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VW - VW Golf Mk5 2004 2009, Golf Plus Mk5 2005 2009, Passat 2006 5-Speed Manual Gearbox 0A4 - Workshop Manual (2010) PDF
VW - VW Golf Mk5 2004 2009, Golf Plus Mk5 2005 2009, Passat 2006 5-Speed Manual Gearbox 0A4 - Workshop Manual (2010) PDF
Workshop Manual
Golf 2004 ➤ , Golf 2009 ➤ ,
Golf Plus 2005 ➤ , Golf Plus 2009 ➤ ,
Passat 2006 ➤
5-speed manual gearbox 0A4
Edition 04.2010
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00 - Technical data
30 - Clutch
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34 - Controls, housing
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35 - Gears, shafts
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39 - Final drive - differential
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Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.
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00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
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1 Gearbox identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
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1.1 Location on gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
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1.2 hole
Identification codes, assembly allocation, capacities, Golf 2004 ▸ . . . . . . . . . . . . . . . . . . 2
spec
1.3 Identification codes, assembly allocation, capacities, Golf 2009 ▸ . . . . . . . . . . . . . . . . . . 4
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1.4 Identification codes, assembly allocation, capacities, Golf Plus 2005 ▸ . . . . . . . . . . . . . . 5
1.5 Identification codes, assembly allocation, capacities, Golf Plus 2009 ▸ . . . . . . . . . . . . . . 6
1.6 Identification codes, assembly allocation and capacities, Passat 2006 ▸ . . . . . . . . . . . . . . 6
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2 Overview - power transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
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4.1 Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
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30 - Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
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1.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
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1.3 Removing and installing over-centre spring, Golf 2004 ▸ . . . . . . . . . . . . . . . . . . . . . . . . . . 18
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1.4 Removing and installing over-centre spring, Golf 2009 ▸ LHD . . . . . . . . . . . . . . . . . . . . . . 22
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1.5 Removing and installing over-centre spring, Golf 2009 ▸ RHD . . . . . . . . . . . . . . . . . . . . . .
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27
1.6 Removing and installing over-centre spring, Golf Plus . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
1.7 Removing and installing over-centre spring, Passat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
1.8 Removing and installing clutch pedal, Golf 2004 ▸ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
1.9 Removing and installing clutch pedal, Golf 2009 ▸ LHD . . . . . . . . . . . . . . . . . . . . . . . . . . 44
1.10 Removing and installing clutch pedal, Golf 2009 ▸ RHD . . . . . . . . . . . . . . . . . . . . . . . . . . 49
1.11 Removing and installing clutch pedal, Golf Plus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
1.12 Removing and installing clutch pedal, Passat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
1.13 Removing and installing mounting bracket, Golf 2004 ▸ . . . . . . . . . . . . . . . . . . . . . . . . . . 61
1.14 Removing and installing mounting bracket, Golf 2009 ▸ LHD . . . . . . . . . . . . . . . . . . . . . . 67
1.15 Removing and installing mounting bracket, Golf 2009 ▸ right-hand drive and Golf Plus right-
hand drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
1.16 Removing and installing mounting bracket, Golf Plus left-hand drive . . . . . . . . . . . . . . . . 79
1.17 Removing and installing mounting bracket, Passat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
1.18 Removing and installing master cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
1.19 Removing and installing clutch position sender G476 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
1.20 Assembly overview - hydraulics (LHD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
1.21 Assembly overview - hydraulics (RHD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
2 Removing and installing slave cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
2.1 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
2.2 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
2.3 Torque settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
3 Bleeding clutch system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
4 Repairing clutch release mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
5 Repairing clutch, in conjunction with dual-mass flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . 105
5.1 Identifying make of clutch, vehicles with 1.9 l - 66 kW turbo diesel engine and vehicles with
1.9 l - 77 kW turbo diesel engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
5.2 Removing and installing Sachs clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
5.3 Repairing Sachs clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
5.4 Removing and installing LuK clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
5.5 Repairing LuK clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
6 Repairing clutch, in conjunction with one-piece flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Contents i
Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus 2009 ➤ , Pass ...
5-speed manual gearbox 0A4 - Edition 04.2010
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1.8 Repairing gear lever and selector housing (from 11.06) . . . . . . . . . . . . . . . . . . . . . . . . . . 125
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1.9 Assembly overview - removing and installing selector cables . . . . . . . . . . . . . . . . . . . . . . 131
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1.10 Plastic relay lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
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2.1 Removing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
2.2 Installing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
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3 Removing and installing gearbox, Golf 2009 ▸ with turbo diesel engine . . . . . . . . . . . . . . 156
3.1 Removing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
s
3.2 Installing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
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4 Removing and installing gearbox, Golf 2009 ▸ with petrol engine . . . . . . . . . . . . . . . . . . . . 171
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5 Removing and installing gearbox, Golf Plus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
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5.2 Installing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
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6 Removing and installing gearbox, Passat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
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6.1 Removing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
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6.2 Installing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
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7 Transporting gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
Prote AG.
ii Contents
Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus 2009 ➤ , Pass ...
5-speed manual gearbox 0A4 - Edition 04.2010
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Contents iii
Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus 2009 ➤ , Pass ...
5-speed manual gearbox 0A4 - Edition 04.2010
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Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus 2009 ➤ , Pass ...
5-speed manual gearbox 0A4 - Edition 04.2010
00 – Technical data
1 Gearbox identification
5-speed manual gearbox 0A4 is installed in following vehicles:
Allocation, Golf 2004 ▸ ⇒ page 2
Allocation, Golf 2009 ▸ ⇒ page 4
Allocation, Golf Plus 2005 ▸ ⇒ page 5
Allocation, Golf Plus 2009 ▸ ⇒ page 6
Allocation, Passat 2006 ▸ ⇒ page 6
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Identification Day Month Year (2003)
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1. Gearbox identification 1
Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus 2009 ➤ , Pass ...
5-speed manual gearbox 0A4 - Edition 04.2010
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Allocation Engine 1.9 l - 77 kW 1.8 l - 110 kW 1.9 l - 77 kW
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turbo diesel turbo diesel
Ratio Final drive 61 : 18 = 3.778 63 : 16 = 3.938 61 : 18 = 3.778
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Capacity of manual gearbox (gear‐ 1.9 l 1.9 l 1.9 l
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Capacity of manual gearbox 1.7 l 1.7 l 1.7 l
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♦ Clutch allocation
1. Gearbox identification 3
Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus 2009 ➤ , Pass ...
5-speed manual gearbox 0A4 - Edition 04.2010
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Capacity of manual gear‐ 1.9 l 1.9 l
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Drive shaft flange ∅ 100 mm 100 mm
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♦ Individual gear ratios
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Allocation Engine 1.9 l - 81 kW 2.0 l - 81 kW 1.6 l - 66 kW
turbo diesel turbo diesel turbo diesel
1.6 l - 77 kW
turbo diesel
Ratio Final drive 61 : 18 = 3.778 61 : 18 = 3.778 62 : 17 = 3.647
Z1 : Z2
Capacity of manual gear‐ 1.9 l 1.9 l 1.9 l
box (gearbox completely
dismantled)
Capacity of manual gear‐ 1.7 l 1.7 l 1.7 l
box ⇒ page 220 (gearbox
partially dismantled)
Drive shaft flange ∅ 100 mm 100 mm 100 mm
The following data can be found in the ⇒ Electronic parts cata‐
logue “ETKA” .
♦ Individual gear ratios
♦ Gear oil
♦ Clutch allocation
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Ratio Final drive 61 : 18 = 3.778 61 : 18 = 3.778
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♦ Clutch allocation
1. Gearbox identification 5
Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus 2009 ➤ , Pass ...
5-speed manual gearbox 0A4 - Edition 04.2010
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Manufactured from 01.09 02.09 05.09
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Allocation Engine 2.0 l - 81 kW 1.6 l - 66 kW 1.9 l - 77 kW
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Identification code Prote
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Manufac‐ from 01.08 11.08 08.09
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Allocation Engine 1.9 l - 77 kW 2.0 l - 81 kW 2.0 l - 81 kW
turbo diesel turbo diesel turbo diesel
1.6 l - 77 kW 1.6 l - 77 kW
turbo diesel turbo diesel
1. Gearbox identification 7
Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus 2009 ➤ , Pass ...
5-speed manual gearbox 0A4 - Edition 04.2010
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Capacity of manual 1.9 l 1.9 l 1.9 l
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2 - Clutch
3 - Manual gearbox
4 - Input shaft
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Gears
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Overall ratio = total ratio = iG x iA = 0.744
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1) Z1 = No. of teeth on driving gear, Z2 = No. of teeth on driven gear
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4.1 Components
4.1.1 Gearbox
♦ When installing the manual gearbox, ensure that the dowel
sleeves between the engine and gearbox are correctly seated.
♦ When installing mounting brackets or waxed components,
clean the contact surfaces. Contact surfaces must be free of
wax and grease.
♦ Allocate bolts and other components using ⇒ Electronic parts
catalogue “ETKA” .
♦ If the gearbox is repaired, fill with gear oil.
Capacity, gearbox completely Capacity, gearbox partially dis‐
dismantled mantled ⇒ page 220
1.9 l 1.7 l
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4.1.3 Sealant
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♦ Evenly apply a thin coat of sealing paste -AMV 188 200 03- .
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Rep. Gr.00 - Technical data Prote AG.
Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus 2009 ➤ , Pass ...
5-speed manual gearbox 0A4 - Edition 04.2010
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♦ Loosen and tighten securing bolts and nuts for covers and
spec
urposes, in part or in wh
housings diagonally.
t to the co
♦ Do not cant especially delicate parts, such as clutch pressure
plates. Loosen and tighten bolts and nuts in stages in a diag‐
onal sequence.
rrectne
♦ Torque settings are specified for unoiled bolts and nuts.
ss
♦ Always renew self-locking bolts and nuts.
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4.1.7 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.
4.1.8 Synchro-rings
♦ Do not interchange. When reusing synchro-rings, always fit to
the same synchromeshed gear.
♦ Check for wear and renew if necessary.
♦ Check grooves -arrow 1- 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”, “signs of abnormal wear” and
“blue discolouration (due to overheating)”.
♦ 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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♦ Before installing, clean and heat with the inductive heater -
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VAS 6414- to maximum 100° C.
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4.1.10 Synchromeshed gears
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4.1.11 Clutch
♦ Ensure that the pressure plate does not cant: loosen and tight‐
rrectness of i
en bolts diagonally and in several gradual stages.
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♦ If the clutch has burnt out, thoroughly clean the clutch housing
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30 – Clutch
1 Repairing clutch mechanismlkswagen AG. Volkswagen AG does no
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♦ Before disconnecting battery, obtain code for radio having anti-theft coding.
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♦ With ignition switched off, disconnect battery ⇒ Electrical system; Rep. Gr. 27 ; Disconnecting and con‐
hole
spec
necting battery .
es, in part or in w
t to the co
♦ When reconnecting battery, refer to ⇒ Electrical system; Rep. Gr. 27 ; Disconnecting and connecting
battery .
rrectness of i
♦ Grease all bearing points and contact surfaces.
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cluster ⇒ page 16
com
tion in
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draulics (LHD) ⇒ page 94
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❑ Always renew
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❑ Bond to mounting
hole
spec
bracket
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3 - Mounting bracket
❑ For mounting clutch
pedal
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❑ Is provided with damp‐
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⇒ page 61
om
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⇒ page 67
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Co
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⇒ page 73
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❑ Removing and instal‐
ling, Golf Plus left-hand
drive ⇒ page 79
❑ Removing and instal‐
ling, Passat
⇒ page 84
4 - Bolt
5 - Over-centre spring
❑ Removing and installing, Golf 2004 ▸ ⇒ page 18
❑ Removing and installing, Golf 2009 ▸ LHD ⇒ page 22
❑ Removing and installing, Golf 2009 ▸ RHD ⇒ page 27
❑ Removing and installing, Golf Plus ⇒ page 32
❑ Removing and installing, Passat ⇒ page 37
6 - Bearing bush
7 - Pivot pin
8 - Clutch pedal
❑ Removing and installing, Golf 2004 ▸ ⇒ page 38
❑ Removing and installing, Golf 2009 ▸ LHD ⇒ page 44
❑ Removing and installing, Golf 2009 ▸ RHD ⇒ page 49
❑ Removing and installing, Golf Plus ⇒ page 54
❑ Removing and installing, Passat ⇒ page 59
9 - Retainer
❑ To remove and install, separate master cylinder from clutch pedal (⇒ Removing and installing clutch
pedal)
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17 - Stop
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Mounting bracket with damping -arrows-
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1.3.1 Removing
– 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 cable guide -2- from steering column.
– Remove footwell vent -3-.⇒ Heating, air conditioning; Rep.
Gr. 80 ; Repairing heating
The crash bar -1- in front of clutch pedal -2- may be secured in
different ways.
Attachment with 2 bolts
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nut -2- and pulling out bolt -5-.
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inder.
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– Swing clutch pedal down slightly and remove over-centre
spring -4- from mounting bracket.
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Install in the reverse order of removal, observing the following:
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– Receptacle -arrow- for tip -A- of clutch pedal must stand ver‐
tically.
nf
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– Insert tip of clutch pedal in bearing recess of over-centre
rm
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– Install crash bar -1- and tighten the 2 bolts to specified torque
⇒ page 22 .
Attachment with 1 bolt
– Install crash bar -1- and tighten bolt -2- to specified torque
⇒ page 22 .
– Install trim and cover below trim on drive side ⇒ General body
repairs, interior; Rep. Gr. 68 .
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1.4.1 Removing
Vehicles with knee airbag
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Continuation for all
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1.4.2 Installing
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– Receptacle -arrow- for tip -A- of clutch pedal must stand ver‐
tically.
– Insert tip of clutch pedal -1- in bearing recess of over-centre
spring.
– Depress clutch pedal slightly, push bolt through and tighten
self-locking nut to specified torque ⇒ page 27 .
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Rep. Gr.30 - Clutch
Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus 2009 ➤ , Pass ...
5-speed manual gearbox 0A4 - Edition 04.2010
– Install crash bar -1- and tighten bolt -2- to specified torque
⇒ page 27 .
Continuation for all
pt
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Component Nm
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bracket
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♦ Pliers -T10005-
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– First check whether a coded radio
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ss
– With ignition switched off, disconnect battery ⇒ Electrical sys‐
ce
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– Push driver seat as far back as possible and put steering wheel
ab
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– Remove trim and cover below trim on driver side ⇒ Body Re‐
h re
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29
c by lksw
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Prote AG. 1. Repairing clutch mechanism
Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus 2009 ➤ , Pass ...
5-speed manual gearbox 0A4 - Edition 04.2010
Note
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1.5.2 Installing
Install in the reverse order of removal, observing the following:
rrectness of i
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spec
urposes, in part or in wh
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– Receptacle -arrow- for tip -A- of clutch pedal must stand ver‐
rrectne
tically.
s
– Insert tip of clutch pedal -1- in bearing recess of over-centre
s o
spring.
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– Depress clutch pedal slightly, push bolt through and tighten
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– Mount cable guide -2- on steering column.
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– Install foot well vent -3-.⇒ Rep. Gr. 80
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– Install bracket for knee airbag ⇒ Interior equipment; Rep. Gr.
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69 ; Airbag; Removing and installing knee airbag bracket (Golf
hole
spec
2009 ▸) .
es, in part or in w
t to the co
– Install trim and cover below trim on drive side ⇒ General body
repairs, interior; Rep. Gr. 68 .
– If disconnected, connect battery ⇒ Electrical system; Rep. Gr.
rrectness of i
27 ; Removing and installing battery .
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Component Nm
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Clutch pedal to mounting bracket 25
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Crash bar to steering column mounting 20
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1.6.1 Removing
– Push driver seat as far back as possible and put steering wheel
in highest position.
– Now remove crash bar -A- from in front of clutch pedal by re‐
moving bolt -B-. G. Volkswagen A AG do
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– Remove bolt -1- and pull universal joint -2- from steering box.
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1.6.2 Installing
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– Insert over-centre spring in mounting bracket from above.
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– Fit universal joint -2- to steering box and screw in new bolt
-1- ⇒ Running gear, axles, steering; Rep. Gr. 48 ; Assembly
overview - Steering .
– Carry out basic setting for steering angle sender -G85- with
vehicle diagnosis, testing and information system -VAS
5051- .
– Install trim and cover below trim on drive side ⇒ General body
repairs, interior; Rep. Gr. 68 .
Component Nm
Crash bar to steering column mounting Bolt M8 = 20
bracket
♦ Renew bolts for crash bar
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1.7.1 Removing
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– Remove mounting bracket ⇒ page 84 .
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– Press over-centre spring from clutch pedal -arrow 1- while
swinging mounting bracket in -direction of arrow 2-.
rrectness of i
– Carefully release tension from over-centre spring.
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• Clutch pedal is separated from master cylinder.
o Vo
by c lksw
cted agen
Prote AG.
– Carefully clamp lower section of clutch pedal in vice having
protective jaw pads.
– Insert over-centre spring in mounting bracket.
– Receptacle -arrow- for tip -A- of clutch pedal must stand ver‐
tically.
– Apply release tool -T10178- to middle of over-centre spring
and swing up mounting bracket.
WARNING
pt
du
an
y li
erm
ab
ility
ot p
Golf 2004 ▸
h re
hole
spec
t to the co
♦ Pliers -T10005-
rrectness of i
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.
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
♦ Torque wrench -V.A.G 1331-
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
co lksw
by
cted agen
Prote AG.
1.8.1 Removing
– 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 cable guide -2- from steering column.
– Remove footwell vent -3-.⇒ Heating, air conditioning; Rep.
Gr. 80 ; Repairing heating
The crash bar -1- in front of clutch pedal -2- may be secured in
different ways.
Attachment with 2 bolts
. Volkswagen AG
gen AG does
swa
– To do this, remove lock washers y V -A- for damping.
o lk not
gu
edb ara
is nte
– Pull off damping. hor eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
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.
– Push damping upwards in area of upper securing nut -1- AG. Volkswagen AG d
agen
above clutch pedal -A- in -direction of arrow-. V olksw
oes
not
g y ua
db ran
rise tee
tho or
au ac
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
atio
m
n
c
i
or
n thi
– Swing clutch pedal forward slightly and remove over-centre
te
sd
a
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
1.8.2 Installing
Install in the reverse order of removal, observing the following:
Note
olkswagen AG
en AG. V
– Insert over-centre spring -2- in mounting bracket fromolabove
ksw
ag does
not
while holding end of spring with assembly tool -T10178-
ed
by V
in in‐ gu
ara
stallation position. ho
ris nte
eo
t
au ra
c
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
t
– Receptacle -arrow- for tip -A- of clutch pedal -1- must be ver‐
ion in
tical.
r
te o
thi
s
iva
spring.
um
fo
en
ng
t.
yi
– Depress clutch pedal slightly, push bolt through and tighten
Co
op py
self-locking nut to specified torque ⇒ page 43 . t. C rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
ce
e
nl
Some cars have damping -arrow- on the clutch pedal mounting
pt
du
an
bracket.
itte
y li
erm
ab
– Return it to installation position.
ility
ot p
wit
, is n
The crash bar -1- in front of clutch pedal -2- may be secured in
h re
different ways.
hole
spec
es, in part or in w
Attachment with 2 bolts
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
– Install crash bar -1- and tighten the 2 bolts to specified torque
t.
yi Co
op
⇒ page 43 . C py
t. rig
gh ht
yri by
Attachment with 1 bolt
op Vo
by c lksw
cted agen
Prote AG.
– Install crash bar -1- and tighten bolt -2- to specified torque
⇒ page 43 .
– Install trim and cover below trim on drive side ⇒ General body
repairs, interior; Rep. Gr. 68 .
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
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
♦ Torque wrench -V.A.G 1331-
urposes, in part or in wh
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
1.9.1 Removing
fo
en
ng
t.
yi Co
op
Vehicles with knee airbag
C py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Note
Prote AG.
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
If fitted, remove damping -arrow- from lower area of clutch pedal
an
d
itte
y li
mounting bracket.
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectne
– Push damping upwards in area of upper securing nut -1-
above clutch pedal -A- in -direction of arrow-.
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
is nte
1.9.2 Installing or eo
h
aut ra
ss c
Install in the reverse order of removal, observing the following:
ce
e
nl
pt
du
an
itte
y li
erm
ab
Note
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Press retainer into notch in clutch pedal -3- until it can be heard
to engage.
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
or
en
ng
t.
yi
while holding end of spring with assembly tool -T10178- in in‐
Co
op py
stallation position.
. C rig
ht ht
rig by
copy Vo
by lksw
cted agen
Prote AG.
ce
le
un
pt
tical.
an
d
itte
y li
erm
– Insert tip -A- of clutch pedal in bearing recess of over-centre
ab
ility
spring.
ot p
wit
– Depress clutch pedal slightly, push bolt through and tighten is n
h re
ole,
self-locking nut to specified torque ⇒ page 49 .
spec
urposes, in part or in wh
t to the co
rrectness o
Some cars have damping -arrow- on the clutch pedal mounting
cial p
f in
bracket.
form
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Install crash bar -1- and tighten bolt -2- to specified torque
⇒ page 49 .
Continuation for all
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
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
1.10.1 Removing
– First check whether a coded radio is fitted. If so, obtain anti-
theft code.
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
– Remove footwell vent -3-.⇒ Heating, air conditioning; Rep.
ot
wit
, is n
h re
hole
spec
– Remove crash bar -1- (bolt -2-).
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
thi
mounting bracket.
s
iva
do
r
rp
cum
fo
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
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
t to the co
– Swing clutch pedal forward slightly and remove over-centre
spring -4- from mounting bracket.
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.
1.10.2 Installing
Install in the reverse order of removal, observing the following:
Note
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se
– Insert over-centre spring -2- in mountingth bracket from above
o tee
or
while holding end of spring with assembly
ss
au
tool -T10178- in in‐ ac
stallation position.
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Receptacle -arrow- for tip -A- of clutch pedal must stand ver‐
tically.
– Insert tip of clutch pedal -1- in bearing recess of over-centre
spring.
– Depress clutch pedal slightly, push bolt through and tighten
self-locking nut to specified torque ⇒ page 54 .
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
– Install crash bar -1- and tighten bolt -2- to specified torque
m
⇒ page 54 .
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
co lksw
by
cted agen
Prote AG.
ce
Special tools and workshop equipment required e
nl
pt
du
an
itte
♦ Pliers -T10005-
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
♦ Torque wrench -V.A.G 1331-
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.
1.11.1 Removing
– 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 cable guide -2- from steering column.
– Remove footwell vent -3-.⇒ Heating, air conditioning; Rep.
Gr. 80 ; Repairing heating
ce
e
nl
pt
du
– Now remove crash bar -A- from in front of clutch pedal by re‐
an
itte
y li
moving bolt -B-.
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
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
– Remove footwell trim by removing nuts -arrows-. t. Cop py
rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Remove bolt -1- and pull universal joint -2- from steering box.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
– To do this, remove lock washers -A- for damping.
es, in part or in w
t to the co
– Pull off damping.
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
c
– Push damping upwards in area of upper securing nut -1-
um
for
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
1.11.2 Installing
h re
hole
spec
es, in part or in w
t to the co
Note
to engage.
m
a
com
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
ce
e
nl
pt
du
an
– Insert tip of clutch pedal in bearing recess of over-centre
itte
y li
spring.
erm
ab
ility
ot p
– Depress clutch pedal slightly, push bolt through and tighten
wit
, is n
self-locking nut to specified torque ⇒ page 59 .
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
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
co lksw
by
cted agen
Prote AG.
ce
e
nl
pt
-1- ⇒ Running gear, axles, steering; Rep. Gr. 48 ; Assembly
du
an
itte
overview - Steering .
y li
erm
ab
ility
– Carry out basic setting for steering angle sender -G85- with
ot p
wit
vehicle diagnosis, testing and information system -VAS
, is n
h re
5051- .
hole
spec
– Install trim and cover below trim on drive side ⇒ General body
es, in part or in w
t to the co
repairs, interior; Rep. Gr. 68 .
rrectness of i
l purpos
nform
ercia
Component Nm
m
at
om
ion
Clutch pedal to mounting bracket 25
c
in t
or
his
ate
do
priv
cum
Crash bar to steering column mounting Bolt M6 = 5
for
en
g
bracket
n
t.
yi Co
op py
Crash bar to steering column mounting Bolt M8 = 20
t. C rig
gh ht
bracket pyri by
Vo
co lksw
by
♦ Renew bolts for crash bar
cted agen
Prote AG.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
1.12.1 Removing
ot p
wit
, is n
h re
– Remove mounting bracket ⇒ page 84 .
hole
spec
– Carefully clamp mounting bracket in vice having protective jaw
es, in part or in w
t to the co
pads.
– Unbolt clutch pedal -1- from mounting bracket -3- by removing
nut -2- and pulling out bolt -5-.
rrectness of i
– Swing clutch pedal forward slightly and remove over-centre
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
co lksw
by
cted agen
Prote AG.
1.12.2 Installing
Install in the reverse order of removal, observing the following:
Note
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
Component Nm
m
tio
thi
s
iva
do
cum
fo
t.
yi Co
Cop py
Special tools and workshop equipment required
t. rig
gh ht
pyri by
Vo
o
♦ Hose clamps to 25 mm -3094-
c by lksw
cted agen
Prote AG.
ce
e
nl
♦ Torque wrench -V.A.G 1331-
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
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
co lksw
by
cted agen
Prote AG.
1.13.1 Removing
LHD
– First check whether a coded radio is fitted. If so, obtain anti-
theft code.
– With ignition switched off, disconnect battery ⇒ Electrical sys‐
tem; Rep. Gr. 27 ; Disconnecting and connecting battery .
– 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
ce
le
un
pt
– Release securing clip -2- using screwdriver or a pointed object
an
d
itte
y li
and pull pipe/hose line -1- off master cylinder.
rm
ab
pe
ility
– Unclip clutch position sender -G476- from master cylinder
ot
wit
, is n
h re
hole
spec
es, in part or in w
Note
t to the co
When performing work in the footwell, put cloths on the carpet to
rrectness of i
protect it from possible brake fluid spills.
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
cum
en
ng
t.
yi Co
– Remove cable guide -2- from steering column. Cop py
t. rig
gh ht
yri
– Remove footwell vent -3-.⇒ Heating, air conditioning; Rep. p by
o Vo
by c
Gr. 80 ; Repairing heating
lksw
cted agen
Prote AG.
The crash bar -1- in front of clutch pedal -2- may be secured in
different ways.
Attachment with 2 bolts
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectne
If fitted, remove damping -arrow- from lower area of clutch pedal
ss
mounting bracket.
o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
– Remove securing nuts -1- and -2-.
l purpos
The upper securing nut -1- is accessible between the relay carrier
and the steering column trim.
nform
ercia
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
co lksw
by
cted agen
Prote AG.
1.13.2 Installing
Install in the reverse order of removal, observing the following:
Note
ce
e
nl
pt
different ways.
du
an
itte
y li
Attachment with 2 bolts
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Install crash bar -1- and tighten the 2 bolts to specified torque
⇒ page 67 .
rrectness of i
Attachment with 1 bolt
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
op
– Install crash bar -1- and tighten bolt -2- to specified torque
C py
t. rig
gh
⇒ page 67 .
ht
pyri by
Vo
co lksw
by
– Install trim and cover below trim on drive side ⇒ General body
cted agen
Prote AG.
repairs, interior; Rep. Gr. 68 .
– Push pipe/hose line -1- with seal -2- onto connection of master
cylinder -4- until securing clip -3- engages audibly.
– Test pipe/hose line by tugging on it.
– After removing hose clamp -3094- , return supply hose to its
original position, if necessary.
– Bleed clutch system ⇒ page 101 .
LHD
– Install battery ⇒ Electrical system; Rep. Gr. 27 ; Removing
and installing 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 .
ce
le
un
pt
Crash bar to steering column mounting 10
an
d
itte
y li
bracket (attachment with 2 bolts)
erm
ab
ility
Crash bar to steering column mounting 20
ot p
wit
bracket (attachment with 1 bolt)
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
1.14 Removing and installing mounting
bracket, Golf 2009 ▸ LHD
rrectne
Special tools and workshop equipment required
s
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectnes
♦ Sealing tool -T10249-
s o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
1.14.1 Removing
– First check whether a coded radio is fitted. If so, obtain anti-
theft code.
– With ignition switched off, disconnect battery ⇒ Electrical sys‐
tem; Rep. Gr. 27 ; Disconnecting and connecting battery .
– 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 ; Removing and installing battery .
Note
Note
Note
olkswagen AG
en AG. V
The installation location
olks of the knee airbag is above
wag does
not the pedal
cluster. ed
byV gu
ara
ris nte
ho eo
aut ra
ss bracket c
– Remove for knee airbag together with crash bar ⇒
ce
le
pt
an
d
y li
rm
ab
ility
ot
wit
, is n
spec
es, in part or in w
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
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
y li
rm
ab
pe
ility
– Pull off damping.
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
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
1.14.2 Installing
rrectness of i
l purpos
nf
ercia
o
Note
rm
m
atio
om
n in
Renew self-locking nuts.
or c
thi
te
sd
iva
cu
bracket.
o
m
f
en
ng
t.
yi Co
Vehicles without knee airbag ht. Cop py
rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– Install crash bar -1- and tighten bolt -2- to specified torque
⇒ page 72 .
Continuation for all
– 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 -3094- , return supply hose to its
original position, if necessary. wage
n AG. Volkswagen AG do
e
olks s no
yV t gu
– Bleed clutch system ⇒ page 101 . edb ara
ris nte
– Install battery ⇒ Electrical system; ho Rep. Gr. 27 ; Removing eo
aut ra
and installing battery . ss c
ce
e
nl
pt
– If removed, install complete air filter housing ⇒ Rep. Gr. 23 ;
du
an
itte
y li
erm
ab
Repairing injection system
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
Component Nm
Mounting bracket to bulkhead 25
nform
ercia
at
om
bracket
in t
or
his
ate
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
Special tools and workshop equipment required
♦ Hose clamps to 25 mm -3094-
rrectne
♦ Sealing tool -T10249-
ss
♦ Hook -3438-
o
cial p
f in
♦ Torque wrench -V.A.G 1331-
form
mer
atio
1.15.1 Removing
om
n
c
i
or
n
Vehicles with knee airbag
thi
te
sd
iva
o
r
cum
r
fo
theft code.
en
ng
t.
yi Co
op
– With ignition switched off, disconnect battery ⇒ Electrical sys‐ C py
t. rig
tem; Rep. Gr. 27 ; Disconnecting and connecting battery .
gh ht
pyri by
Vo
co lksw
by
Vehicles with turbo diesel engine and particle filter cted agen
Prote AG.
Note
an
y li
erm
ab
ility
ot p
spec
Golf
es, in part or in w
t to the co
Note
nf
ercia
cluster.
m
m
atio
om
n in
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
co lksw
by
cted agen
Prote AG.
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
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
co lksw
by
cted agen
Prote AG.
– Push damping upwards in area of upper securing nut -1- AG. Volkswagen AG d
above clutch pedal -A- in -direction of arrow-. lksw
agen oes
not
Vo gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
or
– Remove securing nuts -1- and -2-.
m
m
atio
om
The upper securing nut -1- is accessible between the relay carrier
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.
1.15.2 Installing
Install in the reverse order of removal, observing the following:
Note
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
– Install crash bar -1- and tighten bolt -2- to specified torque
r
te o
thi
⇒ page 78 .
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Fit cable guide -2- onto steering column, secure with cable tie
-1- if necessary.
– Install footwell vent -3-.⇒ Heating, air conditioning; Rep. Gr.
80 ; Repairing heating
Golf
– Install bracket for knee airbag ⇒ Interior equipment; Rep. Gr.
69 ; Airbag; Removing and installing knee airbag bracket (Golf
2009 ▸) .
Continuation for all
– Install trim and cover below trim on drive side ⇒ General body
repairs, interior; Rep. Gr. 68 .
– Press pipe/hose line -2- with seal into connection of master
cylinder.
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
– If present, fold heat shield around the pipe/hose line
es, in part or in w
t to the co
-arrows-.
Vehicles with particle filter
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
or
en
ng
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f in
1.16.1 Removing
form
mer
atio
m
n
c
theft code.
i
or
n thi
te
sd
a
o
pr
en
ng
t.
yi
– Remove complete air filter housing if it is near battery ⇒ Rep.
Co
op py
Gr. 23 ; Repairing diesel direct injection system or ⇒ Rep.
. C rig
ht ht
rig
Gr. 24 ; Repairing injection system . py by
co Vo
by lksw
cted agen
Prote AG.
Note
ce
le
un
pt
-arrow- and remove with electrical connector attached -4-.
an
d
itte
y li
rm
ab
pe
ility
Note
ot
wit
, is n
h re
hole
spec
protect it from possible brake fluid spills.
es, in part or in w
t to the co
– Push driver seat as far back as possible and put steering wheel
in highest position.
rrectness of i
– Remove driver side compartment and cover ⇒ General body
l purpos
nform
ercia
a
com
tio
– Remove cable guide -2- from steering column. n in
r
te o
thi
do
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
If fitted, remove damping -arrow- from lower area of clutch pedal
an
d
itte
mounting bracket.
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi
– To do this, remove lock washers -A- for damping.
Co
Cop py
ht. rig
– Pull off damping. rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
. Volkswag
– Press wiring harnesssw-1-
ageupwards
n AG andenleft
AG d-arrow-
oes using ex‐
Volk
tension -2- fromby-V.A.G 1835- . not
gu
a d ran
ise
– While doing ho this, unbolt upper securing nut for mounting brack‐
r tee
ut or
et. ss
a ac
ce
le
– Then unbolt both lower securing nuts for mounting bracket and
un
pt
an
d
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
atio
1.16.2 Installing
om
n
c
i
or
sd
a
following:
iv
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
at
om
io
– Install footwell vent, cable guide, cover and compartment on
n
c
in t
r
his
e
do
priv
cum
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
– Push pipe/hose line -1- with seal -2- onto connection of master
cylinder -4- until securing clip -3- engages audibly.
– Test pipe/hose line by tugging on it.
– After removing hose clamp -3094- , return supply hose to its
original shape, if necessary.
– Bleed clutch system ⇒ page 101 .
– Install battery tray, battery cover and battery ⇒ Electrical sys‐
tem; Rep. Gr. 27 ; Removing and installing battery .
– If removed, install complete air filter housing ⇒ Rep. Gr. 23 ;
Repairing diesel direct injection system or ⇒ Rep. Gr. 24 ;
Repairing injection system
ce
e
nl
pt
du
1.16.3 Torque settings
an
itte
y li
erm
ab
Component Nm
ility
ot p
wit
, is n
Mounting bracket to bulkhead 25
h re
♦ Renew self-locking nuts
hole
spec
es, in part or in w
Crash bar to steering column mounting Bolt M6 = 5
t to the co
bracket
Crash bar to steering column mounting Bolt M8 = 20
rrectness of i
bracket
♦ Renew bolts for crash bar l purpos
nform
ercia
at
om
ion
c
in t
r
his
ate
do
riv
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
agen
1.17.1 Removing Volksw
oes
not
gu
d by ara
e
LHD horis nte
eo
aut ra
– First check whethersa coded radio is fitted. If so, obtain anti-
s c
theft code.
ce
le
un
pt
an
d
itte
y li
rm
ab
interior; Rep. Gr. 68 ; Compartments, covers and trim panels .
pe
ility
ot
wit
, is n
h re
tem; Rep. Gr. 27 ; Disconnecting and connecting battery .
hole
spec
– Remove complete air filter housing if it is near battery ⇒ Rep.
es, in part or in w
t to the co
Gr. 23 ; Repairing diesel direct injection system or ⇒ Rep.
Gr. 24 ; Repairing injection system .
– Remove battery and battery tray ⇒ Electrical system; Rep.
rrectness of i
Gr. 27 ; Battery; Removing and installing battery .
l purpos
Note
m
a
com
tion in
thi
cum
fo
t.
yi Co
Cop py
t. rig
– Clamp off supply hose to master cylinder using hose clamp gh ht
yri by
-3094- .
op Vo
by c lksw
cted agen
Prote AG.
– If necessary, loosen spring-type clip -3- with assembly tool -
VAS 5024- and pull supply hose off master cylinder.
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
– If present, remove retaining clip -1- and swing front parking aid
s
iva
do
warning buzzer -H22- -2- in -direction of arrow-.
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
1.17.2 Installing
es, in part or in w
t to the co
Install in reverse order of removal. During this step, observe the
following:
rrectness of i
l purpos
Note
nform
ercia
ion
c
his
e
logue “ETKA” .
at
do
priv
cum
or
en
ng
t.
yi
buzzer -H22- ⇒ Electrical system; Rep. Gr. 94 ; Parking aid .
Co
Cop py
ht. rig
– Install crash bar -1- and tighten bolt -2- to specified torque rig ht
py by
⇒ page 88 .
co Vo
by lksw
cted agen
Prote AG.
– Install lower steering column trim ⇒ General body repairs, in‐
terior; Rep. Gr. 68 ; Compartments, covers and trim panels .
– Install driver side footwell cover ⇒ General body repairs, in‐
terior; Rep. Gr. 68 ; Compartments, covers and trim panels .
– Push pipe/hose line -1- with seal -2- onto connection of master
cylinder -4- until securing clip -3- engages audibly.
– Test line by tugging on it.
– After removing hose clamp -3094- , return supply hose to its
original shape, if necessary.
– Bleed clutch system ⇒ page 101 .
LHD AG. Volkswagen AG d
agen oes
ksw
– Install battery tray, battery cover and battery ⇒ Electrical
by V sys‐
o l not
gu
ara
tem; Rep. Gr. 27 ; Removing and installing batteryris.e d
nte
tho eo
– If removed, install complete air filter housing ⇒
ss a Rep. Gr. 23 ;
u ra
c
Repairing diesel direct injection system or ⇒ Rep. Gr. 24 ;
ce
le
Repairing injection system un
pt
an
d
itte
y li
– Reconnect battery and perform work required after connecting
rm
ab
pe
ility
ot
connecting battery .
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
Component Nm
rrectness of i
Mounting bracket to bulkhead 25
l purpos
Crash bar 20
nform
ercia
a
com
tion in
1.18 Removing and installing master cylinder
r
te o
thi
s
iva
do
Special tools and workshop equipment required
r
rp
cum
fo
♦ Pliers -T10005-
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
1.18.1 Removing
– Remove mounting bracket, Golf 2004 ▸ ⇒ page 61 .
– Remove mounting bracket, Golf 2009 ▸ LHD ⇒ page 67 .
– Remove mounting bracket, Golf 2009 ▸ right-hand drive and
Golf Plus right-hand drive ⇒ page 73 .
– Remove mounting bracket, Golf Plus left-hand drive
⇒ page 79 .
– Remove mounting bracket, Passat ⇒ page 84
– 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).
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
1.18.2 Installing
rrectne
• Move clutch pedal to rest position at stop.
– Attach retainer -2- to master cylinder operating rod -1-.
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– 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).
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
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
– Install mounting bracket, Golf 2004 ▸ ⇒ page 61 .
– Install mounting bracket, Golf 2009 ▸ LHD ⇒ page 67 .
rrectne
– Install mounting bracket, Golf 2009 ▸ right-hand drive and Golf
Plus right-hand drive ⇒ page 73 .
ss o
cial p
f
– Install mounting bracket, Golf Plus left-hand drive
inform
⇒ page 79 .
mer
atio
m
n
c
i
or
n thi
te
sd
iva
o
1.19 Removing and installing clutch position
pr
cum
r
fo
en
sender -G476-
ng
t.
yi Co
Cop py
t. rig
Special tools and workshop equipment required opyri
gh by
Vo
ht
c lksw
♦ Hose clamps -3094-
by
cted agen
Prote AG.
1.19.1 Removing
LHD
– First check whether a coded radio is fitted. If so, obtain anti-
theft code.
– With ignition switched off, disconnect battery ⇒ Electrical sys‐
tem; Rep. Gr. 27 ; Disconnecting and connecting battery .
ce
e
nl
pt
du
– In vehicles with particle filter, remove shielding -A- from parti‐
an
itte
y li
cle filter ⇒ Rep. Gr. 26 ; Parts of exhaust system; Assembly
erm
ab
overview - front exhaust pipe with particle filter .
ility
ot p
wit
An insulation mat is installed in conjunction with some engines.
, is n
h re
Appearance may be different from that illustrated.
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
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.
Note
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
1.19.2 Installing
nform
ercia
a
com
tion in
r
te o
thi
Note
s
iva
do
r
rp
cum
fo
t.
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op
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filter ⇒ Rep. Gr. 26 ; Parts of exhaust system; Assembly
erm
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overview - front exhaust pipe with particle filter .
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spec
– Install battery tray and battery⇒ Electrical system; Rep. Gr.
urposes, in part or in wh
connecting battery .
inform
mer
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Passat ⇒ page 59
pt
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7 - Clutch pedal
erm
ab
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ling, Golf 2004 ▸
, is n
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⇒ page 38
hole
spec
❑ Removing and instal‐
es, in part or in w
9 - Seal / O-ring
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10 - Pipe/hose line
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❑ Allocation ⇒ Electronic parts catalogue “ETKA” opyri
gh by
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ht
❑ To remove, remove battery and battery tray ⇒ Electrical system; Rep. Gr. 27 ; Removing and installing by c lksw
cted agen
battery . Prote AG.
11 - Retainer
❑ Secured to body
12 - Seal / O-ring
❑ Pull onto line connection
❑ Insert with brake fluid.
ce
le
14 - Slave cylinder
un
pt
an
d
❑ Removing and installing ⇒ page 98
itte
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rm
ab
15 - Hexagon bolt ⇒ Item 9 (page 104) pe
ility
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16 - Bleeder valve
h re
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spec
es, in part or in w
17 - Dust cap
t to the co
18 - Gearbox
rrectness of i
19 - Retainer
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20 - Hexagon bolt, 20 Nm
nform
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a
com
tion in
Item Material of line connection
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1 Line connection with circumferential groove
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3 Line connection with shoulder -arrow 2- and cir‐
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• For line connection having circumferential groove -arrow 1- Prote AG.
and -arrow 3-, a seal or O-ring must be set there.
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5 - Clip
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6 - Seal / O-ring
❑ Pull onto line connection
rrectness of i
❑ Insert with brake fluid.
❑ Seals/O-rings are adap‐
l purpos
ted to configuration of
line connection
nform
ercia
⇒ page 95
m
❑ Allocation ⇒ Electronic
a
com
ti
parts catalogue “ETKA”
on in
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thi
7 - Retainer s
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der from clutch pedal (⇒
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❑ Golf 2004 ▸ ⇒ page 38 Prote
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22 - Gearbox
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23 - Retainer
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24 - Hexagon bolt, 20 Nm
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es, in part or in w
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97
AG.
1. Repairing clutch mechanism
Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus 2009 ➤ , Pass ...
5-speed manual gearbox 0A4 - Edition 04.2010
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an
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is n
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f inform
i
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– Pull securing clip -arrow 3- off relay lever -B- and remove relay
sd
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lever.
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– Then remove gearbox support -arrow A-.
rrectne
– Place a lint-free cloth under slave cylinder.
ss
– Pull clip for pipe/hose line out of slave cylinder to stop.
o
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– Pull pipe/hose line out of slave cylinder and seal opening.
form
mer
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n
c
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2.2 Installing
by c lksw
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♦ Brake filling and bleeding equipment -V.A.G 1869-
es, in part or in w
t to the co
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Specifications for brake fluid ⇒ Brake systems; Rep. Gr. 47 ;
Bleeding brake system .
– Remove complete air filter housing if it blocks access to bleed‐
er connection (-arrow-, figure below) ⇒ Rep. Gr. 23 ; Repair‐
ing diesel direct injection system or ⇒ Rep. Gr. 24 ; Repairing
injection system
– Connect brake filling and bleeding equipment -VAS 5234- or
-V.A.G 1869- .
To bleed system, use 670 mm bleeder hose -V.A.G 1238/B3- if
necessary.
– Connect bleeder hose to collector bottle of brake bleeding
equipment.
AG. Volkswagen AG d
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1 - Gearbox
2 - Ball stud, 25 Nm
❑ To remove and install,
remove gearbox
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❑ Remove old gen AG
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remove gearbox
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❑ Renewing
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4 - Guide sleeve
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O-ring together
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5 - Retaining spring
mer
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remove gearbox
i
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11 - Plunger
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12 - Assembly bolt
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❑ Secures clutch release lever when gearbox is installed.
wit
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❑ Remove after gearbox has been installed
h re
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spec
es, in part or in w
Note
t to the co
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Removing and installing release lever together with release bear‐
ing
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at
– Install in reverse order of removal.
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Removing and installing release bearing by c lksw
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Prote AG.
– Press together retaining hooks -arrows- on back of clutch re‐
lease lever and remove release bearing -A- from clutch re‐
lease lever.
– To install, press release bearing -A- into clutch release lever
until retaining hooks -arrows- engage.
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The make of the clutch can be determined as follows with the
rrectne
clutch installed:
s
f inform
mer
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n
c
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– Repairing Sachs clutch ⇒ page
Vol
ks109
wa . not
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Outer contour with edgeso-arrows
ris
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ferential crease -arrowa2-
u = LuK clutch = -B-
th
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5.2.1 Removing
• Remove gearbox.
– 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.
pt
du
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ab
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t to the co
orm
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107
co Vo
by lksw
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agen
Prote AG.
Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus 2009 ➤ , Pass ...
5-speed manual gearbox 0A4 - Edition 04.2010
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urposes, in part or in wh
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Checking spring connections and riveted connections
– Check spring connections between pressure plate and cover
rrectne
for cracks as well as rivet connections for secure seating.
ss o
cial p
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Note
inform
mer
atio
m
n
c
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or
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♦ Always renew pressure plate and clutch plate together.
te
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♦ Select clutch plate and pressure plate according to engine
um
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♦ If clutch has burnt out, thoroughly clean clutch housing, fly‐
C py
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wheel and parts of engine facing gearbox to reduce smell of
ht
pyri by
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burnt linings.
c by lksw
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♦ Clean input shaft splines and, on used clutch plates, clean hub
splines; remove corrosion and apply only a very thin coat of
clutch plate spline grease -G 000 100- to splines. Then move
clutch plate to and fro on input shaft until hub moves freely on
shaft. Remove excessive grease.
♦ Pressure plates are protected against corrosion and greased.
Clean contact surface only. Otherwise, the service life of the
clutch will be considerably reduced.
♦ Pressure plate contact surface and clutch plate lining must
make full contact with flywheel. Only then insert securing bolts.
ce
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nl
5.3 Repairing Sachs clutch
pt
du
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itte
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ab
ility
ot p
1 - Dual-mass flywheel
wit
, is n
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❑ Removing and installing
hole
⇒ Rep. Gr. 13
spec
es, in part or in w
❑ Ensure that centring
t to the co
pins fit tightly
❑ Contact surface for
clutch lining must be
rrectness of i
free of grooves, oil and
l purpos
grease
2 - Clutch plate
nform
❑ Allocation ⇒ Electronic mercia
parts catalogue “ETKA”
at
om
io
❑ Removing and installing
n
c
in t
or
⇒ page 107
his
ate
do
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cum
with pressure plate
for
en
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t.
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❑ Installation position
Co
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⇒ page 107 t. C rig
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3 - Pressure plate
co Vo
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❑ Allocation ⇒ Electronic
AG.
5.4.1 Removing
• Remove gearbox.
– Use counterhold -3067- to loosen bolts.
– Loosen bolts in small steps and diagonally.
– Remove pressure plate and clutch plate.
5.4.2 Installing
Install in the reverse order of removal, observing the following:
Note
pt
du
an
itte
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erm
ab
ility
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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
ng
t.
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Cop py
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Prote AG.
Note
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♦ Pressure plate contact surface and clutch plate lining must
erm
ab
make full contact with flywheel. Only then insert securing bolts.
ility
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hole
spec
es, in part or in w
t to the co
– To centre clutch plate, use centring mandrel -3190 A- .
– Tighten all bolts evenly by hand until bolt heads contact pres‐ rrectness of i
sure plate.
l purpos
mass flywheel.
m
at
ion
c
in t
r
• Install gearbox.
o
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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
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by c lksw
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Prote AG.
1 - Dual-mass flywheel
❑ Removing and installing
⇒ 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
❑ Allocation ⇒ Electronic
parts catalogue “ETKA”
❑ Removing and installing
⇒ page 109
❑ Renew only together
with SAC pressure plate
❑ Installation position:
⇒ page 110
3 - SAC pressure plate
❑ SAC means “self-ad‐
justing clutch”
❑ Renew only together
with clutch plate
❑ Allocation ⇒ Electronic
parts catalogue “ETKA”
❑ Removing and installing
⇒ page 109
❑ Check ends of dia‐
phragm spring AG. Volkswagen AG d
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connections ss
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⇒ page 110
nl
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❑ Checking position of adjusting mechanism with new pressure plates only ⇒ page 111
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c
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ate
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priv
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AG. Volkswagen AG d
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es, in part or in w
t to the co
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• Remove gearbox.
nf
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Note
rm
m
atio
om
♦ Renew clutch plates and pressure plates with damaged or loose rivets.
n in
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♦ Select clutch plate and pressure plate according to ⇒ Electronic parts catalogue (ETKA) and engine code.
t
sd
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♦ Check whether dowel sleeves for aligning engine and gearbox are fitted in cylinder block and install if nec‐
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essary.
t.
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♦ If dowel sleeves are not fitted, difficulties shifting gears, clutch problems and possible noises from the gear‐
t. rig
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box (rattling of gears which are not engaged) could occur.
p by
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by c lksw
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Prote AG.
1 - Flywheel
❑ Removing and installing
⇒ Rep. Gr. 13
❑ Ensure that centring
pins fit tightly
❑ Keep contact surface for
clutch lining free of
grooves, oil and grease.
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❑ Allocation ⇒ Electronic byV ua
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❑ Installation position: ss
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ce
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pt
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❑ Centring ⇒ page 114
erm
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❑ Lightly grease splines
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Note
hole
spec
es, in part or in w
t to the co
3 - Pressure plate
❑ Removing and installing
⇒ page 114
rrectness of i
❑ Check ends of dia‐
l purpos
phragm spring
⇒ page 115
nform
ercia
at
connections
om
ion
⇒ page 115
c
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or
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Note
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4 - M6 bolt, 13 Nm, M7 bolt, Cop py
20 Nm
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❑ Determine according to ⇒ Electronic parts catalogue (ETKA)
co Vo
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Prote
❑ Loosen or tighten diagonally and in steps
AG.
Note
Pressure plate contact surface and clutch plate lining must make
full contact with flywheel. Tighten securing bolts diagonally and
evenly to prevent damage to the pressure plate centring hole and
the flywheel centring pins.
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c
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ate
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34 – Controls, housing
1 Repairing selector mechanism
AG. Volkswagen AG d
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I - Removing and installing
ility
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⇒ page 118
is n
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spec
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t to the co
10.06) ⇒ page 123
II - Repairing gear lever and
selector housing (from 11.06)
rrectne
⇒ page 125
s
III - Assembly overview - re‐
s o
f in
n
c
i
or
n thi
te
o
r
⇒ page 139 .
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Prote AG.
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
❑ Removing and instal‐
ling, Golf ⇒ page 118
❑ Removing and instal‐
ling, Golf Plus
⇒ page 120
❑ Removing and instal‐
ling, Passat AG. Volkswagen AG d
agen
⇒ page 121 olksw
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3 - Clamp orise nte
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⇒ Item 2 (page 118) us‐
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V.A.G 1275-
wit
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❑ Always renew
hole
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t to the co
sole
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5 - Noise insulation
❑ Not fitted in all vehicles
nform
ercia
ion
in t
or
his
ate
do
priv
cum
or
en
ng
t.
yi Co
knob and noise insulation, Golf Cop py
ht. rig
rig ht
py by
Special tools and workshop equipment required co Vo
by lksw
cted agen
Prote AG.
Removing
– Pull or carefully lever gaiter upwards out of centre console
frame -arrows-.
With some equipment variations, the gaiter must be levered off
along the front section.
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
ce
le
pt
an
d
itte
y li
The gear knob must be pressed to stop.
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
– Install gear knob and gaiter and squeeze new clamp -arrow-
together.
rrectne
– Then press gaiter into frame of centre console.
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi
1.5 Removing and installing gaiter with gear
Co
Cop py
. rig
knob and noise insulation, Golf Plus
ht ht
rig by
copy Vo
by lksw
cted
Special tools and workshop equipment required
agen
Prote AG.
Removing
– Pull or carefully lever gaiter upwards out of centre console
frame -arrows-.
With some equipment variations, the gaiter must be levered off
along the front section.
ce
e
nl
Installing
pt
du
an
itte
y li
– First set noise insulation in place.
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
Installation position of noise insulation:
rrectness of i
-Arrow A- points in direction of travel.
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
ht
– Install gear knob and gaiter and squeeze new clamp -arrow-
rig by
opy Vo
together. by c lksw
cted agen
Prote AG.
When gear knob is pushed on, it must engage in circumferential
groove in gear lever.
– Then press gaiter into centre console.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
Removing
es, in part or in w
t to the co
– Open ashtray.
– Pull gaiter with plastic frame out of centre console frame -1-
rrectness of i
-arrow-.
l purpos
nform
ercia
at
apart.
om
ion
c
in t
– Pull gaiter upwards, inside out over gear knob.
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Open clamp -arrow- and pull off gear knob together with gaiter.
– Pull off noise insulation.
Installing
– First set noise insulation in place.
– Install gear knob and gaiter and squeeze new clamp -arrow-
together.
– Insert back of gaiter with plastic frame first.
Note
ce
le
3 - Compression spring
un
pt
an
d
itte
4 - Bush
y li
rm
ab
pe
wit
, is n
6 - Cover
h re
hole
spec
7 - Damping
es, in part or in w
t to the co
8 - Damping
9 - Ball socket
rrectness of i
11 - Damping washer
12 - Seal
nform
ercia
tion in
❑ Self-adhesive
r
te o
thi
s
iva
ing
cum
fo
en
ng
t.
13 - Gear lever
yi Co
Cop py
t. rig
14 - Selector housing gh ht
pyri by
Vo
co lksw
by
15 - Bearing bush Prote
cted AG.
agen
16 - Pivot pin
17 - Guide bush
18 - Compression spring
❑ Installing ⇒ page 124
pt
du
an
– Remove securing clip from gear selector cable -A- and gate
itte
y li
ab
ility
ot p
spec
t to the co
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
en
ng
t.
yi Co
op
– Insert compression spring so that extension -A- lies on top of C py
t. rig
pin -arrow-. gh ht
pyri by
Vo
o
by c lksw
– Then pull extension -B- down so that it sits below pin -arrow-. Prote
cted AG.
agen
Note
1 - Base plate
❑ Bend open tabs to re‐
move
❑ Always renew
2 - Seal
❑ Always renew
3 - Gear lever n AG. Volkswagen AG do
lkswage es n
o ot g
❑ Can be removed and in‐ byV ua
d ran
stalled with gear lever ir se tee
tho
guide au or
ac
⇒ Item 15 (page 126) ss
ce
le
installed
un
pt
an
d
itte
y li
4 - Damping washer
erm
ab
ility
❑ Push onto gear lever up
ot p
wit
to stop -arrow-
is n
h re
ole,
5 - Securing clip
spec
urposes, in part or in wh
t to the co
when removing
❑ Always renew
rrectne
6 - Gate selector cable
❑ Lever off gate selector
ss
lever
o
cial p
f i
❑ Press onto gate selector
nform
mechanism
atio
om
n
c
❑ Installation position
i
or
n thi
⇒ page 116
te
sd
iva
o
r
7 - Bush
p
cum
r
fo
en
ng
13 - Compression spring
14 - Bush
15 - Gear lever guide
16 - Hexagon nut M8, 25 Nm, hexagon nut M 6, 8 Nm
❑ Qty. 4
17 - Seal
❑ Between selector housing and underbody
❑ Self-adhesive
❑ Bond to selector housing
18 - Selector housing
❑ With compression spring and gate selector lever
❑ Compression spring and gate selector lever cannot be removed
Note
pt
an
d
itte
mechanism
y li
erm
ab
ility
ot p
h re
♦
ole,
spec
urposes, in part or in wh
Dismantling
– Remove selector mechanism ⇒ page 136 .
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
ce
e
nl
pt
– Use screwdriver to press catches -arrows- of ball socket to‐
du
an
itte
y li
erm
ab
necessary.
ility
ot p
wit
– Lever ball socket -A- with gear lever guide -B- out of selector
, is n
h re
housing.
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
– Then press ball socket off bearing ball of gear lever guide and
remove it.
m
at
om
io
• Please pay attention to guides -A- during the further proce‐
n
c
in t
r
dure.
o
his
ate
do
riv
cum
for
en
ng
t.
yi
– Lever lower end -arrow 1- of compression spring onto shoulder
Co
op py
on gate selector lever as far as stop.
. C rig
ht ht
rig by
copy Vo
by lksw
cted agen
Prote AG.
– Now pull gear lever guide up to stop and pull ball stud out of
gate selector lever -arrow 2-.
Caution
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
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
op py
– Place selector housing with gear lever guide into larger recess t. C rig
gh ht
-arrow- in thrust piece -T10083- . yri
p by
o Vo
by c lksw
cted agen
Prote AG.
ce
le
un
pt
an
d
itte
y li
rm
ab
Note
pe
ility
ot
wit
, is n
For clarity of illustration, only part of the gate selector lever is
h re
hole
shown.
spec
es, in part or in w
t to the co
– Insert end -A- of compression spring into guide from above.
– Pull end -B- of compression spring downwards and insert it
rrectness of i
next to guide (in direction of ball joint).
l purpos
• Please pay attention to guides (⇒ figure above) during the fur‐
ther procedure.
nform
ercia
a
com
tio
thrust piece -T10083- .
n in
r
te o
thi
s
iva
do
r
rp
c
holes for gear and gate selector cable) -arrow 1-.
um
fo
en
ng
t.
yi
– Grease ball stud.
Co
Cop py
ht. rig
– Press ball stud into gate selector lever -arrow 2-. rig ht
py by
co Vo
by lksw
• Guides -A- and tabs -B- are not allowed to be damaged. cted agen
Prote AG.
– Place selector housing with gear lever guide into larger recess
-arrow- in thrust piece -T10083- .
ce
le
un
pt
an
– Lift upper end -A- of compression spring over pin of gate se‐
d
itte
y li
lector lever.
erm
ab
ility
ot p
• Use a new ball socket -B-.
wit
is n
h re
– Grease ball socket and bearing ball of gear lever guide.
ole,
spec
urposes, in part or in wh
– Press ball socket onto bearing ball of gear lever guide up to
t to the co
stop.
– Remove selector housing from thrust piece -T10083- .
rrectne
– Insert lower end -C- of compression spring into guide.
– Lift upper end -A- of compression spring over pin of gate se‐
ss
lector lever into guide.
o
cial p
f inform
– Press ball socket into selector housing -arrows-.
mer
atio
• All 4 locking lugs must engage.
om
n
c
i
or
n
– Fit gear lever, gear selector cable, gate selector cable and
thi
te
sd
base plate ⇒ page 125 .
iva
o
pr
cum
r
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
ce
e
nl
pt
du
an
itte
y li
Note
erm
ab
ility
♦ Lubricate bearing positions and sliding surfaces. ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
1 - Gear selector cable
❑ Connect to cable end-
rrectness of i
piece
l purpos
nform
ercia
at
om
ion
c
⇒ page 134
in t
or
his
e
do
riv
cum
or
en
ng
t.
nism
yi Co
op
⇒ Item 8 (page 125)
C py
t. rig
gh ht
yri by
2 - Gate selector cable
cop Vo
by lksw
cted agen
❑ Connect to cable end-
Prote AG.
piece
⇒ Item 10 (page 131)
❑ Installation position
⇒ page 116
❑ Use cable tie to fix onto
gear selector cable
⇒ page 134
❑ From 11.06, modified
attachment to gate se‐
lector lever inside selec‐
tor mechanism
⇒ Item 6 (page 125)
3 - Securing clip
❑ Always renew
❑ Discontinued in selector
mechanisms from 11.06
⇒ page 125
4 - Selector housing
5 - Securing clip
❑ Always renew
❑ Do not damage cables when removing
6 - Hexagon bolt, 20 Nm
❑ 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
10 - Cable end-piece
❑ After installing, adjust selector mechanism ⇒ page 139
❑ For gate selector cable to relay lever
❑ Do not interchange; cable end-pieces for gate selector cable to relay lever and gear selector cable to
gearbox selector lever are different
❑ For metal relay lever, secured with securing clip ⇒ Item 12 (page 132)
❑ From 05.07, fitted in conjunction with plastic relay lever ⇒ page 134
❑ Removing from plastic relay lever ⇒ page 134
❑ Pressing onto plastic relay lever ⇒ page 134 n AG. Volkswagen AG do
wage es n
❑ Allocation ⇒ page 133 yV
olks ot g
u b ara
ed
11 - Cable end-piece ris nte
utho eo
ra
❑ After installing, adjust selector mechanism
ss
a ⇒ page 139 c
ce
e
pt
du
an
❑ Do not interchange; cable end-pieces for gate selector cable to relay lever and gear selector cable to
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
12 - Securing clip
hole
spec
❑ Always renew
es, in part or in w
t to the co
❑ Not required for plastic relay lever
13 - Securing clip
rrectness of i
❑ Always renew
l purpos
nform
ercia
at
15 - Relay lever
om
ion
c
in t
or
his
te
do
priv
en
ng
t.
❑ Metal relay lever is mounted in bearing bush ⇒ Item 14 (page 132) and secured with securing clip
yi Co
op
⇒ Item 13 (page 132)
C py
t. rig
gh ht
yri
❑ From 05.07, plastic relay lever
p by
co Vo
by lksw
cted
❑ Remove and install plastic relay lever together with cable end-piece ⇒ page 134
agen
Prote AG.
❑ Bearing bushes and securing clip not required for plastic relay lever
16 - Shoe
17 - Gearbox selector lever
❑ Installing ⇒ page 133
❑ Installation position ⇒ page 134
❑ After installing, adjust selector mechanism ⇒ page 139
❑ From 06.06, smaller diameter of support pin for cable end-piece ⇒ page 133
18 - Self-locking hexagon nut, 23 Nm
❑ Always renew
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 10 mm
From 06.06 8.5 mm
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
s c
Installing gearbox selector lever s
ce
e
nl
pt
du
y li
ab
-arrow B-
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.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
ce
le
1 - Gearbox selector lever
un
pt
an
d
itte
y li
2 - Relay lever engages in guide rail of gearbox selector lever via
erm
ab
shoe -arrow-.
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
va
o
pr
cum
r
fo
en
ng
ce
le
ess, swing it in direction of operation.
un
pt
an
d
itte
y li
erm
ab
ility
Relay lever with clip -arrow 1- ot p
wit
is n
h re
ole,
– Pull clip -arrow 1- off and remove relay lever together with ca‐
spec
urposes, in part or in wh
ble end-piece.
t to the co
Continuation for all
Cable end-piece must be located behind catch -arrow 2-.
rrectne
• The cable end-piece can be removed only with the relay lever
removed ⇒ page 135 .
ss o
cial p
f inform
Note
mer
atio
om
n
c
i
or
n
ces.
thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
– Press cable end-piece onto relay lever ⇒ page 136 . t. Cop py
rig
gh ht
– Install relay lever together with cable end-piece to stop. yri
p by
co Vo
by lksw
cted
• Fastener -arrow 1- secures relay lever (⇒ previous figure).
agen
Prote AG.
ce
le
un
pt
Special tools and workshop equipment required
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
atio
m
n
c
theft code. i
or
n thi
te
sd
a
o
r
cum
r
fo
tery .
en
ng
t.
yi Co
op
– Install gaiter with gear knob and noise insulation. Golf
C py
t. rig
gh
⇒ page 118 , Golf Plus ⇒ page 120 , Passat ⇒ page 121
ht
pyri by
Vo
o
by c lksw
Golf 2004 ▸
cted agen
Prote AG.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
t to the co
lever -2-.
l purpos
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
co lksw
by
cted agen
Prote AG.
ce
le
un
pt
stalling parts of exhaust system .
an
d
itte
y li
– Remove underbody panels ⇒ General body repairs, exterior;
rm
ab
pe
ility
Rep. Gr. 50 .
ot
wit
, is n
h re
hole
bles.
spec
es, in part or in w
t to the co
1.11.2 Installing
rrectness of i
Install in the reverse order of removal, observing the following:
l purpos
tion in
thi
s
do
r
follows:
rp
cum
fo
en
ng
Note
pt
du
an
y li
of exhaust system .
erm
ab
ility
ot p
h re
spec
Component
nform
ercia
at
om
in t
r
his
e
do
priv
cum
or
en
ng
t.
yi Co
op py
Special tools and workshop equipment required t. C rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
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
Note
rrectness of i
♦ The following points are essential to ensure correct adjust‐
ment of selector mechanism:
l purpos
nf
ercia
orm
♦ Selector mechanism must move freely.
m
atio
om
n in
c
thi
condition.
te
sd
iva
o
r
rp
cu
o
m
• Gearbox must be in neutral.
f
en
ng
t.
yi Co
op
– Remove air filter housing if bracket -A- and securing mecha‐ C py
t. rig
nism for gear selector cable and gate selector cable are not gh ht
yri by
accessible ⇒ Rep. Gr. 23 ; Repairing diesel direct injection cop Vo
by lksw
cted
system or ⇒ Rep. Gr. 24 ; Repairing injection system .
agen
Prote AG.
ce
e
nl
pt
du
until it engages in selector shaft.
an
itte
y li
erm
ab
– Install gaiter with gear knob and noise insulation. Golf
ility
ot p
wit
, is n
h re
– If noise insulation is present, remove it.
hole
spec
Now secure gear lever as follows:
es, in part or in w
t to the co
– Select neutral using gear lever.
– Guide locking pin -T10027 A- through hole -A- into hole -B-.
rrectness of i
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
ht. rig
rig ht
py by
– Now turn locking mechanisms on gear selector cable and gate
co Vo
by lksw
cted
selector cable end-pieces clockwise to stop
agen
Prote AG.
-direction of arrow-.
Spring presses locking mechanism into original position.
Note
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
– Pull locking pin out of holes -A- and r-B-.
ised
nte
ho eo
ut
– If noise insulation was present,ssinstall it.
a ra
c
ce
e
pt
du
an
⇒ page 118 , Golf Plus ⇒ page 120 , Passat ⇒ page 121
itte
y li
erm
ab
– Check that selector shaft moves freely.
ility
ot p
wit
, is n
h re
or ⇒ Rep. Gr. 24
hole
spec
es, in part or in w
t to the co
rrectness of i
1.12.1 Functional check
l purpos
• With gearbox in neutral, selector lever must rest in gate for 3rd
and 4th gear.
nform
ercia
– Operate clutch.
m
at
om
– Select all gears several times. Pay particular attention to op‐ ion
c
in t
r
his
ate
do
riv
cum
or
en
ng
⇒ page 139 .
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
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
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
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
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
– First check whether a coded radio is fitted. If so, obtain anti-
theft code.
rrectness of i
– With ignition switched off, disconnect battery ⇒ Electrical sys‐
l purpos
a
com
en
ng
t.
yi
– Remove battery and battery tray ⇒ Electrical system; Rep.
Co
op py
Gr. 27 ; Removing and installing battery . t. C rig
gh ht
pyri by
– Remove securing clip -arrow 1- for gear selector cable from
o Vo
by c lksw
cted
gearbox selector lever -A-.
agen
Prote AG.
ce
le
cable.
un
pt
an
d
itte
y li
– Remove bracket -B- from gearbox and pull it off pipe/hose line
rm
ab
-A-.
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
– Then remove gearbox support -arrow A-. s
iva
do
r
rp
cum
– Remove slave cylinder -arrow B-, lay to side and secure with
fo
en
g
t.
yi Co
Cop py
t. rig
gh ht
yri
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Do not operate clutch pedal any more.
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Rear left engine support eye points towards side -arrow-
– Attach shackle -10-222 A /12- at rear left of engine -arrow-.
rrectness of i
– Attach hook - 10-222 A /2- in shackle -10-222 A /12- .
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ion
c
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ate
do
priv
cum
for
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t.
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rig ht
py by
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by lksw
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pt
du
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– Separate exhaust system at double clamp and unbolt exhaust
itte
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pipe bracket from subframe ⇒ Rep. Gr. 26 ; Exhaust system .
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– Remove pendulum support -arrows A-, -B- and -C-. rrectness of i
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c
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ate
do
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Cop py
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– Remove hexagon bolts -arrows- for left assembly mounting Prote AG.
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h re
-arrow-.
hole
spec
es, in part or in w
♦ Be careful of all lines when lowering gearbox.
t to the co
• Securing bolts -arrows- for gearbox bracket -A- must be ac‐
cessible.
rrectness of i
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nform
mercia
at
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c
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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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Prote AG.
– If small cover plate -A- for flywheel behind the right flange shaft
-arrows- is installed, remove it.
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⇒ Rep. Gr. 26 ; Removing and installing parts ofbythe
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– Press gearbox off dowel sleeves and carefully swing towards
rrectness of i
subframe.
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Be careful of all lines when lowering gearbox.
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Note
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ping up gear oil”.
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“No” “Yes” “Yes”
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No oil loss X
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Completely Prote X AG.
dismantled before in‐
stallation
⇒ Item 3
(page 250)
oil capacity
⇒ page 2
Partially X
dismantled after instal‐
• (Gear‐ lation
box ⇒
housing page 220
and
clutch
housing
were not
separa‐
ted.)
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To install gearbox “0A4”, set up gearbox support -3282- with ad‐
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– Screw in support elements -A - and -C- ( pin -3282/29- ) on
es, in part or in w
t to the co
– Place gearbox on engine and gearbox jack .
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pendulum support.
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wards in vicinity of differential.
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ened to specified torque.
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Note
hole
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10 ; Removing and installing engine .
rrectness of i
– Install slave cylinder and tighten bolts -arrows B- to specified
torque ⇒ Item 9 (page 104) .
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ing; Rep. Gr. 40 ; Repairing front suspension .
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– Install drive shaft heat shield, if present -arrows- ⇒ Running cted agen
Prote AG.
gear, axles, steering; Rep. Gr. 40 ; Repairing drive shafts;
Removing and installing drive shafts .
– 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 ; Exhaust system .
– Bolt exhaust system strut -1- onto gearbox and tighten bolt
-arrow- to specified torque ⇒ Rep. Gr. 26 ; Exhaust system .
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pt
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– Attach support -B- to gearbox.
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– Press pipe/hose line -A- into retainer -B- on gearbox.
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Rep. Gr. 24
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connecting battery . h re
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mer
1 M 12 x 65 2 80
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2 M 12 x 150 1 80
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♦ Additionally, start‐
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3 M 12 x 165 Cop
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4 M 10 x 50 3 40
5 M 12 x 85 1 80
6 M6x8 1 10
♦ Small cover plate
for flywheel
3 M10 x 50 3 40
4 M12 x 60 1 80
5 M6 x 8 1 10
♦ Small flywheel
cover plate
pt
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ility
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– Renew bolts.
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2. Removing and installing gearbox, Golf 2004 ▸
Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus 2009 ➤ , Pass ...
5-speed manual gearbox 0A4 - Edition 04.2010
3 Removing and installing gearbox, Golf 2009 ▸ with turbo diesel engine
AG. Volkswagen AG d
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es, in part or in w
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t.
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Cop py
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Prote AG.
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♦ Gearbox lifting tackle
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-3336- for transporting
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ab
gearbox
ility
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♦ Grease for clutch plate
is n
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splines -G 000 100-
ole,
spec
urposes, in part or in wh
♦ Flange bolt M6 x 20
t to the co
♦ Flange bolt M6 x 80
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mer
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Cop py
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rig ht
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by lksw
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Prote AG.
3. Removing and installing gearbox, Golf 2009 ▸ with turbo diesel engine 157
Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus 2009 ➤ , Pass ...
5-speed manual gearbox 0A4 - Edition 04.2010
ce
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un
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together with cable end-piece. In the process, swing it in di‐
an
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rection of operation.
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spec
urposes, in part or in wh
The relay lever was secured with a clip shortly after start of pro‐
t to the co
duction ⇒ page 135 .
rrectne
-arrow 3-.
ss
– Remove cable support bracket from gearbox -arrows-.
o
cial p
f in
– Then raise and secure gear selector cable and gate selector
form
mer
cable.
atio
om
– Remove bracket -B- from gearbox and pull it off pipe/hose line
n
c
i
or
n
-A-.
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t.
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rig ht
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by lksw
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Caution
pt
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ab
pe
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spec
t to the co
bracket on spindles.
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– Raise vehicle.
– Remove noise insulation ⇒ General body repairs, exterior;
nform
ercia
tio
thi
do
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rp
cum
fo
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
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by c lksw
cted agen
Prote AG.
3. Removing and installing gearbox, Golf 2009 ▸ with turbo diesel engine 159
Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus 2009 ➤ , Pass ...
5-speed manual gearbox 0A4 - Edition 04.2010
AG. Volkswagen AG d
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– Remove starter ⇒ Electrical system; Rep. Gr. 27 ; Starter .
ot
wit
, is n
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– If front vehicle level sender -G78- is present, unbolt it from hole
spec
transverse link ⇒ Rep. Gr. 40 ; Removing and installing front
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
– Remove drive shaft heat shield, if present -arrows- ⇒ Running
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te o
thi
s
iva
do
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rp
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fo
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t.
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sible and secure. Do not damage the surface protection ⇒
Co
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Running gear, axles, steering; Rep. Gr. 40 ; Removing and t. C rig
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installing drive shafts . pyri by
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– Separate exhaust system at double clamp and unbolt exhaust Prote AG.
pipe bracket from subframe ⇒ Rep. Gr. 26 ; Exhaust system .
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ab
pe
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wit
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es, in part or in w
t to the co
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nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
– If small cover plate -A- for flywheel behind the right flange shaft
r
rp
cum
-arrows- is installed, remove it.
fo
en
ng
t.
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– Attach bracket -T10346- with bolt -1- to left threaded hole in Cop py
subframe.
t. rig
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pyri by
Vo
co
-1- = Flange bolt M6 x 20.
by lksw
cted agen
Prote AG.
– Secure engine support -3300 A- to bracket -T10346- .
3. Removing and installing gearbox, Golf 2009 ▸ with turbo diesel engine 161
Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus 2009 ➤ , Pass ...
5-speed manual gearbox 0A4 - Edition 04.2010
ce
le
pt
an
d
itte
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– Insert gearbox support -3282- in engine and gearbox jack -
rm
ab
V.A.G 1383A- .
pe
ility
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wit
, is n
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ment plate .
hole
spec
es, in part or in w
t to the co
– Screw in support elements -A - and -C- on adjustment plate
as shown.
– Position engine and gearbox jack under vehicle. Arrow -B- on
rrectness of i
adjustment plate points in direction of vehicle travel.
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mercia
a
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tion in
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te o
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fo
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port on gearbox. Cop py
t. rig
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– Then screw pin -3282/29- into hole on gearbox for securing
p by
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ab
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shown.
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Note
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m
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thi
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Note
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Refer to procedure “Removing gearbox” for required special tools
t. C rig
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⇒ page 157 . pyri by
Vo
co lksw
by
cted agen
Prote AG.
Observe the following table on the subject of “checking and top‐
ping up gear oil”.
“Checking and topping up gear oil”
“No” “Yes” “Yes”
3. Removing and installing gearbox, Golf 2009 ▸ with turbo diesel engine 163
Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus 2009 ➤ , Pass ...
5-speed manual gearbox 0A4 - Edition 04.2010
ce
e
Partially X
nl
pt
du
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dismantled After instal‐
itte
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• (Gear‐ lation
erm
ab
ility
box ⇒
ot p
wit
, is n
h re
and
hole
clutch
spec
housing
es, in part or in w
t to the co
were not
separa‐
ted.)
rrectness of i
l purpos
or
– Always renew self-locking bolts and nuts.
m
m
atio
m
n in
or c
sd
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cu
m
f
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The clutch plate must slide easily to and fro on the input shaft.
– Attach bracket -T10346- with bolt -1- to left threaded hole in
subframe.
– In the process, position bracket -T10346- at the same angle
as the engine.
-1- = Flange bolt M6 x 20.
– Secure engine support -3300 A- to bracket -T10346- .
pt
du
an
itte
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ab
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
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nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
3. Removing and installing gearbox, Golf 2009 ▸ with turbo diesel engine 165
Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus 2009 ➤ , Pass ...
5-speed manual gearbox 0A4 - Edition 04.2010
AG. Volkswagen AG d
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– Install bracket -A- on gearbox using new hexagonal bolts
ce
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rm
ab
pe
ility
ot
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
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Cop py
t. rig
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ce
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nl
curing the left and right assembly mountings have been tight‐
pt
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ened to specified torque.
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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
– Then install drive shafts ⇒ Running gear, axles, steering; Rep.
Gr. 40 ; Removing and installing drive shafts .
l purpos
nform
ercia
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.
3. Removing and installing gearbox, Golf 2009 ▸ with turbo diesel engine 167
Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus 2009 ➤ , Pass ...
5-speed manual gearbox 0A4 - Edition 04.2010
AG. Volkswagen AG d
agen oes
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– Install slave cylinder and tighten bolts -arrowsoris B- to specified
e nte
torque ⇒ Item 9 (page 104) . aut
h eo
ra
ss c
– Then install gearbox support -arrow A- and tighten to specified
ce
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nl
pt
torque ⇒ page 169 .
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erm
ab
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
– Push connector -1- onto reversing light switch -F4- .
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at
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ion
c
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ate
do
priv
cum
for
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t.
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t. rig
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pyri by
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– Attach support -B- to gearbox. cted agen
Prote AG.
er to gearbox
nl
pt
du
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3 M10 x 50 3 40
erm
ab
ility
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4 M12 x 60 1 80
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5 M6 x 8 1 10
h re
hole
♦ Small flywheel
spec
cover plate
es, in part or in w
t to the co
– Renew bolts.
– Screw in all bolts hand-tight.
nform
mercia
ion
c
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
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by c lksw
cted agen
Prote AG.
3. Removing and installing gearbox, Golf 2009 ▸ with turbo diesel engine 169
Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus 2009 ➤ , Pass ...
5-speed manual gearbox 0A4 - Edition 04.2010
ce
le
Bolts -arrows- 60 Nm + 90°
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
urposes, in part or in wh
t to the co
– Renew bolts.
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– Screw in all bolts hand-tight.
– Tighten bolts to specified torque.
ss o
cial p
f
Bolts -arrows- 20 Nm + 90°
inform
mer
atio
m
n
c
shafts .
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or
n thi
te
sd
iva
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pr
cum
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fo
en
ng
t.
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Cop py
ht. rig
rig ht
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by lksw
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Prote AG.
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erm
ab
Special tools and workshop
ility
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equipment required
wit
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♦ Support bracket -10 - 222
ole,
spec
A-
urposes, in part or in wh
t to the co
♦ Adapter -10-222 A /8-
♦ Adapter -10 - 222 A /18-
rrectne
♦ Adjustment plate -3282/39-
♦ Support elements for gear‐
ss
box (determine when set‐
o
cial p
f i
ting adjustment plate on
nform
gearbox support )
mer
atio
m
n
c
i
or
n thi
te
sd
iva
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pr
cum
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fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
♦ Shackle -T10419-
4. Removing and installing gearbox, Golf 2009 ▸ with petrol engine 171
Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus 2009 ➤ , Pass ...
5-speed manual gearbox 0A4 - Edition 04.2010
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
by
172
copy Vo
by lksw
Rep. Gr.34 - Controls, housing cted agen
Prote AG.
Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus 2009 ➤ , Pass ...
5-speed manual gearbox 0A4 - Edition 04.2010
olkswagen AG
en AG. V
– If you are using support -T10036- , apply 2olkholes
swa ∅ 7 mm as
g does
not
shown in illustration. ed
by V gu
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• Dimension -a- = 11 mm aut
ho eo
ra
ss c
• Dimension -b- = 98 mm
ce
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nl
pt
du
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• Dimension -c- = 70 mm
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ility
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es, in part or in w
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At a later point, support bracket -10-222 A- will be put onto lon‐
rrectness of i
gitudinal members with adapters -10 - 222 A /8- .
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Cop py
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4.1 Removing gearbox
ht
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– First check whether a coded radio is fitted. If so, obtain anti-
AG.
theft code.
– With ignition switched off, disconnect battery ⇒ Electrical sys‐
tem; Rep. Gr. 27 ; Disconnecting and connecting battery .
– Then remove engine cover with air filter ⇒ Rep. Gr. 24 ; Re‐
pairing injection system .
– Remove battery and battery tray ⇒ Electrical system; Rep.
Gr. 27 ; Removing and installing battery .
– Release end-piece from gate selector cable ⇒ page 134 .
– Pull clip -arrow 1- off and remove relay lever together with ca‐
ble end-piece.
– Remove securing clip -arrow 2- for gear selector cable from
gearbox selector lever -A-.
– Pull gear selector cable off pin.
– Remove gearbox selector lever -A- by removing nut
-arrow 3-.
4. Removing and installing gearbox, Golf 2009 ▸ with petrol engine 173
Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus 2009 ➤ , Pass ...
5-speed manual gearbox 0A4 - Edition 04.2010
. Volkswagen AG
does gen AG
– Remove cable support bracket
Vol
ksw from gearbox -arrows-.
a
not
y gu
db a
– Then raise and secure
oris
e gear selector cable and gate selector
ran
tee
cable. au
th or
a
ss c
– Remove bracket -B- from gearbox and pull it off pipe/hose line
ce
e
nl
pt
-A-.
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
– Then remove gearbox support -arrow A-.
rrectness of i
– Remove slave cylinder -arrow B-, lay to side and secure with
l purpos
nform
ercia
Caution
m
at
om
ion
c
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or
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ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
– Pull connector -arrow 1- off reversing light switch -F4- .
gh ht
pyri by
Vo
co lksw
by
– Now remove connector -arrow 2- and wire -arrow 3- from cted agen
Prote AG.
starter.
– Remove earth strap at upper engine/gearbox connecting bolt.
– Then remove upper securing bolt on starter.
– Remove upper engine/gearbox connecting bolts.
Note
ce
e
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
– Screw lug tightly into threaded holes, -arrows-.
Torque setting: 10 Nm
rrectness of i
l purpos
WARNING
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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In addition, retaining eye -arrow A-, at front of engine, is needed Cop py
for catching engine.
t. rig
gh ht
pyri by
Vo
co
– Remove transport eye -arrow B- and remove it from retaining
by lksw
cted agen
Prote
eye -arrow A-, without disconnecting line connections ⇒ Rep.
AG.
4. Removing and installing gearbox, Golf 2009 ▸ with petrol engine 175
Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus 2009 ➤ , Pass ...
5-speed manual gearbox 0A4 - Edition 04.2010
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
spec
t to the co
nform
mercia
a
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
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
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erm
ab
ility
– Tilt engine/gearbox assembly by lowering it via spindles of
ot p
wit
support bracket -10 - 222 A- .
, is n
h re
hole
spec
cessible.
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
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
co lksw
by
cted agen
Prote AG.
4. Removing and installing gearbox, Golf 2009 ▸ with petrol engine 177
Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus 2009 ➤ , Pass ...
5-speed manual gearbox 0A4 - Edition 04.2010
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
– Press engine forwards using spindle of engine support -3300
pr
cum
r
fo
t.
yi Co
op
• The air conditioning compressor -2- must not contact -arrow- C py
t. rig
the refrigerant line -1-. gh ht
pyri by
Vo
co lksw
by
• The alternator must not contact the refrigerant line. Prote
cted AG.
agen
AG. Volkswagen AG d
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olksw not
y V gu
d b ara
rise nte
tho eo
au ra
s c
– Then guide right flange shaft past recess -arrow 1-. s
ce
le
un
pt
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rm
ab
ility
above).
ot
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
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iva
do
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cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
yri by
179
cop Vo
by lksw
4. Removing and installing gearbox, Golf 2009 ▸ with petrol engine
Prote
cted AG.
agen
Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus 2009 ➤ , Pass ...
5-speed manual gearbox 0A4 - Edition 04.2010
Note
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
4.2 Installing gearbox aut
hor eo
ra
ss c
ce
e
nl
pt
du
Note
an
itte
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erm
ab
Refer to procedure “Removing gearbox” for required special tools
ility
ot p
⇒ page 173 .
wit
, is n
h re
hole
spec
Observe the following table on the subject of “checking and top‐
es, in part or in w
t to the co
“Checking and topping up gear oil”
rrectness of i
“No” “Yes” “Yes”
Gearbox Original X
l purpos
part
No oil loss X
nf
ercia
or
Completely X
m
m
atio
n in
stallation
or c
⇒ Item 3
thi
te
sd
a
(page 250)
iv
o
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cu
Oil capacity
o
m
f
⇒ page 2
en
ng
t.
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op
Partially X
C py
t. rig
dismantled After instal‐
gh ht
pyri by
• (Gear‐ lation
o Vo
by c lksw
cted agen
box Prote AG.
⇒
housing page 220
and
clutch
housing
were not
separa‐
ted.)
The clutch plate must slide easily to and fro on the input shaft.
– If heat shield is installed, remove it from subframe -arrows-.
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
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ir se tee
tho
u or
a ac
ss
ce
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un
pt
an
d
itte
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erm
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
atio
i
or
n thi
e
sd
va
o
pr
cum
r
fo
en
ng
4. Removing and installing gearbox, Golf 2009 ▸ with petrol engine 181
Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus 2009 ➤ , Pass ...
5-speed manual gearbox 0A4 - Edition 04.2010
AG. Volkswagen AG d
agen oes
olksw not
V
– Guide right flange shaft past flywheel -arrow 2-. ed by gu
ara
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
– Guide left flange shaft -B- past subframe bracket -arrow- as
shown.
l purpos
at
om
io
in t
or
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e
do
riv
cum
for
en
g
t.
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gearbox jack from gearbox. Cop py
ht. rig
rig ht
– Remove engine support -3300 A- and support . py by
co Vo
by lksw
cted agen
Prote AG.
AG. Volkswagen AG d
WARNING lksw
agen oes
not
Vo gu
d by ara
Do not remove support bracket -10 - 222 A- until the orbolts
ise
se‐ nte
eo
curing the left and right assembly mountings have utbeen tight‐
h
a ra
c
ened to specified torque. ss
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
Note
wit
, is n
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hole
t to the co
orm
m
atio
om
n in
or c
thi
te
sd
iva
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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.
4. Removing and installing gearbox, Golf 2009 ▸ with petrol engine 183
AG. Volkswagen AG d
agen oes
ksw
Golf 2004 ➤ , Golf by
V 2009 ➤ , Golf Plus 2005 ➤ ,otGolf
ol n
gu Plus 2009 ➤ , Pass ...
d ara
5-speed manual
orise gearbox 0A4 - Edition 04.2010 nte
h eo
aut ra
c
– Install pendulum
ss
support ⇒ Running gear, axles, steering;
ce
le
Rep. Gr. 40 ; Repairing front suspension . un
pt
an
d
itte
y li
– Assemble exhaust system and attach exhaust system bracket
rm
ab
to subframe ⇒ Rep. Gr. 26 ; Exhaust system .
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
ercia
sender -G78- .
m
a
com
tion in
r
te o
thi
s
iva
do
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rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
ce
le
– Install starter, push on connector -arrow 2- and bolt on wire
un
pt
-arrow 3- ⇒ Electrical system; Rep. Gr. 27 ; Starter .
an
d
itte
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erm
ab
– Install earth strap at upper engine/gearbox connecting bolt.
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectne
– Attach support -B- to gearbox.
ss o
cial p
f
– Press pipe/hose line -A- into retainer -B- on gearbox.
inform
mer
atio
-arrows- to specified torque ⇒ Item 6 (page 131) .
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
– Install gearbox selector lever -A- ⇒ page 133 .
– Tighten hexagon nut -arrow 3- to specified torque
⇒ Item 18 (page 132) .
– Spread a small amount of grease on pin of gearbox selector
lever -A-.
Allocate grease using ⇒ Electronic parts catalogue (ETKA) .
– Connect gear selector cable to gearbox selector lever.
– Renew securing clip -arrow 2- each time it is removed.
– Install relay lever together with cable end-piece ⇒ page 134 .
• Clip -arrow 1- secures relay lever
• Ensure proper engagement of clip.
– Connect gate selector cable to cable end-piece.
– Adjust selector mechanism ⇒ page 139 .
– Remove shackle -10-222 A /12- from engine.
4. Removing and installing gearbox, Golf 2009 ▸ with petrol engine 185
Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus 2009 ➤ , Pass ...
5-speed manual gearbox 0A4 - Edition 04.2010
olkswagen AG
en AG. V
– Remove lug -T10419- from back of engine. olkswag does
not
yV b gu
ara
ed nte
oris eo
th
au ra
c
ss
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– If secondary air inlet valve -N112- -arrow- was removed, install
rrectness of i
it on engine ⇒ Rep. Gr. 26 ; Secondary air system .
– Install battery tray, battery cover and battery ⇒ Electrical sys‐
l purpos
nf
ercia
– Then remove engine cover with air filter ⇒ Rep. Gr. 24 ; Re‐
or
pairing injection system .
m
m
atio
m
n in
or c
thi
e
connecting battery .
t
sd
iva
o
r
rp
cu
– Install lower part of front left wheel housing liner ⇒ General
o
m
f
en
ng
3 M12 x 170 1 80
♦ Additionally, start‐
er to gearbox
4 M10 x 65 3 40
5 M12 x 95 1 80
6 M6 x 8 1 10
♦ Small flywheel
cover plate (not
present here)
ce
le
un
pt
Gearbox bracket to gearbox
an
d
itte
y li
erm
ab
– Renew bolts.
ility
ot p
– Screw in all bolts hand-tight.
wit
is n
h re
ole,
– Tighten bolts to specified torque.
spec
urposes, in part or in wh
Bolts -arrows- 40 Nm + 90°
t to the co
rrectness o
cial p
f in
Gearbox mounting to body
form
mer
atio
– Renew bolts. om
n
c
i
– Screw in all bolts hand-tight.
or
n thi
te
sd
a
o
pr
cum
r
fo
en
Bolts -arrows- 60 Nm + 90°
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
4. Removing and installing gearbox, Golf 2009 ▸ with petrol engine 187
Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus 2009 ➤ , Pass ...
5-speed manual gearbox 0A4 - Edition 04.2010
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
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
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
code.
m
at
om
in t
his
ate
cum
for
– Remove complete air filter housing -1- with intake hose -2- ⇒
en
ng
t.
yi
Rep. Gr. 23 ; Repairing diesel direct injection .
Co
Cop py
t. rig
gh
– Remove battery -3-, battery cover and battery tray ⇒ Electrical
ht
pyri by
Vo
o
system; Rep. Gr. 27 ; Removing and installing battery .
c by lksw
cted agen
Prote AG.
– Remove bolt -arrow- and valve block -4- from front wall of ple‐
num chamber.
– Remove noise insulation -5- from front wall of plenum cham‐
ber.
– Remove front wall of plenum chamber ⇒ General body re‐
pairs, exterior; Rep. Gr. 50 ; Noise insulation .
– Remove securing clip -arrow 1- for gear selector cable from
gearbox selector lever -A-.
ce
e
nl
pt
du
an
– Remove relay lever together with cable end-piece
itte
y li
⇒ page 134 .
erm
ab
ility
ot p
wit
, is n
h re
– 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 bracket -B- from gearbox and pull it off pipe/hose line
-A-.
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
co lksw
by
cted agen
Prote AG.
Caution
ce
e
nl
pt
du
an
– If there are hose and cable connections in area of engine sup‐
itte
y li
erm
port eye for support bracket -10 - 222 A- , remove these now.
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Insert wing supports -T10311- between wing flange and
mounting plate for wing on both sides of vehicle.
rrectness of i
♦ Installation position:
l purpos
nform
ercia
at
om
ion
c
in t
or
Note
his
ate
do
priv
c
Hole -3- can be used to pull out wing supports .
um
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
ce
e
pt
du
an
itte
y li
– Take up weight of engine/gearbox assembly on spindles.
erm
ab
ility
ot p
– Raise vehicle.
wit
, is n
h re
– Remove noise insulation ⇒ General body repairs, exterior;
hole
spec
es, in part or in w
t to the co
– Remove lower part of front left wheel housing liner ⇒ General
body repairs, exterior; Rep. Gr. 66 ; Wheel housing liner .
– Then remove all lines from gearbox.
rrectness of i
l purpos
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.
– Separate connection -arrow 1- or -arrow 2- on charge air hose
⇒ Rep. Gr. 21 ; Charge air system with turbocharger .
ce
le
pt
haust pipe bracket from subframe ⇒ Rep. Gr. 26 ; Removing
an
d
itte
y li
and installing parts of exhaust system .
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
– Remove pendulum support.
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
c
– Remove hexagon bolts -arrows- for left assembly mounting
um
r
fo
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Note
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
– If small cover plate -A- for flywheel behind the right flange shaft
-arrows- is installed, remove it.
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
subframe.
-1- = Flange bolt M6 x 20.
– Secure engine support -3300 A- to bracket -T10346- .
ce
e
pt
du
an
itte
y li
• The alternator must not contact the refrigerant line.
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
Note
nform
ercia
at
om
ion
c
in t
or
his
ate
do
riv
cum
or
en
ng
t.
yi Co
op
– Insert gearbox support -3282- in engine and gearbox jack -
C py
t. rig
V.A.G 1383A- .
gh ht
pyri by
Vo
co lksw
by
– Align arms of gearbox support according to holes in adjust‐cted agen
Prote AG.
ment plate .
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
an
d
itte
ab
past dowel sleeve -arrow- in cylinder block as shown.
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
ercia
shown.
com
tion in
r
thi
do
r
rp
cum
fo
en
ng
t.
yi
Note
Co
Cop py
t. rig
gh ht
yri
Be careful of all lines when lowering gearbox.
p by
o Vo
by c lksw
cted agen
Prote AG.
Note
ce
le
were not
un
pt
an
d
separa‐
itte
y li
ted.)
rm
ab
pe
ility
ot
wit
, is n
h re
screwed must be cleaned of residual locking fluid carefully with
hole
spec
a thread tap.
es, in part or in w
t to the co
– Always renew self-locking bolts and nuts.
– Check whether dowel sleeves for aligning engine and gearbox
rrectness of i
are fitted in cylinder block and install if necessary.
l purpos
a
com
tio
– Clean input shaft splines and apply thin coat of grease for
n in
r
thi
s
iva
do
The clutch plate must slide easily to and fro on the input shaft.
r
rp
cum
fo
en
g
t.
yi Co
subframe. t. Cop py
rig
gh ht
yri
– In the process, position bracket -T10346- at the same angle p by
o Vo
by c
as the engine.
lksw
cted agen
Prote AG.
-1- = Flange bolt M6 x 20.
– Secure engine support -3300 A- to bracket -T10346- .
ce
le
• The pressure pipe must not contact the radiator.
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
Note
rrectness of i
♦ Check that adapters -10 - 222 A /8- are completely located on
longitudinal members -arrows-.
l purpos
nform
mercia
a
To install gearbox “0A4”, set up gearbox support -3282- with ad‐
com
tion in
justment plate -3282/39- .
r
te o
thi
s
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iva
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ment plate .
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. rig
adjustment plate as shown.
t
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pyri by
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co
– Place gearbox on engine and gearbox jack .
by lksw
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– Guide left flange shaft -B- past subframe bracket -arrow- as
shown.
rrectness of i
– Using spindles of gearbox support -3282- , tilt gearbox up‐
l purpos
nform
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a
com
tion in
– Screw in lower engine/gearbox securing bolts and tighten to
r
te o
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– If small cover plate had been installed behind the right-hand
by lksw
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Prote
flange shaft -A-, install it -arrows-.
AG.
WARNING
Do not remove support bracket -10 - 222 A- until the bolts se‐
curing the left and right assembly mountings have been tight‐
ened to specified torque.
AG. Volkswagen AG d
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Install engine and gearbox mounting free sof
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10 ; Removing and installing engine . s
ce
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nl
pt
du
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– Install slave cylinder and tighten bolts -arrows B- to specified
erm
ab
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torque ⇒ Item 9 (page 104) .
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wit
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es, in part or in w
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Gr. 40 ; Removing and installing drive shafts .
rrectness of i
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Prote AG.
5. Removing and installing gearbox, Golf Plus
Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus 2009 ➤ , Pass ...
5-speed manual gearbox 0A4 - Edition 04.2010
AG. Volkswagen AG d
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ility
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spec
urposes, in part or in wh
t to the co
– Install gearbox selector lever -A-.
rrectne
– Tighten hexagon nut -arrow 4- to specified torque
⇒ Item 18 (page 132) .
ss o
– Spread a small amount of grease on pin of gearbox selector
cial p
f i
lever -A-.
nform
mer
atio
om
n
c
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-arrow 1-.
te
sd
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– Install relay lever -B- and secure with securing clip -arrow 3-.
yi Co
Cop py
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by lksw
Allocate grease using ⇒ Electronic parts catalogue (ETKA) . Prote
cted AG.
agen
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2 M 12 x 150 2 80
an
d
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3 M10 x 50 3 40
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5 M6 x 8 1 10
t to the co
♦ Small flywheel
cover plate
rrectness of i
Item -A- dowel sleeves for centring
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– Renew bolts.
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Cop py
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AG. Volkswagen AG d
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es, in part or in w
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r
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s
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Cop py
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AG. Volkswagen AG d
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r
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Cop py
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ab
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urposes, in part or in wh
t to the co
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mer
atio
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n
c
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or
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te
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Cop py
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spec
urposes, in part or in wh
t to the co
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f i
theft code.
nform
mer
n
c
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or
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– If the lifting eyes of the engine for support bracket -10 - 222 A-
te
sd
a
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ce
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du
an
relay lever -B-.
itte
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– Pull gate selector cable from pin.
ility
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, is n
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lever.
hole
spec
Plastic relay lever
es, in part or in w
t to the co
– Remove relay lever together with cable end-piece
⇒ page 134 .
rrectness of i
Continuation for all
l purpos
nform
ercia
at
om
io
– Then raise and secure gear selector cable and gate selector
n
c
in t
or
cable.
his
ate
do
riv
– Remove bracket -B- from gearbox and pull it off pipe/hose line
p
cum
or
-A-.
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t.
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Cop py
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pyri by
Vo
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by c lksw
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Caution
pt
du
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es, in part or in w
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orm
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Cop py
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pyri by
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– Remove drive shaft heat shield, if present -arrows- ⇒ Running
AG.
AG. Volkswagen AG d
agen oes
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– Remove pendulum support from gearbox, bolt -2- and bolt s
ce
le
-3-.
un
pt
an
d
itte
ab
ility
ot p
brackets .
urposes, in part or in wh
t to the co
links .
ss
n
c
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or
sd
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cessible.
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t.
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Cop py
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pyri by
Vo
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by c lksw
cted agen
Prote AG.
– If small cover plate -A- for flywheel behind the right flange shaft
-arrows- is installed, remove it.
AG. Volkswagen AG d
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spec
V.A.G 1383A- .
cial p
f inform
ment plate .
atio
om
n
c
i
or
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te
sd
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as shown.
p
cum
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– Position engine and gearbox jack under vehicle. Arrow -B- on
yi Co
op
adjustment plate points in direction of vehicle travel.
C py
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rig ht
py by
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by lksw
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Prote AG.
Note
Note
nl
pt
du
an
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⇒ page 207 .
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.
t to the co
Gearbox Original X
part
No oil loss X
nform
ercia
Completely X
m
at
om
stallation
in t
or
his
e
⇒ Item 3
at
do
riv
(page 250)
p
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Oil capacity
for
en
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⇒ page 6
n
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op py
Partially X
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pyri by
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• (Gear‐ lation
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box ⇒
AG.
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pt
are fitted in cylinder block and install if necessary.
du
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If dowel sleeves are not fitted, difficulties shifting gears, clutch
erm
ab
ility
problems and possible noises from the gearbox (rattling of gears
ot p
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which are not engaged) could occur. , is n
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hole
spec
es, in part or in w
– Clean input shaft splines and apply thin coat of grease for
t to the co
clutch plate splines -G 000 100- .
The clutch plate must slide easily to and fro on the input shaft.
rrectness of i
To install gearbox “0A4”, set up gearbox support -3282- with ad‐
l purpos
nform
ercia
ment plate .
m
at
– Screw in support elements -A - and -C- ( pin -3282/29- ) on
om
io
adjustment plate as shown.
n
c
in t
or
his
e
do
priv
cum
– Align adjustment plate and gearbox parallel to one another.
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- had been installed behind the right
flange shaft -arrows-, install it.
– Screw in upper engine/gearbox securing bolts and tighten to
specified torque ⇒ page 217 .
WARNING
Note
pt
an
d
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erm
ab
h re
ole,
spec
urposes, in part or in wh
t to the co
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
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pr
cum
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t.
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Cop py
t. rig
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pyri by
Vo
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by c lksw
cted agen
Prote
214
AG.
Rep. Gr.34 - Controls, housing
Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus 2009 ➤ , Pass ...
5-speed manual gearbox 0A4 - Edition 04.2010
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
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hole
spec
– Gearboxes for vehicles with start-stop system: join connector
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
riv
cum
or
en
ng
t.
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op
– Then install gearbox support -arrow A- and tighten to specified
C py
ht. rig
torque ⇒ page 217 . rig ht
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co Vo
by lksw
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Prote AG.
AG. Volkswagen AG d
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– Attach support -B- to gearbox. s
ce
le
un
pt
– Press pipe/hose line -A- into retainer -B- on gearbox.
an
d
itte
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erm
ab
– Install cable support bracket on gearbox and tighten bolts
ility
ot p
wit
is n
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ole,
spec
urposes, in part or in wh
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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pyri by
Vo
co lksw
by
cted agen
Prote AG.
ce
le
– Connect gear selector cable to gearbox selector lever
un
pt
an
-arrow 1-.
d
itte
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erm
ab
Metal relay lever
ility
ot p
wit
– Install relay lever -B- and secure with securing clip -arrow 3-.
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
– Connect gate selector cable to relay lever -arrow 2-.
rrectne
Plastic relay lever
– Install relay lever together with cable end-piece ⇒ page 134 .
ss o
Continuation for all
cial p
f inform
– Adjust selector mechanism ⇒ page 139 .
mer
atio
m
n
c
i
tem; Rep. Gr. 27 ; Removing and installing battery .
or
n thi
te
sd
va
o
pr
c
Gr. 24
um
r
fo
en
ng
t.
yi
– Install engine cover.
Co
Cop py
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– Reconnect battery and perform work required after connecting
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pyri by
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battery ⇒ Electrical system; Rep. Gr. 27 ; Disconnecting and
c by lksw
cted agen
connecting battery . Prote AG.
3 M10 x 50 3 40
4 M12 x 60 1 80
5 M6 x 8 1 10
♦ Small flywheel
cover plate
ce
e
nl
pt
du
an
itte
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erm
ab
ility
– Renew bolts.
ot p
wit
, is n
h re
hole
spec
– Tighten bolts to specified torque.
es, in part or in w
t to the co
Bolts -arrows- 20 Nm + 90°
Drive shaft to flange shaft ⇒ Running gear, axles, steering; Rep.
rrectness of i
Gr. 40 ; Repairing drive shaft; Removing and installing drive
shafts .
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.
7 Transporting gearbox
Special tools and workshop equipment required
♦ Gearbox mounting support -3336-
n AG. Volkswagen AG do
lkswage es n
o ot g
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ir se tee
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un
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an
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ab
ility
– Bolt gearbox lifting tackle -3336- to clutch housing.
ot p
wit
is n
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ole,
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
atio
m
n
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or
-arrow-.
thi
te
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le -3336- . t. Cop py
rig
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– Set gearbox aside, for example in a transport container. yri
p by
co Vo
by lksw
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AG. Volkswagen AG d
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8.1 Preparation
Gear oil specification for manual gearboxes ⇒ Electronic parts
rrectness of i
catalogue “ETKA” .
l purpos
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
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pyri by
Vo
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220
cted agen
Prote
Rep. Gr.34 - Controls, housing
AG.
Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus 2009 ➤ , Pass ...
5-speed manual gearbox 0A4 - Edition 04.2010
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.agen AG. Volkswagen AG do
ksw es n
Vol ot g
d by ua
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ris tee
Secure selector shaft as follows: tho or
au ac
ss
ce
le
un
pt
– Press selector shaft down -direction of arrow 1-.
an
d
itte
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rm
ab
pe
ility
-direction of arrow 2- upwards and at the same time press it in
ot
wit
until it engages in selector shaft.
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
a
com
ti
the oil which runs out.
on in
r
te o
thi
• Selector shaft is locked in place ⇒ page 221
s
iva
do
r
– Drain gear oil by removing oil drain plug -arrow 1- and then
rp
cum
fo
t.
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op
– Install pivot pin -arrow 2- with a new O-ring
C py
t. rig
gh
⇒ Item 7 (page 226) .
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pyri by
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by c lksw
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Prote AG.
ce
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un
pt
– Install complete air filter housing ⇒ Rep. Gr. 23 or ⇒ Rep.
an
d
itte
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Gr. 24
erm
ab
ility
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wit
is n
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ole,
spec
urposes, in part or in wh
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
ng
t.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.
1 - 1st gear
2 - 2nd gear
3 - 3rd gear
4 - 4th gear
5 - 5th gear
6 - Gearbox housing cover
7 - Gearbox housing
8 - Selector mechanism
❑ (Selector forks)
9 - Reverse gear
10 - Clutch housing AG. Volkswagen AG d
agen oes
olksw not
y V gu
11 - Input shaft d b ara
rise nte
ho eo
12 - Output shaft aut ra
c
ss
13 - Differential
ce
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pt
du
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erm
ab
ility
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, is n
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hole
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es, in part or in w
t to the co
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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
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pyri by
Vo
co lksw
by
cted agen
Prote AG.
ce
e
pt
du
an
tling and assembling gearbox
itte
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completely ⇒ page 234 .
erm
ab
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
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
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f
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
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by c lksw
cted agen
Prote AG.
9.3 Removing and installing cover for gearbox housing and 5th gear
1 - Bolt, 18 Nm
❑ For gearbox housing
cover.
2 - Gearbox housing cover
Note
3 - Seal
4 - Bolt, 80 Nm + turn 90° fur‐
ther
❑ Always renew
❑ Fitted section of bolt
head holds dished
spring washer in posi‐
tion
❑ Clean residual locking
fluid from threaded
holes for synchro-hub
securing bolts and 5th
gear wheel with a thread
chaser. Otherwise the
bolts may shear. n AG. Volkswagen AG do
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5 - Dished washer byV
ol ot g
ua
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❑ Installing ⇒ page 246 ir se tee
tho
u or
a ac
6 - Socket head bolt, 25 Nm ss
ce
le
pt
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housing
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erm
ab
7 - Pivot pin
ility
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f inform
atio
n
c
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or
sd
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pr
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fo
12 - Synchro-hub with synchromeshed gear and synchronizing ring for 5th gear
en
ng
t.
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❑ Pull off together with gearbox housing ⇒ page 234 t. Cop py
rig
gh
❑ Pull off individually ⇒ page 228
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pyri by
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co lksw
❑ Dismantling and assembling ⇒ page 269
by
cted agen
Prote AG.
13 - Needle bearing
14 - Gear wheel for 5th gear
❑ Pull off together with gearbox housing ⇒ page 234
❑ Pull off individually ⇒ page 228
ce
le
un
sion spring
pt
an
d
itte
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❑ Removing and installing
rm
ab
⇒ page 294
pe
ility
ot
❑ Assembling
wit
, is n
h re
⇒ page 303
hole
spec
3 - Torx socket head bolt, 25
es, in part or in w
Nm
t to the co
❑ For reverse shaft sup‐
port.
rrectness of i
❑ Self-locking
l purpos
❑ Always renew
4 - Torx socket head bolt, 30
nform
ercia
Nm
m
a
com
tio
port
n in
r
te o
❑ Self-locking
thi
s
iva
do
❑ Always renew
r
rp
cum
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en
g
5 - O-ring
n
t.
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op
❑ Always renew
C py
ht. rig
rig ht
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6 - Pivot pin co Vo
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Prote
7 - Bolt, 25 Nm
AG.
8 - Bolt, 25 Nm
9 - Cover plate
10 - Multi-point socket head
bolt 25 Nm
❑ For reverse shaft sup‐
port.
❑ Always renew
11 - Bolt, 5 Nm
12 - Gearbox neutral position sender -G701-
❑ for vehicles with start/stop system
13 - Gearbox housing
❑ Pull off together with 5th gear ⇒ page 234
❑ Repairing ⇒ page 248
14 - Clutch housing
❑ Repairing ⇒ page 248
15 - Hexagon bolt, 25 Nm and turn 90° further
❑ Always renew
16 - Selector shaft with selector shaft cover
❑ (Selector unit)
❑ Repairing ⇒ page 255
17 - Multi-point socket head bolt 25 Nm
9.5 Removing and installing input shaft, output shaft, differential and selector
forks
1 - Differential
❑ Dismantling and assem‐
bling ⇒ page 303
AG. Volkswagen AG d
2 - Seal lksw
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❑ Qty. 4 ed by ara
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ris
❑ Always renew ut
ho eo
ra
s a c
s
3 - Output shaft
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bling ⇒ page 275
erm
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ility
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hole
spec
es, in part or in w
5 - Reverse shaft
t to the co
❑ Dismantling and assem‐
bling ⇒ page 291
rrectness of i
6 - Input shaft
l purpos
nform
ercia
at
om
io
❑ Dismantling and assem‐
n
c
in t
r
his
ate
❑ Installation position
do
priv
c
⇒ page 241
um
for
en
ng
t.
yi
8 - Torx socket head bolt, 25
Co
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9 - Selector mechanism
o Vo
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❑ (Selector forks)
AG.
Note
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equipment required
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♦ Support plate -VW 309-
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
♦ Drift sleeve -VW 244 B-
rrectne
♦ Hot air blower -V.A.G 1416-
♦ Torque wrench -V.A.G
s
1331-
s o
cial p
f in
♦ -Zweiarmabzieher Kukko
form
mer
210.1-
atio
m
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
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ng
t.
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Cop py
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by
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Prote AG.
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♦ Support bridge -30-211A-
y li
erm
ab
ility
♦ Thrust piece -32 - 111-
ot p
wit
, is n
♦ Thrust piece from assembly
h re
hole
tool -T10030/4-
spec
es, in part or in w
♦ Tube -VW 416 B-
t to the co
♦ Puller -T10309-
rrectness of i
♦ Two arm puller -T10040-
l purpos
♦ With puller hooks -
T10040/2A-
nform
ercia
♦ Thrust piece -T10040/3-
m
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
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Prote AG.
AG. Volkswagen AG d
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9.6.1 Removing ss c
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pt
du
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⇒ page 103 .
erm
ab
ility
ot p
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
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co lksw
by
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230
Prote AG.
Rep. Gr.34 - Controls, housing
Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus 2009 ➤ , Pass ...
5-speed manual gearbox 0A4 - Edition 04.2010
ce
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pt
du
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erm
ab
ility
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hole
spec
es, in part or in w
t to the co
– Remove gearbox housing cover -arrow-.
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
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or c
thi
te
sd
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o
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Prote AG.
-B-
Puller hooks -T10040/2A- come
into contact with ribs in gearbox
housing below gear wheel.
.
nl
pt
du
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– After both gears are engaged, the input shaft and output shaft
erm
ab
are locked. The synchro-hub and gear wheel cannot turn. Both
ility
ot p
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hole
spec
Note
es, in part or in w
t to the co
Pull off synchro-hub for 5th gear together with locking collar and
l purpos
locking pieces.
Use puller -T10309- .
nf
ercia
orm
– First set half sleeve -T10309/1- between 5th gear wheel -A-
m
atio
m
n in
or c
thi
te
sd
iva
o
r
rp
cu
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m
f
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
o
by c lksw
cted agen
Prote AG.
ce
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un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
– Pull off gear wheel for 5th gear. (Shown here on another gear‐
nform
ercia
box.)
m
tion in
thi
s
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Note
fo
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ng
t.
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op py
When pulling off gear wheel, ensure that hooks do not bend out‐ t. C rig
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wards. After pulling off gear wheel for 5th gear, examine for pyri by
Vo
co
damage.
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9.6.2 Installing
Install 5th gear ⇒ page 244 .
– Apply sealant -AMV 188 200 03- evenly to sealing surface of
gearbox cover.
– Install gearbox housing cover ⇒ page 225 .
– Fit clutch release lever and release bearing ⇒ page 103 .
– Top up gear oil ⇒ page 150 .
ce
le
un
pt
♦ Torque wrench -
an
d
V.A.G 1331- itte
y li
rm
ab
pe
ility
♦ -Stehbolzen M 8 x 100 mm-
ot
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
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t.
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ce
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♦ Thrust piece -32 - 111-
an
d
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♦ Thrust piece from assembly
ility
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tool -T10030/4-
wit
is n
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♦ Tube -VW 416 B-
ole,
spec
urposes, in part or in wh
t to the co
♦ Thrust pieces -T10408/2-
♦ Grips -T10408/3-
rrectne
♦ Hexagon bolts M7 x 35 with
washers
ss o
♦ Puller - 2 Kukko 18/1-
cial p
f inform
mer
atio
om
n
c
i
or
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sd
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t.
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Cop py
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♦ Support device -T10323-
erm
ab
ility
ot p
♦ Assembly tool -3253/7-
wit
, is n
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♦ Thrust piece -VW 433-
hole
spec
♦ Torque wrench -V.A.G
es, in part or in w
t to the co
1332-
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
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
9.7.1 Removing
– Remove clutch release lever, release bearing and guide
sleeve ⇒ page 103 .
• Bearings of input shaft and output shaft must not be damaged
when 5th gear is removed and installed.
• Therefore, following tools must be mounted for support at this
stage during attachment of gearbox to gearbox support -VW
353- :
Underneath input shaft:
♦ Support bridge -30-211A-
♦ Thrust piece -32 - 111-
♦ Thrust piece -T10030/4-
– Lock bolt of support bridge -30-211A- with nut -A-.
Underneath bearing support for output shaft:
♦ Support device -T10323-
♦ Assembly tool -3253/7-
♦ Thrust piece -VW 433-
AG. Volkswagen AG d
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Remove selector fork for 5th gear as follows:sed b ara
nte
ri
o eo
– Cover openings with a cloth. aut
h
ra
ss c
– Move selector fork -1- to neutral position.
ce
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nl
pt
du
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– Remove bolt -2- with selector fork for 5th gear.
itte
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erm
ab
– Then remove both bolts -arrows- for pivot pins.
ility
ot p
wit
, is n
h re
hole
spec
– Remove selector fork.
es, in part or in w
t to the co
– Spring -3- and locking collar -4- do not need to be removed.
rrectness of i
– Remove bolts -A- for synchro-hub and gear wheel for 5th gear.
To do this, engage 5th gear -arrow 1- and 1st gear
l purpos
are locked. The synchro-hub and gear wheel cannot turn. Both
orm
atio
om
n in
or c
thi
e
Note
t
sd
iva
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r
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cu
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material out of threaded holes using a thread chaser.
Co
Cop py
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rig ht
py by
co Vo
by lksw
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Prote AG.
– Now remove 3rd bolt -arrow- for reverse shaft support bracket.
n AG. Volkswagen AG do
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pt
an
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itte
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ab
ility
– Gearboxes for vehicles with start-stop system: remove gear‐
ot p
wit
is n
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ole,
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
atio
m
n
c
i
or
sd
iva
o
pr
cum
r
fo
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
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Prote AG.
ce
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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
– Remove pivot pins -A- on top side of gearbox and securing
bolts -B- for gearbox housing to clutch housing in area of dif‐
rrectness of i
ferential.
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
– Remove bolts -A- from clutch housing side for securing clutch
t. rig
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yri
housing to gearbox housing. p by
o Vo
by c lksw
cted agen
Prote AG.
Note
ce
le
♦ Secure the grips so that the bearing does not come in contact
un
pt
with the gear wheel for 5th gear when the gearbox housing is
an
d
itte
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pulled off.
erm
ab
ility
ot p
wit
is n
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Use puller plate -T10408- in conjunction with following special
ole,
tools:
spec
urposes, in part or in wh
t to the co
♦ Grips -T10408/3-
rrectne
♦ Puller Kukko 18/1
– Screw puller plate -T10408- firmly into threaded holes for
ss
gearbox housing cover.
o
cial p
f in
A - Hexagon bolts M7 x 35 with washers
form
mer
atio
Torque setting 18 Nm
om
n
c
i
– Place thrust pieces -T10408/2- on shafts.
or
n thi
te
sd
iva
o
pr
c
– Install pullers Kukko 18/1 -A-.
um
r
fo
en
ng
t.
– Pull off 5th gear synchro-hub, gear wheel for 5th gear and
yi Co
op
gearbox housing by alternately tightening spindles -A- approx.
C py
ht. rig
12 turn.
rig ht
py by
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by lksw
cted
– Heat gear wheel for 5th gear slightly with hot air blower -
agen
Prote AG.
V.A.G 1416- if necessary.
ce
le
– Remove selector forks -A- together with selector plates.
un
pt
an
d
itte
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– Unbolt reverse gear selector mechanism -B-.
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f i
– Remove nuts -B- for output shaft bearing support.
nform
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
py by
co Vo
by lksw
cted agen
Prote AG.
– Remove reverse gear -A-, input shaft -B- and output shaft
-C- one after the other from clutch housing.
– Remove differential.
9.7.2 Installing
– Install differential.
– Always renew sealing rings -arrows- for output shaft bearing
support.
Note
– Insert input shaft -1- and output shaft -2- together. AG. Volkswagen AG d
agen oes
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– Tighten nuts for output shaft bearing support to specified
d by
V tor‐ gu
ara
que ⇒ Item 11 (page 227) . orise nte
eo
h
ut ra
– Set reverse gear wheel -3- on needle bearing
ss a
in clutch hous‐ c
ing.
ce
e
nl
pt
du
an
The shoulder -arrow- faces away from the clutch housing.
itte
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erm
ab
– Ensure that reverse shaft -4- is complete ⇒ page 291 ; do not
ility
ot p
yet fit reverse shaft support to reverse shaft.
wit
, is n
h re
– Fit reverse shaft into clutch housing. hole
spec
es, in part or in w
t to the co
support; a thread chaser may be used.
– Install reverse shaft support.
rrectness of i
– Attach reverse gear selector fork -1- with support for reverse
l purpos
gear selector fork -2-, spring -3- and sliding piece -4-.
nform
mercia
at
om
ion
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
o
by c lksw
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Prote AG.
Installation position, reverse gear
Note
AG. Volkswagen AG d
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pe
ility
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hole
spec
es, in part or in w
t to the co
rrectness of i
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tion in
thi
cover plate.
s
iva
do
r
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en
ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
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Prote AG.
ce
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nl
pt
du
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– Move selector shaft to neutral.
erm
ab
ility
ot p
wit
, is n
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hole
spec
– Bolt on selector shaft cover to specified torque
es, in part or in w
t to the co
– Gearboxes for vehicles with start-stop system: fit gearbox
rrectness of i
neutral position sender -G701- -arrow- and tighten securing
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
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– Install both flange shafts with springs, thrust washers and ta‐
op Vo
by c lksw
pered rings ⇒ page 224 .
cted agen
Prote AG.
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un
pt
an
– Place 5th gear synchro-ring on synchromeshed gear.
d
itte
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rm
ab
– If synchro-hub and locking collar for 5th gear are dismantled,
pe
ility
assemble before installing ⇒ page 269 .
ot
wit
, is n
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hole
The pointed teeth of the locking collar -arrow 1- and the high
t to the co
nform
mercia
a
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
ht. rig
rig ht
py by
co Vo
by lksw
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Prote AG.
Note
AG. Volkswagen AG d
agen oes
– Loosen support for input shaft. Volksw not
gu
by ara
d
rise nte
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WARNING auth
ra
ss c
ce
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pt
du
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itte
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erm
ab
ility
ot p
wit
hub securing bolts and 5th gear wheel with a thread chaser.
, is n
h re
hole
spec
es, in part or in w
– Screw in securing bolts for synchro-hub and gear wheel for 5th
t to the co
gear.
rrectness of i
l purpos
nf
ercia
orm
m
atio
m
n in
c
thi
te
sd
a
o
r
rp
cu
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f
– Tighten securing bolts for synchro-hub and gear wheel for 5th
en
ng
t.
yi
gear to specified torque. ⇒ page 225
Co
Cop py
t. rig
gh ht
pyri by
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co lksw
by
cted agen
Prote AG.
– Tighten bolts -A- for synchro-hub and 5th gear wheel to speci‐
fied torque ⇒ Item 4 (page 225) . To do this, engage 5th gear
-arrow 1- and 1st gear -arrows 2- and -3-.
– After both gears are engaged, the input shaft and output shaft
are locked. The synchro-hub and gear wheel cannot turn. Now
both bolts can be tightened.
– Install 5th gear selector fork.
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
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hole
spec
es, in part or in w
t to the co
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nf
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orm
m
atio
om
n in
or c
thi
te
sd
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cu
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f
en
ng
t.
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Cop py
t. rig
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247
op Vo
by c lksw
Prote
cted 9. Dismantling and assembling gearbox
AG.
agen
Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus 2009 ➤ , Pass ...
5-speed manual gearbox 0A4 - Edition 04.2010
AG. Volkswagen AG d
agen oes
olksw not
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d by ara
ise nte
or eo
h
aut ra
ss c
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nl
pt
du
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itte
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erm
ab
ility
ot p
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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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.
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pt
♦ Puller -VW 228 B- (is not
an
d
itte
required for this gearbox)
y li
erm
ab
ility
♦ Drift -VW 222 A- (not re‐
ot p
wit
quired with this gearbox)
is n
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ole,
spec
urposes, in part or in wh
t to the co
vice)
♦ Thrust piece -3124- (for
two-part seal and sleeve)
rrectne
♦ Multipurpose tool -VW 771-
(for one-piece seal and
ss o
sleeve)
cial p
f inform
♦ Extractor hooks -
mer
atio
m
n
c
i
or
n thi
te
sd
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pr
cum
r
fo
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
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by c lksw
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Prote AG.
ce
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un
pt
an
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itte
2 - Needle bearing
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ab
❑ For output shaft
pe
ility
ot
wit
❑ Removing ⇒ page 252
, is n
h re
❑ Installing and securing
hole
spec
⇒ page 252 .
es, in part or in w
t to the co
3 - Oil filler plug, 35 Nm
❑ The oil level cannot be
checked by removing
rrectness of i
the oil filler plug
l purpos
nform
ercia
a
com
t
⇒ page 2
ion in
r
te o
thi
Capacities, Golf 2009 ▸
s
iva
do
⇒ page 4
r
rp
cum
fo
en
g
t.
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op
⇒ page 5 C py
t. rig
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Capacities, Golf Plus 2009 ▸ cop Vo
by lksw
cted
⇒ page 6 ⇒ page 5
agen
Prote AG.
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un
pt
an
d
11 - Clutch housing
itte
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erm
ab
❑ When renewing, ⇒ adjustment overview ⇒ page 302
ility
ot p
wit
12 - Guide sleeve
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
❑ Driving in oil seal ⇒ page 252
❑ Remove guide sleeve to change oil seal
rrectne
❑ If O-ring is damaged, renew guide sleeve and O-ring together
13 - Socket head bolt
ss o
❑ Removing and installing ⇒ Item 6 (page 103)
cial p
f inform
14 - Seal
mer
atio
❑ Renewing ⇒ page 296
om
n
c
i
or
n
15 - Sleeve
thi
te
sd
va
o
pr
cum
r
fo
en
ng
t.
yi Co
❑ Installing ⇒ page 253 . Cop py
rig
ht ht
rig
16 - One-piece seal and sleeve py by
co Vo
by lksw
❑ If seal is damaged, renew seal and sleeve together cted agen
Prote AG.
❑ Removing ⇒ page 253
❑ Installing ⇒ page 253
17 - Oil drain plug, 35 Nm
18 - Tapered roller bearing outer race
❑ For differential
❑ Removing and installing ⇒ page 303
❑ If renewed, adjust differential ⇒ page 311
19 - Magnet
❑ Held in place by housing joint surface
20 - Oil collector
❑ Installing oil collector in gearbox housing ⇒ page 254
21 - Tapered roller bearing outer race
❑ For differential
❑ Removing and installing ⇒ page 303
❑ If renewed, adjust differential
⇒ page 311
22 - Shim
❑ For differential
❑ Adjustment overview ⇒ page 302
23 - Seal
❑ Renewing ⇒ page 294
n AG. Volkswagen AG do
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spec
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-B-.
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Note
ss
With gearbox dismantled, press sleeve in to stop using thrust
o
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f
piece -3124- .
inform
mer
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n
c
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– To pull out seal and sleeve, apply extractor hooks -VW 771/37-
um
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AG. Volkswagen AG d
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Rep. Gr.34 - Controls, housing
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11 Repairing selector unit
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♦ Tube -T10203-
spec
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c
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1 - Selector unit
❑ Consists of selector
shaft and selector shaft
cover
❑ Components cannot be
separated from each
other
2 - Reversing light switch -F4-
❑ Tighten to 20 Nm
❑ Lightly coat lug with
MoS2 grease.
3 - Angled rod
❑ For adjusting selector
mechanism
❑ Removing ⇒ page 257
❑ Pressing in
⇒ page 257
4 - Relay lever
❑ Installation position
⇒ page 134
❑ From 05.07, plastic re‐
lay lever ⇒ page 134
5 - Bearing bush
❑ Not required for plastic
relay lever
6 - Seal
❑ Lever out with a screw‐
driver
❑ Installing ⇒ page 257 n AG. Volkswagen AG do
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7 - Hexagon nut, 23 Nm d byV
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ran
❑ Self-locking ir se tee
tho
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❑ Always renew ss
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9 - Cap
spec
es, in part or in w
10 - Securing clip
❑ Always renew
rrectness of i
11 - Cover plate
nform
ercia
12 - Spring
❑ Not installed in all gearboxes.
m
at
om
io
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or
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ate
do
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Pressing angled rod -A- into selector
utho shaft cover eo
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Installation position: s
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Marking -arrow- points to upper part of selector shaft.
an
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es, in part or in w
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♦ Thrust piece -VW 431-
rm
ab
pe
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♦ Spacer sleeve -VW 472/2-
ot
wit
, is n
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♦ Drift -10 - 206-
hole
spec
es, in part or in w
t to the co
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l purpos
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mercia
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♦ Clamp -2070-
ab
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nf
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Note
or
thi
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sd
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( ⇒ Item 7 (page 260) ) in order to remove and install selector
f
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t.
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segments, lock washers and angular contact ball bearings.
Co
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5 - 5th gear selector jaw
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❑ Qty. 4
ility
ot
wit
❑ Removing ⇒ page 261
, is n
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hole
spec
outer race ⇒ page 262
es, in part or in w
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❑ Installing ⇒ page 262
7 - Selector fork group with se‐
lector plate
rrectness of i
8 - Selector segment for 1st
l purpos
nform
ercia
⇒ page 261
m
a
❑ After lock washer is in‐
com
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n in
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9 - Selector segment for 3rd
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❑ Identification ⇒ page 261 t. Cop py
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10 - Sliding piece cted agen
Prote AG.
11 - Spring
12 - Selector fork for reverse gear
13 - Support for reverse gear selector fork
14 - Retaining ring
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Note
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Removing angular contact ball bearing
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Pressing inner race -A- of angular contact ball bearing into outer
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Inner race must engage in outer race.
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35 – Gears,
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Input shaft
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1.1 Dismantling and assembling input shaft
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equipment required
h re
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spec
♦ Press tool -VW 407-
urposes, in part or in wh
t to the co
♦ Thrust pad -VW 447 H-
♦ Press tool -VW 412-
rrectne
♦ Tube -VW 422-
s
♦ Thrust plate -VW 401-
s o
cial p
f
♦ Thrust plate -VW 402-
inform
mer
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n
c
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Note
♦ When installing new gear wheels or input shaft, consult technical data ⇒ page 2 and ⇒ Electronic parts
catalogue “ETKA” .
♦ If the position of the tapered roller bearings is affected when parts are exchanged, the input shaft must be
readjusted. See adjustment overview ⇒ page 302 .
1 - Clutch housing
2 - Tapered roller bearing outer
race
❑ Pressing out
⇒ page 266 agen
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⇒ page 266 orise nte
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3 - Tapered roller bearing inner ss a c
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❑ Pressing off
itte
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⇒ page 267
erm
ab
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❑ Pressing on
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⇒ page 267
, is n
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hole
4 - Input shaft
spec
es, in part or in w
t to the co
5 - Gear wheel for 3rd gear
❑ Installation position:
rrectness of i
shoulder faces 4th gear
l purpos
❑ Pressing off
⇒ page 267
nf
ercia
❑ Pressing on
or
⇒ page 268
m
m
atio
m
6 - Retaining ring
o
n in
or c
❑ Always renew
thi
te
sd
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15 - Synchromeshed gear for 5th gear
pt
an
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16 - Synchro-ring for 5th gear
rm
ab
pe
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❑ With cast locking pieces ⇒ page 246
ot
wit
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hole
spec
17 - Spring
es, in part or in w
t to the co
❑ Installation position ⇒ page 269
❑ After gearbox construction date 05 11 1: Bent ends on springs ⇒ page 270
rrectness of i
18 - Locking pieces (Qty. 3)
❑ Installation position ⇒ page 269
l purpos
nform
ercia
a
com
tion in
❑ Pulling off with synchro-hub for 5th gear, from ⇒ page 234 .
r
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thi
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21 - Dished washer
iva
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rp
c
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um
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22 - Bolt ⇒ Item 4 (page 225)
Co
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❑ Always renew
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❑ Fitted section of bolt head holds dished spring in position ⇒ page 246 .
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Pressing on tapered roller bearing inner race
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cial p
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n
c
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Pressing off gear wheel for 4th gear with tapered roller bearing
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AG. Volkswagen AG d
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Pressing in tapered roller
ss au
bearing outer race ra
c
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spec
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nform
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pieces -item 4- a
com
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r
3- Synchro-hub
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Installation position of springs: o
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– Install springs offset 120°. ss
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It must be located under shoulder -B- of locking piece.
erm
ab
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-direction of arrow-.
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spec
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1.2 Adjusting input shaft
l purpos
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♦ Torque wrench -V.A.G
d
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rm
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AG. Volkswagen AG d
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– ut roller bearing outer race without shim into gear‐
Press tapered
a ra
s c
box housing
s to stop.
ce
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un
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– Install input shaft in clutch housing and set gearbox housing
an
d
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in place. Tighten hexagon head bolts to 25 Nm and then turn
erm
ab
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– Fit measuring appliance and dial gauge in clutch housing.
ss o
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n
c
Note
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– Press input shaft in direction of dial gauge
-direction of arrow-.
– Read and note play on dial gauge (example: 1.21 mm).
Note
ce
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Table of shims
nl
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Bearing play Shim
erm
ab
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ot p
Measured value (mm) Thickness (mm)
wit
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0.671…0.699 0.650
h re
hole
0.700…0.724 0.675
spec
0.725…0.749 0.700
es, in part or in w
t to the co
0.750…0.774 0.725
0.775…0.799 0.750
0.800…0.824 0.775
rrectness of i
0.825…0.849 0.800
l purpos
0.850…0.874 0.825
0.875…0.899 0.850
0.900…0.924 0.875
nform
ercia
0.925…0.949 0.900
m
0.950…0.974 0.925
at
om
ion
c
0.975…0.999 0.950
in t
or
1.000…1.024 0.975
his
ate
1.025…1.049 1.000
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1.150…1.174 Prote
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agen
1175…1.199 1.150
1.200…1.224 1.175
1.225…1.249 1.200
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
Note
AG. Volkswagen AG d
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es, in part or in w
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mercia
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ion
c
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ate
do
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2 Output shaft
n AG. Volkswagen AG do
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mercia
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tion in
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Cop py
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Prote AG.
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es, in part or in w
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a
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tion in
r
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Cop py
t. rig
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co lksw
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Prote AG.
AG. Volkswagen AG d
agen oes
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V gu
d by ara
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or eo
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by c lksw
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Prote AG.
Note
♦ The output shaft is dismantled as follows: position separating device under 2nd gear synchromeshed gear
⇒ Item 21 (page 279) and press off as described in ⇒ page 281 . Remove retaining ring
⇒ Item 17 (page 279) . Then press off locking collar with synchro-hub for 1st and 2nd gear as described in
⇒ page 282 .
♦ When installing new gears or new input shaft, refer to ⇒ Electronic parts catalogue “ETKA” and technical
data ⇒ page 2 .
♦ Always renew both tapered roller bearings together as a set.
ce
e
nl
pt
❑ Pressing in
du
an
itte
⇒ page 281
y li
erm
ab
ility
5 - Tapered roller bearing inner
ot p
race small
wit
, is n
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❑ Pulling off ⇒ page 281
hole
spec
❑ Pressing on
es, in part or in w
t to the co
⇒ page 281
6 - Output shaft rrectness of i
❑ Adjusting ⇒ page 287
l purpos
❑ Pressing on
m
at
⇒ page 282
om
ion
c
in t
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8 - Seal
o
his
ate
4) on bearing support
um
for
en
g
bolts
n
t.
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op py
9 - Bearing support
t. C rig
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❑ With large tapered roller bearing outer race and bolts
op Vo
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❑ Change outer race only together with large tapered roller bearing and bearing support Prote AG.
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)
❑ Installation position ⇒ page 282
❑ Check for wear ⇒ page 283
AG. Volkswagen AG d
❑ Check lugs for scoring agen oes
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14 - Outer ring for 1st gear rised
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❑ Installation position ⇒ pages au282
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❑ Check for wear ⇒ page 283
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❑ Renew if scored
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15 - Synchro-ring for 1st gear
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❑ Check for wear ⇒ page 283
hole
spec
16 - Locking collar with synchro-hub for 1st and 2nd gears
es, in part or in w
t to the co
❑ After removing retaining ring, pull off together with bearing support ⇒ page 282 ⇒ Item 17 (page 279)
❑ Dismantling ⇒ page 283
rrectness of i
❑ Assembling locking collar and synchro-hub ⇒ page 283 , ⇒ page 284 and ⇒ page 284
l purpos
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17 - Retaining ring
m
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18 - Synchro-ring for 2nd gear
com
tion in
❑ Check for wear ⇒ page 283
r
te o
thi
s
❑ Assemble so that notches engage in locking pieces of locking collar ⇒ Item 16 (page 279)
iva
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19 - Outer ring for 2nd gear
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❑ Insert in synchro-ring ⇒ Item 18 (page 279) .
Co
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❑ Installation position ⇒ page 285
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❑ Renew if scored
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Prote AG.
20 - Synchro-ring
❑ (Inner ring for 2nd gear)
❑ Check for wear ⇒ page 283
❑ Check lugs for scoring
❑ Installation position ⇒ page 285
21 - Synchromeshed gear for 2nd gear
❑ Installation position ⇒ page 285
22 - Needle bearing
❑ For 2nd gear
23 - Thrust washer
24 - Sleeve for 3rd gear needle bearing
❑ Pressing off with synchromeshed gear for 2nd gear ⇒ page 281
❑ Pressing on ⇒ page 285
25 - Needle bearing
❑ For 3rd gear
26 - Synchromeshed gear for 3rd gear
27 - Synchro-ring for 3rd gear
❑ Check for wear ⇒ page 286
28 - Locking collar with synchro-hub for 3rd and 4th gears
❑ Press off with synchromeshed gears for 2nd gear ⇒ Item 21 (page 279) and 3rd gear
⇒ Item 26 (page 279) ⇒ page 281 .
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nl
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❑ For 4th gear
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32 - Synchromeshed gear for 4th gear
hole
spec
33 - Thrust washer
es, in part or in w
t to the co
34 - Needle bearing
❑ For output shaft
rrectness of i
❑ Removing and installing ⇒ page 252
l purpos
35 - Gearbox housing
36 - Sleeve
nform
ercia
at
om
in t
r
his
ate
do
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or
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t.
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38 - Dished washer
C py
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❑ Installation position ⇒ page 246 py by
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39 - Bolt ⇒ Item 4 (page 225) Prote AG.
❑ Always renew
❑ Removing and installing ⇒ page 234
AG. Volkswagen AG d
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Pressing on small tapered roller bearing inner race Volksw not
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es, in part or in w
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Pressing off 3rd and 4th gear synchro-hub and locking collar, 2nd,
rrectness of i
3rd and 4th gear synchromeshed gears with sleeve for gearbox
housing needle bearing
l purpos
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Note
or c
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Support splitter so that the 1st and 2nd gear locking collar is not
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Cop py
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Prote AG.
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ab
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es, in part or in w
gear.
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Note
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Cop py
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If components are to be reused, ensure that they are matched p by
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with their original gears.
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Prote AG.
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“ETKA” .
ab
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spec
es, in part or in w
nform
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ion
c
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ate
do
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cum
for
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t.
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Cop py
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283
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Prote AG.
2. Output shaft
Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus 2009 ➤ , Pass ...
5-speed manual gearbox 0A4 - Edition 04.2010
Assembly of 1st and 2nd gear locking collar and synchro-hub with
AG. Volkswagen AG d
hollow locking pieces ksw
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• Locking collar has been pushed over synchro-hub.
ise
db ran
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– Insert locking pieces and install springs
sa
utoffset 120°. Angled or
ac
end of spring must locate in hollow locking piece.
s
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ab
ility
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hole
spec
es, in part or in w
t to the co
Assembly of 1st and 2nd gear locking collar and synchro-hub with
solid locking pieces
rrectness of i
• Locking collar has been pushed over synchro-hub.
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Installation position of locking collar with synchro-hub for 1st and
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2nd gears
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Teeth of locking collar -arrow- face splines for 3rd and 4th gear
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synchro-hub -A-. Prote AG.
Pressing on locking collar and synchro-hub for 1st and 2nd gears
Turn synchro-ring so that grooves align with locking pieces.
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ab
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is n
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spec
urposes, in part or in wh
t to the co
Installation position of synchromeshed gear for 2nd gear
Higher shoulder -A- faces 1st gear -B-. Notches in shoulder
rrectne
-arrows- engage in lugs of outer ring ⇒ page 285 .
ss o
cial p
f inform
mer
atio
om
n
c
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t.
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Pressing on sleeve for 3rd gear needle bearing . Cop py
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rig by
copy Vo
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Prote AG.
Dismantling and assembling 3rd and 4th gear locking collar and
synchro-hub
1 - Spring
Allocate springs according to ⇒ Electronic parts catalogue “ET‐
KA” .
Installation with hollow locking pieces ⇒ page 284 .
Installation with solid locking pieces ⇒ page 284 .
2 - Locking piece
Allocate locking pieces according to ⇒ Electronic parts catalogue
“ETKA” .
3 - Locking collar
4 - Synchro-hub
– Slide locking collar over synchro-hub.
Notches for locking pieces in synchro-hub and locking collar must
align.
pt
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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
Assembly of 3rd and 4th gear locking collar and synchro-hub with
solid locking pieces
rrectness of i
-arrows-.
m
at
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ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
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Vo
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286
Prote AG.
Rep. Gr.35 - Gears, shafts
Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus 2009 ➤ , Pass ...
5-speed manual gearbox 0A4 - Edition 04.2010
ce
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nl
pt
du
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ab
ility
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hole
spec
es, in part or in w
t to the co
Pressing on synchro-hub with locking collar for 3rd and 4th gears
rrectness of i
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nf
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orm
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atio
om
n in
or c
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Pressing on sleeve for 4th gear needle bearing
yi Co
Cop py
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Prote AG.
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equipment required
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♦ Universal dial gauge brack‐
rm
ab
et -VW 387- pe
ility
ot
wit
♦ End dimension plate -
, is n
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VW 385/17-
hole
spec
♦ Thrust pad -VW 512-
es, in part or in w
t to the co
♦ Straightening tool -3114/2-
♦ Press tool -VW 407-
rrectness of i
♦ Torque wrench -
l purpos
V.A.G 1331-
♦ Dial gauge
nform
mercia
a
com
tion in
r
te o
thi
s
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Cop py
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Prote AG.
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Note
ab
ility
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the tapered roller bearing settle in one direction.
ole,
spec
urposes, in part or in wh
t to the co
♦ Otherwise the resulting reading will be incorrect.
rrectne
– Set up dial gauge (3 mm measuring range) and set to “0”with
1 mm preload.
ss
– Move output shaft up and down. Read and note play indicated
o
cial p
f
on dial gauge.
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
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Vo
co
2.2.1 Determining thickness of shim
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Prote AG.
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Bearing play = Shim
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(0.65 mm thickness (mm)
ility
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plus determined measured val‐
wit
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h re
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spec
0.990 … 1.039 1.150
urposes, in part or in wh
t to the co
1.090 … 1.139 1.250
1.140 … 1.189 1.300
1.190 … 1.239 1.350
rrectne
1.240 … 1.289 1.400
1.290 … 1.339 1.450
ss
1.340 … 1.389 1.500
o
cial p
f
1.390 … 1.429 1.550
inform
mer
atio
om
n
Note
c
i
or
n thi
te
sd
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pr
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fo
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t.
– Remove output shaft and pull out small tapered roller bearing
yi Co
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outer race ⇒ page 280 .
C py
t. rig
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– Insert shims of determined thickness, thickest shim first.
op Vo
by c lksw
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Prote AG.
• 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 outer race of small tapered roller bearing together with
the calculated shim (0.70 mm in example) ⇒ page 281 and
install output shaft. Tighten bearing support nuts in clutch
housing to 25 Nm and then turn 90° further.
3 Reverse shaft
G. Volkswage
3.1 Dismantling
olks
wage
nA
and assembling
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Special tools
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equipment
ss required c
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pt
♦ Thrust piece -VW 454-
du
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ab
ility
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wit
, is n
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♦ Centring mandrel -12 - 551-
hole
spec
es, in part or in w
t to the co
♦ Press tool -VW 408 A-
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
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Vo
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by
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Prote AG.
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pt
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Note itte
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ility
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After dismantling, always renew needle bearing in clutch housing and reverse shaft support.
wit
, is n
h re
hole
spec
es, in part or in w
1 - Clutch housing
t to the co
2 - Needle bearing
❑ Pulling out ⇒ page 292
rrectness of i
❑ Pressing in
l purpos
⇒ page 293
3 - Reverse gear wheel
nf
ercia
o
4 - Retaining ring
rm
m
atio
❑ Always renew after re‐
om
n in
moving
or c
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Note
n AG. Volkswagen AG do
Pressing needle bearing -A- into sclutch
wage housing es
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pt
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ab
ility
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wit
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hole
spec
es, in part or in w
t to the co
Pressing needle bearing out of reverse shaft support
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
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sd
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Pressing needle bearing into reverse shaft support t. C rig
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Vo
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by c lksw
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Prote AG.
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nl
pt
du
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1 Renewing flange shaft oil seals with
erm
ab
ility
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gearbox installed
wit
, is n
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hole
spec
es, in part or in w
1.1 Renewing oil seal for left flange shaft
t to the co
rrectness of i
Special tools and workshop
equipment required
♦ Multipurpose tool -VW 771- l purpos
nf
ercia
♦ Puller hooks -VW 771/37-
orm
m
atio
om
n in
c
thi
te
sd
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♦ Torque wrench -
iv
o
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rp
cu
V.A.G 1331-
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f
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
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Prote AG.
1.1.1 Removing
– Remove left wheel.
– Remove noise insulation ⇒ General body repairs, exterior;
Rep. Gr. 50 ; Noise insulation .
– Remove lower part of front left wheel housing liner ⇒ General
body repairs, exterior; Rep. Gr. 66 ; Wheel housing liner .
– 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 .
ce
e
nl
pt
– Pull out flange shaft with compression spring.
du
an
itte
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erm
ab
ility
ot p
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
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– Pull out flange shaft oil seal using multipurpose tool -VW 771-
and puller hooks -VW 771/37- .
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
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pyri by
Vo
co lksw
by
cted agen
Prote AG.
1.1.2 Installing
– Drive in new seal to stop, being careful not to cant seal.
– Half-fill space between sealing lip and dust lip with sealing
grease -G 052 128 A1- .
– Insert flange shaft.
– Secure flange shaft with countersunk bolt.
– Attach drive shafts to gearbox ⇒ Running gear, axles, steer‐
ing; Rep. Gr. 40 ; Repairing drive shaft; Removing and instal‐
ling drive shafts .
– Check gear oil ⇒ page 220 .
– Install lower part of front left wheel housing liner ⇒ General
body repairs, exterior; Rep. Gr. 66 ; Wheel housing liner .
– Install noise insulation ⇒ General body repairs, exterior; Rep.
Gr. 50 ; Noise insulation .
– Install wheel ⇒ Running gear, axles, steering; Rep. Gr. 44 ;
Torque settings for mounting wheels .
ce
le
un
pt
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d
itte
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ab
pe
ility
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wit
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hole
spec
es, in part or in w
t to the co
♦ Thrust piece -T10160-
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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op py
♦ Assembly tool -3253/2- t. C rig
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pyri by
Vo
co lksw
by
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Prote AG.
1.3.1 Removing
– Remove noise insulation ⇒ General body repairs, exterior;
Rep. Gr. 50 ; Noise insulation .
– Turn steering to right to full lock.
– Remove drive shaft heat shield, if present -arrows- ⇒ Running
gear, axles, steering; Rep. Gr. 40 ; Repairing drive shafts;
Removing and installing drive shafts .
AG. Volkswagen AG d
agen oes
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erm
ab
ility
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wit
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spec
es, in part or in w
atio
om
n in
or c
thi
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f
en
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t.
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– Pull out flange shaft with compression spring.
Co
Cop py
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Vo
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Prote AG.
Note
Volkswagen AG
♦ Do not damage sleeve. Otherwise, leaks will occur.
swa
gen AG
.
does
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♦ Replace sleeve if damaged ⇒ page 253 .ised by ara
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ab
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1.3.2 Installing
ility
ot
wit
, is n
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– Drive in new seal to stop, being careful not to cant seal.
hole
spec
– Half-fill space between sealing lip and dust lip with sealing
es, in part or in w
t to the co
grease -G 052 128 A1- .
– Insert flange shaft.
rrectness of i
– Secure flange shaft with countersunk bolt.
l purpos
nform
mercia
a
com
tion in
r
te o
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– If turbocharger oil return line was unbolted from engine, bolt it
s
iva
do
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cum
fo
t.
cillaries .
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Cop py
t. rig
– Bolt drive shaft -1- to flange shaft ⇒ Running gear, axles,
gh ht
pyri by
steering; Rep. Gr. 40 ; Repairing drive shaft; Removing and
o Vo
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installing drive shafts .
agen
Prote AG.
1.4 Renewing seal and sleeve together (one-piece seal and sleeve for right
flange shaft)
AG. Volkswagen AG d
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ab
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is n
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spec
urposes, in part or in wh
t to the co
rrectness o
f inform
atio
m
n
c
i
or
n thi
sd
iva
o
r
cum
r
fo
en
ng
t.
♦ Torque wrench -V.A.G 1331- Cop
yi Co
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t. rig
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Vo
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by
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Prote AG.
AG. Volkswagen AG d
agen oes
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ab
1.4.1 Removing
pe
ility
ot
wit
, is n
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hole
spec
es, in part or in w
t to the co
– Remove drive shaft heat shield, if present -arrows- ⇒ Running
gear, axles, steering; Rep. Gr. 40 ; Repairing drive shafts;
rrectness of i
Removing and installing drive shafts .
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
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rp
cum
fo
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ng
t.
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Cop py
– Disconnect drive shaft -1- from flange shaft.
t. rig
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pyri by
Vo
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– Raise drive shaft as high as possible and secure. Take care
c by lksw
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not to damage paint on drive shaft in the process. Prote AG.
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- bywagen AG. Volkswagen AG doe
turning nut -B-. yV
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– Half-fill space between sealing lip and dust lip withtho
rigrease
s
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itte
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erm
ab
ility
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wit
is n
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ole,
spec
urposes, in part or in wh
cillaries .
t to the co
– Bolt drive shaft -1- to flange shaft ⇒ Running gear, axles,
steering; Rep. Gr. 40 ; Repairing drive shaft; Removing and
installing drive shafts .
rrectness o
cial p
f inform
mer
atio
om
n
c
n thi
e
sd
va
o
pr
cum
r
fo
en
ng
2 Adjustment overview
AG. Volkswagen AG d
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ara
ed
If repairs have been carried out to the gearbox, thor it
is
is necessary to nte
eo
adjust the input shaft, output shaft or differential
s au only if compo‐ ra
c
nents have been renewed which have a direct effect on the
s
ce
e
adjustment of the gearbox. To prevent unnecessary adjustments,
nl
pt
du
an
refer to the following table:
itte
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erm
ab
ility
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To be adjusted:
wit
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Input shaft Output shaft Differential
hole
spec
⇒ page 270 ⇒ page 287 ⇒ page 311
es, in part or in w
t to the co
Clutch housing x x x
Input shaft x
rrectness of i
Output shaft x
l purpos
Differential cage x
Tapered roller bearings for input x
nf
ercia
o
shaft
rm
m
atio
Tapered roller bearing for output x
om
n in
shaft
or c
thi
e
sd
iva
o
tial
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rp
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o
m
f
en
ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
3 Differential
AG. Volkswagen AG d
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erm
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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.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
3. Differential 303
Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus 2009 ➤ , Pass ...
5-speed manual gearbox 0A4 - Edition 04.2010
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
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at
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ion
c
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or
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ate
do
priv
cum
for
en
ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
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Prote AG.
Note
1 - Gearbox housing
2 - Shim
❑ For differential
❑ Determining thickness
⇒ page 311
3 - Tapered roller bearing outer
race
❑ Pulling out ⇒ page 308
❑ Pressing in n AG. Volkswagen AG do
lkswage es n
⇒ page 308 by Vo ot g
ua d ran
ise
4 - Tapered roller
ut
ho bearing inner
r tee
or
race ss
a ac
ce
pt
du
an
❑ Pressing on
itte
y li
⇒ page 307
erm
ab
ility
ot p
5 - Differential cage
wit
, is n
h re
spec
❑ Allocate according to ⇒
Electronic parts cata‐
nf
ercia
logue “ETKA” .
orm
m
race
o
n in
or c
thi
sd
iva
❑ Pressing on
o
r
rp
cu
⇒ page 307
o
m
f
en
ng
t.
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7 - Tapered roller bearing outer Cop py
t. rig
race opyri
gh by
Vo
ht
3. Differential 305
Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus 2009 ➤ , Pass ...
5-speed manual gearbox 0A4 - Edition 04.2010
ce
e
nl
pt
du
14 - Compression spring for flange shaft
an
itte
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erm
ab
ility
ot p
15 - Thrust washer
wit
, is n
h re
❑ Installation position ⇒ page 310
hole
spec
16 - Tapered ring
es, in part or in w
t to the co
❑ With grooves to engage in thrust washer
❑ Installation position: taper towards differential cage
rrectness of i
17 - Retaining ring
l purpos
❑ Holds tapered ring, thrust washer and spring in position when flange shaft is removed
18 - One-piece thrust washer
nform
ercia
at
❑ One-piece thrust washer has shoulder in some gearboxes ⇒ page 309
om
ion
c
in t
r
his
ate
do
priv
cum
or
20 - Threaded piece
f
en
ng
t.
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❑ Installing ⇒ page 310 Cop py
t. rig
gh ht
yri
21 - Differential pinion pin p by
co Vo
by lksw
cted
❑ Removing in conjunction with shorter spring pin ⇒ page 309
agen
Prote AG.
ce
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un
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d
itte
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erm
ab
ility
ot p
wit
is n
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ole,
spec
urposes, in part or in wh
t to the co
rrectne
Pressing tapered roller bearing outer race into clutch housing
ss o
No shim is installed in the clutch housing end. 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
py by
co Vo
by lksw
cted agen
Prote AG.
Pulling off tapered roller bearing inner race
– Before fitting extractor, position thrust plate -40 - 105- on dif‐
ferential cage.
Note
Both tapered roller bearing inner races are pulled off the differ‐
ential cage in the same way.
Note
Both tapered roller bearing inner races are pressed onto the dif‐
ferential cage in the same way.
3. Differential 307
Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus 2009 ➤ , Pass ...
5-speed manual gearbox 0A4 - Edition 04.2010
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-
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
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hole
spec
es, in part or in w
⇒ page 309
36.0 (long spring pin), No circumferential
nform
ercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
t.
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op
– Check hole for spring pin in differential cage.
C py
t. rig
gh ht
yri by
The hole in the differential cage was modified for the longer spring cop Vo
by lksw
pin.
cted agen
Prote AG.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
Installing spring pin without circumferential groove
s a (long spring
u ra
c
pin) s
ce
le
un
pt
– Align hole in differential pinion pin with hole in differential cage.
an
d
itte
y li
erm
ab
– Drive in new spring pin with drift -1- until dimension -a- =
ility
ot p
3.0 mm is attained.
wit
is n
h re
• The spring pin must not come in contact with gears with dif‐
ole,
spec
ferential cage installed.
urposes, in part or in wh
t to the co
rrectne
In some gearboxes, the one-piece thrust washer has a shoulder
ss
-A- near the holes
o
cial p
f inform
In this case, the differential cage has a circumferential groove
mer
-B-.
atio
om
n
c
n thi
te
sd
a
o
r
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
3. Differential 309
Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus 2009 ➤ , Pass ...
5-speed manual gearbox 0A4 - Edition 04.2010
ce
le
un
pt
an
d
itte
y li
Installation position of thrust washer for tapered ring -1-.
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
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
wit
h re
hole
♦ Gearbox housing
spec
es, in part or in w
♦ Clutch housing
t to the co
♦ Differential cage
rrectness of i
or the
l purpos
tion in
r
te o
thi
s
iva
Note
do
r
rp
cum
fo
en
Inner and outer tapered roller bearing races are paired. Do not
ng
t.
yi Co
interchange! ht. Cop py
rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
3. Differential 311
Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus 2009 ➤ , Pass ...
5-speed manual gearbox 0A4 - Edition 04.2010
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
3.2.1 Determining thickness of shim
es, in part or in w
t to the co
Example:
Bearing play, measured value Thickness of shim according to
rrectness of i
table
l purpos
0.70 mm 0.95 mm
Table of shims
nform
mercia
at
om
ion
c
in t
or
(mm) (mm)
his
ate
do
riv
cum
or
en
ng
t.
0.500 … 0.549 0.750
yi Co
Cop py
0.550 … 0.599 0.800 ht. rig
rig ht
by
0.600 … 0.649 0.850 copy Vo
by lksw
0.650 … 0.699 0.900 cted agen
Prote AG.
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
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
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
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
3. Differential 313