Gearbox 012 assy
- 1. Tapered roller bearing
- 2. Reverse Gear
- 3. 5th gear
- 4. 4th gear
- 5. 3rd gear
- 6. Gear 2nd gear
- 7. 1st gear
- 8. Tapered roller bearing
- 9. Differential
- 10. Clutch housing
- 11. Ball bearing
- 12. Gear box
- 13. Drive shaft
- 14. Block of gears of an intermediate shaft
Specifications, 5-speed gearbox 012
Code |
AKL/AUF
|
ALP/AAD
|
4-cylinder
|
5-cylinder
| |
Gear ratio: | ||
- main gear |
37:9 = 4.111
|
37:10 = 3.700
|
- first gear |
39:11 = 3.545
|
39:11 = 3.545
|
- second gear |
40:19 = 2.105
|
40:19 = 2.105
|
- third gear |
39:30 = 1.300
|
39:30 = 1.300
|
- fourth gear |
33:35 = 0.943
|
35:34 = 1.029
|
- fifth gear |
30:38 = 0.789
|
31:37 = 0.838
|
- reverse gear |
35:10 = 3.500
|
35:10 = 3.500
|
Speedometer |
electronic
| |
Lubrication volume |
2.35 liters
| |
Specification |
Gear oil G 50 (synthetic)
| |
SAE 75 W 90 | ||
clutch drive |
hydraulic
| |
Clutch disc diameter |
210 mm
|
228 mm
|
Drive shaft flange diameter |
100 mm
|
108 mm
|
Speed in highest gear at 1000 rpm |
34 km/h
|
36 km/h
|
Warning: Do not lubricate the shift lever linkage.
Shift Lever Linkage, Adjust/Check
Withdrawal
1. Disconnect the negative battery cable.
2. Remove the top three engine and gearbox mounting bolts.
3. Disconnect the transmission ground wire from the transmission.
4. Remove the speedometer transmitter connector and the multifunction transmitter connector by squeezing the clips.
5. Disconnect the catalytic converter connector.
6. Remove the protective plate of the gearbox housing.
7. Loosen the exhaust manifold bolts.
8. Remove the front exhaust pipe.
9. Remove the rear cross member.
10. Disconnect the automatic seat belt tensioners from the transmission.
11. Remove the shift rod.
12. Remove the clutch housing protective plate.
13. Remove the drive shaft guard.
14. Disconnect the axles from the gearbox.
15. Turn the steering wheel all the way to the right and secure the axle shafts by tying them to the body.
16. Remove the clutch slave cylinder.
17. Remove the steering mechanism bracket.
18. Install the engine on a support.
19. Mount the gearbox on a support
20. Remove the mounting on the rear left side of the gearbox.
21. Remove the front engine mount.
22. Remove the lower transmission and engine mounting bolts.
23. Lower the gearbox slowly.
Installation
Installation is made in sequence, return to removal.
Pay attention to the following when installing:
- check that the centering sleeves are installed correctly.
- install the clutch slave cylinder in place with the lever so that the bolt is inserted easily.
Warning: The clutch slave cylinder bolt has a pointed end for ease of installation.
Tightening torques for threaded connections
Mounting the gearbox to the engine: | |
- M8 bolts |
25 Nm
|
- M10 bolts |
45 Nm
|
– M12 bolts |
65 Nm
|
Mounting the drive shaft to the flange: | |
– M8 |
45 Nm
|
– M10 |
80 Nm
|
Gearbox to engine
4 cylinder engine
- 1 = bolt M12 x 70
- 2 = bolt M12 x 85
- 3 = bolt M12 x 100
- 4 = bolt M8 x 15
5 cylinder engine
- 1 = bolt M12 x 70
- 2 = bolt M12 x 80
- 3 = bolt M12 x 90
- 4 = bolt M12 x 100
- 5 = bolt M11 x 120
- 6 = bolt M10 x 50
- 7 = bolt M10 x 40
- 8 = bolt M8 x 40
Location of centering sleeves: points A and B
Location of centering sleeves: points A and B
Warning: If you need to replace the final drive housing or tapered roller bearing of the drive gear or hollow shaft and the deviation r is not marked on the bevel gear, the installation position of the drive gear must be determined before removing the gear housing (it is necessary to measure the actual value of the deviation).
Warning: Before installing the transmission case, check that the guide bushings are installed in the transmission case.
Warning: Handle the speedometer transmitter very carefully. Do not drop it, otherwise the speedometer reading may not be accurate.
Final drive mechanism
- 1. Speedometer drive
- 2. Differential
- 3. O-ring
- 4. Final drive cover
- 5. Socket head bolt - 25 Nm
- 6. Retaining ring
- 7. Drive shaft flange
- 8. Socket head bolt - 35 Nm
- 9. Guide bushing with O-ring
- 10. Concave washer
- 11. Retaining ring
- 12. Drive shaft ball bearing
- 13. Retaining ring
- 14. Speedometer transmitter
- 15. Carter final drive
- 16. Socket head bolt - 10 Nm
- 17. Connector for connecting a multi-function transmitter
- 18. Gear lever channel cover
- 19. Multifunction transmitter
- 20. Cover film for multifunction transmitter
- 21. Bolt 25 Nm
- 22. Lock 5th gear and reverse gear
- 23. Retaining ring
Warning: The speedometer actuator1 can be replaced without removing the transmission.
Warning: Differential 2 can be removed without removing the gearbox housing.
Warning: Remove O-ring 3 using tool VW 681.
Warning: Seal final drive cover 4 with AMV 188 200 03.
Warning: Always replace circlips 6 and 23.
Warning: Install the input shaft flange using the VW 295 tool.
Warning: The smaller diameter side of the concave washer 10 faces the guide bush (concave side).
Warning: Retaining rings 11, 13 mark after removal.
Warning: Driveshaft flange O-ring - remove with tool VW 681 and install (5 mm below the surface of the final drive housing) using the VW 195 tool.
Warning: Final drive housing 15: drive shaft flange seal - remove with VW 681 tool. Install (5 mm below the surface of the final drive housing) using tool VW 195. 3rd/4th shift rod bushing - install using tools VW 295 and VW 295A. Seal with AMV 188 200 03.
Warning: Gear lever channel cover 18 - tighten the mounting bolt to 20 Nm
Warning: The lock for 5th and reverse gear 22 can be replaced without removing the gearbox. The bevelled side of the plastic sleeve faces the shift shaft. Tightening torque of mounting bolts: 10 N. m.
Drive Shaft Mechanism
- 1. Internal shift rod
- 2. Shift rod 1st, 2nd, 5th gear and reverse gear with shift fork
- 3. Pinion with hollow shaft
- 4. Gear box
- 5. Socket head bolt - 25 N.m.
- 6. Socket head bolt for reverse axle - 35 Nm
- 7. Socket head bolt - 25 Nm
- 8. Castle
- 9. Socket head bolt - 40 Nm
- 10. Washer
- 11. Switch shaft
- 12. Washer
- 13. Socket head bolt
- 14. 3rd/4th shift rod and shift fork
- 15. Drive shaft
- 16. Retaining ring
- 17. Washer
- 18. Reverse gear
- 19. Needle bearing of driven gear of reverse gear
- 20. Thrust washer
Warning: Remove the sealing ring of the inner shift rod 1 with the tool VW 681 and install flush with the tool VW 460/ 2. With the gearbox installed, carefully remove the sealing ring with a screwdriver and install with the tool VW 423. First, remove the exhaust pipes and gearshift rod to get free space.
Warning: 1st, 2nd, 5th &Reverse Shift Rod with Shift Fork 2 - For disassembly/assembly, remove/install spring pins. The 1st/2nd shift forks can be replaced individually. Replace the 5th/Reverse shift fork only together with the shift ring and shift rod.
Warning: Reverse axle socket head bolt 6 - 35 N.m. The reverse gear axle does not need to be removed to remove the reverse gear.
Warning: 7-25 N.m socket head bolt. Inside of head faces spring/lock safety mechanism.
Warning: Install the lock 8 after installing the shift shaft 11 and the inner shift rod.
Warning: 3rd/4th shift shaft and shift fork: The shift shaft or shift fork can be replaced individually. Replace shift rod bearing if worn.
Removing the shift shaft bolts
The arrows indicate the shift shaft bolts.
Gear shift position
1. 5th/Reverse shift rod with shift fork
2. Shift rod 3rd/4th gear
3. Shift fork 1st / 2nd gear
4. Switch shaft
5. Castle
6. Internal switching rod
Position of input shaft, hollow shaft pinion, shift rods and shift forks
These items should be installed together.
The switching shaft and internal switching shaft can be installed later.
Installing the shift shaft and internal shift rod
- A - shift shaft
- B - internal switching rod
Order of execution
1. Engage 3rd gear.
2. Install the shift shaft.
3. Lay the inner shift rod B sideways over the hole in the final drive case and align it with the bracket socket on the shift shaft.
4. Turn the shift rod inward in the direction of the arrow (see fig. Installing the shift shaft and internal shift rod).
Removing the shift rod bushing
Use a hammer and inner puller A for 18.5-23.5 mm (e.g. 1088 or Kukko 21/3).
Removal and installation of the shift fork bearing
Removal and installation of the oil collector
- The arrow points to the oil pan
Order of execution
1. Remove the oil sump with a screwdriver.
2. Insert the oil sump deep into the transmission case so that the locking tabs on the oil sump engage in the slots in the transmission case.
3. The oil sump cup must face up in the gearbox housing.
Installing the O-ring for the internal selector rod
a = 1 mm
Manual transmission - crankcase, gears, shafts
Drive shaft assembly
- 1. Gear box
- 2. Plastic sleeve
- 3. Needle bearing - drive shaft
- 4. Retaining ring
- 5. 5th gear
- 6. Needle bearing - 4th gear
- 7. 4th gear
- 8. Synchronizer ring
- 9. Sliding clutch - 3rd / 4th gear
- 10. Retaining ring
- 11. Synchronizer hub - 3rd / 4th gear
- 12. Retaining ring
- 13. Retaining ring
- 14. Ball bearing - drive shaft
- 15. Retaining ring
- 16. Carter final drive
- 17. Needle bearing - drive shaft
- 18. Drive shaft
- 19. Needle bearing - 3rd gear
- 20. 3rd gear
- 21. Synchronizer ring - 3rd gear
Warning: Always replace the plastic bushing 2. It is missing from the drive shaft which does not have oil holes for 3rd/4th gears.
Warning: Needle bearing 2 is damaged when removed. Always replace it. Install it with tool VW 416B to a depth of 214 mm, measured from the surface of the crankcase.
Warning: Retaining ring 4 - check the required thickness when replacing the 5th gear.
Warning: Retaining ring 10 - check the required thickness when replacing the synchronizer hub.
Warning: Synchronizer Hub 11 - The protruding rim faces the 3rd gear.
Warning: Circlip 13 - If you are going to use an old ball bearing and shaft, you should measure the thickness of the old circlip and replace it with a new one of the same thickness.
Warning: Retaining ring 15 - if you are going to use an old ball bearing and shaft, you should measure the thickness of the old retaining ring and replace it with a new one of the same thickness
Warning: Needle bearing - drive shaft. Install with tool 40-202.
Removing the needle bearing of the input shaft
Installation depth of needle bearing
a = 39.5 mm
Mounting depth is measured from the bottom edge of the straight edge to the top edge of the bearing.
Installing a ball bearing in the crankcase
Order of execution
1. Install the circlip on the drive shaft.
2. Install the ball bearing on the drive shaft as far as it will go.
3. Install the thrust heel of the release tool 3235 on the ball bearing.
4. Install the 3235 release tool behind the clutch disc splines on the input shaft.
5. Press on the ball bearing by tightening the two bolts B installed in the recesses of the thrust heel A.
6. Press the bearing in until it stops one by one and gradually tighten the two bolts.
Warning: Bolts B must be tightened alternately (e.g. half a turn at a time), otherwise the ball bearing may be rotated and damaged.
Warning: Ball bearing installation position: The open side of the plastic housing must face the guide bush.
Checking the synchronizer ring for wear
Order of execution
1. Install the synchronizer ring on the sliding sleeve and measure the gap a with a feeler gauge at points A, B and C.
2. Add up the resulting values and divide the sum by 3.
3. The resulting value should not be less than 0.5 mm.
Sliding Clutch Installation - 3rd/4th Gear
Groove side (arrow) facing the 3rd gear.
Installing the synchronizer spring
Install the spring (arrow) into the gear by placing the pointed end of the spring in the groove.
Removing the 5th Gear
A = 22-115mm removable device, e.g. Kukko 17/2.
5th Gear Installation
Raised edge faces reverse gear. The lubrication channels face 4th gear.
Removal / installation of the needle bearing of the input shaft
- A = 22-28 mm puller, e.g. Kukko 11/4
- B = hammer VW 771
Warning: Before installing a bearing puller, split/remove the plastic bushing if fitted. To install the bearing, press it with a VW 416B mandrel to a depth of 214 mm, measured from the surface of the crankcase.
Retaining rings
Installing the 4th Gear Retaining Ring
Determine the maximum possible thickness of the retaining ring that can be installed and install it. The retaining ring for the 5th gear is selected in the same way.
Retaining ring thickness, mm | Number |
Retaining ring 3 (brown) | |
2.00
|
902 945.01
|
Retaining ring 4 (blue) | |
1.90
|
902 944.01
|
1.93
|
902 944.02
|
1.96
|
902 944.03
|
1.99
|
902 944.04
|
2.02
|
902 944.05
|
2.05
|
902 944.06
|
Retaining ring 5 | |
1.90
|
902 942.02
|
1.93
|
902 942.03
|
1.96
|
902 942.04
|
1.99
|
902 942.05
|
2.02
|
902 942.06
|
Installation location, selection of circlips
Retaining rings are marked in the figure, they are numbered according to their position on the drive shaft.
Retaining rings 1, 2, 4 and 5 must be selected. The thickness of the retaining ring 3 is always constant.
Determine the required thickness of retaining rings 1 and 2.
Removing the 3rd/4th gear synchronizer hub
- VW 401/ VW 402 = Thrust feet
- 32–12 = disk
- VW 408A = drift
- A = 22-115 mm puller, type Kukko 17/2
Order of execution
1. Install the following tools as shown in the figure. Before installing puller A, press the 3rd gear synchronizer ring (indicated by an arrow) to the 3rd gear.
2. Remove the synchronizer hub.
3rd/4th gear synchronizer hub installation
Installing the plastic sleeve
Install plastic bushing B together with needle bearing A.
Warning: Plastic bushing B is only installed on a drive shaft with lubrication grooves (indicated by an arrow) for 3rd/4th gears.
Drive Shaft Adjustment
1. Secure the drive shaft in a soft-jawed vise
2. Install A, spacer plate 3167, in 3rd gear.
3. Install the crankcase on the spacer plate by sliding it over the pinion gear.
Retaining ring installation
1. Install a depth gauge on the crankcase and measure the distance to the bottom groove on the shaft. a = 28.5 mm.
2. Install a depth gauge on the crankcase and measure the distance to the ball bearing location. b = 26.8 mm.
3. Determine the required thickness of the lower retaining ring. Size x: x = a - b. x \u003d 28.5 - 26.8 \u003d 1.70 mm. Determine Required Retaining Ring Thickness (See table 1).
4. Install the circlip and ball bearing on the shaft using a 30-100 drift.
5. Look for the thickest retaining ring that can be inserted. See table 2.
Table 1
Size | Thickness | Number |
1.64 – 1.71
|
1.69
|
902 941.05
|
1.72 – 1.79
|
1.77
|
902 941.06
|
1.80 – 1.87
|
1.85
|
902 941.07
|
1.88 – 1.95
|
1.93
|
902 941.08
|
1.96 – 2.03
|
2.01
|
902 941.09
|
2.04 – 2.11
|
2.09
|
902 941.10
|
2.12 – 2.19
|
2.17
|
902 941.11
|
2.20 – 2.27
|
2.25
|
902 941.12
|
2.28 – 2.35
|
2.33
|
902 941.13
|
Table 2
Thickness (mm) | Number |
1.69
|
902 941.05
|
1.77
|
902 941.06
|
1.85
|
902 941.07
|
1.93
|
902 941.08
|
2.01
|
902 941.09
|
2.09
|
902 941.10
|
2.17
|
902 941.11
|
2.25
|
902 941.12
|
2.33
|
902 941.13
|
Removing the Outer Race of a Double Row Tapered Roller Bearing
Installing the Outer Race of a Double Row Tapered Roller Bearing
1. Install puller release plate 3128 under outer race.
2. install the VW 771/29 bar and install the bolt on the gearbox housing. When tightening the bolt, the outer clip is removed from the crankcase.
Removing the inner race of a double row tapered roller bearing
Warning: To remove the inner race, the outer race A must be installed.
Installing the Inner Race of a Double Row Tapered Roller Bearing
Drive gear and hollow shaft
- 1. Final drive housing
- 2. Washer S3
- 3. Double row tapered roller bearing - outer race
- 4. Drive gear
- 5. Double row tapered roller bearing - inner race
- 6. Retaining ring
- 7. Needle bearing - 1st gear
- 8. First gear
- 9. Synchronizer ring - 1st gear
- 10. Synchronizer hub - 1st / 2nd gear
- 11. Retaining ring
- 12. Needle bearing - 2nd gear
- 13. Sliding clutch - 1st / 2nd gear
- 14. Synchronizer ring - 2nd gear
- 15. 2nd gear
- 16. Retaining ring
- 17. 3rd gear
- 18. Retaining ring
- 19. 4th gear
- 20. Retaining ring
- 21. Needle bearing - 5th gear
- 22. 5th gear
- 23. Synchronizer ring - 5th gear
- 24. Retaining ring
- 25. Synchronizer hub - 5th gear / reverse gear
- 26. Retaining ring
- 27. Needle bearing - reverse gear
- 28. Sliding Clutch - 5th/Reverse
- 29. Synchronizer ring - reverse gear
- 30. Reverse gear
- 31. Tapered roller bearing - inner race
- 32. Threaded stop sleeve for tapered roller bearing outer race
- 33. Tapered roller bearing - outer race
- 34. Washer S4
- 35. Pressure plate
- 36. Washer
- 37. Gear box
Warning: Pinion 4 matches ring gear (a pair of ring gear / pinion). When replacing a pair of ring gear/drive gear, adjust the installation of the drive gear, as well as the hollow shaft and ring gear.
Warning: The protruding edge of the synchronizer hub 10 faces 2nd gear. Remove hub 10 together with 1st gear. Use thrust plates VW 401 and VW 402. Mount with mandrel VW 415A and bushing VW 519.
Warning: Gear groove 17 faces 4th gear.
Warning: The edge of gear 19 faces the 3rd gear.
Warning: The protruding edge of hub 25 faces the 5th gear. Remove the hub 25 together with the 5th gear. Install with bushing 2010.
Warning: It is not necessary to install the locking threaded bushing 32 when replacing the outer race (this sleeve is only required during production).
Warning: Washer 36 compensates for expansion with temperature (heating). To remove, drill a hole in the washer and remove with a screw.
Installing the synchronizer spring in the gear
Install the spring (arrow) into the gear by inserting the pointed end into the groove.
Check for wear of the synchronizer ring
1. Press the synchronizer ring against the sliding sleeve and measure clearance a with a feeler gauge at points A, B and C.
2. Add up the resulting values and divide the sum by 3.
3. The resulting value should not be less than 0.5 mm.
1st/2nd gear sliding clutch installation
The side with the groove should face the 1st gear.
Removing the 3rd gear
- A = 22-115 mm puller, type Kukko 17/2
3rd gear installation
Installation position: The groove must face the 4th gear.
Removing the 4th gear
4th Gear Installation
Removing the synchronizer hub
Remove the synchronizer hub along with the 5th gear. Use puller A 22–115 mm, type Kukko 17/2.
Synchronizer ring identification
Rings with more than 3 reeds have been discontinued.
Removing the inner race of a tapered roller bearing
Remove the inner race along with the reverse gear. Use puller A 22–115 mm, type Kukko 17/2.
Installing the tapered roller bearing inner race
5th/Reverse sliding clutch installation
Diagonal strip 1 faces the reverse gear.
Groove side 2 faces the 5th gear.
Removing the locking threaded sleeve
Use puller A 22–115 mm, type Kukko 17/2. Bushing installation is not required when replacing the outer race (this sleeve is only required during production).
Removing the outer race of a tapered roller bearing
1. Screw the special removal bolt into the release plate (M10 bolt 50 mm long, ground off at one end to a diameter of M8).
2. Remove the release plate and outer race from the crankcase with a hammer
Installing the Outer Race of a Tapered Roller Bearing
Installing the Tapered Roller Bearing Retaining Ring
Find the thickest retaining ring that can be inserted and install it. The required thickness of the circlips of the synchronizer hub and the thickness of the circlips of the 3rd/4th gears is determined in the same way as the thickness of the circlip of the tapered roller bearing.
List of retaining rings
Retaining ring thickness, mm | Number |
Retaining ring 1 | |
2.00
|
902 945.01
|
2.02
|
902 950.02
|
2.04
|
902 950.03
|
2.06
|
902 950.04
|
2.08
|
902 950.05
|
2.10
|
902 950.06
|
Retaining ring 2 (blue) | |
1.90
|
902 947.01
|
1.93
|
902 947.02
|
1.96
|
902 947.03
|
1.99
|
902 947.04
|
2.02
|
902 947.05
|
Retaining ring 3 (blue) | |
2.50
|
902 947.06
|
Retaining ring 4
| |
1.90
|
902 946.02
|
1.93
|
902 946.03
|
1.96
|
902 946.04
|
1.99
|
902 946.05
|
2.02
|
902 946.06
|
Retaining ring 5 | |
1.87
|
902 952.01
|
1.90
|
902 952.02
|
1.93
|
902 952.03
|
1.96
|
902 952.04
|
Retaining ring 6 (brown) | |
2.00
|
902 945.01
|
Retaining ring 7 (blue) | |
1.90
|
902 944.01
|
1.93
|
902 944.02
|
1.96
|
902 944.03
|
1.99
|
902 944.04
|
2.02
|
902 944.05
|
2.05
|
902 944.06
|
Place of installation / selection of retaining rings
Retaining rings are numbered according to their position on the drive shaft.
Retaining rings 1, 2, 4, 5 and 7 must be selected.
The thickness of retaining rings 3 and 6 is always constant.
Differential assembly
- 1. Differential housing
- 2. Ring gear bolt
- 3. Large roller bearing - inner race
- 4. Speedometer drive gear
- 5. Large roller bearing - outer race
- 6. Washer S1
- 7. Lid
- 8. Thrust washer
- 9. Satellites
- 10. Axis of satellites
- 11. Pin of an axis of satellites
- 12. Gears of semiaxes
- 13. Ring gear
- 14. Small roller bearing - inner race
- 15. Small roller bearing - outer race
- 16. Washer S2
Warnings
- When replacing the differential housing 1, adjust the setting of the ring gear.
- Only use bolts 2 of the required specification. Tighten them evenly in a diagonal pattern.
- Install the large roller bearing 3 using tools VW 295 and VW 551.
- Mark the thickness of the washer 6.
- Lubricate thrust washer 8 with transmission oil before installing.
- Remove the pinion axle 10 with a punch after removing the pin of the pinion axle.
- Remove the pin of the axis of the satellites 11 using a punch.
- The ring gear 13 and the drive gear are fitted to each other. When replacing a pair of ring gear/pinion gear, adjust. To install - heat up to 100°C and install with dowel pins.
- Install the small roller bearing 14 using the sleeve 40–21.
- Mark the thickness of washer S2.
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