5-speed manual gearbox 02R — Output shaft - dismantle and assemble — VW

🧭 Before you start

Fits: platform code POLO

• Special tools named: puller, feeler gauge

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• Support separating appliance so that the 1st. and 2nd. gear locking collar is not pulled off at the same time.
• If the components are not renewed, ensure they are reallocated to the original gear
• The shoulder has a chamfer on one side (arrow B)
• Insert locking pieces and install springs 120° offset. The angled end of the spring must locate in the hollow locking piece.
• Insert locking pieces and install springs 120° offset. The angled end of the circlip must rest at the front of the locking pieces (arrows).

📋 Procedure

1. Fit gripping device and tension behind bearing rollers, then turn bearing and retension gripping device. [Note: Support separating appliance so that the 1st. and 2nd. gear locking collar is not pulled off at the same time.]
2. First remove circlip (arrow).
3. Before fitting puller insert a M10 x 20 hexagon bolt in the output shaft drilling.
4. Fit thrust washer before pressing on the inner race. The shoulder points to the inner race.
5. Place inner ring (A) on 1st. gear wheel.

6. Install outer ring (B)
7. Install synchro-ring(C) [Note: If the components are not renewed, ensure they are reallocated to the original gear]
8. Press inner ring onto cone of selector gear and measure gap "“a”" using a feeler gauge.
9. Press inner ring onto cone of selector gear and measure gap "“a”" using a feeler gauge. [Note: The shoulder has a chamfer on one side (arrow B)]
10. Insert locking pieces and install springs 120° offset. The angled end of the spring must locate in the hollow locking piece.
11. Insert locking pieces and install springs 120° offset. The angled end of the circlip must rest at the front of the locking pieces (arrows).
12. Press inner ring onto cone of selector gear and measure gap "“a”" using a feeler gauge.
13. Slide locking collar over synchro-hub.
14. Insert locking pieces and install springs 120° offset. The angled end of the spring must locate in the hollow locking piece.
15. Insert locking pieces and install springs 120° offset. The angled end of the circlip must rest at the front of the locking pieces (arrows).

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