together when disassembling to prevent the synchronizer package from falling apart.

• Remove circlip (18).

44
44
45
45
46
46
47
47

• Press off components 19-23 from output shaft through bearing housing (24).

• Press off transmission-side bearing (25) from output shaft through inner ring.

• Press off engine-side bearing (26) from output shaft through inner ring.

• Press fit new engine-side bearing (26) on the output shaft through inner ring.

Note:

Use special tool 400 0474 10.

48
48
49
49
50
50
51
51

• Press fit new transmission-side bearing (25) on output shaft through inner ring.

Note:

Position thrust washer (23) before press fitting. The heel is pointing towards the inner ring.

Note:

Use special tool 400 0472 10.

• Press out outer ring of transmission-side bearing of output shaft from bearing housing.

• Press fit outer ring of new transmission-side bearing of output shaft into the bearing housing.

• Press fit new outer ring for engine-side bearing of output shaft together with 0.65 mm shim. Important for subsequent setting of output shaft!

Note:

Use special tool 400 0472 10.

52
52
53
53
54
54
55
55

• Press fit new outer ring of engine-side bearing of input shaft.

Note:

Use special tool 400 0472 10.

• Press fit new drawn cup needle roller bearing with open end for reverse gear into clutch housing.

Note:

Use special tool 400 0476 10.

• Press fit new outer ring of transmission-side bearing of input shaft into transmission housing without shim.

• Press fit roller sleeve for output shaft on transmission side.

Note:

Adhere to nonverbal mounting instructions 9996006720.

56
56
57
57
58
58
59
59

• Secure roller sleeve in the transmission housing at three points (1) with a mandrel, with an offset of 120°.

• Insert differential.

• Attach the transmission housing.

• Fix transmission housing in place with the screws shown. Tightening torque for cover screws: 25 Nm

• Assemble dial gauge as shown and set to "0" with 1 mm preload.

• Move differential up and down, reading the clearance as you do so.

• Measured value + 0.40 mm produces the requisite thickness of the shim.

60
60
61
61
62
62
63
63

• Remove transmission housing.

• Pull out outer ring of transmission-side differential bearing.

• Insert appropriate shim and press fit outer ring again.

• Insert output shaft.

• Tighten nuts for bearing housing (ct. Figure 18). Tightening torque for bearing connector nuts:

25 Nm + 90°

• Assemble dial gauge as shown and set to "0" with 1 mm preload.

• Move output shaft up and down, reading the clearance as you do so.

The required thickness of shim is derived from:

Thickness of shim inserted for measurement (here 0.65 mm) + measured value + 0.20 mm.

• Remove output shaft.

• Pull out outer ring of engine-side bearing of output shaft.

• Replace shim used for measurement with new, calculated shim.

• Press fit outer ring again.

• Insert the input shaft in the clutch cover.

• Reassemble the transmission housing and bolt it fully into place. Tightening torque for the housing screws:

25 Nm + 90°

64
64
65
65
66
66
67
67

• Turn input shaft to allow the tapered roller bearings to set themselves.

Note:

This procedure must be repeated for each further measurement!

• Assemble dial gauge as shown and set to "0" with 1 mm preload.

• Move input shaft in the direction of the arrow, reading the clearance as you do so.

• Determine leveling disc according to table (page 30/31).

• Remove input shaft.

• Pull out outer ring of transmission-side bearing of input shaft.

• Insert leveling disc and press fit outer ring again.

• Repeat measuring procedure with shim press fit. The bearing play should be between 0.01 mm and 0.09 mm.

Note:

If no more bearing play can be measured, but the input shaft has a perceptible tilting clearance, the setting is also correct.

Note:

When assembling the synchronizers, make sure that the recesses and dividers of the individual parts match. (Shown here on the example of first gear.)

• Place inner synchro ring (1) on the speed gear for first gear. The angled dividers (A) point towards the intermediate ring (2).

• Position intermediate ring (2). The dividers (B) lock into place in the recesses (C) of the speed gear.

• Position outer synchro ring (3). The recesses (D) lock into place in the dividers (A) of the inner synchro ring (1).

• Position bearing housing (24), speed gear for first gear (22), needle roller bearing (21) and synchro ring (20).

• Press fit synchronizer body with sliding sleeve (19).

Note:

Use special tool 400 0473 10.

• Fit circlip (18).

Note:

The exploded drawing shows a single synchronization. For transmissions dated after 02.05.2000, this has been replaced with a double synchronization (see Figure 70).

68
68
69
69
70
70
71
71

• Position synchro rings (15–17), speed gear for second gear (14), needle roller bearing (13) and thrust washer (12).

• Press fit sleeve for needle roller bearing for third gear (11) onto output shaft.

Note:

Use special tools 400 0475 10 and 400 0476 10.

• Position needle roller bearing (10), speed gear for third gear (9) and synchro ring (8).

• Press fit synchronizer body with sliding sleeve (7) onto output shaft.

Note:

Use special tool 400 0472 10.

• Press fit sleeve (6) for needle roller bearing for fourth gear onto output shaft.

Note:

Use special tool 400 0474 10.

• Position needle roller bearing (5), synchro ring (4), speed gear for fourth gear (3) and thrust washer (2).

• Press fit sleeve for needle roller bearing for fifth gear (1) onto output shaft.

Note:

Use special tool 400 0474 10.

72
72
73
73
74
74
75
75

• Replace 4 sealing rings (arrows) of bearing housing.

• Insert differential (1) and magnet (2).

• Insert input shaft and output shaft together.

• Tighten nuts of bearing housing (1) of output shaft. Tightening torque for bearing connector nuts:

25 Nm + 90°

76
76
77
77
78
78
79
79

• Position reverse idler gear on drawn cup needle roller bearing with open end.

• Insert reverse shaft with ratchet through reverse idler gear in needle roller bearing.

• Position reverse shaft support on reverse shaft.

• Screw the M8 x 100 mm stud bolts onto the reverse shaft support.

Note:

Bolts help to align the reverse shaft support during the subsequent assembly process.

80
80
81
81
82
82
83
83

• Assemble shift actuating mechanism for reverse gear. Tightening torque of reverse gear screw: 25 Nm

• Insert gear shift forks and gear shift rails.

• Align gear shift rails.

Note:

Sliding blocks must be sitting in the grooves of the sliding sleeves.

Caution:

Reverse gear shift fork must be located underneath the large gear shift fork (see detailed photo).

• Apply sealant to one side of the transmission housing.

• Assemble transmission housing halves.

84
84
85
85
86
86
87
87

• Tighten screws for transmission housing. Tightening torque of housing screws:

25 Nm + 90°

• Insert side screw (1) of reverse gear and tighten by hand.

• Unscrew stud bolts (2) and replace with original screw.

• Tighten both screws one after the other. Tightening torque of screws: 30 Nm

• Tighten housing screws (1) in the clutch bell housing. Tightening torque of housing screws: 25 Nm + 90°

• Clean the 4 bearing journals of the gear shift forks.

• Replace the o-rings of the bearing journals.

• Install the 4 bearing journals. Tightening torque of the bearing journal screws: 25 Nm

Note:

If necessary, adjust the shift actuating mechanism using a screwdriver to ensure that the relevant bearing journal can be installed.

88
88
89
89
90
90
91
91

• Apply sealant.

• Put gear shift rails in neutral position.

• Insert lug (1) into the recess (2) of the transmission housing. Arrange selector shaft so that the shift fingers (3) can be inserted into the gear shift rails.

• Screw on shift actuating mechanism. Tightening torque of shift actuating mechanism screws: 25 Nm

• Screw on selector mass. Tightening torque for flywheel mass nut: 25 Nm

• Apply sealant.

92
92
93
93
94
94
95
95

• Attach cover. Tightening torque for cover screws: 25 Nm

• Press fit toothed gear for fifth gear.

Note:

Surrounding groove must be facing the transmission!

• Press fit synchronizer unit for fifth gear.

Note:

Ensure correct assembly of synchronizer body and synchro ring! The cast-on tabs of the synchro ring (1) must be sitting in the recesses (2) of the synchronizer body.

• Fasten synchronizer unit and toothed gear for fifth gear with respective spring washer and screw (A). Tightening torque of screws: 80 Nm

Note:

To tighten the screws, block the transmission. To do this, press selector sleeve fifth gear (1) downwards, push in selector shaft (2) and rotate anti-clockwise (3).

• Return the selector shaft to neutral after tightening the screws.

Note:

For the neutral position, turn selector shaft clockwise until it pops out independently.

96
96
97
97
98
98
99
99

• Assemble gear shift fork.

• fifth gear should be engaged using selector shaft.

• Loosen screw of selector jaws (1).

• Push sliding sleeve and selector jaws downwards.

• Tighten screw of selector jaws (1). Tightening torque for screw of selector jaws: 25 Nm

• Perform control measurement: It must not be possible to insert a feeler gauge of 0.2 mm in between the sliding sleeve and ratchet.

• Repeat the adjustment procedure, if required.

• fifth gear should be removed using the selector shaft: The sliding sleeve must now be in the neutral position, synchro ring for fifth gear must move freely.

• Shift through all gears.

• Replace the cover seal.

• Put cover of transmission housing into position.

100
100
101
101
102
102
103
103

• Tighten cover screws (1). Tightening torque for cover screws: 10 Nm

• Push new guiding sleeve onto the input shaft.

• Tighten screws (1). Tightening torque of mounting screws:

20 Nm

• Grease sleeve in area of release bearing.

• Fasten the retaining spring to the clutch release lever.

• Install clutch release lever.

• Mount the retaining spring.

• Grease release bearing at contact point with release lever and push into place.

• Install both driveshaft flanges using springs, thrust washers and conical rings. Tightening torque for the flange screws: 25 Nm

104
104
105
105
106
106
107
107

• Install the transmission in the vehicle in accordance with the manufacturer's instructions.

• Fill with transmission fluid in accordance with the vehicle manufacturer's specifications.

108
108

Setting the input shaft tapered roller bearing – Table of shims

Part number for shim set: 464 0003 10

Bearing play

Shim

Measured value (mm)

Thickness (mm)

Spare part no.

0.671

0.699

0.650

02A 311 140

0.700

0.724

0.675

02A 311 140 A

0.725

0.749

0.700

02A 311 140 B

0.750

0.744

0.725

02A 311 140 C

0.775

0.799

0.750

02A 311 140 D

0.800

0.824

0.775

02A 311 140 E

0.825

0.849

0.800

02A 311 140 F

0.850

0.874

0.825

02A 311 140 G

0.875

0.899

0.850

02A 311 140 H

0.900

0.924

0.875

02A 311 140 J

0.925

0.949

0.900

02A 311 140 K

0.950

0.974

0.925

02A 311 140 L

0.975

0.999

0.950

02A 311 140 M

1.000

1.024

0.975

02A 311 140 N

1.025

1.049

1.000

02A 311 140 P

1.050

1.074

1.025

02A 311 140 Q

1.075

1.099

1.050

02A 311 140 R

1.100

1.124

1.075

02A 311 140 S

1.125

1.149

1.100

02A 311 140 T

1.150

1.174

1.125

02A 311 140 AA

1.175

1.199

1.150

02A 311 140 AB

1.200

1.224

1.175

02A 311 140 AC

1.225

1.249

1.200

02A 311 140 AD

1.250

1.274

1.225

02A 311 140 AE

1.275

1.229

1.250

02A 311 140 AF

1.300

1.324

1.275

02A 311 140 AG

Setting the input shaft tapered roller bearing – Table of shims

Part number for shim set: 464 0003 10

Note:

From bearing play greater than 1.325 mm, a combination of two shims may be required.

Bearing play

Shim

Measured value (mm)

Thickness (mm)

Spare part no.

   

02A 311 140

1.325

1.349

1.300

02A 311 140

   

02A 311 140

1.350

1.374

1.325

02A 311 140 A

   

02A 311 140 A

1.375

1.399

1.350

02A 311 140 A

   

02A 311 140 A

1.400

1.424

1.375

02A 311 140 B

   

02A 311 140 B

1.425

1.449

1.400

02A 311 140 B

   

02A 311 140 B

1.450

1.474

1.425

02A 311 140 C

   

02A 311 140 C

1.475

1.499

1.450

02A 311 140 C

   

02A 311 140 C

1.500

1.524

1.475

02A 311 140 D

   

02A 311 140 D

1.525

1.549

1.500

02A 311 140 D

   

02A 311 140 D

1.550

1.574

1.525

02A 311 140 E

   

02A 311 140 E

1.575

1.599

1.550

02A 311 140 E

1.600

1.624

 

02A 311 140 E

1.575

02A 311 140 F

1.625

1.649

1.600

02A 311 140 F

02A 311 140 F

1.650

1.674

1.625

02A 311 140 F

02A 311 140 G

1.675

1.699

1.650

02A 311 140 G

 

02A 311 140 G

1.700

1.724

1.675

02A 311 140 G

 

02A 311 140 H

1.725

1.749

 

02A 311 140 H

 

1.700

02A 311 140 H

1.750

1.774

 

02A 311 140 H

 

1.725

02A 311 140 J

1.775

1.791

 

02A 311 140 J

 

1.750

02A 311 140 J

© 2016 Schaeffler Automotive Aftermarket

9996008950/08.2016

More garage knowledge:

www.repxpert.com