2003-2008 Volkswagen Golf 4 Door OperationandHousing -> 5.1 Transmission, TDI, Removing and Installing User Manual
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OperationandHousing -> 5.1 Transmission, TDI, Removing and Installing 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  
5
Transmission, Removing and Instal‐  
ling, Jetta from MY 2005 , Golf Wag‐  
on from MY 2007 and Golf Wagon  
from MY 2010, Vehicles with AWD  
⇒ “5.1 Transmission, TDI, Removing and Installing”, page 166  
5.1  
Transmission, TDI, Removing and In‐  
stalling  
⇒ “5.1.1 Transmission, Removing”, page 167  
⇒ “5.1.2 Transmission, Installing”, page 178  
⇒ “5.1.3 Tightening Specifications”, page 186  
Special tools and workshop equipment required  
♦ Engine Support Bridge - 10-222A-  
♦ Engine Support Bridge - Engine Support Feet - 10-222A/8-  
♦ Engine Support Bridge - Engine Support 3 - 10-222A/3-  
♦ Engine Support Bridge - Engine Support 18 - 10-222A/18-  
♦ Transmission Support - 3282-  
♦ Support Elements for transmission (determine when mounting  
the Mounting Plate on the Transmission Support )  
♦ Transmission Support - Mounting Plate 33 - 3282/33-  
♦ Transmission Support Jig - 3336- to transport the transmis‐  
sion.  
♦ Torque Wrench 1331 5-50Nm - VAG1331-  
♦ Torque Wrench 1332 40-200Nm - VAG1332-  
♦ Engine and Gearbox Jack - VAS6931-  
♦ Slide Hammer Set - Adapter 40 - VW771/40-  
♦ Hose Clamps - Up To 25mm - 3094-  
♦ Engine Support Bridge - Gearbox Bracket - T10346-  
♦ Grease for Clutch Disc Shaft Splines - G 000 100-  
♦ Allocate the grease for gearshift mechanism. Refer to the  
Parts Catalog.  
♦ M6 x 80 collar bolt  
♦ M10 x 20 hex bolt  
The Engine Support Bridge - 10-222A- and the Engine Support  
Bridge - Engine Support Feet - 10-222A/8- will be mounted on the  
longitudinal members later in the procedure.  
166  
Rep. Gr.34 - Operation and Housing  
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤  
6-Speed Manual Transmission 02Q - Edition 05.2013  
•
To protect the edges of the fender, cover both Engine Support  
Bridge - Engine Support Feet - 10-222A/8- with cloth tape  
-arrow-. Refer to the Parts Catalog (Chemical Materials).  
5.1.1  
Transmission, Removing  
– First check whether a coded radio is installed. If so, obtain the  
anti-theft code.  
– Disconnect the battery ground cable. Refer to ⇒ Electrical  
Equipment; Rep. Gr. 27 ; Battery; Battery, Disconnecting and  
Connecting .  
Later in the procedure, the Engine Support Bridge - 10-222A- is  
connected to the engine lifting eyes.  
– Remove the engine cover if it is blocking the lifting eyes.  
– Remove the air filter housing if it is located near the battery.  
Refer to ⇒ Rep. Gr. 23 ; Diesel Direct Injection System; Air  
Filter Housing, Removing and Installing or ⇒ Rep. Gr. 24 ; Air  
Filter; Air Filter Housing, Removing and Installing .  
– Remove the battery and the battery tray. Refer to ⇒ Electrical  
Equipment; Rep. Gr. 27 ; Battery; Battery, Removing and In‐  
stalling .  
– Remove the lines -A- out from the bracket -B-.  
– Remove the shift cable lock washer -3- from the transmission  
shift lever -1- and remove the cable from the pin -arrow-.  
Metal Relay Lever  
– Remove the selector cable lock washer -4- from the relay lever  
-2- and remove the cable from the pin -arrow-.  
Plastic Relay Lever  
AWD  
5. Transmission, Removing and Installing, Jetta from MY 2005 , Golf Wagon from MY 2007 and Golf Wagon from MY 2010, Vehic1les6w7ith  
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤  
6-Speed Manual Transmission 02Q - Edition 05.2013  
– Remove the cable retainer from the selector cable.  
•
To avoid damage to the selector cable, the cable retainer must  
be disconnected from the selector lever before removal.  
– Pull the securing mechanism all the way forward in direction  
of -arrow 1- and then unlock to the left in direction of  
-arrow 2-.  
– Press the relay lever forward (in the direction of -arrow 3-).  
– The plastic relay lever is removed together with the cable re‐  
tainer later in the procedure.  
Continuation for All  
– Remove the cable bracket from the transmission -arrows-, tie  
up to the side.  
– If equipped, remove the bleeder tube from the bevel gear  
-arrow-.  
Vehicles with A Pipe between the Clutch Master and Slave Cyl‐  
inders  
– Clamp the clutch master cylinder hose using a Hose Clamps  
- Up To 25mm - 3094- .  
168  
Rep. Gr.34 - Operation and Housing  
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤  
6-Speed Manual Transmission 02Q - Edition 05.2013  
Vehicles with A Hose/Line Assembly between the Clutch Master  
and Slave Cylinders  
– Clamp off the hose on the hose/line assembly -A- to the clutch  
slave cylinder using the Hose Clamps - Up To 25mm - 3094- .  
Continuation for All  
– Pull the clamp -arrow- for the hose/line assembly or the pipe  
out all the way to the stop.  
– Remove the hose/line assembly or pipe from the bleeder/  
clutch slave cylinder and seal it off.  
Caution  
Do not press the clutch pedal anymore.  
– Remove the ground cable -1- from the top starter bolt.  
– Disconnect the connector -2- from the Back-Up Lamp Switch  
- F4- .  
– Disconnect the connector and the wire from the starter.  
– Remove the upper engine/transmission connecting bolts  
-arrows-.  
– Remove the upper bolt from the starter.  
– If there are hose and cable connections located near the en‐  
gine lifting eyes for the Engine Support Bridge - 10-222A- ,  
these must now be removed.  
– Install the Engine Support Bridge - Gearbox Bracket - T10346-  
in the most rear hole out of the three holes in the battery tray.  
– Use a collar bolt M6 x 80 or one of the battery tray bolts for  
this.  
– If there are hose and cable connections located near the en‐  
gine lifting eyes for the Engine Support Bridge - 10-222A- ,  
these must now be removed.  
– Position the Engine Support Bridge - 10-222A- in front of the  
hood support.  
AWD  
5. Transmission, Removing and Installing, Jetta from MY 2005 , Golf Wagon from MY 2007 and Golf Wagon from MY 2010, Vehic1les6w9ith  
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤  
6-Speed Manual Transmission 02Q - Edition 05.2013  
– Use:  
– Position the Engine Support Bridge - Engine Support Feet -  
10-222A/8- :  
– Then connect the Engine Support Bridge - Gearbox Bracket -  
T10346- to the Engine Support Bridge - 10-222A- .  
– Hook the Spindles into the left lifting eye on the engine.  
– Pretension the engine/transmission assembly and Engine  
Support Bridge - 10-222A- via the spindles.  
– Loosen left and right front wheel bolts.  
– Raise the vehicle.  
– Remove the front wheels.  
– Remove the lower part of the left front wheel housing liner.  
Refer to ⇒ Body Exterior; Rep. Gr. 66 ; Wheel Housing Liner .  
– Remove the noise insulation. Refer to ⇒ Body Exterior; Rep.  
Gr. 50 ; Noise Insulation .  
170  
Rep. Gr.34 - Operation and Housing  
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤  
6-Speed Manual Transmission 02Q - Edition 05.2013  
– Transmission on vehicles with Start/Stop System: disconnect  
the connector -arrow- from the Transmission Neutral Position  
Sensor - G701- .  
– Remove the bracket from the starter.  
– Remove the starter. Refer to ⇒ Electrical Equipment; Rep. Gr.  
27 ; Starter; Starter, Removing and Installing .  
– Disconnect the connector -arrow 1- or -arrow 2- on the charge  
air hose. Refer to ⇒ Rep. Gr. 21 .  
– Remove the exhaust system bracket from the subframe  
-arrows-.  
– Disconnect the exhaust system at the clamping sleeve  
-arrows-.  
– Tie up the front exhaust pipe.  
AWD  
5. Transmission, Removing and Installing, Jetta from MY 2005 , Golf Wagon from MY 2007 and Golf Wagon from MY 2010, Vehic1les7w1ith  
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤  
6-Speed Manual Transmission 02Q - Edition 05.2013  
– Mark the position of the driveshaft with the flexible disk to the  
bevel gear flange.  
– Remove the driveshaft and flexible disk from the bevel gear  
flange shaft -arrows-.  
– Disconnect the connector -1- from the Oil Level Thermal Sen‐  
sor - G266- .  
– Remove the pendulum support from the transmission.  
Note  
After loosening the pendulum support bolts, the engine/transmis‐  
sion assembly swings forward slightly (toward the front end).  
Ensure that the sealing ring -arrow- in the flange of the driveshaft  
is not damaged during removal and installation.  
– Press the engine/transmission assembly slightly forward (to‐  
ward the front end) and pull the driveshaft off of the bevel gear.  
– Lift the driveshaft and secure it.  
– Remove the left and right coupling rods from the stabilizer bar.  
172  
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 nuts -arrows- for the ball joint on the control arm.  
– Secure the subframe before removing. Refer to ⇒ Suspen‐  
sion, Wheels, Steering; Rep. Gr. 40 ; Subframe; Subframe,  
Securing .  
– Remove the subframe and pendulum support, the stabilizer  
bar, the mounts, the steering gear and control arms. Refer to  
⇒ Suspension, Wheels, Steering; Rep. Gr. 40 ; Subframe;  
Overview - Subframe .  
– Remove the drive axle heat shield from the bevel box  
-arrows-.  
– Remove left and right drive axles from transmission flange  
shafts. Secure the drive axles. Do not damage the protective  
coating when doing this.  
Vehicles without A Particulate Filter  
– Remove the turbocharger oil return line -A- from the engine.  
Refer to ⇒ Rep. Gr. 21 .  
– Remove the transmission mount bolts at the engine and bevel  
gear -arrows 1 and arrows 2-.  
– Remove the transmission mount.  
AWD  
5. Transmission, Removing and Installing, Jetta from MY 2005 , Golf Wagon from MY 2007 and Golf Wagon from MY 2010, Vehic1les7w3ith  
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤  
6-Speed Manual Transmission 02Q - Edition 05.2013  
– Remove the support -A-, if equipped. Refer to ⇒ Rep. Gr. 26 .  
Vehicles with A Particulate Filter  
– Remove the upper particulate filter -A- from the engine  
-arrow 1- and from under the turbocharger -arrow 2-. Refer to  
⇒ Rep. Gr. 26 .  
– Loosen the nuts -1- and remove the nuts -2- to remove the  
particulate filter bracket from the engine.  
– Then tie the particulate filter to the plenum chamber bulkhead.  
– Remove the transmission mount bolts on the engine and bevel  
gear -arrows 1, arrows 2 and arrow 3-.  
The transmission support may not be removed until the transmis‐  
sion is removed from the engine.  
174  
Rep. Gr.34 - Operation and Housing  
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤  
6-Speed Manual Transmission 02Q - Edition 05.2013  
Vehicles with A Vacuum Diaphragm from 11/2009 -arrow 1-  
After 11/2009, a »brace« -arrow 2- is installed under the vacuum  
diaphragm -arrow 1- at the top of the transmission support (grad‐  
ual introduction).  
– Loosen the bolts -A- that connect the transmission mount to  
the engine.  
– Remove the transmission mount bolts -B- on the bevel gear.  
Continuation for All  
– Remove the subframe mount bolts -arrows- on the transmis‐  
sion.  
– Adjuster the spindles on the Engine Support Bridge - 10-222A-  
and lower the transmission to dimension -a-.  
•
Dimension -a- = approximately 60 mm  
Note  
When moving the engine/transmission assembly, be aware of the  
coolant hoses between the engine and heater core; do not strain.  
– Remove the bracket from the transmission -arrows-.  
AWD  
5. Transmission, Removing and Installing, Jetta from MY 2005 , Golf Wagon from MY 2007 and Golf Wagon from MY 2010, Vehic1les7w5ith  
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤  
6-Speed Manual Transmission 02Q - Edition 05.2013  
Metal Relay Lever  
– Remove the lock washer -arrow- from the relay lever -1- and  
then remove the relay lever.  
Plastic Relay Lever  
– Remove the relay lever with the cable retainer. Refer to  
⇒ “1.8 Plastic Relay Lever”, page 89 .  
Continuation for All  
– Remove the gearshift lever from the gearshift shaft.  
– Remove the lower transmission/engine connecting bolts  
-1 and 2- (engine side).  
Note  
Loosen the engine/transmission connecting bolt -3- and leave it  
in so that it is hand-tight.  
Align the Transmission Support - 3282- with the Transmission  
Support - Mounting Plate 33 - 3282/33- in order to remove the  
“02Q AWD” transmission.  
– Insert the Transmission Support - 3282- into the Engine and  
Gearbox Jack - VAS6931- .  
– Align the arms of the Transmission Support - 3282- so that  
they match up with the holes in the Adjustment Plate .  
– Install the Support Elements -A- as illustrated on the Adjust‐  
ment Plate .  
– Install the Transmission Support - Pins 29 - 3282/29- in place  
of the Mounting Element -C-.  
– Position the Engine-Gearbox Jack - VAG1383A- under the  
vehicle. The arrow symbol -B- on the Adjusting Plate points in  
direction of travel.  
– Align the Adjustment Plate so that it is parallel to the trans‐  
mission.  
– Install the Transmission Support - Pins 29 - 3282/29- into the  
hole on the transmission for the pendulum support bolt.  
– Secure the Slide Hammer Set - Adapter 40 - VW771/40- inside  
the threaded hole in the transmission housing as shown.  
– Secure the transmission on the Transmission Support - 3282-  
with an M10 x 20 bolt -A-.  
176  
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 last engine/transmission connecting bolt -3-.  
– Separate the transmission from the engine.  
Vehicles with A Particulate Filter  
– Remove the transmission support -A- from the bevel box -C-.  
Continuation for All  
– Move the transmission near the differential/bevel box slightly  
towards the rear, so that the small cover plate -B- or the inter‐  
mediate plate is not damaged.  
– Then guide the transmission past the flywheel -arrow-.  
– Then turn the transmission using the spindles -1- and -2- for  
the Transmission Support - 3282- so that it is does not touch  
the longitudinal member.  
– Carefully lower the transmission.  
Note  
Pay attention to all of the lines when lowering the transmission.  
AWD  
5. Transmission, Removing and Installing, Jetta from MY 2005 , Golf Wagon from MY 2007 and Golf Wagon from MY 2010, Vehic1les7w7ith  
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤  
6-Speed Manual Transmission 02Q - Edition 05.2013  
5.1.2  
Transmission, Installing  
Note  
♦ Refer to “Transmission, Removing” to get a list of the special  
tools needed. Refer to  
⇒ “5.1 Transmission, TDI, Removing and Installing”,  
page 166 .  
♦ Replace the self-locking nuts and bolts.  
♦ Replace bolts that were tightened with an additional turn.  
♦ Install any cable ties that were loosened or cut off during re‐  
moval at their same location.  
♦ Clean input shaft splines and (on used clutch plates) the hub  
splines, remove corrosion and apply a very thin coating of  
Grease for Clutch Disc Shaft Splines - G 000 100- to the  
splines. Then move the clutch plate back and forth on the input  
shaft until the hub moves freely on the shaft. Excess grease  
must be removed.  
– If the transmission is replaced, transfer the transmission shift  
lever and the relay lever.  
– Clean any locking compound residue from all threaded holes  
using a tap.  
– Check whether there are centering sleeves for the engine/  
transmission in the cylinder block; install if necessary.  
If the alignment sleeves are missing, it will be difficult to shift, there  
will be clutch problems and the transmission may make noises  
(loose rattling).  
– Make sure the intermediate plate is engaged on the sealing  
flange and pushed onto the alignment sleeves -arrows-.  
– Check the release bearing for wear. Replace the clutch slave  
cylinder with release bearing if necessary. Refer to  
⇒ “2.2 Clutch Slave Cylinder with Release Bearing, Removing  
and Installing”, page 52 .  
178  
Rep. Gr.34 - Operation and Housing  
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤  
6-Speed Manual Transmission 02Q - Edition 05.2013  
Align the Transmission Support - 3282- with the Transmission  
Support - Mounting Plate 33 - 3282/33- in order to install the “02Q  
AWD” transmission.  
– Align the Transmission Support arms so that they align with  
the holes in the Adjusting Plate .  
– Install the Support Elements -A- as illustrated on the Adjust‐  
ment Plate .  
– Install the Transmission Support - Pins 29 - 3282/29- in place  
of the Mounting Element -C-.  
– Place the transmission on the Engine and Gearbox Jack -  
VAS6931- .  
– Align the Adjustment Plate so that it is parallel to the trans‐  
mission.  
– Install the Transmission Support - Pins 29 - 3282/29- into the  
hole on the transmission for the pendulum support bolt.  
– Secure the Slide Hammer Set - Adapter 40 - VW771/40- inside  
the threaded hole in the transmission housing as shown.  
– Secure the transmission on the Transmission Support - 3282-  
with an M10 x 20 bolt -A-.  
– Position the Engine and Gearbox Jack - VAS6931- under the  
vehicle. The arrow on the adjusting plate points in direction of  
travel.  
– Position the transmission slightly upwards -arrow- in the area  
near the differential/bevel box using the spindles -1- and -2-  
for the Transmission Support - 3282- .  
AWD  
5. Transmission, Removing and Installing, Jetta from MY 2005 , Golf Wagon from MY 2007 and Golf Wagon from MY 2010, Vehic1les7w9ith  
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤  
6-Speed Manual Transmission 02Q - Edition 05.2013  
Note  
♦ Pay attention to all of the lines when installing the transmis‐  
sion.  
♦ For vehicles with a vacuum diaphragm -arrow-, do not touch  
the vacuum diaphragm with the bevel box while installing.  
Vehicles with A Particulate Filter  
– Lay the transmission support -A- on the bevel box -C- before  
inserting the transmission.  
Continuation for All  
– Guide the transmission past the flywheel -arrow- and the small  
cover plate -B- and the intermediate plate when installing.  
– Align the transmission with respect to the engine and install.  
– Install the engine/transmission connecting bolts  
-1 through 3- and tighten them to the tightening specification.  
Refer to ⇒ “5.1.3 Tightening Specifications”, page 186 .  
– After transmission is bolted to engine at bottom, remove  
Transmission Support - 3282- from transmission.  
– Attach the transmission gearshift lever to the gearshift shaft.  
Refer to  
⇒ Fig. ““Installing the Transmission Shift Lever”“ , page 88 and  
tighten the nut to tightening specification -item 17-  
⇒ Item 17 (page 87) .  
Metal Relay Lever  
– Install the relay lever -1- and the lock washer -arrow-.  
Plastic Relay Lever  
– Install the relay lever with the cable retainer. Refer to  
⇒ “1.8 Plastic Relay Lever”, page 89 .  
180  
Rep. Gr.34 - Operation and Housing  
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤  
6-Speed Manual Transmission 02Q - Edition 05.2013  
Continuation for All  
– Attach the bracket to the transmission using the new bolts  
-arrows- and then tighten them to the tightening specification.  
Refer to ⇒ “5.1.3 Tightening Specifications”, page 186 .  
– Align the engine/transmission in its installed position. To do  
this, tighten the spindles of the Engine Support Bridge -  
10-222A- until the bracket -1- is in complete contact with the  
transmission mount -2-.  
Note  
The transmission mount and bracket must be parallel to one an‐  
other to prevent damaging the thread inside the bracket.  
– Install new hex bolts -arrows- for the transmission mount -2-  
on the bracket -1- and tighten to the tightening specification.  
Refer to ⇒ “5.1.3 Tightening Specifications”, page 186 .  
WARNING  
Only remove the Engine Support Bridge - 10-222A- when all  
subframe mount bolts are tightened to the tightening specifi‐  
cation.  
Note  
Install the engine/transmission mount free of tension. Refer to ⇒  
Rep. Gr. 10 ; Engine, Removing and Installing .  
Vehicles without A Particulate Filter  
– Attach the bevel box transmission support to the engine. Fol‐  
low the tightening sequence when installing the bolts  
-arrows 1 and arrows 2-. Refer to  
⇒ “5.1.3 Tightening Specifications”, page 186 .  
– Attach the turbocharger oil return line -A- to the engine. Refer  
to ⇒ Rep. Gr. 21 .  
AWD  
5. Transmission, Removing and Installing, Jetta from MY 2005 , Golf Wagon from MY 2007 and Golf Wagon from MY 2010, Vehic1les8w1ith  
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤  
6-Speed Manual Transmission 02Q - Edition 05.2013  
– Install the support -A-, if equipped. Refer to ⇒ Rep. Gr. 26 .  
Vehicles with A Particulate Filter  
– Attach the bevel gear transmission mount to the engine and  
bevel gear. Follow the tightening sequence when installing the  
bolts -arrows 1, arrows 2 and arrow 3-. Refer to  
⇒ “5.1.3 Tightening Specifications”, page 186 .  
The bolt heads may be different from those shown in the illustra‐  
tion.  
Vehicles with A Vacuum Diaphragm from 11/2009 -arrow 1-  
After 11/2009, a »brace« -arrow 2- is installed under the vacuum  
diaphragm -arrow 1- at the top of the transmission support (grad‐  
ual introduction).  
– Fasten the bevel gear transmission mount to the engine and  
bevel gear while observing the tightening sequence for the  
bolts -A and B-. Refer to  
⇒ “5.1.3 Tightening Specifications”, page 186 .  
•
The bolt -C- must be screwed in.  
– Attach the particulate filter with the particulate filter bracket to  
the engine. Refer to ⇒ Rep. Gr. 26 .  
Continuation for All  
– Mount the right and left drive axles to the transmission. Refer  
to ⇒ Suspension, Wheels, Steering; Rep. Gr. 40 ; Drive Axles,  
Removing and Installing .  
– Install the drive axle heat shield on the bevel box -arrows-.  
Refer to ⇒ Suspension, Wheels, Steering; Rep. Gr. 40 ; Drive  
Axles, Overview and Servicing; Drive Axle Heat Shield .  
182  
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 subframe and pendulum support, the stabilizer bar,  
the mounts, the steering gear and control arms. Refer to ⇒  
Suspension, Wheels, Steering; Rep. Gr. 40 ; Subframe; Over‐  
view - Subframe .  
– Attach the driveshaft with the flexible disc to the bevel box  
flange -arrows-. Refer to ⇒ Rear Final Drive; Rep. Gr. 39 .  
Note  
♦ The holes for the pendulum support in transmissions from  
05/28/2007 have threaded inserts (for example “Heli Coil”).  
♦ Characteristic: there is a collar on the first thread -arrow-.  
♦ Observe the correct bolts and tightening specifications. Refer  
to ⇒ Suspension, Wheels, Steering; Rep. Gr. 40 ; Subframe;  
Overview - Subframe .  
– Attach the pendulum support to the transmission. Refer to ⇒  
Suspension, Wheels, Steering; Rep. Gr. 40 ; Subframe; Over‐  
view - Subframe .  
– Assemble the exhaust system and then attach the exhaust  
system bracket it to the subframe. Refer to ⇒ Rep. Gr. 26 .  
AWD  
5. Transmission, Removing and Installing, Jetta from MY 2005 , Golf Wagon from MY 2007 and Golf Wagon from MY 2010, Vehic1les8w3ith  
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤  
6-Speed Manual Transmission 02Q - Edition 05.2013  
– Attach the charge air hose -arrow-. Refer to ⇒ Rep. Gr. 21 .  
– Install the upper engine/transmission connecting bolts and  
tighten them to the tightening specification. Refer to  
⇒ “5.1.3 Tightening Specifications”, page 186 .  
– If equipped, install the breather tube -arrow- in the bevel gear  
and tighten to 10 Nm.  
– Position the starter and install the lower bolt. Refer to ⇒ Elec‐  
trical Equipment; Rep. Gr. 27 ; Starter; Starter, Removing and  
Installing .  
– Attach the bracket for the lines to the lower starter bolt.  
– Install the starter bolt and then connect the connector and  
wires to the starter. Refer to ⇒ Electrical Equipment; Rep. Gr.  
27 ; Starter; Starter, Removing and Installing .  
– Attach the ground cable -1- to the top starter bolt.  
– Connect the connector -2- to the Back-Up Lamp Switch - F4- .  
– Transmission on vehicles with Start/Stop System: connect the  
connector -arrow- to the Transmission Neutral Position Sensor  
- G701- .  
184  
Rep. Gr.34 - Operation and Housing  
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤  
6-Speed Manual Transmission 02Q - Edition 05.2013  
– Push the hose/line assembly or pipe -A- into the bleeder/clutch  
slave cylinder to the stop and push the clamp -arrow- down‐  
ward.  
– Pull on the line to make sure it is secure.  
– Remove the Hose Clamps - Up To 25mm - 3094- from the  
hose/line assembly or from the supply hose.  
– After removing the Hose Clamps - Up To 25mm - 3094- , bring  
the return hose back to its original shape.  
– Bleed the clutch mechanism. Refer to  
⇒ “1.10 Clutch Mechanism, Bleeding”, page 48 .  
– Make sure the vacuum hose for the brake system is installed  
correctly. Refer to ⇒ Brake System; Rep. Gr. 47 ; Hydraulic  
System .  
– Attach the cable mounting bracket to the transmission and  
tighten the bolts and nuts -arrows- to the tightening specifica‐  
tion -item 6- ⇒ Item 6 (page 86) and -item 10-  
⇒ Item 10 (page 86) .  
– Apply a small amount of grease to the pin -arrow- on the gear‐  
shift lever -1-.  
Refer to the Parts Catalog for the grease allocation.  
– Slide the shift cable onto the respective pins -arrow- and se‐  
cure it with a new lock washer -3-.  
Metal Relay Lever  
– Apply a small amount of grease to the pin -arrow- of the relay  
lever -2-.  
Refer to the Parts Catalog for the grease allocation.  
– Slide the selector cable onto the respective pins -arrow- and  
secure it with a new lock washer -4-.  
Plastic Relay Lever  
– Insert the selector cable into the cable retainer.  
Continuation for All  
– Adjust the gearshift mechanism. Refer to  
⇒ “1.11 Selector Mechanism, Adjusting”, page 97 .  
AWD  
5. Transmission, Removing and Installing, Jetta from MY 2005 , Golf Wagon from MY 2007 and Golf Wagon from MY 2010, Vehic1les8w5ith  
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤  
6-Speed Manual Transmission 02Q - Edition 05.2013  
– Secure the lines -A- to the bracket -B-.  
– Install the engine cover if necessary.  
– Install the complete air filter housing, if it was removed earlier.  
Refer to ⇒ Rep. Gr. 23 ; Diesel Direct Injection System; Air  
Filter Housing, Removing and Installing .  
– Connect the battery and observe procedure after connecting  
battery. Refer to ⇒ Electrical Equipment; Rep. Gr. 27 ; Battery;  
Battery, Disconnecting and Connecting .  
– Check transmission fluid level inside the manual transmission.  
Refer to ⇒ “8 Transmission Fluid, Checking”, page 192 .  
– Check the gear oil in the bevel box. Refer to  
⇒ “10 Axle Oil in Bevel Box, Checking or Adding”, page 218 .  
– Install the lower part of the left front wheel housing liner. Refer  
to ⇒ Body Exterior; Rep. Gr. 66 ; Wheel Housing Liner .  
– Install the noise insulation. Refer to ⇒ Body Exterior; Rep. Gr.  
50 ; Noise Insulation .  
– Install the wheels. Refer to ⇒ Suspension, Wheels, Steering;  
Rep. Gr. 44 ; Wheel Installation Tightening Specifications .  
– Check the headlamp adjustment if the vehicle has a Left Front  
Level Control System Sensor - G78- . Refer to ⇒ Electrical  
Equipment; Rep. Gr. 94 ; Headlamps; Headlamp, Adjusting .  
5.1.3  
Tightening Specifications  
Transmission to Engine (engine flange face)  
Item  
1
Bolt  
Quantity  
1
Nm  
80  
M12 x 55  
♦ With a short M8 threa‐  
ded pin  
2
3
M12 x 55  
♦ With a long threaded  
pin M8  
1
1
80  
80  
M12 x 70  
or M12 x 65  
4
5
6
M10 x 50  
M10 x 105  
M12 x 165  
♦ With a short M8 threa‐  
ded pin  
2
1
1
40  
40  
80  
♦ Also starter to trans‐  
mission  
186  
Rep. Gr.34 - Operation and Housing  
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤  
6-Speed Manual Transmission 02Q - Edition 05.2013  
Item  
7
Bolt  
Quantity  
1
Nm  
80  
M12 x 165  
♦ With a short M8 threa‐  
ded pin  
♦ Also starter to trans‐  
mission  
-
M6 x 8  
1
10  
♦ Small flywheel cover  
plate (not present on all  
engines)  
-A- and -B-: alignment bushings  
Vehicles without A Particulate Filter  
Install the Transmission Mount.  
The following assembly sequence must be followed when instal‐  
ling the transmission mount:  
– Install the bolts -arrows 1- hand-tight.  
– Tighten the bolts -arrows 2- to 40 Nm.  
– Tighten the bolts -arrows 1- to 40 Nm.  
Vehicles with A Particulate Filter  
Install the Transmission Mount.  
Allocation of bolts  
Item  
Bolt  
Quantity  
1
2
3
M10 x 21  
M10 x 45  
M10 x 62  
3
2
1
The following assembly sequence must be followed when instal‐  
ling the transmission mount:  
– Hand-tighten all bolts.  
– Tighten the bolts -arrows 2 and arrow 3- to 40 Nm.  
– Tighten the bolts -arrows 1- to 40 Nm.  
AWD  
5. Transmission, Removing and Installing, Jetta from MY 2005 , Golf Wagon from MY 2007 and Golf Wagon from MY 2010, Vehic1les8w7ith  
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤  
6-Speed Manual Transmission 02Q - Edition 05.2013  
Vehicles with A Vacuum Diaphragm from 11/2009 -arrow 1-  
From 11/2009, there is a »brace« -arrow 2- under the vacuum  
diaphragm -arrow 1- at the top of the transmission support (run‐  
ning change).  
Allocation of bolts  
Item  
A
B
Bolt  
Quantity  
M10 x 21  
M10 x 45  
2
2
The following assembly sequence must be followed when instal‐  
ling the transmission mount:  
– Hand-tighten all bolts.  
– Tighten the bolts -A- to 40 Nm.  
– Tighten the bolts -B- to 40 Nm.  
Continuation for All  
Transmission Bracket -1- to Transmission.  
– Replace the bolts.  
Tighten the bolts -arrows-: 60 Nm + 90°.  
Transmission to Body  
– Replace the bolts.  
Tighten the bolts -arrows-: 60 Nm + 90°.  
Note  
Install the engine/transmission mount free of tension. Refer to ⇒  
Rep. Gr. 10 ; Engine, Removing and Installing .  
188  
Rep. Gr.34 - Operation and Housing  

Related Topics

OperationandHousing
1 Shift Mechanism, Servicing 1.1 Shift Mechanism Installation Position 1.2 Overview - Selector Mechanism 1.3 Overview - Gearshift Knob and Cover 1.4 Boot with Shifter Knob and Noise Insulation, Removing and Installing 1.5 Overview - Gearshift Lever and Gearshift Housing, through 10/2006 1.6 Overview - Gearshift Lever and Gearshift Housing, from 11/2006 1.7 Overview - Operating Cables 1.8 Plastic Relay Lever 1.9 Selector Mechanism, Removing and Installing 1.10 Gearshift Cable and Selector Cable, Removing and Installing 1.11 Selector Mechanism, Adjusting 1.12 Selector Mechanism, Disassembling and Assembling, from 11/2006 2 Transmission, Removing and Installing, Jetta from MY 2005... Diesel FWD 2.1 Transmission, Removing and Installing 2.2 Tightening Specifications 3 Transmission, Removing and Installing, Jetta from MY 2005... Gasoline FWD 3.1 Transmission, Removing and Installing 3.2 Tightening Specifications 4 Transmission, Removing and Installing, Jetta from MY 11, Diesel and Gasoline 4.1 Transmission, Removing and Installing 4.2 Tightening Specifications 5 Transmission, Removing and Installing, Jetta from MY 2005... AWD 6 Transmission, Transporting 6.1 FWD, Transporting Transmission 6.2 AWD, Transporting Transmission 7 Transmission, Securing in Engine/Transmission Holder 8 Transmission Fluid, Checking 9 Bevel Box, Removing and Installing 9.1 Bevel Box, Vehicles with TDI Engine without Particulate Filter... 9.2 Bevel Box... Vehicles with a Turbo Diesel Engine with a Particulate Filter... 9.3 Bevel Box... Vehicles with a Turbo Diesel Engine with a Particulate Filter... 10 Axle Oil in Bevel Box, Checking or Adding 10.1 Gear Oil in Bevel Box, Checking 10.2 Gear Oil in Bevel Box, Filling 11 Transmission, Disassembling and Assembling 11.1 Overview - Transmission, FWD 11.2 Overview - Transmission, AWD 11.3 Overview - FWD 11.4 Overview - AWD 11.5 Transmission Housing and Gearshift Mechanism, Removing and Installing 11.6 Overview - Input Shaft, Output Shafts... FWD Vehicles 11.7 Overview - Input Shaft, Output Shaft... AWD Vehicles 11.8 Assembly Sequence, Transmission ?without? a Securing Ring A... 11.9 Assembly Sequence: I = Transmission ?with? a Securing Ring A... 12 Transmission Housing, Servicing 13 Clutch Housing, Servicing 14 Shift Unit, Servicing 14.1 Selector Shaft Seal, Replacing 15 Shift Forks, Servicing 16 Special Tools 17 Special Tools

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