Repair Manual VW 02T gearbox INA GearBOX
Special tools Repair Manual for the VW 02T gearbox Drain the transmission fluid (arrow). Remove the gearbox from the vehicle in accordance with the vehicle manufacturer s requirements. 1 Thrust piece: Used to press the double deep groove ball bearing out of the housing. Part number: 400 0428 10 Thrust piece: Used to press the double deep groove ball bearing, including the transmission shafts, into the housing. The tool includes a height compensation washer for different drive-shaft lengths. Part number: 400 0429 10 Hollow shaft: Used to force-fit the fifth gear needle roller bearing sleeve. Part number: 400 0430 10 Unhook the retaining spring (arrow). Unscrew screws (1 and 2). Remove the clutch release unit and guiding sleeve. 2 Thrust piece: Used to force fit the double deep groove ball bearing onto transmission shafts. Part number: 400 0431 10 Thrust piece: Used to disassemble the bearing connector of the double deep groove ball bearing of transmission shafts. Part number: 400 0432 10 Adjustment plate: Used to disassemble the double deep groove ball bearing of transmission shafts. Part number: 400 0433 10 Loosen the screws on the left and right flanged shafts. Completely disassemble the flanged shafts with pressure spring, thrust washer and conical ring. To release, secure the flanged shafts with two screws and the assembly lever. 3 Guide bolts: Part number: 400 0437 10 2 3
Remove the gearbox cover for the fifth gear (arrow). 4 Lift out the differential (1). 8 Clean the sealing face. Pull out the bearing pin (1) (arrow). Remove the gear shift fork (2). Remove the retaining rings (3) and (4). Remove both toothed gears, including the synchronizer package and fifth gear needle roller bearing, from the shafts. 5 Remove the transmitter for the gearbox neutral position. This only applies to vehicles with a start-stop system. 9 Unscrew the screws (1) from the bearing connector. Unscrew the hexagon collar nut (2). 6 Unscrew the selector shaft screws (arrows) and pull out the selector shaft (1), including the lever. Remove both bearing journals (2). 10 Clean the sealing face. Remove the screws for the clutch cover. Lift off the clutch cover. 7 Unscrew the screw for the reverse gear (1). 11 Remove both bearing journals (2). Attention: Take care not to damage the sealing face during this procedure. Clean the sealing face. 4 5
Press the transmission shafts with the bearing connector out of the housing. Disconnect the gear shift mechanism and the reverse gear from the transmission shafts. 12 Replace the drive shaft ring seal. Clean the sealing face before installing the new ring seal. 16 Use special tool 400 0428 10. Attention: Take care not to let components fall off. Press the transmission shafts, including the fifth gear needle roller bearing, out of the bearing connector. After pressing, set the first gear toothed gear back on the output shaft. 13 Replace the flanged shaft ring seal on the engine side. Clean the sealing face before installing the new ring seal. 17 Use special tools 400 0432 10 and 400 0433 10. Special tool 400 0433 10 can only be used if the selector sleeve is connected to the second gear wheel. Position the extrusion punch at the height of the tool shoulder. Attention: Take care not to let components fall off. Replace the flanged shaft ring seal on the transmission side. Clean the sealing face before installing the new ring seal. 14 Install both main bearings on the engine side. Compress the snap ring (arrow) with pliers when pressing in the new main bearings. Attention: After pressing in, check whether the snap ring has snapped into place in the groove of the clutch cover. 18 Remove both main bearings on the engine side. Compress the snap ring (arrow) with pliers when pulling out the bearing. 15 Check the diameter of the output shaft in accordance with non-verbal fitting instructions (999 6005 990) and press the inner ring onto the output shaft if necessary. 19 6 7
Remove the drive shaft snap ring (arrow). 20 Install the drive shaft snap ring. 24 Position and secure the divider between the gear wheel and the synchronizer ring. 21 Press the new bearing connector with deep groove ball bearing (1) onto the drive shaft and output shaft. 25 Use special tools 400 0431 10 and 400 0429 10. Heat the bearing connector to 100 C. Press out the gear wheel, together with the thrust washer and sleeve, from the drive shaft. 22 Force fit the new sleeve (1) for the fifth gear needle roller bearing. 26 Attention: Do not discard the pressed-out sleeve; it is required in the next step. Take care not to let components fall off. Use special tools 400 0430 10 and 400 0429 10. Install the gear wheel and thrust washer on the shaft. Press the new sleeve (arrow) onto the drive shaft. Use the pressed-out sleeve (1) and special tools 400 0431 10 and 400 0430 10 to force fit the new sleeve. 23 Place the shaft package on special tool 400 0428 10. Install the reverse idler gear (1) and the selector actuation mechanism (2). Screw guide bolt 400 0437 10 into the selector actuator mechanism (arrow). 27 8 9
Insert components into the gearbox housing. Thread the guide bolt into the gearbox housing through the bore for fastening the selector actuation mechanism. 28 Install and tighten both bearing journals (1). Tightening torque for the bearing journals: 5Nm + 90 Apply the sealant evenly to the housing-side sealing face (2) of the selector shaft. 32 Press in the bearing connector with the drive shaft and output shaft. Remove the guide bolt after pressing in. Use special tool 400 0429 10. 29 Install and securely screw (arrows) in the selector shaft with lever (1). Tightening torque for the selector cover screws: 5Nm + 90 33 Attention: Check that the selector forks are correctly engaged in the sliding sleeves before pressing in the bearing connector. Replace the o-rings of the four bearing journals. Clean the bearing journals before installing the o-rings. 30 Screw in and tighten the mounting screws (1) for the bearing connector. Tightening torque for the bearing connector screws: 5Nm + 90 Screw in and tighten the hexagon collar nut (2). Tightening torque for the collar nut: 23Nm 34 Screw in and tighten the reverse gear screw (1). Tightening torques for fastening the reverse gear: M6 = 5Nm + 90 M8 = 25Nm + 45 Install and tighten both bearing journals (2). Tightening torque for the bearing journals: 5Nm + 90 31 Install and securely screw in the transmitter 35 for the gearbox neutral position. Tightening torque for the transmitter screw: 6Nm This only applies to vehicles with a start-stop system. 10 11
Insert the differential (1). 36 Attach the new fifth gear needle roller bearing (1). Install the fifth gear speed gear (2), the synchronizer ring (3) and the sliding sleeve (4) on the shaft. 40 Apply sealant evenly on one side of the gearbox housing. Attach the gearbox housing. 37 Insert the fifth gear selector fork (2). Insert the bearing pin (1) until impact clunk/ stop (arrow). Select and install the thickest usable snap ring (3 and 4). 41 Tighten the gearbox housing screws in stages crosswise. Tightening torque for the gearbox housing screws: 5Nm + 90 38 Replace the cover seal. Attention: Use the correct cover seal. 42 Attach the fifth toothed gear (1) with the high shoulder facing upward. 39 Install the gearbox housing cover and tighten the screws crosswise. Tightening torque for the cover screws: 5Nm + 90 43 12 13
Install and securely screw in the flanged shafts with pressure springs, thrust washers and conical rings. Tightening torque for the flanged shafts: 25Nm 44 Notes To screw in, secure the flanged shafts with two screws and the assembly lever. Securely screw in the guiding sleeve (screws 1 and 2). Tightening torque for the guiding sleeve: 5Nm + 90 Install the clutch release lever with the retaining spring and clutch release bearing. Mount the retaining spring. 45 Install the gearbox in the vehicle in accordance with the vehicle manufacturer s requirements. Fill with transmission fluid in accordance with the vehicle manufacturer s requirements. 46 When filling, refer to the Automotive Aftermarket Transmission Info TA0007 Note for 02T gearbox repair. 14 15
999 6006 690 / 07.2015 2015 Schaeffler Automotive Aftermarket GmbH & Co. KG Further information: www.schaeffler-aftermarket.com www.repxpert.com Hotline 00 (0) 000 000-000* *optional subline with legal text