MANUAL TRANS OVERHAUL - TYPE 02A

Article Text
1996 Volkswagen Passat
This file passed thru Volkswagen Technical Site - http://volkswagen.msk.ru

ARTICLE BEGINNING

MANUAL TRANSMISSIONS
Volkswagen Manual Trans. Overhaul - Type 02A
Golf, GTI VR6, Jetta, Jetta III, Passat
APPLICATION & LABOR TIMES

APPLICATION & LABOR TIMES

Vehicle
Application
1995
GTI VR6 .............
Jetta III (3) .......
Passat (3) ..........
1996
GTI VR6 .............
Jetta (3) ...........
Passat (3) ..........

Labor Times
(1) R & I (2) Overhaul

Series

3.8 ......... 4.9

3.8 ......... 4.9
5.9 ......... 4.9

..........
..........
..........

02A
02A
02A

3.8 ......... 4.9

3.8 ......... 4.9
5.9 ......... 4.9

..........
..........
..........

02A
02A
02A

(1) - Removal and installation of transmission from vehicle

chassis.
(2) - Bench overhaul time for transaxle/differential. DOES NOT
include removal and installation.
(3) - Equipped with 2.8L V6 engine.

IDENTIFICATION

Volkswagen Audi Group (VAG) transaxle is identified by a type

number cast into transaxle case. Code letter and production date
information is stamped on a machined surface located on upper portion
of transaxle clutch housing surface.
DESCRIPTION

Type 02A is a 5-speed transaxle consisting of an input shaft,

mainshaft/drive pinion shaft and a differential assembly which
transfers power to front wheels.
LUBRICATION

Use hypoid oil API GL4, MIL-L2105 SAE 80 or G50 SAE 75W90
synthetic lubricant.
TROUBLE SHOOTING

See TROUBLE SHOOTING - BASIC PROCEDURES article in this

section.
ON-VEHICLE SERVICE
SHIFT LINKAGE ADJUSTMENT

1) Place gear selector lever in "N" position. Remove knob and

boot. Remove balance weight. Loosen bolt "A" and nut "B" sufficiently
so that operating cables move freely in centering holes. See Fig. 1.
Install Shift Linkage Gauge (3192). Loosen bolt "C". See Fig. 2.
2) Pivot locating pin under bearing plate. Tighten nut "D".
Place gearshift lever into left detent of slide. Move gearshift lever
and slide together to left stop. Tighten slide with bolt "D". Move
gearshift lever to right detent. Tighten bolt "E". Move gearshift
lever to right detent. Tighten bolt "C".

Fig. 1: Identifying Centering Holes

Courtesy of Volkswagen of America, Inc.

Fig. 2: Installing Shift Linkage Gauge

Courtesy of Volkswagen of America, Inc.

DRIVE AXLE SHAFTS

See appropriate AXLE SHAFTS article in AXLE SHAFTS & TRANSFER

CASES section.
REMOVAL & INSTALLATION

See appropriate MANUAL TRANSMISSION REMOVAL article in

TRANSMISSION SERVICING section.
TRANSAXLE DISASSEMBLY & REASSEMBLY

Disassembly
1) Mount transaxle in mounting fixture and drain oil from
transaxle. Loosen and remove gearbox housing cover bolts and remove
cover. Loosen and remove 5th gear selector fork. See Fig. 3.
2) To facilitate removal of gears, engage transaxle 2nd gear.
Remove 5th gear synchronizer assembly retaining bolt and diaphragm
spring. Using a puller, remove synchronizer assembly, synchronizer
ring and 5th gear. Remove 5th gear needle bearing from shaft. Remove
fixed 5th gear retaining bolt and diaphragm spring. Using a puller,
pull off fixed 5th gear. Return transaxle to Neutral.
3) From gearbox side of transaxle, remove drive flange using
two bolts as a puller tool. Make certain to line up bolts with oil
drain plug so they will bear on reinforced portion of gearbox. Failure
to do so could result in a damaged gearbox. Remove shift fork locating
pins.
4) Remove bearing sleeve cover. Remove oil drain plug if
necessary. Remove gearshift selector mechanism. Loosen and remove
gearbox to clutch housing mounting bolts from both sides of cover.
Carefully remove gearbox housing.
5) Remove guide sleeve, locating dowels, oil drain plug and
magnet from case. See Fig. 4. Remove shift fork assembly. Loosen and
remove 4 output shaft retaining nuts on clutch side of clutch housing.
Discard seals. Remove bolts for reverse shaft support.
6) Remove reverse gear, input shaft and output shaft
assembly, in that order. See Fig. 5. Remove speedometer drive gear.
Remove left hand drive flange. Remove differential assembly.
Reassembly
1) Install bearing housing to clutch cover housing. Place
differential assembly into clutch housing. Install speedometer drive
gear.
2) Install input shaft, output shaft and reverse shaft into
clutch cover housing as an assembly. Install reverse shaft mounting
bolts finger tight. Install new oil seals and nuts on output shaft
retaining bracket studs. Install guide sleeve, locating dowels, oil
drain plug and magnet. Tighten reverse shaft bolts.
NOTE:

Once output shaft retaining bracket stud nuts are tightened

to specification, they must be turned an additional 90

degrees.
3) Install gearbox housing onto clutch cover. Align shift
forks with shift fork locating pins by using a screwdriver or similar
tool to move forks. Insert 4 pins and tighten mounting bolts. Install
bearing sleeve cover, shift shaft selector assembly and drive flange.
4) Install fixed 5th gear, diaphragm spring and mounting bolt
onto output shaft. Install needle bearing, free 5th gear, 5th gear
synchronizer ring, 5th gear synchronizer assembly, diaphragm spring
and mounting bolt onto input shaft. Install 5th gear selector fork,
locating dowels and bolts. Install gearbox housing cover and gasket.

Fig. 3: Exploded View Of Gearbox Housing Cover & 5th Gears

Courtesy of Volkswagen United States, Inc.

Fig. 4: Exploded View Of Gearbox Housing

Courtesy of Volkswagen United States, Inc.

Fig. 5: Exploded View Of Geartrain & Differential

Courtesy of Volkswagen United States, Inc.

COMPONENT DISASSEMBLY & REASSEMBLY

CLUTCH HOUSING

Disassembly
1) Remove oil drain plug, locating dowels, differential
bearing outer race and shim, magnet, output shaft outer bearing race
and adjusting shim. Using puller, extract input shaft needle bearing.
2) Unbolt relay lever brackets, relay lever and springs.
Extract bushing for starter shaft. Remove threaded plug, input shaft
oil seal, drive flange sleeve and oil seal.
Inspection
Inspect clutch housing for cracks, worn or galled bearing
race bores, stripped threads or damaged case machined surfaces.
Reassembly
1) Install drive flange sleeve and oil seal. Install threaded
plug and bushing for starter. Install relay lever, brackets and
springs.
2) Install input shaft needle bearing using bearing driver.
Install shim and bearing outer race for differential assembly. Install
selected adjusting shim and outer bearing race for output shaft.
Install locating dowels and oil drain plug. Install magnet on case
(secured in place by surface of mating housing).
GEARBOX HOUSING

Disassembly
Using a press, remove output shaft needle bearing. Remove
differential outer bearing race, adjustment shim and drive flange oil
seal. Remove input shaft outer bearing race and shim.
Inspection
Inspect clutch housing for cracks, worn or galled bearing
race bores, stripped threads or damaged case machined surfaces.
Reassembly
Using a press, install output shaft needle bearing. Install
outer bearing races and selected adjusting shims for differential and
input shaft. Install output flange oil seal(s).
GEARBOX HOUSING COVER

Disassembly
Remove gearbox housing cover. Remove clutch lever clip,
clutch lever and lever return spring. Remove release bearing, oil seal
and release shaft clip. Remove oil filler plug, needle bearing and
bearing retainer bolt.
Inspection
Inspect clutch housing for cracks, worn or galled bearing

race bores, stripped threads or damaged case machine surfaces.

Reassembly
Install oil filler plug, needle bearing and bearing retainer
bolt. Install release bearing, release shaft oil seal, release shaft
and shaft clip. Install clutch lever, clutch lever return spring, and
lever retaining clip.
INPUT ASSEMBLY

Disassembly
Remove thrust washer from 5th gear end of input shaft. Using
a press, remove inner bearing from clutch end of shaft and inner
bearing race and fixed 4th gear. Remove circlip and remove free 3rd
gear. See Fig. 6.
Inspection
Inspect all bearing surfaces for wear. Inspect gears for
damage to teeth, bearing surfaces and synchronizer tabs. Check
synchronizer rings for wear by installing ring on respective gear and
measuring thickness between ring teeth and gear teeth. All
synchronizer rings except 2nd gear should have a clearance of .043-.
066" (1.1-1.7 mm), and a wear limit minimum thickness of .020" (.5
mm). Second gear synchronizer should have a clearance of .030-.049" (.
75-1.25 mm), and a minimum wear thickness of .010" (.3 mm).
Reassembly
Install free 3rd gear and circlip onto input shaft. Using a
press, install fixed 4th gear, and tapered bearing onto input shaft.
Invert shaft in press and install tapered bearing on clutch end of
shaft. Place thrust washer on end of shaft and hold in place with
grease.

Fig. 6: Exploded View Of Input Shaft

Courtesy of Volkswagen United States, Inc.
OUTPUT SHAFT ASSEMBLY

Disassembly
1) Using a separator plate, position under 2nd gear and press
off components No. 19 (2nd gear) through No. 30 (4th gear) from output
shaft. See Fig. 7.
2) Remove circlip. Using a 2-jaw puller, position under
bearing carrier and pull off synchronizer sleeve along with 1st/2nd
gear synchro-hub assembly. See Fig. 7. Using appropriate puller,
remove tapered roller bearing from output shaft.
Inspection
Inspect output shaft and gears for scoring and wear marks.
Check gear and synchronizer teeth for wear and chipping. Check
synchronizer rings for clearance.
Reassembly
1) Install tapered bearings on output shaft. Using a press
and bearing saddle, install thrust washer, 1st gear, 1st gear
synchronizer ring, needle bearing, 1st/2nd gear synchronizer hub

assembly, 2nd gear, 2nd gear synchronizer ring, needle bearing and
bearing race.
2) Install thrust washer, 3rd gear, 3rd gear synchronizer
ring, needle bearing and needle bearing inner race, 3rd/4th
synchronizer hub assembly, 4th gear, 4th gear synchronizer ring,
needle bearing and race. Place thrust washer on shaft assembly and
hold in place with grease.

Fig. 7: Exploded View Of Output Shaft

Courtesy of Volkswagen United States, Inc.
REVERSE GEAR SHAFT ASSEMBLY

Disassembly
Following removal of both mounting bolts, remove reverse gear
shaft support and needle bearing. Remove helical cut reverse gear,
circlip and straight cut reverse gear. See Fig. 8.
Inspection
Inspect reverse gear shaft for galling or wear. Inspect
reverse gears for wear, chipping or other damage.

Reassembly
Install straight cut reverse gear onto reverse gear shaft.
Install circlip and helical cut reverse gear. Install needle bearing
and gear shaft support.

Fig. 8: Exploded View Of Reverse Gear Assembly

Courtesy of Volkswagen United States, Inc.
DIFFERENTIAL ASSEMBLY

Disassembly
1) Press tapered roller bearings off both ends of
differential housing. Remove ring gear from differential housing if
ring gear or housing needs replacement. See Fig. 9.
2) Remove spring pin. Remove pinion shaft, pinion gears and
one piece thrust washer.
Inspection
Inspect gears and pinion shaft for wear, chipping or galling.
Inspect thrust washer for wear. Replace components as needed.
Reassembly

1) If differential ring gear is being replaced, heat gear to

approximately 212F (100C) and press onto differential housing using
several bolts as guide pins during installation. Torque nuts to 44 ft.
lbs. (60 N.m) and turn an additional 90 degrees.
2) Install one piece thrust washer, pinion gears and pinion
shaft into differential case and secure with spring pin. Press tapered
bearings onto each end of differential carrier.
NOTE:

If installing a new ring gear or pinion, be sure both

components are a matched set. Use NEW ring gear retaining
Bolt Kit (02A 498 088A).

Fig. 9: Exploded View Of Differential Assembly

Courtesy of Volkswagen United States, Inc.
ADJUSTING INPUT SHAFT PRELOAD

NOTE:

The input shaft must be readjusted if the gearbox housing,

clutch housing, input shaft, 4th speed gear or tapered
roller bearings are replaced.

1) Press tapered roller bearing race into gearbox housing

without shim. Install outer bearing race for opposite end of input

shaft in gearbox housing. Place input shaft into clutch housing and
install gearbox. Torque gearbox to clutch housing bolts to 18 ft. lbs.
(25 N.m) and turn each bolt an additional 90 degrees.
2) Install a dial indicator to measure end play of the input
shaft. See Fig. 10. Select a shim from the table based on dial
indicator measurement. See INPUT SHAFT SHIM SELECTION CHART.

Fig. 10: Measuring Input Shaft End Play

Courtesy of Volkswagen United States, Inc.
INPUT SHAFT SHIM SELECTION CHART

Measured End Play - In. (mm)

Specified Shim Size

.026-.027(.671-.699) ..........................
.027-.028 (.700-.724) .........................
.028-.029 (.725-.749) .........................
.029-.030 (.750-.774) .........................
.030-.031 (.775-.799) .........................
.031-.032 (.800-.824) .........................
.032-.033 (.825-.849) .........................
.033-.034 (.850-.874) .........................
.034-.035 (.875-.899) .........................
.035-.036 (.900-.924) .........................
.036-.037 (.925-.949) .........................
.037-.038 (.950-.974) .........................
.038-.039 (.975-.999) .........................
.039-.040 (1.0-1.024) .........................
.040-.041 (1.025-1.049) ......................
.041-.042 (1.050-1.074) ......................
.042-.043 (1.075-1.099) ......................
.043-.044 (1.100-1.124) ......................
.044-.045 (1.125-1.149) ......................
.045-.046 (1.150-1.174) ......................
.046-.047 (1.175-1.199) ......................
.047-.048 (1.200-1.224) ......................
.048-.049 (1.225-1.249) ......................
.049-.050 (1.250-1.299) ......................
.050-.051 (1.275-1.299) ......................
.051-.052 (1.300-1.324) ......................

025 (.650)
026 (.675)
027 (.700)
028 (.725)
029 (.750)
030 (.775)
031 (.800)
032 (.825)
033 (.850)
034 (.875)
035 (.900)
036 (.925)
037 (.950)
038 (.975)
039 (1.000)
040 (1.025)
041 (1.050)
042 (1.075)
043 (1.100)
044 (1.125)
045 (1.150)
046 (1.175)
047 (1.200)
048 (1.225)
049 (1.250)
050 (1.275)

.052-.053
.053-.054
.054-.055
.055-.056
.056-.057
.057-.058
.058-.059
.059-.060
.060-.061
.061-.062
.062-.063
.063-.064
.064-.065
.065-.066
.066-.067
.067-.068
.068-.069
.069-.070
.070-.071

(1.325-1.349)
(1.350-1.374)
(1.375-1.399)
(1.400-1.424)
(1.425-1.449)
(1.450-1.474)
(1.475-1.499)
(1.500-1.524)
(1.525-1.549)
(1.550-1.574)
(1.575-1.599)
(1.600-1.624)
(1.625-1.649)
(1.650-1.674)
(1.675-1.699)
(1.700-1.724)
(1.725-1.749)
(1.750-1.774)
(1.775-1.791)

......................
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051
052
053
054
055
056
057
058
059
060
061
062
063
064
065
066
067
068
069

(1.300)
(1.325)
(1.350)
(1.375)
(1.400)
(1.425)
(1.450)
(1.475)
(1.500)
(1.525)
(1.550)
(1.575)
(1.600)
(1.625)
(1.650)
(1.675)
(1.700)
(1.725)
(1.750)

ADJUSTING OUTPUT SHAFT PRELOAD

NOTE:

Resetting is not necessary unless replacing output shaft

bearings, differential assembly or clutch housing.

1) Install output shaft roller bearing outer races into their

respective clutch and gearbox housings. Insert a .025" (.65 mm) shim
behind clutch housing race. Insert output shaft into clutch housing
and install gearbox housing. Torque plate to 18 ft. lbs. (25 N.m),
then turn each bolt an additional 90 degrees. Set up a dial indicator
and measure up and down movement of output shaft. See Fig. 11.
2) The specified shim size is obtained by adding a constant
of .008" (.20 mm) to recorded dial indicator reading and .025" (.65
mm) shim value. The sum of these three figures will determine shim
size to be installed. Shims are available in sizes from .025" (.65 mm)
to .055" (1.40 mm) in increments of .002" (.05 mm). Output shaft
preload should be 12-18 INCH lbs. (130-180 N.m).

Fig. 11: Measuring Output Shaft End Play

Courtesy of Volkswagen United States, Inc.

ADJUSTING DIFFERENTIAL PRELOAD

NOTE:

Resetting is not necessary unless replacing gearbox housing,

clutch housing, differential housing or differential
bearings.

1) Install differential outer bearing race into their

respective clutch and gearbox housing. Install differential into
clutch housing case and install gearbox housing. Torque gearbox-toclutch housing bolts to 18 ft. lbs. (25 N.m) and turn each bolt an
additional 90 degrees.
2) Set up dial indicator to measure differential end play.
See Fig. 12. The specified bearing shim is obtained by adding a
constant value for preload of .015" (.40 mm) to dial indicator
measurement. This sum is equal to the needed shim size. Shims are
available is various sizes from .025" (.65 mm) to .049" (1.25 mm) in
increments of .002" (.05 mm).
3) Differential bearing preload should be 10-28 INCH lbs.
(120-320 N.m) for new bearings and at least 3 INCH lbs. (30 N.m) for
used bearings.

Fig. 12: Measuring Differential Assembly Clearance

Courtesy of Volkswagen United States, Inc.
TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

Application

Ft. Lbs. (N.m)

Bearing Retainer Bolts ....................... (1)

Fifth Gear Retaining Bolts .......................
Gearbox-To-Clutch Housing Bolts .............. (1)
Oil Fill & Drain Plugs ...........................
Reverse Shaft Support Bolts ......................
Ring Gear Nut ................................ (1)
Shift Fork Locating Pin Bolts ....................
Shift Selector Mounting Bolts ....................
Shift Selector Stop Bolt .........................
Shift Shaft Lock Bolt ............................
Speedometer Drive ................................

18
59
18
18
22
44
18
18
30
18
22

(25)
(80)
(25)
(25)
(30)
(60)
(25)
(25)
(40)
(25)
(30)

INCH lbs. (N.m)

Housing Cover Bolts ...............................
Needle Bearing Retainer Bolt ......................

7 (10)
5 (44)

(1) - Turn fastener an additional 90 degrees.

END OF ARTICLE