Golf Variant 2007

Service
Workshop Manual
Golf Variant 2007 ➤
Golf Variant 2010 ➤
Jettay 2005 ➤
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Service Department. Technical Information
Downloaded from www.Manualslib.com manuals search engine

Service
List of Workshop Manual Repair GroupsList of Workshop Manual
Repair GroupsList of Workshop Manual Repair Groups
Repair Group
00 - Technical data
30 - Clutch
34 - Controls, housing
35 - Gears, shafts
39 - Final drive - differential
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Technical information should always be available to the foremen and mechanics, because their
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All rights reserved.

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

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2007 ➤ , Golf Variant 2010 ➤ , Jetta nte 2005 ➤ , Jetta 2011 ➤
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Contents
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00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
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1 Gearbox identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
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1.1 Location on gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
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1.2 Identification code, assembly allocation and capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Overview - power transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
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3 Calculating overall gear ratio „i“ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4 General repair notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
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4.1 Contact corrosion! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

4.2 Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
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4.3 Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
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30 - Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
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1 Fault finding, power transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
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2 Repairing clutch mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
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2.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
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2.2 Assembly overview - pedal cluster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
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2.3 Removing and installing over-centre spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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2.4 Removing and installing clutch pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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2.5 Removing and installing mounting bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
2.6 Removing and installing master cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
2.7 Removing and installing clutch position sender G476 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
2.8 Assembly overview - hydraulics (LHD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
2.9 Assembly overview - hydraulics (RHD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
2.10 Bleeding clutch system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
3 Repairing clutch release mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
3.1 Removing pipe/hose line and bleeder from and installing on slave cylinder . . . . . . . . . . . . 40
3.2 Removing and installing slave cylinder with release bearing . . . . . . . . . . . . . . . . . . . . . . . . 40
3.3 Removing and installing pipe/hose line or plastic line . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
3.4 Renewing input shaft seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
4 Repairing clutch - vehicles with turbo diesel engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
4.1 Determining clutch manufacturer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
4.2 Removing and installing „Sachs“ clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
4.3 Repairing „Sachs“ clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
4.4 Removing and installing „LuK“ clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
4.5 Repairing „LuK“ clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
5 Repairing clutch - vehicles with petrol engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
5.1 Repairing clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
5.2 Removing and installing clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
34 - Controls, housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
1 Repairing selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
1.1 Installation position of selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
1.2 Overview of selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
1.3 Removing and installing gear knob and frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
1.4 Removing and installing gaiter with gear knob and noise insulation . . . . . . . . . . . . . . . . . . 62
1.5 Repairing gear lever and selector housing (through 10.06) . . . . . . . . . . . . . . . . . . . . . . . . 64
1.6 Repairing gear lever and selector housing (from 11.06) . . . . . . . . . . . . . . . . . . . . . . . . . . 66
1.7 Assembly overview - removing and installing selector cables . . . . . . . . . . . . . . . . . . . . . . 71
1.8 Plastic relay lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
1.9 Removing and installing selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
1.10 Removing and installing gear selector cable and gate selector cable . . . . . . . . . . . . . . . . 80
1.11 Adjusting selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Contents i
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤
6-speed manual gearbox 02Q - Edition 06.2010
2 Removing and installing gearbox in vehicles with turbo diesel engine . . . . . . . . . . . . . . . . 85

2.1 Removing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
2.2 Transporting gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
2.3 Installing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
2.4 Specified torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
3 Removing and installing gearbox, vehicles with petrol engine . . . . . . . . . . . . . . . . . . . . . . 106
3.1 Removing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
3.2 Transporting gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
3.3 Installing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
3.4 Specified torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
4 Checking gearbox oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
5 Dismantling and assembling gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
5.1 Overview - rear final drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
5.2 Assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
5.3 Removing and installing gearbox housing and selector mechanism . . . . . . . . . . . . . . . . . . 130
5.4 Removing and installing input shaft, output shafts, differential and selector rods . . . . . . . . 132
5.5 Assembly order, gearbox »without« retaining ring A for input shaft sealing cover . . . . . . . . 134
5.6 Assembly order, gearbox »with« retaining ring A for input shaft sealing cover . . . . . . . . . . 145
6 Repairing gearbox housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
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7 Repairing clutch housing . . . . . .ol.ks.w.a.g. . . . . . . . . . . . . . d. o.e.s n. o. . . . . . . . . . . . . . . . . . . . . . 167
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8 Repairing selector unit . . .ris.ed. b. . . . . . . . . . . . . . . . . . . . . . . . . . . .ar.an. t . . . . . . . . . . . . . . . . . 172
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Renewing oil seal for selector shaft . . . . . . . . . . . . . . . . . . . . . . . . . . e.or.a. . . . . . . . . . . . . . 173
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9 Repairing selector forks
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35 - Gears, shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
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1 Input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
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1.1 Dismantling and assembling input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
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2 Output shaft for 1st through 4th gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
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2.1 Assembly overview - output shaft for 1st through 4th gears . . . . . . . . . . . . . . . . . . . . . . . . 185
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2.2 Dismantling and assembling output shaft for 1st through 4th gears . . . . . . . . . . . . . . . . . . 187
2.3 Adjusting output shaft for 1st through 4th gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
3 Output shaft for 5th, 6th and reverse gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . rrectness of i 211
3.1 Dismantling and assembling output shaft for 5th, 6th and reverse gears . . . . . . . . . . . . . . 211
3.2 Adjusting output shaft for 5th, 6th and reverse gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
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39 - Final drive - differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227

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1 Renewing flange shaft oil seals with gearbox installed . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227

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1.1 Renewing oil seal for left flange shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227

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1.2 Renewing seal for right flange shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229

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2 Adjustment overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232

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3 Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
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3.1 Dismantling and assembling differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
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3.2 Adjusting differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
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ii Contents

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1 Gearbox identification
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The 6-speed manual gearbox 02Q is installed in the Jetta 2005 ►,
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Allocation ⇒ page 1
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1.1 Location on gearbox
Code letters and date of manufacture -arrow 1- manual gearbox
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Identification code and date of gearbox manufacture -arrow-

Example: GRF 25 11 3
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Identification Day Month Year (2003)
code of manufacture
Additional data provide information about the production facility.
Note
The gearbox code also appears on the vehicle identification

plates.
1.2 Identification code, assembly allocation and capacities

Manual gearbox 6-speed 02Q
Identification code GRF GVT GXC
Manufactured from 05.05 05.05 07.06
to 11.05 11.05 07.06
1. Gearbox identification 1

Identification code GRF GVT GXC
Allocation Model Jetta 2005 ► Jetta 2005 ► Jetta 2005 ►
Golf Variant 2007 ► Golf Variant 2007 ► Golf Variant 2007 ►
Engine 2.0 l - 103 kW 2.0 l - 147 kW 2.0 l - 125 kW
turbo diesel turbo FSI turbo diesel
Ratio: Z2 : Z1 Final drive I 1) 69 : 20 = 3.450 71 : 18 = 3.944 71 : 18 = 3.944
Final drive II2) 69 : 25 = 2.760 71 : 23 = 3.087 71 : 23 = 3.087
Capacity of manual gearbox 2.3 l 2.3 l 2.3 l
Drive shaft flange ∅ 107 mm 107 mm 107 mm
1)Final drive for 1st to 4th gears
2)Final drive for 5th and 6th gears and reverse gear
• The following data can be found in the ⇒ Electronic parts catalogue „ETKA“ .
♦ Individual gear ratios
♦ Specification for gear oil
♦ Allocation of clutch plate and pressure plate

Identification code HDV HVS KNQ
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Allocation by Model
Vol Jetta 2005 ► not
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1.9 l - 77 kW
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Ratio: Z2 : Z1 Final drive I1) 69 : 20 = 3.450 70 : 19 = 3.684 72 : 17 = 4.235

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69 : 25 = 2.760 70 : 24 = 2.917 72 : 22 = 3.273

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Final drive II2)

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1)
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Final drive for 1st to 4th gears

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Identification code KNS KNU KNY
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Allocation Model Jetta 2005 ► Jetta 2005 ► Jetta 2005 ►

Golf Variant 2007 ► Golf Variant 2007 ►
2 Rep. gr.00 - Technical data


Identification code KNS KNU KNY
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Engine wage kW
2.0 ollk-s100 2.0 l - 147
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Final drive II2) 69 : 25 = 2.760 71 : 23 = 3.087 70 : 24 = 2.917
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Identification code KRM KXZ KZS
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Allocation Model Jetta 2005 ► Co Jetta 2005 ► py Jetta 2005 ►
Golf Variant 2010 ► Golf Variant 2007 ► Golf Variant 2007 ►
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2.0 l - 103 kW 2.0 l - 125 kW 2.0 l - 155 kW
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turbo diesel turbo diesel 2.0 l - 147 kW
Ratio: Z2 : Z1 Final drive I1) 69 : 20 = 3.450 70 : 19 = 3.684 70 : 19 = 3.684
Final drive II2) 69 : 25 = 2.760 70 : 24 = 2.917 70 : 24 = 2.917

Identification code LHD LNN NFN
to
Allocation Jetta 2005 ► Model Golf Variant 2010 ► Jetta 2005 ►
Jetta 2011 ►
Engine 2.0 l - 100 kW 1.6 l - 77 kW 2.0 l - 125 kW
turbo diesel turbo diesel turbo diesel
1. Gearbox identification 3

Identification code LHD LNN NFN
Final drive II2) 69 : 25 = 2.760 72 : 22 = 3.273 70 : 24 = 2.917
Capacity of manual gearbox 2.3 l 2.3 l
2.3 l
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Drive shaft flange ∅ 107y Vmm
olks 107 mm s not gu 107 mm
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Final drive for 1st to 4th gears ris nte
2) tho e or
Final drive for 5th and 6th gears and a reverse gear
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Identification code NFP MDL
rrectness of i
Manufactured from 05.10 11.09
to
cial p
Allocation Model Golf Variant 2010 ► Jetta 2011 ►
nform
Engine 2.0 l - 103 kW 2.0 l - 155 kW
mer
turbo diesel
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Ratio: Z2 : Z1 Final drive I 1) 69 : 20 = 3.450 70 : 19 = 3.684
o
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Final drive II2) 69 : 25 = 2.760 70 : 24 = 2.917
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Capacity of manual gearbox 2.3 l 2.3 l

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Drive shaft flange ∅ 107 mm 107 mm
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Final drive for 5th and 6th gears and reverse gear
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2 Overview - power transmission

Designation
-Arrows- indicate direction of travel.
1 - Engine
2 - Clutch
3 - Manual gearbox
4 - Input shaft
5 - Output shaft for 5th, 6th and
reverse gears
6 - Output shaft for 1st through
4th gears
7 - Differential
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Gears
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-Arrows- indicate direction of travel.

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2. Overview - power transmission 5

I - 1st gear agen

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III - 3rd gear aut
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IV - 4th gear
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V - 5th gear
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VI - 6th gear
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R - Reverse gear
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A - Final drive
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3 Calculating overall gear ratio „i“

Example:
6th gear Final drive
Drive gear ZG1 = 43 ZA1 = 25
Driven gear ZG2 = 35 ZA2 = 69
i = ZG2 : ZG1 1)
iG = Gear ratio = ZG2: ZG1= 35 : 43 = 0.814
iA = Final drive ratio = ZG2 : ZG1 = 69 : 25 = 2.760
itotal = Overall ratio = iG x iA = 0.814 x 2.760 = 2.247
Volkswa n AG. gen AG
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1) Z1 = No. of teeth on driving gear, Z2 = V olksof teeth on driven gear
No. not
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3. Calculating overall gear ratio „i“ 7

4 General repair notes

To ensure flawless and successful gearbox repairs, the greatest
care and cleanliness as well as the use of good and proper tools
are essential. Of course, the basic rules for safety also apply dur‐
ing repair work.
A number of instructions generally applicable to the various repair
procedures - which were previously repeated a number of times
at various places in the workshop manual are summarised under
the topic „components“ ⇒ page 8 . They apply to this workshop
manual.
4.1 Contact corrosion!

♦ The gearbox housing and clutch housing are made of a mag‐
nesium alloy.
♦ Bolts and other components in direct contact with the gearbox
AG. Volkswagen AG d
have a surface matched to it. lksw
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♦ If the incorrect componentsrise(bolts,
db nuts, washers and so on) ran
tee
are used, contact corrosion
th will develop. The gearbox housing
o
or
and clutch housing will au
ss be damaged.
ac
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nl
♦ Always install parts listed in the ⇒ Electronic parts catalogue
pt
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„ETKA“ .
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4.2 Special tools
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For a complete list of special tools used in this workshop manual,
ole,
see ⇒ Workshop equipment and special tools .
spec
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4.3 Components
4.3.1 Gearbox rrectness of i

♦ When installing the manual gearbox, ensure that the dowel
cial p
sleeves between the engine and gearbox are correctly seated.

nform
mer
♦ When installing mounting brackets or waxed components,

atio
clean the contact surfaces. Contact surfaces must be free of

m
r co
wax and grease.

n in
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♦ Allocate bolts and other components using ⇒ Electronic parts

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catalogue „ETKA“ .
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♦ Following installation, check gear oil level ⇒ page 126 .

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4.3.2 O-rings, seals, gaskets and sealants

♦ Thoroughly clean housing joint surfaces before applying seal‐
ant .
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♦ Apply sealant -AMV 188 200 03- uniformly but not too thick.
Vol
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♦ Always renew O-rings, seals and gaskets. oris nte
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♦ When seals have been removed, check contact ss surface on c
housings or shafts for burrs and damage and rectify as nec‐
ce
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♦ Before installing radial shaft seals, lightly oil outer diameter
ab
ility
and half-fill space between sealing lips -arrow- with sealing
ot p
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grease -G 052 128 A1- .
is n
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ole,
♦ The open side of the oil seal faces the side with fluid filling.
spec
♦ Press in new oil seals so that sealing lip does not contact the urposes, in part or in wh
t to the co
shaft in the same place as the old seal (make use of insertion
depth tolerances).
rrectness of i
♦ Lightly oil O-rings before installing; this prevents the rings be‐
ing crushed when inserted.
♦ After renewing seals and gaskets, check oil level in gearbox
cial p
and replenish if necessary ⇒ page 126 .
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mer
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4.3.3 Locking devices
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tion
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♦ Do not overstretch retaining rings.
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♦ Always renew retaining rings which have been damaged or
um
for
overstretched.
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♦ Retaining rings must locate properly in grooves.
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♦ Renew spring pins. Installation position: slit -A- should be in co Vo
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4. General repair notes 9

4.3.4 Nuts and bolts

♦ Loosen and tighten securing bolts and nuts for covers and
housings diagonally.
♦ Do not cant especially delicate parts, such as clutch pressure
plates. Loosen and tighten bolts and nuts in stages in a diag‐
onal sequence.
♦ Torque settings are specified for unoiled bolts and nuts.
♦ Always renew self-locking bolts and nuts.
♦ Ensure with threaded connections that contact surfaces as
well as nuts and bolts are rewaxed only after assembly, if nec‐
essary.
♦ Threads of bolts secured with locking fluid must be cleaned
with a wire brush. Then insert bolts with locking fluid -
AMV 185 101 A1- .
♦ Clean threaded holes in which self-locking bolts or bolts with
locking fluid have been inserted, e.g. with a thread chaser.
Otherwise there is a danger that the bolts may shear when
removed again.
4.3.5 Bearings
♦ Install needle bearings with lettered side (thicker metal) to‐
wards fitting tool.
♦ Lubricate all gearbox bearings with gear oil before installing.
♦ Tapered roller bearings fitted to one shaft must be renewed as
a set. Use same make of bearings.
♦ Heat inner races to about 100° C with the inductive heater -
VAS 6414- before installing. en AG. V
olkswagen AG
ag does
ol ksw not
♦ Do not interchange outer or inner
y V races of bearings of the gu
db ara
same size. The bearings are
ris matched in pairs.
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4.3.6 Shims ss c
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pt
♦ Measure shims at several points with a micrometer. The var‐

du
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ious thicknesses make it possible to achieve the exact shim

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thickness required.
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♦ Check for burrs and damage.

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♦ Install only flawless shims.

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4.3.7 Synchro-rings
♦ Do not interchange. When reusing synchro-rings, always fit to
the same gear.
♦ Check for wear and renew if necessary.
♦ Check grooves -arrow 1- of synchro-ring -A- and inner ring for
flat spots (worn grooves).
♦ If synchro-rings are coated, coating must not be damaged.
♦ If an intermediate ring -B- is installed, check the outer friction
surface -arrow 2- and inner friction surface -arrow 3- of this
intermediate ring for »scoring« and »signs of abnormal wear«.
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♦ Check cone of synchromeshed yV
gear
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s no
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of abnormal wear«. isedb ara
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♦ Moisten synchromesh aumechanism with gear oil before instal‐
t or
ac
ling. ss
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4.3.8 Gears, synchro-hubs, inner races for
hole
spec
es, in part or in w
synchromeshed gears
t to the co
♦ Heat inner races for synchromeshed gear to about 100° C with
the inductive heater -VAS 6414- before installing.
rrectness of i
♦ Heat synchro-hub with inductive heater -VAS 6414- to approx.
l purpos
100 °C before installing. Press in to stop when installing so

there is no axial clearance.
n
ercia
f
♦ Heat gears with inductive heater -VAS 6414- to approx. 100 °
orm
C before installing. Press in to stop when installing so there is
m
atio
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no axial clearance. n in
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♦ Observe installation position.

thi
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4.3.9 Synchromeshed gears

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♦ After assembly, check synchromeshed gears for slight play, or
py Co
Co py
for freedom of movement.
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4.3.10 Clutch
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♦ Ensure that the pressure plate does not cant: loosen and tight‐
en bolts diagonally and in several gradual stages.
♦ If the clutch has burnt out, thoroughly clean the clutch housing
as well as the friction surface of flywheel with a cloth to reduce
the smell of burnt linings.
4. General repair notes 11

30 – Clutch
1 Fault finding, power transmission
– Refer to ⇒ Fault finding, power transmission; Rep. gr. 30 ;
Complaints about clutch and clutch mechanism and ⇒ Fault
finding, power transmission; Rep. gr. 34 ; Complaints about
selector mechanism
AG. Volkswagen AG d
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12 Rep. gr.30 - Clutch

2 Repairing clutch mechanism
2.1 Overview
Note n AG. Volkswagen AG do

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Volks ot g
♦ Before disconnecting battery, d obtain code for radio units having anti-theft
by ua
ran coding.
rise tee
o
♦ With ignition switched aoff,
u disconnect battery ⇒ Electrical system; Rep.r agr. 27 ; Disconnecting
th o and con‐
necting battery . ss c
ce
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nl
pt
♦ When reconnecting battery, refer to ⇒ Electrical system; Rep. gr. 27 ; Disconnecting and connecting battery .
du
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♦ Lubricate all bearings and contact surfaces with grease -G 000 450 02- .
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I - Assembly overview - pedal
spec
cluster ⇒ page 14
t to the co
II - Assembly overview - hy‐
draulics (LHD) ⇒ page 34
rrectness of i
III - Assembly overview - hy‐
draulics (RHD) ⇒ page 36
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mer
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2. Repairing clutch mechanism 13

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gen AG
2.2 Assembly overview - pedal clusterwa does
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1 - Bulkhead ss
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2 - Seal
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❑ Always renew
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❑ Between mounting
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bracket and bulkhead
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❑ Self-adhesive
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❑ Bond to mounting
bracket
rrectness of i
3 - Mounting bracket
❑ For mounting clutch
pedal
cial p
nform
❑ Is provided with damp‐
mer
ing in some equipment
a
variants ⇒ page 15
m
tio
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❑ Removing and installing
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⇒ page 23
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4 - Bolt
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5 - Over-centre spring
Co
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⇒ page 15 co Vo
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6 - Bearing bush
AG.
7 - Pivot pin
8 - Clutch pedal
⇒ page 19
9 - Retainer
❑ To remove and install,
separate master cylin‐
der from clutch pedal
⇒ page 19
10 - Seal
❑ Always renew
❑ Between master cylinder and mounting bracket
11 - Master cylinder
❑ Removing and installing after removal of mounting bracket ⇒ page 29
12 - Clutch position sender -G476-
❑ Removing and installing ⇒ page 30
❑ Can be checked using „guided fault finding“ of vehicle diagnostic tester
❑ The clutch position sender -G476- is identified as clutch pedal switch -F36- in „guided fault finding“
13 - Clip
❑ Pull out clip to stop to remove and install pipe/hose line
14 - Supply hose
❑ Rubber
❑ From 12.05, plastic ⇒ page 35
15 - Hexagon nut, 25 Nm
❑ Self-locking

❑ Qty. 3
❑ For mounting bracket on bulkhead
❑ Always renew gen AG. Volkswagen AG
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16 - Hexagond bnut,
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❑ Always
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renew eo
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17 - Stop
ss c
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❑ For clutch pedal
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Mounting bracket with damping -arrows-
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2.3 Removing and installing over-centre
cted agen
Prote AG.
spring
Special tools and workshop equipment required
♦ Release tool -T10178-
2.3.1 Removing
Vehicles with knee airbag
Note
The installation location of the knee airbag is above the pedal

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

theft code.

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

tem; Rep. gr. 27 ; Disconnecting and connecting battery .
Continuation for all
– Push driver seat as far back as possible and put steering wheel
in highest position.
– Remove driver side footwell cover and driver side left trim
panel ⇒ General body repairs, interior; Rep. gr. 68 ; Com‐
partments, covers and trim panels .
– Remove bracket for knee airbag together with crash bar ⇒
Interior equipment; Rep. gr. 69 ; Airbag; Removing and in‐
stalling knee airbag bracket .
Vehicles without knee airbag
– Remove crash bar -1- from in front of clutch pedal by removing
nuts -2-.
lkswage es n
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oris tee
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a ac
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pt
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– If fitted, remove damping -arrow- from lower area of clutch
spec
pedal mounting bracket.
t to the co
rrectness of i
cial p
nform
mer
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– To do this, remove lock washers -A- for damping.

– Pull off damping.

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Golf Variant 2007 ➤ , GolfeVariantor
ac
2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤
ss 6-speed manual gearbox 02Q - Edition 06.2010
ce
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pt
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– Push damping upwards in area of upper securing nut -1-
itte
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above clutch pedal -A- in -direction of arrow-.
erm
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– Unbolt clutch pedal -1- from mounting bracket -3- by removing
Co py
t. rig
nut -2- and pulling out bolt -5-.
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cop by
Vo
lksw
cted agen
Prote AG.
Note
The clutch pedal remains hooked to operating rod of master cyl‐

inder.
– Swing clutch pedal down slightly and remove over-centre

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

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

while holding end of spring with assembly tool -T10178- in in‐
stallation position.
wage es n
Volks ot g
y ua
db ran
• Receptacleo-arrow-
ris
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for tip -A- of clutch pedal must stand tee ver‐
tically. auth or
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– Insert tip -A- of clutch pedal in bearing recess of over-centre ce
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– Depress clutch pedal slightly, push bolt through and tighten

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self-locking nut to specified torque ⇒ page 19 .
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es, in part or in w
t to the co
rrectness of i
Some cars have damping -arrow- on the clutch pedal mounting

bracket.
l purpos
– Return it to installation position.

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ercia

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

n Aand
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Vehicles with knee airbag ho
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au ac
– Install bracket for knee airbag bar ⇒ Inte‐ together
ss with crash
rior equipment; Rep. gr. 69 ; Airbag; Removing and installing
ce
le
un
pt
knee airbag bracket .
an
d
itte
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ab
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– Install driver side footwell cover and driver side left trim panel
, is n
h re
⇒ General body repairs, interior; Rep. gr. 68 ; Compartments,
hole
covers and trim panels .
spec
es, in part or in w
t to the co
– If disconnected, connect battery ⇒ Electrical system; Rep. gr.
27 ; Removing and installing battery .
rrectness of i
2.3.3 Specified torques
l purpos
Component Nm
n
ercia
Clutch pedal to mounting bracket 25
fo
♦ Renew self-locking nuts
rmat
m
com
ion
Crash bar to steering column mounting 10
in
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bracket
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2.4 Removing and installing clutch pedal
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Special tools and workshop equipment required t. Co py
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♦ Pliers -T10005-
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♦ Release tool -T10178-

2.4.1 Removing
Note
The installation location of the knee airbag is above the pedal agen
AG. Volkswagen AG d
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cluster. yV
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– First check whether a coded radio is fitted. If so, obtain
au
th anti- or
ac
theft code. ss
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nl
pt
– With ignition switched off, disconnect battery earth strap ⇒
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Electrical system; Rep. gr. 27 ; Disconnecting and connecting
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battery .
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Continuation for all ot p
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– Push driver seat as far back as possible and put steering wheel
spec
in highest position.
t to the co
rrectness of i
cial p
nform
mer
a
m
tion
co
in t
or
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nuts -2-.
iva
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pr
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or

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en
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t. Co py
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AG. Volkswagen AG d
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– To do this, bremove
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ol lock washers -A- for damping.
not
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– Pull off
thordamping. eo
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spec
t to the co
rrectness of i
cial p
nform
mer
a
m
tio
o
n in
r c
te o
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for
en
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t. Co py
rig
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Prote AG.
– Unbolt clutch pedal -1- from mounting bracket -3- by removing

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

– Release clutch pedal from master cylinder with pliers -

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

– Press retainer into notch in clutch pedal -3- until it can be heard
to engage.
G. Volkswagen AG d
– Insert over-centre spring -2- in mounting bracket from above lkswagen A oes
not
while holding end of spring with assembly tool -T10178- in in‐
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ility
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spec
t to the co
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22
by c lksw
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Rep. gr.30 - Clutch
agen
Prote AG.

• Receptacle -arrow- for tip -A- of clutch pedal must stand ver‐
tically.
– Insert tip -A- of clutch pedal in bearing recess of over-centre
spring.
– Depress clutch pedal slightly, push bolt through and tighten
self-locking nut to specified torque ⇒ page 23 .
Some cars have damping -arrow- on the mounting bracket/clutch

pedal.
– Return it to installation position.
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spec
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t to the co
– Install crash bar -1- in front of clutch pedal by screwing on and
rrectness of i
tightening nuts -2-.
l purpos

– Install bracket for knee airbag together with crash bar ⇒ Inte‐
n
ercia
fo
rm
m
atio
com
n in

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te o
thi
sd
iva
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rp
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fo
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covers and trim panels . i t.

py Co
t. Co py
rig
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by lksw
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Component Nm
Clutch pedal to mounting bracket 25
♦ Renew self-locking nuts

bracket
2.5 Removing and installing mounting

bracket

♦ Hose clamps -3094-
♦ Hose clip pliers -VAS 6362-
AG. Volkswagen AG d
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♦ Sealing tool
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ility
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spec
t to the co
rrectness of i
2.5.1 Removing
cial p
nfo
LHD
mer
rmatio
m

o
n in
c
theft code.
or
thi
te
sd
a

iv
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cu

or
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f
battery .
en
ng
i t.
py Co
Co
– Remove complete air filter housing if it is near battery ⇒ Rep.
py
t. rig
gh
gr. 23 ; Repairing diesel direct injection system or ⇒ Rep. gr.
ht
yri by
op Vo
24 ; Repairing injection system . by c lksw
cted agen
Prote AG.
– Remove battery and battery tray ⇒ Electrical system; Rep. gr.
27 ; Battery; Removing and installing battery .

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

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

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

VAS 6362- and pull supply hose off master cylinder.
– In addition, for disconnecting, you can close it with the sealing
tool -T10249/1- (⇒ figure above).
– Release securing clip -2- using screwdriver
AG. Volksor
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agen
and pull pipe/hose line or plastic
Vol
ksw line -1- off master cylinder.
oes
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– Unclip clutch position rissender -G476- from master cylinder
e nte
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-arrow- and remove
au with electrical connector attached -4-.
t ra
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Note
itte
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ab
ility
When performing work in the footwell, put cloths on the carpet to

ot p
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protect it from possible brake fluid spills.

is n
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spec

t to the co

rrectness of i

cial p
nform

mer
a
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co
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or
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ate
do
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or
f
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t.
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Cop py
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rig ht
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by lksw
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Prote AG.


nuts -2-.

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

t to the co
– Pull off damping.

rrectness of i
cial p
nform
mer
a
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tion
co
in t
or
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t. Co py
rig
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ab
ility
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spec
t to the co
rrectness of i
– Remove nuts -2-.
cial p
nform
– Remove mounting bracket -1-.
mer
a
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thi
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for
en
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t.
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Cop py
ht. rig
rig ht
py by
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by lksw
cted agen
Prote AG.
2.5.2 Installing
Note
♦ Renew self-locking nuts.

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

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

bracket.
wage es n
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ss
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nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
– Install crash bar -1- in front of clutch pedal by screwing on and
rrectness of i
tightening nuts -2-.
– Install bracket for knee airbag together with crash bar ⇒ Inte‐
cial p
nform
mer

atio
m
r co

n in
o
thi
e
t
sd
ir va

o
p
cum
or
covers and trim panels .

f
en
ng
t.
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Cop py
ht. rig
– Push pipe/hose line or plastic line -1- with seal -2- onto con‐
rig ht
py by
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nection of master cylinder -4- until securing clip -3- engages by c lksw
cted agen
audibly. Prote AG.
– Test line by tugging on it.

– After removing hose clamp up to 25 mm ∅ -3094- , return
supply hose to its original shape, if necessary.
– Bleed clutch system ⇒ page 37 .
LHD
– Install battery tray and battery ⇒ Electrical system; Rep. gr.
27 ; Removing and installing battery .
24 ; Repairing injection system .
– Reconnect battery and perform work required after connecting
battery ⇒ Electrical system; Rep. gr. 27 ; Disconnecting and
connecting battery .

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

bracket

2.6 Removing and installing master cylinder

♦ Pliers -T10005-
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es, in part or in w
2.6.1 Removing
t to the co
– Remove mounting bracket ⇒ page 23 .
rrectness of i
– Release retainer for master cylinder operating rod using pliers
-T10005- .
l purpos
nform
mercia
at
m
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o
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ate
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t. Co py
rig
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– Insert spacer -A- between clutch pedal and stop and press
c Vo
by lksw
cted
clutch pedal to spacer.
agen
Prote AG.
♦ Length of spacer = about 40 mm (e.g. 1/2" socket).
– Release securing bar -B- and pull master cylinder out of

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

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

sender -G476-

♦ Hose clamps -3094-
2.7.1 Removing
LHD
theft code.
– With ignition switched off, disconnect battery earth strap .⇒Volkswage
Electrical system; Rep. gr. 27 ; Disconnecting and waconnecting
gen AG n AG d
oes
battery . Volks not
gu
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ise
– Remove complete air filter housing if itthois
r
near battery ⇒ Rep. tee
or
gr. 23 ; Repairing diesel direct injection
ss au
system or ⇒ Rep. gr. ac
ce
e
nl
pt
du
an
– Remove battery and battery tray ⇒ Electrical system; Rep. gr.
itte
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27 ; Battery; Removing and installing battery .
erm
ab
ility
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Right-hand drive
wit
is n
h re
– In vehicles with particle filter, remove shielding -A- from parti‐
ole,
spec
cle filter ⇒ Rep. gr. 26 ; Parts of exhaust system; Assembly
overview - front exhaust pipe with particle filter .
t to the co
An insulation mat is installed in conjunction with some engines.
rrectness of i
cial p
nform
mer
atio
m
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n in
o
thi
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sd
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– Remove heat shield from pipe/hose line -arrows-.

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p
cum
for
en
ng
i t.
py Co
t. Co py
rig
gh ht
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lksw
b
cted agen
Prote AG.

AG. Volkswagen AG d
agen oes
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Golf Variant 2007 ➤ , Golf
hor Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011
is e nte ➤
eo
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6-speed manual gearboxau 02Q - Edition 06.2010 ra
c
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un
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an
d
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If a pipe/hose line -1- with a round component is installed directly
rm
ab
pe
beneath the master cylinder, the pipe/hose line must be removed.
ility
ot
wit
, is n
h re
hole
Note
spec
es, in part or in w
t to the co
During the following work, ensure that no brake fluid lands on
rrectness of i
l purpos
– Place a lint-free cloth under the master cylinder.
n
ercia
form
m
atio
com
n in
r
te o
thi
sd
iva
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rp
cu
fo
m
en
ng
t.
– Clamp off supply hose to master cylinder using hose clamp to
yi Co
op py
25 mm ∅ -3094- . t. C rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Release securing clip -2- with a screwdriver or a pointed object

and pull out of master cylinder to stop.
– Pull pipe/hose line -1- or plastic line out from master cylinder
and seal.
– Disconnect electrical connector -4-.
– Unclip clutch position sender -G476- from master cylinder
-arrow- and remove.
Note
Disregard item -3-.
2.7.2 Installing

Note
♦ Renew hose clips.

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

– Push pipe/hose line -1- or plastic line with seal -2- onto con‐
nection of master cylinder -4- until securing clip -3- engages
audibly.
– Test pipe/hose line by tugging on it.
Right-hand drive
– In vehicles with particle filter, install shielding -A- on particle

filter ⇒ Rep. gr. 26 ; Parts of exhaust system; Assembly over‐
view - front exhaust pipe with particle filter . agen
AG. Volkswagen AG d
o
ksw es n
LHD Vol ot g
d by ua
ran
e
ris tee
– Install battery tray and battery ⇒ Electrical usystem;
tho Rep. gr. or
27 ; Removing and installing battery . ss a ac
ce
e
nl
pt
du
an
itte
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erm

ab
ility
ot p
– Reconnect battery and perform work required after connecting

wit
is n
battery ⇒ Electrical system; Rep. gr. 27 ; Disconnecting and

h re
ole,
connecting battery . spec

t to the co
rrectness of i
cial p
nform
mer
a
m
tion
co
in t
or
his
ate
do
iv
pr
cum
or
f
en
ng
i t.
py Co
t. Co py
rig
gh ht
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cop by
Vo
lksw
cted agen
Prote AG.

2.8 Assembly overview - hydraulics (LHD)
1 - Brake fluid reservoir

2 - Spring-type clip
❑ Not fitted in all vehicles
3 - Supply hose
❑ Rubber
❑ From 12 05, plastic
⇒ page 35
4 - Master cylinder
⇒ page 29
5 - Clip
❑ Pull out clip to stop to re‐
move and install pipe/
hose line or plastic line
❑ Pulled out to side on
some master cylinders
6 - Seal / O-ring
❑ Pull onto line connection
❑ Insert with brake fluid
❑ Seals/O-rings are adap‐
ted to configuration of
line connection
⇒ page 35
❑ Allocation ⇒ Electronic
AG. Volkswagen AG d
parts catalogue „ETKA“ksw
agen oes
n ol ot g
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7 - Retainer ed
b ran
oris tee
❑ To removeautand
h install, or
ac
separatessmaster cylin‐
ce
e
nl
pt
du
⇒ page 19
an
itte
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erm
ab
8 - Clutch pedal
ility
ot p

wit
is n
⇒ page 19
h re
ole,
spec
t to the co
❑ Self-locking
❑ Qty. 3
rrectness of i
❑ Always renew
10 - Pipe/hose line
cial p
❑ Allocation ⇒ Electronic parts catalogue „ETKA“

nform
mer
❑ To remove, remove battery and battery tray ⇒ Electrical system; Rep. gr. 27 ; Removing and installing
a
m
battery .
io
r co
n in

o
thi
te
s
a
do
ir v
11 - Bracket
p
cum
or
❑ For pipe/hose line ⇒ Item 10 (page 34)

f
en
ng
i t.
py Co
❑ Secured to body t. Co py
rig
gh
❑ Hidden by engine/gearbox mounting
ht
yri by
cop Vo
lksw
❑ Retainer identification ⇒ page 36
by
cted agen
Prote AG.

6-speed manual
en AG. V
gearbox 02Q
olkswagen AG
- Edition 06.2010
ag does
ksw not
Vol gu
12 - Plastic line ed
by ara
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ris
tho eo
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c
❑ To remove, remove battery and batterysstray ⇒ Electrical system; Rep. gr. 27 ; Removing and installing
ce
e
battery .
nl
pt
du
an
itte
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erm
ab
13 - Bracket
ility
ot p
wit
is n
❑ For plastic line ⇒ Item 12 (page 34)
h re
ole,
❑ Secured to body
spec
t to the co
❑ Retainer identification ⇒ page 36
14 - Seal / O-ring
rrectness of i
❑ Seals/O-rings are adapted to configuration of line connection ⇒ page 35
cial p
nform
mer
atio
m
15 - Breather
r co
n in
o
thi
te
sd
ir va
16 - Clip
o
p
cum
or
❑ Pull out clip to stop to remove and install pipe/hose line or plastic line or bleeder
f
en
ng
t.
yi Co
op
17 - Bleeder valve C py
ht. rig
ht
rig
❑ Bleeding clutch system ⇒ page 37 py by
co Vo
by lksw
cted agen
18 - Dust cap Prote AG.
19 - Slave cylinder
❑ Can be renewed only with gearbox removed
20 - Gearbox
Seals and O-rings for pipe/hose line or plastic line

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

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

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

2 - Seal
❑ For plastic supply hose olks
wage es n
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V
❑ The seals must be loca‐ d by ua
ran
ise
ted in supply hose thor tee
or
au ac
3 - Supply hose ss
ce
e
nl
❑ Made of plastic
pt
du
an
itte
⇒ page 35
y li
erm
ab
❑ May be made of rubber
ility
ot p
wit
is n
4 - Master cylinder
h re
ole,
spec
⇒ page 29
t to the co
5 - Clip
❑ Pull clip out to stop to re‐
rrectness of i
move or install pipe line
❑ Pulled out to side on
some master cylinders
cial p
6 - Seal / O-ring
nform
mer
atio
m

r co
n in
❑ Seals/O-rings are adap‐
o
thi
te
sd
ted to configuration of
ir va
o
line connection
p
cum
or
⇒ page 35
f
en
ng
i t.
py Co
❑ Allocation ⇒ Electronic . Co py
rig
parts catalogue „ETKA“
t
gh ht
yri by
cop Vo
7 - Retainer
by lksw
cted agen
Prote AG.
❑ To remove and install,
separate master cylin‐
⇒ page 19
8 - Clutch pedal
❑ Self-locking
❑ Qty. 3
❑ Always renew

10 - Bracket ksw
age es n
y Vol ot g
❑ Secured to body db ua
ran
ise tee
or
au
th or
ac
ss
11 - Pipe line
ce
e
nl
pt
du
❑ Pipe and hose/pipe line ⇒ Item 13 (page 37) may be in one piece
an
itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
battery .
spec
12 - Seal / O-ring
t to the co
rrectness of i
cial p
13 - Pipe/hose line
nform
mer
❑ Pipe ⇒ Item 11 (page 37) and hose/pipe line may be in one piece
atio
m

r co
n in
o
thi
te
sd
ir va
o
p
c
battery .
um
for
en
ng
t.
yi
14 - Retainer
Co
Cop py
ht. rig
❑ Secured to body opy
rig by
Vo
ht
c lksw
15 - Seal / O-ring
by
cted agen
Prote AG.
16 - Clip
❑ Pull out clip to stop to remove and install pipe/hose line or bleeder.
17 - Bleeder valve
❑ Bleeding clutch system ⇒ page 37
18 - Dust cap
19 - Bleeder connection
20 - Seal / O-ring
21 - Slave cylinder
❑ Can be renewed only with gearbox removed
22 - Gearbox
2.10 Bleeding clutch system


♦ Brake filling and bleeding equipment -VAS 5234- or
♦ Brake filling and bleeding equipment -V.A.G 1869-
Note AG. Volkswagen AG d

agen oes
olksw not
byV gu
ara
Prefilling system is not necessary! ed
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aut ra
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Specifications for brake fluid ⇒ Brake systems; Rep. gr. 47 ; s
ce
e
nl
Bleeding brake system .
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
– Connect brake filling and bleeding equipment -VAS 5234- or

spec
-V.A.G 1869- .
t to the co
To bleed system, use 670 mm bleeder hose -V.A.G 1238/B3- if
necessary.
rrectness of i
– Connect bleeder hose to collector bottle of brake bleeding

equipment.
– Connect bleeder hose -A- to bleeder -arrow-.
cial p
nform
– Pressurise system to 2 bar.

mer
– Open bleeder valve about 1/4 turn.

a
m
tion
co
in t
r
– Move clutch pedal 15 to 20 times quickly by hand from stop to

o
his
te
stop.
a
do
priv
cum
r
– Close bleeder valve.

fo
en
ng
i t.
py Co
– After completing bleeding procedure, when the pressure of . Co py
2 bar is released, operate clutch pedal ten more times by foot.
t rig
gh ht
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cop Vo
by lksw
cted agen
Prote
AG.

3 Repairing clutch release mechanism

♦ Torque wrench -V.A.G 1331-
lkswage es n
o ot g
byV ua
ed ran
oris tee
uth or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
is n
1 - Gearbox
h re
ole,
2 - Input shaft seal
spec
❑ Renewing ⇒ page 43
t to the co
3 - Slave cylinder with clutch
release bearing
rrectness of i
❑ Are one unit and can be
renewed together only
❑ Do not wash out bear‐
cial p
ing; wipe only
nform
mer
❑ Renew noisy bearings
a
together with slave cyl‐
m
tio
r co
n in
inder
o
thi
e
❑ For some slave cylin‐

t
sd
ir va
ders, divided supply line o

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

Slave cylinder -A- with divided supply line

Volkswagen AG
The supply line for some slave cylinders is divided in the area wagof
en AG. does
the -arrow-. Volks not
gu
by d ara
se nte
Allocation ⇒ Electronic parts catalogue „ETKA“ thori eo
u a ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
3.1 Removing pipe/hose line and bleeder
from and installing on slave cylinder
rrectness of i
Removing pipe/hose line or plastic line from and installing on
bleeder
– To remove, release securing clip -2- with a screwdriver or
cial p
pointed object and pull pipe/hose line or plastic line -4- off
nform
bleeder -1-.
mer
a
m
tion
– To install pipe/hose line or plastic line, push onto bleeder con‐
co
in t
nection with O-ring -3- until securing clip engages audibly.
or
his
ate
do
priv
cum
or
f
en
ng
t.
Removing bleeder from and installing on slave cylinder
yi Co
Cop py
ht. rig
– To remove, release securing clip -2- with a screwdriver or rig ht
py by
pointed object and pull bleeder -4- off slave cylinder -1-. co Vo
by lksw
cted agen
Prote AG.
– To install, check O-ring -3- on slave cylinder. Press bleeder
onto slave cylinder connection until securing clip engages au‐
dibly.
– Check by pulling on bleeder.
3.2 Removing and installing slave cylinder

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

can be renewed only together.
Removing
• Remove gearbox.

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

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

– Remove slave cylinder together with release bearing -A-.
Installing
G. Volkswagen
Install in the reverse order of removal,
lksw
agenobserving the A
A
following:
G do
es n
Vo ot g
by ua
• The securing bolts for istheed slave cylinder must be tightened ran
tee
only in small stages.uthor
or
s a ac
Otherwise, the tabs swith the bolt holes may break off.
ce
e
nl
pt
du
– Bolt on slave cylinder with release bearing
an
itte
y li
⇒ Item 4 (page 39) .
erm
ab
ility
ot p
wit
is n
h re
ole,
– Check O-ring -3- on slave cylinder for damage.
spec
– Press bleeder -4- onto slave cylinder connection -1- until se‐
t to the co
curing clip -2- engages audibly.
– Check by pulling on bleeder.
• Install gearbox. rrectness of i

cial p
nform
mer
a
m
tion
co
in t
or
his
ate
do
riv
3.3 Removing and installing pipe/hose line

p
cum
or
f
or plastic line
en
ng
i t.
py Co
Co py
t. rig
gh ht
yri by
cop Vo
♦ Hose clamps to 25 mm -3094-
by lksw
cted agen
Prote AG.

wage es n
Volks ot g
d by ua
ran
ir se tee
Golf Variant 2007 ➤ ,utGolf
ho Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 or ➤
a ac
6-speed manual gearbox
ss 02Q - Edition 06.2010
ce
e
nl
pt
du
Removing
an
itte
y li
erm
ab
– Remove complete air filter housing ⇒ Rep. gr. 23 ; Repairing
ility
ot p
diesel direct injection system or ⇒ Rep. gr. 24 ; Repairing
wit
is n
injection system .
h re
ole,
spec
Note
t to the co
During the following work, ensure that no brake fluid lands on
rrectness of i
– Clamp off supply hose to master cylinder using hose clamp

cial p
n
-3094- .
fo
mer
rm
Remove pipe/hose line or plastic line from master cylinder as fol‐
atio
m
lows:
o
n in
or c
thi
te
sd
iva
o
pr
cu
or
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– Release securing clip -3- using screwdriver or pointed object

and pull off line -1- with O-ring -2-.
Caution
Do not depress clutch pedal after removing slave cylinder.
Remove pipe/hose line or plastic line from bleeder as follows:
– Release securing clip -2- using screwdriver or pointed object

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

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
utGolf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤
ho eo
a ra
ss 6-speed manual gearbox 02Q - Edition 06.2010
c
ce
e
nl
pt
du
an
– Push pipe/hose line or plastic line -1- with O-ring -2- onto con‐
itte
y li
nection of master cylinder -4- until securing clip -3- engages
erm
ab
audibly.
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness of i
cial p
nform
mer
a
m
tio
r co
n in
o
thi
te
sd
ir va
o
p
cu
or
m
f
en
ng
i t.
py Co
– Push line with O-ring -3- onto bleeder connection until secur‐ Co py
t. rig
ing clip engages audibly. gh ht
yri by
cop by
Vo
lksw
– Test line by tugging on it. Prote
cted AG.
agen

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

♦ extractor lever -T20143/1-

♦ Thrust piece -T40008-
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
r
ho eo
♦ Sealing grease -G 052 128 A1- aut ra
ss c
Procedure
ce
e
nl
pt
du
an
• Remove gearbox.
itte
y li
erm
ab
– Remove slave cylinder with release bearing ⇒ page 40 .
ility
ot p
wit
is n
– Lever out seal for input shaft using lever -T20143/1- .
h re
ole,
spec
Note
t to the co
Do not damage running surface of input shaft for oil seal.
rrectness of i
cial p
nform
mer
a
m
tion
co
in t
or
– Half-fill space between sealing lip and dust lip -arrow- with
his
ate
sealing grease -G 052 128 A1- .
do
iv
pr
cum
or
– Lightly moisten outer circumference of oil seal with gear oil.

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

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

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

equipment required
♦ Counterhold -3067-
♦ Torque wrench -V.A.G
1331-
♦ Centring mandrel -T10097-
♦ Grease for clutch plate
splines -G 000 100-
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
se nte
ori eo
th
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness of i
cial p
nform
mer
atio
m
r co
n in
o
♦ For engines having a crankshaft of smaller diameter or having

thi
te
sd
ir va
needle bearings in the crankshaft - ⇒ page 49 centring man‐

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

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

– Remove noise insulation ⇒ General body repairs, exterior;

Rep. gr. 50 ; Noise insulation .
– Remove noise insulation from engine sump if necessary.
Some notches -arrows- are located in lower region of sump be‐
tween engine -A- and gearbox -B-.
– Check outer contour of flywheel through these notches.
wage es n
Volks ot g
d by ua
ran
ir se tee
tho
or
s au ac
s
ce
le
un
pt
an
d
itte
y li
rm
ab
– In addition, a small cover plate -A- can be removed -arrows-
pe
ility
ot
to enable inspection of flywheel's outer contour.
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
n
ercia
form
m
atio
com
Round outer contour -arrows- = Sachs clutch = -A-

n in
r
te o
– Removing and installing Sachs clutch ⇒ page 47 .

thi
sd
iva
– Repairing Sachs clutch ⇒ page 50 .

r
rp
cu
fo
m
en
ng
Outer contour with edges -arrows 1- and, in addition, a circum‐

t.
yi Co
op
ferential crease -arrow 2- = LuK clutch = -B- C py
ht. rig
ht
rig by
or copy Vo
by lksw
cted agen
Prote AG.

Rounded outer contour -arrows 1- and a circumferential crease

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

Removing
– Remove gearbox ⇒ page 85 .
– Use counterhold -3067- to loosen bolts.
– Loosen bolts in small steps and diagonally.
• As bolts are removed, stop -2- with pin -1- must loosen.
– If stop does not loosen, press pin towards dual-mass flywheel.
– Remove pressure plate and clutch plate.
Installing
Note
AG. Volkswagen AG d
agen oes
lksw not
♦ Select clutchby
V plate and pressure plate according
o gu
ara to engine
codeorand
ise ⇒ Electronic parts catalogue „ETKA“
d
nt.e
th eo
u ra
♦ Check
ss
a whether dowel sleeves for aligning engine and c gearbox
are fitted in cylinder block and install if necessary.
ce
e
nl
pt
du
an
♦ If dowel sleeves are not fitted, difficulties shifting gears, clutch

itte
y li
problems and possible noises from the gearbox (rattling of

erm
ab
ility
gears which are not engaged) could occur.

ot p
wit
is n
h re
ole,
spec
Installation position of clutch plate

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

gearbox.
rrectness of i
cial p
nform
mer
a
m
tion
co
in t
or
his
ate
do
priv
cum
or
f
en
ng
t.
yi Co
Cop py
ht. rig
ht
rig by
copy Vo
by lksw
cted agen
Prote AG.

Checking ends of diaphragm spring

• Wear to half the thickness of the diaphragm spring -arrows- is
permitted. n AG. Volkswagen AG do
wage es n
Volks ot g
y ua
edb ran
ris tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
Checking spring connections and riveted connections
es, in part or in w
t to the co
– Check spring connections between pressure plate and cover
for cracks as well as rivet connections for secure seating.
• A pressure plate with damaged spring connections or with
rrectness of
loose rivet connections -arrows- must be renewed.
l purpos
Note
in
ercia
forma
m
♦ Renew clutch plates and pressure plates with damaged or

com
tion
loose rivet connections.
in
r
te o
thi
♦ Select clutch plate and pressure plate according to engine
sd
iva
code and ⇒ Electronic parts catalogue „ETKA“ .
o
r
rp
cu
fo
m
♦ Clean input shaft splines and, on used clutch plates, clean hub
en
ng
t.
yi
splines; remove corrosion and apply only a very thin coat of
Co
Cop py
clutch plate spline grease -G 000 100- to splines. Then move ht. rig
rig ht
clutch plate to and fro on input shaft until hub moves freely on
py by
co Vo
lksw
shaft. Remove excessive grease.
by
cted agen
Prote AG.
♦ Pressure plates are protected against corrosion and greased.

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

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

having an needle bearing -arrow- in the crankshaft
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
Centring clutch disc and removing and installing pressure
auth plate ra
for engines having a crankshaft of smaller diameter or having a
ss c
ce
e
needle bearing -arrow- in the crankshaft
nl
pt
du
an
itte
y li
erm
ab
Note
ility
ot p
wit
is n
h re
Disregard arrows -A- and -B-.
ole,
spec
t to the co
– Push pressure plate onto centralizing pins.
rrectness of i
– Tighten all bolts evenly by hand until bolt heads contact pres‐
sure plate.
– Tighten bolts in small steps diagonally in order not to damage
cial p
centring holes of pressure plate and centring pins of dual-
nform
mass flywheel ⇒ Item 4 (page 50) .
mer
a
– Install gearbox ⇒ page 85 .
m
tio
o
n in
r c
te o
thi
s
a
do
ir v
p
cum
for
en
ng
i t.
py Co
t. Co py
rig
gh ht
yri by
cop by
Vo
lksw
cted agen
Prote AG.

4.3 Repairing „Sachs“ clutch
1 - Dual-mass flywheel
⇒ Rep. gr. 13
❑ Ensure that centring
pins fit tightly
❑ Contact surface for
clutch lining must be
free of grooves, oil and
grease
2 - Clutch plate
❑ Renew only together
with pressure plate
⇒ page 47
❑ Installation position
⇒ page 47
3 - Thrust plate
❑ With adjusting mecha‐
nism
with clutch plate.
❑ Removing and installing n AG. Volkswagen AG do
wage
⇒ page 47 Volks
es n
ot g
by ua
❑ Check ends of dia‐ ir se
d ran
tee
phragm spring au
tho
or
ac
⇒ page 48 ss
ce
le
❑ Check spring connec‐

un
pt
an
d
tions and riveted con‐

itte
y li
nections ⇒ page 48 .
rm
ab
pe
ility
4 - M6 bolt, 13 Nm, M7 bolt,
ot
wit
, is n
20 Nm
h re
hole
spec
es, in part or in w
❑ Loosen or tighten diagonally in small steps
t to the co
4.4 Removing and installing „LuK“ clutch rrectness of
l purpos
Removing
in
ercia
forma

m
com
tion

in
r
te o
thi

sd
iva
o
r
rp
cu
Installing
fo
m
en
ng
t.
yi Co
Install in the reverse order of removal, observing the following: ht. Cop py
rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Note

♦ Check whether dowel sleeves for aligning engine and gearbox

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

permitted.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
th
au ra
Checking springssconnections and riveted connections c
ce
le
un
pt
– Check spring connections -arrows A- for damage and riveted

an
d
itte
connections -arrows B- for secure seating.

y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
n
ercia
form
m
atio
com
n in
r
te o
thi
sd
iva
o
r
rp
cu
fo
m
en
ng
i t.
py Co
t. Co py
rig
gh ht
yri by
cop by
Vo
lksw
cted agen
Prote AG.

Checking position of adjusting mechanism with new pressure

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

♦ Renew pressure plate and clutch plate together only.
clutch plate spline grease -G 000 100- to splines. Then move
AG. Volkswagen AG d
agen oes
– Reverse counterhold tool -3067- for installation. y Volksw not
gu
db ara
ir se nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
having an needle bearing -arrow- in the crankshaft rrectness of i
cial p
nform
mer
atio
m
r co
n in
o
thi
te
sd
ir va
o
p
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
ht
rig by
copy Vo
by lksw
cted agen
Prote AG.

Centring clutch disc and removing and installing pressure plate

Note agen
AG. Volkswagen AG d
oes
olksw not
byV gu
Disregard arrows -A- and -B-. rised ara
nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
sure plate.
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
4.5 Repairing „LuK“ clutch
l purpos
nform
ercia

m
⇒ Rep. gr. 13
at
m
io
r co
n in t
o
pins fit tightly
his
ate
d
v

i
o
pr
cu
or
m
f
en
ng

i t.
py Co
grease Co py
t. rig
gh ht
yri
2 - Clutch plate
by
cop by
Vo
lksw
cted
agen
Prote AG.
⇒ page 50
with SAC pressure
plate.
❑ Installation position:
⇒ page 51 .
3 - SAC pressure plate
❑ SAC means „self-ad‐
justing clutch“.
with clutch plate.
⇒ page 50
❑ Check ends of dia‐
phragm spring
⇒ page 51
❑ Check spring connec‐
tions and riveted con‐
nections ⇒ page 51 .
4 - M6 bolt, 13 Nm, M7 bolt, 20 Nm
❑ Loosen or tighten diagonally in small steps

5 Repairing clutch - vehicles with petrol engine

equipment required
♦ Counterhold -3067-
♦ Centring mandrel -T10097-
1331-
splines -G 000 100-
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
th
au ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
♦ For engines having a crankshaft of smaller diameter or having

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

es, in part or in w
drel -3176-
t to the co
rrectness of i
l purpos
n
ercia
form
m
atio
com
n in
r
te o
thi
sd
iva
o
r
rp
cu
fo
m
en
ng
i t.
py Co
t. Co py
rig
gh ht
yri by
cop by
Vo
lksw
cted agen
Prote AG.

5.1 Repairing clutch
Note
♦ Check whether dowel sleeves for aligning engine and gearbox are fitted in cylinder block and install if nec‐
essary.
♦ If dowel sleeves are not fitted, difficulties shifting gears, clutch problems and possible noises from the gear‐
box (rattling of gears which are not engaged) could occur.
⇒ Rep. gr. 13
pins fit tightly
grease
2 - Clutch plate
❑ Removing and installing agen
AG. Volkswagen AG d
⇒ page 55 Volksw
oes
not
gu
by ara
❑ Renew only together rised
nte
with SAC pressure utho eo
ra
plate. ss
a c
ce
e
nl
pt
du
an
⇒ page 56 .
itte
y li
erm
ab
3 - SAC pressure plate
ility
ot p
❑ SAC means „self-ad‐

wit
is n
justing clutch“. h re
ole,
spec
with clutch plate.

t to the co
rrectness of i

⇒ page 55
❑ Check ends of dia‐
cial p
phragm spring
nform
⇒ page 56
mer
❑ Checking spring con‐

a
m
tio
nections and riveted

r co
n in
connections
o
thi
e
⇒ page 56
t
s
ir va
do
p
cum
or
4 - M6 bolt, 13 Nm, M7 bolt, 20 Nm

f
en
ng
i t.
❑ Loosen or tighten diagonally in small steps py Co
t. Co py
rig
gh ht
yri by
cop by
Vo
lksw
cted
5.2 Removing and installing clutch
agen
Prote AG.
Removing
5. Repairing clutch - vehicles with petrol engine 55


Installing
olkswagen AG
en AG. V
Install in the reverse order of removal, observing
olks
wag the following: does
not
yV gu
db ara
ir se nte
tho eo
Note au ra
c
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
♦ Check whether dowel sleeves for aligning engine and gearbox
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness of i
• Lettering „Getriebeseite“ -arrow- faces gearbox.

cial p
nform
mer
permitted.
a
m
tion
co
in t
or
his
ate
do
priv
cum
or
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Checking spring connections and riveted connections

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

Checking position of adjusting mechanism with new pressure

plates only
• Both edges -A- of the adjuster ring must be located between
the two notches -arrows B-.
• If the adjuster ring takes up a different position in new pressure
plates, the pressure plate and clutch plate are not allowed to
be installed.
wage es n
• The adjuster ring may take up a position outside the notchesyV
olks ot g
ua
in used clutches. ise
d b ran
r tee
ho
aut or
ac
ss
Note
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
is n
♦ Always renew pressure plate and clutch plate together.
h re
ole,
spec
t to the co
♦ If clutch has burnt out, thoroughly clean clutch housing, fly‐
wheel and parts of engine facing gearbox to reduce smell of
burnt linings.
rrectness of i
cial p
nform
mer
a
m
tion
o

c
in t
r

o
his
te

a
do
iv
pr
cum
r

fo
en
ng
i t.
py Co
t. Co py
rig
gh ht
yri by
cop Vo
– Reverse counterhold tool -3067- for installation. by lksw
cted agen
Prote AG.

having an needle bearing -arrow- in the crankshaft
5. Repairing clutch - vehicles with petrol engine 57

Centring clutch disc and removing and installing pressure plate

Note
Disregard arrows -A- and -B-.

sure plate.
lkswage es n
o ot g
byV ua
ed ran
oris tee
th or
au ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
m
io
r co
n in t
o
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ate
d
iv
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pr
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or
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rig
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34 – Controls, housing
1 Repairing selector mechanism
1.1 Installation position of selector mechanism

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

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Volks ot g
B - Gate selector cable edb
y ua
ran
ir s tee
o
C - Heat shield auth or
ac
ss
❑ Remove before remov‐
ce
e
nl
ing selector mecha‐
pt
du
an
nism.
itte
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erm
ab
1 - Gearbox selector lever
ility
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wit
is n
2 - Relay lever
h re
ole,
spec
t to the co
rrectness of i
cial p
nform
mer
a
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tion
co
in t
or
his
ate
do
priv
cum
or
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Cop py
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rig ht
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Prote AG.
1. Repairing selector mechanism 59

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

♦ Before working on selector mechanism in engine compartment, disconnect earth strap from battery ⇒ Elec‐
trical system; Rep. gr. 27 ; Disconnecting and connecting battery .
♦ When reconnecting battery, perform work required after connecting battery ⇒ Electrical system; Rep. gr.
27 ; Disconnecting and connecting battery .
♦ To work on selector mechanism in engine compartment, remove complete air filter housing if it is located
over selector mechanism ⇒ Rep. gr. 23 ; Repairing diesel direct injection system or ⇒ Rep. gr. 24 ;
Repairing injection system .
♦ Remove selector mechanism to renew selector cables ⇒ page 78 .
♦ Do not kink selector cables. wage es n
Volks ot g
d by ua
ran
ir se tee
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or
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I - Removing and installing ss
gear knob and frame
ce
e
nl
pt
du
⇒ page 62
an
itte
y li
erm
ab
II - Repairing gear lever and
ility
ot p
selector housing (through
wit
10.06) ⇒ page 64
is n
h re
ole,
II - Repairing gear lever and
spec
selector housing (from 11.06)
t to the co
⇒ page 66
III - Assembly overview - re‐
moving and installing selector
rrectness of i
cables ⇒ page 71
cial p
nform
mer
atio
m
r co
n in
o
thi
te
sd
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o
p
cum
for
en
ng
t.
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Cop py
ht. rig
rig ht
py by
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by lksw
cted agen
Prote AG.
Removing and installing selector mechanism ⇒ page 78

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

♦ Hose clip pliers -V.A.G 1275-
AG. Volkswagen AG d
agen oes
olksw not
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au ra
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pt
du
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erm
ab
ility
ot p
wit
is n
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ole,
spec
t to the co
rrectness of i
cial p
nform
mer
a
m
tio
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n in
o
thi
te
sd
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o
p
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or
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py Co
t. Co py
rig
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Prote AG.

1.3 Removing and installing gear knob and frame
1 - Emblem
❑ Can be carefully levered
off gear knob of plastic
or leather
2 - Gear knob
❑ With gaiter
❑ Gear knob and gaiter
cannot be separated
from one another
❑ Always renew together
⇒ page 62
3 - Clamp
❑ For securing gear knob
to gear lever
❑ Secure to gear knob wagen AG. Volkswagen AG does
⇒ Item 2 (page 62)yusing ks not
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hose clip pliers rise-V.A.G
d b ara
nte
1275- utho eo
ra
a
❑ Always renew
ss c
ce
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nl
pt
4 - Frame for centre console
du
an
itte
y li
❑ In some equipment ver‐
erm
ab
sions, forms one part to‐
ility
ot p
gether with centre con‐

wit
is n
sole
h re
ole,
spec
5 - Noise insulation
t to the co
❑ Not fitted in all vehicles

❑ Arrow on noise insula‐
tion points in direction of
rrectness of i
travel
❑ Locking lugs are ar‐
ranged at varying inter‐
cial p
vals
nform
❑ Therefore it can be installed in only one position

mer
a
m
tio
r co
n in
o
thi
e
1.4 Removing and installing gaiter with gear

t
sd
ir va
o
p
cu
knob and noise insulation

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

along the front section.

wage es n
Volks ot g
Golf Variant 2007se➤ d b , Golf Variant 2010 ➤ , Jetta 2005ua➤
y
ran, Jetta 2011 ➤
ri tee
utho 6-speed manual gearbox 02Q - Edition
or 06.2010
a ac
ss
– Pull gaiter with frame for centre console upwards, inside out
ce
le
un
pt
over gear knob.
an
d
itte
y li
erm
ab
– Open clamp -arrow- and pull off gear knob together with gaiter.
ility
ot p
In some versions, the centre console frame remains in the centre
wit
is n
h re
console.
ole,
spec
– If necessary pull off, or carefully lever off, centre console
frame.
t to the co
rrectness of i
– Pull off noise insulation -1-.
cial p
nform
mer
a
m
tio
r co
n in
o
thi
te
sd
iva
o
pr
cu
r
fo
m
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
1.4.2 Installing
– First set noise insulation in place.
Installation position of noise insulation
• -Arrow A- points in direction of travel.
• Catches -arrows B- must engage in centre console.
– If necessary, press frame into centre console.
– Then turn gaiter inside out.
The gear knob must be pressed to stop.
– Install gear knob with frame and gaiter and squeeze new
clamp -arrow- together.
– Then press gaiter with frame into centre console or gaiter into
frame.

1.5 Repairing gear lever and selector housing (through 10.06)
Note
Lubricate bearing points and sliding surfaces with grease -G 000 450 02- .
1 - Lock washer
⇒ page 65
2 - Bush
3 - Compression spring
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4 - Bush Volks ot g
by ua
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5 - Torx screw, 5 Nm thor tee
or
au ac
6 - Cover ss
ce
e
nl
pt
7 - Damping
du
an
itte
y li
erm
8 - Damping
ab
ility
ot p
9 - Ball socket
wit
is n
h re
ole,
10 - Gear lever guide
spec
11 - Damping washer
t to the co
12 - Seal
❑ Between selector hous‐
ing and underbody rrectness of i
❑ Self-adhesive
❑ Bond to selector hous‐
cial p
ing
nform
mer
13 - Selector lever
atio
m
r co
14 - Selector housing
in
o
thi
te
sd
ir va
15 - Bearing bush
o
p
cum
or
16 - Pivot pin
f
en
ng
i t.
py Co
17 - Guide bush Co py
ht. rig
rig ht
py by
co Vo
by lksw
cted
❑ Installing ⇒ page 65
agen
Prote AG.
19 - Gate selector lever

20 - Torx screw, 5 Nm
21 - Seal
❑ Always renew
22 - Base plate
❑ Bend open tabs to remove
❑ Always renew
23 - Gate selector cable
❑ On gate selector lever
24 - Gear selector cable
❑ Removing from and attaching to gear lever guide ⇒ page 65

25 - Lock washer
❑ Always renew
26 - Hexagon nut
❑ M8: 25 Nm
❑ M6: 8 Nm
❑ Qty. 4
27 - Bearing bush
❑ Fits in one position only
28 - Lock washer
❑ Always renew
wage es n
Volks ot g
Removing and installing gate and gear selectord by cables ua
ran
ir se tee
ho
– Remove securing clip from gear selector
au
t cable -A- and gate or
ac
selector cable -B-. ss
ce
le
un
pt
To do this, raise tab using screwdriver -arrow 1- and press off
an
d
itte
y li
securing clip -arrow 2-.
erm
ab
ility
ot p
– Remove gear selector cable -A- from gear lever retainer.
wit
is n
h re
– Remove gate selector cable -B- from retainer of gate selector
ole,
lever.
spec
t to the co
rrectness of i
cial p
nform
mer
a
m
tio
r co
n in
Removing and installing securing clip
o
thi
te
sd
a
– To remove or install securing clip -arrow A-, press spacer bush

iv
o
pr
cu
-arrow B- to stop -in direction of arrow C- using screwdriver

r
fo
m
en
and pull off securing clip.

ng
t.
yi Co
Cop py
ht. rig
ht
rig by
py
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Prote AG.
♦ Do not cant spacer bush when pushing down.
♦ Slot in gear lever for securing clip must be visible.
♦ Carefully release tension from spring.
Installing compression spring

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

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

agen grease -G 000
AG. Volkswagen AG450
doe 02- .
ks s no
Vol t gu
♦ Dismantling and assembling selectoremechanism
db
y ⇒ page 67 . ara
ris nte
utho eo
ra
a c
ss
1 - Base plate
ce
le
un
pt
an
d
❑ Bend open tabs to re‐
itte
y li
move
rm
ab
pe
ility
❑ Always renew
ot
wit
, is n
h re
2 - Seal
hole
spec
❑ Always renew
es, in part or in w
t to the co
3 - Selector lever
❑ Can be removed and in‐
stalled with gear lever
rrectness of i
guide
l purpos
⇒ Item 15 (page 67)

installed
n
ercia
4 - Damping washer
form
❑ Push onto gear lever up
m
atio
com
to stop -arrow-
n in
r
te o
5 - Securing clip
thi
sd
iva
❑ Do not damage cables
o
r
rp
cu
when removing
fo
m
en
ng
t.
yi
❑ Always renew
Co
Cop py
ht. rig
6 - Gate selector cable rig ht
py by
co Vo
lksw
❑ Lever off gate selector
by
cted agen
Prote
lever
AG.
❑ Press onto gate selector

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

AG. Volkswagen AG d
agen oes
lksw not
14 - Bush by
Vo gu
ara
ed
ris nte
15 - Gear lever guide
utho eo
ra
sa c
16 - Hexagon nuts
ce
e
nl
pt
❑ M8: 25 Nm
du
an
itte
y li
❑ M6: 8 Nm
erm
ab
ility
❑ Qty. 4
ot p
wit
is n
17 - Seal
h re
ole,
spec
❑ Between selector housing and underbody
❑ Self-adhesive
t to the co
❑ Bond to selector housing
18 - Selector lever housing
rrectness of i
❑ With compression spring and gate selector lever
❑ Compression spring and gate selector lever cannot be removed
cial p
nform
mer
a
1.6.1 Dismantling and assembling selector
m
tio
r co
n in
mechanism
o
thi
te
sd
ir va
o
p
cu
or
m
f
en
g
♦
n
t.
yi Co
Cop py
thrust piece -T10083-
t. rig
gh ht
pyri by
Vo
o
Dismantling
c by lksw
cted agen
Prote AG.
– Remove selector mechanism ⇒ page 78 .
– Bend open tabs -arrows- of base plate for selector mechanism

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

– Lift upper end -A- of compression spring over tab of gate se‐
lector lever.
– Use screwdriver to press catches -arrows- of ball socket to‐
wards bearing ball of gear lever guide; break off catches if
necessary.
. Volkswagen AG
gen AG does
swa
– Lever ball socket -A- with gear lever guide -B- out of selectorby
Vol
k not
gu
housing. ris
ed ara
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– Then press ball socket off bearing ball of gear lever sguide
au and ra
c
remove it. s
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
• Please pay attention to guides -A- during the further proce‐
rrectness of i
dure.
• They must not be broken off.
cial p
nform
– Lever lower end -arrow 1- of compression spring onto shoulder
mer
on gate selector lever as far as stop.
a
m
tio
o
– Now pull gear lever guide up to stop and pull ball stud out of
n in
r c
te o
gate selector lever -arrow 2-.
thi
s
a
do
ir v
p
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
– Then turn gear lever guide in -direction of arrow 1-.
py by
co Vo
by lksw
cted agen
• Pin -arrow 2- must be in notch in selector housing.
Prote AG.
– Then swing out gear lever guide with gear lever in

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

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

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

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

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

• Pin -arrow 1- is still located in notch in selector housing.
– Turn gear lever guide in -direction of arrow 2- until ball stud
-A- is located in notch in selector housing.
– Place selector housing with gear lever guide into larger recess
-arrow- in thrust piece -T10083- .
Note
To ensure that the selector housing with gear lever guide can be
inserted in the thrust piece , first remove gear lever, if necessary.
AG. Volkswagen A
agen G do
es n
ksw
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ua
b
ed ran
oris tee
th or
au ac
ss
ce
e
nl
pt
du
an
itte
• The gear lever guide must project from the selector housing
y li
erm
ab
up to the stop.
ility
ot p
wit
is n
h re
Note
ole,
spec
For clarity of illustration, only part of the gate selector lever is

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

– Pull end -B- of compression spring downwards and insert it
next to guide (in direction of ball joint).
cial p
nform
• Please pay attention to guides (⇒ figure above) during the fur‐

mer
ther procedure.
atio
m
r co
• They must not be broken off.

n in
o
thi
e
– Carefully remove selector housing with gear lever guide from

t
sd
ir va
thrust piece -T10083- .

o
p
cum
for
en
ng
i t.
py Co
t. Co py
rig
gh ht
yri by
cop by
Vo
lksw
cted agen
Prote AG.

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

holes for gear and gate selector cable) -arrow 1-.
– Grease ball stud.
– Press ball stud into gate selector lever -arrow 2-.
• Guides -A- and tabs -B- are not allowed to be damaged.
– Place selector housing with gear lever guide into larger recess
-arrow- in thrust piece -T10083- .
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
r
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
• The gear lever guide must project from the selector housing
hole
spec
up to the stop.
es, in part or in w
t to the co
– Lift upper end -A- of compression spring over pin of gate se‐
lector lever
• Use a new ball socket -B-. rrectness of i
l purpos
– Grease ball socket and bearing ball of gear lever guide.

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

atio
com
n in
– Insert lower end -C- of compression spring into guide.

r
te o
thi
sd
iva
– Lift upper end -A- of compression spring over pin of gate se‐
o
r
rp
cu
lector lever into guide.

fo
m
en
ng
t.
yi
– Press ball socket into selector housing -arrows-.
Co
Cop py
t. rig
• All locking lugs must clip in.
gh ht
pyri by
Vo
co lksw
by
– Attach gear lever, gear selector cable, gate selector cable and cted agen
Prote AG.
base plate ⇒ page 66 .
– Install selector mechanism ⇒ page 78 .

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

❑ Connect to cable end-
piece
⇒ page 59
❑ From 11.06, modified
attachment to gear lever
inside selector mecha‐
nism
2 - Gate selector cable
❑ Connect to cable end-
piece
⇒ page 59
❑ From 11.06, modified
attachment to gate se‐
lector lever inside selec‐
tor mechanism
3 - Lock washer
❑ Always renew
AG. Volkswagen AG d
agen
❑ Discontinued in selector Volksw
oes
not
mechanisms from 11.06 ed by gu
ara
⇒ page 66 tho
ris nte
eo
au ra
4 - Lock washer ss c
ce
e
nl
❑ Do not damage cables
pt
du
an
when removing
itte
y li
erm
ab
❑ Always renew
ility
ot p
wit
5 - Selector housing
is n
h re
ole,
6 - Hexagon bolt, 20 Nm
spec
❑ For cable support bracket t to the co

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

8 - Grommet
cial p
❑ Cable support bracket mounting on gearbox

nform
mer
9 - Spacer
a
m
tio
r co
10 - Nut, 20 Nm
n in
o
thi
e
❑ For cable support bracket

t
sd
ir va
o
p
cu
11 - Cable end-piece
or
m
f
en
ng
❑ For gate selector cable to relay lever

t.
yi Co
op py
❑ After installing, adjust selector mechanism ⇒ page 82
t. C rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

❑ Do not interchange; cable end-pieces for gate selector cable to relay lever and gear selector cable to
gearbox selector lever are different ⇒ page 73
❑ From 05.07, fitted in conjunction with plastic relay lever ⇒ page 75
❑ Removing from plastic relay lever ⇒ page 75
❑ Pressing onto plastic relay lever ⇒ page 75
❑ Allocation ⇒ page 73
12 - Relay lever
❑ May be made from plastic or metal
❑ Metal relay lever is mounted in bearing bush ⇒ Item 13 (page 72) and secured with securing clip
❑ From 05.07, plastic relay lever
❑ Remove and install plastic relay lever together with cable end-piece ⇒ page 75
❑ Bearing bushes and securing clip not required for plastic relay lever
13 - Bearing bush
❑ Discontinued on relay levers made from plastic
14 - Lock washer
❑ Always renew
❑ Discontinued on relay levers made from plastic
15 - Shoe n AG. Volkswagen AG do
lkswage es n
o ot g
16 - Gearbox selector lever ed byV ua
ran
ris
❑ With damper weight utho tee
or
a ac
❑ Install so that master spline
ss aligns with selector shaft
ce
e
nl
❑ After installing, adjust selector mechanism ⇒ page 82 pt

du
an
itte
❑ Installation position ⇒ page 74 y li

erm
ab
❑ From 06.06, smaller diameter of support pin for cable end-piece ⇒ page 73 ility
ot p
wit
, is n
h re
hole
❑ Self-locking
spec
es, in part or in w
❑ Always renew
t to the co
18 - Cable end-piece
❑ For gear selector cable to gearbox selector lever
rrectness of i

l purpos
❑ Do not interchange; cable end-pieces for gate selector cable to relay lever and gear selector cable to
gearbox selector lever are different ⇒ page 73
nform
mercia
a
m
tio
r co
n in
o
thi
te
sd
iva
o
pr
cu
or
m
f
en
ng
i t.
py Co
t. Co py
rig
gh ht
yri by
y cop Vo
lksw
b
cted agen
Prote AG.

. Volkswagen AG
swa
gen AG does6-speed manual gearbox 02Q - Edition 06.2010
olk not
yV gu
db ara
Allocation of cableorend-pieces
ise nte
h eo
ut ra
The holes in the
ss cable end-pieces
a have different diameters. c
ce
e
nl
pt
Cable end-piece for Dimension „a“
du
an
itte
y li
1 - Gear selector cable to gearbox selector lever 8.5 mm
erm
ab
from 06.06
ility
ot p
wit
, is n
2 - Gear selector cable to gearbox selector lever 10 mm
h re
through 05.06
hole
spec
2. - Gate selector cable to metal relay lever 8 mm
es, in part or in w
t to the co
2. - Gate selector cable to plastic relay lever 10 mm
⇒ page 75
rrectness of i
l purpos
nform
mercia
at
m
io
r co
n in t
o
From 06.06, smaller diameter of support pin for gear selector ca‐
his
ate
ble end-piece
d
iv
o
pr
cu
or
m
f
Support pin for gear selector cable end-piece Dimension „a“
en
ng
i t.
py Co
Co py
Through 05.06 gh
t.
10 mm rig
ht
yri by
From 06.06 op
8.5 mm
c Vo
by lksw
cted agen
Prote AG.
Install gearbox selector lever

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

Installation position of gearbox selector lever and relay lever

1- Gearbox selector lever with damper weight
2- Relay lever engages in guide rail of gearbox selector lever
via shoe -arrow-.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
r
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
Renewing cable end-pieces
– Pull locking mechanisms of end-pieces of gate selector cable
rrectness of i
and gear selector cable forward to stop -arrow 1- and then turn
to left to lock -arrow 2-.
cial p
nform
mer
a
m
tion
co
in t
or
his
ate
do
priv
cum
or
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

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

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with the cable end-piece ⇒ page 75 .
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– Adjust selector mechanism ⇒ page 82 .
hole
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1.8 Plastic relay lever

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

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

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

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gate selector cable.

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Relay lever with catch -arrow 1-

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

– Pull clip -arrow 1- off and remove relay lever together with ca‐
ble end-piece. n AG. Volkswagen A age G do
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• Cable end-piece must be located behindthcatch
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removed ⇒ page 77 .
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Note
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To fit, lubricate bearing points and sliding surfaces with grease -
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spec
G 000 450 02- .
t to the co
– Press cable end-piece onto relay lever ⇒ page 77 .
– Install relay lever together with cable end-piece to stop.
rrectness of i
Relay lever with catch -arrow 1-

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• Catch -arrow 1- secures relay lever.

mer
• Ensure proper engagement.

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

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Relay lever with clip -arrow 1-

• Clip -arrow 1- secures relay lever.
• Ensure proper engagement of clip.
• Cable end-piece must be located behind catch -arrow 2-.
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Levering gate selector cable end-piece off plastic relay lever
ility
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• Relay lever has been removed.
h re
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– Insert a flat-blade screwdriver -A- between bush -B- and relay
spec
lever.
t to the co
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• Relay levers has
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• Cable end-piece may be pressed only onto bush -arrow-.
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• Cable end-piece must move freely on relay lever.
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• It must be located behind catch -arrow 2-.
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1.9 Removing and installing selector mech‐
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♦ Torque wrench -V.A.G 1331- Prote AG.
♦ Grease -G 000 450 02-
1.9.1 Removing
– First check whether a coded radio is fitted. In this case, obtain
anti-theft code.
– With ignition switched off, disconnect battery ⇒ Electrical sys‐
tem; Rep. gr. 27 ; Disconnecting and connecting battery .
– Remove gaiter with selector knob and noise insulation
⇒ page 62 .
– Remove centre console and securing bracket for centre con‐
sole ⇒ General body repairs, interior; Rep. gr. 68 ; Compart‐
ments, covers and trims .

– Remove selector housing nuts -arrows-.

– Remove complete air filter housing if it is over selector mech‐
anism ⇒ Rep. gr. 23 ; Repairing diesel direct injection system
or ⇒ Rep. gr. 24 ; Repairing injection system .
selector lever -1-.
– Pull gear selector cable off pin -arrow-.
Metal relay lever
– Remove securing clip -4- for gate selector cable from relay
lever -2-.
– Pull gate selector cable off pin -arrow-.
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Releasing cable end-piece from gate selector cable
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• To avoid damage to gate selector cable, separate cable end-

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piece from gate selector cable before removal.
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-direction of arrow 1- and then lock by turning to left in
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⇒ page 75 .
rrectness of i
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– Remove cable support bracket from gearbox -arrows-.
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– Remove tunnel cross member ⇒ Rep. gr. 26 ; Removing and
r
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installing parts of exhaust system .
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– Remove underbody panels ⇒ General body repairs, exterior;

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Rep. gr. 50 . i t.
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– Separate front exhaust system at double clamp and detach
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by
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– Remove rear exhaust system and heat shield ⇒ Rep. gr. 26 ;

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

• Distance to body must be same on both sides.

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

23 ; Repairing diesel direct injection system or ⇒ Rep. gr. 24 ; nform
mer

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– Follow procedure after connecting battery ⇒ Electrical system;

n in
o
Rep. gr. 27 ; Battery; Disconnecting and connecting battery .

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1.10 Removing and installing gear selector

f
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cable and gate selector cable
Co
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1.10.1 Removing
Prote AG.
– Remove selector mechanism ⇒ page 78 .

– Bend open tabs -arrows- of selector mechanism cover using n AG. Volkswagen AG do
a screwdriver and remove cover. olks
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– Remove gasket. db ara
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– Pull off securing clips -1 … 4-.
rrectness of i
Note
Securing clips -1 and 4- have been discontinued on selector

cial p
mechanisms from 11.06.
nform
mer
a
– Prise gear selector cable off gear lever and gate selector cable
m
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off gate selector lever with e.g. a screwdriver if necessary.

c
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– Pull gear selector cable and gate selector cable from selector
iva
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housing.
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Release locks -A- for gear and gate selector cables -B- as follows: t. Co py
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♦ Push sliding sleeve forward to stop -arrow 1-.
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♦ Turn sliding sleeve to right to stop -arrow 2- until it engages. Prote AG.
– Remove locking mechanism from Bowden cables.
– Pull off securing clips -1- and -2-.

– Remove cable support bracket from Bowden cables.
1.10.2 Installing

– Secure gear selector cable and gate selector cable to selector

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

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

down tabs -arrows-.
– Install selector mechanism ⇒ page 79 .
1.11 Adjusting selector mechanism

Locking pin -T10027 A-
Note
♦ The following points are essential to ensure ecorrect

n AG. Volkadjust‐
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ment of selector mechanism: olks
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♦ Moving parts of selector mechanism
oris
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d
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force must be in proper condition.
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♦ Selector mechanism must move freely.
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♦ Gearbox, clutch and clutch mechanism must also be in proper

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condition.
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• Gearbox must be in neutral.

h re
ole,
spec
– Remove complete air filter housing if bracket -A- to secure

t to the co
gear selector cable and gate selector cable are not accessible
⇒ Rep. gr. 23 ; Repairing diesel direct injection system or ⇒
Rep. gr. 24 ; Repairing injection system .
rrectness of i
cial p
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mer
a
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Cop py
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rig ht
py by
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by lksw
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Prote AG.

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

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

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

AG. Volkswagen AG d
– Select neutral using gear lever. agen oes
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– Guide locking pin -T10027 A- through hole -A-orisinto
ed hole -B-. nte
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ab
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– Check that gate and selector cables -B- are inserted, free of
tension, into locking devices -A-.
– Now turn locking mechanisms on gear selector cable and gate
rrectness of i
selector cable end pieces clockwise to stop

The spring presses the locking mechanism into original position
cial p
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Prote AG.
1. Repairing selector mechanism

– Now turn angled rod -A- back to original position

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

– If noise insulation was present, install it.
– Install gaiter with selector knob and frame ⇒ page 62 .
– Check that selector shaft moves freely. AG. Volkswagen AG d
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– If removed, reinstall complete air filter housing ⇒ Rep. gr. 23by;Vol not
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Repairing diesel direct injection system or ⇒ Rep. gr. 24 rise;
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Repairing injection system ut
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1.11.1 Functional check
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hole
• With gearbox in neutral, gear lever must rest in gate for 3rd
spec
and 4th gear.
es, in part or in w
t to the co
– Operate clutch.
– Select all gears several times. Pay particular attention to op‐
rrectness of i
eration of reverse gear lock.
l purpos
– If it continues to be difficult to engage a gear after repeated

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

2 Removing and installing gearbox in

vehicles with turbo diesel engine
2.1 Removing gearbox

equipment required
♦ Support bracket -10 - 222
A-
♦ Adapter -10-222 A /8-
♦ Adapter -10-222 A /3- n AG. Volkswagen AG do
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♦ Adapter -10-222 A /18- ed by V ua
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♦ Gearbox support -3282-
autho
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ab
ility
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es, in part or in w
t to the co
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Prote AG.
2. Removing and installing gearbox in vehicles with turbo diesel engine 85

♦ Support elements for gear‐

box (determine when set‐
ting adjustment plate on
gearbox support )
♦ Adjustment plate -3282/33-
♦ Gearbox lifting tackle
-3336- for transporting
gearbox
1331-
1332-
♦ Engine and gearbox jack -
V.A.G 1383 A-
AG. Volkswagen AG d
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form
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♦ Bracket -T10346- ris nte
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♦ Engine support -3300 A- ss c
ce
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nl
♦ Adapter -VW 771/40-
pt
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♦ Hose clamps to 25 mm
erm
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-3094-
ility
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h re
ole,
splines -G 000 100-
spec
♦ Allocate grease using ⇒
t to the co
Electronic parts catalogue
(ETKA) .
rrectness of i
♦ Flange bolt M6 X 20
♦ Hexagon head bolt M10 x
cial p
nform
20
mer
a
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tion
co
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or
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ate
do
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pr
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or
f
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t.
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Cop py
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ht
rig by
copy Vo
by lksw
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Prote AG.
At a later point, support bracket -10-222 A- will be put onto lon‐

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

selector lever -2- and pull cable off pin -arrow-.
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nl
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– Releasing cable end-piece from gate selector cable
ility
ot p
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, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
– The relay lever is removed together with the cable end-piece
l purpos
at a later point.
nform
mercia
a
m
t
– Remove cable support bracket from gearbox -arrows-, lay to
io
r co
n in
side and secure with wire.
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Prote AG.
LHD
-3094- .

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d by V Golf Variant 2007 ➤ , Golf uaVariant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤
ran
rise 6-speed
tee manual gearbox 02Q - Edition 06.2010
tho
u or
a ac
ss
Right-hand drive
ce
e
nl
pt
du
an
– Clamp off hose of pipe/hose line -A- to slave cylinder using
itte
y li
hose clamp -3094- . erm
ab
ility
ot p
wit
is n
h re
– Pull out clip -arrow- for pipe/hose line or plastic line to stop.
ole,
spec
– Pull pipe/hose line or plastic line out from slave cylinder bleed‐
t to the co
er and seal.
Caution
rrectness of i
Do not operate clutch pedal any more.
cial p
nfo
mer
rm
– Remove earth strap -1- from top starter bolt.
atio
om
n in
c
– Separate electrical connector -2- for reversing light switch -

or
thi
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– Remove connector and wire from starter.
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t.
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Cop py
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rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– Remove upper engine/gearbox connecting bolts -arrows-.

– Then remove upper securing bolt on starter.
– Bolt bracket -T10346- to rear of the 3 mounting holes for bat‐

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

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– Set up support bracket -10-222 A- in lfront
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– Use: risedb ran
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♦ Adapter -10-222 A /3- aut or
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♦ Adapter -10-222 A /8-
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♦ Adapter -10-222 A /18-
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ab
ility
– Position adapter -10-222 A /8- :
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• On upper longitudinal carrier, directly before the elevation
h re
hole
(-arrow 1-) next to bolt (-arrow 2-)
spec
es, in part or in w
– Connect bracket -T10346- to support bracket .
t to the co
– Attach spindles in left engine support eyes.
rrectness of i
– Take up weight of engine/gearbox assembly and support
bracket on spindles.
l purpos
nform
ercia
The left drive shaft will be removed in a later step.

m
at
m
io
– With vehicle standing on its wheels, loosen front left flange bolt
r co
n in t
-arrow- 90° at most, or wheel bearing will be damaged ⇒
o
his
e
Running gear, axles, steering; Rep. gr. 40 ; Removing and

at
d
iv
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installing drive shafts .
pr
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or
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f
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ng

i t.
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Rep. gr. 50 ; Noise insulation . Co py
t. rig
gh ht
yri
– Remove lower part of front left wheel housing liner ⇒ General
by
cop by
Vo
lksw
body repairs, exterior; Rep. gr. 66 ; Wheel housing liner . Prote
cted AG.
agen
– Gearboxes for vehicles with start-stop system: pull connector

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

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

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

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

gr. 19 ; Parts of cooling system .
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e d
ris nte
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– Remove exhaust system bracket
ss
au
from subframe -arrows- ⇒ ra
c
Rep. gr. 26 ; Removing and installing parts of exhaust system .
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
– Separate exhaust system at double clamp -arrows-.

– Raise and secure front exhaust pipe or rest it on tunnel bridge.
nform
mercia
at
m
io
r co
n in t
o
his
ate
d
iv
o
pr
cu
or
m
f
en
ng
i t.
py Co
t. Co py
rig
gh ht
yri by
cop by
Vo
lksw
cted agen
Prote AG.

– Remove pendulum support.
– Pull connector -1- off oil level and oil temperature sender -
G266- .
– Remove left coupling rod from anti-roll bar and lay to side ⇒
Running gear, axles, steering; Rep. gr. 40 ; Repairing front
wheel suspension .
– Remove left drive shaft ⇒ Running gear, axles, steering; Rep.
gr. 40 ; Removing and installing drive shafts .
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ir se nte
ho eo
– Remove drive shaft heat shield, if present -arrows-
sa
ut
⇒ Running ra
c
gear, axles, steering; Rep. gr. 40 ; Repairing drive shafts .
s
ce
e
nl
pt
du
– Remove right drive shaft from gearbox, raise and secure it ⇒
an
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness of i
– Remove hexagon bolts -arrows- on left engine/gearbox
mounting -2- from bracket -1-.
cial p
nform
mer
a
m
tio
r co
n in
o
thi
te
s
ir va
do
p
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
ht
rig by
copy Vo
by lksw
cted agen
Prote AG.

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

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

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

⇒ page 75 .
– Remove gearbox selector lever from selector shaft.
wage es n
Volks ot g
by ua
d ran
rise tee
tho
u or
a ac
ss
ce
le
– If small cover plate -A- for flywheel is present, remove it

un
pt
an
d
-arrows-.
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
– Remove lower engine/gearbox connecting bolt -1-.

n
ercia
format
m
com
ion
Note
in
r
te o
thi
sd
iva
Loosen engine/gearbox connecting bolt -3- and leave it installed

o
r
rp
cu
just hand-tight.
fo
m
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

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

subframe.
-1- = Flange bolt M6 x 20.
– Secure engine support -3300 A- to bracket -T10346- .
– Place a cloth between engine support -3300 A- and oil pan.
wage es n
Volks ot g
by ua
d ran
rise tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
– Press engine forwards using spindle of engine support -3300
erm
ab
A- . In the process, observe the following points in particular:
ility
ot p
wit
is n
• The air conditioning compressor -2- must not contact -arrow-
h re
ole,
the refrigerant line -1-.
spec
• The alternator must not contact the refrigerant line.
t to the co
• The pressure pipe must not contact the radiator.
To remove gearbox „02Q“, set up gearbox support -3282- with
rrectness of i
adjustment plate -3282/33- .
– Insert gearbox support -3282- in engine and gearbox jack -
V.A.G 1383 A- .
cial p
nform
– Align arms of gearbox support according to holes in adjust‐
mer
ment plate .
a
m
tio
r co
n in
o
thi
– Attach support elements -A- to adjustment plate as illustrated.
te
sd
ir va
– Screw in pin -3282/29- in place of support element -C-. o

p
cu
or
m
f
en
ng
– Position engine and gearbox jack -V.A.G 1383 A- under vehi‐

i t.
py Co
cle. Arrow -B- on adjustment plate points in direction of vehicle Co py
ht. rig
travel. rig ht
py by
co Vo
by lksw
– Align adjustment plate parallel to gearbox. cted agen
Prote AG.
– Attach adapter -VW 771/40- in threaded hole of gearbox hous‐

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

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

lower connecting bolts for engine/gearbox.
– Press gearbox away from engine, off dowel sleeves.
– Tilt gearbox in area of differential using spindles of gearbox
support -3282- .
• Differential must face upwards.
AG. Volkswagen AG d
agen oes
lksw not
Right flange shaft d by -1-
V must be guided past bolt hole
o guof engine
ara
-2-. orise nte
eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Guide gearbox with differential -A- over subframe and swing

rrectness of i
out.
l purpos
n
ercia
form
m
atio
com
n in
r
te o
thi
sd
iva
o
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rp
cu
fo
m
en
ng
i t.
py Co
t. Co py
rig
gh ht
yri by
y cop Vo
lksw
b
cted agen
Prote AG.

– Observe longitudinal member -arrows-. Then carefully lower

gearbox.
Note
wage es n
olks
Be careful of all lines when lowering
d by
V gearbox. ot g
ua
ran
ir se tee
tho
or
s au ac
s
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
2.2 Transporting gearbox
is n
h re
ole,
spec
t to the co
♦ Gearbox mounting support -3336-
rrectness of i
cial p
nform
mer
a
m
tion
co
in t
or
his
te
iva
do
pr
cum
for
en
ng
t.
yi Co
♦ Workshop hoist -VAS 6100- Cop py
ht. rig
ht
rig by
copy Vo
by lksw
cted agen
Prote AG.
– Bolt gearbox lifting tackle -3336- to clutch housing.

– Adjust support beam on sliding piece using locking pin

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

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

AG. Volklever
swageand
n AG d
relay lever must be transferred to the onew agen
lksw gearbox.
oes
no t gu
V
by
– All threaded holes into which self-locking
ris
ed bolts are to be ara
nte
screwed must be cleaned of residual
utho locking fluid carefully with eo
ra
a thread tap. ss
a c
ce
e
nl
– Check whether dowel sleeves for aligning engine and gearbox

pt
du
an

itte
y li
erm
ab
If dowel sleeves are not fitted, difficulties shifting gears, clutch

ility
ot p
problems and possible noises from the gearbox (rattling of gears

wit
, is n
which are not engaged) could occur.

h re
hole
spec
– Ensure that intermediate plate is hooked into sealing flange

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

t to the co
– Check release bearing for wear. If necessary, renew slave

cylinder with release bearing ⇒ page 40 .
rrectness of i
l purpos
nform
mercia
at
m
io
r co
n in t
o
his
ate
d
iv
o
pr
cu
or
m
f
en
ng
t.
yi Co
Cop py
ht. rig
ht
rig by
copy Vo
by lksw
cted agen
Prote AG.


subframe.
– Place a cloth between engine support -3300 A- and oil pan. agen
AG. Volkswagen AG d
oes
olksw not
V gu
d by ara
ise nte
or eo
th
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness of i
To install gearbox „02Q“, set up gearbox support -3282- with ad‐
justment plate -3282/33- .
cial p
nform
ment plate .
mer
atio
m
r co
n in
o
thi
e
– Screw in pin -3282/29- in place of support element -C-.

t
sd
ir va
o
p
cum
– Place gearbox on engine and gearbox jack -V.A.G 1383 A- .
for
en
ng
i t.
– Align adjustment plate and gearbox parallel to one another.
py Co
t. Co py
rig
gh ht
– Screw pin -3282/29- into hole on gearbox for securing bolt of yri by
cop Vo
pendulum support. by lksw
cted agen
Prote AG.
– Secure adapter -VW 771/40- in threaded hole of gearbox

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

– Now turn gearbox upwards near differential, using spindle of

gearbox support -3282- , and downwards near 6th gear.
– Guide gearbox with differential -A- over subframe.
• The right flange shaft must then be guided past the flywheel
-arrow 2-; observe the intermediate plate -arrow 1-.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
– Right flange shaft -1- must
auth
be guided past bolt hole of engine ra
-2-. ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
– When doing this, use spindles of gearbox support -3282- to

adjust position of gearbox so that longitudinal member
-arrows- is not touched.
n
ercia
for
– Then turn gearbox to installation position via spindles of gear‐

mat
m
com
box support -3282- .

ion
in
r
te o
– Align gearbox on engine dowel sleeves and join.

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

o
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rp
cu
fo
specified torque ⇒ page 104 .

m
en
ng
i t.
py Co
t. Co py
rig
gh ht
yri by
cop by
Vo
lksw
cted agen
Prote AG.

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

– Remove engine support -3300 A- and bracket -T10346- .
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
th
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
is n
h re
– Screw in engine/gearbox connecting bolt -arrow- and tighten
ole,
to specified torque ⇒ page 104 .
spec
– After bottom of gearbox and engine are bolted together, re‐
t to the co
move gearbox support -3282- from gearbox.
– Insert upper engine/gearbox securing bolts and tighten to tor‐
rrectness of i
que specification ⇒ page 104 .
– Attach gearbox selector lever to selector shaft of gearbox
⇒ page 73 and tighten hexagon nut to specified torque
cial p
⇒ Item 17 (page 72) .
nform
mer
– Install relay lever together with cable end-piece ⇒ page 75 .
a
m
tion
co
in t
or
his
te
– Install bracket -1- on gearbox using new hexagonal bolts

iva
do
-arrows- and tighten to specified torque ⇒ page 104 .
pr
cum
for
en
ng
i t.
py Co
t. Co py
rig
gh ht
yri by
cop by
Vo
lksw
cted agen
Prote AG.
– Align engine and gearbox in installation position. To do this,

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

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

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

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

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

for the pendulum support.
♦ Distinguishing feature: shoulder along beginning of thread
-arrow-. n AG. Volkswagen AG do
wage es n
olks ot g
♦ Note corresponding securing bolts and specified d by torque ⇒
V ua
ran
Running gear, axles, steering; Rep. gr. 40 or ; Assembly over‐
ise
tee
view - subframe, anti-roll bar, suspension
au links .
th or
ac
ss
ce
e
nl
pt
du
an
itte
y li
– Install pendulum support ⇒ Running gear, axles, steering;
erm
ab
Rep. gr. 40 ; Assembly overview - Subframe, anti-roll bar,
ility
ot p
suspension links .
wit
is n
h re
– Then install drive shafts ⇒ Running gear, axles, steering; Rep.
ole,
spec
t to the co
rrectness of i
cial p
nform
mer
– Install drive shaft heat shield, if present -arrows- ⇒ Running

a
m
t
io
o
n in
r c
te o
– Install left coupling rod ⇒ Running gear, axles, steering; Rep.

thi
s
a
gr. 40 ; Repairing front suspension .

do
ir v
p
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– If front vehicle level sender -G78- is present, bolt it onto trans‐

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

G266- .
– Assemble exhaust system and attach exhaust system bracket
to subframe ⇒ Rep. gr. 26 ; Removing and installing parts of
exhaust system .
– Install cowling -arrow- together with radiator fans ⇒ Rep. gr.

19 ; Parts of cooling system
– Install charge air pipe on engine ⇒ Rep. gr. 21 ; Charge air
system with turbocharger .
– Install left charge air hose -arrow 1- and -arrow 2- G
⇒. VRep.
olkswagr.
gen AG
21 ; Charge air system with turbochargerlk.swagen A does
n o ot g
yV ua
db ran
ir se tee
tho or
au ac
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
– Fit right charge air hose to charge air cooler ⇒ Rep. gr. 21 ;
ot
wit
Charge air system with turbocharger .

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

spec
system; Rep. gr. 27 ; Starter .

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

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

l purpos
n
ercia
form
m
atio
com
n in
r
te o
thi
sd
iva
o
r
rp
cu
fo
m
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

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

– Push connector -2- onto reversing light switch -F4- .
lkswage es n
o ot g
yV
– Gearboxes ed for vehicles with start-stop system: ujoin
b ara connector
ris nte
-arrow- ut
hoto gearbox neutral position sender -G701- . e or
s a ac
– Push pipe/hose line or plastic line -A- to stop into slave cylinder
s
ce
e
breather and press down clip -arrow-.

nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness of i
– Remove hose clamp -3094- from supply hose.
cial p
– After removing hose clamp -3094- , return supply hose to its

nform
original shape, if necessary.

mer
atio

m
r co
n in
o
thi
te
sd
ir va
o
p
cum
for
en
ng
i t.
py Co
t. Co py
rig
gh ht
yri by
cop Vo
– Check for correct installation position of vacuum hose for
by lksw
cted agen
Prote
brake system, install vacuum hose if necessary ⇒ Rep. gr.
AG.
47 .
– Bolt selector cable support brackets to gearbox and tighten
bolts and nuts -arrows- to specified torque
⇒ Item 6 (page 71) and ⇒ Item 10 (page 71) .
– Insert gate selector cable in cable end-piece.
– Spread a small amount of grease on pin -arrow- of gearbox

selector lever -2-.
Allocate grease using ⇒ Electronic parts catalogue (ETKA) .
– Renew securing clip -1- each time it is removed.
– Install battery tray, battery cover and battery ⇒ Electrical sys‐
tem; Rep. gr. 27 ; Removing and installing battery .
– If complete air filter housing was removed, install it ⇒ Rep. gr.
23 .
– If necessary, install engine cover.
– Connect battery and followAprocedure after connecting battery
G. Volkswagen AG d
⇒ Electrical system; lkswRep.
agen gr. 27 ; Disconnecting
oes
not and con‐
necting batteryd b.y Vo gu
a
e ran
ris tee
– Check gear
ut oil ⇒ page 126 .
ho or
sa ac
– Install lower
s
part of front left wheel housing liner ⇒ General
ce
e
nl
body repairs, exterior; Rep. gr. 66 ; Wheel housing liner .
pt
du
an
itte
y li
– Install noise insulation ⇒ General body repairs, exterior; Rep.
erm
ab
gr. 50 ; Noise insulation .
ility
ot p
wit
is n
– For vehicles with front vehicle level sender -G78- , check
h re
ole,
headlight adjustment ⇒ Electrical system; Rep. gr. 94 ; Lights,
spec
lamps, switches - exterior .
t to the co
2.4 Specified torques rrectness of i
Gearbox to engine
cial p
nform
mer
a
m
tion
co
in t
or
his
ate
do
priv
cum
or
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
Item Bolt Quantity Nm
by lksw
cted agen
Prote AG.
1 M12 x 55 1 80
♦ With short M8 stud
2 M12 x 55 1 80
♦ With long M8 stud
3 M12 x 65 1 80
4 M10 x 50 2 40
5 M10 x 105 1 40
6 M12 x 165 1 80
♦ Additionally, starter to
gearbox


7 M12 x 165 1 80
♦ Additionally,
agen
AG.starter
Volkswato
gen AG
does
olksw gearbox not
V y g ua
db ran
ise t
- tho
r
M6 x 8 1 ee or 10
au ♦ Small flywheel cover ac
ss
plate (not on all en‐
ce
e
nl
pt
gines)
du
an
itte
y li
erm
ab
ility
ot p
wit
is n
Items -A- and -B-: dowel sleeves
h re
ole,
spec
– Renew bolts -1- to -5-.
t to the co
Small cover plate for flywheel on intermediate plate: 10 Nm.
Gearbox bracket -1- to gearbox.
rrectness of i
– Renew bolts.
Bolts -arrows-: 60 Nm and turn 90° further.
cial p
nform
mer
a
m
tio
o
n in
r c
te o
thi
s
a
do
ir v
p
cum
for
en
ng
i t.
py Co
t. Co py
rig
gh
Gearbox to body
ht
yri by
cop by
Vo
lksw
cted
– Renew bolts.
agen
Prote AG.
Note

3 Removing and installing gearbox, ve‐

hicles with petrol engine
3.1 Removing gearbox

equipment required
♦ Support bracket -10 - 222
A-
♦ Adapter -10-222 A /8-
♦ Adapter -10-222 A /3-
♦ Adapter -10-222 A /18-
♦ Gearbox support -3282-
wage es n
Volks ot g
d by ua
ran
ir se tee
tho
or
s au ac
s
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness of i
cial p
nform
mer
a
m
tio
o
n in
r c
te o
thi
s
a
do
ir v
p
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

♦ Support elements for gear‐

box (determine when set‐
ting adjustment plate on
gearbox support )
♦ Adjustment plate -3282/33-
gen AG
. Volkswagen AG
d wa oes
olks not
♦ Gearbox lifting btackle
yV gu
ara
ed
-3336- for otransporting
ris nte
eo
gearboxauth ra
ss c
ce
e
nl
pt
1331-
du
an
itte
y li
erm
ab
ility
1332-
ot p
wit
is n
♦ Engine and gearbox jack -
h re
ole,
V.A.G 1383 A-
spec
t to the co
rrectness of i
cial p
nform
mer
a
m
tio
o
n in
r c
te o
thi
s
a
do
ir v
p
cum
for
en
ng
i t.
py Co
t. Co py
rig
gh ht
yri by
cop by
Vo
lksw
cted agen
Prote AG.
3. Removing and installing gearbox, vehicles with petrol engine 107

♦ 2 x brackets -T10346-
♦ Engine support -3300 A-
♦ Adapter -VW 771/40-
♦ Hose clamps to 25 mm
-3094-
splines -G 000 100-
♦ Allocate grease using ⇒
Electronic parts catalogue
(ETKA) .
♦ Flange bolt M6 X 20.
♦ Hexagon head bolt M10 x
20
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
th
au ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
At a later point, support bracket -10-222 A- will be put onto lon‐

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

ot
wit
, is n
• To prevent damage to edges of wings, cover bottom area of

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

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

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

l purpos

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

rmat
m
to the lifting eyes of engine.

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

in
r
te o
thi
sd
iva
– Remove complete air filter housing if it is located close to the

o
r
rp
cu
battery ⇒ Rep. gr. 24 ; Repairing injection system .

fo
m
en
ng
t.
– Remove battery, battery cover and battery tray ⇒ Electrical
i
py Co
Co py
system; Rep. gr. 27 ; Removing and installing battery . gh
t. rig
ht
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cop by
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selector lever -2- and pull cable off pin -arrow-.
– Releasing cable end-piece from gate selector cable

– The relay lever is removed together with the cable end-piece
at a later point.
– Remove cable support bracket from gearbox -arrows-, lay to

side and secure with wire.
AG. Volkswagen AG d
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LHD
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hole
spec
-3094- .
es, in part or in w
t to the co
rrectness of i
l purpos
nform
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at
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Right-hand drive
– Clamp off hose of pipe/hose line -A- to slave cylinder using
hose clamp -3094- .
– Pull out clip -arrow- for pipe/hose line or plastic line to stop.
– Pull pipe/hose line or plastic line out from slave cylinder bleed‐
er and seal.
Caution
Do not operate clutch pedal any more.
– Remove earth strap -1- from top starter bolt.

– Separate electrical connector -2- for reversing light switch -
F4- .
– Remove connector and wire from starter.
AG. Volkswagen AG d
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– Remove upper engine/gearbox connecting bolts -arrows-.
s
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nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness of i
– Then remove upper securing bolt on starter.

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

mer
tery tray.
a
m
tion
o
– To do this, use a collar bolt M 6 x 80 or a securing bolt for

c
in t
or
battery tray.
his
ate
do
iv
– Remove both foam pieces from upper edge of left and right
pr
cum
or
wings ⇒ Body, front; Rep. gr. 50 .

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

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

AG. Volkswagen AG d
– Use: agen oes
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♦ Adapter -10-222 rA ise/3-
d
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♦ Adapter -10-222
ss
au
A /8- ra
c
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♦ Adapter -10-222 A /18- e
nl
pt
du
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itte
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– Position adapter -10-222 A /8- :
erm
ab
ility
ot p
• On upper longitudinal carrier, directly before the elevation
wit
(-arrow 1-) next to bolt (-arrow 2-)
is n
h re
ole,
– Connect engine and bracket -T10346- to support bracket .
spec
– Take up weight of engine/gearbox assembly and support
t to the co
bracket on spindles.
rrectness of i
cial p
The left drive shaft will be removed in a later step.
nform
mer
– With vehicle standing on its wheels, loosen front left flange bolt
a
-arrow- 90° at most, or wheel bearing will be damaged ⇒
m
tion
o

c
in t
or
his
ate
do
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p
cum
or

f
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ng
t.
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op
– Remove lower part of front left wheel housing liner ⇒ General C py
ht. rig
body repairs, exterior; Rep. gr. 66 ; Wheel housing liner . rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– If front vehicle level sender -G78- is present, unbolt it from

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

air system with turbocharger

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

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

Rep. gr. 26 ; Removing and installing parts of exhaust system
and secure it.
lkswage es n
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oris tee
uth or
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ss
ce
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nl
pt
du
an
– Remove pendulum support.
itte
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erm
ab
ility
ot p
wit
is n
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ole,
spec
t to the co
rrectness of i
cial p
nform
– Pull connector -1- off oil level and oil temperature sender -
mer
G266- .
a
m
tion
co
in t
– Remove left coupling rod from anti-roll bar and lay to side ⇒
or
his
e
Running gear, axles, steering; Rep. gr. 40 ; Repairing front

at
do
riv
wheel suspension .
p
cum
or
f
en
ng
– Remove left drive shaft ⇒ Running gear, axles, steering; Rep. i t.

py Co
gr. 40 ; Removing and installing drive shafts . t. Co py
rig
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– Remove drive shaft heat shield, if present -arrows- ⇒ Running

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

-arrows-.
– Remove hexagon bolts -arrows- on left engine/gearbox

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

l purpos
gine/gearbox assembly.
n
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form
m
atio
com
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te o
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– Remove bracket -1- from gearbox -arrows-.

⇒ page 75 . agen
AG. Volkswagen AG d
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– Remove gearbox eselector
db
yV lever from selector shaft. ua
ran
ris tee
ho
aut or
ac
ss
ce
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nl
pt
du
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erm
ab
ility
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wit
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hole
spec
– Remove engine/gearbox connecting bolt -1-.
es, in part or in w
t to the co
Note
rrectness of i
Loosen engine/gearbox connecting bolts -2- and leave them in‐
l purpos
stalled just hand-tight.
nform
ercia
subframe.
m
at
m
io
– In the process, position bracket -T10346- at the same angle
r co
n in t
as the engine.
o
his
ate
d
v

i
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pr
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or
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f
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t.
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Cop py
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rig ht
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Prote AG.

To remove gearbox „02Q“, set up gearbox support -3282- with
adjustment plate -3282/33- .
– Insert gearbox support -3282- in engine and gearbox jack -
V.A.G 1383 A- .
ment plate .


– Screw in pin -3282/29- instead of support element -C-.
. Volkswagen AG
does gen AG
– Position engine and gearbox olks jack -V.A.G 1383 A- under
wa notvehi‐
cle. Arrow -B- on adjustment
byV plate points in direction of vehicle
gu
ara
ed
travel. horis nte
e t or
au ac
– Align adjustment
ss plate parallel to gearbox.
ce
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pt
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ab
ility
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hole
spec
– Secure adapter -VW 771/40- in threaded hole of gearbox
es, in part or in w
t to the co
– Then screw pin -3282/29- into hole on gearbox for securing
bolt of pendulum support.
rrectness of i
l purpos
(M10x20) -A-.
nform
ercia
bottom -arrow-.
m
at
– Remove connecting bolt -C- and lower connecting bolts.
m
io
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n in t
– Press gearbox away from engine, off dowel sleeves.
o
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ate
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Right flange shaft -1- must be guided past bolt hole of engine
or
m
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Then the right flange shaft -1- must be guided past the notch
-arrow- in the intermediate plate and the flywheel.
– Tilt gearbox in area of differential using spindles of gearbox
support -3282- .
• Differential must face upwards.
– Guide gearbox with differential over subframe -A- and swing
out.

olkswagen AG
en AG. V
Golf Variant 2007 ➤ , Golf kVariant
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not
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– If necessary, turn further upwards near differential gearbox
ss
a ra
c
using spindles of gearbox support -3282- .
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pt
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erm
ab
ility
ot p
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spec
t to the co
rrectness of i
– Swivel gearbox further out and carefully lower.
cial p
nform
mer
Note
a
m
tio
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n in
Be careful of all lines when lowering gearbox.
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3.2 Transporting gearbox

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

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

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

agen
AG. Volkswagen AG d
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Note ris tee
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♦ Refer to procedure „Removing gearbox“ for required special
ce
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pt
tools ⇒ page 106 .

du
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♦ Renew self-locking nuts and bolts.

ab
ility
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♦ Renew bolts which must be tightened further to a torque angle.

wit
is n
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ole,
♦ All cable ties which were opened or cut during removal must
spec
be renewed at the same points.

t to the co
rrectness of i
cial p
– If the gearbox is to be renewed, the gearbox selector lever and

nform
relay lever must be transferred to the new gearbox.

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

m
r co
screwed must be cleaned of residual locking fluid carefully with

in
o
a thread tap.
thi
te
sd
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– Check whether dowel sleeves for aligning engine and gearbox

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If dowel sleeves are not fitted, difficulties shifting gears, clutch C py
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problems and possible noises from the gearbox (rattling of gears rig ht
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which are not engaged) could occur.
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AG. Volkswagen AG d
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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta d by 2005 ➤ , Jetta 2011 ➤ gu
ara
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– Ensure that intermediate plate is hooked into sealing flange
ce
e
nl
pt
and pushed onto dowel sleeves -arrows-.
du
an
itte
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erm
– Check release bearing for wear. If necessary, renew slave
ab
ility
cylinder with release bearing ⇒ page 40 .
ot p
wit
, is n
h re
hole
subframe.
spec
es, in part or in w
– In the process, position bracket -T10346- at the same angle
t to the co
as the engine.
rrectness of i
l purpos
nform
mercia
at
m
io
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n in t
o
his
ate
d
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or
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t.
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Cop py
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rig by
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To install gearbox „02Q“, set up gearbox support -3282- with ad‐
justment plate -3282/33- .
ment plate .

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

. Volkswagen AG
gen AG d
Golf Variant 2007V➤ olks, Golf Variant 2010 ➤ , Jetta
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ised 6-speed manual gearbox 02Q
ara - Edition 06.2010
n
r tee
ho
ut or
– Secure adapter -VW 771/40- inssthreaded
a
hole of gearbox ac
ce
e
nl
pt
du
an
itte
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erm
(M10x20) -A-.
ab
ility
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bottom -arrow-.
h re
ole,
spec
cle. Arrow on adjustment plate points in direction of vehicle
t to the co
travel.
rrectness of i
Note
Be careful of all lines when installing gearbox.

cial p
nform
mer
– Now turn gearbox in area of differential -in direction of arrow-
a
m
tio
using spindles of gearbox support -3282- .
r co
n in
o
thi
e
– Then carefully raise gearbox.

t
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for
en
ng
i t.
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t. Co py
rig
gh ht
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cop by
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Prote AG.
– Guide gearbox with differential -A- over subframe.
– Observe longitudinal member -arrows-.

– Guide gearbox with differential over subframe -A-

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

specified torque ⇒ page 124 . AG. Volkswagen AG do
agen w es n
olks o
– Screw in engine/gearbox
by
V connecting bolt -arrow- and
t gu
tighten
ara
ed
to specified torque
or
is ⇒ page 124 . nte
e th or
au ac
ss
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Remove engine support -3300 A- and bracket -T10346- .
– Screw in lower engine/gearbox securing bolts and tighten to rrectness of i
– After bottom of gearbox and engine are bolted together, re‐
l purpos
move gearbox support -3282- from gearbox.

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

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

r co
n in t
⇒ page 73 and tighten hexagon nut to specified torque

o
his
e
⇒ Item 17 (page 72) .

at
d
iv
o
pr
cu
– Install relay lever together with cable end-piece ⇒ page 75 .

or
m
f
en
ng
t.
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op py
– Install bracket -1- on gearbox using new hexagonal bolts
C
ht. rig
ht
-arrows- and tighten to specified torque ⇒ page 124 .
rig by
copy Vo
by lksw
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Prote AG.

– Align engine and gearbox in installation position. To do this,

raise sufficiently so that bracket -1- completely contacts left
assembly mounting -2-.
– Screw new hexagon bolts -arrows- for left assembly mounting
-2- into bracket -1- and tighten to specified torque
⇒ page 124 .
wage es n
Volks ot g
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Note edb ran
ris tee
tho
u or
a ac
Install engine and gearbox mounting free of tension ⇒ Rep. gr. ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
WARNING
ot p
wit
, is n
h re
Do not remove support bracket -10-222 A- until all bolts se‐
hole
spec
curing the assembly mounting have been tightened to speci‐
es, in part or in w
fied torque.
t to the co
rrectness of i
– If small cover plate -A- for flywheel is present, install it
-arrows- ⇒ page 124 .
l purpos
nform
mercia
at
m
io
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n in t
o
his
ate
d
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or
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t.
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Cop py
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rig ht
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Prote AG.
Note
♦ There are threaded inserts, e.g. „HeliCoil“ in the bolting holes

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

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

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

. Volkswage n AG n AG d
wage oes
– Install left coupling rod ⇒ Running gear, yaxles,
Vol
ks steering; Rep. not
gu
gr. 40 ; Repairing front suspension .ised b ara
nte
r
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
– If front vehicle level sender -G78- is present, bolt it onto trans‐
t to the co
verse link ⇒ Rep. gr. 40 ; Removing and installing front vehicle
level sender -G78- .
rrectness of i
cial p
nform
mer
a
m
tio
r co
n in
o
thi
te
s
a
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p
cum
for
en
ng
– Attach connector -1- to oil level and oil temperature sender -

t.
yi Co
G266- . Cop py
t. rig
gh ht
pyri by
Vo
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cted agen
Prote AG.
– Install cowling -arrow- together with radiator fans ⇒ Rep. gr.

19 ; Parts of cooling system .

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

– Push connector -2- onto reversing light switch -F4- .
– Push pipe/hose line or plastic line -A- to stop into slave cylinder
breather and pressedown
n AG. Voclip
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wag does
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ss
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pt
du
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itte
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erm
ab
ility
ot p
wit
is n

h re
ole,
spec
– Remove hose clamp -3094- from supply hose.

t to the co
– After removing hose clamp -3094- , return supply hose to its

original shape, if necessary.
rrectness of i
cial p
nform
mer
a
m
tio
r co
n in
o
thi
– Check for correct installation position of vacuum hose for

te
s
a
brake system, install vacuum hose if necessary ⇒ Rep. gr.

do
ir v
p
47 .
um
for
en
ng
i t.
– Bolt selector cable support brackets to gearbox and tighten
py Co
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bolts and nuts -arrows- to specified torque t. rig
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– Insert gate selector cable in cable end-piece.
Prote AG.
– Spread a small amount of grease on pin -arrow- of gearbox

selector lever -2-.

Allocate grease using ⇒ Electronic parts catalogue (ETKA) .

– Renew securing clip -1- each time it is removed.
– Install battery tray, battery cover and battery ⇒ Electrical sys‐
tem; Rep. gr. 27 ; Removing and installing battery .
– If removed, install complete air filter housing ⇒ Rep. gr. 24 ;
– Install plenum chamber cover with seal.
⇒ Glazing; Rep. gr. 64 ; Assembly overview - plenum chamber
cover
– Set both foam pieces on upper edge of left and right wings ⇒
Body, front; Rep. gr. 50 .
– If necessary, install engine cover.
– Connect battery and follow procedure after connecting battery
⇒ Electrical system; Rep. gr. 27 ; Disconnecting and con‐
necting battery .
– Check gear oil ⇒ page 126 .
– Install lower part of front left wheel housing liner ⇒ General
n AG. Volkswagen A ge G do
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– Install noise insulation ⇒ General bodybrepairs,
yV
olk exterior; Rep. ot g
ua
gr. 50 ; Noise insulation . ir se
d ran
tee
tho or
– For vehicles with front vehicle slevel
sa
u
sender -G78- , check ac
headlight adjustment ⇒ Electrical system; Rep. gr. 94 ; Lights,
ce
e
nl
lamps, switches - exterior .
pt
du
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itte
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erm
ab
3.4 Specified torques
ility
ot p
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Gearbox to engine
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
m
tio
r co
n in
o
thi
e

t
sd
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1 M12 x 55 1 80
or
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en
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t.
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2 M12 x 55 1 80
rig ht
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♦ With long M8 stud
co Vo
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Prote AG.
3 M12 x 65 1 80
4 M10 x 50 2 40
5 M10 x 105 1 40
6 M12 x 165 1 80
gearbox


7 M12 x 165 1 80
gearbox
- wage
olks M6 x 8 1 10
es n
ot g
ed♦by Small flywheel cover
V ua
ra
ris plate (not on all en‐ nte
tho eo
s au gines) ra
c
s
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nl
pt
du
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itte
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erm
ab
Items -A- and -B-: dowel sleeves
ility
ot p
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– Renew bolts -1- to -5-.
is n
h re
ole,
Small cover plate for flywheel on intermediate plate: 10 Nm.
spec
Gearbox bracket -1- to gearbox.
t to the co
– Renew bolts.
rrectness of i
cial p
nform
mer
a
m
tion
co
in t
or
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ate
do
priv
cum
or
f
en
ng
Gearbox to body
t.
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Cop py
– Renew bolts. ht. rig
rig ht
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Bolts -arrows-: 60 Nm and turn 90° further. by c lksw
cted agen
Prote AG.
Note


4 Checking gearbox oil

AG. Volkswagen AG d
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edb ara
ris nte
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aut ra
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nl
pt
du
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itte
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erm
ab
ility
ot p
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spec
t to the co
♦ Multi-point bit -3357-
rrectness of i
cial p
nform
mer
atio
m
r co
n in
o
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te
sd
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en
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rig
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Gearbox oil specification ⇒ Electronic parts catalogue „ETKA“ .
by
cop by
Vo
lksw
cted agen
Prote AG.

– To check gear oil, remove oil plug -arrow-.
Oil level is correct when gearbox is filled to lower edge of filler
hole.
– Screw in plug -arrow- with new seal.
– Tighten bolt -arrow- to specified torque ⇒ page 127 .
When filling with oil, note the following:
– Remove oil plug -arrow-.
– Fill with gear oil to lower edge of filler hole.
– Screw in plug -arrow- with new seal.
– Tighten bolt -arrow- to specified torque ⇒ page 127 .

Golf Variant 2007 ➤ , Golf
wageVariant 2010 ➤ , Jetta
es n 2005 ➤ , Jetta 2011 ➤
Volks 6-speed manual gearbox ot02Q
gu - Edition 06.2010
by a
ed ran
ris tee
ho
Various versions of oil filler and drain plugs
au
t or
ac
ss
I - Oil filler or oil drain plug with multi-point socket head 45 Nm
ce
e
nl
pt
du
an
II - Oil filler or oil drain plug with hexagon socket head 30 Nm
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness of i
cial p
nform
mer
atio
m
r co
n in
o
thi
te
sd
ir va
o
p
cum
for
en
ng
t.
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Cop py
ht. rig
ht
rig by
copy Vo
by lksw
cted agen
Prote AG.
4. Checking gearbox oil 127

5 Dismantling and assembling gearbox
5.1 Overview - rear final drive
1 - Clutch housing
2 - Reverse shaft
reverse gears
4 - Slave cylinder with clutch
release bearing
5 - Input shaft
4th gears
7 - Differential
wage es n
8 - Right flange shaft y Volks ot g
ua
edb ran
9 - Left flange shaft horis tee
ut or
a ac
10 - Synchromeshed gear for ss
2nd gear
ce
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nl
pt
du
an
itte
11 - Synchromeshed gear for
y li
erm
ab
1st gear
ility
ot p
wit
is n
h re
4th gear
ole,
spec
t to the co
3rd gear
5th gear
rrectness of i
6th gear
cial p

nform
reverse gear
mer
a
m
17 - Gearbox housing
ion
co
in t
or
his
ate
do
iv
pr
cum
or
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

5.2 Assembly overview
l - Removing and installing

gearbox housing and selector
mechanism ⇒ page 130
ll - Removing and installing in‐
put shaft, output shafts, differ‐
ential and selector rods
⇒ page 132
AG. Volkswagen AG d
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itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness of i
cial p
nform
mer
a
m
tion
co
in t
or
his
te
Note
a
do
priv
cum
or
f
From gearbox date 21 01 8, sealing cover for input shaft is se‐

en
ng
i t.
cured with a retaining ring -A-.
py Co
t. Co py
rig
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cop
Assembly order, gearbox »without« retaining ring -A- for input
Vo
by lksw
cted
shaft sealing cover ⇒ page 134
agen
Prote AG.
Assembly order, gearbox »with« retaining ring -A- for input shaft
sealing cover ⇒ page 145
5. Dismantling and assembling gearbox 129

wage es n
olks
5.3 Removing and installing gearbox housing and selector mechanism
d by V ot g
ua
ran
rise tee
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1 - Countersunk bolt, 33 Nm ss
ce
e
nl
pt
2 - Flange shaft with compres‐ du
an
itte
sion spring
y li
erm
ab
ility
ot p
⇒ page 227
wit
is n
h re
❑ Assembling
ole,
spec
⇒ page 233
t to the co
3 - Retaining ring
❑ For sealing cover
rrectness of i
❑ Fitted from gearbox
date 21 01 8
4 - Cover plate
cial p
nform
❑ Secured with retaining
mer
ring from gearbox date
a
m
tion
21 01 8
co
in t
or
❑ Allocate components
his
te
iva
according to ⇒ Elec‐
do
pr
c
tronic parts catalogue
um
for
„ETKA“ .
en
ng
i t.
py Co
Co
5 - Retaining ring
py
ht. rig
rig ht
❑ For deep groove ball
py by
co Vo
by lksw
bearing of input shaft Prote
cted AG.
agen
6 - Reversing light switch -F4- ,
20 Nm
❑ Changed to captive seal
shortly after introduction
of gearbox
⇒ Item 7 (page 130) .
7 - Seal
❑ Not fitted in all gearbox‐
es
❑ Always renew
8 - Oil drain plug
❑ Torque setting ⇒ page 127
9 - Seal
❑ Always renew
10 - Locking bolt, 45 Nm
❑ For selector shaft
11 - Bolt, 15 Nm + turn 90° further
❑ Bolt with captive washer only as replacement part
❑ Always renew; allocate shim according to ⇒ Electronic parts catalogue „ETKA“
❑ Allocation of bolts as replacement part ⇒ page 131
12 - Bolt, 15 Nm + turn 90° further
❑ Without washer
❑ Always renew; allocate shim according to ⇒ Electronic parts catalogue „ETKA“
❑ Allocation of bolts as replacement part ⇒ page 131
13 - Selector unit
❑ (Selector shaft with selector shaft cover)

❑ Repairing ⇒ page 172 .
❑ Removing with gearbox installed:
♦ Remove battery and battery tray ⇒ Electrical system; Rep. gr. 27 ; Battery; Removing and installing battery .
♦ The angled rod ⇒ Item 6 (page 160) for adjusting the selector mechanism must not be engaged.
Volkswagen AG
♦ Remove selector cables and gearbox selector lever s⇒wapage
gen AG71
.
does
olk not
yV gu
♦ Remove locking screw ⇒ Item 10 (page 130)seandd b pull out selector mechanism ara
nte
ri
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14 - Bolt, 20 Nm aut ra
c
ss
❑ Always renew
ce
le
un
pt
an
d
15 - O-ring
itte
y li
rm
ab
❑ Always renew
pe
ility
ot
wit
16 - Clutch housing
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
Allocation of bolts as replacement parts
l purpos
A - Bolt with captive washer
n
ercia
B - Bolt without washer
form
m
atio
C - Bolt with captive washer
com
n in
r
te o
thi
sd
iva
o
r
rp
cu
fo
m
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ng
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py Co
t. Co py
rig
gh ht
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cop by
Vo
lksw
cted agen
Prote AG.

5.4 Removing and installing input shaft, output shafts, differential and selector
rods

4th gears
❑ Dismantling and assem‐
bling ⇒ page 187
⇒ page 133 n AG. Volkswagen AG do
swage es n
2 - Selector rod with selector byV
olk ot g
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fork for 1st and 2nd gears ris
ed ran
tee
tho
❑ Installation position au or
ac
⇒ page 133 ss
ce
e
nl
pt
du
3 - Selector rod with selector
an
itte
y li
fork for 3rd and 4th gears
erm
ab
ility
ot p
⇒ page 133
wit
is n
h re
ole,
spec
reverse gears
t to the co
bling ⇒ page 211
rrectness of i
⇒ page 133
fork for 5th and 6th gears
cial p
nform
mer
⇒ page 133
atio
m
r co
6 - Selector fork for reverse
n in
o
gear
thi
te
sd
ir va
o
p
cum
⇒ page 133
for
en
ng
i t.
❑ Distinguishing py Co
Co py
⇒ page 176 t. rig
gh ht
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❑ Repairing ⇒ page 175 . op
c Vo
by lksw
cted agen
Prote
7 - Input shaft
AG.

bling ⇒ page 178
❑ Always renew deep groove ball bearing on input shaft ⇒ Item 6 (page 180) .
8 - Reverse shaft
❑ With thrust washer
9 - Thrust washer
10 - Breather
❑ Connect to slave cylinder ⇒ Item 14 (page 132)
11 - Clutch housing
13 - O-ring
❑ Moisten with brake fluid before installing

14 - Slave cylinder with clutch release bearing

15 - Bolt
❑ Qty. 3
❑ Always renew
❑ Without locking fluid 12 Nm (only slave cylinders with metal housing)
❑ With locking fluid 15 Nm (for plastic slave cylinders)
❑ Carefully tighten diagonally in small steps so that the bolting eyes of the slave cylinder do not break off
16 - Countersunk bolt, 33 Nm
nA n AG d G. Volkswage
17 - Flange shaft with wage
olkscompression spring
oes
not
y V gu
b ara
❑ Removing ris
ed and installing ⇒ page 227 nte
ho eo
❑ Assembling
au
t ⇒ page 233 ra
c
ss
18 - Differential
ce
le
un
pt
an
d
❑ Dismantling and assembling ⇒ page 233

itte
y li
rm
ab
pe
ility
ot
wit
, is n
Installation position of shafts and selector rods in gearbox
h re
hole
spec
1 - Input shaft
es, in part or in w
t to the co
2 - Output shaft for 1st through 4th gears
3 - Output shaft for 5th, 6th and reverse gear
rrectness of i
4 - Reverse shaft
l purpos
A - Selector rod for 3rd and 4th gears

B - Selector rod for 1st and 2nd gears n
ercia
for
C - Selector rod for 5th and 6th gears

m
m
atio
com
D - Selector fork for reverse gear 1)

n in
r
te o
thi
1)
sd
In some gearboxes, mounting of reverse gear selector fork on

iva
o
r
selector rod for selector fork for 5th and 6th gears - C - . Distin‐
rp
cu
fo
guishing between reverse gear selector forks ⇒ page 176 .

en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

5.5 Assembly order, gearbox »without« retaining ring -A- for input shaft sealing
cover
Removing and installing gearbox housing, selector mechanism,
input shaft, output shafts, differential and selector rods.

equipment required
♦ Support plate -VW 309-
♦ Support clamp -VW 313-
♦ Gearbox support -VW 353-
♦ Sleeve -VW 455- or sleeve
-3160-
♦ Multipurpose tool -VW 771-
♦ -1- Internal puller -Kukko
21/01-
♦ -3- Splitter -Kukko 17/0-
♦ -4- Counter support -Kukko
22/1-
wage es n
Volks ot g
d by ua
ran
ir se tee
tho
or
s au ac
s
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness of i
cial p
nform
mer
a
m
tio
r co
n in
o
thi
te
sd
ir va
o
p
cu
or
m
f
en
ng
t.
yi Co
Cop py
ht. rig
ht
rig by
copy Vo
by lksw
cted agen
Prote AG.

♦ Support bridge -30 - 211 A-

♦ Drift -T10169-
♦ or drift -T10362-
⇒ page 163
1331-
♦ Hot air blower -V.A.G 1416-
wage es n
Volks ot g
by ua
d ran
rise tee
tho
u or
a ac
ss
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e
nl
pt
du
an
itte
y li
erm
♦ Drip tray for workshop hoist -VAS 6208-

ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
m
io
r co
n in t
o
his
ate
d
iv
o
pr
cu
or
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

5.5.1 Removing wage

es n
V olks ot g
– Secure gearbox to assembly stand using d by bolts -arrows-. ua
ran
ir se tee
tho
or
s au ac
s
Note
ce
e
nl
pt
du
an
itte
If one of the bolting holes does not contact the gearbox support ,
y li
erm
ab
lay a washer between the hole and the gearbox support .
ility
ot p
wit
is n
h re
– Rotate gearbox on assembly stand so that oil drain plug is
ole,
below.
spec
– Place drip tray underneath.
t to the co
– Drain gear oil.
rrectness of i
– Remove slave cylinder with clutch release bearing -arrows-.
cial p
nform
mer
a
m
tio
r co
n in
o
thi
te
s
a
do
ir v
p
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted
During the following steps, ensure that the selector shaft is not
agen
Prote AG.
blocked by the angled rod -arrow-.
– Move selector shaft to neutral.
– Remove reversing light switch -F4- -1-.
– Remove locking bolt -2-.
– Then remove bolts -3-.
– Pull selector shaft with selector shaft cover -4- out of gearbox
housing.
– Remove securing bolt for left and right flange shaft by screwing
two bolts into flange and counterholding using a lever.
– Pull out flange shafts with compression spring.

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

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

The lengths of the splines on the input shaft differ to those of the
gearbox.
– Set either installing sleeve -VW 455- over input shaft on clutch
housing
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
se nte
ori eo
th
au ra
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nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
– or set sleeve -3160- over input shaft on clutch housing
t to the co
– Clamp splitter -A-, e.g. -Kukko 17/0- , behind notch in splines
of input shaft.
rrectness of i
The back side of the splitter must rest against installing sleeve -
VW 455- or sleeve -3160- without play.
cial p
nform
mer
a
m
tio
r co
n in
o
thi
te
s
ir va
do
p
cum
– Pierce rubber in centre of cover -C- with a screwdriver.

for
en
ng
t.
yi Co
– Pull cover plate out of gearbox housing. t. Cop py
rig
gh ht
A - Counter support , e.g. -Kukko 22/1- yri
p by
co Vo
by lksw
cted
B - Internal puller, 8 … 12 mm , e.g. -Kukko 21/01-
agen
Prote AG.

Remove retaining ring -C- from deep groove ball bearing of input
shaft in gearbox housing as follows:
– Hold one end of retaining ring with screwdriver -A-.
– Using a screwdriver , -B-, lever other end out of groove in deep
groove ball bearing -direction of arrow-.
– Using screwdriver -B-, lever out securing ring further.
– If present, remove washer -1- from gearbox housing -2-.

• If gearbox housing is to be renewed, check whether washer
must be installed ⇒ page 141 .
– Remove securing bolts -A- for gearbox housing to clutch hous‐

ing. Volkswa n AG. gen AG
wage does
Volks not
gu
by ara
ed nte
oris eo
th
au ra
c
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un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
– Screw adapter -VW 771/40- into threaded hole of gearbox

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

clutch housing in -direction of arrow-.
n
ercia
form
m
atio
com
Note
n in
r
te o
thi
If necessary, carefully apply lever on alternating sides at over‐

sd
iva
o
r
hanging housing shoulders along perimeter, being careful not to

rp
cu
fo
damage sealing surfaces.

en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

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

-2-.
– If gearbox housing is to be renewed, check whether washer
must be re-installed ⇒ page 141 .
lkswage es n
o ot g
byV ua
ed ran
oris tee
th or
au ac
ss
ce
e
nl
pt
du
an
– Remove splitter -A- and installing sleeve VW 455 (fig.) or
itte
y li
sleeve -3160- from input shaft.
erm
ab
ility
ot p
To remove shafts from clutch housing, a second mechanic is re‐
wit
is n
quired.
h re
ole,
spec
t to the co
rrectness of i
cial p
nform
– With left hand, raise differential -1-. With right hand, lift output
mer
shaft for 1st to 4th gear together with selector rods -2- a
m
tio
-arrow A-.
r co
n in
o
thi
te
– At same time, second mechanic lifts input shaft, reverse shaft

s
a
do
ir v
and output shaft for reverse, 5th and 6th gears -3- together
p
cum
with selector rods out of clutch housing -arrow B-.

for
en
ng
i t.
py Co
t. Co py
rig
Note
gh ht
yri by
y cop Vo
lksw
b
cted agen
After shafts are lifted, differential may be set back in clutch hous‐
Prote AG.
ing if desired.
– Remove input shaft oil seal.
Note
Always renew deep groove ball bearing on input shaft

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

AG. Volkswagen AG d
agen oes
olksw not
V gu
by
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jettari2005
se
d ➤ , Jetta 2011 ➤ ara
nte
6-speed manual gearbox 02Q - Edition 06.2010 autho eo
ra
ss c
ce
e
– Insert input shaft -1-, output shaft for 5th and 6th gears -2-
nl
pt
du
together with selector rod -3-, selector fork -4- and reverse
an
itte
y li
shaft -5-.
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness of i
cial p
– Then insert differential -1-.
nform
mer
a
m
ti
Note
o
o
n in
r c
te o
thi
A second mechanic will be required for further installation of
s
a
do
ir v
shafts in clutch housing.

p
cum
for
en
ng
i t.
py Co
– Take output shaft for 1st through 4th gears -3- with selector . Co py
rig
rods -4- in the right hand as shown in figure.
t
gh ht
yri by
cop Vo
– With the left hand, lift differential -1- slightly.
by lksw
cted agen
Prote AG.
– At the same time, a 2nd mechanic must slightly lift input shaft
and output shaft for 5th and 6th gears and reverse gear -2-
together with reverse gear shaft.
– Now insert output shaft for 1st through 4th gears in
-direction of arrow-.
• The teeth of the input shaft, the output shafts and the final drive
input gear of differential must mesh.
– Now, together with a second mechanic, place shafts and dif‐
ferential in their bearing seats.
– Secure support bridge -30 - 211 A- for input shaft to clutch

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

On some gearboxes, flats -A- are present on the deep groove ball
bearing for the input shaft and the bearing support -B-.
Volkswa AG. gen AG
agen does
Check deep groove ball bearing for inputVoshaft
lksw and gearbox hous‐ not
gu
y
ing. se
d b ara
nte
ri
tho eo
Deep groove ball bearing fors ainput
u shaft and gearbox housing ra
c
s
ce
e
No flats on deep groove ball bearing -A- or on bearing support
nl
pt
du
-B- ⇒ page 141
an
itte
y li
erm
Flats on deep groove ball bearing -A- and on bearing support
ab
ility
-B- ⇒ page 142
ot p
wit
is n
h re
From gearbox date 10 04 6 through around gearbox date 20 01 8:
ole,
spec
A washer is installed above and one below the deep groove ball
t to the co
bearing for the input shaft ⇒ Item 6 (page 180) .
Upper washer Outer diameter 78.6 mm
rrectness of i
Lower washer Outer diameter 85 mm
cial p
Measure distance above seat for deep groove ball bearing.
nform
mer
atio
Distance above Dimension „a“ Upper washer
m
r co
deep groove ball
n in
bearing
o
thi
te
sd
ir va
Through gearbox 10 mm no
o
p
cum
or
date 09 04 6
f
en
ng
i t.
From gearbox date 10.7 mm yes
py Co
Co py
10 04 6
t. rig
gh ht
yri by
cop by
Vo
lksw
cted agen
Prote AG.
In the gearbox housing, the area below the seat for the deep
groove ball bearing is also modified -arrow-
Area below bearing seat Lower washer
Through gearbox Not further ma‐ no
date 09 04 6 chined
From gearbox date Machined slightly yes
10 04 6 deeper

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

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

Flats -A- on deep groove ball bearing for input shaft and on bear‐
ing support -B-
• No washers may be laid above or below the deep groove ball
bearing. agen
AG. Volkswagen AG d
oe w s no
olks t gu
• Flats -A- on deep groove ball bearing
ed
by and on bearing support
V
ara
-B- in gearbox housing must line
ho
risup. nte
eo
t
au ra
– Mark flats with coloured marks.
ss c
ce
e
nl
pt
– Transfer markings to upper area of deep groove ball bearing
du
an
itte
and to upper area of bearing support of gearbox housing (⇒
y li
erm
ab
next figure).
ility
ot p
– Heat gearbox housing for about 10 minutes to 100° C in vicinity
wit
is n
h re
of seat for deep groove ball bearing of input shaft using -hot
ole,
air blower- , e.g. -V.A.G 1416- .
spec
t to the co
Note rrectness of i
cial p
nform
♦ Heating is necessary to avoid damage to deep groove ball

mer
bearing when gearbox housing is installed.

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

r co
n in
on gearbox housing -B- and set gearbox housing in place.

o
thi
te
s
a
do
ir v
p
– For all gearboxes, heat gearbox housing for about 10 minutes

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

en
ng
t.
yi Co
shaft using -hot air blower- , e.g. -V.A.G 1416- . t. Cop py
rig
gh ht
– Apply sealant -AMV 188 200 03- evenly to sealing surface of yri
p by
o Vo
clutch housing.
c by lksw
cted agen
Prote AG.

– Set gearbox housing in place and tighten new bolts -A-, -B-
and -C- to specified torque.
Allocation of bolts:
A - Bolt with captive washer
B - Bolt without washer
C - Bolt with captive washer
– If a washer was laid on the deep groove ball bearing before

the gearbox housing was set in place, a washer -1- (outer di‐
ameter = 78.6 mm) must also be placed above the deep
groove ball bearing -2- ⇒ page 141 .
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– Install retaining
y V ring -1- for deep groove ballt gbearing
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– Remove
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– If stop sleeve for selector shaft has been removed, now drive
le
un
pt
it in to stop of tool ⇒ page 163 .

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

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ility
upwards.
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es, in part or in w
t to the co
– Insert selector shaft -1- in lower bearing -2- and in selector

rrectness of i
forks -3-.
l purpos
Note
n
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format
For better clarity, sealing cover is removed in illustration.

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

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

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

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

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

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– Shift through all gears.

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144
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Rep. gr.34 - Controls, housing
agen
Prote AG.

– Drive sealing cover into gearbox housing to stop using thrust

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

ing ring -A- for input shaft sealing cover
Removing and installing gearbox housing, selector mechanism,

input shaft, output shafts, differential and selector rods.
lkswage es n
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agen 5. Dismantling and assembling gearbox


equipment required
♦ Sleeve -VW 455- or sleeve
-3160-
21/01- n AG. Volkswagen AG do
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♦ -3- Splitter -Kukko is17/0-
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♦ -4- Counter support
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-Kukko or
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♦ Support bridge -30-211A-

♦ Drift -T10169-
♦ or drift -T10362-
⇒ page 163
1331-
♦ Hot air blower -V.A.G 1416-
AG. Volkswagen AG d
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5.6.1 Removing
mer
a
m
ti
– Secure gearbox to assembly stand using bolts -arrows-.

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Prote AG.

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

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

h re
ole,
spec
– Pull out flange shafts with compression spring.

t to the co
rrectness of i
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nform
mer
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tion
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Prote AG.

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

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

housing.
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One bolt -arrow- is located
s auoutside of bolting flange. ac
s
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le
un
pt
– Lock input shaft as follows:
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ab
The lengths of the splines on the input shaft differ to those of the
pe
ility
gearbox.
ot
wit
, is n
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hole
spec
– Set either installing sleeve -VW 455- over input shaft on clutch
es, in part or in w
t to the co
housing
rrectness of i
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– or set sleeve -3160- over input shaft on clutch housing

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

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

– Pull sealing cover out of gearbox housing.
A - Counter support , e.g. -Kukko 22/1-
Remove retaining ring -C- from deep groove ball bearing of input
shaft in gearbox housing as follows:
– Hold one end of retaining ring with screwdriver -A-.
– Using a screwdriver , -B-, lever other end out of groove in deep
groove ball bearing -direction of arrow-.
– Using screwdriver -B-, lever out securing ring further.
AG. Volkswagen AG d
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– Remove securing bolts -A- for gearbox housing to clutch hous‐
e
nl
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ility
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t to the co
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mer
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ate
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Rep. gr.34 - Controls, housing
agen
Prote AG.

– Screw adapter VW 771/40 into threaded hole of gearbox hous‐

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

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

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

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Note
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Always renew deep groove ball bearing on input shaft

⇒ Item 6 (page 180) .
rrectness of i
5.6.2 Installing
• A new deep groove ball bearing has been pressed onto the
cial p
input shaft ⇒ Item 6 (page 180) .

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151
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Prote 5. Dismantling and assembling gearbox
AG.

– First insert input shaft -1- and 5th and 6th gear output shaft
-2- together with selector rod -3-, selector fork reverse gear
-4- and reverse shaft -5-.
Note different mounting for reverse gear selector fork.
Reverse gear selector fork -1- is mounted on shaft -2- behind se‐
lector rod for 5th and 6th gear -3-.
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Reverse gear selector fork -1- is mounted on selector rod with
pt
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selector fork for 5th and 6th gear -2-.
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A second mechanic will be required for further installation of
erm
ab
shafts in clutch housing.
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– Take output shaft for 1st through 4th gears -3- with selector
ole,
rods -4- in the right hand as shown in figure.
spec
t to the co
– With the left hand, lift differential slightly.
– At the same time, a 2nd mechanic must slightly lift input shaft
and output shaft for 5th and 6th gears and reverse gear -2-
rrectness of i
together with reverse gear shaft.
– Now insert output shaft for 1st through 4th gears in
-direction of arrow-.
cial p
nfo
• The teeth of the input shaft, the output shafts and the final drive
mer
rm
input gear of differential must mesh.
atio
om
n in
c
– Now, together with a second mechanic, place shafts and dif‐

or
thi
ferential in their bearing seats.
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– Secure support bridge -30-211A- for input shaft to clutch hous‐
f
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t.
ing.
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Note
by lksw
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Prote AG.
For clarity of illustration, clutch housing is shown turned 180°.
– Screw in bolt -A- until input shaft rises slightly.
Deep groove ball bearing of input shaft fits into gearbox housing
in only one position.
There is a flat section on deep groove ball bearing and on the
bearing support for the deep groove ball bearing.
• If the flats -A- and -B- are present, no washer must be placed
above or below the deep groove ball bearing ⇒ page 183 .
• Flats -A- on deep groove ball bearing and on bearing support
-B- in gearbox housing must line up.
– Mark flats with coloured marks.
– Transfer markings to upper area of deep groove ball bearing
and to upper area of bearing support of gearbox housing (⇒
next figure).
– Heat gearbox housing for about 10 minutes to 100° C in vicinity
of seat for deep groove ball bearing of input shaft using -hot
air blower- , e.g. -V.A.G 1416- .

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

bearing when gearbox housing is installed.
♦ Apply sealant -AMV 188 200 03- evenly to sealing surface of
clutch housing.
♦ Line up marking on deep groove ball bearing -A- with marking
on gearbox housing -B- and set gearbox housing in place.
– Set gearbox housing in place and tighten new bolts -A-, -B-
and -C- to specified torque.
Allocation of bolts:
A - Bolt with captive washer.
B - Bolt without washer.
C - Bolt with captive washer.
AG. Volkswagen AG d
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t to the co
– Install retaining ring -1- for deep groove ball bearing of input
shaft.
rrectness of i
– Install support bridge -30 - 211 A- for input shaft.
– If stop sleeve for selector shaft has been removed, now drive
it in to stop of tool ⇒ page 163 .
cial p
nform
– Turn gearbox in repair stand with opening for selector shaft

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

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

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

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If selector shaft cover is tilted
ise
d relative to bolting surface, selector
b ua
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shaft is not inserted inuthlower
or
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– Tighten bolts -3- for selector shaft cover -4-.
du
an
itte
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– Screw in locking bolt -2-, ensuring that angled rod -arrow- is
erm
ab
ility
not engaged.
ot p
wit
is n
– Install reversing light switch -F4- -1-.
h re
ole,
spec
t to the co
rrectness of i
cial p
nform
– Gearboxes for vehicles with start-stop system: fit gearbox
mer
neutral position sender -G701- -arrow- and tighten securing
a
bolt to 6 Nm.
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– Drive in input shaft oil seal flush.

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

– Drive sealing cover into gearbox housing to stop of thrust

piece.
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ran
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ot p
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– Secure sealing cover with retaining ring -A-.
spec
t to the co
rrectness of i
cial p
nform
mer
atio
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n in
o
thi
te
sd
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– Install flange shafts together with springs, thrust washers and
o
p
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tapered rings.
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Prote AG.

6 Repairing gearbox housing

equipment required
♦ Drift sleeve -VW 244 B-
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a gen AG does
♦ Thrust plate -VW
Vol 401-
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♦ Thrust plate
oris -VW 402-
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♦ Press
ss a
tool -VW 407- c
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un
♦ Tube -VW 416 B-
pt
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Prote AG.
6. Repairing gearbox housing 157

♦ Guide pin -VW 436A-

♦ Guide pin -VW 439-
♦ Guide pin -10 - 15-
♦ Thrust piece -3124-
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t to the co
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mer
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♦ Drift -3264-
♦ Assembly tool -3290-
1331-
♦ Drift -T10168-
♦ Drift -T10169- or drift -
T10362- ⇒ page 163
♦ Thrust piece -T10203- wage es n
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t to the co
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cial p
nform
mer
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en
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Cop py
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Prote
♦ -1- Internal puller -Kukko 21/2-
AG.

♦ -4- Counter support -Kukko 22/2-

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

t to the co
❑ Pulling out ⇒ page 162

rrectness of i
8 - Stop sleeve
❑ Pressing out with gearbox dismantled ⇒ page 163
❑ Pressing out with gearbox assembled ⇒ page 163
cial p
❑ Stop sleeve identification ⇒ page 163

nform
mer
❑ Drive in stop sleeve with shoulder ⇒ page 164

a
m
tion
❑ Drive in stop sleeve without shoulder ⇒ page 164

co
in t
or
his
te
9 - Needle bearing
iva
do
r
❑ For reverse shaft

p
cum
for
en
ng
❑ Renew each time after removing yi

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

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

11 - Shim
❑ Adjustment overview ⇒ page 232
12 - Tapered roller bearing outer race
❑ For output shaft for 1st through 4th gears
❑ If renewed, adjust output shaft for 1st through 4th gears ⇒ page 206
13 - Shim
❑ For output shaft for 1st through 4th gears
14 - Tapered roller bearing n Aouter
G. Volkrace
swagen AG
wage does
❑ For differential Volks not
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❑ Removing oris and installing ⇒ page 233 nte
eo
th
❑ Ifss arenewed, adjust differential ⇒ page 232
u ra
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e
15 - Shim
nl
pt
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❑ For differential
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16 - Bearing bush
h re
hole
spec
es, in part or in w
t to the co
17 - Plug rrectness of i
❑ Driving out ⇒ page 165
l purpos

18 - Seal
nform
ercia

m
at
m
io
r co
n in t
o
his
e
Removing sealing cover -A-

at
d
iv
o
pr
cu
– Pierce centre of sealing cover using screwdriver -B- and lever

or
m
f
en
g
out cover -in direction of arrow-.

n
t.
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Cop py
ht. rig
ht
rig by
copy Vo
by lksw
cted agen
Prote AG.
Driving in sealing cover to stop

Removing angled rod for selector shaft

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

• Marking on angled rod -arrow- must face slave cylinder con‐
nection -1-.
• Dimension -a- must be about 45°.
wage es n
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d by ua
ran
ir se tee
tho
or
s au ac
s
Drive in angled rod for selector shaft -arrow- to stop of tool.
ce
e
nl
pt
du
an
itte
y li
erm
ab
Note
ility
ot p
wit
is n
Angled rod must be released while it is being driven in.

h re
ole,
spec
t to the co
rrectness of i
Pulling out selector rod bearing bush

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

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

io
r co
n in
o
thi
te
s
a
do
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p
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

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

n AG. Volkswagen AG
– Set gearbox ohousing
lksw
age on thrust platesd-VW
oes 401- and -VW 402-
not
so that dowel
db
y V sleeves in gearbox housing are gu not damaged.
ara
e nte
ris
utho eo
ra
a c
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
Driving stop sleeve out of assembled gearbox using guide pin -10 t to the co
- 15-
• Remove locking screw and selector shaft.
rrectness of i
– Turn gearbox so that stop sleeve does not fall in gearbox.

l purpos
n
ercia
form
m
atio
com
n in
r
te o
thi
sd
iva
o
r
rp
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fo
m
en
ng
t.
Stop sleeve identification
yi Co
Cop py
ht. rig
Following stop sleeves can be installed:
rig ht
py by
co Vo
by lksw
Stop sleeve with shoulder -arrow 1- ⇒ page 164 .
cted agen
Prote AG.
Stop sleeve without shoulder -arrow 2- ⇒ page 164 .

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

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta A2011
G. Volk➤
swagen AG
agen does
6-speed manual gearbox 02Q - Edition 06.2010 Volksw not
by gu
ara
ed nte
ris
Drive in stop sleeve with shoulder until tool makes contact tho eo
au ra
c
• Clutch housing bolted to gearbox housing. ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness of i
Drive in stop sleeve without shoulder until tool makes contact
• Clutch housing bolted to gearbox housing.
cial p
nform
mer
a
m
tion
co
in t
or
his
ate
do
iv
pr
cum
or
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote
Pulling reverse shaft needle bearing out of gearbox housing
AG.
A - Internal puller, 23.5 … 30 mm , e.g. -Kukko 21/4-

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

newed.
Pressing needle bearing -A- into gearbox housing

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

Pulling out selector shaft bearing bush

– Use thread adapter from counter support -Kukko 22/1-
-arrow-.
– Hold spindle of assembly tool -3290- securely and turn nut
-B-.
A - Internal puller, 14.5 … 18.5 mm , e.g. -Kukko 21/2-
Driving in selector shaft bearing bush -A- to stop of tool.
wage es n
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by ua
d ran
rise tee
tho
u or
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ss
ce
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nl
pt
du
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itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
Driving out plug -1-
rrectness of i
– Drive in plug -1- outwards from inside gearbox housing.
cial p
nform
mer
a
m
tion
co
in t
or
his
ate
do
priv
cum
or
f
en
ng
i t.
py Co
t. Co py
rig
gh ht
yri by
y cop Vo
lksw
b
cted agen
Prote AG.

Driving in plug -1-

– Drive in sealing plug to dimension -a-, about 3 mm below upper
edge of housing, using drift -3264- .
lkswage es n
o ot g
byV ua
d ran
rise tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness of i
cial p
nform
mer
a
m
tio
o
n in
r c
te o
thi
s
a
do
ir v
p
cum
for
en
ng
i t.
py Co
t. Co py
rig
gh ht
yri by
y cop Vo
lksw
b
cted agen
Prote AG.

7 Repairing clutch housing

equipment required
♦ Press tool -VW 407-
♦ Drift -T10168-
21/2-
21/4-
22/1-
22/2-
wage es n
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by ua
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rise tee
tho
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ss
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nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness of i
cial p
nform
mer
a
m
tio
r co
n in
o
thi
te
s
ir va
do
p
cum
for
en
ng
i t.
py Co
t. Co py
rig
gh ht
yri by
y cop Vo
lksw
b
cted agen
Prote AG.
7. Repairing clutch housing 167

1 - Bearing bush
❑ For selector rods
❑ Renew each time after
removing
2 - Reverse gear selector fork
axle
❑ Axle cannot be removed
with workshop tools
❑ If a new clutch housing
is used, a new axle must
be pressed in
⇒ page 171
❑ Place reverse gear se‐
lector fork onto shaft
⇒ page 152
❑ If shaft is not present,
mounting on selector
rod for selector fork for
5th and 6th gear
⇒ page 152
3 - Needle bearing
❑ For reverse shaft
❑ Renew each time after
removing
❑ Pressing in
⇒ page 170
4 - Dowel sleeve agen
AG. Volkswagen AG d
oes
olksw not
❑ Qty. 2 d byV gu
ara
ise nte
r
5 - Clutch housing
ut
ho eo
ra
a c
❑ If renewed: adjust output shafts and differential ⇒ page 232ss
ce
e
nl
pt
du

an
itte
y li

erm
ab
ility
ot p

wit
is n
h re
7 - Seal
ole,
spec

t to the co
8 - Washer
rrectness of i
❑ Installation position: shoulder on inner circumference faces seal ⇒ Item 7 (page 168)
cial p

fo
mer
rm
❑ If renewed, adjust differential ⇒ page 239

atio
om
n in
c
10 - Oil deflector ring

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

t
sd
iva
o
pr
cu

or
m
f
en
ng
i t.
❑ For output shaft for 1st through 4th gears py Co
t. Co py
rig
gh ht
yri by
cop Vo
168
by lksw
cted agen
Rep. gr.34 - Controls, housing Prote AG.

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

B - Internal puller, 14.5 … 18.5 mm , e.g. -Kukko 21/2-
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
r
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
Driving in selector shaft bearing bush to stop of tool

ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness of i
cial p
nform
mer
a
m
tion
co
in t
or
his
ate
do
priv
cum
or
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Pulling needle bearing out of clutch housing

B - Internal puller, 23.5 … 30 mm , e.g. -Kukko 21/4-
Note
. Volkswagen AG
gen AG does
The needle bearing is destroyed during removalVol and must be re‐
ksw
a
not
newed. se
db
y gu
ara
nte
ri
utho eo
ra
a c
ss
ce
e
nl
pt
du
an
Pressing needle bearing -A- into clutch housing
itte
y li
erm
ab
– Before pressing in, lay reverse shaft thrust washer -B- on nee‐
ility
ot p
dle bearing.
wit
is n
h re
ole,
spec
t to the co
rrectness of i
cial p
nform
Removing input shaft oil seal
mer
atio
m
r co
n in
Note
o
thi
te
sd
ir va
o
p
c
When gearbox is removed, oil seal can be removed with drift.
um
for
en
ng
t.
yi Co
Cop py
ht. rig
ht
rig by
copy Vo
by lksw
cted agen
Prote AG.
Driving in input shaft oil seal flush

AG. Volkswagen AG d
ksw
agen 6-speed
oes
n
manual gearbox 02Q - Edition 06.2010
ol ot g
yV ua
db ran
Pressing reverse gear oselector
ris
e
fork shaft into clutch housing tee
h
aut or
ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
m
io
r co
n in t
o
his
ate
d
iv
o
pr
cu
or
m
f
en
ng
i t.
py Co
t. Co py
rig
gh ht
yri by
cop by
Vo
lksw
cted agen
Prote AG.

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

erm
ab
lay lever ⇒ page 75

ility
ot p
wit
is n
6 - Selector unit
h re
ole,
❑ Consists of selector
spec
shaft and selector shaft

t to the co
cover
❑ Components cannot be separated from each other
❑ Can be removed and installed with gearbox installed
rrectness of i
7 - Bearing bush
cial p
❑ Removing and installing ⇒ Item 16 (page 161)

nform
mer
8 - O-ring
a
m
tion
o
❑ Insert in peripheral groove of selector mechanism cover

c
in t
or
❑ Coat with gear oil when installing

his
ate
do
iv
❑ Always renew
pr
cum
or
f
en
ng
9 - Cap
i t.
py Co
Co py
❑ For gearbox breather t. rig
gh ht
yri by
y cop Vo
lksw
b
cted agen
Prote AG.

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

♦ Tube -VW 423-
♦ Oil seal extractor lever -T20143/1-
wage es n
Volks ot g
y ua
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ir s tee
tho
or
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s
ce
le
♦ Sealing grease -G 052 128 A1-

un
pt
an
d
itte
y li
– Remove complete air filter housing if it is over selector shaft

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

pe
ility
Rep. gr. 24 ; Repairing injection system

ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
n
ercia
form
m
atio
com
n in
r
te o
thi
sd
iva
o
r
rp
cu
fo
m
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
173
co Vo
by lksw
Prote
cted AG. 8. Repairing selector unit
agen

Metal relay lever

– Pull off securing clip -2- and press relay lever -3- to side out of
mounting.
wage
Note y Volks
es n
ot g
db ua
e ran
ris tee
If relay lever cannot be removed due to gearbox ubracket,
tho remove or
gate selector cable from relay lever. Guide shoe
ss out of gearbox
a ac
selector lever.
ce
e
nl
pt
du
an
itte
y li
Plastic relay lever
erm
ab
ility
ot p
wit
is n
⇒ page 75 .
h re
ole,
spec
t to the co
– Remove nuts -4- and remove gearbox selector lever -1-.
– Lever out seal using oil seal extractor lever -T20143/1- .
rrectness of i
cial p
nform
mer
a
m
tio
r co
n in
o
thi
te
sd
ir va
o
p
cu
or
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
– Lightly oil outer circumference of new oil seal. py by
co Vo
by lksw
cted agen
– Fill space between sealing lip and dust lip -arrow- with sealing Prote AG.
grease -G 052 128 A1- .
– Drive in seal using thrust piece -VW 423- .

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

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

9 Repairing selector forks

equipment required
♦ Thrust plate -VW 402-
♦ Tube -VW 426-
♦ Thrust piece -VW 431-
21/3-
22/1-
AG. Volkswagen AG d
agen oes
olksw not
y V gu
db ara
ir se nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
m
io
r co
n in t
o
his
ate
d
iv
o
pr
cu
or
m
f
en
ng
t.
yi Co
Cop py
ht. rig
ht
rig by
copy Vo
by lksw
cted agen
Prote AG.
9. Repairing selector forks 175

1 - Rubber dampers
❑ Can be removed from
and inserted in selector
rod by hand
fork for 1st and 2nd gears
fork for 3rd and 4th gears wage
es n
Volks ot g
4 - Selector rod with selector d by ua
ran
fork for 5th and 6th gears rise tee
tho
u or
a ac
5 - Selector fork for reverse ss
ce
le
gear
un
pt
an
d
❑ Is mounted on shaft for
itte
y li
rm
reverse gear selector
ab
pe
ility
fork ⇒ page 152 ot
wit
, is n
❑ From gearbox manufac‐
h re
ture date 06 03 6, ball
hole
spec
sleeve
es, in part or in w
⇒ Item 6 (page 176) is
t to the co
discontinued
❑ Gradually discontinued
rrectness of i
❑ Reverse gear selector
fork is modified
l purpos
❑ If shaft for reverse gear

selector fork is not
n
ercia
f
present, mounting on
orm
selector rod for selector
m
atio
com
fork for 5th and 6th gear
n in
⇒ page 152
r
te o
thi
sd
❑ Distinguishing between
iva
o
r
reverse gear selector

rp
cu
fo
m
forks ⇒ page 176
en
ng
t.
yi Co
❑ Allocation of compo‐ Cop py
. rig
ht ht
rig by
py
parts catalogue (ETKA) co Vo
by lksw
cted agen
Prote
6 - Ball sleeve
AG.

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

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

Through gearbox manufacture date 05 03 6 - pulling out ball

sleeve for reverse gear selector fork
A - Internal puller, 18 … 23 mm , e.g. -Kukko 21/3-
wage es n
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d by ua
ran
ir se tee
tho
or
s au ac
s
ce
e
nl
pt
du
an
itte
y li
erm
ab
Through gearbox manufacture date 05 03 6 - pressing in ball
ility
sleeve for reverse gear selector fork ot p
wit
is n
h re
ole,
spec
t to the co
rrectness of i
cial p
nform
mer
a
m
tio
r co
n in
o
thi
te
s
ir va
do
p
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
ht
rig by
copy Vo
by lksw
cted agen
Prote AG.
9. Repairing selector forks 177

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

equipment required
wage es n
♦ Thrust piece -VW 431- Volks ot g
y ua
edb ran
♦ Thrust piece -VW 432- tho
ir s tee
or
au ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness of i
cial p
nform
mer
atio
m
r co
n in
o
thi
te
sd
ir va
o
p
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
178 Rep. gr.35 - Gears, shafts

AG. Volkswagen AG d
agen oes
♦ Thrust piece -VW 454- olksw not
V gu
d by ara
e nte
♦ Thrust piece -30 - 505- thoris
eo
au ra
♦ Thrust plate -40 - 105- ss c
ce
e
nl
pt
♦ Tube -2040-
du
an
itte
y li
erm
ab
ility
21/5-
ot p
wit
is n
♦ -2- Puller -Kukko 18/1-
h re
ole,
spec
t to the co
rrectness of i
22/2-
cial p
nform
mer
a
m
tion
co
in t
or
his
ate
do
priv
cum
or
f
en
ng
i t.
py Co
t. Co py
rig
gh ht
yri by
cop by
Vo
lksw
cted agen
Prote AG.
Note
♦ Install all bearings on input shaft with gear oil.

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

1 - Retaining ring
❑ For deep groove ball
bearing of input shaft
⇒ page 134
2 - Washer
❑ Outer diameter = 78.6
mm
❑ May be used only in AG. Volkswagen AG d
agen
modified gearbox hous‐ Volksw
oes
not
gu
ings (from gearbox date ed by ara
nte
10 04 6 through around thoris
eo
gearbox date 20 01 8) au ra
c
ss
⇒ page 183
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
3 - Gearbox housing
is n
h re
ole,
❑ From gearbox date
spec
10 04 6 through around
gearbox date 20 01 8,
t to the co
modified in vicinity of
seat for deep groove
ball bearing
rrectness of i
⇒ Item 6 (page 180) ,
washers
⇒ Item 2 (page 180) and
cial p
⇒ Item 4 (page 180) ,
nform
⇒ page 183
mer
❑ From around gearbox
a
m
tio
date 21 01 8, flats on
r co
n in
deep groove ball bear‐
o
thi
e
ing and on bearing sup‐

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

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

– First remove retaining ring from input shaft.
– Before setting up pulling device, set thrust piece -VW 431- and
thrust plate -40 - 105- on input shaft.
– Apply splitter -B- to peripheral groove for retaining ring in bear‐
ing.
A - Puller , e.g. -Kukko 18/1-
B - Splitter, 12 … 75 mm , e.g. -Kukko 17/1-
Pressing off 5th gear wheel

A - Splitter, 22 … 115 mm , e.g. -Kukko 17/2-
wage es n
Volks ot g
d by ua
ran
ir se tee
tho
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Pressing on gear wheel for 5th gear
hole
spec
Groove -arrow- in wheel must face upwards.
es, in part or in w
t to the co
rrectness of i
l purpos
n
ercia
form
m
atio
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n in
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Cop py
ht. rig
rig ht
py by
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by lksw
cted agen
Prote AG.
1. Input shaft 181

Pressing on deep groove ball bearing

Deep groove ball bearing with a rubber ring -arrow-
Shoulder -A- faces press tool -VW 412- . n AG. Volkswagen AG do
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ab
ility
ot p
wit
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ole,
Installation position of deep groove ball bearing
spec
Groove for retaining ring faces upwards -arrow A- and shoulder
t to the co
-arrow B- must face gear wheel for 5th gear.
– Determine and install retaining ring ⇒ page 182 .
rrectness of i
cial p
nform
mer
a
m
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n in
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for
en
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t.
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Cop py
ht. rig
rig ht
py by
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by lksw
cted agen
Prote AG.
Determining thickness of retaining ring

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

„ETKA“ .
The following retaining rings are available:

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

Pulling cylinder roller bearing out of clutch housing

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

– When pressing in, squeeze together retaining ring -arrow- of
cylinder roller bearing, using pliers -A-.
– Remove pliers before cylindrical roller bearing is in installation
position. Retaining ring must engage in groove of clutch hous‐
ing. olksw n AG. V agen AG
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1.1.1 Modification in area of deep groove ball

erm
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ility
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bearing
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ole,
From gearbox date 10 04 6 through around gearbox date 20 01 8:

spec
One washer above and one below bearing seat for deep groove
t to the co
ball bearing ⇒ Item 6 (page 180) .

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

ing seat
cial p
Through gearbox Dimension „a“ = 10 no

nform
date 09 04 6 mm
mer
From gearbox date Dimension „a“ = yes

a
m
tion
10 04 6 10.7 mm
co
in t
r
through around
o
his
e
gearbox date
at
do
riv
20 01 8:
p
cum
or
f
en
ng
From around gear‐ Below bearing seat: no

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

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

slightly deeper
In order for the washer beneath the deep groove ball bearing
⇒ Item 6 (page 180) to fit, the bearing seat for the deep groove
ball bearing -arrow- is machined out slightly.
Beneath bearing seat: Washer beneath
bearing seat
Through gearbox Not further ma‐ no
date chined
09 04 6
From gearbox date Machined slightly yes
10 04 6 deeper
through around
gearbox date
20 01 8:
From around gear‐ Flat -B- for deep no
box date 21 01 8 groove ball bearing
-A-
From around gearbox date 21 01 8, flats on deep groove ball wagen AG. Volkswagen AG doe
bearing -A- and on bearing support -B- of gearbox housing
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• If the flats are present, no washer must be placed ho above or
ris nte
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below the deep groove ball bearing. aut or
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spec
t to the co
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co
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or
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do
pr
cum
for
en
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t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

2 Output shaft for 1st through 4th gears
2.1 Assembly overview - output shaft for 1st

through 4th gears
Dismantling and assembling output shaft for 1st through 4th gears
⇒ page 187 .
Note
♦ If output shaft or tapered roller bearings have been renewed, adjust output shaft ⇒ page 206 .
♦ Always renew both tapered roller bearings together as a set.
1 - Clutch housing
2 - Oil deflector ring
Volkswagen AG
3 - Dished washer wage
n AG. does
olks not
❑ Pulling outed⇒ by page 192
V gu
ara
ris nte
❑ Pressing th in
o eo
⇒ pageau 192 ra
c
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4 - Tapered roller bearing outer

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race
itte
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ility
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❑ Pressing in
wit
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⇒ page 193
h re
ole,
spec
5 - Tapered roller bearing inner

race
t to the co
❑ Pressing off
⇒ page 192
rrectness of i
❑ Pressing on
⇒ page 193
6 - Output shaft
cial p
nform
❑ For 1st through 4th

mer
gears
atio
m
❑ Adjusting ⇒ page 206

r co
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7 - Needle bearing
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❑ For 2nd gear

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2nd gear Cop py
ht. rig
❑ 1st/2nd gear synchroni‐
rig ht
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sation modified from by c lksw
cted agen
gearbox date 26 10 9, Prote AG.
differentiation
⇒ page 195
9 - Synchro-ring (inner ring for
2nd gear)
❑ 1st/2nd gear synchronisation modified from gearbox date 26 10 9, differentiation ⇒ page 195
10 - Outer ring for 2nd gear
11 - Synchro-ring for 2nd gear
2. Output shaft for 1st through 4th gears 185

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

❑ After removing retaining ring ⇒ Item 13 (page 186) , press off with synchromeshed gear for 2nd gear
⇒ page 195
❑ Dismantling ⇒ page 197
❑ Assembling locking collar and synchro-hub ⇒ page 197
13 - Retaining ring
14 - Synchro-ring for 1st gear
15 - Outer ring for 1st gear
16 - Synchro-ring (inner ring for 1st gear)
17 - Needle bearing
❑ For 1st gear
18 - Synchromeshed gear for 1st gear
19 - Thrust washer
❑ For 1st through 4th gears
❑ Qty. 2 gen AG
. Volkswagen AG
swa does
❑ Insert lugs of thrust washer in holes of output
y V shaft
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20 - Washer ho
ris e
ut or
❑ Holds thrust washers ⇒ Item 19 s(page
s a
186) in position on output shaft ac
ce
e
nl
21 - Needle bearing
pt
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❑ For 4th gear
erm
ab
ility
ot p
22 - Synchromeshed gear for 4th gear
wit
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23 - Synchro-ring for 4th gear
ole,
spec
❑ Check for wear ⇒ page 199
24 - Locking collar with synchro-hub for 3rd and 4th gears t to the co
❑ After removing retaining ring ⇒ Item 25 (page 186) , pull off with 4th gear synchromeshed gear
⇒ page 195
rrectness of i

❑ Installation position, locking collar and synchro-hub ⇒ page 199
cial p
❑ Assembling locking collar and synchro-hub ⇒ page 197 and ⇒ page 197
nform

mer
a
m
tion
25 - Retaining ring
co
in t
or
26 - Synchro-ring for 3rd gear

his
ate
do
iv

pr
cum
or
f
en
ng
27 - Outer ring for 3rd gear i t.

py Co
Co
❑ Insert in synchro-ring ⇒ Item 26 (page 186) ; installation position ⇒ page 198
py
t. rig
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❑ Renew if scored
by
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28 - Synchro-ring (inner ring for 3rd gear)
Prote AG.

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

30 - Synchromeshed gear for 3rd gear

31 - Tapered roller bearing inner race
32 - Retaining ring
❑ If tapered roller bearing ⇒ Item 31 (page 187) and output shaft ⇒ Item 6 (page 185) are renewed, rede‐
termine ⇒ page 194
34 - Shim ksw
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❑ Determining
se
d b thickness ⇒ page 206 ua
ran
ri tee
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35 - Gearbox
au housing
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pt
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itte
2.2 Dismantling and assembling output
y li
erm
ab
ility
shaft for 1st through 4th gears
ot p
wit
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1st/2nd gear synchronisation modified from gearbox date 26 10 9,
hole
spec
distinguishing ⇒ page 195
es, in part or in w
t to the co
rrectness of i
l purpos
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at
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o
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ate
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pr
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t.
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Cop py
t. rig
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pyri by
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co lksw
by
cted agen
Prote AG.


equipment required
♦ Press tool -VW 408A-
♦ Tube -VW 415A-
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pt
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itte
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
m
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n in t
o
his
ate
d
iv
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pr
cu
or
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f
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t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.


wage es n
Volks ot g
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ran
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pt
du
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itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness of i
cial p
nform
mer
a
m
tion
co
in t
or
his
te
iva
do
pr
cum
for
en
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t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.


♦ Tube -VW 516-
♦ Tube -VW 519-
♦ Thrust plate -40-105-
AG. Volkswagen AG d
agen oes
olksw not
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d by ara
se nte
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ce
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nl
pt
du
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itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness of i
cial p
nform
mer
a
m
tio
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n in
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thi
te
s
ir va
do
p
cum
for
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

♦ Drift sleeve -40-20-

♦ Drift sleeve -40-21-
♦ Supplementary set for en‐
gine and gearbox support -
VW 540/1 B-
♦ Tapered roller bearing pull‐
er -V.A.G 1582-
♦ Adapter -V.A.G 1582/7-
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ab
ility
ot p
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
m
io
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n in t
o
his
ate
d
iv
o
pr
cu
or
m
f
en
ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

♦ -1- Internal puller -

Kukko 21/7-
♦ -1- Internal puller -

Kukko 21/8-
♦ -2- Puller -Kukko
18/2-
♦ -3- Splitter -Kukko
17/2-
♦ -4- Counter support -
Kukko 22/2-
Pulling dished washer
-A- out of output shaft
Pressing dished washer into output shaft

Dimension „a“ = 2 mm
wage es n
Volks ot g
d by ua
ran
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pt
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itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
Press off tapered roller bearing inner race on side facing clutch
t to the co
housing
rrectness of i
cial p
nform
mer
atio
m
r co
n in
o
thi
te
sd
ir va
o
p
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Press on tapered roller bearing inner race on side facing clutch

housing
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edb ran
ris te
Pullingutapered
tho roller bearing outer race out of clutch ehousing
or
a ac
ss
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness of i
Pressing tapered roller bearing outer race into clutch housing
– Support clutch housing with drift sleeve -40-20- directly below
cial p
bearing support.
nform
mer
a
m
tio
r co
n in
o
thi
te
s
a
do
ir v
p
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote
Pull off tapered roller bearing inner race on side facing gearbox
AG.
housing
Before setting up tapered roller bearing puller :
– Remove retaining ring for tapered roller bearing inner race on
side facing clutch housing.
– Insert press tool -VW 431- into output shaft and place thrust
plate -40-105- on that.

. Volkswage
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005ks➤
wag, eJetta 2011 ➤
n AG n AG d
oes
not
ol
6-speed manual gearbox 02Q - Edition 06.2010 d by V gu
ar
e an
ris tee
tho
Press on tapered roller bearing inner race on side facing
au gearbox or
ac
housing ss
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness of i
– Determine thickest retaining ring which will still fit and install it.
cial p
nform
mer
atio
m
Note
r co
n in
o
thi
e
Allocate retaining rings using ⇒ Electronic parts catalogue (ET‐

t
sd
ir va
KA) .
o
p
cum
for
en
ng
i t.
The following retaining rings are available:
py Co
t. Co py
rig
gh ht
yri
Thickness (mm)
by
y cop Vo
lksw
b
cted agen
1.79 1.83 1.86 Prote 1.89
AG.
1.92 1.95 1.98
Pulling outer race for tapered roller bearing out of gearbox hous‐
ing
Pressing tapered roller bearing outer race into gearbox housing

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

Pulling off synchro-hub and locking collar for 3rd and 4th gears
with synchromeshed gear for 4th gear
– First remove retaining ring.
Pressing off locking collar and synchro-hub for 1st and 2nd gears
After removing retaining ring, press off synchromeshed gear for
2nd gear together with locking collar and synchro-hub.
lkswage es n
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ed ran
oris tee
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pt
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an
2.2.1 Distinguishing 1st/2nd gear synchroni‐
itte
y li
erm
ab
sation
ility
ot p
wit
is n
♦ Up to gearbox date 25 10 9 ⇒ page 195
h re
ole,
spec
♦ From gearbox date 26 10 9 onwards ⇒ page 196
t to the co
1st/2nd gear synchronisation up to gearbox date 25 10 9
Synchro-ring -C- and inner ring -A- are made of brass. Outer ring
rrectness of i
-B- is made of steel.
Assembling 1st to 4th gear output shaft up to gearbox date
25 10 9 ⇒ page 196
cial p
nform
mer
a
m
tio
r co
n in
o
thi
te
sd
ir va
o
p
cu
or
m
f
en
ng
i t.
py Co
t. Co py
rig
gh ht
yri by
y cop Vo
lksw
b
cted agen
Prote AG.

1st/2nd gear synchronisation from gearbox date 26 10 9 onwards

Synchro-ring -C-, outer ring -B- and inner ring -A- are made of swagen AG. Volkswagen AG does
steel. yV
olk not
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edb ara
Assembling 1st to 4th gear output shaft - from gearbox horisdate nte
eo
26 10 9 onwards ⇒ page 200 s aut ra
c
s
ce
le
un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
n
ercia
2.2.2 Assembling 1st to 4th gear output shaft
form
up to gearbox date 25 10 9
m
atio
com
n in
Checking inner ring for 1st, 2nd and 3rd gears for wear
r
te o
thi
sd
iva
– Check projections on inner ring for scoring.
o
r
rp
cu
fo
m
– Press inner ring onto cone of synchromeshed gear and meas‐
en
ng
i t.
ure gap -a- using a feeler gauge.
py Co
t. Co py
rig
gh ht
yri
Gap -a- Installation dimen‐ Wear limit
by
cop Vo
sion
by lksw
cted agen
Prote AG.
1st, 2nd 3rd 0.75 … 1.25 mm 0.3 mm
gears
Checking synchro-rings for 1st, 2nd and 3rd gear for wear
– Press synchro-ring, outer ring and inner ring onto cone of syn‐
chromeshed gear and measure gap -a- using a feeler gauge.
sion
1st, 2nd 3rd 1.2 … 1.8 mm 0.5 mm
gears
– Install 2nd gear synchromeshed gear with needle bearing.

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

2nd gear
– Check lugs -arrows 1- and -arrows 2-AGfor
agen
. Voscoring.
lkswagen AG
do w es n
olks o
– Renew inner ring, outeredring
by and synchro-ring in case of scor‐
V t gu
ara
ing. ho
ris nte
e t or
au ac
– Place inner ring -A-
ss on synchromeshed gear for 2nd gear.
ce
e
Angled lugs -arrows 1- face outer ring -B-. nl
pt
du
an
itte
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– Fit outer ring -B-.
erm
ab
ility
ot p
Lugs -arrows 2- engage in notches -arrows 3- of synchromeshed
wit
is n
gear.
h re
ole,
spec
– Fit synchro-ring -C-.
t to the co
Notches -arrows 4- engage in lugs -arrows 1- of inner ring -A-.
rrectness of i
Dismantling and assembling locking collars and synchro-hubs of
cial p
1st and 2nd gears as well as 3rd and 4th gears
nform
mer
1- Spring
a
m
tion
co
2- Locking piece
in t
or
his
te
3- Locking collar
a
do
priv
cum
or
4- Synchro-hub
f
en
ng
t.
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– Slide locking collar over synchro-hub. Cop py
ht. rig
rig ht
In 3rd and 4th gear, wide collar of synchro-hub and, if present, py by
co Vo
lksw
shoulder on locking collar point in one direction.
by
cted agen
Prote AG.
Notches for locking pieces in synchro-hub and locking collar must

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

gears as well as 3rd and 4th gears
Locking collar has been pushed over synchro-hub.
– Insert locking pieces and install springs offset 120°. Angled
end of spring must locate in hollow locking piece.
Installation position of locking collar with synchro-hub for 1st and

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

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

Lugs -arrows- face synchro-hub and locking collar -A-.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
Installation position of synchro-ring -A- (1st gear ri inner ring)
se nte
tho eo
u ra
Lugs -arrows 1- locate in notches -arrows s2-s a of synchro-ring -B-. c
ce
e
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pt
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itte
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ility
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t to the co
Installing synchromeshed gear for 1st gear with needle bearing rrectness of i
Higher shoulder -A- faces 2nd gear -B-. Notches in shoulder

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

mer

a
m
tio
r co
n in
– Install 4th gear synchromeshed gear with needle bearing.

o
thi
te
sd
ir va
o
p
cu
or
m
f
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Checking synchro-ring for 4th gear for wear

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

4th gears
G. Volkswagen AG d
Wider shoulder of synchro-hub -arrow- faces
lksw
a3rd gear.
gen A oes
not
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un
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pe
ility
ot
wit
, is n
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hole
spec
Pressing on synchro-hub with locking collar for 3rd and 4th gears
es, in part or in w
t to the co
– Turn synchro-ring so that grooves align with locking pieces.
rrectness of i
– Place 3rd gear synchro-ring on locking collar with synchro-hub
l purpos
for 3rd and 4th gears.
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Installation position of 3rd gear outer ring

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Lugs -arrows- face synchro-hub and locking collar -A-. t. Cop py
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Installation position of synchro-ring -A- (3rd gear inner ring)

Lugs -arrows 1- locate in notches -arrows 2- of synchro-ring -B-.
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Installation position
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Higher shoulder
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– Install 3rd gear synchromeshed gear with needle bearing.
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Note
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spec
♦ Press on tapered roller bearing inner race ⇒ page 194 .
t to the co
♦ Determine retaining ring for tapered roller bearing inner race
⇒ page 194 .
2.2.3 Assembling 1st to 4th gear output shaft rrectness of i
- from gearbox date 26 10 9 onwards

cial p
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Check inner friction surface of 1st gear outer ring and 2nd gear
mer
outer ring for wear

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– Place inner ring -1- on cone of synchromeshed gear.

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– Press outer ring -2- on cone of inner ring. Measure gap size
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-a- at 3 points offset by 120° using feeler gauge.

um
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– Make a note of average value.
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1st and 2nd gears 1.00 … 1.80 mm 0.3 mm

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

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1st and 2nd gears as well as 3rd and 4th gears

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1- Spring
t to the co
2- Locking piece
3- Locking collar
rrectness of i
4- Synchro-hub
– Slide locking collar over synchro-hub.
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In 3rd and 4th gear, wide collar of synchro-hub and, if present,

nform
shoulder on locking collar point in one direction.

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

gears as well as 3rd and 4th gears
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Installation position of locking collar with synchro-hub for 1st and
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Identification groove -arrow 1- and narrow collar -arrow 2- of syn‐
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chro-hub face 1st gear.
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Pressing on locking collar and synchro-hub for 1st and 2nd gears
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Installation of synchro-ring
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– Insert synchro-ring -A- into synchro-hub.
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– Insert outer ring -B- into synchro-ring.
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– Insert inner ring -C- into outer ring.
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rrectness of i
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Installing synchromeshed gear for 1st gear with needle bearing
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– Install thrust washers for 1st and 4th gears
– Install 4th gear synchromeshed gear with needle bearing.
Checking synchro-ring for 4th gear for wear

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

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

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Pressing on synchro-hub with locking collar for 3rd and 4th gears
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– Turn synchro-ring so that grooves align with locking pieces.
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t to the co
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Checking inner ring for 3rd gear for wear
cial p
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– Press inner ring onto cone of synchromeshed gear and meas‐
mer
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ure gap -a- using a feeler gauge.
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3rd gear 0.75 … 1.25 mm 0.3 mm

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Prote AG.
Checking synchro-ring for 3rd gear for wear

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

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

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

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

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

♦ Determine retaining ring for tapered roller bearing inner race
⇒ page 194 .
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2.3 Adjusting output shaft for 1st through 4th gears
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♦ Universal dial gauge brack‐
et -VW 387-
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♦ Assembly tool -VW 792-
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♦ Support plate -VW 309- ss
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1331-
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♦ Internal puller -1 - Kukko
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♦ Counter support -4 - Kukko
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22/2-
rrectness of i
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(Determining shim for output shaft)

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

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6-speed manual gearbox 02Q - oEdition
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– Press tapered roller bearing outer race with 1.70 mm thick
ss
ce
le
shim into gearbox housing to stop. In the process, support
un
pt
an
gearbox housing using thrust piece -2050- directly below bear‐
d
itte
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ing support.
rm
ab
pe
ility
– Set complete output shaft for 1st through 4th gears in clutch
ot
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housing.
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spec
es, in part or in w
t to the co
rrectness of i
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– Set gearbox housing in position and tighten bolts -A- as well

as -B- alternately and diagonally to specified torque.
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– Set up measuring tools and secure to clutch housing using bolt

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

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

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

AG. Volks6-speed
wagen A manual gearbox 02Q - Edition 06.2010
agen G do
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Example: ed
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Installed shim au
t 1.70 mm or
ac
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- Measured value 0.14 mm
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+ Preload (constant) 0.20 mm
an
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Shim thickness 1.76 mm
ab
ility
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– Determine thickness of shim from table ⇒ page 209 . is n
h re
ole,
– Remove gearbox housing and pull tapered roller bearing outer
spec
race from gearbox housing.
t to the co
rrectness of i
– Remove inserted shim (1.70 mm thick) from gearbox housing.
cial p
nform
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atio
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2.3.2 Table of shims
o
p
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for
en
ng
i t.
Thickness (mm) py Co
t. Co py
rig
1.45 1.75 gh
2.05
ht
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1.50 1.80 2.10
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1.55 1.85 2.15
1.60 1.90 2.20
1.65 1.95 2.25
1.70 2.00
The various thicknesses make it possible to achieve the exact
shim thickness required.
– Determine part number of shim according to ⇒ Electronic
parts catalogue „ETKA“ .
– Press in tapered roller bearing outer race together with correct
shim (in example 1.75 mm). In the process, support gearbox
housing using thrust piece -2050- directly below bearing sup‐
port.
2.3.3 Carrying out check measurement

• Determined shim installed.

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

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

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

equipment required
♦ Press tool -VW 407- AG. Volkswagen AG d
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♦ Press tool -VW 408 A- by
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♦ Press tool -VW 412- utho eo
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♦ Tube -VW 415 A- s
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3. Output shaft for 5th, 6th and reverse gears 211


♦ Support rail -VW 457-
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♦ Installing sleeve -VW 455-
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♦ Tube -VW 519- aut ra
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♦ Thrust plate -30 - 11-
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♦ Drift sleeve -40 - 20-
♦ Tube -3296-
er -V.A.G 1582-
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♦ -3- Splitter -Kukko 17/2- d by
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♦ -4- Counter support -Kukko 22/2- uth o
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Note
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♦ If output shaft or tapered roller bearings have been renewed, adjust output shaft ⇒ page 222 .
ility
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spec
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1 - Clutch housing
2 - Washer
rrectness of i
❑ Always 0.65 mm thick
race
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nform
mer
❑ Pressing in
atio
m
⇒ page 217
r co
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race
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❑ Pressing on
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⇒ page 221 ht. rig
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5 - Output shaft by c lksw
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❑ For 5th, 6th and reverse
gears
❑ Adjusting ⇒ page 222
6 - Reverse gear synchro-hub
❑ Pressing off
⇒ page 218
⇒ page 218
❑ Pressing on
⇒ page 219
7 - Retaining ring
8 - Reverse gear locking collar
❑ With synchro-ring
9 - Needle bearing
❑ For synchromeshed
gear for reverse gear

10 - Synchromeshed gear for reverse gear

11 - Sleeve
❑ Press off together with synchromeshed gear for reverse gear ⇒ page 218
❑ Installation position: wide shoulder of sleeve faces synchromeshed gear for reverse gear
12 - Retaining ring
13 - Needle bearing
❑ For 6th gear
Volkswagen AG
15 - Synchro-ring for 6th gearwage
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❑ Check for wear ed
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16 - Locking collar
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❑ After sremoving retaining ring ⇒ Item 17 (page 216) , press off with synchromeshed gear for 6th gear
ce
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⇒ page 217
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❑ Assembling locking collar and synchro-hub ⇒ page 219 and ⇒ page 220
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17 - Retaining ring
spec
18 - Needle bearing
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❑ For 5th gear
19 - Synchro-ring for 5th gear
rrectness of i
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21 - Tapered roller bearing inner race

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22 - Retaining ring
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❑ If tapered roller bearing ⇒ Item 21 (page 216) and output shaft ⇒ Item 5 (page 215) are renewed, rede‐
um
for
termine ⇒ page 220

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❑ Pulling out ⇒ page 221 copy Vo
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❑ Pressing in ⇒ page 221 Prote AG.
24 - Shim
❑ Determining thickness ⇒ page 222
26 - Spring
27 - Locking collar
28 - Synchro-hub
29 - Locking pieces (Qty. 3)

Pulling out tapered roller bearing outer race

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

– Fit washer under outer race. wage es n
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– Support clutch housing with drift sleeve
o
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d ran
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bearing support. au
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Pulling off tapered roller bearing inner race
rrectness of i
– Before setting up pulling device, set thrust piece -VW 431- and
thrust plate -40 - 105- on output shaft.
l purpos
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at
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Pressing off synchro-hub and locking collar for 5th and 6th gears
yi Co
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with synchromeshed gear for 6th gear
C py
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– First remove retaining ring. co Vo
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Prote AG.

Pressing off sleeve -A- together with synchromeshed gear for re‐
verse gear
Pressing off reverse gear synchro-hub


– Before setting up pulling device, set thrust plate -30 - 11- on
output shaft.
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Installation position of reverse gear synchro-hub ss
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Stop of reverse gear locking collar -arrow A- faces teeth of output

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shaft -arrow B-.

erm
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ility
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spec
t to the co
rrectness of i
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Rep. gr.35 - Gears, shafts Prote
cted AG.
agen

Pressing on reverse gear synchro-hub

Pressing on sleeve -A-

Installation position: Wide collar faces reverse gear synchro‐
meshed gear.
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Checking synchro-rings for 5th and 6th gear for wear
ility
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wit
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spec
Gap -a- Installation (new) di‐ Wear limit
t to the co
mension
5. and 6th gear 1.0 … 1.7 mm 0.5 mm
rrectness of i
cial p
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mer
a
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Dismantling and assembling locking collar and synchro-hub for

io
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c
5th and 6th gears

r
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1- Spring
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2- Locking piece
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3- Locking collar C py
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– Slide locking collar over synchro-hub.
AG.

align.

Assembling locking collar with synchro-hub for 5th and 6th gears
Pressing on locking collar and synchro-hub for 5th and 6th gears
Pressing on tapered roller bearing inner race

AG. Volkswagen AG d
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– Determine thickest retaining ring which will still fit and install it.
, is n
h re
hole
– Determine retaining ring from table. Part number ⇒ Electronic

parts catalogue „ETKA“ . spec
es, in part or in w
t to the co
Available retaining rings
Thickness (mm)
rrectness of i
1.79 1.89 1.98

l purpos
1.83 1.92
1.86 1.95
nform
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ing

– Support gearbox housing with thrust piece -2050- below bear‐
ing support.
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Prote AG.

3.2 Adjusting output shaft for 5th, 6th and reverse gears

equipment required
♦ Universal dial gauge brack‐ AG. Volkswagen AG d
agen oes
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et -VW 387- by
Vol not
gu
ara
d
ir se nte
♦ Press tool -VW 407- tho eo
au ra
c
♦ Thrust piece -VW 433- ss
ce
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nl
pt
du
♦ Assembly tool -VW 792-
an
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spec
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21/7-
rrectness of i
22/2-
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It is necessary to readjust the output shaft when the following

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

– Press tapered roller bearing outer race with 1.70 mm thick

shim into gearbox housing to stop. In the process, support
gearbox housing using thrust piece -2050- directly below bear‐
ing support.
– Set complete 5th, 6th and reverse gear output shaft in clutch
housing.
AG. Volkswagen AG d
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– Set gearbox housing in position and tighten bolts -A- as well horis nte
eo
as -B- alternately and diagonally to specified torque. aut ra
ss c
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– Set up measuring tools.
e
nl
pt
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or
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– If the edge of the housing protrudes, put washers with a total
ate
do
riv
thickness of 8 mm on bolt -arrow- for securing assembly de‐

p
cum
vice -VW 792- to clutch housing.
for
en
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– Loosen clutch housing/gearbox housing securing bolts diag‐ by lksw
cted agen
Prote AG.
shaft.
– Read and note value on dial gauge (example: 0.25 mm).
Note
♦ If dial gauge indicates no value when clutch housing/gearbox

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

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

- Measured value 0.25 mm

Shim thickness 1.65 mm
– Determine thickness of shim from table ⇒ page 225 .
– Remove gearbox housing and pull tapered roller bearing outer
race from gearbox housing.
– Remove inserted shim (1.70 mm thick) from gearbox housing.
AG. Volkswagen AG d
agen oes
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d by ara
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3.2.2 Table of shims
ri
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Thickness (mm)
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1.50 1.80 2.10
itte
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1.55 1.85 2.15
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1.60 1.90 2.20
is n
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ole,
1.65 1.95 2.25
spec
1.70 2.00
t to the co
1.75 2.05
– Part numbers ⇒ Electronic parts catalogue „ETKA“ .
rrectness of i
cial p
– Press in tapered roller bearing outer race together with correct nform
shim (in example 1.65 mm). In the process, support gearbox
mer
housing using thrust piece -2050- directly below bearing sup‐

atio
m
port.
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3.2.3 Carrying out check measurement

• Determined shim installed.
– Set up measuring tools.

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

thickness of 8 mm on bolt -arrow- for securing assembly de‐
vice -VW 792- to clutch housing.
load.
shaft.
– If correct shim has been selected, dial gauge will indicate a
value between 0.15 mm to 0.25 mm.
AG. Volkswagen AG d
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or
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ate
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Prote AG.

39 – Final drive - differential

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

equipment required
♦ Puller hooks -VW 771/37-
♦ Torque wrench -
V.A.G 1331-
♦ Torque wrench -
V.A.G 1332-
♦ Sealing grease -G 052 128
A1-
♦ Drip tray
AG. Volkswagen AG d
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te
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rig
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227
Prote AG.
1. Renewing flange shaft oil seals with gearbox installed

AG. Volkswagen AG d
agen oes
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V
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 d ➤ , Jetta 2011 ➤
by gu
ara
ir se nte
6-speed manual gearbox 02Q - Edition 06.2010 th o eo
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1.1.1 Removing
mer
a
– Remove left wheel.
m
tion
co
in t
– Remove noise insulation ⇒ General body repairs, exterior; or
his
Rep. gr. 50 ; Noise insulation . ate
do
priv
cum
r
– Remove lower part of front left wheel housing liner ⇒ General
fo
en
ng
t.
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Cop py
ht.
– Remove left drive shaft ⇒ Running gear, axles, steering; Rep.
rig
rig ht
by
gr. 40 ; Repairing drive shafts; Removing and installing drive copy Vo
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shafts . cted agen
Prote AG.
– Place drip tray under gearbox.

– Remove flange shaft securing bolt by screwing two bolts into
flange and counterholding flange shaft with a lever.
– Pull out flange shaft with compression spring.
– Remove flange shaft oil seal.
228 Rep. gr.39 - Final drive - differential

1.1.2 Installing
– Drive in new seal to stop, being careful not to cant seal.
– Half-fill space between sealing lip and dust lip with sealing
grease -G 052 128 A1- .
– Insert flange shaft.

– Secure flange shaft using countersunk bolt and tighten to
specified torque ⇒ Item 10 (page 235) .
– Install left drive shaft ⇒ Running gear, axles, steering; Rep.
gr. 40 ; Repairing drive shafts; Removing and installing drive
shafts .
– Install lower part of front left wheel housing liner ⇒ General
– Install wheel ⇒ Running gear, axles, steering; Rep. gr. 44 ;
Torque settings for mounting wheels .
– Check gear oil ⇒ page 126 . n AG. Volkswagen AG do
wage es n
olks
– Install noise insulation ⇒ Generald bybody repairs, exterior; Rep.
V ot g
ua
gr. 50 ; Noise insulation . orise ran
tee
th or
s au ac
1.2 Renewing seal for right flange shaft
s
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nl
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Special tools and workshop equipment required y li

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ab
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Prote AG.
1. Renewing flange shaft oil seals with gearbox installed 229

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

wage
nshaft
AG. Vo-A-
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doe
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– Secure drive shafts with wire, taking ed care not to damage sur‐
by ara
face protection. thoris nte
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au ra
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Note
pt
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♦ With some engines, the drive shaft cannot be raised and se‐
ility
ot p
cured high enough that the flange shaft can be pulled out.
wit
is n
h re
♦ In that case, remove drive shaft ⇒ Running gear, axles, steer‐

ole,
ing; Rep. gr. 40 ; Removing and installing drive shafts .

spec
t to the co
– Place drip tray under gearbox.

rrectness of i
– Remove flange shaft securing bolt by screwing two bolts into

flange and counterholding flange shaft with a lever.
– Pull out flange shaft with compression spring.
cial p
nform
– Pry seal out using assembly lever.

mer
atio
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Prote AG.

1.2.2 Installing olkswage es n
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– Drive in new seal to stop, being
oris careful not to cant seal.
e
tee
th or
u
– Half-fill space between sealing
ss
a
lip and dust lip with sealing ac
grease -G 052 128 A1- .
ce
le
un
pt
an
d
– Secure flange shaft -A- using countersunk bolt and tighten to
itte
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rm
specified torque ⇒ Item 10 (page 235) .
ab
pe
ility
ot
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
– Attach right drive shaft to gearbox flange shaft -A- ⇒ Running
l purpos
gear, axles, steering; Rep. gr. 40 ; Repairing drive shaft; Re‐

moving and installing drive shafts .
n
ercia
form
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atio
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te o
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– Install drive shaft heat shield, if present, on engine. Tighten
agen
Prote AG.
bolts -arrows- to specified torque ⇒ Running gear, axles,
steering; Rep. gr. 40 ; Repairing drive shafts .
– Check gear oil ⇒ page 126 .
1. Renewing flange shaft oil seals with gearbox installed 231

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

readjust output shaft for 1st through 4th gear, output shaft for 5th,
6th and reverse gear or differential only if components have been
renewed which have a direct effect on the adjustment of the gear‐
box. To prevent unnecessary adjustments, refer to the following
table:
To be adjusted:
Output shaft Output shaft Differential
for 1st for 5th, 6th ⇒ page 239
through 4th and reverse
gears gears
⇒ page 206 ⇒ page 222
Parts renewed: Gearbox housing x x x
Clutch housing x x x
Output shaft for 1st through 4th x
gears
Output shaft for 5th, 6th and reverse x
gears
Differential cage x
Tapered roller bearings for 1st to x
4th gear output shaft
Tapered roller bearings for 5th, 6th x
and reverse gear output shaft
Tapered roller bearing for differen‐ x
tial
AG. Volkswagen AG d
agen oes
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rig
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232
Vo
by lksw
Rep. gr.39 - Final drive - differential cted agen
Prote AG.

3 Differential
3.1 Dismantling and assembling differential

equipment required
♦ Press tool -VW 408 A-
♦ Tube -VW 415 A-
♦ Thrust plate -3005- lkswage es n
o ot g
byV ua
ed ran
oris tee
th or
au ac
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un
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es, in part or in w
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Prote AG.
3. Differential 233
♦ Tube -3259-
♦ Tube -3296-
♦ Tube -3345-
er -V.A.G 1582-
♦ Adapter -V.A.G 1582/6A-
21/7-
♦ -2- Puller -Kukko 18/1-
22/2-
AG. Volkswagen AG d
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pt
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spec
es, in part or in w
t to the co
rrectness of i
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Note
nform
mercia
at
♦ Heat tapered roller bearing inner race to approx. 100 °C before installing.
m
io
r co
n in t
o
his
ate
d
v
♦ If tapered roller bearings, differential cage, gearbox housing or clutch housing is renewed, adjust differential
i
o
pr
cu
or
⇒ page 239 .
m
f
en
ng
t.
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Cop py
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rig by
copy Vo
by lksw
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Prote AG.

1 - Gearbox housing
2 - Shim
❑ Determining thickness
⇒ page 239
3 - Tapered roller bearing outer AG. Volkswagen AG d
race agen oes
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❑ Pulling out ⇒ page 238 d by ara
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❑ Pressing in auth eo
ra
⇒ page 238 ss c
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un
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race
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ab
pe
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❑ Pressing on
, is n
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⇒ page 237
hole
spec
5 - Differential cage
es, in part or in w
t to the co
❑ With riveted final drive
gear
rrectness of
race
l purpos

❑ Pressing on
in
ercia
f
⇒ page 238
orma
m

com
tion
race
in
r
te o
thi
sd
iva
o
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rp
cu
❑ Pressing in
fo
m
⇒ page 237
en
ng
t.
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op
8 - Washer
C py
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rig
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co Vo
by lksw
shoulder on inner cir‐ Prote
cted AG.
agen
cumference faces seal
9 - Clutch housing
10 - Countersunk bolt, 33 Nm
❑ Screw into threaded piece ⇒ Item 22 (page 236)
11 - Right flange shaft
12 - Protective ring
❑ Pry protective ring off flange shaft with a screwdriver, alternating sides ⇒ Item 11 (page 235)
❑ Install with indentation facing away from threaded hole in flange shaft
❑ Push on protective ring to stop by hand
❑ Protective ring must engage in flange shaft
13 - Seal
❑ For right flange shaft
❑ Renewing with gearbox installed ⇒ page 229
14 - Compression spring for flange shaft
❑ Installed behind flange shaft
3. Differential 235
15 - Thrust washer
❑ Installation position: shoulder faces spring, lugs, if present, face tapered ring
AG. Volkswagen AG d
16 - Tapered ring wage
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Volks not
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❑ Installation position: taper towards differential
ed cage
by ara
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is
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17 - Retaining ring au
th ra
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❑ Holds tapered ring, thrust washer and spring in position when flange shaft is removed
ce
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nl
pt
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18 - Sun wheel
itte
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ab
ility
ot p
19 - Differential pinion pin
wit
is n
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❑ Drive out using drift
ole,
spec
t to the co
20 - Spring pin
❑ For securing differential pinion pin
rrectness of i
21 - Planet pinion
cial p
nform
22 - Threaded piece
mer
atio
m
r co
n in
o
23 - One-piece thrust washer
thi
te
sd
ir va
❑ Coat with gear oil when installing
o
p
cum
for
24 - Protective ring
en
ng
i t.
py Co
❑ Pry protective ring off flange shaft with a screwdriver, alternating sides ⇒ Item 25 (page 236) Co py
t. rig
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❑ Install with indentation facing away from threaded hole in flange shaft yri by
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lksw
b
❑ Push on protective ring to stop by hand cted agen
Prote AG.
❑ Protective ring must engage in flange shaft
25 - Left flange shaft
26 - Seal
❑ For left flange shaft
❑ Renewing with gearbox installed ⇒ page 227
Pulling tapered roller bearing outer race out of clutch housing

Note
After pulling out, renew washer.

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

Volkswa
♦ Shoulder on inner circumference
swa
gen AGfaces sealnin
. ge AG
clutch
does housing.
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pt
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itte
– Before setting up pulling device, set thrust plate -40 - 105- on
y li
erm
ab
differential housing.
ility
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wit
is n
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spec
t to the co
rrectness of i
cial p
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mer
atio
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en
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Cop py
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rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

3. Differential 237

Cage with tapered rollers must be easy to turn during pressing.
ing
A - Counter support , e.g. -Kukko 22/2- AG. Volkswagen AG d
agen oes
olksw not
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B - Internal puller, 46 … 58 mm , e.g. -Kukko 21/7- ed b ara
nte
ris
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au ra
ss c
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nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
– Support gearbox housing with tube -3345- directly below bear‐
ing support.
rrectness of i
cial p
nform
mer
a
m
tion
co
in t
or
his
ate
do
priv
c
Removing and installing spring pin for differential pinion pin
um
or
f
en
ng
i t.
Removing py Co
t. Co py
rig
– Cover tapered roller bearing inner race to avoid possible dam‐
gh ht
yri by
cop
age and entry of metal particles.
Vo
by lksw
cted agen
Prote AG.
– Drive out spring pin with chisel, inserting chisel into circum‐
ferential groove.
Installing
– Drive into differential cage to stop.

Installing differential bevel gears

– Lubricate one-piece thrust washer with gear oil and install.
– Install both sun wheels and secure (e.g. with flange shaft).
– Insert planet pinions offset 180° and pivot into position.
Volkswa
– Press in differential pinion pin
swa
(-arrow
gen AG A-) to first
. gen AG
planet
does pinion.
Volk not
gu
– Place threaded pieces by
ed -arrows B- in sun gears.
ara
ris nte
tho eo
Installation position:
au shoulder to sun gear ra
c
ss
– Drive differential pinion pin into final position and secure with
ce
le
un
pt
spring pin.
an
d
itte
y li
rm
ab
pe
ility
3.2 Adjusting differential
ot
wit
, is n
h re
hole
spec
es, in part or in w
equipment required
t to the co
♦ End dimension plate -
rrectness of i
VW 385/17-
l purpos
♦ Universal dial gauge brack‐

et -VW 387-
n
ercia
fo
rmat
m
com
ion
♦ Press tool -VW 408 A-
in
r
te o
thi
♦ Thrust plate -3005-
sd
iva
o
r
rp
cu
fo
m
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
3. Differential 239
olkswagen AG
g en AG. V
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤Vo,lkJetta
swa 2011 ➤ does
not
gu
6-speed manual gearbox 02Q - Edition 06.2010 se
d by ara
nte
ri
ho eo
aut ra
ss c
♦ Tube -3259-
ce
e
nl
pt
du
♦ Tube -3345-
an
itte
y li
erm
ab
ility
ot p
1331-
wit
, is n
h re
hole
spec
21/7-
es, in part or in w
t to the co
22/2-
rrectness of i
l purpos
nform
mercia
at
m
io
r co
n in t
o
his
ate
d
iv
o
pr
cu
or
m
f
en
ng
i t.
py Co
t. Co py
rig
gh ht
yri by
y cop Vo
lksw
b
cted agen
Prote AG.
It is necessary to readjust the differential when the following com‐

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

♦ Shoulder on inner circumference faces seal in clutch housing.

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

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

A - 30 mm dial gauge extension
– Move differential up and down. Read and note play indicated
on dial gauge. (Example: 0.70 mm)
AG. Volkswagen AG d
agen
oes
olksw not
byV gu
ara
ed
is nte
The specified bearing
hor preload is obtained by adding a constant eo
value for preload
aut (0.25 mm) to the reading obtained. ra
ss c
ce
le
Example:
un
pt
an
d
itte
y li
Measured value 0.70 mm

rm
ab
pe
ility

ot
wit
, is n
Thickness of shim = 0.95 mm

h re
hole
spec
– Remove gearbox housing.

es, in part or in w
t to the co
– Pull tapered roller bearing outer race out of gearbox housing.

rrectness of i

l purpos
– Determine part number of shim according to ⇒ Electronic

parts catalogue „ETKA“ .
n
ercia
fo
– Insert shims of determined thickness, thickest shim first.

rmat
m
com
ion
The following shims are available:

in
r
te o
thi
Shim thickness (mm)

sd
iva
o
r
rp
cu
0.65 0.85 1.05 1.25

fo
m
en
ng
0.70 0.90 1.10

i t.
py Co
Co py
0.75 0.95 1.15
t. rig
gh ht
yri by
cop
0.80 1.00 1.20
Vo
by lksw
cted agen
Prote AG.
If the size of shim required is larger than those listed in the table,
insert two shims totalling the correct figure. When using two
shims, install the thicker one first.
3. Differential 241
– Press outer race in again and tighten gearbox housing to

specified torque ⇒ Item 11 (page 130) and
⇒ Item 12 (page 130) .
wage es n
Volks ot g
by ua
d ran
rise tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness of i
cial p
nform
mer
atio
m
r co
n in
o
thi
te
sd
ir va
o
p
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Golf Variant 2007

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Service

Service Department. Technical Information

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matter of course, be observed.

All rights reserved.

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4.1 Contact corrosion! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

2 Removing and installing gearbox in vehicles with turbo diesel engine . . . . . . . . . . . . . . . . 85

2 Output shaft for 1st through 4th gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185

39 - Final drive - differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227

1 Renewing flange shaft oil seals with gearbox installed . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227

1.1 Renewing oil seal for left flange shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227

1.2 Renewing seal for right flange shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229

2 Adjustment overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232

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Identification code and date of gearbox manufacture -arrow-

The gearbox code also appears on the vehicle identification

1.2 Identification code, assembly allocation and capacities

Manual gearbox 6-speed 02Q

Manual gearbox 6-speed 02Q

2.0 l - 100 kW 1.6 l - 77 kW

turbo diesel turbo diesel

Ratio: Z2 : Z1 Final drive I1) 69 : 20 = 3.450 70 : 19 = 3.684 72 : 17 = 4.235

69 : 25 = 2.760 70 : 24 = 2.917 72 : 22 = 3.273

Final drive II2)

Capacity of manual gearbox 2.3 l 2.3 l 2.3 l

Final drive for 1st to 4th gears

♦ Specification for gear oil

♦ Allocation of clutch plate and pressure plate

Allocation Model Jetta 2005 ► Jetta 2005 ► Jetta 2005 ►

2 Rep. gr.00 - Technical data

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Manual gearbox 6-speed 02Q

1)Final drive for 1st to 4th gears

Identification code KRM KXZ KZS

Manufactured from 05.07 05.09 05.09

Manual gearbox 6-speed 02Q

Manual gearbox 6-speed 02Q

Allocation Model Golf Variant 2010 ► Jetta 2011 ►

Final drive II2) 69 : 25 = 2.760 70 : 24 = 2.917

Capacity of manual gearbox 2.3 l 2.3 l

♦ Individual gear ratios

4 Rep. gr.00 - Technical data

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2 Overview - power transmission

-Arrows- indicate direction of travel.

2. Overview - power transmission 5

I - 1st gear agen

6 Rep. gr.00 - Technical data

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3 Calculating overall gear ratio „i“

3. Calculating overall gear ratio „i“ 7

4 General repair notes

4.1 Contact corrosion!

♦ Always install parts listed in the ⇒ Electronic parts catalogue

see ⇒ Workshop equipment and special tools .

4.3.1 Gearbox rrectness of i

sleeves between the engine and gearbox are correctly seated.

♦ When installing mounting brackets or waxed components,

clean the contact surfaces. Contact surfaces must be free of