Volkswagen Workshop Manuals Golf Mk1 Page 3

3/10/2020 Volkswagen Workshop Manuals > Golf Mk1 > Power transmission > 4 Speed Manual Gearbox 020
box 020 > Gearbox mechanics,operation,…
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Donate and help keep workshop manuals Power transmission > 4 Speed Manual Gearbox 020 > Gearbox mechanics,operation,
freely available. construction,diff. > Controls, Housing > Removing and installing housing
Controls, Housing
Removing and installing Housing
Removing
‒ → Installing gearbox in repair stand -

VW.
Other Volkswagen Workshop Manuals

Other Makes
Running gear
Body
Engine, mechanics
Power transmission
4 Speed Manual Gearbox 020
Technical data
Clutch, control
Gearbox mechanics,operation, ‒ → Installing gearbox in repair stand -
Audi.
construction,diff.
Controls, Housing ‒ Pull clutch rod out downwards.
Repairing shift linkage
Adjusting shift linkage
Adjusting gear shift linkage
Modifications to the shift linkage
Boot with cap
One-piece shift rod bearing 1
Relay lever with larger rubber ball
Type of grease
Removing and installing bonded
rubber bushes for gearbox carrier
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3/10/2020 Volkswagen Workshop Manuals > Golf Mk1 > Power transmission > 4 Speed Manual Gearbox 020 > Gearbox mechanics,operation,…
‒ → Fitting support bar for drive shaft -

VW
Download Your A - Locknut M 12.
‒ Lift VW 295a into contact with drive

eManual Now shaft with screw and lock.
O cial Repair Manuals

Website. Instantly
Download Now Online
‒ → Fitting support bar for drive shaft -

Audi.
A - Locknut M 12.
Download
Your
eManual
Now ‒ → Remove cap, circlip and washer
from drive flange.
eManual Online
‒ Pull flange off.
O cial Repair Screw two M 8 x 30 bolts through slots

into flange.
Manuals Website.
Instantly ‒ Take cover off.
‒ Lever circlip off release shaft.
Download Now ‒ Take off release shaft , clutch lever,
Online return spring, release bearing and
sleeve.
DOWNLOAD
‒ → Lever plugs -arrows- out and take

off 3 nuts.
‒ Remove selector shaft retaining screw.
‒ Remove bolt securing reverse gear
shaft.
‒ Screw reversing light switch out.
‒ → Remove selector shaft end plug.
A - Spark plug spanner (Part No. 311

012 205 A).
‒ Move selector forks to neutral and pull

selector shaft out.
Note:
If the selector forks cannot be placed in

neutral the selector shaft cannot be pulled
out. Shaft can then be removed by force as
follows:
‒ → Take circlip -2- off (only on

downward pressure system).
‒ Knock shaft -1- out.
‒ Sheet metal housing -3-, shift finger -4-
and sleeve -5- remain in housing -6-.
‒ If 1st, 2nd or reverse gear are
engaged.
‒ When knocking shaft out, place a nut
between sheet metal housing -3- and
gearbox -6- as a support -arrow-
‒ Renew damaged parts (selector shaft,
shaft, selector forks).
‒ → Remove bolts attaching gearbox

housing.
‒ Pull housing off.
A - Screws two M 7 x 30 bolts (N 10

407.1) through the holes into the
housing.
Installing
If drive shaft has not been dismantled, press

drive shaft ball bearing off ; Fig.1 .
‒ → Press drive shaft bearing into

housing with shims in position.
‒ → Insert clamping bolts and tighten

nuts.
‒ → Align reverse gear shaft. Spacing x

must be the same.
Before Knocking housing on:
a - Screw two M 8 studs into

bearing housing to guide gearbox
housing.
b - Ensure that the drive shaft is
properly supported by bar 30-211 and
adaptor VW 295 A.
‒ → Knock housing on.

‒ Screw in bolt securing reverse gear
shaft.
‒ Screw in bolts securing housing.
‒ Move forks to neutral, insert selector
shaft and install cover.
‒ Install reversing light switch.
‒ Install and adjust retaining screw for
selector shaft => page 34-17
1
‒ → Install drive flange.
‒ Fit washer and circlip
‒ → Press drive flange circlip into

position.
‒ Install cap.
‒ Retighten nuts on clamping bolts to 1.5
mkg and fit plugs.
‒ → Install drive shaft circlip

‒ Install release bearing and sleeve. Fit
release shaft, clutch lever and return
spring. The bent ends of the spring
contact the housing wall and the
centre part hooks on to the clutch
lever.
‒ → Install locking ring (s) for release

shaft.
‒ Fit cover and insert clutch rod.
Modifications
Gearbox housing/end cover
From Assembly date 15 03 5:
The bore in the housing for the end cover

was changed form tapered to cylindrical.
Repair instructions
(Gearbox up to 14 03 5)
When fitting a new gearbox housing use 020

301 051 A housing,end cover 020 301 232 A
and boot 020 301 261 A.
Selector shaft
Up to Assembly date 24 08 5:
Side pressure system.
→ Reverse catch provided by chamfer on

selector shaft -arrow- and retaining screw.
HOME From Assembly date 25 08 5: MENU
Downward pressure system.
→ Reverse catch moved to shift linkage.

Chamfer on selector shaft discontinued,
retaining screw modified, spring at end of
shaft dropped.
Reversing light switch
From Assembly date 07 08 5.
→ The switch is mounted on a bracket -1-

attached to the gearbox and operated by the
selector shaft lever -2-.
Adjust or bend the bracket so that the

reversing lights work properly.
From Assembly date 05 04 6.
→ The switch is in the gearbox again.
Operated by a lug on the reverse gear

selector fork (see => page 34-67 )
1
Clutch lever
From 15 03 5 to 16 03 7
→ Lever with shoulder -1-, secured with one

circlip -2-.
From Assy. date 17 03 7:
→ Lever with no shoulder, secured with two

circlips. Modified release shaft.
Note:
Up to 16 03 7
When installing the new shaft, the new lever

and an additional circlip must be installed.
Checking oil level
Remove checking plug -arrow 1- with 5 mm

Allen key. Oil must be up to lower edge of
hole.
Putting oil in
→ Removing plug -arrow 2-.
Put in gear oil - SAE 80 or 80/90 to MIL-L

2105 (GL 4) specifications - until oil flows out
of level checking hole.
Caution
Oil must be put in slowly to give it time
to level out uniformly in the box. Stop
for a brief period (30 seconds) if
necessary.
Modification
From Assembly date 07 05 4
→ Level checking hole discontinued. Oil is

put in and checked through the filler hole.
Power transmission > 4 Speed Manual Gearbox 020 > Gearbox mechanics,operation,
construction,diff. > Controls, Housing > Removing and installing housing
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3/10/2020 Volkswagen Workshop Manuals > Golf Mk1 > Power transmission > 4 Speed Manual Gearbox 020

box 020 > Gearbox mechanics,operation,…

Volkswagen Workshop Manuals

It's more than

‒ → Installing gearbox in repair stand -

Other Volkswagen Workshop Manuals

‒ → Fitting support bar for drive shaft -

Download Your A - Locknut M 12.

‒ Lift VW 295a into contact with drive

O cial Repair Manuals

‒ → Fitting support bar for drive shaft -

O cial Repair Screw two M 8 x 30 bolts through slots

‒ → Lever plugs -arrows- out and take

‒ → Remove selector shaft end plug.

A - Spark plug spanner (Part No. 311

‒ Move selector forks to neutral and pull

If the selector forks cannot be placed in

‒ → Take circlip -2- off (only on

‒ → Remove bolts attaching gearbox

A - Screws two M 7 x 30 bolts (N 10

If drive shaft has not been dismantled, press

‒ → Press drive shaft bearing into

‒ → Insert clamping bolts and tighten

‒ → Align reverse gear shaft. Spacing x

Before Knocking housing on:

a - Screw two M 8 studs into

‒ → Knock housing on.

‒ → Press drive flange circlip into

‒ → Install drive shaft circlip

‒ → Install locking ring (s) for release

Gearbox housing/end cover

From Assembly date 15 03 5:

The bore in the housing for the end cover

When fitting a new gearbox housing use 020

Side pressure system.

→ Reverse catch provided by chamfer on

HOME From Assembly date 25 08 5: MENU

Downward pressure system.

→ Reverse catch moved to shift linkage.

Reversing light switch

From Assembly date 07 08 5.

→ The switch is mounted on a bracket -1-

Adjust or bend the bracket so that the

From Assembly date 05 04 6.

→ The switch is in the gearbox again.

Operated by a lug on the reverse gear

→ Lever with shoulder -1-, secured with one

From Assy. date 17 03 7:

→ Lever with no shoulder, secured with two

When installing the new shaft, the new lever

Checking oil level

Remove checking plug -arrow 1- with 5 mm

→ Removing plug -arrow 2-.

Put in gear oil - SAE 80 or 80/90 to MIL-L

From Assembly date 07 05 4

→ Level checking hole discontinued. Oil is

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