Repair Manual

VW 02J gearbox
INA GearBOX
Special tools
Pipe section, 50 mm:
• Press fitting of synchronizer
body for third/fourth gear.
• Assembly of support bearing for
input and output shaft.
• Part number: 400 0472 10
Press fit sleeve:
• Press fitting of needle roller
bearing sleeve for third gear.
• Part number: 400 0475 10
Shim set
Shim set:
• Installation location: differential
tapered roller bearing.
• Outside diameter of 67,9 mm
• Part number: 464 0001 10
2
Pipe section, 60 mm:
• Press fitting of synchronizer body
for first/second gear.
• Part number: 400 0473 10
Thrust piece:
• Press fitting of needle roller
bearing sleeve for third gear.
• Assembly/disassembly of reverse
gear shaft needle roller bearing.
• Part number: 400 0476 10
Shim set:
• Installation location: output shaft
tapered roller bearing.
• Outside diameter of 50,2 mm
• Part number: 464 0002 10
Drive-in sleeve:
• Press fitting of needle roller
bearing sleeve for fourth and fifth
gear.
• Assembly of support bearing for
input and output shaft.
• Part number: 400 0474 10
Shim set:
• Installation location: of input
shaft tapered roller bearing.
• Outside diameter of 69.0 mm
• Part number: 464 0003 10
Repair Manual for VW 02J gearbox

• Drain the transmission fluid (arrow). 1

• Then refit the oil drain plug.
Tightening torque of oil drain plug: 25 Nm
• Remove the gearbox from the vehicle in accordance
with the vehicle manufacturer specifications.

• Unhook the retaining spring (arrow). 2

• Remove the release lever and release bearing.

• Remove screws (1) from guiding sleeve. 3

• Remove the guiding sleeve.

3
• Loosen the screws on the left and right drive-
shaft flanges.
• Completely remove the driveshaft flanges
together with pressure spring, thrust washer
and conical ring.

Note: To release, secure the driveshaft flanges

with two screws and a tyre lever.

• Remove screws (1) from transmission 5

housing cover.
4
• Remove transmission cover.

Note: Clean sealing surfaces.

• Remove screws (1) from bearing journals. 6

• Remove gear shift fork fifth gear (2).

• Unscrew screws for synchronizer body and 7

toothed gear fifth gear (A).

Note: To undo the screws, block the

transmission. To do this, press selector
sleeve fifth gear (1) downwards, push
in selector shaft (2) and rotate anti-
clockwise (3).

• Return the selector shaft to neutral after

loosening the screws.

Note: For the neutral position, turn selector

shaft clockwise until it pops
out independently.

4
• Place extractor under speed gear for fifth gear. 8
• Extract synchronizer package and speed gear
from input shaft.

Caution: 
Take care when lifting out synchronizer
package (selector sleeve, thrust pieces
and spring lock washer) to prevent it
from falling apart!

• Place extractor underneath toothed gear 9

fifth gear.
• Remove toothed gear fifth gear.

• Unscrew nut (1) from selector mass. 10

• Remove selector mass.

• Remove screws from selector shaft (arrows). 11

• Remove selector shaft.
• Remove both bearing journals (1).

5
 • Remove both bearing journals (1). 12
• Undo screw on reverse gear (2).
• Remove cover (3).

• Remove screw from reverse gear (arrow). 13

• Remove screws (1) from transmission housing. 14

Caution: Do not unscrew bearing housing

retainer nuts (2) of the output shaft.

• Remove screws from transmission housing. 15

6
• Lift off transmission housing. 16

Caution: Be careful not to damage the sealing

surfaces when doing this.

Note: Clean sealing surfaces.

• Remove gear shift forks and gear shift rails (1). 17

• Remove screw from reverse gear actuator (2).
• Remove reverse gear actuator.

• Remove bearing housing retainer nuts (1) from 18

the output shaft.

• Remove reverse gear (1), input shaft (2) and 19

output shaft (3) from the housing.
• Lift out differential (4).
• Remove magnet (5).

7
• Pull out reverse gear drawn cup needle roller 20
bearing with open end from housing.

• Pull out engine-side bearing ring for input shaft. 21

• Pull out engine-side bearing ring for output shaft. 22

• Remove shim.

• Pull out engine-side bearing ring for differential. 23

8
• Remove flanged shaft seal on the engine side. 24

• Install new engine-side flanged shaft seal. 25

Note: Clean the sealing surface before

installing the new sealing ring.
Note: Adhere to nonverbal mounting
instructions 9996006770.

• Pull out transmission-side bearing ring for 26

differential.
• Remove shim.

• Remove drive flange seal on the transmission 27

side.

9 9
• Install new transmission-side flanged shaft seal. 28

Note: Clean the sealing surface before

installing the new sealing ring.

• Press out transmission-side bearing ring for 29

input shaft together with shim.

• Press out transmission-side bearing ring of 30

output shaft.

• Press out drawn cup needle roller bearing with 31

open end from reverse shaft support.

Note: Use special tool 400 0476 10.

10
• Extract both differential bearings. 32

• Remove speedometer drive. 33

• Drive out roll pin in direction of arrow. 34

• Drive in the new roll pin as far as it will go. 35

11
• Reassemble speedometer drive. 36

• Press fit new differential bearings on both sides. 37

Note: Adhere to nonverbal mounting instructions

9996006760.

• Press fit engine-side bearing ring for 38

differential.

• Press fit transmission-side bearing ring for 39

differential.

Note: 
First press fit bearing ring without shim.

12
• Press off engine-side bearing of input shaft. 40

• Press off transmission-side bearing of input 41

shaft together with toothed gear for fourth
gear, washer and sleeve.

• Press fit engine-side bearing of input shaft. 42

Note: Support bearing when press fitting onto

the inner ring.

• Press fit the toothed gear for fourth gear 43

Note: The shoulder on the toothed gear must

point towards third gear

13
• Press fit transmission-side bearing of input shaft. 44

Note: Use special tool 400 0474 10.

• Position washer (1). 45

• Press fit sleeve (2) for needle roller bearing.

Note: Use special tool 400 0474 10.

• Press fit drawn cup needle roller bearing with 46

open end into reverse shaft support.

• Press off speed gears for second to fourth gears

from output shaft together with synchronizer
package and sleeve (components 1-17).

Note: Lift the components together when

disassembling to prevent
the synchronizer package
from falling apart.

• Remove circlip (18).

47

14
• Press off components 19-23 from output shaft 48
through bearing housing (24).

• Press off transmission-side bearing (25) from 49

output shaft through inner ring.

• Press off engine-side bearing (26) from output 50

shaft through inner ring.

• Press fit new engine-side bearing (26) on the 51

output shaft through inner ring.

Note: Use special tool 400 0474 10.

15
• Press fit new transmission-side bearing (25) on 52
output shaft through inner ring.

Note: Position thrust washer (23) before

press fitting. The heel is pointing
towards the inner ring.

Note: Use special tool 400 0472 10.

• Press out outer ring of transmission-side 53

bearing of output shaft from bearing housing.

• Press fit outer ring of new transmission-side 54

bearing of output shaft into the bearing
housing.

• Press fit new outer ring for engine-side bearing 55

of output shaft together with 0.65 mm shim.
Important for subsequent setting of output
shaft!

Note: Use special tool 400 0472 10.

16
• Press fit new outer ring of engine-side bearing 56
of input shaft.

Note: Use special tool 400 0472 10.

• Press fit new drawn cup needle roller bearing 57

with open end for reverse gear into clutch
housing.

Note: Use special tool 400 0476 10.

• Press fit new outer ring of transmission-side 58

bearing of input shaft into transmission
housing without shim.

• Press fit roller sleeve for output shaft on 59

transmission side.

Note: Adhere to nonverbal mounting

instructions 9996006720.

17
• Secure roller sleeve in the transmission 60
housing at three points (1) with a mandrel, with
an offset of 120°.

• Insert differential. 61
• Attach the transmission housing.

• Fix transmission housing in place with the 62

screws shown.
Tightening torque for cover screws: 25 Nm

• Assemble dial gauge as shown and set to "0" 63

with 1 mm preload.
• Move differential up and down, reading the
clearance as you do so.
• Measured value + 0.40 mm produces the
requisite thickness of the shim.

18
• Remove transmission housing. 64
• Pull out outer ring of transmission-side
differential bearing.
• Insert appropriate shim and press fit outer ring
again.

• Insert output shaft. 65

• Tighten nuts for bearing housing (ct. Figure 18).
Tightening torque for bearing connector nuts:
25 Nm + 90°
• Assemble dial gauge as shown and set to "0"
with 1 mm preload.
• Move output shaft up and down, reading the
clearance as you do so.

The required thickness of shim is derived from: 66

Thickness of shim inserted for measurement
(here 0.65 mm) + measured value + 0.20 mm.

• Remove output shaft.

• Pull out outer ring of engine-side bearing of
output shaft.
• Replace shim used for measurement with new,
calculated shim.
• Press fit outer ring again.

• Insert the input shaft in the clutch cover. 67

• Reassemble the transmission housing and bolt
it fully into place.
Tightening torque for the housing screws:
25 Nm + 90°

19
• Turn input shaft to allow the tapered roller 68
bearings to set themselves.

Note: This procedure must be repeated for

each further measurement!

• Assemble dial gauge as shown and set to "0"

with 1 mm preload.
• Move input shaft in the direction of the arrow,
reading the clearance as you do so.
• Determine leveling disc according to table
(page 30/31).

• Remove input shaft. 69

• Pull out outer ring of transmission-side bearing of input
shaft.
• Insert leveling disc and press fit outer ring again.
• Repeat measuring procedure with shim press fit. The
bearing play should be between 0.01 mm and
0.09 mm.

Note: If no more bearing play can be measured, but

the input shaft has a perceptible tilting
clearance, the setting is also correct.

Note: When assembling the synchronizers, 70

make sure that the recesses and dividers
of the individual parts match. (Shown here on
the example of first gear.)

• Place inner synchro ring (1) on the speed gear for first
gear.
The angled dividers (A) point towards the intermediate
ring (2).
• Position intermediate ring (2). The dividers (B) lock into
place in the recesses (C) of the speed gear.
• Position outer synchro ring (3). The recesses (D) lock into
place in the dividers (A) of the inner synchro ring (1).

• Position bearing housing (24), speed gear for first gear (22), 71
needle roller bearing (21) and synchro ring (20).
• Press fit synchronizer body with sliding sleeve (19).

Note: Use special tool 400 0473 10.

• Fit circlip (18).

Note: The exploded drawing shows a single

synchronization. For transmissions dated after
02.05.2000, this has been replaced with a double
synchronization (see Figure 70).

20
• Position synchro rings (15–17), speed gear for 72
second gear (14), needle roller bearing (13) and
thrust washer (12).
• Press fit sleeve for needle roller bearing for
third gear (11) onto output shaft.

Note: Use special tools 400 0475 10 and

400 0476 10.

• Position needle roller bearing (10), speed gear 73

for third gear (9) and synchro ring (8).
• Press fit synchronizer body with sliding sleeve
(7) onto output shaft.

Note: Use special tool 400 0472 10.

• Press fit sleeve (6) for needle roller bearing for 74

fourth gear onto output shaft.

Note: Use special tool 400 0474 10.

• Position needle roller bearing (5), synchro ring 75

(4), speed gear for fourth gear (3) and thrust
washer (2).
• Press fit sleeve for needle roller bearing for
fifth gear (1) onto output shaft.

Note: Use special tool 400 0474 10.

21
• Replace 4 sealing rings (arrows) of bearing 76
housing.

• Insert differential (1) and magnet (2). 77

• Insert input shaft and output shaft together. 78

• Tighten nuts of bearing housing (1) of output 79

shaft.
Tightening torque for bearing connector nuts:
25 Nm + 90°

22
• Position reverse idler gear on drawn cup needle 80
roller bearing with open end.

• Insert reverse shaft with ratchet through 81

reverse idler gear in needle roller bearing.

• Position reverse shaft support on reverse shaft. 82

• Screw the M8 x 100 mm stud bolts onto the 83

reverse shaft support.

Note: Bolts help to align the reverse shaft

support during the subsequent
assembly process.

23
• Assemble shift actuating mechanism for
reverse gear.
Tightening torque of reverse gear screw: 25 Nm

84

• Insert gear shift forks and gear shift rails.

• Align gear shift rails.

Note: Sliding blocks must be sitting in the

grooves of the sliding sleeves.

Caution: Reverse gear shift fork must be

located underneath the large gear shift
fork (see detailed photo).

85

• Apply sealant to one side of the transmission 86

housing.

• Assemble transmission housing halves. 87

24
• Tighten screws for transmission housing. 88
Tightening torque of housing screws:
25 Nm + 90°
• Insert side screw (1) of reverse gear and tighten
by hand.
• Unscrew stud bolts (2) and replace with original
screw.
• Tighten both screws one after the other.
Tightening torque of screws: 30 Nm

• Tighten housing screws (1) in the clutch bell 89

housing.
Tightening torque of housing screws: 25 Nm + 90°

• Clean the 4 bearing journals of the gear shift forks. 90

• Replace the o-rings of the bearing journals.

• Install the 4 bearing journals. 91

Tightening torque of the bearing journal
screws: 25 Nm

Note: If necessary, adjust the shift actuating

mechanism using a screwdriver to
ensure that the relevant bearing journal
can be installed.

25
• Apply sealant. 92

• Put gear shift rails in neutral position. 93

• Insert lug (1) into the recess (2) of the transmission
housing. Arrange selector shaft so that the shift
fingers (3) can be inserted into the gear shift rails.
• Screw on shift actuating mechanism.
Tightening torque of shift actuating mechanism
screws: 25 Nm

• Screw on selector mass. 94

Tightening torque for flywheel mass nut: 25 Nm

• Apply sealant. 95

26
• Attach cover. 96
Tightening torque for cover screws: 25 Nm

• Press fit toothed gear for fifth gear. 97

Note: Surrounding groove must be facing the

transmission!

• Press fit synchronizer unit for fifth gear. 98

Note: Ensure correct assembly of synchronizer

body and synchro ring! The cast-on
tabs of the synchro ring (1) must be
sitting in the recesses (2) of the
synchronizer body.

• Fasten synchronizer unit and toothed gear for fifth 99

gear with respective spring washer and screw (A).
Tightening torque of screws: 80 Nm

Note:  To tighten the screws, block the transmission.

To do this, press selector sleeve fifth gear (1)
downwards, push in selector shaft (2) and
rotate anti-clockwise (3).

• Return the selector shaft to neutral after tightening
the screws.

Note: For the neutral position, turn selector shaft

clockwise until it pops out independently.

27
• Assemble gear shift fork. 100
• fifth gear should be engaged using selector shaft.
• Loosen screw of selector jaws (1).
• Push sliding sleeve and selector jaws downwards.
• Tighten screw of selector jaws (1). Tightening
torque for screw of selector jaws: 25 Nm

• Perform control measurement: It must not be 101

possible to insert a feeler gauge of 0.2 mm in
between the sliding sleeve and ratchet.
• Repeat the adjustment procedure, if required.
• fifth gear should be removed using the selector
shaft: The sliding sleeve must now be in the neutral
position, synchro ring for fifth gear must move freely.
• Shift through all gears.

• Replace the cover seal. 102

• Put cover of transmission housing into 103

position.

28
• Tighten cover screws (1). 104
Tightening torque for cover screws: 10 Nm

• Push new guiding sleeve onto the input shaft. 105

• Tighten screws (1).
Tightening torque of mounting screws:
20 Nm
• Grease sleeve in area of release bearing.

• Fasten the retaining spring to the clutch 106

release lever.
• Install clutch release lever.
• Mount the retaining spring.
• Grease release bearing at contact point with
release lever and push into place.

• Install both driveshaft flanges using springs, 107

thrust washers and conical rings.
Tightening torque for the flange screws: 25 Nm

29
• Install the transmission in the vehicle in 108
accordance with the manufacturer's instructions.
• Fill with transmission fluid in accordance with the
vehicle manufacturer's specifications.

Setting the input shaft tapered roller bearing – Table of shims

Part number for shim set: 464 0003 10

Bearing play Shim

Measured value (mm) Thickness (mm) Spare part no.
0.671 ... 0.699 0.650 02A 311 140
0.700 ... 0.724 0.675 02A 311 140 A
0.725 ... 0.749 0.700 02A 311 140 B
0.750 ... 0.744 0.725 02A 311 140 C
0.775 ... 0.799 0.750 02A 311 140 D
0.800 ... 0.824 0.775 02A 311 140 E
0.825 ... 0.849 0.800 02A 311 140 F
0.850 ... 0.874 0.825 02A 311 140 G
0.875 ... 0.899 0.850 02A 311 140 H
0.900 ... 0.924 0.875 02A 311 140 J
0.925 ... 0.949 0.900 02A 311 140 K
0.950 ... 0.974 0.925 02A 311 140 L
0.975 ... 0.999 0.950 02A 311 140 M
1.000 ... 1.024 0.975 02A 311 140 N
1.025 ... 1.049 1.000 02A 311 140 P
1.050 ... 1.074 1.025 02A 311 140 Q
1.075 ... 1.099 1.050 02A 311 140 R
1.100 ... 1.124 1.075 02A 311 140 S
1.125 ... 1.149 1.100 02A 311 140 T
1.150 ... 1.174 1.125 02A 311 140 AA
1.175 ... 1.199 1.150 02A 311 140 AB
1.200 ... 1.224 1.175 02A 311 140 AC
1.225 ... 1.249 1.200 02A 311 140 AD
1.250 ... 1.274 1.225 02A 311 140 AE
1.275 ... 1.229 1.250 02A 311 140 AF
1.300 ... 1.324 1.275 02A 311 140 AG

30
Setting the input shaft tapered roller bearing – Table of shims

Part number for shim set: 464 0003 10

Note: From bearing play greater than 1.325 mm, a combination of two shims may be required.

Bearing play Shim

Measured value (mm) Thickness (mm) Spare part no.
02A 311 140
1.325 ... 1.349 1.300
02A 311 140
02A 311 140
1.350 ... 1.374 1.325
02A 311 140 A
02A 311 140 A
1.375 ... 1.399 1.350
02A 311 140 A
02A 311 140 A
1.400 ... 1.424 1.375
02A 311 140 B
02A 311 140 B
1.425 ... 1.449 1.400
02A 311 140 B
02A 311 140 B
1.450 ... 1.474 1.425
02A 311 140 C
02A 311 140 C
1.475 ... 1.499 1.450
02A 311 140 C
02A 311 140 C
1.500 ... 1.524 1.475
02A 311 140 D
02A 311 140 D
1.525 ... 1.549 1.500
02A 311 140 D
02A 311 140 D
1.550 ... 1.574 1.525
02A 311 140 E
02A 311 140 E
1.575 ... 1.599 1.550
02A 311 140 E
02A 311 140 E
1.600 ... 1.624 1.575
02A 311 140 F
02A 311 140 F
1.625 ... 1.649 1.600
02A 311 140 F
02A 311 140 F
1.650 ... 1.674 1.625
02A 311 140 G

1.675 ... 1.699 02A 311 140 G

1.650
02A 311 140 G

1.700 ... 1.724 02A 311 140 G

1.675
02A 311 140 H

1.725 ... 1.749 02A 311 140 H

1.700
02A 311 140 H

1.750 ... 1.774 02A 311 140 H

1.725
02A 311 140 J

1.775 ... 1.791 02A 311 140 J

1.750
02A 311 140 J

31
 9996008950/08.2016
© 2016 Schaeffler Automotive Aftermarket

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