5-speed manual gearbox 02R — Input shaft - adjust — VW

🧭 Before you start

Fits: platform code POLO

• Special tools named: dial gauge

Don't miss

• This preparation is to be repeated for each subsequent measurement, otherwise the gauge will not return to the starting position.
• D.T.I. does not return to original position

🔩 Torque settings

Values can differ between engine variants — check the code stamped on your block.

ℹ️ Always cross-check the exact figure against your vehicle's factory manual before final tightening — a wrong torque can damage the engine. These values are extracted from workshop data and may not cover every variant or revision.

📋 Procedure

1. Press taper roller bearing outer race, without shim, into gearbox housing onto stop.
2. Install input shaft in clutch housing and assemble gearbox housing. Tighten hexagon bolts with 25Nm + 90°. — 25 Nm (18 lb-ft) + 90°
3. Fit measuring appliance and D.T.I. in clutch housing (large taper roller bearing in gearbox housing).
4. Before taking any measurements, rotate input shaft to allow bearings to settle. Preload dial gauge to 1 mm and set to "“0”". [Note: This preparation is to be repeated for each subsequent measurement, otherwise the gauge will not return to the starting position.]
5. Press input shaft in direction of D.T.I. (arrow).

6. Read off and note clearance indicated on D.T.I. (example 1.21). [Note: D.T.I. does not return to original position]
7. Determine thickness of shim from table (Example 1.175).
8. Remove input shaft and press taper roller bearing outer race out of gearbox housing using VW 447i.
9. Press taper roller bearing outer race together with the 1.175 shim into gearbox housing using VW 510
10. Assemble gearbox housing and tighten hexagon head bolts to 25 Nm and then turn 90° further — 25 Nm (18 lb-ft)

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