2003-2008 Volkswagen Golf 4 Door TechnicalData User Manual
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TechnicalData 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  
00 – Technical Data  
1
Transmission Identification, FWD  
(Edition 05.2013)  
⇒ “1.1 Location on Transmission”, page 1  
⇒ “1.2 Codes Letters, Transmission Allocation and Capacities,  
FWD”, page 2  
The 6-speed manual transmission 02Q is installed with a 4-cylin‐  
der engine in the Jetta from MY 2005, the Golf Wagon from MY  
2007, the Golf Wagon from MY 2010 and the Jetta from MY 2011.  
Allocation. Refer to  
⇒ “1.2 Codes Letters, Transmission Allocation and Capacities,  
FWD”, page 2 .  
1.1  
Location on Transmission  
Code letters and build date -arrow 1- manual transmission 02Q  
-arrow 2-  
Manual Transmission 02Q -arrow 2-  
Transmission Codes and Production Date-arrow-  
Example:  
GRF  
I
I
25  
I
I
11  
I
I
3
I
I
Codes  
Day Month  
Year (2003)  
of manufacture  
Additional data and information is provided by the factory.  
Note  
The transmission code is also listed on the vehicle data label.  
1. Transmission Identification, FWD  
1
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤  
6-Speed Manual Transmission 02Q - Edition 05.2013  
1.2  
Codes Letters, Transmission Allocation and Capacities, FWD  
Manual Transmission  
Codes  
6-Speed 02Q FWD  
GVT  
GRF  
GXC  
Manufactured  
from  
05/2005  
05/2005  
07/2006  
through  
11/2005  
11/2005  
07/2006  
Allocation  
Type Jetta from MY 2005 Jetta from MY 2005 Jetta from MY 2005  
Golf Wagon from MY Golf Wagon from MY Golf Wagon from MY  
2007  
2007  
2007  
Engine  
2.0L - 103 kW  
2.0L - 147 kW  
2.0L - 125 kW  
Turbo-Diesel  
Turbo FSI  
Turbo-Diesel  
1)  
Ratio: Z : Z  
69 : 20 = 3.450  
69 : 25 = 2.760  
71 : 18 = 3.944  
71 : 23 = 3.087  
71 : 18 = 3.944  
71 : 23 = 3.087  
Final drive I  
2
1
2)  
Final drive II  
Manual Transmission Capacity  
Refer to ⇒ Fluid Ca‐ Refer to ⇒ Fluid Ca‐ Refer to ⇒ Fluid Ca‐  
pacity Tables; Rep.  
Gr. 03  
pacity Tables; Rep.  
Gr. 03  
pacity Tables; Rep.  
Gr. 03  
Driveshaft Flange Diameter  
107 mm  
107 mm  
107 mm  
1)  
2)  
Final drive for 1st to 4th gear  
Final drive for 5th/6th and reverse gears  
•
Refer to the Parts Catalog for the following information.  
♦ The individual gear ratios  
♦ Transmission fluid specification  
♦ Clutch disc and pressure plate allocation  
Manual Transmission  
Codes  
6-Speed 02Q FWD  
HVS  
HDV  
05/2005  
JLU  
Manufactured  
from  
07/2006  
05/2006  
through  
05/2007  
Allocation  
Type Jetta from MY 2005 Jetta from MY 2005 Jetta from MY 2005  
Golf Wagon from MY Golf Wagon from MY Golf Wagon from MY  
2007  
2007  
2007  
Engine  
2.0L - 96 kW  
turbo diesel  
2.0L - 100 kW  
turbo diesel  
2.0L - 103 kW  
turbo diesel  
2.0L - 125 kW  
2.0L - 100 kW  
Turbo-Diesel  
turbo diesel  
2.0L - 103 kW  
turbo diesel  
1)  
Ratio: Z : Z  
69 : 20 = 3.450  
70 : 19 = 3.684  
70 : 24 = 2.917  
72 : 17 = 4.235  
72 : 22 = 3.273  
Final drive I  
2
1
2)  
69 : 25 = 2.760  
Final drive II  
Manual Transmission Capacity  
Refer to ⇒ Fluid Ca‐ Refer to ⇒ Fluid Ca‐ Refer to ⇒ Fluid Ca‐  
pacity Tables; Rep.  
Gr. 03  
pacity Tables; Rep.  
Gr. 03  
pacity Tables; Rep.  
Gr. 03  
Driveshaft Flange Diameter  
107 mm  
107 mm  
107 mm  
1)  
2)  
Final drive for 1st to 4th gear  
Final drive for 5th/6th and reverse gears  
•
Refer to the Parts Catalog for the following information.  
♦ The individual gear ratios  
♦ Transmission fluid specification  
♦ Clutch disc and pressure plate allocation  
2
Rep. Gr.00 - Technical Data  
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤  
6-Speed Manual Transmission 02Q - Edition 05.2013  
Manual Transmission  
Codes  
6-Speed 02Q FWD  
JLW  
JMA  
KDN  
Manufactured  
from  
05/2006  
06/2006  
05/2007  
through  
05/2007  
06/2007  
01/2008  
Allocation  
Type Jetta from MY 2005 Jetta from MY 2005 Jetta from MY 2005  
Golf Wagon from MY  
2007  
Golf Wagon from MY  
2007  
Engine  
2.0L - 147 kW  
2.0L - 125 KW  
Turbo diesel  
2.0L - 100 kW  
Turbo FSI  
turbo diesel  
2.0L - 103 kW  
turbo diesel  
1)  
Ratio: Z : Z  
71 : 18 = 3.944  
71 : 23 = 3.087  
70 : 19 = 3.684  
70 : 24 = 2.917  
69 : 20 = 3.450  
Final drive I  
2
1
2)  
69 : 25 = 2.760  
Final drive II  
Manual Transmission Capacity  
Refer to ⇒ Fluid Ca‐ Refer to ⇒ Fluid Ca‐ Refer to ⇒ Fluid Ca‐  
pacity Tables; Rep.  
Gr. 03  
pacity Tables; Rep.  
Gr. 03  
pacity Tables; Rep.  
Gr. 03  
Driveshaft Flange Diameter  
107 mm  
107 mm  
107 mm  
1)  
2)  
Final drive for 1st to 4th gear  
Final drive for 5th/6th and reverse gears  
•
Refer to the Parts Catalog for the following information.  
♦ The individual gear ratios  
♦ Transmission fluid specification  
♦ Clutch disc and pressure plate allocation  
Manual Transmission  
Codes  
6-Speed 02Q FWD  
KDS  
KDQ  
KNS  
Manufactured  
from  
07/2007  
07/2007  
11/2007  
through  
03/2008  
06/2008  
10/2008  
Allocation  
Type Jetta from MY 2005 Jetta from MY 2005 Jetta from MY 2005  
Golf Wagon from MY  
2007  
Golf Wagon from MY  
2007  
Golf Wagon from MY  
10  
Engine  
2.0L - 147 kW  
Turbo FSI  
2.0L - 125 KW  
Turbo diesel  
2.0L - 100 kW  
turbo diesel  
2.0L - 103 kW  
turbo diesel  
1)  
Ratio: Z : Z  
71 : 18 = 3.944  
71 : 23 = 3.087  
70 : 19 = 3.684  
70 : 24 = 2.917  
69 : 20 = 3.450  
Final drive I  
2
1
2)  
69 : 25 = 2.760  
Final drive II  
Manual Transmission Capacity  
Refer to ⇒ Fluid Ca‐ Refer to ⇒ Fluid Ca‐ Refer to ⇒ Fluid Ca‐  
pacity Tables; Rep.  
Gr. 03  
pacity Tables; Rep.  
Gr. 03  
pacity Tables; Rep.  
Gr. 03  
Driveshaft Flange Diameter  
107 mm  
107 mm  
107 mm  
1)  
2)  
Final drive for 1st to 4th gear  
Final drive for 5th/6th and reverse gears  
•
Refer to the Parts Catalog for the following information.  
♦ The individual gear ratios  
♦ Transmission fluid specification  
♦ Clutch disc and pressure plate allocation  
1. Transmission Identification, FWD  
3
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤  
6-Speed Manual Transmission 02Q - Edition 05.2013  
Manual Transmission  
Codes  
6-Speed 02Q FWD  
KNY  
KNU  
KRM  
Manufactured  
from  
11/2007  
02/2008  
05/2007  
through  
02/2009  
10/2008  
07/2010  
Allocation  
Type Jetta from MY 2005 Jetta from MY 2005 Jetta from MY 2005  
Golf Wagon from MY  
2007  
Golf Wagon from MY  
2007  
Golf Wagon from MY  
10  
Engine  
2.0L - 147 KW  
2.0L - 155 KW  
2.0L - 125 KW  
Turbo diesel  
2.0L - 100 kW  
turbo diesel  
2.0L - 103 kW  
turbo diesel  
1)  
Ratio: Z : Z  
71 : 18 = 3.944  
71 : 23 = 3.087  
70 : 19 = 3.684  
70 : 24 = 2.917  
69 : 20 = 3.450  
Final drive I  
2
1
2)  
69 : 25 = 2.760  
Final drive II  
Manual Transmission Capacity  
Refer to ⇒ Fluid Ca‐ Refer to ⇒ Fluid Ca‐ Refer to ⇒ Fluid Ca‐  
pacity Tables; Rep.  
Gr. 03  
pacity Tables; Rep.  
Gr. 03  
pacity Tables; Rep.  
Gr. 03  
Driveshaft Flange Diameter  
107 mm  
107 mm  
107 mm  
1)  
2)  
Final drive for 1st to 4th gear  
Final drive for 5th/6th and reverse gears  
•
Refer to the Parts Catalog for the following information.  
♦ The individual gear ratios  
♦ Transmission fluid specification  
♦ Clutch disc and pressure plate allocation  
Manual Transmission  
Codes  
6-Speed 02Q FWD  
KXZ  
KXX  
05/2009  
KZS  
Manufactured  
from  
05/2009  
05/2009  
through  
Allocation  
Type Jetta from MY 2005 Jetta from MY 2005  
Jetta from MY 05  
Golf Wagon from MY Golf Wagon from MY Golf Wagon from MY  
2007  
2007  
07  
Jetta from MY 11  
Engine  
2.0L - 100 kW  
turbo diesel  
2.0L - 100 KW  
turbo diesel  
2.0L - 155 KW  
2.0L - 147 KW  
2.0L - 103 kW  
turbo diesel  
2.0L - 103 KW  
turbo diesel  
2.0L - 125 KW  
turbo diesel  
1)  
Ratio: Z : Z  
69 : 20 = 3.450  
69 : 25 = 2.760  
70 : 19 = 3.684  
70 : 19 = 3.684  
70 : 24 = 2.917  
Final drive I  
2
1
2)  
70 : 24 = 2.917  
Final drive II  
Manual Transmission Capacity  
Driveshaft Flange Diameter  
Refer to ⇒ Fluid Ca‐ Refer to ⇒ Fluid Ca‐ Refer to ⇒ Fluid Ca‐  
pacity Tables; Rep.  
Gr. 03  
pacity Tables; Rep.  
Gr. 03  
pacity Tables; Rep.  
Gr. 03  
107 mm  
107 mm  
107 mm  
   
4
Rep. Gr.00 - Technical Data  
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤  
6-Speed Manual Transmission 02Q - Edition 05.2013  
Manual Transmission  
Codes  
6-Speed 02Q FWD  
KXX  
KXZ  
KZS  
1)  
2)  
Final drive for 1st to 4th gear  
Final drive for 5th/6th and reverse gears  
•
Refer to the Parts Catalog for the following information.  
♦ The individual gear ratios  
♦ Transmission fluid specification  
♦ Clutch disc and pressure plate allocation  
Manual Transmission  
Codes  
6-Speed 02Q FWD  
MDL  
LHD  
10/2008  
NFN  
Manufactured  
from  
11/2009  
05/2009  
through  
Allocation  
Type Jetta from MY 05  
Golf Wagon from MY  
07  
Jetta from MY 2011 Jetta from MY 2005  
Golf Wagon from MY  
10  
Jetta from MY 11  
Engine  
2.0L - 100 kW  
2.0L - 147 KW  
2.0L - 125 KW  
Turbo diesel  
turbo diesel  
2.0L - 103 kW  
turbo diesel  
1)  
2)  
Ratio: Z : Z  
69 : 20 = 3.450  
70 : 19 = 3.684  
70 : 24 = 2.917  
70 : 19 = 3.684  
70 : 24 = 2.917  
Final drive I  
Final drive II  
2
1
69 : 25 = 2.760  
Manual Transmission Capacity  
Refer to ⇒ Fluid Ca‐ Refer to ⇒ Fluid Ca‐ Refer to ⇒ Fluid Ca‐  
pacity Tables; Rep.  
Gr. 03  
pacity Tables; Rep.  
Gr. 03  
pacity Tables; Rep.  
Gr. 03  
Driveshaft Flange Diameter  
107 mm  
107 mm  
107 mm  
1)  
2)  
Final drive for 1st to 4th gear  
Final drive for 5th/6th and reverse gears  
•
Refer to the Parts Catalog for the following information.  
♦ The individual gear ratios  
♦ Transmission fluid specification  
♦ Clutch disc and pressure plate allocation  
Manual Transmission  
Codes  
6-Speed 02Q FWD  
PDA  
NFP  
05/2010  
Manufactured  
from  
12/2012  
through  
Allocation  
Type Golf Wagon from MY Jetta from MY 2011  
2010  
Engine  
2.0L - 103 kW  
Turbo-Diesel  
2.0L - 155 KW  
1)  
Ratio: Z : Z  
69 : 20 = 3.450  
70 : 19 = 3.684  
70 : 24 = 2.917  
Final drive I  
2
1
2)  
69 : 25 = 2.760  
Final drive II  
Manual Transmission Capacity  
Refer to ⇒ Fluid Ca‐ Refer to ⇒ Fluid Ca‐  
pacity Tables; Rep.  
Gr. 03  
pacity Tables; Rep.  
Gr. 03  
1. Transmission Identification, FWD  
5
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤  
6-Speed Manual Transmission 02Q - Edition 05.2013  
Manual Transmission  
Codes  
6-Speed 02Q FWD  
PDA  
NFP  
Driveshaft Flange Diameter  
107 mm  
107 mm  
1)  
2)  
Final drive for 1st to 4th gear  
Final drive for 5th/6th and reverse gears  
•
Refer to the Parts Catalog for the following information.  
♦ The individual gear ratios  
♦ Transmission fluid specification  
♦ Clutch disc and pressure plate allocation  
6
Rep. Gr.00 - Technical Data  
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤  
6-Speed Manual Transmission 02Q - Edition 05.2013  
2
Transmission Identification, AWD  
⇒ “2.1 Location on Transmission”, page 7  
⇒ “2.2 Code Letters, Transmission Allocation and Capacities,  
AWD”, page 7  
The 6 speed manual transmission 02Q AWD is installed along  
with the 4 cylinder turbo diesel engine in the Jetta from MY 2005 ,  
the Golf Wagon from MY 2007, and the Golf Wagon from MY  
2010.  
2.1  
Location on Transmission  
Code letters and build date -arrow 1- manual transmission 02Q,  
AWD-arrow 2-  
Manual Transmission 02Q AWD -arrow 2-  
Engine Code and Build Date -arrow-  
Example:  
HJR  
I
I
04  
I
I
08  
I
I
4
I
I
Codes  
Day Month  
Year (2004)  
of manufacture  
Additional data and information is provided by the factory.  
Note  
The transmission code is also listed in the vehicle data plates.  
2.2  
Code Letters, Transmission Allocation and Capacities, AWD  
Manual Transmission  
Codes  
6-Speed 02Q AWD  
JLS  
FWZ  
JYS  
Manufactured  
from  
08/2004  
07/2007  
03/2006  
05/2007  
05/2007  
11/2007  
through  
2. Transmission Identification, AWD  
7
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤  
6-Speed Manual Transmission 02Q - Edition 05.2013  
Manual Transmission  
Codes  
6-Speed 02Q AWD  
JLS  
FWZ  
JYS  
Allocation  
Type Jetta from MY 2005 Golf Wagon from MY Golf Wagon from MY  
Golf Wagon from MY  
2007  
07  
07  
Engine  
1.9L - 77 KW  
1.9L - 77 KW  
Turbo diesel  
1.9L - 77 KW  
Turbo diesel  
Turbo diesel  
1)  
Ratio: Z : Z  
2
72 : 17 = 4.235  
72 : 22 = 3.273  
72 : 17 = 4.235  
72 : 17 = 4.235  
Final drive I  
1
2)  
72 : 22 = 3.273  
72 : 22 = 3.273  
Final drive II  
Manual Transmission Capacity  
Bevel box capacity  
Driveshaft Flange Diameter  
Refer to ⇒ Fluid Capacity Tables; Rep. Gr. 03  
Refer to ⇒ Fluid Capacity Tables; Rep. Gr. 03  
107 mm  
1)  
2)  
Final drive for 1st to 4th gear  
Final drive for 5th/6th and reverse gears  
•
Refer to the Parts Catalog for the following information.  
♦ The individual gear ratios  
♦ Transmission fluid specification  
♦ Clutch disc and pressure plate allocation  
♦ Bevel box axle oil  
♦ Rear final drive allocation  
Manual Transmission  
Codes  
6-Speed 02Q AWD  
KNQ  
KDX  
KXV  
Manufactured  
from  
05/2007  
02/2008  
07/2009  
through  
05/2008  
Allocation  
Type Golf Wagon from MY Golf Wagon from MY Golf Wagon from MY  
07  
2007  
Golf Variant from MY  
2010  
07  
Engine  
1.9L - 77 KW  
Turbo diesel  
1.9L - 77 KW  
Turbo diesel  
1.6L - 77 KW  
Turbo diesel  
1.9L - 77 KW  
Turbo diesel  
1)  
Ratio: Z : Z  
72 : 17 = 4.235  
72 : 22 = 3.273  
72 : 17 = 4.235  
72 : 17 = 4.235  
72 : 22 = 3.273  
Final drive I  
2
1
2)  
72 : 22 = 3.273  
Final drive II  
Manual Transmission Capacity  
Bevel box capacity  
Driveshaft Flange Diameter  
Refer to ⇒ Fluid Capacity Tables; Rep. Gr. 03  
Refer to ⇒ Fluid Capacity Tables; Rep. Gr. 03  
107 mm  
1)  
2)  
Final drive for 1st to 4th gear  
Final drive for 5th/6th and reverse gears  
•
Refer to the Parts Catalog for the following information.  
♦ The individual gear ratios  
♦ Transmission fluid specification  
♦ Clutch disc and pressure plate allocation  
♦ Bevel box axle oil  
♦ Rear final drive allocation  
   
8
Rep. Gr.00 - Technical Data  
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤  
6-Speed Manual Transmission 02Q - Edition 05.2013  
Manual Transmission  
Codes  
6-Speed 02Q AWD  
LNN  
Manufactured  
from  
07/2009  
through  
Allocation  
Type Golf Wagon from MY  
2010  
Engine  
1.6L - 77 kW  
turbo diesel  
1)  
2)  
Ratio: Z : Z  
72 : 17 = 4.235  
Final drive I  
Final drive II  
2
1
72 : 22 = 3.273  
Manual Transmission Capacity  
Bevel box capacity  
Driveshaft Flange Diameter  
Refer to ⇒ Fluid Capacity Tables; Rep. Gr. 03  
Refer to ⇒ Fluid Capacity Tables; Rep. Gr. 03  
107 mm  
1)  
2)  
Final drive for 1st to 4th gear  
Final drive for 5th/6th and reverse gears  
•
Refer to the Parts Catalog for the following information.  
♦ The individual gear ratios  
♦ Transmission fluid specification  
♦ Clutch disc and pressure plate allocation  
♦ Bevel box axle oil  
♦ Rear final drive allocation  
2. Transmission Identification, AWD  
9
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤  
6-Speed Manual Transmission 02Q - Edition 05.2013  
3
Overview - Transmission, FWD  
Components  
-Arrows- point in the direction of travel  
1 - Engine  
2 - Clutch  
3 - Manual Transmission  
4 - Input Shaft  
5 - Output Shaft for 5th, 6th and  
Reverse Gears (output shaft II)  
6 - Output Shaft for 1st through  
4th Gear (output shaft I)  
7 - Differential  
Ratio  
-Arrows- point in the direction of travel  
10  
Rep. Gr.00 - Technical Data  
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤  
6-Speed Manual Transmission 02Q - Edition 05.2013  
I - 1st Gear  
II - 2nd Gear  
III - 3rd Gear  
IV - 4th Gear  
V - 5th Gear  
VI - 6th Gear  
R - Reverse Gear  
A - Final Drive  
3. Overview - Transmission, FWD  
11  
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤  
6-Speed Manual Transmission 02Q - Edition 05.2013  
4
Overview - Transmission, AWD  
Components  
The -arrows- point in the direction of travel.  
1 - Engine  
2 - Clutch  
3 - Manual Transmission  
4 - Input Shaft  
5 - Output Shaft for 5th, 6th and  
Reverse Gears (output shaft II)  
6 - Output Shaft for 1st through  
4th Gear (output shaft I)  
7 - Differential  
8 - Bevel Box  
9 - Driveshaft  
10 - Haldex Clutch  
11 - Rear Final Drive  
12 - Differential  
Ratio  
The -arrows- point in the direction of travel.  
12  
Rep. Gr.00 - Technical Data  
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤  
6-Speed Manual Transmission 02Q - Edition 05.2013  
I - 1st Gear  
II - 2nd Gear  
III - 3rd Gear  
IV - 4th Gear  
V - 5th Gear  
VI - 6th Gear  
R - Reverse Gear  
A - Final Drive  
W1 - Front Bevel Box  
W2 - Rear Bevel Box  
4. Overview - Transmission, AWD  
13  
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤  
6-Speed Manual Transmission 02Q - Edition 05.2013  
5
Transmission Ratio “i”, Calculating  
Example  
6th Gear  
ZG = 43  
Final Drive  
ZA = 25  
Drive gear  
1
1
Driven gear  
ZG = 35  
ZA = 69  
2
2
1)  
i = ZG : ZG  
2
1
i
= gear ratio = ZG : ZG = 35 : 43 = 0.814  
G
2
1
i = Axle ratio = ZG : ZG = 69 : 25 = 2,760  
A
2
1
i
= total ratio = i x i = 0.814 x 2.760 = 2.247  
total  
G
A
1) Z = Number of teeth on the drive gear, Z = Number of teeth on the driven  
1
2
gear  
14  
Rep. Gr.00 - Technical Data  
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤  
6-Speed Manual Transmission 02Q - Edition 05.2013  
6
Notes on Performance Test, AWD  
– Only test stands with 4 braked rollers should be used for the  
performance test.  
6. Notes on Performance Test, AWD  
15  
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤  
6-Speed Manual Transmission 02Q - Edition 05.2013  
7
General Repair Information  
⇒ “7.1 Safety Precautions, Vehicles with Start/Stop System”,  
page 16  
⇒ “7.2 Contact Corrosion”, page 16  
⇒ “7.3 Special Tools”, page 16  
⇒ “7.4 Components”, page 16  
The highest level of care and cleanliness along with tools that  
function properly are required to ensure a proper and successful  
transmission repair. Of course the general safety precautions also  
apply when carrying out repair work.  
A list of general instructions that apply to multiple repair proce‐  
dures throughout the repair manual are summarized once here  
under the “Components” section. Refer to  
⇒ “7.4 Components”, page 16 . They apply to this repair manual.  
7.1  
Safety Precautions, Vehicles with Start/  
Stop System  
WARNING  
Risk of injury if the engine starts automatically in vehicles with  
a Start/Stop System.  
♦ For vehicles with an activated Start/Stop System (recog‐  
nizable from a notification in the instrument cluster), the  
engine can be started automatically if needed.  
♦ Make sure the Start/Stop system is deactivated when  
working on the vehicle (turn off ignition and turn the ignition  
back on if needed).  
7.2  
Contact Corrosion  
♦ The transmission housing and clutch housing consist of a  
magnesium alloy.  
♦ Bolts and other components, which come into direct contact  
with the transmission, have a surface coating adapted for this.  
♦ Contact corrosion occurs when incorrect components (bolts,  
nuts, washers, etc.) are used. The transmission housing and  
clutch housing are damaged.  
♦ Only install components provided in the Parts Catalog.  
7.3  
Special Tools  
Refer to Workshop Equipment and Special Tools for a complete  
list of special tools used in the repair manual.  
7.4  
Components  
Transmission  
♦ Make sure that the alignment bushings between the engine  
and transmission are positioned correctly when installing the  
manual transmission.  
♦ Clean the contact surfaces when installing brackets and  
waxed components. Contact surfaces must be free of wax and  
grease.  
16  
Rep. Gr.00 - Technical Data  
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤  
6-Speed Manual Transmission 02Q - Edition 05.2013  
♦ Allocate the bolts and other components. Refer to the Parts  
Catalog.  
FWD  
♦ Check the transmission fluid level after installation. Refer to  
⇒ “8 Transmission Fluid, Checking”, page 192 .  
♦ For capacities, refer to  
⇒ “1.2 Codes Letters, Transmission Allocation and Capacities,  
FWD”, page 2 . For specification. Refer to the Parts Catalog.  
AWD  
♦ After installing the transmission and/or bevel box, check the  
transmission fluid level in the manual transmission and the  
gear oil level in the bevel box (Manual Transmission. Refer to  
⇒ “8 Transmission Fluid, Checking”, page 192 ), (Bevel Box.  
Refer to  
⇒ “10 Axle Oil in Bevel Box, Checking or Adding”,  
page 218 ).  
♦ For capacities. Refer to  
⇒ “2.2 Code Letters, Transmission Allocation and Capacities,  
AWD”, page 7 . For specification. Refer to the Parts Catalog.  
O-Rings, Gaskets, Seals and Sealant  
♦ Always thoroughly clean the separating surfaces on the hous‐  
ing before applying the sealant.  
♦ Apply the Sealant - AMV 188 200 03- evenly and not too thick.  
♦ Replace the O-rings, seals and gaskets.  
♦ Flange shaft, input shaft and selector shaft seals are illustrated  
as shaft seals.  
♦ Once a shaft seal or gasket has been removed, check the  
contact surface on the housing or shaft for burrs and damage  
caused by the removal. Repair as necessary.  
♦ Before installing the shaft seals, lightly oil the outer circumfer‐  
ence and fill the space between the sealing lips -arrow- half‐  
way with Grease - G 052 128 A1- .  
♦ The open side on the shaft seals faces the fluid to be sealed  
off.  
♦ Press in new shaft seal, so that the sealing lip does not run on  
the same point as the sealing lip of the old shaft seal (use offset  
tolerance).  
♦ Lightly lubricate the O-rings before inserting to prevent the  
rings from being crushed during assembly.  
♦ Check the fluid level in the manual transmission after replacing  
the seals, O-rings and gaskets (Refer to  
⇒ “8 Transmission Fluid, Checking”, page 192 .) or the fluid  
level in the bevel box (Refer to  
⇒ “10 Axle Oil in Bevel Box, Checking or Adding”,  
page 218 .)  
7. General Repair Information  
17  
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤  
6-Speed Manual Transmission 02Q - Edition 05.2013  
Circlips  
♦ Do not stretch the circlips.  
♦ Installation position for some of the circlips: the circlip is »nar‐  
rower at the top« and so is its installation position. This makes  
it easier for the pliers to grab the circlip when removing and  
installing it.  
♦ Replace damaged or overstretched locking ring after remov‐  
ing.  
♦ The circlips must rest at the bottom of the groove.  
♦ Replace the adapter sleeves. Installation position: the slot  
-A- should align with the line of force -arrow-.  
18  
Rep. Gr.00 - Technical Data  
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤  
6-Speed Manual Transmission 02Q - Edition 05.2013  
Bolts and Nuts  
♦ Always loosen or tighten bolts and nuts on covers and hous‐  
ings diagonally with a tightening sequence.  
♦ Especially delicate components, such as clutch pressure  
plates, must not be distorted. Loosen and tighten bolts and  
nuts in stages in a diagonal sequence.  
♦ The tightening specifications given apply to unoiled bolts and  
nuts.  
♦ Always replace self-locking bolts and nuts.  
♦ Make sure the contact surfaces and visible surfaces on the  
nuts and bolts are waxed after assembling.  
♦ Use a wire brush to clean the threads of the bolts that were  
installed with locking fluid. Then insert the bolts with Locking  
Fluid - AMV 185 101 A1- .  
♦ Clean the threaded holes for the self-locking bolts or for the  
bolts coated with locking fluid (for example with a thread tap).  
Otherwise the bolts could shear the next time they are re‐  
moved.  
♦ Please make sure that the thread pitch is correct so that the  
proper thread tap is used during cleaning, and the thread does  
not get damaged.  
♦ Make sure the contact surfaces and visible surfaces on the  
nuts and bolts are waxed after assembling.  
Bearings  
♦ Install needle bearings with the lettered side (thicker metal)  
facing the fitting tool.  
♦ Insert all the bearings in transmission with transmission fluid.  
♦ Replace all the tapered roller bearings that are on the same  
shaft, and use tapered roller bearings from the same manu‐  
facturer.  
♦ Heat the tapered roller bearing inner races to approximately  
100 °C (212 °F) with the Inductive Heat Unit - VAS6414- before  
installing. Press on to the stop when installing, so there is no  
axial clearance.  
♦ Do not interchange outer and inner bearing races with those  
from other bearing of the same size. The bearings are paired.  
Shims  
♦ Measure the shims at several locations with a micrometer cal‐  
iper. Tolerance variations make it possible to find the exact  
shim thickness required.  
♦ Check for scratches and damages.  
♦ Only install flawless shims.  
Synchronizer Rings  
7. General Repair Information  
19  
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤  
6-Speed Manual Transmission 02Q - Edition 05.2013  
♦ Do not interchange them. When reusing synchronizer rings,  
always install on the same gear wheel.  
♦ Check for wear and replace if necessary.  
♦ Check the grooves -arrow 1- on the synchronizer ring -A- and  
the inner race for flat areas (grooves are worn).  
♦ The coating on the synchronizer rings must not be damaged.  
♦ If an intermediate ring -B- is installed, check the outer friction  
surface -arrow 2- and the inner friction surface -arrow 3- for  
»grooves« and »scoring«.  
♦ Check taper of drive gear for »grooves« and »scoring«.  
♦ Coat the synchronizing ring with transmission fluid and then  
install.  
Gear Wheels, Synchronizer Hubs and Needle Bearing Sleeve  
♦ Warm the needle bearing sleeves to approximately 100 °C  
(212 °F) with an Inductive Heater - VAS6414- .  
♦ Heat the synchronizer hub to approximately 100 °C (212 °F)  
with the Inductive Heat Unit - VAS6414- before installing.  
Press on as far as the stop when installing so there is no axial  
play.  
♦ Heat the gears to approximately 100 °C (212 °F) with the In‐  
ductive Heat Unit - VAS6414- before installing. Press on as far  
as the stop when installing so there is no axial play.  
♦ Pay attention to the installed location.  
Selector Gears  
♦ After assembling, check the selector gears for minimum axial  
clearance and ease of movement.  
Clutch  
♦ Do not tilt the clutch pressure plate. Loosen and tighten it di‐  
agonally and in small steps.  
♦ To reduce odor caused by a burnt clutch, thoroughly clean the  
clutch housing and the flywheel running surface with a clean  
cloth.  
20  
Rep. Gr.00 - Technical Data  

Related Topics

1 Transmission Identification, FWD 1.1 Location on Transmission 1.2 Codes Letters, Transmission Allocation and Capacities, FWD 2 Transmission Identification, AWD 2.1 Location on Transmission 2.2 Code Letters, Transmission Allocation and Capacities, AWD 3 Overview - Transmission, FWD 4 Overview - Transmission, AWD 5 Transmission Ratio ?i?, Calculating 6 Notes on Performance Test, AWD 7 General Repair Information 7.1 Safety Precautions, Vehicles with Start/Stop System 7.2 Contact Corrosion 7.3 Special Tools 7.4 Components

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