Get OperationandHousing Guide for Volkswagen Golf 4 Door Fifth Generation (2003-2008)

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤

6-Speed Manual Transmission 02Q - Edition 05.2013

34 – Operation and Housing

1

Shift Mechanism, Servicing

⇒ “1.1 Shift Mechanism Installation Position”, page 76

⇒ “1.2 Overview - Selector Mechanism”, page 78

⇒ “1.3 Overview - Gearshift Knob and Cover”, page 79

⇒ “1.4 Boot with Shifter Knob and Noise Insulation, Removing and

Installing”, page 79

⇒ “1.5 Overview - Gearshift Lever and Gearshift Housing, through

10/2006”, page 81

⇒ “1.6 Overview - Gearshift Lever and Gearshift Housing, from

11/2006”, page 83

⇒ “1.7 Overview - Operating Cables”, page 85

⇒ “1.8 Plastic Relay Lever”, page 89

⇒ “1.9 Selector Mechanism, Removing and Installing”,

page 92

⇒ “1.10 Gearshift Cable and Selector Cable, Removing and In‐

stalling”, page 96

⇒ “1.11 Selector Mechanism, Adjusting”, page 97

⇒ “1.12 Selector Mechanism, Disassembling and Assembling,

from 11/2006”, page 100

1.1

Shift Mechanism Installation Position

-Arrow A- Gearshift Lever Movement

-Arrow B- Selector Lever Movement

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Rep. Gr.34 - Operation and Housing

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤

6-Speed Manual Transmission 02Q - Edition 05.2013

A - Gearshift Lever Cable

B - Selector Cable

C - Heat Shield

❑ Remove the gearshift

mechanism before re‐

moval

1 - Selector Lever

2 - Relay Lever

1. Shift Mechanism, Servicing

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6-Speed Manual Transmission 02Q - Edition 05.2013

1.2

Overview - Selector Mechanism

Note

♦ Get the anti-theft code for the radio before disconnecting the battery.

♦ Disconnect the ground cable from the battery when working on the gearshift mechanism inside the engine

compartment. Refer to ⇒ Electrical Equipment; Rep. Gr. 27 ; Battery; Battery, Disconnecting and Con‐

necting .

♦ Read the information on what to do after connecting the battery. Refer to ⇒ Electrical System; Rep. Gr.

27 ; Battery; Battery, Removing and Installing .

♦ To work on shift mechanism on engine compartment, remove entire air filter housing if it is located over the

shift mechanism. Refer to ⇒ Rep. Gr. 23 ; Diesel Direct Injection System; Air Filter Housing, Removing and

Installing or ⇒ Rep. Gr. 24 ; Air Filter; Air Filter Housing, Removing and Installing .

♦ The shift mechanism must be removed in order to replace the operating cables. Refer to

⇒ “1.9 Selector Mechanism, Removing and Installing”, page 92 .

♦ Do not bend the operating cables.

I -

⇒ “1.3 Overview - Gearshift

Knob and Cover”, page 79 .

II -

⇒ “1.5 Overview - Gearshift

Lever and Gearshift Housing,

through 10/2006”, page 81 .

II -

⇒ “1.6 Overview - Gearshift

Lever and Gearshift Housing,

from 11/2006”, page 83 .

III -

⇒ “1.7 Overview - Operating

Cables”, page 85

Gearshift mechanism, removing and installing. Refer to

⇒ “1.9 Selector Mechanism, Removing and Installing”,

page 92 .

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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤

6-Speed Manual Transmission 02Q - Edition 05.2013

Adjust the gearshift mechanism. Refer to

⇒ “1.11 Selector Mechanism, Adjusting”, page 97 .

1.3

Overview - Gearshift Knob and Cover

1 - Badge

❑ Can be carefully pried

off a plastic or leather

shift knob

2 - Gearshift Knob

❑ With boot

❑ The shift knob and boot

cannot be separated

from each other.

❑ Always replace together

❑ Removing and instal‐

ling. Refer to

⇒ “1.4 Boot with Shifter

Knob and Noise Insula‐

tion, Removing and In‐

stalling”, page 79 .

3 - Clamp

❑ For securing the shift

knob to the shift lever

❑ Secure on the gearshift

knob -item 2-

⇒ Item 2 (page 79) using

Hose Clamp Pliers -

VAG1275- .

❑ Replace after removing

4 - Center Console Frame

❑ Combined in one piece

with the upper center

console section on

some versions

5 - Noise Insulation

❑ Not on all vehicles

❑ Arrow on noise insula‐

tion points in direction of

travel

❑ Retaining tab spacing varies

❑ Therefore can only be arranged in one position

1.4

Boot with Shifter Knob and Noise Insu‐

lation, Removing and Installing

Special tools and workshop equipment required

♦ Hose Clip Pliers - VAG1275A-

1. Shift Mechanism, Servicing

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6-Speed Manual Transmission 02Q - Edition 05.2013

Removing

– Remove the boot with the center console frame from the cen‐

ter console or pry it out carefully -arrows-.

Note

On some equipment versions, the boot must be pried out at the

front area.

– Fold the boot with the center console frame up over the shifter

knob.

– Open the clamp -arrow- and remove the shift knob and boot.

In some equipment versions, the center console frame remains

in the center console.

– It may be necessary to pull or pry the center console frame out

carefully.

– Remove the noise insulation -1-.

Installing

– Install the noise insulation.

Installation Location, Noise Insulation

•

-Arrow A- points in direction of travel.

The tabs -arrows B- must latch into the center console.

– Press the center console frame into the center console, if nec‐

essary.

– Then turn inner side of boot toward outside.

Install the shift knob all the way on.

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6-Speed Manual Transmission 02Q - Edition 05.2013

– Install the shifter knob with frame and boot and press the new

clamp -arrow- together.

– Press the boot with the frame into the center console or the

boot into the frame.

1.5

Overview - Gearshift Lever and Gearshift Housing, through 10/2006

Note

Lubricate bearing areas and slide surfaces with Grease - G 000 450 02- .

1 - Lock Washer

❑ Removing and instal‐

ling. Refer to

⇒ Fig. ““Removing and

Installing the Lock

Washer”“ , page 83 .

2 - Bushing

3 - Pressure Spring

4 - Bushing

®

5 - TORX Bolt

❑ 5 Nm

6 - Cover

7 - Insulation

8 - Insulation

9 - Bearing Shell

10 - Gearshift Lever Guide

11 - Washer

12 - Seal

❑ Between the gearshift

housing and the under‐

body

❑ Self-adhesive

❑ Affix to the gearshift

housing

13 - Gearshift Lever

14 - Gearshift Housing

15 - Bearing Bushing

16 - Mounting Pin

17 - Guide Bushing

18 - Pressure Spring

❑ Installing. Refer to ⇒ Fig. ““Installing the Pressure Spring”“ , page 83 .

1. Shift Mechanism, Servicing

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6-Speed Manual Transmission 02Q - Edition 05.2013

19 - Selector Bracket

®

20 - TORX Bolt

❑ 5 Nm

21 - Seal

❑ Replace after removing

22 - Base Plate

❑ Bend the tabs in order to remove

❑ Replace after removing

23 - Selector Cable

❑ To the selector bracket

❑ Removing and installing. Refer to

⇒ Fig. ““Detaching from the Selector Cable and the Shift Cable and Attaching”“ , page 82 .

24 - Gearshift Cable

❑ Removing from the shift lever guide and attaching to the shift lever guide. Refer to

⇒ Fig. ““Detaching from the Selector Cable and the Shift Cable and Attaching”“ , page 82

25 - Lock Washer

❑ Replace after removing

26 - Nut

❑ M6: 8 Nm

❑ M8: 25 Nm

❑ Quantity: 4

27 - Bearing Bushing

❑ Fits in one position only

28 - Lock Washer

❑ Replace after removing

Detaching from the Selector Cable and the Shift Cable and At‐

taching

– Remove the lock washer from the shift cable -A- and the se‐

lector cable -B-.

Lift the tab with a screwdriver in direction of -arrow 1- and remove

the lock washer in direction of -arrow 2-.

– Remove the shift cable -A- from the gearshift lever mount.

– Remove the selector cable -B- from the selector bracket

mount.

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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤

6-Speed Manual Transmission 02Q - Edition 05.2013

Removing and Installing the Lock Washer

– Push the bushing -arrow B- all the way in direction of

-arrow C- and remove or install the lock washer -arrow A-.

Note

♦ Do not tilt the bushing when pushing it down.

♦ The slot in the lever for the circlip must be visible.

♦ Carefully release the tension on the spring.

Installing the Pressure Spring

– Install the compression spring so that the brace -A- contacts

upper part of pin -arrow-.

– Pull the brace -B- downward so that it reached the bottom of

the pin -arrow-.

1.6

Overview - Gearshift Lever and Gearshift Housing, from 11/2006

Note

♦ Lubricate the bearing areas and the sliding surfaces.

♦ Refer to the Parts Catalog for the grease allocation.

♦ Gearshift mechanism, disassembling and assembling. Refer to

⇒ “1.12 Selector Mechanism, Disassembling and Assembling, from 11/2006”, page 100 .

1. Shift Mechanism, Servicing

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6-Speed Manual Transmission 02Q - Edition 05.2013

1 - Base Plate

❑ Bend the tabs in order to

remove

❑ Replace after removing

2 - Seal

❑ Replace after removing

3 - Gearshift Lever

❑ Can be removed and in‐

stalled with the shift lev‐

er guide installed

-item 15-

⇒ Item 15 (page 84) .

4 - Washer

❑ Slide out of shift lever as

far as stop -arrow-.

5 - Lock Washer

❑ Be careful not to dam‐

age the cables when re‐

moving them

❑ Replace after removing

6 - Selector Cable

❑ Pry off of selector brack‐

et

❑ Press onto selector

bracket inside the shift

mechanism

❑ Installation position. Re‐

fer to

⇒ “1.1 Shift Mechanism

Installation Position”,

page 76 .

7 - Bushing

8 - Gearshift Cable

❑ Pry off of shift lever guide

❑ Press onto shift lever guide inside the shift mechanism

❑ Installation position. Refer to ⇒ “1.1 Shift Mechanism Installation Position”, page 76 .

9 - Insulation

10 - Bearing Shell

❑ Will get damaged when being removed

❑ Replace after removing

11 - Bushing

12 - Lock Washer

❑ Removing and installing. Refer to ⇒ Fig. ““Removing and Installing the Lock Washer”“ , page 83 .

13 - Pressure Spring

❑ Removing and installing. Refer to ⇒ Fig. ““Removing and Installing the Lock Washer”“ , page 83 .

14 - Bushing

15 - Gearshift Lever Guide

16 - Nut

❑ M6: 8 Nm

❑ M8: 25 Nm

❑ Quantity: 4

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Rep. Gr.34 - Operation and Housing

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6-Speed Manual Transmission 02Q - Edition 05.2013

17 - Seal

❑ Between the gearshift housing and the underbody

❑ Self-adhesive

❑ Affix to the gearshift housing

18 - Gearshift Housing

❑ With spring and selector bracket

❑ Spring and selector bracket cannot be removed

1.7

Overview - Operating Cables

Note

Lubricate the bearing areas and the sliding surfaces. Refer to the Parts Catalog for the grease allocation.

1 - Gearshift Cable

❑ Attach to the cable re‐

tainer -item 18-

⇒ Item 18 (page 87) .

❑ Installation position. Re‐

fer to

⇒ “1.1 Shift Mechanism

Installation Position”,

page 76 .

❑ From 11/2006 changed

fastener on shift lever in‐

side shift mechanism

-item 8-

⇒ Item 8 (page 84)

2 - Selector Cable

❑ Attach to the cable re‐

tainer -item 11-

⇒ Item 11 (page 86) .

❑ Installation position. Re‐

fer to

⇒ “1.1 Shift Mechanism

Installation Position”,

page 76 .

❑ From 11/2006 changed

fastener on selector

bracket inside shift

mechanism -item 6-

⇒ Item 6 (page 84)

3 - Lock Washer

❑ Replace after removing

❑ Discontinued on gear‐

shift mechanisms from

11/2006. Refer to

⇒ “1.6 Overview - Gear‐

shift Lever and Gear‐

shift Housing, from

11/2006”, page 83

4 - Lock Washer

❑ Be careful not to damage the cables when removing them

❑ Replace after removing

1. Shift Mechanism, Servicing

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6-Speed Manual Transmission 02Q - Edition 05.2013

5 - Gearshift Housing

6 - Hex Bolt

❑ 20 Nm

❑ For the cable bracket

❑ Quantity: 2

7 - Cable Bracket

❑ Can be made of plastic or metal

8 - Grommet

❑ Cable mounting bracket to transmission

9 - Spacer

10 - Nut

❑ 20 Nm

❑ For the cable bracket

11 - Cable Retainer

❑ For attaching the selector cable to the relay lever

❑ Adjust the gearshift mechanism after installing. Refer to

⇒ “1.11 Selector Mechanism, Adjusting”, page 97 .

❑ Do not interchange, cable locking mechanisms for selector cable on linkage lever and for shift cable on

transmission shift lever are different. Refer to ⇒ Fig. ““Cable Retainer Allocation”“ , page 87 .

❑ From 05/2007 installed in with the plastic relay lever. Refer to ⇒ “1.8 Plastic Relay Lever”, page 89 .

❑ Removing from plastic relay lever. Refer to ⇒ “1.8 Plastic Relay Lever”, page 89

❑ Installing on plastic relay lever. Refer to ⇒ “1.8 Plastic Relay Lever”, page 89

❑ Allocation. Refer to ⇒ Fig. ““Cable Retainer Allocation”“ , page 87 .

12 - Relay Lever

❑ Installation position. Refer to ⇒ Fig. ““Selector Lever/Relay Lever Installed Position”“ , page 88 .

❑ Adjust the gearshift mechanism after installing. Refer to

⇒ “1.11 Selector Mechanism, Adjusting”, page 97 .

❑ Can be made of plastic or metal

❑ The metal relay lever is placed in the bushings -item 13- ⇒ Item 13 (page 86) and secured with a lock

washer -item 14- ⇒ Item 14 (page 86) .

❑ From 05/2007 plastic relay lever

❑ Plastic relay lever, removing and installing with cable retainer. Refer to

⇒ “1.8 Plastic Relay Lever”, page 89

❑ The bushings and lock washers are not needed with the plastic relay lever

13 - Bearing Bushing

❑ Discontinued on the plastic relay lever

14 - Lock Washer

❑ Replace after removing

❑ Discontinued on the plastic relay lever

15 - Sliding Shoe

16 - Selector Lever

❑ With a balance weight

❑ Insert so that master spline aligns with shift rod

❑ Adjust the gearshift mechanism after installing. Refer to

⇒ “1.11 Selector Mechanism, Adjusting”, page 97 .

❑ Installation position. Refer to ⇒ Fig. ““Selector Lever/Relay Lever Installed Position”“ , page 88 .

❑ From 06/2006 the cable retainer mounting pin has a smaller diameter. Refer to

⇒ Fig. ““As of 06/2006, Smaller Bolt Diameter for the Shift Cable Retainer.”“ , page 87

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Rep. Gr.34 - Operation and Housing

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤

6-Speed Manual Transmission 02Q - Edition 05.2013

17 - Hex Nut

❑ 23 Nm

❑ Self-locking

❑ Replace after removing

18 - Cable Retainer

❑ For attaching the shift cable to the transmission shift lever

❑ Adjust the gearshift mechanism after installing. Refer to

⇒ “1.11 Selector Mechanism, Adjusting”, page 97 .

❑ Do not interchange, cable locking mechanisms for selector cable on linkage lever and for shift cable on

transmission shift lever are different. Refer to ⇒ Fig. ““Cable Retainer Allocation”“ , page 87 .

Cable Retainer Allocation

These holes have different diameters.

Cable Retainer For:

Dimension “a”

8.5 mm

1. - Gearshift cable to gearshift lever from

06/2006

2. - Gearshift cable to gearshift lever to 05/2006

2. - Selector cable to metal relay lever

10 mm

8 mm

2. - Selector cable to plastic relay lever. Refer to

10 mm

⇒ “1.8 Plastic Relay Lever”, page 89

As of 06/2006, Smaller Bolt Diameter for the Shift Cable Retainer.

Mounting Pin for Gearshift Cable Retainer

Through 05/2006

Dimension “a”

10 mm

From 06/2006

8.5 mm

1. Shift Mechanism, Servicing

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6-Speed Manual Transmission 02Q - Edition 05.2013

Installing the Transmission Shift Lever

– When positioning the transmission shift lever, make sure the

gap -arrow A- is placed over the missing selector shaft teeth

-arrow B-.

Selector Lever/Relay Lever Installed Position

1 - Gearshift lever with balance weight

2 - The relay lever grips into the sliding rail on the gearshift lever

via the sliding shoe -arrow-.

Cable Retainer, Replacing

– Pull the securing mechanism forward at the cable retainer from

the shift cable and selector cable as far as the stop in direction

of -1 arrows- and then release it to the left in direction of

-2 arrows-.

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Rep. Gr.34 - Operation and Housing

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤

6-Speed Manual Transmission 02Q - Edition 05.2013

– Remove the gearshift cable lock washer -3- from the gearshift

lever -1-.

– Remove the shift cable from the pins -arrow-.

Metal Relay Lever

– Remove the selector cable circlip -4- from the relay lever -2-.

– Remove the selector cable from the pins.

Plastic Relay Lever

– Remove the relay lever with the cable retainer. Refer to

⇒ “1.8 Plastic Relay Lever”, page 89 .

– Pry the cable retainer out. Refer to

⇒ Fig. ““Removing the Selector Cable Retainer from the Plas‐

tic Relay Lever.”“ , page 92 .

Continuation for All Shift Mechanisms

– Apply a small amount of grease on the pins on the transmis‐

sion shift lever -arrows- -1- and on the relay lever -2-.

•

Refer to the Parts Catalog for the grease allocation.

– Replace the lock washer -3- and the lock washer -4- on the

metal relay lever each time they are removed.

– Attach the shift cable with lock washer -3- (metal relay lever)

and selector cable with lock washer -4-.

Note

If a plastic relay lever is installed, it must be installed together with

the cable retainer. Refer to

⇒ “1.8 Plastic Relay Lever”, page 89 .

– Adjust the gearshift mechanism. Refer to

⇒ “1.11 Selector Mechanism, Adjusting”, page 97 .

1.8

Plastic Relay Lever

A plastic relay lever is installed from 05/2007. Two versions may

be installed.

♦ Relay lever with tab or

♦ Relay lever with clip

Note the following when removing and installing:

•

To remove the relay lever, it is necessary to remove the cable

retainer from the selector cable.

This prevents damage to the selector cable.

– Pull the securing mechanism all the way forward in direction

of -arrow 1- and then unlock to the left in direction of

-arrow 2-.

– Press the relay lever forward (in the direction of -arrow 3-).

1. Shift Mechanism, Servicing

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6-Speed Manual Transmission 02Q - Edition 05.2013

Relay Lever with Tab -arrow 1-

– Press the tab -arrow 1- down as far as the stop and remove

the relay lever together with the cable retainer. Move it in the

operating direction when doing so.

Relay Lever with Clip -arrow 1-.

– Remove the clip -arrow 1- and the relay lever together with the

cable retainer.

Continuation for All

•

The cable retainer must be behind the catch -arrow 2-.

The cable retainer may only be removed with the relay lever

removed. Refer to

⇒ Fig. ““Removing the Selector Cable Retainer from the Plas‐

tic Relay Lever.”“ , page 92 .

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Rep. Gr.34 - Operation and Housing

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤

6-Speed Manual Transmission 02Q - Edition 05.2013

Note

♦ For installing, lubricate the following areas very carefully.

♦ Relay lever shaft -A- in direction of -arrows-.

♦ Gearshift lever glide track -B-, fits into the relay lever.

♦ The relay lever and gearshift lever in the illustration may differ

from the original part.

♦ Refer to the Parts Catalog for the grease allocation.

– Press the cable retainer on the relay lever. Refer to

⇒ Fig. ““Installing the Cable Retainer”“ , page 92 .

– Insert the relay lever together with the cable retainer as far as

the stop.

Relay Lever with Tab -arrow 1-

•

The catch -arrow 1- secures the relay lever.

Make sure it engages securely.

The cable retainer must be behind the catch -arrow 2-.

Relay Lever with Clip -arrow 1-.

•

The clip -arrow 1- secures the relay lever.

Make sure the clips locks securely.

The cable retainer must be behind the catch -arrow 2-.

1. Shift Mechanism, Servicing

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6-Speed Manual Transmission 02Q - Edition 05.2013

Removing the Selector Cable Retainer from the Plastic Relay

Lever.

•

The relay lever is removed.

– Insert a flat-blade screwdriver -A- between the bushing -B- and

the relay lever.

Installing the Cable Retainer

•

The relay lever is removed.

The cable retainer may only be installed at the bushing

-arrow-.

•

The cable retainer must move freely on the relay lever.

It must be behind the tab -arrow 2-.

1.9

Selector Mechanism, Removing and In‐

stalling

Special tools and workshop equipment required

♦ Torque Wrench 1331 5-50Nm - VAG1331-

♦ Refer to the Parts Catalog for the grease allocation.

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Rep. Gr.34 - Operation and Housing

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤

6-Speed Manual Transmission 02Q - Edition 05.2013

Removing

– First check whether a coded radio is installed. If so, obtain the

anti-theft code.

– Disconnect the battery ground cable. Refer to ⇒ Electrical

Equipment; Rep. Gr. 27 ; Battery; Battery, Disconnecting and

Connecting .

– Remove the boot with the shifter knob and noise insulation.

Refer to

⇒ “1.4 Boot with Shifter Knob and Noise Insulation, Removing

and Installing”, page 79 .

– Remove the center console and the center console securing

bracket. Refer to ⇒ Body Interior; Rep. Gr. 68 ; Center Con‐

sole .

– Remove the nuts -arrows-.

– Remove entire air filter housing if it is located over the selector

mechanism. Refer to ⇒ Rep. Gr. 23 ; Diesel Direct Injection

System; Air Filter Housing, Removing and Installing or ⇒ Rep.

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

– Remove the gearshift cable lock washer -3- from the gearshift

lever -1-.

– Remove the shift cable from the pins -arrow-.

Metal Relay Lever

– Remove the selector cable circlip -4- from the relay lever -2-.

– Remove the selector cable from the pins -arrow-.

Plastic Relay Lever

Disconnecting the Cable Retainer from the Selector Cable

•

To avoid damage to the selector cable, the cable retainer must

be disconnected from the selector lever before removal.

– Pull the securing mechanism all the way forward in direction

of -arrow 1- and then unlock to the left in direction of

-arrow 2-.

– Press the relay lever forward (in the direction of -arrow 3-).

– Remove the relay lever with the cable retainer. Refer to

⇒ “1.8 Plastic Relay Lever”, page 89 .

Continuation for All Shift Mechanisms

1. Shift Mechanism, Servicing

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6-Speed Manual Transmission 02Q - Edition 05.2013

– Remove the cable bracket from the transmission -arrows-.

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

Gr. 50 ; Noise Insulation .

– Remove the tunnel braces. Refer to ⇒ Body Exterior; Rep.

Gr. 50 ; Tunnel Brace .

Vehicles with FWD

Caution

Risk of damaging the decoupling element.

♦ Do not bend the decoupling element more than 10°.

♦ Do not load the decoupling element.

♦ Do not damage the wire mesh on the decoupling element.

– Separate the front exhaust system front section at the double

clamp and remove it from the subframe. Refer to ⇒ Rep. Gr.

26 .

– Disengage exhaust system rear section and secure to the

body using for example using a wire. Remove the exhaust

system rear section, if necessary.

AWD Vehicles

– Remove the rear muffler from the retaining straps and remove

the rear section of the exhaust system.

– Remove the exhaust pipe. Refer to ⇒ Rep. Gr. 26 .

– Remove heat shield below the driveshaft.

– Remove the driveshaft. Refer to ⇒ Rear Final Drive; Rep. Gr.

39 .

Continuation for All

– Remove the underbody trim panel nuts -arrows-.

– Remove the lock washers -2 and 3-.

– Lower the underbody trim panel on the inside just enough until

the heat shield -1- for the center tunnel can be removed.

– Pivot shift housing downward and remove with cables.

Installing

Install in reverse order of removal. Note the following:

– Align the shift housing so that it is parallel to the body.

•

The distance on both sides to the body must be equal.

Install the gearshift housing. Refer to -item 26-

⇒ Item 26 (page 82) or -item 16- ⇒ Item 16 (page 84) .

– Attach the cable mounting bracket to the transmission and

tighten the bolts to the tightening specifications -item 6-

⇒ Item 6 (page 86) and -item 10- ⇒ Item 10 (page 86) .

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Rep. Gr.34 - Operation and Housing

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤

6-Speed Manual Transmission 02Q - Edition 05.2013

– Route the cables -1- from the shift mechanism -2- to the trans‐

mission as follows:

•

The cables must run parallel to each other and must not cross

each other.

The cables must be routed inside the depression in the heat

shield -3-.

Note

The heat shield from above is shown in the magnified view.

A clip -A- holds the cables and heat shield to each other in place.

These holes have different diameters.

Cable retainer allocation. Refer to

⇒ Fig. ““Cable Retainer Allocation”“ , page 87

– Apply a small amount of grease on the pins on the transmis‐

sion shift lever -arrows- -1- and on the relay lever -2-.

•

Refer to the Parts Catalog for the grease allocation.

– Replace the lock washer -3- and the lock washer -4- on the

metal relay lever each time they are removed.

– Secure shift cable with lock washer -3- and selector cable with

lock washer -4-.

Cable Retainer with Plastic Relay Lever

– The relay lever and cable retainer must be installed together.

Refer to ⇒ “1.8 Plastic Relay Lever”, page 89 .

– Insert the selector cable into the cable retainer.

Continuation for All Shift Mechanisms

– Install the bracket and the center console. Refer to ⇒ Body

Interior; Rep. Gr. 68 ; Center Console .

– Install the boot with the shifter knob and noise insulation. Refer

to

⇒ “1.4 Boot with Shifter Knob and Noise Insulation, Removing

and Installing”, page 79 .

1. Shift Mechanism, Servicing

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– Install the heat shield -1- under the selector mechanism and

attach with the lock washers -2 and 3-.

– Attach the underbody trim panel to the body -arrows-. Refer to

⇒ Body Exterior; Rep. Gr. 50 ; Underbody Trim Panels .

AWD Vehicles

– Install the driveshaft. Refer to ⇒ Rear Final Drive; Rep. Gr.

39 .

Continuation for All

– Install the exhaust system and align it without tension. Refer

to ⇒ Rep. Gr. 26 .

– Install the tunnel braces under the exhaust system. Refer to

⇒ Body Exterior; Rep. Gr. 50 ; Tunnel Brace .

– Adjust the gearshift mechanism. Refer to

⇒ “1.11 Selector Mechanism, Adjusting”, page 97 .

– If it was removed earlier install the complete air filter housing.

Refer to ⇒ Rep. Gr. 23 ; Diesel Direct Injection System; Air

Filter Housing, Removing and Installing or ⇒ Rep. Gr. 24 ; Air

Filter; Air Filter Housing, Removing and Installing .

– Complete the steps after connecting the battery. Refer to ⇒

Electrical Equipment; Rep. Gr. 27 ; Battery; Battery, Discon‐

necting and Connecting .

1.10

Gearshift Cable and Selector Cable, Re‐

moving and Installing

Removing

– Remove the selector mechanism. Refer to ⇒ page 93 .

– Bend up the tabs -arrows- on the shift mechanism base plate

using a screwdriver and remove the base plate. Only the

straps on the left side of the base plate are shown in the illus‐

tration.

– Remove the seal.

– Remove the lock washers -1 through 4-.

Note

Lock washers -1 and 4- are no longer installed in shift mecha‐

nisms beginning in 11/2006.

– Pry off the shift cable (or the selector lever cable) from the

gearshift lever (or selector lever) with a screwdriver.

– Remove the shift cable and selector cable from the shift hous‐

ing.

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Release the retainers -A- for the shift and selector cables -B- as

follows:

♦ Push the sleeve forward as far as it will go in direction of

-arrow 1-.

♦ Turn the sleeve to the right as far as it will go in direction of

-arrow 2- until it engages.

– Remove the retainers from the cables.

– Remove the lock washers -1 and 2-.

– Remove the cable bracket from the cables.

Installing

Install in reverse order of removal while. Note the following:

– Secure the shift cable and selector cable on the shift housing

with lock washers -2 and 3-.

– Attach the shift cable and the selector cable to the gearshift

lever and the selector lever inside the shift housing and secure

it with lock washers -1 and 4-.

Note

Lock washers -1 and 4- are no longer installed in shift mecha‐

nisms beginning in 11/2006.

– Install the base plate with a new seal on the gearshift housing

-arrows-. Refer to

⇒ Fig. ““Base Plate, Attaching to Gearshift Housing”“ ,

page 105 .

– Install the gearshift mechanism. Refer to ⇒ page 94 .

– Adjust the gearshift mechanism. Refer to

⇒ “1.11 Selector Mechanism, Adjusting”, page 97 .

1.11

Selector Mechanism, Adjusting

Connecting Pin - T10027A-

1. Shift Mechanism, Servicing

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Note

♦ The following is important to make sure the gearshift adjust‐

ment is correct:

♦ Operating and transfer elements of shift mechanism must be

in proper condition.

♦ Shift mechanism must move freely.

♦ The transmission, clutch and clutch mechanism must also be

in proper condition.

•

Transmission in neutral.

– Remove the entire air filter housing if the bracket -A- for the

selector shaft and the securing mechanism for the shift and

selector cables are not accessible through it. Refer to ⇒ Rep.

Gr. 23 ; Diesel Direct Injection System; Air Filter Housing,

Removing and Installing or ⇒ Rep. Gr. 24 ; Air Filter; Air Filter

Housing, Removing and Installing .

– Pull the safety mechanism on the cable retainer for the shift

cable and the selector cable all the way forward in direction of

-arrow 1- and then lock it to the left in direction of -arrow 2-.

Hold the gearshift shaft secure as follows:

– Push the gearshift shaft in direction of -arrow 1-.

– While pressing down selector shaft, rotate lock bolt -A- upward

in direction of -arrow 3- and simultaneously press it in direction

of -arrow 2- until it engages in selector shaft.

– Remove the boot with the shifter knob and frame. Refer to

⇒ “1.4 Boot with Shifter Knob and Noise Insulation, Removing

and Installing”, page 79 .

– If equipped, remove the noise insulation.

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Hold the gearshift shaft secure as follows:

– Move the gearshift lever into neutral.

– Guide the Connecting Pin - T10027A- through the hole -A- and

into the hole -B-.

– Make sure the selector and shift cable -B- are inserted into the

retainer -A- without tension.

– Turn the locking mechanism on the shift cable retainer and the

selector shaft all the way to the right in direction of -arrow 1-.

The spring will push the safety mechanism into the starting posi‐

tion in direction of -arrow 2-.

– Turn the bracket -A- back into the starting position -arrow 2-.

•

The bracket -A- must get pushed out of the transmission in

direction of -arrow 1-.

1. Shift Mechanism, Servicing

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– Pull the Connecting Pin - T10027A- out of the holes

-A and B-.

– If equipped, install the noise insulation.

– Install the boot, the gearshift knob and the frame. Refer to

⇒ “1.4 Boot with Shifter Knob and Noise Insulation, Removing

and Installing”, page 79 .

– Make sure the gearshift shaft moves easily.

– If it was removed earlier install the complete air filter housing.

Refer to ⇒ Rep. Gr. 23 ; Diesel Direct Injection System; Air

Filter Housing, Removing and Installing or ⇒ Rep. Gr. 24 ; Air

Filter; Air Filter Housing, Removing and Installing .

Function

•

The shift lever must rest in the 3rd/4th gear selector lever gate

when the transmission is in neutral.

– Operate the clutch.

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

all the gears. Pay particular attention to the operation of the

reverse gear lock.

– Should a gear fail to engage smoothly after repeated selection,

adjust the gearshift mechanism again. Refer to

⇒ “1.11 Selector Mechanism, Adjusting”, page 97 .

1.12

Selector Mechanism, Disassembling

and Assembling, from 11/2006

Special tools and workshop equipment required

♦ Window Release Tool - T10236-

♦ Press Piece - Multiple Use - VW412-

♦ Over-Center Spring Assembly Tool - T10178- or flat iron, 200

x 25 x 5 mm

♦ Engine Support Bridge - Engine Support 25 - 10-222A/25- or

flat iron, 350 X 30 X 5 mm

♦ - 4- = Puller - Counterstay , for example -Kukko 22/4-

♦ Wedge - T10357-

♦ Press Piece - Block - T10083-

♦ Allocate the grease for gearshift mechanism. Refer to the

Parts Catalog.

Disassembling

– Remove gearshift mechanism. Refer to

⇒ “1.9 Selector Mechanism, Removing and Installing”,

page 92 .

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– Bend up the selector mechanism base plate straps -arrows-

with a screwdriver and remove the base plate. Only the straps

on the left side of the base plate are shown in the illustration.

– Remove seal from shift housing.

– Remove shift cable and selector cable from selector housing.

Refer to ⇒ “1.7 Overview - Operating Cables”, page 85 .

– Raise upper side of spring -A- over selector bracket tab.

– Using a screwdriver, press bearing shell notches -arrows- in

direction of shift lever guide bearing; break off notches if nec‐

essary.

– Pry out bearing shell -A- with shift lever guide -B- from selector

housing.

– Then press bearing shell off shift lever guide bearing and re‐

move.

•

Observe guides -A- in subsequent steps.

They must not break off.

– Raise lower side in direction of -arrow 1- of spring as far as

stop onto shoulder on selector bracket.

– Now raise shift lever guide up as far as stop and remove ball

studs from selector bracket in direction of -arrow 2-.

1. Shift Mechanism, Servicing

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– Turn the gearshift lever in the direction of -arrow 1-.

•

The pins -arrow 2- must be in the shift housing opening.

– Move the gearshift lever guide and the gearshift lever in the

direction of -arrow 3-.

Assembling

Caution

The lower side of the spring in direction of -arrow 1 -can spring

down uncontrolled from the selector bracket shoulder during

subsequent handling.

– Carefully press it down from the selector bracket shoulder.

The spring sides then twist “diagonally” with a loud noise.

– Turn both springs to the right and release the tension on the

ends -A and B-.

•

The ends -A and B- must face in the opposite direction.

Note

The selector shaft must be removed in order to insert the shifter

housing with the selector shaft guide into the Pressing Support .

– Install the shift lever guide into the shift housing.

•

The pins -arrow 1- are still located in the shift housing opening.

– Turn the gearshift lever guide in the direction of -arrow 2- until

the ball head pin -A- is above the opening in the gearshift

housing.

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– Install the gearshift housing with gearshift lever guide into the

larger depression -arrow- in the Press Piece - Block - T10083- .

Note

The selector shaft must be removed in order to insert the shifter

housing with the selector shaft guide into the Pressing Support .

•

The shift lever guide must project out of selector housing as

far as stop.

Note

The selector bracket is only partially shown to provide a better

illustration.

– Insert spring side -A- from above into guide.

– Pull spring side -B- down and insert it near the guide (in di‐

rection of ball head).

– Carefully remove the gearshift housing with the shift lever

guide from the Press Piece - Block - T10083- .

– Move selector bracket back as far as stop (opposite mounting

holes for shifter and selector cable) in direction of -arrow 1-.

– Lubricate ball head pins.

– Press ball head pins into selector bracket -arrow 2-.

•

The guides -A- and the tabs -B- must not be damaged.

– Install the gearshift housing with gearshift lever guide into the

larger depression -arrow- in the Press Piece - Block - T10083- .

1. Shift Mechanism, Servicing

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•

The shift lever guide must project out of selector housing as

far as stop.

– Raise upper side of spring -A- over selector bracket pins.

Use a new bearing shell -B-.

•

– Lubricate bearing shell and shift lever guide bearing.

– Press bearing shell onto shift lever guide bearing as far as

stop.

– Remove selector mechanism from Press Piece - Block -

T10083- .

– Insert lower side -C- of spring into guide.

– Raise upper side of spring -A- over selector bracket pins into

guide.

– Press bearing shell into selector housing -arrows-.

•

All four retaining tabs must engage.

– If equipped install the shift lever in the shift housing.

– Secure the shift cable and selector cable on the shift housing

with lock washers -2 and 3-.

– Install the shift cable -1- on the gearshift lever and selector

cable -4- on the selector lever inside the shift housing.

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Base Plate, Attaching to Gearshift Housing

– Install a new seal -item 2- ⇒ Item 2 (page 84) on the base plate.

Caution

There is a danger of causing damage to the gearshift housing

and base plate.

Tension the gearshift housing only slightly.

– Bend the tabs -arrow- back over all around the base plate to

secure it (only the tabs on the left side of the base plate are

shown in the illustration).

Note

♦ If only one Over-Center Spring Assembly Tool - T10178- is

available, instead of a second Over-Center Spring Assembly

Tool - T10178- the Toothed Belt Tensioner - T10020- can be

used.

♦ A 200 x 25 x 5 mm flat iron can be used in place of an Over-

Center Spring Assembly Tool - T10178- .

♦ A 350 X 30 X 5 mm flat iron can be used in place of an Engine

Support Bridge - Engine Support 25 - 10-222A/25- .

– The tabs can be bent back over using the Wedge - T10357- .

- A- = Puller - Counterstay , for example -22/4-

– Glue a new seal on the gearshift housing .

– Install the gearshift mechanism. Refer to

⇒ “1.9 Selector Mechanism, Removing and Installing”,

page 92 .

1. Shift Mechanism, Servicing

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2

Transmission, Removing and Instal‐

ling, Jetta from MY 2005 , Golf Wag‐

on from MY 2007 and Golf Wagon

from MY 2010, Vehicles with Diesel

Engine and FWD

⇒ “2.1 Transmission, Removing and Installing”, page 106

⇒ “6 Transmission, Transporting”, page 189

⇒ “2.2 Tightening Specifications”, page 124

2.1

Transmission, Removing and Installing

Special tools and workshop equipment required

♦ Support Elements for transmission (determine when mounting

the Mounting Plate on the Transmission Support )

♦ Transmission Support - Mounting Plate 33 - 3282/33-

♦ Transmission Support Jig - 3336- to transport the transmis‐

sion.

♦ Torque Wrench 1331 5-50Nm - VAG1331-

♦ Torque Wrench 1332 40-200Nm - VAG1332-

♦ Engine and Gearbox Jack - VAS6931-

♦ Engine Support Bridge - Gearbox Bracket - T10346-

♦ Engine Support Device - 3300A-

♦ Slide Hammer Set - Adapter 40 - VW771/40-

♦ Hose Clamps - Up To 25 mm - 3094-

♦ Grease for Clutch Disc Shaft Splines - G 000 100-

♦ Engine Support Bridge - 10-222A-

♦ Engine Support Bridge - Engine Support Feet - 10-222A/8-

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

♦ Engine Support Bridge - Engine Support 18 - 10-222A/18-

♦ Transmission Support - 3282-

♦ Allocate the grease for gearshift mechanism. Refer to the

Parts Catalog.

♦ M6 x 20 collar bolt

♦ M6 x 80 collar bolt

♦ M10 x 20 hex bolt

Removing

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

Bridge - Engine Support Feet - 10-222A/8- will be mounted on the

longitudinal members later in the procedure.

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•

To protect the edges of the fender, cover both Engine Support

Bridge - Engine Support Feet - 10-222A/8- with cloth tape

-arrow-. Refer to the Parts Catalog (Chemical Materials).

– See if a coded radio is installed. If so, obtain the anti-theft code.

– Disconnect the battery ground cable. Refer to ⇒ Electrical

Equipment; Rep. Gr. 27 ; Battery; Battery, Disconnecting and

Connecting .

Later in the procedure, the Engine Support Bridge - 10-222A- is

connected to the engine lifting eyes.

– Remove the engine cover if it is blocking the lifting eyes.

– Remove the air filter housing if it is located near the battery.

Refer to ⇒ Rep. Gr. 23 ; Diesel Direct Injection System; Air

Filter Housing, Removing and Installing .

– Remove the battery, the battery cover and the battery tray.

Refer to ⇒ Electrical Equipment; Rep. Gr. 27 ; Battery; Bat‐

tery, Removing and Installing .

– Remove the shift cable lock washer -3- from the transmission

shift lever -1- and remove the cable from the pin -arrow-.

Metal Relay Lever

– Remove the selector cable lock washer -4- from the relay lever

-2- and remove the cable from the pin -arrow-.

Plastic Relay Lever

– Remove the cable retainer from the selector cable.

•

To avoid damage to the selector cable, the cable retainer must

be disconnected from the selector lever before removal.

– Pull the securing mechanism all the way forward in direction

of -arrow 1- and then unlock to the left in direction of

-arrow 2-.

– Press the relay lever forward (in the direction of -arrow 3-).

– The relay lever is removed together with the cable retainer

later in the procedure.

– Remove the cable bracket from the transmission -arrows-, tie

up to the side.

Diesel Engine and FWD

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Vehicles with A Pipe between the Clutch Master and Slave Cyl‐

inders

– Clamp the clutch master cylinder hose using a Hose Clamps

- Up To 25mm - 3094- .

Vehicles with A Hose/Line Assembly between the Clutch Master

and Slave Cylinders

– Clamp off the hose on the hose/line assembly -A- to the clutch

slave cylinder using the Hose Clamps - Up To 25mm - 3094- .

Continuation for All

– Pull the clamp -arrow- for the hose/line assembly or the pipe

out all the way to the stop.

– Remove the hose/line assembly or pipe from the bleeder/

clutch slave cylinder and seal it off.

Caution

Do not press the clutch pedal anymore.

– Remove the ground strap -1- from the top starter bolt.

– Disconnect the connector -2- from the Back-Up Lamp Switch

- F4- .

– Disconnect the connector and the wire from the starter.

– Remove the upper engine/transmission connecting bolts

-arrows-.

– Remove the upper bolt from the starter.

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– Install the Engine Support Bridge - Gearbox Bracket - T10346-

in the most rear hole out of the three holes in the battery tray.

– Use a collar bolt M6 x 80 or one of the battery tray bolts for

this.

– If there are hose and cable connections located near the en‐

gine lifting eyes for the Engine Support Bridge - 10-222A- ,

these must now be removed.

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

hood support.

– Use:

– Position the Engine Support Bridge - Engine Support Feet -

10-222A/8- :

– Then connect the Engine Support Bridge - Gearbox Bracket -

T10346- to the Engine Support Bridge .

– Hook the Spindles into the left lifting eye on the engine.

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– Pretension the engine/transmission assembly and Engine

Support Bridge - 10-222A- via the spindles.

The left drive axle must be removed later in the procedure.

– With the vehicle still standing on its wheels, loosen the left front

collar bolt -arrow- a maximum 90°, otherwise the wheel bear‐

ing will get damaged. Refer to ⇒ Suspension, Wheels, Steer‐

ing; Rep. Gr. 40 ; Drive Axles, Removing and Installing .

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

Gr. 50 ; Noise Insulation .

– Remove the lower part of the left front wheel housing liner.

Refer to ⇒ Body Exterior; Rep. Gr. 66 ; Wheel Housing Liner .

– Transmission on vehicles with Start/Stop System: disconnect

the connector -arrow- from the Transmission Neutral Position

Sensor - G701- .

– Remove the Left Front Level Control System Sensor - G78-

from the control arm, if equipped. Refer to ⇒ Rep. Gr. 40 .

– Remove the bracket from the starter.

– Remove the starter. Refer to ⇒ Electrical Equipment; Rep. Gr.

27 ; Starter; Starter, Removing and Installing .

– Remove the left charge air hose -arrow 1- and -arrow 2- ⇒

Rep. Gr. 21 .

– Remove the charge air pipe from the engine. Refer to ⇒ Rep.

Gr. 21 .

– Remove the right charge air hose from the charge air cooler.

Refer to ⇒ Rep. Gr. 21 .

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– Remove the air shroud -arrow- and the radiator fans. Refer to

⇒ Rep. Gr. 19

– Remove the exhaust system bracket from the subframe

-arrows-. Refer to ⇒ Rep. Gr. 26 .

– Disconnect the exhaust system at the double clamp -arrows-.

– Tie up the front exhaust pipe or lay it on the tunnel brace.

– Remove the pendulum support.

Diesel Engine and FWD

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– Disconnect the connector -1- from the Oil Level Thermal Sen‐

sor - G266- .

– Remove the coupling rod from the stabilizer bar and move it

to the side. Refer to ⇒ Suspension, Wheels, Steering; Rep.

Gr. 40 ; Front Suspension and Control Arm .

– Remove the left drive axle. Refer to ⇒ Suspension, Wheels,

Steering; Rep. Gr. 40 ; Drive Axles, Removing and Installing .

– If equipped remove the drive axle heat shield -arrows-. Refer

to ⇒ Suspension, Wheels, Steering; Rep. Gr. 40 ; Drive Axles,

Overview and Servicing; Drive Axle Heat Shield .

– Remove the right drive axle from the transmission and tie it up.

Refer to ⇒ Suspension, Wheels, Steering; Rep. Gr. 40 ; Drive

Axles, Removing and Installing .

– Remove the hex collar bolts -arrows- on the left subframe

mount -2- from the left bracket -1-.

– Lower the transmission by adjusting the spindles, which are

attached to the engine, to dimension -a- approximately 40 mm.

Note

When moving the engine/transmission assembly, pay attention to

the connection lines, hoses and radiator.

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6-Speed Manual Transmission 02Q - Edition 05.2013

– Remove the bracket -1- from the transmission -arrows-.

Metal Relay Lever

– Remove the lock washer -arrow- from the relay lever -1- and

then remove the relay lever.

Plastic Relay Lever

– Remove the relay lever with the cable retainer. Refer to

⇒ “1.8 Plastic Relay Lever”, page 89 .

Continuation for All

– Remove the gearshift lever from the gearshift shaft.

– Remove the small flywheel cover plate -A- -arrows-, if equip‐

ped.

– Remove the lower engine/transmission connecting bolt -1-.

Note

Loosen the engine/transmission connecting bolt -3- and leave it

in so that it is hand-tight.

Diesel Engine and FWD

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– Tighten the Engine Support Bridge - Gearbox Bracket -

T10346- with the bolt -1- in the left threaded hole in the

subframe.

-1- = M6 x 20 collar bolt

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

Support Bridge - Gearbox Bracket - T10346- .

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

oil pan.

– Push the engine forward using the spindle on the Engine Sup‐

port Device - 3300A- . Note the following when doing this:

•

The A/C compressor -2- must not touch the refrigerant line

-1- -arrow-.

•

The generator must not touch the refrigerant line.

The pressure pipe must not touch the radiator.

Align the Transmission Support - 3282- with the Transmission

Support - Mounting Plate 33 - 3282/33- in order to remove the

“02Q” transmission.

– Insert the Transmission Support - 3282- into the Engine and

Gearbox Jack - VAS6931- .

– Align the arms of the Transmission Support - 3282- so that

they match up with the holes in the Adjustment Plate .

– Install the Support Elements -A- as illustrated on the Adjust‐

ment Plate .

– Install the Transmission Support - Pins 29 - 3282/29- in place

of the Mounting Element -C-.

– Position the Engine-Gearbox Jack - VAG1383A- under the

vehicle. The arrow symbol -B- on the Adjusting Plate points in

direction of travel.

– Align the Adjustment Plate so that it is parallel to the trans‐

mission.

– Secure the Slide Hammer Set - Adapter 40 - VW771/40- inside

the threaded hole in the transmission housing as shown.

– Install the Transmission Support - Pins 29 - 3282/29- into the

hole on the transmission for the pendulum support bolt.

– Secure the transmission on the Transmission Support - 3282-

with an M10 x 20 bolt -A-.

The drift -B- must be flush at the bottom with the guide on the

Transmission Support - 3282- -arrow-.

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6-Speed Manual Transmission 02Q - Edition 05.2013

The engine/transmission connecting bolt -arrow- is removed.

– Remove the engine/transmission connecting bolt -C- and the

lower engine/transmission connecting bolts.

– Separate the transmission from the engine (alignment

sleeves).

– Move the transmission in the area of the differential with the

spindles of the Transmission Support - 3282- into an angled

position.

•

The differential, near the transmission, must face upward.

The right flange shaft -1- must be guided over the bolting eyelet

of the engine -2-.

– Guide the transmission and the differential over the subframe

-A- and swing it out.

Diesel Engine and FWD

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6-Speed Manual Transmission 02Q - Edition 05.2013

– Pay attention to the longitudinal member -arrows-. Then care‐

fully lower the transmission.

Note

Pay attention to all of the lines when lowering the transmission.

Installing

Note

♦ Refer to “Transmission, Removing” to get a list of the special

tools needed. Refer to

⇒ “2.1 Transmission, Removing and Installing”, page 106 .

♦ Replace the self-locking nuts and bolts.

♦ Replace bolts that were tightened with an additional turn.

♦ Install any cable ties that were loosened or cut off during re‐

moval at their same location.

♦ Clean the input shaft splines and (on used clutch plates) the

hub splines. Remove any corrosion and then apply a very thin

coat of Grease for Clutch Disc Shaft Splines - G 000 100- on

the splines. Then move the clutch plate back and forth on the

input shaft until the hub moves freely on the shaft. Excess

grease must be removed.

– If the transmission is replaced, transfer the transmission shift

lever and the relay lever.

– Clean any locking compound residue from all threaded holes

using a tap.

– Check whether there are centering sleeves for the engine/

transmission in the cylinder block; install if necessary.

If the alignment sleeves are missing, it will be difficult to shift, there

will be clutch problems and the transmission may make noises

(loose rattling).

– Make sure the intermediate plate is engaged on the sealing

flange and pushed onto the alignment sleeves -arrows-.

– Check the release bearing for wear. Replace the clutch slave

cylinder with release bearing if necessary. Refer to

⇒ “2.2 Clutch Slave Cylinder with Release Bearing, Removing

and Installing”, page 52 .

116

Rep. Gr.34 - Operation and Housing

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤

6-Speed Manual Transmission 02Q - Edition 05.2013

– Tighten the Engine Support Bridge - Gearbox Bracket -

T10346- with the bolt -1- in the left threaded hole in the

subframe.

-1- = M6 x 20 collar bolt

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

Support Bridge - Gearbox Bracket - T10346- .

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

oil pan.

– Push the engine forward using the spindle on the Engine Sup‐

port Device - 3300A- . Note the following when doing this:

•

The A/C compressor -2- must not touch the refrigerant line

-1- -arrow-.

•

The generator must not touch the refrigerant line.

The pressure pipe must not touch the radiator.

Align the Transmission Support - 3282- with the Transmission

Support - Mounting Plate 33 - 3282/33- in order to install the “02Q”

transmission.

– Align the arms of the Transmission Support - 3282- so that

they match up with the holes in the Adjustment Plate .

– Install the Support Elements -A- as illustrated on the Adjust‐

ment Plate .

– Install the Transmission Support - Pins 29 - 3282/29- in place

of the Mounting Element -C-.

– Place the transmission on the Engine and Gearbox Jack -

VAS6931- .

– Align the Adjustment Plate so that it is parallel to the trans‐

mission.

– Install the Transmission Support - Pins 29 - 3282/29- into the

hole on the transmission for the pendulum support bolt.

– Secure the Slide Hammer Set - Adapter 40 - VW771/40- inside

the threaded hole in the transmission housing as shown.

– Secure the transmission on the Transmission Support - 3282-

with an M10 x 20 bolt -A-.

The drift -B- must be flush at the bottom with the guide on the

Transmission Support - 3282- -arrow-.

– Position the Engine and Gearbox Jack - VAS6931- under the

vehicle. The arrow on the adjusting plate points in direction of

travel.

Note

Pay attention to all of the lines when installing the transmission.

– Lift the transmission carefully.

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– Now turn the transmission upward in the area of the differential

and downward in the area of the 6th gear via the spindles of

the Transmission Support - 3282- .

– Guide the transmission and differential -A- over the subframe.

•

The right flange shaft must be guided past the flywheel

-arrow 2-; pay attention to the intermediate plate -arrow 1-.

– The right flange shaft -1- must be guided over the bolting eye‐

let of the engine -2-.

– At the same time, change the position of the transmission us‐

ing the spindles of the Transmission Support - 3282- so that it

does not come into contact with the longitudinal member

-arrows-.

– Turn the transmission to its installed position using the spin‐

dles of the Transmission Support - 3282- .

– Align the transmission to the engine (alignment sleeves) and

insert it.

118

Rep. Gr.34 - Operation and Housing

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤

6-Speed Manual Transmission 02Q - Edition 05.2013

– Insert engine/transmission bolt -C- and tighten to tightening

specification. Refer to

⇒ “2.2 Tightening Specifications”, page 124 .

– Install lower engine/transmission connecting bolts and tighten

to tightening specification. Refer to

⇒ “2.2 Tightening Specifications”, page 124 .

– Remove the Engine Support Device - 3300A- and Engine

Support Bridge - Gearbox Bracket - T10346- .

– Install the engine/transmission connecting bolt -arrow- and

tighten it to the tightening specification. Refer to

⇒ “2.2 Tightening Specifications”, page 124 .

– After transmission is bolted to engine at bottom, remove the

Transmission Support - 3282- from transmission.

– Install the upper engine/transmission connecting bolts and

tighten them to the tightening specification. Refer to

⇒ “2.2 Tightening Specifications”, page 124 .

– Attach the transmission gearshift lever to the gearshift shaft.

Refer to

⇒ Fig. ““Installing the Transmission Shift Lever”“ , page 88 and

tighten the nut to tightening specification -item 17-

⇒ Item 17 (page 87) .

Metal Relay Lever

– Install the relay lever -1- and the lock washer -arrow-.

Plastic Relay Lever

– Install the relay lever with the cable retainer. Refer to

⇒ “1.8 Plastic Relay Lever”, page 89 .

Continuation for All

– Attach the bracket -1- with the new hex bolts to the transmis‐

sion -arrows- and tighten them to the tightening specification.

Refer to ⇒ “2.2 Tightening Specifications”, page 124 .

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6-Speed Manual Transmission 02Q - Edition 05.2013

– Align the engine/transmission in its installed position. Lift it un‐

til the bracket -1- is in complete contact with the left subframe

mount -2-.

– Install the new hex bolts -arrows- of the left subframe mount

-2- in the bracket -1- and tighten to the tightening position.

Refer to ⇒ “2.2 Tightening Specifications”, page 124 .

Note

Install the engine/transmission mount free of tension. Refer to ⇒

Rep. Gr. 10 ; Engine, Removing and Installing .

WARNING

Only remove the Engine Support Bridge - 10-222A- when all

subframe mount bolts are tightened to the tightening specifi‐

cation.

– Install the flywheel cover plate -A- (if equipped) -arrows-. Refer

to ⇒ “2.2 Tightening Specifications”, page 124 .

Note

♦ There are threaded inserts (for example “Heli Coil”) in the pen‐

dulum support fastening holes.

♦ Characteristic: there is a collar on the first thread -arrow-.

♦ Observe the correct bolts and tightening specifications. Refer

to ⇒ Suspension, Wheels, Steering; Rep. Gr. 40 ; Subframe;

Overview - Subframe .

– Install the pendulum support. Refer to ⇒ Suspension, Wheels,

Steering; Rep. Gr. 40 ; Subframe; Overview - Subframe .

– Install the drive axles. Refer to ⇒ Suspension, Wheels, Steer‐

ing; Rep. Gr. 40 ; Drive Axles, Removing and Installing .

120

Rep. Gr.34 - Operation and Housing

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤

6-Speed Manual Transmission 02Q - Edition 05.2013

– If equipped install the drive axle heat shield -arrows-. Refer to

⇒ Suspension, Wheels, Steering; Rep. Gr. 40 ; Drive Axles,

Overview and Servicing; Drive Axle Heat Shield .

– Install the left coupling rod. Refer to ⇒ Suspension, Wheels,

Steering; Rep. Gr. 40 .

– Install the Left Front Level Control System Sensor - G78- in

the control arm, if equipped. Refer to ⇒ Rep. Gr. 40 .

– Connect the connector -1- to the Oil Level Thermal Sensor -

G266- .

– Assemble the exhaust system and install the exhaust system

bracket to the subframe. Refer to ⇒ Rep. Gr. 26 .

– Install the air shroud -arrow- and the radiator fans. Refer to ⇒

Rep. Gr. 19

– Attach the charge air pipe to the engine. Refer to ⇒ Rep. Gr.

21 .

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6-Speed Manual Transmission 02Q - Edition 05.2013

– Install the left charge air hose -arrow 1- and -arrow 2- ⇒ Rep.

Gr. 21 .

– Attach the right charge air hose to the charge air cooler. Refer

to ⇒ Rep. Gr. 21 .

– Position the starter and install the lower bolt. Refer to ⇒ Elec‐

trical Equipment; Rep. Gr. 27 ; Starter; Starter, Removing and

Installing .

– Attach the bracket for the lines to the lower starter bolt.

– Install the starter bolt and then connect the connector and

wires to the starter. Refer to ⇒ Electrical Equipment; Rep. Gr.

27 ; Starter; Starter, Removing and Installing .

– Attach the ground cable -1- to the top starter bolt.

– Connect the connector -2- to the Back-Up Lamp Switch - F4- .

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

connector -arrow- to the Transmission Neutral Position Sensor

- G701- .

– Push the hose/line assembly or pipe -A- into the bleeder/clutch

slave cylinder to the stop and push the clamp -arrow- down‐

ward.

– Pull on the line to make sure it is secure.

– Remove the Hose Clamps - Up To 25mm - 3094- from the

supply hose.

– After removing the Hose Clamps - Up To 25mm - 3094- , bring

the return hose back to its original shape.

– Bleed the clutch mechanism. Refer to

⇒ “1.10 Clutch Mechanism, Bleeding”, page 48 .

– Make sure the vacuum hose for the brake system is installed

correctly. Refer to ⇒ Brake System; Rep. Gr. 47 ; Hydraulic

System .

122

Rep. Gr.34 - Operation and Housing

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤

6-Speed Manual Transmission 02Q - Edition 05.2013

– Attach the cable mounting bracket to the transmission and

tighten the bolts and nuts -arrows- to the tightening specifica‐

tion -item 6- ⇒ Item 6 (page 86) and -item 10-

⇒ Item 10 (page 86) .

– Apply a small amount of grease to the pin -arrow- on the gear‐

shift lever -1-.

Refer to the Parts Catalog for the grease allocation.

– Slide the shift cable onto the respective pins -arrow- and se‐

cure it with a new lock washer -3-.

Metal Relay Lever

– Apply a small amount of grease to the pin -arrow- of the relay

lever -2-.

Refer to the Parts Catalog for the grease allocation.

– Slide the selector cable onto the respective pins -arrow- and

secure it with a new lock washer -4-.

Plastic Relay Lever

– Insert the selector cable into the cable retainer.

Continuation for All

– Adjust the gearshift mechanism. Refer to

⇒ “1.11 Selector Mechanism, Adjusting”, page 97 .

– Install the battery tray, battery cover and the battery. Refer to

⇒ Electrical Equipment; Rep. Gr. 27 ; Battery; Battery, Re‐

moving and Installing .

– If removed, install complete air filter housing. Refer to ⇒ Rep.

Gr. 23 ; Diesel Direct Injection System; Air Filter Housing,

Removing and Installing .

– Install the engine cover if necessary.

– Connect the battery and observe procedure after connecting

battery. Refer to ⇒ Electrical Equipment; Rep. Gr. 27 ; Battery;

Battery, Disconnecting and Connecting .

– Check the transmission fluid level. Refer to

⇒ “8 Transmission Fluid, Checking”, page 192 .

– Install the lower part of the left front wheel housing liner. Refer

to ⇒ Body Exterior; Rep. Gr. 66 ; Wheel Housing Liner .

– Install the noise insulation. Refer to ⇒ Body Exterior; Rep. Gr.

50 ; Noise Insulation .

– Check the headlamp adjustment if the vehicle has a Left Front

Level Control System Sensor - G78- . Refer to ⇒ Electrical

Equipment; Rep. Gr. 94 ; Headlamps; Headlamp, Adjusting .

Diesel Engine and FWD

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6-Speed Manual Transmission 02Q - Edition 05.2013

2.2

Tightening Specifications

Transmission to Engine (Engine Flange Face)

Item

1

Bolt

Quantity

1

Nm

80

M12 x 55

♦ With a short M8 threa‐

ded pin

2

M12 x 55

♦ With a long threaded

pin M8

1

80

3

4

5

6

M12 x 65

M10 x 50

M10 x 105

1

2

1

80

40

80

M12 x 165

♦ With a short M8 threa‐

ded pin

♦ Also starter to trans‐

mission

7

-

M12 x 165

♦ With a short M8 threa‐

ded pin

1

80

10

♦ Also starter to trans‐

mission

M6 x 8

♦ Small flywheel cover

plate (not present on all

engines)

-A- and -B-: alignment bushings

Transmission Bracket -1- to Transmission.

– Replace the bolts.

Tighten the bolts -arrows-: 60 Nm + 90°.

124

Rep. Gr.34 - Operation and Housing

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤

6-Speed Manual Transmission 02Q - Edition 05.2013

Transmission to Body

– Replace the bolts.

Tighten the bolts -arrows-: 60 Nm + 90°.

Note

Install the engine/transmission mount free of tension. Refer to ⇒

Rep. Gr. 10 ; Engine, Removing and Installing .

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6-Speed Manual Transmission 02Q - Edition 05.2013

3

Transmission, Removing and Instal‐

ling, Jetta from MY 2005 , Golf Wag‐

on from MY 2007 and Golf Wagon

from MY 2010, Vehicles with Gaso‐

line Engine and FWD

⇒ “3.1 Transmission, Removing and Installing”, page 126 .

⇒ “6 Transmission, Transporting”, page 189 .

⇒ “3.2 Tightening Specifications”, page 143 .

3.1

Transmission, Removing and Installing

Special tools and workshop equipment required

♦ Engine Support Bridge - 10-222A-

♦ Engine Support Bridge - Engine Support Feet - 10-222A/8-

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

♦ Engine Support Bridge - Engine Support 18 - 10-222A /18-

♦ Transmission Support - 3282-

♦ Support Elements for transmission (determine when mounting

the Mounting Plate on the Transmission Support )

♦ Transmission Support - Mounting Plate 33 - 3282/33-

♦ Transmission Support Jig - 3336- to transport the transmis‐

sion.

♦ Torque Wrench 1331 5-50Nm - VAG1331-

♦ Torque Wrench 1332 40-200Nm - VAG1332-

♦ Engine and Gearbox Jack - VAS6931-

♦ Engine Support Bridge - Gearbox Bracket - T10346- quantity:

2

♦ Engine Support Device - 3300A-

♦ Slide Hammer Set - Adapter 40 - VW771/40-

♦ Hose Clamps - Up To 25mm - 3094-

♦ Grease for Clutch Disc Shaft Splines - G 000 100-

♦ Allocate the grease for gearshift mechanism. Refer to the

Parts Catalog.

♦ M6 x 20 collar bolt

♦ M6 x 80 collar bolt

♦ M10 x 20 hex bolt

Removing

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

Bridge - Engine Support Feet - 10-222A/8- will be mounted on the

longitudinal members later in the procedure.

126

Rep. Gr.34 - Operation and Housing

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤

6-Speed Manual Transmission 02Q - Edition 05.2013

•

To protect the edges of the fender, cover both Engine Support

Bridge - Engine Support Feet - 10-222A/8- with cloth tape

-arrow-. Refer to the Parts Catalog (Chemical Materials).

– First check whether a coded radio is installed. If so, obtain the

anti-theft code.

– Disconnect the battery ground cable. Refer to ⇒ Electrical

Equipment; Rep. Gr. 27 ; Battery; Battery, Disconnecting and

Connecting .

Later in the procedure, the Engine Support Bridge - 10-222A- is

connected to the engine lifting eyes.

– Remove the engine cover if it is blocking the lifting eyes.

– Remove the air filter housing if it is located near the battery.

Refer to ⇒ Rep. Gr. 24 ; Air Filter; Air Filter Housing, Remov‐

ing and Installing .

– Remove the battery, the battery cover and the battery tray.

Refer to ⇒ Electrical Equipment; Rep. Gr. 27 ; Battery; Bat‐

tery, Removing and Installing .

– Remove the shift cable lock washer -3- from the transmission

shift lever -1- and remove the cable from the pin -arrow-.

Metal Relay Lever

– Remove the selector cable lock washer -4- from the relay lever

-2- and remove the cable from the pin -arrow-.

Plastic Relay Lever

– Remove the cable retainer from the selector cable.

•

To avoid damage to the selector cable, the cable retainer must

be disconnected from the selector lever before removal.

– Pull the securing mechanism all the way forward in direction

of -arrow 1- and then unlock to the left in direction of

-arrow 2-.

– Press the relay lever forward (in the direction of -arrow 3-).

– The relay lever is removed together with the cable retainer

later in the procedure.

– Remove the cable bracket from the transmission -arrows-,

move it to the side and tie it up.

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Vehicles with A Pipe Between the Clutch Master and Slave Cyl‐

inders

– Clamp the clutch master cylinder hose using a Hose Clamps

- Up To 25mm - 3094- .

Vehicles with A Hose/Line Assembly between the Clutch Master

and Slave Cylinders

– Clamp off the hose on the hose/line assembly -A- to the clutch

slave cylinder using the Hose Clamps - Up To 25mm - 3094- .

Continuation for All

– Pull the clamp -arrow- for the hose/line assembly or the pipe

out all the way to the stop.

– Remove the hose/line assembly or pipe from the bleeder/

clutch slave cylinder and seal it off.

Caution

Do not press the clutch pedal anymore.

– Remove the ground cable -1- from the top starter bolt.

– Disconnect the connector -2- from the Back-Up Lamp Switch

- F4- .

– Disconnect the connector and the wire from the starter.

– Remove the upper engine/transmission connecting bolts

-arrows-.

128

Rep. Gr.34 - Operation and Housing

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤

6-Speed Manual Transmission 02Q - Edition 05.2013

– Remove the upper bolt from the starter.

– Install the Engine Support Bridge - Gearbox Bracket - T10346-

in the most rear hole out of the three holes in the battery tray.

– Use a collar bolt M6 x 80 or one of the battery tray bolts for

this.

– Remove the foam piece on the upper edge of the left and right

fender. Refer to ⇒ Body Exterior; Rep. Gr. 50 ; Fender .

– If there are hose and cable connections located near the en‐

gine lifting eyes for the Engine Support Bridge - 10-222A- ,

these must now be removed.

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

hood support.

– Use:

– Position the Engine Support Bridge - Engine Support Feet -

10-222A/8- :

– Attach the engine and the Engine Support Bridge - Gearbox

Bracket - T10346- to the Engine Support Bridge - 10-222A- .

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– Pretension the engine/transmission assembly and Engine

Support Bridge - 10-222A- via the spindles.

The left drive axle must be removed later in the procedure.

– With the vehicle still standing on its wheels, loosen the left front

collar bolt -arrow- a maximum 90°, otherwise the wheel bear‐

ing will get damaged. Refer to ⇒ Suspension, Wheels, Steer‐

ing; Rep. Gr. 40 ; Drive Axles, Removing and Installing .

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

Gr. 50 ; Noise Insulation .

– Remove the lower part of the left front wheel housing liner.

Refer to ⇒ Body Exterior; Rep. Gr. 66 ; Wheel Housing Liner .

– Remove the Left Front Level Control System Sensor - G78-

from the control arm, if equipped. Refer to ⇒ Rep. Gr. 40 .

– Remove the bracket from the starter.

– Remove the starter. Refer to ⇒ Electrical Equipment; Rep. Gr.

27 ; Starter; Starter, Removing and Installing .

– Remove the left charge air hose -arrow 1- and -arrow 2- and

remove the charge air pipe on the engine. Refer to ⇒ Rep.

Gr. 21 .

– Remove the right charge air hose. Refer to ⇒ Rep. Gr. 21 .

– Remove the air shroud -arrow- and the radiator fans. Refer to

⇒ Rep. Gr. 19

130

Rep. Gr.34 - Operation and Housing

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤

6-Speed Manual Transmission 02Q - Edition 05.2013

– Remove the front exhaust pipe from the turbocharger

(-arrow-). Refer to ⇒ Rep. Gr. 26 And secure it.

– Remove the pendulum support.

– Disconnect the connector -1- from the Oil Level Thermal Sen‐

sor - G266- .

– Remove the coupling rod from the stabilizer bar and move it

to the side. Refer to⇒ Suspension, Wheels, Steering; Rep.

Gr. 40 .

– Remove the left drive axle. Refer to ⇒ Suspension, Wheels,

Steering; Rep. Gr. 40 ; Drive Axles, Removing and Installing .

– If equipped remove the drive axle heat shield -arrows-. Refer

to ⇒ Suspension, Wheels, Steering; Rep. Gr. 40 ; Drive Axles,

Overview and Servicing; Drive Axle Heat Shield .

– Remove the right drive axle from the transmission and tie it up.

Refer to ⇒ Suspension, Wheels, Steering; Rep. Gr. 40 ; Drive

Axles, Removing and Installing .

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– Remove the small flywheel cover plate -A- -arrows-, if equip‐

ped.

– Remove the hex collar bolts -arrows- on the left subframe

mount -2- from the left bracket -1-.

– Lower the transmission by adjusting the spindles, which are

attached to the engine, to dimension -a- approximately 40 mm.

Note

When moving the engine/transmission assembly, pay attention to

the connection lines, hoses and radiator.

– Remove the bracket -1- from the transmission -arrows-.

132

Rep. Gr.34 - Operation and Housing

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤

6-Speed Manual Transmission 02Q - Edition 05.2013

Metal Relay Lever

– Remove the lock washer -arrow- from the relay lever -1- and

then remove the relay lever.

Plastic Relay Lever

– Remove the relay lever with the cable retainer

⇒ “1.8 Plastic Relay Lever”, page 89 .

Continuation for All

– Remove the gearshift lever from the gearshift shaft.

– Remove the bolt that connects the engine to the transmission

-1-.

Note

Loosen the engine/transmission connecting bolt -3- and leave it

in so that it is hand-tight.

– Tighten the Engine Support Bridge - Gearbox Bracket -

T10346- with the bolt -1- in the left threaded hole in the

subframe.

– Install the Engine Support Bridge - Gearbox Bracket - T10346-

in the same angled position as the engine.

-1- = M6 x 20 collar bolt

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

Support Bridge - Gearbox Bracket - T10346- .

– Push the engine forward using the spindle on the Engine Sup‐

port Device - 3300A- . Note the following when doing this:

•

The A/C compressor -2- must not touch the refrigerant line

-1- -arrow-.

•

The generator must not touch the refrigerant line.

The pressure pipe must not touch the radiator.

Align the Transmission Support - 3282- with the Transmission

Support - Mounting Plate 33 - 3282/33- in order to remove the

“02Q” transmission.

– Insert the Transmission Support - 3282- into the Engine and

Gearbox Jack - VAS6931- .

– Align the arms of the Transmission Support so that they match

up with the holes in the Adjustment Plate .

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6-Speed Manual Transmission 02Q - Edition 05.2013

– Install the Support Elements -A- as illustrated on the Adjust‐

ment Plate .

– Install the Transmission Support - Pins 29 - 3282/29- in place

of the Mounting Element -C-.

– Position the Engine-Gearbox Jack - VAG1383 A- under the

vehicle. The arrow symbol -B- on the Adjusting Plate points in

direction of travel.

– Align the Adjusting Plate so that it is parallel to the transmis‐

sion.

– Secure the Slide Hammer Set - Adapter 40 - VW771/40- inside

the threaded hole in the transmission housing as shown.

– Install the Transmission Support - Pins 29 - 3282/29- into the

hole on the transmission for the pendulum support bolt.

– Secure the transmission on the Transmission Support - 3282-

with an M10 x 20 bolt -A-.

The drift -B- must be flush at the bottom with the guide on the

Transmission Support - 3282- -arrow-.

– Remove the connecting bolt -C- and the lower connecting

bolts.

– Separate the transmission from the engine (alignment

sleeves).

The right flange shaft -1- must be guided over the bolting eyelet

of the engine -2-.

Guide the right flange shaft -1- past the flywheel and the opening

-arrow- in the intermediate plate.

– Move the transmission in the area of the differential with the

spindles of the Transmission Support - 3282- into an angled

position.

•

The differential, near the transmission, must face upward.

– Guide the transmission and the differential over the subframe

-A- and swing it out.

134

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6-Speed Manual Transmission 02Q - Edition 05.2013

– If necessary, turn the transmission further upward in the area

of the differential using the spindles of the Transmission Mount

- 3282- .

– Swivel the transmission further and carefully lower it.

Note

Pay attention to all of the lines when lowering the transmission.

Installing

Note

♦ Refer to “Transmission, Removing” to get a list of the special

tools needed. Refer to

⇒ “3.1 Transmission, Removing and Installing”, page 126 .

♦ Replace the self-locking nuts and bolts.

♦ Replace bolts that were tightened with an additional turn.

♦ Install any cable ties that were loosened or cut off during re‐

moval at their same location.

♦ Clean input shaft splines and (on used clutch plates) the hub

splines, remove corrosion and apply a very thin coating of

Grease for Clutch Disc Shaft Splines - G 000 100- to the

splines. Then move the clutch plate back and forth on the input

shaft until the hub moves freely on the shaft. Excess grease

must be removed.

– If the transmission is replaced, transfer the transmission shift

lever and the relay lever.

– Clean any locking compound residue from all threaded holes

using a tap.

– Check whether there are centering sleeves for the engine/

transmission in the cylinder block; install if necessary.

If the alignment sleeves are missing, it will be difficult to shift, there

will be clutch problems and the transmission may make noises

(loose rattling).

Gasoline Engine and FWD

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6-Speed Manual Transmission 02Q - Edition 05.2013

– Make sure the intermediate plate is engaged on the sealing

flange and pushed onto the alignment sleeves -arrows-.

– Check the release bearing for wear. Replace the clutch slave

cylinder with release bearing if necessary. Refer to

⇒ “2.2 Clutch Slave Cylinder with Release Bearing, Removing

and Installing”, page 52 .

– Tighten the Engine Support Bridge - Gearbox Bracket -

T10346- with the bolt -1- in the left threaded hole in the

subframe.

– Install the Engine Support Bridge - Gearbox Bracket - T10346-

in the same angled position as the engine.

-1- = M6 x 20 collar bolt

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

Support Bridge - Gearbox Bracket - T10346- .

– Push the engine forward using the spindle on the Engine Sup‐

port Device - 3300A- . Note the following when doing this:

•

The A/C compressor -2- must not touch the refrigerant line

-1- -arrow-.

•

The generator must not touch the refrigerant line.

The pressure pipe must not touch the radiator.

Align the Transmission Support - 3282- with the Transmission

Support - Mounting Plate 33 - 3282/33- in order to install the “02Q”

transmission.

– Align the arms of the Transmission Support so that they match

up with the holes in the Adjustment Plate .

– Install the Support Elements -A- as illustrated on the Adjust‐

ment Plate .

– Install the Transmission Support - Pins 29 - 3282/29- in place

of the Mounting Element -C-.

– Place the transmission on the Engine and Gearbox Jack -

VAS6931- .

– Align the Adjustment Plate so that it is parallel to the trans‐

mission.

– Install the Transmission Support - Pins 29 - 3282/29- into the

hole on the transmission for the pendulum support bolt.

136

Rep. Gr.34 - Operation and Housing

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤

6-Speed Manual Transmission 02Q - Edition 05.2013

– Secure the Slide Hammer Set - Adapter 40 - VW771/40- inside

the threaded hole in the transmission housing as shown.

– Secure the transmission on the Transmission Support - 3282-

with an M10 x 20 bolt -A-.

The drift -B- must be flush at the bottom with the guide on the

Transmission Support - 3282- -arrow-.

– Position the Engine and Gearbox Jack - VAS6931- under the

vehicle. The arrow on the adjusting plate points in direction of

travel.

Note

Pay attention to all of the lines when installing the transmission.

– Using the spindles of the Transmission Support - 3282- , adjust

the transmission so that the differential area is rotated in di‐

rection of -arrow- upward.

– Lift the transmission carefully.

– Guide the transmission and differential -A- over the subframe.

– Pay attention to the longitudinal member -arrows-.

– Move the transmission toward the rear to the subframe.

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6-Speed Manual Transmission 02Q - Edition 05.2013

•

After that, the right flange shaft -1- must be guided past the

flywheel and the cut-out -arrow- in the intermediate plate.

– Turn the transmission to its installed position using the spin‐

dles of the Transmission Support - 3282- .

– Align the transmission to the engine (alignment sleeves) and

insert it.

– Insert engine/transmission bolt -C- and tighten to tightening

specification. Refer to

⇒ “3.2 Tightening Specifications”, page 143 .

– Install the engine/transmission connecting bolt -arrow- and

tighten it to the tightening specification. Refer to

⇒ “3.2 Tightening Specifications”, page 143 .

– Remove the Engine Support Device - 3300A- and Engine

Support Bridge - Gearbox Bracket - T10346- .

– Install lower engine/transmission connecting bolts and tighten

to tightening specification. Refer to

⇒ “3.2 Tightening Specifications”, page 143 .

– After transmission is bolted to engine at bottom, remove the

Transmission Support - 3282- from transmission.

– Install the upper engine/transmission connecting bolts and

tighten them to the tightening specification. Refer to

⇒ “3.2 Tightening Specifications”, page 143 .

– Attach the transmission gearshift lever to the gearshift shaft.

Refer to

⇒ Fig. ““Installing the Transmission Shift Lever”“ , page 88 and

tighten the nut to tightening specification -item 17-

⇒ Item 17 (page 87) .

Metal Relay Lever

– Install the relay lever -1- and the lock washer -arrow-.

Plastic Relay Lever

– Install the relay lever with the cable retainer. Refer to

⇒ “1.8 Plastic Relay Lever”, page 89 .

Continuation for All

138

Rep. Gr.34 - Operation and Housing

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤

6-Speed Manual Transmission 02Q - Edition 05.2013

– Attach the bracket -1- with the new hex bolts to the transmis‐

sion -arrows- and tighten them to the tightening specification.

Refer to ⇒ “3.2 Tightening Specifications”, page 143 .

– Align the engine/transmission in its installed position. Lift it un‐

til the bracket -1- is in complete contact with the left subframe

mount -2-.

– Install the new hex bolts -arrows- of the left subframe mount

-2- in the bracket -1- and tighten to the tightening position.

Refer to ⇒ “3.2 Tightening Specifications”, page 143 .

Note

Install the engine/transmission mount free of tension. Refer to ⇒

Rep. Gr. 10 ; Engine, Removing and Installing .

WARNING

Only remove the Engine Support Bridge - 10-222A- when all

subframe mount bolts are tightened to the tightening specifi‐

cation.

– Install the flywheel cover plate -A- (if equipped) -arrows-. Refer

to ⇒ “3.2 Tightening Specifications”, page 143 .

Note

♦ There are threaded inserts (for example “Heli Coil”) in the pen‐

dulum support fastening holes.

♦ How to recognize: there is a collar on the first thread -arrow-.

♦ Observe the correct bolts and tightening specifications. Refer

to ⇒ Suspension, Wheels, Steering; Rep. Gr. 40 ; Subframe;

Overview - Subframe .

Gasoline Engine and FWD

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6-Speed Manual Transmission 02Q - Edition 05.2013

– Install the pendulum support. Refer to ⇒ Suspension, Wheels,

Steering; Rep. Gr. 40 ; Subframe; Overview - Subframe .

– Assemble the exhaust system. Refer to ⇒ Rep. Gr. 26 .

– Install the drive axles. Refer to ⇒ Suspension, Wheels, Steer‐

ing; Rep. Gr. 40 ; Drive Axles, Removing and Installing .

– If equipped install the drive axle heat shield -arrows-. Refer to

⇒ Suspension, Wheels, Steering; Rep. Gr. 40 ; Drive Axles,

Overview and Servicing; Drive Axle Heat Shield .

– Install the left coupling rod. Refer to ⇒ Suspension, Wheels,

Steering; Rep. Gr. 40 .

– Install the Left Front Level Control System Sensor - G78- in

the control arm, if equipped. Refer to ⇒ Rep. Gr. 40 .

– Connect the connector -1- to the Oil Level Thermal Sensor -

G266- .

140

Rep. Gr.34 - Operation and Housing

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤

6-Speed Manual Transmission 02Q - Edition 05.2013

– Install the air shroud -arrow- and the radiator fans. Refer to ⇒

Rep. Gr. 19

– Install the charge air hoses -arrow 1 and arrow 2- and then

connect the charge air pipe to the engine. Refer to ⇒ Rep. Gr.

21 .

– Position the starter and install the lower bolt. Refer to ⇒ Elec‐

trical Equipment; Rep. Gr. 27 ; Starter; Starter, Removing and

Installing .

– Attach the bracket for the lines to the lower starter bolt.

– Install the starter bolt and then connect the connector and

wires to the starter. Refer to ⇒ Electrical Equipment; Rep. Gr.

27 ; Starter; Starter, Removing and Installing .

– Attach the ground cable -1- to the top starter bolt.

– Connect the connector -2- to the Back-Up Lamp Switch - F4- .

– Push the hose/line assembly or pipe -A- into the bleeder/clutch

slave cylinder to the stop and push the clamp -arrow- down‐

ward.

– Pull on the line to make sure it is secure.

– Remove the Hose Clamp - 3094- from the supply hose.

– After removing the Hose Clamps - Up To 25mm - 3094- , bring

the return hose back to its original shape.

– Bleed the clutch mechanism. Refer to

⇒ “1.10 Clutch Mechanism, Bleeding”, page 48 .

– Make sure the vacuum hose for the brake system is installed

correctly. Refer to ⇒ Brake System; Rep. Gr. 47 ; Hydraulic

System .

Gasoline Engine and FWD

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6-Speed Manual Transmission 02Q - Edition 05.2013

– Attach the cable mounting bracket to the transmission and

tighten the bolts and nuts -arrows- to the tightening specifica‐

tion -item 6- ⇒ Item 6 (page 86) and -item 10-

⇒ Item 10 (page 86) .

– Apply a small amount of grease to the pin -arrow- on the gear‐

shift lever -1-.

Refer to the Parts Catalog for the grease allocation.

– Slide the shift cable onto the respective pins -arrow- and se‐

cure it with a new lock washer -3-.

Metal Relay Lever

– Apply a small amount of grease to the pin -arrow- of the relay

lever -2-.

Refer to the Parts Catalog for the grease allocation.

– Slide the selector cable onto the respective pins -arrow- and

secure it with a new lock washer -4-.

Plastic Relay Lever

– Insert the selector cable into the cable retainer.

Continuation for All

– Adjust the gearshift mechanism. Refer to

⇒ “1.11 Selector Mechanism, Adjusting”, page 97 .

– Install the battery tray, battery cover and the battery. Refer to

⇒ Electrical Equipment; Rep. Gr. 27 ; Battery; Battery, Re‐

moving and Installing .

– Install the air filter housing, if it was removed earlier. Refer to

⇒ Rep. Gr. 24 ; Air Filter; Air Filter Housing, Removing and

Installing .

– Install the plenum chamber cover and seal. Refer to ⇒ Body

Exterior; Rep. Gr. 50 ; Plenum Chamber Cover; Plenum

Chamber Cover, Removing and Installing .

– Attach the foam pieces to the upper edges on the left and right

fenders. Refer to ⇒ Body Exterior; Rep. Gr. 50 ; Fender .

– Install the engine cover if necessary.

– Connect the battery and observe procedure after connecting

battery. Refer to ⇒ Electrical Equipment; Rep. Gr. 27 ; Battery;

Battery, Disconnecting and Connecting .

– Check the transmission fluid level. Refer to

⇒ “8 Transmission Fluid, Checking”, page 192 .

– Install the lower part of the left front wheel housing liner. Refer

to ⇒ Body Exterior; Rep. Gr. 66 ; Wheel Housing Liner .

– Install the noise insulation. Refer to ⇒ Body Exterior; Rep. Gr.

50 ; Noise Insulation .

– Check the headlamp adjustment if the vehicle has a Left Front

Level Control System Sensor - G78- . Refer to ⇒ Electrical

Equipment; Rep. Gr. 94 ; Headlamps; Headlamp, Adjusting .

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Rep. Gr.34 - Operation and Housing

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤

6-Speed Manual Transmission 02Q - Edition 05.2013

3.2

Tightening Specifications

Transmission to Engine (Engine Flange Face)

Item

1

Bolt

Quantity

1

Nm

80

M12 x 55

♦ With a short M8 threa‐

ded pin

2

M12 x 55

♦ With a long threaded

pin M8

1

80

3

4

5

6

M12 x 65

M10 x 50

M10 x 105

1

2

1

80

40

80

M12 x 165

♦ With a short M8 threa‐

ded pin

♦ Also starter to trans‐

mission

7

-

M12 x 165

♦ With a short M8 threa‐

ded pin

1

80

10

♦ Also starter to trans‐

mission

M6 x 8

♦ Small flywheel cover

plate (not present on all

engines)

-A- and -B-: alignment bushings

Transmission Bracket -1- to Transmission.

– Replace the bolts.

Tighten the bolts -arrows-: 60 Nm + 90°.

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6-Speed Manual Transmission 02Q - Edition 05.2013

Transmission to Body

– Replace the bolts.

Tighten the bolts -arrows-: 60 Nm + 90°.

Note

Install the engine/transmission mount free of tension. Refer to ⇒

Rep. Gr. 10 ; Engine, Removing and Installing .

144

Rep. Gr.34 - Operation and Housing

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤

6-Speed Manual Transmission 02Q - Edition 05.2013

4

Transmission, Removing and Instal‐

ling, Jetta from MY 11, Diesel and

Gasoline

⇒ “4.1 Transmission, Removing and Installing”, page 145

⇒ “6 Transmission, Transporting”, page 189

⇒ “4.2 Tightening Specifications”, page 164

4.1

Transmission, Removing and Installing

Special tools and workshop equipment required

♦ Engine Support Bridge - 10-222A-

♦ Transmission Support - 3282-

♦ Engine and Gearbox Jack - VAS6931-

♦ Tensioning Strap - T10038-

♦ Engine Support - Basic Set - T40091-

♦ Engine Support - Supplement Kit - T40093A-

♦ Slide Hammer Set - Adapter 40 - VW771/40- from the Slide

Hammer Set - VW771-

♦ Hose Clamps - Up To 25mm - 3094-

♦ Transmission Support - Pins 29 - 3282/29-

♦ Transmission Support - Mounting Plate 33 - 3282/33-

♦ Support Elements for transmission (determine when mounting

the Mounting Plate on the Transmission Support )

♦ Grease for Clutch Disc Shaft Splines - G 000 100-

♦ Allocate the grease for gearshift mechanism. Refer to the

Parts Catalog.

♦ M10 x 20 hex bolt

Removing

– See if a coded radio is installed. If so, obtain the anti-theft code.

– Disconnect the battery ground cable. Refer to ⇒ Electrical

Equipment; Rep. Gr. 27 ; Battery; Battery, Disconnecting and

Connecting .

– Remove the engine cover. Refer to ⇒ Rep. Gr. 15 ; Cylinder

Head; Engine Cover, Removing and Installing .

– Remove the complete air filter housing. Refer to ⇒ Rep. Gr.

23 ; Diesel Direct Injection System; Air Filter Housing, Re‐

moving and Installing or ⇒ Rep. Gr. 24 ; Air Filter; Air Filter

Housing, Removing and Installing .

4. Transmission, Removing and Installing, Jetta from MY 11, Diesel and Gasoline

145

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤

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– Remove the battery and the battery tray. Refer to ⇒ Electrical

Equipment; Rep. Gr. 27 ; Battery; Battery, Removing and In‐

stalling .

– Remove the shift cable lock washer -1- from the transmission

shift lever -2- and remove the cable from the pin -arrow-.

– Remove the cable retainer from the selector cable.

•

To avoid damage to the selector cable, the cable retainer must

be disconnected from the selector lever before removal.

– Pull the securing mechanism all the way forward in direction

of -arrow 1- and then unlock to the left in direction of

-arrow 2-.

– Press the relay lever forward (in the direction of -arrow 3-).

– The relay lever is removed together with the cable retainer

later in the procedure.

– Remove the cable bracket from the transmission -arrows-,

move it to the side and tie it up.

146

Rep. Gr.34 - Operation and Housing

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤

6-Speed Manual Transmission 02Q - Edition 05.2013

Vehicles with A Pipe between the Clutch Master and Slave Cyl‐

inders

– Clamp the clutch master cylinder hose using a Hose Clamps

- Up To 25mm - 3094- .

Vehicles with A Hose/Line Assembly between the Clutch Master

and Slave Cylinders

– Clamp off the hose on the hose/line assembly -A- to the clutch

slave cylinder using the Hose Clamps - Up To 25mm - 3094- .

Continuation for All

– Pull the clamp -arrow- for the hose/line assembly or the pipe

out all the way to the stop.

– Remove the hose/line assembly or pipe from the bleeder/

clutch slave cylinder and seal it off.

Caution

Do not press the clutch pedal anymore.

– Remove the ground cable -1- from the top starter bolt.

– Disconnect the connector -2- from the Back-Up Lamp Switch

- F4- .

– Disconnect the connector and the wire from the starter.

– Remove the upper engine/transmission connecting bolts

-arrows-.

– Remove the upper bolt from the starter.

– Remove the plenum chamber cover. Refer to ⇒ Body Exterior;

Rep. Gr. 50 ; Plenum Chamber Cover; Plenum Chamber

Cover, Removing and Installing .

4. Transmission, Removing and Installing, Jetta from MY 11, Diesel and Gasoline

147

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤

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– Remove the bolts -arrows- for the left and right lock carrier

retaining brackets.

– Remove the lower mounts on the Engine Support Bridge - En‐

gine Support 28 - 10-222A/28- and replace them with the

Engine Support Bridge - Engine Support 28-2 - 10-222A/

28-2- .

– Remove the bolts -arrows- for securing the engine support

bridge on the lock carrier from the Engine Support Bridge -

Engine Support 28-2 - 10-222A/28-2- .

•

Use the bolts in the Engine Support Bridge - Engine Support

28-2 - 10-222A /28-2- for attaching the Engine Support Bridge

- Engine Support 28 - 10-222A /28- . Not the bolts for the re‐

taining bracket.

– Install the Engine Support Bridge - Engine Support 28 -

10-222A/28- and tighten the bolts to 8 Nm -arrows-.

Caution

A second technician is needed to mount the Engine Support

Bridge - 10-222A- on the vehicle to prevent the Engine Support

Bridge - 10-222A- from tipping.

– If there are hose and cable connections located near the en‐

gine lifting eyes for the Engine Support Bridge - 10-222A- ,

these must now be removed.

Vehicles with Diesel Engines

Install the Engine Support Bridge - 10-222A- as shown.

– First slide the Moveable Joints -2- onto the Square Pipe from

the Engine Support Bridge - 10-222A- .

– Mount the Engine Support Bridge - 10-222A- on the suspen‐

sion strut towers and have a second technician hold it to

prevent it from tipping.

– Push the Engine Support - Basic Set - Square Pipe -

T40091/1- -6- from the front left and right through the Engine

Support Bridge - Engine Support 28 - 10-222A/28- -7- and

place on each side of the Engine Support - Supplement Kit -

Movable Joint - T40093/4- -5-.

– Slide the Engine Support - Basic Set - Rail with Holes -

T40091/2- -4- with the Engine Support - Supplement Kit Mount

148

Rep. Gr.34 - Operation and Housing

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤

6-Speed Manual Transmission 02Q - Edition 05.2013

- T40093/5- -9- in the Engine Support - Supplement Kit -

Moveable Joint - T40093/4- -5-.

– Install the locking pins into the Engine Support - Basic Set -

Rail with Holes - T40091/2- -4- and secure it with the cotter

pins.

1 - Engine Support Bridge - En‐

gine Support 31 - Adapter 2 -

10-222A/31-2-

2 - Engine Support - Basic Set

- Moveable Joint - T40091/3-

3 - Engine Support Bridge - En‐

gine Support 31 - Adapter 1 -

10-222A/31-1-

4 - Engine Support - Basic Set

- Rail with Holes - T40091/2-

5 - Engine Support - Supple‐

ment Kit - Movable Joint -

T40093/4-

6 - Engine Support - Basic Set

- Square Pipe - T40091/1-

7 - Engine Support Bridge - En‐

gine Support 28 - 10-222A/28-

with Engine Support Bridge -

Engine Support 28-2 -

10-222A/28-2-

8 - Engine Support Bridge -

Spindle - 10-222A/11-

9 - Engine Support - Supple‐

ment Kit - Mount 5 - T40093/5-

10 - Engine Support - Bracket

w/Spindle and Hook -

10-222A/10-

Vehicles with Gasoline Engine

Install the Engine Support Bridge - 10-222A- as shown.

– First slide the Moveable Joints -2- onto the Square Pipe from

the Engine Support Bridge - 10-222A- .

– Mount the Engine Support Bridge - 10-222A- on the suspen‐

sion strut towers and have a second technician hold it to

prevent it from tipping.

– Push the Engine Support - Basic Set - Square Pipe -

T40091/1- -5- from the front left and right through the Engine

Support Bridge - Engine Support 28 - 10-222A /28- -6- and

place on each side of the Engine Support - Supplement Kit -

Movable Joint - T40093/4- -4-.

– Push the Engine Support - Basic Set - Rail with Holes -

T40091/2- -7- with the Engine Support - Supplement Kit -

Mount - T40093/5- -8- in the Engine Support - Supplement Kit

- Movable Joint - T40093/4- -4-.

4. Transmission, Removing and Installing, Jetta from MY 11, Diesel and Gasoline

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6-Speed Manual Transmission 02Q - Edition 05.2013

– Install the locking pins into the Engine Support - Basic Set -

Rail with Holes - T40091/2- -7- and secure it with the cotter

pins.

1 - Engine Support Bridge - En‐

gine Support 31 - Adapter 2 -

10-222A/31-2-

2 - Engine Support - Basic Set

- Moveable Joint - T40091/3-

3 - Engine Support Bridge - En‐

gine Support 31 - Adapter 1 -

10-222A/31-1-

4 - Engine Support - Supple‐

ment Kit - Movable Joint -

T40093/4-

5 - Engine Support - Basic Set

- Square Pipe - T40091/1-

6 - Engine Support Bridge - En‐

gine Support 28 - 10-222A/28-

with Engine Support Bridge -

Engine Support 28-2 -

10-222A/28-2-

7 - Engine Support - Basic Set

- Rail with Holes - T40091/2-

8 - Engine Support - Supple‐

ment Kit - Mount 5 - T40093/5-

9 - Engine Support Bridge -

Spindle - 10-222A/11-

❑ Engaged in the engine

lifting eye -arrow-.

All Vehicles

– Tighten all the threaded connections on the Engine Support

Bridge - 10-222A- hand-tight. While doing so, adjust the height

of the Engine Support Bridge - 10-222A- parallel over the En‐

gine Support Bridge - Engine Support 28 - 10-222A/28- .

– Pretension the engine/transmission assembly with the spin‐

dles, but do not lift.

150

Rep. Gr.34 - Operation and Housing

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤

6-Speed Manual Transmission 02Q - Edition 05.2013

The left drive axle must be removed later in the procedure.

– With the vehicle still standing on its wheels, loosen the left front

collar bolt -arrow- a maximum 90°, otherwise the wheel bear‐

ing will get damaged. Refer to ⇒ Suspension, Wheels, Steer‐

ing; Rep. Gr. 40 ; Drive Axles, Removing and Installing .

– Loosen the left front wheel bolts.

– Lift the vehicle, all four take-up points of lifting platform at the

same height.

– Remove the left front wheel.

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

Gr. 50 ; Noise Insulation .

– Remove the left front housing liner. Refer to ⇒ Body Exterior;

Rep. Gr. 66 ; Wheel Housing Liner; Front Wheel Housing Lin‐

er, Removing and Installing .

– Transmission on vehicles with Start/Stop System: disconnect

the connector -arrow- from the Transmission Neutral Position

Sensor - G701- .

– Remove the bracket from the starter.

– Remove the starter. Refer to ⇒ Electrical Equipment; Rep. Gr.

27 ; Starter; Starter, Removing and Installing .

– Remove the left charge air hose -arrow 1 and arrow 2- ⇒ Rep.

Gr. 21 .

– Remove the charge air pipe from the engine. Refer to ⇒ Rep.

Gr. 21 .

– Remove the right charge air hose from the charge air cooler.

Refer to ⇒ Rep. Gr. 21 .

– Remove the air shroud -arrow- and the radiator fans. Refer to

⇒ Rep. Gr. 19

4. Transmission, Removing and Installing, Jetta from MY 11, Diesel and Gasoline

151

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6-Speed Manual Transmission 02Q - Edition 05.2013

Vehicles with Gasoline Engine

– Remove the front exhaust pipe from the turbocharger

(-arrow-). Refer to ⇒ Rep. Gr. 26 .

Vehicles with Diesel Engines

– Remove the exhaust system bracket from the subframe

-arrows-. Refer to ⇒ Rep. Gr. 26 .

– Disconnect the exhaust system at the double clamp -arrows-.

– Tie up the front exhaust pipe or lay it on the tunnel brace.

All Vehicles

– Remove the pendulum support.

152

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6-Speed Manual Transmission 02Q - Edition 05.2013

– Disconnect the connector -1- from the Oil Level Thermal Sen‐

sor - G266- .

– Remove left coupling rod from stabilizer bar and set off to the

side. Refer to ⇒ Suspension, Wheels, Steering; Rep. Gr. 40 .

– Remove the left drive axle. Refer to ⇒ Suspension, Wheels,

Steering; Rep. Gr. 40 ; Drive Axles, Removing and Installing .

– If equipped remove the drive axle heat shield -arrows-. Refer

to ⇒ Suspension, Wheels, Steering; Rep. Gr. 40 ; Drive Axles,

Overview and Servicing; Drive Axle Heat Shield .

– Remove the right drive axle from the transmission and tie it up.

Refer to ⇒ Suspension, Wheels, Steering; Rep. Gr. 40 ; Drive

Axles, Removing and Installing .

– Remove the hex collar bolts -arrows- on the left subframe

mount -2- from the left bracket -1-.

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– Lower the engine/transmission approximately 40 mm to di‐

mension -a- using the spindles on the Engine Support Bridge

- 10-222A- .

Note

When moving the engine/transmission assembly, pay attention to

the connection lines, hoses and radiator.

– Remove the bracket -1- from the transmission -arrows-.

– Remove the relay lever with the cable retainer. Refer to

⇒ “1.8 Plastic Relay Lever”, page 89 .

– Remove the gearshift lever from the gearshift shaft.

– Remove the small flywheel cover plate -A- -arrows-, if equip‐

ped.

– Remove the lower engine/transmission connecting bolts -2-.

Note

Loosen the engine/transmission connecting bolts -1 and 3- and

let them be hand-tight.

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6-Speed Manual Transmission 02Q - Edition 05.2013

Align the Transmission Support - 3282- with the Transmission

Support - Mounting Plate 33 - 3282/33- in order to remove the

“02Q” transmission.

– Insert the Transmission Support - 3282- into the Engine and

Gearbox Jack - VAS6931- .

– Align the arms of the Transmission Support - 3282- so that

they match up with the holes in the Adjustment Plate .

– Install the Support Elements -A- as illustrated on the Adjust‐

ment Plate .

– Install the Transmission Support - Pins 29 - 3282/29- in place

of the Mounting Element -C-.

– Position the Engine-Gearbox Jack - VAG1383 A- under the

vehicle. The arrow symbol -B- on the Adjusting Plate points in

direction of travel.

– Align the Adjusting Plate so that it is parallel to the transmis‐

sion.

– Secure the Slide Hammer Set - Adapter 40 - VW771/40- inside

the threaded hole in the transmission housing as shown.

– Install the Transmission Support - Pins 29 - 3282/29- into the

hole on the transmission for the pendulum support bolt.

– Secure the transmission on the Transmission Support - 3282-

with an M10 x 20 bolt -A-.

The drift -B- must be flush at the bottom with the guide on the

Transmission Support - 3282- -arrow-.

– Remove the engine/transmission connecting bolt -C-.

– Remove the last transmission to engine connecting bolt

-arrow-.

– Separate the transmission from the engine (alignment

sleeves).

– Move the transmission in the area of the differential with the

spindles of the Transmission Support - 3282- into an angled

position.

•

The differential, near the transmission, must face upward.

The right flange shaft -1- must be guided over the bolting eyelet

of the engine -2-.

– Carefully push the engine forward slightly with a second tech‐

nician.

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– Guide the transmission and the differential over the subframe

-A- and swing it out.

– Pay attention to the longitudinal member -arrows-. Then care‐

fully lower the transmission.

Note

Pay attention to all of the lines when lowering the transmission.

Installing

Note

♦ Refer to “Transmission, Removing” to get a list of the special

tools needed. Refer to

⇒ “4.1 Transmission, Removing and Installing”, page 145 .

♦ Replace the self-locking nuts and bolts.

♦ Replace bolts that were tightened with an additional turn.

♦ Install any cable ties that were loosened or cut off during re‐

moval at their same location.

♦ Clean the input shaft splines and (on used clutch plates) the

hub splines. Remove any corrosion and then apply a very thin

coat of Grease for Clutch Disc Shaft Splines - G 000 100- on

the splines. Then move the clutch plate back and forth on the

input shaft until the hub moves freely on the shaft. Excess

grease must be removed.

– If the transmission is replaced, transfer the transmission shift

lever and the relay lever.

– Clean any locking compound residue from all threaded holes

using a tap.

– Check whether there are centering sleeves for the engine/

transmission in the cylinder block; install if necessary.

If the alignment sleeves are missing, it will be difficult to shift, there

will be clutch problems and the transmission may make noises

(loose rattling).

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6-Speed Manual Transmission 02Q - Edition 05.2013

– Make sure the intermediate plate is engaged on the sealing

flange and pushed onto the alignment sleeves -arrows-.

– Check the release bearing for wear. Replace the clutch slave

cylinder with release bearing if necessary. Refer to

⇒ “2.2 Clutch Slave Cylinder with Release Bearing, Removing

and Installing”, page 52 .

Align the Transmission Support - 3282- with the Transmission

Support - Mounting Plate 33 - 3282/33- in order to install the “02Q”

transmission.

– Align the arms of the Transmission Support - 3282- so that

they match up with the holes in the Adjustment Plate .

– Install the Support Elements -A- as illustrated on the Adjust‐

ment Plate .

– Install the Transmission Support - Pins 29 - 3282/29- in place

of the Mounting Element -C-.

– Place the transmission on the Engine and Gearbox Jack -

VAS6931- .

– Align the Adjustment Plate so that it is parallel to the trans‐

mission.

– Install the Transmission Support - Pins 29 - 3282/29- into the

hole on the transmission for the pendulum support bolt.

– Secure the Slide Hammer Set - Adapter 40 - VW771/40- inside

the threaded hole in the transmission housing as shown.

– Secure the transmission on the Transmission Support - 3282-

with an M10 x 20 bolt -A-.

The drift -B- must be flush at the bottom with the guide on the

Transmission Support - 3282- -arrow-.

– Position the Engine and Gearbox Jack - VAS6931- under the

vehicle. The arrow on the adjusting plate points in direction of

travel.

Note

Pay attention to all of the lines when installing the transmission.

– Lift the transmission carefully.

– Carefully push the engine forward slightly with a second tech‐

nician.

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– Now turn the transmission upward in the area of the differential

and downward in the area of the 6th gear via the spindles of

the Transmission Support - 3282- .

– Guide the transmission and differential -A- over the subframe.

•

The right flange shaft must be guided past the flywheel

-arrow 2-; pay attention to the intermediate plate -arrow 1-.

– The right flange shaft -1- must be guided over the bolting eye‐

let of the engine -2-.

– At the same time, change the position of the transmission us‐

ing the spindles of the Transmission Support - 3282- so that it

does not come into contact with the longitudinal member

-arrows-.

– Turn the transmission to its installed position using the spin‐

dles of the Transmission Support - 3282- .

– Align the transmission to the engine (alignment sleeves) and

insert it.

Caution

♦ Brake fluid can escape from the bleeder on the transmis‐

sion.

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6-Speed Manual Transmission 02Q - Edition 05.2013

– Insert engine/transmission bolt -C- and tighten to tightening

specification. Refer to

⇒ “4.2 Tightening Specifications”, page 164 .

– Install lower engine/transmission connecting bolts and tighten

to tightening specification. Refer to

⇒ “4.2 Tightening Specifications”, page 164 .

– Install the engine/transmission connecting bolt -arrow- and

tighten it to the tightening specification. Refer to

⇒ “4.2 Tightening Specifications”, page 164 .

– After transmission is bolted to engine at bottom, remove the

Transmission Support - 3282- from transmission.

– Install the upper engine/transmission connecting bolts and

tighten them to the tightening specification. Refer to

⇒ “4.2 Tightening Specifications”, page 164 .

– Attach the transmission gearshift lever to the gearshift shaft.

Refer to

⇒ Fig. ““Installing the Transmission Shift Lever”“ , page 88 and

tighten the nut to tightening specification -item 17-

⇒ Item 17 (page 87) .

– Install the relay lever with the cable retainer. Refer to

⇒ “1.8 Plastic Relay Lever”, page 89 .

– Attach the bracket -1- with the new hex bolts to the transmis‐

sion -arrows- and tighten them to the tightening specification.

Refer to ⇒ “4.2 Tightening Specifications”, page 164 .

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– Align the engine/transmission in its installed position. Lift it un‐

til the bracket -1- is in complete contact with the left subframe

mount -2-.

Caution

There is a risk of damaging the threads in transmission bracket

by inserting bolts at an angle.

♦ Before installing bolts -arrows-, transmission bracket and

transmission mount support arm must be absolutely par‐

allel to each other. If necessary, lift the back of the trans‐

mission using the Engine and Gearbox Jack - VAS6931- .

Note

Install the engine/transmission mount free of tension. Refer to ⇒

Rep. Gr. 10 .

– Install the new hex bolts -arrows- of the left subframe mount

-2- in the bracket -1- and tighten to the tightening position.

Refer to ⇒ “4.2 Tightening Specifications”, page 164 .

WARNING

Only remove the Engine Support Bridge - 10-222A- when all

subframe mount bolts are tightened to the tightening specifi‐

cation.

– Install the flywheel cover plate -A- (if equipped) -arrows-. Refer

to ⇒ “4.2 Tightening Specifications”, page 164 .

Note

♦ There are threaded inserts (for example “Heli Coil”) in the pen‐

dulum support fastening holes.

♦ Characteristic: there is a collar on the first thread -arrow-.

♦ Pay attention to the corresponding bolts and tightening spec‐

ifications. Refer to ⇒ Suspension, Wheels, Steering; Rep. Gr.

40 ; Subframe; Overview - Subframe .

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6-Speed Manual Transmission 02Q - Edition 05.2013

– Install the pendulum support. Refer to ⇒ Suspension, Wheels,

Steering; Rep. Gr. 40 ; Subframe; Overview - Subframe .

– Install the drive axles. Refer to ⇒ Suspension, Wheels, Steer‐

ing; Rep. Gr. 40 ; Drive Axles, Removing and Installing .

– If equipped install the drive axle heat shield -arrows-. Refer to

⇒ Suspension, Wheels, Steering; Rep. Gr. 40 ; Drive Axles,

Overview and Servicing; Drive Axle Heat Shield .

– Attach the left coupling rod. Refer to ⇒ Suspension, Wheels,

Steering; Rep. Gr. 40 .

– Connect the connector -1- to the Oil Level Thermal Sensor -

G266- .

– Assemble the exhaust system and attach the exhaust system

bracket to the subframe. Refer to ⇒ Rep. Gr. 26 .

– Install the air shroud -arrow- and the radiator fans. Refer to ⇒

Rep. Gr. 19

– Attach the charge air pipe to the engine. Refer to ⇒ Rep. Gr.

21 .

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– Install the left charge air hose -arrow 1- and -arrow 2- ⇒ Rep.

Gr. 21 .

– Install the right charge air hose to the charge air cooler. Refer

to ⇒ Rep. Gr. 21 .

– Position the starter and install the lower bolt. Refer to ⇒ Elec‐

trical Equipment; Rep. Gr. 27 ; Starter; Starter, Removing and

Installing .

– Attach the bracket for the lines to the lower starter bolt.

– Install the starter bolt and then connect the connector and

wires to the starter. Refer to ⇒ Electrical Equipment; Rep. Gr.

27 ; Starter; Starter, Removing and Installing .

– Attach the ground cable -1- to the top starter bolt.

– Connect the connector -2- to the Back-Up Lamp Switch - F4- .

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

connector -arrow- to the Transmission Neutral Position Sensor

- G701- .

– Push the hose/line assembly or pipe -A- into the bleeder/clutch

slave cylinder to the stop and push the clamp -arrow- down‐

ward.

– Pull on the line to make sure it is secure.

– Remove the Hose Clamps - Up To 25mm - 3094- from the

hose/line assembly or from the supply hose.

– After removing the Hose Clamps - Up To 25mm - 3094- , bring

the return hose back to its original shape.

– Bleed the clutch mechanism. Refer to

⇒ “1.10 Clutch Mechanism, Bleeding”, page 48 .

– Make sure the vacuum hose for the brake system is installed

correctly. Refer to ⇒ Brake System; Rep. Gr. 47 ; Hydraulic

System .

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6-Speed Manual Transmission 02Q - Edition 05.2013

– Attach the cable mounting bracket to the transmission and

tighten the bolts and nuts -arrows- to the tightening specifica‐

tion -item 6- ⇒ Item 6 (page 86) and -item 10-

⇒ Item 10 (page 86) .

– Insert the selector cable into the cable retainer.

– Apply a small amount of grease to the pin -arrow- on the gear‐

shift lever -2-.

Refer to the Parts Catalog for the grease allocation.

– Replace the lock washer -1- after every disassembly.

– Adjust the gearshift mechanism. Refer to

⇒ “1.11 Selector Mechanism, Adjusting”, page 97 .

– Install the plenum chamber cover. Refer to ⇒ Body Exterior;

Rep. Gr. 50 ; Plenum Chamber Cover; Plenum Chamber

Cover, Removing and Installing .

– Install the bolts -arrows- for the left and right lock carrier re‐

taining brackets to the tightening specification. Refer to ⇒

Body Exterior; Rep. Gr. 50 ; Lock Carrier; Lock Carrier - At‐

tachments .

– Install the battery tray and the battery. Refer to ⇒ Electrical

Equipment; Rep. Gr. 27 ; Battery; Battery, Removing and In‐

stalling .

– Install the air filter. Refer to ⇒ Rep. Gr. 23 ; Diesel Direct

Injection System; Air Filter Housing, Removing and Installing

or ⇒ Rep. Gr. 24 ; Air Filter; Air Filter Housing, Removing and

Installing .

– Install the engine cover. Refer to ⇒ Rep. Gr. 15 ; Cylinder

Head; Engine Cover, Removing and Installing .

– Connect the battery and observe procedure after connecting

battery. Refer to ⇒ Electrical Equipment; Rep. Gr. 27 ; Battery;

Battery, Disconnecting and Connecting .

– Check the transmission fluid level. Refer to

⇒ “8 Transmission Fluid, Checking”, page 192 .

– Install the left front housing liner. Refer to ⇒ Body Exterior;

Rep. Gr. 66 ; Wheel Housing Liner; Front Wheel Housing Lin‐

er, Removing and Installing .

– Install the noise insulation. Refer to ⇒ Body Exterior; Rep. Gr.

50 ; Noise Insulation .

– Install the wheel. Refer to ⇒ Suspension, Wheels, Steering;

Rep. Gr. 44 ; Wheel Installation Tightening Specifications .

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4.2

Tightening Specifications

Transmission to Engine (Engine Flange Face)

Item

1

Bolt

Quantity

1

Nm

80

M12 x 55

♦ With a short threaded

pin M8 or

M12 x 50

♦ Without threaded pin

2

3

M12 x 55

♦ With a long threaded

pin M8

1

80

M12 x 70

or M12 x 65

4

5

6

M10 x 50

M10 x 105

M12 x 165

♦ With a short M8 threa‐

ded pin

2

1

40

80

♦ Also starter to trans‐

mission

7

-

M12 x 165

♦ With a short M8 threa‐

ded pin

1

80

10

♦ Also starter to trans‐

mission

M6 x 8

♦ Small flywheel cover

plate (not present on all

engines)

-A-: Centering alignment sleeves

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6-Speed Manual Transmission 02Q - Edition 05.2013

Transmission Bracket -1- to Transmission.

– Replace the bolts.

Tighten the bolts -arrows-: 60 Nm + 90°.

Transmission to Body

– Replace the bolts.

Tighten the bolts -arrows-: 60 Nm + 90°.

Note

Install the engine/transmission mount free of tension. Refer to ⇒

Rep. Gr. 10 ; Engine, Removing and Installing .

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5

Transmission, Removing and Instal‐

ling, Jetta from MY 2005 , Golf Wag‐

on from MY 2007 and Golf Wagon

from MY 2010, Vehicles with AWD

⇒ “5.1 Transmission, TDI, Removing and Installing”, page 166

5.1

Transmission, TDI, Removing and In‐

stalling

⇒ “5.1.1 Transmission, Removing”, page 167

⇒ “5.1.2 Transmission, Installing”, page 178

⇒ “5.1.3 Tightening Specifications”, page 186

Special tools and workshop equipment required

♦ Engine Support Bridge - 10-222A-

♦ Engine Support Bridge - Engine Support Feet - 10-222A/8-

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

♦ Engine Support Bridge - Engine Support 18 - 10-222A/18-

♦ Transmission Support - 3282-

♦ Support Elements for transmission (determine when mounting

the Mounting Plate on the Transmission Support )

♦ Transmission Support - Mounting Plate 33 - 3282/33-

♦ Transmission Support Jig - 3336- to transport the transmis‐

sion.

♦ Torque Wrench 1331 5-50Nm - VAG1331-

♦ Torque Wrench 1332 40-200Nm - VAG1332-

♦ Engine and Gearbox Jack - VAS6931-

♦ Slide Hammer Set - Adapter 40 - VW771/40-

♦ Hose Clamps - Up To 25mm - 3094-

♦ Engine Support Bridge - Gearbox Bracket - T10346-

♦ Grease for Clutch Disc Shaft Splines - G 000 100-

♦ Allocate the grease for gearshift mechanism. Refer to the

Parts Catalog.

♦ M6 x 80 collar bolt

♦ M10 x 20 hex bolt

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

Bridge - Engine Support Feet - 10-222A/8- will be mounted on the

longitudinal members later in the procedure.

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•

To protect the edges of the fender, cover both Engine Support

Bridge - Engine Support Feet - 10-222A/8- with cloth tape

-arrow-. Refer to the Parts Catalog (Chemical Materials).

5.1.1

Transmission, Removing

– First check whether a coded radio is installed. If so, obtain the

anti-theft code.

– Disconnect the battery ground cable. Refer to ⇒ Electrical

Equipment; Rep. Gr. 27 ; Battery; Battery, Disconnecting and

Connecting .

Later in the procedure, the Engine Support Bridge - 10-222A- is

connected to the engine lifting eyes.

– Remove the engine cover if it is blocking the lifting eyes.

– Remove the air filter housing if it is located near the battery.

Refer to ⇒ Rep. Gr. 23 ; Diesel Direct Injection System; Air

Filter Housing, Removing and Installing or ⇒ Rep. Gr. 24 ; Air

Filter; Air Filter Housing, Removing and Installing .

– Remove the battery and the battery tray. Refer to ⇒ Electrical

Equipment; Rep. Gr. 27 ; Battery; Battery, Removing and In‐

stalling .

– Remove the lines -A- out from the bracket -B-.

– Remove the shift cable lock washer -3- from the transmission

shift lever -1- and remove the cable from the pin -arrow-.

Metal Relay Lever

– Remove the selector cable lock washer -4- from the relay lever

-2- and remove the cable from the pin -arrow-.

Plastic Relay Lever

AWD

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6-Speed Manual Transmission 02Q - Edition 05.2013

– Remove the cable retainer from the selector cable.

•

To avoid damage to the selector cable, the cable retainer must

be disconnected from the selector lever before removal.

– Pull the securing mechanism all the way forward in direction

of -arrow 1- and then unlock to the left in direction of

-arrow 2-.

– Press the relay lever forward (in the direction of -arrow 3-).

– The plastic relay lever is removed together with the cable re‐

tainer later in the procedure.

Continuation for All

– Remove the cable bracket from the transmission -arrows-, tie

up to the side.

– If equipped, remove the bleeder tube from the bevel gear

-arrow-.

Vehicles with A Pipe between the Clutch Master and Slave Cyl‐

inders

– Clamp the clutch master cylinder hose using a Hose Clamps

- Up To 25mm - 3094- .

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Vehicles with A Hose/Line Assembly between the Clutch Master

and Slave Cylinders

– Clamp off the hose on the hose/line assembly -A- to the clutch

slave cylinder using the Hose Clamps - Up To 25mm - 3094- .

Continuation for All

– Pull the clamp -arrow- for the hose/line assembly or the pipe

out all the way to the stop.

– Remove the hose/line assembly or pipe from the bleeder/

clutch slave cylinder and seal it off.

Caution

Do not press the clutch pedal anymore.

– Remove the ground cable -1- from the top starter bolt.

– Disconnect the connector -2- from the Back-Up Lamp Switch

- F4- .

– Disconnect the connector and the wire from the starter.

– Remove the upper engine/transmission connecting bolts

-arrows-.

– Remove the upper bolt from the starter.

– If there are hose and cable connections located near the en‐

gine lifting eyes for the Engine Support Bridge - 10-222A- ,

these must now be removed.

– Install the Engine Support Bridge - Gearbox Bracket - T10346-

in the most rear hole out of the three holes in the battery tray.

– Use a collar bolt M6 x 80 or one of the battery tray bolts for

this.

– If there are hose and cable connections located near the en‐

gine lifting eyes for the Engine Support Bridge - 10-222A- ,

these must now be removed.

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

hood support.

AWD

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6-Speed Manual Transmission 02Q - Edition 05.2013

– Use:

– Position the Engine Support Bridge - Engine Support Feet -

10-222A/8- :

– Then connect the Engine Support Bridge - Gearbox Bracket -

T10346- to the Engine Support Bridge - 10-222A- .

– Hook the Spindles into the left lifting eye on the engine.

– Pretension the engine/transmission assembly and Engine

Support Bridge - 10-222A- via the spindles.

– Loosen left and right front wheel bolts.

– Raise the vehicle.

– Remove the front wheels.

– Remove the lower part of the left front wheel housing liner.

Refer to ⇒ Body Exterior; Rep. Gr. 66 ; Wheel Housing Liner .

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

Gr. 50 ; Noise Insulation .

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6-Speed Manual Transmission 02Q - Edition 05.2013

– Transmission on vehicles with Start/Stop System: disconnect

the connector -arrow- from the Transmission Neutral Position

Sensor - G701- .

– Remove the bracket from the starter.

– Remove the starter. Refer to ⇒ Electrical Equipment; Rep. Gr.

27 ; Starter; Starter, Removing and Installing .

– Disconnect the connector -arrow 1- or -arrow 2- on the charge

air hose. Refer to ⇒ Rep. Gr. 21 .

– Remove the exhaust system bracket from the subframe

-arrows-.

– Disconnect the exhaust system at the clamping sleeve

-arrows-.

– Tie up the front exhaust pipe.

AWD

^{5. Transmission, Removing and Installing, Jetta from MY 2005 , Golf Wagon from MY 2007 and Golf Wagon from MY 2010, Vehic}1^les7^w1^ith

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6-Speed Manual Transmission 02Q - Edition 05.2013

– Mark the position of the driveshaft with the flexible disk to the

bevel gear flange.

– Remove the driveshaft and flexible disk from the bevel gear

flange shaft -arrows-.

– Disconnect the connector -1- from the Oil Level Thermal Sen‐

sor - G266- .

– Remove the pendulum support from the transmission.

Note

After loosening the pendulum support bolts, the engine/transmis‐

sion assembly swings forward slightly (toward the front end).

Ensure that the sealing ring -arrow- in the flange of the driveshaft

is not damaged during removal and installation.

– Press the engine/transmission assembly slightly forward (to‐

ward the front end) and pull the driveshaft off of the bevel gear.

– Lift the driveshaft and secure it.

– Remove the left and right coupling rods from the stabilizer bar.

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– Remove the nuts -arrows- for the ball joint on the control arm.

– Secure the subframe before removing. Refer to ⇒ Suspen‐

sion, Wheels, Steering; Rep. Gr. 40 ; Subframe; Subframe,

Securing .

– Remove the subframe and pendulum support, the stabilizer

bar, the mounts, the steering gear and control arms. Refer to

⇒ Suspension, Wheels, Steering; Rep. Gr. 40 ; Subframe;

Overview - Subframe .

– Remove the drive axle heat shield from the bevel box

-arrows-.

– Remove left and right drive axles from transmission flange

shafts. Secure the drive axles. Do not damage the protective

coating when doing this.

Vehicles without A Particulate Filter

– Remove the turbocharger oil return line -A- from the engine.

Refer to ⇒ Rep. Gr. 21 .

– Remove the transmission mount bolts at the engine and bevel

gear -arrows 1 and arrows 2-.

– Remove the transmission mount.

AWD

^{5. Transmission, Removing and Installing, Jetta from MY 2005 , Golf Wagon from MY 2007 and Golf Wagon from MY 2010, Vehic}1^les7^w3^ith

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6-Speed Manual Transmission 02Q - Edition 05.2013

– Remove the support -A-, if equipped. Refer to ⇒ Rep. Gr. 26 .

Vehicles with A Particulate Filter

– Remove the upper particulate filter -A- from the engine

-arrow 1- and from under the turbocharger -arrow 2-. Refer to

⇒ Rep. Gr. 26 .

– Loosen the nuts -1- and remove the nuts -2- to remove the

particulate filter bracket from the engine.

– Then tie the particulate filter to the plenum chamber bulkhead.

– Remove the transmission mount bolts on the engine and bevel

gear -arrows 1, arrows 2 and arrow 3-.

The transmission support may not be removed until the transmis‐

sion is removed from the engine.

174

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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤

6-Speed Manual Transmission 02Q - Edition 05.2013

Vehicles with A Vacuum Diaphragm from 11/2009 -arrow 1-

After 11/2009, a »brace« -arrow 2- is installed under the vacuum

diaphragm -arrow 1- at the top of the transmission support (grad‐

ual introduction).

– Loosen the bolts -A- that connect the transmission mount to

the engine.

– Remove the transmission mount bolts -B- on the bevel gear.

Continuation for All

– Remove the subframe mount bolts -arrows- on the transmis‐

sion.

– Adjuster the spindles on the Engine Support Bridge - 10-222A-

and lower the transmission to dimension -a-.

•

Dimension -a- = approximately 60 mm

Note

When moving the engine/transmission assembly, be aware of the

coolant hoses between the engine and heater core; do not strain.

– Remove the bracket from the transmission -arrows-.

AWD

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6-Speed Manual Transmission 02Q - Edition 05.2013

Metal Relay Lever

– Remove the lock washer -arrow- from the relay lever -1- and

then remove the relay lever.

Plastic Relay Lever

– Remove the relay lever with the cable retainer. Refer to

⇒ “1.8 Plastic Relay Lever”, page 89 .

Continuation for All

– Remove the gearshift lever from the gearshift shaft.

– Remove the lower transmission/engine connecting bolts

-1 and 2- (engine side).

Note

Loosen the engine/transmission connecting bolt -3- and leave it

in so that it is hand-tight.

Align the Transmission Support - 3282- with the Transmission

Support - Mounting Plate 33 - 3282/33- in order to remove the

“02Q AWD” transmission.

– Insert the Transmission Support - 3282- into the Engine and

Gearbox Jack - VAS6931- .

– Align the arms of the Transmission Support - 3282- so that

they match up with the holes in the Adjustment Plate .

– Install the Support Elements -A- as illustrated on the Adjust‐

ment Plate .

– Install the Transmission Support - Pins 29 - 3282/29- in place

of the Mounting Element -C-.

– Position the Engine-Gearbox Jack - VAG1383A- under the

vehicle. The arrow symbol -B- on the Adjusting Plate points in

direction of travel.

– Align the Adjustment Plate so that it is parallel to the trans‐

mission.

– Install the Transmission Support - Pins 29 - 3282/29- into the

hole on the transmission for the pendulum support bolt.

– Secure the Slide Hammer Set - Adapter 40 - VW771/40- inside

the threaded hole in the transmission housing as shown.

– Secure the transmission on the Transmission Support - 3282-

with an M10 x 20 bolt -A-.

176

Rep. Gr.34 - Operation and Housing

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6-Speed Manual Transmission 02Q - Edition 05.2013

– Remove the last engine/transmission connecting bolt -3-.

– Separate the transmission from the engine.

Vehicles with A Particulate Filter

– Remove the transmission support -A- from the bevel box -C-.

Continuation for All

– Move the transmission near the differential/bevel box slightly

towards the rear, so that the small cover plate -B- or the inter‐

mediate plate is not damaged.

– Then guide the transmission past the flywheel -arrow-.

– Then turn the transmission using the spindles -1- and -2- for

the Transmission Support - 3282- so that it is does not touch

the longitudinal member.

– Carefully lower the transmission.

Note

Pay attention to all of the lines when lowering the transmission.

AWD

^{5. Transmission, Removing and Installing, Jetta from MY 2005 , Golf Wagon from MY 2007 and Golf Wagon from MY 2010, Vehic}1^les7^w7^ith

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤

6-Speed Manual Transmission 02Q - Edition 05.2013

5.1.2

Transmission, Installing

Note

♦ Refer to “Transmission, Removing” to get a list of the special

tools needed. Refer to

⇒ “5.1 Transmission, TDI, Removing and Installing”,

page 166 .

♦ Replace the self-locking nuts and bolts.

♦ Replace bolts that were tightened with an additional turn.

♦ Install any cable ties that were loosened or cut off during re‐

moval at their same location.

♦ Clean input shaft splines and (on used clutch plates) the hub

splines, remove corrosion and apply a very thin coating of

Grease for Clutch Disc Shaft Splines - G 000 100- to the

splines. Then move the clutch plate back and forth on the input

shaft until the hub moves freely on the shaft. Excess grease

must be removed.

– If the transmission is replaced, transfer the transmission shift

lever and the relay lever.

– Clean any locking compound residue from all threaded holes

using a tap.

– Check whether there are centering sleeves for the engine/

transmission in the cylinder block; install if necessary.

If the alignment sleeves are missing, it will be difficult to shift, there

will be clutch problems and the transmission may make noises

(loose rattling).

– Make sure the intermediate plate is engaged on the sealing

flange and pushed onto the alignment sleeves -arrows-.

– Check the release bearing for wear. Replace the clutch slave

cylinder with release bearing if necessary. Refer to

⇒ “2.2 Clutch Slave Cylinder with Release Bearing, Removing

and Installing”, page 52 .

178

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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤

6-Speed Manual Transmission 02Q - Edition 05.2013

Align the Transmission Support - 3282- with the Transmission

Support - Mounting Plate 33 - 3282/33- in order to install the “02Q

AWD” transmission.

– Align the Transmission Support arms so that they align with

the holes in the Adjusting Plate .

– Install the Support Elements -A- as illustrated on the Adjust‐

ment Plate .

– Install the Transmission Support - Pins 29 - 3282/29- in place

of the Mounting Element -C-.

– Place the transmission on the Engine and Gearbox Jack -

VAS6931- .

– Align the Adjustment Plate so that it is parallel to the trans‐

mission.

– Install the Transmission Support - Pins 29 - 3282/29- into the

hole on the transmission for the pendulum support bolt.

– Secure the Slide Hammer Set - Adapter 40 - VW771/40- inside

the threaded hole in the transmission housing as shown.

– Secure the transmission on the Transmission Support - 3282-

with an M10 x 20 bolt -A-.

– Position the Engine and Gearbox Jack - VAS6931- under the

vehicle. The arrow on the adjusting plate points in direction of

travel.

– Position the transmission slightly upwards -arrow- in the area

near the differential/bevel box using the spindles -1- and -2-

for the Transmission Support - 3282- .

AWD

^{5. Transmission, Removing and Installing, Jetta from MY 2005 , Golf Wagon from MY 2007 and Golf Wagon from MY 2010, Vehic}1^les7^w9^ith

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6-Speed Manual Transmission 02Q - Edition 05.2013

Note

♦ Pay attention to all of the lines when installing the transmis‐

sion.

♦ For vehicles with a vacuum diaphragm -arrow-, do not touch

the vacuum diaphragm with the bevel box while installing.

Vehicles with A Particulate Filter

– Lay the transmission support -A- on the bevel box -C- before

inserting the transmission.

Continuation for All

– Guide the transmission past the flywheel -arrow- and the small

cover plate -B- and the intermediate plate when installing.

– Align the transmission with respect to the engine and install.

– Install the engine/transmission connecting bolts

-1 through 3- and tighten them to the tightening specification.

Refer to ⇒ “5.1.3 Tightening Specifications”, page 186 .

– After transmission is bolted to engine at bottom, remove

Transmission Support - 3282- from transmission.

– Attach the transmission gearshift lever to the gearshift shaft.

Refer to

⇒ Fig. ““Installing the Transmission Shift Lever”“ , page 88 and

tighten the nut to tightening specification -item 17-

⇒ Item 17 (page 87) .

Metal Relay Lever

– Install the relay lever -1- and the lock washer -arrow-.

Plastic Relay Lever

– Install the relay lever with the cable retainer. Refer to

⇒ “1.8 Plastic Relay Lever”, page 89 .

180

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6-Speed Manual Transmission 02Q - Edition 05.2013

Continuation for All

– Attach the bracket to the transmission using the new bolts

-arrows- and then tighten them to the tightening specification.

Refer to ⇒ “5.1.3 Tightening Specifications”, page 186 .

– Align the engine/transmission in its installed position. To do

this, tighten the spindles of the Engine Support Bridge -

10-222A- until the bracket -1- is in complete contact with the

transmission mount -2-.

Note

The transmission mount and bracket must be parallel to one an‐

other to prevent damaging the thread inside the bracket.

– Install new hex bolts -arrows- for the transmission mount -2-

on the bracket -1- and tighten to the tightening specification.

Refer to ⇒ “5.1.3 Tightening Specifications”, page 186 .

WARNING

Only remove the Engine Support Bridge - 10-222A- when all

subframe mount bolts are tightened to the tightening specifi‐

cation.

Note

Install the engine/transmission mount free of tension. Refer to ⇒

Rep. Gr. 10 ; Engine, Removing and Installing .

Vehicles without A Particulate Filter

– Attach the bevel box transmission support to the engine. Fol‐

low the tightening sequence when installing the bolts

-arrows 1 and arrows 2-. Refer to

⇒ “5.1.3 Tightening Specifications”, page 186 .

– Attach the turbocharger oil return line -A- to the engine. Refer

to ⇒ Rep. Gr. 21 .

AWD

^{5. Transmission, Removing and Installing, Jetta from MY 2005 , Golf Wagon from MY 2007 and Golf Wagon from MY 2010, Vehic}1^les8^w1^ith

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6-Speed Manual Transmission 02Q - Edition 05.2013

– Install the support -A-, if equipped. Refer to ⇒ Rep. Gr. 26 .

Vehicles with A Particulate Filter

– Attach the bevel gear transmission mount to the engine and

bevel gear. Follow the tightening sequence when installing the

bolts -arrows 1, arrows 2 and arrow 3-. Refer to

⇒ “5.1.3 Tightening Specifications”, page 186 .

The bolt heads may be different from those shown in the illustra‐

tion.

Vehicles with A Vacuum Diaphragm from 11/2009 -arrow 1-

After 11/2009, a »brace« -arrow 2- is installed under the vacuum

diaphragm -arrow 1- at the top of the transmission support (grad‐

ual introduction).

– Fasten the bevel gear transmission mount to the engine and

bevel gear while observing the tightening sequence for the

bolts -A and B-. Refer to

⇒ “5.1.3 Tightening Specifications”, page 186 .

•

The bolt -C- must be screwed in.

– Attach the particulate filter with the particulate filter bracket to

the engine. Refer to ⇒ Rep. Gr. 26 .

Continuation for All

– Mount the right and left drive axles to the transmission. Refer

to ⇒ Suspension, Wheels, Steering; Rep. Gr. 40 ; Drive Axles,

Removing and Installing .

– Install the drive axle heat shield on the bevel box -arrows-.

Refer to ⇒ Suspension, Wheels, Steering; Rep. Gr. 40 ; Drive

Axles, Overview and Servicing; Drive Axle Heat Shield .

182

Rep. Gr.34 - Operation and Housing

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤

6-Speed Manual Transmission 02Q - Edition 05.2013

– Install the subframe and pendulum support, the stabilizer bar,

the mounts, the steering gear and control arms. Refer to ⇒

Suspension, Wheels, Steering; Rep. Gr. 40 ; Subframe; Over‐

view - Subframe .

– Attach the driveshaft with the flexible disc to the bevel box

flange -arrows-. Refer to ⇒ Rear Final Drive; Rep. Gr. 39 .

Note

♦ The holes for the pendulum support in transmissions from

05/28/2007 have threaded inserts (for example “Heli Coil”).

♦ Characteristic: there is a collar on the first thread -arrow-.

♦ Observe the correct bolts and tightening specifications. Refer

to ⇒ Suspension, Wheels, Steering; Rep. Gr. 40 ; Subframe;

Overview - Subframe .

– Attach the pendulum support to the transmission. Refer to ⇒

Suspension, Wheels, Steering; Rep. Gr. 40 ; Subframe; Over‐

view - Subframe .

– Assemble the exhaust system and then attach the exhaust

system bracket it to the subframe. Refer to ⇒ Rep. Gr. 26 .

AWD

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– Attach the charge air hose -arrow-. Refer to ⇒ Rep. Gr. 21 .

– Install the upper engine/transmission connecting bolts and

tighten them to the tightening specification. Refer to

⇒ “5.1.3 Tightening Specifications”, page 186 .

– If equipped, install the breather tube -arrow- in the bevel gear

and tighten to 10 Nm.

– Position the starter and install the lower bolt. Refer to ⇒ Elec‐

trical Equipment; Rep. Gr. 27 ; Starter; Starter, Removing and

Installing .

– Attach the bracket for the lines to the lower starter bolt.

– Install the starter bolt and then connect the connector and

wires to the starter. Refer to ⇒ Electrical Equipment; Rep. Gr.

27 ; Starter; Starter, Removing and Installing .

– Attach the ground cable -1- to the top starter bolt.

– Connect the connector -2- to the Back-Up Lamp Switch - F4- .

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

connector -arrow- to the Transmission Neutral Position Sensor

- G701- .

184

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6-Speed Manual Transmission 02Q - Edition 05.2013

– Push the hose/line assembly or pipe -A- into the bleeder/clutch

slave cylinder to the stop and push the clamp -arrow- down‐

ward.

– Pull on the line to make sure it is secure.

– Remove the Hose Clamps - Up To 25mm - 3094- from the

hose/line assembly or from the supply hose.

– After removing the Hose Clamps - Up To 25mm - 3094- , bring

the return hose back to its original shape.

– Bleed the clutch mechanism. Refer to

⇒ “1.10 Clutch Mechanism, Bleeding”, page 48 .

– Make sure the vacuum hose for the brake system is installed

correctly. Refer to ⇒ Brake System; Rep. Gr. 47 ; Hydraulic

System .

– Attach the cable mounting bracket to the transmission and

tighten the bolts and nuts -arrows- to the tightening specifica‐

tion -item 6- ⇒ Item 6 (page 86) and -item 10-

⇒ Item 10 (page 86) .

– Apply a small amount of grease to the pin -arrow- on the gear‐

shift lever -1-.

Refer to the Parts Catalog for the grease allocation.

– Slide the shift cable onto the respective pins -arrow- and se‐

cure it with a new lock washer -3-.

Metal Relay Lever

– Apply a small amount of grease to the pin -arrow- of the relay

lever -2-.

Refer to the Parts Catalog for the grease allocation.

– Slide the selector cable onto the respective pins -arrow- and

secure it with a new lock washer -4-.

Plastic Relay Lever

– Insert the selector cable into the cable retainer.

Continuation for All

– Adjust the gearshift mechanism. Refer to

⇒ “1.11 Selector Mechanism, Adjusting”, page 97 .

AWD

^{5. Transmission, Removing and Installing, Jetta from MY 2005 , Golf Wagon from MY 2007 and Golf Wagon from MY 2010, Vehic}1^les8^w5^ith

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6-Speed Manual Transmission 02Q - Edition 05.2013

– Secure the lines -A- to the bracket -B-.

– Install the engine cover if necessary.

– Install the complete air filter housing, if it was removed earlier.

Refer to ⇒ Rep. Gr. 23 ; Diesel Direct Injection System; Air

Filter Housing, Removing and Installing .

– Connect the battery and observe procedure after connecting

battery. Refer to ⇒ Electrical Equipment; Rep. Gr. 27 ; Battery;

Battery, Disconnecting and Connecting .

– Check transmission fluid level inside the manual transmission.

Refer to ⇒ “8 Transmission Fluid, Checking”, page 192 .

– Check the gear oil in the bevel box. Refer to

⇒ “10 Axle Oil in Bevel Box, Checking or Adding”, page 218 .

– Install the lower part of the left front wheel housing liner. Refer

to ⇒ Body Exterior; Rep. Gr. 66 ; Wheel Housing Liner .

– Install the noise insulation. Refer to ⇒ Body Exterior; Rep. Gr.

50 ; Noise Insulation .

– Install the wheels. Refer to ⇒ Suspension, Wheels, Steering;

Rep. Gr. 44 ; Wheel Installation Tightening Specifications .

– Check the headlamp adjustment if the vehicle has a Left Front

Level Control System Sensor - G78- . Refer to ⇒ Electrical

Equipment; Rep. Gr. 94 ; Headlamps; Headlamp, Adjusting .

5.1.3

Tightening Specifications

Transmission to Engine (engine flange face)

Item

1

Bolt

Quantity

1

Nm

80

M12 x 55

♦ With a short M8 threa‐

ded pin

2

3

M12 x 55

♦ With a long threaded

pin M8

1

80

M12 x 70

or M12 x 65

4

5

6

M10 x 50

M10 x 105

M12 x 165

♦ With a short M8 threa‐

ded pin

2

1

40

80

♦ Also starter to trans‐

mission

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6-Speed Manual Transmission 02Q - Edition 05.2013

Item

7

Bolt

Quantity

1

Nm

80

M12 x 165

♦ With a short M8 threa‐

ded pin

♦ Also starter to trans‐

mission

-

M6 x 8

1

10

♦ Small flywheel cover

plate (not present on all

engines)

-A- and -B-: alignment bushings

Vehicles without A Particulate Filter

Install the Transmission Mount.

The following assembly sequence must be followed when instal‐

ling the transmission mount:

– Install the bolts -arrows 1- hand-tight.

– Tighten the bolts -arrows 2- to 40 Nm.

– Tighten the bolts -arrows 1- to 40 Nm.

Vehicles with A Particulate Filter

Install the Transmission Mount.

Allocation of bolts

Item

Bolt

Quantity

1

2

3

M10 x 21

M10 x 45

M10 x 62

3

2

1

The following assembly sequence must be followed when instal‐

ling the transmission mount:

– Hand-tighten all bolts.

– Tighten the bolts -arrows 2 and arrow 3- to 40 Nm.

– Tighten the bolts -arrows 1- to 40 Nm.

AWD

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6-Speed Manual Transmission 02Q - Edition 05.2013

Vehicles with A Vacuum Diaphragm from 11/2009 -arrow 1-

From 11/2009, there is a »brace« -arrow 2- under the vacuum

diaphragm -arrow 1- at the top of the transmission support (run‐

ning change).

Allocation of bolts

Item

A

B

Bolt

Quantity

M10 x 21

M10 x 45

2

The following assembly sequence must be followed when instal‐

ling the transmission mount:

– Hand-tighten all bolts.

– Tighten the bolts -A- to 40 Nm.

– Tighten the bolts -B- to 40 Nm.

Continuation for All

Transmission Bracket -1- to Transmission.

– Replace the bolts.

Tighten the bolts -arrows-: 60 Nm + 90°.

Transmission to Body

– Replace the bolts.

Tighten the bolts -arrows-: 60 Nm + 90°.

Note

Install the engine/transmission mount free of tension. Refer to ⇒

Rep. Gr. 10 ; Engine, Removing and Installing .

188

Rep. Gr.34 - Operation and Housing

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤

6-Speed Manual Transmission 02Q - Edition 05.2013

6

Transmission, Transporting

⇒ “6.1 FWD, Transporting Transmission”, page 189

⇒ “6.2 AWD, Transporting Transmission”, page 189

6.1

FWD, Transporting Transmission

Special tools and workshop equipment required

♦ Transmission Support Jig - 3336-

♦ Shop Crane - VAS6100-

– Attach the Transmission Support Jig - 3336- to the clutch

housing.

– Move the support arm on the sliding bar using the locking bolt

-arrow-.

Number of visible holes = 6.

– Lift the transmission with a workshop crane and the Trans‐

mission Support Jig - 3336- .

– Set the transmission down, for example, into the transport

container.

6.2

AWD, Transporting Transmission

Special tools and workshop equipment required

♦ Transmission Support Jig - 3336-

♦ Shop Crane - VAS6100-

– Attach the Transmission Support Jig - 3336- to the clutch

housing.

6. Transmission, Transporting

189

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– Move the support arm on the sliding bar using the locking bolt

-arrow-.

Number of visible holes = 9.

– Lift the transmission with a workshop crane and the Trans‐

mission Support Jig - 3336- .

– Set the transmission down, for example, into the transport

container.

190

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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤

6-Speed Manual Transmission 02Q - Edition 05.2013

7

Transmission, Securing in Engine/

Transmission Holder

Special tools and workshop equipment required

♦ Holding Plate - VW309A-

♦ Transmission Support - VW353-

♦ Engine and Transmission Holder - VAS6095A-

Procedure

– Secure the transmission with the Transmission Support -

VW353- to the Holding Plate - VW309- -arrows-.

– Insert the Holding Plate - VW309- in the Engine and Gearbox

Bracket - VAS6095A- .

7. Transmission, Securing in Engine/Transmission Holder

191

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8

Transmission Fluid, Checking

Special tools and workshop equipment required

♦ Torque Wrench 1331 5-50Nm - VAG1331-

♦ Triple Square Socket Driver - 3357-

♦ Used Oil Collection and Extraction Unit - SMN372500-

Transmission fluid specification. Refer to the Parts Catalog.

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

Gr. 50 ; Noise Insulation .

– Place the Used Oil Collection and Extraction Unit -

SMN372500- under the transmission.

– Remove the plug for checking the transmission fluid level

-arrow-.

The level is correct when the transmission fluid comes up to the

bottom edge of oil filler hole.

– Install the plug -arrow- with a new seal.

– Tighten the plug -arrow- to the tightening specification. Refer

to

⇒ Fig. ““Different Versions of the Oil Fill and Drain Plugs”“ ,

page 192 .

Note the Following when Filling for the First Time

– Remove the plug -arrow-.

– Add transmission fluid until it reaches the lower edge of the

filler hole.

– Install the plug -arrow- with a new seal.

– Tighten the plug -arrow- to the tightening specification. Refer

to

⇒ Fig. ““Different Versions of the Oil Fill and Drain Plugs”“ ,

page 192 .

– Install the noise insulation. Refer to ⇒ Body Exterior; Rep. Gr.

50 ; Noise Insulation .

Different Versions of the Oil Fill and Drain Plugs

I - Oil filler or drain plug with multi-point socket head, 45 Nm

II - Oil filler or drain plug with hex socket head, 30 Nm

192

Rep. Gr.34 - Operation and Housing

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤

6-Speed Manual Transmission 02Q - Edition 05.2013

9

Bevel Box, Removing and Installing

⇒ “9.1 Bevel Box, Vehicles with TDI Engine without Particulate

Filter, Removing and Installing”, page 193

⇒ “9.2 Bevel Box, Removing and Installing, Vehicles with a Turbo

Diesel Engine with a Particulate Filter, through approximately

10/2009”, page 201

⇒ “9.3 Bevel Box, Removing and Installing, Vehicles with a Turbo

Diesel Engine with a Particulate Filter, through Approximately

11/2009”, page 211

9.1

Bevel Box, Vehicles with TDI Engine

without Particulate Filter, Removing and

Installing

⇒ “9.1.1 Bevel Box, Removing”, page 193

⇒ “9.1.2 Bevel Box, Installing”, page 198

⇒ “9.1.3 Tightening Specifications”, page 201

Special tools and workshop equipment required

♦ Socket And Extended Bit - T10107A-

♦ Torque Wrench 1331 5-50Nm - VAG1331-

♦ Allocate the grease for gearshift mechanism. Refer to the

Parts Catalog.

9.1.1

Bevel Box, Removing

Check whether a breather tube -arrow- is mounted on the bevel

gear.

– Remove the entire air filter housing if necessary. Refer to ⇒

Rep. Gr. 23 ; Diesel Direct Injection System; Air Filter Hous‐

ing, Removing and Installing .

To remove breather tube, shift mechanism must be removed from

transmission:

– Remove the shift cable lock washer -3- from the transmission

shift lever -1- and remove the cable from the pin -arrow-.

Metal Relay Lever

– Remove the selector cable lock washer -4- from the relay lever

-2- and remove the cable from the pin -arrow-.

Plastic Relay Lever

9. Bevel Box, Removing and Installing

193

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– Remove the cable retainer from the selector cable.

•

To avoid damage to the selector cable, the cable retainer must

be disconnected from the selector lever before removal.

– Pull the securing mechanism all the way forward in direction

of -arrow 1- and then unlock to the left in direction of

-arrow 2-.

– Press the relay lever forward (in the direction of -arrow 3-).

– Remove the cable bracket from the transmission -arrows-, tie

up to the side.

– Remove the breather tube from the bevel gear -arrow-.

Continuation for All

– Raise the vehicle.

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

Gr. 50 ; Noise Insulation .

– Disconnect the exhaust system at the clamping sleeve and

remove the exhaust system bracket from the subframe

-arrows-.

– Tie up the front exhaust pipe.

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– Mark the position of the driveshaft with the flexible disk to the

bevel gear flange.

– Remove the driveshaft and flexible disk from the bevel gear

flange shaft -arrows-.

– Disconnect the connector -1- from the Oil Level Thermal Sen‐

sor - G266- .

– Remove the pendulum support from the transmission.

Note

After loosening the pendulum support bolts, the engine/transmis‐

sion assembly swings forward slightly (toward the front end).

Ensure that the sealing ring -arrow- in the flange of the driveshaft

is not damaged during removal and installation.

– Press the engine/transmission assembly slightly forward (to‐

ward the front end) and pull the driveshaft off of the bevel gear.

– Lift the driveshaft and secure it.

– Remove the left and right coupling rods from the stabilizer bar.

9. Bevel Box, Removing and Installing

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– Remove the nuts -arrows- for the ball joint on the control arm.

– Secure the subframe before removing. Refer to ⇒ Suspen‐

sion, Wheels, Steering; Rep. Gr. 40 ; Subframe; Subframe,

Securing .

– Remove subframe with pendulum support, stabilizer bar,

brackets, steering gear and control arms. Refer to ⇒ Suspen‐

sion, Wheels, Steering; Rep. Gr. 40 ; Subframe; Overview -

Subframe .

– Remove the right drive axle heat shield from bevel box

-arrows-.

– Remove right drive axle from transmission flange shaft.

– Secure the drive axle. Do not damage the protective coating

when doing this.

– Remove the turbocharger oil return line -A- from the engine.

Refer to ⇒ Rep. Gr. 21 .

– Remove the transmission mount bolts at the engine and bevel

gear -arrows 1 and arrows 2-.

– Remove the transmission mount.

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– Remove the support -A-, if equipped. Refer to ⇒ Rep. Gr. 26 .

– Remove the right flange shaft bolt with a Socket for example

Socket and Extended Bit - T10107A- -arrow 1-.

Note

Right flanged shaft remains in bevel box.

– Remove the lower bevel gear mounting bolts -arrows- at the

manual transmission.

– Remove upper bevel box mounting bolt at manual transmis‐

sion:

A heat shield -arrow A- is installed on the upper side of the bevel

box on some vehicles.

The bolt -arrow B- is accessible from under the heat shield.

The bolt -arrow C- is accessible from above the heat shield.

– Carefully press bevel box off manual transmission while pro‐

tecting it against falling through.

– Remove bevel box.

9. Bevel Box, Removing and Installing

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– The heat shield -A- must be removed -arrows- if the bevel box

is being replaced.

9.1.2

Bevel Box, Installing

Install in reverse order of removal while. Note the following:

– With the manual transmission installed, lubricate differential

splines with Grease for Clutch Disc Shaft Splines - G 000 100- .

– If the bevel box is being replaced, then install heat shield -A-.

– Tighten the mounting bolts -arrows- to 5 Nm.

– Slide on bevel box completely on manual transmission, while

doing this, join splines of input shaft/bevel box centrally with

differential.

– Bring the right drive axle splines and the differential bevel gear

into alignment. Rotate the flange shaft if necessary.

– With proper tooth position and central guiding, bevel box slips

up to stop against manual transmission.

A heat shield -arrow A- is installed on the upper side of the bevel

box on some transmissions.

– Upper bevel box mounting bolts at manual transmission are

accessible as follows:

The bolt -arrow B- is accessible from under the heat shield.

The bolt -arrow C- is accessible from above the heat shield.

Note

Do not pull bevel box with mounting bolts against the transmis‐

sion. Otherwise bevel box is canted and mounting eyelets can

break off.

– Attach the bevel box transmission support to the engine. Fol‐

low the tightening sequence when installing the bolts

-arrows 1 and arrows 2-. Refer to

⇒ “9.1.3 Tightening Specifications”, page 201 .

– Attach the turbocharger oil return line -A- to the engine. Refer

to ⇒ Rep. Gr. 21 .

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– Install the support -A-, if equipped. Refer to ⇒ Rep. Gr. 26 .

– Mount the right drive axle to the transmission. Refer to ⇒ Sus‐

pension, Wheels, Steering; Rep. Gr. 40 ; Drive Axles, Re‐

moving and Installing .

– Attach the right drive axle heat shield to the bevel box

-arrows- and tighten it to the tightening specification. Refer to

⇒ “9.1.3 Tightening Specifications”, page 201 .

– Install subframe with pendulum support, stabilizer bar, brack‐

ets, steering gear and control arms. Refer to ⇒ Suspension,

Wheels, Steering; Rep. Gr. 40 ; Subframe; Overview - Sub‐

frame .

– Attach the driveshaft with the flexible disc to the bevel box

flange -arrows-. Refer to ⇒ Rear Final Drive; Rep. Gr. 39 .

9. Bevel Box, Removing and Installing

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Note

♦ The holes for the pendulum support in transmissions from

05/28/2007 have threaded inserts (for example “Heli Coil”).

♦ Characteristic: there is a collar on the first thread -arrow-.

♦ Pay attention to the corresponding bolts and tightening spec‐

ifications. Refer to ⇒ Suspension, Wheels, Steering; Rep. Gr.

40 ; Subframe; Overview - Subframe .

– Attach the pendulum support to the transmission. Refer to ⇒

Suspension, Wheels, Steering; Rep. Gr. 40 ; Subframe; Over‐

view - Subframe .

– Assemble the exhaust system and then attach the exhaust

system bracket it to the subframe. Refer to ⇒ Rep. Gr. 26 .

– Check the gear oil in the bevel box. Refer to

⇒ “10 Axle Oil in Bevel Box, Checking or Adding”, page 218 .

– Check transmission fluid level inside the manual transmission.

Refer to ⇒ “8 Transmission Fluid, Checking”, page 192 .

– Install the noise insulation. Refer to ⇒ Body Exterior; Rep. Gr.

50 ; Noise Insulation .

– If equipped, install the breather tube -arrow- in the bevel gear

and tighten to 10 Nm.

If shift mechanism was removed from transmission:

– Attach the cable mounting bracket to the transmission and

tighten the bolts and nuts -arrows- to the tightening specifica‐

tion -item 6- ⇒ Item 6 (page 86) and -item 10-

⇒ Item 10 (page 86) .

– Install and adjust shift mechanism. Refer to

⇒ “1.9 Selector Mechanism, Removing and Installing”,

page 92 .

– Install complete air filter housing. Refer to ⇒ Rep. Gr. 23 ;

Diesel Direct Injection System; Air Filter Housing, Removing

and Installing .

– Check the headlamp adjustment if the vehicle has a Left Front

Level Control System Sensor - G78- . Refer to ⇒ Electrical

Equipment; Rep. Gr. 94 ; Headlamps; Headlamp, Adjusting .

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9.1.3

Tightening Specifications

Installing the Transmission Support on TDI Vehicles

The following assembly sequence must be followed when instal‐

ling the transmission mount:

– Install the bolts -arrows 1- hand-tight.

– Tighten the bolts -arrows 2- to 40 Nm.

– Tighten the bolts -arrows 1- to 40 Nm.

Bevel box to manual transmission

♦ Replace the bolts.

-item 17-

⇒ Item 17

(page 235)

Right heat shield/drive axle to bevel gear

20 Nm

9.2

Bevel Box, Removing and Installing, Ve‐

hicles with a Turbo Diesel Engine with a

Particulate Filter, through approximately

10/2009

⇒ “9.2.1 Bevel Box, Removing”, page 202

⇒ “9.2.2 Bevel Box, Installing”, page 208

⇒ “9.2.3 Tightening Specifications”, page 210

Note

Transmission mount from approximately 11/2009: Bevel Box, Re‐

moving and installing. Refer to

⇒ “9.3 Bevel Box, Removing and Installing, Vehicles with a Turbo

Diesel Engine with a Particulate Filter, through Approximately

11/2009”, page 211 .

Identification: The Transmission Support is Secured with the Bolts

-arrows 1 … 3- to the Engine and the Bevel Box through Approx‐

imately 10/2009.

Special tools and workshop equipment required

♦ Socket And Extended Bit - T10107A-

♦

♦ Torque Wrench 1331 5-50Nm - VAG1331-

♦ Shop Crane - Drip Tray - VAS6208-

♦ Allocate the grease for gearshift mechanism. Refer to the

Parts Catalog.

9. Bevel Box, Removing and Installing

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Note

Transmission mount from approximately 11/2009: Bevel Box, Re‐

moving and installing. Refer to

⇒ “9.3 Bevel Box, Removing and Installing, Vehicles with a Turbo

Diesel Engine with a Particulate Filter, through Approximately

11/2009”, page 211 .

9.2.1

Bevel Box, Removing

Check whether a breather tube -arrow- is mounted on the bevel

gear.

– Remove the entire air filter housing if necessary. Refer to ⇒

Rep. Gr. 23 ; Diesel Direct Injection System; Air Filter Hous‐

ing, Removing and Installing .

To remove breather tube, shift mechanism must be removed from

transmission:

– Remove the shift cable lock washer -3- from the transmission

shift lever -1- and remove the cable from the pin -arrow-.

Metal Relay Lever

– Remove the selector cable lock washer -4- from the relay lever

-2- and remove the cable from the pin -arrow-.

Plastic Relay Lever

– Remove the cable retainer from the selector cable.

•

To avoid damage to the selector cable, the cable retainer must

be disconnected from the selector lever before removal.

– Pull the securing mechanism all the way forward in direction

of -arrow 1- and then unlock to the left in direction of

-arrow 2-.

– Press the relay lever forward (in the direction of -arrow 3-).

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– Remove the cable bracket from the transmission -arrows-, tie

up to the side.

– Remove the breather tube from the bevel gear -arrow-.

Continuation for All

The right driveshaft must be removed later in the procedure.

– With the vehicle still standing on its wheels, loosen the right

front collar bolt -arrow- a maximum 90°, otherwise the wheel

bearing will get damaged. Refer to ⇒ Suspension, Wheels,

Steering; Rep. Gr. 40 ; Drive Axles, Removing and Installing .

– Raise the vehicle.

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

Gr. 50 ; Noise Insulation .

– Disconnect the exhaust system at the clamping sleeve and

remove the exhaust system bracket from the subframe

-arrows-.

– Tie up the front exhaust pipe.

9. Bevel Box, Removing and Installing

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– Mark the position of the driveshaft with the flexible disk to the

bevel gear flange.

– Remove the driveshaft and flexible disk from the bevel gear

flange shaft -arrows-.

– Disconnect the connector -1- from the Oil Level Thermal Sen‐

sor - G266- .

– Remove the pendulum support from the transmission.

Note

After loosening the pendulum support bolts, the engine/transmis‐

sion assembly swings forward slightly (toward the front end).

Ensure that the sealing ring -arrow- in the flange of the driveshaft

is not damaged during removal and installation.

– Press the engine/transmission assembly slightly forward (to‐

ward the front end) and pull the driveshaft off of the bevel gear.

– Lift the driveshaft and secure it.

– Remove the left and right coupling rods from the stabilizer bar.

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– Remove the nuts -arrows- for the ball joint on the control arm.

– Secure the subframe before removing. Refer to ⇒ Suspen‐

sion, Wheels, Steering; Rep. Gr. 40 ; Subframe; Subframe,

Securing .

– Remove subframe with pendulum support, stabilizer bar,

brackets, steering gear and control arms. Refer to ⇒ Suspen‐

sion, Wheels, Steering; Rep. Gr. 40 ; Subframe .

– Remove the support -A- (if equipped). Refer to ⇒ Rep. Gr.

26 ; Exhaust System .

– Remove the right drive axle heat shield from bevel box

-arrows-.

– Remove the right drive axle. Refer to ⇒ Suspension, Wheels,

Steering; Rep. Gr. 40 ; Drive Axles, Removing and Installing .

– Place the Drip Tray for example Shop Crane - Drip Tray -

VAS6208- under the transmission.

9. Bevel Box, Removing and Installing

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– Drain the fluid from the bevel box -A-.

– Remove the right flange shaft bolt -arrow- with the Socket And

Extended Bit - T10107A- and install two bolts in the flange and

counterhold the flange shaft with the pry bar.

– Finally, insert and tighten new bolts -A-.

Bolt M10 X 1 = 15 Nm

Bolt M20 X 1.5 = 60 Nm

– Attach the Puller - Flanged Shaft - T10037- to the flange shaft.

Note

To remove right flange shaft, use Seal Installer - Crankshaft -

T10037- to avoid damaging the bearing on flange shaft.

– Place a spacer (for example, Press Piece - Bushing - VW434- )

between the transmission support and the Stub Shaft coun‐

terhold Tool - Knurled Nut - T10371/1- .

– Align the Puller - Flanged Shaft - T10037- parallel to the flange

using the Spindle -A-.

– Pull out the right flange shaft.

– Seal the bevel box with a Cover Cap - T10460- .

– Remove the engine cover.

– Remove the upper particulate filter -A- from the engine

-arrow 1- and from under the turbocharger -arrow 2-. Refer to

⇒ Rep. Gr. 26 ; Exhaust System .

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– Loosen the nuts -1- and remove the nuts -2- to remove the

particulate filter bracket from the engine.

– Then tie the particulate filter to the plenum chamber bulkhead.

– Remove the turbocharger support. Refer to ⇒ Rep. Gr. 21 .

– Remove the EGR cooler (do not remove the coolant hoses) ⇒

Rep. Gr. 26 ; EGR System .

– Remove the transmission mount bolts on the engine and bevel

gear -arrows 1-, -arrows 2- and -arrow 3-.

– Remove the transmission mount.

– Remove the lower bevel gear mounting bolts -arrows- at the

manual transmission.

– Remove upper bevel box mounting bolt at manual transmis‐

sion:

A heat shield -arrow A- is installed on the upper side of the bevel

box on some vehicles.

The bolt -arrow B- is accessible from under the heat shield.

The bolt -arrow C- is accessible from above the heat shield.

– Carefully press bevel box off manual transmission while pro‐

tecting it against falling through.

– Remove bevel box.

9. Bevel Box, Removing and Installing

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– If replacing the bevel box, check whether the heat shield -A-

must be removed.

9.2.2

Bevel Box, Installing

Install in reverse order of removal while. Note the following:

– With the manual transmission installed, lubricate differential

splines with Grease for Clutch Disc Shaft Splines - G 000 100- .

– If the bevel box is being replaced, then install heat shield -A-.

– Tighten the mounting bolts -arrows- to 5 Nm.

– Slide on bevel box completely on manual transmission, while

doing this, join splines of input shaft/bevel box centrally with

differential.

– With proper tooth position and central guiding, bevel box slips

up to stop against manual transmission.

A heat shield -arrow A- is installed on the upper side of the bevel

box on some transmissions.

– Upper bevel box mounting bolts at manual transmission are

accessible as follows:

The bolt -arrow B- is accessible from under the heat shield.

The bolt -arrow C- is accessible from above the heat shield.

Note

Do not pull bevel box with mounting bolts against the transmis‐

sion. Otherwise bevel box is canted and mounting eyelets can

break off.

– Attach the bevel gear transmission mount to the engine and

bevel gear. Follow the tightening sequence when installing the

bolts -arrows 1, 2, and 3-. Refer to

⇒ “9.2.3 Tightening Specifications”, page 210 .

– Install the turbocharger support. Refer to ⇒ Rep. Gr. 21 .

– Attach the particulate filter with the particulate filter bracket to

the engine. Refer to ⇒ Rep. Gr. 26 .

– Install the EGR cooler (do not open the coolant system) ⇒

Rep. Gr. 26 ; EGR System .

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– Install the support -A-, if equipped. Refer to ⇒ Rep. Gr. 26 .

– Carefully drive in the left flange shaft. While doing so turn the

flange shaft so that the bearing does not get damaged.

– Install flange shaft with a screw and tighten to tightening spec‐

ification -item 13- ⇒ Item 13 (page 401) .

– Install the right drive axle. Refer to ⇒ Suspension, Wheels,

Steering; Rep. Gr. 40 ; Drive Axles, Removing and Installing .

– Attach the right drive axle heat shield to the bevel box

-arrows- and tighten it to the tightening specification. Refer to

⇒ “9.1.3 Tightening Specifications”, page 201 .

– Install subframe with pendulum support, stabilizer bar, brack‐

ets, steering gear and control arms. Refer to ⇒ Suspension,

Wheels, Steering; Rep. Gr. 40 ; Subframe .

– Attach the driveshaft with the flexible disc to the bevel box

flange -arrows-. Refer to ⇒ Rear Final Drive; Rep. Gr. 39 .

9. Bevel Box, Removing and Installing

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Note

♦ The holes for the pendulum support in transmissions from

05/28/2007 have threaded inserts (for example “Heli Coil”).

♦ Characteristic: there is a collar on the first thread -arrow-.

♦ Pay attention to the corresponding bolts and tightening spec‐

ifications. Refer to ⇒ Suspension, Wheels, Steering; Rep. Gr.

40 ; Subframe; Overview - Subframe .

– Attach the pendulum support to the transmission. Refer to ⇒

Suspension, Wheels, Steering; Rep. Gr. 40 ; Subframe; Over‐

view - Subframe .

– Assemble the exhaust system and then attach the exhaust

system bracket it to the subframe. Refer to ⇒ Rep. Gr. 26 .

– Check the gear oil in the bevel box. Refer to

⇒ “10 Axle Oil in Bevel Box, Checking or Adding”, page 218 .

– Check transmission fluid level inside the manual transmission.

Refer to ⇒ “8 Transmission Fluid, Checking”, page 192 .

– Install the noise insulation. Refer to ⇒ Body Exterior; Rep. Gr.

50 ; Noise Insulation .

– If equipped, install the breather tube -arrow- in the bevel gear

and tighten to 10 Nm.

If shift mechanism was removed from transmission:

– Attach the cable mounting bracket to the transmission and

tighten the bolts and nuts -arrows- to the tightening specifica‐

tion -item 6- ⇒ Item 6 (page 86) and -item 10-

⇒ Item 10 (page 86) .

– Install and adjust shift mechanism. Refer to

⇒ “1.9 Selector Mechanism, Removing and Installing”,

page 92 .

– Install complete air filter housing. Refer to ⇒ Rep. Gr. 23 ;

Diesel Direct Injection System; Air Filter Housing, Removing

and Installing .

– Check the headlamp adjustment if the vehicle has a Left Front

Level Control System Sensor - G78- . Refer to ⇒ Electrical

Equipment; Rep. Gr. 94 ; Headlamps; Headlamp, Adjusting .

9.2.3

Tightening Specifications

Bevel box to manual transmission

♦ Replace the bolts.

⇒ Item 17

(page 235)

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Install the Transmission Mount

Allocation of bolts

Item

Bolt

Quantity

1

2

3

M10 x 21

M10 x 45

M10 x 62

3

2

1

The following assembly sequence must be followed when instal‐

ling the transmission mount:

– Hand-tighten all bolts.

– Tighten the bolts -arrows 2 and 3- to 40 Nm.

– Tighten the bolts -arrows 1- to 40 Nm.

9.3

Bevel Box, Removing and Installing, Ve‐

hicles with a Turbo Diesel Engine with a

Particulate Filter, through Approximate‐

ly 11/2009

⇒ “9.3.1 Bevel Box, Removing”, page 211

⇒ “9.3.2 Bevel Box, Installing”, page 215

⇒ “9.3.3 Tightening Specifications”, page 217

Note

Transmission mount through approximately 10/2009; Bevel box,

Removing and installing. Refer to

⇒ “9.2 Bevel Box, Removing and Installing, Vehicles with a Turbo

Diesel Engine with a Particulate Filter, through approximately

10/2009”, page 201 .

Identifying Feature

After 11/2009, a »Brace« -arrow 2- Is Installed Under the Vacuum

Diaphragm -arrow 1- At the top of the Transmission Support

(Gradual Introduction).

The Transmission Mount Is Connected to the Engine and Bevel

Gear with the Bolts -A and B-.

Special tools and workshop equipment required

♦ Puller - Flanged Shaft - T10037-

♦ Socket And Extended Bit - T10107A-

♦ Cover Cap - T10460-

♦ Shop Crane - Drip Tray - VAS6208-

9.3.1

Bevel Box, Removing

– Remove the noise insulation under the engine/transmission

assembly. Refer to ⇒ Body Exterior; Rep. Gr. 50 ; Noise In‐

sulation .

9. Bevel Box, Removing and Installing

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– Remove the right driveshaft heat shield from bevel box

-arrows-.

– Remove the right drive axle. Refer to ⇒ Suspension, Wheels,

Steering; Rep. Gr. 40 ; Drive Axles, Removing and Installing .

– Mark the position of the drive axle with the flexible disk with

respect to the bevel gear flange with paint.

– Remove the driveshaft from the bevel box -arrows-. Refer to

⇒ Rear Final Drive; Rep. Gr. 39 .

– Slide the front driveshaft pipe all the way back.

– Place a cloth on the subframe to prevent damaging the paint

on the driveshaft.

– Position the driveshaft on the subframe.

– Remove the engine cover.

– Remove the upper particulate filter -A- from the engine

-arrow 1- and from under the turbocharger -arrow 2-. Refer to

⇒ Rep. Gr. 26 .

– Loosen the nuts -1- and remove the nuts -2- to remove the

particulate filter bracket from the engine.

– Then tie the particulate filter to the plenum chamber bulkhead.

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– Remove the exhaust system bracket from the subframe

-arrows-.

– Remove the pendulum support from the transmission, bolt

-1- and bolt -2-.

– Press the engine/transmission sub-assembly slightly toward

the front end and secure it in this position with a suitable wood

block -A-.

– Place the Drip Tray for example Shop Crane - Drip Tray -

VAS6208- under the transmission.

– Drain the fluid from the bevel box -A-.

– Install the new drain plug and tighten it to 15 Nm.

– Remove the right flange shaft bolt -arrow- with the Socket And

Extended Bit - T10107A- and install two bolts in the flange and

counterhold the flange shaft with the pry bar.

9. Bevel Box, Removing and Installing

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– Attach the Puller - Flanged Shaft - T10037- to the flange shaft.

Note

To remove right flange shaft, use Puller - Flanged Shaft - T10037-

to avoid damaging the bearing on flange shaft.

– If necessary, place a spacer (for example, Press Piece - Bush‐

ing - VW434- ) between the transmission support and the Stub

Shaft counterhold Tool - Knurled Nut - T10371/1- .

– Align the Puller - Flanged Shaft - T10037- parallel to the flange

using the Spindle -A-.

– Pull out the right flange shaft.

– Seal the bevel box with a Cover Cap - T10460- .

– Remove the turbocharger support. Refer to ⇒ Rep. Gr. 21 .

– Remove the transmission support bolts -A and B- from the en‐

gine and the bevel box.

– Remove the transmission mount.

– Remove the upper bevel box bolts -arrows- on the manual

transmission.

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– Remove the lower bevel box bolts -arrows- on the manual

transmission.

– Carefully push the bevel box off the manual transmission and

remove it.

9.3.2

Bevel Box, Installing

Install in reverse order of removal while. Note the following:

Install the bevel box with the flange shaft removed.

– Coat the splines on the manual transmission differential with

Grease For Clutch Disc Shaft Splines - G 000 100- .

– Slide on bevel box completely on manual transmission, while

doing this, join splines of input shaft/bevel box centrally with

differential.

– With proper tooth position and central guiding, bevel box slips

up to stop against manual transmission.

Note

Do not pull bevel box with mounting bolts against the transmis‐

sion. Otherwise bevel box is canted and mounting eyelets can

break off.

– Install the upper bolts (-arrows-) that attach the bevel box to

the manual transmission and tighten them to 40 Nm + 90°.

– Install the lower bolts -arrows- that attach the bevel box to the

manual transmission and tighten them to 40 Nm + 90°.

9. Bevel Box, Removing and Installing

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– Fasten the bevel gear transmission mount to the engine and

bevel gear while observing the tightening sequence for the

bolts -A and B-. Refer to

⇒ “9.3.3 Tightening Specifications”, page 217 .

– Install the turbocharger support. Refer to ⇒ Rep. Gr. 21 .

– Attach the particulate filter with the particulate filter bracket to

the engine. Refer to ⇒ Rep. Gr. 26 .

– Carefully drive in the left flange shaft. While doing so turn the

flange shaft so that the bearing does not get damaged.

– Install flange shaft with a screw and tighten to tightening spec‐

ification -item 13- ⇒ Item 13 (page 401) .

– Install the right drive axle. Refer to ⇒ Suspension, Wheels,

Steering; Rep. Gr. 40 ; Drive Axles, Removing and Installing .

– Fill the bevel box with gear oil. Refer to

⇒ “10 Axle Oil in Bevel Box, Checking or Adding”, page 218 .

– Attach the right drive axle heat shield to the bevel box

-arrows- and tighten it to the tightening specification. Refer to

⇒ “9.1.3 Tightening Specifications”, page 201 .

– Attach the driveshaft with the flexible disc to the bevel box

flange -arrows-. Refer to ⇒ Rear Final Drive; Rep. Gr. 39 .

Note

♦ The holes for the pendulum support in transmissions from

05/28/2007 have threaded inserts (for example “Heli Coil”).

♦ Characteristic: there is a collar on the first thread -arrow-.

♦ Pay attention to the corresponding bolts and tightening spec‐

ifications. Refer to ⇒ Suspension, Wheels, Steering; Rep. Gr.

40 ; Subframe; Overview - Subframe .

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– Attach the pendulum support to the transmission. Refer to ⇒

Suspension, Wheels, Steering; Rep. Gr. 40 ; Subframe; Over‐

view - Subframe .

– Assemble the exhaust system and then attach the exhaust

system bracket it to the subframe. Refer to ⇒ Rep. Gr. 26 .

– Install the noise insulation. Refer to ⇒ Body Exterior; Rep. Gr.

50 ; Noise Insulation .

9.3.3

Tightening Specifications

Bevel box to manual

transmission

⇒ Item 17 (page 235)

♦ Replace the bolts.

Allocation of the transmission support bolts to the engine and

bevel box

Item

A

B

Bolt

Quantity

M10 x 21

M10 x 45

2

– Hand-tighten all bolts.

– Tighten the bolts -B- to 40 Nm.

– Tighten the bolts -A- to 40 Nm.

9. Bevel Box, Removing and Installing

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10

Axle Oil in Bevel Box, Checking or

Adding

⇒ “10.1 Gear Oil in Bevel Box, Checking”, page 218

⇒ “10.2 Gear Oil in Bevel Box, Filling”, page 219

Special tools and workshop equipment required

♦ Torque Wrench 1331 5-50Nm - VAG1331-

♦ Used Oil Collection and Extraction Unit - SMN372500-

♦ Charging Device For Haldex Coupling 2 - VAS6291A-

♦ Charging Device For Haldex Coupling 2 - Adapter 3 -

VAS6291/3-

♦ It is necessary to use the Oil Filler - Adapter 6 - VAS6262/6-

on some oil containers.

Bevel Box is Attached to the Side of Manual Transmission and

has A Separate Self-Contained Oil System.

Bevel box gear oil. Refer to the Parts Catalog.

Check transmission fluid level inside the manual transmission.

Refer to ⇒ “8 Transmission Fluid, Checking”, page 192 .

10.1

Gear Oil in Bevel Box, Checking

Requirements

•

Bevel box must be in the installation position.

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

Gr. 50 ; Noise Insulation .

– Remove the right drive axle heat shield from bevel box

-arrows-.

– Place the Used Oil Collection and Extraction Unit -

SMN372500- under the bevel box.

Note

Cover area below oil filler bolt -arrow- with a cloth.

– Remove the oil filler plug -arrow- in the bevel box.

The oil filler plug -arrow- must be replaced.

Oil level is correct if bevel box is filled with oil as far as bottom

edge of oil fill hole.

If oil comes in contact with bevel box, remove the bevel box care‐

fully.

– Add gear oil if necessary. Refer to

⇒ “10.2 Gear Oil in Bevel Box, Filling”, page 219 .

– Install the new oil filler plug -arrow-.

– Tighten the bolt to the specification. Refer to

⇒ “10.2.1 Tightening Specification”, page 221 .

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10.2

Gear Oil in Bevel Box, Filling

Requirements

•

Bevel box must be in the installation position.

– Remove the right drive axle heat shield from bevel box

-arrows-.

– Use the Charging Device For Haldex Coupling 2 - VAS6291A-

to fill.

– Route the Charging Device For Haldex Coupling 2 -

VAS6291A- hose through the engine compartment.

– If the vehicle has a particulate filter -A-, guide the hose from

the Charging Device For Haldex Coupling 2 - VAS6291- past

the filter on the right side.

Note

Cover area below oil filler bolt -arrow- with a cloth.

– Place the Used Oil Collection and Extraction Unit -

SMN372500- under the bevel box.

– Remove the oil filler plug -arrow- in the bevel box.

– Disconnect the Charging Device For Haldex Coupling 2 -

Adapter 3 - VAS6291/3- and the elbow -A-.

10. Axle Oil in Bevel Box, Checking or Adding

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– Install the Adapter to the stop.

– Attach the elbow -A- to the Adapter .

– Make sure that the valve -arrow- is closed.

– Install the oil container -A- on the Charging Device For Haldex

Coupling 2 - VAS6291- .

Note

It is necessary to use the Wheel Alignment System - Wheel

Adapter Extensions - VAS6292/6- on some oil containers.

•

The hose must not sag.

– Open the valve -arrow- and hold the oil container as shown.

The bevel box is now filled.

– Lift the vehicle after a few minutes.

Note

♦ If the bevel gear is filled correctly, oil should leak out of the

Adapter .

♦ If no oil is escaping, lower the vehicle and perform filling pro‐

cedure again.

– Lift the vehicle.

– If oil leaks from the Adapter , set down the oil reservoir (for

example, on a tool trolley).

A portion of the excess oil runs back into the oil container.

– When the fluid stops running back, press the button in direction

of -arrow- and remove the Charging Device For Haldex Cou‐

pling 2 (shown on the Charging Device For Haldex Coupling

2 - Adapter 2 - VAS6291/2- ).

– Make sure there is still oil in the Charging Device For Haldex

Coupling 2 - VAS6291A- hose.

– Remove the Adapter .

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– Install the new oil filler plug -arrow-.

– Tighten the oil filler plug to the specification. Refer to

⇒ “10.2.1 Tightening Specification”, page 221 .

•

Carefully remove any oil that has flowed onto the bevel box

and other components.

– Attach the right drive axle heat shield (if equipped) to the bevel

box -arrows- and then tighten to the tightening specification.

Refer to ⇒ “10.2.1 Tightening Specification”, page 221 .

– Install the noise insulation. Refer to ⇒ Body Exterior; Rep. Gr.

50 ; Noise Insulation .

10.2.1

Tightening Specification

Oil Filler Plug

15 Nm

20 Nm

♦ Replace the bolt.

Right heat shield/drive axle to bevel gear

10. Axle Oil in Bevel Box, Checking or Adding

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11

Transmission, Disassembling and

Assembling

⇒ “11.1 Overview - Transmission, FWD”, page 222

⇒ “11.2 Overview - Transmission, AWD”, page 224

⇒ “11.3 Overview - FWD”, page 225

⇒ “11.4 Overview - AWD”, page 226

⇒ “11.5 Transmission Housing and Gearshift Mechanism, Re‐

moving and Installing”, page 228

⇒ “11.6 Overview - Input Shaft, Output Shafts, Differentials and

Shift Rods, Removing and Installing, for FWD Vehicles”,

page 231

⇒ “11.7 Overview - Input Shaft, Output Shaft, Differential, Bevel

Box and Shift Rods, Removing and Installing, for AWD Vehicles”,

page 234

⇒ “11.8 Assembly Sequence, Transmission without a Securing

Ring A for the Metal Cover for the Input Shaft”, page 235

⇒ “11.9 Assembly Sequence: I = Transmission with a Securing

Ring A for the Metal Cover for the Input Shaft; II = Transmission

with Plastic Cover for Input Shaft”, page 247

11.1

Overview - Transmission, FWD

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6-Speed Manual Transmission 02Q - Edition 05.2013

1 - Clutch Housing

2 - Reverse Shaft

3 - 5th, 6th and Reverse Gear

Output Shaft

4 - Clutch Slave Cylinder with

Release Bearing

5 - Input Shaft

6 - 1st through 4th Gear Output

Shaft

7 - Differential

8 - Right Flange Shaft

9 - Left Flange Shaft

10 - 2nd Gear Wheel

11 - 1st Gear Wheel

12 - 4th Gear Wheel

13 - 3rd Gear Wheel

14 - 5th Gear Wheel

15 - 6th Gear Wheel

16 - Reverse Gear Wheel

17 - Transmission Housing

11. Transmission, Disassembling and Assembling

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11.2

Overview - Transmission, AWD

1 - Clutch Housing

2 - Reverse Shaft

3 - 5th, 6th and Reverse Gear

Output Shaft

4 - Clutch Slave Cylinder with

Release Bearing

5 - Input Shaft

6 - 1st through 4th Gear Output

Shaft

7 - Differential

8 - Bevel Box

9 - Right Flange Shaft

10 - Head Bevel Gear with In‐

put Shaft

11 - Shaft Bevel Gear

12 - Output Flange

13 - Left Flange Shaft

14 - 2nd Gear Wheel

15 - 1st Gear Wheel

16 - 4th Gear Wheel

17 - 3rd Gear Wheel

18 - 5th Gear Wheel

19 - 6th Gear Wheel

20 - Reverse Gear Wheel

21 - Transmission Housing

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11.3

Overview - FWD

l -

⇒ “11.5 Transmission Housing

and Gearshift Mechanism, Re‐

moving and Installing”,

page 228 .

ll -

⇒ “11.6 Overview - Input Shaft,

Output Shafts, Differentials

and Shift Rods, Removing and

Installing, for FWD Vehicles”,

page 231 .

11. Transmission, Disassembling and Assembling

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Note

♦ Metal and plastic covers are installed for the input shaft.

♦ The plastic cover does not require the securing ring -A-.

I = Metal Cover for Input Shaft

Through transmis‐ »Without« securing

Assembly se‐

quence. Refer to

⇒ “11.8 Assembly

Sequence, Trans‐

mission without a

Securing Ring A for

the Metal Cover for

the Input Shaft”,

page 235 .

sion manufacture

date 1/20/08

ring -A-

From transmission

manufacture date

1/21/08

»With« securing

ring -A-

Assembly se‐

quence. Refer to

⇒ “11.9 Assembly

Sequence: I =

Transmission with a

Securing Ring A for

the Metal Cover for

the Input Shaft; II =

Transmission with

Plastic Cover for In‐

put Shaft”,

page 247 .

II = Plastic Cover for Input Shaft

»Without« securing ring -A- Assembly sequence. Refer to

⇒ “11.9 Assembly Sequence: I

= Transmission with a Secur‐

ing Ring A for the Metal Cover

for the Input Shaft; II = Trans‐

mission with Plastic Cover for

Input Shaft”, page 247 .

11.4

Overview - AWD

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6-Speed Manual Transmission 02Q - Edition 05.2013

l -

⇒ “11.5 Transmission Housing

and Gearshift Mechanism, Re‐

moving and Installing”,

page 228 .

ll -

⇒ “11.7 Overview - Input Shaft,

Output Shaft, Differential, Bev‐

el Box and Shift Rods, Remov‐

ing and Installing, for AWD

Vehicles”, page 234

11. Transmission, Disassembling and Assembling

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Note

♦ Metal and plastic covers are installed for the input shaft.

♦ The plastic cover does not require the securing ring -A-.

I = Metal Cover for Input Shaft

Through transmis‐ »Without« securing

Assembly se‐

quence. Refer to

⇒ “11.8 Assembly

Sequence, Trans‐

mission without a

Securing Ring A for

the Metal Cover for

the Input Shaft”,

page 235 .

sion manufacture

date 1/20/08

ring -A-

From transmission

manufacture date

1/21/08

»With« securing

ring -A-

Assembly se‐

quence. Refer to

⇒ “11.9 Assembly

Sequence: I =

Transmission with a

Securing Ring A for

the Metal Cover for

the Input Shaft; II =

Transmission with

Plastic Cover for In‐

put Shaft”,

page 247 .

II = Plastic Cover for Input Shaft

Always »without« securing ring Assembly sequence. Refer to

-A-

⇒ “11.9 Assembly Sequence: I

= Transmission with a Secur‐

ing Ring A for the Metal Cover

for the Input Shaft; II = Trans‐

mission with Plastic Cover for

Input Shaft”, page 247 .

11.5

Transmission Housing and Gearshift Mechanism, Removing and Installing

228

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1 - Bolt

❑ 33 Nm

2 - Flange Shaft with Pressure

Spring

❑ Removing and instal‐

ling. Refer to

⇒ “1.1 Left Flange Shaft

Seal, Replacing”,

page 369 .

❑ Assembling. Refer to

⇒ “5.1 FWD Differential,

Disassembling and As‐

sembling”, page 394 .

3 - Circlip

❑ For the metal cover

❑ Installed from transmis‐

sion date of manufac‐

ture 1/20/08

❑ Not used in plastic cov‐

ers

4 - Cap

❑ Made of metal or plastic

❑ Made of metal: secured

with securing ring

-item 3-

⇒ Item 3 (page 229)

from transmission man‐

ufacture date 1/21/2008

❑ Made of plastic: the cir‐

clip -item 3-

⇒ Item 3 (page 229) was

discontinued

❑ Allocate the compo‐

nents using the Parts

Catalog.

5 - Circlip

❑ For the grooved ball bearing/input shaft -item 1- ⇒ Item 1 (page 310) .

6 - Back-Up Lamp Switch - F4- , 20 Nm

❑ Short after series introduction of transmission with permanent seal -item 7- ⇒ Item 7 (page 229)

7 - Seal

❑ Not installed on all transmissions

❑ Replace after removing

8 - Oil Drain Plug

❑ Tightening specification. Refer to

⇒ Fig. ““Different Versions of the Oil Fill and Drain Plugs”“ , page 192 .

9 - Seal

❑ Replace after removing

10 - Bolt

❑ 6 Nm

11 - Transmission Neutral Position Sensor - G701-

❑ For vehicles with the Start/Stop System

12 - Locking Bolt

❑ Metal locking bolt 45 Nm

❑ Plastic locking bolt 30 Nm

11. Transmission, Disassembling and Assembling

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❑ For the selector shaft

❑ Replace locking bolt after removing

❑ Metal or plastic locking bolt

13 - Bolt

❑ Replace after disassembling. Refer to the Parts Catalog for allocation.

❑ There are different bolts and tightening specifications

♦ Internal hex round head = »through transmission manufacture date 12/6/2009«, aluminum bolt M8 = 8 Nm

and 180° additional turn

♦ Internal hex round head = »through transmission manufacture date 12/7/2009«, aluminum bolt M9 = 15 Nm

and 180° additional turn

♦ Outer hex head = steel bolt = 15 Nm and 90° additional turn

❑ Steel bolts allocation. Refer to

⇒ Fig. ““If the Steel Bolts (out hex head) are the Replacement Part, Pay Attention to the Allocation”“ ,

page 231

14 - Bolt

❑ Replace after disassembling. Refer to the Parts Catalog for allocation.

❑ There are different bolts and tightening specifications

♦ Internal hex round head = »through transmission manufacture date 12/6/2009«, aluminum bolt M8 = 8 Nm

and 180° additional turn

♦ Internal hex round head = »through transmission manufacture date 12/7/2009«, aluminum bolt M9 = 15 Nm

and 180° additional turn

♦ Outer hex head = steel bolt = 15 Nm and 90° additional turn

❑ Steel bolts allocation. Refer to

⇒ Fig. ““If the Steel Bolts (out hex head) are the Replacement Part, Pay Attention to the Allocation”“ ,

page 231

15 - Gearshift Unit

❑ (Gearshift shaft with gearshift cover)

❑ Servicing. Refer to ⇒ “14 Shift Unit, Servicing”, page 273 .

❑ Removing with the transmission installed:

♦ Remove the battery and the battery tray. Refer to ⇒ Electrical Equipment; Rep. Gr. 27 ; Battery; Battery,

Removing and Installing .

♦ The locking elbow -item 6- ⇒ Item 6 (page 262) for adjusting the shift mechanism must not be engaged

♦ Remove the cables and gearshift lever. Refer to ⇒ “1.7 Overview - Operating Cables”, page 85 .

♦ Remove the locking bolt -item 12- ⇒ Item 12 (page 229) and remove the shift mechanism.

16 - Bolt

❑ 20 Nm

❑ Replace after removing

17 - O-Ring

❑ Replace after removing

18 - Clutch Housing

❑ Servicing. Refer to ⇒ “13 Clutch Housing, Servicing”, page 269 .

19 - Transmission Housing

❑ Servicing. Refer to ⇒ “12 Transmission Housing, Servicing”, page 261 .

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6-Speed Manual Transmission 02Q - Edition 05.2013

If the Steel Bolts (out hex head) are the Replacement Part, Pay

Attention to the Allocation

A - Bolt with permanent washer

B - Bolt without washer

C - Bolt with permanent washer

11.6

Overview - Input Shaft, Output Shafts,

Differentials and Shift Rods, Removing

and Installing, for FWD Vehicles

⇒ “11.6.1 Shafts and Gearshift Rods in Transmission Installation

Location”, page 233

11. Transmission, Disassembling and Assembling

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1 - 1st through 4th Gear Output

Shaft

❑ Disassembling and as‐

sembling. Refer to

⇒ “2.2 Output Shaft, 1st

to 4th Gears, Disassem‐

bling and Assembling”,

page 321 .

❑ Installation position. Re‐

fer to

⇒ “11.6.1 Shafts and

Gearshift Rods in

Transmission Installa‐

tion Location”,

page 233 .

2 - Gearshift Rod with 1st Gear

and 2nd Gear Shift Fork

❑ Installation position. Re‐

fer to

⇒ “11.6.1 Shafts and

Gearshift Rods in

Transmission Installa‐

tion Location”,

page 233 .

3 - Gearshift Rod with 3rd Gear

and 4th Gear Shift Fork

❑ Installation position. Re‐

fer to

⇒ “11.6.1 Shafts and

Gearshift Rods in

Transmission Installa‐

tion Location”,

page 233 .

4 - 5th, 6th and Reverse Gear

Output Shaft

❑ Disassembling and as‐

sembling. Refer to

⇒ “3 5th, 6th and Reverse Gear Output Shaft”, page 344 .

❑ Installation position. Refer to

⇒ “11.6.1 Shafts and Gearshift Rods in Transmission Installation Location”, page 233 .

5 - Gearshift Rod with 5th Gear and 6th Gear Shift Fork

❑ Installation position. Refer to

⇒ “11.6.1 Shafts and Gearshift Rods in Transmission Installation Location”, page 233 .

6 - Reverse Gear Shift Fork

❑ Installation position. Refer to

⇒ “11.6.1 Shafts and Gearshift Rods in Transmission Installation Location”, page 233 .

❑ Difference. Refer to ⇒ Fig. ““Reverse Gear Shift Fork Differentiation”“ , page 278

❑ Servicing. Refer to ⇒ “15 Shift Forks, Servicing”, page 277 .

7 - Input Shaft

❑ Disassembling and assembling. Refer to ⇒ “1.1 Overview - Input Shaft”, page 310 .

❑ Replace grooved ball bearing on driveshaft after removing -item 6- ⇒ Item 6 (page 311) .

8 - Reverse Shaft

❑ With a thrust washer

9 - Thrust Washer

10 - Bleeder

❑ Connect with clutch slave cylinder -item 14- ⇒ Item 14 (page 233)

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11 - Clutch Housing

❑ Servicing. Refer to ⇒ “13 Clutch Housing, Servicing”, page 269 .

12 - Input Shaft Seal

❑ Replacing. Refer to ⇒ “2.4 Input Shaft Seal, Replacing”, page 55 .

13 - O-Ring

❑ Install on the line connection

❑ Coat with brake fluid before installing

14 - Clutch Slave Cylinder with Release Bearing

15 - Bolt

❑ Quantity: 3

❑ Replace after removing

❑ Removing and installing -item 4- ⇒ Item 4 (page 50) .

16 - Bolt

❑ 33 Nm

17 - Flange Shaft with Pressure Spring

❑ Removing and installing. Refer to

⇒ “1 Flange Shaft Seals, Manual Transmission Installed, Replacing for FWD Vehicles”, page 369 .

❑ Assembling. Refer to ⇒ “5.1 FWD Differential, Disassembling and Assembling”, page 394 .

18 - Differential

❑ Disassembling and assembling. Refer to

⇒ “5.1 FWD Differential, Disassembling and Assembling”, page 394 .

11.6.1

Shafts and Gearshift Rods in Transmis‐

sion Installation Location

1 - Input Shaft

2 - 1st through 4th Gear Output Shaft

3 - 5th, 6th and Reverse Gear Output Shaft

4 - Reverse Shaft

A - 3rd and 4th Gear Gearshift Rod

B - 1st and 2nd Gear Gearshift Rod

C - 5th and 6th Gear Gearshift Rod

1)

D - Reverse gear shift fork

1)

On some transmissions, the bearing on the reverse gear shift

fork on the shift rod for 5th and 6th gear shift fork -C-. Refer to

⇒ Fig. ““The Reverse Gear Shift Fork -1- is Mounted on the Gear‐

shift Rod with the 5th and 6th Gear Shift Fork -2-.”“ , page 254 .

Difference, reverse gear shift forks. Refer to

⇒ Fig. ““Reverse Gear Shift Fork Differentiation”“ , page 278 .

11. Transmission, Disassembling and Assembling

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11.7

Overview - Input Shaft, Output Shaft, Differential, Bevel Box and Shift Rods,

Removing and Installing, for AWD Vehicles

1 - 1st through 4th Gear Output

Shaft

❑ Installation position. Re‐

fer to

⇒ “11.6.1 Shafts and

Gearshift Rods in

Transmission Installa‐

tion Location”,

page 233 .

❑ Disassembling and as‐

sembling. Refer to

⇒ “2.2 Output Shaft, 1st

to 4th Gears, Disassem‐

bling and Assembling”,

page 321 .

2 - Gearshift Rod with 1st Gear

and 2nd Gear Shift Fork

❑ Installation position. Re‐

fer to

⇒ “11.6.1 Shafts and

Gearshift Rods in

Transmission Installa‐

tion Location”,

page 233 .

❑ Servicing. Refer to

⇒ “15 Shift Forks, Serv‐

icing”, page 277 .

3 - Gearshift Rod with 3rd Gear

and 4th Gear Shift Fork

❑ Installation position. Re‐

fer to

⇒ “11.6.1 Shafts and

Gearshift Rods in

Transmission Installa‐

tion Location”,

page 233 .

❑ Servicing. Refer to

⇒ “15 Shift Forks, Serv‐

icing”, page 277 .

4 - 5th, 6th and Reverse Gear Output Shaft

❑ Installation position. Refer to

⇒ “11.6.1 Shafts and Gearshift Rods in Transmission Installation Location”, page 233 .

❑ Disassembling and assembling. Refer to ⇒ “3 5th, 6th and Reverse Gear Output Shaft”, page 344 .

5 - Gearshift Rod with 5th Gear and 6th Gear Shift Fork

❑ Installation position. Refer to

⇒ “11.6.1 Shafts and Gearshift Rods in Transmission Installation Location”, page 233 .

6 - Reverse Gear Shift Fork

❑ Installation position. Refer to

⇒ “11.6.1 Shafts and Gearshift Rods in Transmission Installation Location”, page 233 .

❑ Difference. Refer to ⇒ Fig. ““Reverse Gear Shift Fork Differentiation”“ , page 278

❑ Servicing. Refer to ⇒ “15 Shift Forks, Servicing”, page 277 .

7 - Input Shaft

❑ Installation position. Refer to

⇒ “11.6.1 Shafts and Gearshift Rods in Transmission Installation Location”, page 233 .

❑ Disassembling and assembling. Refer to ⇒ “1.1 Overview - Input Shaft”, page 310 .

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❑ Replace grooved ball bearing on driveshaft after removing -item 6- ⇒ Item 6 (page 311) .

8 - Reverse Shaft

❑ With a thrust washer

9 - Thrust Washer

10 - Bleeder

❑ Connect with clutch slave cylinder

11 - Clutch Housing

❑ Servicing. Refer to ⇒ “13 Clutch Housing, Servicing”, page 269 .

12 - Input Shaft Seal

❑ Replacing. Refer to ⇒ “2.4 Input Shaft Seal, Replacing”, page 55 .

13 - O-Ring

❑ Install on the line connection

❑ Coat with brake fluid before installing

14 - Clutch Slave Cylinder with Release Bearing

15 - Bolt

❑ Quantity: 3

❑ Replace after removing

❑ Removing and installing -item 4- ⇒ Item 4 (page 50) .

16 - Bolt

❑ Removing and installing -item 13- ⇒ Item 13 (page 401) .

17 - Bolt

❑ 40 Nm + 90°

❑ Quantity: 4

❑ Replace after removing

18 - Bevel Box

❑ Seals, flange shaft bearing and output flange bearing inside the bevel box. Refer to

⇒ “3 Overview - Seals, Flange Shaft Bearing and Output Flange Bearing inside the Bevel Box”,

page 377 .

19 - Differential

❑ Disassembling and assembling. Refer to

⇒ “5.2 Differential, AWD, Disassembling and Assembling”, page 399 .

11.8

Assembly Sequence, Transmission

»without« a Securing Ring -A- for the

Metal Cover for the Input Shaft

Special tools and workshop equipment required

♦ Holding Plate - VW309A-

♦ Holding Fixture - VW313-

♦ Transmission Support - VW353-

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♦ Press Piece - Multiple Use - VW455- or Press Piece - Front

Wishbone - 3160-

♦ Slide Hammer Set - VW771-

♦ Puller - Kukko Internal - 12-16mm - 21/1-

♦ Puller - Kukko Quick Action Separating Tool - 5-60mm - 17/0-

♦ Puller - Kukko Counterstay - 22/1-

♦ Bracket - Multiple Use - 30-211A-

♦ Seal Installer - Crankshaft - T10042-

♦ Locking Sleeve Drift - T10169-

♦ or Locking Sleeve Drift - T10362-

⇒ Fig. ““Lock Sleeve Differentiation”“ , page 266

♦ Seal Installer - Driveshaft - T40008-

♦ Torque Wrench 1331 5-50Nm - VAG1331-

♦ Hot Air Blower - VAG1416-

♦ Shop Crane - Drip Tray - VAS6208-

♦ Socket And Extended Bit - T10107A-

♦ Sealing Compound - AMV 188 200 03-

Disassembling

– Attach the transmission to the assembly stand with bolts

-arrows-.

Note

If one of the fastening holes does not touch the Transmission

Support place shims between the hole and the Transmission

Support .

– Turn the transmission in the assembly stand so that the drain

plug is facing down.

– Place the Drip Tray underneath.

– Drain gear oil from manual transmission.

AWD Transmission

– Remove the bolt for the right flange shaft with the Socket

Wrench for example Socket And Extended Bit - T10107A- .

– Remove the four bolts -arrows- (only three bolts are shown in

the illustration) that attach the bevel box to the transmission.

– Carefully press bevel box off manual transmission while pro‐

tecting it against falling through.

Transmission for FWD

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– Remove the right flange shaft (the illustration shows the left

flange shaft).

Continuation for All

– Remove the clutch slave cylinder with the release bearing

-arrows-.

Make Sure the Gearshift Shaft Is Not Blocked by the Lock Elbow

-arrow-.

– Move the gearshift shaft into neutral.

– Remove the Back-Up Lamp Switch - F4- -1-.

– Remove the locking bolt -2-.

– Then remove the bolts -3-.

– Remove selector shaft with shift cover -4- from transmission

housing.

Note

Use the Pry Lever - 80-200- to press against the spring force of

the securing bushing in direction of -arrow- so that the gearshift

shaft -1- does not touch the securing bushing -2- when removing.

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– Remove the left flange shaft bolt. To do this, install two bolts

into the flange and counterhold the flange using a pry bar.

– Remove the left flange shaft and the pressure spring.

– Remove the bolts -B- that connect the clutch housing to the

transmission housing.

Note

One bolt -arrow- is located outside of the bolting flange.

– Secure the input shaft as follows:

The Stub Shaft Splines on the Input Shaft has Different Lengths

on the Transmission.

– Either place the Press Piece - Multiple Use - VW455- over the

input shaft on the clutch housing.

– Or place the Press Piece - Front Wishbone - 3160- over the

input shaft on the clutch housing.

– Tension the Separating Tool -A-, for example Puller - Kukko

Quick Action Separating Tool - 5-60mm - 17/0- , tightly behind

the splines on the input shaft.

The back of the Puller - Kukko Quick Action Separating Tool -

5-60mm - 17/0- must touch the Press Piece - Multiple Use -

VW455- or the Press Piece - Front Wishbone - 3160- free-of-play.

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– Pierce the rubber piece in the center of the cover -C- using a

screwdriver.

– Remove the cover from the transmission housing.

A - Counter Support , for example Puller - Kukko Counterstay -

22/1-

B - Internal Puller 8 to 12 mm , for example Puller - Kukko Internal

- 12-16mm - 21/01-

Note

♦ Can push through the center of the cover for removing the

cover -1-

♦ Pry the cover -2- carefully off the transmission housing.

Remove the locking ring -C- from the grooved ball bearing on the

input shaft/transmission housing as follows:

– Hold one end of the locking ring secure using the Screwdriver

-A-.

– Pry the other end out of the groove in the grooved ball bearing

in direction of -arrow- using the screwdriver -B-.

– Pry out the rest of the locking ring using the Screwdriver -B-.

– Remove the washer -1- from the transmission housing -2-, if

equipped.

•

If transmission is replaced, see if the washer must be installed.

Refer to ⇒ page 242 .

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– Remove the bolts -A- that attach the transmission housing to

the clutch housing.

– Install the Slide Hammer Set - Adapter 40 - VW771/40- into

the threaded hole in the transmission housing.

– Heat the transmission housing in the area near the bearing

seat for the grooved ball bearing/input shaft to approximately

100 °C (212 °F) for approximately 10 minutes using a Hot Air

Blower , for example, Hot Air Blower - VAG1416- .

– Remove the transmission housing from the clutch housing in

direction of -arrow- using Slide Hammer Set - Hammer -

VW771/1- .

Note

If necessary, carefully pry up all around and alternating between

sides on protruding flange. Be careful not to damage the sealing

surfaces.

– Remove the washer -1- from the grooved ball bearing -2-, if

equipped.

– If transmission is replaced, see if the washer must be reinstal‐

led. Refer to ⇒ page 242 .

– Remove the Separating Tool -A- and the Press Piece - Multiple

Use - VW455- (illustration) or the Press Piece - Front Wish‐

bone - 3160- from the input shaft.

A second technician is needed to help remove the shafts from the

clutch housing.

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– Lift the differential -1- with the left hand. With the right hand,

left the output shaft for 1st to 4th gear together with the shift

rods -2- -arrow A-.

– At the same time, the 2nd technician lifts the input, reverse

and output shaft for 5th/6th gear -3- together with the selector

rods out of the clutch housing -arrow B-.

Note

If necessary, differential can be shifted again in clutch housing

after lifting shafts.

– Remove the input shaft seal.

Note

Always replace the grooved ball bearing on the input shaft

-item 6- ⇒ Item 6 (page 311) .

Assembling

•

A new grooved ball bearing is pressed onto the input shaft

-item 6- ⇒ Item 6 (page 311) .

– Install the input shaft -1-, the 5th/6th gear and reverse gear

output shaft -2- the gearshift rod -3-, the shift fork -4- and the

reverse shaft -5-.

– Then install the differential -1-.

Note

A second technician is needed to help install the shafts into the

clutch housing.

– Hold the output shaft for 1st through 4th gear -3- and the gear‐

shift rods -4- with the right hand.

– Lift the differential -1- slightly with the left hand.

– Have the second technician lift the input shaft, the 5th/6th gear

output shaft and reverse gear -2- together with the reverse

shaft slightly at the same time.

– Install the 1st to 4th gear output shaft in direction of -arrow-.

•

Places of input shaft, output shafts and final drive gear/differ‐

ential must engage.

– Together with a second technician, now displace shafts and

differential in their bearing seats.

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– Secure the Bracket - Multiple Use - 30-211A- for the input shaft

on the clutch housing.

Note

The clutch housing is shown in the illustration rotated 180°.

– Install the bolt -A- just far enough until the input shaft starts to

lift.

With Some Transmissions, there are Flattened Sides -A- on the

input Shaft Grooved Ball Bearing and on the Bearing Mount -B-.

Check the input shaft grooved ball bearing and the transmission

housing.

Input Shaft Grooved Ball Bearing and Transmission Housing

No flattened sides on the grooved ball bearing -A- and bearing

mount -B-. Refer to ⇒ page 242

Flattened sides on the grooved ball bearing -A- and bearing

mount -B-. Refer to

⇒ Fig. ““On Some Transmissions”“ , page 243

From Transmission Build Date 4.10.06 through Approximately

1.21.08

One Washer Each Is Inserted above and below the Input Shaft

Grooved Ball Bearing -item 6- ⇒ Item 6 (page 311) .

Upper washer

Lower washer

Outer circumfer‐

ence

78.6 mm

85 mm

Outer circumfer‐

ence

Measure the Shoulder Above the Grooved Ball Bearing Mount.

Shoulder Above

Grooved Ball Bear‐

ing

Dimension “a”

Upper Washer

Through transmis‐

sion build date

4/9/06

10 mm

no

From transmission

10.7 mm

yes

build date 10 04 6

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The Area Under the Grooved Ball Bearing Seat in the Transmis‐

sion Housing Has Been Changed -arrow-

Area Below the Bearing Seat

Lower Washer

no

Through transmis‐

sion build date

4/9/06

not deeper.

From transmission

slightly deeper.

yes

build date 10 04 6

– Place a washer (85 mm outer circumference) -1- on the

grooved ball bearing -2-.

On Some Transmissions

Flattened Areas -A- on the Input Shaft Grooved Ball Bearing and

Bearing Mount -B-.

•

Do not place any washers above and below the grooved ball

bearing.

•

The flattened sides -A- on the grooved ball bearing and on the

bearing mount -B- must align in the transmission housing.

– Mark the flattened side with color.

– Transfer the markings to the upper area of the grooved ball

bearing and to the upper area of the transmission housing

bearing mount (⇒ next figure).

– Heat the transmission housing in the area near the bearing

seat for the grooved ball bearing/input shaft to approximately

100 °C (212 °F) for approximately 10 minutes using a Hot Air

Blower , for example, Hot Air Blower - VAG1416- .

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Note

♦ It is necessary to heat the transmission housing so that the

grooved ball bearing is not damaged when the housing is be‐

ing installed.

♦ Align the marking on the grooved ball bearing -A- with the

marking on the transmission housing -B- and mount the trans‐

mission housing.

– For all transmissions heat the transmission housing with Hot

Air Blower - VAG1416- for example the Hot Air Blower -

VAG1416- in the grooved ball bearing/input shaft bearing set

area to 100 °C (212 °F) for approximately 10 minutes.

– Apply Sealing Paste - AMV 188 200 03- evenly onto the seal‐

ing surface of the clutch housing.

– Install the transmission housing and tighten the new bolts

-A-, -B and C- to the tightening specification.

If the steel bolts (out hex head) are the replacement part, pay

attention to the allocation:

A - Bolt with permanent washer

B - Bolt without washer

C - Bolt with permanent washer

– If a washer was mounted on the grooved ball bearing before

installation, then a washer -1- (outer diameter = 78.6 mm) must

be installed after installation -2-. Refer to ⇒ page 242 .

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– Install the grooved ball bearing/input shaft locking ring -1-.

– Remove the Bracket - Multiple Use - 30-211A- for the input

shaft.

– Install the selector shaft lock sleeve all the way onto the tool.

Refer to ⇒ Fig. ““Lock Sleeve Differentiation”“ , page 266 .

– Turn the transmission with opening for selector shaft in as‐

sembly stand upward.

Note

Use the Pry Lever - 80-200- to press against the spring force of

the securing bushing direction of -arrow- when installing so that

the gearshift shaft -1- does not touch the securing bushing -2-

when removing.

– Install the gearshift shaft -1- into the lower bearing -2- and into

the shift forks -3-.

Note

The cover is not shown in the illustration -item 2-

⇒ Item 2 (page 262) .

– Push the gearshift shaft -1- against the retaining sleeve -2- in

direction of -arrow- and guide is through the shift fork all the

way down using the shift finger -3-.

•

The gearshift cover -4- must stand parallel to the bolting sur‐

face on the transmission housing.

•

It must be possible to move the gearshift shaft easily (forward

and backward).

Note

If the gearshift cover is at an angle to the bolting surface, then the

gearshift shaft is not installed into the lower bearing.

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– Tighten the bolts -3- on the cover/gearshift shaft -4-.

– Install the locking bolt -2-, lock elbow -arrow- must not be in‐

stalled when doing so.

– Install the Back-Up Lamp Switch - F4- -1-.

– Install the input shaft seal.

– Install clutch slave cylinder with release bearing and tighten

bolts -arrows- to tightening specification -item 4-

⇒ Item 4 (page 50) .

– Move the gearshift lever (selector lever) through all the gears.

– Drive the cap into transmission housing to all the way in the

Seal Installer - Crankshaft - T10042- .

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– Install the left flange shaft and pressure spring, the thrust

washer and the tapered ring.

Transmission for FWD

– Install the right flange shaft and pressure spring, the thrust

washer and the tapered ring.

AWD Transmission

Install the bevel box into the manual transmission as follows:

– With a manual transmission, lubricate the differential splines

with Grease for Clutch Disc Shaft Splines - G 000 100- .

– Slide on bevel box completely on manual transmission, while

doing this, join splines of input shaft/bevel box centrally with

differential.

– Bring the right driveshaft splines and the differential bevel gear

into alignment. Rotate the flange shaft if necessary.

– With proper tooth position and central guiding, bevel box slips

up to stop against manual transmission.

Note

Do not pull bevel box with mounting bolts against the transmis‐

sion. Otherwise bevel box is canted and mounting eyelets can

break off.

– Tighten the 4 bevel box connecting bolts -arrows- (only 3 are

shown in illustration) at manual transmission.

– Tighten the bolt for the right flange shaft with the Socket

Wrench for example Socket And Extended Bit - T10107A- .

11.9

Assembly Sequence: I = Transmission

»with« a Securing Ring -A- for the Metal

Cover for the Input Shaft; II = Transmis‐

sion with Plastic Cover for Input Shaft

The Plastic Cover for the Input Shaft Does Not Require the Se‐

curing Ring -A-.

Special tools and workshop equipment required

♦ Holding Plate - VW309A-

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♦ Holding Fixture - VW313-

♦ Transmission Support - VW353-

♦ Press Piece - Multiple Use - VW455- or Press Piece - Front

Wishbone - 3160-

♦ Slide Hammer Set - VW771-

♦ Puller - Kukko Internal - 12-16mm - 21/1-

♦ Puller - Kukko Quick Action Separating Tool - 5-60mm - 17/0-

♦ Puller - Kukko Counterstay - Kukko 22/1-

♦ Bracket - Multiple Use - 30-211A-

♦ Seal Installer - Drive Flange - T10143- or Seal Installer - Out‐

put Shaft Oil Seal - T10180-

♦ Locking Sleeve Drift - T10169-

♦ or Locking Sleeve Drift - T10362-

⇒ Fig. ““Lock Sleeve Differentiation”“ , page 266

♦ Seal Installer - Driveshaft - T40008-

♦ Torque Wrench 1331 5-50Nm - VAG1331-

♦ Hot Air Blower - VAG1416-

♦ Shop Crane - Drip Tray - VAS6208-

♦ Socket And Extended Bit - T10107A-

♦ Sealing Compound - AMV 188 200 03-

Disassembling

– Attach the transmission to the assembly stand with bolts

-arrows-.

Note

If one of the fastening holes does not touch the Transmission

Support place shims between the hole and the Transmission

Support .

– Turn the transmission in the assembly stand so that the drain

plug is facing down.

– Place the Drip Tray underneath.

– Drain gear oil from manual transmission.

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AWD Transmission

– Remove the bolt for the right flange shaft with the Socket

Wrench for example Socket And Extended Bit - T10107A- .

– Remove the four bolts -arrows- (only three bolts are shown in

the illustration) that attach the bevel box to the transmission.

– Carefully press bevel box off manual transmission while pro‐

tecting it against falling through.

Transmission for FWD

– Remove the right flange shaft (the illustration shows the left

flange shaft).

Continuation for All

– Remove the clutch slave cylinder with the release bearing

-arrows-.

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

Transmission Neutral Position Sensor - G701- -arrow-.

11. Transmission, Disassembling and Assembling

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Make Sure the Gearshift Shaft Is Not Blocked By the Lock Elbow

-arrow-.

– Move the gearshift shaft into neutral.

– Remove the Back-Up Lamp Switch - F4- -1-.

– Remove the locking bolt -2-.

– Then remove the bolts -3-.

– Remove selector shaft with shift cover -4- from transmission

housing.

Note

Use the Pry Lever - 80-200- to press against the spring force of

the securing bushing in direction of -arrow- so that the gearshift

shaft -1- does not touch the securing bushing -2- when removing.

– Remove the left flange shaft bolt. To do this, install two bolts

into the flange and counterhold the flange using a pry bar.

– Remove the left flange shaft and the pressure spring.

– Remove the bolts -B- that connect the clutch housing to the

transmission housing.

Note

One bolt -arrow- is located outside of the bolting flange.

– Secure the input shaft as follows:

The Stub Shaft Splines on the Input Shaft has Different Lengths

on the Transmission.

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– Either place the Press Piece - Multiple Use - VW455- over the

input shaft on the clutch housing.

– Or place the Press Piece - Front Wishbone - 3160- over the

input shaft on the clutch housing.

– Tension the Separating Tool -A-, for example Puller - Kukko

Quick Action Separating Tool - 5-60mm - Kukko 17/0- , tightly

behind the splines on the input shaft.

The back of the Separating Tool - 5-60mm must touch the Press

Piece - Multiple Use - VW455- or the Press Piece - Front Wish‐

bone - 3160- free-of-play.

Metal Cover

– Remove the cap/input shaft circlip -A-.

– Pierce the rubber piece in the center of the cover -C- using a

Screwdriver .

– Remove the cover from the transmission housing.

A - Counter Support , for example Puller - Kukko Counterstay -

22/1-

B - Internal Puller 8 to 12 mm , for example Puller - Kukko Internal

- 12-16mm - 21/1-

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Plastic Cover

Carefully remove all tabs -A-. Do not damage the transmission

housing when doing so.

– Pry out the cover.

•

Ensure that the individual cover parts are removed as neces‐

sary.

Continuation for All

Remove the locking ring -C- from the grooved ball bearing on the

input shaft/transmission housing as follows:

– Hold one end of the locking ring secure using the Screwdriver

-A-.

– Pry the other end out of the groove in the grooved ball bearing

in direction of -arrow- using the screwdriver -B-.

– Pry out the rest of the locking ring using the Screwdriver -B-.

– Remove the bolts -A- that attach the transmission housing to

the clutch housing.

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– Install Slide Hammer Set - Adapter 40 - VW771/40- into the

threaded hole in the transmission housing.

– Heat the transmission housing in the area near the bearing

seat for the grooved ball bearing/input shaft to approximately

100 °C (212 °F) for approximately 10 minutes using a Hot Air

Blower , for example, Hot Air Blower - VAG1416- .

– Remove the transmission housing from the clutch housing in

direction of -arrow- using Slide Hammer Set - Hammer -

VW771/1- .

Note

If necessary, carefully pry up all around and alternating between

sides on protruding flange. Be careful not to damage the sealing

surfaces.

– Remove the Separating Tool -A- and the Press Piece - Multiple

Use VW455 or the Press Piece - Front Wishbone - 3160- from

the input shaft.

A second technician is needed to help remove the shafts from the

clutch housing.

– Lift the differential -1- with the left hand. With the right hand,

lift the output shaft for 1st to 4th gear together with the gearshift

rods -2- -arrow A-.

– At the same time, the 2nd technician lifts the input, reverse

and output shaft for 5th/6th gear and reverse gear -3- together

with the selector rods out of the clutch housing -arrow B-

Note

If necessary, differential can be shifted again in clutch housing

after lifting shafts.

– Remove the input shaft seal.

Note

Always replace the grooved ball bearing on the input shaft

-item 6- ⇒ Item 6 (page 311) .

Assembling

•

A new grooved ball bearing is pressed onto the input shaft

-item 6- ⇒ Item 6 (page 311) .

11. Transmission, Disassembling and Assembling

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– Install the input shaft -1-, the 5th/6th gear and reverse gear

output shaft -2-, the gearshift rod -3-, the reverse gear shift

fork -4- and reverse shaft -5-.

Pay Attention to the Different Bearing for the Reverse Gear Shift

Fork.

The Reverse Gear Shift Fork -1- is Mounted on the Axle -2- behind

the 5th and 6th Gear Shift Rod -3-.

The Reverse Gear Shift Fork -1- is Mounted on the Gearshift Rod

with the 5th and 6th Gear Shift Fork -2-.

Continuation for All

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– Then install the differential -1-.

Note

A second technician is needed to help install the shafts into the

clutch housing.

– Hold the output shaft for 1st through 4th gear -3- and the gear‐

shift rods -4- with the right hand.

– Slightly lift the differential with the left hand.

– Have the second technician lift the input shaft, the 5th/6th gear

output shaft and reverse gear -2- together with the reverse

shaft slightly at the same time.

– Install the 1st to 4th gear output shaft in direction of -arrow-.

•

Places of input shaft, output shafts and final drive gear/differ‐

ential must engage.

– Together with a second technician, now displace shafts and

differential in their bearing seats.

– Secure the Bracket - Multiple Use - 30-211A- for the input shaft

to the clutch housing.

Note

The clutch housing is shown in the illustration rotated 180°.

– Install the bolt -A- just far enough until the input shaft starts to

lift.

The Grooved Ball Bearing/Input Shaft Only Fits in One Position

in the Transmission Housing.

There is a flattened area on the grooved ball bearing and the

bearing mount.

•

If the flattened areas -A and B- are present, do not insert any

washers above and below the grooved ball bearing. Refer to

⇒ “1.2.1 Grooved Ball Bearing Changes”, page 315 .

•

The flattened sides -A- on the grooved ball bearing and on the

bearing mount -B- must align in the transmission housing.

– Mark the flattened side with color.

– Transfer the markings to the upper area of the grooved ball

bearing and to the upper area of the transmission housing

bearing mount (⇒ next figure).

– Heat the transmission housing in the area near the bearing

seat for the grooved ball bearing/input shaft to approximately

100 °C (212 °F) for approximately 10 minutes using a Hot Air

Blower , for example, Hot Air Blower - VAG1416- .

11. Transmission, Disassembling and Assembling

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Note

♦ It is necessary to heat the transmission housing so that the

grooved ball bearing is not damaged when the housing is be‐

ing installed.

♦ Apply Sealing Paste - AMV 188 200 03- evenly onto the seal‐

ing surface of the clutch housing.

♦ Align the marking on the grooved ball bearing -A- with the

marking on the transmission housing -B- and mount the trans‐

mission housing.

– Install the transmission housing and tighten the new bolts

-A, B and C- to the tightening specification.

If the steel bolts (out hex head) are the replacement part, pay

attention to the allocation:

A - Bolt with permanent washer

B - Bolt without washer

C - Bolt with permanent washer

– Install the grooved ball bearing/input shaft locking ring -1-.

– Remove the Bracket - Multiple Use - 30-211A- for the input

shaft.

– Install the selector shaft lock sleeve all the way onto the tool.

Refer to ⇒ Fig. ““Lock Sleeve Differentiation”“ , page 266 .

– Turn the transmission with opening for selector shaft in as‐

sembly stand upward.

Note

Use the Pry Lever - 80-200- to press against the spring force of

the securing bushing direction of -arrow- when installing so that

the gearshift shaft -1- does not touch the securing bushing -2-

when removing.

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– Install the gearshift shaft -1- into the lower bearing -2- and into

the shift forks -3-.

Note

The cover is not shown in the illustration -item 2-

⇒ Item 2 (page 262) .

– Push the gearshift shaft -1- against the retaining sleeve -2- in

direction of -arrow- and guide is through the shift fork all the

way down using the shift finger -3-.

•

The gearshift cover -4- must stand parallel to the bolting sur‐

face on the transmission housing.

•

It must be possible to move the gearshift shaft easily (forward

and backward).

Note

If the gearshift cover is at an angle to the bolting surface, then the

gearshift shaft is not installed into the lower bearing.

– Tighten the bolts -3- on the gearshift cover -4-.

– Install the locking bolt -2-, lock elbow -arrow- must not be in‐

stalled when doing so.

– Install the Back-Up Lamp Switch - F4- -1-.

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

Transmission Neutral Position Sensor - G701- -arrow- and

tighten the bolt to 6 Nm.

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– Install the input shaft seal so that it is flush.

– Install the clutch slave cylinder with release bearing. Refer to

⇒ “2 Clutch Release Mechanism, Servicing”, page 50 .

– Move the gearshift lever (selector lever) through all the gears.

– Install the cover as follows:

Cover Differentiation

-I- = metal cover; secured with securing ring -A-.

-II- = plastic cover; without securing ring.

Allocation

Mounting Area for

the Cover

Cap

Installation

-Arrow A- = vertical

Made of metal

Refer to

⇒ Fig. ““Metal Cov‐

er”“ , page 259

-Arrow B- = at an

angle

Plastic

Refer to

⇒ Fig. ““Plastic Cov‐

er”“ , page 259

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Metal Cover

– Install the cap all the way into the transmission housing.

– Secure the cap with the locking ring -A-.

Plastic Cover

– Install the cap all the way into the transmission housing.

Continuation for All

•

Always pay attention to the cover allocation. Refer to

⇒ Fig. ““Allocation”“ , page 258 .

•

Leaks in the case of incorrect installation.

Allocate the cap. Refer to the Parts Catalog.

– Install the left flange shaft and pressure spring, the thrust

washer and the tapered ring.

Transmission for FWD

– Install the right flange shaft and pressure spring, the thrust

washer and the tapered ring.

11. Transmission, Disassembling and Assembling

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AWD Transmission

Install the bevel box into the manual transmission as follows:

– With a manual transmission, lubricate the differential splines

with Grease for Clutch Disc Shaft Splines - G 000 100- .

– Slide on bevel box completely on manual transmission, while

doing this, join splines of input shaft/bevel box centrally with

differential.

– Bring the right drive axle splines and the differential bevel gear

into alignment. Rotate the flange shaft if necessary.

– With proper tooth position and central guiding, bevel box slips

up to stop against manual transmission.

Note

Do not pull bevel box with mounting bolts against the transmis‐

sion. Otherwise bevel box is canted and mounting eyelets can

break off.

– Tighten the 4 bevel box connecting bolts -arrows- (only 3 are

shown in illustration) at manual transmission.

– Tighten the bolt for the right flange shaft with the Socket

Wrench for example Socket And Extended Bit - T10107A- .

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12

Transmission Housing, Servicing

Special tools and workshop equipment required

♦ Bearing Driver - Multiple Use - VW244B-

♦ Transmission Support - VW353-

♦ Press Plate - VW401-

♦ Press Plate - VW402-

♦ Press Piece - Rod - VW407-

♦ Press Piece - 37mm - VW416B-

♦ Guide Pin - VW436A-

♦ Press Piece - Guide Pin - VW439-

♦ Slide Hammer Set - Hammer - VW771-

♦ Crankshaft Holding Fixture - VW801-

♦ Guide Pins - 10-15-

♦ Press Piece - Pivot Mount Bushing - 3124-

♦ Bearing Installer - Crankshaft Pilot Bearing - 3264-

♦ Subframe Support Tool - 3290-

♦ Torque Wrench 1331 5-50Nm - VAG1331-

♦ Bushing Driver - Selector Shaft - T10168-

♦ Locking Sleeve Drift - T10169- or Locking Sleeve Drift -

T10362- ⇒ Fig. ““Lock Sleeve Differentiation”“ , page 266

♦ Breather Tube Tool - T10203-

♦ -1- Puller - Kukko Internal - 14-19mm - 21/2-

♦ -1- Puller - Kukko Internal - 20-30mm - 21/4-

♦ -4- Puller - Kukko Counterstay - 22/2-

♦ Thread adaptor from Puller - Kukko Counterstay - 22/1-

12. Transmission Housing, Servicing

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1 - Transmission Housing

❑ When replacing: adjust

the output shafts and

differential. Refer to

⇒ “4 Overview - Adjust‐

ment”, page 393

❑ Changes to the grooved

ball bearing/input shaft

mount area -item 3-

⇒ Item 3 (page 310)

❑ Changes near the

mount area for the cov‐

er/input shaft -item 4-

⇒ Item 4 (page 229)

❑ Refer to the Parts Cata‐

log.

2 - Cap

❑ Removing. Refer to

⇒ Fig. ““Removing the

Cover -A- ”“ ,

page 264 .

❑ Installing. Refer to

⇒ Fig. ““Installing the

Cover”“ , page 264 .

3 - Oil Drain Plug

❑ Tightening specifica‐

tion. Refer to

⇒ Fig. ““Different Ver‐

sions of the Oil Fill and

Drain Plugs”“ ,

page 192 .

4 - Seal

❑ If present, replace after

removing

5 - Oil Filler Plug

❑ Tightening specification. Refer to

⇒ Fig. ““Different Versions of the Oil Fill and Drain Plugs”“ , page 192 .

6 - Locking Elbow

❑ Adjusting the gearshift mechanism. Refer to ⇒ “1.11 Selector Mechanism, Adjusting”, page 97 .

❑ Can be replaced with transmission not disassembled

❑ Removing. Refer to ⇒ Fig. ““Removing the Locking Elbow for the Gearshift Shaft”“ , page 264 .

❑ Installation position. Refer to ⇒ Fig. ““Installed Position: Locking Elbow”“ , page 265 .

❑ Installing. Refer to

⇒ Fig. ““Drive Lock Elbow -arrow- for Selector Shaft In Up to Tool Stop.”“ , page 265 .

7 - Bearing Bushing

❑ For the selector rods

❑ Removing. Refer to ⇒ Fig. ““Removing the Shift Rod Bearing Bushing”“ , page 265 .

❑ Installing. Refer to

⇒ Fig. ““Installing the Shift Rod Bearing Bushing All the Way Onto the Tool”“ , page 265 .

8 - Retaining Sleeve

❑ Removing when the transmission is disassembled. Refer to

⇒ Fig. ““Removing the Retaining Sleeve -A- from the Transmission Housing”“ , page 266

❑ Removing when the transmission is not disassembled. Refer to

⇒ Fig. ““Removing the Retaining Sleeve on A Transmission Not Disassembled using the Guide Pins

-10-15- .”“ , page 266

❑ Different retaining sleeves. Refer to ⇒ Fig. ““Lock Sleeve Differentiation”“ , page 266

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❑ Installing a retaining sleeve with a shoulder. Refer to

⇒ Fig. ““Drive In Lock Sleeve with Shoulder as far as Stop on Tool”“ , page 266

❑ Installing the retaining sleeve without a shoulder. Refer to

⇒ Fig. ““Drive in Lock Sleeve without Shoulder as far as Stop on Tool”“ , page 267

9 - Needle Sleeve

❑ For the reverse shaft

❑ Always replace if removed

❑ Removing. Refer to

⇒ Fig. ““Removing the Reverse Shaft Needle Sleeve from the Transmission Housing”“ , page 267 .

❑ Installing. Refer to

⇒ Fig. ““Installing the Needle Sleeve -A- into the Transmission Housing”“ , page 267 .

10 - Outer Race/Tapered Roller Bearing

❑ Output shaft, 5th/6th and reverse gears

❑ Removing and installing. Refer to

⇒ “3.1 Overview - Input Shaft, 5th/6th and Reverse Gears”, page 344 .

❑ When replacing: adjust output shaft for 5th/6th and reverse gear. Refer to

⇒ “3.3 Output Shaft, 5th, 6th and Reverse Gears, Adjusting”, page 353 .

11 - Shim

❑ Output shaft, 5th/6th and reverse gears

❑ Adjustment overview. Refer to ⇒ “4 Overview - Adjustment”, page 393 .

12 - Outer Race/Tapered Roller Bearing

❑ Output shaft, 1st to 4th gears

❑ Removing and installing. Refer to

⇒ “2.2 Output Shaft, 1st to 4th Gears, Disassembling and Assembling”, page 321 .

❑ Adjust, if output shaft for 1st to 4th gear is replaced. Refer to

⇒ “2.3 Output Shaft 1st through 4th Gear, Adjusting”, page 340 .

13 - Shim

❑ Output shaft, 1st to 4th gears

❑ Adjustment overview. Refer to ⇒ “4 Overview - Adjustment”, page 393 .

14 - Outer Race/Tapered Roller Bearing

❑ For the differential

❑ FWD, removing and installing. Refer to

⇒ “5.1 FWD Differential, Disassembling and Assembling”, page 394 .

❑ AWD, removing and installing. Refer to

⇒ “5.2 Differential, AWD, Disassembling and Assembling”, page 399 .

❑ When replacing: adjust the differential. Refer to ⇒ “5.3 Differential, Adjusting”, page 405

15 - Shim

❑ For the differential

❑ Adjustment overview. Refer to ⇒ “4 Overview - Adjustment”, page 393 .

16 - Bearing Bushing

❑ For the selector shaft

❑ Removing. Refer to ⇒ Fig. ““Removing the Selector Shaft Bearing Bushing”“ , page 267 .

❑ Installing. Refer to

⇒ Fig. ““Installing the Gearshift Shaft Bearing Bushing -A- All the Way onto the Tool”“ , page 268 .

17 - Plugs

❑ Removing. Refer to ⇒ Fig. ““Removing the Plug -1- ”“ , page 268 .

❑ Installing. Refer to ⇒ Fig. ““Installing the Plug -1- ”“ , page 268 .

18 - Seal

❑ For the left flange shaft

❑ FWD, replacing. Refer to ⇒ “1.1 Left Flange Shaft Seal, Replacing”, page 369 .

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❑ AWD, replacing. Refer to ⇒ “1.1 Left Flange Shaft Seal, Replacing”, page 369 .

Removing the Cover -A-

– Pierce the rubber in the center of the cover with a screwdriver

-B- and pry it out of the cover in direction of -arrow-.

Installing the Cover

Removing the Locking Elbow for the Gearshift Shaft

– Remove the elbow in its unlocked position.

– Guide a screwdriver -A- into hole of lock elbow -B-.

– Pry out the locking elbow in direction of -arrow-.

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Installed Position: Locking Elbow

•

The mark on the locking elbow -arrow- must point toward the

connection on the clutch slave cylinder -1-.

Dimension -a- must be approximately 45°.

•

Drive Lock Elbow -arrow- for Selector Shaft In Up to Tool Stop.

Note

The locking elbow must be unlocked when being installed.

Removing the Shift Rod Bearing Bushing

A - 14.5 to 18.5 mm Internal Puller , for example Puller - Kukko

Internal - 14-19mm - 21/2-

B - Counter Support , for example, Puller - Kukko Counterstay -

22/2-

Installing the Shift Rod Bearing Bushing All the Way Onto the Tool

12. Transmission Housing, Servicing

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Removing the Retaining Sleeve -A- from the Transmission Hous‐

ing

– Place transmission housing on Press Plate - VW401- and

Press Plate - VW402- in such a way so that the alignment

sleeves inside the transmission housing do not get damaged.

Removing the Retaining Sleeve on A Transmission Not Disas‐

sembled using the Guide Pins - 10-15- .

•

Locking bolt and selector shaft removed.

– Turn the transmission so that the retaining sleeve cannot fall

into the transmission.

Lock Sleeve Differentiation

The following lock sleeves may be installed:

Lock sleeve with a shoulder -arrow 1-. Refer to

⇒ Fig. ““Drive In Lock Sleeve with Shoulder as far as Stop on

Tool”“ , page 266 .

Lock sleeve without a shoulder -arrow 2-

⇒ Fig. ““Drive in Lock Sleeve without Shoulder as far as Stop on

Tool”“ , page 267 .

Allocate the components. Refer to the Parts Catalog.

Drive In Lock Sleeve with Shoulder as far as Stop on Tool

•

The transmission housing is bolted to the clutch housing.

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Drive in Lock Sleeve without Shoulder as far as Stop on Tool

The transmission housing is bolted to the clutch housing.

•

Removing the Reverse Shaft Needle Sleeve from the Transmis‐

sion Housing

A - Internal Puller - 23.5 - 30 mm , for example Puller - Kukko

Internal - 20-30mm - 21/4-

B - Counter Support , for example, Puller - Kukko Counterstay -

22/2-

Note

The needle sleeve will get damaged when it is removed and must

be replaced.

Installing the Needle Sleeve -A- into the Transmission Housing

– While installing, place thrust washer -B- for the reverse shaft

onto the needle sleeve.

– Support the transmission housing with the Press Piece -

37mm - VW416B- directly under the bearing mount.

Removing the Selector Shaft Bearing Bushing

– Use the thread adapter from Puller - Kukko Counterstay - 22/1-

-arrow-.

– Hold the spindle on the Subframe Support Tool - 3290- and

turn the nut -B-.

A - 14.5 to 18.5 mm Internal Puller , for example Puller - Kukko

Internal - 14-19mm - 21/2-

12. Transmission Housing, Servicing

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Installing the Gearshift Shaft Bearing Bushing -A- All the Way on‐

to the Tool

Removing the Plug -1-

– Remove the plug -1- from the inside of the transmission hous‐

ing to the outside.

Installing the Plug -1-

– Using the Bearing Installer - Crankshaft Pilot Bearing - 3264- ,

drive in the sealing plugs to dimension -a- approximately 3 mm

below the upper edge of the housing.

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13

Clutch Housing, Servicing

Special tools and workshop equipment required

♦ Press Piece - Rod - VW407-

♦ Bushing Driver - Selector Shaft - T10168-

♦ Seal Installer - Driveshaft - T40008-

♦ Puller - Kukko Internal - 14-19mm - 21/2-

♦ Puller - Kukko Internal - 20-30mm - 21/4-

♦ Puller - Kukko Counterstay - 22/1-

♦ Puller - Kukko Counterstay - 22/2-

1 - Bearing Bushing

❑ For the selector rods

❑ Always replace if re‐

moved

❑ Removing. Refer to

⇒ Fig. ““Removing the

Shift Rod Bearing Bush‐

ing”“ , page 271 .

❑ Installing. Refer to

⇒ Fig. ““Installing the

Shift Rod Bearing Bush‐

ing All the Way onto the

Tool”“ , page 271 .

2 - Axle for the Reverse Gear

Shift Fork

❑ The axle cannot be re‐

moved with workshop

tools.

❑ A new axle must be in‐

stalled when using a

new clutch housing. Re‐

fer to

⇒ Fig. ““Installing the

Axle for the Reverse

Gear Shift Fork into the

Clutch Housing”“ ,

page 272

❑ Mount the reverse gear

shift fork on the axle.

Refer to

⇒ Fig. ““The Reverse

Gear Shift Fork -1- is

Mounted on the

Axle -2- behind the 5th

and 6th Gear Shift

Rod -3-.”“ , page 254

❑ Bearing on the shift rod

for the 5th and 6th gear shift fork. Refer to

⇒ Fig. ““The Reverse Gear Shift Fork -1- is Mounted on the Gearshift Rod with the 5th and 6th Gear Shift

Fork -2-.”“ , page 254

❑ Refer to the Parts Catalog.

3 - Needle Sleeve

❑ For the reverse shaft

❑ Always replace if removed

❑ Removing. Refer to ⇒ Fig. ““Removing the Needle Sleeve from the Clutch Housing”“ , page 271 .

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❑ Installing. Refer to ⇒ Fig. ““Installing the Needle Sleeve -A- into the Clutch Housing”“ , page 271 .

4 - Alignment Sleeve

❑ Quantity: 2

5 - Clutch Housing

❑ When replacing: adjust the output shafts and differential. Refer to

⇒ “4 Overview - Adjustment”, page 393

6 - Input Shaft Seal

❑ Removing. Refer to ⇒ Fig. ““Remove the Seal for the Input Shaft”“ , page 272 .

❑ Installing. Refer to ⇒ Fig. ““Installing the Seal for the Input Shaft”“ , page 272 .

7 - Seal

❑ FWD - for the right flange shaft

♦ Replace the right flange shaft for FWD. Refer to ⇒ “1.2 Right Flange Shaft Seal, Replacing”, page 370

❑ For the bevel box for AWD vehicles; between the manual transmission and the bevel box

♦ Replace if the manual transmission is installed and for AWD vehicles. Refer to

⇒ “2.3 Bevel Box Seal, Replacing, with Manual Transmission Installed”, page 375

♦ Remove using the Puller - Crankshaft/Power Steering Seal - 2 - T20143/2-

♦ Can be driven in to the stop with a Seal Installer - Crankshaft - T40007- in a disassembled transmission.

8 - Washer

❑ For the differential

❑ Installed position: shoulder on inner diameter faces toward seal -item 7- ⇒ Item 7 (page 270)

9 - Outer Race/Tapered Roller Bearing

❑ For the differential

❑ FWD, removing and installing. Refer to

⇒ “5.1 FWD Differential, Disassembling and Assembling”, page 394 .

❑ AWD, removing and installing. Refer to

⇒ “5.2 Differential, AWD, Disassembling and Assembling”, page 399 .

❑ When replacing: adjust the differential. Refer to ⇒ “5.3 Differential, Adjusting”, page 405

10 - Oil Deflector Ring

❑ Installed position: shoulder at hole points toward output shaft

11 - Outer Race/Tapered Roller Bearing

❑ Output shaft, 1st to 4th gears

❑ Removing and installing. Refer to

⇒ “2.2 Output Shaft, 1st to 4th Gears, Disassembling and Assembling”, page 321 .

❑ Adjust, if output shaft for 1st to 4th gear is replaced. Refer to

⇒ “2.3 Output Shaft 1st through 4th Gear, Adjusting”, page 340 .

12 - Outer Race/Tapered Roller Bearing

❑ Output shaft, 5th/6th and reverse gears

❑ Removing and installing. Refer to

⇒ “3.1 Overview - Input Shaft, 5th/6th and Reverse Gears”, page 344 .

❑ When replacing: adjust output shaft for 5th/6th and reverse gear. Refer to

⇒ “3.3 Output Shaft, 5th, 6th and Reverse Gears, Adjusting”, page 353 .

13 - Washer

❑ Output shaft, 5th/6th and reverse gears

❑ Always 0.65 mm thick

14 - Cylindrical Roller Bearing

❑ For the input shaft

❑ Removing and installing. Refer to ⇒ “1.1 Overview - Input Shaft”, page 310 .

15 - Magnet

❑ Held in place by housing joint surface

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16 - Cap

❑ Not on all clutch housings

Removing the Shift Rod Bearing Bushing

A - Counter Support , for example Puller - Kukko Counterstay -

22/1-

B - 14.5 to 18.5 mm Internal Puller , for example Puller - Kukko

Internal - 14-19mm - 21/2-

Installing the Shift Rod Bearing Bushing All the Way onto the Tool

Removing the Needle Sleeve from the Clutch Housing

A - Counter Support , for example, Puller - Kukko Counterstay -

22/2-

B - Internal Puller - 23.5 - 30 mm , for example Puller - Kukko

Internal - 20-30mm - 21/4-

Note

The needle sleeve will get damaged when it is removed and must

be replaced.

Installing the Needle Sleeve -A- into the Clutch Housing

– While installing, place thrust washer -B- for the reverse shaft

onto the needle sleeve.

13. Clutch Housing, Servicing

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Remove the Seal for the Input Shaft

Note

Use the drift to remove the seal with the clutch housing removed.

Installing the Seal for the Input Shaft

Installing the Axle for the Reverse Gear Shift Fork into the Clutch

Housing

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14

Shift Unit, Servicing

⇒ “14.1 Selector Shaft Seal, Replacing”, page 274

Note

♦ Lubricate the bearing areas and sliding surfaces.

♦ Refer to the Parts Catalog for the grease allocation.

1 - Hex Nut

❑ 23 Nm

❑ Self-locking

❑ Replace after removing

2 - Selector Lever

❑ Insert so that master

spline aligns with shift

rod

❑ Can be replaced with

the shift mechanism still

installed

❑ Installation position. Re‐

fer to

⇒ Fig. ““Selector Lever/

Relay Lever Installed

Position”“ , page 88 .

❑ Installing. Refer to

⇒ Fig. ““Installing the

Transmission Shift Lev‐

er”“ , page 88 .

❑ Adjust the gearshift

mechanism after instal‐

ling. Refer to

⇒ “1.11 Selector Mech‐

anism, Adjusting”,

page 97 .

3 - Sliding Shoe

❑ Attached into the relay

lever -item 5-

⇒ Item 5 (page 273)

4 - Bearing Bushing

❑ Not needed for the plas‐

tic relay lever

5 - Relay Lever

❑ Installation position. Refer to ⇒ Fig. ““Selector Lever/Relay Lever Installed Position”“ , page 88 .

❑ Adjust the gearshift mechanism after installing. Refer to

⇒ “1.11 Selector Mechanism, Adjusting”, page 97 .

❑ Plastic relay lever from 05/2007. Refer to ⇒ “1.8 Plastic Relay Lever”, page 89 .

6 - Gearshift Unit

❑ Consisting of the gearshift shaft and the gearshift cover

❑ The components cannot be separated from each other

❑ Can be removed and installed with the transmission installed

❑ Gearshift shaft adapted together with the revised reverse gear shift fork bearing -item 5-

⇒ Item 5 (page 277)

❑ Allocation, gearshift shafts. Refer to ⇒ Fig. ““Allocation, Gearshift Shafts”“ , page 274

14. Shift Unit, Servicing

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7 - Bearing Bushing

❑ For the selector shaft

❑ Removing and installing -item 16- ⇒ Item 16 (page 263) .

8 - O-Ring

❑ Insert in the groove in the shift cover

❑ Install with transmission fluid

❑ Replace after removing

9 - Cap

❑ For the transmission ventilation

10 - Lock Washer

❑ For the relay lever

❑ Not on the plastic relay lever

❑ Replace after removing

11 - Gearshift Shaft Seal

❑ Replacing. Refer to ⇒ “14.1 Selector Shaft Seal, Replacing”, page 274 .

Allocation, Gearshift Shafts

Number of Selector Fingers

on the Selector Shaft

Bearing, Reverse Gear Shift

Fork

Fig.-A-= 2 shift fingers

-arrow 1- and -arrow 2-

On the axle for the reverse gear

shift fork. Refer to

⇒ Fig. ““The Reverse Gear Shift

Fork -1- is Mounted on the

Axle -2- behind the 5th and 6th

Gear Shift Rod -3-.”“ ,

page 254

Fig. -B- = 1 shift finger

-arrow 3-

Gearshift rod with shift fork for

5th and 6th gear. Refer to

⇒ Fig. ““The Reverse Gear Shift

Fork -1- is Mounted on the Gear‐

shift Rod with the 5th and 6th

Gear Shift Fork -2-.”“ ,

page 254

14.1

Selector Shaft Seal, Replacing

Special tools and workshop equipment required

♦ Press Piece - Shift Rod/Alternator - VW423-

♦ Puller - Crankshaft/Power Steering Seal - 1 - T20143/1-

♦ Sealing Grease - G 052 128 A1-

– Remove entire air filter housing if it is located above the se‐

lector shaft. Refer to ⇒ Rep. Gr. 23 ; Diesel Direct Injection

System; Air Filter Housing, Removing and Installing or ⇒ Rep.

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

274

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Metal Relay Lever

– Remove the clip -2- and the relay lever -3-.

Note

If the relay lever cannot be removed due to the transmission

bracket, remove selector cable from relay lever. Remove the slide

shoe from the transmission shift lever.

Plastic Relay Lever

– Remove the relay lever with the cable retainer. Refer to

⇒ “1.8 Plastic Relay Lever”, page 89 .

Continuation for All Shift Mechanisms

– Remove the nut -4- and the transmission gearshift lever -1-.

– Pry out the seal using the Puller - Crankshaft/Power Steering

Seal - 1 - T20143/1- .

– Lightly oil the new gasket on the outer edge.

– Fill the space between the sealing/dust lip -arrow- halfway with

Sealing Grease - G 052 128 A1- .

14. Shift Unit, Servicing

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– Install the seal using Press Piece - Shift Rod/Alternator -

VW423- .

Install in reverse order of removal.

– Attach the transmission gearshift lever to the gearshift shaft

-item 1- ⇒ Item 1 (page 273) and tighten the nut to the tight‐

ening specification.

Note

The gearshift lever can be installed in only one position.

– Adjust the gearshift mechanism. Refer to

⇒ “1.11 Selector Mechanism, Adjusting”, page 97 .

– If it was removed earlier install the complete air filter housing.

Refer to ⇒ Rep. Gr. 23 ; Diesel Direct Injection System; Air

Filter Housing, Removing and Installing or ⇒ Rep. Gr. 24 ; Air

Filter; Air Filter Housing, Removing and Installing .

276

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6-Speed Manual Transmission 02Q - Edition 05.2013

15

Shift Forks, Servicing

Special tools and workshop equipment required

♦ Press Plate - VW402-

♦ Press Piece - Rod - VW411-

♦ Press Piece - Multiple Use - VW426-

♦ Press Piece - Multiple Use - VW431-

♦ Puller - Kukko Internal - 18.5-23.5mm - 21/3-

♦ Puller - Kukko Counterstay - 22/1-

1 - Rubber Damper

❑ Can be removed and in‐

stalled by hand

2 - Gearshift Rod with 1st Gear

and 2nd Gear Shift Fork

3 - Gearshift Rod with 3rd Gear

and 4th Gear Shift Fork

4 - Gearshift Rod with 5th Gear

and 6th Gear Shift Fork

❑ On some transmission,

is also for the reverse

gear shift fork bearing

5 - Reverse Gear Shift Fork

❑ On the axle for the re‐

verse gear shift fork. Re‐

fer to

⇒ Fig. ““The Reverse

Gear Shift Fork -1- is

Mounted on the

Axle -2- behind the 5th

and 6th Gear Shift

Rod -3-.”“ , page 254

❑ From transmission

manufacture date

3/6/06, ball sleeve

-item 6-

⇒ Item 6 (page 277) has

been omitted

❑ Sliding omission

❑ Reverse gear shift fork

is adapted

❑ If the axle for the reverse

gear shift fork is deleted,

bearing on the shift rod

for the 5th and 6th gear

shift fork. Refer to

⇒ Fig. ““The Reverse Gear Shift Fork -1- is Mounted on the Gearshift Rod with the 5th and 6th Gear Shift

Fork -2-.”“ , page 254

❑ Reverse gear shift fork differentiation. Refer to

⇒ Fig. ““Reverse Gear Shift Fork Differentiation”“ , page 278

❑ Refer to the Parts Catalog.

6 - Ball Sleeve

❑ Removing. Refer to

⇒ Fig. ““Through Transmission Manufacture Date 3/5/06 - Remove Reverse Gear Shift Fork Ball

Sleeve”“ , page 278 .

15. Shift Forks, Servicing

277

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❑ Installing. Refer to

⇒ Fig. ““Through Transmission Manufacture Date 3/5/06 - Press In Reverse Gear Shift Fork Ball Sleeve”“ ,

page 278 .

❑ From transmission manufacture date 3/6/06, ball sleeve has been omitted

❑ Sliding omission

Reverse Gear Shift Fork Differentiation

Dimension “a” mm Reverse Gear Shift

Fork

Mounting

24

18

with ball sleeve

without ball sleeve

On the axle for the re‐

verse gear shift fork.

Refer to

⇒ Fig. ““The Reverse

Gear Shift Fork -1- is

Mounted on the

Axle -2- behind the

5th and 6th Gear Shift

Rod -3-.”“ , page 254

15

without ball sleeve

Gearshift rod with

shift fork for 5th and

6th gear. Refer to

⇒ Fig. ““The Reverse

Gear Shift Fork -1- is

Mounted on the

Gearshift Rod with

the 5th and 6th Gear

Shift Fork -2-.”“ , page

254

Through Transmission Manufacture Date 3/5/06 - Remove Re‐

verse Gear Shift Fork Ball Sleeve

A - Internal Puller 18 to 23 mm , for example Puller - Kukko Internal

- 18.5-23.5mm - 21/3-

B - Counter Support , for example Puller - Kukko Counterstay -

22/1-

Through Transmission Manufacture Date 3/5/06 - Press In Re‐

verse Gear Shift Fork Ball Sleeve

278

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6-Speed Manual Transmission 02Q - Edition 05.2013

16

Special Tools

Special tools and workshop

equipment required

♦ Bearing Driver - Multiple

Use - VW244B-

♦ Transmission Support -

VW353-

♦ Press Plate - VW401-

♦ Press Plate - VW402-

♦ Press Piece - Rod -

VW407-

♦ Press Piece - 37mm -

VW416B-

16. Special Tools

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♦ Guide Pin - VW436A-

♦ Press Piece - Guide Pin -

VW439-

♦ Slide Hammer Set - Ham‐

mer - VW771-

♦ Crankshaft Holding Fixture

- VW801-

♦ Guide Pins - 10-15-

♦ Press Piece - Pivot Mount

Bushing - 3124-

280

Rep. Gr.34 - Operation and Housing

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6-Speed Manual Transmission 02Q - Edition 05.2013

♦ Bracket - Multiple Use -

30-211A-

♦ Seal Installer - Crankshaft -

T10042-

♦ Locking Sleeve Drift -

T10169-

♦ or Locking Sleeve Drift -

T10362-

⇒ Fig. ““Lock Sleeve Differ‐

entiation”“ , page 266

♦ Seal Installer - Driveshaft -

T40008-

♦ Torque Wrench 1331

5-50Nm - VAG1331-

♦ Hot Air Blower - VAG1416-

16. Special Tools

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♦ Bearing Installer - Crank‐

shaft Pilot Bearing - 3264-

♦ Subframe Support Tool -

3290-

♦ Torque Wrench 1331

5-50Nm - VAG1331-

♦ Bushing Driver - Selector

Shaft - T10168-

♦ Locking Sleeve Drift -

T10169- or Locking Sleeve

Drift - T10362-

⇒ Fig. ““Lock Sleeve Differ‐

entiation”“ , page 266

♦ Breather Tube Tool -

T10203-

282

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6-Speed Manual Transmission 02Q - Edition 05.2013

♦ Holding Plate - VW309A-

♦ Holding Fixture - VW313-

♦ Transmission Support -

VW353-

♦ Press Piece - Multiple Use

- VW455- or Press Piece -

Front Wishbone - 3160-

♦ Slide Hammer Set -

VW771-

♦ -1- Puller - Kukko Internal -

12-16mm - 21/1-

♦ -3- Puller - Kukko Quick Ac‐

tion Separating Tool -

5-60mm - 17/0-

♦ -4- Puller - Kukko Counter‐

stay - 22/1-

16. Special Tools

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♦ Press Piece - Rod -

VW407-

♦ Bushing Driver - Selector

Shaft - T10168-

♦ Seal Installer - Driveshaft -

T40008-

♦ -1- Puller - Kukko Internal -

14-19mm - 21/2-

♦ -1- Puller - Kukko Internal -

20-30mm - 21/4-

♦ -4- Puller - Kukko Counter‐

stay - 22/1-

♦ -4- Puller - Kukko Counter‐

stay - 22/2-

284

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6-Speed Manual Transmission 02Q - Edition 05.2013

♦ Support Elements for trans‐

mission (determine when

mounting the Mounting

Plate on the Transmission

Support )

♦ Transmission Support -

Mounting Plate 33 -

3282/33-

♦ Transmission Support Jig -

3336- to transport the

transmission.

♦ Torque Wrench 1331

5-50Nm - VAG1331-

♦ Torque Wrench 1332

40-200Nm - VAG1332-

♦ Engine and Gearbox Jack -

VAS6931-

16. Special Tools

285

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♦ Press Plate - VW402-

♦ Press Piece - Rod -

VW411-

♦ Press Piece - Multiple Use

- VW426-

♦ Press Piece - Multiple Use

- VW431-

♦ -1- Puller - Kukko Internal -

18.5-23.5mm - 21/3-

♦ -4- Puller - Kukko Counter‐

stay - 22/1-

286

Rep. Gr.34 - Operation and Housing

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6-Speed Manual Transmission 02Q - Edition 05.2013

♦ Bracket - Multiple Use -

30-211A-

♦ Seal Installer - Drive Flange

- T10143- or Seal Installer -

Output Shaft Oil Seal -

T10180-

♦ Locking Sleeve Drift -

T10169-

♦ or Locking Sleeve Drift -

T10362-

⇒ Fig. ““Lock Sleeve Differ‐

entiation”“ , page 266

♦ Seal Installer - Driveshaft -

T40008-

♦ Torque Wrench 1331

5-50Nm - VAG1331-

♦ Hot Air Blower - VAG1416-

16. Special Tools

287

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♦ Engine Support Bridge -

Gearbox Bracket - T10346-

quantity: 2

♦ Engine Support Device -

3300A-

♦ Slide Hammer Set - Adapt‐

er 40 - VW771/40-

♦ Hose Clamps - Up To

25mm - 3094-

♦ Grease for Clutch Disc

Shaft Splines - G 000 100-

288

Rep. Gr.34 - Operation and Housing

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6-Speed Manual Transmission 02Q - Edition 05.2013

♦ Engine Support Bridge -

10-222A-

♦ Engine Support Bridge -

Engine Support Feet -

10-222A/8-

♦ Engine Support Bridge -

Engine Support 3 -

10-222A /3-

♦ Engine Support Bridge -

Engine Support 18 -

10-222A /18-

♦ Transmission Support -

3282-

16. Special Tools

289

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6-Speed Manual Transmission 02Q - Edition 05.2013

♦ Release Tool - T10236-

♦ Thrust Disc - VW412-

♦ Assembly Tool - T10178- or

flat iron, 200 x 25 x 5

♦ Adapter - 10-222A/25- or

flat iron, 350 x 30 x 5

♦ -4- Counter-Support , for

example -Kukko 22/4-

♦ Wedge - T10357-

♦ Thrust Block - T10083-

♦ Used Oil Collection and Extraction Unit - SMN372500-

290

Rep. Gr.34 - Operation and Housing

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6-Speed Manual Transmission 02Q - Edition 05.2013

♦ Connecting Pin - T10027A-

♦ Puller - Flanged Shaft - T10037-

♦ Thrust Block - T10083-

♦ Socket And Extended Bit - T10107A-

16. Special Tools

291

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♦ Engine Support Bridge - Gearbox Bracket - T10346-

♦ Cover Cap - T10460-

♦ Pulling Hook - T20143/1-

♦ Hose Clip Pliers - VAG1275A-

292

Rep. Gr.34 - Operation and Housing

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6-Speed Manual Transmission 02Q - Edition 05.2013

♦ Engine and Transmission Holder - VAS6095-

♦ Shop Crane - VAS6100-

♦ Drip Tray for VAS6100 - VAS6208-

♦ Charging Device For Haldex Coupling 2 - VAS6291A-

♦ Charging Device For Haldex Coupling 2 - Adapter 3 -

VAS6291/3-

16. Special Tools

293

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♦ It is necessary to use the Oil Filler - Adapter 6 - VAS6262/6-

on some oil containers.

♦ Sleeve - VW423-

♦ -1- Puller - Kukko Internal - 14-19mm - 21/2-

♦ -1- Puller - Kukko Internal - 20-30mm - 21/4-

♦ -4- Puller - Kukko Counterstay - 22/2-

♦ Thread adaptor from Puller - Kukko Counterstay - 22/1-

294

Rep. Gr.34 - Operation and Housing

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6-Speed Manual Transmission 02Q - Edition 05.2013

♦ Transmission Support Jig - 3336-

♦ Triple Square Socket Driver - 3357-

16. Special Tools

295

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17

Special Tools

Special tools and workshop

equipment required

♦ Bearing Driver - Multiple

Use - VW244B-

♦ Transmission Support -

VW353-

♦ Press Plate - VW401-

♦ Press Plate - VW402-

♦ Press Piece - Rod -

VW407-

♦ Press Piece - 37mm -

VW416B-

296

Rep. Gr.34 - Operation and Housing

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤

6-Speed Manual Transmission 02Q - Edition 05.2013

♦ Guide Pin - VW436A-

♦ Press Piece - Guide Pin -

VW439-

♦ Slide Hammer Set - Ham‐

mer - VW771-

♦ Crankshaft Holding Fixture

- VW801-

♦ Guide Pins - 10-15-

♦ Press Piece - Pivot Mount

Bushing - 3124-

17. Special Tools

297

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6-Speed Manual Transmission 02Q - Edition 05.2013

♦ Bracket - Multiple Use -

30-211A-

♦ Seal Installer - Crankshaft -

T10042-

♦ Locking Sleeve Drift -

T10169-

♦ or Locking Sleeve Drift -

T10362-

⇒ Fig. ““Lock Sleeve Differ‐

entiation”“ , page 266

♦ Seal Installer - Driveshaft -

T40008-

♦ Torque Wrench 1331

5-50Nm - VAG1331-

♦ Hot Air Blower - VAG1416-

298

Rep. Gr.34 - Operation and Housing

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤

6-Speed Manual Transmission 02Q - Edition 05.2013

♦ Bearing Installer - Crank‐

shaft Pilot Bearing - 3264-

♦ Subframe Support Tool -

3290-

♦ Torque Wrench 1331

5-50Nm - VAG1331-

♦ Bushing Driver - Selector

Shaft - T10168-

♦ Locking Sleeve Drift -

T10169- or Locking Sleeve

Drift - T10362-

⇒ Fig. ““Lock Sleeve Differ‐

entiation”“ , page 266

♦ Breather Tube Tool -

T10203-

17. Special Tools

299

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♦ Holding Plate - VW309A-

♦ Holding Fixture - VW313-

♦ Transmission Support -

VW353-

♦ Press Piece - Multiple Use

- VW455- or Press Piece -

Front Wishbone - 3160-

♦ Slide Hammer Set -

VW771-

♦ -1- Puller - Kukko Internal -

12-16mm - 21/1-

♦ -3- Puller - Kukko Quick Ac‐

tion Separating Tool -

5-60mm - 17/0-

♦ -4- Puller - Kukko Counter‐

stay - 22/1-

300

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6-Speed Manual Transmission 02Q - Edition 05.2013

♦ Press Piece - Rod -

VW407-

♦ Bushing Driver - Selector

Shaft - T10168-

♦ Seal Installer - Driveshaft -

T40008-

♦ -1- Puller - Kukko Internal -

14-19mm - 21/2-

♦ -1- Puller - Kukko Internal -

20-30mm - 21/4-

♦ -4- Puller - Kukko Counter‐

stay - 22/1-

♦ -4- Puller - Kukko Counter‐

stay - 22/2-

17. Special Tools

301

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6-Speed Manual Transmission 02Q - Edition 05.2013

♦ Engine Support Bridge -

10-222A-

♦ Transmission Support -

3282-

♦ Engine and Gearbox Jack -

VAS6931-

♦ Tensioning Strap - T10038-

♦ Engine Support - Basic Set

- T40091-

♦ Engine Support - Supple‐

ment Kit - T40093A-

302

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6-Speed Manual Transmission 02Q - Edition 05.2013

♦ Press Plate - VW402-

♦ Press Piece - Rod -

VW411-

♦ Press Piece - Multiple Use

- VW426-

♦ Press Piece - Multiple Use

- VW431-

♦ -1- Puller - Kukko Internal -

18.5-23.5mm - 21/3-

♦ -4- Puller - Kukko Counter‐

stay - 22/1-

17. Special Tools

303

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6-Speed Manual Transmission 02Q - Edition 05.2013

♦ Bracket - Multiple Use -

30-211A-

♦ Seal Installer - Drive Flange

- T10143- or Seal Installer -

Output Shaft Oil Seal -

T10180-

♦ Locking Sleeve Drift -

T10169-

♦ or Locking Sleeve Drift -

T10362-

⇒ Fig. ““Lock Sleeve Differ‐

entiation”“ , page 266

♦ Seal Installer - Driveshaft -

T40008-

♦ Torque Wrench 1331

5-50Nm - VAG1331-

♦ Hot Air Blower - VAG1416-

304

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6-Speed Manual Transmission 02Q - Edition 05.2013

♦ Window Release Tool -

T10236-

♦ Press Piece - Multiple Use

- VW412-

♦ Over-Center Spring As‐

sembly Tool - T10178- or

flat iron, 200 x 25 x 5 mm

♦ Engine Support Bridge -

Engine Support 25 -

10-222A/25- or flat iron,

350 X 30 X 5 mm

♦ - 4- = Puller - Counterstay ,

for example -22/4-

♦ Wedge - T10357-

♦ Used Oil Collection and Extraction Unit - SMN372500-

17. Special Tools

305

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6-Speed Manual Transmission 02Q - Edition 05.2013

♦ Connecting Pin - T10027A-

♦ Thrust Block - T10083-

♦ Pulling Hook - T20143/1-

♦ Hose Clip Pliers - VAG1275A-

306

Rep. Gr.34 - Operation and Housing

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6-Speed Manual Transmission 02Q - Edition 05.2013

♦ Engine and Transmission Holder - VAS6095-

♦ Shop Crane - VAS6100-

♦ Drip Tray for VAS6100 - VAS6208-

♦ Press Piece - Shift Rod/Alternator - VW423-

17. Special Tools

307

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6-Speed Manual Transmission 02Q - Edition 05.2013

♦ -1- Puller - Kukko Internal - 14-19mm - 21/2-

♦ -1- Puller - Kukko Internal - 20-30mm - 21/4-

♦ -4- Puller - Kukko Counterstay - 22/2-

♦ Thread adaptor from Puller - Kukko Counterstay - 22/1-

♦ Hose Clamps - Up To 25mm - 3094-

♦ Transmission Support - Pins 29 - 3282/29-

♦ Transmission Support - Mounting Plate 33 - 3282/33-

308

Rep. Gr.34 - Operation and Housing

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6-Speed Manual Transmission 02Q - Edition 05.2013

♦ Transmission Support Jig - 3336-

♦ Triple Square Socket Driver - 3357-

17. Special Tools

309

OperationandHousing for Your Volkswagen Golf 4 Door Fifth Generation (2003-2008)

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