LuK Repair Solution for manual transmissions. Disassembly and assembly Special tool/failure diagnosis VW 02J

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1 LuK Repair Solution for manual transmissions Disassembly and assembly Special tool/failure diagnosis VW 02J

2 The content of this brochure shall not be legally binding and is for information purposes only. To the extent legally permissible, Schaeffler Automotive Aftermarket GmbH & Co. KG assumes no liability out of or in connection with this brochure. Copyright Schaeffler Automotive Aftermarket GmbH & Co. KG April 2017 All rights reserved. Any copying, distribution, reproduction, making publicly available or other publication of this brochure in whole or in extracts without the prior written consent of Schaeffler Automotive Aftermarket GmbH & Co. KG is prohibited.

3 Schaeffler in the Automotive Aftermarket more innovation, more quality and more service. Schaeffler in the Automotive Aftermarket four strong brands. Whenever a vehicle needs to go to the garage, our products and repair solutions are usually first choice to fix them. With our four strong brands LuK, INA, FAG, and Ruville, we are a reliable global partner offering repair solutions for passenger cars, light and heavy commercial vehicles as well as tractors. Whether for the transmission, engine, or chassis all products are based on a comprehensive systems approach. Innovation, technical expertise, and the highest material and manufacturing quality make us not only one of the leading development partners for vehicle manufacturers, but also a pioneering provider of value-retaining spare parts and complete repair solutions always in original equipment quality. Our comprehensive portfolio includes products and repair solutions for clutches and clutch release systems, engine and transmission applications, and chassis applications. All components are optimally tuned to work together perfectly, and allow fast and professional parts replacement. Schaeffler REPXPERT the service brand for garage professionals. Under the REPXPERT brand we offer a comprehensive package of services for the products and repair solutions of the LuK, INA, FAG, and Ruville brands. Looking for specific information or damage diagnosis? Are you in need of particular tools to make your everyday garage routine easier? Whether online portal, service hotline, installation instructions and videos, training seminars, or events all technical services are provided in just one place. Then simply register for free in just a few clicks at: For over 50 years, Schaeffler has offered everything needed for transmission repair. With its LuK RepSet family (LuK RepSet, LuK RepSet Pro, LuK RepSet DMF, and LuK RepSet 2CT) Schaeffler supports garages with professional clutch repair. The portfolio includes the entire hydraulic release system and the dual-mass flywheel.

4 Special tools Pipe section, 50 mm: Press fitting of synchronizer body for third/fourth gear. Assembly of support bearing for input and output shaft. Part number: Pipe section, 60 mm: Press fitting of synchronizer body for first/second gear. Part number: 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: Press fit sleeve: Press fitting of needle roller bearing sleeve for third gear. Part number: Thrust piece: Press fitting of needle roller bearing sleeve for third gear. Assembly/disassembly of reverse gear shaft needle roller bearing. Part number: Shim set 4 Shim set: Installation location: output shaft tapered roller bearing. Outside diameter of 62.2 mm Part number: Shim set: Installation location: differential tapered roller bearing. Outside diameter of 68.0 mm Part number: Shim set: Installation location: of input shaft tapered roller bearing. Outside diameter of 69.0 mm Part number:

5 Repair Manual VW 02J gearbox 1 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. 2 Unhook the retaining spring (arrow). Remove the release lever and release bearing. 3 Remove screws (1) from guiding sleeve. Remove the guiding sleeve. 5

6 4 Loosen the screws on the left and right driveshaft flanges. Completely remove the driveshaft flanges together with pressure spring, thrust washer and conical ring. To release, secure the driveshaft flanges with two screws and a tyre lever. 5 Remove screws (1) from transmission housing cover. Remove transmission cover. Clean sealing surfaces. 6 Remove screws (1) from bearing journals. Remove gear shift fork fifth gear (2). 6

7 7 Unscrew screws for synchronizer body and toothed gear fifth gear (A). 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. For the neutral position, turn selector shaft clockwise until it pops out independently. 8 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! 9 Place extractor underneath toothed gear fifth gear. Remove toothed gear fifth gear. 7

8 10 Unscrew nut (1) from selector mass. Remove selector mass. 11 Remove screws from selector shaft (arrows). Remove selector shaft. Remove both bearing journals (1). 12 Remove both bearing journals (1). Undo screw on reverse gear (2). Remove cover (3). 13 Remove screw from reverse gear (arrow). 8

9 14 Remove screws (1) from transmission housing. Do not unscrew bearing housing retainer nuts (2) of the output shaft. 15 Remove screws from transmission housing. 16 Lift off transmission housing. Caution: Be careful not to damage the sealing surfaces when doing this. Clean sealing surfaces. 17 Remove gear shift forks and gear shift rails (1). Remove screw from reverse gear actuator (2). Remove reverse gear actuator. 9

10 18 Remove bearing housing retainer nuts (1) from the output shaft. 19 Remove reverse gear (1), input shaft (2) and output shaft (3) from the housing. Lift out differential (4). Remove magnet (5). 20 Pull out reverse gear drawn cup needle roller bearing with open end from housing. 21 Pull out engine-side bearing ring for input shaft. 10

11 22 Pull out engine-side bearing ring for output shaft. Remove shim. 23 Pull out engine-side bearing ring for differential. 24 Remove flanged shaft seal on the engine side. 25 Install new engine-side flanged shaft seal. Clean the sealing surface before installing the new sealing ring. Adhere to nonverbal mounting instructions

12 26 Pull out transmission-side bearing ring for differential. Remove shim. 27 Remove drive flange seal on the transmission side. 28 Install new transmission-side flanged shaft seal. Clean the sealing surface before installing the new sealing ring. 29 Press out transmission-side bearing ring for input shaft together with shim. 12

13 30 Press out transmission-side bearing ring of output shaft. 31 Press out drawn cup needle roller bearing with open end from reverse shaft support. Use special tool Extract both differential bearings. 33 Remove speedometer drive. 13

14 34 Drive out roll pin in direction of arrow. 35 Drive in the new roll pin as far as it will go. 36 Reassemble speedometer drive. 37 Press fit new differential bearings on both sides. Adhere to nonverbal mounting instructions

15 38 Press fit engine-side bearing ring for differential. 39 Press fit transmission-side bearing ring for differential. First press fit bearing ring without shim. 40 Press off engine-side bearing of input shaft. 41 Press off transmission-side bearing of input shaft together with toothed gear for fourth gear, washer and sleeve. 15

16 42 Press fit engine-side bearing of input shaft. Support bearing when press fitting onto the inner ring. 43 Press fit the toothed gear for fourth gear The shoulder on the toothed gear must point towards third gear 44 Press fit transmission-side bearing of input shaft. Use special tool Position washer (1). Press fit sleeve (2) for needle roller bearing. Use special tool

17 46 Press fit drawn cup needle roller bearing with open end into reverse shaft support. 47 Press off speed gears for second to fourth gears from output shaft together with synchronizer package and sleeve (components 1-17). Lift the components together when disassembling to prevent the synchronizer package from falling apart. Remove circlip (18). 48 Press off components from output shaft through bearing housing (24). 49 Press off transmission-side bearing (25) from output shaft through inner ring. 17

18 50 Press off engine-side bearing (26) from output shaft through inner ring. 51 Press fit new engine-side bearing (26) on the output shaft through inner ring. Use special tool Press fit new transmission-side bearing (25) on output shaft through inner ring. Position thrust washer (23) before press fitting. The heel is pointing towards the inner ring. Use special tool Press out outer ring of transmission-side bearing of output shaft from bearing housing. 18

19 54 Press fit outer ring of new transmission-side bearing of output shaft into the bearing housing. 55 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! Use special tool Press fit new outer ring of engine-side bearing of input shaft. Use special tool Press fit new drawn cup needle roller bearing with open end for reverse gear into clutch housing. Use special tool

20 58 Press fit new outer ring of transmission-side bearing of input shaft into transmission housing without shim. 59 Press fit roller sleeve for output shaft on transmission side. Adhere to nonverbal mounting instructions Secure roller sleeve in the transmission housing at three points (1) with a mandrel, with an offset of Insert differential. Attach the transmission housing. 20

21 62 Fix transmission housing in place with the screws shown. Tightening torque for cover screws: 25 Nm 63 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 mm produces the requisite thickness of the shim. 64 Remove transmission housing. Pull out outer ring of transmission-side differential bearing. Insert appropriate shim and press fit outer ring again. 65 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. 21

22 66 The required thickness of shim is derived from: Thickness of shim inserted for measurement (here 0.65 mm) + measured value 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. 67 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 Turn input shaft to allow the tapered roller bearings to set themselves. 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 34/35). 22

23 69 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. If no more bearing play can be measured, but the input shaft has a perceptible tilting clearance, the setting is also correct. 70 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). 71 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). Use special tool Fit circlip (18). The exploded drawing shows a single synchronization. For transmissions dated after , this has been replaced with a double synchronization (see Figure 70). 23

24 72 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. Use special tools and 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. Use special tool Press fit sleeve (6) for needle roller bearing for fourth gear onto output shaft. Use special tool 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. Use special tool

25 76 Replace 4 sealing rings (arrows) of bearing housing. 77 Insert differential (1) and magnet (2). 78 Insert input shaft and output shaft together. 79 Tighten nuts of bearing housing (1) of output shaft. Tightening torque for bearing connector nuts: 25 Nm

26 80 Position reverse idler gear on drawn cup needle roller bearing with open end. 81 Insert reverse shaft with ratchet through reverse idler gear in needle roller bearing. 82 Position reverse shaft support on reverse shaft. 83 Screw the M8 x 100 mm stud bolts onto the reverse shaft support. Bolts help to align the reverse shaft support during the subsequent assembly process. 26

27 Assemble shift actuating mechanism for reverse gear. Tightening torque of reverse gear screw: 25 Nm 84 Insert gear shift forks and gear shift rails. Align gear shift rails. Sliding blocks must be sitting in the grooves of the sliding sleeves. 85 Caution: Reverse gear shift fork must be located underneath the large gear shift fork (see detailed photo). 86 Apply sealant to one side of the transmission housing. 87 Assemble transmission housing halves. 27

28 88 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 89 Tighten housing screws (1) in the clutch bell housing. Tightening torque of housing screws: 25 Nm Clean the 4 bearing journals of the gear shift forks. Replace the o-rings of the bearing journals. 91 Install the 4 bearing journals. Tightening torque of the bearing journal screws: 25 Nm If necessary, adjust the shift actuating mechanism using a screwdriver to ensure that the relevant bearing journal can be installed. 28

29 92 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 95 Apply sealant. 29

30 96 Attach cover. Tightening torque for cover screws: 25 Nm 97 Press fit toothed gear for fifth gear. Surrounding groove must be facing the transmission! 98 Press fit synchronizer unit for fifth gear. 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. 30

31 99 Fasten synchronizer unit and toothed gear for fifth gear with respective spring washer and screw (A). Tightening torque of screws: 80 Nm 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. For the neutral position, turn selector shaft clockwise until it pops out independently. 100 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 101 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. 31

32 102 Replace the cover seal. 103 Put cover of transmission housing into position. 104 Tighten cover screws (1). Tightening torque for cover screws: 10 Nm 105 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. 32

33 106 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. 107 Install both driveshaft flanges using springs, thrust washers and conical rings. Tightening torque for the flange screws: 25 Nm 108 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. 33

34 Setting the input shaft tapered roller bearing Table of shims Part number for shim set: Bearing play Shim Measured value (mm) Thickness (mm) Spare part no A A A A B A C A D A E A F A G A H A J A K A L A M A N A P A Q A R A S A T A AA A AB A AC A AD A AE A AF A AG 34

35 Setting the input shaft tapered roller bearing Table of shims Part number for shim set: From bearing play greater than mm, a combination of two shims may be required. Bearing play Shim Measured value (mm) Thickness (mm) Spare part no A A A A A A A 02A A A A 02A B A B 02A B A B 02A C A C 02A C A C 02A D A D 02A D A D 02A E A E 02A E A E 02A F A F 02A F A F 02A G A G 02A G A G 02A H A H 02A H A H 02A J A J 02A J 35

36 Optional sender details (highlighted) Optional sender details (2nd line of text) Optional sender details (3rd line of text) *optional subline with legal text / Schaeffler Automotive Aftermarket GmbH & Co. KG

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