Get TechnicalData -> 7 General Repair Information 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

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

TechnicalData -> 7 General Repair Information for Your Volkswagen Golf 4 Door Fifth Generation (2003-2008)

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