5 speed 02R MZL gearbox oil capacity

[apsol]

Around 2 years ago, I changed the gearbox oil on my tdi, I bought 2 liters of it (febi bilstein 21829 75w), I also removed one of the pivot pins and drained some more as indicated on the workshop manual.

Since then, the gearbox has been leaking on that pivot pin and on the vw cap which I didn't touch.

In the meantime I've read that the pivot pin o-ring (N90362001) should be changed, which explains why it's leaking, I didn't change it.

Yesterday, I drained the oil to put some teflon tape on the drain plug since it's also leaking and measured 1,2L of oil that came out. I didn't take the pivot pin because I don't have the o-ring yet.

Now here's my problem, I decided to fill the leftover from the bottle I had because why not (600ml) and the rest with the oil I just drained (600ml more). As I was reaching the 1L I looked below and it was already leaking all over the place, made a mess on the floor.

I don't get it why did this happen, the car was level, the gearbox was not overfilled before, I've checked 2 times the oil level in the past months and it was right by the lower edge of the fill hole. I ended up jacking the side and put the 200ml more. The manual doesn't mention the gearbox being tilted and having to fill through the reverse sensor, the correct level should be by the lower edge for my car.

I'm really struggling to remember (no sh** sherlock) how much I drained when I did the change but judging from the leftover I atleast filled 1.4L.

Since the manual says the gearbox takes 2l I don't understand why I only put 1.4l at the time but I'm sure I didn't drain the full 2l either. I guess that's the capacity when the gearbox is rebuild as I checked the A04 5 speed which should be similar and it says 1.9l rebuild, 1.7l oil change.

To sum up, as I don't really know how much oil there is in the gearbox, can I drain it again including taking off the pivot pin and fill atleast 1.7l ? As I think I've been driving with low oil ever since although it was at the lower edge. Is there a risk of overfilling ?

 

[TurboABA]

I have no idea what vehicle you have, but 2L seems to be the capacity for that code.

Audi Workshop Service and Repair Manuals > A1 > Power transmission | 5-speed manual gearbox 02R | Technical data | Gearbox identification | Code letters, allocation, transmission ratios, capacities

A1 > Audi Workshop Service and Repair Manuals > Power transmission | 5-speed manual gearbox 02R | Technical data | Gearbox identification | Code letters, allocation, transmission ratios, capacities

workshop-manuals.com

 

[TurboABA]

Making some assumptions.....

 

[apsol]

That's where I took the info of but it's not complete. I tried grabbing info from many makes and models.

And it doesn't say how much should your pour in. Just says to fill until it drips but as I said it starts dripping before I fill what I drained and since I filled 1.4l 2 years ago I don't think overfilled in the first place.

I think the best I gotta do to have piece of mind is drain everything and fill the correct amount. I've read about the 5th gear not getting enough oil if the level is low but I don't know if that still applies to my gearbox, since it's 02R instead of 02J.

On the 5 speed 0A4 it mentions

Capacity of manual gearbox (gearbox completely dismantled)

1.9 l​

Capacity of manual gearbox → Chapter (gearbox partially dismantled)

1.7 l​

Filling with gear oil

Top up oil in container to 1.7 litres.

But for my gearbox I can't find anywhere that info, only that it takes 2l.

I may be trying to solve a problem that doesn't exist, that's also a possibility. lol

 

[SamL]

Did you solve the possible problem? I have vw golf with 5 speed transmission. Code is ”LEG” and manual says 2 litres as well like yours. And all instructions where same, fill up untill it flows out of the filler hole. My problem was that I only got in like 1.5 litres. I did let the transmission go on first gear (car jacked up) on in idle about 2mins and filled it up again, it was still about the same so about 1.5L. When I drained old oil out there was about 1.5litres as well. But it is so strange because the manual says 2 litres.

 

[SamL]

Old oil where changed one year earlier from other mechanic and they changed same way like i did. But now i haven't noticed any problems so should I be worried?

 

[Matt-98AHU]

I've taken apart a couple 02R my work has gotten for cheap from VW classic, and then swapped a 02J rear case half onto it so it fits and works for Mk4s... Resetting all the tolerances and such.

The 02Rs I've done recently have had a feature I typically only see on 0A4 bellhousings here: the passage underneath the pinion shaft, above where the magnet resides, is closed off. This is why you need to drain from the shift pin AND why you need to fill from a point higher than the fill plug, because the drainage into the differential region is non-existent. It only gets oil splashed in there through the pinion gear when the internals are moving or by splashing over the top of the pinion when the vehicle is rolling.

The two photos I have here is of a 0A4 and 02J showing the difference. The 02R will look like a combination of the two, because it will have the provision for the vehicle speed sensor like the 02J, but it will have the bit of casting blocking the drainage into the differential region like the 0A4.

02J:



0A4, this bit of casting will be about the same on an 02R:



I could probably dig up a fresh 02R bellhousing at work tomorrow and get photos of it as well.

 

[SamL]

Okay that explains a lot. So should I put more oil in there? So there might be the half litre left from that old oil that did not came out when I unplugged that drain hole. Because of that closed magnet? Or did I got complitely wrong? And what is shift pin.

 

[Matt-98AHU]

Okay that explains a lot. So should I put more oil in there? So there might be the half litre left from that old oil that did not came out when I unplugged that drain hole. Because of that closed magnet? Or did I got complitely wrong? And what is shift pin.

I didn't read your first post closely enough about the transmission code "LEG". I was basing the above info off of the original poster having a 02R family MQ250 transmission.

After poking around in VW's parts cat for awhile, I find that your "LEG" code is a smaller MQ200 0AF family transmission. Whole different animal that we did not get a lot of here. I haven't taken any of those apart so I really don't have any good information for you on that specific transmission.