D3E8002315F Manual Transmission

Service
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Service Department. Technical Information

Service
List of Workshop Manual Repair GroupsList of Workshop Manual
Repair GroupsList of Workshop Manual Repair Groups
Repair Group
00 - General, Technical Data
30 - Clutch AG. Volkswagen AG d
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34 - Controls, Housing byV
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35 - Gears, Shafts ris nte
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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 © 2014 Volkswagen AG, Wolfsburg D3E8002315F

Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus 2009 ➤ , Pass ...
Manual Transmission - Edition 07.2014
Contents
00 - General, Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Calculating Transmission Ratio “i” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 General Repair Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.3 Safety Precautions, Vehicles with Start/Stop System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.4 Transmission Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2 Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.1 Overview - Powertrain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.1 Code Letters, Transmission Allocation, Ratios and Capacities, Golf from MY 2004 . . . . . . 8
3.2 Code Letters, Transmission Allocation, Ratios and Capacities, Golf from MY 2009 . . . . . . 11
3.3 Engine Codes, Transmission Allocation, Ratios and Capacities, Golf Plus from MY 2005
........................................................................ 12
3.4 Engine Codes, Transmission Allocation, Ratios and Capacities, Golf Plus from MY 2009
........................................................................ 13
3.5 Engine Codes, Transmission Allocations, Ratios and Capacities, Passat from MY 2006 . . 13
30 - Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.1 Clutch System, Bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.2 Determining Clutch Manufacturer, 1.9L 66 kW Turbo Diesel and 1.9L 77 kW Turbo Diesel
........................................................................ 16
2.1 Clutch Mechanism Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.2 Overview - Pedal Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2.3 Overview - Hydraulics . . . . . . . . . . . . . . . . . . . . .en. A. G. ..V.o.lk.sw. a.g.en. A. G. . . . . . . . . . . . . . . . . . . 23
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2.4 Overview - Clutch Release Mechanism . . V.o.lk.sw. . . . . . . . . . . . . . . . . . .es. n.o.t g. . . . . . . . . . . . . 25
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2.5 Overview - “Sachs” Clutch . . . . . . . .ri.se.d. . . . . . . . . . . . . . . . . . . . . . . . . . . . .ar.an. t . . . . . . . . . 26
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2.6 Clutch Assembly Overview, “LuK” aut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .e.or.a . . . . . .
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2.7 Clutch Assembly Overview, with sSingle Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
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2.8 Hydraulics Assembly Overview, RHD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . pt 30

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3 Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . y li 32

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3.1 Over-Center Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ility 32

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3.2 Clutch Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
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3.3 Mounting Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

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3.4 Clutch Master Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

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3.5 Clutch Position Sensor G476 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

3.6 Slave Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
3.7 Clutch Release Mechanism, Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
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3.8 “Sachs” Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

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3.9 “LuK” Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

3.10 Clutch, With Single Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
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4 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
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34 - Controls, Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
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1.1 Transmission Fluid, Checking and Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

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2.1 Shift Mechanism Installation Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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2.2 Overview - Gearshift Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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2.3 Overview - Gearshift Knob and Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
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2.4 Overview - Gearshift Lever and Gearshift Housing, through 10/2006 . . . . . . . . . . . . . . . . 97
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2.5 Overview - Gearshift Lever and Gearshift Housing, from 11/2006 . . . . . . . . . . . . . . . . . . . . 99
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2.6 Operating Cables Assembly Overview, Cable Bracket and Metal Relay Lever . . . . . . . . . . 101
2.7 Operating Cables Assembly Overview, Cable Bracket and Plastic Relay Lever . . . . . . . . 104
2.8 Selector Mechanism, Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
2.9 Overview - Subframe Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
2.10 Transmission Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
2.11 Overview - Transmission Disassembling and Assembling . . . . . . . . . . . . . . . . . . . . . . . . . . 112
2.12 Overview - Transmission Housing Cover and 5th Gear, Removing and Installing . . . . . . . . 113
2.13 Overview - Transmission Housing and Gearshift Mechanism, Removing and Installing . . 115
2.14 Transmission Housing and Clutch Housing Assembly Overview . . . . . . . . . . . . . . . . . . . . 116
2.15 Overview - Shift Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
2.16 Overview - Shift Forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
2.17 Input Shaft, Output Shafts, Differential and Shift Forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
3 Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
3.1 Shift Knob with Boot and Noise Insulation, Golf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
3.2 Gearshift Knob with Boot and Noise Insulation, Golf Plus . . . . . . . . . . . . . . . . . . . . . . . . . . 124
3.3 Boot with Shifter Knob and Noise Insulation, Passat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
3.4 Plastic Relay Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
3.5 Selector Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
3.6 Transmission, Golf from MY 2004 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
3.7 Transmission, Golf from MY 2009, with Turbo Diesel . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
3.8 Transmission, Golf from MY 2009, Gasoline Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
3.9 Transmission, Golf Plus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
3.10 Transmission, Passat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
3.11 Transmission, Transporting . . . . . . . . . . . . . . . . . . . . .a.ge. n. A.G.. .V.ol.ks.w.a.ge. n. A. G. d.o. . . . . . . . . . . 205
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3.12 Assembly Sequence, Transmission Housing Cover olks 5th Gear . . . . . . . . . s.no. t .g . . . . . . 206
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3.13 Transmission Housing and Clutch Housing, Servicing orise . . . . . . . . . . . . . . . . . . . . . . . .an. te.e. . 210
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3.14 Shift Unit, Servicing . . . . . . . . . . . . . . . s.au. t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .or.ac 213
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3.15 Shift Forks, Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
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4 Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
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4.1 Gearshift Mechanism, from 11/2006 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
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4.2 Transmission, Assembly Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
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5 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
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35 - Gears, Shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251
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1.1 Overview - Input Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251
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1.2 Input Shaft, Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253
1.3 Overview - Output Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257
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1.4 Output Shaft, Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261

1.5 Overview - Reverse Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264
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2.1 Input Shaft Seal, Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265

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3.1 Input Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266

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3.2 Output Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271

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3.3 Reverse Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279

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4 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281
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39 - Final Drive, Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 289
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1.1 Differentiating Right Flange Shaft Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 289
2.1 Adjustment Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 290
2.2 Overview - Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 290
2.3 Differential, Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293
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3.1 Flange Shaft Seal, Left, With Installed Manual Transmission . . . . . . . . . . . . . . . . . . . . . . 295
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4.1 Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
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5 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305
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6 Revision History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311
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Contents iii
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iv Contents
00 – General, Technical Data

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1 General Information Volksw
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⇒ “1.1 Calculating Transmission Ratio i ”, page 1 ss c
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⇒ “1.2 General Repair Information”, page 1
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⇒ “1.3 Safety Precautions, Vehicles with Start/Stop System”,
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⇒ “1.4 Transmission Identification”, page 4
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1.1 Calculating Transmission Ratio “i” es, in part or in w
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5th Gear Final Drive
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Drive gear ZG1= 39 ZA1= 18
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iA= axle ratio= ZA2 : ZA1= 61 : 18= 3.389

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1.2 General Repair Information
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Edition 12/2011, Version 19.0

Carefulness, cleanliness and the correct tools are required for
transmission repairs to be successful. The usual basic safety pre‐
cautions apply when making vehicle repairs.
Some of the general information that is included with other pro‐
cedures in this manual is summarized here. They apply to this
repair manual.
Transmission
♦ Make sure that the alignment sleeves between the engine and
transmission are positioned correctly when installing the trans‐
mission.
♦ Clean the contact surfaces when installing the brackets as well
as any waxed components. Contact surfaces must be free of
grease and wax.
♦ For the correct bolts and other components, refer to the Parts
Catalog.
♦ Fill the transmission fluid when repairing the manual trans‐
mission.
Capacity, refer to
⇒ “3.1 Code Letters, Transmission Allocation, Ratios and Ca‐
pacities, Golf from MY 2004”, page 8 , or
pacities, Golf from MY 2009”, page 11 , or
⇒ “3.3 Engine Codes, Transmission Allocation, Ratios and Ca‐
pacities, Golf Plus from MY 2005”, page 12 , or
pacities, Golf Plus from MY 2009”, page 13 , or
1. General Information 1
⇒ “3.5 Engine Codes, Transmission Allocations, Ratios and Ca‐

pacities, Passat from MY 2006”, page 13 .
Seals, Sealing Rings
♦ Thoroughly clean the separating surfaces and then apply
Sealant - AMV 188 200 03- .
♦ Apply the sealing compound evenly and not too thick.
♦ Fill the space between the sealing lips -arrow- on the radial
shaft seal halfway with Sealing Grease - G 052 128 A1- .
♦ The open side of the seals point toward the fluid to be sealed
in.
♦ After installing, check the transmission fluid level, refer to
⇒ “1.1 Transmission Fluid, Checking and Filling”, page 90
♦ Lightly lubricate O-rings before installing to prevent them from
being crushed when inserting.
Sealant wage
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♦ Always thoroughlyeclean d by the separating surfaces on theguhous‐
ara
ing before applying
ho
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♦ Apply the Sealing
ss Compound - AMV 188 200 03- evenly and c
not too thick. ce
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2 Rep. Gr.00 - General, Technical Data

♦ Replace the circlips.

♦ Do not overstretch the circlips.
♦ The circlips must fit completely inside the groove.
♦ Replace the adapter sleeves. Installed position: slot is longi‐
tudinal to line of force.
Bolts and Nuts
♦ Always loosen or tighten bolts and nuts on covers and hous‐
ings diagonally.
♦ Especially delicate parts, such as clutch pressure plates, must
not be distorted. Loosen and tighten bolts and nuts inastages
gen AG
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does
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♦ The tightening specifications stated applyhoto
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and bolts. aut or
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♦ Always replace self-locking nuts and bolts.
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♦ Make sure the contact surfaces and visible surfaces on the
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nuts and bolts are waxed after assembling.
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♦ Use a thread cutter to clean all threaded holes containing self-
wit
is n
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locking bolts to remove any locking compound residue. Oth‐
ole,
erwise the bolts could shear the next time they are removed.
spec
♦ Please make sure that the thread pitch is correct so that the
t to the co
proper thread cutter is used during cleaning, and the thread
does not get damaged.
rrectne
Bearings
♦ Install the new tapered roller bearings. It is not necessary to
ss
oil them.
o
cial p
f inform
♦ Install needle bearings with lettered side (thicker metal) racing
mer
the fitting tool.
atio
om
n
♦ Replace all the tapered roller bearings that are on the same
c
i
or
n thi
shaft. Use tapered roller bearings from the same manufactur‐
te
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er.
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♦ To install, heat the bearing inner races to approximately 100 °

en
ng
t.
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C (212 °F) with Inductive Heater - VAS6414- .
Co
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♦ Do not interchange inner and outer bearing races with those
ht
pyri by
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from other bearings of the same size, bearings are paired.
co lksw
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Adjusting Shims
♦ Measure the shims at several locations with a micrometer cal‐
iper. Tolerance variations make it possible to find the exact
shim thickness required.
♦ Check for burrs and damage.
♦ Only install perfect shims.
Synchronizer Rings
♦ Do not interchange them. When reusing synchronizer rings,

always install to the same gear wheel.
♦ Check for wear and replace if necessary.
AG. Volkswagen AG d
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♦ Check the grooves -arrow 1- on the synchronizer
olks
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ring -A- and not
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the inner race for flat areas (grooves
sed are worn).
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♦ The coating on the synchronizer
au rings must not be damaged.
t ra
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ss
♦ If an intermediate ring -B- is installed, check the intermediate
ce
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ring on the outer contact surface -arrow 2- and inner contact
an
itte
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surface -arrow 3- for grooves, scoring and blue coloring (from
erm
ab
overheating).
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♦ Check taper on the drive gear for »grooves« and »scoring«.
, is n
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hole
♦ Coat the synchronizing with transmission fluid and then install.
spec
es, in part or in w
Gear Wheels
t to the co
♦ Clean and warm to maximum 100 °C (212 °F) using the In‐
ductive Heat Unit - VAS6414- before installing.
rrectness of i
Selector Gears
l purpos
♦ After assembling, check the selector gears for minimum axial

clearance and ease of movement.
nform
ercia
Clutch
m
at
om
io
♦ Do not tilt the clutch pressure plate. Loosen and tighten it di‐
n
c
in t
or
agonally and in small steps.
his
ate
do
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♦ To reduce odor caused by a burnt clutch, thoroughly clean the

p
cum
or
clutch housing and the flywheel running surface with a clean

f
en
ng
cloth.
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1.3 Safety Precautions, Vehicles with Start/
py by
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Stop System
Prote AG.
WARNING
There is a risk of injury if the engine starts automatically in ve‐

hicles with the Start/Stop System.
♦ For vehicles with an activated Start/Stop System (recog‐
nizable from a notification in the instrument cluster), the
motor can be started automatically if needed.
♦ Make sure the Start/Stop System is disabled when work‐
ing on the vehicle (turn off ignition, if needed, turn the
ignition back on).
1.4 Transmission Identification

Code Letters and Build Date -arrow 1- Manual Transmission 0A4
-arrow 2-

Manual Transmission 0A4 -arrow 2-
Transmission Code Letters and Build Date

Example: FNE 10 11 3
I I I I
I I I I agen
AG. Volkswagen AG d
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Codes Day Month Year (2003)d by Vo gu
ara
of manufacture
orise nte
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For additional data and information contact the factory.
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The transmission code is also listed in the vehicle data plates.
wit
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orm
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2 Description and Operation olk ot g
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⇒ “2.1 Overview - Powertrain”, page 6 auth or
ac
ss
2.1 Overview - Powertrain
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Name
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-Arrows- point in the direction of travel
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spec
1 - Engine
t to the co
2 - Clutch
3 - Manual Transmission
rrectne
4 - Input Shaft
5 - Output Shaft
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6 - Differential
inform
mer
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Ratio
-Arrows- point in the direction of travel

I - 1st Gear
II - 2nd Gear
III - 3rd Gear
IV - 4th Gear
V - 5th Gear
R - Reverse Gear
A - Final Drive
AG. Volkswagen AG d
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2. Description and Operation 7

3 Specifications
pacities, Golf from MY 2004”, page 8
pacities, Golf from MY 2009”, page 11
pacities, Golf Plus from MY 2005”, page 12
pacities, Golf Plus from MY 2009”, page 13
⇒ “3.5 Engine Codes, Transmission Allocations, Ratios and Ca‐
pacities, Passat from MY 2006”, page 13
3.1 Code Letters, Transmission Allocation, Ratios and Capacities, Golf from MY
2004
Manual Transmission 5-Speed Manual Transmission 0A4
Codes FNE GQQ HGR
Manufactured from 08/2003 08/2003 03/2005
through 08/2003 08/2006 08/2006
Allocation Engine 1.9L - 77 kW 1.9L - 77 kW 2.5L - 110 kW
Turbo diesel Turbo diesel
Ratio Final Drive 61 : 18 = 3.389 61 : 18 = 3.389 62 : 17 = 3.647
Z1 : Z2
Manual transmission capacity 2.0 liter (2.11 quarts)
(transmission completely disas‐
sembled)
Manual transmission capacity, re‐ 1.8 liters (1.9 quarts)
fer to
⇒ “1.1 Transmission Fluid, Check‐
ing and Filling”, page 90 (trans‐
mission partly disassembled)
Drive Axle flange diameter AG. Volkswagen AG d
agen 100 mm oes 100 mm 100 mm
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Refer to the Parts Catalog for
ris
edthe following information:
ara
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♦ The individual gear sratios
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♦ Transmission fluid
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Codes HDR GTB JCT

es, in part or in w
t to the co

through 08/2006 03/2004 06/2008
rrectness of i
Allocation Engine 2.0L - 85 kW 2.5L - 110 KW 2.5L - 110 KW

l purpos
Z1 : Z2
nform
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Rep. Gr.00 - General, Technical Data Prote
cted AG.
agen

Codes wage
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GTB JCT
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Vol t u
Drive Axle flange
ed by diameter 100 gmmara 108 mm 108 mm
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Refer to
au the Parts Catalog for
t the following information:or ac
ss
♦ The individual gear ratios
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Codes JCR JCU JCV
rrectness of i
through 06/2008 06/2008 06/2008
l purpos
turbo diesel
1.9L - 77 kW
nform
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turbo diesel
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at
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Z1 : Z2
n
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or

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ate

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mission partly disassembled) Prote AG.
Drive Axle flange diameter 108 mm 100 mm 108 mm

Refer to the Parts Catalog for the following information:

Codes FNC HJK KCL
through 12/2006 12/2006 06/2008
Allocation Engine 1.9L - 77 kW 1.8L - 110 KW 1.9L - 77 kW
turbo diesel turbo diesel
Z1 : Z2
sembled)
fer to
3. Specifications 9

AG. Volkswagen AG d
♦ Transmission fluid lksw
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♦ Clutch allocation rise
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Codes KBL KCD JQP
rm
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through , is n 06/2008 12/2007 06/2008
h re
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spec
turbo diesel
es, in part or in w
t to the co
Z1 : Z2
rrectness of i
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sembled)
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fer to
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♦ The individual gear ratios t. Cop py
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♦ Clutch allocation Prote AG.

Codes KPF LHW
Manufac‐ from 07/2007 04/2008
tured through 06/2008 06/2008
Allocation Engine 2.5L - 125 KW 1.9L - 77 kW
turbo diesel
Ratio Final Drive 61 : 18 = 3.778 62 : 17 = 3.647
Z1 : Z2
Manual transmission ca‐ 2.0 liter (2.11 quarts)
pacity (transmission com‐
pletely disassembled)
Manual transmission ca‐ 1.8 liters (1.9 quarts)
pacity, refer to
⇒ “1.1 Transmission Fluid,
Checking and Filling”,
page 90 (transmission
partly disassembled)
Drive Axle flange diameter 100 mm 100 mm

3.2 Code Letters, Transmission Allocation, Ratios and Capacities, Golf from MY
2009
Codes KQM LLL LHW
Manufac‐ from 06/2008 08/2008 05/2009
tured through 05/2009
Allocation Engine 1.9L - 81 KW 2.0L - 81 KW 1.6L - 66 kW
turbo diesel turbo diesel turbo diesel
2.0L - 81 KW 1.6L - 77 kW
. Volkswagen AG
gen AG
Ratio Final Drive olkswa61 : 18 = 3.778 does 61 : 18 = 3.778
no 62 : 17 = 3.647
Z1 : Z2 db
yV t gu
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rise nt
Manual transmission thoca‐ 2.0 liter e(2.11
eo quarts)
pacity (transmission
s au com‐ ra
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pacity, refer to
erm
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t to the co
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♦ Clutch allocation ss o
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n
c
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or
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Codes LUB KCD KPF

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Manufac‐ from 05/2009 08/2009 08/2009

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turbo diesel
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Ratio Final Drive Prote
cted 62 : 17 = 3.647AG. 62 : 17 = 3.647
agen 61 : 18 = 3.778
Z1 : Z2
pacity, refer to
3. Specifications 11

Codes MDZ LEA
Manufac‐ from 11/2009 05/2010
tured through
Allocation Engine 1.9L - 77 kW 2.5L - 125 KW
turbo diesel
Ratio Final Drive 61 : 18 = 3.778 61 : 18 = 3.778
Z1 : Z2
pacity, refer to
Drive Axle flange diameter 100 mm 100 mm
AG. Volkswagen AG d
agen
♦ Transmission fluid Volksw
oes
not
by gu
d ara
♦ Clutch allocation orise nte
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3.3 Engine Codes, Transmission Allocation, Ratios and Capacities, Golf Plus
du
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itte
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from MY 2005
erm
ab
ility
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hole
Codes HNV JCX KBL
spec
es, in part or in w
t to the co
through 05/2006 01/2009 01/2009
rrectness of i
1.9L - 77 kW 1.9L - 77 kW
l purpos

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ercia
Z1 : Z2
orm
m

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c
sembled)
or
thi
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o
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ing and Filling”, page 90 (trans‐ Cop py
t. rig
gh ht
pyri by
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by lksw
cted agen
Prote AG.

3.4 Engine Codes, Transmission Allocation, Ratios and Capacities, Golf Plus
from MY 2009
Codes KQM LHW LUB
through
Allocation Engine 2.0L - 81 KW 1.6L - 66 KW 1.9L - 77 kW
1.6L - 77 KW
turbo diesel
Z1 : Z2
sembled)
fer to AG. Volkswagen AG d
⇒ “1.1 Transmission Fluid, Check‐ agen oes
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ing and Filling”, page 90 (trans‐ d by
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ara
mission partly disassembled) orise nte
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Drive Axle flange diameter 100 mm ss a 100 mm 100 mm ra
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un
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erm
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ility
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spec
t to the co
3.5 Engine Codes, Transmission Allocations, Ratios and Capacities, Passat
from MY 2006
rrectne
ss o
Codes HNV JCX JQP
cial p
f inform
Manufac‐ from 01/2005 05/2006 05/2007
mer
tured through 05/2006 11/2008 11/2008
atio
om
n
c

i
or
n thi
te
sd
a
1.9L - 77 kW
iv
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turbo diesel
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op py
Z1 : Z2 t. C rig
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yri by
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by c lksw
pacity (transmission cted agen
Prote AG.
completely disassem‐
bled)
pacity, refer to
⇒ “1.1 Transmission Flu‐
id, Checking and Filling”,
Drive Axle flange diame‐ 100 mm 100 mm 107 mm
ter

Codes JVF KBM KJF
Manufac‐ from 03/2007 05/2007 12/2007
tured through 11/2008 11/2008 10/2010
Allocation Engine 2.0L - 85kW 1.9L - 77 kW 2.0L - 81 kW
Ratio Final 72 : 17 = 4.235 62 : 17 = 3.647 62 : 17 = 3.647
Z1 : Z2 Drive
Manual transmission 2.0 liter (2.11 quarts)
capacity (transmission
bled)
Manual transmission 1.8 liters (1.9 quarts)
capacity, refer to
⇒ “1.1 Transmission
Fluid, Checking and Fill‐
ing”, page 90 (trans‐
mission partly disas‐
sembled) . Volkswagen AG
gen AG does
Drive Axle flange diam‐ Volkswa 100 mm not 100 mm 100 mm
eter ed
by gu
ara
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aut ra
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t to the co
Codes KBL LHP MDM

Manufac‐ from 01/2008 11/2008 08/2009
rrectness of i

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1.6L - 77 kW 1.6L - 77 kW
nform
ercia

m
Ratio Final 61 : 18 = 3.778 62 : 17 = 3.647 62 : 17 = 3.647

at
om
io
Z1 : Z2 Drive
n
c
in t
or
Manual transmission 2.0 liter (2.11 quarts)

his
ate
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bled)
n
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Manual transmission 1.8 liters (1.9 quarts)
C py
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capacity, refer to
rig ht
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⇒ “1.1 Transmission by c lksw
cted agen
Fluid, Checking and Fill‐ Prote AG.
ing”, page 90 (trans‐
mission partly disas‐
sembled)
Drive Axle flange diam‐ 100 mm 100 mm 100 mm
eter


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spec
t to the co
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cial p
f inform
mer
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Cop py
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30 – Clutch
1 General Information
⇒ “1.1 Clutch System, Bleeding”, page 16
⇒ “1.2 Determining Clutch Manufacturer, 1.9L 66 kW Turbo Diesel
and 1.9L 77 kW Turbo Diesel”, page 16
1.1 Clutch System, Bleeding

Special tools and workshop equipment required
♦ Brake Charger/Bleeder Unit - VAS5234- or AG. Volkswagen AG d
agen oes
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♦ Brake Charger/Bleeder Unit - VAG1869- sed b ara
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It is not necessary to pre-fill the system.
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ility
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For the correct brake fluid specification, refer to ⇒ Brake System;
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h re
Rep. Gr. 47 ; Brake System, Bleeding .
hole
spec
– Remove the entire air filter housing if the bleeder (-arrow- low‐
es, in part or in w
er illustration) is not accessible, refer to ⇒ Rep. Gr. 23 ;
t to the co
Servicing the Diesel Direct Fuel Injection System and ⇒ Rep.
Gr. 24 ; Servicing the Fuel Injection System .
rrectness of i
– Connect the Brake Charger/Bleeder Unit - VAS5234- or -
VAG1869- .
l purpos
It is necessary to use the Bleeder Hose (670 mm) - VAG1238/B3-

to bleed.
nf
ercia
orm
– Connect the bleeder hose to the brake bleeder unit collector
m
atio
m
bottle.
o
n in
or c
thi
– Connect the bleeder hose to the bleeder -arrow-.

te
sd
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– Apply 2 bar (29 psi) pressure to the system.

rp
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ng
– Open the bleeder valve.

t.
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– Drain approximately 100 cm3 of brake fluid. opyri
gh by
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ht
c by lksw
– Close the bleeder valve. cted agen
Prote AG.
– Operate the pedal rapidly from stop to stop, 10 to 15 times.

– Open the bleeder valve.
– Drain another 50 cm3 of brake fluid.
– Close the bleeder valve.
– Press the clutch pedal a few times after bleeding the system.
– Install the complete air filter housing, if it was removed earlier,
refer to ⇒ Rep. Gr. 23 ; Servicing the Diesel Direct Fuel In‐
jection System and ⇒ Rep. Gr. 24 ; Servicing the Fuel
Injection System .
1.2 Determining Clutch Manufacturer, 1.9L

66 kW Turbo Diesel and 1.9L 77 kW
Turbo Diesel
It is possible to tell which clutch the vehicle has with the trans‐
mission installed:
16 Rep. Gr.30 - Clutch

– Remove the noise insulation, refer to ⇒ Body Exterior; Rep.

Gr. 50 ; Noise Insulation .
There are some openings -arrows- between the engine -A- and
the transmission -B- near the bottom of the oil pan.
– Check the outer contour of the flywheel through this opening.
– On different engines, the outer contour of the flywheel can also

be inspected by removing the small cover plate -A-.
Round Outer Contour -arrow- = Clutch Made by Sachs = -A-
. Volkswagen AG
gen AG does
Overview - “Sachs”VClutch,
olks
wa refer to not
gu
⇒ “2.5 Overviewed-bySachs Clutch”, page 26 . ara
nte
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aut ra
ss c
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un
pt
an
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itte
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erm
ab
ility
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is n
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ole,
– Clutch, Removing and Installing, Sachs, refer to

spec
⇒ “3.8 Sachs Clutch”, page 80 .

t to the co
Squared Outer Contour -arrows 1- and in Addition, a Pleat all the

Way Around -arrow 2- = Clutch Made by LuK = -B-
rrectne
or
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
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fo
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
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by c lksw
cted agen
Prote AG.
Round Outer Contour -arrows 1- and a Circulated Depression

-arrow 2- = Clutch Manufacturer, LuK = -B-
– Overview - Clutch, “LuK”, refer to
⇒ “2.6 Clutch Assembly Overview, LuK ”, page 27 .
– LuK Clutch, Removing and Installing, refer to
⇒ “3.9 LuK Clutch”, page 83 .
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2 Description and Operation

⇒ “2.1 Clutch Mechanism Overview”, page 19
⇒ “2.2 Overview - Pedal Assembly”, page 21
⇒ “2.3 Overview - Hydraulics”, page 23
⇒ “2.4 Overview - Clutch Release Mechanism”, page 25
⇒ “2.5 Overview - Sachs Clutch”, page 26
⇒ “2.6 Clutch Assembly Overview, LuK ”, page 27
⇒ “2.7 Clutch Assembly Overview, with Single Flywheel”,
page 28
2.1 Clutch Mechanism Overview
Note
♦ Get the anti-theft code for the radio before disconnecting the battery.
♦ Disconnect the battery ground cable, refer to ⇒ Electrical System; Rep. Gr. 27 ; Battery, Disconnecting and
Connecting .
♦ Refer to ⇒ Electrical Equipment; Rep. Gr. 27 ; Battery, Disconnecting and Connecting when connecting
the battery.
♦ Lubricate all bearing areas and contact surfaces.
♦ Grease allocation, refer to the Parts Catalog.
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I-
⇒ “2.2 Overview - Pedal As‐
sembly”, page 21
II -
⇒ “2.3 Overview - Hydraulics”,
page 23
III -
⇒ “2.8 Hydraulics Assembly
Overview, RHD”, page 30
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Rep. Gr.30 - Clutch cted agen
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2.2 Overview - Pedal Assembly
1 - Bulkhead
❑ With a mount for the
bracket
2 - Seal
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❑ Self-adhesive ss a c
ce
le
❑ Attached to the bracket

un
pt
an
d
itte
3 - Bracket
y li
erm
ab
❑ For the clutch pedal
ility
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mount
wit
is n
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❑ Some equipment ver‐
ole,
spec
sions have a damper,
refer to
t to the co
⇒ Fig. ““Bracket with
Damper -arrow- ”“ ,
page 22
rrectne
❑ Removing and Instal‐
ling, Golf from MY 2004,
ss
refer to, refer to
o
cial p
f
⇒ “3.3.1 Mounting
inform
Bracket,Golf from MY
mer
2004”, page 52 .
atio
m

o
n
c
i
or
n
ling, Golf from MY 2009
thi
te
refer to sd
iva
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r
⇒ “3.3.2 Bracket,Golf
p
cum
r
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from MY 2009”,
en
ng
t.
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page 56 .
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rig
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ling, Golf Plus, refer to op Vo
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⇒ “3.3.4 Mounting cted agen
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Bracket, Golf Plus”,
page 66 .
ling, Passat, refer to ⇒ “3.3.5 Mounting Bracket, Passat”, page 71 .
4 - Bolt
5 - Over-Center Spring
❑ Removing and Installing, Golf from MY 2004, refer to
⇒ “3.1.1 Over-Center Spring, Golf from MY 2004”, page 32 .
❑ Removing and Installing, Golf from MY 2009, refer to
❑ Removing and Installing, Golf Plus, refer to ⇒ “3.1.4 Over-Center Spring, Golf Plus”, page 44
❑ Removing and Installing, Passat, refer to ⇒ “3.1.5 Over-Center Spring,Passat”, page 48 .
6 - Bearing Bushing
7 - Mounting Pin
8 - Clutch Pedal
❑ Removing and Installing, Golf from MY 2004, Golf from MY 2009 LHD, Golf from MY 2009 RHD, Golf
Plus, refer to ⇒ “3.2.1 Clutch Pedal,Golf from MY 2004, Golf from MY 2009 and Golf Plus”, page 49 .
❑ Removing and Installing, Passat, refer to ⇒ “3.2.2 Clutch Pedal,Passat”, page 50 .

9 - Base Plate
❑ Removing and Installing, Golf from MY 2004, Golf from MY 2009 LHD, Golf Plus, refer to
⇒ “3.2.1 Clutch Pedal,Golf from MY 2004, Golf from MY 2009 and Golf Plus”, page 49 .
10 - Seal
❑ Always replace.
❑ Between the master cylinder and the bracket
11 - Master Cylinder
❑ Removing and installing after removing the bracket, refer to ⇒ “3.4 Clutch Master Cylinder”, page 73
12 - Clutch Position Sensor - G476-
❑ Removing and installing, refer to ⇒ “3.5 Clutch Position Sensor G476 ”, page 75 .
❑ Can be checked in “Guided Fault Finding” using the Vehicle Diagnostic Tester
❑ The Clutch Position Sensor - G476- is called the Clutch Pedal Switch - F36- in “Guided Fault Finding”.
13 - Clamp
❑ The clamp must be removed in order to remove/install the hose/line assembly
14 - Supply Hose
❑ Rubber
❑ From 12/2005, plastic, refer to ⇒ Fig. ““Plastic Supply Hose-1-.”“ , page
agen
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❑ Golf from MY 2009 and Golf Plus from MY 2009, madebyofV plastic, refer to
o gu
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⇒ Fig. ““Plastic Supply Hose-1-.”“ , page 24 ris
ed
nte
tho eo
15 - Self-Locking Nut s au ra
c
s
❑ 25 Nm
ce
e
nl
pt
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❑ Always replace.
itte
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❑ Quantity: 3
ility
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❑ For the bracket to the bulkhead
wit
, is n
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16 - Hex Nut
hole
spec
❑ 25 Nm
es, in part or in w
t to the co
❑ Always replace.
17 - Stop
rrectness of i
❑ For the clutch pedal
l purpos
Bracket with Damper -arrow- nf

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2.3 Overview - Hydraulics
1 - Brake Fluid Reservoir

2 - Spring Clamp
❑ Not on all vehicles
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❑ From 12/2005, ut
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refer to ss a c
⇒ Fig. ““Plastic Supply
ce
le
un
pt
Hose-1-.”“ , page 24
an
d
itte
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❑ Golf from MY 2009 and
erm
ab
Golf Plus from MY 2009,
ility
ot p
made of plastic, refer to
wit
is n
⇒ Fig. ““Plastic Supply
h re
ole,
Hose-1-.”“ , page 24
spec
4 - Master Cylinder
t to the co
❑ Removing and instal‐
ling, refer to
rrectne
⇒ “3.4 Clutch Master
Cylinder”, page 73 .
s
5 - Clamp
s o
cial p
f
❑ The clamp must be re‐
inform
moved in order to re‐
mer
move/install the hose/

atio
m
line assembly
o
n
c
i
or
n thi
e
6 - Base Plate
t
sd
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❑ When removing and in‐

p
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fo
stalling, remove the

en
ng
t.
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clutch master cylinder
Co
op py
from the clutch pedal,
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from MY 2009 RHD and
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Golf Plus refer to

⇒ “3.2.1 Clutch
Pedal,Golf from MY
2004, Golf from MY 2009 and Golf Plus”, page 49 , Passat refer to
⇒ “3.2.2 Clutch Pedal,Passat”, page 50 .
7 - Clutch Pedal
❑ Removing and Installing, Golf from MY 2004, Golf from MY 2009 LHD, Golf from MY 2009 RHD, Golf
Plus, refer to ⇒ “3.2.1 Clutch Pedal,Golf from MY 2004, Golf from MY 2009 and Golf Plus”, page 49 .
8 - Hex Nut, -item 15- ⇒ Item 15 (page 22)
9 - Seal/O-Ring
❑ Install on the line connection
❑ Install with brake fluid
❑ Seals/O-rings suitable for the line connection material, refer to
⇒ Fig. ““Seals/O-Ring for the Pipe/Hose Lines”“ , page 24
❑ Allocation, refer to the Parts Catalog.
10 - Hose/Line Assembly
❑ To remove, remove the battery and battery tray, refer to ⇒ Electrical Equipment; Rep. Gr. 27 ; Battery,
Removing and Installing .

11 - Bracket
❑ Attached to the body
12 - Seal/O-Ring
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e refer to
⇒ Fig.s a““Seals/O-Ring
ut for the Pipe/Hose Lines”“ , pageor24 ac
s
ce
le
un
pt
an
d
13 - Clamp
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14 - Clutch Slave Cylinder
, is n
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❑ Removing and installing, refer to ⇒ “3.6 Slave Cylinder”, page 77 .
hole
spec
es, in part or in w
15 - Hex Bolt -item 9- ⇒ Item 9 (page 25)
t to the co
16 - Bleed Valve
❑ Clutch System, Bleeding, refer to ⇒ “1.1 Clutch System, Bleeding”, page 16 .
rrectness of i
17 - Dust Cap
l purpos
18 - Transmission
nform
ercia
19 - Bracket
m
a
20 - Hex Bolt
com
tion in
❑ 20 Nm
r
te o
thi
s
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Seals/O-Ring for the Pipe/Hose Lines

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Item Line Connection Version
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-arrow 1-
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2 Line connection with a shoulder -arrow 2-

3 Line connection with a shoulder -arrow 2- and with
a groove all the way around -arrow 3-
• The seal / O-ring must be installed in the groove -arrow 1- and
-arrow 3-.
Plastic Supply Hose-1-.

• The seals -2- must be inside the supply hose.

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2.4 Overview - Clutch Release Mechanism
aut
ho or
ac
ss
ce
le
un
pt
1 - Transmission
an
d
itte
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erm
ab
2 - Ball Stud
ility
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❑ 25 Nm
wit
is n
h re
❑ For removing and instal‐
ole,
spec
ling, remove the trans‐
mission
t to the co
❑ Remove grease from
extractor lever contact
surfaces
rrectne
❑ Grease using lubricat‐
ing grease Lubricating
ss
Grease - G 000 100- .
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cial p
f inform
3 - Input Shaft Seal
mer
atio
❑ Replacing, refer to
om
⇒ “2.1 Input Shaft Seal,
n
c
i
or
n
Replacing”, page 265 .
thi
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4 - Guide Sleeve
i
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❑ with vulcanized O-ring cop Vo
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❑ If the O-ring is dam‐
Prote AG.
aged, then replace the

guide sleeve and the O-
ring
5 - Spring
mission
❑ Attach to the clutch re‐
lease lever
6 - Cylinder Bolt
❑ 20 Nm
7 - Clutch Release Lever
❑ For removing and installing, remove the transmission
❑ remove and install together with release bearing, refer to
⇒ Fig. ““Removing and Installing the Release Bearing”“ , page 80
❑ remove grease already present
8 - Release Bearing
❑ For removing and installing, remove the transmission
❑ Do not wash the bearing, just wipe it off.
❑ Replace loud bearings
❑ removing from and installing in the clutch release lever, refer to
⇒ Fig. ““Removing and Installing the Release Bearing”“ , page 80
❑ Lubricate release lever contact surface with MoS 2 grease
9 - Hex Bolt
❑ 20 Nm
10 - Clutch Slave Cylinder

11 - Plunger
12 - Bolt
❑ Secures the clutch release aglever
en AG.when installing
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❑ Remove after installing
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ce
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Use an M8 x 35 bolt if the assembly

un
pt
an
d
bolt -item 12- ⇒ Item 12 (page 26) is

itte
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rm
missing.
ab
pe
ility
ot
wit
, is n
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hole
2.5 Overview - “Sachs” Clutch
spec
es, in part or in w
t to the co
Clutch allocation, refer to the Parts Catalog.
rrectness of i
1 - Dual Mass Flywheel
l purpos
ling, refer to ⇒ Rep. Gr.

13 .
nform
ercia
❑ Single flywheel: from

05/2006: together with
m
a
com
t
the 1.4 L - 125 kW en‐
ion in
gine
r
te o
thi
s
iva
do
r

rp
cum
fo
the 1.6L - 66 kW turbo

en
ng
t.
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diesel engine and 1.6L -
Co
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77 kW turbo diesel en‐ t. C rig
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❑ Single flywheel: togeth‐ cted agen
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er with the 1.4L - 103 kW
engine and 1.4L - 118
kW engine
ling, refer to ⇒ Engine
Mechanical; Rep. Gr.
13 .
❑ Make sure it fits secure‐
ly on the centering pins
2 - Clutch Plate
❑ Allocation, refer to the
Parts Catalog.
ling, refer to
⇒ “3.8 Sachs Clutch”,
page 80 .
❑ Only replace together
with the pressure plate
❑ Installed position, refer
to
⇒ Fig. ““Clutch Plate In‐
stalled Position”“ ,
page 81 .
3 - Pressure Plate
❑ With adjustment mechanism
❑ Only replace together with the clutch plate
❑ Removing and installing, refer to ⇒ “3.8 Sachs Clutch”, page 80 .

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❑ Check the ends of the diaphragm
ss
a
spring, refer to c
⇒ Fig. ““Check the Ends of the Diaphragm Spring”“ , page 81
ce
le
un
pt
an
❑ Checking the spring connections and rivet connections, refer to
d
itte
y li
⇒ Fig. ““Checking the Spring Connections and Rivet Connections”“ , page 81
rm
ab
pe
ility
4 - Bolt
ot
wit
, is n
h re
❑ M7 bolt: 20 Nm
hole
spec
❑ M6 bolt: 13 Nm es, in part or in w
t to the co
❑ Loosen and tighten in small steps and in diagonal sequence
rrectness of i
l purpos
2.6 Clutch Assembly Overview, “LuK”

nform
mercia
a
com
ti
1 - Dual Mass Flywheel
on in
r
te o
thi
s
iva
ling, refer to ⇒ Rep. Gr.
do
r
rp
c
13 .
um
fo
en
g

n
t.
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op
ly on the centering pins C py
ht. rig
rig ht
❑ Keep the clutch lining py by
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contact surface free of
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grooves, oil and grease.
Prote AG.

the 1.6L - 66 kW turbo
diesel engine and 1.6L -
77 kW turbo diesel en‐
gine
2 - Clutch Plate
Parts Catalog.
ling, refer to
⇒ “3.9 LuK Clutch”,
page 83 .
with the SAC pressure
plate
❑ Installed position: Refer
to
⇒ Fig. ““Clutch Plate In‐
stalled Position”“ ,
page 83
3 - SAC Pressure Plate
❑ SAC = “self-adjusting
clutch”
with the clutch plate
Parts Catalog.
❑ Removing and installing, refer to ⇒ “3.9 LuK Clutch”, page 83 .
❑ Check the ends of the diaphragm spring, refer to
❑ Checking the spring connection and rivet connections, refer to

❑ Only check position of the adjustment mechanism with new pressure plates, refer to
⇒ Fig. ““Only Check Position of Adjustment Mechanism with New Pressure Plates”“ , page 84
4 - Bolt
❑ M6 bolt: 13 Nm
❑ M7 bolt: 20 Nm
❑ Loosen and tighten in small steps and in diagonal sequence
2.7 Clutch Assembly Overview, with Single

Flywheel
Note
♦ Replace clutch plates and pressure plates if the rivets are damaged or loose.
♦ Allocate the clutch plate and pressure plate according to the Parts Catalog and the engine code.
♦ Make sure the engine to transmission centering sleeves are installed in the cylinder block, install if neces‐
sary.
♦ If the alignment sleeves are missing, it will be difficult to shift, there will be clutch problems and the trans‐
mission may make noises (loose rattling).
AG. Volkswagen AG d
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spec
es, in part or in w
t to the co
rrectness of i
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nf
ercia
orm
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om
n in
or c
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1 - Flywheel lkswage es n
o ot g
❑ Removing and Instal‐ byV ua
d ran
ling, refer to ⇒ Rep. Gr. ir se tee
tho
or
13 . au ac
ss
ce
e
nl
pt
ly on the centering pins
du
an
itte
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❑ Keep the clutch lining
erm
ab
contact surface free of
ility
ot p
grooves, oil and grease
wit
, is n
h re
2 - Clutch Plate
hole
spec
es, in part or in w
t to the co
Parts Catalog.
❑ The spring cage faces
the pressure plate
rrectness of i
❑ Centering, refer to
l purpos
⇒ Fig. ““Centering the

Clutch Plate and Re‐
moving and Installing
nform
ercia
Pressure Plate.”“ ,
page 85
m
at
om
io
❑ Lightly grease the
n
c
in t
or
splines
his
ate
do
priv
c
Note
um
for
en
ng
t.
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Clean input shaft splines and, in Cop py
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case of used clutch plates, clean
t
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hub splines, remove corrosion and cop Vo
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apply only a very thin coating of Lu‐
cted agen
Prote AG.
bricant - G 000 100- on input shaft
splines. Then move the clutch plate
back and forth on the input shaft un‐
til the hub moves freely on the shaft.
Remove any excess grease.
3 - Pressure Plate
ling, refer to
⇒ Fig. ““Centering the Clutch Plate and Removing and Installing Pressure Plate.”“ , page 85 .
❑ Check the ends of the diaphragm spring, refer to
❑ Checking the spring connections and rivet connections, refer to
⇒ Fig. ““Checking the Spring Connections and Rivet Connections”“ , page 86
Note
The pressure plates are corrosion-

protected and lubricated. Only the
running surfaces may be cleaned,
otherwise the service life of the
clutch will be shortened considera‐
bly.
4 - Bolt
❑ M6 bolt: 13 Nm
❑ M7 bolt: 20 Nm
❑ Loosen/tighten diagonally and in steps
❑ Allocate according to the Parts Catalog.

2.8 Hydraulics Assembly Overview, RHD
1 - Brake Fluid Reservoir

2 - Seal
❑ For the plastic supply
hose
❑ The gaskets must be in‐
side the supply hose.
3 - Supply Hose
❑ Plastic
❑ May also be made of
rubber -item 3-
⇒ Item 3 (page 23)
4 - Master cylinder
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❑ Removing and instal‐ agen oes
olksw not
ling, refer to d by
V gu
ara
⇒ “3.4 Clutch Master orise nte
eo
Cylinder”, page 73 . aut
h
ra
ss c
5 - Clamp
ce
e
nl
pt
du
an
❑ To remove and install
itte
y li
the line, remove the clip
erm
ab
up to the stop
ility
ot p
wit
❑ It is also pulled out at the
, is n
h re
side on some master
hole
spec
cylinders.
es, in part or in w
t to the co
6 - Seal/O-Ring
❑ Install on the line con‐
nection
rrectness of i
l purpos
❑ Seals/O-rings suitable
for the line connection
material, refer to
nf
ercia
⇒ Fig. ““Seals/O-Ring
rm
m
atio
for the Pipe/Hose

om
Lines”“ , page 24
n in
or c
thi

te
sd
iva
o
r
rp
cu
7 - Base plate
o
m
f
en
ng
❑ For removing and installing, detach the master cylinder from the clutch pedal (⇒ Clutch Pedal, Removing
t.
yi Co
op
and Installing) C py
t. rig
gh ht
❑ Golf from MY 2004, Golf from 2009 LHD, Golf from MY 2009 RHD and Golf Plus, refer to yri
p by
o Vo
⇒ “3.2.1 Clutch Pedal,Golf from MY 2004, Golf from MY 2009 and Golf Plus”, page 49 .
by c lksw
cted agen
Prote AG.
❑ Passat
8 - Clutch Pedal
Removing and Installing, Golf from MY 2004, Golf from MY 2009 LHD, Golf from MY 2009 RHD, Golf Plus,
refer to ⇒ “3.2.1 Clutch Pedal,Golf from MY 2004, Golf from MY 2009 and Golf Plus”, page 49 .
9 - Hex nut, -item 15- ⇒ Item 15 (page 22)
10 - Bracket
❑ Attached to the body
11 - Line
❑ The pipe line and pipe/hose line -item 13- ⇒ Item 13 (page 31) may also be a single piece.

12 - Seal/O-Ring
13 - Hose/Line Assembly
14 - Bracket
❑ Secured on the ABS/EDL bracket
15 - Bracket agen
AG. Volkswagen AG d
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16 - Seal/O-Ring ut
hor eo
a ra
ss c
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17 - Clamp
spec

18 - Clutch slave cylinder t to the co
rrectne
19 - Hex bolt -item 9- ⇒ Item 9 (page 25)

s
20 - Bleed Valve
s o
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❑ Clutch System, Bleeding, refer to ⇒ “1.1 Clutch System, Bleeding”, page 16 .

inform
mer
21 - Dust Cap
atio
om
22 - Transmission
n
c
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23 - Bracket
t
sd
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24 - Hex Bolt, 20 Nm
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3 Removal and Installation

⇒ “3.1 Over-Center Spring”, page 32
⇒ “3.2 Clutch Pedal”, page 49
⇒ “3.3 Mounting Bracket”, page 52
⇒ “3.4 Clutch Master Cylinder”, page 73
⇒ “3.5 Clutch Position Sensor G476 ”, page 75
⇒ “3.6 Slave Cylinder”, page 77
⇒ “3.7 Clutch Release Mechanism, Servicing”, page 79
⇒ “3.8 Sachs Clutch”, page 80
⇒ “3.9 LuK Clutch”, page 83
⇒ “3.10 Clutch, With Single Flywheel”, page 85
3.1 Over-Center Spring

⇒ “3.1.1 Over-Center Spring, Golf from MY 2004”, page 32
⇒ “3.1.4 Over-Center Spring, Golf Plus”, page 44
⇒ “3.1.5 Over-Center Spring,Passat”, page 48
3.1.1 Over-Center Spring, Golf from

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♦ Over-Center Spring Assembly Tool
sa
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ac
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♦ Torque Wrench 1331 5-50Nm - VAG1331-
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pt
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Removing
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ility
– Move the driver seat all the way back and raise the steering
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wheel to the highest position.

is n
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ole,
– Remove the trim and the cover under the trim on the driver
spec
side, refer to ⇒ Body Interior; Rep. Gr. 68 .

t to the co
– Remove the cable guide -2- from the steering column.

– Remove the footwell vent -3-, refer to ⇒ Heating, Ventilation
rrectne
and Air Conditioning; Rep. Gr. 80 ; Heating, Servicing .

There are Different Ways of Securing the Impact Bolster -1- in
ss
Front of the Clutch Pedal -2-.

o
cial p
f in
Securing with Two Bolts

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– Remove the crash bolster -1- (two bolts).

Securing with One Bolt
– Remove the crash bolster -1- (1 bolt -2-).
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Remove the damper -arrow- at the bottom of the bracket/clutch
es, in part or in w
pedal, if equipped.
t to the co
rrectness of i
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nf
ercia
orm
m
atio
om
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– Remove the washers -A- for the damper.

– Remove the damper.
3. Removal and Installation 33

– Push the damper near the upper nut -1- above the clutch pedal
-A- in direction of -arrow-.
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– Remove the nut -2- and the bolt -5- and then remove the clutch
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pedal -1- from the bracket -3-.
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Note
ole,
spec
The clutch pedal remains engaged in the master cylinder actuator
t to the co
rod.
rrectne
– Move the clutch pedal downward and remove the over-center
spring -4-.
ss o
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f inform
mer
atio
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Replace the self-locking nuts.
– Install the over-center spring -2- into the bracket from the top
and hold the end of the spring in its installed position using the
Over-Center Spring Assembly Tool - T10178- .

– The mounting area -arrow- for the clutch pedal pivot pin -A-
must be positioned vertically.
– Insert the clutch pedal pivot pin into the mounting cup of the
over-center spring. wage
es ks not
Vol gu
– Press the clutch pedal slightly, push the bolt through
ed
by and tight‐ ara
nte
en the self-locking nut, tightening specification.
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Some vehicles have a damper -arrow- on the mounting bracket/
ole,
spec
clutch pedal.
t to the co
– Bring the damper back into the installation position.
rrectne
ss o
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f inform
mer
atio
om
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c
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– Install the crash bolster -1- and tighten the two bolts to the
tightening specification.

– Install the crash brace -1- and tighten the bolt -2- to the tight‐
ening specification.
– Install the trim and the cover on the driver side, refer to ⇒ Body
Interior; Rep. Gr. 68 .
Tightening Specifications
Component Nm
Clutch pedal to bracket 25
♦ Replace the self-locking nuts.
Impact bolster to mounting bracket/steering 10

column (secured with two bolts)
column (secured with one bolt)
♦ Replace the impact bolster bolts
3.1.2 Over-Center Spring, Golf from MY 2009

♦ Over-Center Spring Assembly Tool - T10178-
Removing AG. Volkswagen AG d
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Vehicles with a Knee Airbag by
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The knee airbag is installed above the foot pedal assembly.
an
d
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ab
pe
ility
– First check whether a coded radio is installed. If so, obtain the
ot
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, is n
anti-theft code.
h re
hole
– Disconnect the battery ground cable, refer to ⇒ Electrical Sys‐

spec
tem; Rep. Gr. 27 ; Battery, Disconnecting and Connecting .

es, in part or in w
t to the co
Continuation for All

rrectness of i

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ercia
Vehicles with a Knee Airbag

m
a
com
– Remove the knee airbag bracket and crash bolster, refer to ⇒

tion in
Interior Equipment; Rep. Gr. 69 ; Airbag; Bracket, Knee Air‐

r
te o
thi
bag, Removing and Installing (Golf from MY 2009) .

s
iva
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Continuation For All

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– Remove the cable guide -2- from the steering column. Cop
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– Remove the footwell vent -3-, refer to ⇒ Heating, Ventilation gh ht
yri by
op Vo
by c lksw
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Prote AG.
Vehicles Without Knee Airbag

– Remove the crash bolster -1- (bolt -2-).

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ility
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, is n
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hole
pedal, if equipped.
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
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or
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ate
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for
en
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– Push the insulation near the nut -1- above the clutch pedal
-A- upward in direction of -arrow-.
Note

rod.
– Move the clutch pedal downward and remove ethe over-center

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Install in reverse order of removal. au ra
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om
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c

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ate
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– Insert the clutch pedal pivot pin -1- into the mounting cup of
the over-center spring.
– Press the clutch pedal slightly, push the bolt through and tight‐

clutch pedal.
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es, in part or in w
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nf
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atio
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or c
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– Attach the cable guide -2- to the steering column.

– Install the footwell vent -3-, refer to ⇒ Rep. Gr. 80 .
– Install the knee airbag bracket and crash bolster, refer to ⇒
– If disconnected, connect the battery, refer to ⇒ Electrical
Equipment; Rep. Gr. 27 ; Battery, Removing and Installing .
Component Nm
Crash bolster to mounting bracket/steering 20

column
♦ Replace the impact bolster bolt
3.1.3 Over-center Spring, Removing and In‐

stalling, Golf from 2009 RHD
♦ Clutch Pedal Pliers - T10005-
Removing agen
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– First check whether a coded radio is installed. If so, obtain the d byV gu
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– Disconnect the battery ground cable, refer to ⇒ Electrical
ss a
Sys‐ c
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un
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an
d
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ab
pe
ility
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– Remove trim on the driver side and the cover below the trim
wit
, is n
⇒ Body Repair; Rep. Gr. 68 .

h re
hole
spec
– Remove the knee airbag bracket, refer to ⇒ Interior Equip‐

es, in part or in w
ment; Rep. Gr. 69 ; Airbag; Bracket, Knee Airbag, Removing

t to the co
and Installing (Golf from MY 2009) .

rrectness of i

l purpos
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Rep. Gr.30 - Clutch Prote AG.


pedal, if equipped.
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– Remove the washers -A- for the tdamper.
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or
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– Remove the damper. ss
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or c
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-A- in -direction of arrow-.
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Note
hole
spec
es, in part or in w
t to the co
rod.
rrectness of i
– Move the clutch pedal downward and remove the over-center
spring -4-.
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
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Installing C py
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Note Prote AG.


clutch pedal.
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es, in part or in w
t to the co
rrectness of i
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tion in
r
te o
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– Install the footwell vent -3-, refer to ⇒ Rep. Gr. 80 .
– Install the knee airbag bracket, refer to ⇒ Interior Equipment;
Rep. Gr. 69 ; Airbag; Bracket, Knee Airbag, Removing and
Installing (Golf from MY 2009) .
Component Nm

column
3.1.4 Over-Center Spring, Golf Plus

Removing
– Carefully cut the cable tie -1-.
– Remove the cable guide -2- from the steering column. olkswage es n
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db
– Remove the footwell vent -3-, refer to ⇒ Heating, rVentilation ran
ise tee
and Air Conditioning; Rep. Gr. 80 ; Heating, Servicing
ut
ho . or
a ac
ss
ce
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nl
pt
du
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ab
ility
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spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
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ate
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en
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44
cted agen
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Rep. Gr.30 - Clutch
– Remove the bolt -B- and the crash bolster -A- in front of the
clutch pedal.
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– Remove the nuts
au -arrows- and the footwell trim panel.
th or
ac
ss
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d
itte
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rm
ab
pe
ility
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, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
– Remove the bolt -1- and the universal joint -2- from the steer‐
ing gear.
nform
mercia
a
com
tion in
r
te o
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pedal, if equipped.

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– Remove the damper. agen oes
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is n
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t to the co
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cial p
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mer
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c
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Note
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The clutch pedal remains engaged by
Vin
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s
master cylinder actuator
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– Move the clutch pedal
s downward
s and remove the over-center
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spring -4-.
nl
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ility
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Installing
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nf
ercia
orm
m
atio
om
n in
or c
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– Install the over-center spring into the bracket from the top.
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– Press the clutch pedal slightly, push the bolt through and tight‐ cted agen
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clutch pedal.

– Install the crash bolster -A- and tighten the bolt -B- to the tight‐
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es, in part or in w
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– Mount the universal joint -2- on the steering gear and install
l purpos
the new bolt -1-, refer to ⇒ Suspension, Wheels, Steering;

Rep. Gr. 48 ; Overview - Steering Column .
nform
ercia
– Perform a basic setting on the Steering Angle Sensor - G85-

m
a
using the Vehicle Diagnostic Tester .
com
tion in
r
te o
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Component Nm
t. Cop py
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Crash bolster to mounting bracket/steering M6 bolt = 5

column
column
3.1.5 Over-Center Spring,Passat

Removing
– Remove the mounting bracket, refer to
⇒ “3.3.5 Mounting Bracket, Passat”, page 71 .
– Carefully tension the lower area of the clutch pedal in a vise
with protective jaws.
– Remove the clutch pedal from the clutch master cylinder, refer
to ⇒ “3.2.2 Clutch Pedal,Passat”, page 50 .
– Remove the over-center spring from the clutch pedal in direc‐
tion of -arrow 1- and at the same time move the bracket in
direction of -arrow 2-.
– Carefully release the tension on the over-center spring.

– Move the bracket again into the end position and remove the
over-center spring.
Installing
• The clutch pedal is separated from the clutch master cylinder.
– Carefully tension the lower area of the clutch pedal in a vise
with protective jaws.
– Install the over-center spring into the bracket.
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– The mounting area -arrow- for the clutch pedal pivotorispin -A-
e nte
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must be positioned vertically. aut
h
ra
ss c
– Mount the Over-Center Spring Assembly Tool - T10178- in the
ce
le
un
pt
center area of the over-center spring and move the mounting
an
d
itte
bracket upward.
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rm
ab
pe
ility
– Squeeze the over-center spring in direction of -arrow 1-.
ot
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, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
– At the same time move the bracket just far enough downward
in direction of -arrow 2- until the over-center spring can be
l purpos
pushed onto the clutch pedal mounting pin -A-.
nform
ercia
WARNING
m
a
com
tion in
If installed incorrectly, the over-center spring will jump uncon‐
r
te o
trolled out of the mounting bracket.
thi
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iva
do
r
Place a cloth under the over-center spring.

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en
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Check the function of the over-center spring.

n
t.
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.
Move the bracket up and down a few times.
ht rig
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– Attach the clutch pedal to the clutch master cylinder, refer to
⇒ “3.2.2 Clutch Pedal,Passat”, page 50 .
– Install mounting bracket, Passat, refer to
3.2 Clutch Pedal

⇒ “3.2.1 Clutch Pedal,Golf from MY 2004, Golf from MY 2009 and
Golf Plus”, page 49
⇒ “3.2.2 Clutch Pedal,Passat”, page 50
3.2.1 Clutch Pedal,Golf from MY 2004, Golf

from MY 2009 and Golf Plus
Torque Wrench 1331 5-50Nm - VAG1331-

Removing the Over-Center Spring First:

Golf from MY 2004, refer to
Golf from MY 2009, refer to
Golf Plus, refer to
⇒ “3.1.4 Over-Center Spring, Golf Plus”, page 44
– Release the clutch pedal from clutch master cylinder using the
Clutch Pedal Pliers - T10005- .
– Remove the clutch pedal.
Installing
Note
– Attach the mount -2- to the clutch master cylinder actuator rod
-1-.
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Installing the Over-Center Spring and sClutch Pedal: c
ce
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un
pt
Golf from MY 2004, Refer to ⇒ Fig. ““Installing”“ , page 34 .
an
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itte
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Golf from MY 2009, Refer to ⇒ Fig. ““Installing”“ , page 59
erm
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ility
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Golf Plus, Refer to ⇒ Fig. ““Installing”“ , page 47
wit
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rrectne
3.2.2 Clutch Pedal,Passat

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inform
mer

atio
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o
n
c
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or
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Removing
t
sd
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– Remove the mounting bracket, refer to

um
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fo
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ng
⇒ “3.3.5 Mounting Bracket, Passat”, page 71 . yi

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– Carefully tension the bracket in a vice. Use jaw protectors. t. C rig
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– Move the clutch pedal foreword and remove the over-center
spring -4-.
– Release clutch pedal from master cylinder with Clutch Pedal
Pliers - T10005- .
– Remove the clutch pedal.

Installing
Install in reverse order of removal. Note the following:
Note
– Install the mount -2- on the clutch master cylinder actuator rod
-1-.
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Vehicles With a Knee Airbag
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Removing
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cylinder as far as the stop.
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Golf 2004 ➤ , Golf 2009 ➤th, Golf Plus 2005 ➤ , Golf Plus 2009 ➤ , Pass
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Rep. Gr. 68 ; Storage Compartments, Covers and Trim .

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a
com
tion in
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te o
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– Remove the bolt -2- and the crash bolster -1-. t. Cop py
rig
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Prote AG.
– Remove the clip -1- (if present) and move the Front Parking
Aid Warning Buzzer - H22- -2- in the direction of -arrow-.
– Remove the insulation if the lower mounting bracket nuts are

covered -arrows-.
The upper nut -1- is accessible through the opening of the lower

– Pull the mounting bracket -3- off the studs.

Installing
Note
AG. Volkswagen AG d
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♦ Replace the self-locking
Volnuts.
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oes
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ed
♦ Replace the hose orisclamps nte
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♦ Allocate all components
ss according to the Parts Catalog. c
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an
– If present, install the clip for the Front Parking Aid Warning
itte
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Buzzer - H22- , refer to ⇒ Electrical Equipment; Rep. Gr. 94 ;
erm
ab
Parking Aid .
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spec
es, in part or in w
t to the co
rrectness of i
– Install the lower steering column trim, refer to ⇒ Body Interior;
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Rep. Gr. 68 ; Storage Compartments, Covers and Panels .

– Install the driver side footwell cover, refer to ⇒ Body Interior;
nf
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Rep. Gr. 68 ; Storage Compartments, Covers and Trim .
orm
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– Press the hose/line assembly -1- and seal -2- onto the clutch t. C rig
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master cylinder connection -4- until the clip -3- clicks into yri
p by
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place.
c by lksw
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Prote AG.
Component Nm
Crash bolster 20
3.4 Clutch Master Cylinder


Removing
– Remove the mounting bracket, Golf from MY 2004, refer to
⇒ “3.3.1 Mounting Bracket,Golf from MY 2004”, page 52 .
– Remove the mounting bracket, Golf from MY 2009, refer to
⇒ “3.3.2 Bracket,Golf from MY 2009”, page 56 .
– Remove the mounting bracket, Golf Plus, refer to
⇒ “3.3.4 Mounting Bracket, Golf Plus”, page 66 .
– Remove the mounting bracket, Passat, refer to
– Disengage the mount for the clutch master cylinder actuator
rod using the Clutch Pedal Pliers - T10005- .
n AG. Volkswagen AG
– Place a spacer -A- between olks
wthe
ageclutch pedal and the
doesstop and
not
then push the clutch pedal
d by V as far as the spacer. gu
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♦ Spacer length =uapproximately
tho 40 mm (for example 1/2 sock‐ e or a
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et). ss
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– Disengage the securing bracket -B- and remove the clutch

an
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master cylinder from the bracket in direction of

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-arrows 1 and 2-.

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Removing
, is n
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hole
• Move the clutch pedal up to the stop in its resting position.

spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
– Install the mount -2- on the clutch master cylinder actuator rod
om
ion
-1-.
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ate
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en
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t. rig
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Prote AG.

– Place a spacer -A- between the clutch pedal and the stop and
then push the clutch pedal as far as the spacer.
♦ Spacer length = approximately 40 mm (for example 1/2 sock‐
et).
– Install the clutch master cylinder on the bracket in direction of
-arrows 1 and 2-.
– Push the clutch master cylinder actuator rod -1- in direction of

arrow until the mount -2- clicks into the place in the clutch
pedal.
– Install the mounting bracket, Golf from MY 2004, refer
n Ato
G. Volkswagen AG d
wage oes
⇒ “3.3.1 Mounting Bracket,Golf from MY 2004”,
yV
o page 52 .
lks not
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– Install the mounting bracket, Golf from rMY
is 2009, refer to tee
tho
⇒ “3.3.2 Bracket,Golf from MY 2009”,sa
u page 56 . or
ac
s
– Install the bracket, Golf Plus, refer to
ce
le
un
pt
⇒ “3.3.4 Mounting Bracket, Golf Plus”, page 66 .
an
d
itte
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erm
ab
– Install the mounting bracket, Passat, refer to
ility
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3.5 Clutch Position Sensor - G476-
spec
t to the co
♦ Hose Clamps - Up To 25 mm - 3094- rrectne
Removing
ss
anti-theft code.
o
cial p
f inform
mer
atio
om
n
c
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Prote AG.

If a Hose/Line Assembly or Plastic Line -1- with a Round Com‐
ponent is Installed Directly Below the Master Cylinder, then it is
Necessary to Remove the Hose/Line Assembly or Plastic Line.
Note
While performing the following work, make sure no brake fluid

comes into contact with the longitudinal member or the transmis‐
sion. If it does, clean the area thoroughly.
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– Clamp off the supply hose
aut to the master cylinder using a Hose ra
s c
Clamps - Up To 25mm s - 3094- .
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– Disengage the locking clamp -2- using a screwdriver or a poin‐
an
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ted tool and pull the master cylinder out until it stops.
erm
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ility
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– Remove the hose/line assembly or plastic line -1- from the
wit
is n
master cylinder and seal it.
h re
ole,
spec
cylinder in direction of -arrow- and remove it.

t to the co
rrectne
– Disconnect the connector -4-.

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Installing
f inform
mer

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Note
thi
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♦ Replace the hose clamps

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♦ Allocate all components according to the Parts Catalog. t. Cop py
rig
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If the Hose/Line Assembly or Plastic Line was Removed:
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Prote AG.

– Press the hose/line assembly -1- or plastic line into the master
cylinder connection -4- with the new seal -2- until the securing
clip -3- engages audibly.
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Special toolsorisand
ed
workshop equipment required nte
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♦ Torque
ss a Wrench 1331 5-50Nm - VAG1331- c
ce
e
Removing
nl
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anti-theft code.
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h re

hole
spec
es, in part or in w
– Remove the complete air filter housing if the slave cylinder is

t to the co
not accessible, refer to ⇒ Rep. Gr. 23 ; Diesel Direct Injection

System, Servicing or ⇒ Rep. Gr. 24 ; Fuel Injection System,
Servicing .
rrectness of i
– Remove the shift cable lock washer -arrow 1- from the selector
l purpos
lever -A-.
– Remove the shift cable from the pins.
nform
ercia
Metal Relay Lever

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at
om
io
– Remove the selector cable circlip -2- from the relay lever -B-.
n
c
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or
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– Remove the selector cable from the pins.

ate
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– Remove the lock washer -arrow 3- from the relay lever -B- and
um
for
then remove the relay lever.

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Plastic Relay Lever t. C rig
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– Remove the relay lever together with the cable retainer from
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the transmission, refer to
agen
Prote AG.
⇒ “3.4 Plastic Relay Lever”, page 127 .
– Remove the nut -arrow 4- and then remove the transmission
shift lever -A-.

– Remove the cable mounting bracket from the transmission

-arrows-.
– Tie up the shift cable and the selector cable.
– Remove the bracket -B- from the transmission and then pull it
off the hose/line assembly -A-.
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– Remove the transmission support -arrows A-.
t to the co
– Place a lint-free cloth under the master cylinder.
– Remove the clamp for the hose/line assembly from the clutch
rrectness of i
slave cylinder.
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– Pull the hose/line assembly out of the slave cylinder and plug
it.
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– Remove the clutch slave cylinder -arrows B-.
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Caution
or
thi
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Do not press the clutch pedal anymore.
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Installing t. C rig
gh ht
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by
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Prote AG.

– Install the clutch slave cylinder and tighten the bolts

-arrows B- to the tightening specification.
– Attach the hose/line assembly to the clutch slave cylinder.
– Push the pipe/hose line clamp all the way in.
– Install the transmission support -arrows A-.
– Bleed the clutch system after installing the clutch slave cylin‐
der, refer to ⇒ “1.1 Clutch System, Bleeding”, page 16 .
Assemble the gearshift mechanism, refer to
⇒ “2.6 Operating Cables Assembly Overview, Cable Bracket and
Metal Relay Lever”, page 101 .
Adjust the gearshift mechanism, refer to
⇒ “2.8 Selector Mechanism, Adjusting”, page 106 .
Injection System .
– Connect the battery ground cable, refer to ⇒ Electrical Equip‐
ment; Rep. Gr. 27 ; Battery, Disconnecting and Connecting .
Clutch slave cylinder to transmission -item 9-
⇒ Item 9 (page 25) .
Transmission support to transmission bracket and transmission:

– Replace the bolts.
– Tighten all bolts hand-tight.
– Tighten the bolt -arrows- to 20 Nm +90°.
AG. Volkswagen AG d
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3.7 Clutch Release Mechanism, Servicing

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ole,
spec

t to the co
Remove and Install the Clutch Release Lever with the Release
Bearing
rrectne
– Unhook the spring -arrow 1-.

– Remove the clutch release lever -arrow 2- and release bear‐
s
ing.
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f in
– Install in reverse order of removal.

form
mer
atio
om
n
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Cop py
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rig ht
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Prote AG.

Removing and Installing the Release Bearing

– Squeeze the hooks -arrows- on the back of the clutch release
lever and remove the release bearing -A- from the clutch re‐
lease lever.
– Press the release bearing -A- into the clutch release lever until
the hooks -arrows- engage.
3.8 “Sachs” Clutch

♦ Flywheel Retainer - 3067-
♦ Alignment Tool - Clutch Plate - 3190A-
♦ Grease for Clutch Disc Shaft Splines - G 000 100-
Removing
Note
♦ Replace clutch plates and pressure plates if the rivets are

damaged or loose.
♦ Replace the pressure plate and the clutch plate together.
♦ Either a “Sachs” or a “LuK” clutch may be installed.
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gen AG d
♦ Allocate clutch disc and Vthrust
olks plate using the engines ncode,
wa oe
ot
refer to the Parts Catalog.
ed
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ris nte
o
Clean the inputaushaft splines and (on used clutch plates) the or a
e
♦ th
hub splines. Remove
ss any corrosion and then apply a very thin c
coat of Grease for Clutch Disc Shaft Splines - G 000 100- on
ce
e
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the splines. Then move the clutch plate back and forth on the
an
itte
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input shaft until the hub moves freely on the shaft. Remove
erm
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any excess grease.

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♦ The pressure plates are corrosion-protected and lubricated.

h re
Only the running surfaces may be cleaned. Otherwise the

hole
spec
service life of the clutch will be shortened considerably.

es, in part or in w
t to the co
♦ The pressure plate contact surface and the clutch plate lining
must completely touch the flywheel. Install the bolts.
♦ Make sure the alignment bushings for centering the engine/
rrectness of i
transmission are installed inside the cylinder block. Install

l purpos
them if necessary.
♦ If the alignment sleeves are missing, it will be difficult to shift,
nform
ercia
there will be clutch problems and the transmission may make

noises (loose rattling).
m
at
om
ion
c
in t
• Remove the transmission.

or
his
ate
do
riv
– Insert Flywheel Retainer - 3067- to loosen the bolts.

p
cum
for
– Loosen the bolt diagonally in small steps.

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ng
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• When loosening, the stop -2- and the bolt -1- must loosen up . C rig
ht ht
together.
rig by
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cted agen
Prote AG.

– If the stop does not loosen: push the bolt toward the dual mass
flywheel.
– Remove the pressure plate and the clutch plate.
Installing
AG. Volkswagen AG d
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Note orise
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♦ Replace the pressure plate and the clutch plate together. Al‐ ss c
ce
e
locate thrust plate and clutch disc according to the engine
nl
pt
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code, refer to the Parts Catalog.
an
itte
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ab
♦ Check whether there are centering sleeves for the engine/
ility
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transmission in the cylinder block; install if necessary.
wit
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spec
es, in part or in w
t to the co
Clutch Plate Installed Position
rrectness of i
• “Getriebeseite” (transmission side) faces the transmission.
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Check the Ends of the Diaphragm Spring p by
co Vo
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• Wear up to half the thickness of the diaphragm spring Prote AG.
-arrows- is permitted.
Checking the Spring Connections and Rivet Connections

– Check the spring connections between the pressure plate and
the cover for cracks and make sure the rivet connections are
tight.

– Move the Flywheel Retainer - 3067- during installation.
lkswage es n
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ir se tee
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a ac
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ility
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When Installing, Tighten Bolts as Follows so Pressure Plate Does
h re
Not Distort (Causing Shuddering on Acceleration) :
hole
spec
– Make sure the stop pin (position sensor) -arrow- moves easily.
es, in part or in w
t to the co
• When doing this, the stop pin -arrow- must lift off from the
pressure plate.
rrectness of i
– Position the pressure plate on the alignment pins.
l purpos
– Use Alignment Tool - Clutch Plate - 3190A- to center the clutch

plate.
nf
ercia
– Install all the bolts evenly, by hand, until the bolt heads contact
orm
the pressure plate.
m
atio
om
n in
c
– Tighten the bolts in small steps and in diagonal sequence to

or
thi
prevent damaging the centering holes of the pressure plate
te
sd
a
and the centering pins of the dual mass flywheel.

iv
o
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rp
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Tightening specification: -item 4- ⇒ Item 4 (page 27)

f
en
ng
t.
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op
• Install the transmission.
C py
t. rig
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Prote AG.

3.9 “LuK” Clutch

Removing
AG. Volkswagen AG d
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Note rised
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♦ Replace clutch plates and pressure plates if the rivets are ss c
ce
le
damaged or loose.
un
pt
an
d
itte
♦ Replace the pressure plate and the clutch plate together.
y li
erm
ab
ility
♦ Either a “Sachs” or a “LuK” clutch may be installed.
ot p
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is n
♦ Allocate clutch disc and thrust plate using the engine code,
h re
ole,
refer to the Parts Catalog.
spec
♦ Clean the input shaft splines and (on used clutch plates) the
t to the co
hub splines. Remove any corrosion and then apply a very thin
coat of Grease for Clutch Disc Shaft Splines - G 000 100- on
the splines. Then move the clutch plate back and forth on the
rrectne
input shaft until the hub moves freely on the shaft. Remove
any excess grease.
ss o
♦ The pressure plates are corrosion-protected and lubricated.
cial p
f in
Only the running surfaces may be cleaned. Otherwise the
form
mer
service life of the clutch will be shortened considerably.
atio
m
♦ The pressure plate contact surface and the clutch plate lining
o
n
c
i
must completely touch the flywheel. Install the bolts.
or
n thi
te
sd
va
♦ Make sure the alignment bushings for centering the engine/

i
o
pr
cum
r
fo
en
ng
them if necessary.
t.
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Cop py
♦ If the alignment sleeves are missing, it will be difficult to shift, ht. rig
rig ht
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noises (loose rattling). Prote
cted AG.
agen
• Remove the transmission.

– Insert Flywheel Retainer - 3067- to loosen the bolts.
– Loosen the bolt diagonally in small steps.
– Remove the pressure plate and the clutch plate.
Installing
Note
♦ Replace the pressure plate and the clutch plate together. Al‐
locate thrust plate and clutch disc according to the engine
code, refer to the Parts Catalog.
♦ Check whether there are centering sleeves for the engine/
transmission in the cylinder block; install if necessary.
Clutch Plate Installed Position

• “Getriebeseite” (transmission side) faces the transmission.

Check the Ends of the Diaphragm Spring lkswage es n
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yV ua
• Wear up to half the thickness of the diaphragm spring ir se
d b ran
tee
-arrows- is permitted. utho
or
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ss
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itte
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erm
ab
ility
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, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
– Check the spring connections -arrows A- for damage and
make sure the rivet connections -arrows B- are tight.
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
Only Check Position of Adjustment Mechanism with New Pres‐
t. rig
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Prote
• Both edges -A- of the adjusting ring must be located between
AG.
both notches -arrows B-.

• If the adjusting ring takes on a different position with new pres‐
sure plates, pressure plate and clutch plate must not be in‐
stalled.
• With used clutches, the adjusting ring may take on a position
outside of the notches.

– Move the Flywheel Retainer - 3067- during installation.

– Position the pressure plate on the alignment pins.
– Use Alignment Tool - Clutch Plate - 3190A- to center the clutch
plate.
When Installing, Tighten Bolts as Follows so Pressure Plate Does
Not Distort (Causing Shuddering
gen Aon
G. VAcceleration)
olkswagen AG :
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olks no
– Install all the boltsdevenly,
by
V by hand, until the bolt heads
t gucontact
ara
the pressure plate.
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ise nte
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h
ut or
– Tighten the
ss bolts in small steps and in diagonal sequence to c
a a
prevent damaging the centering holes of the pressure plate
ce
le
un
pt
and the centering pins of the dual mass flywheel.
an
d
itte
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rm
Tightening specification: -item 4- ⇒ Item 4 (page 28)
ab
pe
ility
ot
• Install the transmission.
wit
, is n
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hole
spec
3.10 Clutch, With Single Flywheel
es, in part or in w
t to the co
rrectness of i
♦ Alignment Tool - Clutch Plate - 3190A-
l purpos
nform
ercia
Centering the Clutch Plate and Removing and Installing Pressure

Plate.
m
a
com
tio
– Loosen or tighten the bolts diagonally and in steps.
n in
r
te o
thi
– Install the Flywheel Retainer - 3067- when removing.

s
iva
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cum
fo
en
ng
Note
t.
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Cop py
t. rig
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The pressure plate contact surface and the clutch plate lining yri
p by
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must completely touch the flywheel. Tighten securing bolts in di‐
c by lksw
cted agen
agonal sequence equally so that centering holes of pressure plate
Prote AG.
and centering pins of flywheel do not become damaged.
Check the Ends of the Diaphragm Spring

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


– Check the spring connections between the pressure plate and
the cover for cracks and make sure the rivet connections are
tight.
• Replace the pressure plate if the spring connections are dam‐
aged or if the rivet connections -arrows- are loose.
AG. Volkswagen AG d
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ility
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, is n
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spec
es, in part or in w
t to the co
rrectness of i
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orm
m
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om
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or c
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t.
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Cop py
t. rig
gh ht
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co lksw
by
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Prote AG.

4 Special Tools
Special tools and workshop

equipment required
♦ Hose Clamps - Up To
25mm - 3094-
♦ Torque Wrench 1331
5-50Nm - VAG1331-
♦ Hose Clip Pliers -
VAS5024A-
AG. Volkswagen AG d
agen oes
olksw not
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d by ara
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ss c
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erm
ab
ility
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is n
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ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
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pr
cum
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t.
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Cop py
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4. Special Tools 87

♦ Alignment Tool - Clutch agen
AG. Volkswagen AG d
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Plate - 3190A- olksw not
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♦ Torque Wrench 1331 horis
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5-50Nm - VAG1331- aut ra
ss c
ce
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♦ Grease for Clutch Disc
un
pt
Shaft Splines - G 000 100-
an
d
itte
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rm
ab
pe
ility
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, is n
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es, in part or in w
t to the co
rrectness of i
l purpos
nform
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com
tion in
r
te o
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s
iva
do
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en
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t.
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Cop py
ht. rig
rig ht
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cted agen
Prote AG.

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♦ Brake Charger/Bleeder Unit - VAG1869-
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♦ Brake Charger/Bleeder Unit - VAS5234- or
4. Special Tools 89
34 – Controls, Housing
⇒ “1.1 Transmission Fluid, Checking and Filling”, page 90
1.1 Transmission Fluid, Checking and Fill‐

ing
It is not possible to check the transmission fluid level by removing
oil filler plug.
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♦ Hose (approximately 600 mm long, outside diameter 10 mm)

with commercially available funnel.
1.1.1 Preparing
Transmission fluid specification for the manual transmission, refer
to the Parts Catalog.
– Remove the entire air filter housing, refer to ⇒ Rep. Gr. 23 or
⇒ Rep. Gr. 24 .
90 Rep. Gr.34 - Controls, Housing


Clean the transmission.
Caution
To drain the transmission fluid, it is necessary to remove the

journal for shift forks in transmission.
To avoid that the position of the shift forks is changed, for ex‐
ample by involuntarily operating shift mechanism, shift rod
must be secured.
Hold the Gearshift Shaft Secure as Follows:
– Push the gearshift shaft in direction of -arrow 1-.

– While press the gearshift shaft down, rotate the bracket -A- in
direction of -arrow 2- upward andensimultaneously press it in
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Use a Clean Container (3 liters (3.17 quarts)) That Has Scale

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• Shift rod is secured, refer to ⇒ Fig. ““”“ , page 91
rrectness of i
– Remove the drain plug -arrow 1- and the pivot pin -arrow 2-
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and drain the transmission fluid.

– Install the pivot pin -arrow 2- with a new O-ring -item 7-
nform
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⇒ Item 7 (page 115) .

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– Install the drain plug -arrow 1- -item 17-
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⇒ Item 17 (page 117) .

– Turn the bracket -A- back into its initial position in direction of
-arrow- so that the shift rod can move freely again.
1.1.3 Transmission Fluid, Filling

Add Transmission Fluid into the Container To 1.8 Liters (1.9
Quarts).
Transmission fluid specification for the manual transmission, refer
to the Parts Catalog.
– Remove the Back-Up Lamp Switch - F4- -arrow-.
– Connect a 10 mm diameter hose that is approximately 600 mm
long to a funnel.
– Insert the hose into mounting hole in the back-up lamp switch
(second technician) and fill the transmission fluid.
– Install the Back-Up Lamp Switch - F4- -arrow- -item 2-
⇒ Item 2 (page 119) .
– Check function of shift mechanism, refer to
⇒ “2.8.1 Function”, page 108 .
– Install the entire air filter housing, refer to ⇒ Rep. Gr. 23 or ⇒
Rep. Gr. 24 .
– Install the noise insulation, refer to ⇒ Body Exterior; Rep. Gr.
50 ; Noise Insulation .
AG. Volkswagen AG d
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⇒ “2.1 Shift Mechanism Installation Position”, page 93
⇒ “2.2 Overview - Gearshift Mechanism”, page 95
⇒ “2.3 Overview - Gearshift Knob and Cover”, page 95
⇒ “2.4 Overview - Gearshift Lever and Gearshift Housing, through
10/2006”, page 97
⇒ “2.5 Overview - Gearshift Lever and Gearshift Housing, from
11/2006”, page 99
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⇒ “2.6 Operating Cables Assembly Overview, Cable Bracket and agen does
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⇒ “2.11 Overview - Transmission Disassembling and Assem‐
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spec
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t to the co
⇒ “2.12 Overview - Transmission Housing Cover and 5th Gear,
Removing and Installing”, page 113
⇒ “2.13 Overview - Transmission Housing and Gearshift Mecha‐
rrectness of i
nism, Removing and Installing”, page 115
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⇒ “2.14 Transmission Housing and Clutch Housing Assembly

Overview”, page 116
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⇒ “2.15 Overview - Shift Unit”, page 119

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⇒ “2.16 Overview - Shift Forks”, page 120
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⇒ “2.17 Input Shaft, Output Shafts, Differential and Shift Forks”,
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2.2 Overview - Gearshift Mechanism
Note
♦ Note radio code on vehicles with coded radio.

♦ Disconnect the ground cable from the battery when working on the gearshift mechanism inside the engine
compartment, refer to to ⇒ Electrical Equipment; Rep. Gr. 27 ; Battery, Disconnecting and Connecting .
♦ Read the information on what to do after connecting the battery, refer to ⇒ Electrical System; Rep. Gr. 27 ;
Battery, Removing and Installing .
♦ When working on the selector mechanism in the engine compartment, remove the complete air filter housing,
if it is located above the selector mechanism, refer to ⇒ Rep. Gr. 23 ; Diesel Direct Injection System,
Servicing or ⇒ Rep. Gr. 24 ; Fuel Injection System, Servicing .
♦ The shift mechanism must be removed in order to replace the operating cables, refer to
⇒ “3.5 Selector Mechanism”, page 129 .
♦ Do not bend the operating cables.
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Knob and Cover”, page 95 AG. Volkswagen AG d
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2.3 Overview - Gearshift Knob and Cover


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2 - Gearshift Knob
❑ With boot
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❑ The shift knob and boot
cannot be separated
s
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⇒ “3.1 Shift Knob with
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⇒ “3.3 Boot with Shifter
Knob and Noise Insula‐
tion, Passat”,
page 125 .
3 - Clamp
❑ For securing the shift
knob to the shift lever
❑ Secure on the gearshift
knob -item 2-
⇒ Item 2 (page 96) using
Hose Clamp Pliers -
VAG1275- .
❑ Always replace.
4 - Center Control Cover
❑ Combined in one piece with the upper center console section on some versions
5 - Noise Insulation
❑ Not on all vehicles
❑ Arrow on noise insulation points in direction of travel
❑ Retaining tab spacing varies
❑ Therefore can only be arranged in one position

2.4 Overview - Gearshift Lever and Gearshift Housing, through 10/2006
Note
♦ Lubricate the bearing areas and the sliding surfaces.

1 - Lock Washer
❑ Removing and instal‐ agen
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5 - TORX® Bolt, 5 Nm
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6 - Cover
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7 - Insulation
8 - Insulation
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9 - Bearing Shell
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10 - Gearshift Lever Guide

11 - Washer
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12 - Seal
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14 - Selector Housing
15 - Bearing Bushing
16 - Mounting Pin
17 - Guide Bushing
18 - Pressure Spring
❑ Installing, refer to ⇒ Fig. ““Installing the Pressure Spring”“ , page 98 .
19 - Selector Bracket
20 - TORX® Bolt, 5 Nm
21 - Seal
❑ Always replace.
22 - Base Plate
❑ Bend the tabs in order to remove
❑ Always replace.
❑ Attaching, refer to ⇒ “4.1.1 Base Plate, Installing”, page 219 .

23 - Selector Cable
❑ To the selector bracket
❑ Removing and installing, refer to
⇒ Fig. ““Detaching from the Selector Cable and the Shift Cable and Attaching”“ , page 98 .
24 - Gearshift Cable
❑ Removing from the shift lever guide and attaching to the shift lever guide, refer to
⇒ Fig. ““Detaching from the Selector Cable and the Shift Cable and Attaching”“ , page 98
25 - Lock Washer
❑ Always replace.
26 - Nut
❑ M6 nut: 8 Nm
❑ M8 nut: 25 Nm
❑ Quantity: 4
❑ Fits in one position only
28 - Lock Washer
❑ Always replace.
Detaching from the Selector Cable and the Shift Cable and At‐
taching
– Remove the lock washer from the shift cable -A- and the se‐
lector cable -B-.
Lift the tab with a screwdriver in direction of -arrow 1- and remove
the lock washer in direction of -arrow 2-.
– Remove the shift cable -A- from the gearshift lever mount.
– Remove the selector cable -B-
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– Install the compression spring so that the brace -A- contacts

upper part of pin -arrow-.
rrectness of i
– Pull the brace -B- downward so that it reached the bottom of

the pin -arrow-.
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2.5 Overview - Gearshift Lever and Gearshift Housing, ofrom 11/2006 th e
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♦ Gearshift Mechanism, Disassembling and Assembling, refer to
es, in part or in w
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⇒ “4.1 Gearshift Mechanism, from 11/2006”, page 216 .
rrectness of i
1 - Base Plate
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❑ Bend the tabs in order to

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❑ Always replace.
orm
❑ Attaching, refer to
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-item 15-
⇒ Item 15 (page 100) .
4 - Washer
❑ Slide out of shift lever as
far as stop -arrow-.
5 - Lock Washer
❑ Be careful not to dam‐
age the cables when re‐
moving them
❑ Always replace.
6 - Selector Cable
❑ Pry off of selector brack‐
et
❑ Press onto selector
bracket inside the shift
mechanism
to
⇒ “2.1 Shift Mechanism
Installation Position”,
page 93 .
7 - Bushing
8 - Gearshift Cable
❑ Pry off of shift lever guide
❑ Press onto shift lever guide inside the shift mechanism
❑ Installed position, refer to ⇒ “2.1 Shift Mechanism Installation Position”, page 93 .
9 - Insulation
10 - Bearing Shell
❑ Will get damaged when being removed
❑ Always replace.

11 - Bushing
12 - Lock Washer
❑ Removing and installing, refer to ⇒ Fig. ““Removing and Installing the Lock Washer”“ , page 100 .
13 - Pressure Spring
14 - Bushing
15 - Gearshift Lever Guide
16 - Nut
❑ M6 nut: 8 Nm
❑ M8 nut: 25 Nm
❑ Quantity: 4
17 - Seal
❑ Between the gearshift housing and the underbody
❑ Self-adhesive
❑ Affix to the gearshift housing
❑ With spring and selector bracket
❑ Spring and selector bracket cannot be removed
Removing and Installing the Lock Washer

– Push the spacer -arrow B- all the way in direction of
-arrow C- using a screwdriver and remove the circlip
-arrow A-.
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2.6 Operating Cables Assembly Overview, Cable Bracket and Metal Relay
Lever
Note

1 - Gearshift Cable
❑ Attach to the cable re‐
tainer -item 11-
⇒ Item 11 (page 102) .
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refer to -item 8-
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2 - Selector Cable
rrectness of i
❑ Attach to the cable re‐

tainer, refer to -item 10-
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bracket inside shift
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3 - Lock Washer
❑ Always replace.
❑ Discontinued on shift mechanisms from 11/2006, refer to
⇒ “2.7 Operating Cables Assembly Overview, Cable Bracket and Plastic Relay Lever”, page 104
5 - Lock Washer
❑ Always replace.
❑ Be careful not to damage the cables when removing them

6 - Hex Bolt
❑ 20 Nm
❑ Quantity: 3
❑ For the cable bracket
7 - Cable Mounting Bracket
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❑ Adjust the gearshift mechanism after installing, refer to
h re
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spec
❑ For attaching the selector cable to the relay lever
t to the co
❑ Do not interchange, cable locking mechanisms for selector cable on linkage lever and for shift cable on
transmission shift lever are different
rrectne
❑ Allocation, refer to ⇒ Fig. ““Cable Retainer Allocation”“ , page 103
11 - Cable Retainer
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❑ For attaching the shift cable to the transmission shift lever
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13 - Lock Washer
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❑ Always replace.
15 - Relay Lever
❑ Metal
❑ Installed position, refer to ⇒ Fig. ““Selector Lever/Relay Lever Installed Position”“ , page 104 .
❑ Install the metal relay lever into the bushings -item 14- ⇒ Item 14 (page 102) and secure it with a lock
washer -item 13- ⇒ Item 13 (page 102) .
❑ From 05/2007 plastic relay lever
16 - Sliding Shoe
17 - Gearshift Lever
❑ Installing, refer to ⇒ Fig. ““Installing the Transmission Shift Lever”“ , page 103 .
❑ As of 06/2006 smaller bolt diameter for the cable retainer, refer to
⇒ Fig. ““As of 06/2006, Smaller Bolt Diameter for the Shift Cable Retainer”“ , page 103

18 - Hex Nut
❑ 23 Nm
❑ Self-Locking
❑ Always replace.
Cable Retainer Allocation

These holes have different diameters.
Cable Retainer For: Dimension “a”
1.- shift cable to transmission shift lever from 8.5 mm
06/2006
2.- shift cable to transmission shift lever to 05.06 10 mm
2. - Selector cable to metal relay lever 8 mm
2. - Selector cable to plastic relay lever, refer to 10 mm
⇒ “3.4 Plastic Relay Lever”, page 127
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As of 06/2006, Smaller Bolt Diameter for the Shift Cable Retainer
, is n
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hole
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Shift Cable Retainer Mounting Screws Dimension “a”

es, in part or in w
t to the co
through 05/2006 10 mm
from 06/2006 8.5 mm
rrectness of i
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Installing the Transmission Shift Lever

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Selector Lever/Relay Lever Installed Position

1 - Gearshift Lever
2 - The relay lever fits into the sliding rail on the transmission se‐
lector lever via the sliding shoe -arrow-.
Cable Tie Installation Locations

– Wrap the cable tie -arrow- in a crossover pattern around the
cables and attach it as illustrated.
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2.7 Operating Cables Assembly Overview, Cable Bracket and Plastic Relay
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1 - Gearshift Shaft with Gear‐

shift Cover
2 - Sliding Shoe
3 - Relay Lever
❑ Plastic
❑ Allocation, refer to the AG. Volkswagen AG d
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Position”“ , page 104 .
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nism, Adjusting”,
spec
page 106 .
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❑ Plastic relay lever, Re‐
moving and Installing
with Cable Retainer, re‐
rrectne
fer to
⇒ “3.4 Plastic Relay
Lever”, page 127
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4 - Cable Retainer
inform
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❑ Adjust the gearshift
atio
mechanism after instal‐
om
ling, refer to
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⇒ “2.8 Selector Mecha‐
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page 106 .
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❑ For attaching the selec‐

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❑ Remove from the relay lever, refer to ⇒ “3.4 Plastic Relay Lever”, page 127
❑ Press onto the relay lever, refer to ⇒ “3.4 Plastic Relay Lever”, page 127
5 - Cable Retainer
❑ For attaching the shift cable to the transmission shift lever
6 - Lock Washer
❑ Always replace.
7 - Lock Washer
❑ Always replace.
8 - Selector Cable
❑ Attach to the cable retainer -item 4- ⇒ Item 4 (page 105) .

9 - Gearshift Cable
❑ Attach to the cable retainer -item 5- ⇒ Item 5 (page 105) .
11 - Lock Washer
❑ Always replace.
12 - Cable Mounting Bracket
❑ Plastic
❑ Adjust after installing the selector mechanism, refer to
13 - Hex Bolt
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❑ Quantity: 3
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❑ Cable mounting bracket to transmission
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15 - Spacer
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❑ Quantity: 3
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16 - Nut -item 7- ⇒ Item 7 (page 119)
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17 - Gearshift Lever
❑ Installing, refer to ⇒ Fig. ““Installing the Transmission Shift Lever”“ , page 103 .
❑ Adjust the gearshift mechanism after installing, refer to rrectness of i
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18 - Seal
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❑ Replacing, refer to -item 6- ⇒ Item 6 (page 119) .

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❑ ⇒ Relay lever with clip, refer to ⇒ Fig. ““Relay Lever With Clip -arrow 1-.”“ , page 127
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2.8 Selector Mechanism, Adjusting

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♦ Connecting Pin - T10027A-
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Note
♦ The following is important to make sure the gearshift adjust‐

ment is correct:
♦ The shift mechanism operating and transfer elements must
work properly.
♦ Shift mechanism must move freely.
♦ The transmission, clutch and clutch mechanism must also be
in proper condition.
• Transmission in neutral.

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– Remove the air filter housing if the elbow piece -A- and the
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lock mechanism of the shift cable and selector cable are not
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accessible, refer to ⇒ Rep. Gr. 23 ; Servicing the Diesel Direct
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Fuel Injection System or ⇒ Rep. Gr. 24 ; Servicing The Fuel
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– Pull the safety mechanism on the cable retainer for the shift
nform
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cable and the selector cable all the way forward in direction of
-arrow 1- and then lock it to the left in direction of -arrow 2-.
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Hold the gearshift shaft secure as follows:

– Push the gearshift shaft in direction of -arrow 1-.
– While press the gearshift shaft down, rotate the bracket -A- in
direction of -arrow 2- upward and simultaneously press it in
until it engages in the gearshift shaft.
– Removing and installing the boot with gearshift knob and noise
insulation. Golf, refer to
⇒ “3.1 Shift Knob with Boot and Noise Insulation, Golf ”, page
123 , Golf Plus
⇒ “3.2 Gearshift Knob with Boot and Noise Insulation, Golf
Plus”, page 124 , Passat
⇒ “3.3 Boot with Shifter Knob and Noise Insulation, Passat”,
page 125
– If equipped, remove the noise insulation.
Hold the gearshift shaft secure as follows:
– Move the gearshift lever into neutral.
– Guide the Connecting Pin - T10027A- through the hole -A- and
into the hole -B-.

– Now turn the locking mechanism on the shift cable retainer

and selector shaft toward the right as far as the stop direction
of -arrow-.
The spring will push the safety mechanism into the starting posi‐
tion.
– Turn the bracket -A- back into the starting position direction of
-arrow-. gen AG
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Note
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The bracket -A- must be pressed out of the selector housing as
far as the stop and it must face toward the rear. ss o
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– Pull the Connecting Pin T10027A out of the holes -A- and
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– If equipped, install the noise insulation.
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insulation. Golf
123 , Golf Plus
page 125
– Make sure the gearshift shaft moves easily.
– Install the entire air filter housing, if necessary, refer to ⇒ Rep.
Gr. 23 or ⇒ Rep. Gr. 24 .
2.8.1 Function
• The shift lever must rest in the 3rd/4th gear selector lever gate
when the transmission is in neutral.
– Operate the clutch.

– Move the gearshift lever (selector lever) several times through

all the gears. Pay particular attention to the operation of the
reverse gear lock.
– Should a gear fail to engage smoothly after repeated nselection,
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2.9 Overview - Subframe
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1 - Bolt
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❑ 20 Nm + 90°
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❑ Always replace.
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❑ Transmission support to
ole,
transmission bracket
spec
and transmission
t to the co
❑ Tightening sequence,
refer to
⇒ Fig. ““Transmission
rrectne
Support to Transmis‐
sion Bracket and Trans‐
s
mission”“ , page 110
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2 - Transmission Support
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❑ To the transmission
atio
m
bracket and transmis‐

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3 - Engine Mount with Engine

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Support
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❑ Refer to ⇒ Rep. Gr. 10 .

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5 - Pendulum Support
6 - Bolt
transmission
7 - Bolt
transmission
8 - Bolt
❑ 40 Nm + 90°
❑ Always replace.
❑ Transmission bracket to transmission.
9 - Transmission Bracket
10 - Transmission Mount
❑ Checking adjustment, refer to ⇒ Rep. Gr. 10 .
❑ Adjusting, refer to ⇒ Rep. Gr. 10 .
11 - Bolt
❑ Transmission mount to chassis

12 - Bolt
❑ 60 Nm + 90°
❑ Always replace.
❑ Transmission mount to transmission bracket
Attaching the Transmission Mount to the Transmission Bracket

– Replace the bolts -arrows-.
– Tighten the bolt to the tightening specification.
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Transmission Support to Transmission Bracket and Transmission
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– Tighten both bolts -arrows- hand-tight at first.
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2.10 Transmission Overview
1 - 1st Gear
2 - 2nd Gear
3 - 3rd Gear
4 - 4th Gear
5 - 5th Gear
6 - Transmission Housing Cov‐
er
7 - Transmission Housing
8 - Selector Mechanism
❑ (Shift forks)
9 - Reverse Drive Gear
10 - Clutch Housing
11 - Input Shaft
12 - Output Shaft
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13 - Differential yV
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Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus 2009 ➤ , APass
G. Volk...
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Manual Transmission - Edition 07.2014 agen does
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2.11 Overview - Transmission Disassembling and Assembling au
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I - Overview - Transmission
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Housing and 5th Gear Cover,
rm
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Removing and Installing, Refer
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ility
to
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⇒ “2.12 Overview - Transmis‐
h re
sion Housing Cover and 5th
hole
spec
Gear, Removing and Instal‐
es, in part or in w
ling”, page 113 .
t to the co
II - Overview - Transmission
Housing and Gearshift Mecha‐
rrectness of i
nism, Removing and Installing,
Refer to
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⇒ “2.13 Overview - Transmis‐
sion Housing and Gearshift
nform
ercia
Mechanism, Removing and In‐

stalling”, page 115 .
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III - Removing and installing in‐
n in
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put shaft, output shaft, differ‐

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ential and shift forks, Refer to
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⇒ “2.17 Input Shaft, Output
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Shafts, Differential and Shift
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Forks”, page 121 .
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gear, removing and attaching,
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Refer to
⇒ “3.12 Assembly Sequence,
Transmission Housing Cover
and 5th Gear”, page 206 .
Transmission, Assembly Se‐

quence, Disassembling and
Assembling, Refer to
⇒ “4.2 Transmission, Assem‐
bly Sequence”, page 220 .

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2.12 Overview - yTransmission Housing Cover and 5th Gear, Removing and In‐
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1 - Bolt
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❑ 18 Nm
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❑ Cover to transmission
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2 - Transmission Housing Cov‐
hole
spec
er
es, in part or in w
❑ From 11/2010 with mag‐
t to the co
net, refer to
⇒ Fig. ““Transmission
Housing Cover with a
rrectness of i
Magnet -A- ”“ ,
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page 114
Note
nform
mercia
♦ Note that oil will leak out when
a
com
tio
cover is removed with the trans‐
n in
r
mission installed.
te o
thi
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♦ Therefore the oil must be drained
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and then filled again later, refer
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to
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⇒ “1.1 Transmission Fluid, C py
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Checking and Filling”, page 90 .
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3 - Seal Prote AG.
4 - Bolt
❑ 80 Nm Plus 90° Addi‐
tional Turn
❑ Always replace.
❑ Hold with the adapter on
the plate spring bolt
head in position
❑ Clean synchronizer hub
and 5th gear drive gear
threaded holes of lock‐
ing compound residue
with a thread tap. Otherwise, there is the danger that the screws could shear off.
5 - Plate Spring
❑ Installing, refer to
⇒ Fig. ““Installed Position of Plate Springs for 5th Gear Synchronizer Hub and Drive Gear Securing
Bolts”“ , page 231 .
6 - Cylinder Bolt
❑ 25 Nm
❑ For the pivot pin to the transmission housing
7 - Pivot Pin
8 - 5th Gear Shift Fork
❑ Disassembling and assembling, refer to ⇒ “3.15 Shift Forks, Servicing”, page 214 .
9 - Spring
❑ Offset version
❑ Installing, refer to ⇒ Fig. ““Installation of Offset Springs -A- ”“ , page 270
10 - 5th Gear Locking Collar
❑ Installed position, refer to ⇒ Fig. ““5th Gear Locking Collar/Synchronizer Hub Assembly”“ , page 269 .

❑ Adjusting, refer to ⇒ Fig. ““Adjusting 5th Gear”“ , page 232 .
11 - Locking Pieces (quantity: 3)
❑ Installed position, refer to ⇒ Fig. ““5th Gear Synchronizing”“ , page 269 .
12 - Synchronizer Hub with Gear Wheel and 5th Gear Synchronizer Ring
❑ Remove together with the transmission housing, refer to
⇒ “4.2 Transmission, Assembly Sequence”, page 220
❑ Removing individually, refer to
⇒ “3.12 Assembly Sequence, Transmission Housing Cover and 5th Gear”, page 206
❑ Disassembling and assembling, refer to
⇒ Fig. ““5th Gear Locking Collar/Synchronizer Hub Assembly”“ , page 269 .
13 - Needle Bearing
14 - 5th Gear Wheel
❑ Remove together with the transmission housing, refer to
❑ Removing individually, refer to
⇒ “3.12 Assembly Sequence, Transmission Housing Cover and 5th Gear”, page 206
❑ Installed position, refer to ⇒ Fig. ““Installed Position, 5th Gear Wheel”“ , page 229 .
Transmission Housing Cover with a Magnet -A-

The magnet can be inserted only into a cover with a recess
-arrow-.
The magnet is held in place by the bolt for the 5th gear shift fork
pivot pin when the cover is installed.
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2.13 Overview - Transmission Housing and Gearshift Mechanism, Removing

and Installing
1 - Bolt
❑ 25 Nm
2 - Flange Shaft with Pressure
Spring
ling, refer to
⇒ “3.1 Flange Shaft
Seal, Left, With Installed
Manual Transmission”,
page 295 or
⇒ “3.2 Seal, Right, With
Installed Manual Trans‐
mission, Two-Part for
Flange Shaft and
Sleeve”, page 296 .. wage
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❑ Assembling, refer to d byV
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⇒ “4.1 Differential”, o
ir se
ran
tee
page 301 . auth or
ac
ss
3 - Inner TORX® Bolt
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❑ 25 Nm
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❑ Always replace.
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❑ For the reverse shaft
wit
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support
h re
ole,
❑ Self-locking
spec
4 - TORX® Socket Bolt
t to the co
❑ 30 Nm
❑ For the reverse shaft
rrectne
support
❑ Self-locking
ss o
❑ Always replace.
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5 - O-Ring
mer
atio
❑ Always replace.
om
n
c
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6 - Pivot Pin
thi
te
sd
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7 - Bolt
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9 - Cap Prote AG.
10 - Internal Multipoint Bolt

❑ 25 Nm
❑ For the reverse shaft support
❑ Always replace.
11 - Bolt
❑ 5 Nm
12 - Transmission Neutral Position Sensor - G701-
❑ For vehicles with the Start/Stop System
❑ Remove together with 5th gear, refer to ⇒ “4.2 Transmission, Assembly Sequence”, page 220 .

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❑ Servicing, refer to ⇒ “3.13 Transmission Housing
s and Clutch Housing, Servicing”, page 210 .
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14 - Clutch Housing
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❑ Servicing, refer to ⇒ “3.13 Transmission Housing and Clutch Housing, Servicing”, page 210 .
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15 - Hex Bolt
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❑ 25 Nm and 90° additional turn
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❑ Always replace.
spec
es, in part or in w
t to the co
16 - Gearshift Shaft with Gearshift Cover
❑ (Shift unit)
❑ Servicing, refer to ⇒ “3.14 Shift Unit, Servicing”, page 213 .
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17 - Internal Multipoint Bolt l purpos
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2.14 Transmission Housing and Clutch Housing Assembly Overview
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❑ When replacing: adjust
f
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Co
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⇒ “2.1 Adjustment Over‐ py by
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2 - Needle Bearing
❑ For the output shaft
❑ Removing, refer to
⇒ Fig. ““Removing the
Needle Bearing”“ , page
210 .
❑ Installing and securing,
refer to
⇒ Fig. ““Installing the
Needle Bearing”“ , page
211
3 - Oil Filler Plug
❑ 35 Nm
❑ The transmission fluid
level cannot be checked
by removing oil filler
plug.
❑ If transmission was dis‐
assembled, it must be
filled before being instal‐
led again.
❑ Manual transmission
bled)
♦ 2.0 liter (2.11 quarts)
❑ Manual transmission
capacity
⇒ “1.1 Transmission
Fluid, Checking and Fill‐
ing”, page 90 (transmission partly disassembled)
♦ 1.8 liters (1.9 quarts)
4 - Outer Race/Tapered Roller Bearing

❑ Removing and installing, refer to ⇒ “3.2 Output Shaft”, page 271 .
❑ When replacing: adjust the output shaft, refer to ⇒ “1.4 Output Shaft, Adjusting”, page 261 .
5 - Shim
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❑ For the output shaft agen oes
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6 - Shim tho eo
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❑ For the input shaft
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❑ Adjustment overview, refer to ⇒ “1.2 Input Shaft, Adjusting”, page 253 .
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❑ Removing and installing, refer to ⇒ “3.1 Input Shaft”, page 266 .
hole
spec
❑ When replacing: adjust the input shaft, refer to ⇒ “1.2 Input Shaft, Adjusting”, page 253
es, in part or in w
t to the co
rrectness of i
❑ Removing and installing, refer to ⇒ “3.1 Input Shaft”, page 266 .
❑ When replacing: adjust the input shaft, refer to ⇒ “1.2 Input Shaft, Adjusting”, page 253
l purpos
9 - Needle Sleeve
nform
ercia
❑ Removing and installing, refer to ⇒ “3.3 Reverse Shaft”, page 279 .

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at
10 - Alignment Sleeve
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ion
c
❑ Quantity: 2
in t
or
his
ate
11 - Clutch Housing
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❑ When replacing: ⇒ adjustment overview, refer to ⇒ “2.1 Adjustment Overview”, page 290
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❑ Removing the seal, refer to ⇒ Fig. ““Removing the Seal From the Guide Sleeve”“ , page 211
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❑ Installing the seal, refer to ⇒ Fig. ““Installing the Seal All The Way Into the Guide Sleeve”“ , page 211
❑ Remove the guide sleeve to replace the seal
❑ If the O-ring is damaged, then replace the guide sleeve and the O-ring
13 - Cylinder Bolt
❑ Removing and installing, refer to -item 6- ⇒ Item 6 (page 25) .
14 - Seal
❑ Replacing, refer to ⇒ “3.1 Flange Shaft Seal, Left, With Installed Manual Transmission”, page 295 or
⇒ “3.2 Seal, Right, With Installed Manual Transmission, Two-Part for Flange Shaft and Sleeve”,
page 296 ..
15 - Sleeve
❑ For the seal -item 14- ⇒ Item 14 (page 117)
❑ Removing, refer to ⇒ Fig. ““Prying out the Sleeve -arrow- ”“ , page 211 .
❑ Installing, refer to ⇒ Fig. ““Installing the Sleeve”“ , page 212 .
16 - Seal and Sleeve One-Piece
❑ If the seal is damaged, then replace both the seal and sleeve.
❑ Removing, refer to ⇒ Fig. ““Removing the Sleeve and Seal”“ , page 212 .
❑ Installing, refer to ⇒ Fig. ““Installing the Sleeve and Seal”“ , page 212 .
17 - Oil Drain Plug
❑ 35 Nm
❑ For the differential
❑ Removing and installing, refer to ⇒ “4.1 Differential”, page 301

❑ When replacing: adjust the differential, refer to ⇒ “2.3 Differential, Adjusting”, page 293
19 - Magnet
❑ Held in place by housing joint surface
20 - Oil Catch Tray
❑ Install the oil catch tray into the transmission housing, refer to
⇒ Fig. ““Installing the Oil Catch Tray -A- into the Transmission”“ , page 212
❑ Removing and installing, refer to ⇒ “4.1 Differential”, page 301
❑ When replacing: adjust the differential
Refer to ⇒ “2.3 Differential, Adjusting”, page 293
22 - Shim
❑ Adjustment overview, refer to ⇒ “2.1 Adjustment Overview”, page 290 .
23 - Seal
❑ Replacing, refer to ⇒ “3.1 Flange Shaft Seal, Left, With Installed Manual Transmission”, page 295 or
page 296 ..
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2.15 Overview - Shift Unit
1 - Gearshift Unit
❑ Consisting of the gear‐
shift shaft and the gear‐
shift cover
❑ The components cannot
be separated from each
other
2 - Back-Up Lamp Switch - F4-
❑ Tighten to 20 Nm.
❑ Coat the tab lightly with
MoS 2 grease.
swage es n
3 - Locking Elbow byV
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❑ For adjusting hor the shift
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mechanismaut or
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Locking Elbow -A- from
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the Shift Cover”“ ,
pe
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page 213 .
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hole
⇒ Fig. ““Pressing the
spec
Locking Elbow -A- Into
es, in part or in w
Selector Cover”“ ,
page 213 t to the co
4 - Relay Lever
rrectness of i

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⇒ Fig. ““Selector Lever/
Relay Lever Installed
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Position”“ , page 104 .

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❑ Plastic relay lever from

com
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05/2007, refer to
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⇒ “3.4 Plastic Relay

thi
s
Lever”, page 127 .

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5 - Bearing Bushing
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6 - Seal
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❑ Pry out with a screwdriver Prote
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agen
❑ Installing, refer to ⇒ Fig. ““Installing the Seal”“ , page 213 .

7 - Hex Nut
❑ 23 Nm
❑ Always replace.
❑ Self-locking
8 - Gearshift Lever
❑ Insert so that master spline aligns with shift rod
❑ Can be replaced with the shift mechanism still installed
9 - Cap
❑ For the transmission ventilation
10 - Lock Washer
❑ Always replace.

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aut Transmission - Edition 07.2014 or
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11 - Cap
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12 - Spring
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❑ Not installed in all transmissions
h re
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❑ Install if present
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t to the co
2.16 Overview - Shift Forks
rrectnes
Note
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The shift fork group (-item 7- ⇒ Item 7 (page 120) ) does not need
form
mer
to be disassembled to remove and install shift segments, lock
atio
m
washers and angular contact ball bearings.

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1 - 5th Gear Shift Segment

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❑ Identification, refer to
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Identification”“ , yri
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❑ The shift segment must Prote AG.
still rotate easily after

the lock washer is instal‐
led.
2 - Lock Washer
❑ Always replace.
Lock Washer”“ ,
page 214 .
Lock Washer”“ ,
page 214 .
3 - 5th Gear Shift Fork
4 - Bolt
❑ 25 Nm
5 - 5th Gear Shift Jaw
6 - Angular Contact Ball Bear‐
ing
❑ Quantity: 4
Angular Contact Ball
Bearing”“ , page 215 .
❑ Installing the bearing in‐
ner race into the outer
race, refer to
Angular Contact Ball Bearing Inner Race -A- into the Outer Race”“ , page 215
❑ Installing, refer to ⇒ Fig. ““Installing the Angular Contact Ball Bearing into the Shift Fork”“ , page 215 .
7 - Shift Fork Group with Gearshift Rails
8 - 1st/2nd Gear Shift Segment
❑ Identification, refer to ⇒ Fig. ““Shift Segment Identification”“ , page 214 .

❑ The shift segment must still rotate easily after the lock washer is installed.
9 - 3rd/4th Gear Shift Segment
❑ Identification, referwato
gen⇒AFig.
G. Vol““Shift Segment
kswagen AG
does Identification”“ , page 214 .
olks no
❑ The shift segment
db
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ua lock washer is installed.
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10 - Glide utho or
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11 - Spring
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12 - Reverse Gear Shift Fork
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13 - Support for the Reverse Gear Shift Fork
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14 - Locking Ring
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2.17 Input Shaft, Output Shafts, Differential and Shift Forks
rrectness of i
1 - Differential
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❑ Disassembling and as‐

sembling, refer to
⇒ “4.1 Differential”,
nform
ercia
page 301 .
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at
2 - Seal
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❑ Always replace.
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or
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❑ Quantity: 4
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3 - Output Shaft
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⇒ “3.2 Output Shaft”, py by
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page 271 .
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4 - Reverse Shaft Support
sembling, refer to
⇒ “3.3 Reverse Shaft”,
page 279 .
5 - Reverse Shaft
sembling, refer to
⇒ “3.3 Reverse Shaft”,
page 279 .
6 - Input Shaft
sembling, refer to
⇒ “3.1 Input Shaft”, page
266 .
7 - Reverse Gear Shift Fork
sembling, refer to
⇒ “3.15 Shift Forks,
Servicing”, page 214 .
to ⇒ “3.15 Shift Forks, Servicing”, page 214 .
8 - Inner TORX® Bolt
❑ 25 Nm
9 - Selector Mechanism
❑ (Shift forks)

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Manual Transmission -uthEdition 07.2014
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❑ Disassembling and assembling, refer to ⇒ “3.15 Shift Forks, Servicing”, page 214 .
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10 - Clutch Housing
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❑ Servicing, refer to ⇒ “3.13 Transmission Housing and Clutch Housing, Servicing”, page 210 .
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11 - Nut , is n
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❑ 25 Nm and 90° additional turn
hole
spec
❑ Always replace.
es, in part or in w
t to the co
❑ 4 nuts for the bearing mount
12 - Flange Shaft with Pressure Spring
rrectness of i
⇒ “3.1 Flange Shaft Seal, Left, With Installed Manual Transmission”, page 295 or
l purpos
page 296 .
nf
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❑ Assembling, refer to ⇒ “4.1 Differential”, page 301 .
orm
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atio
13 - Bolt
om
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❑ 25 Nm
or
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⇒ “3.1 Shift Knob with Boot and Noise Insulation, Golf ”,
page 123
⇒ “3.2 Gearshift Knob with Boot and Noise Insulation, Golf Plus”,
page 124
⇒ “3.3 Boot with Shifter Knob and Noise Insulation, Passat”, page
125
⇒ “3.4 Plastic Relay Lever”, page 127
⇒ “3.5 Selector Mechanism”, page 129
⇒ “3.6 Transmission, Golf from MY 2004”, page 133
⇒ “3.7 Transmission, Golf from MY 2009, with Turbo Diesel”, page
146
⇒ “3.8 Transmission, Golf from MY 2009, Gasoline Engine”, page
161
⇒ “3.9 Transmission, Golf Plus”, page 177
⇒ “3.10 Transmission, Passat”, page 193
⇒ “3.11 Transmission, Transporting”, page 205
⇒ “3.12 Assembly Sequence, Transmission
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⇒ “3.14 Shift Unit, Servicing”, page 213
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⇒ “3.15 Shift Forks, Servicing”, page 214

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3.1 Shift Knob with Boot and Noise Insula‐

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♦ Hose Clip Pliers - VAG1275A-
rrectne
Removing
s
– Pull boot upward out of center console frame or carefully pry

s o
out -arrows-.
cial p
f inform
On Some Equipment Versions, You Must Pry Out Boot At Front

mer
Area.
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– Roll the boot up over the shift knob.
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– Open the clamp -arrow- and
or
iseremove the shift knob and boot. nte
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In some equipment versions,
ss
a the center console frame remains c
in the center console.
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t to the co
– Then the center console frame must be pulled out or carefully
rrectne
pried out -arrow 1-.
– Remove the noise insulation -arrow 2-.
ss o
Installing
cial p
f inform
– Install the noise insulation.
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Installation Location, Noise Insulation:
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-Arrow A- points in direction of travel. cted agen
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The tabs -arrows B- must latch into the center console.

– Then press frame into center console.
– Then turn inner side of boot toward outside.
Install the shift knob all the way on.
– Install the shift knob and boot and press the new clamp to‐
gether -arrow-.
– Then press boot into frame in center console.
3.2 Gearshift Knob with Boot and Noise In‐

sulation, Golf Plus

Removing
– Pull boot upward out of center console frame or carefully pry
out -arrows-.
On Some Equipment Versions, You Must Pry Out Boot at Front
Area.
– Open the clamp -arrow- and remove the shift knob and boot.
– Remove the noise insulation.

Installing
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Installation Location, Noise Insulation:
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-Arrow A- points in direction of travel.
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– Turn the inside of the boot toward the outside. spec

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at
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gether -arrow-.
ion
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When connecting, the shift knob must engage all around in the
his
ate
shift lever groove.

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– Press the boot into the center console

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3.3 Boot with Shifter Knob and Noise Insu‐

lation, Passat
♦ Backrest Panel Tool - 3370-

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– Open the ashtray. ris ed
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– Push the Backrest
ss a Panel Tool - 3370- all the way under the ra
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plastic frame for the boot in direction of -arrow 1-.
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– Remove boot with plastic frame from center console frame

itte
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-A- in direction of -arrow 2-
erm
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– Hold the frame for the center console -A- tight.
wit
is n
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It must not be removed.
ole,
spec
Connectors for various switched could be loosened unintention‐
t to the co
ally.
rrectne
– Open the clamp -arrow- and remove the shift knob and boot.
ss
– Remove the noise insulation.
o
cial p
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Installing
form
mer
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c
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Installation Location, Noise Insulation

-Arrow A- points in direction of travel.
– Turn the inside of the boot toward the outside.
Install the shift knob all the way on.
gether -arrow-.
– First insert boot plastic frame at rear.

3.4 Plastic Relay Lever

From 05/2007 - Plastic Relay Lever
• To remove the relay lever, it is necessary to remove the cable
retainer from the selector cable.
This prevents damage to the selector cable.

– Pull the securing mechanism all the way forward in direction
of -arrow 1- and then unlock to the left in direction of
-arrow 2-.
– Press the relay lever forward (in the direction of -arrow 3-).
Relay Lever With Tab -arrow 1- (⇒ Previous Illustration).
– Press the tab -arrow 1- (⇒previous illustration) down to the
stop and remove the relay lever together with the cable re‐
tainer. Move it in the operating direction when doing so.
AG. Volkswagen AG d
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Relay Lever With Clip -arrow 1-. by Vol not
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– Remove the clip -arrow 1- tand
ho the relay lever together with the
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cable retainer. s au ra
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The cable retainer must be behind the catch -arrow 2-.

erm
ab
ility
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• The cable retainer may only be removed with the relay lever
wit
removed, refer to
, is n
h re
⇒ Fig. ““Removing the Selector Cable Retainer from the Plas‐

hole
spec
tic Relay Lever.”“ , page 128

es, in part or in w
t to the co
rrectness of i
l purpos
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Golf 2004 ➤ , Golf 2009 ➤ w,agGolf
en AGPlus 2005 n➤
AG, dGolf
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Manual Transmissiond by- Edition 07.2014
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rrectness of i
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• For installing, lubricate the following areas very carefully.

• Relay lever shaft -A- -arrows-.
nform
ercia
• Gearshift lever glide track -B-, fits into the relay lever.
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• The relay lever and gearshift lever in the illustration may differ
n in
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from the Original Part.

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• Grease allocation, refer to the Parts Catalog.
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– Press the cable retainer on the relay lever, refer to
ng
t.
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⇒ Fig. ““Installing the Cable Retainer”“ , page 129 . ht. Cop py
rig
rig ht
– Insert the relay lever together with the cable retainer as far as py by
co Vo
the stop.
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• The tab -arrow 1- secures the relay lever (⇒ previous illustra‐
tion).
• Make sure it engages securely.
• The cable retainer must be behind the tab -arrow 2- (⇒ previ‐
ous illustration).
Removing the Selector Cable Retainer from the Plastic Relay

Lever.
• The relay lever is removed
– Insert a flat-blade screwdriver -A- between the bushing -B- and
the relay lever.

Installing the Cable Retainer

• The relay lever is removed
• The cable retainer may only be installed at the bushing
-arrow-.
• The cable retainer must move freely on the relay lever.
. Volkswagen AG
does gen AG
• It must be behind the tab -arrowolks 2-, refer to
wa not
by V Relay Lever”“ , page 127
⇒ Fig. ““From 05/2007 - Plastic gu
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3.5 Selector Mechanism
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Removing
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anti-theft code.
rrectness of i
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tem; Rep. Gr. 27 ; Battery, Removing and Installing .

nform
ercia

m
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123 , Golf Plus
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iva
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page 125
fo
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ng
t.
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Golf from MY 2004 Cop py
ht. rig
rig ht
– Remove the footwell trim panel from the center console and py by
co Vo
the ashtray or storage compartment and then remove the cen‐
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ter console, refer to ⇒ Body Interior; Rep. Gr. 68 ; Storage
AG.
Compartments, Covers and Trim; Center Console, Removing

and Installing .
Golf from MY 2009
– Remove the ashtray or storage compartment from the center
console, refer to ⇒ Body Interior; Rep. Gr. 68 ; Storage Com‐
partments, Covers and Trim; Center Console, Removing and
Installing .

The Footwell Rear Channel is Located Above the Bracket for the
Center Console on Some Vehicles:
– Remove the footwell rear channel (refer to ⇒ Heating, Venti‐
lation and Air Conditioning; Rep. Gr. 80 ) to do so remove the
center console (refer to ⇒ Body Interior; Rep. Gr. 68 ; Storage
Compartments, Covers and Trim; Center Console, Removing
and Installing ).
Continuation for All Golf Models from MY 2009
– Remove the nut from the bracket in the center console, refer
to ⇒ Body Interior; Rep. Gr. 68 ; Storage Compartments,
Covers and Trim; Center
wage Console, Removing
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– Remove the nuts ed
by from the gearshift housing, referuto
ara
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⇒ Fig. ““Remove
thoris the Nuts -arrows-.”“ , page 130 . eo
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– Lower sthe
s gearshift housing. c
ce
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un
pt
• If it is not possible to lower the gearshift housing, then the nuts
an
d
itte
on the gearshift housing are located under the bracket on the
y li
erm
ab
center console.
ility
ot p
wit
• It will be necessary to remove the bracket from the center
is n
h re
console, refer to ⇒ Body Interior; Rep. Gr. 68 ; Storage Com‐
ole,
spec
Installing .
Golf Plus t to the co
– Remove the upper section and, if equipped, the center console
rrectne
bracket, refer to ⇒ Body Interior; Rep. Gr. 68 ; Storage Com‐

s
Installing .
s o
cial p
f in
If the Center Console Bracket Cannot be Removed Separately:

form
mer
– Remove the center console, refer to ⇒ Body Interior; Rep. Gr.

atio
m
68 ; Storage Compartments, Covers and Trim .

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or
n thi
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– Remove the Interior Monitoring Sensor - G273- (if equipped)

um
r
fo
from the rear nuts, refer to ⇒ Electrical Equipment; Rep. Gr.

en
ng
t.
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96 . t. Cop py
rig
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pyri by
Remove the Nuts -arrows-.
co Vo
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cted agen
Prote AG.
– Remove the air filter housing if it is located above the selector
shaft, refer to ⇒ Rep. Gr. 23 ; Diesel Direct Injection System,
– Remove the shift cable lock washer -3- from the gearshift lever
-1-.


Metal Relay Lever
– Remove the selector cable circlip -4- from the relay lever -2-.
Plastic Relay Lever
Disconnecting the Cable Retainer from the Selector Cable

– Pull the securing mechanism all the way forward in direction
of -arrow 1- and then unlock to the left in direction of
-arrow 2-.
– Press the relay lever forward (in the direction of -arrow 3-).
– Remove the relay lever with the cable retainer, refer to
Continuation for All Shift Mechanisms
– Remove the cable bracket from the transmission -arrows-.
Unclip the hose line -A- from the bracket -B- beforehand, if
necessary.
gen AG. Volkswagen A
– Remove the tunnel brace, refer to ⇒olkRep.
swa Gr. 26 ; Exhaust does no
G
System . db
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– Separate the front exhaustusystem
tho front section at the double or
clamp and remove it froms the subframe, refer to ⇒ Rep. Gr.
s a ac
26 ; Exhaust System .
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– Remove the floor panel trim, refer to ⇒ Body Exterior; Rep.

itte
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erm
Gr. 50 .
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ility
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– Pivot shift housing downward and remove with cables.

h re
hole
spec
Installing
es, in part or in w
t to the co

– Align the shift housing so that it is parallel to the body.
rrectness of i
• The distance on both sides to the body must be equal.

l purpos
For tightening the shift housing, refer to -item 26-

⇒ Item 26 (page 98) or -item 16- ⇒ Item 16 (page 100) .
nform
mercia
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– Route the cables -1- from the shift mechanism -2- to the trans‐
mission as follows:
♦ After the cables cross each other diagonally -arrow-, they must
run parallel to each other up to the cable mounting bracket on
the transmission.
♦ Make sure the cable tie -arrow- for attaching the cables is in‐
stalled correctly. Installation location, refer to agen
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⇒ Fig. ““Cable Tie Installation Locations”“ , page 104 . olksw not
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♦ The cables must be routed inside the depression in the heat thori
eo
shield -3-. sa
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A clip -A- holds the cables and heat shield to each other in place.
rrectness of i
These holes have different diameters.
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Allocation of Cable Retainers, Refer to

⇒ Fig. ““Cable Retainer Allocation”“ , page 103
nform
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– Apply a small amount of grease on the -arrows- on the trans‐

mission shift lever pins -1- and on the relay lever pins -2-.
• Grease allocation, refer to the Parts Catalog.
– Replace the lock washer -3- and the lock washer -4- on the
metal relay lever each
wagtime
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– Secure the shift d b cable with the lock washer -3- and uthe
y ara selector
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cable withthothe lock washer -4-.
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Cable Retainer
ss with Plastic Relay Lever c
ce
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– The relay lever and cable retainer must be installed together,
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refer to ⇒ “3.4 Plastic Relay Lever”, page 127 .
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– Insert the selector cable into the cable retainer.
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Continuation for All Shift Mechanisms
h re
hole
spec
– Install the center console, refer to ⇒ Body Interior; Rep. Gr.
es, in part or in w
68 ; Storage Compartments, Covers and Trim .
t to the co
rrectness of i
123 , Golf Plus
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nform
ercia

page 125
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– Install the floor panel trim, refer to ⇒ Body Exterior; Rep. Gr. tion in
r
50 .
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– Assemble the exhaust system free of tension and attach the

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tunnel braces, refer to ⇒ Rep. Gr. 26 ; Exhaust System .

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Adjust the gearshift mechanism, refer to Cop py
t. rig
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Injection System .
– Complete the steps after connecting the battery, refer to ⇒
Electrical Equipment; Rep. Gr. 27 ; Battery, Disconnecting
and Connecting .
Component
Selector housing to body -item 26- ⇒ Item 26 (page 98) or
-item 16- ⇒ Item 16 (page 100)
Cable mounting bracket to transmission, refer to -item 6-
3.6 Transmission, Golf from MY 2004

⇒ “3.6.1 Transmission, Removing”, page 134
⇒ “3.6.2 Transmission, Installing”, page 139
⇒ “3.6.3 Tightening Specifications”, page 145
♦ Engine Support Bridge - 10-222A-
♦ Engine Support Bridge - Engine Support Feet - 10-222A/8-
♦ Engine Support Bridge - Additional Hooks (2 pc.) - 10-222A/
2-

♦ Engine Support Bridge - Engine Support 3 - 10-222A/3-

♦ Engine Support - Automatic Transmission Adapter - 10-222A/
16-
♦ Transmission Support - 3282-
♦ The left rear lifting eye on the engine faces the side, refer to
⇒ Fig. ““The Left Rear Lifting Eye on the Engine Faces the Side
-arrow- ”“ , page 136 Engine/Gearbox Support Shackle (2 pc.)
- 10-222A/12-
♦ Transmission Support - Mounting Plate 39 - 3282/39-
♦ Transmission Support Elements (determine when mounting
the Adjustment Plate on the Transmission Support )
♦ Engine and Gearbox Jack - VAS6931-
♦ Transmission Support Jig - 3336- to transport the transmis‐
sion.
♦ For the correct grease, refer to the Parts Catalog.
3.6.1 Transmission, Removing

anti-theft code.
– Disconnect the battery ground cable,grefer
n AG.to
Vo⇒
lksElectrical
wagen AG Sys‐
lkswa e
tem; Rep. Gr. 27 ; Battery, Disconnecting and does
Connecting .not
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– If the lifting eye on the engine
ris
e meant for the Engine Support nte
utho
Bridge - 10-222A- is covered by a cover or the air filter, remove eo
ra
a
it, refer to ⇒ Rep. Gr.ss 23 ; Servicing the Diesel Direct Fuel c
Injection System or ⇒ Rep. Gr. 24 ; Servicing The Fuel In‐
ce
e
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jection System .
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– Remove entire air filter housing, if it is located near the battery,

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refer to ⇒ Rep. Gr. 23 ; Diesel Direct Injection System, Serv‐

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icing or ⇒ Rep. Gr. 24 ; Fuel Injection System, Servicing .

h re
hole
– Remove the battery and the battery tray, refer to ⇒ Electrical

spec
es, in part or in w

t to the co
lever -A-.
rrectness of i

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Metal Relay Lever

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Plastic Relay Lever

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⇒ “3.4 Plastic Relay Lever”, page 127 . C py
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shift lever -A-.


-arrows-.
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– Remove slave cylinder -arrow B- and lay aside, secure with
ole,
spec
wire, do not open wiring system.
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Caution
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– Disconnect the ground cable from the upper engine/transmis‐
f in
sion bolt.
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– Disconnect the connector -arrow 1- from the Back-Up Lamp
i
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Switch - F4- .
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– Remove the connector -arrow 2- and wire -arrow 3- from the

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– Remove the upper bolt from the starter.
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– Remove the upper engine/transmission bolts. cop Vo
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cted agen
Prote AG.
– If there are hose and cable connections located near the en‐
gine lifting eyes for the Engine Support Bridge - 10-222A- ,
these must now be removed.

– Position the Engine Support Bridge - 10-222A- with the Engine

Support Bridge - Engine Support Feet - 10-222A/8- , the En‐
gine Support Bridge - Engine Support 3 - 10-222A/3- and the
Engine Support - Automatic Transmission Adapter - 10-222A/
16- in front of the hood support.
– Engage the right front Engine Support - Bracket w/Spindle and
Hook - 10-222A/10- on the engine.
The Left Rear Lifting Eye on the Engine Faces the Side -arrow-
– Install the Engine/Gearbox Support Shackle (2 pc.) - 10-222A/
12- on the rear left of the engine -arrow-.
– Engage the Engine Support Bridge - Additional Hooks (2 pc.)
- 10-222A/2- in the Engine/Gearbox Support Shackle (2 pc.) -
10-222A/12- .
– Then connect the Engine Support Bridge - Additional Hooks
(2 pc.) - 10-222A/2- with the Transmission Support
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Plate 16 - 10-222A/16- . wage es n
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The Left Rear Lifting Eye on the Engine Faces Upward -arrow-:
un
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– Engage the Transmission Support - Mounting Plate 2 -

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10-222A/2- .
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(2 pc.) - 10-222A/2- with the Transmission Support - Mounting

hole
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Plate 16 - 10-222A/16- .
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t to the co

– Preload the engine/transmission assembly slightly using the
spindles.
rrectness of i
– Raise the vehicle.

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ercia
– Remove the lower part of the left front wheel housing liner,
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refer to ⇒ Body Exterior; Rep. Gr. 66 ; Wheel Housing Liner .

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– Remove all wires from the transmission.

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– Remove the drive axle heat shield, if equipped, -arrows-, refer

to ⇒ Suspension, Wheels, Steering; Rep. Gr. 40 ; Drive Axle,
Servicing; Drive Axle, Removing and Installing .
– Separate the exhaust system at the double clamp and remove
the exhaust pipe bracket from the subframe, refer to ⇒ Rep.
– Remove the drive axles from the flange shafts and tie them up
as high as possible. Be careful not to damage the surface pro‐
tection.
– Remove the pendulum support -arrows A-, -B- and -C-.

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es, in part or in w
– Remove the left assembly mounting hex bolts -arrows- from t to the co
the transmission mounting.
rrectness of i
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– Bring engine/transmission assembly into angled position by
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lowering it via the spindles on the Engine Support Bridge -
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Note
♦ Lower the threaded spindle on the Engine Support - Automatic

Transmission Adapter - 10-222A/16- using the wing nut until
the threads are flush -arrow-.
♦ Pay attention to the lines when lowering the transmission.
• The bolts -arrows- for the transmission bracket -A- must be

accessible.

– Remove the transmission bracket -A- -arrows-.
– Remove the small cover plate -A- for the flywheel (if equipped)
behind the right flange shaft -arrow-.
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– Remove the exhaust system brace -1- from the transmissionsed b ara
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-arrow-. hori
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– Remove the starter, refer to ⇒ Electrical Equipment; Rep.
s Gr.
s c
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le
27 ; Starter .
un
pt
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d
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Align the Transmission Support - 3282- with the Transmission
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Support - Mounting Plate 39 - 3282/39- in order to remove the
pe
ility
transmission.
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– Insert the Transmission Support - 3282- into the Engine and
hole
spec
Gearbox Jack - VAS6931- .
es, in part or in w
t to the co
– Align the arms of the Transmission Support so that they match
up with the holes in the Adjustment Plate .
rrectness of i
– Install the Mounting Elements -A- and -C-, on the Adjusting
Plate , as illustrated.
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– Position the Engine-Transmission Jack under the vehicle. The

arrow symbol -B- on the Adjusting Plate points in the direction
nform
ercia
of travel.
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– Align the Adjusting Plate so that it is parallel to the transmis‐

sion and secure the safety support to the transmission.
– Install the Transmission Support - Pins 29 - 3282/29- into the
rear hole on the transmission for the pendulum support bolt.
– Remove the lower engine/transmission bolts.
– Disconnect the exhaust system if it is not possible to remove

the lower bolts -arrows-, refer to ⇒ Rep. Gr. 26 ; Exhaust
System .
– Remove the transmission from the alignment bushings and

carefully move it toward the subframe.
– Rotate transmission downward in area of differential.
– Push the engine forward slightly with a second technician.
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– Carefully lower transmission while guiding right flange shaft

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-A- into flywheel/intermediate plate area as shown.

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– Use spindles on the Transmission Support - 3282- to adjust

ole,
spec
the position of the transmission while lowering it.

t to the co
Note
rrectne
Pay attention to the lines when lowering the transmission.

ss o
cial p
f inform
mer
atio
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3.6.2 Transmission, Installing

o
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Refer to “Transmission, Removing” to get a list of the special tools
Co
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⇒ “3.6 Transmission, Golf from MY 2004”, page 133 .
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Pay Attention to the Following List for the Subject -“Transmission

Fluid, Checking and Filling”
“Transmission Fluid, Checking and Filling”
No Yes Yes
Transmis‐ Original X
sion Part
no oil outlet X
Was com‐ X
pletely dis‐ before in‐
assembled stallation
-item 3-
n AG. V lkswagen AG do
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lkswage ⇒ Item 3 es n
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(page 116) ot g
ua
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tee
auth sion fluid or
ac
ss capacity,
refer to
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⇒ “3.1 Code
an
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Letters,
erm
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Transmis‐
ility
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sion Alloca‐
wit
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tion, Ratios
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ole,
and Ca‐
spec
pacities,
Golf from
t to the co
MY 2004”,
page 8 .
Was parti‐ X rrectne
ally disas‐ after instal‐
sembled lation, refer
ss
• (the to
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f i
trans‐ ⇒
nform
mission “1.1 Trans‐

mer
atio
housing mission
om
and the Fluid,

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c
i
or
clutch Checking
thi
te
sd
housing and Filling”,

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were not page 90 .

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other)
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Prote AG.
– Clean all threaded holes for self-locking bolts with a thread tap
to remove any locking fluid residue.
– Always replace self-locking nuts and bolts.
– Make sure the alignment bushings for centering the engine/
them if necessary.
If the alignment sleeves are missing, it will be difficult to shift, there
will be clutch problems and the transmission may make noises
(loose rattling).
– Make sure the intermediate plate fits correctly on the engine.
– Clean the drive axle splines and grease lightly with Grease For
Clutch Disc Shaft Splines - G 000 100- .
It must be possible to slide the clutch plate back and forth on the
input shaft.
Support - Mounting Plate 39 - 3282/39- in order to install the
transmission.


– Install the Mounting Elements -A- and -C- ( Transmission Sup‐
port - Pins 29 - 3282/29- ) on the Adjusting Plate as illustrated.
– Place the transmission on the Engine and Gearbox Jack .
– Align the Adjustment Plate so that it is parallel to the trans‐
mission.

– Position the Engine/Gearbox Jack under the vehicle. The
-arrow symbol B- on the adjustment plate points in the direc‐
tion of travel.
– Using the spindles of the Transmission Support - 3282- , screw
the transmission downward in the area of the differential.
– Then carefully lift transmission, when doing so, guide the right
flange shaft -A- in the area of the flywheel/intermediate plate
as shown.
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– Using the spindles ofVthe
olks Transmission Support - 3282-
wa oes
not , screw
the transmissionedupward
by in the area of the differential.
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ara
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– Raise the transmission
au
th up to the engine. ra
ss c
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– Align the transmission with the engine and install it.

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– Install lower engine/transmission connecting bolts and tighten

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to tightening specification, refer to

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⇒ “3.6.3 Tightening Specifications”, page 145 .

h re
hole
spec
– After the transmission is attached to the engine, remove the

es, in part or in w
Engine and Gearbox Jack from the transmission.

t to the co
– Install small cover plate, if equipped, behind right flange shaft

rrectness of i
-A- -arrows-.
l purpos
– Install the upper engine/transmission bolts and tighten them

to the specification, refer to
nf
ercia
orm
m
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om
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thi
te
sd
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ng
t.
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Cop py
t. rig
gh ht
pyri by
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co lksw
by
cted agen
Prote AG.

– Attach the bracket -A- with the new bolts to the transmission
-arrows- and tighten them to the tightening specification, refer
to ⇒ “3.6.3 Tightening Specifications”, page 145 .
– Align the engine/transmission via both spindles of the Engine

Support Bridge - 10-222A- in the installation position.
– Install new bolts -arrows- of left assembly mounting into trans‐
mission mount and tighten to tightening specification, refer to
WARNING
Only remove Engine Support Bridge - 10-222A- when the left

and right subframe mount bolts are tightened to the tightening
specification.
Note
Install the engine/transmission mount free of tension, refer to ⇒

Rep. Gr. 10 ; Engine, Removing and Installing .
wage e
– Install the slave cylinder and tighten
Vol the bolts to the specifica‐ ot gu
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by
tion -item 9- ⇒ Item 9 (pageris25)
e , -arrows B-.
d ara
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tho or
– Attach the transmissions support
au -arrows A- and tighten it to the ac
tightening specification,
s refer to
ce
e

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pt
du
an
itte
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– Attach the drive axles to the transmission, refer to ⇒ Suspen‐

erm
ab
sion, Wheels, Steering; Rep. Gr. 40 ; Front Suspension,

ility
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Servicing .
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h re
hole
spec
es, in part or in w
t to the co
– Install the drive axle heat shield, if equipped, -arrows-, refer to

rrectness of i
⇒ Suspension, Wheels, Steering; Rep. Gr. 40 ; Drive Axle,

l purpos
nf
ercia
orm
m
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om
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en
ng
t.
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Cop py
t. rig
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co lksw
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cted agen
Prote AG.

– Install the pendulum support with new screws -arrows A-, -B-
and -C-, refer to ⇒ Suspension, Wheels, Steering; Rep. Gr.
40 ; Front Suspension, Servicing .
– Assemble the exhaust system and then attach it to the sub‐
frame, refer to ⇒ Rep. Gr. 26 ; Exhaust System .
– Install the turbocharger strut -1- on the transmission and tight‐

en the bolt -arrow- to the specification, refer to ⇒ Rep. Gr.
26 ; Exhaust System .
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or e
h
– Connect the connector
aut -1- to the Back-Up Lamp Switch - F4- . or ac
ss
– Install the starter, connect the connector -arrow 2- and attach
ce
e
nl
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the wire -arrow 3-, refer to ⇒ Electrical Equipment; Rep. Gr.

an
itte
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27 ; Starter .
erm
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ility
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– Attach the ground cable to the upper engine/transmission con‐

wit
necting bolt.
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hole
– Make sure the vacuum hose for the brake system is installed
spec
correctly. Install a vacuum hose, if necessary, refer to ⇒ Rep.

es, in part or in w
t to the co
Gr. 47 .
rrectness of i
l purpos
– Attach the bracket -B- to the transmission.

– Press the hose/line assembly -A- into the bracket -B- on the
nform
ercia
transmission.
m
at
– Attach the cable mounting bracket to the transmission and

om
io
tighten the bolts -arrows- to the tightening specification

n
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or
-item 6- ⇒ Item 6 (page 102) .

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– Install the gearshift lever -A-.

– Tighten the nut -arrow 4- to the tightening specification
-item 18- ⇒ Item 18 (page 103) .
– Apply a small amount of grease to the transmission shift lever
pins -A-.
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For the correct grease, refer to the Parts Catalog. Volksw not
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– Connect the shift cable with the transmission shift
horis lever nte
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-arrow 1-. aut ra
c
ss
Metal Relay Lever
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an
– Install the relay lever -B- and secure it with a lock washer itte
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erm
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-arrow 3-.
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– Apply a small amount of grease to the relay lever pins -B-.
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hole
For the correct grease, refer to the Parts Catalog.
spec
es, in part or in w
– Attach the selector cable to the relay lever -arrow 2-.
t to the co
Plastic Relay Lever
– Install the relay lever with the cable retainer, refer to
rrectness of i
l purpos

– Adjust the gearshift mechanism, refer to
nf
ercia
o
rm
m
atio
m
– Install the battery tray, battery cover and the battery, refer to
o
n in
c
⇒ Electrical Equipment; Rep. Gr. 27 ; Battery, Removing and

or
thi
e
Installing .
t
sd
iva
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– Install the engine cover and the air filter housing, refer to ⇒
o
m
f
en
ng
Rep. Gr. 23 and ⇒ Rep. Gr. 24 .

t.
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Cop py
– Connect the battery and complete the steps after connecting
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the battery, refer to ⇒ Electrical Equipment; Rep. Gr. 27 ; p by
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Battery, Disconnecting and Connecting . Prote
cted AG.
agen
– Install the lower part of the left front wheel housing liner, refer
to ⇒ Body Exterior; Rep. Gr. 66 ; Wheel Housing Liner .

3.6.3 Tightening Specifications

Transmission to a Gasoline Engine
Item Bolt Quantity Nm
1 M 12 x 65 2 80
2 M 12 x 150 1 80
♦ Also starter to
transmission
3 M 12 x 165 1 80
♦ Also starter to
transmission
4 M10 x 50 3 40
5 M 12 x 85 1 80
6 M6 x 8 1 10
♦ Small flywheel
cover plate
-A- alignment sleeves for centering
Transmission to Diesel Engine

1 M12 x 55 2 80
2 M 12 x 150 2 80
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3 M10 x 50 au ra
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s 40 c
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le
4 M 12 x 60 1 80
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an
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5 M6 x 8 1 10
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♦ Small flywheel
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cover plate
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spec
t to the co
Transmission Bracket to Transmission.
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s

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Bolts -arrows- 40 Nm + 90°

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gen AG. Volkswagen A
Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf kPlus
swa 2009 ➤ , Pass ...does no
G
Vol t gu
Manual Transmission - Edition 07.2014 ed
by ara
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tho eo
Transmission Mount to Body ss
au ra
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pt
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Bolts -arrows- 20 Nm +90°

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Drive Axle on the flange shaft, refer to ⇒ Suspension, Wheels,

f
en
ng
t.
Steering; Rep. Gr. 40 ; Drive Axle, Servicing; Drive Axles, Re‐
yi Co
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moving and Installing .
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3.7 Transmission, Golf from MY 2009, with

Turbo Diesel
♦ Engine Support Bridge - Gearbox Adapter - 10-222A/18-
♦ Engine Support Bridge - Gearbox Bracket - T10346-
♦ or Engine Support Device - Gearbox Bracket - T10346/1-
♦ Engine Support Device - 3300A-
sion.
♦ M6 x 20 collar bolt

Golf 2004
AG. Vo➤
lksw, aGolf
gen A2009 ➤ , Golf Plus 2005 ➤ , Golf Plus 2009 ➤ , Pass ...
agen G do
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olksw ot g
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♦ M6 x 80 collar
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♦ The Engine
ss
Support Bridge - 10-222A- and the Engine Sup‐
ce
le
port Bridge - Engine Support Feet - 10-222A/8- will be moun‐
un
pt
an
ted on the longitudinal members later in the procedure.
d
itte
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• To protect the edges of the fender, cover both Engine Support
pe
ility
Bridge - Engine Support Feet - 10-222A/8- with cloth tape
ot
wit
, is n
-arrow-, refer to the Parts Catalog.
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
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nform
mercia
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t
ion in
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anti-theft code.
r
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t.
yi Co
tem; Rep. Gr. 27 ; Battery, Disconnecting and Connecting .ht. Cop py
rig
rig ht
– If the lifting eye on the engine meant for the Engine Support
py by
co Vo
Bridge - 10-222A- is covered by a cover or the air filter, remove
by lksw
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it, refer to ⇒ Rep. Gr. 23 ; Servicing the Diesel Direct Fuel
AG.
Injection System or ⇒ Rep. Gr. 24 ; Servicing The Fuel In‐

jection System
– Remove entire air filter housing, if it is located near the battery,
refer to ⇒ Rep. Gr. 23 ; Diesel Direct Injection System, Serv‐
icing or ⇒ Rep. Gr. 24 ; Fuel Injection System, Servicing .
– Remove the battery and the battery tray, refer to ⇒ Electrical
– Remove the cable retainer from the selector cable, refer to
⇒ Fig. ““Disconnecting the Cable Retainer from the Selector
Cable”“ , page 131 .
– Remove the clip -arrow 1- and then remove the relay lever and
the cable retainer.
Note
The relay lever is secured by a notch on some vehicles, refer to

lever -A-.
shift lever -A-.


-arrows-.
AG. Volkswagen AG d
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– Remove the transmission support -arrows A-. s
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Caution
h re
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es, in part or in w
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rrectness of i
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Switch - F4- .
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ercia
orm

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atio
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starter.
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or c

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– Remove the upper engine/transmission bolts. C py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– Install Engine Support Bridge - Gearbox Bracket - T10346- or

-T10346/1- on rear hole out of the three battery carrier mount‐
ing holes.
– Use a collar bolt M6 x 80 or one of the battery tray bolts for
this.

– Position the Engine Support Bridge - 10-222A- in front of the

hood support.
– Use:
– Position the Engine Support Bridge - Engine Support Feet -
10-222A/8- :
• On the upper longitudinal members, directly in front of the
ridge (-arrow 1-) next to the bolt (-arrow 2-)
– Connect the Engine Support Bridge - Gearbox Bracket -
T10346- or Engine Support Device - Gearbox Bracket -
T10346/1- with the Extractor .
– Hook the Spindles into the left lifting eye on the engine.
– Pretension the engine/transmission assembly and Engine
Support Bridge via the spindles.
– Remove all wires from the transmission. wagen AG. Volkswagen AG does
ks not
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– Transmission on vehicles with oStart/Stop
ris
e
System: disconnect nte
eo
the connector -arrow- from the
auth Transmission Neutral Position ra
Sensor - G701- . ss c ce
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– Remove the starter, refer to ⇒ Electrical Equipment; Rep. Gr.

l purpos
27 ; Starter .
– Remove the Left Front Level Control System Sensor - G78-
nform
ercia
from the transverse link, if equipped, refer to ⇒ Rep. Gr. 40 ;

Left Front Level Control System Sensor - G78- Removing and
m
at
Installing .
om
ion
c
in t
or
his
ate
do
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for
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tection, refer to ⇒ Suspension, Wheels, Steering; Rep. Gr.
40 ; Drive Axle, Removing and Installing .
– Remove the pendulum support.
wage e
– Remove the left assemblyy Vmounting
olks hex bolts -arrows-sfrom
not
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ise
d b ara
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tho
– Bring engine/transmission
au assembly into angled position by or
ac
ss spindles on the Engine Support Bridge -
lowering it via the
ce
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10-222A- .
un
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• Dimension -a- = approximately 50 mm

rrectness of i
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nform
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tion in
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AG. Volkswagen AG d
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– Remove the aut small cover plate -A- for the flywheel (if equipped)
h
ra
behind the
s right flange shaft -arrow-.
s c
ce
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nl
pt
– Remove the engine/transmission bolt near the right flange.
du
an
itte
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ab
ility
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t to the co
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– Tighten the Engine Support Bridge - Gearbox Bracket -

T10346- or the Engine Support Device - Gearbox Bracket -
T10346/1- with the bolt -1- in the left threaded hole in the
nf
ercia
subframe.
orm
m
atio
-1- = M6 x 20 collar bolt

om
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– Secure the Engine Support Device - 3300A- on the Bracket .

thi
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– Place a cloth between Engine Support Device - 3300A- and

o
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cu
oil pan.
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t.
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Cop py
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Prote AG.
– Push the engine forward using the spindle on the Engine Sup‐
port Device - 3300A- . Note the following when doing this:
• The A/C compressor -2- must not touch the refrigerant line
-1- -arrow-.
• The generator must not touch the refrigerant line.
• The pressure pipe must not touch the radiator.
transmission.


wage es n
– Position the Engine-Transmission Jack under they Vvehicle.
olks The ot g
ua
arrow symbol -B- on the Adjusting Plate points sedin
b the direction ran
ri
of travel. ut
ho
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t to the co
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ss o
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mer
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c
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System .
c by lksw
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– Carefully lower the transmission while guiding the right flange

shaft -A- past the alignment sleeve in the cylinder block
-arrow- as illustrated.
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an
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ility
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ole,
– Guide the left flange shaft -B- past the subframe console
spec
-arrow- as illustrated. Move the Engine/Transmission Jack

with the transmission to the front.
t to the co
rrectnes
Note
s o
cial p
f inform
mer
atio
om
n
c
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sd
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Note
t. C rig
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Refer to “Transmission, Removing” to get a list of the special tools cted agen
Prote AG.
needed, refer to
⇒ “3.7 Transmission, Golf from MY 2009, with Turbo Diesel”, page
146 .
Pay attention to the following list for the subject -“Transmission

No Yes Yes
sion Part
no oil outlet X


Was com‐ X
-item 3-
⇒ Item 3
(page 116)
transmis‐
sion fluid
capacity,
refer to
⇒ “3.1 Code
Letters,
Transmis‐
sion Alloca‐
tion, Ratios
and Ca‐
pacities,
Golf from
MYen2004”,
AG. Volkswagen AG d
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ag oes
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Was parti‐ rised X ara
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ally disas‐ ut
ho after instal‐ eo
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sembled ss a lation, refer c
• (the to
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pt
trans‐ ⇒
an
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housing mission
pe
ility
and the Fluid,
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clutch Checking
h re
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spec
were not page 90 .
es, in part or in w
separa‐ t to the co
ted from
each
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ercia

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com
tion in

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te o
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(loose rattling).
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– Clean the drive axle splines and grease lightly with Grease For cted agen
Prote AG.
input shaft.


subframe.
– Install the Bracket in the same angled position as the engine.
-1- -arrow-.
transmission.

port - Pins 29 - 3282/29- ) on the Adjusting Plateolkas
en AG. V
illustrated.
swa gen AG
ag does
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– Place the transmission on the Engine
by
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– Align the Adjustment Platetho so that it is parallel to the trans‐ eo
mission. s au ra
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ility
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t to the co

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tion of travel.
ss o

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nform
mer
atio
om
n
c
i
or
n thi
te
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cum
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fo
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t.
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Prote AG.

– Carefully raise the transmission while guiding the right flange

en AG . Volkswag
– Using the spindles of the Transmission
ksw
agen Support - 3282-
AG do,escrew
s no
the transmission upward in by Vthe area of the differential.
ol t gu
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ise
– Raise the transmission
tho up to the engine.
r tee
or
u ac
sa
– Align the transmission
s with the engine and install it.
ce
e
nl
pt
du
an
itte
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erm
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ility
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wit
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spec
– Remove the Engine Support Device - 3300A- and Bracket .
es, in part or in w
t to the co
-A- -arrows-.
rrectness of i

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nf
ercia
orm
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atio
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-arrows- and tighten them to the tightening specification, refer p by
o Vo
by c lksw
to ⇒ “3.7.3 Tightening Specifications”, page 160 . Prote
cted AG.
agen


WARNING

specification.
Note

– Install the pendulum support, refer to ⇒ Suspension, Wheels,

Steering; Rep. Gr. 40 ; Servicing the Front Suspension .
– Install the drive axles, refer to ⇒ Suspension, Wheels, Steer‐
ing; Rep. Gr. 40 ; Drive Axles, Servicing; Drive Axles, Re‐
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss ce
le
un
pt
an
d
itte
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ab

ility
ot p

wit
is n

h re
ole,

spec

t to the co
rrectness o
cial p
f inform
mer
atio
– If equipped, install the Left Front Level Control System Sensor

om
- G78- -arrows-, refer to ⇒ Rep. Gr. 40 ; Left Front Level

c
i
or
Control System Sensor - G78- Removing and Installing .

thi
te
sd
iva
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pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

– Transmission on vehicles with Start/Stop System: connect the

connector -arrow- to the Transmission Neutral Position Sensor
- G701- .
– Install the slave cylinder and tighten the bolts to the specifica‐
tion -item 9- ⇒ Item 9 (page 25) , -arrows B-.
– Attach the transmission support -arrows A- and tighten it to the
tightening specification, refer to
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
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un
pt
an
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ab
pe
ility
– Connect the connector -1- to the Back-Up Lamp Switch - F4- .
ot
wit
, is n
h re
hole
spec
es, in part or in w
27 ; Starter .
t to the co
necting bolt.
rrectness of i
l purpos

Gr. 47 .
nform
mercia
a
com
tion in

r
te o
thi
s
iva
do
r
transmission.
rp
cum
fo
en
ng

t.
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op
C py
t. rig
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ht
pyri by
Vo
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by c lksw
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Prote AG.

– Install the transmission shift lever -A-, refer to

⇒ Fig. ““Installing the Transmission Shift Lever”“ , page 103 .
AG. Volkswagen
– Coat the pin on the gearshift
lksw
agen lever withAG
a dsmall
oes amount of
not
grease -A-. d by Vo gu
a
e ran
ris tee
For the correct
ut
ho grease, refer to the Parts Catalog. or
sa ac
– Attach
s
the shift cable to the gearshift lever.
ce
le
un
pt
– Replace the lock washer -arrow 2-.
an
d
itte
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rm
ab
– Install the relay lever together with the cable retainer, refer to
pe
ility
⇒ Fig. ““Relay Lever With Clip -arrow 1-.”“ , page 127 .
ot
wit
, is n
h re
• The clip -arrow 1- secures the relay lever.
hole
spec
• Make sure the clips locks securely.
es, in part or in w
t to the co
Note
rrectness of i
The relay lever is secured by a notch on some vehicles, refer to
l purpos
nform
ercia
– Connect the selector cable to the cable retainer.

m
a
com
tion in
r
te o
thi
s
iva
do
r

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fo
Installing .
en
ng
t.
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– Install the engine cover and the air filter housing, refer to ⇒
C py
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Rep. Gr. 23 and ⇒ Rep. Gr. 24 .
gh ht
pyri by
Vo
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by c lksw
cted agen
Prote AG.
the battery, refer to ⇒ Electrical Equipment; Rep. Gr. 27 ;
Battery, Disconnecting and Connecting .
– Check the headlamp adjustment if the vehicle has a Left Front
Level Control System Sensor - G78- , refer to ⇒ Electrical
Equipment; Rep. Gr. 94 ; Exterior Lights, Lamps and
Switches .


Transmission to Engine
1 M 12 x 50 2 80
2 M 12 x 150 2 80 AG. Volkswagen AG d
agen oes
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♦ Also starter to by Vol not
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ara
transmission rise
d
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tho eo
au ra
3 M10 x 50 3 ss 40 c
ce
le
4 M 12 x 60 1 80
un
pt
an
d
5 M6 x 8 itte 1 10
y li
rm
ab
♦ Small flywheel
pe
ility
cover plate
ot
wit
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not present on all
hole
spec
es, in part or in w
t to the co
rrectness of i
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nform
ercia

m
a
com
tion in
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te o
thi
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iva
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t.
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Cop py
Transmission Mount to Body
t. rig
gh ht
pyri by
Vo
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c by lksw
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Prote AG.


3.8 Transmission, Golf from MY 2009, Gas‐

oline Engine
♦ Engine Support Bridge - Gearbox Adapter - 10-222A/18-
♦ Engine Support Plate - T10419-
♦ Engine/Gearbox Support Shackle (2 pc.) - 10-222A/12-
♦ Torque Wrench 1331 5-50Nm
wage
n AG-. VVAG1331-
olkswagen AG
doe
ks s no
Vol t gu
♦ Torque Wrenched1332
by 40-200Nm - VAG1332- ara
is nte
or
♦ Transmission
au Support Jig - 3336- to transport
th the transmis‐ eo
ra
sion. ss c
ce
e
nl
pt

du
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erm
ab
ility
ot p
♦ Quantity: 2 M6 x 20 hex socket head bolt

wit
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h re
hole
spec
es, in part or in w
♦ Engine Support Device - Gearbox Support - T10036A-

t to the co
♦ or Engine Support Device - Gearbox Support - T10036-

– If using the Engine Support Device - Gearbox Support -
rrectness of i
T10036- , drill two holes 7 mm diameter, as illustrated.

l purpos
• Dimension -a- = 11 mm.

• Dimension -b- = 98 mm
nf
ercia
orm
• Dimension -c- = 70 mm
m
atio
om
n in
or c
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te
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Cop py
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Vo
co lksw
by
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Prote AG.

The Engine Support Bridge - 10-222A- and the Engine Support

Bridge - Engine Support Feet - 10-222A/8- will be mounted on the
longitudinal members later in the procedure.
• To protect the edges of the fender, cover both Engine Support
Bridge - Engine Support Feet - 10-222A/8- with cloth tape
-arrow-, refer to the Parts Catalog.

anti-theft code.
olksw
– Remove the engine cover and air filter,
wagrefer
en AG.to
V
⇒ Rep. Gr.does
agen AG
Volks .
24 ; Fuel Injection System, Servicing not
gu
by d ara
se nte
– Remove the battery and the
tho battery tray, refer to ⇒ Electrical
ri e or
Equipment; Rep. Gr. 27
s a ; Battery, Removing and Installing .
u ac
s
ce
le
– Remove the cable retainer from the selector cable, refer to

un
pt
an
d
itte
y li
erm
ab
– Remove the clip -arrow 1- and the relay lever together with the
ility
ot p
cable retainer.
wit
is n
h re
ole,
spec
lever -A-.
t to the co

shift lever -A-.
rrectness o
cial p

inform
-arrows-.
mer
atio
m

o
n
c
i
or
thi
te
sd
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ng
t.
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by
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Prote AG.


Caution

Switch - F4- .
starter. n AG. Volkswagen AG age does
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– Disconnect the ground cable from the bupper
yV
ol engine/transmis‐ gu
ara
sion bolt. ris
ed
nte
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– Remove the upper bolt from the
ss
au starter. ra
c
ce
e
– Remove the upper engine/transmission bolts.

nl
pt
du
an
itte
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erm
ab
ility
ot p
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h re
– Remove the vacuum hose to prevent damaging it -arrow-, re‐
hole
fer to ⇒ Rep. Gr. 47 .
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
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om
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or c
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Note
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♦ The Engine Support Bridge - 10-222A- will be attached to the C py
t. rig
engine and will be used to lower the engine/transmission later
gh ht
pyri by
in the procedure.
o Vo
by c lksw
cted agen
Prote AG.
♦ Some engines have a Secondary Air Injection Solenoid Valve
- N112- -arrow -on the back.
• Both upper threaded holes for the Secondary Air Injection Sol‐
enoid Valve - N112- screws are needed to attach the engine
to the Engine Support Bridge - 10-222A- ⇒; -arrows- lower il‐
lustration.
• For this reason it is necessary to remove the Secondary Air
Injection Solenoid Valve - N112- , refer to ⇒ Rep. Gr. 26 ;
Secondary Air Injection System .

– Attach the Engine Support Plate - T10419- to the back of the

engine direction of -arrow-.
– Tighten the Engine Support Plate inside the threaded holes

-arrows-.
Tightening specification: 10 Nm
WARNING
Always tighten the bolts to the tightening specification.
The lifting eye -arrow A- at the front of the engine is also used to
hold the engine.
– Release the transport strap -arrow B- and remove it from the
lifting eye -arrow A-. Do not disconnect the wire connections,
refer to ⇒ Rep. Gr. 15 ; Cylinder Head, Valvetrain .
AG. Volkswagen AG d
agen oes
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y V gu
d b ara
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ility
ot p
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h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
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ate
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164
AG.
Rep. Gr.34 - Controls, Housing

hood support.
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n A-GEngine
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en AG Feet -
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olks no
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• On the upper longitudinal
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to the bolt (-arrow 2-) eo
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12- on the front left of the engine.
pt
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– Connect the Engine Support Plate - T10419- and the Engine/
rm
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pe
Gearbox Support Shackle (2 pc.) - 10-222A/12- with the Ex‐
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tractor .
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m
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27 ; Starter . on in
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from the transverse link, if equipped, refer to ⇒ Rep. Gr. 40 ;

um
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Left Front Level Control System Sensor - G78- Removing and

n
t.
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Installing . Cop py
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wage es n
– Remove the four nuts -2- and bolts -3- and remove the front y Volks ot g
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– Remove the left assembly mounting hex bolts -arrows- from
p by
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the transmission mounting. Prote
cted AG.
agen

10-222A- .
accessible.

– Remove the heat shield from the subframe -arrows-, if equip‐

ped.
AG. Volkswagen AG d
agen oes
olksw not
– Attach the Engine Support Deviced by V
- Gearbox Support - gu
ara
T10036- or the Engine Support
horise Device - Gearbox Support - nte
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T10036A- to the subframe
aut using two M6 x 20 hex socket head ra
c
bolts -arrows-. ss
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-A-.
ss o
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-1- -arrow-.
transmission.


of travel.

AG. Volkswagen AG d
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olksw not
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or eo
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– Remove the transmission from the alignment bushings and s
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rrectness of i
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– Guide the right flange shaft past the hole -arrow 1-.
nf
ercia
– Carefully lower the transmission.

orm
m
atio
– Guide the right flange shaft past the flywheel -arrow 2- (⇒ up‐
om
per illustration).
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Note
Note

needed, refer to AG. Volkswagen AG d
⇒ “3.8 Transmission, Golf from MY 2009, Gasoline Engine”, page lksw
agen oes
not
161 . db
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Fluid, Checking and Filling” ss
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No Yes Yes
ility
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Transmis‐
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Original X
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t to the co
Was com‐ X
rrectne
-item 3-
⇒ Item 3
(page 116)
ss
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sion fluid
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atio
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⇒ “3.1 Code
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or
n
Letters,
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te
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Golf from yri
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MY 2004”,
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page 8 .
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Was parti‐ X
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ally disas‐ after
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them if necessary.
m
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ht ht
rig by
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lksw
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cted agen
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input shaft.
AG.
– Remove the heat shield from the subframe -arrows-, if equip‐

ped.
– Attach the Engine Support Device - Gearbox Support -

T10036- or the Engine Support Device - Gearbox Support -
T10036A- to the subframe using two M6 x 20 hex socket head
bolts -arrows-.

– Secure the Engine Support Device - 3300A- on the Support

-A-.
-1- -arrow-.
transmission.

port - Pins 29 - 3282/29- ) on the Adjusting
gen AG
Plate asagillustrated.
. Volksw en AG
d wa oes
olks not
– Place the transmission on the
db
yEngine
V and Gearbox Jack . gu
ara
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ris
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mission. s au ra
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es, in part or in w
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rrectness of i

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tion of travel.
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nf
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orm
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Cop py
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gh ht
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by
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Prote AG.

– Guide the right flange shaft past the flywheel -arrow 2-.
AG. Volkswagen AG d
agen oes
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– Guide the left flange shaft by V-B- past the subframe console
ol
gu
ara
-arrow- as illustrated. rise
d
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shaft past the hole -arrow 1- ⇒ previous ra
c
illustration
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nl
pt
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– Raise the transmission up to the engine.
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rrectness of i
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– Attach the heat shield to the subframe, if it was removed earlier

-arrows-.
nf
ercia

rm

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n in
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WARNING

specification.
Note
Install the engine/transmission mount free Aof

G. Vtension,
olkswagenrefer
AG doto ⇒
Rep. Gr. 10 ; Engine, RemovingVoand agen
lksw Installing . es n
ot
y gu
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rise nte
– Install the drive axles,uthrefer
o to ⇒ Suspension, Wheels, Steer‐ eo
ra
ing; Rep. Gr. 40 ; sDrive
sa Axles, Servicing; Drive Axles, Re‐ c
ce
e
nl
pt
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gh ht
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by
cted agen
Prote AG.

– If equipped, install the Left Front Level Control System Sensor

- G78- -arrows-, refer to ⇒ Rep. Gr. 40 ; Left Front Level
Control System Sensor - G78- Removing and Installing .
n AG. Volkswagen AG
– Install the vacuum hose -arrow-,
olks
wagerefer to ⇒ Rep. Gr.
doe47
s no .
yV t gu
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tion -item 9- ⇒ Item 9 (page 25) , -arrows B-. rrectness of i
l purpos

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– Connect the connector -1- to the Back-Up Lamp Switch - F4- .
gh ht
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by
– Install the starter, connect the connector -arrow 2- and attach Prote
cted AG.
agen
27 ; Starter .
necting bolt.
Gr. 47 .

. Volkswagen AG
a gen AG does
Vol
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gu
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db ara
– Press the hose/line assembly
ris -A-
e
into the bracket -B- on the nte
transmission. utho eo
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ss
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pt
an
d
-item 6- ⇒ Item 6 (page 102) . itte
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t to the co
– Install the transmission shift lever -A-, refer to
rrectne
⇒ Fig. ““Installing the Transmission Shift Lever”“ , page 103 .
ss
-item 18- ⇒ Item 18 (page 103) .
o
cial p
f in
form
mer
pins -A-.
atio
om
n
c
i
or
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– Attach the shift cable to the transmission shift lever.

t
sd
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um
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• The clip -arrow 1- secures the relay lever.
c by lksw
cted agen
Prote AG.
• Make sure the clips locks securely.
– Install the selector cable any the cable retainer.
– Remove the Engine/Gearbox Support Shackle (2 pc.) -
10-222A/12- from the engine.
– Attach the transport strap to the lifting eye on the engine

-arrow A- and tighten it -arrow B-, refer to ⇒ Rep. Gr. 15 ;
Cylinder Head, Valvetrain .

– Remove the Engine Support Plate - T10419- from the back of

the engine.
– If removed, install the Secondary Air Injection Solenoid Valve

- N112- -arrow- on the engine, refer to ⇒ Rep. Gr. 26 ; Sec‐
ondary Air Injection System .
Installing .
– Remove the engine cover and air filter, refer to ⇒ Rep. Gr.
24 ; Fuel Injection System, Servicing .
n AG. Volkswagen AG age does
ksw not
– Install the noise insulation, refer to ⇒by VBody
ol Exterior; Rep. Gr. gu
ara
50 ; Noise Insulation . ris
ed
nte
tho eo
– Check the headlamp adjustment
ss
au if the vehicle has a Left Front ra
c
ce
e
nl

pt
du
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Switches .
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1 M 12 x 65 2 80
2 M 12 x 170 1 80
rrectness of i
♦ Also starter to
l purpos
transmission
3 M 12 x 170 1 80
nf
ercia
♦ Also starter to
rm
m
transmission
atio
om
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or c
4 M 10 x 65 3 40
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5 M 12 x 95 1 80
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6 M6 x 8 1 10
o
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♦ Small flywheel
t.
yi Co
op
cover plate (not C py
t. rig
present here)
gh ht
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by c lksw
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Prote AG.



– Tighten the bolt to the tightening
wage
specification.
n AG. Volkswagen AG
doe
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Vol tg
Bolts -arrows- ed by 60 Nm + 90°
ua
ran
ris tee
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ss
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nl
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ility
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wit
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hole
– Replace the bolts. spec

es, in part or in w

t to the co

rrectness of i

l purpos

nform
mercia
at
om
ion
c
in t
or
3.9 Transmission, Golf Plus

his
ate
do
priv

um
for
en
ng
t.
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Cop py
t. rig
gh ht
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Vo
co lksw
by
Special tools and workshop equipment required cted agen
Prote AG.

♦ Engine Support Bridge - Additional Hooks (2 pc.) - 10-222A/
2-
16-
♦ The left rear lifting eye on the engine faces the side, refer to
⇒ Fig. ““The Left Rear Lifting Eye on the Engine Faces the

Side-arrow- ”“ , page 180 Engine/Gearbox Support Shackle

(2 pc.) - 10-222A/12-
♦ Engine Support Bridge - Gearbox Bracket - T10346-
♦ or Engine Support Device - Gearbox Bracket - T10346/1-
♦ Mud Wing Compensation Plate - T10311-
♦ For the correct grease, refer to the Parts Catalog. agen
AG. Volkswagen AG d
oes
olksw not
V
♦ M6 x 20 collar bolt ed by gu
ara
ris nte
o eo
h
aut ra
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– See if a coded radio is installed. If so, obtain the anti-theft code.

nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
– Remove the cover from the engine.
, is n
h re
hole
– Remove the air filter housing -1- and the intake hose -2-, refer
spec
to ⇒ Rep. Gr. 23 ; Diesel Direct Injection System, Servicing .
es, in part or in w
t to the co
– Remove the battery -3-, the battery cover and the battery tray,
refer to ⇒ Electrical Equipment; Rep. Gr. 27 ; Battery, Re‐
rrectness of i
– Remove the bolt -arrow- and remove the valve block -4- from
l purpos
the plenum chamber bulkhead.

– Remove the noise insulation -5- from the bulkhead plenum
nform
ercia
chamber.
m
at
om
i
– Remove the plenum chamber bulkhead, refer to ⇒ Body Ex‐
on
c
terior; Rep. Gr. 50 ; Body Front .
in t
or
his
ate
– Remove the shift cable lock washer -arrow 1- from the selector do
priv
c
lever -A-.
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for
en
ng
t.
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op
C py
t. rig
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Metal Relay Lever
op Vo
by c lksw
cted agen
Prote
AG.

Plastic Relay Lever
shift lever -A-.


-arrows-.

Caution

sion bolt.
– Disconnect the connector for the backup lamps -arrow 1-.

– Remove the connector -arrow
AG. Volks2-
waand
gen Awire
G do -arrow 3- from the
agen
starter. Volksw es n
ot
y gu
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– Removeorthe
ise upper bolt from the starter. nte
eo
h
ut ra
– Remove
ss
a
the upper engine/transmission bolts. c
ce
le
un
pt
an
d

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erm

ab
ility
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is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
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cum
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en
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t.
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Cop py
t. rig
gh ht
pyri by
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179
by c lksw
cted
3. Removal and Installation
agen
Prote AG.
– On both sides of the vehicle, insert the Mud Wing Compen‐

sation Plate - T10311- between the fender bolting edge and
the underlying fender bolting plate.
♦ Installed position:
“R” (-1-) means right side of the vehicle.
“L” is not shown in the illustrations; it means left side of the vehicle.
The arrow -2- always points in driving direction
Note
The hole -3- can be used to remove the Mud Wing Compensation
Plate - T10311- .

hood support.
– Use:
16-
– Attach the Spindle to the right lifting eye on the engine. lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
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du
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itte
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ility
ot p
wit
, is n
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hole
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es, in part or in w
The Left Rear Lifting Eye on the Engine Faces the Side-arrow-
t to the co

12- on the rear left of the engine -arrow-.
rrectness of i
– Engage the Engine Support Bridge - Additional Hooks (2 pc.)

l purpos
- 10-222A/2- in the Engine/Gearbox Support Shackle (2 pc.) -

10-222A/12- .
nf
ercia

or

m
m
atio
Plate 16 - 10-222A/16- .
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n in
or c
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te
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ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

The Left Rear Lifting Eye on the Engine Faces Upward -arrow-:
– Engage the Transmission Support - Mounting Plate 2 -
10-222A/2- .
Plate 16 - 10-222A/16- .
spindles.
– Transmission on vehicles with Start/Stop System: disconnect

the connector -arrow- from the Transmission Neutral Position
Sensor - G701- .
– Disconnect the connector -arrow 1- or -arrow 2- on the charge

air hose, refer to ⇒ Rep. Gr. 21 ; Charge Air System with
Turbocharger .
lkswage es n
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byV ua
d ran
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ss
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ility
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, is n
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ercia

m

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com
tion in
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te o
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s
iva
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rp
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ng
t.
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Cop py
t. rig
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pyri by
181
co Vo
by lksw
cted 3. Removal and Installation
agen
Prote AG.

lkswage es n
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byV ua
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ss
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nl
pt
du
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10-222A- .
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erm
ab
ility
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Note
h re
hole
spec
♦ Lower the threaded spindle on the Engine Support - Automatic
es, in part or in w
Transmission Adapter - 10-222A/16- using the wing nut until
t to the co
the threads are flush -arrow-.
♦ Pay attention to the lines when lowering the transmission.
rrectness of i
l purpos

accessible.
nf
ercia

rm
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om
n in
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Cop py
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gh ht
pyri by
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co lksw
by
cted agen
Prote AG.

– Remove the small cover plate -A- for the flywheel (if equipped)
behind the right flange shaft -arrow-.
AG. Volkswagen AG d
agen oes
olksw not
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d by ara
ise nte
– Remove the exhaust system brace -1- from theutransmission
thor eo
ra
-arrow-, if equipped. ss a c
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un
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an
d
27 ; Starter .
itte
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rm
ab
pe
ility
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, is n
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es, in part or in w
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nform
ercia
subframe.
m
a
com
tion in
r
te o
thi
s
iva
– Place a cloth between Engine Support Device - 3300A- and
do
r
rp
c
oil pan.
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fo
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote
AG.

-1- -arrow-.

Note
♦ Check that the Engine Support Bridge - Engine Support Feet

- 10-222A/8- is completely on the longitudinal members
-arrows-.
♦ Adjust the position of the Adapter using the front spindle on
the Engine Support Bridge - 10-222A- .

transmission.

of travel.
lkswage es n
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byV ua
d ran
ir se tee
tho
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un
pt
an
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ab
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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
tio

n in
r

te o
thi
s
System .
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do
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cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.


AG. Volkswagen AG d
agen oes
olksw not
– Carefully lower the transmission while guiding the righteflangebyV gu
ara
d
horis nte
eo
-arrow- as illustrated. aut ra
ss c
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e
nl
pt
du
an
itte
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erm
ab
ility
ot p
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, is n
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hole
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es, in part or in w
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l purpos

nf
ercia
orm
m
atio
m
Note
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Note

needed, refer to ⇒ “3.9 Transmission, Golf Plus”, page 177 .

No Yes Yes
sion Part
no oil outlet X


Was com‐ X
-item 3-
⇒ Item 3
(page 116)
lkstransmis‐
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location,
pe
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Ratios and
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Capacities,
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Golf Plus
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2005”,
t to the co
page 12 .
Was parti‐ X
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them if necessary.
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input shaft.


subframe.
– Install the Bracket in the same angled position as the engine.
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Note
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- 10-222A/8- is completely on the longitudinal members

o
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mission.


tion of travel.
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the transmission upward in the area of the differential.
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ate
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specification.
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Note
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ht
pyri by
ing; Rep. Gr. 40 ; Drive Axles, Servicing; Drive Axles, Re‐
o Vo
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– If removed, install the turbocharger strut -1- on the transmis‐

sion and tighten the bolt -arrow- to the specification, refer to
⇒ Rep. Gr. 26 ; Exhaust System .
– Install the charge air hose -arrow 1- or -arrow 2-, refer to ⇒

Rep. Gr. 21 ; Charge Air System with Turbocharger .
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27 ; Starter .
necting bolt.
Gr. 47 . olkswage es n
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-item 18- ⇒ Item 18 (page 103) .
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cted agen
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-arrow 3-.
Plastic Relay Lever
– Install the plenum chamber bulkhead, refer to ⇒ Body Exterior;
Rep. Gr. 50 ; Body Front .

Manual Transmission - Edition 07.2014 wage
e ks s no
Vol t gu
by ara
– Attach the noise insulation -5- to the bulkhead plenumrischam‐
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ce
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-arrow-.
pt
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rm
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– Install the complete air filter housing -1- and the intake hose
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es, in part or in w
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– Install the engine cover.
rrectness of i
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1 M12 x 55 2 80
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♦ Also starter to
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3 M10 x 50 3 40
4 M 12 x 60 1 80
5 M6 x 8 1 10
♦ Small flywheel
cover plate




Bolts -arrows- lkswage 20 Nm +90° es not
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Drive Axle on the flange shaft,
horis refer to ⇒ Suspension, Wheels, nte
eo
Steering; Rep. Gr. 40 ; Drive
ut Axle, Servicing; Drive Axles, Re‐ ra
sa c
moving and Installing . s
ce
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pe
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3.10 Transmission, Passat
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agen
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sion.

anti-theft code.

– If the lifting eye on the engine meant for the Engine Support
Bridge - 10-222A- is covered by a cover or the air filter, remove
it, refer to ⇒ Rep. Gr. 23 ; Diesel Direct Injection System,
– Then remove entire air filter housing, refer to ⇒ Rep. Gr. 23
or ⇒ Rep. Gr. 24 .
– Remove the battery, the battery cover and the battery tray,
refer to ⇒ Electrical Equipment; Rep. Gr. 27 ; Battery, Re‐
lever -A-.
Metal Relay Lever
Plastic Relay Lever
wage e
– Remove the nut -arrow 4- and theny Vremove
olks the transmission s not gu
shift lever -A-. ed
b ara
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– Remove the cable mounting
ss bracket from the transmission c
-arrows-.
ce
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c
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sion bolt.

AG. Volkswagen AG d
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Golf u2004
tho ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf e o Plus
ra 2009 ➤ , Pass ...
a
ss Manual Transmission c - Edition 07.2014
ce
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nl
pt
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an
– Disconnect the connector for the backup lamps -arrow 1-.
itte
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ility
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starter.
wit
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spec
– Remove the upper engine/transmission bolts.
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
– Mount the Engine Support Bridge - 10-222A- with the Engine
orm
Support Bridge - Engine Support 3 - 10-222A/3- and the En‐
m
atio
m
gine Support Bridge - Engine Support Feet - 10-222A/8- in

o
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c
front of the hood support.

or
thi
te
sd
a

iv
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spindles.
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pyri by
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– Transmission on vehicles with Start/Stop System: disconnect

the connector -arrow- from the Transmission Neutral Position
Sensor - G701- .

tection.


-arrows-, if equipped, refer to ⇒ Rep. Gr. 40 ; Left Front Level
Control System Sensor - G78- , Removing and Installing .
– Remove the left and right coupling rods from the stabilizer bar.
– Remove the nuts -arrows- for the ball joint on the control arm.
AG. Volkswagen AG d
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or eo
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aut ra
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– Remove the pendulum support from the transmission, bolt
hole
spec
-2- and bolt -3-.
es, in part or in w
t to the co
– Remove the steering gear from the subframe and tie it up.
– Secure the secure before removing, refer to ⇒ Suspension,
Wheels, Steering; Rep. Gr. 40 ; Overview - Subframe, Sta‐
rrectness of i
bilizer Bar and Control Arm; Subframe and Mounts, Securing .
l purpos
– Remove the subframe, the pendulum support, the stabilizer

bar and the control arms, refer to ⇒ Suspension, Wheels,
nform
ercia
Steering; Rep. Gr. 40 ; Overview - Subframe, Stabilizer Bar

and Control Arms .
m
at
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lowering it via the spindle on the Engine Support Bridge - C py
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10-222A- .
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• The bolts -arrows- for the transmission bracket -A- must be Prote
cted AG.
agen
accessible.

AG. Volkswagen AG d
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– Remove y V small cover plate -A- for the flywheel
the
b gu
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the right flange shaft -arrow-. nte
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ility
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rrectness of i
– If equipped, remove exhaust system brace -1- from transmis‐

sion and from exhaust system, if necessary -arrow- (attach‐
l purpos
ment to exhaust system is not visible in illustration).

nform
ercia
27 ; Starter .
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com
tion in

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te o
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C py
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of travel.


n AG. Volkswagen A G do
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System .
hole
spec
– Press transmission off alignment sleeves and carefully lower.
es, in part or in w
t to the co
rrectness of i
l purpos
Note
Pay attention to the lines when lowering the transmission. nform

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io

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ate
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t.
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C py
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needed, refer to ⇒ “3.10 Transmission, Passat”, page 193 .
rig ht
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Pay Attention to the Following List for the Subject -“Transmission
No Yes Yes
sion Part
no oil outlet X


Was com‐ X
⇒ Vehicle
diagnostic
tester
-item 3-
⇒ Item 3
(page 116)
transmis‐
sion fluid
capacity,
AG. Volkswagen AG drefer to
agen ⇒ “3.5
oes En‐
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from MY
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wit
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page 13 .
h re
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spec
Was parti‐ X
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t to the co
• (the to
trans‐ ⇒
rrectness of i

housing mission
l purpos
and the Fluid,

clutch Checking
nf
ercia

or
were not page 90 .

m
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– Always replace self-locking nuts and bolts. co Vo
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them if necessary.
(loose rattling).
input shaft.
transmission.


mission.
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– Install the Transmission Support - Pins 29 - 3282/29-
ss a into the c
ce
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nl
pt
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ab
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tion of travel.
ot p
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nform
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– Install small cover plate -A-, if equipped, behind right flange
at
om
io
shaft -arrows-.
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WARNING
Only remove Engine Support Bridge - 10-222A- when all the

left and right subframe mount bolts are tightened to the tight‐
Note

– Attach the drive axles to the transmission, refer to ⇒ Suspen‐

sion, Wheels, Steering; Rep. Gr. 40 ; Front Suspension,
Servicing .

– Install the subframe/control arm with the pendulum support,
refer to ⇒ Suspension, Wheels, Steering; Rep. Gr. 40 ; Over‐
view - Subframe, Stabilizer Bar and Control Arms .
– Attach the steering gear to the subframe, refer to ⇒ Suspen‐
sion, Wheels and Steering; Rep. Gr. 48 .
lkswage es n
o ot g
byV ua
d ran
ir se
– Attach the pendulum support to the transmission tho and tighten tee
or
the bolts -2- and -3-, refer to ⇒ Suspension,
ss
au
Wheels, Steering; ac
Rep. Gr. 40 ; Front Suspension, Servicing .
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ility
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es, in part or in w
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rrectness of i
l purpos
nform
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om
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c
in t
or
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ate
do
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en
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t.
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201
Prote AG.
3. Removal and Installation
– Install the Left Front Level Control System Sensor - G78-

-arrows-, if equipped, refer to ⇒ Rep. Gr. 40 ; Left Front Level
Control System Sensor - G78- , Removing and Installing .
– Install the exhaust system brace -1- at the transmission for the
exhaust system if applicable and tighten the bolts -arrow- to
the specification. The illustration does not show the exhaust
system mount, refer to ⇒ Rep. Gr. 26 ; Exhaust System .
lkswage es n
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tho
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- G701- .
, is n
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spec
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rrectness of i
l purpos
nform
mercia
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om
io
tion -item 9- ⇒ Item 9 (page 25) , -arrows B-.

n
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e

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t.
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– Connect the connector for the backup lamps -arrow 1-.

27 ; Starter .
necting bolt.
Gr. 47 .

transmission.
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r
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-item 18- ⇒ Item 18 (page 103) .
pins -A-.
– Connect the shift cable with the transmission shift lever
-arrow 1-.
Metal Relay Lever
– Install the relay lever -B- and secure it with a lock washer
-arrow 3-.
Plastic Relay Lever
⇒ Electrical Equipment; Rep.agen
AGr.
G. Vo27
lksw; aBattery,
gen AG Removing and
does
Installing . Volksw not
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– Install the entire
ho
ris air filter housing, refer to ⇒ Rep. Gr. 23ntor
ee ⇒
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ut or
ac
ss
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e
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– Check the headlamp adjustment if the vehicle has a Left Front
rrectness of i

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Switches .
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ate
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1 M12 x 55 2 80
2 M 12 x 150 2 80
♦ Also starter to
transmission
3 M10 x 50 3 40
4 M 12 x 60 1 80
5 M6 x 8 1 10
♦ Small flywheel
cover plate

AG. Volkswagen AG d
Transmission Mount to Body olksw
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Transmission Support to Transmission Bracket and Transmis‐

sion:
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atio
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c
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n thi

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3.11 Transmission, Transporting
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Special tools and workshop equipment required Prote AG.

♦ Transmission Support Jig - 3336-

– Attach the Transmission Support Jig - 3336- to the clutch
housing.
– Move the support arm on the sliding bar using the locking bolt
-arrow-.
Number of visible holes = 5.
– Lift the transmission with a workshop crane and the Trans‐
mission Support Jig - 3336- .
– Set the transmission down, for example, into the transport
container.
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3.12 Assembly Sequence, Transmission
aut
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s
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Note
ility
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♦ If only 5th has to be removed, follow this procedure:

h re
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spec
♦ If it is necessary to remove the transmission housing, refer to

the work procedure: Transmission, Disassembling and As‐

t to the co
sembling, refer to
⇒ “4.2 Transmission, Assembly Sequence”, page 220 .
rrectne

s
♦ Holding Plate - VW309A-

s o
cial p
f in
♦ Transmission Support - VW353-

form
mer
♦ Bearing/Bushing Installer - Multiple Use - VW295-

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♦ Bearing Driver - Multiple Use - VW244B-

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♦ For example Hot Air Blower VAG1416 - VAG1416-

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♦ Puller -Kukko 2-arm, Up to 90mm Witdth, 100mm Length - C py
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♦ -M 8 x 100 mm Stud Bolt- cted agen
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♦ Bracket - Multiple Use - 30-211A-

♦ Bearing Installer - Multiple Use - 32-111-
♦ Assembly Tool Kit - Press Piece 2 - T10030/4-
♦ Press Piece - 37mm - VW416B-

♦ Puller - Transmission Gears - T10309-

♦ Puller - Two Arm - T10040-
♦ With the Puller - Two Arm w/Thrust Piece - T10040/2A-
♦ Support Bridge - T10323-
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♦ Rear Wheel Bearing Kit - Piece 7 - 3253/7- agen oes
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♦ Press Piece - Multiple Use - VW433- orise nte
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♦ Press Piece - Multiple Use - 40-105- ss a c
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3.12.1 Removing
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– Remove the clutch release lever and release bearing, refer to ot p
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⇒ “3.7 Clutch Release Mechanism, Servicing”, page 79 .
hole
spec
• Be careful not to damage the bearing for the input and output
es, in part or in w
shafts when removing and installing 5th gear.
t to the co
• When securing the transmission to the Transmission Support
- VW353- , mount the following tools for support:
rrectness of i
Under the Input Shaft:
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• Input shaft may be supported by Bearing Installer - Multiple

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Use - 32-111- only at a later time.

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Under the Output Shaft Bracket
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♦ Rear Wheel Bearing Kit - Piece 7 - 3253/7-
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♦ Press Piece - Multiple Use - VW433-
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– Secure the transmission on the Transmission Support -

VW353- .

– Remove the transmission housing cover -arrow-.
– Check that the Puller - Two Arm w/Thrust Piece - T10040/2A-

can be installed correctly under the 5th gear wheel.
Puller - Two Arm w/Thrust Piece - T10040/2A- Cannot be In‐ agen
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-A- “Combined removal” risof the:
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Puller - Two Arm w/Thrust Piece - “5th gear synchronizer
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T10040/2A- prematurely touch sa
hub”, “5th gear swheel” and
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the: “transmission housing”, re‐

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♦ transmission housing wall fer to
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⇒ “4.2 Transmission, As‐
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♦ the ribbing in the transmission sembly Sequence”,
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housing under the gear wheel page 220 .
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Puller - Two Arm w/Thrust Piece -
es, in part or in w
T10040/2A- touch the ribs in the
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transmission housing under the
gear wheel.
rrectness of i
Puller - Two Arm w/Thrust Piece - T10040/2A- Can Be Installed
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Correctly.
5th gear is removed individually ⇒ , refer to
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⇒ Fig. ““Removing Just the 5th Gear.”“ , page 208

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Removing Just the 5th Gear.
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– Cover the openings with a cloth.

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– Move the shift fork -1- into neutral.

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– Remove the bolt -2- for 5th gear with a shift jaw.
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– Remove the pivot pin.
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– Remove the shift fork.

– It is not necessary to remove the spring -3- and the locking
collar -4-.

– Engage 5th gear -arrow 1- and 1st gear -arrows 2- and -3- and
then remove the bolts -A- for the synchronizer hub and for the
5th gear wheel.
– The input and output shafts are blocked after engaging both
gears, the synchronizer hub and the toothed gear cannot turn.
Both bolts can be loosened now.
Note
Remove any locking compound residue still in the threaded holes

using a thread tap if the shafts are not going to be replaced.
Remove 5th Gear Synchronizer Hub Together with Locking Collar

and Locking Pieces.
Use the Puller - Transmission Gears - T10309- .
– First insert the Puller - Transmission Gears - Half Shell -
T10309/1- between 5th gear drive gear -A- and 5th gear shift
fork mount -B-.
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• The Puller - Transmission
Vol Gears - Half Shell - T10309/1-
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ed bsynchronizer ring.
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– Press the halfautshell
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into the end position, if necessary. or
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– Turn the Puller - Transmission Gears - Half Shell - T10309/1- ce
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on the opposite side in direction of -arrow-.
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– Install the Puller - Transmission Gears - Threaded Insert -

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T10309/3- into the Half Shell .

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– Install the second Puller - Transmission Gears - Half Shell -

T10309/1- and push back the Puller - Transmission Gears -
Tube - T10309/2- on the tool.
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– Check synchronizer hub after pulling for damage.

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– Replace synchronizer ring.

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– Remove 5th gear selector gear with needle bearing.

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– Remove the 5th gear wheel. (shown here on a different trans‐

mission).
– Install the hook first -A-.
B - Press Piece - Multiple Use - 40-105-
Note
When remove drive gear, make sure the hook does not bend out‐
ward. Check the 5th gear for damage.
3.12.2 Installing
Install 5th Gear, Refer to
⇒ “4.2.3 5th Gear, Installing”, page 229 .
– Apply Sealant - AMV 188 200 03- evenly on the cover sealing
surface for the transmission housing.
– Install the transmission housing cover, refer to
⇒ “2.12 Overview - Transmission Housing Cover and 5th
Gear, Removing and Installing”, page 113 .
– Install the clutch release lever and release bearing, refer to
– Fill the transmission fluid, refer to ⇒ page 140 .
3.13 Transmission Housing and Clutch

Housing, Servicing
♦ Bearing/Bushing Installer - Multiple Use - VW295A-
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♦ Press Piece - Multiple Use - VW512- rise nte
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♦ Press Piece - Front Control Arm - 2040- ss c
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♦ Puller - Starter Bushing - VW228B- (not needed with this

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transmission)
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♦ Pilot Drift - VW222A- (not needed with this transmission)

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spec
♦ Seal Installer - Driver Set - 3066- (spindle)

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♦ Press Piece - Pivot Mount Bushing - 3124- (the seal and

sleeve are in two pieces)
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♦ Slide Hammer Set - VW771- (the seal and sleeve are a single
piece)
s
♦ Slide Hammer Set - Hook - VW771/37- (the seal and sleeve

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are a single piece) Seal Installer - One-Piece Seal - T10148-

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(the seal and sleeve are a single piece)

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Removing the Needle Bearing

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Rep. Gr.34 - Controls, Housing
Installing the Needle Bearing

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– Secure the needle bearing at three points inside yV
othe transmis‐
lks ot g
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sion housing, offset by 120°, using a mandrel. ed b ran
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Removing the Seal From the Guide Sleeve
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Installing the Seal All The Way Into the Guide Sleeve
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Prying out the Sleeve -arrow-

Installing the Sleeve

– Install the spindle -A- on the Seal Installer - Driver Set - 3066-
into the threaded piece on the differential.
– Turn the nut -B- and pull the sleeve all the way over the Press
Piece - Pivot Mount Bushing - 3124- .
Note
If transmission is disassembled, press sleeve in onto stop with the

Press Piece - Pivot Mount Bushing - 3124- .
Removing the Sleeve and Seal

The sleeve has a shoulder on the inside.
– Mount the Slide Hammer Set - Hook - VW771/37- behind the
shoulder inside the sleeve.
– Using force, push the Slide Hammer Set - Hook - VW771/37-
into the sleeve.
Installing the Sleeve and Seal

– Clean the seal in the transmission.
– Install the spindle -A- on the Seal Installer - Driver Set - 3066-
into the threaded piece on the differential.
– Turn the nut -B- and pull the sleeve all the way over the Seal
Installer - One-Piece Seal - T10148- . agen
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If transmission is disassembled, press sleeve in onto stop using
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Seal Installer - One-Piece Seal - T10148- .

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Installing the Oil Catch Tray -A- into the Transmission

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– Insert the oil catch tray into the hole -arrow 1- and groove
hole
spec
-arrow 2- at the same time.

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3.14 Shift Unit, Servicing

♦ Breather Tube Tool - T10203-
♦ Press Piece - Shift Rod/Alternator - VW423-
Removing the Locking Elbow -A- from the Shift Cover
– Remove the outer part of the locking elbow.
– Then carefully pry out the locking elbow with a screwdriver.
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Pressing the Locking Elbow -A- Into Selector Coverhoris tee
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Installed position: ss
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The marking -arrow- faces toward upper part of gearshift shaft.
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Installing the Seal

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3.15 Shift Forks, Servicing

♦ Press Plate - VW402-
♦ Subframe Support Tool - Press Piece - 3290/1-
♦ Subframe Bushing Tool Kit - 3301-
♦ Press Piece - Bushing - 50mm Diameter - VW431-
♦ Press Piece - Multiple Use Spacer Sleeve - VW472/2-
♦ Valve Guide/Clutch Release Push Rod Seal Drift - 10-206-
♦ Pry Lever - 80-200- . Volkswagen AG
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♦ Assembly Mandrel for y V Gear Selector Rod - 10-508- t gua
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♦ Spring Strut Compressor
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Shift SegmentssIdentification
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Dimension -a-
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1 - 1st gear and 2nd gear selector segments = 11.4 mm
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2 - 3rd gear and 4th gear selector segments = 7.7 mm
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3 - 5th gear selector segments = 12.1 mm
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Removing the Lock Washer t to the co

– Secure shift fork in vise with protective jaws -B-.
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– Pry off the lock washer -A- in the direction of -arrow-.

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Installing the Lock Washer

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– Press the lock washer in the groove in the shift segment using
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Note
The shift segment must still rotate easily after the lock washer is
installed.
A - 10 mm socket wrench
B - Protective Jaws

Removing the Angular Contact Ball Bearing
Note
Be careful not to bend the shift forks when removing and installing
the angular contact ball bearing.
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Installing the Angular Contact Ball Bearing Inner Race -A- into the
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Outer Race
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ility
The bearing inner race must engage with outer race. ot p
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Installing the Angular Contact Ball Bearing into the Shift Fork
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The recess in the Subframe Support Tool - Press Piece - 3290/1-

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point to the ball bearing.

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Shift Fork With the Shift Segments Installed

Dimension -a- (mm)
1st/2nd gear selector fork 87.2 to 87.4
3rd/4th gear selector fork 93.6 to 93.8
Shift segment allocation, refer to
⇒ Fig. ““Shift Segment Identification”“ , page 214

4 Disassembly and .Assembly

Volkswag AG en AG
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⇒ “4.1 Gearshift Mechanism,
Vol from 11/2006”, page 216 ot g
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⇒ “4.2 Transmission,
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4.1 Gearshift
ss Mechanism, from 11/2006
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♦ Window Release Tool - T10236-
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♦ - 2- = Counter-Support for example, from -Kukko- Series 16
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♦ Wedge - T10357-
♦ Press Piece - Block - T10083-
ss o
Disassembling
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– Remove gearshift mechanism, refer to
mer
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– Remove the seal -item 17- ⇒ Item 17 (page 100) from the
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n thi
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gearshift housing.
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– Bend open the tabs -arrows- on the base plate with a screw‐
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driver. (Only the tabs on the left side of the base plate are yi
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shown in the illustration). t. Cop py
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– Remove shift cable and selector cable from selector housing, p by
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refer to
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⇒ “2.5 Overview - Gearshift Lever and Gearshift Housing, from
AG.
11/2006”, page 99 .
– Raise upper side of spring -A- over selector bracket tab.
– Using a screwdriver, press bearing shell notches -arrows- in

direction of shift lever guide bearing; break of notches if nec‐
essary.
– Pry out bearing shell -A- with shift lever guide -B- from selector
housing.

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Manual Transmission n-teEdition 07.2014
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– Then press bearing shell off shift lever guide bearing and re‐ ss c
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• Observe guides -A- in subsequent steps.
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ility
• They must not break off.
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– Raise lower side in direction of -arrow 1- of spring as far as
hole
spec
stop onto shoulder on selector bracket.
es, in part or in w
t to the co
rrectness of i
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– Now raise shift lever guide up as far as stop and remove ball
studs from selector bracket in direction of -arrow 2-.
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– Turn the gearshift lever in the direction of -arrow 1-.

• The pins -arrow 2- must be in the shift housing opening.
– Move the gearshift lever guide and the gearshift lever in the
direction of -arrow 3-.
Assembling
Caution
The lower side of the spring (-arrow 1- ⇒ upper illustration) can

spring down uncontrolled from the selector bracket shoulder
during subsequent handling.
– Carefully press it down from the selector bracket shoulder.

The spring sides then twist “diagonally” with a loud noise.
– Turn both springs to the right and release the tension on the
ends -A- and -B-.
• the ends -A- and -B- must face in the opposite direction.
4. Disassembly and Assembly 217

– Insert shift lever guide in selector housing.

• The pins -arrow 1- are still located in the shift housing opening.
– Turn the gearshift lever guide in the direction of -arrow 2- until
the ball head pin -A- is above the opening in the gearshift
housing.
– Install the gearshift housing with gearshift lever guide into the
larger depression -arrow- in the Press Piece - Block - T10083- .
AG. Volkswagen AG d
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• The shift lever guide must project out of selector housing as
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far as stop.
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Note
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The selector bracket is only partially shown to provide a better
spec
illustration.
– Insert spring side -A- from above into guide. t to the co

rrectne
– Pull spring side -B- down and insert it near the guide (in di‐
rection of ball head).
ss
• Observe guides (see upper illustration) in subsequent steps.

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• They must not break off.

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– Carefully remove the gearshift housing with the shift lever

om
guide from the Press Piece - Block - T10083- .

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– Move the selector bracket all the way to the rear (opposite
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mounting holes for shift and selector cable) in direction of

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-arrow 1-.
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– Lubricate ball head pins.
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– Press ball head pins into selector bracket -arrow 2-. by c lksw
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• The guides -A- and the tabs -B- must not be damaged.

– Install the gearshift housing with gearshift lever guide into the
larger depression -arrow- in the Press Piece - Block - T10083- .
• The shift lever guide must project out of selector housing as

far as stop.
– Raise upper side of spring -A- over selector bracket pins. AG. Volkswagen AG d
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• Use a new bearing shell -B-. by Vol
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– Lubricate bearing shell and shift lever guide bearing.
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– Press bearing shell onto shift lever guide bearing
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– Remove selector mechanism from Press Piece - Block -
erm
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T10083- .
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– Insert lower side -C- of spring into guide.
h re
hole
– Raise upper side of spring -A- over selector bracket pins into
spec
guide.
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t to the co
– Press bearing shell into selector housing in direction of
-arrows-.
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• All four retaining tabs must engage.
l purpos
– Install the shift cable or selector cable, refer to

⇒ “4.1 Gearshift Mechanism, from 11/2006”, page 216 .
nform
ercia
– Install the base plate, refer to

⇒ “4.1.1 Base Plate, Installing”, page 219 .
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– Glue a new seal -item 12- ⇒ Item 12 (page 97) or -item 17-
in t
or
⇒ Item 17 (page 100) on the gearshift housing.
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ate
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– Install the gearshift mechanism, refer to

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4.1.1 Base Plate, Installing
Caution
There is a danger of causing damage to the gearshift housing

and base plate.
Apply very light pressure on the gearshift housing.

– Install a new seal on the base plate.

– Bend the tabs -arrow- back over all around the base plate to
secure it (only the tabs on the left side of the base plate are
shown in the illustration). agen
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– The tabs can be bent back over using the Wedge - T10357- ed by .
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-A- = Counter-Support for example, from -Kukko- modelaut line 16
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4.2 Transmission, Assembly Sequence
hole
spec
es, in part or in w
Removing and Installing Transmission Housing Cover, Transmis‐
t to the co
sion Housing, Selector Shaft with Selector Cover, Input Shaft,
Output Shaft, Differential and Selector Mechanism.
rrectness of i
l purpos

♦ Transmission Support - VW353-
nf
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or
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♦ Bearing Driver - Multiple Use - VW244B-
n in
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♦ For example Hot Air Blower VAG1416 - VAG1416-

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♦ -M 8 x 100 mm Stud Bolt-
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♦ Press Piece - 37mm - VW416B-
♦ Puller - Transmission Gears - T10408-
♦ Puller - Transmission Gears - Thrust Piece - T10408/2-
♦ Spacer Plate - T10408/3-
♦ M7 x 35 bolts with washers
♦ Puller - Kukko Puller - 60-150mm Width, 200mm Length -
18/1-
4.2.1 Removing
– Remove the clutch release lever, the release bearing and the
guide sleeve, refer to

• Be careful not to damage the bearing for the input and output
shafts when removing and installing 5th gear.
• When securing the transmission to the Transmission Support
- VW353- , mount the following tools for support:
Under the Input Shaft:
– Secure the bolt on the Bracket - Multiple Use - 30-211A- with
the nut -A-.
Under the Output Shaft Bracket
– Secure the transmission on the Transmission Support -

VW353- .
– Place the Drip Tray for VAG1202A - VAG1306- underneath.
– Open the oil filler plug and the oilendrain
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– Drain the transmission bfluid.
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– Remove the transmission housing cover -arrow-.

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Remove the 5th gear shift fork as follows:

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– Cover the openings with a cloth.

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– Move the shift fork -1- into neutral.

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– Remove both bolts -arrows- for the pivot pin. by c lksw
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– Remove the pivot pin.
– Remove the shift fork.
– It is not necessary to remove the spring -3- and the locking
collar -4-.

– Engage 5th gear -arrow 1- and 1st gear -arrows 2- and -3- and
then remove the bolts -A- for the synchronizer hub and for the
5th gear wheel.
Note
Remove any locking compound residue still in the threaded holes

using a thread tap if the shafts are not going to be replaced.
– Remove both bolts -arrows- for the reverse shaft support.
– Remove the 3rd bolt -arrow- from the reverse shaft support.
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– Transmission on vehicles with Stop/Start system: remove the

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Transmission Neutral Position Sensor - G701- -arrow-.

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– Move the gearshift shaft into neutral and remove the gearshift
shaft with the gearshift cover. Remove the bolts -arrows- and
pull the gearshift shaft out of the transmission housing.
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– Remove the cover -A- and pivot pin -B- on the bottom of the
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– Remove pivot pins -A- on top side of transmission and bolts
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-B- for transmission housing to clutch housing in area of dif‐

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– Remove the bolts -A- that connect the clutch and transmission
housing.
Note
Do not remove the nuts -B- for the bearing mount on the output
shaft.

– Remove both flange shafts.

– Remove the flange shafts with the springs, thrust washers and
tapered rings.
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Remove the Following Components
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Together with the Transmis‐ ra
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♦ 5th Gear Synchronizer Hub
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♦ 5th Gear Wheel
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• Both Spacer Plate - T10408/3- must be attached to the 5th
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• The Spacer Plate must be located above the 2 ribs on the
es, in part or in w
housing, opposite each other -arrows-.
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Note
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♦ There is a needle bearing under the 5th gear wheel.

♦ Secure the Straps so that the needle bearing does not touch
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the 5th gear wheel when removing the transmission housing.

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Use the Puller - Transmission Gears - T10408- Together with the

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Following Special Tools:

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♦ Puller - Transmission Gears - Thrust Piece - T10408/2-

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♦ Puller - Kukko Puller - 60 - 150mm With, 200 mm Length -
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– Secure the Puller - Transmission Gears - T10408- in the threa‐
ded holes in the transmission housing cover.
A - M7 x 35 bolts with washers
Tightening specification 18 Nm
– Place the Puller - Transmission Gears - Thrust Piece -
T10408/2- on the shaft.

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– Install the Puller - Kukko Puller - 60 - 150mm With,
Vol
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– Remove the 5th gear synchronizer hub, au the 5th
th gear wheel ra
and the transmission housing by tightening the spindles -A- -
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( approximately 12 turn ).
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– Warm the 5th gear wheel slightly using the Hot Air Blower -
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– Remove the nuts -B- from the bearing mount/output shaft.

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– Remove the shift forks -A- together with the gearshift rails.
– Remove the gearshift mechanism/reverse gear -B-.
– Remove the reverse gear -A-, the input shaft -B- and the output
shaft -C-, one after the other, from the clutch housing.
– Remove the differential.

4.2.2 Installing
– Install the differential.
– Always replace the seals -arrows- for the bearing mount/out‐
put shaft.
Note
The illustration only shows 3 of the 4 seals.
– Insert output shaft -1- and output shaft -2- together.

– Tighten the output shaft bearing mount nuts to the specifica‐
tion -item 11- ⇒ Item 11 (page 122) .
– Place reverse gear drive gear -3- on needle bearing in clutch
housing.
Shoulder -arrow- faces away from clutch housing.
– Make sure the reverse shaft -4- is complete, refer to
⇒ “3.3 Reverse Shaft”, page 279 ; do not mount the support
on the reverse shaft.
– Install the reverse shaft into the clutch housing.
– Clean all threaded holes in reverse shaft supports of locking
compound; cleaning can be done with a thread tap.
– Mount the reverse shaft support.
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– Install the reverse gear shift fork -1- d bywith
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reverse gear shift fork -2-, the ospring
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-3- and the sliding piece nte
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Reverse gear location

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– Install the gearshift mechanism/reverse gear -A-.

– Install the shift forks -B- together with the gearshift rails.
Reverse gear supports -C- are located in front of selector rails.
– Screw M 8 x 100 mm studs -A- into reverse shaft support so

that the shaft is aligned after fitting the transmission housing.
– Align the gearshift rails.
Note
The shift segments must be installed in the grooves on the locking

collars.
– Apply the Sealant - AMV 188 200 03- evenly onto the sealing
surface of the clutch housing.
– Install the transmission housing.
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Install the bolts for the reverse
ed
by shaft support -arrow- as follows:
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– Install the bolt -a-.auth ra
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– Remove studs -A- (⇒ upper illustration).
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– Install the bolt -c-.

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Tightening sequence:
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– Tighten the bolt -a- to 30 Nm.

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spec
– Tighten the bolt -b- (⇒ lower illustration) to 25 Nm.

es, in part or in w
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– Tighten the bolt -c- to 25 Nm (⇒ previous illustration).

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– Install the pivot pin -arrow- for the shift forks. To do this align
shift mechanism using a screwdriver, so that the relevant pivot
pin can be installed.
surface of the cap.
– Install the gearshift shaft cover.
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Install the gearshift shaft cover as follows:

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– Move the gearshift rail into the neutral position.
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– Move the gearshift shaft into neutral.
spec
– Position the selector shaft so that selector finger -arrow- is in‐
t to the co
serted into the selector rails.
– Tighten the selector shaft selector cover to the specification
rrectne
-item 17- ⇒ Item 17 (page 116) .
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– Transmission on vehicles with Stop/Start system: install the
inform
Transmission Neutral Position Sensor - G701- -arrow- and
mer
tighten the screw to the tightening specification -item 11- atio

m
⇒ Item 11 (page 115) .

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– Install both flange shafts with springs, thrust washers and ta‐
pered rings, refer to
⇒ “2.11 Overview - Transmission Disassembling and Assem‐
bling”, page 112
Install 5th Gear, Refer to
⇒ “4.2.3 5th Gear, Installing”, page 229 .

4.2.3 5th Gear, Installing

• Pay attention that the Bracket - Multiple Use - 30-211A- and
the Support Bridge - T10323- are installed.
– Secure the bolt on the Bracket - Multiple Use - 30-211A- with
the nut -A-.
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Installed Position, 5th Gear Wheel
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The groove all the way around -arrow- faces the transmission
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– Install the 5th gear wheel.

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Checking 5th Gear Synchronizer Ring

– Before reinstalling drive gear and synchronizer ring for 5th
gear, press the synchronizer ring onto the taper of the drive
gear and measure the gap dimension -a- using a feeler gauge.
Gap Dimension Installation Dimen‐ Wear Limit
-a- sion
5th Gear 1.1 to 1.7 mm 0.5 mm
– Install 5th gear wheel with needle bearing.
– Place the 5th gear synchronizer ring onto the selector gear.
– If disassembled, assemble the 5th gear locking collar/syn‐
chronizer hub, refer to
⇒ Fig. ““5th Gear Locking Collar/Synchronizer Hub Assem‐
bly”“ , page 269 .
Installed Position of 5th Gear Synchronizer Hub/Locking Collar

The pointed teeth on the locking collar -arrow 1- and the high col‐
lar on the synchronizer hub -arrow 2- face the transmission hous‐
ing.
The notches -arrow 3- on the synchronizer hub must line up with
the cast locking pieces on the synchronizer ring, refer to
( ⇒ Fig. ““5th Gear Synchronizer Ring with Cast Locking Pieces”“ ,
page 230 lower).
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5th Gear Synchronizer Ring withaCast
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– Cover all openings with a cloth to prevent foreign objects from
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getting into the transmission.

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– Install the 5th gear synchronizer hub

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Note
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Make sure there is enough clearance when installing the syn‐

on in
chronizer ring.
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– Loosen the input shaft support.
WARNING
Wear safety gloves.
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– Clean synchronizer hub and 5thVol
kgear
swa drive gear threaded
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Otherwise, there is the danger
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– Screw-in synchronizer hub screws and 5th gear wheel.
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Installed Position of Plate Springs for 5th Gear Synchronizer Hub
and Drive Gear Securing Bolts
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The outer diameter -arrows- faces 5th gear.
ss
– Tighten the bolts for the synchronizer hub and 5th gear drive
o
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gear to the specification, refer to
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Gear, Removing and Installing”, page 113 .
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gear wheel to the tightening specification, refer to -item 4-
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⇒ Item 4 (page 113) .
– Install the 5th gear shift fork.

Adjusting 5th Gear

– Engage 5th gear. Loosen the bolt -1-. Press locking collar and
shift jaw in direction of arrow, then tighten bolt -1- to 25 Nm.
• Check measurement: it must not be possible to slide a 0.2 mm
feeler gauge between the locking collar and drive gear. Repeat
the adjusting procedure if necessary.
– Remove 5th gear. The locking collar must be in the neutral
position. The synchronizer ring must move freely.
– Move the gearshift lever (selector lever) through all the gears.
– Install transmission housing cover, refer to
Gear, Removing and Installing”, page 113
– Install the guide sleeve for the release bearing, refer to agen AG. Volkswagen AG do
⇒ “3.7 Clutch Release Mechanism, Servicing”, page Vol79 .
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– Install the clutch release lever and release bearing,
ris refer to tee
⇒ “3.7 Clutch Release Mechanism, Servicing”, tho page 79 . or
au ac
ss
– Fill the transmission fluid, Golf from MY 2004, refer to
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⇒ page 140
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– Transmission Fluid, Golf from MY 2009, Turbo Diesel, Filling,
ility
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refer to ⇒ page 153
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– Fill the transmission fluid; Golf from MY 2009 with gasoline
hole
engine, refer to ⇒ page 169
spec
es, in part or in w
– Transmission Fluid, Filling, Golf Plus, refer to ⇒ page 185
t to the co
– Transmission Fluid, Filling, Passat, refer to ⇒ page 198
rrectness of i
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5 Special Tools

equipment required
♦ Bearing/Bushing Installer -
Multiple Use - VW295-
Multiple Use - VW295A-
♦ Press Piece - Multiple Use
- VW447H-
- VW512-
♦ Press Piece - Front Control
Arm - 2040-
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5. Special Tools 233

♦ Engine and Gearbox Jack -

VAS6931-
♦ Engine Support Bridge -
Gearbox Bracket - T10346-
♦ or Engine Support Device -
Gearbox Bracket -
T10346/1-
♦ Engine Support Device -
3300A- AG. Volkswagen AG d
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♦ Torque Wrench 1331 ed b ara
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5-50Nm - VAG1331- tho r eo
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40-200Nm - VAG1332-
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♦ Transmission Support Jig -
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3336- to transport the
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equipment required
♦ Transmission Support -
VW353-
Multiple Use - VW295-
♦ Bearing Driver - Multiple
Use - VW244B-
♦ For example Hot Air Blower
VAG1416 - VAG1416-
5-50Nm - VAG1331-
♦ Puller -Kukko 2-arm, Up to
90mm Witdth, 100mm
Length - 20-1-
♦ -M 8 x 100 mm Stud Bolt-
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equipment required
10-222A-
Engine Support Feet -
10-222A/8-
3282-
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♦ Bracket - Multiple Use -

30-211A-
♦ Bearing Installer - Multiple
Use - 32-111-
♦ Assembly Tool Kit - Press
Piece 2 - T10030/4-
♦ Press Piece - 37mm -
VW416B-
♦ Puller - Transmission
Gears - T10309-
♦ Puller - Two Arm - T10040-
♦ With the Puller - Two Arm
w/Thrust Piece -
T10040/2A-
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Special tools and workshop AG. Volkswagen AG d

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♦ Engine Support Bridge - orise nte
10-222A- aut
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Engine Support Feet -
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10-222A/8-
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Gearbox Adapter -
, is n
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10-222A/18-
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es, in part or in w
t to the co
Mounting Plate 39 -
3282/39-
♦ Transmission Support Ele‐
rrectness of i
ments (determine when
mounting the Adjustment
l purpos
Plate on the Transmission

Support )
nform
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a
3282-
com
tion in
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h Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005
ut or ➤ , Golf Plus 2009 ➤ , Pass ...
a ac
ss Manual Transmission - Edition 07.2014
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♦ Rear Wheel Bearing Kit - ot
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Piece 7 - 3253/7-
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spec
es, in part or in w
- VW433-
t to the co
40-200Nm - VAG1332-
rrectness of i
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mercia
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♦ Bracket - Multiple Use -

30-211A-
Use - 32-111-
♦ Assembly Tool Kit - Press
Piece 2 - T10030/4-
VW416B-
Gears - T10408-
Gears - Thrust Piece -
T10408/2-
♦ M7 x 35 bolts with washers
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Mounting Plate 39 -
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Gearbox Bracket -
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♦ Mud Wing Compensation
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♦ Puller - Starter Bushing -

VW228B- (not needed with
this transmission)
♦ Pilot Drift - VW222A- (not
needed with this transmis‐ agen
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♦ Seal Installer - Driver Set - horis nte
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♦ Slide Hammer Set - Hook -
VW771/37- (the seal and
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equipment required
♦ Subframe Support Tool -
Press Piece - 3290/1-
♦ Subframe Bushing Tool Kit
- 3301-
♦ Press Piece - Bushing -
50mm Diameter - VW431-
Spacer Sleeve - VW472/2-
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♦ Valve Guide/Clutch Re‐ Volkswa not
lease Push Rod Seal Drift
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Mounting Plate 39 -
3282/39-
ments (determine when
mounting the Adjustment
Plate on the Transmission
Support )
VAS6931-
5-50Nm - VAG1331-
40-200Nm - VAG1332-
transmission.
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VAS6931-
3300A-
5-50Nm - VAG1331-
40-200Nm - VAG1332-
transmission.
fer to the Parts Catalog.
♦ Quantity: 2 M6 x 20 hex
socket head bolt
Gearbox Support -
T10036A-
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♦ Window Release Tool -

T10236-
- VW412-
♦ Over-Center Spring As‐
sembly Tool - T10178-
Engine Support 25 -
10-222A/25-
♦ - 2- = Counter-Support for
example, from -Kukko- Ser‐
ies 16
♦ Wedge - T10357-
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♦ Connecting Pin - T10027A-

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♦ Press Piece - Block - T10083- au
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♦ Seal Installer - One-Piece Seal - T10148- (the seal and sleeve

are a single piece)
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♦ Breather Tube Tool - T10203-
♦ Engine Support Plate - T10419-

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♦ Puller - Kukko Puller - 60-150mm Width, 200mm Length -

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♦ Engine/Gearbox Support Shackle (2 pc.) - 10-222A/12-
♦ Assembly Mandrel for Gear Selector Rod - 10-508-
♦ Pry Lever - 80-200-

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♦ Spring Strut Compressor - 2070-

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♦ Transmission Support Jig - 3336-
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35 – Gears, Shafts
⇒ “1.1 Overview - Input Shaft”, page 251
⇒ “1.2 Input Shaft, Adjusting”, page 253
⇒ “1.3 Overview - Output Shaft”, page 257
⇒ “1.4 Output Shaft, Adjusting”, page 261
⇒ “1.5 Overview - Reverse Shaft”, page 264
1.1 Overview - Input

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♦ The input shaft must be adjusted because the position of the tapered roller bearing is affected when parts
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are replaced. Pay attention to the adjustment overview, refer to ⇒ “2.1 Adjustment Overview”, page 290 .
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1 - Clutch Housing
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2 - Outer Race/Tapered Roller
Bearing
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Outer Race/Tapered s
Roller Bearing”“ ,
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page 266
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Outer Race/Tapered
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Roller Bearing”“ ,
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page 266
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Taper Roller Bearing”“ , Prote AG.
page 266
Bearing Inner Race/
Taper Roller Bearing”“ ,
page 267
4 - Input Shaft
❑ Adjusting, refer to, refer
to
⇒ “1.2 Input Shaft, Ad‐
justing”, page 253 .
5 - 3rd Gear Wheel
❑ Installed position: shoul‐
der faces 4th gear
3rd Gear Wheel”“ , page
267

❑ Installing, refer to ⇒ Fig. ““Installing 3rd Gear Wheel”“ , page 267
6 - Locking Ring
❑ Always replace.
7 - 4th Gear Wheel
❑ Removing with the outer race/tapered roller bearing and sleeve, refer to
⇒ Fig. ““Removing the 4th Gear Wheel With the Tapered Roller Bearing and Sleeve”“ , page 267
❑ Installing, refer to ⇒ Fig. ““Removingw4th
agenGear Wheel”“ A
AG. Volkswagen , G
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8 - Bearing Inner Race/Taper Rollertho Bearing ee
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❑ Installing, refer to ⇒ Fig. ““Installing the Bearing Inner Race/Taper Roller Bearing”“ , page 268
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9 - Thrust Washer
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❑ Installing, refer to ⇒ Fig. ““Installing the Outer Race/Tapered Roller Bearing”“ , page 269
t to the co
11 - Shim
❑ Selecting thickness, refer to, refer to ⇒ “1.2 Input Shaft, Adjusting”, page 253 .
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13 - Sleeve
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❑ For the needle bearing

❑ Pressing off with 4th gear drive gear and tapered roller bearing inner race
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❑ Installing, refer to ⇒ Fig. ““Installing the Needle Bearing Sleeve”“ , page 268
te o
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❑ Mount before installing the thrust washer, refer to -item 9- ⇒ Item 9 (page 252) .
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14 - Needle Bearing
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15 - 5th Gear Wheel
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❑ With cast locking pieces, refer to Prote AG.
⇒ Fig. ““5th Gear Synchronizer Ring with Cast Locking Pieces”“ , page 230
❑ Checking for wear, refer to ⇒ Fig. ““Checking 5th Gear Synchronizer Ring”“ , page 230
17 - Spring
❑ Installed position, refer to ⇒ Fig. ““5th Gear Locking Collar/Synchronizer Hub Assembly”“ , page 269 .
❑ From transmission build date 05 11 1 offset springs, refer to
⇒ Fig. ““Installation of Offset Springs -A- ”“ , page 270
18 - Locking Pieces (quantity: 3)
❑ Installed position, refer to ⇒ Fig. ““5th Gear Synchronizing”“ , page 269 .
19 - 5th Gear Synchronizer Hub
❑ remove from, refer to ⇒ “4.2 Transmission, Assembly Sequence”, page 220
20 - 5th Gear Locking Collar
❑ remove with 5th gear synchronizer hub from, refer to
21 - Plate Spring
❑ Installed position, refer to
22 - Screw -item 4- ⇒ Item 4 (page 113)
❑ Always replace.
252 Rep. Gr.35 - Gears, Shafts

❑ Holds in position with the adapter on the plate spring bolt head, refer to
Bolts”“ , page 231
1.2 Input Shaft, Adjusting

(Choosing the adjusting shim for the input shaft)
♦ Dial Gauge Holder - VW387-
♦ Measuring Set - Magnetic Plate - 50mm - VW385/17-
♦ Press Piece - VW447i-
♦ Press Piece - Rod - VW407-
♦ Torque Wrench 1331 5-50Nm - VAG1331- n AG. Volkswagen AG do
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♦ Dial Gauge d byV ua
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A new input shaft adjustment is required when
utho the following com‐ or
ponents have been replaced: ss
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♦ Transmission Housing
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♦ Clutch Housing
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♦ 4th Gear Wheel
hole
spec
or the
es, in part or in w
t to the co
♦ Tapered roller bearing
Adjustment overview, refer to
rrectness of i
⇒ “2.1 Adjustment Overview”, page 290 .
l purpos
Requirement:
• Remove any sealant still on the sealing surfaces on the clutch
nform
ercia
and transmission housings.

m
at
– Press the taper roller bearing outer race into the clutch housing
om
ion
all the way.

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Golf 2004 ➤ , Golf 2009 ➤ , Golf by
VPlus 2005 ➤ , Golf Plus 2009o➤
ol n t
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d ara
Manual Transmission - Edition oris 07.2014
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– Install the outer race/tapereds roller bearing all the way into the
s
ce
le
transmission housing without the adjusting shim.
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– Install the input shaft into the clutch housing and mount the
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transmission housing. Tighten the bolts to 25 Nm with a 90°
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– Install the measuring device and the dial gauge in the clutch
o
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housing.
inform
mer
– Rotate the input shaft before measuring so the tapered roller
atio
bearing settles. Set the dial gauge with 1 mm pretension to “0”.
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Repeat this process each time a measurement is taken otherwise

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– Press the input shaft toward the dial gauge direction of

-arrow-.
– Read and make note of the play on the dial gauge (example:
1.21 mm).
Note
The dial gauge does not return to its starting position.
Determining the shim

Example:
Bearing Clearance Measured Adjustment Shim Thickness
Value According to the Table
1.21 mm 1.175 mm
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Shim Table
Bearing Play Shim
Measured Value (mm) Thickness (mm)
0.671 to 0.699 0.650
0.700 to 0.724 0.675
0.725 to 0.749 0.700
0.750 to 0.774 0.725
0.775 to 0.799 0.750
0.800 to 0.824 0.775
0.825 to 0.849 0.800
0.850 to 0.874 0.825
0.875 to 0.899 0.850 agen
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0.975 to 0.999 0.950 s
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1.000 to 1.024 0.975
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1.050 to 1.074 1.025
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1.125 to 1.149 1.100
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1.150 to 1.174 1.125
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1.175 to 1.199 1.150
1.200 to 1.224 1.175
1.225 to 1.249 1.200
rrectness of i
1.250 to 1.274, 1.225
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1.275 to 1.229 1.250

1.300 to 1.324 1.275
1.325 to 1.349 1.300
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1.350 to 1.374 1.325

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1.375 to 1.399 1.350
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1.400 to 1.424 1.375
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1.425 to 1.449 1.400
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1.450 to 1.474 1.425
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1.475 to 1.499 1.450
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1.500 to 1.524 1.475

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1.600 to 1.624 1.575
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1.625 to 1.649 1.600

1.650 to 1.674 1.625
1.675 to 1.699 1.650
1.700 to 1.724 1.675
Note
For the correct shims, refer to the Parts Catalog.
– Remove the drive axle and pry out the outer race/tapered roller
bearing using the Press Piece - VW447i- from the transmis‐
sion housing.
– Install the shim with the correct thickness, thickest shim first.
If the measured shim thickness is larger than those listed in the
Table, then install two shims that add up to the necessary thick‐
ness.

– Press the outer race/tapered roller bearing and the selected

shim (1.175 mm in the example) into the transmission housing
using the Press Piece - Multiple Use - VW510- .
– Assemble the transmission housing and tighten the hex bolts
to 25 Nm plus an additional 90°.
Checking Measurement
– Install the measuring device and the dial gauge.

– Turn the input shaft so that the tapered roller bearings settle.
– Press the input shaft in direction of -arrow-.
– Bearing play should be between 0.01 and 0.09 mm.
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The adjustment is OK if it is not possible to measure
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1.3 Overview - Output Shaft
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♦ Disassemble the output shaft as follows: place the separating device under the 2nd gear wheel -item 21-
⇒ Item 21 (page 259) and remove it as described, refer to
rrectness of i
⇒ Fig. ““Removing the Synchronizer and 3rd/4th Gear Locking Collar, 2nd, 3rd and 4th Gear Wheels With
the Needle Bearing Sleeve and Output Shaft”“ , page 272 . Remove the locking ring -item 17-
l purpos
⇒ Item 17 (page 259) . Remove the locking collar and the 1st/2nd gear synchronizer hub as described in,
refer to ⇒ Fig. ““Removing the Locking Collar with the Synchronizer Hub and Bearing Mount”“ , page 272 .
nf
ercia
♦ Refer to the Parts Catalog and to the Technical data when installing new gear wheels or a new output shaft.
orm
m
atio
♦ Replace both tapered roller bearings together.
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1 - Nut olks
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❑ 25 Nm and 90° addition‐ by ua
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❑ 4 nuts for the bearing ss
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❑ Always replace. itte
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2 - Clutch Housing
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3 - Shim
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❑ Adjustment overview,
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refer to
⇒ “2.1 Adjustment Over‐
view”, page 290 .
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4 - Small Outer Race/Tapered
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⇒ Fig. ““Remove the

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⇒ Fig. ““Installing the In‐
ner Race/Small Ta‐
pered Roller Bearing”“ , page 272
6 - Output Shaft
❑ Adjusting, refer to ⇒ “1.4 Output Shaft, Adjusting”, page 261 .
7 - Bearing Inner Race/Large Tapered Roller Bearing
❑ Removing, refer to ⇒ Fig. ““Removing the Inner Race/Large Tapered Roller Bearing”“ , page 273
❑ Installing, refer to ⇒ Fig. ““Installing the Inner Race/Large Tapered Roller Bearing”“ , page 273
8 - Seal
❑ Place the four seals on the bearing mount bolts.
9 - Bearing Mount
❑ With the large outer race/tapered roller bearing and bolts
❑ Replace the outer race only together with the large tapered roller bearing and bearing mount
10 - Thrust Washer
❑ The collar on the thrust washer faces the tapered roller bearing
11 - 1st Gear Wheel
12 - Needle Bearing
❑ For 1st gear
13 - Synchronizer Ring
❑ (Inner race for 1st gear)

⇒ Fig. ““Installed Position of the Inner Race, the Outer Race and the 1st Gear Synchronizer Ring”“ , page
273 .
❑ Checking for wear, refer to
⇒ Fig. ““Checking Inner Race for 1st gear and 2nd Gear for Wear”“ , page 273
❑ Check for scoring
14 - 1st Gear Outer Race
⇒ Fig. ““Installed Position of the Inner Race, the Outer Race and the 1st Gear Synchronizer Ring”“ , page
273 .
⇒ Fig. ““Checking 1st Gear and 2nd Gear Synchronizing Ring for Wear”“ , page 274
❑ Replace if there are grooves or scoring
15 - 1st Gear Synchronizer Ring
❑ Installed position, refer to en AG. Volkswagen AG
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16 - Locking Collar With Synchronizer Hub for 1st and 2nd Gears
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❑ Assembling operating sleeve/synchronizer hub, refer to

t to the co
⇒ Fig. ““Disassembling and Assembling Locking Collar and Synchronizer Hub for 1st and 2nd Gears”“ ,
page 274 ,
⇒ Fig. ““Assembly: Locking Collar/Synchronizer Hub for 1st and 2nd Gears Together with Locking Pieces
rrectness of i
that are Hollow on the Inside”“ , page 274 and

⇒ Fig. ““Assembly: Locking Collar/Synchronizer Hub for 1st and 2nd Gears Together With Locking Pieces
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⇒ Fig. ““Installed Position: Locking Collar/Synchronizer Hub For 1st and 2nd Gears”“ , page 275 .
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⇒ Fig. ““Installing the Locking Collar/Synchronizer Hub for 1st and 2nd Gears.”“ , page 275
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19 - 2nd Gear Outer Race
❑ Insert into synchronizer ring -item 18- ⇒ Item 18 (page 259) .
❑ Installed position, refer to ⇒ Fig. ““Installed Position of 2nd Gear Outer Race”“ , page 275 .
❑ Replace if there are grooves or scoring
20 - Synchronizer Ring
❑ (Inner race for 2nd gear)
❑ Check for scoring
⇒ Fig. ““Installed Position: Synchronizer Ring -A- (2nd Gear Inner Race)”“ , page 276 .
21 - 2nd Gear Wheel
❑ Installed position, refer to ⇒ Fig. ““Installed Position: 2nd Gear Wheel”“ , page 276 .

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23 - Thrust Washer
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24 - Sleeve for the 3rd Gear Needle Bearing
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With the Needle Bearing Sleeve and Output Shaft”“ , page 272
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❑ Installing, refer to ⇒ Fig. ““Installing the Sleeve for the 3rd Gear Needle Bearing”“ , page 276
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25 - Needle Bearing urposes, in part or in wh
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❑ For 3rd gear
26 - 3rd Gear Wheel
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27 - 3rd Gear Synchronizer Ring
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⇒ Fig. ““Assembly: Locking Collar/Synchronizer Hub for 3rd and 4th Gears Together With Locking Pieces
That Are Not Hollow”“ , page 277 .
❑ Installed position: locking collar/synchronizer hub, refer to
⇒ Fig. ““Installed Position: Locking Collar/Synchronizer Hub for 3rd and 4th Gears”“ , page 278
⇒ Fig. ““Installing the Synchronizer Hub with Locking Collar for 3rd and 4th Gears”“ , page 278
29 - Sleeve
❑ For the needle bearing
❑ Removing with the locking collar and the 3rd/4th gear synchronizer hub -item 28-
⇒ Item 28 (page 260) , refer to
❑ Installing, refer to ⇒ Fig. ““Installing the Sleeve for the 4th Gear Needle Bearing”“ , page 278
30 - Needle Bearing
❑ For 4th gear
31 - 4th Gear Synchronizer Ring
❑ Checking for wear, refer to ⇒ Fig. ““Checking 3rd/4th Gear Synchronizing Ring for Wear”“ , page 276
32 - 4th Gear Wheel
33 - Thrust Washer
34 - Needle Bearing
❑ Removing and Installing, refer to ⇒ Fig. ““Removing the Needle Bearing”“ , page 210
36 - Sleeve
❑ For the needle bearing/output shaft

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❑ Installing, referutto
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1.4 Output Shaft, Adjusting
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♦ Torque Wrench 5-50Nm - VAG1331-
♦ Dial Gauge
♦ Puller - Kukko Internal - 36-46mm - 21/6-
♦ Puller - Kukko Counterstay - 22/2-
It is necessary to adjust the output shaft if the following compo‐
nents were replaced:
♦ Output Shaft
♦ Clutch Housing
or
♦ Tapered roller bearing
Adjustment overview, refer to
Requirements:
• Remove any sealant still on the sealing surfaces on the clutch
and transmission housings.
– Press the outer race/small tapered roller bearing with the ad‐
justment shim 0.65 mm into the clutch housing as far as the
stop, refer to
⇒ Fig. ““Installing the Small Outer Race/Tapered Roller Bear‐
ing”“ , page 271 .
– Install output shaft and tighten the bearing mount nuts to 25
Nm, and then a 90° additional turn.
– Rotate the output shaft 20 to 30 times in one direction.

Note
♦ It must be rotated in one direction so the tapered roller bearing

rollers are seated in one direction.
♦ Therefore, it must also be rotated 20 to 30 times in one direc‐
tion.
♦ Otherwise the measurements will be incorrect.
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– Install dial gauge (3 mm measuring range) and ed set to “0” with
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Bearing Play = Adjustment Shim Thickness
(Adjustment Shim 0.65 mm According to the Table
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0.740 mm 0.900 mm
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Shim Table
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Bearing Play = Adjustment Shim

(Adjustment Shim 0.65 mm Thickness (mm)
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0.990 to 1.039 1.150

1.040 to 1.089 1.200
1.090 to 1.139 1.250
1.140 to 1.189 1.300
1.190 to 1.239 1.350
1.240 to 1.289 1.400
1.290 to 1.339 1.450
1.340 to 1.389 1.500
1.390 to 1.429 1.550
Note
For the correct shims, refer to the Parts Catalog.
– Remove the output shaft and then remove the small taper roll‐
er bearing outer race, refer to
⇒ Fig. ““Remove the Small Outer Race/Tapered Roller Bear‐
ing”“ , page 271
• If the previous 0.65 mm adjustment shim will be inserted again,
check it for damage.
ness.
Tolerance variations make it possible to find the exact shim thick‐
ness required.

– Press in small tapered roller bearing outer race with deter‐

mined shim (0.70 mm as in example), refer to
⇒ Fig. ““Installing the Small Outer Race/Tapered Roller Bear‐
ing”“ , page 271 and install output shaft. Tighten the bearing
mount nut in the clutch housing to 25 Nm and then turn 90°
further.
1.5 Overview - Reverse Shaft
Note
Always replace the needle sleeve after removing it from the clutch housing or from the reverse shaft support.
1 - Clutch Housing
2 - Needle Sleeve
Needle Sleeve from the
Clutch Housing”“ ,
page 279
Needle Sleeve -A- into
the Clutch Housing”“ ,
page 279
3 - Reverse Drive Gear
4 - Locking Ring
❑ Always replace after re‐
moving
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7 - Needle Sleeve
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Needle Sleeve from the
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Reverse Shaft Sup‐

port”“ , page 279
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⇒ Fig. ““Installing the Needle Sleeve into the Reverse Shaft Support”“ , page 280
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8 - Reverse Shaft Support

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⇒ “2.1 Input Shaft Seal, Replacing”, page 265
2.1 Input Shaft Seal, Replacing

♦ Press Piece - Front Control Arm - 2040-
– Remove the transmission.
– Remove the clutch release lever with the release bearing and
– Drive seal out of guide sleeve.
Note
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– Fill the space between the sealing and dust lip -arrow- halfway
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with Sealing Grease - G 052 128 A1- .

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– Lightly coat the outer circumference of the seal with transmis‐

t to the co
sion fluid.
– Install the seal all the way into the guide sleeve.
rrectness of i
– Install the clutch release lever with the release bearing and
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3 Disassembly and Assembly

⇒ “3.1 Input Shaft”, page 266
⇒ “3.2 Output Shaft”, page 271
⇒ “3.3 Reverse Shaft”, page 279
3.1 Input Shaft

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♦ Press Tube - 41-501-
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♦ -3- Puller - Kukko Quick Action Separating Tool - 12-75mm -

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Removing the Outer Race/Tapered Roller Bearing

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Removing the Bearing Inner Race/Taper Roller Bearing

A - Puller - Kukko Quick Action Separating Tool - 12-75mm -Kuk‐
ko 17/1-

Installing the Bearing Inner Race/Taper Roller Bearing
Removing the 4th Gear Wheel With the Tapered Roller Bearing
and Sleeve
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Removing 4th Gear Wheel

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Removing the Outer Race/Tapered Roller Bearing

Installing the Outer Race/Tapered Roller Bearing

– Install with shim after adjusting input shaft.
5th Gear Synchronizing

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Installed Position of the Springs with Locking Pieces that are Not
Hollow Inside:
The angled end of the spring must be positioned in front of the
locking pieces -arrows-.
Installed Position of the Springs with Locking Pieces that are Hol‐
low Inside:
– The angled end of the spring must engage into the hollow
locking piece (⇒ illustration following the next one).

Installation of Offset Springs -A-

These springs are installed on both sides.
– Springs are only installed in conjunction with hollow locking
pieces.
– Insert locking pieces (installed position: Refer to
⇒ Fig. ““5th Gear Synchronizing”“ , page 269 ).
Spring installed position:

– Install the circlips 120° offset.
– Angled end -A- of spring must engageAG. Vinto
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♦ Puller - Taper Roller Bearing - VAG1582-
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♦ Puller - Taper Roller Bearing - Adapter 4 - VAG1582/4-
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♦ Puller - Kukko Counterstay - 4-Kukko 22/2-
♦ Puller - Kukko Quick Action Separating Tool - 22-115mm - 3-
Kukko 17/2-
Remove the Small Outer Race/Tapered Roller Bearing
A - Puller - Kukko Internal - 36-46mm for example -Kukko 21/6-
B - Counter Support , for example, Puller - Kukko Counterstay -
Kukko 22/2-
Installing the Small Outer Race/Tapered Roller Bearing

Removing the Inner Race/Small Tapered Roller Bearing

A - Protective jaws/vise
– Mount the grip and apply tension behind rolling the bearing.
Then rotate the bearing and apply tension to the grip.
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Installing the Inner Race/Small Tapered Roller Bearing
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Removing the Synchronizer and 3rd/4th Gear Locking Collar,
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2nd, 3rd and 4th Gear Wheels With the Needle Bearing Sleeve
and Output Shaft
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A - Puller - Quick Action Separating Tool - 22-115mm , for exam‐
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Removing the Locking Collar with the Synchronizer Hub and
Bearing Mount
– Remove the locking ring -arrow- first.

Removing the Inner Race/Large Tapered Roller Bearing

A - Jaw protectors
– Before installing puller, insert a M10 x 20 bolt into the
agen
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. Volkin
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Installing the Inner Race/Large Tapered Roller Bearing
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Installed Position of the Inner Race, the Outer Race and the 1st
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The tabs -arrow 2- must lock into the retainers -arrow 3- in the
gear wheel.
– Install the synchronizer ring -C-.
The retainers -arrow 4- lock in the tabs -arrow 1- on the inner race
-A-.
Note
If the parts are not to be replaced, make sure they are reallocated
to their original gear.
Checking Inner Race for 1st gear and 2nd Gear for Wear
– Press the inner race onto taper on the gear wheel and meas‐
ure the gap dimension -a- with a feeler gauge.
Gap dimension Installation Dimen‐ Wear Limit
-a- sion
1st and 2nd gear 0.75 to 1.25 mm 0.3 mm

Checking 1st Gear and 2nd Gear Synchronizing Ring for Wear
– Press synchronizer ring, outer race and inner race onto taper
of gear wheel and measure gap dimension -a- using a feeler
gauge.
-a- sion
1st and 2nd gear 1.2 to 1.8 mm 0.5 mm
Disassembling and Assembling Locking Collar and Synchronizer

Hub for 1st and 2nd Gears
1 - Spring
For the correct springs, refer to the Parts Catalog
Assembly in conjunction with hollow locking pieces, refer to
⇒ Fig. ““Assembly: Locking Collar/Synchronizer Hub for 1st and
2nd Gears Together with Locking Pieces that are Hollow on the
. Volkswagen AG
Inside”“ , page 274 . swa
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es, in part or in w
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The collar has the same width on both side of the synchronizer
hub.
rrectness of i
The Shoulder Has a Chamfer on one Side -arrow B-.
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The bevel on the synchronizer hub collar and the splines on the
outside of the locking collar -arrow A- face in the same direction
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The notches on the synchronizer hub and locking collar for the
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locking pieces -arrow C- must line up.

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Assembly: Locking Collar/Synchronizer Hub for 1st and 2nd

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Assembly: Locking Collar/Synchronizer Hub for 1st and 2nd
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Installed Position: Locking Collar/Synchronizer Hub For 1st and

2nd Gears
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Installing the Locking Collar/Synchronizer Hub for 1st and 2nd

Gears.
Turn the synchronizer ring so that the grooves line up with the
locking pieces.
Installed Position of 2nd Gear Outer Race

The tabs -arrows- face 1st gear -A-.

Installed Position: Synchronizer Ring -A- (2nd Gear Inner Race)

The tabs -arrow 1- engage into the holes -arrow 2- inside the
synchronizer ring -B-.
Installed Position: 2nd Gear Wheel

The higher collar -A- faces toward 1st gear -B-. The notches in
the collar -arrow- lock into the tabs
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⇒ Fig. ““Installed Position of olksw Gear Outer Race”“ , page
2nd not 275 .
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Installing the Sleeve for the 3rd Gear Needle Bearing
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Checking 3rd/4th Gear Synchronizing Ring for Wear

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1st Gear 1.0 to 1.7 mm 0.5 mm

3rd Gear 1.0 to 1.7 mm
4th Gear 1.0 to 1.7 mm

Disassembling and Assembling Locking Collar and Synchronizer

Hub for 3rd/4th Gears
1 - Spring
For the correct springs, refer to the Parts Catalog.
Assembly in conjunction with hollow locking pieces, refer to
2nd Gears Together with Locking Pieces that are Hollow on the
Inside”“ , page 274 .
Assembly in conjunction with locking pieces that are not hollow,
refer to
2nd Gears Together With Locking Pieces That Are Not Hollow”“ ,
page 275 .
2 - Locking piece
For the correct locking pieces, refer to the Parts Catalog.
3 - Locking collar
4 - Synchronizer Hub
– Slide the locking collar over the synchronizer hub.
The notches for the locking pieces on the synchronizer hub and
locking collar must line up with each other.
swage es n
Assembly: Locking Collar/Synchronizer Hub for 3rd and 4th by Vo lk ot g
ua
Gears Together with locking Pieces That Are Hollow on therisInside
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Assembly: Locking Collar/Synchronizer Hub for 3rd and 4th
rrectness of i
Gears Together With Locking Pieces That Are Not Hollow
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– Install the locking pieces and springs offset by 120°. The an‐ nform
ercia
gled end of the spring must be positioned in front of the locking

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Installed Position: Locking Collar/Synchronizer Hub for 3rd and

4th Gears
The bevel -arrow- faces 4th gear.
Installing the Synchronizer Hub with Locking Collar for 3rd and
4th Gears
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Installing the Sleeve for the 4th Gear Needle Bearing tho r eo
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Installing the Sleeve for the Needle Bearing/Output Shaft
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3.3 Reverse Shaft
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♦ Press Piece - Multiple Use - VW447H-
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♦ Centering/Press Pin - 12-551-
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♦ -1- Puller - Kukko Internal - 14-19mm - 21/2-
♦ -4- Puller - Kukko Counterstay - 22/1-
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Removing the Needle Sleeve from the Clutch Housing
m
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atio
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A - Counter Support , for example -Kukko 22/1-

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B - Puller - Kukko Internal - 14-19mm , for example -Kukko 21/2-

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Installing the Needle Sleeve -A- into the Clutch Housing
Removing the Needle Sleeve from the Reverse Shaft Support

Installing the Needle Sleeve into the Reverse Shaft Support
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4 Special Tools

equipment required
♦ Press Piece - Rod -
VW407-
♦ Press Piece - Multiple Use agen
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♦ Press Piece - Rod - horis
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♦ Press Piece - Shift Rod/Al‐
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VW407-
VW412-
- VW512-
♦ Puller - Taper Roller Bear‐
ing - VAG1582-
ing - Adapter 4 -
VAG1582/4-
ing - Adapter 5 -
VAG1582/5-
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Use - 32-111-
VW408A-
VW409-
♦ Support Channels -
VW457-
- VW519-
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- VW429-
VW415A-
- VW447H-
- VW454-
- VW455-
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- VW454-
- VW447H-
VW411-
♦ Centering/Press Pin -
12-551-
VW408A-
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♦ Dial Gauge Holder -

VW387-
♦ Measuring Set - Magnetic
Plate - 50mm - VW385/17-
AG. Volkswagen AG d
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♦ Press Piece - Multiple Use Volksw
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♦ Press Piece - VW447i- auth
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5-50Nm - VAG1331-
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♦ Dial Gauge Holder -

VW387-
♦ Measuring Set - Magnetic
Plate - 50mm - VW385/17-
- VW512-
♦ Door Alignment Device -
Replacement Stud -
3114/2-
VW407-
♦ Torque Wrench 5-50Nm -
VAG1331-
♦ Dial Gauge
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♦ Press Piece - 28x100mm -

VW421-
- VW454-
- VW510-
♦ -3- Puller - Kukko Quick Ac‐
tion Separating Tool -
12-75mm - 17/1-
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♦ Bearing/Bushing Installer - Multiple Use - VW295- cted agen
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♦ Press Piece - Front Control Arm - 2040-

39 – Final Drive, Differential

⇒ “1.1 Differentiating Right Flange Shaft Seals”, page 289
1.1 Differentiating Right Flange Shaft Seals

The seal -1- for the right flange shaft is inside the sleeve -2-.
There are different versions:
The seal -1- and the sleeve -2- are two separate parts. Charac‐
teristics: the notches are arranged in circle in sleeve -arrow-.
Seal, Replacing, refer to
⇒ “3.2 Seal, Right, With Installed Manual Transmission, Two-Part
for Flange Shaft and Sleeve”, page 296 .
The seal -1- and the sleeve -2- are a single part. Characteristics:
no opening in the sleeve.
Replace the seal and the sleeve together, refer to
⇒ “3.3 Seal and Sleeve, One-Piece Right Flange Shaft Seal and
Sleeve, With Installed Manual Transmission”, page 298 .
AG. Volkswagen AG d
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Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ed 2009 ➤ , Pass ...
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Manual Transmission - Edition 07.2014 ut
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⇒ “2.1 Adjustment Overview”, page 290
ility
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⇒ “2.2 Overview - Differential”, page 290
, is n
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⇒ “2.3 Differential, Adjusting”, page 293
spec
es, in part or in w
t to the co
2.1 Adjustment Overview
rrectness of i
Note
l purpos
If repairs have been performed on the transmission, it is only nec‐
essary to adjust the input shaft, output shaft or differential if
nf
ercia
components have been replaced which have a direct effect on the
orm
adjustment of the transmission, refer to Table to avoid any un‐ m
atio
m
necessary adjusting. o
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or c
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iv
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Input Shaft Output Shaft Differential
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⇒ “1.2 Input ⇒ “1.4 Out‐ ⇒ “2.3 Differ‐ C py
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Replaced part: Transmission Housing x x

Clutch Housing x x x
Input Shaft x
Output Shaft x
Differential housing x
Output shaft tapered roller bearing x
Output shaft tapered roller bearing x
Differential tapered roller bearing x
4th Gear Wheel x
2.2 Overview - Differential
Note
♦ Heat the inner race / tapered roller bearing to 100 °C (212 °F) before installing.
♦ Replace both tapered roller bearings together.
♦ Adjust differential, refer to ⇒ “2.1 Adjustment Overview”, page 290 when replacing tapered roller bearing,
differential housing, transmission housing and clutch housing.
290 Rep. Gr.39 - Final Drive, Differential

2 - Shim
❑ Selecting thickness, re‐
fer to
⇒ “2.3 Differential, Ad‐
justing”, page 293 .
3 - Outer Race/Tapered Roller
Bearing
Outer Race/Tapered
Roller Bearing from the
Transmission Hous‐ agen
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⇒ Fig. ““Installing the aut
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Bearing Inner Race/
page 301
rrectness of i
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Bearing Inner Race/

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ercia
page 302
m
5 - Differential Housing
at
om
ion
❑ With final drive gear
c
in t
or
wheel his
ate
do
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❑ Thrust washer union fitted to differential housing, refer to

p
cum
or
⇒ Fig. ““On Some Transmissions, the Thrust Washer Union Has a Ridge -A-.”“ , page 304
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6 - Inner Race / Tapered Roller Bearing
AG.
❑ Removing, refer to ⇒ Fig. ““Removing the Bearing Inner Race/Taper Roller Bearing”“ , page 301
❑ Installing, refer to ⇒ Fig. ““Installing the Bearing Inner Race/Taper Roller Bearing”“ , page 302
⇒ Fig. ““Removing the Outer Race/Tapered Roller Bearing from the Clutch Housing”“ , page 301
⇒ Fig. ““Installing Outer Race/Tapered Roller Bearing Into the Clutch Housing”“ , page 301
8 - Clutch Housing
9 - Sleeve
❑ For mounting the seal -item 10- ⇒ Item 10 (page 291)
❑ Removing and installing, refer to ⇒ “3.5 Selector Mechanism”, page 129 .
10 - Seal
❑ Left flange shaft seal, inserting with transmission installed, refer to
⇒ “3.1 Flange Shaft Seal, Left, With Installed Manual Transmission”, page 295 .

❑ Right flange shaft seal, inserting with transmission installed (right flange shaft and sleeve seal consist of
two parts), refer to
page 296
11 - Seal and Sleeve One-Piece
❑ If the seal is damaged, then replace both the seal and sleeve, refer to
⇒ “3.3 Seal and Sleeve, One-Piece Right Flange Shaft Seal and Sleeve, With Installed Manual Trans‐
mission”, page 298 .
12 - Bolt
❑ 25 Nm
❑ Install with the threaded piece -item 20- ⇒ Item 20 (page 292)
13 - Flange Shaft
⇒ “3.1 Flange Shaft Seal, Left, With Installed Manual Transmission”, page 295 or
page 296 ..
14 - Flange Shaft Pressure Spring
❑ Installed behind the flange shafts
15 - Thrust Washer
❑ Installed position, refer to ⇒ Fig. ““Installed Position: Tapered Ring Thrust Washer -1- ”“ , page 304 .
16 - Tapered Ring
❑ With grooves for the thrust washer
❑ Installed position: ball toward the differential housing
17 - Locking Ring
❑ Holds the tapered ring, the thrust washer and the pressure spring when the flange shaft is removed
18 - Thrust Washer Union
❑ Availability, refer to Parts Catalog. olkswage es n
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19 - Large Differential Bevel Gear

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20 - Threaded Piece
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21 - Differential Taper Axle

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❑ Removing, with a short spring pin, refer to ⇒ “3.14 Shift Unit, Servicing”, page 213
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❑ Removing, with a long spring pin, refer to ⇒ “3.14 Shift Unit, Servicing”, page 213
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❑ Long tension sleeve: sheared off when removing, refer to
⇒ Fig. ““Spring Pin Without Surrounding Groove (Long Spring Pin), Removing: Press Out the Differential
Bevel Gear Axle”“ , page 303
❑ Long tension sleeve: installing, refer to
⇒ Fig. ““Spring Pin Without Surrounding Groove (Long Spring Pin), Installing”“ , page 303
23 - Small Differential Bevel Gear
24 - Large Differential Bevel Gear
2.3 Differential, Adjusting

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A new differential adjustment is required when the following com‐
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♦ Transmission Housing
♦ Clutch Housing rrectness of i
♦ Differential housing
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– Press tapered roller bearing outer race into transmission hous‐

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the Transmission Housing.”“ , page 302 .
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Bearing inner- and outer race of tapered roller bearing are paired.
Do not interchange them.
– Press tapered roller bearing outer race into clutch housing,

using Press Piece - Multiple Use - 30-205- , refer to
⇒ Fig. ““Installing Outer Race/Tapered Roller Bearing Into the
Clutch Housing”“ , page 301 .
– Insert differential into clutch housing.

– Mount the transmission housing and tighten the five bolts to

25 Nm.
– Install the dial gauge and set it to “0” with a 1 mm pre-load.
– Move differential up and down, read off play on dial gauge and
note. (example: 0.70 mm).
Determining the Shim
Example:
Bearing Clearance Measured Adjustment Shim Thickness
Value According to the Table
0.70 mm 0.95 mm
Shim Table
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0.450 to 0.499 0.700 ss
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0.500 to 0.549 0.750

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0.600 to 0.649 0.850
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0.650 to 0.699 0.900
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0.750 to 0.799 1.000
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0.800 to 0.849 1.050
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0.850 to 0.899 1.100
0.900 to 0.949 1.150
0.950 to 0.999 1.200
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1.000 to 1.049 1.250
1.050 to 1.099 1.300
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1.100 to 1.149 1.350

1.150 to 1.199 1.400
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For the correct shims, refer to the Parts Catalog. do

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– Remove the transmission housing and remove the tapered op
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roller bearing outer race from the transmission housing.
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Removing the Outer Race/Tapered Roller Bearing from the Prote
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Transmission Housing
A - Counter Support , for example, Puller - Kukko Counterstay -
Kukko 22/2-
B - Internal Puller 46 to 58 mm , for example -Kukko 21/7-
ness.
Tolerance variations make it possible to find the exact shim thick‐
ness required.
– Install the tapered roller bearing inner race again, refer to
⇒ Fig. ““Installing the Outer Race/Tapered Roller Bearing Into
the Transmission Housing.”“ , page 302 and fasten the trans‐
mission housing.


⇒ “3.1 Flange Shaft Seal, Left, With Installed Manual Transmis‐
sion”, page 295
⇒ “3.2 Seal, Right, With Installed Manual Transmission, Two-Part
for Flange Shaft and Sleeve”, page 296
⇒ “3.3 Seal and Sleeve, One-Piece Right Flange Shaft Seal and
Sleeve, With Installed Manual Transmission”, page 298
3.1 Flange Shaft Seal, Left, With Installed

Manual Transmission
♦ Slide Hammer Set - VW771-
♦ Slide Hammer Set - Hook - VW771/37-
♦ Seal Installer - Flange Shaft Oil Seal - T10160-
♦ Drip Tray for VAG1202A - VAS6208-
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– Remove the left swheel.
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refer to ⇒ Body Exterior; Rep. Gr. 66 ; Wheel Housing Liner . wit
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– Turn the steering wheel to the left.

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es, in part or in w
– Remove the drive axle from the flange shaft, refer to ⇒ Sus‐
t to the co
pension, Wheels, Steering; Rep. Gr. 40 ; Drive Axle, Servic‐

ing; Drive Axles, Removing and Installing .
rrectness of i
– Tie the drive axle as high up as possible. Do not damage the

paint on the drive axle.
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– Place the drip tray under the transmission.

nform
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– Remove the flange shaft bolt. To do this, install two bolts into
the flange and counterhold the flange shaft using a pry bar.
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– Remove the flange shaft and the pressure spring.

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– Remove the flange seal using the Slide Hammer - VW771-

and the Slide Hammer Set - Hook - VW771/37- .
3.1.2 Installing
– Install the seal all the way in without tilting it.
– Fill the space between the sealing and dust lip halfway with
Sealing Grease - G 052 128 A1- .
– Install the flange shaft.
– Attach the flange shaft with screw.
– Install the drive axle on the transmission, refer to ⇒ Suspen‐
sion, Wheels, Steering; Rep. Gr. 40 ; Drive Axle, Servicing;
Drive Axles, Removing and Installing .
– Check the transmission fluid level, refer to
⇒ “1.1 Transmission Fluid, Checking and Filling”, page 90 .
– Install the lower part ofwthe
agenleft front wheelAG
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– Install the noise
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– Install the wheel, refer to ⇒ Suspension, Wheels, Steering;

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Rep. Gr. 44 ; Wheel Installation Tightening Specifications .

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3.1.3 Tightening Specification

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Flange Shaft to Transmission (Conical Head Bolt) -item 12-

hole
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⇒ Item 12 (page 292) .

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3.2 Seal, Right, With Installed Manual

Transmission, Two-Part for Flange
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Shaft and Sleeve

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♦ Seal Installer - Flange Shaft Oil Seal - T10160-

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♦ Rear Wheel Bearing Kit - Cross Head - 3253/2-

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– Turn steering as far as possible toward right.
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– Remove the drive axle -1- from the flange shaft.
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– Place container under transmission and engine.
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– Remove turbocharger oil return line from engine, if necessary
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– Place the drip tray under the transmission.
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– Pry out the seal with a screwdriver -A- in direction of -arrow-.

Support the screwdriver on the Rear Wheel Bearing Kit - Cross
Head - 3253/2- .
Note
♦ Be careful not to damage the sleeve otherwise there will be

leaks.
♦ Replace the sleeve if it is damaged, refer to
⇒ Fig. ““Prying out the Sleeve -arrow- ”“ , page 211 .

Manual Transmission - Edition 07.2014 en AG. V
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3.2.2 Installing by ara
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– Install the seal all the way in without tilting it. au ra
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– Attach the turbocharger oil return line to the engine, if it was
ss o
removed earlier, refer to -arrow- ⇒ Rep. Gr. 21 ; Turbocharger
cial p
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Charge Air System, Turbocharger and Attachments, Remov‐
form
mer
ing and Installing .
atio
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– Attach the drive axle -1- to the flange shaft, refer to ⇒ Sus‐
o
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c
i
pension, Wheels, Steering; Rep. Gr. 40 ; Drive Axles, Serv‐
or
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icing, Drive Axles, Drive Axles, Removing and Installing .

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– Check the transmission fluid level and fill if necessary, refer to

⇒ Item 12 (page 292) .
3.3 Seal and Sleeve, One-Piece Right

Flange Shaft Seal and Sleeve, With In‐
stalled Manual Transmission
♦ Seal Installer - One-Piece Seal - T10148-
♦ Spindle from the Seal Installer - Driver Set - 3066-
♦ Slide Hammer Set - VW771-
♦ Slide Hammer Set - Hook - VW771/37-

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3.3.1 Removing
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Gr. 50 ; Noise Insulation . itte
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– Turn steering as far as possible toward right.
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– Remove the drive axle -1- from the flange shaft.
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– Place container under transmission and engine.
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System, Turbocharger with Attachments, Removing and In‐
stalling .
– Remove the seal and the sleeve together.

A ridge is located on the internal diameter of the sleeve.
– Attach the Slide Hammer Set - Hook - VW771/37- directly be‐
hind the ridge inside the sleeve.
– Using force, push the Slide Hammer Set - Hook - VW771/37-
into the sleeve.
3.3.2 Installing
– Clean the seal in the transmission.

– Install the seal and the sleeve together.

A - Install the Spindle on the Seal Installer - Driver Set - 3066- into
the threaded piece in the differential.
B - M12 Nut
– Turn the nut -B- and pull the seal with the sleeve all the way
over the Seal Installer - One-Piece Seal - T10148- .
– Attach the turbocharger oil return line to the engine, if it was

removed earlier -arrow-, refer to ⇒ Rep. Gr. 21 ; Turbocharger
Charge Air System, Turbocharger and Attachments, Remov‐
ing and Installing .
– Attach the drive axle -1- to the flange shaft, refer to ⇒ Sus‐
pension, Wheels, Steering; Rep. Gr. 40 ; Drive Axles, Serv‐
icing, Drive Axles, Drive Axles, Removing and Installing .
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– Check the transmission fluid level and fill if necessary, refer to
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⇒ Item 12 (page 292) .

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⇒ “4.1 Differential”, page 301
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4.1 Differential
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♦ Puller - Taper Roller Bearing - VAG1582-
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♦ Press Piece - Multiple Use - 30-205-
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♦ Bearing Installer - Wheel Bearing - 3144-
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♦ Bearing Installer - Taper Roller Bearing - 2007-

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♦ Puller - Kukko Internal - 46-56mm - 1-Kukko 21/7- C py
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Removing the Outer Race/Tapered Roller Bearing from the
AG.
Clutch Housing
– Remove the sleeve for the seal/flange shaft beforehand.
Installing Outer Race/Tapered Roller Bearing Into the Clutch

Housing
There is no adjusting shim on the side of the clutch housing.
Removing the Bearing Inner Race/Taper Roller Bearing

– Mount the Press Piece - Multiple Use - 40-105- on the differ‐
ential housing before removing the puller.
Note
Both tapered roller bearing inner races are pulled off from the dif‐
ferential housing in the same way.

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differential housing in the same way.
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Removing the Outer Race/Tapered Roller Bearing from the
Transmission Housing
rrectness of i
A - Counter Support , for example, Puller - Kukko Counterstay -
l purpos
Kukko 22/2-
B - Internal Puller 46 to 58 mm , for example, Puller - Kukko In‐
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Installing the Outer Race/Tapered Roller Bearing Into the Trans‐ C py
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– Install the adjusting shim under the outer race. cted agen
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– Support the transmission housing with the Bearing Installer -

Wheel Bearing - 3144- directly under the bearing mount.
Differentiating the Spring Pins

Dimension “a” mm Identifying Feature
28.5 (short spring pin), Groove all the way
Removing and Installing, refer to around -arrows-
⇒ “3.14 Shift Unit, Servicing”,
page 213
36.0 (long spring pin), no surrounding groove
removing, refer to
⇒ “3.14 Shift Unit, Servicing”,
page 213 ,
installing, refer to
⇒ Fig. ““Spring Pin Without Sur‐
rounding Groove (Long Spring Pin),
Installing”“ , page 303

Allocation, Differential Housing

– Check the spring pin hole in the differential housing.
The hole in the differential housing was modified due to the longer
spring pin.
Hole Spring Pin Length (mm)
-A- 28.5 (short spring pin)
-A- and -B- 36.0 (long spring pin)
AG. Volkswagen AG d
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Spring Pin With Surrounding Groove (Short SpringthPin):
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– Remove the adapter sleeve using a chisel.
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Installing
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es, in part or in w
– Drive into the differential housing up to the stop.
t to the co
rrectness of i
Spring Pin Without Surrounding Groove (Long Spring Pin), Re‐
l purpos
moving: Press Out the Differential Bevel Gear Axle

Spring pin is sheared off when it is removed.
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– Drive remaining part of roller pin out of differential housing.
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Spring Pin Without Surrounding Groove (Long Spring Pin), In‐
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stalling
– Align the hole in the differential bevel gear axle to the hole in
the differential housing.
– Drive a new spring pin in to dimension -a- = 3.0 mm using a
drift -1-.
• The spring pin must not come in contact with the transmission
when the differential housing is installed.

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Golf 2004
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Manual
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On Some Transmissions, the Thrust Washer Union Has a Ridge
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– Insert thrust washer union with transmission fluid.
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– Install the thrust washer union so that it engages into the
groove -B- of the differential housing.
rrectness o
cial p
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Installing the Differential Planetary Gears and Differential Bevel
mer
Gear Axle
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– Insert thrust washer union with transmission fluid.
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– Install and secure both large differential planetary gears, for
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– Insert threaded pieces -arrow B- into the large differential

planetary gears.
Installed position: shoulder faces the differential bevel gear
– Drive differential planetary gear axle into final position and se‐
cure with spring pin.
Installed Position: Tapered Ring Thrust Washer -1-

The collar -arrow- faces the pressure spring -B-.
Some transmissions are not equipped with ridges -A-.
The ridges -A- face the tapered ring -1-.

5 Special Tools
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VW408A-
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♦ Bearing Installer - Wheel
Bearing - 3144-
♦ Bearing Installer - Taper
Roller Bearing - 2007-
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♦ Seal Installer - One-Piece

Seal - T10148-
♦ Spindle from the Seal In‐
staller - Driver Set - 3066-
VW771-
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♦ Drip Tray for VAG1202A -
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♦ 1. Puller - Kukko Internal -
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♦ 4. Puller - Kukko Counter‐
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VW771-
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♦ Seal Installer - Flange Shaft
Oil Seal - T10160-
♦ Drip Tray for VAG1202A -
VAS6208-
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♦ Rear Wheel Bearing Kit - Cross Head - 3253/2-
Edition K0258990421 FU 10/30/2014 - ESP
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6 Revision History
Re Dat Job Type Feedback # Notes Editor
vi‐ e
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1 10/ Factory Up‐ N/A Eric

30/ date Puter‐
201 baugh
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6. Revision History 311

Cautions & Warnings
Please read these WARNINGS and CAUTIONS before proceeding with maintenance
and repair work. You must answer that you have read and you understand these
WARNINGS and CAUTIONS before you will be allowed to view this information.
•= If you lack the skills, tools and equipment, or a suitable workshop for any procedure described in this manual, we
suggest you leave such repairs to an authorized Volkswagen retailer or other qualified shop. We especially urge
you to consult an authorized Volkswagen retailer before beginning repairs on any vehicle that may still be covered
wholly or in part by any of the extensive warranties issued by Volkswagen.
•= Disconnect the battery negative terminal (ground strap) whenever you work on the fuel system or the electrical
system. Do not smoke or work near heaters or other fire hazards. Keep an approved fire extinguisher handy.
•= Volkswagen is constantly improving its vehicles and sometimes these changes, both in parts and specifications,
are made applicable to earlier models. Therefore, part numbers listed in this manual are for reference only. Always
check with your authorized Volkswagen retailer parts department for the latest information.
n AG do AG. Volkswagen
•= Any time the battery has been disconnected on an automaticwagetransmission vehicle,
es nit will be necessary to
Volks ot g
reestablish Transmission Control Module (TCM) basic
d by settings using the VAG 1551 Scanua Tool (ST).
r e an
ris tee
tho or
•= Never work under a lifted vehicle unless supported on stands designed for Do not support it iss ausolidly the purpose.ac
s
a vehicle on cinder blocks, hollow tiles or other props that may crumble under continuous load. Never work under a
ce
le
un
pt
vehicle that is supported solely by a jack. Never work under the vehicle while the engine is running.
an
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•= For vehicles equipped with an anti-theft radio, be sure of the correct radio activation code before disconnecting the
ility
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battery or removing the radio. If the wrong code is entered when the power is restored, the radio may lock up and
wit
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become inoperable, even if the correct code is used in a later attempt.
ole,
spec
•= If you are going to work under a vehicle on the ground, make sure that the ground is level. Block the wheels to
t to the co
keep the vehicle from rolling. Disconnect the battery negative terminal (ground strap) to prevent others from
starting the vehicle while you are under it.
rrectne
•= Do not attempt to work on your vehicle if you do not feel well. You increase the danger of injury to yourself and
others if you are tired, upset or have taken medicine or any other substances that may impair you or keep you from
ss
being fully alert. o
cial p
f inform
mer
•= Never run the engine unless the work area is well ventilated. Carbon monoxide (CO) kills.
atio
om
n
c
•= Always observe good workshop practices. Wear goggles when you operate machine tools or work with acid. Wear
i
or
n thi
e
goggles, gloves and other protective clothing whenever the job requires working with harmful substances.
t
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•= Tie long hair behind your head. Do not wear a necktie, a scarf, loose clothing, or a necklace when you work near
en
ng
i t.
machine tools or running engines. If your hair, clothing, or jewelry were to get caught in the machinery, severe py Co
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injury could result. ht. rig
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•= Do not re-use any fasteners that are worn or deformed in normal use. Some fasteners are designed to be used
agen
Prote AG.
only once and are unreliable and may fail if used a second time. This includes, but is not limited to, nuts, bolts,
washers, circlips and cotter pins. Always follow the recommendations in this manual - replace these fasteners with
new parts where indicated, and any other time it is deemed necessary by inspection.
Page 1 of 3
© 2002 Volkswagen of America, Inc.
All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other intellectual property rights of
Volkswagen of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice. No part of this document may be reproduced, stored in a
retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, nor may these materials be modified or reposted to other sites, without
the prior expressed written permission of the publisher.
Version 1.0
Cautions & Warnings
•= Illuminate the work area adequately but safely. Use a portable safety light for working inside or under the vehicle.
Make sure the bulb is enclosed by a wire cage. The hot filament of an accidentally broken bulb can ignite spilled
fuel or oil.
•= Friction materials such as brake pads and clutch discs may contain asbestos fibers. Do not create dust by
grinding, sanding, or by cleaning with compressed air. Avoid breathing asbestos fibers and asbestos dust.
Breathing asbestos can cause serious diseases such as asbestosis or cancer, and may result in death.
AG. Volkswagen AG d
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•= Finger rings should b
o
y Vbe removed so that they cannott gcause
ua electrical shorts, get caught in running machinery, or be
ed ran
crushed by heavy ris parts. te
tho eo
s au ra
c
•= s
Before starting a job, make certain that you have all the necessary tools and parts on hand. Read all the
ce
e
nl
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instructions thoroughly; do not attempt shortcuts. Use tools that are appropriate to the work and use only
du
an
itte
replacement parts meeting Volkswagen specifications. Makeshift tools, parts and procedures will not make good
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repairs.
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•= Catch draining fuel, oil or brake fluid in suitable containers. Do not use empty food or beverage containers that
h re
hole
might mislead someone into drinking from them. Store flammable fluids away from fire hazards. Wipe up spills at
spec
es, in part or in w
once, but do not store the oily rags, which can ignite and burn spontaneously.
t to the co
•= Use pneumatic and electric tools only to loosen threaded parts and fasteners. Never use these tools to tighten
fasteners, especially on light alloy parts. Always use a torque wrench to tighten fasteners to the tightening torque
rrectness of i
listed.
l purpos
•= Keep sparks, lighted matches, and open flame away from the top of the battery. If escaping hydrogen gas is
ignited, it will ignite gas trapped in the cells and cause the battery to explode.
nform
mercia
at
•= Be mindful of the environment and ecology. Before you drain the crankcase, find out the proper way to dispose of
om
ion
the oil. Do not pour oil onto the ground, down a drain, or into a stream, pond, or lake. Consult local ordinances that
c
in t
or
govern the disposal of wastes.

his
ate
do
priv
cum
or
•= The air-conditioning (A/C) system is filled with a chemical refrigerant that is hazardous. The A/C system should be
f
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ng
t.
serviced only by trained automotive service technicians using approved refrigerant recovery/recycling equipment,
i
py Co
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trained in related safety precautions, and familiar with regulations governing the discharging and disposal of
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•= Before doing any electrical welding on vehicles equipped with anti-lock brakes (ABS), disconnect the battery
negative terminal (ground strap) and the ABS control module connector.
•= Do not expose any part of the A/C system to high temperatures such as open flame. Excessive heat will increase
system pressure and may cause the system to burst.
•= When boost-charging the battery, first remove the fuses for the Engine Control Module (ECM), the Transmission
Control Module (TCM), the ABS control module, and the trip computer. In cases where one or more of these
components is not separately fused, disconnect the control module connector(s).
•= Some of the vehicles covered by this manual are equipped with a supplemental restraint system (SRS), that
automatically deploys an airbag in the event of a frontal impact. The airbag is operated by an explosive device.
Handled improperly or without adequate safeguards, it can be accidentally activated and cause serious personal
injury. To guard against personal injury or airbag system failure, only trained Volkswagen Service technicians
should test, disassemble or service the airbag system.
Page 2 of 3
© 2002 Volkswagen of America, Inc.
the prior expressed written permission of the publisher.
Version 1.0
Cautions & Warnings
•= Do not quick-charge the battery (for boost starting) for longer than one minute, and do not exceed 16.5 volts at the
battery with the boosting cables attached. Wait at least one minute before boosting the battery a second time.
•= Never use a test light to conduct electrical tests of the airbag system. The system must only be tested by trained
Volkswagen Service technicians using the VAG 1551 Scan Tool (ST) or an approved equivalent. The airbag unit
must never be electrically tested while it is not installed in the vehicle.
•= Some aerosol tire inflators are highly flammable. Be extremely cautious when repairing a tire that may have been
inflated using an aerosol tire inflator. Keep sparks, open flame or other sources of ignition away from the tire repair
area. Inflate and deflate the tire at least four times before breaking the bead from the rim. Completely remove the
tire from the rim before attempting any repair.
•= When driving or riding in an airbag-equipped vehicle, never hold test equipment in your hands or lap while the
vehicle is in motion. Objects between you and the airbag can increase the risk of injury in an accident.
I have read and I understand these Cautions and Warnings.
AG. Volkswagen AG d
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Page 3 of 3
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© 2002 Volkswagen of America, Inc. t. C rig
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the prior expressed written permission of the publisher. Prote AG.
Version 1.0

D3E8002315F Manual Transmission

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Service Department. Technical Information

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Copyright © 2014 Volkswagen AG, Wolfsburg D3E8002315F

00 - General, Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

2.8 Hydraulics Assembly Overview, RHD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . pt 30

3 Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . y li 32

3.1 Over-Center Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ility 32

3.3 Mounting Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

3.4 Clutch Master Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

3.5 Clutch Position Sensor G476 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

3.8 “Sachs” Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

3.9 “LuK” Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

1.1 Transmission Fluid, Checking and Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

2 Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

2.5 Overview - Gearshift Lever and Gearshift Housing, from 11/2006 . . . . . . . . . . . . . . . . . . . . 99

4 Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216

5 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233

1.4 Output Shaft, Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261

2 Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265

2.1 Input Shaft Seal, Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265

3 Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266

3.1 Input Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266

3.2 Output Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271

3.3 Reverse Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279

3 Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295

6 Revision History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311

00 – General, Technical Data

Driven gear ZG2= 29 ZA2= 61

I= Z2 : Z1, refer to 1).

iA= axle ratio= ZA2 : ZA1= 61 : 18= 3.389

Edition 12/2011, Version 19.0

⇒ “3.5 Engine Codes, Transmission Allocations, Ratios and Ca‐

♦ Do not allow any Sealing Compound to get into the ventilation y li

2 Rep. Gr.00 - General, Technical Data

♦ Replace the circlips.

♦ Make sure the contact surfaces and visible surfaces on the

♦ Use a thread cutter to clean all threaded holes containing self-

the fitting tool.

♦ To install, heat the bearing inner races to approximately 100 °

♦ Do not interchange them. When reusing synchronizer rings,

ring on the outer contact surface -arrow 2- and inner contact

♦ Coat the synchronizing with transmission fluid and then install.

♦ After assembling, check the selector gears for minimum axial

agonally and in small steps.

♦ To reduce odor caused by a burnt clutch, thoroughly clean the

clutch housing and the flywheel running surface with a clean

There is a risk of injury if the engine starts automatically in ve‐

1.4 Transmission Identification

4 Rep. Gr.00 - General, Technical Data

Manual Transmission 0A4 -arrow 2-

Transmission Code Letters and Build Date

The transmission code is also listed in the vehicle data plates.

6 Rep. Gr.00 - General, Technical Data

2. Description and Operation 7

Manual Transmission 5-Speed Manual Transmission 0A4

Codes HDR GTB JCT

Manufactured from 01/2005 08/2003 05/2006

Allocation Engine 2.0L - 85 kW 2.5L - 110 KW 2.5L - 110 KW

(transmission completely disas‐

Manual transmission capacity, re‐ 1.8 liters (1.9 quarts)

⇒ “1.1 Transmission Fluid, Check‐

ing and Filling”, page 90 (trans‐

mission partly disassembled)