VW Amarok, 6-Speed Manual Gearbox

Service
List of Workshop Manual Repair GroupsList of Workshop Manual

Repair GroupsList of Workshop Manual Repair Groups
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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safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
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matter of course, be observed.
All rights reserved.

No reproduction without prior agreement from publisher.
Copyright © 2010 Volkswagen AG, Wolfsburg MEX5R006920

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤
6-speed manual gearbox 02Q - Edition 06.2010
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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12 Rep. gr.30 - Clutch

2 Repairing clutch mechanism
2.1 Overview
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♦ When reconnecting battery, refer to ⇒ Electrical system; Rep. gr. 27 ; Disconnecting and connecting 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
spec
cluster ⇒ page 14
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II - Assembly overview - hy‐
draulics (LHD) ⇒ page 34
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III - Assembly overview - hy‐
draulics (RHD) ⇒ page 36
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2. Repairing clutch mechanism 13

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1 - Bulkhead ss
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2 - Seal
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❑ Between mounting
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bracket and bulkhead
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❑ Self-adhesive
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❑ Bond to mounting
bracket
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3 - Mounting bracket
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❑ For mounting clutch

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❑ Is provided with damp‐
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❑ Removing and installing

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5 - Over-centre spring
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6 - Bearing bush
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7 - Pivot pin
8 - Clutch pedal
⇒ page 19
9 - Retainer
❑ To remove and install,
separate master cylin‐
der from clutch pedal
⇒ page 19
10 - Seal
❑ Always renew
❑ Between master cylinder and mounting bracket
11 - Master cylinder
❑ Removing and installing after removal of mounting bracket ⇒ page 29
12 - Clutch position sender -G476-
❑ Removing and installing ⇒ page 30
❑ 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 35
15 - Hexagon nut, 25 Nm
❑ Self-locking

❑ Qty. 3
❑ For mounting bracket on bulkhead
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16 - Hexagond bnut,
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2.3 Removing and installing over-centre
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spring
Special tools and workshop equipment required
♦ Release tool -T10178-
2.3.1 Removing
Vehicles with knee airbag
Note
The installation location of the knee airbag is above the pedal

cluster.
– First check whether a coded radio is fitted. If so, obtain anti-

theft code.

– With ignition switched off, disconnect battery ⇒ Electrical sys‐

tem; Rep. gr. 27 ; Disconnecting and connecting battery .
Continuation for all
– Push driver seat as far back as possible and put steering wheel
in highest position.
– Remove driver side footwell cover and driver side left trim
panel ⇒ General body repairs, interior; Rep. gr. 68 ; Com‐
partments, covers and trim panels .
– Remove bracket for knee airbag together with crash bar ⇒
Interior equipment; Rep. gr. 69 ; Airbag; Removing and in‐
stalling knee airbag bracket .
Vehicles without knee airbag
– Remove crash bar -1- from in front of clutch pedal by removing
nuts -2-.
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– If fitted, remove damping -arrow- from lower area of clutch spec

pedal mounting bracket.
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– To do this, remove lock washers -A- for damping.

– Pull off damping.

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– Push damping upwards in area of upper securing nut -1-
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– Unbolt clutch pedal -1- from mounting bracket -3- by removing
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nut -2- and pulling out bolt -5-.
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Note
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The clutch pedal remains hooked to operating rod of master cyl‐
inder.
– Swing clutch pedal down slightly and remove over-centre

spring -4- from mounting bracket.
2.3.2 Installing
Install in the reverse order of removal, observing the following:
Note
Renew self-locking nuts.

– Insert over-centre spring -2- in mounting bracket from above

while holding end of spring with assembly tool -T10178- in in‐
stallation position.
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• Receptacleo-arrow-
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– Insert tip -A- of clutch pedal in bearing recess of over-centre
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– Depress clutch pedal slightly, push bolt through and tighten
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self-locking nut to specified torque ⇒ page 19 .

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– Return it to installation position.

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– Install crash bar -1- in front of clutch pedal by screwing on

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– Install bracket for knee airbag bar ⇒ Inte‐ together
ss with crash
rior equipment; Rep. gr. 69 ; Airbag; Removing and installing
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knee airbag bracket .
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– Install driver side footwell cover and driver side left trim panel
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⇒ General body repairs, interior; Rep. gr. 68 ; Compartments, ole,
covers and trim panels .
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– If disconnected, connect battery ⇒ Electrical system; Rep. gr.
27 ; Removing and installing battery .
rrectne
2.3.3 Specified torques
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Clutch pedal to mounting bracket 25
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2.4 Removing and installing clutch pedal
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♦ Pliers -T10005- p by
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♦ Release tool -T10178-

2.4.1 Removing
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– With ignition switched off, disconnect battery earth strap ⇒
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Electrical system; Rep. gr. 27 ; Disconnecting and connecting
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– Push driver seat as far back as possible and put steering wheel
spec
in highest position.
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– If fitted, remove damping -arrow- from lower area of clutch


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– To do this, bremove
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lock washers -A- for damping.
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– Pull off
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– Unbolt clutch pedal -1- from mounting bracket -3- by removing

nut -2- and pulling out bolt -5-.
– Swing clutch pedal forward slightly and remove over-centre
spring -4- from mounting bracket.

– Release clutch pedal from master cylinder with pliers -

T10005- .
– Remove clutch pedal.
2.4.2 Installing
Note
Renew self-locking nuts.
– Attach retainer -2- to master cylinder operating rod -1-.

– Press retainer into notch in clutch pedal -3- until it can be heard
to engage.
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– Insert over-centre spring -2- in mounting bracket from above lkswagen A oes
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Rep. gr.30 - Clutch
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• Receptacle -arrow- for tip -A- of clutch pedal must stand ver‐
tically.
– Insert tip -A- 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 23 .
Some cars have damping -arrow- on the mounting bracket/clutch

pedal.
– Return it to installation position.
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– Install crash bar -1- in front of clutch pedal by screwing on and
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tightening nuts -2-.
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– Install bracket for knee airbag together with crash bar ⇒ Inte‐ f inform
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⇒ General body repairs, interior; Rep. gr. 68 ; Compartments,

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Component Nm
Clutch pedal to mounting bracket 25
♦ Renew self-locking nuts

bracket
2.5 Removing and installing mounting

bracket

♦ Hose clamps -3094-
♦ Hose clip pliers -VAS 6362-
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♦ Sealing tool
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2.5.1 Removing
o
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LHD
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– Remove complete air filter housing if it is near battery ⇒ Rep.
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gr. 23 ; Repairing diesel direct injection system or ⇒ Rep. gr.
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24 ; Repairing injection system .
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– Remove battery and battery tray ⇒ Electrical system; Rep. gr.
27 ; Battery; Removing and installing battery .

Note
♦ During the following work, ensure that no brake fluid lands on

longitudinal member or gearbox. If this does happen, clean the
affected areas thoroughly.
♦ Place a lint-free cloth under the master cylinder.
– Clamp off supply hose to master cylinder using hose clamp to

25 mm ∅ -3094- .
– If necessary, loosen spring-type clip -3- with hose clip pliers -

VAS 6362- and pull supply hose off master cylinder.
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– In addition, for disconnecting, you can close it with the sealing
tool -T10249/1- (⇒ figure above).
– Release securing clip -2- using screwdriver
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and pull pipe/hose line or plastic
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– Unclip clutch position rissender -G476- from master cylinder
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-arrow- and removeu thowith electrical connector attached -4-. eo
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When performing work in the footwell, put cloths on the carpet to

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nuts -2-.
– If fitted, remove damping -arrow- from lower area of clutch

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– To do this, remove lock washers -A- for damping.

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– Pull off damping.

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– Remove nuts -2-.
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– Remove mounting bracket -1-.

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2.5.2 Installing
Note
♦ Renew self-locking nuts.

♦ Renew hose clips.
♦ Allocate all components according to ⇒ Electronic parts cata‐
logue „ETKA“ .

Some cars have damping -arrow- on the clutch pedal mounting

bracket.
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– Install crash bar -1- in front of clutch pedal by screwing on and
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tightening nuts -2-.
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– Install bracket for knee airbag together with crash bar ⇒ Inte‐
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– Push pipe/hose line or plastic line -1- with seal -2- onto con‐
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nection of master cylinder -4- until securing clip -3- engages by c lksw
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– 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 37 .
LHD
– Install battery tray and battery ⇒ Electrical system; Rep. gr.
27 ; Removing and installing battery .
– Reconnect battery and perform work required after connecting
battery ⇒ Electrical system; Rep. gr. 27 ; Disconnecting and
connecting battery .

Component Nm
Mounting bracket to body 25
♦ Renew self-locking nuts.

bracket

2.6 Removing and installing master cylinder

♦ Pliers -T10005-
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2.6.1 Removing
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– Remove mounting bracket ⇒ page 23 .
rrectness of i
– Release retainer for master cylinder operating rod using pliers
-T10005- .
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– Insert spacer -A- between clutch pedal and stop and press
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clutch pedal to spacer.
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♦ Length of spacer = about 40 mm (e.g. 1/2" socket).
– Release securing bar -B- and pull master cylinder out of

mounting bracket -arrow 1- and -arrow 2-.
2.6.2 Installing
• Move clutch pedal to rest position at stop.

– Attach retainer -2- to master cylinder operating rod -1-.
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– Insert spacer -A- between clutch pedal and stop and press
pe
ility
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♦ Length of spacer = about 40 mm (e.g. 1/2" socket).
hole
spec
es, in part or in w
– Engage master cylinder in mounting bracket -arrow 1- and
t to the co
-arrow 2-.
rrectness of i
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– Press master cylinder operating rod -1- in copy Vo
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-direction of arrow- until retainer -2- engages audibly in clutch cted agen
Prote AG.
pedal.
– Install mounting bracket ⇒ page 23 .
2.7 Removing and installing clutch position

sender -G476-

♦ Hose clamps -3094-
2.7.1 Removing
LHD
theft code.
– With ignition switched off, disconnect battery earth strap .⇒Volkswage
Electrical system; Rep. gr. 27 ; Disconnecting and waconnecting
gen AG n AG d
oes
battery . Volks not
gu
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– Remove complete air filter housing if itthois
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or
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ss au
system or ⇒ Rep. gr. ac
ce
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un
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– Remove battery and battery tray ⇒ Electrical system; Rep. gr.

itte
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27 ; Battery; Removing and installing battery .
rm
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pe
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Right-hand drive
ot
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– In vehicles with particle filter, remove shielding -A- from parti‐
hole
spec
cle filter ⇒ Rep. gr. 26 ; Parts of exhaust system; Assembly
es, in part or in w
overview - front exhaust pipe with particle filter .
t to the co
An insulation mat is installed in conjunction with some engines.
rrectness of i
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nform
mercia
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tion in
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thi
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– Remove heat shield from pipe/hose line -arrows-.

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Cop py
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rig ht
py by
co Vo
by lksw
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If a pipe/hose line -1- with a round component is installed directly
erm
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beneath the master cylinder, the pipe/hose line must be removed.
ility
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During the following work, ensure that no brake fluid lands on
rrectne
– Place a lint-free cloth under the master cylinder.
ss o
cial p
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mer
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– Clamp off supply hose to master cylinder using hose clamp to
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cardiagn.com
– Release securing clip -2- with a screwdriver or a pointed object
and pull out of master cylinder to stop.
– Pull pipe/hose line -1- or plastic line out from master cylinder
and seal.
– Disconnect electrical connector -4-.
– Unclip clutch position sender -G476- from master cylinder
-arrow- and remove.
Note
Disregard item -3-.
2.7.2 Installing

Note
♦ Renew hose clips.

♦ Allocate all components according to ⇒ Electronic parts cata‐
logue „ETKA“ .
If the pipe/hose line was removed

– Push pipe/hose line -1- or plastic line with seal -2- onto con‐
nection of master cylinder -4- until securing clip -3- engages
audibly.
– Test pipe/hose line by tugging on it.
Right-hand drive
cardiagn.com
– In vehicles with particle filter, install shielding -A- on particle
filter ⇒ Rep. gr. 26 ; Parts of exhaust system; Assembly over‐
view - front exhaust pipe with particle filter . agen
AG. Volkswagen AG d
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d by ua
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– Install battery tray and battery ⇒ Electrical usystem;
tho Rep. gr. or
27 ; Removing and installing battery . ss a ac
ce
le
un
– Remove complete air filter housing if it is near battery ⇒ Rep. pt

an
d

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– Reconnect battery and perform work required after connecting

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battery ⇒ Electrical system; Rep. gr. 27 ; Disconnecting and

h re
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connecting battery .
spec
es, in part or in w
t to the co
rrectness of i
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nform
mercia
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tion in
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Cop py
t. rig
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co lksw
by
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2.8 Assembly overview - hydraulics (LHD)
1 - Brake fluid reservoir

2 - Spring-type clip
❑ Not fitted in all vehicles
3 - Supply hose
❑ Rubber
❑ From 12 05, plastic
⇒ page 35
4 - Master cylinder
⇒ page 29
5 - Clip
❑ Pull out clip to stop to re‐
move and install pipe/
hose line or plastic line
❑ Pulled out to side on
some master cylinders
6 - Seal / O-ring
❑ Pull onto line connection
❑ Insert with brake fluid
cardiagn.com
❑ Seals/O-rings are adap‐
ted to configuration of
line connection
⇒ page 35
❑ Allocation ⇒ Electronic
AG. Volkswagen AG d
parts catalogue „ETKA“ksw
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7 - Retainer ed
b ran
oris tee
❑ To removeautand install,
h or
ac
separatessmaster cylin‐
ce
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un
pt
⇒ page 19
an
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8 - Clutch pedal
pe
ility
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wit
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⇒ page 19
h re
hole
spec
es, in part or in w
t to the co
❑ Self-locking
❑ Qty. 3
rrectness of i
❑ Always renew
l purpos
10 - Pipe/hose line
❑ Allocation ⇒ Electronic parts catalogue „ETKA“
nform
ercia
❑ To remove, remove battery and battery tray ⇒ Electrical system; Rep. gr. 27 ; Removing and installing
m
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com
battery .
ion in
r

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11 - Bracket
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❑ For pipe/hose line ⇒ Item 10 (page 34)

en
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❑ Secured to body t. Cop py
rig
gh
❑ Hidden by engine/gearbox mounting
ht
pyri by
Vo
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by c lksw
❑ Retainer identification ⇒ page 36 Prote
cted AG.
agen

6-speed manual
en AG. V
gearbox 02Q
olkswagen AG
- Edition 06.2010
ag does
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12 - Plastic line ed
by ara
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❑ To remove, remove battery and batterysstray ⇒ Electrical system; Rep. gr. 27 ; Removing and installing
ce
le
battery .
un
pt
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erm
ab
13 - Bracket
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❑ For plastic line ⇒ Item 12 (page 34)
h re
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❑ Secured to body
spec
t to the co
❑ Retainer identification ⇒ page 36
14 - Seal / O-ring
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❑ Seals/O-rings are adapted to configuration of line connection ⇒ page 35
cial p
f inform
mer
atio
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15 - Breather
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16 - Clip
i
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❑ Pull out clip to stop to remove and install pipe/hose line or plastic line or bleeder
en
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17 - Bleeder valve
py
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t. C rig
gh ht
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❑ Bleeding clutch system ⇒ page 37 p by
o Vo
by c lksw
cted agen
18 - Dust cap Prote AG.
19 - Slave cylinder
❑ Can be renewed only with gearbox removed
20 - Gearbox
Seals and O-rings for pipe/hose line or plastic line

Item Material of line connection
1 Line connection with circumferential groove
-arrow 1-
2 Line connection with shoulder -arrow 2-
Supply hose -1- of plastic

• The seals -2- must be located in supply hose housing.

Retainer identification
Dim. „a“ mm Line configuration
8 Plastic line
6 Pipe/hose line
2.9 Assembly overview - hydraulics (RHD)
1 - Brake fluid reservoir

2 - Seal
AG. Volkswagen AG d
❑ For plastic supply hose olksw
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❑ The seals must be loca‐ ed by ara
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ted in supply hose hor eo
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3 - Supply hose ss
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❑ Made of plastic
pt
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itte
⇒ page 35
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❑ May be made of rubber
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4 - Master cylinder
h re
hole
spec
⇒ page 29
es, in part or in w
t to the co
5 - Clip
❑ Pull clip out to stop to re‐
rrectness of i
move or install pipe line
❑ Pulled out to side on
l purpos
some master cylinders

6 - Seal / O-ring
nf
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or
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m
atio
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❑ Seals/O-rings are adap‐

thi
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sd
ted to configuration of
iva
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line connection
rp
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o
⇒ page 35
f
en
ng
t.
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❑ Allocation ⇒ Electronic Cop py
t. rig
parts catalogue „ETKA“ opyri
gh by
Vo
ht
by c
7 - Retainer
lksw
cted agen
Prote AG.
❑ To remove and install,
separate master cylin‐
⇒ page 19
8 - Clutch pedal
❑ Self-locking
❑ Qty. 3
❑ Always renew

10 - Bracket olks
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❑ Secured to body by ua
ed ran
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au
tho
or
ac
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11 - Pipe line
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❑ Pipe and hose/pipe line ⇒ Item 13 (page 37) may be in one piece
an
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12 - Seal / O-ring
t to the co
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13 - Pipe/hose line
nform
ercia
❑ Pipe ⇒ Item 11 (page 37) and hose/pipe line may be in one piece
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14 - Retainer
Co
Cop py
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❑ Secured to body
ht ht
rig by
copy Vo
lksw
15 - Seal / O-ring
by
cted agen
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16 - Clip
❑ Pull out clip to stop to remove and install pipe/hose line or bleeder.
17 - Bleeder valve
❑ Bleeding clutch system ⇒ page 37
18 - Dust cap
19 - Bleeder connection
20 - Seal / O-ring
21 - Slave cylinder
❑ Can be renewed only with gearbox removed
22 - Gearbox
2.10 Bleeding clutch system


♦ Brake filling and bleeding equipment -VAS 5234- or
♦ Brake filling and bleeding equipment -V.A.G 1869-
cardiagn.com
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Prefilling system is not necessary!
d ran
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ss
Specifications for brake fluid ⇒ Brake systems; Rep. gr. 47 ;
ce
e
nl
Bleeding brake system .

pt
du
an
itte
– Remove complete air filter housing if it is near battery ⇒ Rep. y li

erm
gr. 23 ; Repairing diesel direct injection system or ⇒ Rep. gr. ab

ility
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24 ; Repairing injection system . wit

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– Connect brake filling and bleeding equipment -VAS 5234- or
hole
spec
-V.A.G 1869- .
es, in part or in w
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
– Connect bleeder hose -A- to bleeder -arrow-.

nf
ercia
– Pressurise system to 2 bar.

orm
m
– Open bleeder valve about 1/4 turn.

atio
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– Move clutch pedal 15 to 20 times quickly by hand from stop to

thi
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stop.
sd
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– Close bleeder valve.

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– After completing bleeding procedure, when the pressure of . Cop py
2 bar is released, operate clutch pedal ten more times by foot.
t rig
gh ht
pyri by
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co
by lksw
cted agen
Prote
AG.

3 Repairing clutch release mechanism

♦ Torque wrench -V.A.G 1331-
lkswage es n
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ab
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1 - Gearbox
h re
ole,
2 - Input shaft seal
spec
❑ Renewing ⇒ page 43
t to the co
3 - Slave cylinder with clutch
release bearing
rrectne
cardiagn.com
❑ Are one unit and can be
renewed together only
ss
❑ Do not wash out bear‐
o
cial p
f
ing; wipe only
inform
mer
❑ Renew noisy bearings
atio
together with slave cyl‐
om
n
inder
c
i
or
n thi
e
❑ For some slave cylin‐

t
sd
va
ders, divided supply line

i
o
pr
cum
r
⇒ page 40
fo
en
ng
t.
yi
Co
op py
⇒ page 40 t. C rig
gh ht
pyri by
Vo
4 - Bolt
co lksw
by
cted agen
Prote
❑ Qty. 3
AG.
❑ Always renew
❑ Without locking fluid
12 Nm (only slave cylin‐
ders with metal housing)
❑ With locking fluid 15 Nm
(for plastic slave cylin‐
ders)
❑ Carefully tighten diago‐
nally in small steps so
that the bolting eyes of
the slave cylinder do not
break off
5 - O-ring
3. Repairing clutch release mechanism 39

Slave cylinder -A- with divided supply line

Volkswagen AG
The supply line for some slave cylinders is divided in the area agof
en AG. does
ksw
the -arrow-. by
Vol not
gu
ara
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se nte
Allocation ⇒ Electronic parts catalogue „ETKA“ thori eo
u a 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
3.1 Removing pipe/hose line and bleeder
from and installing on slave cylinder
rrectness of i
Removing pipe/hose line or plastic line from and installing on
bleeder
l purpos
– To remove, release securing clip -2- with a screwdriver or

pointed object and pull pipe/hose line or plastic line -4- off
nf
ercia
o
bleeder -1-.
rm
m
atio
m
– To install pipe/hose line or plastic line, push onto bleeder con‐

o
n in
c
nection with O-ring -3- until securing clip engages audibly.

or
thi
te
sd
a

iv
cardiagn.com
r
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f
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ng
t.
Removing bleeder from and installing on slave cylinder
yi Co
Cop py
ht. rig
– To remove, release securing clip -2- with a screwdriver or rig ht
py by
pointed object and pull bleeder -4- off slave cylinder -1-. co Vo
by lksw
cted agen
Prote AG.
– To install, check O-ring -3- on slave cylinder. Press bleeder
onto slave cylinder connection until securing clip engages au‐
dibly.
– Check by pulling on bleeder.
3.2 Removing and installing slave cylinder

with release bearing
Note
Slave cylinder and release bearing are a single component and

can be renewed only together.
Removing
• Remove gearbox.

– Release securing clip -2- with a screwdriver or pointed object

and pull bleeder -4- off slave cylinder -1-.
– Remove bolts -arrows-.

– Remove slave cylinder together with release bearing -A-.
Installing
G. Volkswagen
Install in the reverse order of removal,
lksw
agenobserving the A
A
following:
G do
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• The securing bolts for isthe
ed slave cylinder must be tightened
b ran
tee
only in small stages.
ut
hor
or
sa ac
Otherwise, the tabs swith the bolt holes may break off.
ce
le
un
pt
– Bolt on slave cylinder with release bearing
an
d
itte
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⇒ Item 4 (page 39) .
erm
ab
cardiagn.com
ility
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wit
is n
h re
ole,
– Check O-ring -3- on slave cylinder for damage.
spec
– Press bleeder -4- onto slave cylinder connection -1- until se‐
curing clip -2- engages audibly. t to the co
– Check by pulling on bleeder.
rrectne
• Install gearbox.
s

s o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
va
3.3 Removing and installing pipe/hose line

i
o
pr
cum
r
fo
or plastic line
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
♦ Hose clamps to 25 mm -3094-
c by lksw
cted agen
Prote AG.

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
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Golf Variant 2007 ➤ ,utGolf
ho Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 eo ➤
ra
a
6-speed manual gearbox
ss 02Q - Edition 06.2010 c
ce
le
un
pt
Removing
an
d
itte
y li
erm
ab
– Remove complete air filter housing ⇒ Rep. gr. 23 ; Repairing
ility
ot p
diesel direct injection system or ⇒ Rep. gr. 24 ; Repairing
wit
injection system . is n
h re
ole,
spec
Note
t to the co
During the following work, ensure that no brake fluid lands on
rrectne
ss o
– Clamp off supply hose to master cylinder using hose clamp
cial p
f in
-3094- .
form
mer
Remove pipe/hose line or plastic line from master cylinder as fol‐
atio
m
lows:
o
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
cardiagn.com
– Release securing clip -3- using screwdriver or pointed object
and pull off line -1- with O-ring -2-.
Caution
Do not depress clutch pedal after removing slave cylinder.
Remove pipe/hose line or plastic line from bleeder as follows:
– Release securing clip -2- using screwdriver or pointed object

and pull line -4- with O-ring -3- off bleeder -1-.
Installing

AG. Volkswagen AG d
agen oes
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d b ara
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utGolf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta
ho
2005 ➤ , Jetta 2011 ➤
eo
ra
a
ss 6-speed manual gearbox 02Q - Edition 06.2010
c
ce
e
nl
pt
du
an
– Push pipe/hose line or plastic line -1- with O-ring -2- onto con‐
itte
y li
nection of master cylinder -4- until securing clip -3- engages
erm
ab
audibly.
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.
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op
– Push line with O-ring -3- onto bleeder connection until secur‐ C py
t. rig
ing clip engages audibly. gh ht
pyri by
Vo
co lksw
by
– Test line by tugging on it. Prote
cted AG.
agen

cardiagn.com
– Install complete air filter housing ⇒ Rep. gr. 23 ; Repairing
diesel direct injection system or ⇒ Rep. gr. 24 ; Repairing
injection system
3.4 Renewing input shaft seal

♦ extractor lever -T20143/1-

♦ Thrust piece -T40008-
AG. Volkswagen AG d
agen oes
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♦ Sealing grease -G 052 128 A1- aut
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Procedure
ce
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un
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an
d
• Remove gearbox.
itte
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erm
ab
– Remove slave cylinder with release bearing ⇒ page 40 .
ility
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wit
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– Lever out seal for input shaft using lever -T20143/1- .
h re
ole,
spec
Note
t to the co
Do not damage running surface of input shaft for oil seal.
cardiagn.com
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n
– Half-fill space between sealing lip and dust lip -arrow- with
thi
te
sd
a
sealing grease -G 052 128 A1- .

iv
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cum
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fo
– Lightly moisten outer circumference of oil seal with gear oil.

en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– Drive seal in flush using thrust piece -T40008- .

– Install slave cylinder with release bearing ⇒ page 40 .
• Install gearbox.

4 Repairing clutch - vehicles with turbo diesel engine
Special tools and workshop

equipment required
♦ Counterhold -3067-
♦ Torque wrench -V.A.G
1331-
♦ Centring mandrel -T10097-
♦ Grease for clutch plate
splines -G 000 100-
AG. Volkswagen AG d
agen oes
olksw not
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d b ara
rise nte
tho eo
au ra
ss c
ce
le
cardiagn.com
un
pt
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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
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nform
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a
com
tion in
r
te o
♦ For engines having a crankshaft of smaller diameter or having

thi
s
iva
needle bearings in the crankshaft - ⇒ page 49 centring man‐

do
r
rp
drel -3176-
um
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
4.1 Determining clutch manufacturer

A clutch manufactured by either „Sachs“ or „LuK“ may be instal‐
led.
The make of the clutch can be determined as follows with the
clutch installed:
4. Repairing clutch - vehicles with turbo diesel engine 45

– Remove noise insulation ⇒ General body repairs, exterior;

Rep. gr. 50 ; Noise insulation .
– Remove noise insulation from engine sump if necessary.
Some notches -arrows- are located in lower region of sump be‐
tween engine -A- and gearbox -B-.
– Check outer contour of flywheel through these notches.
AG. Volkswagen AG d
agen oes
olksw not
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d by ara
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or eo
h
aut ra
ss c
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nl
pt
du
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itte
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erm
ab
– In addition, a small cover plate -A- can be removed -arrows-
ility
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to enable inspection of flywheel's outer contour.
cardiagn.com
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
Round outer contour -arrows- = Sachs clutch = -A-

ion
c
in t
or
– Removing and installing Sachs clutch ⇒ page 47 .

his
ate
do
riv
– Repairing Sachs clutch ⇒ page 50 .

p
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Outer contour with edges -arrows 1- and, in addition, a circum‐

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Rounded outer contour -arrows 1- and a circumferential crease

-arrow 2- = LuK clutch = -B-
– Removing and installing LuK clutch ⇒ page 50 .
– Repairing LuK clutch ⇒ page 53 .
4.2 Removing and installing „Sachs“ clutch

Removing
– Remove gearbox ⇒ page 85 .
– 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.
cardiagn.com
Installing
Note
lkswage es n
♦ Select clutchby V plate and pressure plate according
o ot g
ua to engine
codeorand
ise ⇒ Electronic parts catalogue „ETKA“
d ran
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th or
♦ au
Check whether dowel sleeves for aligning engine and ac gearbox
ss
are fitted in cylinder block and install if necessary.
ce
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♦ If dowel sleeves are not fitted, difficulties shifting gears, clutch

itte
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problems and possible noises from the gearbox (rattling of

erm
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gears which are not engaged) could occur.

ot p
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spec
Installation position of clutch plate

t to the co
• Lettering „Getriebeseite“ and protruding spring cage face

gearbox.
rrectness o
cial p
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mer
atio
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n
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fo
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Cop py
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Checking ends of diaphragm spring

• Wear to half the thickness of the diaphragm spring -arrows- is
permitted. n AG. Volkswagen AG do
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Checking spring connections and riveted connections
es, in part or in w
t to the co
– Check spring connections between pressure plate and cover
for cracks as well as rivet connections for secure seating.
• A pressure plate with damaged spring connections or with
rrectness of i
loose rivet connections -arrows- must be renewed.
l purpos
Note
nform
mercia
♦ Renew clutch plates and pressure plates with damaged or
at
om
i
loose rivet connections.
on
c
in t
or
cardiagn.com
♦ Select clutch plate and pressure plate according to engine
his
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code and ⇒ Electronic parts catalogue „ETKA“ .

p
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♦ Clean input shaft splines and, on used clutch plates, clean hub
en
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splines; remove corrosion and apply only a very thin coat of
Co
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clutch plate spline grease -G 000 100- to splines. Then move
t. rig
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clutch plate to and fro on input shaft until hub moves freely on
p by
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lksw
shaft. Remove excessive grease.
by
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♦ Pressure plates are protected against corrosion and greased.

Clean contact surface only. Otherwise, the service life of the
clutch will be considerably reduced.
♦ Pressure plate contact surface and clutch plate lining must
make full contact with flywheel. Only then insert securing bolts.
– Reverse counterhold tool -3067- for installation.

For engines having a crankshaft of smaller diameter -arrow- or

having an needle bearing -arrow- in the crankshaft
AG. Volkswagen AG d
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Centring clutch disc and removing and installing pressure
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s c
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needle bearing -arrow- in the crankshaft
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Disregard arrows -A- and -B-.
hole
spec
es, in part or in w
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– Push pressure plate onto centralizing pins.
rrectness of i
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– Tighten all bolts evenly by hand until bolt heads contact pres‐
sure plate.
l purpos
– Tighten bolts in small steps diagonally in order not to damage

centring holes of pressure plate and centring pins of dual-
nf
ercia
mass flywheel ⇒ Item 4 (page 50) .
orm
m
atio
– Install gearbox ⇒ page 85 .
om
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4.3 Repairing „Sachs“ clutch
1 - Dual-mass flywheel
⇒ 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
parts catalogue „ETKA“
❑ Renew only together
with pressure plate
⇒ page 47
❑ Installation position
⇒ page 47
3 - Thrust plate
❑ With adjusting mecha‐
nism
cardiagn.com
with clutch plate.
❑ Removing and installing agen
AG. Volkswagen AG d
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⇒ page 47 olksw not
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❑ Check ends of dia‐ rised
nte
phragm spring aut
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⇒ page 48 ss c
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❑ Check spring connec‐

nl
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tions and riveted con‐
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nections ⇒ page 48 .
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4 - M6 bolt, 13 Nm, M7 bolt,
wit
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20 Nm
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spec
es, in part or in w
❑ Loosen or tighten diagonally in small steps

t to the co
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4.4 Removing and installing „LuK“ clutch

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Install in the reverse order of removal, observing the following: ht. Cop py
rig
rig ht
py by
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Note

♦ Check whether dowel sleeves for aligning engine and gearbox

• Lettering „Getriebeseite“ (gearbox side) faces gearbox.

permitted.
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Checking springs connections and riveted connections
s c
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– Check spring connections -arrows A- for damage and riveted

an
d
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connections -arrows B- for secure seating.

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Checking position of adjusting mechanism with new pressure

plates only
• Both edges -A- of the adjuster ring must be located between
the two notches -arrows B-.
• If the adjuster ring takes up a different position in new pressure
plates, the pressure plate and clutch plate are not allowed to
be installed.
• The adjuster ring may take up a position outside the notches
in used clutches.
Note

♦ Renew pressure plate and clutch plate together only.
cardiagn.com
wage
– Reverse counterhold tool -3067- for installation. yV
olks es n
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d b ua
ran
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rm
ab
pe
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wit
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spec
es, in part or in w
t to the co

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thi
s
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t.
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Cop py
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by
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Centring clutch disc and removing and installing pressure plate

for engines having a crankshaft of smaller diameter or having a

lkswage es n
o ot g
byV ua
Disregard arrows -A- and -B-. ir se
d ran
tee
tho
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Continuation for all ss
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ot p
sure plate.
wit
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spec
es, in part or in w
t to the co
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4.5 Repairing „LuK“ clutch
l purpos
nform
ercia

m
⇒ Rep. gr. 13
at
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om
io
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c
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or
pins fit tightly
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grease C py
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2 - Clutch plate
p by
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⇒ page 50
with SAC pressure
plate.
❑ Installation position:
⇒ page 51 .
3 - SAC pressure plate
❑ SAC means „self-ad‐
justing clutch“.
with clutch plate.
⇒ page 50
❑ Check ends of dia‐
phragm spring
⇒ page 51
❑ Check spring connec‐
tions and riveted con‐
nections ⇒ page 51 .
4 - M6 bolt, 13 Nm, M7 bolt, 20 Nm

5 Repairing clutch - vehicles with petrol engine

equipment required
♦ Counterhold -3067-
♦ Centring mandrel -T10097-
1331-
splines -G 000 100-
cardiagn.com
AG. Volkswagen AG d
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♦ For engines having a crankshaft of smaller diameter or having

ole,
spec
needle bearings in the crankshaft - ⇒ page 58 centring man‐

drel -3176-
t to the co
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f inform
mer
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n
c
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Cop py
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pyri by
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Prote AG.

5.1 Repairing clutch
Note
♦ 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.
⇒ Rep. gr. 13
pins fit tightly
grease
2 - Clutch plate
cardiagn.com
AG. Volkswagen AG d
agen
⇒ page 55 Volksw
oes
not
gu
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❑ Renew only together rise
d
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with SAC pressure utho eo
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plate. ss a c
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⇒ page 56 .
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3 - SAC pressure plate
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wit
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hole
spec

es, in part or in w
with clutch plate.

t to the co
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⇒ page 55
l purpos
❑ Check ends of dia‐

phragm spring
nform
ercia
⇒ page 56
m
❑ Checking spring con‐

at
om
io
nections and riveted

n
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r
connections
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⇒ page 56
at
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4 - M6 bolt, 13 Nm, M7 bolt, 20 Nm

f
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t.
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5.2 Removing and installing clutch
agen
Prote AG.
Removing
5. Repairing clutch - vehicles with petrol engine 55


Installing
olkswagen AG
en AG. V
Install in the reverse order of removal, observing
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♦ Check whether dowel sleeves for aligning engine and gearbox
ility
ot p
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spec
es, in part or in w
t to the co
rrectness of i
• Lettering „Getriebeseite“ -arrow- faces gearbox.
l purpos
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o
rm
m
permitted.
atio
om
n in
or c
thi
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t.
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Cop py
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gh ht
pyri by
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co lksw
by
cted agen
Prote AG.
Checking spring connections and riveted connections

– Check spring connections -arrows A- for damage and riveted
connections -arrows B- for secure seating.

Checking position of adjusting mechanism with new pressure

plates only
• Both edges -A- of the adjuster ring must be located between
the two notches -arrows B-.
• If the adjuster ring takes up a different position in new pressure
plates, the pressure plate and clutch plate are not allowed to
be installed.
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• The adjuster ring may take up a position outside the notchesyV
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in used clutches. ise
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♦ Always renew pressure plate and clutch plate together.
h re
ole,
spec
t to the co
♦ If clutch has burnt out, thoroughly clean clutch housing, fly‐
wheel and parts of engine facing gearbox to reduce smell of
burnt linings.
rrectne
s
s o
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form
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– Reverse counterhold tool -3067- for installation.
c by lksw
cted agen
Prote AG.

5. Repairing clutch - vehicles with petrol engine 57

Centring clutch disc and removing and installing pressure plate

for engines having a crankshaft of smaller diameter or having a
Note
Disregard arrows -A- and -B-.

sure plate.
AG. Volkswagen AG d
agen oes
olksw not
cardiagn.com
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nl
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34 – Controls, housing
1 Repairing selector mechanism
1.1 Installation position of selector mechanism

Arrow -A- Gear selection movement
Arrow -B- Gate selection movement
A - Gear selector cable agen

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C - Heat shield aut
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❑ Remove before remov‐
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un
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pt
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1 - Gearbox selector lever
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2 - Relay lever
h re
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spec
t to the co
rrectne
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mer
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c
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t.
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rig ht
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Prote AG.
1. Repairing selector mechanism 59

1.2 Overview of selector mechanism
Note
♦ Note radio code for vehicles with coded radio.

♦ Before working on selector mechanism in engine compartment, disconnect earth strap from battery ⇒ Elec‐
trical system; Rep. gr. 27 ; Disconnecting and connecting battery .
♦ When reconnecting battery, perform work required after connecting battery ⇒ Electrical system; Rep. gr.
27 ; Disconnecting and connecting battery .
♦ To work on selector mechanism in engine compartment, remove complete air filter housing if it is located
over selector mechanism ⇒ Rep. gr. 23 ; Repairing diesel direct injection system or ⇒ Rep. gr. 24 ;
Repairing injection system .
♦ Remove selector mechanism to renew selector cables ⇒ page 78 .
AG. Volkswagen AG d
agen
♦ Do not kink selector cables. Volksw
oes
not
by gu
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rise nte
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I - Removing and installing ss c
gear knob and frame
ce
le
un
pt
⇒ page 62
an
d
itte
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ab
II - Repairing gear lever and
ility
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selector housing (through
wit
10.06) ⇒ page 64
is n
cardiagn.com
h re
ole,
II - Repairing gear lever and
spec
selector housing (from 11.06)
t to the co
⇒ page 66
III - Assembly overview - re‐
moving and installing selector
rrectne
cables ⇒ page 71
ss o
cial p
f inform
mer
atio
om
n
c
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te
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pr
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t.
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Cop py
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Prote AG.
Removing and installing selector mechanism ⇒ page 78

Adjust selector mechanism ⇒ page 82 .
60 Rep. gr.34 - Controls, housing

♦ Hose clip pliers -V.A.G 1275-
cardiagn.com
AG. Volkswagen AG d
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mer
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c
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fo
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t.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
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Prote AG.

1.3 Removing and installing gear knob and frame
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
⇒ page 62
3 - Clamp
❑ For securing gear knob
to gear lever
❑ Secure to gear knob wagen AG. Volkswagen AG does
⇒ Item 2 (page 62)yusing ks not
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❑ Always renew
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4 - Frame for centre console

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❑ In some equipment ver‐

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ab
sions, forms one part to‐

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5 - Noise insulation
es, in part or in w
t to the co
❑ Not fitted in all vehicles

❑ Arrow on noise insula‐
tion points in direction of
rrectness of i
travel
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❑ Locking lugs are ar‐

ranged at varying inter‐
vals
nform
ercia
❑ Therefore it can be installed in only one position

m
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ion
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1.4 Removing and installing gaiter with gear

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knob and noise insulation

um
for
en
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t.
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Cop py
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1.4.1 Removing pyri by
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Prote
– Pull or carefully prise gaiter with frame for centre console up‐
AG.
wards out of centre console -arrows-.
Note
With some equipment variations, the gaiter must be levered off

along the front section.

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Golf Variant 2007se➤ d , Golf Variant 2010 ➤ , Jetta 2005ua➤
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ri tee
utho 6-speed manual gearbox 02Q - Edition
or 06.2010
a ac
ss
– Pull gaiter with frame for centre console upwards, inside out
ce
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nl
pt
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over gear knob.
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ab
– Open clamp -arrow- and pull off gear knob together with gaiter.
ility
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In some versions, the centre console frame remains in the centre
wit
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console.
hole
spec
– If necessary pull off, or carefully lever off, centre console
es, in part or in w
frame.
t to the co
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l purpos
– Pull off noise insulation -1-.
nform
mercia
at
om
ion
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or
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ate
do
priv
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for
en
ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
cardiagn.com
1.4.2 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.
– If necessary, press frame into centre console.
– Then turn gaiter inside out.
The gear knob must be pressed to stop.
– Install gear knob with frame and gaiter and squeeze new
clamp -arrow- together.
– Then press gaiter with frame into centre console or gaiter into
frame.

1.5 Repairing gear lever and selector housing (through 10.06)
Note
Lubricate bearing points and sliding surfaces with grease -G 000 450 02- .
1 - Lock washer
⇒ page 65
2 - Bush
3 - Compression spring AG. Volkswagen AG d
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4 - Bush olksw not
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5 - Torx screw, 5 Nm hor eo
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6 - Cover ss c
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7 - Damping
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8 - Damping
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9 - Ball socket
wit
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10 - Gear lever guide
hole
spec
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es, in part or in w
11 - Damping washer
t to the co
12 - Seal
❑ Between selector hous‐
rrectness of i
ing and underbody

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❑ Self-adhesive
❑ Bond to selector hous‐
ing
nform
mercia
13 - Selector lever
at
om
ion
c
14 - Selector housing
in t
or
his
ate
15 - Bearing bush
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priv
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or
16 - Pivot pin
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en
ng
t.
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op
17 - Guide bush C py
ht. rig
rig ht
18 - Compression spring
py by
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by lksw
cted
❑ Installing ⇒ page 65
agen
Prote AG.
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
24 - Gear selector cable
❑ Removing from and attaching to gear lever guide ⇒ page 65

25 - Lock washer
❑ Always renew
26 - Hexagon nut
❑ M8: 25 Nm
❑ M6: 8 Nm
❑ Qty. 4
27 - Bearing bush
❑ Fits in one position only
28 - Lock washer
❑ Always renew
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Removing and installing gate and gear selectord b cables ua
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– Remove securing clip from gear selector
aut cable -A- and gate or
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selector cable -B-. ss
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securing clip -arrow 2-.
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– Remove gear selector cable -A- from gear lever retainer.
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– Remove gate selector cable -B- from retainer of gate selector
hole
lever.
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Removing and installing securing clip tion in

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– To remove or install securing clip -arrow A-, press spacer bush

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♦ Do not cant spacer bush when pushing down.
♦ Slot in gear lever for securing clip must be visible.
♦ Carefully release tension from spring.
Installing compression spring

– Insert compression spring so that extension -A- lies on top of
pin -arrow-.
– Then pull extension -B- down so that it sits below pin -arrow-.

1.6 Repairing gear lever and selector housing (from 11.06)
Note
♦ Lubricate bearing points and sliding surfaceswwith

agen grease -G 000
AG. Volkswagen AG450
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♦ Dismantling and assembling selectoremechanism
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1 - Base plate
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❑ Bend open tabs to re‐
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2 - Seal
hole
spec
❑ Always renew
es, in part or in w
t to the co
3 - Selector lever
❑ Can be removed and in‐
stalled with gear lever
rrectness of i
guide
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⇒ Item 15 (page 67)

installed
nf
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4 - Damping washer
orm
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❑ Push onto gear lever up
m
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to stop -arrow-
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5 - Securing clip
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❑ Do not damage cables
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when removing
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❑ Always renew
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❑ Lever off gate selector
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lever
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❑ Press onto gate selector

lever inside selector
mechanism
⇒ page 59
7 - Bush
❑ Lever off gear lever
guide
❑ Press onto gear lever
guide inside selector mechanism
❑ Installation position ⇒ page 59
9 - Damping
10 - Ball socket
❑ Will be damaged when removed
❑ Always renew
11 - Bush
12 - Lock washer
13 - Compression spring

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16 - Hexagon nuts
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❑ M8: 25 Nm
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❑ M6: 8 Nm
erm
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❑ Qty. 4
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17 - Seal
h re
hole
spec
❑ Between selector housing and underbody
es, in part or in w
❑ Self-adhesive
t to the co
❑ Bond to selector housing
18 - Selector lever housing
rrectness of i
❑ With compression spring and gate selector lever
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❑ Compression spring and gate selector lever cannot be removed
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1.6.1 Dismantling and assembling selector
om
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mechanism
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thrust piece -T10083- ht. rig
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Dismantling by c lksw
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– Remove selector mechanism ⇒ page 78 .
– Bend open tabs -arrows- of base plate for selector mechanism

using screwdriver and remove base plate; (tabs in front area
of base plate are not illustrated).
– Remove seal from selector housing.
– Remove gear and gate selector cables from selector housing
⇒ page 71 .

– Lift upper end -A- of compression spring over tab of gate se‐
lector lever.
– Use screwdriver to press catches -arrows- of ball socket to‐
wards bearing ball of gear lever guide; break off catches if
necessary.
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– Lever ball socket -A- with gear lever guide -B- out of selector by
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– Then press ball socket off bearing ball of gear lever sguide
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• Please pay attention to guides -A- during the further proce‐
rrectne
dure.
• They must not be broken off.
ss o
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– Lever lower end -arrow 1- of compression spring onto shoulder
form
mer
on gate selector lever as far as stop.
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– Now pull gear lever guide up to stop and pull ball stud out of
n
c
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gate selector lever -arrow 2-.
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– Then turn gear lever guide in -direction of arrow 1-.
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• Pin -arrow 2- must be in notch in selector housing.
Prote AG.
– Then swing out gear lever guide with gear lever in

-direction of arrow 3-.
Assembling
Caution
The lower end of the compression spring (-arrow 1- ⇒ figure

above) can snap off the shoulder of the gate selector lever out
of control during the further procedure.
– Therefore, carefully press it down off shoulder of gate selector

lever.
The ends of the compression spring then become tensioned „di‐
agonally“ with a loud noise.

– Slacken ends -A- and -B- by turning both round to right.

• Ends -A- and -B- must point in opposite directions.
– Fit gear lever guide with gear lever in selector housing.

• Pin -arrow 1- is still located in notch in selector housing.
– Turn gear lever guide in -direction of arrow 2- until ball stud
-A- is located in notch in selector housing.
cardiagn.com
– Place selector housing with gear lever guide into larger recess
-arrow- in thrust piece -T10083- .
Note
To ensure that the selector housing with gear lever guide can be
inserted in the thrust piece , first remove gear lever, if necessary.
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• The gear lever guide must project from the selector housing
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Note
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For clarity of illustration, only part of the gate selector lever is

t to the co
shown.
rrectness of i
– Insert end -A- of compression spring into guide from above.

l purpos
– Pull end -B- of compression spring downwards and insert it

next to guide (in direction of ball joint).
nform
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• Please pay attention to guides (⇒ figure above) during the fur‐

ther procedure.
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• They must not be broken off.

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– Carefully remove selector housing with gear lever guide from

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thrust piece -T10083- .

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– Move gate selector lever back to stop (opposite from mounting

holes for gear and gate selector cable) -arrow 1-.
– Grease ball stud.
– Press ball stud into gate selector lever -arrow 2-.
• Guides -A- and tabs -B- are not allowed to be damaged.
– Place selector housing with gear lever guide into larger recess
-arrow- in thrust piece -T10083- .
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• The gear lever guide must project from the selector housing
hole
spec
up to the stop.
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t to the co
– Lift upper end -A- of compression spring over pin of gate se‐
lector lever
rrectness of i
• Use a new ball socket -B-.

l purpos
– Grease ball socket and bearing ball of gear lever guide.

– Press ball socket onto bearing ball of gear lever guide up to
nform
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stop.
m
– Remove selector housing from thrust piece -T10083- .

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tion in
– Insert lower end -C- of compression spring into guide.

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– Lift upper end -A- of compression spring over pin of gate se‐
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lector lever into guide.

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– Press ball socket into selector housing -arrows-.
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• All locking lugs must clip in. rig ht
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– Attach gear lever, gear selector cable, gate selector cable and cted agen
Prote AG.
base plate ⇒ page 66 .
– Install selector mechanism ⇒ page 78 .

1.7 Assembly overview - removing and installing selector cables
Note
Lubricate bearing points and sliding surfaces with grease -G 000 450 02- .

❑ Connect to cable end-
piece
⇒ page 59
❑ From 11.06, modified
attachment to gear lever
inside selector mecha‐
nism
2 - Gate selector cable
❑ Connect to cable end-
piece
cardiagn.com
⇒ page 59
❑ From 11.06, modified
attachment to gate se‐
lector lever inside selec‐
tor mechanism
3 - Lock washer
❑ Always renew
AG. Volkswagen AG d
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❑ Discontinued in selector Volksw
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⇒ page 66 horis nte
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4 - Lock washer ss c
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❑ Do not damage cables

un
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when removing
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❑ Always renew ab
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5 - Selector housing
, is n
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hole
6 - Hexagon bolt, 20 Nm
spec
es, in part or in w
❑ For cable support bracket

t to the co
❑ Qty. 2
7 - Cable support bracket
rrectness of i
❑ May be made from plastic or metal

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8 - Grommet
❑ Cable support bracket mounting on gearbox
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9 - Spacer
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10 - Nut, 20 Nm
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❑ For cable support bracket

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11 - Cable end-piece
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❑ For gate selector cable to relay lever

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❑ After installing, adjust selector mechanism ⇒ page 82
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❑ Do not interchange; cable end-pieces for gate selector cable to relay lever and gear selector cable to
gearbox selector lever are different ⇒ page 73
❑ From 05.07, fitted in conjunction with plastic relay lever ⇒ page 75
❑ Removing from plastic relay lever ⇒ page 75
❑ Pressing onto plastic relay lever ⇒ page 75
❑ Allocation ⇒ page 73
12 - Relay lever
❑ May be made from plastic or metal
❑ Metal relay lever is mounted in bearing bush ⇒ Item 13 (page 72) and secured with securing clip
❑ From 05.07, plastic relay lever
❑ Remove and install plastic relay lever together with cable end-piece ⇒ page 75
❑ Bearing bushes and securing clip not required for plastic relay lever
13 - Bearing bush
❑ Discontinued on relay levers made from plastic
14 - Lock washer
❑ Always renew
❑ Discontinued on relay levers made from plastic
15 - Shoe
cardiagn.com
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16 - Gearbox selector lever ed by
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❑ With damper weight ut
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❑ Install so that master spline
ss aligns with selector shaft c
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❑ From 06.06, smaller diameter of support pin for cable end-piece ⇒ page 73
ility
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❑ Self-locking
spec
es, in part or in w
❑ Always renew
t to the co
18 - Cable end-piece
❑ For gear selector cable to gearbox selector lever
rrectness of i

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❑ Do not interchange; cable end-pieces for gate selector cable to relay lever and gear selector cable to
gearbox selector lever are different ⇒ page 73
nform
mercia
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ion
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or
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Allocation of cableorend-pieces
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Cable end-piece for Dimension „a“
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1 - Gear selector cable to gearbox selector lever 8.5 mm
erm
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from 06.06
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2 - Gear selector cable to gearbox selector lever 10 mm
h re
through 05.06
hole
spec
2. - Gate selector cable to metal relay lever 8 mm
es, in part or in w
t to the co
2. - Gate selector cable to plastic relay lever 10 mm
⇒ page 75
rrectness of i
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From 06.06, smaller diameter of support pin for gear selector ca‐
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Support pin for gear selector cable end-piece Dimension „a“

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Through 05.06 10 mm
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From 06.06 8.5 mm
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Install gearbox selector lever

– When fitting the gearbox selector lever, ensure that the gap
-arrow A- is aligned with the master spline -arrow B-.

Installation position of gearbox selector lever and relay lever

1- Gearbox selector lever with damper weight
2- Relay lever engages in guide rail of gearbox selector lever
via shoe -arrow-.
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Renewing cable end-pieces
– Pull locking mechanisms of end-pieces of gate selector cable
rrectness of i
and gear selector cable forward to stop -arrow 1- and then turn
to left to lock -arrow 2-.
l purpos
cardiagn.com
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co lksw
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Prote AG.

– Remove securing clip -3- for gear selector cable from gearbox
selector lever -1-.
– Pull gear selector cable off pin -arrow-.
Metal relay lever
– Remove securing clip -4- for gate selector cable from relay
lever -2-.
– Pull gate selector cable from pin.
Plastic relay lever
– Remove relay lever together with cable end-piece
⇒ page 75 .
– Carefully pry off cable end-piece ⇒ page 77 .
Continued for all selector mechanisms
– Spread a small quantity of grease -G 000 450 02- on pin
-arrows- of gearbox selector lever -1- and, as needed, relay
lever pin -2-.
– Renew securing clip -3- and, for metal relay lever, securing
clip -4- each time they are removed.
gen AG
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– Secure gear selector bycable with securing clip -3- and, for
V t gu metal
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relay lever, gateorselector cable with securing clip -4-.
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Note
nl
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If a plastic relay lever is installed, it must be mounted together

ab
ility
with the cable end-piece ⇒ page 75 .

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– Adjust selector mechanism ⇒ page 82 .

hole
spec
es, in part or in w
t to the co
1.8 Plastic relay lever

From 05.07, relay lever is made from plastic. 2 versions may be
rrectness of i
installed.
l purpos
♦ Relay lever with catch or

♦ Relay lever with clip
nf
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or
Comply with the following during removal and installation work:

m
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• To remove relay lever, first separate cable end-piece from

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gate selector cable.

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This will avoid damage to the gate selector cable

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-direction of arrow 1- and then lock by turning to left in Cop py
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– Then push relay lever forwards (-in direction of arrow 3-).
by lksw
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Prote AG.

Relay lever with catch -arrow 1-

– Press catch -arrow 1- down to stop and remove relay lever
together with cable end-piece. In the process, swing it in di‐
rection of operation.
Relay lever with clip -arrow 1-

– Pull clip -arrow 1- off and remove relay lever together with ca‐
ble end-piece. n AG. Volkswagen A G do
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Continuation for all Volks ot g
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• Cable end-piece must be located behindthcatch
or -arrow 2-. tee
or
au ac
• The cable end-piece can be removed only with the relay lever ss
ce
le
removed ⇒ page 77 .
un
pt
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ab
ility
Note
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To fit, lubricate bearing points and sliding surfaces with grease -
ole,
spec
G 000 450 02- .
– Press cable end-piece onto relay lever ⇒ page 77 . t to the co

– Install relay lever together with cable end-piece to stop.
rrectness
Relay lever with catch -arrow 1-

o
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• Catch -arrow 1- secures relay lever.

form
mer
atio
• Ensure proper engagement.

om
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• Cable end-piece must be located behind catch -arrow 2-.

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Cop py
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rig ht
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Relay lever with clip -arrow 1-

• Clip -arrow 1- secures relay lever.
• Ensure proper engagement of clip.
• Cable end-piece must be located behind catch -arrow 2-.
AG. Volkswagen AG d
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Levering gate selector cable end-piece off plastic relay lever
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• Relay lever has been removed.
h re
hole
– Insert a flat-blade screwdriver -A- between bush -B- and relay
spec
es, in part or in w
lever.
t to the co
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• Relay levers has been removed.
s c
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• Cable end-piece may be pressed only onto bush -arrow-.
du
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• Cable end-piece must move freely on relay lever.
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1.9 Removing and installing selector mech‐
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Cop py
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Special tools and workshop equipment required py by
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Prote AG.
♦ Grease -G 000 450 02-
1.9.1 Removing
– First check whether a coded radio is fitted. In this case, obtain
anti-theft code.
– With ignition switched off, disconnect battery ⇒ Electrical sys‐
tem; Rep. gr. 27 ; Disconnecting and connecting battery .
– Remove gaiter with selector knob and noise insulation
⇒ page 62 .
– Remove centre console and securing bracket for centre con‐
sole ⇒ General body repairs, interior; Rep. gr. 68 ; Compart‐
ments, covers and trims .

– Remove selector housing nuts -arrows-.

– 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 .
selector lever -1-.
– Pull gear selector cable off pin -arrow-.
Metal relay lever
– Remove securing clip -4- for gate selector cable from relay
lever -2-.
– Pull gate selector cable off pin -arrow-.
AG. Volkswagen AG d
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Plastic relay lever olksw not
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Releasing cable end-piece from gate selector cable
ce
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• To avoid damage to gate selector cable, separate cable end-

itte
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piece from gate selector cable before removal.
ab
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-direction of arrow 1- and then lock by turning to left in
h re
ole,
spec
t to the co
⇒ page 75 .
rrectne
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– Remove cable support bracket from gearbox -arrows-.
cial p
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mer

Rep. gr. 50 ; Noise insulation . atio
om
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c
– Remove tunnel cross member ⇒ Rep. gr. 26 ; Removing and

or
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installing parts of exhaust system .

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– Remove underbody panels ⇒ General body repairs, exterior;

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en
ng
Rep. gr. 50 .
t.
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Cop py
– Separate front exhaust system at double clamp and detach ht. rig
rig ht
from subframe ⇒ Rep. gr. 26 ; Removing and installing parts
py by
co Vo
by lksw
of exhaust system . Prote
cted AG.
agen
– Remove rear exhaust system and heat shield ⇒ Rep. gr. 26 ;

Removing and installing parts of exhaust system .
– Swing selector housing down and remove with selector ca‐
bles.
1.9.2 Installing
– Align selector housing parallel to body.

• Distance to body must be same on both sides.

Secure selector housing ⇒ Item 26 (page 65) or
⇒ Item 16 (page 67) .
– Install cable support bracket on gearbox and tighten bolts to
specified torques ⇒ Item 6 (page 71) and
⇒ Item 10 (page 71) .
The holes in the cable end-pieces have different diameters.
Allocation of cable end-pieces ⇒ page 73
– Spread a small quantity of grease -G 000 450 02- on pin
-arrows- of gearbox selector lever -1- and, as needed, relay
lever pin -2-.
– Renew securing clip -3- and, for metal relay lever, securing
clip -4- each time they are removed.
– Secure gear selector cable with securing clip -3- and gate se‐
lector cable with securing clip -4-.
Cable end-piece to plastic relay lever
– Fit relay lever and cable end-piece together ⇒ page 75 .
AG. Volkswagen AG d
– Insert gate selector cable in cable end-piece. agen oes
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– Install centre console securing bracket and
s a centre console ⇒ c
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General body repairs, interior; Rep. gr. 68 ; Compartments,
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covers and trims .
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– Install gaiter with selector knob and noise insulation
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⇒ page 62 .
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– Install underbody panels ⇒ General body repairs, exterior;
h re
hole
Rep. gr. 50 .
spec
es, in part or in w
– Install heat shield.
t to the co
– Assemble exhaust system free of tension and attach tunnel
cross member ⇒ Rep. gr. 26 ; Removing and installing parts
rrectness of i
of exhaust system .
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– If complete air filter housing was removed, install it ⇒ Rep. gr.
nform
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23 ; Repairing diesel direct injection system or ⇒ Rep. gr. 24 ;

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– Follow procedure after connecting battery ⇒ Electrical system;

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Rep. gr. 27 ; Battery; Disconnecting and connecting battery .

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1.10 Removing and installing gear selector

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1.10.1 Removing
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– Remove selector mechanism ⇒ page 78 .

– Bend open tabs -arrows- of selector mechanism cover using n AG. Volkswagen AG do
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– Pull off securing clips -1 … 4-.
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inform
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– Prise gear selector cable off gear lever and gate selector cable
om
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off gate selector lever with e.g. a screwdriver if necessary.
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– Pull gear selector cable and gate selector cable from selector
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housing.
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Release locks -A- for gear and gate selector cables -B- as follows: Cop py
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♦ Turn sliding sleeve to right to stop -arrow 2- until it engages. Prote AG.
– Remove locking mechanism from Bowden cables.
– Pull off securing clips -1- and -2-.

– Remove cable support bracket from Bowden cables.
1.10.2 Installing

– Secure gear selector cable and gate selector cable to selector

housing using securing clips -2 and 3-.
– Press gear selector cable onto gear lever and gate selector
cable onto gate selector lever in selector housing and secure
with clips -1 and 4-
Note
Securing clips -1 and 4- have been discontinued on selector

mechanisms from 11.06.
– Fit seal and secure selector mechanism cover by pressing

down tabs -arrows-.
– Install selector mechanism ⇒ page 79 .
cardiagn.com
1.11 Adjusting selector mechanism
Locking pin -T10027 A-
Note
♦ The following points are essential to ensure ecorrect

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♦ Selector mechanism must move freely.
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♦ Gearbox, clutch and clutch mechanism must also be in proper

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• Gearbox must be in neutral.

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spec
– Remove complete air filter housing if bracket -A- to secure

es, in part or in w
t to the co
gear selector cable and gate selector cable are not accessible
⇒ Rep. gr. 23 ; Repairing diesel direct injection system or ⇒
Rep. gr. 24 ; Repairing injection system .
rrectness of i
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Prote AG.

– Pull locking mechanisms on gate selector cable and gear se‐

lector cable end-pieces forward to stop -direction of arrow 1-
and then turn to left to lock -direction of arrow 2-.
Secure selector shaft as follows:

– Press selector shaft down -direction of arrow 1-.
– While pressing down selector shaft, turn angled rod -A- in
-direction of arrow 3- upwards and at the same time press it in
-direction of arrow 2- until it engages in selector shaft.
cardiagn.com
– Remove gaiter with selector knob and frame ⇒ page 62 .
– If noise insulation is present, remove it.
Now secure gear lever as follows:

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– Select neutral using gear lever. agen oes
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– Guide locking pin -T10027 A- through hole -A-orisinto hole -B-.
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– 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
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selector cable end pieces clockwise to stop

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The spring presses the locking mechanism into original position

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Prote AG.
1. Repairing selector mechanism
– Now turn angled rod -A- back to original position

• During this procedure, angled rod -A- must be pressed out of
gearbox in -direction of arrow 1-.
– Pull locking pin -T10027 A- out of holes -A- and -B-.

– If noise insulation was present, install it.
– Install gaiter with selector knob and frame ⇒ page 62 .
– Check that selector shaft moves freely. . Volkswagen AG
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– If removed, reinstall complete air filter housing ⇒ Rep. gr. 23by;Volk not
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Repairing injection system ut
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1.11.1 Functional check
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• With gearbox in neutral, gear lever must rest in gate for 3rd
spec
and 4th gear.
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– Operate clutch.
– Select all gears several times. Pay particular attention to op‐
rrectness of i
eration of reverse gear lock.
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– If it continues to be difficult to engage a gear after repeated

attempts, repeat adjustment procedure of selector mechanism
⇒ page 82 .
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Prote AG.

2 Removing and installing gearbox in

vehicles with turbo diesel engine
2.1 Removing gearbox

equipment required
♦ Support bracket -10 - 222
A-
♦ Adapter -10-222 A /8-
♦ Adapter -10-222 A /3- n AG. Volkswagen AG do
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♦ Adapter -10-222 A /18- ed by V ua
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♦ Gearbox support -3282-
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2. Removing and installing gearbox in vehicles with turbo diesel engine 85

♦ Support elements for gear‐

box (determine when set‐
ting adjustment plate on
gearbox support )
♦ Adjustment plate -3282/33-
♦ Gearbox lifting tackle
-3336- for transporting
gearbox
1331-
1332-
♦ Engine and gearbox jack -
V.A.G 1383 A-
cardiagn.com
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♦ Bracket -T10346- oris nte
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♦ Engine support -3300 A- ss c
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♦ Adapter -VW 771/40-
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♦ Hose clamps to 25 mm
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Electronic parts catalogue
(ETKA) .
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♦ Flange bolt M6 X 20 l purpos
♦ Flange bolt M6 X 80
♦ Hexagon head bolt M10 x
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Prote AG.
At a later point, support bracket -10-222 A- will be put onto lon‐

gitudinal members with adapters -10 - 222 A /8- .
• To prevent damage to edges of wings, cover bottom area of
both adapters -10 - 222 A /8- with self-adhesive fabric tape
-arrow- ⇒ Electronic parts catalogue (ETKA chemical sub‐
stances) .
Removing
– Check whether a coded radio is fitted. If so, obtain anti-theft
code.
battery .
At a later point, the support bracket -10-222 A- will be connected
to the lifting eyes of engine.
– If engine cover blocks access, remove engine cover.
– Remove complete air filter housing if it is located close to the
battery ⇒ Rep. gr. 23 ; Repairing diesel direct injection sys‐
tem .
– Remove battery, battery cover and battery tray ⇒ Electrical
system; Rep. gr. 27 ; Removing and installing battery .

selector lever -2- and pull cable off pin -arrow-.
AG. Volkswagen AG d
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– Releasing cable end-piece from gate selector cable
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– The relay lever is removed together with the cable end-piece
l purpos
at a later point.
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rm
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– Remove cable support bracket from gearbox -arrows-, lay to

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side and secure with wire.

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LHD
-3094- .

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– Clamp off hose of pipe/hose line -A- to slave cylinder using
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– Pull out clip -arrow- for pipe/hose line or plastic line to stop.
hole
spec
– Pull pipe/hose line or plastic line out from slave cylinder bleed‐
es, in part or in w
t to the co
er and seal.
Caution
rrectness of i
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Do not operate clutch pedal any more.
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– Remove earth strap -1- from top starter bolt.
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– Separate electrical connector -2- for reversing light switch -

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– Remove connector and wire from starter.
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cardiagn.com
– Remove upper engine/gearbox connecting bolts -arrows-.
– Then remove upper securing bolt on starter.
– Bolt bracket -T10346- to rear of the 3 mounting holes for bat‐

tery tray.
– To do this, use a collar bolt M 6 x 80 or a securing bolt for
battery tray.
– If there are hose and cable connections in area of engine sup‐
port eye for support bracket -10-222 A- , remove these now.

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– Set up support bracket -10-222 A- in lfront
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♦ Adapter -10-222 A /8-
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♦ Adapter -10-222 A /18-
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– Position adapter -10-222 A /8- :
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• On upper longitudinal carrier, directly before the elevation
h re
hole
(-arrow 1-) next to bolt (-arrow 2-)
spec
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– Connect bracket -T10346- to support bracket .
t to the co
– Attach spindles in left engine support eyes.
rrectness of i
– Take up weight of engine/gearbox assembly and support
bracket on spindles.
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The left drive shaft will be removed in a later step.

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– With vehicle standing on its wheels, loosen front left flange bolt
n
c
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-arrow- 90° at most, or wheel bearing will be damaged ⇒

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Running gear, axles, steering; Rep. gr. 40 ; Removing and

at
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installing drive shafts .

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Rep. gr. 50 ; Noise insulation . C py
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– Remove lower part of front left wheel housing liner ⇒ General
p by
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body repairs, exterior; Rep. gr. 66 ; Wheel housing liner . Prote
cted AG.
agen
– Gearboxes for vehicles with start-stop system: pull connector

-arrow- off gearbox neutral position sender -G701- .
– If front vehicle level sender -G78- is present, unbolt it from

transverse link ⇒ Rep. gr. 40 ; Removing and installing front
vehicle level sender -G78- .
– Remove bracket from starter.
– Remove starter ⇒ Electrical system; Rep. gr. 27 ; Starter .

– Remove left charge air hose -arrow 1- and -arrow 2- ⇒ Rep.

gr. 21 ; Charge air system with turbocharger .
– Remove charge air pipe from engine ⇒ Rep. gr. 21 ; Charge
air system with turbocharger .
– Remove right charge air hose from charge air cooler ⇒ Rep.
gr. 21 ; Charge air system with turbocharger .
– Remove cowling -arrow- together with radiator fans ⇒ Rep.

gr. 19 ; Parts of cooling system .
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cardiagn.com
d ran
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– Remove exhaust system bracket
ss
au
from subframe -arrows- ⇒ ac
Rep. gr. 26 ; Removing and installing parts of exhaust system .
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es, in part or in w
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– Separate exhaust system at double clamp -arrows-.

– Raise and secure front exhaust pipe or rest it on tunnel bridge.
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Prote AG.

– Remove pendulum support.
– Pull connector -1- off oil level and oil temperature sender -
G266- .
– Remove left coupling rod from anti-roll bar and lay to side ⇒
Running gear, axles, steering; Rep. gr. 40 ; Repairing front
wheel suspension .
– Remove left drive shaft ⇒ Running gear, axles, steering; Rep.
gr. 40 ; Removing and installing drive shafts .
AG. Volkswagen AG d
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cardiagn.com
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– Remove drive shaft heat shield, if present -arrows-
s aut ⇒ Running ra
c
gear, axles, steering; Rep. gr. 40 ; Repairing sdrive shafts .
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– Remove right drive shaft from gearbox, raise and secure it ⇒
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– Remove hexagon bolts -arrows- on left engine/gearbox

mounting -2- from bracket -1-.
nform
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Cop py
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Prote AG.

– Lower gearbox about 40 mm, dimension -a-, by adjusting spin‐

dles attached to engine.
Note
Observe connecting lines, hoses and radiator when moving en‐

gine/gearbox assembly.
– Remove bracket -1- from gearbox -arrows-.

⇒ page 75 .
– Remove gearbox selector lever from selector shaft.
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– If small cover plate -A- for flywheel is present, remove it

un
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-arrows-.
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– Remove lower engine/gearbox connecting bolt -1-.

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Note
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Loosen engine/gearbox connecting bolt -3- and leave it installed

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Prote AG.

– Attach bracket -T10346- with bolt -1- to left threaded hole in

subframe.
-1- = Flange bolt M6 x 20.
– Secure engine support -3300 A- to bracket -T10346- .
– Place a cloth between engine support -3300 A- and oil pan.
AG. Volkswagen AG d
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– Press engine forwards using spindle of engine support -3300
rm
ab
A- . In the process, observe the following points in particular:
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• The air conditioning compressor -2- must not contact -arrow-
h re
the refrigerant line -1-.
hole
spec
es, in part or in w
• The alternator must not contact the refrigerant line.
t to the co
• The pressure pipe must not contact the radiator.
To remove gearbox „02Q“, set up gearbox support -3282- with
rrectness of i
adjustment plate -3282/33- .
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– Insert gearbox support -3282- in engine and gearbox jack -

V.A.G 1383 A- .
cardiagn.com
nform
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– Align arms of gearbox support according to holes in adjust‐

m
ment plate .
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– Attach support elements -A- to adjustment plate as illustrated. thi

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– Screw in pin -3282/29- in place of support element -C-.

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– Position engine and gearbox jack -V.A.G 1383 A- under vehi‐

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– Attach adapter -VW 771/40- in threaded hole of gearbox hous‐

ing as shown in illustration.
– Then screw pin -3282/29- into hole on gearbox for securing
bolt of pendulum support.
– Secure gearbox to gearbox support -3282- using bolt
(M10x20) -A-.

Pin -B- must lie flush with guide from gearbox support -3282- at
bottom -arrow-.
Engine/gearbox connecting bolt -arrow- has been removed.
– Remove connecting bolt for engine/gearbox -C- as well as

lower connecting bolts for engine/gearbox.
– Press gearbox away from engine, off dowel sleeves.
– Tilt gearbox in area of differential using spindles of gearbox
support -3282- .
• Differential must face upwards.
cardiagn.com
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– Guide gearbox with differential -A- over subframe and swing

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– Observe longitudinal member -arrows-. Then carefully lower

gearbox.
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♦ Gearbox mounting support -3336-
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♦ Workshop hoist -VAS 6100- Cop py
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Prote AG.
– Bolt gearbox lifting tackle -3336- to clutch housing.

– Adjust support beam on sliding piece using locking pin

-arrow-.
Number of holes visible = 6.
– Lift gearbox using workshop crane and gearbox lifting tackle
-3336- .
– Set gearbox aside, for example in a transport container.
2.3 Installing gearbox
Note
♦ Refer to procedure „Removing gearbox“ for required special

tools ⇒ page 85 .
♦ Renew self-locking nuts and bolts.
♦ Renew bolts which must be tightened further to a torque angle.
♦ All cable ties which were opened or cut during removal must
be renewed at the same points.
cardiagn.com
♦ Clean input shaft splines and, on used clutch plate, hub
splines. Remove corrosion and apply only a very thin coat of
– If the gearbox is to be renewed, the gearbox selector olklever

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relay lever must be transferred to the onew
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– All threaded holes into which self-locking
ris
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screwed must be cleaned of residual
utho locking fluid carefully with eo
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a thread tap. ss
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– Check whether dowel sleeves for aligning engine and gearbox

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– Ensure that intermediate plate is hooked into sealing flange

es, in part or in w
and pushed onto dowel sleeves -arrows-.

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– Check release bearing for wear. If necessary, renew slave

cylinder with release bearing ⇒ page 40 .
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subframe.
– Place a cloth between engine support -3300 A- and oil pan. wage
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To install gearbox „02Q“, set up gearbox support -3282- with ad‐
l purpos
justment plate -3282/33- .

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ment plate .
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– Attach support elements -A- to adjustment plate as illustrated.
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– Screw in pin -3282/29- in place of support element -C-.
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– Screw pin -3282/29- into hole on gearbox for securing bolt of yri
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pendulum support.
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– Secure adapter -VW 771/40- in threaded hole of gearbox

housing as shown in figure.
(M10x20) -A-.
bottom -arrow-.
cle. Arrow on adjustment plate points in direction of vehicle
travel.
Note
Be careful of all lines when installing gearbox.
– Then carefully raise gearbox.

– Now turn gearbox upwards near differential, using spindle of

gearbox support -3282- , and downwards near 6th gear.
– Guide gearbox with differential -A- over subframe.
• The right flange shaft must then be guided past the flywheel
-arrow 2-; observe the intermediate plate -arrow 1-.
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– Right flange shaft -1- must
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– When doing this, use spindles of gearbox support -3282- to

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adjust position of gearbox so that longitudinal member

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-arrows- is not touched.

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– Then turn gearbox to installation position via spindles of gear‐

atio
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box support -3282- .

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– Align gearbox on engine dowel sleeves and join.

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– Screw in engine/gearbox connecting bolt -C- and tighten to

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specified torque ⇒ page 104 .

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– Screw in lower engine/gearbox securing bolts and tighten to

– Remove engine support -3300 A- and bracket -T10346- .
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– Screw in engine/gearbox connecting bolt -arrow- and tighten
hole
to specified torque ⇒ page 104 .
spec
es, in part or in w
– After bottom of gearbox and engine are bolted together, re‐
t to the co
move gearbox support -3282- from gearbox.
– Insert upper engine/gearbox securing bolts and tighten to tor‐
rrectness of i
que specification ⇒ page 104 .
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– Attach gearbox selector lever to selector shaft of gearbox

⇒ page 73 and tighten hexagon nut to specified torque
⇒ Item 17 (page 72) .
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– Install relay lever together with cable end-piece ⇒ page 75 .
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– Install bracket -1- on gearbox using new hexagonal bolts

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-arrows- and tighten to specified torque ⇒ page 104 .
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– Align engine and gearbox in installation position. To do this,

raise sufficiently so that bracket -1- completely contacts left
assembly mounting -2-.
– Screw new hexagon bolts -arrows- for left assembly mounting
-2- into bracket -1- and tighten to specified torque
⇒ page 104 .
Note
Install engine and gearbox mounting free of tension ⇒ Rep. gr.

10 ; Removing and installing engine .
WARNING
Do not remove support bracket -10-222 A- until all bolts se‐

curing the assembly mounting have been tightened to speci‐
fied torque.

– If small cover plate -A- for flywheel is present, install it

-arrows- ⇒ page 104 .
Note
♦ There are threaded inserts, e.g. „HeliCoil“ in the bolting holes

for the pendulum support.
♦ Distinguishing feature: shoulder along beginning of thread
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♦ Note corresponding securing bolts and specified by V torque ⇒ ua
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Running gear, axles, steering; Rep. gr. 40 or ; Assembly over‐
is tee
view - subframe, anti-roll bar, suspension
au links .
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– Install pendulum support ⇒ Running gear, axles, steering;
rm
ab
Rep. gr. 40 ; Assembly overview - Subframe, anti-roll bar,
pe
ility
suspension links .
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– Then install drive shafts ⇒ Running gear, axles, steering; Rep.
hole
spec
es, in part or in w
t to the co
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– Install drive shaft heat shield, if present -arrows- ⇒ Running

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gear, axles, steering; Rep. gr. 40 ; Repairing drive shafts .

ion in
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– Install left coupling rod ⇒ Running gear, axles, steering; Rep.

thi
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gr. 40 ; Repairing front suspension .

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– If front vehicle level sender -G78- is present, bolt it onto trans‐

verse link ⇒ Rep. gr. 40 ; Removing and installing front vehicle
level sender -G78- .
– Attach connector -1- to oil level and oil temperature sender -

G266- .
– Assemble exhaust system and attach exhaust system bracket
to subframe ⇒ Rep. gr. 26 ; Removing and installing parts of
exhaust system .
cardiagn.com
– Install cowling -arrow- together with radiator fans ⇒ Rep. gr.
19 ; Parts of cooling system
– Install charge air pipe on engine ⇒ Rep. gr. 21 ; Charge air
system with turbocharger .
– Install left charge air hose -arrow 1- and -arrow 2- G
⇒. VRep.
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21 ; Charge air system with turbochargerlk.swagen A does
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– Fit right charge air hose to charge air cooler ⇒ Rep. gr. 21 ;
ot p
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Charge air system with turbocharger .

, is n
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hole
– Then install starter and secure with lower bolt ⇒ Electrical

spec
system; Rep. gr. 27 ; Starter .

es, in part or in w
t to the co
– Secure wiring retainer to lower starter bolt.

– Install upper starter bolt; attach connector and wiring to starter
rrectness of i
⇒ Electrical system; Rep. gr. 27 ; Starter .

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– Attach earth strap -1- to upper starter bolt.

– Push connector -2- onto reversing light switch -F4- .
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– Gearboxes ise for vehicles with start-stop system: join
d b ara connector
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-arrow- uthoto
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gearbox neutral position sender -G701- . e or
s a ac
– Pushs pipe/hose line or plastic line -A- to stop into slave cylinder
ce
le
breather and press down clip -arrow-.

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– Remove hose clamp -3094- from supply hose.

– After removing hose clamp -3094- , return supply hose to its
nform
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original shape, if necessary.

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– Check for correct installation position of vacuum hose for
by lksw
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brake system, install vacuum hose if necessary ⇒ Rep. gr.
AG.
47 .
– Bolt selector cable support brackets to gearbox and tighten
bolts and nuts -arrows- to specified torque
⇒ Item 6 (page 71) and ⇒ Item 10 (page 71) .
– Insert gate selector cable in cable end-piece.
– Spread a small amount of grease on pin -arrow- of gearbox

selector lever -2-.
Allocate grease using ⇒ Electronic parts catalogue (ETKA) .
– Renew securing clip -1- each time it is removed.
– Install battery tray, battery cover and battery ⇒ Electrical sys‐
tem; Rep. gr. 27 ; Removing and installing battery .
– If complete air filter housing was removed, install it ⇒ Rep. gr.
23 .
– If necessary, install engine cover.
– Connect battery and followAprocedure after connecting battery
G. Volkswagen AG d
⇒ Electrical system; l
Rep.
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agen gr. 27 ; Disconnecting
oes
not and con‐
necting batteryd b.y Vo gu
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ut oil ⇒ page 126 .
– Check gear
ho or
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– Install lower
s
part of front left wheel housing liner ⇒ General
ce
le
body repairs, exterior; Rep. gr. 66 ; Wheel housing liner .

un
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– Install noise insulation ⇒ General body repairs, exterior; Rep.
erm
ab
gr. 50 ; Noise insulation .
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– For vehicles with front vehicle level sender -G78- , check h re

ole,
headlight adjustment ⇒ Electrical system; Rep. gr. 94 ; Lights, spec

lamps, switches - exterior .
cardiagn.com
t to the co
2.4 Specified torques

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Gearbox to engine
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Item Bolt Quantity Nm
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1 M12 x 55 1 80
♦ With short M8 stud
2 M12 x 55 1 80
♦ With long M8 stud
3 M12 x 65 1 80
4 M10 x 50 2 40
5 M10 x 105 1 40
6 M12 x 165 1 80
♦ Additionally, starter to
gearbox


7 M12 x 165 1 80
♦ Additionally,
agen
AG.starter
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plate (not on all en‐
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Items -A- and -B-: dowel sleeves
h re
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spec
– Renew bolts -1- to -5-.
es, in part or in w
t to the co
Small cover plate for flywheel on intermediate plate: 10 Nm.
Gearbox bracket -1- to gearbox.
rrectness of i
– Renew bolts.
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Bolts -arrows-: 60 Nm and turn 90° further.
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Gearbox to body
rig ht
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– Renew bolts.
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Note

3 Removing and installing gearbox, ve‐

hicles with petrol engine
3.1 Removing gearbox

equipment required
♦ Support bracket -10 - 222
A-
♦ Adapter -10-222 A /8-
♦ Adapter -10-222 A /3-
♦ Adapter -10-222 A /18-
♦ Gearbox support -3282-
cardiagn.com
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♦ Support elements for gear‐

box (determine when set‐
ting adjustment plate on
gearbox support )
♦ Adjustment plate -3282/33-
gen AG
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♦ Gearbox lifting btackle
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1332-
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♦ Engine and gearbox jack -
h re
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V.A.G 1383 A-
spec
es, in part or in w
t to the co
rrectness of i
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3. Removing and installing gearbox, vehicles with petrol engine 107

♦ 2 x brackets -T10346-
♦ Engine support -3300 A-
♦ Adapter -VW 771/40-
♦ Hose clamps to 25 mm
-3094-
splines -G 000 100-
♦ Allocate grease using ⇒
Electronic parts catalogue
(ETKA) .
♦ Flange bolt M6 X 20.
♦ Flange bolt M6 X 80
♦ Hexagon head bolt M10 x
20
cardiagn.com
AG. Volkswagen AG d
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At a later point, support bracket -10-222 A- will be put onto lon‐

ab
ility
gitudinal members with adapters -10 - 222 A /8- .

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• To prevent damage to edges of wings, cover bottom area of

h re
hole
both adapters -10 - 222 A /8- with self-adhesive fabric tape

spec
-arrow- ⇒ Electronic parts catalogue (ETKA chemical sub‐

es, in part or in w
t to the co
stances) .
theft code.
rrectness of i

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battery .
nform
ercia
At a later point, the support bracket -10-222 A- will be connected

m
to the lifting eyes of engine.

at
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ion
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– If engine cover blocks access, remove engine cover.

in t
or
his
ate
– Remove complete air filter housing if it is located close to the

do
priv
battery ⇒ Rep. gr. 24 ; Repairing injection system .

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for
en
ng
t.
– Remove battery, battery cover and battery tray ⇒ Electrical
yi Co
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system; Rep. gr. 27 ; Removing and installing battery . t. C rig
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selector lever -2- and pull cable off pin -arrow-.
– Releasing cable end-piece from gate selector cable

– The relay lever is removed together with the cable end-piece
at a later point.
cardiagn.com
– Remove cable support bracket from gearbox -arrows-, lay to
side and secure with wire.
AG. Volkswagen AG d
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-3094- .
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Right-hand drive
– Clamp off hose of pipe/hose line -A- to slave cylinder using
hose clamp -3094- .
– Pull out clip -arrow- for pipe/hose line or plastic line to stop.
– Pull pipe/hose line or plastic line out from slave cylinder bleed‐
er and seal.
Caution
Do not operate clutch pedal any more.
– Remove earth strap -1- from top starter bolt.

– Separate electrical connector -2- for reversing light switch -
F4- .
– Remove connector and wire from starter.
cardiagn.com
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– Remove upper engine/gearbox connecting bolts -arrows-.
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t to the co
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– Then remove upper securing bolt on starter.

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cial p
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– Bolt bracket -T10346- to rear of the 3 mounting holes for bat‐

form
mer
tery tray.
atio
om
– To do this, use a collar bolt M 6 x 80 or a securing bolt for

n
c
i
or
battery tray.
thi
te
sd
iva
– Remove both foam pieces from upper edge of left and right
pr
cum
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fo
wings ⇒ Body, front; Rep. gr. 50 .

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ng
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– If there are hose and cable connections in area of engine sup‐ C py
t. rig
port eye for support bracket -10 - 222 A- , remove these now. gh ht
pyri by
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Prote AG.

– Set up support bracket -10-222 A- in front of bonnet support.

– Use: olkswage es n
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♦ Adapter -10-222 rA ise/3-
d ran
tee
tho
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♦ Adapter -10-222
ss
au
A /8- ac
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♦ Adapter -10-222 A /18-

nl
pt
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itte
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– Position adapter -10-222 A /8- :
erm
ab
ility
ot p
• On upper longitudinal carrier, directly before the elevation
wit
(-arrow 1-) next to bolt (-arrow 2-)
, is n
h re
hole
– Connect engine and bracket -T10346- to support bracket .
spec
es, in part or in w
– Take up weight of engine/gearbox assembly and support
t to the co
bracket on spindles.
rrectness of i
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The left drive shaft will be removed in a later step.
nform
ercia
– With vehicle standing on its wheels, loosen front left flange bolt
m
at
-arrow- 90° at most, or wheel bearing will be damaged ⇒
om
ion
c
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or
his
ate
do
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or

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– Remove lower part of front left wheel housing liner ⇒ General C py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– If front vehicle level sender -G78- is present, unbolt it from

transverse link ⇒ Rep. gr. 40 ; Removing and installing front
vehicle level sender -G78- .
– Remove bracket from starter.
– Remove starter ⇒ Electrical system; Rep. gr. 27 ; Starter .
– Remove left charge air hose -arrow 1- and -arrow 2- and
charge air pipe from engine ⇒ Rep. gr. 21 ; Charge air system
with turbocharger .
– Remove right charge air hose -arrow 2- ⇒ Rep. gr. 21 ; Charge

air system with turbocharger

– Remove cowling -arrow- together with radiator fans ⇒ Rep.

gr. 19 ; Parts of cooling system .
– Disconnect front exhaust pipe from turbocharger (-arrow-) ⇒

Rep. gr. 26 ; Removing and installing parts of exhaust system
and secure it.
AG. Volkswagen AG d
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cardiagn.com
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– Remove pendulum support.
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ility
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spec
es, in part or in w
t to the co
rrectness of i
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nf
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– Pull connector -1- off oil level and oil temperature sender -
rm
m
G266- .
atio
om
n in
c
– Remove left coupling rod from anti-roll bar and lay to side ⇒
or
thi
e
Running gear, axles, steering; Rep. gr. 40 ; Repairing front

t
sd
iva
wheel suspension .
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gr. 40 ; Removing and installing drive shafts . ht. Cop py
rig
rig ht
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Prote AG.

– Remove drive shaft heat shield, if present -arrows- ⇒ Running

– Remove right drive shaft from gearbox, raise and secure it ⇒
– If small cover plate -A- for flywheel is present, remove it

-arrows-.
cardiagn.com
– Remove hexagon bolts -arrows- on left engine/gearbox
mounting -2- from bracket -1-.
AG. Volkswagen AG d
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– Lower gearbox about 60 mm, dimension -a-, by adjusting spin‐
hole
spec
dles attached to engine.
es, in part or in w
t to the co
Note
rrectness of i
Observe connecting lines, hoses and radiator when moving en‐

l purpos
gine/gearbox assembly.
nform
mercia
a
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tion in
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– Remove bracket -1- from gearbox -arrows-.

⇒ page 75 . agen
AG. Volkswagen AG d
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– Remove gearbox eselector
db
yV lever from selector shaft. ua
ran
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– Remove engine/gearbox connecting bolt -1-.
es, in part or in w
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Note
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Loosen engine/gearbox connecting bolts -2- and leave them in‐
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stalled just hand-tight.
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subframe.
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– In the process, position bracket -T10346- at the same angle
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To remove gearbox „02Q“, set up gearbox support -3282- with
adjustment plate -3282/33- .
– Insert gearbox support -3282- in engine and gearbox jack -
V.A.G 1383 A- .
ment plate .


– Screw in pin -3282/29- instead of support element -C-.
. Volkswagen AG
does gen AG
– Position engine and gearbox olks jack -V.A.G 1383 A- under
wa notvehi‐
cle. Arrow -B- on adjustment
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– Align adjustment
ss plate parallel to gearbox.
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– Secure adapter -VW 771/40- in threaded hole of gearbox
es, in part or in w
t to the co
– Then screw pin -3282/29- into hole on gearbox for securing
bolt of pendulum support.
rrectness of i
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(M10x20) -A-.
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bottom -arrow-.
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– Remove connecting bolt -C- and lower connecting bolts.
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– Press gearbox away from engine, off dowel sleeves.
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Then the right flange shaft -1- must be guided past the notch
-arrow- in the intermediate plate and the flywheel.
– Tilt gearbox in area of differential using spindles of gearbox
support -3282- .
• Differential must face upwards.
– Guide gearbox with differential over subframe -A- and swing
out.

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– If necessary, turn further upwards near differential gearbox
ss
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using spindles of gearbox support -3282- .
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– Swivel gearbox further out and carefully lower.
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3.2 Transporting gearbox

♦ Gearbox mounting support -3336-
♦ Workshop hoist -VAS 6100-

– Bolt gearbox lifting tackle -3336- to clutch housing.
– Adjust support beam on sliding piece using locking pin

-arrow-.
Number of holes visible = 6.
– Lift gearbox using workshop crane and gearbox lifting tackle
-3336- .
– Set gearbox aside, for example in a transport container.
cardiagn.com
3.3 Installing gearbox
agen
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tools ⇒ page 106 .

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♦ Renew self-locking nuts and bolts.

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hole
spec
be renewed at the same points.

es, in part or in w
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– If the gearbox is to be renewed, the gearbox selector lever and

nf
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relay lever must be transferred to the new gearbox.

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– All threaded holes into which self-locking bolts are to be

om
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screwed must be cleaned of residual locking fluid carefully with

or c
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– Check whether dowel sleeves for aligning engine and gearbox

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– Ensure that intermediate plate is hooked into sealing flange
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and pushed onto dowel sleeves -arrows-.
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– Check release bearing for wear. If necessary, renew slave
ab
ility
cylinder with release bearing ⇒ page 40 .
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subframe.
spec
– In the process, position bracket -T10346- at the same angle
t to the co
as the engine.
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cardiagn.com
To install gearbox „02Q“, set up gearbox support -3282- with ad‐
justment plate -3282/33- .
ment plate .

– Screw in pin -3282/29- instead of support element -C-.
– Place gearbox on engine and gearbox jack -V.A.G 1383 A- .
– Align adjustment plate and gearbox parallel to one another.
– Screw pin -3282/29- into hole on gearbox for securing bolt of
pendulum support.

. Volkswagen AG
gen AG d
Golf Variant 2007V➤ olks, Golf Variant 2010 ➤ , Jetta
wa oes
not 2005 ➤ , Jetta 2011 ➤
by gu
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– Secure adapter -VW 771/40- inssthreaded
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hole of gearbox ac
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(M10x20) -A-.
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t to the co
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– Now turn gearbox in area of differential -in direction of arrow-
atio
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using spindles of gearbox support -3282- .

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– Then carefully raise gearbox.

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– Guide gearbox with differential -A- over subframe.
– Observe longitudinal member -arrows-.

– Guide gearbox with differential over subframe -A-

-in direction of arrow-.
– Swing rear of gearbox towards subframe.
• Then the right flange shaft -1- must be guided past the flywheel
and the notch -arrow- in the intermediate plate.
– Then turn gearbox to installation position via spindles of gear‐
box support -3282- .
– Align gearbox on engine dowel sleeves and join.
– Screw in engine/gearbox connecting bolt -C- and tighten to

specified torque ⇒ page 124 . AG. Volkswagen AG do
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– Screw in engine/gearbox
db
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orise
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– Remove engine support -3300 A- and bracket -T10346- .
– Screw in lower engine/gearbox securing bolts and tighten to
rrectness of i

– After bottom of gearbox and engine are bolted together, re‐
l purpos
move gearbox support -3282- from gearbox.

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– Insert upper engine/gearbox securing bolts and tighten to tor‐

que specification ⇒ page 124 .
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– Attach gearbox selector lever to selector shaft of gearbox

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⇒ page 73 and tighten hexagon nut to specified torque

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⇒ Item 17 (page 72) .

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– Install relay lever together with cable end-piece ⇒ page 75 .

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-arrows- and tighten to specified torque ⇒ page 124 . yri
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– Align engine and gearbox in installation position. To do this,

raise sufficiently so that bracket -1- completely contacts left
assembly mounting -2-.
– Screw new hexagon bolts -arrows- for left assembly mounting
-2- into bracket -1- and tighten to specified torque
⇒ page 124 .
AG. Volkswagen AG d
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Install engine and gearbox mounting free of tension ⇒ Rep. gr. ss c
ce
10 ; Removing and installing engine . le
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WARNING
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Do not remove support bracket -10-222 A- until all bolts se‐
hole
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curing the assembly mounting have been tightened to speci‐
es, in part or in w
fied torque.
t to the co
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– If small cover plate -A- for flywheel is present, install it
-arrows- ⇒ page 124 .
l purpos
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Note
♦ There are threaded inserts, e.g. „HeliCoil“ in the bolting holes

for the pendulum support.
♦ Identification: shoulder along beginning of thread -arrow-.
♦ Note corresponding securing bolts and specified torque ⇒
Running gear, axles, steering; Rep. gr. 40 ; Assembly over‐
view - subframe, anti-roll bar, suspension links .
– Install pendulum support ⇒ Running gear, axles, steering;

Rep. gr. 40 ; Assembly overview - Subframe, anti-roll bar,
suspension links .
– Assemble exhaust system ⇒ Rep. gr. 26 ; Removing and
installing parts of exhaust system .
– Then install drive shafts ⇒ Running gear, axles, steering; Rep.

– Install drive shaft heat shield, if present -arrows- ⇒ Running

. Volkswage n AG n AG d
wage oes
– Install left coupling rod ⇒ Running gear, yaxles,
Vol
ks steering; Rep. not
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gr. 40 ; Repairing front suspension .ised b ara
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– If front vehicle level sender -G78- is present, bolt it onto trans‐
t to the co
verse link ⇒ Rep. gr. 40 ; Removing and installing front vehicle
level sender -G78- .
rrectness of i
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– Attach connector -1- to oil level and oil temperature sender -

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– Install cowling -arrow- together with radiator fans ⇒ Rep. gr.

19 ; Parts of cooling system .

– Fit charge air hoses -arrow 1- and -arrow 2- and charge air
pipe on engine ⇒ Rep. gr. 21 ; Charge air system with turbo‐
charger .
– Then install starter and secure with lower bolt ⇒ Electrical
system; Rep. gr. 27 ; Starter .
– Secure wiring retainer to lower starter bolt.
– Install upper starter bolt; attach connector and wiring to starter
⇒ Electrical system; Rep. gr. 27 ; Starter .
– Attach earth strap -1- to upper starter bolt.

– Push connector -2- onto reversing light switch -F4- .
– Push pipe/hose line or plastic line -A- to stop into slave cylinder
breather and pressedown
n AG. Voclip
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– Remove hose clamp -3094- from supply hose.

es, in part or in w
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– After removing hose clamp -3094- , return supply hose to its

original shape, if necessary.
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l purpos
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– Check for correct installation position of vacuum hose for

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– Bolt selector cable support brackets to gearbox and tighten
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– Insert gate selector cable in cable end-piece.
Prote AG.
– Spread a small amount of grease on pin -arrow- of gearbox

selector lever -2-.

Allocate grease using ⇒ Electronic parts catalogue (ETKA) .

– Renew securing clip -1- each time it is removed.
– Install battery tray, battery cover and battery ⇒ Electrical sys‐
tem; Rep. gr. 27 ; Removing and installing battery .
– If removed, install complete air filter housing ⇒ Rep. gr. 24 ;
– Install plenum chamber cover with seal.
⇒ Glazing; Rep. gr. 64 ; Assembly overview - plenum chamber
cover
– Set both foam pieces on upper edge of left and right wings ⇒
Body, front; Rep. gr. 50 .
– If necessary, install engine cover.
– Connect battery and follow procedure after connecting battery
⇒ Electrical system; Rep. gr. 27 ; Disconnecting and con‐
necting battery .
– Check gear oil ⇒ page 126 .
– Install lower part of front left wheel housing liner ⇒ General
n AG. Volkswagen A ge G do
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– Install noise insulation ⇒ General bodybrepairs,
yV
olk exterior; Rep. ot g
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gr. 50 ; Noise insulation . ris
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– For vehicles with front vehicle slevel
sa
u
sender -G78- , check ac
headlight adjustment ⇒ Electrical system; Rep. gr. 94 ; Lights,
ce
le
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lamps, switches - exterior .

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3 M12 x 65 1 80
4 M10 x 50 2 40
5 M10 x 105 1 40
6 M12 x 165 1 80
gearbox


7 M12 x 165 1 80
gearbox
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Items -A- and -B-: dowel sleeves
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spec
Gearbox bracket -1- to gearbox.
t to the co
– Renew bolts.
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– Renew bolts. ht. rig
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Note


4 Checking gearbox oil

AG. Volkswagen AG d
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♦ Multi-point bit -3357-
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Gearbox oil specification ⇒ Electronic parts catalogue „ETKA“ .
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– To check gear oil, remove oil plug -arrow-.
Oil level is correct when gearbox is filled to lower edge of filler
hole.
– Screw in plug -arrow- with new seal.
– Tighten bolt -arrow- to specified torque ⇒ page 127 .
When filling with oil, note the following:
– Remove oil plug -arrow-.
– Fill with gear oil to lower edge of filler hole.
– Screw in plug -arrow- with new seal.
– Tighten bolt -arrow- to specified torque ⇒ page 127 .

Golf Variant 2007 ➤ , GolfageVariant
n AG. Vol2010 ➤ , Jetta
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Various versions of oil filler and drain plugs
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I - Oil filler or oil drain plug with multi-point socket head 45 Nm
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II - Oil filler or oil drain plug with hexagon socket head 30 Nm
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4. Checking gearbox oil 127

5 Dismantling and assembling gearbox
5.1 Overview - rear final drive
1 - Clutch housing
2 - Reverse shaft
3 - Output shaft for 5th, 6th and
reverse gears
4 - Slave cylinder with clutch
release bearing
5 - Input shaft
6 - Output shaft for 1st through
4th gears
7 - Differential
AG. Volkswagen AG d
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9 - Left flange shaft horis nte
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10 - Synchromeshed gear for ss c
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11 - Synchromeshed gear for
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5th gear rrectness of i
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6th gear
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reverse gear
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17 - Gearbox housing
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5.2 Assembly overview
l - Removing and installing

gearbox housing and selector
mechanism ⇒ page 130
ll - Removing and installing in‐
put shaft, output shafts, differ‐
ential and selector rods
⇒ page 132
AG. Volkswagen AG d
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shaft sealing cover ⇒ page 134
agen
Prote AG.
Assembly order, gearbox »with« retaining ring -A- for input shaft
sealing cover ⇒ page 145
5. Dismantling and assembling gearbox 129

AG. Volkswagen AG d
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1 - Countersunk bolt, 33 Nm ss c
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⇒ page 227
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❑ Assembling
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spec
⇒ page 233
es, in part or in w
t to the co
3 - Retaining ring
❑ For sealing cover
rrectness of i
❑ Fitted from gearbox
l purpos
date 21 01 8
4 - Cover plate
nform
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❑ Secured with retaining

m
ring from gearbox date
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21 01 8
on
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6 - Reversing light switch -F4- ,
20 Nm
❑ Changed to captive seal
shortly after introduction
of gearbox
⇒ Item 7 (page 130) .
7 - Seal
❑ Not fitted in all gearbox‐
es
❑ Always renew
8 - Oil drain plug
❑ Torque setting ⇒ page 127
9 - Seal
❑ Always renew
10 - Locking bolt, 45 Nm
❑ For selector shaft
11 - Bolt, 15 Nm + turn 90° further
❑ Bolt with captive washer only as replacement part
❑ Always renew; allocate shim according to ⇒ Electronic parts catalogue „ETKA“
❑ Allocation of bolts as replacement part ⇒ page 131
12 - Bolt, 15 Nm + turn 90° further
❑ Without washer
❑ Always renew; allocate shim according to ⇒ Electronic parts catalogue „ETKA“
❑ Allocation of bolts as replacement part ⇒ page 131
13 - Selector unit
❑ (Selector shaft with selector shaft cover)

❑ Repairing ⇒ page 172 .
❑ Removing with gearbox installed:
♦ Remove battery and battery tray ⇒ Electrical system; Rep. gr. 27 ; Battery; Removing and installing battery .
♦ The angled rod ⇒ Item 6 (page 160) for adjusting the selector mechanism must not be engaged.
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5.4 Removing and installing input shaft, output shafts, differential and selector
rods
1 - Output shaft for 1st through

4th gears
❑ Dismantling and assem‐
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⇒ page 133
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⇒ page 133
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6 - Selector fork for reverse
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7 - Input shaft
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bling ⇒ page 178
❑ Always renew deep groove ball bearing on input shaft ⇒ Item 6 (page 180) .
8 - Reverse shaft
❑ With thrust washer
9 - Thrust washer
10 - Breather
❑ Connect to slave cylinder ⇒ Item 14 (page 132)
11 - Clutch housing
13 - O-ring
❑ Moisten with brake fluid before installing

14 - Slave cylinder with clutch release bearing

15 - Bolt
❑ Qty. 3
❑ Always renew
❑ Without locking fluid 12 Nm (only slave cylinders with metal housing)
❑ With locking fluid 15 Nm (for plastic slave cylinders)
❑ Carefully tighten diagonally in small steps so that the bolting eyes of the slave cylinder do not break off
16 - Countersunk bolt, 33 Nm
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❑ Removing rise and installing ⇒ page 227
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❑ Dismantling and assembling ⇒ page 233

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Installation position of shafts and selector rods in gearbox
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1 - Input shaft
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2 - Output shaft for 1st through 4th gears
3 - Output shaft for 5th, 6th and reverse gear
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4 - Reverse shaft
A - Selector rod for 3rd and 4th gears
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B - Selector rod for 1st and 2nd gears

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C - Selector rod for 5th and 6th gears

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D - Selector fork for reverse gear 1)

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In some gearboxes, mounting of reverse gear selector fork on

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selector rod for selector fork for 5th and 6th gears - C - . Distin‐
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5.5 Assembly order, gearbox »without« retaining ring -A- for input shaft sealing
cover
Removing and installing gearbox housing, selector mechanism,
input shaft, output shafts, differential and selector rods.

equipment required
♦ Support plate -VW 309-
♦ Support clamp -VW 313-
♦ Gearbox support -VW 353-
♦ Sleeve -VW 455- or sleeve
-3160-
♦ Multipurpose tool -VW 771-
♦ -1- Internal puller -Kukko
21/01-
♦ -3- Splitter -Kukko 17/0-
♦ -4- Counter support -Kukko
22/1-
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♦ Support bridge -30 - 211 A-

♦ Drift -T10169-
♦ or drift -T10362-
⇒ page 163
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♦ Hot air blower -V.A.G 1416-
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♦ Drip tray for workshop hoist -VAS 6208-

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5.5.1 Removing agen

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– Secure gearbox to assembly stand using ed bolts -arrows-.
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If one of the bolting holes does not contact the gearbox support ,
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– Rotate gearbox on assembly stand so that oil drain plug is
hole
below.
spec
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– Place drip tray underneath.
t to the co
– Drain gear oil.
rrectness of i
– Remove slave cylinder with clutch release bearing -arrows-.
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During the following steps, ensure that the selector shaft is not
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blocked by the angled rod -arrow-.
– Move selector shaft to neutral.
– Remove reversing light switch -F4- -1-.
– Remove locking bolt -2-.
– Then remove bolts -3-.
– Pull selector shaft with selector shaft cover -4- out of gearbox
housing.
– Remove securing bolt for left and right flange shaft by screwing
two bolts into flange and counterholding using a lever.
– Pull out flange shafts with compression spring.

– Remove bolts -B-, which secure gearbox housing to clutch

housing.
Note
One bolt -arrow- is located outside of bolting flange.
– Lock input shaft as follows:

The lengths of the splines on the input shaft differ to those of the
gearbox.
– Set either installing sleeve -VW 455- over input shaft on clutch
housing
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– or set sleeve -3160- over input shaft on clutch housing
es, in part or in w
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– Clamp splitter -A-, e.g. -Kukko 17/0- , behind notch in splines
of input shaft.
rrectness of i
The back side of the splitter must rest against installing sleeve -
VW 455- or sleeve -3160- without play.
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– Pierce rubber in centre of cover -C- with a screwdriver.

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B - Internal puller, 8 … 12 mm , e.g. -Kukko 21/01-
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Remove retaining ring -C- from deep groove ball bearing of input
shaft in gearbox housing as follows:
– Hold one end of retaining ring with screwdriver -A-.
– Using a screwdriver , -B-, lever other end out of groove in deep
groove ball bearing -direction of arrow-.
– Using screwdriver -B-, lever out securing ring further.
– If present, remove washer -1- from gearbox housing -2-.

• If gearbox housing is to be renewed, check whether washer
must be installed ⇒ page 141 .
cardiagn.com
– Remove securing bolts -A- for gearbox housing to clutch hous‐
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– Screw adapter -VW 771/40- into threaded hole of gearbox

t to the co
housing.
– Heat gearbox housing using hot air blower , e.g. -V.A.G 1416-
rrectness of i
in vicinity of bearing seat for deep groove ball bearing for input
shaft for about 10 minutes to about 100 °C.
l purpos
– Using multi-purpose tool -VW 771/1- , pull gearbox housing off

clutch housing in -direction of arrow-.
nform
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If necessary, carefully apply lever on alternating sides at over‐

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– If present, remove washer -1- from deep groove ball bearing

-2-.
– If gearbox housing is to be renewed, check whether washer
must be re-installed ⇒ page 141 .
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– Remove splitter -A- and installing sleeve VW 455 (fig.) or

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– With left hand, raise differential -1-. With right hand, lift output
m
shaft for 1st to 4th gear together with selector rods -2-
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-arrow A-.
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– At same time, second mechanic lifts input shaft, reverse shaft

s
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with selector rods out of clutch housing -arrow B-.

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After shafts are lifted, differential may be set back in clutch hous‐
Prote AG.
ing if desired.
– Remove input shaft oil seal.
Note
Always renew deep groove ball bearing on input shaft

⇒ Item 6 (page 180) .
5.5.2 Installing
• A new deep groove ball bearing has been pressed onto the
input shaft ⇒ Item 6 (page 180) .

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– Insert input shaft -1-, output shaft for 5th and 6th gears -2-
un
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together with selector rod -3-, selector fork -4- and reverse
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– Then insert differential -1-.
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Note
o
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c
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A second mechanic will be required for further installation of
sd
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shafts in clutch housing.

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– Take output shaft for 1st through 4th gears -3- with selector Cop py
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rods -4- in the right hand as shown in figure. opyri
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– With the left hand, lift differential -1- slightly.
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cardiagn.com
– At the same time, a 2nd mechanic must slightly lift input shaft
and output shaft for 5th and 6th gears and reverse gear -2-
together with reverse gear shaft.
– Now insert output shaft for 1st through 4th gears in
-direction of arrow-.
• The teeth of the input shaft, the output shafts and the final drive
input gear of differential must mesh.
– Now, together with a second mechanic, place shafts and dif‐
ferential in their bearing seats.
– Secure support bridge -30 - 211 A- for input shaft to clutch

housing.
Note
For clarity of illustration, clutch housing is shown turned 180°.
– Screw in bolt -A- until input shaft rises slightly.

On some gearboxes, flats -A- are present on the deep groove ball
bearing for the input shaft and the bearing support -B-.
Volkswa AG. gen AG
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Deep groove ball bearing fors ainput
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No flats on deep groove ball bearing -A- or on bearing support
un
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-B- ⇒ page 141
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Flats on deep groove ball bearing -A- and on bearing support
ab
ility
-B- ⇒ page 142
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From gearbox date 10 04 6 through around gearbox date 20 01 8:
ole,
spec
A washer is installed above and one below the deep groove ball
t to the co
bearing for the input shaft ⇒ Item 6 (page 180) .
Upper washer Outer diameter 78.6 mm
rrectne
Lower washer Outer diameter 85 mm
ss o
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Measure distance above seat for deep groove ball bearing.
nform
mer
atio
Distance above Dimension „a“ Upper washer
om
deep groove ball
n
c
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bearing
thi
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Through gearbox 10 mm no
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date 09 04 6
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From gearbox date 10.7 mm yes
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In the gearbox housing, the area below the seat for the deep
groove ball bearing is also modified -arrow-
Area below bearing seat Lower washer
Through gearbox Not further ma‐ no
date 09 04 6 chined
From gearbox date Machined slightly yes
10 04 6 deeper

– If necessary, lay a washer (outer diameter = 85 mm) -1- on

deep groove ball bearing -2-.
For some gearboxes:

Flats -A- on deep groove ball bearing for input shaft and on bear‐
ing support -B-
• No washers may be laid above or below the deep groove ball
bearing. agen
AG. Volkswagen AG d
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• Flats -A- on deep groove ball bearing
ed
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V
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-B- in gearbox housing must line
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– Mark flats with coloured marks.
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– Transfer markings to upper area of deep groove ball bearing
an
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and to upper area of bearing support of gearbox housing (⇒
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– Heat gearbox housing for about 10 minutes to 100° C in vicinity
wit
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of seat for deep groove ball bearing of input shaft using -hot
hole
air blower- , e.g. -V.A.G 1416- .
spec
es, in part or in w
t to the co
rrectness of i
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Note
nform
♦ Heating is necessary to avoid damage to deep groove ball

ercia
bearing when gearbox housing is installed.

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♦ Line up marking on deep groove ball bearing -A- with marking

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on gearbox housing -B- and set gearbox housing in place.

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– For all gearboxes, heat gearbox housing for about 10 minutes

um
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to 100° C in vicinity of seat for deep groove ball bearing of input

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shaft using -hot air blower- , e.g. -V.A.G 1416- . t. Cop py
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– Apply sealant -AMV 188 200 03- evenly to sealing surface of yri
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clutch housing.
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– Set gearbox housing in place and tighten new bolts -A-, -B-
and -C- to specified torque.
Allocation of bolts:
A - Bolt with captive washer
B - Bolt without washer
C - Bolt with captive washer
– If a washer was laid on the deep groove ball bearing before

the gearbox housing was set in place, a washer -1- (outer di‐
ameter = 78.6 mm) must also be placed above the deep
groove ball bearing -2- ⇒ page 141 .
cardiagn.com
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– Install retaining
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– Remove
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– If stop sleeve for selector shaft has been removed, now drive
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– Turn gearbox in repair stand with opening for selector shaft

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– Insert selector shaft -1- in lower bearing -2- and in selector

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forks -3-.
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Note
nform
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For better clarity, sealing cover is removed in illustration.

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Cop py
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rig ht
py by
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Prote AG.

– Now press selector shaft -1- against stop sleeve -2- in

-direction of arrow- and guide downwards with selector finger
-3- through selector forks to stop.
• Selector shaft cover -4- must be parallel to bolting surface on
gearbox housing.
• Selector shaft must move freely in gate selection direction
(upwards and downwards).
Note
If selector shaft cover is tilted relative to bolting surface, selector

shaft is not inserted in lower bearing.
– Tighten bolts -3- for selector shaft cover -4-.

– Screw in locking bolt -2-, ensuring that angled rod -arrow- is
not engaged.
– Install reversing light switch -F4- -1-.
– Install left and right flange shaft with springs, thrust washers
and tapered rings.
cardiagn.com
– Drive in input shaft oil seal.
AG. Volkswagen AG d
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– Install slave cylinder with release bearing and tighten bolts

rm
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-arrows- to specified torque ⇒ Item 4 (page 39) .

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– Shift through all gears.

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spec
es, in part or in w
t to the co
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nform
mercia
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Rep. gr.34 - Controls, housing
agen
Prote AG.
– Drive sealing cover into gearbox housing to stop using thrust

piece -T10042- .
5.6 Assembly order, gearbox »with« retain‐

ing ring -A- for input shaft sealing cover
cardiagn.com
Removing and installing gearbox housing, selector mechanism,
input shaft, output shafts, differential and selector rods.
AG. Volkswagen AG d
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Prote
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agen 5. Dismantling and assembling gearbox

equipment required
♦ Sleeve -VW 455- or sleeve
-3160-
AG. Volkswagen AG d
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♦ -3- Splitter -Kukko is17/0-
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♦ -4- Counter support
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n
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n thi
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sd
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cum
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fo
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Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.

♦ Support bridge -30-211A-

♦ Drift -T10169-
♦ or drift -T10362-
⇒ page 163
1331-
♦ Hot air blower -V.A.G 1416-
cardiagn.com
AG. Volkswagen AG d
agen oes
olksw not
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aut ra
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nl
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es, in part or in w
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nf
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5.6.1 Removing
orm
m
atio
m
– Secure gearbox to assembly stand using bolts -arrows-.

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Prote AG.

Note
If one of the bolting holes does not contact the gearbox support ,
lay a washer between the hole and the gearbox support .
– Rotate gearbox on assembly stand so that oil drain plug is

below.
– Place drip tray underneath.
– Drain gear oil.
– Remove slave cylinder with clutch release bearing -arrows-.
cardiagn.com
During the following steps, ensure that the selector shaft is not
blocked by the angled rod -arrow-.
– Move selector shaft to neutral.
– Remove reversing light switch -F4- -1-.
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– Remove locking bolt -2-. agen oes
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– Then remove bolts -3-. orise
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– Pull selector shaft with selector shaft
ss a cover -4- out of gearbox c
housing.
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– Remove securing bolt for left and right flange shaft by screwing
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two bolts into flange and counterholding using a lever.

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– Pull out flange shafts with compression spring.

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– Gearboxes for vehicles with start-stop system: remove gear‐

box neutral position sender -G701- -arrow-.
– Remove bolts -B-, which secure gearbox housing to clutch

housing.
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One bolt -arrow- is located
ss a outside of bolting flange. c
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– Lock input shaft as follows:
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The lengths of the splines on the input shaft differ to those of the
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– Set either installing sleeve -VW 455- over input shaft on clutch
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– or set sleeve -3160- over input shaft on clutch housing

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– Clamp splitter -A-, e.g. -Kukko 17/0- , behind notch in splines t. Cop py
of input shaft.
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The back side of the splitter must rest against installing sleeve -
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VW 455- or sleeve -3160- without play.
AG.

– Remove retaining ring -A- for input shaft sealing cover.
– Pierce rubber in centre of cover -C- with a screwdriver .

– Pull sealing cover out of gearbox housing.
A - Counter support , e.g. -Kukko 22/1-
cardiagn.com
Remove retaining ring -C- from deep groove ball bearing of input
shaft in gearbox housing as follows:
– Hold one end of retaining ring with screwdriver -A-.
– Using a screwdriver , -B-, lever other end out of groove in deep
groove ball bearing -direction of arrow-.
– Using screwdriver -B-, lever out securing ring further.
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– Remove securing bolts -A- for gearbox housing to clutch hous‐

le
un
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ing.
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t to the co
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mer
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Rep. gr.34 - Controls, housing
agen
Prote AG.
– Screw adapter VW 771/40 into threaded hole of gearbox hous‐

ing.
– Heat gearbox housing using hot air blower , e.g. -V.A.G 1416-
in vicinity of bearing seat for deep groove ball bearing for input
shaft for about 10 minutes to about 100° C.
– Using multi-purpose tool VW 771/1 , pull gearbox housing off
clutch housing in -direction of arrow-.
Note
If necessary, carefully apply assembly lever on alternating sides

at overhanging housing shoulders along perimeter, being careful
not to damage sealing surfaces.
– Remove splitter -A- and installing sleeve VW 455 or sleeve

-3160- from input shaft.
To remove shafts from clutch housing, a second mechanic is re‐
quired.
cardiagn.com
– With left hand, raise differential -1-. With right hand, lift output
shaft for 1st to 4th gear together with selector rods -2-
-arrow A-.
– At same time, second mechanic lifts input shaft, reverse shaft
and output shaft for reverse, 5th and 6th gears -3- together
with selector rods out of clutch housing -arrow B-. G. Volkswagen nA AG do
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After shafts are lifted, differential may be set back in clutch hous‐
s
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– Remove input shaft oil seal.

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Note
hole
spec
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Always renew deep groove ball bearing on input shaft

⇒ Item 6 (page 180) .
rrectness of i
5.6.2 Installing
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• A new deep groove ball bearing has been pressed onto the
input shaft ⇒ Item 6 (page 180) .
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Prote 5. Dismantling and assembling gearbox
AG.
– First insert input shaft -1- and 5th and 6th gear output shaft
-2- together with selector rod -3-, selector fork reverse gear
-4- and reverse shaft -5-.
Note different mounting for reverse gear selector fork.
Reverse gear selector fork -1- is mounted on shaft -2- behind se‐
lector rod for 5th and 6th gear -3-.
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Reverse gear selector fork -1- is mounted on selector rod with
pt
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selector fork for 5th and 6th gear -2-.
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– Then insert differential -1-. ed
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A second mechanic will be required for further installation of
erm
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shafts in clutch housing.
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– Take output shaft for 1st through 4th gears -3- with selector
ole,
rods -4- in the right hand as shown in figure.
spec
t to the co
– With the left hand, lift differential slightly.
– At the same time, a 2nd mechanic must slightly lift input shaft
and output shaft for 5th and 6th gears and reverse gear -2-
rrectne
together with reverse gear shaft.
– Now insert output shaft for 1st through 4th gears in
ss o
-direction of arrow-.
cial p
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• The teeth of the input shaft, the output shafts and the final drive
mer
input gear of differential must mesh.
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– Now, together with a second mechanic, place shafts and dif‐
i
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ferential in their bearing seats.
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– Secure support bridge -30-211A- for input shaft to clutch hous‐
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ing.
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Note
by lksw
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Prote AG.
For clarity of illustration, clutch housing is shown turned 180°.
– Screw in bolt -A- until input shaft rises slightly.
Deep groove ball bearing of input shaft fits into gearbox housing
in only one position.
There is a flat section on deep groove ball bearing and on the
bearing support for the deep groove ball bearing.
• If the flats -A- and -B- are present, no washer must be placed
above or below the deep groove ball bearing ⇒ page 183 .
• Flats -A- on deep groove ball bearing and on bearing support
-B- in gearbox housing must line up.
– Mark flats with coloured marks.
– Transfer markings to upper area of deep groove ball bearing
and to upper area of bearing support of gearbox housing (⇒
next figure).
– Heat gearbox housing for about 10 minutes to 100° C in vicinity
of seat for deep groove ball bearing of input shaft using -hot
air blower- , e.g. -V.A.G 1416- .

Note
♦ Heating is necessary to avoid damage to deep groove ball

bearing when gearbox housing is installed.
♦ Apply sealant -AMV 188 200 03- evenly to sealing surface of
clutch housing.
♦ Line up marking on deep groove ball bearing -A- with marking
on gearbox housing -B- and set gearbox housing in place.
– Set gearbox housing in place and tighten new bolts -A-, -B-
and -C- to specified torque.
Allocation of bolts:
A - Bolt with captive washer.
B - Bolt without washer.
C - Bolt with captive washer.
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– Install retaining ring -1- for deep groove ball bearing of input t to the co
shaft.
rrectne
– Install support bridge -30 - 211 A- for input shaft.

– If stop sleeve for selector shaft has been removed, now drive
ss
it in to stop of tool ⇒ page 163 .

o
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– Turn gearbox in repair stand with opening for selector shaft

form
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upwards.
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– Insert selector shaft -1- in lower bearing -2- and in selector Cop py
forks -3-.
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Prote AG.
Note
For better clarity, sealing cover is removed in illustration.

– Now press selector shaft -1- against stop sleeve -2- in

-direction of arrow- and guide downwards with selector finger
-3- through selector forks to stop.
• Selector shaft cover -4- must be parallel to bolting surface on
gearbox housing.
• Selector shaft must move freely in gate selection direction
(upwards and downwards).

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If selector shaft cover is tilted
ir se
d relative to bolting surface, selector
b ua
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shaft is not inserted inuthlower bearing.
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– Tighten bolts -3- for selector shaft cover -4-.
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– Screw in locking bolt -2-, ensuring that angled rod -arrow- is
erm
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not engaged.
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– Install reversing light switch -F4- -1-.
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es, in part or in w
t to the co
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– Gearboxes for vehicles with start-stop system: fit gearbox

or
neutral position sender -G701- -arrow- and tighten securing
m
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bolt to 6 Nm.
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Prote AG.
– Drive in input shaft oil seal flush.

– Install slave cylinder with release bearing ⇒ page 39 .
– Shift through all gears.

– Drive sealing cover into gearbox housing to stop of thrust

piece.
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– Secure sealing cover with retaining ring -A-.
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– Install flange shafts together with springs, thrust washers and

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tapered rings.
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Prote AG.

6 Repairing gearbox housing

equipment required
♦ Drift sleeve -VW 244 B-
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♦ Thrust plate -VW
Vol 401-
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♦ Thrust plate
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♦ Press
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♦ Tube -VW 416 B-
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mer
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Prote AG.
6. Repairing gearbox housing 157

♦ Guide pin -VW 436A-

♦ Guide pin -VW 439-
♦ Guide pin -10 - 15-
♦ Thrust piece -3124-
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Cop py
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Prote AG.

♦ Drift -3264-
♦ Assembly tool -3290-
1331-
♦ Drift -T10168-
♦ Drift -T10169- or drift -
T10362- ⇒ page 163
AG. Volkswagen AG d
♦ Thrust piece -T10203- agen oes
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♦ -1- Internal puller -Kukko 21/2-
AG.

♦ -4- Counter support -Kukko 22/2-

1 - Gearbox housing
❑ If renewed: adjust out‐
put shafts and differen‐
tial ⇒ page 232
❑ Changes in area of sup‐
port for deep groove ball
bearing for input shaft
⇒ Item 3 (page 180) .
❑ Allocation of compo‐
nents via ⇒ Electronic
parts catalogue (ETKA)
2 - Cover plate
❑ Removing ⇒ page 161
❑ Driving in ⇒ page 161
3 - Oil drain plug
❑ Torque setting
⇒ page 127
4 - Seal
❑ Always renew, if part of
original equipment
5 - Oil filler plug
❑ Torque setting
⇒ page 127
cardiagn.com
6 - Angled rod
AG. Volkswagen AG d
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❑ Can be renewedhor with eo
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gearboxss a assembled ra
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⇒ page 162
erm
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7 - Bearing bush
hole
spec
❑ For selector rods

es, in part or in w
t to the co
❑ Pulling out ⇒ page 162

rrectness of i
8 - Stop sleeve
❑ Pressing out with gearbox dismantled ⇒ page 163
l purpos
❑ Pressing out with gearbox assembled ⇒ page 163

❑ Stop sleeve identification ⇒ page 163
nf
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orm
❑ Drive in stop sleeve with shoulder ⇒ page 164

m
atio
m
❑ Drive in stop sleeve without shoulder ⇒ page 164

o
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9 - Needle bearing
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❑ For reverse shaft

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❑ Pressing in ⇒ page 164 p by
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10 - Tapered roller bearing outer race Prote AG.
❑ For output shaft for 5th, 6th and reverse gears

❑ If renewed, adjust output shaft for 5th, 6th and reverse gears ⇒ page 222

11 - Shim
❑ Adjustment overview ⇒ page 232
12 - Tapered roller bearing outer race
❑ For output shaft for 1st through 4th gears
❑ If renewed, adjust output shaft for 1st through 4th gears ⇒ page 206
13 - Shim
14 - Tapered roller bearing n Aouter
G. Volkrace
swagen AG
swage does
❑ For differential yV
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❑ Removing oris
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and installing ⇒ page 233 nte
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❑ Ifss arenewed, adjust differential ⇒ page 232
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15 - Shim
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16 - Bearing bush
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17 - Plug
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❑ Driving out ⇒ page 165

l purpos

18 - Seal
nform
ercia

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Removing sealing cover -A-

at
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– Pierce centre of sealing cover using screwdriver -B- and lever

um
for
en
g
out cover -in direction of arrow-.

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Cop py
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Prote AG.
Driving in sealing cover to stop

Removing angled rod for selector shaft

– Break off angled rod in released position.
– Insert a screwdriver -A- in hole for angled rod -B-.
– Lever out angled rod in -direction of arrow-.
Installation position of angled rod

• Marking on angled rod -arrow- must face slave cylinder con‐
nection -1-.
• Dimension -a- must be about 45°.
cardiagn.com
AG. Volkswagen AG d
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Drive in angled rod for selector shaft -arrow- to stop of tool.
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Note
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Angled rod must be released while it is being driven in.

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Pulling out selector rod bearing bush

nform
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A - Internal puller, 14.5 … 18.5 mm , e.g. -Kukko 21/2-

m
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B - Counter support , e.g. -Kukko 22/2-

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Driving in selector shaft bearing bush to stop of tool
Pressing stop sleeve -A- out of gearbox housing

n AG. Volkswagen AG
– Set gearbox ohousing
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n t
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Driving stop sleeve out of assembled gearbox using guide pin -10
- 15-
• Remove locking screw and selector shaft.
rrectness of i
– Turn gearbox so that stop sleeve does not fall in gearbox.

l purpos
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ion
c
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Stop sleeve identification
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Cop py
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Following stop sleeves can be installed:
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Stop sleeve with shoulder -arrow 1- ⇒ page 164 . cted agen
Prote AG.
Stop sleeve without shoulder -arrow 2- ⇒ page 164 .

Allocate components according to ⇒ Electronic parts catalogue
„ETKA“ .

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta A2011
G. Volk➤
swagen AG
agen does
6-speed manual gearbox 02Q - Edition 06.2010 Volksw not
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Drive in stop sleeve with shoulder until tool makes contact tho
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• Clutch housing bolted to gearbox housing. s
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Drive in stop sleeve without shoulder until tool makes contact l purpos
• Clutch housing bolted to gearbox housing.
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Pulling reverse shaft needle bearing out of gearbox housing
AG.
A - Internal puller, 23.5 … 30 mm , e.g. -Kukko 21/4-

Note
The needle bearing is destroyed during removal and must be re‐

newed.
Pressing needle bearing -A- into gearbox housing

– Before pressing in, lay reverse shaft thrust washer -B- on nee‐
dle bearing.
– Support gearbox housing with tube -VW 416 B- directly below
bearing support.

Pulling out selector shaft bearing bush

– Use thread adapter from counter support -Kukko 22/1-
-arrow-.
– Hold spindle of assembly tool -3290- securely and turn nut
-B-.
A - Internal puller, 14.5 … 18.5 mm , e.g. -Kukko 21/2-
Driving in selector shaft bearing bush -A- to stop of tool.
AG. Volkswagen AG d
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Driving out plug -1-
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– Drive in plug -1- outwards from inside gearbox housing.
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Prote AG.

Driving in plug -1-

– Drive in sealing plug to dimension -a-, about 3 mm below upper
edge of housing, using drift -3264- .
cardiagn.com
AG. Volkswagen AG d
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c
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Cop py
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Prote AG.

7 Repairing clutch housing

equipment required
♦ Press tool -VW 407-
♦ Drift -T10168-
21/2-
21/4-
22/1-
22/2-
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or
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au ac
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es, in part or in w
t to the co
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nform
mercia
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com
tion in
r
te o
thi
s
iva
do
r
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cum
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t.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.
7. Repairing clutch housing 167

1 - Bearing bush
❑ For selector rods
❑ Renew each time after
removing
2 - Reverse gear selector fork
axle
❑ Axle cannot be removed
with workshop tools
❑ If a new clutch housing
is used, a new axle must
be pressed in
⇒ page 171
❑ Place reverse gear se‐
lector fork onto shaft
⇒ page 152
❑ If shaft is not present,
mounting on selector
rod for selector fork for
5th and 6th gear
⇒ page 152
cardiagn.com
3 - Needle bearing
❑ For reverse shaft
❑ Renew each time after
removing
❑ Pressing in
⇒ page 170
4 - Dowel sleeve wage
es n
olks ot g
❑ Qty. 2 d byV ua
ran
ir se tee
5 - Clutch housing
utho
or
a ac
❑ If renewed: adjust output shafts and differential ⇒ page 232 ss
ce
le
un
pt

an
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ility
ot p

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is n
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7 - Seal
ole,
spec

t to the co
8 - Washer
rrectne
❑ Installation position: shoulder on inner circumference faces seal ⇒ Item 7 (page 168)
ss
o
cial p
f in

form
mer
❑ If renewed, adjust differential ⇒ page 239

atio
om
n
c
10 - Oil deflector ring

i
or
n thi
e
❑ Installation position: shoulder on hole faces output shaft

t
sd
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cum

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Co
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168
by lksw
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Rep. gr.34 - Controls, housing Prote AG.
❑ If renewed, adjust output shaft for 1st through 4th gears ⇒ page 206
❑ If renewed, adjust output shaft for 5th, 6th and reverse gears ⇒ page 222
13 - Washer
❑ Always 0.65 mm thick
14 - Cylindrical roller bearing
❑ For input shaft
15 - Magnet
❑ Held in place by housing joint surface
16 - Cap
❑ Not fitted in all clutch housings
Pulling out selector rod bearing bush

cardiagn.com
B - Internal puller, 14.5 … 18.5 mm , e.g. -Kukko 21/2-
AG. Volkswagen AG d
agen oes
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ab
Driving in selector shaft bearing bush to stop of tool

ility
ot p
wit
is n
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ole,
spec
t to the co
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cial p
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mer
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n
c
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te
sd
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pr
cum
r
fo
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t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Pulling needle bearing out of clutch housing

B - Internal puller, 23.5 … 30 mm , e.g. -Kukko 21/4-
Note
. Volkswagen AG
gen AG does
The needle bearing is destroyed during removal olkand
swa must be re‐ not
yV
newed. se
d b gu
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ri
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Pressing needle bearing -A- into clutch housing

itte
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erm
ab
– Before pressing in, lay reverse shaft thrust washer -B- on nee‐
ility
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dle bearing.
wit
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spec
t to the co
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cial p
f inform
Removing input shaft oil seal
mer
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n
c
i
or
n
Note
thi
te
sd
iva
o
pr
When gearbox is removed, oil seal can be removed with drift. cum
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fo
en
ng
t.
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Cop py
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Prote AG.
Driving in input shaft oil seal flush

AG. Volkswagen AG d
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agen 6-speed
oes
n
manual gearbox 02Q - Edition 06.2010
ol ot g
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Pressing reverse gear oselector
ris
e
fork shaft into clutch housing tee
h
aut or
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ss
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un
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mercia
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tion in
r
te o
thi
s
iva
do
r
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cum
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en
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t.
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Cop py
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cardiagn.com
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

8 Repairing selector unit
Note
Lubricate bearing points and running surfaces with grease -G 000 450 02- .
❑ Self-locking
❑ Always renew
2 - Gearbox selector lever
❑ Install so that master
spline aligns with selec‐
tor shaft
❑ Can be renewed with
the selector mechanism
installed
⇒ page 74
❑ After installing, adjust
selector mechanism
⇒ page 82
cardiagn.com
3 - Shoe
❑ Clip into relay lever
4 - Bearing bush
❑ Not required for plastic
relay lever
5 - Relay lever AG. Volkswagen AG d
agen oes
olksw not
❑ Installation position ed byV gu
ara
⇒ page 74 horis nte
eo
ut
❑ After installing, adjust ss a ra
c
selector mechanism,
ce
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un
pt
⇒ page 82
an
d
itte
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❑ From 05.07, plastic re‐

rm
ab
lay lever ⇒ page 75

pe
ility
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6 - Selector unit
h re
hole
❑ Consists of selector
spec
shaft and selector shaft

es, in part or in w
t to the co
cover
❑ Components cannot be separated from each other
❑ Can be removed and installed with gearbox installed
rrectness of i
7 - Bearing bush
l purpos

❑ Removing and installing ⇒ Item 16 (page 161)
nform
ercia
8 - O-ring
m
a
com
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❑ Insert in peripheral groove of selector mechanism cover

n in
r
te o
thi
❑ Coat with gear oil when installing

s
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do
❑ Always renew
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9 - Cap
n
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op py
❑ For gearbox breather
. C rig
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Prote AG.

10 - Lock washer
❑ For relay lever
❑ Not fitted on plastic relay lever
❑ Always renew
11 - Seal for selector shaft
8.1 Renewing oil seal for selector shaft

♦ Tube -VW 423-
cardiagn.com
♦ Oil seal extractor lever -T20143/1-
AG. Volkswagen AG d
agen oes
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V gu
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♦ Sealing grease -G 052 128 A1-

nl
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– Remove complete air filter housing if it is over selector shaft

erm
ab
⇒ Rep. gr. 23 ; Repairing diesel direct injection system or ⇒

ility
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Rep. gr. 24 ; Repairing injection system

wit
, is n
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es, in part or in w
t to the co
rrectness of i
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nf
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Cop py
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173
op Vo
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Prote
cted AG. 8. Repairing selector unit
agen
Metal relay lever

– Pull off securing clip -2- and press relay lever -3- to side out of
mounting.
AG. Volkswagen AG d
agen oes
Note y Volksw not
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If relay lever cannot be removed due to gearbox ubracket,
tho remove eo
ra
gate selector cable from relay lever. Guide shoe
ss a
out of gearbox c
selector lever.
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e
nl
pt
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Plastic relay lever erm
ab
ility
ot p
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⇒ page 75 .
h re
hole
spec
es, in part or in w
t to the co
– Remove nuts -4- and remove gearbox selector lever -1-.
– Lever out seal using oil seal extractor lever -T20143/1- .
rrectness of i
l purpos
nform
mercia
at
om
cardiagn.com
ion
c
in t
or
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ate
do
priv
cum
for
en
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t.
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Cop py
t. rig
gh ht
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– Lightly oil outer circumference of new oil seal. p by
co Vo
by lksw
cted agen
– Fill space between sealing lip and dust lip -arrow- with sealing Prote AG.
grease -G 052 128 A1- .
– Drive in seal using thrust piece -VW 423- .

Carry out further installation in the reverse sequence noting the
following points:
– Install gearbox selector lever on selector shaft of gearbox and
tighten hexagon nut to specified torque ⇒ Item 1 (page 172) .
Note
The gearbox selector lever can be installed in only one position.

– If removed, install complete air filter housing ⇒ Rep. gr. 23 ;
Repairing diesel direct injection system or ⇒ Rep. gr. 24 ;

9 Repairing selector forks

equipment required
♦ Thrust plate -VW 402-
♦ Tube -VW 426-
♦ Thrust piece -VW 431-
21/3-
22/1-
cardiagn.com
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es, in part or in w
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l purpos
nform
mercia
at
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ion
c
in t
or
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ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.
9. Repairing selector forks 175

1 - Rubber dampers
❑ Can be removed from
and inserted in selector
rod by hand
fork for 1st and 2nd gears
fork for 3rd and 4th gears agen
AG. Volkswagen AG d
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4 - Selector rod with selector byV gu
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fork for 5th and 6th gears horis
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5 - Selector fork for reverse ss c
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un
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❑ Is mounted on shaft for itte
y li
rm
reverse gear selector
ab
pe
ility
fork ⇒ page 152
ot
wit
, is n
❑ From gearbox manufac‐
h re
ture date 06 03 6, ball
hole
spec
sleeve
es, in part or in w
⇒ Item 6 (page 176) is
t to the co
discontinued
❑ Gradually discontinued
rrectness of i
❑ Reverse gear selector
fork is modified
l purpos
cardiagn.com
❑ If shaft for reverse gear
selector fork is not
nform
ercia
present, mounting on
selector rod for selector
m
a
com
ti
fork for 5th and 6th gear
on in
⇒ page 152
r
te o
thi
s
❑ Distinguishing between
iva
do
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reverse gear selector

rp
cum
fo
forks ⇒ page 176
en
ng
t.
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❑ Allocation of compo‐ Cop py
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parts catalogue (ETKA) co Vo
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6 - Ball sleeve
AG.

❑ Pressing in ⇒ page 177
❑ From gearbox manufacture date 06 03 6, ball sleeve is discontinued
❑ Gradually discontinued
Distinguishing between reverse gear selector forks

Dim. „a“ mm Selector fork for re‐ Mounting
verse gear
24 With ball sleeve On reverse gear se‐
18 Without ball sleeve lector fork shaft
⇒ page 152
15 Without ball sleeve On selector rod with
selector fork for 5th
and 6th gears
⇒ page 152

Through gearbox manufacture date 05 03 6 - pulling out ball

sleeve for reverse gear selector fork
A - Internal puller, 18 … 23 mm , e.g. -Kukko 21/3-
AG. Volkswagen AG d
agen oes
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ara
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Through gearbox manufacture date 05 03 6 - pressing in ball
ility
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sleeve for reverse gear selector fork
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es, in part or in w
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cardiagn.com
m
at
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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
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
9. Repairing selector forks 177

35 – Gears, shafts
1 Input shaft
1.1 Dismantling and assembling input shaft

equipment required
♦ Press tool -VW 412- AG. Volkswagen AG d
agen oes
♦ Thrust piece -VW 431- olksw not
V gu
d by ara
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♦ Thrust piece -VW 432- horis
eo
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ab
cardiagn.com
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f inform
mer
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n
c
i
or
n thi
te
sd
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o
pr
cum
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fo
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t.
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Cop py
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o
by c lksw
cted agen
Prote AG.
178 Rep. gr.35 - Gears, shafts

swage es n
♦ Thrust piece -VW 454- yV
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ua
d b ran
♦ Thrust piece -30 - 505- ir se tee
tho
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♦ Thrust plate -40 - 105- ss
ce
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un
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♦ Tube -2040-
an
d
itte
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♦ -1- Internal puller -Kukko rm
ab
pe
ility
21/5-
ot
wit
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♦ -2- Puller -Kukko 18/1-
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
22/2-
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
cardiagn.com
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Note
♦ Install all bearings on input shaft with gear oil.

♦ Always renew deep groove ball bearing ⇒ Item 6 (page 180) .
1. Input shaft 179

1 - Retaining ring
❑ For deep groove ball
bearing of input shaft
⇒ page 134
2 - Washer
❑ Outer diameter = 78.6
mm
❑ May be used only in AG. Volkswagen AG d
agen
modified gearbox hous‐ olksw
oes
not
ings (from gearbox date byV gu
ara
ed
nte
10 04 6 through around horis
eo
gearbox date 20 01 8) aut ra
s c
⇒ page 183 s
ce
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un
pt
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ab
pe
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wit
3 - Gearbox housing
, is n
h re
❑ From gearbox date
hole
spec
10 04 6 through around
es, in part or in w
gearbox date 20 01 8,
t to the co
modified in vicinity of
seat for deep groove
ball bearing
rrectness of i
cardiagn.com
⇒ Item 6 (page 180) ,
l purpos
washers
⇒ Item 2 (page 180) and
⇒ Item 4 (page 180) ,
nform
ercia
⇒ page 183
m
❑ From around gearbox
a
com
tio
date 21 01 8, flats on
n in
r
deep groove ball bear‐

te o
thi
ing and on bearing sup‐
s
iva
do
port for deep groove ball
r
rp
cum
fo
bearing ⇒ page 183

en
ng
t.
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❑ Allocation of compo‐ Cop py
nents via ⇒ Electronic parts catalogue (ETKA) ht. rig
rig ht
py by
o Vo
4 - Washer
by c lksw
cted agen
Prote AG.
❑ Outer diameter = 85 mm
❑ May be used only in modified gearbox housings (from gearbox date 10 04 6 through around gearbox
date 20 01 8) ⇒ page 183
❑ Allocation of components via ⇒ Electronic parts catalogue (ETKA)
5 - Retaining ring
❑ If deep groove ball bearing ⇒ Item 6 (page 180) and input shaft ⇒ Item 8 (page 181) are renewed,
redetermine ⇒ page 182
6 - Deep groove ball bearing
❑ Always renew
❑ Pulling off ⇒ page 181
❑ Pressing on ⇒ page 182
❑ From around gearbox date 21 01 8, flats on deep groove ball bearing and on bearing support for deep
groove ball bearing ⇒ page 184
7 - Gear wheel for 5th gear
❑ Offered as replacement part together with input shaft
❑ Pressing off ⇒ page 181
❑ Installation position: peripheral groove -arrow- faces deep groove ball bearing ⇒ Item 6 (page 180)

8 - Input shaft
❑ With gear wheels for 3rd, 4th and 6th gears
9 - Cylindrical roller bearing
❑ With retaining ring
❑ Installation position: retaining ring in bearing faces input shaft
10 - Clutch housing
Pulling off deep groove ball bearing

– First remove retaining ring from input shaft.
– Before setting up pulling device, set thrust piece -VW 431- and
thrust plate -40 - 105- on input shaft.
– Apply splitter -B- to peripheral groove for retaining ring in bear‐
ing.
A - Puller , e.g. -Kukko 18/1-
B - Splitter, 12 … 75 mm , e.g. -Kukko 17/1-
cardiagn.com
Pressing off 5th gear wheel
A - Splitter, 22 … 115 mm , e.g. -Kukko 17/2-
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
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aut ra
ss c
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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Pressing on gear wheel for 5th gear
ole,
spec
Groove -arrow- in wheel must face upwards.

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
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
1. Input shaft 181

Pressing on deep groove ball bearing

Deep groove ball bearing with a rubber ring -arrow-
Shoulder -A- faces press tool -VW 412- . 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
Installation position of deep groove ball bearing
hole
spec
es, in part or in w
Groove for retaining ring faces upwards -arrow A- and shoulder
t to the co
-arrow B- must face gear wheel for 5th gear.
– Determine and install retaining ring ⇒ page 182 .
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
c
cardiagn.com
or
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.
Determining thickness of retaining ring

– Insert a 1.86 mm thick retaining ring -A- in groove of input shaft
and press upwards.
– Measure distance between deep groove ball bearing -B- and
installed retaining ring -A- using feeler gauge -C-.
– Remove retaining ring used for measuring purposes.
– Determine retaining ring from table.
Note
Allocate retaining rings according to ⇒ Electronic parts catalogue

„ETKA“ .
The following retaining rings are available:

Measured value Retaining ring thick‐ Axial play (mm)
(mm) ness (mm)
0.01…0.05 1.86 0.01…0.05
0.05…0.07 1.89 0.01…0.05
0.07…0.10 1.92 0.01…0.05
0.10…0.13 1.95 0.01…0.05
0.13…0.16 1.98 0.01…0.05

Pulling cylinder roller bearing out of clutch housing

– When pulling out, squeeze together retaining ring -arrow- of
cylindrical roller bearing, using pliers -C-.
Pressing cylindrical roller bearing into clutch housing

– When pressing in, squeeze together retaining ring -arrow- of
cylinder roller bearing, using pliers -A-.
– Remove pliers before cylindrical roller bearing is in installation
position. Retaining ring must engage in groove of clutch hous‐
ing. olksw n AG. V agen AG
wage does
Volks not
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by ara
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oris eo
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au ra
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nl
pt
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1.1.1 Modification in area of deep groove ball

erm
ab
ility
ot p
bearing
wit
, is n
h re
From gearbox date 10 04 6 through around gearbox date 20 01 8:

hole
spec
es, in part or in w
One washer above and one below bearing seat for deep groove
t to the co
ball bearing ⇒ Item 6 (page 180) .

Above bearing seat:
rrectness of i
Bearing seat Washer above bear‐

l purpos
ing seat
Through gearbox Dimension „a“ = 10 no
nf
ercia
date 09 04 6 mm
orm
m
From gearbox date Dimension „a“ = yes

atio
m
10 04 6 10.7 mm
o
n in
or c
through around
thi
e
gearbox date
t
sd
iva
20 01 8:
r
rp
cu
o
m
f
en
ng
From around gear‐ Below bearing seat: no

t.
yi Co
box date 21 01 8 flat for deep groove . Cop py
ball bearing
t rig
gh ht
pyri by
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co lksw
by
Beneath bearing seat: cted agen
Prote AG.
1. Input shaft 183

From gearbox date 10 04 6 through around gearbox date 20 01 8

slightly deeper
In order for the washer beneath the deep groove ball bearing
⇒ Item 6 (page 180) to fit, the bearing seat for the deep groove
ball bearing -arrow- is machined out slightly.
Beneath bearing seat: Washer beneath
bearing seat
Through gearbox Not further ma‐ no
date chined
09 04 6
From gearbox date Machined slightly yes
10 04 6 deeper
through around
gearbox date
20 01 8:
From around gear‐ Flat -B- for deep no
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From around gearbox date 21 01 8, flats on deep groove ball wagen AG. Volkswagen AG doe
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2 Output shaft for 1st through 4th gears
2.1 Assembly overview - output shaft for 1st

through 4th gears
Dismantling and assembling output shaft for 1st through 4th gears
⇒ page 187 .
Note
♦ If output shaft or tapered roller bearings have been renewed, adjust output shaft ⇒ page 206 .
♦ Always renew both tapered roller bearings together as a set.
1 - Clutch housing
2 - Oil deflector ring
Volkswagen AG
3 - Dished washer wage
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5 - Tapered roller bearing inner

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❑ Pressing off
⇒ page 192
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❑ Pressing on
⇒ page 193
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6 - Output shaft
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❑ For 1st through 4th

gears
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❑ Adjusting ⇒ page 206

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differentiation
⇒ page 195
9 - Synchro-ring (inner ring for
2nd gear)
❑ 1st/2nd gear synchronisation modified from gearbox date 26 10 9, differentiation ⇒ page 195
10 - Outer ring for 2nd gear
11 - Synchro-ring for 2nd gear
2. Output shaft for 1st through 4th gears 185

12 - Locking collar with synchro-hub for 1st and 2nd gears

❑ After removing retaining ring ⇒ Item 13 (page 186) , press off with synchromeshed gear for 2nd gear
⇒ page 195
❑ Dismantling ⇒ page 197
❑ Assembling locking collar and synchro-hub ⇒ page 197
13 - Retaining ring
14 - Synchro-ring for 1st gear
15 - Outer ring for 1st gear
16 - Synchro-ring (inner ring for 1st gear)
17 - Needle bearing
❑ For 1st gear
18 - Synchromeshed gear for 1st gear
19 - Thrust washer
❑ For 1st through 4th gears
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24 - Locking collar with synchro-hub for 3rd and 4th gears

❑ After removing retaining ring ⇒ Item 25 (page 186) , pull off with 4th gear synchromeshed gear
⇒ page 195
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❑ Installation position, locking collar and synchro-hub ⇒ page 199

❑ Assembling locking collar and synchro-hub ⇒ page 197 and ⇒ page 197
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25 - Retaining ring
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26 - Synchro-ring for 3rd gear

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28 - Synchro-ring (inner ring for 3rd gear)
Prote AG.

❑ Check lugs for scoring
29 - Needle bearing
❑ For 3rd gear

30 - Synchromeshed gear for 3rd gear

31 - Tapered roller bearing inner race
32 - Retaining ring
❑ If tapered roller bearing ⇒ Item 31 (page 187) and output shaft ⇒ Item 6 (page 185) are renewed, rede‐
termine ⇒ page 194
34 - Shim ksw
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❑ Determining
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distinguishing ⇒ page 195
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equipment required
♦ Press tool -VW 408A-
♦ Tube -VW 415A-
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♦ Tube -VW 516-
♦ Tube -VW 519-
♦ Thrust plate -40-105-
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♦ Drift sleeve -40-20-

♦ Drift sleeve -40-21-
♦ Supplementary set for en‐
gine and gearbox support -
VW 540/1 B-
♦ Tapered roller bearing pull‐
er -V.A.G 1582-
♦ Adapter -V.A.G 1582/7-
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♦ -1- Internal puller -

Kukko 21/7-
♦ -1- Internal puller -

Kukko 21/8-
♦ -2- Puller -Kukko
18/2-
♦ -3- Splitter -Kukko
17/2-
♦ -4- Counter support -
Kukko 22/2-
Pulling dished washer
-A- out of output shaft
cardiagn.com
Pressing dished washer into output shaft
Dimension „a“ = 2 mm
AG. Volkswagen AG d
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Press on tapered roller bearing inner race on side facing clutch

housing
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Pullingutapered
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Pressing tapered roller bearing outer race into clutch housing

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– Support clutch housing with drift sleeve -40-20- directly below

bearing support.
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Pull off tapered roller bearing inner race on side facing gearbox
AG.
housing
Before setting up tapered roller bearing puller :
– Remove retaining ring for tapered roller bearing inner race on
side facing clutch housing.
– Insert press tool -VW 431- into output shaft and place thrust
plate -40-105- on that.

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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005ks➤
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Determining thickness of retaining ring
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– Determine thickest retaining ring which will still fit and install it.
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Note
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Allocate retaining rings using ⇒ Electronic parts catalogue (ET‐

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The following retaining rings are available:
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Thickness (mm) py by
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1.79 1.83 1.86 1.89
Prote AG.
1.92 1.95 1.98
Pulling outer race for tapered roller bearing out of gearbox hous‐
ing
Pressing tapered roller bearing outer race into gearbox housing

– Fit shim under outer race.
– Support gearbox housing with thrust piece -2050- below bear‐
ing support.
Dismantle output shaft.
Note
Pull off tapered roller bearing inner race on side facing clutch
housing ⇒ page 193 .

Pulling off synchro-hub and locking collar for 3rd and 4th gears
with synchromeshed gear for 4th gear
– First remove retaining ring.
Pressing off locking collar and synchro-hub for 1st and 2nd gears
After removing retaining ring, press off synchromeshed gear for
2nd gear together with locking collar and synchro-hub.
AG. Volkswagen AG d
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2.2.1 Distinguishing 1st/2nd gear synchroni‐
itte
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♦ From gearbox date 26 10 9 onwards ⇒ page 196
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1st/2nd gear synchronisation up to gearbox date 25 10 9
Synchro-ring -C- and inner ring -A- are made of brass. Outer ring
-B- is made of steel. rrectness of i
Assembling 1st to 4th gear output shaft up to gearbox date
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25 10 9 ⇒ page 196
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1st/2nd gear synchronisation from gearbox date 26 10 9 onwards

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Assembling 1st to 4th gear output shaft - from gearbox horisdate nte
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2.2.2 Assembling 1st to 4th gear output shaft

up to gearbox date 25 10 9
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Checking inner ring for 1st, 2nd and 3rd gears for wear
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– Press inner ring onto cone of synchromeshed gear and meas‐
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ure gap -a- using a feeler gauge.
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1st, 2nd 3rd 0.75 … 1.25 mm 0.3 mm
gears
Checking synchro-rings for 1st, 2nd and 3rd gear for wear
– Press synchro-ring, outer ring and inner ring onto cone of syn‐
chromeshed gear and measure gap -a- using a feeler gauge.
Gap -a- Installation dimen‐ Wear limit
sion
1st, 2nd 3rd 1.2 … 1.8 mm 0.5 mm
gears
– Install 2nd gear synchromeshed gear with needle bearing.

Installation position of outer ring, inner ring and synchro-ring for

2nd gear
– Check lugs -arrows 1- and -arrows 2-AGfor
agen
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– Renew inner ring, outeredring
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– Place inner ring -A-
ss on synchromeshed gear for 2nd gear.
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Angled lugs -arrows 1- face outer ring -B-.
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Dismantling and assembling locking collars and synchro-hubs of
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1st and 2nd gears as well as 3rd and 4th gears
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2- Locking piece
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Notches for locking pieces in synchro-hub and locking collar must

align.
Assembling locking collars and synchro-hubs for 1st and 2nd

gears as well as 3rd and 4th gears
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.
Installation position of locking collar with synchro-hub for 1st and

2nd gears
Identification groove -arrow 1- and narrow collar -arrow 2- of syn‐
chro-hub face 1st gear.

Pressing on locking collar and synchro-hub for 1st and 2nd gears
Turn synchro-ring so that grooves align with locking pieces.
– Install retaining ring.
Insert synchro-ring for 1st gear.
Installation position of 1st gear outer ring

Lugs -arrows- face synchro-hub and locking collar -A-.
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Higher shoulder -A- faces 2nd gear -B-. Notches in shoulder

-arrows- engage in lugs of outer ring ⇒ page 198 .
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– Install thrust washers for 1st and 4th gears

m

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– Install 4th gear synchromeshed gear with needle bearing.

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Checking synchro-ring for 4th gear for wear

– Press synchro-ring onto cone of synchromeshed gear and
measure gap -a- using feeler gauge.
sion
4th gear 1.0 … 1.7 mm 0.5 mm
Installation position of locking collar with synchro-hub for 3rd and

4th gears
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Wider shoulder of synchro-hub -arrow- faces
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Pressing on synchro-hub with locking collar for 3rd and 4th gears
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– Turn synchro-ring so that grooves align with locking pieces.
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– Place 3rd gear synchro-ring on locking collar with synchro-hub
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for 3rd and 4th gears.
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Installation position of 3rd gear outer ring

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Installation position of synchro-ring -A- (3rd gear inner ring)

Lugs -arrows 1- locate in notches -arrows 2- of synchro-ring -B-.
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Installation position
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Higher shoulder
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– Install 3rd gear synchromeshed gear with needle bearing.
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Note
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spec
♦ Press on tapered roller bearing inner race ⇒ page 194 .
es, in part or in w
t to the co
♦ Determine retaining ring for tapered roller bearing inner race
⇒ page 194 .
cardiagn.com
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2.2.3 Assembling 1st to 4th gear output shaft

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- from gearbox date 26 10 9 onwards

nf
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Check inner friction surface of 1st gear outer ring and 2nd gear
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1st and 2nd gears 1.00 … 1.80 mm 0.3 mm

Check outer friction surface of 1st gear outer ring and 2nd gear
outer ring for wear
– Check inner surface of synchro-ring -arrow- for scoring and
radial contact scoring, renew if necessary.
– Place inner ring, outer ring and synchro-ring on cone of inner
ring.
– Press on synchro-ring with outer ring whilst turning at same
time in order to seat them.
– Measure gap size -a- at 3 points offset by 120° using feeler
gauge.
– Make a note of average value.
sion
1st and 2nd gears 1.00 … 1.80 mm 0.8 mm
– Install 2nd gear synchromeshed gear with needle bearing.
Installation of outer ring, inner ring and synchro-ring for 2nd gear
– Place inner ring -A- on synchromeshed gear.
Lugs -1- point away from synchromeshed gear.
– Fit outer ring -B-.
cardiagn.com
Lugs -2- engage in notches -3- of synchromeshed gear.
– Fit synchro-ring -C-.
Larger notches -4- engage in lugs -1- of inner ring -A-.
AG. Volkswagen AG d
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Dismantling and assembling locking collars and synchro-hubs of

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1- Spring
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2- Locking piece
3- Locking collar
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4- Synchro-hub
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– Slide locking collar over synchro-hub.

In 3rd and 4th gear, wide collar of synchro-hub and, if present,
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Assembling locking collars and synchro-hubs for 1st and 2nd

gears as well as 3rd and 4th gears
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Pressing on locking collar and synchro-hub for 1st and 2nd gears
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– Install thrust washers for 1st and 4th gears
– Install 4th gear synchromeshed gear with needle bearing.
Checking synchro-ring for 4th gear for wear

sion
4th gear 1.0 … 1.7 mm 0.5 mm
Installation position of locking collar with synchro-hub for 3rd and

4th gears
Wider shoulder of synchro-hub -arrow- faces 3rd gear.

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Checking synchro-ring for 3rd gear for wear
– Press synchro-ring, outer ring and inner ring onto cone of syn‐
chromeshed gear and measure gap -a- using a feeler gauge.
sion
3rd gear 1.2 … 1.8 mm 0.5 mm
– Place 3rd gear synchro-ring on locking collar with synchro-hub
for 3rd and 4th gears.
Installation position of 3rd gear outer ring

Lugs -arrows- face synchro-hub and locking collar -A-.

Installation position of synchro-ring -A- (3rd gear inner ring)

Lugs -arrows 1- locate in notches -arrows 2- of synchro-ring -B-.
Installation position of 3rd gear synchromeshed gear

Higher shoulder -A- faces 4th gear -B-. Notches in shoulder
– Install 3rd gear synchromeshed gear with needle bearing.
Note
♦ Press on tapered roller bearing inner race ⇒ page 194 .

♦ Determine retaining ring for tapered roller bearing inner race
⇒ page 194 .
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2.3 Adjusting output shaft for 1st through 4th gears
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(Determining shim for output shaft)

It is necessary to readjust the output shaft when the following
components are renewed:
♦ Gearbox housing
♦ Clutch housing
♦ Output shaft for 1st to 4th gear or
♦ Tapered roller bearing for output shaft
Adjustment overview ⇒ page 232
Prerequisites:
• Sealing surfaces of clutch and gearbox housings must be free
of sealant.
• When taking measurements, install only the output shaft to be
measured.

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– Press tapered roller bearing outers race with 1.70 mm thick
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– Set gearbox housing in position and tighten bolts -A- as well

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– Set up measuring tools and secure to clutch housing using bolt

-arrow-.
– Set dial gauge (3 mm measuring range) to „0“ with 1 mm pre‐
load.
– Loosen clutch housing/gearbox housing securing bolts diag‐
onally until the bolts release the gearbox housing or output
shaft.
– Read and note value on dial gauge (example: 0.14 mm).
Note
♦ If no value is indicated when clutch housing/gearbox housing

securing bolts are loosened:
♦ Install 1.95 mm shim or, if necessary, 2.20 mm shim for meas‐
urement.
♦ Allocate shims using ⇒ Electronic parts catalogue (ETKA) .
2.3.1 Determining thickness of shim

Specified bearing preload is obtained as follows:
Subtracting measured value (0.14 mm) from inserted shim
(1.70 mm).
Add a constant value for preload (0.20 mm).

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2.3.2 Table of shims

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Thickness (mm)
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1.55 1.85 2.15
1.60 1.90 2.20
1.65 1.95 2.25
1.70 2.00
The various thicknesses make it possible to achieve the exact
shim thickness required.
– Determine part number of shim according to ⇒ Electronic
parts catalogue „ETKA“ .
– Press in tapered roller bearing outer race together with correct
shim (in example 1.75 mm). In the process, support gearbox
housing using thrust piece -2050- directly below bearing sup‐
port.
2.3.3 Carrying out check measurement

• Determined shim installed.

– Set up measuring tools and secure to clutch housing using bolt

-arrow-.
load.
shaft.
– If correct shim has been selected, dial gauge will indicate a
value between 0.15 mm to 0.25 mm.
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3 Output shaft for 5th, 6th and reverse

gears
3.1 Dismantling and assembling output shaft for 5th, 6th and reverse gears

equipment required
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3. Output shaft for 5th, 6th and reverse gears 211


♦ Support rail -VW 457-
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♦ Drift sleeve -40 - 20-
♦ Tube -3296-
er -V.A.G 1582-
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♦ If output shaft or tapered roller bearings have been renewed, adjust output shaft ⇒ page 222 .
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1 - Clutch housing
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2 - Washer
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❑ Always 0.65 mm thick
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❑ Pressing in
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⇒ page 217
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❑ For 5th, 6th and reverse
gears
❑ Adjusting ⇒ page 222
6 - Reverse gear synchro-hub
❑ Pressing off
⇒ page 218
⇒ page 218
❑ Pressing on
⇒ page 219
7 - Retaining ring
8 - Reverse gear locking collar
❑ With synchro-ring
9 - Needle bearing
❑ For synchromeshed
gear for reverse gear

10 - Synchromeshed gear for reverse gear

11 - Sleeve
❑ Press off together with synchromeshed gear for reverse gear ⇒ page 218
❑ Installation position: wide shoulder of sleeve faces synchromeshed gear for reverse gear
12 - Retaining ring
13 - Needle bearing
❑ For 6th gear
Volkswagen AG
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17 - Retaining ring
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18 - Needle bearing
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❑ For 5th gear
19 - Synchro-ring for 5th gear
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❑ Pressing in ⇒ page 221 Prote AG.
24 - Shim
❑ Determining thickness ⇒ page 222
26 - Spring
27 - Locking collar
28 - Synchro-hub
29 - Locking pieces (Qty. 3)

Pulling out tapered roller bearing outer race

Note
After pulling out, check washer for damage and renew if neces‐
sary.
Pressing tapered roller bearing outer race into clutch housing

– Fit washer under outer race. lkswage es n
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Pulling off tapered roller bearing inner race
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thrust plate -40 - 105- on output shaft.
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Pressing off sleeve -A- together with synchromeshed gear for re‐
verse gear
Pressing off reverse gear synchro-hub

cardiagn.com
– Before setting up pulling device, set thrust plate -30 - 11- on
output shaft.
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Installation position of reverse gear synchro-hub s
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Pressing on reverse gear synchro-hub

Pressing on sleeve -A-

Installation position: Wide collar faces reverse gear synchro‐
meshed gear.
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Checking synchro-rings for 5th and 6th gear for wear
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Dismantling and assembling locking collar and synchro-hub for

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– Slide locking collar over synchro-hub.
AG.

align.

Assembling locking collar with synchro-hub for 5th and 6th gears
Pressing on locking collar and synchro-hub for 5th and 6th gears
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Pressing on tapered roller bearing inner race
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– Determine retaining ring from table. Part number ⇒ Electronic

spec

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Available retaining rings

Thickness (mm)
rrectness of i
1.79 1.89 1.98

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1.83 1.92
1.86 1.95
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– Support gearbox housing with thrust piece -2050- below bear‐
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3.2 Adjusting output shaft for 5th, 6th and reverse gears

equipment required
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It is necessary to readjust the output shaft when the following
components are renewed:
♦ Gearbox housing
♦ Clutch housing
♦ Output shaft for 5th, 6th and reverse gears or
♦ Tapered roller bearing for output shaft
Adjustment overview ⇒ page 232 .
Prerequisites:
• Sealing surfaces of clutch and gearbox housings must be free
of sealant.
• When taking measurements, install only the output shaft to be
measured.

– Press tapered roller bearing outer race with 1.70 mm thick

shim into gearbox housing to stop. In the process, support
gearbox housing using thrust piece -2050- directly below bear‐
ing support.
– Set complete 5th, 6th and reverse gear output shaft in clutch
housing.
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– Read and note value on dial gauge (example: 0.25 mm).
Note
♦ If dial gauge indicates no value when clutch housing/gearbox

housing securing bolts are loosened, install a 1.95 mm shim
or, if necessary, a 2.20 mm shim.
♦ Allocate shims according to ⇒ Electronic parts catalogue „ET‐
KA“ .
3.2.1 Determining thickness of shim

The specified bearing preload will be attained by subtracting the
measured value (0.25 mm) from the inserted shim (1.70 mm) and
adding a constant value for preload (0.20 mm).
Example:
Installed shim 1.70 mm

- Measured value 0.25 mm

Shim thickness 1.65 mm
– Determine thickness of shim from table ⇒ page 225 .
– Remove gearbox housing and pull tapered roller bearing outer
race from gearbox housing.
– Remove inserted shim (1.70 mm thick) from gearbox housing.
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3.2.3 Carrying out check measurement

• Determined shim installed.
– Set up measuring tools.

– If the edge of the housing protrudes, put washers with a total

thickness of 8 mm on bolt -arrow- for securing assembly de‐
vice -VW 792- to clutch housing.
load.
shaft.
– If correct shim has been selected, dial gauge will indicate a
value between 0.15 mm to 0.25 mm.
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39 – Final drive - differential

1 Renewing flange shaft oil seals with
gearbox installed
1.1 Renewing oil seal for left flange shaft

equipment required
♦ Puller hooks -VW 771/37-
♦ Torque wrench -
V.A.G 1331-
♦ Torque wrench -
V.A.G 1332-
♦ Sealing grease -G 052 128
A1-
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♦ Drip tray
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1. Renewing flange shaft oil seals with gearbox installed
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– Place drip tray under gearbox.
– Remove flange shaft securing bolt by screwing two bolts into
flange and counterholding flange shaft with a lever.
– Pull out flange shaft with compression spring.
– Remove flange shaft oil seal.
228 Rep. gr.39 - Final drive - differential

1.1.2 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 using countersunk bolt and tighten to
specified torque ⇒ Item 10 (page 235) .
– Install left drive shaft ⇒ Running gear, axles, steering; Rep.
gr. 40 ; Repairing drive shafts; Removing and installing drive
shafts .
– Install lower part of front left wheel housing liner ⇒ General
– Install wheel ⇒ Running gear, axles, steering; Rep. gr. 44 ;
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Torque settings for mounting wheels .
– Check gear oil ⇒ page 126 . AG. Volkswagen AG d
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1.2 Renewing seal for right flange shaft
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1. Renewing flange shaft oil seals with gearbox installed 229

♦ Sealing grease -G 052 128 A1-
1.2.1 Removing
– Remove drive shaft heat shield from engine -arrows-, if fitted.
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– Removing right drive shaft from gearbox flange
wage
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– Place drip tray under gearbox.

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– Remove flange shaft securing bolt by screwing two bolts into

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– Pry seal out using assembly lever.

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bolts -arrows- to specified torque ⇒ Running gear, axles,
steering; Rep. gr. 40 ; Repairing drive shafts .
– Check gear oil ⇒ page 126 .
1. Renewing flange shaft oil seals with gearbox installed 231

2 Adjustment overview
Note
If repairs have been carried out on the gearbox, it is necessary to

readjust output shaft for 1st through 4th gear, output shaft for 5th,
6th and reverse gear or differential only if components have been
renewed which have a direct effect on the adjustment of the gear‐
box. To prevent unnecessary adjustments, refer to the following
table:
To be adjusted:
Output shaft Output shaft Differential
for 1st for 5th, 6th ⇒ page 239
through 4th and reverse
gears gears
⇒ page 206 ⇒ page 222
Parts renewed: Gearbox housing x x x
Clutch housing x x x
Output shaft for 1st through 4th x
gears
Output shaft for 5th, 6th and reverse x
gears
cardiagn.com
Differential cage x
Tapered roller bearings for 1st to x
4th gear output shaft
Tapered roller bearings for 5th, 6th x
and reverse gear output shaft
Tapered roller bearing for differen‐ x
tial
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Rep. gr.39 - Final drive - differential cted agen
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3 Differential
3.1 Dismantling and assembling differential

equipment required
♦ Press tool -VW 408 A-
♦ Tube -VW 415 A-
♦ Thrust plate -3005- lkswage es n
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3. Differential 233
♦ Tube -3259-
♦ Tube -3296-
♦ Tube -3345-
er -V.A.G 1582-
♦ Adapter -V.A.G 1582/6A-
21/7-
♦ -2- Puller -Kukko 18/1-
22/2-
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1 - Gearbox housing
2 - Shim
❑ Determining thickness
⇒ page 239
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9 - Clutch housing
10 - Countersunk bolt, 33 Nm
❑ Screw into threaded piece ⇒ Item 22 (page 236)
11 - Right flange shaft
12 - Protective ring
❑ Pry protective ring off flange shaft with a screwdriver, alternating sides ⇒ Item 11 (page 235)
❑ Install with indentation facing away from threaded hole in flange shaft
❑ Push on protective ring to stop by hand
❑ Protective ring must engage in flange shaft
13 - Seal
❑ For right flange shaft
❑ Renewing with gearbox installed ⇒ page 229
14 - Compression spring for flange shaft
❑ Installed behind flange shaft
3. Differential 235
15 - Thrust washer
❑ Installation position: shoulder faces spring, lugs, if present, face tapered ring
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18 - Sun wheel
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20 - Spring pin
❑ For securing differential pinion pin
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21 - Planet pinion
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22 - Threaded piece
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23 - One-piece thrust washer
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❑ Protective ring must engage in flange shaft
25 - Left flange shaft
26 - Seal
❑ For left flange shaft
❑ Renewing with gearbox installed ⇒ page 227
Pulling tapered roller bearing outer race out of clutch housing

Note
After pulling out, renew washer.

Press tapered roller bearing outer race with washer into clutch
housing
– First insert washer.
Note
♦ Observe installation position of washer.

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3. Differential 237

Cage with tapered rollers must be easy to turn during pressing.
ing
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– Support gearbox housing with tube -3345- directly below bear‐
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– Drive out spring pin with chisel, inserting chisel into circum‐
ferential groove.
Installing
– Drive into differential cage to stop.

Installing differential bevel gears

– Lubricate one-piece thrust washer with gear oil and install.
– Install both sun wheels and secure (e.g. with flange shaft).
– Insert planet pinions offset 180° and pivot into position.
Volkswa
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(-arrow
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3.2 Adjusting differential
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♦ End dimension plate -
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VW 385/17-
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♦ Universal dial gauge brack‐

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3. Differential 239
olkswagen AG
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It is necessary to readjust the differential when the following com‐

ponents are renewed:
♦ Gearbox housing
♦ Clutch housing
♦ Differential cage or
♦ Tapered roller bearing of differential
Adjustment overview ⇒ page 232 .
– Press tapered roller bearing outer race with washer into clutch
housing.
Note
♦ Observe installation position of washer.

♦ Shoulder on inner circumference faces seal in clutch housing.

– Press tapered roller bearing outer race, without shim, into

gearbox housing.
– Fit differential into clutch housing.
– Fit gearbox housing and tighten 5 bolts to specified torque
– Press differential in direction of clutch housing while turning it
eight times.
– Press differential in direction of gearbox housing while turning
it eight times.
– Attach dial gauge and set to „0“ with 1 mm preload.

A - 30 mm dial gauge extension
– Move differential up and down. Read and note play indicated
on dial gauge. (Example: 0.70 mm)
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– Remove gearbox housing.

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– Pull tapered roller bearing outer race out of gearbox housing.

rrectness of i

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– Determine part number of shim according to ⇒ Electronic

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– Insert shims of determined thickness, thickest shim first.

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Shim thickness (mm)

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0.65 0.85 1.05 1.25

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0.70 0.90 1.10

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If the size of shim required is larger than those listed in the table,
insert two shims totalling the correct figure. When using two
shims, install the thicker one first.
3. Differential 241
– Press outer race in again and tighten gearbox housing to

specified torque ⇒ Item 11 (page 130) and
⇒ Item 12 (page 130) .
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VW Amarok, 6-Speed Manual Gearbox

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Service

List of Workshop Manual Repair GroupsList of Workshop Manual

matter of course, be observed.

All rights reserved.

Copyright © 2010 Volkswagen AG, Wolfsburg MEX5R006920

12 Rep. gr.30 - Clutch

2 Repairing clutch mechanism

Note AG. Volkswagen AG d

I - Assembly overview - pedal

2. Repairing clutch mechanism 13

bracket and bulkhead

❑ For mounting clutch

❑ Is provided with damp‐

❑ Removing and installing

14 Rep. gr.30 - Clutch

❑ For clutch pedal

Mounting bracket with damping -arrows-

The installation location of the knee airbag is above the pedal

– First check whether a coded radio is fitted. If so, obtain anti-

2. Repairing clutch mechanism 15

– With ignition switched off, disconnect battery ⇒ Electrical sys‐

– If fitted, remove damping -arrow- from lower area of clutch spec

– To do this, remove lock washers -A- for damping.

16 Rep. gr.30 - Clutch

– Swing clutch pedal down slightly and remove over-centre

Renew self-locking nuts.

2. Repairing clutch mechanism 17

– Insert over-centre spring -2- in mounting bracket from above

– Depress clutch pedal slightly, push bolt through and tighten

self-locking nut to specified torque ⇒ page 19 .

Some cars have damping -arrow- on the clutch pedal mounting

– Return it to installation position.

Vehicles without knee airbag

18 Rep. gr.30 - Clutch

– Install crash bar -1- in front of clutch pedal by screwing on

♦ Renew self-locking nuts

♦ Release tool -T10178-

2. Repairing clutch mechanism 19

Continuation for all

– Remove bracket for knee airbag together with crash bar ⇒

stalling knee airbag bracket .

Vehicles without knee airbag

– Remove crash bar -1- from in front of clutch pedal by removing

Continuation for all

– If fitted, remove damping -arrow- from lower area of clutch

20 Rep. gr.30 - Clutch

– Unbolt clutch pedal -1- from mounting bracket -3- by removing

2. Repairing clutch mechanism 21

– Release clutch pedal from master cylinder with pliers -

Renew self-locking nuts.

– Attach retainer -2- to master cylinder operating rod -1-.

Some cars have damping -arrow- on the mounting bracket/clutch

knee airbag bracket .

Continuation for all

⇒ General body repairs, interior; Rep. gr. 68 ; Compartments,

covers and trim panels .

Crash bar to steering column mounting 10

2.5 Removing and installing mounting

2. Repairing clutch mechanism 23

♦ Hose clamps -3094-

♦ Hose clip pliers -VAS 6362-

– First check whether a coded radio is fitted. If so, obtain anti-

– With ignition switched off, disconnect battery earth strap ⇒

Electrical system; Rep. gr. 27 ; Disconnecting and connecting