02T Gearbox — Dismantling and assembling input shaft — VW

🧭 Before you start

Support the clutch housing, squeeze the bearing retaining ring and press the roller bearing out or in until the ring engages. Fit T10084/A and T10081, remove the retaining ring and press off 3rd gear with its hub. Assemble synchro-hubs with locking pieces and springs offset 120°, check synchro-ring gap, measure with a 2.0 mm test ring, select the final ring, heat the inner bearing race to about 100 °C and press on. Fit the 5th gear stop ring with tube 2010.

Fits: platform codes 6S3, 6S4

• Special tools named: T10084, feeler gauge

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• Remove the pliers before the bearing reaches its seat; the retaining ring must engage the housing groove.
• Fit locking pieces in the deeper notches and offset springs 120°, angled end in the hollow piece.
• Measure synchro-ring gap (a) with a feeler gauge before assembly.
• Select the final retaining ring after measuring with a 2.0 mm test ring.
• Heat the inner bearing race to about 100 °C before pressing it on.

Written for this job from the workshop steps below · TorqFix editorial.

📋 Procedure

1. When pulling out, squeeze together retaining ring (arrow) of cylindrical roller bearing, using pliers (C).
2. Support clutch housing with tubeVW 415 A directly below bearing support. (Tube is not shown in figure.)
3. When pressing in, squeeze together retaining ring (arrow) for cylindrical roller bearing using pliers (A).
4. Remove pliers before cylindrical roller bearing is in installation position. Retaining ring must engage in groove of clutch housing.
5. Slide locking collar for 1st and 2nd gear towards 2nd gear.

6. Then slide pressure plate T10084/A onto input shaft to stop from side.
7. Insert centring pins in thrust piece T10081 into holes in input and output shafts.
8. First remove retaining ring.
9. Position splitter (B) behind teeth of synchromeshed gear for 4th gear which engage in the other gear wheel (not dog teeth) and tension.
10. After removing retaining ring, press off 3rd gear synchromeshed gear together with locking collar and synchro-hub.
11. Slide locking collar over synchro-hub.
12. Insert locking pieces in deeper notches (arrows) and install springs offset 120°. Angled end of spring must locate in hollow locking piece.
13. Press synchro-ring onto cone of synchromeshed gear and measure gap (a) using feeler gauge.
14. Insert a 2.0 mm thick retaining ring (A) in groove of input shaft and press upwards (arrow).
15. Measure distance between inner race (B) and installed retaining ring (A) using feeler gauge (C).
16. Remove retaining ring used for measuring purposes.
17. Determine retaining ring from table. [Note: Allocate retaining rings using Electronic parts catalogue.]
18. Heat inner bearing mounting to approx. 100 °C before pressing on.
19. Unclip hooks (A) of stop ring from synchro-hub using a screwdriver.
20. Slide locking collar over synchro-hub.
21. Insert locking pieces in deeper notches (arrows) and install springs offset 120°. Angled end of spring must locate in hollow locking piece.
22. Press on stop ring using tube2010.
23. Insert stop ring together with tube2010 into 5th gear synchro-hub/locking collar (observe installation position ).
24. Press stop ring downwards until hooks engage.

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