Get OperationandHousing -> 12 Transmission Housing, Servicing 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

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

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

6-Speed Manual Transmission 02Q - Edition 05.2013

1 - Transmission Housing

❑ When replacing: adjust

the output shafts and

differential. Refer to

⇒ “4 Overview - Adjust‐

ment”, page 393

❑ Changes to the grooved

ball bearing/input shaft

mount area -item 3-

⇒ Item 3 (page 310)

❑ Changes near the

mount area for the cov‐

er/input shaft -item 4-

⇒ Item 4 (page 229)

❑ Refer to the Parts Cata‐

log.

2 - Cap

❑ Removing. Refer to

⇒ Fig. ““Removing the

Cover -A- ”“ ,

page 264 .

❑ Installing. Refer to

⇒ Fig. ““Installing the

Cover”“ , page 264 .

3 - Oil Drain Plug

❑ Tightening specifica‐

tion. Refer to

⇒ Fig. ““Different Ver‐

sions of the Oil Fill and

Drain Plugs”“ ,

page 192 .

4 - Seal

❑ If present, replace after

removing

5 - Oil Filler Plug

❑ Tightening specification. Refer to

⇒ Fig. ““Different Versions of the Oil Fill and Drain Plugs”“ , page 192 .

6 - Locking Elbow

❑ Adjusting the gearshift mechanism. Refer to ⇒ “1.11 Selector Mechanism, Adjusting”, page 97 .

❑ Can be replaced with transmission not disassembled

❑ Removing. Refer to ⇒ Fig. ““Removing the Locking Elbow for the Gearshift Shaft”“ , page 264 .

❑ Installation position. Refer to ⇒ Fig. ““Installed Position: Locking Elbow”“ , page 265 .

❑ Installing. Refer to

⇒ Fig. ““Drive Lock Elbow -arrow- for Selector Shaft In Up to Tool Stop.”“ , page 265 .

7 - Bearing Bushing

❑ For the selector rods

❑ Removing. Refer to ⇒ Fig. ““Removing the Shift Rod Bearing Bushing”“ , page 265 .

❑ Installing. Refer to

⇒ Fig. ““Installing the Shift Rod Bearing Bushing All the Way Onto the Tool”“ , page 265 .

8 - Retaining Sleeve

❑ Removing when the transmission is disassembled. Refer to

⇒ Fig. ““Removing the Retaining Sleeve -A- from the Transmission Housing”“ , page 266

❑ Removing when the transmission is not disassembled. Refer to

⇒ Fig. ““Removing the Retaining Sleeve on A Transmission Not Disassembled using the Guide Pins

-10-15- .”“ , page 266

❑ Different retaining sleeves. Refer to ⇒ Fig. ““Lock Sleeve Differentiation”“ , page 266

262

Rep. Gr.34 - Operation and Housing

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

6-Speed Manual Transmission 02Q - Edition 05.2013

❑ Installing a retaining sleeve with a shoulder. Refer to

⇒ Fig. ““Drive In Lock Sleeve with Shoulder as far as Stop on Tool”“ , page 266

❑ Installing the retaining sleeve without a shoulder. Refer to

⇒ Fig. ““Drive in Lock Sleeve without Shoulder as far as Stop on Tool”“ , page 267

9 - Needle Sleeve

❑ For the reverse shaft

❑ Always replace if removed

❑ Removing. Refer to

⇒ Fig. ““Removing the Reverse Shaft Needle Sleeve from the Transmission Housing”“ , page 267 .

❑ Installing. Refer to

⇒ Fig. ““Installing the Needle Sleeve -A- into the Transmission Housing”“ , page 267 .

10 - Outer Race/Tapered Roller Bearing

❑ Output shaft, 5th/6th and reverse gears

❑ Removing and installing. Refer to

⇒ “3.1 Overview - Input Shaft, 5th/6th and Reverse Gears”, page 344 .

❑ When replacing: adjust output shaft for 5th/6th and reverse gear. Refer to

⇒ “3.3 Output Shaft, 5th, 6th and Reverse Gears, Adjusting”, page 353 .

11 - Shim

❑ Output shaft, 5th/6th and reverse gears

❑ Adjustment overview. Refer to ⇒ “4 Overview - Adjustment”, page 393 .

12 - Outer Race/Tapered Roller Bearing

❑ Output shaft, 1st to 4th gears

❑ Removing and installing. Refer to

⇒ “2.2 Output Shaft, 1st to 4th Gears, Disassembling and Assembling”, page 321 .

❑ Adjust, if output shaft for 1st to 4th gear is replaced. Refer to

⇒ “2.3 Output Shaft 1st through 4th Gear, Adjusting”, page 340 .

13 - Shim

❑ Output shaft, 1st to 4th gears

❑ Adjustment overview. Refer to ⇒ “4 Overview - Adjustment”, page 393 .

14 - Outer Race/Tapered Roller Bearing

❑ For the differential

❑ FWD, removing and installing. Refer to

⇒ “5.1 FWD Differential, Disassembling and Assembling”, page 394 .

❑ AWD, removing and installing. Refer to

⇒ “5.2 Differential, AWD, Disassembling and Assembling”, page 399 .

❑ When replacing: adjust the differential. Refer to ⇒ “5.3 Differential, Adjusting”, page 405

15 - Shim

❑ For the differential

❑ Adjustment overview. Refer to ⇒ “4 Overview - Adjustment”, page 393 .

16 - Bearing Bushing

❑ For the selector shaft

❑ Removing. Refer to ⇒ Fig. ““Removing the Selector Shaft Bearing Bushing”“ , page 267 .

❑ Installing. Refer to

⇒ Fig. ““Installing the Gearshift Shaft Bearing Bushing -A- All the Way onto the Tool”“ , page 268 .

17 - Plugs

❑ Removing. Refer to ⇒ Fig. ““Removing the Plug -1- ”“ , page 268 .

❑ Installing. Refer to ⇒ Fig. ““Installing the Plug -1- ”“ , page 268 .

18 - Seal

❑ For the left flange shaft

❑ FWD, replacing. Refer to ⇒ “1.1 Left Flange Shaft Seal, Replacing”, page 369 .

12. Transmission Housing, Servicing

263

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

6-Speed Manual Transmission 02Q - Edition 05.2013

❑ AWD, replacing. Refer to ⇒ “1.1 Left Flange Shaft Seal, Replacing”, page 369 .

Removing the Cover -A-

– Pierce the rubber in the center of the cover with a screwdriver

-B- and pry it out of the cover in direction of -arrow-.

Installing the Cover

Removing the Locking Elbow for the Gearshift Shaft

– Remove the elbow in its unlocked position.

– Guide a screwdriver -A- into hole of lock elbow -B-.

– Pry out the locking elbow in direction of -arrow-.

264

Rep. Gr.34 - Operation and Housing

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

6-Speed Manual Transmission 02Q - Edition 05.2013

Installed Position: Locking Elbow

•

The mark on the locking elbow -arrow- must point toward the

connection on the clutch slave cylinder -1-.

Dimension -a- must be approximately 45°.

•

Drive Lock Elbow -arrow- for Selector Shaft In Up to Tool Stop.

Note

The locking elbow must be unlocked when being installed.

Removing the Shift Rod Bearing Bushing

A - 14.5 to 18.5 mm Internal Puller , for example Puller - Kukko

Internal - 14-19mm - 21/2-

B - Counter Support , for example, Puller - Kukko Counterstay -

22/2-

Installing the Shift Rod Bearing Bushing All the Way Onto the Tool

12. Transmission Housing, Servicing

265

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

6-Speed Manual Transmission 02Q - Edition 05.2013

Removing the Retaining Sleeve -A- from the Transmission Hous‐

ing

– Place transmission housing on Press Plate - VW401- and

Press Plate - VW402- in such a way so that the alignment

sleeves inside the transmission housing do not get damaged.

Removing the Retaining Sleeve on A Transmission Not Disas‐

sembled using the Guide Pins - 10-15- .

•

Locking bolt and selector shaft removed.

– Turn the transmission so that the retaining sleeve cannot fall

into the transmission.

Lock Sleeve Differentiation

The following lock sleeves may be installed:

Lock sleeve with a shoulder -arrow 1-. Refer to

⇒ Fig. ““Drive In Lock Sleeve with Shoulder as far as Stop on

Tool”“ , page 266 .

Lock sleeve without a shoulder -arrow 2-

⇒ Fig. ““Drive in Lock Sleeve without Shoulder as far as Stop on

Tool”“ , page 267 .

Allocate the components. Refer to the Parts Catalog.

Drive In Lock Sleeve with Shoulder as far as Stop on Tool

•

The transmission housing is bolted to the clutch housing.

266

Rep. Gr.34 - Operation and Housing

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

6-Speed Manual Transmission 02Q - Edition 05.2013

Drive in Lock Sleeve without Shoulder as far as Stop on Tool

The transmission housing is bolted to the clutch housing.

•

Removing the Reverse Shaft Needle Sleeve from the Transmis‐

sion Housing

A - Internal Puller - 23.5 - 30 mm , for example Puller - Kukko

Internal - 20-30mm - 21/4-

B - Counter Support , for example, Puller - Kukko Counterstay -

22/2-

Note

The needle sleeve will get damaged when it is removed and must

be replaced.

Installing the Needle Sleeve -A- into the Transmission Housing

– While installing, place thrust washer -B- for the reverse shaft

onto the needle sleeve.

– Support the transmission housing with the Press Piece -

37mm - VW416B- directly under the bearing mount.

Removing the Selector Shaft Bearing Bushing

– Use the thread adapter from Puller - Kukko Counterstay - 22/1-

-arrow-.

– Hold the spindle on the Subframe Support Tool - 3290- and

turn the nut -B-.

A - 14.5 to 18.5 mm Internal Puller , for example Puller - Kukko

Internal - 14-19mm - 21/2-

12. Transmission Housing, Servicing

267

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

6-Speed Manual Transmission 02Q - Edition 05.2013

Installing the Gearshift Shaft Bearing Bushing -A- All the Way on‐

to the Tool

Removing the Plug -1-

– Remove the plug -1- from the inside of the transmission hous‐

ing to the outside.

Installing the Plug -1-

– Using the Bearing Installer - Crankshaft Pilot Bearing - 3264- ,

drive in the sealing plugs to dimension -a- approximately 3 mm

below the upper edge of the housing.

268

Rep. Gr.34 - Operation and Housing

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

6-Speed Manual Transmission 02Q - Edition 05.2013

Clutch Housing, Servicing

Special tools and workshop equipment required

♦ Press Piece - Rod - VW407-

♦ Bushing Driver - Selector Shaft - T10168-

♦ Seal Installer - Driveshaft - T40008-

♦ Puller - Kukko Internal - 14-19mm - 21/2-

♦ Puller - Kukko Internal - 20-30mm - 21/4-

♦ Puller - Kukko Counterstay - 22/1-

♦ Puller - Kukko Counterstay - 22/2-

1 - Bearing Bushing

❑ For the selector rods

❑ Always replace if re‐

moved

❑ Removing. Refer to

⇒ Fig. ““Removing the

Shift Rod Bearing Bush‐

ing”“ , page 271 .

❑ Installing. Refer to

⇒ Fig. ““Installing the

Shift Rod Bearing Bush‐

ing All the Way onto the

Tool”“ , page 271 .

2 - Axle for the Reverse Gear

Shift Fork

❑ The axle cannot be re‐

moved with workshop

tools.

❑ A new axle must be in‐

stalled when using a

new clutch housing. Re‐

fer to

⇒ Fig. ““Installing the

Axle for the Reverse

Gear Shift Fork into the

Clutch Housing”“ ,

page 272

❑ Mount the reverse gear

shift fork on the axle.

Refer to

⇒ Fig. ““The Reverse

Gear Shift Fork -1- is

Mounted on the

Axle -2- behind the 5th

and 6th Gear Shift

Rod -3-.”“ , page 254

❑ Bearing on the shift rod

for the 5th and 6th gear shift fork. Refer to

⇒ Fig. ““The Reverse Gear Shift Fork -1- is Mounted on the Gearshift Rod with the 5th and 6th Gear Shift

Fork -2-.”“ , page 254

❑ Refer to the Parts Catalog.

3 - Needle Sleeve

❑ For the reverse shaft

❑ Always replace if removed

❑ Removing. Refer to ⇒ Fig. ““Removing the Needle Sleeve from the Clutch Housing”“ , page 271 .

13. Clutch Housing, Servicing

269

OperationandHousing -> 12 Transmission Housing, Servicing for Your Volkswagen Golf 4 Door Fifth Generation (2003-2008)

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