Get OperationandHousing -> 11.9 Assembly Sequence: I = Transmission ?with? 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

– 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

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

6-Speed Manual Transmission 02Q - Edition 05.2013

♦ 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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Rep. Gr.34 - Operation and Housing

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

6-Speed Manual Transmission 02Q - Edition 05.2013

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

249

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

6-Speed Manual Transmission 02Q - Edition 05.2013

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.

250

Rep. Gr.34 - Operation and Housing

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

6-Speed Manual Transmission 02Q - Edition 05.2013

– 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-

11. Transmission, Disassembling and Assembling

251

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

6-Speed Manual Transmission 02Q - Edition 05.2013

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.

252

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 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

253

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

6-Speed Manual Transmission 02Q - Edition 05.2013

– 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

254

Rep. Gr.34 - Operation and Housing

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

6-Speed Manual Transmission 02Q - Edition 05.2013

– 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

255

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.

♦ 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.

256

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 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.

11. Transmission, Disassembling and Assembling

257

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

6-Speed Manual Transmission 02Q - Edition 05.2013

– 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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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 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

259

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

6-Speed Manual Transmission 02Q - Edition 05.2013

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- .

260

Rep. Gr.34 - Operation and Housing

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

6-Speed Manual Transmission 02Q - Edition 05.2013

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

261

OperationandHousing -> 11.9 Assembly Sequence: I = Transmission ?with? a Securing Ring A... for Your Volkswagen Golf 4 Door Fifth Generation (2003-2008)

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