5-speed manual gearbox 02J

Chapter overview

• Technical data
  1
• 1 Gearbox identification
  1
• 1.1 Gearbox identification
  1
• 1.2 Identification code, assembly allocation, ratios, capacities
  2
• 2 Transmission layout
  6
• 2.1 Transmission layout
  6
• 3 Calculating overall ratio "i"
  8
• 3.1 Calculating overall ratio "i"
  8
• 4 General repair instructions
  8
• 4.1 General repair instructions
  8
• Clutch
  11
• 1 Servicing clutch control
  11
• 1.1 Servicing clutch control
  11
• 1.2 Assembly overview - Pedal cluster
  12
• 1.3 Removing and installing over-centre spring
  15
• 1.4 Removing and installing clutch pedal
  17
• 1.5 Assembly overview - Hydraulic system
  19
• 1.6 Removing and installing master cylinder
  22
• 1.7 Bleeding clutch system
  27
• 2 Servicing clutch release mechanism
  28
• 2.1 Servicing clutch release mechanism
  28
• 3 Repairing clutch
  30
• 3.1 Repairing clutch
  30
• Controls, Housing
  36
• 1 Servicing selector mechanism up to 05.99
  36
• 1.1 Servicing selector mechanism up to 05.99
  36
• 1.2 Installation position of gear selector mechanism
  36
• 1.3 Assembly overview - removing and installing selector cables
  38
• 1.4 Removing and installing selector mechanism
  43
• 1.5 Servicing gear stick housing
  46
• 1.6 Servicing gear stick
  50
• 1.7 Adjusting gear selector mechanism
  54
• 2 Servicing selector mechanism as of 06.99
  59
• 2.1 Servicing selector mechanism as of 06.99
  59
• 2.2 Installation position of gear selector mechanism
  59
• 2.3 Removing and installing gear stick knob and cover
  62
• 2.4 Servicing gear stick and gear stick housing
  64
• 2.5 Assembly overview - removing and installing selector cables
  68
• 2.6 Removing and installing selector mechanism
  71
• 2.7 Adjusting gear selector mechanism
  75
• 3 Removing and installing gearbox
  78
• 3.1 Removing and installing gearbox
  78
• 3.2 Modifying support rails VW 457/1
  80
• 3.3 Modifying guide 10-222 A/21 from support device 10-222 A
  80
• 4 Checking gearbox oil
  97
• 4.1 Checking gearbox oil
  97
• 5 Dismantling and assembling gearbox
  99
• 5.1 Dismantling and assembling gearbox
  99
• 5.2 Overview
  99
• 5.3 Assembly overview
  101
• 5.4 Removing and installing cover for gearbox housing and 5th gear
  102
• 5.5 Removing and installing gearbox housing and selector mechanism
  105
• 5.6 Removing and installing input shaft, output shaft (pinion shaft), differential and selector forks
  107
• 5.7 Assembly sequence
  110
• 6 Repairing gearbox housing and clutch housing
  128
• 6.1 Repairing gearbox housing and clutch housing
  128
• 7 Dismantling and assembling selector mechanism on gearbox side, up to 05.99
  140
• 7.1 Dismantling and assembling selector mechanism on gearbox side, up to 05.99
  140
• 8 Dismantling and assembling selector mechanism on gearbox side from 06.99
  145
• 8.1 Dismantling and assembling selector mechanism on gearbox side from 06.99
  145
• 9 Dismantling and assembling selector forks
  151
• 9.1 Dismantling and assembling selector forks
  151
• Gears, Shafts
  160
• 1 Dismantling and assembling input shaft
  160
• 1.1 Dismantling and assembling input shaft
  160
• 2 Adjusting input shaft
  174
• 2.1 Adjusting input shaft
  174
• 2.2 Table of adjustment shims
  176
• 2.3 Carrying out check measurement
  178
• 3 Dismantling and assembling output shaft
  179
• 3.1 Dismantling and assembling output shaft
  179
• 3.2 From gearbox manufacturing date 09.00: Revised 1st gear synchromesh
  205
• 4 Adjusting output shaft
  209
• 4.1 Adjusting output shaft
  209
• 5 Dismantling and assembling reverse shaft
  211
• 5.1 Dismantling and assembling reverse shaft
  211
• Final drive, Differential
  216
• 1 Renewing flanged shaft oil seals (gearbox installed)
  216
• 1.1 Renewing flanged shaft oil seals (gearbox installed)
  216
• 1.2 Renewing oil seal for left flanged shaft
  216
• 1.3 Renewing oil seal for right flanged shaft
  218
• 2 Dismantling and assembling differential
  223
• 2.1 Dismantling and assembling differential
  223
• 3 Adjustment overview
  238
• 3.1 Adjustment overview
  238
• 4 Adjusting differential
  239
• 4.1 Adjusting differential
  239