Beruflich Dokumente
Kultur Dokumente
Workshop Manual
Golf Variant 2007 ➤
Golf Variant 2010 ➤
Jetta 2005 ➤
6-speed manual gearbox 02S
Edition 07.2009
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Repair Group
00 - Technical data
30 - Clutch
34 - Controls, housing
35 - Gears, shafts
39 - Final drive - differential
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Technical information should always be available to the foremen and mechanics, because their
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careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
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Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Gearbox identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Location on gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . n.A.G.. .V.ol.ks.w.a.g.en. A. G. . . . . . . . . . . . . . . . 1
1.2 Identification code, assembly allocation and capacities wage . . . . . . . . . . . . . d.o.es. n. . . . . . . . . . . . 1
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2 Overview - power transmission . . . . . . . r.is.ed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ra.nt.e . . . . . 5
tho eo
3 Calculating overall gear ratio “i” . . . s.a.u . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .r a.c . . 7
s
4 General repair notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
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4.1 Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
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30 - Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
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1 Fault finding, power transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
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2.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
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2.2 Assembly overview - pedal cluster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.3 Removing and installing over-centre spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
rrectne
2.4 Removing and installing clutch pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2.5 Removing and installing mounting bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
s
2.6 Removing and installing master cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
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2.7 Removing and installing clutch position sender G476 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
inform
2.8 Assembly overview - hydraulics (LHD vehicles) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
mer
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2.9 Assembly overview - hydraulics (RHD vehicles) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
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3 Repairing clutch release mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
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34 - Controls, housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
1 Fault finding, power transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
2 Repairing selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
2.1 Installation position of selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
2.2 Overview of selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
2.3 Removing and installing gear knob and frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
2.4 Removing and installing gaiter with gear knob and noise insulation . . . . . . . . . . . . . . . . . . 61
2.5 Repairing gear lever and selector housing (through 10.06) . . . . . . . . . . . . . . . . . . . . . . . . 63
2.6 Repairing gear lever and selector housing (from 11.06) . . . . . . . . . . . . . . . . . . . . . . . . . . 65
2.7 Assembly overview - removing and installing selector cables . . . . . . . . . . . . . . . . . . . . . . 70
2.8 Plastic relay lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
2.9 Removing and installing selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
2.10 Removing and installing gear selector cable and gate selector cable . . . . . . . . . . . . . . . . 78
2.11 Adjusting selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
3 Removing and installing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
3.1 Removing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
3.2 Installing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
4 Checking and topping up gear oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
4.1 Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Contents i
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
6-speed manual gearbox 02S - Edition 07.2009
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3 Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
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ii Contents
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
6-speed manual gearbox 02S - Edition 07.2009
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1 Gearbox identification a ra
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The 6-speed manual gearbox 02S is installed in the Jetta 2005 ▸,
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in the Golf Variant 2007 ▸ and in the Golf Variant 2010 ▸ in con‐
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junction with a 4-cylinder engine.
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Code letters and date of manufacture -arrow 1- Manual gearbox
02S -arrow 2-
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Note
1. Gearbox identification 1
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
6-speed manual gearbox 02S - Edition 07.2009
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Manual gearbox 6-speed 02S
Identification code GQP GXV rrectness of i JAU
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Allocation Model
Jetta 2005 ▸ Jetta 2005 ▸ Jetta 2005 ▸
Golf Variant 2007 ▸ Golf Variant 2007 ▸ Golf Variant 2007 ▸
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Capacity of manual gearbox 1.9 l 1.9 l 1.9 l
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Drive shaft flange ∅ 100 mm 100 mm 107 mm
• The following data can be found in the ⇒ Electronic parts catalogue “ETKA” .
♦ Individual gear ratios
♦ Specification for gear oil
♦ Allocation of clutch plate and pressure plate
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Identification code JCP JCQ JYG
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09.06 to 09.06
Allocation Jetta 2005 ▸ Model Jetta 2005 ▸ Jetta 2005 ▸
Golf Variant 2007 ▸ Golf Variant 2007 ▸ Golf Variant 2007 ▸
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Engine 2.0 l - 110 kW 1.4 l - 125 kW 1.4 l - 125 kW
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Capacity of manual gearbox (gear‐ 2.1 l 2.1 l 2.1 l
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Capacity of manual gearbox 1.9 l 1.9 l 1.9 l
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Drive shaft flange ∅ 100 mm 100 mm 100 mm
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♦ Specification for gear oil Prote AG.
1. Gearbox identification 3
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
6-speed manual gearbox 02S - Edition 07.2009
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1 - Engine
2 - Clutch
3 - Manual gearbox
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5- Output shaft by Vo lk ot g
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6- Differential
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Ratio
-Arrows- indicate direction of travel.
I - 1st gear
II - 2nd gear
III - 3rd gear
IV - 4th gear
V - 5th gear
VI - 6th gear
R - Reverse gear
A - Final drive
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6th gear Final drive
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Drive gear ZG1 = 45 ZA1 = 18
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iG = Gear ratio = ZG2: ZG1= 34 : 45 = 0.756
iA = Final drive ratio = ZA2 : ZA1 = 60 : 18 = 3.389
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itotal = Overall ratio = iG x iA = 0.756 x 3.389 = 2.562
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♦ When installing mounting brackets or waxed components,
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♦ Allocate bolts and other components using ⇒ Electronic parts
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⇒ page 99
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♦ After removing gaskets and seals, always inspect contact sur‐
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face of housing or shaft for burrs resulting from removal or for
other signs of damage.
♦ Before installing radial shaft seals, lightly oil outer diameter
and half-fill space between sealing lips -arrow- with sealing
grease -G 052 128 A1- .
♦ The open side of the oil seal faces the side with fluid filling.
♦ Press in new oil seals so that sealing lip does not contact the
shaft in the same place as the old seal (make use of insertion
depth tolerances).
♦ Lightly oil O-rings before installing; this prevents the rings be‐
ing crushed when inserted.
♦ After renewing seals and gaskets, check oil level in gearbox
and replenish if necessary ⇒ page 99 .
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♦ Torque settings are specified for unoiled bolts and nuts.
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♦ Always renew self-locking bolts and nuts.
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4.1.5 Bearing
♦ Install needle bearings with lettered side (thicker metal) to‐
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VAS 6414- before installing.
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4.1.6 Shims
♦ Measure shims at several points with a micrometer. The var‐
ious thicknesses make it possible to achieve the exact shim
thickness required.
♦ Check for burrs and damage.
♦ Install only flawless shims.
4.1.7 Synchro-rings
♦ Do not interchange. When reusing synchro-rings, always fit to
the same gear.
♦ Check for wear and renew if necessary.
♦ Check grooves -arrow 1- of synchro-ring -A- and inner ring for
flat spots (worn grooves).
♦ If synchro-rings are coated, coating must not be damaged.
♦ If an intermediate ring -B- is installed, check the outer friction
surface -arrow 2- and inner friction surface -arrow 3- of this
intermediate ring for “scoring” and “signs of abnormal wear”.
♦ Check cone of synchromeshed gear for “scoring” and “signs
of abnormal wear”.
♦ Moisten synchromesh mechanism with gear oil before instal‐
ling.
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♦ Heat inner races for synchromeshed gear to about 100° C with
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4.1.10 Clutch
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Rep. Gr.00 - Technical data
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
6-speed manual gearbox 02S - Edition 07.2009
♦ Ensure that the pressure plate does not cant: loosen and tight‐
en bolts diagonally and in several gradual stages.
♦ If the clutch has burnt out, thoroughly clean the clutch housing
as well as the friction surface of flywheel with a cloth to reduce
the smell of burnt linings.
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30 – Clutch
1 Fault finding, power transmission
– Refer to ⇒ Fault finding, power transmission; Rep. Gr. 30 ;
Complaints about clutch and clutch mechanism and ⇒ Fault
finding, power transmission; Rep. Gr. 34 ; Complaints about
selector mechanism
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2.1 Overview
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♦ Before disconnecting battery, obtain code for radio units having anti-theft coding.
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♦ With ignition switched off, disconnect battery earth strap ⇒ Electrical system; Rep. Gr. 27 ; Disconnecting
and connecting battery .
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♦ When reconnecting battery, refer to ⇒ Electrical system; Rep. Gr. 27 ; Disconnecting and connecting
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battery .
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♦ Lubricate all bearings and contact surfaces with grease -G 000 450 02- .
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I - Assembly overview - pedal
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III - Assembly overview - hy‐
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1 - Bulkhead
❑ With support for mount‐
ing bracket
2 - Seal
❑ Always renew
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3 - Mounting bracket
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❑ Removing and installing
⇒ page 25
4 - Bolt
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5 - Over-centre spring
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❑ Removing and installing
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⇒ page 15
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6 - Bearing bush
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7 - Pivot pin
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n thi
e
8 - Clutch pedal
t
sd
iva
o
pr
⇒ page 20
en
ng
t.
yi Co
op
9 - Retainer
C py
ht. rig
rig ht
❑ To remove and install,
py by
co Vo
by lksw
separate master cylin‐ Prote
cted AG.
agen
der from clutch pedal
⇒ page 20
10 - Seal
❑ Always renew
❑ Between master cylinder and mounting bracket
11 - Master cylinder
❑ Removing and installing after removal of mounting bracket ⇒ page 25
12 - Clutch position sender -G476-
❑ Removing and installing ⇒ page 33
❑ Can be checked using “guided fault finding” of vehicle diagnostic tester
❑ The clutch position sender -G476- is identified as clutch pedal switch -F36- in “guided fault finding”.
13 - Clip
❑ Pull out clip to stop to remove and install pipe/hose line
14 - Supply hose
❑ Rubber
❑ From 12.05, plastic ⇒ page 38
15 - Hexagon nut, 25 Nm
❑ Self-locking
ce
le
un
pt
❑ Always renew
an
d
itte
y li
erm
ab
16 - Hexagon nut, 25 Nm
ility
ot p
❑ Always renew
wit
is n
h re
17 - Stop
ole,
spec
urposes, in part or in wh
t to the co
Mounting bracket with damping -arrows-
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
2.3.1 Removing
Vehicles with knee airbag
Note
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
Attachment with
ss a2 bolts
u ra
c
ce
e
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
– Pull off damping.
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Note
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
2.3.2 Installing
h re
hole
spec
Install in the reverse order of removal, observing the following:
es, in part or in w
t to the co
Note
rrectness of i
Renew self-locking nuts.
l purpos
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
• Receptacle -arrow- for tip -A- of clutch pedal must stand ver‐
tically.
– Insert tip of clutch pedal in bearing recess of over-centre
spring.
– Depress clutch pedal slightly, push bolt through and tighten
self-locking nut to specified torque ⇒ page 20 .
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
The crash bar -1- in front of clutch pedal -2- may be secured in
t to the co
different ways.
Attachment with 2 bolts
rrectness of i
– Install crash bar -1- and tighten the 2 bolts to specified torque
l purpos
⇒ page 20 .
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
g
t.
yi Co
Cop py
– Install crash bar -1- and tighten bolt -2- to specified torque
t. rig
gh ht
yri
⇒ page 20 .
p by
o Vo
by c lksw
cted agen
Continuation for all
Prote AG.
ce
le
un
pt
an
d
itte
y li
Special tools and workshop equipment required
erm
ab
ility
ot p
♦ Pliers -T10005-
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
2.4.1 Removing
Vehicles with knee airbag
Note
ce
e
nl
pt
du
an
itte
Note
y li
erm
ab
ility
ot p
wit
, is n
cluster.
h re
hole
spec
es, in part or in w
t to the co
theft code.
– With ignition switched off, disconnect battery earth strap ⇒
Electrical system; Rep. Gr. 27 ; Disconnecting and connecting
rrectness of i
battery .
l purpos
nform
mercia
at
om
i
Gr. 80 ; Repairing heating .
on
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
The crash bar -1- in front of clutch pedal -2- may be secured in
different ways.
Attachment with 2 bolts
– Remove crash bar -1- (2 bolts).
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tio
– To do this, remove lock washers -A- for damping.
n in
r
te o
thi
– Pull off damping.
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
2.4.2 Installing
hole
spec
es, in part or in w
Note
rrectness of i
l purpos
– Press retainer into notch in clutch pedal -3- until it can be heard
atio
m
to engage.
o
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
m
• Receptacle -arrow- for tip -A- of clutch pedal must stand ver‐
o
n in
c
tically.
or
thi
te
sd
a
o
r
spring.
rp
cu
o
m
f
en
ng
t.
– Depress clutch pedal slightly, push bolt through and tighten op
yi Co
self-locking nut to specified torque ⇒ page 25 .
C py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
The crash bar -1- in front of clutch pedal -2- may be secured in
different ways.
Attachment with 2 bolts
– Install crash bar -1- and tighten the 2 bolts to specified torque
⇒ page 25 .
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
tho eo
Attachment with 1 sbolt
au ra
c
s
ce
e
– Install crash bar -1- and tighten bolt -2- to specified torque
nl
pt
du
⇒ page 25 .
an
itte
y li
erm
ab
Continuation for all
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
80 ; Repairing heating .
m
at
om
in t
or
– Install bracket for knee airbag together with crash bar ⇒ Inte‐
his
ate
cum
for
en
ng
t.
Continuation for all
yi Co
Cop py
ht. rig
– Install trim and cover below trim on drive side ⇒ General body rig ht
py by
repairs, interior; Rep. Gr. 68 . co Vo
by lksw
cted agen
Prote AG.
– If disconnected, connect battery ⇒ Electrical system; Rep. Gr.
27 ; Removing and installing battery .
ce
e
nl
pt
du
an
♦ Hose clamps to 25 mm Ø -3094-
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
2.5.1 Removing
LHD
– First check whether a coded radio is fitted. If so, obtain anti-
theft code.
– With ignition switched off, disconnect battery earth strap ⇒
Electrical system; Rep. Gr. 27 ; Disconnecting and connecting
battery .
– Remove complete air filter housing if it is near battery ⇒ Rep.
Gr. 23 ; Repairing diesel direct injection system or ⇒ Rep.
Gr. 24 ; Repairing injection system .
– Remove battery and battery tray ⇒ Electrical system; Rep.
Gr. 27 ; Battery; Removing and installing battery .
Note
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectne
– If necessary, loosen spring-type clip -3- with hose clip pliers -
VAS 6362- and pull supply hose off master cylinder.
ss o
– In addition, for disconnecting, you can close it with the sealing
cial p
f in
tool -T10249/1- (⇒ figure above).
form
mer
atio
– Release securing clip -2- using screwdriver or a pointed object
om
and pull pipe/hose line or plastic line -1- off master cylinder.
n
c
i
or
n thi
e
sd
va
o
pr
cum
r
fo
en
ng
t.
yi Co
op
Note
C py
t. rig
gh ht
pyri by
Vo
o
by c
When performing work in the footwell, put cloths on the carpet to
lksw
cted agen
Prote
protect it from possible brake fluid spills.
AG.
Note
The crash bar -1- in front of clutch pedal -2- may be secured in
different ways.
Attachment with 2 bolts
– Unbolt crash bar (2 bolts).
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
wit
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
above clutch pedal -A- in -direction of arrow-.
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
2.5.2 Installing
Install in the reverse order of removal, observing the following:
Note
The crash bar -1- in front of clutch pedal -2- may be secured in
different ways.
Attachment with 2 bolts
n AG. Volkswagen AG do
– Install crash bar -1- and tighten the 2 bolts to specified torque olks
wage es n
ot g
⇒ page 31 . db
y V ua
ran
e
ris tee
tho or
au ac
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
Attachment with 1 bolt
hole
spec
es, in part or in w
– Install crash bar -1- and tighten bolt -2- to specified torque
t to the co
⇒ page 31 .
Continuation for all
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
cum
fo
t.
yi
80 ; Repairing heating; Removing and installing left footwell
Co
op py
vent . t. C rig
gh ht
pyri by
Vehicles with knee airbag
o Vo
by c lksw
cted agen
Prote AG.
– Install bracket for knee airbag together with crash bar ⇒ Inte‐
rior equipment; Rep. Gr. 69 ; Airbag; Removing and installing
knee airbag bracket .
Continuation for all
– Install trim and cover below trim on drive side ⇒ General body
repairs, interior; Rep. Gr. 68 .
– Push pipe/hose line or plastic line -1- with seal -2- onto con‐
nection of master cylinder -4- until securing clip -3- engages
audibly.
– Test line by tugging on it.
– After removing hose clamp up to 25 mm ∅ -3094- , return
supply hose to its original shape, if necessary.
– Bleed clutch system ⇒ page 42 .
LHD
– Install battery ⇒ Electrical system; Rep. Gr. 27 ; Removing
and installing battery .
– If complete air filter housing was removed, install it ⇒ Rep.
Gr. 23 ; Repairing diesel direct injection system or ⇒ Rep.
Gr. 24 ; Repairing injection system . AG. Volkswagen n AG do
wage es n
Volks ot g
by ua
ed ran
oris tee
th or
au ac
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
Component Nm
ility
ot p
wit
Mounting bracket to bulkhead 25
is n
h re
♦ Renew self-locking nuts.
ole,
spec
urposes, in part or in wh
t to the co
bracket (attachment with 2 bolts)
Crash bar to steering column mounting 20
rrectne
bracket (attachment with 1 bolt)
♦ Renew bolts for crash bar
ss o
cial p
f
2.6 Removing and installing master cylinder
inform
mer
atio
n
c
♦ Pliers -T10005-
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
2.6.1 Removing
– Remove mounting bracket ⇒ page 25 .
– Insert spacer -A- between clutch pedal and stop and press
clutch pedal to spacer.
♦ Length of spacer = about 40 mm (e.g. 1/2" socket)
Volkswa
– Release securing bar -B- and pullswmaster
agen
AG.cylindergeout
n AGof
does
mounting bracket -arrow 1- band
y V -arrow 2-.
olk not
gu
a
ed ran
oris tee
th or
au ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
2.6.2 Installing
l purpos
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
– Insert spacer -A- between clutch pedal and stop and press
clutch pedal to spacer.
♦ Length of spacer = about 40 mm (e.g. 1/2" socket)
AG. Volkswagen AG d
agen oes
olksw not
V
– Press master cylinder operating erod d b -1- in
y gu
ara
-direction of arrow- until retainer
thoris-2- engages audibly in clutch nte
eo
pedal. s au ra
c
s
ce
– Install mounting bracket ⇒ page 25 .
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
2.7 Removing and installing clutch position
sender -G476-
l purpos
or
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
2.7.1 Removing
LHD
– First check whether a coded radio is fitted. If so, obtain anti-
theft code.
– With ignition switched off, disconnect battery earth strap ⇒
Electrical system; Rep. Gr. 27 ; Disconnecting and connecting
battery .
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Remove heat shield from pipe/hose line -arrows-.
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
Continuation for all Cop
yi Co
py
t. rig
If a pipe/hose line -1- with a round component is installed directly gh ht
yri by
beneath the master cylinder, the pipe/hose line must be removed.
op Vo
by c lksw
cted agen
Prote AG.
Note
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
– Release securing clip -2- with a screwdriver or a pointed object
hole
spec
and pull out of master cylinder to stop.
es, in part or in w
t to the co
– Pull pipe/hose line -1- or plastic line out from master cylinder
and seal.
rrectness of i
– Disconnect electrical connector -4-.
– Unclip clutch position sender -G476- from master cylinder
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
2.7.2 Installing
Install in the reverse order of removal, observing the following:
Note
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
pt
du
an
y li
erm
ab
h re
10 - Pipe/hose line
hole
spec
t to the co
❑ To remove, remove battery and battery tray ⇒ Electrical system; Rep. Gr. 27 ; Removing and installing
battery .
rrectness of i
11 - Bracket
❑ Secured to body
l purpos
12 - Seal / O-ring
nf
ercia
thi
e
sd
iva
o
r
rp
cu
13 - Clip
o
m
f
en
ng
ce
e
nl
pt
du
18 - Gearbox
an
itte
y li
erm
ab
19 - Bracket
ility
ot p
wit
20 - Hexagon bolt, 20 Nm
, is n
h re
hole
spec
es, in part or in w
t to the co
Item Material of line connection
rrectness of i
-1- Line connection with circumferential groove
-arrow 1-
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
pt
⇒ page 20
an
d
itte
y li
rm
8 - Clutch pedal
ab
pe
ility
wit
, is n
h re
9 - Hexagon nut, 25 Nm
hole
spec
❑ Self-locking
es, in part or in w
t to the co
❑ Qty. 3
❑ For mounting bracket on bulkhead
rrectness of i
❑ Always renew
l purpos
10 - Bracket
❑ Secured to body
nform
ercia
11 - Pipe line
m
❑ Pipe and hose/pipe line ⇒ Item 13 (page 40) may be in one piece
a
com
tion in
thi
❑ To remove, remove battery and battery tray ⇒ Electrical system; Rep. Gr. 27 ; Removing and installing
s
iva
do
battery .
r
rp
cum
fo
en
g
12 - Seal / O-ring
n
t.
yi Co
op
❑ Pipe ⇒ Item 11 (page 39) and hose/pipe line may be in one piece
C py
t. rig
gh ht
yri
❑ Pull onto line connection
p by
co Vo
by lksw
cted agen
Prote AG.
19 - Flange bolt, 20 Nm
un
pt
an
d
itte
20 - Bleeder valve
y li
erm
ab
wit
is n
21 - Dust cap
h re
ole,
spec
22 - Gearbox
urposes, in part or in wh
t to the co
23 - Bracket
24 - Hexagon bolt, 20 Nm
rrectnes
f in
atio
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
2.10.1 Removing
– First check whether a coded radio is fitted. If so, obtain anti-
theft code.
ce
le
un
pt
an
d
y li
rm
box ⇒ page 73 .
ab
pe
ility
ot
wit
, is n
h re
– Remove gearbox selector lever -A- by removing nut
hole
spec
-arrow 4-.
es, in part or in w
t to the co
– Remove cable support bracket from gearbox -arrows-.
– Then raise and secure gear selector cable and gate selector
rrectness of i
cable.
l purpos
– Remove retainer -B- from gearbox and pull it off pipe/hose line
-A-.
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Caution
2.10.2 Installing
Install in the reverse order of removal, observing the following:
– Install slave cylinder and tighten bolts -arrows B- to specified
torque.
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– Insert pipe/hose line into slave cylinder to stop. ksw
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– Push securing clip into pipe/hose line to stop. ised b ara
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– Test pipe/hose line by tugging on it. s aut ra
c
s
– Then install gearbox support -arrows A-.
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pt
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– Bleed clutch system after installing slave cylinder
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ab
⇒ page 44 .
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Assembling selector mechanism ⇒ page 70 .
, is n
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hole
Adjust selector mechanism ⇒ page 80 .
spec
es, in part or in w
t to the co
Gr. 23 ; Repairing diesel direct injection system or ⇒ Rep.
Gr. 24 ; Repairing injection system .
rrectness of i
– Connect battery earth ⇒ Electrical system; Rep. Gr. 27 ; Dis‐
connecting and reconnecting battery .
l purpos
nform
ercia
at
om
ion
Gearbox selector lever to selector shaft ⇒ Item 18 (page 71) .
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– Renew bolts. Cop py
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– Screw in all bolts hand-tight. py by
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– Tighten bolts to specified torque. Prote AG.
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Bleeding brake system .
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erm
ab
er connection (-arrow-, figure below) ⇒ Rep. Gr. 23 ; Repair‐
ility
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wit
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injection system
h re
hole
spec
– Connect brake filling and bleeding equipment -VAS 5234- or
es, in part or in w
-V.A.G 1869- .
t to the co
To bleed system, use 670 mm bleeder hose -V.A.G 1238/B3- if
necessary.
rrectness of i
– Connect bleeder hose to collector bottle of brake bleeding
equipment.
l purpos
nform
ercia
at
om
in t
or
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cum
for
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1 - Gearbox
2 - Ball stud, 25 Nm
❑ To remove and install,
remove gearbox
❑ Remove old grease AG. Volkswagen AG d
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from contact surface of by Vol
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clutch release lever rise
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❑ Grease with clutch plate
s aut ra
c
spline grease - s
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G 000 100- .
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pt
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ab
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remove gearbox
wit
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❑ Renewing
hole
spec
t to the co
4 - Guide sleeve
❑ To remove and install,
remove gearbox
rrectness of i
O-ring together
orm
m
5 - Retaining spring
atio
om
n in
thi
remove gearbox
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lever
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6 - Socket head bolt, 20 Nm Cop py
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7 - Clutch release lever p by
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cted
❑ To remove and install,
agen
Prote AG.
remove gearbox
❑ Remove and install to‐
gether with release bearing ⇒ page 45 .
❑ Remove old grease
8 - Release bearing
❑ To remove and install, remove gearbox
❑ Do not wash out bearing; wipe only
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nl
pt
du
9 - Flange bolt, 20 Nm
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itte
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ab
10 - Slave cylinder
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11 - Plunger
hole
spec
es, in part or in w
12 - Assembly bolt
t to the co
❑ Secures clutch release lever when gearbox is installed.
❑ Remove after gearbox has been installed.
rrectness of i
Note
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nform
ercia
at
ing
om
ion
c
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ate
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for
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Cop py
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AG. Volkswagen AG d
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or eo
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aut ra
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ce
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un
pt
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ab
ility
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led.
h re
ole,
spec
clutch installed:
t to the co
f inform
mer
atio
om
n
c
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or
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te
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Cop py
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46
op Vo
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Rep. Gr.30 - Clutch Prote
cted AG.
agen
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
6-speed manual gearbox 02S - Edition 07.2009
n AG. Volkswagen AG do
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– In addition, a small cover d b plate -A- can be removed to enable ua
ran
ir se
inspection of flywheel's
tho outer contour. tee
or
au ac
Round outer contour -arrows- = Sachs clutch = -A-
ss
ce
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pt
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ility
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hole
spec
es, in part or in w
t to the co
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or
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ate
do
priv
cum
for
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t.
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Cop py
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pyri by
Vo
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Prote AG.
4.2.1 Removing
– Remove gearbox ⇒ page 84 .
– Use counterhold -3067- to loosen bolts.
– Loosen bolts in small steps and diagonally.
• As bolts are removed, stop -2- with pin -1- must loosen.
– If stop does not loosen, press pin towards dual-mass flywheel.
– Remove pressure plate and clutch plate.
AG. Volkswagen AG d
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4.2.2 Installing
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spec
urposes, in part or in wh
Note
t to the co
f in
n
c
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t.
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Cop py
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Prote AG.
Note
clutch plate to and fro on input shaft until hub moves freely on pt
du
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♦ Pressure plates are protected against corrosion and greased. ility
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spec
make full contact with flywheel. Only then insert securing bolts.
t to the co
– Tighten all bolts evenly by hand until bolt heads contact pres‐
sure plate.
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at
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ion
in t
or
mass flywheel.
do
priv
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or
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Cop py
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rig ht
py by
co Vo
by lksw
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Prote AG.
1 - Dual-mass flywheel
❑ Removing and installing
⇒ Rep. Gr. 13
❑ Ensure that centring gen AG. Volkswagen AG d
pins fit tightly Volkswa oes
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❑ Contact surface
rised for nte
clutch lining
ut
ho must be eo
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free of
ss a
grooves, oil and c
grease
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un
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an
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2 - Clutch plate
itte
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ab
❑ Allocation ⇒ Electronic
pe
ility
parts catalogue “ETKA”
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wit
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❑ Removing and installing
hole
⇒ page 48
spec
es, in part or in w
t to the co
with pressure plate
❑ Installation position
⇒ page 48
rrectness of i
3 - Pressure plate
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❑ Allocation ⇒ Electronic
parts catalogue “ETKA” nform
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nism
com
tion in
thi
⇒ page 48
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fo
phragm spring
en
ng
t.
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⇒ page 49
Co
Cop py
t.
❑ Check spring connec‐
rig
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tions and riveted con‐ op Vo
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nections ⇒ page 49 . cted agen
Prote AG.
❑ Renew only together
with clutch plate.
4 - Bolt M6, 13 Nm, Bolt M7,
20 Nm
❑ Loosen or tighten diagonally in small steps
4.4.1 Removing
– Remove gearbox ⇒ page 84 .
– Use counterhold -3067- to loosen bolts.
– Loosen bolts in small steps and diagonally.
– Remove pressure plate and clutch plate.
4.4.2 Installing
Install in the reverse order of removal, observing the following:
ce
le
⇒ Electronic parts catalogue “ETKA” .
un
pt
an
d
itte
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♦ Check whether dowel sleeves for aligning engine and gearbox
rm
ab
are fitted in cylinder block and install if necessary.
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♦ If dowel sleeves are not fitted, difficulties shifting gears, clutch
h re
problems and possible noises from the gearbox (rattling of
hole
spec
gears which are not engaged) could occur. es, in part or in w
t to the co
Installation position of clutch plate
• Lettering “Getriebeseite” (gearbox side) faces gearbox.
rrectness of i
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ercia
permitted.
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com
tion in
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Cop py
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rig ht
py by
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by lksw
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Prote AG.
Checking spring connections and riveted connections
– Check spring connections -arrows A- for damage and riveted
connections -arrows B- for secure seating.
ce
le
un
pt
Note
an
d
itte
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rm
ab
pe
ility
♦ Renew clutch plates and pressure plates with damaged or
ot
wit
, is n
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hole
spec
es, in part or in w
t to the co
code and ⇒ Electronic parts catalogue “ETKA” .
♦ If clutch has burnt out, thoroughly clean clutch housing, fly‐
rrectness of i
wheel and parts of engine facing gearbox to reduce smell of
burnt linings.
l purpos
♦ Clean input shaft splines and, on used clutch plates, clean hub
splines; remove corrosion and apply only a very thin coat of
nform
ercia
a
com
ti
shaft. Remove excessive grease.
on in
r
te o
thi
♦ Pressure plates are protected against corrosion and greased.
s
iva
c
clutch will be considerably reduced.
um
fo
en
ng
t.
yi
♦ Pressure plate contact surface and clutch plate lining must
Co
op py
make full contact with flywheel. Only then insert securing bolts.
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ht ht
rig by
copy Vo
by lksw
cted agen
Prote AG.
– Reverse counterhold tool -3067- for installation.
– Push pressure plate onto centralizing pins.
– To centre clutch plate, use centring mandrel -3190 A- .
– Tighten all bolts evenly by hand until bolt heads contact pres‐
sure plate.
– Tighten bolts in small steps diagonally in order not to damage
centring holes of pressure plate and centring pins of dual-
mass flywheel.
– Install gearbox ⇒ page 92 .
1 - Dual-mass flywheel
❑ Removing and installing
⇒ Rep. Gr. 13
❑ Ensure that centring
pins fit tightly
❑ Contact surface for
clutch lining must be
free of grooves, oil and
grease
2 - Clutch plate
❑ Allocation ⇒ Electronic
parts catalogue “ETKA”
❑ Removing and installing
⇒ page 50
❑ Renew only together
with SAC pressure
plate.
❑ Installation position:
⇒ page 51 .
3 - SAC pressure plate
❑ SAC means “self-ad‐
justing clutch”.
❑ Renew only together
with clutch plate.
❑ Allocation ⇒ Electronic
parts catalogue “ETKA”
❑ Removing and installing AG. Volkswagen AG d
agen oes
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⇒ page 50 by
Vol not
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ara
ed
❑ Check ends of dia‐ horis nte
eo
phragm spring aut ra
c
⇒ page 51 ss
ce
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nl
an
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ab
connections ⇒ page 51
ility
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❑ Checking position of adjusting mechanism with new pressure plates only ⇒ page 52
wit
, is n
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spec
t to the co
rrectness of i
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nform
mercia
at
om
ion
c
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or
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ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
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by c lksw
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Prote AG.
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nl
pt
du
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ab
Special tools and workshop
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equipment required
wit
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♦ Counterhold -3067-
hole
spec
♦ Centring mandrel -3190 A-
es, in part or in w
t to the co
♦ Torque wrench -
V.A.G 1331-
rrectness of i
♦ Grease for clutch plate
splines -G 000 100- l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
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f
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
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by c lksw
cted agen
Prote AG.
(Gearbox removed)
Note
♦ Renew clutch plates and pressure plates with damaged or loose rivets.
♦ Select clutch plate and pressure plate according to ⇒ Electronic parts catalogue “ETKA” and engine codes.
♦ Check whether dowel sleeves for aligning engine and gearbox are fitted in cylinder block and install if nec‐
essary.
♦ If dowel sleeves are not fitted, difficulties shifting gears, clutch problems and possible noises from the gear‐
box (rattling of gears which are not engaged) could occur.
1 - Flywheel
❑ Removing and installing
⇒ Rep. Gr. 13
❑ Ensure that centring
pins fit tightly
❑ Keep contact surface for
clutch lining free of
grooves, oil and grease.
2 - Clutch plate
❑ Allocation ⇒ Electronic
parts catalogue “ETKA”
❑ Installation position:
spring cage faces pres‐
sure plate
❑ Centring ⇒ page 55
❑ Lightly grease splines
Note
ce
e
nl
pt
du
an
❑ Check spring connec‐
itte
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tions and riveted con‐
erm
ab
nections ⇒ page 56 .
ility
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wit
, is n
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Note
hole
spec
es, in part or in w
t to the co
4 - Bolt M6, 13 Nm, Bolt M7,
20 Nm
❑ Allocate according to ⇒
rrectness of i
Electronic parts catalogue “ETKA” .
l purpos
nf
ercia
or
Centring clutch plate and removing and installing pressure plate
m
m
atio
m
n in
or c
thi
e
sd
iva
o
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rp
cu
o
m
f
en
ng
t.
Note Cop
yi Co
py
t. rig
gh ht
Pressure plate contact surface and clutch plate lining must make pyri by
Vo
co
full contact with flywheel. Tighten bolts diagonally and evenly to
by lksw
cted agen
Prote
prevent damage to the centring holes in the pressure plate hous‐
AG.
AG. Volkswagen AG d
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olksw not
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d b ara
rise nte
tho eo
au ra
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un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
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cum
fo
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.
34 – Controls, housing
1 Fault finding, power transmission
– Refer to ⇒ Fault finding, power transmission; Rep. Gr. 30 ;
Complaints about clutch and clutch mechanism and ⇒ Fault
finding, power transmission; Rep. Gr. 34 ; Complaints about
selector mechanism
AG. Volkswagen AG d
agen oes
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ed
ris nte
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aut ra
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ce
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un
pt
an
d
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erm
ab
ility
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wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
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o
pr
cum
r
fo
en
ng
t.
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Cop py
ht. rig
rig ht
by
57
copy Vo
by lksw
cted 1. Fault finding, power transmission
agen
Prote AG.
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
6-speed manual gearbox 02S - Edition 07.2009
AG. Volkswagen AG d
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olksw not
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or eo
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aut ra
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ce
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nl
pt
du
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itte
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erm
ab
ility
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wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
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nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
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by c lksw
58
cted agen
Prote
Rep. Gr.34 - Controls, housing
AG.
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
6-speed manual gearbox 02S - Edition 07.2009
Note
ce
e
pt
du
an
itte
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erm
ab
ility
♦ Do not kink selector cables.
ot p
wit
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hole
spec
I - Removing and installing
es, in part or in w
t to the co
gear knob and frame
⇒ page 61
II - Repairing gear lever and
rrectness of i
selector housing (through
10.06) ⇒ page 63
l purpos
⇒ page 65
m
at
om
in t
his
e
cables ⇒ page 70
at
do
priv
cum
for
en
ng
t.
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Cop py
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rig ht
py by
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by lksw
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Prote AG.
AG. Volkswagen AG d
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ility
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wit
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hole
spec
es, in part or in w
♦ Torque wrench -V.A.G 1331-
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
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cum
fo
en
ng
t.
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Cop py
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rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
1 - Emblem
❑ Can be carefully levered
off gear knob of plastic
or leather
2 - Gear knob
❑ With gaiter
❑ Gear knob and gaiter
cannot be separated
from one another
❑ Always renew together
❑ Removing and installing
⇒ page 61 AG. Volkswagen AG d
agen oes
lksw not
3 - Clamp d by
Vo gu
ara
e nte
❑ For securing gear knob horis
eo
to gear lever aut ra
ss c
❑ Secure to gear knob
ce
le
un
pt
⇒ Item 2 (page 61) using
an
d
itte
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rm
ab
1275-
pe
ility
ot
❑ Always renew
wit
, is n
h re
4 - Frame for centre console
hole
spec
❑ In some equipment ver‐
es, in part or in w
t to the co
sions, forms one part to‐
gether with centre con‐
sole
rrectness of i
5 - Noise insulation
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nform
ercia
a
com
thi
vals
s
iva
do
r
rp
en
ng
t.
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Cop py
t. rig
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2.4 Removing and installing gaiter with gear
ht
pyri by
Vo
o
by c lksw
knob and noise insulation
cted agen
Prote AG.
– Pull or carefully prise gaiter with frame for centre console up‐
wards out of centre console -arrows-.
Note
– Pull gaiter with frame for centre console upwards, inside out
over gear knob.
– Open clamp -arrow- and pull off gear knob together with gaiter.
In some versions, the centre console frame remains in the centre
console.
– If necessary pull off, or carefully lever off, centre console
frame.
2.4.1 Installing
– First set noise insulation in place.
Installation position of noise insulation
• -Arrow A- points in direction of travel.
• Catches -arrows B- must engage in centre console. agen
AG. Volkswagen AG d
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olksw not
– If necessary, press frame into centre console. d by V gu
ara
rise nte
– Then turn gaiter inside out. utho eo
ra
s a c
s
The gear knob must be pressed to stop.
ce
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nl
pt
du
an
itte
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erm
ab
ility
ot p
– Install gear knob with frame and gaiter and squeeze new
wit
, is n
h re
spec
– Then press gaiter with frame into centre console or gaiter into
es, in part or in w
frame.
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.
Note
Lubricate bearing points and sliding surfaces with grease -G 000 450 02- .
1 - Securing clip
❑ Removing and installing
⇒ page 64
AG. Volkswagen AG d
agen
2 - Bush Volksw
oes
not
by gu
d ara
3 - Compression spring orise nte
th eo
u ra
4 - Bush ss a c
ce
le
5 - Torx screw, 5 Nm
un
pt
an
d
itte
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6 - Cover
erm
ab
ility
ot p
7 - Damping
wit
is n
h re
8 - Damping
ole,
spec
urposes, in part or in wh
9 - Ball socket
t to the co
10 - Gear lever guide
11 - Damping washer
rrectne
12 - Seal
s
❑ Between selector hous‐
s o
ing and underbody
cial p
f inform
❑ Self-adhesive
mer
atio
❑ Bond to selector hous‐
om
ing
n
c
i
or
n thi
e
13 - Gear lever
t
sd
iva
o
pr
cum
14 - Selector lever housing
r
fo
en
ng
t.
yi
15 - Bearing bush
Co
Cop py
t. rig
gh
16 - Pivot pin
ht
pyri by
Vo
co lksw
by
cted
17 - Guide bush
agen
Prote AG.
18 - Compression spring
❑ Installing ⇒ page 64
19 - Gate selector lever
20 - Torx screw, 5 Nm
21 - Seal
❑ Always renew
22 - Base plate
❑ Bend open tabs to remove
❑ Always renew
23 - Gate selector cable
❑ On gate selector lever
❑ Removing and installing ⇒ page 64
24 - Gear selector cable
❑ Removing from and attaching to gear lever guide ⇒ page 64
25 - Securing clip
❑ Always renew
26 - Hexagon nut
❑ M8: 25 Nm
❑ M6: 8 Nm
❑ Qty. 4
27 - Bearing bush
❑ Fits in one position only
28 - Securing clip
❑ Always renew
AG. Volkswagen AG d
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rise nte
tho eo
au ra
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ce
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nl
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itte
ab
ility
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spec
es, in part or in w
t to the co
Note
orm
m
n in
c
thi
e
pin -arrow-.
t
sd
iva
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– Then pull extension -B- down so that it sits below pin -arrow-.
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Cop py
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Prote AG.
Note
♦ Lubricate bearing points and sliding surfaces with grease -G 000 450 02- .
♦ Dismantling and assembling selector mechanism ⇒ page 66 .
1 - Base plate
❑ Bend open tabs to re‐
move
❑ Always renew
2 - Seal
❑ Always renew
3 - Selector lever
❑ Can be removed and in‐
stalled with gear lever
guide
⇒ Item 15 (page 66)
installed
4 - Damping washer
❑ Push onto gear lever up
to stop -arrow-
5 - Securing clip
❑ Do not damage cables
when removing
n AG. Volkswagen AG do
❑ Always renew lkswage es n
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6 - Gate selector cable o
ir se tee
th or
❑ Lever off gate selector ss
au ac
lever
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lever inside selector
erm
ab
mechanism
ility
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⇒ page 58 h re
hole
spec
7 - Bush
es, in part or in w
t to the co
9 - Damping
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10 - Ball socket
n
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❑ Always renew
p
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for
en
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11 - Bush
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op py
12 - Securing clip
t. C rig
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❑ Removing and installing ⇒ page 64 cop Vo
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13 - Compression spring
AG.
14 - Bush
15 - Gear lever guide
16 - Hexagon nut
❑ M8: 25 Nm
❑ M6: 8 Nm
❑ Qty. 4
17 - Seal
❑ Between selector housing and underbody
❑ Self-adhesive
❑ Bond to selector housing
18 - Selector lever housing
❑ With compression spring and gate selector lever
❑ Compression spring and gate selector lever cannot be removed
ce
le
un
pt
an
d
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rm
ab
pe
ility
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t to the co
– Remove seal from selector housing.
– Remove gear and gate selector cables from selector housing
rrectness of i
⇒ page 78 .
l purpos
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mercia
a
com
tion in
r
te o
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iva
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cum
fo
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t.
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Cop py
t. rig
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Vo
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by
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Prote AG.
ce
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un
necessary.
pt
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rm
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pe
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, is n
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hole
spec
es, in part or in w
t to the co
– Lever ball socket -A- with gear lever guide -B- out of selector
rrectness of i
housing.
l purpos
– Then press ball socket off bearing ball of gear lever guide and
remove it.
nform
mercia
a
com
tion in
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te o
thi
s
iva
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cum
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t.
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Cop py
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rig ht
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• Please pay attention to guides -A- during the further proce‐ co Vo
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Prote AG.
Caution
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es, in part or in w
– Place selector housing with gear lever guide into larger recess t to the co
-arrow- in thrust piece -T10083- .
rrectness of i
Note
l purpos
To ensure that the selector housing with gear lever guide can be
inserted in the thrust piece , first remove gear lever, if necessary.
nf
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orm
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• The gear lever guide must project from the selector housing
t.
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up to the stop. ht. Cop py
rig
rig ht
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Note
cted agen
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– Place selector housing with gear lever guide into larger recess
-arrow- in thrust piece -T10083- .
AG. Volkswagen AG d
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• The gear lever guide must project from the selector by housing
Vo gu
ara
up to the stop. orised
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– Lift upper end -A- of compression springssover pin of gate se‐
a c
lector lever
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• Use a new ball socket -B-.
itte
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– Grease ball socket and bearing ball of gear lever guide.
ility
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stop.
hole
spec
es, in part or in w
t to the co
– Insert lower end -C- of compression spring into guide.
– Lift upper end -A- of compression spring over pin of gate se‐ rrectness of i
lector lever into guide.
l purpos
– Attach gear lever, gear selector cable, gate selector cable and
m
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priv
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Cop py
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Note
Lubricate bearing points and sliding surfaces with grease -G 000 450 02- .
ce
le
un
pt
⇒ Item 10 (page 71)
an
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❑ Installation position
rm
ab
⇒ page 58
pe
ility
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❑ Use cable tie to fix onto
, is n
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gear selector cable
hole
spec
⇒ page 73
es, in part or in w
t to the co
⇒ page 78
❑ From 11.06, modified
rrectness of i
attachment to gate se‐
lector lever inside selec‐
l purpos
tor mechanism
⇒ Item 6 (page 65)
nform
ercia
3 - Securing clip
m
❑ Always renew
a
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tion in
❑ Discontinued in selector
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5 - Securing clip
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❑ Do not damage cables when removing
co Vo
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Prote AG.
6 - Hexagon bolt, 20 Nm
❑ Qty. 3
❑ For cable support bracket
7 - Cable support bracket
❑ May be made from plastic or metal
8 - Grommet
❑ Cable support bracket mounting on gearbox
9 - Spacer
AG . Volkswage
10 - Cable end-piece ksw
agen
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not
Vol
❑ For gate selector cable to relay lever ed by gu
ara
ris nte
❑ After installing, adjust selector mechanism
ut
ho ⇒ page 80 eo
ra
a
❑ Do not interchange; cable end-pieces
ss for gate selector cable to relay lever and gearc selector cable to
ce
e
gearbox selector lever are different
nl
pt
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❑ For metal relay lever, secured with securing clip ⇒ Item 12 (page 71)
itte
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❑ From 05.07, fitted in conjunction with plastic relay lever ⇒ page 73
ility
❑ Removing from plastic relay lever ⇒ page 73 ot p
wit
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❑ Pressing onto plastic relay lever ⇒ page 73
hole
spec
❑ Allocation ⇒ page 72
es, in part or in w
t to the co
11 - Cable end-piece
❑ For gear selector cable to gearbox selector lever
rrectness of i
❑ After installing, adjust selector mechanism ⇒ page 80
l purpos
❑ Do not interchange; cable end-pieces for gate selector cable to relay lever and gear selector cable to
gearbox selector lever are different
❑ Allocation ⇒ page 72
nf
ercia
orm
12 - Securing clip
m
atio
om
❑ Always renew
n in
or c
thi
❑ Not required for plastic relay lever
te
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13 - Securing clip
o
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❑ Always renew
t.
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❑ Not required for plastic relay lever t. C rig
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14 - Bearing bush
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Prote
❑ Not required for plastic relay lever
AG.
15 - Relay lever
❑ Installation position ⇒ page 72
❑ After installing, adjust selector mechanism ⇒ page 80
❑ May be made from plastic or metal
❑ Metal relay lever is mounted in bearing bush ⇒ Item 14 (page 71) and secured with securing clip
⇒ Item 13 (page 71)
❑ From 05.07, plastic relay lever
❑ Remove and install plastic relay lever together with cable end-piece ⇒ page 73
❑ Bearing bushes and securing clip not required for plastic relay lever
16 - Shoe
17 - Gearbox selector lever
❑ With damper weight
❑ Install so that master spline aligns with selector shaft
❑ Installation position ⇒ page 72
❑ After installing, adjust selector mechanism ⇒ page 80
❑ From 06.06, smaller diameter of support pin for cable end-piece ⇒ page 72
18 - Hexagon nut, 23 Nm
❑ Self-locking
❑ Always renew
From 06.06, smaller diameter of support pin for gear selector ca‐
ble end-piece
Support pin for gear selector cable end-piece Dimension “a”
n AG. Volkswagen AG do
Through 05.06 olkswage 10 mm
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From 06.06 ir se
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o tee
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ility
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t to the co
nform
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ion
c
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or
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ate
do
priv
cum
for
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t.
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Cop py
t. rig
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by
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Prote AG.
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ss
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2.8 Plastic relay lever
nl
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From 05.07, relay lever is made from plastic. 2 versions may be erm
ab
ility
installed.
ot p
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, is n
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hole
spec
♦ Relay lever with clip
es, in part or in w
t to the co
Comply with the following during removal and installation work:
• To remove relay lever, first separate cable end-piece from
rrectness of i
gate selector cable.
l purpos
nform
ercia
at
om
io
– Then push relay lever forwards (-in direction of arrow 3-).
n
c
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or
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ate
do
priv
cum
for
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ng
t.
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Cop py
t. rig
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Prote AG.
Note
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pt
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rm
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Relay lever with catch -arrow 1-
pe
ility
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hole
spec
• Ensure proper engagement.
es, in part or in w
t to the co
• Cable end-piece must be located behind catch -arrow 2-.
rrectness of i
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mercia
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tion in
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Cop py
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Relay lever with clip -arrow 1- op Vo
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• Clip -arrow 1- secures relay lever.
AG.
AG. Volkswagen AG d
agen oes
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• Relay lever has been removed. by Vol not
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• Cable end-piece may be pressed only onto bush -arrow-.
thor eo
au ra
c
• Cable end-piece must move freely on relay lever. ss
ce
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un
pt
• It must be located behind catch -arrow 2-.
an
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pe
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hole
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es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tio
thi
anism
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fo
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t.
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2.9.1 Removing Cop py
t. rig
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Special tools and workshop equipment required cop Vo
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Prote AG.
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pt
an
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erm
ab
ility
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is n
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ole,
spec
urposes, in part or in wh
t to the co
rrectne
♦ Grease -G 000 450 02-
– First check whether a coded radio is fitted. If so, obtain anti-
ss
theft code.
o
cial p
f in
– With ignition switched off, disconnect battery earth strap ⇒
form
mer
atio
m
tery .
o
n
c
i
or
n
– Remove gaiter with selector knob and noise insulation
thi
te
sd
a
⇒ page 61 .
iv
o
pr
cum
r
fo
t.
sole ⇒ General body repairs, interior; Rep. Gr. 68 ; Compart‐
yi Co
op
ments, covers and trims .
C py
t. rig
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yri by
– Remove selector housing nuts -arrows-. cop Vo
by lksw
cted agen
Prote AG.
– Remove complete air filter housing if it is over selector mech‐
anism ⇒ Rep. Gr. 23 ; Repairing diesel direct injection system
or ⇒ Rep. Gr. 24 ; Repairing injection system .
– Remove securing clip -3- for gear selector cable from gearbox
selector lever -1-.
– Pull gear selector cable off pin.
Metal relay lever
– Remove securing clip -4- for gate selector cable from relay
lever -2-.
– Pull gate selector cable from pin.
Plastic relay lever
ce
le
– Pull locking mechanism forward to stop in
un
pt
an
d
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-direction of arrow 2-.
rm
ab
pe
ility
ot
wit
, is n
h re
Continued for all selector mechanisms
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
a
com
tion in
– Remove tunnel cross member ⇒ Rep. Gr. 26 ; Removing and
r
te o
thi
installing parts of exhaust system .
s
iva
do
r
rp
c
– Separate front exhaust system at double clamp and detach
um
fo
en
from subframe ⇒ Rep. Gr. 26 ; Removing and installing parts
ng
t.
yi Co
of exhaust system . ht. Cop py
rig
rig ht
– Remove rear exhaust system and heat shield ⇒ Rep. Gr. 26 ;
py by
co Vo
Removing and installing parts of exhaust system .
by lksw
cted agen
Prote AG.
– Remove underbody panels ⇒ General body repairs, exterior;
Rep. Gr. 50 .
– Swing selector housing down and remove with selector ca‐
bles.
2.9.2 Installing
Install in the reverse order of removal, observing the following:
– Align selector housing parallel to body.
• Distance to body must be same on both sides.
– Secure selector housing ⇒ Item 26 (page 64) or
⇒ Item 16 (page 66) .
– Route cables -1- from selector mechanism -2- to gearbox as
follows:
♦ After cables cross over -arrow-, they must be routed parallel
to one another as far as cable support bracket on gearbox.
♦ Make sure that cable tie -arrow- for securing cables is installed
correctly. Installation position ⇒ page 73 .
♦ Cables must be laid in the intended indentation in heat shield
-3-.
Note
AG. Volkswagen AG d
agen oes
olksw not
y V gu
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– Spread a small quantity of greaseth-Go 000 450 02- on pins
r eo
-arrows- of gearbox selector lever
s a -1- and relay lever -2-.
u ra
c
s
ce
e
– Renew securing clips -3- and -4- each time they are removed.
nl
pt
du
an
itte
y li
– Secure gear selector cable with securing clip -3- and gate se‐
erm
ab
lector cable with securing clip -4-.
ility
ot p
wit
Cable end-piece to plastic relay lever
, is n
h re
hole
spec
es, in part or in w
t to the co
Continued for all selector mechanisms
rrectness of i
– Install centre console ⇒ General body repairs, interior; Rep.
Gr. 68 ; Compartments, covers and trims .
l purpos
nform
ercia
at
om
io
– If removed, reinstall underbody panels ⇒ General body re‐
n
c
in t
r
his
ate
do
riv
cum
or
en
ng
of exhaust system .
t.
yi Co
Cop py
t. rig
Adjust selector mechanism ⇒ page 80 . opyri
gh by
Vo
ht
c
– If removed, install complete air filter housing ⇒ Rep. Gr. 23 ;
by lksw
cted agen
Prote
Repairing diesel direct injection system or ⇒ Rep. Gr. 24 ;
AG.
2.10.1 Removing
– Remove selector mechanism ⇒ page 75 .
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
– Pull off securing clips -2 and 3-. (Securing clips -1 and 4- have
l purpos
nform
ercia
– Pull gear selector cable and gate selector cable from selector
m
a
housing.
com
tion in
r
te o
thi
s
iva
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cum
fo
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ng
t.
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Cop py
t. rig
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pyri by
Vo
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Release locks -A- for gear and gate selector cables -B- as follows:
cted agen
Prote AG.
2.10.2 Installing
Install in the reverse order of removal, observing the following:
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
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erm
ab
ility
ot p
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
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sd
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Note
o
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en
ng
t.
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op py
♦ The following points are essential to ensure correct adjust‐ t. C rig
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ment of selector mechanism: pyri by
Vo
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by c lksw
cted
♦ Moving parts of selector mechanism and elements transferring
agen
Prote AG.
force must be in proper condition.
♦ Selector mechanism must move freely.
♦ Gearbox, clutch and clutch mechanism must also be in proper
condition.
n AG. Volkswagen AG do
lkswage es n
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– Pull locking mechanisms on gate selector cable and gear se‐
ss
ce
le
pt
and then turn to left to lock -direction of arrow 2-.
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
a
– While pressing down selector shaft, turn angled rod -A- in
com
tio
-direction of arrow 2- upwards and at the same time press it in
n in
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cum
fo
en
g
t.
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Cop py
Now secure gear lever as follows:
t. rig
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pyri by
Vo
o
– Select neutral using gear lever.
c by lksw
cted agen
Prote AG.
– Guide locking pin -T10027 A- through hole -A- into hole -B-.
– Check that gate and selector cables -B- are inserted, free of
tension, into locking devices -A-.
– Now turn locking mechanisms on gear selector cable and gate
selector cable end pieces clockwise to stop
-direction of arrow 1-.
The spring presses the locking mechanism into original position
-direction of arrow 2-.
AG. Volkswagen AG d
agen oes
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Note
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ility
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is n
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spec
urposes, in part or in wh
t to the co
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cial p
i
or
n thi
e
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pr
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en
ng
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e
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pt
du
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erm
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ility
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es, in part or in w
t to the co
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at
om
ion
c
in t
or
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ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.
AG. Volkswagen AG d
agen oes
olksw not
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rise nte
tho eo
au ra
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nl
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du
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ility
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wit
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hole
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es, in part or in w
t to the co
rrectness of i
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nform
mercia
at
om
ion
c
in t
or
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ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.
AG. Volkswagen AG d
agen oes
olksw not
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d by ara
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or eo
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ce
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un
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an
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ab
ility
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is n
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spec
urposes, in part or in wh
t to the co
battery .
form
mer
atio
is not accessible.
c
i
or
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e
sd
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t.
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– Remove battery and battery tray ⇒ Electrical system; Rep.
C py
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Gr. 27 ; Battery; Removing and installing battery .
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by c lksw
– Remove securing clip -arrow 1- for gear selector cable from
Prote
cted AG.
agen
gearbox selector lever -A-.
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– Then remove gearbox support -arrow A-.
s
ce
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un
pt
– Remove slave cylinder -arrow B-, lay to side and secure with
an
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ility
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Caution
is n
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t to the co
f inform
mer
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n
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Prote AG.
ce
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un
pt
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rm
ab
pe
ility
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spec
– Set up support bracket -10 - 222 A- together with adapters -10
es, in part or in w
- 222 A /8- , adapter -10 - 222 A /3- and adapter -10 - 222 A /
t to the co
16- in front of gas struts for bonnet.
– Attach hook -10 - 222 A /10- at front right of engine. rrectness of i
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nform
mercia
a
com
tion in
r
te o
thi
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Cop py
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Vo
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by
cted agen
Prote AG.
– Now attach hook -10 - 222 A /2- at rear left of engine -arrow-.
– Then connect hook -10 - 222 A /2- using adapter -10 - 222 A /
16- .
Continuation for all vehicles . Volkswagen AG
gen AG does
swa
– Position adapter -10 - 222 A /8- directly over wing bolting y Volk not
gu
points. risedb ara
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– Take up weight of engine/gearbox assembly ons auspindles. ra
c
s
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e
– Raise vehicle.
nl
pt
du
an
itte
– Remove noise insulation ⇒ General body repairs, exterior;
y li
erm
ab
Rep. Gr. 50 ; Noise insulation .
ility
ot p
wit
– Remove lower part of front left wheel housing liner ⇒ General
, is n
h re
body repairs, exterior; Rep. Gr. 66 ; Wheel housing liner .
hole
spec
– Then remove all lines from gearbox.
es, in part or in w
t to the co
– Remove drive shaft heat shield from engine -arrows-, if fitted.
rrectness of i
Vehicles with 1.4 l petrol engine
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
op py
– Separate exhaust system -arrows 1-, remove front exhaust t. C rig
gh ht
pipe and unscrew front exhaust pipe bracket from subframe pyri by
Vo
o
by c
-arrows 2- ⇒ Rep. Gr. 26 ; Parts of exhaust system .
lksw
cted agen
Prote AG.
Vehicles with turbo diesel engines and vehicles with 2.0 l - 110 kW
petrol engines
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
– Tilt engine/gearbox assembly by lowering
rised it via spindles of nte
support bracket -10 - 222 A- . ut
ho eo
ra
s a c
s
ce
e
nl
pt
du
Note
an
itte
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erm
ab
♦ Lower threaded spindle, shown here with adapter -10 - 222 A /
ility
ot p
16- , using winged nut, but not more than until spindle is flush
wit
, is n
h re
hole
spec
♦ Be careful of all lines when lowering gearbox.
es, in part or in w
t to the co
• Securing bolts -arrows- for gearbox bracket -A- must be ac‐
cessible.
rrectness of i
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– If small cover plate -A- for flywheel behind the right flange shaft
-arrows- is installed, remove it.
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
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e
nl
pt
du
an
itte
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erm
ab
ility
ot p
– Remove exhaust system strut -1-, if present, from gearbox
wit
, is n
-arrow-.
h re
hole
spec
– Remove starter ⇒ Electrical system; Rep. Gr. 27 ; Starter .
es, in part or in w
t to the co
To remove gearbox “02S”, set up gearbox support -3282- with
adjustment plate -3282/39- .
rrectness of i
– Insert gearbox support -3282- in engine and gearbox jack -
V.A.G 1383A- .
l purpos
nf
ercia
orm
m
atio
om
n in
c
thi
e
as shown.
t
sd
iva
o
r
rp
cu
– Position engine and gearbox jack under vehicle. Arrow -B- on
o
m
f
en
ng
ce
le
un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
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ole,
spec
urposes, in part or in wh
t to the co
♦ Gearbox mounting support -3336-
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
op py
Procedure t. C rig
gh ht
pyri by
– Bolt gearbox lifting tackle -3336- to clutch housing.
co Vo
by lksw
cted agen
Prote AG.
pt
du
y li
ping up gear oil”.
erm
ab
ility
ot p
h re
spec
Gearbox Original X
es, in part or in w
part
t to the co
No oil loss X
Completely X
rrectness of i
stallation
⇒ Item 3
(page 134)
nf
ercia
Oil capacity
orm
⇒ page 1
m
atio
om
Partially X
n in
or c
• (Gear‐ lation
sd
iva
o
r
box ⇒
rp
cu
o
housing page 99
f
en
ng
t.
yi
and
Co
op py
clutch
t. C rig
gh ht
yri
housing
p by
co Vo
were not
by lksw
cted agen
separa‐
Prote AG.
ted.)
The clutch plate must slide easily to and fro on the input shaft.
To install gearbox “02S”, set up gearbox support -3282- with ad‐
justment plate -3282/39- .
– Align arms of gearbox support according to holes in adjust‐
ment plate .
– Screw in support elements -A - and -C- ( pin -3282/29- ) on
adjustment plate as shown.
– Place gearbox on gearbox jack .
– Align adjustment plate and gearbox parallel to one another.
pt
an
d
itte
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ab
ility
wit
is n
f in
from gearbox.
atio
om
n
c
– If small cover plate -A- had been installed behind the right
i
or
n thi
e
sd
iva
o
pr
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
pt
an
d
specified torque.
itte
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
Note
spec
es, in part or in w
t to the co
a
com
thi
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
– Install drive shaft heat shield, if present, on engine -arrows- ⇒
Prote AG.
– Install pendulum support with new bolts -arrows A-, -B- and
-C- ⇒ Running gear, axles, steering ; Rep. Gr. 40 ; Repairing
front suspension .
– Assemble exhaust system and attach exhaust system bracket
to subframe ⇒ Rep. Gr. 26 ; Removing and installing parts of
exhaust system .
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
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erm
ab
ility
bolt -arrow- to specified torque ⇒ Rep. Gr. 26 ; Removing and
ot p
wit
installing parts of exhaust system .
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
his
e
do
priv
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
pt
an
d
itte
ab
pe
ility
ot
h re
hole
1 M12 x 50 3 80
t to the co
2 M12 x 55 1 80
♦ With M8 stud
rrectness of i
♦ Additionally, start‐
er to gearbox
l purpos
3 M12 x 150 1 80
nform
ercia
♦ With M8 stud
m
♦ Additionally, start‐
com
tion in
er to gearbox
r
te o
thi
s
iva
4 M12 x 60 2 80
do
r
rp
cum
5 M10 x 50 2 40
fo
en
ng
t.
yi Co
op
Item -A- dowel sleeves for centring C py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
ce
le
un
er to gearbox
pt
an
d
itte
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erm
ab
3 M12 x 165 1 80
ility
ot p
♦ Additionally, start‐
wit
is n
er to gearbox
h re
ole,
spec
4 M10 x 50 3 40
urposes, in part or in wh
t to the co
5 M12 x 85 1 80
6 M6 x 8 1 10
♦ Small cover plate
rrectne
for flywheel
ss
Item -A- dowel sleeves for centring
o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
e
1 M12 x 55 2 80
t
sd
iva
o
r
2 M12 x 150 2 80
p
cum
r
fo
♦ Additionally, start‐ en
ng
t.
yi
er to gearbox
Co
Cop py
t. rig
gh ht
yri
3 M10 x 50 3 40
p by
o Vo
by c lksw
cted
4 M12 x 60 1 80
agen
Prote AG.
5 M6 x 8 1 10
♦ Small cover plate
for flywheel
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
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hole
spec
es, in part or in w
t to the co
4.1 Preparation
Gear oil for manual gearboxes ⇒ Electronic parts catalogue “ET‐
nform
ercia
KA” .
m
at
om
in t
his
e
injection system .
at
do
priv
en
g
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Clean gearbox.
Caution
To drain gear oil, a pivot pin for the selector forks in the gearbox
must be removed.
To prevent the positions of the selector forks from being
changed, e.g. due to accidental operation of the selector mech‐
anism, the selector shaft must be locked in position.
ce
e
pt
du
an
until it engages in selector shaft.
itte
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
4.2 Draining gear oil
l purpos
or
atio
m
– Drain gear oil by removing oil drain plug -arrow 1- and then
o
n in
or c
sd
iva
cu
m
f
en
ng
t.
yi Co
– Screw in oil drain plug -arrow 1- ⇒ Item 17 (page 135) . t. Cop py
rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
1 - 1st gear
2 - 2nd gear
3 - 3rd gear
4 - 4th gear
5 - 5th gear
AG. Volkswagen AG d
6 - 6th gear ksw
agen oes
not
Vol
by gu
7 - Gearbox housing cover ised ara
nte
or eo
h
8 - Gearbox housing s aut ra
c
s
9 - Selector mechanism
ce
le
un
pt
an
d
❑ (Selector forks)
itte
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erm
ab
10 - Reverse gear wheel
ility
ot p
wit
is n
11 - Clutch housing
h re
ole,
spec
12 - Input shaft
urposes, in part or in wh
t to the co
13 - Output shaft
14 - Differential
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
ce
le
pt
an
d
y li
⇒ page 108
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
5.3 Removing and installing cover for gearbox housing and 5th and 6th gear
1 - Gearbox housing
❑ Pull off together with 5th
and 6th gears
⇒ page 115 .
❑ Repairing ⇒ page 132 . n AG. Volkswagen AG do
lkswage es n
o ot g
yV
2 - Gear wheel for 5th gear sed b ua
ran
ir tee
❑ Pull off individually autho
or
ac
⇒ page 109 ss
ce
le
pt
an
d
gearbox housing
itte
y li
⇒ page 115
erm
ab
ility
ot p
3 - Sleeve
wit
is n
h re
4 - Gear wheel for 6th gear
ole,
spec
urposes, in part or in wh
t to the co
⇒ page 109
❑ Pull off together with
gearbox housing
rrectne
⇒ page 115
5 - Cylindrical roller bearing in‐
ss
ner race
o
cial p
f in
❑ For output shaft
form
mer
atio
m
n
c
i
or
n
inner race for cylindrical
thi
te
o
r
shaft
p
cum
r
fo
en
ng
ce
le
❑ Mark before removing
un
pt
an
d
❑ Do not interchange with cylinder roller bearing inner race of output shaft.
itte
y li
rm
ab
❑ From gearbox date 21 08 6, combined with thrust washer in one component ⇒ Item 12 (page 105)
pe
ility
ot
wit
, is n
h re
hole
11 - Thrust washer
spec
es, in part or in w
t to the co
12 - Inner race for cylindrical roller bearing with thrust washer
❑ For input shaft
rrectness of i
❑ From gearbox date 21 08 6
l purpos
nform
ercia
a
❑ Renew together with needle bearing
com
tion in
❑ Larger diameter from gearbox date 21 08 6
r
te o
thi
s
iva
do
r
rp
cum
fo
14 - Needle bearing
en
ng
t.
yi Co
❑ For 6th gear . Cop py
rig
ht
❑ Renew together with sleeve rig ht
py by
co Vo
❑ Larger diameter from gearbox date 21 08 6
by lksw
cted agen
Prote AG.
❑ Allocate components according to ⇒ Electronic parts catalogue “ETKA” .
15 - Synchromeshed gear for 6th gear
❑ Adapted to sleeve and needle bearing from gearbox date 21 08 6
❑ Allocate components according to ⇒ Electronic parts catalogue “ETKA” .
16 - Wave spring washer
❑ From gearbox date 26 05 8
❑ Allocate according to ⇒ Electronic parts catalogue “ETKA”
17 - Synchro-ring for 6th gear
18 - Locking collar with synchro-hub for 5th and 6th gears
❑ Pull off individually ⇒ page 109
❑ Pull off together with gearbox housing ⇒ page 115
❑ Dismantling and assembling ⇒ page 157 and ⇒ page 157
❑ From gearbox date 12 06 6, locking collar modified ⇒ page 157
❑ Adjusting, through gearbox date 11 06 6 ⇒ page 130
❑ Adjusting, from gearbox date 12 06 6 ⇒ page 131
❑ Installation of springs with angled ends for locking pieces ⇒ page 158
19 - Synchro-ring for 5th gear
❑ Will be damaged during removal of input shaft
❑ Always renew
ce
ture date
le
un
pt
an
d
itte
Through 20 08 6 21 31
y li
rm
From 21 08 6 23.4 37 ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
ce
le
un
pt
5.4 Removing and installing gearbox housing and shift mechanism
an
d
itte
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erm
ab
ility
ot p
wit
1 - Countersunk bolt, 25 Nm
is n
h re
ole,
2 - Flange shaft with compres‐
spec
urposes, in part or in wh
sion spring
t to the co
❑ Removing and installing
⇒ page 184
❑ Assembling
rrectne
⇒ page 193
s
3 - Torx socket head bolt, 25
s o
Nm
cial p
f inform
❑ For reverse shaft sup‐
port mer
atio
om
❑ Self-locking
n
c
i
or
n thi
❑ Always renew
te
sd
iva
o
pr
c
4 - Torx socket head bolt, 30
um
r
fo
Nm
en
ng
t.
yi Co
op
❑ For reverse shaft sup‐ C py
ht. rig
port rig ht
py by
o Vo
❑ Self-locking
by c lksw
cted agen
Prote AG.
❑ Always renew
5 - O-ring
❑ Always renew
6 - Pivot pin
7 - Bolt, 25 Nm
8 - Bolt, 25 Nm
9 - Cover plate
10 - Multi-point socket head
bolt 25 Nm
❑ For reverse shaft sup‐
port
❑ Always renew
11 - Gearbox housing
❑ Pull off together with 5th and 6th gears ⇒ page 115 .
❑ Repairing ⇒ page 132 .
12 - Clutch housing
❑ Repairing ⇒ page 132 .
13 - Hexagon bolt, 25 Nm and turn 90° further
❑ Always renew
14 - Selector shaft with selector shaft cover
(Selector unit)
❑ Repairing ⇒ page 142 .
15 - Multi-point socket head bolt 25 Nm
ce
le
un
pt
❑ Dismantling and assem‐
an
d
itte
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bling ⇒ page 193 rm
ab
pe
ility
2 - Seal
ot
wit
, is n
❑ Qty. 4
h re
hole
❑ Always renew
spec
es, in part or in w
t to the co
3 - Output shaft
❑ Dismantling and assem‐
bling ⇒ page 163
rrectness of i
4 - Reverse shaft support
l purpos
nform
ercia
5 - Reverse shaft
m
a
❑ Dismantling and assem‐
com
tion in
bling ⇒ page 181
r
te o
thi
6 - Input shaft
s
iva
do
r
rp
c
❑ Dismantling and assem‐
um
fo
en
g
t.
yi Co
op py
7 - Selector fork for reverse
t. C rig
gh ht
yri
gear p by
co Vo
by lksw
❑ Dismantling and assem‐
cted agen
Prote AG.
bling ⇒ page 145
❑ Installation position
⇒ page 123
8 - Torx socket head bolt, 25
Nm
9 - Selector mechanism
❑ (Selector forks)
❑ Dismantling and assem‐
bling ⇒ page 145
10 - Clutch housing
❑ Repairing ⇒ page 132 .
11 - Hexagon nut, 25 Nm and then turn 90° further
❑ 4 nuts for bearing support
❑ Always renew
12 - Flange shaft with compression spring
❑ Removing and installing ⇒ page 184
❑ Assembling ⇒ page 193
13 - Countersunk bolt, 25 Nm
Note
ce
e
nl
pt
du
an
itte
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erm
ab
Special tools and workshop
ility
ot p
equipment required
wit
, is n
h re
♦ Support plate -VW 309-
hole
spec
es, in part or in w
t to the co
♦ Drift -VW 295-
♦ Drift sleeve -VW 244 B-
rrectness of i
♦ Hot air blower -V.A.G 1416-
l purpos
nf
ercia
orm
♦ -Zweiarmabzieher Kukko
m
atio
m
210.1-
o
n in
or c
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
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a ac
ss
ce
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nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
ce
e
nl
pt
du
an
itte
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erm
ab
ility
• The input shaft can be supported by the thrust piece -32 - 111-
ot p
wit
only at a later point.
, is n
h re
hole
spec
es, in part or in w
t to the co
♦ Assembly tool -3253/7-
rrectness of i
♦ Thrust piece -VW 433-
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
-B-
Puller hooks -T10040/2A- come
into contact with ribs in gearbox
housing below gear wheel.
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
– Remove -bolts A- for inner bearing races from input and output
spec
urposes, in part or in wh
shafts, engaging 5th gear -arrow 1- and 1st gear -arrow 2- and
t to the co
-arrow 3-.
– Input shaft and output shaft are locked when both gears are
engaged. Both bolts can now be loosened.
rrectness
Note
o
cial p
f inform
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Pull off gear wheel for 6th gear with inner race of cylindrical
roller bearing for output shaft.
A - Two arm puller , e.g. -Kukko 20/10-
gen AG
. Volkswagen AG
d wa oes
olks not
B - Hexagon bolt, M10 xd20,
by 17 mm AF
V gu
ara
e nte
ris
utho eo
ra
a c
Note ss
ce
e
nl
pt
du
an
6th gear wheel with cylindrical roller bearing inner race can also
itte
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erm
be pulled off using two arm puller -T10040- and puller hooks -
ab
ility
T10040/2A- .
ot p
wit
, is n
h re
– Heat gear wheel slightly with hot air blower -V.A.G 1416- if
hole
spec
necessary.
es, in part or in w
t to the co
Pull off synchromeshed gear for 6th gear together with cylinder
roller bearing inner race for input shaft, thrust washer and syn‐
chro-ring for 6th gear only or together with synchro-hub for 5th
rrectness of i
and 6th gears, needle bearing inner race for 6th gear and syn‐
chro-ring for 5th gear.
l purpos
nform
ercia
Note
m
at
om
ion
c
below the synchro-ring for 5th gear and above the synchro-ring
in t
or
for 6th gear ⇒ Item 20 (page 105) and ⇒ Item 16 (page 105) . his
ate
do
priv
cum
or
en
ng
t.
yi Co
Cop py
t.
– First set half sleeve -T10309/1- between output shaft -A- and
rig
gh ht
yri by
support for selector fork for 5th and 6th gear -B-. cop Vo
by lksw
cted agen
Prote
• The half sleeve -T10309/1- must be positioned beneath the
AG.
synchro-ring.
– Turn half sleeve -T10309/1- to opposite side
-direction of arrow-.
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
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ir se tee
tho
u or
a ac
ss
ce
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un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
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ole,
spec
– First set up puller hooks -A-.
urposes, in part or in wh
t to the co
-B- = Thrust piece -T10040/3-
or
rrectne
Thrust plate -40 - 105-
ss o
Note
cial p
f inform
mer
♦ When pulling off gear wheel, ensure that hooks do not bend
atio
m
outwards. After pulling off 5th gear wheel, examine for dam‐
o
n
c
age.
i
or
n thi
te
sd
a
♦ Heat gear wheel slightly with hot air blower -V.A.G 1416- if
iv
o
pr
necessary.
um
r
fo
en
ng
t.
yi Co
Cop py
t. rig
5.6.2 Installing cover for gearbox housing and
gh ht
pyri by
Vo
co
5th and 6th gears
by lksw
cted agen
Prote AG.
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
atio
n
c
i
or
n thi
sd
va
sleeve ⇒ page 44 .
i
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
ce
e
nl
pt
• Bearings of input shaft and output shaft must not be damaged
du
an
itte
when 5th and 6th gears are removed and installed.
y li
erm
ab
ility
• Therefore, following tools must be mounted for support at this
ot p
wit
stage during attachment of gearbox to gearbox support -VW
, is n
h re
353- :
hole
spec
Underneath input shaft:
es, in part or in w
t to the co
♦ Support bridge -30-211A-
♦ Thrust piece -32 - 111-
rrectness of i
♦ Thrust piece -T10030/4-
l purpos
nform
ercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi
– Secure gearbox on gearbox support -VW 353- .
Co
Cop py
t. rig
gh
– Place drip tray underneath.
ht
pyri by
Vo
o
by c lksw
– Remove oil filler plug and oil drain plug.
cted agen
Prote AG.
– Unscrew -bolts A- for inner bearing races from input and output
shafts, engage 5th gear -arrow 1- and 1st gear -arrow 2- and
n AG. Volkswagen AG do
-arrow 3- for this. olks
wage es n
o V t gu
by
– Input shaft and output shaft
ris are locked when both gears are
ed
ara
nte
engaged. Both bolts canut now be loosened.
ho eo
ra
a c
ss ce
e
nl
pt
du
Note
an
itte
y li
erm
ab
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
– Now remove 3rd bolt -arrow- for reverse shaft support bracket.
– Remove cover plate -A- and pivot pins -B- from underside of
gearbox.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
ferential.
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Remove bolts -A- from clutch housing side for securing clutch
housing to gearbox housing.
Note
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
o
– Remove both flange aut shafts.
h eo
ra
ss c
– Remove flange shafts together with springs, thrust washers
ce
le
un
pt
and tapered rings.
an
d
itte
y li
Pull off following components together with gearbox housing:
erm
ab
ility
ot p
wit
is n
h re
♦ Gear wheel for 6th gear
ole,
spec
urposes, in part or in wh
t to the co
rrectne
Use puller plate -T10408- in conjunction with following special
ss
tools:
o
cial p
f in
♦ Thrust pieces -T10408/2-
form
mer
n
c
n thi
e
sd
iva
o
pr
en
ng
t.
yi
Torque setting 18 Nm
Co
Cop py
ht. rig
– Place thrust pieces -T10408/2- on shafts. rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– Install puller Kukko 18/1 .
– Pull off 5th and 6th gear synchro-hub, 6th gear wheel, 5th gear
wheel and gearbox housing by alternately tightening spindles
-A- (1/2 rotation) of pullers Kukko 18/2 .
– Heat 5th and 6th gear wheels slightly with hot air blower -
V.A.G 1416- if necessary.
AG. Volkswagen AG d
agen oes
olksw not
V gu
by
– Remove nuts -B- for output shaft risebearing
d support. ara
nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
– Remove reverse gear -A-, input shaft -B- and output shaft
-C- one after the other from clutch housing.
l purpos
– Remove differential.
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c
5.7.2 Assembling gearbox
lksw
cted agen
Prote AG.
– Install differential.
– Always renew sealing rings -arrows- for output shaft bearing
support.
Note
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectne
Installation position, reverse gear
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
– Bolt on reverse gear selector mechanism -A-, tightening to Prote AG.
specified torque ⇒ Item 8 (page 108) .
– Install selector forks -B- together with selector plates.
Reverse gear support pin -C- is located in front of selector plates.
ce
le
un
pt
an
d
y li
locking collars.
erm
ab
ility
ot p
wit
is n
h re
ole,
clutch housing.
spec
urposes, in part or in wh
t to the co
Install reverse shaft support bolts -arrow- as follows:
rrectne
– Install bolt -a-.
– Remove stud -A- (⇒ figure above).
ss o
cial p
f
– Install bolt -c-.
inform
mer
Tightening sequence:
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
– Tighten bolt -b- to 25 Nm. opyri
gh by
Vo
ht
c
– Tighten bolt -c- (⇒ figure below) to 25 Nm.
by lksw
cted agen
Prote AG.
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
– Drive on gear wheel for 5th gear.
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
ce
le
un
pt
Gap -a- Installation (new) di‐ Wear limit
an
d
itte
mension
y li
erm
ab
ility
5th and 6th gears 1.1 … 1.7 mm 0.5 mm
ot p
wit
is n
h re
– Install 5th gear synchromeshed gear with needle bearing.
ole,
spec
urposes, in part or in wh
From gearbox date 26 05 8: set corrugated spring washer on
t to the co
synchromeshed gear for 5th gear ⇒ Item 20 (page 105)
– Place 5th gear synchro-ring on synchromeshed gear.
rrectne
– If synchro-hub and locking collar for 5th and 6th gears are dis‐
mantled, assemble before installing ⇒ page 157 ,
⇒ page 157 and ⇒ page 158 .
ss o
cial p
f
– Observe other modifications to locking collar for 5th and 6th
inform
gears from gearbox date 12 06 6 ⇒ page 157 .
mer
atio
m
n
c
i
or
n thi
te
sd
iva
o
Installation position, synchro-hub and locking collar for 5th and
pr
cum
r
fo
6th gears
en
ng
t.
yi Co
op
Shoulder -arrow 1- faces 6th gear. C py
t. rig
gh ht
yri
The supports -arrow 2- of the synchro-hub align with the cast
p by
o Vo
by c lksw
locking pieces of the synchro-ring (arrows in figure below). Prote
cted AG.
agen
5th gear and 6th gear synchro-rings with cast locking pieces
-arrows-
– Cover all openings in gearbox housing with a cloth to prevent
foreign bodies from entering gearbox.
Note
– Heat inner race of cylindrical roller bearing for 6th gear syn‐
chromeshed gear to maximum 100° C and drive onto input
shaft.
WARNING
Note
AG. Volkswagen
Do not interchange inner races wagof
en cylindrical roller bearings
AG do
es n of in‐
olks
put and output shafts.d by V ot g
ua
re an
ris tee
tho or
– Heat bearing inner race -B- to cylindrical
au roller maximum ac
ss
100° C and drive onto input shaft.
ce
le
un
pt
an
d
itte
y li
WARNING
rm
ab
pe
ility
ot
h re
hole
spec
es, in part or in w
Cylindrical roller bearing inner race -B- and thrust washer -A- are
combined in one component.
rrectness of i
WARNING
m
a
com
tio
thi
s
iva
do
r
rp
en
ng
t.
yi
– Set sleeve -A- on gear wheel for 5th gear.
Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
128
Prote AG.
Rep. Gr.34 - Controls, housing
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
r
ut Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , oJetta 2005 ➤
ho e
a ra
ss 6-speed manual gearbox 02S - Edition c 07.2009
ce
e
nl
pt
du
an
Installation position of gear wheel for 6th gear:
itte
y li
erm
ab
Groove -B- faces away from sleeve -A-.
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
sleeve -A- see previous figure).
m
atio
om
n in
or c
thi
WARNING
te
sd
iva
o
r
rp
cu
Wear protective gloves!
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh
– Heat 6th gear wheel to maximum 100° C and press on.
ht
pyri by
Vo
o
by c lksw
cted
– Shift locking collar for 5th and 6th gear to freewheel position
agen
Prote AG.
to enable synchromeshed gear for 6th gear to turn while gear
wheel for 6th gear is being pressed on.
– Drive on gear wheel for 6th gear, being careful that teeth of
gear wheel and synchromeshed gear for 6th gear mesh.
WARNING
y li
When 5th or 6th gear is engaged, the selector fork for 5th and 6th
erm
ab
wit
is n
– Switch to neutral.
h re
ole,
spec
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
130
cted agen
Prote AG.
Rep. Gr.34 - Controls, housing
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
6-speed manual gearbox 02S - Edition 07.2009
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
is nte
• 5th gear engaged. uth or eo
ra
s a c
• Check measurement: it should not be possible to insert a 0.2°
s
ce
le
pt
an
d
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erm
ab
– If necessary, repeat adjustment.
ility
ot p
wit
is n
h re
ole,
When 5th or 6th gear is engaged, the selector fork for 5th and 6th
spec
urposes, in part or in wh
t to the co
– Switch to neutral.
• Locking collar must now be in the neutral position. Synchro-
rrectne
ring must move freely.
– Shift through all gears.
ss o
cial p
f
Continuation for all
inform
mer
– Apply sealant -AMV 188 200 03- evenly to sealing surface of atio
m
n
c
i
or
sd
iva
o
pr
cum
r
en
ng
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
s c
♦ Thrust piece -T10148- (for one-piece seal and sleeve) Differ‐ s
ce
le
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted
133
agen
Prote AG.
6. Repairing gearbox housing and clutch housing
. Volkswagen AG
gen AG does
swa
Golf Variant 2007 ➤ , Golf Variant 2010 y V ➤ , Jetta 2005 ➤
olk not
gu
b ara
6-speed manual gearbox 02S - Editionrised
07.2009 nte
ho eo
aut ra
1- Gearbox housing ss c
ce
le
un
❑ If renewed: adjust input
pt
an
d
shaft and differential
itte
y li
erm
⇒ page 192
ab
ility
ot p
2 - Needle bearing
wit
is n
h re
❑ For output shaft
ole,
spec
urposes, in part or in wh
❑ Removing ⇒ page 135
t to the co
❑ Installing and securing
⇒ page 136 .
3 - Oil filler plug, 30 Nm
rrectne
❑ The oil level cannot be
checked by removing
ss o
the oil filler plug
cial p
f in
❑ If the gearbox was dis‐
form
mer
atio
m
prior to installation
o
n
c
i
or
n
Capacity ⇒ page 1 .
thi
te
sd
iva
o
pr
c
4 - Tapered roller bearing outer
um
r
fo
race
en
ng
t.
yi Co
op
❑ For output shaft C py
ht. rig
rig ht
❑ Removing and installing py by
o Vo
⇒ page 163
by c lksw
cted agen
Prote AG.
❑ If replaced: Adjust out‐
put shaft ⇒ page 176 .
5 - Shim
❑ For output shaft
❑ Adjustment overview
⇒ page 192
6 - Shim
❑ For input shaft
❑ Adjustment overview
⇒ page 158
7 - Tapered roller bearing outer race
❑ For input shaft
❑ Removing and installing ⇒ page 150
❑ If renewed: adjust input shaft ⇒ page 158
8 - Tapered roller bearing outer race
❑ For input shaft
❑ Removing and installing ⇒ page 150
❑ If renewed: adjust input shaft ⇒ page 158
9 - Needle bearing
❑ Removing and installing ⇒ page 181
10 - Dowel sleeve
❑ Qty. 2
11 - Clutch housing
❑ When renewing, ⇒ adjustment overview ⇒ page 192
12 - Guide sleeve
❑ With input shaft seal and vulcanised O-ring
❑ Driving out oil seal ⇒ page 136 .
❑ Driving in oil seal ⇒ page 136 .
ce
e
nl
pt
du
an
❑ Installing ⇒ page 137
itte
y li
erm
ab
17 - Oil drain plug, 30 Nm
ility
ot p
wit
, is n
h re
hole
❑ For differential
spec
es, in part or in w
t to the co
❑ If renewed, adjust differential ⇒ page 200
19 - Magnet
rrectness of i
❑ Held in place by housing joint surface
l purpos
20 - Oil collector
❑ Installing oil collector in gearbox housing ⇒ page 137
nf
ercia
orm
atio
m
❑ For differential
o
n in
or c
sd
iva
cu
o
m
f
en
ng
22 - Shim yi
t.
Co
op
❑ For differential
C py
t. rig
gh ht
yri
❑ Adjustment overview ⇒ page 192 p by
co Vo
by lksw
cted agen
23 - Seal Prote AG.
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
Driving oil seal out
ss
aof guide sleeve ac
ce
le
un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectne
Driving oil seal into guide sleeve to stop
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Pulling in sleeve
– Clean sleeve seat in gearbox.
– Screw spindle -A- of assembly device -3066- into threaded
piece of differential.
– Pull sleeve in to stop using thrust piece -3124- by turning nut
-B-.
Note
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
Pulling in sleeve and seal aut
h
ra
ss c
– Clean seat for seal in gearbox.
ce
le
un
pt
an
d
y li
rm
piece of differential.
ab
pe
ility
ot
nut -B-. h re
hole
spec
es, in part or in w
t to the co
Note
piece -T10148- .
l purpos
multaneously.
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
pt
an
d
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rm
ab
ility
ot
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
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do
r
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Cop py
ht. rig
rig ht
by
139
copy Vo
by lksw
cted 7. Repairing gearbox housing cover
agen
Prote AG.
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
6-speed manual gearbox 02S - Edition 07.2009
n AG. Volkswagen AG do
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– Heat gearbox housing cover with hot air blower -V.A.G 1416-
wit
is n
spec
Note
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f inform
n
c
– Heat gearbox housing cover with hot air blower -V.A.G 1416-
i
or
n thi
sd
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pr
t.
yi Co
Cop py
t. rig
gh ht
yri by
Note cop Vo
by lksw
cted agen
Prote AG.
Cylindrical roller bearings must be pressed into cover to stop.
ce
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un
pt
an
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erm
ab
ility
ot p
wit
is n
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ole,
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
AG. Volkswagen AG d
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♦ Tube -VW 423- olksw not
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or eo
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nl
pt
du
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wit
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hole
spec
es, in part or in w
t to the co
♦ Torque wrench -V.A.G 1331-
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
1 - Selector unit
❑ Consists of selector
shaft and selector shaft
cover
❑ Components cannot be
separated from each
other gen AG
. Volkswagen AG
d wa oes
olks not
2 - -Schalter für Rückfahr‐
db
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ara
leuchten- -F4- orise nte
eo
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ut
❑ Tightenss ato 20 Nm ra
c
❑ Lightly coat lug with
ce
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nl
pt
du
MoS2 grease
an
itte
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erm
ab
3 - Angled rod
ility
ot p
wit
, is n
mechanism
h re
hole
spec
❑ Removing ⇒ page 144
es, in part or in w
❑ Pressing in
t to the co
⇒ page 144
4 - Relay lever
rrectness of i
❑ Installation position
l purpos
⇒ page 72
❑ From 05.07, plastic re‐
lay lever ⇒ page 73
nform
mercia
5 - Bearing bush
at
om
io
❑ Not required for plastic
n
c
in t
or
relay lever
his
ate
do
riv
6 - Seal
p
cum
for
t.
yi Co
driver t. Cop py
rig
❑ Installing ⇒ page 144
gh ht
pyri by
Vo
o
by c lksw
7 - Hexagon nut, 23 Nm cted agen
Prote AG.
❑ Self-locking
❑ Always renew
8 - Gearbox selector lever
❑ Install so that master spline aligns with selector shaft
❑ Can be renewed with the selector mechanism installed
❑ Installation position ⇒ page 72
9 - Cap
❑ For gearbox breather
10 - Securing clip
❑ Not required for plastic relay lever
11 - Cover plate
12 - Spring
❑ Not fitted in all gearboxes
AG. Volkswagen AG d
agen oes
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du
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spec
es, in part or in w
t to the co
Inserting oil seal to stop
rrectness of i
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nf
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orm
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n in
or c
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t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
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Prote AG.
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nl
pt
du
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Special tools and workshop
ility
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equipment required
wit
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hole
spec
es, in part or in w
t to the co
♦ Assembly tool -3301-
♦ Thrust piece -VW 431-
rrectness of i
♦ Spacer sleeve -VW 472/2-
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
♦ Clamp -2070-
n AG. Volkswagen AG do
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un
pt
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d
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erm
ab
ility
ot p
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is n
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spec
urposes, in part or in wh
Note
t to the co
It is not necessary to dismantle the selector fork group ( ⇒ Item 7 (page 147) ) in order to remove and install
selector segments, lock washers and angular contact ball bearings.
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
ce
e
nl
pt
du
freely.
an
itte
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erm
ab
2 - Lock washer
ility
ot p
❑ Always renew
wit
, is n
h re
❑ Removing ⇒ page 148
hole
spec
❑ Installing ⇒ page 148
es, in part or in w
t to the co
3 - Selector fork for 5th and 6th
gears
❑ Adjusting ⇒ page 131
rrectness of i
4 - Bolt, 25 Nm
l purpos
nform
ercia
at
om
io
❑ Qty. 4
n
c
in t
or
do
riv
cum
or
en
ng
t.
yi
❑ Installing ⇒ page 149
Co
Cop py
ht. rig
7 - Selector fork group with se‐
rig ht
py by
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lector plate by c lksw
cted agen
Prote AG.
8 - 1st/2nd gear selector seg‐
ment
❑ Identification
⇒ page 148
❑ After lock washer is in‐
stalled, segment must
still rotate freely
9 - Selector segment for 3rd and 4th gear
❑ Identification ⇒ page 148
❑ After lock washer is installed, segment must still rotate freely
10 - Sliding piece
11 - Spring
12 - Selector fork for reverse gear
13 - Support for reverse gear selector fork
14 - Retaining ring
ce
le
un
pt
an
d
itte
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ab
pe
ility
ot
wit
, is n
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hole
spec
Installing lock washer
es, in part or in w
t to the co
– Press lock washer into groove of selector segment using sock‐
et and spinner handle.
rrectness of i
Note
l purpos
nform
ercia
freely.
m
a
com
ti
-A- Spinner handle with 10 mm socket
on in
r
te o
thi
-B- Vice jaw protectors
s
iva
do
r
rp
cum
fo
t.
yi Co
Cop py
ht. rig
rig ht
Note py by
co Vo
by lksw
cted agen
Prote AG.
When removing and installing angular contact ball bearing, do not
bend selector forks.
Pressing inner race -A- of angular contact ball bearing into outer
race
Inner race must engage in outer race.
G. Volkswag
Selector fork with selector
swa
gen Asegments installed
en AG
does
olk not
yV gu
db Dim. -a- n(mm)
ara
e
ris t ee
ho
ut
1st/2nds agear selector
fork 87.2 … 87.4r ac
o
s
3rd/4th gear selector fork 93.6 … 93.8
ce
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nl
pt
du
an
itte
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
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rp
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m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
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by c lksw
cted agen
Prote AG.
35 – Gears, shafts
1 Input shaft
ce
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nl
pt
du
an
itte
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♦ Pressure plate -VW 402-
erm
ab
ility
ot p
wit
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
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Note
ce
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nl
pt
du
an
itte
♦ When installing new gears, refer to ⇒ Electronic parts catalogue “ETKA” and technical data ⇒ page 1 .
y li
erm
ab
ility
♦ If the position of the tapered roller bearings is affected when parts are exchanged, the input shaft must be
ot p
wit
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
151
by lksw
cted agen
Prote AG.
1. Input shaft
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
6-speed manual gearbox 02S - Edition 07.2009
1 - Clutch housing
2 - Tapered roller bearing outer
race
❑ Pressing out
⇒ page 154
❑ Pressing in
⇒ page 154 AG. Volkswagen AG d
agen oes
lksw not
3 - Tapered roller bearing inner d by
Vo gu
ara
race orise nte
h eo
❑ Pressing off aut ra
s c
⇒ page 154 s
ce
le
un
pt
❑ Pressing on
an
d
⇒ page 154 itte
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erm
ab
ility
4 - Input shaft
ot p
wit
is n
h re
ole,
spec
5 - Gear wheel for 3rd gear
urposes, in part or in wh
❑ Installation position:
t to the co
shoulder faces 4th gear
❑ Pressing off
rrectne
⇒ page 155
❑ Pressing on
s
⇒ page 155
s o
cial p
f i
6 - Retaining ring
nform
mer
❑ Always renew
atio
om
n
c
i
or
n thi
e
sd
va
o
pr
cum
er race and sleeve
r
fo
en
ng
⇒ page 155
t.
yi Co
op py
❑ Pressing on t. C rig
gh ht
⇒ page 155 yri
p by
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by c lksw
❑ Collar faces 3rd gear cted agen
Prote AG.
pt
an
d
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erm
ab
wit
h re
ole,
24 - Thrust washer
t to the co
f inform
❑ Do not interchange with cylinder roller bearing inner race of output shaft.
mer
atio
m
n
c
i
or
sd
a
o
pr
cum
r
en
ng
t.
yi Co
27 - Bolt ⇒ Item 9 (page 104) t. Cop py
rig
gh
❑ Allocation ⇒ page 106
ht
pyri by
Vo
co lksw
❑ Self-locking
by
cted agen
Prote AG.
❑ Always renew
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
ut ra
Pressing in tapered roller bearing outer race ss a c
ce
le
un
pt
an
d
itte
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ab
pe
ility
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wit
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Pressing off gear wheel for 4th gear with tapered roller bearing
and sleeve
AG. Volkswagen AG d
agen oes
olksw not
y V gu
b ara
Pressing off gear wheel for 3rd gear
orise
d
nte
th eo
au ra
ss c
ce
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un
pt
an
d
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectne
Pressing on gear wheel for 3rd gear
Shoulder faces 4th gear
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
Pressing on gear wheel for 4th gear Prote
cted AG.
agen
AG. Volkswagen AG d
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olksw not
y V gu
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rise nte
tho eo
au ra
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pt
an
d
itte
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ab
pe
ility
ot
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
156
cted agen
Prote AG.
Rep. Gr.35 - Gears, shafts
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
6-speed manual gearbox 02S - Edition 07.2009
Deeper notches in both sides of locking collar for 5th and 6th
gears -arrows- from gearbox date 12 06 6
olkswagen AG
en AG. V
Dimension -a- Through
olks
wag gearbox From gearbox
does
not date
(6th gear side)ed by V date 11 06 6 12 06 gu 6
ara
ris nte
ut
ho 1.5 mm 1.8 mm e or
a ac
ss
ce
Dimension -b- Through gearbox From gearbox date
le
un
pt
(5th gear side) date 11 06 6 12 06 6
an
d
itte
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erm
ab
1.5 mm 2.0 mm
ility
ot p
wit
– Allocate locking collar and synchro-hub for 5th and 6th gears
is n
h re
according to ⇒ Electronic parts catalogue “ETKA” .
ole,
spec
urposes, in part or in wh
Due to the deeper notches, the adjustment procedure for 5th and
t to the co
6th gears has been changed:
– Adjusting 5th and 6th gears to gearbox manufacture date
11 06 6 ⇒ page 130 .
rrectne
– Adjusting 5th and 6th gears from gearbox manufacture date
s
12 06 6 ⇒ page 131 .
s o
cial p
f inform
Dismantling and assembling locking collar and synchro-hub for
mer
atio
om
n
1- Spring
c
i
or
n thi
te
sd
2- Locking piece
iva
o
pr
cum
r
3- Synchro-hub
fo
en
ng
t.
yi Co
4- Locking collar Cop py
ht. rig
rig ht
– Slide locking collar over synchro-hub. py by
co Vo
by lksw
cted agen
Deeper notches -arrow A- for locking pieces in synchro-hub and
Prote AG.
notches -arrow B- in locking collar must align.
Assembling locking collar and synchro-hub for 5th and 6th gears
• Locking collar has been pushed over synchro-hub.
– Insert locking pieces in deeper notches -arrows- and install
springs offset 120°. Angled end of spring must locate in hollow
locking piece.
Note
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
Installation position of springs
wit
, is n
h re
– Install springs offset 120°.
hole
spec
– Angled end -A- of spring must locate in hollow locking piece.
es, in part or in w
t to the co
It must be located under shoulder -B- of locking piece.
Bent ends always face away from synchro-hub
rrectness of i
-direction of arrow-.
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nf
ercia
orm
m
atio
om
n in
c
thi
te
sd
iva
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rp
cu
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f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
AG. Volkswagen AG d
agen oes
olksw not
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d b ara
rise nte
tho eo
au ra
ss c
ce
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un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
do
r
♦ Gearbox housing
rp
cum
fo
en
ng
♦ Clutch housing
t.
yi Co
Cop py
t.
♦ Input shaft
rig
gh ht
pyri by
Vo
co
♦ Gear wheel for 4th gear
by lksw
cted agen
Prote AG.
or the
♦ Tapered roller bearing
Adjustment overview ⇒ page 192 .
Requirement:
• Sealing surfaces of clutch and gearbox housings must be free
of sealant.
ce
le
un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Press tapered roller bearing outer race without shim into gear‐
box housing to stop.
rrectness of i
– Install input shaft in clutch housing and set gearbox housing
in place. Tighten hexagon head bolts to 25 Nm and then turn
l purpos
90° further.
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
– Fit measuring appliance and dial gauge in clutch housing. Cop py
t. rig
gh ht
yri
– Before taking any measurements, rotate input shaft to allow p by
co Vo
bearings to settle. Set dial gauge to “0” with 1 mm preload.
by lksw
cted agen
Prote AG.
Note
Note
ce
le
un
pt
Measured value (mm) Thickness (mm)
an
d
itte
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rm
0.671…0.699 0.650
ab
pe
ility
0.700…0.724 0.675
ot
wit
0.725…0.749 0.700
, is n
h re
0.750…0.774 0.725
hole
spec
0.775…0.799 0.750
es, in part or in w
0.800…0.824 0.775
t to the co
0.825…0.849 0.800
0.850…0.874 0.825
rrectness of i
0.875…0.899 0.850
0.900…0.924 0.875
l purpos
0.925…0.949 0.900
0.950…0.974 0.925
nform
ercia
0.975…0.999 0.950
1.000…1.024 0.975
m
a
com
ti
1.025…1.049 1.000
on in
r
te o
1.050…1.074 1.025
thi
s
iva
1.075…1.099 1.050
do
r
1.100…1.124 1.075
rp
cum
fo
en
g
1.125…1.149 1.100
n
t.
yi Co
1.150…1.174 1.125
Cop py
ht. rig
1175…1.199 1.150
rig ht
py by
o Vo
1.200…1.224 1.175
by c lksw
cted agen
1.225…1.249 1.200
Prote AG.
1.250…1.274 1.225
1.275…1.229 1.250
1.300…1.324 1.275
1.325…1.349 1.300
1.350…1.374 1.325
1.375…1.399 1.350
1.400…1.424 1.375
1.425…1.449 1.400
1.450…1.474 1.425
1.475…1.499 1.450
1.500…1.524 1.475
1.525…1.549 1.500
1.550…1.574 1.525
1.575…1.599 1.550
1.600…1.624 1.575
1.625…1.649 1.600
1.650…1.674 1.625
1.675…1.699 1.650
1.700…1.724 1.675
Note
Note
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
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ris nte
ho eo
aut ra
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ce
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nl
pt
du
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itte
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erm
ab
ility
ot p
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
2 Output shaft
ce
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nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
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♦ The output shaft is dismantled as follows: position separating device under 2nd gear synchromeshed gear
⇒ Item 21 (page 168) and press off as described in ⇒ page 170 . Remove retaining ring
⇒ Item 17 (page 168) . Then press off locking collar with synchro-hub for 1st and 2nd gear as described in
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⇒ page 171 .
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♦ When installing new gears or new input shaft, refer to ⇒ Electronic parts catalogue “ETKA” and technical
data ⇒ page 1 .
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⇒ page 192
4 - Small tapered roller bearing
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❑ Removing ⇒ page 169
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⇒ page 170
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5 - Small tapered roller bearing
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18 - Synchro-ring for 2nd gear
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❑ Installation position ⇒ page 174
❑ Renew if scored
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20 - Synchro-ring
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24 - Sleeve for 3rd gear needle bearing.
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❑ Pressing off with synchromeshed gear for 2nd gear ⇒ page 170
❑ Pressing on ⇒ page 174
25 - Needle bearing
❑ For 3rd gear
26 - Synchromeshed gear for 3rd gear
27 - Synchro-ring for 3rd gear
❑ Check for wear ⇒ page 175
28 - Locking collar with synchro-hub for 3rd and 4th gears
❑ Press off with 2nd gear synchromeshed gear ⇒ Item 19 (page 168) and 3rd gear ⇒ Item 24 (page 168)
⇒ page 170 .
❑ Dismantling ⇒ page 175
❑ Assembling locking collar and synchro-hub ⇒ page 175 , ⇒ page 175 and ⇒ page 175
❑ Installation position, locking collar and synchro-hub ⇒ page 176
❑ Pressing on ⇒ page 176
29 - Sleeve
❑ For needle bearing
❑ Press off with 3rd and 4th gear ⇒ Item 28 (page 168) locking collar and synchro-hub ⇒ page 170 .
❑ Pressing on ⇒ page 176
30 - Needle bearing
❑ For 4th gear
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38 - Sleeve
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39 - Gear wheel for 6th gear
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❑ Pull off individually ⇒ page 109
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❑ Pull off together with gearbox housing ⇒ page 115
hole
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40 - Cylindrical roller bearing inner race
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❑ For output shaft
❑ Larger outer diameter from gearbox date 21 08 6
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❑ Allocation ⇒ page 106
❑ Mark before removing
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❑ Self-locking
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Pressing off 3rd and 4th gear synchro-hub and locking collar, 2nd,
3rd and 4th gear synchromeshed gears with sleeve for gearbox
housing needle bearing
A - Splitter, 22 … 115 mm , e.g. -Kukko 17/2-
B - Hexagon bolt M10 x 20, 17 mm AF
Note
Support splitter so that the 1st and 2nd gear locking collar is not
pulled off at the same time.
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Pulling off large tapered roller bearing inner race
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Checking 1st and 2nd gear synchro-ring
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– Press synchro-ring, outer
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Dismantling and assembling locking collar and synchro-hub for
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Allocate locking pieces according to ⇒ Electronic parts catalogue
“ETKA” .
Collar is equally wide on both sides of synchro-hub.
The collar has a chamfer on one side -arrow B-.
Chamfer on collar of synchro-hub and outer teeth of locking collar
-arrow A- face in same direction after assembly.
Notches -arrow C- in synchro-hub and sliding collar for locking
pieces must align.
Assembly of 1st and 2nd gear locking collar and synchro-hub with
hollow locking pieces
• Locking collar has been pushed over synchro-hub.
– Insert locking pieces and install springs offset 120°. Angled
end of spring must locate in hollow locking piece.
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– Insert locking pieces and install springs offset 120°. Springs
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Installation position of locking collar with synchro-hub for 1st and
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Teeth of locking collar -arrow- face splines for 3rd and 4th gear
synchro-hub -A-.
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Pressing on locking collar and synchro-hub for 1st and 2nd gears
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Turn synchro-ring so that grooves align with locking pieces.
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3rd gear 1.0...1.7 mm 0.5 mm
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4th gear 1.0...1.7 mm
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Dismantling and assembling 3rd and 4th gear locking collar and
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1 - Spring
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Installation with solid locking pieces ⇒ page 175
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– Slide locking collar over synchro-hub.
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Assembly of 3rd and 4th gear locking collar and synchro-hub with
hollow locking pieces
Locking collar has been pushed over synchro-hub.
– Insert locking pieces and install springs offset 120°. Angled
end of spring must locate in hollow locking piece.
Assembly of 3rd and 4th gear locking collar and synchro-hub with
solid locking pieces
• Locking collar has been pushed over synchro-hub.
– Insert locking pieces and install springs offset 120°. Springs
must seat with angled ends in front of locking pieces
-arrows-.
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Pressing on synchro-hub with locking collar for 3rd and 4th gears
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Pressing on sleeve for 4th gear needle bearing t. C rig
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♦ Torque wrench -
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– Press small tapered roller bearing outer race together with a
0.65 mm thick shim into clutch housing to stop ⇒ page 170 .
– Insert output shaft and tighten nuts for bearing support to 25
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Nm, then turn 90° further.
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Example:
Installed shim 0.65 mm
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Note
After dismantling, always renew needle bearing in clutch housing and reverse shaft support.
1 - Clutch housing
2 - Needle bearing
❑ Pulling out ⇒ page 182
❑ Pressing in
⇒ page 183
3 - Reverse gear wheel
4 - Retaining ring
❑ Always renew after re‐
moving.
❑ Carefully fit new retain‐
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7 - Needle bearing
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❑ Pressing out
⇒ page 183
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❑ Pressing in
⇒ page 183
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⇒ page 115
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– Remove lower part of front left wheel housing liner ⇒ General
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body repairs, exterior; Rep. Gr. 66 ; Wheel housing liner .
– Turn steering to left lock.
– Disconnect drive shaft from flange shaft ⇒ Running gear,
axles, steering; Rep. Gr. 40 ; Repairing drive shaft; Removing
and installing drive shafts .
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– Pull out flange shaft oil seal using multipurpose tool -VW 771-
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Seal -1- and sleeve -2- are two parts. Identification: notches along
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spec
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Renew seal and sleeve together ⇒ page 189 .
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sleeve for right flange shaft)
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1.3.1 Removing
– Remove noise insulation ⇒ General body repairs, exterior;
Rep. Gr. 50 ; Noise insulation .
– Turn steering to right to full lock.
– Remove drive shaft heat shield from engine, if fitted.
– Disconnect drive shaft -1- from flange shaft.
– Raise drive shaft as high as possible and secure. Take care
not to damage paint on drive shaft in the process.
– Place drip tray under gearbox and engine.
– Unbolt turbocharger oil return line from engine -arrow- ⇒ Rep.
Gr. 21 ; Charge air system for turbocharger; Removing and
installing turbocharger with ancillaries . wage
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– Remove flange shaft securing bolt by screwing two bolts into
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♦ Replace sleeve if damaged ⇒ page 136 .
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1.3.2 Installing
– Drive in new seal to stop, being careful not to cant seal.
– Half-fill space between sealing lip and dust lip with sealing
grease -G 052 128 A1- .
– Insert flange shaft.
– Secure flange shaft with countersunk bolt.
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– Check gear oil ⇒ page 99 .
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1.4 Renewing seal and sleeve together (one-piece seal and sleeve for right
flange shaft)
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1.4.1 Removing
– Remove noise insulation ⇒ General body repairs, exterior;
Rep. Gr. 50 ; Noise insulation .
– Turn steering to right to full lock.
– Remove drive shaft heat shield from engine, if fitted.
– Disconnect drive shaft -1- from flange shaft.
– Raise drive shaft as high as possible and secure. Take care
not to damage paint on drive shaft in the process.
– Place drip tray under gearbox and engine.
– Unbolt turbocharger oil return line from engine -arrow- ⇒ Rep.
Gr. 21 ; Charge air system for turbocharger; Removing and
installing turbocharger with ancillaries .
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1.4.2 Installing
– Clean seat for seal in gearbox.
– Pull in seal and sleeve together.
A - Screw spindle of assembly tool -3066- into threaded piece of
differential.
B - Nut M12
– Pull in seal with sleeve to stop using thrust piece -T10148- by
turning nut -B-.
– Half-fill space between sealing lip and dust lip with sealing
grease -G 052 128 A1- .
– Insert flange shaft.
– Secure flange shaft with countersunk bolt.
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– Install drive shaft heat shield, if present, on engine ⇒ Running
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– Check gear oil ⇒ page 99 .
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Gr. 50 ; Noise insulation .
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Flange shaft to gearbox (countersunk bolt)
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2 Adjustment overview
Note
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⇒ page 158 ⇒ page 176 ⇒ page 200
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Output shaft x
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Input shaft tapered roller bearing x
Tapered roller bearing for output x
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shaft
Tapered roller bearing for differen‐ x
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Gear wheel for 4th gear x
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♦ Adapter -V.A.G 1582/3-
♦ Press tool -VW 412-
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♦ Pressure plate -VW 401-
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3. Differential 193
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
6-speed manual gearbox 02S - Edition 07.2009
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♦ If tapered roller bearings, differential cage, gearbox housing or clutch housing are renewed, adjust differ‐
hole
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1 - Gearbox housing
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2 - Shim
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❑ Determining thickness
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⇒ page 200
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⇒ page 197
5 - Differential cage
❑ With final drive gear
❑ Differential cage adap‐
ted to one-piece thrust
washer ⇒ page 199
❑ Allocation ⇒ Electronic
parts catalogue “ETKA”
6 - Tapered roller bearing inner
race
❑ Pulling off ⇒ page 197
❑ Pressing on
⇒ page 197
7 - Tapered roller bearing outer
race
❑ Pressing out
⇒ page 196
❑ Pressing in
⇒ page 197
8 - Clutch housing
9 - Sleeve
❑ To support oil seal ⇒ Item 10 (page 195) .
❑ Removing and installing ⇒ page 132
10 - Seal
❑ Renewing oil seal for left flange shaft with gearbox installed ⇒ page 184
❑ Renewing seal for right flange shaft with gearbox installed (two-part seal and sleeve for right flange shaft)
⇒ page 186
11 - One-piece seal and sleeve
❑ If seal is damaged, renew seal and sleeve together ⇒ page 189
3. Differential 195
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
6-speed manual gearbox 02S - Edition 07.2009
12 - Countersunk bolt, 25 Nm
❑ Screw into threaded piece ⇒ Item 20 (page 196)
13 - Flange shaft
❑ Removing and installing ⇒ page 184
14 - Compression spring for flange shaft
15 - Thrust washer
❑ Installation position ⇒ page 200
16 - Tapered ring
❑ With grooves to engage in thrust washer
❑ Installation position: taper towards differential cage
17 - Retaining ring
❑ Holds tapered ring, thrust washer and spring in position when flange shaft is removed
18 - One-piece thrust washer
❑ Coat with gear oil when installing
❑ One-piece thrust washer has shoulder in some gearboxes ⇒ page 199
19 - Sun wheel
❑ Installing ⇒ page 199
20 - Threaded piece
❑ Installing ⇒ page 199
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❑ Installing ⇒ page 199 ut
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❑ For securing differential pinion pin
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24 - Sun wheel
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Pulling off tapered roller bearing inner races
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– Before fitting extractor, position thrust plate -40 - 105- on dif‐
ferential cage.
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Both tapered roller bearing inner races are pulled off the differ‐
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Pulling outer race for tapered roller bearing out of gearbox hous‐
ing
A - Counter support , e.g. -Kukko 22/2-
B - Internal puller, 46 … 58 mm , e.g. -Kukko 21/7-
3. Differential 197
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
6-speed manual gearbox 02S - AEdition 07.2009
G. Volkswagen A
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Pressing tapered roller bearinged
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– Fit shim under outer au race.
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– Support gearbox housing directly below bearing mounting us‐
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– Check hole for spring pin in differential cage.
The hole in the differential cage was modified for the longer spring
pin.
Hole Length of spring pin (mm)
-A- 28.5 (short spring pin)
-A- and -B- 36.0 (long spring pin)
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– Align hole in differential pinion pin with hole in differential cage.
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– Drive in new spring pin with drift -1- until dimension -a- =
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3.0 mm is attained.
• The spring pin must not come in contact with gears with dif‐
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– Lubricate one-piece thrust washer with gear oil and install.
– Install one-piece thrust washer so that it engages in groove
-B- in differential cage.
3. Differential 199
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♦ Universal dial gauge brack‐
et -VW 387-
♦ End dimension plate -
VW 385/17-
♦ Press tool -VW 407-
♦ Thrust plate -30 - 205-
♦ Torque wrench -
V.A.G 1331-
♦ Internal puller -1 - Kukko
21/7-
♦ Counter support -4 - Kukko
22/2-
♦ Dial gauge
Note
Inner and outer tapered roller bearing races are paired. Do not
interchange!
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3. Differential 201
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
6-speed manual gearbox 02S - Edition 07.2009
Note
pt
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correct shim (in example 0.95 mm) again ⇒ page 198 and bolt
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