Get OperationandHousing -> 11.5 Transmission Housing and Gearshift Mechanism, Removing and Installing 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

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

Rep. Gr.34 - Operation and Housing

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

6-Speed Manual Transmission 02Q - Edition 05.2013

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

229

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

6-Speed Manual Transmission 02Q - Edition 05.2013

❑ 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 .

230

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 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

231

OperationandHousing -> 11.5 Transmission Housing and Gearshift Mechanism, Removing and Installing for Your Volkswagen Golf 4 Door Fifth Generation (2003-2008)

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