Car manual transmission Volkswagen Passat B4

Features of the mechanical gearbox
A four- or five-speed gearbox type 02A with synchronizers on all forward gears is combined with a differential and final drive, the gear ratio of which can have several values...

Removal and installation the gearbox
Place the vehicle on a lift. Disconnect the reversing light switch connector. On vehicles with a turbocharged diesel engine, remove the supercharging system pipes. On vehicles...

Disassembling the gearbox
Clean the gearbox, drain the oil from the gearbox housing by unscrewing the oil drain plug (Fig. 4-14), and install it on a disassembly stand. Remove the driven shaft-gear of the...

Primary shaft of the gearbox
To disassemble, install the primary shaft with the fourth gear pinion on the support dies and press the bushing, thrust washer, inner ring of the rear roller bearing and the...

Assembling the primary shaft
Install the 3rd gear pinion on the primary shaft with the flange facing the retaining ring. Install the retaining ring. Press the 4th gear pinion onto the primary shaft with the...

Determining the thickness of the adjusting ring of the primary shaft bearings
Using an indicator, check the axial movement of the primary shaft (table 4-4), then measure the moment of resistance to rotation of the primary shaft bearings, which should be no...

Secondary shaft of the gearbox
To disassemble the secondary shaft (Fig. 4-29), place support plates under the 2nd gear pinion and, using a press resting on the end of the secondary shaft (Fig. 4-26), press out...

Secondary shaft assembly
Before assembly, check the technical condition of the parts and replace damaged parts if necessary. To check the degree of wear of the synchronizer locking rings, apply the rings...

Selecting an adjusting ring for adjusting the preload of secondary shaft bearings
If the secondary shaft, main gear or clutch housing tapered roller bearings are replaced, adjust the shaft roller bearing preload. Install a 0.65 mm thick adjusting ring and the...

Replacing the bearings of the reverse intermediate gear axle
Note: Each time the reverse idler gear shaft is removed, replace the bearings and snap ring with new ones. Using a puller with internal jaws, press the needle bearing of the...

Differential
To disassemble, press out the outer bearing rings from the clutch housing and gearbox housing sockets. Remove the adjusting ring from the clutch housing socket. Using a puller or...

Selecting the differential bearing adjusting ring
Note: This operation is performed in case of replacement of the clutch housing or gearbox housing, differential box or roller bearings. Press the outer bearing rings into the...

Gearbox assembly
Install new sealing rings on the secondary shaft front bearing cover mounting bolts. Install the primary shaft, secondary shaft (Fig. 4-38) and reverse intermediate gear shaft...

Removal and installation shift and gear selection cables
Removing and installing the shift and gear selection cables is not particularly difficult. The operation is performed through the bottom of the car after removing the exhaust pipe...

Adjusting the gear shift drive
Place the gear shift lever in neutral. Remove the gear shift knob and boot. Loosen the nuts securing the shift and gear selection cables to the gearbox. Remove the reverse light...

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