5-speed-manual-gearbox-(02T and 0AP) — Planet pinion - disassemble and assemble — VW

🧭 Before you start

Fits: VW Polo 9N (2001–2009)

• Special tools named: feeler gauge

📋 Procedure

1. When removing it, compress the bearing circlip (arrow) with pliers (C).
2. Support the clutch housing by placing the Pressure pipeVW 415A (not shown in fig.) directly under the bearing support.
3. When installing, compress the bearing circlip (arrow) with pliers (A).
4. Remove the pliers just before the bearing is in the correct installation position. The circlip shall be locked in the clutch housing hole.
5. ⚠ Prevents uncontrolled motions of circlip. — After removing the circlip, disengage with the moving wheel of the 2nd gear and the engaging sleeve with synchronizer.

6. Install 4th gear wheel (A) on planet pinion.
7. Install circlips (2) and (3).
8. Install 3rd gear wheel (B) on planet pinion.
9. Install circlip (1).
10. Press the inner ring against the gear cone and measure the distance (a) with a feeler gauge.
11. Press the synchroniser ring, internal and external tracks against the gear cone and measure the distance (a) with a feeler gauge.
12. Install inner ring (A) on the 2nd gear wheel. The curve shoulders (arrow 1) shall face the outer ring (B).
13. Install the outer ring (B) over. The flanges (arrow 2) shall fit in the grooves (arrow 3) of the gear.
14. Install the synchronizer ring (C) over. The grooves (arrow 4) shall fit in the relieves (arrow 1) on inner ring (A).
15. Press the engaging sleeve on the synchronizer.
16. Install the limiters in the deeper grooves (arrows).
17. Install the limiters in the deeper grooves (arrows).
18. Install springs (B) and (C) displaced by (a). [Note: (a) = 120°]
19. The folded end of the spring shall fit into the limiter's hole.
20. Turn the synchronizer ring in order to match flanges and limiters.
21. Install the 1st gear circlip on the engaging sleeve/synchronizer.

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