GOLF MK7 Manual Transmission

Service
Repair Manual
Golf 2015 ➤
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Service Department. Technical Information

Service
List of Workshop Manual Repair Groups
Repair Group
00 - General, Technical Data
30 - Clutch
34 - Controls, Housing
35 - Gears, Shafts
39 - Final Drive, Differential
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Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.
All rights reserved.

No reproduction without prior agreement from publisher.
Copyright © 2015 Volkswagen AG, Wolfsburg D4B8041661E

Golf 2015 ➤ , Golf Variant 2015 ➤
Manual Transmission - Edition 12.2014
Contents
00 - General, Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Start/Stop System Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.1 Transmission Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3 Repair Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3.1 General Repair Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
4 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4.1 Transmission/Engine Allocation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4.2 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4.3 Gear Ratio Calculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
5 Overview - Powertrain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
5.1 Overview - Powertrain, Front Wheel Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
6 Electrical Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
6.1 Component Location Overview - Electrical Components . . . . . . . . . . . . . . . . . . . . . . . . . . 10
30 - Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1 Clutch Mechanism
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1.1 Component
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1.2 risedOverview - Pedal Assembly . . . . . .ar.an.t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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1.3 tho Overview - Clutch Hydraulics . . . . . . . .e.or.a. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
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Overview - Clutch Release Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
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1.5 Clutch Pedal, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

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1.6 Bearing Bushing, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

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1.7 Over-Center Spring, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

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1.8 Return Spring, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

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1.9 Mounting Bracket, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

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1.10 Clutch Master Cylinder, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

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1.11 Clutch Slave Cylinder, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

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1.12 Clutch Mechanism Lines, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

1.13 Clutch Mechanism, Bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
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1.14 Clutch Master and Clutch Slave Cylinder, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

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1.15 Clutch Position Sensor G476 , Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . 34

1.16 Clutch Release Mechanism, Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
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2 Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
2.1 Overview - Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
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2.2 Clutch, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

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3 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
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34 - Controls, Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
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1 Selector Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
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1.1 Selector Mechanism Installation Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
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1.2 Overview - Gearshift Knob and Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
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53
1.4 Gearshift Knob, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
1.5 Selector Mechanism, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
1.6 Selector Mechanism, Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
1.7 Selector Mechanism, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
1.8 Selector Shaft Seal, Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
2 Transmission, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
2.1 Transmission, Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
2.2 Transmission, Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Contents i
2.3 Transmission Tightening Specifications . . . . . . w . a. g.e.n.A.G.. V. o.lk. s.w.a.ge. n. A.G. d.o.e. . . . . . . . . . . . . . . 86

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3 Subframe Mount . . . . . . . . . . . . . . . . . . .d.by. V. . . . . . . . . . . . . . . . . . . . . . . . .t g. u.a.r . . . . . . . . . 87
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3.1 Overview - Subframe Mount . . . . . . th.o.ris. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . t.ee. o. . . . . . 87
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4 Transmission, Transporting . . . . s.s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .c . . . . 89
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5 Transmission, Disassembling and Assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
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5.1 Schematic Overview - Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
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5.2 Overview - Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
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5.3 Overview - Transmission Housing Cover and 5th Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
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5.4 Overview - Transmission Housing and Selector Mechanism . . . . . . . . . . . . . . . . . . . . . . . . 95
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5.5 Overview - Shift Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
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5.6 Overview - Input Shaft, Output Shafts, Differential, Gearshift Rods . . . . . . . . . . . . . . . . . . 97
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5.7 Overview - Shift Forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
5.8 Shift Unit, Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
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5.9 Shift Forks, Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
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5.10 Transmission Housing Cover and 5th Gear, Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

5.11 Transmission, Disassembling and Assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
5.12 Transmission Housing Cover and 5th Gear, Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
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6 Transmission Housing and Clutch Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
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6.1 Overview - Transmission Housing and Clutch Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119

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6.2 Transmission Housing, Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
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6.3 Clutch Housing, Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122

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7 Securing on Engine and Transmission Holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
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8 Transmission Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
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8.1 Transmission Fluid Level, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . pyri
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8.2 Transmission Fluid, Draining and Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
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9 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
35 - Gears, Shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141

1 Input Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
1.1 Overview - Input Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
1.2 Input Shaft, Disassembling and Assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
1.3 Input Shaft, Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
1.4 Input Shaft Seal, Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
2 Output Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
2.1 Overview - Output Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
2.2 Output Shaft, Disassembling and Assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
2.3 Output Shaft, Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
3 Reverse Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
3.1 Overview - Reverse Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
3.2 Reverse Shaft, Disassembling and Assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
4 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
39 - Final Drive, Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183

1 Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
1.1 Component Location Overview - Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
1.2 Left Seal, Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
1.3 Right Seal, Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
2 Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
2.1 Overview - Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
2.2 Differential, Disassembling and Assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
2.3 Differential, Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
3 Adjustment Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
4 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
ii Contents
5 Revision History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
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iv Contents
00 – General, Technical Data

1 Safety Precautions
(Edition 12.2014)
⇒ “1.1 Start/Stop System Safety Precautions”, page 1
1.1 Start/Stop System Safety Precautions
WARNING
There is a risk of injury if the engine starts automatically in ve‐

hicles with the Start/Stop System. wage
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1. Safety Precautions 1
2 Identification
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Transmission Code Letters and Build Date
Example: FNE 10 11 3
I I I I
I I I I
Codes Day Month Year (2003)
of manufacture
For additional data and information contact the factory.
Note
The transmission code is also listed in the vehicle data plates.
2 Rep. Gr.00 - General, Technical Data

3 Repair Information
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⇒ “3.1 General Repair Information”, page 3 yV
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3.1 General Repair Information utho tee
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Carefulness, cleanliness and the correct tools are required for
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transmission repairs to be successful. The usual basic safety pre‐
pt
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cautions apply when making vehicle repairs.
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Some general repair information that applies to several proce‐
ility
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dures throughout this manual is summarized. They apply to this
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repair manual.
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Special Tools and Equipment
es, in part or in w
t to the co
For a complete list of special tools used in the Repair Manual.
Refer to Workshop Equipment and Special Tools.
rrectness of i
Transmission
l purpos
♦ Make sure that the alignment sleeves between the engine and
transmission are positioned correctly when installing the trans‐
mission.
nform
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♦ Clean the contact surfaces when installing brackets as well as

m
at
parts that have been waxed. Contact surfaces must be free of
om
ion
wax and grease.
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♦ Allocate the bolts and other components. Refer to the Parts

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Catalog.
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♦ Fill the transmission fluid when repairing the manual trans‐

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Seals, Sealing Rings cop Vo
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♦ Thoroughly clean the separating surfaces and then apply
AG.
Sealing Compound - AMV 188 200 03- .

♦ 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.
♦ Lightly lubricate O-rings before installing to prevent them from
being crushed when inserting.
Sealant
♦ Always thoroughly clean the separating surfaces on the hous‐
ing before applying the Sealant .
♦ Apply the Sealing Compound - AMV 188 200 03- evenly and
not too thick.
♦ Do not allow any Sealing Compound to get into the ventilation
holes.
3. Repair Information 3
Fasteners
♦ Replace the circlips.

♦ Do not overstretch the circlips.
♦ The circlips must fit completely inside the groove.
♦ Replace the adapter sleeves. Installed position: slot is length‐
wise 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 in stages
in a diagonal sequence.
♦ The tightening specifications stated apply to non-oiled nuts
and bolts.
♦ Replace self-locking bolts and nuts after removing them.
♦ Make sure the contact surfaces and visible surfaces on the
nuts and bolts are waxed after assembling.
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AG. Volkswagen AG d
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♦ Use a thread cutter to clean byall threaded holes containing self-guar
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locking bolts to removeor any locking compound residue. Oth‐
is tee
h
erwise the bolts could
au shear the next time they are removed.
t or
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♦ Please make sure that the thread pitch is correct so that the
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proper thread cutter is used during cleaning, and the thread

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does not get damaged.

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Bearings
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♦ Insert the bearings with transmission fluid.

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♦ Install the new tapered roller bearings. It is not necessary to

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oil them.
t to the co
♦ Install needle bearings with lettered side (thicker metal) racing

the fitting tool.
rrectness of i
♦ Replace all the tapered roller bearings that are on the same
l purpos
shaft. Use tapered roller bearings from the same manufactur‐

er.
nform
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♦ To install, warm the inner races/tapered roller bearing to ap‐

proximately 100 °C (212 °F) with Inductive Heater -
m
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VAS6414- .
on in
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♦ Do not interchange outer and inner bearing races with those

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from other bearing of the same size. The bearings are paired.
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Adjusting Shims
♦ Measure the shims at several locations with a micrometer cal‐
iper. It is possible to measure the necessary shim thickness
by the different tolerances.
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♦ Check for burrs and damage. ksw
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Synchronizer Rings
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♦ Do not interchange them. When reusing synchronizer rings,
spec
always install to the same gear wheel.
es, in part or in w
t to the co
♦ Check for wear and replace if necessary.
♦ Check the grooves -arrow 1- on the synchronizer ring -A- and
rrectness of i
the inner race for flat areas (grooves are worn).
l purpos
♦ The coating on the synchronizer rings must not be damaged.

♦ If an intermediate ring -B- is installed, check this intermediate
nform
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ring on the outer friction surface -arrow 2- and inner friction

surface -arrow 3- for »grooves«, »wear grooves« and »blue
m
at
om
coloring (from overheating)«.
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♦ Check taper of drive gear for »grooves« and »scoring«.
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♦ Coat the synchronizing with transmission fluid and then install.

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Toothed Gears, Synchronizer Hubs

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♦ Clean and warm to maximum 100 °C (212 °F) using the In‐
ht. rig
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ductive Heat Unit - VAS6414- before installing. copy Vo
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♦ Pay attention to the installed location.
AG.
Selector Gears
♦ After assembling, check the selector gears for minimum axial
clearance and ease of movement.
Clutch
♦ Do not tilt the clutch pressure plate. Loosen and tighten it di‐
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
cloth.
3. Repair Information 5
4 Technical Data
⇒ “4.1 Transmission/Engine Allocation”, page 6
⇒ “4.2 Capacities”, page 6
⇒ “4.3 Gear Ratio Calculation”, page 7
4.1 Transmission/Engine Allocation

⇒ “4.1.1 Transmission/Engine Allocation, Golf”, page 6
⇒ “4.1.2 Transmission/Engine Allocation, Golf Wagon”,
page 6
4.1.1 Transmission/Engine Allocation, Golf

Manual Transmission 5-Speed Manual Transmission 0A4
Codes NZA
Manufactured from 06/2013
through
Allocation Engine 1.8L - 125 kW
Ratio Final Drive 61 : 18 = 3.389
Z1 : Z2
Drive axle flange diameter 100 mm
Refer to the Parts Catalog for the following information:
♦ The individual gear ratios
♦ Transmission fluid
♦ Clutch allocation
AG. Volkswagen AG d
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4.1.2 Transmission/Engine Allocation, Golf Wagon or eo
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Manual Transmission 5-Speed Manual Transmission 0A4
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Codes QSY
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Manufactured from 11/2014

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Allocation Engine 1.8L - 125 kW

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urposes, in part or in wh
Ratio Final Drive 61 : 18 = 3.389

Z1 : Z2
t to the co
Drive Axle flange diameter 100 mm

rrectne
Refer to the Parts Catalog for the following information:

♦ The individual gear ratios
ss o
♦ Transmission fluid
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♦ Clutch allocation
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4.2 Capacities
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Manual transmission capacity Refer to ⇒ Fluid Capacity Tables; Rep. Gr. 03

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Manual transmission capacity Refer to ⇒ Fluid Capacity Tables; Rep. Gr. 03
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4.3 Gear Ratio Calculation

Example:
6th Gear Final Drive
Drive gear ZG1 = 47 ZA1 = 18
Driven gear ZG2 = 31 ZA2 = 61 wagen AG. Volkswagen AG doe
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iG = gear ratio = ZG2 : ZG1 = 31 : 47 = 0.660
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iA= axle ratio= ZA2 : ZA1= 61 : 18= 3.389
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itotal = total ratio = iG x iA = 0.660 x 3.389 = 2.237
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4. Technical Data 7
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5 Overview - Powertrain ir se
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⇒ “5.1 Overview - Powertrain, Front Wheel Drive”, page 8 s au ac
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5.1 Overview - Powertrain, Front Wheel Drive
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The -arrows- point in the direction of travel.
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1 - Engine
es, in part or in w
t to the co
2 - Clutch
3 - Manual Transmission
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4 - Input Shaft l purpos
5 - Output Shaft
6 - Differential
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Ratio
The -arrows- point in the direction of travel.

I - 1st Gear
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IV - 4th Gear ss a ra
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V - 5th Gear
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R - Reverse Gear
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5. Overview - Powertrain 9
Golf 2015 ➤ , Golf Variant
gen 2015
AG. Vol➤
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⇒ “6.1 Component Location Overview - Electrical Components”,
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6.1 Component Location Overview - Electri‐
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⇒ “6.1.1 Component Location Overview - Electrical Components,
es, in part or in w
t to the co
Manual Transmission”, page 10
⇒ “6.1.2 Component Location Overview - Electrical Components,
Clutch Mechanism”, page 10
rrectness of i
6.1.1 Component Location Overview - Electri‐
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cal Components, Manual Transmission
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Back-Up Lamp Switch - F4- -arrow -
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Component location: on the shift unit

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Back-Up Lamp Switch - F4- , Removing and installing. Refer to
te
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⇒ “5.5 Overview - Shift Unit”, page 96 .

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Transmission Neutral Position Sensor - G701- -arrow -

Component location: on top of the oil filler plug.
Transmission Neutral Position Sensor - G701- , Removing and
installing. Refer to
⇒ “5.4 Overview - Transmission Housing and Selector Mecha‐
nism”, page 95 .
6.1.2 Component Location Overview - Electri‐

cal Components, Clutch Mechanism
Clutch Position Sensor - G476- -arrow-
Installed location: in the passenger compartment on the clutch
master cylinder.
Clutch Position Sensor - G476- , Removing and installing. Refer
to
⇒ “1.15 Clutch Position Sensor G476 , Removing and Installing”,
page 34 .

30 – Clutch
1 Clutch Mechanism
⇒ “1.1 Component Location Overview - Clutch Mechanism”, page
11
⇒ “1.2 Overview - Pedal Assembly”, page 13
⇒ “1.3 Overview - Clutch Hydraulics”, page 15
⇒ “1.4 Overview - Clutch Release Mechanism”, page 18
⇒ “1.5 Clutch Pedal, Removing and Installing”, page 19
⇒ “1.6 Bearing Bushing, Removing and Installing”, page 20
⇒ “1.7 Over-Center Spring, Removing and Installing”, page 21
⇒ “1.8 Return Spring, Removing and Installing”, page 23
⇒ “1.9 Mounting Bracket, Removing and Installing”, page 26
⇒ “1.10 Clutch Master Cylinder, Removing and Installing”,
page 29
⇒ “1.11 Clutch Slave Cylinder, Removing and Installing”,
page 30
⇒ “1.12 Clutch Mechanism Lines, Removing and Installing”, page
31 n AG. Volkswagen A G do
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⇒ “1.13 Clutch Mechanism, Bleeding”, page 33 olks ot g
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⇒ “1.14 Clutch Master and Clutch Slave Cylinder, ris
ho Checking”,
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page 34 ss
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⇒ “1.15 Clutch Position Sensor G476 , Removing and Installing”,

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page 34
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⇒ “1.16 Clutch Release Mechanism, Servicing”, page 35
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1.1 Component Location Overview - Clutch Mechanism
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es, in part or in w
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1. Clutch Mechanism 11
I - Refer to
⇒ “1.2 Overview - Pedal As‐
sembly”, page 13
II - Refer to
⇒ “1.3.1 Overview - Clutch Hy‐
draulics”, page 15
III - Refer to
⇒ “1.3.2 Overview - Clutch Hy‐
draulics, RHD”, page 17
AG. Volkswagen AG d
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12 Rep. Gr.30 - Clutch

1.2 Overview - Pedal Assembly
1 - Clutch Master Cylinder

❑ Removing and instal‐
ling. Refer to
⇒ “1.10 Clutch Master
Cylinder, Removing and
Installing”, page 29 .
2 - Bearing Bushing
ling. Refer to
⇒ “1.6 Bearing Bushing,
Removing and Instal‐
ling”, page 20 .
❑ Do not lubricate
3 - Clamp
❑ The clamp must be re‐
moved in order to re‐
move/install the hose/
line assembly
4 - Seal
❑ Self-adhesive
❑ Replace after removing
the clutch master cylin‐n AG. Volkswagen A
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❑ Glue to clutchsed b master ua
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5 - Clutch Position
ss Sensor -
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G476-
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❑ Can be checked in Gui-

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❑ Allocation. Refer to the

spec
Parts Catalog.
es, in part or in w
t to the co

ling. Refer to ⇒ “1.15 Clutch Position Sensor G476 , Removing and Installing”, page 34 .
rrectness of i
6 - Bearing Axle
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7 - Rubber Stop
m
8 - Nut
com
tion in
❑ 25 Nm
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❑ For the bracket to the bulkhead

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❑ Quantity: 3
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❑ Self-locking
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9 - Bearing Shell
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❑ Quantity: 2
❑ Installed on both sides
❑ Installed in connection with over-center spring only
10 - Bracket
❑ For the clutch pedal
❑ Removing and installing. Refer
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Bracket, Removing and Installing”, page 26 .
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11 - Return Spring
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❑ Installed depending on the date of manufacture
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❑ Removing and installing. Refer to ⇒ “1.8 Return Spring, Removing and Installing”, page 23 .
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❑ Do not grease the mount on the bracket.
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12 - Mounting Pin
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❑ For the clutch master cylinder
hole
spec
es, in part or in w
t to the co
13 - Over-Center Spring
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❑ There are different versions; allocation. Refer to the Parts Catalog.

❑ Removing and installing. Refer to ⇒ “1.7 Over-Center Spring, Removing and Installing”, page 21 .
nf
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14 - Bearing Bushing
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15 - Slide Bushing
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❑ For return spring mounting
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❑ Install on clutch pedal
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❑ Lubricate to the return spring mount
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Prote AG.
❑ Grease. Refer to the Parts Catalog.
16 - Mounting Pin
❑ For plunger/clutch master cylinder
17 - Clutch Pedal
❑ Removing and installing. Refer to ⇒ “1.5 Clutch Pedal, Removing and Installing”, page 19 .
18 - Pedal Rubber
19 - Bearing Bushing
20 - Tension Spring
❑ For the clutch pedal
❑ Removing and installing ⇒ removing and installing over-center spring. Refer to
⇒ “1.7 Over-Center Spring, Removing and Installing”, page 21 .
21 - Damping Element
❑ Installed in connection with tension spring only

AG. Volkswagen AG d
agen oes Golf 2015 ➤ , Golf Variant 2015 ➤
olksw not
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ara Manual Transmission - Edition 12.2014
ris nte
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1.3 ssOverview - Clutch Hydraulics
au ac
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⇒ “1.3.1 Overview - Clutch Hydraulics”, page 15
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1.3.1 Overview - Clutch Hydraulics
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1 - Hex Bolt
hole
spec
❑ Tightening specifica‐
es, in part or in w
t to the co
tion. Refer to
⇒ “1.4 Overview - Clutch
Release Mechanism”,
rrectness of i
page 18 .
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2 - Bleed Valve
❑ 4.5 Nm
nform
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❑ Bleed clutch mecha‐

nism. Refer to
m
a
⇒ “1.13 Clutch Mecha‐
com
tion in
nism, Bleeding”,
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page 33 .
thi
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3 - Dust Cap
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4 - Supply Hose
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5 - Brake Fluid Reservoir
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6 - Seals
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❑ Must be located inside
the supply hose.
7 - Clutch Master Cylinder
ling. Refer to
⇒ “1.10 Clutch Master
8 - Clamp
line assembly
9 - Seal/O-Ring
❑ Replace if damaged
❑ Install on the line con‐
nection
❑ Install with brake fluid
❑ Seals/O-rings suitable for the line connection material. Refer to
⇒ Fig. ““Sealing Rings/O-Rings for Hose/Line Assembly or Pipe”“ , page 16
❑ Allocation. Refer to the Parts Catalog.
10 - Hose/Line Assembly
❑ Removing and installing. Refer to
⇒ “1.12 Clutch Mechanism Lines, Removing and Installing”, page 31 .
11 - Bracket
❑ For hose/line assembly
12 - Seal/O-Ring
❑ Install on the line connection
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❑ Seals/O-rings suitable for the line connection material.
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⇒ Fig. ““Sealing Rings/O-Rings for Hose/Line d Assembly or Pipe”“ , page 16
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❑ Allocation. Refer to the Parts Catalog. autho
or
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13 - Clamp
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❑ The clamp must be removed in order to remove/install the hose/line assembly
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14 - Clutch Slave Cylinder
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❑ Removing and installing. Refer to ⇒ “1.11 Clutch Slave Cylinder, Removing and Installing”, page 30 .
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Disconnect and Connect Clutch Mechanism Wires
t to the co
Separating
– Open the clip -3- with a screwdriver and remove the hose/line
rrectness of i
assembly -1- from the connection -4-.
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Connecting
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Note
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ion
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♦ An O-ring can also be installed instead of a seal -2-. Refer to
or
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⇒ Fig. ““Sealing Rings/O-Rings for Hose/Line Assembly or

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Pipe”“ , page 16 .
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♦ Replace the damaged seal -2-.

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– Press in the hose/line assembly -1- at the connection -4- until
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the clip -3- engages audibly.
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– Pull on the hose/line assembly to make sure it is secure.
Sealing Rings/O-Rings for Hose/Line Assembly or Pipe

Item Line Connection Version
1 Line connection with a groove all the way around
-arrow 1-
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-.

1.3.2 Overview - Clutch Hydraulics, RHD

❑ Removing and Instal‐
ling. Refer to
⇒ “1.11 Clutch Slave
2 - Bleed Valve
❑ Bleed clutch mecha‐
nism. Refer to
⇒ “1.13 Clutch Mecha‐
nism, Bleeding”,
page 33 .
❑ 4.5 Nm
3 - Dust Cap
4 - Supply Hose
5 - Brake Fluid Reservoir
6 - Seals
❑ must be located inside
the supply hose.
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8 - Clamp
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9 - Seal/O-Ring t to the co
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❑ Seals/O-rings suitable for the line connection material
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10 - Bracket
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❑ For hose/line assembly

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❑ Removing and Installing. Refer to

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❑ Seals/O-rings suitable for the line connection material
13 - Clamp
❑ The clamp must be removed in order to remove/install the hose/line assembly
14 - Hex bolt
❑ Tightening specification. Refer to ⇒ “1.4 Overview - Clutch Release Mechanism”, page 18 .
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1 - Transmission
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2 - Ball Stud
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❑ 25 Nm
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ole,
spec
mission
❑ Remove grease from
t to the co
extractor lever contact
surfaces
rrectne
❑ Grease the contact sur‐
face on the ball stud with
Grease for Clutch Disc
ss
Shaft Splines -
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G 000 100-
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3 - Input Shaft Seal
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❑ Replacing. Refer to
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⇒ “1.4 Input Shaft Seal,
thi
te
Replacing”, page 152 .
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❑ Replace the guide
sleeve and O-ring if the
O-ring is damaged.
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
⇒ Fig. ““Remove and Install the Clutch Release Lever with the Release Bearing”“ , page 35
❑ Remove grease already present
❑ Grease the contact surface on the ball stud with Grease for Clutch Disc Shaft Splines - G 000 100-
8 - Release Bearing
❑ Do not wash the bearing, just wipe it off.
❑ Replace loud bearings

AG. Volkswagen AG d Manual Transmission - Edition 12.2014
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❑ Removingd bfrom y V and installing in the clutch releasegu
ara lever
⇒ Fig. o““Removing
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ss
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9 - Hex Bolt
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❑ 20 Nm
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❑ Removing and installing. Refer to ⇒ “1.11 Clutch Slave Cylinder, Removing and Installing”, page 30 .
h re
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11 - Plunger
es, in part or in w
t to the co
12 - Bolt
❑ Secures the clutch release lever when installing transmission
❑ Remove after installing the transmission
rrectness of i
❑ Use an M8 x 35 bolt if the assembly bolt is missing.
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1.5 Clutch Pedal, Removing and Installing

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– Move the driver seat as far back as possible.

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– Position the steering wheel as far upward as possible.
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– If installed near bracket: remove the bracket -arrow- with the
Co
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Parking Aid Control Module - J446- . Refer to ⇒ Electrical t. C rig
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Equipment; Rep. Gr. 94 ; Parking Aid; Overview - Parking Aid yri
p by
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and push aside.
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– Remove the return spring. (Refer to
⇒ “1.8 Return Spring, Removing and Installing”, page 23 .)
or remove the over-center spring. Refer to
⇒ “1.7 Over-Center Spring, Removing and Installing”,
page 21 .
Remove the Clutch Pedal Bearing Axle as Follows:

-1- = 14 mm internal socket wrench
A 14 mm hex socket wrench can also be used instead of a 14 mm
internal socket wrench.
• The clutch pedal bearing axle needs to be turned all the way
to the left, in direction of -arrow-.
The Brackets -A- will be Damaged.
– Move the clutch pedal a little so that the bearing axle can be
removed.
Installing
Install in reverse order of removal. Note the following:
-1- = 14 mm internal socket wrench
A 14 mm hex socket wrench can also be used instead of a 14 mm
internal socket wrench.
• Replace bearing axle after removing.
– Press on the clutch pedal a little and push the new bearing
axle through all the way.
– Turn the bearing axle all the way to the right, in direction of
-arrow-.
• The retainers -A- must engage audibly.
– Install the return spring (Refer to
⇒ “1.8 Return Spring, Removing and Installing”, page 23 .)
or install the over-center spring. Refer to wage
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⇒ “1.7 Over-Center Spring, Removing and Installing”, y Volks ot g
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page 21 . rised b ran
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– Install bracket -arrow- with Parking Aid - Controls Module
s
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le
J446- . Refer to ⇒ Electrical Equipment; Rep. Gr. 94 ; Parking

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Aid; Overview - Parking Aid .
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1.6 Bearing Bushing, Removing and Instal‐
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Disconnect the battery ground cable. Refer to ⇒ Electrical Equip‐

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ment; Rep. Gr. 27 ; Battery; Battery, Disconnecting and Con‐

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move the studs -1- to the right side.
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The openings -1- and the pin -2- face in the same direction.

– Remove the bearing bushing -A- from the openings -1-.
Installing
– Turn the valve fitter such that the openings -1- or pin -2- are
visible.
The openings -1- and the pin -2- face in the same direction.
– Fit the bearing bushing -A- in the openings -1- and rotate into
place.
– Use a new mounting pin to connect the valve fitter/clutch mas‐
ter cylinder to the clutch pedal.
– Connect the battery. Refer to ⇒ Electrical Equipment; Rep.
Gr. 27 ; Battery; Battery, Disconnecting and Connecting
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Vehicles with a Knee Airbag
spec
– Remove the driver side knee airbag -1-. Refer to ⇒ Body In‐
terior; Rep. Gr. 69 ; Knee Airbags; Overview - Knee Airbag . t to the co
Vehicles without Knee Airbag

rrectne

s
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Continuation for All

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– Remove driver side footwell vent -1-. Refer to ⇒ Heating,
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Ventilation and Air Conditioning; Rep. Gr. 87 ; Air Routing; rig ht
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Driver Side Footwell Vent, Removing and Installing .
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– Remove the Data Bus on Board Diagnostic Interface - J533-

-1- from the bracket. Refer to ⇒ Electrical Equipment; Rep.
Gr. 97 ; Control Modules; Component Location Overview -
Control Modules and push it aside.
– Remove bolt -2-, unclip the crash bolster -1- and push aside.
wage es n
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move the mounting pin -1- for the valveed b
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– If present, push the clutch pedal
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and remove the over-center spring -2-.

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Installing
• The bearing shells -arrows- for the pins -1- are installed.
– Pull the clutch pedal into the passenger compartment (⇒ in
direction of -arrow A- in the previous illustration).
– Fit the pins -1- into the bracket mounts -2-.
– Fit the mounting -3- into the clutch pedal mount -4-.
• If the clutch pedal is pushed in direction of -arrow B- (⇒ previ‐
ous illustration), the over-center spring will fold in the direction
of the bracket.
– Insert the crash bolster -1- and tighten the bolt -2-. Refer to ⇒
Body Interior; Rep. Gr. 70 ; Instrument Panel Central Tube;
Overview - Instrument Panel Central Tube .
– Install the Data Bus on Board Diagnostic Interface - J533- . wagen AG. Volkswagen AG doe
Refer to ⇒ Electrical Equipment; Rep. Gr. 97 ; Control yMod‐Vol
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au
t
Ven‐ or
ac
tilation and Air Conditioning; Rep. Gr. 87 ; Air Routing; Driver
s
ce
le
Side Footwell Vent, Removing and Installing .

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pt
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– Install the driver side knee airbag. Refer to ⇒ Body Interior;
ot
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Rep. Gr. 69 ; Knee Airbags; Overview - Knee Airbag .
h re
hole
spec
es, in part or in w
t to the co
Gr. 27 ; Battery; Battery, Disconnecting and Connecting .
rrectness of i
1.8 Return Spring, Removing and Installing
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Ventilation and Air Conditioning; Rep. Gr. 87 ; Air Routing;

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– Press the retainers together in direction of -arrows- and re‐

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move the mounting pin -1- for the valve lifter/clutch master
erm
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cylinder to the right.

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Rep. Gr.30 - Clutch
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– Moveautthe
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ac
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• For the return spring -1- (⇒ previous illustration), slightly
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grease the following areas on the clutch pedal:

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• Slide bushing on the return spring mounting area -A-:

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• Ridge -C-
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• Grease. Refer to the Parts Catalog.
– Move the clutch pedal in direction of -arrow- and engage the
return spring -1- (⇒ previous illustration).
– Insert the crash bolster -1- and tighten the bolt -2-. Refer to ⇒
Body Interior; Rep. Gr. 70 ; Instrument Panel Central Tube;
Overview - Instrument Panel Central Tube .
– Install the Data Bus on Board Diagnostic Interface - J533- .
Refer to ⇒ Electrical Equipment; Rep. Gr. 97 ; Control Mod‐
ules; Component Location Overview - Control Modules .
– Install the driver side footwell vent. Refer to ⇒ Heating, Ven‐
1.9 Mounting Bracket, Removing and Instal‐

ling
Special tools and workshop equipment required
♦ Hose Clamps - Up To 25 mm - 3094-
♦ Torque Wrench 1331 5-50Nm - VAG1331-
♦ Sealing Tool - T10249-
♦ Sealing Tool - T10249/1-
Caution
This procedure contains mandatory replaceable parts. Refer

to component overview prior to starting procedure.
Mandatory Replacement Parts

♦ Nuts - Mounting Bracket to wBody
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– Move the driverau
thseat as far back as possible. eo
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ility
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terior; Rep. Gr. 69 ; Knee Airbags; Overview - Knee Airbag .

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– Remove the entire air filter housing if the clutch mechanism
wit
, is n
lines are not accessible. Refer to ⇒ Engine Mechanical, Fuel
h re
hole
Injection and Ignition; Rep. Gr. 24 ; Air Filter; Air Filter Hous‐
spec
ing, Removing and Installing .
es, in part or in w
t to the co
– Remove the battery. Refer to ⇒ Electrical Equipment; Rep.
rrectness of i
Caution
l purpos
Danger of leaking brake fluid.
nform
ercia
♦ Be careful not to get any brake fluid on the longitudinal

m
a
member or on the transmission when performing the fol‐
com
tio
lowing work. If it does, clean the area thoroughly.
n in
r
te o
thi
♦ Place a lint-free cloth under the clutch master cylinder.

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iva
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– Unclamp the supply hose -2- to the clutch master cylinder with C py
ht. rig
a Hose Clamps - Up To 25mm - 3094- . rig ht
py by
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Note
♦ A slight deformation of the supply hose remains after the Hose

Clamps - Up To 25mm - 3094- have been unclamped.
♦ The supply hose is therefore not defective.
♦ After removing the Hose Clamp up to 25 mm - 3094- , the
supply hose must be formed back into its original shape.
– Remove clip for hose/line assembly -1- all the way and remove
hose/line assembly.
– Seal off openings.
– Remove the clutch master cylinder return hose and seal with
the Sealing Tool - T10249/1- .
Note
When working inside the footwell, cover the carpet with cloths to
protect it from leaking brake fluid.
– Disconnect the connector -2- from the Clutch Position Sensor

- G476- .
– Remove nuts -arrows- and bracket -1-.
Installing
– Replace self-locking nuts and clutch master cylinder seals af‐
ter removing them. n AG. Volkswagen AG age does
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– Insert the crash bolster -1- and tightenbthey V bolt -2-. Refer to ⇒
ol not
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ara
Body Interior; Rep. Gr. 70 ; Instrument
rised Panel Central Tube;
nte
Overview - Instrument Panel Central
ut
ho Tube . eo
ra
a c
ss
– Install the Data Bus on Board Diagnostic Interface - J533- .
ce
le
un
Refer to ⇒ Electrical Equipment; Rep. Gr. 97 ; Control Mod‐

pt
an
d
ules; Component Location Overview - Control Modules .

itte
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erm
ab
– Install the driver side footwell vent. Refer to ⇒ Heating, Ven‐

ility
ot p

wit
is n

h re
ole,
spec

t to the co

rrectne
Note
ss o
cial p
The battery will be installed and connected later.

inform
mer
atio

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– Connect hose/line assembly -1- with connection

⇒ Fig. ““Disconnect and Connect Clutch Mechanism Wires”“ ,
page 16 .
– Connect the supply hose -2- to the clutch master cylinder.
• After removing the Hose Clamp up to 25 mm - 3094- , the
supply hose must be formed back into its original shape.
– Bleed the clutch mechanism. Refer to
⇒ “1.13 Clutch Mechanism, Bleeding”, page 33 .
– Install drivers side knee airbag and connect the battery. Refer
to ⇒ Body Interior; Rep. Gr. 69 ; Knee Airbags; Overview -
Knee Airbag and ⇒ Electrical Equipment; Rep. Gr. 27 ;
Battery; Battery, Disconnecting and Connecting .
– Install and connect the battery. Refer to ⇒ Electrical Equip‐
ment; Rep. Gr. 27 ; Battery; Battery, Disconnecting and
Connecting .
Tightening Specifications
♦ Mounting bracket to bulkhead. Refer to
⇒ “1.2 Overview - Pedal Assembly”, page 13 .
1.10 Clutch Master Cylinder, Removing and

Installing
Removing lkswage es n
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Note au or
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♦ Before replacing the clutch master cylinder due to an assumed
pt
an
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defect, perform the Guided Fault Finding Vehicle Diag‐

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ab
nostic Tester first.
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♦ When working inside the footwell, cover the carpet with cloths
wit
is n
h re
to protect it from leaking brake fluid.
ole,
spec
– Remove the bracket. Refer to

t to the co
⇒ “1.9 Mounting Bracket, Removing and Installing”, page 26 .

– Remove the Clutch Position Sensor - G476- . Refer to
rrectne
⇒ “1.15 Clutch Position Sensor G476 , Removing and Instal‐

ling”, page 34 .
ss
– Release retainers in direction of -arrows- and remove mount‐

o
cial p
ing pin -2-.

inform
mer
– Remove clutch master cylinder -1-.

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Replace mounting pin after removing.

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– Install the bracket. Refer to Cop py
⇒ “1.9 Mounting Bracket, Removing and Installing”, page 26 .
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– Install the Clutch Position Sensor - G476- . Refer to
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⇒ “1.15 Clutch Position Sensor G476 , Removing and Instal‐
AG.
ling”, page 34 .
1.11 Clutch Slave Cylinder, Removing and

Installing
♦ Hose Clamps - Up To 25 mm - 3094- agen
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Removing
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Note
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♦ Before replacing the clutch master cylinder due to an assumed

defect, perform the Guided Fault Finding Vehicle Diag‐
nform
ercia
nostic Tester first.

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♦ If the clutch slave cylinder is removed from the transmission
ion in
with the hose/line assembly connected, do not operate (de‐
r
te o
thi
press) clutch pedal any more. Otherwise, the pistons are
s
iva
do
pushed out of the clutch slave cylinder and thus damaged.
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– Remove the entire air filter housing if it makes the clutch slave
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cylinder inaccessible. Refer to ⇒ Engine Mechanical, Fuel In‐
jection and Ignition; Rep. Gr. 24 ; Air Filter; Air Filter Housing,
Removing and Installing .
– Remove the transmission support -arrows-.
– Remove the battery and the battery tray if necessary. Refer to
⇒ Electrical Equipment; Rep. Gr. 27 ; Battery; Battery, Re‐
moving and Installing .

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– Place a lint-free cloth under the clutch slave cylinder.
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– Release the clamp -A- with a screwdriver and remove the
itte
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hose/line assembly -B- from the connection.
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ility
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– Remove the hose/line assembly -B- from the clutch slave cyl‐
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inder and seal off the openings. , is n
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spec
– Remove the bolts -arrows- and the clutch slave cylinder.
es, in part or in w
t to the co
Caution
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There is a risk of contamination from the leaking brake fluid.
l purpos
♦ When the hose/line assembly is separated from the con‐

nection, do not press the clutch pedal.
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♦ Lubricate all bearing areas and contact surfaces.
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♦ Allocation of the grease. Refer to the Parts Catalog.
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– Install the clutch slave cylinder -A- and secure with the bolts
-arrows-.
– Connect the hose/line assembly -B-
⇒ Fig. ““Disconnect and Connect Clutch Mechanism Wires”“ ,
page 16 .
⇒ “1.13 Clutch Mechanism, Bleeding”, page 33 .
– Install the air filter housing if it was removed earlier. Refer to
⇒ Engine Mechanical, Fuel Injection and Ignition; Rep. Gr.
24 ; Air Filter; Air Filter Housing, Removing and Installing .
– Install the battery and the battery tray if they were removed
earlier. Refer to ⇒ Electrical Equipment; Rep. Gr. 27 ; Battery;
Overview - Battery .
♦ Refer to
⇒ “1.4 Overview - Clutch Release Mechanism”, page 18 .
♦ Transmission support to transmission bracket and transmis‐
sion -arrows-. Refer to
⇒ “3.1 Overview - Subframe Mount”, page 87 .
1.12 Clutch Mechanism Lines, Removing

and Installing

Removing AG. Volkswagen AG d
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– Remove the entire air filter housing if the clutchd bmechanism
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lines are not accessible. Refer to ⇒ EngineorMechanical,
ise
Fuel nte
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Injection and Ignition; Rep. Gr. 24 ; Air Filter;
aut
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Air Filter Hous‐ ra
ing, Removing and Installing . ss c
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– Remove the battery and the battery tray. Refer to ⇒ Electrical
an
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Equipment; Rep. Gr. 27 ; Battery; Battery Tray, Removing and
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Danger of leaking brake fluid.
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♦ Be careful not to get any brake fluid on the longitudinal
member or on the transmission when performing the fol‐
rrectness of i
lowing work. If it does, clean the area thoroughly.
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♦ Place a lint-free cloth under the clutch master cylinder.
nform
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– Unclamp the supply hose -2- to the clutch master cylinder with
m
a Hose Clamps - Up To 25mm - 3094- .
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ply hose must be formed back into its original shape.
– Remove clip for hose/line assembly -1- all the way and remove
hose/line assembly.
– Remove the clamp -A- until stop and remove the hose/line as‐
sembly -B-.
Note
Ignore -arrows-.
– Seal the open lines and connections with clean plugs if nec‐
essary from the Engine Bung Set - VAS6122- .
– Free up the hose/line assembly and remove it.

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– Connect the hose/line assembly -1- with the connection on the
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clutch master cylinder and the clutch slave cylinder.
hole
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– Pull on the line to make sure it is secure.
es, in part or in w
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• After removing the Hose Clamp up to 25mm - 3094- , the return
hose -2- must be formed back into its original shape.
rrectness of i
⇒ “1.13 Clutch Mechanism, Bleeding”, page 33 . l purpos
– Install the battery tray and the battery. Refer to ⇒ Electrical
Equipment; Rep. Gr. 27 ; Battery; Battery Tray, Removing and
nform
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Installing .
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1.13 Clutch Mechanism, Bleeding
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♦ Bleeder Hose (670 mm) - VAG1238/B3-
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♦ The system must be bled after working on the hydraulic clutch

mechanism.
♦ Make sure no brake fluid gets on the transmission when per‐
forming the following work.
♦ It is not necessary to pre-fill the system.
♦ Before bleeding, fill the brake fluid reservoir to the “Max” mark‐
ing with brake fluid.
♦ The clutch pedal is in the neutral position and is not pressed.
♦ Brake fluid: allocation. Refer to the Parts Catalog.
– Remove the air filter housing if the bleed valve (-arrow- lower
illustration) is not accessible. Refer to ⇒ Engine Mechanical,
Fuel Injection and Ignition; Rep. Gr. 24 ; Air Filter; Air Filter
Housing, Removing and Installing .
– Return clutch pedal to the rest position.

– Remove cap from the bleed valve -arrow-.
– Connect the Brake Charger/Bleeder Unit - VAS5234- .
– Connect the bleed hose with the collector bottle pressure
hose.
If necessary use the Bleeder Hose (670 mm) - VAG1238/B3- .
– Switch the Brake Charger/Bleeder Unit - VAS5234- on.
• Working pressure 2.0 bar (29 psi).
– Open the bleed valve.
– Let approximately 100 cm (3.381 oz.)3 of brake fluid flow out.
– Close the bleed valve.
– Operate the clutch pedal rapidly from stop to stop, 10 to 15
times.
– Open the bleed valve.
– Let another 50 cm (1.690 oz.)3 of brake fluid flow out.
– Close the bleed valve.
– Turn off the Brake Charger/Bleeder Unit - VAS5234- and re‐
lease the pressure from the device completely.
– Press the clutch pedal a few times after bleeding the system.
– While doing this check the function of the clutch mechanism.
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♦ Bleed Valve. Refer to orise nte
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⇒ “1.3 Overview - Clutch Hydraulics”,
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1.14 Clutch Master and Clutch Slave Cylin‐

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Before replacing the clutch master cylinder due to an assumed

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agnostic Tester first.

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1.15 Clutch Position Sensor - G476- , Re‐

moving and Installing
rrectne
Removing
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– Disconnect the connector -arrow- from the Clutch Position

inform
Sensor - G476- .
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– Release the Clutch Position Sensor - G476- -2- on the clutch
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master cylinder -1- in direction of -arrow- and remove it.
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remain intact.
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• The Clutch Position Sensor - G476- must engage audibly.
rrectness of i
• Adapt the Clutch Position Sensor - G476- in the Guided
Fault Finding using the Vehicle Diagnostic Tester .
l purpos
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1.16 Clutch Release Mechanism, Servicing
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• The transmission is removed.

Remove and Install the Clutch Release Lever with the Release
Bearing
– Disengage the spring -arrow 1-.
– Remove the clutch release lever -arrow 2- and release bear‐
ing.
– Install in reverse order of removal.
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.
– Install the transmission. Refer to
⇒ “2 Transmission, Removing and Installing”, page 67 .
2 Clutch
⇒ “2.1 Overview - Clutch”, page 36
⇒ “2.2 Clutch, Removing and Installing”, page 39
2.1 Overview - Clutch

⇒ “2.1.1 Overview - Clutch, with Dual Mass Flywheel, Sachs”,
page 36
⇒ “2.1.2 Overview - Clutch, with Dual Mass Flywheel, LuK”, page
37
⇒ “2.1.3 Overview - Clutch, with Single Flywheel”, page 38
2.1.1 Overview - Clutch, with Dual

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Gr. 13 ; Cylinder Block,

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Transmission Side; Fly‐
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❑ Keep the clutch lining
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grooves, oil and grease.
2 - Clutch Plate
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Parts Catalog.
ling. Refer to
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⇒ “2.2.1 Clutch, Remov‐

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a
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Dual Mass Flywheel,

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3 - Pressure Plate
❑ With adjustment mech‐
anism
with the clutch plate
Parts Catalog.
ling. Refer to ⇒ “2.2.1 Clutch, Removing and Installing, with Dual Mass Flywheel, Sachs”, page 39 .
❑ Check the ends of the diaphragm spring. Refer to
⇒ Fig. ““Check the Ends of the Diaphragm Spring”“ , page 41
❑ Checking the spring connections and rivet connections. Refer to
⇒ Fig. ““Checking the Spring Connections and Rivet Connections”“ , page 41
4 - Bolt
❑ M 6: 13 Nm

❑ M 7: 20 Nm
❑ Loosen and tighten in small steps and in diagonal sequence
2.1.2 Overview - Clutch, with Dual Mass Flywheel, LuK
1 - Flywheel
❑ Removing and instal‐ AG. Volkswagen AG d
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Gr. 13 ; Cylinder Block, d by
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Transmission Side; Fly‐ orise nte
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wheel, Removing and aut
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Installing . ss c
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grooves, oil and grease.
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2 - Clutch Plate
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Parts Catalog.
rrectne
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LuK”, page 42 .
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⇒ Fig. ““Clutch Plate In‐

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❑ SAC = “self-adjusting Prote AG.
clutch”
with the clutch plate
Parts Catalog.
⇒ “2.2.2 Clutch, Removing and Installing, with Dual Mass Flywheel, LuK”, page 42 .
❑ Check the ends of the diaphragm spring. Refer to
⇒ Fig. ““Check the Ends of the Diaphragm Spring”“ , page 41
❑ Checking the spring connection and rivet connections. Refer to
⇒ Fig. ““Checking the Spring Connections and Rivet Connections”“ , page 41
4 - Bolt
❑ M 6: 13 Nm
❑ M 7: 20 Nm
2. Clutch 37
2.1.3 Overview - Clutch, with Single Flywheel
1 - Flywheel
ling. Refer to ⇒ Rep.
Gr. 13 ; Cylinder Block,
Transmission Side; Fly‐
wheel, Removing and
Installing .
grooves, oil and grease
2 - Clutch Plate AG. Volkswagen AG d
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❑ Allocation. Refer to the Volksw
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❑ Centering. Refer to ut
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Single Flywheel”,
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page 45
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3 - Pressure Plate
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Single Flywheel”,
page 45 .
rrectness of i
❑ Check the ends of the
diaphragm spring. Refer
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to
⇒ Fig. ““Check the Ends
of the Diaphragm
nf
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Spring”“ , page 47
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❑ Checking the spring

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⇒ Fig. ““Check the

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Spring Connection and Rivet Connections”“ , page 47

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❑ M 7: 20 Nm
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2.2 Clutch, Removing and Installing

⇒ “2.2.1 Clutch, Removing and Installing, with Dual Mass Fly‐
wheel, Sachs”, page 39
⇒ “2.2.2 Clutch, Removing and Installing, with Dual Mass Fly‐
wheel, LuK”, page 42
⇒ “2.2.3 Clutch, Removing and Installing, with Single Flywheel”,
page 45
2.2.1 Clutch, Removing and Installing, with

Dual Mass Flywheel, Sachs
♦ Flywheel Retainer - 3067-
♦ Alignment Tool - Clutch Plate - 3190A-
♦ Grease for Clutch Disc Shaft Splines - G 000 100- AG. Volkswagen AG d
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Removing d by ara
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• The transmission is removed. aut ra
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– Insert the Flywheel Retainer - 3067- to loosen the bolts.
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When Removing, Loosen the Bolts as Follows so that the Clutch
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Pressure Plate Does Not Distort (Causing Shuddering on Accel‐
ility
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– Loosen the bolt diagonally in small steps.
hole
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es, in part or in w
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ate
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2. Clutch 39
• When loosening, the stop -2- and the bolt -1- must loosen up
together.
– If the stop does not loosen: push the bolt toward the dual mass
flywheel.
– Remove the pressure plate and the clutch plate.
Installing
Note
♦ Allocate clutch pressure plate and clutch plate according to the

engine code. Refer to the Parts Catalog.
♦ Clean the input shaft splines and (on used clutch plates) the
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
input shaft until the hub moves freely on the shaft. Remove
any excess grease.
♦ The clutch pressure plates are corrosion-protected and
greased. With the exception of the friction surface on the clutch
plate, do not clean the clutch pressure plate. This will shorten
the service life of the clutch considerably.
♦ The friction surfaces on the clutch pressure plate and on the
flywheel must be cleaned thoroughly (degreased).
clutch housing, the flywheel and the side of the engine facing
toward the transmission.
♦ Only use compressed air to clean the dual mass flywheel.
♦ The clutch plate linings must sit completely on the flywheel and
on the clutch pressure plate friction surface. Install the bolts.
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♦ Tighten the bolts diagonally in small steps so as to not
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the centering holes in the pressure plate and the centering
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♦ Make sure the alignment sleeves for centering the engine/

un
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transmission are installed inside the cylinder block. Install

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them if necessary.
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♦ If the alignment sleeves are missing, it will be difficult to shift,

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there will be clutch problems and the transmission may make

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noises (loose rattling).

hole
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Clutch Plate Installed Position

• “Transmission side” label faces the transmission.
rrectness of i
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tion in
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Check the Ends of the Diaphragm Spring

• Wear up to half the thickness of the diaphragm spring
-arrows- is permitted.
Checking the Spring Connections and Rivet Connections

I - Pull-spring OK
• Slight offset in the outer area -arrows A-.
II - Pull-springs damaged
• The clutch pressure plates must be replaced if the pull-spring
is bent or broken off -arrow B-.
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– Make sure the rivet connections -arrows B- fit correctly on all ss c
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pull-springs -arrows A-.

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• Replace any clutch pressure plates that have loose rivet con‐
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nections -arrows B-.

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– Install the Flywheel Retainer - 3067- .

nform
ercia
– Install the clutch pressure plate on the centering pins.

m
– Center the clutch plate with the Alignment Tool - Clutch Plate
at
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- 3190A- .
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2. Clutch 41
When Installing, Tighten Bolts as Follows so Clutch Pressure

Plate Does Not Distort (Causing Shuddering On Acceleration):
– Make sure the stop pin (position sensor) -arrow- moves easily.
– Install all bolts evenly, by hand, until the bolt heads touch the
clutch pressure plate.
– Tighten the bolt diagonally in small steps.
Volkswagen AG
• When doing this, the stop pin -arrow- must lift off from
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– Install the transmission. Refer to ho
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⇒ “2.2 Transmission, Installing”, page
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♦ Refer to
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ility
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Dual Mass Flywheel, LuK
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♦ Grease for Clutch Disc Shaft Splines - G 000 100-
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Removing
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When Removing, Loosen the Bolts as Follows so that the Clutch
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Pressure Plate Does Not Distort (Causing Shuddering On Accel‐
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eration):
– Loosen the bolt diagonally in small steps.

– Remove the clutch pressure plate and clutch plate.

Installing
Note

AG. Volkswagen
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♦ Tighten the bolts diagonally in small steps so as to not damage

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the centering holes in the pressure plate and the centering pins
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Clutch Plate Installed Position

• “Transmission side” label faces the transmission.
2. Clutch 43

Note
Allocate clutch pressure plate and clutch plate according to the

Checking the Pull-Springs and Rivet Connection

I - Pull-spring OK
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Checking the Spring Connections and Rivet Connections
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nections -arrows B-.
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Only Check Position of Adjustment Mechanism with New Pres‐

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• With used clutches, the adjusting ring may take on a position

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– Install the clutch pressure plate on the centering pins.
atio
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– Center the clutch plate with the Alignment Tool - Clutch Plate
o
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- 3190A- .
thi
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When Installing, Tighten Bolts as Follows So Clutch Pressure

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– Install all bolts evenly, by hand, until the bolt heads touch the . Cop py
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– Tighten the bolts diagonally in small steps.
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⇒ “2.2 Transmission, Installing”, page 77 .
♦ Pressure plate on the flywheel. Refer to
⇒ “2.1.2 Overview - Clutch, with Dual Mass Flywheel, LuK”,
page 37 .

Single Flywheel
Removing
• The transmission is removed.
2. Clutch 45

When Removing, Loosen the Bolts as Follows So That the Clutch
Pressure Plate Does Not Distort (Causing Shuddering on Accel‐ n AG. Volkswagen A
eration): olks
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– Loosen the bolt diagonally in small steps. db ara
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– Remove the pressure plate and the clutch plate.
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Installing
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Note
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hub splines. Remove any corrosion and then apply a very thin
coat of Grease for Clutch Disc Shaft Splines - G 000 100- on
rrectne
the splines. Then move the clutch plate back and forth on the
input shaft until the hub moves freely on the shaft. Remove
any excess grease.
ss o
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inform
mer
atio
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toward the transmission. t. C rig
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on the clutch pressure plate friction surface. Install the bolts.
♦ Tighten the bolts diagonally in small steps so as to not damage
the centering holes in the pressure plate and the centering pins
on the flywheel.
them if necessary.
noises (loose rattling).
• Clutch plate installed location: The labeling

“Getriebeseite” (transmission side) or the shorter end of the
hub with the spring cage faces the pressure plate.

AG. Volkswagen AG d
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Vol Golf 2015n➤ ot g, Golf Variant 2015 ➤
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d
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t-eeEdition 12.2014
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Check the Spring Connection and Rivet Connections
nform
ercia
– Check the spring connection between the pressure plate and

the cover for cracks and make sure the rivet connections are
m
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tight.
ion in
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– Replace the pressure plate if the springs are damaged or if the
thi
s
iva
rivet connections -arrows- are loose.
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Checking the Pull-Springs and Rivet Connection

I - Pull-spring OK
– Check the spring connections -arrows A- for damage and
make sure the rivet connections -arrows B- are tight.
• Replace a clutch pressure plate with severely kinked or broken
spring connections and loose rivet connections.
– Make sure the rivet connections -arrows B- fit correctly on all

nections -arrow B-.
2. Clutch 47
Checking the Metal Ring

– Check the metal ring in the clutch pressure plate -arrow- for
damage.
• Replace any clutch pressure plates that have a broken metal
ring.
– Use the Alignment Tool - Clutch Plate - 3190A- to center the

clutch plate.
– Tighten the bolt diagonally in small steps.
♦ Pressure plate on the flywheel. Refer to
⇒ “2.1.3 Overview - Clutch, with Single Flywheel”, page 38 .
AG. Volkswagen AG d
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ate
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3 Special Tools
Special tools and workshop

equipment required
♦ Alignment Tool - Clutch
Plate - 3190A-
♦ Torque Wrench 1331
5-50Nm - VAG1331-
♦ Grease for Clutch Disc
Shaft Splines - G 000 100-wagen AG. Volkswagen AG does
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♦ Sealing Tool - T10249-
Prote AG.
3. Special Tools 49
♦ Brake Charger/Bleeder Unit - VAG1869-
lkswage es n
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byV ua
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ir se tee
tho
or
♦ Brake Charger/Bleeder
au Unit - VAS5234- or ac
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34 – Controls,
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AG. VoHousing
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1 tho Selector Mechanism
ris tee
or
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⇒ “1.1 Selector Mechanism Installation Position”, page 51
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an
⇒ “1.3 Overview - Selector Mechanism”, page 53
d
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⇒ “1.2 Overview - Gearshift Knob and Cover”, page 52
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⇒ “1.4 Gearshift Knob, Removing and Installing”, page 54
is n
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ole,
⇒ “1.5 Selector Mechanism, Removing and Installing”,
spec
page 56
t to the co
⇒ “1.6 Selector Mechanism, Adjusting”, page 63
⇒ “1.7 Selector Mechanism, Checking”, page 65
rrectne
⇒ “1.8 Selector Shaft Seal, Replacing”, page 65
ss
1.1 Selector Mechanism Installation Position
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-Arrow A- Gearshift Lever Movement
mer
atio
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-Arrow B- Selector Lever Movement

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A - Gearshift Lever Cable

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B - Selector Cable
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C - Heat Shield
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❑ Remove the shift mech‐
py by
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Prote
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agen
1 - Gearshift Lever
2 - Selector Relay Lever
1. Selector Mechanism 51
1.2 Overview - Gearshift Knob and Cover
1 - Gearshift Housing with

Gearshift Lever
2 - Nut
❑ M6: 8 Nm
❑ M8: 25 Nm
3 - Bracket
❑ For the center console
❑ Overview. Refer to ⇒
Body Interior; Rep. Gr.
68 ; Center Console;
Overview - Center Con‐
sole .
4 - Bracket
❑ For the center console
❑ Overview. Refer to ⇒
Body Interior; Rep. Gr.
68 ; Center Console;
Overview - Center Con‐
sole .
5 - Noise Insulation
6 - Badge
❑ Can be carefully pried
off the plastic or leather
gearshift knob using
Trim Removal Wedge -
3409- .
7 - Gearshift Knob agen
AG. Volkswagen AG d
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❑ With boot by Vo gu
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❑ The shift knob and boot rise nte
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cannot be separated s aut ra
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from each other. s
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❑ Always replace together

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ling. Refer to ⇒ “1.4 Gearshift Knob, Removing and Installing”, page 54 .

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8 - Center Console
h re
hole
❑ Overview. Refer to ⇒ Body Interior; Rep. Gr. 68 ; Center Console; Overview - Center Console .
spec
es, in part or in w
9 - Clamp
t to the co
❑ For securing the shift knob to the shift lever

rrectness of i
❑ Secure on the gearshift knob using Hose Clamp Pliers - VAG1275- .

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52 Rep. Gr.34 - Controls, Housing

1.3 Overview - Selector Mechanism
Note
♦ Lubricate the bearing areas and the sliding surfaces.

♦ Grease allocation. Refer to the Parts Catalog.
AG. Volkswagen AG d
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1 - Gearshift Shaft with Gear‐
orise nte
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shift Cover aut
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2 - Sliding Shoe
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3 - Relay Lever
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Parts Catalog.
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hole
to
spec
⇒ Fig. ““Selector Lever/
es, in part or in w
t to the co
Relay Lever Installed
Position”“ , page 61
❑ Adjust the gearshift
rrectness of i
mechanism after instal‐
ling. Refer to
l purpos
⇒ “1.6 Selector Mecha‐

nism, Adjusting”,
nform
ercia
page 63 .
❑ Relay lever and cable
m
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ti
retainer, removing and
on in
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⇒ Fig. ““Remove the Re‐
s
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lay Lever and the Cable

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Retainer.”“ , page 58
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4 - Cable Retainer ht. Cop py
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❑ For attaching the selec‐ rig ht
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tor cable to the relay lev‐
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❑ Adjust the gearshift

mechanism after instal‐
ling. Refer to
⇒ “1.6 Selector Mecha‐
nism, Adjusting”,
page 63 .
❑ Do not interchange, ca‐
ble locking mechanisms
for selector cable on
linkage lever and for shift cable on transmission shift lever are different
❑ Allocation. Refer to ⇒ Fig. ““Cable Retainer Allocation”“ , page 60 .
❑ Remove from the relay lever. Refer to
⇒ Fig. ““With the Relay Lever Removed: Pry the Selector Cable Retainer Off of the Relay Lever.”“ , page
59
❑ Press onto the relay lever. Refer to
⇒ Fig. ““Installing the Selector Cable Retainer on the Relay Lever”“ , page 59
5 - Cable Retainer
❑ For attaching the shift cable to the transmission shift lever
❑ Adjust the gearshift mechanism after installing. Refer to
⇒ “1.6 Selector Mechanism, Adjusting”, page 63 .
❑ Do not interchange, cable locking mechanisms for selector cable on linkage lever and for shift cable on
transmission shift lever are different
❑ Allocation. Refer to ⇒ Fig. ““Cable Retainer Allocation”“ , page 60 .
6 - Lock Washer
7 - Lock Washer
❑ Be careful not to damage the cables when removing them
8 - Selector Cable
❑ Attach to the cable retainer
❑ Do not bend
❑ Installed position. Refer to ⇒ “1.1 Selector Mechanism Installation Position”, page 51
9 - Gearshift Cable
❑ Attach to the cable retainer
❑ Do not bend
❑ Installed position. Refer to ⇒ “1.1 Selector Mechanism Installation Position”, page 51
10 - Gearshift Housing
11 - Seal
❑ Between the gearshift housing and the underbody
❑ Replace after removing the gearshift housing
❑ Self-adhesive
❑ Affix to the gearshift housing
12 - Cable Mounting Bracket
❑ Adjust the gearshift mechanism .after installing. Refer to
AG Volkswagen AG d
⇒ “1.6 Selector Mechanism,
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oes.
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13 - Hex Bolt ed
b ran
oris tee
❑ 20 Nm au
th or
ac
ss
❑ For the cable bracket
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un
pt
❑ Quantity: 3
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14 - Grommet
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ility
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❑ Quantity: 3
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❑ Cable mounting bracket to transmission

ole,
spec
15 - Spacer
t to the co
❑ Quantity: 3
16 - Nut
rrectne
❑ Tightening specification. Refer to ⇒ “5.5 Overview - Shift Unit”, page 96 .

17 - Gearshift Lever
ss o
❑ Insert so that master spline aligns with shift rod. Refer to

cial p
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⇒ Fig. ““Installing the Transmission Shift Lever”“ , page 62

form
mer
❑ Installed position. Refer to ⇒ Fig. ““Selector Lever/Relay Lever Installed Position”“ , page 61
atio
m
❑ Adjust the gearshift mechanism after installing. Refer to

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or

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18 - Gearshift Shaft Seal

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pr
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❑ Replacing. Refer to ⇒ “5.5 Overview - Shift Unit”, page 96 .

en
ng
t.
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19 - Clip
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Prote AG.
1.4 Gearshift Knob, Removing and Instal‐
ling

♦ Hose Clip Pliers - VAG1275A-

♦ Wedge Set - T10383-
♦ Wedge Set - Wedge 1 - T10383/1-
♦ or the equivalent equipment, Backrest Panel Tool - 3370-
Caution


♦ Clamp - Shift Knob to Shift Lever
Removing
– Use the Wedge Set - Wedge 1 - T10383/1- to carefully pry out
the selector lever boot from the center console insert in direc‐
tion of -arrows-.
or
– Open the ashtray.

– Push the Backrest Panel Tool - 3370- as illustrated, under the
plastic frame for the boot in direction of -arrow 1- until stop.
– Remove boot with plastic frame from center console frame
-A- in direction of -arrow 2- . Volkswag AG en AG
agen does
– Roll the selector lever boot up yover
Vol the gearshift knob.
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– Open the clamp -arrow- and remove the gearshift lever knob
ot p
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with the shift lever boot.

is n
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ole,
Installing
spec

t to the co
– Press the gearshift knob and the selector lever boot all the way
up on the gearshift lever.
rrectne
– Secure the gearshift knob with clamp -arrow- on the gearshift

lever (⇒ previous illustration). Use the Hose Clamp Pliers -
ss
VAG1275- to do this.
o
cial p
f inform
mer
atio
om
n
c
i
or
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te
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pr
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Prote AG.
1. Selector Mechanism
1.5 Selector Mechanism, Removing and In‐

stalling
Caution


♦ Lock Washer - Cable Retainer
♦ Lock Washer - Gearshift Cable
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– Disconnect the battery groundsecable.
d b Refer to ⇒ Electrical ara
nte
Equipment; Rep. Gr. 27 ; Battery;
thori
Battery, Disconnecting and eo
Connecting . s au ra
c
s
ce
e
– Remove the boot with the gearshift knob and, if necessary,

nl
pt
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remove the noise insulation from the center console frame as
an
itte
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well. Refer to
erm
ab
⇒ “1.4 Gearshift Knob, Removing and Installing”, page 54 .
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The Footwell Rear Channel is Located Above the Bracket for the
h re
Center Console on Some Vehicles:
hole
spec
es, in part or in w
– Remove the center console. Refer to ⇒ Body Interior; Rep.
t to the co
Gr. 68 ; Center Console; Center Console, Removing and In‐
stalling .
rrectness of i
– Remove rear channel footwell. Refer to ⇒ Heating, Ventilation
and Air Conditioning; Rep. Gr. 87 ; Air Routing; Overview - Air
l purpos
Routing and Air Distribution in Passenger Compartment .

– Remove the nuts from the center console mounting bracket.
nf
ercia
Refer to ⇒ Body Interior; Rep. Gr. 68 ; Center Console; Center

orm
Console, Removing and Installing .

m
atio
om
n in
– Remove the nuts from the gearshift housing. Refer to

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⇒ Fig. ““Installed Position of Gearshift Housing

thi
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a
Nuts -arrows-.”“ , page 57 .

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– Lower the gearshift housing.

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• If it is not possible to lower the gearshift housing, then the nuts C py
ht. rig
on the gearshift housing are located under the bracket on the rig ht
py by
center console.
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Prote AG.
• Remove the center console mounting bracket. Refer to ⇒
Body Interior; Rep. Gr. 68 ; Center Console; Center Console,
If the Center Console Bracket Cannot be Removed Separately:
– Remove the center console. Refer to ⇒ Body Interior; Rep.
Gr. 68 ; Center Console; Center Console, Removing and In‐
stalling .

Installed Position of Gearshift Housing Nuts -arrows-.

– Remove the nuts -arrows-.
– Remove center console and center console mounting bracket.
Refer to ⇒ Body Interior; Rep. Gr. 68 ; Center Console; Over‐
view - Center Console .
– Remove rear channel footwell. Refer to ⇒ Heating, Ventilation
and Air Conditioning; Rep. Gr. 87 ; Air Routing; Overview - Air
Routing and Air Distribution in Passenger Compartment .
Installed Position of Noise Insulation and Gearshift Housing Nuts

-arrows-.
– Remove noise insulation and gearshift housing nuts
-arrows-. . Volkswag AG en AG
agen do
– Remove noise insulation from yV
olthe
es n
ksw gearshift housing. Refer oto
tg
⇒ Body Interior; Rep. Gr.
ised 68 ; Center Console; Overview - uara
b
nte
Center Console . tho
r eo
u ra
sa c
– Remove the air filters housing if it is located over the gearshift
ce
le
mechanism. Refer to ⇒ Engine Mechanical, Fuel Injection and

un
pt
an
d
Glow Plug; Rep. Gr. 23 ; Air Filter; Overview - Air Filter Hous‐
itte
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ing or ⇒ Engine Mechanical, Fuel Injection and Ignition; Rep.

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Gr. 24 ; Air Filter; Air Filter Housing, Removing and Installing .

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– Remove the shift cable from the gearshift lever pins.

h re
hole
spec
Disconnecting the Cable Retainer from the Selector Cable

es, in part or in w
t to the co
– Pull the securing mechanism all the way forward in direction

of -arrow 1- and then unlock to the left in direction of
-arrow 2-.
rrectness of i
– Push the relay lever forward (in direction of -arrow 3-).

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mercia
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tion in
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Prote AG.
Remove the Relay Lever and the Cable Retainer.

– Remove the clip -arrow 1- and then remove the relay lever
together with the cable retainer -arrow 2-.
AG. Volkswagen AG d
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– Remove the cable bracket from the transmission -arrows-.

Unclip the hose line -A- from the bracket -B- beforehand, if
nf
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necessary.
orm
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atio
m
Caution
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n in
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There is a danger of causing damage to the decoupling ele‐
iva
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r
ment on the exhaust pipe.

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♦ Pay attention to ⇒ Rep. Gr. 26 ; Emissions Control; Over‐

t.
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view - Emissions Control .
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– Remove the exhaust pipe under the gearshift mechanism. Re‐
AG.
fer to ⇒ Rep. Gr. 26 ; Exhaust Pipes/Mufflers; Overview -

Muffler .
– Remove the heat shield under the gearshift mechanism.
Removing the heat shield. Refer to ⇒ Body Exterior; Rep. Gr.
66 ; Molding/Trim/Extensions/Trim Panels; Floor Heat Shield,
– Pivot shift housing downward and remove with cables.

With the Relay Lever Removed: Pry the Selector Cable Retainer
Off of the Relay Lever.
– Insert a screwdriver -A- between the bushing -B- and the relay
lever.
Installing
AG. Volkswagen AG d
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Installing the Selector Cable Retainer on the Relay Lever
es, in part or in w
t to the co
• The relay lever is removed.
• Lubricate cable retainer locating bore.
rrectness of i
• Grease allocation. Refer to the Parts Catalog.
l purpos
• The cable retainer may only be installed at the bushing in di‐

rection of -arrow-.
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ercia
o
• The cable retainer must move freely on the relay lever.
rm
m
atio
m
• The cable retainer must be behind the tab.

o
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• Make sure it engages securely.
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– Align the shift housing so that is it parallel to the body.
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• The distance on both sides to the body must be equal.
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Install the gearshift housing. rig ht
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Cable Tie Installation Locations
Prote AG.
– Wrap the cable tie -arrow- in a crossover pattern around the

cables and attach it as illustrated.
– Route the cables -1- from the gearshift mechanism -2- to the
transmission 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.
♦ The cable tie -arrow- for securing the cables must be installed
correctly. Installation location. Refer to
⇒ Fig. ““Cable Tie Installation Locations”“ , page 59 .
♦ The cables must be routed inside the depression in the heat
shield -3-.
A clip -A- holds the cables and heat shield to each other in place.
AG. Volkswagen AG d
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Cable Retainer Allocation

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These holes have different diameters.

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Cable Retainer For: Dimension “a”

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1. - Shift cable to transmission selector lever 8.5 mm

t to the co
2. - selector cable to relay lever 10 mm

rrectness of i
l purpos
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Prote AG.

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-.
AG. Volkswagen AG d
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• Lubricate the following areas very carefully when installing.

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• Relay lever shaft -A- -arrows-.
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• Gearshift lever glide track -B-, fits into the relay lever.
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• Cable retainer locating bore.

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Installing the Transmission Shift Lever

– When positioning the transmission shift lever, make sure the
tooth gap -arrow A- is placed over the missing selector shaft
teeth -arrow B-.
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– Secure the shift cable with new lock washers to the gearshift
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Install the Relay Lever and the Cable Retainer Together.
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Lubricate the bearing areas and the sliding surfaces. Grease al‐
com
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location. Refer to the Parts Catalog.
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– Install the relay lever and cable retainer -arrow 2- all the way
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– Install the clip -arrow 1- and make sure it is locked into place. t. Cop py
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– Install the selector cable in the cable retainer. pyri by
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– Install the center console. Refer to ⇒ Body Interior; Rep. Gr. Prote AG.
68 ; Center Console; Center Console, Removing and Instal‐
ling .
– Install the boot with the shifter knob and noise insulation. Refer
to ⇒ “1.4 Gearshift Knob, Removing and Installing”, page 54 .
– Install the heat shield under the gearshift mechanism. Refer
to ⇒ Body Exterior; Rep. Gr. 66 ; Molding/Trim/Extensions/
Trim Panels; Floor Heat Shield, Removing and Installing .
– Assemble the exhaust system free of tension. Refer to ⇒ Rep.
Gr. 26 ; Exhaust Pipes/Mufflers; Overview - Muffler .
– Adjust the gearshift mechanism. Refer to
24 ; Air Filter; Air Filter Housing, Removing and Installing or ⇒
Engine Mechanical, Fuel Injection and Glow Plug; Rep. Gr.
23 ; Air Filter; Overview - Air Filter Housing .
♦ Refer to
⇒ “1.2 Overview - Gearshift Knob and Cover”, page 52
♦ Refer to ⇒ “1.3 Overview - Selector Mechanism”, page 53 .

1.6 Selector Mechanism, Adjusting

♦ Connecting Pin - T10027A-
Adjusting Requirements
• Operating and transfer elements of shift mechanism must be
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• Shift mechanism
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• The transmission,
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be
in proper
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• Transmission in neutral.
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– Remove the entire air filter housing if the bracket -A- and the
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securing mechanism for the shift and selector cables are not
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Ignition; Rep. Gr. 24 ; Air Filter; Air Filter Housing, Removing
hole
spec
and Installing .
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– Pull the safety mechanism on the cable retainer for the shift
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cable and the selector cable all the way forward in direction of
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-arrow 1- and then lock it to the left in direction of -arrow 2-.

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Secure the gearshift shaft as follows:

– Push the gearshift shaft down in the 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.
– Remove the boot and, if possible, the noise insulation from the
center console. Refer to
Secure the gearshift shaft as follows:
– Install the gearshift lever in neutral and, if necessary, press the
gearshift lever to the left and hold.
– Guide the Connecting Pin - T10027A- through the noise insu‐
lation -A-, hole -B- and into hole -C-.
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– Position the safety mechanism on the cable retainer for the
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shift cable and selector cable all the way to the right in direction
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of -arrow-.
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The spring will push the safety mechanism into the starting posi‐
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– Push the angle -A- back in the starting position direction of

-arrow-.
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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.

– Remove the Locking Pin from the noise insulation -A- and the
holes -B and C-.
– Install the boot and if the insulation (if equipped). Refer to
– Make sure the gearshift shaft moves easily.
1.7 Selector Mechanism, Checking

• The gearshift lever must rest in the 3rd/4th gear gate when the
transmission is in neutral.
– Operate the clutch.
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– Move the gearshift lever (selector lever) several timesVolthrough
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– It will be necessary to adjust the gearshiftssmechanism again if c
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a hook does not appear each time a gear is engaged. Refer

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to ⇒ “1.6 Selector Mechanism, Adjusting”, page 63 .
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1.8 Selector Shaft Seal, Replacing
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♦ Press Piece - Shift Rod/Alternator - VW423-
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♦ Sealing Grease - G 052 128 A1-
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Caution
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– Remove transmission shift lever and relay lever. Refer to

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⇒ “1.3 Overview - Selector Mechanism”, page 53 .

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– Remove the seal with a screwdriver.

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– Lightly oil new seal on outer circumference.

– Fill the space between the sealing and dust lip -arrow- halfway
with Sealing Grease - G 052 128 A1- .
– Drive in the seal using the Press Piece - Shift Rod/Alternator

- VW423- .
– Install the gearshift lever and relay lever. Refer to
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2 Transmission, Removing and Instal‐

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⇒ “2.1 Transmission, Removing”, page 67
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⇒ “2.2 Transmission, Installing”, page
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⇒ “2.3 Transmission Tightening Specifications”,
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page 86
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2.1 Transmission, Removing
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♦ Engine Support Bridge - 10-222A-
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spec
♦ Engine Support Bridge - Gearbox Adapter - 10-222A/29-
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♦ Engine Support Bridge - Engine Support 18 - 10-222A/18-
♦ Engine/Gearbox Support Shackle (2 pc.) - 10-222A/12-
rrectne
♦ Transmission Support - Pins 29 - 3282/29-
♦ Transmission Support - 3282-
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♦ Transmission Support - Mounting Plate 39 - 3282/39-
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♦ Transmission Support Elements (determine when mounting
atio
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the Adjustment Plate on the Transmission Support )

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♦ Engine and Gearbox Jack - VAS6931-
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♦ Transmission Support Jig - 3336- to transport the transmis‐
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♦ Allocate the grease for gearshift mechanism. Refer to the

Parts Catalog.
♦ Engine Support Bridge - Special Hook (2 pc.) - 10-222A/20-
♦ Spindle from the Seal Installer - Driver Set - 3066- or M8 x 105
bolt
♦ Seal Installer - One-Piece Seal - T10148-
♦ Engine Support - Basic Set Square Pipe - T40091/1- (quantity
2)
♦ Engine Support - Basic Set Movable Joint - T40091/3- (quan‐
tity 2)
♦ Engine Support - Supplement Kit Spindle - T40093/3- (quan‐
tity 2) from the Engine Support - Supplement Kit - T40093A-
♦ Engine Support Brackets - T40093/3-6- (quantity 2)
Caution


♦ Bolt - Transmission Support to Transmission
♦ Bolt - Transmission Support to Transmission Bracket
♦ Bolt - Pendulum Support to Transmission
2. Transmission, Removing and Installing 67

♦ Bolt - Pendulum Support to Subframe

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♦ Bolts - Transmission
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♦ Bolts - Transmission
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♦ Lock Washer
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♦ Nut - Coupling Rod to Stabilizer Bar
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♦ Bolts - CV Boot to Inner CV Joint
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♦ Seals - Transmission
spec
– Disconnect the battery ground cable. Refer to ⇒ Electrical
t to the co
Equipment; Rep. Gr. 27 ; Battery; Battery, Disconnecting and
Connecting .
rrectne
– Remove the engine cover. Refer to ⇒ Rep. Gr. 10 ; Engine
Cover; Engine Cover, Removing and Installing .
ss
– Remove the air filter housing. Refer to ⇒ Engine Mechanical,
o
cial p
f
inform
mer
atio
m
– Remove the battery and the battery tray -1- -arrows-. Refer to
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c
⇒ Electrical Equipment; Rep. Gr. 27 ; Battery; Battery Tray,

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– Remove the cable retainer from the selector cable. Refer to

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⇒ Fig. ““Disconnecting the Cable Retainer from the Selector

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Cable”“ , page 57 .
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Prote AG.
– Remove the clip -arrow 1- and then remove the relay lever and
the cable retainer.
– Remove the shift cable lock washer -arrow 2- from the selector
lever -A-.
– Remove the shift cable from the gearshift lever pins.
– Remove the nut -arrow 3- 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.
– If equipped, remove the bracket -B- from the transmission.
Remove the bracket from the hose/line assembly -A-.

– Remove the transmission support -A arrows-.

– Remove the clutch slave cylinder -B arrows- lay aside and se‐
cure with wire. Do not open the line system.
Caution
The clutch slave cylinder could be damaged.

♦ If the clutch slave cylinder is removed from the transmis‐
sion with pipe/hose line still connected, do not press the
clutch pedal.
– Remove the ground cable upward from the engine/transmis‐

sion connecting bolt or from the upper starter bolt.
– Disconnect the connector -arrow 1- from the Back-Up Lamp

Switch - F4- . agen
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– Remove the connector
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– Remove the
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– Remove the upper engine/transmission bolts.
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– Unlock the retaining tab in direction of -arrow- and remove the

left engine cover mount -1-.
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Golf 2015 ➤ , Golf Variant 2015 ➤ horis
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Manual Transmission - Edition 12.2014 ss a ra
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– Unclip the right mount -1- for the engine cover from the bracket
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-2-.
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– Attach the Engine Support Bridge - 10-222A- as follows:
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The following are needed:
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♦ Engine Support - Bracket w/Spindle and hook - 10-222A/20-
♦ Engine/Gearbox Support Shackle (2 pc.) - 10-222A/12- (is
rrectne
needed if the Spindle from the Engine Support Bridge cannot
be engaged in the engine lifting eye).
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(quantity 2)
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– Insert the Engine Support Bridge - Engine Support 29 - Prote AG.
10-222A/29- between the fender bolting edge and the fender
bolting plate underneath it on both sides of the vehicle.
♦ Installed position:
“L” = -1- Adapter is Installed on the “right” Side of the Vehicle
( Adapter Locks in the Hole on the Fender).
“R” (Not Illustrated Here), Adapter is Installed on the “left” Side of

the Vehicle.
The arrow -2- on the Engine Support Bridge - Engine Support 29
- 10-222A/29- always points in the direction of travel.
– Slide the Engine Support Bridge - Engine Support 18 -

10-222A/18- and two Engine Support - Basic Set Movable
Joint - T40091/3- onto the Engine Support Bridge - 10-222A- .
– Tighten the Engine Support Bridge - 10-222A- on the Engine
Support Bridge - Engine Support 29 - 10-222A/29- .
-A- = Engine Support Brackets - T40093/3-6- (⇒ next illustration)
– Remove the filler tube for the windshield washer system wash‐
er fluid reservoir. Refer to ⇒ Electrical Equipment; Rep. Gr.
92 ; Windshield Washer System; Washer Fluid Reservoir, Re‐

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Manual Transmission
c - Edition 12.2014
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– If present, remove wires from the front area of both longitudinal
an
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members -arrow-. Do not disconnect line system.
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ility
– Place the Engine Support Brackets - T40093/3-6- on both lon‐
ot
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gitudinal members (the right longitudinal member is illustrated
h re
here).
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es, in part or in w
– If necessary, carefully unclip the A/C system pipe in the front
t to the co
area. Do not disconnect the line system. Refer to ⇒ Heating,
Ventilation and Air Conditioning; Rep. Gr. 87 ; Refrigerant
Circuit; System Overview - Refrigerant Circuit .
rrectness of i
• The Engine Support Brackets - T40093/3-6- locks respectively
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with the pins -A- behind the tab on the longitudinal member
-arrow-.
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– Install the Engine Support - Supplement Kit Spindle -

T40093/3- .
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– Connect the Engine Support - Supplement Kit Spindle -
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T40093/3- over the Engine Support - Basic Set Square Pipe -
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T40091/1- with the Engine Support Bridge - 10-222A- and
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tension it (⇒ previous illustration).

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♦ The Engine Support - Basic Set - Square Pipe - T40091/1-
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Prote AG.
must not touch the windshield.
♦ The Engine Support Bridge - Engine Support 18 - 10-222A/18-
must not lie on the windshield wiper arm.
– Engage the Spindles with the Engine Support Bridge - Special

Hook (2 pc.) - 10-222A/20- and if necessary with the Engine/
Gearbox Support Shackle (2 pc.) - 10-222A/12- in the engine
lifting eyes.
– Pretension the engine/transmission assembly and Engine
Support Bridge via the Spindles .
– Raise the vehicle and remove the left front wheel.
– Remove the noise insulation. Refer to ⇒ Body Exterior; Rep.
Gr. 66 ; Noise Insulation; Overview - Noise Insulation .
– Remove the lower section of the left front wheel housing liner.
Refer to ⇒ Body Exterior; Rep. Gr. 66 ; Wheel Housing Liner;
Front Wheel Housing Liner, Removing and Installing .
– Remove the nut -arrow- and then remove the wire mount.

– Remove all wires from the transmission.

– Transmission on vehicles with Start/Stop System: disconnect
the connector -arrow- from the Transmission Neutral Position
Sensor - G701- .
– Remove the starter. Refer to ⇒ Electrical Equipment; Rep. Gr.
27 ; Starter; Starter, Removing and Installing .
olkswagen AG
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– Remove the nuts -1- from both sides of the coupling
olks rod -3-.
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– Remove the coupling rod -3- from both sidesed of the stabilizer nte
ris
bar -2-. tho eo
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– If equipped, remove the Left Front Level Control System Sen‐
rrectne
sor - G78- from the lower control arm. Refer to ⇒ Suspension,
Wheels, Steering; Rep. Gr. 43 ; Level Control System Sensor;
Overview - Front Level Control System Sensor .
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– Remove the drive axle heat shield -arrows- (if equipped). Re‐ rig ht
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fer to ⇒ Suspension, Wheels, Steering; Rep. Gr. 40 ; Drive
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Axle; Drive Axle Heat Shield, Removing and Installing . Prote AG.
– 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. Refer to ⇒ Suspension, Wheels, Steering; Rep. Gr.
40 ; Drive Axle; Drive Axle, Removing and Installing .

– Install the two bolts into the flange and counterhold the flange
shaft with the pry lever to remove the right flange shaft bolt
-arrow-.
– Remove the flange shaft.
Note
♦ Check the seal for leaks before removing the flange shaft. If
the seal has leaks, replace it when installing. Refer to
⇒ “1.3 Right Seal, Replacing”, page 185 .
♦ If transmission fluid leaks out while removing the flange shaft,
drain and refill transmission fluid on the installed transmission G. Volkswagen
and installed flange shaft. Refer to ksw
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⇒ “8 Transmission Fluid”, page 125 . by
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– Attach the spindle -A- from the Seal Installer
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ce
3066- into the threaded piece on the differential.
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– Insert the Seal Installer - One-Piece Seal - T10148- and se‐
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cure with the nut -B-.
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♦ The Seal Installer - One-Piece Seal - T10148- protects the
right seal and the transmission from dirt.
♦ A M8 x 105 mm bolt may be installed by hand into the differ‐
rrectness of i
ential threaded piece instead of a spindle -A-.
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Caution
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mercia
There is a danger of causing damage to the decoupling ele‐
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ment.
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♦ Pay attention. Refer to ⇒ Rep. Gr. 26 ; Emissions Control;

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Overview - Emissions Control .

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– Remove the bracket bolts -arrows- for the exhaust system on
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– Disconnect the exhaust system at the clamping sleeve

-arrow-. Refer to ⇒ Rep. Gr. 26 ; Exhaust Pipes/Mufflers;
Overview - Muffler .
– Remove bolts -1 through 3- and remove pendulum support.
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– Loosen the hose clamps -arrows- and remove horthe
is
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air hose -A-. Refer to ⇒ Engine Mechanical,s aFuel Injection and ra
c
Ignition; Rep. Gr. 21 ; Charge Air System;s Overview - Charge
ce
le
Air System .
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– If present, remove nut -arrow- and ground cable.

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– Remove the left assembly mounting hex bolts -arrows- from

the transmission mounting.
– Turn the spindles on the Engine Support Bridge - 10-222A-

and lower the transmission to dimension -a-.
• Dimension -a- = approximately 50 mm
– Remove the transmission bracket -A- -arrows-.

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Align the Transmission Support - 3282- with the Transmission
Support - Mounting Plate 39 - 3282/39- in order to remove the
“0A4” transmission.
rrectness of i
– Insert the Transmission Support - 3282- into the Engine and
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Gearbox Jack - VAS6931- .

– Align the arms of the Transmission Support so that they match
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up with the holes in the Adjustment Plate .

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– Install the Mounting Elements -A and C-, on the Adjusting

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– Position the Engine-Transmission Jack under the vehicle. The

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arrow symbol -B- on the Adjusting Plate points in the direction

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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 for the pendulum support bolt on the transmission.
– Remove the engine/transmission bolt near the right flange
-arrow-.
– Remove the lower engine/transmission bolts.
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– Remove theauttransmission
h
from the alignment bushings andor a
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– Tip the transmission over the adjusting spindle for the Trans‐
mission Support - 3282- in the direction of -arrow-.
nform
ercia
– Carefully push the engine forward slightly with a second tech‐

nician.
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– Carefully lower the transmission with the Engine and Gearbox

Jack - VAS6931- , while making sure that the right flange shaft
seal -1- is guided through without any damage to the pressure
plate -arrow-.
– Guide the left flange shaft -B- past the subframe -arrow- as
shown. Move the Engine and Gearbox Jack with theGtrans‐
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mission to the front. lksw
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– When lowering, change position of transmission
ise
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– Reinsert the right flange shaft if necessary and tighten the bolt
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-arrow- to the tightening specification.
rrectness of i
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Pay attention to the lines when lowering the transmission.
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Transmission, transporting. Refer to

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⇒ “4 Transmission, Transporting”, page 89 . at

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ion
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Tightening Specification
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♦ Flange shaft to transmission. Refer to

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or
⇒ “2.1 Overview - Differential”, page 189 .

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2.2 Transmission, Installing
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Caution


♦ Bolt - Transmission Support to Transmission
♦ Bolt - Transmission Support to Transmission Bracket
♦ Bolt - Pendulum Support to Transmission
♦ Bolt - Pendulum Support to Subframe
♦ Bolts - Transmission Bracket to Transmission
♦ Bolts - Transmission Mount to Transmission Bracket
♦ Lock Washer - Cable Retainer


♦ Nut - Coupling Rod to Stabilizer Bar
♦ Seals - Transmission
Note
Refer to “Transmission, Removing” to get a list of the special tools

needed. Refer to ⇒ “2.1 Transmission, Removing”, page 67 .
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
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⇒ Item 3
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(page 119)
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Refer to
hole
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⇒ “4.2 Ca‐
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pacities”,
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page 6 .
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ally disas‐ after instal‐
rrectness of i
sembled lation. Re‐
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• (the fer to
trans‐ ⇒ “8 Trans‐
mission mission
nform
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housing Fluid”, page

and the 125 .
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clutch
on in
housing
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– Use a thread cutter to carefully clean all threaded holes con‐ Prote
cted AG.
agen
taining self-locking bolts to remove any locking compound
residue.
– Replace self-locking screws and nuts after removing them.
– Make sure the alignment sleeves 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.
– Check clutch release bearing for wear, replace if necessary.
Align the Transmission Support - 3282- with the Transmission
Support - Mounting Plate 39 - 3282/39- in order to install the “0A4”
transmission.
– Align the arms of the Transmission Support so that they match
up with the holes in the Adjustment Plate .
– 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 -
VAS6931- .
– Align the Adjustment Plate so that it is parallel to the trans‐
mission.
– Install the Transmission Support - Mounting Plate 29 -

3282/29- into the rear hole in the transmission for the pendu‐
lum support bolt.
– Position the Engine and Gearbox Jack under the vehicle. The
-arrow symbol B- on the adjusting plate points in direction of
travel.
– Remove from a new transmission or replacement transmis‐gen AG

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♦ Check the seal for leaks before removing the flange shaft. If
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the seal has leaks, replace it when installing. Refer to

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♦ If transmission fluid leaks out while removing the flange shaft,

h re
drain and refill transmission fluid on the installed transmission

hole
spec
and installed flange shaft. Refer to

es, in part or in w
⇒ “8 Transmission Fluid”, page 125 .

t to the co
– Attach the spindle -A- for the Seal Installer - Driver Set - 3066-
rrectness of i
into the threaded piece on the differential.

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– Insert the Seal Installer - One-Piece Seal - T10148- and se‐

cure with the nut -B-.
nform
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Note
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tion in
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♦ The Seal Installer - One-Piece Seal - T10148- protects the

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right seal and the transmission from dirt.

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♦ An M8 x 105 mm bolt may be installed by hand into the differ‐

en
ng
t.
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ential threaded piece instead of a spindle -A-.
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– Tip the transmission over the adjusting spindle for the Trans‐
mission Support - 3282- in the direction of -arrow-.
– Push the engine forward slightly with a second technician.
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– Carefully lift the transmission with the Engine and Gearbox
Jack , while making sure that the seal -1- is guided through
without any damage to the pressure plate -arrow-.
rrectness of i
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Guide the left flange shaft -B- past the subframe -arrow-.
by lksw
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– Align the transmission with the engine and install it.
– Install the bolt for the engine/transmission in the area of the

right flange shaft -arrow- (Refer to
⇒ “2.3 Transmission Tightening Specifications”, page 86 .)
and tighten.
– Install lower engine/transmission connecting bolts and tighten.
Refer to
⇒ “2.3 Transmission Tightening Specifications”, page 86 .
– After the transmission is attached to the engine, remove the
Engine and Gearbox Jack from the transmission.

– Reinsert the right flange shaft and tighten the bolt -arrow- to
the tightening specification. Refer to
– Install upper engine/transmission connecting bolts and tight‐
en. Refer to
⇒ “2.3 Transmission Tightening Specifications”, page 86 .
– Attach the transmission bracket -A- with new hex collar bolts
-arrows- to the transmission and tighten. Refer to
– Align the engine/transmission in its installed position. Lift until

the transmission bracket is touching the transmission mount
completely. AG. Volkswagen AG d
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Risk of damaging threads in transmission bracket by inserting ss c
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♦ Before installing bolts -arrows-, transmission bracket and
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transmission mount support arm must be absolutely par‐
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allel to each other. If necessary, lift the back of the trans‐
wit
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mission using the Engine and Gearbox Jack .
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es, in part or in w
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Note
rrectness of i
Install the engine/transmission mount free of tension. Refer to ⇒
Engine Mechanical, Fuel Injection and Ignition; Rep. Gr. 10 ;
l purpos
Subframe Mount; Subframe Mount, Adjusting .

nform
ercia
– Install new bolts -arrows- of left assembly mounting into trans‐

mission mount and tighten to tightening specification. Refer to
m
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om

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ate
Caution
do
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Risk of accident!
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• Only remove Engine Support Bridge - 10-222A- when all
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subframe mount bolts are tightened to the tightening spec‐
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Prote AG.

– If equipped install the ground cable on the transmission mount

-arrow-.
– Install the pendulum support with new bolts -1 to 3-. Refer to

10 ; Subframe Mount; Pendulum Support, Removing and In‐
stalling .
– Assemble the exhaust system. Refer to ⇒ Rep. Gr. 26 ; Emis‐
sions Control; Overview - Emissions Control .
– Attach the drive axles to the transmission.agRefer tool⇒

en AG. V
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agen AG
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pension, Wheels, Steering; Rep. Gr.Vo40lksw; Drive Axle; Drive not
gu
Axle, Removing and Installing . sed by ara
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or
– Attach the drive axle heat shield
au
th -arrows- (if equipped). Refer or
ac
to ⇒ Suspension, Wheels,ssSteering; Rep. Gr. 40 ; Drive Axle;
ce
le
Drive Axle Heat Shield, Removing and Installing .

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pt
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– If equipped, attach the Left Front Level Control System Sensor

- G78- on the lower control arm. Refer to ⇒ Suspension,
rrectne
Wheels, Steering; Rep. Gr. 43 ; Level Control System Sensor;

Overview - Front Level Control System Sensor .
ss o
cial p
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Prote AG.

– Install the coupling rod -3- on both side of the stabilizer bar
-2-. Refer to ⇒ Engine Mechanical, Fuel Injection and Ignition;
Rep. Gr. 10 ; Subframe Mount; Overview - Subframe Mount .
– Connect the connector -1- to the Oil Level Thermal Sensor -

G266- .
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– Transmission on vehicles with Start/Stop System:
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connector -arrow- to the Transmission Neutral
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– Install the clutch slave cylinder and tighten the bolts

-B arrows-. Refer to
rrectness of i

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– Install and secure the transmission support -A arrows-. Refer

to ⇒ “3.1 Overview - Subframe Mount”, page 87 .
nform
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– Connect the connector -1- to the Back-Up Lamp Switch - F4- .

– Install the starter, connect the connector -arrow 2- and attach
the wire -arrow 3-. Refer to ⇒ Electrical Equipment; Rep. Gr.
27 ; Starter; Overview - Starter .
– If equipped, install the upper ground cable.
– Make sure the vacuum hose for the brake system is installed
correctly. Install a vacuum hose, if necessary. Refer to ⇒
Brake System; Rep. Gr. 47 ; Brake Booster/Brake Master
Cylinder; Overview - Brake Booster/Brake Master Cylinder .
– If equipped, attach the bracket -B- on the transmission.

– If necessary press the hose/line assembly -A- into the bracket
-B- on the transmission.
– Mount the cable bracket on the transmission and tighten the
bolts -arrows-. Refer to
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– Install the transmission shift lever -A-. Refer to

⇒ Fig. ““Installing the Transmission Shift Lever”“ , page 62 .
– Tighten the hex nut -arrow 3-. Refer to
– Coat the pin on the gearshift lever with a small amount of
grease -A-.
Allocate the grease for gearshift mechanism. Refer to the Parts
Catalog.
– Attach the shift cable to the gearshift lever.
– Replace the lock washer -arrow 2- after removing.
– Install the relay lever together with the cable retainer. Refer to
⇒ Fig. ““Remove the Relay Lever and the Cable Retainer.”“ ,
page 58 .
AG. Volkswagen AG d
The clip -arrow 1- secures the relay lever. agen oes
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• Make sure the clips locks securely. rise
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– Connect the selector cable to the cable
ss a retainer. ra
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– Adjust the gearshift mechanism. Refer to

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pt
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– If unclipped, carefully clip in the A/C system pipe and do not
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disconnect the line system. Refer to ⇒ Heating, Ventilation
wit
is n
and Air Conditioning; Rep. Gr. 87 ; Refrigerant Circuit; System
h re
ole,
Overview - Refrigerant Circuit .
spec
– Install fuel filter. Do not open the line system. Refer to ⇒ Rep.
t to the co
Gr. 20 ; Fuel Filter; Overview - Fuel Filter .
rrectne
Note
ss
If when removing the flange shaft, the transmission fluid leaks out,
o
cial p
f
drain and fill the transmission fluid for the installed transmission
inform
and flange shaft. Refer to ⇒ “8 Transmission Fluid”, page 125 .
mer
atio
om
– Install the battery tray, battery and the battery cover. Refer to
n
c
i
or
⇒ Electrical Equipment; Rep. Gr. 27 ; Battery; Battery, Re‐ n thi

te
sd

iva
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pr
cum
r
– Install the air filter housing. Refer to ⇒ Engine Mechanical,

fo
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ng
t.
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op
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t. rig
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– Install the engine cover. Refer to ⇒ Rep. Gr. 10 ; Engine cop Vo
by lksw
Cover; Engine Cover, Removing and Installing .
cted agen
Prote AG.
– Connect the battery and follow the procedure regarding what

to do after connecting a battery. Refer to ⇒ Electrical Equip‐
ment; Rep. Gr. 27 ; Battery; Battery, Disconnecting and
Connecting .

– Install the left charge air hose -A- -arrows-. Refer to ⇒ Engine
Mechanical, Fuel Injection and Ignition; Rep. Gr. 21 ; Charge
Air System; Overview - Charge Air System .
– Install the lower section of the left front wheel housing liner.
– Install the noise insulation. Refer to ⇒ Body Exterior; Rep. Gr.
66 ; Noise Insulation; Overview - Noise Insulation .
– Check the headlamp adjustment on vehicles with Left Front
Level Control System Sensor - G78- . Refer to ⇒ Electrical
Equipment; Rep. Gr. 94 ; Headlamp; Headlamp, Adjusting .
2.3 Transmission Tightening Specifications

Item Bolt Quantity Nm
1 M12 x 50 2 80
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2 M12 x 150 swa 2
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3 M10 sx 50 or
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4 M12 x 60 1 80
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5 6x8 1 10
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♦ Small flywheel
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cover plate
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(Not present on all)
es, in part or in w
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-A- alignment sleeves for centering

Component Nm
rrectness of i
Mount for lower starter plug wires 23

l purpos
Ground cable on the upper starter plug 20

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3 Subframe Mount
⇒ “3.1 Overview - Subframe Mount”, page 87
3.1 Overview - Subframe Mount
1 - Bolt
❑ 20 Nm +90°
❑ Transmission support to
transmission bracket
and transmission
❑ Tightening sequence.
Refer to
⇒ Fig. ““Transmission
Support to Transmis‐
sion Bracket and Trans‐
mission”“ , page 88
2 - Transmission Support
❑ To the transmission
bracket and transmis‐
sion
3 - Engine Mount with Engine
Support
❑ Refer to ⇒ Engine Me‐
chanical, Fuel Injection
and Ignition; Rep. Gr.
AG. Volkswagen AG d
10 ; Subframe Mount; ksw
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Overview - Subframe by V o gu
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Mount . ris
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4 - Bolt ss
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❑ Pendulum support to
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le
un
pt
the subframe. Refer to

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d
itte
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⇒ Engine Mechanical,
rm
ab
Fuel Injection and Igni‐

pe
ility
tion; Rep. Gr. 10 ; Sub‐

ot
wit
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frame Mount; Overview

h re
hole
- Subframe Mount .
spec
es, in part or in w
5 - Pendulum Support
t to the co
❑ Refer to ⇒ Engine Me‐

chanical, Fuel Injection
and Ignition; Rep. Gr. 10 ; Subframe Mount; Overview - Subframe Mount .
rrectness of i
6 - Bolt
l purpos
❑ Pendulum support to the transmission. Refer to ⇒ Engine Mechanical, Fuel Injection and Ignition; Rep.
Gr. 10 ; Subframe Mount; Overview - Subframe Mount .
nform
ercia
7 - Bolt
m
a
com
tio
❑ Pendulum support to the transmission. Refer to ⇒ Engine Mechanical, Fuel Injection and Ignition; Rep.
n in
r
Gr. 10 ; Subframe Mount; Overview - Subframe Mount .

te o
thi
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do
8 - Bolt
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❑ 40 Nm +90°
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❑ Replace after removing t. Cop py
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❑ Tightening sequence. Refer to ⇒ Fig. ““Transmission Bracket -A- to Transmission.”“ , page 88
ht
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❑ Transmission bracket to transmission. Prote
cted AG.
agen
3. Subframe Mount 87
9 - Transmission Bracket
10 - Transmission Mount
❑ Check the adjustment. Refer to ⇒ Engine Mechanical, Fuel Injection and Ignition; Rep. Gr. 10 ; Subframe
Mount; Subframe Mount, Checking Adjustment
❑ Adjusting. Refer to ⇒ Engine Mechanical, Fuel Injection and Ignition; Rep. Gr. 10 ; Subframe Mount;
Subframe Mount, Adjusting
11 - Bolt
❑ Transmission mount to chassis
❑ Refer to ⇒ Engine Mechanical, Fuel Injection and Ignition; Rep. Gr. 10 ; Subframe Mount; Overview -
Subframe Mount .
12 - Bolt
❑ 60 Nm +90°
❑ Tightening sequence. Refer to
⇒ Fig. ““Attaching the Transmission Mount to the Transmission Bracket”“ , page 88
❑ Transmission mount to transmission bracket
Attaching the Transmission Mount to the Transmission Bracket

– Replace the bolts -arrows-.
– Tighten all bolts hand-tight.
– Tighten the bolt to the tightening specification.
AG. Volkswagen AG d
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Transmission Support to Transmission Bracket and Transmission

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h re
hole
spec
– Tighten both bolts -arrows- hand-tight at first.

es, in part or in w
t to the co

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orm
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atio
m
Transmission Bracket -A- to Transmission.

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– Tighten all bolts hand-tight.

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Prote AG.

4 Transmission, Transporting
♦ Transmission Support Jig - 3336-
♦ Shop Crane - VAS6100-
– Attach the Transmission Support Jig - 3336- to the clutch
housing.
AG. Volkswagen AG d
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– Move the support arm on dthe by sliding bar using the locking bolt
V gu
ara
-arrow-. orise nte
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Number of visible holes
ss a
= 5. c
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nl
– Lift the transmission using the Shop Crane - VAS6100- and
pt
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the Transmission Support Jig - 3336- .
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– Set the transmission down, for example, into the transport
ility
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container.
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Prote AG.
4. Transmission, Transporting 89
5 Transmission, Disassembling and

Assembling
⇒ “5.1 Schematic Overview - Transmission”, page 90
⇒ “5.2 Overview - Transmission”, page 92
⇒ “5.3 Overview - Transmission Housing Cover and 5th Gear”,
page 93
⇒ “5.4 Overview - Transmission Housing and Selector Mecha‐
nism”, page 95
⇒ “5.5 Overview - Shift Unit”, page 96
⇒ “5.6 Overview - Input Shaft, Output Shafts, Differential, Gear‐
shift Rods”, page 97
⇒ “5.7 Overview - Shift Forks”, page 98
⇒ “5.8 Shift Unit, Servicing”, page 99 AG. Volkswagen AG d
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⇒ “5.9 Shift Forks, Servicing”, page 100 d by
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⇒ “5.10 Transmission Housing Cover and 5th Gear, Removing”,
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page 101 ss a c
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⇒ “5.11 Transmission, Disassembling and Assembling”,
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⇒ “5.12 Transmission Housing Cover and 5th Gear, Installing”,
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5.1 Schematic Overview - Transmission
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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
13 - Differential
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5. Transmission, Disassembling and Assembling 91

5.2 Overview - Transmission
I - Refer to
⇒ “5.3 Overview - Transmis‐
sion Housing Cover and 5th
Gear”, page 93
II - Refer to
⇒ “5.4 Overview - Transmis‐
sion Housing and Selector
Mechanism”, page 95
II - Refer to
⇒ “5.5 Overview - Shift Unit”,
page 96
II - Refer to
⇒ “5.8 Shift Unit, Servicing”,
page 99
III - Refer to
⇒ “5.6 Overview - Input Shaft,
Output Shafts, Differential,
Gearshift Rods”, page 97
III - Refer to
⇒ “5.7 Overview - Shift Forks”,
page 98
III - Refer to
⇒ “5.9 Shift Forks, Servicing”, n AG. Volkswagen A
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5.3 Overview - Transmission Housing Cover and 5th Gear
1 - Bolt
❑ 18 Nm
❑ Cover to transmission
housing
❑ Quantity: 5
2 - Transmission Housing Cov‐
er
❑ With a magnet. Refer to agen
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♦ Note that oil will leak out when
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the transmission housing cover
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is removed with the transmission
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installed.
spec
♦ Therefore the oil must be drained
t to the co
and then filled again later. Refer
to
⇒ “8 Transmission Fluid”,
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page 125 .
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3 - Seal
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4 - Bolt
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❑ 80 Nm +90°
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5 - Plate Spring
❑ Installing. Refer to
⇒ Fig. ““Installed Position of Plate Springs for 5th Gear Synchronizer Hub and Gear Securing Bolts”“ ,
page 117 .
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 ⇒ “5.9 Shift Forks, Servicing”, page 100 .
❑ Adjusting. Refer to ⇒ Fig. ““Adjusting 5th Gear”“ , page 118 .
9 - Spring
❑ Offset version
❑ Installing. Refer to ⇒ Fig. ““Installation of Offset Springs -A- ”“ , page 148
10 - 5th Gear Locking Collar
❑ Installed position. Refer to ⇒ Fig. ““5th Gear Locking Collar/Synchronizer Hub Assembly”“ , page 147

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❑ Adjusting. Refer
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❑ Installed position. Refer to ⇒ Fig. ““5th Gear Synchronizing”“ , page 147
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12 - Synchronizer Hub with Gear Wheel and 5th Gear Synchronizer Ring
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❑ Remove together with the transmission housing. Refer to
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⇒ “5.11 Transmission, Disassembling and Assembling”, page 105
h re
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spec
❑ Remove individually. Refer to
es, in part or in w
⇒ “5.10 Transmission Housing Cover and 5th Gear, Removing”, page 101
t to the co
❑ Disassembling and assembling. Refer to
⇒ Fig. ““5th Gear Locking Collar/Synchronizer Hub Assembly”“ , page 147 .
rrectness of i
13 - Needle Bearing
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❑ For the 5th gear wheel

14 - 5th Gear Wheel
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❑ Remove together with the transmission housing. Refer to

⇒ “5.11 Transmission, Disassembling and Assembling”, page 105
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❑ Remove individually. Refer to
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❑ Installed position. Refer to ⇒ Fig. ““Installed Position, 5th Gear Wheel”“ , page 115
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Magnet can only be inserted in the cover with notch -arrow-.
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The magnet is held in place by the bolt for the 5th gear shift fork
pivot pin when the cover is installed.

5.4 Overview - Transmission Housing and Selector Mechanism
1 - Bolt
❑ 25 Nm
2 - Flange Shaft with Pressure
Spring
ling. Refer to
⇒ “1.3 Right Seal, Re‐
placing”, page 185 .
❑ Assembling. Refer to
⇒ “2 Differential”,
page 189 .
3 - Inner TORX® Bolt
❑ 25 Nm
❑ For the reverse shaft
support
❑ Self-locking agen
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❑ Self-locking
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6 - Pivot Pin
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7 - Bolt
❑ 25 Nm
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8 - Bolt
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❑ 25 Nm
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9 - Cap
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10 - Internal Multi-Point Bolt

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❑ For vehicles with the Start/Stop System
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❑ Remove together with 5th gear. Refer to
⇒ “5.11 Transmission, Disassembling and Assembling”, page 105 .
❑ Servicing. Refer to ⇒ “6 Transmission Housing and Clutch Housing”, page 119 .
14 - Clutch Housing
15 - Hex Bolt
❑ 25 Nm +90°

16 - Gearshift Shaft with Gearshift Cover
❑ (Shift unit)
❑ Servicing. Refer to ⇒ “5.8 Shift Unit, Servicing”, page 99 .
17 - Internal Multi-Point Bolt
❑ 25 Nm
5.5 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-
❑ 20 Nm
❑ Coat the tab lightly with
MoS 2 grease.
3 - Locking Elbow
❑ For adjusting the shift
mechanism
❑ Removing. Refer to
⇒ Fig. ““Removing the
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Selector Cover”“ ,
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4 - Relay Lever
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⇒ Fig. ““Selector Lever/

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Relay Lever Installed

Position”“ , page 61
5 - Clip
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❑ Secure the relay lever in

the gearshift cover
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6 - Seal
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❑ Replacing. Refer to ⇒ “1.8 Selector Shaft Seal, Replacing”, page 65 .

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7 - Nut
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8 - Gearshift Lever
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❑ Installing. Refer to ⇒ Fig. ““Installing the Transmission Shift Lever”“ , page 62 . p by
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9 - Cap Prote AG.
❑ For the transmission ventilation

10 - Cap
11 - Spring
❑ Not installed in all transmissions
❑ Install if present
5.6 Overview - Input Shaft, Output Shafts, Differential, Gearshift Rods
1 - Differential
❑ Disassembling and as‐
sembling. Refer to
⇒ “2 Differential”,
page 189 .
2 - Seal
❑ Quantity: 4
3 - Output Shaft agen
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4 - Reverse Shaft Support
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❑ Disassembling and as‐ y li

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page 170 .
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5 - Reverse Shaft
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sembling. Refer to
⇒ “3 Reverse Shaft”,
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page 170 .
6 - Input Shaft
ss

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sembling. Refer to
inform
⇒ “1 Input Shaft”,
mer
page 141 .
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7 - Reverse Gear Shift Fork

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⇒ “5.9 Shift Forks, Serv‐

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icing”, page 100 .
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8 - Inner TORX® Bolt
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❑ 25 Nm
9 - Selector Mechanism
❑ (Shift forks)
❑ Disassembling and assembling. Refer to ⇒ “5.9 Shift Forks, Servicing”, page 100 .
10 - Clutch Housing
11 - Nut
❑ 25 Nm +90°

❑ Quantity: 4
12 - Flange Shaft with Pressure Spring
❑ Removing and installing. Refer to ⇒ “1.3 Right Seal, Replacing”, page 185 .
❑ Assembling. Refer to ⇒ “2 Differential”, page 189 .
13 - Bolt
❑ 25 Nm
5.7 Overview - Shift Forks
Note
♦ The shift fork group does not need to be disassembled to re‐

move and install shift segments, lock washers and angular
contact ball bearings.
♦ Shift Forks, Servicing. Refer to
⇒ “5.9 Shift Forks, Servicing”, page 100 .
1 - 5th Gear Shift Segment

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Lock Washer”“ ,
page 100 .
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⇒ Fig. ““Installing the

Lock Washer”“ ,
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3 - 5th Gear Shift Fork

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❑ Quantity: 4
Angular Contact Ball
Bearing”“ , page 101 .
❑ Installing the bearing in‐
ner race into the outer race. Refer to
⇒ Fig. ““Installing the Angular Contact Ball Bearing Inner Race -A- into the Outer Race”“ , page 101

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❑ Installing. Refer to ⇒ Fig. oris ““Installing the Angular Contact Ball Bearing
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❑ The shift segment must still rotate easily after the lock washer is installed.
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10 - Glide
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12 - Reverse Gear Shift Fork

13 - Support for the Reverse Gear Shift Fork
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14 - Circlip
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♦ Torque Wrench 1331 5-50Nm - VAG1331- p by
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– Remove the shift unit. Refer to Prote AG.
⇒ “5.4 Overview - Transmission Housing and Selector Mech‐
anism”, page 95 .
Removing the Locking Elbow -A- from the Shift Cover
– Remove the outer part of the locking elbow.
– Pry out the locking elbow with a screwdriver.
Pressing the Locking Elbow -A- into Selector Cover

Installed position:
The marking -arrow- faces toward upper part of gearshift shaft.
– Install the shift unit. Refer to
anism”, page 95 .

5.9 Shift Forks, Servicing

♦ Press Plate - VW402-
♦ Subframe Support Tool - Press Piece - 3290/1-
♦ Press Piece - Multiple Use - VW431-
♦ Subframe Bushing Tool Kit - 3301-
♦ Press Piece - Multiple Use Spacer Sleeve - VW472/2-
♦ Valve Guide/Clutch Release Push Rod Seal Drift - 10-206-
♦ Pry Lever - 80-200- olkswage es n
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♦ Assembly Mandrel for ir se Gear Selector Rod - 10-508-
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♦ Spring Strut Compressor
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Shift Segment Identification

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1 - 1st and 2nd gear shift 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 shift segments = 12.1 mm
t to the co
Removing the Lock Washer
– Secure shift fork in vise with protective jaws -B-.
rrectne
– Pry off the lock washer -A- in the direction of -arrow-.
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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.
Installing the Angular Contact Ball Bearing Inner Race -A- into the
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The bearing inner race must engage with
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Installing the Angular Contact Ball Bearing into the Shift Fork
The recess in the Subframe Support Tool - Press Piece - 3290/1-
rrectness of i
point to the ball bearing.
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Shift Fork with the Shift Segments Installed
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Dimension -a- (mm)
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1st/2nd gear shift fork 87.2 to 87.4
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3rd/4th gear shift fork 93.6 to 93.8

Shift segment allocation
⇒ Fig. ““Shift Segment Identification”“ , page 100
5.10 Transmission Housing Cover and 5th

Gear, Removing
♦ Holding Plate - VW309A-
♦ or Holding Plate - VW309A-
♦ Transmission Support - VW353-

♦ Bearing/Bushing Installer - Multiple Use - VW295-

♦ Bearing Driver - Multiple Use - VW244B-
♦ For example Hot Air Blower - VAG1416-
♦ Bracket - Multiple Use - 30-211A-
♦ Bearing Installer - Multiple Use - 32-111-
♦ Assembly Tool Kit - Press Piece 2 - T10030/4- from the Hy‐
draulic Press - Bushing Tool Kit - T10030-
♦ Press Piece - 37mm - VW416B-
♦ Puller - Transmission Gears - T10309-
♦ Puller - Two Arm - T10040-
♦ With the Puller - Two Arm w/Thrust Piece - T10040/2A-
♦ Puller - Two Arm Thrust Piece - T10040/3-
♦ Support Bridge - T10323-
♦ Rear Wheel Bearing Kit - Piece 7 - 3253/7-
♦ Press Piece - Multiple Use - 40-105- AG. Volkswagen AG d
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♦ Bolts - Plate Spring to Transmission spec

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5th Gear and Transmission Housing Cover, Installing. Refer to
page 114 .
rrectness of i
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♦ If only 5th has to be removed, follow this procedure:

m
♦ Pay attention to the work procedure if the transmission hous‐

com
tion in
ing must be removed. Refer to

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⇒ “5.11 Transmission, Disassembling and Assembling”, page

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– Remove the clutch release lever and release bearing. Refer

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to ⇒ “1.16 Clutch Release Mechanism, Servicing”, page 35 .
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• 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- , install the following tools for support:
Under the Input Shaft:
♦ Assembly Tool Kit - Press Piece 2 - T10030/4-
• Input shaft may be supported by Bearing Installer - Multiple
Use - 32-111- only at a later time.
Under the Output Shaft Bracket
– Secure the transmission on the Transmission Support -

VW353- .
– Remove the transmission housing cover -arrow-.
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– Make sure the Puller - Two Arm w/Thrust Piece - T10040/2A-

spec
can be installed correctly under the 5th gear wheel.

es, in part or in w
t to the co
Puller - Two Arm w/Thrust Piece - T10040/2A- cannot be In‐

stalled Correctly.
rrectness of i
-A- “Combined” removal of the:

Puller - Two Arm w/Thrust Piece - “5th gear synchronizer
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T10040/2A- prematurely touch hub”, “5th gear wheel” and

the: “transmission housing”.
nf
♦ Transmission housing wall Refer to

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⇒ “5.11 Transmission, Dis‐

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♦ The ribbing in the transmission assembling and Assem‐

atio
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housing under the 5th gear bling”, page 105 .

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Correctly.
5th gear is removed individually ⇒
⇒ Fig. ““5th Gear, Removing Separately”“ , page 104

5th Gear, Removing Separately

– Cover the openings in the transmission housing with a cloth.
– Move the shift fork -1- into neutral.
– Remove the bolt -2- with the shift jaw for 5th gear.
– Remove both bolts -arrows- for the pivot pin.
– Remove the pivot pin.
– Remove the 5th gear shift fork.
– It is not necessary to remove the spring -3- and the locking
collar -4-.
– Remove the bolts -A- for the synchronizer hub and for the 5th
gear wheel. Do this by engaging 5th gear -arrow 1- and 1st
gear -arrow 2- and -3-.
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– The input shaft and the output shaft wagare blocked after both
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Remove any locking compound residue still in the threaded holes
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Remove 5th Gear Synchronizer Hub Together with Locking Collar
hole
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and Locking Pieces.
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To Do This Use the Puller - Transmission Gears - T10309- . t to the co
– Insert the Puller - Transmission Gears - Half Shell - T10309/1-

rrectness of i
between the 5th gear wheel -A- and the mount for 5th gear
shift fork -B-.
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• The Puller - Transmission Gears - Half Shell - T10309/1- must

be placed under the synchronizer ring.
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– Press the Puller into the end position, if necessary.

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– Rotate the Puller - Transmission Gears - Half Shell - T10309/1-

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to the opposite side in direction of -arrow-.

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– Install the Puller - Transmission Gears - Threaded Insert -

T10309/3- in the Puller - Transmission Gears - Half Shell .
– Insert the second Puller - Transmission Gears - Half Shell -
T10309/1- and put the Puller - Transmission Gears - Tube -
T10309/2- on the tool.
– Check synchronizer hub after pulling for damage.
– Replace the synchronizer ring.
– Remove the 5th gear selector gear with needle bearing.
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– Remove the 5th gear wheel.ss a c
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– Insert the hook -A-.
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B - Puller - Two Arm Thrust Piece - T10040/3- or M10 x 20 bolt,
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Note
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♦ When remove drive gear, make sure the hook does not bend
outward. Check the 5th gear for damage.
rrectness of i
♦ Slightly heat 5th gear wheel with Hot Air Blower - VAG1416-
if necessary.
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5th gear and transmission housing cover, installing. Refer to nf

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page 114 .
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5.11 Transmission, Disassembling and As‐

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♦ Bearing Driver - Multiple Use - VW244B-
♦ For example Hot Air Blower VAG1416 - VAG1416-
♦ Assembly Tool Kit - Press Piece 2 - T10030/4- from the Hy‐
draulic Press - Bushing Tool Kit - T10030-
♦ Press Piece - 37mm - VW416B-
♦ Puller - Transmission Gears - T10408-
♦ Puller - Transmission Gears - Thrust Piece - T10408/2-

♦ Spacer Plate - T10408/3-

♦ M7 x 35 hex collar bolt and washer (components of the Puller
- Transmission Gears - T10408- )
♦ Press Piece - Multiple Use - VW433- agen
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♦ Torque Wrench 1332 40-200Nm - eVAG1332- d byV gu
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♦ -2- Puller - Kukko Puller - 60-150mm
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Width, 200mm Length - eo
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Kukko 18/1- (quantity 2) ss c
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♦ Shop Crane - Drip Tray - VAS6208-
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♦ Inductive Heater - VAS6414-
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♦ Sealing Compound - AMV 188 200 03-
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♦ M8 x 100 mm stud bolt
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Caution
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♦ Bolts - Plate Spring to Transmission
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♦ Nut - Gearshift Lever to Gearshift Unit

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Transmission Housing Cover, Transmission Housing, Gearshift

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Shaft with Gearshift Cover, Input Shaft, Output Shaft, Differential

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and Gearshift Mechanism, Removing and Installing

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Transmission, Disassembling . Cop py
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– Remove the clutch release lever, the release bearing and the
rig by
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guide sleeve. Refer to
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⇒ “1.16 Clutch Release Mechanism, Servicing”, page 35 .
Prote AG.
• 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- , install the following tools for support:
Under the Input Shaft:
♦ Assembly Tool Kit - Press Piece 2 - T10030/4-
– Secure the bolt on the Bracket - Multiple Use - 30-211A- with
the nut -A-.
Under the Output Shaft Bracket


VW353- .
– Place the Drip Tray underneath.
– Open the oil filler plug and the oil drain plug.
– Drain the transmission fluid.
– Remove the transmission housing cover -arrow-.
Remove the 5th gear shift fork as follows:

– Move the shift fork -1- into neutral.
– Remove the bolt -2- with the shift jaw for 5th gear.
– Remove both bolts -arrows- for the pivot pin.
– Remove the pivot pin.
– Remove the 5th gear shift fork.
– It is not necessary to remove the spring -3- and the locking
collar -4-.
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– Engage 5th gearis-arrow
ed b 1- and 1st gear -arrows 2 and 3-
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then remove thethor bolts -A- for the synchronizer hub and for the
eo
5th gear wheel.
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– The input shaft and the output shaft are blocked after both
nl
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gears are engaged. The synchronizer hub and the gear wheel
itte
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cannot turn. Both bolts can be loosened now.

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Note
hole
spec
es, in part or in w
Remove any locking compound residue still in the threaded holes

t to the co
using a thread tap if the shafts are not going to be replaced.

rrectness of i
– Remove both bolts -arrows- for the reverse shaft support.

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– Remove the third bolt -arrow- from the reverse shaft support.
– Transmission on vehicles with Stop/Start system: remove the

Transmission Neutral Position Sensor - G701- -arrow-.
AG. Volkswagen AG d
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– Move the gearshift shaft into neutral and remove the gearshift
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shaft with the gearshift cover. Remove the bolts -arrows- and
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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 nform
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transmission.
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– Remove pivot pins -A- on top side of transmission and bolts

-B- for transmission housing to clutch housing in area of dif‐
ferential.
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– ut that connect the clutch and transmission
Remove the boltss a-A- ra
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housing. s
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Do not remove the nuts -B- for the bearing mount on the output
h re
shaft.
hole
spec
es, in part or in w
t to the co
rrectness of i
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– Remove both flange shafts.

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

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

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

Special Tools:
♦ Puller - Transmission Gears - Thrust
wage Piece - T10408/2-
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♦ Spacer Plate - T10408/3-ed by ara
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♦ Kukko 18/1 puller (quantity:
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– Install the Puller - Transmission Gears - T10408- in the threa‐
ce
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pt
ded holes in the transmission housing cover using the bolts
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itte
-A-.
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A - M7 x 35 Hex Bolts with Washers
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Tightening specification 18 Nm
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hole
spec
– Place the Puller - Transmission Gears - Thrust Piece -
es, in part or in w
T10408/2- on the shaft.
t to the co
– Install Kukko puller 18/1 -A-.
rrectness of i
– Remove the 5th gear synchronizer hub, the 5th gear wheel
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and the transmission housing by tightening the spindles -A-

(approximately 1/2 turn), alternating from side to side.
nf
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– Warm the 5th gear wheel slightly using the Hot Air Blower -
orm
VAG1416- .
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– Remove the nuts -B- from the bearing mount/output shaft.

– Remove the shift forks -A- together with the gearshift rails.
– Remove the gearshift mechanism/reverse gear -B-.
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– Remove the reverse gear -A-, the input shaft -B- and thed boutput
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shaft -C-, one after the other, from the clutch housing.orise nte
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– Remove the differential. ss a c
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Assembling the Transmission nl
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– Install the differential.
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spec
es, in part or in w
t to the co
– Replace the sealing rings -arrows- for output shaft bearing
rrectness of i
mount after removing.
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Note
nform
mercia
The illustration only shows 3 of the 4 seals.
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– Insert output shaft -1- and output shaft -2- together. copy Vo
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– Tighten the nuts for the bearing mount / output shaft.
AG.
– Install the reverse gear wheel -3- on the needle bearing inside
the clutch housing.
Shoulder -arrow- faces away from clutch housing.
– Make sure the reverse shaft -4- is complete. Refer to
⇒ “3.2 Reverse Shaft, Disassembling and Assembling”,
page 170 . 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.

– Install the reverse gear shift fork -1- with the support olks
wfor
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reverse gear shift fork -2-, the spring -3- and thed b sliding piece
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-4-. or
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Reverse gear location
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– Install the gearshift mechanism/reverse gear -A-. rig ht
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– Install the shift forks -B- together with the gearshift rails. Prote
cted AG.
agen
Reverse gear supports -C- are located in front of selector rails.
– Install the M8 x 100 stud bolts -A- into reverse shaft support
so that this shaft is aligned after mounting the transmission
housing.
– Align the gearshift rails.
Note
The shift segments must be installed in the grooves on the locking

collars.
– Apply Sealing Paste - AMV 188 200 03- evenly onto the seal‐
ing surface of the clutch housing.
– Install the transmission housing and tighten it secure.
Install the bolts for the reverse shaft support -arrow- as follows:
– Install the bolt -a-.
– Remove stud bolts -A- (⇒ upper illustration).

– Install the bolt -c-.
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Tightening sequence: ss
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– Tighten the bolt -a- (⇒ upper illustration).
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– Tighten the bolt -b-.
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– Tighten the bolt -c- (⇒ upper illustration).
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es, in part or in w
t to the co
rrectness of i
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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
nform
ercia
pin can be installed.

m
– Apply Sealing Paste - AMV 188 200 03- evenly onto the cap
at
om
io
sealing surface.
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– Install the gearshift shaft cover.

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Prote AG.
Install the gearshift shaft cover as follows:

– Move the gearshift rail into the neutral position.
– Apply Sealing Paste - AMV 188 200 03- evenly onto the seal‐
ing surface of the gearshift cover.
– Move the gearshift shaft into neutral.
– Position the selector shaft so that selector finger -arrow- is in‐
serted into the selector rails.
– Tighten the gearshift shaft gearshift cover.

– Transmission on vehicles with Stop/Start system: install the

Transmission Neutral Position Sensor - G701- -arrow- and
tighten the screw.
– Install both flange shafts with springs, thrust washers and ta‐
pered rings. Refer to ⇒ “2 Differential”, page 189 .
♦ Refer to
anism”, page 95
♦ Refer to
⇒ “5.6 Overview - Input Shaft, Output Shafts, Differential,
Gearshift Rods”, page 97 .
♦ Flange shaft to transmission (conical head bolt). Refer to
⇒ “2.1 Overview - Differential”, page 189 .
5th Gear and Transmission Housing Cover, Installing. Refer to
page 114 .
5.12 Transmission Housing Cover and 5th

Gear, Installing
AG. Volkswagen AG d Caution

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This procedure ise
dcontains
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mandatory replaceable parts.
ara Refer
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to component thor overview prior to starting procedure. eo
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♦ Bolts - Plate Spring to Transmission

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Rep. Gr.34 - Controls, Housing
olkswagen AG
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Refer to ksw
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Vol
⇒ “5.10 Transmission Housing Cover and 5th Gear, ed
b Removing”,
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ara
page 101 , “Transmission Housing Cover and h5th oris Gear, Remov‐ nte
eo
ing” to get a list of the special tools needed. aut ra
c
ss
• Pay attention that the Bracket - Multiple Use - 30-211A- and
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le
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pt
the Support Bridge - T10323- is installed.
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– Secure the bolt on the Bracket - Multiple Use - 30-211A- with
ility
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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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– To install, heat the 5th gear wheel to approximately 100 °C
en
ng
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(212 °F) with the Inductive Heater - VAS6414- .
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WARNING
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by c lksw
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Prote AG.
Wear safety gloves.
– Install the 5th gear wheel.

Checking 5th Gear Synchronizer Ring

– Before re-installing the gear wheel and the 5th gear synchron‐
izer ring push the synchronizer ring onto the taper of the drive
gear. Measure the gap dimension -a- with 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 synchronizer hub/ n AG. Volkswagen AG do
locking collar before installing. Refer to lkswage es n
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⇒ Fig. ““5th Gear Locking Collar/Synchronizer ed
b Hub
yV Assem‐ ua
ran
bly”“ , page 147 . horis tee
t or
au ac
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Installed Position of 5th Gear Synchronizer Hub/Locking Collar
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The pointed teeth on the locking collar -arrow 1- and the high col‐
itte
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lar on the synchronizer hub -arrow 2- face the transmission hous‐
rm
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ing.
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The notches -arrow 3- on the synchronizer hub must line up with
h re
hole
the cast locking pieces on the synchronizer ring
spec
( ⇒ Fig. ““5th Gear Synchronizer Ring with Cast Locking Pieces”“ ,
es, in part or in w
page 116 lower).
t to the co
rrectness of i
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5th Gear Synchronizer Ring with Cast Locking Pieces
nform
ercia
– Cover all openings with a cloth to prevent foreign objects from

getting into the transmission.
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tion in
– To install, heat the 5th gear synchronizer hub to approximately
r
te o
thi
100 °C (212 °F) with the Inductive Heater - VAS6414- .
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WARNING
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Cop py
.
Wear safety gloves.
t rig
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co lksw
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Prote AG.
– Install the 5th gear synchronizer hub
Note
Make sure there is enough clearance when installing the syn‐

chronizer ring.

– Loosen the support for the input shaft.

If it has not been done already, locking fluid residue from the
threaded holes for the synchronizer hub bolts and 5th gear wheel
must be cleaned with a thread tap.
Otherwise, there is the danger that the bolts could shear off.
– Screw-in new synchronizer hub bolts and 5th gear wheel.
AG. Volkswagen AG d
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Installed Position of Plate Springs for 5th Gear Synchronizer
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and Gear Securing Bolts se
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The outer diameter -arrows- faces 5th gear. aut ra
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– Engage 5th gear -arrow 1- and 1st gear -arrows 2 and 3- and
rrectne
then tighten the bolts -A- for the synchronizer hub and for the
5th gear wheel.
ss
– The input shaft and the output shaft are blocked after both
o
cial p
f
gears are engaged. The synchronizer hub and the gear wheel
inform
cannot turn. Both bolts can be loosened now.
mer
atio
m
– Install the 5th gear shift fork.

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Adjusting 5th Gear ris
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– Engage 5th gear. Loosenssthe bolt -1-. Push the locking collar au ra
c
and the shift jaw in direction of -arrow-. Tighten the bolt -1- to
ce
le
un
the tightening specification.
pt
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• Check measurement: it must not be possible to slide a 0.2 mm
rm
ab
pe
feeler gauge between the locking collar and drive gear. Repeat
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the adjusting procedure if necessary.
wit
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– Remove 5th gear. The locking collar must be in the neutral
hole
spec
position. The synchronizer ring must move freely.
es, in part or in w
t to the co
– Move the gearshift lever (selector lever) through all the gears.
– Install the transmission housing cover. Refer to
rrectness of i
⇒ “5.3 Overview - Transmission Housing Cover and 5th Gear”,
page 93 .
l purpos
– Install the release bearing guide sleeve. Refer to

nform
ercia
– Install the clutch release lever and release the bearing. Refer
m
a
to ⇒ “1.16 Clutch Release Mechanism, Servicing”, page 35 .
com
tion in
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– Fill the transmission fluid. Refer to ⇒ page 78 .

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♦ Refer to
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⇒ “5.3 Overview - Transmission Housing Cover and 5th Gear”, t. Cop py
page 93
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♦ Refer to ⇒ “5.7 Overview - Shift Forks”, page 98 .
lksw
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Prote AG.

6 Transmission Housing and Clutch

Housing
⇒ “6.1 Overview - Transmission Housing and Clutch Housing”,
page 119
⇒ “6.2 Transmission Housing, Servicing”, page 121
⇒ “6.3 Clutch Housing, Servicing”, page 122
6.1 Overview - Transmission Housing and Clutch Housing
❑ When replacing: adjust
the input shaft and dif‐
ferential. Refer to
⇒ “3 Adjustment Over‐
view”, page 198
2 - Needle Bearing
❑ For the output shaft
Needle Bearing”“ , page
121 .
❑ Installing and securing.
Refer to
Needle Bearing”“ , page
121
3 - Transmission Fluid Filler
Plug AG. Volkswagen AG d
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❑ 35 Nm d by V gu
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❑ The transmission fluid uthor eo
level cannot be checked ss a ra
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by removing oil filler
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plug.
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❑ If transmission was dis‐

rm
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assembled, it must be
pe
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filled before being instal‐

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led again.
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hole
❑ Manual transmission
spec
es, in part or in w
capacity (transmission
t to the co
completely disassem‐
bled). Refer to ⇒ Fluid
Capacity Tables; Rep.
rrectness of i
Gr. 03
❑ Manual transmission
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capacity (transmission
partly disassembled). Refer to ⇒ Fluid Capacity Tables; Rep. Gr. 03
nform
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4 - Outer Race/Tapered Roller Bearing

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❑ Refer to ⇒ “2.2 Output Shaft, Disassembling and Assembling”, page 158

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❑ When replacing: adjust the output shaft. Refer to ⇒ “2.3 Output Shaft, Adjusting”, page 166 .
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❑ For the input shaft
6. Transmission Housing and Clutch Housing 119

❑ Removing and installing. Refer to ⇒ “1.2 Input Shaft, Disassembling and Assembling”, page 143 .
❑ When replacing: adjust the input shaft. Refer to ⇒ “1.3 Input Shaft, Adjusting”, page 148
❑ Removing and installing. Refer to ⇒ “1.2 Input Shaft, Disassembling and Assembling”, page 143 .
❑ When replacing: adjust the input shaft. Refer to ⇒ “1.3 Input Shaft, Adjusting”, page 148
9 - Needle Sleeve
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❑ Removing and installing. Refer to ⇒ “3.2 Reverse Shaft, Disassembling
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❑ Quantity: 2 tho or
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11 - Clutch Housing
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❑ When replacing: ⇒ adjustment overview. Refer to ⇒ “3 Adjustment Overview”, page 198
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12 - Guide Sleeve
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❑ With sealing ring for the drive axle and vulcanized O-ring
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❑ Removing the seal. Refer to ⇒ Fig. ““Removing the Seal from the Guide Sleeve”“ , page 122
es, in part or in w
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❑ Installing the seal. Refer to ⇒ Fig. ““Installing the Seal All the Way Into the Guide Sleeve”“ , page 122
❑ Remove the guide sleeve to replace the seal.
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❑ Replace the guide sleeve and O-ring if the O-ring is damaged.
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13 - Cylinder Bolt
❑ Removing and installing. Refer to ⇒ “1.4 Overview - Clutch Release Mechanism”, page 18 .
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14 - Seal with Sleeve

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❑ Replace the seal and the sleeve together.
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❑ Replace when the transmission is installed. Refer to ⇒ “1.3 Right Seal, Replacing”, page 185 .
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❑ Replacing the removed transmission. Refer to ⇒ “6.3 Clutch Housing, Servicing”, page 122 .
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❑ For the differential
❑ Removing and installing. Refer to ⇒ “2 Differential”, page 189
❑ When replacing: adjust the differential. Refer to ⇒ “2.3 Differential, Adjusting”, page 194
17 - Magnet
❑ Held in place by housing joint surface
18 - 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 122
❑ Removing and installing. Refer to ⇒ “2 Differential”, page 189
❑ When replacing: adjust the differential. Refer to ⇒ “2.3 Differential, Adjusting”, page 194
20 - Shim

21 - Seal
❑ For the left flange shaft
❑ Replacing. Refer to ⇒ “1.3 Right Seal, Replacing”, page 185 .Volkswa
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♦ Bearing/Bushing Installer - Multiple Use - VW295A-
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♦ Press Piece - Front Control Arm - 2040-
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♦ Seal - Guide Sleeve

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Installing the Needle Bearing

– Secure the needle bearing at three points inside the transmis‐
sion housing, offset by 120°, using a mandrel.
6. Transmission Housing and Clutch Housing 121

Removing the Seal from the Guide Sleeve
Installing the Seal All the Way Into the Guide Sleeve
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Installing the Oil Catch Tray -A- into the Transmissionhor eo
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– Insert the oil catch tray into the hole -arrow
s 1- and groove
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-arrow 2- at the same time.

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6.3 Clutch Housing, Servicing

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♦ Slide Hammer Set - VW771-

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♦ Slide Hammer Set - Hook - VW771/37-

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♦ Spindle from the Seal Installer - Driver Set - 3066-

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– Slide Hammer Set - Hook - VW771/37- behind the shoulder
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– Using force, push the Slide Hammer Set - Hook - VW771/37-

into the sleeve.

Installing the Sleeve and Seal

– Clean the seal seat inside the transmission.
– Attach the spindle -A- for 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- .
Note
If transmission is disassembled, press sleeve in onto stop using

Seal Installer - One-Piece Seal - T10148- .
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7 Securing on Engine and Transmis‐ s
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VW353- .
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– Place a Shop Crane - Drip Tray - VAS6208- for example un‐
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⇒ “8.2 Transmission Fluid, Draining and Filling”, page 125
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8.1 Transmission Fluid Level, Checking
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It is not possible to check the transmission fluid level by removing
oil filler plug.
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The Transmission Fluid Level In Transmission Can Only be

Checked When the Transmission Fluid Has Been Drained Com‐
pletely and then Filled Again. Refer to
⇒ “8.2 Transmission Fluid, Draining and Filling”, page 125 .
8.2 Transmission Fluid, Draining and Filling

♦ Hose (approximately 600 mm long, outside diameter 10 mm)
with commercially available funnel.
Transmission Fluid, Draining
Transmission fluid. Refer to the Parts Catalog.
– Remove the entire air filter housing if it is located above the
gearshift lever. Refer to ⇒ Engine Mechanical, Fuel Injection
and Ignition; Rep. Gr. 24 ; Air Filter; Air Filter Housing, Re‐
8. Transmission Fluid 125

Clean the transmission.
Caution
To drain gear oil, journal for shift forks in transmission must be

removed.
To avoid that the position of the shift forks is changed, for ex‐
ample by involuntarily operating shift mechanism, shift rod
must be secured.
AG. Volkswagen AG d
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Secure the Gearshift
aut Shaft as Follows: ra
c
ss
– Push the gearshift shaft down in the direction of -arrow 1-.
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– While press the gearshift shaft down, rotate the bracket -A- in
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direction of -arrow 2- upward and simultaneously press it in
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until it engages in the gearshift shaft.
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• The gearshift shaft is secured.
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es, in part or in w
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Use a Clean Container that Holds three Liters (3.17 quarts) With
a Scale Printed On It To Catch the Transmission Fluid.
nf
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– Remove the drain plug -arrow 1- and then the pivot pins for
or
the shift forks -arrow 2- and drain the transmission fluid.

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– Install the pivot pins for the shift forks -arrow 2- with a new O-
n in
or c
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anism”, page 95 .
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– Install the oil drain plug -arrow 1- -item 15-

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– Rotate the bracket -A- back into its starting position direction
of -arrow- so that the gearshift shaft moves freely.
Transmission Fluid, Filling
• The oil drain plug is tightened to the tightening specification.
• Install the shift fork journal with a new O-ring. Refer to
anism”, page 95 .
Transmission fluid. Refer to the Parts Catalog.
Fill the Transmission Fluid Capacity into the Container to 1.8 Lit‐
ers (1.9 quarts).

– Remove the Back-Up Lamp Switch - F4- -arrow-.

– Hose (approximately 600 mm (23.6 in.) long, outside diameter
10 mm) with commercially available funnel.
– Insert the hose into the hole in the Back-Up Lamp Switch - F4-
(seconded technician) and fill the transmission fluid.
– Reinstall the Back-Up Lamp Switch - F4- -arrow-. Refer to
– Check the selector mechanism function. Refer to
⇒ “1.7 Selector Mechanism, Checking”, page 65 .
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8. Transmission Fluid 127

9 Special Tools

equipment required
♦ Transmission Support -
Mounting Plate 39 -
3282/39-
♦ Transmission Support Ele‐
ments (determine when
mounting the Adjustment
Plate on the Transmission
Support )
♦ Engine and Gearbox Jack -
VAS6931-
5-50Nm - VAG1331-
40-200Nm - VAG1332-
♦ Transmission Support Jig -
3336- to transport the
transmission.
♦ Grease for Clutch Disc
Shaft Splines - G 000 100-
♦ Allocate the grease for
gearshift mechanism. Re‐
fer to the Parts Catalog.
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Rep. Gr.34 - Controls, Housing
♦ Engine Support Bridge -

10-222A-
Gearbox Adapter -
10-222A/29-
Engine Support 18 -
10-222A/18-
♦ Engine/Gearbox Support
Shackle (2 pc.) - 10-222A/
12-
Pins 29 - 3282/29-
3282-
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9. Special Tools 129

♦ Bearing/Bushing Installer -
Multiple Use - VW295-
Multiple Use - VW295A-
♦ Press Piece - Multiple Use
- VW447H-
- VW512-
- VW454-
♦ Press Piece - Front Control
Arm - 2040-
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♦ Holding Plate - VW309A-

VW353-
Multiple Use - VW295-
♦ Bearing Driver - Multiple
Use - VW244B-
♦ For example Hot Air Blower
- VAG1416-
5-50Nm - VAG1331-
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♦ Subframe Support Tool -
Press Piece - 3290/1-
- VW431-
♦ Subframe Bushing Tool Kit
- 3301-
Spacer Sleeve - VW472/2-
♦ Valve Guide/Clutch Re‐
lease Push Rod Seal Drift -
10-206-
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♦ Bracket - Multiple Use -

30-211A-
♦ Bearing Installer - Multiple
Use - 32-111-
♦ Assembly Tool Kit - Press
Piece 2 - T10030/4- from
the Hydraulic Press - Bush‐
ing Tool Kit - T10030-
♦ Press Piece - 37mm -
VW416B-
♦ Puller - Transmission
Gears - T10309-
♦ Puller - Two Arm - T10040-
♦ With the Puller - Two Arm
w/Thrust Piece -
T10040/2A-
♦ Puller - Two Arm Thrust
Piece - T10040/3-
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♦ Rear Wheel Bearing Kit -
Piece 7 - 3253/7-
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40-200Nm - VAG1332-
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♦ Bracket - Multiple Use -

30-211A-
♦ Bearing Installer - Multiple
Use - 32-111-
♦ Assembly Tool Kit - Press
Piece 2 - T10030/4- from
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♦ Press Piece - 37mm - byV
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♦ Puller - Transmission ss au ac
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♦ M7 x 35 hex collar bolt and
washer (components of the
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Puller - Transmission
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♦ Connecting Pin - T10027A-

♦ Breather Tube Tool - T10203-
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tity 2)


tity 2) from the Engine Support - Supplement Kit - T40093A-
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♦ Shop Crane - VAS6100-

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♦ Shop Crane - Drip Tray - VAS6208-
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♦ Press Piece - Shiftise Rod/Alternator - VW423-
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♦ M8 x 100 mm stud bolt

35 – Gears, Shafts
1 Input Shaft
⇒ “1.1 Overview - Input Shaft”, page 141
⇒ “1.2 Input Shaft, Disassembling and Assembling”, page 143
⇒ “1.3 Input Shaft, Adjusting”, page 148
⇒ “1.4 Input Shaft Seal, Replacing”, page 152
1.1 Overview - Input Shaft
Note
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♦ The input shaft amust
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or
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are replaced. Pay
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♦ Replace both tapered roller bearings together.
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hubs to approximately 100 °C (212 °F) using an Inductive Heat Unit - VAS6414- before installing them.
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1. Input Shaft 141

1 - Clutch Housing
2 - Outer Race/Tapered Roller
Bearing
Outer Race/Tapered
Roller Bearing”“ ,
page 144
Outer Race/Tapered
Roller Bearing”“ ,
page 144
3 - Inner Race / Tapered Roller
Bearing
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5 - 3rd Gear Wheel
❑ Installed position: shoul‐
der faces 4th gear
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3rd Gear Wheel”“ , page
145
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❑ Installing. Refer to ⇒ Fig. ““Installing 3rd Gear Wheel”“ , page 145
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8 - Inner Race / Tapered Roller Bearing
❑ Removing with 4th gear wheel and sleeve. Refer to
❑ Installing. Refer to ⇒ Fig. ““Installing the Inner Race/Tapered Roller Bearing”“ , page 146
9 - Thrust Washer
❑ Removing. Refer to ⇒ Fig. ““Installing the Outer Race/Tapered Roller Bearing”“ , page 147
❑ Installing. Refer to ⇒ Fig. ““Installing the Outer Race/Tapered Roller Bearing”“ , page 147
11 - Shim
❑ Selecting thickness. Refer to ⇒ “1.3 Input Shaft, Adjusting”, page 148 .
142 Rep. Gr.35 - Gears, Shafts

13 - Sleeve
❑ For the 5th gear needle bearing
❑ Pressing off with 4th gear drive gear and the inner race/tapered roller bearing. Refer to
❑ Installing. Refer to ⇒ Fig. ““Installing the Needle Bearing Sleeve”“ , page 146
❑ Mount before installing the thrust washer -item 9- ⇒ Item 9 (page 142) .
14 - Needle Bearing
❑ For 5th gear
15 - 5th Gear Wheel
16 - 5th Gear Synchronizer Ring
❑ With cast locking pieces. Refer to
⇒ Fig. ““5th Gear Synchronizer Ring with Cast Locking Pieces”“ , page 116
❑ Checking for wear. Refer to ⇒ Fig. ““Checking 5th Gear Synchronizer Ring”“ , page 116
17 - Spring
❑ Installation position. Refer to
⇒ Fig. ““5th Gear Locking Collar/Synchronizer Hub Assembly”“ , page 147 and
⇒ Fig. ““Installation of Offset Springs -A- ”“ , page 148
18 - Locking Pieces (quantity: 3)
❑ Installed position. Refer to ⇒ Fig. ““5th Gear Synchronizing”“ , page 147
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21 - Plate Spring
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❑ Holds in position with the adapter on the plate spring bolt head. Refer to
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page 117
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⇒ “5.10 Transmission Housing Cover and 5th Gear, Removing”, page 101 .
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❑ Tightening specification. Refer to

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⇒ “5.3 Overview - Transmission Housing Cover and 5th Gear”, page 93 .

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1.2 Input Shaft, Disassembling and Assem‐

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♦ Press Piece - Multiple Use - VW447H-
♦ Press Piece - Shift Rod/Alternator - VW422-
♦ Press Piece - Rod - VW408A-
1. Input Shaft 143

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Installing the Outer Race/Tapered Roller Bearing
Removing the Inner Race/Tapered Roller Bearing

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

Installing the Inner Race/Tapered Roller Bearing
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Removing the 4th Gear Wheel with the Tapered Roller Bearing
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Removing the 3rd Gear Wheel

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Installing 3rd Gear Wheel
1. Input Shaft 145

Manual Transmission - Edition 12.2014 agen
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5th Gear Synchronizing
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1- Springs for Locking Pieces

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2- Locking Collar with 3 Notches -arrow A- for Locking Pieces
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5th Gear Locking Collar/Synchronizer Hub Assembly

– Slide the locking collar over the synchronizer hub.
The pointed teeth -A- and the shoulder -B- on the synchronizer
hub face in the same direction. Recesses for locking pieces in
locking collar and synchronizer hub must line up. (Refer to
⇒ Fig. ““5th Gear Synchronizing”“ , page 147 ).
– Insert locking pieces (installed position: Refer to
– Install the springs offset by 120° under the tabs -C-.
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).
1. Input Shaft 147

Installation of Offset Springs -A-

These springs are installed won
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Spring installed position:
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– Install the spring offset by 120°.
rrectness of i
– Angled end -A- of spring must engage into the hollow locking
piece.
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The spring must be located below the tab -B- of the locking pieces.
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The offset end always faces away from the synchronizer hub in
direction of -arrow-.
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♦ Dial Gauge Holder - VW387-
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♦ Measuring Set - Magnetic Plate - 50mm - VW385/17-
♦ Press Piece - VW447i-
♦ Dial Gauge
A new input shaft adjustment is required when the following com‐
ponents have been replaced:
♦ Transmission Housing
♦ Clutch Housing
♦ Input Shaft
♦ 4th Gear Wheel
or the
♦ Tapered roller bearing
Adjustment overview. Refer to
⇒ “3 Adjustment Overview”, page 198 .
Requirement:
• Remove any sealant remaining on the sealing surfaces on the
clutch and transmission housings.

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– Press the taper roller bearing outer
ut
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all the way. ss
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– Install the outer race/tapered roller bearing all the way into the
s
transmission housing without the adjusting shim.
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– Install the input shaft into the clutch housing and mount the
form
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transmission housing. Install the hex bolts. Refer to
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anism”, page 95 .
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– Install the measuring device and the dial gauge in the clutch
housing.
– Rotate the input shaft before measuring so the tapered roller
bearing settles. Set the dial gauge with 1 mm pretension to “0”.
Note
Repeat this process each time a measurement is taken otherwise

the dial gauge will not go back to its start setting.
1. Input Shaft 149

– 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 agen
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Measured Value (mm)
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0.671 to u0.699
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0.725 to 0.749 0.700
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0.750 to 0.774 0.725
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0.775 to 0.799 0.750
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0.800 to 0.824 0.775
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0.850 to 0.874 0.825
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0.875 to 0.899 0.850
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0.900 to 0.924 0.875
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0.925 to 0.949 0.900
0.950 to 0.974 0.925
rrectness of i
0.975 to 0.999 0.950
1.000 to 1.024 0.975
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1.025 to 1.049 1.000

1.050 to 1.074 1.025
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1.075 to 1.099 1.050

1.100 to 1.124 1.075
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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

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1.200 to 1.224 1.175

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1.225 to 1.249 1.200

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1.250 to 1.274 1.225
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1.350 to 1.374 1.325

1.375 to 1.399 1.350
1.400 to 1.424 1.375
1.425 to 1.449 1.400
1.450 to 1.474 1.425
1.475 to 1.499 1.450
1.500 to 1.524 1.475
1.525 to 1.549 1.500
1.550 to 1.574 1.525
1.575 to 1.599 1.550
1.600 to 1.624 1.575
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
Allocate the 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.
1. Input Shaft 151

– 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- .
– Install the transmission housing and tighten the bolts.
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 must be between a minimum 0.01 to maximum
0.09 mm.
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The adjustment is OK if it is not u possible to measure the bearing
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1.4 Input Shaft Seal, Replacing
rrectness of i
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♦ Bearing/Bushing Installer - Multiple Use - VW295A- nform

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– Remove the transmission. Refer to

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⇒ “2.1 Transmission, Removing”, page 67 .

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⇒ “1.16 Clutch Release Mechanism, Servicing”, page 35 . t. Cop py
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– Drive seal out of guide sleeve. p by
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– Coat the outer circumference of the seal lightly with transmis‐
sion fluid.
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– Install the seal all the wayorise into the guide sleeve. nte
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– Install the clutch release
ss a lever with the release bearing and c
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⇒ “1.16 Clutch Release Mechanism, Servicing”, page 35 .
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♦ Refer to
⇒ “1.4 Overview - Clutch Release Mechanism”, page 18
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1. Input Shaft 153

2 Output Shaft
⇒ “2.1 Overview - Output Shaft”, page 154
⇒ “2.2 Output Shaft, Disassembling and Assembling”,
page 158
⇒ “2.3 Output Shaft, Adjusting”, page 166
2.1 Overview - Output Shaft
Note
♦ Disassemble the output shaft as follows:

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⇒ Item 21 (page 157) and remove by
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⇒ Fig. ““Removing the 3rd/4th
ris
ed Gear Synchronizer Hub/Locking Collar,
ara
nt 2nd Gear Wheel, 3rd and 4th Gear
with Output Shaft Needle
utho Bearing Sleeve”“ , page 160 . Remove theeelocking
or ring -item 17-
⇒ Item 17 (page 156)
ss a. Remove the locking collar and the 1st/2nd gear asynchronizer
c hub as described.
Refer to
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⇒ Fig. ““Removing the Locking Collar with the Synchronizer Hub and Bearing Mount”“ , page 160 .
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♦ Consult the Parts Catalog and the Technical data when installing new gear wheels or a new output shaft.
erm
ab
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Refer to ⇒ “4 Technical Data”, page 6 .
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♦ Wearing safety gloves, warm the inner race/tapered roller bearing, the gear wheels and the synchronizer
es, in part or in w
hubs to approximately 100 °C (212 °F) using an Inductive Heat Unit - VAS6414- before installing them.
t to the co
rrectness of i
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1 - Nut
❑ 4 nuts for the bearing
mount
❑ Tightening specifica‐
tion. Refer to
⇒ “5.6 Overview - Input
Shaft, Output Shafts, agen
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h
2 - Clutch Housing s aut ra
c
s
3 - Shim
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❑ Adjustment overview.
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Refer to
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is n
⇒ “3 Adjustment Over‐
h re
ole,
view”, page 198 .
spec
4 - Small Outer Race/Tapered
t to the co
Roller Bearing
⇒ Fig. ““Remove the
rrectne
Small Outer Race/Ta‐
pered Roller Bearing”“ ,
s
page 159 .
s o
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inform
mer
Small Outer Race/Ta‐
atio
m

o
n
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i
or
n
page 159
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5 - Small Inner Race/Tapered

i
o
pr
cum
Roller Bearing
r
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ng
t.
yi
Co
op py
⇒ Fig. ““Removing the t. C rig
gh ht
Inner Race/Small Ta‐ yri
p by
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by c lksw
cted agen
page 159
Prote AG.
❑ Installing. Refer to ⇒ Fig. ““Installing the Inner Race/Small Tapered Roller Bearing”“ , page 160
6 - Output Shaft
❑ Adjusting. Refer to ⇒ “2.3 Output Shaft, Adjusting”, page 166 .
7 - Inner Race/Tapered Roller Bearing
❑ Removing. Refer to ⇒ Fig. ““Removing the Inner Race/Large Tapered Roller Bearing”“ , page 160
❑ Installing. Refer to ⇒ Fig. ““Installing the Inner Race/Large Tapered Roller Bearing”“ , page 161
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
2. Output Shaft 155

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
161
❑ Checking for wear. Refer to
⇒ Fig. ““Checking Inner Race for 1st Gear and 2nd Gear for Wear”“ , page 161
❑ Check for scoring
14 - 1st Gear Outer Race
161
⇒ Fig. ““Checking 1st Gear and 2nd Gear Synchronizing Ring for Wear”“ , page 161
❑ Replace if there are grooves or scoring
15 - 1st Gear Synchronizer Ring
161
⇒ Fig. ““Checking 1st Gear and 2nd Gear Synchronizing Ring for Wear”“en AG. V
,opage 161
lkswagen AG
ag does
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16 - Locking Collar with Synchronizer Hub for 1st and 2nd Gearsby Vol ot g
ua
ed ra
❑ After removing the locking ring -item 17- ⇒ Item 17 (page horis 156) , remove with the bearing mount.ntRefer
ee
to ⇒ Fig. ““Removing the Locking Collar with the Synchronizer
aut
Hub and Bearing Mount”“ , page 160 or
ac
ss
❑ Disassembling. Refer to
ce
le
un
pt
⇒ Fig. ““Disassembling and Assembling Locking Collar and Synchronizer Hub for 1st and 2nd Gears”“ ,
an
d
itte
page 162 .
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ab
❑ Assembling operating sleeve/synchronizer hub. Refer to
pe
ility
ot
⇒ Fig. ““Disassembling and Assembling Locking Collar and Synchronizer Hub for 1st and 2nd Gears”“ ,
wit
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page 162 ,
h re
hole
⇒ Fig. ““Assembly: Locking Collar/Synchronizer Hub for 1st and 2nd Gears Together with Locking Pieces
spec
That Are Hollow on the Inside”“ , page 162 and
es, in part or in w
t to the co
⇒ Fig. ““Assembly: Locking Collar/Synchronizer Hub for 1st and 2nd Gears Together with locking Pieces
That Are Not Hollow”“ , page 162
rrectness of i
⇒ Fig. ““Installed Position: Locking Collar/Synchronizer Hub for 1st and 2nd Gears”“ , page 163
l purpos
⇒ Fig. ““Installing the Locking Collar/Synchronizer Hub for 1st and 2nd Gears.”“ , page 163
nform
ercia
17 - Circlip
m
18 - 2nd Gear Synchronizer Ring

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tion in

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❑ Install so that cut-outs engage in engagement pieces of locking collar for 1st and 2nd gear.
r
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19 - 2nd Gear Outer Race

n
t.
yi Co
op
❑ Insert in the 2nd gear synchronizer ring -item 18- ⇒ Item 18 (page 156) .
C py
t. rig
gh ht
yri
❑ Installed position. Refer to ⇒ Fig. ““Installed Position of 2nd Gear Outer Race”“ , page 163 p by
o Vo
by c lksw
cted
❑ Replace if there are grooves or scoring
agen
Prote AG.
20 - Synchronizer Ring
❑ (Inner race for 2nd gear)
❑ Check for scoring
⇒ Fig. ““Installed Position: Synchronizer Ring -A- (2nd Gear Inner Race)”“ , page 163

21 - 2nd Gear Wheel

❑ Installed position. Refer to ⇒ Fig. ““Installed Position: 2nd Gear Wheel”“ , page 164
22 - Needle Bearing
❑ For 2nd gear
23 - Thrust Washer
24 - Sleeve
❑ For the 3rd gear needle bearing
❑ Removing with the 2nd gear wheel. Refer to
⇒ Fig. ““Removing the 3rd/4th Gear Synchronizer Hub/Locking Collar, 2nd Gear Wheel, 3rd and 4th Gear
with Output Shaft Needle Bearing Sleeve”“ , page 160
❑ Installing. Refer to ⇒ Fig. ““Installing the Sleeve for the 3rd Gear Needle Bearing”“ , page 164
25 - Needle Bearing
❑ For 3rd gear
26 - 3rd Gear Wheel
27 - 3rd Gear Synchronizer Ring
❑ Checking for wear. Refer to ⇒ Fig. ““Checking 3rd/4th Gear Synchronizing Ring for Wear”“ , page 164
28 - Locking Collar with Synchronizer Hub for 3rd and 4th Gears
❑ Remove with 2nd gear wheel and 3rd gear. Refer to
❑ Disassembling. Refer to
⇒ Fig. ““Disassembling and Assembling Locking Collar and Synchronizer Hub for 3rd/4th Gears”“ , page
165 .
❑ Assembling the locking collar/synchronizer hub. Refer to
⇒ Fig. ““Disassembling and Assembling Locking Collar and Synchronizer Hub for 3rd/4th Gears”“ , page
165 , AG. Volkswagen AG d
agen
⇒ Fig. ““Assembly: LockingVoCollar/Synchronizer
lksw Hub for
oes
n3rd
ot g and 4th Gears Together with Locking Pieces
that are Hollow on theeInside”“db
y , page 165 and ua
ran
⇒ Fig. ““Assembly: tLocking
ho
ris
Collar/Synchronizer Hub for 3rd andte4th e o Gears Together with Locking Pieces
that are Not Hollow”“
s au , page 165 . ra
c
s
❑ Installed position: locking collar/synchronizer hub. Refer to
ce
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un
pt
⇒ Fig. ““Installed Position: Locking Collar/Synchronizer Hub for 3rd and 4th Gears”“ , page 166
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pe
⇒ Fig. ““Installing the Synchronizer Hub with Locking Collar for 3rd and 4th Gears”“ , page 166
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29 - Sleeve
h re
hole
❑ For the 4th gear needle bearing

spec
es, in part or in w
❑ Removing with the locking collar and the 3rd/4th gear synchronizer hub. Refer to
t to the co
❑ Installing. Refer to ⇒ Fig. ““Installing the Sleeve for the 4th Gear Needle Bearing”“ , page 166
rrectness of i
30 - Needle Bearing
l purpos
❑ For 4th gear

nform
ercia
31 - 4th Gear Synchronizer Ring

m
❑ Checking for wear. Refer to ⇒ Fig. ““Checking 3rd/4th Gear Synchronizing Ring for Wear”“ , page 164
a
com
tion in
32 - 4th Gear Wheel

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33 - Thrust Washer
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34 - Needle Bearing
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ng
t.
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❑ For the output shaft t. Cop py
rig
gh
❑ Removing and installing. Refer to ⇒ Fig. ““Removing the Needle Bearing”“ , page 121
ht
pyri by
Vo
co lksw
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cted agen
Prote AG.
2. Output Shaft 157

36 - Sleeve
❑ For the needle bearing/output shaft
❑ Installing. Refer to ⇒ Fig. ““Installing the Sleeve for the Needle Bearing/Output Shaft”“ , page 166
37 - 5th Gear Wheel
⇒ “5.10 Transmission Housing Cover and 5th Gear, Removing”, page 101 .
38 - Plate Spring
page 117
39 - Bolt
❑ Holds in position with the adapter on the plate spring bolt head. Refer to
page 117
⇒ “5.10 Transmission Housing Cover and 5th Gear,
AG. VoRemoving”,
lkswagen AG page 101 .
agen does
ksw
❑ Tightening specification. Refer to by V ol not
gu
a
⇒ “5.3 Overview - Transmission rHousing
ised Cover and 5th Gear”, page 93 .rante
tho eo
s au ra
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nl
2.2 Output Shaft, Disassembling and As‐

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Special tools and workshop equipment required wit

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es, in part or in w

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♦ Puller - Taper Roller Bearing - VAG1582-
rrectness of i
♦ Puller - Taper Roller Bearing - Adapter 4 - VAG1582/4-

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♦ Support Channels - VW457- yi

t.
Co
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♦ Press Piece - Multiple Use - VW 519-
t. C rig
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Prote AG.
♦ Press Piece - 60mm - VW415A-
♦ -1- Puller - Kukko Internal - 36-46mm - 21/6-


17/2-
♦ -4- Puller - Kukko Counterstay - 22/2-
♦ Feeler Gauge
Caution


♦ Nuts - Bearing Mount
♦ Seals - Bearing Mount Bikts
Remove the Small Outer Race/Tapered Roller Bearing
A - Internal Puller - 37-46mm for example Puller - Kukko Internal
- 36-46mm - Kukko 21/6-
B - Counter Support , for example, Puller - Kukko Counterstay -
Kukko 22/2-
AG. Volkswagen AG d
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Installing the Small Outer Race/Tapered
ss a
Roller Bearing c
ce
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un
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t to the co
rrectnes
Removing the Inner Race/Small Tapered Roller Bearing

s o
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f in
A - Protective jaws/vise
form
mer
– Attach grip and securely clamp it behind bearing rollers. Then

atio
m
turn the bearing and apply tension to the grip.

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n
c
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or
n thi
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t.
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Cop py
t. rig
gh ht
pyri by
Vo
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by c lksw
cted agen
Prote AG.
2. Output Shaft 159

Installing the Inner Race/Small Tapered Roller Bearing
Removing the 3rd/4th Gear Synchronizer Hub/Locking Collar,

2nd Gear Wheel, 3rd and 4th Gear with Output Shaft Needle
Bearing Sleeve
A - Puller - Quick Action Separating Tool - 22-115mm - Kukko
17/2- , for example.
B - M10 x 20, 17 mm Hex Bolt
Note
Support the separating tool so that the 1st/2nd gear locking collar
does not come off as well.
Removing the Locking Collar with the Synchronizer Hub and

Bearing Mount
– Remove the locking ring -arrow- beforehand.
AG. Volkswagen AG d
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Removing the Inner Race/Large Tapered Roller Bearing

h re
hole
spec
-A- vise protectors

es, in part or in w
t to the co
– Before installing puller, insert a M10 x 20 bolt into the hole in

the output shaft.
rrectness of i
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Prote AG.

Installing the Inner Race/Large Tapered Roller Bearing

-A- thrust washer
– Install the thrust washer before installing the inner race. The
shoulder faces the inner race.
Installed Position of the Inner Race, the Outer Race and the 1st
Gear Synchronizer Ring
– Place inner race -A- on drive gear for 1st gear.
The angled tabs -arrow 1- face the outer race -B-.
– Install the outer race -B-.
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-.
AG. Volkswagen AG d
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If the parts are not to be replaced, makeuthsure
or
they are reallocated eo
to their original gear. ss a ra
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Checking Inner Race for 1st Gear and 2nd Gear for Wear
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– Install the inner race onto taper of selector gear and then ility
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measure gap dimension -a- with a feeler gauge. wit

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-a- sion
t to the co
1st and 2nd gear 0.75 to 1.25 mm 0.3 mm

rrectness o
cial p
f inform
mer
Checking 1st Gear and 2nd Gear Synchronizing Ring for Wear
atio
om
– Install the synchronizer ring, outer race and inner race onto
n
c
i
or
taper of selector gear and then measure the gap dimension

thi
te
-a- with a feeler gauge.

sd
iva
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t.
-a- sion
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Cop py
ht. rig
1st and 2nd gear 1.2 to 1.8 mm 0.5 mm
rig ht
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by lksw
cted agen
Prote AG.
2. Output Shaft 161

Disassembling and Assembling Locking Collar and Synchronizer

Hub for 1st and 2nd Gears
1 - Spring
Spring allocation. 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
Inside”“ , page 162 .
Assembly in conjunction with locking pieces that are not hollow.
Refer to gen AG
. Volkswagen AG
does
⇒ Fig. ““Assembly: Locking Collar/Synchronizer Hub for 1st and Volkswa not
2nd Gears Together with locking Pieces That Are Not Hollow”“ed, by gu
ara
page 162 . ho
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2 - Locking collar ss
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3 - Synchronizer Hub
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4 - Locking piece
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Allocate the locking pieces. Refer to the Parts Catalog.
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The collar has the same width on both side of the synchronizer
hole
spec
hub.
es, in part or in w
t to the co
The Shoulder Has a Chamfer on One Side -arrow B-
The bevel on the synchronizer hub collar and the splines on the
rrectness of i
outside of the locking collar -arrow A- face in the same direction
after being assembled.
l purpos
The notches on the synchronizer hub and locking collar for the
locking pieces -arrow C- must line up.
nform
mercia
Assembly: Locking Collar/Synchronizer Hub for 1st and 2nd
a
com
tio
Gears Together with Locking Pieces That Are Hollow on the In‐
n in
r
side
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thi
s
iva
do
• The locking collar is pushed over the synchronizer hub.
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fo
– Install the locking pieces and springs offset by 120°. The an‐
en
ng
t.
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gled end of the spring must engage into the hollow locking Cop py
piece.
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Prote AG.
Assembly: Locking Collar/Synchronizer Hub for 1st and 2nd

Gears Together with locking Pieces That Are Not Hollow
– Install the locking pieces and springs offset by 120°.
• The angled end of the spring must be positioned in front of the
locking pieces -arrows-.

Installed Position: Locking Collar/Synchronizer Hub for 1st and

2nd Gears
The teeth of the locking collar -arrow- point toward the splines of
the 3rd/4th gear synchronizer hub -A-.
. Volkswagen AG
gen AG does
swa
Installing the Locking y V Collar/Synchronizer Hub for o1st
olk n t
gu and 2nd
Gears. risedb ara
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Turn the synchronizer ring so that the grooves line up with the
ra
s c
locking pieces.
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Installed Position of 2nd Gear Outer Race t to the co

rrectness of i
The tabs -arrows- face 1st gear -A-.
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tion in
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Cop py
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Installed Position: Synchronizer Ring -A- (2nd Gear Inner Race)
p by
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The tabs -arrow 1- engage into the holes -arrow 2- inside the
Prote AG.
synchronizer ring -B-.
2. Output Shaft 163

Installed Position: 2nd Gear Wheel

The higher collar -A- faces toward 1st gear -B-. The notches in
the collar -arrow- lock into the tabs on the outer race. Refer to
⇒ Fig. ““Installed Position of 2nd Gear
gen AG
Outer
. VolkswRace”“
agen AG , page 163 .
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Installing the Sleeve for the 3rd Gear Needle Bearing
hole
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t to the co
rrectness of i
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tion in
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Checking 3rd/4th Gear Synchronizing Ring for Wear
s
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– Press synchronizer ring onto taper of the gear wheel and

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measure gap dimension -a- using a feeler gauge.

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Cop py
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Gap Dimension Installation Dimen‐ Wear limit
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cop Vo
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Prote AG.
3rd and 4th gear 1.0 to 1.7 mm 0.5 mm

Disassembling and Assembling Locking Collar and Synchronizer

Hub for 3rd/4th Gears
1 - Spring
Allocate 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
Inside”“ , page 162 .
olkswagen AG
en AG. V
Assembly in conjunction with locking pieces that ksware not hollow.
ag does
not
Vol
Refer to ed
by gu
ara
⇒ Fig. ““Assembly: Locking Collar/Synchronizer
horis Hub for 1st and nte
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2nd Gears Together with locking Pieces
aut That Are Not Hollow”“ , ra
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page 162 . ss
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2 - Locking piece
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Allocate the locking pieces. Refer to the Parts Catalog.
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ility
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3 - Locking collar
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4 - Synchronizer Hub
spec
es, in part or in w
– Slide the locking collar over the synchronizer hub.
t to the co
The notches for the locking pieces on the synchronizer hub and
locking collar must line up with each other.
rrectness of i
Assembly: Locking Collar/Synchronizer Hub for 3rd and 4th
l purpos
Gears Together with Locking Pieces that are Hollow on the Inside
The locking collar is pushed over the synchronizer hub.
nform
mercia
a
com
ti
gled end of the spring must engage into the hollow locking
on in
piece.
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t.
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Cop py
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Prote AG.
Assembly: Locking Collar/Synchronizer Hub for 3rd and 4th
Gears Together with Locking Pieces that are Not Hollow
gled end of the spring must be positioned in front of the locking
pieces -arrows-.
2. Output Shaft 165

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
lkswage es n
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Installing the Sleeve for the 4th Gear Needle Bearing
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rrectness o
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Installing the Sleeve for the Needle Bearing/Output Shaft

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2.3 Output Shaft, Adjusting

(Selecting the correct adjusting shim for the output shaft)

♦ Door Alignment Device - Replacement Stud - 3114/2-

♦ Dial Gauge
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 remaining 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 159 . olks
wage es n
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– Install the output shaft and tightenristhe
ed nuts for the bearing nte
mount. utho eo
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– Rotate the output shaft 20 to 30 times in one direction. ce
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Note
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♦ For this reason, it must be rotated in one direction so the ta‐

h re
ole,
pered roller bearing rollers are seated in one direction.

spec
♦ Therefore, it must also be rotated 20 to 30 times in one direc‐

t to the co
tion.
♦ Otherwise the measurements will be incorrect.
rrectness o
cial p
f inform
mer
atio
om
n
c
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te
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Cop py
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rig ht
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Prote AG.
2. Output Shaft 167

wage es n
– Install dial gauge (3 mm measuring olks
Vrange) and set to “0” with ot g
by ua
1 mm pre-load. rised ran
tee
tho or
– Move the input shaft up andau down, check the play on the dial ac
ss
gauge and make a note of it.
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pt
du
Determining the Shim
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The specified bearing tension is reached when the adjustment
ility
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shim (0.65 mm) is added to the measured value.
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Example:
hole
spec
es, in part or in w
Bearing Play = Adjustment Shim Thickness
t to the co
(Adjustment Shim 0.65 mm According to the Table
Plus the Measured Value)
0.740 mm 0.900 mm
rrectness of i
l purpos
Shim Table
Bearing Play = Adjustment Shim
nform
ercia
(Adjustment Shim 0.65 mm Thickness (mm)

Plus the Measured Value)
m
at
om
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0.650 0.750
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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
– 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 159
– Install the shim with the correct thickness, thickest shim first.
• If the previous 0.65 mm adjustment shim will be inserted again,
it must be checked for damage.
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.
Tolerance variations make it possible to find the exact shim thick‐
ness required.
– Press in the outer race/small tapered roller bearing with de‐
termined shim (0.70 mm as in example). Refer to
⇒ Fig. ““Installing the Small Outer Race/Tapered Roller Bear‐
ing”“ , page 159 and install output shaft.

– Tighten the nut for the bearing mount in the clutch housing.
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♦ Bearing mount to the clutch housing. Refer to horis tee
⇒ “5.6 Overview - Input Shaft, Output Shafts,s aDifferential,
ut or
ac
Gearshift Rods”, page 97 . s
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2. Output Shaft 169

3 Reverse Shaft
⇒ “3.1 Overview - Reverse Shaft”, page 170
⇒ “3.2 Reverse Shaft, Disassembling and Assembling”,
page 170
3.1 Overview - Reverse Shaft
Note
Always replace the needle sleeve after removing it from the clutch housing or from the reverse shaft support.
AG. Volkswagen AG d
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1 - Clutch Housing d by V gu
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page 171
3 - Reverse Drive Gear
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4 - Circlip
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5 - Reverse Gear Wheel
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❑ Remove before replac‐

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❑ Collar faces reverse
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agen
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7 - Needle Sleeve
Needle Sleeve from the
Reverse Shaft Sup‐
port”“ , page 171
Needle Sleeve into the Reverse Shaft Support”“ , page 172
8 - Reverse Shaft Support
❑ Removing and installing. Refer to ⇒ “5.11 Transmission, Disassembling and Assembling”, page 105 .
3.2 Reverse Shaft, Disassembling and As‐

sembling


♦ Centering/Press Pin - 12-551-
Caution


♦ Needle Sleeve - Reverse Shaft
Removing the Needle Sleeve from the Clutch Housing
A - Puller - Kukko Counterstayt - 22/1- , for example.
B - Puller - Kukko Internal - 14-19mm - 21/2- , for example.
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3. Reverse Shaft 171

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Installing the Needle Sleeve into the Reverse Shaft Support
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4 Special Tools
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♦ Press Piece - Multiple Use d by V gu
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♦ Press Piece - Rod - d b ua
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♦ Puller - Taper Roller Bear‐
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ing - Adapter 4 -
VAG1582/4-
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ing - Adapter 5 -
VAG1582/5-
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♦ Bearing Installer - Multiple rised
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♦ Support Channels -
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AG. Volkswagen AG d
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d by Golf 2015 ➤ , Golf Variant
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thor Manual Transmission - Edition e 12.2014
or
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equipment required
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♦ Dial Gauge Holder - aut ra
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♦ Dial Gauge Holder -

VW387-
Plate - 50mm - VW385/17-
- VW512-
♦ Door Alignment Device -
Replacement Stud -
3114/2-
♦ Press Piece - Rod - AG. Volkswagen AG d
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♦ Press Piece - 28x100mm -

VW421-
- VW454-
- VW510-
♦ -3- Puller - Kukko Quick Ac‐
tion Separating Tool -
12-75mm - Kukko 17/1-
AG. Volkswagen AG d
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180
AG.
Rep. Gr.35 - Gears, Shafts
n AG. Volkswagen AG do Manual Transmission - Edition 12.2014
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♦ Bearing/Bushing Installerby - Multiple Use - VW295-
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17/2-
AG. Volkswagen AG d
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39 – Final Drive, Differential

1 Seals
⇒ “1.1 Component Location Overview - Seals”, page 183
⇒ “1.2 Left Seal, Replacing”, page 183
⇒ “1.3 Right Seal, Replacing”, page 185
1.1 Component Location Overview - Seals
1 - Input Shaft Seal

⇒ “1.4 Input Shaft Seal,
Replacing”, page 152 .
2 - Seal
⇒ “1.3 Right Seal, Re‐
placing”, page 185 .
3 - Seal
❑ Replacing. Refer to AG. Volkswagen AG d
⇒ “1.2 Left Seal, Replac‐ agen oes
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4 - Gearshift Shaft
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❑ Replacing.
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Seal, Replacing”,
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♦ Seal Installer - Flange Shaft Oil Seal - T10160-
♦ Used Oil Collection and Extraction Unit - SMN372500-
1. Seals 183
AG. Volkswagen AG d
Manual Transmission - Edition 12.2014 ksw
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♦ Torque Wrench 1331 5-50Nm - VAG1331- orise nte
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– Remove the left wheel.

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– Remove the lower section of the left front wheel housing liner.
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– Turn the steering wheel to the left.
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– Remove drive axle from flange shaft. Refer to ⇒ Suspension,

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Wheels, Steering; Rep. Gr. 40 ; Drive Axle; Drive Axle, Re‐ Cop py
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– Tie the drive axle as high up as possible. Do not damage the
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paint on the drive axle.
AG.
– Place the Used Oil Collection and Extraction Unit -

SMN372500- or Drip Tray under the transmission.
– Remove the flange shaft bolt. To do this, install two bolts into
the flange and counterhold the flange shaft using a pry bar.
– Remove the flange shaft and the pressure spring.
– Remove the flange shaft seal using the Slide Hammer Set -
VW771- and the Slide Hammer Set - Hook - VW771/37- .
184 Rep. Gr.39 - Final Drive, Differential

Installing
– Lightly oil new seal on outer circumference.
– Install the seal all the way in without tilting it.

– Install the flange shaft.
– Press the flange shaft against the transmission and secure it
with the bolt.
– Attach the drive axles to the transmission. Refer to ⇒ Sus‐
pension, Wheels, Steering; Rep. Gr. 40 ; Drive Axle; Drive
Axle, Removing and Installing .
– Check the transmission fluid and fill if necessary. Refer to
– Install the lower section of the left front wheel housing liner.
– Install the wheel. Refer to ⇒ Suspension, Wheels, Steering;
Rep. Gr. 44 ; Wheels and Tires; Wheel Bolt Tightening Spec‐
ifications . . Volkswag AG en AG
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♦ Refer to ⇒ “2.1 Overview - rise
Differential”, page 189 . nte
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♦ Spindle from the Seal Installer - Driver Set - 3066-

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♦ Used Oil Collection and Extraction Unit - SMN372500-

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1. Seals 185
Right Flange Shaft Seal, Replacing
Note
♦ The seal -1- and the sleeve -2- are a single part.
♦ The seal and the sleeve can only be replaced together.

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– Remove the noise insulation. Refer to d by⇒ Body Exterior; Rep.
V o gu
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Gr. 66 ; Noise Insulation; Overview oris - Noise Insulation .
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– Turn steering as far as possible
ss a toward right. c
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– Remove the drive axle heat shield if equipped -arrows-.
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– Remove drive axle -1- from flange shaft. Refer to ⇒ Suspen‐

m
a
sion, Wheels, Steering; Rep. Gr. 40 ; Drive Axle; Drive Axle,
com
tio
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r
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– Tie the drive axle as high up as possible. Do not damage the thi
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♦ On some engines, the drive axle cannot be tied up so that the Prote
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transmission flange shaft can be removed.
AG.
♦ Remove the right drive axle. Refer to ⇒ Suspension, Wheels,

Steering; Rep. Gr. 40 ; Drive Axle; Drive Axle, Removing and
Installing .
– Place the Used Oil Collection and Extraction Unit -

SMN372500- or Drip Tray under the transmission.
– Remove the flange shaft bolt -arrow-. To do this, install two

bolts into the flange and counterhold the flange shaft using a
tire iron.
– Remove the flange shaft and the pressure spring.

The seal is located in a metal housing.

– Remove the seal and the sleeve together.
A ridge is located on the internal diameter of the sleeve.
– Install 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.
Installing
– Clean the seal seat inside 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- .
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– Fill the space between the sealing
aut and dust lip -arrow- halfway
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ra
with Sealing Grease - G 052s 128 A1- .
s c
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– Install the flange shaft.
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– Press the flange shaft against the transmission and secure it

ss
with the bolt -arrow-.

o
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– Fasten the right drive axle to the flange shaft. Refer to ⇒ Sus‐
form
mer
pension, Wheels, Steering; Rep. Gr. 40 ; Drive Axle; Drive

atio
Axle, Removing and Installing .

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1. Seals 187
– Attach the drive axle heat shield -arrows- (if equipped). Refer
to ⇒ Suspension, Wheels, Steering; Rep. Gr. 40 ; Drive Axle;
Drive Axle Heat Shield, Removing and Installing .
– Check the transmission fluid and fill if necessary. Refer to
Tightening Specification
♦ Refer to ⇒ “2.1 Overview - Differential”, page 189 .
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2 Differential
⇒ “2.1 Overview - Differential”, page 189
⇒ “2.2 Differential, Disassembling and Assembling”, page 190
⇒ “2.3 Differential, Adjusting”, page 194
2.1 Overview - Differential
2 - Shim
❑ Selecting thickness. Re‐
fer to
⇒ “2.3 Differential, Ad‐
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rrectne
4 - Inner Race / Tapered Roller
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Inner Races/Tapered
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atio
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6 - Inner Race / Tapered Roller Bearing

❑ Removing. Refer to ⇒ Fig. ““Removing the Inner Races/Tapered Roller Bearings”“ , page 191
❑ Installing. Refer to ⇒ Fig. ““Installing the Inner Races/Tapered Roller Bearings”“ , page 191
⇒ Fig. ““Removing the Outer Race/Tapered Roller Bearing from the Clutch Housing”“ , page 191
⇒ Fig. ““Installing Outer Race/Tapered Roller Bearing Into the Clutch Housing”“ , page 191
8 - Clutch Housing
9 - Seal
❑ With sleeve
2. Differential 189
❑ If the seal is damaged, then replace both the seal and sleeve. Refer to
10 - Bolt
❑ 25 Nm
11 - Flange Shaft
❑ Removing and installing. Refer to ⇒ “1 Seals”, page 183 .
12 - Flange Shaft Pressure Spring
13 - Thrust Washer
❑ Installed position. Refer to ⇒ wFig.
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15 - Circlip
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16 - Seal
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❑ Replacing. Refer to ⇒ “1.2 Left Seal, Replacing”, page 183 .
t to the co
2.2 Differential, Disassembling and Assem‐
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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-

♦ Bearing Installer - Taper Roller Bearing - 2007-

Note
♦ Heat the inner race / tapered roller bearing to 100 °C (212 °F)
before installing.
♦ Adjust the differential when replacing the tapered roller bear‐
ing, differential, transmission housing or clutch housing. Refer
to ⇒ “3 Adjustment Overview”, page 198 .
Removing the Outer Race/Tapered Roller Bearing from the

Clutch Housing n AG. Volkswagen A ge G do
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⇒ “1.3 Right Seal,
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Installing Outer Race/Tapered Roller Bearing Into the Clutch
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Removing the Inner Races/Tapered Roller Bearings

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– Mount the Press Piece - Multiple Use - 40-105- on the differ‐

ential housing before removing the puller.
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Installing the Inner Races/Tapered Roller Bearings
Note
Inner race/tapered roller bearing for transmission housing and

clutch housing are installed using the same special tools
2. Differential 191
Removing the Outer Race/Tapered Roller Bearing from the

Transmission Housing
A - Counter Support , for example, Puller - Kukko Counterstay -
22/2-
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mission Housing.
hole
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es, in part or in w
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– Support the transmission housing with the Bearing Installer -
Wheel Bearing - 3144- directly under the bearing mount.
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36.0 (long spring pin), no surrounding groove

removing. Refer to
⇒ Fig. ““Spring Pin Without Sur‐
rounding Groove (Long Spring Pin),
Removing: Press Out the Differential
Bevel Gear Axle”“ , page 193 ,
⇒ Fig. ““Spring Pin Without Sur‐
rounding Groove (Long Spring Pin),
Installing”“ , page 193
Allocation, 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)

Spring Pin with Surrounding Groove (Short Spring Pin): Remov‐

ing and Installing
Removing agen
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Cover the inner race/tapered roller bearing in order to prevent
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Spring Pin Without Surrounding Groove (Long Spring Pin), Re‐

moving: Press Out the Differential Bevel Gear Axle
t to the co
Spring pin is sheared off when it is removed.
rrectne
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ss o
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Spring Pin Without Surrounding Groove (Long Spring Pin), In‐ cum
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– Install the new adapter sleeve to dimension -a- = 3.0 mm using Prote AG.
a mandrel -1-.
• The spring pin must not come in contact with the transmission
when the differential housing is installed.
On Some Transmissions, the Thrust Washer Union Has a Ridge

-A-.
Also, the differential housing has a groove -B- all the way around
it.
– Insert thrust washer union with transmission fluid.
– Install the thrust washer union so that it fits into the groove
-B- in the differential housing.
2. Differential 193
Installing the Differential Planetary Gears and Differential Bevel

Gear Axle
– Insert thrust washer union with transmission fluid.
– Install and secure both large differential planetary gears, for
example, with a flange shaft.
– Insert the small differential planetary gears 180° offset and
pivot them into position.
– Press the differential bevel gear axle -arrow A- up to the first
small differential bevel gear.
– Insert threaded pieces -arrow B- into the large n AG. Volkswagen AG do
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ss axle up the end position and
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Installed Position: Tapered Ring Thrust Washer -1-
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The ridges -A- face the tapered ring -1-.
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♦ Press Piece - Multiple Use - 30-205-
♦ Dial Gauge
A new differential adjustment is required when the following com‐
ponents have been replaced:
♦ Transmission Housing
♦ Clutch Housing
♦ Differential Housing
or the

♦ Differential tapered roller bearing

Adjustment Overview. Refer to
– Press tapered roller bearing outer race into transmission hous‐
ing without shim, using Press Piece - Multiple Use - 30-205- .
Refer to
⇒ Fig. ““Installing the Outer Race/Tapered Roller Bearing Into
the Transmission Housing.”“ , page 192 .
Note
Bearing inner race 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 191 .
– Insert differential into clutch housing.
– Position the transmission housing and tighten the 5 bolts to
the tightening specification.
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2. Differential 195
– Attach the Dial Gauge Holder - VW387- and set the dial gauge
to “0” with 1 mm preload.
– Move differential up and down, read off play on dial gauge and AG. Volkswagen
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Bearing Clearance Measured Adjustment Shim Thickness
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Shim Table
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Bearing Play Shim
Measured value Thickness
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(mm) (mm)
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0.303 to 0.449 0.650

0.450 to 0.499 0.700
0.500 to 0.549 0.750
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0.550 to 0.599 0.800

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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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1.050 to 1.099 1.300
1.100 to 1.149 1.350
1.150 to 1.199 1.400
Note

– Remove the transmission housing and remove the tapered

roller bearing outer race from the transmission housing.
A - Counter Support , for example, Puller - Kukko Counterstay -
22/2-
B - Internal Puller 46 to 58 mm , for example Puller - Kukko Internal
- 46-56mm - 21/7-
– Install the shim with theAG
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variations make it possible to find the exact shim thick‐
ce
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ness required.
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⇒ Fig. ““Installing the Outer Race/Tapered Roller Bearing Into
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mission housing.
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♦ Refer to
anism”, page 95 .
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2. Differential 197
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A re-adjustment of the drive axle, output shaft or differential is only
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ot
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ence on transmission adjustment, have been replaced. Note the
h re
following table to avoid unnecessary adjustments:
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to be adjusted:
Input Shaft Output Shaft Differential
. Refer to . Refer to Refer to
rrectness of i
⇒ “1.3 Input ⇒ “2.3 Out‐ ⇒ “2.3 Differ‐
Shaft, Ad‐ put Shaft, ential, Ad‐
l purpos
justing”, Adjusting”, justing”,

page 148 . page 166 . page 194 .
nform
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Replaced part: Transmission Housing x x

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Clutch Housing x x x
com
tion in
Input Shaft x
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Differential tapered roller bearing x
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4th Gear Wheel x

4 Special Tools

VW408A-
- VW 473-
- 30-205-
♦ Bearing Installer - Wheel
Bearing - 3144-
♦ Bearing Installer - Taper
Roller Bearing - 2007-
40-200Nm - VAG1332-
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equipment required
♦ Dial Gauge Holder -
VW387-
Plate - 50mm - VW385/17-
VW407-
- 30-205-
5-50Nm - VAG1331-
♦ -1- Puller - Kukko Internal -
46-56mm - 21/7-
♦ -4- Puller - Kukko Counter‐
stay - 22/2-
♦ Dial Gauge
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♦ Seal Installer - One-Piece

Seal - T10148-
♦ Spindle from the Seal In‐
staller - Driver Set - 3066-
♦ Slide Hammer Set -
VW771-
♦ Slide Hammer Set - Hook -
VW771/37- agen
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ing - VAG1582-
ing - Adapter 3 -
VAG1582/3-
- VW412-
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♦ Slide Hammer Set -

VW771-
♦ Slide Hammer Set - Hook -
VW771/37-
♦ Seal Installer - Flange Shaft
Oil Seal - T10160-
♦ Used Oil Collection and Ex‐
traction Unit - SMN372500-
5-50Nm - VAG1331-
♦ Sealing Grease - G 052 128
A1-
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5 Revision History
DRUCK NUMBER: K0059240221
Fac‐ Edit Job Fe Notes Quality
tory Edi‐ Type ed‐ Checke
Edi‐ tion ba d By
tion ck
12.2 8/14/ Edi‐ Jim H

014 2015 torial
Re‐
view
12.2 02/1 Link Updated ext-rl tags Eric P
014 3/20 Chec
15 king
12.2 01/1 Fac‐ Eric P
014 6/20 tory
15 Up‐
date
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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.
•= Any time the battery has been disconnected on an automatic transmission vehicle, it will be necessary to
reestablish Transmission Control Module (TCM) basic settings using the VAG 1551 Scan Tool (ST).
•= Never work under a lifted vehicle unless it is solidly supported on stands designed for the purpose. Do not support
a vehicle on cinder blocks, hollow tiles or other props that may crumble under continuous load. Never work under a
vehicle that is supported solely by a jack. Never work under the vehicle while the engine is running.
•= For vehicles equipped with an anti-theft radio, be sure of the correct radio activation code before disconnecting the
battery or removing the radio. If the wrong code is entered when the power is restored, the radio may lock up and
become inoperable, even if the correct code is used. Vin
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•= If you are going to work under a vehicleised on the ground, make sure that thearaground
nte is level. Block the wheels to
r
tho
keep the vehicle from rolling. Disconnect the battery negative terminal (ground e ostrap) to prevent others from
u ra
starting the vehicle while youss aare under it. c
ce
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un
pt
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d
•= Do not attempt to work on your vehicle if you do not feel well. You increase the danger of injury to yourself and
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others if you are tired, upset or have taken medicine or any other substances that may impair you or keep you from
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•= Never run the engine unless the work area is well ventilated. Carbon monoxide (CO) kills.
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•= Always observe good workshop practices. Wear goggles when you operate machine tools or work with acid. Wear
goggles, gloves and other protective clothing whenever the job requires working with harmful substances.
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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
machine tools or running engines. If your hair, clothing, or jewelry were to get caught in the machinery, severe
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injury could result.

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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
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only once and are unreliable and may fail if used a second time. This includes, but is not limited to, nuts, bolts,
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washers, circlips and cotter pins. Always follow the recommendations in this manual - replace these fasteners with
n in
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new parts where indicated, and any other time it is deemed necessary by inspection.
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© 2002 Volkswagen of America, Inc. cted agen
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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
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grinding, sanding, or by cleaning with compressed
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does asbestos fibers and asbestos dust.
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Breathing asbestos can cause serious y Vdiseases such as asbestosis orot cancer,
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•= Finger rings should be removedau so that they cannot cause electrical shorts, getorcaught
ac in running machinery, or be
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crushed by heavy parts.
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•= Before starting a job, make certain that you have all the necessary tools and parts on hand. Read all the
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instructions thoroughly; do not attempt shortcuts. Use tools that are appropriate to the work and use only
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replacement parts meeting Volkswagen specifications. Makeshift tools, parts and procedures will not make good
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•= Catch draining fuel, oil or brake fluid in suitable containers. Do not use empty food or beverage containers that
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might mislead someone into drinking from them. Store flammable fluids away from fire hazards. Wipe up spills at
once, but do not store the oily rags, which can ignite and burn spontaneously.
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•= Use pneumatic and electric tools only to loosen threaded parts and fasteners. Never use these tools to tighten
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fasteners, especially on light alloy parts. Always use a torque wrench to tighten fasteners to the tightening torque
listed.
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•= Keep sparks, lighted matches, and open flame away from the top of the battery. If escaping hydrogen gas is
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ignited, it will ignite gas trapped in the cells and cause the battery to explode.
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•= Be mindful of the environment and ecology. Before you drain the crankcase, find out the proper way to dispose of
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the oil. Do not pour oil onto the ground, down a drain, or into a stream, pond, or lake. Consult local ordinances that
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•= The air-conditioning (A/C) system is filled with a chemical refrigerant that is hazardous. The A/C system should be ht. rig
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automotive chemical refrigerants.
•= 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.
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.
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Page 3 of 3
© 2002 Volkswagen of America, Inc.
Version 1.0

GOLF MK7 Manual Transmission

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Service

Service Department. Technical Information

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Copyright © 2015 Volkswagen AG, Wolfsburg D4B8041661E

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

1.5 Clutch Pedal, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

1.6 Bearing Bushing, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

1.7 Over-Center Spring, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

1.8 Return Spring, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

1.9 Mounting Bracket, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

1.10 Clutch Master Cylinder, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

1.11 Clutch Slave Cylinder, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

1.12 Clutch Mechanism Lines, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

1.14 Clutch Master and Clutch Slave Cylinder, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

1.15 Clutch Position Sensor G476 , Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . 34

2.2 Clutch, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

2.3 Transmission Tightening Specifications . . . . . . w . a. g.e.n.A.G.. V. o.lk. s.w.a.ge. n. A.G. d.o.e. . . . . . . . . . . . . . . 86

5.6 Overview - Input Shaft, Output Shafts, Differential, Gearshift Rods . . . . . . . . . . . . . . . . . . 97

5.10 Transmission Housing Cover and 5th Gear, Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

6.1 Overview - Transmission Housing and Clutch Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119

6.2 Transmission Housing, Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

6.3 Clutch Housing, Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122

35 - Gears, Shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141

39 - Final Drive, Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183

5 Revision History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204

00 – General, Technical Data

1.1 Start/Stop System Safety Precautions

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

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

2 Rep. Gr.00 - General, Technical Data

♦ Clean the contact surfaces when installing brackets as well as

♦ Allocate the bolts and other components. Refer to the Parts

♦ Fill the transmission fluid when repairing the manual trans‐

Sealing Compound - AMV 188 200 03- .

♦ Replace the circlips.

proper thread cutter is used during cleaning, and the thread

does not get damaged.

♦ Insert the bearings with transmission fluid.

♦ Install the new tapered roller bearings. It is not necessary to

♦ Install needle bearings with lettered side (thicker metal) racing

shaft. Use tapered roller bearings from the same manufactur‐

♦ To install, warm the inner races/tapered roller bearing to ap‐

♦ Do not interchange outer and inner bearing races with those

4 Rep. Gr.00 - General, Technical Data

♦ Do not interchange them. When reusing synchronizer rings,

♦ The coating on the synchronizer rings must not be damaged.

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

coloring (from overheating)«.

♦ Check taper of drive gear for »grooves« and »scoring«.

♦ Coat the synchronizing with transmission fluid and then install.

Toothed Gears, Synchronizer Hubs

4.1 Transmission/Engine Allocation

4.1.1 Transmission/Engine Allocation, Golf

Manufactured from 11/2014

Allocation Engine 1.8L - 125 kW

Ratio Final Drive 61 : 18 = 3.389

Drive Axle flange diameter 100 mm

Refer to the Parts Catalog for the following information:

Manual transmission capacity Refer to ⇒ Fluid Capacity Tables; Rep. Gr. 03

6 Rep. Gr.00 - General, Technical Data

4.3 Gear Ratio Calculation

8 Rep. Gr.00 - General, Technical Data

⇒ “6.1 Component Location Overview - Electrical Components”,

6.1 Component Location Overview - Electri‐