D4B807C95D6-5-Speed Manual Gearbox 0AH

Service
Workshop Manual
Golf Sportsvan 2018 ➤
5-speed manual gearbox 0AH
Edition 11.2017
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Service Department. Technical Information

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

No reproduction without prior agreement from publisher.
Copyright © 2017 Volkswagen AG, Wolfsburg D4B807C95D6

5-speed manual gearbox 0AH - Edition 11.2017
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Safety measures when working on vehicles with a start/stop system . . . . . . . . . . . . . . . . 1
2 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.1 Gearbox identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3.1 Allocation gearbox - engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3.2 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3.3 Calculation of gear ratios . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
4 Overview - power. Vtransmission .............................................. 4
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6.1s General repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
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30 - Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
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1 Clutch operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
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1.1 Overview of fitting locations – clutch mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

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1.2 Assembly overview - pedal cluster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
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Assembly overview - clutch hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
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1.4 Assembly overview - clutch release mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.5 Removing and installing bearing bush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.6 Checking clutch master cylinder and clutch slave cylinder . . . . . . . . . . . . . . . . . . . . . . . . 16
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1.7 Removing and installing clutch position sender G476 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

1.8 Removing and installing return spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
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1.9 Removing and installing over-centre spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

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1.10 Removing and installing clutch pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

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1.11 Removing and installing mounting bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

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1.12 Removing and installing clutch master cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

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1.13 Removing and installing clutch slave cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

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1.14 Removing and installing lines for clutch mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

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1.15 Bleeding clutch mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

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1.16 Repairing clutch release mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

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2 Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
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2.1 Assembly overview - clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
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2.2 Removing and installing clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
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34 - Controls, housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
1 Selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
1.1 Installation position - selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
1.2 Assembly overview - gear knob and cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
1.3 Assembly overview - selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
1.4 Removing and installing gear knob . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
1.5 Removing and installing selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
1.6 Repairing selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
1.7 Adjusting selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
1.8 Checking selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
2 Removing and installing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
2.1 Removing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
2.2 Install gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
2.3 Specified torques for gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
3 Assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
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3.1 Assembly overview - assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

4 Transporting gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
5 Gear oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
5.1 Checking gear oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
6 Installing to engine and gearbox support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
7 Dismantling and assembling gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
7.1 Schematic overview - gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
7.2 Assembly overview - gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
7.3 Assembly overview - cover for gearbox housing and 5th gear . . . . . . . . . . . . . . . . . . . . . . 81
7.4 Assembly overview - clutch housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
7.5 Assembly overview - shafts, differential, selector mechanism . . . . . . . . . . . . . . . . . . . . . . 83
7.6 Assembly overview - selector unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
7.7 Assembly overview - selector forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
7.8 Repairing selector forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
7.9 Repairing selector unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
7.10 Renewing oil seal for selector shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
7.11 Dismantling and assembling gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
8 Gearbox housing, clutch housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
8.1 Assembly overview - gearbox housing and clutch housing . . . . . . . . . . . . . . . . . . . . . . . . 103
8.2 Repairing gearbox housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
35 - Gears, shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

1 Input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
1.1 Assembly overview - input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
1.2 Dismantling and assembling input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
1.3 Renewing input shaft seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
2 Output shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
2.1 Assembly overview - output shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
2.2 Dismantling and assembling output shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
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1 Oil seals . . . . . . . . . . . . . . . . . . . . . . . . .ris.e.d .b . . . . . . . . . . . . . . . . . . . . . . . . . . . .ar.an.t . . . . . . 127
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1.1 Overview of fitting locations - seals . a.ut.h . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . e.or.a. . . 127
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1.2 Renewing left oil seal . . . . . . . . . . .s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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1.3 Renewing right oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130

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2 Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
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2.2 Dismantling and assembling differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135

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2.3 Adjusting differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140

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Contents
00 – Technical data
1 Safety information
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♦ Deactivate the start/stop system when working on vehicle.
Switch off ignition.
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♦ Switch on the ignition briefly only if required.
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1. Safety information 1
2 Identification
⇒ “2.1 Gearbox identification”, page 2
2.1 Gearbox identification

Configuration of identification codes and construction data on
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Codes and production date of gearbox

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2 Rep. gr.00 - Technical data

3 Technical data
⇒ “3.1 Allocation gearbox - engine”, page 3 .
⇒ “3.2 Capacities”, page 3 .
⇒ “3.3 Calculation of gear ratios”, page 3 .
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Drive gear ZG1 = 46 ZA1 = 24

Driven gear ZG2 = 33 ZA2 = 70
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iG = gear ratio = ZG2 : ZG1 = 33 : 46 = 0.717
iA = final drive ratio = ZA2 : ZA1 = 70 : 24 = 2.917
itotal = Overall ratio = iG x iA = 0.717 x 2.917 = 2.091
1) Z1 = No. of teeth on driving gear, Z2 = No. of teeth on driven gear
3. Technical data 3
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3 - Manual gearbox
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6 - Differential
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Ratio
-Arrows- point in direction of travel.

I - 1st gear
II - 2nd gear
III - 3rd gear
IV - 4th gear
V - 5th gear
R - Reverse gear
A - Final drive
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4. Overview - power transmission 5

5 Electrical components
⇒ “5.1 Overview of fitting locations - electrical components”, page
6
5.1 Overview of fitting locations - electrical

components
⇒ “5.1.1 Overview of fitting locations – electrical components,
manual gearbox”, page 6
⇒ “5.1.2 Overview of fitting locations – electrical components,
clutch mechanism”, page 6
5.1.1 Overview of fitting locations – electrical components, manual gearbox
1 - Reversing light switch - F4-

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❑ Fitting location:
ss in area
ce
le
of selector unit beneath

un
pt
angled rod for securing

an
d
itte
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selector shaft
erm
ab
ility
❑ Removing and installing

ot p
wit
⇒ page 83
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
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or
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e
5.1.2 Overview of fitting locations – electrical

t
sd
iva
o
pr
components, clutch mechanism

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Clutch position sender - G476- -arrow- t. Cop py
rig
gh ht
Location: in passenger compartment on clutch master cylinder. pyri by
Vo
o
by c lksw
cted agen
Removing and installing clutch position sender - G476- Prote AG.
⇒ page 12

6 Repair instructions
⇒ “6.1 General repair instructions”, page 7
6.1 General repair instructions

To ensure flawless and successful gearbox repairs, the greatest
care and cleanliness as well as the use of good and proper tools
are essential. Of course, the basic rules for safety also apply dur‐
ing repair work.
A number of general notes on the individual repair procedures,
which can otherwise be found in the relevant sections of the man‐
ual, are summarised here. They apply for this particular workshop
manual.
Special tool
For a complete list of special tools used in this workshop manual,
see ⇒ Workshop equipment and special tools .
Gearbox
ks wage es
♦ When installing the manual Vol gearbox, ensure that the odowel
n t
gu
by
sleeves between the
ris
e engine and gearbox are correctly seated.
d ara
nt
o ee
th or
♦ When installing
s au mounting brackets or waxed components, ac
clean the contact surfaces. Contact surfaces must be free of
s
ce
le
wax and grease.

un
pt
an
d
itte
y li
♦ Allocate bolts and other components using the ⇒ Electronic
rm
parts catalogue (ETKA) . ab

pe
ility
ot
wit
, is n
♦ If the gearbox is repaired, fill with gear oil. h re

hole
spec
Gaskets and seals
es, in part or in w
t to the co
After removing gaskets and seals, always inspect contact surfa‐

ces of housing and shaft for burrs resulting from removal or for
other signs of damage.
rrectness of i
♦ Thoroughly clean joint surfaces and apply sealant .

l purpos
♦ Allocation ⇒ Electronic parts catalogue (ETKA)

♦ Before installing radial oil seals, half-fill space between sealing
nform
ercia
lips with sealing grease -arrow-.

m
a
com
♦ Allocate grease using ⇒ Electronic parts catalogue (ETKA) .

ion in
r
te o
♦ The open side of the oil seals faces toward the side with fluid
thi
s
iva
filling.
do
r
rp
cum
fo
♦ Lightly oil O-rings before installing; this prevents the rings be‐
en
ng
t.
yi
ing crushed when inserted.
Co
Cop py
t. rig
Sealant
gh ht
pyri by
Vo
co lksw
by
♦ Thoroughly clean housing joint surfaces before applying seal‐ cted agen
Prote AG.
ant .
♦ Apply sealant uniformly and not too thickly.
♦ Allocation ⇒ Electronic parts catalogue (ETKA) .
♦ Breather holes must remain free of sealant .
6. Repair instructions 7
Locking devices
♦ Renew retaining rings.

♦ Do not overstretch retaining rings.
AG. Volkswagen AG d
agen oes
♦ Retaining rings must locate
Vol properly in grooves.
ksw not
gu
y
db ara
♦ Renew spring pins.orInstallation
ise position: slot must be in line ntee
h
with direction of aforce.
ut or
ac
ss
Nuts and bolts
ce
e
nl
pt
du
an
itte
♦ Loosen and tighten securing bolts and nuts for covers and
y li
erm
ab
housings alternately and diagonally.
ility
ot p
♦ Do not cant especially delicate parts, such as clutch pressure

wit
, is n
plates. Loosen and tighten bolts and nuts alternately and in

h re
hole
stages.
spec
es, in part or in w
♦ Specified torques given are for unoiled nuts, bolts and screws. t to the co
♦ Renew self-locking bolts and nuts after each removal.

rrectness of i
♦ Ensure with threaded connections that contact surfaces as

well as nuts and bolts are rewaxed only after assembly, if nec‐
l purpos
essary.
♦ Use a thread chaser to clear residual locking fluid from all
nform
ercia
threaded holes into which self-locking bolts are to be screwed.

Otherwise there is a danger of bolts shearing when subse‐
m
at
om
quently being removed.

on
c
in t
or
♦ Check pitch of thread, to ensure correct thread chaser is used

his
ate
to clean threads and to ensure the threads are not damaged.

do
priv
cum
or
Mountings
f
en
ng
t.
yi Co
op
♦ Lubricate all bearings with gear oil before installing. C py
ht. rig
rig ht
py by
♦ Install new tapered roller bearings as supplied and do not lu‐ co Vo
by lksw
bricate additionally. cted agen
Prote AG.
♦ Install needle bearings with lettered side (thicker metal) to‐

wards fitting tool.
♦ Tapered roller bearings fitted to one shaft must be renewed as
a set. Use same make of bearings.
♦ Heat inner races to about 100 °C with the inductive heater -
VAS 6414- before installing.
♦ Do not interchange outer or inner races of bearings of the
same size. The bearings are matched in pairs.

Shims
♦ Measure shims at several points with a micrometer. The var‐
ious tolerances make it possible to achieve the exact shim
thickness required.
♦ Check for burrs and damage.
♦ Install only flawless shims.
Synchro-rings
♦ Do not interchange them. When reusing synchro-rings, always

fit to the same synchromeshed gear.
♦ Check for wear and renew if necessary.
wage es n
♦ Check grooves -arrow 1- of synchro-ring -A- and inner ring yfor Volks ot g
flat spots (worn grooves). ir se
d b ua
ran
o tee
h
♦ If synchro-rings are coated, coating must not be damaged.
aut or
ac
ss
♦ If an intermediate ring -B- is installed, check the outer friction
ce
le
un
pt
surface -arrow 2- and inner friction surface -arrow 3- of this
an
d
itte
y li
intermediate ring for »scoring«, »signs of abnormal wear« and
rm
ab
»blue discolouration (due to overheating)«.
pe
ility
ot
wit
, is n
♦ Check the cone of the synchromeshed gear for »scoring« and
h re
»signs of abnormal wear«.
hole
spec
♦ Moisten synchromesh mechanism with gear oil before instal‐
es, in part or in w
t to the co
ling.
Gears and synchro-hubs
rrectness of i
♦ Before installing, clean and heat with the inductive heater -
VAS 6414- to maximum 100°C.
l purpos
♦ Observe installation position
nform
ercia
Synchromeshed gears
m
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com
t
♦ After assembly, check synchromeshed gears for slight play, or
ion in
for freedom of movement.
r
te o
thi
s
iva
Clutch operation
do
r
rp
cum
fo
Disconnect battery earth strap ⇒ Electrical system; Rep. gr. 27 ;

en
ng
t.
Battery; Disconnecting and connecting battery .
yi Co
Cop py
t. rig
When reconnecting battery, refer to ⇒ Electrical system; Rep. gr. gh ht
yri by
27 ; Battery; Disconnecting and connecting battery . cop Vo
by lksw
cted agen
Prote AG.
Clutch
♦ Ensure that the pressure plate does not cant: loosen and tight‐
en bolts alternately and diagonally and in several gradual
stages.
♦ In order to reduce the smell of a burned clutch, the clutch
housing as well as the stopping face of the flywheel must be
thoroughly cleaned with a cloth.
6. Repair instructions 9
30 – Clutch
1 Clutch operation
⇒ “1.1 Overview of fitting locations – clutch mechanism”,
page 10
⇒ “1.2 Assembly overview - pedal cluster”, page 12
⇒ “1.3 Assembly overview - clutch hydraulics”, page 14
⇒ “1.4 Assembly overview - clutch release mechanism”,
page 15
⇒ “1.5 Removing and installing bearing bush”, page 16
⇒ “1.6 Checking clutch master cylinder and clutch slave cylinder”,
page 16
⇒ “1.7 Removing and installing clutch position sender G476 ”,
page 17
⇒ “1.8 Removing and installing return spring”, page 17
⇒ “1.9 Removing and installing over-centre spring”, page 20
⇒ “1.10 Removing and installing clutch pedal”, page 22
⇒ “1.11 Removing and installing mounting bracket”, page 24
olkswagen AG
en AG. V
⇒ “1.12 Removing and installing clutch master cylinder”, olkswag does
not
page 28 ed
by
V gu
ara
ris nte
⇒ “1.13 Removing and installing clutch slave cylinder”,
au
tho eo
ra
page 28 ss c
ce
e
nl
⇒ “1.14 Removing and installing lines for clutch mechanism”,
pt
du
an
itte
page 31
y li
erm
ab
⇒ “1.15 Bleeding clutch mechanism”, page 33
ility
ot p
wit
, is n
⇒ “1.16 Repairing clutch release mechanism”, page 35
h re
hole
spec
1.1 Overview of fitting locations – clutch mechanism
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.
10 Rep. gr.30 - Clutch

I-
⇒ “1.2 Assembly overview -
pedal cluster”, page 12
II -
clutch hydraulics”, page 14
LHD vehicles
III -
clutch hydraulics”, page 14
RHD vehicles
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
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rp
cum
fo
en
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t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
1. Clutch operation 11
1.2 Assembly overview - pedal cluster
1 - Clutch master cylinder

⇒ page 28
2 - Bearing bush
⇒ page 16
❑ Do not grease
. Volkswagen AG
a gen AG does
3 - Clip Vol
ksw not
gu
by ara
❑ To remove pipe/hose rise d
nte
line, pull out clip to ustop
tho eo
ra
a c
❑ Can be pressed in s as far
s
ce
le
as stop before fitting line

un
pt
an
d
itte
y li
4 - Seal
rm
ab
pe
❑ Self-adhesive
ility
ot
wit
, is n
❑ Renew after removing
h re
the clutch master cylin‐
hole
spec
der.
es, in part or in w
t to the co
❑ Glue onto clutch master
cylinder
5 - Clutch position sender -
rrectness of i
G476-
l purpos
❑ Can be checked using

⇒ Vehicle diagnostic
tester in Guided Fault nform
ercia
Finding mode
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❑ Allocation ⇒ Electronic
tion in
parts catalogue (ETKA)

r
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thi

s
iva
do
⇒ page 17
r
rp
cum
fo
en
g
6 - Pivot pin
n
t.
yi Co
op py
❑ Renew after removal t. C rig
gh ht
yri
❑ Do not grease
p by
o Vo
by c lksw
cted agen
Prote
7 - Buffer stop
AG.
8 - Hexagon nut
❑ For mounting bracket to bulkhead
❑ Qty. 3
❑ Self-locking
❑ Renew after removal
❑ 25 Nm
9 - Bearing shell
❑ Qty. 2
❑ Installed on both sides.
❑ Only fitted in conjunction with over-centre spring.
❑ Do not grease
10 - Mounting bracket
❑ For clutch pedal
❑ Removing and installing ⇒ page 24
❑ Drive bushes into holes in plenum chamber bulkhead for mounting pins of bearing bracket using Drift -
VW 207-

11 - Return spring
❑ Installed depending on version.
❑ Do not grease mounting on mounting bracket
Volkswagen AG
12 - Pivot pin agen
AG. does
olksw not
❑ For clutch d bmaster cylinder.
yV gu
ara
ise nte
❑ Renew tho after removal
r eo
au ra
❑ Do s not grease
s c
ce
le
un
pt
13 - Over-centre spring
an
d
itte
y li
erm
ab
ility
❑ Different versions exist; for correct version refer to ⇒ Electronic parts catalogue (ETKA)
ot p
wit
is n
h re
ole,
❑ Do not grease
spec
14 - Bearing bush
t to the co
❑ Do not grease
15 - Sliding bush
rrectne
s
❑ For mounting return spring
s o
cial p
f
❑ Fit onto clutch pedal
inform
mer
❑ Grease when mounting return spring.

atio
m
❑ Grease ⇒ Electronic parts catalogue (ETKA)

o
n
c
i
or
n thi
16 - Pivot pin
te
sd
va
❑ For plunger/clutch master cylinder

i
o
pr
cum
r
fo

en
ng
t.
yi Co
op
❑ Do not grease C py
t. rig
gh ht
yri
17 - Clutch pedal
p by
co Vo
by lksw
cted
agen
Prote AG.
❑ Do not grease
18 - Pedal rubber
19 - Bearing bush
❑ Do not grease
20 - Spring
❑ For clutch pedal
❑ Removing and installing ⇒ Removing and installing over-centre spring ⇒ page 20
❑ Do not grease
21 - Damping piece
❑ Only fitted in conjunction with extension spring.
❑ Do not grease
1.3 Assembly overview - clutch hydraulics
1 - Hexagon bolt
❑ Specified torque
⇒ page 15
2 - Bleeder valve
❑ Bleeding clutch mecha‐
nism ⇒ page 33
⇒ page 33
3 - Dust cap
4 - Supply hose
5 - Brake fluid reservoir
6 - Seals
❑ Must be fitted in supply
hose
❑ If damaged, renew to‐
gether with supply hose
7 - Clutch master cylinder
⇒ page 28 AG. Volkswagen AG d
agen oes
ksw
8 - Clip by Vol not
gu
ara
d
❑ To remove pipe/hose rise nte
ho eo
line, pull out clip to stop aut ra
c
ss
❑ Can be pressed in as far
ce
le
un
as stop before fitting line
pt
an
d
itte
y li
9 - Seal / O-ring
rm
ab
pe
ility
❑ Renew if damaged
ot
wit
, is n
❑ Pull onto line connection
h re
hole
spec
❑ Insert with brake fluid
es, in part or in w
❑ Seals/O-rings are adap‐
t to the co
ted to configuration of
line connection
⇒ page 31
rrectness of i
❑ Allocation ⇒ Electronic parts catalogue (ETKA)
l purpos
10 - Bracket
❑ For pipe/hose assembly
nform
ercia
❑ Different retainers for LHD and RHD vehicles.

m
a
com
ti

on in
r
te o
thi
11 - Pipe/hose line
s
iva
do
❑ Different lengths for LHD and RHD vehicles.

r
rp
cum
fo

en
ng
t.
yi Co
op
❑ Removing and installing ⇒ page 31 C py
t. rig
gh ht
yri by
12 - Seal / O-ring cop Vo
by lksw
cted agen
❑ Renew if damaged Prote AG.
❑ Pull onto line connection

❑ Insert with brake fluid
❑ Seals/O-rings are adapted to configuration of line connection ⇒ page 31

13 - Clip
❑ To remove pipe/hose line, pull out clip to stop
❑ Can be pressed in as far as stop before fitting line
14 - Clutch slave cylinder
1.4 Assembly overview - clutch release mechanism
1 - Release bearing agen

AG. Volkswagen AG d
oes
lksw not
❑ Remove and install d byto‐
Vo gu
ara
gether with clutch
orise re‐ nte
lease lever aand
ut guide
h eo
ra
sleeve ⇒ page
ss 35 c
ce
le
❑ Do not wash out bear‐

un
pt
an
d
ing; wipe only

itte
y li
rm
ab
❑ Renew noisy bearings
pe
ility
ot
wit
2 - Bolt
, is n
h re
hole
spec
❑ 5 Nm +90°
es, in part or in w
t to the co
3 - Clutch release lever
❑ Remove and install to‐
rrectness of i
gether with clutch re‐
lease bearing and guide
l purpos
sleeve ⇒ page 35 .
❑ Remove old grease nform
ercia
❑ Grease contact surface

m
of ball-head pin with

a
com
ti
grease for clutch plate

on in
splines .
r
te o
thi
s
iva
❑ Allocate grease using ⇒

do
r
rp
Electronic parts cata‐

um
fo
logue (ETKA) .
en
ng
t.
yi Co
op
4 - Retaining spring
C py
t. rig
gh ht
yri
❑ Secure to clutch release
p by
co Vo
by lksw
lever Prote
cted AG.
agen
5 - Guide bush
❑ Remove and install to‐
gether with clutch re‐
lease bearing and clutch
release lever
⇒ page 35
6 - Ball-head pin
❑ Remove old grease
❑ Grease contact surface of ball-head pin with grease for clutch plate splines .
❑ Allocate grease using ⇒ Electronic parts catalogue (ETKA) .
❑ 20 Nm
7 - Input shaft seal
❑ Renew after removal ⇒ page 117
8 - Gearbox
9 - Hexagon bolt
❑ 20 Nm
. Volkswagen AG
5-speed manual gearboxk0AH
swa - Edition 11.2017does n
gen AG
ol ot g
yV ua
db ran
10 - Clutch slave cylinderorise
tee
h
ut or
❑ Removing andsinstalling
sa ⇒ page 28 ac
ce
le
un
pt
an
d
itte
y li
1.5 Removing and installing bearing bush
rm
ab
pe
ility
ot
Removing
wit
, is n
h re
hole
Disconnect battery ⇒ Electrical system; Rep. gr. 27 ; Battery;
spec
Disconnecting and reconnecting battery .
es, in part or in w
t to the co
– Compress catches -arrows- and take out pin -1- towards right
side.
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
– Turn plunger of clutch master cylinder so that recesses -1- and . Cop py
pin -2- are visible.
ht rig
rig ht
py by
co Vo
Recesses -1- and pin -2- are facing the same direction.
by lksw
cted agen
Prote AG.
– Remove bearing bush -A- from recesses -1-.
Installing
– Turn plunger of clutch master cylinder so that recesses -1- and
pin -2- are visible.
Recesses -1- and pin -2- are facing the same direction.
– Fit and swivel bearing bush -A- into recesses -1-.
– Connect plunger/clutch master cylinder with the clutch pedal
using a new pivot pin.
– Connect battery ⇒ Electrical system; Rep. gr. 27 ; Battery;
Disconnecting and connecting battery .
1.6 Checking clutch master cylinder and

clutch slave cylinder
Carry out Guided Fault Finding using ⇒ Vehicle diagnostic
tester before renewing clutch master cylinder due to suspected
fault.

1.7 Removing and installing clutch position

sender
wage
-n AG476-
G. Volkswagen AG d
oe
ks s no
Vol t gu
Removing ed by ara
is nte
or
– Move
au driver seat as far back as
th possible. eo
ra
ss c
– If fitted, remove footwell cover on driver side ⇒ General body
ce
le
un
pt
repairs, interior; Rep. gr. 68 ; Compartments/covers .
an
d
itte
y li
– Unplug electrical connector -arrow- at clutch position sender -
erm
ab
ility
G476- .
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
– Release clutch position sender - G476- -item 2- at clutch mas‐
cial p
f in
ter cylinder -1- -arrow- and remove.
form
mer
atio
Installing
om
n
c
i
Install in reverse order of removal, observing the following:
or
n thi
te
sd
a
• The catch -arrow- on the clutch position sender - G476- must

iv
o
pr
be in good order.
um
r
fo
en
ng
t.
yi
• The clutch position sender - G476- must audibly engage.
Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
1.8 Removing and installing return spring

Removing
– Move driver seat as far back as possible.
– Move steering wheel to uppermost position using the entire
range of adjustment of the steering column.
Vehicles with knee airbag

– Remove knee airbag -1- on driver side ⇒ General body re‐
pairs, interior; Rep. gr. 69 ; Knee airbags; Assembly overview
- knee airbag .
Vehicles without knee airbag
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
s c
Continuation for all s
ce
le
un
pt
– Remove footwell vent on driver's side -1- ⇒ Heating, air con‐
an
d
itte
y li
ditioning; Rep. gr. 87 ; Air duct; Assembly overview - air
rm
ab
routing and air distribution in passenger compartment .
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
– Take data bus diagnostic interface - J533- -1- out of bracket

⇒ Electrical system; Rep. gr. 97 ; Control units; Overview of
nform
ercia
fitting locations - control units , and push to one side.

m
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
o
by c lksw
cted agen
Prote AG.
– Unscrew bolt -2-, detach crash bar -1-, and push it to one side.

– Compress catches -arrows- and pull out pivot pin -1- for plung‐
er/clutch master cylinder towards right side.
AG. Volkswagen AG d
agen oes
lksw not
– Swivel clutch pedal towards rear in -direction of arrow-,d bdetach
yV
o gu
ara
return spring -1- and remove. orise nte
th eo
u ra
Installing ss a c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
io
• For return spring -1- (⇒ figure above), grease following areas
n
c
in t
or
on clutch pedal:
his
ate
do
riv
• Slide bush in mounting areas -A- for return spring

p
cum
for
en
g
• Web -B-
n
t.
yi Co
Cop py
• Web -C-
t. rig
gh ht
pyri by
Vo
o
• Allocate grease using ⇒ Electronic parts catalogue (ETKA) .
c by lksw
cted agen
Prote AG.
– Swivel clutch pedal in direction of -arrow-, and attach return
spring -1- (⇒ figure above).
– Insert crash bar -1- and tighten bolt -2- ⇒ General body re‐
pairs, interior; Rep. gr. 70 ; Dash panel central tube; Assembly
overview - dash panel central tube .
– Install data bus diagnostic interface - J533- ⇒ Electrical sys‐
tem; Rep. gr. 97 ; Control units; Overview of fitting locations -
control units .
– Remove footwell vent on driver's side ⇒ Heating, air condi‐
tioning; Rep. gr. 87 ; Air duct; Assembly overview - air routing
and air distribution in passenger compartment .
– Install knee airbag on driver side ⇒ General body repairs, in‐
terior; Rep. gr. 69 ; Knee airbags; Assembly overview - knee
airbag .
1.9 Removing and installing over-centre

spring wage
es n
olks ot g
Removing byV ua
d ran
ir se tee
o
– Move driver seat as far back as possible. auth or
ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
- knee airbag .
rrectness of i
Disconnect battery earth strap ⇒ Electrical system; Rep. gr. 27 ;
l purpos
Battery; Disconnecting and connecting battery .

Continuation for all
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu

o
m
f
en

ng
t.
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– If the bracket for parking aid control unit - J446- / park assist
spec
steering control unit - J791- is fitted next to the clutch pedal,
es, in part or in w
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remove bracket ⇒ Electrical system; Rep. gr. 94 ; Park assist
steering . Do not disconnect any lines.
rrectness of i
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– Compress catches -arrows- and pull out pivot pin -1- for plung‐
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– If present, detach and remove extension spring -1- by pushing

clutch pedal in direction of -arrow B-.
– Bring clutch pedal into rest position.
– Pull clutch pedal in -direction of arrow A-, and detach and re‐
move over-centre spring -2-.
Installing
• The bearing shells -arrows- for the pins -1- are installed.
– Pull clutch pedal into passenger compartment (⇒
-direction of arrow A- in previous illustration).
– Insert pins -1- into supports -2- of mounting bracket.
– Insert mounting -3- into support -4- of clutch pedal.
• When the clutch pedal is pressed in -direction of arrow B- (⇒
previous fig.), the over-centre spring flips over towards the
mounting bracket.
– If the bracket with parking aid control unit - J446- / park assist
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steering . Do not disconnect
or
ise any lines. an
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– Insert crash bar -1- and tighten bolt -2- ⇒ General body re‐ s
ce
le
pairs, interior; Rep. gr. 70 ; Dash panel central tube; Assembly

un
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overview - dash panel central tube .

itte
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– Install data bus diagnostic interface - J533- ⇒ Electrical sys‐
ility
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tem; Rep. gr. 97 ; Control units; Overview of fitting locations -
wit
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control units .
h re
ole,
spec
tioning; Rep. gr. 87 ; Air duct; Assembly overview - air routing t to the co
rrectne

terior; Rep. gr. 69 ; Knee airbags; Assembly overview - knee
ss
airbag .
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1.10 Removing and installing clutch pedal

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Removing
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– Move driver seat as far back as possible. opyri
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– Move steering wheel to uppermost position using the entire Prote
cted agen
AG.

RHD vehicles with Climatronic
– Remove right temperature flap control motor - V159- ⇒ Heat‐
ing, air conditioning; Rep. gr. 87 ; Control motors; Overview
of fitting locations - front control motors .
– Remove return spring ⇒ page 17 or over-centre spring
⇒ page 20 .

Remove pivot pin the for the clutch pedal as follows:

– Break off both locking devices -A- using a screwdriver -1-.
-1- = 14 mm hexagon bit.

LHD vehicles
A 14 mm hexagon key can be used instead of the 14 mm hexagon
bit.
• The pivot pin for the clutch pedal must be turned to the left to
stop, -direction of arrow-.
– Move clutch pedal slightly so that the pivot pin can be pulled
out. olksw AG. V agen AG
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-1- = 14 mm hexagon bit.
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LHD vehicles
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A 14 mm hexagon key can be used instead of the 14 mm hexagon
hole
spec
bit.
es, in part or in w
t to the co
• Renew pivot pin after removing. rrectness of i
– Depress clutch pedal slightly and push new pivot pin through
to stop.
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– Turn pivot pin to right to stop, -direction of arrow-.

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• Locking devices -A- must audibly engage.

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– Install return spring ⇒ page 17 or over-centre spring

ion in
⇒ page 20 .
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RHD vehicles with Climatronic

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– Install right temperature flap control motor - V159- ⇒ Heating,

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t.
air conditioning; Rep. gr. 87 ; Control motors; Overview of
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fitting locations - front control motors . t. C rig
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steering control unit - J791- has been removed beforehand,
install bracket ⇒ Electrical system; Rep. gr. 94 ; Park assist
Golf Sportsvan 2018 ➤ n AG. Volkswagen AG do
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1.11 Removing and installing mounting tho
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bracket
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Special tools and workshop equipment required
itte
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♦ Hose clamps to 25 mm - 3094-
ility
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spec
es, in part or in w
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♦ Torque wrench - V.A.G 1331-
or c
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♦ Sealing tool - T10249-
Removing
– Move driver seat as far back as possible.


- knee airbag .

routing and air distribution in passenger compartment .

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es, in part or in w
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– Remove complete air filter housing if it prevents access to the

l purpos
lines for clutch mechanism ⇒ Rep. gr. 24 ; Air filter; Removing

and installing air filter housing .
nform
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RHD vehicles
An insulation mat is installed in conjunction with some engines.
Appearance may be different from that illustrated.
– Remove insulation mat. Note item -1 to 4-.
LHD vehicles
– Remove battery tray ⇒ Electrical system; Rep. gr. 27 ; Battery;
Removing and installing battery .
Caution
Risk of leaking brake fluid.

♦ During the following work, ensure that no brake fluid lands
on longitudinal member or gearbox. If this does happen,
clean the affected areas thoroughly.
♦ Lay a lint-free cloth under clutch master cylinder.
– Using hose clamp - 3094- , clamp off supply hose -2- to clutch
master cylinder.
Note
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♦ Clamping off the supply hose with the hose clamp - 3094- will
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♦ However, this does not damage the supply hose.utho eo
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♦ After removing the hose clamp - 3094- , the supply hose must
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be returned to its original shape.

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– Pull out clip for pipe/hose line -1- as far as stop, and detach
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– Seal openings.
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– Disconnect supply hose from clutch master cylinder and plug t to the co
hose using sealing tool - T10249/1- . rrectness o
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Note
When performing work in the footwell, put cloths on the floor cov‐
ering to protect it from possible brake fluid spills.
– Unplug electrical connector -2- at clutch position sender -

G476- .
– Remove nuts -arrows- and detach mounting bracket -1-.
Installing
– Renew self-locking nuts and seal for clutch master cylinder
after removing.
steering control unit - J791- has been removed beforehand,
install bracket ⇒ Electrical system; Rep. gr. 94 ; Park assist
– Insert crash bar -1- and tighten bolt -2- ⇒ General body re‐
pairs, interior; Rep. gr. 70 ; Dash panel central tube;
n AAssembly
G. Volkswagen AG d
overview - dash panel central tube . lkswage oes
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– Install data bus diagnostic interfaceori-seJ533- ⇒ Electrical sys‐ nte
tem; Rep. gr. 97 ; Control units; aOverview
ut
h of fitting locations - eo
ra
control units . ss c
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le
un
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tioning; Rep. gr. 87 ; Air duct; Assembly overview - air routing
y li
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terior; Rep. gr. 69 ; Knee airbags; Assembly overview - knee spec
es, in part or in w
airbag . t to the co
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Note
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The battery is installed and connected at a later stage.

nform
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– Connect pipe/hose assembly -1- to connection ⇒ page 30 .

n in
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– Connect supply hose -2- at clutch master cylinder.

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• After removing the hose clamp - 3094- , the supply hose must
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RHD vehicles
– If fitted, fold insulation mat in the sequence -1, 2, 3- around
lines.
– Secure insulation mat with lock washer -4-.
– Bleed clutch mechanism ⇒ page 33 .
– Install and/or connect battery ⇒ General body repairs, interior;
Rep. gr. 69 ; Knee airbags; Assembly overview - knee airbag
and ⇒ Electrical system; Rep. gr. 27 ; Battery; Connecting
and disconnecting battery .
– Install and/or connect battery ⇒ Electrical system; Rep. gr.
27 ; Battery; Disconnecting and connecting battery .
Specified torques
♦ For securing mounting bracket to plenum chamber bulkhead
⇒ page 12
1.12 Removing and installing clutch master

cylinder
Removing
Note
♦ Before replacing the clutch master cylinder due a suspected

defect, use Guided Fault Finding ⇒ Vehicle diagnostic
tester.
♦ When performing work in the footwell, put cloths on the floor
covering to protect it from possible brake fluid spills. AG. Volkswagen AG d
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– Remove mounting bracket ⇒ page 24 . ise
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– Remove clutch position sender - G476- ⇒ page
s a 17 .
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– Release catches -arrows- and press out pivot pin -2-.

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– Detach clutch master cylinder -1-.

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Installing
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spec
Renew pivot pins after removing.

es, in part or in w
t to the co
– Install mounting bracket ⇒ page 24 .

– Install clutch position sender - G476- ⇒ page 17 .
rrectness of i
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1.13 Removing and installing clutch slave

nf
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cylinder
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Rep. gr.30 - Clutch Prote
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Removing
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spec
Note
es, in part or in w
t to the co
♦ Before replacing the clutch slave cylinder due a suspected

defect, you must first use Guided Fault Finding ⇒ Vehicle
rrectness of i
diagnostic tester.
l purpos
♦ Make sure you do not depress the clutch pedal if the clutch
slave cylinder is removed from the gearbox with the pipe/hose
assembly still attached. Otherwise the piston will be pressed
nform
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out of the clutch slave cylinder and thus destroyed.

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Removing and installing battery .

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– Lay a lint-free cloth under clutch slave cylinder.ss c
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nl
– Release clip -A- with a screwdriver and disconnect pipe/hose
pt
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assembly -B- from connection.
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– Pull pipe/hose assembly -B- out of clutch slave cylinder and
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seal openings.
wit
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hole
– Remove bolts -arrows- and remove clutch slave cylinder.
spec
es, in part or in w
t to the co
Caution
Risk of contamination due to brake fluid spill.
rrectness of i
♦ Do not operate clutch pedal after pipe/hose assembly has
l purpos
been disconnected.
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Installing
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Note
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♦ Grease all bearing surfaces and contact surfaces. Cop py
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– Fit clutch slave cylinder -A- and secure with bolts -arrows-.
– Connect pipe/hose assembly -B- ⇒ page 30 .
Disconnecting and connecting lines for clutch hydraulics

Disconnecting
– Release clip -3- with a screwdriver and disconnect pipe/hose
assembly -1- from connection -4-.
Connecting
Note
♦ It is also possible to install an O-ring instead of the seal -2-

⇒ page 31 .
♦ Renew seal -2- if damaged.
– Press pipe/hose assembly -1- into connection -4- until clip

-3- engages audibly.
– Test pipe/hose assembly by tugging on it.

Seals and O-rings for pipe/hose assembly or pipe line

Item Material of line connection
1 Line connection with circumferential groove
-arrow 1-
2 Line connection with shoulder -arrow 2- AG. Volkswagen AG d
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3 Line connection with shoulder -arrow 2- and cir‐
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ss -arrow 1-
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and -arrow 3-, a seal or O-ring must be set there.
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– Install battery tray ⇒ Electrical system; Rep. gr. 27 ; Battery;
ility
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Removing and installing battery tray .
wit
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– Install battery and battery cover ⇒ Electrical system; Rep. gr.
hole
spec
27 ; Battery; Removing and installing battery .
es, in part or in w
t to the co
Specified torques
♦ Clutch slave cylinder to gearbox ⇒ page 14
rrectness of i
1.14 Removing and installing lines for clutch
l purpos
mechanism
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m
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ion
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t.
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Cop py
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rig ht
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Prote AG.
Removing
– Remove complete air filter housing if it prevents access to the
lines for clutch mechanism ⇒ Rep. gr. 24 ; Air filter; Removing
and installing air filter housing .
RHD vehicles
An insulation mat is installed in conjunction with some engines.
Appearance may be different from that illustrated.
– Remove insulation mat. Note item -1 to 4-.
Caution
Risk of leaking brake fluid.

♦ During the following work, ensure that no brake fluid lands
on longitudinal member or gearbox. If this does happen,
clean the affected areas thoroughly.
♦ Lay a lint-free cloth under clutch master cylinder.
– Using hose clamp - 3094- , clamp off supply hose -2- to clutch
master cylinder.
Note
♦ Clamping off the supply hose with the hose clamp - 3094- will
cause a permanent deformation.
♦ However, this does not damage the supply hose.
♦ After removing the hose clamp - 3094- , the supply hose must
– Pull out clip for pipe/hose line -1- as far as stop, and detach
pipe/hose line.
AG. Volkswagen AG d
– Seal openings. lksw
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– Pull out clip -A- as far asthstop
ori and pull off pipe/hose assembly eo
-B-. s au ra
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– Seal openings.
nl
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Note
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-Arrows- can be disregarded.

hole
spec
es, in part or in w
– Seal off open lines and connections if necessary with clean

t to the co
plugs from engine bung set - VAS 6122- .

– Move pipe/hose assembly clear and remove it.
rrectness of i
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Installing
nform
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– Connect pipe/hose assembly -1- to clutch master cylinder and

m
clutch slave cylinder.

at
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– Test line by tugging on it.

in t
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ate
• After removing the hose clamp - 3094- , the supply hose -2-
do
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must be returned to its original shape.

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RHD vehicles
– If fitted, fold insulation mat in the sequence -1, 2, 3- around
lines.
– Secure insulation mat with lock washer -4-.
1.15 Bleeding clutch mechanism

♦ Brake filling and bleeding unit - VAS 5234-
lkswage es n
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Note
rrectness of i
♦ The clutch system must always be bled after performing work

l purpos
on the hydraulic clutch mechanism.

nf
♦ When performing the following steps, make sure that no brake

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fluid escapes onto the gearbox.

rm
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♦ Prefilling system is not necessary!

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♦ Before bleeding, fill brake fluid reservoir with brake fluid up to

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♦ Brake fluid: Allocation ⇒ Electronic parts catalogue (ETKA) . t. C rig
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– Remove complete air filter housing if it prevents access to cted agen
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bleeder valve (-arrow- figure below) ⇒ Rep. gr. 24 ; Air filter;
Removing and installing air filter housing .
– Move clutch pedal back to its rest position. AG. Volkswagen AG d

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– Remove protective cap from bleeder valve -arrow-.d by V gu
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– Connect brake filling and bleeding equipment u.tho eo
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– Fit bleeder hose, and connect it to pressure hose of collector
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bottle.
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To bleed system, use 670 mm long bleed hose - V.A.G 1238/B3-
erm
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– Switch on brake filling and bleeding equipment .
h re
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spec
• Working pressure 2.0 bar.
es, in part or in w
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– Open bleeder valve.
– Allow about 100 cm3 of brake fluid to flow out.
rrectness of i
– Close bleeder valve.
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– Rapidly operate pedal from stop to stop 10 to 15 times.

– Open bleeder valve.
nform
ercia
– Allow another 50 cm3 of brake fluid to flow out.

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at
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– Close bleeder valve.
c
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– Switch off brake filling and bleeding equipment and relieve

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pressure completely from equipment.

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– Depress clutch pedal several times after completion of bleed‐

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Specified torque:
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Component Nm
Bleeder valve 4.5

1.16 Repairing clutch release mechanism

Special tools and work‐
shop equipment re‐
quired
♦ Torque wrench -
V.A.G 1331-
♦ Grease for splines

♦ Allocate grease using
⇒ Electronic parts
catalogue (ETKA) .
Removing and installing
clutch release lever -A-
with release bearing and
guide sleeve
• Gearbox has been re‐
moved.
– Unscrew bolts n AG. Volkswagen AG do
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– Pull clutch release
tho tee
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sleeve off input shaft

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and ball stud.

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Install in reverse order of

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removal.
wit
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– Installing gearbox
hole
spec
⇒ page 67
es, in part or in w
t to the co
Specified torques
• Guide sleeve to gear‐
rrectness of i
box ⇒ page 15
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Removing and installing guide sleeve from/to clutch release bear‐

ing
– Remove clutch release lever together with release bearing
and guide sleeve ⇒ page 35 .
– Push guide sleeve -3- upwards out of release bearing -2-.
– Turn guide sleeve -3- about 90° in direction of arrow relative
to release bearing -2- until locking lugs of guide sleeve align
with grooves -4- of release bearing.
– Pull guide sleeve out of release bearing in this position.
Install in reverse order of removal.
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– Install clutch release lever together with release bearing and kswagen AG does
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guide sleeve ⇒ page 35 . Vol gu
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Removing and installing release bearing au
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– Remove clutch release lever together with release bearing
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and guide sleeve ⇒ page 35 .
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– Press together locking lugs -arrows- on back of clutch release
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lever and remove release bearing -A- from clutch release lev‐
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– To install, press release bearing -A- into clutch release lever
spec
es, in part or in w
until retaining lugs -arrows- engage.
t to the co
– Grease contact surface for clutch release lever on ball-head
pin with grease for clutch plate splines .
rrectness of i
– Install clutch release lever together with release bearing and
guide sleeve ⇒ page 35 .
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2 Clutch gen AG. Volkswagen AG d

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⇒ “2.1 Assembly
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⇒ “2.2 Removing
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2.1 Assembly overview - clutch
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1 - Flywheel
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⇒ Rep. gr. 13 ; Cylinder
h re
ole,
block (gearbox end);
spec
Removing and installing
t to the co
flywheel .
❑ Ensure that centring
pins fit tightly
rrectne
❑ Keep contact surface for
clutch lining free of
ss
grooves, oil and grease.
o
cial p
f in
2 - Clutch plate
form
mer
atio
m

o
n
c
i
or
❑ Centring ⇒ page 38 n thi

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sd
va
3 - Thrust plate
i
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pr
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r
fo

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ng
t.
yi
⇒ page 38
Co
Cop py
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❑ Check ends of dia‐
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phragm spring cop Vo
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cted
⇒ page 40
agen
Prote AG.
❑ Check spring connec‐

tions and riveted con‐
nections ⇒ page 40 .
4 - Bolt
❑ Loosen or tighten alter‐
nately and diagonally in
small steps (1 full turn)
❑ M 6: 13 Nm
❑ M 7: 20 Nm
2. Clutch 37
2.2 Removing and installing clutch
Special tools and workshop

equipment required
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♦ Counter-hold tool - 3067-
AG.
♦ Centring mandrel - 3190 A-

Removing
• Gearbox is removed.

– Use counter-hold tool - 3067- to loosen bolts.

To prevent the pressure plate from becoming distorted during re‐
moval (causes clutch grab when driving off), always keep to the
following procedure when unbolting the pressure plate:
– Loosen all bolts alternately and diagonally in small steps (1 full
turn).
– Remove pressure plate and clutch plate.
Installing
Note
♦ Select clutch pressure plate and pressure plate according to

engine code and ⇒ Electronic parts catalogue (ETKA) .
♦ Clean splines of drive shaft and, if the clutch plate has been
used, clean the splines of the hub. Remove corrosion and ap‐
ply a very thin coat of clutch plate spline grease to splines.
G. Volkswagen AG d
Then, move the clutch plate back swaand
gen Aforth on the driveoesshaft
until the hub moves easilybon olk
y V the shaft. Remove excess
not
gu
ara
grease. orised
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ut
♦ Clutch pressure plates
ss
a are protected against corrosion and ra
c
greased. With the exception of the friction surface for the
ce
le
un
clutch plate, the clutch pressure plate must not be cleaned.
pt
an
d
Service life of clutch will otherwise be shortened considerably.

itte
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ab
♦ The friction surface of the clutch pressure plate and the fly‐
ility
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wheel must be cleaned (degreased) thoroughly.
wit
is n
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ole,
♦ If the clutch has burnt out, thoroughly clean the gearbox hous‐
spec
ing in the clutch area and the engine facing the gearbox in
order to reduce the smell of burnt linings.

t to the co
♦ Clutch plate linings must make full contact with flywheel and
friction surface of clutch pressure plate. Only then insert se‐
rrectne
curing bolts.
♦ Tighten or loosen securing bolts alternately and diagonally in
ss
small steps (1 full turn) in order not to damage centring holes

o
cial p
f i
of pressure plate and centring pins of flywheel.

nform
mer
♦ Check whether dowel sleeves for aligning engine and gearbox

atio
m
are fitted in cylinder block and install if necessary.

o
n
c
i
or
n thi
♦ If dowel sleeves are not fitted, difficulties shifting gears, clutch

te
sd
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problems and possible noises from the gearbox (rattling of

iv
o
pr
gears which are not engaged) could occur.

um
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fo
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ng
t.
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Cop py
t. rig
• Installation position of clutch plate: Lettering yri
gh by
ht
““Getriebeseite”” (gearbox side), or shorter hub end with
op Vo
by c lksw
spring cage must face pressure plate.
cted agen
Prote AG.
2. Clutch 39
Check ends of diaphragm spring

• Wear to half the thickness of the diaphragm spring -arrows- is
permitted.
Check spring connection and riveted fastenings.

– Check spring connection between thrust plate and cover for
cracks and make sure rivet fastenings are seated tightly.
. Volkswag AG en AG
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– If pressure plate has damaged
Vol
ksw springs or loose rivets nconnec‐
ot g
tions -arrows-, it mustd bybe renewed. ua
ran
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ac
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Check extension springs and riveted connections

spec
es, in part or in w
I - Extension springs OK.

t to the co
• Minor kinks on the outside area -arrows A- have series pro‐

duction status.
rrectness of i
II - Extension springs damaged

l purpos
• Renew clutch pressure plate if springs are broken or badly

bent -arrow B-.
nform
ercia
– Check spring connections -arrows A- for damage, and make

m
sure that rivet joints -arrows B- are firmly seated.

com
tion in
r
• Renew clutch pressure plate if spring connections are broken

te o
thi
or badly bent, or if riveting is loose.

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– Make sure rivet joints -arrows B- on all extension springs

-arrows A- are firmly seated.
– Tighten all bolts one after another (clockwise) to final torque.
• Renew clutch pressure plate if riveting -arrow B- is loose.

Check metal ring.

– Check that metal ring in clutch pressure plate -arrow- is not
damaged.
• Renew clutch pressure plate if metal ring is broken.
– To centre clutch plate, use centring mandrel - 3190 A- .

– Loosen or tighten alternately and diagonally in small steps (1
full turn)
– Installing gearbox ⇒ page 67 AG. Volkswagen AG d
agen oes
ksw
Specified torques by Vol not
gu
ara
d
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♦ Pressure plate to flywheel ⇒ page 37 . thor eo
au ra
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nl
pt
du
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ab
ility
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spec
es, in part or in w
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2. Clutch 41
Golf Sportsvan 2018 ➤ . Volkswagen AG
gen AG
5-speed manual gearbox 0AH - Editionolk11.2017 does
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34 – Controls, housing
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1 Selector mechanism
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ility
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⇒ “1.1 Installation position - selector mechanism”, page 42
wit
, is n
h re
⇒ “1.2 Assembly overview - gear knob and cover”, page 44
hole
spec
⇒ “1.3 Assembly overview - selector mechanism”, page 45
es, in part or in w
t to the co
⇒ “1.4 Removing and installing gear knob”, page 46
⇒ “1.5 Removing and installing selector mechanism”, page 48
rrectness of i
⇒ “1.6 Repairing selector mechanism”, page 51
l purpos
⇒ “1.7 Adjusting selector mechanism”, page 54
nform
ercia
⇒ “1.8 Checking selector mechanism”, page 56

m
1.1 Installation position - selector mecha‐
at
om
ion
c
nism
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ate
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Note
f
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t.
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Cop py
♦ Disconnect battery before working on selector mechanism in
t. rig
gh ht
yri
engine compartment ⇒ Electrical system; Rep. gr. 27 ; Bat‐
p by
co Vo
by lksw
tery; Disconnecting and connecting battery . Prote
cted AG.
agen
♦ Removing and installing selector mechanism ⇒ page 48
Arrow -A- Gear selection movement

Arrow -B- Gate selection movement
42 Rep. gr.34 - Controls, housing

A - Gear selector cable

B - Gate selector cable . Volkswagen AG
gen AG does
swa
C - Heat shield yV
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❑ Remove before remov‐ orise nte
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ing selector mecha‐aut
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nism. ss c
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1 - Gearbox selector lever
du
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2 - Gate relay lever
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1. Selector mechanism 43
1.2 Assembly overview - gear knob and cover

AG. Volkswagen AG d
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1 - Selector housing with gear Volksw not
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lever d b ara
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2 - Hexagon nut aut ra
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❑ M 8, 20 Nm
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❑ M 6, 8 Nm
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3 - Securing bracket
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❑ Version depends on re‐
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spective vehicle
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spec
❑ Assembly overview ⇒
General body repairs,
t to the co
interior; Rep. gr. 68 ;
Centre console; Assem‐
bly overview - centre
rrectne
console
4 - Securing bracket
ss o
❑ Version depends on re‐
cial p
f in
spective vehicle
form
mer
❑ Assembly overview ⇒
atio
m
General body repairs,

o
n
c
interior; Rep. gr. 68 ;
i
or
n thi
e
Centre console; Assem‐

t
sd
va
bly overview - centre

i
o
pr
cum
console
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5 - Noise insulation t. Cop py
rig
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6 - Emblem yri
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❑ Except for GT versions cted agen
Prote AG.
❑ Can be carefully levered
off gear knob of plastic
or leather using a wedge
- 3409-
7 - Gear knob
❑ With gaiter
❑ Gear knob and gaiter
cannot be separated from one another
❑ Always renew together
8 - Centre console
❑ Assembly overview ⇒ General body repairs, interior; Rep. gr. 68 ; Centre console; Assembly overview
- centre console
9 - Clip
❑ For securing gear knob to gear lever
❑ Secure to gear knob using hose clip pliers - V.A.G 1275 A-

1.3 Assembly overview - selector mechanism
Note
♦ Lubricate bearing positions and sliding surfaces.

AG. Volkswagen AG d
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1 - Selector shaft with selector byV
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shaft cover rised
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2 - Seal ss a ra
c
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⇒ page 91
an
d
itte
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3 - Slide block
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ility
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hole
spec
es, in part or in w
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❑ Greasing ⇒ page 52 .
❑ Fitting position
⇒ page 51
rrectness of i
❑ After installing, adjust
l purpos
selector mechanism
⇒ page 54
❑ Remove and install gate
nform
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relay lever together with

m
cable end-piece
a
com
tio
⇒ page 52
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5 - Cable end-piece thi

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❑ For gate selector cable

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❑ After installing, adjust Cop py
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selector mechanism py
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⇒ page 54 co Vo
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❑ Do not interchange; ca‐ Prote AG.
ble end-pieces securing

gate selector cable to
gate relay lever and
gear selector cable to
gearbox selector lever
are different
❑ Allocation ⇒ page 51 .
❑ Removing from gate re‐
lay lever ⇒ page 53
❑ Pressing onto gate relay lever ⇒ page 53
❑ Greasing ⇒ page 52 .
❑ Install so that master spline aligns with selector shaft ⇒ page 52
❑ Fitting position ⇒ page 51
❑ After installing, adjust selector mechanism ⇒ page 54
7 - Hexagon nut
❑ Specified torque ⇒ page 84
8 - Cable end-piece
❑ For gear selector cable to gearbox selector lever
❑ After installing, adjust selector mechanism ⇒ page 54
❑ Do not interchange; cable end-pieces securing gate selector cable to gate relay lever and gear selector
cable to gearbox selector lever are different
❑ Allocation ⇒ page 51 .
9 - Securing clip
10 - Gate change cable
❑ Connect to cable end-piece. AG. Volkswagen AG d
agen oes
❑ Fitting position ⇒ page 42 olksw not
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11 - Gear change cable horis
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❑ Connect to cable end-piece. ss a c
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12 - Hexagon nut
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13 - Seal
h re
hole
❑ Between selector housing and underbody
spec
es, in part or in w
❑ Renew selector housing after removing
t to the co
❑ Self-adhesive
❑ Bond to selector lever housing
rrectness of i
14 - Selector housing
l purpos
15 - Securing clip
nf
ercia
or
❑ Do not damage cables when removing
m
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16 - Hexagon bolt
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❑ Qty. 3
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❑ For cable support bracket
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op
❑ 20 Nm C py
t. rig
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17 - Cable support bracket op Vo
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cted agen
❑ After installing, adjust selector mechanism ⇒ page 54 Prote AG.
18 - Grommet
❑ Qty. 3
❑ Cable support bracket mounting on gearbox
19 - Spacer
❑ Qty. 3
20 - Clip
1.4 Removing and installing gear knob


♦ Hose clip pliers - V.A.G 1275 A-
AG. Volkswagen AG d
agen oes
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♦ Wedges - T10383-
ce
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spec
t to the co
rrectness o
cial p
f
♦ or front-end hook - 3370- , depending on equipment version
inform
mer
atio
om
n
c
i
or
n thi
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Cop py
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rig ht
py by
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by lksw
cted agen
Prote AG.
Removing
– Using removal wedge -T10383/1- , carefully pry gear lever
boot off centre console insert -arrows-.
– Plastic frame for gear lever gaiter can also be carefully levered
off centre console using wedge - T10383/1- .
AG. Volkswagen AG d
agen oes
olksw not
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Golf Sportsvan 2018 ➤ d by ara
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r
5-speed manual gearbox 0AH - Edition 11.2017utho eo
ra
s a c
s
– Pull gear lever gaiter upwards off gear knob.
ce
e
nl
pt
du
an
itte
– Open clamp -arrow- and pull off gear knob together with gear
y li
erm
ab
lever gaiter.
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Installing
, is n
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hole
spec
es, in part or in w
– Press gear knob together with gear lever gaiter onto gear lever
t to the co
as far as stop.
– Attach gear knob with clamp -arrow- (⇒ previous fig.) to gear
rrectness of i
lever. Use hose clip pliers - V.A.G 1275 A- to do this.
l purpos
nf
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orm
m
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1.5 Removing and installing selector mech‐
ng
t.
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op
anism
C py
t. rig
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pyri by
Vo
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by c
lksw
cted agen
Prote AG.
Removing
– Disconnect battery ⇒ Electrical system; Rep. gr. 27 ; Battery;
– Remove gear knob with gaiter ⇒ page 46 .
– Remove centre console with securing bracket ⇒ General body
repairs, interior; Rep. gr. 68 ; Centre console; Assembly over‐
view - centre console .
– Remove footwell air duct ⇒ Heating, air conditioning; Rep. gr.
87 ; Air duct; Assembly overview - air routing and air distribu‐
tion in passenger compartment .
Installation position of nuts -arrows- for insulation and selector
housing
– Unscrew nuts -arrows- for insulation and selector housing.
– Remove damping from selector housing ⇒ General body re‐
pairs, interior; Rep. gr. 68 ; Centre console; Assembly over‐
view - centre console .
– Remove complete air filter housing if it is located over selector
mechanism ⇒ Rep. gr. 24 ; Air filter; Removing and installing
air filter .

AG. Volkswagen AGolf Sportsvan 2018 ➤
agen G do
5-speed
Volksw manual gearbox 0AH es n- Edition 11.2017
ot
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db ara
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Remove gear selector cable and gate relay lever
tho with
r
gate se‐ eo
lector cable end-piece. s au ra
c
s
ce
le
– Remove securing clip -1- for gear selector cable -2- from gear‐
un
pt
an
d
box selector lever -3-.
itte
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– Pull gear selector cable -2- off pin.
pe
ility
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– Remove gate relay lever -4- together with gate selector cable
h re
end-piece ⇒ page 52 .
hole
spec
es, in part or in w
t to the co
rrectness of i
– Remove cable support bracket from gearbox -arrows-.
l purpos
– Remove heat shield below selector mechanism ⇒ General

body repairs, exterior; Rep. gr. 66 ; Mouldings/trims/exten‐
nform
ercia
sions; Removing and installing floor heat shield .

m
a
com
t
– Swing selector lever housing down and remove with selector
ion in
cables.
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With gate relay lever removed: levering cable end-piece for gate
AG.
selector cable off gate relay lever

– Fit a flat-bladed screwdriver between bush -B- and gate relay
lever -A-.
Installing
Install in the reverse order of removal, observing the following.
– Align selector housing parallel to body.
• Distance to body must be same on both sides.
Bolt on selector housing.
– Route Bowden cables -1- from selector mechanism -2- to

gearbox as follows:
• Bowden cables must lie parallel to each other and must not
cross.
• Bowden cables must be laid in the intended indentation in heat
shield -3-.
Clip -A- holds cables and heat shield together in position.

The holes in the cable end-pieces have different diameters.
lkswage es n
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d ran
ir se tee
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a ac
ss
Allocation of cable end-pieces ⇒ page 51
ce
le
un
pt
an
d
itte
– Apply a small amount of grease to pins of gearbox selector

y li
rm
lever -3- and gate relay lever -4- ⇒ page 52 . ab

pe
ility
ot

wit
, is n
h re
hole
– Renew securing clip -1- for cable end-piece -2- after each re‐
spec
moval.
es, in part or in w
t to the co
– Install gate relay lever -4- and cable end-piece together

⇒ page 52 .
rrectness of i
– Insert gate selector cable in cable end-piece on gate relay

lever.
l purpos
– Install damping on selector housing ⇒ General body repairs,

interior; Rep. gr. 68 ; Centre console; Assembly overview -
nform
ercia
centre console .
m
– Install centre console ⇒ General body repairs, interior; Rep.

com
tion in
gr. 68 ; Centre console; Assembly overview - centre console .

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Prote AG.

– Renew clamp -arrow-.

Adjust selector mechanism ⇒ page 54 .
– Install gaiter with gear knob ⇒ page 46 .
– Install heat shield below selector mechanism ⇒ General body
repairs, exterior; Rep. gr. 66 ; Mouldings/trims/extensions;
Removing and installing floor heat shield .
– Assemble exhaust system free of tension ⇒ Rep. gr. 26 ;
Exhaust pipes/silencers; Assembly overview - silencer .
– If removed, install complete air filter housing ⇒ Rep. gr. 24 ;
Air filter; Removing and installing air filter housing .
Specified torques
♦ Selector housing to body
⇒ “1.2 Assembly overview - gear knob and cover”, page 44
♦ Selector cable support bracket to gearbox
⇒ “1.3 Assembly overview - selector mechanism”, page 45
1.6 Repairing selector mechanism

Allocation of cable end-pieces
Cable end-piece for Dimension “a”
-1- Gear selector cable to gearbox selector lks wage
lever 8.5 mm es n
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byV ua
-2- Gate selector cable to gate relay ir se lever
d 10 mm ran
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ility
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es, in part or in w
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Installation position of gearbox selector lever/gate relay lever

rrectness of i

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2 - Gate relay lever engages in guide rail of gearbox selector lever

via shoe -arrow-.
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Gate relay lever: thoroughly grease following areas in particular

prior to installation
• Shaft -A- of gate relay lever -arrows-; amount of grease:
0.2 grams. wage
es ks not
Vol gu
• Allocate grease using ⇒ Electronic parts catalogue
ed
by (ETKA) . ara
nte
ris
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ility
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hole
Gearbox selector lever: thoroughly grease following areas in par‐
spec
ticular prior to installation
es, in part or in w
t to the co
• Guide rail -B- of gearbox selector lever into which gate relay
lever engages.
rrectness of i
• Support pin for cable end-piece.
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• Illustration of gate relay lever and gearbox selector lever may
nform
ercia
differ from actual components.

m
at
om
ion
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Install gearbox selector lever

p
cum
for
– When fitting the gearbox selector lever, ensure that the gap
en
ng
t.
yi
-arrow A- is aligned with the master spline -arrow B-.
Co
Cop py
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Prote AG.
Removing and installing gate relay lever

– Pull locking mechanism forward to stop in
-direction of arrow 1-, and then lock it by turning to left in
-direction of arrow 2-.

– Then push gate relay lever forwards (-direction of arrow 3-).

– Pull off clip -arrow 1- and remove gate relay lever together with
cable end-piece.
Cable end-piece must be located behind catch -arrow 2-.
• It is permissible to remove cable end-piece only after gate re‐
lay lever has been removed ⇒ page 53 .
– Press cable end-piece onto gate relay lever ⇒ page 53 .
– Insert gate relay lever together with cable end-piece as far as
stop.
• The clip -arrow 1- secures gate relay lever.
• Ensure proper engagement of clip.
• Cable end-piece must be located behind catch -arrow 2- (⇒
previous figure). AG. Volkswagen AG d
agen oes
olksw not
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• Allocate grease using ⇒ Electronic parts catalogue (ETKA) . Prote AG.
• Cable end-piece may be pressed only onto bush -arrow-.

• Cable end-piece must move freely on gate relay lever.
• The cable end-piece must be located behind catch.
• Ensure proper engagement.
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Prerequisites for adjustment

• Moving parts of selector mechanism and elements transferring
force must be in proper condition.
• Selector mechanism must move freely.
• Gearbox, clutch and clutch mechanism must be in proper con‐
dition.
• Gearbox must be in neutral.
– Remove complete air filter housing if the angled rod for se‐
curing selector shaft and the securing mechanism for the gear
selector cable and gate selector cable are not accessible. ⇒
Rep. gr. 24 ; Air filter; Removing and installing air filter housing
Open cable end-pieces on gearbox:
– Pull locking mechanisms on gate selector cable and gear se‐
lector cable end-pieces forward to stop -direction of arrow 1-
and then turn to left to lock -direction of arrow 2-.
• It must be possible to push both cables into the locking mech‐
anisms.

Move selector shaft in correct position for adjustment:

– Press selector shaft down in -direction of arrow 1-.
– While pressing down selector shaft, turn angled rod -A- in di‐
rection of -arrow 2-, and at the same time press it in until it
engages in selector shaft. gen AG
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– Remove gaiter from centre console ⇒ page 46 .
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– Pull gear lever gaiter upwards off gear knob.
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Secure selector lever as follows:
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– Move gear lever to neutral position and, if necessary, keep
pressing the gear lever to the left.
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– Guide locking pin - T10027 A- through the damping -A- and
hole -B- into hole -C-.
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– Wrap left seat belt -1- around gear lever so that belt holds lev‐ Prote
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The gear lever is secured by the locking pin - T10027A- (-A-).
In addition, the seat belt presses the gear lever against the stop
for 1st and 2nd gear -direction of arrow-.
This takes all »play out of the selector mechanism«.
Adjusting the selector mechanism:

– Gate and selector cables -B- must be inserted, free of tension,
into locking elements -A-.
– Now turn locking mechanisms on gear selector cable and gate
selector cable end pieces clockwise to stop
The spring presses the locking mechanism into original position
– Now turn angled rod -A- back to original position in direction

of -arrow-.
• During this procedure, angled rod -A- must be pressed out of
gearbox in -direction of arrow-.
– Pull locking pin out of damping -A- and holes -B- and -C-. AG. Volkswagen AG d
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– Check selector mechanism ⇒ page 56 . ss
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– If removed, install complete air filter housing ⇒ Rep. gr. 24 ;
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Air filter; Removing and installing air filter housing .
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1.8 Checking selector mechanism
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• With gearbox in neutral, gear lever must be in gear lever gate
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⇒ page 54 .

2 Removing and installing gearbox

⇒ “2.1 Removing gearbox”, page 57
⇒ “2.2 Install gearbox”, page 67
⇒ “2.3 Specified torques for gearbox”, page 72
2.1 Removing gearbox

equipment required
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♦ Support - 10 - 222 A-
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♦ Adapter - 10 - 222 A /29-

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♦ Adapter - 10 - 222 A /18-

♦ Shackle - 10 - 222 A /12- qty. 2
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♦ Pin - 3282/45-
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♦ Not required: pin - 3282/29-

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57
Prote AG.
2. Removing and installing gearbox
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♦ Adjustment plate - 3282/31-

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♦ Engine and gearbox jack - V.A.G 1383 A-

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♦ Or engine and gearbox jack - VAS 6931-
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♦ Square tube - T40091/1- , qty. 2
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♦ Connecting piece - T40091/3- , qty. 2

♦ Spindle - T40093 /3- from engine support supplementary set
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- T40093- , qty. 2
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♦ Adapter - T40093/3-6- , qty. 2 (check and modify as necessary

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⇒ page 60 )
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♦ or adapter - T40093/3-6A- , qty. 2

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♦ Assembly tool - T10519-

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♦ Grease for splines
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Prote AG.

2. Removing and installing gearbox 59

Check adapters - T40093/3-6- and modify as necessary

– If necessary, cut off the marked area.
– Round off front edges.
– Protect adapter against corrosion.
– Then, mark adapters - T40093/3-6- as -T40093/3-6A- .
At a later point, support bracket - 10-222 A- will be fitted onto
longitudinal members with adapters - T40093/3-6A- .
• To prevent damage to the longitudinal members, wrap the
front section of the adapters - T40093/3-6A- with textile-rein‐
forced adhesive tape ⇒ Electronic parts catalogue (ETKA
chemical substances) . n AG. Volkswagen A G do
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– Remove battery tray ⇒ Electrical system; Rep. gr. by
ed 27 ; Battery;
ua
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Removing and installing battery . oris tee
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– Remove complete air filter housing ⇒ Rep. gr. 24 ; Air filter;
ss
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Removing and installing air filter housing .

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– Remove securing clip -1- for gear selector cable from gearbox
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selector lever -B-.
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– Remove gate relay lever -A- together with cable end-piece
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⇒ page 52 .
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– Remove gearbox selector lever -B- by removing nut
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-arrow 2-.
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– Unscrew bolts -arrows- and lay cable support bracket together
with Bowden cables to one side.
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– Unscrew bolts -arrows- and place clutch slave cylinder to one

side. Do not disconnect lines.
Caution
Risk of damage to clutch slave cylinder.

♦ Make sure you do not press the clutch pedal if the clutch
slave cylinder is removed from the gearbox with the pipe/
hose assembly still attached.
– If fitted, remove earth strap.

– Then remove upper securing bolt on starter.
– Remove upper engine/gearbox connecting bolts.
– If there are hose and cable connections in area of engine sup‐
port eyes for support bracket - 10 - 222 A- , remove these now.
– Install support bracket - 10-222 A- as follows:
Required material:
♦ Adapter - 10 - 222 A /18-
♦ Shackle - 10 - 222 A /12- , qty 2 (required when spindles of
engine support bracket cannot be hooked into lifting eyes of
engine).
♦ 2 x Adapter - 10 - 222 A /29-
♦ Square tube - T40091/1- , qty. 2
♦ Connecting piece - T40091/3- , qty. 2
♦ Spindle - T40093 /3- , qty. 2
♦ 2 x Adapter - T40093/3-6A-
– On both sides of vehicle, insert adapters - 10 w-a222

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Arrow -2- always points in direction of travel.

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• Fit adapters - 10 - 222 A /29- directly onto the outer edge,

which faces towards wing -arrows-.
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61
agen
Prote AG.
2. Removing and installing gearbox
– Push adapter - 10 - 222 A /18- and two connecting pieces -

T40091/3- onto support bracket - 10-222 A- .
– Secure support bracket - 10-222 A- to adapters - 10 - 222 A /
29- .
-A- = adapter - T40093/3-6A- (⇒ next figure)
– If present, pull off wires in front area of flange on both longi‐

tudinal members -arrow-. Do not disconnect pipe/hose sys‐
tem.
– Place adapters - T40093/3-6A- onto both longitudinal mem‐
bers (the illustration shows the left longitudinal member).
– If necessary, carefully unclip any pipes for air conditioning
system in front area. Do not disconnect pipe/hose system ⇒
Heating, air conditioning; Rep. gr. 87 ; Refrigerant circuit;
System overview - refrigerant circuit .
• Each of the adapters - T40093/3-6A- locks with pin -A- behind
the web of the longitudinal member -arrow-.
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• If necessary, push adapter - T40093/3-6A- into position
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– Screw in spindles - T40093 /3- .
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– Connect spindles - T40093 /3- via square tubes - T40091/1-
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illustration).
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– Then, attach spindles in lifting eyes of engine, using shackles

h re
hole
- 10 - 222 A /12- as needed.

spec
es, in part or in w
– Take up weight of engine/gearbox assembly and support

t to the co
bracket on spindles .
rrectness of i
– Remove lower part of front left wheel housing liner ⇒ General

body repairs, exterior; Rep. gr. 66 ; Wheel housing liner; As‐
l purpos
sembly overview - front wheel housing liner .

– Remove noise insulation ⇒ General body repairs, exterior;
nform
ercia
Rep. gr. 66 ; Noise insulation; Assembly overview - noise in‐

sulation .
m
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– Remove nut -arrow- and remove retainer for electrical lines.

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– Remove starter ⇒ Electrical system; Rep. gr. 27 ; Starter .

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– Pull connector -1- off oil level and oil temperature sender -
G266- .
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– If fitted, unbolt front vehicle level sender - G78- from trans‐
erm
ab
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verse link ⇒ Running gear, axles, steering; Rep. gr. 43 ;
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Vehicle level sender; Assembly overview - front vehicle level
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– Disconnect electrical connectors:

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1- Reversing light switch - F4-

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2- Gearbox neutral position sender - G701-

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– Separate exhaust system from engine ⇒ Rep. gr. 26 ; Emis‐

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sion control; Assembly overview - emission control .
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Risk of damage to flexible joint.

♦ Observe ⇒ Rep. gr. 26 ; Emission control; Assembly
overview - emission control .
– Remove pendulum support.

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– Unscrew nut -1- from coupling rod -3- on both sides.
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– Withdraw coupling rod -3- from anti-roll bar -2- on both sides.
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– To make more space available for working, swing right sus‐
nform
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pension strut outwards and support it with hook -2024 A /1- as

shown in illustration.
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– If fitted, remove drive shaft heat shield -arrows- ⇒ Running

gear, axles, steering; Rep. gr. 40 ; Drive shaft; Removing and
installing drive shaft heat shield .
– Remove drive shafts from flange shafts and tie them up as
high as possible. Do not damage surface protection ⇒ Run‐
ning gear, axles, steering; Rep. gr. 40 ; Drive shaft; Removing
and installing drive shaft .
– If fitted, unscrew nut -arrow- and detach earth wire.

– Remove hexagon bolts -arrows- for left assembly mounting

from gearbox mounting.
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– Lower gearbox by adjusting spindles of engine support brack‐
spec
et - 10 - 222 A- as far as distance -a-.
es, in part or in w
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• Dimension -a- = approx. 40 mm
• Observe the differential in the area of the subframe.
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– Remove bolts -arrows 2- and detach gearbox support from
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Bolts -2 and 3- securing gearbox to engine as well as starter bolts

-4 and 5- have been removed.
– Unscrew bolts -7 and 8- securing gearbox to engine.
– Bolts -1, 6 and 9- securing gearbox to engine are to be un‐
screwed at a later point.

– Bolt assembly tool - T10519/1- to subframe. Tighten bolts to

20 Nm.
– Attach support device - 3300 A- to assembly tool - T10519/1- .
Tighten bolts to 20 Nm.
– If possible, position engine support - 3300 A- next to sump
-arrow-.
– Place cloth between engine support - 3300 A- and engine.
– Push engine forwards, making sure not to strike against radi‐
ator.
Gearbox support - 3282- is aligned with adjustment plate -

3282/31- for removal of gearbox.
• The adjustment plate fits only in one position.
– Insert gearbox support - 3282- into engine and gearbox jack .
– Align arms of gearbox support according to holes in adjust‐
ment plate .
– Attach support elements -A- to adjustment plate as illustrated.
– Screw in pin - 3282/45- instead of support element -C-.
– Position engine and gearbox jack under vehicle. Arrow -B- on
adjustment plate points in direction of vehicle travel.
– Align adjustment plate parallel to gearbox.

-A- = pin - 3282/45- with flange nut M 8.
– Screw flange nut M 8 onto pin A-G3282/45-
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– Unscrew bolt -arrow-.
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– Unscrew bolt above -A- and below right flange shaft.

hole
spec
– Unscrew all remaining bolts securing gearbox to engine.

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– Press gearbox off dowel sleeves.

– Observe intermediate plate on engine.
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– Swing differential downwards via spindle of gearbox support -

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3282- .
• The right flange shaft is located near the lower bolt hole of the
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engine.
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– Then carefully guide gearbox with right flange shaft past fly‐
wheel and intermediate plate -arrow 2-.
– Lower gearbox, being careful of subframe -arrow 1-.
– When lowering gearbox, change position of gearbox using
spindles of gearbox support - 3282- .
Note
Be careful of all lines when lowering gearbox.
⇒ “2.2 Install gearbox”, page 67
2.2 Install gearbox
Note
Refer to procedure “Removing gearbox” for required special tools

⇒ page 57 .
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– Check whether dowel sleeves for aligning engine and gearbox
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– Make sure that intermediate plate is engaged on sealing
t to the co
flange -top arrow- and pushed onto dowel sleeves
-bottom arrows-.
– Clean input shaft splines and apply thin coat of grease for
rrectne
clutch plate splines .
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The clutch plate must slide easily to and fro on the input shaft.
s o
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– Bolt assembly tool - T10519/1- to subframe. Tighten bolts to

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-arrow-.
– Place cloth between engine support - 3300 A- and engine.
– Push engine forwards, making sure not to strike against radi‐
ator.

Gearbox support - 3282- is aligned with adjustment plate -

3282/31- for installation of gearbox.
– Insert gearbox support - 3282- into engine and gearbox jack .
– Align arms of gearbox support according to holes in adjust‐
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t to the co
adjustment plate points in direction of vehicle travel.
A = pin - 3282/45- with flange nut M 8.
rrectne
– Screw flange nut M 8 onto pin - 3282/45- to secure gearbox.
ss
– Then raise gearbox carefully and guide past subframe.
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Note
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– Start securing bolts for engine and gearbox in area of sump
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and tighten bolts ⇒ page 72 .
– Screw in and tighten engine/gearbox connecting bolt -arrow-

⇒ page 72 .

– Screw in and tighten bolt above -A- and below right flange
shaft ⇒ page 72 .
– After gearbox has been bolted to engine, remove engine and
gearbox jack from gearbox by unscrewing nut -A- (⇒ previous
illustration).
– Remove engine support - 3300 A- and assembly tool -
T10519/1- .
– Install gearbox support using new bolts -arrows 2-

⇒ page 73 .
– Align engine/gearbox assembly in installation position; to do
so, tighten spindles of support bracketA-G10
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ings; Adjusting assembly mountings .
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h re
bolts securing the assembly mounting have been tightened to
hole
spec
specified torque.
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Note t to the co
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Install engine and gearbox mounting free of tension ⇒ Rep. gr.

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10 ; Removing and installing engine; Installing engine .

nf
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– Do not remove engine support bracket - 10 - 222 A- until all

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– Install pendulum support with new bolts ⇒ Rep. gr. 10 ; As‐

sembly mountings; Assembly overview - assembly mount‐
ings .
– Check adjustment of assembly mountings ⇒ Rep. gr. 10 ;
Assembly mountings; Checking adjustment of assembly
mountings .
– Install exhaust system free of tension ⇒ Rep. gr. 26ge; nEmission
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– Install drive shafts ⇒ Running gear, axles, steering; Rep. gr.
erm
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40 ; Drive shaft; Removing and installing drive shafts .
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– If fitted, install drive shaft heat shield -arrows- ⇒ Running gear,
h re
axles, steering; Rep. gr. 40 ; Drive shaft; Removing and in‐
hole
spec
stalling drive shaft heat shield .
es, in part or in w
t to the co
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– If present, bolt front left vehicle level sender - G78- to trans‐
m
atio
m
verse link ⇒ Running gear, axles, steering; Rep. gr. 43 ;

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c
Vehicle level sender; Assembly overview - front vehicle level

or
thi
sender .
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– Install coupling rod -3- to anti-roll bar -2- on both sides ⇒

Running gear, axles, steering; Rep. gr. 40 ; Subframe; As‐
sembly overview - subframe .

– Connect connector -1- to oil level and oil temperature sender

- G266- .
– Install starter ⇒ Electrical system; Rep. gr. 27 ; Starter .
– If fitted, connect earth strap at top.
– Fit connector onto reversing light switch - F4- .
– Check for correct installation position of vacuum hose for
brake system. Fit vacuum hose, if necessary ⇒ Brake system;
Rep. gr. 47 ; Brake servo/brake master cylinder .
– Install clutch slave cylinder ⇒ page 28 .

n AG. Volkswagen AG
– Gearboxes for vehicles witholkstart-stop
swa
ge system: join connector
does
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-arrow- to gearbox neutral
db
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– Install cable support bracket on gearbox, and tighten bolts
-arrows- ⇒ page 45 .
rrectness o
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– Install gearbox selector lever -B- ⇒ page 45 .

– Tighten hexagon nut -arrow 2- ⇒ page 45 .
– Install gate relay lever -A- together with cable end-piece
⇒ page 52 .
– Spread small amount of grease on pin of gearbox selector
lever -B-.
Allocate grease using ⇒ Electronic parts catalogue (ETKA) .
– Attach gear selector cable to gearbox selector lever.
– Renew securing clip -arrow 1- after removal.
– Adjust selector mechanism ⇒ page 54 .
– If unclipped, carefully clip in pipe for air conditioning. Do not
open pipe/hose system ⇒ Heating, air conditioning; Rep. gr.
87 ; Refrigerant circuit; System overview - refrigerant circuit .
– Install engine cover panel or air filter cover ⇒ Rep. gr. 24 ; Air
filter; Removing and installing air filter housing .
– Check position of filler pipe for washer fluid reservoir of wind‐
screen washer system ⇒ Electrical system; Rep. gr. 92 ;
Windscreen washer system; Removing and installing washer
fluid reservoir .
– Check gear oil ⇒ page 76 .
– Install lower part of front left wheel housing liner ⇒ General
body repairs, exterior; Rep. gr. 66 ; Wheel housing liner; As‐
sembly overview - front wheel housing liner .
– Install noise insulation ⇒ General body repairs, exterior; Rep.
gr. 66 ; Noise insulation; Assembly noverview
AG. Volksw-anoise
gen AG insula‐
tion . lkswage does
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– For vehicles with frontorleft
ise vehicle level sender - G78- , check ante
headlight adjustment au ⇒ Electrical system; Rep. gr. 94 ; Head‐
th eo
ra
lights; Adjusting headlights
ss . c
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specified by manufacturer ⇒ Paintwork manual .

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2.3 Specified torques for gearbox

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Item Bolt Quantity Nm

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t to the co
1 M12 x 60 2 80
2 M12 x 150 2 80
♦ Additionally, start‐
rrectness of i
er to gearbox
l purpos
3 M 10 x 55 3 40
4 M12 x 70 2 80
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Item -A- dowel sleeves for centring

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Rep. gr.34 - Controls, housing
3 Assembly mountings
olkswagen AG
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⇒ “3.1 Assembly overview
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does page 73
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3.1 Assembly overview - assembly mountings
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1 - Bolt
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❑ ⇒ Rep. gr. 10 ; Assem‐
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ab
bly mountings; Assem‐
ility
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wit
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mountings
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2 - Engine support
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3 - Engine mounting
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4 - Bolt
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mountings
6 - Bolt
mountings
7 - Bracket
8 - Bolt
❑ ⇒ Rep. gr. 10 ; Assembly mountings; Assembly overview - assembly mountings
9 - Pendulum support
10 - Bolt
❑ Pendulum support to subframe
11 - Bolt
❑ Pendulum support to gearbox
12 - Bolts
❑ Pendulum support to gearbox
3. Assembly mountings 73
13 - Bolt
❑ Gearbox mounting to gearbox bracket
❑ Before tightening; specified torques ⇒ Rep. gr. 10 ; Assembly mountings; Adjusting assembly mountings
14 - Bolt
❑ Gearbox mounting to gearbox bracket
❑ Before tightening; specified torques ⇒ Rep. gr. 10 ; Assembly mountings; Adjusting assembly mountings
15 - Bolt
❑ Gearbox mounting to body
16 - Gearbox mounting
17 - Gearbox support
18 - Bolt
❑ Gearbox support to gearbox
❑ Qty. 3
❑ 40 Nm +90°
AG. Volkswagen AG d
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lkswage es n Golf Sportsvan 2018 ➤
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at
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– Bolt gearbox lifting tackle - 3336- to clutch housing.
c
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– Adjust support beam on sliding piece using locking pin

-arrow-.
No. of holes visible = 6
– Lift gearbox using workshop crane and gearbox lifting tackle -
3336- .
– Set gearbox aside, for example in a transport container.
4. Transporting gearbox 75
5 Gear oil
⇒ “5.1 Checking gear oil level”, page 76
5.1 Checking gear oil level

♦ Socket bit - 3357- for oil filler plug with multi-point socket head
bolt
AG. Volkswagen AG d
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Gear oil ⇒ Electronic parts catalogue (ETKA)

i
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sulation . opyri
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– To check gear oil, remove oil plug -arrow-.
lksw
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Oil level is correct when gearbox is filled to lower edge of filler
hole.
– If necessary, fill with gear oil to lower edge of filler hole.
– Tighten oil plug -arrow- to specified torque.

Various versions of oil filler and drain plug

I - Oil filler plug/oil drain plug with multi-point socket head, 25 Nm
II - Oil filler plug/oil drain plug with hexagon socket head, 30 Nm
gr. 66 ; Noise insulation; Assembly overview - noise insula‐
tion .
AG. Volkswagen AG d
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5. Gear oil 77
6 Installing to engine and gearbox sup‐

port olkswage
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♦ Adapter - T10235-
nform
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♦ Support clamp - VW 313-
– Secure gearbox on engine and gearbox support - VW 540-

-arrows-.

7 Dismantling and assembling gearbox

⇒ “7.1 Schematic overview - gearbox”, page 79
⇒ “7.2 Assembly overview - gearbox”, page 80
⇒ “7.3 Assembly overview - cover for gearbox housing and 5th n AG. Volkswagen A
gear”, page 81 olks
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⇒ “7.4 Assembly overview - clutch housing”, pageris82
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⇒ “7.5 Assembly overview - shafts, differential,
ss
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nism”, page 83
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⇒ “7.6 Assembly overview - selector unit”, page 84
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⇒ “7.7 Assembly overview - selector forks”, page 86
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⇒ “7.8 Repairing selector forks”, page 87
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⇒ “7.9 Repairing selector unit”, page 90
spec
⇒ “7.10 Renewing oil seal for selector shaft”, page 91
t to the co
⇒ “7.11 Dismantling and assembling gearbox”, page 93
rrectne
7.1 Schematic overview - gearbox
ss o
1 - 1st gear
cial p
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2 - 2nd gear
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3 - 3rd gear
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8 - Reverse gear wheel Prote
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agen
9 - Selector mechanism
❑ (Selector forks)
10 - Clutch housing
11 - Input shaft
12 - Output shaft
13 - Differential
7. Dismantling and assembling gearbox 79

7.2 Assembly overview - gearbox

AG. Volkswagen AG d
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⇒ “7.3 Assembly overview - rise
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cover for gearbox housing and autho eo
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clutch housing”, page 82
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III -
⇒ “7.6 Assembly overview - se‐
lector unit”, page 84
rrectness of i
III -
l purpos
⇒ “7.7 Assembly overview - se‐

lector forks”, page 86
nform
ercia
III -
m
⇒ “7.8 Repairing selector
a
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forks”, page 87
n in
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⇒ “7.9 Repairing selector unit”,
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⇒ “7.10 Renewing oil seal for
rig
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Prote AG.

7.3 Assembly overview - cover for gearbox housing and 5th gear
1 - Gearbox housing
❑ Repairing ⇒ page 103
2 - Gear wheel for 5th gear
⇒ page 93
3 - Retaining ring
❑ Determining thickness
⇒ page 102
4 - Seal
❑ Renew if damaged
5 - Gearbox housing cover
Note
If gearbox housing cover is installed

with gearbox installed, check oil lev‐
el and top up with gear oil
⇒ page 76 .
6 - Bolt
❑ 5 Nm and turn 90° fur‐
ther
7 - Retaining ring
⇒ page 102 AG. Volkswagen AG d
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9 - Synchro-ring for 5th gear

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10 - Synchromeshed gear, 5th gear

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11 - Needle bearing
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❑ For 5th gear

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12 - 5th gear selector fork

rrectness of i
13 - Pivot pin
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❑ For 5th gear selector fork

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7. Dismantling and assembling gearbox
7.4 Assembly overview - clutch housing
1 - Countersunk bolt
⇒ page 134
2 - Flange shaft with compres‐
sion spring
⇒ page 93
❑ Assembling
⇒ page 134
3 - Bolt
ther
4 - Clutch housing
5 - Gearbox housing
6 - Clutch release lever
❑ With guide sleeve and olkswage es n
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⇒ page 82 ss
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⇒ page 15
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7.5 Assembly overview - shafts, differential, selector mechanism
1 - Differential
❑ Dismantling and assem‐
bling ⇒ page 134
2 - Gearbox housing
3 - Oil drain plug
⇒ page 77
4 - Flange shaft with compres‐
sion spring AG. Volkswagen AG d
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❑ Assembling aut ho eo
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⇒ page 134 s s c
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⇒ page 134
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6 - Bolt
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❑ For securing bearing
spec
support for input and
t to the co
output shafts.
❑ Self-locking
❑ 5 Nm and turn 90° fur‐ rrectne
ther
ss o
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inform
❑ For selector mechanism

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❑ Self-locking
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10 - Bolt
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❑ 5 Nm and turn 90° further
11 - Selector shaft with selector shaft cover
❑ (Selector unit)
12 - Bolt
13 - Bolt
❑ 6 Nm
14 - Gearbox neutral position sender - G701-
❑ for vehicles with start/stop system

15 - Reversing light switch - F4-

❑ Switch without seal: clean thread of switch if necessary
❑ Switch without seal: install switch with sealant if necessary
❑ For allocation of sealant, refer to ⇒ Electronic parts catalogue (ETKA) .
❑ Switch with encapsulated seal: renew switch
❑ Switch with separate seal: renew seal
❑ Lightly coat lug with MoS2 grease
❑ Remove noise insulation with gearbox installed ⇒ General body repairs, exterior; Rep. gr. 66 ; Noise
insulation; Assembly overview – noise insulation .
❑ 20 Nm
16 - Seal
❑ Not fitted in all gearboxes
AG. Volkswagen AG d
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17 - Selector mechanism orise nte
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18 - Input shaft and output shaft with bearing mounting and deep groove ball bearing
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❑ Pressing bearing support off and on: Dismantling and assembling input shaft ⇒ page 108
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❑ Dismantling and assembling input shaft ⇒ page 108
hole
spec
❑ Dismantling and assembling output shaft ⇒ page 121
es, in part or in w
t to the co
19 - Reverse gear shaft
20 - Reverse gear wheel
rrectness of i
21 - Bolt
l purpos

❑ For securing shaft for reverse gear
nform
ercia

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22 - Oil collector
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23 - Magnet
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24 - Oil guide
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7.6 Assembly overview - selector unit
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Prote AG.
Note
♦ Lubricate bearing positions and sliding surfaces.


1 - Sleeve
❑ For selector shaft
❑ Driving out ⇒ Fig.
⇒ page 91
❑ Driving in ⇒ page 91
2 - Selector shaft with selector
shaft cover
❑ Renew together
3 - Angled rod
❑ For adjusting selector
mechanism
❑ Removing ⇒ page 90
⇒ page 51
5 - Bearing bush
❑ Not required for plastic
gate relay lever.
6 - Seal
⇒ page 91
7 - Cap
❑ For gearbox breather
❑ Illustration may differ
from original compo‐
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❑ Install so that master yV
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9 - Hexagon nut
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❑ 23 Nm
spec
es, in part or in w
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7.7 Assembly overview - selector forks
Note
It is not necessary to dismantle the selector fork group in order to dismantle and assemble detent segments,
lock washers and angular contact ball bearings.
1 - Selector fork group with se‐

lector plate
2 - Selector segment for 3rd
and 4th gear
❑ Identification
⇒ page 88
❑ After installation, selec‐
tor segment must still ro‐
tate freely
3 - Angular contact ball bearing
❑ Qty. 4
❑ Press inner race into
outer race ⇒ page 90
❑ Installing ⇒ page 90
4 - Clamping washer
❑ Removing ⇒ page 89 n AG. Volkswagen AG do
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❑ Installing ⇒ page 89 yV
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5 - 1st/2nd gear selector seg‐ ir se tee
tho
ment au or
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❑ Identification
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⇒ page 88
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❑ After lock washer is in‐
erm
stalled, segment must ab

ility
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still rotate freely wit

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❑ Selector fork with selec‐
hole
spec
tor segment
es, in part or in w
⇒ page 89
t to the co
6 - 5th gear selector fork with

selector segment
rrectness of i
❑ Selector segment is per‐

manently connected to
l purpos
selector fork.
❑ Identification ⇒ page 88
nform
ercia
7 - Pivot pin
m
at
om
❑ For 5th gear selector fork

on
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7.8 Repairing selector forks

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equipment required
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spec
es, in part or in w
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rrectness of i
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nform
mercia
at
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ion
c
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ate
do
priv
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♦ Thrust plate - VW 402-

♦ Thrust piece - 3290/1-
♦ Assembly tool - 3301-
♦ Thrust piece - VW 431-
♦ Spacer sleeve - VW 472/2-
♦ Drift - 10-206-

♦ Release lever -
80-200-
♦ Assembly mandrel -
10-508-
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♦ Tensioning device -
es, in part or in w
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2070-
rrectness of i
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c
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Identification of selector
en
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segments and selector
Co
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fork for 5th gear with se‐ ht. rig
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Dimension -a- Prote AG.
1- Selector segment
for 1st and 2nd
gears = 10.35 mm
2- Selector segment
for 3rd and 4th
gears = 78.6 mm
3- 5th gear selector
fork with selector
segments =
79.5 mm

Selector fork for 1st and 2nd gears with selector segments
Dimension -a- = 75 mm AG. Volkswagen AG d
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Removing lock washer
t to the co
– Clamp selector fork in vice with protective jaw covers -B-.
– Lever off lock washer -A- in -direction of arrow-.
rrectness of i
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at
om
ion
c
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or
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do
priv
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Installing lock washer

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– Press lock washer into groove of detent segment using socket C py
t. rig
and spinner handle.
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Prote AG.
Note
After lock washer is installed, detent segment must still rotate

freely.
A - Spinner handle with 10 mm socket

B - Protective jaw covers
Removing angular contact ball bearing
Note
When removing and installing angular contact ball bearing, do not

bend selector forks.

Pressing inner race -A- of angular contact ball bearing into outer
race
Inner race must engage in outer race.
Pulling angular contact ball bearing into selector fork to stop AG. Volkswagen AG d
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Depression in thrust piece - 3290/1- faces ball bearing. by V ol
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7.9 Repairing selector unit
rrectness of i
l purpos
♦ Tube - T10203-
nf
ercia
orm
m
atio
om
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Prote AG.
– Remove selector mechanism ⇒ page 83 .

Removing angled rod -A- from selector shaft cover
– Remove outer part of angled rod.
– Then carefully pry out angled rod using a screwdriver.

Drive angled rod -A- into selector shaft cover

Installation position:
Marking -1- aligns with marking -2- on selector cover.
– Install selector mechanism ⇒ page 83 .
AG. Volkswagen AG d
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Driving out selector shaft
utho sleeve -A- eo
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Driving in selector shaft sleeve -A- to stop

ss o
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mer
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c
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sd
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pr
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Prote
7.10 Renewing oil seal for selector shaft
AG.

♦ Tube - VW 423-
AG. Volkswagen AG d
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♦ Sealing grease
wit
is n
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ole,
spec
– Remove gearbox selector lever and gate relay lever
t to the co
⇒ page 45 .
– Lever seal out using a screwdriver.
rrectne
– Lightly oil outer circumference of new oil seal.
s
– Half-fill space between sealing lip and dust lip -arrow- with
s o
sealing grease .
cial p
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mer
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n
c
i
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sd
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pr
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cted
Inserting oil seal -A- onto stop
agen
Prote AG.
– Install gearbox selector lever and gate relay lever

⇒ page 45 .

7.11 Dismantling and assembling gearbox

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

equipment required
AG. Volkswagen AG d
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♦ Support clamp - VW 313-

rrectness of i

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♦ Press tool - VW 412-

nf
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♦ Adapter - T10235-
m
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♦ Guide pin - T10079-

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AG. Volkswagen AG d
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nf
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♦ Engine and gearbox support - VW 540- wage

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♦ Drip tray - V.A.G 1306- byV ua
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♦ Thrust block - T10083-
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♦ Washer - T10083/1-
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h re
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spec
♦ Thrust plate - 3074-
es, in part or in w
t to the co
♦ Sealant
rrectness of i
♦ Allocation ⇒ Electronic parts catalogue (ETKA) l purpos
Dismantling gearbox
– Secure gearbox to engine and gearbox support ⇒ page 78 .
nform
ercia
– Place drip tray underneath.

m
a
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tio
– Drain gear oil.
n in
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– Remove clutch release lever -A- together with release bearing
s
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and guide sleeve -arrows-.
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– Remove right flange shaft securing bolt -B-.

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– Remove flange shaft along with spring, thrust washer and ta‐ Prote AG.
pered ring.
– Remove gearbox housing cover -arrow-.
– Pull out pivot pin -1- for 5th gear -2- and remove selector fork.
– Remove retaining ring -3- for 5th gear synchro-hub.
– Remove retaining ring -4- for 5th gear wheel.
– Remove 5th gear synchro-hub and 5th gear wheel.

– Remove bearing mounting securing bolts -A- from input and

output shafts.
– Unscrew hexagon collared nut -B- for securing reverse gear
selector mechanism.
– Unscrew securing bolt for flange shaft -C- by screwing two
bolts into flange and counter holding flange shaft with a lever.
– Pull out flange shaft -C- with spring.
– Turn gearbox in support bracket so that clutch housing is up‐
wards.
– Remove securing bolts from clutch housing side for securing
clutch housing to gearbox housing.
– Remove clutch housing, if necessary carefully levering up all
around along protruding housing flange and alternating be‐
tween sides, being careful not to damage sealing surfaces.
– Do not cant clutch housing in order to prevent damage to roller
bearings and their bearing seats on the input and output
shafts.
– Remove differential -A- from gearbox housing.
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t to the co
rrectnes
– Then remove oil collector -A- and oil guide -B- with magnet
s o
from gearbox housing.

cial p
f inform
mer
atio
om
n
c
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n thi
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sd
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Prote AG.

– Gearboxes for vehicles with start-stop

AG. Vosystem:
lkswagen Aremove gear‐
box neutral position sender s- agen
wG701- -arrow-.
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t to the co
– Remove selector shaft with selector cover -A-. Place selector
shaft in neutral. Then remove bolts -arrows- and pull selector
rrectne
shaft out of gearbox housing.
– Remove pivot pins -B- located on underside of gearbox.
ss o
– Screw out reversing light switch - F4- -C-.
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
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pr
cum
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fo
en
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t.
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op
– Remove bolt -A- for securing reverse gear wheel shaft. C py
t. rig
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– Remove pivot pins -B- located on bottom of gearbox. cop Vo
by lksw
cted agen
Prote AG.
Note
Do not remove sealing cover -arrow- when dismantling gearbox.

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Golf Sportsvan
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ac
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pt
du
an
– Press out input shaft, output shaft with bearing mounting, se‐
itte
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lector mechanism (selector forks) and reverse gear together.
erm
ab
ility
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Note
hole
spec
es, in part or in w
♦ Position gearbox housing so that dowel sleeves in the gearbox
t to the co
will not be damaged.
♦ When pressing out, get help from second mechanic to ensure
rrectness of i
components do not fall out.
l purpos
– Press input shaft and output shaft off bearing mounting with
deep groove ball bearing ⇒ page 112 .
nf
ercia
or
Assembling gearbox
m
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Note
thi
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♦ Press bearing mounting with deep groove ball bearing onto
o
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input shaft and output shaft ⇒ page 116 .

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♦ Press needle roller bearing sleeve for synchromeshed gear for
t. rig
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5th gear onto input shaft ⇒ page 116 .
p by
co Vo
by lksw
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Prote AG.
– Position assembled components, input shaft -2- and output

shaft -1- with bearing mounting for deep groove ball bearing,
in thrust piece - T10085- .
– Insert selector mechanism (selector forks) -4- in the shaft lock‐
ing collars.
– Install reverse gear shaft -3- with reverse gear.

– Screw guide pin - T10079- onto stud (secures reverse gear)

-arrow-.
– Insert components together in gearbox housing. To do this,
guide guide pin - T10079-gethrough
AG. Volkshole
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lector mechanism inVolgearbox
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– Remove guide
or pin - T10079- .
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Note the following
ss
a
before pressing in: ac
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rrectness of i
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♦ Selector forks engage correctly in locking collars.

♦ Check dimension -a- for output shaft teeth.
nform
mercia
at
om
i
Note
on
c
in t
or
his
te
♦ Due to different spline heights, dimension -a-, output shafts of

a
do
riv
individual gearboxes have different lengths.

p
cum
for
en
g
♦ A shim - T10083/1- (3 mm thick) may have to be fitted on the

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input shaft to ensure that the input shaft and the output shaft C py
ht. rig
are always pressed in evenly. rig ht
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♦ This is the reason why dimension -a- for output shaft teeth cted agen
Prote AG.
must be measured.
Dimension -a- = 30.6 mm

Fit washer - T10083/1- onto input shaft ⇒ next figure.
Place shim - T10083/1- onto input shaft and carefully press in

bearing mounting together with input shaft and output shaft to
stop

Carefully press in bearing mounting together with input shaft and

output shaft to stop.
– Install bolt -A- for securing reverse gear wheel shaft.

– Install pivot pin -B- in bottom of gearbox.
Note
AG. Volkswagen AG d
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Cap -arrow- is fitted. d by Vo gu
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ab
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– Install pivot pin -B- in top of gearbox.
wit
, is n
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– To do this, move selector shaft to neutral position.
hole
spec
– Apply sealant evenly to sealing surface of selector mechanism
es, in part or in w
t to the co
cover.
– Install selector shaft with selector cover -A-. Then tighten bolts
-arrows-.
rrectness of i
– Screw in reversing light switch - F4- -C-.
l purpos
nform
mercia
at
om
ion
– Gearboxes for vehicles with Start/Stop system: fit gearbox
c
in t
or
neutral position sender - G701- -arrow- and tighten securing

his
ate
bolt to specified torque ⇒ page 83 .

do
priv
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for
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Cop py
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– Using new bolts -A-, tighten bearing mounting for input and
output shafts.
Note
Tighten bolts to specified torque, working from centre outwards

using alternate sequence.
– Tighten hexagon flange nut -B- for securing selector mecha‐

nism (selector forks).
– Then insert oil collector -A- in notch -1- and in hole -2- of gear‐
box housing.
– Now insert oil guide -B- into gearbox housing.

– The magnet is inserted into the
wage
n Aoil
G. Vguide -B-.
olkswagen AG
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spec
– Install differential -A-.

t to the co
– Apply sealant evenly to sealing surface.

rrectne
– Secure clutch housing to gearbox housing.

– Turn gearbox in support bracket so that gearbox housing is
s
upwards.
s o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
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pr
cum
r
fo
en
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t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Installation position of gear wheel for 5th gear -1-:

The high shoulder -arrow- faces gearbox housing cover.
– Install gear wheel for 5th gear -1-.
– Install 5th gear synchromeshed gear with needle bearing.
– Place 5th gear synchro-ring on synchromeshed gear.
– Install 5th gear synchro-hub complete with locking collar and
stop ring.
– Insert 5th gear selector fork -2- and push in pivot pin -1- to stop
in direction of -arrow-. AG. Volkswagen
n AG do
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Determine new retainingrisring
ed -arrow-. ran
tee
tho
or
– Determine thickest aupossible retaining rings which will still fit for ac
ss
input shaft -3- and output shaft -4- and install them.
ce
le
un
pt
Available retaining rings ⇒ Electronic Parts Catalogue (ETKA)
an
d
itte
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ab
Thickness (mm)
pe
ility
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2.00 2.10
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2.20
spec
es, in part or in w
t to the co
– Install gearbox housing cover.
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
– Install both flange shafts with springs, thrust washers and ta‐
te o
thi
pered rings.
s
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– Install clutch release lever together with release bearing and

fo
en
g
guide sleeve ⇒ page 35 .

n
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.
Specified torques
t rig
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co
♦ ⇒ “7.5 Assembly overview - shafts, differential, selector mech‐
by lksw
cted agen
Prote
anism”, page 83
AG.
♦ Gearbox housing to clutch housing

⇒ “7.4 Assembly overview - clutch housing”, page 82 .
♦ Gearbox housing cover
⇒ “7.3 Assembly overview - cover for gearbox housing and 5th
gear”, page 81 .
♦ Flange shaft to gearbox (countersunk bolt)
⇒ “2.1 Assembly overview - differential”, page 134

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8 Gearbox housing, clutch housing
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⇒ “8.1 Assembly overview - gearbox housing and clutch housing”,
wit
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page 103
h re
hole
spec
⇒ “8.2 Repairing gearbox housing”, page 105
es, in part or in w
t to the co
8.1 Assembly overview - gearbox housing and clutch housing
rrectness of i
1 - Clutch housing
l purpos
❑ If renewed, adjust differ‐

ential ⇒ page 140
nf
ercia
2 - Input shaft seal
orm
m
atio
om
⇒ page 117
n in
or c
thi
e
3 - Ball-head pin
t
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⇒ Item 6 (page 15)
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4 - Seal
C py
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❑ For right flange shaft
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agen
Prote AG.
⇒ page 127
5 - Oil filler plug
⇒ page 76
6 - Shim
❑ For differential
⇒ page 140
7 - Tapered roller bearing outer
race
❑ Pressing out of and into
clutch housing
⇒ page 134
❑ If renewed, adjust differ‐
ential ⇒ page 140
8 - Bolt
ther
9 - Tapered roller bearing outer race
❑ Pulling out of and pressing into clutch housing ⇒ page 134
❑ If renewed, adjust differential ⇒ page 140
10 - Dowel sleeve
❑ Qty. 2
11 - Gearbox housing
❑ If renewed, adjust differential ⇒ page 140
12 - Oil drain plug
❑ Specified torque ⇒ page 76
8. Gearbox housing, clutch housing 103

13 - Seal
❑ For left flange shaft
14 - Sleeve
❑ For selector shaft
❑ Driving out ⇒ Fig. ⇒ page 91
15 - Cap
❑ Apply sealant before bolting on.
16 - Retaining ring
❑ Insert in groove of cylindrical roller bearing
17 - Retaining ring
❑ Insert in groove of cylindrical roller bearing
18 - Cylindrical roller bearing
❑ For input shaft
❑ Pulling out and pressing in ⇒ page 106
❑ For output shaft
❑ Pulling out and pressing in ⇒ page 119
20 - Plug
❑ Present on some gearboxes
❑ Insert into hole in clutch housing.
en AG. V
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8.2 Repairing gearbox housing

Special tools and work‐
shop equipment re‐
quired
♦ Centring mandrel -
12-551-
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Driving out selector shaft n thi

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Driving in selector shaft sleeve -A- to stop

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8. Gearbox housing, clutch housing 105

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35 – Gears, shafts
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1 Input shaft
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⇒ “1.1 Assembly overview - input shaft”, page 106
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⇒ “1.2 Dismantling and assembling input shaft”, page 108
rrectne
⇒ “1.3 Renewing input shaft seal”, page 117
1.1 Assembly overview - input shaft
ss o
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Note
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♦ When installing new gears or new input shaft, refer to ⇒ Electronic parts catalogue (ETKA) and technical
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♦ Install all bearings, synchromeshed gears and synchro-rings on input shaft with gear oil.
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1 - Retaining ring
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⇒ page 115
2 - 5th gear locking collar with
synchro-hub
⇒ page 93
❑ Dismantling
⇒ page 116
❑ Assembling 5th gear
locking collar and syn‐
chro-hub ⇒ page 117
⇒ page 116
❑ Check for wear
⇒ page 113
4 - Synchromeshed gear, 5th
gear
5 - Needle bearing
❑ For 5th gear
❑ Renew together with
sleeve
6 - Sleeve
❑ For 5th gear needle
bearing
❑ Renew together with
needle bearing
❑ Press off with bearing
support and deep
groove ball bearing
⇒ page 112
❑ Pressing on ⇒ page 116
106 Rep. gr.35 - Gears, shafts

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❑ Pressing off ⇒ page 112
spec
❑ Pressing on, from ⇒ page 115
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9 - Input shaft
rrectne
10 - Needle bearing
❑ For 3rd gear
ss
11 - Synchromeshed gear for 3rd gear
o
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12 - Synchro-ring for 3rd gear
mer
❑ Check for wear ⇒ page 113
atio
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13 - Locking collar with synchro-hub for 3rd and 4th gear
i
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❑ Press off with 3rd gear synchromeshed gear ⇒ page 112
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❑ Dismantling ⇒ page 113
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❑ Installation position, locking collar and synchro-hub ⇒ page 113
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❑ Check for wear ⇒ page 113
15 - Synchromeshed gear for 4th gear
16 - Sleeve
❑ For 4th gear needle bearing
❑ Renew together with needle bearing
17 - Needle bearing
❑ For 4th gear
❑ Renew together with sleeve
18 - Thrust washer
19 - Cylindrical roller bearing inner race
❑ Pulling off is also possible ⇒ page 112
20 - Retaining ring
❑ Renew
❑ Determining thickness ⇒ page 115
❑ With retaining ring
❑ Pressing in ⇒ page 112 .
❑ Installation position: retaining ring in bearing faces input shaft
22 - Clutch housing
23 - Spring
1. Input shaft 107

24 - 3rd and 4th gear locking collar

25 - 3rd and 4th gear synchro-hub
26 - Locking pieces (qty. 3)
27 - Spring
28 - Locking pieces (Qty. 3)
29 - Synchro-hub for 5th gear
30 - Locking collar for 5th gear
31 - Stop ring
❑ Prevents locking pieces from drifting out
❑ Detaching ⇒ page 116
1.2 Dismantling and assembling input shaft

equipment required
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♦ Press tool - VW 412- agen
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♦ Tube - VW 516-
♦ Extension - 30 - 23-
♦ Drift sleeve - 30 - 100-
1. Input shaft 109

♦ Thrust block - T10083-
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♦ Washer - T10083/1-
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♦ Circlip pliers - VW 161 A-
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♦ Tube - 2010-

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♦ Internal puller - VAS 251 611- , or e.g. internal puller - Kukko

21/5-
♦ Counter support - VAS 251 623- , or e.g. counter support -
Kukko 22/2-
♦ Puller - VAS 251 417- , or e.g. puller - Kukko 18/1-
♦ Splitter - VAS 251 409- or e.g. splitter - Kukko 17/1-
♦ Circlip pliers - VW 161 A-
♦ -Feeler gauge-
Pulling cylindrical roller bearing out of clutch housing
– When pulling out, squeeze together retaining ring -arrow- of
cylindrical roller bearing, using pliers -C-.
A - Counter support - VAS 251 623- , or e.g. counter support -
Kukko 22/2-
B - Internal puller - VAS 251 611- , or e.g. internal puller - Kukko
21/5-
1. Input shaft 111

Pressing cylindrical roller bearing into clutch housing

– Support gearbox housing with tube - VW 415 A- (not visible in
figure) directly below bearing support.
– When pressing in, squeeze together retaining ring -arrow- for
cylindrical roller bearing using pliers -A-.
– Remove pliers before cylindrical roller bearing is in installation
position. Retaining ring must engage in groove of clutch hous‐
ing.
Pressing off bearing mounting with deep groove ball bearing

– Slide locking collar for 1st and 2nd gear towards 2nd gear.
– Then slide thrust plate - T10084/A- sideways onto input shaft
to stop.
– Insert centring pins in thrust piece - T10081- into holes in input
and output shafts.
Press off cylindrical roller bearing inner race together with thrust
AG. Volkswagen AG d
washer, 4th gear synchromeshed gear with needle lksw bearing, lock‐
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Inner race for cylindrical roller bearing can also be pulled off to‐
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– First remove retaining ring with snap ring pliers - VW 161 A- .

l purpos
– Position splitter -B- behind teeth of synchromeshed gear for

4th gear which engage in the other gear wheel (not dog teeth)
and tension.
nform
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A - Puller - VAS 251 417- , or e.g. puller - Kukko 18/1-

m
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B - Splitter - VAS 251 409- or e.g. splitter - Kukko 17/1-

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Dismantling and assembling 3rd and 4th gear locking collar and
synchro-hub
1- Spring
2- Sliding sleeve
3- Synchro-hub
4- Locking piece
– Slide locking collar over synchro-hub.
Deeper notches -arrow A- for locking pieces in synchro-hub and
notches -arrow B- in locking collar must align.
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Assembling locking collar and synchro-hub for 3rd and 4th gears
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– Insert locking pieces in deeper notches -arrows- and install
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springs offset 120°. Angled end of spring must locate in hollow
hole
spec
locking piece.
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Installation position of locking collar with synchro-hub for 3rd and

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4th gears
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If present, groove on face -arrow- is towards 4th gear.

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High collar faces 3rd gear.

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Checking synchro-ring for wear

– Press synchro-ring onto cone of synchromeshed gear and
measure gap -a- using feeler gauge.
– Measure gap size -a- at 3 points offset by 120° using feeler
gauge.
– Make a note of average value.
Gap -a- Installation dimen‐ Wear limit
sion
3rd, 4th and 5th 1.1 … 1.7 mm 0.5 mm
gear
1. Input shaft 113

Pressing on synchro-hub with locking collar for 3rd and 4th gears
If present, groove on face of locking collar faces towards 4th gear.
High collar of synchro-hub faces 3rd gear.
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Pressing on sleeve -A- for 4th gear needle bearing
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– After pressing on sleeve -A-, fit 4th gear needle bearing, 4th itte
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Pressing on inner race -A- for cylindrical roller bearing
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Determining thickness of retaining ring

– Insert a 2.0 mm thick retaining ring -A- in groove of input shaft
and press upwards -arrow-.
– Measure distance between inner race -B- and installed retain‐
ing ring-A- using feeler gauge -C-.
– Remove retaining ring (only used for measuring purposes).
– Determine retaining ring from table.
Note
Allocate retaining rings using ⇒ Electronic parts catalogue (ET‐

KA) .
Available retaining rings

Measured value Retaining ring thick‐ Axial play (mm)
(mm) ness (mm)
0.05 … 0.14 2.0 0.05 … 0.15
0.15 … 0.24 2.1 0.05 … 0.15
0.25 … 0.34 2.2 0.05 … 0.15
0.35 … 0.44 2.3 0.05 … 0.15
0.45 … 0.51 2.4 0.05 … 0.10
Press bearing mounting with deep groove ball bearing onto input
shaft and output shaft.
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♦ Due to different spline heights, dimension -a-, output shafts of

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♦ To ensure that bearing support is always evenly pressed onto
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shafts, it is necessary for shafts always to be inserted evenly
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into thrust block - T10083- .
hole
spec
es, in part or in w
♦ If necessary, insert a shim - T10083/1- (3 mm thick) into
t to the co
mounting hole for input shaft ⇒ page 115 .
♦ This is the reason why dimension -a- for output shaft teeth rrectness of i
must be measured.
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Dimension -a- = 30.6 mm

Insert shim - T10083/1- ⇒ next figure.
nf
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m
atio
m
Fit shim - T10083/1- .

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1. Input shaft 115

Pressing on bearing support

– Heat inner bearing mounting to approx. 100 °C before press‐
ing on.
WARNING
Wear protective gloves.
Pressing on sleeve -A- for 5th gear needle bearing
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Removing stop ring
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– Using a screwdriver, unclip hooks -A- of check ring from syn‐
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chro-hub.
hole
spec
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Dismantling and assembling 5th gear locking collar and synchro-

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2- Locking piece
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5- Stop ring
– Slide locking collar over synchro-hub.
Deeper notches -arrow C- for locking pieces in synchro-hub and
notches -arrow D- in locking collar must align.

Assembling 5th gear locking collar/synchro-hub

– Insert locking pieces in deeper notches -arrows- and install
locking piece.
Installing stop ring

– Press on stop ring using tube - 2010- .
– Insert stop ring together with tube - 2010- into 5th gear syn‐
chro-hub/locking collar (observe installation position
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– Press stop ring sdownwards until hooks engage.
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1.3 Renewing input shaft seal

ss

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♦ Removal tool - T20143/1-

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1. Input shaft 117

♦ Thrust piece - T40008- wage

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♦ Sealing grease
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– Remove manual gearbox.

– Remove clutch release lever with release bearing and guide
nform
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sleeve ⇒ page 35
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– Lever out input shaft seal.
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Note
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Do not damage oil seal running surface on input shaft.

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– Half-fill space between sealing lip and dust lip of new seal with
sealing grease .
– Lightly moisten outer circumference of oil seal with gear oil.
Driving in input shaft oil seal flush

– Install clutch release lever with release bearing and guide
sleeve ⇒ page 35
– Install manual gearbox.

2 Output shaft
⇒ “2.1 Assembly overview - output shaft”, page a119
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⇒ “2.2 Dismantling and assembling output
ed
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2.1 Assembly overview
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♦ When installing new gears or new input shaft, refer to ⇒ Electronic parts catalogue (ETKA) and technical
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data.
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spec
♦ Install all bearings, synchromeshed gears and synchro-rings on output shaft with gear oil.
es, in part or in w
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♦ Do not interchange synchro-rings. When reusing always fit to the original gear.
rrectness of i
1 - Clutch housing
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❑ With retaining ring

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❑ Pressing in
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⇒ page 122 .
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❑ Installation position: re‐

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❑ If an inner race as bear‐
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ing seat for cylindrical
AG.
roller bearing is present,

it cannot be removed
from output shaft
❑ Check bearing seat or
inner race of cylindrical
roller bearing for scoring
and damage
❑ If cylindrical roller bear‐
ing inner race or bearing
seat is damaged or
scored, renew output
shaft and cylindrical roll‐
er bearing together
❑ Installation position:
shoulder faces 3rd gear
⇒ page 123
5 - Retaining ring
6 - Retaining ring
7 - Gear wheel for 3rd gear
❑ Installation position: shoulder faces 4th gear ⇒ page 123
8 - Retaining ring
2. Output shaft 119

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9 - Synchromeshed gear, 2nd gear ss
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10 - Needle bearing
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❑ For 2nd gear
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11 - Inner ring for 2nd gear
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❑ Check lugs for scoring
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❑ Checking synchro-ring, outer ring and inner ring together for wear ⇒ page 123
t to the co
12 - Outer bearing race for 2nd gear
rrectness of i
❑ Renew if scored
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13 - Synchro-ring for 2nd gear
nform
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14 - Locking collar with synchro-hub for 1st and 2nd gear
s
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❑ After removing retaining ring, press off with 2nd gear synchromeshed gear ⇒ page 123
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❑ Dismantling ⇒ page 124
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❑ Assembling locking collar and synchro-hub ⇒ page 124 and ⇒ page 124 C py
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15 - Retaining ring
❑ Pressing out ⇒ page 123
16 - Synchro-ring for 1st gear
❑ Assemble so that notches engage in locking pieces of locking collar.
17 - Outer ring for 1st gear
❑ Check for scoring or signs of abnormal wear
❑ Insert in synchro-ring
18 - Inner ring for 1st gear
❑ Check lugs for scoring
19 - Needle bearing
❑ For 1st gear
20 - Synchromeshed gear, 1st gear
21 - Bearing mounting with deep groove ball bearing
❑ Renew deep groove ball bearing only together with bearing mounting


❑ Installation position: shoulder faces gearbox housing cover ⇒ page 102
24 - Retaining ring
❑ Renew after removal AG. Volkswagen AG d
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❑ Determining thickness ⇒ page 102 olksw not
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25 - Spring horis nte
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❑ Fitting position ⇒ page 124 ss a c
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26 - Sliding sleeve
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27 - Synchro-hub
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28 - Locking pieces (qty. 3)
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2.2 Dismantling and assembling output shaft
t to the co
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equipment required
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♦ Tube - VW 415 A-
2. Output shaft 121

♦ Thrust piece - VW 432-

♦ Drift sleeve - 30 - 100-

21/5-
♦ Counter support -
VAS 251 621- , or e.g.
counter support -
Kukko 22/1-
Pulling cylindrical roller

bearing out of clutch agen
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B - Internal puller - VAS

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251 611- , or e.g. internal

puller - Kukko 21/5-
rrectness of i
Pressing cylindrical roller bearing into clutch housing

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– Support gearbox housing with tube - VW 415 A- (not visible in

figure) directly below bearing support.
nform
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– When pressing in, squeeze together retaining ring -arrow- for

m
at
cylindrical roller bearing using pliers -A-.

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– Remove pliers before cylindrical roller bearing is in installation

or
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Pressing retaining ring -1- out of groove

»Push« retaining ring off shaft.
A - Protective gloves
WARNING
Ensure retaining ring does not spring out uncontrolled.
Pressing off 1st and 2nd gear locking collar and synchro-hub
– After removing retaining ring, press off synchromeshed gear
for 2nd gear together with locking collar and synchro-hub.
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Installation position of 3rd gear and 4th gear
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– Install gear wheel for 4th gear -A- on output shaft.

spec
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Installation position: t to the co
Collar -arrow 1- faces 3rd gear wheel -B-.

rrectness of i
– Install retaining rings -2- and -3-.

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– Install gear wheel for 3rd gear -B- on output shaft.

nf
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Collar -arrow 2- faces gear wheel for 4th gear -A-.

rm
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– Install retaining ring -1-.

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Checking 1st and 2nd gear synchro-ring, outer ring and inner ring
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Prote AG.
Gap “a” Installation dimen‐ Wear limit

sion
1st and 2nd gears 1.1 - 1.8 mm 0.5 mm
Note
Always renew inner ring, outer ring and synchro-ring together.
2. Output shaft 123

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

2nd gear
– Place inner ring -A- on 2nd gear synchromeshed gear.
Angled lugs -arrow 1- face outer ring -B-.
– Fit outer ring -B-.
Lugs -arrow 2- engage in notches -arrow 3- of synchromeshed
gear.
– Fit synchro-ring -C-.
Notches -arrow 4- engage in lugs -arrow 1- of inner race -A-.
Dismantling and assembling locking collar and synchro-hub for

1st and 2nd gears
1- Spring
2- Sliding sleeve
3- Synchro-hub
4- Locking piece
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– Slide locking collar d over synchro-hub.
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After assembly, the groove on the face -arrow A- and the higher
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shoulder -arrow B- of synchro-hub face outer splines of the lock‐

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Assembling locking collar with synchro-hub for 1st and 2nd gears
rrectness of i

– Insert locking pieces in deeper cut-outs -arrows- and install
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locking piece.
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Pressing on locking collar and synchro-hub for 1st and 2nd gears
Groove in locking collar for selector fork faces 1st gear and teeth
for reverse gear face 2nd gear.
– Turn synchro-ring so that grooves align with locking pieces.
Fitting retaining ring

– Place 1st gear synchro-ring in locking collar/synchro-hub.
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Installation position
oris of 1st gear outer ring tee
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Lugs -arrows-
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Installation position of 1st gear inner ring -A-

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2. Output shaft 125

Installation position of synchromeshed gear for 1st gear

Higher shoulder -A- faces 2nd gear -B-. Notches in shoulder
-arrows- engage in lugs of outer ring ⇒ page 125 .
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39 – Final drive - differential

1 Oil seals
⇒ “1.1 Overview of fitting locations - seals”, page 127
⇒ “1.2 Renewing left oil seal”, page 128
⇒ “1.3 Renewing right oil seal”, page 130
1.1 Overview of fitting locations - seals
1 - Seal
❑ For input shaft
⇒ page 117
2 - Seal
❑ For right flange shaft
⇒ page 130
3 - Seal
❑ For left flange shaft
⇒ page 128
4 - Seal
❑ For selector shaft n AG. Volkswagen AG do
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❑ Renew after removaly Vo lks ot g
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⇒ page 91 ise
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1. Oil seals 127

1.2 Renewing left oil seal

⇒ “1.2.1 Renewing oil seal for left flange shaft”, page 128
1.2.1 Renewing oil seal for left flange shaft

equipment required
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♦ Multi-purpose tool - VW 771-

♦ Extractor hook - VW 771/37-
♦ Drip tray - V.A.G 1306-
♦ or drip tray for workshop hoist - VAS 6208-
♦ Sealing grease
Removing
– Remove left wheel.
128 Rep. gr.39 - Final drive - differential


sulation .
– Turn steering to left lock.
– Unbolt drive shaft from flange shaft ⇒ Running gear, axles,
steering; Rep. gr. 40 ; Drive shaft; Removing and installing
drive shaft .
– If possible, lift drive shafts clear and tie in place; do not damage
surface protection.
– Remove flange shaft securing .bolts.
VolkswScrew
agen AG2 bolts into flange
and counter hold flange gen AGusing a lever.
washaft does
olks no
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– Pull out flange ris shaft with compression spring. If necessary,
ed ran
tee
unscrew engine/gearbox
utho securing bolt in area of flange shaft.
or
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es, in part or in w
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– Pull out flange shaft oil seal using multi-purpose tool - VW 771-
and puller hooks - VW 771/37- .
rrectness of i
l purpos
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1. Oil seals 129

Installing agen
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– Drive in new seal to stop, beinged by careful not to cant seal. ara
nte
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– Half-fill space betweenausealing
th lip and dust lip with sealing ra
grease . ss c
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– Insert flange shaft.
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– Press flange shaft against gearbox and secure.
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– If removed, reinstall engine/gearbox connecting bolt in area of
wit
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flange shaft ⇒ page 72 .
h re
ole,
spec
– Install drive shaft to flange shaft ⇒ Running gear, axles, steer‐
ing; Rep. gr. 40 ; Drive shaft; Removing and installing drive
t to the co
shaft .
– Check gear oil level and top up to lower edge of oil filler hole
rrectne
if necessary ⇒ page 76 .
ss
gr. 66 ; Noise insulation; Assembly overview - noise insula‐
o
cial p
f
tion .
inform
mer
– Attach wheel ⇒ Running gear, axles, steering; Rep. gr. 44 ;
atio
m
Wheels, tyres; Specified torque for wheel bolts .

o
n
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Specified torques
thi
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♦ Flange shaft to gearbox ⇒ page 134

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⇒ “1.3.1 Renewing oil seal for right flange shaft”, page 130 co Vo
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1.3.1 Renewing oil seal for right flange shaft


equipment required
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♦ Multi-purpose tool - VW 771-

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♦ Drip tray - V.A.G 1306-
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♦ or drip tray for workshop hoist - VAS 6208-
♦ Sealing grease
Removing
sulation .
1. Oil seals 131

– If fitted, remove drive shaft heat shield -arrows- ⇒ Running

gear, axles, steering; Rep. gr. 40 ; Drive shaft; Removing and
installing drive shaft heat shield .
– Unbolt drive shaft from flange shaft ⇒ Running gear, axles,
steering; Rep. gr. 40 ; Drive shaft; Removing and installing
drive shaft .
– If possible, lift drive shafts clear and tie in place; do not damage
surface protection.
– Remove flange shaft securing bolts. Screw 2 bolts into flange

and counter hold flange shaft using a lever.
AG spring. Ifennecessary, . Volkswag
– Pull out flange shaft with compression
ksw
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unscrew engine/gearboxbsecuring
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ol
bolt in area of flange shaft.
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– Pull out flange shaft oil seal using multi-purpose tool - VW 771-
es, in part or in w
and puller hooks - VW 771/37- or prise out using a lever. t to the co

rrectness of i
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mercia
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Installing
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– Drive in new seal to stop, being careful not to cant seal.
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– Half-fill space between sealing lip and dust lip with sealing yri
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– Insert flange shaft.
– Press flange shaft against gearbox and secure.
– If removed, reinstall engine/gearbox connecting bolt in area of
flange shaft ⇒ page 72 .
– Install drive shaft ⇒ Running gear, axles, steering; Rep. gr.
40 ; Drive shaft; Removing and installing drive shaft .

– If fitted, install drive shaft heat shield -arrows- ⇒ Running gear,

axles, steering; Rep. gr. 40 ; Drive shaft; Removing and in‐
stalling drive shaft heat shield .
– Check gear oil level and top up to lower edge of oil filler hole
if necessary ⇒ page 76 .
gr. 66 ; Noise insulation .
Specified torques
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♦ Flange shaft to gearbox ⇒ page 134olks ot g
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1. Oil seals 133

2 Differential
⇒ “2.1 Assembly overview - differential”, page 134
⇒ “2.2 Dismantling and assembling differential”, page 135
⇒ “2.3 Adjusting differential”, page 140
2.1 Assembly overview - differential
❑ 25 Nm
2 - Right flange shaft
3 - Compression spring for
flange shaft
❑ Installed behind flange
shafts
4 - Thrust washer
shoulder towards spring
5 - Tapered ring
taper towards differen‐
tial cage
6 - Retaining ring
❑ Holds tapered ring,
thrust washer and
spring in position when
flange shaft is removed
7 - Left flange shaft AG. Volkswagen AG d
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8 - Oil seal for left flange shaft olksw not
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❑ Renew after removal orise nte
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⇒ page 128 aut
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9 - Tapered roller bearing outer
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❑ Pressing in
wit
⇒ page 138 .
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10 - Tapered roller bearing in‐

spec
ner race
es, in part or in w
t to the co
❑ Pulling off ⇒ page 138

rrectness of i
11 - Differential
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❑ With final drive gear

12 - Tapered roller bearing inner race
nf
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❑ Pulling off ⇒ page 138

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13 - Tapered roller bearing outer race

thi
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❑ Pressing out ⇒ page 139 .

iv
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❑ Pressing in ⇒ page 139 .

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134
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Prote AG.
Rep. gr.39 - Final drive - differential
14 - Shim
❑ Determining thickness ⇒ page 140
15 - Oil seal for right flange shaft
16 - Clutch housing
❑ ⇒ “8 Gearbox housing, clutch housing”, page 103
❑ ⇒ “8 Gearbox housing, clutch housing”, page 103
2.2 Dismantling and assembling differential

equipment required
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♦ Press tool - VW 408 A-
♦ Tube - VW 418 A-
2. Differential 135
AG. Volkswagen AG d
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5-speed manualhoris gearbox 0AH - Edition 11.2017 nte
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♦ Installing sleeve - VW 455-

♦ Drift sleeve - 40-21-
♦ Tube - 30-14-
♦ Tube - 2040-
♦ Thrust piece - 3002-

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♦ Counter-hold tool - 3067-

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♦ Tube - 3259-
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♦ Grip tool - V.A.G 1582/3-
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Prote AG.
♦ Do not apply: tools 1-4

21/7-
2. Differential 137
♦ Counter support - VAS 251 623- , or e.g. counter support -

Kukko 22/2-
Note
♦ Heat tapered roller bearing inner races to 100 °C before in‐

stalling.
♦ Always renew both tapered roller bearings together as a set.
♦ If tapered roller bearings, differential cage, gearbox housing
or clutch housing is renewed, adjust differential ⇒ page 140 .
Pulling outer race for tapered roller bearing out of gearbox hous‐
ing
A - Counter support - VAS 251 623- , or e.g. counter support -
Kukko 22/2-
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Pressing tapered roller bearing outer race into gearbox
au housing ra
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– Support gearbox housing with tube - 3259- directly below

un
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bearing support.
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Pulling off tapered roller bearing and inner race

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Pressing on tapered roller bearing inner races

– Support inner race on opposite side using installing sleeve -
VW 455- .
Shoulder of installing sleeve - VW 455- faces towards differential
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Both tapered roller bearing inner races are pressed onto the dif‐
un
pt
ferential cage in the same way.
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Pressing tapered roller bearing outer race -A- out of clutch hous‐
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es, in part or in w
21/7-
t to the co
– Clamp internal puller securely behind tapered roller bearing
outer race.
rrectness of i
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Pressing tapered roller bearing outer race into clutch housing
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Allocation of differential cage for removing and installing spring

pin
– Check hole for spring pin in differential cage.
Bore Length of spring Clamping sleeve
pin (mm)
-A- 24.0 (short Removing Installing
spring pin) ⇒ page 140 ⇒ page 140
-A- and -B- 36.0 (long spring Removing Installing
pin) ⇒ page 140 ⇒ page 140
Through-hole 36.0 (long spring Removing Installing
pin) ⇒ page 140 ⇒ page 140
2. Differential 139
Golf Sportsvan 2018 ➤ n AG. Volkswagen AG do
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Pressing off differential pinion pin, and shearing uoff
th spring
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When pressed out, spring pin will be sheared off.
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– Remove remainder of spring pin from differential cage.
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Removing long spring pin to remove differential pinion pin
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– Drive spring pin -A- out of hole -arrow- in differential housing

using a 5 mm diameter drift -B-.
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If there is no hole -arrow- in the differential cage, shear off the
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Installing differential bevel gears
– Lubricate one-piece thrust washer with gear oil and install.
– Install both sun wheels and secure (e.g. with flange shaft).
– Insert both planet pinions offset 180° and pivot into position.
– Press in differential pinion pin (-arrow A-) to first planet pinion.
– Place threaded pieces -arrows B- in sun gears.
Installing spring pin for differential pinion pin

– Align hole in differential pinion pin with hole in differential cage.
– Using a drift, drive in spring pin -1- until a dimension
-a- of 2.5 mm is attained.
• Spring pin -1- must not touch clutch housing.
2.3 Adjusting differential


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♦ End dimension plate - VW 385/17-

♦ Universal dial gauge holder - VW 387-
♦ Press tool - VW 408 A-
2. Differential 141
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♦ Thrust plate - 30-205-

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♦ Tube - 30-14-
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♦ Tube - 2040-
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♦ Tube - 3259-
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♦ Do not apply: tools 1-4

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♦ Dial gauge - VAS 6080A-

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21/7-
♦ Thrust plate - 30 - 205-
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It is necessary to readjust the differential when the following
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♦ Gearbox housing ss a c
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♦ Clutch housing
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♦ Differential cage
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♦ Tapered roller bearing of differential
hole
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– Pressing tapered roller bearing outer race (gear wheel slide)
es, in part or in w
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into gearbox housing.
rrectness of i
Note
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Inner and outer tapered roller bearing races are paired. Do not
interchange!
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2. Differential 143
– Press tapered roller bearing outer race (opposite gear wheel)

with no shim into gearbox housing.
– Insert differential in gearbox housing.
– Fit clutch housing and tighten the 5 bolts.
– Attach dial gauge and set to “0” with 1 mm preload.

A - 30 mm dial gauge extension
– Set dial gauge to “0” with 1 mm preload for bearing.
– Move differential up and down. Read and note play indicated
on dial gauge. (Example: 1.50 mm)
Determining thickness of shim
The specified bearing preload is obtained by adding a constant
value for preload (0.35 mm) to the reading obtained.
Example:
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Thickness of shim = ut 1.85 mm
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– Remove clutch housing and press out tapered roller bearing

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outer race -A-.

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– Allocate shim(s) using ⇒ Electronic parts catalogue (ETKA) .
spec
The various thicknesses make it possible to achieve the exact
t to the co
shim thickness required.
If the size of shim required is larger than those listed in the ⇒ rrectne
Electronic parts catalogue (ETKA) , insert two shims totalling the
correct figure.
s
– Insert correct shim (in example 1.85 mm) and press tapered
s o
cial p
roller bearing outer race into clutch housing again.

inform
mer
– Bolt clutch housing to gearbox housing.

atio
m
Specified torques
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♦ Gearbox housing to clutch housing ⇒ page 82

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D4B807C95D6-5-Speed Manual Gearbox 0AH

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D4B807C95D6-5-Speed Manual Gearbox 0AH

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Service

Service Department. Technical Information

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Copyright © 2017 Volkswagen AG, Wolfsburg D4B807C95D6

1.1 Overview of fitting locations – clutch mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

1.7 Removing and installing clutch position sender G476 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

1.9 Removing and installing over-centre spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

1.10 Removing and installing clutch pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

1.11 Removing and installing mounting bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

1.12 Removing and installing clutch master cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

1.13 Removing and installing clutch slave cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

1.14 Removing and installing lines for clutch mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

1.15 Bleeding clutch mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

1.16 Repairing clutch release mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

3.1 Assembly overview - assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

35 - Gears, shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

1.3 Renewing right oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130

2.1 Assembly overview - differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134

2.2 Dismantling and assembling differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135

2.3 Adjusting differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140

1.1 Safety measures when working on ve‐

hicles with a start/stop system

2.1 Gearbox identification

Codes and production date of gearbox

The gearbox code is also included on the vehicle data stickers.

2 Rep. gr.00 - Technical data

Manufactured from February 2017

Ratio Final drive 73 : 18 = 4.055

3.3 Calculation of gear ratios

Drive gear ZG1 = 46 ZA1 = 24

4 Rep. gr.00 - Technical data

4. Overview - power transmission 5

5.1 Overview of fitting locations - electrical

5.1.1 Overview of fitting locations – electrical components, manual gearbox

1 - Reversing light switch - F4-

of selector unit beneath

angled rod for securing

❑ Removing and installing

5.1.2 Overview of fitting locations – electrical

components, clutch mechanism

6 Rep. gr.00 - Technical data

6.1 General repair instructions

wax and grease.

parts catalogue (ETKA) . ab

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

After removing gaskets and seals, always inspect contact surfa‐

♦ Thoroughly clean joint surfaces and apply sealant .

♦ Allocation ⇒ Electronic parts catalogue (ETKA)

lips with sealing grease -arrow-.

♦ Allocate grease using ⇒ Electronic parts catalogue (ETKA) .

♦ Renew retaining rings.

♦ Do not cant especially delicate parts, such as clutch pressure

plates. Loosen and tighten bolts and nuts alternately and in

♦ Renew self-locking bolts and nuts after each removal.

♦ Ensure with threaded connections that contact surfaces as

threaded holes into which self-locking bolts are to be screwed.

quently being removed.

♦ Check pitch of thread, to ensure correct thread chaser is used

to clean threads and to ensure the threads are not damaged.

♦ Install needle bearings with lettered side (thicker metal) to‐

8 Rep. gr.00 - Technical data

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

♦ Check the cone of the synchromeshed gear for »scoring« and

♦ Observe installation position