6-Speed Manual Gearbox 02S PDF

Service
Workshop Manual
Golf Variant 2007 ➤
Golf Variant 2010 ➤
Jetta 2005 ➤
6-speed manual gearbox 02S
Edition 07.2009
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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
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All rights reserved.

No reproduction without prior agreement from publisher.
Copyright © 2010 Volkswagen AG, Wolfsburg MEX5R007520

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
6-speed manual gearbox 02S - Edition 07.2009
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Gearbox identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Location on gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . n.A.G.. .V.ol.ks.w.a.g.en. A. G. . . . . . . . . . . . . . . . 1
1.2 Identification code, assembly allocation and capacities wage . . . . . . . . . . . . . d.o.es. n. . . . . . . . . . . . 1
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2 Overview - power transmission . . . . . . . r.is.ed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ra.nt.e . . . . . 5
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3 Calculating overall gear ratio “i” . . . s.a.u . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .r a.c . . 7
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4 General repair notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
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4.1 Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
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30 - Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
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1 Fault finding, power transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
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2 Repairing clutch mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
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2.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
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2.2 Assembly overview - pedal cluster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.3 Removing and installing over-centre spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
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2.4 Removing and installing clutch pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2.5 Removing and installing mounting bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
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2.6 Removing and installing master cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
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2.7 Removing and installing clutch position sender G476 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
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2.8 Assembly overview - hydraulics (LHD vehicles) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
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2.9 Assembly overview - hydraulics (RHD vehicles) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
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2.10 Removing and installing slave cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
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2.11 Bleeding clutch system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

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3 Repairing clutch release mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
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4 Repairing clutch, in conjunction with dual-mass flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . 46

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4.1 Determining clutch manufacturer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
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4.2 Removing and installing Sachs clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
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4.3 Repairing Sachs clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . cted
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4.4 Removing and installing LuK clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
4.5 Repairing LuK clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
5 Repairing clutch, in conjunction with one-piece flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . 54
34 - Controls, housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
1 Fault finding, power transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
2 Repairing selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
2.1 Installation position of selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
2.2 Overview of selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
2.3 Removing and installing gear knob and frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
2.4 Removing and installing gaiter with gear knob and noise insulation . . . . . . . . . . . . . . . . . . 61
2.5 Repairing gear lever and selector housing (through 10.06) . . . . . . . . . . . . . . . . . . . . . . . . 63
2.6 Repairing gear lever and selector housing (from 11.06) . . . . . . . . . . . . . . . . . . . . . . . . . . 65
2.7 Assembly overview - removing and installing selector cables . . . . . . . . . . . . . . . . . . . . . . 70
2.8 Plastic relay lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
2.9 Removing and installing selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
2.10 Removing and installing gear selector cable and gate selector cable . . . . . . . . . . . . . . . . 78
2.11 Adjusting selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
3 Removing and installing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
3.1 Removing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
3.2 Installing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
4 Checking and topping up gear oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
4.1 Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Contents i
4.2 Draining gear oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

4.3 Filling with gear oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
5 Dismantling and assembling gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
5.1 Overview - gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
5.2 Assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
5.3 Removing and installing cover for gearbox housing and 5th and 6th gear . . . . . . . . . . . . 104
5.4 Removing and installing gearbox housing and shift mechanism . . . . . . . . . . . . . . . . . . . . 107
5.5 Removing and installing input shaft, output shaft, differential and selector forks . . . . . . . . 108
5.6 Assembly sequence - Removing and installing cover for gearbox housing and 5th and 6th
gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
5.7 Assembly sequence - Dismantling and assembling gearbox completely . . . . . . . . . . . . . . 115
6 Repairing gearbox housing and clutch housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
7 Repairing gearbox housing cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
8 Repairing selector unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
9 Dismantling and assembling selector forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
35 - Gears, shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150

1 Input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
1.1 Dismantling and assembling input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
1.2 Adjusting input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
2 Output shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
2.1 Dismantling and assembling output shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
2.2 Adjusting output shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
3 Reverse shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
3.1 Dismantling and assembling reverse shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
39 - Final drive - differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184

1 Renewing flange shaft oil seals with gearbox installed . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
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1.2 Distinguishing seals for ed
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1.3 Renewing seal (two-part ris seal and sleeve for right flange shaft) tee.o. . . . . . . . . . . . . . . . . . . . . 186
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1.4 Renewing seal sands a sleeve together (one-piece seal and sleeve foracright flange shaft) . . . . 189
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2 Adjustment overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192

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3 Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
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3.1 Dismantling and assembling differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193

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3.2 Adjusting differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200

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ii Contents
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1 Gearbox identification a ra
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Code letters and date of manufacture -arrow 1- Manual gearbox
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Manual gearbox 02S -arrow 2-

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Identification code and date of gearbox manufacture

Example: FNG 12 11 3
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Identification Day Month Year (2003)
code of manufacture
Additional data provide information about the production facility.
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The gearbox code also appears on the vehicle identification

plates.
1.2 Identification code, assembly allocation and capacities

Manual gearbox 6-speed 02S
Identification code FNG HYG GQM
Manufactured from 05.05 05.06 05.05
to 05.05 09.06
Allocation Model Jetta 2005 ▸ Jetta 2005 ▸ Jetta 2005 ▸
Golf Variant 2007 ▸ Golf Variant 2007 ▸ Golf Variant 2007 ▸
1. Gearbox identification 1

Identification code FNG HYG GQM
Engine 1.9 l - 74 kW 1.4 l - 103 kW 1.9 l - 74 kW
turbo diesel turbo diesel
1.9 l - 77 kW 1.9 l - 77 kW
turbo diesel turbo diesel
Ratio Final drive 62 : 17 = 3.647 61 : 18 = 3.389 61 : 18 = 3.389
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Drive shaft flange ∅ 100 mm 100 mm 107 mm

Identification code JYL JCL JCN
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2 Rep. Gr.00 - Technical data


Identification code JYL JCL JCN
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Ratio Final drive 62 : 17 = 3,647
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Capacity of manual gearbox (gear‐ 2.1 l
Capacity of manual gearbox 1.9 l
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Drive shaft flange ∅ 100 mm
1. Gearbox identification 3

Identification code JXP JXR KWB
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2 Overview - power transmission

Designation
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2 - Clutch
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Ratio
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2. Overview - power transmission 5

I - 1st gear
II - 2nd gear
III - 3rd gear
IV - 4th gear
V - 5th gear
VI - 6th gear
R - Reverse gear
A - Final drive
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6th gear Final drive
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iA = Final drive ratio = ZA2 : ZA1 = 60 : 18 = 3.389
rrectness of i
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1) Z1 = No. of teeth on driving gear, Z2 = No. of teeth on driven gear
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3. Calculating overall gear ratio “i” 7

4 General repair notes

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

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

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♦ When installing mounting brackets or waxed components,
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clean the contact surfaces. Contact surfaces must be free of
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wax and grease.
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spec
♦ Allocate bolts and other components using ⇒ Electronic parts
catalogue “ETKA” . t to the co

♦ Capacity ⇒ page 1 .
rrectne
♦ If the gearbox is repaired, fill with gear oil.

Capacity, gearbox completely Gearbox capacity, gearbox
ss
dismantled partially dismantled

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⇒ page 99
inform
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2.1 l 1.9 l
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4.1.2 O-rings, seals, gaskets and sealants

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♦ Thoroughly clean housing joint surfaces before applying seal‐

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♦ After removing gaskets and seals, always inspect contact sur‐
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face of housing or shaft for burrs resulting from removal or for
other signs of damage.
♦ Before installing radial shaft seals, lightly oil outer diameter
and half-fill space between sealing lips -arrow- with sealing
grease -G 052 128 A1- .
♦ The open side of the oil seal faces the side with fluid filling.
♦ Press in new oil seals so that sealing lip does not contact the
shaft in the same place as the old seal (make use of insertion
depth tolerances).
♦ Lightly oil O-rings before installing; this prevents the rings be‐
ing crushed when inserted.
♦ After renewing seals and gaskets, check oil level in gearbox
and replenish if necessary ⇒ page 99 .

4.1.3 Locking devices

♦ Do not overstretch retaining rings.
♦ Always renew retaining rings which have been damaged or
overstretched.
♦ Retaining rings must locate properly in grooves.
♦ Renew spring pins. Installation position: slit -A- should be in
line with the line of force -arrow-.
4.1.4 Nuts and bolts

♦ Loosen nuts or bolts in the order opposite to the tightening
sequence.
♦ Nuts and bolts which secure covers and housings should be
loosened and tightened diagonally in stages if no tightening
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♦ Torque settings are specified for unoiled bolts and nuts.
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♦ Always renew self-locking bolts and nuts.
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♦ Threads of bolts secured with locking fluid must be cleaned

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with a wire brush. Then insert bolts with locking fluid -

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AMV 185 101 A1- . spec

es, in part or in w
♦ Clean threaded holes in which self-locking bolts or bolts with

t to the co
locking fluid have been inserted, e.g. with a thread chaser.

Otherwise there is a danger that the bolts may shear when
removed again.
rrectness of i
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4.1.5 Bearing
♦ Install needle bearings with lettered side (thicker metal) to‐
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wards fitting tool.

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♦ Lubricate all gearbox bearings with gear oil before installing.

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♦ Tapered roller bearings fitted to one shaft must be renewed as

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a set. Use same make of bearings.

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♦ Heat inner races to about 100° C with the inductive heater -

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VAS 6414- before installing.
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4. General repair notes 9

4.1.6 Shims
♦ Measure shims at several points with a micrometer. The var‐
ious thicknesses make it possible to achieve the exact shim
thickness required.
♦ Check for burrs and damage.
♦ Install only flawless shims.
4.1.7 Synchro-rings
♦ Do not interchange. When reusing synchro-rings, always fit to
the same gear.
♦ Check for wear and renew if necessary.
♦ Check grooves -arrow 1- of synchro-ring -A- and inner ring for
flat spots (worn grooves).
♦ If synchro-rings are coated, coating must not be damaged.
♦ If an intermediate ring -B- is installed, check the outer friction
surface -arrow 2- and inner friction surface -arrow 3- of this
intermediate ring for “scoring” and “signs of abnormal wear”.
♦ Check cone of synchromeshed gear for “scoring” and “signs
of abnormal wear”.
♦ Moisten synchromesh mechanism with gear oil before instal‐
ling.
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4.1.8 Gears, synchro-hubs, inner races for Vo gu
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synchromeshed gears aut
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♦ Heat inner races for synchromeshed gear to about 100° C with
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the inductive heater -VAS 6414- before installing.

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♦ Heat synchro-hub with inductive heater -VAS 6414- to approx.

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100 °C before installing. Press in to stop when installing so

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there is no axial clearance.

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♦ Heat gears with inductive heater -VAS 6414- to approx. 100 °

spec
C before installing. Press in to stop when installing so there is

es, in part or in w
no axial clearance.
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♦ Observe installation position.

rrectness of i
4.1.9 Synchromeshed gears

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♦ After assembly, check synchromeshed gears for slight play, or

for freedom of movement.
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4.1.10 Clutch
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♦ When removing gearbox, remove slave cylinder without dis‐

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connecting pipes.
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♦ If the clutch slave cylinder is removed with the hydraulic line

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attached, do not depress clutch pedal. Otherwise the piston

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Rep. Gr.00 - Technical data
♦ Ensure that the pressure plate does not cant: loosen and tight‐
en bolts diagonally and in several gradual stages.
♦ If the clutch has burnt out, thoroughly clean the clutch housing
as well as the friction surface of flywheel with a cloth to reduce
the smell of burnt linings.
AG. Volkswagen AG d
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4. General repair notes 11

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

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2 Repairing clutch mechanism
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2.1 Overview
hole
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Note
rrectness of i
♦ Before disconnecting battery, obtain code for radio units having anti-theft coding.
l purpos
♦ With ignition switched off, disconnect battery earth strap ⇒ Electrical system; Rep. Gr. 27 ; Disconnecting
and connecting battery .
nf
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♦ When reconnecting battery, refer to ⇒ Electrical system; Rep. Gr. 27 ; Disconnecting and connecting
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battery .
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♦ Lubricate all bearings and contact surfaces with grease -G 000 450 02- .
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I - Assembly overview - pedal
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II - Assembly overview - hy‐ yri
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draulics (LHD) ⇒ page 37 cop Vo
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III - Assembly overview - hy‐
AG.
draulics (RHD) ⇒ page 39
2. Repairing clutch mechanism 13

2.2 Assembly overview - pedal cluster
1 - Bulkhead
❑ With support for mount‐
ing bracket
2 - Seal
❑ Always renew
❑ Between mounting agen
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❑ Bond to mounting aut ra
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3 - Mounting bracket
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❑ For mounting clutch
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❑ Is provided with damp‐
h re
ole,
ing in some equipment
spec
variants ⇒ page 15
t to the co
❑ Removing and installing
⇒ page 25
4 - Bolt
rrectne
5 - Over-centre spring
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⇒ page 15
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6 - Bearing bush
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7 - Pivot pin
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8 - Clutch pedal
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⇒ page 20
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9 - Retainer
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⇒ page 20
10 - Seal
❑ Always renew
❑ Between master cylinder and mounting bracket
11 - Master cylinder
❑ Removing and installing after removal of mounting bracket ⇒ page 25
12 - Clutch position sender -G476-
❑ Removing and installing ⇒ page 33
❑ Can be checked using “guided fault finding” of vehicle diagnostic tester
❑ The clutch position sender -G476- is identified as clutch pedal switch -F36- in “guided fault finding”.
13 - Clip
❑ Pull out clip to stop to remove and install pipe/hose line
14 - Supply hose
❑ Rubber
❑ From 12.05, plastic ⇒ page 38
15 - Hexagon nut, 25 Nm
❑ Self-locking

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❑ Qty. 3 aut
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❑ For mounting bracket on bulkhead
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❑ Always renew
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❑ Always renew
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17 - Stop
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❑ For clutch pedal
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Mounting bracket with damping -arrows-
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2.3 Removing and installing over-centre

spring
Special tools and workshop equipment required
♦ Release tool -T10178-
2.3.1 Removing
Vehicles with knee airbag
Note
The installation location of the knee airbag is above the pedal

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

theft code.

– With ignition switched off, disconnect battery earth strap ⇒

Electrical system; Rep. Gr. 27 ; Disconnecting and connecting
battery .
Continuation for all
– Push driver seat as far back as possible and put steering wheel
in highest position.
– Remove trim and cover below trim on drive side ⇒ General
body repairs, interior; Rep. Gr. 68 .
– Remove bracket for knee airbag together with crash bar ⇒
Interior equipment; Rep. Gr. 69 ; Airbag; Removing and in‐
stalling knee airbag bracket .
– Remove cable guide -2- from steering column.
– Remove footwell vent -3- ⇒ Heating, air conditioning; Rep.
Gr. 80 ; Repairing heating .
Vehicles without knee airbag
The crash bar -1- in front of clutch pedal -2- may be secured in
different ways.
AG. Volkswagen AG d
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Attachment with
ss a2 bolts
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– Remove crash bar -1- (2 bolts).

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Attachment with 1 bolt

– Remove crash bar -1- (1 bolt -2-).
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– If fitted, remove damping -arrow- from lower area of clutch

pedal mounting bracket.
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– To do this, remove lock washers -A- for damping.
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– Pull off damping.
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– Push damping upwards in area of upper securing nut -1-

above clutch pedal -A- in -direction of arrow-.

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

nut -2- and pulling out bolt -5-.
Note
The clutch pedal remains hooked to operating rod of master cyl‐

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

spring -4- from mounting bracket.
AG. Volkswagen AG d
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2.3.2 Installing
h re
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spec
Install in the reverse order of removal, observing the following:
es, in part or in w
t to the co
Note
rrectness of i
Renew self-locking nuts.
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– Insert over-centre spring -2- in mounting bracket from above

nf
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while holding end of spring with assembly tool -T10178- in in‐ or

stallation position.
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• Receptacle -arrow- for tip -A- of clutch pedal must stand ver‐
tically.
– Insert tip of clutch pedal in bearing recess of over-centre
spring.
– Depress clutch pedal slightly, push bolt through and tighten
self-locking nut to specified torque ⇒ page 20 .

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

bracket.
– Return it to installation position.
AG. Volkswagen AG d
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Attachment with 2 bolts
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– Install crash bar -1- and tighten the 2 bolts to specified torque
l purpos
⇒ page 20 .
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– Install crash bar -1- and tighten bolt -2- to specified torque
t. rig
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⇒ page 20 .
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– Mount cable guide -2- on steering column.

– Install footwell vent -3- ⇒ Heating, air conditioning; Rep. Gr.
80 ; Repairing heating .
– Install bracket for knee airbag together with crash bar ⇒ Inte‐
rior equipment; Rep. Gr. 69 ; Airbag; Removing and installing
knee airbag bracket .
– Install trim and cover below trim on drive side ⇒ General body
repairs, interior; Rep. Gr. 68 .
– If disconnected, connect battery ⇒ Electrical system; Rep. Gr.
27 ; Removing and installing battery .

2.3.3 Specified torques

Component Nm
Clutch pedal to mounting bracket 25
♦ Renew self-locking nuts
Crash bar to steering column mounting 10

bracket (attachment with 2 bolts)
Crash bar to steering column mounting swagen AG. Vo20
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♦ Renew bolts for crash bar horise nte
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2.4 Removing and installing clutch pedal
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ab
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♦ Pliers -T10005-
wit
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spec
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f inform
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♦ Release tool -T10178- i

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2.4.1 Removing
Note

cluster.

theft code.
battery .


– Push driver seat as far back as possible and put steering wheel
in highest position. en AG. V
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– Remove trim and cover below trim on drive y V side ⇒ General gu
db ara
body repairs, interior; Rep. Gr. 68 . rise nte
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Vehicles with knee airbag s au ra
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Note
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cluster.
h re
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spec
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theft code.
rrectness of i
battery .
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on
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different ways.
– Remove crash bar -1- (2 bolts).


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– If fitted, remove damping -arrow- fromy Vlower
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– Pull off damping.
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– Unbolt clutch pedal -1- from mounting bracket -3- by removing

nut -2- and pulling out bolt -5-.
– Swing clutch pedal down slightly and remove over-centre
spring -4- from mounting bracket.
– Release clutch pedal from master cylinder with pliers -

T10005- .
– Remove clutch pedal.
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2.4.2 Installing
hole
spec
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t to the co
Note
rrectness of i
l purpos
Renew self-locking nuts.

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

orm
m
– Press retainer into notch in clutch pedal -3- until it can be heard
atio
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to engage.
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– Insert over-centre spring -2- in mounting
olks
wage bracket from above
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while holding end of spring with
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Some cars have damping -arrow- on the mounting bracket/clutch

pedal.
– Return it to installation position.

different ways.
– Install crash bar -1- and tighten the 2 bolts to specified torque
⇒ page 25 .
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⇒ page 25 .
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– Install footwell vent -3- ⇒ Heating, air conditioning; Rep. Gr.
nform
ercia
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– If disconnected, connect battery ⇒ Electrical system; Rep. Gr.

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

♦ Renew bolts for crash bar
2.5 Removing and installing mounting

bracket

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♦ Hose clamps to 25 mm Ø -3094-
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♦ Hose clip pliers -VAS 6362-

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♦ Sealing tool -T10249-
2.5.1 Removing
LHD
theft code.
battery .
– Remove complete air filter housing if it is near battery ⇒ Rep.
Gr. 23 ; Repairing diesel direct injection system or ⇒ Rep.
Gr. 24 ; Repairing injection system .
– Remove battery and battery tray ⇒ Electrical system; Rep.
Gr. 27 ; Battery; Removing and installing battery .

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

longitudinal member or gearbox. If this does happen, clean the
affected areas thoroughly.
♦ Place a lint-free cloth under the
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VAS 6362- and pull supply hose off master cylinder.
ss o
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cial p
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tool -T10249/1- (⇒ figure above).
form
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and pull pipe/hose line or plastic line -1- off master cylinder.
n
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t
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-arrow- and remove with electrical connector attached -4-.

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When performing work in the footwell, put cloths on the carpet to
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protect it from possible brake fluid spills.
AG.
– Remove trim and cover below trim on drive side ⇒ General

body repairs, interior; Rep. Gr. 68 .
Note

cluster.

– Remove bracket for knee airbag together with crash bar ⇒

Interior equipment; Rep. Gr. 69 ; Airbag; Removing and in‐
stalling knee airbag bracket .
different ways.
– Unbolt crash bar (2 bolts).

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

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pedal mounting bracket.

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– Remove securing nuts -1- and -2-.

The upper securing nut -1- is accessible between the relay carrier
and the steering column trim.
– Remove mounting bracket -3-.
2.5.2 Installing

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

bracket.
Note
♦ Renew self-locking nuts.

♦ Renew hose clips.
♦ Allocate all components according to ⇒ Electronic parts cata‐
logue “ETKA” .
different ways.
– Install crash bar -1- and tighten the 2 bolts to specified torque olks
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⇒ page 31 . db
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⇒ page 31 .
rrectness of i
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nform
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– Install footwell vent -3- ⇒ Heating, Air conditioning; Rep. Gr.

en
ng
t.
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80 ; Repairing heating; Removing and installing left footwell
Co
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o Vo
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– Install trim and cover below trim on drive side ⇒ General body
repairs, interior; Rep. Gr. 68 .

– Push pipe/hose line or plastic line -1- with seal -2- onto con‐
nection of master cylinder -4- until securing clip -3- engages
audibly.
– Test line by tugging on it.
– After removing hose clamp up to 25 mm ∅ -3094- , return
supply hose to its original shape, if necessary.
– Bleed clutch system ⇒ page 42 .
LHD
– Install battery ⇒ Electrical system; Rep. Gr. 27 ; Removing
and installing battery .
– If complete air filter housing was removed, install it ⇒ Rep.
Gr. 24 ; Repairing injection system . AG. Volkswagen n AG do
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Mounting bracket to bulkhead 25
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♦ Renew self-locking nuts.
ole,
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bracket (attachment with 1 bolt)
♦ Renew bolts for crash bar
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2.6 Removing and installing master cylinder
inform
mer
atio

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♦ Pliers -T10005-
or
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2.6.1 Removing
– Remove mounting bracket ⇒ page 25 .

– Release retainer for master cylinder operating rod using pliers

-T10005- .
– Insert spacer -A- between clutch pedal and stop and press
clutch pedal to spacer.
♦ Length of spacer = about 40 mm (e.g. 1/2" socket)
Volkswa
– Release securing bar -B- and pullswmaster
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2.6.2 Installing
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• Move clutch pedal to rest position at stop.

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

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– Insert spacer -A- between clutch pedal and stop and press
clutch pedal to spacer.
♦ Length of spacer = about 40 mm (e.g. 1/2" socket)
– Engage master cylinder in mounting bracket -arrow 1- and

-arrow 2-.
AG. Volkswagen AG d
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– Install mounting bracket ⇒ page 25 .
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2.7 Removing and installing clutch position
sender -G476-
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♦ Hose clamps -3094-

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2.7.1 Removing
LHD
theft code.
battery .


Right-hand drive
– In vehicles with particle filter, remove shielding -A- from parti‐
cle filter ⇒ Rep. Gr. 26 ; Parts of exhaust system; Assemblygen AG
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An insulation mat is installed in conjunction withorisome
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– Remove heat shield from pipe/hose line -arrows-.
rrectness of i
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Continuation for all Cop
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op Vo
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Prote AG.
Note
During the following work, ensure that no brake fluid lands on

longitudinal member or gearbox. If this does happen, clean the
affected areas thoroughly.

– Clamp off supply hose to master cylinder using hose clamp to

25 mm ∅ -3094- .
AG. Volkswagen AG d
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– Release securing clip -2- with a screwdriver or a pointed object
hole
spec
and pull out of master cylinder to stop.
es, in part or in w
t to the co
– Pull pipe/hose line -1- or plastic line out from master cylinder
and seal.
rrectness of i
– Disconnect electrical connector -4-.
– Unclip clutch position sender -G476- from master cylinder
l purpos
-arrow- and remove.
nform
mercia
at
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c
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Cop py
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by
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2.7.2 Installing
Note
Allocate all components according to ⇒ Electronic parts cata‐

logue “ETKA” .

If the pipe/hose line was removed

– Push pipe/hose line -1- or plastic line with seal -2- onto con‐
nection of master cylinder -4- until securing clip -3- engages
audibly.
– Test pipe/hose line by tugging on it.
– After removing hose clamp up to 25 mm ∅ -3094- , return
supply hose to its original shape, if necessary.
– Bleed clutch system ⇒ page 42 .
Right-hand drive
– In vehicles with particle filter, install shielding -A- on particle

filter ⇒ Rep. Gr. 26 ; Parts of exhaust system; Assembly
overview - front exhaust pipe with particle filter .
LHD
– Install battery tray and battery⇒ Electrical system; Rep. Gr.
olkswagen AG
en AG. V
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nf
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Cop py
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rig ht
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Prote AG.

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

2 - Spring-type clip
3 - Supply hose
❑ Rubber
❑ From 12.05, plastic in
some vehicles
⇒ page 38
4 - Master cylinder
⇒ page 31
5 - Clip
❑ Pull out clip to stop to re‐
move and install pipe/
hose line
6 - Retainer
separate master cylin‐
⇒ page 20
7 - Clutch pedal
⇒ page 20
❑ Self-locking
❑ Qty. 3
❑ For mounting bracket on AG. Volkswagen AG d
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9 - Seal / O-ring ss a ra
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❑ Pull onto line connection
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❑ Insert with brake fluid

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❑ Seals/O-rings are adapted to configuration of line connection ⇒ page 38

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❑ Allocation ⇒ Electronic parts catalogue “ETKA”

wit
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10 - Pipe/hose line
hole
spec

es, in part or in w
t to the co
❑ To remove, remove battery and battery tray ⇒ Electrical system; Rep. Gr. 27 ; Removing and installing
battery .
rrectness of i
11 - Bracket
❑ Secured to body
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12 - Seal / O-ring
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13 - Clip
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14 - Slave cylinder
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15 - Hexagon bolt, 20 Nm agen

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16 - Bleeder valve d by V gu
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❑ Bleeding clutch system ⇒ page 42 uthor eo
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17 - Dust cap s
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18 - Gearbox
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19 - Bracket
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Seals and O-rings for pipe and hose lines
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Item Material of line connection
rrectness of i
-1- Line connection with circumferential groove
-arrow 1-
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-2- Line connection with shoulder -arrow 2-
nf
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2.9 Assembly overview - hydraulics (RHD vehicles)
1 - Brake fluid reservoir

2 - Seal
❑ For plastic supply hose
❑ The seals must be loca‐
ted in supply hose
3 - Supply hose
❑ Rubber
❑ From 12.05, plastic in
some vehicles
⇒ page 38
4 - Master cylinder
⇒ page 31
5 - Clip
❑ Pull clip out to stop to re‐
move or install pipe line
❑ Pulled out to side on
some master cylinders
6 - Seal / O-ring
❑ Seals/O-rings are adap‐
ted to configuration of
line connection
⇒ page 38
❑ Allocation ⇒ Electronic
parts catalogue “ETKA” wage
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7 - Retainer byV ua
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❑ To remove and install, utho
or
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⇒ page 20
an
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8 - Clutch pedal
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❑ Self-locking
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❑ Qty. 3
❑ For mounting bracket on bulkhead
rrectness of i
❑ Always renew
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10 - Bracket
❑ Secured to body
nform
ercia
11 - Pipe line
m
❑ Pipe and hose/pipe line ⇒ Item 13 (page 40) may be in one piece
a
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12 - Seal / O-ring
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13 - Pipe/hose line
❑ Pipe ⇒ Item 11 (page 39) and hose/pipe line may be in one piece
battery .
14 - Bracket
❑ Secured to retainer for ABS/EDL
15 - Bracket
❑ For ABS/EDL
16 - Seal / O-ring
17 - Clip . Volkswagen AG
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❑ Pull out clip to stop to remove
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18 - Slave cylinder ris
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19 - Flange bolt, 20 Nm
un
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20 - Bleeder valve
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❑ Bleeding clutch system ⇒ page 42

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21 - Dust cap
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spec
22 - Gearbox
t to the co
23 - Bracket
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2.10 Removing and installing slave cylinder

s o
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form
mer
atio
♦ Torque wrench -V.A.G 1331-

om
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2.10.1 Removing
theft code.


battery .
– Remove complete air filter housing if it is over slave cylinder
⇒ Rep. Gr. 23 ; Repairing diesel direct injection system or ⇒
Rep. Gr. 24 ; Repairing injection system .
– Remove securing clip -arrow 1- for gear selector cable from
gearbox selector lever -A-.
– Pull gear selector cable from pin.
Metal relay lever
– Remove securing clip -arrow 2- for gate selector cable from
relay lever -B-.
AG. Volkswagen AG d
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– Pull gate selector cable from pin. Vo lksw
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– Pull securing clip -arrow 3- off relay lever -B- and remove
orise
relay nte
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Plastic relay lever
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un
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an
d
– Remove relay lever together with cable end-piece from gear‐

itte
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box ⇒ page 73 .
ab
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– Remove gearbox selector lever -A- by removing nut
hole
spec
-arrow 4-.
es, in part or in w
t to the co
– Remove cable support bracket from gearbox -arrows-.
– Then raise and secure gear selector cable and gate selector
rrectness of i
cable.
l purpos
– Remove retainer -B- from gearbox and pull it off pipe/hose line
-A-.
nform
mercia
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tion in
r
te o
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– Then remove gearbox support -arrow A-.

– Place a lint-free cloth under slave cylinder.
– Pull clip for pipe/hose line out of slave cylinder to stop.
– Pull pipe/hose line out of slave cylinder and seal opening.
– Remove slave cylinder -arrows B-.
Caution
Do not operate clutch pedal any more.

2.10.2 Installing
– Install slave cylinder and tighten bolts -arrows B- to specified
torque.
AG. Volkswagen AG d
– Insert pipe/hose line into slave cylinder to stop. ksw
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– Push securing clip into pipe/hose line to stop. ised b ara
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– Test pipe/hose line by tugging on it. s aut ra
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– Then install gearbox support -arrows A-.
ce
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– Bleed clutch system after installing slave cylinder
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⇒ page 44 .
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Assembling selector mechanism ⇒ page 70 .
, is n
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hole
Adjust selector mechanism ⇒ page 80 .
spec
es, in part or in w
t to the co
rrectness of i
– Connect battery earth ⇒ Electrical system; Rep. Gr. 27 ; Dis‐
connecting and reconnecting battery .
l purpos
nform
ercia
Slave cylinder to gearbox ⇒ Item 9 (page 45)

m
at
om
ion
Gearbox selector lever to selector shaft ⇒ Item 18 (page 71) .
c
in t
or
his
te
Selector cable support bracket to gearbox ⇒ Item 6 (page 70)

a
do
priv
cum
or
Gearbox support to gearbox bracket and gearbox:

f
en
ng
t.
yi Co
– Renew bolts. Cop py
ht. rig
rig ht
– Screw in all bolts hand-tight. py by
co Vo
by lksw
cted agen
– Tighten bolts to specified torque. Prote AG.
Bolts -arrows- 20 Nm + 90°
2.11 Bleeding clutch system

♦ Brake filling and bleeding equipment -VAS 5234- or

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

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Prefilling system is not necessary! rised ara
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Specifications for brake fluid ⇒ Brake
s systems; Rep. Gr. 47 ;
s c
ce
Bleeding brake system .
e
nl
pt
du
an
itte
– Remove complete air filter housing if it blocks access to bleed‐
y li
erm
ab
er connection (-arrow-, figure below) ⇒ Rep. Gr. 23 ; Repair‐
ility
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ing diesel direct injection system or ⇒ Rep. Gr. 24 ; Repairing
wit
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injection system
h re
hole
spec
– Connect brake filling and bleeding equipment -VAS 5234- or
es, in part or in w
-V.A.G 1869- .
t to the co
To bleed system, use 670 mm bleeder hose -V.A.G 1238/B3- if
necessary.
rrectness of i
– Connect bleeder hose to collector bottle of brake bleeding
equipment.
l purpos
– Connect bleeder hose to bleeder -arrow-.
nform
ercia
– Pressurise system to 2 bar.

m
at
om
– Open bleeder valve. ion

c
in t
or
– Bleed off about 100 cm3 brake fluid.

his
ate
do
riv
– Close bleeder valve.

p
cum
for
en
ng
– Rapidly operate pedal from stop to stop 10 to 15 times.

t.
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Cop py
t. rig
– Open bleeder valve. opyri
gh by
Vo
ht
by c lksw
– Bleed off an additional 50 cm3 brake fluid. Prote
cted AG.
agen
– Close bleeder valve.

– Depress clutch pedal several times after completion of bleed‐
ing process.

3 Repairing clutch release mechanism

1 - Gearbox
2 - Ball stud, 25 Nm
remove gearbox
❑ Remove old grease AG. Volkswagen AG d
agen oes
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from contact surface of by Vol
gu
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clutch release lever rise
d
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❑ Grease with clutch plate
s aut ra
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spline grease - s
ce
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G 000 100- .
nl
pt
du
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itte
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3 - Input shaft seal

erm
ab
ility

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remove gearbox
wit
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❑ Renewing
hole
spec
⇒ Item 12 (page 134)

es, in part or in w
t to the co
4 - Guide sleeve
remove gearbox
rrectness of i
❑ With vulcanised O-ring

l purpos
❑ If O-ring is damaged, re‐

new guide sleeve and
nf
ercia
O-ring together
orm
m
5 - Retaining spring
atio
om
n in

or c
thi
remove gearbox
te
sd
iva
❑ Secure to clutch release

o
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rp
cu
lever
o
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6 - Socket head bolt, 20 Nm Cop py
t. rig
gh ht
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7 - Clutch release lever p by
co Vo
by lksw
cted
agen
Prote AG.
remove gearbox
❑ Remove and install to‐
gether with release bearing ⇒ page 45 .
❑ Remove old grease
8 - Release bearing
❑ To remove and install, remove gearbox
❑ Do not wash out bearing; wipe only

n AG. Volkswagen AG do 6-speed manual gearbox 02S - Edition 07.2009
lk swage es n
Vo ot g
❑ Renew noisy ed bearings
by ua
ran
ris tee
❑ Removing
utho from and inserting in clutch release lever ⇒or page 45
a ac
❑ Lubricate contact surfaces of release lever with MoS grease.
ss
2
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nl
pt
du
9 - Flange bolt, 20 Nm
an
itte
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ab
10 - Slave cylinder
ility
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wit
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11 - Plunger
hole
spec
es, in part or in w
12 - Assembly bolt
t to the co
❑ Secures clutch release lever when gearbox is installed.
❑ Remove after gearbox has been installed.
rrectness of i
Note
l purpos
nform
ercia
Removing and installing release lever together with release bear‐

m
at
ing
om
ion
c
in t
r
– Unhook spring -arrow 1-.

o
his
ate
do
riv
– Pull off release lever -arrow 2- and release bearing.

p
cum
for
– Install in reverse order of removal. en

ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Removing and installing release bearing

– Press together locking lugs -arrows- on back of clutch release
lever and remove release bearing -A- from clutch release lev‐
er.
– To install, press release bearing -A- into clutch release lever
until locking lugs -arrows- engage.
3. Repairing clutch release mechanism 45

4 Repairing clutch, in conjunction with dual-mass flywheel
Special tools and workshop

equipment required
♦ Counterhold -3067-
♦ Centring mandrel -3190 A-
♦ Torque wrench -V.A.G
1331-
♦ Grease for clutch plate
splines -G 000 100-
AG. Volkswagen AG d
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4.1 Determining clutch manufacturer

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ility
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A clutch manufactured by either “Sachs” or “LuK” may be instal‐

wit
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led.
h re
ole,
spec
The make of the clutch can be determined as follows with the

clutch installed:
t to the co
– Remove noise insulation ⇒ General body repairs, exterior;

Rep. Gr. 50 ; Noise insulation .
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
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o
pr
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r
fo
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t.
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Cop py
t. rig
gh ht
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46
op Vo
by c lksw
Rep. Gr.30 - Clutch Prote
cted AG.
agen
Some notches -arrows- are located in lower region of sump be‐

tween engine -A- and gearbox -B-.
– Check outer contour of flywheel through these notches.
lkswage es n
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– In addition, a small cover d b plate -A- can be removed to enable ua
ran
ir se
inspection of flywheel's
tho outer contour. tee
or
au ac
Round outer contour -arrows- = Sachs clutch = -A-
ss
ce
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nl
pt
du
– Removing and installing Sachs clutch ⇒ page 48 .
an
itte
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erm
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ility
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wit
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hole
spec
es, in part or in w
t to the co
rrectness of i
– Repairing Sachs clutch ⇒ page 50 .

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

ferential crease -arrow 2- = LuK clutch = -B-
nform
ercia
or
m
at
om
ion
c
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or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
4. Repairing clutch, in conjunction with dual-mass flywheel 47

Rounded outer contour -arrows 1- and a circumferential crease

-arrow 2- = LuK clutch = -B-
– Removing and installing LuK clutch ⇒ page 50 .
– Repairing LuK clutch ⇒ page 53 .
4.2 Removing and installing Sachs clutch
4.2.1 Removing
– Remove gearbox ⇒ page 84 .
– Use counterhold -3067- to loosen bolts.
– Loosen bolts in small steps and diagonally.
• As bolts are removed, stop -2- with pin -1- must loosen.
– If stop does not loosen, press pin towards dual-mass flywheel.
– Remove pressure plate and clutch plate.
AG. Volkswagen AG d
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4.2.2 Installing
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wit
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ole,
spec
Note
t to the co
♦ Renew pressure plate and clutch plate together only. Select

clutch plate and pressure plate according to engine code and
rrectne
⇒ Electronic parts catalogue “ETKA” .

♦ Check whether dowel sleeves for aligning engine and gearbox
s
are fitted in cylinder block and install if necessary.

s o
cial p
f in
♦ If dowel sleeves are not fitted, difficulties shifting gears, clutch

form
mer
problems and possible noises from the gearbox (rattling of

atio
gears which are not engaged) could occur.

om
n
c
i
or
n thi
e
Installation position of clutch plate

t
sd
iva
o
pr
• Lettering “Getriebeseite” (gearbox side) faces gearbox.

um
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Checking ends of diaphragm spring

• Wear to half the thickness of the diaphragm spring -arrows- is
permitted.
Checking spring connections and riveted connections

– Check spring connections between pressure plate and cover
for cracks as well as rivet connections for secure seating.
Note
♦ Renew clutch plates and pressure plates with damaged or

loose rivet connections.
♦ Always renew pressure plate and clutch plate together.
♦ Select clutch plate and pressure plate according to engine
code and ⇒ Electronic parts catalogue “ETKA” .
♦ If clutch has burnt out, thoroughly clean clutch housing, fly‐lksw
wheel and parts of engine facing gearbox to reduce
agensmell of
AG. Vo agen AG
does
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burnt linings. by
Vol not
gu
d ara
ise nte
♦ Clean input shaft splines and, on used tho rclutch plates, clean hub eo
splines; remove corrosion and applys au only a very thin coat of ra
c
clutch plate spline grease -G 000 100- to splines. Then move
s
ce
e
nl
clutch plate to and fro on input shaft until hub moves freely on pt
du
shaft. Remove excessive grease. an

itte
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erm
ab
♦ Pressure plates are protected against corrosion and greased. ility
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Clean contact surface only. Otherwise, the service life of the

wit
, is n
clutch will be considerably reduced.

h re
hole
spec
♦ Pressure plate contact surface and clutch plate lining must

es, in part or in w
make full contact with flywheel. Only then insert securing bolts.
t to the co
– Reverse counterhold tool -3067- for installation.

rrectness of i
– Push pressure plate onto centralizing pins.

l purpos
– To centre clutch plate, use centring mandrel -3190 A- .

nform
ercia
– Tighten all bolts evenly by hand until bolt heads contact pres‐
sure plate.
m
at
om
ion
– Tighten bolts in small steps diagonally in order not to damage

c
in t
or
centring holes of pressure plate and centring pins of dual-

his
ate
mass flywheel.
do
priv
cum
or
– Install gearbox ⇒ page 92 .

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

4.3 Repairing Sachs clutch
1 - Dual-mass flywheel
⇒ Rep. Gr. 13
❑ Ensure that centring gen AG. Volkswagen AG d
pins fit tightly Volkswa oes
not
gu
by ara
❑ Contact surface
rised for nte
clutch lining
ut
ho must be eo
ra
free of
ss a
grooves, oil and c
grease
ce
le
un
pt
an
d
2 - Clutch plate
itte
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ab
pe
ility
parts catalogue “ETKA”
ot
wit
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h re
hole
⇒ page 48
spec
es, in part or in w
❑ Renew only together
t to the co
with pressure plate
❑ Installation position
⇒ page 48
rrectness of i
3 - Pressure plate
l purpos
parts catalogue “ETKA” nform
ercia
❑ With adjusting mecha‐

m
nism
com
tion in

r
te o
thi
⇒ page 48
s
iva
do
r
❑ Check ends of dia‐

rp
cum
fo
phragm spring
en
ng
t.
yi
⇒ page 49
Co
Cop py
t.
❑ Check spring connec‐
rig
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tions and riveted con‐ op Vo
by c lksw
nections ⇒ page 49 . cted agen
Prote AG.
with clutch plate.
4 - Bolt M6, 13 Nm, Bolt M7,
20 Nm
❑ Loosen or tighten diagonally in small steps
4.4 Removing and installing LuK clutch
4.4.1 Removing
– Remove gearbox ⇒ page 84 .
– Use counterhold -3067- to loosen bolts.
– Loosen bolts in small steps and diagonally.
– Remove pressure plate and clutch plate.
4.4.2 Installing

AG. Volkswagen AG d
agen oes
olksw not
Note d byV gu
ara
ise nte
or eo
th
♦ Renew pressure plate and clutch plate together
s au only. Select ra
c
clutch plate and pressure plate according to engine code and s
ce
le
⇒ Electronic parts catalogue “ETKA” .
un
pt
an
d
itte
y li
♦ Check whether dowel sleeves for aligning engine and gearbox
rm
ab
pe
ility
ot
wit
, is n
♦ If dowel sleeves are not fitted, difficulties shifting gears, clutch
h re
problems and possible noises from the gearbox (rattling of
hole
spec
gears which are not engaged) could occur. es, in part or in w
t to the co
Installation position of clutch plate
• Lettering “Getriebeseite” (gearbox side) faces gearbox.
rrectness of i
l purpos

• Wear to half the thickness of the diaphragm spring -arrows- is
nform
ercia
permitted.
m
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– Check spring connections -arrows A- for damage and riveted
connections -arrows B- for secure seating.

Checking position of adjusting mechanism with new pressure

plates only
• Both edges -A- of the adjuster ring must be located between
the two notches -arrows B-.
• If the adjuster ring takes up a different position in new pressure
plates, the pressure plate and clutch plate are Anot
G. Vallowed
olkswagento
AG do
be installed. agen es n
olksw ot
V y gu
db ara
• The adjuster ring may take up oarisposition
e outside the notches nte
in used clutches. au
th eo
ra
ss c
ce
le
un
pt
Note
an
d
itte
y li
rm
ab
pe
ility
♦ Renew clutch plates and pressure plates with damaged or
ot
loose rivet connections.
wit
, is n
h re
hole
♦ Renew pressure plate and clutch plate together only.
spec
es, in part or in w
♦ Select clutch plate and pressure plate according to engine
t to the co
code and ⇒ Electronic parts catalogue “ETKA” .
♦ If clutch has burnt out, thoroughly clean clutch housing, fly‐
rrectness of i
wheel and parts of engine facing gearbox to reduce smell of
burnt linings.
l purpos
♦ Clean input shaft splines and, on used clutch plates, clean hub
splines; remove corrosion and apply only a very thin coat of
nform
ercia
clutch plate spline grease -G 000 100- to splines. Then move

clutch plate to and fro on input shaft until hub moves freely on
m
a
com
ti
shaft. Remove excessive grease.
on in
r
te o
thi
♦ Pressure plates are protected against corrosion and greased.
s
iva
Clean contact surface only. Otherwise, the service life of the do

r
rp
c
clutch will be considerably reduced.
um
fo
en
ng
t.
yi
♦ Pressure plate contact surface and clutch plate lining must
Co
op py
make full contact with flywheel. Only then insert securing bolts.
. C rig
ht ht
rig by
copy Vo
by lksw
cted agen
Prote AG.
– Reverse counterhold tool -3067- for installation.
– Push pressure plate onto centralizing pins.
– To centre clutch plate, use centring mandrel -3190 A- .
– Tighten all bolts evenly by hand until bolt heads contact pres‐
sure plate.
– Tighten bolts in small steps diagonally in order not to damage
centring holes of pressure plate and centring pins of dual-
mass flywheel.
– Install gearbox ⇒ page 92 .

4.5 Repairing LuK clutch
1 - Dual-mass flywheel
⇒ Rep. Gr. 13
❑ Ensure that centring
pins fit tightly
❑ Contact surface for
clutch lining must be
free of grooves, oil and
grease
2 - Clutch plate
⇒ page 50
with SAC pressure
plate.
❑ Installation position:
⇒ page 51 .
3 - SAC pressure plate
❑ SAC means “self-ad‐
justing clutch”.
with clutch plate.
❑ Removing and installing AG. Volkswagen AG d
agen oes
ksw
⇒ page 50 by
Vol not
gu
ara
ed
❑ Check ends of dia‐ horis nte
eo
phragm spring aut ra
c
⇒ page 51 ss
ce
e
nl
❑ Checking spring con‐

pt
du
an
itte
nections and riveted

y li
erm
ab
connections ⇒ page 51
ility
ot p
❑ Checking position of adjusting mechanism with new pressure plates only ⇒ page 52
wit
, is n
h re
4 - Bolt M6, 13 Nm, Bolt M7, 20 Nm

hole
spec
❑ Loosen or tighten diagonally in small steps

es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

AG. Volkswagen AG d
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤lkswagen oes
not
o
6-speed manual gearbox 02S - Edition 07.2009 db
yV gu
ara
e nte
ris
tho eo
au ra
5 Repairing clutch, in conjunction with one-piece flywheel
s s c
ce
e
nl
pt
du
an
itte
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erm
ab
ility
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equipment required
wit
, is n
h re
♦ Counterhold -3067-
hole
spec
♦ Centring mandrel -3190 A-
es, in part or in w
t to the co
♦ Torque wrench -
V.A.G 1331-
rrectness of i
splines -G 000 100- l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
(Gearbox removed)
Note
♦ Renew clutch plates and pressure plates with damaged or loose rivets.
♦ Select clutch plate and pressure plate according to ⇒ Electronic parts catalogue “ETKA” and engine codes.
♦ Check whether dowel sleeves for aligning engine and gearbox are fitted in cylinder block and install if nec‐
essary.
♦ If dowel sleeves are not fitted, difficulties shifting gears, clutch problems and possible noises from the gear‐
box (rattling of gears which are not engaged) could occur.

1 - Flywheel
⇒ Rep. Gr. 13
❑ Ensure that centring
pins fit tightly
❑ Keep contact surface for
clutch lining free of
grooves, oil and grease.
2 - Clutch plate
spring cage faces pres‐
sure plate
❑ Centring ⇒ page 55
❑ Lightly grease splines
Note
3 - Pressure plate n AG. Volkswagen AG do

wage
❑ Removing and installing olks es n
ot g
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⇒ page 55 d b ua
ran
ir se tee
❑ Check ends of dia‐ autho
or
ac
phragm spring ss
⇒ page 56
ce
e
nl
pt
du
an
❑ Check spring connec‐
itte
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tions and riveted con‐
erm
ab
nections ⇒ page 56 .
ility
ot p
wit
, is n
h re
Note
hole
spec
es, in part or in w
t to the co
4 - Bolt M6, 13 Nm, Bolt M7,
20 Nm
❑ Allocate according to ⇒
rrectness of i
Electronic parts catalogue “ETKA” .
l purpos
❑ Loosen or tighten diagonally and in steps
nf
ercia
or
Centring clutch plate and removing and installing pressure plate
m
m
atio
m
– Loosen or tighten bolts diagonally in stages.

o
n in
or c
thi
e
– Reverse position of counterhold -3067- when removing.

t
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
Note Cop
yi Co
py
t. rig
gh ht
Pressure plate contact surface and clutch plate lining must make pyri by
Vo
co
full contact with flywheel. Tighten bolts diagonally and evenly to
by lksw
cted agen
Prote
prevent damage to the centring holes in the pressure plate hous‐
AG.
ing and the centring pins in the flywheel.
5. Repairing clutch, in conjunction with one-piece flywheel 55


• Wear up to half the thickness of the diaphragm spring is per‐
mitted.

– Check spring connections between pressure plate and cover
for cracks as well as rivet connections for secure seating.
• A pressure plate with damaged spring connections or with
loose rivet connections -arrows- must be renewed.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

34 – Controls, housing
1 Fault finding, power transmission
– Refer to ⇒ Fault finding, power transmission; Rep. Gr. 30 ;
Complaints about clutch and clutch mechanism and ⇒ Fault
finding, power transmission; Rep. Gr. 34 ; Complaints about
selector mechanism
AG. Volkswagen AG d
agen oes
olksw not
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ara
ed
ris nte
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aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
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Cop py
ht. rig
rig ht
by
57
copy Vo
by lksw
cted 1. Fault finding, power transmission
agen
Prote AG.
2 Repairing selector mechanism
2.1 Installation position of selector mechanism

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

B - Gate selector cable
C - Heat shield
❑ Remove before remov‐
ing gear selector mech‐
anism
1 - Gearbox selector lever
2 - Relay lever
AG. Volkswagen AG d
agen oes
olksw not
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d by ara
ise nte
or eo
h
aut ra
ss c
ce
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nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
58
cted agen
Prote
Rep. Gr.34 - Controls, housing
AG.
2.2 Overview of selector mechanism
Note
♦ Note radio code for vehicles with coded radio.

♦ Before working on selector mechanism in engine compartment, disconnect earth strap from battery ⇒ Elec‐
trical system; Rep. Gr. 27 ; Disconnecting and connecting battery .
AG. Volkswagen AG d
agen
♦ When reconnecting
Vol battery, perform work required
ksw
oes
not after connecting battery ⇒ Electrical system; Rep. Gr.
27 ; Disconnecting
se
db
y
and connecting battery .
g ua
ran
ori tee
♦ To workauon selector mechanism in engine compartment,or remove
th
ac complete air filter housing if it is located
over selector
ss mechanism ⇒ Rep. Gr. 23 ; Repairing diesel direct injection system or ⇒ Rep. Gr. 24 ;
ce
e
Repairing injection system .

nl
pt
du
an
itte
♦ Remove selector mechanism to renew selector cables ⇒ page 75 .
y li
erm
ab
ility
♦ Do not kink selector cables.
ot p
wit
, is n
h re
hole
spec
I - Removing and installing
es, in part or in w
t to the co
gear knob and frame
⇒ page 61
II - Repairing gear lever and
rrectness of i
selector housing (through
10.06) ⇒ page 63
l purpos
II - Repairing gear lever and

selector housing (from 11.06)
nform
ercia
⇒ page 65
m
at
om
III - Assembly overview - re‐

on
c
in t
moving and installing selector

or
his
e
cables ⇒ page 70
at
do
priv
cum
for
en
ng
t.
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Cop py
ht. rig
rig ht
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cted agen
Prote AG.
Removing and installing selector mechanism ⇒ page 75

Adjust selector mechanism ⇒ page 80 .
2. Repairing selector mechanism 59

♦ Hose clip pliers -V.A.G 1275-
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
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r
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cum
fo
en
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t.
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Cop py
ht. rig
rig ht
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by lksw
cted agen
Prote AG.
60 Rep. Gr.34 - Controls, housing

2.3 Removing and installing gear knob and frame
1 - Emblem
❑ Can be carefully levered
off gear knob of plastic
or leather
2 - Gear knob
❑ With gaiter
❑ Gear knob and gaiter
cannot be separated
from one another
❑ Always renew together
⇒ page 61 AG. Volkswagen AG d
agen oes
lksw not
3 - Clamp d by
Vo gu
ara
e nte
❑ For securing gear knob horis
eo
to gear lever aut ra
ss c
❑ Secure to gear knob
ce
le
un
pt
⇒ Item 2 (page 61) using
an
d
itte
hose clip pliers -V.A.G
y li
rm
ab
1275-
pe
ility
ot
❑ Always renew
wit
, is n
h re
4 - Frame for centre console
hole
spec
❑ In some equipment ver‐
es, in part or in w
t to the co
sions, forms one part to‐
gether with centre con‐
sole
rrectness of i
5 - Noise insulation
l purpos
❑ Not fitted in all vehicles

❑ Arrow on noise insula‐
nform
ercia
tion points in direction of

travel
m
a
com
❑ Locking lugs are ar‐ tion in

ranged at varying inter‐
r
te o
thi
vals
s
iva
do
r
rp
❑ Therefore it can be installed in only one position

um
fo
en
ng
t.
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Cop py
t. rig
gh
2.4 Removing and installing gaiter with gear
ht
pyri by
Vo
o
by c lksw
knob and noise insulation
cted agen
Prote AG.
– Pull or carefully prise gaiter with frame for centre console up‐
wards out of centre console -arrows-.
Note
With some equipment variations, the gaiter must be levered off

along the front section.

– Pull gaiter with frame for centre console upwards, inside out
over gear knob.
– Open clamp -arrow- and pull off gear knob together with gaiter.
In some versions, the centre console frame remains in the centre
console.
– If necessary pull off, or carefully lever off, centre console
frame.
– Pull off noise insulation -1-.
2.4.1 Installing
– First set noise insulation in place.
Installation position of noise insulation
• -Arrow A- points in direction of travel.
• Catches -arrows B- must engage in centre console. agen
AG. Volkswagen AG d
oes
olksw not
– If necessary, press frame into centre console. d by V gu
ara
rise nte
– Then turn gaiter inside out. utho eo
ra
s a c
s
The gear knob must be pressed to stop.
ce
e
nl
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itte
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erm
ab
ility
ot p
– Install gear knob with frame and gaiter and squeeze new
wit
, is n
h re
clamp -arrow- together.

hole
spec
– Then press gaiter with frame into centre console or gaiter into
es, in part or in w
frame.
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
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ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

2.5 Repairing gear lever and selector housing (through 10.06)
Note
Lubricate bearing points and sliding surfaces with grease -G 000 450 02- .
1 - Securing clip
⇒ page 64
AG. Volkswagen AG d
agen
2 - Bush Volksw
oes
not
by gu
d ara
3 - Compression spring orise nte
th eo
u ra
4 - Bush ss a c
ce
le
5 - Torx screw, 5 Nm
un
pt
an
d
itte
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6 - Cover
erm
ab
ility
ot p
7 - Damping
wit
is n
h re
8 - Damping
ole,
spec
9 - Ball socket
t to the co
10 - Gear lever guide
11 - Damping washer
rrectne
12 - Seal
s
❑ Between selector hous‐
s o
ing and underbody
cial p
f inform
❑ Self-adhesive
mer
atio
❑ Bond to selector hous‐
om
ing
n
c
i
or
n thi
e
13 - Gear lever
t
sd
iva
o
pr
cum
14 - Selector lever housing
r
fo
en
ng
t.
yi
15 - Bearing bush
Co
Cop py
t. rig
gh
16 - Pivot pin
ht
pyri by
Vo
co lksw
by
cted
17 - Guide bush
agen
Prote AG.
18 - Compression spring
❑ Installing ⇒ page 64
19 - Gate selector lever
20 - Torx screw, 5 Nm
21 - Seal
❑ Always renew
22 - Base plate
❑ Bend open tabs to remove
❑ Always renew
23 - Gate selector cable
❑ On gate selector lever
24 - Gear selector cable
❑ Removing from and attaching to gear lever guide ⇒ page 64

25 - Securing clip
❑ Always renew
26 - Hexagon nut
❑ M8: 25 Nm
❑ M6: 8 Nm
❑ Qty. 4
27 - Bearing bush
❑ Fits in one position only
28 - Securing clip
❑ Always renew
Removing and installing gate and gear selector cables

– Remove securing clip from gear selector cable -A- and gate
selector cable -B-.
To do this, raise tab using screwdriver -arrow 1- and press off
securing clip -arrow 2-.
– Remove gear selector cable -A- from gear lever retainer.
– Remove gate selector cable -B- from retainer of gate selector
lever.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
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e
nl
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itte
Removing and installing securing clip

y li
erm
ab
ility
– To remove or install securing clip -arrow A-, press spacer bush

ot p
wit
-arrow B- to stop in direction of arrow -arrow C- using screw‐

, is n
h re
driver and pull off securing clip.

hole
spec
es, in part or in w
t to the co
Note
♦ Do not cant spacer bush when pushing down.

rrectness of i
♦ Slot in gear lever for securing clip must be visible.

l purpos
♦ Carefully release tension from spring.

nf
ercia
orm
m
Installing compression spring

atio
om
n in
c
– Insert compression spring so that extension -A- lies on top of

or
thi
e
pin -arrow-.
t
sd
iva
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rp
cu
– Then pull extension -B- down so that it sits below pin -arrow-.
o
m
f
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ng
t.
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Cop py
t. rig
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co lksw
by
cted agen
Prote AG.

2.6 Repairing gear lever and selector housing (from 11.06)
Note
♦ Lubricate bearing points and sliding surfaces with grease -G 000 450 02- .
♦ Dismantling and assembling selector mechanism ⇒ page 66 .
1 - Base plate
❑ Bend open tabs to re‐
move
❑ Always renew
2 - Seal
❑ Always renew
3 - Selector lever
❑ Can be removed and in‐
stalled with gear lever
guide
installed
4 - Damping washer
❑ Push onto gear lever up
to stop -arrow-
5 - Securing clip
❑ Do not damage cables
when removing
❑ Always renew lkswage es n
o ot g
byV ua
d ran
6 - Gate selector cable o
ir se tee
th or
❑ Lever off gate selector ss
au ac
lever
ce
e
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pt
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❑ Press onto gate selector

an
itte
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lever inside selector
erm
ab
mechanism
ility
ot p
❑ Installation position wit

, is n
⇒ page 58 h re
hole
spec
7 - Bush
es, in part or in w
t to the co

❑ Lever off gear lever
guide
rrectness of i
❑ Press onto gear lever

l purpos
guide inside selector mechanism

❑ Installation position ⇒ page 58
nform
ercia
9 - Damping
m
at
om
io
10 - Ball socket
n
c
in t
or
❑ Will be damaged when removed

his
ate
do
riv
❑ Always renew
p
cum
for
en
g
11 - Bush
n
t.
yi Co
op py
12 - Securing clip
t. C rig
gh ht
yri by
❑ Removing and installing ⇒ page 64 cop Vo
by lksw
cted agen
Prote
13 - Compression spring
AG.

14 - Bush
15 - Gear lever guide
16 - Hexagon nut
❑ M8: 25 Nm
❑ M6: 8 Nm
❑ Qty. 4
17 - Seal
❑ Between selector housing and underbody
❑ Self-adhesive
❑ Bond to selector housing
❑ With compression spring and gate selector lever
❑ Compression spring and gate selector lever cannot be removed
2.6.1 Dismantling and assembling selector

mechanism
♦
thrust piece -T10083-
Dismantling
– Remove selector mechanism ⇒ page 75 .
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
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ab
pe
ility
ot
wit
, is n
– Bend open tabs -arrows- of base plate for selector mechanism

h re
using screwdriver and remove base plate; (tabs in front area
hole
of base plate are not illustrated). spec

es, in part or in w
t to the co
– Remove seal from selector housing.
– Remove gear and gate selector cables from selector housing
rrectness of i
⇒ page 78 .
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

AG. Volkswagen AG d
agen oes
lksw not
– Lift upper end -A- of compression spring over tab of gate se‐ byV
o gu
ara
lector lever. rised
nte
ho eo
ut
– Use screwdriver to press catches -arrows- of ball ssocket
s a to‐ ra
c
wards bearing ball of gear lever guide; break off catches if
ce
le
un
necessary.
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Lever ball socket -A- with gear lever guide -B- out of selector
rrectness of i
housing.
l purpos
– Then press ball socket off bearing ball of gear lever guide and
remove it.
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
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cum
fo
en
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t.
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Cop py
ht. rig
rig ht
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• Please pay attention to guides -A- during the further proce‐ co Vo
by lksw
dure. cted agen
Prote AG.
• They must not be broken off.
– Lever lower end -arrow 1- of compression spring onto shoulder

on gate selector lever as far as stop.
– Now pull gear lever guide up to stop and pull ball stud out of
gate selector lever -arrow 2-.
– Then turn gear lever guide in -direction of arrow 1-.

• Pin -arrow 2- must be in notch in selector housing.
– Then swing out gear lever guide with gear lever in
-direction of arrow 3-.
Assembling
Caution
The lower end of the compression spring (-arrow 1- ⇒ figure

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

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

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

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

• Pin -arrow 1- is still located inagnotch inolselector
en AG. V
kswagen Ahousing.
G do
e w s no
olks t
– Turn gear lever guide ed
bin
y V-direction of arrow 2- until ball stud
gu
ara
-A- is located in notch
horis in selector housing. nte
e t or
au ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
– Place selector housing with gear lever guide into larger recess t to the co
-arrow- in thrust piece -T10083- .
rrectness of i
Note
l purpos
To ensure that the selector housing with gear lever guide can be
inserted in the thrust piece , first remove gear lever, if necessary.
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
• The gear lever guide must project from the selector housing
t.
yi Co
up to the stop. ht. Cop py
rig
rig ht
py by
co Vo
by lksw
Note
cted agen
Prote AG.
For clarity of illustration, only part of the gate selector lever is

shown.
– Insert end -A- of compression spring into guide from above.

– Pull end -B- of compression spring downwards and insert it
next to guide (in direction of ball joint).
• Please pay attention to guides (⇒ figure above) during the fur‐
ther procedure.
• They must not be broken off.
– Carefully remove selector housing with gear lever guide from
thrust piece -T10083- .

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

holes for gear and gate selector cable) -arrow 1-.
– Grease ball stud.
– Press ball stud into gate selector lever -arrow 2-.
• Guides -A- and tabs -B- are not allowed to be damaged.
– Place selector housing with gear lever guide into larger recess
-arrow- in thrust piece -T10083- .
AG. Volkswagen AG d
agen oes
lksw not
• The gear lever guide must project from the selector by housing
Vo gu
ara
up to the stop. orised
nte
h eo
ut ra
– Lift upper end -A- of compression springssover pin of gate se‐
a c
lector lever
ce
e
nl
pt
du
an
• Use a new ball socket -B-.
itte
y li
erm
ab
– Grease ball socket and bearing ball of gear lever guide.
ility
ot p
wit
, is n
– Press ball socket onto bearing ball of gear lever guide up to
h re
stop.
hole
spec
es, in part or in w
– Remove selector housing from thrust piece -T10083- .
t to the co
– Insert lower end -C- of compression spring into guide.
– Lift upper end -A- of compression spring over pin of gate se‐ rrectness of i
lector lever into guide.
l purpos
– Press ball socket into selector housing -arrows-.

• All locking lugs must clip in.
nform
ercia
– Attach gear lever, gear selector cable, gate selector cable and
m
at
om
base plate ⇒ page 65 .

ion
c
in t
or
– Install selector mechanism ⇒ page 75 .

his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

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

❑ Connect to cable end-
piece
⇒ page 58
❑ Use cable tie to fix onto
gate selector cable
⇒ page 73
⇒ page 78
❑ From 11.06, modified
attachment to gear lever
inside selector mecha‐
nism agen
AG. Volkswagen AG d
oes
⇒ Item 8 (page 65) olksw not
byV gu
ara
ed
2 - Gate selector cable horis nte
eo
ut ra
❑ Connect to cable end- ss a c
piece
ce
le
un
pt
an
d
itte
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rm
ab
⇒ page 58
pe
ility
ot
wit
❑ Use cable tie to fix onto
, is n
h re
gear selector cable
hole
spec
⇒ page 73
es, in part or in w
t to the co
⇒ page 78
❑ From 11.06, modified
rrectness of i
attachment to gate se‐
lector lever inside selec‐
l purpos
tor mechanism
nform
ercia
3 - Securing clip
m
❑ Always renew
a
com
tion in
❑ Discontinued in selector
r
te o
thi
mechanisms from 11.06 ⇒ page 65

s
iva
do
r

rp
cum
fo
en
ng
5 - Securing clip
t.
yi Co
Cop py
❑ Always renew ht. rig
rig ht
py by
❑ Do not damage cables when removing
co Vo
by lksw
cted agen
Prote AG.
❑ Qty. 3
❑ For cable support bracket
7 - Cable support bracket
❑ May be made from plastic or metal
8 - Grommet
❑ Cable support bracket mounting on gearbox

9 - Spacer
AG . Volkswage
10 - Cable end-piece ksw
agen
n AG d
oes
not
Vol
❑ For gate selector cable to relay lever ed by gu
ara
ris nte
❑ After installing, adjust selector mechanism
ut
ho ⇒ page 80 eo
ra
a
❑ Do not interchange; cable end-pieces
ss for gate selector cable to relay lever and gearc selector cable to
ce
e
gearbox selector lever are different
nl
pt
du
an
❑ For metal relay lever, secured with securing clip ⇒ Item 12 (page 71)
itte
y li
erm
ab
❑ From 05.07, fitted in conjunction with plastic relay lever ⇒ page 73
ility
❑ Removing from plastic relay lever ⇒ page 73 ot p
wit
, is n
h re
❑ Pressing onto plastic relay lever ⇒ page 73
hole
spec
❑ Allocation ⇒ page 72
es, in part or in w
t to the co
11 - Cable end-piece
❑ For gear selector cable to gearbox selector lever
rrectness of i
❑ After installing, adjust selector mechanism ⇒ page 80
l purpos
❑ Do not interchange; cable end-pieces for gate selector cable to relay lever and gear selector cable to
gearbox selector lever are different
nf
ercia
orm
12 - Securing clip
m
atio
om
❑ Always renew
n in
or c
thi
❑ Not required for plastic relay lever
te
sd
iva
o
r
rp
cu
13 - Securing clip
o
m
f
en
ng
❑ Always renew
t.
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op py
❑ Not required for plastic relay lever t. C rig
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14 - Bearing bush
o Vo
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cted agen
Prote
AG.
15 - Relay lever
❑ May be made from plastic or metal
❑ Metal relay lever is mounted in bearing bush ⇒ Item 14 (page 71) and secured with securing clip
❑ From 05.07, plastic relay lever
❑ Remove and install plastic relay lever together with cable end-piece ⇒ page 73
❑ Bearing bushes and securing clip not required for plastic relay lever
16 - Shoe
❑ With damper weight
❑ Install so that master spline aligns with selector shaft
❑ From 06.06, smaller diameter of support pin for cable end-piece ⇒ page 72
❑ Self-locking
❑ Always renew

Allocation of cable end-pieces

The holes in the cable end-pieces have different diameters.
Cable end-piece for Dimension “a”
1 - Gear selector cable to gearbox selector lever 8.5 mm
from 06.06
2 - Gear selector cable to gearbox selector lever 10 mm
through 05.06
2. - Gate selector cable to metal relay lever 8 mm
2. - Gate selector cable to plastic relay lever 10 mm
⇒ page 73
From 06.06, smaller diameter of support pin for gear selector ca‐
ble end-piece
Support pin for gear selector cable end-piece Dimension “a”
Through 05.06 olkswage 10 mm
es n
ot g
yV u
From 06.06 ir se
d b 8.5 mm aran
o tee
h
aut or
ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
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Installation position of gearbox selector lever and relay lever

hole
spec
1 - Gearbox selector lever with damper weight

es, in part or in w
t to the co
2 - Relay lever engages in guide rail of gearbox selector lever via

shoe -arrow-.
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
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co lksw
by
cted agen
Prote AG.

Fitting position of cable tie for cables

– Wind cable tie -arrow- around the selector cables in a figure
eight and secure them as shown in figure.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
2.8 Plastic relay lever
nl
pt
du
an
itte
y li
From 05.07, relay lever is made from plastic. 2 versions may be erm
ab
ility
installed.
ot p
wit
, is n
♦ Relay lever with catch or
h re
hole
spec
♦ Relay lever with clip
es, in part or in w
t to the co
Comply with the following during removal and installation work:
• To remove relay lever, first separate cable end-piece from
rrectness of i
gate selector cable.
l purpos
This will avoid damage to the gate selector cable

– Pull locking mechanism forward to stop in
nform
ercia
-direction of arrow 1- and then lock by turning to left in

m
at
om
io
– Then push relay lever forwards (-in direction of arrow 3-).
n
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.
Relay lever with catch -arrow 1-

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

Relay lever with clip -arrow 1-

– Pull clip -arrow 1- off and remove relay lever together with ca‐
ble end-piece.
• Cable end-piece must be located behind catch -arrow 2-.
• The cable end-piece can be removed only with the relay lever
removed ⇒ page 75 .
Note
To fit, lubricate bearing points and sliding surfaces awith

gen Agrease
G. Volksw-agen AG d
oes
G 000 450 02- . yV
olksw not
gu b ara
ed nte
oris e
– Press cable end-piece onto relayalever
ut
h ⇒ page 75 . or
ac
ss
– Install relay lever together with cable end-piece to stop.
ce
le
un
pt
an
d
itte
y li
rm
ab
Relay lever with catch -arrow 1-
pe
ility
ot
wit
, is n
• Catch -arrow 1- secures relay lever.
h re
hole
spec
• Ensure proper engagement.
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
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cum
fo
en
ng
t.
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Cop py
t. rig
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Relay lever with clip -arrow 1- op Vo
by c lksw
cted agen
Prote
• Clip -arrow 1- secures relay lever.
AG.
• Ensure proper engagement of clip.


Levering gate selector cable end-piece off plastic relay lever

• Relay lever has been removed.
– Insert a flat-blade screwdriver -A- between bush -B- and relay
lever.
Pressing on cable end-piece
AG. Volkswagen AG d
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• Relay lever has been removed. by Vol not
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• Cable end-piece may be pressed only onto bush -arrow-.
thor eo
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• Cable end-piece must move freely on relay lever. ss
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un
pt
• It must be located behind catch -arrow 2-.
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2.9 Removing and installing selector mech‐

n in
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2.9.1 Removing Cop py
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Special tools and workshop equipment required cop Vo
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♦ Torque wrench -V.A.G d1331-by
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s au ra
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t to the co
rrectne
♦ Grease -G 000 450 02-
ss
theft code.
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cial p
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form
mer
Electrical system; Rep. Gr. 27 ; Removing and installing bat‐
atio
m
tery .
o
n
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or
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– Remove gaiter with selector knob and noise insulation
thi
te
sd
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⇒ page 61 .
iv
o
pr
cum
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fo
– Remove centre console and securing bracket for centre con‐

en
ng
t.
sole ⇒ General body repairs, interior; Rep. Gr. 68 ; Compart‐
yi Co
op
ments, covers and trims .
C py
t. rig
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– Remove selector housing nuts -arrows-. cop Vo
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cted agen
Prote AG.
– Remove complete air filter housing if it is over selector mech‐
anism ⇒ Rep. Gr. 23 ; Repairing diesel direct injection system
or ⇒ Rep. Gr. 24 ; Repairing injection system .
– Remove securing clip -3- for gear selector cable from gearbox
selector lever -1-.
– Pull gear selector cable off pin.
Metal relay lever
– Remove securing clip -4- for gate selector cable from relay
lever -2-.
– Pull gate selector cable from pin.
Plastic relay lever

AG. Volkswagen AG d
agen Golf
oes Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
olksw not
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ed
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Releasing
ss a cable end-piece from gate selector cable c
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– Pull locking mechanism forward to stop in
un
pt
an
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-direction of arrow 1- and then lock by turning to left in

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– Then push relay lever forwards (-in direction of arrow 3-).
wit
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Continued for all selector mechanisms
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
– Remove cable support bracket from gearbox -arrows-; if nec‐

essary, unclip pipe/hose -A- from bracket -B- first.
nform
ercia

m
a
com
tion in
– Remove tunnel cross member ⇒ Rep. Gr. 26 ; Removing and
r
te o
thi
installing parts of exhaust system .
s
iva
do
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rp
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– Separate front exhaust system at double clamp and detach
um
fo
en
from subframe ⇒ Rep. Gr. 26 ; Removing and installing parts
ng
t.
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of exhaust system . ht. Cop py
rig
rig ht
– Remove rear exhaust system and heat shield ⇒ Rep. Gr. 26 ;
py by
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Removing and installing parts of exhaust system .
by lksw
cted agen
Prote AG.
– Remove underbody panels ⇒ General body repairs, exterior;
Rep. Gr. 50 .
– Swing selector housing down and remove with selector ca‐
bles.
2.9.2 Installing
– Align selector housing parallel to body.
• Distance to body must be same on both sides.
– Secure selector housing ⇒ Item 26 (page 64) or
⇒ Item 16 (page 66) .
– Route cables -1- from selector mechanism -2- to gearbox as
follows:
♦ After cables cross over -arrow-, they must be routed parallel
to one another as far as cable support bracket on gearbox.
♦ Make sure that cable tie -arrow- for securing cables is installed
correctly. Installation position ⇒ page 73 .
♦ Cables must be laid in the intended indentation in heat shield
-3-.
Note
In the close-up, the heat shield is shown from above.

Clip -A- holds cables and heat shield together in position.

– Install cable support bracket on gearbox and tighten bolts to
specified torques ⇒ Item 6 (page 70) .
The holes in the cable end-pieces have different diameters.
Allocation of cable end-pieces ⇒ page 72
AG. Volkswagen AG d
agen oes
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y V gu
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– Spread a small quantity of greaseth-Go 000 450 02- on pins
r eo
-arrows- of gearbox selector lever
s a -1- and relay lever -2-.
u ra
c
s
ce
e
– Renew securing clips -3- and -4- each time they are removed.
nl
pt
du
an
itte
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– Secure gear selector cable with securing clip -3- and gate se‐
erm
ab
lector cable with securing clip -4-.
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Cable end-piece to plastic relay lever
, is n
h re
hole
– Fit relay lever and cable end-piece together ⇒ page 73 .
spec
es, in part or in w
– Insert gate selector cable in cable end-piece.
t to the co
Continued for all selector mechanisms
rrectness of i
– Install centre console ⇒ General body repairs, interior; Rep.
Gr. 68 ; Compartments, covers and trims .
l purpos
– Install gaiter with selector knob and noise insulation

⇒ page 61 .
nform
ercia
– Install heat shield.

m
at
om
io
– If removed, reinstall underbody panels ⇒ General body re‐
n
c
in t
r
pairs, exterior; Rep. Gr. 50 .

o
his
ate
do
riv
– Assemble exhaust system free of tension and attach tunnel

p
cum
or
cross member ⇒ Rep. Gr. 26 ; Removing and installing parts

f
en
ng
of exhaust system .
t.
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Cop py
t. rig
Adjust selector mechanism ⇒ page 80 . opyri
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Vo
ht
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– If removed, install complete air filter housing ⇒ Rep. Gr. 23 ;
by lksw
cted agen
Prote
Repairing diesel direct injection system or ⇒ Rep. Gr. 24 ;
AG.
Repairing injection system

– Follow procedure after connecting battery ⇒ Electrical system;
Rep. Gr. 27 ; Battery; Disconnecting and connecting battery .
2.10 Removing and installing gear selector

cable and gate selector cable
2.10.1 Removing
– Remove selector mechanism ⇒ page 75 .

AG. Volkswagen AG d
lksw6-speed
agen manual gearbox
oes 02S - Edition 07.2009
n
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– Bend open tabs -arrows- of selector mechanism
ho
ris cover using tee
a screwdriver and remove cover. aut or
ac
ss
– Remove gasket.
ce
le
un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
– Pull off securing clips -2 and 3-. (Securing clips -1 and 4- have
l purpos
been discontinued.) Lever gear selector cable off gear lever

and gate selector cable off gate selector lever using a screw‐
driver.
nform
ercia
– Pull gear selector cable and gate selector cable from selector
m
a
housing.
com
tion in
r
te o
thi
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Cop py
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Release locks -A- for gear and gate selector cables -B- as follows:
cted agen
Prote AG.
♦ Push sliding sleeve forward to stop -arrow 1-.

♦ Turn sliding sleeve to right to stop -arrow 2- until it engages.
– Remove locking mechanism from Bowden cables.
– Pull off securing clips -1- and -2-.

– Remove cable support bracket from Bowden cables.
2.10.2 Installing

– Secure gear selector cable and gate selector cable to selector

housing using securing clips -2 and 3-.
– Press gear selector cable onto gear lever and gate selector
cable onto gate selector lever in selector housing. (Securing
clips -1 and 4- have been discontinued.)
– Fit seal and secure selector mechanism cover by pressing

down tabs -arrows-.
– Install selector mechanism ⇒ page 77 .
– Adjust selector mechanism ⇒ page 80 .
AG. Volkswagen AG d
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2.11 Adjusting selector mechanism

itte
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♦ Locking pin -T10027 A-

h re
hole
spec
es, in part or in w
t to the co
rrectness of i
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Note
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♦ The following points are essential to ensure correct adjust‐ t. C rig
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ment of selector mechanism: pyri by
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♦ Moving parts of selector mechanism and elements transferring
agen
Prote AG.
force must be in proper condition.
♦ Selector mechanism must move freely.
♦ Gearbox, clutch and clutch mechanism must also be in proper
condition.
• Gearbox must be in neutral.

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

gear selector cable and gate selector cable are not accessible
⇒ Rep. Gr. 23 ; Repairing diesel direct injection system or ⇒
Rep. Gr. 24 ; Repairing injection system .
lkswage es n
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– Pull locking mechanisms on gate selector cable and gear se‐
ss
ce
le
lector cable end-pieces forward to stop -direction of arrow 1-

un
pt
and then turn to left to lock -direction of arrow 2-.
an
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itte
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pe
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ot
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, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
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Secure selector shaft as follows:
nform
ercia
– Press selector shaft down -direction of arrow 1-.

m
a
– While pressing down selector shaft, turn angled rod -A- in
com
tio
-direction of arrow 2- upwards and at the same time press it in
n in
r
te o
until it engages in selector shaft.

thi
s
iva
do
– Remove gaiter with selector knob and frame ⇒ page 61 .

r
rp
cum
fo
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– If noise insulation is present, remove it.

n
t.
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Cop py
Now secure gear lever as follows:
t. rig
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pyri by
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– Select neutral using gear lever.
c by lksw
cted agen
Prote AG.
– Guide locking pin -T10027 A- through hole -A- into hole -B-.

– Check that gate and selector cables -B- are inserted, free of
tension, into locking devices -A-.
– Now turn locking mechanisms on gear selector cable and gate
selector cable end pieces clockwise to stop
The spring presses the locking mechanism into original position
– Now turn angled rod -A- back to original position

-direction of arrow-.
AG. Volkswagen AG d
agen oes
olksw not
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rise nte
tho eo
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The angled rod -A- must be pressed out of selector housing to
wit
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stop and point to rear.
h re
ole,
spec
t to the co
rrectness o
cial p
– Pull locking pin out of holes -A- and -B-.

inform
mer
– If noise insulation was present, install it.

atio
om
– Install gaiter with selector knob and frame ⇒ page 61 .

n
c
i
or
n thi
e
– Check that selector shaft moves freely.

t
sd
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pr
cum
– If removed, reinstall complete air filter housing ⇒ Rep. Gr.

r
fo
en
ng
23 ; Repairing diesel direct injection system or ⇒ Rep. Gr.

t.
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op
24 ; Repairing injection system C py
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2.11.1 Functional check

• With gearbox in neutral, gear lever must rest in gate for 3rd
and 4th gear.
– Operate clutch.
– Select all gears several times. Pay particular attention to op‐
eration of reverse gear lock.

swage es n
– If it continues to be difficult by V to engage a gear after repeated
o lk ot g
ua
attempts, repeat adjustment
ir se
d procedure of selector mechanismrante
⇒ page 80 . tho eo
au ra
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ss
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itte
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ility
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wit
, is n
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spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
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at
om
ion
c
in t
or
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ate
do
priv
cum
for
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t.
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Cop py
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pyri by
Vo
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by
cted agen
Prote AG.

3 Removing and installing gearbox

equipment required
♦ Vehicles with turbo diesel
engines and vehicles with
2.0l - 110 kW petrol engines
♦ Hook - 10 - 222 A /2-
♦ Adapter -10 - 222 A /3-
♦ Adapter -10 - 222 A /16-
♦ Hook -10 - 222 A /10-
♦ All vehicles
♦ Support bracket -10 - 222
A-
♦ Adapter -10 - 222 A /8-
♦ Pin -3282/29-
♦ Gearbox support -3282-
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
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ce
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nl
pt
du
an
itte
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erm
ab
ility
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wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
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ate
do
priv
cum
for
en
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t.
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Cop py
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pyri by
Vo
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by
cted agen
Prote AG.

♦ Adjustment plate -3282/39-

♦ Engine and gearbox jack -
V.A.G 1383A-
1331-
1332-
♦ Gearbox mounting support
-3336-
♦ Grease -G 000 450 02-
splines -G 000 100-
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
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or eo
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aut ra
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un
pt
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t to the co
3.1 Removing gearbox

rrectne

theft code.
s

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cial p

f in
battery .
form
mer
atio
– Remove engine cover if engine lifting eye arrow -10 - 222 A-

om
is not accessible.
c
i
or
n thi
e

t
sd
iva

pr
cum
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fo

en
ng
t.
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op
C py
t. rig
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pyri by
Vo
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by c lksw
– Remove securing clip -arrow 1- for gear selector cable from
Prote
cted AG.
agen
3. Removing and installing gearbox 85

– Pull gear selector cable from pin.

Metal relay lever
– Remove securing clip -arrow 2- for gate selector cable from
relay lever -B-.
– Pull gate selector cable from pin.
– Pull securing clip -arrow 3- off relay lever -B- and remove relay
lever.
Plastic relay lever
– Remove relay lever together with cable end-piece
⇒ page 73 .
– Remove gearbox selector lever -A- by removing nut
-arrow 4- (⇒ previous figure).
– Remove cable support bracket from gearbox -arrows-.

– Then raise and secure gear selector cable and gate selector
cable.
– Remove retainer -B- from gearbox and pull it off pipe/hose line
-A-.
lkswage es n
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– Then remove gearbox support -arrow A-.
s
ce
le
un
pt
– Remove slave cylinder -arrow B-, lay to side and secure with
an
d
itte
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wire. Do not disconnect pipes.

erm
ab
ility
ot p
wit
Caution
is n
h re
ole,
spec
Do not operate clutch pedal any more.

t to the co
– Remove earth strap at upper engine/gearbox connecting bolt.

rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
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t.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.

– Pull connector -arrow 1- off reversing light switch -F4- .

– Now remove connector -arrow 2- and wire -arrow 3- from
starter.
– Then remove upper securing bolt on starter.
– Remove upper engine/gearbox connecting bolts.
– If there are hose and cable connections in area of engine sup‐
port eye for support bracket -10 - 222 A- , remove these now.
Vehicles with 1.4 l petrol engine
– Set up support bracket -10 - 222 A- together with adapters -10

- 222 A /8- in front of gas struts for bonnet.
Vehicles with turbo diesel enginesagand vehicles
en AG. Volkswagwith
en AG2.0
doels- 110 kW
petrol engines yV
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th or
au ac
ss
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un
pt
an
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ab
pe
ility
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wit
, is n
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hole
spec
– Set up support bracket -10 - 222 A- together with adapters -10
es, in part or in w
- 222 A /8- , adapter -10 - 222 A /3- and adapter -10 - 222 A /
t to the co
16- in front of gas struts for bonnet.
– Attach hook -10 - 222 A /10- at front right of engine. rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
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fo
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t.
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Cop py
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pyri by
Vo
co lksw
by
cted agen
Prote AG.

– Now attach hook -10 - 222 A /2- at rear left of engine -arrow-.
– Then connect hook -10 - 222 A /2- using adapter -10 - 222 A /
16- .
Continuation for all vehicles . Volkswagen AG
gen AG does
swa
– Position adapter -10 - 222 A /8- directly over wing bolting y Volk not
gu
points. risedb ara
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tho eo
– Take up weight of engine/gearbox assembly ons auspindles. ra
c
s
ce
e
– Raise vehicle.
nl
pt
du
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itte
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erm
ab
ility
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wit
– Remove lower part of front left wheel housing liner ⇒ General
, is n
h re
body repairs, exterior; Rep. Gr. 66 ; Wheel housing liner .
hole
spec
– Then remove all lines from gearbox.
es, in part or in w
t to the co
– Remove drive shaft heat shield from engine -arrows-, if fitted.
rrectness of i
Vehicles with 1.4 l petrol engine
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
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cu
o
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f
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ng
t.
yi Co
op py
– Separate exhaust system -arrows 1-, remove front exhaust t. C rig
gh ht
pipe and unscrew front exhaust pipe bracket from subframe pyri by
Vo
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by c
-arrows 2- ⇒ Rep. Gr. 26 ; Parts of exhaust system .
lksw
cted agen
Prote AG.
Vehicles with turbo diesel engines and vehicles with 2.0 l - 110 kW
petrol engines
– Separate exhaust system at double clamp and remove ex‐

haust pipe bracket from subframe ⇒ Rep. Gr. 26 ; Removing
and installing parts of exhaust system .
Continuation for all vehicles
– Disconnect drive shafts from flange shafts and tie up as high
as possible, being careful not to damage surface protection.

– Remove pendulum support.

First remove bolt -arrow A- and then bolts -B- and -C-.
– Remove hexagon bolts -arrows- for left assembly mounting

from gearbox mounting.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
– Tilt engine/gearbox assembly by lowering
rised it via spindles of nte
support bracket -10 - 222 A- . ut
ho eo
ra
s a c
s
ce
e
nl
pt
du
Note
an
itte
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erm
ab
♦ Lower threaded spindle, shown here with adapter -10 - 222 A /
ility
ot p
16- , using winged nut, but not more than until spindle is flush
wit
, is n
with nut -arrow-.
h re
hole
spec
♦ Be careful of all lines when lowering gearbox.
es, in part or in w
t to the co
• Securing bolts -arrows- for gearbox bracket -A- must be ac‐
cessible.
rrectness of i
– Remove gearbox bracket -A- -arrows-.

l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

– If small cover plate -A- for flywheel behind the right flange shaft
-arrows- is installed, remove it.
lkswage es n
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d ran
ir se tee
tho
u or
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ss
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
– Remove exhaust system strut -1-, if present, from gearbox
wit
, is n
-arrow-.
h re
hole
spec
– Remove starter ⇒ Electrical system; Rep. Gr. 27 ; Starter .
es, in part or in w
t to the co
To remove gearbox “02S”, set up gearbox support -3282- with
adjustment plate -3282/39- .
rrectness of i
– Insert gearbox support -3282- in engine and gearbox jack -
V.A.G 1383A- .
l purpos
– Align arms of gearbox support according to holes in adjust‐

ment plate .
nf
ercia
orm
m
atio
om
n in
c
– Screw in support elements -A - and -C- on adjustment plate

or
thi
e
as shown.
t
sd
iva
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cu
– Position engine and gearbox jack under vehicle. Arrow -B- on
o
m
f
en
ng
adjustment plate points in direction of vehicle travel.

t.
yi Co
Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Align adjustment plate parallel to gearbox and lock safety sup‐

port on gearbox.
– Then screw pin -3282/39- into hole on gearbox for securing
bolt of pendulum support.
– Remove lower engine/gearbox connecting bolts.

– Press gearbox off dowel sleeves and carefully swing towards

subframe.
– Turn gearbox downwards in vicinity of differential.
– Have a second mechanic push engine forwards slightly.
– Carefully lower gearbox, guiding with right flanged shaft -A-

past intermediate plate of flywheel as shown.
– When lowering gearbox, change position of gearbox using
spindles of gearbox support -3282- . . Volkswagen AG
gen AG d wa oes
olks not
byV gu
ara
Note ed nte
ris
tho eo
au ra
c
Be careful of all lines when lowering ss
gearbox.
ce
le
un
pt
an
d
itte
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erm
ab
ility
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wit
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3.1.1 Transporting gearbox
h re
ole,
spec
t to the co
♦ Gearbox mounting support -3336-
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
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pr
cum
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fo
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Procedure t. C rig
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pyri by
– Bolt gearbox lifting tackle -3336- to clutch housing.
co Vo
by lksw
cted agen
Prote AG.

– Adjust support beam on sliding piece using locking pin

-arrow-.
Number of holes visible = 5.
– Lift gearbox using workshop crane and gearbox lifting tackle
-3336- .
– Set gearbox aside, for example in a transport container.
3.2 Installing gearbox

AG. Volkswagen AG d
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Refer to procedure
thor “Removing and installing gearbox” fortere‐
eo
quired special
ss a tools ⇒ page 84 .
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nl
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du
Observe the following table on the subject of “checking and top‐ an

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ping up gear oil”.
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“Checking and topping up gear oil”

wit
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“No” “Yes” “Yes”

hole
spec
Gearbox Original X
es, in part or in w
part
t to the co
No oil loss X
Completely X
rrectness of i
dismantled Before in‐

l purpos
stallation
⇒ Item 3
(page 134)
nf
ercia
Oil capacity
orm
⇒ page 1
m
atio
om
Partially X
n in
or c
dismantled After instal‐

thi
te
• (Gear‐ lation
sd
iva
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box ⇒
rp
cu
o
housing page 99
f
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ng
t.
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and
Co
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housing
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were not
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ted.)
– All threaded holes into which self-locking bolts are to be

screwed must be cleaned of residual locking fluid carefully with
a thread chaser.
– Always renew self-locking bolts and nuts.
– Check whether dowel sleeves for aligning engine and gearbox
If dowel sleeves are not fitted, difficulties shifting gears, clutch
problems and possible noises from the gearbox (rattling of gears
which are not engaged) could occur.
– Ensure that intermediate plate is correctly seated on engine.
– Clean input shaft splines and apply thin coat of grease for
clutch plate splines -G 000 100- .

The clutch plate must slide easily to and fro on the input shaft.
To install gearbox “02S”, set up gearbox support -3282- with ad‐
justment plate -3282/39- .
– Align arms of gearbox support according to holes in adjust‐
ment plate .
– Screw in support elements -A - and -C- ( pin -3282/29- ) on
adjustment plate as shown.
– Place gearbox on gearbox jack .
– Align adjustment plate and gearbox parallel to one another.
– Screw pin -3282/29- into hole on gearbox for securing bolt of

pendulum support.
– Position gearbox jack under vehicle. Arrow -B- on adjustment
plate points in direction of vehicle travel.
– Using spindles of gearbox support -3282- , tilt gearbox down‐
wards in vicinity of differential. G. Volkswagen nA AG do
wage e
– Have a second mechanicy Vpush
olks engine forwards slightly.
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th or
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ss
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un
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– Then carefully raise gearbox, guiding with right flange shaft

erm
ab
ility
-A- past flywheel and intermediate plate as shown.

ot p
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– Using spindles of gearbox support -3282- , tilt gearbox up‐

h re
ole,
wards in vicinity of differential.

spec
– Raise gearbox to engine.

t to the co
• The engine must still be pushed forwards (2nd mechanic).

rrectne
– Align gearbox to engine and join.

– Screw in lower engine/gearbox securing bolts and tighten to
s
specified torque ⇒ page 96 .

s o
cial p
f in
– After gearbox has been bolted to engine, remove gearbox jack

form
mer
from gearbox.
atio
om
n
c
– If small cover plate -A- had been installed behind the right
i
or
n thi
e
flange shaft -arrows-, install it.

t
sd
iva
o
pr
– Screw in upper engine/gearbox securing bolts and tighten to

um
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fo
specified torque ⇒ page 96 .

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ng
t.
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Cop py
t. rig
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pyri by
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by c lksw
cted agen
Prote AG.

– Install bracket -A- on gearbox using new hexagonal bolts

-arrows- and tighten to specified torque ⇒ page 96 .
– Align engine and gearbox in installation position using both

spindles of support bracket -10-222A- .
– Install new bolts -arrows- for left assembly mounting in gear‐
box mounting and tighten to aspecified
gen AG
. Volktorque
swagen⇒
AGpage
do 96 .
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olks ot g
byV ua
ed ran
WARNING ris tee
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au ac
ss
Do not remove support bar -10-222 A- until all bolts securing
ce
le
the left and right assembly mountings have been tightened to

un
pt
an
d
specified torque.
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pe
ility
ot
wit
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hole
Note
spec
es, in part or in w
t to the co
Install engine and gearbox mounting free of tension ⇒ Rep. Gr.

10 ; Removing and installing engine .
rrectness of i
– Install slave cylinder and tighten bolts -arrows B- to specified

l purpos
torque ⇒ Item 9 (page 45) .

– Then install gearbox support with new bolts -arrow A- and
nform
ercia
tighten to specified torque ⇒ page 96 .

m
a
com
– Attach drive shafts to gearbox ⇒ Running gear, axles, steer‐

ion in
ing; Rep. Gr. 40 ; Repairing drive shaft; Removing and instal‐

r
te o
thi
ling drive shafts .

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iva
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rp
cum
fo
en
ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
– Install drive shaft heat shield, if present, on engine -arrows- ⇒
Prote AG.
Running gear, axles, steering; Rep. Gr. 40 ; Repairing drive

shaft .

– Install pendulum support with new bolts -arrows A-, -B- and
-C- ⇒ Running gear, axles, steering ; Rep. Gr. 40 ; Repairing
front suspension .
– Assemble exhaust system and attach exhaust system bracket
to subframe ⇒ Rep. Gr. 26 ; Removing and installing parts of
exhaust system .
AG. Volkswagen AG d
agen oes
olksw not
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d by ara
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nl
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an
itte
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erm
– Bolt exhaust system strut -1-, if present, to gearbox and tighten
ab
ility
bolt -arrow- to specified torque ⇒ Rep. Gr. 26 ; Removing and
ot p
wit
installing parts of exhaust system .
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
– Push connector -1- onto reversing light switch -F4- .
at
om
ion
c
– Install starter, push on connector -arrow 2- and bolt on wire

in t
or
his
e
-arrow 3- ⇒ Electrical system; Rep. Gr. 27 ; Starter .

at
do
priv
– Install earth strap at upper engine/gearbox connecting bolt.

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for
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t.
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Prote AG.
– Attach support -B- to gearbox.

– Press pipe/hose line -A- into retainer -B- on gearbox.
– Install cable support bracket on gearbox and tighten bolts
-arrows- to specified torque ⇒ Item 6 (page 70) .

– Install gearbox selector lever -A-.

– Tighten hexagon nut -arrow 4- to specified torque
⇒ Item 18 (page 71) .
– Spread a small amount of grease -G 000 450 02- on pin of
– Connect gear selector cable to gearbox selector lever
-arrow 1-.
Metal relay lever
– Install relay lever -B- and secure with securing clip -arrow 3-.
– Spread a small amount of grease -G 000 450 02- on pin of
relay lever -B-.
– Connect gate selector cable to relay lever -arrow 2-.
Plastic relay lever
– Install relay lever together with cable end-piece ⇒ page 73 .
– Adjust selector mechanism ⇒ page 80 .
– Install battery tray and battery⇒ Electrical system; Rep. Gr.
– If removed, reinstall engine cover and complete air filter hous‐
ing ⇒ Rep. Gr. 23 ; Repairing diesel direct injection engine or
⇒ Rep. Gr. 24 ; Repairing injection system
– Reconnect battery and perform work required after connecting
battery ⇒ Electrical system; Rep. Gr. 27 ; Disconnecting and
connecting battery . n AG. Volkswagen AG do
lkswage es n
– Install lower part of front left wheel housing liner ⇒ General byV
o ot g
ua
body repairs, exterior; Rep. Gr. 66 ; Wheel housing ir seliner .
d ran
tee
tho
u or
– Install noise insulation ⇒ General body repairs, ss
a exterior; Rep. ac
Gr. 50 ; Noise insulation .
ce
le
un
pt
an
d
itte
3.2.1 Specified torques y li

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Gearbox to 1.4 l petrol engine wit

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h re
hole
Item Bolt Quantity Nm

spec
es, in part or in w
1 M12 x 50 3 80
t to the co
2 M12 x 55 1 80
♦ With M8 stud
rrectness of i
♦ Additionally, start‐
er to gearbox
l purpos
3 M12 x 150 1 80
nform
ercia
♦ With M8 stud
m
com
tion in
er to gearbox
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4 M12 x 60 2 80
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5 M10 x 50 2 40
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op
Item -A- dowel sleeves for centring C py
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Prote AG.

Gearbox to 2.0 l/100 kW petrol engine

AG. Volkswagen AG d
agen oes
Item Bolt y Volksw Quantity Nm
not
g
b ua
ed ran
1 M12oris x 65 2 80 tee
th or
2 ss
M12
x 150
au 1 80 ac
ce
le
un
er to gearbox
pt
an
d
itte
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erm
ab
3 M12 x 165 1 80
ility
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er to gearbox
h re
ole,
spec
4 M10 x 50 3 40
t to the co
5 M12 x 85 1 80
6 M6 x 8 1 10
♦ Small cover plate
rrectne
for flywheel
ss
Item -A- dowel sleeves for centring
o
cial p
f inform
mer
Gearbox to turbo diesel engine
atio
om
Item Bolt Quantity Nm
n
c
i
or
n thi
e
1 M12 x 55 2 80
t
sd
iva
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2 M12 x 150 2 80
p
cum
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fo
♦ Additionally, start‐ en
ng
t.
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er to gearbox
Co
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3 M10 x 50 3 40
p by
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4 M12 x 60 1 80
agen
Prote AG.
5 M6 x 8 1 10
♦ Small cover plate
for flywheel
Item -A- dowel sleeves for centring
Gearbox bracket to gearbox

– Renew bolts.
– Screw in all bolts hand-tight.
– Tighten bolts to specified torque.

Gearbox mounting to body

– Renew bolts.
Gearbox support to gearbox bracket and gearbox

– Renew bolts.
Drive shaft to flange shaft ⇒ Running gear, axles, steering; Rep.
Gr. 40 ; Repairing drive shaft; Removing and installing drive
shafts .
AG. Volkswagen AG d
agen oes
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an
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erm
ab
ility
ot p
wit
, is n
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spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
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Cop py
t. rig
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pyri by
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by c lksw
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Prote AG.

4 Checking and topping up gear oil

It is not possible to check the gear oil level by unscrewing the oil
filler plug.
The angle of the engine/gearbox unit means the lower edge of

the fill hole -arrow 1- is below the oil level -arrow 2-.
The oil level in the gearbox can only be checked by completely
draining the gear oil and then refilling:

olks
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yV ua
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rise tee
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ility
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spec
es, in part or in w
t to the co
♦ Hose (approx. 600 mm long, external diameter 10 mm) with

rrectness of i
funnel, commercially available

l purpos
4.1 Preparation
Gear oil for manual gearboxes ⇒ Electronic parts catalogue “ET‐
nform
ercia
KA” .
m
at
om
– Remove complete air filter housing ⇒ Rep. Gr. 23 ; Repairing

on
c
in t
diesel direct injection system or ⇒ Rep. Gr. 24 ; Repairing

or
his
e
injection system .
at
do
priv

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for
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Prote AG.
4. Checking and topping up gear oil 99

Clean gearbox.
Caution
To drain gear oil, a pivot pin for the selector forks in the gearbox
must be removed.
To prevent the positions of the selector forks from being
changed, e.g. due to accidental operation of the selector mech‐
anism, the selector shaft must be locked in position.
Secure selector shaft as follows:

agen
AG. Volkswagen AG d
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– Press selectorthoshaft down -direction of arrow 1-. tee
or
au ac
– ss
While pressing down selector shaft, turn angled rod -A- in
ce
e
-direction of arrow 2- upwards and at the same time press it in

nl
pt
du
an
until it engages in selector shaft.
itte
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
4.2 Draining gear oil
l purpos
Use a clean container with a scale and a 3-litre capacity to catch

the oil which runs out.
nf
ercia
or
• Selector shaft is locked in place ⇒ page 100 .

m
m
atio
m
– Drain gear oil by removing oil drain plug -arrow 1- and then
o
n in
or c
pivot pin -arrow 2-.

thi
te
sd
iva
– Install pivot pin -arrow 2- with a new O-ring

o
r
rp
cu
⇒ Item 5 (page 107) .

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m
f
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ng
t.
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– Screw in oil drain plug -arrow 1- ⇒ Item 17 (page 135) . t. Cop py
rig
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pyri by
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by c lksw
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Prote AG.
– Now turn angled rod -A- back to original position

-direction of arrow- so that selector shaft can move again.

4.3 Filling with gear oil

Top up oil in container to 1.9 litres.
Gearbox oil specification ⇒ Electronic parts catalogue “ETKA” .
– Remove reversing light switch -F4- -arrow-.
– Connect hose (approx. 600 mm long, external diameter
10 mm) to commercially available funnel.
– Insert hose in fitting hole for reversing light switch -F4- (2nd
mechanic) and fill gear oil.
– Install reversing light switch -F4- -arrow-
⇒ Item 2 (page 143) .
– Check operation of selector mechanism ⇒ page 82 .
– Install complete air filter housing ⇒ Rep. Gr. 23 ; .Repairing
Volkswagen AG
diesel direct injection system or ⇒ Rep. kGr. gen AG
l swa 24 ; Repairing does
not
injection system by Vo gu
a d ran
ise
– Install noise insulation ⇒ General
ut
ho body repairs, exterior; Rep.
r tee
or
Gr. 50 ; Noise insulation . ss a ac
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
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om
n in
or c
thi
te
sd
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Cop py
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Prote AG.
4. Checking and topping up gear oil 101

5 Dismantling and assembling gearbox
5.1 Overview - gearbox
1 - 1st gear
2 - 2nd gear
3 - 3rd gear
4 - 4th gear
5 - 5th gear
AG. Volkswagen AG d
6 - 6th gear ksw
agen oes
not
Vol
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7 - Gearbox housing cover ised ara
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8 - Gearbox housing s aut ra
c
s
9 - Selector mechanism
ce
le
un
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an
d
❑ (Selector forks)
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ab
10 - Reverse gear wheel
ility
ot p
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11 - Clutch housing
h re
ole,
spec
12 - Input shaft
t to the co
13 - Output shaft
14 - Differential
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
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Cop py
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by c lksw
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Prote AG.

5.2 Assembly overview

Assembly sequence - Removing and installing cover for gearbox
housing and 5th and 6th gear ⇒ page 109 .
Assembly sequence - Dismantling and assembling gearbox com‐
pletely ⇒ page 115 .
I - Removing and installing

cover for gearbox housing and
5th and 6th gears
⇒ page 104
AG. Volkswagen AG d
agen oes
II - Removing and installing olksw not
y V gu
gearbox housing and shift ise
d b ara
nte
mechanism ⇒ page 107 . uthor eo
a ra
s c
III - Removing and installing in‐ s
ce
le
put shaft, output shaft, differ‐

un
pt
an
d
ential and selector forks

itte
y li
⇒ page 108
erm
ab
ility
ot p
wit
is n
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ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
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or
n thi
te
sd
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Cop py
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Prote AG.
5. Dismantling and assembling gearbox 103

5.3 Removing and installing cover for gearbox housing and 5th and 6th gear
1 - Gearbox housing
❑ Pull off together with 5th
and 6th gears
⇒ page 115 .
❑ Repairing ⇒ page 132 . n AG. Volkswagen AG do
lkswage es n
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2 - Gear wheel for 5th gear sed b ua
ran
ir tee
❑ Pull off individually autho
or
ac
⇒ page 109 ss
ce
le
❑ Pull off together with

un
pt
an
d
gearbox housing
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⇒ page 115
erm
ab
ility
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3 - Sleeve
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4 - Gear wheel for 6th gear
ole,
spec
❑ Pull off individually
t to the co
⇒ page 109
❑ Pull off together with
gearbox housing
rrectne
⇒ page 115
5 - Cylindrical roller bearing in‐
ss
ner race
o
cial p
f in
❑ For output shaft
form
mer
❑ Mark before removing
atio
m
❑ Do not interchange with

o
n
c
i
or
n
inner race for cylindrical
thi
te
roller bearing of input

sd
iva
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shaft
p
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fo
en
ng
❑ Larger outer diameter yi

t.
Co
from gearbox date . Cop py
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6 - Bolt
❑ Allocation of bolts
⇒ page 106
❑ To gearbox date 20 08 6: 40 Nm and 180° further
❑ From gearbox date 21 08 6: 80 Nm and then turn 90° further
❑ Self-locking
❑ Always renew
❑ Clean residual locking fluid from threaded holes for securing bolts for synchro-hub for 5th and 6th gears
and gear wheel for 6th gear with a thread chaser. Otherwise the bolts may shear.
7 - Gearbox housing cover
❑ With cylindrical roller bearings for input and output shafts
❑ Cylindrical roller bearings for input and output shafts from gearbox date 21 08 6 with larger outer diameter
⇒ page 140
❑ Repairing ⇒ page 138 .
8 - Bolt, 18 Nm
❑ Qty. 5
❑ For gearbox housing cover.
9 - Bolt
❑ For input shaft

❑ Allocation of bolts ⇒ page 106
❑ To gearbox date 20 08 6: 40 Nm and 180° further
❑ From gearbox date 21 08 6: 80 Nm and then turn 90° further
❑ Self-locking
❑ Always renew
❑ Clean residual locking fluid from threaded holes for
wage
securing
n AG. Volkswagbolts
en AG for synchro-hub for 5th and 6th gears
doe
and gear wheel for 6th gear with a thread
yV
ochaser. Otherwise the boltss nmay
lks ot g shear.
u b ara
ed
10 - Cylindrical roller bearing inner race horis nte
eo
ut ra
❑ For input shaft ss a c
ce
le
un
pt
an
d
❑ Do not interchange with cylinder roller bearing inner race of output shaft.
itte
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rm
ab
❑ From gearbox date 21 08 6, combined with thrust washer in one component ⇒ Item 12 (page 105)
pe
ility
ot
❑ Allocation of inner race for cylindrical roller bearing ⇒ page 106
wit
, is n
h re
hole
11 - Thrust washer
spec
es, in part or in w
❑ Through gearbox date 20 08 6
t to the co
12 - Inner race for cylindrical roller bearing with thrust washer
❑ For input shaft
rrectness of i
❑ From gearbox date 21 08 6
l purpos
❑ Allocation of inner race for cylindrical roller bearing ⇒ page 106

13 - Sleeve
nform
ercia
❑ For 6th gear needle bearing.

m
a
❑ Renew together with needle bearing
com
tion in
❑ Larger diameter from gearbox date 21 08 6
r
te o
thi
s
iva
❑ Allocate components according to ⇒ Electronic parts catalogue “ETKA” .
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14 - Needle bearing
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❑ For 6th gear . Cop py
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❑ Renew together with sleeve rig ht
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❑ Larger diameter from gearbox date 21 08 6
by lksw
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Prote AG.
15 - Synchromeshed gear for 6th gear
❑ Adapted to sleeve and needle bearing from gearbox date 21 08 6
16 - Wave spring washer
❑ Allocate according to ⇒ Electronic parts catalogue “ETKA”
17 - Synchro-ring for 6th gear
18 - Locking collar with synchro-hub for 5th and 6th gears
❑ Pull off individually ⇒ page 109
❑ Pull off together with gearbox housing ⇒ page 115
❑ Dismantling and assembling ⇒ page 157 and ⇒ page 157
❑ From gearbox date 12 06 6, locking collar modified ⇒ page 157
❑ Adjusting, through gearbox date 11 06 6 ⇒ page 130
❑ Adjusting, from gearbox date 12 06 6 ⇒ page 131
❑ Installation of springs with angled ends for locking pieces ⇒ page 158
❑ Will be damaged during removal of input shaft
❑ Always renew


22 - Needle bearing
❑ For 5th gear
23 - Socket head bolt, 25 Nm
❑ For pivot pin to gearbox housing
24 - Pivot pin
25 - Selector fork for 5th and 6th gears
26 - Selector jaw for 5th and 6th gears
27 - Bolt, 25 Nm
Allocation of securing bolts and cylindrical roller bearing inner

races for input shaft
Gearbox manufac‐ Dim. “a” mm Dim. “b” mm
ture date
Through 20 08 6 21 31
From 21 08 6 23.4 37
• Additionally: in‐
ner race and
thrust washer
combined in one
component
-arrow-
lkswage es n
o ot g
Allocation of securing bolts and cylindrical roller bearing inner d by V ua
ran
races for output shaft o
ir se tee
th or
au ac
Gearbox manufac‐ Dim. “a” mm Dim. “b” smm
s
ce
ture date
le
un
pt
an
d
itte
Through 20 08 6 21 31
y li
rm
From 21 08 6 23.4 37 ab
pe
ility
ot
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es, in part or in w
t to the co
rrectness of i
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Prote AG.

AG. Volkswagen AG d
agen oes
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Golf Variant
ut
h 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005e o➤
o
ra
a
ss 6-speed manual gearbox 02S - Edition 07.2009c
ce
le
un
pt
5.4 Removing and installing gearbox housing and shift mechanism
an
d
itte
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erm
ab
ility
ot p
wit
1 - Countersunk bolt, 25 Nm
is n
h re
ole,
2 - Flange shaft with compres‐
spec
sion spring
t to the co
⇒ page 184
❑ Assembling
rrectne
⇒ page 193
s
3 - Torx socket head bolt, 25
s o
Nm
cial p
f inform
❑ For reverse shaft sup‐
port mer
atio
om
❑ Self-locking
n
c
i
or
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❑ Always renew
te
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❑ For reverse shaft sup‐ C py
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❑ Self-locking
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Prote AG.
❑ Always renew
5 - O-ring
❑ Always renew
6 - Pivot pin
7 - Bolt, 25 Nm
8 - Bolt, 25 Nm
9 - Cover plate
10 - Multi-point socket head
bolt 25 Nm
❑ For reverse shaft sup‐
port
❑ Always renew
11 - Gearbox housing
❑ Pull off together with 5th and 6th gears ⇒ page 115 .
12 - Clutch housing
13 - Hexagon bolt, 25 Nm and turn 90° further
❑ Always renew
14 - Selector shaft with selector shaft cover
(Selector unit)
15 - Multi-point socket head bolt 25 Nm

5.5 Removing and installing oinput agenshaft, output dshaft,

not differential and selector
AG. gen AG Volkswa
oes
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forks y V gu
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1 - Differential
ce
le
un
pt
❑ Dismantling and assem‐
an
d
itte
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bling ⇒ page 193 rm
ab
pe
ility
2 - Seal
ot
wit
, is n
❑ Qty. 4
h re
hole
❑ Always renew
spec
es, in part or in w
t to the co
3 - Output shaft
bling ⇒ page 163
rrectness of i
4 - Reverse shaft support
l purpos

bling ⇒ page 181
nform
ercia
5 - Reverse shaft
m
a
com
tion in
bling ⇒ page 181
r
te o
thi
6 - Input shaft
s
iva
do
r
rp
c
um
fo
en
g
bling ⇒ page 150

n
t.
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op py
7 - Selector fork for reverse
t. C rig
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bling ⇒ page 145
⇒ page 123
Nm
9 - Selector mechanism
❑ (Selector forks)
bling ⇒ page 145
10 - Clutch housing
11 - Hexagon nut, 25 Nm and then turn 90° further
❑ 4 nuts for bearing support
❑ Always renew
12 - Flange shaft with compression spring
❑ Assembling ⇒ page 193

5.6 Assembly sequence - Removing and in‐

stalling cover for gearbox housing and
5th and 6th gear
Note
♦ Follow the working procedure

swa
gedescribed
n AG. Volkswbelow
agen AG
ifdoonly
es the 5th
and 6th gears have to
by
be
Vol removed:
k not
gu
d ara
e
♦ If the gearbox housing
thoris has to be removed, follow the workingnte
eo
procedure: Dismantling
au and assembling gearbox completely r ac
ss
⇒ page 115 .
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
equipment required
wit
, is n
h re
♦ Support plate -VW 309-
hole
spec
es, in part or in w
♦ Gearbox support -VW 353-
t to the co
♦ Drift -VW 295-
♦ Drift sleeve -VW 244 B-
rrectness of i
♦ Hot air blower -V.A.G 1416-
l purpos

1331-
nf
ercia
orm
♦ -Zweiarmabzieher Kukko
m
atio
m
210.1-
o
n in
or c
♦ -Stehbolzen M 8 x 100 mm-

thi
te
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rp
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by
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Prote AG.

♦ Support bridge -30-211A-

♦ Thrust piece -32 - 111-
♦ Thrust piece from assembly
tool -T10030/4-
♦ Tube -VW 416 B-
♦ Puller -T10309-
♦ Two arm puller -T10040- or
two arm puller -Kukko
20/10-
♦ With puller hooks -
T10040/2A-
♦ Thrust piece -T10040/3-
AG. Volkswagen AG d
agen oes
olksw not
byV gu
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nl
pt
du
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
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Prote AG.

♦ Support device -T10323-

♦ Assembly tool -3253/7-
♦ Thrust piece -VW 433-
♦ Thrust plate -40 - 105-
1332-
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ab
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es, in part or in w
t to the co
5.6.1 Removing cover for gearbox housing

rrectness of i
and 5th and 6th gears

l purpos
– Remove clutch release lever and release bearing ⇒ page 44 .

nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
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t.
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Cop py
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by
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Prote AG.

• Bearings of input shaft and output shaft must not be damaged

when 5th and 6th gears are removed and installed.
• Therefore, following tools must be mounted for support at this
stage during attachment of gearbox to gearbox support -VW
AG. Volkswagen AG d
353- : ksw
agen oes
n
Vol ot g
Underneath input shaft: d by ua
ran
e
ris tee
tho
♦ Support bridge -30-211A- s au or
ac
s
ce
e
nl
pt
du
an
itte
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erm
ab
ility
• The input shaft can be supported by the thrust piece -32 - 111-
ot p
wit
only at a later point.
, is n
h re
hole
Underneath bearing support for output shaft:
spec
es, in part or in w
t to the co
rrectness of i
l purpos
– Secure gearbox on gearbox support -VW 353- .
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Remove gearbox housing cover -arrow-.

– Remove cover, if necessary carefully levering up all around
along protruding housing flange and alternating between
sides, being careful not to damage sealing surfaces.

– Check whether puller hooks -T10040/2A- can be inserted cor‐

rectly under 5th gear wheel.
Puller hooks -T10040/2A- cannot be inserted correctly.
-A- Removal of “synchro-hub
Puller hooks -T10040/2A- make 5th/6th gear”, “6th gear
contact too soon with: wheel”, “ 5th gear wheel”
♦ gearbox housing wall and “gearbox housing” to‐
gether ⇒ page 115
♦ ribs in gearbox housing under
5th gear wheel
-B-
Puller hooks -T10040/2A- come
into contact with ribs in gearbox
housing below gear wheel.
Puller hooks -T10040/2A- cannot be inserted correctly.

5th/6th gear can be removed individually ⇒ page 113
Remove 5th and 6th gears individually

– Remove selector fork for 5th and 6th gears as follows:
– Cover openings with a cloth.
– Engage 5th gear -arrows 1- and -2-.
– Remove selector jaw for 5th and 6th gears -bolt A-.
– Then remove both bolts -B- for pivot pins.
– Pull out pivot pins.
AG. Volkswagen AG d
agen oes
– Remove selector fork for 5thy Vand
olks 6th gears.
w not
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b ara
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th
au ra
c
ss
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le
un
pt
an
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itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
– Remove -bolts A- for inner bearing races from input and output
spec
shafts, engaging 5th gear -arrow 1- and 1st gear -arrow 2- and
t to the co
-arrow 3-.
– Input shaft and output shaft are locked when both gears are
engaged. Both bolts can now be loosened.
rrectness
Note
o
cial p
f inform
If the shafts are to be reused, clean residual locking material out

mer
of threaded holes using a thread chaser.

atio
om
n
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or
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Prote AG.

– Pull off gear wheel for 6th gear with inner race of cylindrical
roller bearing for output shaft.
A - Two arm puller , e.g. -Kukko 20/10-
gen AG
. Volkswagen AG
d wa oes
olks not
B - Hexagon bolt, M10 xd20,
by 17 mm AF
V gu
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ris
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Note ss
ce
e
nl
pt
du
an
6th gear wheel with cylindrical roller bearing inner race can also
itte
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erm
be pulled off using two arm puller -T10040- and puller hooks -
ab
ility
T10040/2A- .
ot p
wit
, is n
h re
– Heat gear wheel slightly with hot air blower -V.A.G 1416- if
hole
spec
necessary.
es, in part or in w
t to the co
Pull off synchromeshed gear for 6th gear together with cylinder
roller bearing inner race for input shaft, thrust washer and syn‐
chro-ring for 6th gear only or together with synchro-hub for 5th
rrectness of i
and 6th gears, needle bearing inner race for 6th gear and syn‐
chro-ring for 5th gear.
l purpos
nform
ercia
Note
m
at
om
From gearbox date 26 05 8, a wave spring washer is installed
ion
c
below the synchro-ring for 5th gear and above the synchro-ring
in t
or
for 6th gear ⇒ Item 20 (page 105) and ⇒ Item 16 (page 105) . his
ate
do
priv
cum
or
Use puller -T10309- .

f
en
ng
t.
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Cop py
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– First set half sleeve -T10309/1- between output shaft -A- and
rig
gh ht
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support for selector fork for 5th and 6th gear -B-. cop Vo
by lksw
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Prote
• The half sleeve -T10309/1- must be positioned beneath the
AG.
synchro-ring.
– Turn half sleeve -T10309/1- to opposite side

– Set threaded insert -T10309/3- in half shell .

– Now fit second half shell -T10309/1- and set tube -T10309/2-
over assembly.
– After parts are pulled off, check synchro-hub for damage.
– Renew synchro-ring for 5th gear.
– Now remove sleeve from gear wheel for 5th gear.
lkswage es n
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byV ua
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un
pt
an
d
itte
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erm
ab
ility
ot p
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is n
– Pull off gear wheel for 5th gear.
h re
ole,
spec
– First set up puller hooks -A-.
t to the co
-B- = Thrust piece -T10040/3-
or
rrectne
Thrust plate -40 - 105-
ss o
Note
cial p
f inform
mer
♦ When pulling off gear wheel, ensure that hooks do not bend
atio
m
outwards. After pulling off 5th gear wheel, examine for dam‐
o
n
c
age.
i
or
n thi
te
sd
a
♦ Heat gear wheel slightly with hot air blower -V.A.G 1416- if
iv
o
pr
necessary.
um
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fo
en
ng
t.
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Cop py
t. rig
5.6.2 Installing cover for gearbox housing and
gh ht
pyri by
Vo
co
5th and 6th gears
by lksw
cted agen
Prote AG.
Installing 5th/6th gears ⇒ page 123 .

– Apply sealant -AMV 188 200 03- evenly to sealing surface of
gearbox housing cover.
– Install cover for gearbox housing and tighten bolts to specified
torques ⇒ page 104 .
– Fit clutch release lever and release bearing ⇒ page 44 .
– Fill with gear oil ⇒ page 92 .
5.7 Assembly sequence - Dismantling and

assembling gearbox completely
Removing and installing gearbox housing cover, clutch housing,
selector shaft with selector mechanism cover, input shaft, output
shaft, differential and selector mechanism.


equipment required
♦ Support plate -VW 309-
♦ Gearbox support -VW 353-
♦ Drift -VW 295-
♦ Drift sleeve -VW 244 B-
♦ Hot air blower -V.A.G 1416-
1331-
♦ -Stehbolzen M 8 x 100 mm-
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un
pt
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itte
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ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
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Cop py
t. rig
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co lksw
by
cted agen
Prote AG.


♦ Thrust piece from assembly
tool -T10030/4-
♦ Tube -VW 416 B-
♦ Puller plate -T10408-
♦ Thrust pieces -T10408/2-
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
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aut ra
ss c
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un
pt
an
d
itte
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rm
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pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.


1332-
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
♦ Mounting -2 Kukko 18/1- (Qty. 2)

an
d
itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
♦ Hexagon bolts M7 x 35 with washers

mer
atio
5.7.1 Dismantling gearbox

om
n
c
i
or
n thi
– Remove clutch release lever, release bearing and guide

te
sd
va
sleeve ⇒ page 44 .
i
o
pr
cum
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fo
en
ng
t.
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Cop py
t. rig
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by c lksw
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Prote AG.

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
e nte
horis Golf Variant 2007 ➤ , Golf Variant 2010
e o ➤ , Jetta 2005 ➤
ut
ss a 6-speed manual gearbox 02S ra
c- Edition 07.2009
ce
e
nl
pt
• Bearings of input shaft and output shaft must not be damaged
du
an
itte
when 5th and 6th gears are removed and installed.
y li
erm
ab
ility
• Therefore, following tools must be mounted for support at this
ot p
wit
stage during attachment of gearbox to gearbox support -VW
, is n
h re
353- :
hole
spec
Underneath input shaft:
es, in part or in w
t to the co
rrectness of i
l purpos
– Lock bolt of support bridge -30-211A- with nut -A-.
nform
ercia
Underneath bearing support for output shaft:

m
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
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– Secure gearbox on gearbox support -VW 353- .
Co
Cop py
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– Place drip tray underneath.
ht
pyri by
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by c lksw
– Remove oil filler plug and oil drain plug.
cted agen
Prote AG.
– Drain gear oil.
– Remove gearbox housing cover -arrow-.

– Remove cover, if necessary carefully levering up all around
along protruding housing flange and alternating between
sides, being careful not to damage sealing surfaces.

– Remove selector fork for 5th and 6th gears as follows:

– Cover openings with a cloth.
– Engage 5th gear -arrows 1- and -2-.
– Remove selector jaw for 5th and 6th gears -bolt A-.
– Then remove both bolts -B- for pivot pins.
– Pull out pivot pins.
– Remove selector fork for 5th and 6th gears.
– Unscrew -bolts A- for inner bearing races from input and output
shafts, engage 5th gear -arrow 1- and 1st gear -arrow 2- and
-arrow 3- for this. olks
wage es n
o V t gu
by
– Input shaft and output shaft
ris are locked when both gears are
ed
ara
nte
engaged. Both bolts canut now be loosened.
ho eo
ra
a c
ss ce
e
nl
pt
du
Note
an
itte
y li
erm
ab
If the shafts are to be reused, clean residual locking material out

ility
ot p
of threaded holes using a thread chaser.

wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
– Remove both bolts -arrows- for reverse shaft support bracket.

m
at
om
ion
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or
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ate
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for
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Prote AG.

– Now remove 3rd bolt -arrow- for reverse shaft support bracket.
– Remove selector shaft with selector mechanism cover, placing

selector shaft in neutral position. Then remove bolts -arrows-
and pull selector shaft out of gearbox housing.
– Remove cover plate -A- and pivot pins -B- from underside of
gearbox.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
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au ra
ss c
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un
pt
an
d
itte
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erm
ab
ility
ot p
– Remove pivot pins -A- on top side of gearbox and securing

wit
is n
bolts -B- for gearbox housing to clutch housing in area of dif‐

h re
ole,
ferential.
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
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fo
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pyri by
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co lksw
by
cted agen
Prote AG.

– Remove bolts -A- from clutch housing side for securing clutch
housing to gearbox housing.
Note
Do not remove nuts -B- for output shaft bearing support.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
o
– Remove both flange aut shafts.
h eo
ra
ss c
– Remove flange shafts together with springs, thrust washers
ce
le
un
pt
and tapered rings.
an
d
itte
y li
Pull off following components together with gearbox housing:
erm
ab
ility
ot p
♦ Synchro-hub for 5th/6th gears
wit
is n
h re
♦ Gear wheel for 6th gear
ole,
spec
t to the co
rrectne
Use puller plate -T10408- in conjunction with following special
ss
tools:
o
cial p
f in
♦ Thrust pieces -T10408/2-
form
mer
♦ Puller Kukko 18/1 (Qty. 2)

atio
om
n
c
– Screw puller plate -T10408- firmly into threaded holes for

i
or
n thi
e

t
sd
iva
o
pr
A - Hexagon bolts M7 x 35 with washers

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Torque setting 18 Nm
Co
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– Place thrust pieces -T10408/2- on shafts. rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– Install puller Kukko 18/1 .
– Pull off 5th and 6th gear synchro-hub, 6th gear wheel, 5th gear
wheel and gearbox housing by alternately tightening spindles
-A- (1/2 rotation) of pullers Kukko 18/2 .
– Heat 5th and 6th gear wheels slightly with hot air blower -
V.A.G 1416- if necessary.

– Remove selector forks -A- together with selector plates.

– Unbolt reverse gear selector mechanism -B-.
AG. Volkswagen AG d
agen oes
olksw not
V gu
by
– Remove nuts -B- for output shaft risebearing
d support. ara
nte
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un
pt
an
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rm
ab
pe
ility
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hole
spec
es, in part or in w
t to the co
rrectness of i
– Remove reverse gear -A-, input shaft -B- and output shaft
-C- one after the other from clutch housing.
l purpos
– Remove differential.
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
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Cop py
t. rig
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5.7.2 Assembling gearbox
lksw
cted agen
Prote AG.
– Install differential.
– Always renew sealing rings -arrows- for output shaft bearing
support.
Note
The figure shows only 3 of the 4 sealing rings.

– Insert input shaft -1- and output shaft -2- together.

– Tighten nuts for output shaft bearing support to specified tor‐
que ⇒ Item 11 (page 108) .
– Set reverse gear wheel -3- on needle bearing in clutch hous‐
ing.
The shoulder -arrow- faces away from the clutch housing.
– Ensure that reverse shaft -4- is complete ⇒ page 181 ; do not
yet fit reverse shaft support to reverse shaft.
– Fit reverse shaft into clutch housing.
– Clean locking fluid from all threaded holes in reverse shaft
support; a thread chaser may be used.
– Place reverse shaft support on reverse shaft. AG. Volkswagen AG d
agen oes
olksw not
y V gu
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– Attach reverse gear selector fork -1- withrisesupport for reverse nte
ho eo
gear selector fork -2-, spring -3- andasliding piece -4-.
ut ra
c
ss
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le
un
pt
an
d
itte
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erm
ab
ility
ot p
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is n
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ole,
spec
t to the co
rrectne
Installation position, reverse gear
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
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pr
cum
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fo
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t.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
– Bolt on reverse gear selector mechanism -A-, tightening to Prote AG.
specified torque ⇒ Item 8 (page 108) .
– Install selector forks -B- together with selector plates.
Reverse gear support pin -C- is located in front of selector plates.

– Screw M8 x 100 mm studs -A- into reverse shaft support so

that shaft is aligned after
gen AG
gearbox
. Volkswaghousing
en AG is fitted.
a does
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– Align selector
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Note
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The selector segments must be positioned in the grooves on the

itte
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locking collars.
erm
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ility
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clutch housing.
spec
– Fit gearbox housing.
t to the co
Install reverse shaft support bolts -arrow- as follows:
rrectne
– Install bolt -a-.
– Remove stud -A- (⇒ figure above).
ss o
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– Install bolt -c-.
inform
mer
Tightening sequence:
atio
om
– Tighten bolt -a- to 30 Nm.
n
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Cop py
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– Tighten bolt -b- to 25 Nm. opyri
gh by
Vo
ht
c
– Tighten bolt -c- (⇒ figure below) to 25 Nm.
by lksw
cted agen
Prote AG.
– Install pivot pin -arrow- for selector forks. Do this by aligning

selector mechanism with a screwdriver so that respective pivot
pin can be installed.
cover plate.
– Fit selector shaft cover.

Install selector shaft with selector shaft cover plate as follows:

– Place selector plates in neutral.
selector mechanism cover.
– Move selector shaft to neutral.
– Position selector shaft so that selector finger -arrow- is inser‐
ted in selector plates.
– Bolt on selector shaft cover ⇒ Item 15 (page 107) .
Installation position, 5th gear wheel

The circumferential groove -arrow- faces gearbox housing.
AG. Volkswagen AG d
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spec
– Drive on gear wheel for 5th gear.
es, in part or in w
t to the co
rrectness of i
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nf
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Cop py
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rig ht
py by
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by lksw
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Prote AG.

olkswagen AG
en AG. V
Checking 5th gear synchro-ring and 6th gear synchro-ring
olks
wag does
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y V gu
db ara
– Before installing synchromeshed gears and synchro-rings
rise for nte
5th and 6th gear, press synchro-rings onto cones
aut
ho
of synchro‐ eo
ra
meshed gears and measure gap -a- with as feeler gauge.
s c
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un
pt
Gap -a- Installation (new) di‐ Wear limit
an
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itte
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erm
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ility
5th and 6th gears 1.1 … 1.7 mm 0.5 mm
ot p
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is n
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– Install 5th gear synchromeshed gear with needle bearing.
ole,
spec
From gearbox date 26 05 8: set corrugated spring washer on
t to the co
synchromeshed gear for 5th gear ⇒ Item 20 (page 105)
– Place 5th gear synchro-ring on synchromeshed gear.
rrectne
– If synchro-hub and locking collar for 5th and 6th gears are dis‐
mantled, assemble before installing ⇒ page 157 ,
⇒ page 157 and ⇒ page 158 .
ss o
cial p
f
– Observe other modifications to locking collar for 5th and 6th
inform
gears from gearbox date 12 06 6 ⇒ page 157 .
mer
atio
m
These modifications are very important for the later adjustment of

o
n
c
the 5th and 6th gears.
i
or
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sd
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Installation position, synchro-hub and locking collar for 5th and
pr
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6th gears
en
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Shoulder -arrow 1- faces 6th gear. C py
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The supports -arrow 2- of the synchro-hub align with the cast
p by
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locking pieces of the synchro-ring (arrows in figure below). Prote
cted AG.
agen
5th gear and 6th gear synchro-rings with cast locking pieces
-arrows-
– Cover all openings in gearbox housing with a cloth to prevent
foreign bodies from entering gearbox.

– Drive on synchro-hub for 5th and 6th gear.
Note
When driving on, ensure that synchro-ring moves freely.
– Heat inner race of cylindrical roller bearing for 6th gear syn‐
chromeshed gear to maximum 100° C and drive onto input
shaft.
WARNING
Wear protective gloves!
– Install synchro-ring for 6th gear.

From gearbox date 26 05 8: set corrugated spring washer on
synchromeshed gear for 6th gear ⇒ Item 16 (page 105) .
– Install 6th gear synchromeshed gear with needle bearing.
Through gearbox date 20 08 6
– Set thrust washer -A- in place.
Note
AG. Volkswagen
Do not interchange inner races wagof
en cylindrical roller bearings
AG do
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olks
put and output shafts.d by V ot g
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– Heat bearing inner race -B- to cylindrical
au roller maximum ac
ss
100° C and drive onto input shaft.
ce
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un
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WARNING
rm
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wit
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spec
es, in part or in w
From gearbox date 21 08 6

t to the co
Cylindrical roller bearing inner race -B- and thrust washer -A- are
combined in one component.
rrectness of i
– Heat cylindrical roller bearing inner race to maximum 100° C

l purpos
and drive onto input shaft.

nform
ercia
WARNING
m
a
com
tio

n in
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thi
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um
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– Set sleeve -A- on gear wheel for 5th gear.
Co
Cop py
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pyri by
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co lksw
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cted agen
128
Prote AG.
AG. Volkswagen AG d
agen oes
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ut Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , oJetta 2005 ➤
ho e
a ra
ss 6-speed manual gearbox 02S - Edition c 07.2009
ce
e
nl
pt
du
an
Installation position of gear wheel for 6th gear:
itte
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erm
ab
Groove -B- faces away from sleeve -A-.
ility
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“Or” groove -arrow 1- near shoulder -arrow 2- faces away from
orm
sleeve -A- see previous figure).
m
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WARNING
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Cop py
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– Heat 6th gear wheel to maximum 100° C and press on.
ht
pyri by
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cted
– Shift locking collar for 5th and 6th gear to freewheel position
agen
Prote AG.
to enable synchromeshed gear for 6th gear to turn while gear
wheel for 6th gear is being pressed on.
– Drive on gear wheel for 6th gear, being careful that teeth of
gear wheel and synchromeshed gear for 6th gear mesh.
– Heat cylindrical roller bearing inner race -A- to maximum

100° C and drive onto output shaft.
WARNING
– Loosen support for input shaft.

Clean residual locking fluid from threaded holes for securing bolts
-A- for synchro-hub for 5th and 6th gears and gear wheel for 6th
gear with a thread chaser. Otherwise the bolts may shear.
Please note allocation of securing bolts ⇒ page 106 and
⇒ page 106 .
– Tighten securing bolts for synchro-hub and gear wheels for 5th
and 6th gears to specified torque ⇒ page 104 .

– To tighten securing bolts -A-, engage 2 gears -arrows 1-

through -3-.
– Install selector forks for 5th and 6th gears.
Adjusting 5th and 6th gears through gearbox manufacture date

11 06 6
– Engage 5th gear.
– Loosen bolt -1-.
– Insert two 0.5 mm feeler gauges -A- above both selector seg‐
ments -arrows- (to 6th gear) into locking collar.
– Then press the selector jaw and the locking collar down
-arrows- and tighten bolt -1- to 25 Nm.
• 5th gear engaged.

n AG. Volkswagen AG
• Check measurement: it should be possibleolks
wage to insert a 0.5°mm
does
not
feeler gauge without play betweend by Vlocking collar and each se‐ gu
ara
lector segment -arrow- on the
orisside
e
of 6th gear. nte
e h
ut or
– If necessary, repeat adjustment.
ss
a ac
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un
– Engage 5th gear and then 6th gear.

pt
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When 5th or 6th gear is engaged, the selector fork for 5th and 6th
erm
ab
gear should have slight clearance in the selector jaw.

ility
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is n
– Switch to neutral.
h re
ole,
spec
• Locking collar must now be in the neutral position. Synchro-

ring must move freely.

t to the co
– Shift through all gears.

rrectness o
cial p
f inform
mer
atio
om
n
c
i
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sd
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t.
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Cop py
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co lksw
by
130
cted agen
Prote AG.
Adjusting 5th and 6th gear from gearbox manufacture date

12 06 6
– Engage 5th gear.
– Loosen bolt -1-.
– Then press the selector jaw and the locking collar down
-arrows- and tighten bolt -1- to 25 Nm.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
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• 5th gear engaged. uth or eo
ra
s a c
• Check measurement: it should not be possible to insert a 0.2°
s
ce
le
mm feeler gauge between locking collar and each selector

un
pt
an
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segment -arrow- on the side of 6th gear.

itte
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erm
ab
– If necessary, repeat adjustment.
ility
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– Engage 5th gear and then 6th gear.
h re
ole,
When 5th or 6th gear is engaged, the selector fork for 5th and 6th
spec
gear should have slight clearance in the selector jaw.
t to the co
– Switch to neutral.
• Locking collar must now be in the neutral position. Synchro-
rrectne
ring must move freely.
– Shift through all gears.
ss o
cial p
f
inform
mer
– Apply sealant -AMV 188 200 03- evenly to sealing surface of atio
m

o
n
c
i
or
– Install gearbox housing cover ⇒ page 104 .

thi
te
sd
iva
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pr
cum
r
– Install both flange shafts with compression springs, thrust

fo
en
ng
washers and tapered rings ⇒ page 184 .

t.
yi Co
Cop py
– Fit release bearing guide sleeve ⇒ page 44 . ht. rig
rig ht
py by
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– Fit clutch release lever and release bearing ⇒ page 44 .
by lksw
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Prote AG.
– Fill with gear oil ⇒ page 92 .

6 Repairing gearbox housing and clutch housing

equipment required
♦ Drift -VW 295-
♦ Adapter -VW 295 A-
♦ Thrust pad -VW 447 H-
♦ Thrust pad -VW 512-
♦ Tube -VW 415 A-
AG. Volkswagen AG d
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ility
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, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
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t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

♦ Puller -VW 228 B- (is not

required for this gearbox)
♦ Drift -VW 222 A- (not re‐
quired with this gearbox)
♦ Assembly device -3066-
(Spindle from assembly de‐
vice)
♦ Thrust piece -3124- (for
two-part seal and sleeve)
Differentiation ⇒ page 185
♦ Multipurpose tool -VW 771-
(for one-piece seal and
sleeve) Differentiation
⇒ page 185
♦ Extractor hooks -
VW 771/37- (for one-piece
seal and sleeve) Differen‐
tiation ⇒ page 185
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
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aut ra
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♦ Thrust piece -T10148- (for one-piece seal and sleeve) Differ‐ s
ce
le
entiation ⇒ page 185

un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
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pr
cum
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fo
en
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t.
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Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted
133
agen
Prote AG.
6. Repairing gearbox housing and clutch housing
. Volkswagen AG
gen AG does
swa
Golf Variant 2007 ➤ , Golf Variant 2010 y V ➤ , Jetta 2005 ➤
olk not
gu
b ara
6-speed manual gearbox 02S - Editionrised
07.2009 nte
ho eo
aut ra
1- Gearbox housing ss c
ce
le
un
❑ If renewed: adjust input
pt
an
d
shaft and differential
itte
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erm
⇒ page 192
ab
ility
ot p
2 - Needle bearing
wit
is n
h re
ole,
spec
❑ Removing ⇒ page 135
t to the co
❑ Installing and securing
⇒ page 136 .
3 - Oil filler plug, 30 Nm
rrectne
❑ The oil level cannot be
checked by removing
ss o
the oil filler plug
cial p
f in
❑ If the gearbox was dis‐
form
mer
mantled, it must be filled
atio
m
prior to installation
o
n
c
i
or
n
Capacity ⇒ page 1 .
thi
te
sd
iva
o
pr
c
4 - Tapered roller bearing outer
um
r
fo
race
en
ng
t.
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op
❑ For output shaft C py
ht. rig
rig ht
❑ Removing and installing py by
o Vo
⇒ page 163
by c lksw
cted agen
Prote AG.
❑ If replaced: Adjust out‐
put shaft ⇒ page 176 .
5 - Shim
❑ Adjustment overview
⇒ page 192
6 - Shim
❑ For input shaft
⇒ page 158
7 - Tapered roller bearing outer race
❑ For input shaft
❑ If renewed: adjust input shaft ⇒ page 158
❑ For input shaft
❑ If renewed: adjust input shaft ⇒ page 158
9 - Needle bearing
10 - Dowel sleeve
❑ Qty. 2
11 - Clutch housing
❑ When renewing, ⇒ adjustment overview ⇒ page 192
12 - Guide sleeve
❑ With input shaft seal and vulcanised O-ring
❑ Driving out oil seal ⇒ page 136 .
❑ Driving in oil seal ⇒ page 136 .

❑ Remove guide sleeve to change oil seal
❑ If O-ring is damaged, renew guide sleeve and O-ring together
13 - Socket head bolt, 20 Nm
❑ Self-locking
❑ Always renew
14 - Seal
❑ Renew
15 - Sleeve
❑ For seal ⇒ Item 14 (page 135) .
❑ Removing ⇒ page 136 AG. Volkswagen AG d
agen oes
❑ Installing ⇒ page 137Volksw not
g by ua
ed ran
16 - One-piece sealhand ris sleeve tee
ut o or
❑ If seal is damaged,
ss
a renew seal and sleeve together ac
ce
e
nl
pt
du
an
itte
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erm
ab
17 - Oil drain plug, 30 Nm
ility
ot p
wit
, is n
h re
hole
❑ For differential
spec
es, in part or in w
t to the co
❑ If renewed, adjust differential ⇒ page 200
19 - Magnet
rrectness of i
❑ Held in place by housing joint surface
l purpos
20 - Oil collector
❑ Installing oil collector in gearbox housing ⇒ page 137
nf
ercia
orm

m
atio
m
o
n in
or c

thi
te
sd
iva
❑ If renewed, adjust differential ⇒ page 200

o
r
rp
cu
o
m
f
en
ng
22 - Shim yi
t.
Co
op
C py
t. rig
gh ht
yri
❑ Adjustment overview ⇒ page 192 p by
co Vo
by lksw
cted agen
23 - Seal Prote AG.
❑ Renewing ⇒ page 184
Driving out needle roller bearing
6. Repairing gearbox housing and clutch housing 135

Driving needle bearing in to stop

– Secure needle bearing in gearbox housing at three points
(120° offset) using a punch.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
Driving oil seal out
ss
aof guide sleeve ac
ce
le
un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectne
Driving oil seal into guide sleeve to stop
ss o
cial p
f inform
mer
atio
om
n
c
i
or
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sd
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fo
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t.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.
Levering out sleeve -arrow- using screwdriver

Pulling in sleeve
– Clean sleeve seat in gearbox.
– Screw spindle -A- of assembly device -3066- into threaded
piece of differential.
– Pull sleeve in to stop using thrust piece -3124- by turning nut
-B-.
Note
With gearbox dismantled, press sleeve in to stop using thrust

piece -3124- .
Pulling out sleeve and seal

There is a shoulder in the inner diameter of the sleeve.
– To pull out seal and sleeve, apply extractor hooks -VW 771/37-
behind shoulder in sleeve.
– Press extractor hooks -VW 771/37- forcefully into sleeve while
pulling.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
Pulling in sleeve and seal aut
h
ra
ss c
– Clean seat for seal in gearbox.
ce
le
un
pt
an
d
– Screw spindle -A- of assembly device -3066- into threaded

itte
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rm
piece of differential.
ab
pe
ility
ot
– Pull sleeve in to stop using thrust piece -T10148- by turning wit

, is n
nut -B-. h re
hole
spec
es, in part or in w
t to the co
Note
With gearbox dismantled, press sleeve in to stop using thrust

rrectness of i
piece -T10148- .
l purpos
Installing oil collector -A- in gearbox housing

nform
ercia
– Insert oil collector in hole -arrow 1- and groove -arrow 2- si‐

m
multaneously.
com
tion in
r
te o
thi
s
iva
do
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rp
cum
fo
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
6. Repairing gearbox housing and clutch housing 137

7 Repairing gearbox housing cover
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
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aut ra
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un
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ab
ility
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wit
is n
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spec
t to the co
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cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
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pr
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fo
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t.
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Cop py
t. rig
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pyri by
Vo
o
by c lksw
cted agen
Prote AG.

♦ Pressure plate -VW 401-
♦ Press tool -VW 407-
♦ Support bridge -2011-
♦ Internal puller -1 - Kukko 21/5-
♦ Counter support -4 - Kukko 22/1-
♦ In addition from gearbox date 21 08 6, assembly tool -3348/2-

1 - Cylindrical roller bearing

cylindrical roller bearing
for input shaft
❑ Pulling out ⇒ page 139
❑ Larger diameter from
gearbox date 21 08 6
⇒ page 140
❑ Pressing in through
gearbox date 20 08 6:
⇒ page 140
❑ Pressing in from gear‐
box date 21 08 6:
⇒ page 140
❑ Locking ⇒ page 141
2 - Cylindrical roller bearing
❑ For input shaft
cylindrical roller bearing
for output shaft
❑ Larger diameter from
gearbox date 21 08 6
⇒ page 140
❑ Pressing in through
gearbox date 20 08 6:
⇒ page 140
❑ Pressing in from gear‐
box date 21 08 6:
⇒ page 140
❑ Locking ⇒ page 141
3 - Gearbox housing cover
AG. Volkswagen AG d
❑ Cylindrical roller bear‐ agen oes
olksw not
ings modified from gearbox date 21 d08
by 6 ⇒ page 140
V gu
ar
e an
ris tee
tho or
au ac
ss
Pulling cylindrical roller bearing out of gearbox housing cover
ce
le
un
pt
an
d
A - Internal puller, 30 … 37 mm , e.g. -Kukko 21/5-

itte
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rm
ab
B - Counter support , e.g. -Kukko 22/1-

pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
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t.
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Cop py
ht. rig
rig ht
by
139
copy Vo
by lksw
cted 7. Repairing gearbox housing cover
agen
Prote AG.
Pulling cylindrical roller bearing out of gearbox housing cover

Allocation of cylindrical roller bearings

Gearbox manufac‐ Dim. “a” mm Dim. “b” mm
ture date
Through 20 08 6 43 43
From 21 08 6 47 47
lkswage es n
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byV ua
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ir se tee
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ss
ce
le
un
pt
an
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Pressing cylindrical roller bearing into gearbox housing cover -

itte
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through gearbox date 20 08 6

erm
ab
ility
ot p
– Heat gearbox housing cover with hot air blower -V.A.G 1416-
wit
is n
in vicinity of bearing seat to about 100° C.

h re
ole,
spec
– Insert cylindrical roller bearing in heated housing and press in

using workshop press until heat exchange has taken place.

t to the co
Note
rrectne
Cylindrical roller bearings must be pressed into cover to stop.

ss o
cial p
f inform
Pressing cylindrical roller bearing into gearbox housing cover -

mer
from gearbox date 21 08 6

atio
om
n
c
– Heat gearbox housing cover with hot air blower -V.A.G 1416-
i
or
n thi
in vicinity of bearing seat to about 100° C.

te
sd
iva
o
pr
– Insert cylindrical roller bearing in heated housing and press in

um
r
fo
using workshop press until heat exchange has taken place.

en
ng
t.
yi Co
Cop py
t. rig
gh ht
yri by
Note cop Vo
by lksw
cted agen
Prote AG.
Cylindrical roller bearings must be pressed into cover to stop.

Secure cylindrical roller bearing in gearbox housing cover by pe‐

ening -arrows-. wage
e ks s no
Vol t gu
d by ara
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ris
tho eo
au ra
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ss
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ot p
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is n
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t to the co
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cial p
f inform
mer
atio
om
n
c
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te
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t.
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Cop py
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pyri by
Vo
o
by c lksw
cted agen
Prote AG.
7. Repairing gearbox housing cover 141

8 Repairing selector unit

♦ Tube -T10203-
AG. Volkswagen AG d
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♦ Tube -VW 423- olksw not
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1 - Selector unit
❑ Consists of selector
shaft and selector shaft
cover
❑ Components cannot be
separated from each
other gen AG
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2 - -Schalter für Rückfahr‐
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❑ Tightenss ato 20 Nm ra
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❑ Lightly coat lug with
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MoS2 grease
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3 - Angled rod
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❑ For adjusting selector
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spec
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❑ Pressing in
t to the co
⇒ page 144
4 - Relay lever
rrectness of i
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⇒ page 72
❑ From 05.07, plastic re‐
lay lever ⇒ page 73
nform
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5 - Bearing bush
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❑ Not required for plastic
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relay lever
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6 - Seal
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❑ Lever out with a screw‐

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7 - Hexagon nut, 23 Nm cted agen
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❑ Self-locking
❑ Always renew
❑ Install so that master spline aligns with selector shaft
❑ Can be renewed with the selector mechanism installed
9 - Cap
❑ For gearbox breather
10 - Securing clip
11 - Cover plate
12 - Spring
❑ Not fitted in all gearboxes
8. Repairing selector unit 143

Removing angled rod -A- from selector shaft cover

– Remove outer part of angled rod.
– Then carefully lever out angled rod using a screwdriver.
Pressing angled rod -A- into selector shaft cover

Installation position:
Marking -arrow- points to upper part of selector shaft.
AG. Volkswagen AG d
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Inserting oil seal to stop
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AG. Volkswagen AG d
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6-speed ntemanual gearbox 02S - Edition 07.2009
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9 Dismantling and assembling selector forks
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equipment required
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♦ Thrust piece -3290/1-
t to the co
♦ Assembly tool -3301-
rrectness of i
♦ Spacer sleeve -VW 472/2-
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♦ Drift -10 - 206-
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♦ Removal lever -80–200-
9. Dismantling and assembling selector forks 145

♦ Drift -10 - 508-
♦ Clamp -2070-
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Note
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It is not necessary to dismantle the selector fork group ( ⇒ Item 7 (page 147) ) in order to remove and install
selector segments, lock washers and angular contact ball bearings.
rrectness o
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1 - Selector segment for 5th

and 6th gears AG. Volkswagen AG d
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❑ Identification olksw not
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⇒ page ed 148
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❑ After
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2 - Lock washer
ility
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❑ Always renew
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3 - Selector fork for 5th and 6th
gears
❑ Adjusting ⇒ page 131
rrectness of i
4 - Bolt, 25 Nm
l purpos
5 - Selector jaw for 5th and 6th

gears
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6 - Angular contact ball bearing

m
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❑ Qty. 4
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❑ Removing ⇒ page 148 his

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❑ Press inner race into

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outer race ⇒ page 149

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7 - Selector fork group with se‐
rig ht
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8 - 1st/2nd gear selector seg‐
ment
❑ Identification
⇒ page 148
❑ After lock washer is in‐
stalled, segment must
still rotate freely
9 - Selector segment for 3rd and 4th gear
❑ Identification ⇒ page 148
❑ After lock washer is installed, segment must still rotate freely
10 - Sliding piece
11 - Spring
12 - Selector fork for reverse gear
13 - Support for reverse gear selector fork
14 - Retaining ring

Identifying selector segments

Dimension -a-
1 - 1st and 2nd gear selector segments = 11.4 mm
2 - 3rd and 4th gear selector segments = 7.7 mm
3 - 5th and 6th gear selector segments = 12.1 mm
Removing lock washer

– Clamp selector fork in vice with protective jaw covers -B-.
AG. Volkswagen AG d
– Lever off lock washer -A- in -direction of arrow-. agen oes
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Installing lock washer
es, in part or in w
t to the co
– Press lock washer into groove of selector segment using sock‐
et and spinner handle.
rrectness of i
Note
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After lock washer is installed, selector segment must still rotate
nform
ercia
freely.
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-A- Spinner handle with 10 mm socket
on in
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thi
-B- Vice jaw protectors
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Removing angular contact ball bearing

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When removing and installing angular contact ball bearing, do not
bend selector forks.

Pressing inner race -A- of angular contact ball bearing into outer
race
Inner race must engage in outer race.
Pulling angular contact ball bearing into selector fork to stop

Depression in thrust piece -3290/1- faces ball bearing.
G. Volkswag
Selector fork with selector
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1st/2nds agear selector
fork 87.2 … 87.4r ac
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3rd/4th gear selector fork 93.6 … 93.8
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Selector segment assignment ⇒ page 148 .

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

equipment required
AG. Volkswagen AG d
♦ Thrust pad -VW 447 H- agen oes
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♦ Press tool -VW 412- orise nte
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♦ Press tool -VW 408 A-
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150 Rep. Gr.35 - Gears, shafts

♦ Drift sleeve -41 - 501-

♦ Thrust pad -VW 447 i-
♦ Splitter -3 - Kukko 17/1-
AG. Volkswagen AG d
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♦ When installing new gears, refer to ⇒ Electronic parts catalogue “ETKA” and technical data ⇒ page 1 .
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♦ If the position of the tapered roller bearings is affected when parts are exchanged, the input shaft must be
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readjusted. See adjustment overview ⇒ page 192 .

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151
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1. Input shaft
1 - Clutch housing
race
❑ Pressing out
⇒ page 154
❑ Pressing in
⇒ page 154 AG. Volkswagen AG d
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3 - Tapered roller bearing inner d by
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❑ Pressing off aut ra
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⇒ page 154 s
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❑ Pressing on
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⇒ page 154 itte
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4 - Input shaft
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5 - Gear wheel for 3rd gear
t to the co
shoulder faces 4th gear
❑ Pressing off
rrectne
⇒ page 155
❑ Pressing on
s
⇒ page 155
s o
cial p
f i
6 - Retaining ring
nform
mer
❑ Always renew
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❑ Pressing off with ta‐

t
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pered roller bearing out‐

i
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⇒ page 155
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❑ Pressing on t. C rig
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❑ Collar faces 3rd gear cted agen
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8 - Tapered roller bearing inner race

❑ Pressing off with 4th gear wheel and sleeve ⇒ page 155 .
❑ Pressing on ⇒ page 156
9 - Thrust washer
❑ Pressing out ⇒ page 156
❑ Pressing in ⇒ page 156
11 - Shim
❑ Determining thickness ⇒ page 158
13 - Sleeve
❑ For needle bearing
❑ Press off with gear wheel for 4th gear and tapered roller bearing inner race ⇒ page 155
❑ Set thrust washer ⇒ Item 9 (page 152) in place before installing
14 - Needle bearing


❑ With cast locking pieces ⇒ page 127
❑ Check for wear ⇒ page 127
18 - Locking collar with synchro-hub for 5th and 6th gears
❑ Dismantling and assembling ⇒ page 157 and ⇒ page 157
❑ From gearbox date 12 06 6, locking collar modified ⇒ Item 18 (page 105)
❑ Adjusting 5th and 6th gears, from gearbox date 12 06 6 ⇒ page 131
❑ Adjusting 5th and 6th gears, through gearbox date 11 06 6 ⇒ page 130
❑ Installation of springs with angled ends for locking pieces ⇒ page 158
❑ With cast locking pieces ⇒ page 127
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❑ Allocate according to o⇒ agen
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21 - Synchromeshed rigear d b for 6th gear ⇒ Item 15 (page 105)ara
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22 - Needle bearing
ss a ⇒ Item 14 (page 105)
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❑ For 6th gear
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❑ Renew together with sleeve

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23 - Sleeve ⇒ Item 13 (page 105)

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❑ For 6th gear needle bearing.

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❑ Renew together with needle bearing

spec
24 - Thrust washer
t to the co

25 - Cylindrical roller bearing inner race
rrectne

ss o

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f inform
❑ Do not interchange with cylinder roller bearing inner race of output shaft.
mer
atio
m
26 - Inner race for cylindrical roller bearing with thrust washer

o
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or

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❑ For input shaft

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27 - Bolt ⇒ Item 9 (page 104) t. Cop py
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❑ Self-locking
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❑ Always renew
1. Input shaft 153

Pressing out tapered roller bearing outer race
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Pressing in tapered roller bearing outer race ss a c
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Pressing off tapered roller bearing inner race

A - Splitter -Kukko 17/1-
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Pressing on tapered roller bearing inner race

Pressing off gear wheel for 4th gear with tapered roller bearing
and sleeve
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Pressing off gear wheel for 3rd gear
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Pressing on gear wheel for 3rd gear
Shoulder faces 4th gear
ss o
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Pressing on gear wheel for 4th gear Prote
cted AG.
agen
Shoulder faces 3rd gear
1. Input shaft 155

Pressing on tapered roller bearing inner race
Pressing on sleeve for needle bearing
Pressing out tapered roller bearing outer race
AG. Volkswagen AG d
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Pressing in tapered roller bearing outer race

un
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– Install with shim after adjusting input shaft.

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Rep. Gr.35 - Gears, shafts
Deeper notches in both sides of locking collar for 5th and 6th
gears -arrows- from gearbox date 12 06 6
olkswagen AG
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Dimension -a- Through
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does
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(6th gear side)ed by V date 11 06 6 12 06 gu 6
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Dimension -b- Through gearbox From gearbox date
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(5th gear side) date 11 06 6 12 06 6
an
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1.5 mm 2.0 mm
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– Allocate locking collar and synchro-hub for 5th and 6th gears
is n
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according to ⇒ Electronic parts catalogue “ETKA” .
ole,
spec
Due to the deeper notches, the adjustment procedure for 5th and
t to the co
6th gears has been changed:
– Adjusting 5th and 6th gears to gearbox manufacture date
11 06 6 ⇒ page 130 .
rrectne
– Adjusting 5th and 6th gears from gearbox manufacture date
s
12 06 6 ⇒ page 131 .
s o
cial p
f inform
Dismantling and assembling locking collar and synchro-hub for
mer
5th and 6th gears
atio
om
n
1- Spring
c
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2- Locking piece
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3- Synchro-hub
fo
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4- Locking collar Cop py
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– Slide locking collar over synchro-hub. py by
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Deeper notches -arrow A- for locking pieces in synchro-hub and
Prote AG.
notches -arrow B- in locking collar must align.
Assembling locking collar and synchro-hub for 5th and 6th gears
• Locking collar has been pushed over synchro-hub.
– Insert locking pieces in deeper notches -arrows- and install
springs offset 120°. Angled end of spring must locate in hollow
locking piece.
Note
♦ From gearbox date 26 05 8, a wave spring washer is installed

below the synchro-ring for 5th gear and above the synchro-
ring for 6th gear ⇒ Item 16 (page 152) and
⇒ Item 20 (page 153) .
♦ In this case, install only locking piece springs without angled
ends (as shown in ⇒ page 157 - item 1).
1. Input shaft 157

Installing springs with bent ends -A-

The modified springs are installed on both sides.
– Spring are installed only in conjunction with locking pieces
which are hollow on the inner side.
– Insert locking pieces. olkswage es n
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Installation position of springs
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– Install springs offset 120°.
hole
spec
– Angled end -A- of spring must locate in hollow locking piece.
es, in part or in w
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It must be located under shoulder -B- of locking piece.
Bent ends always face away from synchro-hub
rrectness of i
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1.2 Adjusting input shaft

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(Determining input shaft shim)
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equipment required
♦ Universal dial gauge brack‐
et -VW 387-
♦ End dimension plate -
VW 385/17-
♦ Thrust pad -VW 447 i-
1331-
♦ Dial gauge
AG. Volkswagen AG d
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It is necessary to readjust the input shaft only when the following

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components are renewed:

thi
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♦ Gearbox housing
rp
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♦ Clutch housing
t.
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Cop py
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♦ Input shaft
rig
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or the
♦ Tapered roller bearing
Adjustment overview ⇒ page 192 .
Requirement:
• Sealing surfaces of clutch and gearbox housings must be free
of sealant.
1. Input shaft 159

– Press tapered roller bearing outer race into gearbox n Ahousing

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– Press tapered roller bearing outer race without shim into gear‐
box housing to stop.
rrectness of i
– Install input shaft in clutch housing and set gearbox housing
in place. Tighten hexagon head bolts to 25 Nm and then turn
l purpos
90° further.
nform
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– Fit measuring appliance and dial gauge in clutch housing. Cop py
t. rig
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– Before taking any measurements, rotate input shaft to allow p by
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bearings to settle. Set dial gauge to “0” with 1 mm preload.
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Prote AG.
Note
This step must be repeated for each subsequent measurement,

or the dial gauge will not return to the starting position.
– Press input shaft in direction of dial gauge

– Read and note play on dial gauge (example: 1.21 mm).
Note
Dial gauge does not return to original position.
1.2.1 Determining thickness of shim

Example:
Bearing play, measured value Thickness of shim according to
table
1.21 mm 1.175 mm

AG. VGolf
olkswaVariant
gen AG 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
agen 6-speed
not manual gearbox 02S - Edition 07.2009
does
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Table of shims hor eo
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Bearing play s
Shim
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Measured value (mm) Thickness (mm)
an
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rm
0.671…0.699 0.650
ab
pe
ility
0.700…0.724 0.675
ot
wit
0.725…0.749 0.700
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0.750…0.774 0.725
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0.775…0.799 0.750
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0.800…0.824 0.775
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0.825…0.849 0.800
0.850…0.874 0.825
rrectness of i
0.875…0.899 0.850
0.900…0.924 0.875
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0.925…0.949 0.900
0.950…0.974 0.925
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0.975…0.999 0.950
1.000…1.024 0.975
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1.025…1.049 1.000
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1.050…1.074 1.025
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1.075…1.099 1.050
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1.100…1.124 1.075
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1.125…1.149 1.100
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1.150…1.174 1.125
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1.200…1.224 1.175
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1.225…1.249 1.200
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1.250…1.274 1.225
1.275…1.229 1.250
1.300…1.324 1.275
1.325…1.349 1.300
1.350…1.374 1.325
1.375…1.399 1.350
1.400…1.424 1.375
1.425…1.449 1.400
1.450…1.474 1.425
1.475…1.499 1.450
1.500…1.524 1.475
1.525…1.549 1.500
1.550…1.574 1.525
1.575…1.599 1.550
1.600…1.624 1.575
1.625…1.649 1.600
1.650…1.674 1.625
1.675…1.699 1.650
1.700…1.724 1.675
Note
Allocate shims according to ⇒ Electronic parts catalogue “ETKA” .
– Remove input shaft and press outer race of tapered roller

bearing out of gearbox housing using thrust plate -VW 447 i- .
– Insert shims of determined thickness, thickest shim first.
If the size of shim required is larger than those listed in the table,
insert two shims totalling the correct figure.
– Press outer race of tapered roller bearing together with the
shim (1.175 mm in example) into gearbox housing using thrust
pad -VW 510- .
1. Input shaft 161

– Set gearbox housing in place and tighten hexagon head bolts

to 25 Nm and then turn 90° further.
1.2.2 Carrying out check measurement

– Set up measuring appliance and dial gauge.
– Rotate input shaft so that tapered roller bearings settle.
– Press input shaft in -direction of arrow-.
– Bearing play should be min. 0.01 ... max. 0.09 mm.
Note
If the bearing play cannot be measured, but input shaft play is

perceptible and the input shaft turns freely, the adjustment is ac‐
ceptable.
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2 Output shaft
2.1 Dismantling and assembling output shaft

equipment required
♦ Puller -V.A.G 1582-
♦ Adapter -V.A.G 1582/4-
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2. Output shaft 163


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♦ Tube -VW 415 A-
♦ Thrust pad -VW 447 H-
♦ Tube -2040-
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♦ Tube -VW 416 B-

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2. Output shaft 165

♦ Internal puller -1- Kukko 21/6-
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♦ The output shaft is dismantled as follows: position separating device under 2nd gear synchromeshed gear
⇒ Item 21 (page 168) and press off as described in ⇒ page 170 . Remove retaining ring
⇒ Item 17 (page 168) . Then press off locking collar with synchro-hub for 1st and 2nd gear as described in
rrectness of i
⇒ page 171 .
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♦ When installing new gears or new input shaft, refer to ⇒ Electronic parts catalogue “ETKA” and technical
data ⇒ page 1 .
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♦ Always renew both tapered roller bearings together as a set.
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6-speed manual
AG. Vogearbox
lkswagen A02S - Edition 07.2009
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1 - Hexagon nut, 25 Nm and ed
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❑ 4 nuts for bearing sup‐ au ac
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⇒ page 192
4 - Small tapered roller bearing
outer race
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❑ Pressing in
⇒ page 170
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5 - Small tapered roller bearing
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❑ Pulling off ⇒ page 170

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❑ Pressing on
⇒ page 171
8 - Seal
❑ Place sealing rings (Qty.
4) on bearing support
bolts
9 - Bearing support
❑ With large tapered roller bearing outer race and bolts
❑ Change outer race only together with large tapered roller bearing and bearing support
10 - Thrust washer
❑ Shoulder of thrust washer faces tapered roller bearing
11 - Synchromeshed gear for 1st gear
12 - Needle bearing
❑ For 1st gear
13 - Synchro-ring
❑ (Inner ring for 1st gear)
❑ Check lugs for scoring
14 - Outer ring for 1st gear
❑ Renew if scored
15 - Synchro-ring for 1st gear
2. Output shaft 167

16 - Locking collar with synchro-hub for 1st and 2nd gears
❑ After removing retaining ring ⇒ Item 17 (page 168) , pull off together with bearing support ⇒ page 171
❑ Dismantling ⇒ page 172 n AG. Volkswagen AG do
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❑ Pressing on ⇒ page 173 ss au ra
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❑ Assemble so that notches engage in locking pieces of locking collar ⇒ Item 16 (page 168)
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19 - Outer ring for 2nd gear
spec
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❑ Insert in synchro-ring ⇒ Item 18 (page 168) .
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❑ Renew if scored
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20 - Synchro-ring
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❑ (Inner ring for 2nd gear)

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❑ Check lugs for scoring
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21 - Synchromeshed gear for 2nd gear
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24 - Sleeve for 3rd gear needle bearing.
AG.
❑ Pressing off with synchromeshed gear for 2nd gear ⇒ page 170
25 - Needle bearing
❑ For 3rd gear
26 - Synchromeshed gear for 3rd gear
27 - Synchro-ring for 3rd gear
28 - Locking collar with synchro-hub for 3rd and 4th gears
❑ Press off with 2nd gear synchromeshed gear ⇒ Item 19 (page 168) and 3rd gear ⇒ Item 24 (page 168)
⇒ page 170 .
❑ Dismantling ⇒ page 175
❑ Assembling locking collar and synchro-hub ⇒ page 175 , ⇒ page 175 and ⇒ page 175
❑ Installation position, locking collar and synchro-hub ⇒ page 176
29 - Sleeve
❑ For needle bearing
❑ Press off with 3rd and 4th gear ⇒ Item 28 (page 168) locking collar and synchro-hub ⇒ page 170 .
30 - Needle bearing
❑ For 4th gear


33 - Thrust washer
34 - Needle bearing
36 - Sleeve
❑ For output shaft needle bearing
❑ Pressing off ⇒ page 170
❑ Pressing on ⇒ page 176 wage
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❑ Larger outer diameter from gearbox date 21 08 6
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❑ Do not interchange with inner race for cylindrical roller bearing of input shaft
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41 - Bolt ⇒ Item 6 (page 104)

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❑ Allocation ⇒ page 106 a

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2. Output shaft 169

Pressing in small tapered roller bearing outer race
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Pulling off small tapered roller bearing inner race
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A - Vice with protective jaws
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– Fit adapter and tighten behind bearing rollers, then turn bear‐
es, in part or in w
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ing and retighten gripping device.
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Pressing off 3rd and 4th gear synchro-hub and locking collar, 2nd,
3rd and 4th gear synchromeshed gears with sleeve for gearbox
housing needle bearing
A - Splitter, 22 … 115 mm , e.g. -Kukko 17/2-
B - Hexagon bolt M10 x 20, 17 mm AF
Note
Support splitter so that the 1st and 2nd gear locking collar is not
pulled off at the same time.

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Pressing off locking collar with synchro-hub and bearing support
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– First remove retaining ring -arrow-.
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Pulling off large tapered roller bearing inner race
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A - Protective jaws
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– Before fitting puller, insert a M10 × 20 hexagon bolt in the out‐

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Pressing on large tapered roller bearing inner race

-A- Thrust washer
– Fit thrust washer before pressing on inner race. Shoulder
faces inner race.
Installation position of outer ring, inner ring and synchro-ring for

1st gear
– Place inner ring -A- on synchromeshed gear for 1st gear.
Angled lugs -arrow 1- face outer ring -B-.
– Fit outer ring -B-.
Lugs -arrow 2- engage in notches -arrow 3- of synchromeshed
gear.
– Fit synchro-ring -C-.
Notches -arrow 4- engage in lugs -arrow 1- of inner ring -A-.
Note
If components are not to be renewed, ensure that they are match‐

ed with their original gears.
2. Output shaft 171

Checking 1st and 2nd gear inner ring for wear

– Press inner ring onto cone of synchromeshed gear and meas‐
ure gap -a- using a feeler gauge.
mension
1st and 2nd gears 0.75 … 1.25 mm 0.3 mm
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Checking 1st and 2nd gear synchro-ring
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– Press synchro-ring, outer
ss a ring and inner ring onto cone of syn‐ c
chromeshed gear and measure gap -a- using a feeler gauge.
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Dismantling and assembling locking collar and synchro-hub for
1st and 2nd gears
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1 - Spring
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mer
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Installation with hollow locking pieces ⇒ page 173 .

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Installation with solid locking pieces ⇒ page 173

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Allocate locking pieces according to ⇒ Electronic parts catalogue
“ETKA” .
Collar is equally wide on both sides of synchro-hub.
The collar has a chamfer on one side -arrow B-.
Chamfer on collar of synchro-hub and outer teeth of locking collar
-arrow A- face in same direction after assembly.
Notches -arrow C- in synchro-hub and sliding collar for locking
pieces must align.

Assembly of 1st and 2nd gear locking collar and synchro-hub with
hollow locking pieces
– Insert locking pieces and install springs offset 120°. Angled
end of spring must locate in hollow locking piece.
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Installation position of locking collar with synchro-hub for 1st and
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Teeth of locking collar -arrow- face splines for 3rd and 4th gear
synchro-hub -A-.
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Pressing on locking collar and synchro-hub for 1st and 2nd gears
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Turn synchro-ring so that grooves align with locking pieces.
2. Output shaft 173

Installation position of 2nd gear outer ring

Lugs -arrows- face 1st gear -A-.
Installation position of synchro-ring (2nd gear inner ring) -A-

Lugs -arrow 1- engage in notches -arrow 2- in synchro-ring -B-.
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Installation position of synchromeshed gear for 2nd gear

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-arrows- engage in lugs of outer ring ⇒ page 174 .

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Pressing on sleeve for 3rd gear needle bearing

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Checking synchro-rings for 3rd and 4th gear for wear

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3rd gear 1.0...1.7 mm 0.5 mm
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4th gear 1.0...1.7 mm
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Dismantling and assembling 3rd and 4th gear locking collar and
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1 - Spring
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Allocate springs according to ⇒ Electronic parts catalogue “ET‐

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Installation with hollow locking pieces ⇒ page 175 .

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– Slide locking collar over synchro-hub.
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Notches for locking pieces in synchro-hub and locking collar must

align.
Assembly of 3rd and 4th gear locking collar and synchro-hub with
hollow locking pieces
Locking collar has been pushed over synchro-hub.
– Insert locking pieces and install springs offset 120°. Angled
end of spring must locate in hollow locking piece.
Assembly of 3rd and 4th gear locking collar and synchro-hub with
solid locking pieces
– Insert locking pieces and install springs offset 120°. Springs
must seat with angled ends in front of locking pieces
-arrows-.
2. Output shaft 175

Installation position of locking collar with synchro-hub

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Pressing on synchro-hub with locking collar for 3rd and 4th gears
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Pressing on sleeve for output shaft needle bearing
2.2 Adjusting output shaft

(Determining shim for output shaft)


equipment required
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♦ Torque wrench -
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♦ Puller -2- Kukko 18/0- (threaded spindle)
2. Output shaft 177

♦ Adapter -VW 771/15-
It is necessary to readjust the output shaft when the following

components are renewed:
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• Sealing surfaces of clutch and gearbox housings must be free
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spec
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– Press small tapered roller bearing outer race together with a
0.65 mm thick shim into clutch housing to stop ⇒ page 170 .
– Insert output shaft and tighten nuts for bearing support to 25
rrectness of i
Nm, then turn 90° further.
l purpos
– Turn output shaft 20 to 30 times in one direction.
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Note
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♦ The shaft must be turned in one direction so that the rollers of

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♦ It is necessary to turn the shaft 20 to 30 times to achieve this.

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– Set up dial gauge (3 mm measuring range) and set to “0”with

1 mm preload.
-A- = threaded spindle from puller --Kukko 18/0- .
– Move output shaft up and down and note dial gauge reading
(example: 0.20 mm).
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The specified bearing preload is obtained by adding a constant
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preload figure (0.10 … 0.15 mm) to the reading obtained (0.20
hole
spec
mm) and the thickness of the shim installed (0.65 mm).
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Example:
Installed shim 0.65 mm
rrectness of i
+ Measured value 0.20 mm
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+ Preload (constant) 0.15 mm

Shim thickness 1.00 mm
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Example:
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Bearing play = Thickness of shim according to
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0.850 mm 1.000 mm
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Table of shims
AG.
Bearing play = Shim

(0.65 mm shim thickness (mm)
ue)
0.650 0.750
0.660 … 0.689 0.800
0.690 … 0.739 0.850
0.740 … 0.789 0.900
0.790 … 0.839 0.950
0.840 … 0.889 1.000
0.890 … 0.939 1.050
0.940 … 0.989 1.100
0.990 … 1.039 1.150
1.040 … 1.089 1.200
1.090 … 1.139 1.250
1.140 … 1.189 1.300
1.190 … 1.239 1.350
1.240 … 1.289 1.400
2. Output shaft 179

Bearing play = Shim

(0.65 mm shim thickness (mm)
ue)
1.290 … 1.339 1.450
1.340 … 1.389 1.500
1.390 … 1.429 1.550
Note
– Insert shims of determined thickness, thickest shim first.

• If the previously used 0.65 mm shim is to be reinstalled, check
it for damage.
If the size of shim required is larger than those listed in the table,
insert two shims totalling the correct figure.
The various thicknesses make it possible to achieve the exact
shim thickness required.
– Press in small tapered roller bearing outer race together with
the correct shim (in example 1.00 mm) ⇒ page 170 and install
output shaft. Tighten bearing support nuts in clutch housing to
25 Nm and then turn 90° further.
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3 Reverse shaft
3.1 Dismantling and assembling reverse shaft

equipment required
♦ Thrust pad -VWwa447
gen AH-
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3. Reverse shaft 181

Note
After dismantling, always renew needle bearing in clutch housing and reverse shaft support.
1 - Clutch housing
2 - Needle bearing
❑ Pressing in
⇒ page 183
3 - Reverse gear wheel
4 - Retaining ring
❑ Always renew after re‐
moving.
❑ Carefully fit new retain‐
ing ring AG. Volkswagen AG d
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❑ Remove retaining ring
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before renewing.
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❑ Shoulder faces reverse
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6 - Reverse shaft h re
hole

spec
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7 - Needle bearing
t to the co
❑ Pressing out
⇒ page 183
rrectness of i
❑ Pressing in
⇒ page 183
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8 - Reverse shaft support

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⇒ page 115
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Pulling needle bearing out of clutch housing

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

newed.

Pressing needle bearing -A- into clutch housing
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Pressing needle bearing out of reverse shaft support
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3. Reverse shaft 183

39 – Final drive - differential

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

equipment required
♦ Puller hooks -VW 771/37-
♦ Thrust piece -T10160-
♦ Drip tray -V.A.G 1306- or
drip tray for workshop hoist
-VAS 6208-
♦ Torque wrench -
V.A.G 1331-
AG. Volkswagen AG d
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a
Removing
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– Remove left wheel.

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– Remove noise insulation ⇒ General body repairs, exterior; t. C rig
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– Remove lower part of front left wheel housing liner ⇒ General
agen
Prote AG.
– Turn steering to left lock.
– Disconnect drive shaft from flange shaft ⇒ Running gear,
axles, steering; Rep. Gr. 40 ; Repairing drive shaft; Removing
and installing drive shafts .
184 Rep. Gr.39 - Final drive - differential

– Raise drive shaft as high as possible and secure. Take care

not to damage paint on drive shaft in the process.
– Place drip tray under gearbox.
– Remove flange shaft securing bolt by screwing two bolts into
flange and counterholding flange shaft with a lever.
– Pull out flange shaft with compression spring.
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– Pull out flange shaft oil seal using multipurpose tool -VW 771-
hole
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and puller hooks -VW 771/37- .
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1.1.2 Installing do
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– Insert flange shaft.
agen
Prote AG.
– Secure flange shaft with countersunk bolt.

– Attach drive shaft to gearbox ⇒ Running gear, axles, steering;
Rep. Gr. 40 ; Repairing drive shaft; Removing and installing
drive shafts .
– Check gear oil ⇒ page 99 .
– Install lower part of front left wheel housing liner ⇒ General
– Install noise insulation ⇒ General body repairs, exterior; Rep.
– Install wheel ⇒ Running gear, axles, steering; Rep. Gr. 44 ;
Torque settings for mounting wheels .
1.1.3 Torque setting

Flange shaft to gearbox (countersunk bolt)
1.2 Distinguishing seals for right flange

shaft
The seal -1- for the right flange shaft is located in a sleeve -2-.
1. Renewing flange shaft oil seals with gearbox installed 185

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Seal -1- and sleeve -2- are two parts. Identification: notches along
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Renew seal ⇒ page 186 .
hole
spec
Seal -1- and sleeve -2- are one piece. Identification: no notches
es, in part or in w
t to the co
in sleeve.
Renew seal and sleeve together ⇒ page 189 .
rrectness of i
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1.3 Renewing seal (two-part seal and

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♦ Drip tray for workshop hoist -VAS 6208-

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1.3.1 Removing
– Turn steering to right to full lock.
– Remove drive shaft heat shield from engine, if fitted.
– Disconnect drive shaft -1- from flange shaft.
– Place drip tray under gearbox and engine.
– Unbolt turbocharger oil return line from engine -arrow- ⇒ Rep.
Gr. 21 ; Charge air system for turbocharger; Removing and
installing turbocharger with ancillaries . wage
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flange and counterholding flange shaft with a lever. y li

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– Pull out flange shaft with compression spring. wit

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es, in part or in w
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ercia
– Lever out seal using screwdriver -A- supporting screwdriver

m
at
on assembly tool -3253/2- .

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Note
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♦ Do not damage sleeve. Otherwise, leaks will occur.

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♦ Replace sleeve if damaged ⇒ page 136 .
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1.3.2 Installing
– Drive in new seal to stop, being careful not to cant seal.
– Half-fill space between sealing lip and dust lip with sealing
grease -G 052 128 A1- .
– If turbocharger oil return line was unbolted from engine, bolt it

on again now -arrow- ⇒ Rep. Gr. 21 ; Charge air system for
turbocharger; Removing and installing turbocharger with an‐
cillaries . n AG. Volkswagen AG ge does
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– Bolt drive shaft -1- to flange
yV
olk shaft ⇒ Running gear, axles,
not
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steering; Rep. Gr. ri40 ed b; Repairing drive shaft; Removing and
ara
s nte
installing drive shafts
ut
ho
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a ac
ss
– Install drive shaft heat shield, if present, on engine ⇒ Running ce
le
un
gear, axles, steering; Rep. Gr. 40 ; Repairing drive shafts . pt

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1.4 Renewing seal and sleeve together (one-piece seal and sleeve for right
flange shaft)
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♦ Spindle from assembly tool -3066-
♦ Puller hooks -VW 771/37-

♦ Drip tray for workshop hoist -VAS 6208-
1.4.1 Removing
– Turn steering to right to full lock.
– Remove drive shaft heat shield from engine, if fitted.
– Disconnect drive shaft -1- from flange shaft.
– Place drip tray under gearbox and engine.
– Unbolt turbocharger oil return line from engine -arrow- ⇒ Rep.
Gr. 21 ; Charge air system for turbocharger; Removing and
installing turbocharger with ancillaries .
AG. Volkswagen AG d
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flange and counterholding flange shaft with a lever.

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– Pull out flange shaft with compression spring.

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es, in part or in w
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– Pull out seal and sleeve together.

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There is a shoulder in the inner circumference of the sleeve.

m
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– Apply puller hooks -VW 771/37- directly behind shoulder in

n in
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sleeve.
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– Press extractor hooks -VW 771/37- forcefully into sleeve while

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1.4.2 Installing
– Clean seat for seal in gearbox.
– Pull in seal and sleeve together.
A - Screw spindle of assembly tool -3066- into threaded piece of
differential.
B - Nut M12
– Pull in seal with sleeve to stop using thrust piece -T10148- by
turning nut -B-.
– Half-fill space between sealing lip and dust lip with sealing
grease -G 052 128 A1- .
– If turbocharger oil return line was unbolted from engine, wage

bolt
n AG.itVolkswagen AG do
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on again now -arrow- ⇒ Rep. Gr. 21 ; Charge yair V system for
olks ot g
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turbocharger; Removing and installing turbocharger
ed b with an‐ ran
ris
cillaries . utho tee
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– Bolt drive shaft -1- to flange shaft ⇒ Running
s gear, axles,
ce
le
steering; Rep. Gr. 40 ; Repairing drive shaft; Removing and

un
pt
an
d
installing drive shafts .

itte
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– Install drive shaft heat shield, if present, on engine ⇒ Running
ility
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wit
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2 Adjustment overview
Note
If repairs have been carried out to the gearbox, it is necessary to

adjust the input shaft, output shaft or differential only if compo‐
nents have been renewed which have a direct effect on the
adjustment of the gearbox. To prevent unnecessary adjustments,AG. Volkswagen AG d
refer to the following table: lksw
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or
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ss Input shaft Output shaft Differential
ce
⇒ page 158 ⇒ page 176 ⇒ page 200
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Parts renewed: Gearbox housing x x
itte
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Clutch housing x x x
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Input shaft x
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Output shaft x
hole
spec
es, in part or in w
Differential cage x
t to the co
Input shaft tapered roller bearing x
Tapered roller bearing for output x
rrectness of i
shaft
Tapered roller bearing for differen‐ x
l purpos
tial
Gear wheel for 4th gear x
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AG. Volkswagen AG d
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3.1 Dismantling and assembling differential
ce
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Special tools and workshop pe
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♦ Tapered roller bearing pull‐
spec
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3. Differential 193

♦ Sleeve -3144-
♦ Thrust piece -2007-
1332-
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AG. Volkswagen AG d
lksw
agen Golf
oes Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
not
o
ara 6-speed manual gearbox 02S - Edition 07.2009
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Note
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♦ Heat tapered roller bearing inner race to 100° C before installing.
erm
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♦ Always renew both tapered roller bearings together as a set.
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♦ If tapered roller bearings, differential cage, gearbox housing or clutch housing are renewed, adjust differ‐
hole
spec
ential ⇒ page 192 .
es, in part or in w
t to the co
1 - Gearbox housing
rrectness of i
2 - Shim
l purpos
❑ Determining thickness
nform
ercia
⇒ page 200
m
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race
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❑ Pressing in
p
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⇒ page 198
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❑ Pressing on
AG.
⇒ page 197
5 - Differential cage
❑ With final drive gear
❑ Differential cage adap‐
ted to one-piece thrust
washer ⇒ page 199
6 - Tapered roller bearing inner
race
❑ Pressing on
⇒ page 197
race
❑ Pressing out
⇒ page 196
❑ Pressing in
⇒ page 197
8 - Clutch housing
9 - Sleeve
❑ To support oil seal ⇒ Item 10 (page 195) .
10 - Seal
❑ Renewing oil seal for left flange shaft with gearbox installed ⇒ page 184
❑ Renewing seal for right flange shaft with gearbox installed (two-part seal and sleeve for right flange shaft)
⇒ page 186
11 - One-piece seal and sleeve
❑ If seal is damaged, renew seal and sleeve together ⇒ page 189
3. Differential 195
❑ Screw into threaded piece ⇒ Item 20 (page 196)
13 - Flange shaft
14 - Compression spring for flange shaft
15 - Thrust washer
16 - Tapered ring
❑ With grooves to engage in thrust washer
❑ Installation position: taper towards differential cage
17 - Retaining ring
❑ Holds tapered ring, thrust washer and spring in position when flange shaft is removed
18 - One-piece thrust washer
❑ Coat with gear oil when installing
❑ One-piece thrust washer has shoulder in some gearboxes ⇒ page 199
19 - Sun wheel
20 - Threaded piece
21 - Differential pinion pin AG. Volkswagen AG d
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❑ Drive out using drift ed byV gu
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❑ Installing ⇒ page 199 ut
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22 - Spring pin s
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❑ For securing differential pinion pin
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❑ Removing and installing short spring pin ⇒ page 198
h re
hole
❑ Long spring pin is sheared off when removed ⇒ page 199
spec
es, in part or in w
❑ Installing long spring pin ⇒ page 199

23 - Planet pinion t to the co
rrectness of i
24 - Sun wheel
l purpos

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Pressing tapered roller bearing outer race out of clutch housing

om
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c
– First remove seating sleeve for flange shaft seal.

or
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Pressing tapered roller bearing outer race into clutch housing byV
olk ot g
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Pulling off tapered roller bearing inner races
rrectne
– Before fitting extractor, position thrust plate -40 - 105- on dif‐
ferential cage.
ss o
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Note
mer
atio
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Both tapered roller bearing inner races are pulled off the differ‐
n
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ential cage in the same way.
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Pressing on tapered roller bearing inner race yri
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Note
The inner races of tapered roller bearings for gearbox housing

and clutch housing are pressed on with the same press tools.
Pulling outer race for tapered roller bearing out of gearbox hous‐
ing
A - Counter support , e.g. -Kukko 22/2-
B - Internal puller, 46 … 58 mm , e.g. -Kukko 21/7-
3. Differential 197
6-speed manual gearbox 02S - AEdition 07.2009
G. Volkswagen A
n G do
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Volks ot
Pressing tapered roller bearinged
by outer race into gearbox housingguara
ris nte
o
– Fit shim under outer au race.
th eo
ra
ss c
– Support gearbox housing directly below bearing mounting us‐
ce
e
nl
pt
ing sleeve -3144- .
du
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Spring pin identification
rrectness of i
l purpos
Dim. “a” mm Identification

28.5 (short spring pin) Circumferential groove
nform
ercia
Removing and installing -arrows-

⇒ page 198
m
at
om
i
36.0 (long spring pin), No circumferential
on
c
Removing ⇒ page 199 , groove
in t
or
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e
Installing ⇒ page 199

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Allocation of differential cages co Vo
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– Check hole for spring pin in differential cage.
The hole in the differential cage was modified for the longer spring
pin.
Hole Length of spring pin (mm)
-A- 28.5 (short spring pin)
-A- and -B- 36.0 (long spring pin)
Removing and installing spring pin with circumferential groove

(short spring pin)
Removing
– Cover tapered roller bearing inner race and speedometer drive
gear to avoid possible damage and ingress of metal particles.
– Drive out spring pin with chisel, inserting chisel into circum‐
ferential groove.
Installing
– Drive into differential cage to stop.

Removing spring pin without circumferential groove (long spring

pin); pressing out differential pinion pin
. Volkswagen AG
a gen AG d
When pressedVoout,
lksw spring pin will be sheared
oes
not off.
g
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db r
– Driveoriremainder
se of spring pin out of differentialancage
tee and dif‐
ferential
au
th
pinion pin. or
a
ss c
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nl
pt
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Installing spring pin without circumferential groove (long spring
t to the co
pin)
– Align hole in differential pinion pin with hole in differential cage.
rrectness of i
– Drive in new spring pin with drift -1- until dimension -a- =
l purpos
3.0 mm is attained.
• The spring pin must not come in contact with gears with dif‐
nf
ercia
ferential cage installed.
orm
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In some gearboxes, the one-piece thrust washer has a shoulder

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-A- near the holes.
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In this case, the differential cage has a circumferential groove
rig ht
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– Lubricate one-piece thrust washer with gear oil and install.
– Install one-piece thrust washer so that it engages in groove
-B- in differential cage.
Installing differential bevel gears and differential pinion pin

– Lubricate one-piece thrust washer with gear oil and install.
– Install both sun wheels and secure (e.g. with flange shaft).
– Insert planet pinions offset 180° and pivot into position.
– Press in differential pinion pin (-arrow A-) to first planet pinion.
– Place threaded pieces -arrows B- in sun gears.
Installation position: shoulder to sun gear
– Drive differential pinion pin into final position and secure with
spring pin.
3. Differential 199
AG. Volkswagen AG d
agen oes
Golf Variant 2007 ➤ , Golf Variant Vo2010
lksw ➤ , Jetta 2005 ➤ not
gu
by
6-speed manual gearbox 02S ris
e - Edition 07.2009
d ara
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au ra
Installation position of thrust washer
ss for tapered ring -1-. c
ce
le
un
The shoulder -arrow- points towards spring -B-.
pt
an
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Some gearboxes have lugs -A-.
erm
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Lugs -A- face tapered ring -1-.
wit
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rrectness o
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3.2 Adjusting differential
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Special tools and workshop gh ht
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equipment required cop Vo
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et -VW 387-
VW 385/17-
♦ Torque wrench -
V.A.G 1331-
♦ Internal puller -1 - Kukko
21/7-
♦ Counter support -4 - Kukko
22/2-
♦ Dial gauge

It is necessary to readjust the differential when the following com‐

ponents are renewed:
♦ Gearbox housing
♦ Clutch housing
♦ Differential cage
or the
♦ Tapered roller bearing of differential
– Press tapered roller bearing outer race without shim into gear‐
box housing using thrust piece -30 - 205- ⇒ page 198 .
Note
Inner and outer tapered roller bearing races are paired. Do not
interchange!
– Press outer race of tapered roller

G. Volkbearing
swagen AGinto clutch housing
using thrust plate -30 - gen A⇒
wa205- page 197 . does
olks no
V t gu
by ara
– Fit differential
ris into clutch housing.
ed nte
tho eo
– Set gearbox
ss
au housing in place and tighten 5 bolts to 25 Nm. ra
c
ce
le
– Attach dial gauge and set to “0” with 1 mm preload.

un
pt
an
d
itte
y li
– Move differential up and down. Read and note play indicated

erm
ab
on dial gauge. (Example: 0.70 mm)

ility
ot p
wit
is n
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ole,
spec
t to the co
rrectness o
cial p

inform
mer
The specified bearing preload is obtained by adding a constant

atio
m
value for preload (0.25 mm) to the reading obtained.

o
n
c
i
or
n thi
Example:
te
sd
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Measured value 0.70 mm

um
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+ Preload (constant) 0.25 mm

t.
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Cop py
Thickness of shim = 0.95 mm
t. rig
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Example:
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Bearing play, measured value Thickness of shim according to

table
0.70 mm 0.95 mm
Table of shims
Bearing play Shim
bearing clearance Thickness
(mm) (mm)
3. Differential 201
Bearing play Shim

0.303 … 0.449 0.650
0.450 … 0.499 0.700
0.500 … 0.549 0.750
0.550 … 0.599 0.800
0.600 … 0.649 0.850
0.650 … 0.699 0.900
0.700 … 0.749 0.950
0.750 … 0.799 1.000
0.800 … 0.849 1.050
0.850 … 0.899 1.100
0.900 … 0.949 1.150
0.950 … 0.999 1.200
1.000 … 1.049 1.250
1.050 … 1.099 1.300
1.100 … 1.149 1.350
1.150 … 1.199 1.400
Note
– Remove gearbox housing and pull tapered roller bearing outer

race from gearbox housing.
A - Counter support , e.g. -Kukko 22/2-
B - Internal puller, 46 … 58 mm , e.g. -Kukko 21/7-
. Volkswagen AG
– Insert shims of determined thickness, thickest
ksw
shim
agen AGfirst. does
ol not
y V gu
If the size of shim required is larger than isedthose
b listed in the table, ara
nte
insert two shims totalling the correctthfigure.
or eo
au ra
s c
The various thicknesses make it possible
s to achieve the exact
ce
le
shim thickness required.

un
pt
an
d
itte
y li
– Press in tapered roller bearing outer race together with the

rm
ab
correct shim (in example 0.95 mm) again ⇒ page 198 and bolt
pe
ility
gearbox housing tight.

ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
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com
tion in
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te o
thi
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en
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Cop py
t. rig
gh ht
pyri by
Vo
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by c lksw
cted agen
Prote AG.

6-Speed Manual Gearbox 02S PDF

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6-Speed Manual Gearbox 02S PDF

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Service

Service Department. Technical Information

All rights reserved.

Copyright © 2010 Volkswagen AG, Wolfsburg MEX5R007520

2 Repairing clutch mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

2.10 Removing and installing slave cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

2.11 Bleeding clutch system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

4 Repairing clutch, in conjunction with dual-mass flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . 46

4.2 Draining gear oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

35 - Gears, shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150

39 - Final drive - differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184

2 Adjustment overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192

3.1 Dismantling and assembling differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193

3.2 Adjusting differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200

Manual gearbox 02S -arrow 2-

Identification code and date of gearbox manufacture

The gearbox code also appears on the vehicle identification

1.2 Identification code, assembly allocation and capacities

Manual gearbox 6-speed 02S

♦ Specification for gear oil

Manufactured from 05.05 05.05 11.05

Engine 2.0 l - 110 kW 2.0 l - 110 kW 1.4 l - 125 kW

Ratio Final drive 62 : 17 = 3.647 63 : 16 = 3.938 62 : 17 = 3.647

Capacity of manual gearbox (gear‐ 2.1 l 2.1 l 2.1 l

Manual gearbox 6-speed 02S

2 Rep. Gr.00 - Technical data

Manual gearbox 6-speed 02S

Manual gearbox 6-speed 02S

Manufactured 05.06 from 05.06 09.06

Ratio Final drive 63 : 16 = 3.938 62 : 17 = 3.647 62 : 17 = 3.647

box completely dismantled)

♦ Allocation of clutch plate and pressure plate

Manual gearbox 6-speed 02S

Manual gearbox 6-speed 02S

4 Rep. Gr.00 - Technical data

2 Overview - power transmission

2. Overview - power transmission 5

6 Rep. Gr.00 - Technical data

1) Z1 = No. of teeth on driving gear, Z2 = No. of teeth on driven gear

3. Calculating overall gear ratio “i” 7

4 General repair notes

4.1 Components n AG. Volkswagen AG

♦ When installing the manual gearbox, ensure that the dowel

sleeves between the engine and gearbox are correctly seated.

clean the contact surfaces. Contact surfaces must be free of

wax and grease.

catalogue “ETKA” . t to the co

♦ If the gearbox is repaired, fill with gear oil.

dismantled partially dismantled

4.1.2 O-rings, seals, gaskets and sealants

♦ Thoroughly clean housing joint surfaces before applying seal‐

8 Rep. Gr.00 - Technical data

4.1.3 Locking devices

4.1.4 Nuts and bolts

♦ Threads of bolts secured with locking fluid must be cleaned

with a wire brush. Then insert bolts with locking fluid -

AMV 185 101 A1- . spec

♦ Clean threaded holes in which self-locking bolts or bolts with

locking fluid have been inserted, e.g. with a thread chaser.

wards fitting tool.

♦ Lubricate all gearbox bearings with gear oil before installing.

♦ Tapered roller bearings fitted to one shaft must be renewed as

a set. Use same make of bearings.