Workshop Manual Transporter 2016 8-29

Service
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Service Department. Technical Information

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00 - Technical data
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30 - Clutch
34 - Controls, housing
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35 - Gears, shafts
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39 - Final drive - differential
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Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.
All rights reserved.

No reproduction without prior agreement from publisher.
Copyright © 2019 Volkswagen AG, Wolfsburg D4B80561BF3

6-speed manual gearbox 0A5 - Edition 06.2019
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Safety measures when working on vehicles with a start/stop system . . . . . . . . . . . . . . . . 1
1.2 Safety precautions when using testers and measuring instruments during a road test . . . . 1
2 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.1 Gearbox identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.2 Identification of bevel box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3 Repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.1 General repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4.1 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4.2 Allocation gearbox - engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4.3 Calculation of gear ratios . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
5 Overview - power transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
5.1 Overview - power transmission - front-wheel drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
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5.2 Overview - power transmission - all-wheel drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
6 Electrical components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
6.1 Overview of fitting locations - electrical components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
30 - Clutch . . . . . . . . . . . . . . . . . . .n.AG. ..V.olk.s.wa. g.en. A.G. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

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1.1 Assembly overview ris - pedal cluster . . . . . . . . . . . . . . . . . . n.te.e. . . . . . . . . . . . . . . . . . . . . . . .
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1.2 Assembly overviewuth - clutch hydraulics . . . . . . . . . . . . . . . . . o.r a. . . . . . . . . . . . . . . . . . . . . . 21
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1.3 Assembly overview - clutch release mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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1.4 Removing and installing clutch pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

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1.5 Removing and installing over-centre spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

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1.6 Removing and installing mounting bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

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

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1.8 Removing and installing clutch slave cylinder together with release bearing . . . . . . . . . . . . 33
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1.9 Removing and installing bleeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

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1.10 Bleeding clutch mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

1.11 Removing and installing clutch pedal switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
1.12 Checking clutch master cylinder and clutch slave cylinder . . . . . . . . . . . . . . . . . . . . . . . . 37
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2 Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
2.1 Assembly overview - clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
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2.2 Removing and installing clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

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34 - Controls, housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
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1 Bevel box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
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1.1 Assembly overview - bevel box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

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1.2 Removing bevel box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

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1.3 Installing bevel box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

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1.4 Checking gear oil level in bevel box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
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1.5 Installing repair kit for stub shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
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2 Selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
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2.1 Installation position - selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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2.2 Assembly overview - gear knob and cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

2.3 Assembly overview - Gear lever and selector housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
2.4 Assembly overview - Selector cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
2.5 Removing and installing selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
2.6 Adjusting selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
2.7 Renewing selector shaft seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Contents i
3 Removing and installing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

3.1 Specified torques for gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
3.2 Removing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
3.3 Installing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
4 Assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
4.1 Assembly overview - assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
5 Transporting gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
6 Dismantling and assembling gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
6.1 Schematic overview - gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
6.2 Differentiating between gearboxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
6.3 Assembly overview - gearbox housing and selector mechanism . . . . . . . . . . . . . . . . . . . . 109
6.4 Assembly overview - selector unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
6.5 Assembly overview - input shaft, output shafts, differential, selector rods . . . . . . . . . . . . . . 114
6.6 Assembly overview - selector forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
6.7 Dismantling and assembling gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
7 Gearbox housing, clutch housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
7.1 Assembly overview - gearbox housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
7.2 Assembly overview - clutch housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
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7.3 Repairing gearbox housing ................................................ 150
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Checking gear oil level, gearboxes “with” oil filler plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
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9.2 Checking gear oil level, gearboxes “without” oil filler plug . . . . . . . . . . . . . . . . . . . . . . . . . . 157
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35 - Gears, shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159

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1 Input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159

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1.1 Assembly overview - input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159

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1.2 Dismantling and assembling input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163

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2 Output shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175

2.1 Assembly overview - output shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
2.2 Dismantling and assembling output shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
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2.3 Adjusting output shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210

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39 - Final drive - differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211

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1 Oil seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211

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1.1 Overview of fitting locations - seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211

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1.2 Renewing left seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212

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1.3 Renewing right oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215

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1.4 Renewing input shaft seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220

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2 Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
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2.1 Assembly overview - differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
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2.2 Dismantling and assembling differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
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2.3 Adjusting differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
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3 Components of bevel box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
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3.1 Renewing bevel box seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
ii Contents
00 – Technical data
1 Safety information
(VRL013199; Edition 06.2019)
⇒ “1.1 Safety measures when working on vehicles with a start/
stop system”, page 1
⇒ “1.2 Safety precautions when using testers and measuring in‐
struments during a road test”, page 1
1.1 Safety measures when working on vehicles with a start/stop system

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– Deactivate start/stop system by switching off the ignition.

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1.2 Safety precautions when using testers and measuring instruments during
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Risk of injury caused by unsecured testing and measuring instru‐
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– Secure testing and measuring instruments on the rear seat.

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– Have a second person operate the test and measuring equip‐

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1. Safety information 1
2 Identification
⇒ “2.1 Gearbox identification”, page 2
⇒ “2.2 Identification of bevel box”, page 3
2.1 Gearbox identification

Location on gearbox
♦ Code letters and production date -arrow 1-
♦ Manual gearbox 0A5 -arrow 2-
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Identification code Day Month Year 2004 of manufacture
Additional data depend on manufacture.
Note
The gearbox code is also included on the vehicle data stickers.
2 Rep. gr.00 - Technical data

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Codes and production dates of bevel box

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Example ZSB.09N. 123456 SDP KQK 201108

409.053.C
-1- -2- -3- -4- -5-
Part number Serial number Manufacturer’s Code Production date
(6 digits) code (day/month/
year)
2. Identification 3
3 Repair instructions
⇒ “3.1 General repair instructions”, page 4
3.1 General repair instructions

To ensure flawless and successful gearbox repairs, the greatest
care and cleanliness as well as the use of good and proper tools
are essential. Of course, the basic rules for safety also apply dur‐
ing repair work.
A number of general notes on the individual repair procedures,
which can otherwise be found in the relevant sections of the man‐
ual, are summarised here. They apply for this particular workshop
manual.
Special tool
For a complete list of special tools used in this workshop manual,
see ⇒ "Workshop equipment and special tools"
Gearbox
♦ When installing the manual gearbox, ensure that the dowel
sleeves between the engine and gearbox are correctly seated.
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♦ When installing mounting brackets or waxed components,
clean the contact surfaces. Contact surfaces must be free of
wax and grease.
♦ Allocate bolts and other components using the ⇒ Electronic
parts catalogue (ETKA) .
♦ If manual gearbox is repaired, fill with gear oil; fill volume
⇒ page 8 .
♦ If manual gearbox is replaced, check oil level in manual gear‐
box and top up if necessary ⇒ page 156 .
♦ If bevel box is replaced, check axle oil level in bevel box and
top up if necessary ⇒ page 51 .
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Renew gaskets, seals and O-rings after ieach se
d b removal. ara
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Seals for flange shafts, drive shaft and
s a selector shaft are also re‐
ut ra
c
ferred to as oil seals. s
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Rep. gr.00 - Technical data Prote AG.
After removing gaskets and seals, always inspect contact surfa‐

ces of housing and shaft for burrs resulting from removal or for
other signs of damage.
♦ Thoroughly clean parting surfaces and apply sealant ⇒ Elec‐
tronic parts catalogue (ETKA) .
♦ Before installing radial shaft seals, lightly oil outer diameter
and half-fill space between sealing lips -arrow- with sealing
grease .
♦ Assign sealing grease for radial oil seal using ⇒ Electronic
parts catalogue (ETKA) .
♦ The open side of the oil seals faces toward the side with fluid
filling.
♦ Lightly oil O-rings before installing; this prevents the rings be‐
ing crushed when inserted.
Sealant
♦ Thoroughly clean housing joint surfaces before applying seal‐
ing paste .
♦ Evenly apply a thin coat of sealing paste ⇒ Electronic parts
satelettronica
catalogue (ETKA) .
♦ Breather holes must remain free of sealing paste .
Locking devices
AG. Volkswagen AG d
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♦ Do not overstretch retaining rings.

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♦ Installation position for retaining rings: At the top, the ring is ab

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»narrower« and its installation position therefore as well. This wit

, is n
make it possible for the pliers to gain a better grip during re‐
h re
hole
moval and installation.

spec
es, in part or in w
♦ Renew retaining rings which have been damaged or over‐

t to the co
stretched after removal.

♦ Retaining rings must locate properly in grooves.
rrectness of i
♦ Renew spring pins. Installation position: slit -A- should be in

l purpos
line with the line of force -arrow-.

nform
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Prote AG.
3. Repair instructions 5
Nuts and bolts

♦ Loosen and tighten securing bolts and nuts for covers and
housings diagonally with no specified tightening sequence.
♦ Do not cant especially delicate parts, such as clutch pressure
plates. Loosen and tighten bolts and nuts alternately and in
stages.
♦ Specified torques given are for unoiled nuts, bolts and screws.
♦ Renew self-locking bolts and nuts after each removal.
♦ Ensure with threaded connections that contact surfaces as
well as nuts and bolts are rewaxed only after assembly, if nec‐
essary.
♦ Clean threads of bolts which are to be installed with locking
fluid using a wire brush. Then insert bolts coated with locking
fluid ⇒ Electronic parts catalogue (ETKA) .
♦ Threaded holes into which self-locking bolts or bolts coated
with locking fluid are screwed, must be cleaned (e.g. with a
thread tap). Otherwise there is a danger of bolts shearing
when subsequently being removed.
satelettronica
♦ Check pitch of thread, to ensure correct thread chaser is used
to clean threads and to ensure the threads are not damaged.
Mountings
♦ Install all bearings, apart from new tapered roller bearings,
with gear oil.
♦ Install new tapered roller bearings as supplied and do not lu‐
bricate additionally.
♦ Install needle bearings with lettered side (thicker metal) to‐
wards fitting tool.
♦ Tapered roller bearings fitted to one shaft must be renewed as
a set. Use same make of bearings.
wage es n
♦ Before installing, heat tapered roller bearing inner races to y Volks ot g
ua
about 100 °C using inductive heater - VAS 6414- . ise
db ran
r tee
ho
♦ Do not interchange outer or inner races of bearings
sa
uof
t
the or
ac
same size. The bearings are matched in pairs. s
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pt
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Shims
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♦ Measure shims at several points with a micrometer. The var‐

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ious tolerances make it possible to achieve the exact shim

, is n
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thickness required.
hole
spec
♦ Check for burrs and damage.

es, in part or in w
t to the co
♦ Install only flawless shims.

rrectness of i
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Prote AG.

Synchro-rings
♦ Do not interchange them. When reusing synchro-rings, always
fit to the same synchromeshed gear.
♦ Check for wear and renew if necessary.
♦ Check grooves -arrow 1- of synchro-ring -A- and inner ring for
flat spots (worn grooves).
♦ If synchro-rings are coated, coating must not be damaged.
♦ If an intermediate ring -B- is installed, check the outer friction
surface -arrow 2- and inner friction surface -arrow 3- of this
intermediate ring for »scoring«, »signs of abnormal wear« and
»blue discolouration (due to overheating)«.
♦ Check the cone of the synchromeshed gear for »scoring« and
»signs of abnormal wear«.
♦ Moisten synchromesh mechanism with gear oil before instal‐
ling.
Gears and synchro-hubs
♦ Clean before pressing on. Heat to approx. 100°C using induc‐
tive heater - VAS 6414- .
satelettronica
♦ Observe installation position
Synchromeshed gears
♦ After assembly, check synchromeshed gears for slight play, or
for freedom of movement.
Clutch AG. Volkswagen AG d
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♦ Ensure that the pressure plate does d by Vnot cant: loosen and tight‐ gu
ara
en bolts alternately and diagonally
orise and in several gradual nte
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stages. auth
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♦ In order to reduce the smell of a burned clutch, the clutch
ce
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nl
pt
housing as well as the stopping face of the flywheel must be

du
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itte
thoroughly cleaned with a cloth.

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3. Repair instructions 7
4 Technical data
⇒ “4.1 Capacities”, page 8
⇒ “4.2 Allocation gearbox - engine”, page 8
⇒ “4.3 Calculation of gear ratios”, page 11
4.1 Capacities
⇒ “4.1.1 Capacities, manual gearbox”, page 8
⇒ “4.1.2 Capacities, bevel box”, page 8
4.1.1 Capacities, manual gearbox lksw

agen
AG. Volkswagen AG d
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Capacity of manual 2.7 litrerised
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Gear oil specification ⇒ Electronic parts
s catalogue (ETKA) .
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4.1.2 Capacities, bevel box
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Capacity of bevel 0.8 l
satelettronica
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box
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Axle oil specification ⇒ Electronic Parts Catalogue (ETKA)
spec
es, in part or in w
t to the co
4.2 Allocation gearbox - engine
⇒ “4.2.1 Allocation gearbox - engine, front-wheel drive”,
rrectness of i
page 8
l purpos
⇒ “4.2.2 Allocation gearbox - engine, all-wheel drive”, page 9
4.2.1 Allocation gearbox - engine, front-wheel drive
nform
ercia
Manual gearbox 6-speed 0A5, front-wheel drive

m
at
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ion
Identification code PSV PSX PSZ
c
in t
or
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Allocation Model Transporter 2016 ► Transporter 2016 ► Transporter 2016 ►

at
do
priv
Engine 2.0 l - 62 kW 2.0 l - 150 kW 2.0 l - 110 kW FSI

um
for
turbo diesel turbo diesel

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2.0 l - 110 kW Cop py
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Ratio: Z2 : Z1 Final drive I 69 : 15 = 4.600 69 : 15 = 4.600 69 : 15 = 4.600
co lksw
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cted agen
Prote AG.
Final drive II 69 : 21 = 3.286 69 : 21 = 3.286 69 : 21 = 3.286
Final drive III 69 : 19 = 3.632 69 : 19 = 3.632 69 : 19 = 3.632
• Final drive I for 1st and 2nd gear
• Final drive II for 3rd and 4th gear
• Final drive III for reverse gear
• 5th and 6th gears are located on the input shaft.
Glean following data from ⇒ Electronic parts catalogue (ETKA) :
♦ Production dates
♦ Individual gear ratios
♦ Allocation of drive shaft flanges
♦ Allocation of clutch


Identification code RLF RLH RLJ
Allocation Model Transporter 2016 ► Transporter 2016 ► Transporter 2016 ►
Engine 2.0 l - 103 kW 2.0 l - 103 kW 2.0 l - 132 kW
turbo diesel turbo diesel turbo diesel
Final drive II 69 : 21 = 3.286 69 : 21 = 3.286 69 : 21 = 3.286
Final drive III 69 : 19 = 3.632 69 : 19 = 3.632 69 : 19 = 3.632
satelettronica

Identification code RLM
Allocation Model Transporter 2016 ►
Engine 2.0 l - 110 kW FSI
Ratio: Z2 : Z1 Final drive I 69 : 15 = 4.600
Final drive II 69 : 21 = 3.286
Final drive III
. Volkswagen AG
69 : 19 = 3.632
gen AG does
• Final drive I for 1st and
Vol
ks2nd gear
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• Final drive II for
or 3rd and 4th gear
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• Final drivessIII
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for reverse gear c
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4.2.2 Allocation gearbox - engine, all-wheel drive

Manual gearbox 6-speed 0A5, four-wheel drive
nform
ercia
Identification code NTH PAQ PAR

m
a
com
tio
Allocation Model Transporter 4MO‐ Transporter 4MO‐ Transporter 4MO‐

n in
r
TION 2016 ► TION 2016 ► TION 2016 ►

te o
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turbo diesel
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turbo diesel turbo diesel

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2.0 l - 103 kW
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4. Technical data
agen
Prote AG.

Identification code NTH PAQ PAR
Final drive II 69 : 21 = 3.286 69 : 21 = 3.286 71 : 19 = 3.737
Final drive III 69 : 19 = 3.632 69 : 19 = 3.632 71 : 17 = 4.177
♦ Allocation of rear final drive
satelettronica
Identification code PAS PAW PSW
TION 2016 ► TION 2016 ► TION 2016 ►
AG. Volkswagen AG d
Ratio: Z2 : Z1 Final drive I 69 : 15 = l4.600
ksw
agen
69 : 15 = 4.600
oes
no 69 : 15 = 4.600
o t gu
yV
Final drive II 69ris:ed21
b
= 3.286 69 : 21 = 3.286 ara 69 :
nte 21 = 3.286
o e
Final drive III au 69 : 19 = 3.632
th
69 : 19 = 3.632 69o:r a19 = 3.632
ss c
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Identification code PSY RLG RLK

do
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TION 2016 ► TION 2016 ► TION 2016 ►

t.
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Ratio: Z2 : Z1 Final drive I 69 : 15 = 4.600 69 : 15 = 4.600
agen
Prote AG.
69 : 15 = 4.600
Final drive II 69 : 21 = 3.286 69 : 21 = 3.286 69 : 21 = 3.286


Identification code PSY RLG RLK
Final drive III 69 : 19 = 3.632 69 : 19 = 3.632 69 : 19 = 3.632
satelettronica
Identification code RLL
Allocation Model Transporter 4MOTION 2016 ►
Engine 2.0 l - 132 kW
turbo diesel
Ratio: Z2 : Z1 Final drive I 69 : 15 = 4.600
. Volkswagen AG
Final drive II wage
n AG 69 : 21
does= 3.286
Volks not
Final drive III ed by 69 : 19 = 3.632
gu
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• Final drive I for 1st and 2nd gear ut
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• Final drive II for 3rd and 4th gear ce
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4.3 Calculation of gear ratios

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Example:
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6th gear Final drive

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Drive gear ZG1 = 40 ZA1 = 21 yi

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by lksw
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Prote AG.
teeth on driven gear)
iG = gear ratio = ZG2: ZG1= 29 : 40 = 0.725
4. Technical data 11
iA = Final drive ratio = ZG2 : ZG1 = 69 : 21 = 3.286

itotal = overall ratio = iG x iA = 0.725 x 3.286 = 2.382
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
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or eo
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satelettronica
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mercia
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tion in
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Cop py
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AG. Volkswagen AG d
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ara
ed
horis Transporter
nte
e o 2016 ➤
aut 6-speed manual gearbox 0A5 - Editionr a06.2019
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5 Overview - power transmission
itte
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⇒ “5.1 Overview - power transmission - front-wheel drive”,
wit
is n
page 13
h re
ole,
⇒ “5.2 Overview - power transmission - all-wheel drive”,
spec
page 15
t to the co
5.1 Overview - power transmission - front-wheel drive
rrectne
Designation:
-Arrows- point in direction of travel.
ss o
cial p
f in
1 - Engine
form
mer
atio
2 - Clutch
om
n
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i
or
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3 - Manual gearbox
thi
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4 - Input shaft
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5 - Output shaft for 1st/
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2nd gear op
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6 - Output shaft for reverse py by
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7 - Output shaft for 3rd/
4th gear
8 - Differential
Ratio
5. Overview - power transmission 13

I - 1st gear
II - 2nd gear
III - 3rd gear
IV - 4th gear
V - 5th gear
VI - 6th gear
R - Reverse gear
A - Final drive
satelettronica
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
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aut ra
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nl
pt
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es, in part or in w
t to the co
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Prote AG.

5.2 Overview - power transmission - all-wheel drive

Designation:
1 - Engine
2 - Clutch
3 - Manual gearbox
4 - Input shaft
2nd gear
6 - Output shaft for reverse
gear
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7 - Output shaft for 3rd/ y Vo lks ot g
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4th gear ir se
d b ran
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8 - Bevel box aut or
ac
ss
9 - Differential
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10 - Propshaft
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11 - Haldex coupling
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12 - Rear final drive
h re
hole
spec
13 - Differential
es, in part or in w
t to the co
rrectness of i
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Prote AG.
5. Overview - power transmission 15

I - 1st gear
II - 2nd gear
III - 3rd gear
IV - 4th gear
V - 5th gear
VI - 6th gear
R - Reverse gear
A - Final drive AG. Volkswagen AG d
agen oes
olksw not
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W1 - Drive assembly of bevel d b ara
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box thor eo
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W2 - Drive assembly of rear fi‐ ss
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nal drive
nl
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c
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ate
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Prote AG.

6 Electrical components
⇒ “6.1 Overview of fitting locations - electrical components”, page
17
6.1 Overview of fitting locations - electrical

components
⇒ “6.1.1 Overview of fitting locations - electrical components,
manual gearbox”, page 17
⇒ “6.1.2 Overview of fitting locations – electrical components,
clutch mechanism”, page 17
6.1.1 Overview of fitting locations

agen
AG. -
Voelectrical
lkswagen AG
does
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components, manualdb
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gearbox not
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Reversing light switch - F4- -2
ut -
ho or
a ac
ss
Fitting location: in area of selector unit next to starter -3-.
ce
le
un
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Removing and installing reversing light switch - F4-
d
itte
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⇒ page 109 .
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ab
satelettronica
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Gearbox neutral position sender - G701- -arrow -
l purpos
Fitting location: in area of selector unit beneath reversing light

switch - F4- next to starter.
nform
ercia
Removing and installing gearbox neutral position sender - G701-

m
a
com
ti
⇒ page 109 .
on in
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6.1.2 Overview of fitting locations – electrical
components, clutch mechanism
Clutch pedal switch - F36- -1-
Fitting location: on pedal cluster.
Removing and installing clutch pedal switch - F36- ⇒ page 36
Note
♦ The clutch pedal switch - F36- is not fitted in all vehicles.

♦ The clutch position sender - G476- may be installed as an al‐
ternative. The clutch position sender and clutch master cylin‐
der form one unit and cannot be replaced individually ⇒
Electronic Parts Catalogue (ETKA) . Removing and installing
clutch master cylinder ⇒ page 28 .
6. Electrical components 17
30 – Clutch
1 Clutch operation
Volkswa
⇒ “1.1 Assembly overview - pedal
swa
cluster”,
gen AG page 18
. gen AG
does
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⇒ “1.2 Assembly overview ed b- clutch hydraulics”, page 21 ara
nte
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⇒ “1.3 Assembly overview
aut - clutch release mechanism”, ra
c
page 23 ss
ce
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nl
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⇒ “1.4 Removing and installing clutch pedal”, page 23
an
itte
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⇒ “1.5 Removing and installing over-centre spring”, page 24
ility
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⇒ “1.6 Removing and installing mounting bracket”, page 25
wit
, is n
h re
hole
⇒ “1.7 Removing and installing clutch master cylinder”,
spec
page 28
es, in part or in w
t to the co
⇒ “1.8 Removing and installing clutch slave cylinder together with
release bearing”, page 33
rrectness of i
⇒ “1.9 Removing and installing bleeder”, page 34
satelettronica
l purpos
⇒ “1.10 Bleeding clutch mechanism”, page 35

⇒ “1.11 Removing and installing clutch pedal switch”, page 36
nf
ercia
o
⇒ “1.12 Checking clutch master cylinder and clutch slave cylin‐
rm
m
atio
der”, page 37
om
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c
1.1 Assembly overview - pedal cluster

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♦ Grease all bearing points and contact surfaces.
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♦ Allocate grease using ⇒ Electronic parts catalogue (ETKA) . cted agen
Prote AG.
18 Rep. gr.30 - Clutch

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by Transporter ara 2016 ➤
ise nte
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ho 6-speed manual gearbox 0A5 - Edition 06.2019 eo
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s
1 - Bolt
ce
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nl
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❑ For mounting bracket to
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bulkhead
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❑ To unscrew, remove
wit
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plenum chamber cover.
h re
hole
❑ 25 Nm
spec
es, in part or in w
2 - Bulkhead
t to the co
❑ With support for mount‐
ing bracket
rrectness of i
3 - Mounting bracket
❑ For mounting clutch l purpos
pedal
nf
ercia
❑ Removing and installing
or
⇒ page 25
m
m
atio
om
4 - Nut
n in
or c
thi
❑ For mounting bracket to
te
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bulkhead
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❑ Renew after removal
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❑ 25 Nm t. Cop py
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5 - Mounting bracket yri
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❑ For mounting accelera‐ cted agen
Prote AG.
tor pedal and brake ped‐
al
⇒ page 25
6 - Nut
❑ 25 Nm
7 - Nut
❑ For connecting plate on
clutch pedal mounting
bracket.
❑ 9 Nm
8 - Nut
❑ For connecting plate on brake pedal mounting bracket.
❑ 9 Nm
9 - Connecting plate
10 - Clutch pedal switch - F36-
❑ Installed in some vehicles
❑ Removing, installing and adjusting ⇒ page 36
11 - Clutch pedal
❑ Remove after removing over-centre spring
❑ Removing and installing ⇒ page 23
12 - Support
❑ Removing and installing ⇒ Item 4 (page 21)
13 - Nut
❑ For securing clutch master cylinder to mounting bracket
1. Clutch operation 19
❑ 25 Nm
14 - Clutch master cylinder
❑ On vehicles with clutch position sender - G476- , the clutch master cylinder and the clutch position sender
- G476- are one unit. They cannot be renewed individually ⇒ Electronic Parts Catalogue (ETKA) .
15 - Supply hose
16 - Over-centre spring
17 - Nut
❑ For mounting bracket to bulkhead
❑ 25 Nm
18 - Bolt
19 - Seal
❑ Between mounting bracket and bulkhead
❑ Fit onto clutch master cylinder
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1.2 Assembly overview - clutch hydraulics
Note
♦ Grease all bearing points and contact surfaces.

♦ Allocate grease using ⇒ Electronic parts catalogue (ETKA) .
1 - Brake fluid reservoir

2 - Supply hose
3 - Bulkhead
4 - Support agen
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❑ Remove s
⇒ page 22
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⇒ page 22
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⇒ page 23
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6 - Clutch master cylinder

❑ Removing and installing t to the co
⇒ page 32
rrectness of i
7 - Clip
l purpos
❑ Pull out clip to stop to re‐

move and install pipe/
hose line
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8 - Seal
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❑ Renew if damaged
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❑ Pull onto line connection

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9 - Pipe/hose line
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logue (ETKA)
10 - Bracket
❑ Secured to bulkhead
11 - Bracket
❑ Secured to body
12 - Seal
❑ Insert with brake fluid
❑ For allocation refer to ⇒ Electronic parts catalogue (ETKA)
13 - Bleeder
14 - Clip
❑ Pull out clip as far as stop to remove and install pipe/hose line or bleeder.
15 - Bleeder valve
❑ Bleeding clutch mechanism ⇒ page 35
❑ Flattened on both sides: close as far as stop
❑ With hexagon: 4.5 Nm.
16 - Dust cap n AG. Volkswagen AG do
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18 - Gearbox
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Levering off retainer -A- in -direction of arrow-
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spec
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Pressing operating rod/clutch master cylinder into retainer -A- in

thi
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1.3 Assembly overview - clutch release mechanism
1 - Gearbox
2 - Input shaft seal
❑ Renewing ⇒ page 220
3 - Clutch slave cylinder with gen AG. Volkswagen AG d
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slave cylinder
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⇒ page 33
spec
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4 - Bolt
t to the co
❑ Qty. 3
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❑ 15 Nm
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5 - Seal
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❑ Insert with brake fluid at

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1.4 Removing and installing clutch pedal

Special tools and workshop equipment required
♦ Torque wrench - V.A.G 1331-
Removing
– Remove clutch pedal mounting bracket ⇒ page 25 .
– Remove over-centre spring ⇒ page 24 .
– Separate clutch pedal from clutch master cylinder

⇒ page 32 .
– Remove nut -A-.
– Unscrew bolt and remove clutch pedal.
Installing
Install in reverse order of removal, observing the following:
– The retainer -A- must be fitted to the clutch master cylinder

operating rod -B-.
– Press clutch pedal in -direction of arrow- until it engages. En‐
sure that it is properly locked.
– Install over-centre spring ⇒ page 24 .
satelettronica
Specified torques
♦ ⇒ “1.1 Assembly overview - pedal cluster”, page 18
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1.5 Removing and installing over-centre au ac
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spring
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Removing
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– Remove clutch pedal mounting bracket ⇒ page 25 .

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– Carefully clamp lower section of mounting bracket/clutch ped‐

hole
spec
al in vice with protective jaw pads.

es, in part or in w
t to the co
– Press clutch pedal as far as stop.

– Compress over-centre spring -B- using pliers -A-.
rrectness of i
– First remove over-centre spring from bar -C- of mounting

bracket.
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– Then guide away from clutch pedal pin.

nform
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– Carefully release tension from over-centre spring.

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– Press clutch pedal as far as stop.
– Compress removed over-centre spring -B- using pliers -A-.
• The mounting area for the clutch pedal pin must be horizontal.
– First fit over-centre spring in clutch pedal pin.
– Then lock over-centre spring into mounting bracket extension
-C-.
– Carefully release tension from over-centre spring.
WARNING
If over-centre spring is improperly installed, it will jump uncon‐

trolled out of mounting bracket.
♦ Cover over-centre spring ewith a cloth.
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♦ Check function of
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♦ Operate clutch
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Specified torques
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1.6 Removing and installing mounting

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

♦ Hose clamps to 25 mm - 3094-
rrectness of i
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Removing ss a c
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– Disconnect battery earth strap ⇒ Electrical system; Rep. gr.
pt
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27 ; Battery; Disconnecting and connecting battery .
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– Remove battery and battery cover ⇒ Electrical system; Rep.
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gr. 27 ; Battery; Removing and installing battery .
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– Remove dash panel insert ⇒ Electrical system; Rep. gr. 90 ;
hole
spec
satelettronica
Dash panel insert; Assembly overview - dash panel insert .
es, in part or in w
t to the co
– Remove lower cover on driver side ⇒ General body repairs,
interior; Rep. gr. 68 ; Compartments/covers; Removing and
installing dash panel end trim on driver side .
rrectness of i
– Unscrew nut -arrow- for mounting bracket through opening of
l purpos
removed dash panel insert.

– Remove plenum chamber cover ⇒ General body repairs, ex‐
nform
ercia
terior; Rep. gr. 50 ; Bulkhead; Assembly overview - plenum

chamber cover .
m
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Risk of leaking brake fluid.
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♦ Lay a lint-free cloth under clutch master cylinder. Prote AG.
– To facilitate accessibility to clutch master cylinder, pull off side

battery cover from bulkhead.
– Clamp off supply hose -1- to clutch master cylinder with hose
clamp - 3094- .
– Pull off supply hose -1- from connection -arrow- of clutch mas‐
ter cylinder -2-.
– Pull out clip -3- for pipe/hose line to stop.
– Pull out pipe/hose line -4- from clutch master cylinder -2- and
seal.

Note
♦ In addition to clamping off, the sealing tool - T10249/1- can be

used to clamp off the supply hose.
♦ Clamping off the plastic supply hose with the hose clamp -
3094- will cause a permanent deformation.
♦ However, this does not damage the supply hose.
♦ After removing the hose clamp - 3094- , the supply hose must
be returned to its original shape.
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– In plenum chamber, yV
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-2-. ir se
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– Unscrew aut bolt -2- for clutch pedal mounting bracket. or a
c
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– If fitted, remove clutch pedal switch - F36- ⇒ page 36 .
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pt
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– If fitted, disconnect electrical connector from clutch position
y li
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sender - G476- .
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Note
hole
spec
es, in part or in w
The electric wire is located on the right-hand side of the mounting

bracket for clutch pedal and is clipped in on the mounting bracket. t to the co
rrectness of i
– Remove connecting plate ⇒ Item 9 (page 19) between clutch

pedal mounting bracket and brake pedal mounting bracket.
l purpos
– Unscrew nut -arrow- for clutch pedal mounting bracket.

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– Detach relay carrier with diagnostic connection -1- from cross-

tube for dash panel insert and place carefully above.
– Pull clutch pedal mounting bracket -2- from stud bolts and
carefully remove.
Installing
– If fitted, install clutch pedal switch - F36- ⇒ page 36 .
– Tighten nut -arrow- of mounting bracket.

– Install dash panel insert ⇒ Electrical system; Rep. gr. 90 ;
Dash panel insert; Assembly overview - dash panel insert .
– Install lower cover on driver side ⇒ General body repairs, in‐
terior; Rep. gr. 68 ; Compartments/covers; Removing and
– Install noise insulation ⇒ General body repairs, exterior; Rep.
gr. 50 ; Bulkhead; Assembly overview - plenum chamber cov‐
er .
– Press in pipe/hose line -4- at connection of clutch master cyl‐

inder -2- until securing clip -3- engages audibly.
– Test line by tugging on it.
– Fit supply hose -1- on connection -arrow- of clutch master cyl‐
inder. agen
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– After removing hose clamps - 3094- , return supply hose to d bits
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– If removed, fit side battery cover on stud of bulkhead.
ss c
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– Install battery and battery cover ⇒ Electrical system; Rep. gr.
pt
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d
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27 ; Battery; Removing and installing battery .
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– Bleed clutch mechanism ⇒ page 35 .
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Specified torques
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spec
es, in part or in w
t to the co
♦ ⇒ “1.2 Assembly overview - clutch hydraulics”, page 21
1.7 Removing and installing clutch master
rrectness of i
cylinder
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⇒ “1.7.1 Removing and installing clutch master cylinder with

mounting bracket installed”, page 28
nform
ercia
⇒ “1.7.2 Removing and installing clutch master cylinder with

m
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mounting bracket removed”, page 32
on in
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1.7.1 Removing and installing clutch master

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cylinder with mounting bracket installed

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♦ Sealing tool - T10249-
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Removing
Note
♦ Before replacing the clutch master cylinder due a suspected

defect, use Guided Fault Finding ⇒ Vehicle diagnostic
tester.
♦ When performing work in the footwell, put cloths on the floor
covering to protect it from possible brake fluid spills.
♦ On vehicles with clutch position sender - G476- , the clutch
master cylinder and the clutch position sender - G476- are one
unit ⇒ Electronic Parts Catalogue (ETKA) .

– Remove battery and battery cover ⇒ Electrical system; Rep.
gr. 27 ; Battery; Removing and installing battery .
AG. Volkswagen AG d
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– Remove lower
ss
cover on driver side ⇒ General body repairs,
ce
le
un
pt
an
d
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– If fitted, remove clutch pedal switch - F36- ⇒ page 36 .
pe
ility
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Caution
hole
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es, in part or in w
Risk of leaking brake fluid.
t to the co
♦ During the following work, ensure that no brake fluid lands
on longitudinal member or gearbox. If this does happen,
rrectness of i
clean the affected areas thoroughly.
l purpos
♦ Lay a lint-free cloth under clutch master cylinder.
nform
ercia
– To facilitate accessibility to clutch master cylinder, pull off side

m
a
battery cover from bulkhead.
com
tion in
– Clamp off supply hose -1- to clutch master cylinder with hose
r
te o
thi
clamp - 3094- .
s
iva
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– Pull off supply hose -1- from connection -arrow- of clutch mas‐
um
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en
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ter cylinder -2-.

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– Pull out clip -3- for pipe/hose line to stop.
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– Pull out pipe/hose line -4- from clutch master cylinder -2- and by c lksw
cted agen
seal. Prote AG.
Note
♦ In addition to clamping off, the sealing tool - T10249/1- can be

used to clamp off the supply hose.
♦ Clamping off the plastic supply hose with the hose clamp -
3094- will cause a permanent deformation.
♦ However, this does not damage the supply hose.
♦ After removing the hose clamp - 3094- , the supply hose must
be returned to its original shape.
– Move clutch pedal to rest position.

Release clutch master cylinder operating rod from clutch pedal
as follows:

– Press sides of retainer inwards -in direction of arrow- using

pliers - T10005- .
Note
To assist clarity, clutch pedal is shown with mounting bracket re‐

moved.
– Pull clutch pedal in direction of retainer -A- for clutch pedal

switch - F36- .
– If fitted, separate electrical connector for clutch position send‐
er - G476- and remove from mounting bracket.
Note
The electric wire is located on the right-hand side of the mounting

bracket for clutch pedal and is clipped in on the mounting bracket.
– Unscrew securing nuts -2- of clutch master cylinder -1-.
satelettronica
– Pull out clutch master cylinder -1- downwards.
Installing
Insert clutch master cylinder into retainer.
– Fit new securing nuts -2- for clutch master cylinder -1- and
tighten to specified torque. n AG. Volkswagen AG do
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The retainer -A- must be fitted to the clutch master cylinder op‐
erating rod -B-.
– Push clutch pedal in direction of -arrow- until it engages.
rrectne
Check that it is securely locked.

s
– If featured, join electrical connector for clutch position sender

s o
- G476- and clip in on mounting bracket.

cial p
f inform
– If fitted, install clutch pedal switch - F36- ⇒ page 36 .

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Prote 1. Clutch operation
AG.
– Press in pipe/hose line -4- at connection of clutch master cyl‐

inder -2- until securing clip -3- engages audibly.
– Fit supply hose -1- on connection -arrow- of clutch master cyl‐
inder.
– After removing hose clamps - 3094- , return supply hose to its
original position and shape, if necessary.
– If removed, fit side battery cover on stud of bulkhead.
– Install battery and battery cover ⇒ Electrical system; Rep. gr.
27 ; Battery; Removing and installing battery .
Specified torques
1.7.2 Removing and installing clutch master

cylinder with mounting bracket removed
satelettronica
♦ Pliers - T10005-
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Removing
wit
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ole,
spec

t to the co
– Remove over-centre spring ⇒ page 24 .

– Move clutch pedal to rest position.
rrectne
Release clutch master cylinder operating rod from clutch pedal

as follows:
ss
– Press sides of retainer inwards -in direction of arrow- using

o
cial p
pliers - T10005- .
inform
mer
– Pull clutch pedal in direction of retainer -A- for clutch pedal

atio
m
switch - F36- .
o
n
c
i
or
– Then unscrew securing nuts for clutch master cylinder on

thi
te
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mounting bracket.
iv
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– Pivot retainer on actuator rod/clutch master cylinder by 90°.

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– Remove clutch master cylinder from mounting bracket studs. C py
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– Tighten new nuts securing clutch master cylinder on mounting

bracket to specified torque.

– The retainer -A- must be fitted to the clutch master cylinder

operating rod -B-.
– Press clutch pedal in -direction of arrow- until it engages. En‐
sure that it is properly locked.
– Install over-centre spring ⇒ page 24 .
Specified torques
AG. Volkswagen AG d
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1.8 Removing and installing clutch slave
s
ce
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nl
pt
du
cylinder together with release bearing
an
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es, in part or in w
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t to the co
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Removing
Prote AG.
• Gearbox is removed.
– Release securing clip -2- with a screwdriver and pull off bleed‐
er -4- from clutch slave cylinder -1-
– Remove bolts -arrows-.

– Remove clutch slave cylinder together with release bearing
-A-.
Installing
• The securing bolts for the clutch slave cylinder must be tight‐
ened only in small stages.
Otherwise, the tabs with the bolt holes may break off.
– Securely bolt on clutch slave cylinder with clutch release bear‐
ing ⇒ page 23 .
– Check O-ring -3- on clutch slave cylinder for damage.

– Press in bleeder -4- on clutch slave cylinder connection -1-
until securing clip -2- engages audibly.
– Check by pulling on bleeder.
– Install gearbox ⇒ page 89 .
satelettronica
1.9 Removing and installing bleeder
Removing line -4- and installing on bleeder -1- AG. Volkswagen AG d
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V or pointed object
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– To install, push line -4- with O-ring
ss a -3- onto connection of c
bleeder -1- until securing clip -2- engages audibly.
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spec
Removing bleeder -4- from and installing on clutch slave cylinder

t to the co
– To remove, release securing clip -2- using a screwdriver. Pull

bleeder -4- off clutch slave cylinder -1-.
rrectne
– To install, check O-ring -3- on clutch slave cylinder. Press

bleeder onto clutch slave cylinder connection until securing
clip engages audibly.
ss o
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– Check by pulling on bleeder.

inform
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1.10 Bleeding clutch mechanism
Note
♦ Bleeding may only be carried out using brake filling and bleed‐
ing equipment.
♦ The connection of the bleeding equipment must be free of flu‐
ids containing mineral oil.

♦ Brake filling and bleeding equipment - VAS 5234-
satelettronica
AG. Volkswagen AG d
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Note
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♦ The clutch system must always be bled after performing work
erm
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on the hydraulic clutch mechanism.
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♦ When performing the following steps, make sure that no brake
h re
fluid gets onto the gearbox.
ole,
spec
♦ Prefilling system is not necessary!
t to the co
♦ Before bleeding, fill brake fluid reservoir with brake fluid up to
“max.” mark.
♦ Clutch pedal is at rest position, is not being depressed. rrectne
♦ Brake fluid: allocation ⇒ Electronic Parts Catalogue (ETKA) .
ss o
cial p
f inform
– Move clutch pedal back to its rest position.

mer
atio
– Connect brake filling and bleeding unit - VAS 5234- .

om
n
c
i
or
– Remove cap from bleeder screw.

thi
te
sd
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To bleed system, use 670 mm long bleed hose - V.A.G 1238/B3-

i
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if necessary.
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– Connect bleeder hose -A- to bleeder screw -arrow-.

– Then connect bleeder hose with bottle of brake filling and
bleeding unit .
– Switch on brake filling and bleeding equipment .
• Working pressure 2.0 bar.
– Open bleeder valve by about 1/4 turn. agen
AG. Volkswagen AG d
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– Allow about 100 cm3 of brake fluid to flow out. rise d ara
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– Close bleeder valve. ss a ra
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– Rapidly operate pedal from stop to stop 10 to 15 times.
un
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– Open bleeder valve by about 1/4 turn.
erm
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ility
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– Allow another 50 cm3 of brake fluid to flow out.
wit
is n
h re
ole,
– Close bleeder valve.
spec
♦ Bleeder valve with hexagon, specified torque: ⇒ page 21
t to the co
♦ Bleeder valve flattened on both sides: close as far as stop
satelettronica
– Switch off brake filling and bleeding equipment and relieve
rrectne
pressure completely from equipment.
s
– Depress clutch pedal several times after completion of bleed‐
s o
ing process.
cial p
f inform
Specified torques
mer
atio
m
♦ ⇒ “1.2 Assembly overview - clutch hydraulics”, page 21

o
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1.11 Removing and installing clutch pedal

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switch
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To ensure that clutch pedal switch - F36- is securely seated in
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pedal cluster, clutch pedal switch may only be installed once.
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Removing
cted agen
Prote AG.
– Remove lower cover on driver side ⇒ General body repairs,

– Pull connector -1- off clutch pedal switch - F36- .
– Turn clutch pedal switch - F36- on housing 45° anti-clockwise
in direction of -arrow- and pull out of support -2-.
Installing
– Pull out plunger of clutch switch - F36- to stop.
• Clutch pedal must be in rest position.
– Now insert clutch pedal switch - F36- into assembly opening.
– To lock, turn clutch pedal switch - F36- on housing clockwise
through 45°.
– Push connector onto clutch pedal switch - F36- .

1.12 Checking clutch master cylinder and

clutch slave cylinder
Carry out Guided Fault Finding using ⇒ Vehicle diagnostic
tester before renewing clutch master cylinder due to suspected
fault.
satelettronica
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2 Clutch
⇒ “2.1 Assembly overview - clutch”, page 38
⇒ “2.2 Removing and installing clutch”, page 38
2.1 Assembly overview - clutch
1 - Flywheel
❑ Ensure that centring
pins fit tightly
❑ Contact surface for
clutch lining must be
free of grooves, oil and
grease
⇒ Rep. gr. 13 ; Cylinder
block (gearbox end);
Removing and installing
flywheel .
satelettronica
2 - Clutch plate
❑ Fitting position: the AG. Volkswagen AG d
raised section of the agen oes
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faces pressure plate horis nte
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❑ Text ss a ra
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“Getriebeseite” (gear‐
ce
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nl
box side), if present,
pt
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faces pressure plate or
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erm
ab
gearbox
ility
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⇒ page 38
h re
hole
spec
es, in part or in w
t to the co
logue (ETKA)
3 - Thrust plate
rrectness of i
l purpos
logue (ETKA)
nform
ercia
⇒ page 38
m
at
4 - Bolt
om
ion
c
❑ Loosen or tighten diag‐

in t
or
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e
onally in small steps

at
do
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❑ For allocation refer to ⇒ Electronic parts catalogue (ETKA)

p
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❑ M 6 = 13 Nm
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❑ M 7 = 20 Nm
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2.2 Removing and installing clutch

♦ Centring mandrel - T10372-
♦ Counter-hold tool - 3386-
satelettronica
AG. Volkswagen AG d
agen oes
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♦ Torque wrench - V.A.G 1331- aut ra
ss c
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♦ Clutch plate spline grease ⇒ Electronic parts catalogue (ET‐

KA)
nform
ercia
Removing
m
a
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ti
– Remove gearbox ⇒ page 69 .

on in
r
te o
thi
– Insert centring drift - T10372- -B- into clutch pressure plate

s
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– Use counter-hold tool - 3386- -A- to loosen bolts.

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Prote AG.
2. Clutch 39
– Loosen all bolts -arrows A- in small stages and diagonal se‐

quence.
• When pressure plate is loosened, pins of flywheel -arrows B-
should become loose as well.
– Remove pressure plate -1- with clutch plate.
Installing
Note
Friction surface of clutch pressure plate and flywheel must be

cleaned (degreased) thoroughly.
– Clean input shaft splines as well as hub splines (if clutch plate
is used) to remove dirt and corrosion.
V
– Apply thin coat of clutch plate spline grease to splines.
satelettronica
– Move clutch plate back and forth on input shaft until hub moves
freely on shaft.
– Remove excess grease.
– Lettering “Getriebeseite” -arrow- faces gearbox.
– Check diaphragm spring -2- of clutch pressure plate -1-.

wage es n
• Wear to half the thickness of the diaphragm spring yV
o -arrows- is
lks ot g
permitted. ir se
d b ua
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pe
ility
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hole
spec
es, in part or in w
t to the co
rrectness of i
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nform
mercia
a
com
tion in
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te o
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Prote AG.

– Checking spring connections and riveted connections.

I - Extension springs OK.
• Minor kinks on the outside area -arrows A- have series pro‐
duction status.
II - Extension springs damaged
• Renew clutch pressure plate if springs are broken or badly
bent -arrow B-.
– Make sure rivet joints -arrows B- on all extension springs
satelettronica
-arrows A- are firmly seated.
• Renew clutch pressure plate if riveting -arrows B- is loose.
Specified torques
♦ ⇒ “2.1 Assembly overview - clutch”, page 38
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mer
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2. Clutch 41
34 – Controls, housing
1 Bevel box
⇒ “1.1 Assembly overview - bevel box”, page 42
⇒ “1.2 Removing bevel box”, page 44
⇒ “1.3 Installing bevel box”, page 48
⇒ “1.4 Checking gear oil level in bevel box”, page 51
⇒ “1.5 Installing repair kit for stub shaft”, page 52
1.1 Assembly overview - bevel box
Note
Removing and installing bevel box ⇒ page 44 .
satelettronica
1 - Stub shaft
⇒ page 241
❑ Installing repair kit for
AG. Volkswagen AG d
stub shaft ⇒ page 52 lksw
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not
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2 - Retaining ring ise
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3 - Bearing mounting s au ra
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❑ For deep groove ball
ce
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nl
pt
bearing
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⇒ Item 4 (page 42) .

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ility
4 - Deep groove ball bearing

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❑ Installing deep groove

h re
ball bearing
hole
spec
⇒ page 52
es, in part or in w
t to the co
5 - Retaining ring
❑ The second retaining
ring is not installed on all
rrectness of i
stub shafts
l purpos
6 - Retaining ring
7 - Retaining ring
nf
ercia
or
❑ For bearing mounting in

m
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atio
bevel box
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8 - Dust seal
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9 - O-ring
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10 - Retaining ring p by
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11 - Bolt
❑ 35 Nm
42 Rep. gr.34 - Controls, housing

12 - Securing bolt
❑ Specified torque ⇒ page 44
13 - Securing bolt
❑ Specified torque ⇒ page 44
14 - Bevel box carrier
❑ Assembly sequence ⇒ page 44
15 - Radial oil seal
❑ For right stub shaft.
16 - Combined plug screw
❑ 10 Nm
17 - Magnetic screw
❑ 45 Nm
18 - Seal
19 - Bolt
satelettronica
❑ Qty. 4
❑ 40 Nm +45°
❑ For left stub shaft, interior
❑ For left stub shaft, exterior
❑ Renewing ⇒ page 239 n AG. Volkswagen AG do
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22 - Radial oil seal ir se
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❑ For drive flange auth or
ac
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23 - Protective cap an
itte
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24 - Deflector ring ab
ility
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25 - Output flange
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hole
spec
es, in part or in w
26 - O-ring
t to the co

27 - Shim
rrectness of i
28 - Retaining ring
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1. Bevel box 43
Observe assembly sequence when installing gearbox carrier

-3-:
Stage Bolts Specified torque
AG. Volkswagen AG d
agen oes
1 -2- Screw in by hand Vol
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2 -1- 45 Nm ris
ed
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3 -2- 45 Nm s a u ra
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1.2 Removing bevel box
hole
spec
es, in part or in w
t to the co
Special tools and workshop
equipment required
rrectness of i
l purpos
satelettronica
nform
mercia
a
com
tion in
r
te o
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s
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♦ Engine and gearbox jack - V.A.G 1383 A- with universal sup‐
port - V.A.G 1359/2-
♦ Or engine and gearbox jack - VAS 6931-
♦ Socket insert - T10107 A-

♦ Counter-hold tool - T10140-

♦ or counter-hold tool - T50053-
KA)
Removing
– Loosen wheel bolts on front left and front right.
– Raise vehicle.
– Remove front wheels.
– If fitted, remove noise insulation ⇒ General body repairs, ex‐
terior; Rep. gr. 66 ; Noise insulation; Assembly overview -
noise insulation .
– Loosen nuts -1- of propshaft heat shield -2-, and remove them.
– Remove front propshaft ⇒ Rep. gr. 39 ; Propshaft; Removing
and installing propshaft .
Vehicles with diesel engines
– Remove particulate filter ⇒ Rep. gr. 26 ; Emission control;
satelettronica
Removing and installing particulate filter .
Vehicles with petrol engines
– Remove downstream catalytic converter ⇒ Rep.wagr. 26
gen AG. ;Volkswagen AG d
oes
Emission control; Removing and installing catalytic
yV
olks converter . not
gu b ara
ed
Continued for all vehicles oris nte
e
th or
au ac
– Fix subframe in position prior to removal
ss ⇒ Running gear,
axles, steering; Rep. gr. 40 ; Subframe; Fixing subframe in
ce
le
un
pt
position .
an
d
itte
y li
rm
ab
– Remove subframe without steering rack ⇒ Running gear,
pe
ility
axles, steering; Rep. gr. 40 ; Subframe; Removing and instal‐
ot
wit
, is n
ling subframe without steering rack .
h re
hole
– Pull right drive shaft off stub shaft of bevel box and tie it up ⇒
spec
es, in part or in w
Running gear, axles, steering; Rep. gr. 40 ; Drive shaft; Re‐

t to the co
moving and installing drive shaft .
– Unscrew bolt -1-, and remove bracket -2-.

rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
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Cop py
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rig ht
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cted agen
Prote AG.
1. Bevel box 45
– Remove bolts -1- and -2-. Remove gearbox carrier -3- from
rear engine support and from bevel box.
– Release wiring harness -1- from retainer -2-.
AG. Volkswagen AG d
agen oes
olksw not
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satelettronica
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– Pull connector -1- off oil level and oil temperature sender -
ility
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G266- .
wit
is n
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ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
m
– Unbolt rear engine support -1- from cylinder block -4-.

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n
c
i
or
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AG. Volkswagen AG d
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ho 6-speed manual e ogearbox
ra
0A5 - Edition 06.2019
s a c
s
– Remove retaining ring -arrow A- and seal -arrow B- of stub
ce
e
nl
pt
du
shaft.
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itte
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ility
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es, in part or in w
t to the co
rrectness of i
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– Remove countersunk bolt for right stub shaft with socket -
nform
ercia
T10107 A- . Counterhold stub shaft with counterhold tool -

T10140- or counterhold tool - T50053- when doing this.
m
at
om
ion
c
in t
or
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e
Note
at
do
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cum
or
Leave stub shaft in installation position in bevel box and do not

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pull out.
yi
satelettronica
Co
Cop py
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rig ht
– Unscrew universal joint of steering rack from steering pinion
py by
co Vo
by lksw
and remove track rods from wheel bearing housing ⇒ Running Prote
cted AG.
agen
gear, axles, steering; Rep. gr. 48 ; Steering rack; Assembly
overview - steering rack .
– Secure steering rack with track rods to body.
– Remove top bevel box/dual clutch gearbox connecting bolts

-arrows-.
– Place used oil collection and extraction unit - VAS 6622A- be‐
low gearbox.
WARNING
Risk of injury from hot gearbox oil.

• Wear protective goggles.
• Wear acid-resistant gloves
– Remove bottom bevel box/dual clutch gearbox connecting

bolts -arrows-.
Note
A second mechanic is required for further removal.
– Carefully push bevel box off dual clutch gearbox.

– Turn bevel box until propshaft flange is at top.
– Lower bevel box, and guide it past subframe by turning it sev‐
eral times.
– Place bevel box on engine and gearbox jack - V.A.G 1383 A-
or engine and gearbox jack - VAS 6931- .
1. Bevel box 47
1.3 Installing bevel box

– Grease splines of differential -arrows- with grease for clutch
plate splines ⇒ Electronic Parts Catalogue (ETKA) .
– Align splines of right stub shaft and differential bevel gear; turn
stub shaft as necessary.
Note
The aid of a second mechanic is required for fitting the bevel box.
– Turn bevel box until propshaft flange is at top.

– Lift bevel box and guide it past steering rack.
– Turn bevel box into installation position and bolt fully onto
manual gearbox. In the process, guide splines of bevel box lay
shaft concentrically together with
wage
splines
n AG. Volkof
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Note utho eo
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♦ Ensure that installation position of stub shaft does not change ce
e
nl
pt
du
(is not pushed out of bevel box). an

itte
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erm
ab
♦ Do not use securing bolts to pull bevel box onto gearbox, or ility
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bevel box will cant and bolt holes can break off.
wit
, is n
h re
hole
spec
– Screw in bottom bevel box/dual clutch gearbox connecting

es, in part or in w
bolts -arrows- and tighten to specified torque

t to the co
⇒ Item 19 (page 43) .

rrectness of i
l purpos
nf
ercia
orm
m
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om
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– Screw in top bevel box/dual clutch gearbox connecting bolts

o
m
f
en
-arrows- and tighten to specified torque ⇒ Item 19 (page 43) .

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Transporterot g
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ara ➤
ed
o6-speed
ris manual gearbox 0A5 - Edition 06.2019
nte
eo
th
au ra
c
ss
– Screw in countersunk bolt for right stub shaft with socket -
ce
e
nl
T10107 A- , and tighten it. Counterhold stub shaft using coun‐
pt
du
an
terhold tool - T10140- or counterhold tool - T50053- while
itte
y li
doing so.
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
– Renew retaining ring -arrow A- and oil seal -arrow B- of stub l purpos
shaft.
nform
ercia
– Lubricate right stub shaft splines with clutch plate spline

m
at
om
i
grease .
on
c
in t
or
– Mount steering rack on universal joint and track rods on wheel
his
ate
bearing housing ⇒ Running gear, axles, steering; Rep. gr.
do
priv
c
48 ; Steering rack; Assembly overview - steering rack .
um
for
en
g
satelettronica
n
t.
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Cop py
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– Fit rear engine support -1- on cylinder block -4-. Tighten bolts
-2- and bolt -3- ⇒ Rep. gr. 10 ; Assembly mountings; Assem‐
bly overview - assembly mountings .
– Bolt gearbox carrier -3- to rear engine support and bevel box
(bolts -1- and -2-). Note tightening sequence when doing so
⇒ page 44 .
Vehicles with diesel engines
– Install diesel particulate filter ⇒ Rep. gr. 26 ; Emission control;
Removing and installing diesel particulate filter .
Vehicles with petrol engines
– Install downstream catalytic converter ⇒ Rep. gr. 26 ; Emis‐
sion control; Removing and installing catalytic converter .
Continued for all vehicles
1. Bevel box 49
– Secure bracket -2- with bolts -1- to bevel box.

– Press right drive shaft onto stub shaft ⇒ Running gear, axles,
steering; Rep. gr. 40 ; Drive shaft; Removing and installing
drive shaft .
– Install steering rack and bracket for rear engine support to
subframe ⇒ Running gear, axles, steering; Rep. gr. 48 ;
Steering rack; Assembly overview - steering rack .
– Install subframe with bracket for rear engine support ⇒ Run‐
ning gear, axles, steering; Rep. gr. 40 ; Subframe; Removing
and installing subframe without steering rack .
– Install front propshaft ⇒ Rep. gr. 39 ; Propshaft; Removing
– Secure propshaft heat shield -2- using nuts -1-.
satelettronica
– If fitted, screw on nut -arrow- at bottom of vehicle level sender.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
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aut ra
ss c
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
– Connect connector of oil level and oil temperature sensor -

, is n
h re
G266- -1-, and route wiring harness.

hole
spec
– Check oil level in gearbox ⇒ page 156 .

es, in part or in w
t to the co
– If present, install noise insulation ⇒ General body repairs, ex‐

noise insulation .
rrectness of i
– Install wheels ⇒ Running gear, axles, steering; Rep. gr. 44 ;

l purpos
Wheels, tyres; Specified torques for wheel bolts .

Specified torques
nf
ercia
orm
♦ ⇒ “1.1 Assembly overview - bevel box”, page 42

m
atio
om
n in
♦ ⇒ Rep. gr. 10 ; Assembly mountings; Assembly overview -

or c
assembly mountings
thi
te
sd
iva
♦ ⇒ Rep. gr. 26 ; Emission control system; Assembly overview

r
rp
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- emission control system

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ng
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♦ ⇒ Rep. gr. 39 ; Propshaft; Assembly overview - propshaft C py
ht. rig
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cted agen
Prote AG.

AG. Volkswagen AG d
agen oes
olksw not
V
d by Transporter
gu
ara 2016 ➤
ise nte
thor 6-speed manual gearbox 0A5 - Edition
e or 06.2019
au ac
ss
1.4 Checking gear oil level in bevel box
ce
le
un
pt
an
d
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♦ Filling device - VAS 6291-
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♦ Drip tray for workshop hoist - VAS 6208-
Note
Bevel box is bolted to side of gearbox and has its own oil supply.
Requirement
• Bevel box must be in installation position.
• Vehicle on four-pillar lifting platform or over an inspection pit
to ensure it is absolutely level.
• Engine not running.
Test sequence
noise insulation .
1. Bevel box 51
– Place drip tray for workshop hoist - VAS 6208- under bevel
box.
– Unscrew oil filler plug -arrow-.
Oil level is correct when bevel box is filled to lower edge of filler
hole.
– Tighten oil filler plug -arrow- ⇒ page 42 .
Observe the following for initial filling:
– Unscrew oil filler plug -arrow-.
– Using filling device for Haldex coupling 2 - VAS 6291- , add
enough oil so that it runs out between the adapter of the filling
device and the final drive housing.
– Tighten oil filler plug -arrow- ⇒ page 42 .
noise insulation .
Specified torques
♦ ⇒ “1.1 Assembly overview - bevel box”, page 42
satelettronica
1.5 Installing repair kit for stub shaft
Note
Adhere to the general repair notes for bearings and shims

⇒ page 4 .
AG. Volkswagen AG d
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♦ Thrust plate - VW402-

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♦ Inductive heater - VAS 6414-
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Installing deep groove ball bearings to stub shaft

– Insert retaining ring -2- into lower groove -arrow- of stub shaft
-1-.
• The retaining ring must be fully engaged.
• It must not be possible to turn the retaining ring by hand in the
annular groove of the stub shaft.
1. Bevel box 53
Inserting deep groove ball bearing -1- in bearing mounting -2-

– Heat bearing mounting -2- to approx. 70°C.
– Insert deep groove ball bearing -1- in bearing mounting -2-
without canting it.
• Push deep groove ball bearing -1- to stop into bearing mount‐
ing -2-.
– Insert retaining ring -3- into annular groove -arrow- of bearing
mounting -2-.
annular groove of the bearing mounting.
Pressing stub shaft -3- into deep groove ball bearing -2-
– Use inductive heater - VAS 6414- to heat grooved ball bearing
with bearing mounting -2- to approx. 100°C.
• The shoulder of the bearing mounting -arrow- must face to‐
wards the retaining ring -1- when pressing in.
satelettronica
• Align thrust plates - VW401-g,e-VW402-
n AG. Volkswand
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such a way that the stub ol swa -3- does not rest dagainst
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– Press in stubashaft
ut -3- until it rests against retaining ring -1-. or a
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Stub shaft with two retaining rings

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Note
The second retaining ring is not installed on all stub shafts.

nform
mercia
a
com
– Insert second retaining ring -1- into annular groove of stub

tion in
shaft in front of deep groove ball bearing -2-.

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annular groove of the stub shaft. Cop
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– Install stub shaft for bevel box ⇒ page 241 . opy
rig by
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2 Selector mechanism
⇒ “2.1 Installation position - selector mechanism”, page 55
⇒ “2.2 Assembly overview - gear knob and cover”, page 56
⇒ “2.3 Assembly overview - Gear lever and selector housing”,
page 57
⇒ “2.4 Assembly overview - Selector cables”, page 59
⇒ “2.5 Removing and installing selector mechanism”, page 60
⇒ “2.6 Adjusting selector mechanism”, page 63
⇒ “2.7 Renewing selector shaft seal”, page 67
2.1 Installation position - selector mechanism

Arrow -A- = gear selection movement
Arrow -B- = gate selection movement
A - Gear selector cable
satelettronica
B - Gate selector cable AG. Volkswagen AG d
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1 - Gearbox selector lever olksw not
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2 - Relay lever horis
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2. Selector mechanism 55
2.2 Assembly overview - gear knob and cover
1 - Emblem
❑ Can be carefully levered
off gear knob using re‐
moval wedge - 3409-
2 - Bolt n AG. Volkswagen AG do
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❑ 6 Nm yV
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4 - Compression spring
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6 - Gear lever
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2.3 Assembly overview - Gear lever and selector housing
Note
Lubricate bearing positions and sliding surfaces with grease ⇒ Electronic parts catalogue (ETKA) .
1 - Gear lever
2 - Selector housing
3 - Cable end-piece
❑ For gate selector cable
❑ If renewed:
♦ Press off ball head of gear
lever e.g. with an open-jaw
spanner.
♦ Release at gate selector
cable ⇒ page 63
satelettronica
♦ When installing, connect
agen to
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4 - Securing
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❑ For gear selector cable

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⇒ page 58
t to the co
7 - Securing clip
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to selector housing
8 - Gate change cable
nform
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❑ Replace together with

m
gear selector cable

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9 - Gear change cable

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❑ 20 Nm +90°
13 - Nut
14 - Cable end-piece
❑ If renewed:
♦ Press off ball head of gear lever e.g. with an open-jaw spanner
♦ Release at gear selector cable ⇒ page 63
♦ When installing, connect to gear selector cable ⇒ page 63
15 - Bolt
❑ For gear lever to selector housing
❑ 8 Nm +90°
Removing and installing long-arm spring

Removing olkswage es n
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– Press cable end-piece -3- off selector lever ball head,
ir se e.g. with
d ran
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an open-jaw spanner. utho
or
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– Unclip pivot pin -1-.
ce
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– Pull long-arm spring -2- off selector housing. d
itte
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Installing
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– First hook grey lug of long-arm spring underneath pin
spec
-arrow B-.
es, in part or in w
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– Then hook black lug of long-arm spring above pin -arrow A-.
satelettronica
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2.4 Assembly overview - Selector cables
Note
♦ Lubricate bearing positions and sliding surfaces with grease ⇒ Electronic parts catalogue (ETKA) .
♦ Gear selector cable and gate selector cable are one unit and can only be renewed together.
♦ Do not kink selector cables.
1 - Selector housing
2 - Securing clip
3 - Cable end-piece
❑ If renewed:
♦ Press off ball head of gear
lever e.g. with an open-jaw
satelettronica
spanner.
♦ Release at gate selector
cable ⇒ page 63
♦ When installing, connect to
gate selector cable
⇒ page 63
4 - Gate change cable
❑ Press onto relay lever
⇒ Item 6 (page 59)
❑ Fitting position
⇒ page 55
5 - Bolt AG. Volkswagen AG d
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❑ 23 Nm
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6 - Relay lever
itte
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⇒ page 60
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❑ Before installing, clean

h re
hole
bearing points and slid‐

spec
ing surfaces and lubri‐

es, in part or in w
t to the co
cate with grease ⇒

Electronic Parts Cata‐
logue (ETKA)
rrectness of i
7 - Securing clip
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8 - Slide block
nform
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9 - Gearbox selector lever

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❑ Install so that master spline aligns with selector shaft

ion in
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❑ After installing, adjust selector mechanism ⇒ page 63

te o
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❑ Fitting position ⇒ page 60

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2. Selector mechanism
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❑ Renew after removal rise nte
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11 - Retaining clip
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❑ Must be pressed to remove cable end-pieces
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12 - Gear change cable
spec
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❑ Press onto gearbox selector lever ⇒ Item 9 (page 59)
t to the co
13 - Cable end-piece
rrectness of i
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❑ If renewed:
♦ Release at gear selector cable ⇒ page 63
nform
ercia
♦ Press off ball head of gear lever e.g. with an open-jaw spanner
m
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♦ When installing, connect to gear selector cable ⇒ page 63
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Installation position of gearbox selector lever/relay lever

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agen
2.5 Removing and installing selector mech‐

anism
♦ Grease ⇒ Electronic parts catalogue (ETKA)

Removing
– Pull selector lever sleeve up out of gear lever panel and slip
over selector lever knob.

– Remove centre footwell trim w⇒ageGeneral

n AG. Volkbody repairs,
swagen AG
does interior;
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– Disconnect connector
tho
ris -1-. e or
au ac
– Pull wiring harness
ss -3- out of coolant expansion tank -2-.
ce
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nl
pt
– Unscrew bolts -4-.
du
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itte
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– Remove coolant expansion tank -2-, and lay it to one side. Do
ab
ility
not open cooling system.
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Vehicles with diesel engine
h re
hole
spec
– Remove connecting hose between intake manifold and charge
es, in part or in w
air cooler ⇒ Rep. gr. 21 ; Charge air system; Assembly over‐
t to the co
view - charge air system hose connections .
rrectness of i
l purpos
– Remove gear selector cable -A- from gearbox selector lever

and gate selector cable -B- from relay lever. To do this, push
securing clips -arrow 1- and -arrow 2-.
nform
ercia
– Remove cable support bracket -C- from gearbox by operating

m
at
catch in direction of arrow -3-.
om
satelettronica
on
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– Loosen and fold back floor covering on driver side until bolts
-arrows- are accessible.
– Unscrew bolts -arrows- for operating cables on body.
– Remove gear and gate selector cable on selector housing
⇒ page 57 .
– Detach selector housing from dash panel cross-member

-arrows- and remove.
Installing
AG. Volkswagen AG d
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olksw not
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– Pull back catch of cable support bracket -1- -arrow A- and in‐
nl
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satelettronica
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sert into gearbox -2- -arrow B-.
itte
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Cop py
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rig ht
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Catch -1- must engage in gearbox.

– Spread a small quantity of grease ⇒ Electronic Parts Cata‐
logue (ETKA) on pins of gearbox selector lever -4- and of relay
lever -3-.
– Press gear selector cable -5- onto gearbox selector lever -4-
and gate selector cable -2- onto relay lever -3-.
– Check that cables are firmly seated on gearbox selector lever
and relay lever.
Securing clip must be engaged.
– Install connecting hose between intake manifold and charge
air cooler ⇒ Rep. gr. G. Volkswair
agen AG
swa21
gen;ACharge system;
does Assembly over‐
view - charge bair
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olk not
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Continued for
tho all vehicles
ri tee
or
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– Fit gear
ss and gate selector cable on selector housing
ce
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⇒ page 57 .
nl
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– Adjust selector mechanism ⇒ page 63 .
erm
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satelettronica
ility
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– Install centre footwell trim ⇒ General body repairs, interior;
wit
Rep. gr. 70 ; Dash panel; Assembly overview - dash panel .
, is n
h re
hole
– Connect battery ⇒ Electrical system; Rep. gr. 27 ; Battery;
spec
Disconnecting and connecting battery .
es, in part or in w
Specified torques t to the co
♦ ⇒ “2.3 Assembly overview - Gear lever and selector housing”,

rrectness of i
page 57
l purpos
♦ ⇒ “2.4 Assembly overview - Selector cables”, page 59

nform
ercia
2.6 Adjusting selector mechanism

m
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♦ Pin - T10027 A-
his
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♦ Gauge - T10216-
The following points are essential to ensure correct adjustment of

selector mechanism:
♦ Moving parts of operating elements and elements that transfer
force must function correctly.
♦ Selector mechanism must move freely.
♦ Gearbox, clutch and clutch mechanism must also be in proper
satelettronica
condition.
Procedure
• Gearbox is in neutral at the start of procedure.
• Selector shaft must be movable in gate selection movement
in -direction of arrow-.
Note n AG. Volkswagen AG do

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– Pull out gear lever gaiter with cover upwards out of gear
ss
a
lever ac
panel and slip over gear knob.
ce
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Multivan
itte
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pe
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ility
ot
interior; Rep. gr. 70 ; Dash panel; Assembly overview - dash
wit
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panel .
h re
hole
spec
Transporter
es, in part or in w
t to the co
– If necessary, remove centre footwell trim ⇒ General body re‐
pairs, interior; Rep. gr. 70 ; Dash panel; Assembly overview -
dash panel .
rrectness of i
l purpos
Note
nform
ercia
Only remove the centre footwell trim if access to the gate selector
cable locking mechanism in particular is not possible.
m
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olksw
AG. V agen AG
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– Push down locking mechanism db
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gear selector cable to stop oris -arrow-.
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– Push down locking mechanism -1- on cable end-piece -2- on
rrectness of i
gate selector cable to stop -arrow-.
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Engage 2nd gear using gearbox selector lever as follows:
op Vo
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Prote
– Pull selector shaft on gearbox selector lever upwards in
AG.
-direction of arrow 1-.

– When pulling selector shaft upwards, push gauge - T10216-
laterally, from left side of vehicle, between gearbox selector
lever -A- and selector mechanism cover -B- onto selector shaft
as far as stop.
– Allow gearbox selector lever to spring back onto gauge -
T10216- and shift gearbox selector lever backwards in
-direction of arrow 2-.
Note
If the 2nd gear cannot be engaged, shift gearbox selector lever

without gauge - T10216- backwards within selector gate of 1st/
2nd gear. Lift gearbox selector lever approx. 7 mm when doing
this.
Secure selector lever as follows:

– Move gear lever in neutral position leftwards into selector lever
gate for 1st and 2nd gears.
– Guide locking pin - T10027 A- through hole -A- of gear lever
into hole -B- of selector housing.
– Now press in -direction of arrow- against lug of securing mech‐

anism for cable end-piece -1- on gate selector cable.
Spring presses locking mechanism into original position.
AG. Volkswagen AG d
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olksw not
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– Then press in -directionoriof
s arrow- against lug of securing
e nte
mechanism for cableauend-piece
th -A- on gear selector cable. eo
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Spring presses locking mechanism into original position.
ce
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hole
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– Pull out locking pin - T10027 A- from holes of selector lever
l purpos
-A- and selector housing -B-.

nform
mercia
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tion in
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– Using gearbox selector lever -A-, shift gearbox in
cted agen
Prote AG.
-direction of arrow- to neutral position.
– If fitted, remove gauge - T10216- from selector shaft.
Carry out functional test on selector mechanism.
• With gearbox in neutral, gear lever must rest in selector lever
gate for 3rd and 4th gear.
– Depress clutch pedal.
– Select all gears several times. Pay particular attention to op‐
eration of reverse gear lock.
Should a gear fail to engage smoothly after repeated selection,
the vertical play of the selector shaft should be checked as fol‐
lows:
– Engage 1st gear.
– Press gear lever left to stop and release.
– At the same time, a second mechanic should observe selector
shaft in gearbox.

– When gear lever is moved, selector shaft must have approxi‐

mately 1 mm clearance in -direction of arrow-.
– If this is not the case, adjust selector mechanism again.
Multivan
Volkswagen AG
– Install centre left knee padding ⇒ General body repairs, inte‐ agen
AG. does
ksw
rior; Rep. gr. 70 ; Dash panel; Assembly overview - dash
by
Vol not
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ara
panel . ris
ed nte
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Transporter ss au ra
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– If removed, install centre footwell trim ⇒ General body repairs,
nl
pt
du
an
interior; Rep. gr. 70 ; Dash panel; Assembly overview - dash
itte
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panel .
erm
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ility
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– Clip gear lever gaiter with cover into gear lever panel.
hole
spec
– If removed, install charge air hose ⇒ Rep. gr. 21 ; Charge air
es, in part or in w
t to the co
system; Assembly overview - charge air system hose connec‐
tions .
rrectness of i
2.7 Renewing selector shaft seal
satelettronica
l purpos
nf
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♦ Tube - VW 423-
orm
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Cop py
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rig ht
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Prote AG.
♦ Assign sealing grease for radial oil seal using ⇒ Electronic

Parts Catalogue (ETKA) .
Removing
– Remove selector lever -1- from selector shaft.
– Remove guide shoe -arrow- of relay lever -2- from guide rail
of gearbox selector lever.
– Carefully lever out seal for selector shaft using a screwdriver
or extractor tool - T20143/1- .
Installing
– Lightly oil outer circumference of new oil seal.

– Half-fill space between sealing lip -arrow- and dust lip with
sealing grease for radial oil seal .
satelettronica
– Drive in oil seal using tube - VW 423- . Ensure that seal does
not cant when doing so.
• Lettering on seal must face outwards (to pressing tool).
AG. Volkswagen AG d
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– Position gearbox selector lever -1- on selector shaft such that

hole
spec
master spline aligns with selector shaft.

es, in part or in w
t to the co
– Fit guide shoe -arrow- of relay lever -2- in guide rail of gearbox
selector lever.
– Tighten new nut for gearbox selector lever on selector shaft to
rrectness of i
specified torque.
l purpos
– After installing, adjust selector mechanism ⇒ page 63 .

– Check gear oil level ⇒ page 156 .
nform
ercia
Specified torques
m
at
om
ion
♦ ⇒ “2.4 Assembly overview - Selector cables”, page 59

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3 Removing and installing gearbox

⇒ “3.1 Specified torques for gearbox”, page 69
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⇒ “3.2 Removing gearbox”,
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⇒ “3.3 Installinghorgearbox”,
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3.1 Specified torques for gearbox
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Gearbox to engine, diesel engine without intermediate plate
itte
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-A- and -B-: dowel sleeves for centring
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Item Bolt Quantity Nm
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spec
1 M12 x 60 1 80
es, in part or in w
2 M12 x 70 4 80
t to the co
3 M10 x 50 3 40
rrectness of i
Note
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satelettronica
A centre hex stud is installed at position -1- on vehicles with front-
nform
ercia
wheel drive.
m
at
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Gearbox to engine, diesel engine with intermediate plate
or
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ate
-A- and -B-: dowel sleeves for centring

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Item Bolt Quantity Nm

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3 M10 x 65 3 40
Prote AG.
Note
♦ A centre hex stud is installed at position -1- on vehicles with

front-wheel drive.
♦ The connecting bolt in the starter hole is 70 mm in length.
3.2 Removing gearbox

⇒ “3.2.1 Removing gearbox, vehicles with front-wheel drive”,
page 69
⇒ “3.2.2 Removing gearbox, vehicles with all-wheel drive”,
page 78
3.2.1 Removing gearbox, vehicles with front-wheel drive
3. Removing and installing gearbox 69


equipment required
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♦ Support - 10 - 222 A-
♦ Hook - 10 - 222 A /2-
♦ Shackle - 10 - 222 A /12-
♦ Adapter - 10 - 222 A /16-
♦ Adapter - 10 - 222 A /23- with adapter - 10 - 222 A /23-1-
♦ Hose clamp to 25 mm - 3094-

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nform
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com
tion in
r
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Cop py
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Prote AG.
♦ Gearbox support - 3282-

♦ Adjustment plate - 3282/40-
♦ Engine and gearbox jack - V.A.G 1383 A-
KA)
♦ Grease for selector mechanism ⇒ Electronic Parts Catalogue
(ETKA)

Modify adapter - 10 - 222 A /23- with adapter - 10 - 222 A /23-1-

as follows:
– Remove cap -1-.
– Remove cap -2- and unscrew underlying support bolt -3-.
– Insert adapter - 10 - 222 A /23-1- -4- into adapter - 10 - 222
A /23- -5-.
– Fit bolt -6- from underneath into adapter - 10 - 222 A /23- ,
screw in by hand and then tighten to 40 Nm.
Removing
satelettronica
– Remove bulkhead panels -arrows- on left and right from ple‐
num chamber ⇒ General body repairs, interior; Rep. gr. 50 ;
Bulkhead; Assembly overview - bulkhead .
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– Release connector -1- and pull off. ss c
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un
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– Pull wiring harness -3- out of coolant expansion tank -2-.

an
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– Unscrew bolts -4- from coolant expansion tank -2-.

ab
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– Pull off coolant expansion tank -2- upwards and place to one
wit
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side.
h re
hole
spec
es, in part or in w
t to the co
Note
♦ Removal of the connecting hose between the intake manifold

rrectness of i
and the charge air cooler depends on the fitting location of the
charge air cooler.
l purpos
♦ In the case of engines conforming to different exhaust emis‐

sion standards, the fitting locations of the individual compo‐
nform
ercia
nents of the charge air system are arranged differently.

m
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tion in
– If required, remove connecting hose between intake manifold

r
te o
and charge air cooler ⇒ Rep. gr. 21 ; Charge air system;

thi
s
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Assembly overview - charge air system hose connections .

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Prote AG.


securing clips -arrow 1- and -arrow 2-.
– Remove cable support bracket -C- from gearbox by pressing
catch in -direction of arrow 3- (pulling back).
– Remove right cover and battery cover ⇒ General body repairs,
exterior; Rep. gr. 63 ; Front bumper .
– Remove deflector caps for suspension struts.
olkswagen AG
en AG. V
– Convert adapter - 10 - 222 A /23- with adapter o-lk10
swa- 222 A /
g does
not
23-1- ⇒ page 72 . ed
by V gu
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aut ra
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– Place adapter - 10 - 222 A /23-1- suspension strut ats rear on
ce
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nl
-arrow A- and at front on lock carrier -arrow B-.
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– Secure support bracket - 10 - 222 A- in conjunction with adapt‐

er - 10 - 222 A /16- on adapter - 10 - 222 A /23- .
nf
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♦ To avoid the spindle blocking when the engine/gearbox as‐

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sembly is lowered, lubricate spindle and spindle guide of
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adapter - 10 - 222 A /16- . en

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support eye for support bracket - 10 - 222 A- , remove these pyri by
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♦ Position adapter - 10 - 222 A /16- so that neither exhaust gas
recirculation valve - N18- nor bracket for vacuum supply is
damaged.
– Hook shackle - 10 - 222 A /12- into rear retaining eye on engine

and insert hook - 10 - 222 A /2- in on adapter - 10 - 222 A /
16- .
– Take up weight of engine/gearbox assembly on adapter - 10
- 222 A /16- .

The left drive shaft will be removed in a later step.

– With vehicle standing on its wheels, loosen front left flange bolt
-arrow- 90° at most, or wheel bearing will be damaged ⇒
– Raise vehicle.
noise insulation .
Vehicles with petrol engine
– Remove catalytic converter -1- bracket -3-.

– Unscrew bolts -2- and -3- and remove bracket.
– Remove left drive shaft ⇒ Running gear, axles, steering; Rep.
satelettronica
gr. 40 ; Drive shafts; Removing and installing drive shafts .
– Fix subframe in position prior to removal ⇒ Running gear,
position .
ling subframe without steering rack . wage
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Note tho eo
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Lead sealing of tachograph sender - G75- may only to be carried

un
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out by authorised specialist workshops ⇒ Electrical system; Rep.
an
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gr. 90 .
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– If present, disconnect connector -arrow- for tachograph send‐
h re
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er - G75- .
spec
t to the co
rrectness o
cial p
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Prote AG.

– Unscrew bolts -arrows- of right drive shaft.

– Pull right drive shaft -1- off gearbox stub shaft, raise and se‐
cure.
– Gearboxes for vehicles with start-stop system: pull connector

-arrow- off gearbox neutral position sender - G701- .
– Remove retainer for electrical wires from upper starter bolt.
satelettronica
– If fitted, unscrew earth strap -1- from lower starter bolt.
– Pull off connector for reversing light switch - F4- -2-.
– Remove starter ⇒ Electrical system; Rep. gr. 27 ; Starter;
Removing and installing starter . swa
gen AG
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– Clamp off hose of pipe/hose line -A- to clutch slave cylinder

ole,
using hose clamp up to 25 mm - 3094- .

spec
– Pull out clip -arrow- for pipe/hose line onto stop.

t to the co
– Pull off pipe/hose line with bleeder from clutch slave cylinder.
rrectne
Caution
ss o
Risk of contamination due to brake fluid spill.

cial p
f inform
♦ Do not operate clutch pedal after detaching pipe/hose line

mer
from bleeder connection on clutch slave cylinder.

atio
om
n
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– Support gearbox using engine and gearbox jack - V.A.G 1383

iv
o
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A- or engine and gearbox jack - VAS 6931- .

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– Unscrew bolts -arrows- for left assembly mounting.

– Remove engine and gearbox jack .
Note
♦ When lowering or moving the engine/gearbox assembly, en‐

agen
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sure that no lines and hoses are crimped or trapped.
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♦ If necessary, unclip the lines and vacuum lines orfrom
ise the re‐ tee
tainers on the bulkhead. au
th or
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un
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an
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– When lowering engine/gearbox assembly, watch out for cool‐
erm
ab
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ant hose of heat exchanger coolant pipe -1-.
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– There are different lengths of coolant hose. If necessary, the
h re
ole,
coolant hose must be pulled off the coolant pipe.
spec
t to the co
satelettronica
rrectness o
cial p
f inform
mer
– Lower engine/gearbox assembly with adapter - 10 - 222 A /16-
atio
m
of support bracket - 10 - 222 A- to dimension -a- (approx. 100

o
n
c
i
or
n
mm).
thi
te
sd
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– Measure dimension -a- between lower side of left longitudinal

i
o
pr
cum
r
member -1- and bolting surface of gearbox mounting -2-.

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– Remove upper engine/gearbox connecting bolts -arrows-.

– If there is a support for particulate filter -1-, remove it

-arrows-.
– Remove engine/gearbox connecting bolts -2-.
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– Unscrew bolts -1-. ss c
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Note
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Do not remove bolts -arrows- yet.
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spec
To remove gearbox “0A5”, set up gearbox support - 3282/40- with
es, in part or in w
satelettronica
adjustment plate - 3282- .
t to the co
– Insert gearbox support - 3282- in engine and gearbox jack -
V.A.G 1383 A- or engine and gearbox jack - VAS 6931- .
rrectness of i
– Fit adjustment plate - 3282/40- on gearbox support - 3282-
l purpos
( adjustment plate fits in only one position).

– Align arms of gearbox support according to holes in adjust‐
nform
ercia
ment plate .
m
at
The symbols on the adjusting plate indicate the supports required.
om
io
The arrow on the adjustment plate points in direction of travel. n
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ate
– Position engine and gearbox jack with gearbox support - 3282-

do
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under gearbox.
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Cop py
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– Bolt safety support -arrow- to gearbox.

– Remove engine/gearbox connecting bolts -arrows-.

– Press gearbox off engine (dowel sleeves) and carefully swing
towards left longitudinal member.
– Before lowering gearbox, check whether engine wiring har‐
ness is located above gearbox selector lever.
– Lower gearbox carefully. When doing this, guide reversing

light switch - F4- -arrow- past left longitudinal member.
satelettronica
AG. Volkswagen AG d
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3.2.2 Removing gearbox, vehicles with all-wheel drive au ra
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equipment required
satelettronica
AG. Volkswagen AG d
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♦ Support - 10 - 222 A-
ss o
♦ Hook - 10 - 222 A /2-
cial p
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♦ Shackle - 10 - 222 A /12-

mer
atio
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♦ Adapter - 10 - 222 A /16-

o
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♦ Adapter - 10 - 222 A /23- with adapter - 10 - 222 A /23-1-

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♦ Hose clamp to 25 mm - 3094-

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♦ Adjustment plate - 3282/65-
♦ Engine and gearbox jack - V.A.G 1383 A-
♦ Pin - 3282/54-

♦ Pin - 3282/45-

KA)
♦ Grease for selector mechanism ⇒ Electronic Parts Catalogue
(ETKA)
Modify adapter - 10 - 222 A /23- with adapter - 10 - 222 A /23-1-
as follows:
satelettronica
– Remove cap -1-.
– Remove cap -2- and unscrew underlying support bolt -3-.
– Insert adapter - 10 - 222 A /23-1- -4- into adapter - 10 - 222
A /23- -5-.
– Fit bolt -6- from underneath into adapter - 10 - 222 A /23- ,
screw in by hand and then tighten to 40 Nm.
Removing
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un
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– Remove bulkhead panels -arrows- on left and right from ple‐

an
d
itte
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num chamber ⇒ General body repairs, interior; Rep. gr. 50 ;

erm
ab
Bulkhead; Assembly overview - bulkhead .

ility
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t to the co
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agen 3. Removing and installing gearbox
– Release connector -1- and pull off.

– Pull wiring harness -3- out of coolant expansion tank -2-.
– Unscrew bolts -4- from coolant expansion tank -2-.
– Pull off coolant expansion tank -2- upwards and place to one
side.

securing clips -arrow 1- and -arrow 2-. olksw AG. V agen AG
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– Remove cable support bracket ol-C-
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catch in -direction of arrow
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– Remove right cover andau battery cover ⇒ General body repairs,
or
ac
exterior; Rep. gr. 63
s ; Front bumper .
s
ce
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satelettronica
nl
pt
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– Remove deflector caps for suspension struts.
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– Convert adapter - 10 - 222 A /23- with adapter - 10 - 222 A /
ility
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23-1- ⇒ page 81 .
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– Place adapter - 10 - 222 A /23-1- at rear on suspension strut
es, in part or in w
-arrow A- and at front on lock carrier -arrow B-.

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nf
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– Secure support bracket - 10 - 222 A- in conjunction with adapt‐

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er - 10 - 222 A /16- on adapter - 10 - 222 A /23-1- .

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Cop py
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♦ To avoid the spindle blocking when the engine/gearbox as‐
sembly is lowered, lubricate spindle and spindle guide of
adapter - 10-222A /16- .
♦ If there are hoses and cable connections in area of engine
support eye for support bracket - 10 - 222 A- , remove these
now.
♦ Position adapter - 10 - 222 A /16- so that neither exhaust gas
recirculation valve - N18- nor bracket for vacuum supply is
damaged.

– Hook shackle - 10 - 222 A /12- into rear retaining eye on engine

and insert hook - 10 - 222 A /2- in on adapter - 10 - 222 A /
16- . wage
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– Take up weight of engine/gearbox
ed
by assembly on adapter - 10 ara
nte
- 222 A /16- . thoris eo
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pt
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ility
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es, in part or in w
The left drive shaft will be removed in a later step.
t to the co
– With vehicle standing on its wheels, loosen front left flange bolt
-arrow- 90° at most, or wheel bearing will be damaged ⇒
rrectness of i
l purpos
nf
ercia
– Raise vehicle.
satelettronica
rm
m
atio
om
n in
c

or
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e

t
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noise insulation .
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f
en
ng
– Remove particulate filter ⇒ Rep. gr. 26 ; Emission control;

t.
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Removing and installing particulate filter . Cop py
ht. rig
rig ht
– Remove front propshaft ⇒ Rep. gr. 39 ; Propshaft; Removing py by
co Vo
by lksw
cted agen
Prote AG.
– Remove left drive shaft ⇒ Running gear, axles, steering; Rep.
gr. 40 ; Drive shafts; Removing and installing drive shafts .
– Fix subframe in position prior to removal ⇒ Running gear,
position .
ling subframe without steering rack .
– Pull right drive shaft off stub shaft of bevel box and tie it up ⇒
Note
The anti-tamper seal of the tachograph sender - G75- must only

be attached by authorised specialist workshops.

– If present, disconnect connector -arrow- for tachograph send‐

er - G75- .
– Unscrew bolts -1- and remove bracket for diesel particulate

filter -2-.
satelettronica
– Unscrew bolts -1- and -2-, and remove gearbox carrier -3- from
rear engine support.
AG. Volkswagen AG d
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pt
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– Unbolt rear engine support -1- from cylinder block -4- ⇒ Rep.
ility
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gr. 10 ; Assembly mountings; Assembly overview - assembly

wit
mountings .
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es, in part or in w
t to the co
rrectness of i
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nform
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Cop py
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– Remove engine/gearbox connecting bolt -arrow-.
AG. Volkswagen AG d
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spec
– Release wiring harness -1- from retainer -2-.
t to the co
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– Pull connector off oil level and temperature sensor - G266-
um
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– Remove engine/gearbox connecting bolt -1-. t. C rig
gh ht
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Prote AG.
– Gearboxes for vehicles with start-stop system: pull connector

-arrow- off gearbox neutral position sender - G701- .
– Remove retainer for electrical wires from upper starter bolt.

– If fitted, unscrew earth strap -1- from lower starter bolt.

– Pull off connector for reversing light switch - F4- -2-.
– Remove starter ⇒ Electrical system; Rep. gr. 27 ; Starter;
Removing and installing starter .
– Clamp off hose of pipe/hose line -A- to clutch slave cylinder

using hose clamp up to 25 mm - 3094- .
– Pull out clip -arrow- for pipe/hose line onto stop.
– Pull off pipe/hose line with bleeder from clutch slave cylinder.
Caution
satelettronica
Risk of contamination due to brake fluid spill.
♦ Do not operate clutch pedal after detaching pipe/hose line
from bleeder connection on clutch slave cylinder.
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– Unscrew universal joint of steeringyrack Vol from steering pinion
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and remove track rods from wheel ed bbearing housing ⇒ Running ara
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gear, axles, steering; Rep. gr. ris
tho 48 ; Steering rack; Assembly eo
overview - steering rack .ss au ra
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– Secure steering rack with track rods to body.

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– Support gearbox using engine and gearbox jack - V.A.G 1383

erm
ab
A- or engine and gearbox jack - VAS 6931- .

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– Unscrew bolts for left power unit mounting -arrows-.

hole
spec
– Remove engine and gearbox jack .

es, in part or in w
t to the co
Note
rrectness of i
♦ When lowering or moving the engine/gearbox assembly, en‐

l purpos
sure that no lines and hoses are crimped or trapped.

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nf
ercia
tainers on the bulkhead.

orm
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– When lowering engine/gearbox assembly, watch out for cool‐

t
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ant hose of heat exchanger coolant pipe -1-.

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t.
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coolant hose must be pulled off the coolant pipe ⇒ Rep. gr. C py
t. rig
19 ; Cooling system/coolant; Connection diagram - coolant gh ht
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hoses . cop Vo
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Prote AG.

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Transporter gu 2016 ➤
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ho6-speed
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manual gearbox 0A5 - Edition 06.2019
eo
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– Lower engine/gearbox assembly to dimension -a- (approx.
ce
e
nl
100 mm) using spindle of support bracket - 10 - 222 A- .
pt
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– Measure dimension -a- between lower side of left longitudinal
erm
ab
member -1- and bolting surface of gearbox mounting -2-.
ility
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– When lowering engine/gearbox assembly, guide front engine
h re
hole
support with support mounting past body.
spec
es, in part or in w
– Ensure clearance between engine and right longitudinal mem‐
t to the co
ber.
Gearbox mounting to gearbox
rrectness of i
– Unscrew bolts -arrows- and remove gearbox mounting from l purpos
nf
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gearbox.
orm
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or c
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t.
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Cop py
t. rig
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by c lksw
cted agen
Prote AG.
– Remove upper engine/gearbox connecting bolts -arrows-.
– Remove engine/gearbox connecting bolts -1-.
Note
Do not remove bolts -arrows- yet.
To remove “0A5 all-wheel drive” gearbox, set up gearbox support

- 3282- with adjustment plate - 3282/65- .
– Insert gearbox support - 3282- in engine and gearbox jack -
V.A.G 1383 A- or engine and gearbox jack - VAS 6931- .
ment plate .
The symbols on the adjusting plate - 3282/65- indicate the sup‐
ports required. The arrow on the adjustment plate does not point
in direction of travel.


under vehicle.
– Secure support -arrow- to gearbox with a bolt M10 x 20.
– Support bevel box with support bracket of gearbox support -
satelettronica
3282- .
Note
Due to the modified housing contour of the bevel box, the mount‐
ing pin has to be rotated by 90° and the bend must point to the
right-hand side of the vehicle.
– Remove engine/gearbox connecting bolts -arrows-.

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– Press gearbox off engine (dowel sleeves) and carefully swing
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towards left longitudinal member. Volks not
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– Before lowering gearbox, check whether engine ho wiring har‐
r eo
ut
ness is located above gearbox selector lever.
ss
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erm
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ility
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spec
es, in part or in w
t to the co
– Lower gearbox carefully. When doing this, guide reversing

light switch - F4- -arrow- on longitudinal member and output
flange of bevel box past steering rack.
rrectness of i
l purpos
Note
When lowering the gearbox, take note of the power steering lines.
nf
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Rep. gr.34 - Controls, housing Prote AG.
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horis
eo Transporter 2016 ➤
ut
ss a 6-speed manual gearbox ra
c 0A5 - Edition 06.2019
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le
un
pt
3.3 Installing gearbox
an
d
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rm
ab
⇒ “3.3.1 Installing gearbox, vehicles with front-wheel drive”, page
pe
ility
89
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⇒ “3.3.2 Installing gearbox, vehicles with all-wheel drive”,
hole
spec
page 94
es, in part or in w
t to the co
3.3.1 Installing gearbox, vehicles with front-
wheel drive
rrectness of i
l purpos
Note
nform
mercia
a
♦ Refer to procedure “Removing gearbox” for required special
com
tio
tools ⇒ page 69 .
n in
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te o
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♦ Renew bolts that are tightened with turning further angle after
um
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each removal.
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t.
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satelettronica
py
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t. C rig
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screwed must be carefully cleaned of residual locking fluid us‐ p by
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ing a thread chaser.
lksw
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Prote AG.
♦ All cable ties which have been opened or cut during removal
must be renewed and placed in the same position when in‐
stalling.
♦ Clean splines of drive shaft and, if the clutch plate has been
used, clean the splines of the hub. Remove corrosion, and
apply a very thin coat of clutch plate spline grease to splines
⇒ Electronic Parts Catalogue (ETKA) . Then, move the clutch
plate back and forth on the drive shaft until the hub moves
easily on the shaft. Remove excessive grease.
Caution
When doing any repair work, especially in the engine compart‐

ment, pay attention to the following due to the cramped condi‐
tions:
♦ Route all the various lines and electrical wiring so that they
are in their original positions.
♦ Make sure there is adequate clearance from all moving or
hot parts.
If current gearbox is re-installed:

– Renew retaining ring -arrow A- and left oil seal -arrow B- on
stub shaft.

– Renew oil seal -arrow- on right on stub shaft.

Continued for all gearboxes
– Grease left and right stub shaft splines -2- with clutch plate
spline grease ⇒ Electronic Parts Catalogue (ETKA) .
– Check whether dowel sleeves for aligning engine and gearbox
are fitted in cylinder block and install if necessary.
If dowel sleeves are not fitted, difficulties shifting gears, clutch
problems and possible noises from the gearbox (rattling of gears
which are not engaged) could occur.
– Check clutch release bearing for wear. Renew clutch slave
cylinder with release bearing if necessary ⇒ page 33 .
– Ensure that intermediate plate is correctly seated on engine.
To install gearbox “0A5”, set up gearbox support - 3282- with ad‐
justment plate - 3282/40- .
ment plate .
The symbols on the adjusting plate indicate the supports required.
The arrow on the adjustment plate points in direction of travel.
satelettronica
– Place gearbox on engine and gearbox jack - V.A.G 1383 A- or
engine and gearbox jack - VAS 6931- .
– Align adjustment plate and gearbox parallel to one another.
wage
– Lock safety support -arrow- toVogearbox.
lks es n
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pt
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ab
ility
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, is n
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spec
es, in part or in w
t to the co

rrectness of i
under gearbox.
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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t. rig
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– Raise gearbox, and guide reversing light switch - F4- -arrow-

past left longitudinal member.
– Align gearbox to engine.
Caution AG. Volkswagen AG d

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♦ Brake fluid may escape out of clutch hslave
orise
cylinder/bleed‐ nte
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er on gearbox. aut ra
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ss
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– Insert gearbox. It must be possible to guide the engine and
itte
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gearbox together by hand until the engine flange and gearbox
erm
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ility
flange make contact all around.
ot p
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– Screw one engine/gearbox connecting bolt finger-tight in each
h re
ole,
side.
spec
t to the co
– Tighten bolts -arrows- to specified torque.
– After gearbox has been bolted to engine, remove gearbox
rrectne
support - 3282- .
satelettronica
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
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pr
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r
fo
en
ng
t.
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– Screw in upper engine/gearbox connecting bolts -arrows- and
Co
op py
tighten.
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ht ht
rig by
copy Vo
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cted agen
Prote AG.
– Tighten engine/gearbox connecting bolts -2- to specified tor‐

que.
– If present, install support for diesel particulate filter -1- ⇒ Rep.
gr. 26 ; Cleansing exhaust emissions .
– Align engine and gearbox in installation position using spin‐
dles of adapter - 10 - 222 A /16- .

– Install left assembly mounting using new hexagon bolts

-arrows- and tighten bolts.
WARNING
Do not remove support bracket - 10 - 222 A- until the bolts

securing the assembly mounting have been tightened to speci‐
fied torque.
– Install front engine support mounting, and tighten bolts

⇒ page 103 .
– If present, connect connector for tachograph sender - G75- .
Note

– Slide pipe/hose line -A- with bleeder connection to stop onto
satelettronica
clutch slave cylinder. Then, push down clip -arrow-. agen
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– Test line by tugging on it. d by V gu
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– Remove hose clamp to 25 mm - 3094- . autho eo
ra
ss c
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pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Install starter ⇒ Electrical system; Rep. gr. 27 ; Starter; As‐
sembly overview - starter .
– If featured, screw earth strap -1- onto lower starter bolt.
rrectness of i
– Push on connector for reversing light switch - F4- -2-.
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
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rp
cum
fo
en
ng
t.
– Gearboxes for vehicles with start-stop system: join connector
yi Co
op py
-arrow- to gearbox neutral position sender - G701- . t. C rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

– Push right drive shaft -1- onto gearbox stub shaft.

– Screw bolts -arrows- into front engine support, and tighten
them to specified torque ⇒ Running gear, axles, steering;
AG. VolkswRep.
agen AG
gr. 40 ; Drive shaft; Removing and installingagen does
olksw drive shaft . not
V y gu
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– Install left drive shaft ⇒ Runningorigear,
se axles, steering; Rep. nte
gr. 40 ; Drive shaft; Removing au
thand installing drive shaft . eo
ra
ss c
ce
e
nl
pt
du
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itte
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erm
ab
ility
Vehicles with petrol engine
ot p
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– Install bracket for catalytic converter ⇒ Rep. gr. 26 ; Exhaust
h re
hole
gas treatment; Assembly overview - exhaust gas treatment .
spec
es, in part or in w
t to the co
rrectness of i
– Pull back catch of cable support bracket -1- -arrow A- and in‐
l purpos
sert into gearbox -2- -arrow B-.
satelettronica
nf
ercia
orm
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om
n in
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te
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Cop py
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Prote AG.


– Lightly grease pin of gearbox selector lever -4- and relay lever
-3- with grease for selector mechanism ⇒ Electronic Parts
Catalogue (ETKA) .
– Check selector cables are securely attached to gearbox se‐
lector lever and relay lever.
Securing clips must be engaged.
– Check function of selector mechanism and adjust if necessary
⇒ page 63 .
view – charge air system .
– If necessary, fit coolant hose on coolant pipe and replenish
coolant ⇒ Rep. gr. 19 ; Cooling system/coolant; Draining and
filling coolant .
– Put on deflector caps for suspension struts.
satelettronica
– Install bulkhead panels ⇒ General body repairs, exterior; Rep.
gr. 50 ; Bulkhead; Assembly overview - bulkhead .
– Connect battery and follow procedure after connecting battery
⇒ Electrical system; Rep. gr. 27 ; Battery; Disconnecting and
connecting battery .
– Install right cover and battery cover ⇒ General body repairs,
exterior; Rep. gr. 63 ; Front bumper . n AG. Volkswagen A
age G do
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– Check gear oil level ⇒ page 156 . by Vol ot g
ua
ed ran
– If present, install noise insulation ⇒ General
oris body repairs, ex‐ tee
th or
terior; Rep. gr. 66 ; Noise insulation;
ss auAssembly overview - ac
noise insulation .
ce
le
un
pt
an

d
itte
y li

erm
ab
ility
ot p
Specified torques
wit
is n
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♦ ⇒ “3.1 Specified torques for gearbox”, page 69

ole,
spec
♦ ⇒ “4.1 Assembly overview - assembly mountings”, page 103

t to the co
3.3.2 Installing gearbox, vehicles with all-

rrectne
wheel drive
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
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Cop py
t. rig
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by c lksw
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Prote AG.

AG. Volkswagen AG d
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b
Note rise
d ara
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au ra
♦ Refer to procedure “Removing
s gearbox” for required special
s c
tools ⇒ page 78 .
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
♦ Renew bolts that are tightened with turning further angle after ot p
each removal.
wit
is n
h re
ole,
♦ All threaded holes into which self-locking bolts are to be
spec
screwed must be carefully cleaned of residual locking fluid us‐
t to the co
ing a thread chaser.
♦ All cable ties which have been opened or cut during removal
must be renewed and placed in the same position when in‐
rrectne
stalling.
♦ Clean splines of drive shaft and, if the clutch plate has been
ss
used, clean the splines of the hub. Remove corrosion, and
o
cial p
f i
apply a very thin coat of clutch plate spline grease to splines
nform
⇒ Electronic Parts Catalogue (ETKA) . Then, move the clutch
mer
atio
plate back and forth on the drive shaft until the hub moves
om
easily on the shaft. Remove excessive grease.
satelettronica
c
i
or
n thi
te
sd
iva
o
pr
c
Caution
um
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fo
en
ng
t.
yi Co
op
When doing any repair work, especially in the engine compart‐ C py
t. rig
ment, pay attention to the following due to the cramped condi‐
gh ht
pyri by
tions:
co Vo
by lksw
cted agen
Prote AG.
♦ Route all the various lines and electrical wiring so that they
are in their original positions.
♦ Make sure there is adequate clearance from all moving or
hot parts.
If current gearbox is re-installed:

– Renew circlip -arrow A- and O-ring -arrow B- on left stub shaft.

AG. Volkswagen A
n G do
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Volks ot g
– Renew circlip -arrow A- and O-ring ed -arrow B- on
by right stub ua
ran
shaft. oris tee
th or
au ac
Continued for all gearboxes ss
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le
un
pt
– Grease splines of stub shafts on left and right with grease for
an
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clutch plate splines ⇒ Electronic Parts Catalogue (ETKA) .
y li
erm
ab
ility
– Check whether dowel sleeves for aligning engine and gearbox
ot p
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are fitted in cylinder block and install if necessary.
is n
h re
ole,
If dowel sleeves are not fitted, difficulties shifting gears, clutch
spec
problems and possible noises from the gearbox (rattling of gears
t to the co
which are not engaged) could occur.
– Ensure that intermediate plate is correctly seated on engine.
rrectne
To install “0A5 all-wheel drive” gearbox, set up gearbox support
- 3282- with adjustment plate - 3282/65- .
ss
o
cial p
f
ment plate .
inform
mer
The symbols on the adjusting plate - 3282/65- indicate the sup‐
atio
m
ports required. The arrow on the adjustment plate does not point
o
n
c
in direction of travel.
i
or
n thi
satelettronica
te
sd
a
– Place gearbox on engine and gearbox jack - V.A.G 1383 A- .

iv
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cum
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en
ng
– Align adjustment plate - 3282/65- and gearbox parallel to one

t.
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another. C py
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– Secure support -arrow- to gearbox with a bolt M10 x 20.
py by
co Vo
by lksw
cted agen
Prote AG.
– Support bevel box with support bracket of gearbox support -

3282- .
Note
Due to the modified housing contour of the bevel box, the mount‐
ing pin has to be rotated by 90° and the bend must point to the
right-hand side of the vehicle.

– Raise gearbox. When doing this, guide reversing light switch

- F4- -arrow- on longitudinal member and propshaft flange of
bevel box past steering rack.
Note
When raising the gearbox, take note of the power steering lines.
– Align gearbox to engine.
Caution
♦ Brake fluid may escape out of clutch slave cylinder/bleed‐

er on gearbox.
– Insert gearbox. It must be possible to guide the engine and

gearbox together by hand until the engine flange and gearbox
flange make contact all around.
– Screw one engine/gearbox connecting bolt finger-tight in each
satelettronica
side.
– Tighten engine/gearbox connecting bolts -arrows- to specified

torque. AG. Volkswagen AG d
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– After gearbox has been bolted to engine, remove gearbox
byV
ol
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support - 3282- . ris
ed
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– Tighten engine/gearbox connecting bolts -1-.ss au ra
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t to the co
– Screw in engine/gearbox connecting bolt -arrow- behind bevel
box and tighten.
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
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ate
do
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cum
for
en
ng
t.
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– Tighten upper engine/gearbox connecting bolts -arrows-.
AG. Volkswagen AG d
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– Install gearbox mounting on gearbox using bolts -arrows-.

un
pt
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itte
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– Raise engine/gearbox using spindles of adapter - 10 - 222 A /
rm
ab
16- and align in installation position.
pe
ility
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hole
spec
es, in part or in w
t to the co
satelettronica
rrectness of i
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– Install left assembly mounting using new hexagon bolts nform

ercia
-arrows- and tighten bolts.

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tion in
WARNING
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iva
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Do not remove support bracket - 10 - 222 A- until the bolts

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securing the assembly mounting have been tightened to speci‐

fo
en
g
fied torque.
n
t.
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– Mount steering rack on universal joint and track rods on wheel by c lksw
cted agen
bearing housing ⇒ Running gear, axles, steering; Rep. gr. Prote AG.
48 ; Steering rack; Assembly overview - steering rack .
– Slide pipe/hose line -A- with bleeder connection to stop onto

clutch slave cylinder. Then, push down clip -arrow-.
– Remove hose clamp to 25 mm - 3094- .

– Install starter ⇒ Electrical system; Rep. gr. 27 ; Starter; Re‐

moving and installing starter .
– If featured, screw earth strap -1- onto lower starter bolt.
– Push on connector for reversing light switch - F4- -2-.
lkswage es n
o ot g
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d ran
ir se tee
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u or
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– Gearboxes for vehicles with start/stop system: join connector
ss
ce
e
-arrow- to gearbox neutral position sender - G701- .
nl
pt
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itte
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erm
ab
ility
ot p
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hole
spec
es, in part or in w
satelettronica
t to the co
rrectness of i
l purpos
– Push connector onto oil level and temperature sensor - G266-

-2-.
nf
ercia
or
– Tighten engine/gearbox connecting bolt -1- to specified tor‐
m
m
atio
que.
om
n in
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thi
te
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co lksw
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cted agen
Prote AG.
– Clip wiring harness -1- into retainer -2- of gearbox housing.

– Bolt rear engine support -1- to cylinder block -4- ⇒ Rep. gr.
10 ; Assembly mountings; Assembly overview - assembly
mountings .
AG. Volkswagen AG d
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– Bolt gearbox carrier -3- to rear engine support and bevel box
hole
spec
(bolts -1- and -2-). Note tightening sequence when doing so
es, in part or in w
⇒ page 44 .
t to the co
rrectness of i
l purpos
satelettronica
nform
mercia
at
om
ion
c
in t
or
his
ate
– Install bracket for diesel particulate filter -2- ⇒ Rep. gr. 26 ;
do
priv
c
Exhaust gas treatment; Assembly overview - exhaust gas
um
for
treatment .
en
ng
t.
yi Co
Cop py
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rig ht
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Prote AG.

– If featured, join electrical connector for tachograph sender -

G75- -arrow-.
Note

– Press right drive shaft onto bevel box stub shaft ⇒ Running
gear, axles, steering; Rep. gr. 40 ; Drive shaft; Removing and
installing drive shaft .
– Install left drive shaft ⇒ Running gear, axles, steering; Rep.
gr. 40 ; Drive shaft; Removing and installing drive shaft .
– Install front propshaft ⇒ Rep. gr. 39 ; Propshaft; Removing
– Install diesel particulate filter ⇒ Rep. gr. 26 ; Emission control;
satelettronica
Removing and installing diesel particulate filter .
AG. Volkswagen AG d
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– Pull back d bycatch of cable support bracket -1-gu-arrow
V
ara A- and in‐
sert into
oris gearbox -2- -arrow B-.
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– Lightly grease pin of gearbox selector leveryV
olk-4- and relay lever
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-3- with grease for selector mechanism ed ⇒ Electronic Parts
b ran
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Catalogue (ETKA) . utho tee
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– Check selector cables are securely attached to gearbox se‐
rm
ab
lector lever and relay lever.
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Securing clips must be engaged.
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– Check function of selector mechanism and adjust if necessary
spec
es, in part or in w
⇒ page 63 .
t to the co
view – charge air system .
rrectness of i
– If necessary, fit coolant hose on coolant pipe and replenish
l purpos
coolant ⇒ Rep. gr. 19 ; Cooling system/coolant; Draining and

filling coolant .
nform
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– Put on deflector caps for suspension struts.

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– Install bulkhead panels ⇒ General body repairs, exterior; Rep.
on in
gr. 50 ; Bulkhead; Assembly overview - bulkhead .
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– Connect battery and follow procedure after connecting battery
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connecting battery .
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rig ht
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– Check oil level in gearbox ⇒ page 156 . Prote AG.
– Check gear oil level in bevel box ⇒ page 51 .

noise insulation .
Specified torques
♦ ⇒ “3.1 Specified torques for gearbox”, page 69
♦ ⇒ “4.1 Assembly overview - assembly mountings”, page 103

AG. Volkswagen AG d
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ss
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⇒ “4.1 Assembly overview - assembly mountings”, page 103
wit
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4.1 Assembly overview - assembly mount‐
ole,
spec
ings
t to the co
Gearbox mounting to body
– Renew bolts -arrow- each time after removing.
rrectne
Component Specified torque
ss
Bolts securing gearbox mount‐ 50 Nm +90°
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Gearbox mounting to gearbox
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– Renew bolts -arrow- each time after removing. copy Vo
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Bolts securing gearbox mount‐ 50 Nm +90°
ing to gearbox
Front engine support

– Renew bolt -1- each time after removing.
Bolt for front engine support 90 Nm +180°
4. Assembly mountings 103

5 Transporting gearbox
♦ Extensions - 2024 A /1-
♦ Lifting tackle - 3033-
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♦ Shackle - 10 - 222 A /12-

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♦ Workshop hoist - VAS 6100-

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Vehicles with front-wheel drive
Shackle - 10 - 222 A /12- -C- in conjunction with hook - 10 - 222
rrectne
A /2- -B- and workshop hoist - VAS 6100- -A- can be used to
transport manual gearbox -1- and to set up gearbox support -
s
3282- .
s o
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– Fasten shackle - 10 - 222 A /12- to gearbox casing.
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– Support gearbox with workshop crane - VAS 6100- and hook
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- 10 - 222 A /2- .
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p by
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support - 3282- , extensions - 2024 A /1- and shackles - 10 - 222 Prote
cted AG.
agen
A /12- can be used in conjunction with lifting tackle - 3033- and
workshop hoist - VAS 6100- .
– Secure extensions - 2024 A /1- to gearbox housing and to
bevel box housing.
– Support gearbox with workshop hoist - VAS 6100- and lifting
tackle - 3033- in conjunction with shackles - 10 - 222 A /12- .
5. Transporting gearbox 105

6 Dismantling and assembling gearbox

⇒ “6.1 Schematic overview - gearbox”, page 106
⇒ “6.2 Differentiating between gearboxes”, page 108
⇒ “6.3 Assembly overview - gearbox housing and selector mech‐
anism”, page 109
⇒ “6.4 Assembly overview - selector unit”, page 113
⇒ “6.5 Assembly overview - input shaft, output shafts, differential,
selector rods”, page 114
⇒ “6.6 Assembly overview - selector forks”, page 115
⇒ “6.7 Dismantling and assembling gearbox”, page 116 AG. Volkswagen AG d
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6.1 Schematic overview - gearbox orised ara
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⇒ “6.1.1 Schematic overview - gearbox, front-wheel drive”,
ss a c
page 106
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⇒ “6.1.2 Schematic overview - gearbox, all-wheel drive”,

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page 107
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6.1.1 Schematic overview - gearbox, front-wheel drive
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1 - Clutch housing
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gear
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2nd gear
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4 - Clutch slave cylinder with
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release bearing
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5 - Input shaft
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gears for 5th and 6th
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6 - Output shaft for 3rd/4th gear

7 - Differential
8 - Right stub shaft
9 - Left stub shaft
10 - Gearbox housing
11 - Synchromeshed gear for 4th gear
12 - Synchromeshed gear for 3rd gear
14 - Synchromeshed gear, 5th gear
15 - Synchromeshed gear, 2nd gear
16 - Synchromeshed gear, 1st gear
17 - Synchromeshed gear for reverse gear
6.1.2 Schematic overview - gearbox, all-wheel drive
satelettronica
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1 - Clutch housing
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2 - Output
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4 - Clutch slave cylinder with

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5 - Input shaft
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gears for 5th and 6th

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6. Dismantling and assembling gearbox 107


7 - Differential
8 - Bevel box
9 - Right stub shaft
10 - Layshaft
11 - Output flange
12 - Shaft bevel gear
13 - Bevel gear with stub shaft
14 - Left stub shaft
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17 - Synchromeshed gear for
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18 - Synchromeshed gear
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19 - Synchromeshed gear, 5th gear
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20 - Synchromeshed gear, 2nd gear

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21 - Synchromeshed gear, 1st gear
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6.2 Differentiating between gearboxes
The following components are different, when a bolted deep
rrectne
groove ball bearing is used:

♦ Gearbox housing is closed and has no sealing cover
ss o
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♦ Input shaft is shorter and has different diameter

inform
mer
♦ Deep groove ball bearing is larger and has bolted bearing plate
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Gearbox with sealing cover on gearbox housing

1 - Cap
2 - Locking plate
3 - Bolts for locking plate

Gearbox without sealing cover on gearbox housing

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1 - Deep groove ball bearing in gearbox housing
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2 - Bolts for deep groove ball bearing
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6.3 Assembly overview - gearbox housing
and selector mechanism
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⇒ “6.3.1 Assembly overview - gearbox housing and selector
l purpos
mechanism, gearbox with sealing cover on gearbox housing”,

page 109
nform
ercia
⇒ “6.3.2 Assembly overview - gearbox housing and selector

mechanism, gearbox without sealing cover on gearbox housing”,
satelettronica
m
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page 112
on
c
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or
6.3.1 Assembly overview - gearbox housing and selector mechanism, gearbox
his
ate
do
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with sealing cover on gearbox housing

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AG. Volkswagen AG d
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Transporter 2016 ➤ autho eo
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6-speed manual gearbox 0A5 - Edition 06.2019 ss c
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1 - Countersunk bolt
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❑ Specified torque
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⇒ page 222
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2 - Left stub shaft
hole
spec
❑ With spring
es, in part or in w
t to the co
⇒ page 212
❑ Assembling
rrectness of i
⇒ page 222
l purpos
3 - Retaining ring
❑ For deep groove ball
nf
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bearing of input shaft
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4 - Bolt
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❑ 5 Nm
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5 - Locking plate
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6 - Cap
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7 - Nut Cop py
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❑ 15 Nm +45°
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8 - Reversing light switch - F4-
agen
Prote AG.
❑ Switch without seal:

clean thread of switch if
necessary
❑ Switch without seal: in‐
stall switch with sealant
if necessary
❑ For allocation of seal‐
ant, refer to ⇒ Electronic
parts catalogue (ET‐
KA) .
❑ Switch with encapsula‐
ted seal: renew switch
❑ Switch with separate
seal: renew seal
❑ Lightly coat lug with MoS2 grease
❑ 20 Nm
9 - Seal
❑ Not fitted in all gearboxes
❑ If fitted, renew after removal
10 - Bolt
❑ 6 Nm
11 - Gearbox neutral position sender - G701-
❑ for vehicles with start/stop system
12 - Bolt
❑ 20 Nm +90°
13 - O-ring
14 - Selector unit
❑ Repairing ⇒ page 113
15 - Double stud
❑ 25 Nm

16 - Bolt
❑ 20 Nm +90°
17 - Cable support bracket
❑ For selector mechanism
❑ Secured to gearbox.
❑ Removing and installing mounting for cable support bracket ⇒ page 111
18 - Clutch housing
20 - Seal
❑ Discontinued
21 - Oil drain plug
❑ 35 Nm
Removing and installing mounting for cable support bracket
satelettronica
Removing
– Remove spacers -3- from grommets -2-.
AG. Volkswagen
– Then lever grommets wagout
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AG do
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– First sinsert grommets -2- in cable support -1-.
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Installation position of spacers -3-: larger diameter faces inner

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side of support bracket.

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– Press spacers into grommets from inside of cable support

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bracket.
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6.3.2 Assembly overview - gearbox housing and selector mechanism, gearbox

without sealing cover on gearbox housing
olks
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1 - Countersunk bolt tho eo
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⇒ page 222
un
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itte
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2 - Left stub shaft
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ab
pe
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❑ With spring
ot
wit
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⇒ page 212
hole
spec
❑ Assembling
es, in part or in w
t to the co
⇒ page 222
3 - Nut
rrectness of i
❑ For reverse gear selec‐
tor fork
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❑ 15 Nm +45°
4 - Reversing light switch - F4-
nform
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satelettronica
m
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com
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❑ Lightly coat lug with
n in
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MoS2 grease
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5 - Bolt
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❑ 6 Nm C py
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6 - Gearbox neutral position
py by
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sender - G701- Prote
cted AG.
agen
❑ for vehicles with start/

stop system
7 - Bolt
❑ Gearbox housing on
clutch housing
❑ 20 Nm +90°
8 - O-ring
9 - Selector unit
10 - Bolt
❑ 25 Nm
11 - Bolt
❑ M8 x 32
❑ 25 Nm +90°
12 - Cable support bracket
❑ Removing and installing mounting for cable support bracket ⇒ page 111
13 - Bolt
❑ M8 x 75
❑ 25 Nm +90°
14 - Bolt
❑ Clutch housing to gearbox housing

❑ 20 Nm +90°
15 - Clutch housing
17 - Oil drain plug
❑ Specified torque ⇒ Item 13 (page 147)
6.4 Assembly overview - selector unit
1 - Selector unit
❑ Consists of selector
shaft and selector shaft
cover
❑ Components cannot be
separated from each
other
2 - Seal for selector shaft
satelettronica
AG. Volkswagen AG d
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3 - Cap olksw not
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4 - Dowel sleeve ss a c
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5 - O-ring
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spec
❑ Coat with gear oil when
t to the co
installing
rrectne
6 - Bearing bush
❑ For selector shaft in
ss
gearbox housing
o
cial p
f in
❑ Removing ⇒ page 152
form
mer
❑ Driving in ⇒ page 152

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6.5 Assembly overview - input shaft, output shafts, differential, selector rods

gear
❑ Dismantling and assem‐ agen
AG. Volkswagen AG d
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❑ Fitting position rised
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⇒ page 115 aut
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⇒ page 115
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❑ Dismantling and assem‐
es, in part or in w
t to the co
bling ⇒ page 182
⇒ page 115
rrectness of i
satelettronica
4 - Selector rod with selector
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fork for 1st/2nd gear

nf
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⇒ page 115
orm
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5 - Output shaft for 3rd/
atio
m
4th gear
o
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❑ Dismantling and assem‐
thi
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bling ⇒ page 191

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⇒ page 115
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6 - Selector rod with selector
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by
fork for 3rd/4th gear copy Vo
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❑ Fitting position Prote AG.
⇒ page 125
7 - Input shaft
gears for 5th/6th gear
❑ Dismantling and assembling ⇒ page 163
8 - Selector rod with selector fork for 5th/6th gear
9 - Clutch housing
10 - Differential

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Installation position of shafts and selector
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1 - Output shaft for reverse sgearedb ara
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2 - Output shaft for 1st/2nd
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3 - Input shaft
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A - Selector fork for reverse gear
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B - Selector rod for 1st/2nd gear
h re
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spec
C - Selector rod for 5th/6th gear
t to the co
D - Selector rod for 3rd/4th gear
6.6 Assembly overview - selector forks
rrectness
1 - Selector rod
o
cial p
f in
❑ With selector fork for
form
mer
5th and 6th gears.
atio
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satelettronica
2 - Sliding bushes
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❑ For selector shafts
thi
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❑ Removing from and in‐

i
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pr
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stalling in gearbox hous‐

fo
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ing ⇒ page 150

t.
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❑ Removing from and in‐
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⇒ page 152
lksw
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3 - Ball sleeves
4 - Selector rod
3rd and 4th gears.
5 - Selector rod
1st and 2nd gears.
6 - Selector fork for reverse
gear
7 - Nuts
⇒ page 109

AG. Volkswagen AG d
agen oes
Transporter 2016 ➤ Vol
ksw not
gu
by
6-speed manual gearbox 0A5 - Editionris06.2019
ed ara
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tho eo
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6.7 Dismantling and assembling gearbox ss c
ce
le
un
pt
⇒ “6.7.1 Dismantling and assembling gearbox, gearbox with seal‐
an
d
itte
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ing cover on gearbox housing”, page 116
rm
ab
pe
ility
⇒ “6.7.2 Dismantling and assembling gearbox, gearbox without
ot
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sealing cover on gearbox housing”, page 132
h re
hole
spec
6.7.1 Dismantling and assembling gearbox, gearbox with sealing cover on gear‐
es, in part or in w
t to the co
box housing
Removing and installing gearbox housing, selector unit, input
rrectness of i
shaft, output shafts, differential and selector rods.
l purpos

equipment required
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♦ Retainer - VW 309-
♦ Gearbox support - VW 353-
♦ Installing sleeve - VW 455-
♦ Multi-purpose tool - VW 771-
♦ Support bridge - 30 - 211 A- or support bridge - T10323-
♦ Fitting tool - 3046-

AG. Volkswagen AG d
agen oes
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es, in part or in w
t to the co
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nform
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ion
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ate
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♦ Counter-hold tool - 3435- opyri
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♦ Thrust piece - T10042-
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♦ Hot-air blower - V.A.G 1416-
♦ -1- internal puller, e.g. KUKKO 21-01 - VAS 251 603-
♦ -3- splitter, e.g. KUKKO 17-0 - VAS 251 407-
♦ -4- counter support, e.g. KUKKO 22-1 - VAS 251 621-

6-speed manual gearbox 0A5 - Edition n AG. Volkswagen AG do
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♦ Assembly drift - 3384- (with front-wheel drive)

♦ Socket - T10107 A- (with four-wheel drive)
♦ Thrust piece - T10232- (with front-wheel drive)
♦ Extractor hook - T20143-

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♦ Sealing paste ⇒ Electronic parts catalogue (ETKA)
t to the co
Dismantling
rrectness of i
– Secure gearbox to assembly stand ⇒ page 155 .
l purpos
– Drain gear oil.
nform
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satelettronica
Gearbox for front-wheel drive
m
at
– Remove clutch slave cylinder with clutch release bearing
om
-arrows A-. ion

c
in t
or
his
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– Remove securing bolt for right stub shaft -arrow B-. Counter‐
a
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hold stub shaft with counter-hold tool - T10140- or counter-

p
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hold tool - T50053- when doing this.

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– Pull out stub shaft. C py
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– Lever out stub shaft oil seal with assembly lever.
cop Vo
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Prote AG.
Gearbox for all-wheel drive

– Remove clutch slave cylinder with clutch release bearing
-arrows A-.
– Remove securing bolt for right stub shaft with socket and ex‐
tended bit 6 mm - T10107 A- . Counterhold stub shaft with
counter-hold tool - T10140- or counter-hold tool - T50053-
when doing this.
Note
♦ Leave stub shaft in installation position in bevel box and do not

pull out.
♦ If the stub shaft is removed, the gear oil in the bevel box must
first be drained.
– Tighten 4 connecting bolts -arrows B- (only 3 are shown in

figure) of bevel box on manual gearbox.
– Carefully press bevel box off gearbox, taking care that it does
not fall.

– Lever bevel box oil seal out of clutch housing using puller hook
- T20143/2- .

– Unscrew bolts for securing clutch housing to gearbox housing.
satelettronica
– Lock input shaft -B-. To do so, place installing sleeve - VW
455- on clutch housing over input shaft.
– Clamp splitter, e.g. KUKKO 17-0 - VAS 251 407- -A- behind
notch in splines of input shaft.
• The back side of splitter must rest against installing sleeve -
VW455- without play.
– Place selector shaft of selector unit in neutral.
AG. Volkswagen AG d
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– Gearboxes for vehicles with start-stop system: remove gear‐
ce
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un
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box neutral position sender - G701- -arrow-.

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Note
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Disregard items -A and C-.

spec
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Rep. gr.34 - Controls, housing
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– Unscrew centre hex stud for selector unit -B- from gearbox
housing.
– Remove reversing light switch - F4- -A-.
– Pull selector unit out of gearbox housing
-in direction of arrow- while turning selector unit 180°.
• Selector fingers of selector unit must be guided through se‐
lector rods.
– Remove cable support bracket -C-.
– Unscrew nuts -D-.
– If fitted, remove tachograph sender - G75- -1-.
satelettronica
– Remove locking plate -1-.
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– Pierce rubber in centre of cover -C- with a screwdriver.

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– Pull sealing cover out of gearbox housing.

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A - Counter support, e.g. KUKKO 22-1 - VAS 251 621-

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B - Internal puller e.g. KUKKO 21-01 - VAS 251 603-

hole
spec
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Prote AG.
6. Dismantling and assembling gearbox
Note
Sealing cover -1- can also be levered off carefully using a screw‐
driver -2-.
Remove circlip -C- from deep groove ball bearing of input shaft
as follows:
– Hold one end of circlip using screwdriver -A-.
– With a second screwdriver -B-, lever other end of circlip out of
groove in deep groove ball bearing -arrow-.
– Using screwdriver -B-, lever circlip out further.
satelettronica
AG. Volkswagen AG d
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– Unscrew and remove
aut securing bolt for left stub shaft -A-. ra
c
Counterhold stub
ss
shaft with counter-hold tool - T10140- or
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counter-hold tool - T50053- when doing this.

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– Pull out stub shaft.

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– Pull out stub shaft oil seal using multi-purpose tool - VW 771-
wit
and multi-purpose tool - VW 771/37- .

, is n
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hole
– Remove bolts -B- and -C- for securing gearbox housing to

spec
clutch housing.
es, in part or in w
t to the co
Note
rrectness of i
Cover plate -D- and bolts -E- do not need to be removed in order
l purpos
to remove gearbox housing.

nform
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c
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do
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Cop py
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Prote AG.

– Screw multi-purpose tool - VW 771/44- to stop into threaded

hole of gearbox housing, and counterlock it with nut -A-.
– Heat gearbox housing using e.g. hot air blower - V.A.G 1416-
in vicinity of bearing seat for deep groove ball bearing/input
shaft for about 10 minutes to approx. 100°C.
– Detach gearbox housing from clutch housing using multi-pur‐
pose tool VW 771 . At same time, press gearbox housing away
from clutch housing at housing shoulder -arrow- using assem‐
bly lever -B-.
– Remove splitter -A- and installing sleeve - VW 455- from input
satelettronica
shaft -B-.
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– Remove reverse gear selector fork -A-. ce
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t to the co
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– Raise input shaft -1- in -direction of arrow- until counterhold

tool - 3435- can be pushed in.
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– Secure stub shaft -1- to differential so that differential can be

raised during following steps.
– Remove output shaft for 3rd/4th gear -2- together with selector
rod -3-.
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– Remove output shaft for reverse gear output shaft -A- and then
, is n
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output shaft for 1st/2nd gear -B- together with selector rod
hole
spec
-C- from clutch housing.
es, in part or in w
t to the co
rrectness of i
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satelettronica
nform
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c
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– Remove input shaft -1- together with selector rod -2-.

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– Pull out differential -3- on stub shaft.

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– Remove input shaft oil seal.

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Always renew deep groove ball bearing on input shaft
⇒ Item 16 (page 161) .
Installing
• A new deep groove ball bearing has been pressed onto the
input shaft ⇒ Item 16 (page 161) .
– Secure support bridge - 30 - 211 A- or support bridge - T10323-

for input shaft to clutch housing and to gearbox support - VW
353- .
– When doing this, place washers or a nut -A- with a total thick‐
ness of about 16 mm between clutch housing and support
bridge - 30 - 211 A- or support bridge - T10323- .
– Insert input shaft -1- in clutch housing together with selector
rod for 5th/6th gear.
C-
Lock nut

. Volkswagen AG
gen AG does
Raise input shaft -1- to dimension -a- by turning spindle of fitting
Vol
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not
tool - 3046- . Then tighten lock nut ⇒ page 124 . ed
by gu
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• Dimension -a- = 10 mm. utho eo
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– Secure left stub shaft -arrow- to differential -1- so that differ‐
rrectness of i
ential can be raised during following steps.
l purpos
– Insert differential -1-.

– Place output shaft for 1st/2nd gear -2- together with selector
nf
ercia
rod -4- into bearing seat. Then, swing it towards input shaft
or
-3-.
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– Guide reverse gear output shaft -1- under teeth of 1st gear
ht
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synchromeshed gear -arrow A- and then set in bearing seat
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-arrow B-. Prote AG.
– Fit output shaft for 3rd/4th gear -2- together with selector rod
for 3rd/4th gear -1-.
Installation position of selector rod for 3rd and 4th gears (no.
-1-)
Shorter arm -arrow- faces clutch housing.
– Detach left stub shaft -3- from differential.

– Loosen lock nut -C-.

– Lower input shaft -B- via spindle of fitting tool - 3046- far
enough that it remains slightly under tension (raised about
AG. Volkswagen AG d
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– Insert reverse gear selector fork -A- in locking collar of reverse
spec
gear output shaft.
es, in part or in w
t to the co
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satelettronica
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• Studs -arrows- must be vertical before gearbox housing is set
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• Deep groove ball bearing of input shaft fits into gearbox hous‐ Cop py
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• Flats -A- on deep groove ball bearing and on bearing support
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-B- in gearbox housing must line up.
AG.
– Mark flat sections with colour.

– Transfer markings to upper area of deep groove ball bearing
and to upper area of bearing support of gearbox housing (⇒
next illustration).
– Heat gearbox housing using, e.g. hot air blower - V.A.G 1416-
for about 10 minutes to 100 °C in vicinity of seat for deep
groove ball bearing of input shaft.
Note
Heating is necessary to avoid damage to deep groove ball bear‐

ing when gearbox housing is installed.
– Apply sealant evenly to sealing surface of clutch housing.

– Line up marking on deep groove ball bearing -A- with marking

on gearbox housing -B- and set gearbox housing in place.
– Note studs for reverse gear selector fork ⇒ page 126 .
• Do not cant gearbox housing when setting it in place. Guide
parallel to clutch housing.
– Install retaining ring -1- for deep groove ball bearing of input
shaft.
– Remove support bridge - 30 - 211 A- or support bridge -
T10323- for input shaft.
– Tighten bolts for securing clutch housing to gearbox housing.
satelettronica
AG. Volkswagen AG d
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– Tighten bolts -B- and -C- for securing gearbox
rised housing to ara
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clutch housing. ut
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Note
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If sealing cover -D- and bolts -E- were removed, install these parts
ility
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now. Renew bolts -E-.
wit
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t to the co
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mer
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– Lightly oil outer diameter of new oil seal for left stub shaft and
thi
te
sd
drive in onto stop using thrust piece - T10232- .

iva
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Cop py
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Prote AG.

– Fill space between dust lip and sealing lip half full with sealing
grease ⇒ Electronic Parts Catalogue (ETKA) .
– Insert left stub shaft -A- together with compression spring,

thrust washer and tapered ring.
– Tighten left stub shaft securing bolt. Counterhold stub shaft
with counterhold tool - T10140- or counterhold tool - T50053-
when doing this.
Install selector unit as follows:
– Turn gearbox in repair stand with opening for selector unit up‐
satelettronica
wards.
– Move selector rods to neutral.
AG. Volkswagen AG d
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– Guide selector unit with selector finger -1- through reverse

wit
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gear selector fork, selector rod for 1st/2nd gears and selector
h re
hole
rod for 5th and 6th gear

spec
es, in part or in w
– Then turn selector unit 180° -in direction of arrow- and insert
t to the co
into gearbox housing to stop.

In the process, guide selector fingers -1- and -2- through selector
rrectness of i
rods.
l purpos
• Selector shaft must move freely in gate selection direction

(upwards and downwards).
nf
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– Tighten double flange bolts -1-.

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– Screw in reversing light switch - F4- -2-.

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– Tighten bolts -3-.

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– Fit cable support bracket -4-.
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– Gearbox for vehicles with Start/stop system: insert gearbox
cop Vo
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cted
neutral position sender - G701- -arrow- and tighten securing
agen
Prote AG.
bolt to specified torque.

– If present, install tachograph sender - G75- -1-.
– Before installing new input shaft seal, lightly oil outer diameter
and half-fill space between sealing lips -arrow- with sealing
grease .
satelettronica
AG. Volkswagen AG d
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– Drive in new input shaft seal.

pt
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es, in part or in w
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nf
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orm
– Lightly oil outer diameter of new oil seal for right stub shaft and
m
atio
m
drive in onto stop using assembly drift - 3384- .

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Cop py
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– Fill space between dust lip and sealing lip half full with sealing agen
AG. Volkswagen AG d
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grease ⇒ Electronic Parts Catalogue (ETKA) . olksw not
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– Insert stub shaft -arrow B- together with compression spring,
rrectness of i
– Tighten right stub shaft securing bolt. Counterhold stub shaft
l purpos

when doing this.
nform
ercia
– Install clutch slave cylinder with clutch release bearing using

new bolts -arrows A-.
m
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satelettronica
on in
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Cop py
Gearbox for all-wheel drive ht. rig
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– Drive oil seal for bevel box into clutch housing up to stop. Do by c lksw
cted agen
not cant oil seal in the process.
Prote AG.
– Fill space between dust lip and sealing lip half full with sealing
grease ⇒ Electronic Parts Catalogue (ETKA) .

– Install clutch slave cylinder using new bolts -arrows A-.

Attach bevel box to manual gearbox as follows.
– On manual gearbox, grease splines of differential with grease
⇒ Electronic Parts Catalogue (ETKA) .
– Push bevel box with stub shaft installed completely
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wage onto gear‐ es n
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– Guide splines of bevel box lay shaft
uth concentrically together
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with differential splines. ss
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– Align splines of right stub shaft and differential bevel gear; turn
pt
du
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stub shaft as necessary.
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– If splines are correctly positioned and shafts are centred, then
ility
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bevel box will slide to stop against gearbox.
wit
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spec
Note
es, in part or in w
t to the co
♦ Ensure that installation position of right stub shaft does not
change (is not pushed out of bevel box).
rrectness of i
♦ Do not use securing bolts to pull the bevel box against the
satelettronica
l purpos
gearbox as otherwise the bevel box will cant and the securing
eyes could break off.
nf
ercia
or
Tighten 4 connecting bolts -arrows B- (only 3 are shown in figure)
m
m
atio
of bevel box on manual gearbox.
om
n in
or c
– Use socket and extended bit 6 mm - T10107 A- to screw coun‐
thi
te
tersunk bolt for right stub shaft tight. Counterhold stub shaft
sd
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when doing this.
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Continued for all gearboxes C py
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– Shift through all gears. cop Vo
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Prote AG.
– Drive sealing cover into gearbox housing to stop of thrust piece
- T10042- .
– Secure locking plate -1- with bolts.

Specified torques
♦ ⇒ “1.3 Assembly overview - clutch release mechanism”, page
23
♦ ⇒ “2.1 Assembly overview - differential”, page 222
♦ ⇒ “6.3.1 Assembly overview - gearbox housing and selector
mechanism, gearbox with sealing cover on gearbox housing”,
page 109
♦ ⇒ “6.4 Assembly overview - selector unit”, page 113

6.7.2 Dismantling and assembling gearbox, gearbox without sealing cover on

gearbox housing
Removing and installing gearbox housing, selector unit, input
shaft, output shafts, differential and selector rods.

equipment required
wage
satelettronica
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♦ Gearbox support - VW 353- Cop py
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♦ Installing sleeve - VW 455- p by
co Vo
by lksw
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♦ Multi-purpose tool - VW 771- Prote AG.
♦ Support bridge - 30 - 211 A-

♦ Fitting tool - 3046-

AG. Volkswagen AG d
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wit
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es, in part or in w
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satelettronica
l purpos
nform
mercia
at
om
ion
c
in t
or
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ate
do
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for
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Cop py
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Prote AG.
♦ Assembly drift - 3384- (with front-wheel drive)

♦ Socket - T10107 A- (with four-wheel drive)
♦ Thrust piece - T10232- (with front-wheel drive)
♦ Counter-hold tool - T50053- or counter-hold tool - T10140-
♦ Splitter, e.g. KUKKO 17-0 - VAS 251 407-

AG. Volkswagen AG d
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♦ Counter-hold tool - 3435-
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♦ Guide bolt - T10341-

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Cop py
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♦ Sealing paste ⇒ Electronic parts catalogue (ETKA)

Dismantling
– Secure gearbox to assembly stand ⇒ page 155 .
– Drain gear oil.
– Unscrew bolts for clutch slave cylinder -arrows A-.
– Remove clutch slave cylinder together with clutch release
bearing.
– Remove securing bolt for right stub shaft -arrow B-. Counter‐
hold stub shaft with counter-hold tool - T10140- or counter-
hold tool - T50053- when doing this.
– Lever out stub shaft oil seal with assembly lever.

AG. Volkswagen AG d
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– Unscrew bolts for clutch slave cylinder -arrows A-.
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es, in part or in w
– Remove securing bolt for right stub shaft with socket and ex‐
t to the co
tended bit 6 mm - T10107 A- . Counterhold stub shaft with
when doing this.
rrectness of i
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♦ Leave stub shaft in installation position in bevel box and do not
orm
pull out.
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♦ If the stub shaft is removed, the gear oil in the bevel box must
or c
first be drained.
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– Tighten 4 connecting bolts -arrows B- (only 3 are shown in
o
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figure) of bevel box on manual gearbox.

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– Carefully press bevel box off gearbox, taking care that it does
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– Lever bevel box oil seal out of clutch housing using puller hook
- T20143/2- .

– Unscrew bolts for securing clutch housing to gearbox housing.

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– Lock input shaft -B-. To do so, place installing sleeveby-V VW
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455- on clutch housing over input shaft. rised
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– Clamp splitter, e.g. KUKKO 17-0 - VAS 251ss407- -A- behind
a ra
c
notch in splines of input shaft.
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• The back side of splitter must rest against installing sleeve
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– Unscrew bolts -arrow-.
rrectness of i
– Remove cable support bracket -1-.
l purpos
– Place selector shaft of selector unit in neutral.
nform
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– Gearboxes for vehicles with start-stop system: remove gear‐ co Vo
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box neutral position sender - G701- -arrow-. cted agen
Prote AG.

– Unscrew nuts -C-.
– Remove bolts for selector unit -B- from gearbox housing.
– Pull selector unit out of gearbox housing while turning selector
unit 180°.
• Selector fingers of selector unit must be guided through se‐
lector rods.
– If fitted, remove tachograph sender - G75- -1-.

– Remove retaining ring -arrow A- and O-ring -arrow B- from left

stub shaft.
– Unscrew bolts for gearbox housing on clutch housing

-arrows-.
– Unscrew bolts for deep groove ball bearing -1-.
– Unscrew bolt for left stub shaft. Counterhold stub shaft -2- with
when doing this.
satelettronica
and hook - VW 771/37- .
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– Screw
au adapter - VW 771/44- -C- to stop into threaded of ac hole
ss
gearbox housing. Counterlock adapter - VW 771/44- with nut
ce
e
-B-.
nl
pt
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itte
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– Pull gearbox housing off clutch housing using multi-purpose

erm
ab
tool - VW771- -A- . At same time, press gearbox housing away

ility
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from clutch housing at housing shoulder -arrow- using assem‐

wit
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bly lever -D-.

h re
hole
spec
es, in part or in w
t to the co
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at
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ion
c
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for
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– Remove splitter -A- and installing sleeve - VW 455- from input

shaft -B-.
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– Remove reverse gear selector fork -A-.
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satelettronica
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– Raise input shaft -1- in -direction of arrow- until counterhold

tool - 3435- can be pushed in.
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ate
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for
en
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– Secure stub shaft -1- to differential so that differential can be

raised during following steps.
– Remove output shaft for 3rd/4th gear -2- together with selector
rod -3-.

– Remove output shaft for reverse gear output shaft -A- and then
output shaft for 1st/2nd gear -B- together with selector rod
-C- from clutch housing.
– Remove input shaft -1- together with selector rod -2-.

– Pull out differential -3- on stub shaft.
– Remove input shaft oil seal.
Assembling
satelettronica
– Secure support bridge - 30 - 211 A- or support bridge - T10323-
for input shaft to clutch housing and to gearbox support - VW
353- .
– When doing this, place washers or a nut -A- with a total thick‐
ness of about 16 mm between clutch housing and support
bridge - 30 - 211 A- or support bridge - T10323- .
AG. Volkswagen AG d
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– Insert input shaft -1- in clutchVohousing
lksw together with selector
es n
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rod for 5th/6th gear. se
d by ua
ran
i tee
or
Installation position of selector
au
th rod for 5th/6th gear ⇒ page 115 or
ac
ss
C - Lock nut
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rm
ab
– Raise input shaft -1- to dimension -a- by turning spindle of fit‐

pe
ility
ting tool - 3046- . Then, tighten lock nut.

ot
wit
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• Dimension -a- = 10 mm.

hole
spec
es, in part or in w
t to the co
rrectness of i
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– Secure left stub shaft -arrow- to differential -1- so that differ‐

ential can be raised during following steps.
– Insert differential -1-.
– Place output shaft for 1st/2nd gear -2- together with selector
rod -4- into bearing seat. Then, swing it towards input shaft
-3-.
– Guide reverse gear output shaft -1- under teeth of 1st gear
synchromeshed gear -arrow A-, and then set in bearing seat
-arrow B-.
satelettronica
– Fit output shaft for 3rd/4th gear -2- together with selector rod
for 3rd/4th gear -1-.
Installation position of selector rod for 3rd/4th gear -1-
AG. Volkswagen A gen G do
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Shorter arm -arrow- faces clutch
by
Vhousing.
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– Detach left stub shaft -3-
tho from differential.
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or
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– Loosen lock nut -C-.

spec
es, in part or in w
– Lower input shaft -B- via spindle of fitting tool - 3046- far
t to the co
enough that it remains slightly pre-loaded (raised about 2 mm).

Tighten lock nut -C- again.
rrectness of i
l purpos
nform
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ion
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– Insert reverse gear selector fork -A- in locking collar of reverse

gear output shaft.
• Studs -arrows- must be vertical before gearbox housing is set
in place.
Deep groove ball bearing -1- of input shaft fits into gearbox hous‐
ing in only one position.
– Screw guide pins - T10341- -A- into threads of deep groove
ball bearing -1- at opposing positions.
– Align »tab« of deep groove ball bearing -arrow- with clutch
housing as shown in illustration.
– Apply sealant evenly to sealing surface of clutch housing.
satelettronica
– Fit gearbox housing ge-1-
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rests againsty Vclutch housing -2-.
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– Note tguide
ho
ris pins - T10341- -A- and studs for reverse
nte
e ogear se‐
lector
s au fork -3-. ra
c
s
ce
– Screw in two bolts for deep groove ball bearing -arrows- al‐
le
un
pt
ternately to stop, but do not tighten them yet.

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– Remove the two guide pins - T10341- -A-.

pe
ility
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spec
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t to the co
– Screw in remaining bolts for deep groove ball bearing -1-, and
tighten all bolts to specified torque.
rrectness of i
– Remove support bridge - 30 - 211 A- or support bridge -

l purpos
T10323- for input shaft.

– Screw bolts for gearbox housing into clutch housing
nform
ercia
-arrows-, and tighten them.

m
– Insert left stub shaft -2- together with compression spring,

com
tion in

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– Tighten left stub shaft securing bolt. Counterhold stub shaft

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when doing this.

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– Screw bolts for clutch housing into gearbox housing, and tight‐
en them to specified torque.
Install selector unit as follows:
– Turn gearbox in repair stand with opening for selector unit up‐
wards.
– Move selector rods to neutral.
– Guide selector unit with selector finger -1- through reverse

gear selector fork, selector rod for 1st/2nd gear and selector
rod for 5th/6th gear.
– Then turn selector unit 180° -in direction of arrow- and insert
into gearbox housing to stop.
olkswagen AG
en AG. V
In the process, guide selectorolfingers
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• Selector shaft must
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– Tighten selector unit -B-.

wit
is n
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– Screw in reversing light switch - F4- -A-, and tighten it.

ole,
spec
– Tighten nuts for reverse gear selector fork -C-.

t to the co
– Gearbox for vehicles with start/stop system: install gearbox

neutral position sender - G701- -arrow-, and tighten bolt.
rrectness o
cial p
f inform
mer
atio
om
– Screw in bolts -arrows- for cable support bracket -1-, and tight‐
c
i
or
n thi
en them.
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cum
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fo
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t.
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rig ht
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co Vo
by lksw
cted agen
Prote AG.

– If present, screw in tachograph sender - G75- -1-, and tighten

it.
– Drive in new oil seal for left stub shaft ⇒ page 214 .
– Drive in new input shaft oil seal ⇒ page 221 .

– Drive new seal in onto limit stop. olkswage es n
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spec
es, in part or in w
t to the co
• Lightly oil new oil seal on outer diameter.
• Half-fill space between sealing lip and dust lip -arrow- with
sealing grease .
rrectness of i
l purpos
nf
ercia
orm
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atio
om
n in
or c
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– Insert stub shaft -arrow B- together with compression spring,
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– Tighten right stub shaft securing bolt. Counterhold stub shaft cop Vo
by lksw
cted agen
Prote AG.
when doing this.
– Install clutch slave cylinder with clutch release bearing using
new bolts -arrows A-.


– Drive oil seal for bevel box into clutch housing up to stop. Do
AG. Volkswagen AG d
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• Half-fill space between sealing lip and dust lip -arrow- with
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wit
sealing grease .
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hole
spec
es, in part or in w
t to the co
rrectness of i
satelettronica
l purpos
nform
mercia
a
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tion in
r
te o
thi
s
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rp
cum
fo
en
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t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

– Install clutch slave cylinder using new bolts -arrows A-.

Attach bevel box to manual gearbox as follows.
– On manual gearbox, grease splines of differential with grease
⇒ Electronic Parts Catalogue (ETKA) .
– Push bevel box with stub shaft installed completely onto gear‐
box.
– Guide splines of bevel box lay shaft concentrically together
with differential splines.
gen AG
. Volkswagen AG
a does
lksw n
– Align splinesdofby right stub shaft and differential bevel
Vo ot g
ua gear; turn
stub shaftoras
i necessary.
se ran
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– If splines
ss
a are correctly positioned and shafts are centred,athen
c
bevel box will slide to stop against gearbox.
ce
le
un
pt
an
d
itte
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rm
ab
Note
pe
ility
ot
wit
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♦ Ensure that installation position of right stub shaft does not
h re
hole
change (is not pushed out of bevel box).
spec
es, in part or in w
♦ Do not use securing bolts to pull the bevel box against the
satelettronica
t to the co
gearbox as otherwise the bevel box will cant and the securing
eyes could break off.
rrectness of i
Tighten 4 connecting bolts -arrows B- (only 3 are shown in figure)
l purpos
of bevel box on manual gearbox.

– Use socket and extended bit 6 mm - T10107 A- to screw coun‐
nform
ercia
tersunk bolt for right stub shaft tight. Counterhold stub shaft
m
a
com
when doing this.

ion in
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te o

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iva
do
– Shift through all gears.

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Specified torques
n
t.
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Cop py
♦ ⇒ “1.3 Assembly overview - clutch release mechanism”, page
t. rig
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23
p by
co Vo
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cted agen
Prote AG.
♦ ⇒ “6.4 Assembly overview - selector unit”, page 113

mechanism, gearbox without sealing cover on gearbox hous‐
ing”, page 112

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7 Gearbox housing, clutch housing olk ot g
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⇒ “7.1 Assembly overview - gearbox housing”,au page 146
th or
ac
ss
⇒ “7.2 Assembly overview - clutch housing”, page 148
ce
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un
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d
⇒ “7.3 Repairing gearbox housing”, page 150
itte
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ab
⇒ “7.4 Repairing clutch housing”, page 152
pe
ility
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7.1 Assembly overview - gearbox housing
h re
hole
spec
es, in part or in w
t to the co
Note
If gearbox housing or tapered roller bearing is renewed, install new shims of the same thickness as the old
rrectness of i
ones.
l purpos
1 - Gearbox housing
nform
ercia
2 - Oil filler plug

m
a
com
tio
❑ Depending on equip‐
satelettronica
n in
r
ment
te o
thi
s
iva
❑ 35 Nm
do
r
rp
cum
fo
3 - Dowel sleeve
en
ng
t.
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❑ For centring selector Cop py
t. rig
unit on gearbox housing opyri
gh by
Vo
ht
c lksw
4 - Sliding bushes
by
cted agen
Prote AG.
❑ Driving in ⇒ page 151
5 - Tapered roller bearing outer
race
❑ For output shaft for 1st/
2nd gear
❑ Pressing in
⇒ page 191 .
6 - Shim
❑ For output shaft for 1st/
2nd gear
❑ Is damaged during re‐
moval
❑ When renewing, install
with shim of same thick‐
ness
race
❑ For output shaft for 3rd/
4th gear
❑ Pulling out ⇒ page 200
❑ Pressing in ⇒ page 200 .
8 - Shim
❑ For output shaft for 3rd/4th gear
❑ Is damaged during removal

❑ When renewing, install with shim of same thickness
9 - Solenoid
❑ Glue into gearbox housing with sealant ⇒ Electronic Parts Catalogue (ETKA) .
10 - Tapered roller bearing outer race
❑ For reverse gear output shaft
❑ Pressing in ⇒ spage n AG. Volkswagen AG do
wage 207 . es k not
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11 - Shim sed by ua
ran
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❑ For authreverse gear output shaft
o
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ility
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12 - Tapered roller bearing inner race
wit
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❑ For differential
h re
hole
spec
❑ Pulling off ⇒ page 227
es, in part or in w
t to the co
satelettronica
13 - Oil drain plug
❑ 35 Nm
rrectness of i
14 - Left seal
l purpos

nform
mercia
at
om
ion
c
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or
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ate
do
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cum
for
en
ng
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Cop py
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rig ht
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cted agen
Prote AG.
7. Gearbox housing, clutch housing 147

7.2 Assembly overview - clutch housing
Note
If clutch housing or tapered roller bearing is renewed, install new shims of the same thickness as the old ones.

race
4th gear
❑ Pressing in
⇒ page 195 .
2 - Shim
4th gear
moval
satelettronica
with shim of same thick‐
ness
3 - Retaining ring
❑ Insert in circumferential
groove in clutch housing
4 - Cylindrical roller bearing
❑ For input shaft AG. Volkswagen AG d
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❑ Renew together ed bywith in‐
V gu
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⇒ Item 18 aut (page 162) ra
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❑ Pressing in
an
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⇒ page 154 .
erm
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5 - Sliding bushes
wit
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h re
hole
spec

es, in part or in w
❑ Installing ⇒ page 154

t to the co
6 - Dowel sleeve
rrectness of i
7 - Clutch housing
l purpos
8 - Input shaft seal

nform
ercia
9 - Sealing ring, right

m
at

om
ion
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10 - Plug
or
his
ate
❑ For vehicles without tachograph

do
priv
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❑ 40 Nm
f
en
ng
t.
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11 - Tachograph sender - G75- t. Cop py
rig
❑ For vehicles with tachograph
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Vo
o
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❑ 40 Nm
lksw
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Prote AG.

12 - Oil deflector ring

❑ Installation position: shoulder on hole faces reverse gear output shaft
13 - Shim
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❑ For reverse gear outputlkshaftgen AG does
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14 - Tapered roller abearing
ut
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outer race or
ac
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❑ For reverse gear output shaft
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15 - Shim
hole
spec
es, in part or in w
t to the co
❑ Installation position: shoulder on inner diameter faces oil seal ⇒ Item 9 (page 148)
16 - Shim
rrectness of i
❑ Adjusting differential ⇒ page 230
l purpos
satelettronica
nform
ercia
m
at
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io
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❑ For output shaft for 1st/2nd gear
um
for
en
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n
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op py
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19 - Shim
co lksw
by
cted agen
Prote
❑ For output shaft for 1st/2nd gear
AG.

❑ Installation position: shoulder on hole faces output shaft for 1st/2nd gear

7.3 Repairing gearbox housing

equipment required
AG. Volkswagen AG d
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es, in part or in w
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Prote AG.
♦ Press tool - 30-505-
♦ Thrust piece - 3124-
♦ Assembly tool - 3290-
♦ Drift - T10168-

♦ Adapter - VW 771/15-
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♦ -1- internal puller, e.g.
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KUKKO 21-2 - VAS

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KUKKO 21-3 - VAS
m
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251 607-
tion in
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♦ -4- counter support,
thi
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e.g. KUKKO 22-2 -
do
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VAS 251 623-

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Pulling out sliding bush op
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-C- for selector rod
C py
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A - Counter support, e.g. cop Vo
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KUKKO 22-2 - VAS 251
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Prote AG.
623-
B - Internal puller e.g.
607-
Driving in sliding bushes for selector rod to stop

Pulling out selector shaft bearing bush

A - Internal puller e.g. KUKKO 21-2 - VAS 251 605- n AG. Volkswagen AG do
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– Use thread adapter from counter support, e.g. KUKKOd b22-1 yV
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VAS 251 621- -arrow-. o
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tee
th or
u
– Hold spindle of assembly tool - 3290- securelyssand turn nut
a ac
-B-.
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Driving in selector shaft bearing bush -A- to stop of tool.
t to the co
rrectness of i
l purpos
nform
ercia
satelettronica
m
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tion in
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7.4 Repairing clutch housing

♦ Press tool - VW408A-

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♦ Press tool - 30-505-


Procedure
Pulling cylinder roller bearing out of clutch housing
– Remove retaining ring before removing cylindrical roller bear‐
ing.
Pressing cylindrical roller bearing into clutch housing

– Install retaining ring.
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A - Internal puller e.g. KUKKO 21-3 - VAS 251 607-
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olkswagen AGTransporter 2016 ➤
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6-speed
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♦ Gearbox support - VW353-
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Procedure
– Secure gearbox to assembly stand using bolts -arrows-.
– Turn gearbox in support bracket so that oil drain plug is down‐
wards.
– Place drip tray for workshop hoist - VAS 6208- underneath.
– Drain gear oil.
8. Securing to engine and gearbox support 155

9 Gear oil
⇒ “9.1 Checking gear oil level, gearboxes with oil filler plug”, page
156
⇒ “9.2 Checking gear oil level, gearboxes without oil filler plug”,
page 157
9.1 Checking gear oil level, gearboxes

“with” oil filler plug
♦ Multi-point bit - 3357-
satelettronica
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♦ Allocate gear oil using ⇒ Electronic Parts Catalogue (ETKA) .

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Test sequence
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noise insulation . Prote AG.
– Place drip tray for workshop hoist - VAS 6208- below gearbox.

– To check gear oil, remove oil filler plug -arrow-.

The oil level is correct, when the gearbox is filled to lower edge
of filler hole.
– If necessary, fill with gear oil to lower edge of oil filler hole.
– Screw in oil filler plug -arrow-, and tighten it to specified torque.
Observe the following for initial filling:
– Remove oil filler plug -arrow-.
– Fill with gear oil to lower edge of filler hole.
– Screw in oil filler plug and tighten to specified torque.
noise insulation .
9.2 Checking gear oil level, gearboxes

“without” oil filler plug
satelettronica
terior; Rep. gr. 66 ; Noise insulation; Removing and installing
noise insulation .
The oil level in the gearbox can be checked only by completely
draining the gear oil and then refilling it . Volkswage
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• The oil drain plug -arrow-hoisristightened to specified torque. nte
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Capacity ⇒ page 8
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• Selector shaft is in neutral position (shown here on a different

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9. Gear oil 157

– Disconnect electrical connector on reversing light switch - F4-

-A-.
– Fit a hose (approx. 600 mm long, external diameter 10 mm)
onto a funnel (commercially available). . Volkswage AG n AG d
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Collect any escaping gear oil with a cloth.
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– Install reversing light switch - F4- -A-.
satelettronica
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Specified torques
nform
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mechanism, gearbox without sealing cover on gearbox hous‐

ing”, page 112
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35 – Gears, shafts
1 Input shaft
⇒ “1.1 Assembly overview - input shaft”, page 159
⇒ “1.2 Dismantling and assembling input shaft”, page 163
1.1 Assembly overview - input shaft

⇒ “1.1.1 Assembly overview - input shaft, gearbox with sealing
cover on gearbox housing”, page 159
⇒ “1.1.2 Assembly overview - input shaft, gearbox without sealing
cover on gearbox housing”, page 161
1.1.1 Assembly overview - input shaft, gearbox with sealing cover on gearbox
housing
Note
satelettronica
♦ Install all bearings on input shaft with gear oil.
♦ Always renew deep groove ball bearing ⇒ Item 16 (page 161) .
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agen 1. Input shaft
1 - Clutch housing
2 - Cylindrical roller bearing
❑ Pressing in
⇒ page 154 .
❑ Renew together with
⇒ Item 5 (page 160) AG. Volkswagen AG d
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❑ Pressing on
⇒ page 166
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❑ Renew together with
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⇒ Item 2 (page 160)
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6 - Gear wheel
❑ 4th gear
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⇒ page 165
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❑ 5th gear Prote AG.
10 - Synchro-ring
❑ 5th gear
❑ Check for wear ⇒ page 166
11 - Locking collar with synchro-hub
❑ For 5th and 6th gear.
❑ After removing retaining ring, press off with 5th gear synchromeshed gear ⇒ page 165
❑ Dismantling ⇒ page 167
❑ Assembling locking collar and synchro-hub ⇒ page 167
❑ Pressing on ⇒ page 167
12 - Retaining ring
13 - Needle bearing
❑ For 6th gear
14 - Synchro-ring
❑ 6th gear
❑ 6th gear
160 Rep. gr.35 - Gears, shafts


❑ After removing circlip, press off with 6th gear synchromeshed gear ⇒ page 165
17 - Retaining ring
19 - Retaining ring
❑ For deep groove ball bearing of input shaft
1.1.2 Assembly overview - input shaft, gearbox without sealing cover on gearbox
housing
1 - Bolts
❑ 16 Nm +90°
satelettronica
2 - Bolt
❑ 90 Nm +180°
❑ Pressing on
⇒ page 174
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9 - Synchro-ring
❑ 6th gear
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❑ Check for wear

⇒ page 172
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10 - Locking collar with syn‐

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❑ For 5th and 6th gear.

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❑ Press off with synchro‐

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❑ Assembling ⇒ page 172 .

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1. Input shaft 161

11 - Synchro-ring
❑ 5th gear
❑ 5th gear
13 - Needle bearing
❑ For 5th gear synchromeshed gear
14 - Clutch housing
15 - Cylindrical roller bearing agen
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18 - Cylindrical roller bearing inner race
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❑ Press off with gear wheel for 4th gear
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❑ Pressing off ⇒ page 171
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❑ Renew together with ⇒ Item 15 (page 162)
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19 - Gear wheel
❑ 4th gear
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20 - Input shaft
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1.2.1 Dismantling and assembling input shaft, gearbox with sealing cover on
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♦ Thrust plate - VW 401-

♦ Press tool - VW 407-
♦ Press tool - VW 408 A-
♦ Thrust piece - VW 454-
1. Input shaft 163

satelettronica
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♦ -2- puller, e.g. KUKKO 18-1 - VAS 251 417-

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Pressing off deep groove ball bearing with 6th gear synchro‐
meshed gear
– Remove retaining ring before pressing off.
A - Splitter, e.g. KUKKO 17-2 - VAS 251 411-
Pressing off synchro-hub and locking collar for 5th/6th gear with
synchromeshed gear for 5th gear
satelettronica
Pulling off inner race -D- for cylindrical roller bearing
– Clamp input shaft in vice with jaw
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The inner ring for the inner bearing race can also be pressed off
h re
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together with the gear wheel for 4th gear ⇒ page 165 .
spec
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Pressing off gear wheel for 4th gear

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1. Input shaft 165

Pressing on gear wheel for 4th gear

• Installation position: high collar -arrow- faces pressing tool.
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Pressing on inner race -A- for cylindrical roller bearing
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5th and 6th gear 1.0 - 1.9 mm 0.5 mm

Dismantling and assembling locking collar and synchro-hub for

5th and 6th gear
1- Spring
2- Locking piece
3- Sliding sleeve
4- Synchro-hub
– Slide locking collar over synchro-hub.
Notches for locking pieces in synchro-hub and locking collar must
align.
Assembling locking collar with synchro-hub for 5th and 6th gear
Locking collar has been pushed over synchro-hub.
– Fit locking pieces and install springs offset 120°. Angled end
of spring must locate in hollow locking piece.
satelettronica
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Assembling locking collar and synchro-hub for 5th/6th gear
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Pressing on locking collar and synchro-hub for 5th/6th gear nform
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1. Input shaft 167

Pressing on deep groove ball bearing

• Installation position of deep groove ball bearing: Groove for
retaining ring points upwards -arrow A-. The shoulder
-arrow B- must face 6th gear synchromeshed gear.
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♦ Tube - VW416B-
satelettronica
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♦ Socket insert - T10035-

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1. Input shaft 169

♦ Workshop press - VAS 6654-

Dismantling
– Clamp input shaft -1- in vice with jaw protectors -A-.
– Unscrew bolt -2- using special wrench XZN 14 - T10035- -B-.
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Pressing off deep groove ball bearing -1- with 6th th gear synchro‐
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⇒ Item 6 (page 161) from input shaft.

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Pressing off inner race -1-, synchro-hub and locking collar for 5th/
6th gear -2- and synchromeshed gear for 5th gear -3-
A - Press tool - VW408A-
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Pressing off inner race for cylindrical roller bearing and gear
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wheel for 4th gear
o
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⇒ Item 17 (page 162) .
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– Heat gear wheel for 4th gear to about 100 °C with inductive
heater - VAS 6414- .
• Installation position: high collar -arrow- faces pressing tool.
1. Input shaft 171

Pressing on inner race for cylindrical roller bearing -A-

– Heat inner race for cylindrical roller bearing -A- to about 100 °
C with inductive heater - VAS 6414- .
– Install retaining ring. agen
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Checking synchro-rings for 5th/6th gear for wear
satelettronica
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– Press synchro-ring onto cone of synchromeshed gear and
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measure gap -a- using feeler gauge.
form
mer
atio
Gap -a- Installation dimen‐ Wear limit
om
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5th and 6th gear 1.0 - 1.9 mm 0.5 mm

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Dismantling locking collar and synchro-hub for 5th/6th gear
1- Spring
2- Locking piece
3- Sliding sleeve
4- Synchro-hub

– Slide locking collar over synchro-hub.
Notches for locking pieces in synchro-hub and locking collar must
align.
• Locking collar has been pushed over synchro-hub.
– Fit locking pieces and install springs offset 120°. Angled end
of spring must locate in hollow locking piece.


High shoulder of synchro-hub -arrow- faces synchromeshed gear
of 5th gear.
– Fit needle bearing for synchromeshed gear of 5th gear -2- and
synchromeshed gearenof AG5th
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G input shaft.
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Pressing on locking collar and synchro-hub for 5th/6th gear

– After pressing on synchro-hub, fit thrust washer
⇒ Item 8 (page 161) .
rrectness of i
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Pressing on inner race for 6th gear needle bearing -1-

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A - Press tool - VW412- opyri
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B - Press tool - VW454- Prote
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C - Pressure plate - VW402-

– Heat inner race for 6th gear needle bearing -1- to about 100 °
C with inductive heater - VAS 6414- .
– After pressing on inner race, fit 6th gear needle bearing, syn‐
chromeshed gear for 6th gear and thrust washer.
1. Input shaft 173

Pressing on deep groove ball bearing -1-

A - Press tool - VW412-
B - Tube - VW416B- AG. Volkswagen AG d
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– Clamp input shaft -1- in vice with jaw protectors -A-.
ole,
spec
– Tighten bolt -2- to specified torque using special wrench XZN
t to the co
14 - T10035- -B-.
Specified torques
rrectne
♦ ⇒ “1.1.2 Assembly overview - input shaft, gearbox without
ss
satelettronica
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2 Output shaft
d b ua
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⇒ “2.1 sAssembly
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overview - output shaft”, page 175 ac
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nl
⇒ “2.2 Dismantling and assembling output shaft”, page 182
pt
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⇒ “2.3 Adjusting output shaft”, page 210
erm
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2.1 Assembly overview - output shaft
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⇒ “2.1.1 Assembly overview - output shaft for 1st/2nd gear”, page
spec
175
es, in part or in w
t to the co
⇒ “2.1.2 Assembly overview - output shaft for 3rd/4th gear”, page
178
rrectness of i
⇒ “2.1.3 Assembly overview - output shaft for reverse gear”, page
180
l purpos
2.1.1 Assembly overview - output shaft for 1st/2nd gear
nform
mercia
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Note
ion
c
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satelettronica
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♦ Output shaft ⇒ Item 7 (page 176) cannot be renewed at this time. If output shaft is worn, gearbox must be
at
do
riv
renewed.
p
cum
for
en
♦ If tapered roller bearing is renewed, install new shims of the same thickness as the old ones.
ng
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2. Output shaft 175

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Transporter 2016 ➤ ut
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1 - Clutch housing
d
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pe
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ot
wit
3 - Shim
, is n
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hole
❑ Note thickness
spec
es, in part or in w
t to the co
moval
rrectness of i
race
l purpos
❑ Pressing in
nform
⇒ page 185 . mercia
a
com
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5 - Tapered roller bearing inner
ion in
race
r
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thi
❑ Pressing off
s
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do
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⇒ page 187
rp
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❑ Pressing on
n
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⇒ page 191 Cop py
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6 - Dished washer p by
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Prote AG.
❑ Pressing in
⇒ page 186 .
7 - Output shaft
❑ For 1st and 2nd gear
❑ Cannot be renewed; if
worn, renew gearbox
8 - Thrust washer
❑ For needle bearing
❑ Removing from output
shaft ⇒ page 187
❑ Pressing on
⇒ page 187
9 - Needle thrust bearing
10 - Needle bearing
❑ For 1st gear
❑ 1st gear
❑ With idler gear for reverse gear on opposite side
12 - Synchro-ring
❑ (Inner ring for 1st gear)
❑ Check lugs for scoring
13 - Outer ring
❑ 1st gear
❑ Renew if scored
❑ Place on synchro-ring ⇒ Item 12 (page 176)

14 - Synchro-ring
❑ 1st gear
15 - Needle thrust bearing
16 - Locking collar with synchro-hub for 1st and 2nd gear
❑ After removing retaining ring ⇒ Item 17 (page 177) , press off with 1st gear synchromeshed gear
⇒ page 186
17 - Retaining ring n AG. Volkswagen AG do
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18 - Needle bearing byV
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❑ For 2nd gear ir se tee
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19 - Synchro-ring ss
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❑ 2nd gear
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❑ Assemble so that notches engage in locking pieces of locking collar ⇒ Item 16 (page 177) .
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20 - Outer ring
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hole
❑ For 2nd gear
spec
es, in part or in w
❑ Insert in synchro-ring ⇒ Item 19 (page 177) ; installation position ⇒ page 190
t to the co
❑ Renew if scored
21 - Synchro-ring
rrectness of i
❑ (Inner ring for 2nd gear)
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❑ 2nd gear
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❑ Pull off with 2nd gear synchromeshed gear ⇒ page 186 Cop py
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24 - Retaining ring
agen
Prote AG.

26 - Shim
❑ Note thickness
2. Output shaft 177

2.1.2 Assembly overview - output shaft for 3rd/4th gear
Note
renewed.
1 - Clutch housing
2 - Shim
❑ Note thickness
❑ Is damaged during re‐ agen
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❑ Renew after removal orise nte
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3 - Tapered roller bearing outer ss a c
race
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satelettronica
itte
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❑ Pressing in
ab
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⇒ page 195 .
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race
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❑ Pressing on
⇒ page 200
rrectness of i
5 - Output shaft
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❑ For 3rd and 4th gear

worn, renew gearbox
nf
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6 - Needle bearing
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❑ For 4th gear
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8 - Synchro-ring
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❑ Check for wear
AG.
⇒ page 197
⇒ page 197
9 - Outer ring
❑ For 4th gear
❑ Renew if scored
❑ Place on synchro-ring ⇒ Item 8 (page 178)
10 - Synchro-ring
❑ 4th gear

11 - Locking collar with synchro-hub AG. Volkswagen AG d

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❑ For 3rd and 4th gear Volksw
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❑ After removing circlip ⇒ Item 12 (page 179) , press
rised off with 4th gear synchromeshed gear
nte ⇒ page 196
ho eo
❑ Dismantling ⇒ page 197 au
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12 - Retaining ring
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13 - Needle bearing
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spec
❑ For 3rd gear
es, in part or in w
t to the co
14 - Synchro-ring
❑ 3rd gear
rrectness of i
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❑ Assemble so that notches engage in locking pieces of locking collar ⇒ Item 11 (page 179) .
15 - Outer ring
nform
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❑ For 3rd gear

m
at
satelettronica
❑ Insert in synchro-ring ⇒ Item 14 (page 179) ; installation position ⇒ page 198
om
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❑ Renew if scored
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16 - Synchro-ring
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❑ (Inner ring for 3rd gear)

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❑ Check for wear ⇒ page 197 opyri
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❑ Fitting position ⇒ page 199 by c lksw

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❑ 3rd gear
18 - Gear wheel
❑ 5th gear
❑ Press off with 3rd gear synchromeshed gear ⇒ page 196
19 - Gear wheel
❑ 6th gear
20 - Retaining ring
23 - Shim
❑ Note thickness
❑ Will be damaged when removed; renew
2. Output shaft 179

2.1.3 Assembly overview - output shaft for reverse gear
Note
renewed.
AG. Volkswagen AG d
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1- Clutch housing ised b ara
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2- Oil deflector ring aut ra
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ss
3 - Shim
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❑ Note thickness
itte
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❑ Will be damaged when
pe
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ot
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satelettronica
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❑ Pressing in
rrectness of i
⇒ page 204 .
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race
nform
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❑ Pressing on
m
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⇒ page 206
on in
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6 - Dished washer
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❑ Pressing in
en
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⇒ page 205 .
Co
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7 - Output shaft
rig ht
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❑ For reverse gear Prote
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agen
worn, renew gearbox
8 - Roller bearing
❑ For synchromeshed
gear for reverse gear
9 - Needle bearing
❑ For synchromeshed
gear for reverse gear
❑ Removing and installing stop ring and spring ⇒ page 207 .
11 - Reverse gear locking collar
❑ With synchro-ring
12 - Reverse gear synchro-hub
❑ Press off together with reverse gear synchromeshed gear ⇒ Item 13 (page 181) after removing retaining
ring ⇒ page 205
❑ Installation position: stop -arrow- for reverse gear locking collar faces retaining ring
⇒ Item 13 (page 181) .

13 - Retaining ring
16 - Shim n AG. Volkswagen AG do
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❑ Note thickness byV
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❑ Is damaged during hor removal
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mer
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n
c
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Cop py
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by
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Prote AG.
2. Output shaft 181

2.2 Dismantling and assembling output

shaft
⇒ “2.2.1 Dismantling and assembling output shaft for 1st/
2nd gear”, page 182
⇒ “2.2.2 Dismantling and assembling output shaft for 3rd/4th
gear”, page 191
⇒ “2.2.3 Dismantling and assembling reverse gear output shaft”,
page 200
⇒ “2.2.4 Removing stop ring and spring from and installing on
reverse gear synchromeshed gear”, page 207
2.2.1 Dismantling and assembling output shaft for 1st/2nd gear

equipment required
satelettronica
AG. Volkswagen AG d
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c
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Cop py
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♦ Thrust plate - VW 401- copy Vo
by lksw
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AG.


♦ Tube - VW 415 A-
lkswage es n
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ir se tee
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es, in part or in w
t to the co
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nf
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m
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♦ Thrust plate - VW 447 i-
♦ Tube - VW 516-
♦ Thrust plate - 30 - 205-
2. Output shaft 183

AG. Volkswagen AG d
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satelettronica
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ab
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, is n
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spec
es, in part or in w
t to the co
rrectness of i
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nform
mercia
at
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c
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ate
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en
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♦ Thrust plate - 3062-

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♦ -1- two-arm puller, e.g. KUKKO 20-10 - VAS 251 001-
♦ Feeler gauge

♦ Thrust piece -
T10266-
AG. Volkswagen AG d
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Pulling tapered roller
ility
ot p
bearing outer race out of
wit
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clutch housing
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spec
A - Counter support, e.g.

t to the co
625-
satelettronica
rrectne
KUKKO 21-89 - VAS 251
619-
ss o
cial p
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Note
form
mer
atio
m
♦ To fit the internal pull‐

o
n
c
er -B-, the collar of the

i
or
n thi
e
oil deflector must first

t
sd
va
be damaged, for ex‐

i
o
pr
cum
r
ample by bending it
fo
en
ng
with a drift. Renew

t.
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damaged oil deflec‐ C py
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tor. rig ht
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♦ After pulling out, re‐ cted agen
Prote AG.
new damaged shim.
Pressing tapered roller bearing outer race into clutch housing

– Before pressing in, insert oil deflector plate and shim.
– Support clutch housing with tube - VW 415 A- directly below
bearing support.
2. Output shaft 185

Pulling dished washer -C- out of output shaft

Note
If the internal puller slips out of the hole in the dished washer, use
the internal puller which is one size larger.
Pressing dished washer -A- into output shaft -B- to stop of tool
– Place thrust piece - 3401- with collar -arrow- on dished washer
-A-.
Pressing depth of dished washer is then about 2.20 mm.
satelettronica
AG. Volkswagen AG d
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Pulling off tapered roller bearing inner race with 2nd gear syn‐
e
nl
pt
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chromeshed gear
an
itte
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ab
– Remove retaining ring before pulling off.

ility
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– Shift locking collar for 1st/2nd gear to 1st gear.

, is n
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hole
– Apply puller hooks behind constant mesh teeth of 2nd gear

spec
synchromeshed gear (not dog teeth).

es, in part or in w
t to the co
A - Two-arm puller, e.g. KUKKO 20-10 - VAS 251 001-

rrectness of i
l purpos
Pressing off 1st/2nd gear synchro-hub and locking collar with

nform
ercia
1st gear synchromeshed gear

m
at
om
ion
c
in t
Note
or
his
ate
do
riv
Depending on the fit between synchro-hub and output shaft, these

p
cum
or
parts may be removed by hand in some gearboxes.

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ng
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Cop py
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Pressing off tapered roller bearing inner race

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Driving off thrust washer -A- for needle thrust bearing
h re
hole
spec
– Clamp output shaft in vice with jaw protectors -B-.
es, in part or in w
t to the co
– Use a driver -C- on alternate sides of thrust washer to drive it
off output shaft. Do not damage splines when doing this.
rrectness of i
l purpos
satelettronica
nf
ercia
orm
m
atio
om
n in
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e
Pressing on thrust washer -A- for needle thrust bearing

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Cop py
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rig ht
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Prote AG.
Checking 1st/2nd gear inner ring for wear

– Press inner ring onto cone of synchromeshed gear and meas‐
ure gap -a- using a feeler gauge.
sion
1st and 2nd gears 0.75 - 1.25 mm 0.3 mm
2. Output shaft 187

AG. Volkswagen AG d
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Checking 1st/2nd gear synchro-rings for wear olksw not
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– Press synchro-ring, outer ring and inner ring onto cone ofthorsyn‐
i
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chromeshed gear and measure gap -a- using a feeler s a gauge.
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un
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1st and 2nd gears 1.0 - 1.8 mm 0.5 mm
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ility
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hole
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es, in part or in w
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Installation position of outer ring, inner ring and synchro-ring for
rrectness of i
1st gear
l purpos
– Place inner ring -A- on synchromeshed gear for 1st gear.

• Angled lugs -arrows 1- face outer ring -B-.
nform
ercia
– Fit outer ring -B-.

m
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tio
• Lugs -arrows 2- engage in notches -arrows 3- of synchro‐
n in
satelettronica
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meshed gear.
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– Fit synchro-ring -C-.
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• Notches -arrows 4- engage in lugs -arrows 1- of inner ring

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Installation position of needle thrust bearing

– Place larger needle thrust bearing (outer diameter 63.7 mm)
-2- on thrust washer of output shaft -1-.
• Needles must face thrust washer -arrow A- and the smooth
side -arrow B- faces upwards.
– Bring needle bearing -3- and synchromeshed gear for 1st gear
-4- into position.
– Place smaller needle thrust bearing (outer diameter 58.7 mm)
-5- on 1st gear synchromeshed gear.
• Needles must face synchromeshed gear -arrow C- and the
smooth side -arrow D- faces upwards.

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aut6-speed manual gearbox 0A5 - Edition 06.2019 ra
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1st/2nd gear
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ility
– Remove springs -1- when disassembling.
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1- Spring
h re
ole,
spec
2- Locking piece
t to the co
3- Locking collar »installation position« ⇒ page 189
4- Synchro-hub »installation position« ⇒ page 189
rrectne
– To assemble, slide locking collar over synchro-hub.
s
• Installation position: narrower notches in synchro-hub align
s o
with notches in locking collar.
cial p
f inform
mer
Assembling locking collar and synchro-hub for 1st/2nd gear
atio
om
n
c
i
or
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te
– Fit locking pieces and install springs offset 120°.
sd
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• Angled end of spring must locate in hollow locking piece.

fo
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op
satelettronica
C py
ht. rig
rig ht
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by lksw
cted agen
Prote AG.
Installation position of locking collar and synchro-hub for 1st/

2nd gear
• Collar -arrow 1- of locking collar faces synchromeshed gear
for 1st gear.
• Higher shoulder and lubrication grooves of synchro-hub
-arrow 2- face synchromeshed gear for 2nd gear.
Pressing on locking collar and synchro-hub for 1st/2nd gear

2. Output shaft 189

Installation position of 2nd gear outer ring

Lugs -arrows- face synchro-hub and locking collar -A-.
Installation position of synchro-ring -A- (2nd gear inner ring)

Lugs -arrows 1- locate in notches -arrows 2- of synchro-ring -B-.
AG. Volkswagen AG d
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Installation position of synchromeshed gear for 2nd gear
ab
ility
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Higher shoulder -A- faces 1st gear -B-. Notches in shoulder

wit
is n
-arrows- engage in lugs of outer ring ⇒ page 190 .

h re
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spec
t to the co
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mer
Pressing on tapered roller bearing inner race

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Pulling outer race for tapered roller bearing out of gearbox hous‐
ing
After pulling out, renew damaged shim.
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Pressing tapered roller bearing outer race into gearbox housing
itte
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ab
– Before pressing in, fit shim under outer race.
ility
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– Support gearbox housing with thrust piece - VW 432- below
h re
bearing support.
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
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at
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c
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ate
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2.2.2 Dismantling and assembling output shaft for 3rd/4th gear
C py
ht. rig
rig ht
py by
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Prote AG.
2. Output shaft 191


equipment required
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es, in part or in w
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c
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rig ht
♦ Thrust plate - VW 401- py by
co Vo
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cted agen
♦ Thrust plate - VW 402- Prote AG.

♦ Tube - VW 415 A-

AG. Volkswagen AG d
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agen 6-speed oesmanual gearbox
not 0A5 - Edition 06.2019
Vo gu
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Cop py
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♦ Support rails - VW 457-
♦ Tube - VW 519-
2. Output shaft 193

AG. Volkswagen AG d
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satelettronica
wit
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cial p
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mer
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t.
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op py
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Prote AG.
♦ Tapered roller bearing puller - V.A.G 1582-
♦ Grip tool - V.A.G 1582/4-


KUKKO 21-7 - VAS
251 615-

KUKKO 21-8 - VAS
6775-
♦ -4- counter support,
e.g. KUKKO 22-2 -
VAS 251 623-
satelettronica
♦ Feeler gauge
clutch housing
623-
KUKKO 21-8 - VAS
6775-
After pulling out, renew AG. Volkswagen AG d
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damaged shim. by Vol not
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Pressing tapered rollers abearing outer race into clutch housing
ut ra
c
s
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un
pt
an
d
itte
– Support clutch housing with tube - VW 415 A- directly below

y li
rm
ab
bearing support.
pe
ility
ot
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, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
Pulling off tapered roller bearing inner race

– Before fitting puller, position press tool - VW 431- in output
nform
ercia
shaft and set thrust plate - 40 - 105- on it.

m
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com
tion in
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Cop py
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by
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2. Output shaft 195

6-speed manual gearbox 0A5 - Edition 06.2019 agen
AG. Volkswagen AG d
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Pressing off gear wheel for 6th gear rised b ara
nte
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– Remove retaining ring before pressing off. aut ra
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rm
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es, in part or in w
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rrectness of i
Pressing off 5th gear wheel
l purpos
– Place tools beneath 3rd gear synchromeshed gear such that

no parts will be damaged when pressing off.
nform
mercia
a
Note
com
tion in
r
te o
If 5th gear wheel is close to circumferential groove -arrow- during
thi
satelettronica
s
iva
pressing procedure, secure output shaft against falling.
do
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t.
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Cop py
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Pressing off 3rd/4th gear synchro-hub and locking collar with Prote
cted AG.
agen
4th gear synchromeshed gear
– Place tools beneath 4th gear synchromeshed gear such that
no parts will be damaged when pressing off.

– Before setting up pulling device, set thrust plate - 30 - 11- on
output shaft.

AG. Volkswagen AG d
Checking 3rd/4th gear inner ring for
lksw
wear
agen oes
not
o
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– Press inner ring onto coneris
e of synchromeshed gear and meas‐ ran
d b a
tee
ure gap -a- using a feeler
utho gauge. or
a ac
ss
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un
pt
sion
an
d
itte
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3rd and 4th gears 0.75 - 1.25 mm 0.3 mm
rm
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pe
ility
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spec
es, in part or in w
t to the co
Checking 3rd/4th gear synchro-rings for wear
rrectness of i
– Press synchro-ring, outer ring and inner ring onto cone of syn‐
chromeshed gear and measure gap -a- using a feeler gauge.
l purpos
nform
ercia
sion
m
3rd gear 1.0 - 1.8 mm 0.5 mm
a
com
tio
satelettronica
n in
4th gear 1.0 - 1.9 mm 0.5 mm
r
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Cop py
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Installation position of 4th gear outer ring, inner ring and synchro-
gh ht
pyri by
ring
co Vo
by lksw
cted agen
Prote AG.
– Place inner ring -A- on synchromeshed gear for 4th gear.
• Angled lugs -arrows 1- face outer ring -B-.
– Fit outer ring -B-.
• Lugs -arrows 2- engage in notches -arrows 3- of synchro‐
meshed gear.
– Fit synchro-ring -C-.
• Notches -arrows 4- engage in lugs -arrows 1- of inner ring
-A-.

3rd/4th gear
– Remove springs -1- when disassembling.
1- Spring
2- Locking piece
3- Sliding sleeve
4- Synchro-hub »installation position« ⇒ page 198
– To assemble, slide locking collar over synchro-hub.
• Installation position: narrower notches in synchro-hub align
with notches in locking collar.
2. Output shaft 197

Assembling locking collar and synchro-hub for 3rd/4th gear

– Fit locking pieces and install springs offset 120°.
• Angled end of spring must locate in hollow locking piece.
Installation position of locking collar and synchro-hub for 3rd/

4th gear
Higher shoulder of synchro-hub -arrow- faces 4th gear.
satelettronica
lkswage es n
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o
Pressing onss alocking
u
collar and synchro-hub for 3rd/4th gear r ac
ce
e

nl
pt
du
an
itte
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erm
ab
ility
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, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
Installation position of 3rd gear outer ring

Lugs -arrows- face synchro-hub and locking collar -A-.
nf
ercia
orm
m
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om
n in
or c
thi
te
sd
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Cop py
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pyri by
Vo
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by
cted agen
Prote AG.

AG. Volkswagen AG d
agen oes
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s aut
6-speed
ra
c manual gearbox 0A5 - Edition 06.2019
s
ce
le
un
Installation position of synchro-ring -A- (3rd gear inner ring)
pt
an
d
itte
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Lugs -arrows 1- locate in notches -arrows 2- of synchro-ring -B-.
rm
ab
pe
ility
ot
wit
, is n
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hole
spec
es, in part or in w
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rrectness of i
l purpos
Installation position of 3rd gear synchromeshed gear
nform
ercia
Higher shoulder -A- points to 4th gear -B-. Notches in shoulder

m
a
com
ti
-arrows- engage in lugs of outer ring ⇒ page 198 .
on in
r
te o
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s
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satelettronica
C py
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Vo
co lksw
by
cted agen
Prote AG.

– Heat gear wheel to about 150 °C.
– Press on gear wheel quickly so that heat is not immediately
transferred to output shaft.
Pressing on 6th gear wheel
Note
When the 5th gear wheel has been pressed off in the previous
step, let the output shaft cool off first.
– Heat gear wheel to about 150 °C.

– Press on gear wheel quickly so that heat is not immediately
transferred to output shaft.
2. Output shaft 199

AG. Volkswagen AG d
agen oes
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satelettronica
rrectness of i
l purpos
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ing
m
at
om
io
A - Spindle of counter support, e.g. KUKKO 22-2 - VAS 251 623- n
c
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Cop py
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Prote AG.

2.2.3 Dismantling and assembling reverse gear output shaft


equipment required
AG. Volkswagen AG d
agen oes
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rrectness o
cial p
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mer
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Cop py
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Prote
AG.

2. Output shaft 201

AG. Volkswagen AG d
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ab
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Cop py
♦ Removing and installing tool - VW 459- ht. rig
rig ht
py by
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♦ Tube - VW 463/2-
by lksw
cted agen
Prote AG.
♦ Tube - VW 516-

AG. Volkswagen AG d
lksw
agen oes
no Transporter 2016 ➤
o
d by
V
6-speed manualt ggearbox
ua
ran 0A5 - Edition 06.2019
e
oris tee
th or
au ac
ss
ce
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nl
pt
du
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erm
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ility
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es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
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ate
do
priv
satelettronica
um
for
en
ng
t.
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Cop py
t. rig
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Vo
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by c lksw
cted agen
Prote AG.

♦ Tapered roller bearing puller - V.A.G 1582-
2. Output shaft 203

AG. Volkswagen AG d
agen oes
olksw not
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Transporter 2016 ➤ rise
d b ara
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un
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♦ Spacer sleeve - VW
an
d
itte
472/2-
y li
erm
ab
ility
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♦ Tube - VW 426-
mer
atio
om
n
c
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or
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satelettronica
Co
Cop py
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by
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Prote AG.

clutch housing
– Position sleeve of re‐
moving and installing
tool - VW 459/1- over
bearing seat with
shoulder facing coun‐
ter support -A-.
623-
615-
After pulling out, renew
damaged shim.

– Before pressing in, insert oil deflector plate and shim.
– Support clutch housing with thrust piece - VW 473- directly
below bearing support.

Pulling dished washer -C- out of output shaft

B - Internal puller e.g. KUKKO 21-2 - VAS 251AG
605-
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Note oris tee
th or
au ac
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If the internal puller slips out of the hole in the dished washer, use
ce
e
the internal puller which is one size larger.
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
h re
Pressing dished washer -A- into output shaft -B- to stop of tool
hole
spec
– Place thrust piece - 3401- with collar -arrow- on dished washer
es, in part or in w
t to the co
-A-.
Pressing depth of dished washer is then about 2.20 mm.
rrectness of i
l purpos
satelettronica
nform
mercia
at
om
ion
c
in t
or
his
ate
Pressing off tapered roller bearing inner race
do
priv
cum
or

f
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Pressing off reverse gear synchro-hub with reverse gear syn‐

chromeshed gear
2. Output shaft 205

lkswage es n
o ot g
byV ua
d ran
ir se
Transporter 2016 ➤ tho tee
or
u
6-speed manual gearbox 0A5 - Edition 06.2019 ss
a ac
ce
e
nl
pt
du
an
itte
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erm
ab
– Before setting up pulling device, set press tool - VW 431- on
ility
ot p
output shaft.
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
Pressing on reverse gear synchro-hub
orm
m
atio
– Locate reverse gear synchromeshed gear with needle and
om
n in
roller bearings on output shaft. c
or
thi
te
– Press on reverse gear synchro-hub.
sd
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cu
• Stop -arrow- faces pressing tool.
o
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– Install retaining ring. op py
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Prote AG.

ing
– Position thrust piece - 3118- over bearing seat with shoulder
facing counter support -A-.

– Support gearbox housing with tube - VW 463/2- directly below
bearing support.
Note
satelettronica
Position the tube - VW 463/2- so that the rib on the housing
-arrow- is not damaged.
olkswagen AG
en AG. V
2.2.4 Removing Vol
ksw stop ring and spring
ag does
not
gu
from and installing on reverse gear syn‐
y
chromeshed
or
ise
d b
gear ara
nte
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c
s
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le
un
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an
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itte
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erm
ab
ility
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wit
is n
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t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
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pr
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fo
en
ng
t.
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Cop py
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Vo
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2. Output shaft 207


equipment required
AG. Volkswagen AG d
agen oes
olksw not
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d b ara
rise nte
tho eo
au ra
ss c
ce
le
satelettronica
un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
♦ Thrust plate - VW 401- n thi

te
sd
iva

pr
cum
r
fo
en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Removing
– Using a drift, carefully drive stop ring -A- off reverse gear syn‐
chromeshed gear -C-.
Secure spring -B- against springing away.
Installing
– Insert spring -B- in synchromeshed gear -C-.
• The bent end of the spring -arrow 1- must be hooked into the
hole -2- in the synchromeshed gear.
– Then place stop ring -A- on synchromeshed gear.
• Notches in stop ring -arrows 3- and in synchromeshed gear
-arrows 4- must be aligned.
satelettronica
– Carefully press stop ring -A- onto synchromeshed gear. Spring
-arrows- must be compressed during this step.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
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h
aut ra
ss c
ce
le
un
pt
– Finally, secure stop ring -A- on synchromeshed gear using a

an
d
itte
y li
blunt punch -B-.

erm
ab
ility
ot p
– Locate punch in groove -arrow- of synchromeshed gear.

wit
is n
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ole,
spec
t to the co
rrectness o
cial p
f inform
mer
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om
n
c
i
or
n thi
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fo
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t.
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Cop py
t. rig
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Vo
o
by c lksw
cted agen
Prote AG.
2. Output shaft 209

2.3 Adjusting output shaft
Note
♦ It is currently not possible to renew the output shaft and there‐

fore it is not adjusted. If output shaft is worn, gearbox must be
renewed.
♦ The components on the output shaft as well as the gearbox
and clutch housing can be renewed without adjusting the out‐
put shaft.
♦ Renew damaged shims.
♦ Use new shims of identical sizes as those removed ⇒ Elec‐
tronic Parts Catalogue (ETKA) .
satelettronica
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
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un
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hole
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es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
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tion in
r
te o
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iva
do
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t.
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Cop py
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Prote AG.

39 – Final drive - differential

1 Oil seals
⇒ “1.1 Overview of fitting locations - seals”, page 211
⇒ “1.2 Renewing left seal”, page 212
⇒ “1.3 Renewing right oil seal”, page 215
⇒ “1.4 Renewing input shaft seal”, page 220
1.1 Overview of fitting locations - seals
1 - Seal
❑ All-wheel drive only
❑ For right stub shaft in
bevel box
satelettronica
2 - Seal
❑ For output flange/prop‐
shaft
3 - Seal
❑ Low wage
es n
lks
❑ For left stub shaft in bev‐ d byV
o ot g
ua
el box o
ir se
ran
tee
th or
❑ Renewing ⇒ page 236 s au ac
s
ce
le
4 - Seal
un
pt
an
d

itte
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erm
ab
❑ High
ility
ot p
❑ For left stub shaft in bev‐

wit
is n
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el box
ole,
spec

t to the co
5 - Seal
❑ Right
rrectne
❑ On manual gearbox
❑ Renewing for front-
s
wheel drive
s o
⇒ page 215
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❑ Renewing for all-wheel

mer
drive ⇒ page 219

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6 - Seal
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1. Oil seals 211

1.2 Renewing left seal

equipment required
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♦ Extractor hook - VW 771/37-
212 Rep. gr.39 - Final drive - differential

♦ Sealing grease for radial shaft oil seal ⇒ Electronic parts cata‐
logue (ETKA)
♦ Grease for splines of stub shaft ⇒ Electronic Parts Catalogue
(ETKA)
Removing
The right drive shaft will be removed in a later step.
satelettronica
– While vehicle is still standing on its wheels, loosen front right
flange bolt -arrow- by a maximum of 90°, otherwise the wheel
bearing will be damaged. ⇒ Running gear, axles, steering;
Rep. gr. 40 ; Drive shaft; Removing and installing drive shaft .
– Remove front left wheel bolts.
– Raise vehicle.
– Remove left wheel.
noise insulation .
– If fitted, remove noise insulation for left drive shaft from wheel
housing.
– If fitted, remove noise insulation
olks from gearbox.
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– Remove left drive shaft ris ⇒ Running gear, axles, steering; Rep. ntee
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gr. 40 ; Drive shafts;th Removing and installing drive shafts .
o
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– Remove circlip -arrow A- from stub shaft -arrow B-.

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Prote AG.
– Unscrew stub shaft securing bolt -arrow-, counterholding stub

shaft with counterhold tool - T10140- or counterhold tool -
T50053- while doing so.
– Remove stub shaft with compression spring.
and puller hooks - VW 771/37- .
Installing
– Lightly oil outer diameter of new oil seal, and drive it in to stop.
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– Half-fill space between sealing lip and dust lip -arrow- with
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– Renew O-ring -arrow B- on left stub shaft.

– Then install retaining ring -arrow A- on stub shaft.
– Grease splines of stub shaft with grease ⇒ Electronic Parts
Catalogue (ETKA) ⇒ .
wage
– Install left drive shaft ⇒ Running gear, axles, steering; olks Rep. es n
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gr. 40 ; Drive shaft; Removing and installingsedrive d b shaft . ua
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– If present, install noise insulation for leftaudrive shaft in wheel
t or
ac
housing. ss
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– If present, attach noise insulation to gearbox.
ility
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noise insulation .
spec
es, in part or in w
– Attach wheel ⇒ Running gear, axles, steering; Rep. gr. 44 ;
t to the co
Wheels, tyres; Specified torque for wheel bolts .
Specified torques
rrectness of i
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1.3 Renewing right oil seal
nform
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⇒ “1.3.1 Renewing right oil seal on manual gearbox, front-wheel

m
at
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drive”, page 215
ion
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⇒ “1.3.2 Renewing seal on right of manual gearbox - all wheel
his
ate
drive”, page 219
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1.3.1 Renewing right oil seal on manual gearbox, front-wheel drive

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1. Oil seals 215


equipment required
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logue (ETKA)

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6-speed manual gearbox 0A5 - Edition
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♦ Grease for splines of stub shaft ⇒ Electronic Parts Catalogue
pt
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Removing
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– Loosen front right wheel bolts.
h re
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– Raise vehicle.
es, in part or in w
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– Remove right wheel.
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noise insulation .
l purpos
– If fitted, remove noise insulation for right drive shaft from wheel
housing.
nf
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– Separate threaded connection securing wheel bearing hous‐
rm
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ing to lower swivel joint ⇒ Running gear, axles, steering; Rep.
atio
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gr. 40 ; Lower suspension link, swivel joint; Assembly over‐

o
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or c
view - lower suspension link, swivel joint .
thi
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o
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-arrows-.
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– Pull right drive shaft off gearbox stub shaft, raise and secure. op
satelettronica
C py
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Prote AG.
– Unscrew stub shaft securing bolt -arrow-, counterholding stub

shaft with counterhold tool - T10140- or counterhold tool -
T50053- while doing so.
– Remove stub shaft with compression spring.
– Lever out stub shaft oil seal e.g. with lever.
Installing
– Lightly oil outer diameter of new oil seal, and drive it in to stop.
1. Oil seals 217

– Half-fill space between sealing lip and dust lip -arrow- with
sealing grease .
– Insert stub shaft with spring.
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– Tighten countersunk bolt for stub shaft -arrow-. Counterhold
hole
spec
stub shaft when doing this.
es, in part or in w
t to the co
rrectness of i
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satelettronica
nform
mercia
at
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ion
c
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ate
– Renew O-ring -arrow- of stub shaft.
do
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– Grease splines of stub shaft with grease ⇒ Electronic Parts

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Catalogue (ETKA) .
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– Push right drive shaft -A- onto gearbox stub shaft.

– Screw bolts -arrows- into rear engine support ⇒ Running gear,
axles, steering; Rep. gr. 40 ; Drive shaft; Removing and in‐
stalling drive shaft .
– Join wheel bearing housing to lower swivel joint ⇒ Running
gear, axles, steering; Rep. gr. 40 ; Lower suspension link,
swivel joint; Assembly overview - lower suspension link, swivel
joint .
– If present, install noise insulation for right drive shaft in wheel
housing.
noise insulation .
– Attach wheel ⇒ Running gear, axles, steering; Rep. gr. 44 ;
Wheels, tyres; Specified torque for wheel bolts .
Specified torques

1.3.2 Renewing seal on right of manual gear‐

box - all wheel drive
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logue (ETKA)
Procedure
– Remove bevel box ⇒ page 42 .
1. Oil seals 219

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– Lever bevel box oil seal out of clutch housing.
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– Lightly oil new oil seal on outer diameter. Fill space between
nform
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sealing lips -arrow- half full with sealing grease for radial oil
seal ⇒ Electronic Parts Catalogue (ETKA) .
m
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– Drive oil seal for bevel box into clutch housing up to stop. Do
– Install bevel box ⇒ page 42 .
– Check gear oil level in bevel box ⇒ page 156 .
1.4 Renewing input shaft seal


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Procedure
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– Remove gearbox ⇒ page 69 .
l purpos

bearing ⇒ page 33 .
nform
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Removing input shaft oil seal -1-

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A - Extractor tool - T20143-
satelettronica
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Driving in input shaft oil seal flush

A - Press tool - T10233-
– Install clutch slave cylinder together with clutch release bear‐
ing ⇒ page 33 .
– Install gearbox ⇒ page 89 .
1. Oil seals 221

2 Differential
⇒ “2.1 Assembly overview - differential”, page 222
⇒ “2.2 Dismantling and assembling differential”, page 224
⇒ “2.3 Adjusting differential”, page 230
2.1 Assembly overview - differential
1 - Gearbox housing
olkswagen AG
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2 - Tapered roller bearing inner ksw
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❑ Pulling off ⇒ page 227uthor eo
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❑ Pressing in ss c
⇒ page 227 .
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❑ Pressing in
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⇒ page 228 .
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4 - Differential
❑ With final drive gear
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5 - Sender ring
❑ Not fitted in all gearbox‐
s
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❑ Drive off differential with
drift inform
mer
atio
❑ Pressing on
om
⇒ page 228
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agen
race
❑ Pressing in
⇒ page 229 .
8 - Shim
❑ Adjusting differential ⇒ page 230
9 - Baffle plate
❑ Installation position: shoulder on inner diameter faces clutch housing
10 - Clutch housing
11 - Seal
❑ Renewing on left side ⇒ page 212
❑ Renewing on right side ⇒ page 215
12 - Countersunk bolt
❑ 35 Nm

13 - O-ring
14 - Stub shaft
❑ For allocation, refer to ⇒ Electronic Parts Catalogue (ETKA)
15 - Compression spring for stub shaft
❑ Installed behind stub shaft
16 - Thrust washer
❑ Installation position: shoulder towards spring
17 - Tapered ring
❑ Installation position: taper towards differential cage
18 - Retaining ring
❑ Holds tapered ring, thrust washer and compression spring in position when stub shaft is removed
19 - Seal
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❑ For right stub gen AG
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❑ Renewing
sed ⇒ page 241
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20 - Retaining
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satelettronica
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❑ Renew after removal ce
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21 - Bevel box
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22 - Seal
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❑ Small seal for sealing stub shaft/bevel box on manual gearbox

spec

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23 - Seal
❑ Large seal between bevel box and manual gearbox
rrectne

ss o
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2. Differential 223
2.2 Dismantling and assembling

swa
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♦ Tube - VW 416 B-

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♦ Assembly ring - 10 - 9- has been discontinued. Use thrust

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piece - T10266- instead ⇒ page 227

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2. Differential 225
satelettronica
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♦ Wheel bearing tube - 3345-

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♦ -1- internal puller, e.g. KUKKO 21-8 - VAS 6775-
rrectne

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♦ -2- Puller hooks - Kukko 1 - 200-

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♦ Press tool - T10266-
satelettronica
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♦ Using the inductive sheater
sa - VAS 6414- , heat tapered roller c
bearing inner races to about 100°C before installing. Wear
ce
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♦ Always renew both tapered roller bearings together as a set.

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Pulling tapered roller bearing inner race from gearbox housing

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Pressing tapered roller bearing inner race into gearbox housing

rrectness of i
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Note
nf
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- T10266- instead ⇒ page 227 .

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2. Differential 227
Pulling off tapered roller bearing outer race

A - Two-arm puller, e.g. KUKKO 20-10 - VAS 251 001- with
200 mm hooks.
Note
♦ To fit hooks, open arms -B- by unscrewing nut -arrow-. Then

attach hook with puller -A- installed.
♦ As soon as outer race has been raised slightly, loosen two arm
puller and press hooks outwards.
Pressing outer ring/tapered roller bearing into differential
Note

satelettronica
AG. Volkswagen AG d
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Press in sender ring -A- to stop.
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– Clamp puller -A- near flat sides of differential under inner race.
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Pulling tapered roller bearing outer race out of clutch housing
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After pulling out, renew damaged shim. C py
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– Before pressing in, insert baffle plate and shim.
Note
Observe installation position of washer. Shoulder on inner diam‐

eter faces seal.
Removing spring pin for differential pinion pin

– Cover tapered roller bearing inner race to prevent possible
damage and ingress of metal particles.
– Drive out spring pin with chisel, inserting chisel into circum‐
ferential groove.
2. Differential 229
Installing spring pin for differential pinion pin

– Align hole in differential pinion pin with hole in differential.
– Drive in spring pin with drift -1- until dimension -a- = 5 ± 0.5
mm is attained.
AG. Volkswagen AG d
Installing one-piece thrust washer
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– Lubricate one-piece thrustrise washer with gear oil.
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– Install one-piece thrust
s au washer in such a way that lug -A- en‐ ra
c
gages in groove -B- in differential.
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Installing differential bevel gears
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– Install one-piece thrust washer moistened with gear oil
⇒ page 227 . ss
– Install both sun wheels and secure (e.g. with stub shaft).
o
cial p
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– Insert planet pinions offset 180° and pivot into position.

mer
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– Press in differential pinion pin (-arrow A-) to first planet pinion.

om
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– Place threaded pieces -arrows B- in sun gears.

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Installation position: shoulder to sun gear

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t.
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2.3 Adjusting differential
c by lksw
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equipment required
satelettronica
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♦ End dimension plate - 385/17-
♦ Universal dial gauge holder - VW 387-
rrectness of i
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nform
ercia

m
at
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ion
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ate
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for
en
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Cop py
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pyri by
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cted agen
Prote AG.
2. Differential 231
satelettronica
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pt
du
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, is n
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hole
spec
es, in part or in w
♦ Adjusting device for crown wheel - VW 521-

♦ Assembly ring - 10 - 9- has been discontinued. Use thrust t to the co
piece - T10266- instead ⇒ page 233
rrectness of i
♦ Sleeve - 3144-
l purpos
♦ Tube - 3259-
nf
♦ Wheel bearing tube - 3345-

ercia
orm
m
♦ -1- internal puller, e.g. KUKKO 21-8 - VAS 6775-

atio
om
n in
c

or
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t.
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Cop py
t. rig
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Prote AG.

♦ Press tool - T10266-
It is necessary to readjust the differential when the differential is

renewed.
Procedure
– Press tapered roller bearing outer race, without shim, into
clutch housing.
satelettronica
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
– Press tapered roller bearing inner race into gearbox housing.

itte
y li
erm
ab
ility
ot p
wit
Note
, is n
h re
hole
spec

es, in part or in w

t to the co
– Fit differential into clutch housing.

rrectness of i
– Fit clutch housing and tighten 5 bolts to specified torque.

l purpos
nform
ercia
– Secure special crown wheel adjusting tool - VW 521/4- with

m
crown wheel adjusting tool - VW 521/13- to differential cage

at
om
io
on gearbox housing side.

n
c
in t
or
his
e
– Press differential in direction of clutch housing while turning it

at
do
riv
8 times.
p
cum
for
– Turn gearbox in support bracket so that clutch housing is up‐

en
ng
t.
yi Co
wards. t. Cop py
rig
gh ht
pyri by
Vo
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by
cted agen
Prote AG.
2. Differential 233
AG. Volkswagen AG d
agen oes
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d b ara
Transporter 2016 ➤ orise nte
eo
h
s aut ra
c
s
ce
le
un
– Secure universal dial gauge bracket - VW 387- to clutch hous‐
pt
an
d
ing and set dial gauge to “0” with 1 mm preload.
itte
y li
rm
ab
pe
– Move differential up and down using crown wheel adjusting
ility
ot
tool - VW 521/4- . Read and note play indicated on dial gauge
wit
, is n
(e.g. 0.70 mm).
h re
hole
spec
Determine shim from table ⇒ page 235 .
es, in part or in w
t to the co
• Perform measurement as shown in figure. Otherwise the
measured value will be wrong.
rrectness of i
Determining thickness of shim
l purpos
– Remove gearbox housing.
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
op
satelettronica
C py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

– Withdraw tapered roller bearing outer race from clutch hous‐

ing:
B - Internal puller e.g. KUKKO 21-8 - VAS 6775-
– Place washer in clutch housing.
Note
Observe installation position of washer. Shoulder on inner diam‐

eter faces seal.
– Then insert shim of determined thickness (in example,

0.95 mm).
The following shims are available:
Bearing play Shim
bearing clearance Thickness (mm)
(mm)
satelettronica
0.359 … 0.430 0.65
0.431 … 0.480 0.70
0.48 … 0.530 0.75
0.531 … 0.580 0.80
0.581 … 0.630 0.85
0.63 … 0.680 0.90
0.681 … 0.730 0.95
0.731 … 0.780 1.00
0.78 … 0.830 1.05
0.831 … 0.880 1.10
0.881 … 0.930 1.15
0.931 … 0.980 1.20
0.981 … 1.030 1.25
1.031 … 1.080 1.30wagen AG. Volkswagen AG does
1.081 … 1.130 olks
V1.35
not
gu
d by ara
1.131 to 1.162 or
ise 1.40 nte
e
th or
au ac
ss
ce
e
nl
Note
pt
du
an
itte
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erm
ab
Allocate shims using ⇒ Electronic parts catalogue (ETKA) .

ility
ot p
wit
, is n
If the size of shim required is larger than those listed in the table,
h re
hole
insert two shims totalling the correct figure.

spec
es, in part or in w
The various thicknesses allow for achieving the exact shim thick‐
t to the co
ness required.
– Press in outer race again and bolt gearbox housing tight.
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
2. Differential 235
3 Components of bevel box

⇒ “3.1 Renewing bevel box seals”, page 236
3.1 Renewing bevel box seals

⇒ “3.1.1 Renewing small seal on left of bevel box between manual
gearbox and bevel box”, page 236
⇒ “3.1.2 Renewing large seal on left of bevel box between manual
gearbox and bevel box”, page 239
⇒ “3.1.3 Renewing seal on right of bevel box”, page 241
⇒ “3.1.4 Renewing seal for output flange on bevel box”,
page 245
3.1.1 Renewing small seal on left of bevel box between manual gearbox and
bevel box
satelettronica
AG. Volkswagen AG d
agen oes
olksw not
y V gu
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rise nte
tho eo
au ra
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un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

♦ Multi-purpose tool - VW 771- with extractor hook - VW 771/37-

♦ Drift sleeve - 40-20-

♦ Depth gauge
logue (ETKA)
Removing
satelettronica
Note
wage es n
The seal between the right stub shaft andy Vbevel
olks box output shaft ot g
ua
can only be renewed with the bevel box
ris
e removed.
d b ran
tee
tho or
au ac
– Remove bevel box ⇒ page 42
s .
s
ce
e
nl
pt
– Secure bevel box with M10 x 60 bolts and nuts to gearbox
du
an
itte
support - 2004- -arrows-.
y li
erm
ab
ility
ot p
wit
box.
, is n
h re
hole
– Drain oil from bevel box.

spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
– Pull off dust seal from stub shaft by levering off retaining tabs
o
r
rp
cu
-arrow-.
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh
Note
ht
pyri by
Vo
o
by c lksw
cted agen
Prote
Always renew dust seal -A-.
AG.
3. Components of bevel box 237

– Lever off retaining ring -B- from bearing mounting -C- using 2
screwdrivers.
Note
If the circlip -B- is not loose, slightly press on the bearing mounting
-C- until the circlip moves and can be removed. If fitted, do not
remove the snap ring -A- for the bearing -D-.
– Position bevel box and special tools as illustrated.
Note
Have a second mechanic support the bevel box.
– Press out right stub shaft -A- with bearing mounting and bear‐
satelettronica
ing.
– Calculate installation depth of seal using depth gauge and
note result.
– Press down seal -A- with 3 mm screwdriver.
Note
. Volkswag
♦ To do this, position kscrewdriver
swa
gen AG at different
en AG
dopoints
es to prevent
seal from canting. yV
ol not
gu
edb ara
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♦ Do not damageho -B- bearing. eo
aut ra
ss c
– Turn bevel box in assembly bracket with bolting surface for
ce
e
nl
pt
du
gearbox upwards.
an
itte
y li
erm
ab
ility
ot p
wit
– Pull out oil seal using multi-purpose tool - VW 771/1- and puller
, is n
h re
hooks - VW 771/37- .
hole
spec
Installing
es, in part or in w
t to the co

rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

– Lightly oil new oil seal on outer diameter.

– Fill space between sealing lips -arrow- half full with sealing
grease for radial oil seal ⇒ Electronic Parts Catalogue (ET‐
KA) .
Note
Observe installation depth.
lkswage es n
Vo ot g
– Drive in oil seal eto
d stop without canting using thrust piece
by ua
ran -
T10142- . thor is tee
or
au ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
satelettronica
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
– Position bevel box and special tools as illustrated.
l purpos
Note
nform
ercia

m
at
om
ion
c
in t
– Press in right stub shaft and bearing mounting -A- with drift
or
his
e
sleeve - 40-20- until circlip can be inserted.

at
do
priv
– Install dust seal.

um
for
en
ng
t.
yi
Co
Cop py
t. rig
gh
– After installing bevel box, fill with oil and check oil level in bevel
ht
pyri by
Vo
o
box ⇒ page 51 .
c by lksw
cted agen
Prote AG.
3.1.2 Renewing large seal on left of bevel box between manual gearbox and bevel
box

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
satelettronica
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
ht. rig
rig ht
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Special tools and workshop equipment required co Vo
by lksw
cted agen
Prote
♦ Thrust piece - T10143- or thrust piece - T50049-
AG.

♦ Depth gauge
logue (ETKA)
Removing
Note
Seal for output shaft of bevel box on manual gearbox can only be
renewed with bevel box removed.

– Secure bevel box with M10 x 60 bolts and nuts to gearbox
olks
wage es n
ot g
support - 2004- -arrows-. db
y V ua
ran
e
ris tee
– Turn bevel box in assembly bracket with bolting
tho surface for or
au
gearbox upwards. ss ac
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Calculate installation depth of seal using depth gauge and
note result.
rrectness of i
– Lever out seal using puller hooks - T20143/2- .
l purpos
Installing
nform
ercia

m
at
om
io
satelettronica
n
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
– Lightly oil new oil seal on outer diameter. rig ht
py by
co Vo
by lksw
– Fill space between sealing lips -arrow- half full with sealing cted agen
Prote AG.
grease for radial oil seal ⇒ Electronic Parts Catalogue (ET‐
KA) .
Note
Observe installation depth.
– Drive in oil seal to stop without canting using thrust piece -

T10143- or thrust piece - T50049- .
– After installing bevel box, check oil level in bevel box
⇒ page 51 .
3.1.3 Renewing seal on right of bevel box
Note
Right seal for stub shaft/bevel box can be renewed only with bevel
box removed.

satelettronica
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec

t to the co

♦ Assembly tool - T10214-
rrectne

ss
♦ Drift sleeve - 40-20-

o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

satelettronica
♦ Sealing grease for radial shaft oil seal ⇒ Electronic parts cata‐gen AG. Volkswagen AG d
logue (ETKA) Vol
ksw
a oes
not
by gu
ara
♦ Plastic mallet ed nte
oris eo
th
au ra
c
ss
ce
le
Note
un
pt
an
d
itte
y li
Always insure proper seating of tools and components throughout
erm
ab
ility
the entire procedure. If necessary, seek assistance (second me‐
ot p
chanic).
wit
is n
h re
ole,
spec
Removing
t to the co
– Secure bevel box with M10 x 60 bolts and nuts to gearbox rrectne
bracket - 2004- -arrows-.
s
box.
s o
cial p
f in
– Drain oil from bevel box.

form
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

– Pull off dust seal -A- from right stub shaft by levering off se‐
curing tabs -arrow-.
Note
Renew dust seal -A- after removing.
– Lever off retaining ring -B- from bearing mounting -C- using 2
screwdrivers.
Note
If the circlip -B- is not loose, slightly press on the bearing mounting
-C- until the circlip moves and can be removed. If fitted, do not
remove the snap ring -A- for the bearing -D-.
satelettronica
– Position bevel box and special tool as illustrated.
Note
Have a second mechanic support the bevel box. n AG. Volkswagen AG do

lkswage es n
o ot g
byV ua
– Press out stub shaft/bevel box -A- together ir se with bearing
d ran
tee
mounting and bearing. utho
or
a ac
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
– Lever out seal by pushing it on one side in direction of

wit
is n
-arrow-.
h re
ole,
spec
– Remove seal.
t to the co
Installing
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

– Lightly oil new oil seal on outer diameter. Fill space between
sealing lips -arrow- half full with sealing grease for radial oil
seal ⇒ Electronic Parts Catalogue (ETKA) .
– Drive in oil seal to stop without canting using thrust piece -

T10143- .
satelettronica
– Position bevel box and special
agen
tool
AG. Vas
olksillustrated.
wagen AG
do
ksw es n
Vol ot g
d by ua
ran
e
ris
Note tho
tee
or
au ac
ss
ce
e
nl
pt
du
an
itte
y li
– Press in right stub shaft and bearing mounting -A- with drift
erm
ab
sleeve - 40-20- until circlip can be inserted.

ility
ot p
wit
, is n
– Install dust seal.

h re
hole
spec

es, in part or in w
t to the co
– After installing bevel box, fill with oil and check oil level in bevel
box ⇒ page 51 .
rrectness of i
3.1.4 Renewing seal for output flange on bevel box

l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.


equipment required
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
satelettronica
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
e

t
sd
iva
o
pr
cum

r
fo
en
ng
t.
yi
♦ Depth gauge
Co
Cop py
t. rig
gh ht
♦ Sealing grease for radial shaft oil seal ⇒ Electronic parts cata‐ yri
p by
o Vo
logue (ETKA)
c by lksw
cted agen
Prote AG.
Removing
noise insulation .
– Remove front propshaft ⇒ Rep. gr. 39 ; Propshaft; Removing

– Remove circlip ring with appropriate circlip pliers.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
– Pull off output flange of bevel box using puller, e.g. KUKKO
ce
e
nl
pt
18-1 - VAS 251 417- . du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
satelettronica
rrectness of i
l purpos
nf
ercia
Note
orm
m
atio
m
When pulling off, do not cant the output flange as damage to the
o
n in
or c
dust protection cover -arrow- will ensue.
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– Prior to removing the seal, determine and note the installation

depth.
– Lever out seal using puller hooks - T20143/2- .
Installing

AG. Volkswagen AG d
agen oes
– Lightly oil new oil seal on outer diameter. olksw not
V gu
d by ara
e
– Fill space between sealing lips -arrow- half
horisfull with sealing nte
eo
grease ⇒ Electronic Parts Catalogue s(ETKA)
au
t
. ra
c
s
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Drive in oil seal without canting using thrust piece - T10143- .
rrectness of i
l purpos
Note
nform
ercia
Do not exceed the determined installation depth value.

m
at
om
io
– Install output flange of bevel box together with dust seal.
n
c
satelettronica
in t
or
his
e
– Fit circlip.
at
do
priv
c
– Install front propshaft on bevel box ⇒ Rep. gr. 39 ; Propshaft;
um
for
en
Removing and installing propshaft .
ng
t.
yi Co
op py
– Check gear oil level in bevel box ⇒ page 51 . t. C rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
terior; Rep. gr. 66 ; Noise insulation; Assembly overview - Prote AG.
noise insulation .

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Service

Service Department. Technical Information

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Copyright © 2019 Volkswagen AG, Wolfsburg D4B80561BF3

30 - Clutch . . . . . . . . . . . . . . . . . . .n.AG. ..V.olk.s.wa. g.en. A.G. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

1.4 Removing and installing clutch pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

1.5 Removing and installing over-centre spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

1.6 Removing and installing mounting bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

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

1.9 Removing and installing bleeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

1.10 Bleeding clutch mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

2.2 Removing and installing clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

1.1 Assembly overview - bevel box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

1.2 Removing bevel box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

1.3 Installing bevel box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

2.2 Assembly overview - gear knob and cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

3 Removing and installing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

35 - Gears, shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159

1 Input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159

1.1 Assembly overview - input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159

1.2 Dismantling and assembling input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163

2 Output shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175

2.3 Adjusting output shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210

39 - Final drive - differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211

1 Oil seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211

1.1 Overview of fitting locations - seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211

1.2 Renewing left seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212

1.3 Renewing right oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215

1.4 Renewing input shaft seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220

3.1 Renewing bevel box seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236

1.1 Safety measures when working on vehicles with a start/stop system

– Deactivate start/stop system by switching off the ignition.

a road test spec

When the front passenger airbag is triggered in an accident, in‐

sufficiently secured testing and measuring instruments become

– Secure testing and measuring instruments on the rear seat.

– Have a second person operate the test and measuring equip‐

ment on the rear seat.

2.1 Gearbox identification

Identification code Day Month Year 2004 of manufacture

Additional data depend on manufacture.

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

2 Rep. gr.00 - Technical data

Codes and production dates of bevel box

Example ZSB.09N. 123456 SDP KQK 201108

3.1 General repair instructions

After removing gaskets and seals, always inspect contact surfa‐

♦ Do not overstretch retaining rings.

♦ Installation position for retaining rings: At the top, the ring is ab

»narrower« and its installation position therefore as well. This wit

moval and installation.

♦ Renew retaining rings which have been damaged or over‐

stretched after removal.

♦ Renew spring pins. Installation position: slit -A- should be in

line with the line of force -arrow-.

Nuts and bolts

♦ Measure shims at several points with a micrometer. The var‐

ious tolerances make it possible to achieve the exact shim

♦ Check for burrs and damage.

♦ Install only flawless shims.

6 Rep. gr.00 - Technical data

housing as well as the stopping face of the flywheel must be