D3E802367A7-5-Speed Manual Gearbox 02C Four-Wheel Drive
Uploaded by
Bruno RedonD3E802367A7-5-Speed Manual Gearbox 02C Four-Wheel Drive
Uploaded by
Bruno RedonService
Workshop Manual
Bora 1999 ➤
Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive
Edition 01.2010
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Service Department. Technical Information
Service
List of Workshop Manual Repair Groups
Repair Group
00 - Technical data
30 - Clutch
34 - Controls, housing
35 - Gears, shafts
39 - Final drive - rear differential
39 - Final drive - front differential agen
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Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.
All rights reserved.
No reproduction without prior agreement from publisher.
Copyright © 2015 Volkswagen AG, Wolfsburg D3E802367A7
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Gearbox identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Location on gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Codes and production dates of gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.3 Identification code, assembly allocation, ratios, capacities . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Identifying rear final drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.1 Location on rear final drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.2 Codes and production dates of gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.3 Identification code, assembly allocation, ratios, capacities . . . . . . . . . . . . . . . . . . . . . . . . 5
3 Overview - power transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4 Calculation of gear ratios . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4.1 Notes on performance test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
5 General repair notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
30 - Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1 Repairing clutch mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.1 Assembly overview - pedal cluster . . . . . . . . . . . . . . . ..V.o.lk.sw. a. g.e. . . . . . . . . . . . . . . . . . . . . . 15
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1.2 Distinguishing between clutch pedal switches F36
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1.3 Removing and installing clutch pedal switch ed b F36 with rectangular housing .ua.ra. . . . . . . . . .
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1.4 Removing and installing clutch pedal ut
hoswitch F36 with round housing . . . . . . . . e. o. . . . . . .
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1.5 Removing and installing over-centre ss spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . c. . . . . . 17
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1.6 Removing and installing clutch pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
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1.7 Assembly overview - hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
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1.8 Removing and installing master cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
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1.9 Bleeding clutch system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
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2 Repairing clutch release mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
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2.1 Assembly overview clutch release mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
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3 Repairing clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
3.1 Assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
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34 - Controls, housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
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1 Connecting VAS 5051 and selecting functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
2 Electrical and electronic components and their locations . . . . . . . . . . . . . . . . . . . . . . . . . . 33 nf
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2.1 Overview of electrical and electronic components and their locations . . . . . . . . . . . . . . . . 33
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2.2 Removing and installing all-wheel drive control unit J492 . . . . . . . . . . . . . . . . . . . . . . . . . . 35
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2.3 Removing and installing Haldex coupling pump V181 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
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3 Electrical check of Haldex coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
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4 Repairing selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
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4.1 Installation position of selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
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4.2 Removing and installing gear knob and cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
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4.3 Repairing gear lever and selector housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
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4.4 Assembly overview - removing and installing selector cables . . . . . . . . . . . . . . . . . . . . . . 48
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4.5 Removing and installing selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
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4.6 Adjusting selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
5 Removing and installing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
5.1 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
5.2 Transporting gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
5.3 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
5.4 Specified torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
6 Removing and installing bevel box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
7 Checking gear oil in manual gearbox with bevel box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Contents i
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
8 Dismantling and assembling gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
8.1 Overview - gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
8.2 Assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
8.3 Removing and installing cover for gearbox housing and 5th gear . . . . . . . . . . . . . . . . . . . . 79
8.4 Removing and installing gearbox housing and selector mechanism . . . . . . . . . . . . . . . . . . 80
8.5 Removing and installing input shaft, output shaft, differential and selector forks . . . . . . . . 81
8.6 Procedure for removing and installing gearbox housing cover, gearbox housing, selector
mechanism, input shaft, output shaft, differential and selector forks . . . . . . . . . . . . . . . . . . 82
9 Assembly overview - Repairing gearbox housing and clutch housing . . . . . . . . . . . . . . . . 93
10 Dismantling and assembling selector mechanism on gearbox side . . . . . . . . . . . . . . . . . . 99
10.1 Assembly overview - selector shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
11 Dismantling and assembling selector forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
35 - Gears, shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
1 Dismantling and assembling input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
1.1 Assembly overview - input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
1.2 Modification in springs for 5th gear synchronisation from gearbox date 05 11 1. . . . . . . . . 115
2 Adjusting input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
2.1 Adjusting input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
2.2 Table of shims . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
2.3 Carrying out check measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
3 Adjusting output shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
4 Dismantling and assembling output shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
4.1 Assembly overview - output shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
4.2 1st gear synchronisation changed from gearbox date 04 09 0 . . . . . . . . . . . . . . . . . . . . . . 136
5 Dismantling and assembling reverse shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
39 - Final drive - rear differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
1 Propshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
1.1 Assembly overview - repairing propshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
1.2 Removing and installing propshaft . . . . . . . . . . w. a.g.en. A. G . ..V.o.lk.sw
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1.3 Removing and installing front flexible coupling by
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1.4 Removing and installing rear flexible coupling oris
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2 Haldex coupling . . . . . . . . . . . . .ss. a. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . r.ac. . . . . 158
2.1 Checking function of Haldex coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
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2.2 Checking oil level or changing oil in Haldex coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
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2.3 Changing oil filter for Haldex coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
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3 Modifying gearbox support VW 353 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
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4 Checking gear oil in rear final drive and topping up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
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5 Removing and installing rear final drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
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6 Renewing propshaft flange oil seal on rear final drive (final drive removed) . . . . . . . . . . . . 168
7 Renewing flange shaft oil seals (final drive installed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
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8 Renewing O-ring between Haldex coupling and pinion housing (final drive removed) . . . . 173
9 Renewing O-rings for rear final drive housing cover (final drive installed) . . . . . . . . . . . . . . 176
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10 Dismantling and assembling rear final drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
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10.1 Assembly overviews - rear final drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
10.2 Removing and installing cover for Haldex coupling and plates . . . . . . . . . . . . . . . . . . . . . . 178
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10.3 Removing and installing pinion housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
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10.4 Removing and installing differential and bevel gear with stub shaft . . . . . . . . . . . . . . . . . . 181
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10.5 Removing and installing cover for Haldex coupling from plate housing . . . . . . . . . . . . . . . . 183
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Contents
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11 Dismantling and assembling differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
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11.1 Assembly overview - differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
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12 Repair shaft bevel gear mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
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12.1 Assembly overview - bevel gear mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
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12.2 Assembly sequence - bevel gear mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
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13 Repairing bearings for bevel gear with stub shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
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13.1 Assembly overview - bearings for bevel gear with stub shaft . . . . . . . . . . . . . . . . . . . . . . . . 216
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13.2 Assembly sequence - bearings for bevel gear with stub shaft . . . . . . . . . . . . . . . . . . . . . . 218
14 Adjusting shaft bevel gear and bevel gear with stub shaft (final drive gear set) . . . . . . . . 224
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14.1 General notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
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14.2 Adjustment and marking of final drive gear sets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
14.3 Position of shims . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
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Adjustment overview - rear final drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
14.5 Recommended sequence for new adjustment of final drive gear set . . . . . . . . . . . . . . . . . . 226
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14.6 Adjusting shaft bevel gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
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14.7 Adjusting bevel gear (with stub shaft) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231
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39 - Final drive - front differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
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1 Renewing oil seals for flange shafts or right-hand drive flange (gearbox installed) . . . . . . 236
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1.1 Renewing oil seal for left flange shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
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1.2 Renewing oil seal for flange shaft or right drive flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
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2 Renewing bevel box output flange oil seal (bevel box removed) . . . . . . . . . . . . . . . . . . . . 240
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3 Dismantling and assembling differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242
3.1 Assembly overview - differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242
3.2 Assembly sequence - differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243
4 Adjustment overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247
5 Adjusting differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248
6 Dismantling and assembling bevel box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250
6.1 Bevel box - assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250
6.2 Assembly sequence - bevel box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253
7 Renewing needle bearing (polygon bearing) for right output shaft or for right flange shaft
........................................................................ 265
8 Adjusting shaft bevel gear and bevel gear with stub shaft (final drive gear set) . . . . . . . . 269
8.1 General notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269
8.2 Adjustment and marking of final drive gear sets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269
8.3 Position of shims . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270
8.4 Adjustment overview - bevel box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270
8.5 Recommended sequence for new adjustment of final drive gear set . . . . . . . . . . . . . . . . . . 271
8.6 Determining shim "S4" thickness when renewing output flange . . . . . . . . . . . . . . . . . . . . 271
8.7 Adjusting shaft bevel gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272
8.8 Adjusting bevel gear (with stub shaft) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277
Contents iii
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
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iv Contents
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
00 – Technical data
1 Gearbox identification
The 5-speed manual gearbox 02C, four-wheel drive is installed in
the Golf 4MOTION 1999 ▸ and the Bora 4MOTION 1999 ▸ in
conjunction with a 4-cylinder engine.
Allocation ⇒ page 1 .
1.1 Location on gearbox
Codes and production date of gearbox -arrow 1-
Manual gearbox 02C, four wheel drive -arrow 2-
Manual gearbox 02C, four wheel drive
Manual gearbox 02C, four wheel drive -arrow 2- agen
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1.2 Codes and production dates of gearbox
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Example: EAG 15 10 8
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I I I I
Identification Day Month Year -1998-
code of manufacture
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Additional data depend on manufacture.
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1.3 Identification code, assembly allocation, ratios, capacities
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Manual gearbox 5 speed 02C, four wheel drive
Identification code EAG EAH ERW
Manufactured from 10.98 10.98 01.00
to 08.00 08.00 08.00
1. Gearbox identification 1
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
Manual gearbox 5 speed 02C, four wheel drive
Identification code EAG EAH ERW
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Allocation Model Golf 4MOTIONlk1999 swa 4MOTION 1999oes
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Engine 1.9 l - 66 kW 1.8 l - 92 kW 2.0 l - 85 kW
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turbo diesel 2.0 l - 88 kW
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Ratio: Z2 : Z1 Final drive erm 62 : 17 = 3.647 72 : 17 = 4.235 64 : 15 = 4.267
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1st gear 34 : 9 = 3.778 34 : 9 = 3.778 34 : 9 = 3.778
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2nd gear 33 : 16 = 2.063 33 : 16 = 2.063 33 : 16 = 2.063
h re
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spec
3rd gear 34 : 26 = 1.308 34 : 25 = 1.360 34 : 25 = 1.360
es, in part or in w
t to the co
4th gear 33 : 36 = 0.917 35 : 34 = 1.029 35 : 34 = 1.029
5th gear 33 : 46 = 0.717 36 : 43 = 0.837 31 : 38 = 0.816
6th gear - - -
rrectness of i
Reverse gear 18 : 9 x 36 : 20 = 3.600 18 : 9 x 36 : 20 = 3.600 18 : 9 x 36 : 20 = 3.600
l purpos
Speedometer 13 : 22 = 0.591 13 : 22 = 0.591 13 : 22 = 0.591
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Identification code EAG EAH ERW
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Capacity 2.4 l
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Specification Gearbox oil G50 SAE 75W-90 (synthetic oil)
p
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Clutch operation hydraulic hydraulic hydraulic
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Clutch plate ∅ 219 mm1) 215 mm 215 mm
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Overall ratio in top gear 2.615 3.545 3.482
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Rear final drive allocation EHQ, END, EUN, EHQ, EUL, FGU, EUL, FGU, FWT
codes FGW, FWV FWT
All gearboxes can also be filled with gear oil -G 052 726 A2 SAE
75W- .
1) Dual-mass flywheel
Manual gearbox 5 speed 02C, four wheel drive
Identification code EWF EWG EWJ
Manufactured from 08.00 08.00 08.00
to 09.00 09.00 09.00
Allocation Model Golf 4MOTION 1999 Golf 4MOTION 1999 Golf 4MOTION 1999
▸ ▸ ▸
Bora 4MOTION 1999 Bora 4MOTION 1999 Bora 4MOTION 1999
▸ ▸ ▸
Engine 1.9 l - 66 kW 1.8 l - 92 kW 2.0 l - 85 kW
turbo diesel 2.0 l - 88 kW
Ratio: Z2 : Z1 Final drive 62 : 17 = 3.647 72 : 17 = 4.235 64 : 15 = 4.267
1st gear 34 : 9 = 3.778 34 : 9 = 3.778 34 : 9 = 3.778
2nd gear 33 : 16 = 2.063 33 : 16 = 2.063 33 : 16 = 2.063
3rd gear 34 : 26 = 1.308 34 : 25 = 1.360 34 : 25 = 1.360
4th gear 33 : 36 = 0.917 35 : 34 = 1.029 35 : 34 = 1.029
5th gear 33 : 46 = 0.717 36 : 43 = 0.837 31 : 38 = 0.816
6th gear - - -
Reverse gear 18 : 9 x 36 : 20 = 3.600 18 : 9 x 36 : 20 = 3.600 18 : 9 x 36 : 20 = 3.600
2 Rep. Gr.00 - Technical data
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
Manual gearbox 5 speed 02C, four wheel drive
Identification code EWF EWG EWJ
Speedometer 13 : 22 = 0.591 13 : 22 = 0.591 13 : 22 = 0.591
From 08.00 onwards, mounting of right flange shaft.
Right flange shaft and drive flange are one part.
Identification code EWF EWG EWJ
Capacity agen
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Specification db
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215 mm c 215 mm
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Drive shaft flange ∅ 100 mm 100 mm 100 mm
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Overall ratio in top gear 2.615 3.545 3.482
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Rear final drive allocation END, EUN, FGW, EUL, FGU, FWT EUL, FGU, FWT
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codes FWV
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All gearboxes can also be filled with gear oil -G 052 726 A2 SAE
75W- .
2) Dual-mass flywheel
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Manual gearbox 5 speed 02C, four wheel drive
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Identification code EWK EWL EWN
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Manufactured from 09.00 09.00 09.00
to 01.02 07.01 01.02 orm
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Allocation Model Golf 4MOTION 1999 Golf 4MOTION 1999 Golf 4MOTION 1999
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Bora 4MOTION 1999 Bora 4MOTION 1999 Bora 4MOTION 1999
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Engine 1.9 l - 66 kW 1.8 l - 92 kW 2.0 l - 85 kW
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Ratio: Z2 : Z1 yri
Final drive 62 : 17 = 3.647 72 : 17 = 4.235 64 : 15 = 4.267
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1st gear 34 : 9 = 3.778 34 : 9 = 3.778 34 : 9 = 3.778
agen
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2nd gear 33 : 16 = 2.063 33 : 16 = 2.063 33 : 16 = 2.063
3rd gear 34 : 26 = 1.308 34 : 25 = 1.360 34 : 25 = 1.360
4th gear 33 : 36 = 0.917 35 : 34 = 1.029 35 : 34 = 1.029
5th gear 33 : 46 = 0.717 36 : 43 = 0.837 31 : 38 = 0.816
6th gear - - -
Reverse gear 18 : 9 x 36 : 20 = 3.600 18 : 9 x 36 : 20 = 3.600 18 : 9 x 36 : 20 = 3.600
Speedometer 13 : 22 = 0.591 13 : 22 = 0.591 13 : 22 = 0.591
From 09.00 onwards, modified synchronisation for 1st gear and
modified selector mechanism on gearbox side
Identification code EWK EWL EWN
Capacity 2.4 l
Specification Gearbox oil G50 SAE 75W-90 (synthetic oil)
Clutch operation hydraulic hydraulic hydraulic
Clutch plate ∅ 219 mm 3)
215 mm 215 mm
1. Gearbox identification 3
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
AG. Volkswagen AG d
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Identification code EWK
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Rear final drive allocation END, EUN, FGW, EUL, FGU, FWT EUL, FGU, FWT
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3) Dual-mass flywheel
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4 Rep. Gr.00 - Technical data
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
2 Identifying rear final drive
2.1 Location on rear final drive
The final drive 02D is allocated to the 6-speed manual gearbox
02C, four-wheel drive.
Allocation ⇒ page 5
In the vicinity of the oil fill plug
Near connector for Haldex coupling
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Example: DTW 16 10 8
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I I I I
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Identification Day Month Year -1998-
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code of manufacture
Additional data depend on manufacture.
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Identification code END 4)
EHQ EUL
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Allocation Model Golf 4MOTION 1999 Golf 4MOTION 1999 Golf 4MOTION 1999
▸ ▸ ▸
Bora 4MOTION 1999 Bora 4MOTION 1999 Bora 4MOTION 1999
▸ ▸ ▸
2. Identifying rear final drive 5
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
Rear final drive 02D
Identification code END 4)
EHQ EUL
Engine 1.9 l - 66 kW
1.8 l - 92 kW 1.8 l - 92 kW
turbo diesel
2.0 l - 85 kW
2.0 l - 88 kW
Ratio: Z2 : Z1 Front and rear 17 : 27 x 27 : 17 = 1.00 17 : 27 x 27 : 17 = 1.00 17 : 27 x 27 : 17 = 1.00
bevel gears
Final drive capacity 1.0 l
Specification Gear oil -G 052 145 A SAE 75W-90- (synthetic oil)
Haldex coupling capacity 0.42 l
Haldex coupling change capacity 0.25 l
Specification High-performance oil for Haldex coupling -G 052 175 A1-
Drive shaft flange ∅ 100 mm 100 mm 100 mm
Manual gearbox allocation EAG, EWF, EWK EAG, EAH EAH, ERW, EWG,
codes EWJ, EWL, EWN
4) Reinforced dished spring in Haldex coupling
From 05.99, changed control unit for Haldex coupling.
Rear final drive 02D
Identification code EUN 5) FGU FGW 5)
Manufactured from 05.99 02.01 02.01
to 02.01 05.01 05.01
Allocation Model Golf 4MOTION 1999 Golf 4MOTION 1999 Golf 4MOTION 1999
▸ ▸ ▸
Bora 4MOTION 1999 Bora 4MOTION 1999 Bora 4MOTION 1999
▸ ▸ ▸
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Engine
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1.9 l - 66 dkW
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Specification Gear oil -G 052 145 A SAE 75W-90- (synthetic oil)
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Haldex coupling capacity 0.42 l
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Haldex coupling change capacity 0.25 l
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Specification High-performance oil for Haldex coupling -G 052 175 A1-
es, in part or in w
t to the co
Drive shaft flange ∅ 100 mm 100 mm 100 mm
Manual gearbox allocation EAG, FWF, EWK EAH, ERW, EWG, EAG, EWF, EWK
codes EWJ, EWL, EWN
rrectness of i
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5) Reinforced dished spring in Haldex coupling
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From 05.99, changed control unit for Haldex coupling.
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From 02.01, changes in materials on Haldex coupling.
com
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Identification code FWT FWV 6)
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6 Rep. Gr.00 - Technical data
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
Rear final drive 02D
Identification code FWT FWV 6)
Allocation Model Golf 4MOTION 1999 Golf 4MOTION 1999
▸ ▸
Bora 4MOTION 1999 Bora 4MOTION 1999
▸ ▸
Engine 2.0 l - 85 kW 1.9 l - 66 kW
n AG. Volkswagen A
2.0 l - 88 kW olkswage turbo diesel G does no
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Ratio: Z2 : Z1 Front and rear 17 : 27 x 27 : i17se = 1.00 17 : 27 x 27 : 17 = 1.00
db ara
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bevel gears ut
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Final drive capacity ss 1.0 l c
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Specification Gear oil -G 052 145 A SAE 75W-90- (synthetic oil)
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Haldex coupling capacity 0.42 l
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Haldex coupling change capacity 0.25 l
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Specification High-performance oil for Haldex coupling -G 052 175 A1-
h re
hole
Drive shaft flange ∅ 100 mm 100 mm
spec
es, in part or in w
Manual gearbox allocation EAH, ERW, EWG, EAG, EWF, EWK
t to the co
codes EWJ, EWL, EWN
rrectness of i
6) Reinforced dished spring in Haldex coupling
l purpos
From 05.01, modified housing for Haldex coupling and modified
cover for oil reservoir of Haldex coupling.
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2. Identifying rear final drive 7
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
n AG. Volkswagen AG do
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3 Overview - power transmission
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Designation auth or
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-Arrows- point in direction of travel.
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1 - Engine
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2 - Clutch
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3 - Manual gearbox
spec
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4 - Input shaft
t to the co
5 - Output shaft
6 - Differential
rrectne
7 - Bevel box
ss o
8 - Propshaft
cial p
f inform
9 - Haldex coupling
mer
atio
m
10 - Rear final drive
o
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11 - Differential
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Ratio
-Arrows- point in direction of travel.
8 Rep. Gr.00 - Technical data
Bora 1999 ➤ , Golf 1998 ➤
AG. Volk5-speed
swagen AGmanual gearbox 02C, four-wheel drive - Edition 01.2010
agen does
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I - 1st gear d b ara
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II - 2nd gearaut ra
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III - 3rd gear
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IV - 4th gear
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V - 5th gear
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R - Reverse gear
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spec
A - Final drive
urposes, in part or in wh
t to the co
W1 - Front bevel box
W2 - Rear bevel box
rrectness o
cial p
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3. Overview - power transmission 9
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
4 Calculation of gear ratios
Example:
5th gear Final drive
Drive gear ZG1 = 37 ZA1 = 14
Driven gear ZG2 = 50 ZG2 = 69
i = ZG2 : ZG1 7)
iG = Gear ratio = ZG2: ZG1= 37 : 50 = 0.740
iA = Final drive ratio = ZG2 : ZG1 = 69 : 14 = 4.929
itotal = Overall ratio = iG x iA = 0.740 x 4.929 = 3.647
7) Z1 = No. of teeth on driving gear, Z2 = No. of teeth on driven gear
4.1 Notes on performance test
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10 Rep. Gr.00 - Technical data
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
5 General repair notes
To ensure flawless and successful gearbox repairs, the greatest
care and cleanliness as well as the use of good and proper tools
are essential. Of course, the basic rules for safety also
AG. apply
Volkswadur‐
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A number of generally applicable instructions
ris
e for the various re‐ nte
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pair procedures — which were previously repeated at numerous eo
ra
a
places in the Workshop Manualss— are summarised here. They c
apply to this workshop manual.
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Gearbox
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♦ When installing the manual gearbox, ensure that the dowel
ot p
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sleeves between the engine and gearbox are correctly seated.
, is n
h re
hole
♦ When installing mounting brackets or waxed components,
spec
clean the contact surfaces. Contact surfaces must be free of
es, in part or in w
t to the co
wax and grease.
♦ When exchanging a gearbox or bevel box, fill with gear oil.
rrectness of i
♦ Capacities and specifications ⇒ page 1 .
l purpos
♦ When changing a rear final drive, top up gearbox with gear oil
and top up Haldex coupling with oil to lower edge of filler hole.
nform
ercia
♦ Capacities and specifications ⇒ page 5 .
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at
Seals and sealing rings
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♦ Thoroughly clean joint surfaces and apply sealant AMV 188
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200 03.
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♦ Apply sealant uniformly but not too thick.
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♦ Radial oil seals. yri
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Before installing:
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Lightly oil outer diameter and half-fill space between sealing lips
-arrow- with sealing grease for radial oil seal -G 052 128 A1- .
After installation:
♦ Checking oil level in manual gearbox with bevel box
⇒ page 75 .
♦ Checking oil level in rear final drive ⇒ page 158 .
Radial oil seal for propshaft flange and shaft bevel gear on rear
final drive
♦ Lightly oil around outside circumference and between sealing
lips with high performance oil for Haldex couplings -G 052 175
A1- .
♦ After installation, check oil level in Haldex coupling
⇒ page 158 .
Locking devices
5. General repair notes 11
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
♦ Renew retaining rings.
♦ Do not overstretch retaining rings.
♦ Retaining rings must locate properly in grooves.
♦ Renew spring pins. Installation position: slot longitudinal to line
of force.
Nuts and bolts
♦ Loosen and tighten securing bolts and nuts for covers and
housings diagonally.
♦ Loosen and tighten securing bolts and nuts for covers and
housings diagonally.
♦ Torque settings are specified for unoiled bolts and nuts.
♦ Always renew self-locking bolts and nuts.
♦ Ensure with threaded connections that contact surfaces as
well as nuts and bolts are rewaxed only after assembly, if nec‐
essary.
♦ Use a thread chaser to clear residual locking fluid from all
threaded holes into which self-locking bolts are to be screwed.
Otherwise there is a danger of bolts shearing when subse‐
quently being removed.
Bearings
♦ Install new tapered roller bearings as supplied and do not lu‐
bricate additionally.
♦ Install needle bearings with lettered side (thicker metal) to‐
wards fitting tool.
♦ Tapered roller bearings fitted to one shaft must be renewed as
a set. Use same make of bearings.
♦ Heat inner races to about 100° C before installing. AG. Volkswagen AG d
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Shims ss
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♦ Measure shims at several points with a micrometer. The var‐
an
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ious thicknesses make it possible to achieve the exact shim
erm
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thickness required.
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♦ Check for burrs and damage.
is n
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ole,
♦ Install only flawless shims.
spec
urposes, in part or in wh
Synchro-rings
t to the co
♦ Do not interchange. When reusing synchro-rings, always fit to
the same synchromeshed gear.
rrectne
♦ Check for wear and renew if necessary.
ss
♦ Moisten with gear oil before installing.
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Gear wheels
form
mer
atio
♦ Before installing, clean and heat with inductive heater -VAS
om
6414- to maximum 100 °C.
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Guided fault finding, vehicle self-diagnosis and testing
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12 Rep. Gr.00 - Technical data
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
♦ Before performing repairs on the Haldex coupling, determine
the cause of the fault as accurately as possible using vehicle
diagnosis, testing and information system -VAS 5051- in
modes of operation “Guided fault finding”, “Vehicle self-diag‐
nosis” and “Test instruments”.
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5. General repair notes 13
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
30 – Clutch
1 Repairing clutch mechanism
I - Assembly overview - pedal
cluster ⇒ page 15
II - Assembly overview - hy‐
draulics ⇒ page 20
Note
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♦ Disconnect battery earth strap.
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♦ Note radio code for vehicles
ris
ed with ran
tee
coded radio. ut
ho or
a ac
ss
♦ Lubricate all bearings and con‐
ce
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nl
tact surfaces with polycarbamide
pt
du
an
grease -G 052 142 A2- .
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spec
es, in part or in w
t to the co
rrectness of i
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14 Rep. Gr.30 - Clutch
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
1.1 Assembly overview - pedal cluster
1 - Bulkhead
❑ With support for mount‐
ing bracket and master
cylinder
2 - Seal
❑ Always renew
3 - Mounting bracket
❑ For mounting clutch
pedal
4 - Bolt
5 - Mounting bracket
❑ For mounting accelera‐
tor pedal and brake ped‐
al
6 - Self-locking hexagon nut,
25 Nm agen
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7 - Connecting
ut
ho plate or
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8 - Self-locking hexagon nut,
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25 Nm
pt
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❑ Always renew
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9 - Bearing bush
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10 - Pivot pin
hole
spec
11 - Clutch pedal
es, in part or in w
t to the co
❑ Removing and installing
⇒ page 19
12 - Retainer
rrectness of i
❑ Removing and installing
l purpos
⇒ Item 4 (page 21)
13 - Self-locking hexagon nut,
nform
ercia
25 Nm
m
at
❑ Always renew
om
ion
c
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14 - Master cylinder
o
his
ate
❑ Removing and installing ⇒ page 22
do
priv
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or
15 - Supply hose
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16 - Over-centre spring C py
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❑ Removing and installing ⇒ page 17 p by
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17 - Over-centre spring mounting Prote AG.
❑ Insert into mounting bracket
❑ To renew master cylinder, removing and installing ⇒ page 22
18 - Clutch pedal switch -F36-
❑ Distinguishing ⇒ page 16
❑ Removing and installing clutch pedal switch with rectangular housing ⇒ page 16
❑ Removing and installing clutch pedal switch with round housing ⇒ page 17
19 - Stop
❑ For clutch pedal
1. Repairing clutch mechanism 15
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
❑ Installation position ⇒ page 25
20 - Self-locking hexagon nut, 25 Nm
❑ Always renew
1.2 Distinguishing between clutch pedal
switches -F36-
-A- = clutch pedal switch with rectangular housing -arrow-
– Removing and installing ⇒ page 16
-B- = clutch pedal switch with round housing -arrow-
– Removing and installing ⇒ page 17
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1.3 Removing and installing clutch pedal
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switch -F36- with rectangular housing
h re
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spec
To ensure sufficiently secure seating in mounting bracket for
urposes, in part or in wh
clutch pedal, clutch pedal switch -F36- may be installed only once.
t to the co
1.3.1 Removing
rrectne
– Remove driver side footwell cover ⇒ General body repairs,
interior; Rep. Gr. 68 ; Compartments, covers and trims .
ss
– Pull connector off clutch pedal switch -F36- .
o
cial p
f inform
– Turn clutch pedal switch -F36- on housing 90° anti-clockwise
mer
and pull out of support.
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Note
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In some vehicles, the clutch pedal switch -F36 - must be turned
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90° to the right to be removed. There are different notches for the
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1.3.2 Installing new clutch pedal switch
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– Pull out plunger to stop.
– Push down clutch pedal by hand as far as possible.
– Place clutch pedal switch in mounting and turn 90° to right.
16 Rep. Gr.30 - Clutch
AG. Volkswagen AG d
agen oeBora
s no 1999 ➤ , Golf 1998 ➤
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5-speed ed manual gearbox 02C, four-wheel drive
b ara - Edition 01.2010
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Note
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In some vehicles, the clutch pedal switch -F36 - must be turned
erm
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ility
90° to the left to be removed. There are different notches for the
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clutch pedal switch in the support on the mounting bracket.
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spec
– Release clutch pedal. es, in part or in w
t to the co
Clutch pedal must be in end position.
– Install driver side footwell cover ⇒ General body repairs, in‐
rrectness of i
terior; Rep. Gr. 68 ; Compartments, covers and trims .
l purpos
1.4 Removing and installing clutch pedal
switch -F36- with round housing
nform
ercia
To ensure sufficiently secure seating in mounting bracket for
m
at
clutch pedal, clutch pedal switch -F36- may be installed only once.
om
ion
c
in t
r
1.4.1 Removing
o
his
ate
do
riv
– Remove driver side footwell cover ⇒ General body repairs,
p
cum
or
interior; Rep. Gr. 68 ; Compartments, covers and trims .
f
en
ng
t.
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– Pull connector -1- off clutch pedal switch -F36- .
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– Turn clutch pedal switch -F36- -2- on mounting bracket 45° co Vo
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anti-clockwise and pull out of support.
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Note
The clutch pedal remains in rest position (do not depress).
1.4.2 Installing new clutch pedal switch
Distinguishing between clutch pedal switches
Clutch pedal switch
-A- = “without light dome” on • Pull plunger out fully prior to
plunger head -arrow- installation.
-B- = “with light dome” on plung‐ • Plunger is not allowed to be
er head -arrow- pulled out.
• Clutch pedal -4- (⇒ previous figure) must be in rest position.
– Guide clutch pedal switch -F36- through access hole, press
against clutch pedal and secure by turning 45° to right.
– Push connector onto clutch pedal switch -F36- .
– Install driver side footwell cover ⇒ General body repairs, in‐
terior; Rep. Gr. 68 ; Compartments, covers and trims .
1.5 Removing and installing over-centre
spring
Special tools and workshop equipment required
1. Repairing clutch mechanism 17
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
♦ Assembly clip -T10111-
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Additional required information
t to the co
♦ Workshop Manual Golf 1998 ▸, Bora 1999 ▸ General body
repairs, interior
rrectness of i
Removing
l purpos
– Remove lower cover on driver side. ⇒ Body Repairs; Rep. Gr.
70 ; Interior; Repair group 70; Dash panel; Removing and in‐
nform
ercia
stalling dash panel
m
at
– Fit assembly clip -T10111- onto over-centre spring from right.
om
ion
c
in t
r
– Ensure that the assembly clip is seated correctly on over-cen‐
o
his
te
tre spring:
a
do
priv
cum
or
1 - The rear part of assembly clip must be positioned on the over-
f
en
ng
centre spring so that the claws fit over extension -1-.
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2 - Press clutch pedal lightly towards the bulkhead panel.
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– Hook the lug -2- of assembly clip into cut-out of over-centre
by
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spring.
AG.
– Now press clutch pedal as far as possible towards bulkhead
panel until the over-centre spring can be removed downwards
from mountings on bearing bracket and clutch pedal.
– Bring clutch pedal to rest position.
– Turn over-centre spring together with assembly clip -T10111-
in -direction of arrow A- and take out downwards in
-direction of arrow B-.
Installing
– Pull clutch pedal into passenger compartment.
18 Rep. Gr.30 - Clutch
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
– Insert over-centre spring together with assembly clip -T10111-
upwards in -direction of arrow A- into bearing bracket and then
turn in -direction of arrow B-.
– Insert over-centre spring into rear mounting first -arrow A-.
– Press clutch pedal towards bulkhead panel until the over-cen‐
tre spring seats on the mounting lug -arrow B- of clutch pedal.
– Bring clutch pedal to rest position and simultaneously remove
assembly clip.
– Remove driver's side lower cover. ⇒ Body Repairs; Rep. Gr.
70 ; Interior; Repair group 70; Dash panel; Removing and in‐
stalling dash panel
1.6 Removing and installing clutch pedal
Special tools and workshop equipment required n AG. Volkswagen AG do
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♦ Release tool -3309- ir se
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spec
es, in part or in w
t to the co
rrectness of i
♦ Pliers -10 - 208 A-
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at
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ate
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Removing
AG.
– Remove over-centre spring ⇒ page 17 .
– Separate clutch pedal from master cylinder ⇒ page 22 and
push operating rod towards engine compartment to stop.
1. Repairing clutch mechanism 19
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
– Remove nut -A-.
– Pull bolt out until clutch pedal can be removed.
Installing
Install in the reverse order of removal, observing the following:
– Install over-centre spring ⇒ page 17 .
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– The retainer -A- must be fitted to the master cylinder operating
an
d
itte
rod -B-.
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pe
ility
– Press clutch pedal in direction of arrow until it engages, en‐
ot
suring that it is correctly located.
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, is n
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hole
– Fill brake fluid reservoir up to “MAX” marking with brake fluid
spec
⇒ Brake systems; Rep. Gr. 47 .
es, in part or in w
t to the co
– Bleed clutch system when fluid level is below “MIN” marking
⇒ page 25 .
rrectness of i
l purpos
nform
ercia
1.7 Assembly overview - hydraulic system
m
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tion in
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20 Rep. Gr.30 - Clutch
AG. Volkswagen AG d
agen oes Bora 1999 ➤ , Golf 1998 ➤
olksw not
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ed5-speed manual gearbox 02C, four-wheel
b ara drive - Edition 01.2010
ris nte
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1 - Brake fluid reservoir au ra
c
ss
ce
le
2 - Supply hose
un
pt
an
d
itte
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3 - Master cylinder
rm
ab
pe
ility
❑ Removing and installing
ot
wit
⇒ page 22 , is n
h re
hole
4 - Retainer
spec
es, in part or in w
❑ Renew only with master
t to the co
cylinder removed
❑ Removing ⇒ page 22
rrectness of i
❑ Pressing on
⇒ page 22
l purpos
5 - Clutch pedal
❑ Removing and installing
nform
ercia
⇒ page 19
m
a
com
ti
6 - Self-locking hexagon nut,
on in
25 Nm
r
te o
thi
s
iva
❑ Always renew
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❑ Qty. 2
fo
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7 - O-ring . Cop py
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❑ Always renew rig ht
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❑ Pull onto line connection
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❑ Moisten with brake fluid
before installing
8 - Pipe/hose line
❑ Assign according to
electronic parts cata‐
logue
9 - Bracket
❑ Secured to body
10 - Dust cap
11 - Bleeder valve
❑ Bleeding clutch system ⇒ page 25
12 - Slave cylinder
❑ Remove the following components before removing slave cylinder:
❑ Gear selector cable from gearbox selector lever ⇒ page 48
❑ Relay lever and actuating arm for gate selector cable ⇒ page 43
❑ After installing, adjust selector mechanism ⇒ page 53
13 - Flange bolt, 20 Nm
14 - Gearbox
15 - Clip
❑ Pull out clip to stop to remove and install pipe/hose line
16 - O-ring
❑ Always renew
❑ Pull onto line connection
❑ Moisten with brake fluid before installing
17 - Cable support bracket
18 - Bracket
❑ Attach to cable support bracket
1. Repairing clutch mechanism 21
Bora 1999 ➤ , Golf 1998 ➤ agen
AG. Volkswagen AG d
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5-speed manual gearbox 02C, four-wheel drive - Edition
b y V 01.2010
ol
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19 - Clip au
th or
ac
ss
❑ Pull out clip to stop to remove and install pipe/hose line
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Lever off retainer -A- in direction of arrow.
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spec
es, in part or in w
t to the co
rrectness of i
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ercia
orm
m
atio
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Press master cylinder operating rod in retainer -A- (direction of
o
n in
c
arrow)
or
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te
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1.8 Removing and installing master cylinder
Special tools and workshop equipment required
♦ Release tool -3309-
♦ Pliers -10 - 208 A-
22 Rep. Gr.30 - Clutch
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
Additional required information
♦ Workshop Manual Golf 1998 ▸, Bora 1999 ▸ General body wage
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repairs, interior yV
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Removing thoris e or
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– Remove intake hose -1-, connector -2- and hose -3- from air
ss
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mass meter.
nl
pt
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– Remove complete air filter housing by removing bolts -4- and
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-5- ⇒ Rep. Gr. 24 ; Servicing injection system .
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es, in part or in w
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– Pull supply hose -A- off brake fluid reservoir and seal.
nf
ercia
– Pull clip -B- for pipe/hose line out of master cylinder.
orm
m
– Pull pipe/hose line -C- out of master cylinder and seal.
atio
om
n in
c
– Remove lower cover on driver side. ⇒ Body Repairs; Rep. Gr.
or
thi
e
70 ; Interior; Repair group 70; Dash panel; Removing and in‐
t
sd
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stalling dash panel
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– Now remove complete clutch pedal mounting bracket as fol‐
lows:
– Unbolt connecting plate -A- first -arrows 1-.
– Then unbolt securing nuts -arrows 2- for mounting bracket
-B-.
– Remove mounting bracket.
1. Repairing clutch mechanism 23
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
Release master cylinder operating rod from clutch pedal as fol‐
lows:
– Insert clip -3309- in notch of clutch pedal -arrows A-. The let‐
tering “top/oben” -B- faces away from clutch pedal.
– Press clip together with pliers -10 - 208 A- in recesses agen
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– Turn stop -A- for clutch pedal in direction of arrow and remove.
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urposes, in part or in wh
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cial p
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– Then push slave cylinder first in direction of arrow 1 onto stop.
i
or
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It must not be covered in upper area by over-centre spring mount‐
iv
o
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ing -arrow 2-.
um
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fo
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ng
t.
– Then swing it in direction of arrow 3 out of mounting bracket.
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Install in the reverse order of removal, observing the following: Prote
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– The retainer -A- must be fitted to the master cylinder operating
rod -B-.
– Pull piston rod out of master cylinder slightly and hold using
pliers.
– At the same time, press clutch pedal in direction of arrow until
it engages, ensure that it locks properly.
24 Rep. Gr.30 - Clutch
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
– Fit stop -A- for clutch pedal again.
Installation position:
The retaining clip -arrow- points towards master cylinder -B-.
– Bleed clutch system after installing master cylinder
⇒ page 25 .
1.9 Bleeding clutch system
Special tools and workshop equipment required
♦ Brake filling and bleeding equipment -V.A.G 1869-
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– Brake fluid specifications ⇒ Brake systems; Rep. Gr. 47 ;
, is n
h re
Brake, brake hydraulics .
hole
spec
– To bleed system, use 670 mm long bleeder hose -V.A.G 1238/
es, in part or in w
t to the co
B- 3 if necessary.
– Connect bleeder hose to collector bottle of brake bleeding
equipment.
rrectness of i
– Connect bleed hose to slave cylinder -B- and open bleed
l purpos
valve.
– Depress clutch pedal several times after completion of bleed‐
nf
ercia
ing process.
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1. Repairing clutch mechanism 25
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
2 Repairing clutch release mechanism
2.1 Assembly overview clutch release
mechanism
Special tools and workshop equipment required
♦ Torque wrench -V.A.G 1331-
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1 - Gearbox d byV
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2 - Ball stud, 25 Nm utho
or
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❑ Lubricate with MoS2 ss
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grease.
un
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3 - Input shaft seal
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❑ Renewing
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⇒ Item 13 (page 95)
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4 - Guide sleeve spec
es, in part or in w
❑ With vulcanised or bon‐
t to the co
ded O-ring
❑ If O-ring is damaged or
has come loose, renew
rrectness of i
guide sleeve and O-ring
together
l purpos
❑ Lubricate guide sleeve
in area of release bear‐
nform
ercia
ing with MoS2 grease.
m
a
com
ti
5 - Retaining spring
on in
r
te o
❑ Secure to clutch release
thi
s
iva
lever
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6 - Socket head bolt, 20 Nm
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❑ Self-locking t. Cop py
rig
❑ Always renew
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7 - Clutch release lever cted agen
Prote AG.
8 - Release bearing
❑ Do not wash out bear‐
ing; wipe only
❑ Renew noisy bearings
❑ Lubricate contact surfa‐
ces of release lever with
MoS2 grease.
26 Rep. Gr.30 - Clutch
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
9 - Flange bolt, 20 Nm
10 - Slave cylinder
❑ Removing and installing ⇒ Item 12 (page 21)
11 - Plunger
❑ Grease plunger head with MoS2 grease.
12 - Assembly bolt
❑ Secures clutch release lever when gearbox is installed.
❑ Remove after gearbox has been installed.
AG. Volkswagen AG d
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Note olksw not
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If assemblyut bolt
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( ⇒ Itemss12 (page 27) ) is not avail‐
a c
able, an M8 x 35 bolt can be used.
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erm
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ility
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es, in part or in w
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or
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ate
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pyri by
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Prote AG.
2. Repairing clutch release mechanism 27
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
3 Repairing clutch AG. Volkswagen AG d
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3.1 Assembly overview or eo
th
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Special tools and workshop
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equipment required
erm
ab
ility
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♦ Counterhold -3067-
wit
is n
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♦ Centring mandrel -3190 A-
ole,
spec
urposes, in part or in wh
♦ Torque wrench -
V.A.G 1331-
t to the co
rrectness o
cial p
f inform
mer
atio
om
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or
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Note
♦ Before replacing the clutch and pressure plate, refer to Fault
finding, Power transmission No.9 - Defects in clutch and clutch
mechanism.
♦ Renew clutch plates and pressure plates with damaged or
loose rivets.
♦ Select clutch plate and pressure plate according to engine
code and ⇒ Electronic parts catalogue “ETKA” .
28 Rep. Gr.30 - Clutch
AG. Volkswagen AG d
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s no ➤ , Golf 1998 ➤
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V
5-speed manual ed by gearbox 02C, four-wheel drive -aEdition
ran 01.2010
ris tee
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or
1 - Flywheel ss
au ac
❑ Ensure that centring
ce
le
un
pt
pins fit tightly
an
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❑ Contact surface for
erm
ab
clutch lining must be
ility
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free of grooves, oil and
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grease
ole,
spec
❑ Removing and installing
urposes, in part or in wh
⇒ engine; Rep. Gr. 13
t to the co
2 - Clutch plate
❑ Diameter ⇒ page 1
rrectne
❑ Installation position on
dual-mass flywheel:
ss
shorter hub end -arrow-
o
cial p
f
points towards pressure
inform
plate.
mer
atio
❑ Installation position with
om
single piece flywheel:
n
c
i
or
n
spring cage faces pres‐
thi
te
sd
a
sure plate
iv
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pr
cum
❑ Centring ⇒ page 30
r
fo
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ng
t.
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❑ Lightly grease splines
Co
Cop py
t. rig
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Note
p by
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Clean input shaft splines and, on
used clutch plates, hub splines; re‐
move corrosion and apply only a
very thin coat of grease -G 000 100-
to the input shaft splines. Then
move clutch plate to and fro on input
shaft until hub moves freely on
shaft. Remove excessive grease.
3 - Pressure plate
❑ Removing and installing
⇒ page 30
❑ Check ends of diaphragm spring ⇒ page 30
Note
Pressure plates are protected
against corrosion and greased.
Clean contact surface only; other‐
wise the service life of the clutch will
be considerably reduced.
4 - Bolt
❑ Determine according to ⇒ ETKA (electronic parts catalogue)
❑ On dual-mass flywheel
❑ 13 Nm
❑ On single-piece flywheel
❑ 20 Nm
❑ Loosen or tighten diagonally and in steps
3. Repairing clutch 29
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
Centring clutch plate and removing and installing pressure plate
– Loosen or tighten bolts diagonally in stages.
– Reverse position of counterhold -3067- when removing.
AG. Volkswagen AG d
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Note Volksw
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Pressure plate contact surfaceuthand
or
clutch plate lining must make eo
full contact with flywheel. Tighten
ss a bolts diagonally and evenly to ra
c
prevent damage to the centring holes in the pressure plate hous‐
ce
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nl
ing and the centring pins in the flywheel.
pt
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erm
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ility
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Checking ends of diaphragm spring
wit
, is n
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• Wear up to half the thickness of the diaphragm spring is per‐
hole
mitted.
spec
es, in part or in w
t to the co
rrectness of i
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30 Rep. Gr.30 - Clutch
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
34 – Controls, housing
1 Connecting -VAS 5051- and select‐
ing functions
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Special tools
ise
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or tee
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♦ Vehicle
au diagnosis, testing and information system -VAS
t or
ac 5051-
ss
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♦ Diagnosis wiring -VAS 5051/1-
nform
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WARNING
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♦ During a road test, always secure testing and measuring
n
c
in t
or
equipment on the back seat.
his
ate
do
riv
♦ These devices may be operated only by a passenger dur‐
p
cum
or
ing a road test.
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Cop py
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– Remove diagnostic connection cover -1- .
p by
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– With ignition switched off, connect tester -VAS 5051- to diag‐
Prote AG.
nostic connection with diagnostic cable -VAS 5051/1- or -
VAS 5051/3- .
1. Connecting VAS 5051 and selecting functions 31
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
– Switch on tester -arrow-.
The tester is operational when it displays a picture of a car.
– Switch on ignition.
– Touch button/field for "Guided Fault Finding" on screen.
– Select one after another:
♦ Brand
♦ Model
♦ Model year
♦ Version
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♦ Engine code olks es n
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– Confirm data entered. ir se tee
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Wait until tester has read all control
ss units in vehicle.
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– Press Go to button and select “Function/component selec‐
pt
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tion” function.
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ab
ility
Now follow information given on screen to start desired functions.
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32 Rep. Gr.34 - Controls, housing
AG. Volkswagen AG d
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olksw not
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02C, four-wheel drive - Edition 01.2010
ris
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2 Electrical and electronic components
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and their locations
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2.1 Overview of electrical and electronic components and their locations
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t to the co
1 - All-wheel drive control unit
-J492-
❑ Location ⇒ page 34
rrectness of i
❑ Forms a unit together
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with oil pressure control
motor -V184- and hy‐
draulic temperature
nf
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sender -G271- .
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❑ Overview - control units
om
⇒ page 34 .
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or c
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❑ Removing and installing
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⇒ page 35
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2 - Engine control unit
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❑ Location ⇒ page 34 C py
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❑ The following signals py by
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four-wheel drive control
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unit -J492- via the data
bus:
❑ Engine speed
❑ Accelerator pedal posi‐
tion
❑ Engine torque
❑ Removing and installing
⇒ Rep. Gr. 23 ; of re‐
spective engine code or
⇒ Rep. Gr. 24 ; of re‐
spective engine code
3 - ABS control unit -J104-
❑ Location: on hydraulic
unit, on left in engine
compartment
❑ The following signals
are transmitted to the
four-wheel drive control
unit -J492- via the data bus:
❑ Rotational speeds of wheels
❑ Longitudinal acceleration
❑ Brake actuation
❑ Removing and installing ⇒ Brake system; Rep. Gr. 45
4 - Haldex coupling pump -V181-
❑ Location ⇒ page 34
❑ Can be checked using “guided fault finding” of -VAS 5051-
❑ Removing and installing ⇒ page 36
5 - Diagnostic connection
❑ Location: in centre console below operating control unit for heating and air conditioning.
6 - Brake light switch -F-
❑ Location: on brake pedal
2. Electrical and electronic components and their locations 33
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
❑ Can be checked using “guided fault finding” of -VAS 5051-
❑ Removing and installing ⇒ Brake systems; Rep. Gr. 46 ; Assembly overview - brake pedal; Removing
and installing brake pedal .
7 - Handbrake warning switch -F9-
❑ Location ⇒ page 35
❑ Can be checked using “guided fault finding” of -VAS 5051-
❑ Removing and installing ⇒ Brake systems; Rep. Gr. 46 ; Assembly overview - handbrake lever
All-wheel drive control unit -J492-
Location: control unit -arrow- is located on right front of rear final
drive.
Removing and installing ⇒ page 35
Overview - control units
One must differentiate between two types of four-wheel drive
control unit -J492- :
♦ To end of 04.99 not all control units are capable of diagnosis.
In the event of customer complaints concerning these vehi‐
cles, a complete electrical test must be carried out
⇒ page 38 .
♦ From 05.99 all control units are capable of diagnosis. This new
control unit generation can be identified only by the part num‐
ber of the control unit. In case of complaints, perform “guided
fault finding” with -VAS 5051- .
Allocation of control unit ⇒ ETKA (electronic parts catalogue)
AG. Volkswagen AG d
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Haldex coupling pump -V181- o lksw
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Location: Haldex coupling pumporis -arrow- is located on right front
e nte
eo
of rear final drive below control
aut
h
unit. ra
ss c
Removing and installing ⇒ page 36
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un
pt
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Engine control unit
rrectness of i
Location: control unit is located in plenum chamber.
l purpos
Removing and installing control unit:
⇒ Rep. Gr. 23 ; of respective engine code
nform
ercia
⇒ Rep. Gr. 24 ; of respective engine code
m
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tion in
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py by
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Prote AG.
34 Rep. Gr.34 - Controls, housing
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
Handbrake warning switch -F9-
Location: switch -arrow- is located on hand brake lever.
Removing and installing handbrake warning switch
⇒ Brake systems; Rep. Gr. 46 ; Assembly overview - handbrake
lever .
2.2 Removing and installing aall-wheel
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control unit -J492-ed by Vol not
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Special tools and workshop equipment
au
tho required eo
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♦ Torque wrench -V.A.G 1331-
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t to the co
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Removing
nform
ercia
– Switch off ignition.
m
at
om
io
– Separate connector at rear final drive and pull connector out
n
c
in t
r
of retainer.
o
his
ate
do
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for
en
ng
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Cop py
t. rig
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pyri by
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co lksw
by
cted agen
Prote AG.
– Pull off connector for Haldex coupling pump -arrow 1-.
– Place drip tray under final drive.
– Remove bolts -arrows 2-.
– Remove control unit.
Installing
Install in the reverse order of removal, observing the following:
2. Electrical and electronic components and their locations 35
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
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Bora 1999 ➤ , Golf 1998 ➤ ho ris
eo
ut
5-speed manual gearbox 02C, four-wheel drive
ss a - Edition 01.2010 ra
c
ce
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nl
pt
– Renew O-rings -A- and -B-, if installed.
du
an
itte
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erm
If a seal is installed ⇒ Item 13 (page 178) , renew it.
ab
ility
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– Tighten bolts to specified torque ⇒ Item 15 (page 179) .
wit
, is n
h re
– Check oil level in Haldex coupling ⇒ page 158 .
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
2.3 Removing and installing Haldex cou‐
orm
m
pling pump -V181-
atio
om
n in
or c
Special tools and workshop equipment required
thi
te
sd
iva
♦ Torque wrench -V.A.G 1331-
o
r
rp
cu
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m
f
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
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by c lksw
cted agen
Prote AG.
♦ Multipurpose tool -VW 771-
Removing
– Switch off ignition.
– Unbolt rear propshaft with flexible coupling and vibration
damper from rear final drive -arrows- and carefully press for‐
wards ⇒ page 146 .
36 Rep. Gr.34 - Controls, housing
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
– Pull off connector for Haldex coupling pump -arrow 1-.
– Place drip tray under final drive.
– Remove bolts -arrows 2-.
– Then turn pump slightly to right.
AG. Volkswagen AG d
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– Pull out pump (direction of arrow). ss c
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un
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Installing
an
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Install in the reverse order of removal, observing the following:
rm
ab
pe
ility
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wit
, is n
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spec
es, in part or in w
t to the co
rrectness of i
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– Renew gasket -A-.
nform
ercia
– Renew O-rings -B- and -C-.
m
– Observe different diameters:
a
com
tion in
♦ ∅ O-ring -B- = 31.5 mm
r
te o
thi
s
iva
♦ ∅ O-ring -C- = 33 mm
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– Push in pump to stop.
en
ng
t.
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op
– Tighten bolts to specified torque ⇒ Item 21 (page 179) . C py
t. rig
gh ht
yri by
– Check oil level in Haldex coupling ⇒ page 158 . cop Vo
by lksw
cted agen
Prote AG.
2. Electrical and electronic components and their locations 37
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
3 Electrical check of Haldex coupling
Special tools and workshop
equipment required
♦ Hand multimeter -
V.A.G 1526 A-
♦ Vehicle diagnosis, testing
and information system -
VAS 5051-
♦ Diagnostic cable -
VAS 5051/1- or -
VAS 5051/3-
♦ Auxiliary measuring set -
V.A.G 1594 A-
AG. Volkswagen AG d
agen oes
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es, in part or in w
t to the co
rrectness of i
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Additional required information
s
iva
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♦ “Current Flow Diagrams, Electrical Fault-Finding and Fitting
um
fo
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g
Locations” folder
n
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Test steps only apply for:
. C rig
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rig by
py Vo
♦ Cars (up to 05.99) not capable of diagnosis ⇒ page 34 .
co lksw
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Prote AG.
Test preconditions
♦ Function of Haldex coupling OK; checking ⇒ page 158 .
♦ Oil level of Haldex coupling OK; checking ⇒ page 158 .
♦ All fuses according to current flow diagram OK (remove fuses
from holder to check them).
♦ Voltage supply OK (at least 10.0 V)
♦ Brake light OK
♦ Correct engine control unit and ABS control unit installed
(check coding and control unit identification numbers).
38 Rep. Gr.34 - Controls, housing
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
Overview of test steps
Component to be tested
Voltage supply to four-wheel drive control unit -J492- – Perform test step 1
Function of brake light switch -F- – Perform test step 2
Function of handbrake warning switch -F9- – Perform test step 3
Inspection of data bus cables – Perform test step 4
Function of Haldex coupling pump -V181- and – Perform test step 5
function of oil pressure control motor -V184- .
Performing electrical test. AG. Volkswagen AG d
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– Switch off ignition for all testbysteps.
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– Raise vehicle. thor eo
au ra
c
– Separate connectors on rear final drive.
s
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Note
erm
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♦ Use hand multimeter -V.A.G 1526 A- and auxiliary cables from
is n
h re
-V.A.G 1594 A- for testing.
ole,
spec
urposes, in part or in wh
♦ The correct measuring range must be selected each time be‐
t to the co
fore auxiliary cables are connected. Otherwise electronic com‐
ponents can be destroyed!
rrectness
Contact assignment of connector
o
cial p
f in
1 - Supply voltage (terminal X)
form
mer
atio
2 - Earth (terminal 31)
om
n
c
3 - Positive connection, terminal 54 (brake light, brake light switch)
or
n thi
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4 - Handbrake warning switch -F9-
iv
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pr
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fo
5 - K-wire for diagnosis
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t.
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6 - Vacant
C py
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7 - Data bus connection to engine control unit and ABS control cop Vo
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unit (CAN low).
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8 - Data bus connection to engine control unit and ABS control
unit (CAN high).
Test step 1
Check of voltage supply from four-wheel drive control unit -J492- .
– Switch to 20 V measuring range.
– Switch on ignition.
3. Electrical check of Haldex coupling 39
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
– Measure between contact 1 and contact 2 (earth) on detached
connector.
Specification: battery voltage
If specification is not obtained, repair wiring referring to current
flow diagram. ⇒ "Current Flow Diagrams, Electrical Fault-Finding
and Fitting Locations"
– Switch off ignition.
Test step 2 agen
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Check of brake light switch -F- function. ed byV gu
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– Switch to 20 V measuring range. aut
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– Switch on ignition.
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– Measure between contact 3 and contact 2 (earth) on detached
erm
ab
connector.
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Specification: less than 0.5 V
h re
ole,
– Operate brake pedal.
spec
urposes, in part or in wh
t to the co
Specification: battery voltage
If specifications are not obtained, repair wiring referring to current
flow diagram. ⇒ "Current Flow Diagrams, Electrical Fault-Finding
rrectne
and Fitting Locations"
If specifications are still not obtained, renew brake light switch -
ss o
F- ⇒ Brake systems; Rep. Gr. 46 ; Assembly overview - brake
cial p
f i
pedal; Removing and installing brake pedal .
nform
mer
Test step 3
atio
om
n
c
Check of function of handbrake warning switch -F9- .
i
or
n thi
te
sd
a
– Switch to 20 V measuring range.
iv
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pr
cum
r
fo
– Switch on ignition.
en
ng
t.
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Cop py
– Measure between contact 4 and contact 2 (earth) on detached ht. rig
rig ht
connector.
py by
co Vo
by lksw
cted agen
Specification: greater than 6 V
Prote AG.
– Apply handbrake.
Specification: less than 0.5 V
If specifications are not obtained, check wiring to dash panel in‐
sert (T32a/13) for open circuit or short circuit to positive. ⇒
"Current Flow Diagrams, Electrical Fault-Finding and Fitting Lo‐
cations"
If specifications are not obtained, check wiring from contact -
T32/1- (dash panel insert) via fuse no. 11 (5 A) to terminal 15.
If no fault can be found, renew handbrake warning switch -F9- ⇒
Brake systems; Rep. Gr. 46 ; Assembly overview - handbrake
lever .
Test step 4
Check of function of data bus wiring.
– Switch to 2 k Ω measuring range.
40 Rep. Gr.34 - Controls, housing
AG. Volkswagen AG d
agen oes
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ra Bora 1999 ➤ , Golf 1998 ➤
a
ss 5-speed manual gearbox 02C, c four-wheel drive - Edition 01.2010
ce
e
nl
pt
du
an
– Measure between contact 7 and contact 8 (earth) on detached
itte
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connector.
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ility
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Specifications: 50 … 70 70 Ω
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If specification is not obtained
hole
spec
– Check data bus wiring according to current flow diagram for
es, in part or in w
t to the co
open circuit or short circuit or improper routing. To do this, pull
off multi-pin connector for all control units connected to the
data bus.
rrectness of i
– Switch to 20 MΩ measuring range.
l purpos
– Perform the following resistance checks on disconnected con‐
nector of control unit -J492-:
nf
ercia
orm
m
Between contacts Specification
atio
om
n in
c
7+8 ∞Ω
or
thi
te
7+1 ∞Ω
sd
iva
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cu
8+1 ∞Ω
o
m
f
en
ng
t.
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7+2 ∞Ω
Co
Cop py
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op 8+2
yri
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ht
∞Ω
by c lksw
cted agen
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– Also check data bus wires for open circuit. Wire resistance:
maximum 1.5 Ω
If specifications are not obtained
– Repair wiring according to current flow diagram. ⇒ "Current
Flow Diagrams, Electrical Fault-Finding and Fitting Locations"
If specifications are obtained
– Reconnect multi-pin connector of all control units, read fault
memories of all control units connected to data bus and rectify
faults, if any.
Test step 5
Check of function of Haldex coupling pump -V181- and function
of oil pressure control motor -V184- .
3. Electrical check of Haldex coupling 41
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
– Join connector for four-wheel drive control unit -J492- .
– Connect vehicle diagnosis, testing and information system -
VAS 5051- ⇒ page 31 .
– Apply handbrake.
– Start vehicle.
– Operate clutch pedal and engage 1st gear.
– Drive off slowly, whereby it must be observed that rear wheels
attempt to drive against handbrake.
Note
Release clutch slowly or engine will stall.
If it is not observed that rear wheels attempt to drive against
handbrake
♦ Check 2-pin connector on Haldex coupling pump -V181- and
check wiring according to current flow diagram. ⇒ "Current
Flow Diagrams, Electrical Fault-Finding and Fitting Locations"
♦ If no fault could be found, then oil pressure control motor -
V184- is defective.
Note
The oil pressure control motor -V184- is integrated in the four-
wheel drive control unit.
If it is observed that rear wheels attempt to drive against hand‐
brake
– Operate clutch pedal and select vehicle system “03 - Brake
electronics” on -VAS 5051- .
AG. Volkswagen AG d
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– The control unit identification is displayedd biny Vfield -2- of the gu
ara
vehicle diagnosis, testing and information oris system.
e nte
eo
h
ut ra
– After the control unit has reported,s drive off again in 1st gear
s a c
with handbrake applied.
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nl
pt
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an
Only the front wheels should turn.
itte
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erm
ab
If it is still observed that the rear wheels attempt to drive against
ility
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the handbrake, then the four-wheel drive control unit is defective.
wit
, is n
h re
– Renew four-wheel drive control unit -J492- ⇒ page 35 .
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
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42
by lksw
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Rep. Gr.34 - Controls, housing Prote AG.
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
4 Repairing selector mechanism
4.1 Installation position of selector
lksw
amechanism
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db ran
ir se tee
A - Gear selector cable ut
ho or
a ac
ss
B - Gate selector cable
ce
le
un
pt
an
C - Heat shield
d
itte
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rm
ab
❑ Remove before remov‐
pe
ility
ing gear selector mech‐
ot
wit
anism
, is n
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hole
Arrow -A- gear selection move‐
spec
ment
es, in part or in w
t to the co
Arrow -B- gate selection move‐
ment
rrectness of i
1 - Gearbox selector lever
l purpos
2 - Relay lever
nform
mercia
a
com
tion in
r
te o
thi
s
iva
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cum
fo
en
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t.
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Cop py
t. rig
gh ht
pyri by
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co lksw
by
cted agen
Prote AG.
4. Repairing selector mechanism 43
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
I - Removing and installing
gear knob and cover
⇒ page 45
II - Repairing gear lever and
selector housing ⇒ page 46
III - Assembly overview - re‐
moving and installing selector
cables ⇒ page 48
Removing and installing selec‐
tor mechanism ⇒ page 49
Adjust selector mechanism
⇒ page 53 .
Note
♦ Before working on the selector
mechanism, disconnect earth
strap from the battery in the en‐
gine compartment.
♦ Note radio code for vehicles with
coded radio.
AG. Volkswagen AG d
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ility
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wit
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ole,
spec
Special tools and workshop equipment required
urposes, in part or in wh
t to the co
♦ Torque wrench -V.A.G 1331-
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
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cum
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fo
en
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t.
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Cop py
t. rig
gh ht
pyri by
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co lksw
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cted agen
Prote AG.
44 Rep. Gr.34 - Controls, housing
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
♦ Pliers -V.A.G 1275-
AG. Volkswagen AG d
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4.2 Removing and installing gear knob and cover
an
itte
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ility
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1 - Gear knob
, is n
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❑ Remove and install to‐
hole
spec
gether with cover
es, in part or in w
t to the co
2 - Cover
❑ Separating from gear
knob ⇒ page 46
rrectness of i
❑ Connecting to gear
l purpos
knob before installing
⇒ page 46
nform
ercia
❑ Remove and install to‐
gether with gear knob
m
at
om
io
3 - Clamp
n
c
in t
or
his
e
4 - Clamp
at
do
priv
❑ To secure gear knob on
cum
for
gear lever
en
ng
t.
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op
❑ Secure to gear knob C py
t. rig
⇒ Item 1 (page 45) using gh ht
yri by
pliers -V.A.G 1275- . cop Vo
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5 - Frame
4. Repairing selector mechanism 45
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
Separating cover from gear knob and assembling with gear knob
– Turn cover inside out.
– Carefully lever off clamping sleeve -arrow- with a screwdriver
while pulling gear knob out.
Installation is carried out in the reverse sequence. When doing
this, note the following:
– Insert gear knob in cover.
– Push clamping sleeve onto gear knob and engage.
– Install gear knob and cover together.
4.3 Repairing gear lever and selector hous‐
ing
Note
Lubricate bearing positions and sliding surfaces with polycarba‐
mide grease -G 052 142 A2- .
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1 - Securing clip orise nte
th eo
❑ Removing and installing s au ra
c
⇒ page 47 s
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2 - Bush
an
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3 - Compression spring
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4 - Bush
, is n
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hole
5 - Torx bolt, 5 Nm
spec
es, in part or in w
6 - Cover
t to the co
7 - Damping
rrectness of i
8 - Ball socket
l purpos
9 - Gear lever guide
10 - Damping washer
nf
ercia
o
11 - Seal
rm
m
atio
❑ Between selector hous‐
om
n in
ing and underbody
or c
thi
e
❑ Self-adhesive
t
sd
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❑ Bond to selector hous‐
cu
o
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f
ing
en
ng
t.
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op
12 - Bolt, 25 Nm
C py
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13 - Bracket cop Vo
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❑ Secured to body
Prote AG.
14 - Hexagon nut, 25 Nm
❑ For bracket on body.
46 Rep. Gr.34 - Controls, housing
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
15 - Selector lever
16 - Damping
17 - Selector lever housing
18 - Bearing bush
19 - Pivot pin
20 - Guide bush
21 - Compression spring
❑ Installing ⇒ page 48
22 - Gate selector lever
23 - Torx bolt, 5 Nm
24 - Base plate
❑ Bend open tabs to remove
❑ Renew
25 - Gate selector cable
❑ On gate selector lever agen
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❑ Installation position ⇒ page 43 d by V gu
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rise nte
26 - Gear selector cable utho eo
ra
a c
❑ Press onto gear lever guide ss
ce
le
un
❑ Installation position ⇒ page 43
pt
an
d
itte
y li
27 - Securing clip
erm
ab
ility
ot p
28 - Hexagon nut, 25 Nm
wit
is n
h re
29 - Bearing bush
ole,
spec
urposes, in part or in wh
❑ Fits in one position only
t to the co
30 - Securing clip
rrectne
Removing and installing securing clip
ss
– To remove or install securing clip, pull selector lever in direc‐
o
cial p
f
tion of arrow -A- and at same time push down spacer bush in
inform
direction of arrow -B- to stop using screwdriver.
mer
atio
om
n
c
i
Note
or
n thi
te
sd
iva
o
r
♦ Do not cant spacer bush when pushing down.
p
cum
r
fo
en
ng
♦ Slot in gear lever for securing clip must be visible.
t.
yi Co
Cop py
t. rig
♦ Carefully release tension from spring. opyri
gh by
Vo
ht
c by lksw
cted agen
Prote AG.
4. Repairing selector mechanism 47
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
Installing compression spring n AG. Volkswagen AG do
lk swage es n
– Insert compression spring so that by V extension -A- lies under‐
o ot g
ua
neath pin -arrow-. ir se
d ran
tee
tho
u or
– Then pull extension -B-
ss
ato selector lever so that it sits on top ac
of pin -arrow-.
ce
le
un
pt
an
d
itte
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erm
ab
ility
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wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
4.4 Assembly overview - removing and in‐
stalling selector cables
rrectness
Note
o
cial p
f inform
Lubricate all mountings and sliding surfaces with polycarbamide
mer
atio
grease part no. G 052 142 A2.
om
n
c
i
or
n thi
te
sd
va
1 - Gear selector cable
i
o
pr
cum
r
fo
❑ Press onto gear lever
en
ng
t.
yi
guide
Co
Cop py
. rig
❑ Installation position
t
gh ht
yri by
⇒ page 43 cop Vo
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2 - Gate selector cable
AG.
❑ On gate selector lever
❑ Installation position
⇒ page 43
3 - Securing clip
4 - Securing clip
❑ Do not damage cables
when removing
5 - Selector lever housing
6 - Cable support bracket
7 - Grommet
❑ Cable support bracket
mounting on gearbox
8 - Spacer
9 - Hexagon bolt, 25 Nm
❑ For cable support brack‐
et
10 - Cable end-piece
❑ For gate selector cable
to relay lever
❑ Renew after removing
from relay lever
⇒ Item 14 (page 49)
❑ From 01.01 with end-to-
end holes
❑ From this date, not nec‐
essary renew
48 Rep. Gr.34 - Controls, housing
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
❑ Secured with securing clip
❑ Removing and installing ⇒ page 49
11 - Cable end-piece
❑ For gear selector cable to gearbox selector lever
❑ Renew after removing from gearbox selector lever ⇒ Item 16 (page 49)
❑ From 01.01 with end-to-end holes
❑ From this date, not necessary renew
❑ Secured with w securing
agen
AG. Vclip
olkswagen AG
does
o lks not
❑ Removing db
y V and installing ⇒ page 49 gu
ar
e an
ris tee
12 - Securing
ut
ho clip or
a ac
ss
13 - Bearing bush
ce
le
un
pt
an
14 - Relay lever
d
itte
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rm
ab
❑ Installation position ⇒ page 49
pe
ility
ot
15 - Shoe
wit
, is n
h re
hole
16 - Gearbox selector lever
spec
es, in part or in w
❑ With damper weight
t to the co
❑ Install so that master spline aligns with selector shaft
❑ After installing, adjust selector mechanism ⇒ page 53
rrectness of i
❑ Installation position ⇒ page 49
l purpos
17 - Self-locking hexagon nut, 20 Nm
❑ Always renew
nform
mercia
a
com
tio
Installation position of gearbox selector lever/relay lever
n in
r
te o
thi
1 - Gearbox selector lever
s
iva
do
r
rp
- With damper weight
um
fo
en
ng
t.
yi
2 - Relay lever
Co
Cop py
t. rig
- Locates in guide rail of gearbox selector lever via shoe -arrow-.
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
4.5 Removing and installing selector mech‐
anism
Additional required information
♦ Workshop Manual Golf 1998 ▸, Bora 1999 ▸ Engine, mechan‐
ics
4. Repairing selector mechanism 49
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
Removing
Selector mechanisms through 12.00
– Only if the gear selector cable, the gate selector cable or the
cable end piece is to be renewed, may the cable end piece
-A- or -B- be levered out with 13 mm open jaw spanner -1-
If the above-named parts are not to be renewed
AG. Volkswagen AG d
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nl
pt
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an
itte
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erm
ab
– Pull locking mechanisms on gate selector cable and gear se‐
ility
ot p
lector cable forward to stop -direction of arrow 1- and then turn
wit
, is n
to left to lock -direction of arrow 2-.
h re
hole
spec
Selector mechanisms from 01.01
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
m
– Remove securing clip -3- for gear selector cable from gearbox
o
n in
c
selector lever -1-.
or
thi
te
sd
a
– Remove securing clip -4- for gate selector cable from relay
iv
o
r
rp
cu
lever -2-.
o
m
f
en
ng
t.
yi
– Pull gate selector cable and gear selector cables off pins
Co
op py
-arrows-. t. C rig
gh ht
pyri by
Continued for all selector mechanisms
co Vo
by lksw
cted agen
Prote AG.
– Remove cable support bracket from gearbox -arrows-, if nec‐
essary unclip hoses on cable support bracket first.
50 Rep. Gr.34 - Controls, housing
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
– Carefully lever cover off centre console -arrows-.
– Pull cover to rear off centre console.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
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aut ra
ss c
ce
le
un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectne
– Then destroy clamp -arrow- and pull off gear knob with cover.
– Remove rubber cover, if fitted.
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
Vo
– Now remove front securing nuts for selector housing
co lksw
by
cted agen
-arrows-. Prote AG.
4. Repairing selector mechanism 51
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
– Then remove rear securing nuts -arrows- for selector housing.
– Remove cross member below exhaust system.
– Separate front exhaust system behind front pipe and remove
with catalytic converter (2nd mechanic) ⇒ Rep. Gr. 26 ; Re‐
moving and installing parts of exhaust system .
– Now remove rear and front heat shield.
– Remove propshaft ⇒ page 146 .
– Swing selector housing down and remove with selector ca‐
bles.
Installing
n AG. Volkswagen AG do
wage
Install in the reverse order of removal, observing the following: olks es n
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byV ua
d ran
Selector mechanisms through 12.00 ir se tee
tho
u or
a ac
ss
ce
le
Note un
pt
an
d
itte
y li
erm
If cable locking mechanisms have been removed, they must be
ab
ility
renewed.
ot p
wit
is n
h re
ole,
spec
– Spread a small amount of polycarbamide grease -G 052 142
urposes, in part or in wh
A2- in recesses of cable locking mechanisms -A- and -B-.
t to the co
Note
rrectne
The seals -arrows- outside the recess must be free of grease.
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
– Press gear selector cable onto gearbox selector lever and gate
cum
r
fo
selector cable onto relay lever -arrows-.
en
ng
t.
yi Co
op
If cable end-pieces were not removed:
C py
t. rig
gh ht
yri by
– Connect gear selector cable and gate selector cable to re‐ cop Vo
by lksw
cted
spective cable end-pieces.
agen
Prote AG.
Selector mechanisms from 01.01
Note
Cable end-pieces are equipped with holes for securing them to
gearbox selector lever or relay lever.
The holes in the cable end-pieces have different diameters.
52 Rep. Gr.34 - Controls, housing
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
Allocation
Cable end-piece for Dimension “a”
Gear selector cable to gearbox selector lever 10 mm
Gate selector cable to relay lever 8 mm
The cable end-pieces no longer need to be renewed after being
dismantled.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
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ed
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– Spread a small quantity of polycarbamide grease -G 052 142
ce
le
un
A2- on pins -arrows- of gearbox selector lever -1- and relay
pt
an
d
itte
lever -2-.
y li
erm
ab
– Renew securing clips -3- and -4- each time they are removed.
ility
ot p
wit
is n
– Secure gear selector cable with securing clip -3- and gate se‐
h re
ole,
lector cable with securing clip -4-.
spec
urposes, in part or in wh
Continued for all selector mechanisms
t to the co
– Align selector housing parallel to body.
• Distance to body must be same on both sides.
rrectne
Adjust selector mechanism ⇒ page 53 .
ss o
Specified torques
cial p
f inform
Selector housing to body ⇒ Item 12 (page 46) and
mer
⇒ Item 28 (page 47)
atio
om
n
c
Cross member to body ⇒ Rep. Gr. 26 ; Removing and installing
i
or
n thi
parts of exhaust system .
te
sd
iva
o
pr
Selector cable support bracket to gearbox ⇒ Item 9 (page 48)
cum
r
fo
en
ng
t.
yi Co
op
4.6 Adjusting selector mechanism
C py
ht. rig
rig ht
py by
Vo
Special tools and workshop equipment required
co lksw
by
cted agen
Prote AG.
♦ Locking pin -T10027-
4. Repairing selector mechanism 53
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
Note
♦ The following points are essential to ensure correct adjust‐
ment of selector mechanism:
♦ Moving parts of operating elements and elements transferring
force must be in proper condition.
♦ Selector mechanism must move freely.
♦ Gearbox, clutch and clutch mechanism must also be in proper
condition.
• Gearbox must be in neutral.
– Pull locking mechanisms on gate selector cable and gear se‐
lector cable forward to stop in direction of arrow -1- and then
turn to left to lock in direction of arrow -2-.
Secure selector shaft as follows:
– Press selector shaft down (direction of arrow -1-).
olkswagen AG
en AG. V
– While pressing selector shaft down, oturn
lksw locking pin -A- in di‐ es not
ag do
rection of arrow -2-. d byV gu
ara
e nte
ris
This locks the selector shaft and
au
tho it cannot be moved any more. eo
ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
– Pull the gear stick cover off the centre console -arrow-.
urposes, in part or in wh
t to the co
– Pull rubber cover towards selector lever knob, if part of original
equipment.
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
54 Rep. Gr.34 - Controls, housing
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
Now secure gear lever as follows:
– Guide locking pin -T10027- through hole -A- into hole -B-.
– Now turn locking mechanism on gear selector cable and gate
selector cable clockwise to stop (direction of arrow).
Spring presses locking mechanism into original position.
AG. Volkswagen AG d
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olksw not
– Now turn angled rod -A- backdto by original position
V gu
ara
-direction of arrow-. orise nte
eo
h
ut ra
• Bracket -A- must be horizontal.
ss a c ce
le
un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
– Pull locking pin -T10027- out of holes -A- and -B-.
rrectne
– Clip gaiter into frame.
ss
Functional check
o
cial p
f inform
• With gearbox in neutral, gear lever must rest in gate for 3rd
mer
and 4th gear.
atio
om
n
c
– Operate clutch.
i
or
n thi
te
sd
a
– Select all gears several times. Pay particular attention to op‐
iv
o
r
eration of reverse gear lock.
p
cum
r
fo
en
ng
t.
Should a gear fail to engage smoothly after repeated selection, op
yi Co
vertical play of selector shaft should be checked as follows:
C py
t. rig
gh ht
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– Engage 1st gear.
op Vo
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cted agen
Prote AG.
– Press gear lever left to stop and release.
– At the same time, a second mechanic should observe selector
shaft in gearbox.
4. Repairing selector mechanism 55
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
– When gear lever is moved, selector shaft must move approx.
1 mm (in direction of arrow).
– If this is not the case, adjust selector mechanism ⇒ page 53 .
AG. Volkswagen AG d
agen oes
olksw not
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d by ara
ise nte
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h
aut ra
ss c
ce
e
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56 Rep. Gr.34 - Controls, housing
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
5 Removing and installing gearbox
5.1 Removing
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Special tools and workshop equipment required
hole
spec
♦ Support bracket -10 - 222 A-
es, in part or in w
t to the co
♦ Rack -10 - 222 A /1-
♦ Engine and gearbox jack -V.A.G 1383 A-
rrectness of i
♦ Gearbox support -3282-
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♦ Adjustment plate -3282/18-
nf
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♦ Pin -3282/48-
orm
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♦ Mounting pin -3282/49-
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♦ Support -3282/59- (2x)
or
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Prote AG.
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
♦ Engine support -3300 A- n AG. Volkswagen AG do
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♦ Support rail -T10036- d byV ua
ran
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♦ Gearbox mounting
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support or
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-3336- ss
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♦ Torque wrench -
pt
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V.A.G 1332-
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Additional required information
♦ Workshop Manual Golf 1998 ▸, Bora 1999 ▸ Engine, mechan‐
ics
♦ Workshop Manual Golf 1998 ▸, Bora 1999 ▸, Running gear,
axles, steering front and four-wheel drive
♦ Workshop Manual Golf 1998 ▸, Bora 1999 ▸ Electrical system
Removing
– First check whether a coded radio is fitted. If so, obtain anti-
theft code.
– With ignition switched off, disconnect battery earth strap.
– Remove cover from engine.
58 Rep. Gr.34 - Controls, housing
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
– Remove intake hose -1-, connector -2- and hose -3- from air
mass meter.
– Remove complete air filter housing by removing bolts -4- and
-5- ⇒ Rep. Gr. 24 ; Servicing injection system .
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– Remove cable support bracket from gearbox -arrows-, if nec‐
ot
wit
, is n
essary unclip hoses on cable support bracket first.
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
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tion in
– Pull off gate selector cable -A- with relay lever, remove secur‐
r
te o
thi
ing clip -arrow- to do this.
s
iva
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rp
– Remove gear selector cable -B- with gearbox selector lever,
um
fo
en
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remove nut -arrow- to do this.
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– Tie up selector cable with gearbox selector lever and gate se‐
. C rig
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lector cable with relay lever. py by
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– Pull connector off speedometer sender -arrow 1-.
– Pull off reversing light connector -arrow 2-.
5. Removing and installing gearbox 59
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
– Remove slave cylinder, lay to side and secure with wire. Do
not disconnect pipes.
Note
Do not depress clutch pedal.
– Remove cable retainer -arrow 1- from starter.
– Remove wiring and cable from starter.
– Remove earth strap at upper engine/gearbox connecting bolt.
. Volkswage
– Then remove upper securing bolt -arrow
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– Remove upper engine/gearbox ise
connecting
db bolts. ua
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– If there are hose and cablea connections in area of engine sup‐
u or
ac
ss -10 - 222 A- , remove these now.
port eye for support bracket
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– Fit support bracket -10 - 222 A- in conjunction with racks -10
h re
- 222 A /1- .
hole
spec
– Take up weight of engine/gearbox assembly on spindles.
es, in part or in w
t to the co
– If present, remove wiring and cable from gearbox.
– Remove centre and left parts of noise insulation below engine
rrectness of i
and gearbox, if fitted.
l purpos
– Turn wheels to left lock.
– Disconnect drive shafts from flange shafts and tie up as high
nform
ercia
as possible, being careful not to damage surface protection.
m
at
om
– Separate exhaust system and if necessary remove from sub‐
ion
c
frame ⇒ Rep. Gr. 26 ; Removing and installing parts of
in t
or
exhaust system .
his
ate
do
riv
– Place drip tray under gearbox and engine.
p
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for
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– Unbolt turbocharger oil return line from engine -arrow- ⇒ Rep. C py
t. rig
Gr. 21 ; Charge air system with turbocharger; Removing and gh ht
yri by
installing turbocharger with ancillaries . cop Vo
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cted agen
Prote AG.
60 Rep. Gr.34 - Controls, housing
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
– Remove bevel box carrier from engine and bevel box
-arrows-.
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– If small cover plate -A-ut for flywheel behind bevel box is instal‐
ho eo
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led, remove it -arrows-.
ss a c
ce
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nl
– Remove lower flywheel cover plate, if part of original equip‐
pt
du
an
ment.
itte
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ab
– Mark position of propshaft with flexible coupling relative to
ility
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bevel box flange.
wit
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hole
spec
es, in part or in w
t to the co
rrectness of i
– Unbolt propshaft with flexible coupling from bevel box flange
l purpos
-arrows-.
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c
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– Then remove gearbox support -arrow A- from gearbox.
AG.
– Remove hexagon bolts -arrows B- of left-hand hand assembly
mounting from gearbox mounting.
– Tilt engine/gearbox assembly by lowering the left spindle of
support bracket -10 - 222 A- .
• Securing bolts -arrows- for gearbox bracket -A- must be ac‐
cessible.
5. Removing and installing gearbox 61
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
– Remove gearbox bracket -A- -arrows-.
– Remove power assisted steering line from starter and gear‐
box.
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– Bolt support rail -T10036- to both pendulum support securing
itte
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holes on subframe (bolts -A-).
erm
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– Fit engine support -3300 A- so that it almost touches subframe
wit
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and bolt on -arrows-.
h re
hole
spec
– Carefully press engine and gearbox forwards.
es, in part or in w
t to the co
Note
rrectness of i
Observe connecting lines and hoses when moving engine/gear‐
l purpos
box assembly.
nf
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o
– Remove rear lower engine/gearbox connecting bolt
rm
m
-arrow A-.
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– Remove bolt of bevel box -arrow B- to allow the mounting pin
or
thi
-3282/49- of gearbox support -3282- to engage.
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To remove gearbox 02C with bevel box, set up gearbox support
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-3282- with adjustment plate -3282/18- .
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– Align arms of gearbox support according to holes in adjust‐
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– Screw in support elements -A-, as illustrated on adjustment
plate .
Arrow symbol -B- on adjustment plate points in vehicle driving
direction.
62 Rep. Gr.34 - Controls, housing
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
– Place gearbox jack under vehicle.
– Align adjustment plate parallel to gearbox and lock safety sup‐
port on gearbox.
– Remove lower engine/gearbox connecting bolts.
– Remove starter ⇒ Rep. Gr. 27 ; Starter; Removing and in‐
stalling starter .
– Press gearbox off dowel sleeves.
– Now swing gearbox forwards -arrow-, lower slightly and set at
an angle using gearbox support -3282- so as to maintain
clearance to body and subframe.
– Then lower gearbox carefully, when doing this guide flange/
bevel box -A- past support device for engine -3300 A- . agen AG. Volkswagen AG doe
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– Lower gearbox observing subframe -arrow-. t to the co
– When lowering gearbox, change position of gearbox using
rrectne
spindles of gearbox support -3282- .
ss
Note
o
cial p
f inform
Observe power assisted steering line when lowering gearbox.
mer
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5. Removing and installing gearbox 63
AG. Volkswagen AG d
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Bora 1999 ➤ , Golf 1998 ➤ Vol
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5-speed manual gearbox 02C,
rised four-wheel drive - Edition 01.2010 ran
t ee
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5.2 Transporting gearbox ss
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le
un
pt
– Bolt gearbox lifting tackle -3336- to clutch housing.
an
d
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es, in part or in w
t to the co
rrectness of i
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– Adjust support beam on sliding piece using locking pin
-arrow-.
m
a
com
tion in
No. of holes visible = 10
r
te o
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– Lift gearbox using workshop crane and gearbox lifting tackle
s
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do
-3336- .
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– Set gearbox down.
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5.3 Installing
64 Rep. Gr.34 - Controls, housing
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
Note
♦ Before installing gearbox press clutch release lever towards
gearbox housing and secure with assembly pin, assembly bolt
or M8 x 35 bolt. Remove after gearbox has been installed. The
hole will then be sealed by the 3rd cable support bracket se‐
curing bolt or plugged.
♦ When replacing gearbox, the senders for speedometer (Fig.),
gear selector and relay lever must be transferred to new as‐
sembly.
– Clean input shaft splines and lightly grease with grease -G 000
100- .
The clutch plate must slide easily to and fro on the input shaft.
– Check whether dowel sleeves for aligning engine and gearbox
are fitted in cylinder block and install if necessary.
– Ensure that intermediate plate, if present, is correctly seated
on engine.
– Bolt support rail -T10036- to both pendulum support securing
holes on subframe -arrows-.
– Fit engine support -3300 A- so that it almost touches subframe
and bolt on -arrows-.
– Press engine forward carefully.
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Observe power assisted steeringised b
line. ara
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To install gearbox 02Cs with bevel box, set up gearbox support
s c
ce
-3282- with adjustment plate -3282/18- .
e
nl
pt
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itte
– Align arms of gearbox support according to holes in adjust‐
y li
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ab
ment plate.
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– Screw in support elements -A- as illustrated on adjustment
h re
hole
plate.
spec
es, in part or in w
Arrow symbol -B- on adjustment plate points in vehicle driving
t to the co
direction.
– Place gearbox on gearbox jack.
rrectness of i
– Align adjustment plate and gearbox parallel to each other and
l purpos
lock safety support on gearbox.
nform
mercia
at
om
ion
c
in t
or
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ate
do
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cum
for
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cted agen
Prote AG.
5. Removing and installing gearbox 65
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
– Place gearbox jack under vehicle.
– Rotate gearbox to left using spindles of gearbox support
-3282- .
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– Then raise gearbox carefully and guide past subframe
pt
du
an
-arrow-.
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spec
es, in part or in w
t to the co
rrectness of i
l purpos
– Then guide the gearbox with bevel box -A- carefully past sup‐
nform
ercia
port device for engine -3300 A- .
m
at
om
i
– Now swing gearbox to rear and bring to installation position
on
c
using gearbox mounting -3282- .
in t
or
his
ate
– Insert gearbox.
do
priv
cum
for
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Note Cop py
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Observe power assisted steering line.
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Prote AG.
– Then install starter and secure with lower bolt ⇒ Rep. Gr. 27 ;
Starter; Removing and installing starter .
– Fit bracket for power assisted steering line to starter and gear‐
box.
– Screw in lower engine/gearbox securing bolts and tighten to
specified torque ⇒ page 71 .
– Remove engine support -3300 A- -arrows-.
– Then remove bolts -A- and remove support rail -T10036- .
66 Rep. Gr.34 - Controls, housing
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
– Install rear engine/gearbox connecting bolt -arrow A- and tight‐
en to specified torque ⇒ page 71 .
– Install bevel box bolt -arrow B- ⇒ page 72 .
– Screw in upper engine/gearbox securing bolts and tighten to
specified torque ⇒ page 71 .
– Install gearbox bracket -A- using new bolts -arrows- and tight‐
en to specified torque ⇒ page 71 .
– Align engine and gearbox in installation position.
– Now install hexagon bolts -arrows- for engine mounting in right
assembly mounting ⇒ Engine; Rep. Gr. 10 ; Removing and
installing engine; assembly mounting .
– Secure power steering oil reservoir above right-hand assem‐
bly mounting.
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ab
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ility
– Install new hexagon bolts -arrows B- for left assembly mount‐
ot
wit
, is n
ing in gearbox mounting and tighten to specified torque
h re
⇒ page 71 .
hole
spec
es, in part or in w
– Then install gearbox support -arrow A- on gearbox and tighten
t to the co
to specified torque ⇒ page 71 .
WARNING
rrectness of i
l purpos
Do not remove support bracket -10 - 222 A- until the bolts se‐
curing the left gearbox bracket have been tightened to speci‐
fied torque.
nform
mercia
a
com
tion in
r
te o
thi
s
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Prote AG.
5. Removing and installing gearbox 67
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
Volkswa
– If small cover plate -A-swfor
ageflywheel
n AG. was removed
gen AG
does from behind
bevel box, installbyitV-arrows-.
olk not
gu
a
d ran
se
– Install lowerthoflywheel
ri cover plate, if part of original equipment.
tee
o
au ra
c
ss
ce
le
un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Bolt bevel box carrier to engine and bevel box -arrows-
⇒ page 74 .
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
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cum
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en
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t.
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op py
– Bolt turbocharger oil return line to engine -arrow- ⇒ Rep. Gr.
t. C rig
gh ht
yri
21 ; Charge air system with turbocharger; Removing and in‐ p by
o Vo
by c
stalling turbocharger with ancillaries .
lksw
cted agen
Prote AG.
– Press engine/gearbox assembly towards bulkhead panel,
carefully guiding bevel box pin into propshaft flange.
Note
♦ When removing and installing gearbox, do not damage seal in
the propshaft flange.
♦ Renew propshaft if damaged.
♦ Ensure that propshaft is horizontal when pushing onto centring
pin.
68 Rep. Gr.34 - Controls, housing
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
– Bolt propshaft with flexible coupling to bevel box flange
-arrows- and tighten to specified torque
⇒ Item 4 (page 143) .
AG. Volkswagen AG d
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pt
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ility
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– Install pendulum support -arrows A and B- ⇒ Running gear,
wit
, is n
axles, steering; Rep. Gr. 40 ; Repairing front suspension; I -
h re
hole
Assembly overview - subframe, anti-roll bar, suspension links .
spec
es, in part or in w
– Use new bolts for securing.
t to the co
– Attach drive shafts to gearbox ⇒ Running gear, axles, steering
- front and four-wheel drive; Rep. Gr. 40 ; Repairing drive
rrectness of i
shafts; Removing and installing drive shaft .
l purpos
– Reconnect exhaust system ⇒ Rep. Gr. 26 ; Removing and
installing parts of exhaust system .
nf
ercia
orm
m
atio
om
n in
c
– Install slave cylinder and tighten bolts to specified torque
or
thi
e
⇒ Item 9 (page 27) .
t
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Prote AG.
– Install selector cable support bracket on gearbox and tighten
bolts -arrows- to specified torque ⇒ Item 9 (page 48) . If nec‐
essary push in hose line on selector cable support bracket.
5. Removing and installing gearbox 69
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
– Fit gear selector cable -B- with gearbox selector lever
-arrow-.
– Tighten hexagon nut -arrow- to specified torque
⇒ Item 17 (page 49) .
– Fit gate selector cable -A- with relay lever and secure
-arrow-.
– Attach connector for reversing light -arrow 2-. Attach all other
electrical connections and earth wires to gearbox and to the
engine/gearbox securing bolts.
AG. Volkswagen AG d
– Attach connector to speedometer sender -arrow 1-. agen oes
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ility
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hole
spec
– Install complete air filter housing (bolts -4- and -5-) and then
es, in part or in w
push intake hose -1-, connector -2- and hose -3- onto air mass
t to the co
meter ⇒ Rep. Gr. 24 ; Repairing injection system .
– Connect earth strap to battery.
rrectness of i
l purpos
Note
nf
Note radio code for vehicles with coded radio.
ercia
orm
m
atio
m
– Checking gear oil in manual gearbox with bevel box
o
n in
c
⇒ page 75 .
or
thi
te
sd
a
Gear oil specification ⇒ page 1
iv
o
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rp
cu
o
– Adjust selector mechanism ⇒ page 53 .
f
en
ng
t.
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op
– Install engine cover. C py
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– Install noise insulation, if fitted. copy Vo
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Prote AG.
70 Rep. Gr.34 - Controls, housing
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
5.4 Specified torques
Gearbox to engine
Item Bolt Quantity Nm
1 M12 n AG. Volkswagen AG d3
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not
80
o
2 8) d by V M12 x 150 2 gu
ara 80
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se nte
3 th M10 x 50 3 e o 40
au ra
4ss 10) M7 x 12 2 10
c
ce
le
5 11) M7 x 12 1 10
un
pt
an
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8) Additionally, starter to gearbox
erm
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ility
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9) Only on engines with an aluminium sump,
wit
is n
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10) Large flywheel cover plate only on engines with sheet steel sump (sump
ole,
painted black)
spec
urposes, in part or in wh
11) Small flywheel cover plate
t to the co
Items A + B - Dowel sleeves
rrectne
Gearbox bracket -A- to gearbox
– Renew bolts.
ss o
cial p
f
Bolts -arrows- 50 Nm + 90°
inform
mer
atio
om
n
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Gearbox to body
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Bolts -A- 25 Nm
Bolts -B- 100 Nm
– Renew bolts -B-.
Note
Install engine and gearbox mounting free of tension ⇒ Engine;
Rep. Gr. 10 ; Removing and installing engine; Assembly mount‐
ing .
5. Removing and installing gearbox 71
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
6 Removing and installing bevel box
Special tools and workshop equipment required
♦ Socket -V.A.G 1669-
♦ Torque wrench -V.A.G 1332-
AG. Volkswagen AG d
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♦ Drip tray
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Additional required information
rm
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♦ Workshop Manual Golf 1998 ▸, Bora 1999 ▸ Engine, mechan‐
ot
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ics
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hole
♦ Workshop Manual Golf 1998 ▸, Bora 1999 ▸, Running gear,
spec
axles, steering - front and four-wheel drive
es, in part or in w
t to the co
Removing
– Mark position of propshaft with flexible coupling relative to
rrectness of i
bevel box flange.
l purpos
– Unbolt propshaft with flexible coupling from bevel box flange
-arrows-.
nform
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– Disconnect right drive shaft from gearbox.
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– Raise drive shaft as high as possible and secure. Take care
ion in
not to damage paint on drive shaft in the process.
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– If a cap is fitted, remove it by piercing cap centre with a screw‐
do
r
driver and levering out.
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t.
– Remove right output shaft bolt or right flange shaft bolt using
yi Co
op
socket -V.A.G 1669- or commercially available 6 mm socket .
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– Separate exhaust system at double clamp ⇒ Rep. Gr. 26 ;
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Removing and installing parts of exhaust system .
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72 Rep. Gr.34 - Controls, housing
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
– Remove pendulum support from subframe -arrows A-.
– Carefully press engine and gearbox forwards.
– Carefully pull front propshaft off centring pin.
Note
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Do not damage seal olkin
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propshaft flange during
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– Placess adrip tray under gearbox and engine. ac
ce
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pt
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– Unbolt turbocharger oil return line -arrow- from engine ⇒ Rep.
itte
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Gr. 21 ; Charge pressure system with turbocharger; Remov‐
ab
ility
ing and installing turbocharger with ancillaries .
ot p
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– Drain gear oil from bevel box.
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
– Remove bevel box carrier from engine and bevel box
mer
-arrows-.
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– Remove bevel box/gearbox connecting bolts.
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– Press bevel box off gearbox.
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– Remove bevel box.
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Install in the reverse order of removal, observing the following:
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6. Removing and installing bevel box 73
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
Note
♦ Always renew O-ring for sealing bevel box and gearbox
-arrow A- and oil seals for sealing holes for oil supply system
-arrows B and C-, lightly coating with oil.
♦ Push bevel box completely onto gearbox, ensuring that
splines of bevel box input shaft are guided centrally onto dif‐
ferential connecting piece.
♦ Also bring splines of right flange shaft or drive flange with out‐
put shaft into alignment.
♦ If the position of the splines and the centre guide are correct,
then the bevel box will slide on to stop against the gearbox.
Turn left drive shaft slightly if necessary.
♦ Do not use securing bolts to pull bevel box onto gearbox, or
bevel box will cant and bolt holes can break off.
♦ When removing and installing, do not damage seals in prop‐
shaft flanges.
♦ Renew propshaft if damaged.
♦ Ensure that propshaft is horizontal when pushing onto centring
pin.
♦ Renew seal for drive shaft, if present ⇒ Running gear, axles,
steering - front and four-wheel drive; Rep. Gr. 40 ; Repairing
drive shaft .
♦ Join exhaust pipe at double clamp ⇒ Rep. Gr. a26
gen;ARemoving
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and installing parts of exhaust system . y Volksw es n
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♦ Unbolt turbocharger oil return linehfrom
oris engine ⇒ Rep. Gr. tee
21 ; Charge pressure system fors auturbocharger;
t
Removing and or
ac
installing turbocharger with ancillaries .
s
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un
pt
♦ Checking gear oil in manual gearbox with bevel box
an
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⇒ page 75 .
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Installing bevel box/engine carrier free of tension.
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When installing bevel box carrier, observe following sequence:
urposes, in part or in wh
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– Screw in all bolts hand-tight.
– Tighten bolts -B- and -C- first to 10 Nm.
rrectne
– Tighten bolts -A- to 25 Nm.
– Tighten bolts -B- and -C- to 40 Nm.
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Torque settings
inform
mer
Bevel box to gearbox 40 Nm + 45°
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Flexible joint with heat shield to bevel box flange
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⇒ Item 4 (page 143) .
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Drive shaft to flange shaft ⇒ Running gear, axles, steering - front
um
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and four-wheel drive; Rep. Gr. 40 ; Repairing drive shafts, Re‐
en
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t.
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moving and installing drive shafts . . Cop py
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74 Rep. Gr.34 - Controls, housing
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
7 Checking gear oil in manual gearbox
with bevel box
Special tools and workshop equipment required
♦ Torque wrench -V.A.G 1331-
Checking
Note
Gearbox and bevel box are filled together through the oil filler hole
in the gearbox.
Gear oil specification ⇒ page 1
– To check gear oil, remove oil plug -arrow-.
Oil level is correct when gearbox is filled to lower edge of filler
hole.
– Tighten bolt -arrow- to specified torque ⇒ Item 3 (page 95) .
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When filling with oil, note the following:
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– Remove oil plug -arrow-. ed nte
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– Fill with gear oil to lowerssedge of filler hole. c
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– Screw in plug -arrow-.
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– Start engine, engage gear and allow gearbox to turn for ap‐
erm
ab
prox. 2 minutes.
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– Stop engine and remove plug -arrow-.
h re
hole
spec
– Top up oil to lower edge of filler hole again.
es, in part or in w
t to the co
– Tighten bolt -arrow- to specified torque ⇒ Item 3 (page 95) .
rrectness of i
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7. Checking gear oil in manual gearbox with bevel box 75
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
8 Dismantling and assembling gearbox
8.1 Overview - gearbox
1 - 1st gear
2 - 2nd gear
3 - 3rd gear
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5 - 5th gear rise
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6 - Gearbox housing ss a ra
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❑ Repairing ⇒ page 93
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7 - Selector mechanism
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❑ (Selector forks)
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❑ Dismantling and assem‐
, is n
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bling ⇒ page 103
hole
spec
8 - Selector mechanism
es, in part or in w
t to the co
❑ Dismantling and assem‐
bling ⇒ page 99
rrectness of i
9 - Input gear for 1st gear syn‐
chromeshed gear and reverse
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gear
10 - Clutch housing
nf
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❑ Repairing ⇒ page 93
rm
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11 - Input shaft
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❑ Dismantling and assem‐
thi
te
sd
bling ⇒ page 108
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12 - Output shaft cu
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❑ Dismantling and assem‐
Co
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13 - Differential
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❑ Dismantling and assem‐
76 Rep. Gr.34 - Controls, housing
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
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14 - Bevel box tho tee
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❑ Removing and installing with gearbox installed
ss ⇒ page 72
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❑ Removing and installing with gearbox removed ⇒ page 82
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❑ Dismantling and assembling ⇒ page 250
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15 - Shaft bevel gear
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❑ Is paired to bevel gear (with stub shaft)
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spec
16 - Bevel gear with stub shaft
urposes, in part or in wh
❑ Paired with shaft bevel gear
t to the co
17 - Output shaft
❑ Pull out of bevel gear housing with drive flange
rrectne
❑ Right-hand flange shaft is installed in some gearboxes
ss
18 - Drive flange
o
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f i
❑ Pull out together with output shaft
nform
mer
❑ Right-hand flange shaft is installed in some gearboxes
atio
om
19 - Output flange
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20 - Bevel box connecting piece
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❑ Pulling off ⇒ page 198
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21 - Flange shaft
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8. Dismantling and assembling gearbox 77
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive
gen AG
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8.2 Assembly overview
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78 Rep. Gr.34 - Controls, housing
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
Dismantling and assembling procedure ⇒ page 82
l - Removing and installing cover for gearbox housing and 5th
gear ⇒ page 79 .
II - Removing and installing gearbox housing and selector mech‐
anism ⇒ page 80 .
III - Removing and installing input shaft, output shaft, differential
and selector forks ⇒ page 81 .
8.3 Removing and installing cover for gearbox housing and 5th gear
1 - Hexagon bolt, 10 Nm
❑ For gearbox housing
cover.
2 - Gearbox housing cover
Note
If gearbox housing cover is installed
with gearbox installed, check oil lev‐
el and top up with gear oil
⇒ page 75 .
3 - Seal
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Torx socket head bolt M10, 80 by Vo gu
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❑ Always renew au
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❑ Fitted section of bolt
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head holds dished
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spring washer in posi‐
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5 - Dished washer
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❑ Installing ⇒ page 91
hole
spec
es, in part or in w
6 - Socket head bolt, 25 Nm
t to the co
❑ For pivot pin to gearbox
housing
rrectness of i
7 - Pivot pin
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8 - 5th gear selector fork
❑ Dismantling and assem‐
nform
ercia
bling ⇒ page 103
❑ Adjusting ⇒ page 92
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9 - Locking collar for 5th gear
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❑ Installation position
at
do
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⇒ page 90
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❑ Adjusting ⇒ page 92
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10 - Synchro-hub with synchromeshed gear and synchronising ring for 5th gear
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❑ Dismantling and assembling ⇒ page 93
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11 - Needle bearing
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12 - Gear wheel for 5th gear
❑ Installation position ⇒ page 89
8. Dismantling and assembling gearbox 79
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
8.4 Removing and installing gearbox housing and selector mechanism
1 - Countersunk bolt, 25 Nm
2 - Flange shaft with compres‐
sion spring
❑ Removing and installing
⇒ page 171
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3 - Bolt, 30 Nm ir se
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tee
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❑ For reverse shaft sup‐ aut or
ac
port ss
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❑ Self-locking
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❑ Always renew
erm
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ility
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4 - O-ring
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❑ Always renew
h re
hole
spec
5 - Pivot pin
es, in part or in w
t to the co
6 - Bolt, 25 Nm
7 - Bolt, 25 Nm
rrectness of i
8 - Cover plate
l purpos
9 - Gearbox housing
❑ Repairing ⇒ page 93
nform
ercia
10 - Clutch housing
m
at
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i
❑ Repairing ⇒ page 93
on
c
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11 - Hexagon bolt, 25 Nm and
his
ate
turn 90° further
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cum
or
12 - Selector mechanism
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❑ Dismantling and assem‐ Cop py
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13 - Hexagon bolt, 25 Nm
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80 Rep. Gr.34 - Controls, housing
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
8.5 Removing and installing input shaft, output shaft, differential and selector
forks
1 - Differential
❑ Dismantling and assem‐
bling ⇒ page 198
2 - Seal
❑ Qty. 4
❑ Always renew
3 - Output shaft
❑ Dismantling and assem‐
bling ⇒ page 123
❑ Adjusting ⇒ page 120
4 - Reverse shaft support
❑ Dismantling and assem‐
bling ⇒ page 138
5 - Reverse shaft
❑ Dismantling and assem‐
bling ⇒ page 138
6 - Input shaft agen
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❑ Adjusting ⇒ page 116 ss a ra
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7 - Selector fork for reverse
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❑ Dismantling and assem‐
ility
ot p
bling ⇒ page 103
wit
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❑ Installation position
h re
ole,
⇒ page 88
spec
urposes, in part or in wh
8 - Bolt, 25 Nm
t to the co
9 - Selector mechanism
❑ (Selector forks)
❑ Dismantling and assem‐ rrectne
bling ⇒ page 103
ss o
cial p
10 - Clutch housing
f inform
❑ Repairing ⇒ page 93
mer
atio
m
11 - Hexagon nut, 25 Nm and then turn 90° further
o
n
c
i
or
❑ 4 nuts for bearing support
thi
te
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Prote AG.
8. Dismantling and assembling gearbox 81
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
8.6 Procedure for removing and installing gearbox housing cover, gearbox
housing, selector mechanism, input shaft, output shaft, differential and se‐
lector forks
Special tools and workshop
equipment required
♦ Support plate -VW 309-
♦ Gearbox support -VW 353-
♦ Drift -VW 295-
♦ Drift sleeve -VW 244 B-
♦ Hot air blower -V.A.G 1416-
♦ Torque wrench -
V.A.G 1331-
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♦ Socket -V.A.G 1669-
com
tion in
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82 Rep. Gr.34 - Controls, housing
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
♦ Two-arm puller -1 - Kukko 20/10- with Matra V170 pulling hook
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♦ Studs M8 x 100 mm
spec
urposes, in part or in wh
♦ Hexagon bolt M10 x 20
t to the co
Removing
rrectne
– Drain gear oil from gearbox and bevel box.
– If a cap is fitted, remove it by piercing cap centre with a screw‐
s
driver and levering out.
s o
cial p
f in
– Remove right output shaft bolt or right flange shaft bolt using
form
mer
socket -V.A.G 1669- or commercially available 6 mm socket.
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om
n
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or
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Note
te
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Right flange shaft or drive flange with output shaft remains in
r
fo
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bevel box.
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– Remove four bevel box/gearbox connecting bolts -arrow A- pyri by
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and -arrow B-.
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– Press bevel box off gearbox.
– Bolt gearbox to repair stand.
– Remove clutch release lever and release bearing ⇒ page 26 .
– Unbolt guide sleeve ⇒ page 26 .
– Remove gearbox housing cover -arrow-.
8. Dismantling and assembling gearbox 83
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
– Remove 5th gear selector fork -arrow-
Note
Before lifting the locking collar, take off spring and lock body. Then
afterwards replace locking collar on synchro-hub again, but with‐
out selector fork.
– Remove bolts -A- for synchro-hub and 5th gear, to do this se‐
lect 1st gear -arrows 2 and 3- and 5th gear -arrow 1-.
– After both gears are engaged, the input shaft and output shaft
are locked. The synchro-hub and gear wheel cannot turn. Both
bolts can now be loosened.
– Pull off synchro-hub with 5th gear wheel and take off needle
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-A- Two-arm puller -Kukko 20/10- with hooks -Matra V/170.-
rm
ab
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-B- Hexagon head bolt M10×20
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– Pull off gear wheel for 5th gear.
hole
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es, in part or in w
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-A- Two-arm puller -Kukko 20/10- with hooks -Matra V/170.-
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tion in
-B- Hexagon head bolt M10×20
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Removal sequence:
iva
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– Assemble two arm puller and centre by turning screw
en
ng
t.
-arrow-. Cop
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– Pull gear wheel off using two arm puller, first heating with hot rig ht
py by
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Note
When pulling off gear wheel, ensure that hooks do not bend out‐
wards, further tightening bolt -arrow- if necessary. After pulling off
gear wheel for 5th gear, examine for damage.
84 Rep. Gr.34 - Controls, housing
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
– Remove left-hand flange shaft by removing countersunk bolt
-arrow-.
– Remove both bolts -arrows- for reverse shaft support bracket.
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– Remove selector shaft with selector mechanism cover, placingkswagen AG does
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selector shaft in neutral position. Then remove bolts -arrows-
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and pull selector shaft out of gearbox housing. rise nte
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urposes, in part or in wh
t to the co
– Remove cover plate -A- and pivot pins -B- from underside of
gearbox.
rrectness o
cial p
f inform
mer
atio
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8. Dismantling and assembling gearbox 85
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
– Remove pivot pins -A- on top side of gearbox and securing
bolts -B- for gearbox housing to clutch housing in area of dif‐
ferential.
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– Remove bolts -A- from clutch housing side for securing clutch
erm
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housing to gearbox housing.
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Note
spec
urposes, in part or in wh
t to the co
Do not remove nuts -B- for output shaft bearing support.
rrectness o
cial p
f inform
mer
– Remove gearbox housing, if necessary carefully levering up
atio
m
all around along protruding housing flange and alternating be‐
o
n
c
tween sides -arrows-, being careful not to damage sealing
i
or
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surfaces.
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– Remove selector forks -A- together with selector plates.
– Unbolt reverse gear selector mechanism -B-.
86 Rep. Gr.34 - Controls, housing
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
– Remove nuts for output shaft bearing support.
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– Remove reverse gear -A-, input shaft -B- and output shaft
h re
hole
-C- one after the other from clutch housing.
spec
es, in part or in w
– Install differential.
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
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te o
thi
– Always renew sealing rings -arrows- for output shaft bearing
s
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support.
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The figure shows only 3 of the 4 sealing rings.
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– Remove differential.
Installing
– Install input shaft, output shaft and reverse shaft together.
– Tighten nuts for output shaft bearing support to specified tor‐
que ⇒ Item 11 (page 81) .
– Clean residual locking fluid from threads in reverse shaft sup‐
port -arrow-. Threads can be cleaned using a thread chaser.
– Install reverse shaft support.
– Install reverse gear selector mechanism.
8. Dismantling and assembling gearbox 87
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
Installation position, reverse gear
– Install selector forks together with selector plates.
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– Screw M8 x 100 mm studs -A- into reverse ir se
d shaft support so ran
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that shaft is aligned after gearbox housing
utho
is fitted. or
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ss
– Align selector plates.
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The selector segments must be positioned in the grooves on the
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locking collars.
spec
urposes, in part or in wh
t to the co
– Fit gearbox housing.
Install reverse shaft support bolts -arrow- as follows:
rrectne
– Install bolt -a-.
ss o
cial p
f inform
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– Remove stud -A-.
AG.
88 Rep. Gr.34 - Controls, housing
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
– Install bolt -b- and tighten by hand.
Tightening sequence:
1. - Bolt -a- 30 Nm
2. - Bolt -b- 30 Nm
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– Install pivot pin -arrow- for selector forks. Do this by aligning
ility
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selector mechanism with a screwdriver so that respective pivot
wit
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pin can be installed.
h re
ole,
spec
– Fit selector shaft cover.
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
atio
m
Install selector shaft as follows:
o
n
c
i
or
n
– Place selector plates in neutral.
thi
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– Locate lug -arrow 1- in recess in gearbox housing. Position
pr
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selector shaft so that selector finger -arrow 2- is inserted in the
en
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selector plates.
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– Install selector shaft cover.
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Installation position, 5th gear wheel
The circumferential groove -arrow- faces gearbox housing.
8. Dismantling and assembling gearbox 89
AG. Volkswagen AG d
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Bora 1999 ➤ , Golf 1998 ➤ rise
d b ara
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5-speed manual gearbox 02C, four-wheel drive - Edition
autho
01.2010 eo
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– Drive on gear wheel for 5th gear.
un
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Check 5th gear synchro-ring.
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– Before installing synchromeshed gear and synchro-ring for 5th
cial p
f in
gear, press synchro-ring onto cone of synchromeshed gear
form
and measure gap -a- with a feeler gauge. mer
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Gap -a- Installation (new) di‐ Wear limit
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5th gear 1,1 ... 1.7 mm 0.5 mm
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– Install 5th gear synchromeshed gear with needle bearing.
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– Place 5th gear synchro-ring on synchromeshed gear.
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– Assemble 5th gear synchro-hub and locking collar before in‐ cted agen
Prote AG.
stalling ⇒ page 114 .
Installation position 5th gear synchro-hub and locking collar
The pointed teeth of the locking collar -arrow 1- and the high
shoulder of the synchro-hub -arrow 2- face the gearbox housing.
The synchro-hub mountings -arrow 3- align with the 5th gear syn‐
chro-ring cast locking pieces.
5th gear synchro-ring with cast locking pieces -arrows-
90 Rep. Gr.34 - Controls, housing
AG. Volkswagen AG d
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Vol Bora 1999 ➤n,otGolf
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– Drive on 5th gear synchro-hub. ss
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When driving on, ensure that synchro-ring moves freely.
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spec
– Screw in securing bolts for synchro-hub and gear wheel for 5th
es, in part or in w
gear.
t to the co
rrectness of i
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Installation position of dished springs for securing bolts for gear
wheel and synchro-hub for 5th gear
nf
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or
The outer diameter (concave side -arrows-) faces 5th gear.
m
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– Engage two gears before tightening securing bolts for 5th gear
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synchro-hub and gear wheel.
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– To do this, engage 1st gear -arrow 2- and -arrow 3- and 5th
gear -arrow 1-.
– Tighten securing bolts for synchro-hub and gear wheel for 5th
gear -arrows- to specified torque ⇒ Item 4 (page 79) .
– Install 5th gear selector fork.
8. Dismantling and assembling gearbox 91
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Bora 1999 ➤ y,VGolf 1998 ➤
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5-speed manual
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ho eo
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Adjusting 5ths gear
s c
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un
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– Engage 5th gear. Loosen bolt -1-. Push locking collar and se‐
an
d
itte
lector jaw in direction of arrow and then tighten bolt -1- to 25
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Nm.
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• Check measurement: It must not be possible to slide a 0.2 mm
, is n
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feeler gauge between locking collar and gear wheel. If neces‐
hole
spec
sary, repeat adjustment.
es, in part or in w
t to the co
– Disengage 5th gear. Locking collar must now be in the neutral
position. Synchro-ring must move freely.
– Mount gearbox housing cover.
rrectness of i
– Install complete left flange shaft ⇒ Item 2 (page 80) .
l purpos
– Install release bearing guide sleeve ⇒ page 26 .
nform
ercia
– Install clutch release lever and release bearing ⇒ page 26 .
m
a
Install bevel box as follows:
com
tion in
r
te o
thi
– Always renew O-ring for sealing bevel box and gearbox
s
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do
-arrow A- and oil seals for sealing sleeves for oil supply system
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-arrows B and C-, lightly coating with oil.
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– Push bevel box completely onto gearbox, ensuring that . Cop py
splines of bevel box input shaft are guided centrally onto dif‐
ht rig
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– Also bring splines of right flange shaft or drive flange with out‐
AG.
put shaft into alignment.
– If splines are correctly positioned and shafts are centred, then
bevel box will slide to stop against gearbox.
– Do not use securing bolts to pull bevel box onto gearbox, or
bevel box will cant and bolt holes can break off.
– Tighten bevel box/gearbox connecting bolts -arrows A- and
-B- to specified torque ⇒ page 74 .
– Tighten flange shaft countersunk bolt or drive flange with out‐
put shaft with socket -V.A.G 1669- or commercially available
6 mm socket insert to specified torque ⇒ Item 4 (page 250)
and hold against turning with drift.
92 Rep. Gr.34 - Controls, housing
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
9 Assembly overview
agen
AG. Volksw-agRepairing
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gearbox housing and clutch housing
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♦ Drift -VW 295-
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♦ Adapter -VW 295 A-
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♦ Thrust pad -VW 447 H-
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♦ Thrust pad -VW 512-
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hole
spec
♦ Tube -VW 415 A-
es, in part or in w
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♦ Thrust piece -VW 454-
rrectness of i
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9. Assembly overview - Repairing gearbox housing and clutch housing 93
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
♦ Drift -VW 222 A-
♦ Torque wrench -
V.A.G 1331-
♦ Internal puller -1 - Kukko
22/1-
♦ Counter support -4 - Kukko
22/1-
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Prote AG.
94 Rep. Gr.34 - Controls, housing
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
1 - Gearbox housing
❑ If renewed: adjust input
shaft and differential
⇒ page 247
2 - Needle bearing
❑ For output shaft
❑ Removing ⇒ page 96
❑ Installing and securing
⇒ page 97 .
3 - Oil filler plug, 30 Nm
❑ Without magnet
4 - Shim n AG. Volkswagen AG do
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❑ For input shaft by Vo ot g
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❑ Adjustment overview
horis tee
⇒ page 247
s aut or
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5 - Tapered roller bearing outer
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race
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❑ For input shaft
erm
ab
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❑ Pressing out
wit
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⇒ page 114
h re
hole
❑ Pressing in
spec
⇒ page 114
es, in part or in w
t to the co
❑ If renewed: adjust input
shaft ⇒ page 116
rrectness of i
6 - Tapered roller bearing outer
race
l purpos
❑ For output shaft
❑ Removing and installing
nf
ercia
⇒ page 129
orm
m
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❑ If replaced: Adjust out‐
om
put shaft ⇒ page 120 .
n in
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7 - Shim
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❑ For output shaft
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❑ Adjustment overview ⇒ page 247
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8 - Tapered roller bearing outer race
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❑ For input shaft
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❑ Removing and installing ⇒ page 111
AG.
❑ If renewed: adjust input shaft ⇒ page 116
9 - Needle bearing
❑ Removing and installing ⇒ page 140
10 - Dowel sleeve
❑ Qty. 2
11 - Starter bush
❑ Pulling out ⇒ page 97
❑ Driving in ⇒ page 98
❑ Can be renewed with gearbox installed.
12 - Clutch housing
❑ When renewing: adjustment overview ⇒ page 247
13 - Guide sleeve
❑ With input shaft seal and vulcanised or bonded O-ring
9. Assembly overview - Repairing gearbox housing and clutch housing 95
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
❑ Driving out oil seal ⇒ page 97 .
❑ Driving in oil seal ⇒ page 97 .
❑ Remove guide sleeve to change oil seal
❑ If O-ring is damaged or has come loose, renew guide sleeve and O-ring together
14 - Socket head bolt, 20 Nm
❑ Self-locking
❑ Always renew
15 - Speedometer drive
❑ Aluminium, tighten to 30 Nm
❑ Plastic (polyamide), tighten to 10 Nm
16 - Oil drain plug, 30 Nm
❑ Without magnet
17 - Tapered roller bearing outer race
❑ For differential
❑ Driving in and out ⇒ Item 13 (page 201) .
❑ If renewed, adjust differential ⇒ page 248
18 - Magnet
❑ Held in place by housing joint surface
19 - Tapered roller bearing outer race
❑ For differential
❑ Driving in and out ⇒ page 198 .
❑ If renewed, adjust differential ⇒ page 248 AG. Volkswagen AG d
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20 - Shim d byV gu
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❑ For differential hor eo
aut ra
❑ Adjustment overview ⇒ page
ss 247 c
ce
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nl
21 - Seal
pt
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❑ Renewing ⇒ page 236
erm
ab
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Driving out needle roller bearing
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
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m
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96 Rep. Gr.34 - Controls, housing
AG. Volkswagen ABora
G do 1999 ➤ , Golf 1998 ➤
agen es n
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5-speed manual by V gearbox 02C, four-wheel drive
ol ot g - Edition 01.2010
ua
ed ran
ris tee
o
Driving needle bearing in to stop aut
h or
ac
ss
– Secure needle bearing in gearbox housing at three points
ce
e
nl
pt
(120° offset) using a punch.
du
an
itte
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erm
ab
ility
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, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
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Driving oil seal out of guide sleeve
nform
mercia
at
om
ion
c
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or
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ate
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for
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Prote AG.
Driving oil seal into guide sleeve to stop
Pulling out starter bush
-A- Internal puller -Kukko 21/1- 12 … 14.5 mm
-B- Counter support -Kukko 22/1-
9. Assembly overview - Repairing gearbox housing and clutch housing 97
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
Driving in starter bush n AG. Volkswagen AG do
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Prote AG.
98 Rep. Gr.34 - Controls, housing
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
10 Dismantling and assembling selector
mechanism on gearbox side
10.1 Assembly overview - selector shaft
Special tools and workshop
equipment required
♦ Guide pin -VW 439- n AG. Volkswagen AG do
lkswage es n
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♦ Pressure plate -VW 401- ed by V ua
ran
ir s tee
♦ Press tool -VW 408 A-autho
or
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♦ Thrust pad -VW 447 i-
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♦ Thrust piece -3129-
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♦ Torque wrench -V.A.G 1331-
10. Dismantling and assembling selector mechanism on gearbox side 99
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
♦ Internal puller -1 - Kukko 21/3-
1 - Selector shaft
❑ From gearbox date
04 09 0 modification of
stop sleeve so that se‐
lector shaft is guided in‐
to 4th gear gate during
downshift from 5th gear
to 4th gear ⇒ page 102
2 - Stop ring
3 - Ball sleeve
❑ Removing ⇒ page 101
❑ Pressing in
⇒ page 101
4 - Selector mechanism cover
❑ From gearbox date AG. Volkswagen AG d
agen
04 09 0 with additional Volksw
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not
bolt so that selector ed by gu
ara
shaft is guided into 4ththoris nte
eo
gear gate during down‐ s au ra
c
shift from 5th gear tos 4th
ce
le
gear ⇒ page 102
un
pt
an
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5 - Reversing light switch,
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20 Nm
ility
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❑ Lightly coat lug with
is n
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MoS2 grease
ole,
spec
urposes, in part or in wh
6 - Cap
t to the co
❑ For gearbox breather
7 - Relay lever
rrectne
❑ Installation position
⇒ page 49
ss o
8 - Bearing bush
cial p
f inform
9 - Seal
mer
atio
❑ Lever out with a screwdriver
om
n
c
❑ Installing ⇒ page 101
i
or
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10 - Securing clip
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11 - Hexagon nut
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❑ ⇒ Item 17 (page 49) Cop py
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12 - Gearbox selector lever p by
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❑ Install so that master spline aligns with selector shaft
agen
Prote AG.
❑ Can be renewed with the selector mechanism installed
100 Rep. Gr.34 - Controls, housing
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
❑ Installation position ⇒ page 49
13 - Cover plate
❑ From gearbox date 06 08 1 with catch for selector shaft ⇒ page 102
Removing ball sleeve from selector mechanism cover
– Before pulling out ball sleeve, destroy plastic cage and remove
balls.
-A- Internal puller -Kukko 21/3- , 18.5…23.5 mm
Knocking ball sleeve into selector mechanism cover
AG. Volkswagen AG d
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Inserting oil seal to stop
urposes, in part or in wh
t to the co
When gearbox is installed, oil seal can be inserted with pipe -
VW 423- .
rrectness o
cial p
f inform
mer
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Prote AG.
10. Dismantling and assembling selector mechanism on gearbox side 101
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
Selector shaft cover and selector shaft modified
From gearbox date 04 09 0, bolt -2- is installed in selector shaft
cover -1-.
Torque setting:
15 Nm
Stop sleeve of selector shaft has been provided with an extension
-3- in this connection.
Functional check
During a downshift from 5th to 4th gear, bolt -2- guides selector
shaft along the extension -3- into to 4thwgear
agen gate.
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Selector shaft and cover plate modified
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From gearbox date 06 08 1, selector shaft has recesses -A-
ole,
spec
worked into it.
urposes, in part or in wh
t to the co
Spring -B- is inserted into cover plate.
Functional check
rrectne
When a forwards gear is engaged, selector shaft is locked in cov‐
er plate by one of recesses -A-, with spring -B-.
ss o
cial p
f inform
mer
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Prote AG.
102 Rep. Gr.34 - Controls, housing
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
11 Dismantling and assembling selector forks
Special tools and workshop
equipment required
♦ Pressure plate -VW 402-
♦ Thrust piece -3290/1- from
assembly tool -3290-
♦ Assembly tool -3301-
♦ Thrust piece -VW 431-
♦ Spacer sleeve -VW 472/2-
♦ Drift -10 - 206-
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♦ Removal lever -80 - 200-
hole
spec
es, in part or in w
t to the co
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11. Dismantling and assembling selector forks 103
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
♦ Drift -10 - 508-
♦ Clamp -2070-
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It is not necessary to dismantle the selector fork group
du
an
itte
⇒ Item 7 (page 105) in order to dismantle and assemble selector
y li
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segments, lock washers and angular contact ball bearings.
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104 Rep. Gr.34 - Controls, housing
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
1 - 5th gear selector segment
❑ Identification
⇒ page 106
❑ After lock washer is in‐
stalled, selector seg‐
ment must still rotate
freely.
2 - Lock washer
❑ Always renew
❑ Removing ⇒ page 106
AG. Volkswagen AG d
❑ Installing ⇒ page 106 agen oes
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3 - 5th gear selector fork rise
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❑ Adjusting ⇒ page 92 s aut ra
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4 - Bolt, 25 Nm
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5 - 5th gear selector jaw
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6 - Angular contact ball bearing
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❑ Qty. 4
h re
hole
❑ Removing ⇒ page 106
spec
es, in part or in w
❑ Press inner race into
t to the co
outer race ⇒ page 107
❑ Installing ⇒ page 107
rrectness of i
7 - Selector fork group with se‐
lector plate
l purpos
8 - 1st/2nd gear selector seg‐
ment
nform
ercia
❑ Identification
m
at
⇒ page 106
om
ion
c
in t
❑ After lock washer is in‐
or
his
e
stalled, segment must
at
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still rotate freely
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9 - Selector segment for 3rd
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❑ Identification ⇒ page 106
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❑ After lock washer is installed, segment must still rotate freely Prote
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10 - Sliding piece
11 - Spring
12 -
Selector fork for reverse gear
13 - Support for reverse gear selector fork
14 - Retaining ring
15 -
11. Dismantling and assembling selector forks 105
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
Identifying selector segments
Dimension a
-1- = 1st and 2nd gear selector segments = 12.1 mm
1st and 2nd gear selector segments in conjunction with modified
synchronisation = 11.4 mm
Shorter selector segments may also be installed in previous gear‐
boxes.
-2- = 3rd and 4th gear selector segments = 7.7 mm
-3- = 5th gear selector segments = 12.1 mm
Removing lock washer
– Clamp selector fork in vice with protective jaw covers -B-.
– Lever off lock washer -A- in -direction of arrow-.
Installing lock washer
– Press lock washer into groove of selector segment using sock‐
et and spinner handle.
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After lock washer is installed, selector segment must still rotate
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freely.
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-A- Spinner handle with 10 mm socket
pt
du
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-B- Vice jaw protectors
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ility
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Removing angular contact ball bearing
h re
hole
spec
es, in part or in w
Note
t to the co
When removing and installing angular contact ball bearing, do not
bend selector forks.
rrectness of i
l purpos
nform
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at
om
ion
c
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or
his
ate
do
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Prote AG.
106 Rep. Gr.34 - Controls, housing
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
Pressing inner race -A- of angular contact ball bearing into outer
race
Inner race must engage in outer race.
Pulling angular contact ball bearing into selector fork to stop
Depression in thrust piece -3290/1- faces ball bearing.
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Selector fork with selector segments installed
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ility
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Dim. -a- (mm)
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1st/2nd gear selector fork 87,2 ... 87,9 h re
hole
spec
1st/2nd gear selector forks in conjunc‐ 88,4 ... 89,1
es, in part or in w
tion with modified synchronisation
t to the co
3rd/4th gear selector fork 96,0 ... 96,7
rrectness of i
Selector segment allocation ⇒ page 106 .
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orm
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11. Dismantling and assembling selector forks 107
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
35 – Gears, shafts
1 Dismantling and assembling input
shaft
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1.1 Assembly overview - input shaft d byV
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Special tools and workshop ss c
equipment required
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un
pt
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♦ Press tool -VW 407-
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♦ Thrust pad -VW 447 H-
ility
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♦ Press tool -VW 412-
h re
hole
spec
♦ Tube -VW 422-
es, in part or in w
t to the co
♦ Pressure plate -VW 401-
♦ Press tool -VW 408 A-
rrectness of i
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nform
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com
tion in
r
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thi
s
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Cop py
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Prote AG.
108 Rep. Gr.35 - Gears, shafts
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
♦ Tube -VW 421-
♦ Thrust pad -VW 447 i-
♦ Thrust piece -VW 454-
♦ Thrust pad -VW 510-
♦ Drift sleeve -41 - 501-
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pe
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spec
es, in part or in w
t to the co
rrectness of i
l purpos
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mercia
a
com
tion in
r
te o
thi
s
iva
do
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Note
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♦ When installing new gear wheels, consult technical data
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⇒ page 1 . by c lksw
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♦ If the position of the tapered roller bearings is affected when
parts are exchanged, the input shaft must be readjusted. See
adjustment overview ⇒ page 247 .
1. Dismantling and assembling input shaft 109
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
1 - Clutch housing
2 - Tapered roller bearing outer
race
❑ Removing ⇒ page 111
❑ Pressing in
⇒ page 111
3 - Tapered roller bearing inner
race
❑ Pressing off
⇒ page 112
❑ Pressing on
⇒ page 112
4 - Input shaft
❑ Adjusting ⇒ page 116
5 - Gear wheel for 3rd gear
❑ Collar faces 4th gear
❑ Pressing off
⇒ page 112
❑ Pressing on
⇒ page 113
6 - Retaining ring
❑ Always renew
7 - Gear wheel for 4th gear
❑ Collar faces 3rd gear
❑ Pressing off with ta‐
pered roller bearing in‐
ner race and sleeve agen
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⇒ page 112 olksw not
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❑ Pressing on orise nte
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⇒ page 113 auth
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8 - Tapered roller bearing inner
ce
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un
pt
race
an
d
itte
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❑ Pressing off with 4th gear wheel and sleeve ⇒ page 112 .
rm
ab
pe
❑ Pressing on ⇒ page 113 ility
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9 - Thrust washer
hole
spec
10 - Tapered roller bearing outer race
es, in part or in w
t to the co
❑ Pressing out ⇒ page 114
❑ Pressing in ⇒ page 114
rrectness of i
11 - Shim
l purpos
❑ Determining thickness ⇒ page 116
12 - Gearbox housing
nform
ercia
13 - Sleeve
m
❑ For needle bearing
com
tion in
❑ Press off with gear wheel for 4th gear and tapered roller bearing inner race ⇒ page 112
r
te o
thi
s
❑ Pressing on ⇒ page 113
iva
do
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❑ Set thrust washer ⇒ Item 9 (page 110) in place before installing
um
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14 - Needle bearing
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❑ For 5th gear
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15 - Synchromeshed gear for 5th gear Prote
cted AG.
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❑ Pull off together with 5th gear synchro-hub ⇒ page 82 .
110 Rep. Gr.35 - Gears, shafts
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
16 - Synchro-ring for 5th gear
❑ With cast locking pieces ⇒ page 90
❑ Check for wear ⇒ page 90
17 - Spring
❑ Installation position ⇒ page 114
❑ From gearbox date 05 11 1, spring has been changed ⇒ page 115 .
18 - Locking pieces (Qty. 3)
❑ Installation position ⇒ page 114
❑ From gearbox date 05 03 1, locking pieces which are hollow on the inside have been installed.
19 - Synchro-hub for 5th gear
❑ Removing and installing ⇒ page 82
20 - Locking collar for 5th gear
❑ Removing and installing ⇒ page 82
21 - Dished washer
❑ Installation position ⇒ page 91
22 - Torx socket head bolt M10
❑ ⇒ Item 4 (page 79)
Pressing out tapered roller bearing outer race
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Pressing in tapered roller bearing outer race ce
le
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pe
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hole
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es, in part or in w
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Prote AG.
1. Dismantling and assembling input shaft 111
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
Pressing off tapered roller bearing inner race
-A- Splitter -Kukko 17/1-
Pressing on tapered roller bearing inner race
Pressing off gear wheel for 4th gear with tapered roller bearing
inner race and sleeve
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Pressing off gear wheel for 3rd gear
ility
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hole
spec
es, in part or in w
t to the co
rrectness of i
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nf
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112 Rep. Gr.35 - Gears, shafts
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
Pressing on gear wheel for 3rd gear
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Pressing on gear wheel for 4th gear
un
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Shoulder faces 3rd gear
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t to the co
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Pressing on tapered roller bearing inner race inform
mer
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om
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i
or
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Pressing on sleeve for needle bearing
1. Dismantling and assembling input shaft 113
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
Pressing out tapered roller bearing outer race
AG. Volkswagen AG d
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Pressing in tapered roller bearing outer race rise nte
tho eo
au ra
– Install with shim after adjusting input
s shaft.
s c
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nl
pt
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itte
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erm
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ility
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, is n
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spec
es, in part or in w
t to the co
rrectness of i
5th gear synchronisation
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1 - Springs for lock pieces
nform
ercia
2 - Locking collar with 3 recesses -arrows A- for the locking pieces
-item 4-
m
at
om
io
3 - Synchro-hub
n
c
in t
or
his
e
4 - Installation position of locking pieces: extension -arrow B-
at
do
riv
faces the pointed teeth of the locking collar -2-
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for
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Assembling 5th gear locking collar/synchro-hub
– Slide locking collar over synchro-hub.
Pointed teeth -A- and shoulder -B- of synchro-hub face in same
direction. The recesses for the locking pieces in locking collar and
synchro-hub must be aligned ⇒ page 114 .
– Insert locking pieces, installation position: ⇒ page 114 .
– Install springs below shoulder -C-, offset 120°. Springs must
seat with angled ends in front of locking pieces -arrows-.
114 Rep. Gr.35 - Gears, shafts
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
1.2 Modification in springs for 5th gear syn‐
chronisation from gearbox date 05 11 1.
Introduction began gradually.
From the above-named gearbox date, ends -A- of springs are
offset.
The modified springs are installed on both sides.
– Modified springs can be installed in earlier gearboxes only in
conjunction with locking pieces which are hollow on the inside.
– Insert locking pieces, installation position: ⇒ page 114 .
Installation position of springs
– Install springs offset 120°.
– Angled end -A- of spring must locate in hollow locking piece.
It must be located under shoulder -B- of locking piece.
+
Bent ends always face away from synchro-hub
-direction of arrow-.
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spec
urposes, in part or in wh
t to the co
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cial p
f inform
mer
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c
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1. Dismantling and assembling input shaft 115
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
2 Adjusting input shaft
2.1 Adjusting input shaft
Special tools and workshop
equipment required
♦ Gearbox support -VW 353-
♦ End dimension plate -
VW 385/17-
♦ Universal dial gauge brack‐
et -VW 387-
♦ Thrust pad -VW 447 i-
♦ Thrust pad -VW 510-
♦ Torque wrench -
V.A.G 1331-
AG. Volkswagen AG d
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es, in part or in w
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♦ Universal dial gauge bracket -VW 387-
en
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♦ Dial gauge
116 Rep. Gr.35 - Gears, shafts
AG. Volkswagen AG d
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Volksw
oes
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by gu
ed 5-speed manual gearbox ara02C, four-wheel drive - Edition 01.2010
nte
ris
ho eo
ut r
It is necessary sto
s readjust the input shaft only when the following ac
a
components are renewed:
ce
e
nl
pt
du
an
♦ Gearbox housing itte
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erm
ab
♦ Clutch housing
ility
ot p
wit
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♦ Input shaft
h re
hole
spec
♦ Gear wheel for 4th gear
es, in part or in w
t to the co
or the
♦ Tapered roller bearing
rrectness of i
Adjustment overview ⇒ page 247
l purpos
– Press tapered roller bearing outer race into gearbox housing
to stop without shim using thrust pad -VW 510- .
nform
ercia
– Install input shaft in clutch housing and set gearbox housing
in place. Tighten hexagon bolts to specified torque
m
at
om
i
⇒ Item 11 (page 80) .
on
c
in t
or
– Install universal dial gauge bracket -VW 387- and dial gauge
his
ate
into clutch housing (large tapered roller bearing in gearbox
do
priv
c
housing).
um
for
en
ng
t.
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– Before taking any measurements, rotate input shaft to allow
Co
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bearings to settle. Set dial gauge to “O” with 1 mm preload.
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Note
This step must be repeated for each subsequent measurement,
or the dial gauge will not return to the starting position.
– Press input shaft in direction of dial gauge
-direction of arrow-.
– Read and note clearance indicated on dial gauge (example
1.21).
Note
Dial gauge does not return to original position.
– Determine thickness of shim from table ⇒ page 117 (example
1.175 mm).
– Remove input shaft and press tapered roller bearing outer
race out of gearbox housing using thrust plate -VW 447 i- .
– Press tapered roller bearing outer race together with 1.175
shim into gearbox housing using thrust pad -VW 510- .
– Fit gearbox housing and tighten new hexagon bolts to speci‐
fied torque ⇒ Item 11 (page 80) .
2.2 Table of shims
Bearing play Shim
bearing clearance Thickness Part number
(mm) (mm)
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
2. Adjusting input shaft 117
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
Bearing play Shim
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
1.325 ... 1.349 1.300 02A 311 140
02A 311 140
1.350 ... 1.374 1.325 02A 311 140 agen AG. Volkswagen AG d
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1.375 ... 1.399 1.350 02A rise311 140 A 02A
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140 A eo
ra
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1.400 ... 1.424 1.375 s 02A 311 140 A 02A ce
le
311 140 B
un
pt
an
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1.425 ... 1.449 1.400 02A 311 140 B 02A
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311 140 B
ility
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1.450 ... 1.474 1.425 02A 311 140 B 02A
wit
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311 140 C
h re
ole,
1.475 ... 1.499 1.450 02A 311 140 C 02A
spec
urposes, in part or in wh
311 140 C
t to the co
1.500 ... 1.524 1.475 02A 311 140 C 02A
311 140 D
rrectne
1.525 ... 1.549 1.500 02A 311 140 D 02A
311 140 D
s
1.550 ... 1.574 1.525 02A 311 140 D 02A
s o
311 140 E
cial p
f inform
1.575 ... 1.599 1.550 02A 311 140 E 02A
mer
311 140 E
atio
om
1.600 ... 1.624 1.575 02A 311 140 E 02A
n
c
i
or
311 140 F
thi
te
sd
a
1.625 ... 1.649 1.600 02A 311 140 F 02A
iv
o
pr
311 140 F
um
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ng
t.
1.650 ... 1.674 1.625 02A 311 140 F 02A
op
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1.675 ... 1.699 1.650 02A 311 140 G 02A
p by
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311 140 G Prote
cted AG.
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1.700 ... 1.724 1.675 02A 311 140 G 02A
311 140 H
1.725 ... 1.749 1.700 02A 311 140 H 02A
311 140 H
118 Rep. Gr.35 - Gears, shafts
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
Bearing play Shim
1.750 ... 1.774 1.725 02A 311 140 H 02A
311 140 J
1.775 ... 1.791 1.750 02A 311 140 J 02A
311 140 J
2.3 Carrying out check measurement
– Install universal dial gauge bracket -VW 387- and dial gauge.
– Rotate input shaft so that tapered roller bearings settle.
– Press input shaft in direction of arrow.
– Bearing play should be min. 0.01 G… max.
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2. Adjusting input shaft 119
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
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Special tools and workshop
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♦ Universal dial gauge brack‐
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hole
spec
♦ End dimension plate -
es, in part or in w
VW 385/17-
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♦ Thrust pad -VW 512-
rrectness of i
♦ Straightening tool -3114/2-
l purpos
♦ Press tool -VW 407-
♦ Torque wrench -
nform
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V.A.G 1331-
m
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♦ Dial gauge
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It is necessary to readjust the output shaft when the following
components are renewed:
♦ Final drive gear set
♦ Clutch housing
or
♦ Tapered roller bearing
Adjustment overview ⇒ page 247
120 Rep. Gr.35 - Gears, shafts
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
– Press small tapered roller bearing outer race together with a
0.65 mm thick shim into clutch housing to stop.
– Install output shaft and tighten nuts for output shaft bearing
support to specified torque ⇒ Item 11 (page 81) .
– Set up dial gauge (3 mm measuring range) and set to “O”with
1 mm preload.
– Move output shaft up and down and note dial gauge reading
(example: 0.30 mm).
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Determining thickness of shim.
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The specified bearing preload is obtained by adding a constant
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the thickness of the shim installed (0.65 mm).
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Example:
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Installed shim 0.65 mm
+ Measured value 0.30 mm rrectne
+ Preload (constant) 0.20 mm
Shim thickness 1.15 mm
ss o
– Remove output shaft and pull out small tapered roller bearing
cial p
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outer race ⇒ page 129 .
form
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The following shims are available:
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Thickness (mm) Part number
or
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0.65 020 311 391 P
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0.70 020 311 391 Q
um
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0.75 op
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020 311 391 Co
0.80 020 311 391 A
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0.90 020 311 391 C
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0.95 020 311 391 D
1.00 020 311 391 E
1.05 020 311 391 F
1.10 020 311 391 G
1.15 020 311 391 H
1.20 020 311 391 J
1.25 020 311 391 K
1.30 020 311 391 L
1.35 020 311 391 M
1.40 020 311 391 N
The various thicknesses make it possible to achieve the exact
shim thickness required.
3. Adjusting output shaft 121
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
– Press in small tapered roller bearing outer race together with
the correct shim (in example 1.15 mm) and install output shaft.
Tighten bearing support nut in clutch housing to prescribed
torque ⇒ Item 11 (page 81) .
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122 Rep. Gr.35 - Gears, shafts
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
4 Dismantling and assembling output
shaft
4.1 Assembly overview - output shaft
Special tools and workshop
equipment required
♦ Press tool -VW 407-
♦ Press tool -VW 412-
♦ Thrust pad -VW 512-
♦ Puller -V.A.G 1582-
♦ Adapter -V.A.G 1582/4-
♦ Adapter -V.A.G 1582/5-
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4. Dismantling and assembling output shaft 123
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
♦ Pressure plate -VW 402-
♦ Thrust piece -32 - 111-
♦ Press tool -VW 408 A-
♦ Press tool -VW 409-
♦ Support rails -VW 457-
♦ Tube -VW 519- n AG. Volkswagen AG do
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124 Rep. Gr.35 - Gears, shafts
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
♦ Thrust ring -VW 429-
♦ Tube -VW 415 A-
♦ Thrust pad -VW 447 H-
♦ Thrust piece -VW 454-
♦ Installing sleeve -VW 455-
♦ Drift sleeve - 41 - 501-
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♦ Counter support -4 - Kukko 22/2-
4. Dismantling and assembling output shaft 125
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
♦ Two-arm puller -1 - Kukko 20/10- with 250 mm long hooks
♦ Hexagon bolt M10 x 20
Note
The output shaft is dismantled as follows: - Position separating
device under 2nd gear synchromeshed gear
⇒ Item 19 (page 128) and press off as shown in Fig.
⇒ page 130 . - Remove retaining ring ⇒ Item 15 (page 128) . -
Position two-arm puller under bearing support
⇒ Item 9 (page 127) and pull off locking collar withen1st
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gear synchro-hub as shown in Fig. ⇒ page 130 olks .
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parts are exchanged, the output shaft must be readjusted. See
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adjustment overview ⇒ page 247 .
spec
es, in part or in w
♦ Always renew both tapered roller bearings together as a set.
t to the co
♦ Removing and installing output shaft ⇒ page 82 .
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126 Rep. Gr.35 - Gears, shafts
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
1 - Hexagon nut
❑ ⇒ Item 11 (page 81)
2 - Clutch housing
3 - Shim
❑ Determining thickness
⇒ page 120
4 - Small tapered roller bearing
outer race
❑ Removing ⇒ page 129
❑ Pressing in
⇒ page 129
5 - Small tapered roller bearing
inner race
❑ Pulling off ⇒ page 130
❑ Pressing on
⇒ page 130
6 - Output shaft
❑ Paired with final drive
gear wheel. Always re‐
new as a set.
❑ Adjusting ⇒ page 120
7 - Large tapered roller bearing
inner race
❑ Pulling off ⇒ page 131
❑ Pressing on
⇒ page 131 AG. Volkswagen AG d
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❑ Place sealing rings (Qty. ss c
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9 - Bearing support
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10 - Thrust washer
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❑ Shoulder of thrust washer faces tapered roller bearing
11 - Synchromeshed gear for 1st gear
rrectness of i
❑ From gearbox date 04 09 0 onwards, 1st gear synchronisation was changed ⇒ page 136
l purpos
12 - Needle bearing
❑ For 1st gear
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13 - Synchro-ring for 1st gear
m
❑ Check for wear ⇒ page 131
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❑ Identification ⇒ page 131
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❑ Distinguishing ⇒ page 132
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❑ After removing retaining ring ⇒ Item 15 (page 128) , pull off via bearing support ⇒ page 130
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❑ Assembling locking collar and synchro-hub ⇒ page 132
❑ Installation position ⇒ page 132
4. Dismantling and assembling output shaft 127
Bora 1999 ➤ , Golf 1998 ➤ AG. Volkswagen AG d
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❑ Pressing on ⇒ page 133 oris nte
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❑ From gearbox date 04 09 0 onwards, 1st gear synchronisation was changed ⇒ page 136 au ra
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15 - Retaining ring
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16 - Synchro-ring for 2nd gear
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❑ Identification ⇒ page 131
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❑ Distinguishing ⇒ page 132
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❑ Check for wear ⇒ page 133
spec
es, in part or in w
❑ Assemble so that notches engage in locking pieces of locking collar ⇒ Item 14 (page 127)
t to the co
17 - Outer ring
❑ Insert in synchro-ring ⇒ Item 16 (page 128) ; installation position ⇒ page 133
rrectness of i
❑ Renew if scored
18 - Synchro-ring l purpos
❑ (Inner ring)
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❑ Check for wear ⇒ page 133
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❑ Check lugs for scoring
ion
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❑ Installation position ⇒ page 134
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19 - Synchromeshed gear for 2nd gear
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21 - Thrust washer Prote AG.
22 - Sleeve for 3rd gear needle bearing.
❑ Pressing off with synchromeshed gear for 2nd gear ⇒ page 130
❑ Pressing on ⇒ page 134
23 - Needle bearing
❑ For 3rd gear
24 - Synchromeshed gear for 3rd gear
25 - Synchro-ring for 3rd gear
❑ Check for wear ⇒ page 131
26 - Locking collar with synchro-hub for 3rd and 4th gears
❑ Press off with 2nd gear synchromeshed gear ⇒ Item 19 (page 128) and 3rd gear ⇒ Item 24 (page 128)
⇒ page 130 .
❑ Dismantling ⇒ page 134
❑ Installation position, locking collar and synchro-hub ⇒ page 135
❑ Assembling locking collar and synchro-hub ⇒ page 134
❑ Pressing on ⇒ page 135
27 - Sleeve
❑ For needle bearing
❑ Press off with locking collar and synchro-hub for 3rd and 4th gears ⇒ Item 26 (page 128)
❑ Pressing on ⇒ page 135
28 - Needle bearing
❑ For 4th gear
29 - Synchro-ring for 4th gear
❑ Check for wear ⇒ page 131
128 Rep. Gr.35 - Gears, shafts
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
30 - Synchromeshed gear for 4th gear
31 - Thrust washer
32 - Needle bearing
❑ For output shaft
❑ Removing and installing ⇒ page 93
33 - Gearbox housing
34 - Sleeve
❑ For output shaft needle roller bearing
❑ Pressing off ⇒ page 130
❑ Pressing on ⇒ page 136
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36 - Dished washer s au ra
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❑ Installation position ⇒ page 91
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37 - Torx socket head bolt M10
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❑ ⇒ Item 4 (page 79)
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Pulling out small tapered roller bearing outer race
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-A- Internal puller 37 ... 46 mm -Kukko 21/6-
-B- Counter support -Kukko 22/2-
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4. Dismantling and assembling output shaft 129
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
Pulling off small tapered roller bearing inner race
-A- Vice with jaw protectors
– Fit adapter and tighten behind bearing rollers, then turn bear‐
ing and retighten gripping device.
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Pressing off 3rd and 4th gear synchro-hub/locking collar, 2nd, 3rd
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and 4th gear wheels with gearbox housing needle roller bearing
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-A- Splitter 22 … 115 mm -Kukko 17/2-
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Support splitter so that the 1st and 2nd gear locking collar is not
pulled off at the same time.
Pulling off locking collar with synchro-hub via bearing support
-A- Two-arm puller -Kukko 20/10- with 250 mm long hooks
-B- 17 mm hexagon bolt, 10 x 20 mm
Note
Remove circlip before pulling off individual components.
130 Rep. Gr.35 - Gears, shafts
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
Pulling off large tapered roller bearing inner race
-A- Vice jaw protectors
– Before fitting puller, insert a M10 x 20 hexagon bolt in output
shaft drilling.
Pressing on large tapered roller bearing inner race
-A- Thrust washer
– Fit thrust washer before pressing on inner race. Shoulder
faces inner race.
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– Press synchro-ring onto cone of synchromeshed gear and
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measure gap “a” using feeler gauge.
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Gap “a” Installation (new) di‐ Wear limit
mension
1st gear 1.0 ... 1.7 mm 0.5 mm
3rd gear 1.0 … 1.7 mm rrectness of i
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4th gear 1.0 … 1.7 mm
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Identifying 1st and 2nd gear synchro-rings
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♦ 1st gear synchro-ring - 3 ground-down half teeth -arrow-
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♦ 2nd gear synchro-ring - 3 half teeth -arrow- or 2 ground-down
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replacement part for the 2nd gear synchro-ring.
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4. Dismantling and assembling output shaft 131
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
Distinguishing 1st and 2nd gear synchro-rings
♦ 1st gear synchro-ring - no recesses
♦ 2nd gear synchro-ring - three recesses -arrows-
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Dismantling and assembling locking collar and synchro-hub for
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4 - Locking piece
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– Slide locking collar over synchro-hub.
The wide shoulder of the synchro-hub -arrow A- and the outer
rrectness of i
splines of the locking collar -arrow B- face opposite directions af‐
ter assembly. Recesses for locking pieces on synchro-hub and
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Assembling locking collar with synchro-hub for 1st and 2nd gears
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– Insert locking pieces and install springs offset 120°. Angled
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end of spring must locate in hollow locking piece.
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Installation position of locking collar with synchro-hub for 1st and
2nd gears
The locking collar splines -arrow 1- point to splines for 3rd/4th
gear synchro-hub -A-.
The wide shoulder of the synchro-hub -arrow 2- then faces to 1st
gear -B-.
132 Rep. Gr.35 - Gears, shafts
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
Pressing on locking collar and synchro-hub for 1st and 2nd gears
Note
Before pressing on, place 1st gear synchro-ring on 1st gear
wheel.
Checking 2nd gear synchro-rings for wear
– Press synchro-ring, outer ring and inner ring onto cone of syn‐
chromeshed gear and measure gap “a” using a feeler gauge.
Gap “a” Installation (new) di‐ Wear limit
mension
2nd gear 1.2 ... 1.8 mm 0.5 mm
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Checking inner ring for wear
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– Press inner ring onto cone of 2nd gear synchromeshed gear
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and measure gap “a” with a feeler gauge.
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4. Dismantling and assembling output shaft 133
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Bora 1999 ➤ , Golf 1998 ➤ aut
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5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010 s
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Installation position synchro-ring (inner-ring) -A-
itte
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Lugs -arrow 1- engage in notches -arrow 2- in synchro-ring -B-.
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Installation position of synchromeshed gear for 2nd gear
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Higher shoulder -A- faces 1st gear -B-. Notches in shoulder
n
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-arrows- engage in lugs of outer ring ⇒ page 133 .
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Pressing on sleeve for 3rd gear needle bearing
Dismantling and assembling 3rd and 4th gear locking collar and
synchro-hub
1 - Spring
2 - Locking piece
3 - Locking collar
4 - Synchro-hub
– Slide locking collar over synchro-hub.
Notches for locking pieces in synchro-hub and locking collar must
align.
134 Rep. Gr.35 - Gears, shafts
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
Assembling locking collar and synchro-hub for 3rd and 4th gears
Locking collar has been pushed over synchro-hub.
Locking pieces are hollow on inside.
– Insert locking pieces and install springs offset 120°. Angled
end of spring must locate in hollow locking piece.
Locking pieces are not hollow on inside.
– Insert locking pieces and install springs offset 120°. Springs
must seat with angled ends in front of locking pieces.
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Installation position of locking collar with synchro-hub
ised b for 3rd and ara
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4th gears hor eo
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Chamfer -arrow- faces 4th gear. s
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Pressing on synchro-hub with locking collar for 3rd and 4th gears
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Pressing on sleeve for 4th gear needle bearing
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Prote AG.
4. Dismantling and assembling output shaft 135
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
Pressing on sleeve for output shaft needle bearing
4.2 1st gear synchronisation changed from
gearbox date 04 09 0
Following new components have been added or existing ones
changed:
♦ -A- Inner ring
♦ -B- Outer ring
♦ -C- Synchro-ring
olkswagen AG
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With additional notches
olk-4-
swa for lugs -1- of innerdring
g oes -A-.
not
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♦ Synchromeshed
or
ise gear for 1st gear
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With additional
ss
a notches -3- for lugs -2- of outer ring -B-. c
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♦ The same inner ring, outer ring and synchro-ring is also in‐
wit
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stalled on 2nd gear.
h re
hole
spec
♦ If components are not to be renewed, ensure that they are
es, in part or in w
matched with their original gears.
t to the co
Installation position of inner ring, outer ring and synchro-ring for
rrectness of i
1st gear
l purpos
– Place inner ring -A- on synchromeshed gear for 1st gear.
Angled lugs -arrows 1- face outer ring -B-.
nform
ercia
– Fit outer ring -B-.
m
at
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ion
Lugs -arrows 2- engage in notches -arrows 3- of synchromeshed
c
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ate
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– Fit synchro-ring -C-.
p
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Notches -arrows 4- engage in lugs -arrows 1- of inner ring -A-.
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136 Rep. Gr.35 - Gears, shafts
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
Check 1st gear inner ring for wear.
– Press inner ring onto cone of synchromeshed gear and meas‐
ure gap “a” using a feeler gauge.
Gap “a” Installation (new) di‐ Wear limit
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1st gear 0.75 ... 1.25 mm by Vol 0.3 mm not
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Check 1st gear synchro-ring and outer ring for wear.
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– Press synchro-ring, outer ring and inner ring onto cone of syn‐
h re
hole
chromeshed gear and measure gap “a” using a feeler gauge.
spec
es, in part or in w
t to the co
Gap “a” Installation (new) di‐ Wear limit
mension
1st gear 1.2 ... 1.8 mm 0.5 mm
rrectness of i
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Assembling locking collar and locking pieces with 1st and 2nd
or c
gear synchro-hub
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With introduction of modified 1st gear synchronisation, collar is
equally wide on both sides of synchro-hub.
The collar has a chamfer on one side -arrow B-.
Chamfer on collar of synchro-hub and outer teeth of locking collar
-arrow A- face in same direction after assembly.
Notches -arrow C- in synchro-hub and sliding collar for locking
pieces must align.
Installation position of locking collar with synchro-hub for 1st and
2nd gears
Teeth of locking collar -arrow- face splines for 3rd and 4th gear
synchro-hub -A-.
– Remove and reinstall 1st and 2nd gear synchro-hub as de‐
scribed previously.
4. Dismantling and assembling output shaft 137
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
5 Dismantling and assembling reverse shaft
AG. Volkswagen AG d
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Special tools and workshop sed b ara
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equipment required hori
eo
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♦ Thrust piece -VW 454- ss
ce
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un
pt
♦ Thrust pad -VW 447 H-
an
d
itte
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rm
ab
♦ Press tool -VW 411-
pe
ility
ot
♦ Centring mandrel -12 - 551-
wit
, is n
h re
hole
♦ Pressure plate -VW 401-
spec
es, in part or in w
♦ Press tool -VW 408 A-
t to the co
rrectness of i
l purpos
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♦ Press tool -VW 407-
138 Rep. Gr.35 - Gears, shafts
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♦ Internal puller -1 - Kukko 21/2-
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urposes, in part or in wh
t to the co
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mer
♦ Counter support -4 - Kukko 22/1-
atio
om
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After dismantling, always renew needle bearing in clutch housing
fo
en
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and reverse shaft support.
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1 - Clutch housing cted agen
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2 - Needle bearing
❑ Pulling out ⇒ page 140
❑ Pressing in
⇒ page 140
3 - Reverse gear wheel
4 - Retaining ring
❑ Always renew after re‐
moving.
5 - Synchromeshed gear for re‐
verse gear
❑ Remove retaining ring
before renewing.
❑ Shoulder faces reverse
gear wheel
6 - Reverse shaft
❑ Removing ⇒ page 82
7 - Needle bearing
❑ Pressing out
⇒ page 140
❑ Pressing in
⇒ page 140
8 - Reverse shaft support
❑ Removing and installing
⇒ page 82
5. Dismantling and assembling reverse shaft 139
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
Pulling needle bearing out of clutch housing
-A- Counter support -Kukko 22/1-
-B- Internal puller -Kukko 21/2- , 14.5 ... 18.5 mm
Note
olksw
The needle bearing is destroyed agduring
en AG. Vremoval anddomust
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Pressing needle bearing -A- into clutch housing
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itte
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spec
es, in part or in w
t to the co
rrectness of i
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nform
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Pressing needle bearing out of reverse shaft support
m
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ion
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Pressing needle bearing into reverse shaft support
140 Rep. Gr.35 - Gears, shafts
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
39 – Final drive - rear differential
1 Propshaft
1.1 Assembly overview - repairing propshaft
Special tools and workshop
equipment required
♦ Drive shaft fitting appliance
-VW 391-
♦ Pressure plate -VW 401-
♦ Pressure plate -VW 402-
♦ Press tool -VW 407-
♦ Press tool -VW 408A-
♦ Drift sleeve -VW 244B-
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es, in part or in w
t to the co
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1. Propshaft 141
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
♦ Support sleeve -VW 522-
♦ Tensioner -40 - 204 A-
♦ Hose clip pliers -V.A.G AG. Volkswagen AG d
agen oes
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♦ Torque wrench -V.A.G hor eo
ut
1331/- ss a ra
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♦ Circlip pliers -VW 161 A-
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♦ Puller -2 - Kukko 18/0-
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♦ Splitter -3 - Kukko 17/1-
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es, in part or in w
t to the co
rrectness of i
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Note
♦ To obtain the quietest possible running, the entire propshaft is
balanced during manufacture. It is not possible to balance the
entire propshaft or separate propshaft tubes with workshop
equipment. Therefore, in the event of damage to the front or
rear propshaft tube, the entire propshaft must always be re‐
newed.
♦ Keep propshaft straight; store and transport fully extended on‐
ly.
♦ Before removing, mark positions of all parts relative to each
other. Reinstall in the same position otherwise imbalance will
be excessive, the mountings could be damaged causing rum‐
bling noises.
142 Rep. Gr.39 - Final drive - rear differential
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
1 - Gearbox with bevel box
2 - 12-point flange bolt, 60 Nm
3 - Flexible coupling with heat
shield
❑ Removing and installing
⇒ page 151
❑ Installation position
⇒ page 153
4 - 12-point flange bolt, 60 Nm
5 - Front propshaft tube
❑ Do not damage centring
sleeve or seal inside
flange when removing
and installing.
6 - Socket head bolt, 40 Nm
7 - Locking plate
8 - Clamp
❑ Tightening ⇒ page 145
9 - Constant velocity joint boot
❑ Drive off with a drift be‐
fore pressing off con‐
stant velocity joint
❑ Check for damage
10 - Dished washer
❑ Inner circumference
serrated.
❑ Installation position:
Large diameter lies
against constant veloci‐
ty joint.
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11 - Seal wage does
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❑ Renewing: pull off protective foil and stickeonto
db
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12 - Constant velocity joint au
th eo
ra
ss c
❑ Pressing off ⇒ page 144
ce
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nl
pt
❑ Pressing on ⇒ page 145
du
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❑ Filling with grease: press 25 g grease -G6.3- into joint from each side (50 g total). Add grease if necessary
erm
ab
when renewing joint boot.
ility
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13 - Retaining ring
h re
hole
❑ Renew
spec
es, in part or in w
❑ Remove and install with circlip pliers -VW 161A- .
t to the co
14 - Hexagon bolt, 45 Nm
15 - Washer
rrectness of i
❑ Always renew
l purpos
16 - Flange
nform
ercia
❑ Pulling off ⇒ page 145
❑ Pulling on ⇒ page 145
m
at
om
ion
17 - Intermediate bearing
c
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or
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❑ Pulling off ⇒ page 146
at
do
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❑ Installation position ⇒ page 146
p
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❑ Driving on ⇒ page 146
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143
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Prote AG.
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
18 - Bolt, 25 Nm
19 - Rear propshaft tube
❑ Do not damage centring sleeve or seal inside flange when removing and installing.
20 - 12-point flange bolt, 60 Nm
❑ Modification: from 06.99, new securing bolts with 12-point socket heads.
❑ Two of the new securing bolts might be installed with balancing discs instead of washers.
❑ Balancing washers on bolts have been discontinued with introduction of balancing nuts
⇒ Item 21 (page 144) and balancing washers ⇒ Item 22 (page 144) on bolts ⇒ Item 23 (page 144) .
21 - Balancing nut wage
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❑ Not fitted on all propshafts.
d byV ua
ran
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❑ If flange bolt ⇒thItem 23 (page 144) is loosened, balancing nut
o tee and balancing washer
or
⇒ Item 22 (page
ss
au
144) must not be reinstalled. ac
ce
le
22 - Balancing washer
un
pt
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itte
❑ Not fitted on all propshafts.
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erm
ab
❑ If flange bolt ⇒ Item 23 (page 144) is loosened, balancing nut and balancing washer
ility
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⇒ Item 21 (page 144) must not be reinstalled.
wit
is n
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23 - 12-point flange bolt, 60 Nm
ole,
spec
urposes, in part or in wh
❑ Modification: From 09.02 onwards, new securing bolts with balancing nuts ⇒ Item 21 (page 144) and
t to the co
balancing washers ⇒ Item 22 (page 144) were introduced for some propshafts
❑ Two of the new securing bolts might be installed with a balancing nut and balancing washer.
❑ If securing bolts are unscrewed, balancing washer and balancing nut are not allowed to be reinstalled
rrectne
Note
ss o
cial p
Balancing washers in conjunction
inform
with bolt ⇒ Item 20 (page 144) are
mer
not installed then.
atio
om
n
c
i
or
24 - Flexible coupling with vibration damper
thi
te
sd
va
❑ Removing and installing ⇒ page 153
i
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pr
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fo
❑ Installation position ⇒ page 156
en
ng
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25 - Rear final drive C py
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Pressing off constant velocity joint
144 Rep. Gr.39 - Final drive - rear differential
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
Pressing on constant velocity joint
– Press on carefully.
– Tighten tensioner -40 - 204 A- securely. Propshaft must not
be pushed down within tensioner -40 - 204 A- , or paintwork
will be damaged.
– Repair possible paint damage as follows: remove residual
grease or oil with nitro thinner -L 001 600- . Apply 2 component
acrylic paint -ALN 769 041- with hardener -ALZ 009 001- .
Tightening clamp
Allocate clamps using ⇒ Electronic parts catalogue (ETKA) .
Pulling off flange
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t to the co
Pulling on flange
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orm
m
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1. Propshaft 145
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
Pulling off intermediate bearing
– Rubber guide of intermediate bearing must be cut through and
metal casing removed.
A - Splitter, 12…75 mm , e.g. -Kukko 17/1-
B - Puller , e.g. -Kukko 18/0-
AG. Volkswagen AG d
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Installation position of intermediate bearing
ise
d b ara
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The longer support -A- faces to left
s a in direction of travel -arrow-.
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ility
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c
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Driving on intermediate bearing
or
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ate
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– Drive on intermediate bearing to stop.
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1.2 Removing and installing propshaft
Special tools and workshop equipment required
146 Rep. Gr.39 - Final drive - rear differential
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel
. Volkswage
drive - Edition 01.2010
AG n AG d
agen oes
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♦ Torque wrench -V.A.G 1331- db
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es, in part or in w
t to the co
rrectness of i
♦ Torque wrench -V.A.G 1332-
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Additional required information cted agen
Prote AG.
♦ Workshop Manual Golf 1998 ▸, Bora 1999 ▸ Engine, mechan‐
ics
♦ Workshop Manual Golf 1998 ▸, Bora 1999 ▸, Running gear,
axles, steering - front and four-wheel drive
A twin pillar lifting platform should be used when working on the
propshaft.
Note
♦ Before removing, mark positions of all parts relative to each
other. Reinstall in the same position otherwise imbalance will
be excessive, the mountings could be damaged causing rum‐
bling noises.
♦ Keep propshaft straight; store and transport fully extended on‐
ly.
Removing
– Remove retainer -1- above exhaust system -arrows-.
– Separate exhaust system at double clamp -2- and remove with
catalytic converter (2nd mechanic).
– Remove rear part of exhaust system ⇒ Rep. Gr. 26 ; Remov‐
ing and installing parts of exhaust system .
– Now remove rear and front heat shield.
1. Propshaft 147
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
– Unbolt front propshaft tube with flexible coupling from bevel
box flange -arrows-.
– Remove pendulum support from subframe -arrows A-.
– Separate front propshaft from rear propshaft -arrows-.
– Carefully press engine and gearbox forwards.
– Carefully pull front propshaft off centring pin.
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Note
h re
ole,
spec
When removing and installing do not damage seals in propshaft
urposes, in part or in wh
flanges.
t to the co
– Swing front propshaft down and remove.
rrectness o
cial p
f inform
mer
atio
om
n
c
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or
n thi
te
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Prote AG.
148 Rep. Gr.39 - Final drive - rear differential
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
– Unbolt rear propshaft with flexible coupling and vibration
damper from rear final drive -arrows-.
– Unbolt propshaft intermediate bearing from vehicle.
– Carefully pull rear propshaft off centring pin.
AG. Volkswagen AG d
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Note ss c
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un
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♦ Flexible coupling and vibration damper cannot be separated
itte
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from one another.
rm
ab
pe
ility
♦ Do not cant propshaft during removal; pull horizontally off cen‐
ot
wit
, is n
tring pin. Centring sleeve seal must not be damaged -arrow-;
h re
otherwise the complete propshaft must be renewed.
hole
spec
es, in part or in w
t to the co
Installing
Install in the reverse order of removal, observing the following:
rrectness of i
l purpos
Note
nform
ercia
♦ Do not damage seals in propshaft flanges -arrow- during re‐
moval and installation.
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a
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tion in
♦ Renew propshaft if damaged.
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♦ Do not cant front or rear propshaft tube; push horizontally onto
do
r
respective centring pin.
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Installation position for rear flexible coupling
Prote AG.
♦ Three projecting sleeves each on Haldex coupling flange and
propshaft flange engage in mounting holes of flexible coupling.
– Attach propshaft to Haldex coupling flange so that markings
-arrows- align.
1. Propshaft 149
AG. Volkswagen AG d
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Bora 1999 ➤ , Golf 1998 ➤ ut
ho eo
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a
5-speed manual gearbox 02C, four-wheel
ss drive - Edition 01.2010 c
ce
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un
pt
From 06.99, new balancing discs and new securing bolts between
an
d
itte
y li
propshaft and Haldex coupling flange have been used -arrows-.
rm
ab
pe
ility
The new securing bolts have 12-point socket heads.
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
Two of the new securing bolts might be installed with one bal‐
ancing disc each.
m
a
com
tion in
– Balancing discs must always be replaced with washers -A-.
r
te o
thi
Allocation of washers ⇒ ETKA (Electronic parts catalogue)
s
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do
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Cop py
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rig ht
py by
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cted agen
Prote AG.
From 09.02 onwards: Securing bolts with balancing nuts and bal‐
ancing washers for propshaft on flexible coupling -arrows-.
Balancing washers -A- (⇒ previous Fig.) are discontinued in that
case.
Installing intermediate bearing free of tension.
– Align intermediate bearing in its elongated holes so that prop‐
shaft is not under tension.
– Do not tighten intermediate bearing bolts to body until after
propshaft has been installed.
Note
♦ If droning noises occur during travel, note the following:
♦ Unbolt propshaft with flexible coupling from Haldex coupling
flange and offset it by one hole.
♦ If droning noises are still audible, front propshaft must be ro‐
tated one more hole.
Specified torques
150 Rep. Gr.39 - Final drive - rear differential
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
. Volkswagen AG
gen AG does
Pendulum support on subframe -arrows A- ⇒ RunningVogear, lksw
a
not
axles, steering - front and four-wheel drive; Rep. Gr. ed 40 ; Repair‐
by gu
ara
ing front suspension; I - Assembly overview - subframe,
horis anti-roll nte
eo
bar, suspension links . s aut ra
c
s
Intermediate bearing to body ⇒ Item 18 (page 144) .
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nl
pt
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itte
Flexible coupling with damper to Haldex coupling flange
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erm
ab
⇒ Item 20 (page 144) .
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Flexible joint with heat shield to bevel box flange
, is n
h re
⇒ Item 4 (page 143)
hole
spec
Connecting bolts to constant velocity joint ⇒ Item 6 (page 143) .
es, in part or in w
t to the co
Flexible coupling with heat shield to propshaft
⇒ Item 2 (page 143)
rrectness of i
Flexible coupling with vibration damper to propshaft
⇒ Item 23 (page 144)
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1.3 Removing and installing front flexible
nf
ercia
o
coupling
rm
m
atio
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Special tools and workshop equipment required
n in
or c
thi
e
♦ Torque wrench -V.A.G 1331-
t
sd
iva
o
r
rp
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f
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Cop py
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pyri by
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by
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Prote AG.
♦ Torque wrench -V.A.G 1332-
Additional required information
♦ Workshop Manual Golf 1998 ▸, Bora 1999 ▸ Engine, mechan‐
ics
A twin pillar lifting platform should be used when working on the
propshaft.
1. Propshaft 151
Bora 1999 ➤ , Golf 1998 ➤
. Volkswagen AG
5-speed manual gearbox 02C,kfour-wheel
swa
gen AG drive - Editiondoes01.2010
n ol ot g
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ris tee
tho or
Note ss
au ac
ce
le
un
pt
♦ Before removing, mark positions of all parts relative to each
an
d
itte
other. Reinstall in the same position otherwise imbalance will
y li
rm
ab
be excessive, the mountings could be damaged causing rum‐
pe
ility
bling noises.
ot
wit
, is n
h re
♦ Do not flex propshaft.
hole
spec
es, in part or in w
Removing
t to the co
– Unbolt flexible coupling with heat shield from front propshaft
(only one of the three bolts is visible here -arrow-).
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
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do
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rp
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op py
– Unbolt flexible coupling from bevel box flange -arrows-.
. C rig
ht ht
rig by
py Vo
– Separate exhaust system behind front pipe ⇒ Rep. Gr. 26 ;
co lksw
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cted agen
Removing and installing parts of the exhaust system . Prote AG.
– Remove pendulum support from subframe -arrows A-.
– Carefully press engine and gearbox forwards.
– Now carefully remove flexible coupling.
Installing
Install in the reverse order of removal, observing the following:
152 Rep. Gr.39 - Final drive - rear differential
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
Installation position of front flexible coupling
AG. Volkswagen AG d
♦ Heat shield -arrow- faces intermediate
lksw
bearing.
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♦ Three projecting sleeves reach
ise
d b
on gearbox flange and prop‐ ara
nte
shaft flange engage in umounting
tho holes of flexible coupling. eo
ra
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ility
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hole
spec
es, in part or in w
t to the co
Note
rrectness of i
♦ When removing and installing, do not damage seals in prop‐
shaft flanges.
l purpos
♦ Renew propshaft if damaged.
nf
ercia
o
♦ Ensure that propshaft is horizontal when pushed onto respec‐
rm
m
tive guide pin.
atio
om
n in
or c
Torque settings ⇒ page 150
thi
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1.4 Removing and installing rear flexible coupling
t.
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pyri by
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co lksw
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Prote AG.
1. Propshaft 153
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
Special tools and workshop
equipment required
♦ Gearbox support -2004-
♦ Torque wrench -
V.A.G 1331-
♦ Torque wrench -
V.A.G 1332-
♦ Engine and gearbox jack -
V.A.G 1383 A- with univer‐
sal gearbox mounting -
V.A.G 1359/2-
AG. Volkswagen AG d
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rm
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ot
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
Additional required information
m
a
com
tion in
♦ Workshop Manual Golf 1998 ▸, Bora 1999 ▸ Engine, mechan‐
r
te o
ics
thi
s
iva
do
A twin pillar lifting platform should be used when working on the
r
rp
cum
fo
propshaft.
en
ng
t.
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Cop py
t. rig
gh ht
Note pyri by
Vo
co lksw
by
cted agen
Prote AG.
♦ Before removing, mark positions of all parts relative to each
other. Reinstall in the same position otherwise imbalance will
be excessive, the mountings could be damaged causing rum‐
bling noises.
♦ Do not flex propshaft.
154 Rep. Gr.39 - Final drive - rear differential
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
Removing
– Unbolt flexible coupling from rear final drive -arrows-.
– Remove retainer -1- above exhaust system -arrows-.
– Separate exhaust system at double clamp -2- and remove with
catalytic converter (2nd mechanic).
– Remove rear part of exhaust system ⇒ Rep. Gr. 26 ; Remov‐
ing and installing parts of exhaust system .
– Now remove rear heat shield.
– Unbolt propshaft intermediate bearing from vehicle.
– Remove pendulum support from subframe -arrows A-.
AG. Volkswagen AG d
agen oes
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an
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Position engine and gearbox jack -V.A.G 1383 A- with univer‐
sal mounting -V.A.G 1359/2- and a wooden block under rear
propshaft.
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
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t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
1. Propshaft 155
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
– Carefully press engine and gearbox forwards, bringing pen‐
dulum support in contact in front of subframe -arrow-.
– Secure pendulum support with bolt -1- (M8 x 80 mm) and nut
. Volkswagen AG
-2- to subframe. swagen AG does
k not
y Vol gu
– Repair possible paint damage assefollows:
db remove residual ara
nte
grease or oil with nitro thinner -L
thor001
i
600- . Apply 2 component eo
acrylic paint -ALN 769 041-ss awith
u
hardener -ALZ 009 001- . ra
c
ce
e
nl
pt
du
an
itte
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erm
ab
ility
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wit
, is n
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hole
– Secure propshaft to gearbox jack against falling with belt -A-.
spec
es, in part or in w
– To unbolt rear propshaft tube, push forwards.
t to the co
– Do this by securing gearbox jack -2004- with bolt -B- and -M10-
nut to flexible coupling with vibration damper and support it on
rrectness of i
flange of rear propshaft -arrow-.
l purpos
– Lower propshaft slightly and remove flexible coupling.
Installing
nform
ercia
Install in the reverse order of removal, observing the following:
m
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
♦ When removing and installing, do not damage seals in prop‐
shaft flanges.
♦ Renew propshaft if damaged.
♦ Ensure that propshaft is horizontal when pushed onto respec‐
tive guide pin.
Installation position for rear flexible coupling
♦ Three projecting sleeves each on Haldex coupling flange and
propshaft flange engage in mounting holes of flexible coupling.
– Attach propshaft to Haldex coupling flange so that markings
-arrows- align.
156 Rep. Gr.39 - Final drive - rear differential
AG. Volkswagen AG d
agen oes
olksw not Bora 1999 ➤ , Golf 1998 ➤
byV gu
ara
rised
5-speed manual ntegearbox 02C, four-wheel drive - Edition 01.2010
ho eo
aut ra
From
s 06.99, new balancing discs and new securing bolts cbetween
s
ce
le
propshaft and Haldex coupling flange have been used -arrows-.
un
pt
an
d
itte
The new securing bolts have 12-point socket heads.
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
Two of the new securing bolts might be installed with one bal‐
ancing disc each.
nform
ercia
– Balancing discs must always be replaced with washers -A-.
m
a
com
tio
Allocation of washers ⇒ ETKA (Electronic parts catalogue)
n in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
From 09.02 onwards: Securing bolts with balancing nuts and bal‐
ancing washers for propshaft on flexible coupling -arrows-.
Balancing washers -A- (⇒ previous Fig.) are discontinued in that
case.
Installing intermediate bearing free of tension.
– Align intermediate bearing in its elongated holes so that prop‐
shaft is not under tension.
– Do not tighten intermediate bearing bolts to body until after
propshaft has been installed.
Note
♦ If droning noises occur during travel, note the following:
♦ Unbolt propshaft with flexible coupling from Haldex coupling
flange and offset it by one hole.
♦ If droning noises are still audible, front propshaft must be ro‐
tated one more hole.
Torque settings ⇒ page 150
1. Propshaft 157
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
2 Haldex coupling agen
AG. Volkswagen AG d
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2.1 Checking function of Haldex coupling ho eo
aut ra
ss c
– Drive front wheels of vehicle onto rolling road.
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e
nl
pt
du
an
itte
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erm
ab
WARNING
ility
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, is n
Keep the area in front of the vehicle clear. Carry out test with
h re
care to avoid damage.
hole
spec
es, in part or in w
t to the co
– Engage 1st gear and slowly start driving.
• If the vehicle is not pushed off the rolling road at an engine
rrectness of i
speed of 1500 rpm, then the Haldex coupling is defective.
l purpos
Note
nf
ercia
orm
♦ When the front wheels are driven whilst the rear wheels are
m
atio
m
stationary, the Haldex coupling will lock up. This means that
o
n in
c
the rear wheels are also driven.
or
thi
te
sd
a
♦ The Haldex coupling can accept differing speeds for a short
iv
o
r
rp
cu
period without locking up only with 1st gear engaged and en‐
o
m
f
en
ng
gine speed slightly above idling speed.
t.
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2.2 Checking oil level or changing oil in Hal‐
rig by
copy Vo
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dex coupling
cted agen
Prote AG.
Checking oil level in Haldex coupling
Special tools and workshop equipment required
♦ Torque wrench -V.A.G 1331-
♦ Vehicle diagnosis, testing and information system -VAS 5051-
158 Rep. Gr.39 - Final drive - rear differential
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
♦ Diagnostic cable -VAS 5051/1- or -VAS 5051/3-
– Connect vehicle diagnosis, testing and information system -
VAS 5051- ⇒ page 31 .
– In the display, select “Running gear (repair group 01; 40 …
49)”.
– Select “Four-wheel drive with Haldex coupling” on display.
– Select “01 - Self-diagnosis-capable system” on display.
– Select “Four-wheel drive Haldex” on display.
– Select “Electrical components” on display.
– Select “Oil temperature” on display.
• The oil temperature must gbe between
en AG. Volkswa20
genand
AG 40 ?. a does
lksw n
• The oil temperature
db
y Vcan be attained by running engine
o ot g
ua until
warm. or
ise ran
te
h eo
ut ra
– Remove soil
s a inspection plug -arrow-. c
ce
e
nl
Oil level is correct when Haldex coupling is filled to lower edge,
pt
du
an
or at least to within about 3 mm of lower edge, of inspection hole.
itte
y li
erm
ab
– Tighten oil plug -arrow- to specified torque
ility
ot p
⇒ Item 4 (page 180) .
wit
, is n
h re
– If oil level is not correct, change oil in Haldex coupling
hole
spec
⇒ page 159 .
es, in part or in w
t to the co
Changing oil in Haldex coupling
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
2. Haldex coupling 159
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
Special tools and workshop AG. Volkswagen AG d
agen oes
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equipment required by
Vol not
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ara
ed
is nte
♦ Torque wrench - hor eo
ut
V.A.G 1331- ss a ra
c
ce
le
♦ Hand-cartridge gun -
un
pt
an
V.A.G 1628-
d
itte
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erm
ab
♦ Vehicle diagnosis, testing
ility
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and information system -
wit
VAS 5051- is n
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ole,
spec
♦ Diagnostic cable -
urposes, in part or in wh
VAS 5051/1- or -
t to the co
VAS 5051/3-
♦ High-performance oil for
rrectne
Haldex coupling -G 052
175 A1- (specification
⇒ page 5 )
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
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pr
cum
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fo
en
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t.
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pyri by
Vo
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by c lksw
cted agen
Prote AG.
Container size 0.25 l - Part no. G 052 175 A1
– Connect vehicle diagnosis, testing and information system -
VAS 5051- ⇒ page 31 .
– In the display, select “Running gear (repair group 01; 40 …
49)”.
– Select “Four-wheel drive with Haldex coupling” on display.
– Select “01 - Self-diagnosis-capable system” on display.
– Select “Four-wheel drive Haldex” on display.
– Select “Electrical components” on display.
– Select “Oil temperature” on display.
• The oil temperature must be between 20 and 40 ?.
• The oil temperature can be attained by running engine until
warm.
– Place drip tray underneath.
160 Rep. Gr.39 - Final drive - rear differential
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
– Remove drain plug -arrow- and drain oil completely.
– Insert cartridge with 0.25 l oil in hand-cartridge gun -
V.A.G 1628- .
– Have drain plug with new seal ready.
– Guide hand-cartridge gun -V.A.G 1628- vertically into drain
hole -arrow-.
– Pump oil completely into Haldex coupling.
– Lay hand-cartridge gun -V.A.G 1628- aside and immediately
screw in drain plug with new seal and tighten to specified tor‐
que ⇒ Item 4 (page 178) .
– Check oil level in Haldex coupling ⇒ page 158 .
2.3 Changing oil filter for Haldex Acoupling
G. Volkswagen n AG do
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Special tools and workshop equipment required
yV
olks ot g
ua
b
ed ran
♦ Angled ring spanner -T10066- thoris tee
or
au ac
ss
ce
e
nl
pt
du
an
itte
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erm
ab
ility
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wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
Removing
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– Place drip tray underneath.
nf
ercia
– Loosen oil filter with angled ring spanner -T10066- and screw
rm
out.
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om
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c
Installing
or
thi
te
sd
a
Location: oil filter -A- - hidden by sub-frame - is located on right-
iv
o
r
hand side of vehicle near front bearing bracket -B-.
rp
cu
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m
f
en
ng
t.
– Moisten O-ring of new oil filter with oil for Haldex coupling.
yi Co
Cop py
t. rig
– Screw in oil filter -A- and tighten to specified torque with span‐ gh ht
yri by
ner -T10066- ⇒ Item 9 (page 180) . cop Vo
by lksw
cted agen
Prote AG.
– Check oil level in Haldex coupling ⇒ page 158 and change oil
in Haldex coupling if necessary ⇒ page 159 .
2. Haldex coupling 161
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
3 Modifying gearbox support -VW 353-
Gearbox support -VW 353- must be modified to secure rear final
drive to assembly bracket.
Dimensions are given in mm.
– Mark hole -arrow 1- as shown in figure.
– Drill a 15 mm ∅ hole -arrow 1- in gearbox holder.
– Enlarge hole -arrow 2- to 15 mm ∅.
AG. Volkswagen AG d
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ss c
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nl
pt
du
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itte
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erm
ab
ility
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wit
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hole
spec
es, in part or in w
t to the co
rrectness of i
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nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
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f
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
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co lksw
by
cted agen
Prote AG.
162 Rep. Gr.39 - Final drive - rear differential
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C,
en AGfour-wheel
. Volkswagendrive
AG - Edition 01.2010 ag does
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4 Checking gear oil in rear final drive ris nte
tho eo
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and topping up ss c
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Checking
an
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Gear oil specification ⇒ page 5
ility
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– To check gear oil, remove oil plug -arrow-.
, is n
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hole
The oil level is correct when the rear final drive is filled to the lower
spec
edge of the filler hole.
es, in part or in w
t to the co
– Tighten oil plug -arrow- to specified torque
⇒ Item 4 (page 182) .
rrectness of i
Filling
l purpos
When filling with oil, note the following:
– Remove oil plug -arrow-.
nf
ercia
or
– Fill with gear oil to lower edge of filler hole.
m
m
atio
m
– Tighten oil plug -arrow- to specified torque
o
n in
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⇒ Item 4 (page 182) .
thi
te
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Prote AG.
4. Checking gear oil in rear final drive and topping up 163
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
5 Removing and installing rear final drive lkswagen AG. Volkswagen AG does no
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Special tools and workshop aut
ho eo
ra
equipment required ss c
ce
le
un
♦ Engine and gearbox jack -
pt
an
d
itte
V.A.G 1383 A- with univer‐
y li
erm
ab
sal gearbox mounting -
ility
ot p
V.A.G 1359/2-
wit
is n
h re
♦ Torque wrench -
ole,
V.A.G 1332-
spec
urposes, in part or in wh
♦ Multi-point bit -T10035-
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
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o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Additional required information
♦ Workshop Manual Golf 1998 ▸, Bora 1999 ▸ Engine, mechan‐
ics
♦ Workshop Manual Golf 1998 ▸, Bora 1999 ▸, Running gear,
axles, steering - front and four-wheel drive
Removing
– Remove rear section of exhaust system ⇒ Rep. Gr. 26 ; Re‐
moving and installing parts of exhaust system.
– Remove heat shield from vehicle floor under luggage com‐
partment.
– Mark position of rear propshaft tube on final drive flange with
paint.
164 Rep. Gr.39 - Final drive - rear differential
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
– Unbolt rear propshaft with flexible coupling and vibration
damper from rear final drive -arrows-.
– Separate right-hand drive shaft at flange and tie between up‐
per and lower transverse link.
– Separate left-hand drive shaft at flange and tie to lower trans‐
verse link.
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– Remove securing bolts -A- and -B- for front mounting bracket
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for final drive.
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– Remove bolts -C- for securing final drive mounting bracket to
ot
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subframe with socket insert -T10035- .
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spec
es, in part or in w
t to the co
rrectness of i
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nform
ercia
– Position engine and gearbox jack -V.A.G 1383 A- with univer‐
sal gearbox support -V.A.G 1359/2- only under final drive and
m
secure final drive.
com
tion in
r
– Remove left and right hand subframe securing bolts
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(-arrow A-).
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fo
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Figure only shows one of the two securing bolts.
– Pull connector off Haldex coupling connection -arrow C-.
– Pull breather pipes on left and right out of carrier -arrow-.
Note
Figure only shows left-hand vent pipe.
– Lower final drive slightly using engine and gearbox jack -
V.A.G 1383 A- and carefully pull out of subframe.
– Lower final drive.
5. Removing and installing rear final drive 165
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
– If final drive is to be renewed or mounted on assembly stand,
remove bearing bracket -A-.
Installing
Install in the reverse order of removal, observing the following:
♦ Always use new bolts to secure subframe to body.
– Observe different securing bolts for front mounting bracket of
final drive.
Bolts -A- M10 x 40
Bolt -B- M10 x 55
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♦ When removing and installing, do not damage seals in prop‐
rm
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shaft flanges.
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♦ Renew propshaft if damaged.
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spec
♦ Do not cant front or rear propshaft tube; push horizontally onto
es, in part or in w
respective centring pin.
t to the co
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– Attach propshaft to Haldex coupling flange so that markings
m
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-arrows- align.
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166 Rep. Gr.39 - Final drive - rear differential
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
From 06.99, new balancing discs and new securing bolts between
propshaft and Haldex coupling flange have been used -arrows-.
The new securing bolts have 12-point socket heads.
Two of the new securing bolts might be installed with one bal‐
ancing disc each.
– Balancing discs must always be replaced with washers -A-.
Allocation of washers ⇒ ETKA (Electronic parts catalogue)
Note
♦ If droning noises occur during travel, note the following:
♦ Unbolt propshaft with flexible coupling from Haldex coupling
flange and offset it by one hole.
♦ If droning noises are still audible, front propshaft must be ro‐
tated one more hole.
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– Check gear oil in rear final drive d ⇒ page 163 .
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– Check oil level in Haldexau coupling ⇒ page 158 .
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Specified torques
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Front mounting bracket on rear final drive ⇒ Running gear, axles,
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steering; front and four-wheel drive; Rep. Gr. 42 ; Assembly
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overview - subframe with final drive
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h re
hole
steering; front and four-wheel drive; Rep. Gr. 42 ; Assembly
spec
overview - subframe with final drive
es, in part or in w
t to the co
Rear mounting bracket on rear final drive ⇒ Running gear, axles,
steering; front and four-wheel drive; Rep. Gr. 42 ; Assembly
overview - subframe with final drive
rrectness of i
Rear mounting bracket on subframe ⇒ Running gear, axles,
l purpos
steering; front and four-wheel drive; Rep. Gr. 42 ; Assembly
overview - subframe with final drive
nf
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Drive shaft to flange shaft ⇒ Running gear, axles, steering - front
rm
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and four-wheel drive; Rep. Gr. 42 ; Repairing drive shafts; Re‐
atio
m
moving and installing drive shafts .
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Flexible coupling with damper to Haldex coupling flange
t
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⇒ Item 24 (page 144) .
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5. Removing and installing rear final drive 167
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
6 Renewing propshaft flange oil seal on rear final drive (final drive re‐
moved)
Special tools and workshop
equipment required
♦ Support plate -VW 309-
♦ Gearbox support -VW 353-
(modifying ⇒ page 162 ).
♦ Gearbox support -2004-
♦ Release lever -VW 681-
♦ Thrust piece -T10019-
♦ Torque wrench -
V.A.G 1601-
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168 Rep. Gr.39 - Final drive - rear differential
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
Removing
– Clamp rear final drive in assembly stand.
– To secure part, use M12 bolts with 1.5 mm pitch.
– Remove propshaft flange hexagon nut.
A - Hexagon bolts M10 x 20
Note
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When loosening hexagon
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– Pull off propshaft flange. If it is difficult to move, use three arm
pe
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puller -A-.
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-A- Three arm puller -Kukko 45/2-
hole
spec
– Pull out seal using oil seal extractor lever -VW 681- .
es, in part or in w
t to the co
Installing
– Lightly oil new seal around outer circumference and between
rrectness of i
sealing lips with high-performance oil for Haldex coupling -G
052 175 A1- before installing.
l purpos
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mercia
– Drive new oil seal in flush.
com
tion in
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– Install propshaft flange.
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6. Renewing propshaft flange oil seal on rear final drive (final drive removed) 169
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
– Insert new hexagon nuts with locking fluid -D 000 600 A2- and
tighten to specified torque ⇒ Item 1 (page 178) .
A - Hexagon bolts M10 x 20
Note
When tightening hexagon nuts for propshaft flange, counterhold
using pipe -C- with gearbox bracket -2004- (2nd mechanic).
– Install rear final drive ⇒ page 177 .
– Check oil level in Haldex coupling ⇒ page 158 .
– Specifications ⇒ page 5 .
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170 Rep. Gr.39 - Final drive - rear differential
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
7 Renewing flange shaft oil seals (final drive installed)
Special tools and workshop
equipment required
♦ Puller -T10037-
♦ Drift -VW 195-
♦ Torque wrench -
V.A.G 1332-
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Additional required information
agen
Prote AG.
♦ Workshop Manual Golf 1998 ▸, Bora 1999 ▸, Running gear,
axles, steering - front and four-wheel drive
Note
All figures show left side of final drive. Removal and installation
of flange shaft and oil seal on right-hand side is identical.
Removing
– Separate left-hand drive shaft at flange and tie to lower trans‐
verse link.
– Separate right-hand drive shaft at flange and tie between up‐
per and lower transverse link.
– Place drip tray under gearbox.
7. Renewing flange shaft oil seals (final drive installed) 171
Bora 1999 ➤ , Golf 1998 ➤ . Volkswagen AG
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5-speed manual gearbox 02C,ol swa
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– Remove flange shaft. To do thothis, screw lower support of puller or
s au
-T10037- into housing -arrow-. ac
s
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nl
– Pry seal out using assembly lever.
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Installing erm
ab
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es, in part or in w
t to the co
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– Drive new seal in onto limit stop.
l purpos
– Half-fill space between sealing lip and dust lip with sealing
grease for radial oil seal -G 052 128 A1- .
nform
ercia
– Clamp flange shaft in vice with protective jaw covers.
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– Press retaining ring out of groove in flange shaft using new
AG.
retaining ring -A-.
– Drive in flange shaft with plastic mallet.
– Renew flange shaft/drive shaft seal (pull off protective foil and
glue seal into joint).
– Install drive shaft ⇒ Running gear, axles, steering - front and
four-wheel drive; Rep. Gr. 42 ; Repairing drive shafts; Re‐
moving and installing drive shafts .
– Check gear oil in rear final drive ⇒ page 163 .
172 Rep. Gr.39 - Final drive - rear differential
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
8 Renewing O-ring between Haldex coupling and pinion housing (final
drive removed)
Special tools and workshop
equipment required
♦ Support plate -VW 309-
♦ Gearbox support -VW 353-
modifying gearbox support
⇒ page 162
♦ Torque wrench -
V.A.G 1331- wage
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8. Renewing O-ring between Haldex coupling and pinion housing (final drive removed) 173
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
Removing
– Tighten rear final drive to assembly stand.
– To secure part, use M12 bolts with 1.5 mm pitch.
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– Now remove all securing nuts for pinion housing -arrows-.
nform
mercia
a
Note
com
tion in
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te o
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Figure shows only 3 of the nuts.
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– Remove pinion housing, screwing in bolts -A- evenly so that
housing does not cant.
– Then remove O-ring -A-.
Installing
Install in the reverse order of removal, observing the following:
174 Rep. Gr.39 - Final drive - rear differential
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
– Insert O-ring -A- with gear oil.
– Insert shim(s) -B- of same thickness again.
– Check gear oil in rear final drive ⇒ page 163 .
– Check oil level in Haldex coupling ⇒ page 158 .
Torque setting:
Pinion housing to rear final drive housing ⇒ Item 7 (page 180) .
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urposes, in part or in wh
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8. Renewing O-ring between Haldex coupling and pinion housing (final drive removed) 175
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
AG. Volkswagen AG d
9 Renewing O-rings for rear final drive Vol
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Special tools and workshop equipment required ss a c
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♦ Torque wrench -V.A.G 1331-
pt
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nf
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Removing
orm
m
atio
– Drain gear oil.
om
n in
c
– Remove left or right flange shaft ⇒ page 171 .
or
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– Pull breather -arrow- out of rear final drive housing.
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– Remove right or left cover, screwing in bolts -A- evenly so that
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– Remove right cover together with differential.
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– Then remove O-ring -A-.
Installing
Install in the reverse order of removal, observing the following:
– Insert O-ring -A- with gear oil.
– Fill with gear oil to lower edge of filler hole.
– Press breather into rear final drive housing.
– Check gear oil in rear final drive ⇒ page 163 .
Torque setting:
Cover to rear final drive housing ⇒ Item 10 (page 182) or
⇒ Item 16 (page 183) .
176 Rep. Gr.39 - Final drive - rear differential
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
10 Dismantling and assembling rear fi‐
nal drive
10.1 Assembly overviews - rear final drive
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Prote AG.
10. Dismantling and assembling rear final drive 177
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
I - Removing and installing cover for Haldex coupling and plates
⇒ page 178 .
II - Removing and installing pinion housing ⇒ page 179 .
III - Removing and installing differential and bevel gear with stub
shaft ⇒ page 181 .
Removing and installing cover for Haldex coupling from plate
housing ⇒ page 183 . gen AG
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Procedure for dismantling and assembling ⇒ paged b186
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10.2 Removing and installing cover for Haldex coupling and plates ho
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1 - Hexagon nut, 220 Nm
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❑ Unscrewing
pe
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⇒ page 189
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❑ Fitting ⇒ page 196
h re
hole
❑ Insert with locking fluid -
spec
es, in part or in w
D 000 600-
t to the co
2 - Propshaft flange
❑ Pulling off ⇒ page 190
rrectness of i
3 - Hexagon bolt, 50 Nm
l purpos
4 - Oil drain plug, 15 Nm
❑ For Haldex coupling oil
nform
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5 - Seal
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❑ Always renew
n in
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6 - Haldex coupling cover
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❑ Remove together with
rp
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plate housing
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❑ To install, separate from Cop py
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⇒ page 192 co Vo
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7 - O-ring
AG.
❑ Always renew
❑ Moisten with high-per‐
formance oil for Haldex
coupling
8 - Ring
❑ Insert in pinion housing
9 - Roller
❑ Qty. 3
10 - Wheel roller
❑ Qty. 6
11 - Cam disc
❑ Observe installation position ⇒ page 194
12 - O-ring
❑ Qty. 3
❑ Always renew
❑ Insert in Haldex coupling cover
13 - Seal
❑ Always renew
178 Rep. Gr.39 - Final drive - rear differential
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
❑ O-rings may also be installed in some final drives ⇒ page 35
14 - All-wheel drive control unit -J492-
❑ Removing and installing ⇒ page 35
15 - Socket head bolt, 6 Nm
16 - Set of plates
❑ Observe installation position of outer and inner plates ⇒ page 194
17 - Hub
18 - Thrust washer
❑ Observe installation position ⇒ page 193
19 - Needle thrust bearing
❑ With thrust washer for needle thrust bearing agen
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❑ Installation position ⇒ page 193 d byV
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20 - Haldex coupling pump -V181- ut
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❑ Removing and installing ⇒ page 36 ss c
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21 - Socket head bolt, 6 Nm
an
d
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22 - Seal
ab
pe
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❑ Always renew
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23 - O-ring
hole
spec
❑ Always renew
es, in part or in w
t to the co
24 - O-ring
❑ Always renew
rrectness of i
25 - Pinion housing
l purpos
❑ ⇒ Item 8 (page 180)
nform
ercia
10.3 Removing and installing pinion housing
m
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tion in
12) Adjustment work is required if these components are replaced
r
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⇒ page 208 .
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10. Dismantling and assembling rear final drive 179
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
1 - Socket head bolt, 10 Nm AG. Volkswagen AG d
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2 - Cover by Vol not
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❑ For pinion housingrise nte
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❑ Has additional
ss a seal if ra
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cover is aluminium
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⇒ page 181
pt
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❑ Has inserted seal if cov‐
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ab
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pe
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⇒ page 181
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❑ Determine according to
hole
gearbox code using ⇒
spec
es, in part or in w
ETKA (electronic parts
t to the co
catalogue) ⇒ page 5
3 - Seal
rrectness of i
❑ Always renew
l purpos
❑ Made of various materi‐
als; allocate according
to ⇒ ETKA (electronic
nform
ercia
parts catalogue)
m
a
4 - Oil filler plug, 30 Nm
com
tion in
r
5 - Magnet
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s
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❑ Insert in cover
do
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⇒ Item 2 (page 180)
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6 - Seal
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7 - Hexagon nut, 45 Nm
AG.
❑ Insert with locking fluid -
D 197 300 A1-
❑ Renew
8 - Pinion housing 12)
❑ Removing ⇒ page 191
❑ Installing ⇒ page 193
❑ Repair shaft bevel gear mounting ⇒ page 207
❑ Sealing surface was increased for plastic cover ⇒ Item 2 (page 180) ⇒ page 181
❑ Determine according to ⇒ ETKA (electronic parts catalogue)
9 - Oil filter
❑ Tighten to 35 Nm
10 - O-ring
❑ Always renew
❑ Insert with Haldex coupling oil
11 - O-ring
❑ Always renew
❑ Coat with gear oil when installing
❑ Renewing ⇒ page 173
12 - Shim S3
❑ Note thickness
❑ Adjustment overview ⇒ page 208
13 - Rear final drive housing 12)
❑ Clean locking fluid from threads of studs for securing pinion housing
180 Rep. Gr.39 - Final drive - rear differential
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
Different versions of pinion housing covers
I - Aluminium cover -A- with additional seal -B-
II - Plastic cover with vulcanised seal -arrow 1-
Note
♦ Allocate seal for oil filler plug -arrow 2- via ⇒ ETKA (electronic
parts catalogue) .
♦ Use plastic cover only with pinion housing with wider sealing
surface ⇒ page 181 .
Pinion housing has wider sealing surface for cover -arrow-
Width of pinion housing sealing surface for plastic cover, dimen‐
sion -a- = 7 mm G. Volkswagen nA AG do
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Width of pinion housing ysealing
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10.4 Removing and installing differential and
spec
es, in part or in w
bevel gear with stub shaft
t to the co
13) Adjustment work is required if these components are replaced
⇒ page 208 .
rrectness of i
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10. Dismantling and assembling rear final drive 181
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
1 - Rear final drive housing 13)
2 - Stud, 10 Nm
3 - Oil drain plug, 25 Nm
❑ With magnet
4 - Oil filler plug, 25 Nm
❑ Capacity and specifica‐
tion ⇒ page 5
❑ Checking gear oil in rear
final drive ⇒ page 163
5 - Breather
❑ Pull out of rear final drive
housing before remov‐
ing differential
⇒ Item 9 (page 182)
6 - Bracket
❑ For wiring harness con‐
nector
❑ Various versions.
❑ Determine according to
⇒ ETKA (electronic AG. Volkswagen AG d
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7 - Hexagon bolt, 10 Nm ho
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❑ Qty. 2 ss
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8 - O-ring
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❑ Coat with gear oil when
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❑ Renewing with rear final
hole
spec
drive installed
es, in part or in w
⇒ page 176
t to the co
9 - Differential, complete
❑ Remove with cover ⇒ page 192
rrectness of i
❑ Install with cover, tightening hexagon head bolts ⇒ Item 16 (page 183) in stages diagonally
l purpos
⇒ page 193
❑ Dismantling and assembling ⇒ page 198
nform
ercia
10 - Hexagon bolt, 25 Nm
m
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11 - Right flange shaft
on
c
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❑ Removing ⇒ page 191
his
ate
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❑ Drive in with plastic hammer.
p
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12 - Retaining ring
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❑ Removing and installing ⇒ page 172 py by
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13 - Bevel gear with stub shaft 13)
agen
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❑ Bevel gear with stub shaft is matched with shaft bevel gear
❑ Determine according to gearbox code using ⇒ ETKA (electronic parts catalogue) ⇒ page 5
❑ Repairing bearings for bevel gear with stub shaft ⇒ page 216
14 - O-ring
❑ Always renew
❑ Coat with gear oil when installing
❑ Renewing with rear final drive installed ⇒ page 176
182 Rep. Gr.39 - Final drive - rear differential
n AG. Volkswagen AG do
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5-speed manual
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tee 01.2010
tho
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15 - Cover 13) ss
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❑ Removing ⇒ page 192
pt
du
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❑ Installing ⇒ page 192
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16 - Hexagon bolt, 25 Nm
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17 - Retaining ring
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hole
spec
❑ Always renew
es, in part or in w
❑ Removing and installing ⇒ page 172
t to the co
18 - Left flange shaft
❑ Removing ⇒ page 191
rrectness of i
❑ Drive in with plastic hammer.
l purpos
nform
ercia
10.5 Removing and installing cover for Haldex coupling from plate housing
m
at
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ion
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or
Special tools and workshop
his
te
equipment required
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or
♦ Pressure plate -VW 401-
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♦ Pressure plate -VW 402- Cop py
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♦ Press tool -VW 412- Prote AG.
♦ Extractor lever -VW 681-
♦ Centring mandrel -12 - 551-
10. Dismantling and assembling rear final drive 183
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
Special tools and workshop
equipment required
♦ Drift sleeve -41 - 501-
♦ Tube -3253/1-
♦ Tube -3296-
♦ Thrust piece -T10019-
♦ Internal puller -1 - Kukko
21/2-
♦ Counter support -4 - Kukko
22/1-
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es, in part or in w
t to the co
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Prote AG.
184 Rep. Gr.39 - Final drive - rear differential
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
1 - Seal
❑ For propshaft flange
❑ Renewing ⇒ page 168
❑ Pull out with oil seal ex‐
tractor lever -VW 681- .
❑ Drive in flush thrust
piece -T10019- .
2 - Retaining ring
3 - Deep groove ball bearing
❑ Pressing out
⇒ page 186
❑ Pressing in
⇒ page 186
4 - Haldex coupling cover
❑ Determine according to
⇒ ETKA (electronic
parts catalogue)
5 - Dished washer
❑ Installation position:
large ∅ (concave side)
faces plate housing
⇒ Item 15 (page 185)
❑ Observe various ver‐
sions
❑ Determine according to agen
AG. Volkswagen AG d
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⇒ ETKA (electronic Volksw not
gu
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parts catalogue) d b ara
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6 - Needle thrust bearing aut ra
c
washer ss
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7 - Needle thrust bearing
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washer
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8 - Needle thrust bearing
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9 - Needle thrust bearing
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10 - Needle thrust bearing
t to the co
11 - Needle thrust bearing rrectness of i
12 - Thrust washer
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13 - Thrust washer
14 - Thrust washer
nform
ercia
15 - Plate housing
m
at
om
❑ Pressing out Haldex coupling cover ⇒ page 192
ion
c
in t
or
16 - Needle bearing
his
ate
do
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❑ Pulling out ⇒ page 186
p
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❑ Pressing in ⇒ page 186
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10. Dismantling and assembling rear final drive 185
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
Pressing deep groove ball bearing out of Haldex coupling cover AG. Volkswagen AG d
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– First remove retaining ring. d by
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Pressing deep groove ball bearing into Haldex coupling cover
– Install retaining ring.
rrectness of i
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-A- Counter support -Kukko 22/1-
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-B- Internal puller -Kukko 21/2- 14.5 … 18.5 mm
AG.
-C- Jaw protectors
Pressing needle bearing into plate housing to stop
10.6 Assembly overview - Removing and installing Haldex coupling cover with
plate housing, set of plates, pinion housing with shaft bevel gear, bevel gear
with stub shaft and differential
186 Rep. Gr.39 - Final drive - rear differential
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
Special tools and workshop
equipment required
♦ Support plate -VW 309-
♦ Support clamp -VW 313-
♦ Gearbox support -VW 353-
modifying gearbox support
⇒ page 162
♦ Pressure plate -VW 402-
♦ Press tool -VW 412-
♦ Removal lever -80 - 200-
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t to the co
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orm
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Prote AG.
10. Dismantling and assembling rear final drive 187
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
Special tools and workshop
equipment required
AG. Volkswagen AG d
agen oes
♦ Multipurpose tool -VW 771- Volksw not
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d by ara
e
♦ Puller hooks -VW 771/37- horis nte
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♦ Gearbox support -2004- ss c
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♦ Assembly tool -3253/1-
pt
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♦ Hook -3438-
rm
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♦ Thrust piece -T10019-
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♦ Puller -T10037-
hole
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es, in part or in w
♦ 2 hexagon bolts M10 x 20
t to the co
rrectness of i
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♦ Angled ring spanner -T10066-
188 Rep. Gr.39 - Final drive - rear differential
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
♦ Three arm puller -Kukko 45/2-
Removing
– Remove retainer -arrow- for electrical wiring from rear final
drive.
– Drain gear oil and high-performance oil for Haldex coupling.
AG. Volkswagen AG d
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– Tighten rear final drive to assembly d bystand.
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– To secure part, use M12 bolts uthwith
o 1.5 mm pitch. eo
ra
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spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
atio
om
– Remove propshaft flange hexagon nut.
c
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or
n thi
te
A - Hexagon bolts M10 x 20
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When loosening hexagon nuts for propshaft flange, counterhold cop Vo
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using pipe -C- with gearbox bracket -2004- (2nd mechanic). cted agen
Prote AG.
10. Dismantling and assembling rear final drive 189
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
– Pull off propshaft flange. If it is difficult to move, use three arm
. Volkswagen AG
puller -A-. w a gen AG does
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-A- Three arm puller -Kukko 45/2-
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t to the co
– Pull off connector -1- to Haldex coupling pump.
– Remove securing bolts -arrows A-.
rrectness of i
– Remove control unit -2- for Haldex coupling.
l purpos
– Remove bolts -arrows B- for pump -3-.
nform
ercia
– Then turn pump slightly to right (clockwise).
m
– Pull out pump using, e.g. multi-purpose tool -VW 771- and
at
om
io
puller hook -VW 771/37- ⇒ page 37 .
n
c
in t
or
his
e
– Loosen oil filter -4- with spanner -T10066- and screw out.
at
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– Remove cover -A- from pinion housing -arrows-. . Cop py
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– Remove bolts for Haldex coupling cover from pinion housing.
rig by
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– Insert screwdrivers -A- in notches -arrow- in cover and lever
off cover.
– Pull cover together with plate housing out of pinion housing.
– Remove the 6 wheel rollers and the 3 rollers from pinion hous‐
ing.
– Now remove cam disc, set of plates, hub and thrust washer.
190 Rep. Gr.39 - Final drive - rear differential
n AG. Volkswagen AG do
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d ran
ir se 5-speed manual gearbox 02C, four-wheel tee drive - Edition 01.2010
tho
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ss
– Using hook -3438- , pull needle thrust bearing with washer out
ce
le
of pinion housing.
un
pt
an
d
itte
y li
– Now remove all securing nuts for pinion housing.
erm
ab
ility
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is n
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ole,
spec
urposes, in part or in wh
t to the co
rrectness
– Remove pinion housing, screwing in hexagon head bolts -A-
o
cial p
f
evenly so that housing does not cant.
inform
mer
– Remove shim S3.
atio
om
n
c
i
or
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te
sd
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fo
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t.
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Prote AG.
– Remove left flange shaft, screwing lower support of puller -
T10037- in cover on left -arrow- (fig. shows final drive instal‐
led).
– Remove right flange shaft, screwing lower support of puller -
T10037- into housing -arrow-.
10. Dismantling and assembling rear final drive 191
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
– Pull breather -arrow- out of rear final drive housing.
– Remove right cover (next to oil filler plug), screwing in bolts
-A- evenly so that cover does not cant.
– Remove right cover together with differential.
– Remove left cover.
Note
Removal is identical to removal of right cover ⇒ page 192 .
– Remove bevel gear with stub shaft.
Installing
– First press plate housing out of Haldex coupling cover.
AG. Volkswagen AG d
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– Insert bevel gear with stub shaft.
spec
urposes, in part or in wh
t to the co
– Install left cover with new O-ring.
– Moisten O-ring with gear oil.
rrectne
– Tighten hexagon bolts to specified torque
⇒ Item 16 (page 183) .
ss o
cial p
f inform
mer
atio
om
n
c
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Prote AG.
192 Rep. Gr.39 - Final drive - rear differential
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
– Insert right cover with differential and new O-ring -A- (mois‐
tened with gear oil) and tighten bolts evenlywand
agendiagonally. AG doe
AG. Volkswagen
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Vol t gu
– Tighten hexagon bolts to specified torque
ed
by ara
⇒ Item 10 (page 182) . ho
ris nte
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t
au ra
– Press breather into rear final sdrive
s housing. c
ce
le
un
pt
– Drive in left and right flange shafts with plastic hammer. First
an
d
itte
install new retaining ring ⇒ page 172 .
y li
erm
ab
ility
– Install shim S3.
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is n
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ole,
spec
urposes, in part or in wh
t to the co
– Insert new O-ring -A- in circumferential groove of pinion hous‐
ing and moisten with gear oil.
rrectne
– Install pinion housing with shaft bevel gear.
Installation position:
ss o
Oil filter mounting is located above oil filler plug.
cial p
f inform
– Screw in hexagon nuts with locking fluid -D 197 300 A1- and
mer
tighten in stages diagonally to specified torque
atio
m
⇒ Item 7 (page 180) .
o
n
c
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te
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t.
– Lay washer -1- for needle thrust bearing in pinion housing with
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– Then set needle thrust bearing -2- in place.
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– Then insert thrust washer -3- with larger smooth surface
-arrow B- facing hub -4-.
– Now push hub -4- onto shaft bevel gear with the 3 holes
-arrow C- facing upwards.
10. Dismantling and assembling rear final drive 193
Bora 1999 ➤ , Golf 1998 ➤
. Volkswagen AG
5-speed manual gearbox 02C, gen AG
afour-wheel drive - Edition
does 01.2010
lksw o n ot g
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– Lay first inner plate -2- inhopinion
ris housing -1-. tee
aut or
ac
– Then insert first outerssplate -3- and then the remaining 6 inner
and outer plates.
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pt
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t to the co
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tion in
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te o
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– Ensure that cam track remains visible when cam disc -A- is
s
iva
installed.
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Installation position:
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The 3 shortened teeth -arrows- must engage in the mating teeth
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of the hub.
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– Turn plate housing -A- while inserting it -arrows-, guiding hous‐
ing onto cam disc and set of plates.
– Lay the 3 rollers -B- in recesses of plate housing.
– Also set the 6 wheel rollers -C- in plate housing.
Note
The plate housing is shaped so that rollers and wheel rollers can
only be fit in one position.
– Then install ring -D-.
194 Rep. Gr.39 - Final drive - rear differential
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
– Lay thicker thrust washer -A- on wheel rollers and rollers in
plate housing.
– On top of that, lay needle thrust bearing -B- and thin thrust
washer -C- for needle thrust bearing.
Note
♦ The individual needle thrust bearing packets -1- through -3-
are allocated according to the diameters of the pistons in
Haldex coupling cover.
♦ Ensure that gap -arrow- between needle thrust bearing pack‐
ets -2- and -3- is of uniform size all around the circumference.
– Insert dished spring -4- with greater diameter (concave side)
facing ring ⇒ page 194 .
– Moisten O-rings -arrows A- and -arrow B- with high-perform‐
ance oil for Haldex coupling and insert in Haldex coupling
cover.
– Pull out middle piston -arrow C- about 5 mm uniformly around
the entire circumference.
– Carefully set Haldex clutch coupling -1- on pinion housing
-2-.
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– Screw in securing bolts -arrows- diagonallyagenin stages of 1/AG does
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– Gap -arrow A- must closeauniformly.
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Bolts must not become tight as long as there is a gap. It is possible
ot
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that a needle thrust bearing packet has slipped to the piston. Then
, is n
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remove cover and reposition needle thrust bearing.
hole
spec
es, in part or in w
– Tighten hexagon bolts to specified torque
t to the co
⇒ Item 3 (page 178) .
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
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195
cop Vo
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Prote
cted AG. 10. Dismantling and assembling rear final drive
agen
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel
en AG. V drive
olkswag-enEdition
AG 01.2010
ag does
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y Vol gu
– Secure cover -A- with new seal ed (observe
b different versions ara
nte
⇒ page 181 ) to pinion housingoris -arrows-. eo
th
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ss
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nl
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itte
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ility
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spec
es, in part or in w
t to the co
rrectness of i
– Install oil filter -4- and tighten to specified torque
⇒ Item 9 (page 180) .
l purpos
– Install pump -3- for Haldex coupling and control unit for Haldex
coupling -2-. Tighten bolts -arrows A- and -arrow B- to speci‐
nf
ercia
fied torque ⇒ Item 21 (page 179) or page
orm
⇒ Item 15 (page 179) .
m
atio
om
n in
– Push on connector -1- for pump.
or c
thi
te
sd
– Lightly oil new seal around outer circumference and between
iva
o
r
sealing lips with high-performance oil for Haldex coupling -G
rp
cu
o
m
052 175 A1- before installing.
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– Drive new oil seal in flush.
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– Install propshaft flange.
– Insert new hexagon nuts with locking fluid -D 000 600 A2- and
tighten to specified torque ⇒ Item 1 (page 178) .
A - Hexagon bolts M10 x 20
Note
When tightening hexagon nuts for propshaft flange, counterhold
using pipe -C- with gearbox bracket -2004- (2nd mechanic).
– Remove rear final drive from assembly bracket.
196 Rep. Gr.39 - Final drive - rear differential
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
– Install retainer -arrow- for electrical wiring on rear final drive.
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10. Dismantling and assembling rear final drive 197
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Bora 1999 ➤ by
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5-speed orismanual gearbox 02C, four-wheel drive -anEdition
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11 Dismantling and assembling differen‐
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11.1 Assembly overview - differential
hole
spec
es, in part or in w
t to the co
Special tools and workshop
equipment required
rrectness of i
♦ Puller -V.A.G 1582-
l purpos
♦ Adapter -V.A.G 1582/3-
♦ Press tool -VW 412-
nf
ercia
or
♦ Thrust plate - 40 - 105-
m
m
atio
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♦ Pressure plate -VW 401-
o
n in
or c
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♦ Pressure plate -VW 402-
t
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198 Rep. Gr.39 - Final drive - rear differential
Bora
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♦ Press tool -VW 408 A- s au ac
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♦ Thrust piece -VW 473-
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♦ Thrust plate -30 - 205-
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♦ Sleeve -3144-
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♦ Thrust piece -2007-
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hole
spec
♦ Torque wrench -
es, in part or in w
V.A.G 1332-
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11. Dismantling and assembling differential 199
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♦ Adapter -VW 295a-
un
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d
itte
♦ Press tool -VW 407-
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ility
♦ Thrust pad -VW 447 i-
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♦ Drift sleeve -40 - 21-
h re
ole,
spec
♦ Internal puller -1 - Kukko
urposes, in part or in wh
21/7-
t to the co
♦ Puller -2 - Kukko 18/1-
rrectne
♦ Splitter -3 - Kukko 17/1-
♦ Counter support -4 - Kukko
ss
22/1-
o
cial p
f inform
mer
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Note
♦ Heat tapered roller bearing inner race to 100° C before instal‐
ling.
♦ Always renew both tapered roller bearings together as a set.
♦ If tapered roller bearings, differential cage, gearbox housing
or clutch housing are renewed, adjust differential
⇒ page 248 .
200 Rep. Gr.39 - Final drive - rear differential
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
1 - Countersunk bolt, 25 Nm
❑ Screw into threaded
piece
⇒ Item 20 (page 202)
2 - Flange shaft
❑ Removing and installing
⇒ page 171
3 - Compression spring for
flange shaft
4 - Thrust washer
❑ Installation position:
shoulder towards spring
❑ Installation position with
modified thrust washer
⇒ page 206
5 - Tapered ring
❑ With grooves to engage
in thrust washer
❑ Installation position:
taper towards differen‐
tial cage
6 - Retaining ring
❑ Holds tapered ring,
thrust washer and
spring in position when
flange shaft is removed
7 - Gearbox housing
8 - Clutch housing
9 - Differential cage
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❑ Whenthrenewing
or final eo
drive
ss a gear, drill out rivet heads ⇒ page 204
u ra
c
❑ Attach final drive gear with bolts ⇒ page 205
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le
un
pt
an
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itte
10 - Bevel box connecting piece
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❑ Pressed onto differential housing
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ility
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❑ Press on and off only with differential housing removed
, is n
h re
❑ Pulling off ⇒ page 206
hole
spec
❑ Pressing on ⇒ page 206
es, in part or in w
t to the co
11 - Speedometer drive wheel
❑ Fit into differential housing to stop before pressing on tapered roller bearing inner race
rrectness of i
⇒ Item 12 (page 201)
l purpos
12 - Tapered roller bearing inner race
❑ Before removing, pull connecting piece off ⇒ Item 10 (page 201)
nform
ercia
❑ Pulling off ⇒ page 203
m
❑ Pressing on ⇒ page 203
a
com
tion in
13 - Tapered roller bearing outer race
r
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❑ Pressing out ⇒ page 202
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❑ Pressing in ⇒ page 203
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14 - Tapered roller bearing inner race
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❑ Pulling off ⇒ page 203
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11. Dismantling and assembling differential 201
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
❑ Pressing on ⇒ page 203
15 - Tapered roller bearing outer race
❑ Pulling out ⇒ page 203
❑ Pressing in ⇒ page 204
16 - Shim
❑ Determining thickness ⇒ page 248
17 - Spring pin
❑ For securing differential pinion pin
❑ Removing and installing ⇒ page 205
18 - Differential pinion pin
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19 - Small differential bevel gear ir se
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❑ Installing ⇒ page 205 aut or
ac
ss
20 - Threaded piece
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❑ Installing ⇒ page 205
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21 - Large differential bevel gear
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❑ Installing ⇒ page 205
is n
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22 - One-piece thrust washer
spec
urposes, in part or in wh
❑ Coat with gear oil when installing
t to the co
23 - Seal
❑ Renewing ⇒ page 171
rrectne
24 - Bolt
ss
25 - Differential cage
o
cial p
f i
❑ Bolt to final drive gear ⇒ page 205
nform
mer
26 - Final drive gear wheel atio
om
❑ Riveted in production
n
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or
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❑ Bolted ⇒ page 205
te
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❑ Heat to 100 °C before installing
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❑ Pressing off ⇒ page 204
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❑ Paired with output shaft. Renew only as a set.
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27 - Backing plate
28 - Nut 60 Nm and turn 45° further
Pressing tapered roller bearing outer race out of clutch housing
– First remove seating sleeve for flange shaft seal.
202 Rep. Gr.39 - Final drive - rear differential
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
Pressing tapered roller bearing outer race into clutch housing
No shim is installed in the clutch housing end.
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Pulling off tapered roller bearing inner races
hole
spec
– Before fitting extractor, position thrust plate -40 - 105- on dif‐
es, in part or in w
t to the co
ferential cage.
rrectness of i
Note
l purpos
♦ Both tapered roller bearing inner races are pulled off the dif‐
ferential cage in the same way.
nf
ercia
♦ Before pulling tapered roller bearing inner race off speedom‐
orm
eter drive wheel pull connecting piece off ⇒ Fig.
m
atio
m
⇒ page 206 .
o
n in
or c
thi
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Pressing on tapered roller bearing inner race
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The tapered roller bearing inner races for gearbox housing and
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clutch housing are pressed on with the same press tools.
AG.
Pulling outer race for tapered roller bearing out of gearbox hous‐
ing
-A- Counter support -Kukko 22/2-
-B- Internal puller -Kukko 21/7- 46 … 58 mm
11. Dismantling and assembling differential 203
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
Pressing tapered roller bearing outer race into gearbox housing
– Fit shim under outer race.
– Support gearbox housing with sleeve -3144- directly below
bearing support.
Drilling out rivet heads
– Drill out rivet heads with 12 mm drill bit from countersunk side
and drive rivet out with drift.
Note
Clean differential before and after drilling, protecting tapered roller
bearing from drillings.
Pressing off final drive gear
– Place thrust plate -40 - 105- on differential cage.
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Installation position of final drive gear wit
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hole
The circular groove -A- faces bolt-on surface of differential hous‐
spec
ing.
es, in part or in w
t to the co
rrectness of i
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Prote AG.
204 Rep. Gr.39 - Final drive - rear differential
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
Heating final drive gear wheel to approx. 100 °C and installing
– Use bolts -A- from repair kit to guide final drive gear into po‐
sition during installation.
WARNING
Wear protective gloves!
Bolting final drive gear and differential cage together
Use special bolts with backing plates and nuts according to ⇒
ETKA (electronic parts catalogue) .
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Removing and installing spring pin for differential pinion pin
spec
urposes, in part or in wh
♦ Removing
t to the co
– Cover tapered roller bearing inner race and speedometer drive
gear to avoid possible damage and ingress of metal particles.
rrectne
– Drive out spring pin with chisel, inserting chisel into circum‐
ferential groove.
ss o
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♦ Installing
inform
mer
– Drive into differential cage to stop.
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Installing differential bevel gear
p
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– Lubricate one-piece thrust washer with gear oil and install.
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– Install both sun wheels and secure (e.g. with flange shaft).
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– Insert planet pinions offset 180° and pivot into position.
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– Press in differential pinion pin (-arrow A-) to first planet pinion.
– Place threaded pieces -arrows B- in sun gears.
Installation position: shoulder to sun gear
– Drive differential pinion pin into final position and secure with
spring pin.
11. Dismantling and assembling differential 205
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
Pulling off connecting piece
-A- Connecting piece
-B- Puller -Kukko 18/1-
-C- Splitter -Kukko 17/1- 12…75 mm
Pressing on connecting piece -A- for bevel box
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Modified thrust washer for tapered ring -1-
ot
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Installation position:
hole
If there are no lugs -A-, collar -arrow- faces spring -B-. spec
es, in part or in w
t to the co
rrectness of i
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nform
mercia
a
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tion in
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Prote AG.
206 Rep. Gr.39 - Final drive - rear differential
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
12 Repair shaft bevel gear mounting
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Dismantling and assembling procedure ⇒ page 208 s
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14) Adjustment work is required if these components are replaced
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⇒ page 208 .
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Note
h re
hole
spec
A 4 mm hole is located on the bottom side of the pinion housing
es, in part or in w
t to the co
near bolting flange on rear final drive housing. If oil leaks out here,
renew seals ⇒ Item 5 (page 207) .
rrectness of i
l purpos
1 - 12-point nut for shaft bevel
gear
❑ Unscrewing
nform
ercia
⇒ page 212
m
a
❑ Fitting ⇒ page 214
com
tion in
❑ Insert with Loctite 638
r
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s
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2 - Small tapered roller bearing
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inner race14)
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3 - Small tapered roller bearing
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❑ Pressing out co Vo
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⇒ page 212
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❑ Pressing in
⇒ page 213
❑ Insert with Loctite 638
4 - Pinion housing 14)
❑ Removing and installing
⇒ page 179
5 - Oil seals
❑ For shaft bevel gear
❑ Pulling out ⇒ page 213
❑ Assembling
⇒ page 213
❑ Inserting in installation
position ⇒ page 214
❑ Driving in ⇒ page 214
6 - Large tapered roller bearing
outer race14)
❑ Pressing out
⇒ page 212
❑ Pressing in
⇒ page 213
❑ Insert with Loctite 638
7 - Large tapered roller bearing inner race 14)
❑ Pulling off ⇒ page 212
❑ Pressing on ⇒ page 214
12. Repair shaft bevel gear mounting 207
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Bora 1999 ➤ , Golf 1998 ➤ ut
ho eo
ra
a
5-speed manual gearbox 02C, four-wheel
s drive - Edition 01.2010
s c
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le
un
pt
8 - Spacer sleeve
an
d
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❑ Always renew
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ility
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❑ Is paired to bevel gear (with stub shaft)
ole,
spec
urposes, in part or in wh
❑ Determine according to gearbox code using electronic parts catalogue ⇒ page 5
t to the co
❑ Clean locking fluid from thread
rrectne
12.2 Assembly sequence - bevel gear mounting
ss o
cial p
f i
Special tools and workshop
nform
equipment required
mer
atio
m
♦ Drift sleeve -VW 192-
o
n
c
i
or
n thi
♦ Support clamp -VW 313-
te
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♦ Pressure plate -VW 401-
p
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♦ Pressure plate -VW 402-
t.
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♦ Press tool -VW 408 A-
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♦ Press tool -VW 412-
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Prote AG.
208 Rep. Gr.39 - Final drive - rear differential
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
♦ Thrust piece -VW 432-
♦ Thrust pad -VW 510-
♦ Multipurpose tool -VW 771-
♦ Puller hooks -VW 771/37- AG. Volkswagen AG d
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♦ Support -40 - 103- d by Vo gu
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♦ Tube -2010- utho eo
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12. Repair shaft bevel gear mounting 209
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
♦ Thrust piece -2050-
♦ Tube -3118-
♦ Drift -3138-
♦ Assembly tool -3253/1-
♦ Tapered roller bearing pull‐
er -V.A.G 1582-
♦ Adapter -V.A.G 1582/1-
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es, in part or in w
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o
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Prote
210
AG.
Rep. Gr.39 - Final drive - rear differential
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
♦ Torque wrench -
V.A.G 1601-
♦ Gearbox support -T10108-
♦ Assembly tool -T10114-
♦ Internal puller -1 - Kukko
21/8-
♦ Torque wrench -
V.A.G 1332-
♦ Torque gauge,
0...600 Ncm, commercially
available
AG. Volkswagen AG d
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hole
spec
es, in part or in w
t to the co
rrectness of i
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Pinion housing removed from rear final drive housing
⇒ page 179 .
nform
ercia
Dismantling
m
a
com
tio
– Attach pinion housing to gearbox support from below as
n in
r
te o
shown in figure (oil filter = -arrow B-) at the hole marked -1-
thi
s
-arrow A-.
iva
do
r
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cum
fo
– Then align pinion housing with remaining 3 holes and secure.
en
ng
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Prote AG.
12. Repair shaft bevel gear mounting 211
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
– Remove 12-point nut for shaft bevel gear.
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A - 3/4” drive ratchet by
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th
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♦ When removing 12-point nut, secure shaft bevel gear against
itte
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falling out.
rm
ab
pe
ility
♦ The loosening torque is very high. If necessary, add an ex‐
ot
wit
, is n
tension to the ratchet.
h re
hole
spec
es, in part or in w
– Remove inner race for small tapered roller bearing and spacer
t to the co
sleeve.
– Press small tapered roller bearing outer race out of pinion
rrectness of i
housing.
l purpos
nform
mercia
a
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tion in
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te o
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– Press large tapered roller bearing outer race -A- out of pinion copy Vo
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housing. cted agen
Prote AG.
-B- Internal puller -Kukko 21/8- 56 … 70 mm
– Pull large tapered roller bearing inner race off shaft bevel gear.
– Clean thread on nut.
212 Rep. Gr.39 - Final drive - rear differential
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
– Pull shaft bevel gear oil seal out of pinion housing.
Assembling
Note
Clean locking fluid from seats for tapered roller bearing outer
races in pinion housing.
– Coat outer race for small shaft bevel gear with locking fluid
Loctite 638 and press into pinion housing.
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– Assemble new oil seals for shaft bevel gear as follows:
rrectness of i
– Put new oil seals together -arrows A- with locking lugs
-arrows- of oil seal offset from each other.
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– With the seals together, twist in opposite directions -arrow B-
until locking lugs -arrows- engage in each other -arrow C-.
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12. Repair shaft bevel gear mounting 213
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
– Insert assembled oil seals -A- for shaft bevel gear in pinion
housing.
Installation position:
Seal with smaller outer diameter -arrow- faces pinion housing.
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– Drive assembled oil seals for shaft bevel gear into pinion
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ole,
⇒ page 211 .
spec
urposes, in part or in wh
t to the co
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mer
atio
– Press large tapered roller bearing inner race onto shaft bevel
om
gear.
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– Moisten sealing lips of oil seals with high-performance oil for
t
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Haldex coupling -G 052 175 A1- .
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– Insert shaft bevel gear in pinion housing.
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– Coat thread of 12-point nut with Loctite 638 .
– Screw on 12-point nut for shaft bevel gear.
214 Rep. Gr.39 - Final drive - rear differential
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
– Tighten 12-point nut to 120 Nm, measure friction torque
⇒ page 215 and if necessary increase tightening torque until
specified friction torque is attained.
A - 3/4” drive ratchet
– Turn torque wrench -V.A.G 1332- to right to tighten.
– Use 1/2” to 3/4” adapter.
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200 ... 250 Ncm 30 ... 50 Ncm
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– Measure friction torque.
rrectness of i
A - Torque gauge, 0 … 600 Ncm, commercially available
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B - 1/2” to 3/4” adapter
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12. Repair shaft bevel gear mounting 215
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
13 Repairing bearings for bevel gear
with stub shaft
13.1 Assembly overview - bearings for bevel gear with stub shaft
Special tools and workshop
equipment required
♦ Pressure plate -VW 401-
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♦ Press tool -VW 412- rised
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♦ Tube -VW 415 A- ss a ra
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♦ Tube -32 - 109-
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erm
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Dismantling and assembling procedure ⇒ page 218
16) Adjustment work is required if these components are replaced
⇒ page 208 .
216 Rep. Gr.39 - Final drive - rear differential
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
1 - Left flange shaft
❑ Removing ⇒ page 191
❑ Drive in with plastic
hammer.
2 - Dust plate
❑ For flange shaft
❑ Pressing off
⇒ page 218
❑ Pressing on
⇒ page 218
3 - Seal
❑ Levering out with as‐
sembly lever
❑ Drive in to stop with drift
sleeve -VW 195-
4 - Cover 16)
❑ Removing ⇒ page 192
❑ Installing ⇒ page 192
5 - Rear final drive housing 16)
6 - Shim S2
❑ Note thickness
❑ Adjustment overview
⇒ page 208
7 - Small tapered roller bearing
outer race16)
❑ Driving out ⇒ page 222
❑ Pressing in
⇒ page 222 agen
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⇒ page 222
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❑ Determine according to gearbox code using ⇒ ETKA (electronic parts catalogue) ⇒ page 5
hole
spec
10 - Large tapered roller bearing inner race 16)
es, in part or in w
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❑ Pressing off ⇒ page 221
❑ Pressing on ⇒ page 223
rrectness of i
11 - Large tapered roller bearing outer race16)
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❑ Pulling out ⇒ page 222
❑ Pressing in ⇒ page 223
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12 - Shim S1
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13. Repairing bearings for bevel gear with stub shaft 217
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
Pressing off dust plate
-A- Splitter -Kukko 17/2- 22 … 115 mm
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13.2 Assembly sequence - bearings for bevel gear with stub shaft
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218 Rep. Gr.39 - Final drive - rear differential
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
Special tools and workshop
equipment required
♦ Pressure plate -VW 401-
♦ Pressure plate -VW 402-
♦ Press tool -VW 407-
♦ Press tool -VW 409-
♦ Press tool -VW 412-
♦ Tube -VW 415 A-
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13. Repairing bearings for bevel gear with stub shaft 219
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
♦ Thrust pad -VW 447 i-
♦ Removal and installing tool
-VW 459/1-
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220 Rep. Gr.39 - Final drive - rear differential
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
♦ Tube -3253/1-
♦ Tube -3296-
♦ Support tube -3416/3-
♦ Splitter -3 - Kukko 17/2-
♦ Two arm puller -1 - Kukko
20/10- with hooks -Matra V/
170-
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Bevel gear with stub shaft is removed from rear final drive housing
rrectness of i
⇒ page 181 .
l purpos
Dismantling
– Press inner race of large tapered roller bearing off bevel gear
nform
ercia
(with stub shaft).
m
-A- Splitter -Kukko 17/2- 22 … 115 mm
a
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tion in
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13. Repairing bearings for bevel gear with stub shaft 221
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
– Press small tapered roller bearing inner race off stub shaft.
-A- Splitter -Kukko 17/2- 22 … 115 mm
– Pull outer race of large tapered roller bearing out of cover.
-A- Two-arm puller -1 - Kukko 20/10- with hooks -Matra V/170-
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– Drive small tapered roller bearing outer race out of rear final
erm
ab
drive housing.
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Note
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urposes, in part or in wh
t to the co
Differential removed.
Assembling
rrectness o
cial p
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mer
– Press small tapered roller bearing outer race into rear final
atio
m
drive housing.
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222 Rep. Gr.39 - Final drive - rear differential
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
– Press inner race of large tapered roller bearing onto bevel gear
(with stub shaft).
– Press small tapered roller bearing inner race onto stub shaft.
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– Press large tapered roller bearing outer race into cover.
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13. Repairing bearings for bevel gear with stub shaft 223
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
14 Adjusting shaft bevel gear and bevel
gear with stub shaft (final drive gear
set)
14.1 General notes
Careful adjustment of final drive gear set is essential to ensure
that bevel gears give long service and run quietly. Therefore, gen AG the
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bevel gear with stub shaft and shaft bevel gear are y Volkmatched dur‐ not
gu
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d b ara
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mesh pattern and silent running. The position
utho for quietest running eo
ra
is obtained by moving the shaft bevel gear
ss a axially and, at the same c
time, maintaining the backlash within the specified tolerances.
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Renew final drive gear set (bevel gear with stub shaft and shaft
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bevel gear) together only!
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14.2 Adjustment and marking of final drive gear sets
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spec
A - Bevel gear with stub shaft
es, in part or in w
t to the co
B - Shaft bevel gear
1 - Pair number of final drive
rrectness of i
gear set.
❑ In example: 5050
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2 - Shaft bevel gear allowance
(D = +2)
nf
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❑ Adjustment dimension
m
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3 - Backlash (Sd = 0.12)
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4 - Dimension “R”: actual di‐
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set.
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❑ In example: R = 34.14
means R = 43.14 mm
C - Actual dimension between
axis of bevel gear with stub
shaft and back of shaft bevel
gear at point of quietest run‐
ning for this gear set. It is 70.00
mm.
Ro - Length of test machine
master gauge used. “Ro” =
42.70 mm
r - This allowance “r” must first
be determined ⇒ page 230 .
224 Rep. Gr.39 - Final drive - rear differential
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
AG. Volkswagen n AG do
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14.3 Position of shims
V
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S1 - Shim for friction torque of
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tapered roller bearing for bevel
pt
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S2 - Shim for bevel gear with
ility
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S3 - Shim for shaft bevel gear
spec
es, in part or in w
t to the co
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14.4 Adjustment overview - rear final drive
Note
If repairs have been carried out to the rear final drive, adjusting
the shaft bevel gear, bevel gear or complete final drive gear set
is necessary only if components having a direct effect on the ad‐
justment of the final drive. To prevent unnecessary adjustments,
refer to the following table:
To be adjusted:
Shaft bevel gear Bevel gear (with stub
(S3) shaft)
via deviation “r” (S1 and S2)
⇒ page 226 ⇒ page 231
Parts renewed: Pinion housing x
Rear final drive housing x x
14. Adjusting shaft bevel gear and bevel gear with stub shaft (final drive gear set) 225
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
Final drive gear set x x
(Shaft bevel gear and bevel gear
with stub shaft)
Tapered roller bearing for shaft bevel x
gear
Tapered roller bearing for bevel gear x
(with stub shaft)
Cover (side of bevel gear with stub x17)
shaft)
17) Adjust only S1 via previously measured total friction torque.
14.5 Recommended sequence for new ad‐
justment of final drive gear set
If shaft bevel gear and bevel gear (with stub shaft) have to be
adjusted, then in the interests of an efficient procedure keep to
the following order:
1. Adjust friction torque and shaft bevel gear (S3).
– Adjust preload of tapered roller bearing for shaft bevel gear via wagen AG. Volkswagen AG doe
friction torque measurement. yV
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– Determine thickness of shim "S3" and insert. The shaft tho
ris bevel nte
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gear is thus fixed axially so that the dimension from
ss
a centre of
u ac
bevel gear with stub shaft to face of shaft bevel gear corre‐
ce
le
un
sponds to the installation dimension "R" determined during
pt
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production.
itte
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– Carry out check measurement of S3.
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2. Adjust bevel gear (with stub shaft) (S1 and S2).
h re
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spec
urposes, in part or in wh
– Adjust preload of tapered roller bearing for bevel gear (with
t to the co
stub shaft) via Stotal.
– Adjust backlash. Select shims “S1” and "S2" so that the pre‐
rrectne
scribed backlash between bevel gear with stub shaft and shaft
bevel gear is obtained.
s
– Check backlash.
s o
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The purpose of this adjustment is to re-establish the position of‐ f inform
mer
fering the quietest running as calculated on the test machine
atio
during production. The utmost care and cleanliness during all as‐
om
sembly work and measurements are essential to achieve a good
n
c
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result.
thi
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14.6 Adjusting shaft bevel gear
pr
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Prote AG.
226 Rep. Gr.39 - Final drive - rear differential
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
Special tools and workshop
equipment required
♦ Support plate -VW 309-
♦ Universal measuring tool -
VW 385-
♦ Gearbox support -T10108-
♦ Assembly tool -T10114-
♦ Torque wrench -
V.A.G 1332-
♦ Dial gauge
♦ Torque gauge,
0...600 Ncm, commercially
available
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Readjustment of the shaft bevel gear is required if
t to the co
♦ Pinion housing
♦ Rear final drive housing
rrectness of i
♦ Tapered roller bearing for shaft bevel gear
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♦ Final drive gear set
m
at
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Adjustment overview ⇒ page 225
o
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Adjusting friction torque.
p
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– Screw on 12-point nut for shaft bevel gear.
n
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Prote AG.
14. Adjusting shaft bevel gear and bevel gear with stub shaft (final drive gear set) 227
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
– Tighten 12-point nut to 120 Nm, measure friction torque
and if necessary increase tightening torque until specified fric‐
tion torque is attained.
A - 3/4” drive ratchet
– Turn torque wrench -V.A.G 1332- to right to tighten.
– Use 1/2” to 3/4” adapter.
Note
Increase torque setting slowly and check friction torque at regular
intervals. If the prescribed friction torque is exceeded, the spacer
sleeve must be renewed and the adjustment repeated. A spacer
sleeve which has been compressed too much cannot be reused.
Following friction torques are to be set:
New bearings Used bearings18)
200 ... 250 Ncm 30 ... 50 Ncm
18) run for at least 50 km (30 miles)
– Measure friction torque.
-A- Torque gauge, 0 … 600 Ncm, commercially available
-B- 1/2” to 3/4” adapter.
Determine thickness of shim "S3".
– Install pinion housing complete with shaft bevel gear and tem‐
porary shim S3 * (1.3 mm thick).
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Note utho eo
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As a test prerequisite, a temporary shim S3 of 1.30 mm must be
nl
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installed. It is referred to below as S3 . After measured value “e”
y li
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is determined, S3 * is replaced with final shim S3.
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– Do not insert O-ring.
hole
spec
es, in part or in w
– Adjust setting ring of universal measuring tool -VW 385/1- to
t to the co
dimension a = 38 mm.
– Set sliding positioning ring to dimension b = 35 mm.
rrectness of i
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Prote AG.
228 Rep. Gr.39 - Final drive - rear differential
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
– Set up universal mandrel according to figure. Measuring
gauge extension -VW 385/16- = 12.3 mm. Set master gauge
-VW 385/30- to Ro = 42.70 mm.
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– Set dial gaugeVto
olks“0” with 2 mm preload. s not
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– After removing
or
ise universal gauge, push on -VW 385/39-
ran
te to stop.
th eo
au ra
c
ss
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
h re
hole
– Place end measurement plate on head of shaft bevel gear.
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
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– Insert universal mandrel.
o
r
rp
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f
en
ng
– Fit cover and tighten hexagon bolts.
t.
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op py
– Use sliding setting ring to pull centring disc outwards until
t. C rig
gh ht
yri
mandrel can still just be turned by hand. p by
co Vo
by lksw
cted agen
Prote AG.
14. Adjusting shaft bevel gear and bevel gear with stub shaft (final drive gear set) 229
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
– Determine dimension “e”. Turn test gauge until point of dial
gauge makes contact with end
wage
n AGmeasuring
. Volkswagen plate
AG do and indicates
es n
max. deflection (return
y Volkspoint). The measured value ot is
gu dimen‐
sion “e” (in black
isedscale).
b Example: 0.28 mm ara
n r tee
ho
– Remove universal
au
t
test gauge. or
ac
ss
ce
le
un
pt
an
d
Note
itte
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erm
ab
ility
ot p
Finally, check again whether dial gauge returns to “0” with 2 mm
wit
is n
preload with master gauge -VW 385/30- applied. Otherwise re‐
h re
peat measurement.
ole,
spec
urposes, in part or in wh
t to the co
Determine thickness of shim "S3".
S3 = S3 * + r + e
rrectne
(“e” in black scale)
s
S3 = S3 * + r - e
s o
cial p
f in
(“e” in red scale)
form
mer
atio
om
n
c
Note
i
or
n thi
te
sd
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♦ If measurement is obtained on red scale, subtract value “e”.
i
o
pr
cum
r
fo
en
ng
♦ If measurement is obtained on black scale, add value “e”.
t.
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op py
♦ Allowance “r”, relative to master gauge “Ro” must be calcula‐
t. C rig
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yri
ted according to the following formula. p by
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cted agen
Prote AG.
Formula: r = R - Ro
R - value written on bevel gear (in example, 43.14 mm).
- Length of master gauge used
r = 43.14 mm - 42.70 mm
r = 0.44 mm
Example:
Value indicated on dial gauge “e” 0.28 mm
Calculated allowance “r” for this gear set 0.44 mm
Installed shim S3 * 1.30 mm
Shim thickness "S3" = 2.02 mm
Note
Allocate shims using ⇒ ETKA (electronic parts catalogue) .
230 Rep. Gr.39 - Final drive - rear differential
Bora 1999 ➤ , Golf 1998 ➤
n AG. Volkswagen AG do
lkswage 5-speed manual egearbox
s n 02C, four-wheel drive - Edition 01.2010
Vo ot g
d by ua
r
se ante
Available shims for riS
tho 3 eo
au ra
ss c
Shim thickness (mm)
ce
e
nl
pt
du
1.30 1.69 2.08
an
itte
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erm
ab
1.33 1.72 2.11
ility
ot p
1.36 1.75 2.14
wit
, is n
h re
1.39 1.78 2.17
hole
spec
1.42 1.81 2.20
es, in part or in w
t to the co
1.45 1.84 2.23
1.48 1.87 2.26
rrectness of i
1.51 1.90 2.29
l purpos
1.54 1.93 2.32
1.57 1.96 2.35
nform
ercia
1.60 1.99 2.38
m
1.63 2.02 2.41
at
om
ion
c
1.66 2.05 2.44
in t
or
his
ate
– Remove pinion housing complete with shaft bevel gear and
do
priv
c
1.3 mm shim.
um
for
en
ng
t.
yi
– Install determined shim S3.
Co
Cop py
t. rig
gh ht
Two shims which total the measured value may be installed. yri
p by
co Vo
by lksw
cted
Carry out check measurement - check dimension “r”.
agen
Prote AG.
Insert universal test gauge and measure dimension “r”.
If the correct shims have been selected, the dial gauge, read anti-
clockwise on the red scale, must now indicate the calculated
allowance “r” within a tolerance of +0.04 mm.
14.7 Adjusting bevel gear (with stub shaft)
14. Adjusting shaft bevel gear and bevel gear with stub shaft (final drive gear set) 231
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
Special tools and workshop
equipment required
♦ Gearbox support -VW 353-
♦ End dimension plate -
VW 385/17- agen
AG. Volkswagen AG d
oes
olksw not
♦ Universal dial gauge brack‐ ed byV gu
ara
et -VW 387- horis nte
eo
aut ra
♦ Adjustable measuring lever ss c
-VW 388-
ce
e
nl
pt
du
an
♦ Adjusting device for crown itte
y li
erm
ab
wheel -VW 521-
ility
ot p
♦ Dial gauge
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
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t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
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Prote AG.
Readjustment of the bevel gear (with stub shaft) is required if
♦ Rear final drive housing
♦ Tapered roller bearing for bevel gear with stub shaft
♦ Cover
or the
♦ Final drive gear set
is renewed.
Adjustment overview ⇒ page 225
Adjust preload of tapered roller bearing for bevel gear (with stub
shaft).
The shaft bevel gear is removed.
– Fit 1.0 mm shim in small tapered roller bearing outer race seat
(S2 side).
As a test condition, a temporary shim S2 of 1.00 mm is installed.
It is referred to below as S2 . After backlash is determined, S2 *
is replaced with final shim S2.
– Press in outer race ⇒ page 223 .
232 Rep. Gr.39 - Final drive - rear differential
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
– Fit bevel gear with stub shaft with tapered roller bearing.
– Install cover with large tapered roller bearing outer race but
without O-ring, flange shaft seal and without shim S1.
– Attach dial gauge and set to “0” with 2 mm preload.
– Move bevel gear with stub shaft up and down (direction of ar‐
row).
– Read play from dial gauge and determine Stotal.
Example:
"Stotal" = S2 * + measured value + preload
Fitted shim(s) S2 * 1.00 mm
Measured value (example) 0.90 mm
Preload (constant value) 0.30 mm
Stotal = 2.20 mm
Determine thickness of shim S1 .
Note
♦ After backlash is determined, temporary shim S1 * is replaced
with final shim S1.
♦ The total shim thickness "Stotal" remains unchanged.
S1 = Stotal - S2
Example:
n AG. Volkswagen AG do
Total shim thickness "Stotal" lkswage 2.20 mmes n
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Fitted shim(s) S2 ir se
d b - 1.00 mm ran
o tee
th or
Thickness of shim S1 au = 1.20 mm ac
ss
ce
le
un
pt
Available shims for S1 ⇒ page 234 .
an
d
itte
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rm
ab
Measure backlash.
pe
ility
ot
Pinion housing with shaft bevel gear and S3installed
wit
, is n
h re
hole
Install bevel gear with stub shaft: S1 is installed on the cover side
spec
es, in part or in w
and S2 in the rear final drive housing.
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
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rp
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t.
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Cop py
t. rig
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pyri by
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by
cted agen
Prote AG.
14. Adjusting shaft bevel gear and bevel gear with stub shaft (final drive gear set) 233
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
– Set up measuring tools.
♦ Dimension “a” = 43.5 mm
♦ Screw in adjustable measuring lever -VW 388- so that dial
gauge extension is at right angles to surface to be measured.
– Turn bevel gear with stub shaft to stop. Set dial gauge to 0,
turn back bevel gear with stub shaft and read backlash. Note
reading.
– Loosen clamping sleeve locking screw and after turning bevel
gear with stub shaft a further 90°, repeat complete measuring
process 3 more times. Add the four results and calculate the
average backlash.
Calculating average backlash.
Example:
1. Measurement 0.30 mm
+ 2. Measurement 0.31 mm
+ 3. Measurement 0.30 mm
+ 4. Measurement 0.29 mm
Total 1.20 mm AG. Volkswagen AG d
agen oes
olksw not
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Average backlash: 1.20 mm / 4 = 0.30 mm. rise nte
tho eo
au ra
Determine thickness of shim S2. ss c
ce
le
un
pt
= Inserted shim
an
S2
d
itte
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rm
ab
- Average backlash
pe
ility
ot
+ Lift (constant value)
wit
, is n
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hole
Lift = 0.20 mm
spec
es, in part or in w
Example:
t to the co
S2 Inserted shim 1.00 mm
rrectness of i
- Average backlash 0.30 mm
l purpos
0.70 mm
+ Lift (constant value) 0.20 mm
nform
ercia
S2 = 0.90 mm
m
a
com
tion in
r
Note
te o
thi
s
iva
do
r
rp
Allocate shims using ⇒ ETKA (electronic parts catalogue) .
um
fo
en
ng
t.
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op
Available shims for S2 C py
t. rig
gh ht
pyri by
Vo
Shim thickness (mm)
co lksw
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cted agen
Prote AG.
0.65 0.90 1.15
0.70 0.95 1.20
0.75 1.00 1.25
0.80 1.05
0.85 1.10
– Install determined shim S2 in place of S2. *.
Two shims which total the measured value may be installed.
234 Rep. Gr.39 - Final drive - rear differential
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
– The various thicknesses make it possible to achieve the exact
shim thickness required.
– Press outer race in again and fit bevel gear with stub shaft.
Determine thickness of shim S1.
S1 = Stotal - S2
Example:
S1 = 2.20 mm - 0.90 mm
S1 = 1.30 mm
Note
Allocate shims using ⇒ ETKA (electronic parts catalogue) .
Available shims for S1
Shim thickness (mm)
0.65 0.90 1.15AG. Volkswagen AG d
wagen oes
0.70 0.95 y Volks
1.20 not
gu
d b ara
0.75 1.00 orise 1.25 nte
eo
th
u
0.80 1.05ss a ra
c
ce
le
0.85 1.10
un
pt
an
d
itte
y li
– Allocate shim(s) using electronic parts catalogue.
rm
ab
pe
ility
– Insert determined S1 shim.
ot
wit
, is n
h re
Two shims which total the measured value may be installed.
hole
spec
– Various tolerances make it possible to obtain the exact shim
es, in part or in w
t to the co
thickness required.
– Press outer race in again.
rrectness of i
– Fit cover.
l purpos
Carrying out control measurement - measure backlash.
– It must be 0.12…0.20 mm.
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
14. Adjusting shaft bevel gear and bevel gear with stub shaft (final drive gear set) 235
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
39 – Final drive - front differential
1 Renewing oil seals for flange shafts
or right-hand drive flange (gearbox
installed)
n AG. Volkswagen A
1.1 Renewing oil seal
Vol
kfor
swa left flange shaft
ge G do
es n
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db ran
Special tools and workshop oequipment
ris
e
required tee
h
ut or
♦ Multipurpose tool -VW
ss 771-
a ac
ce
le
un
pt
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d
itte
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
♦ Puller hooks -VW 771/37-
nform
ercia
♦ Drift -3106-
m
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
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Cop py
t. rig
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pyri by
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by
cted agen
Prote AG.
♦ Torque wrench -V.A.G 1331-
♦ Drip tray
Additional required information
♦ Workshop Manual Golf 1998 ▸, Bora 1999 ▸, Running gear,
axles, steering - front and four-wheel drive
236 Rep. Gr.39 - Final drive - front differential
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
– Observe general repair instructions ⇒ page 11 .
Removing
– Remove centre and left parts of noise insulation below engine
and gearbox, if fitted.
– Unbolt drive shaft from flange shaft.
– Raise drive shaft as high as possible and secure. Take care
not to damage paint on drive shaft in the process.
– Remove flange shaft securing bolt by screwing two bolts into
flange and counterholding flange shaft with a lever.
– Place drip tray under gearbox.
– Pull out flange shaft with compression spring.
– Pull out flange shaft oil seal using multi-purpose tool -VW 771-
AG. Volkswagen AG d
and puller hooks -VW 771/37- . ksw
agen oes
n ol ot g
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Installing sedb ran
ri tee
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aut or
ac
ss
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nl
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ility
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wit
, is n
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hole
spec
es, in part or in w
t to the co
– Drive in new seal to stop, being careful not to cant seal.
– Half-fill space between sealing lip and dust lip with sealing
rrectness of i
grease for radial oil seal -G 052 128 A1- .
l purpos
– Insert flange shaft.
– Secure flange shaft using countersunk bolt and tighten to
nform
ercia
specified torque ⇒ Item 1 (page 201) .
m
at
– Bolt left drive shaft to flange shaft ⇒ Running gear, axles,
om
steering - front and four-wheel drive; Rep. Gr. 40 ; Repairing ion
c
in t
or
drive shafts; Removing and installing drive shafts .
his
ate
do
riv
– Checking gear oil in manual gearbox with bevel box
p
cum
or
⇒ page 75 .
f
en
ng
t.
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– Install noise insulation, if fitted. Cop py
t. rig
gh ht
pyri by
Vo
o
1.2 Renewing oil seal for flange shaft or right drive flange
c by lksw
cted agen
Prote AG.
1. Renewing oil seals for flange shafts or right-hand drive flange (gearbox installed) 237
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
Special tools and workshop
equipment required
♦ Drift sleeve -3158- n AG. Volkswagen AG do
lkswage es n
o ot g
♦ Puller -T10037- d byV ua
ran
ir se tee
♦ Torque wrench - au tho
or
ac
V.A.G 1331- ss
ce
le
un
♦ Hexagon key -V.A.G 1669-
pt
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d
itte
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rm
ab
pe
ility
ot
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.
Additional required information
♦ Workshop Manual Golf 1998 ▸, Bora 1999 ▸, Running gear,
axles, steering - front and four-wheel drive
– Observe general repair instructions ⇒ page 11 .
Removing
– Only loosen drive shaft/wheel hub nut when vehicle is standing
on its own wheels.
– Remove centre and right parts of noise insulation below en‐
gine and gearbox, if fitted.
– Remove drive shaft ⇒ Running gear, axles, steering - front
and four-wheel drive; Rep. Gr. 40 ; Servicing drive shaft; Re‐
moving and installing drive shaft .
– If a cap is fitted, remove it by piercing cap centre with a screw‐
driver and levering out.
– Place drip tray under gearbox.
– Remove right output shaft bolt or right flange shaft bolt using
hexagon key -V.A.G 1669- or commercially available 6 mm
socket.
238 Rep. Gr.39 - Final drive - front differential
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox
en AG. Volk02C,
swagefour-wheel
n AG drive - Edition 01.2010
ag does
ksw not
Vol gu
– Bolt puller -T10037- to flange shaft or righted
b drive flange.
y ara
nte
oris eo
– Use knurled nut -T10037/1- and lower au
th
support -A- to align ra
puller parallel with flange shaft or
ss drive flange. c
ce
le
un
pt
– Pull out output shaft drive flange or right flange shaft.
an
d
itte
y li
erm
– Pry seal out using assembly lever.
ab
ility
ot p
Installing
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
– Drive new seal in onto limit stop.
i
or
n thi
te
sd
a
– Half-fill space between sealing lip and dust lip with sealing
iv
o
pr
c
grease for radial oil seal -G 052 128 A1- .
um
r
fo
en
ng
t.
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– Drive flange shaft or drive flange with output shaft in carefully,
Co
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turn shaft when doing this. t. C rig
gh ht
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– Secure flange shaft or drive flange with output shaft using
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countersunk bolt and tighten to specified torque Prote AG.
⇒ Item 4 (page 250) .
– Press new sealing cap into right drive flange.
– Install drive shaft ⇒ Running gear, axles, steering - front and
four-wheel drive; Rep. Gr. 40 ; Repairing drive shafts; Re‐
moving and installing drive shafts .
– Screw nut (self-locking) onto drive shaft and only tighten with
vehicle standing on its wheels ⇒ Running gear, axles, steering
- front and four-wheel drive; Rep. Gr. 40 ; Repairing drive
shafts; Removing and installing drive shafts .
– Checking gear oil in manual gearbox with bevel box
⇒ page 75 .
– Install noise insulation, if fitted.
1. Renewing oil seals for flange shafts or right-hand drive flange (gearbox installed) 239
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
2 Renewing bevel box output flange oil seal (bevel box removed)
Special tools and workshop
equipment required
♦ Crankshaft seal insertion
tool -VW 204 B-
♦ Drift sleeve - 40 - 21-
♦ Gearbox support -3221-
♦ Support plate -3221/1A-
♦ Torque wrench -
V.A.G 1601-
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lkswage es n
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ir se tee
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u or
a ac
ss
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ility
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wit
, is n
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Note
hole
spec
es, in part or in w
t to the co
The bevel box oil seal for the propshaft output flange can only be
renewed with the bevel box removed.
rrectness of i
– Remove bevel box ⇒ page 72 .
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
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ng
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Cop py
t. rig
gh ht
pyri by
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co lksw
by
cted agen
Prote AG.
240 Rep. Gr.39 - Final drive - front differential
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
– Secure bevel box in gearbox support.
– Remove hexagon nut using socket -A-.
– Swing bevel box so that output flange points upwards.
– Remove output flange.
– Lever out seal using a screwdriver.
– Drive new oil seal in flush.
– Half-fill space between sealing lip and dust lip with sealing
grease for radial oil seal -G 052 128 A1- .
– Install output shaft and tighten to specified torque
⇒ Item 30 (page 252) .
– Install bevel box ⇒ page 72 .
– Checking gear oil in manual gearbox with bevel box
⇒ page 75 .
AG. Volkswagen AG d
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spec
urposes, in part or in wh
t to the co
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cial p
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mer
atio
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n
c
i
or
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te
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t.
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Cop py
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rig ht
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Prote AG.
2. Renewing bevel box output flange oil seal (bevel box removed) 241
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
3 Dismantling and assembling differen‐ AG. Volkswagen AG d
tial yV
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3.1 Assembly overview - differential ss
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Dismantling and assembling procedure ⇒ page 243
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ility
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1 - Differential cage
wit
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2 - Differential pinion pin hole
spec
❑ Secure with spring pin
es, in part or in w
t to the co
3 - Spring pin
❑ For securing differential
rrectness of i
pinion pin
❑ Removing ⇒ page 245
l purpos
4 - Retaining ring
nf
ercia
❑ Always renew
orm
m
5 - Ball bearing for differential
atio
om
n in
❑ Pressing out
or c
thi
⇒ page 245
te
sd
iva
❑ Pressing in
o
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rp
cu
⇒ page 245
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6 - Cover Cop py
ht. rig
❑ Removing with differen‐
rig ht
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tial ⇒ page 192 by c lksw
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Prote AG.
❑ Installing with differen‐
tial ⇒ page 193
❑ Pressing off differential
⇒ page 244
❑ Pressing onto differen‐
tial ⇒ page 246
7 - Retaining ring
❑ Always renew
8 - Seal
❑ Levering out with as‐
sembly lever
❑ Drive in to stop with drift
sleeve -VW 195-
9 - Small differential bevel gear
❑ Installing ⇒ page 245
10 - Large differential bevel gear
❑ Installing ⇒ page 245
11 - One-piece thrust washer
❑ Coat with gear oil when installing
242 Rep. Gr.39 - Final drive - front differential
AG. Volkswagen AG d
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olksw not
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Bora 1999 ➤ , Golf 1998 ➤
a
ss 5-speed manual gearbox 02C, four-wheel c drive - Edition 01.2010
ce
le
un
pt
3.2 Assembly sequence - differential
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ab
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ility
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Special tools and workshop
, is n
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equipment required
hole
spec
♦ Pressure plate -VW 401-
es, in part or in w
t to the co
♦ Pressure plate -VW 402-
♦ Press tool -VW 407-
rrectness of i
♦ Press tool -VW 411-
l purpos
♦ Press tool -VW 412-
nform
ercia
♦ Tube -VW 418 A-
m
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Prote AG.
3. Dismantling and assembling differential 243
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
♦ Thrust piece -VW 433-
♦ Support rails -VW 457-
♦ Removal and installing tool
-VW 459/2-
♦ Tube -VW 516-
♦ Sleeve -3144-
♦ Tube -3296-
AG. Volkswagen AG d
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– Pry seal out using assembly lever.
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– Press cover from differential. cted agen
Prote AG.
– Remove large retaining ring.
244 Rep. Gr.39 - Final drive - front differential
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
– Press ball bearing out of cover.
– Press out planet pinions, shearing off spring pin.
– Drive remains of spring pin out of differential pinion pin and
differential housing.
n AG. Volkswagen A
– Remove planet pinions
olks
and
wage one-piece thrust
G do
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no
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– Swing sun rgears
ise
d out of openings on sides of differential
ara
nte cage
and remove.
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– Lubricate one-piece thrust washer with gear oil and install.
d
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– Install both sun wheels and secure (e.g. with flange shaft). ab
pe
ility
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wit
, is n
h re
– Insert planet pinions offset 180° and swing in by turning one
hole
spec
of the flange shafts.
es, in part or in w
t to the co
– Drive differential pinion pin into final position and secure with
spring pin.
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– Press ball bearing into cover.
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– Secure with large retaining ring.
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Prote AG.
3. Dismantling and assembling differential 245
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
– Press cover onto differential.
– Secure with small retaining ring.
– Drive new oil seal in flush ⇒ page 172 .
AG. Volkswagen AG d
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Prote AG.
246 Rep. Gr.39 - Final drive - front differential
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
4 Adjustment overview
Note
If repairs have been carried out to the gearbox, it is only necessary
to adjust the input shaft, output shaft or differential if components
have been renewed which have a direct effect on the adjustment
of the gearbox. To prevent unnecessary adjustments, refer to the
following table:
To be adjusted:
Input shaft Output shaft Differential
⇒ page 116 ⇒ page 120 ⇒ page 248
Parts renewed: Gearbox housing x x
Clutch housing x x x
Input shaft x
Output shaft (final drive) x
Differential cage x
Input shaft tapered roller bearing x
Tapered roller bearing for output x
shaft
Tapered roller bearing for differen‐ x
tial
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4. Adjustment overview 247
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
5 Adjusting differential
Special tools and workshop
equipment required
♦ End dimension plate - AG. Volkswagen AG d
agen
VW 385/17- olksw
oes
not
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ara
d
♦ Universal dial gauge brack‐
orise nte
eo
et -VW 387- aut
h
ra
ss c
♦ Thrust piece -VW 473-
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un
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d
♦ Thrust plate -30 - 205-
itte
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ab
pe
♦ Torque wrench -
ility
ot
V.A.G 1331-
wit
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♦ Dial gauge
hole
spec
es, in part or in w
t to the co
rrectness of i
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Prote AG.
It is necessary to readjust the differential when
♦ Gearbox housing
♦ Clutch housing
♦ Differential cage
or the
♦ Tapered roller bearing of differential
have been renewed.
Adjustment overview ⇒ page 247 .
– Press tapered roller bearing outer race without shim into the
clutch housing using thrust piece -30 - 205- ⇒ page 203 .
Note
Inner and outer tapered roller bearing races are paired. Do not
interchange.
248 Rep. Gr.39 - Final drive - front differential
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
– Press tapered roller bearing outer race without shim into the
gearbox housing using thrust piece -30 - 205- ⇒ page 204 .
– Fit differential into clutch housing.
– Fit clutch housing and tighten 5 bolts to specified torque
⇒ Item 11 (page 80) .
– Press differential in direction of clutch housing while turning it
eight times.
– Press differential in direction of gearbox housing while turning
it eight times.
– Attach dial gauge and set to “0” with 1 mm preload.
– Move differential up and down. Read and note play indicated
on dial gauge. (Example: 0.70 mm)
Note
When performing measurement, do not turn differential or the
bearings will settle and the result of the measurement will be fal‐
sified.
Determining thickness of shim.
The specified bearing preload is obtained by adding a constant
value for preload (0.40 mm) to the reading obtained.
Example:
Measured value 0.70 mm
+ Preload (constant) 0.40 mm
Thickness of shim = 1.10 mm
AG. Volkswagen AG d
agen oes
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– Remove gearbox housing and pull out tapered roller by V bearing
ol not
gu
ara
outer race out of gearbox housing ⇒ page 203 rise or press out
d
nte
with thrust piece -VW 473- . utho eo
ra
s a c
s
– Insert shims of determined thickness, thickest shim first. ce
le
un
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The following shims are available:
d
itte
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ab
Thickness (mm) Part number
ility
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0,65 02A 409 210
h re
ole,
0,70 02A 409 210 A
spec
0,75 02A 409 210 B
urposes, in part or in wh
t to the co
0,80 02A 409 210 C
0,85 02A 409 210 D
0,90 02A 409 210 E
rrectne
0,95 02A 409 210 F
1,00 02A 409 210 G
1,05 02A 409 210 H
ss o
cial p
1,10 02A 409 210 J
inform
1,15 02A 409 210 K
mer
1,20 02A 409 210 L
atio
m
1,25 02A 409 210 M
o
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c
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If the size of shim required is larger than those listed in the table,
t
sd
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insert two shims totalling the correct figure.
pr
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The various thicknesses make it possible to achieve the exact
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– Press outer race in again and tighten gearbox housing to tor‐
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que setting ⇒ Item 11 (page 80) . Prote
cted AG.
agen
5. Adjusting differential 249
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
6 Dismantling and assembling bevel
box
6.1 Bevel box - assembly overview
Dismantling and assembling procedure ⇒ page 253
19) Adjustment work is required if these components are replaced
⇒ page 253 .
Note
There are gearboxes with output shaft ⇒ Item 8 (page 250) , drive
flange ⇒ Item 7 (page 250) and gearboxes with flange shaft
⇒ Item 5 (page 250) . These components must not be mixed up.
If renewed, they must be reallocated to the relevant gearbox.
1 - Sealing cap
❑ Will be destroyed during
removal.
❑ Always renew
2 - Retaining ring n AG. Volkswagen AG do
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❑ Always renew yV
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3 - Dished washer
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❑ Cone ss points towards cir‐
a ac
clip
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4 - Countersunk bolt, 25 Nm
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❑ For output shaft
ility
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⇒ Item 8 (page 250) or
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for flange shaft
h re
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⇒ Item 5 (page 250) on
spec
differential of manual
urposes, in part or in wh
gearbox
t to the co
5 - Flange shaft
rrectne
6 - Needle bearing (polygon
bearing)
s
❑ Qty. 2
s o
cial p
❑ Only for flange shaft
inform
⇒ Item 5 (page 250)
mer
❑ Renewing ⇒ page 265
atio
om
n
c
7 - Drive flange
or
n thi
te
sd
❑ Pull out together with
iva
o
r
output shaft
p
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⇒ Item 8 (page 250)
en
ng
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⇒ page 237
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❑ Pressing off yri
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⇒ page 264 cop Vo
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❑ Pressing on Prote AG.
⇒ page 264
8 - Output shaft
❑ Pull out of bevel gear housing with drive flange ⇒ Item 7 (page 250) ⇒ page 237
9 - Needle bearing (polygon bearing)
❑ Renewing ⇒ page 265
250 Rep. Gr.39 - Final drive - front differential
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
❑ Only for output shaft
10 - Retaining ring
❑ Always renew
11 - Seal
❑ Levering out with assembly lever
❑ Drive in to stop with drift sleeve -3158- ⇒ page 239
❑ Renewing with gearbox installed ⇒ page 237
12 - Bolt, 25 Nm
13 - Cover 19)
❑ Removing ⇒ page 259
❑ Do not cant when installing. Tighten securing bolts diagonally and in stages
14 - O-ring
❑ Always renew
❑ Must lie in circumferential groove.
15 - Shim S1 n AG. Volkswagen AG do
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❑ Note thickness yV
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❑ Adjustment overview ⇒ page 270 oris tee
th or
u
16 - Large tapered roller bearing for supporting
ss
a
bevel gear with stub shaft 19) ac
ce
e
nl
Inner race:
pt
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itte
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❑ Pulling off ⇒ page 260
erm
ab
ility
ot p
❑ Pressing on ⇒ page 262
wit
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Outer race:
hole
spec
❑ Pressing out ⇒ page 260
es, in part or in w
t to the co
❑ Pressing in ⇒ page 262
17 - Bevel gear with stub shaft 19)
rrectness of i
❑ Paired with shaft bevel gear ⇒ Item 27 (page 252) .
l purpos
❑ Cannot be pressed off input shaft.
❑ Adjusting ⇒ page 277
nf
ercia
18 - Small tapered roller bearing for supporting bevel gear with stub shaft 19)
orm
m
atio
Inner race:
om
n in
or c
❑ Pressing off ⇒ page 260
thi
te
sd
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❑ Pressing on ⇒ page 262
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Outer race:
f
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❑ Pressing out ⇒ page 260
C py
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❑ Pressing in ⇒ page 261 p by
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19 - Shim S2 Prote AG.
❑ Note thickness
❑ Adjustment overview ⇒ page 270
20 - Final drive housing 19)
❑ Drain oil then and secure bevel box on assembly stand using gearbox support -3221- ⇒ page 253 .
21 - Seal
❑ Always renew
❑ Insert stepped side into final drive housing
22 - O-ring
❑ Always renew
6. Dismantling and assembling bevel box 251
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
23 - Seal
❑ Always renew
❑ Insert stepped side into final drive housing
24 - Oil drain plug, 25 Nm
❑ With magnet
25 - Roller sleeve
❑ Pulling out ⇒ page 261
❑ Pressing in ⇒ page 261
26 - Retaining ring
❑ Always renew
❑ Removing ⇒ page 261
27 - Shaft bevel gear 19)
❑ Is paired to bevel gear (with stub shaft)
❑ Clean thread
❑ Adjusting ⇒ page 272 AG. Volkswagen AG d
agen oes
ksw 19)
28 - Large tapered roller bearing for shaft bevel by V gear
ol not
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Inner race: thor eo
au ra
c
❑ Pulling off ⇒ page 259 ss
ce
le
un
❑ Pressing on ⇒ page 262
pt
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d
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Outer race:
rm
ab
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ility
❑ Pulling out ⇒ page 258
ot
wit
, is n
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❑ Pressing in ⇒ page 263
hole
spec
29 - Output flange 19)
es, in part or in w
t to the co
30 - Hexagon nut, 350 Nm
❑ Unscrewing ⇒ page 258
rrectness of i
❑ Fitting ⇒ page 263
l purpos
❑ Always renew
❑ Coat with gear oil when installing
nform
ercia
31 - Shim S4
m
❑ Note thickness
com
tion in
❑ Adjustment overview ⇒ page 270
r
te o
thi
s
❑ Fit onto spacer ring ⇒ Item 32 (page 252) before installing oil seal ⇒ Item 33 (page 252) and before
iva
do
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inserting inner race for small tapered roller bearing ⇒ Item 34 (page 252)
rp
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32 - Spacer ring
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❑ Installation position: chamfer faces shaft bevel gear ⇒ Item 27 (page 252)
t. rig
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❑ Fit onto shaft bevel gear ⇒ Item 27 (page 252) before installing oil seal ⇒ Item 33 (page 252) and before
cop Vo
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inserting shim S4 as well as inner race for small tapered roller bearing ⇒ Item 34 (page 252)
agen
Prote AG.
33 - Seal
❑ Replace only with bevel box removed ⇒ page 240
❑ Pinion housing ⇒ Item 36 (page 253) does not have to be removed
34 - Small tapered roller bearing for shaft bevel gear 19)
Outer race:
❑ Pressing out ⇒ page 258
❑ Pressing in ⇒ page 263
Inner race:
❑ Place in outer race.
252 Rep. Gr.39 - Final drive - front differential
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
35 - Bolt, 25 Nm
36 - Pinion housing 19)
❑ Removing ⇒ page 258
❑ Installing ⇒ page 263
❑ Do not cant when installing. Tighten securing bolts diagonally and in stages.
37 - O-ring gen AG
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❑ Always renew yV
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❑ Must lie in circumferential groove.
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38 - Shim S3 ss
ac
ce
le
❑ Note thickness
un
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an
d
itte
❑ Adjustment overview ⇒ page 270
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pe
ility
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6.2 Assembly sequence - bevel box
hole
spec
es, in part or in w
t to the co
Special tools and workshop
equipment required
rrectness of i
♦ Crankshaft seal insertion
tool -VW 204 B-
l purpos
♦ Drift sleeve -40 - 21-
nform
ercia
♦ Gearbox support -3221-
m
a
♦ Support plate -3221/1A-
com
tion in
r
♦ Torque wrench -
te o
thi
V.A.G 1601-
s
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rp
cum
fo
en
ng
t.
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cted agen
Prote AG.
6. Dismantling and assembling bevel box 253
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
♦ Pressure plate -VW 401- AG. Volkswagen AG d
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♦ -DruckplatteVW 402- olksw not
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♦ Press tool -VW 407- rise nte
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♦ Press tool -VW 408 A- ss c
ce
le
un
pt
♦ Tube -VW 415 A-
an
d
itte
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rm
♦ Torque wrench -
ab
pe
ility
V.A.G 1331-
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
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a
com
tion in
r
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thi
s
iva
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ng
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Cop py
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cted agen
Prote AG.
254 Rep. Gr.39 - Final drive - front differential
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
♦ Support rails -VW 457-
♦ Press tool -VW 412-
♦ Puller -V.A.G 1582-
♦ Adapter -V.A.G 1582/1-
♦ Thrust piece -VW 473-
♦ Thrust pad -VW 447 H-
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ility
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es, in part or in w
t to the co
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orm
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te
sd
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ng
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Cop py
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pyri by
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cted agen
Prote AG.
6. Dismantling and assembling bevel box 255
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
Special tools and workshop
equipment required
♦ Crankshaft seal insertion
tool -VW 191-
♦ Thrust piece -2050-
♦ Drift -VW 460/2-
♦ Thrust piece -VW 454-
♦ Internal puller -1 - Kukko
21/3-
♦ Internal puller -1 - Kukko
21/7-
♦ Internal puller -1 - Kukko
21/8-
♦ Splitter -3 - Kukko 17/2-
♦ Counter support -4 - Kukko
22/1-
♦ Counter support -4 - Kukko
22/2-
AG. Volkswagen AG d
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ility
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es, in part or in w
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orm
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atio
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te
sd
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Cop py
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Vo
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256
Prote AG.
Rep. Gr.39 - Final drive - front differential
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
Special tools and workshop
equipment required
♦ Thrust pieces for pinion
shaft bearing -VW 470-
♦ Thrust pad -VW 512-
♦ Tube -VW 771/33-
♦ Drift sleeve -40 - 20-
♦ Extension -3161-
♦ Puller -T10037-
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Dismantling bevel box
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ility
– Drain gear oil.
ot p
wit
, is n
– Secure bevel box in gearbox support. h re
hole
spec
es, in part or in w
t to the co
Note
If the output flange hexagon nut is not to be loosened, then the
rrectness of i
bevel box can be held in gearbox support -2004- for dismantling
and assembling.
l purpos
nf
ercia
orm
m
atio
om
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te
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Cop py
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Prote AG.
6. Dismantling and assembling bevel box 257
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
– Remove output flange hexagon nut.
-A- Socket for 3/4" drive
– Remove output flange.
– Lever out seal using a screwdriver.
– Take out shaft bevel gear small tapered roller bearing inner
race.
– Remove pinion housing -1-. Bolt hexagon bolts -arrows- in
evenly so that the pinion housing is not canted.
Note
Pinion housing can also be removed and installed with output
flange fitted.
– Remove shim S3.
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– Press small tapered roller bearing outer race out of pinion d by ua
ran
housing. ir se tee
tho
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a ac
-A- Internal puller -Kukko 21/7- 46 … 58 mm ss
ce
e
nl
pt
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itte
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erm
ab
ility
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wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
– Pull outer race of large tapered roller bearing out of pinion
housing.
l purpos
-A- Internal puller -Kukko 21/7- 46 … 58 mm
nf
ercia
-B- Counter support -Kukko 22/-
orm
m
– Take shaft bevel gear out with shim S4 and spacer ring.
atio
om
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Cop py
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Prote AG.
258 Rep. Gr.39 - Final drive - front differential
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
– Pull large tapered roller bearing inner race off shaft bevel gear.
– Fit adapter and tension well behind the bearing rollers. Then
turn bearing and retighten adapter.
– Bolt puller -T10037- to flange shaft or right drive flange.
– Use knurled nut -T10037/1- and lower support -A- to align
puller parallel with flange shaft or drive flange.
– Pull out output shaft drive flange or right flange shaft.
– If seal is to be renewed, lever it out now.
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es, in part or in w
t to the co
– Remove cover. Bolt hexagon bolts -A- in evenly so that the
cover does not cant.
rrectness of i
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ate
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Cop py
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Prote AG.
6. Dismantling and assembling bevel box 259
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
– Press large tapered roller bearing outer race out of cover.
-A- Internal puller -Kukko 21/8- 56 … 70 mm
– Remove bevel gear with input shaft.
– Press inner race of large tapered roller bearing off bevel gear
(with stub shaft).
-A- Splitter -Kukko 17/2- 22 … 115 mm
– Press small tapered roller bearing inner race off stub shaft.
-A- Splitter -Kukko 17/2- 22 … 115 mm n AG. Volkswagen AG
wage doe s no
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Inner race can also be pressed off using tapered roller bearing
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puller -V.A.G 1582- and adapter -V.A.G 1582/3- but first place
pt
du
an
press piece -40 - 105- on input shaft.
itte
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– Pressing small tapered roller bearing outer race out of final
es, in part or in w
t to the co
drive housing.
-A- Internal puller -Kukko 21/7- 46 … 58 mm
rrectness of i
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Cop py
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Prote AG.
260 Rep. Gr.39 - Final drive - front differential
Bora 1999 ➤ , Golf 1998 ➤
n AG. Volkswagen AG do
5-speed manual gearbox 02C,lkswage
four-wheel drive - Editiones01.2010
no
o V t gu
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– Remove circlip for roller sleeve from final drive housing.ho
ris
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To do this: ss c
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pt
– Lift one end of retaining ring out of groove by turning screw‐
an
d
itte
driver -A-.
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– Use screwdriver -B- to lift this end and grip to lever out further.
ot
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t to the co
rrectness of i
– Pull roller sleeve out of final drive housing.
-A- Counter support -Kukko 22/1- l purpos
nform
ercia
-B- Internal puller -Kukko 21/3- 13 … 23 mm
m
Assembling bevel box
a
com
tion in
r
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thi
s
Note
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Adjustment overview ⇒ page 270 .
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Cop py
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Vo
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– Press roller sleeve into final drive housing. The lettering faces Prote AG.
press tool. Carefully press in to stop.
– Fit new circlip in final drive housing.
– Pressing small tapered roller bearing outer race into final drive
housing. First fit shim S2.
Note
Interrupt pressing operation as soon as possible to allow tube -
VW 771/33- to be seated over the complete circumference of the
outer race.
6. Dismantling and assembling bevel box 261
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
– Press small tapered roller bearing inner race onto stub shaft.
– Press inner race of large tapered roller bearing onto bevel gear
(with stub shaft).
– Insert bevel gear with input shaft into final drive housing.
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– Insert shim S1 into cover and press
ss in large tapered roller c
ce
le
bearing outer race.
un
pt
an
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– Install cover with new O-ring.
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Note
h re
hole
spec
Do not cant when installing. Tighten securing bolts diagonally and
es, in part or in w
t to the co
in stages.
rrectness of i
l purpos
– Press large tapered roller bearing inner race onto shaft bevel
gear.
nform
ercia
– Insert tapered roller bearing with shim S4 and spacer ring into
m
final drive housing, chamfer of spacer ring faces tapered roller
com
tion in
bearing
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Prote AG.
262 Rep. Gr.39 - Final drive - front differential
AG. Volkswagen AG d
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olksw not
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nte
four-wheel drive - Edition 01.2010
ris
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– Press
ss a small tapered roller bearing outer race into pinion
c hous‐
ing.
ce
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un
pt
an
d
itte
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ab
ility
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wit
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h re
ole,
spec
urposes, in part or in wh
t to the co
rrectne
– Press large tapered roller bearing outer race into pinion hous‐
ss o
ing.
cial p
f inform
– Fit shim S3 onto final drive housing.
mer
atio
m
– Install pinion housing with new O-ring.
o
n
c
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or
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Note
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♦ Do not cant when installing. Tighten securing bolts diagonally
Co
op py
and in stages to specified torque ⇒ Item 35 (page 253) .
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♦ Pinion housing can also be removed and installed with output
by c lksw
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flange fitted.
Prote AG.
– Fit small tapered roller bearing inner race for shaft bevel gear.
– Drive new oil seal for output flange in flush.
– Half-fill space between sealing lip and dust lip with sealing
grease for radial oil seal -G 052 128 A1- .
– Install output flange. Output shaft nut threads and shaft bevel
gear threads must be clean.
– Tighten hexagon nut for output flange to specified torque
⇒ Item 30 (page 252) .
– Drive in new oil seal for flange shaft or drive flange with output
shaft to stop ⇒ page 239 .
– Half-fill space between sealing lip and dust lip with sealing
grease for radial oil seal -G 052 128 A1- .
6. Dismantling and assembling bevel box 263
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
– Press drive flange off output shaft.
– Press drive flange onto output shaft.
– Drive flange shaft or drive flange with output shaft in carefully,
turn shaft when doing this. en AG. V
olkswagen AG
ag does
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– Secure flange shaft or drive flange with output shaft by using
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countersunk bolt and tighten to specified torqueris
ed
nte
⇒ Item 4 (page 250) . autho eo
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– If there was a sealing cap fitted, renew it.
ce
le
un
pt
an
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itte
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erm
ab
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spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
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c
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Cop py
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Prote AG.
264 Rep. Gr.39 - Final drive - front differential
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
7 Renewing needle bearing (polygon bearing) for right output shaft or
for right flange shaft
Special tools and workshop
equipment required
♦ Pressure plate -VW 401-
♦ Pressure plate -VW 402-
♦ Press tool -VW 407-
♦ Press tool -VW 412-
♦ Assembly tool -3253/5-
♦ Assembly tool -T10047-
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Prote AG.
7. Renewing needle bearing (polygon bearing) for right output shaft or for right flange shaft 265
AG. Volkswagen AG d
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Bora 1999 ➤ , Golf 1998 ➤ thor eo
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5-speed manual gearbox 02C, four-wheel
ss a drive - Edition 01.2010 c
ce
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♦ Crankshaft seal insertion
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ab
tool -VW 204 B-
ility
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♦ Puller -T10037-
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♦ Torque wrench -
spec
urposes, in part or in wh
V.A.G 1331-
t to the co
♦ Hexagon key -V.A.G 1669-
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cial p
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mer
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c
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Additional required information
♦ Workshop Manual Golf 1998 ▸, Bora 1999 ▸, Running gear,
axles, steering - front and four-wheel drive
Removing
– Only loosen drive shaft/wheel hub nut when vehicle is standing
on its own wheels.
– Remove centre and right parts of noise insulation below en‐
gine and gearbox, if fitted.
– Remove drive shaft ⇒ Running gear, axles, steering - front
and four-wheel drive; Rep. Gr. 40 ; Servicing drive shaft; Re‐
moving and installing drive shaft .
– If a cap is fitted, remove it by piercing cap centre with a screw‐
driver and levering out.
– Place drip tray under gearbox.
– Remove right output shaft bolt or right flange shaft bolt using
hexagon key -V.A.G 1669- or commercially available 6 mm
socket.
266 Rep. Gr.39 - Final drive - front differential
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
– Bolt puller -T10037- to flange shaft or right drive flange.
– Use knurled nut -T10037/1- and lower support -A- to align
puller parallel with flange shaft or drive flange.
– Pull out output shaft drive flange or right flange shaft.
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Now assemble tensioning tool -T10047- as follows:
h re
hole
spec
– Align both parts of tool so that marks “A” are opposite one
es, in part or in w
another.
t to the co
– The shoulders -arrows- must then be below the bearing.
– Now screw both halves together to stop.
rrectness of i
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ion
c
in t
or
– Lever off retaining ring -A- for needle bearing(s).
his
ate
do
riv
– To avoid damage to running surface of bearing on shaft, turn
p
cum
or
shaft during pressing procedure -arrow-.
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Installing C py
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Set up tensioning tool -T10047- ⇒ page 267 . cop Vo
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Prote AG.
7. Renewing needle bearing (polygon bearing) for right output shaft or for right flange shaft 267
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
– To avoid damage to running surface of bearing on shaft, turn
shaft during pressing procedure -arrow-.
– Secure needle bearing(s) with a new retaining ring.
– Drive flange shaft or drive flange with output shaft in carefully,
turn shaft when doing this. wagen AG. Volkswagen AG doe
ks s no
Vol t
– Secure flange shaft oreddrive
by flange with output shaft usingguara
countersunk bolt and ris tighten to specified torque nte
tho eo
⇒ Item 4 (page s250)
au . ra
c s
– If there was a sealing cap fitted, renew it.
ce
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nl
pt
du
an
itte
– Install drive shaft ⇒ Running gear, axles, steering - front and
y li
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ab
four-wheel drive; Rep. Gr. 40 ; Repairing drive shafts; Re‐
ility
ot p
moving and installing drive shafts .
wit
, is n
h re
– Screw nut (self-locking) onto drive shaft and only tighten with
hole
vehicle standing on its wheels ⇒ Running gear, axles, steering
spec
es, in part or in w
- front and four-wheel drive; Rep. Gr. 40 ; Repairing drive
t to the co
shafts; Removing and installing drive shafts .
– Checking gear oil in manual gearbox with bevel box
⇒ page 75 .
rrectness of i
– Install noise insulation, if fitted.
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nform
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at
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ion
c
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or
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ate
do
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Prote AG.
268 Rep. Gr.39 - Final drive - front differential
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
8 Adjusting shaft bevel gear and bevel
gear with stub shaft (final drive gear
set)
8.1 General notes
Careful adjustment of final drive gear set is essential to ensure
that bevel gears give long service and run quietly. Therefore, the
bevel gear with stub shaft and shaft bevel gear are matched dur‐
ing production and checked on testing machines to ensure correct
mesh pattern and silent running. The position for quietest running
is obtained by moving the shaft bevel gear axially and, at the same
time, maintaining the backlash within the specified tolerances.
The deviation “r” based on the master gauge “Ro” is marked on
the bevel gear. Renew final drive gear set (bevel gear with stub
shaft and shaft bevel gear) together only!
8.2 Adjustment and marking of final drive gear sets
A - Bevel gear with stub shaft
B - Shaft bevel gear
1 - Pair number -8033- of final
drive gear set
2 - Shaft bevel gear allowance
(D = -3-) AG. Volkswagen AG d
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❑ Adjustment dimension by
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3 - Backlash (Sdss a=u 0.20) ra
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❑ Check dimension
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4 - Allowance “r” is based on
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ab
the test machine master gauge
pe
ility
used in the production. The al‐
ot
wit
lowance “r” is always given in
, is n
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1/100 mm. Example: “38” indi‐
hole
spec
cates r = 0.38 mm.
es, in part or in w
t to the co
Ro - Length of test machine
master gauge used. “Ro” =
36.20 mm
rrectness of i
R - Actual distance between
l purpos
axis of bevel gear (with stub
shaft) and face of shaft bevel
gear at point with quietest run‐
nform
ercia
ning for this particular final
drive gear set.
m
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com
tion in
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Cop py
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Prote AG.
8. Adjusting shaft bevel gear and bevel gear with stub shaft (final drive gear set) 269
Bora 1999 ➤ , Golf 1998 ➤
n AG. Volkswagen AG do
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
lkswage es n
o o t gu
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ir se nte
8.3 Position of shims aut
ho eo
ra
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nl
pt
S1 - Shim for friction torque of
du
an
itte
tapered roller bearing for bevel
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gear with stub shaft
ility
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wit
S2 - Shim for friction torque
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and position of bevel gear with
hole
spec
stub shaft
es, in part or in w
t to the co
S3 - Shim for shaft bevel gear
S4 - Shim for friction torque of
tapered roller bearing for shaft
rrectness of i
bevel gear
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nf
ercia
orm
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or c
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8.4 Adjustment overview - bevel box
Note
If repairs have been carried out to the gearbox, adjusting the shaft
bevel gear, bevel gear or complete gear set is necessary only if
components have been renewed which have a direct effect on the
adjustment of the final drive. To prevent unnecessary adjust‐
ments, refer to the following table:
To be adjusted:
Shaft bevel gear Bevel gear (with
(S3 and S4) stub shaft)
via allowance “r” (S1 and S2)
⇒ page 272 ⇒ page 277
Parts renewed: Final drive housing x20) x
Cover x21)
270 Rep. Gr.39 - Final drive - front differential
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
Final drive gear set x x
(Shaft bevel gear and bevel gear with stub
shaft)
Tapered roller bearing for shaft bevel gear x
Tapered roller bearing for bevel gear (with x
stub shaft)
Pinion housing x
Output flange x22)
20) Only S3 ⇒ page 275 . The shaft bevel gear is dismantled together with
the pinion housing. Therefore the shim S4 remains undisturbed.
21) Only S1 via previously measured total friction torque.
22) Only S4 via difference in dimension ⇒ page 271 .
8.5 Recommended sequence for new ad‐
justment of final drive gear set
If shaft bevel gear and bevel gear (with stub shaft) have to be
adjusted, then in the interests of an efficient procedure keep to
the following order: AG. Volkswagen A
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wage es n
1. Adjust shaft bevel gear (S3 and S4). Volks ot g
by ua
ed ran
ris tee
– Determine thickness of shim "S4" and insert.
tho This sets the or
au
preload for the tapered roller bearing of
ss the shaft bevel gear.
ac
ce
e
nl
– Determine thickness of shim "S3" and insert. The shaft bevel
pt
du
an
itte
gear is thus fixed axially so that the dimension from centre of
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erm
ab
bevel gear with stub shaft to face of shaft bevel gear corre‐
ility
ot p
sponds to the installation dimension "R" determined during
wit
, is n
production.
h re
hole
spec
– Carry out check measurement of S3.
es, in part or in w
t to the co
2. Adjust bevel gear (with stub shaft) (S1 and S2).
– Adjust bevel gear tapered roller bearing preload via Stotal and
rrectness of i
adjust friction torque.
l purpos
– Adjust backlash. Select shims “S1” and "S2" so that the pre‐
scribed backlash between bevel gear with stub shaft and shaft
bevel gear is obtained.
nf
ercia
orm
– Check backlash.
m
atio
om
n in
The purpose of this adjustment is to re-establish the position of‐
or c
thi
fering the quietest running as calculated on the test machine
te
sd
a
during production. The utmost care and cleanliness during all as‐
iv
o
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rp
cu
sembly work and measurements are essential to achieve a good
o
m
f
en
result.
ng
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8.6 Determining shim "S4" thickness when
t. C rig
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renewing output flange
c by lksw
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Prote AG.
This adjustment is only necessary if the output flange is renewed.
Its purpose is to reestablish the shaft bevel gear tapered roller
bearing preloading.
8. Adjusting shaft bevel gear and bevel gear with stub shaft (final drive gear set) 271
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
– Measure length of old and new output flange shafts and de‐
termine difference.
Example:
Old output flange 25.80 mm
New output flange 25.60 mm
Difference 0.20 mm
If the new output flange is longer, install an S4 shim which is
thinner by the difference.
If the old output flange is longer, install an S4 shim which is thicker
by the difference.
Available shims for S4 ⇒ page 275 .
– The various thicknesses make it possible to achieve the exact
shim thickness required.
8.7 Adjusting shaft bevel gear
Special tools and workshop
equipment required
♦ Universal measuring tool -
VW 385-
♦ Tube -VW 415 A-
olkswagen AG
en AG. V
♦ Gearbox support -3221-olkswag does
not
V gu
by ara
♦ Support plate -3221/1A-
or
ise
d
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ut ra
♦ Torque wrench
ss
a - c
V.A.G 1601-
ce
le
un
pt
an
d
♦ Torque wrench -
itte
y li
V.A.G 1332-
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
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com
tion in
r
te o
thi
s
iva
do
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rp
cum
fo
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.
272 Rep. Gr.39 - Final drive - front differential
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
♦ Torque wrench -V.A.G 1331-
AG. Volkswagen AG d
agen oes
olksw not
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d by ara
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or eo
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nl
pt
du
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itte
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ab
ility
ot p
♦ Thrust piece -VW 473-
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
♦ Thrust piece -2050-
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
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Prote AG.
♦ Soldering wire ∅ 1.5 mm
♦ Torque gauge, 0...600 Ncm, commercially available
♦ Dial gauge
♦
Readjustment of the shaft bevel gear is required if
♦ Final drive housing
♦ Tapered roller bearing for shaft bevel gear
♦ Final drive gear set
or
♦ Pinion housing
is renewed.
Adjustment overview ⇒ page 270
8. Adjusting shaft bevel gear and bevel gear with stub shaft (final drive gear set) 273
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
Determine thickness of shim "S4".
– Press outer race of large tapered roller bearing for shaft bevel
gear into pinion housing with press piece -2050- .
– Press outer race of small tapered roller bearing for shaft bevel
gear into pinion housing with press piece -VW 473- .
– Press large tapered roller bearing inner race onto shaft bevel
gear with tube -VW 415 a- .
– -A- Put on soldering wire of 1.5 mm ∅ instead of shim S4.
– Put on spacer ring -B- with chamfer facing tapered roller bear‐
ing inner race.
– Fit shaft bevel gear.
– Fit small tapered roller bearing inner race and output flange
and fit hexagon nut.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
ut ra
– -A- Screw in hexagon bolt M10s as counterhold.
s a c
ce
e
nl
-B- Socket insert
pt
du
an
itte
y li
– Tighten hexagon nut to 20 Nm, loosen or completely remove
erm
ab
hexagon bolt -A-.
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
– Measure friction torque.
-A- Torque gauge, commercially available, 0 … 600 Ncm
nform
ercia
-B- Socket insert
m
at
om
ion
– Increase torque setting if necessary to achieve the prescribed
c
in t
or
friction torque.
his
ate
do
priv
cum
for
en
g
Note
n
t.
yi Co
Cop py
ht. rig
Only increase torque setting slowly thereby reading off friction rig ht
py by
torque regularly; if the prescribed friction torque is exceeded then
co Vo
by lksw
cted
the soldering wire must be renewed and the adjustment repeated.
agen
Prote AG.
Following friction torques are to be set:
New bearings Used bearings23)
100 ... 240 Ncm 30 ... 50 Ncm
23) run for at least 50 km (30 miles)
– Remove shaft bevel gear and carefully remove crushed sol‐
dering wire.
274 Rep. Gr.39 - Final drive - front differential
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
– Measure thickness of soldering wire at a well crushed together
area where there is no lip.
– Select shim(s) of same thickness.
Note
Allocate shims using ⇒ ETKA (electronic parts catalogue) .
Available shims for S4
Shim thickness (mm)
0.65 0.95 1.25
0.70 1.00 1.30
0.75 1.05 1.35
0.80 1.10 1.40
0.85 1.15
0.90 1.20
– The various thicknesses make it possible to achieve the exact
shim thickness required.
– Fit shim S4 and install shaft bevel gear.
– Tighten nut for output flange to specified torque
⇒ Item 30 (page 252) .
-A- Socket for 3/4" drive
n AG. Volkswagen AG do
wage es n
Carry out control measurement - check friction torque.yV
olks ot g
d b ua
e ran
Friction torques ⇒ page 274 horis tee
ut or
a ac
If necessary, correct with a thinner (more
ss friction torque) or thicker
(less friction torque) S4 shim. ce
le
un
pt
an
d
itte
Determine thickness of shim S3. y li
rm
ab
pe
ility
– Install pinion housing with shaft bevel gear and installed shim
ot
wit
, is n
S4.
h re
hole
spec
– Do not insert O-ring.
es, in part or in w
t to the co
– Adjust setting ring of universal measuring tool -VW 385/1- to
dimension a = 75 mm.
rrectness of i
– Set sliding positioning ring to dimension b = 32 mm.
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
8. Adjusting shaft bevel gear and bevel gear with stub shaft (final drive gear set) 275
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
– Set up universal mandrel according to figure. Measuring
gauge extension -VW 385/20- = 3 mm. n AG. Volkswagen AG do
lkswage es n
o ot g
yV
Set master gauge -VW 385/30- to Ro = 36.20 mm. d b ua
ran
ir se tee
ho
– Set dial gauge to 0 with 3 mm preload. aut or
ac
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
– Place end measurement plate on head of shaft bevel gear.
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi
– Insert universal mandrel.
Co
Cop py
t. rig
gh
– Fit cover and tighten hexagon bolts.
ht
pyri by
Vo
co lksw
by
– Use sliding setting ring to pull centring disc outwards until
cted agen
Prote AG.
mandrel can still just be turned by hand.
276 Rep. Gr.39 - Final drive - front differential
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
– Determine dimension “e”. Turn test gauge until point of dial
gauge makes contact with end measuring plate and indicates
max. deflection (return point). The measured value is dimen‐
sion “e” (in red scale). Example: 0.47 mm
– Remove universal test gauge.
Note
n AG. Volkswagen AG do
lkswage es n
o ot g
yV u
Finally, check again
ir se
d b
whether dial gauge returns to “0” awith ran 3 mm
tee
preload withutmaster
ho gauge -VW 385/30- applied. Otherwise orre‐
peat measurement.
ss
a ac
ce
e
nl
pt
du
Determine thickness of shim "S3".
an
itte
y li
erm
ab
S3 = e + r
ility
ot p
wit
, is n
e - Calculated value (max. deflection)
h re
hole
spec
r - Deflection (given in 1/100 mm on bevel gear)
es, in part or in w
t to the co
Example:
Value indicated on dial gauge “e” 0.47 mm
rrectness of i
Deviation inscribed on bevel gear “r” +0.38 mm
l purpos
Shim thickness "S3" = 0.85 mm
nform
mercia
at
Note
om
ion
c
in t
or
Allocate shims using ⇒ ETKA (electronic parts catalogue) .
his
ate
do
priv
cum
or
Available shims for S3
f
en
ng
t.
yi Co
op
Shim thickness (mm)
C py
t. rig
gh ht
yri by
0.65 0.90 1.15
cop Vo
by lksw
cted agen
0.70 0.95 1.20
Prote AG.
0.75 1.00 1.25
0.80 1.05
0.85 1.10
– The various thicknesses make it possible to achieve the exact
shim thickness required.
– Remove pinion housing with shaft bevel gear.
– Install determined shim S3.
Carry out check measurement - check dimension “R”.
Insert universal mandrel and measure dimension “R”.
With correctly selected shims, the dial gauge, reading anti clock‐
wise (red number range), must indicate the value of the noted
deviation “r” on the bevel gear to within a tolerance of + 0.04 mm.
8.8 Adjusting bevel gear (with stub shaft)
8. Adjusting shaft bevel gear and bevel gear with stub shaft (final drive gear set) 277
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
Special tools and workshop
equipment required
♦ End dimension plate -
VW 385/17-
♦ Universal dial gauge brack‐
et -VW 387-
♦ Adjustable measuring lever
-VW 388-
AG. Volkswagen AG d
♦ Adjusting device for crown agen oes
olksw not
V
wheel -VW 521/4- d by gu
ara
rise nte
o
♦ Adjusting device for crown auth eo
ra
wheel -VW 521/13- ss c
ce
e
nl
pt
♦ Dial gauge
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Readjustment of the bevel gear (with stub shaft) is required if Prote AG.
♦ Final drive housing
♦ Cover
♦ Tapered roller bearing for bevel gear with stub shaft
or the
♦ Final drive gear set
is renewed.
Adjustment overview ⇒ page 270
Adjust preload of tapered roller bearing for bevel gear with stub
shaft (friction torque).
The shaft bevel gear is removed.
– Fit 1.2 mm shim in small tapered roller bearing outer race seat
(S2 side).
As a test condition, a temporary shim S2 of 1.20 mm is installed.
It is referred to below as S2 . After backlash is determined, S2 *
is replaced with final shim S2.
– Press in outer race ⇒ page 261 .
278 Rep. Gr.39 - Final drive - front differential
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
– Fit bevel gear with stub shaft with tapered roller bearing.
– Install cover with large tapered roller bearing outer race but
without O-ring, drive flange seal and without shim S1.
– Press bevel gear with stub shaft in direction of cover while
turning eight times.
– Press bevel gear with stub shaft in direction of outer race of
small tapered roller bearing while turning eight times.
– Set up dial gauge (2 mm preload) -A- dial gauge extension 30
mm.
– Move bevel gear with stub shaft up and down
(-direction of arrow-).
– Read play from dial gauge and determine Stotal.
Example:
"Stotal" = S2 * + measured value + preload
Fitted shim(s) S2 * 1.20 mm
Measured value (example) 0.45 mm
Preload (constant value) 0.30 mm
Stotal = 1.95 mm
Determine thickness of shim S1 .
AG. Volkswagen AG d
agen oes
olksw not
y V gu
b ara
Note rise
d
nte
tho eo
au ra
♦ After backlash is determined, temporary shim S1 is replaced ss * c
ce
e
nl
with final shim S1.
pt
du
an
itte
y li
♦ The total shim thickness "Stotal" remains unchanged.
erm
ab
ility
ot p
wit
, is n
S1 = Stotal - S2
h re
hole
spec
Example:
es, in part or in w
t to the co
Total shim thickness "Stotal" 1.95 mm
Fitted shim(s) S2 - 1.20 mm
rrectness of i
Thickness of shim S1 = 0.75 mm
l purpos
Available shims for S1 ⇒ page 281 .
nf
ercia
Measure backlash.
rm
m
atio
m
Pinion housing with shaft bevel gear and S3installed
o
n in
or c
thi
e
Install bevel gear with stub shaft: S1 is installed on the cover side
t
sd
iva
o
r
rp
cu
and S2 in the final drive housing.
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
8. Adjusting shaft bevel gear and bevel gear with stub shaft (final drive gear set) 279
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
– Set up measuring tools.
♦ Dial gauge extension about 25 mm long
♦ Dimension “a” = 39 mm
♦ Screw in adjustable measuring lever -VW 388- so that dial
gauge extension is at right angles to surface to be measured.
– Turn bevel gear with stub shaft to stop. Set dial gauge to 0,
turn back bevel gear with stub shaft and read backlash. Note
reading.
– Loosen clamping sleeve locking screw and after turning bevel
gear with stub shaft a further 90°, repeat complete measuring
process 3 more times. Add the four results and calculate the
average backlash.
Calculating average backlash.
Example:
1. Measurement 0.45 mm
+ 2. Measurement 0.44 mm
+ 3. Measurement 0.45 mm
+ 4. Measurement 0.46 mm
Total 1.80 mm
Average backlash = 1.80 mm / 4 = 0.45 mm.
Determine thickness of shim S2.
S2 = Inserted shim
n AG. Volkswagen AG do
- Average backlash
olks
wage es n
ot g
y V
+ Lift (constant
se
db value) ua
ran
ri tee
tho or
Lift = 0.20 smm
au ac
s
ce
le
Example:
un
pt
an
d
itte
y li
S2 Inserted shim 1.20 mm
erm
ab
ility
ot p
- Average backlash 0.45 mm
wit
is n
0.70 mm
h re
ole,
spec
+ Lift (constant value) 0.20 mm
urposes, in part or in wh
t to the co
S2 = 0.95 mm
rrectne
Note
s
Allocate shims using ⇒ ETKA (electronic parts catalogue) .
s o
cial p
f inform
Available shims for S2
mer
atio
om
Shim thickness (mm)
n
c
i
or
n thi
e
0.15 0.50 0.90
t
sd
iva
o
pr
0.20 0.60 1.20
cum
r
fo
en
ng
0.30 0.70
t.
yi Co
op py
0.40 0.80
. C rig
ht ht
rig by
copy Vo
– The various thicknesses make it possible to achieve the exact
by lksw
cted agen
Prote
shim thickness required.
AG.
– Install determined shim S2 in place of S2. *.
280 Rep. Gr.39 - Final drive - front differential
Bora 1999 ➤ , Golf 1998 ➤
5-speed manual gearbox 02C, four-wheel drive - Edition 01.2010
Two shims which total the measured value may be installed.
. Volkswagen AG
– Press outer race in again and fit bevel gear with stub shaft.kswagen AG does
not
ol
yV gu
Determine thickness of shim S1. edb ara
nte
ris
tho eo
S1 = Stotal - S2 au ra
c
ss
ce
le
un
pt
Example:
an
d
itte
y li
S1 = 1.95 mm - 0.95 mm
rm
ab
pe
ility
S1 = 1.00 mm
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
Note
Allocate shims using ⇒ ETKA (electronic parts catalogue) .
rrectness of i
l purpos
Available shims for S1
Shim thickness (mm)
nform
ercia
0,70 0,95 1,20
m
a
com
tio
0,75 1,00 1,25
n in
r
te o
thi
0,80 1,05 1,30
s
iva
do
r
0,85 1,10 1,35
rp
cum
fo
en
g
0,90 1,15
n
t.
yi Co
Cop py
t.
– Various tolerances make it possible to obtain the exact shim
rig
gh ht
yri by
thickness required. op Vo
by c lksw
cted agen
Prote
– Insert determined S1 shim.
AG.
Two shims which total the measured value may be installed.
– Press outer race in again.
– Fit cover.
Carrying out control measurement - measure backlash.
– It must be 0.15…0.20 mm.
8. Adjusting shaft bevel gear and bevel gear with stub shaft (final drive gear set) 281
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