Available circlips

WARNING: This page does not describe the selected car, but rather 21 other vehicles, including the 2002 Volkswagen Cabrio, 2001 Volkswagen Cabrio, 2000 Volkswagen Cabrio, 1999 Volkswagen Jetta, and 1999 Volkswagen Golf. However, it is still accessible from the selected car via links, so may be relevant.

Vehicles with 1.8 liter and 1.9 liter engines:

CIRCLIP SPECIFICATIONS FOR VEHICLES WITH 1.8L AND 1.9L ENGINES (INPUT SHAFT, OUTPUT SHAFT)

Part no.	Size - mm (in.)	Identification
020 311 381	2.5 (0.098)	Brown
020 311 381 A	2.6 (0.102)	Black
020 311 381 B	2.7 (0.106)	Plain metal
020 311 381 C	2.8 (0.110)	Copper
020 311 381 D	2.9 (0.114)	Brass
020 311 381 E	3.0 (0.118)	Blue

Vehicles with 2.0 liter, 115 hp engine (larger diameter):

CIRCLIP SPECIFICATION FOR VEHICLES WITH 2.0L, 115 HP ENGINE - LARGER DIAMETER (INPUT SHAFT, OUTPUT SHAFT)

Part no.	Size - mm (in.)	Identification
020 311 381 F	2.5 (0.098)	Brown
020 311 381 G	2.6 (0.102)	Black
020 311 381 H	2.7 (0.106)	Plain metal
020 311 381 J	2.8 (0.110)	Copper
020 311 381 K	2.9 (0.114)	Brass
020 311 381 L	3.0 (0.118)	Blue

CAUTION: Part numbers are listed for reference only. Always check with your Parts department for the latest information.

NOTE: If the input shaft has not been disassembled:

Press off deep groove ball bearing page, see INPUT SHAFT, DISASSEMBLING AND ASSEMBLING .

Install assembled input shaft without bearing.
Input shaft is supported by bridge 30-211 A, needle bearing drift VW 295 A and M12 lock nut: see ASSEMBLING .

NOTE: Vehicles with 2.0 liter, 85 kW (115 hp) engine are equipped with an additional circlip -A-: see ASSEMBLING .

Install 4th gear on output shaft and secure with circlip.

Fig 1: Installing 4th Gear On Output Shaft And Secure With Circlip

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Installation position of 4th gear: shoulder (arrow) faces toward splines -A- for 5th gear

Fig 2: Identifying Installation Position Of 4th Gear

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Press in deep groove ball bearing for input shaft.
Installation position: wide shoulder (arrow) on inner race faces press tool

Fig 3: Pressing In Deep Groove Ball Bearing For Input Shaft

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Install tension bracket (arrow).

Fig 4: Installing Tension Bracket

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NOTE:

The tension bracket only fits in one position.
The bolts must be tightened again after the transmission housing is installed.

Before installing shift fork set, insert lower spring (arrow) for selector rod into clutch housing.

Fig 5: Inserting Lower Spring For Selector Rod Into Clutch Housing

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Install shift fork set and align shift jaws.
1. - 1st/2nd gear shift fork
  Arrow points toward recess for bridge -CB
2. - 3rd/4th gear shift fork
3. - Bridge with 5th gear shift tube
4. - Reverse gear shift fork
Slide selector rod into position.

Fig 6: Installing Shift Fork Set And Aligning Shift Jaws

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Align reverse idler gear shaft.
Distances -x- are identical.

Fig 7: Aligning Reverse Idler Gear Shaft

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Drive on transmission housing.
CAUTION: Make sure that the support bridge 30-211 A and VW 295 A needle bearing drift provide the input shaft with satisfactory support, see ASSEMBLING .

Fig 8: Driving On Transmission Housing
Courtesy of VOLKSWAGEN OF AMERICA, INC.
Install Torx® bolt for reverse idler gear shaft.
Tightening torque: 20 N.m (15 ft lb)
Install hex -head bolts to secure housing.
Tightening torque: 25 N.m (18 ft lb)
Tighten bolts for deep groove bearing tension bracket.
Tightening torque: 15 N.m (11 ft lb)
Heat 5th gear to approx. 100 °C (212 °F) and install.
Installation position: groove (arrow) faces upward (circular groove on vehicles with 2.0 liter engine)
Install thrust washer and circlip.

Fig 9: Installing Thrust Washer And Circlip

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NOTE: Circlip for 5th gear on vehicles with 2.0 liter, 85 kW (115 hp) engine, see ASSEMBLING .

Install synchronizer hub for 5th gear complete with operating sleeve, gear, shift fork for 5th gear and new securing plate.
Use tube wrench 3059 to screw shift tube clockwise into shift lock.
Thread shift tube back out to adjust projection -x-.
Dimension -x- = 5.0 mm (0.197 in.)

Fig 10: Threading Shift Tube Back Out To Adjust Projection -x-

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CAUTION:

DO NOT extract the selector rod from the shift tube (e.g. with an incorrectly aligned tube wrench).
Otherwise, the shift forks could come apart inside, making it necessary to disassemble the transmission again.
If necessary, insert a screwdriver through the slot in the side to hold the selector rod while removing the slot wrench.

Engage 5th gear and reverse gear (front shift jaw down): see ASSEMBLING .
Coat threads of new synchronizer hub bolt with VW D6 locking fluid and tighten using 12 mm 12-point sockethead wrench.
Tightening torque: 150 N.m (111 ft lb)
Move shift fork to neutral position.
Insert selector shaft -1-.
Install selector shaft spring -2- and cover -3-.
Tightening torque: 50 N.m (47 ft lb)

Fig 11: Installing Selector Shaft, Selector Shaft Spring And Cover

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NOTE: If the cover was sealed with a seal ring (-4-), it should also be replaced - part no. N 903 543 01.

Install lock bolt for selector shaft with sealant, part no. AMV 188 200 03.
Tightening torque: 40 N.m (30 ft lb)

CAUTION: Part numbers are listed for reference only. Always check with your Parts department for the latest information.

The 5th gear selector fork is adjusted as follows:

NOTE: Perform this adjustment with the greatest care to prevent the transmission from jumping out of gear.

Check protrusion of shift tube. Use 3059 tube wrench to adjust if necessary.
Dimension -x- = 5.0 mm (0.197 in.)
Bolt gear selector shaft lever onto selector shaft and engage 5th gear (pull l

Fig 12: Checking Protrusion Of Shift Tube

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Raise operating sleeve together with shift fork slightly (to compensate for free play in linkage components).
Align operating sleeve -1- with selector fork -2- so there is no free play to 5th gear -3-.
- Clearance -a- must exist between operating sleeve and 5th gear.
- Dimension -a- = 1.3 mm (.051 in)
Fig 13: Aligning Operating Sleeve With Selector Fork
Courtesy of VOLKSWAGEN UNITED STATES, INC.
If necessary, adjust dimension -a- by turning selector tube.
Disengage 5th gear.
- Operating sleeve must be in neutral position.
- Synchronizer ring must move freely.
Support shift fork using tools -A- approximately 12 mm (0.47 in.) thick (e.g. two open-end wrenches, 19 mm and 24 mm).
Drive on new securing plate.

Fig 14: Supporting Shift Fork & Driving On New Securing Plate

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Before installing the cover (arrow):

Fig 15: Installing Cover

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Install new gasket (where applicable).
Release tension on input shaft support bridge, see Figure in Disassembling .
Starting at 5th gear end, guide clutch pushrod into input shaft.
Install clutch release bearing on clutch push rod.

After installing cover:

Shift through all gears to make sure they engage correctly.
Install drive flanges, see Drive flange oil seals, removing and installing .