02T Gearbox — Dismantling and assembling output shaft — VW

🧭 Before you start

Fits: platform codes 6S3, 6S4

• Special tools named: feeler gauge

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• Remove pliers before cylindrical roller bearing is in installation position. Retaining ring must engage in groove of clutch housing.
• Ensure retaining ring does not spring out uncontrolled. — After removing retaining ring, press off synchromeshed gear for 2nd gear together with locking collar and synchro-hub.
• Insert locking pieces in deeper cut-outs (arrows) and install springs offset 120°. Angled end of spring must locate in hollow locking piece.

📋 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. ⚠ Ensure retaining ring does not spring out uncontrolled. — After removing retaining ring, press off synchromeshed gear for 2nd gear together with locking collar and synchro-hub.

6. Install gear wheel for 4th gear (A) on output shaft.
7. Install retaining rings (2) and (3).
8. Install gear wheel for 3rd gear (B) on output shaft.
9. Install retaining ring (1).
10. Press inner ring onto cone of synchromeshed gear and measure gap (a) using a feeler gauge.
11. Press synchro-ring, outer ring and inner ring onto cone of synchromeshed gear and measure gap (a) using a feeler gauge.
12. Place inner ring (A) on synchromeshed gear for 2nd gear.
13. Fit outer ring (B).
14. Fit synchro-ring (C).
15. Slide locking collar over synchro-hub.
16. Insert locking pieces in deeper cut-outs (arrows) and install springs offset 120°. Angled end of spring must locate in hollow locking piece.
17. Turn synchro-ring so that grooves align with locking pieces.
18. Place 1st gear synchro-ring in locking collar/synchro-hub.

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