Get OperationandHousing -> 11.8 Assembly Sequence, Transmission ?without? a Securing Ring A... 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

❑ 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-

11. Transmission, Disassembling and Assembling

235

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

6-Speed Manual Transmission 02Q - Edition 05.2013

♦ 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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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 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.

11. Transmission, Disassembling and Assembling

237

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

6-Speed Manual Transmission 02Q - Edition 05.2013

– 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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Rep. Gr.34 - Operation and Housing

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

6-Speed Manual Transmission 02Q - Edition 05.2013

– 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 .

11. Transmission, Disassembling and Assembling

239

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

6-Speed Manual Transmission 02Q - Edition 05.2013

– 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.

240

Rep. Gr.34 - Operation and Housing

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

6-Speed Manual Transmission 02Q - Edition 05.2013

– 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.

11. Transmission, Disassembling and Assembling

241

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

6-Speed Manual Transmission 02Q - Edition 05.2013

– 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

242

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 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- .

11. Transmission, Disassembling and Assembling

243

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

6-Speed Manual Transmission 02Q - Edition 05.2013

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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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 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.

11. Transmission, Disassembling and Assembling

245

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

6-Speed Manual Transmission 02Q - Edition 05.2013

– 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- .

246

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 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-

11. Transmission, Disassembling and Assembling

247

OperationandHousing -> 11.8 Assembly Sequence, Transmission ?without? a Securing Ring A... for Your Volkswagen Golf 4 Door Fifth Generation (2003-2008)

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