Section 115 (6 SPD. Manual Transmission 02Y All Wheel Drive)
WARNING: This page is about a different car, the 2004 Volkswagen R32. However, it is still accessible from the selected car via links, so may be relevant.
- 00 - General, Technical Data
- 30 - Clutch
- 34 - Manual Transmission - Controls, Housing
- Vehicle Diagnosis, Testing and Information System VAS 5051 , connecting and selecting function
- Electrical/electronic components and locations
- Haldex Clutch, testing
- Selector lever mechanism, servicing
- Installed position of components at transmission
- Shift knob and cover, removing and installing
- Boot, separating from shift lever and assembling with shift knob
- Shift lever and shift mechanism housing, servicing
- Operating cables, assembly overview
- Selector mechanism, removing and installing
- Shift mechanism, adjusting in transmissions with lock bolts (up to transmission manufacture date 180503)
- Shift mechanism, adjusting in transmissions with lock elbow (as of transmission manufacture date 190503)
- Function, checking
- Transmission, removing and installing
- Bevel gear transfer case, removing and installing
- Gear oil, checking
- Transmission, disassembling and assembling
- Transmission overview
- Assembly overview
- Transmission housing and manual transmission, disassembling and assembling up to transmission manufacture date 180503
- Transmission housing and manual transmission, disassembling and assembling as of transmission manufacture date 190503
- Input shaft, output shafts (pinion shafts), differential, bevel gear transfer case and selector rods, removing and installing
- Notes
- Installed position of input shaft and output shafts (pinion shafts) in transmission up to transmission manufacture date 180503
- Installed position of complete shift mechanism in transmission, up to transmission manufacture date 180503:
- Installed position of shafts and selector rods in transmission, as of transmission manufacture date 190503:
- Sequence of disassembly and assembly for transmission up to manufacture date 180503
- Sequence of disassembly and assembly for transmissions as of manufacture date 190503
- Transmission housing, servicing
- Transmission housing, servicing up to transmission manufacture date 180503
- Notes
- Driving out lock sleeve
- Driving in lock sleeve up to stop
- Driving out lock bolt
- Driving in lock bolt until stop
- Pulling out bushing for selector rod
- Driving in bushing for selector rod flush
- Pulling needle sleeve for reverse shaft off transmission housing
- Pressing needle sleeve - A - into transmission housing
- Transmission housing, servicing as of transmission manufacture date 190503
- Notes
- Removing cap - A -
- Drive in cap up to stop
- Different versions of oil filler and oil drain plugs
- Removing lock elbow for selector shaft
- Installed position of lock elbow
- Driving lock elbow - arrow - for selector shaft in to tool stop
- Pulling out bushing for selector rod
- Driving in bushing for selector rod to tool stop
- Pressing lock sleeve - A - out of transmission housing
- Driving out lock sleeve for non-disassembled transmission using guide pin 10-15
- Driving in lock sleeve until tool stop
- Pulling needle sleeve for reverse shaft off transmission housing
- Pressing needle sleeve - A - into transmission housing
- Pulling out bushing for selector shaft
- Driving bushing - A - for selector shaft in to tool stop
- Driving out sealing plugs - 1 -
- Driving in sealing plugs - 1 -
- Transmission housing, servicing up to transmission manufacture date 180503
- Clutch housing, servicing
- Clutch housing, servicing up to transmission manufacture date 180503
- Clutch housing, servicing as of transmission manufacture date 190503
- Notes
- Pulling out bushing for selector rod
- Driving in bushing for selector rod to tool stop
- Pulling needle sleeve off clutch housing
- Pressing needle sleeve - A - into clutch housing
- Removing seal for input shaft
- Driving in seal for input shaft flush
- Press axle for reverse gear shift fork into clutch housing
- Pulling cylindrical roller bearing off clutch housing
- Pressing cylindrical roller bearing into clutch housing
- Shift mechanism on transmission side, disassembling and assembling
- Shift forks, servicing
- 35 - Manual Transmission - Gears, Shafts
- Input shaft
- Input shaft, disassembling and assembling up to transmission manufacture date 180503
- Notes
- Pulling outer race/tapered roller bearing out of transmission housing
- Pressing outer race/tapered roller bearing into transmission housing
- Pulling off inner race/tapered roller bearing
- Pressing off 5th gear
- Pressing off gear wheel for 3rd/4th and 6th gears
- Pressing off inner race/tapered roller bearing
- Pressing on gear wheel for 3rd/4th and 6th gears
- Pressing on inner race/tapered roller bearing
- Pressing on 5th gear
- Determining circlip
- Pulling outer race/tapered roller bearing off clutch housing
- Installed position of outer race/tapered roller bearing in clutch housing
- As of transmission manufacture date 06040: Pressing in tapered roller bearing outer race
- Input shaft, adjusting up to transmission manufacture date 180503
- Input shaft, disassembling and assembling as of transmission manufacture date 190503
- Input shaft, disassembling and assembling up to transmission manufacture date 180503
- Output shaft for 1st to 4th gear
- Output shaft for 1st to 4th gear, disassembling and assembling
- Notes
- Pulling dished washer - A - off output shaft
- Pressing dished washer in output shaft to stop
- Pulling out tapered roller bearing outer race
- Pressing outer race/tapered roller bearing into clutch housing
- Pulling off inner race/tapered roller bearing
- Pulling off synchronizer hub/operating sleeve for 3rd and 4th gear over gear wheel for 4th gear
- Pressing off operating sleeve and synchronizer hub for 1st and 2nd gears
- Pressing off inner race/tapered roller bearing
- Pressing on inner race/tapered roller bearing
- Checking 1st, 2nd and 3rd gear inner races for wear
- Checking 1st, 2nd and 3rd gear synchronizer rings for wear
- Installed position of outer race, inner race and synchronizer ring, 2nd gear
- Disassembling and assembling operating sleeve and synchronizer hub for 1st and 2nd gears as well as 3rd and 4th gears
- Assembling operating sleeve/synchronizer hub for 1st and 2nd gears as well as 3rd and 4th gears
- Installed position of operating sleeve/synchronizers for 1st and 2nd gear
- Pressing on operating sleeve/synchronizer hub for 1st and 2nd gear
- Installed position of outer race for 1st and 3rd gear
- Installed position of synchronizer ring - A - (inner race for 1st and 3rd gear)
- Installed position of gear wheel for 1st and 3rd gear
- Installed position of operating sleeve/synchronizers for 3rd and 4th gear
- Pressing on synchronizer hub with operating sleeve for 3rd and 4th gears
- Checking 4th gear synchronizer ring for wear
- Determining circlip
- Pulling outer race/tapered roller bearing out of transmission housing
- Pressing outer race/tapered roller bearing into transmission housing
- Output shaft for 1st to 4th gear, adjusting
- Output shaft for 1st to 4th gear, disassembling and assembling
- Output shaft for 5th/6th and reverse gear
- Output shaft for 5th/6th and reverse gear, disassembling and assembling
- Notes
- Pulling out tapered roller bearing outer race
- Pressing outer race/tapered roller bearing into clutch housing
- Pulling off inner race/tapered roller bearing
- Pressing off synchronizer hub/operating sleeve for 5th and 6th gear with 6th gear wheel
- Pressing off sleeve - A - over reverse gear wheel
- Pressing off synchronizer hub for reverse gear
- Installed position of synchronizer hub for reverse gear
- Pressing on synchronizer hub for reverse gear
- Pressing on sleeve - A -
- Checking synchronizer ring for 5th and 6th gears for wear
- Disassembling and assembling operating sleeve and synchronizer hub for 5th and 6th gears
- Assembling operating sleeve/synchronizers for 5th and 6th gears
- Pressing on operating sleeve/synchronizer hub for 5th and 6th gears
- Pressing on inner race/tapered roller bearing
- Determining circlip
- Pulling outer race/tapered roller bearing out of transmission housing
- Pressing outer race/tapered roller bearing into transmission housing
- Output shaft for 5th/6th and reverse gears, adjusting
- Output shaft for 5th/6th and reverse gear, disassembling and assembling
- Input shaft
- 39F - Final drive, front differential
- Flanged shaft seals, replacing (manual transmission and bevel gear transfer case installed)
- Seal for output flange of bevel gear transfer case, replacing (bevel gear transfer case removed)
- Differential for manual transmission
- Differential, disassembling and assembling
- Notes
- Pulling outer race/tapered roller bearing off clutch housing
- Pressing outer race/tapered roller bearing into clutch housing
- Pulling off inner races/tapered roller bearing
- Pressing on inner races/tapered roller bearing
- Pulling outer race/tapered roller bearing out of transmission housing
- Pressing outer race/tapered roller bearing into transmission housing
- Removing and installing roll pin for differential bevel gear axle
- Installing small differential bevel gears
- Pull off connecting sleeve - A -
- Pressing on connecting sleeve - A - for bevel gear transfer case
- Differential, adjusting
- Differential, disassembling and assembling
- Adjustment overview for manual transmission
- Bevel gear transfer case
- Needle bearing, replacing
- Shaft and head bevel gear (gear set), adjusting
- General notes
- Gear set, adjusting and marking
- Shim location
- Adjustment overview (bevel gear transfer case)
- Recommended sequence for adjusting gear set
- Adjustment shim "S 4", determining when replacing output flange
- Shaft bevel gear, adjusting
- Head bevel gear, adjusting
- 39R - Final drive, rear differential
- Driveshaft
- Haldex clutch, checking function
- Seals
- O-rings, replacing
- Rear final drive, removing and installing
- Gear oil in rear final drive, checking
- Oil level in Haldex clutch, checking and changing
- Rear final drive, disassembling and assembling
- Rear final drive, disassembling and assembling
- Cover for Haldex clutch and clutch plates, removing and installing
- Drive pinion housing, removing and installing
- Differential and head bevel gear / input shaft, removing and installing
- Cover for Haldex clutch / disc housing, removing and installing
- Disassembly and assembly sequence
- Differential for rear final drive
- Bearing for shaft bevel gear, servicing
- Bearing for head bevel gear / input shaft, servicing
- Shaft and head bevel gear (gear set), adjusting
- General notes
- Gear set, adjusting and marking
- Shim location
- Adjustment overview (rear final drive)
- Recommended sequence for adjusting gear set
- Shaft bevel gear, adjusting
- Head bevel gear, adjusting