Volkswagen B3 Passat Manual Transmission 02A 34 Manual Transmission - Controls, Assembly (Page GR-34) 02A 5-speed. Gearshift cable/lever installing

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2 34 Manual Transmission - Controls, Assembly (Page GR-34) 02A 5-speed Gearshift cable/lever installing Gearshift housing repairing Gearshift lever repairing lever/relay lever, installing Gearshift mechanism adjusting/checking modifications repairing repairing linkage Selector housing cap installing Shift lever rubber cover positioning Technical data chart Transmission controls, overview removing/installing

3 Technical data (Page ) Code letters Production ACG from 5/88 to - Application type engine Passat 2.0 Liter 100 KW (134 hp) final drive 71:18 = st gear 34:9 = nd gear 40:19 = Ratios 3rd gear 39:29 = th gear 34:35 = th gear 35:44 = reverse gear 19:9, 36:20 = Lubricant capacity 2.0 Liters (2.1 US qts) specification API GL4, Mil-L 2105, SAE 80 or G50 Synthetic, SAE 75W-90 Clutch actuation Clutch disc diameter Axle shaft flange diameter hydraulic 228 mm 100 mm

4 Technical data (Page ) Code letters Production AYK from 8/90 to - Application type engine Passat 2.0 Liter 100 KW (134 hp) final drive 70:19 = st gear 34:9 = nd gear 36:17 = Ratios 3rd gear 40:28 = th gear 35:34 = th gear 36:43 = reverse gear 19:9, 36:20 = Lubricant capacity 2.0 Liters (2.1 US qts) specification API GL4, Mil-L 2105, SAE 80 or G50 Synthetic, SAE 75W-90 Clutch actuation Clutch disc diameter Axle shaft flange diameter hydraulic 228 mm 100 mm

5 Transmission controls, assembly (Page ) A - Gearshift cable for shift mechanism B - Selector cable for selector movement C - Front heat shield holds operating cables in position remove before removing gearshift mechanism 1 - Transmission gearshift lever 2 - Relay lever

6 Gearshift mechanism, repairing (Page ) Notes: Before removing the gearshift mechanism, remove catalytic converter - Repair Group 26, and front heat shield - section Remove gearshift mechanism as a complete unit to change operating cables. Do not bend operating cables. Gearshift mechanism, adjusting/checking, section Lubricate bearing locations and sliding contact surfaces with MoS 2 grease. I - Section II - Section III - Section 34-90

7 Gearshift linkage, repairing (Page ) Note Lubricate bearing locations and sliding contact surfaces with MoS 2 grease. 1 - Gearshift cable installed position, section Selector cable installed position, section install selector cable before installing gearshift cable 3 - Shaft circlip when removing circlip do not damage boot 4 - Shouldered bolt - 25 Nm (18 ft lb) gearshift cable to transmission gearshift lever 5 - Gearshift cable/transmission gearshift lever bushing press out insulating piece from end piece, to replace boot 6 - Washer installed position, section 34-50

8 Gearshift linkage, repairing (Page ) 7 - Transmission gearshift lever fits in only one position after removing/installing lever, adjust gearshift mechanism, section installed position, section Nm (18 ft lb) 9 - Cotter pin Nm (7 ft lb) self-locking (always replace) 11 - Boot/gearshift cable carefully pull over gearshift cable end piece apply MoS 2 grease Nm (18 ft lb) 13 - Support 14 - Boot/selector cable carefully pull over selector cable end piece 15 - Bolt install with MoS 2 grease 16 - Relay lever remove relay lever from transmission before removing the clutch assembly installed position, section Nm (11 ft lb) loosen only to adjust gearshift mechanism 18 - Stud 19 - Selector cable/relay lever bushing drive out and in with drift Nm (11 ft lb) 21 - Rubber washer 22 - Gearshift cable/gearshift lever bushing press out and in with drift 23 - Selector cable/selector bracket bushing press out and in with drift

9 Gearshift mechanism, modified (Page ) Beginning with transmission build date , modifications have been made to the shift mechanism. Also, a shift mechanism balance weight has been installed in production since 10/91 All vehicles with 6-cylinder engines have been produced with the modified shift mechanism. The new and modified components will fit earlier vehicles except those with a G60 G-charger. The following components were modified or have been added: 1 Support 2 Mounting bolts 25 Nm (18 ft lb) 3 Grommets 4 Spacers Shift mechanism on transmission 1 Relay lever

10 2 Mounting nut 15 Nm (11 ft lb) 3 Carrier pull tab in direction of arrow to remove/install selector cable 4 Shift lever 5 Bolt/threaded shaft 25 Nm (18 ft lb) 6 Balance weight only install on vehicles up to 10/91 together with shift cable (8) remove to adjust shift mechanism 7 Mounting nut 25 Nm (18 ft lb) 8 Shift cable use with balance weight (6) Note The adjustment procedure for the new shift mechanism is unchanged from the previous version.

11 Gearshift mechanism, modified (Page ) Shift mechanism on transmission, assembly 1 Relay lever 2 Spacer press into relay lever 3 Carrier 4 Bolt press into carrier 5 Bushings install on axle of carrier 6 Gearshift cover Modified bracket for relay lever Dimension New Previous a width 40 mm 33 mm b height from trans housing 85 mm 60 mm

12 Transmission gearshift cable to gearshift lever, installing (Page ) place washer A between shift cable B and shift lever C, and position with bolt D washer prevents jamming during shifting tighten bolt D tightening torque 25 Nm (18 ft lb)

13 Transmission gearshift lever/relay lever, installing (Page ) 1 - Transmission gearshift lever 2 - Relay lever lubricate with MoS 2 grease meshes into notch of transmission gearshift lever via sliding projection (arrow)

14 Gearshift housing, repairing (Page ) 1 - Gearshift knob 2 - Trim consists of leatherette boot and rubber covering remove boot-portion of trim first rubber cover installing section Plastic nut remove plastic nut before removing gearshift mechanism 4 - Spacer install between transmission bracket and gearshift housing 5 - Gasket install between gearshift housing and underbody 6-15 Nm (11 ft lb) 7 - Gearshift housing 8 - Gasket install between operating cables and gearshift housing

15 9 - Gasket install between gearshift housing and cover

16 Shift lever rubber cover, positioning (Page ) press shift boot frame onto center console press rubber cover A over shoulder of shift lever guide B (see illustration below) upper part of rubber covering A must lie beneath the shoulder (arrow) of shift lever guide B CAUTION! If assembly is misaligned during installation, rubber cover could slip at compression spring area, creating problems during shifting.

17 Gearshift lever, repairing (Page ) 1 - Sleeve approximately 20 mm from gearshift knob holds trim in position 2 - Locking washer 3 - Spacer 4 - Compression spring 5 - Shift lever guide 6 - Circlip 7 - Washer cone faces shift lever guide 8 - Gearshift lever 9 - Cotter pins Nm (18 ft lb) 11 - Cover Nm (18 ft lb)

18 install after installing heat shield 13 - Selector cable at selector bracket 14 - Gearshift cable at shift lever 15 - Selector bracket

19 Gearshift lever, repairing (Page ) 16 - Bearing plate Nm (11 ft lb) 18 - Pivot stud 19 - Cap installing, section Bushing 21 - Selector housing after installation of complete gearshift lever, install selector housing in bearing plate 22 - Torsion spring 23 - Bushing guide rests on bushing 24 - Bushing 25 - Locking washer 26 - Bushing fits only in one position

20 Selector housing cap, installing (Page ) press on laterally (arrow) press opening, to form a slit Note Heat cap, if necessary (e.g., hot water).

21 Gearshift mechanism, adjusting/checking (Page ) Adjusting place gearshift lever in neutral remove gearshift lever knob and shift boot assembly loosen bolt A and nut B until operating cables move freely in centering holes loosen bolt C install shift lever gage pivot locating pin (for attaching gage) under bearing plate and tighten nut D press gearshift lever into left detent of slide press gearshift lever with slide to left stop (direction of arrow) and tighten slide with bolt E move gearshift lever to right detent (direction of arrow) tighten bolt C

22 Gearshift mechanism, adjusting/checking (Page ) install wedge and locating pin push in wedge between gearshift lever and cover until there is no play Note Wedge must not raise transmission gearshift lever. attach operating cables in this position; check position of the wedge remove wedge and pin remove shift/lever gage Checking start engine and press down on clutch pedal wait approximately 3-6 seconds, until transmission input shaft comes to a standstill shift into all gears, several times, noticing effectiveness-of reverse gear pawl Note If any gear binds or drags, check transmission rod travel, as follows: shift into first gear press shift lever to the left, up to stop; release have assistant watch shift rod on transmission rod must travel approximately 1 mm (3/64 in.) in direction of arrow, when activating shift lever Note If rod travel is not within specifications:

23 shift out of first gear loosen nut A at selector cable mounting lug minimal cable play at lug is normal reposition cable/lug slightly, toward instrument panel tighten nut A selector cable play will be increased install shift boot assembly and gearshift lever knob

24 Gearshift mechanism, adjusting/checking (Page ) Note To obtain a correct gearshift adjustment, the following conditions are required: 1. Shift linkage operating satisfactorily 2. Shift/selector cable mounting components, in satisfactory condition 3. Shift/selector cable boots, in satisfactory condition 4. Shift cables operating smoothly 5. Transmission and clutch, in satisfactory condition

25 Transmission, removing/installing (Page ) Transmission, removing/installing Removing disconnect ground strap from battery disconnect electrical connectors from transmission on vehicles with G-charger, remove connecting tubing to intercooler, Repair Group 21 remove gearshift cable from transmission gearshift lever, section remove selector cable with relay lever from transmission, section remove cable support from transmission remove clutch slave cylinder and place aside secure with wire do not open hydraulic lines secure with wire do not open hydraulic lines remove driveshaft for speedometer on transmission remove engine/transmission bolts from above if necessary, remove intake hose from air-flow sensor remove 3 bolts A on mount, right, for engine B

26 remove hex head bolt C on mount D, left, for transmission Note For vehicles with ABS, the hex head bolt for the left mount is difficult to access. If necessary, remove overflow reservoir for cooling system, Repair Group 19. remove fan with cover and mount

27 Transmission, removing/installing (Page ) remove nut A for front transmission bracket, B install device A in conjunction with bases A/1 CAUTION! Bases A/1 are adapted to the angle of the body. If the previous bases are used, an accident could occur. slightly tighten engine/transmission support via spindles remove starter and front transmission bracket

28 remove transmission support A from transmission remove balance weight from mount remove heat shield for inner right constant. velocity joint remove driveshafts from flanges and tie up remove transmission bracket B from transmission press engine/transmission mount rearward and remove lower mounting bolt C for transmission bracket push engine/transmission mount as far as possible to right and lower slightly via left spindle remove small cover for gear carrier housing and bolts for cover position a transmission jack under transmission and remove lower engine/transmission attachment bolt pry transmission from bushings and lower carefully

29 Transmission, removing/installing (Page ) Installing install transmission in reverse order press clutch release lever toward transmission housing and secure by mounting pin or bolt M 8 x 22 remove pin after transmission is installed. plug bore when installing transmission, make sure cover fits properly install engine/transmission mount free of tension adjust gearshift mechanism, section

30 Tightening torques (Page ) Transmission to engine (M 12) Starter to transmission and engine (M 10) Driveshaft to flange Left transmission bracket and transmission support to mount Transmission support to transmission Right rear transmission bracket to mount Front transmission bracket to rubber bonded bushing Cable support to transmission Gearshift cable to gearshift lever Slave cylinder to transmission Balance weight to mount 80 Nm (59 ft lb) 60 Nm (44 ft lb) 45 Nm (33 ft lb) 60 Nm (18 ft lb) 60 Nm (44 ft lb) 25 Nm (18 ft lb) 60 Nm (44 ft lb) 25 Nm (18 ft lb) 25 Nm (18 ft lb) 25 Nm (18 ft lb) 30 Nm (22 ft lb)