5-speed manual gearbox 02T — Dismantling and assembling differential — VW

🧭 Before you start

Fits: platform code POLO

• Special tools named: puller

Don't miss

• Install shim S1, always 1 mm thick, under outer race.
• Both taper roller bearing inner races are pulled off the differential housing in the same way.

📋 Procedure

1. Install shim S1, always 1 mm thick, under outer race.
2. Support clutch housing directly under bearing mounting using tube3259 .
3. Before fitting puller, install installing sleeveVW 455 and press piece 3002 on differential housing. [Note: Both taper roller bearing inner races are pulled off the differential housing in the same way.]
4. Support opposite side of inner race using installing sleeveVW 455.
5. Support clutch housing directly under wheel bearing tube3345.

6. Drive out rest of spring pin from differential housing.
7. Lubricate one piece thrust washer with gearbox oil and install.
8. Install both sun wheels and secure (e.g. with flanged shaft).
9. Install planet wheels 180° apart and pivot into position.
10. Push planet wheel axis shaft (arrow A) in until first planet wheel.
11. Position of flange nuts (arrows B) on sunwheels. Installation position: direction notch towards sunwheel.
12. Install planet wheel axis shaft into final position and secure with spring pin.

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