2002 Volkswagen Cabrio Service & Repair Manual Software
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Golf 1998 , Bora 1999 ➤
5-speed manual gearbox 02C four-wheel drive
Geartype
02C
Edition 07.2001
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
Golf 1998 , Bora 1999 ➤
5-speed manual gearbox 02C four-wheel drive
Repair Group
00 - Technical data
30 - Clutch
34 - Controls, Housing
35 - Gears, Shafts
39 - Final drive, Differential rear
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 K0051007820
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Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
1 Gearbox identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
1.1 Gearbox identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
1.2 Code letters, assembly allocation, ratios, capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
2 Rear final drive identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
2.1 Rear final drive identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
2.2 Code letters, assembly allocation, ratios, capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
3 Transmission layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
3.1 Transmission layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
4 Calculating overall ratio "i" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
4.1 Calculating overall ratio "i" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
4.2 Notes on brake and performance tests and towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
5 General repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
5.1 General repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
30 - Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
1 Servicing clutch control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
1.1 Servicing clutch control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
1.2 Assembly overview - Pedal cluster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
1.3 Removing and installing over-centre spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
1.4 Removing and installing clutch pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
1.5 Assembly overview - Hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
1.6 Removing and installing master cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
1.7 Bleeding clutch system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
2 Servicing clutch release mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
2.1 Servicing clutch release mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
3 Servicing clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
3.1 Servicing clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
34 - Controls, Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
1 Connecting VAS 5051 and selecting functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
1.1 Connecting VAS 5051 and selecting functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
2 Locations of electrical/electronic components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
2.1 Locations of electrical/electronic components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
2.2 Removing and installing four-wheel drive control unit -J492 . . . . . . . . . . . . . . . . . . . . . . . .42
2.3 Removing and installing Haldex coupling pump -V181- . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
3 Electrical check of Haldex coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
3.1 Electrical check of Haldex coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
4 Servicing gear selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
4.1 Servicing gear selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
4.2 Installation position of gear selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
4.3 Removing and installing selector lever knob and gaiter . . . . . . . . . . . . . . . . . . . . . . . . . . . .55
4.4 Servicing gear stick and gear stick housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57
4.5 Assembly overview - removing and installing selector cables . . . . . . . . . . . . . . . . . . . . . . . .61
4.6 Removing and installing gear selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65
4.7 Adjusting gear selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70
5 Removing and installing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
5.1 Removing and installing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
6 Removing and installing bevel box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .94
6.1 Removing and installing bevel box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .94
7 Checking oil in manual gearbox with bevel box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .97
Golf 1998 , Bora 1999 ➤
5-speed manual gearbox 02C four-wheel drive - Edition 07.2001
Contents i
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7.1 Checking oil in manual gearbox with bevel box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .97
8 Dismantling and assembling gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .99
8.1 Dismantling and assembling gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .99
8.2 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .99
8.3 Assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .102
8.4 Removing and installing cover for gearbox housing and 5th gear . . . . . . . . . . . . . . . . . . . .103
8.5 Removing and installing gearbox housing and selector mechanism . . . . . . . . . . . . . . . . . .105
8.6 Removing and installing input shaft, output shaft (pinion shaft), differential and selector forks
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .107
8.7 Assembly sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .109
9 Servicing gearbox housing and clutch housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .127
9.1 Servicing gearbox housing and clutch housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .127
10 Dismantling and assembling gearbox selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . .137
10.1 Dismantling and assembling gearbox selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . .137
11 Dismantling and assembling selector forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .144
11.1 Dismantling and assembling selector forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .144
35 - Gears, Shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .153
1 Dismantling and assembling input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .153
1.1 Dismantling and assembling input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .153
1.2 From gearbox build date 05 11 1 circlips for 5th gear synchronisation have been modified
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .166
2 Adjusting input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .168
2.1 Adjusting input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .168
2.2 Table of adjustment shims . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
2.3 Performing measurement check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .172
3 Dismantling and assembling output shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .173
3.1 Dismantling and assembling output shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .173
3.2 From gearbox build date 04 09 0 the synchronisation for 1st gear has been modified . . . .197
4 Adjusting output shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .201
4.1 Adjusting output shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .201
5 Dismantling and assembling reverse shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .205
5.1 Dismantling and assembling reverse shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .205
39 - Final drive, Differential rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .211
1 Renewing oil seals for flange shafts or right-hand drive flange (gearbox installed) . . . . . . . .211
1.1 Renewing oil seals for flange shafts or right-hand drive flange (gearbox installed) . . . . . . . .211
1.2 Renewing left-hand flange shaft oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .211
1.3 Renewing oil seal for flange shaft or right-hand drive flange . . . . . . . . . . . . . . . . . . . . . . . .214
2 Replacing bevel box output flange oil seal (bevel box removed) . . . . . . . . . . . . . . . . . . . . . .216
2.1 Replacing bevel box output flange oil seal (bevel box removed) . . . . . . . . . . . . . . . . . . . . . .216
3 Dismantling and assembling differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .218
3.1 Dismantling and assembling differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .218
4 Adjustment overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
4.1 Adjustment overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
5 Adjusting differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .234
5.1 Adjusting differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .234
6 Dismantling and assembling bevel box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .237
6.1 Dismantling and assembling bevel box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .237
7 Renewing needle roller bearing (polygon bearing) for right output shaft or right flanged shaft
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .260
7.1 Renewing needle roller bearing (polygon bearing) for right output shaft or right flanged shaft
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .260
8 Adjusting shaft bevel gear and bevel gear (gear set) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .263
Golf 1998 , Bora 1999 ➤
5-speed manual gearbox 02C four-wheel drive - Edition 07.2001
ii Contents
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8.1 Adjusting shaft bevel gear and bevel gear (gear set) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .263
8.2 General notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .263
8.3 Adjusting and marking of gear sets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .264
8.4 Position of shims . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .266
8.5 Adjustment overview (bevel box) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .266
8.6 Recommended sequence for adjusting gear set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .267
8.7 Determining shim "S4" thickness when replacing output flange . . . . . . . . . . . . . . . . . . . . . .267
8.8 Adjusting shaft bevel gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .268
8.9 Adjusting bevel gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .275
9 Removing and installing propshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .279
9.1 Removing and installing propshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .279
9.2 Removing and installing front flexible coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .284
9.3 Removing and installing rear flexible coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .287
10 Servicing propshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .292
10.1 Servicing propshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .292
11 Checking function of Haldex coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .301
11.1 Checking function of Haldex coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .301
12 Renewing propshaft flange oil seal on rear final drive (final drive removed) . . . . . . . . . . . .302
12.1 Renewing propshaft flange oil seal on rear final drive (final drive removed) . . . . . . . . . . . .302
13 Renewing flange shaft oil seal (final drive installed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .305
13.1 Renewing flange shaft oil seal (final drive installed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .305
14 Renewing O-ring for Haldex coupling drive pinion housing (final drive removed) . . . . . . . .308
14.1 Renewing O-ring for Haldex coupling drive pinion housing (final drive removed) . . . . . . . .308
15 Renewing O-rings for rear axle housing cover (final drive installed) . . . . . . . . . . . . . . . . . .310
15.1 Renewing O-rings for rear axle housing cover (final drive installed) . . . . . . . . . . . . . . . . . .310
16 Removing and installing rear final drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .312
16.1 Removing and installing rear final drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .312
17 Checking rear final drive oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .317
17.1 Checking rear final drive oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .317
18 Checking oil level in Haldex coupling or changing oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .317
18.1 Checking oil level in Haldex coupling or changing oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .317
18.2 Checking Haldex coupling oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .317
18.3 Changing oil in Haldex coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .319
18.4 Changing Haldex coupling oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .320
19 Dismantling and assembling rear final drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .322
19.1 Dismantling and assembling rear final drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .322
19.2 Removing and installing Haldex coupling cover and plates . . . . . . . . . . . . . . . . . . . . . . . . . .323
19.3 Removing and installing pinion housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .327
19.4 Removing and installing differential and input shaft bevel gear . . . . . . . . . . . . . . . . . . . . . .331
19.5 Removing and installing Haldex coupling plate housing cover . . . . . . . . . . . . . . . . . . . . . .335
19.6 Assembly sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .340
20 Dismantling and assembling differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .353
20.1 Dismantling and assembling differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .353
21 Servicing shaft bevel gear bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .359
21.1 Servicing shaft bevel gear bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .359
22 Servicing input shaft bevel gear bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .371
22.1 Servicing input shaft bevel gear bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .371
23 Adjusting bevel gear and shaft bevel gear (gear set) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .381
23.1 Adjusting bevel gear and shaft bevel gear (gear set) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .381
23.2 General notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .381
23.3 Adjusting and marking of gear sets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .382
23.4 Position of shims . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .384
23.5 Adjustment overview (rear final drive) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .384
23.6 Recommended sequence for adjusting gear set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .385
Golf 1998 , Bora 1999 ➤
5-speed manual gearbox 02C four-wheel drive - Edition 07.2001
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