Gearbox 0AH

Service
Workshop Manual
Octavia III 2013 ➤
Octavia III 2014 ➤
Manual gearbox 0AH
Edition 10.2013
Service Department. Technical Information

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
Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.
Octavia III 2013 ➤ , Octavia III 2014 ➤
Manual gearbox 0AH - Edition 10.2013
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Identification of the gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Location on the gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Identification characters, aggregate assignment, ratios, capacities . . . . . . . . . . . . . . . . . . 2
2 Overview of Transmission System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.1 Designation of components and transmission ratios . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3 General repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.1 Safety measures for working on vehicles with start/stop system . . . . . . . . . . . . . . . . . . . . 4
3.2 General repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
30 - Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1 Repairing clutch control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.2 Assembly overview - pedal cluster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.3 Assembly overview - clutch hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.4 Assembly overview - clutch release mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.5 Removing and installing bearing bush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.6 Checking the master and slave cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.7 Removing and installing clutch position sender G476 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.8 Removing and installing the over-centre helper spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.9 Removing and installing tension spring and over-centre helper spring . . . . . . . . . . . . . . . . 17
1.10 Removing and installing clutch pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
1.11 Removing and installing bearing block for clutch pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
1.12 Removing and installing the master cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
1.13 Removing and installing clutch slave cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
1.14 Removing and installing cables for clutch control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
1.15 Bleeding the clutch control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
1.16 Repairing the clutch release mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
2 Repairs on the clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
2.1 Assembly overview - clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
2.2 Removing and installing clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
34 - Controls, housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
1 Selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
1.1 Fitting location of shift mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
1.2 Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
1.3 Summary of components - Gearshift knob with shift lever collar . . . . . . . . . . . . . . . . . . . . 37
1.4 Removing and installing gearshift knob with shift lever collar . . . . . . . . . . . . . . . . . . . . . . 37
1.5 Assembly overview - Selector cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
1.6 Summary of components - Gearshift mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
1.7 Removing and installing selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
1.8 Dismantling and assembling selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
1.9 Removing and installing shift cable and selector cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
1.10 Adjusting selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
2 Removing and installing the gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
2.1 Removing the gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
2.2 Installing the gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
2.3 Specified torques for gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
3 Gear oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
3.1 Checking gear oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
4 Disassembling and assembling the gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
4.1 Schematic overview - Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Contents i
4.2 Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

4.3 Summary of components- Gearbox housing cover and 5th gear . . . . . . . . . . . . . . . . . . . . 71
4.4 Summary of components - Clutch housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
4.5 Summary of components - Drive shaft, output shaft, differential gear, gearshift mechanism,
and gearshift forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
4.6 Summary of components - Gearshift unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
4.7 Assembly overview - shift forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
4.8 Repairing gearshift forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
4.9 Repairing gearshift unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
4.10 Replace the gasket ring of the gearshift shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
4.11 Disassembling and assembling the gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
5 Gearbox housing and clutch housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
5.1 Summary of components - Gearbox housing and clutch housing . . . . . . . . . . . . . . . . . . . . 89
35 - Gears, shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
1 Input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
1.1 Summary of components - Drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
1.2 Disassembling and assembling the drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
1.3 Renewing input shaft seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
2 Output shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
2.1 Summary of components - Output shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
2.2 Disassembling and assembling the output shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
39 - Final drive - differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

1 Gasket rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
1.1 Summary of components - Gasket rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
1.2 Replacing left sealing ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
1.3 Replacing right sealing ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
2 Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
2.1 Summary of components - Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
2.2 Disassembling and assembling differential gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
2.3 Adjusting the differential gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
ii Contents
00 – Technical data
1 Identification of the gearbox
(SRL000644; Edition 10.2013)
Edition 10.2013; version 2.0
Location on the gearbox ⇒ page 1 .
Identification characters, aggregate assignment, ratios, capaci‐
ties ⇒ page 2 .
1.1 Location on the gearbox

Identification characters and production date -arrow 1-.
Identification of the gearbox 0AH -arrow 2-.
Gearbox 0AH -arrow 2-
Codes and production date of gearbox

Example: PKH 22 08 2
I I I I
Engine Day Month Manufac‐
code turing year
(2012)
Additional data provides information about the production facility.
Note
The gearbox identification characters also appear on the vehicle

data sticker.
1. Identification of the gearbox 1

1.2 Identification characters, aggregate assignment, ratios, capacities

Manual gearbox 5 speed 0AH
front-wheel-drive
Engine code PKG NHW
Manufac‐ from 12.2012 12.2012
tured to
Allocation Engine 1.2 ltr./63 kW TSI 1.2 ltr./77 kW TSI
Ratio Final drive 73 : 18 = 4,055
1st gear 49 : 13 = 3,769
2nd gear 43 : 22 = 1,954
3rd gear 41 : 32 = 1,281
4th gear 37 : 42 = 0,881
5th gear 35 : 52 = 0,673
Reverse gear 35 : 24 x 24 : 11 = 3,182
New filling 2, 2 l
Top-up Filled for life, no top-up
Lubricant Gear oil
⇒ electronic catalogue of original parts
Clutch operation hydraulic
Clutch disc ∅ ⇒ Electronic Catalogue of Original Parts
Drive shaft flange ∅ 100 mm
Volkswagen Technical Site: http://vwts.ru http://vwts.info

огромный архив документации по автомобилям Volkswagen, Skoda, Seat, Audi
2 Rep. gr.00 - Technical data

2 Overview of Transmission System

Designation of components and transmission ratios
⇒ page 3 .
2.1 Designation of components and transmission ratios
Note
The -arrows- show the direction of travel.
1 - Engine
2 - Clutch
3 - Manual gearbox
4 - Input shaft
5 - Output shaft
6 - Differential
I - 1st gear
II - 2nd gear
III - 3rd gear
IV - 4th gear
V - 5th gear
R - Reverse gear
A - Final drive
2. Overview of Transmission System 3

3 General repair instructions

Safety precautions when working on vehicles with start-stop sys‐
tem ⇒ page 4 .
General repair information ⇒ page 4 .
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 generally valid notes for individual repair operations
- which are otherwise listed several times at numerous points in
the workshop manual - are summarized here. They apply to this
workshop manual.
3.1 Safety measures for working on vehi‐

cles with start/stop system
WARNING
On vehicles with start-stop system, there is the risk of injury

from automatic engine start.
♦ Deactivate the start-stop system when working on the ve‐
hicle. Switch off ignition.
♦ If required switch on the ignition for a short period of time.
3.2 General repair instructions

Gearbox
♦ When installing the manual gearbox, ensure that the dowel
sleeves between the engine and gearbox are correctly seated.
♦ When installing carriers as well as waxed components, the
contact surfaces must be cleaned. Contact surfaces must be
free of wax and grease.
♦ Bolts and other attachments should have a classification in the
⇒ Electronic Catalogue of Original Parts .
♦ After installing, check the gear oil level ⇒ page 68 .
♦ Filling capacity ⇒ page 2 .
Gaskets and seals
♦ Before installing radial shaft seals, lightly oil outer diameter
and half-fill space between sealing lips with sealing grease -
G 052 128 A1- -arrow-.
♦ The open side of the sealing rings faces the side with fluid
filling.
♦ After installing, check the gear oil level ⇒ page 68 .
♦ Before inserting, lightly oil the O-rings in order to prevent the
rings being damaged during installation.
Sealant
♦ Thoroughly clean housing joint surfaces before applying seal‐
ant.
♦ Apply sealant - AMV 188 200 03- evenly and not too thickly.
♦ No sealant must get into the ventilation holes.

Locking devices
♦ Replace circlips.
♦ Do not overstretch retaining rings.
♦ Circlips must be positioned in the base of the groove.
♦ Replace tensioning sleeves, installation location: Slot in the
direction of the force.
Nuts and bolts
♦ Loosen and tighten securing bolts and nuts for covers and
housings diagonally.
♦ Do not twist particularly sensitive parts - e.g. clutch pressure
plates - slacken and tighten diagonally across in stages.
♦ Specified torques given are for unlubricated nuts, bolts and
screws.
♦ Always replace screws to be screwed in with locking agent and
self-locking nuts.
♦ It is important to ensure at all bolted connections that the con‐
tact surfaces as well as the nuts and bolts are waxed only after
being installed, should this be necessary.
♦ Clean all threaded holes into which bolts are screwed in with
locking agent, using a thread tap to remove hardened locking
agent residues. Otherwise there is a risk that the bolts will
shear at the next disassembling.
Bearing
♦ Lubricate all bearings with gear oil before installing.
♦ New taper roller bearings are fitted as supplied and do not
require any additional lubrication.
♦ Position needle bearing with the lettered side (thicker end) to‐
wards the drift pin.
♦ Always jointly replace tapered-roller bearings on the same
shaft and use products of the same manufacturer.
♦ Heat the inner rings with an induction heater unit , e.g. -VAS
6414- , to approx. 100°C before pressing on.
♦ Do not exchange the outer and inner rings of bearings of the
same size. The bearings are matched in pairs.
3. General repair instructions 5

Shims
♦ Gauge shims at several points with a micrometer. The various
thicknesses make it possible to achieve the exact shim thick‐
ness required.
♦ Check for burrs or damage.
♦ Install only flawless shims.
Synchro-rings
♦ Do not interchange. When reusing synchro-rings, always fit to

the same synchromeshed gear.
♦ Check for wear and renew if necessary.
♦ Check grooves -arrow 1- on synchronizer ring -A-, or check
the inside of the ring for flattened parts (grooves worn).
♦ 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- for »scor‐
ing« and »signs of abnormal wear«, »and blue discolouration
(caused by overheating)«.
♦ Check the cone of the sliding gear for »scoring« and »signs of
abnormal wear«.
♦ Install synchronisation with gearbox oil.
Pinions
♦ Clean and heat with induction heater unit , e.g. -VAS 6414- ,
to max. 100°C before pressing on.
Synchromeshed gears
♦ After installing, check the gear wheels for small axial play/
clearance.
Clutch
♦ Do not tilt the clutch pressure plate; release and tighten cross‐
wise in small stages.
♦ If the clutch has burnt out, thoroughly clean the clutch housing
and the friction surface of flywheel with a cloth to reduce the
smell of burnt linings.

30 – Clutch
1 Repairing clutch control
Overview ⇒ page 7 .
Summary of components - Foot controls ⇒ page 9 .
Assembly overview - clutch hydraulics ⇒ page 11 .
Assembly overview - clutch release mechanism ⇒ page 12 .
Removing and installing bearing bush ⇒ page 13 .
Checking the master and slave cylinder ⇒ page 14 .
Removing and installing clutch position sender -G476-
⇒ page 14 .
Removing and installing over-centre helper spring ⇒ page 15 .
Removing and installing tension spring and over-centre helper
spring ⇒ page 17 .
Removing and installing clutch pedal ⇒ page 19 .
Removing and installing bearing block for clutch pedal
⇒ page 20 .
Removing and installing master cylinder ⇒ page 24 .
Remove and install slave cylinder ⇒ page 24 .
Removing and installing cables for clutch control ⇒ page 25 .
Bleed clutch mechanism ⇒ page 27 .
Repairing the clutch release mechanism ⇒ page 28 .
1.1 Overview
1. Repairing clutch control 7

I - Summary of components -
Foot controls ⇒ page 9
II - Assembly overview - clutch
hydraulics ⇒ page 11
❑ Left-hand drive
III - Assembly overview - clutch
hydraulics
❑ Right-hand drive
8 Rep. gr.30 - Clutch

1.2 Assembly overview - pedal cluster
1 - Master cylinder
❑ removing and installing
⇒ page 24
2 - Bearing bush
⇒ page 13
3 - Clip
❑ to remove and install the
tube-hose line pull out
retaining clip up to the
stop
4 - Seal
❑ Self-adhesive
❑ after removing the mas‐
ter cylinder, replace ⇒
Electronic Catalogue of
Original Parts
❑ stick onto the master
cylinder
5 - Clutch position sender -
G476-
❑ check ⇒ Vehicle diag‐
nostic tester in the oper‐
ating mode Targeted
fault finding
❑ Assignment ⇒ Electron‐
ic Catalogue of Original
Parts
⇒ page 14
6 - Carrier bolt
❑ after removing, replace
⇒ Electronic Catalogue
of Original Parts
7 - Spring stop
8 - Hexagon nut, 25 Nm
❑ Pillar to front wall
❑ Qty. 3
❑ self-locking
❑ after removing, replace ⇒ Electronic Catalogue of Original Parts
9 - Bearing shell
❑ Qty. 2
❑ is installed on both sides
❑ mounted only in combination with over-centre helper spring
10 - Bearing bracket
❑ For clutch pedal
❑ removing and installing ⇒ page 20
11 - Over-centre helper spring
❑ installed according to the type

12 - Carrier bolt
❑ for master cylinder
13 - Over-centre helper spring
❑ different versions, assignment ⇒ Electronic Catalogue of Original Parts
14 - Bearing bush
15 - Carrier bolt
❑ of the tappet for master cylinder
16 - Clutch pedal
17 - Pedal rubber
18 - Bearing bush
19 - Tension spring
❑ For clutch pedal
20 - Damping element
❑ is only mounted in combination with tension spring

1.3 Assembly overview - clutch hydraulics
1 - Hexagon bolt, 20 Nm
2 - Bleeder valve, 4,5 Nm
❑ Bleeding the clutch con‐
trol ⇒ page 27
3 - Dust cap
4 - Supply hose
5 - Brake fluid reservoir
6 - Seal
❑ must be located on the
return hose
7 - Master cylinder
⇒ page 24
8 - Clip
❑ to remove and install the
tube-hose line pull out
retaining clip up to the
stop
9 - Seal / O-ring
❑ Renew if damaged.
❑ fit onto the line connec‐
tion
❑ Insert with brake fluid
❑ Gasket rings/O-rings
are adapted to the ver‐
sion of the line connec‐
tion ⇒ page 12
Parts
10 - Bracket
❑ for tube-hose line
11 - Tube-hose line
❑ Assignment ⇒ Electronic Catalogue of Original Parts
12 - Seal / O-ring
❑ Renew if damaged.
❑ fit onto the line connection
❑ Insert with brake fluid
❑ Gasket rings/O-rings are adapted to the version of the line connection ⇒ page 12
❑ Assignment ⇒ Electronic Catalogue of Original Parts
13 - Clip
❑ to remove and install the tube-hose line pull out retaining clip up to the stop
14 - Slave cylinder


Disconnect the cables for the clutch control and connect

Separate
– Unlock the clip -3- with a screwdriver and disconnect the tube-
hose line -1- from the connection -4-.
Connect
Note
♦ An O-ring can also be installed instead of the gasket ring -2-

⇒ page 12 .
♦ Replace damaged gasket ring -2-.
– Push in the tube-hose line -1- at the connection -4- until the
clip -3- locks audibly into place.
– For testing pull on the tube-hose line.
Seals and O-rings for pipe and hose lines

Pos. Material of line connection
1 Line connection with circumferential groove
-arrow 1-
2 Line connection with shoulder -arrow 2-
3 Line connection with shoulder -arrow 2- and cir‐
cumferential groove -arrow 3-
• In case of a line connection with round slot -arrow 1- and
-arrow 3-, a gasket ring/O-ring must be inserted.
1.4 Assembly overview - clutch release mechanism

1 - Clutch release lever

❑ Remove and install to‐
gether with the clutch re‐
lease lever and guide
bushing ⇒ page 28
❑ Remove original grease
from the contact surface
of the ball pin
❑ Grease the contact sur‐
face of the ball pin with -
G 000 100-
2 - Release bearing
❑ Remove and install to‐
lease lever and guide
bushing ⇒ page 28
❑ Do not wash out bear‐
ing; wipe only
❑ Renew noisy bearings
3 - Bolt, turn 5 Nm + 90° further
❑ Renew.
4 - Slave cylinder
⇒ page 24
5 - Gearbox
6 - Input shaft seal
❑ Renew. ⇒ page 99 .
7 - Guide sleeve
❑ remove and install to‐
lease lever and clutch
release bearing
⇒ page 28
8 - ball pin, 20 Nm
❑ Remove original grease from the contact surface of the ball pin
❑ Grease the contact surface of the ball pin with -G 000 100-
9 - Retaining spring
❑ secured to clutch release lever
1.5 Removing and installing bearing bush

Removing
– Disconnect battery earth strap ⇒ Electrical System; Rep. gr.
27 .

– Press the catches -arrows- and detach the studs -1- to the
right.
– Turn the master cylinder tappet so that the recesses -1- and
bolt -2- are visible.
The recesses -1- and bolt -2- are facing the same direction.
– Remove bearing bush -A- from recesses -1-.
Install
– Turn the master cylinder tappet so that the recesses -1- and
bolt -2- are visible.
The recesses -1- and bolt -2- are facing the same direction.
– Fit the bearing bush -A- into the recesses -1- and turn it in the
tappet lug until flush.
– Connect the master cylinder tappet with the clutch pedal, to
do so use the new carrier bolt ⇒ Electronic catalogue of orig‐
inal parts .
– Connect battery ⇒ Electrical System; Rep. gr. 27 .
1.6 Checking the master and slave cylinder

Before the master cylinder must be replaced due to a fault, first
of all carry out the test in the Targeted fault finding ⇒ Ve‐
hicle diagnostic tester.
1.7 Removing and installing clutch position

sender - G476-
Removing
– Push the driver seat as far as possible towards the rear.
– Disconnect the plug connection -arrow- at the clutch position
sender - G476- .

– Unlock catch -arrow- of clutch position sender - G476- -2- at

master cylinder -1- and remove.
Install
Installation is performed in the reverse order, while paying atten‐
tion to the following:
• The catch -arrow- at the clutch position sender - G476- must
not be damaged.
• The clutch position sender - G476- must click audibly into
place.
1.8 Removing and installing the over-centre

helper spring
Removing
27 .
– If present, remove the knee airbag -1- on the driver's side ⇒
Body Work; Rep. gr. 69 .
– Remove the footwell vent -1- on the driver's side ⇒ Heating,

Air Conditioning; Rep. gr. 87 .

– Remove data bus diagnostic interface - J533- -1- from bracket

⇒ Electrical System; Rep. gr. 97 and push it to the side.
– Unscrew screw -2-, unhook crash strut -1- aushängen and

push it to the side.
– Press the catches -arrows- and detach the carrier bolt -1- of
the tappet for master cylinder to the right.
– Swivel the clutch pedal in -direction of arrow-, unhook and re‐

move over-centre helper spring -1-.

Install
– Connect the master cylinder tappet with the clutch pedal, to
do so use the new carrier bolt ⇒ Electronic catalogue of orig‐
inal parts .
– Insert crash strut -1- and tighten screw -2- ⇒ Body Work; Rep.
gr. 70 .
– Install data bus diagnostic interface - J533- ⇒ Electrical Sys‐
tem; Rep. gr. 97 .
– Install footwell vent driver's side ⇒ Heating, Air Conditioning;
Rep. gr. 87 .
– Install knee airbag driver's side, in case it was removed ⇒
1.9 Removing and installing tension spring

and over-centre helper spring
Removing
27 .




– Press the catches -arrows- and detach the carrier bolt -1- of
the tappet for master cylinder to the right.
– If present, unhook the tension spring -1- and remove, while

doing so pull the clutch pedal in -direction of arrow A-.
– Pull the clutch pedal in -direction of arrow A-, unhook the over-
centre helper spring -2- and remove.
Install
• The bearing shells -arrows- of the bolts -1- are installed.
– Pull the clutch pedal in -direction of arrow A- (⇒ previous fig‐
ure) into the passenger compartment.

– Inser the bolt -1- into the mount -2- of the carrier.
– Insert the bearing -3- into the mount -4- for the clutch pedal.
– Press the clutch pedal in -direction of arrow B- (⇒ previous
figure), until the over-centre helper spring engages in direction
of carrier.
– Connect the tappet for master cylinder with the clutch pedal,
to do so use the new carrier bolt ⇒ Electronic catalogue of
original parts .
gr. 70 .
tem; Rep. gr. 97 .
Rep. gr. 87 .
1.10 Removing and installing clutch pedal

Removing
27 .
– Remove the mount -arrow- with the parking aid control unit -
J446- ⇒ Electrical System; Rep. gr. 94 (if installed in the area
of the carrier) and push it to the side.
Right-hand drive with Climatronic system
– Removing right temperature flap control motor - V159- ⇒
Heating, Air conditioning; Rep. gr. 87 .
Continued for all versions
– Removing over-centre helper spring from carrier ⇒ page 15 ,
or removing over-centre helper spring from carrier
⇒ page 17 .
Remove bearing block for clutch pedal

-1- - Socket wrench (SW 14)
• To remove, turn the bearing bolt for the coupling pedal towards
the left in the -direction of the arrow- until the bolts -B- are
horizontal.
Note
As a result, the catches -A- are destroyed and the bearing bolt
must be replaced ⇒ Electronic Catalogue of Original Parts .
– Slightly move the clutch pedal in order to pull out the bearing
bolt.

Install bearing block for clutch pedal

-1- - Socket wrench (SW 14)
– Slightly press on the clutch pedal and insert a new bearing bolt
⇒ Electronic catalogue of original parts .
• It is important that the bolts -A- are positioned horizontally.
– Turn the bearing bolt to the right in -direction of arrow-.
• The catches -B- must click audibly into place.
• Then the bolts -A- are positioned vertically.
– Installing over-centre helper spring at carrier ⇒ page 15 or in‐
stalling over-centre helper spring at carrier ⇒ page 17 .
Right-hand drive with Climatronic system
– Installing right temperature flap control motor - V159- ⇒ Heat‐
ing, Air conditioning; Rep. gr. 87 .
– If present, install the mount -arrow- with the parking aid control
unit - J446- ⇒ Electrical System; Rep. gr. 94 .
1.11 Removing and installing bearing block

for clutch pedal
Special tools and workshop equipment required
♦ Hose clamp - MP7-602 (3094)-
♦ Sealing tool - T10249-
Removing
– Remove the complete air filter housing if the cables for the
clutch control are not accessible ⇒ Engine; Rep. gr. 24 .
27 .
Left-hand drive
– Remove battery ⇒ Electrical System; Rep. gr. 27 .

Right-hand drive
A heat-protection matting is installed in combination with certain
engines. The appearance may differ from the figure.
– Remove heat-protection matting. Pay attention to the positions
-1...4-.
Caution
There is a danger that the brake fluid may drip out.

♦ During the following work, ensure that no brake fluid lands
on longitudinal member or gearbox. If this is the case,
clean the affected area thoroughly.
♦ Lay a lint-free cloth under master cylinder.
– Disconnect return hose -2- to master cylinder with hose clamp

- MP7-602 (3094)-
Note
♦ If the return hose with hose clamp - MP7-602 (3094)- is dis‐

connected, it will forever be deformed.
♦ However the return hose is not defective.
♦ After removing the hose clamp - MP7-602 (3094)- , it may be
necessary to bring the return hose back into its initial position.
– Pull out the clip -3- at the tube-hose line up to the stop and
detach the tube-hose line.
– Close the openings.
– Detach the return hose -2- from the master cylinder and close
with the sealing tool - T10249/1- .
– Push the driver seat as far as possible towards the rear.
– Push steering wheel as far as possible towards the top, while
doing so use the entire adjustment range of the steering col‐
umn.






Note
When working in the footwell, protect the underbody cover with

cloths from escaping brake fluid.
– Disconnect the plug connection -2- at the clutch position send‐

er - G476- .
– Unscrew nuts -arrows- and remove carrier -1-.
Install
Note
Replace self-locking nuts each time they are removed.
gr. 70 .
tem; Rep. gr. 97 .
Rep. gr. 87 .
– Connect tube-hose line -1- with connector ⇒ page 12 .

– Fit return hose -2- on master cylinder.
• After removing the hose clamp - MP7-602 (3094)- , it may be
Right-hand drive
– If present, coil the heat-protection matting in the sequence
-1, 2 and 3- around the cable.
– Secure the heat-protection matting with the circlip -4-.
– Bleed clutch mechanism ⇒ page 27 .
– Install battery ⇒ Electrical System; Rep. gr. 27 .
Tightening torques
♦ Bearing bracket for clutch pedal on front wall ⇒ page 9 .

1.12 Removing and installing the master cyl‐

inder
Removing
Note
♦ Before the master cylinder must be replaced due to a fault, first

♦ When working in the footwell, protect the underbody cover with
cloths from escaping brake fluid.
– Remove bearing bracket for clutch pedal ⇒ page 20 .

– Remove clutch position sender - G476- ⇒ page 14 .
– Unlock catches -arrows- and push out carrier bolt -2-.
– Remove master cylinder -1-.
Install
After removing, replace carrier bolt ⇒ Electronic Catalogue of
Original Parts .
– Install bearing bracket for clutch pedal ⇒ page 20 .
– Install clutch position sender - G476- ⇒ page 14 .
1.13 Removing and installing clutch slave

cylinder
♦ Hose clamp - MP7-602 (3094)-
♦ Grease - G 000 100-
Removing
Note
♦ Before the master cylinder must be replaced due to a fault, first

♦ If the slave cylinder with the tube-hose line is removed from
the gearbox, do no longer depress the clutch pedal. Other‐
wise, the piston can be pressed out of the slave cylinder and
thus be destroyed.

27 .

– Lay a lint-free cloth under slave cylinder.

– Unlock the clip -A- with a screwdriver and disconnect the tube-
hose line -B- from the connection.
– Pull pipe/hose line -B- out from slave cylinder and seal hose.
– Unscrew screws -arrows- and remove slave cylinder.
Caution
There is a risk of contamination through escaping brake fluid.

♦ If the tube-hose line is disconnected from the connection,
do no longer depress the clutch pedal.
Install
Note
♦ Grease all bearing points and contact surfaces with grease.

♦ Assignment grease ⇒ Electronic Catalogue of Original Parts .
– Fit slave cylinder -A- and tighten screws -arrows-.

– Connect tube-hose line -B- ⇒ page 12 .
Tightening torque
♦ Slave cylinder to gearbox ⇒ page 11 .
1.14 Removing and installing cables for

clutch control
♦ Hose clamp - MP7-602 (3094)-
Removing
– Remove the complete air filter housing if the cables for the
clutch control are not accessible ⇒ Engine; Rep. gr. 24 .
– Remove battery and battery tray ⇒ Electrical System; Rep.
gr. 27 .

Right-hand drive
A heat-protection matting is installed in combination with certain
engines. The appearance may differ from the figure.
– Remove heat-protection matting. Pay attention to the positions
-1...4-.
Caution
There is a danger that the brake fluid may drip out.

♦ During the following work, ensure that no brake fluid lands
on longitudinal member or gearbox. If this is the case,
clean the affected area thoroughly.
♦ Lay a lint-free cloth under master cylinder.
– Disconnect return hose -2- to master cylinder with hose clamp

- MP7-602 (3094)-
Note
♦ If the return hose with hose clamp - MP7-602 (3094)- is dis‐

connected, it will forever be deformed.
♦ However the return hose is not defective.
♦ After removing the hose clamp - MP7-602 (3094)- , it may be
– Pull the clip at the tube-hose line out of the master cylinder up
to the stop and detach the tube-hose line.
– Pull out the clip -A- up to the stop and detach the tube-hose
line -B- to the master cylinder.
Note
Ignore -arrows-.
– Close the open lines and connections, if necessary with a

clean plug from the plug set for engine - VAS 6122- .
– Loosen tube-hose line and remove.

Install
– Connect the tube-hose line -1- with connectors at the master
cylinder and at the slave cylinder.
– Test line by tugging on it.
• After removing the hose clamp - MP7-602 (3094)- , it may be
necessary to bring the return hose -2- back into its initial po‐
sition.
Right-hand drive
– If present, coil the heat-protection matting in the sequence
-1, 2 and 3- around the cable.
– Secure the heat-protection matting with the circlip -4-.
– Install the battery tray and battery ⇒ Electrical System; Rep.
gr. 27 .
1.15 Bleeding the clutch control

♦ Brake filling and bleeding device , e.g. -VAS 5234- or -ROM‐
ESS-
Note
♦ The system must be bled after performing work on the hy‐

draulic clutch control.
♦ When performing the following work, make sure no brake fluid
comes into contact with the gearbox.
♦ Prefilling system is not necessary!
♦ Before bleeding, fill brake fluid reservoir up to “Max” marking
with brake fluid.
♦ Clutch pedal in home position, not operated.
♦ Specification of brake fluid ⇒ Electronic catalogue of original
parts .
– If the vent valve is not accessible, remove the complete air

filter housing (-arrow- in the illustration below) ⇒ Engine; Rep.
gr. 24 .

– Put the clutch pedal in home position.

– Remove cap from vent valve -arrow-.
– Connect the brake filling and bleeding device - VAS 5234- or
-V.A.G 1869- .
– Fit on bleeder hose and connect to pressure hose of drip bot‐
tle.
To bleed system, use 670 mm bleeder hose - V.A.G 1238/B3- if
necessary.
– Switch on brake filling and bleeding device .
• Working pressure: 2.0 bar
– Open bleeder valve.
– Allow about 100 cm3 of brake fluid to flow out.
– Close bleeder valve.
– Rapidly operate clutch pedal from stop to stop 10 to 15 times.
– Open bleeder valve.
– Allow another 50 cm3 of brake fluid to flow out.
– Close bleeder valve.
– Switch off brake filling and bleeding device and release all of
the pressure from the device.
– Depress clutch pedal several times after completion of bleed‐
ing process.
– At the same time check the operation of the clutch control.
Tightening torque
♦ Vent valve ⇒ page 11 .
1.16 Repairing the clutch release mechanism

♦ Grease - G 000 100-
Removing and installing clutch release lever -A- with release
bearing and guide sleeve
• Gearbox is removed.
Removing
– Unscrew screws -arrows-.
– Separate the clutch release lever together with the release
bearing and guide sleeve from the drive shaft and ball stud.
Install
Installation is carried out in the reverse order.
– Assembling gearbox ⇒ page 69 .
Tightening torque
Guide bushing to gearbox ⇒ page 12 .

Remove and install guide bushing from the release bearing

Removing
– Remove the clutch release lever together with the clutch re‐
lease bearing and the guide bushing ⇒ page 28 .
– Push guide bushing -3- toward top out of the release bearing
-2-.
– Rotate the guide bushing -3- opposite the release bearing
-2- by approx. 90° in the -direction of the arrow- until the catch
pegs of the guide bushing are aligned with the slots -4- of the
release bearing.
– In this position remove the guide sleeve from the release bear‐
ing.
Install
Installation is carried out in the reverse order.
– Install the clutch release lever together with the release bear‐
ing and guide bushing ⇒ page 28 .
Removing and installing release bearing

Removing
– Press together locking lugs -arrows- on back of clutch release
lever and remove release bearing -A- from clutch release lev‐
er.
Install
– Press the release bearing -A- into the clutch release lever until
the catch pegs -arrows- lock into position.
– Grease contact surface on the clutch release lever with grease
- G 000 100- .

2 Repairs on the clutch

Assembly overview - clutch ⇒ page 30
Removing and installing clutch ⇒ page 30 .
2.1 Assembly overview - clutch
1 - Flywheel
❑ Removing and Installing
⇒ Engine; Rep. gr. 13
❑ Ensure that centring
pins fit tightly
❑ Keep contact surface for
clutch lining free of
grooves, oil and grease
2 - Clutch plate
Parts
❑ center ⇒ page 30
3 - Pressure plate
⇒ page 30
❑ Check ends of dia‐
phragm spring
⇒ page 32
❑ Check springs and rive‐
ted joints ⇒ page 32
4 - Bolt
Parts
❑ release or tighten in
small stages crosswise
❑ Specified torque:
♦ M6: 13 Nm
♦ M7: 20 Nm
2.2 Removing and installing clutch

♦ Counterholder - MP1-223 (3067)-
♦ Centering mandrel - MP3-475A (3190A)-
♦ Grease - G 000 100-
Removing
• Gearbox is removed.

– Insert counterholder - MP1-223 (3067)- when slackening the

bolts.
Note
In order to avoid a deformation of the pressure plate when re‐

moving it (this leads to jerking during start-up), the bolts on the
pressure plate must be loosened in small stages crosswise.
– Loosen and remove all bolts.

– Remove pressure plate and clutch disc.
Install
Note
♦ Assign the clutch disc and pressure plate in accordance with

engine identification characters ⇒ Electronic Catalogue of
Original Parts .
♦ Clean input shaft splines and, on used clutch plates, the hub
splines too. Remove corrosion and grease the splines with an
ultra-thin layer of grease - G 000 100- . Then move clutch plate
to and fro on input shaft until hub moves freely on shaft. Re‐
move excessive grease.
♦ Pressure plates are protected against corrosion and greased.
Except for the friction surface for the clutch disc, the pressure
plates may not be cleaned, doing so would reduce the lifetime
of the clutch considerably.
♦ The friction surfaces for the clutch pressure plate and for the
flywheel must be cleaned thoroughly (remove grease).
♦ If the clutch has burnt out, thoroughly clean the clutch housing,
the flywheel and the engine in the area of the clutch to reduce
the smell of burnt linings.
♦ The clutch disc must be centred with the centring pin -
MP3-475A (3190A)- and the lining must lie completely on the
fly wheel and the friction surface for the clutch pressure plate.
Do not fit the securing bolts until you have done so.
♦ Tighten the securing bolts evenly crosswise in small stages to
prevent damage to the centring holes for the pressure plate
and the centring pins of the flywheel.
♦ Check whether the dowel sleeves for centring the engine/
gearbox are present in the cylinder block; insert if necessary.
♦ If the dowel sleeves are not installed, there are problems with
the gearshift and the clutch or the gearbox is loud (sound of
loose wheels).
2. Repairs on the clutch 31

• Installation location of the clutch disc: The lettering “gearbox

side” or the shorter end of the lock hub with the spring cage
faces the pressure plate.
Check ends of diaphragm spring

• Wear is allowed up to half the thickness of the membrane
springs -arrows-.
Check tension springs and riveted joints
– Check tension springs -Arrows A- between the pressure plate

and its covers for cracks.
– Check all riveted joints -arrows B- for firm seating.
• Replace a pressure plate with damaged springs/free riveted
joints.

Condition of the springs and riveted joints

I - Tension springs are OK
• Slight bends in the external area -arrow A- are part of the
standard condition.
II - Tension springs are damaged
• Clutch plates with strongly bent or broken feather joints
-arrow B- must be replaced.
Check metal plate ring

– Check metal plate ring -arrow- in the clutch plate for damage.
• Replace the clutch plates with the broken metal plate ring.
– Centre clutch disc with centering pin - MP3-475A (3190A)- .

– Insert counterholder - MP1-223 (3067)- when tightening the
bolts.
– Bring all bolts to the end stop position crosswise in small
stages.
– Installing the gearbox ⇒ page 61 .
Tightening torque
♦ Pressure plate to flywheel ⇒ page 30 .
2. Repairs on the clutch 33

34 – Controls, housing
1 Selector mechanism
Fitting location of shift mechanism ⇒ page 34 .
Summary of components ⇒ page 36 .
Summary of components - Gearshift knob with shift lever collar
⇒ page 37 .
Removing and installing gearshift knob with shift lever collar
⇒ page 37 .
Summary of components - Control cables ⇒ page 38 .
Summary of components - Gearshift mechanism ⇒ page 43 .
Removing and installing shift mechanism ⇒ page 45 .
Dismantling and assembling selector mechanism ⇒ page 48 .
Remove and install shift cable and selector cable ⇒ page 51 .
Adjust selector mechanism ⇒ page 52
1.1 Fitting location of shift mechanism
Note
♦ Disconnect earth strap at battery before carrying out work on

the shift mechanism in the engine compartment ⇒ Electrical
System; Rep. gr. 27 .
♦ After the battery earth strap is disconnected and re-connected,
carry out additional operations ⇒ Electrical System; Rep. gr.
27 .
♦ Removing and installing shift mechanism ⇒ page 45 .
-Arrow A- Shift movement

-Arrow B- Selector movement
34 Rep. gr.34 - Controls, housing

A - Gear selector cable

B - Gate selector cable
C - Heat shield
❑ Remove before remov‐
ing selector mecha‐
nism.
1 - Gearshift lever
2 - Relay lever
1. Selector mechanism 35
1.2 Summary of components
Note
♦ Disconnect earth strap at battery before carrying out work on the shift mechanism in the engine compartment
⇒ Electrical System; Rep. gr. 27 .
♦ After the battery earth strap is disconnected and re-connected, carry out additional operations ⇒ Electrical
♦ Remove selector mechanism to renew selector cables ⇒ page 45 .
♦ Do not kink selector cables.
I - Summary of components -
Gearshift knob with shift lever
collar ⇒ page 37
II - Assembly overview - shift
mechanism ⇒ page 43
III - Summary of components -
Control cables ⇒ page 38

1.3 Summary of components - Gearshift knob with shift lever collar
1 - Gear knob
❑ With gaiter
❑ The gearshift knob and
collar cannot be separa‐
ted
⇒ page 37
❑ Plaque of gearshift lever
can only be separated
from the gearshift knob
e.g. with a screwdriver.
Parts
❑ always replace together
⇒ Electronic Catalogue
of Original Parts
2 - Collar
❑ with frame
3 - Open warm-type clamp
❑ For securing gear knob
to gear lever
❑ always replace ⇒ Elec‐
tronic Catalogue of
Original Parts
1.4 Removing and installing gearshift knob

with shift lever collar
♦ Release tool - T30098-
♦ Hose strap pliers , e.g. -V.A.G 1275-
Removing
– Push the unlocking tool - T30098- into the gap in the rear cen‐
tre between decorative frame and control lever sleeve
-arrow 1-.
– Use the unlocking tool - T30098- to lever the control lever the
control lever sleeve carefully out of the centre console
-arrow 2-.
– Pull gaiter upwards, inside out over gear knob.
– Open clamp -arrow- and pull off gear knob together with gaiter.
Install
– Press the gearshift knob together with the collar as far as the
stop onto the shift lever.
Note
When inserting the gearshift knob on the shift lever the gearshift
knob must lock into the round slot of the gearshift lever.
– Attach gearshift knob with new clamp -arrow- onto gearshift

lever using hose binding claw .
1.5 Assembly overview - Selector cables
Note
♦ Coat bearings and friction surfaces with grease.

♦ Assign the grease via the ⇒ Electronic Catalogue of Original Parts .

1 - Gearshift shaft with cover

2 - Sealing ring
3 - Shoe
4 - Relay lever
Parts
❑ Fitting position
⇒ page 41
❑ After installing, adjust
selector mechanism
⇒ page 52
❑ Remove relay lever to‐
gether with cable lock
for selector cable
⇒ page 42 .
5 - Cable end-piece
❑ For gate selector cable
to relay lever
❑ After installing, adjust
selector mechanism
⇒ page 52
❑ do not interchange, ca‐
ble locks for selector ca‐
ble at relay lever and for
shift cable at gearshift
lever are different, as‐
signment ⇒ page 40
❑ Remove from relay lev‐
er ⇒ page 43
❑ Press onto relay lever
⇒ page 43
6 - Gearshift lever
❑ insert in such a way that the interrupted spacing of the teeth matches the gearshift shaft ⇒ page 42
❑ Fitting position ⇒ page 41
❑ After installing, adjust selector mechanism ⇒ page 52
7 - Hexagon nut
❑ Tightening torque ⇒ page 74
8 - Cable end-piece
❑ For gear selector cable to gearbox selector lever
❑ After installing, adjust selector mechanism ⇒ page 52
❑ do not interchange, cable locks for selector cable at relay lever and for shift cable at gearshift lever are
different, assignment ⇒ page 40
9 - Safety mechanism
❑ Renew.
10 - Gate selector cable
❑ connected with cable end-piece for selector cable
11 - Gear selector cable
❑ connected with cable end-piece for gear selector cable
12 - Seal
❑ Between selector housing and underbody
❑ replace after removing the shift housing
❑ Self-adhesive
❑ stuck onto the shift housing
13 - Selector housing
❑ disassembling and assembling ⇒ page 48
14 - Safety mechanism
❑ Renew.
❑ do not damage cables when removing
15 - Hexagon bolt, 20 Nm
❑ Qty. 2
❑ for attaching cable support
16 - Cable support
❑ for attaching cable support
18 - Grommet
❑ Qty. 3
❑ for mounting of cable support to gearbox
19 - Spacer
❑ Qty. 3
20 - Clip
Allocation of cable end-pieces

The holes in the cable end-pieces have different diameters.
Cable end-piece Dimension “a”
-1- Shift cable at gearbox shift lever 8.5 mm
-2- Selector cable at relay lever 10 mm

Installation position of gearbox selector lever and relay lever

1 - Gearshift lever
2 - Relay lever is inserted over the sliding shoe -arrow- into the
sliding rail of the gearbox shift lever
• During installation, the following areas in particular must be

greased thoroughly:
• Shaft -A- of the relay lever -arrows-.
• Apply grease to guide rail -B- of gearbox selector lever in which
the shoe of the relay lever engages.
• Pins for securing the cable locks.
Note
♦ Assign the grease via the ⇒ Electronic Catalogue of Original

Parts .
♦ The picture of the gearbox selector lever and relay lever may
differ from the original part.

Install gearbox selector lever

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

– Press the safety mechanism on the cable lock for the selector
cable forwards in the -direction of the arrow 1- until the stop,
afterwards lock it by turning to the left in the
-direction of the arrow 2- so that the gate selector cable re‐
mains loose.
– Turn the relay lever towards the front in the
-direction of the arrow 3- and separate the cable end-piece
from the gate selector cable.
– Pull off clip -arrow 1- and remove relay lever together with ca‐
ble end-piece for the gate selector cable.
Note
♦ Cable end-piece for gate selector cable must be located be‐

hind catch -arrow 2-.
♦ It is only permissible to remove cable end-piece for gate se‐
lector cable after the disassembled relay lever has been re‐
moved ⇒ page 43 .
Install
– Press cable end-piece for gate selector cable onto relay lever
⇒ page 43 .
– Insert the relay lever with attached cable end-piece for gate
selector cable as far as the stop.
– Secure the relay lever with a clip -arrow 1- (⇒ previous figure).
Note
♦ Ensure proper engagement of clip.

♦ Cable end-piece for gate selector cable must be located be‐
hind catch -arrow 2- (⇒ previous figure).

Lever out cable end-piece for gate selector cable from the relay
lever while the gate selector cable is disconnected.
• Relay lever has been removed.
– Insert cross-head screwdriver -A- between bushing -B- and
relay lever.
Press cable end-piece for gate selector cable onto relay lever
• Relay lever has been removed.
• The bolt for the cable end-piece for gate selector cable must
be greased ⇒ Electronic Catalogue of Original Parts .
• The cable lock must only be pressed onto the bushing
-arrow-.
• Cable end-piece must move freely on relay lever.
• Cable end-piece must be located behind catch -arrow 2-.
⇒ page 42
1.6 Summary of components - Gearshift

mechanism
Note
Grease all bearing and contact surfaces with grease -G 000 450
02- .
1 - Base plate
❑ Bend open tabs to re‐
move
tronic Catalogue of
Original Parts
2 - Seal
tronic Catalogue of
Original Parts
3 - Selector lever
4 - O-ring
❑ insert onto gearshift lev‐
er -arrow- up to the stop
❑ in case of damage re‐
place ⇒ Electronic
Catalogue of Original
Parts
5 - Locking clip
❑ do not damage cables
when removing
tronic Catalogue of
Original Parts
6 - Gate selector cable
⇒ page 51
⇒ page 38
❑ adjust ⇒ page 52
7 - Bush for selector cable
8 - Gear selector cable
❑ adjust ⇒ page 52
9 - Damping
10 - Bearing shell
❑ when removing, the catches are usually damaged
❑ always replace ⇒ Electronic Catalogue of Original Parts
11 - Bush
12 - Lock washer
13 - Compression spring
14 - Bush
15 - Shift lever guide
16 - Nut
❑ M8: 25 Nm

❑ M6: 8 Nm
17 - Seal
❑ between shift housing and body
❑ Self-adhesive
18 - Selector housing
❑ with pressure spring and selector angle
❑ Pressure spring as well as selector angle cannot be removed
Removing and installing lock washer

– Hold the gearshift lever -2-.
– Press spacer sleeve -3- in direction of arrow.
– Remove lock washer -1-.
Removing and installing damping -arrow-

– Press the pressure spring arm -A- as far as possible to the left
until it is located outside the damping -arrow-.
– Press the shift lever to the lift and pull off the damping.
• After installing the damping, the pressure spring arms -A- and
-B- must rest on the damping -arrow-.
1.7 Removing and installing selector mech‐

anism
1.7.1 Removing
Note
After the battery earth strap is disconnected and connected, carry

out additional operations ⇒ Electrical System; Rep. gr. 27 .
– Disconnect the battery-earth strap with the ignition off ⇒ Elec‐

trical System; Rep. gr. 27 .
– Remove air filter ⇒ Engine; Rep. gr. 24 , if it is installed above
the gearbox.
-arrow 1-.
-arrow 2-.
– Open clamp -arrow- and pull off gear knob together with gaiter.
– Remove the centre console ⇒ Body Work; Rep. gr. 68 .
– Unscrew nuts -arrows- attaching the shift housing.
– Remove safety mechanism -1- for cable end-piece for gear

selector cable -2- and remove cable end-piece for gear selec‐
tor cable with attached gear selector cable from the pin of
gearbox selector lever -3-.
– Remove the cable end-piece for gate selector cable together
with the relay lever -4- ⇒ page 42 .

– Disconnect the Bowden cable support from gearbox

-arrows-.
– Remove the sound dampening system ⇒ Body Work; Rep.
gr. 50 .
– Remove underbody cover on right and left -arrows-.

– Detach tunnel bridges below the exhaust system ⇒ Engine;
Rep. gr. 26 .
Caution
There is a risk of damaging the decoupling element in the pre-

exhaust pipe should not be bent by more than 10°.
– Detach exhaust system below the exhaust system ⇒ Engine;

Rep. gr. 26 .
– Remove the heat shield below the gearshift mechanism ⇒
– Swivel shift housing down and remove with selector cables.
1.7.2 Install
Installation is carried out in the reverse order. When installing,
note the following:
– Align selector housing parallel to body and screw tightly.
• The distance to the vehicle body is the same on both sides.
– Lay the shift cable and selector cable from the selector hous‐
ing to the gearbox.
• The control cables must run parallel to one another and not
cross each other.
The holes in the cable locks have different diameters ⇒ page 40
– Apply a small quantity of grease onto the studs of the gearbox
shift lever -3- and of the relay lever -4- ⇒ page 41 .
– Install cable end-piece for gear selector cable -2- and lock with
a new securing mechanism -1-.
– Install relay lever -4- together with cable end-piece for relay
lever ⇒ page 42 .
– Insert the gate selector cable for the cable end-piece for gate
selector cable to the relay lever.
– Install the centre console ⇒ Body Work; Rep. gr. 68 .
– Adjust selector mechanism ⇒ page 52

– Install gearshift knob with collar ⇒ page 37 .
– Attach the heat shield below the gearshift mechanism ⇒ Body
Work; Rep. gr. 66 .
– Assemble the exhaust system free of stress ⇒ ; Rep. gr. 26
and tunnel bridges.
– Install the noise insulation ⇒ Body Work; Rep. gr. 50 .
– Install battery tray, if it has been removed ⇒ Electrical System;
Rep. gr. 27 .
Note
After the battery earth strap is disconnected and connected, carry

out additional operations ⇒ Electrical System; Rep. gr. 27 .

– Install air filter ⇒ Engine; Rep. gr. 24 , if it has been removed.
Tightening torques
♦ Selector housing to body ⇒ page 43 .
♦ Selector cable support bracket to gearbox ⇒ page 38 .
♦ Remove the underbody cover ⇒ Body Work; Rep. gr. 50 .
1.8 Dismantling and assembling selector

mechanism
♦ Insert base - T10083-
♦ Grease - G 000 450 02-
1.8.1 Dismantling
– Remove selector mechanism ⇒ page 45 .
– Bend up tabs -arrows- of base plate for the shift mechanism
using a screwdriver and remove base plate.
– Remove gasket ring.

– Remove lock washers -2 and 3- (lock washers -1 and 4- are

no longer available), selector cable and shift cable must be
levered off from the shift lever or selector lever e.g. with a
screwdriver.
– Remove shift lever.
Note
♦ Hold the gearshift lever -2-.

♦ Press spacer sleeve -3- -in direction of arrow-.
♦ Remove lock washer -1-.
– Offset the top pressure spring arm -A- via the peg of the se‐
lector angle.
– Press the catches of the bearing shell -arrows- e.g. with a
screwdriver in -direction of arrow- (the catch can break off).
– Slacken bearing shell -A- and shift lever guide -B- from shift
housing.
– Remove bearing shell -A- from shift lever guide -B-.
– Press bottom pressure spring arm -arrow 1- onto shoulder of

selector angle.
Note
♦ When removing the shift lever guide, the guides -A- must not
be damaged.
♦ Bottom pressure spring arm -arrow 1- can slide uncontrolled
out of the shoulder of the selector angle during further han‐
dling.
– Remove shift lever guide from shift housing upwards

-arrow 2-.
1.8.2 Assembling
– Place shift lever guide into the shift housing and while doing
so insert the bottom pressure spring arm -B- and the top pres‐
sure spring arm -A- into the guides (see fig. N34-10865).
Note
For purposes of clear presentation, only the selector angle plate

is partially illustrated.
– Adjust selector angle up to the stop in -direction of arrow 1-

and press the ball pin for shift lever guide into the selector
angle -arrow 2-.
Note
When installing, ensure that the guides -A- and the tabs -B- are
not damaged.
– Lay shift housing or shift lever guide underneath with insert

base - T10083- in such a way that this guide is shifted as far
as possible from the shift housing.
– Offset the top pressure spring arm -A- via the peg of the se‐
lector angle.
– Press new bearing shell -B- (coat with grease -G 000 450 02- )
up to the stop onto the ball of shift lever guide.
– Remove shift housing from the insert base - T10083- .
– Insert top pressure arm -A- into the guide.
– Press bearing shell -B- in -direction of arrow- up to the stop
into the shift housing (all catches of the bearing shell must click
into place audibly).
– Install shift lever.

– Attach shift cable and selector cable to shift housing with cir‐
clips -2 and 3-.
– Press shift cable and selector cable onto shift lever and se‐
lector lever into shift housing (lock washers -1 and 4- are no
longer available).
– Install gasket and attach base plate for shift mechanism by

bending up the tabs -arrows-.
– Install selector mechanism ⇒ page 45 .
1.9 Removing and installing shift cable and

selector cable
1.9.1 Removing
– Bend up tabs -arrows- of base plate for the shift mechanism
using a screwdriver and remove base plate.
– Remove gasket ring.
– Remove lock washers -2 and 3- (lock washers -1 and 4- are

no longer available), selector cable and shift cable must be
levered off from the shift lever or selector lever e.g. with a
screwdriver.
– Remove shift cable and selector cable from shift housing.
Unlock catches -A- for shift cable and selector cable as follows:
– Slide sliding sleeve forwards up to the stop -arrow 1-.
– Turn sliding sleeve to the right up to the stop -arrow 2- until it
locks in place.
– Remove the catches from the cables.
– Remove circlips -1- and -2-.

– Remove the cable support from the cables.
1.9.2 Install
Installation is carried out in the reverse order. When installing,
note the following:
– Attach shift cable and selector cable to shift housing with cir‐
clips -2 and 3-.
– Press shift cable and selector cable onto shift lever and se‐
lector lever into shift housing (lock washers -1 and 4- are no
longer available).
– Install gasket and attach base plate for shift mechanism by

bending up the tabs -arrows-.
1.10 Adjusting selector mechanism

♦ Release tool - T30098-

♦ Rig pin - T10027A-
Note
The following points are essential to ensure correct adjustment of

selector mechanism:
• Gearbox, clutch and clutch control in perfect condition.

• Shift mechanism operates freely.
• Control elements and transmission elements of the shift mech‐
anism are in perfect condition.
• Gearbox must be in neutral.
-arrow 1-.
-arrow 2-.
– Guide shift lever in Neutral position to the left into the 1st/2nd
gear gate via the leg.
– Lock shift lever with rig pin -T10027A- .

– Remove air filter ⇒ Engine; Rep. gr. 24 , if it is installed above
the gearbox.
Unlock cable locks for shift cable and selector cable as follows:
– Push sliding sleeve at shift cable and at selector cable for‐

wards up to the stop -arrow 1-.
– Turn the sliding sleeves in direction of the -arrows 2- as far as
the stop until they lock in place.
Note
The cables can be moved in the catches.
• Gearbox must be in neutral.
Lock the gearshift shaft as follows:

– Push down the gearbox shift lever in the
-direction of the arrow 1- into the gear gate of the 1st/2nd gear.
Turn the angle lever -A- in -direction of arrow 2-, until it locks.
This locks the gearshift shaft and can no longer be moved.
– Make sure that the shift cable and selector cable sit stress-free
in the catches.
– Turn sliding sleeves at shift cable and selector cable in

-direction of the arrow- up to the stop.
The springs push the sliding sleeves back into the initial position.
Note
The shift cables are now adjusted.
– Turn angle lever -A- back to the initial position (in

-direction of arrow-).
– Pull rig pin -T10027A- out of the gearshift mechanism.
– Install shift lever collar.
– Inspect gearshift mechanism ⇒ page 54 .
1.10.1 Checking function

• The shift lever must be positioned in neutral position in the
selector gear gate of the 3rd/4th gear.
– Actuate clutch pedal.
– Select all gears several times. Pay particular attention to prop‐
er operation of the reverse gear lock.
If a problem arises when shifting the gear again:
– Re-adjust selector mechanism ⇒ page 52

2 Removing and installing the gearbox

Removing the gearbox ⇒ page 55 .
Installing the gearbox ⇒ page 61 .
Specified torques for gearbox ⇒ page 67
2.1 Removing the gearbox

♦ Supporting device - T30099-
♦ Adapter - T40091/3-
♦ Adapter - MP9-200/18-
♦ Support - 10-222A/31-
♦ Surface - T30119-
♦ Hook - MP9-200/10 (10-222A/10)-
♦ Gearbox mount - 3282-
♦ Adjusting plate - 3282/46-
♦ Engine/gearbox jack , e.g. -V.A.G 1383 A-
♦ Gearbox attachment device - MP3-478 (3336)-
♦ Grease - G 000 100-
– Remove battery and battery tray ⇒ Electrical System; Rep.
gr. 27 .
– Completely remove the air filter ⇒ Engine; Rep. gr. 24 , if it is
installed above the gearbox.
– Remove securing mechanism -1- for gear selector cable from
the pin of gearbox selector lever -B-.
– Remove relay lever -A- together with cable end-piece for gate
selector cable ⇒ page 42 .
– Remove nut -arrow 2- and remove the gearbox selector lever
-B-.
– Unscrew the bolts -arrows- and lay the cable support with
control cables to the side.
2. Removing and installing the gearbox 55

– Unscrew the bolts -arrows- and lay the slave cylinder to the
side; do not open the hydraulic system.
Caution
Do not operate clutch pedal any more!
– Screw out bottom fixing screw for top starter and screw out the
upper engine/gearbox connecting bolts.
Note
If hose and cable connections are located in the area of the lifting
eye of the engine for the hook - MP9-200/10- , these must now
be removed.
– Fit supporting device -T30099- .

– Slightly take up weight of engine/gearbox assembly on spin‐
dles of the hook - MP9-200/10- .
gr. 66 .
– Remove the bottom part of the front left wheelhouse liner ⇒
– Unscrew the nut -arrow- and remove the bracket for the elec‐
trical cables.
– Removing starter ⇒ Electrical System; Rep. gr. 27 .
– Unscrew the front left vehicle level sensor - G78- , where

available, from the transverse arm ⇒ Chassis; Rep. gr. 43 .

– Disconnect existing electrical plug connections:

1- Gearbox neutral position sender - G701-
2- Reversing light switch - F4-
Caution
There is risk of damaging the decoupling element of the ex‐

haust system.
– Unscrew bolts -arrows- for holders for exhaust systems on the

assembly carrier.
– Separate exhaust system at the clamping sleeve -arrow-.
– Remove pendulum support.

– Unscrew nut -1- from both sides of anti-roll bar bracket -3-.
– Pull anti-roll bar bracket -3- on both sides out of the anti-roll
bar -2-.
– If present, remove heat shield for drive shaft -arrows- ⇒ Chas‐

sis; Rep. gr. 40 .
– Remove drive shafts from flange shafts and tie up as far as
possible, do not damage the surface protection ⇒ Chassis;
Rep. gr. 40 .
– Unscrew nut -arrow- and remove earth strap from gearbox

mount.
– Unscrew the bolts -arrows 1- from the gearbox mount.

– Lower the gearbox by adjusting the spindles of the hook -

MP9-200/10 (10-222A/10)- by the dimension -a-.
• Dimension -a- = 60 mm
– Screw out bolts -arrows 2- and remove gearbox console.
Connecting screws -2, 3- for engine/gearbox and bolts -4, 5- on

the starter are unscrewed.
– Unscrew the connecting screws -7, 8- for engine/gearbox.
Note
Connecting screws -1, 6,9- are unscrewed for engine/gearbox

later.
The gearbox support - 3282- is to be adjusted before removing

the gearbox “0AH” with the aim of the adjusting plate - 3282/46- .
– Insert gearbox support - 3282- into engine/gearbox jack -
V.A.G 1383 A- .
– Lay adjusting plate - 3282/46- onto gearbox support - 3282- .
• The adjusting plate only fits in one position.
• The arrow symbol on the adjusting plate points in the direction
of travel.
– Align arms of the gearbox support with the holes in the ad‐
justing plate.
– Insert mounting bolts as shown on the adjusting plate.
– Align adjustment plate parallel to gearbox.

– Secure bolts - 3282- on the gearbox with M8 nut -arrow-.

The bolt - 3282- should stand on a level with the guide on the
gearbox holder - 3282- .
– Screw in the pins - 3282/29- into the rear hole for the fixing
screw of the pendulum support.
– Remove engine/gearbox connecting screw -arrow-.
– Remove engine/gearbox connecting screw -A-.

– Remove remaining engine/gearbox connecting bolts.
– Press the gearbox out of the dowel sleeves and carefully swing
towards the upper part of the vehicle.
– Carefully pass with the flange shaft right -A- on the flywheel/
at the intermediate plate.

– Turn the gearbox with the counterweight upwards and rotate

the cover for 5th gear downwards.
– Lower the gearbox, while doing so pay attention to ensuring
sufficient distance of the flange shaft -A- towards the flywheel
and the flange shaft -B- towards the assembly carrier.
Note
♦ Observe all lines when lowering the gearbox.

♦ While the gearbox is reduced, a 2nd mechanic presses the
engine carefully forwards if required.
♦ If necessary, adjust the position of the gearbox when lowering
over the spindles of the gearbox support - 3282- .
2.1.1 Transporting the gearbox

♦ Gearbox attachment device - MP3-478 (3336)-
♦ Workshop crane , e.g. -V.A.S 6100-
– Screw down gearbox suspension device - MP3-478 (3336)-
onto clutch housing.
– Adjust supporting arm at slide piece with locking pin -arrow-.

No. of holes visible = 5
– Raise gearbox with workshop crane and gearbox suspension
device - MP3-478 (3336)- .
– Set gearbox aside, for example in a transport container.
2.2 Installing the gearbox
Note
Refer to procedure “Removing gearbox” for required special tools

⇒ page 55 .
– Clean all threaded holes into which bolts are screwed in with
locking agent, using a suitable thread tap to remove old locking
agent residues.

– After the installation, replace screws to be screwed in with

locking agent and self-locking nuts.
– Check whether the dowel sleeves for centring the engine/
gearbox are present in the cylinder block; insert if necessary.
If the dowel sleeves are not installed, there are problems with the
gearshift and the clutch or the gearbox is loud (sound of loose
wheels).
– Check whether the intermediate plate is suspended from the
sealing flange -arrow top- and slid onto the dowel sleeves
-arrows below-.
– Clean splines of drive shaft and apply a thin film of grease -
G 000 100- .
The clutch plate must slide easily to and fro on the input shaft.
The gearbox support - 3282- is to be adjusted before installing
the gearbox “0AH” with the aim of the adjusting plate - 3282/46- .
– Insert gearbox support - 3282- into engine/gearbox jack -
V.A.G 1383 A- .
– Position adjusting plate - 3282/46- onto the gearbox support -
3282- (adjusting plate fits in only one position).
– Align arms of the gearbox mount to match the holes in the
adjusting plate .
– Insert mounting bolts as shown on the adjusting plate.
– Place the gearbox on the gearbox mount - 3282- .
– Align the adjusting plate parallel to the gearbox.
– Screw in the pins - 3282/29- into the rear hole for the fixing
screw of the pendulum support.

– Secure bolts - 3282- on the gearbox with M8 nut -arrow-.

The bolt - 3282- should stand on a level with the guide on the
gearbox holder - 3282- .
– Turn the gearbox with the counterweight upwards and rotate
the cover for 5th gear downwards.
– Position engine/gearbox jack - V.A.G 1383 A- below vehicle,
arrow symbol on adjusting plate points in the direction of travel.
– Carefully raise the gearbox.
• The gearbox faces with the cover for 5th gear towards the up‐
per part of the vehicle.
Note
♦ Be careful of all lines when installing gearbox.

♦ A 2nd mechanic carefully pushes the engine towards the front.
– Pass the gearbox with the flange shaft left -B- at the assembly
carrier and with the flange shaft right -A- at the coupling pres‐
sure plate.
– Carefully pass with the flange shaft right -A- on the flywheel
as displayed.
– Align gearbox in the fitting position opposite the engine.
– Insert gearbox, screw in the bolt above and below the

-arrow- of the flange shaft on the right, and tighten
⇒ page 67 .
– Screw in the remaining lower engine/gearbox connecting bolts
and tighten ⇒ page 67 .
– Remove the gearbox holder - 3282- after screwing on the en‐
gine/gearbox.

– Install the gearbox console with the new bolts -arrow 2- and
tighten to 40 Nm and turn 90° further.
– By tightening the spindles of the hook - MP9-200/10- align the
motor/gearbox aggregate in the fitting position until the gear‐
box console rests against the gearbox mount.
Caution
There is a risk of damaging the thread in the gearbox console

by tightening the bolts obliquely.
♦ To avoid damages to the threads in the gearbox console,
gearbox bearings and gearbox console must run parallel
to one another.
– Insert new bolts -arrows 1- and tighten to 60 Nm and turn 90°

further.
– Install earth cable -arrow-.
Caution
Risk of injury!
• Do not remove support bracket - T30099- until all bolts
securing the assembly mounting have been tightened to
specified torque.
– Insert new bolts and install pendulum support ⇒ Engine; Rep.

gr. 10 .
– Check the setting of the assembly bracket ⇒ Engine; Rep. gr.
10 .
– Assemble exhaust system free of stress ⇒ Engine; Rep. gr.
26 .
– Install the drive shifts ⇒ Chassis; Rep. gr. 40 .

– If present, screw heat shield for drive shaft -arrows- ⇒ Chas‐
sis; Rep. gr. 40 .


– Screw the front left vehicle level sensor - G78- , where avail‐
able, on the transverse arm ⇒ Chassis; Rep. gr. 43 .
– On both sides, install the anti-roll bar bracket -3- to the anti-
roll bar -2- on both sides ⇒ Chassis; Rep. gr. 40 .
– Mount plug -1- at the oil level and oil temperature sender -
G266- .
– Check that the vacuum hose of the brake system is installed

correctly, install a vacuum hose where necessary ⇒ Brake
system; Rep. gr. 47 .
– Installing starter and electrical cables -arrow- ⇒ Electrical sys‐
tem; Rep. gr. 27 .
– Screw in the upper engine/gearbox connecting bolts and tight‐
en ⇒ page 67 .

– Install clutch slave cylinder ⇒ page 24 .

– On gearboxes of vehicles with the start-stop system: Plug the
connector -arrow- to the transmission neutral sender - G701- .
– Attack cable support to gearbox and tighten the bolts

-arrows- ⇒ page 38 .
– Install gearshift lever -B- ⇒ page 38 .

– Screw on hexagon nut -arrow 2- ⇒ page 38 .
– Install relay lever -A- together with cable end-piece for gate
selector cable ⇒ page 42 .
– Spread a small amount of grease on pin of gearbox selector
lever -B-.
Assignment grease for gearshift mechanism ⇒ Electronic Cata‐
logue of Original Parts .
– Connect gear selection cable with gearbox selector lever.
Note
Replace safety mechanism -arrow 1- after removal.

– Install the battery tray, battery and battery cover ⇒ Electrical
– Check gear oil level ⇒ page 68 .
– Install the bottom part of the front left wheelhouse liner ⇒ Body
Work; Rep. gr. 66 .
– On vehicles with front left vehicle level sensor - G78- , check
headlight beam setting ⇒ Electrical System; Rep. gr. 94 .

2.3 Specified torques for gearbox

Vehicles with 1.2 l / 63; 77 kW TSI engines
Pos. Bolt Piece Nm
1 M12 × 60 2 80
2 M12 × 165 + M8 x 16 2 80
♦ additional starter
to gearbox
3 M10 × 55 3 40
4 M12 × 70 2 80
Pos. -A-: Dowel sleeves for centering

3 Gear oil
Check gear oil level ⇒ page 68 .
3.1 Checking gear oil level

♦ Socket wrench insert - T30023 (3357)-
Gearbox oil specification and amount of oil in gearbox
⇒ page 2 .
Procedure
gr. 66 .
– Unscrew locking screw for oil filler hole -arrow- for checking
the oil.
The oil is at the correct level if the gear is filled up to the lower
edge of the oil filler hole.
– Where necessary, pour in gear oil up to lower edge of the filler
hole.
– Screw in plug -arrow-.
Torque for different versions of oil filler plug and oil drain plug
I - Oil filler plug and oil drain plug with internal serration: 25 Nm
II - Oil filler plug and oil drain plug with Allan key: 30 Nm

4 Disassembling and assembling the

gearbox
Schematic overview - Gearbox ⇒ page 69
Summary of components ⇒ page 70 .
Removing gearbox housing cover and 5th gear ⇒ page 71
Summary of components - Clutch housing ⇒ page 72 .
Summary of components - Drive shaft, output shaft, differential
gear, gearshift mechanism, and gearshift forks ⇒ page 73 .
Summary of components - Gearshift unit ⇒ page 74 .
Assembly overview - shift forks ⇒ page 76
Repairing gearshift unit ⇒ page 78
Replacing the gasket ring for the gearshift shaft ⇒ page 80 .
Repairing gearshift forks ⇒ page 77 .
Disassembling and assembling the gearbox ⇒ page 80 .
4.1 Schematic overview - Gearbox
1 - 1st gear
2 - 2nd gear
3 - 3rd gear
4 - 4th gear
5 - 5th gear
6 - Cover for gearbox housing
7 - Gearbox housing
8 - Reverse gear sliding gear
9 - Selector mechanism
❑ (Gearshift forks)
10 - Clutch housing
11 - Input shaft
12 - Output shaft
13 - Differential
4. Disassembling and assembling the gearbox 69

4.2 Summary of components
I - Removing gearbox housing

cover and 5th gear
⇒ page 71
II - Summary of components -
Clutch housing ⇒ page 72 .
Drive shaft, output shaft, differ‐
ential gear, gearshift mecha‐
nism, and gearshift forks
⇒ page 73 .
Gearshift unit ⇒ page 74 .
III - Assembly overview - shift
forks ⇒ page 76
III - Repairing gearshift forks
⇒ page 77 .
III - Repairing gearshift unit
⇒ page 78
III - Replacing the gasket ring
for the gearshift shaft
⇒ page 80 .

4.3 Summary of components- Gearbox housing cover and 5th gear
1 - Gearbox housing
2 - 5th gear pinion
⇒ page 88
3 - Lock washer
❑ Renew.
❑ Determine thickness
⇒ page 88
4 - Seal
5 - Cover for gearbox housing
Note
After installing the cover for the

gearbox housing of a gearbox in‐
stalled in a vehicle, check the gear
oil level and where necessary refill
with gearbox oil ⇒ page 68 .

❑ Renew.
7 - Lock washer
❑ Renew.
⇒ page 88
8 - Synchronizer body with slid‐
ing sleeve and stop ring for 5th
gear
❑ disassembling and as‐
sembling ⇒ page 91
9 - 5th gear synchronizer ring
10 - 5th gear sliding gear
11 - Needle bearing
❑ 5th gear
12 - Gearshift fork for 5th gear
❑ Shift segments are connected inseparably with the gearshift fork
❑ Identification ⇒ page 77
13 - Carrier bolt
❑ for 5th gear gearshift fork

4.4 Summary of components - Clutch housing
1 - Conical screw
⇒ page 112
2 - Flange shaft with pressure
spring
⇒ page 80
❑ complete ⇒ page 112
❑ Renew.
4 - Clutch housing
❑ repairing ⇒ page 89
5 - Gearbox housing
6 - Clutch release lever
❑ with guide bushing and
clutch release bearing
⇒ page 28
7 - Bolt
⇒ page 12

4.5 Summary of components - Drive shaft, output shaft, differential gear, gear‐
shift mechanism, and gearshift forks
1 - Differential
❑ disassembling and as‐
sembling ⇒ page 112
2 - Gearbox housing
3 - Oil drain plug
❑ Tightening torque
⇒ page 68
4 - Flange shaft with pressure
spring
⇒ page 80
❑ complete ⇒ page 112
5 - Conical screw
⇒ page 112
❑ to secure the bearing
support with grooved
ball bearings for the
drive and output shaft
❑ replace ⇒ Electronic
Catalogue of Original
Parts
7 - Hexagon collar nut, 23 Nm
❑ Selector mechanism
❑ self-locking
❑ Renew.
8 - O-ring
❑ Renew.
9 - Carrier bolt
❑ Renew.
❑ (Gearshift unit)
❑ Renew.
13 - Screw, 6 Nm
14 - Gearbox neutral position sender - G701-
❑ on vehicles with start-stop system
15 - Reversing light switch - F4- , 20 Nm
❑ new version with captive sealing ring
16 - Sealing ring
❑ not present on all gearboxes

17 - Selector mechanism
❑ (Gearshift forks)
18 - Drive shaft and output shaft with bearing support for grooved ball bearings
❑ the bearing support must be replaced each time the gearbox housing is replaced
❑ pressing off and on bearing support ⇒ page 94
❑ Disassembling and assembling the drive shaft ⇒ page 91
❑ Disassembling and assembling the output shaft ⇒ page 101
19 - Axle for reverse gear sliding gear
20 - Reverse gear sliding gear
❑ for securing the axle for reverse gear sliding gear
❑ Renew.
22 - Oil drip pan
23 - Magnet
24 - Oil guide part
4.6 Summary of components - Gearshift

unit
Note
♦ Coat bearings and friction surfaces with grease.

♦ Assign the grease via the ⇒ Electronic Catalogue of Original
Parts .

1 - Bushing
❑ for gearshift shaft
❑ extracting ⇒ page 79
❑ inserting ⇒ page 79
❑ replace jointly
3 - Locking angle
❑ for setting the gearshift
mechanism
❑ removing ⇒ page 79
4 - Relay lever
⇒ page 41
5 - Retaining clip
6 - Sealing ring
7 - Cap
❑ for gearbox bleeder
8 - Gearshift lever
❑ Display may vary from
original part
❑ insert in such a way that
the interrupted spacing
of the teeth matches the
gearshift shaft
❑ Can be renewed with
the selector mechanism
installed
⇒ page 41
❑ self-locking
❑ Renew.

4.7 Assembly overview - shift forks
Note
The gearshift fork group does not have to be disassembled for the disassembly and assembly of the shift
segments, clamping plates and angular ball bearings.
1 - Gearshift fork group with

shift guides
2 - 3rd/4th gear shift segment
❑ Identification
⇒ page 77
❑ It must still be possible
to rotate the shift seg‐
ment freely once as‐
sembled
3 - Angular ball bearings
❑ Qty. 4
❑ installing ⇒ page 78
4 - Circlip
❑ Renew.
5 - 1st/2nd gear shift segment
❑ Identification
⇒ page 77
❑ It must still be possible
to rotate the shift seg‐
ment freely once the Cir‐
clip is assembled
❑ Gearshift fork with shift
segments ⇒ page 77
6 - 5th gear shift fork with shift
segments
❑ Shift segments are con‐
nected inseparably with
the gearshift fork
❑ Identification
⇒ page 77
7 - Carrier bolt
❑ for 5th gear gearshift fork

4.8 Repairing gearshift forks

♦ Pressure plate - MP3-407 (VW 402)-
♦ Pressure element - 3290/1- from assembly device - T30100
(3290)-
♦ Assembly tool - MP5-402 (3301)-
♦ Thrust piece - MP3-453 (VW 431)-
♦ Distance sleeve - MP3-458 (VW 472)-
♦ Driver - MP1-304 (10-206)-
♦ Removal tool for inner lining of the door panel - MP8-602/1
(80-200)-
Identification of the shift segments and shift fork for 5th gear with
shift segments
Dimension -a-
1- Shift segments 1st/2nd gear = 10.0 mm
2- 3rd/4th gear shift segment = 78.6 mm
3- 5th gear shift fork with shift segments = 79.5 mm
1st/2nd gear shift fork with shift segments

Dimension -a- = 78 mm
Removing the circlip

– Secure the shift fork in a vice fitted with protective jaws -B-.
– Lift off the circlip -A- in -direction of the arrow-.

Fitting the circlip

– Press the circlip with a handle wrench into the slot of the shift
segment.
Note
It must still be possible to rotate the shift segment freely once the
Circlip is assembled.
A - Handle wrench (SW 10)

B - Protective jaws
Removing the angular ball bearings
Note
Do not bend the shift forks when removing and installing the an‐
gular ball bearings.
Insert the angular ball bearings up to the stop into the gearshift
fork
The recess in the thrust piece - 3290/1- points towards the ball
bearing.
4.9 Repairing gearshift unit

♦ Centering mandrel - MP3-463 (12-551)-
♦ Pressure spindle - MP3-448 (VW 408 A)-
♦ Thrust piece - T40008-
♦ Sealant - AMV 188 200 03-


Remove locking angle -A- from gearshift cover
– Remove the outer part of the locking angle.
– Then lever out the locking angle carefully with a screwdriver.
Drive locking angle -A- into gearshift cover

Fitting position:
The marking -1- points towards the marking -2- on the gear‐
shift cover.
Remove the bushing -A- for the shiftgear shaft
Drive in the bushing -A- for the shift rod up to the stop

4.10 Replace the gasket ring of the gearshift

shaft
♦ Tube - MP3-479 (VW 423)-
♦ Sealing grease ⇒ Electronic Catalogue of Original Parts
– Remove the gearshift lever and relay lever ⇒ page 38 .
– Lever out gasket ring with a screwdriver.
– Lightly oil new gasket ring at outer surface.
– Fill space between sealing lip and dust lip -arrow- with sealing
grease .
Insert gasket ring -A- up to the stop

– Install the gearshift lever and relay lever ⇒ page 38 .
4.11 Disassembling and assembling the

gearbox
Removing and installing cover for gearbox housing, clutch hous‐
ing, gearshift shaft with gearshift cover, drive shaft, output shaft,
differential gear and gearshift mechanism
♦ Assembly stand - MP9-101-
♦ Bracket - MP1-202-
♦ Adapter - T10235-
♦ Pressure spindle - MP3-408 (VW 412)-
♦ Pressure spindle - VW 407-
♦ Adapter - T10235-
♦ Guide bolt - T10079-
♦ Catch pan , e.g. -VAS 6208-

♦ Washer - T10083/1-
♦ Pressure screw - 3074-
♦ Cap - T10080-
♦ Sealant - AMV 188 200 03-
Disassembling gearbox
– Secure gearbox -arrows- to the assembly stand - MP9-101-
with bracket - MP1-202- and adapters - T10235- .
– Place catch pan underneath.
– Drain out gear oil.
– Remove clutch release lever -A- together with release bearing

and guide sleeve ⇒ page 28 .
– Release fixing screw for right flange shaft.

– To this end insert 2 screws in the flange and counterhold the
flange shaft using an assembly lever.
– Pull out the right flange shaft together with pressure spring,
stop disc and conical ring.
– Unscrew the cover -arrow- for the gearbox housing carefully

remove.

– Pull out the support bolt -1- for the 5th gear shift fork -2- and
remove gearshift fork.
– Remove circlip -3- for 5th gear synchronizer body.
– Remove the sliding sleeve with synchronizer body, 5th gear
sliding gear with synchronizer ring and needle bearing from
the output shaft.
– Remove circlip -4- for 5th gear pinion and remove the pinion.
– Release the fixing screws -A- for the bearing support of the
drive shaft and output shaft.
– Unscrew hexagon collar nut -B- for shift mechanism (fitting of
the reverse gear).
– Unscrew the fixing screw for the flange shaft-C-; to do this,
insert two screws in the flange and hold the flange shaft using
an assembly lever.
– Remove flange shaft -C- together with pressure spring.
– Then turn the gearbox in the assembly stand with the clutch
housing upwards.
– Remove bolts which are used to secure the gearbox housing
from the clutch housing.
– Carefully release the clutch housing from the projecting hous‐
ing lands and make sure the sealing surfaces are not damaged
in the process.
– Clutch housing must not tilt, so that the roller bearing and its
bearing assembly on the drive shaft and output shaft are not
damaged.
– Remove the differential gear -A- from the gearbox housing.

– Afterwards, remove the oil drip pan -A- and the oil guide part
-B- with the solenoid from the gearbox housing.
– On gearboxes of vehicles with the start-stop system: Remove

transmission neutral sender - G701- -arrow-.
– Remove the gearshift shaft with cover -A-. While doing so, put
the gearshift shaft into Neutral. Subsequently unscrew screws
-arrows- and remove the gearshift shaft from the gearbox
housing.
– Remove the bearing bolts -B- at the top of the gearbox.
– Unscrew the reversing lights switch -C-.
– Unscrew the screw -A- for securing the shaft for reverse gear.
– Remove the bearing bolts -B- at the bottom of the gearbox.
Note
The screw cap -arrow- is not to be dismantled when disassem‐

bling the gearbox.

– Press off the drive shaft and output shaft together with the
bearing support, gearshift mechanism (shift forks) and reverse
gear.
Note
♦ Position the gearbox housing in such a way that the dowel

sleeves in the gearbox housing are not damaged.
♦ During the pressing off procedure request the assistance of
second mechanic to prevent components from falling.
– Remove the bearing support with grooved ball bearings from

the drive shaft and output shaft ⇒ page 95 .
Assembling gearbox
Note
♦ Pressing the bearing support with grooved ball bearings onto

the drive and output shaft ⇒ page 98 .
♦ Pressing the sleeve of the 5th gear pinion needle bearing onto
the drive shaft ⇒ page 98 .
– Place the assembled components drive shaft -2-, output shaft

-1- with bearing support and grooved ball bearings in the thrust
piece - T10085- .
– Insert the gearshift mechanism (shift forks) -4- in the sliding
sleeves of the shaft.
– Insert the shaft for reverse gear -3- with the reverse gear.

– Screw guide bolts - T10079- into the threaded bolts (Fitting

reverse gear) -arrow-.
– Insert the parts into the gearbox housing together. Guide the
guide pin - T10079- through the bore for securing the gearshift
mechanism in the gearbox housing.
– Unscrew guide bolt - T10079- .
Before pressing on, pay attention to the following:
♦ To click in the shift forks into the sliding sleeves correctly.

♦ Check the dimension -a- on the input shaft serration.
Note
♦ The drive shafts of the individual gearboxes have different

lengths due to the different heights of the serration, dimension
-a-.
♦ In order to press in the drive shaft and the output shaft at the
same time, a 3 mm thick washer - T10083/1- must be posi‐
tioned onto the drive shaft, if necessary.
♦ Therefore, the dimension -a- of the output shaft serration must
be measured.
Dimension -a- = 30.6 mm

Put disc - T10083/1-
– into position ⇒ page 85 .
Fit the washer - T10083/1- onto the drive shaft and carefully press
in the bearing support together with the drive shaft and the output
shaft up to the stop.

Press on the bearing support with the drive and output shaft up
to the arrester
– Tighten the screw -A- for the shaft for reverse gear.
– Install the carrier bolt -B- at the bottom of the gearbox.
– Screw on the reversing lights switch -C-.

– Install the carrier bolt -B- at the top of the gearbox.
– Put the gearshift guides into Neutral.
– Apply sealant - AMV 188 200 03- uniformly on the sealing sur‐
face of the gearshift cover.
– Install the gearshift shaft with cover -A-. Subsequently tighten
the bolts -arrows-.
– On gearboxes of vehicles with the start-stop system: Installing

transmission neutral sender - G701- -arrow- and tighten fixing
screw to tightening torque ⇒ Item 13 (page 73) .

– Use new screws -A- to secure the bearing support to the drive
shaft and output shaft.
Note
Gradually tighten the screws according to the torque starting from

the middle and crosswise ⇒ Item 6 (page 73) .
– Screw in hexagon collar nut -B- for the gearshift mechanism

(shift forks).
– Afterwards, insert the oil drip pan -A- into the recess -1- and
into the hole -2- of the gearbox housing.
– Next, install the oil guide part -B- with inserted solenoid into
the gearbox housing.
– Insert differential gear -A-.

– Apply sealant - AMV 188 200 03- uniformly on the sealing sur‐
face.
– Screw down the clutch housing onto the gearbox housing.
– Then turn the gearbox in the assembly stand with the gearbox
housing upwards.

– Fit the 5th gear pinion -1-.

Fitting position of the 5th gear pinion
The highest collar -arrow- points to the gearbox housing cover.
– Mount the 5th gear sliding gear with needle bearing.
– Position the 5th gear synchronizer ring on the sliding gear.
– Mount the synchronizer body 5th gear together with sliding
sleeve and stop ring.
– Insert the 5th gear shift fork -2- and push the carrier bolts -1-
up to the stop in the -direction of arrow-.
– Determine the new circlip -arrow-.
– For the drive shaft -3- and output shaft -4- select the thickest
possible circlip that may be installed, and fit.
The following circlips are available ⇒ Electronic Catalogue of
Original Parts
Thickness (mm)
2.00 2.10
2.20
– Tighten cover for gearbox housing.
– Install both flange shafts together with pressure springs, stop

discs and conical rings.
Tightening torques
♦ Drive shaft, output shaft, differential gear, gearshift mecha‐
nism, and gearshift forks ⇒ page 73 .
♦ Gearbox housing and clutch housing ⇒ page 72 .
♦ Cover for gearbox housing ⇒ page 71
♦ Flange shafts on gearbox (conical screws) ⇒ page 112

5 Gearbox housing and clutch housing

Summary of components - Gearbox housing and clutch housing
⇒ page 89 .
5.1 Summary of components - Gearbox housing and clutch housing
1 - Clutch housing
❑ when replacing, set the
differential gear
⇒ page 115
2 - Sealing ring
❑ for drive shaft
3 - Ball pin
⇒ page 12
4 - Sealing ring
❑ for right flange shaft
❑ replace, on installed
gearbox ⇒ page 110
5 - Oil filler plug
❑ Tightening torque
⇒ page 68
6 - Adjusting washer
❑ for differential gear
⇒ page 115
7 - Outer ring/tapered-roller
bearing
❑ press out of the clutch
housing and press into
the coupling housing
⇒ page 112
❑ when replacing, set the
differential gear
⇒ page 115
❑ Renew.
9 - Outer ring/tapered-roller bearing
❑ remove from the gearbox housing and press into the gearbox housing ⇒ page 112
❑ when replacing, set the differential gear ⇒ page 115
10 - Fitting sleeve
❑ Qty. 2
11 - Gearbox housing
❑ when replacing, set the differential gear ⇒ page 115
12 - Oil drain plug
❑ Tightening torque ⇒ page 68
5. Gearbox housing and clutch housing 89

13 - Sealing ring
❑ for left flange shaft
❑ replace, on installed gearbox ⇒ page 108
14 - Bushing
❑ extracting ⇒ page 79
15 - Screw cap
❑ Before screwing down apply sealing agent - AMV 188 200 03-
16 - Circlip
❑ insert in the cylinder roller bearing groove
17 - Circlip
❑ insert in the cylinder roller bearing groove
18 - Cylindrical-roller bearing
❑ for drive shaft
❑ extracting and inserting ⇒ page 91
❑ for output shaft
❑ extracting and inserting ⇒ page 101
20 - Plug
❑ present on certain gearboxes
❑ inserted into the hole in the clutch housing

35 – Gears, shafts
1 Input shaft
Summary of components - Drive shaft ⇒ page 91 .
Disassembling and assembling the drive shaft ⇒ page 94 .
Replace gasket ring for drive shaft ⇒ page 99
1.1 Summary of components - Drive shaft
Note
♦ When installing new pinions or a new drive shaft observe the technical data ⇒ page 1 and instructions in
the ⇒ Electronic Catalogue of Original Parts .
♦ Insert all bearings, sliding gears and synchronizer rings onto the drive shaft with gear oil.
♦ Do not interchange the synchronizer rings, if re-used always assign to the original sliding gear.
1 - Circlip
❑ replace after disassem‐
bly
⇒ page 88
2 - Sliding sleeve with 5th gear
synchronizer body
⇒ page 80
❑ disassembling
⇒ page 99
❑ Assemble sliding sleeve
and 5th gear synchron‐
izer body ⇒ page 99
⇒ page 99
❑ check for wear
⇒ page 96
5 - Needle bearing
❑ 5th gear
❑ replace together with
bushing
6 - Bushing
❑ for 5th gear needle
bearing
❑ replace together with
needle bushing
❑ press off with bearing
support for grooved ball
bearing ⇒ page 95
❑ pressing on
⇒ page 98
Volkswagen Technical Site: http://vwts.ru http://vwts.info 1. Input shaft 91

7 - Gearbox housing
8 - Bearing support with grooved ball bearings
❑ Always replace grooved ball bearing together with the bearing support
❑ Replace bearing support after each time the gearbox housing is undone
❑ Pulling off ⇒ page 95
❑ pressing on ⇒ page 97
9 - Input shaft
10 - Needle bearing
❑ 3rd gear
11 - 3rd gear sliding gear
12 - 3rd gear synchronizer ring
❑ check for wear ⇒ page 96
13 - Sliding sleeve with 3rd and 4th gear synchronizer body
❑ pull off with 3rd gear sliding gear ⇒ page 95
❑ disassembling ⇒ page 95
❑ Fitting position sliding sleeve and synchronizer body ⇒ page 96
❑ assembling ⇒ page 95
16 - Bushing
❑ for 4th gear needle bearing
❑ replace together with needle bushing
❑ pull off with 3rd gear sliding gear ⇒ page 95
17 - Needle bearing
❑ 4th gear
❑ replace together with bushing
18 - Thrust washer
19 - Inner ring/cylindrical-roller bearing
20 - Circlip
❑ Renew.
❑ Determine thickness ⇒ page 97
❑ with circlip
❑ Fitting position: The circlip in the bearing points towards the drive shaft
22 - Clutch housing
23 - Spring
92 Rep. gr.35 - Gears, shafts

24 - Sliding sleeve 3rd and 4th gear

25 - Synchronizer body for 3rd and 4th gear
26 - Arrester
❑ Qty. 3
27 - Spring
28 - Arrester
❑ Qty. 3
29 - 5th gear synchronizer body
30 - 5th gear sliding sleeve
31 - Stop ring
❑ prevents the arresters from wandering
❑ dismantling ⇒ page 98
1. Input shaft 93
1.2 Disassembling and assembling the

drive shaft
♦ Pressure spindle - MP3-423 (VW407)-
♦ Tube - MP3-450 (VW 415 A)-
♦ Tube - MP3-451 (VW 422)-
♦ Distance sleeve - MP3-458 (VW 472/2)-
♦ Tube - MP3-414 (VW 516)-
♦ Cap - T30066 (30 - 23)-
♦ Drive bushing - MP1-316 (30-100)-
♦ Circlip pliers - VW 161A-
♦ Tube - MP3-429 (2010)-
♦ Washer - T10083/1-
♦ Pressure plate - T10084A-
♦ Interior extractor - Kukko 21/5-
♦ Countersupport - Kukko 22/2-
♦ Feeler gauges
Pull out the cylindrical-roller bearing from the clutch housing
– When removing the compress circlip -arrow- of the cylindrical-
roller bearing with pliers -C-.
A - Countersupport , e.g. -Kukko 22/2-
B - Interior extractor 30...37 mm , e.g. -Kukko 21/5-
Drive the cylindrical-roller bearing into the clutch housing

– Support the clutch housing by positioning pipe section -
VW 415 A- (not visible in figure) directly under the bearing
support.
– When inserting compress circlip -arrow- of the cylindrical-roller
bearing with pliers -A-.
– Let go of the pliers before the cylindrical-roller bearing is in
fitting position. The circlip must lock into the clutch housing
slot.

Detach bearing support with grooved ball bearings

– Sliding sleeve for 1st and 2nd gear to 2nd gear.
– Slide the pressure plate - T10084/A- sideways up to stop onto
the drive shaft.
– Insert centring pins of thrust piece - T10081- into the holes of
the drive shaft and output shaft.
remove inner ring for cylindrical-roller bearing

– First remove compress circlip with circlip pliers - VW 161 A- .
– Remove inner ring for cylindrical-roller bearing together with
thrust washer, 4th °gear sliding gear with needle bearing, slid‐
ing sleeve and synchronizer body for 3rd °and 4th °gear and
3rd °gear sliding gear.
Disassembling and assembling the sliding sleeve and 3rd and 4th
gear synchronizer body
1- Spring
2- Sliding sleeve
3- Synchronizer body
4- Arrester
– Slide the sliding sleeve over the synchronizer body.
The deeper recesses -arrow A- of the arresters in the synchron‐
izer body and the recesses -arrow B- in the sliding sleeve must
be positioned above one another.
Assembling the sliding sleeve and 3rd and 4th gear synchronizer
body
• The sliding sleeve is drawn over the synchronizer body.
– Insert the arresters in the deeper recesses -arrows- and mount
the springs with 120° offset. The angled end of the spring must
grip into the hollow arrester.
1. Input shaft 95
Fitting position of the sliding sleeve and 3rd and 4th gear syn‐
chronizer body
The groove on the front side -arrow- points towards the 4th gear.
Check synchronizer ring for wear

– Press the synchronizer ring on the cone of the sliding gear and
measure clearance -a- with a feeler gauge.
Clearance -a- Installation dimen‐ Wear limit
sion
3rd, 4th and 5th gear 1.1...1.7 mm 0.5 mm
Press on the synchronizer body with the 3rd and 4th gear sliding
sleeve
Press on the bushing -A- for the 4th °gear needle bearing
– After pressing in the sleeve -A- needle bearing 4th gear, install
synchronizer ring with 4th gear sliding gear and thrust washer.

Press on the inner ring -A- for the cylindrical-roller bearing
Determining the circlip

– Insert circlip -A- with a thickness of 2.0 mm in the slot of the
drive shaft and push upwards -arrow-.
– Measure dimension between inner ring -B- and positioned cir‐
clip -A- using a feeler gauge -C-.
– Remove the circlip used to take the measurement.
– Determine the first circlip required according to the table.
Note
Assign the circlips via the ⇒ Electronic catalogue of original parts .
The following circlips are available.

Measured value Circlip thickness Axial play (mm)
(mm) (mm)
0.05…0.14 2.0 0.05…0.15
0.15…0.24 2.1 0.05…0.15
0.25…0.34 2.2 0.05…0.15
0.35…0.44 2.3 0.05…0.15
0.45…0.51 2.4 0.05…0.10
Pressing the bearing support with grooved ball bearings onto the
drive and output shaft
Note
♦ The output shafts of the individual gearboxes have different

lengths due to the different heights of the serration, dimension
-a- (the installed shafts are shown here).
♦ In order to press in the bearing support evenly onto the shafts,
it is necessary that the shafts are also positioned evenly on
the insert base - T10083- .
♦ A 3 mm thick washer - T10083/1- must be inserted in the fas‐
tening opening of the drive shaft, if necessary ⇒ page 98 .
♦ Therefore, the dimension -a- of the output shaft serration must
be measured.
Dimension -a- = 30.6 mm

Insert washer - –T10083/1- ⇒ page 98 .
1. Input shaft 97
Insert washer - T10083/1-
Pressing on the bearing support

– Before pressing on the bearing support heat it to approximate‐
ly 100 °C.
WARNING
Wear protective gloves!
Press on the bushing -A- for the 5th gear needle bearing
Removing the stop ring

– Bend back the hook -A- of the stop ring from the synchronizer
body with a screwdriver.

Disassembling and assembling the 5th gear sliding sleeve and

synchronizer body
1- Spring
2- Arrester
3- Synchronizer body - fitting position: The groove on the front
side -arrow A- and the wide collar -arrow B- point towards
the 5th gear.
4- Sliding sleeve
5- Stop ring
The deeper recesses -arrow C- of the arresters in the synchron‐
izer body and the recesses -arrow D- in the sliding sleeve must
Assemble sliding sleeve and 5th gear synchronizer body

Installing the stop ring

– Press the stop ring onto the tube - 2010- .
– Insert the stop ring together with the tube - 2010- in the syn‐
chronizer body with 5th gear sliding sleeve (Observe fitting
position ⇒ page 99 ).
Lock the hooks -arrow 1- in the recesses -arrow 2- of the syn‐
chronizer body arresters.
– Push the stop ring down until the hooks click into position.
1.3 Renewing input shaft seal

♦ Puller hooks - T20143/1-
♦ Sealing grease - G 052 128 A1-
1. Input shaft 99
Procedure
– Removing the gearbox.
– Lever out gasket ring for drive shaft with ejection hook -
T20143/1- .
Note
Do not damage the running surface of the gasket ring for the on
the input shaft.
– Fill space between sealing lip and dust lip -arrow- with sealing
grease - G 052 128 A1- .
– Slightly moisten the outer circumference of the gasket ring with
gearbox oil.
Insert the gasket ring for the drive shaft until flush
– Install clutch release lever together with release bearing and
guide sleeve ⇒ page 12 .
– Install gearbox.

2 Output shaft
Summary of components - Output shaft ⇒ page 101 .
Disassemble and assemble output shaft ⇒ page 103 .
2.1 Summary of components - Output shaft
Note
♦ When installing new pinions or a new output shaft observe the technical data ⇒ page 1 and ⇒ Electronic
Catalogue of Original Parts .
♦ Insert all bearings, sliding gears and synchronizer rings onto the output shaft with gear oil.
♦ Do not interchange the synchronizer rings, if re-used always assign to the original sliding gear.
1 - Clutch housing
❑ with circlip
❑ Fitting position: The cir‐
clip in the bearing points
towards the output shaft
3 - Output shaft
❑ with inner ring/cylindri‐
cal-roller bearing
❑ inner ring cannot be re‐
moved from output shaft
❑ with scoring or damage
to the inner ring for the
cylindrical-roller bear‐
ing, replace the drive
shaft and cylindrical-
roller bearing together
4 - 4th gear pinion
❑ Fitting position: Collar
points to the 3rd gear
⇒ page 104
5 - Circlip
6 - Circlip
7 - 3rd gear pinion
points to the 4th gear
⇒ page 104
8 - Circlip
9 - 2nd gear sliding gear
10 - Needle bearing
❑ 2nd gear
11 - Inner ring for 2nd gear
2. Output shaft 101

12 - Outer ring for 2nd gear

❑ placed on the inner ring for 2nd gear
❑ replace if there are any traces of scoring or friction
13 - 2nd gear synchronizer ring
14 - Sliding sleeve with 1st and 2nd gear synchronizer body
❑ after removing the circlip, remove with the 2nd gear sliding gear ⇒ page 104
❑ disassembling ⇒ page 105
❑ Assemble sliding sleeve and synchronizer body ⇒ page 105
15 - Circlip
❑ pushing out ⇒ page 103
16 - 1st gear synchronizer ring
❑ insert in such a way that the recesses lock into the arresters of the sliding sleeve for 1st and 2nd gear
17 - Outer ring for 1st gear
❑ inserted into synchronizer ring for 1st gear, fitting location ⇒ page 106
❑ replace if there are any traces of scoring or friction
18 - Inner ring for 1st gear
❑ Check pegs for damage
19 - Needle bearing
❑ 1st gear
20 - 1st gear sliding gear
21 - Bearing support with grooved ball bearings
❑ Always replace grooved ball bearing together with the bearing support
❑ the bearing support must be replaced each time the gearbox housing is replaced
23 - 5th gear pinion
❑ Fitting position: collar points towards the cover of the gearbox housing ⇒ page 88
24 - Circlip
❑ replace after disassembly
25 - Spring

26 - Sliding sleeve
27 - Synchronizer body
28 - Arrester
❑ Qty. 3
2.2 Disassembling and assembling the out‐

put shaft
♦ Pressure spindle - MP3-423 (VW407)-
♦ Tube - MP3-450 (VW 415 A)-
♦ Thrust piece - MP3-4014 (VW 432)-
♦ Drive bushing - MP1-316 (30-100)-
♦ Thrust piece - MP3-427 (40-21)-
♦ Interior extractor - 1- Kukko 21/5-
♦ Countersupport - 4- Kukko 22/2-
Pull out the cylindrical-roller bearing from the clutch housing
– When removing the compress circlip -arrow- of the cylindrical-
roller bearing with pliers -C-.
Drive the cylindrical-roller bearing into the clutch housing

– Support the clutch housing by positioning pipe section -
VW 415 A- (not visible in figure) directly under the bearing
support.
– When inserting compress circlip -arrow- of the cylindrical-roller
bearing with pliers -A-.
– Let go of the pliers before the cylindrical-roller bearing is in
fitting position. The circlip must lock into the clutch housing
slot.
Press the circlip -1- out of the slot

A - Protective glove
WARNING
Prevent uncontrolled ejection of the circlip.
2. Output shaft 103

Removing the sliding sleeve and synchronizer body 1st and 2nd
gear
– After removing the circlip jointly remove the 2nd gear sliding
gear and the sliding sleeve/synchronizer body.
Fitting position of gear pinion of 3rd and gear pinion of 4th

– Place the 4th gear pinion -A- on the output shaft.
Fitting position:
The collar -arrow 1- points towards the 3rd gear pinion -B-.
– Insert circlips -2- and -3-.
– Place the 3rd gear pinion -B- on the output shaft.
Fitting position:
The collar -arrow 2- points towards the 4th gear pinion -A-.
– Insert circlip -1-.
Check 1st and 2nd gear inner ring for wear

– Press the inner ring on the cone of the sliding gear and meas‐
ure clearance -a- with a feeler gauge.
sion
1st and 2nd gear 0.75...1.25 mm 0.3 mm
Check 1st and 2nd gear synchronizer ring for wear

– Press the synchronizer ring, outer ring and inner ring on the
cone of the sliding gear and measure clearance -a- with a
feeler gauge.
sion
1st and 2nd gear 1.2...1.8 mm 0.5 mm

Fitting position of the outer ring, inner ring and 2nd gear syn‐
chronizer ring
– Place the inner ring -A- on the 2nd gear sliding gear.
The angled lands -arrow 1- point towards the outer ring -B-.
– Position the outer ring -B-.
Lock the pegs -arrows 2- in the recesses -arrows 3- of the sliding
gear.
– Position the synchronizer ring -C-.
Lock the recesses -arrows 4- in the pegs -arrows 1- of the inner
ring -A-.
Disassembling and assembling the sliding sleeve and 1st and 2nd
gear synchronizer body
1- Spring
2- Sliding sleeve
3- Synchronizer body
4- Arrester
Fitting position:
After assembly the groove on the front side -arrow A- and the
higher collar -arrow B- of the synchronizer body point towards the
outer serration of the sliding sleeve -arrow C-.
The deeper recesses -arrow D- of the arresters in the synchron‐
izer body and the recesses -arrow E- in the sliding sleeve must
Assembling the sliding sleeve and 1st and 2nd gear synchronizer
body
2. Output shaft 105

Press on the sliding sleeve and 1st and 2nd gear synchronizer
body
Fitting position:
The slot for the shift fork in the sliding sleeve points towards the
1st gear, the serration of the reversing gear points towards the
2nd gear.
– Rotate the synchronizer ring in such a way that the slots are
flush with the arresters.
Insert the circlip

– Insert the 1st gear synchronizer ring in the sliding sleeve with
synchronizer body.
Fitting position of the 1st gear outer ring

The pegs -arrows- point towards the reversing gear serration.
Fitting position for 1st gear inner ring -A-

The pegs -arrow 1- lock into the recesses -arrow 2- of the syn‐
chronizer ring -B-.

Fitting position 1st gear sliding gear

The higher collar -A- points towards the 2nd gear -B-. The re‐
cesses in the collar -arrows- are pushed into the pegs of the outer
ring (-arrow- ⇒ page 106 ).
2. Output shaft 107

39 – Final drive - differential

1 Gasket rings
Summary of components - Gasket rings ⇒ page 108 .
Replace left gasket ring ⇒ page 108
Replace right gasket ring ⇒ page 110
1.1 Summary of components - Gasket rings
1 - Sealing ring
❑ for drive shaft
2 - Sealing ring
3 - Sealing ring
4 - Sealing ring
1.2 Replacing left sealing ring

Replacing the left flange shaft gasket ring ⇒ page 108 .
1.2.1 Replacing the left flange shaft gasket

ring
♦ Multi-purpose tool - MP3-419 (VW 771)-
♦ Puller hooks - MP3-419/37 (VW 771/37)-
108 Rep. gr.39 - Final drive - differential


Removing
– Remove left wheel.
gr. 66 .
– Turn steering to full left lock.
– Unscrew drive shaft from flange shaft ⇒ Chassis; Rep. gr.
40 .
– Strap up output shaft as far as possible, being careful not to
damage the surface protection.
– Position the catch pan under the gearbox.
– Unscrew the fixing screw for the flange shaft; to do this, insert
two bolts in the flange and hold the flange shaft using an as‐
sembly lever.
– Remove flange shaft together with pressure spring.
– Pull out gasket ring for flange shaft with multi-purpose tool -
MP3-419 (VW 771)- and puller hooks - MP3-419/37 (VW
771/37)- .
Install
– 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 the flange shaft.
– Secure the flange shaft with the conical screw and tighten with
tightening torque.
– Bolt drive shaft to flange shaft ⇒ Chassis; Rep. gr. 40 .
– Check gear oil level, if necessary fill up to lower edge of filler
hole ⇒ page 68 .
– Install wheel ⇒ Chassis; Rep. gr. 44 .
Tightening torques
♦ Flange shaft to gearbox ⇒ page 112
1. Gasket rings 109

1.3 Replacing right sealing ring

Replacing the right flange shaft gasket ring ⇒ page 110 .
1.3.1 Replacing the right flange shaft seal ring

♦ Multi-purpose tool - MP3-419 (VW 771)-
♦ Puller hooks - MP3-419/37 (VW 771/37)-
Removing
gr. 66 .
– If present, remove heat shield for drive shaft -arrows- ⇒ Chas‐
sis; Rep. gr. 40 .
– Unscrew drive shaft from flange shaft ⇒ Chassis; Rep. gr.
40 .
– Strap up output shaft as far as possible, being careful not to
damage the surface protection.
– Position the catch pan under the gearbox.
– Unscrew the fixing screw for the flange shaft; to do this, insert
two bolts in the flange and hold the flange shaft using an as‐
sembly lever.
– Remove flange shaft together with pressure spring.
– Pull out gasket ring for flange shaft with multi-purpose tool -
MP3-419 (VW 771)- and puller hooks - MP3-419/37 (VW
771/37)- or with the assembly lever.
Install

– 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 the flange shaft.
– Secure the flange shaft with the conical screw and tighten with
tightening torque.
– Bolt drive shaft to flange shaft ⇒ Chassis; Rep. gr. 40 .
– If present, install heat shield for drive shaft -arrows- ⇒ Chas‐

sis; Rep. gr. 40 .
– Check gear oil level, if necessary fill up to lower edge of filler
hole ⇒ page 68 .
Tightening torques
♦ Flange shaft to gearbox ⇒ page 112
1. Gasket rings 111

2 Differential
Summary of components - Differential ⇒ page 112 .
Disassembling and assembling differential gear ⇒ page 113 .
Setting the differential gear ⇒ page 115 .
2.1 Summary of components - Differential
1 - Conical screw, 25 Nm
❑ screwed with threaded
part
⇒ Item 8 (page 112)
2 - Right flange shaft
3 - Compression spring
❑ for flange shaft
❑ fitted behind flange
shaft
4 - Thrust washer
for compression spring
5 - Conical ring
❑ Fitting position: Cone for
differential gear housing
6 - Circlip
❑ holds the conical ring,
stop disc and pressure
spring in position when
the flange shaft is re‐
moved
7 - Large differential bevel gear
8 - Threaded part
9 - Differential bevel gear shaft
❑ The tensioning sleeve is
cut during removal
⇒ page 115
10 - Small differential bevel
gear
11 - Stop disc compound
❑ insert with gear oil
12 - Flange shaft left
13 - Sealing ring

15 - Inner ring/tapered-roller bearing

16 - Differential gear housing
❑ with gear pinion for final drive
17 - Tensioning sleeve
❑ to secure the differential bevel gear shaft
❑ is cut when removing ⇒ page 115
18 - Inner ring/tapered-roller bearing
20 - Adjusting washer
21 - Sealing ring
22 - Clutch housing
2.2 Disassembling and assembling differen‐

tial gear
♦ Tube - MP3-409 (VW 418 A)-
♦ Thrust plate - MP3-464 (30-205)-
♦ Press-on sleeve - MP3-412 (VW 455)-
♦ Distance sleeve - MP3-458 (VW 472/2)-
♦ Thrust piece - MP3-427 (40-21)-
♦ Pressure pipe - MP6-408 (30-14)-
♦ Pipe - T30041 (2040)-
♦ Thrust piece - MP3-431 (3002)-
♦ Counterholder - MP1-223 (3067)-
♦ Tube - MP6-419 (3259)-
♦ Tapered-roller bearing extractor - V.A.G 1582-
2. Differential 113
♦ Gripper - V.A.G 1582/3-

♦ Countersupport - Kukko 22/2-
Note
♦ Before installing heat the inner ring of the tapered-roller bear‐

ing to 100°C.
♦ Replace both tapered-roller bearings together.
♦ When replacing the tapered-roller bearings, the differential
housing, the gearbox housing or the clutch housing, set the
differential gear ⇒ page 115 .
Remove outer ring/tapered-roller bearing from gearbox housing

Press in outer ring/tapered-roller bearing in the gearbox housing

– Support the gearbox housing with a pipe - 3259- directly below
the bearing support.
Removing inner ring/tapered-roller bearing
Note
Both inner rings/tapered-roller bearings of the differential gear

housing are removed in the same way.
Press on inner ring/tapered-roller bearing

– Support the opposite side of the inner ring with an insertion
bushing - VW 455- .
The shoulder of the insertion bushing - VW 455- points to the dif‐
ferential gear housing.
Note
Both inner rings/tapered-roller bearings of the differential gear

housing are pressed on in the same way.

Remove the outer ring/tapered-roller bearing -A- from the clutch

housing
– tension the interior extractor behind the outer ring/tapered-
roller bearing.
Press in outer ring/tapered-roller bearing in the clutch housing
Press out differential bevel gear shaft

The tensioning sleeve is cut during pressing out.
– Drive the remaining part of the tensioning sleeve out of the
differential gear housing.
Install differential bevel gears

– Install stop disc compound with gearbox oil.
– Insert both large differential bevel gears and secure (e.g. with
flange shaft).
– Insert the small differential bevel gears offset at 180° and turn
into the fitting position.
– Slide in the differential bevel gear shaft -arrow A- up to the first
small differential bevel gear.
– Insert the threaded parts -arrows B- in the large differential
bevel gears.
– Drive in the differential bevel gear shaft up to end position and
secure with tensioning sleeve.
2.3 Adjusting the differential gear

♦ End dimension plate - 50 mm - MP3-405/17 (VW 385/17)-
♦ Universal dial gauge bracket - MP3-447 (VW 387)-
2. Differential 115

♦ Thrust plate - MP3-464 (30-205)-
♦ Pressure pipe - MP6-408 (30-14)-
♦ Pipe - T30041 (2040)-
♦ Pipe key - MP3-433 (3059)-
♦ Dial gauge
The differential gear must be re-set when the following compo‐
nents are replaced:
♦ Gearbox housing,
♦ clutch housing,
♦ Differential gear housing
or
♦ tapered-roller bearings of the differential gear.
– Press in outer ring/tapered-roller bearing (pinion side) in the
gearbox housing.
Note
The inner and outer ring of the tapered-roller bearing are paired.
Do not interchange!
– Press the outer ring/tapered-roller bearing (opposite pinion

side) without adjusting washer into the clutch housing.
– Insert the differential gear in the gearbox housing.
– Position the clutch housing and tighten 5 screws to the given
tightening torque.


– Assemble the dial gauge.

A - Dial gauge extension 30 mm
– Set the dial gauge to “0” with 1 mm bias.
– Move the differential shaft up and down, read off and write
down the clearance on the dial gauge (in this example: 1.50
mm).
Determine the adjusting washer
The prescribed bearing preload is reached by adding to the es‐
tablished measured value a constant compression value (0.35
mm).
Example
measured value 1.50 mm
+ pressing (constant value) 0.35 mm
Thickness of the adjusting washer = 1.85 mm
– Remove the clutch housing and remove the outer ring/ta‐

pered-roller bearing -A-.
– Assign the adjusting washers via the ⇒ Electronic Catalogue
of Original Parts .
The various thicknesses make it possible to achieve the exact
shim thickness required.
If the measured washer thickness is greater than the one listed in
the ⇒ Electronic catalogue of original parts , 2 washers corre‐
sponding to the measured value may be fitted.
– Insert adjusting washer with the required thickness (in this ex‐
ample 1.85 mm) and press the outer ring/tapered-roller bear‐
ing back into the clutch housing.
– Put the clutch housing into place and tighten the bolts.
Tightening torques
♦ Gearbox housing and clutch housing ⇒ page 72 .
2. Differential 117

Gearbox 0AH

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Service

Service Department. Technical Information

4.2 Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

39 - Final drive - differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

1.1 Location on the gearbox

Gearbox 0AH -arrow 2-

Codes and production date of gearbox

The gearbox identification characters also appear on the vehicle

1. Identification of the gearbox 1

1.2 Identification characters, aggregate assignment, ratios, capacities

Volkswagen Technical Site: http://vwts.ru http://vwts.info

2 Rep. gr.00 - Technical data

2 Overview of Transmission System

2.1 Designation of components and transmission ratios

The -arrows- show the direction of travel.

2. Overview of Transmission System 3

3 General repair instructions

3.1 Safety measures for working on vehi‐

On vehicles with start-stop system, there is the risk of injury

3.2 General repair instructions

4 Rep. gr.00 - Technical data

3. General repair instructions 5

♦ Do not interchange. When reusing synchro-rings, always fit to

6 Rep. gr.00 - Technical data

1. Repairing clutch control 7

8 Rep. gr.30 - Clutch

1.2 Assembly overview - pedal cluster

1. Repairing clutch control 9

10 Rep. gr.30 - Clutch

1.3 Assembly overview - clutch hydraulics

Volkswagen Technical Site: http://vwts.ru http://vwts.info

1. Repairing clutch control 11

Disconnect the cables for the clutch control and connect

♦ An O-ring can also be installed instead of the gasket ring -2-

Seals and O-rings for pipe and hose lines

1.4 Assembly overview - clutch release mechanism

12 Rep. gr.30 - Clutch

1 - Clutch release lever

1.5 Removing and installing bearing bush

1. Repairing clutch control 13

1.6 Checking the master and slave cylinder

1.7 Removing and installing clutch position

14 Rep. gr.30 - Clutch

– Unlock catch -arrow- of clutch position sender - G476- -2- at

1.8 Removing and installing the over-centre

– Remove the footwell vent -1- on the driver's side ⇒ Heating,

1. Repairing clutch control 15

– Remove data bus diagnostic interface - J533- -1- from bracket

– Unscrew screw -2-, unhook crash strut -1- aushängen and

– Swivel the clutch pedal in -direction of arrow-, unhook and re‐

16 Rep. gr.30 - Clutch

1.9 Removing and installing tension spring

– Remove the footwell vent -1- on the driver's side ⇒ Heating,

1. Repairing clutch control 17

– Remove data bus diagnostic interface - J533- -1- from bracket

– Unscrew screw -2-, unhook crash strut -1- aushängen and

– If present, unhook the tension spring -1- and remove, while

18 Rep. gr.30 - Clutch

1.10 Removing and installing clutch pedal

Remove bearing block for clutch pedal

1. Repairing clutch control 19

Install bearing block for clutch pedal

1.11 Removing and installing bearing block

20 Rep. gr.30 - Clutch