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Service

Workshop Manual
Golf Variant 2007 ➤
Golf Variant 2010 ➤
Jetta 2005 ➤
6-speed manual gearbox 02S
Edition 07.2009

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Service Department. Technical Information


Service
List of Workshop Manual Repair GroupsList of Workshop Manual
Repair GroupsList of Workshop Manual Repair Groups

Repair Group
00 - Technical data
30 - Clutch
34 - Controls, housing
35 - Gears, shafts
39 - Final drive - differential

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Technical information should always be available to the foremen and mechanics, because their
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careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
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safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a C py
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All rights reserved.


No reproduction without prior agreement from publisher.

Copyright © 2010 Volkswagen AG, Wolfsburg MEX5R007520


Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
6-speed manual gearbox 02S - Edition 07.2009

Contents

00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Gearbox identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Location on gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . n.A.G.. .V.ol.ks.w.a.g.en. A. G. . . . . . . . . . . . . . . . 1
1.2 Identification code, assembly allocation and capacities wage . . . . . . . . . . . . . d.o.es. n. . . . . . . . . . . . 1
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2 Overview - power transmission . . . . . . . r.is.ed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ra.nt.e . . . . . 5
tho eo
3 Calculating overall gear ratio “i” . . . s.a.u . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .r a.c . . 7
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4 General repair notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

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4.1 Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

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30 - Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

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1 Fault finding, power transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

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2 Repairing clutch mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

spec
urposes, in part or in wh

2.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

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2.2 Assembly overview - pedal cluster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.3 Removing and installing over-centre spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

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2.4 Removing and installing clutch pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2.5 Removing and installing mounting bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

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2.6 Removing and installing master cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

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2.7 Removing and installing clutch position sender G476 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

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2.8 Assembly overview - hydraulics (LHD vehicles) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
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2.9 Assembly overview - hydraulics (RHD vehicles) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
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2.10 Removing and installing slave cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

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2.11 Bleeding clutch system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42


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3 Repairing clutch release mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

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4 Repairing clutch, in conjunction with dual-mass flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . 46


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4.1 Determining clutch manufacturer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
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4.2 Removing and installing Sachs clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
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4.3 Repairing Sachs clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . cted
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4.4 Removing and installing LuK clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
4.5 Repairing LuK clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
5 Repairing clutch, in conjunction with one-piece flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . 54

34 - Controls, housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
1 Fault finding, power transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
2 Repairing selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
2.1 Installation position of selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
2.2 Overview of selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
2.3 Removing and installing gear knob and frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
2.4 Removing and installing gaiter with gear knob and noise insulation . . . . . . . . . . . . . . . . . . 61
2.5 Repairing gear lever and selector housing (through 10.06) . . . . . . . . . . . . . . . . . . . . . . . . 63
2.6 Repairing gear lever and selector housing (from 11.06) . . . . . . . . . . . . . . . . . . . . . . . . . . 65
2.7 Assembly overview - removing and installing selector cables . . . . . . . . . . . . . . . . . . . . . . 70
2.8 Plastic relay lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
2.9 Removing and installing selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
2.10 Removing and installing gear selector cable and gate selector cable . . . . . . . . . . . . . . . . 78
2.11 Adjusting selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
3 Removing and installing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
3.1 Removing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
3.2 Installing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
4 Checking and topping up gear oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
4.1 Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

Contents i
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
6-speed manual gearbox 02S - Edition 07.2009

4.2 Draining gear oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100


4.3 Filling with gear oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
5 Dismantling and assembling gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
5.1 Overview - gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
5.2 Assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
5.3 Removing and installing cover for gearbox housing and 5th and 6th gear . . . . . . . . . . . . 104
5.4 Removing and installing gearbox housing and shift mechanism . . . . . . . . . . . . . . . . . . . . 107
5.5 Removing and installing input shaft, output shaft, differential and selector forks . . . . . . . . 108
5.6 Assembly sequence - Removing and installing cover for gearbox housing and 5th and 6th
gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
5.7 Assembly sequence - Dismantling and assembling gearbox completely . . . . . . . . . . . . . . 115
6 Repairing gearbox housing and clutch housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
7 Repairing gearbox housing cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
8 Repairing selector unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
9 Dismantling and assembling selector forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145

35 - Gears, shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150


1 Input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
1.1 Dismantling and assembling input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
1.2 Adjusting input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
2 Output shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
2.1 Dismantling and assembling output shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
2.2 Adjusting output shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
3 Reverse shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
3.1 Dismantling and assembling reverse shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181

39 - Final drive - differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184


1 Renewing flange shaft oil seals with gearbox installed . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
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1.1 Renewing oil seal for left flange lksw shaft . . . . . . . . . . . .es. n.o.t . . . . . . . . . . . . . . . . . . . . . . . . . . .
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1.2 Distinguishing seals for ed
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ran 185
1.3 Renewing seal (two-part ris seal and sleeve for right flange shaft) tee.o. . . . . . . . . . . . . . . . . . . . . 186
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1.4 Renewing seal sands a sleeve together (one-piece seal and sleeve foracright flange shaft) . . . . 189
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2 Adjustment overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192


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3 Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
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3.1 Dismantling and assembling differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193


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3.2 Adjusting differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200


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ii Contents
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
6-speed manual gearbox 02S - Edition 07.2009

AG. Volkswagen AG d
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1 Gearbox identification a ra
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The 6-speed manual gearbox 02S is installed in the Jetta 2005 ▸,

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Allocation ⇒ page 1 .

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Code letters and date of manufacture -arrow 1- Manual gearbox
02S -arrow 2-

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Manual gearbox 02S -arrow 2-


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Identification code and date of gearbox manufacture


Example: FNG 12 11 3
I I I I
I I I I
Identification Day Month Year (2003)
code of manufacture
Additional data provide information about the production facility.

Note

The gearbox code also appears on the vehicle identification


plates.

1.2 Identification code, assembly allocation and capacities


Manual gearbox 6-speed 02S
Identification code FNG HYG GQM
Manufactured from 05.05 05.06 05.05
to 05.05 09.06
Allocation Model Jetta 2005 ▸ Jetta 2005 ▸ Jetta 2005 ▸
Golf Variant 2007 ▸ Golf Variant 2007 ▸ Golf Variant 2007 ▸

1. Gearbox identification 1
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
6-speed manual gearbox 02S - Edition 07.2009

Manual gearbox 6-speed 02S


Identification code FNG HYG GQM
Engine 1.9 l - 74 kW 1.4 l - 103 kW 1.9 l - 74 kW
turbo diesel turbo diesel
1.9 l - 77 kW 1.9 l - 77 kW
turbo diesel turbo diesel
Ratio Final drive 62 : 17 = 3.647 61 : 18 = 3.389 61 : 18 = 3.389
Z1 : Z2
Capacity of manual gearbox (gear‐ 2.1 l 2.1 l 2.1 l
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Identification code GQP GXV rrectness of i JAU
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Manufactured from 05.05 05.05 11.05


to 07.05 08.06 07.06
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Allocation Model
Jetta 2005 ▸ Jetta 2005 ▸ Jetta 2005 ▸
Golf Variant 2007 ▸ Golf Variant 2007 ▸ Golf Variant 2007 ▸
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Engine 2.0 l - 110 kW 2.0 l - 110 kW 1.4 l - 125 kW


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Drive shaft flange ∅ 100 mm 100 mm 107 mm
• The following data can be found in the ⇒ Electronic parts catalogue “ETKA” .
♦ Individual gear ratios
♦ Specification for gear oil
♦ Allocation of clutch plate and pressure plate

Manual gearbox 6-speed 02S


Identification code JYL JCL JCN
Manufactured from 09.06 05.06 05.06
to 09.06 09.06
Allocation Model Jetta 2005 ▸ Jetta 2005 ▸ Jetta 2005 ▸
Golf Variant 2007 ▸ Golf Variant 2007 ▸ Golf Variant 2007 ▸
Engine 2.0 l - 110 kW 1.9 l - 77 kW 2.0 l - 110 kW
turbo diesel
Ratio Final drive 63 : 16 = 3.938 61 : 18 = 3.389 62 : 17 = 3.647
Z1 : Z2

2 Rep. Gr.00 - Technical data


Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
6-speed manual gearbox 02S - Edition 07.2009

Manual gearbox 6-speed 02S


Identification code JYL JCL JCN
Capacity of manual gearbox (gear‐ 2.1 l 2.1 l 2.1 l
box completely dismantled)
Capacity of manual gearbox 1.9 l 1.9 l 1.9 l
⇒ page 99 (gearbox partially dis‐
mantled)
Drive shaft flange ∅ 100 mm 100 mm 100 mm
• The following data can be found in the ⇒ Electronic
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Identification code JCP JCQ JYG
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Manufactured 05.06 from 05.06 09.06

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09.06 to 09.06
Allocation Jetta 2005 ▸ Model Jetta 2005 ▸ Jetta 2005 ▸
Golf Variant 2007 ▸ Golf Variant 2007 ▸ Golf Variant 2007 ▸

rrectness of i
Engine 2.0 l - 110 kW 1.4 l - 125 kW 1.4 l - 125 kW
l purpos

Ratio Final drive 63 : 16 = 3.938 62 : 17 = 3.647 62 : 17 = 3.647


Z1 : Z2

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Capacity of manual gearbox (gear‐ 2.1 l 2.1 l 2.1 l

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Capacity of manual gearbox 1.9 l 1.9 l 1.9 l
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♦ Allocation of clutch plate and pressure plate

Manual gearbox 6-speed 02S


Identification code JXP JXR KWB
Manufactured from 09.06 09.06 07.08
to
Allocation Model Jetta 2005 ▸ Jetta 2005 ▸ Jetta 2005 ▸
Golf Variant 2007 ▸ Golf Variant 2007 ▸ Golf Variant 2007 ▸
Golf Variant 2010 ▸
Engine 1.4 l - 103 kW 2.0 l - 110 kW 1.4 l - 118 kW
Ratio Final drive 62 : 17 = 3,647
Z1 : Z2
Capacity of manual gearbox (gear‐ 2.1 l
box completely dismantled)
Capacity of manual gearbox 1.9 l
⇒ page 99 (gearbox partially dis‐
mantled)
Drive shaft flange ∅ 100 mm

1. Gearbox identification 3
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
6-speed manual gearbox 02S - Edition 07.2009

Manual gearbox 6-speed 02S


Identification code JXP JXR KWB
• The following data can be found in the ⇒ Electronic parts catalogue “ETKA” .
♦ Individual gear ratios
♦ Specification for gear oil
♦ Allocation of clutch plate and pressure plate

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4 Rep. Gr.00 - Technical data


Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
6-speed manual gearbox 02S - Edition 07.2009

2 Overview - power transmission


Designation
-Arrows- indicate direction of travel.

1 - Engine
2 - Clutch
3 - Manual gearbox
4 - Input shaft n AG. Volkswagen AG do
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5- Output shaft by Vo lk ot g
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6- Differential
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Ratio
-Arrows- indicate direction of travel.

2. Overview - power transmission 5


Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
6-speed manual gearbox 02S - Edition 07.2009

I - 1st gear
II - 2nd gear
III - 3rd gear
IV - 4th gear
V - 5th gear
VI - 6th gear
R - Reverse gear
A - Final drive

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6 Rep. Gr.00 - Technical data


Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
6-speed manual gearbox 02S - Edition 07.2009
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3 Calculating overall gear ratio “i” tho
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6th gear Final drive

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Drive gear ZG1 = 45 ZA1 = 18

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Driven gear ZG2 = 34 ZA2 = 60

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i = Z2 : Z1 1)
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iG = Gear ratio = ZG2: ZG1= 34 : 45 = 0.756
iA = Final drive ratio = ZA2 : ZA1 = 60 : 18 = 3.389

rrectness of i
itotal = Overall ratio = iG x iA = 0.756 x 3.389 = 2.562
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1) Z1 = No. of teeth on driving gear, Z2 = No. of teeth on driven gear

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3. Calculating overall gear ratio “i” 7


Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
6-speed manual gearbox 02S - Edition 07.2009

4 General repair notes


To ensure flawless and successful gearbox repairs, the greatest
care and cleanliness as well as the use of good and proper tools
are essential. Of course, the basic rules for safety also apply dur‐
ing repair work.
A number of instructions generally applicable to the various repair
procedures - which were previously repeated a number of times
at various places in the workshop manual are summarised under
the topic “components” ⇒ page 8 . They apply to this workshop
manual.

4.1 Components n AG. Volkswagen AG


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♦ When installing the manual gearbox, ensure that the dowel

pt
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sleeves between the engine and gearbox are correctly seated.


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♦ When installing mounting brackets or waxed components,

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clean the contact surfaces. Contact surfaces must be free of

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wax and grease.

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spec
♦ Allocate bolts and other components using ⇒ Electronic parts
urposes, in part or in wh

catalogue “ETKA” . t to the co


♦ Capacity ⇒ page 1 .
rrectne

♦ If the gearbox is repaired, fill with gear oil.


Capacity, gearbox completely Gearbox capacity, gearbox
ss

dismantled partially dismantled


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⇒ page 99
inform
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2.1 l 1.9 l
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4.1.2 O-rings, seals, gaskets and sealants


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♦ Thoroughly clean housing joint surfaces before applying seal‐


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♦ Always renew O-rings, seals and gaskets. yri
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♦ After removing gaskets and seals, always inspect contact sur‐
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face of housing or shaft for burrs resulting from removal or for
other signs of damage.
♦ Before installing radial shaft seals, lightly oil outer diameter
and half-fill space between sealing lips -arrow- with sealing
grease -G 052 128 A1- .
♦ The open side of the oil seal faces the side with fluid filling.
♦ Press in new oil seals so that sealing lip does not contact the
shaft in the same place as the old seal (make use of insertion
depth tolerances).
♦ Lightly oil O-rings before installing; this prevents the rings be‐
ing crushed when inserted.
♦ After renewing seals and gaskets, check oil level in gearbox
and replenish if necessary ⇒ page 99 .

8 Rep. Gr.00 - Technical data


Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
6-speed manual gearbox 02S - Edition 07.2009

4.1.3 Locking devices


♦ Do not overstretch retaining rings.
♦ Always renew retaining rings which have been damaged or
overstretched.
♦ Retaining rings must locate properly in grooves.
♦ Renew spring pins. Installation position: slit -A- should be in
line with the line of force -arrow-.

4.1.4 Nuts and bolts


♦ Loosen nuts or bolts in the order opposite to the tightening
sequence.
♦ Nuts and bolts which secure covers and housings should be
loosened and tightened diagonally in stages if no tightening
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♦ Torque settings are specified for unoiled bolts and nuts.
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♦ Always renew self-locking bolts and nuts.
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♦ Threads of bolts secured with locking fluid must be cleaned


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with a wire brush. Then insert bolts with locking fluid -


h re
hole

AMV 185 101 A1- . spec


es, in part or in w

♦ Clean threaded holes in which self-locking bolts or bolts with


t to the co

locking fluid have been inserted, e.g. with a thread chaser.


Otherwise there is a danger that the bolts may shear when
removed again.
rrectness of i
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4.1.5 Bearing
♦ Install needle bearings with lettered side (thicker metal) to‐
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wards fitting tool.


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♦ Lubricate all gearbox bearings with gear oil before installing.


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♦ Tapered roller bearings fitted to one shaft must be renewed as


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a set. Use same make of bearings.


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♦ Heat inner races to about 100° C with the inductive heater -


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VAS 6414- before installing.
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4. General repair notes 9


Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
6-speed manual gearbox 02S - Edition 07.2009

4.1.6 Shims
♦ Measure shims at several points with a micrometer. The var‐
ious thicknesses make it possible to achieve the exact shim
thickness required.
♦ Check for burrs and damage.
♦ Install only flawless shims.

4.1.7 Synchro-rings
♦ Do not interchange. When reusing synchro-rings, always fit to
the same gear.
♦ Check for wear and renew if necessary.
♦ Check grooves -arrow 1- of synchro-ring -A- and inner ring for
flat spots (worn grooves).
♦ If synchro-rings are coated, coating must not be damaged.
♦ If an intermediate ring -B- is installed, check the outer friction
surface -arrow 2- and inner friction surface -arrow 3- of this
intermediate ring for “scoring” and “signs of abnormal wear”.
♦ Check cone of synchromeshed gear for “scoring” and “signs
of abnormal wear”.
♦ Moisten synchromesh mechanism with gear oil before instal‐
ling.

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♦ Heat inner races for synchromeshed gear to about 100° C with
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the inductive heater -VAS 6414- before installing.


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♦ Heat synchro-hub with inductive heater -VAS 6414- to approx.


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100 °C before installing. Press in to stop when installing so


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there is no axial clearance.


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♦ Heat gears with inductive heater -VAS 6414- to approx. 100 °


spec

C before installing. Press in to stop when installing so there is


es, in part or in w

no axial clearance.
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♦ Observe installation position.


rrectness of i

4.1.9 Synchromeshed gears


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♦ After assembly, check synchromeshed gears for slight play, or


for freedom of movement.
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4.1.10 Clutch
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♦ When removing gearbox, remove slave cylinder without dis‐


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connecting pipes.
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Rep. Gr.00 - Technical data
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
6-speed manual gearbox 02S - Edition 07.2009

♦ Ensure that the pressure plate does not cant: loosen and tight‐
en bolts diagonally and in several gradual stages.
♦ If the clutch has burnt out, thoroughly clean the clutch housing
as well as the friction surface of flywheel with a cloth to reduce
the smell of burnt linings.

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4. General repair notes 11


Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
6-speed manual gearbox 02S - Edition 07.2009

30 – Clutch
1 Fault finding, power transmission
– Refer to ⇒ Fault finding, power transmission; Rep. Gr. 30 ;
Complaints about clutch and clutch mechanism and ⇒ Fault
finding, power transmission; Rep. Gr. 34 ; Complaints about
selector mechanism

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12 Rep. Gr.30 - Clutch


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ss 6-speed manual gearbox 02S c - Edition 07.2009

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2.1 Overview
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Note

rrectness of i
♦ Before disconnecting battery, obtain code for radio units having anti-theft coding.
l purpos

♦ With ignition switched off, disconnect battery earth strap ⇒ Electrical system; Rep. Gr. 27 ; Disconnecting
and connecting battery .

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♦ When reconnecting battery, refer to ⇒ Electrical system; Rep. Gr. 27 ; Disconnecting and connecting

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battery .
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♦ Lubricate all bearings and contact surfaces with grease -G 000 450 02- .

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I - Assembly overview - pedal
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cluster ⇒ page 14
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II - Assembly overview - hy‐ yri
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draulics (LHD) ⇒ page 37 cop Vo
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III - Assembly overview - hy‐
AG.

draulics (RHD) ⇒ page 39

2. Repairing clutch mechanism 13


Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
6-speed manual gearbox 02S - Edition 07.2009

2.2 Assembly overview - pedal cluster

1 - Bulkhead
❑ With support for mount‐
ing bracket
2 - Seal
❑ Always renew
❑ Between mounting agen
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❑ Bond to mounting aut ra
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3 - Mounting bracket

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❑ For mounting clutch

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❑ Is provided with damp‐

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ing in some equipment

spec
variants ⇒ page 15
urposes, in part or in wh

t to the co
❑ Removing and installing
⇒ page 25
4 - Bolt

rrectne
5 - Over-centre spring

ss
❑ Removing and installing

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⇒ page 15

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6 - Bearing bush

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7 - Pivot pin
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8 - Clutch pedal
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❑ Removing and installing


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⇒ page 20
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9 - Retainer
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❑ To remove and install,
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der from clutch pedal
⇒ page 20
10 - Seal
❑ Always renew
❑ Between master cylinder and mounting bracket
11 - Master cylinder
❑ Removing and installing after removal of mounting bracket ⇒ page 25
12 - Clutch position sender -G476-
❑ Removing and installing ⇒ page 33
❑ Can be checked using “guided fault finding” of vehicle diagnostic tester
❑ The clutch position sender -G476- is identified as clutch pedal switch -F36- in “guided fault finding”.
13 - Clip
❑ Pull out clip to stop to remove and install pipe/hose line
14 - Supply hose
❑ Rubber
❑ From 12.05, plastic ⇒ page 38
15 - Hexagon nut, 25 Nm
❑ Self-locking

14 Rep. Gr.30 - Clutch


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6-speed manual gugearbox 02S - Edition 07.2009
ara
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❑ Qty. 3 aut
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❑ For mounting bracket on bulkhead

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❑ Always renew

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16 - Hexagon nut, 25 Nm

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❑ Always renew

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17 - Stop
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urposes, in part or in wh

❑ For clutch pedal

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Mounting bracket with damping -arrows-

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2.3 Removing and installing over-centre


spring
Special tools and workshop equipment required
♦ Release tool -T10178-

2.3.1 Removing
Vehicles with knee airbag

Note

The installation location of the knee airbag is above the pedal


cluster.

– First check whether a coded radio is fitted. If so, obtain anti-


theft code.

2. Repairing clutch mechanism 15


Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
6-speed manual gearbox 02S - Edition 07.2009

– With ignition switched off, disconnect battery earth strap ⇒


Electrical system; Rep. Gr. 27 ; Disconnecting and connecting
battery .
Continuation for all
– Push driver seat as far back as possible and put steering wheel
in highest position.
– Remove trim and cover below trim on drive side ⇒ General
body repairs, interior; Rep. Gr. 68 .
Vehicles with knee airbag
– Remove bracket for knee airbag together with crash bar ⇒
Interior equipment; Rep. Gr. 69 ; Airbag; Removing and in‐
stalling knee airbag bracket .
Continuation for all
– Remove cable guide -2- from steering column.
– Remove footwell vent -3- ⇒ Heating, air conditioning; Rep.
Gr. 80 ; Repairing heating .
Vehicles without knee airbag
The crash bar -1- in front of clutch pedal -2- may be secured in
different ways.

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Attachment with
ss a2 bolts
u ra
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– Remove crash bar -1- (2 bolts).


nl

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es, in part or in w

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Attachment with 1 bolt


– Remove crash bar -1- (1 bolt -2-).
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16 Rep. Gr.30 - Clutch


Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
6-speed manual gearbox 02S - Edition 07.2009

– If fitted, remove damping -arrow- from lower area of clutch


pedal mounting bracket.
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– To do this, remove lock washers -A- for damping.

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orm
– Pull off damping.
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– Push damping upwards in area of upper securing nut -1-


above clutch pedal -A- in -direction of arrow-.

2. Repairing clutch mechanism 17


Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
6-speed manual gearbox 02S - Edition 07.2009

– Unbolt clutch pedal -1- from mounting bracket -3- by removing


nut -2- and pulling out bolt -5-.

Note

The clutch pedal remains hooked to operating rod of master cyl‐


inder.

– Swing clutch pedal down slightly and remove over-centre


spring -4- from mounting bracket.
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2.3.2 Installing

h re
hole

spec
Install in the reverse order of removal, observing the following:
es, in part or in w

t to the co
Note

rrectness of i
Renew self-locking nuts.
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– Insert over-centre spring -2- in mounting bracket from above


nf
ercia

while holding end of spring with assembly tool -T10178- in in‐ or


stallation position.
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• Receptacle -arrow- for tip -A- of clutch pedal must stand ver‐
tically.
– Insert tip of clutch pedal in bearing recess of over-centre
spring.
– Depress clutch pedal slightly, push bolt through and tighten
self-locking nut to specified torque ⇒ page 20 .

18 Rep. Gr.30 - Clutch


Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
6-speed manual gearbox 02S - Edition 07.2009

Some cars have damping -arrow- on the clutch pedal mounting


bracket.
– Return it to installation position.
Vehicles without knee airbag

AG. Volkswagen AG d
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hole

spec
es, in part or in w

The crash bar -1- in front of clutch pedal -2- may be secured in

t to the co
different ways.
Attachment with 2 bolts

rrectness of i
– Install crash bar -1- and tighten the 2 bolts to specified torque
l purpos

⇒ page 20 .

nform
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– Install crash bar -1- and tighten bolt -2- to specified torque
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⇒ page 20 .
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Continuation for all
Prote AG.

– Mount cable guide -2- on steering column.


– Install footwell vent -3- ⇒ Heating, air conditioning; Rep. Gr.
80 ; Repairing heating .
Vehicles with knee airbag
– Install bracket for knee airbag together with crash bar ⇒ Inte‐
rior equipment; Rep. Gr. 69 ; Airbag; Removing and installing
knee airbag bracket .
Continuation for all
– Install trim and cover below trim on drive side ⇒ General body
repairs, interior; Rep. Gr. 68 .
– If disconnected, connect battery ⇒ Electrical system; Rep. Gr.
27 ; Removing and installing battery .

2. Repairing clutch mechanism 19


Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
6-speed manual gearbox 02S - Edition 07.2009

2.3.3 Specified torques


Component Nm
Clutch pedal to mounting bracket 25
♦ Renew self-locking nuts

Crash bar to steering column mounting 10


bracket (attachment with 2 bolts)
Crash bar to steering column mounting swagen AG. Vo20
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bracket (attachment with 1 bolt) byV
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erm

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2.4.1 Removing
Vehicles with knee airbag

Note

The installation location of the knee airbag is above the pedal


cluster.

– First check whether a coded radio is fitted. If so, obtain anti-


theft code.
– With ignition switched off, disconnect battery earth strap ⇒
Electrical system; Rep. Gr. 27 ; Disconnecting and connecting
battery .

20 Rep. Gr.30 - Clutch


Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
6-speed manual gearbox 02S - Edition 07.2009

Continuation for all


– Push driver seat as far back as possible and put steering wheel
in highest position. en AG. V
olkswagen AG
ag does
ol ksw not
– Remove trim and cover below trim on drive y V side ⇒ General gu
db ara
body repairs, interior; Rep. Gr. 68 . rise nte
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The installation location of the knee airbag is above the pedal

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cluster.

h re
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spec
es, in part or in w

– First check whether a coded radio is fitted. If so, obtain anti-

t to the co
theft code.
– With ignition switched off, disconnect battery earth strap ⇒
Electrical system; Rep. Gr. 27 ; Disconnecting and connecting

rrectness of i
battery .
l purpos

Continuation for all


– Remove cable guide -2- from steering column.

nform
mercia

– Remove footwell vent -3- ⇒ Heating, air conditioning; Rep.

at
om

i
Gr. 80 ; Repairing heating .

on
c

in t
or

Vehicles without knee airbag

his
ate

do
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cum
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Cop py
ht. rig
rig ht
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co Vo
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Prote AG.

The crash bar -1- in front of clutch pedal -2- may be secured in
different ways.
Attachment with 2 bolts
– Remove crash bar -1- (2 bolts).

Attachment with 1 bolt


– Remove crash bar -1- (1 bolt -2-).
Continuation for all

2. Repairing clutch mechanism 21


Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
6-speed manual gearbox 02S - Edition 07.2009
n AG. Volkswagen AG do
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– If fitted, remove damping -arrow- fromy Vlower
olks area of clutch ot g
ua
pedal mounting bracket. ise
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es, in part or in w

t to the co
rrectness of i
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nform
mercia

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tio
– To do this, remove lock washers -A- for damping.

n in
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te o

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– Pull off damping.

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– Push damping upwards in area of upper securing nut -1-


above clutch pedal -A- in -direction of arrow-.

22 Rep. Gr.30 - Clutch


Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
6-speed manual gearbox 02S - Edition 07.2009

– Unbolt clutch pedal -1- from mounting bracket -3- by removing


nut -2- and pulling out bolt -5-.
– Swing clutch pedal down slightly and remove over-centre
spring -4- from mounting bracket.

– Release clutch pedal from master cylinder with pliers -


T10005- .
– Remove clutch pedal.
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2.4.2 Installing
hole

spec
es, in part or in w

Install in the reverse order of removal, observing the following:


t to the co

Note
rrectness of i
l purpos

Renew self-locking nuts.


nf
ercia

– Attach retainer -2- to master cylinder operating rod -1-.


orm
m

– Press retainer into notch in clutch pedal -3- until it can be heard
atio
m

to engage.
o

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Prote AG.

2. Repairing clutch mechanism 23


Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
6-speed manual gearbox 02S - Edition 07.2009
n AG. Volkswagen A
– Insert over-centre spring -2- in mounting
olks
wage bracket from above
G do
es n
o
while holding end of spring with
d by assembly tool -T10178- in in‐ t gua
V
ran
stallation position. or
ise
tee
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au ac
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t to the co
rrectness of i
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orm
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atio
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• Receptacle -arrow- for tip -A- of clutch pedal must stand ver‐
o

n in
c

tically.
or

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– Insert tip -A- of clutch pedal in bearing recess of over-centre


iv

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spring.
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– Depress clutch pedal slightly, push bolt through and tighten op
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self-locking nut to specified torque ⇒ page 25 .
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Some cars have damping -arrow- on the mounting bracket/clutch


pedal.
– Return it to installation position.
Vehicles without knee airbag

24 Rep. Gr.30 - Clutch


Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
6-speed manual gearbox 02S - Edition 07.2009

The crash bar -1- in front of clutch pedal -2- may be secured in
different ways.
Attachment with 2 bolts
– Install crash bar -1- and tighten the 2 bolts to specified torque
⇒ page 25 .

AG. Volkswagen AG d
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Attachment with 1 sbolt
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– Install crash bar -1- and tighten bolt -2- to specified torque
nl

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⇒ page 25 .

an
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Continuation for all

ility
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wit
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h re
hole

spec
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t to the co
rrectness of i
l purpos

– Mount cable guide -2- on steering column.


– Install footwell vent -3- ⇒ Heating, air conditioning; Rep. Gr.
nform
ercia

80 ; Repairing heating .
m

at
om

Vehicles with knee airbag


ion
c

in t
or

– Install bracket for knee airbag together with crash bar ⇒ Inte‐
his
ate

rior equipment; Rep. Gr. 69 ; Airbag; Removing and installing


do
riv

knee airbag bracket .


p

cum
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en
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t.
Continuation for all
yi Co
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ht. rig
– Install trim and cover below trim on drive side ⇒ General body rig ht
py by
repairs, interior; Rep. Gr. 68 . co Vo
by lksw
cted agen
Prote AG.
– If disconnected, connect battery ⇒ Electrical system; Rep. Gr.
27 ; Removing and installing battery .

2.4.3 Specified torques


Component Nm
Clutch pedal to mounting bracket 25
♦ Renew self-locking nuts

Crash bar to steering column mounting 10


bracket (attachment with 2 bolts)
Crash bar to steering column mounting 20
bracket (attachment with 1 bolts)
♦ Renew bolts for crash bar

2.5 Removing and installing mounting


bracket
Special tools and workshop equipment required

2. Repairing clutch mechanism 25


AG. Volkswagen AG d
agen oes
olksw not
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rise nte
GolfautVariant 2007 ➤ , Golf Variant 2010 ➤ , Jetta e2005
ho
or
ac

6-speed manual gearbox 02S - Edition 07.2009
ss

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an
♦ Hose clamps to 25 mm Ø -3094-
itte

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t to the co
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♦ Hose clip pliers -VAS 6362-


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♦ Sealing tool -T10249-

2.5.1 Removing
LHD
– First check whether a coded radio is fitted. If so, obtain anti-
theft code.
– With ignition switched off, disconnect battery earth strap ⇒
Electrical system; Rep. Gr. 27 ; Disconnecting and connecting
battery .
– Remove complete air filter housing if it is near battery ⇒ Rep.
Gr. 23 ; Repairing diesel direct injection system or ⇒ Rep.
Gr. 24 ; Repairing injection system .
– Remove battery and battery tray ⇒ Electrical system; Rep.
Gr. 27 ; Battery; Removing and installing battery .

26 Rep. Gr.30 - Clutch


Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
6-speed manual gearbox 02S - Edition 07.2009

Continuation for all

Note

♦ During the following work, ensure that no brake fluid lands on


longitudinal member or gearbox. If this does happen, clean the
affected areas thoroughly.
♦ Place a lint-free cloth under the
swa
gmaster
en AG. V cylinder.
olkswagen AG
does
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yV gu
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– Clamp off supply hose
or to master
ise
cylinder using hose clamp toantee
25 mm ∅ -3094-au.th or
ac
ss

ce
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d
itte

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ab
ility
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wit
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h re
ole,

spec
urposes, in part or in wh

t to the co
rrectne
– If necessary, loosen spring-type clip -3- with hose clip pliers -
VAS 6362- and pull supply hose off master cylinder.

ss o
– In addition, for disconnecting, you can close it with the sealing
cial p

f in
tool -T10249/1- (⇒ figure above).

form
mer

atio
– Release securing clip -2- using screwdriver or a pointed object
om

and pull pipe/hose line or plastic line -1- off master cylinder.
n
c

i
or

n thi
e

– Unclip clutch position sender -G476- from master cylinder


t

sd
va

-arrow- and remove with electrical connector attached -4-.


i

o
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cum
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fo

en
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t.
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Note
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When performing work in the footwell, put cloths on the carpet to
lksw
cted agen
Prote
protect it from possible brake fluid spills.
AG.

– Remove trim and cover below trim on drive side ⇒ General


body repairs, interior; Rep. Gr. 68 .
Vehicles with knee airbag

Note

The installation location of the knee airbag is above the pedal


cluster.

2. Repairing clutch mechanism 27


Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
6-speed manual gearbox 02S - Edition 07.2009

– Remove bracket for knee airbag together with crash bar ⇒


Interior equipment; Rep. Gr. 69 ; Airbag; Removing and in‐
stalling knee airbag bracket .
– Remove cable guide -2- from steering column.
– Remove footwell vent -3- ⇒ Heating, air conditioning; Rep.
Gr. 80 ; Repairing heating .
Vehicles without knee airbag

The crash bar -1- in front of clutch pedal -2- may be secured in
different ways.
Attachment with 2 bolts
– Unbolt crash bar (2 bolts).

Attachment with 1 bolt


– Remove crash bar -1- (1 bolt -2-).
Continuation for all

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
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aut ra
ss c
ce
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un

pt
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rm

ab
pe

ility

– If fitted, remove damping -arrow- from lower area of clutch


ot

wit

pedal mounting bracket.


, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
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do
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rp

cum
fo

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
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co Vo
by lksw
cted agen
Prote AG.

28 Rep. Gr.30 - Clutch


Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
6-speed manual gearbox 02S - Edition 07.2009

– To do this, remove lock washers -A- for damping.


– Pull off damping. n AG. Volkswagen AG do
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o ot g
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tho
u or
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ss

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un

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d
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rm

ab
pe

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

– Push damping upwards in area of upper securing nut -1-

t to the co
above clutch pedal -A- in -direction of arrow-.

rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
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do
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cum
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

– Remove securing nuts -1- and -2-.


The upper securing nut -1- is accessible between the relay carrier
and the steering column trim.
– Remove mounting bracket -3-.

2.5.2 Installing
Install in the reverse order of removal, observing the following:

2. Repairing clutch mechanism 29


Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
6-speed manual gearbox 02S - Edition 07.2009

Some cars have damping -arrow- on the clutch pedal mounting


bracket.

Note

♦ Renew self-locking nuts.


♦ Renew hose clips.
♦ Allocate all components according to ⇒ Electronic parts cata‐
logue “ETKA” .

Vehicles without knee airbag

The crash bar -1- in front of clutch pedal -2- may be secured in
different ways.
Attachment with 2 bolts
n AG. Volkswagen AG do
– Install crash bar -1- and tighten the 2 bolts to specified torque olks
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⇒ page 31 . db
y V ua
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au ac
ss

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pt
an
d
itte

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rm

ab
pe

ility
ot

wit
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h re
Attachment with 1 bolt
hole

spec
es, in part or in w

– Install crash bar -1- and tighten bolt -2- to specified torque

t to the co
⇒ page 31 .
Continuation for all

rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

– Mount cable guide -2- on steering column.


do
r
rp

cum
fo

– Install footwell vent -3- ⇒ Heating, Air conditioning; Rep. Gr.


en
ng

t.
yi
80 ; Repairing heating; Removing and installing left footwell
Co
op py
vent . t. C rig
gh ht
pyri by
Vehicles with knee airbag
o Vo
by c lksw
cted agen
Prote AG.
– Install bracket for knee airbag together with crash bar ⇒ Inte‐
rior equipment; Rep. Gr. 69 ; Airbag; Removing and installing
knee airbag bracket .
Continuation for all
– Install trim and cover below trim on drive side ⇒ General body
repairs, interior; Rep. Gr. 68 .

30 Rep. Gr.30 - Clutch


Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
6-speed manual gearbox 02S - Edition 07.2009

– Push pipe/hose line or plastic line -1- with seal -2- onto con‐
nection of master cylinder -4- until securing clip -3- engages
audibly.
– Test line by tugging on it.
– After removing hose clamp up to 25 mm ∅ -3094- , return
supply hose to its original shape, if necessary.
– Bleed clutch system ⇒ page 42 .
LHD
– Install battery ⇒ Electrical system; Rep. Gr. 27 ; Removing
and installing battery .
– If complete air filter housing was removed, install it ⇒ Rep.
Gr. 23 ; Repairing diesel direct injection system or ⇒ Rep.
Gr. 24 ; Repairing injection system . AG. Volkswagen n AG do
wage es n
Volks ot g
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2.5.3 Specified torques

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Component Nm

ility
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wit
Mounting bracket to bulkhead 25
is n

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♦ Renew self-locking nuts.
ole,

spec
urposes, in part or in wh

Crash bar to steering column mounting 10

t to the co
bracket (attachment with 2 bolts)
Crash bar to steering column mounting 20

rrectne
bracket (attachment with 1 bolt)
♦ Renew bolts for crash bar

ss o
cial p

f
2.6 Removing and installing master cylinder
inform
mer

atio

Special tools and workshop equipment required


om

n
c

♦ Pliers -T10005-
or

n thi
te

sd
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pr

cum
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fo

en
ng

t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

2.6.1 Removing
– Remove mounting bracket ⇒ page 25 .

2. Repairing clutch mechanism 31


Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
6-speed manual gearbox 02S - Edition 07.2009

– Release retainer for master cylinder operating rod using pliers


-T10005- .

– Insert spacer -A- between clutch pedal and stop and press
clutch pedal to spacer.
♦ Length of spacer = about 40 mm (e.g. 1/2" socket)
Volkswa
– Release securing bar -B- and pullswmaster
agen
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n AGof
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mounting bracket -arrow 1- band
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es, in part or in w

t to the co
rrectness of i

2.6.2 Installing
l purpos

• Move clutch pedal to rest position at stop.


nform
ercia

– Attach retainer -2- to master cylinder operating rod -1-.


m

at
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ion
c

in t
or

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ate

do
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cum
for

en
ng

t.
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Cop py
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gh ht
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by c lksw
cted agen
Prote AG.

32 Rep. Gr.30 - Clutch


Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
6-speed manual gearbox 02S - Edition 07.2009

– Insert spacer -A- between clutch pedal and stop and press
clutch pedal to spacer.
♦ Length of spacer = about 40 mm (e.g. 1/2" socket)

– Engage master cylinder in mounting bracket -arrow 1- and


-arrow 2-.

AG. Volkswagen AG d
agen oes
olksw not
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– Press master cylinder operating erod d b -1- in
y gu
ara
-direction of arrow- until retainer
thoris-2- engages audibly in clutch nte
eo
pedal. s au ra
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ce
– Install mounting bracket ⇒ page 25 .
e
nl

pt
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erm

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ility
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wit
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h re
hole

spec
es, in part or in w

t to the co
rrectness of i
2.7 Removing and installing clutch position
sender -G476-
l purpos

Special tools and workshop equipment required


nf
ercia

or

♦ Hose clamps -3094-


m
m

atio
om

n in
or c

thi
te

sd
iva

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rp

cu
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f

en
ng

t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

2.7.1 Removing
LHD
– First check whether a coded radio is fitted. If so, obtain anti-
theft code.
– With ignition switched off, disconnect battery earth strap ⇒
Electrical system; Rep. Gr. 27 ; Disconnecting and connecting
battery .

2. Repairing clutch mechanism 33


Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
6-speed manual gearbox 02S - Edition 07.2009

– Remove complete air filter housing if it is near battery ⇒ Rep.


Gr. 23 ; Repairing diesel direct injection system or ⇒ Rep.
Gr. 24 ; Repairing injection system .
– Remove battery and battery tray ⇒ Electrical system; Rep.
Gr. 27 ; Battery; Removing and installing battery .
Right-hand drive
– In vehicles with particle filter, remove shielding -A- from parti‐
cle filter ⇒ Rep. Gr. 26 ; Parts of exhaust system; Assemblygen AG
. Volkswagen AG
does
overview - front exhaust pipe with particle filter . Volkswa not
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An insulation mat is installed in conjunction withorisome
se engines. nte
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ab
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ility
ot

wit
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h re
hole

spec
es, in part or in w

t to the co
– Remove heat shield from pipe/hose line -arrows-.

rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
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rp

cum
fo

en
ng

t.
Continuation for all Cop
yi Co
py
t. rig
If a pipe/hose line -1- with a round component is installed directly gh ht
yri by
beneath the master cylinder, the pipe/hose line must be removed.
op Vo
by c lksw
cted agen
Prote AG.

Note

During the following work, ensure that no brake fluid lands on


longitudinal member or gearbox. If this does happen, clean the
affected areas thoroughly.

34 Rep. Gr.30 - Clutch


Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
6-speed manual gearbox 02S - Edition 07.2009

– Clamp off supply hose to master cylinder using hose clamp to


25 mm ∅ -3094- .

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
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ce
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nl

pt
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erm

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ility
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, is n

h re
– Release securing clip -2- with a screwdriver or a pointed object
hole

spec
and pull out of master cylinder to stop.
es, in part or in w

t to the co
– Pull pipe/hose line -1- or plastic line out from master cylinder
and seal.

rrectness of i
– Disconnect electrical connector -4-.
– Unclip clutch position sender -G476- from master cylinder
l purpos

-arrow- and remove.

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

2.7.2 Installing
Install in the reverse order of removal, observing the following:

Note

Allocate all components according to ⇒ Electronic parts cata‐


logue “ETKA” .

2. Repairing clutch mechanism 35


Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
6-speed manual gearbox 02S - Edition 07.2009

If the pipe/hose line was removed


– Push pipe/hose line -1- or plastic line with seal -2- onto con‐
nection of master cylinder -4- until securing clip -3- engages
audibly.
– Test pipe/hose line by tugging on it.
– After removing hose clamp up to 25 mm ∅ -3094- , return
supply hose to its original shape, if necessary.
– Bleed clutch system ⇒ page 42 .
Right-hand drive

– In vehicles with particle filter, install shielding -A- on particle


filter ⇒ Rep. Gr. 26 ; Parts of exhaust system; Assembly
overview - front exhaust pipe with particle filter .
LHD
– Install battery tray and battery⇒ Electrical system; Rep. Gr.
27 ; Removing and installing battery .
– If complete air filter housing was removed, install it ⇒ Rep.
Gr. 23 ; Repairing diesel direct injection system or ⇒ Rep.
Gr. 24 ; Repairing injection system .
olkswagen AG
en AG. V
– Reconnect battery and perform work required after connectingolkswag does
not
battery ⇒ Electrical system; Rep. Gr. 27 ; Disconnectingedand
by
V gu
ara
connecting battery . ho
ris nte
eo
t
au ra
c
ss
ce
e
nl

pt
du

an
itte

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erm

ab
ility
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wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

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r
rp

cu
o

m
f

en
ng

t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

36 Rep. Gr.30 - Clutch


Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
6-speed manual gearbox 02S - Edition 07.2009

2.8 Assembly overview - hydraulics (LHD vehicles)

1 - Brake fluid reservoir


2 - Spring-type clip
3 - Supply hose
❑ Rubber
❑ From 12.05, plastic in
some vehicles
⇒ page 38
4 - Master cylinder
❑ Removing and installing
⇒ page 31
5 - Clip
❑ Pull out clip to stop to re‐
move and install pipe/
hose line
6 - Retainer
❑ To remove and install,
separate master cylin‐
der from clutch pedal
⇒ page 20
7 - Clutch pedal
❑ Removing and installing
⇒ page 20
8 - Hexagon nut, 25 Nm
❑ Self-locking
❑ Qty. 3
❑ For mounting bracket on AG. Volkswagen AG d
agen
bulkhead olksw
oes
not
byV gu
ara
❑ Always renew rised
nte
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ut
9 - Seal / O-ring ss a ra
c
❑ Pull onto line connection
ce
e
nl

pt
du

an

❑ Insert with brake fluid


itte

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erm

ab

❑ Seals/O-rings are adapted to configuration of line connection ⇒ page 38


ility
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❑ Allocation ⇒ Electronic parts catalogue “ETKA”


wit
, is n

h re

10 - Pipe/hose line
hole

spec

❑ Allocation ⇒ Electronic parts catalogue “ETKA”


es, in part or in w

t to the co

❑ To remove, remove battery and battery tray ⇒ Electrical system; Rep. Gr. 27 ; Removing and installing
battery .
rrectness of i

11 - Bracket
❑ Secured to body
l purpos

12 - Seal / O-ring
nf
ercia

❑ Pull onto line connection


orm
m

❑ Insert with brake fluid


atio
om

❑ Seals/O-rings are adapted to configuration of line connection ⇒ page 38


n in
or c

thi
e

❑ Allocation ⇒ Electronic parts catalogue “ETKA”


t

sd
iva

o
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rp

cu

13 - Clip
o

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f

en
ng

❑ Pull out clip to stop to remove and install pipe/hose line


t.
yi Co
Cop py
.
14 - Slave cylinder
ht rig
rig ht
py by
Vo
❑ Removing and installing ⇒ page 40
co lksw
by
cted agen
Prote AG.

2. Repairing clutch mechanism 37


Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
6-speed manual gearbox 02S - Edition 07.2009

15 - Hexagon bolt, 20 Nm agen


AG. Volkswagen AG d
oes
olksw not
16 - Bleeder valve d by V gu
ara
ise nte
❑ Bleeding clutch system ⇒ page 42 uthor eo
a ra
s c
17 - Dust cap s

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nl

pt
du
18 - Gearbox

an
itte

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erm

ab
19 - Bracket

ility
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wit
20 - Hexagon bolt, 20 Nm
, is n

h re
hole

spec
es, in part or in w

Seals and O-rings for pipe and hose lines

t to the co
Item Material of line connection

rrectness of i
-1- Line connection with circumferential groove
-arrow 1-
l purpos

-2- Line connection with shoulder -arrow 2-

nf
ercia

orm
m

atio
om

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or c

thi
te

sd
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cu
o

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f

en
ng

From 12.05, plastic supply hose -1- in some vehicles


t.
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Cop py
• The seals -2- must be located in supply hose.
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

38 Rep. Gr.30 - Clutch


Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
6-speed manual gearbox 02S - Edition 07.2009

2.9 Assembly overview - hydraulics (RHD vehicles)

1 - Brake fluid reservoir


2 - Seal
❑ For plastic supply hose
❑ The seals must be loca‐
ted in supply hose
3 - Supply hose
❑ Rubber
❑ From 12.05, plastic in
some vehicles
⇒ page 38
4 - Master cylinder
❑ Removing and installing
⇒ page 31
5 - Clip
❑ Pull clip out to stop to re‐
move or install pipe line
❑ Pulled out to side on
some master cylinders
6 - Seal / O-ring
❑ Pull onto line connection
❑ Insert with brake fluid
❑ Seals/O-rings are adap‐
ted to configuration of
line connection
⇒ page 38
❑ Allocation ⇒ Electronic
parts catalogue “ETKA” wage
n AG. Volkswagen AG do
es n
olks ot g
7 - Retainer byV ua
d ran
ir se tee
❑ To remove and install, utho
or
separate master cylin‐ ss
a ac
der from clutch pedal
ce
le
un

pt

⇒ page 20
an
d
itte

y li
rm

8 - Clutch pedal
ab
pe

ility

❑ Removing and installing ⇒ page 20


ot

wit
, is n

h re

9 - Hexagon nut, 25 Nm
hole

spec

❑ Self-locking
es, in part or in w

t to the co

❑ Qty. 3
❑ For mounting bracket on bulkhead
rrectness of i

❑ Always renew
l purpos

10 - Bracket
❑ Secured to body
nform
ercia

11 - Pipe line
m

❑ Pipe and hose/pipe line ⇒ Item 13 (page 40) may be in one piece
a
com

tion in

❑ Allocation ⇒ Electronic parts catalogue “ETKA”


r
te o

thi

❑ To remove, remove battery and battery tray ⇒ Electrical system; Rep. Gr. 27 ; Removing and installing
s
iva

do

battery .
r
rp

cum
fo

en
g

12 - Seal / O-ring
n

t.
yi Co
op
❑ Pipe ⇒ Item 11 (page 39) and hose/pipe line may be in one piece
C py
t. rig
gh ht
yri
❑ Pull onto line connection
p by
co Vo
by lksw
cted agen
Prote AG.

2. Repairing clutch mechanism 39


Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
6-speed manual gearbox 02S - Edition 07.2009
❑ Insert with brake fluid
❑ Seals/O-rings are adapted to configuration of line connection ⇒ page 38
❑ Allocation ⇒ Electronic parts catalogue “ETKA”
13 - Pipe/hose line
❑ Pipe ⇒ Item 11 (page 39) and hose/pipe line may be in one piece
❑ Allocation ⇒ Electronic parts catalogue “ETKA”
❑ To remove, remove battery and battery tray ⇒ Electrical system; Rep. Gr. 27 ; Removing and installing
battery .
14 - Bracket
❑ Secured to retainer for ABS/EDL
15 - Bracket
❑ For ABS/EDL
16 - Seal / O-ring
❑ Pull onto line connection
❑ Insert with brake fluid
❑ Seals/O-rings are adapted to configuration of line connection ⇒ page 38
❑ Allocation ⇒ Electronic parts catalogue “ETKA”
17 - Clip . Volkswagen AG
gen AG does
❑ Pull out clip to stop to remove
Volkand
swa install pipe/hose line not
y gu
db ara
18 - Slave cylinder ris
e nte
tho eo
❑ Removing and installing
sa
u ⇒ page 40 ra
c
s
ce
le

19 - Flange bolt, 20 Nm
un

pt
an
d
itte

20 - Bleeder valve
y li
erm

ab

❑ Bleeding clutch system ⇒ page 42


ility
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wit
is n

21 - Dust cap
h re
ole,

spec

22 - Gearbox
urposes, in part or in wh

t to the co

23 - Bracket
24 - Hexagon bolt, 20 Nm
rrectnes

2.10 Removing and installing slave cylinder


s o
cial p

f in

Special tools and workshop equipment required


form
mer

atio

♦ Torque wrench -V.A.G 1331-


om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

2.10.1 Removing
– First check whether a coded radio is fitted. If so, obtain anti-
theft code.

40 Rep. Gr.30 - Clutch


Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
6-speed manual gearbox 02S - Edition 07.2009

– With ignition switched off, disconnect battery earth strap ⇒


Electrical system; Rep. Gr. 27 ; Disconnecting and connecting
battery .
– Remove complete air filter housing if it is over slave cylinder
⇒ Rep. Gr. 23 ; Repairing diesel direct injection system or ⇒
Rep. Gr. 24 ; Repairing injection system .
– Remove securing clip -arrow 1- for gear selector cable from
gearbox selector lever -A-.
– Pull gear selector cable from pin.
Metal relay lever
– Remove securing clip -arrow 2- for gate selector cable from
relay lever -B-.
AG. Volkswagen AG d
agen
– Pull gate selector cable from pin. Vo lksw
oes
not
gu
d by ara
– Pull securing clip -arrow 3- off relay lever -B- and remove
orise
relay nte
eo
lever. aut
h
ra
ss c
Plastic relay lever

ce
le
un

pt
an
d

– Remove relay lever together with cable end-piece from gear‐


itte

y li
rm

box ⇒ page 73 .

ab
pe

ility
ot

Continuation for all

wit
, is n

h re
– Remove gearbox selector lever -A- by removing nut
hole

spec
-arrow 4-.
es, in part or in w

t to the co
– Remove cable support bracket from gearbox -arrows-.
– Then raise and secure gear selector cable and gate selector

rrectness of i
cable.
l purpos

– Remove retainer -B- from gearbox and pull it off pipe/hose line
-A-.

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

– Then remove gearbox support -arrow A-.


– Place a lint-free cloth under slave cylinder.
– Pull clip for pipe/hose line out of slave cylinder to stop.
– Pull pipe/hose line out of slave cylinder and seal opening.
– Remove slave cylinder -arrows B-.

Caution

Do not operate clutch pedal any more.

2. Repairing clutch mechanism 41


Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
6-speed manual gearbox 02S - Edition 07.2009

2.10.2 Installing
Install in the reverse order of removal, observing the following:
– Install slave cylinder and tighten bolts -arrows B- to specified
torque.
AG. Volkswagen AG d
– Insert pipe/hose line into slave cylinder to stop. ksw
agen oes
not
ol
yV gu
– Push securing clip into pipe/hose line to stop. ised b ara
nte
or eo
h
– Test pipe/hose line by tugging on it. s aut ra
c
s
– Then install gearbox support -arrows A-.

ce
e
nl

pt
du

an
itte
– Bleed clutch system after installing slave cylinder

y li
erm

ab
⇒ page 44 .

ility
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wit
Assembling selector mechanism ⇒ page 70 .
, is n

h re
hole
Adjust selector mechanism ⇒ page 80 .

spec
es, in part or in w

– If complete air filter housing was removed, install it ⇒ Rep.

t to the co
Gr. 23 ; Repairing diesel direct injection system or ⇒ Rep.
Gr. 24 ; Repairing injection system .

rrectness of i
– Connect battery earth ⇒ Electrical system; Rep. Gr. 27 ; Dis‐
connecting and reconnecting battery .
l purpos

2.10.3 Specified torques

nform
ercia

Slave cylinder to gearbox ⇒ Item 9 (page 45)


m

at
om

ion
Gearbox selector lever to selector shaft ⇒ Item 18 (page 71) .
c

in t
or

his
te

Selector cable support bracket to gearbox ⇒ Item 6 (page 70)


a

do
priv

cum
or

Gearbox support to gearbox bracket and gearbox:


f

en
ng

t.
yi Co
– Renew bolts. Cop py
ht. rig
rig ht
– Screw in all bolts hand-tight. py by
co Vo
by lksw
cted agen
– Tighten bolts to specified torque. Prote AG.

Bolts -arrows- 20 Nm + 90°

2.11 Bleeding clutch system


Special tools and workshop equipment required
♦ Brake filling and bleeding equipment -VAS 5234- or

42 Rep. Gr.30 - Clutch


Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
6-speed manual gearbox 02S - Edition 07.2009

♦ Brake filling and bleeding equipment -V.A.G 1869-

Note AG. Volkswagen AG d


agen oes
olksw not
V gu
by
Prefilling system is not necessary! rised ara
nte
ho eo
aut ra
Specifications for brake fluid ⇒ Brake
s systems; Rep. Gr. 47 ;
s c

ce
Bleeding brake system .
e
nl

pt
du

an
itte

– Remove complete air filter housing if it blocks access to bleed‐

y li
erm

ab
er connection (-arrow-, figure below) ⇒ Rep. Gr. 23 ; Repair‐

ility
ot p

ing diesel direct injection system or ⇒ Rep. Gr. 24 ; Repairing

wit
, is n

injection system

h re
hole

spec
– Connect brake filling and bleeding equipment -VAS 5234- or
es, in part or in w

-V.A.G 1869- .

t to the co
To bleed system, use 670 mm bleeder hose -V.A.G 1238/B3- if
necessary.

rrectness of i
– Connect bleeder hose to collector bottle of brake bleeding
equipment.
l purpos

– Connect bleeder hose to bleeder -arrow-.

nform
ercia

– Pressurise system to 2 bar.


m

at
om

– Open bleeder valve. ion


c

in t
or

– Bleed off about 100 cm3 brake fluid.


his
ate

do
riv

– Close bleeder valve.


p

cum
for

en
ng

– Rapidly operate pedal from stop to stop 10 to 15 times.


t.
yi Co
Cop py
t. rig
– Open bleeder valve. opyri
gh by
Vo
ht
by c lksw
– Bleed off an additional 50 cm3 brake fluid. Prote
cted AG.
agen

– Close bleeder valve.


– Depress clutch pedal several times after completion of bleed‐
ing process.
– If complete air filter housing was removed, install it ⇒ Rep.
Gr. 23 ; Repairing diesel direct injection system or ⇒ Rep.
Gr. 24 ; Repairing injection system .

2. Repairing clutch mechanism 43


Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
6-speed manual gearbox 02S - Edition 07.2009

3 Repairing clutch release mechanism


Special tools and workshop equipment required
♦ Torque wrench -V.A.G 1331-

1 - Gearbox
2 - Ball stud, 25 Nm
❑ To remove and install,
remove gearbox
❑ Remove old grease AG. Volkswagen AG d
agen oes
ksw not
from contact surface of by Vol
gu
ara
clutch release lever rise
d
nte
ho eo
❑ Grease with clutch plate
s aut ra
c
spline grease - s
ce
e

G 000 100- .
nl

pt
du

an
itte

y li

3 - Input shaft seal


erm

ab
ility

❑ To remove and install,


ot p

remove gearbox
wit
, is n

h re

❑ Renewing
hole

spec

⇒ Item 12 (page 134)


es, in part or in w

t to the co

4 - Guide sleeve
❑ To remove and install,
remove gearbox
rrectness of i

❑ With vulcanised O-ring


l purpos

❑ If O-ring is damaged, re‐


new guide sleeve and
nf
ercia

O-ring together
orm
m

5 - Retaining spring
atio
om

n in

❑ To remove and install,


or c

thi

remove gearbox
te

sd
iva

❑ Secure to clutch release


o
r
rp

cu

lever
o

m
f

en
ng

t.
yi Co
6 - Socket head bolt, 20 Nm Cop py
t. rig
gh ht
yri
7 - Clutch release lever p by
co Vo
by lksw
cted
❑ To remove and install,
agen
Prote AG.
remove gearbox
❑ Remove and install to‐
gether with release bearing ⇒ page 45 .
❑ Remove old grease
8 - Release bearing
❑ To remove and install, remove gearbox
❑ Do not wash out bearing; wipe only

44 Rep. Gr.30 - Clutch


Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
n AG. Volkswagen AG do 6-speed manual gearbox 02S - Edition 07.2009
lk swage es n
Vo ot g
❑ Renew noisy ed bearings
by ua
ran
ris tee
❑ Removing
utho from and inserting in clutch release lever ⇒or page 45
a ac
❑ Lubricate contact surfaces of release lever with MoS grease.
ss
2

ce
e
nl

pt
du

9 - Flange bolt, 20 Nm

an
itte

y li
erm

ab
10 - Slave cylinder

ility
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❑ Removing and installing ⇒ page 40

wit
, is n

h re
11 - Plunger
hole

spec
es, in part or in w

12 - Assembly bolt

t to the co
❑ Secures clutch release lever when gearbox is installed.
❑ Remove after gearbox has been installed.

rrectness of i
Note
l purpos

nform
ercia

Removing and installing release lever together with release bear‐


m

at
ing
om

ion
c

in t
r

– Unhook spring -arrow 1-.


o

his
ate

do
riv

– Pull off release lever -arrow 2- and release bearing.


p

cum
for

– Install in reverse order of removal. en


ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Removing and installing release bearing


– Press together locking lugs -arrows- on back of clutch release
lever and remove release bearing -A- from clutch release lev‐
er.
– To install, press release bearing -A- into clutch release lever
until locking lugs -arrows- engage.

3. Repairing clutch release mechanism 45


Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
6-speed manual gearbox 02S - Edition 07.2009

4 Repairing clutch, in conjunction with dual-mass flywheel

Special tools and workshop


equipment required
♦ Counterhold -3067-
♦ Centring mandrel -3190 A-
♦ Torque wrench -V.A.G
1331-
♦ Grease for clutch plate
splines -G 000 100-

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un

pt
an
d
itte

4.1 Determining clutch manufacturer


y li
erm

ab
ility
ot p

A clutch manufactured by either “Sachs” or “LuK” may be instal‐


wit
is n

led.
h re
ole,

spec

The make of the clutch can be determined as follows with the


urposes, in part or in wh

clutch installed:
t to the co

– Remove noise insulation ⇒ General body repairs, exterior;


Rep. Gr. 50 ; Noise insulation .
rrectness o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
yri by

46
op Vo
by c lksw
Rep. Gr.30 - Clutch Prote
cted AG.
agen
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
6-speed manual gearbox 02S - Edition 07.2009

Some notches -arrows- are located in lower region of sump be‐


tween engine -A- and gearbox -B-.
– Check outer contour of flywheel through these notches.

n AG. Volkswagen AG do
lkswage es n
o ot g
yV
– In addition, a small cover d b plate -A- can be removed to enable ua
ran
ir se
inspection of flywheel's
tho outer contour. tee
or
au ac
Round outer contour -arrows- = Sachs clutch = -A-
ss

ce
e
nl

pt
du

– Removing and installing Sachs clutch ⇒ page 48 .

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i

– Repairing Sachs clutch ⇒ page 50 .


l purpos

Outer contour with edges -arrows 1- and, in addition, a circum‐


ferential crease -arrow 2- = LuK clutch = -B-
nform
ercia

or
m

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

4. Repairing clutch, in conjunction with dual-mass flywheel 47


Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
6-speed manual gearbox 02S - Edition 07.2009

Rounded outer contour -arrows 1- and a circumferential crease


-arrow 2- = LuK clutch = -B-
– Removing and installing LuK clutch ⇒ page 50 .
– Repairing LuK clutch ⇒ page 53 .

4.2 Removing and installing Sachs clutch

4.2.1 Removing
– Remove gearbox ⇒ page 84 .
– Use counterhold -3067- to loosen bolts.
– Loosen bolts in small steps and diagonally.
• As bolts are removed, stop -2- with pin -1- must loosen.
– If stop does not loosen, press pin towards dual-mass flywheel.
– Remove pressure plate and clutch plate.

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un

pt
an
d
itte

4.2.2 Installing
y li
erm

ab
ility
ot p

Install in the reverse order of removal, observing the following:


wit
is n

h re
ole,

spec
urposes, in part or in wh

Note
t to the co

♦ Renew pressure plate and clutch plate together only. Select


clutch plate and pressure plate according to engine code and
rrectne

⇒ Electronic parts catalogue “ETKA” .


♦ Check whether dowel sleeves for aligning engine and gearbox
s

are fitted in cylinder block and install if necessary.


s o
cial p

f in

♦ If dowel sleeves are not fitted, difficulties shifting gears, clutch


form
mer

problems and possible noises from the gearbox (rattling of


atio

gears which are not engaged) could occur.


om

n
c

i
or

n thi
e

Installation position of clutch plate


t

sd
iva

o
pr

• Lettering “Getriebeseite” (gearbox side) faces gearbox.


um
r
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

48 Rep. Gr.30 - Clutch


Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
6-speed manual gearbox 02S - Edition 07.2009

Checking ends of diaphragm spring


• Wear to half the thickness of the diaphragm spring -arrows- is
permitted.

Checking spring connections and riveted connections


– Check spring connections between pressure plate and cover
for cracks as well as rivet connections for secure seating.

Note

♦ Renew clutch plates and pressure plates with damaged or


loose rivet connections.
♦ Always renew pressure plate and clutch plate together.
♦ Select clutch plate and pressure plate according to engine
code and ⇒ Electronic parts catalogue “ETKA” .
♦ If clutch has burnt out, thoroughly clean clutch housing, fly‐lksw
wheel and parts of engine facing gearbox to reduce
agensmell of
AG. Vo agen AG
does
ksw
burnt linings. by
Vol not
gu
d ara
ise nte
♦ Clean input shaft splines and, on used tho rclutch plates, clean hub eo
splines; remove corrosion and applys au only a very thin coat of ra
c
clutch plate spline grease -G 000 100- to splines. Then move
s
ce
e
nl

clutch plate to and fro on input shaft until hub moves freely on pt
du

shaft. Remove excessive grease. an


itte

y li
erm

ab
♦ Pressure plates are protected against corrosion and greased. ility
ot p

Clean contact surface only. Otherwise, the service life of the


wit
, is n

clutch will be considerably reduced.


h re
hole

spec

♦ Pressure plate contact surface and clutch plate lining must


es, in part or in w

make full contact with flywheel. Only then insert securing bolts.
t to the co

– Reverse counterhold tool -3067- for installation.


rrectness of i

– Push pressure plate onto centralizing pins.


l purpos

– To centre clutch plate, use centring mandrel -3190 A- .


nform
ercia

– Tighten all bolts evenly by hand until bolt heads contact pres‐
sure plate.
m

at
om

ion

– Tighten bolts in small steps diagonally in order not to damage


c

in t
or

centring holes of pressure plate and centring pins of dual-


his
ate

mass flywheel.
do
priv

cum
or

– Install gearbox ⇒ page 92 .


f

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

4. Repairing clutch, in conjunction with dual-mass flywheel 49


Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
6-speed manual gearbox 02S - Edition 07.2009

4.3 Repairing Sachs clutch

1 - Dual-mass flywheel
❑ Removing and installing
⇒ Rep. Gr. 13
❑ Ensure that centring gen AG. Volkswagen AG d
pins fit tightly Volkswa oes
not
gu
by ara
❑ Contact surface
rised for nte
clutch lining
ut
ho must be eo
ra
free of
ss a
grooves, oil and c
grease

ce
le
un

pt
an
d

2 - Clutch plate
itte

y li
rm

ab
❑ Allocation ⇒ Electronic
pe

ility
parts catalogue “ETKA”
ot

wit
, is n

h re
❑ Removing and installing
hole

⇒ page 48

spec
es, in part or in w

❑ Renew only together

t to the co
with pressure plate
❑ Installation position
⇒ page 48

rrectness of i
3 - Pressure plate
l purpos

❑ Allocation ⇒ Electronic
parts catalogue “ETKA” nform
ercia

❑ With adjusting mecha‐


m

nism
com

tion in

❑ Removing and installing


r
te o

thi

⇒ page 48
s
iva

do
r

❑ Check ends of dia‐


rp

cum
fo

phragm spring
en
ng

t.
yi
⇒ page 49
Co
Cop py
t.
❑ Check spring connec‐
rig
gh ht
yri by
tions and riveted con‐ op Vo
by c lksw
nections ⇒ page 49 . cted agen
Prote AG.
❑ Renew only together
with clutch plate.
4 - Bolt M6, 13 Nm, Bolt M7,
20 Nm
❑ Loosen or tighten diagonally in small steps

4.4 Removing and installing LuK clutch

4.4.1 Removing
– Remove gearbox ⇒ page 84 .
– Use counterhold -3067- to loosen bolts.
– Loosen bolts in small steps and diagonally.
– Remove pressure plate and clutch plate.

4.4.2 Installing
Install in the reverse order of removal, observing the following:

50 Rep. Gr.30 - Clutch


Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
6-speed manual gearbox 02S - Edition 07.2009
AG. Volkswagen AG d
agen oes
olksw not
Note d byV gu
ara
ise nte
or eo
th
♦ Renew pressure plate and clutch plate together
s au only. Select ra
c
clutch plate and pressure plate according to engine code and s

ce
le
⇒ Electronic parts catalogue “ETKA” .

un

pt
an
d
itte

y li
♦ Check whether dowel sleeves for aligning engine and gearbox

rm

ab
are fitted in cylinder block and install if necessary.

pe

ility
ot

wit
, is n
♦ If dowel sleeves are not fitted, difficulties shifting gears, clutch

h re
problems and possible noises from the gearbox (rattling of
hole

spec
gears which are not engaged) could occur. es, in part or in w

t to the co
Installation position of clutch plate
• Lettering “Getriebeseite” (gearbox side) faces gearbox.

rrectness of i
l purpos

Checking ends of diaphragm spring


• Wear to half the thickness of the diaphragm spring -arrows- is

nform
ercia

permitted.
m

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Checking spring connections and riveted connections
– Check spring connections -arrows A- for damage and riveted
connections -arrows B- for secure seating.

4. Repairing clutch, in conjunction with dual-mass flywheel 51


Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
6-speed manual gearbox 02S - Edition 07.2009

Checking position of adjusting mechanism with new pressure


plates only
• Both edges -A- of the adjuster ring must be located between
the two notches -arrows B-.
• If the adjuster ring takes up a different position in new pressure
plates, the pressure plate and clutch plate are Anot
G. Vallowed
olkswagento
AG do
be installed. agen es n
olksw ot
V y gu
db ara
• The adjuster ring may take up oarisposition
e outside the notches nte
in used clutches. au
th eo
ra
ss c

ce
le
un

pt
Note

an
d
itte

y li
rm

ab
pe

ility
♦ Renew clutch plates and pressure plates with damaged or
ot

loose rivet connections.

wit
, is n

h re
hole

♦ Renew pressure plate and clutch plate together only.

spec
es, in part or in w

♦ Select clutch plate and pressure plate according to engine

t to the co
code and ⇒ Electronic parts catalogue “ETKA” .
♦ If clutch has burnt out, thoroughly clean clutch housing, fly‐

rrectness of i
wheel and parts of engine facing gearbox to reduce smell of
burnt linings.
l purpos

♦ Clean input shaft splines and, on used clutch plates, clean hub
splines; remove corrosion and apply only a very thin coat of

nform
ercia

clutch plate spline grease -G 000 100- to splines. Then move


clutch plate to and fro on input shaft until hub moves freely on
m

a
com

ti
shaft. Remove excessive grease.

on in
r
te o

thi
♦ Pressure plates are protected against corrosion and greased.
s
iva

Clean contact surface only. Otherwise, the service life of the do


r
rp

c
clutch will be considerably reduced.
um
fo

en
ng

t.
yi
♦ Pressure plate contact surface and clutch plate lining must
Co
op py
make full contact with flywheel. Only then insert securing bolts.
. C rig
ht ht
rig by
copy Vo
by lksw
cted agen
Prote AG.
– Reverse counterhold tool -3067- for installation.
– Push pressure plate onto centralizing pins.
– To centre clutch plate, use centring mandrel -3190 A- .
– Tighten all bolts evenly by hand until bolt heads contact pres‐
sure plate.
– Tighten bolts in small steps diagonally in order not to damage
centring holes of pressure plate and centring pins of dual-
mass flywheel.
– Install gearbox ⇒ page 92 .

52 Rep. Gr.30 - Clutch


Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
6-speed manual gearbox 02S - Edition 07.2009

4.5 Repairing LuK clutch

1 - Dual-mass flywheel
❑ Removing and installing
⇒ Rep. Gr. 13
❑ Ensure that centring
pins fit tightly
❑ Contact surface for
clutch lining must be
free of grooves, oil and
grease
2 - Clutch plate
❑ Allocation ⇒ Electronic
parts catalogue “ETKA”
❑ Removing and installing
⇒ page 50
❑ Renew only together
with SAC pressure
plate.
❑ Installation position:
⇒ page 51 .
3 - SAC pressure plate
❑ SAC means “self-ad‐
justing clutch”.
❑ Renew only together
with clutch plate.
❑ Allocation ⇒ Electronic
parts catalogue “ETKA”
❑ Removing and installing AG. Volkswagen AG d
agen oes
ksw
⇒ page 50 by
Vol not
gu
ara
ed
❑ Check ends of dia‐ horis nte
eo
phragm spring aut ra
c
⇒ page 51 ss
ce
e
nl

❑ Checking spring con‐


pt
du

an
itte

nections and riveted


y li
erm

ab

connections ⇒ page 51
ility
ot p

❑ Checking position of adjusting mechanism with new pressure plates only ⇒ page 52
wit
, is n

h re

4 - Bolt M6, 13 Nm, Bolt M7, 20 Nm


hole

spec

❑ Loosen or tighten diagonally in small steps


es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

4. Repairing clutch, in conjunction with dual-mass flywheel 53


AG. Volkswagen AG d
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤lkswagen oes
not
o
6-speed manual gearbox 02S - Edition 07.2009 db
yV gu
ara
e nte
ris
tho eo
au ra
5 Repairing clutch, in conjunction with one-piece flywheel
s s c

ce
e
nl

pt
du

an
itte

y li
erm

ab
Special tools and workshop

ility
ot p
equipment required

wit
, is n

h re
♦ Counterhold -3067-

hole

spec
♦ Centring mandrel -3190 A-

es, in part or in w

t to the co
♦ Torque wrench -
V.A.G 1331-

rrectness of i
♦ Grease for clutch plate
splines -G 000 100- l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

(Gearbox removed)

Note

♦ Renew clutch plates and pressure plates with damaged or loose rivets.
♦ Select clutch plate and pressure plate according to ⇒ Electronic parts catalogue “ETKA” and engine codes.
♦ Check whether dowel sleeves for aligning engine and gearbox are fitted in cylinder block and install if nec‐
essary.
♦ If dowel sleeves are not fitted, difficulties shifting gears, clutch problems and possible noises from the gear‐
box (rattling of gears which are not engaged) could occur.

54 Rep. Gr.30 - Clutch


Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
6-speed manual gearbox 02S - Edition 07.2009

1 - Flywheel
❑ Removing and installing
⇒ Rep. Gr. 13
❑ Ensure that centring
pins fit tightly
❑ Keep contact surface for
clutch lining free of
grooves, oil and grease.
2 - Clutch plate
❑ Allocation ⇒ Electronic
parts catalogue “ETKA”
❑ Installation position:
spring cage faces pres‐
sure plate
❑ Centring ⇒ page 55
❑ Lightly grease splines

Note

3 - Pressure plate n AG. Volkswagen AG do


wage
❑ Removing and installing olks es n
ot g
yV
⇒ page 55 d b ua
ran
ir se tee
❑ Check ends of dia‐ autho
or
ac
phragm spring ss
⇒ page 56

ce
e
nl

pt
du

an
❑ Check spring connec‐
itte

y li
tions and riveted con‐
erm

ab
nections ⇒ page 56 .

ility
ot p

wit
, is n

h re
Note
hole

spec
es, in part or in w

t to the co
4 - Bolt M6, 13 Nm, Bolt M7,
20 Nm
❑ Allocate according to ⇒

rrectness of i
Electronic parts catalogue “ETKA” .
l purpos

❑ Loosen or tighten diagonally and in steps

nf
ercia

or
Centring clutch plate and removing and installing pressure plate
m
m

atio
m

– Loosen or tighten bolts diagonally in stages.


o

n in
or c

thi
e

– Reverse position of counterhold -3067- when removing.


t

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
Note Cop
yi Co
py
t. rig
gh ht
Pressure plate contact surface and clutch plate lining must make pyri by
Vo
co
full contact with flywheel. Tighten bolts diagonally and evenly to
by lksw
cted agen
Prote
prevent damage to the centring holes in the pressure plate hous‐
AG.

ing and the centring pins in the flywheel.

5. Repairing clutch, in conjunction with one-piece flywheel 55


Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
6-speed manual gearbox 02S - Edition 07.2009

Checking ends of diaphragm spring


• Wear up to half the thickness of the diaphragm spring is per‐
mitted.

Checking spring connections and riveted connections


– Check spring connections between pressure plate and cover
for cracks as well as rivet connections for secure seating.
• A pressure plate with damaged spring connections or with
loose rivet connections -arrows- must be renewed.

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un

pt
an
d
itte

y li
rm

ab
pe

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

56 Rep. Gr.30 - Clutch


Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
6-speed manual gearbox 02S - Edition 07.2009

34 – Controls, housing
1 Fault finding, power transmission
– Refer to ⇒ Fault finding, power transmission; Rep. Gr. 30 ;
Complaints about clutch and clutch mechanism and ⇒ Fault
finding, power transmission; Rep. Gr. 34 ; Complaints about
selector mechanism

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un

pt
an
d
itte

y li
erm

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
by
57
copy Vo
by lksw
cted 1. Fault finding, power transmission
agen
Prote AG.
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
6-speed manual gearbox 02S - Edition 07.2009

2 Repairing selector mechanism

2.1 Installation position of selector mechanism


Arrow -A- Gear selection movement
Arrow -B- Gate selection movement

A - Gear selector cable


B - Gate selector cable
C - Heat shield
❑ Remove before remov‐
ing gear selector mech‐
anism
1 - Gearbox selector lever
2 - Relay lever

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw

58
cted agen
Prote
Rep. Gr.34 - Controls, housing
AG.
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
6-speed manual gearbox 02S - Edition 07.2009

2.2 Overview of selector mechanism

Note

♦ Note radio code for vehicles with coded radio.


♦ Before working on selector mechanism in engine compartment, disconnect earth strap from battery ⇒ Elec‐
trical system; Rep. Gr. 27 ; Disconnecting and connecting battery .
AG. Volkswagen AG d
agen
♦ When reconnecting
Vol battery, perform work required
ksw
oes
not after connecting battery ⇒ Electrical system; Rep. Gr.
27 ; Disconnecting
se
db
y
and connecting battery .
g ua
ran
ori tee
♦ To workauon selector mechanism in engine compartment,or remove
th
ac complete air filter housing if it is located
over selector
ss mechanism ⇒ Rep. Gr. 23 ; Repairing diesel direct injection system or ⇒ Rep. Gr. 24 ;

ce
e

Repairing injection system .


nl

pt
du

an
itte

♦ Remove selector mechanism to renew selector cables ⇒ page 75 .

y li
erm

ab
ility
♦ Do not kink selector cables.
ot p

wit
, is n

h re
hole

spec
I - Removing and installing
es, in part or in w

t to the co
gear knob and frame
⇒ page 61
II - Repairing gear lever and

rrectness of i
selector housing (through
10.06) ⇒ page 63
l purpos

II - Repairing gear lever and


selector housing (from 11.06)
nform
ercia

⇒ page 65
m

at
om

III - Assembly overview - re‐


on
c

in t

moving and installing selector


or

his
e

cables ⇒ page 70
at

do
priv

cum
for

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Removing and installing selector mechanism ⇒ page 75


Adjust selector mechanism ⇒ page 80 .
Special tools and workshop equipment required

2. Repairing selector mechanism 59


Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
6-speed manual gearbox 02S - Edition 07.2009

♦ Hose clip pliers -V.A.G 1275-

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c

ce
le
un

pt
an
d
itte

y li
rm

ab
pe

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w
♦ Torque wrench -V.A.G 1331-

t to the co
rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

60 Rep. Gr.34 - Controls, housing


Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
6-speed manual gearbox 02S - Edition 07.2009

2.3 Removing and installing gear knob and frame

1 - Emblem
❑ Can be carefully levered
off gear knob of plastic
or leather
2 - Gear knob
❑ With gaiter
❑ Gear knob and gaiter
cannot be separated
from one another
❑ Always renew together
❑ Removing and installing
⇒ page 61 AG. Volkswagen AG d
agen oes
lksw not
3 - Clamp d by
Vo gu
ara
e nte
❑ For securing gear knob horis
eo
to gear lever aut ra
ss c
❑ Secure to gear knob

ce
le
un

pt
⇒ Item 2 (page 61) using

an
d
itte

hose clip pliers -V.A.G

y li
rm

ab
1275-
pe

ility
ot

❑ Always renew

wit
, is n

h re
4 - Frame for centre console
hole

spec
❑ In some equipment ver‐
es, in part or in w

t to the co
sions, forms one part to‐
gether with centre con‐
sole

rrectness of i
5 - Noise insulation
l purpos

❑ Not fitted in all vehicles


❑ Arrow on noise insula‐

nform
ercia

tion points in direction of


travel
m

a
com

❑ Locking lugs are ar‐ tion in


ranged at varying inter‐
r
te o

thi

vals
s
iva

do
r
rp

❑ Therefore it can be installed in only one position


um
fo

en
ng

t.
yi Co
Cop py
t. rig
gh
2.4 Removing and installing gaiter with gear
ht
pyri by
Vo
o
by c lksw
knob and noise insulation
cted agen
Prote AG.

– Pull or carefully prise gaiter with frame for centre console up‐
wards out of centre console -arrows-.

Note

With some equipment variations, the gaiter must be levered off


along the front section.

2. Repairing selector mechanism 61


Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
6-speed manual gearbox 02S - Edition 07.2009

– Pull gaiter with frame for centre console upwards, inside out
over gear knob.
– Open clamp -arrow- and pull off gear knob together with gaiter.
In some versions, the centre console frame remains in the centre
console.
– If necessary pull off, or carefully lever off, centre console
frame.

– Pull off noise insulation -1-.

2.4.1 Installing
– First set noise insulation in place.
Installation position of noise insulation
• -Arrow A- points in direction of travel.
• Catches -arrows B- must engage in centre console. agen
AG. Volkswagen AG d
oes
olksw not
– If necessary, press frame into centre console. d by V gu
ara
rise nte
– Then turn gaiter inside out. utho eo
ra
s a c
s
The gear knob must be pressed to stop.
ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

– Install gear knob with frame and gaiter and squeeze new
wit
, is n

h re

clamp -arrow- together.


hole

spec

– Then press gaiter with frame into centre console or gaiter into
es, in part or in w

frame.
t to the co
rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

62 Rep. Gr.34 - Controls, housing


Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
6-speed manual gearbox 02S - Edition 07.2009

2.5 Repairing gear lever and selector housing (through 10.06)

Note

Lubricate bearing points and sliding surfaces with grease -G 000 450 02- .

1 - Securing clip
❑ Removing and installing
⇒ page 64
AG. Volkswagen AG d
agen
2 - Bush Volksw
oes
not
by gu
d ara
3 - Compression spring orise nte
th eo
u ra
4 - Bush ss a c

ce
le
5 - Torx screw, 5 Nm
un

pt
an
d
itte

y li
6 - Cover
erm

ab
ility
ot p

7 - Damping

wit
is n

h re
8 - Damping
ole,

spec
urposes, in part or in wh

9 - Ball socket

t to the co
10 - Gear lever guide
11 - Damping washer

rrectne
12 - Seal

s
❑ Between selector hous‐

s o
ing and underbody
cial p

f inform
❑ Self-adhesive
mer

atio
❑ Bond to selector hous‐
om

ing

n
c

i
or

n thi
e

13 - Gear lever
t

sd
iva

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pr

cum
14 - Selector lever housing
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fo

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ng

t.
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15 - Bearing bush
Co
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gh
16 - Pivot pin
ht
pyri by
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cted
17 - Guide bush
agen
Prote AG.

18 - Compression spring
❑ Installing ⇒ page 64
19 - Gate selector lever
20 - Torx screw, 5 Nm
21 - Seal
❑ Always renew
22 - Base plate
❑ Bend open tabs to remove
❑ Always renew
23 - Gate selector cable
❑ On gate selector lever
❑ Removing and installing ⇒ page 64
24 - Gear selector cable
❑ Removing from and attaching to gear lever guide ⇒ page 64

2. Repairing selector mechanism 63


Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
6-speed manual gearbox 02S - Edition 07.2009

25 - Securing clip
❑ Always renew
26 - Hexagon nut
❑ M8: 25 Nm
❑ M6: 8 Nm
❑ Qty. 4
27 - Bearing bush
❑ Fits in one position only
28 - Securing clip
❑ Always renew

Removing and installing gate and gear selector cables


– Remove securing clip from gear selector cable -A- and gate
selector cable -B-.
To do this, raise tab using screwdriver -arrow 1- and press off
securing clip -arrow 2-.
– Remove gear selector cable -A- from gear lever retainer.
– Remove gate selector cable -B- from retainer of gate selector
lever.

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agen oes
olksw not
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Removing and installing securing clip


y li
erm

ab
ility

– To remove or install securing clip -arrow A-, press spacer bush


ot p

wit

-arrow B- to stop in direction of arrow -arrow C- using screw‐


, is n

h re

driver and pull off securing clip.


hole

spec
es, in part or in w

t to the co

Note

♦ Do not cant spacer bush when pushing down.


rrectness of i

♦ Slot in gear lever for securing clip must be visible.


l purpos

♦ Carefully release tension from spring.


nf
ercia

orm
m

Installing compression spring


atio
om

n in
c

– Insert compression spring so that extension -A- lies on top of


or

thi
e

pin -arrow-.
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– Then pull extension -B- down so that it sits below pin -arrow-.
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Prote AG.

64 Rep. Gr.34 - Controls, housing


Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
6-speed manual gearbox 02S - Edition 07.2009

2.6 Repairing gear lever and selector housing (from 11.06)

Note

♦ Lubricate bearing points and sliding surfaces with grease -G 000 450 02- .
♦ Dismantling and assembling selector mechanism ⇒ page 66 .

1 - Base plate
❑ Bend open tabs to re‐
move
❑ Always renew
2 - Seal
❑ Always renew
3 - Selector lever
❑ Can be removed and in‐
stalled with gear lever
guide
⇒ Item 15 (page 66)
installed
4 - Damping washer
❑ Push onto gear lever up
to stop -arrow-
5 - Securing clip
❑ Do not damage cables
when removing
n AG. Volkswagen AG do
❑ Always renew lkswage es n
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byV ua
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6 - Gate selector cable o
ir se tee
th or
❑ Lever off gate selector ss
au ac
lever
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❑ Press onto gate selector


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lever inside selector
erm

ab
mechanism
ility
ot p

❑ Installation position wit


, is n

⇒ page 58 h re
hole

spec

7 - Bush
es, in part or in w

t to the co

8 - Gear selector cable


❑ Lever off gear lever
guide
rrectness of i

❑ Press onto gear lever


l purpos

guide inside selector mechanism


❑ Installation position ⇒ page 58
nform
ercia

9 - Damping
m

at
om

io

10 - Ball socket
n
c

in t
or

❑ Will be damaged when removed


his
ate

do
riv

❑ Always renew
p

cum
for

en
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11 - Bush
n

t.
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op py
12 - Securing clip
t. C rig
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❑ Removing and installing ⇒ page 64 cop Vo
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13 - Compression spring
AG.

❑ Removing and installing ⇒ page 64

2. Repairing selector mechanism 65


Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
6-speed manual gearbox 02S - Edition 07.2009

14 - Bush
15 - Gear lever guide
16 - Hexagon nut
❑ M8: 25 Nm
❑ M6: 8 Nm
❑ Qty. 4
17 - Seal
❑ Between selector housing and underbody
❑ Self-adhesive
❑ Bond to selector housing
18 - Selector lever housing
❑ With compression spring and gate selector lever
❑ Compression spring and gate selector lever cannot be removed

2.6.1 Dismantling and assembling selector


mechanism
Special tools and workshop equipment required

thrust piece -T10083-
Dismantling
– Remove selector mechanism ⇒ page 75 .
AG. Volkswagen AG d
agen oes
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– Bend open tabs -arrows- of base plate for selector mechanism


h re
using screwdriver and remove base plate; (tabs in front area
hole

of base plate are not illustrated). spec


es, in part or in w

t to the co
– Remove seal from selector housing.
– Remove gear and gate selector cables from selector housing
rrectness of i

⇒ page 78 .
l purpos

nform
mercia

a
com

tion in
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te o

thi
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t.
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Cop py
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cted agen
Prote AG.

66 Rep. Gr.34 - Controls, housing


Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
6-speed manual gearbox 02S - Edition 07.2009
AG. Volkswagen AG d
agen oes
lksw not
– Lift upper end -A- of compression spring over tab of gate se‐ byV
o gu
ara
lector lever. rised
nte
ho eo
ut
– Use screwdriver to press catches -arrows- of ball ssocket
s a to‐ ra
c
wards bearing ball of gear lever guide; break off catches if

ce
le
un
necessary.

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rm

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pe

ility
ot

wit
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hole

spec
es, in part or in w

t to the co
– Lever ball socket -A- with gear lever guide -B- out of selector

rrectness of i
housing.
l purpos
– Then press ball socket off bearing ball of gear lever guide and
remove it.

nform
mercia

a
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tion in
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te o

thi
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Cop py
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• Please pay attention to guides -A- during the further proce‐ co Vo
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dure. cted agen
Prote AG.

• They must not be broken off.

– Lever lower end -arrow 1- of compression spring onto shoulder


on gate selector lever as far as stop.
– Now pull gear lever guide up to stop and pull ball stud out of
gate selector lever -arrow 2-.

– Then turn gear lever guide in -direction of arrow 1-.


• Pin -arrow 2- must be in notch in selector housing.
– Then swing out gear lever guide with gear lever in
-direction of arrow 3-.
Assembling

Caution

The lower end of the compression spring (-arrow 1- ⇒ figure


above) can snap off the shoulder of the gate selector lever out
of control during the further procedure.

– Therefore, carefully press it down off shoulder of gate selector


lever.
The ends of the compression spring then become tensioned “di‐
agonally” with a loud noise.

2. Repairing selector mechanism 67


Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
6-speed manual gearbox 02S - Edition 07.2009

– Slacken ends -A- and -B- by turning both round to right.


• Ends -A- and -B- must point in opposite directions.

– Fit gear lever guide in selector housing.


• Pin -arrow 1- is still located inagnotch inolselector
en AG. V
kswagen Ahousing.
G do
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olks t
– Turn gear lever guide ed
bin
y V-direction of arrow 2- until ball stud
gu
ara
-A- is located in notch
horis in selector housing. nte
e t or
au ac
ss

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e
nl

pt
du

an
itte

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erm

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ility
ot p

wit
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h re
hole

spec
es, in part or in w

– Place selector housing with gear lever guide into larger recess t to the co
-arrow- in thrust piece -T10083- .
rrectness of i

Note
l purpos

To ensure that the selector housing with gear lever guide can be
inserted in the thrust piece , first remove gear lever, if necessary.
nf
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orm
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• The gear lever guide must project from the selector housing
t.
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up to the stop. ht. Cop py
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cted agen
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For clarity of illustration, only part of the gate selector lever is


shown.

– Insert end -A- of compression spring into guide from above.


– Pull end -B- of compression spring downwards and insert it
next to guide (in direction of ball joint).
• Please pay attention to guides (⇒ figure above) during the fur‐
ther procedure.
• They must not be broken off.
– Carefully remove selector housing with gear lever guide from
thrust piece -T10083- .

68 Rep. Gr.34 - Controls, housing


Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
6-speed manual gearbox 02S - Edition 07.2009

– Move gate selector lever back to stop (opposite from mounting


holes for gear and gate selector cable) -arrow 1-.
– Grease ball stud.
– Press ball stud into gate selector lever -arrow 2-.
• Guides -A- and tabs -B- are not allowed to be damaged.

– Place selector housing with gear lever guide into larger recess
-arrow- in thrust piece -T10083- .

AG. Volkswagen AG d
agen oes
lksw not
• The gear lever guide must project from the selector by housing
Vo gu
ara
up to the stop. orised
nte
h eo
ut ra
– Lift upper end -A- of compression springssover pin of gate se‐
a c
lector lever

ce
e
nl

pt
du

an
• Use a new ball socket -B-.
itte

y li
erm

ab
– Grease ball socket and bearing ball of gear lever guide.

ility
ot p

wit
, is n

– Press ball socket onto bearing ball of gear lever guide up to

h re
stop.
hole

spec
es, in part or in w

– Remove selector housing from thrust piece -T10083- .

t to the co
– Insert lower end -C- of compression spring into guide.
– Lift upper end -A- of compression spring over pin of gate se‐ rrectness of i
lector lever into guide.
l purpos

– Press ball socket into selector housing -arrows-.


• All locking lugs must clip in.
nform
ercia

– Attach gear lever, gear selector cable, gate selector cable and
m

at
om

base plate ⇒ page 65 .


ion
c

in t
or

– Install selector mechanism ⇒ page 75 .


his
ate

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priv

cum
for

en
ng

t.
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Cop py
t. rig
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pyri by
Vo
o
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cted agen
Prote AG.

2. Repairing selector mechanism 69


Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
6-speed manual gearbox 02S - Edition 07.2009

2.7 Assembly overview - removing and installing selector cables

Note

Lubricate bearing points and sliding surfaces with grease -G 000 450 02- .

1 - Gear selector cable


❑ Connect to cable end-
piece
⇒ Item 11 (page 71)
❑ Installation position
⇒ page 58
❑ Use cable tie to fix onto
gate selector cable
⇒ page 73
❑ Removing and installing
⇒ page 78
❑ From 11.06, modified
attachment to gear lever
inside selector mecha‐
nism agen
AG. Volkswagen AG d
oes
⇒ Item 8 (page 65) olksw not
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ed
2 - Gate selector cable horis nte
eo
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❑ Connect to cable end- ss a c
piece

ce
le
un

pt
⇒ Item 10 (page 71)

an
d
itte

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❑ Installation position
rm

ab
⇒ page 58
pe

ility
ot

wit
❑ Use cable tie to fix onto
, is n

h re
gear selector cable
hole

spec
⇒ page 73
es, in part or in w

❑ Removing and installing

t to the co
⇒ page 78
❑ From 11.06, modified
rrectness of i
attachment to gate se‐
lector lever inside selec‐
l purpos

tor mechanism
⇒ Item 6 (page 65)
nform
ercia

3 - Securing clip
m

❑ Always renew
a
com

tion in

❑ Discontinued in selector
r
te o

thi

mechanisms from 11.06 ⇒ page 65


s
iva

do
r

4 - Selector lever housing


rp

cum
fo

en
ng

5 - Securing clip
t.
yi Co
Cop py
❑ Always renew ht. rig
rig ht
py by
❑ Do not damage cables when removing
co Vo
by lksw
cted agen
Prote AG.
6 - Hexagon bolt, 20 Nm
❑ Qty. 3
❑ For cable support bracket
7 - Cable support bracket
❑ May be made from plastic or metal
8 - Grommet
❑ Cable support bracket mounting on gearbox

70 Rep. Gr.34 - Controls, housing


Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
6-speed manual gearbox 02S - Edition 07.2009

9 - Spacer
AG . Volkswage
10 - Cable end-piece ksw
agen
n AG d
oes
not
Vol
❑ For gate selector cable to relay lever ed by gu
ara
ris nte
❑ After installing, adjust selector mechanism
ut
ho ⇒ page 80 eo
ra
a
❑ Do not interchange; cable end-pieces
ss for gate selector cable to relay lever and gearc selector cable to

ce
e
gearbox selector lever are different

nl

pt
du

an
❑ For metal relay lever, secured with securing clip ⇒ Item 12 (page 71)

itte

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erm

ab
❑ From 05.07, fitted in conjunction with plastic relay lever ⇒ page 73

ility
❑ Removing from plastic relay lever ⇒ page 73 ot p

wit
, is n

h re
❑ Pressing onto plastic relay lever ⇒ page 73
hole

spec
❑ Allocation ⇒ page 72
es, in part or in w

t to the co
11 - Cable end-piece
❑ For gear selector cable to gearbox selector lever

rrectness of i
❑ After installing, adjust selector mechanism ⇒ page 80
l purpos

❑ Do not interchange; cable end-pieces for gate selector cable to relay lever and gear selector cable to
gearbox selector lever are different
❑ Allocation ⇒ page 72

nf
ercia

orm
12 - Securing clip
m

atio
om

❑ Always renew

n in
or c

thi
❑ Not required for plastic relay lever
te

sd
iva

o
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rp

cu
13 - Securing clip
o

m
f

en
ng

❑ Always renew
t.
yi Co
op py
❑ Not required for plastic relay lever t. C rig
gh ht
pyri by
14 - Bearing bush
o Vo
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cted agen
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❑ Not required for plastic relay lever
AG.

15 - Relay lever
❑ Installation position ⇒ page 72
❑ After installing, adjust selector mechanism ⇒ page 80
❑ May be made from plastic or metal
❑ Metal relay lever is mounted in bearing bush ⇒ Item 14 (page 71) and secured with securing clip
⇒ Item 13 (page 71)
❑ From 05.07, plastic relay lever
❑ Remove and install plastic relay lever together with cable end-piece ⇒ page 73
❑ Bearing bushes and securing clip not required for plastic relay lever
16 - Shoe
17 - Gearbox selector lever
❑ With damper weight
❑ Install so that master spline aligns with selector shaft
❑ Installation position ⇒ page 72
❑ After installing, adjust selector mechanism ⇒ page 80
❑ From 06.06, smaller diameter of support pin for cable end-piece ⇒ page 72
18 - Hexagon nut, 23 Nm
❑ Self-locking
❑ Always renew

2. Repairing selector mechanism 71


Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
6-speed manual gearbox 02S - Edition 07.2009

Allocation of cable end-pieces


The holes in the cable end-pieces have different diameters.
Cable end-piece for Dimension “a”
1 - Gear selector cable to gearbox selector lever 8.5 mm
from 06.06
2 - Gear selector cable to gearbox selector lever 10 mm
through 05.06
2. - Gate selector cable to metal relay lever 8 mm
2. - Gate selector cable to plastic relay lever 10 mm
⇒ page 73

From 06.06, smaller diameter of support pin for gear selector ca‐
ble end-piece
Support pin for gear selector cable end-piece Dimension “a”
n AG. Volkswagen AG do
Through 05.06 olkswage 10 mm
es n
ot g
yV u
From 06.06 ir se
d b 8.5 mm aran
o tee
h
aut or
ac
ss
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e
nl

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itte

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erm

ab
ility
ot p

wit
, is n

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Installation position of gearbox selector lever and relay lever


hole

spec

1 - Gearbox selector lever with damper weight


es, in part or in w

t to the co

2 - Relay lever engages in guide rail of gearbox selector lever via


shoe -arrow-.
rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

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priv

cum
for

en
ng

t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

72 Rep. Gr.34 - Controls, housing


Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
6-speed manual gearbox 02S - Edition 07.2009

Fitting position of cable tie for cables


– Wind cable tie -arrow- around the selector cables in a figure
eight and secure them as shown in figure.

n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss

ce
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2.8 Plastic relay lever

nl

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itte

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From 05.07, relay lever is made from plastic. 2 versions may be erm

ab
ility
installed.
ot p

wit
, is n

♦ Relay lever with catch or

h re
hole

spec
♦ Relay lever with clip
es, in part or in w

t to the co
Comply with the following during removal and installation work:
• To remove relay lever, first separate cable end-piece from

rrectness of i
gate selector cable.
l purpos

This will avoid damage to the gate selector cable


– Pull locking mechanism forward to stop in

nform
ercia

-direction of arrow 1- and then lock by turning to left in


-direction of arrow 2-.
m

at
om

io
– Then push relay lever forwards (-in direction of arrow 3-).

n
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.

Relay lever with catch -arrow 1-


– Press catch -arrow 1- down to stop and remove relay lever
together with cable end-piece. In the process, swing it in di‐
rection of operation.

2. Repairing selector mechanism 73


Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
6-speed manual gearbox 02S - Edition 07.2009

Relay lever with clip -arrow 1-


– Pull clip -arrow 1- off and remove relay lever together with ca‐
ble end-piece.
Continuation for all
• Cable end-piece must be located behind catch -arrow 2-.
• The cable end-piece can be removed only with the relay lever
removed ⇒ page 75 .

Note

To fit, lubricate bearing points and sliding surfaces awith


gen Agrease
G. Volksw-agen AG d
oes
G 000 450 02- . yV
olksw not
gu b ara
ed nte
oris e
– Press cable end-piece onto relayalever
ut
h ⇒ page 75 . or
ac
ss
– Install relay lever together with cable end-piece to stop.

ce
le
un

pt
an
d
itte

y li
rm

ab
Relay lever with catch -arrow 1-
pe

ility
ot

wit
, is n

• Catch -arrow 1- secures relay lever.

h re
hole

spec
• Ensure proper engagement.
es, in part or in w

t to the co
• Cable end-piece must be located behind catch -arrow 2-.

rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
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do
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rp

cum
fo

en
ng

t.
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Cop py
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yri by
Relay lever with clip -arrow 1- op Vo
by c lksw
cted agen
Prote
• Clip -arrow 1- secures relay lever.
AG.

• Ensure proper engagement of clip.


• Cable end-piece must be located behind catch -arrow 2-.

74 Rep. Gr.34 - Controls, housing


Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
6-speed manual gearbox 02S - Edition 07.2009

Levering gate selector cable end-piece off plastic relay lever


• Relay lever has been removed.
– Insert a flat-blade screwdriver -A- between bush -B- and relay
lever.

Pressing on cable end-piece

AG. Volkswagen AG d
agen oes
ksw
• Relay lever has been removed. by Vol not
gu
d ara
ise nte
• Cable end-piece may be pressed only onto bush -arrow-.
thor eo
au ra
c
• Cable end-piece must move freely on relay lever. ss

ce
le
un

pt
• It must be located behind catch -arrow 2-.

an
d
itte

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rm

ab
pe

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

a
com

tio

2.9 Removing and installing selector mech‐


n in
r
te o

thi

anism
s
iva

do
r
rp

cum
fo

en
ng

t.
yi Co
2.9.1 Removing Cop py
t. rig
gh ht
yri by
Special tools and workshop equipment required cop Vo
by lksw
cted agen
Prote AG.

2. Repairing selector mechanism 75


Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
6-speed manual gearbox 02S - Edition 07.2009
. Volkswage AG n AG d
agen oes
olksw not
♦ Torque wrench -V.A.G d1331-by
V gu
ara
rise nte
tho eo
s au ra
c
s

ce
le
un

pt
an
d
itte

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erm

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectne
♦ Grease -G 000 450 02-
– First check whether a coded radio is fitted. If so, obtain anti-

ss
theft code.

o
cial p

f in
– With ignition switched off, disconnect battery earth strap ⇒

form
mer

Electrical system; Rep. Gr. 27 ; Removing and installing bat‐

atio
m

tery .
o

n
c

i
or

n
– Remove gaiter with selector knob and noise insulation

thi
te

sd
a

⇒ page 61 .
iv

o
pr

cum
r
fo

– Remove centre console and securing bracket for centre con‐


en
ng

t.
sole ⇒ General body repairs, interior; Rep. Gr. 68 ; Compart‐
yi Co
op
ments, covers and trims .
C py
t. rig
gh ht
yri by
– Remove selector housing nuts -arrows-. cop Vo
by lksw
cted agen
Prote AG.
– Remove complete air filter housing if it is over selector mech‐
anism ⇒ Rep. Gr. 23 ; Repairing diesel direct injection system
or ⇒ Rep. Gr. 24 ; Repairing injection system .

– Remove securing clip -3- for gear selector cable from gearbox
selector lever -1-.
– Pull gear selector cable off pin.
Metal relay lever
– Remove securing clip -4- for gate selector cable from relay
lever -2-.
– Pull gate selector cable from pin.
Plastic relay lever

76 Rep. Gr.34 - Controls, housing


AG. Volkswagen AG d
agen Golf
oes Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
olksw not
byV gu
ara6-speed manual gearbox 02S - Edition 07.2009
ed
ris nte
ho eo
ut ra
Releasing
ss a cable end-piece from gate selector cable c

ce
le
– Pull locking mechanism forward to stop in
un

pt
an
d

-direction of arrow 1- and then lock by turning to left in


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-direction of arrow 2-.
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– Then push relay lever forwards (-in direction of arrow 3-).

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Continued for all selector mechanisms
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

– Remove cable support bracket from gearbox -arrows-; if nec‐


essary, unclip pipe/hose -A- from bracket -B- first.

nform
ercia

– Remove noise insulation ⇒ General body repairs, exterior;


m

Rep. Gr. 50 ; Noise insulation .

a
com

tion in
– Remove tunnel cross member ⇒ Rep. Gr. 26 ; Removing and
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te o

thi
installing parts of exhaust system .

s
iva

do
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– Separate front exhaust system at double clamp and detach

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en
from subframe ⇒ Rep. Gr. 26 ; Removing and installing parts
ng

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of exhaust system . ht. Cop py
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– Remove rear exhaust system and heat shield ⇒ Rep. Gr. 26 ;
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Removing and installing parts of exhaust system .
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cted agen
Prote AG.
– Remove underbody panels ⇒ General body repairs, exterior;
Rep. Gr. 50 .
– Swing selector housing down and remove with selector ca‐
bles.

2.9.2 Installing
Install in the reverse order of removal, observing the following:
– Align selector housing parallel to body.
• Distance to body must be same on both sides.
– Secure selector housing ⇒ Item 26 (page 64) or
⇒ Item 16 (page 66) .
– Route cables -1- from selector mechanism -2- to gearbox as
follows:
♦ After cables cross over -arrow-, they must be routed parallel
to one another as far as cable support bracket on gearbox.
♦ Make sure that cable tie -arrow- for securing cables is installed
correctly. Installation position ⇒ page 73 .
♦ Cables must be laid in the intended indentation in heat shield
-3-.

Note

In the close-up, the heat shield is shown from above.

2. Repairing selector mechanism 77


Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
6-speed manual gearbox 02S - Edition 07.2009

Clip -A- holds cables and heat shield together in position.


– Install cable support bracket on gearbox and tighten bolts to
specified torques ⇒ Item 6 (page 70) .
The holes in the cable end-pieces have different diameters.
Allocation of cable end-pieces ⇒ page 72

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– Spread a small quantity of greaseth-Go 000 450 02- on pins
r eo
-arrows- of gearbox selector lever
s a -1- and relay lever -2-.
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e

– Renew securing clips -3- and -4- each time they are removed.
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– Secure gear selector cable with securing clip -3- and gate se‐
erm

ab
lector cable with securing clip -4-.

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Cable end-piece to plastic relay lever
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hole

– Fit relay lever and cable end-piece together ⇒ page 73 .

spec
es, in part or in w

– Insert gate selector cable in cable end-piece.

t to the co
Continued for all selector mechanisms

rrectness of i
– Install centre console ⇒ General body repairs, interior; Rep.
Gr. 68 ; Compartments, covers and trims .
l purpos

– Install gaiter with selector knob and noise insulation


⇒ page 61 .

nform
ercia

– Install heat shield.


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io
– If removed, reinstall underbody panels ⇒ General body re‐
n
c

in t
r

pairs, exterior; Rep. Gr. 50 .


o

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ate

do
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– Assemble exhaust system free of tension and attach tunnel


p

cum
or

cross member ⇒ Rep. Gr. 26 ; Removing and installing parts


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of exhaust system .
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Adjust selector mechanism ⇒ page 80 . opyri
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– If removed, install complete air filter housing ⇒ Rep. Gr. 23 ;
by lksw
cted agen
Prote
Repairing diesel direct injection system or ⇒ Rep. Gr. 24 ;
AG.

Repairing injection system


– Follow procedure after connecting battery ⇒ Electrical system;
Rep. Gr. 27 ; Battery; Disconnecting and connecting battery .

2.10 Removing and installing gear selector


cable and gate selector cable

2.10.1 Removing
– Remove selector mechanism ⇒ page 75 .

78 Rep. Gr.34 - Controls, housing


Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
AG. Volkswagen AG d
lksw6-speed
agen manual gearbox
oes 02S - Edition 07.2009
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– Bend open tabs -arrows- of selector mechanism
ho
ris cover using tee
a screwdriver and remove cover. aut or
ac
ss
– Remove gasket.

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es, in part or in w

t to the co
rrectness of i
– Pull off securing clips -2 and 3-. (Securing clips -1 and 4- have
l purpos

been discontinued.) Lever gear selector cable off gear lever


and gate selector cable off gate selector lever using a screw‐
driver.

nform
ercia

– Pull gear selector cable and gate selector cable from selector
m

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housing.
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Release locks -A- for gear and gate selector cables -B- as follows:
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♦ Push sliding sleeve forward to stop -arrow 1-.


♦ Turn sliding sleeve to right to stop -arrow 2- until it engages.
– Remove locking mechanism from Bowden cables.

– Pull off securing clips -1- and -2-.


– Remove cable support bracket from Bowden cables.

2.10.2 Installing
Install in the reverse order of removal, observing the following:

2. Repairing selector mechanism 79


Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
6-speed manual gearbox 02S - Edition 07.2009

– Secure gear selector cable and gate selector cable to selector


housing using securing clips -2 and 3-.
– Press gear selector cable onto gear lever and gate selector
cable onto gate selector lever in selector housing. (Securing
clips -1 and 4- have been discontinued.)

– Fit seal and secure selector mechanism cover by pressing


down tabs -arrows-.
– Install selector mechanism ⇒ page 77 .
– Adjust selector mechanism ⇒ page 80 .

AG. Volkswagen AG d
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2.11 Adjusting selector mechanism


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Special tools and workshop equipment required


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♦ Locking pin -T10027 A-


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rrectness of i
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♦ The following points are essential to ensure correct adjust‐ t. C rig
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ment of selector mechanism: pyri by
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♦ Moving parts of selector mechanism and elements transferring
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force must be in proper condition.
♦ Selector mechanism must move freely.
♦ Gearbox, clutch and clutch mechanism must also be in proper
condition.

• Gearbox must be in neutral.

80 Rep. Gr.34 - Controls, housing


Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
6-speed manual gearbox 02S - Edition 07.2009

– Remove complete air filter housing if bracket -A- to secure


gear selector cable and gate selector cable are not accessible
⇒ Rep. Gr. 23 ; Repairing diesel direct injection system or ⇒
Rep. Gr. 24 ; Repairing injection system .

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– Pull locking mechanisms on gate selector cable and gear se‐
ss

ce
le

lector cable end-pieces forward to stop -direction of arrow 1-


un

pt
and then turn to left to lock -direction of arrow 2-.

an
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es, in part or in w

t to the co
rrectness of i
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Secure selector shaft as follows:

nform
ercia

– Press selector shaft down -direction of arrow 1-.


m

a
– While pressing down selector shaft, turn angled rod -A- in
com

tio
-direction of arrow 2- upwards and at the same time press it in
n in
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until it engages in selector shaft.


thi
s
iva

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– Remove gaiter with selector knob and frame ⇒ page 61 .


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rp

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– If noise insulation is present, remove it.


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Now secure gear lever as follows:
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– Select neutral using gear lever.
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– Guide locking pin -T10027 A- through hole -A- into hole -B-.

2. Repairing selector mechanism 81


Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
6-speed manual gearbox 02S - Edition 07.2009

– Check that gate and selector cables -B- are inserted, free of
tension, into locking devices -A-.
– Now turn locking mechanisms on gear selector cable and gate
selector cable end pieces clockwise to stop
-direction of arrow 1-.
The spring presses the locking mechanism into original position
-direction of arrow 2-.

– Now turn angled rod -A- back to original position


-direction of arrow-.

AG. Volkswagen AG d
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The angled rod -A- must be pressed out of selector housing to

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stop and point to rear.

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urposes, in part or in wh

t to the co
rrectness o
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– Pull locking pin out of holes -A- and -B-.


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mer

– If noise insulation was present, install it.


atio
om

– Install gaiter with selector knob and frame ⇒ page 61 .


n
c

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or

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e

– Check that selector shaft moves freely.


t

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– If removed, reinstall complete air filter housing ⇒ Rep. Gr.


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fo

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23 ; Repairing diesel direct injection system or ⇒ Rep. Gr.


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24 ; Repairing injection system C py
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2.11.1 Functional check


• With gearbox in neutral, gear lever must rest in gate for 3rd
and 4th gear.
– Operate clutch.
– Select all gears several times. Pay particular attention to op‐
eration of reverse gear lock.

82 Rep. Gr.34 - Controls, housing


Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
6-speed manual gearbox 02S - Edition 07.2009
n AG. Volkswagen AG do
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– If it continues to be difficult by V to engage a gear after repeated
o lk ot g
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attempts, repeat adjustment
ir se
d procedure of selector mechanismrante
⇒ page 80 . tho eo
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2. Repairing selector mechanism 83


Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
6-speed manual gearbox 02S - Edition 07.2009

3 Removing and installing gearbox

Special tools and workshop


equipment required
♦ Vehicles with turbo diesel
engines and vehicles with
2.0l - 110 kW petrol engines
♦ Hook - 10 - 222 A /2-
♦ Adapter -10 - 222 A /3-
♦ Adapter -10 - 222 A /16-
♦ Hook -10 - 222 A /10-
♦ All vehicles
♦ Support bracket -10 - 222
A-
♦ Adapter -10 - 222 A /8-
♦ Pin -3282/29-
♦ Gearbox support -3282-

AG. Volkswagen AG d
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for

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pyri by
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Prote AG.

84 Rep. Gr.34 - Controls, housing


Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
6-speed manual gearbox 02S - Edition 07.2009

♦ Adjustment plate -3282/39-


♦ Engine and gearbox jack -
V.A.G 1383A-
♦ Torque wrench -V.A.G
1331-
♦ Torque wrench -V.A.G
1332-
♦ Gearbox mounting support
-3336-
♦ Grease -G 000 450 02-
♦ Grease for clutch plate
splines -G 000 100-

AG. Volkswagen AG d
agen oes
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t to the co

3.1 Removing gearbox


rrectne

– First check whether a coded radio is fitted. If so, obtain anti-


theft code.
s

– With ignition switched off, disconnect battery earth strap ⇒


s o
cial p

Electrical system; Rep. Gr. 27 ; Disconnecting and connecting


f in

battery .
form
mer

atio

– Remove engine cover if engine lifting eye arrow -10 - 222 A-


om

is not accessible.
c

i
or

n thi
e

– Remove complete air filter housing if it is near battery ⇒ Rep.


t

sd
iva

Gr. 23 ; Repairing diesel direct injection system or ⇒ Rep.


pr

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fo

Gr. 24 ; Repairing injection system .


en
ng

t.
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op
– Remove battery and battery tray ⇒ Electrical system; Rep.
C py
t. rig
Gr. 27 ; Battery; Removing and installing battery .
gh ht
pyri by
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by c lksw
– Remove securing clip -arrow 1- for gear selector cable from
Prote
cted AG.
agen
gearbox selector lever -A-.

3. Removing and installing gearbox 85


Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
6-speed manual gearbox 02S - Edition 07.2009

– Pull gear selector cable from pin.


Metal relay lever
– Remove securing clip -arrow 2- for gate selector cable from
relay lever -B-.
– Pull gate selector cable from pin.
– Pull securing clip -arrow 3- off relay lever -B- and remove relay
lever.
Plastic relay lever
– Remove relay lever together with cable end-piece
⇒ page 73 .
Continuation for all
– Remove gearbox selector lever -A- by removing nut
-arrow 4- (⇒ previous figure).

– Remove cable support bracket from gearbox -arrows-.


– Then raise and secure gear selector cable and gate selector
cable.
– Remove retainer -B- from gearbox and pull it off pipe/hose line
-A-.

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– Then remove gearbox support -arrow A-.
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– Remove slave cylinder -arrow B-, lay to side and secure with
an
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wire. Do not disconnect pipes.


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Caution
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Do not operate clutch pedal any more.


urposes, in part or in wh

t to the co

– Remove earth strap at upper engine/gearbox connecting bolt.


rrectness o
cial p

f inform
mer

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86 Rep. Gr.34 - Controls, housing


Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
6-speed manual gearbox 02S - Edition 07.2009

– Pull connector -arrow 1- off reversing light switch -F4- .


– Now remove connector -arrow 2- and wire -arrow 3- from
starter.
– Then remove upper securing bolt on starter.
– Remove upper engine/gearbox connecting bolts.
– If there are hose and cable connections in area of engine sup‐
port eye for support bracket -10 - 222 A- , remove these now.
Vehicles with 1.4 l petrol engine

– Set up support bracket -10 - 222 A- together with adapters -10


- 222 A /8- in front of gas struts for bonnet.
Vehicles with turbo diesel enginesagand vehicles
en AG. Volkswagwith
en AG2.0
doels- 110 kW
petrol engines yV
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– Set up support bracket -10 - 222 A- together with adapters -10
es, in part or in w

- 222 A /8- , adapter -10 - 222 A /3- and adapter -10 - 222 A /
t to the co
16- in front of gas struts for bonnet.
– Attach hook -10 - 222 A /10- at front right of engine. rrectness of i
l purpos

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3. Removing and installing gearbox 87


Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
6-speed manual gearbox 02S - Edition 07.2009

– Now attach hook -10 - 222 A /2- at rear left of engine -arrow-.
– Then connect hook -10 - 222 A /2- using adapter -10 - 222 A /
16- .
Continuation for all vehicles . Volkswagen AG
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– Position adapter -10 - 222 A /8- directly over wing bolting y Volk not
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– Take up weight of engine/gearbox assembly ons auspindles. ra
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– Raise vehicle.

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– Remove noise insulation ⇒ General body repairs, exterior;

y li
erm

ab
Rep. Gr. 50 ; Noise insulation .

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