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New Beetle 1999 ➤
02T 5-speed gearbox
Gearbox ID
FLU GEQ GSE GAH GEW GSG
Edition 09.2001
Service
Service Department. Technical Information
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List of Workshop Manual Repair GroupsList of Workshop Manual
Repair GroupsList of Workshop Manual Repair Groups
New Beetle 1999 ➤
02T 5-speed gearbox
Repair Group
00 - Technical data
30 - Clutch
34 - Controls, Housing
35 - Gears, Shafts
39 - Final drive, Differential
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.
Service
All rights reserved.
No reproduction without prior agreement from publisher.
Copyright © 2010 Volkswagen AG, Wolfsburg K0051638920
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Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
1 Gearbox identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
1.1 Gearbox identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
1.2 Identification code, assembly allocation, ratios, capacities . . . . . . . . . . . . . . . . . . . . . . . . . .2
2 Power transmission diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
2.1 Power transmission diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
3 Calculating the demultiplication ratio "i" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
3.1 Calculating the demultiplication ratio "i" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
4 General notes on the repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
4.1 General notes on the repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
30 - Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
1 Clutch mechanism: repairing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.1 Clutch mechanism: repairing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.2 General assembly diagram- pedal gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
1.3 Removing and installing neutral retaining spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
1.4 Clutch pedal: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
1.5 Assembly overview - hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
1.6 Clutch pump: Removal and installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
1.7 Clutch pump: removal and installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
1.8 Pipe unit and hose: removal and installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
1.9 Bleed clutch system: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
2 Declutching unit: repairing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
2.1 Declutching unit: repairing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
3 Repairing clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
3.1 Repairing clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
34 - Controls, Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
1 Servicing gear drive mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
1.1 Servicing gear drive mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
1.2 Gear drive mechanism mounting position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
1.3 Gear lever dust cover and knob: removal and installation . . . . . . . . . . . . . . . . . . . . . . . . . .41
1.4 Gear lever and protective cover: repairing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
1.5 Drive mechanism cables: disassembly and reassembly; - general assembly diagram . . . .47
1.6 Removing and installing gear selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
1.7 Gear drive mechanism: adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54
2 Gearbox: removal and installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58
2.1 Gearbox: removal and installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58
2.2 Modifying support rail VW 457/1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60
3 Gear oil level: checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73
3.1 Gear oil level: checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73
4 Dismantling and assembling gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75
4.1 Dismantling and assembling gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75
4.2 Gearbox assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75
4.3 The installation and removal of the gearbox housing and 5th gear . . . . . . . . . . . . . . . . . . . .78
4.4 Clutch housing: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .81
4.5 Input shaft, secondary shaft (thrust sprocket shaft), differential, drive mechanism and
gearbox brackets: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .83
4.6 Installation sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87
4.7 Gearbox support 3221: modify . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89
5 Repairing gearbox housing and clutch housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .97
5.1 Repairing gearbox housing and clutch housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .97
New Beetle 1999 ➤
02T 5-speed gearbox - Edition 09.2001
Contents i
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6 Gear drive mechanism: dismantling and assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .105
6.1 Gear drive mechanism: dismantling and assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .105
7 Dismantling and assembling selector forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .108
7.1 Dismantling and assembling selector forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .108
7.2 Dismantling and assembling selector forks: Gearbox codes FNT, FLU, GEQ, GAH, GEW
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .109
7.3 Dismantling and assembling selector forks: Gearbox codes GSE, GSG . . . . . . . . . . . . . . . .115
35 - Gears, Shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .124
1 Dismantling and assembling input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .124
1.1 Dismantling and assembling input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .124
2 Dismantling and assembling output shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .141
2.1 Dismantling and assembling output shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .141
39 - Final drive, Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .155
1 Oil seal for flanged shaft: renew . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .155
1.1 Oil seal for flanged shaft: renew . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .155
1.2 Renewing oil seal for left flanged shaft: Gearbox codes FNT, FLU, GAH . . . . . . . . . . . . . .155
1.3 Renewing oil seal for left flanged shaft: Gearbox codes GEQ, GSE, GEW, GSG . . . . . . . .158
1.4 Renewing oil seal for right flanged shaft: Gearbox codes FNT, FLU, GAH . . . . . . . . . . . . . .161
1.5 Renewing oil seal for right flanged shaft: Gearbox codes GEQ, GSE, GEW, GSG . . . . . . . .164
2 Dismantling and assembling differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .166
2.1 Dismantling and assembling differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .166
2.2 Dismantling and assembling differential: Gearbox codes: FNT, FLU, GAH . . . . . . . . . . . . . .166
2.3 Dismantling and assembling differential: Gearbox codes: GEQ, GSE, GEW, GSG . . . . . .179
3 Adjusting differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .192
3.1 Adjusting differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .192
3.2 Adjusting differential: Gearbox codes FNT, FLU, GAH . . . . . . . . . . . . . . . . . . . . . . . . . . . .192
3.3 Adjusting differential: Gearbox codes GEQ, GSE, GEW, GSG . . . . . . . . . . . . . . . . . . . . . .197
New Beetle 1999 ➤
02T 5-speed gearbox - Edition 09.2001
ii Contents
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00 - Technical data
1 - Gearbox identification
1.1 - Gearbox identification
The 5 speed manual gearbox 02T is fitted along with the 4-cylinder injection motor (4-valve drag roller lever)
in the New Beetle 2002 ä.
Allocation =>Page 2 .
-> Location on gearbox
Gearbox codes and manufacture dates (arrow)
-> Identification code and date of gearbox manufacture
Example: FLU 08 09 1
I I I I
I I I I
Identification
code
Day Month Year (2001)
of manufacture
Additional data depend on manufacture.
New Beetle 1999 ➤
02T 5-speed gearbox - Edition 09.2001
1.1 - Gearbox identification 1
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Note:
The gearbox identification code also appears on the vehicle data plates.
1.2 - Identification code, assembly allocation, ratios, capacities
Manual gearbox 02T 5-speed
Identification code FLU GEQ GSE
Allocation Model New Beetle 2002 ä New Beetle 2002 ä New Beetle 2002 ä
Engine 1.4 l - 55 kW 1.4 l - 55 kW 1.4 l - 55 kW
Demultiplication: Z2 :
Z1
Final drive 68 : 15 = 4.533 68 : 15 = 4.533 68 : 15 = 4.533
1st gear 38 : 11 = 3.455 38 : 11 = 3.455 38 : 11 = 3.455
2nd gear 44 : 21 = 2.095 44 : 21 = 2.095 44 : 21 = 2.095
3rd gear 43 : 30 = 1.433 43 : 30 = 1.433 43 : 30 = 1.433
4th gear 41 : 38 = 1.079 41 : 38 = 1.079 41 : 38 = 1.079
5th gear 40 : 47 = 0.851 40 : 47 = 0.851 40 : 47 = 0.851
6th gear - - -
Reverse 35 : 24 x 24 : 11 = 3.182 35 : 24 x 24 : 11 = 3.182 35 : 24 x 24 : 11 = 3.182
Speedometer electronic electronic electronic
Capacity 1.9 litre 2.0 litre 2.0 litre
Specification Gear oil G50 SAE 75W90 (synthetic oil)
Clutch mechanism Hydraulic Hydraulic Hydraulic
Clutch plate ø 200 mm 200 mm 200 mm
Drive shaft flange ø 90 mm 1) 90 mm 1) 90 mm 1)
itotal in highest gear 3.858 3.858 3.858
Manual gearbox 02T 5-speed
Identification code FNT
Allocation Model New Beetle 2002 ä
Engine 1.4 l - 55 kW
Demultiplication:
Z2 : Z1
Final drive 68 : 15 = 4.533
1st gear 38 : 11 = 3.455
2nd gear 44 : 21 = 2.095
3rd gear 43 : 30 = 1.433
4th gear 41 : 38 = 1.079
5th gear 40 : 47 = 0.851
6th gear -
Reverse 35 : 24 x 24 : 11 =
3.182
Speedometer electronic
Capacity 1.9 litre
Specification Gear oil G50 SAE
75W90 (synthetic
oil)
Clutch mechanism Hydraulic
Clutch plate ø 200 mm
Drive shaft flange ø 90 mm 1)
New Beetle 1999 ➤
02T 5-speed gearbox - Edition 09.2001
2 00 - Technical data
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Manual gearbox 02T 5-speed
itotal in highest gear 3,858
1) for homocinetic joint
Manual gearbox 02T 5-speed
Identification code GAH GEW GSG
Allocation Model New Beetle Cabriolet
2003 ä
New Beetle Cabriolet
2003 ä
New Beetle Cabriolet
2003 ä
Engine 1.4 l - 55 kW 1.4 l - 55 kW 1.4 l - 55 kW
Demultiplication: Z2 :
Z1
Final drive 68 : 15 = 4.533 68 : 15 = 4.533 68 : 15 = 4.533
1st gear 49 : 13 = 3.769 49 : 13 = 3.769 49 : 13 = 3.769
2nd gear 44 : 21 = 2.095 44 : 21 = 2.095 44 : 21 = 2.095
3rd gear 43 : 30 = 1.433 43 : 30 = 1.433 43 : 30 = 1.433
4th gear 41 : 38 = 1.079 41 : 38 = 1.079 41 : 38 = 1.079
5th gear 40 : 47 = 0.851 40 : 47 = 0.851 40 : 47 = 0.851
6th gear - - -
Reverse 35 : 24 x 24 : 11 = 3.182 35 : 24 x 24 : 11 = 3.182 35 : 24 x 24 : 11 = 3.182
Speedometer electronic electronic electronic
Capacity 1.9 litre 2.0 litre 2.0 litre
Specification Gear oil G50 SAE 75W90 (synthetic oil)
Clutch mechanism Hydraulic Hydraulic Hydraulic
Clutch plate ø 200 mm 200 mm 200 mm
Drive shaft flange ø 90 mm 1) 90 mm 1) 90 mm 1)
itotal in highest gear 3.858 3.858 3.858
1) for homocinetic joint
New Beetle 1999 ➤
02T 5-speed gearbox - Edition 09.2001
1.2 - Identification code, assembly allocation, ratios, capacities 3
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2 - Power transmission diagram
2.1 - Power transmission diagram
Description
1 Engine
2 Coupling
3 Manual gearbox
4 Input shaft
5 Secondary shaft/ thrust sprocket shaft
6 Differential
The arrows point in the direction of travel
New Beetle 1999 ➤
02T 5-speed gearbox - Edition 09.2001
4 00 - Technical data
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Ratio
I - 1. gear
II - 2. gear
III - 3. gear
IV - 4. gear
V - 5. gear
R - Reverse
A - Final drive
T - Speedometer control
The arrows point in the direction of travel
New Beetle 1999 ➤
02T 5-speed gearbox - Edition 09.2001
2.1 - Power transmission diagram 5
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3 - Calculating the demultiplication ratio "i"
3.1 - Calculating the demultiplication ratio "i"
Example:
5th gear Final drive
Sprocket Drive ZG1 = 47 ZA1 = 15
Armature sprocket ZG2 = 40 ZA2 = 68
i= Z2: Z1 1)
iG = gear demultiplication = ZG2: ZG1 = 40 : 47 =0.851
iA = selector demultiplication = ZA2: ZA1 = 68 : 15 = 4.533
itotal = total demultiplication = total demultiplication
= iG x iA = 0.851 x 4.533 = 3.858
1) Z1 = Number of teeth on drive sprocket, Z2 = number of teeth on armature sprocket
4 - General notes on the repair
4.1 - General notes on the repair
To repair the gearbox perfectly and successfully the greatest care and levels of cleanliness have to be used.
The tools also have to be in perfect condition. Naturally, when carrying out a repair the general relative safety
rules have to be borne in mind.
Here is a summary of a series of general notes on different repairs which are repeated throughout the Workshop
Manual. These notes are valid for this Workshop Manual.
Gearbox
◆ The gearbox is made of magnesium.
◆ The finishing on the screws and other parts that are in direct contact with the gearbox are made from a
material especially adapted to magnesium.
◆ The use of other parts that are not the recommended parts cause corrosion which in turn damages the
gearbox.
◆ Consult the Parts Catalogue so that the correct screws and other parts can be assigned.
◆ On fitting the manual gearbox, check that the adaptor sockets between the engine and the gearbox are
correctly seated.
◆ Clean the contact surfaces when support blocks or enclosed components are being fitted. There should be
no traces of wax or grease whatsoever on the surfaces.
◆ When changing the gearbox, gear oil always has to be filled to the bottom edge of filling hole.
◆ Filling level and specification => page 2 .
Gaskets, seals
◆ Thoroughly clean the contact surfaces and apply sealant AMV 188 200 03.
◆ Apply the sealant evenly; do not apply too much.
◆ Replace the O-rings.
◆ Radial shaft seals.
Before installing:
New Beetle 1999 ➤
02T 5-speed gearbox - Edition 09.2001
6 00 - Technical data
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2009 Volkswagen Beetle Download Service & Repair Manual
- Models Covered:
- Volkswagen Beetle 1.4L 5MT (75 HP)
- Volkswagen Beetle 1.6L 5MT (102 HP)
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- Volkswagen Beetle 1.9L TDI 5MT (105 HP)
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- Volkswagen Beetle 2.0L 6AT (115 HP)
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