Repair Manual

VW 02T gearbox
INA GearBOX
Special tools
Thrust piece:
• Used to press the double deep
groove ball bearing out of the
housing.
• Part number: 400 0428 10
Thrust piece:
• Used to force fit the double
deep groove ball bearing onto
transmission shafts.
• Part number: 400 0431 10
Guide bolts:
• Part number: 400 0437 10
2 3
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
Thrust piece:
• Used to disassemble the
bearing connector of the double
deep groove ball bearing of
transmission shafts.
• Part number: 400 0432 10
Hollow shaft:
• Used to force-fit the fifth gear
needle roller bearing sleeve.
• Part number: 400 0430 10
Adjustment plate:
• Used to disassemble the double
deep groove ball bearing of
transmission shafts.
• Part number: 400 0433 10
Repair Manual for the VW 02T gearbox
• Drain the transmission fluid (arrow). 1
• Remove the gearbox from the vehicle in
accordance with the vehicle manufacturer’s
requirements.
• Unhook the retaining spring (arrow). 2
• Unscrew screws (1 and 2).
• Remove the clutch release unit and guiding
sleeve.
• Loosen the screws on the left and right 3
flanged shafts.
• Completely disassemble the flanged shafts with
pressure spring, thrust washer and conical ring.
Note: To release, secure the flanged shafts with
two screws and the assembly lever.
• Remove the gearbox cover for the fifth 4 • Lift out the differential (1). 8
gear (arrow).

Note: Clean the sealing face.

• Pull out the bearing pin (1) (arrow). 5 • Remove the transmitter for the gearbox neutral 9
• Remove the gear shift fork (2). position.
• Remove the retaining rings (3) and (4).
• Remove both toothed gears, including the Note: This only applies to vehicles with a
synchronizer package and fifth gear needle start-stop system.
roller bearing, from the shafts.

• Unscrew the screws (1) from the bearing 6 • Unscrew the selector shaft screws (arrows) 10
connector. and pull out the selector shaft (1), including the
• Unscrew the hexagon collar nut (2). lever.
• Remove both bearing journals (2).

Note: Clean the sealing face.

• Remove the screws for the clutch cover. 7 • Unscrew the screw for the reverse gear (1). 11
• Lift off the clutch cover. • Remove both bearing journals (2).

Attention: Take care not to damage the sealing

face during this procedure.

Note: Clean the sealing face.

4 5
• Press the transmission shafts with the bearing 12 • Replace the drive shaft ring seal. 16
connector out of the housing.
• Disconnect the gear shift mechanism and the Note: Clean the sealing face before installing
reverse gear from the transmission shafts. the new ring seal.

Note: Use special tool 400 0428 10.

Attention: Take care not to let components fall off.

• Press the transmission shafts, including the 13 • Replace the flanged shaft ring seal on the 17
fifth gear needle roller bearing, out of the engine side.
bearing connector.
• After pressing, set the first gear toothed gear Note: Clean the sealing face before installing
back on the output shaft. the new ring seal.

Note: 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.
Note: Clean the sealing face before installing
the new ring seal.
14 • Install both main bearings on the engine side. 18
• 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.

• Remove both main bearings on the engine side. 15 • Check the diameter of the output shaft in 19
• Compress the snap ring (arrow) with pliers accordance with non-verbal fitting instructions
when pulling out the bearing. (999 6005 990) and press the inner ring onto
the output shaft if necessary.

6 7
• Remove the drive shaft snap ring (arrow). 20
• Position and secure the divider between the 21
gear wheel and the synchronizer ring.
• Press out the gear wheel, together with the 22
thrust washer and sleeve, from the drive shaft.
Attention: Do not discard the pressed-out sleeve;
it is required in the next step.
Take care not to let components fall off.
• Install the gear wheel and thrust washer on 23
the shaft.
• Press the new sleeve (arrow) onto the drive shaft.
Note: Use the pressed-out sleeve (1) and
special tools 400 0431 10 and
400 0430 10 to force fit the new sleeve.
8 9
• Install the drive shaft snap ring. 24
• Press the new bearing connector with deep 25
groove ball bearing (1) onto the drive shaft and
output shaft.
Note: Use special tools 400 0431 10 and
400 0429 10.
Heat the bearing connector to 100°C.
• Force fit the new sleeve (1) for the fifth gear 26
needle roller bearing.
Note: Use special tools 400 0430 10
and 400 0429 10.
• Place the shaft package on special 27
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).
• Insert components into the gearbox housing.
• Thread the guide bolt into the gearbox housing
through the bore for fastening the selector
actuation mechanism.
• Press in the bearing connector with the drive
shaft and output shaft.
• Remove the guide bolt after pressing in.
Note: Use special tool 400 0429 10.
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.
• 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°
10
28 • Install and tighten both bearing journals (1). 32
Tightening torque for the bearing journals:
5Nm + 90°
• Apply the sealant evenly to the housing-side
sealing face (2) of the selector shaft.
29 • Install and securely screw (arrows) in the 33
selector shaft with lever (1).
Tightening torque for the selector cover
screws: 5Nm + 90°
30 • Screw in and tighten the mounting screws (1) 34
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
31 • Install and securely screw in the transmitter 35
for the gearbox neutral position.
Tightening torque for the transmitter screw: 6Nm
Note: This only applies to vehicles with a
start-stop system.
11
• Insert the differential (1). 36 • Attach the new fifth gear needle roller bearing (1). 40
• Install the fifth gear speed gear (2), the
synchronizer ring (3) and the sliding sleeve (4)
on the shaft.

• Apply sealant evenly on one side of the 37 • Insert the fifth gear selector fork (2). 41
gearbox housing. • Insert the bearing pin (1) until impact clunk/
• Attach the gearbox housing. stop (arrow).
• Select and install the thickest usable snap ring
(3 and 4).

• Tighten the gearbox housing screws in stages 38 • Replace the cover seal. 42
crosswise.
Tightening torque for the gearbox housing Attention: Use the correct cover seal.
screws: 5Nm + 90°

• Attach the fifth toothed gear (1) with the high 39 • Install the gearbox housing cover and tighten 43
shoulder facing upward. the screws crosswise.
Tightening torque for the cover screws: 5Nm + 90°

12 13
• Install and securely screw in the flanged shafts 44 Notes
with pressure springs, thrust washers and
conical rings.
Tightening torque for the flanged shafts: 25Nm

Note: To screw in, secure the flanged shafts

with two screws and the assembly lever.

• Securely screw in the guiding sleeve (screws 1 45

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.

Note: Install the gearbox in the vehicle in

accordance with the vehicle
manufacturer’s requirements.

• Fill with transmission fluid in accordance with 46

the vehicle manufacturer’s requirements.

Note: When filling, refer to the Automotive

Aftermarket Transmission Info TA0007 —
“Note for 02T gearbox repair”.

14 15
 © 2015 Schaeffler Automotive Aftermarket GmbH & Co. KG
999 6006 690 / 07.2015

Further information:
www.schaeffler-aftermarket.com
www.repxpert.com
Hotline 00 (0) 000 000-000*
*optional subline with legal text