2003-2008 Volkswagen Golf 4 Door OperationandHousing -> 11 Transmission, Disassembling and Assembling User Manual
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OperationandHousing -> 11 Transmission, Disassembling and Assembling for Your 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  
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  
222  
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 - 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  
223  
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤  
6-Speed Manual Transmission 02Q - Edition 05.2013  
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  
224  
Rep. Gr.34 - Operation and Housing  
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤  
6-Speed Manual Transmission 02Q - Edition 05.2013  
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  
225  
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  
»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  
226  
Rep. Gr.34 - Operation and Housing  
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤  
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  
227  
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  
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤  
6-Speed Manual Transmission 02Q - Edition 05.2013  
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)  
232  
Rep. Gr.34 - Operation and Housing  
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤  
6-Speed Manual Transmission 02Q - Edition 05.2013  
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  
233  
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤  
6-Speed Manual Transmission 02Q - Edition 05.2013  
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 .  
234  
Rep. Gr.34 - Operation and Housing  
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  
236  
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.  
238  
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  
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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.  
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  
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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  
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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 .  
244  
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  
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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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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  
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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.  
248  
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  
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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  
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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  
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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  
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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.  
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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  
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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  
258  
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  

Related Topics

OperationandHousing
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