MANUAL TRANS OVERHAUL - TYPE 020

Article Text
1996 Volkswagen Golf
This file passed thru Volkswagen Technical Site - http://volkswagen.msk.ru

ARTICLE BEGINNING

MANUAL TRANSMISSIONS
Volkswagen Type 020
Cabrio, Golf III, GTI, Jetta III
APPLICATION & LABOR TIMES

APPLICATION & LABOR TIMES

Vehicle
Application

Labor Times
(1) R & I (2) Overhaul

1995
Cabrio & Golf III ...
Jetta III
4-Cylinder .........
1996
Cabrio ..............
Golf & Jetta
4-Cylinder
Gas Engine .......

Series

3.8 .... 4.9

.........

020 (CHE)

3.8 .... 4.9

.........

020 (CHE)

3.8 .... 4.9

.........

020 (DFQ)

3.8 .... 4.9

.........

020 (DFQ)

(1) - Removal and installation of transmission from vehicle

chassis.
(2) - Bench overhaul time for transaxle and differential. DOES NOT
include removal and installation.

IDENTIFICATION

Transaxles are identified by a type number as well as a 2

letter suffix. Transmission type is cast into transmission case. Code
letter and production date information is stamped on a machined
surface located on upper portion of engine-to-transaxle mating
surface.
DESCRIPTION

Type 020 is a 5-speed transaxle consisting of an input shaft,

mainshaft/drive pinion shaft and a differential assembly which
transfers power to front wheels.
LUBRICATION & ADJUSTMENTS

Use hypoid oil API GL4, MIL-L2105 SAE 75 or G50 SAE 75W90
synthetic lubricant. See appropriate MANUAL TRANSMISSION SERVICING
article in TRANSMISSION SERVICING section for adjustments.
TROUBLE SHOOTING

See TROUBLE SHOOTING - BASIC PROCEDURES article in this

section.
ON-VEHICLE SERVICE
CHECKING SHIFT LINKAGE ADJUSTMENT

Shift into 1st gear, push gearshift lever to left stop.

Release lever. Lever should spring back to right. Shift lever should
rest in 3rd/4th gear plane. To adjust position, transmission in
neutral and loosen clamp at selector shaft. Insert Position Gauge (VW
3104) on shift lever housing. Align selector rod/lever. Retighten
clamp. If gear fails to engage smoothly during repeated shifting,
engage 1st gear. Press shift lever gently to left to remove play.
Distance between gearshift housing to travel stop must be .04-.06" (11.5 mm). Adjust by turning eccentric adjuster in shifter housing.
Torque clamping bolt to 18 INCH lbs. (2 N.m).
DRIVE FLANGE OIL SEAL

Remove axle shaft from mounting flange. Remove drive flange

cover, circlip and dished washer. Remove axle flange using puller. Pry
seal out of transaxle case. To install, drive new seal in using Driver
(30-212). Fill lips of new seal with lubricant. Install flange into
differential case. Install dished washer, circlip and flange cover.
Install axle shaft and tighten to 30 ft. lbs. (40 N.m). Check
transaxle oil level.
DRIVE AXLE SHAFTS

See appropriate AXLE SHAFTS article in AXLE SHAFTS & TRANSFER

CASES section.
REMOVAL & INSTALLATION

See appropriate MANUAL TRANSMISSION REMOVAL article in

TRANSMISSION SERVICING section.
TRANSAXLE DISASSEMBLY
DISASSEMBLY

1) Mount transaxle in Mounting Fixture (VW 309 and 353), if

available. Install input shaft support bridge Special Tool (VW 295a
and 30-211a), if available. Drain gearbox oil. Remove clutch push rod
from input shaft.
2) Remove bolts from transmission housing cover. Remove
entire assembly. Remove selector shaft lock nut and vehicle speed
sensor. Remove selector shaft cover together with spring. Bring shift
forks to neutral position and remove selector shaft. Remove Torx bolt
to remove reverse idler gear shaft.

3) From gearbox side of transaxle, remove drive flange cover,

circlip, and dished washer. Using a puller, remove drive flange. See
Fig. 1.
4) Engage 5th gear and reverse gear. Remove synchronizer hub
retaining bolt. Remove selector tube securing plate. Turn selector
tube counter-clockwise, DO NOT pull, to remove from shift fork. Remove
synchronizer hub together with 5th gear and shift fork using 2 levers
to pry free. Use caution to avoid damage to housing sealing surfaces.
Remove circlip and thrust washer for 5th gear. On vehicles with 2.0L
engine, 5th gear circlip is replaced by a securing plate. Remove 5th
gear using puller if necessary.
5) Remove tension bracket on input shaft deep groove ball
bearing. Pull off transmission housing. Pull selector rod from bore
and remove shift fork. Remove 4th gear circlip from output shaft.
Vehicles using 2.0L engine are equipped with a second circlip. Remove
4th gear using puller if necessary. Ensure reverse gear is not
engaged, remove input shaft assembly. Remove 3rd and 2nd gear, using
puller if necessary. Remove synchronizer ring and needle bearings.
Drive out reverse gear shaft with bolt using plastic hammer. Remove
reverse gear from relay lever. Pull off synchronizer hub and 1st gear
together with 2nd gear needle bearing inner race. See Fig. 2.
6) Remove bearing cover bolts, thrust washer and cover.
Remove output shaft Remove right side drive flange, thrust washer,
tapered ring and differential assembly.

Fig. 1: Identifying Internal Components

Courtesy of Volkswagen United States, Inc.

Fig. 2: Exploded View Of Output Shaft

Courtesy of Volkswagen United States, Inc.
REASSEMBLY

1) Install differential assembly into clutch housing. Install

output shaft and bearing cover. Torque to specifications. See
TORQUE SPECIFICATIONS. With shoulder on inner diameter facing bearing
cover, install thrust washer. Install synchronizer hub, 1st gear with
2nd gear needle bearing inner race, to output shaft with groove on
face and outside teeth on operating sleeve facing 1st gear. Heat
1st/2nd gear synchronizer hub to approximately 212(0) F (100(0) C),

drive firmly into place aligning grooves in synchronizer ring with

keys. Install reverse idler gear.
2) Install 2nd gear needle bearing race. Ensure race is
firmly seated. Install needle bearings, synchronizer ring, 2nd gear
and 3rd gear with shoulder facing 2nd gear. Install new circlip which
allows for minimal amount of axial play. Circlips are available in
sizes from .098" (2.5 mm) to .0118" (3.0 mm) in increments of .004" (.
1 mm).
3) Install input shaft, without bearing, into clutch housing.
Install 4th gear, with shoulder facing toward spline of 5th gear, and
install circlip(s). Press in deep groove ball bearing with wide
shoulder facing outward. Install tension bracket. Insert selector rod
lower spring into clutch housing. Install 3rd/4th gear shift fork,
1st/2nd gear shift fork, reverse gear shift fork and 5th gear selector
bridge and tube. 1st/2nd gear shift fork is recessed to clear bridge.
Slide selector rod into position. Align reverse idler gear shaft. See
Figs. 1 and 3.
4) Install transmission housing making sure Support Bridge
(30-211a) and (VW 295a) Needle Bearing Drift provide input shaft with
satisfactory support. Install torx bolt to idler gear shaft. Torque to
15 ft. lbs (20 N.m). Install hex head bolts to secure housing. Torque
to 18 ft. lbs. (25 N.m). Torque bolts to deep groove bearing tension
bracket to 11 ft. lbs. (15 N.m). Heat 5th gear to approximately 212(0)
F (100(0) C) and install (circular groove facing upward on vehicles
with 2.0L engines). Install thrust washer and circlip. On vehicles
with 2.0L engines securing plate is used in place of circlip. See
Fig. 4.

Fig. 3: Shift Fork Alignment

Courtesy of Volkswagen United States, Inc.

Fig. 4: Exploded View Of 5th Gear Cover

Courtesy of Volkswagen United States, Inc.
5) Using Tube Wrench (VW 3059), screw shift tube clockwise
into shift lock. Thread shift tube back out to adjust shift tube
height "A". See Fig. 5.
CAUTION: Do not extract selector rod from shift tube. It may cause
shift fork to come apart inside, making it necessary to
disassemble transmission again. If necessary, insert
screwdriver through slot to hold selector rod while removing
tube wrench.
6) Engage 5th gear and reverse. Coat threads of new
synchronizer hub bolt (M17) with locktite, install, torque to 111 ft.
lbs (150 N.m). Move shift fork to neutral position. Insert selector
shaft, selector shaft spring and cover with new seal ring. Torque to
47 ft lbs. (50 N.m). Install selector shaft lock bolt with sealant.
Torque to 30 ft. lbs. (40 N.m).
7) Adjust 5th gear selector fork. Use caution in performing
this adjustment to prevent transmission from jumping out of gear.

Check height "A" of shift tube. See Fig. 5. Adjust if necessary. Bolt
gear selector shaft lever onto selector shaft and engage 5th gear.
Raise operating sleeve together with shift fork to compensate for free
play in linkage components. Align operating sleeve with selector fork
so there is no free play to 5th gear. Clearance between 5th gear and
synchronizer hub should be .197" (5.0 mm). If necessary, adjust
clearance by turning selector tube. Ensure synchronizer ring moves
freely. Support shift fork, drive on new securing plate.
8) Release tension on input shaft support bridge. Starting at
5th gear end, install clutch pushrod into input shaft. Install clutch
release bearing on clutch push rod. Install new gasket to housing
cover. Install cover. Shift through all gears to ensure correct
engagement. Install drive flanges, dished washers, circlips, and new
drive flange covers.

Fig. 5: Adjusting Shift Tube Height

Courtesy of Volkswagen United States, Inc.
COMPONENT DISASSEMBLY & REASSEMBLY
CLUTCH HOUSING

Disassembly
1) Remove oil drain plug, locating dowels, differential
bearing outer race and shim .04" (1.0 mm) thick, magnet, output shaft
outer bearing race and adjusting shim. Using puller, extract input
shaft needle bearing.
2) Unbolt relay lever brackets, relay lever and springs.
Extract bushing for starter shaft. Remove threaded plug (color coded),
input shaft oil seal, drive flange sleeve and oil seal.See Fig. 6.
Inspection
Inspect clutch housing for cracks, worn or galled bearing
race bores, stripped threads or damaged case machine surfaces.

Reassembly
1) Install drive flange sleeve and oil seal. Install threaded
plug (Green) and bushing for starter. Install relay lever, brackets
and springs.
CAUTION: It is essential that threaded plug installed is correct for
specific application. Green: for 1.8L, 1.9L Turbo Diesel and
2.0L engine with 210 mm clutch. White plug available for
engines with 200 mm clutch. (not applicable for
U.S.A./Canada). If White plug is installed in place of
Green, damage to TDC sensor and flywheel markings will
result.
2) Install input shaft needle bearing using bearing driver.
Install shim and bearing outer race for differential assembly. Install
selected adjusting shim and outer bearing race for output shaft.
Install locating dowels and oil drain plug. Install magnet on case
using Sealant (AMV 188 200 03 or equivalent).

Fig. 6: Exploded View Of Clutch Cover

Courtesy of Volkswagen United States, Inc.
GEARBOX HOUSING

Disassembly
Remove locating dowels, backup light switch, vent sleeve and

cover. Using a suitable driver, remove output shaft needle bearing.

Remove selector shaft, stop cover, spring, retaining plate and
circlip. Remove ball sleeve, oil seal and protective cover. Remove
differential outer bearing race, selected adjustment shim and drive
flange oil seal. Remove tensioner plate, input shaft bearing and shim.
See Fig. 7.
Inspection
Inspect clutch housing for cracks, worn or galled bearing
race bores, stripped threads or damaged case machine surfaces.
Reassembly
Install drive flange sealing ring. Install differential
adjustment shim, outer bearing race and drive flange oil seal. Using
driver, install output shaft needle bearing, stop cover with ball
sleeve, ball sleeve shaft and oil seal. Install protective cover.
Install input shaft bearing and shim and secure in place with
tensioning plate. Install vent sleeve, cover, back-up light switch
with new seal and locating dowels.

Fig. 7: Exploded View Of Gearbox Housing

Courtesy of Volkswagen United States, Inc.
GEARBOX HOUSING COVER

Disassembly
Remove gearbox housing cover. Remove release shaft. Remove
clutch lever clip, clutch lever and lever return spring. Remove
release bearing, oil seal and release shaft clip. Remove oil filler

plug, needle bearing and bearing retainer bolt.See Fig. 8.

Inspection
Inspect clutch housing for cracks, worn or galled bearing
race bores, stripped threads or damaged case machine surfaces.
Reassembly
Install oil filler plug, needle bearing and bearing retainer
bolt. Install release bearing, release shaft oil seal, release shaft
and shaft clip. Install clutch lever, clutch lever return spring, and
lever retaining clip.
INPUT ASSEMBLY

Disassembly
Using a press, remove bearing, being careful not to damage
tension bracket. Remove tension bracket, 4th gear, 4th gear needle
bearing and 4th gear synchronizer ring. Remove 3rd/4th synchronizer
circlip and press 3rd/4th synchronizer off input shaft. Remove 3rd
gear synchronizer ring, 3rd gear and 3rd gear needle bearing. Remove
seal and bushing for clutch pushrod.See Fig. 9.
Inspection
Inspect all bearing surfaces for wear. Inspect gears for
damage to teeth, bearing surfaces and synchronizer tabs. Check
synchronizer rings for wear. Wear limit minimum is .02 (.5 mm). See
Fig. 10.
Reassembly
1) Install bushing and seal for clutch rod into input shaft.
Install 3rd gear needle bearing, 3rd gear and 3rd gear synchronizer
ring.
2) Press 3rd/4th gear synchronizer assembly onto input shaft.
Install 4th gear synchronizer ring, 4th gear needle bearing and 4th
gear. Install tension bracket

Fig. 8: Exploded View Of Transmission Housing Cover

Courtesy of Volkswagen United States, Inc.

MANUAL TRANS OVERHAUL - TYPE 020 Article Text (p. 12)

Fig. 9: Exploded View Of Input Shaft

Courtesy of Volkswagen United States, Inc.

Fig. 10: Measuring Synchronizer Ring Clearance

Courtesy of Volkswagen United States, Inc.
DIFFERENTIAL ASSEMBLY

Disassembly
1) Press tapered roller bearings off both ends of
differential housing. Remove rivets from differential ring gear
assembly only if ring gear is to be replaced. Rivets can be removed
using either a hacksaw to cut off rivet heads and then driving them
out with a punch or by drilling them out using a 12 mm drill bit.
2) Remove circlips that hold differential pinion shaft inside
carrier. Remove pinion gears and one piece thrust washer.
Inspection
Inspect gears for wear, chipped teeth or galling. Inspect
thrust washer for wear. Replace components as needed.
Reassembly
1) If differential ring gear is being replaced, heat gear to
approximately 212F (100C) and press onto differential housing using
several bolts as guide pins during installation. Install special
retaining bolts and nuts from Repair Kit (171 498 088 A).
2) Install one piece thrust washer, pinion gears and pinion
shaft into differential case. Attach circlips to pinion gear shaft.
Press tapered bearings onto each end of differential carrier.
NOTE:

If installing a new ring gear or pinion, be sure both

components are a matched set. Always use NEW ring gear
retaining bolts.

ADJUSTING OUTPUT SHAFT PRELOAD

NOTE:

Adjustment is not necessary unless any of the following

parts have been replaced: output shaft bearings,
differential or pinion gears.

1) Install roller bearing outer race into clutch housing with

a .025" (.65 mm) shim. Install output shaft and bearing retainer
plate. Torque plate to 18 ft. lbs. (25 N.m) plus an additional 1/4
turn (90 degrees). Set up a dial indicator and measure up and down
movement of output shaft. See Fig. 11.
2) The specified .008" (.20 mm) bearing preload is obtained
by adding .008" (.20 mm) to recorded dial indicator reading and .025"
(.65 mm) shim value. The sum of these three figures will determine
size of shim to be installed behind output shaft bearing race in
clutch housing. Shims are available in sizes from .025" (.65 mm) to .
055" (1.40 mm) in increments of .002" (.05 mm).

Fig. 11: Measuring Output Shaft End Play

Courtesy of Volkswagen United States, Inc.
ADJUSTING DIFFERENTIAL PRELOAD

NOTE:

Adjustment is not necessary unless any of the following

parts have been replaced: final drive housing, final drive
cover, differential bearings, differential housing and/or
ring gear/pinion.

1) Install differential outer bearing race and .04" (1.0 mm)

shim into clutch housing. Install other differential outer bearing
race into bearing housing without shim. Install differential into
clutch housing case and install gearbox housing with seal. Torque
gearbox bolts to 18 ft. lbs. (25 N.m).
2) Set up dial indicator and measure differential side play.
See Fig. 12. The specified .015" (.4 mm) bearing preload is obtained
by adding a preload of .015" (.4 mm) to dial indicator measurement.
The needed bearing preload shim height is determined by this
calculation. Shims are available in various increments from .006" (.15
mm) to .040" (1.0 mm).

Fig. 12: Measuring Differential Side Play

Courtesy of Volkswagen United States, Inc.
TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

Application

Ft. Lbs. (N.m)

Back-Up Light Switch ............................. 15 (20)

Deep Groove Bearing Tension ...................... 11 (15)
Fifth Gear Cover Bolts ........................... 18 (25)
Fillister Head Screws ............................ 18 (25)
Gearbox To Clutch Housing ........................ 18 (25)
Idler Gear Shaft Bolt ............................ 15 (20)
Oil Fill and Drain Plugs ......................... 18 (25)
Output Shaft Bearing Cover ....................... 30 (40)
Shift Relay Bracket .............................. 18 (25)
Shift Shaft Cover ................................ 37 (50)
Shift Shaft Lock Bolt ............................ 30 (40)
Synchronizer Hub Bolt (M17) .................... 111 (150)
INCH lbs. (N.m)
Needle Bearing Retainer Bolt ......................
Shifter Housing Clamp Bolt ........................
Speedometer Drive Retainer Bolt ...................
Vehicle Speed Sensor ..............................

44
18
44
44

(5)
(2)
(5)
(5)

END OF ARTICLE

MANUAL TRANS OVERHAUL - TYPE 020 Article Text (p. 16)