VW Jetta 7 Manual Transmission 02s Eng

Service
Repair Manual
Jetta 2018 ➤
6-Speed Manual Transmission 02S
Edition 04.2021
Service Department. Technical Information

Service
List of Workshop Manual Repair Groups
Repair Group
00 - General, Technical Data
30 - Clutch
34 - Controls, Housing
35 - Gears, Shafts
39 - Final Drive, Differential
Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness
and safety. In addition, the normal basic safety precautions for working on motor vehicles must, as
a matter of course, be observed.
Jetta 2018 ➤
6-Speed Manual Transmission 02S - Edition 04.2021
Contents
00 - General, Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Safety Precautions when Working on Vehicles with Start/Stop System . . . . . . . . . . . . . . 1
1.2 Safety Precautions during Road Test with Testing Equipment . . . . . . . . . . . . . . . . . . . . . . 1
2 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.1 Transmission Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3 Repair Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.1 General Repair Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4.1 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4.2 Transmission/Engine Allocation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4.3 Gear Ratio Calculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
5 Overview - Drivetrain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
5.1 Overview - Drivetrain, FWD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
6 Electrical Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
6.1 Component Location Overview - Electrical Components . . . . . . . . . . . . . . . . . . . . . . . . . . 14
30 - Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1 Clutch Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.1 Overview - Pedal Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.2 Overview - Clutch Hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
1.3 Overview - Clutch Release Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
1.4 Clutch Pedal, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
1.5 Over-Center Spring, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
1.6 Return Spring, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
1.7 Mounting Bracket, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
1.8 Bearing Bushing, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
1.9 Clutch Master Cylinder, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
1.10 Clutch Slave Cylinder, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
1.11 Clutch Mechanism Lines, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
1.12 Clutch Mechanism, Bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
1.13 Clutch Master and Clutch Slave Cylinder, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
1.14 Clutch Position Sensor G476, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
1.15 Clutch Release Mechanism, Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
2 Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
2.1 Clutch Manufacturers, Differentiating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
2.2 Overview - Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
2.3 Clutch, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
34 - Controls, Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
1 Shift Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
1.1 Shift Mechanism Installation Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
1.2 Overview - Gearshift Knob and Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
1.3 Overview - Shift Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
1.4 Gearshift Knob, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
1.5 Shift Mechanism, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
1.6 Shift Mechanism, Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
1.7 Shift Mechanism, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
1.8 Selector Shaft Seal, Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
2 Transmission, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
2.1 Transmission Tightening Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
2.2 Transmission, Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Contents i
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2.3 Transmission, Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

3 Assembly Mounts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
3.1 Overview - Assembly Mounts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
4 Transmission, Transporting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
5 Transmission, Disassembling and Assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
5.1 Schematic Overview - Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
5.2 Overview - Transmission Housing Cover and 5th/6th Gear . . . . . . . . . . . . . . . . . . . . . . . . 125
5.3 Overview - Transmission Housing and Gearshift Mechanism . . . . . . . . . . . . . . . . . . . . . . 127
5.4 Overview - Shift Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
5.5 Overview - Input Shaft, Output Shafts, Differential and Shift Rods . . . . . . . . . . . . . . . . . . 130
5.6 Overview - Shift Forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
5.7 Shift Unit, Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
5.8 Shift Forks, Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
5.9 Transmission Housing Cover and 5th/6th Gear, Removing . . . . . . . . . . . . . . . . . . . . . . . . 142
5.10 Transmission, Disassembling and Assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
5.11 5th/6th Gear and Transmission Housing Cover, Installing . . . . . . . . . . . . . . . . . . . . . . . . . . 167
6 Transmission Housing and Clutch Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
6.1 Overview - Transmission Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
6.2 Overview - Clutch Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
6.3 Overview - Transmission Housing Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
6.4 Transmission Housing, Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
6.5 Clutch Housing, Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
6.6 Transmission Housing Cover, Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
7 Securing on Engine and Transmission Holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
8 Transmission Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
8.1 Transmission Fluid Level, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
8.2 Transmission Fluid, Draining and Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
35 - Gears, Shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203

1 Input Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
1.1 Overview - Input Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
1.2 Input Shaft, Disassembling and Assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
1.3 Input Shaft, Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
2 Output Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
2.1 Overview - Output Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
2.2 Output Shaft, Disassembling and Assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
2.3 Output Shaft, Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234
3 Reverse Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
3.1 Overview - Reverse Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
3.2 Reverse Shaft, Disassembling and Assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242
39 - Final Drive, Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246

1 Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246
1.1 Component Location Overview - Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246
1.2 Left Seal, Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246
1.3 Right Seal, Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249
1.4 Input Shaft Seal, Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254
2 Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257
2.1 Overview - Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257
2.2 Differential, Disassembling and Assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259
2.3 Differential, Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266
3 Adjustment Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270
4 Revision History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271
ii Contents
Jetta 2018 ➤
00 – General, Technical Data

1 Safety Precautions
(Edition 04.2021)
⇒ P1.1 recautions when Working on Vehicles with Start/Stop
System”, page 1
⇒ P1.2 recautions during Road Test with Testing Equipment”,
page 1
1.1 Safety Precautions when Working on

Vehicles with Start/Stop System
WARNING
Risk of injury if the engine starts automatically in vehicles

with a Start/Stop System.
♦ Deactivate the Start-Stop system when working on the
vehicle. Switch the ignition off.
♦ Only switch the ignition on briefly when necessary.
1.2 Safety Precautions during Road Test

with Testing Equipment
If testing equipment must be used during a road test, note the
following:
WARNING
There is a risk of an accident due to distractions and improp‐

erly secured testing equipment.
Risk of the front passenger airbag deploying during an acci‐
dent.
• Operating testing equipment while driving is a distrac‐
tion.
• Testing equipment that is not secured properly increases
the risk of personal injury.
♦ Always secure testing equipment to the rear seat with a
strap and have a second technician operate it in the rear
seat.
To prevent personal injury and damage to electrical and elec‐

tronic components, observe the following:
♦ Only connect and disconnect test equipment when the igni‐
tion is off.
Caution
Risk of destroying electronic components when disconnect‐

ing the battery.
♦ Follow the steps when disconnecting the battery.
1. Safety Precautions 1
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– Disconnect the battery. Refer to ⇒ Electrical Equipment;

Rep. Gr. 27; Battery; Battery, Disconnecting and Connect‐
ing.
2 Rep. Gr.00 - General, Technical Data

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2 Identification
⇒ I2.1 dentification”, page 3
2.1 Transmission Identification

Code and Production Date -arrow 1- for Manual Transmission
02S -arrow 2-
Manual Transmission 02S -arrow 2-
Transmission Codes and Production Date
Example: NBJ 22 01 4
I I I I
I I I I
Codes Day Month Year (2014)
of manufacture
Additional data and information is provided by the factory.
2. Identification 3
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Note
The transmission code is also listed in the vehicle data plates.

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3 Repair Information
⇒ R3.1 epair Information”, page 5
3.1 General Repair Information

The highest level of care and cleanliness along with tools that
function properly are required to ensure a proper and success‐
ful transmission repair. The usual basic safety precautions ap‐
ply when making vehicle repairs.
Some general repair information for individual repair proce‐
dures, that appear many times throughout the repair manual,
is summarize here. They apply to this repair manual.
Special Tools
Refer to Workshop Equipment and Special Tools for a complete
list of special tools used in the repair manual.
Transmission
♦ Make sure that the alignment bushings between the engine
and transmission are positioned correctly when installing the
manual transmission.
♦ Clean the contact surfaces when installing the mounting
brackets as well as parts that have been waxed. Contact
surfaces must be free of wax and grease.
♦ Allocate the bolts and other components. Refer to the
⇒ Electronic Parts Catalog (ETKA).
♦ Fill the transmission fluid when repairing the manual trans‐
mission.
Seals and Gaskets
♦ Thoroughly clean the separating surfaces and apply Sealing

Paste.
♦ Flange shaft, input shaft and selector shaft seals are illustra‐
ted as radial shaft seals.
♦ After removing seals and gaskets, check the contact surfa‐
ces on the housings or shafts for burrs and damage caused
by the removal. Repair as necessary.
♦ Fill the space between the sealing lips halfway with Grease
-arrow- before installing the radial shaft seal.
♦ The open side of the gaskets point toward the fluid to be
sealed in.
♦ Lightly lubricate the O-rings before inserting to prevent the
rings from being crushed during assembly.
3. Repair Information 5
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Sealant
♦ Always thoroughly clean the separating surfaces on the
housing before applying the Sealing Compound.
♦ Apply Sealing Compound evenly and not too thickly.
♦ Do not allow any Sealing Compound to get into the bleed
holes.
Circlips
♦ Do not stretch the circlips.

♦ Installation position for some of the circlips: the circlip
is »narrower at the top« and so is its installation position.
This makes it easier for the pliers to grab the circlip when
removing and installing it.
♦ Always replace damaged or stretched circlips.
♦ The circlips must rest at the bottom of the groove.
♦ Replace the adapter sleeves. Installation position: the slot
-A- should align with the line of force -arrow-.

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Bolts and Nuts
♦ Always loosen or tighten bolts and nuts on covers and hous‐

ings diagonally.
♦ Especially delicate components, such as clutch pressure
plates, must not be distorted. Loosen and tighten bolts and
nuts in stages in a diagonal sequence.
♦ The tightening specifications given apply to unoiled bolts and
nuts.
♦ Replace self-locking bolts and nuts after removing them.
♦ Make sure the contact surfaces and visible surfaces on the
nuts and bolts are waxed after assembling.
♦ Use a wire brush to clean the threads of the bolts that were
installed with locking fluid. Next, use Locking Compound to
install the bolts.
♦ Use a thread cutter to clean all threaded holes containing
self-locking bolts to remove any locking compound residue.
Otherwise the bolts could shear the next time they are re‐
moved.
♦ Please make sure that the thread pitch is correct so that the
proper thread cutter is used during cleaning, and the thread
does not get damaged.
Bearings
♦ Insert the bearings with transmission fluid.
♦ Install the new tapered roller bearings. It is not necessary to
oil them.
♦ Install needle bearings with the lettered side (thicker metal)
facing the fitting tool.
♦ Replace all the tapered roller bearings that are on the same
shaft, and use tapered roller bearings from the same manu‐
facturer.
♦ To install, warm the inner races to approximately 100 °C
(212 °F) with the Inductive Heater -VAS6414-.
♦ Do not interchange outer and inner bearing races with those
from other bearing of the same size. The bearings are
paired.
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Shims
♦ Measure the shims at several locations with a micrometer

caliper. It is possible to measure the necessary shim thick‐
ness by the different tolerances.
♦ Check for burrs or damage.
♦ Only install perfect shims.
Synchronizer Rings
♦ Do not interchange them. When reusing synchronizer rings,

always install on the same gear assembly.
♦ Check for wear and replace if necessary.
♦ Check the grooves -arrow 1- on the synchronizer ring -A-
and the inner race for flat areas (grooves are worn).
♦ The coating on the synchronizer rings must not be damaged.
♦ If an intermediate ring -B- is installed, check this in‐
termediate ring on the outer friction surface -arrow 2-
and inner friction surface -arrow 3- for »grooves«, »wear
grooves« and »blue coloring (from overheating)«.
♦ Check the gear assembly taper for »wear
grooves« and »scoring«.
♦ Coat the synchronizing with transmission fluid and then in‐
stall.

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Toothed Gears, Synchronizer Hubs

♦ Before installing, clean and warm to a maximum of 100 °C
(212 °F) using the Inductive Heater -VAS6414-.
♦ Pay attention to the installation position.
Gear Assemblies
♦ After assembling, check the gear assemblies for minimum
axial clearance and ease of movement.
Clutch
♦ Do not tilt the clutch pressure plate. Loosen and tighten it
diagonally and in small steps.
♦ To reduce odor caused by a burnt clutch, thoroughly clean
the clutch housing and the flywheel running surface with a
clean cloth.
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4 Technical Data
⇒ 4.1 , page 10
⇒ A4.2 llocation”, page 10
⇒ R4.3 atio Calculation”, page 10
4.1 Capacities
Manual transmission capacity Refer to ⇒ Fluid Capacity Tables; Rep. Gr. 03
(transmission completely disas‐
sembled)
Manual transmission capacity Refer to ⇒ Fluid Capacity Tables; Rep. Gr. 03
(transmission partly disassem‐
bled). Refer to ⇒ F8 luid”, page
199 .
4.2 Transmission/Engine Allocation

Manual Transmission 6-Speed 02S
Codes RSW TDZ TKJ
Allocation Engine 1.4L -110 kW 1.4L -110 kW 1.4L -110 kW
Ratio Final Drive 62 : 17 = 3.647 61: 18 = 3.389 62 : 17 = 3.647
Z1 : Z2
Refer to the ⇒ Electronic Parts Catalog (ETKA) for the following information:
♦ The individual gear ratios
♦ Clutch allocation
♦ Transmission fluid
♦ Drive axle flange diameter
Manual Transmission 6-Speed 02S

Codes TKR
Allocation Engine 1.4L -110 kW
Ratio Final Drive 61: 18 = 3.389
Z1 : Z2
Refer to the ⇒ Electronic Parts Catalog (ETKA) for the following information:
♦ The individual gear ratios
♦ Clutch allocation
♦ Transmission fluid
♦ Drive axle flange diameter
4.3 Gear Ratio Calculation

Example:
6th Gear Final Drive
Drive gear ZG1 = 45 ZA1 = 17
Driven gear ZG2 = 33 ZA2 = 62

Jetta 2018 ➤
i = Z2 : Z1 (Z1 = number of teeth on the drive gear, Z2 =

number of teeth on the driven gear)
iG = gear ratio = ZG 2: ZG1 = 33 : 45 = 0.733
iA = axle ratio = ZA 2: ZA1 = 62 : 17 = 3.647
itotal = total ratio = iG x iA = 0.733 x 3.647 = 2.673
4. Technical Data 11
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5 Overview - Drivetrain
⇒ -5.1 Drivetrain, FWD”, page 12
5.1 Overview - Drivetrain, FWD

Name
The -arrows- point in the direction of travel.
1 - Engine
2 - Clutch
3 - Manual Transmission
4 - Input Shaft
5 - Output Shaft
6 - Differential
Ratio
The -arrows- point in the direction of travel.

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I - 1st Gear
II - 2nd Gear
III - 3rd Gear
IV - 4th Gear
V - 5th Gear
VI - 6th Gear
R - Reverse Gear
A - Final Drive
5. Overview - Drivetrain 13
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6 Electrical Components
⇒ L6.1 ocation Overview - Electrical Components”, page 14
6.1 Component Location Overview - Elec‐

trical Components
⇒ L6.1.1 ocation Overview - Electrical Components, Manual
Transmission”, page 14
⇒ L6.1.2 ocation Overview - Electrical Components, Clutch
Mechanism”, page 15
6.1.1 Component Location Overview - Elec‐

trical Components, Manual Transmis‐
sion
Back-Up Lamp Switch -F4- -arrow-
Component location: on the shift unit

Back-Up Lamp Switch -F4-, Removing and installing. Refer to ⇒
-5.4 Shift Unit”, page 129 .
Transmission Neutral Position Sensor -G701- -arrow-
Component location: on top of the oil filler plug.

Transmission Neutral Position Sensor -G701-, Removing and
installing. Refer to ⇒ -5.3 Transmission Housing and Gearshift
Mechanism”, page 127 .

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6.1.2 Component Location Overview - Elec‐

trical Components, Clutch Mechanism
Clutch Position Sensor -G476- -arrow-
Installed location: in the passenger compartment on the clutch

master cylinder.
Clutch Position Sensor -G476-, Removing and installing. Refer
to ⇒ C1.14 lutch Position SensorG476, Removing and Instal‐
ling”, page 47 .
6. Electrical Components 15
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30 – Clutch
1 Clutch Mechanism
⇒ -1.1 Pedal Assembly”, page 16
⇒ -1.2 Clutch Hydraulics”, page 19
⇒ -1.3 Clutch Release Mechanism”, page 24
⇒ P1.4 edal, Removing and Installing”, page 26
⇒ S1.5 pring, Removing and Installing”, page 27
⇒ S1.6 pring, Removing and Installing”, page 31
⇒ B1.7 racket, Removing and Installing”, page 34
⇒ B1.8 ushing, Removing and Installing”, page 39
⇒ M1.9 aster Cylinder, Removing and Installing”, page 40
⇒ S1.10 lave Cylinder, Removing and Installing”, page 41
⇒ M1.11 echanism Lines, Removing and Installing”, page 43
⇒ M1.12 echanism, Bleeding”, page 45
⇒ M1.13 aster and Clutch Slave Cylinder, Checking”, page 47
⇒ C1.14 lutch Position SensorG476, Removing and Installing”,
page 47
⇒ R1.15 elease Mechanism, Servicing”, page 48
1.1 Overview - Pedal Assembly
16 Rep. Gr.30 - Clutch

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1 - Clutch Master Cylinder

❑ Removing and instal‐
ling. Refer to ⇒
M1.9 aster Cylinder,
Removing and Instal‐
ling”, page 40 .
2 - Bearing Bushing
ling. Refer to ⇒
B1.8 ushing, Removing
and Installing”, page
39 .
❑ Do not lubricate
3 - Clip
❑ The clamp must be re‐
moved in order to re‐
move/install the hose/
line assembly
4 - Seal
❑ Replace after removing
the clutch master cylin‐
der
❑ Self-adhesive
❑ Glue to the clutch mas‐
ter cylinder
5 - Clutch Position Sensor -
G476-
❑ Can be checked in
Guided Fault Find-
ing . Refer to Vehicle
Diagnostic Tester.
❑ Allocation. Refer to the
⇒ Electronic Parts Cat‐
alog (ETKA).
ling. Refer to ⇒ C1.14 lutch Position SensorG476, Removing and Installing”, page 47 .
6 - Bearing Axle
7 - Stop Buffer
8 - Nut
❑ 25 Nm
❑ For the mounting bracket to the bulkhead
❑ Self-locking
❑ Quantity: 3
9 - Bearing Shell
❑ Installed on both sides
❑ Installed in connection with over-center spring only
❑ Quantity: 2
10 - Mounting Bracket
❑ For the clutch pedal
1. Clutch Mechanism 17
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❑ Removing and installing. Refer to ⇒ B1.7 racket, Removing and Installing”, page 34 .
❑ Use a Piston Pin Drift -VW207- to drive the bushings into the holes for the mounting bracket pins on
the bulkhead.
11 - Return Spring
❑ Installed depending on the date of manufacture
❑ Removing and installing. Refer to ⇒ S1.6 pring, Removing and Installing”, page 31 .
❑ Do not grease the mount on the mounting bracket.
12 - Mounting Pin
❑ For the clutch master cylinder
13 - Over-Center Spring
❑ There are different versions; allocate accordingly. Refer to the ⇒ Electronic Parts Catalog (ETKA).
❑ Removing and installing. Refer to ⇒ S1.5 pring, Removing and Installing”, page 27 .
14 - Bearing Bushing
15 - Slide Bushing
❑ For return spring mounting
❑ Install on clutch pedal
❑ Lubricate to the return spring mount
❑ Refer to the ⇒ Electronic Parts Catalog (ETKA) for the grease.
16 - Mounting Pin
❑ For plunger/clutch master cylinder
17 - Clutch Pedal
❑ Removing and installing. Refer to ⇒ P1.4 edal, Removing and Installing”, page 26 .
18 - Pedal Rubber
19 - Bearing Bushing
20 - Tension Spring
❑ For the clutch pedal
❑ Removing and installing ⇒ removing and installing over-center spring. Refer to ⇒ S1.5 pring, Remov‐
ing and Installing”, page 27 .
21 - Damping Element
❑ Installed in connection with tension spring only

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1.2 Overview - Clutch Hydraulics

⇒ -1.2.1 Clutch Hydraulics”, page 19
⇒ -1.2.2 Clutch Hydraulics, RHD Vehicles (Not for North Ameri‐
can Market)”, page 22
1.2.1 Overview - Clutch Hydraulics
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1 - Hex Bolt
❑ Tightening Specifica‐
tion. Refer to ⇒
-1.3 Clutch Release
Mechanism”, page
24 .
2 - Bleeder Valve
❑ 4.5 Nm
❑ Bleeding the clutch
mechanism. Refer to
⇒ M1.12 echanism,
Bleeding”, page 45 .
3 - Dust Cap
4 - Hose
5 - Brake Fluid Reservoir
6 - Seals
❑ Must be located inside
the hose.
ling. Refer to ⇒
ling”, page 40 .
8 - Clip
line assembly
9 - Seal/O-Ring
❑ Replace if damaged
❑ Install on the line con‐
nection
❑ Install with brake fluid
❑ Seals/O-rings suitable for the line connection version. Refer to ⇒ Fig. ““Seals/O-Rings for Hose/Line
Assembly or Pipe”“, page 21 .
❑ Allocation. Refer to the ⇒ Electronic Parts Catalog (ETKA).
10 - Bracket
❑ For hose/line assembly
11 - Hose/Line Assembly
❑ Removing and installing. Refer to ⇒ M1.11 echanism Lines, Removing and Installing”, page 43 .
12 - Seal/O-Ring
❑ Install on the line connection
13 - Clip
❑ The clamp must be removed in order to remove/install the hose/line assembly

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14 - Clutch Slave Cylinder

❑ Removing and installing. Refer to ⇒ S1.10 lave Cylinder, Removing and Installing”, page 41 .
Disconnect and Connect the Clutch Mechanism Lines
Separating
– Open the clip -3- with a screwdriver and remove the hose/
line assembly -1- from the connection -4-.
Connecting
Note
♦ An O-ring can also be installed instead of a seal -2-. Refer

to ⇒ Fig. ““Seals/O-Rings for Hose/Line Assembly or Pipe”“,
page 21 .
♦ Replace the damaged seal -2-.
– Press in the hose/line assembly -1- at the connection -4-

until the clip -3- engages audibly.
– Pull on the hose/line assembly to make sure it is secure.
Seals/O-Rings for Hose/Line Assembly or Pipe
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Item Line Connection Version

1 Line connection with a groove all the way around
-arrow 1-
2 Line connection with collar -arrow 2-
3 Line connection with collar -arrow 2- and with
groove all the way around -arrow 3-
• The seal / O-ring must be installed in the groove
-arrows 1 and 3-.
1.2.2 Overview - Clutch Hydraulics, RHD Vehicles (Not for North American
Market)

Jetta 2018 ➤

ling. Refer to ⇒
S1.10 lave Cylinder,
ling”, page 41 .
2 - Bleeder Valve
❑ Bleeding the clutch
mechanism. Refer to
⇒ M1.12 echanism,
❑ 4.5 Nm
3 - Dust Cap
4 - Hose
5 - Brake Fluid Reservoir
6 - Seals
❑ Must be located inside
the hose.
ling. Refer to ⇒
ling”, page 40 .
8 - Clip
line assembly
9 - Seal/O-Ring
❑ Install on the line con‐
nection
10 - Bracket
❑ For hose/line assembly
11 - Hose/Line Assembly
❑ Removing and installing. Refer to ⇒ M1.11 echanism Lines, Removing and Installing”, page 43 .
12 - Seal/O-Ring
❑ Install on the line connection
13 - Clip
❑ The clamp must be removed in order to remove/install the hose/line assembly
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14 - Hex Bolt
❑ Tightening Specification. Refer to ⇒ -1.3 Clutch Release Mechanism”, page 24 .
1.3 Overview - Clutch Release Mechanism

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1 - Transmission
2 - Ball Stud
❑ 25 Nm
❑ For removing and in‐
stalling, remove the
transmission
❑ Remove grease from
the release lever con‐
tact surfaces
❑ Grease the clutch re‐
lease lever surface with
Lubricating Grease for
Clutch Plate Splines
3 - Input Shaft Seal
❑ Replacing. Refer to ⇒
S1.4 haft Seal, Replac‐
ing”, page 254 .
4 - Guide Sleeve
❑ Replace the guide
sleeve and O-ring to‐
gether if the O-ring is
damaged.
❑ With vulcanized O-ring
transmission
5 - Spring
❑ Attach to the clutch re‐
lease lever
transmission
6 - Cylinder Bolt
❑ 20 Nm
7 - Clutch Release Lever
❑ For removing and installing, remove the transmission
❑ Remove and install together with release bearing. Refer to ⇒ Fig. ““Remove and Install the Clutch
Release Lever with the Release Bearing”“, page 48 .
❑ Remove grease already present
❑ Grease the ball stud contact surface with Grease for Clutch Plate Shaft Splines.
8 - Release Bearing
❑ Replace loud bearings
❑ For removing and installing, remove the transmission
❑ Do not wash the bearing, just wipe it off.
❑ Removing from the clutch release lever and inserting in the clutch release lever. Refer to ⇒ Fig.
““Removing and Installing the Release Bearing”“, page 49
❑ Lubricate the release lever contact surface with MoS 2 grease
9 - Hex Bolt
❑ 20 Nm
❑ Removing and installing. Refer to ⇒ S1.10 lave Cylinder, Removing and Installing”, page 41 .
11 - Plunger
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12 - Bolt
❑ Secures the clutch release lever when installing the transmission
❑ Remove after installing the transmission
❑ Use an M8 x 35 bolt if the assembly bolt is missing.
1.4 Clutch Pedal, Removing and Installing

Removing
– Move the driver seat as far back as possible.
– Move the steering wheel upward as far as possible.
– If installed near the mounting bracket: remove the bracket
-arrow- with the Parking Aid Control Module -J446- (refer to
⇒ Electrical Equipment; Rep. Gr. 94; Parking Aid; Overview -
Parking Aid) and push to the side.
– Remove the return spring. (Refer to ⇒ S1.6 pring, Removing

and Installing”, page 31 .) or remove the over-center spring.
Refer to ⇒ S1.5 pring, Removing and Installing”, page 27 .
Remove the Clutch Pedal Bearing Axle as Follows:
-1- = 14 mm internal socket wrench

A 14 mm hex socket wrench can also be used instead of a 14
mm internal socket wrench.
• The clutch pedal bearing axle needs to be turned all the way
to the left, in direction of -arrow-.
The Brackets -A- will be Damaged.
– Move the clutch pedal a little so that the bearing axle can be
removed.

Jetta 2018 ➤
Installing
Install in the reverse order of removal while noting the following:

-1- = 14 mm internal socket wrench
A 14 mm hex socket wrench can also be used instead of a 14
mm internal socket wrench.
• Replace bearing axle after removing.
– Press on the clutch pedal a little and push the new bearing
axle through all the way.
– Turn the bearing axle all the way to the right, in direction of
-arrow-.
• The retainers -A- must engage audibly.
– Install the return spring (Refer to ⇒ S1.6 pring, Removing
and Installing”, page 31 .) or install the over-center spring.
Refer to ⇒ S1.5 pring, Removing and Installing”, page 27 .
– If removed, install the bracket -arrow- with the Parking Aid

Control Module -J446-. Refer to ⇒ Electrical Equipment;
Rep. Gr. 94; Parking Aid; Overview - Parking Aid.
1.5 Over-Center Spring, Removing and In‐

stalling
Removing
Vehicles with Knee Airbag
– Remove the driver side knee airbag -1-. Refer to ⇒ Body
Interior; Rep. Gr. 69; Knee Airbags; Overview - Knee Airbag.
Jetta 2018 ➤
Vehicles without Knee Airbag

Disconnect the battery ground cable. Refer to ⇒ Electrical
Equipment; Rep. Gr. 27; Battery; Battery, Disconnecting and
Connecting.
Continuation for All
– Remove the driver side footwell vent -1-. Refer to ⇒ Heating,

Ventilation and Air Conditioning; Rep. Gr. 87; Air Routing;
Overview - Air Routing and Air Distribution in Passenger
Compartment.
– Remove the Data Bus on Board Diagnostic Interface -J533-
-1- from the bracket (refer to ⇒ Electrical Equipment; Rep.
Gr. 97; Control Modules; Component Location Overview -
Control Modules) and push it aside.
– Remove the bolt -2-, unclip the crash bolster -1- and push
aside.

Jetta 2018 ➤
– Press the retainers together in direction of -arrows- and re‐

move the mounting pin -1- for the valve lifter/clutch master
cylinder to the right.
– If present, push the clutch pedal in the direction of -arrow B-

to disengage and remove the tension spring -1-.
– Bring the clutch pedal to the resting position.

– Pull the clutch pedal in direction of -arrow A- and disengage
and remove the over-center spring -2-.
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Installing

• The bearing shells -arrows- for the pins -1- are installed.
– Pull the clutch pedal into the passenger compartment (⇒ in
direction of -arrow A- in the previous illustration).
– Fit the pins -1- into the mounting bracket mounts -2-.
– Fit the mounting -3- into the clutch pedal mount -4-.
• If the clutch pedal is pushed in the direction of -arrow B- (⇒
previous illustration), the over-center spring will fold in the
direction of the mounting bracket.
– Use a new mounting pin to connect the piston/clutch master
cylinder to the clutch pedal.
– Insert the crash bolster -1- and tighten the bolt -2-. Refer to
⇒ Body Interior; Rep. Gr. 70; Instrument Panel Crossmem‐
ber, Overview - Instrument Panel Crossmember.
– Install the Data Bus on Board Diagnostic Interface -J533-.

Refer to ⇒ Electrical Equipment; Rep. Gr. 97; Control Mod‐
ules; Component Location Overview - Control Module.
– Install the driver side footwell vent. Refer to ⇒ Heating, Ven‐
tilation and Air Conditioning; Rep. Gr. 87; Air Routing; Over‐
view - Air Routing and Air Distribution in Vehicle Interior.
– Install the driver knee airbag. Refer to ⇒ Body Interior; Rep.
Gr. 69; Knee Airbags; Overview - Knee Airbag.
– Connect the battery. Refer to ⇒ Electrical Equipment; Rep.
Gr. 27; Battery; Battery, Disconnecting and Connecting.

Jetta 2018 ➤
1.6 Return Spring, Removing and Installing

Removing

Connecting.

Compartment.
Jetta 2018 ➤
aside.
– Press the retainers together in direction of -arrows- and re‐

move the mounting pin -1- for the valve lifter/clutch master
cylinder to the right.
– Move the clutch pedal in the direction of -arrow-, disengage

the return spring -1- and remove.

Jetta 2018 ➤
Installing
• For the return spring -1- (see previous illustration), slightly
grease the following areas on the clutch pedal:
• Slide bushing at the mounting areas -A- for the return spring.
• Ridge -B-
• Ridge -C-
• Refer to the ⇒ Electronic Parts Catalog (ETKA) for the
grease.
– Move the clutch pedal in the direction of -arrow- and engage
the return spring -1- (see previous illustration).
Jetta 2018 ➤

1.7 Mounting Bracket, Removing and In‐

stalling
Special tools and workshop equipment required
♦ Hose Clamps - Up To 25 mm -3094-
♦ Torque Wrench 1331 5-50Nm -VAG1331-

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♦ Sealing Tool -T10249-
Removing

Connecting.

Compartment.
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aside.
– Remove the entire air filter housing if the clutch mechanism

lines are not accessible. Refer to ⇒ Rep. Gr. 24; Air Filter;
Air Filter Housing, Removing and Installing.
– Remove the battery. Refer to ⇒ Electrical Equipment; Rep.
Gr. 27; Battery; Battery, Removing and Installing.
Caution
Danger of leaking brake fluid.

♦ Be careful not to get any brake fluid on the longitudinal
member or on the transmission when performing the
following work. If it does, clean the area thoroughly.
♦ Place a lint-free cloth under the clutch master cylinder.
– Clamp off the hose -2- to the clutch master cylinder using
-3094-.

Jetta 2018 ➤
Note
♦ There will be a permanent deformation in the hose after

using the -3094-.
♦ However, the hose is not faulty.
♦ After removing the -3094-, the hose must be formed back
into its original shape.
– Remove the clip for the hose/line assembly -1- all the way
and remove the hose/line assembly.
– Seal off openings.
– Remove the hose from the clutch master cylinder and seal it
with the -T10249/1-.
Jetta 2018 ➤
Note
When working inside the footwell, cover the carpet with cloths to
protect it from leaking brake fluid.
– Disconnect the connector -2- from the Clutch Position Sen‐

sor -G476-.
– Remove the nuts -arrows- and mounting bracket -1-.
Installing

– Replace the self-locking nuts and clutch master cylinder
seals after removing them.
Note
The battery will be installed and connected later.

Jetta 2018 ➤

– Connect the hose/line assembly -1- with connection. Refer
to ⇒ Fig. ““Disconnect and Connect the Clutch Mechanism
Lines”“, page 21 .
– Connect the hose -2- to the clutch master cylinder.

• After removing the -3094-, the hose must be formed back
– Bleed the clutch mechanism. Refer to ⇒ M1.12 echanism,
– Install and connect the battery. Refer to ⇒ Body Interior;
Rep. Gr. 69; Knee Airbags, Overview - Knee Airbag and
⇒ Electrical Equipment; Rep. Gr. 27; Battery; Battery, Dis‐
connecting and Connecting.
– Install and connect the battery. Refer to ⇒ Electrical Equip‐
ment; Rep. Gr. 27; Battery; Battery, Disconnecting and Con‐
necting.
Tightening Specifications
♦ Refer to ⇒ -1.1 Pedal Assembly”, page 16
1.8 Bearing Bushing, Removing and Instal‐

ling
Removing
Connecting.
– Press together the retainers in direction of -arrows- and re‐
move the studs -1- to the right side.
Jetta 2018 ➤
– Turn the valve fitter such that the openings -1- or the pin -2-
are visible.
The openings -1- and the pin -2- face in the same direction.
– Remove the bearing bushing -A- from the openings -1-.
Installing
– Turn the valve fitter such that the openings -1- or the pin -2-
are visible.
The openings -1- and the pin -2- face in the same direction.
– Fit the bearing bushing -A- in the openings -1- and rotate
into place.
1.9 Clutch Master Cylinder, Removing and

Installing
Note
♦ Before replacing the clutch master cylinder due to an as‐

sumed defect, perform the Guided Fault Finding . Refer
to Vehicle Diagnostic Tester first.
♦ When working inside the footwell, cover the carpet with
cloths to protect it from leaking brake fluid.
Removing
– Remove the mounting bracket. Refer to ⇒ B1.7 racket, Re‐
moving and Installing”, page 34 .

Jetta 2018 ➤
– Remove the Clutch Position Sensor -G476-. Refer to ⇒

C1.14 lutch Position SensorG476, Removing and Installing”,
page 47 .
– Release the retainers in direction of -arrows- and remove the
mounting pin -2-.
– Remove the clutch master cylinder -1-.

Installing
Replace mounting pin after removing.
– Install the mounting bracket. Refer to ⇒ B1.7 racket, Remov‐
ing and Installing”, page 34 .
– Install the Clutch Position Sensor -G476-. Refer to ⇒
C1.14 lutch Position SensorG476, Removing and Installing”,
page 47 .
1.10 Clutch Slave Cylinder, Removing and

Installing
Jetta 2018 ➤
Note
♦ Before replacing the clutch master cylinder due to an as‐

sumed defect, perform the Guided Fault Finding . Refer
to Vehicle Diagnostic Tester first.
♦ If the clutch slave cylinder is removed from the transmission
with the hose/line assembly connected, do not operate (de‐
press) clutch pedal any more. Otherwise, the pistons are
pushed out of the clutch slave cylinder and thus damaged.
Removing

Connecting.
– Remove the transmission support -arrows-.
– Place a lint-free cloth under the clutch slave cylinder.
– Release the clamp -A- with a screwdriver and remove the

hose/line assembly -B- from the connection.

Jetta 2018 ➤
– Remove the hose/line assembly -B- from the clutch slave

cylinder and seal off the openings.
– Remove the bolts -arrows- and the clutch slave cylinder.
Caution
There is a risk of contamination from the leaking brake fluid.

♦ When the hose/line assembly is separated from the con‐
nection, do not press the clutch pedal.
Installing
Note
♦ Lubricate all bearing areas and contact surfaces.

♦ Allocation of the grease. Refer to the ⇒ Electronic Parts
Catalog (ETKA).
– Install the clutch slave cylinder -A- and secure with the bolts
-arrows-.
– Connect the hose/line assembly -B-. Refer to ⇒ Fig. ““Dis‐

connect and Connect the Clutch Mechanism Lines”“, page
21 .
♦ Refer to ⇒ -1.3 Clutch Release Mechanism”, page 24
♦ Refer to ⇒ -3.1 Assembly Mounts”, page 118
1.11 Clutch Mechanism Lines, Removing

and Installing
Jetta 2018 ➤
♦ Engine Bung Set -VAS6122-

Removing
– Remove the entire air filter housing if the clutch mechanism
lines are not accessible. Refer to ⇒ Rep. Gr. 24; Air Filter;
– Remove the battery and battery tray. Refer to ⇒ Electrical
Equipment; Rep. Gr. 27; Battery; Battery, Removing and
Installing.
Caution
Danger of leaking brake fluid.

♦ Be careful not to get any brake fluid on the longitudinal
member or on the transmission when performing the
following work. If it does, clean the area thoroughly.
♦ Place a lint-free cloth under the clutch master cylinder.
– Clamp off the hose -2- to the clutch master cylinder using
-3094-.
Note
♦ There will be a permanent deformation in the hose after

using the -3094-.
♦ However, the hose is not faulty.
♦ After removing the -3094-, the hose must be formed back

Jetta 2018 ➤
– Remove the clip for the hose/line assembly -1- all the way
and remove the hose/line assembly.
– Remove the clamp -A- until stop and remove the hose/line
assembly -B-.
Note
Ignore -arrows-.
– Seal the open lines and connections with clean plugs, if

necessary from the -VAS6122-.
– Free up the hose/line assembly and remove it.
Installing

– Connect the hose/line assembly -1- with the connection on
the clutch master cylinder and the clutch slave cylinder.
– Pull on the line to make sure it is secure.
• After removing the -3094-, the return hose -2- must be
formed back into its original shape.
– Install the battery tray and the battery. Refer to ⇒ Electrical
Equipment; Rep. Gr. 27; Battery; Battery, Removing and
Installing.
1.12 Clutch Mechanism, Bleeding

Jetta 2018 ➤
♦ Brake Filling and Bleeding Equipment -VAS6860- or -

VAG1869-
♦ Bleeder Hose (670 mm) - VAG1238/B3-
Note
♦ Bleed the system after working on the hydraulic clutch

mechanism.
♦ Make sure no brake fluid gets on the transmission when
performing the following work.
♦ It is not necessary to pre-fill the system.
♦ Before bleeding, fill the brake fluid reservoir to the “Max”
marking with brake fluid.
♦ The clutch pedal is in the neutral position and is not pressed.
♦ Brake fluid: allocation. Refer to the ⇒ Electronic Parts Cata‐
log (ETKA).
– Remove the entire air filter housing if the bleeder valve

(-arrow-; see illustration below) is not accessible. Refer to
⇒ Rep. Gr. 24; Air Filter; Air Filter Housing, Removing and
Installing.
– Return the clutch pedal to the resting position.

– Remove the protective cap from the bleeder valve -arrow-.
– Connect the -VAS5234- or - VAG1869-.
– Connect the bleeder hose with the collector bottle pressure
hose.
If necessary, use the - VAG1238/B3-.
– Switch the Brake Charger/Bleeder Unit on.
• Working pressure 2.0 bar (29 psi).
– Open the breather valve.

Jetta 2018 ➤
– Let approximately 100 cm3 of brake fluid flow out.

– Close the breather valve.
– Operate the clutch pedal rapidly from stop to stop, 10 to 15
times.
– Open the breather valve.
– Let another 50 cm 3 of brake fluid flow out.
– Close the breather valve.
– Turn off the Brake Charger/Bleeder Unit and release the
pressure from the device completely.
– Press the clutch pedal a few times after bleeding the system.
– While doing so, check the function of the clutch mechanism.
♦ Refer to ⇒ -1.2 Clutch Hydraulics”, page 19
1.13 Clutch Master and Clutch Slave Cylin‐

der, Checking
Before replacing the clutch master cylinder due to an assumed
defect, perform the Guided Fault Finding . Refer to Vehicle
Diagnostic Tester first.
1.14 Clutch Position Sensor -G476-, Re‐

moving and Installing
Removing
– Disconnect the connector -arrow- from the Clutch Position
Sensor -G476-.
– Release the Clutch Position Sensor -G476- -2- from the

clutch master cylinder -1- in direction of -arrow- and remove
it.
Jetta 2018 ➤
Installing
• The tab -arrow- on the Clutch Position Sensor -G476- must
be intact.
• The Clutch Position Sensor -G476- must engage audibly.
1.15 Clutch Release Mechanism, Servicing

• The transmission is removed.

Remove and Install the Clutch Release Lever with the Release
Bearing

Jetta 2018 ➤
– Disengage the spring -arrow 1-.

– Remove the clutch release lever -arrow 2- and release bear‐
ing.
– Install in reverse order of removal.
Removing and Installing the Release Bearing
– Squeeze the hooks -arrows- on the back of the clutch re‐

lease lever and remove the release bearing -A- from the
clutch release lever.
– Press the release bearing -A- into the clutch release lever
until the hooks -arrows- engage.
– Install the transmission. Refer to ⇒ R2 emoving and Instal‐
ling”, page 90 .
Jetta 2018 ➤
2 Clutch
⇒ M2.1 anufacturers, Differentiating”, page 50
⇒ -2.2 Clutch”, page 51
⇒ R2.3 emoving and Installing”, page 54
2.1 Clutch Manufacturers, Differentiating

Either a “Sachs” or a “LuK” clutch may be installed.
The clutch manufacturer can be determined as follows with the
transmission installed:
– Remove the noise insulation. Refer to ⇒ Body Exterior; Rep.
Gr. 66; Noise Insulation; Overview - Noise Insulation.
There are several cut-outs -arrows- between the engine -A- and
the transmission -B- at the bottom of the engine oil pan.
– Check the outer contour of the flywheel through these open‐

ings.
– The outer contour of the flywheel can also be inspected by
removing the small cover plate -A-.
Round Outer Contour -arrows- = Sachs Clutch = -A-

– To remove and install a Sachs clutch. Refer to ⇒
R2.3.1 emoving and Installing, with Dual Mass Flywheel,
Sachs”, page 54 .

Jetta 2018 ➤
– To service a Sachs clutch. Refer to ⇒ -2.2.1 Clutch, with

Dual Mass Flywheel, Sachs”, page 51 .
Squared Outer Contour -arrows 1- and in Addition, a Pleat all

the Way Around -arrow 2- = clutch made by LuK = -B-
or
Round Outer Contour -1 arrows- and a Seam all the Way
Around -arrow 2- = LuK clutch = -B-
– To remove and install a LuK clutch. Refer to ⇒ R2.3.2 emov‐

ing and Installing, with Dual Mass Flywheel, LuK”, page
59 .
– To service a LuK clutch. Refer to ⇒ -2.2.2 Clutch, with Dual
Mass Flywheel, LuK”, page 52 .
2.2 Overview - Clutch

⇒ -2.2.1 Clutch, with Dual Mass Flywheel, Sachs”, page 51
⇒ -2.2.2 Clutch, with Dual Mass Flywheel, LuK”, page 52
⇒ -2.2.3 Clutch, with Single Flywheel”, page 53
2.2.1 Overview - Clutch, with Dual Mass Flywheel, Sachs
2. Clutch 51
Jetta 2018 ➤
1 - Dual Mass Flywheel

ling. Refer to ⇒ Rep.
Gr. 13; Cylinder Block,
Transmission Side; Fly‐
wheel, Removing and
Installing.
❑ Make sure it fits se‐
curely on the centering
pins
❑ Keep the clutch lining
contact surface free
of grooves, oil and
grease.
2 - Clutch Plate
❑ Only replace together
with the pressure plate
alog (ETKA).
ling. Refer to ⇒
R2.3.1 emoving and In‐
stalling, with Dual Mass
Flywheel, Sachs”, page
54 .
❑ Installation position.
Refer to ⇒ Fig. ““Clutch
Plate Installation Posi‐
tion”“, page 57 .
3 - Pressure Plate
with the clutch plate
❑ With adjustment mech‐
anism
⇒ Electronic Parts Catalog (ETKA).
❑ Removing and installing. Refer to ⇒ R2.3.1 emoving and Installing, with Dual Mass Flywheel, Sachs”,
page 54 .
❑ Diaphragm Spring Ends, Checking. Refer to ⇒ Fig. ““Check the Ends of the Diaphragm Spring”“, page
57 .
❑ Checking the spring connections and rivet connections. Refer to ⇒ Fig. ““Checking the Spring Connec‐
tions and Rivet Connections”“, page 58 .
4 - Bolt
❑ M 6: 13 Nm
❑ M 7: 20 Nm
❑ Loosen and tighten in small steps and in diagonal sequence
2.2.2 Overview - Clutch, with Dual Mass Flywheel, LuK

Jetta 2018 ➤
1 - Flywheel
wheel, Removing and
Installing.
pins
contact surface free
of grooves, oil and
grease.
2 - Clutch Plate
alog (ETKA).
ling. Refer to ⇒
stalling, with Dual Mass
Flywheel, LuK”, page
59 .
with the SAC pressure
plate
❑ Installed position. Refer
to ⇒ Fig. ““Clutch Plate
Installation Position”“,
page 61 .
3 - SAC Pressure Plate
❑ SAC = “self-adjusting
clutch”
with the clutch plate
❑ Removing and installing. Refer to ⇒ R2.3.2 emoving and Installing, with Dual Mass Flywheel, LuK”,
page 59 .
❑ Diaphragm Spring Ends, Checking. Refer to ⇒ Fig. ““Check the Ends of the Diaphragm Spring”“, page
62 .
❑ Tension Springs and Rivet Connection, Checking. Refer to ⇒ Fig. ““Tension Springs and Rivet Con‐
nection, Checking”“, page 62 .
4 - Bolt
❑ M 6: 13 Nm
❑ M 7: 20 Nm
2.2.3 Overview - Clutch, with Single Flywheel
2. Clutch 53
Jetta 2018 ➤
1 - Flywheel
wheel, Removing and
Installing.
pins
contact surface free of
grooves, oil and grease
2 - Clutch Plate
alog (ETKA).
❑ Centering. Refer to ⇒
stalling, with Single Fly‐
wheel”, page 64 .
3 - Pressure Plate
ling. Refer to ⇒
stalling, with Single Fly‐
wheel”, page 64 .
❑ Diaphragm Spring
Ends, Checking. Refer
to ⇒ Fig. ““Check the
Ends of the Diaphragm
Spring”“, page 66 .
❑ Checking the spring
connections and rivet
connections. Refer to ⇒
Fig. ““Check the Spring
Connection and Rivet
Connections”“, page 67 .
4 - Bolt
❑ M 6: 13 Nm
❑ M 7: 20 Nm
2.3 Clutch, Removing and Installing

⇒ R2.3.1 emoving and Installing, with Dual Mass Flywheel,
Sachs”, page 54
⇒ R2.3.2 emoving and Installing, with Dual Mass Flywheel,
LuK”, page 59
⇒ R2.3.3 emoving and Installing, with Single Flywheel”, page
64
2.3.1 Clutch, Removing and Installing, with Dual Mass Flywheel, Sachs

Jetta 2018 ➤
Special tools and workshop

equipment required
♦ Flywheel Retainer -3067-

♦ Alignment Tool - Clutch Plate -3190A-
♦ Lubricating Grease for Clutch Plate Splines
♦ Refer to the ⇒ Electronic Parts Catalog (ETKA) for the
grease allocation.
Removing
2. Clutch 55
Jetta 2018 ➤

– Insert the - 3067- to loosen the bolts.
When Removing, Loosen the Clutch Pressure Plate as Follows
so That the Pressure Plate Does Not Distort (Causing Shudder‐
ing on Acceleration):
– Loosen all bolts diagonally in small steps.
• When loosening, the stop -2- and the bolt -1- must loosen up
together.
– If the stop does not loosen: push the bolt toward the dual
mass flywheel.
– Remove the pressure plate and the clutch plate.
Installing

Jetta 2018 ➤
Note
♦ Allocate clutch pressure plate and clutch plate according to

the engine code. Refer to the ⇒ Electronic Parts Catalog
(ETKA).
♦ Clean the input shaft splines and (on used clutch plates) the
hub splines. Remove any corrosion and only apply a very
thin coating of Lubricating Grease for Clutch Plate Splines
on the splines. Then move the clutch plate back and forth
on the input shaft until the hub moves freely on the shaft.
Remove any excess grease.
♦ The clutch pressure plates are corrosion-protected and
greased. With the exception of the friction surface on the
clutch plate, do not clean the clutch pressure plate. This will
shorten the service life of the clutch considerably.
♦ The friction surfaces on the clutch pressure plate and on the
flywheel must be cleaned thoroughly (degreased).
the clutch housing, the flywheel and the side of the engine
facing toward the transmission.
♦ Only use compressed air to clean the dual mass flywheel.
♦ The clutch plate linings must sit completely on the flywheel
and on the clutch pressure plate friction surface. Install the
bolts.
♦ Tighten the bolts diagonally in small steps so as to not
damage the centering holes in the pressure plate and the
centering pins on the flywheel.
♦ Make sure the alignment sleeves for centering the en‐
gine/transmission are installed inside the cylinder block. In‐
stall them if necessary.
♦ If the alignment sleeves are missing, it will be difficult to
shift, there will be clutch problems and the transmission may
make noises (loose rattling).
Clutch Plate Installation Position
• “Transmission side” label faces the transmission.

Check the Ends of the Diaphragm Spring
2. Clutch 57
Jetta 2018 ➤
• Wear up to half the thickness of the diaphragm spring

-arrows- is permitted.
Checking the Spring Connections and Rivet Connections
I - Tension spring OK
• Slight offset in the outer area -arrows A-.
II - Tension spring damaged
• Clutch pressure plates must be replaced if the tension
springs are bent or broken off -arrow B-.
– Make sure the rivet connections -B arrows- have a secure fit
at all tension springs -A arrows-.
• Replace any clutch pressure plates that have loose rivet

connections -arrows B-.

Jetta 2018 ➤
– Install the -3067-.
– Install the clutch pressure plate on the centering pins.

– Center the clutch plate with the -3190A-.
When Installing, Tighten Bolts as Follows so Clutch Pressure
Plate Does Not Distort (Causing Shuddering on Acceleration):
– Make sure the stop pin (position sensor) -arrow- moves easi‐
ly.
– Install all bolts evenly, by hand, until the bolt heads touch the
clutch pressure plate.
– Tighten the bolt diagonally in small steps.
• When doing this, the stop pin -arrow- must lift off from the
pressure plate.
– Install the transmission. Refer to ⇒ I2.3 nstalling”, page 107 .
♦ Refer to ⇒ -2.2.1 Clutch, with Dual Mass Flywheel, Sachs”,
page 51
2.3.2 Clutch, Removing and Installing, with Dual Mass Flywheel, LuK
2. Clutch 59
Jetta 2018 ➤

equipment required

grease allocation.
Removing

Jetta 2018 ➤

– Remove the clutch pressure plate and clutch plate.
Installing
Note

(ETKA).
♦ Only use compressed air to clean the dual mass flywheel.
bolts.
Clutch Plate Installation Position
2. Clutch 61
Jetta 2018 ➤
• “Transmission side” label faces the transmission.


Note
Allocate clutch pressure plate and clutch plate according to the

engine code. Refer to the ⇒ Electronic Parts Catalog (ETKA).
Tension Springs and Rivet Connection, Checking

Jetta 2018 ➤

Checking the Spring Connections and Rivet Connections
– Make sure the rivet connections -arrows B- have a secure fit

at all tension springs -arrows A-.
connections -arrows B-.
Only Check the Position of the Adjustment Mechanism with
New Pressure Plates
• Both edges -A- of the adjusting ring must be located be‐

tween both notches -arrows B-.
• If the adjusting ring takes on a different position with new
pressure plates, pressure plate and clutch plate must not be
installed.
• With used clutches, the adjusting ring may take on a position
outside of the notches.
– Install the -3067-.
2. Clutch 63
Jetta 2018 ➤
– Install the clutch pressure plate on the centering pins.

– Center the clutch plate with the -3190A-.
When Installing, Tighten Bolts as Follows so Clutch Pressure
Plate Does Not Distort (Causing Shuddering on Acceleration):
– Install all bolts evenly, by hand, until the bolt heads touch the
clutch pressure plate.
– Install the transmission. Refer to ⇒ R2 emoving and Instal‐
ling”, page 90 .
♦ Refer to ⇒ -2.2.2 Clutch, with Dual Mass Flywheel, LuK”,
page 52
2.3.3 Clutch, Removing and Installing, with Single Flywheel

Jetta 2018 ➤

equipment required

Removing
• Transmission is removed.
2. Clutch 65
Jetta 2018 ➤

– Remove the pressure plate and the clutch plate.
Installing
Note

(ETKA).
bolts.
• Clutch plate installed location: the labeling “Getriebeseite”

(transmission side) or the shorter end of the hub with the
spring cage faces the pressure plate.

Jetta 2018 ➤

Check the Spring Connection and Rivet Connections
– Check the spring connection between the pressure plate and

the cover for cracks and make sure the rivet connections are
secure.
– Replace the pressure plate if the springs are damaged or if
the rivet connections -arrows- are loose.
Tension Springs and Rivet Connection, Checking
2. Clutch 67
Jetta 2018 ➤

– Check the spring connections -arrows A- for damage and
make sure the rivet connections -arrows B- are tight.
• Replace a clutch pressure plate with severely kinked or bro‐
ken spring connections and loose rivet connections.
– Make sure the rivet connections -arrows B- have a secure fit
at all tension springs -arrows A-.
– Tighten all bolts clockwise to the final tightening specifica‐

tion.
connections -arrow B-.
Checking the Metal Ring
– Check the metal ring in the clutch pressure plate -arrow- for
damage.
• Replace any clutch pressure plates that have a broken metal
ring.
– Use the -3190A- to center the clutch plate.

Jetta 2018 ➤

– Install the transmission. Refer to ⇒ I2.3 nstalling”, page 107 .
♦ Refer to ⇒ -2.2.3 Clutch, with Single Flywheel”, page 53
2. Clutch 69
Jetta 2018 ➤
34 – Controls, Housing
1 Shift Mechanism
⇒ M1.1 echanism Installation Position”, page 70
⇒ -1.2 Gearshift Knob and Cover”, page 71
⇒ -1.3 Shift Mechanism”, page 71
⇒ K1.4 nob, Removing and Installing”, page 73
⇒ M1.5 echanism, Removing and Installing”, page 75
⇒ M1.6 echanism, Adjusting”, page 84
⇒ M1.7 echanism, Checking”, page 87
⇒ S1.8 haft Seal, Replacing”, page 88
1.1 Shift Mechanism Installation Position

-Arrow A- Gearshift Lever Movement
-Arrow B- Selector Lever Movement
A - Shift Cable for Gearshift

Movement
B - Selector Cable for Selec‐
tion Movement
C - Heat Shield
❑ Remove the shift mech‐
anism before removal.
1 - Shift Lever
2 - Selector Relay Lever
70 Rep. Gr.34 - Controls, Housing

Jetta 2018 ➤
1.2 Overview - Gearshift Knob and Cover
1 - Gearshift Housing with

Gearshift Lever
2 - Nut
❑ M 6: 8 Nm
❑ M 8: 20 Nm
3 - Bracket
❑ For the center console
❑ Overview. Refer to
⇒ Body Interior; Rep.
Gr. 68; Center Console;
Overview - Center Con‐
sole.
4 - Bracket
❑ For the center console
❑ Overview. Refer to
⇒ Body Interior; Rep.
Gr. 68; Center Console;
Overview - Center Con‐
sole.
5 - Noise Insulation
6 - Badge
❑ Can be carefully pried
off the plastic or leath‐
er gearshift knob us‐
ing the Trim Removal
Wedge -3409-.
7 - Gearshift Knob
❑ Always replace togeth‐
er
❑ The shift knob and boot
cannot be separated
from each other.
❑ With boot
❑ Removing and installing. Refer to ⇒ -1.3 Shift Mechanism”, page 71 .
8 - Center Console
❑ Overview. Refer to ⇒ Body Interior; Rep. Gr. 68; Center Console; Overview - Center Console.
9 - Clamp
❑ For securing the gearshift knob to the selector lever
❑ Secure on the gearshift knob using Hose Clamp Pliers -VAG1275-.
1.3 Overview - Shift Mechanism
Note
♦ Lubricate the bearing areas and the sliding surfaces.

♦ Refer to the ⇒ Electronic Parts Catalog (ETKA) for the grease allocation.
1. Shift Mechanism 71
Jetta 2018 ➤
1 - Gearshift Shaft with Gear‐

shift Cover
2 - Slide Block
3 - Relay Lever
❑ Refer to the ⇒ Electron‐
ic Parts Catalog (ET‐
KA) for the allocation.
Refer to ⇒ Fig. ““Shift
Lever/Relay Lever In‐
stallation Position”“,
page 82 .
❑ After installing, adjust
the shift mechanism.
Refer to ⇒ M1.6 echan‐
ism, Adjusting”, page
84 .
❑ Relay Lever and Ca‐
ble Retainer, Removing
and installing. Refer to
⇒ Fig. ““Relay Lever,
Removing with Cable
Retainer”“, page 77 .
4 - Cable Retainer
❑ For attaching the selec‐
tor cable to the relay
lever
❑ After installing, adjust
the shift mechanism.
Refer to ⇒ M1.6 echan‐
ism, Adjusting”, page
84 .
❑ Do not interchange, ca‐
ble retainers for selec‐
tor cable on relay lever
and for shift cable on
transmission shift lever
are different
❑ Allocation. Refer to ⇒ Fig. ““Cable Retainer Allocation”“, page 81 .
❑ Remove from the relay lever. Refer to ⇒ Fig. ““With the Relay Lever Removed: Pry the Selector Cable
Retainer off of the Relay Lever.”“, page 78 .
❑ Press onto the relay lever. Refer to ⇒ Fig. ““Installing the Selector Cable Retainer on the Relay Lever”
“, page 79 .
5 - Cable Retainer
❑ For attaching the shift cable to the selector lever
❑ After installing, adjust the shift mechanism. Refer to ⇒ M1.6 echanism, Adjusting”, page 84 .
❑ Do not interchange, cable retainers for selector cable on relay lever and for shift cable on transmission
shift lever are different
❑ Allocation. Refer to ⇒ Fig. ““Cable Retainer Allocation”“, page 81 .
6 - Lock Washer
7 - Lock Washer
❑ Be careful not to damage the cables when removing them
8 - Selector Cable
❑ Attach to the cable retainer

Jetta 2018 ➤
❑ Do not bend
❑ Installation position. Refer to ⇒ M1.1 echanism Installation Position”, page 70 .
9 - Shift Cable
❑ Attach to the cable retainer
❑ Do not bend
❑ Installation position. Refer to ⇒ M1.1 echanism Installation Position”, page 70 .
10 - Shifter Housing
11 - Seal
❑ Replace after removing the gearshift housing
❑ Between the selector housing and the underbody
❑ Self-adhesive
❑ Affix to the selector housing
12 - Cable Bracket
13 - Hex Bolt
❑ 20 Nm
❑ For the cable bracket
❑ Quantity: 3
14 - Grommet
❑ Cable bracket mounting to transmission
❑ Quantity: 3
15 - Spacer
❑ Quantity: 3
16 - Nut
❑ Tightening Specification. Refer to ⇒ -5.4 Shift Unit”, page 129 .
17 - Shift Lever
❑ Insert so that staggered tooth pattern aligns with gearshift shaft. Refer to ⇒ Fig. ““Shift Lever, Instal‐
ling”“, page 82 .
❑ Installation position. Refer to ⇒ Fig. ““Shift Lever/Relay Lever Installation Position”“, page 82 .
18 - Gearshift Shaft Seal
❑ Replacing. Refer to ⇒ S1.8 haft Seal, Replacing”, page 88 .
19 - Clip
1.4 Gearshift Knob, Removing and Instal‐

ling
Jetta 2018 ➤
♦ Wedge Set -T10383-
♦ Or Backrest Panel Tool -3370-, depending on the equipment
♦ Hose Clip Pliers -VAG1275A-
Removing
– Use the -T10383/1- to carefully pry out the selector lever

boot from the center console insert -arrows-.
or
– Open the ashtray.

Jetta 2018 ➤
– Push the -3370- all the way under the plastic frame for the
boot in direction of -arrow 1- as shown.
– Remove the boot with the plastic frame from the center con‐
sole frame -A- in direction of -arrow 2-
– Roll the selector lever boot up over the gearshift knob.
– Open the clamp -arrow- and remove the gearshift lever knob
with the shift lever boot.
Installing
– Press the gearshift knob and the selector lever boot all the
way up on the gearshift lever.
– Secure the gearshift knob with clamp -arrow- on the gear‐
shift lever (⇒ previous illustration). Use the -VAG1275A- for
this.
1.5 Shift Mechanism, Removing and Instal‐

ling
Jetta 2018 ➤
Removing
– Disconnect the battery ground cable. Refer to ⇒ Electrical
System; Rep. Gr. 27; Battery; Battery, Removing and Instal‐
ling.
– Remove the boot with the gearshift knob and, if necessary,
remove the noise insulation from the center console frame
as well. Refer to ⇒ K1.4 nob, Removing and Installing”, page
73 .
The Footwell Rear Channel Is Located above the Nut for the
Center Console on Some Vehicles:
– Remove the center console. Refer to ⇒ Body Interior; Rep.
Gr. 68; Center Console; Center Console, Removing and In‐
stalling.
– Remove the footwell rear channel. Refer to ⇒ Heating, Ven‐
view - Air Routing and Air Distribution in Passenger Com‐
partment.
– Remove the nuts for the center console securing bracket.

Refer to ⇒ Body Interior; Rep. Gr. 68; Center Console; Cen‐
ter Console, Removing and Installing.
– Remove the gearshift housing nuts.
– Lower the gearshift housing.
• If it is not possible to lower the gearshift housing, then the
nuts on the gearshift housing are located under the bracket
on the center console.
• The center console securing bracket must be removed. Re‐
fer to ⇒ Body Interior; Rep. Gr. 68; Center Console; Center
Console, Removing and Installing.

Jetta 2018 ➤
For Vehicles Where the Center Console Securing Bracket Can‐

not Be Removed Separately:
– Remove the center console. Refer to ⇒ Body Interior; Rep.
Gr. 68; Center Console; Center Console, Removing and In‐
stalling.
– Remove the center console with the center console securing
bracket. Refer to ⇒ Body Interior; Rep. Gr. 68; Center Con‐
sole; Overview - Center Console.
– Remove the footwell rear channel. Refer to ⇒ Heating, Ven‐
view - Air Routing and Air Distribution in Passenger Com‐
partment.
Installation Position of Noise Insulation and Gearshift Housing
Nuts -arrows-
– Remove the noise insulation and gearshift housing nuts

-arrows-.
– Remove the noise insulation from the gearshift housing. Re‐
fer to ⇒ Body Interior; Rep. Gr. 68; Center Console; Over‐
view - Center Console.
– Remove the entire air filter housing if it is located over the
gearshift mechanism. Refer to ⇒ Rep. Gr. 24; Air Filter; Air
Filter Housing, Removing and Installing.
– Remove the shift cable from the gearshift lever pins.
Cable Retainer, Separating from Selector Cable
– Pull the securing mechanism all the way forward in direc‐

tion of -arrow 1- and then unlock to the left in direction of
-arrow 2-.
– Push the relay lever forward (in direction of -arrow 3-).
Relay Lever, Removing with Cable Retainer
Jetta 2018 ➤
– Remove the clip -arrow 1- and then remove the relay lever
together with the cable retainer -arrow 2-.
– Remove the cable bracket from the transmission -arrows-.
Unclip the hose line -A- from the bracket -B- beforehand, if
necessary.
Caution
Risk of damaging the decoupling element on the exhaust

pipe.
♦ Pay attention to ⇒ Rep. Gr. 26; Emissions Control Sys‐
tem; Overview - Emissions Control System.
– Remove the exhaust pipe under the shift mechanism. Refer

to ⇒ Rep. Gr. 26; Exhaust Pipes/Muffler; Front Exhaust Pipe,
Removing and Installing.
– Remove the heat shield under the gearshift mechanism.
Heat Shield, Removing. Refer to ⇒ Body Exterior; Rep. Gr. 66;
Trim Strips / Trim / Extensions / Trim Panels; Floor Heat Shield,
– Pivot the shifter housing downward and remove it with the
shift cables.
With the Relay Lever Removed: Pry the Selector Cable Retain‐
er off of the Relay Lever.

Jetta 2018 ➤
– Insert a screwdriver -A- between the bushing -B- and the

relay lever.
Installing
Installing the Selector Cable Retainer on the Relay Lever
• The relay lever is removed.

• Lubricate cable retainer locating bore.
grease allocation.
• The cable retainer may only be installed at the bushing in
direction of -arrow-.
• The cable retainer must move freely on the relay lever.
• The cable retainer must be behind the tab.
• Make sure it engages securely.
– Align the shift housing so that is it parallel to the body.
• The distance on both sides to the body must be equal.
Install the gearshift housing.
Cable Tie Installation Position
Jetta 2018 ➤
– Wrap the cable tie -arrow- in a crossover pattern around the

cables and attach it as shown.
– Route the cables -1- from the gearshift mechanism -2- to the
transmission as follows:
♦ After the cables cross each other diagonally -arrow-, they

must run parallel to each other up to the cable bracket on
the transmission.
♦ The cable tie -arrow- for securing the cables must be instal‐
led correctly. Installation position. Refer to ⇒ Fig. ““Cable Tie
Installation Position”“, page 79 .
♦ The cables must be routed inside the depression in the heat
shield -3-.
A clip -A- holds the cables and heat shield to each other in
place.

Jetta 2018 ➤
Cable Retainer Allocation
The holes in the cable retainers have different diameters.

Cable Retainer for: Dimension “a”
1. - Shift cable to transmission selector lever 8.5 mm
2. - Selector lever cable to selector relay lever 10 mm
– Coat the gearshift lever pins with a small amount of grease.
• Lubricate the following areas very carefully when installing.
• Relay lever shaft -A- -arrows-.

• Gearshift lever guide rail -B-, fits into the relay lever.
Jetta 2018 ➤
• Cable retainer locating bore.

grease allocation.
• The relay lever and gearshift lever shown may differ from the
original part.
Shift Lever/Relay Lever Installation Position
1 - Shift Lever
2 - The selector relay lever fits into the sliding rail on the trans‐
mission selector lever via the sliding shoe -arrow-.
Shift Lever, Installing

Jetta 2018 ➤
– When positioning the transmission shift lever, make sure the

tooth gap -arrow A- is placed over the missing selector shaft
teeth -arrow B-.
– Secure the shift cable with new lock washers to the gearshift
lever.
Install the Relay Lever and the Cable Retainer Together.
Note
Lubricate the bearing areas and the sliding surfaces. Refer to

the ⇒ Electronic Parts Catalog (ETKA) for the grease allocation.
– Install the relay lever and cable retainer -arrow 2- all the way
into the gearshift cover.
– Install the clip -arrow 1- and make sure it is locked into
place.
– Install the selector cable in the cable retainer.
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– Install the center console. Refer to ⇒ Body Interior; Rep.

Gr. 68; Center Console; Overview - Center Console.
– Install the boot with the gearshift knob and noise insulation.
Refer to ⇒ K1.4 nob, Removing and Installing”, page 73 .
– Install the heat shield under the gearshift mechanism. Refer
to ⇒ Body Exterior; Rep. Gr. 66; Trim Strips / Trim / Exten‐
sions / Trim Panels; Floor Heat Shield, Removing and Instal‐
ling.
– Assemble the exhaust system free of tension. Refer to
⇒ Rep. Gr. 26; Exhaust Pipes/Mufflers; Overview - Muffler.
– Adjust the gearshift mechanism. Refer to ⇒ M1.6 echanism,
Adjusting”, page 84 .
– Install the air filter housing if it was removed earlier. Refer to
Installing.
♦ Refer to ⇒ -1.2 Gearshift Knob and Cover”, page 71
♦ Refer to ⇒ -1.3 Shift Mechanism”, page 71
1.6 Shift Mechanism, Adjusting

♦ Connecting Pin -T10027A-
Adjusting Requirements
• Operating and transfer elements of shift mechanism must be
in proper condition.
• Shift mechanism must move freely.
• The transmission, clutch and clutch mechanism must also
be in proper condition.
• Transmission in neutral.
– Remove the entire air filter housing if the bracket -A- for se‐
curing the gearshift shaft and safety mechanism for the shift
cable and selector cable is not accessible. Refer to ⇒ Rep.
Gr. 24; Air Filter; Air Filter Housing, Removing and Installing.

Jetta 2018 ➤
– Pull the safety mechanism on the cable retainer from the

shift cable and the selector cable all the way forward in
the direction of -arrow 1- and then lock it to the left in the
direction of -arrow 2-.
Secure the gearshift shaft as follows:
– Push the gearshift shaft down in the direction of -arrow 1-.

– While pressing the gearshift shaft down, rotate the bracket
-A- in the direction of -arrow 2- upward and simultaneously
press it in until it engages in the gearshift shaft.
– Remove the boot and if possible, the noise insulation from
the center console. Refer to ⇒ K1.4 nob, Removing and
Installing”, page 73 .
Secure the gearshift lever as follows:
Jetta 2018 ➤
– Install the gearshift lever in neutral and, if necessary, press

the gearshift lever to the left and hold.
– Guide the -T10027A- through the noise insulation -A-, hole
-B- and into hole -C-.
– Turn the safety mechanism on the cable retainer for the
shift cable and selector cable all the way to the right in the
direction of -arrow-.
The spring will push the safety mechanism into the starting
position.
– Turn the bracket -A- back to the starting position in the direc‐
tion of -arrow-.

Jetta 2018 ➤
Note
The bracket -A- must be pressed out of the selector housing as

far as the stop and it must face toward the rear.
– Remove the -T10027A- from the noise insulation -A- and the
holes -B and C-.
– Install the boot and the noise insulation (if equipped). Refer
to ⇒ K1.4 nob, Removing and Installing”, page 73 .
– Make sure the gearshift shaft moves easily.
– Install the air filter housing if it was removed earlier. Refer to
Installing.
1.7 Shift Mechanism, Checking

• The gearshift lever must be in the 3rd/4th gear selector lever
gate when in neutral.
– Operate the clutch.
– Move the shift lever several times through all the gears.
Make sure the reverse gear lock is working correctly.
– It will be necessary to adjust the gearshift mechanism again
if a hook does not appear each time a gear is engaged.
Refer to ⇒ M1.6 echanism, Adjusting”, page 84 .
Jetta 2018 ➤
1.8 Selector Shaft Seal, Replacing

♦ Press Piece - Shift Rod/Alternator -VW423-
♦ Puller - Crankshaft/Power Steering Seal -T20143/1-
♦ Sealing Grease
grease allocation.
– Remove the gearshift lever and relay lever. Refer to ⇒
-1.3 Shift Mechanism”, page 71 .
– Remove the seal using the -T20143/1- or a screwdriver.
– Lightly oil the outer edge of the new seal.
– Fill the area between the sealing lip and dust lip -arrow-
halfway with Sealing Grease.
Install the Seal All the Way

Jetta 2018 ➤
– Install the gearshift lever and relay lever. Refer to ⇒

-1.3 Shift Mechanism”, page 71 .
Jetta 2018 ➤
2 Transmission, Removing and Instal‐

ling
⇒ T2.1 ightening Specifications”, page 90
⇒ R2.2 emoving”, page 90
⇒ I2.3 nstalling”, page 107
2.1 Transmission Tightening Specifications

Transmission to Engine
Item Bolt Quantity Nm

1 M12 x 60 2 80
2 M12 x 165 2 80
♦ Also starter to
transmission
3 M10 x 55 3 40
4 M12 x 70 2 80
Item -A- alignment sleeves for centering
Component Nm
Wire bracket to lower starter bolt 23
Ground wire to upper starter bolt 20
2.2 Transmission, Removing

Jetta 2018 ➤

equipment required
♦ Engine Support Bridge -10-222A-

♦ Engine Support Bridge - Engine Support 29 -10-222A/29-
♦ Engine/Gearbox Support Shackle (2pc.) -10-222A/12-
♦ Transmission Support - Pins 29 -3282/29-
♦ Transmission Support -3282-
2. Transmission, Removing and Installing 91

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♦ Transmission Support - Mounting Plate 39 -3282/39-

♦ Support Elements for transmission (determine when mount‐
ing the Mounting Plate on the Transmission Support)
♦ Engine and Gearbox Jack -VAS6931-
♦ Transmission Support Jig -3336- for transporting the trans‐
mission
♦ Determine the shift mechanism grease using the ⇒ Electron‐
ic Parts Catalog (ETKA).

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♦ Spindle from the Seal Installer - Driver Set -3066- or M8 x

105 bolt
♦ Seal Installer - One-Piece Seal -T10148-
♦ Square Pipe -T40091/1- (quantity: 2)
♦ Engine Support - Joint Fixture -T40091/3- (quantity: 2)

♦ Spindle -T40093/3- (quantity: 2) from the Engine Support
Supplement Set -T40093B-

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♦ Engine Support Brackets -T40093/3-6A- (quantity: 2)
♦ or Engine Support Brackets -T40093/3-6A- (quantity: 2)

Engine Support Brackets -T40093/3-6-, Checking and Replac‐
ing if Necessary
– Disconnect the marked area if necessary.

– Round off the front edges.
– Protect the Bracket against corrosion.
– Then mark the -T40093/3-6- with -T40093/3-6A-.
The -10-222A- and the -T40093/3-6A- will be mounted on the
longitudinal members later in the procedure.
• So that the longitudinal members will not be damaged, tape
around the -T40093/3-6A- in the front area with cloth tape.
Refer to the ⇒ Electronic Parts Catalog (ETKA) (Chemical
Materials).
– Disconnect the battery ground cable. Refer to ⇒ Electrical
Connecting.
– Remove the air filter housing. Refer to ⇒ Rep. Gr. 24; Air
Filter; Air Filter Housing, Removing and Installing.
– Remove the bolts -arrows- and battery tray -1-. Refer to
⇒ Electrical Equipment; Rep. Gr. 27; Battery; Battery, Re‐
moving and Installing.

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– Remove the cable retainer from the selector cable. Refer to

⇒ Fig. ““Cable Retainer, Separating from Selector Cable”“,
page 77 .
– Remove the clip -arrow 1- and then remove the relay lever
and the cable retainer.
– Remove the shift cable lock washer -arrow 2- from the selec‐
tor lever -A-.
– Remove the shift cable from the gearshift lever pins.
– Remove the nut -arrow 3- and then remove the transmission
shift lever -A-.
– Remove the cable bracket from the transmission -arrows-.
– Tie up the shift cable and the selector cable.

– If equipped, remove the bracket -B- from the transmission
and remove it from the hose/line assembly -A-.
– Remove the transmission support -arrows A-.

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– Remove clutch slave cylinder -arrow B- and lay aside, se‐

cure with wire, do not open line system.
Caution
The clutch slave cylinder could be damaged.

♦ If the clutch slave cylinder is removed from the transmis‐
sion with pipe/hose line still connected, do not press the
clutch pedal.
– Remove the ground cable upward from the engine/transmis‐

sion connecting bolt or from the upper starter bolt.
– Disconnect the connector -arrow 1- from the Back-Up Lamp

Switch -F4-.
– Remove the connector -arrow 2- and wire -arrow 3- from the
starter.
– Remove the upper bolt from the starter.
– Remove the upper engine/transmission bolts.
– If there are hose and cable connections located near the en‐
gine lifting eyes for the -10-222A-, these must be removed.
– Mount the -10-222A- as follows:
The following are needed:
♦ Engine/Gearbox Support Shackle -10-222A/12-, quantity: 2
(required if the Spindles from the Engine Support Bridge
cannot be engaged in the engine lifting eyes).
(quantity: 2)
♦ Square Pipe -T40091/1- (quantity: 2)

Jetta 2018 ➤
♦ Engine Support - Joint Fixture -T40091/3- (quantity: 2)

♦ Spindle -T40093 /3- (quantity: 2)
♦ Engine Support Brackets -T40093/3-6A- (quantity: 2)
– On both sides of the vehicle, insert the -10-222A/29- be‐
tween the fender bolting edge and the fender bolting plate
underneath it.
♦ Installation position:
“L” = -1- Adapter is inserted on the “right” side of the vehicle
(Adapter locks in place in the fender opening).
“R” (not illustrated here), Adapter is installed on the “left” side of
the vehicle.
The arrow -2- on the -10-222A/29- always points in the direction
of travel.

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– Slide the -10-222A/18- and the two -T40091/3- onto the

-10-222A-.
– Tighten the -10-222A- on the -10-222A/29-.
-A- = -T40093/3-6A- (see the next illustration).
– If present, remove wires from the front area of both longitudi‐
nal members -arrow-. Do not disconnect the line system

Jetta 2018 ➤
– Place the -T40093/3-6A- on both longitudinal members (the

right longitudinal member is illustrated here).
– If necessary, carefully unclip the A/C system pipe in the front
area. Do not disconnect the line system. Refer to ⇒ Heating,
Ventilation and Air Conditioning; Rep. Gr. 87; Refrigerant
Circuit; System Overview - Refrigerant Circuit.
• The -T40093/3-6A- lock to the respective pin -A- behind the
tab on the longitudinal member -arrow-.
• Place the -T40093/3-6A- on the left longitudinal member di‐
rectly behind the filler tube for the washer fluid reservoir -B-.
• If necessary, push the -T40093/3-6A- into position.
– Install the -T40093/3-.
– Connect the -T40093/3- to the -10-222A- using the -
T40091/1- and tension (see the previous illustration).
Note
♦ The -T40091/1- must not touch the windshield.

♦ The -10-222A/18- must not lie on the windshield wiper arm.
– If necessary, the Spindles can then be engaged in the en‐

gine lifting eyes using the -10-222A/12-.
– Lightly pretension the engine/transmission assembly and
Engine Support Bridge using the Spindles.
– Raise the vehicle and remove the left front wheel.
– Remove the lower section of the left front wheel housing
liner. Refer to ⇒ Body Exterior; Rep. Gr. 66; Wheel Housing
Liner; Overview - Front Wheel Housing Liner.
– Remove the nut -arrow- and then remove the wire bracket.

Jetta 2018 ➤
– Remove the starter. Refer to ⇒ Electrical Equipment; Rep.

Gr. 27; Starter; Starter, Removing and Installing.
– Remove all wires from the transmission.
– Transmission for vehicles with Start/Stop System: discon‐

nect the connector -arrow- from the Transmission Neutral
Position Sensor -G701-.
– Remove the nuts -1- from both sides of the coupling rod -3-.
– Remove the coupling rod -3- from both sides of the stabilizer
bar -2-.
– If equipped, remove the Left Front Level Control System
Sensor -G78- from the lower control arm. Refer to ⇒ Sus‐
pension, Wheels, Steering; Rep. Gr. 43; Level Control Sys‐
tem Sensor; Overview - Front Level Control System Sensor.

Jetta 2018 ➤
– If equipped, remove the drive axle heat shield -arrows-. Re‐

fer to ⇒ Suspension, Wheels, Steering; Rep. Gr. 40; Drive
Axle; Drive Axle Heat Shield, Removing and Installing.
– Remove the drive axles from the flange shafts and tie them
up as high as possible. Be careful not to damage the surface
protection. Refer to ⇒ Suspension, Wheels, Steering; Rep.
Gr. 40; Drive Axle, Drive Axle, Removing and Installing.
– Remove the engine/transmission connecting bolt -A- above
the right flange shaft.
– Remove the right flange shaft bolt -arrow- -B-. Insert two
bolts in the flange and counterhold the flange shaft with the
extractor lever.

Jetta 2018 ➤
Note
♦ Check the seal for leaks before removing the flange shaft.
If the seal has leaks, replace it when installing. Refer to ⇒
S1.3 eal, Replacing”, page 249 .
♦ If transmission fluid leaks out while removing the flange
shaft, the transmission fluid must be drained and refilled on
the installed transmission and installed flange shaft. Refer to
⇒ F8 luid”, page 199 .
– Remove the right flange shaft.

– Install the spindle -A- from the -3066- in the threaded piece
on the differential.
– Insert the -T10148- and secure with the nut -B-.
Note
♦ The -T10148- protects the right seal and the transmission

from dirt.
♦ An M8 x 105 mm bolt may be installed by hand into the
differential threaded piece instead of a spindle -A-.
Caution
Risk of damaging the decoupling element.

♦ Pay attention to ⇒ Rep. Gr. 26; Emissions Control Sys‐
tem; Overview - Emissions Control System.
– Remove the bolts -arrows- for the exhaust system bracket

from the subframe.

Jetta 2018 ➤
– Separate the exhaust system at the clamping sleeve -arrow-.

Refer to ⇒ Rep. Gr. 26; Emissions Control System; Over‐
view - Emissions Control System.
– Remove the bolts -1 through 3- and remove the pendulum

support.
– If present, remove the nut -arrow- and ground cable.

Jetta 2018 ➤
– Remove the left subframe mount hex bolts -arrows- from the
transmission mounting.
– Lower the transmission (the transmission moves toward the

front).
• Dimension -a- = approximately 50 mm

– Remove the transmission bracket -A- -arrows-.
Set up the -3282- with the -3282/39- to remove the transmission

“02S”.

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– Insert the -3282- into the -VAS6931-.

– Align the arms of the Transmission Support so that they
align with the holes in the Adjustment Plate.
– Install the Mounting Elements -A- and -C-, on the Adjusting
Plate, as illustrated.
– Position the Engine and Transmission Jack under the vehi‐
cle. The arrow symbol -B- on the Adjusting Plate points in
the direction of travel.
– Align the adjusting plate so that it is parallel to the transmis‐
sion and secure the safety support to the transmission.
– Install the -3282/29- into the rear hole for the pendulum sup‐
port bolt on the transmission.
– Remove the engine/transmission bolt -arrow- under the right

flange shaft.
– Remove the lower engine/transmission connecting bolts.
– Remove the transmission from the alignment bushings and
carefully move it toward the subframe.

Jetta 2018 ➤
– Tip the transmission forward in the direction of -arrow- using

the spindle on the -3282-.
– Carefully push the engine forward slightly with a second

technician.
– Carefully lower the transmission with the -VAS6931-, while
making sure that the right flange shaft seal -1- is guided
through without any damage to the pressure plate -arrow-.
– Prefill the left flange shaft -B- as shown on the subframe

-arrow-. Move the Engine and Gearbox Jack with the trans‐
mission to the front.

Jetta 2018 ➤
– When lowering, change the transmission position using the

spindles on the -3282-.
Note
Pay attention to all of the lines when lowering the transmission.
– If necessary, re-insert the right flange shaft and tighten the

countersunk bolt -arrow-.
♦ Refer to ⇒ -2.1 Differential”, page 257
2.3 Transmission, Installing
Note
Refer to “Transmission, Removing” to get a list of the required

special tools. Refer to ⇒ R2.2 emoving”, page 90 .
Pay attention to the following chart for the subject - “Transmis‐

sion Fluid, Checking and Filling”:
“Transmission Fluid, Checking and Filling”
»No« »Yes« »Yes«
Transmis‐ Original X
sion Part
No fluid X
leaking

Jetta 2018 ➤
“Transmission Fluid, Checking and Filling”

Was com‐ X
pletely dis‐ before in‐
assembled stallation
-item 2-
⇒ Item 2
(page 176)
transmis‐
sion fluid
capacity.
Refer to
⇒ 4.1 ,
page 10
Was parti‐ X
ally disas‐ after instal‐
sembled lation. Re‐
• (The fer to
trans‐ ⇒ F8 luid”,
mission page 199 .
housing
and the
clutch
housing
were
not sep‐
arated
from
each
other)
– Use a thread cutter to carefully clean all threaded holes con‐

taining self-locking bolts to remove any locking fluid residue.
– Replace self-locking bolts and nuts after removing them.
– Make sure the alignment sleeves for centering the en‐
If the alignment sleeves are missing, it will be difficult to shift,
there will be clutch problems and the transmission may make
noises (loose rattling).
– Make sure the intermediate plate fits correctly on the engine.
– Clean the splines on the input shaft and then lubricate them
lightly with Grease for Clutch Plate Shaft Splines.
It must be possible to slide the clutch plate back and forth on
the input shaft.
The -3282- is set up with the -3282/39- to install the transmis‐
sion.

Jetta 2018 ➤
– Align the arms of the -3282- so that they align with the holes
in the Adjustment Plate.
– Install the Mounting Elements -A and C- (Transmission Sup‐
port - Pins 29 -3282/29-) as shown on the Adjusting Plate.
– Place the transmission on the Engine and Gearbox Jack.
– Align the Adjusting Plate and transmission so that they are
parallel to each other.
– Install the -3282/29- into the rear hole for the pendulum sup‐
port bolt on the transmission.
– Position the Engine and Gearbox Jack under the vehicle.

The -arrow symbol B- on the adjusting plate points in direc‐
tion of travel.
– On a new transmission or replacement transmission remove
the right flange shaft -arrow-.
– Check the flange shaft seal for leaks and replace if necessa‐
ry. Refer to ⇒ 1 , page 246 .
– Install the spindle -A- from the -3066- in the threaded piece
on the differential.

Jetta 2018 ➤
– Insert the -T10148- and secure with the nut -B-.
Note
♦ The -T10148- protects the right seal and the transmission

from dirt.
♦ An M8 x 105 mm bolt may be installed by hand into the
differential threaded piece instead of a spindle -A-.
– Tip the transmission forward in the direction of -arrow- using

the spindle on the -3282-.
– Push the engine forward slightly with a second technician.

– Carefully lift the transmission with the -VAS6931-, while
making sure that the seal -1- is guided through without any
damage to the pressure plate -arrow-.
– Guide the left flange shaft -B- past the subframe -arrow-.

Jetta 2018 ➤
– Align the transmission with the engine and install it.

– Tighten the engine/transmission connecting bolt -A- above
the right flange shaft with the tightening specification.
– Reinsert the right flange shaft and tighten the countersunk

bolt -arrow- to the tightening specification.
– Install the lower engine/transmission connecting bolts and
tighten. Refer to ⇒ T2.1 ightening Specifications”, page 90 .
– After the transmission is attached to the engine, remove the
Engine and Gearbox Jack from the transmission.
– Install the upper engine/transmission connecting bolts and
tighten. Refer to ⇒ T2.1 ightening Specifications”, page 90 .
– Attach the transmission bracket -A- with new hex collar bolts
to the transmission -arrows- and tighten. Refer to ⇒ -3.1 As‐
sembly Mounts”, page 118 .
– Align the engine/transmission in its installation position. To

do so, lift it just enough so that the transmission completely
touches the left subframe mount.
– Align the engine/transmission in the installation position via
both spindles of the -10-222A-.

Jetta 2018 ➤
Caution
There is a risk of damaging the threads in the transmission

bracket by inserting the bolts at an angle.
♦ The transmission bracket and the transmission mount
support arm must be absolutely parallel to each other
before installing the bolts -arrows-. If necessary, lift the
back of the transmission using the Engine and Gearbox
Jack.
Note
Install the engine/transmission mount free of tension. Refer to

⇒ Rep. Gr. 10; Subframe Mount; Subframe Mount, Adjusting.
– Install new bolts -arrows- and tighten. Refer to ⇒ -3.1 As‐

sembly Mounts”, page 118 .
Caution
Risk of accident!
• Only remove the -10-222A- if all of the bolts for the
assembly mount are tightened to the tightening specifi‐
cation.
– If equipped, install the ground wire on the transmission

mount -arrow-.
– Install the pendulum support with new bolts -1 to 3-. Refer

to ⇒ Rep. Gr. 10; Assembly Mounts; Pendulum Support,

Jetta 2018 ➤
– Assemble the exhaust system and attach the exhaust sys‐

tem bracket to the subframe. Refer to ⇒ Rep. Gr. 26; Ex‐
haust Pipes/Mufflers; Overview - Muffler.
– Attach the drive axles to the transmission. Refer to ⇒ Sus‐
pension, Wheels, Steering; Rep. Gr. 40; Drive Axle; Drive
Axle, Removing and Installing.
– If equipped, install the right drive axle heat shield on the

engine -arrows-. Refer to ⇒ Suspension, Wheels, Steering;
Rep. Gr. 40; Drive Axle; Drive Axle Heat Shield, Removing
and Installing.
– If equipped, install the Left Front Level Control System Sen‐
sor -G78- on the lower control arm. Refer to ⇒ Suspension,
Wheels, Steering; Rep. Gr. 43; Level Control System Sen‐
sor; Overview - Front Level Control System Sensor.
– Install the coupling rod -3- on the stabilizer bar -2- on

both sides. Refer to ⇒ Suspension, Wheels, Steering; Rep.
Gr. 40; Subframe; Overview - Subframe.

Jetta 2018 ➤
– Connect the connector -1- to the Oil Level Thermal Sensor

-G266-.
– Transmission for vehicles with Start/Stop System: connect

the connector -arrow- to the Transmission Neutral Position
Sensor -G701-.
– Connect the connector -1- to the Back-Up Lamp Switch -F4-.

Jetta 2018 ➤
– Install the starter by connecting the connector -arrow 2- and

installing the line -arrow 3-. Refer to ⇒ Electrical Equipment;
Rep. Gr. 27; Starter; Starter, Removing and Installing.
– Install the bracket for the wires -arrow-.
– Install the clutch slave cylinder and tighten the bolts

-B arrows-. Refer to ⇒ -1.3 Clutch Release Mechanism”,
page 24 .
– Install and secure the transmission support -A arrows-. Refer

to ⇒ -3.1 Assembly Mounts”, page 118 .
– Make sure the vacuum hose for the brake system is installed
correctly. If necessary, install the vacuum hose. Refer to
⇒ Brake System; Rep. Gr. 47; Brake Booster/Master Brake
Cylinder.
– Attach the bracket -B- to the transmission.
– Press the hose/line assembly -A- into the bracket -B- on the
transmission.
– Mount the cable bracket on the transmission and tighten the
bolts -arrows-. Refer to ⇒ -1.3 Shift Mechanism”, page 71 .

Jetta 2018 ➤
– Install the gearshift lever -A-. Refer to ⇒ Fig. ““Shift Lever,

Installing”“, page 82 .
– Remove the nut -arrow 3-. Refer to ⇒ -5.4 Shift Unit”, page
129 .
– Insert the relay lever together with the cable retainer and
secure with the clip -arrow 1-. Refer to ⇒ Fig. ““Install the
Relay Lever and the Cable Retainer Together.”“, page 83 .
While doing so, grease the relay lever and the gearshift lever
guide rail.
• Determine the shift mechanism grease using the ⇒ Electron‐
ic Parts Catalog (ETKA).
• The clip -arrow 1- secures the relay lever.
• Make sure the clips locks securely.
– Coat the pin on the gearshift lever with a small amount of
grease -A-.
– Place the shift cable on the selector lever -A- and secure
with the new lock washer -arrow 2-.
– Connect the selector cable to the cable retainer.
– Adjust the gearshift mechanism. Refer to ⇒ M1.6 echanism,
– If unclipped, carefully clip in the A/C system pipe and do not
disconnect the line system. Refer to ⇒ Heating, Ventilation
and Air Conditioning; Rep. Gr. 87; Refrigerant Circuit; Sys‐
tem Overview - Refrigerant Circuit.
Note
If when removing the flange shaft, the transmission fluid leaks

out, drain and fill the transmission fluid for the installed trans‐
mission and flange shaft. Refer to ⇒ F8 luid”, page 199 .
– Install the battery tray, battery and the battery cover. Refer
to ⇒ Electrical Equipment; Rep. Gr. 27; Battery; Battery, Re‐
– Install the cover for the engine and/or air filter. Refer to
Installing.
– Install the filler tube for the windshield washer system wash‐
er fluid reservoir. Refer to ⇒ Electrical Equipment; Rep.
Gr. 92; Windshield Washer System; Washer Fluid Reservoir,

Jetta 2018 ➤
– Install the lower section of the left front wheel housing liner.
Refer to ⇒ Body Exterior; Rep. Gr. 66; Wheel Housing Liner;
Overview - Front Wheel Housing Liner.
– Install the noise insulation. Refer to ⇒ Body Exterior; Rep.
– Install the wheel. Refer to ⇒ Suspension, Wheels, Steering;
Rep. Gr. 44; Wheels, Tires; Wheel Bolts, Tightening Specifi‐
cations.
– Check the headlamp adjustment on vehicles with Left Front
Level Control System Sensor -G78-. Refer to ⇒ Electrical
Equipment; Rep. Gr. 94; Headlamp; Headlamp, Adjusting.

Jetta 2018 ➤
3 Assembly Mounts
⇒ -3.1 Assembly Mounts”, page 118
3.1 Overview - Assembly Mounts

Jetta 2018 ➤
1 - Bolt
❑ 20 Nm +90°
❑ Tightening sequence.
Refer to ⇒ Fig. ““Trans‐
mission Support to
Transmission Bracket
and Transmission”“,
page 120 .
❑ Transmission support
to transmission bracket
and transmission
2 - Transmission Support
❑ To the transmission
bracket and transmis‐
sion
3 - Engine Mount with Engine
Support
❑ Refer to ⇒ Rep.
Gr. 10; Assembly
Mounts; Overview - As‐
sembly Mounts.
4 - Bolt
❑ Pendulum support to
the subframe. Refer to
⇒ Rep. Gr. 10; Assem‐
bly Mounts; Overview -
Assembly Mounts.
5 - Pendulum Support
❑ Refer to ⇒ Rep.
Gr. 10; Assembly
Mounts; Overview - As‐
sembly Mounts.
6 - Bolt
❑ Pendulum support to the transmission. Refer to ⇒ Rep. Gr. 10; Assembly Mounts; Overview - Assem‐
bly Mounts.
7 - Bolt
❑ Pendulum support to the transmission. Refer to ⇒ Rep. Gr. 10; Assembly Mounts; Overview - Assem‐
bly Mounts.
8 - Bolt
❑ 40 Nm +90°
❑ Tightening sequence. Refer to ⇒ Fig. ““Transmission Bracket -A- to Transmission.”“, page 120 .
❑ Transmission bracket to transmission.
9 - Transmission Bracket
10 - Transmission Mount
❑ Adjustment, Checking. Refer to ⇒ Rep. Gr. 10; Assembly Mounts; Assembly Mount Adjustment,
Checking.
❑ Adjusting. Refer to ⇒ Rep. Gr. 10; Assembly Mounts; Assembly Mount, Adjusting.
11 - Bolt
❑ Transmission mount to chassis
❑ Refer to ⇒ Rep. Gr. 10; Assembly Mounts; Overview - Assembly Mounts.
12 - Bolt
3. Assembly Mounts 119

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❑ 60 Nm +90°
❑ Tightening sequence. Refer to ⇒ Fig. ““Attaching the Transmission Mount to the Transmission Brack‐
et”“, page 120 .
❑ Transmission mount to transmission bracket
Attaching the Transmission Mount to the Transmission Bracket
– Replace the bolts -arrows-.

– Tighten all bolts hand-tight.
– Tighten the bolt to the tightening specification.
Transmission Support to Transmission Bracket and Transmis‐
sion

– Tighten both bolts -arrows- hand-tight at first.
Transmission Bracket -A- to Transmission.

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– Tighten all bolts hand-tight.
3. Assembly Mounts 121

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4 Transmission, Transporting
♦ Transmission Support Jig -3336-
♦ Shop Crane -VAS6100-
– Attach the -3336- to the clutch housing.
– Move the support arm on the sliding bar using the locking
bolt -arrow-.

Jetta 2018 ➤
Number of visible holes = 5.

– Lift the transmission using the -VAS6100- and the -3336-.
– Set the transmission down, for example, into the transport
container.
4. Transmission, Transporting 123

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5 Transmission, Disassembling and

Assembling
⇒ O5.1 verview - Transmission”, page 124
⇒ -5.2 Transmission Housing Cover and 5th/6th Gear”, page
125
⇒ -5.3 Transmission Housing and Gearshift Mechanism”, page
127
⇒ -5.4 Shift Unit”, page 129
⇒ -5.5 Input Shaft, Output Shafts, Differential and Shift Rods”,
page 130
⇒ -5.6 Shift Forks”, page 132
⇒ U5.7 nit, Servicing”, page 135
⇒ F5.8 orks, Servicing”, page 137
⇒ H5.9 ousing Cover and 5th/6th Gear, Removing”, page 142
⇒ D5.10 isassembling and Assembling”, page 150
⇒ G5.11 ear and Transmission Housing Cover, Installing”, page
167
5.1 Schematic Overview - Transmission

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1 - 1st Gear
2 - 2nd Gear
3 - 3rd Gear
4 - 4th Gear
5 - 5th Gear
6 - 6th Gear
7 - Transmission Housing
Cover
9 - Shift Mechanism
❑ (Shift forks)
10 - Reverse Drive Gear
11 - Clutch Housing
12 - Input Shaft
13 - Output Shaft
14 - Differential
5.2 Overview - Transmission Housing Cover and 5th/6th Gear
5. Transmission, Disassembling and Assembling 125

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❑ Remove together with
the 5th/6th gear. Re‐
fer to ⇒ D5.10 isassem‐
bling and Assembling”,
page 150 .
❑ Servicing. Refer to
⇒ H6.4 ousing, Servic‐
ing”, page 182 .
2 - 5th Gear
❑ Remove individually.
Refer to ⇒ H5.9 ous‐
ing Cover and 5th/6th
Gear, Removing”, page
142 .
the transmission hous‐
ing. Refer to ⇒
D5.10 isassembling
and Assembling”, page
150 .
3 - Sleeve
4 - 6th Gear
❑ Remove individually.
Refer to ⇒ H5.9 ous‐
ing Cover and 5th/6th
Gear, Removing”, page
142 .
the transmission hous‐
ing. Refer to ⇒
D5.10 isassembling
150 .
5 - Inner Race/Cylindrical
Roller Bearing
❑ For the output shaft
❑ Mark before removing
❑ Do not confuse with the input shaft inner race/cylindrical roller bearing
6 - Bolt
❑ 80 Nm +90°
❑ Self-locking
7 - Transmission Housing Cover
❑ With cylindrical roller bearing for input and output shaft
❑ Servicing. Refer to ⇒ H6.6 ousing Cover, Servicing”, page 194 .
8 - Bolt
❑ 18 Nm
❑ For cover to transmission housing
❑ Quantity: 5
9 - Bolt
❑ 80 Nm +90°

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❑ For the input shaft
❑ Self-locking
10 - Inner Race/Cylindrical Roller Bearing with Thrust Washer
❑ Do not confuse with the output shaft inner race/cylindrical roller bearing
11 - Sleeve
❑ Replace together with the needle bearing
❑ For the 6th gear needle bearing
12 - Needle Bearing
❑ Replace together with the sleeve
❑ For 6th gear
13 - 6th Gear Assembly
14 - Spring Washer
15 - 6th Gear Synchronizer Ring
16 - 5th/6th Gear Locking Collar with Synchronizer Hub
❑ Remove individually. Refer to ⇒ H5.9 ousing Cover and 5th/6th Gear, Removing”, page 142 .
❑ Remove together with the transmission housing. Refer to ⇒ D5.10 isassembling and Assembling”,
page 150 .
❑ Disassembling and Assembling. Refer to ⇒ Fig. ““5th/6th Gear Locking Collar and Synchronizer Hub,
Disassembling and Assembling”“, page 210 and ⇒ Fig. ““5th/6th Gear Locking Collar/Synchronizer
Hub, Assembling”“, page 211 .
❑ Adjusting. Refer to ⇒ Fig. ““5th/6th Gear, Adjusting”“, page 172 .
❑ It is damaged when removing from the input shaft with the Puller - Transmission Gears -T10309A-.
Refer to ⇒ page 148 .
18 - Spring Washer
20 - Needle Bearing
❑ For 5th gear
21 - Cylinder Bolt
❑ 25 Nm
❑ For the pivot pin to the transmission housing
22 - Pivot Pin
23 - 5th/6th Gear Shift Fork
24 - 5th/6th Gear Shift Jaw
25 - Bolt
❑ 25 Nm
5.3 Overview - Transmission Housing and Gearshift Mechanism

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1 - Bolt
❑ 25 Nm
2 - Flange Shaft with Pres‐
sure Spring
ling. Refer to ⇒
S1.2 eal, Replacing”,
page 246 .
❑ Assembling. Refer to ⇒
2 , page 257 .
3 - TORX® Socket Bolt
❑ 25 Nm
❑ For the reverse shaft
support
❑ Self-locking
❑ 25 Nm
support
❑ Self-locking
5 - O-Ring
6 - Pivot Pin
7 - Bolt
❑ 25 Nm
8 - Bolt
❑ 25 Nm
9 - Cap
10 - Internal Multi-Point Bolt
❑ 25 Nm
❑ For the reverse shaft support
11 - Bolt
❑ 5 Nm
12 - Transmission Neutral Position Sensor -G701-
❑ For vehicles with the Start/Stop System
❑ Remove together with the 5th/6th gear. Refer to ⇒ D5.10 isassembling and Assembling”, page 150 .
❑ Servicing. Refer to ⇒ H6 ousing and Clutch Housing”, page 175 .
14 - Clutch Housing
15 - Hex Bolt
❑ 25 Nm +90°
16 - Gearshift Shaft with Gearshift Cover
(Shift unit)

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❑ Servicing. Refer to ⇒ U5.7 nit, Servicing”, page 135 .
17 - Internal Multi-Point Bolt
❑ 25 Nm
5.4 Overview - Shift Unit

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1 - Shift Unit
❑ Consisting of the selec‐
tor shaft and the gear‐
shift cover
❑ The components can‐
not be separated from
each other
2 - Back-Up Lamp Switch -F4-
❑ 20 Nm
❑ Coat the tab lightly with
MoS 2 grease.
3 - Locking Elbow
❑ For adjusting the shift
mechanism
❑ Removing. Refer to ⇒
Fig. ““Locking Elbow
-A-, Removing from
Gearshift Cover”“, page
136 .
❑ Installing. Refer to ⇒
Fig. ““Locking Elbow
-A-, Pressing into Gear‐
shift Cover”“, page
136 .
4 - Relay Lever
Refer to ⇒ Fig. ““Shift
Lever/Relay Lever In‐
stallation Position”“,
page 82 .
5 - Clip
❑ Secures the relay lever
in the gearshift cover
❑ Replacing. Refer to ⇒ S1.8 haft Seal, Replacing”, page 88 .
7 - Nut
❑ 23 Nm
❑ Self-locking
8 - Shift Lever
❑ Installing. Refer to ⇒ Fig. ““Shift Lever, Installing”“, page 82 .
9 - Cap
❑ For the transmission ventilation
10 - Cap
11 - Spring
❑ Not installed on all transmissions
❑ Install if present
5.5 Overview - Input Shaft, Output Shafts, Differential and Shift Rods

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1 - Differential
❑ Disassembling and As‐
sembling. Refer to ⇒ 2 ,
page 257 .
2 - Seal
❑ Quantity: 4
3 - Output Shaft
sembling. Refer to ⇒
S2.2 haft, Disassem‐
bling and Assembling”,
page 221 .
4 - Reverse Shaft Support
S3 haft”, page 240 .
5 - Reverse Shaft
❑ With »reverse gear as‐
sembly«. Refer to ⇒
-3.1.1 Reverse Shaft
with Reverse Gear As‐
sembly”, page 240 .
❑ With »reverse gear
locking collar« (on
some transmissions).
Refer to ⇒ -3.1.2 Re‐
verse Shaft, with Re‐
verse Gear Locking
Collar”, page 241 .
6 - Input Shaft
❑ Refer to ⇒ S1 haft”,
page 203
7 - Reverse Gear Shift Fork
❑ Only with the »reverse gear assembly«
♦ Disassembling and Assembling. Refer to ⇒ F5.8 orks, Servicing”, page 137 .
❑ Omitted with the »reverse gear locking collar«
♦ Reverse gear shift mechanism is then replaced with a gearshift rail. Refer to ⇒ -5.6 Shift Forks”, page
132 .
❑ 25 Nm
9 - Shift Mechanism
❑ (Shift forks)
❑ With the »reverse gear assembly«
♦ Disassembling and Assembling. Refer to ⇒ -5.6.1 Shift Forks with Reverse Gear Assembly”, page 132 .
❑ With the »reverse gear locking collar« (on some transmissions)
♦ Disassembling and Assembling. Refer to ⇒ -5.6.2 Shift Forks with Reverse Gear Locking Collar”, page
134 .
10 - Clutch Housing
11 - Nut
❑ 25 Nm +90°

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❑ 4 nuts for the bearing mount
12 - Flange Shaft with Pressure Spring
❑ Removing and installing. Refer to ⇒ S1.2 eal, Replacing”, page 246 .
❑ Assembling. Refer to ⇒ 2 , page 257 .
13 - Bolt
❑ 25 Nm
5.6 Overview - Shift Forks

⇒ -5.6.1 Shift Forks with Reverse Gear Assembly”, page 132
⇒ -5.6.2 Shift Forks with Reverse Gear Locking Collar”, page
134
5.6.1 Overview - Shift Forks with Reverse

Gear Assembly
The -arrow- Points to the Reverse Gear Assembly
Note
♦ The shift fork group does not need to be disassembled to

remove and install shift segments, lock washers and angular
contact ball bearings.
♦ Shift Forks, Servicing. Refer to ⇒ F5.8 orks, Servicing”, page
137 .

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1 - 5th/6th Gear Shift Seg‐

ment
❑ Identification. Refer to
⇒ Fig. ““Shift Segment
Identification”“, page
139 .
❑ The shift segment must
still rotate easily after
the lock washer is in‐
stalled.
2 - Lock Washer
Fig. ““Lock Washer,
Removing”“, page 140 .
Fig. ““Lock Washer, In‐
stalling”“, page 140 .
4 - Bolt
tion. Refer to ⇒
-5.2 Transmission
Housing Cover and
5th/6th Gear”, page
125 .
6 - Angular Contact Ball Bear‐
ing
Fig. ““Angular Contact
Ball Bearing, Remov‐
ing”“, page 140 .
❑ Bearing Inner Race, In‐
stalling in Outer Race.
Refer to ⇒ Fig. ““Angular Contact Ball Bearing Inner Race -A-, Pushing into Outer Race”“, page 141 .
❑ Installing. Refer to ⇒ Fig. ““Angular Contact Ball Bearing, Installing All the Away in Shift Fork”“, page
141 .
❑ Quantity: 4
7 - Shift Fork Group with Gearshift Rails
8 - 1st/2nd Gear Shift Segment
❑ Identification. Refer to ⇒ Fig. ““Shift Segment Identification”“, page 139 .
❑ The shift segment must still rotate easily after the lock washer is installed.
9 - 3rd/4th Gear Shift Segment
10 - Gliding Piece
11 - Spring
12 - Reverse Gear Shift Fork
13 - Support for the Reverse Gear Shift Fork
14 - Circlip

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5.6.2 Overview - Shift Forks with Reverse

Gear Locking Collar
The -arrow- Points to the Reverse Gear Locking Collar
Note
♦ The shift fork group does not need to be disassembled to

remove and install shift segments, lock washers and angular
contact ball bearings.
♦ Shift Forks, Servicing. Refer to ⇒ F5.8 orks, Servicing”, page
137 .

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1 - 5th/6th Gear Shift Seg‐

ment
❑ Identification. Refer to
⇒ Fig. ““Shift Segment
Identification”“, page
139 .
❑ The shift segment must
still rotate easily after
the lock washer is in‐
stalled.
2 - Lock Washer
Fig. ““Lock Washer,
Fig. ““Lock Washer, In‐
stalling”“, page 140 .
4 - Bolt
tion. Refer to ⇒
-5.2 Transmission
Housing Cover and
5th/6th Gear”, page
125 .
6 - Angular Contact Ball Bear‐
ing
Fig. ““Angular Contact
Ball Bearing, Remov‐
❑ Bearing Inner Race, In‐
stalling in Outer Race.
Refer to ⇒ Fig. ““Angular Contact Ball Bearing Inner Race -A-, Pushing into Outer Race”“, page 141 .
❑ Installing. Refer to ⇒ Fig. ““Angular Contact Ball Bearing, Installing All the Away in Shift Fork”“, page
141 .
❑ Quantity: 4
7 - Shift Fork Group with Gearshift Rails
❑ With gearshift rail for the reverse gear shift mechanism -arrow-
8 - 1st/2nd Gear Shift Segment
9 - 3rd/4th Gear Shift Segment
5.7 Shift Unit, Servicing


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♦ Breather Tube Tool -T10203-
– Remove the shift unit. Refer to ⇒ -5.3 Transmission Hous‐

ing and Gearshift Mechanism”, page 127 .
Locking Elbow -A-, Removing from Gearshift Cover
– Remove the outer part of the locking elbow.

– Carefully pry out the locking elbow with a screwdriver.
Locking Elbow -A-, Pressing into Gearshift Cover

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Installation position:
The marking -arrow- faces toward upper section of the selector
shaft.
– Install the shift unit. Refer to ⇒ -5.3 Transmission Housing
and Gearshift Mechanism”, page 127 .
5.8 Shift Forks, Servicing

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equipment required
♦ Press Plate -VW402-

♦ Subframe Support Tool - Press Piece -3290/1-
♦ Subframe Bushing Tool Kit -3301-
♦ Press Piece - Multiple Use -VW431-
♦ Spacer Sleeve -VW472/2-
♦ Valve Guide/Clutch Release Push Rod Seal Drift -10-206-

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♦ Pry Lever -80-200-
♦ Assembly Mandrel for Gear Selector Rod -10-508-
♦ Spring Strut Compressor -2070-
Shift Segment Identification
Dimension -a-
1 - 1st and 2nd gear shift segments = 11.4 mm
2 - 3rd and 4th gear shift segments = 7.7 mm
3 - 5th and 6th gear shift segments = 12.1 mm

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Lock Washer, Removing
– Secure shift fork in vise with protective jaws -B-.

– Pry out the lock washer -A- in the direction of -arrow-.
Lock Washer, Installing
– Press the lock washer in the groove in the shift segment

using a socket wrench.
Note
The shift segment must still rotate easily after the lock washer is
installed.
A - 10 mm Socket Wrench
B - Protective Jaws
Angular Contact Ball Bearing, Removing

Jetta 2018 ➤
Note
Be careful not to bend the shift forks when removing and instal‐
ling the angular contact ball bearing.
Angular Contact Ball Bearing Inner Race -A-, Pushing into Out‐
er Race
The bearing inner race must engage with the outer race.
Angular Contact Ball Bearing, Installing All the Away in Shift
Fork
The recess in the - 3290/1- point to the ball bearing.

Shift Fork with Shift Segments Installed
Dimension -a- (mm)

1st/2nd gear shift fork 87.2 to 87.4
3rd/4th gear shift fork 93.6 to 93.8

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Shift segment allocation. Refer to ⇒ Fig. ““Shift Segment Identi‐

fication”“, page 139 .
5.9 Transmission Housing Cover and 5th/6th Gear, Removing

equipment required
♦ Holding Plate -VW309A-

♦ or Holding Plate -VW309A-
♦ Transmission Support -VW353-
♦ Bearing/Bushing Installer - Multiple Use -VW295-
♦ Bearing Driver - Multiple Use -VW244B-
♦ Wiring Harness Repair Set - Hot Air Blower -VAS1978/14A-,
for example

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♦ Support Bridge -T10323-

♦ Rear Wheel Bearing Kit - Piece 7 -3253/7-
♦ Press Piece - Multiple Use -40-105-

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♦ Bracket - Multiple Use -30-211A-

♦ Bearing Installer - Multiple Use -32-111-
♦ Assembly Tool Kit - Press Piece 2 -T10030/4-
♦ Press Piece - 37mm -VW416B-
♦ Puller - Transmission Gears -T10309A-
♦ Puller - Two Arm -T10040-
♦ With the Puller - Two Arm w/Thrust Piece -T10040/2A-

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♦ Or for the 6th gear: Two-Arm Puller -VAS251001-
Note
♦ If only the 5th/6th gear must be removed, follow this proce‐

dure:
♦ Pay attention to the work procedure if the transmission hous‐
ing must be removed. Refer to ⇒ D5.10 isassembling and
Assembling”, page 150 .
– Remove the clutch release lever and release bearing. Refer

to ⇒ R1.15 elease Mechanism, Servicing”, page 48 .
• Do not damage the bearing for the input and output shafts
when removing and installing 5th/6th gear.
• When securing the transmission to the -VW353-, the follow‐
ing tools must be mounted for support:
Under the Input Shaft:

• The input shaft may only be supported by the Bearing Instal‐
ler - Multiple Use -32-111- at a later time.
Under the Output Shaft Bearing Mount:

Jetta 2018 ➤

– Secure the transmission on the -VW353-.
– Remove the transmission housing cover -arrow-.

– Remove the cover; if necessary, carefully pry it out of the
protruding ridges all the way around by alternating from side
to side. Do not damage the sealing surfaces while doing so.
– Make sure the -T10040/2A- can be installed correctly under
the 5th gear.
Puller - Two Arm w/Thrust Piece -T10040/2A- cannot be in‐

stalled correctly.
-A- “Combined” removal of:
- T10040/2A- prematurely touch‐ “5th/6th gear synchroniz‐
es the: er hub”, “5th gear” and
♦ Transmission housing wall “transmission housing”.
Refer to ⇒ D5.10 isassem‐
♦ The ribbing in the transmis‐ bling and Assembling”,
sion housing under the 5th page 150 .
gear.
-B-
-T10040/2A- touches the ribbing
in the transmission housing un‐
der the 5th gear.

Jetta 2018 ➤
Puller - Two Arm w/Thrust Piece -T10040/2A- can be instal‐

led correctly.
5th/6th gear can be removed separately. Refer to ⇒ Fig.
““5th/6th Gear, Removing Separately”“, page 147 .
5th/6th Gear, Removing Separately
– Remove the 5th/6th gear shift fork as follows:

– Cover the openings in the transmission housing with a cloth.
– Engage the 5th gear -arrows 1 and 2-.
– Remove the 5th/6th gear shift jaw -bolt A-.
– Then remove both -B bolts- for the pivot pins.
– Remove the pivot pin.
– Remove the 5th/6th gear shift fork.
– Remove the -A bolts- for the bearing inner races from the
input and output shafts. To do so, engage 5th gear -arrow 1-
and 1st gear -arrows 2 and 3-.

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– The input shaft and the output shaft are blocked after both
gears are engaged. Both bolts can be loosened now.
Note
If the shafts are not being replaced, use a thread tap to remove
any locking fluid residue from the threaded holes.
– Remove the 6th gear with the inner race/cylindrical roller

bearing for the output shaft.
A - Two-Arm Puller, for example, Two-Arm Puller -VAS251001-

B - M10 x 20 Hex Bolt, 17 mm
Note
The 6th gear with the inner race/cylindrical roller bearing can
also be removed using the -T10040- and the -T10040/2A-.
– If necessary, warm the gear slightly using the -

VAS1978/14A-, for example.
Remove the 6th Gear Assembly Alone with the Input Shaft
Inner Race/Cylindrical Roller Bearing, Thrust Washer and 6th
Gear Synchronizer Ring, or Remove the 6th Gear Assembly
Together with the 5th/6th Gear Synchronizer Hub, 6th Gear
Needle Bearing Inner Race and 5th Gear Synchronizer Ring.
Use the Puller - Transmission Gears -T10309A-
– First insert the Half Shell -T10309/1- between the output
shaft -A- and the mount for the 5th/6th gear shift fork -B-.
• The -T10309/1- must be placed under the synchronizer ring.

– Press the half shell into the end position, if necessary.

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– Turn the - T10309/1- onto the opposite side in the direction

of -arrow-.
– Insert the -T10309/3- into the -T10309/1-.
– Insert the second -T10309/1- and put the -T10309/2- over

the tool.
– Check the synchronizer hub for damage after the removal
procedure.
– If necessary, replace the synchronizer ring.
Note
♦ There is a spring washer installed both under the 5th gear

synchronizer ring and above the 6th gear synchronizer ring.
Refer to ⇒ -5.2 Transmission Housing Cover and 5th/6th
Gear”, page 125 .
♦ Check both spring washers for damage.
– Now remove the sleeve from the 5th gear.

– Remove the 5th gear.
– Insert the hook -A-.

-B- = -T10040/3-
or

Jetta 2018 ➤
-40-105-
Note
♦ When removing the gear, make sure the hooks do not bend
outward. Check the 5th gear for damage after the removal
procedure.
♦ If necessary, warm the gear slightly using the -
5th/6th Gear and Transmission Housing Cover, Installing. Refer

to ⇒ G5.11 ear and Transmission Housing Cover, Installing”,
page 167 .
5.10 Transmission, Disassembling and Assembling

equipment required

♦ Bearing Driver - Multiple Use -VW244B-

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♦ Wiring Harness Repair Set - Hot Air Blower -VAS1978/14A-,

for example

♦ Assembly Tool Kit - Press Piece 2 -T10030/4- from the Hy‐
draulic Press - Bushing Tool Kit -T10030-
♦ Puller - Transmission Gears -T10408-
♦ Thrust Pieces -T10408/2-
♦ Spacer Plate -T10408/3-
♦ M7 x 35 hex bolts with washers (components of the Puller -
Transmission Gears -T10408-)

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♦ -2- Puller -VAS251417- (quantity: 2)

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♦ Inductive Heater -VAS6414-
♦ Sealing Compound
♦ Select the sealing compound. Refer to the ⇒ Electronic Parts
Catalog (ETKA).
♦ M8 x 100 mm stud bolt
Transmission Housing Cover, Transmission Housing, Gearshift
Shaft with Gearshift Cover, Input Shaft, Output Shaft, Differen‐
tial and Gearshift Mechanism, Removing and Installing
Transmission, Disassembling
– Remove the clutch release lever, the release bearing and
the guide sleeve. Refer to ⇒ R1.15 elease Mechanism, Serv‐
icing”, page 48 .
• Do not damage the bearing for the input and output shafts
when removing and installing 5th/6th gear.
• When securing the transmission to the -VW353-, the follow‐
ing tools must be mounted for support:
Under the Input Shaft:

– Secure the bolt from the Bracket - Multiple Use -30-211A-
with the nut -A-.

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Under the Output Shaft Bearing Mount:

– Secure the transmission on the Transmission Support -
VW353-.
– Place the Drip Tray underneath.

– Open the oil filler plug and the oil drain plug.
– Drain the transmission fluid.
– Remove the transmission housing cover -arrow-.
– Remove the cover; if necessary, carefully pry it out of the
protruding ridges all the way around by alternating from side
to side. Do not damage the sealing surfaces while doing so.
– Remove the 5th/6th gear shift fork as follows:
– Engage the 5th gear in direction of -arrows 1 and 2-.

– Remove the 5th/6th gear shift jaw -bolt A-.
– Then remove both -B bolts- for the pivot pins.
– Remove the pivot pin.
– Remove the 5th/6th gear shift fork.

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– Remove the -A bolts- for the bearing inner races from the
input and output shafts. To do so, engage 5th gear -arrow 1-
and 1st gear -arrows 2 and 3-.
Note
If the shafts are not being replaced, use a thread tap to remove
any locking fluid residue from the threaded holes.
– Remove both bolts -arrows- for the reverse shaft support.
– Now remove the third bolt -arrow- for the reverse shaft sup‐
port.

Jetta 2018 ➤
– Transmission on vehicles with Start/Stop System: remove

the Transmission Neutral Position Sensor -G701- -arrow-.
– Move the gearshift shaft into neutral and remove the gear‐
shift shaft with the gearshift cover. Remove the bolts
-arrows- and pull the gearshift shaft out of the transmission
housing.
– Remove the cover -A- and pivot pin -B- on the bottom of the
transmission.

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– Remove the pivot pins -A- on top side of transmission and

bolts -B- for transmission housing to clutch housing in area
of differential.
– Remove the bolts -A- that connect the clutch and transmis‐
sion housing.
Note
Do not remove the nuts -B- for the bearing mount on the output
shaft.
– Remove both flange shafts.
– Remove the flange shafts with the springs, thrust washers

and tapered rings.

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Remove Following Components Together with Transmission

Housing:
♦ 5th/6th gear synchronizer hub

♦ 6th gear
♦ 5th gear
• Both -T10408/3- must be attached to the 5th gear.
• The Plates must always be arranged above the two housing
ribs that are opposite each other -arrows-.
Note
♦ There is a needle bearing under the 5th gear.

♦ Secure the Plates so that it does not touch the 5th gear
when removing the transmission housing.
Use the -T10408- with the Following Special Tools:
♦ Thrust Pieces -T10408/2-

♦ Spacer Plate -T10408/3-
♦ Puller - VAS251417 (quantity: 2)
– Fasten the -T10408- in the threaded holes for the transmis‐
sion housing cover with the bolts -A-.
A - M7 x 35 Hex Bolts with Washers
Tightening specification: 18 Nm
– Place the -T10408/2- on the shafts.
– Mount the VAS251417 -A-.

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– Remove the 5th/6th gear synchronizer hub, the 6th gear,

the 5th gear and the transmission housing by tightening the
spindles -A- (approximately 1/2 turn) and alternating from
side to side.
– If necessary, warm the 5th gear and the 6th gear slightly
using the -VAS1978/14A-.
– Remove the nuts -B- from the bearing mount/output shaft.
– Remove the shift forks -A- together with the gearshift rails.

Jetta 2018 ➤
Transmission with Reverse Gear Assembly -arrow-
– Remove the shift mechanism/reverse gear -B- (see the pre‐

vious image).
– Remove the reverse gear -A-, the input shaft -B- and the
output shaft -C-, one after the other, from the clutch housing.
Transmission with Reverse Gear Locking Collar -arrow-
– Remove the input shaft -1-, output shaft -2- and reverse
shaft -3- from the clutch housing together.

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– Remove the differential.
Transmission, Assembling
– Install the differential.

– Replace the sealing rings -arrows- for the bearing mount/
output shaft after removing.
Note
The illustration only shows 3 of the 4 seals.
Transmission with Reverse Gear Assembly -arrow-
– Insert the input shaft -1- and output shaft -2- together.

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– Tighten the nuts for the bearing mount / output shaft.

– Install the reverse gear wheel -3- on the needle bearing
inside the clutch housing.
The collar -arrow- faces away from clutch housing.
– Make sure the reverse shaft -4- is complete. Refer to ⇒
-3.1.1 Reverse Shaft with Reverse Gear Assembly”, page
240 . Do not mount the support on the reverse shaft.
– Install the reverse shaft into the clutch housing.
– Clean all threaded holes in reverse shaft supports of locking
compound; cleaning can be done with a thread tap.
– Place the reverse shaft support on the reverse shaft.
– Install the reverse gear shift fork -1- with the support for
the reverse gear shift fork -2-, the spring -3- and the sliding
piece -4-.
Reverse Gear Installation Position
– Fasten the shift mechanism/reverse gear -A-. Refer to ⇒

-5.5 Input Shaft, Output Shafts, Differential and Shift Rods”,
page 130 .

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– Install the shift forks -B- together with the gearshift rails.
The pin for the reverse gear support -C- is in front of the gear‐
shift rails.
Transmission with Reverse Gear Locking Collar -arrow-
• Clean all threaded holes in reverse shaft supports of locking

compound; cleaning can be done with a thread tap.
• Position the input shaft -1-, output shaft -2- and reverse
shaft -3- facing each other as shown on, for example, a
workbench.
• Hold the input shaft -1- in place with the -3435-.
• The splines -arrow- on the reverse gear locking collar face
the reverse gear assembly.

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– Insert the input shaft -1-, output shaft -2- and reverse shaft
-3- together.
The output shaft -2- contacts the differential.

– So that the output shaft -2- can be inserted into the clutch
housing, have a second technician turn the differential if
necessary.
– Tighten the nuts for the bearing mount / output shaft.
– Mount the shift forks -A- together with the gearshift rails.
The reverse gear support -B- is located in front of the gearshift

rails.
• The gearshift rail for the reverse gear engages in the reverse
gear locking collar -arrow-.
– Install the M8 x 100 stud bolts -A- into reverse shaft support
so that the shaft is aligned after fitting the transmission hous‐
ing.
– Align the gearshift rails.

Jetta 2018 ➤
Note
The shift segments must be installed in the grooves on the

locking collars.
– Apply Sealing Compound evenly onto the sealing surface of

the clutch housing.
– Install the transmission housing and tighten it secure.
Install the bolts for the reverse shaft support -arrow- as follows:
– Install the bolt -a-.

– Remove the stud bolts -A- (see upper illustration).
– Install the bolt -c-.
Tightening sequence:
– Tighten the bolt -a- (see upper illustration).

– Tighten the bolt -b-.
– Tighten the bolt -c- (see upper illustration).
– Install the pivot pin -arrow- for the shift forks. To do so, align
the shift mechanism with a screwdriver so that the respec‐
tive pivot pin can be installed.

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– Apply the Sealing Compound evenly on the sealing surface

on the cap.
– Install the gearshift shaft cover.
Install the gearshift shaft with the gearshift cover as follows:
– Move the gearshift rails to neutral.

– Apply Sealing Compound evenly onto the sealing surface of
the gearshift cover.
– Move the gearshift shaft into neutral.
– Position the gearshift shaft so that the shift finger -arrow- is
inserted into the gearshift rails.
– Tighten the gearshift cover for the gearshift shaft.
– Transmission for vehicles with Stop/Start system: install the
Transmission Neutral Position Sensor -G701- -arrow- and
tighten the bolt.
– Install both flange shafts with the pressure springs, thrust

washers and tapered rings. Refer to ⇒ -2.1 Differential”,
page 257 .

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♦ Refer to ⇒ -5.3 Transmission Housing and Gearshift Mecha‐
nism”, page 127
♦ Refer to ⇒ -5.5 Input Shaft, Output Shafts, Differential and
Shift Rods”, page 130
5th/6th Gear and Transmission Housing Cover, Installing. Refer
to ⇒ G5.11 ear and Transmission Housing Cover, Installing”,
page 167 .
5.11 5th/6th Gear and Transmission Hous‐

ing Cover, Installing
Refer to ⇒ H5.9 ousing Cover and 5th/6th Gear, Removing”,
page 142 (“Transmission Housing Cover and 5th/6th Gear, Re‐
moving”) to get a list of the special tools needed.
• Make sure that the -30-211A- and the -T10323- are installed.
– Secure the bolt from the -30-211A- with the nut -A-.
5th Gear Installation Position

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The groove all the way around -arrow- faces the transmission
housing.
– Install the 5th gear.
5th Gear Synchronizer Ring and 6th Gear Synchronizer Ring,

Checking
– Push the synchronizer rings onto the gear assembly taper

before reinstalling the 5th and 6th gear assemblies and the
5th and 6th gear synchronizer rings. Measure the gap di‐
mension -a- with a feeler gauge.
Gap Dimension Installed Dimension Wear Limit
-a-
5th/6th gear 1.1 to 1.7 mm 0.5 mm
– Install the 5th gear assembly with the needle bearing.
Spring Washer, Mounting on 5th Gear Assembly. Refer to ⇒
-5.2 Transmission Housing Cover and 5th/6th Gear”, page
125 .
– Place the 5th gear synchronizer ring on the gear assembly.

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– If disassembled, assemble the 5th/6th gear synchronizer

hub/locking collar before installing. Refer to ⇒ Fig. ““5th/6th
Gear Locking Collar/Synchronizer Hub, Assembling”“, page
211 and ⇒ Fig. ““5th/6th Gear Locking Collar and Synchron‐
izer Hub, Disassembling and Assembling”“, page 210 .
5th/6th Gear Synchronizer Hub/Locking Collar Installation Posi‐
tion
The ridge -arrow 1- faces the 6th gear.

The synchronizer hub mounts -arrow 2- are in line with the
synchronizer ring locking pieces (arrows in the image below).
5th/6th Gear Synchronizer Rings with Locking Pieces -arrows-
– Cover all openings in the transmission housing with a cloth

to prevent foreign objects from getting into the transmission.
– Install the 5th/6th gear synchronizer hub.

Jetta 2018 ➤
Note
Make sure there is enough clearance when installing the syn‐

chronizer ring.
– Warm the inner race/cylindrical roller bearing for the 6th gear
assembly to a maximum of 100 °C (212 °F) and install it on
the input shaft.
WARNING
Wear safety gloves.
– Install the 6th gear synchronizer ring.

Spring Washer, Positioning on 6th Gear Synchronizer Ring. Re‐
fer to ⇒ -5.2 Transmission Housing Cover and 5th/6th Gear”,
page 125 .
– Install the 6th gear assembly with the needle bearing.
The inner race/cylindrical roller bearing -B- and the thrust wash‐
er -A- are combined into one component.
– Warm the inner race/cylindrical roller bearing to a maximum

of 100 °C (212 °F) and install it on the input shaft.
WARNING
Wear safety gloves.
– Position the sleeve -A- on the 5th gear.

6th Gear Installation Position

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The groove -B- faces away from the sleeve -A-.
»Or« the groove -arrow 1- near the collar -arrow 2- faces away
from the sleeve -A- (also see previous image).
WARNING
Wear safety gloves.
– Warm the 6th gear to a maximum of 100 °C (212 °F) and

install it.
– Move the 5th/6th gear locking collar to neutral. The 6th gear
assembly can then be turned when installing the 6th gear.
– Install the 6th gear. Pay attention to the spline meshing of
the 6th gear and the 6th gear assembly.
– Warm the inner race/cylindrical roller bearing -A- to a maxi‐
mum of 100 °C (212 °F) and install it on the output shaft.
– Now loosen the support for the input shaft.

Jetta 2018 ➤
Use a thread tap to remove any locking fluid residue from the
threaded holes for the bolts -A-, for the 5th/6th gear synchroniz‐
er hub and the 6th gear.
Otherwise, there is a risk of the bolts shearing off.
– Tighten the bolts for the 5th/6th gear and synchronizer hub.
Refer to ⇒ -5.2 Transmission Housing Cover and 5th/6th
Gear”, page 125 .
– To tighten the bolts -A-, engage two gears
-arrows 1 through 3-.
– Install the 5th/6th gear shift fork.
5th/6th Gear, Adjusting

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– Engage 5th gear.

– Loosen the bolt -1-.
– Push the shift jaw and locking collar downward -arrows- and
tighten the bolt -1- to the tightening specification.
• 5th gear is engaged.
• Measurement check: it must not be possible to insert a 0.2
mm feeler gauge between the locking collar and both shift
segments -arrow- on the 6th gear side.
– Repeat the adjusting procedure if necessary.

– Engage 5th gear and then 6th gear.
The 5th/6th gear shift fork must have a small amount of play in
the shift jaw when 5th or 6th gear is engaged.
– Take out of gear.
• The locking collar must now be in neutral. The synchronizer
ring must move freely.
– Move through all the gears.
– Apply the Sealing Compound evenly onto the sealing sur‐
face of the transmission housing cover.
– Install the transmission housing cover. Refer to ⇒
-5.2 Transmission Housing Cover and 5th/6th Gear”, page
125 .
– Install the release bearing guide sleeve. Refer to ⇒
-1.3 Clutch Release Mechanism”, page 24 .
– Install the clutch release lever and release bearing. Refer to
⇒ R1.15 elease Mechanism, Servicing”, page 48 .
– Fill the transmission fluid. Refer to ⇒ page 107 .

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♦ Refer to ⇒ -5.2 Transmission Housing Cover and 5th/6th
Gear”, page 125
♦ Refer to ⇒ -5.6 Shift Forks”, page 132

Jetta 2018 ➤
6 Transmission Housing and Clutch

Housing
⇒ -6.1 Transmission Housing”, page 175
⇒ -6.2 Clutch Housing”, page 178
⇒ -6.3 Transmission Housing Cover”, page 180
⇒ H6.4 ousing, Servicing”, page 182
⇒ H6.5 ousing, Servicing”, page 189
⇒ H6.6 ousing Cover, Servicing”, page 194
6.1 Overview - Transmission Housing
6. Transmission Housing and Clutch Housing 175

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❑ Adjustment Overview.
Refer to ⇒ O3 verview”,
page 270 .
❑ Note the different hous‐
ing versions. Refer to ⇒
page 177 .
2 - Fluid Filler Plug
❑ 35 Nm
❑ The transmission flu‐
id level cannot be
checked by removing
the filler plug.
3 - Shim
page 270 .
4 - Outer Race/Tapered Roll‐
er Bearing
ling. Refer to ⇒
S6.4.1 haft in Trans‐
mission Housing, Re‐
moving and Installing”,
page 182 .
❑ When replacing: adjust
the input shaft. Refer to
⇒ S1.3 haft, Adjusting”,
page 211 .
5 - Roller Sleeve
ling. Refer to ⇒ S6.4.2 haft in Transmission Housing, Removing and Installing”, page 183 .
❑ Note the different bearing versions. Refer to ⇒ page 177 .
6 - Fluid Catch Tray
❑ Install the fluid catch tray in the transmission housing. Refer to ⇒ Fig. ““Fluid Catch Tray -A-, Inserting
in Transmission Housing”“, page 178 .
7 - Outer Race/Tapered Roller Bearing
❑ For the differential
❑ Removing and installing. Refer to ⇒ i6.4.3 n Transmission Housing, Removing and Installing”, page
187 .
❑ When replacing, adjust the differential. Refer to ⇒ A2.3 djusting”, page 266 .
8 - Shim
❑ Adjustment Overview. Refer to ⇒ O3 verview”, page 270 .
9 - Seal
❑ For the left flange shaft
❑ Replacing. Refer to ⇒ S1.2 eal, Replacing”, page 246 .

Jetta 2018 ➤
Differentiation of Output Shaft Bearings
Note
Refer to the ⇒ Electronic Parts Catalog (ETKA) for transmission

housing and roller sleeve allocation.
Roller Sleeve -1- with Circlip
A - Transmission Housing with Circlip Groove

B - Roller Bearing Circlip
Roller Sleeve with Circlip, Removing and installing. Refer to ⇒
Fig. ““Roller Sleeve with Circlip, Removing”“, page 186 .
Roller Sleeve -1- without Circlip
A - Transmission Housing with Outer Race Collar

B - Roller Bearing Outer Race
Roller Sleeve without Circlip, Removing and installing. Refer to
⇒ Fig. ““Roller Sleeve without Circlip, Removing”“, page 185 .

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Fluid Catch Tray -A-, Inserting in Transmission Housing
– Insert the fluid catch tray into the hole -arrow 1- and groove
-arrow 2- at the same time.
6.2 Overview - Clutch Housing

Jetta 2018 ➤

er Bearing
ling. Refer to ⇒ i6.5.3 n
Clutch Housing, Re‐
moving and Installing”,
page 193 .
❑ When replacing, adjust
the differential. Refer to
⇒ A2.3 djusting”, page
266 .
2 - Fluid Drain Plug
❑ 35 Nm
3 - Magnet
❑ Held in place by hous‐
ing separating surface
er Bearing
ling. Refer to ⇒
S6.5.2 haft in Clutch
Housing, Removing
191 .
❑ When replacing: adjust
the output shaft. Refer
to ⇒ S2.3 haft, Adjust‐
ing”, page 234 .
❑ Note the different ver‐
sions. Refer to ⇒ Fig.
““Note the Difference
between Tapered Roll‐
er Bearings”“, page
236 .
5 - Shim
❑ Note the different versions. Refer to ⇒ Fig. ““Note the Difference between Tapered Roller Bearings”“,
page 236 .
❑ Removing and installing. Refer to ⇒ S6.5.1 haft in Clutch Housing, Removing and Installing”, page
189 .
❑ When replacing: adjust the input shaft. Refer to ⇒ S1.3 haft, Adjusting”, page 211 .
7 - Needle Sleeve
❑ Removing and installing. Refer to ⇒ S3.2 haft, Disassembling and Assembling”, page 242 .
8 - Alignment Sleeves
❑ Quantity: 2
9 - Clutch Housing
10 - Guide Sleeve

Jetta 2018 ➤
❑ With input shaft seal and vulcanized O-ring
❑ Replace the guide sleeve and O-ring together if the O-ring is damaged.
❑ Input Shaft Seal, Removing and installing. Refer to ⇒ S1.4 haft Seal, Replacing”, page 254 .
11 - Cylinder Bolts
❑ Tightening Specification. Refer to -item 6- ⇒ Item 6 (page 25) .
12 - Seal with Sleeve
❑ Replace seal and sleeve together. Refer to ⇒ S1.3 eal, Replacing”, page 249
❑ For the right flange shaft
13 - Trip Recorder Drive Wheel
❑ 30 Nm
❑ For vehicles with trip recorder
6.3 Overview - Transmission Housing Cover

Jetta 2018 ➤
1 - Cylindrical Roller Bearing

❑ Do not confuse with the
input shaft cylindrical
roller bearing
❑ Removing. Refer to
⇒ Fig. ““Cylindrical
Roller Bearing, Remov‐
ing from Transmission
Housing Cover”“, page
195 .
Fig. ““Cylindrical Roller
Bearing, Installing in
Transmission Housing
Cover”“, page 196 .
❑ Secure. Refer to ⇒
Fig. ““Cylindrical Roll‐
er Bearing, Securing
in Transmission Hous‐
ing Cover by Peening
-arrows- ”“, page 197
2 - Cylindrical Roller Bearing
❑ Do not confuse with the
output shaft cylindrical
roller bearing
⇒ Fig. ““Cylindrical
Roller Bearing, Remov‐
ing from Transmission
Housing Cover”“, page
196 .
Fig. ““Cylindrical Roller
Bearing, Installing in
Transmission Housing
Cover”“, page 196 .
❑ Secure. Refer to ⇒ Fig. ““Cylindrical Roller Bearing, Securing in Transmission Housing Cover by
Peening -arrows- ”“, page 197
3 - Transmission Housing Cover
4 - Magnet
❑ Can only be inserted into the cover with the recess -arrow-.
5 - Clip
❑ Holds the magnet in place

Jetta 2018 ➤
6.4 Transmission Housing, Servicing

⇒ S6.4.1 haft in Transmission Housing, Removing and Instal‐
ling”, page 182
⇒ S6.4.2 haft in Transmission Housing, Removing and Instal‐
ling”, page 183
⇒ i6.4.3 n Transmission Housing, Removing and Installing”,
page 187
6.4.1 Bearing/Input Shaft in Transmission

Housing, Removing and Installing
♦ Press Piece - Rod -VW407-
♦ Press Piece - Multiple Use -VW447i-
Note
Pay attention to the adjustment overview. Refer to ⇒ O3 ver‐

view”, page 270 .

Jetta 2018 ➤
Outer Race/Tapered Roller Bearing, Removing
Outer Race/Tapered Roller Bearing, Installing
– Before installing the outer race, insert the determined shim.

Refer to ⇒ S1.3 haft, Adjusting”, page 211 .
6.4.2 Bearing/Output Shaft in Transmission Housing, Removing and Installing

Jetta 2018 ➤

equipment required

♦ Thrust Piece from Subframe Bushing Tool Kit -3301-
♦ Bearing Installer - Control Arm -3346-
♦ Bearing Installer - Needle Bearing -30-506B-

Jetta 2018 ➤

♦ Press Piece - Multiple Use -VW447H-
♦ Press Piece - Ball Joint/Bushing -3051-
♦ Bearing Installer - Wheel Bearing/Ball Bearing -VW442-
Note
♦ There is no shim on the transmission housing side.

♦ Note the different bearing versions. Refer to ⇒ page 177 .
Roller Sleeve without Circlip, Removing

Jetta 2018 ➤
Roller Sleeve without Circlip, Installing until Stop
– Secure the needle bearing at three points inside the trans‐

mission housing, offset by 120°, using a drift.
Roller Sleeve with Circlip, Removing
– When removing the roller sleeve -1-, press the circlip -2-
together with pliers

Jetta 2018 ➤
Roller Sleeve with Circlip, Installing
– Place the transmission housing on the -30-14- in the roller

sleeve area.
– Press the circlip together and press the roller sleeve on until
the circlip clips in all around the groove.
6.4.3 Bearing/Differential in Transmission Housing, Removing and Installing

Jetta 2018 ➤

equipment required
♦ Press Piece - Rod -VW408A-

♦ Bearing Installer - Wheel Bearing -3144-
♦ Bearing Installer - Taper Roller Bearing -2007-
♦ -1- Internal Puller -VAS251615- (Kukko 21/7)

Jetta 2018 ➤
♦ -4- Counter Support -VAS251623- (Kukko 22/2)
Note

view”, page 270 .
Outer Race/Tapered Roller Bearing, Removing from Transmis‐

sion Housing
A - -VAS251623- (Kukko 22/2)

B - -VAS251615- (Kukko 21/7)
Outer Race/Tapered Roller Bearing, Installing in Transmission
Housing
– Before pressing on the outer race, insert the determined

shim. Refer to ⇒ A2.3 djusting”, page 266 .
– Support the transmission housing with the -3144- directly
under the bearing mount.
6.5 Clutch Housing, Servicing

⇒ S6.5.1 haft in Clutch Housing, Removing and Installing”, page
189
⇒ S6.5.2 haft in Clutch Housing, Removing and Installing”, page
191
⇒ i6.5.3 n Clutch Housing, Removing and Installing”, page 193
6.5.1 Bearing/Input Shaft in Clutch Housing,

Removing and Installing

Jetta 2018 ➤
Note
There is no adjusting shim on the side of the clutch housing.

Jetta 2018 ➤
6.5.2 Bearing/Output Shaft in Clutch Hous‐

ing, Removing and Installing
♦ -1- Internal Puller -VAS251613- (Kukko 21/6)
♦ -4- Counter Support -VAS251623- (Kukko 22/2)


Jetta 2018 ➤
♦ Seal Installer - Flywheel Oil Seal Kit - Seal Installer -2003/3-
Note

view”, page 270 .
Outer Race/Tapered Roller Bearing -C-, Removing
A - -VAS251623- (Kukko 22/2)

B - -VAS251613- (Kukko 21/6)
So that the bolting surface for the bearing mount in the clutch
housing is not damaged, position the -2003/3- on this surface.
Note
Pay attention to the different versions. Refer to ⇒ Fig. ““Note the

Difference between Tapered Roller Bearings”“, page 236 .

Jetta 2018 ➤
– Before installing the outer race, insert the determined shim.

Refer to ⇒ S2.3 haft, Adjusting”, page 234 .
6.5.3 Bearing/Differential in Clutch Housing,

Removing and Installing

Jetta 2018 ➤
Note
6.6 Transmission Housing Cover, Servicing

Jetta 2018 ➤

♦ Support Bridge -2011-
♦ -1- Internal Puller -VAS251611-
♦ -4- Counter Support -VAS251621-
♦ Bearing Installer - Multiple Use -3348/2-
Cylindrical Roller Bearing, Removing from Transmission Hous‐
ing Cover

Jetta 2018 ➤
A - Internal Puller, for example Internal Puller -VAS251611-

B - Counter Support, for example -VAS251621-
Cylindrical Roller Bearing, Removing from Transmission Hous‐
ing Cover
A - Internal Puller, for example -VAS251611-

B - Counter Support, for example -VAS251621-
Cylindrical Roller Bearing, Installing in Transmission Housing
Cover
– Warm the transmission housing cover near the bear‐

ing seats to approximately 100 °C (212 °F) using the -
– Insert the cylindrical roller bearing into the warmed housing
and then push it down with the workshop press until the
temperatures have equalized.

Jetta 2018 ➤
Note
The cylindrical roller bearings must be pressed all the way into
the cover.
Cylindrical Roller Bearing, Securing in Transmission Housing

Cover by Peening -arrows-

Jetta 2018 ➤
7 Securing on Engine and Transmis‐

sion Holder
♦ Shop Crane - Drip Tray -VAS6208-

– Secure the transmission on the -VW353-.
– Place a Drip Tray for example -VAS6208- underneath.

Jetta 2018 ➤
8 Transmission Fluid
⇒ F8.1 luid Level, Checking”, page 199
⇒ F8.2 luid, Draining and Filling”, page 200
8.1 Transmission Fluid Level, Checking

It is not possible to check the transmission fluid level by remov‐

ing oil filler plug.
Due to the angle of the engine/transmission assembly, the low‐

er edge of the filler hole -arrow 1- is located below the fluid level
-arrow 2-.
8. Transmission Fluid 199

Jetta 2018 ➤
The Transmission Fluid Level Can Only Be Checked When the

Transmission Fluid Has Been Drained Completely and Then
Refilled. Refer to ⇒ F8.2 luid, Draining and Filling”, page 200 .
8.2 Transmission Fluid, Draining and Fill‐

ing
♦ Hose (approximately 600 mm long, outside diameter 10 mm)

with commercially available funnel.
Transmission Fluid, Draining
Transmission fluid specification. Refer to the ⇒ Electronic Parts
Catalog (ETKA).
– Remove the air filter housing. Refer to ⇒ Rep. Gr. 24; Air
Filter; Air Filter Housing, Removing and Installing.
Clean the transmission.
Caution
To drain gear oil, journal for shift forks in transmission must

be removed.
To avoid that the position of the shift forks is changed, for
example by involuntarily operating shift mechanism, shift rod
must be secured.

Jetta 2018 ➤
Secure the Gearshift Shaft as Follows:
– Push the gearshift shaft down in the direction of -arrow 1-.

– While press the gearshift shaft down, rotate the bracket -A-
in direction of -arrow 2- upward and simultaneously press it
in until it engages in the gearshift shaft.
• The gearshift shaft is secured.
Use a Clean Container that Holds 3 Liters (3.17 quarts) with a
Scale Printed on it to Catch the Transmission Fluid.
– Remove the drain plug -arrow 1- and then the pivot pins for
the shift forks -arrow 2- and drain the transmission fluid.
– Install the pivot pins for the shift forks -arrow 2- with a new
O-ring. Refer to ⇒ -5.3 Transmission Housing and Gearshift
Mechanism”, page 127 .
– Install the drain plug -arrow 1- -item 2- ⇒ Item 2 (page 179) .
– Rotate the bracket -A- back into its starting position direction
of -arrow- so that the gearshift shaft moves freely.
8. Transmission Fluid 201

Jetta 2018 ➤
Transmission Fluid, Filling

• The drain plug is tightened to the tightening specification.
• Install the shift fork journal with a new O-ring. Refer to
⇒ -5.3 Transmission Housing and Gearshift Mechanism”,
page 127 .
Filling 2.1 liters (2.21 quarts) of Transmission Fluid in the Con‐
tainer
Transmission fluid specification. Refer to the ⇒ Electronic Parts
Catalog (ETKA).
– Remove the Back-Up Lamp Switch -F4- -arrow-.
– Connect a hose (approximately 600 mm long, outside diam‐

eter 10 mm) with commercially available funnel.
– Insert the hose into the locating bore of the Back-Up Lamp
Switch -F4- (second technician) and fill the transmission flu‐
id.
– Reinstall the Back-Up Lamp Switch -F4- -arrow-. Refer to ⇒
-5.4 Shift Unit”, page 129 .
– Check the shift mechanism function. Refer to ⇒ M1.7 echan‐
ism, Checking”, page 87 .
– Install the air filter housing. Refer to ⇒ Rep. Gr. 24; Air Filter;


Jetta 2018 ➤
35 – Gears, Shafts
1 Input Shaft
⇒ -1.1 Input Shaft”, page 203
⇒ S1.2 haft, Disassembling and Assembling”, page 205
⇒ S1.3 haft, Adjusting”, page 211
1.1 Overview - Input Shaft
Note
♦ Install all input shaft bearings with transmission fluid.

♦ The input shaft must be adjusted because the position of the tapered roller bearing is affected when parts
are replaced. Pay attention to the adjustment overview. Refer to ⇒ O3 verview”, page 270 .
♦ Wearing safety gloves, warm the gears and synchronizer hubs to approximately 100 °C (212 °F) using
the Inductive Heater -VAS6414- to install them.
When Installing New Gears or a New Input Shaft, Pay Attention

to the Different Versions:
♦ Technical Data. Refer to ⇒ D4 ata”, page 10 .
♦ Refer to the ⇒ Electronic Parts Catalog (ETKA).
1. Input Shaft 203

Jetta 2018 ➤
1 - Clutch Housing
page 270 .
er Bearing
ling. Refer to ⇒
Housing, Removing
189 .
3 - Inner Race/Tapered Roller
Bearing
⇒ Fig. ““Inner Race/Ta‐
pered Roller Bearing
(Clutch Side), Remov‐
Fig. ““Inner Race/Ta‐
pered Roller Bearing
(Clutch Side), Instal‐
ling”“, page 210 .
4 - Input Shaft
-1.1 Input Shaft”, page
203 .
❑ Adjusting. Refer to ⇒
S1.3 haft, Adjusting”,
page 211 .
5 - 3rd Gear
❑ Installation position:
collar faces 4th gear
❑ Removing. Refer to ⇒ Fig. ““3rd Gear, Removing”“, page 208 .
❑ Installing. Refer to ⇒ Fig. ““3rd Gear, Installing”“, page 209 .
6 - Circlip
7 - 4th Gear
❑ Installation position: collar faces 3rd gear
❑ Removing. Refer to ⇒ Fig. ““4th Gear with Tapered Roller Bearing and Sleeve, Removing”“, page 208 .
❑ Installing. Refer to ⇒ Fig. ““4th Gear, Installing”“, page 209 .
8 - Inner Race/Tapered Roller Bearing
❑ Installing. Refer to ⇒ Fig. ““Inner Race/Tapered Roller Bearing, Installing”“, page 209 .
9 - Thrust Washer
❑ Removing and installing. Refer to ⇒ S6.4.1 haft in Transmission Housing, Removing and Installing”,
page 182 .
11 - Shim
❑ Selecting thickness. Refer to ⇒ S1.3 haft, Adjusting”, page 211 .
204 Rep. Gr.35 - Gears, Shafts

Jetta 2018 ➤
13 - Sleeve
❑ Installing. Refer to ⇒ Fig. ““5th Gear Needle Bearing Sleeve, Installing”“, page 209 .
14 - Needle Bearing
❑ For 5th gear
16 - Spring Washer
❑ With cast locking pieces. Refer to ⇒ Fig. ““5th/6th Gear Synchronizer Rings with Locking Pieces
-arrows- ”“, page 169 .
❑ Checking for Wear. Refer to ⇒ Fig. ““5th Gear Synchronizer Ring and 6th Gear Synchronizer Ring,
Checking”“, page 168 .
18 - 5th/6th Gear Locking Collar with Synchronizer Hub
❑ Remove together with the transmission housing. Refer to ⇒ D5.10 isassembling and Assembling”,
page 150 .
❑ Disassembling and Assembling. Refer to ⇒ Fig. ““5th/6th Gear Locking Collar and Synchronizer Hub,
Disassembling and Assembling”“, page 210 and ⇒ Fig. ““5th/6th Gear Locking Collar/Synchronizer
Hub, Assembling”“, page 211 .
❑ With cast locking pieces. Refer to ⇒ Fig. ““5th/6th Gear Synchronizer Rings with Locking Pieces
-arrows- ”“, page 169 .
❑ Checking for Wear. Refer to ⇒ Fig. ““5th Gear Synchronizer Ring and 6th Gear Synchronizer Ring,
Checking”“, page 168 .
20 - Spring Washer
22 - Needle Bearing
❑ Replace together with the sleeve
❑ For 6th gear
23 - Sleeve
❑ Replace together with the needle bearing
24 - Inner Race/Cylindrical Roller Bearing with Thrust Washer
25 - Bolt
❑ Tightening Specification. Refer to ⇒ -5.2 Transmission Housing Cover and 5th/6th Gear”, page 125 .
❑ Self-locking
1.2 Input Shaft, Disassembling and Assembling
1. Input Shaft 205

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equipment required

♦ Press Piece - Open -VW422-

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♦ Press Tube -41-501-
♦ Press Piece - Press Tube -30-100-
♦ -3- Splitter -VAS251409-
1. Input Shaft 207

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Input Shaft, Disassembling

Inner Race/Tapered Roller Bearing (Clutch Side), Removing
A - Splitter -VAS251409-
4th Gear with Tapered Roller Bearing and Sleeve, Removing
3rd Gear, Removing

Jetta 2018 ➤
– Before removing the 3rd gear, remove the circlip -item 6- ⇒

Item 6 (page 204) .
Input Shaft, Assembling
3rd Gear, Installing
The collar faces 4th gear.

– Install the circlip -item 6- ⇒ Item 6 (page 204) .
4th Gear, Installing
The collar faces 3rd gear.

Inner Race/Tapered Roller Bearing, Installing
5th Gear Needle Bearing Sleeve, Installing
1. Input Shaft 209

Jetta 2018 ➤
– Before pressing on the sleeve, insert the thrust washer

-item 9- ⇒ Item 9 (page 204) .
Inner Race/Tapered Roller Bearing (Clutch Side), Installing
5th/6th Gear Locking Collar and Synchronizer Hub, Disassem‐

bling and Assembling
1- Spring
2- Locking Piece
3- Synchronizer Hub
4- Locking Collar
– Slide the locking collar over the synchronizer hub.

Jetta 2018 ➤
The deeper recesses -arrow A- for the locking pieces inside the
synchronizer hub and the recesses -arrow B- inside the locking
collar must align.
5th/6th Gear Locking Collar/Synchronizer Hub, Assembling
• The locking collar is pushed over the synchronizer hub.

– Insert the locking pieces in the deep recesses -arrows- and
install springs offset by 120°. The angled end of the spring
must engage into the hollow locking piece.
1.3 Input Shaft, Adjusting

(Choosing the shim for the input shaft)
1. Input Shaft 211

Jetta 2018 ➤

equipment required
♦ Dial Indicator Holder -VW387-

♦ Measuring Set - Magnetic Plate - 50mm -VW385/17-
♦ Press Piece - Multiple Use -VW447i-
♦ Dial Gauge
A new input shaft adjustment is required when the following
components have been replaced:
♦ Transmission Housing
♦ Clutch Housing
♦ Input Shaft
♦ 4th Gear
Or the
♦ Tapered roller bearing
Adjustment Overview. Refer to ⇒ O3 verview”, page 270 .

Jetta 2018 ➤
Requirements
• The sealing surfaces of the clutch and transmission housing
must be cleaned of sealant.
– Press the outer race/tapered roller bearing all the way into
the clutch housing.
– Install the outer race/tapered roller bearing all the way into
the transmission housing without the adjusting shim.
– Install the input shaft into the clutch housing and mount the
transmission housing. Install the hex bolts -item 15- ⇒ Item
15 (page 128) .
– Install the measuring device and the dial gauge in the clutch
housing.
– Rotate the input shaft before measuring so the tapered roller

bearing settles. Set the dial gauge with 1 mm pretension to
“0”.
1. Input Shaft 213

Jetta 2018 ➤
Note
Repeat this process each time a measurement is taken other‐

wise the dial gauge will not go back to its starting position.
– Press the input shaft toward the dial gauge in direction of

-arrow-.
– Read and make note of the play on the dial gauge (example:
1.21 mm).
Note
The dial gauge does not return to its starting position.
Shim, Determining
Example:
Bearing Clearance Measured Adjustment Shim Thickness
Value According to the Table
1.21 mm 1.175 mm
Shim Table
Bearing Play Shim
Measured Value (mm) Thickness (mm)
0.671 to 0.699 0.650
0.700 to 0.724 0.675
0.725 to 0.749 0.700
0.750 to 0.774 0.725
0.775 to 0.799 0.750
0.800 to 0.824 0.775
0.825 to 0.849 0.800
0.850 to 0.874 0.825
0.875 to 0.899 0.850
0.900 to 0.924 0.875
0.925 to 0.949 0.900
0.950 to 0.974 0.925
0.975 to 0.999 0.950
1.000 to 1.024 0.975
1.025 to 1.049 1.000
1.050 to 1.074 1.025
1.075 to 1.099 1.050
1.100 to 1.124 1.075

Jetta 2018 ➤
Bearing Play Shim

Measured Value (mm) Thickness (mm)
1.125 to 1.149 1.100
1.150 to 1.174 1.125
1.175 to 1.199 1.150
1.200 to 1.224 1.175
1.225 to 1.249 1.200
1.250 to 1.274 1.225
1.275 to 1.299 1.250
1.300 to 1.324 1.275
1.325 to 1.349 1.300
1.350 to 1.374 1.325
1.375 to 1.399 1.350
1.400 to 1.424 1.375
1.425 to 1.449 1.400
1.450 to 1.474 1.425
1.475 to 1.499 1.450
1.500 to 1.524 1.475
1.525 to 1.549 1.500
1.550 to 1.574 1.525
1.575 to 1.599 1.550
1.600 to 1.624 1.575
1.625 to 1.649 1.600
1.650 to 1.674 1.625
1.675 to 1.699 1.650
1.700 to 1.724 1.675
Note
Allocate the shims. Refer to the ⇒ Electronic Parts Catalog

(ETKA).
– Remove the input shaft and press the outer race/tapered

roller bearing out of the transmission housing.
If the measured shim thickness is larger than those listed in the

table, then install two shims that correspond to the measured
value.
– Install the shim with the correct thickness, thickest shim first.
– Press the outer race/tapered roller bearing and the selected
shim (1.175 mm in the example) together into the transmis‐
sion housing.
1. Input Shaft 215

Jetta 2018 ➤
– Install the transmission housing and tighten the hex bolts

-item 15- ⇒ Item 15 (page 128) .
Checking Measurement
– Install the measuring device and the dial gauge.

– Turn the input shaft so that the tapered roller bearings settle.
– Press the input shaft in direction of -arrow-.
– The bearing play must be a minimum of 0.01 to a maximum
of 0.09 mm.
Note
The adjustment is OK if it is not possible to measure the bearing

play and yet the input shaft still have a noticeable tilting clear‐
ance and is easy to turn.
nism”, page 127

Jetta 2018 ➤
2 Output Shaft
⇒ -2.1 Output Shaft”, page 217
⇒ S2.3 haft, Adjusting”, page 234
2.1 Overview - Output Shaft
Note
♦ Replace both tapered roller bearings together.

♦ Install all bearings on the output shaft with transmission fluid.
♦ Wearing safety gloves, warm the inner races/tapered roller bearings, gears and synchronizer hubs to
approximately 100 °C (212 °F) using the Inductive Heater -VAS6414- to install them.
When Installing New Gears or a New Output Shaft, Pay Atten‐

tion to the Different Versions:
♦ Technical Data. Refer to ⇒ D4 ata”, page 10 .
♦ Refer to the ⇒ Electronic Parts Catalog (ETKA).
2. Output Shaft 217

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1 - Nut
tion. Refer to ⇒
-5.5 Input Shaft, Out‐
put Shafts, Differential
and Shift Rods”, page
130 .
❑ 4 nuts for the bearing
mount
2 - Clutch Housing
page 270 .
3 - Shim
❑ Selecting thickness.
Refer to ⇒ S2.3 haft,
er Bearing
ling. Refer to ⇒
Housing, Removing
191 .
Bearing
⇒ Fig. ““Inner Race/Ta‐
pered Roller Bearing,
Fig. ““Small Inner Race/
Tapered Roller Bearing, Installing”“, page 234 .
6 - Output Shaft
❑ Adjusting. Refer to ⇒ S2.3 haft, Adjusting”, page 234 .
7 - Inner Race/Tapered Roller Bearing on Bearing Mount
❑ Removing. Refer to ⇒ Fig. ““Inner Race/Tapered Roller Bearing on Bearing Mount, Removing”“, page
225 .
❑ Installing. Refer to ⇒ Fig. ““Inner Race/Tapered Roller Bearing on Bearing Mount, Installing”“, page
226 .
8 - Seal
❑ Place on the bearing mount threaded pins
❑ Quantity: 4
9 - Bearing Mount
❑ Replace the outer race only together with the tapered roller bearing and bearing mount
❑ With outer race/tapered roller bearing and threaded pins
10 - Thrust Washer
❑ The collar on the thrust washer faces the tapered roller bearing
11 - 1st Gear Assembly

Jetta 2018 ➤
12 - Needle Bearing
❑ For 1st gear
13 - Inner Synchronizer Ring
❑ For 1st gear
❑ Installation position. Refer to ⇒ Fig. ““Installation Position for 1st Gear Inner Race, Outer Race and
Synchronizer Ring”“, page 226 .
❑ Checking for Wear. Refer to ⇒ Fig. ““1st and 2nd Gear Inner Race, Checking for Wear”“, page 226 .
14 - 1st Gear Outer Race
❑ Checking for Wear. Refer to ⇒ Fig. ““1st and 2nd Gear Synchronizer Ring, Checking for Wear”“, page
227 .
15 - 1st Gear Synchronizer Ring
227 .
16 - 1st and 2nd Gear Locking Collar with Synchronizer Hub
❑ After removing the circlip -item 17- ⇒ Item 17 (page 219) , remove with the bearing mount. Refer to ⇒
Fig. ““Locking Collar with Synchronizer Hub and Bearing Mount, Removing”“, page 225
❑ Disassembling and Assembling. Refer to ⇒ Fig. ““1st and 2nd Gear Locking Collar and Synchronizer
Hub, Disassembling and Assembling”“, page 227 .
❑ Installation position. Refer to ⇒ Fig. ““1st and 2nd Gear Locking Collar/Synchronizer Hub Installation
Position”“, page 229 .
❑ Installing. Refer to ⇒ Fig. ““1st and 2nd Gear Locking Collar/Synchronizer Hub, Installing”“, page 229 .
17 - Circlip
18 - 2nd Gear Synchronizer Ring
227 .
19 - 2nd Gear Outer Race
❑ Installation position. Refer to ⇒ Fig. ““2nd Gear Outer Race Installation Position”“, page 229 .
20 - Inner Synchronizer Ring
❑ For 2nd gear
227 .
❑ Installation position. Refer to ⇒ Fig. ““Synchronizer Ring (2nd Gear Inner Race) Installation Position
-A- ”“, page 230 .
21 - 2nd Gear Assembly
❑ Installation position. Refer to ⇒ Fig. ““2nd Gear Assembly Installation Position”“, page 230 .
22 - Needle Bearing
❑ For 2nd gear
23 - Thrust Washer
24 - Sleeve
❑ For 3rd gear needle bearing
❑ Removing. Refer to ⇒ Fig. ““3rd/4th Gear Synchronizer Hub/Locking Collar, 2nd, 3rd and 4th Gear
Assemblies, Thrust Washer and Sleeve, Removing”“, page 224 .
❑ Installing. Refer to ⇒ Fig. ““3rd Gear Needle Bearing Sleeve, Pressing On”“, page 230 .
25 - Needle Bearing
❑ For 3rd gear
26 - 3rd Gear Assembly
2. Output Shaft 219

Jetta 2018 ➤
27 - 3rd Gear Synchronizer Ring

❑ Checking for Wear. Refer to ⇒ Fig. ““3rd and 4th Gear Synchronizer Ring, Checking for Wear”“, page
231 .
28 - 3rd and 4th Gear Locking Collar with Synchronizer Hub
❑ Disassembling and Assembling. Refer to ⇒ Fig. ““3rd and 4th Gear Locking Collar and Synchronizer
Hub, Disassembling and Assembling”“, page 231 .
❑ Locking Collar/Synchronizer Hub Installation Position. Refer to ⇒ Fig. ““3rd and 4th Gear Locking
Collar/Synchronizer Hub Installation Position”“, page 232 .
❑ Installing. Refer to ⇒ Fig. ““3rd and 4th Gear Synchronizer Hub with Locking Collar, Installing”“, page
233 .
29 - Sleeve
❑ Installing. Refer to ⇒ Fig. ““4th Gear Needle Bearing Sleeve, Installing”“, page 233 .
30 - Needle Bearing
❑ For 4th gear
❑ Checking for Wear. Refer to ⇒ Fig. ““3rd and 4th Gear Synchronizer Ring, Checking for Wear”“, page
231 .
33 - Thrust Washer
34 - Roller Sleeve
❑ Removing and installing. Refer to ⇒ S6.4.2 haft in Transmission Housing, Removing and Installing”,
page 183 .
❑ Note the different bearing versions. Refer to ⇒ page 177 .
❑ Note the different housing versions. Refer to ⇒ page 177 .
36 - Inner Race/Roller Sleeve
❑ For roller sleeve/output shaft
❑ Installing. Refer to ⇒ Fig. ““Sleeve for Needle Bearing/Output Shaft, Installing”“, page 233 .
37 - 5th Gear
❑ Remove with the transmission housing. Refer to ⇒ D5.10 isassembling and Assembling”, page 150 .
38 - Sleeve
39 - 6th Gear
❑ Remove with the transmission housing. Refer to ⇒ D5.10 isassembling and Assembling”, page 150 .
40 - Inner Race/Cylindrical Roller Bearing
❑ Do not confuse with the input shaft inner race/cylindrical roller bearing
41 - Bolt
❑ Tightening Specification. Refer to ⇒ -5.2 Transmission Housing Cover and 5th/6th Gear”, page 125 .

Jetta 2018 ➤
❑ Self-locking
2.2 Output Shaft, Disassembling and Assembling

equipment required

♦ Taper Roller Bearing Extractor -VAG1582A-
♦ Puller - Taper Roller Bearing - Adapter 4 -VAG1582/4-
2. Output Shaft 221

Jetta 2018 ➤

♦ Support Channels -VW457-

Jetta 2018 ➤
♦ Press Piece - Press Tube -30-100-

♦ Press Piece - 60mm -VW415A-
♦ Press Piece - Front Control Arm -2040-
♦ Press Tube -41-501-
2. Output Shaft 223

Jetta 2018 ➤
♦ -3- Splitter -VAS251411-
♦ Feeler Gauge
Output Shaft, Disassembling
Inner Race/Tapered Roller Bearing, Removing
A - Protective Jaws/Vise
– Attach grip and securely clamp it behind bearing rollers.
Then turn the bearing and tension the grip again.
3rd/4th Gear Synchronizer Hub/Locking Collar, 2nd, 3rd and 4th
Gear Assemblies, Thrust Washer and Sleeve, Removing

Jetta 2018 ➤
A - 22 to 115 mm Separating Tool, for example, Splitter -

VAS251411-
B - M10 x 20, 17 mm hex bolt
Note
Support the Separating Tool so that the 1st/2nd gear locking

collar does not come off as well.
Locking Collar with Synchronizer Hub and Bearing Mount, Re‐

moving
– Before pressing off, remove the circlip -arrow-.

Inner Race/Tapered Roller Bearing on Bearing Mount, Remov‐
ing
A - Protective Jaws/Vise
– Before installing puller, insert a M10 x 20 bolt into the hole in
the output shaft.
2. Output Shaft 225

Jetta 2018 ➤
Output Shaft, Assembling

Inner Race/Tapered Roller Bearing on Bearing Mount, Installing
A - Thrust Washer
– Install the thrust washer before installing the inner race. The
collar faces the inner race.
Installation Position for 1st Gear Inner Race, Outer Race and
Synchronizer Ring
– Install the inner race -A- on the 1st gear assembly.

The angled tabs -arrow 1- face the outer race -B-.
– Install the outer race -B-.
The tabs -arrow 2- lock into the gear assembly cut-outs
-arrow 3-.
– Install the synchronizer ring -C-.
The cut-outs -arrow 4- must engage in the tabs -arrow 1- on the
inner race -A-.
Note
If the components are not being replaced, make sure the syn‐
chronizer rings are reallocated to their original gear.
1st and 2nd Gear Inner Race, Checking for Wear

Jetta 2018 ➤
– Push the inner race onto the gear assembly taper and then
measure the gap dimension -a- with a feeler gauge.
-a-
1st and 2nd gear 0.75 to 1.25 mm 0.3 mm
1st and 2nd Gear Synchronizer Ring, Checking for Wear
– Push the synchronizer ring, outer race and inner race onto
the gear assembly taper and then measure the gap dimen‐
sion -a- with a feeler gauge.
-a-
1st and 2nd gear 1.2 to 1.8 mm 0.5 mm
1st and 2nd Gear Locking Collar and Synchronizer Hub, Disas‐
sembling and Assembling
1 - Spring
Spring allocation. Refer to the ⇒ Electronic Parts Catalog (ET‐
KA).
2. Output Shaft 227

Jetta 2018 ➤
Installing with the hollow locking pieces. Refer to ⇒ Fig. ““1st

and 2nd Gear Locking Collar/Synchronizer Hub with Hollow
Locking Pieces, Assembling”“, page 228 .
Installing with the locking pieces that are not hollow. Refer to ⇒
Fig. ““1st and 2nd Gear Locking Collar/Synchronizer Hub with
Non-Hollow Locking Pieces, Assembling”“, page 228 .
2 - Locking Collar
3 - Synchronizer Hub
4 - Locking Piece
Select the locking pieces. Refer to the ⇒ Electronic Parts Cata‐
log (ETKA).
The collar has the same width on both side of the synchronizer
hub.
The Collar has a Bevel on One Side -arrow B-
The bevel on the synchronizer hub collar and the splines on the
outside of the locking collar -arrow A- face in the same direction
after being assembled.
The notches on the synchronizer hub and locking collar for the
locking pieces -arrow C- must line up.
1st and 2nd Gear Locking Collar/Synchronizer Hub with Hollow
Locking Pieces, Assembling

– Install the locking pieces and springs offset by 120°. The
angled end of the spring must engage into the hollow locking
piece.
1st and 2nd Gear Locking Collar/Synchronizer Hub with Non-
Hollow Locking Pieces, Assembling

Jetta 2018 ➤

angled end of the spring must be positioned in front of the
locking pieces -arrows-.
1st and 2nd Gear Locking Collar/Synchronizer Hub Installation
Position
The teeth on the locking collar -arrow- point toward the splines
for the 3rd/4th gear synchronizer hub -A-.
1st and 2nd Gear Locking Collar/Synchronizer Hub, Installing
Turn the synchronizer ring so that the grooves line up with the
locking pieces.
– Install the circlip -arrow-.
2nd Gear Outer Race Installation Position
2. Output Shaft 229

Jetta 2018 ➤
The tabs -arrows- face 1st gear -A-.

Synchronizer Ring (2nd Gear Inner Race) Installation Position
-A-
The tabs -arrow 1- engage into the holes -arrow 2- inside the
synchronizer ring -B-.
2nd Gear Assembly Installation Position
The higher collar -A- faces toward 1st gear -B-. The notches in
the collar -arrow- lock into the tabs on the outer race. Refer to ⇒
Fig. ““2nd Gear Outer Race Installation Position”“, page 229 .
– Place the thrust washer on the 2nd gear assembly.
3rd Gear Needle Bearing Sleeve, Pressing On

Jetta 2018 ➤
3rd and 4th Gear Synchronizer Ring, Checking for Wear
– Push the synchronizer ring onto the gear assembly taper

and then measure the gap dimension -a- with a feeler
gauge.
-a-
3rd and 4th gear 1.0 to 1.7 mm 0.5 mm
3rd and 4th Gear Locking Collar and Synchronizer Hub, Disas‐
sembling and Assembling
1 - Spring
Spring allocation. Refer to the ⇒ Electronic Parts Catalog (ET‐
KA).
Installing with the hollow locking pieces. Refer to ⇒ Fig. ““3rd
and 4th Gear Locking Collar/Synchronizer Hub with Hollow
Locking Pieces, Assembling”“, page 232 .
Installing with the locking pieces that are not hollow. Refer to
⇒ Fig. ““3rd and 4th Gear Locking Collar/Synchronizer Hub with
Non-Hollow Locking Pieces, Assembling”“, page 232 .
2. Output Shaft 231

Jetta 2018 ➤
2 - Locking Piece
Select the locking pieces. Refer to the ⇒ Electronic Parts Cata‐
log (ETKA).
3 - Locking Collar
4 - Synchronizer Hub
– Slide the locking collar over the synchronizer hub.
The notches for the locking pieces on the synchronizer hub and
locking collar must line up with each other.
3rd and 4th Gear Locking Collar/Synchronizer Hub with Hollow
Locking Pieces, Assembling
The locking collar is pushed over the synchronizer hub.

angled end of the spring must engage into the hollow locking
piece.
3rd and 4th Gear Locking Collar/Synchronizer Hub with Non-
Hollow Locking Pieces, Assembling

angled end of the spring must be positioned in front of the
locking pieces -arrows-.
3rd and 4th Gear Locking Collar/Synchronizer Hub Installation
Position

Jetta 2018 ➤
The bevel -arrow- faces the 4th gear.

3rd and 4th Gear Synchronizer Hub with Locking Collar, Instal‐
ling
4th Gear Needle Bearing Sleeve, Installing
Sleeve for Needle Bearing/Output Shaft, Installing
– Before pressing on, insert the thrust washer -item 33- ⇒ Item
33 (page 220) .
2. Output Shaft 233

Jetta 2018 ➤
Small Inner Race/Tapered Roller Bearing, Installing
2.3 Output Shaft, Adjusting

equipment required

♦ Door Alignment Device - Replacement Stud -3114/2-

Jetta 2018 ➤

♦ Dial Gauge

♦ -2- Puller -VAS251415- (threaded spindle)
♦ Slide Hammer Set - Threaded Piece -VW771/15-
♦ Seal Installer - Flywheel Oil Seal Kit - Seal Installer -2003/3-
(Selecting the Correct Adjusting Shim for the Output Shaft)

It is necessary to adjust the output shaft if the following compo‐
nents were replaced:
♦ Output Shaft
♦ Clutch Housing
or
♦ Tapered roller bearing
2. Output Shaft 235

Jetta 2018 ➤
Requirements
• Remove any Sealant remaining on the sealing surfaces of
the clutch and transmission housing.
Note the Difference between Tapered Roller Bearings
♦ I = Outer race/tapered roller bearing “without collar”

♦ II = Outer race/tapered roller bearing “with collar” -arrow-
♦ Press the outer race/tapered roller bearing “without collar”

with a “0.60 mm” shim all the way into the clutch housing.
♦ Press the outer race/tapered roller bearing “with collar” with
a “0.65 mm” shim all the way into the clutch housing.
Procedure for All
– Insert the output shaft and tighten the nuts for the bearing
mount.
– Rotate the output shaft 20 to 30 times in one direction.
Note
♦ For this reason, it must be rotated in one direction so the

tapered roller bearing rollers are seated in one direction.
♦ Otherwise the measurements will be incorrect.
– Install the dial gauge (3 mm measuring range) and set to “0”

with 1 mm pre-load.

Jetta 2018 ➤
-A- = threaded spindle from the -VAS251415-.

– Move the input shaft up and down, check the play on the dial
gauge and make a note of it.
Shim, Determining
The specified bearing tension is reached when the shim (0.65
mm or 0.60 mm) is added to the measured value.
Outer Race Tapered Roller Bearing “without collar” = item I
Example:
Bearing Play = Adjustment Shim Thickness
(0.60 mm shim According to the Table
+ measured value 0.330 =
0.930 mm )
0.930 mm 1.000 mm
Shim Table
Measured Value Adjustment Shim
Thickness (mm)
... 0.000 0.600
0.000 to 0.629 0.650
0.630 to 0.679 0.700
0.680 to 0.729 0.750
0.730 to 0.779 0.800
0.780 to 0.829 0.850
0.830 to 0.879 0.900
0.880 to 0.929 0.950
2. Output Shaft 237

Jetta 2018 ➤

Thickness (mm)
0.930 to 0.979 1.000
0.980 to 1.029 1.050
1.030 to 1.079 1.100
1.080 to 1.129 1.150
1.130 to 1.179 1.200
1.180 to 1.229 1.250
1.230 to 1.279 1.300
1.280 to 1.329 1.350
1.330 to 1.342 1.400
Outer Race/Tapered Roller Bearing “with collar” -arrow- = item
II
Example:
Bearing Play = Adjustment Shim Thickness
(shim 0.65 mm According to the Table
+ measured value 0.230 =
0.880 mm)
0.880 mm 0.950 mm
Shim Table
Thickness (mm)
... 0.000 0.650
0.000 to 0.679 0.700
0.680 to 0.729 0.750
0.730 to 0.779 0.800
0.780 to 0.829 0.850
0.830 to 0.879 0.900
0.880 to 0.929 0.950
0.930 to 0.979 1.000
0.980 to 1.029 1.050
1.030 to 1.079 1.100
1.080 to 1.129 1.150
1.130 to 1.179 1.200
1.180 to 1.229 1.250
1.230 to 1.279 1.300
1.280 to 1.329 1.350
1.330 to 1.379 1.400
1.380 to 1.429 1.450

Jetta 2018 ➤
Note

(ETKA).
– Remove the output shaft and remove the small outer race/
tapered roller bearing -C-.
A - Counter Support -VAS 251623-

B - Internal Puller -VAS251613-
So that the bolting surface for the bearing mount in the clutch
housing is not damaged, position the -2003/3- on this surface.
• If the used shim is installed again, check it for damage.
If the measured shim thickness is larger than those listed in the
table, then install two shims that correspond to the measured
value.
Tolerance variations make it possible to measure the exact
shim thickness required.
– Press in the small outer race/tapered roller bearing with the
determined shim.
– Install the output shaft and the tighten the bearing mount
nuts in the clutch housing -item 11- ⇒ Item 11 (page 131) .
♦ Refer to ⇒ -5.5 Input Shaft, Output Shafts, Differential and
Shift Rods”, page 130
2. Output Shaft 239

Jetta 2018 ➤
3 Reverse Shaft
⇒ -3.1 Reverse Shaft”, page 240
3.1 Overview - Reverse Shaft

⇒ -3.1.1 Reverse Shaft with Reverse Gear Assembly”, page
240
⇒ -3.1.2 Reverse Shaft, with Reverse Gear Locking Collar”,
page 241
3.1.1 Overview - Reverse Shaft with Re‐

verse Gear Assembly
The -arrow- Points to the Reverse Gear Assembly
Note
♦ Reverse Shaft, Disassembling and Assembling. Refer to ⇒ S3.2 haft, Disassembling and Assembling”,
page 242
♦ Always replace the needle sleeve after removing it from the clutch housing or from the reverse shaft
support.

Jetta 2018 ➤
1 - Clutch Housing
2 - Needle Sleeve
Fig. ““Needle Sleeve,
Removing from Clutch
Housing”“, page 244 .
Fig. ““Needle Sleeve
-A-, Installing in Clutch
3 - Reverse Drive Gear
4 - Circlip
❑ Mount the new circlip
carefully
❑ Do not stretch
5 - Reverse Gear Assembly
❑ Remove the circlip be‐
fore replacing
❑ Collar faces reverse
gear
6 - Reverse Shaft
ling. Refer to ⇒
D5.10 isassembling
150 .
7 - Needle Sleeve
Removing from Re‐
verse Shaft Support”“,
page 244 .
❑ Installing. Refer to ⇒ Fig. ““Needle Sleeve, Pressing into Reverse Shaft Support”“, page 245 .
❑ Removing and installing. Refer to ⇒ D5.10 isassembling and Assembling”, page 150 .
3.1.2 Overview - Reverse Shaft, with Re‐

verse Gear Locking Collar
3. Reverse Shaft 241

Jetta 2018 ➤
The -arrow- Points to the Reverse Gear Locking Collar
Note
♦ Reverse Shaft, Disassembling and Assembling. Refer to ⇒ -3.1.1 Reverse Shaft with Reverse Gear
Assembly”, page 240
♦ Always replace the needle sleeve after removing it from the clutch housing or from the reverse shaft
support.
1 - Clutch Housing
2 - Needle Sleeve
Removing from Clutch
Fig. ““Needle Sleeve
-A-, Installing in Clutch
3 - Reverse Shaft
❑ With reverse gear
ling. Refer to ⇒
D5.10 isassembling
150 .
4 - Reverse Gear Locking
Collar
splines point to reverse
gear assembly
5 - Washer
6 - Needle Bearing
❑ For reverse gear as‐
sembly
❑ Install with transmission
fluid
7 - Reverse Gear Assembly
splines point to reverse
gear locking collar
8 - Thrust Washer
9 - Needle Sleeve
❑ Removing. Refer to ⇒ Fig. ““Needle Sleeve, Removing from Reverse Shaft Support”“, page 244 .
❑ Installing. Refer to ⇒ Fig. ““Needle Sleeve, Pressing into Reverse Shaft Support”“, page 245 .
❑ Removing and installing. Refer to ⇒ D5.10 isassembling and Assembling”, page 150 .
3.2 Reverse Shaft, Disassembling and Assembling

Jetta 2018 ➤

equipment required

♦ Centering/Press Pin -12-551-

Jetta 2018 ➤

Needle Sleeve, Removing from Clutch Housing
A - Counter Support, for example -VAS251621-

B - 14.5 - 18.5 mm Internal Puller, for example Internal Puller
-VAS251605-
Note
The needle sleeve will get damaged when it is removed and

must be replaced.
Needle Sleeve -A-, Installing in Clutch Housing
Needle Sleeve, Removing from Reverse Shaft Support

Jetta 2018 ➤
Needle Sleeve, Pressing into Reverse Shaft Support

Jetta 2018 ➤
39 – Final Drive, Differential

1 Seals
⇒ L1.1 ocation Overview - Seals”, page 246
⇒ S1.2 eal, Replacing”, page 246
⇒ S1.3 eal, Replacing”, page 249
⇒ S1.4 haft Seal, Replacing”, page 254
1.1 Component Location Overview - Seals
1 - Input Shaft Seal

ing”, page 254 .
2 - Seal
❑ For the right flange
shaft
page 249 .
3 - Seal
page 246 .
ing”, page 88 .
1.2 Left Seal, Replacing
246 Rep. Gr.39 - Final Drive, Differential

Jetta 2018 ➤

equipment required
♦ Slide Hammer Set -VW771-

♦ Slide Hammer Set - Hook -VW771/37-
♦ Seal Installer - Flange Shaft Oil Seal -T10160-
♦ Used Oil Collection and Extraction Unit -SMN372500-
♦ Sealing Grease
grease allocation.
Removing
– Remove the left wheel.
– Remove the lower section of the left front wheel housing
liner. Refer to ⇒ Body Exterior; Rep. Gr. 66; Wheel Housing
Liner; Overview - Front Wheel Housing Liner.
– Turn the steering wheel to the left.
1. Seals 247
Jetta 2018 ➤
– Remove the drive axle from the flange shaft. Refer to ⇒ Sus‐
– Tie the drive axle up as high as possible. Do not damage the
paint on the drive axle while doing so.
– Place the Drip Tray under the transmission.
– Remove flange shaft bolt. To do this, install two bolts on the
flange and counterhold the flange shaft with a pry bar.
– Remove the flange shaft with the pressure spring.

– Remove the flange shaft seal using the -VW771- and the
-VW771/37-.
Installing
– Lightly oil the outer edge of the new seal.

– Install the seal all the way in without tilting it.

Jetta 2018 ➤
– Insert the flange shaft.

– Press the flange shaft against the transmission and secure it
with the bolt.
– Attach the drive axles to the transmission. Refer to ⇒ Sus‐
– Check the transmission fluid and fill if necessary. Refer to ⇒
F8 luid”, page 199 .
– Install the lower section of the left front wheel housing liner.
Refer to ⇒ Body Exterior; Rep. Gr. 66; Wheel Housing Liner;
Overview - Front Wheel Housing Liner.
– Install the wheel. Refer to ⇒ Suspension, Wheels, Steering;
Rep. Gr. 44; Wheels, Tires; Wheel Bolts, Tightening Specifi‐
cations.
1.3 Right Seal, Replacing
1. Seals 249
Jetta 2018 ➤

♦ Seal Installer - One-Piece Seal -T10148-
♦ Spindle from the Seal Installer - Driver Set -3066-
♦ Slide Hammer Set -VW771-
♦ Slide Hammer Set - Hook -VW771/37-

Jetta 2018 ➤
♦ Used Oil Collection and Extraction Unit -SMN372500-
♦ Sealing Grease
grease allocation.
Note
The seal -1- and the sleeve -2- are a single part.
The seal and the sleeve can only be replaced together.
Removing
– Turn steering as far as possible toward right.
– Remove the drive axle heat shield if equipped -arrows-.
– Remove the drive axle -1- from the flange shaft. Refer to
⇒ Suspension, Wheels, Steering; Rep. Gr. 40; Drive Axle;
Drive Axle, Removing and Installing.
1. Seals 251
Jetta 2018 ➤
– Tie the drive axle up as high as possible. Do not damage the

paint on the drive axle while doing so.
Note
♦ On some engines, the drive axle cannot be tied up far

enough so that the transmission flange shaft can be re‐
moved.
♦ Then remove the right drive axle. Refer to ⇒ Suspension,
Wheels, Steering; Rep. Gr. 40; Drive Axle; Drive Axle, Re‐
– Place the Drip Tray under the transmission.

– Remove flange shaft bolt. To do this, install two bolts on the
flange and counterhold the flange shaft with a pry bar.
– Remove the flange shaft with the pressure spring.

– Remove the seal and the sleeve together.
A ridge is located on the inner diameter of the sleeve.

Jetta 2018 ➤
– Install the -VW771/37- directly behind the ridge inside the

sleeve.
– Using force, push the -VW771/37- into the sleeve.
Installing
– Clean the seal seat inside the transmission.
– Install the seal and the sleeve together.
A - Install the Spindle on the -3066- into the threaded piece in

the differential.
B - M12 Nut
– Turn the nut -B- and pull the seal with the sleeve all the way
over the -T10148-.
– Insert the flange shaft.

– Press the flange shaft against the transmission and secure it
with the bolt -arrow-.
1. Seals 253
Jetta 2018 ➤
– Fasten the right drive axle to the flange shaft. Refer to

⇒ Suspension, Wheels, Steering; Rep. Gr. 40; Drive Axle;
Drive Axle, Removing and Installing.
– If equipped, attach the drive axle heat shield -arrows-. Refer
to ⇒ Suspension, Wheels, Steering; Rep. Gr. 40; Drive Axle;
Drive Axle Heat Shield, Removing and Installing.
– Check the transmission fluid and fill if necessary. Refer to ⇒

F8 luid”, page 199 .
1.4 Input Shaft Seal, Replacing

♦ Bearing/Bushing Installer - Multiple Use -VW295A-

Jetta 2018 ➤
♦ Press Piece - Front Control Arm -2040-
♦ Radial Shaft Seal Sealing Grease

grease allocation.
• Transmission is removed.
– Remove the clutch release lever with the release bearing
and guide sleeve. Refer to ⇒ -1.3 Clutch Release Mecha‐
nism”, page 24 .
– Drive the seal out of the guide sleeve.
Note
Be careful not to damage the contact surface for the seal on the
input shaft.
– Fill the area between the sealing/dust lip -arrow- halfway

with Sealing Grease.
1. Seals 255
Jetta 2018 ➤
– Coat the outer circumference of the seal lightly with trans‐

mission fluid.
– Install the seal all the way into the guide sleeve.
– Install the clutch release lever with the release bearing and
guide sleeve. Refer to ⇒ -1.3 Clutch Release Mechanism”,
page 24 .
♦ Refer to ⇒ -1.3 Clutch Release Mechanism”, page 24

Jetta 2018 ➤
2 Differential
⇒ -2.1 Differential”, page 257
⇒ D2.2 isassembling and Assembling”, page 259
⇒ A2.3 djusting”, page 266
2.1 Overview - Differential
Note
♦ To install, warm the inner races/tapered roller bearings to approximately 100 °C (212 °F) with Inductive
Heater -VAS6414-. Wear protective gloves.
♦ Replace both tapered roller bearings together.
♦ Adjust the differential when replacing the tapered roller bearing, differential housing, transmission housing
or clutch housing. Refer to ⇒ O3 verview”, page 270 .
2. Differential 257
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2 - Shim
❑ Selecting thickness.
Refer to ⇒ A2.3 djust‐
ing”, page 266 .
er Bearing
⇒ Fig. ““Outer Race/
Tapered Roller Bear‐
ing, Removing from
Transmission Housing”
“, page 263 .
Fig. ““Outer Race/Ta‐
pered Roller Bearing,
Installing in Transmis‐
sion Housing”“, page
263 .
Bearing
Fig. ““Inner Races/Ta‐
pered Roller Bearings,
Fig. ““Inner Races/Ta‐
pered Roller Bearings,
Installing”“, page 262 .
5 - Differential
❑ With final drive gear
wheel
❑ Thrust washer union fit‐
ted to differential hous‐
ing. Refer to ⇒ Fig. ““On Some Transmissions, the Thrust Washer Union Has a Ridge -A- in the Area
of the Hole.”“, page 265
❑ Spring pin hole adapted to the length of the spring pin. Refer to ⇒ Fig. ““Differential Housing Alloca‐
tion”“, page 264
6 - Inner Race/Tapered Roller Bearing
❑ Removing. Refer to ⇒ Fig. ““Inner Races/Tapered Roller Bearings, Removing”“, page 262 .
❑ Installing. Refer to ⇒ Fig. ““Inner Races/Tapered Roller Bearings, Installing”“, page 262 .
❑ Removing. Refer to ⇒ Fig. ““Outer Race/Tapered Roller Bearing, Removing from Clutch Housing”“,
page 261 .
❑ Installing. Refer to ⇒ Fig. ““Outer Race/Tapered Roller Bearing, Installing in Clutch Housing”“, page
262 .
8 - Clutch Housing
9 - Seal with Sleeve
❑ For the right flange shaft
❑ If the seal is damaged, then replace both the seal and sleeve. Refer to ⇒ S1.3 eal, Replacing”, page
249 .
10 - Bolt
❑ 25 Nm

Jetta 2018 ➤
❑ Install with the threaded piece.
11 - Flange Shaft
❑ Left Flange Shaft, Removing and installing. Refer to ⇒ S1.2 eal, Replacing”, page 246 .
❑ Right flange shaft, Removing and installing. Refer to ⇒ S1.3 eal, Replacing”, page 249 .
12 - Flange Shaft Pressure Spring
13 - Thrust Washer
❑ Installation position. Refer to ⇒ Fig. ““Installed Position: Tapered Ring Thrust Washer -1- ”“, page 266 .
14 - Tapered Ring
❑ With grooves for the thrust washer
❑ Installation position: taper faces the differential housing
15 - Circlip
❑ Holds the tapered ring, the thrust washer and the pressure spring when the flange shaft is removed
16 - Seal
❑ Replacing. Refer to ⇒ S1.2 eal, Replacing”, page 246 .
2.2 Differential, Disassembling and Assembling

equipment required
2. Differential 259
Jetta 2018 ➤
♦ Puller - Taper Roller Bearing -VAG1582-


♦ Bearing Installer - Wheel Bearing -3144-
♦ Bearing Installer - Taper Roller Bearing -2007-

Jetta 2018 ➤

Outer Race/Tapered Roller Bearing, Removing from Clutch
Housing
– Before removing, remove the right flange shaft seal. Refer to

⇒ -2.1 Differential”, page 257 .
2. Differential 261
Jetta 2018 ➤
Outer Race/Tapered Roller Bearing, Installing in Clutch Housing

Inner Races/Tapered Roller Bearings, Removing
– Before installing the puller, mount the -40-105- onto the dif‐
ferential housing.
Note
Both tapered roller bearing inner races are removed from the
differential housing in the same way.
Inner Races/Tapered Roller Bearings, Installing
Note
Inner race/tapered roller bearing for transmission housing and

clutch housing are installed using the same special tools

Jetta 2018 ➤
Outer Race/Tapered Roller Bearing, Removing from Transmis‐

sion Housing
A - Counter Support, for example, -VAS251623-

B - Internal Puller, for example, -VAS251615-
Outer Race/Tapered Roller Bearing, Installing in Transmission
Housing
– Install the washer under the outer race.

– Support the transmission housing with the -3144- directly
under the bearing mount.
Differentiating the Spring Pins
Dimension “a” mm Identifying Feature

28.5 (short tension sleeve), Groove all the way
Removing and installing. Refer to around -arrows-
⇒ Fig. ““Adapter Sleeve with Sur‐
rounding Groove (Short Adapter
Sleeve): Removing and Installing”“,
page 264 .
2. Differential 263
Jetta 2018 ➤
Dimension “a” mm Identifying Feature

36.0 (long spring pin), No surrounding groove
Refer to ⇒ Fig. ““Adapter Sleeve
without Surrounding Groove (Long
Adapter Sleeve), Removing: Press
out the Differential Bevel Gear Axle”
“, page 264 for removing
and ⇒ Fig. ““Spring Pin without
Surrounding Groove (Long Adapter
Sleeve), Installing”“, page 265 , for
installing.
Differential Housing Allocation
– Check the hole in the differential housing for the spring pin.
The hole in the differential housing was modified due to the
longer adapter sleeve.
Hole Spring Pin Length (mm)
-A- 28.5 (short adapter sleeve)
-A- and -B- 36.0 (long adapter sleeve)
Adapter Sleeve with Surrounding Groove (Short Adapter
Sleeve): Removing and Installing
Removing
– Cover the inner race/tapered roller bearing in order to pre‐
vent possible damage and entry of shavings.
– Position a chisel in the surrounding groove in order to drive
out the adapter sleeve.
Installing
– Drive into the differential housing until it stops.
Adapter Sleeve without Surrounding Groove (Long Adapter
Sleeve), Removing: Press out the Differential Bevel Gear Axle

Jetta 2018 ➤
Spring pin is sheared off when it is removed.

– Drive remaining part of roller pin out of differential housing.
Spring Pin without Surrounding Groove (Long Adapter Sleeve),
Installing
– Align the hole in the differential bevel gear axle to the hole in
the differential housing.
– Install the new adapter sleeve to dimension -a- = 3.0 mm
using a drift -1-.
• The spring pin must not come in contact with the transmis‐
sion when the differential housing is installed.
On Some Transmissions, the Thrust Washer Union Has a
Ridge -A- in the Area of the Hole.
Also, the differential housing has a groove -B- all the way
around it.
– Insert the thrust washer union with transmission fluid.
– Install the thrust washer union so that it fits into the groove
-B- in the differential housing.
2. Differential 265
Jetta 2018 ➤
Differential Bevel Gears and Differential Bevel Gear Axle, Instal‐

ling
– Insert the thrust washer union with transmission fluid.

– Insert both large differential bevel gears and secure them (to
the flange shaft, for example).
– Insert the small differential bevel gears at an offset of 180°
and move them into place.
– Press the differential bevel gear axle -arrow A- up to the first
small differential bevel gear.
– Insert the threaded pieces -B arrows- into the large differen‐
tial bevel gears.
Installation position: collar faces the differential bevel gear.
– Install the differential bevel gear axle up the end position and
secure it with a new adapter sleeve.
Installed Position: Tapered Ring Thrust Washer -1-
The collar -arrow- faces the pressure spring -B-.

Some transmissions are not equipped with ridges -A-.
The ridges -A- face the tapered ring -1-.
2.3 Differential, Adjusting

Jetta 2018 ➤

equipment required

♦ Dial Gauge
A new differential adjustment is required when the following
components have been replaced:
♦ Transmission Housing
♦ Clutch Housing
♦ Differential Housing
Or the
♦ Differential tapered roller bearing
2. Differential 267
Jetta 2018 ➤

– Press the outer race/tapered roller bearing into transmission
housing without shim, using -30-205-. Refer to ⇒ Fig. ““Out‐
er Race/Tapered Roller Bearing, Installing in Transmission
Note
Bearing inner race and outer race of tapered roller bearing are
paired. Do not interchange them.
– Press outer race/tapered roller bearing into the clutch hous‐

ing using the -30-205-. Refer to ⇒ Fig. ““Outer Race/Tapered
Roller Bearing, Installing in Clutch Housing”“, page 262 .
– Insert the differential into the clutch housing.
– Position the transmission housing and tighten the five bolts
to the tightening specification.
– Mount the -VW387- and set the dial gauge to “0” with 1 mm
pretension.
– Move the differential up and down, read off play on dial

gauge and note. (example: 0.70 mm).
Shim, Determining
The specified bearing pre-load is obtained by adding a constant
pre-load figure of 0.25 mm to the reading obtained.
Example:
Measured value 0.70 mm
+ preload (constant value) 0.25 mm
Shim thickness = 0.95 mm
Example:
Bearing Clearance Measured Adjustment Shim Thickness
Value According to the Table
0.70 mm 0.95 mm
Shim Table
Bearing Play Shim
Measured value Thickness
(mm) (mm)
0.303 to 0.449 0.650
0.450 to 0.499 0.700
0.500 to 0.549 0.750

Jetta 2018 ➤
Bearing Play Shim

0.550 to 0.599 0.800
0.600 to 0.649 0.850
0.650 to 0.699 0.900
0.700 to 0.749 0.950
0.750 to 0.799 1.000
0.800 to 0.849 1.050
0.850 to 0.899 1.100
0.900 to 0.949 1.150
0.950 to 0.999 1.200
1.000 to 1.049 1.250
1.050 to 1.099 1.300
1.100 to 1.149 1.350
1.150 to 1.199 1.400
Note

(ETKA).
– Remove the transmission housing and remove the tapered

roller bearing outer race from the transmission housing.
A - Counter Support, for example, -VAS251623-

B - Internal Puller, for example, -VAS251615-
If the measured shim thickness is larger than those listed in
the table, then install two shims that add up to the necessary
thickness.
Tolerance variations make it possible to find the exact shim
thickness required.
– Re-install the outer race/tapered roller bearing with the se‐
lected shim (in the example: 0.95 mm) (refer to ⇒ Fig. ““Out‐
er Race/Tapered Roller Bearing, Installing in Transmission
Housing”“, page 263 ) and tighten the transmission housing.
nism”, page 127
2. Differential 269
Jetta 2018 ➤
3 Adjustment Overview
Note
A re-adjustment of the drive axle, output shaft or differential is

only required if components, which have a direct influence on
transmission adjustment, have been replaced. Note the follow‐
ing table to avoid unnecessary adjustments:
To be adjusted:
Input Shaft Output Shaft Differential
Refer to . Refer to . Refer to
⇒ S1.3 haft, ⇒ S2.3 haft, ⇒ A2.3 djust‐
Adjusting”, Adjusting”, ing”, page
page 211 page 234 . 266 .
Replaced part: Transmission Housing x x
Clutch Housing x x x
Input Shaft x
Output Shaft x
Differential x
Output shaft tapered roller bearing x
Output shaft tapered roller bearing x
Differential tapered roller bearing x
4th Gear x

Jetta 2018 ➤
4 Revision History
DRUCK NUMBER: K0059079721
Fac‐ Edit Job Fee Notes Quality
tory Edi‐ Type dba Checke
Edi‐ tion ck d By
tion
04.2 06/1 Cor‐ N/A Fixed metadata for the Eric P.
021 0/20 rec‐ new Elsa DCP rule
21 tion changes
04.2 06/0 Fac‐ N/A Eric P.
021 9/20 tory
21 Up‐
date
11.2 02/2 Fac‐ N/A Eric P.
018 7/20 tory
19 Up‐
date
06.2 07/3 Lo‐ 136 Changed metatdata from Eric P.
018 1/20 cal 708 AU1,BX5 to BU3 for re‐
18 Feed 3 pair group 30.
back
06.2 06/1 Laun N/A Eric P.
018 8/20 ch -
18 CO
12.2 03/2 Fac‐ N/A Eric P.
017 1/20 tory
18 New
4. Revision History 271

VW Jetta 7 Manual Transmission 02s Eng

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Service

Service Department. Technical Information

00 - General, Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

2.3 Transmission, Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

35 - Gears, Shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203

39 - Final Drive, Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246

00 – General, Technical Data

1.1 Safety Precautions when Working on

Risk of injury if the engine starts automatically in vehicles

1.2 Safety Precautions during Road Test

There is a risk of an accident due to distractions and improp‐

To prevent personal injury and damage to electrical and elec‐

Risk of destroying electronic components when disconnect‐

– Disconnect the battery. Refer to ⇒ Electrical Equipment;

2 Rep. Gr.00 - General, Technical Data

2.1 Transmission Identification

Manual Transmission 02S -arrow 2-

Transmission Codes and Production Date

The transmission code is also listed in the vehicle data plates.

4 Rep. Gr.00 - General, Technical Data

3.1 General Repair Information

♦ Thoroughly clean the separating surfaces and apply Sealing

♦ Do not stretch the circlips.

6 Rep. Gr.00 - General, Technical Data

Bolts and Nuts

♦ Always loosen or tighten bolts and nuts on covers and hous‐

♦ Measure the shims at several locations with a micrometer

♦ Do not interchange them. When reusing synchronizer rings,

8 Rep. Gr.00 - General, Technical Data

Toothed Gears, Synchronizer Hubs

4.2 Transmission/Engine Allocation

Manual Transmission 6-Speed 02S

4.3 Gear Ratio Calculation

10 Rep. Gr.00 - General, Technical Data

i = Z2 : Z1 (Z1 = number of teeth on the drive gear, Z2 =

5.1 Overview - Drivetrain, FWD

12 Rep. Gr.00 - General, Technical Data

6.1 Component Location Overview - Elec‐

6.1.1 Component Location Overview - Elec‐

Component location: on the shift unit

Component location: on top of the oil filler plug.

14 Rep. Gr.00 - General, Technical Data

6.1.2 Component Location Overview - Elec‐

Installed location: in the passenger compartment on the clutch

1.1 Overview - Pedal Assembly

16 Rep. Gr.30 - Clutch

1 - Clutch Master Cylinder

18 Rep. Gr.30 - Clutch

1.2 Overview - Clutch Hydraulics

1.2.1 Overview - Clutch Hydraulics

20 Rep. Gr.30 - Clutch

14 - Clutch Slave Cylinder

Disconnect and Connect the Clutch Mechanism Lines

♦ An O-ring can also be installed instead of a seal -2-. Refer

– Press in the hose/line assembly -1- at the connection -4-

Item Line Connection Version

22 Rep. Gr.30 - Clutch

1 - Clutch Slave Cylinder

1.3 Overview - Clutch Release Mechanism