5-Speed Manual Gearbox 0A4 PDF

Service
Workshop Manual
Golf 2004 ➤ , Golf 2009 ➤ ,
Golf Plus 2005 ➤ , Golf Plus 2009 ➤ ,
Passat 2006 ➤
5-speed manual gearbox 0A4
Edition 04.2010
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Service Department. Technical Information

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00 - Technical data
30 - Clutch
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34 - Controls, housing
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35 - Gears, shafts
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39 - Final drive - differential
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Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.
All rights reserved.

No reproduction without prior agreement from publisher.
Copyright © 2010 Volkswagen AG, Wolfsburg K0058990420

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00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
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1 Gearbox identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
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1.1 Location on gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
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1.2 hole
Identification codes, assembly allocation, capacities, Golf 2004 ▸ . . . . . . . . . . . . . . . . . . 2
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1.3 Identification codes, assembly allocation, capacities, Golf 2009 ▸ . . . . . . . . . . . . . . . . . . 4
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1.4 Identification codes, assembly allocation, capacities, Golf Plus 2005 ▸ . . . . . . . . . . . . . . 5
1.5 Identification codes, assembly allocation, capacities, Golf Plus 2009 ▸ . . . . . . . . . . . . . . 6
1.6 Identification codes, assembly allocation and capacities, Passat 2006 ▸ . . . . . . . . . . . . . . 6
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2 Overview - power transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
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3 Calculating overall gear ratio “i” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

4 General repair notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
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4.1 Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
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30 - Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
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1 Repairing clutch mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

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1.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
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1.2 Assembly overview - pedal cluster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

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1.3 Removing and installing over-centre spring, Golf 2004 ▸ . . . . . . . . . . . . . . . . . . . . . . . . . . 18
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1.4 Removing and installing over-centre spring, Golf 2009 ▸ LHD . . . . . . . . . . . . . . . . . . . . . . 22
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1.5 Removing and installing over-centre spring, Golf 2009 ▸ RHD . . . . . . . . . . . . . . . . . . . . . .
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1.6 Removing and installing over-centre spring, Golf Plus . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
1.7 Removing and installing over-centre spring, Passat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
1.8 Removing and installing clutch pedal, Golf 2004 ▸ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
1.9 Removing and installing clutch pedal, Golf 2009 ▸ LHD . . . . . . . . . . . . . . . . . . . . . . . . . . 44
1.10 Removing and installing clutch pedal, Golf 2009 ▸ RHD . . . . . . . . . . . . . . . . . . . . . . . . . . 49
1.11 Removing and installing clutch pedal, Golf Plus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
1.12 Removing and installing clutch pedal, Passat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
1.13 Removing and installing mounting bracket, Golf 2004 ▸ . . . . . . . . . . . . . . . . . . . . . . . . . . 61
1.14 Removing and installing mounting bracket, Golf 2009 ▸ LHD . . . . . . . . . . . . . . . . . . . . . . 67
1.15 Removing and installing mounting bracket, Golf 2009 ▸ right-hand drive and Golf Plus right-
hand drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
1.16 Removing and installing mounting bracket, Golf Plus left-hand drive . . . . . . . . . . . . . . . . 79
1.17 Removing and installing mounting bracket, Passat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
1.18 Removing and installing master cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
1.19 Removing and installing clutch position sender G476 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
1.20 Assembly overview - hydraulics (LHD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
1.21 Assembly overview - hydraulics (RHD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
2 Removing and installing slave cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
2.1 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
2.2 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
2.3 Torque settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
3 Bleeding clutch system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
4 Repairing clutch release mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
5 Repairing clutch, in conjunction with dual-mass flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . 105
5.1 Identifying make of clutch, vehicles with 1.9 l - 66 kW turbo diesel engine and vehicles with
1.9 l - 77 kW turbo diesel engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
5.2 Removing and installing Sachs clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
5.3 Repairing Sachs clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
5.4 Removing and installing LuK clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
5.5 Repairing LuK clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
6 Repairing clutch, in conjunction with one-piece flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Contents i
Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus 2009 ➤ , Pass ...
5-speed manual gearbox 0A4 - Edition 04.2010
34 - Controls, housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116

1 Repairing selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
1.1 Installation position of selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
1.2 Overview of selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
1.3 Removing and installing gear knob and cover . w . a. g.e.n .AG
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1.4 Removing and installing gaiter with gear knob by and noise insulation, Golf . . .gu.a.r . . . . . . . . .
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1.5 Removing and installing gaiter with gear r knob and noise insulation, Golf Plus . .nt.ee. . . . . . .
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1.6 Removing and installing gaiter withs aselector u lever knob and noise insulation, Passat r ac. . . . 121
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1.7 Repairing gear lever and selector housing (through 10.06) . . . . . . . . . . . . . . . . . . . . . . . . 123
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1.8 Repairing gear lever and selector housing (from 11.06) . . . . . . . . . . . . . . . . . . . . . . . . . . 125
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1.9 Assembly overview - removing and installing selector cables . . . . . . . . . . . . . . . . . . . . . . 131
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1.10 Plastic relay lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
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1.11 Removing and installing selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
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1.12 Adjusting selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
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2 Removing and installing gearbox, Golf 2004 ▸ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
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2.1 Removing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
2.2 Installing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
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3 Removing and installing gearbox, Golf 2009 ▸ with turbo diesel engine . . . . . . . . . . . . . . 156
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4 Removing and installing gearbox, Golf 2009 ▸ with petrol engine . . . . . . . . . . . . . . . . . . . . 171
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5 Removing and installing gearbox, Golf Plus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
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6 Removing and installing gearbox, Passat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
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7 Transporting gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
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8 Checking and topping up gear oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220

8.1 Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
8.2 Draining gear oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
8.3 Fill with gear oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
9 Dismantling and assembling gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
9.1 Overview - gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
9.2 Assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
9.3 Removing and installing cover for gearbox housing and 5th gear . . . . . . . . . . . . . . . . . . . . 225
9.4 Removing and installing gearbox housing and selector mechanism . . . . . . . . . . . . . . . . . . 226
9.5 Removing and installing input shaft, output shaft, differential and selector forks . . . . . . . . 227
9.6 Assembly sequence - removing and installing cover for gearbox housing and 5th gear . . 228
9.7 Assembly sequence - Dismantling and assembling gearbox completely . . . . . . . . . . . . . . 234
10 Repairing gearbox housing and clutch housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248
11 Repairing selector unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255
12 Dismantling and assembling selector forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258
35 - Gears, shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263

1 Input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263
1.1 Dismantling and assembling input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263
1.2 Adjusting input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270
2 Output shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275
2.1 Dismantling and assembling output shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275
2.2 Adjusting output shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287
ii Contents
3 Reverse shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291

3.1 Dismantling and assembling reverse shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291
39 - Final drive - differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294

1 Renewing flange shaft oil seals with gearbox installed . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294
1.1 Renewing oil seal for left flange shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294
1.2 Distinguishing seals for right flange shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295
1.3 Renewing seal (two-part seal and sleeve for right flange shaft) . . . . . . . . . . . . . . . . . . . . . . 296
1.4 Renewing seal and sleeve together (one-piece seal and sleeve for right flange shaft) . . . . 299
2 Adjustment overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302
3 Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303
3.1 Dismantling and assembling differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303
3.2 Adjusting differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311
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00 – Technical data
1 Gearbox identification
5-speed manual gearbox 0A4 is installed in following vehicles:
Allocation, Golf 2004 ▸ ⇒ page 2
Allocation, Golf 2009 ▸ ⇒ page 4
Allocation, Golf Plus 2005 ▸ ⇒ page 5
Allocation, Golf Plus 2009 ▸ ⇒ page 6
Allocation, Passat 2006 ▸ ⇒ page 6
1.1 Location on gearbox

Codes and production date -arrow 1- manual gearbox 0A4
-arrow 2-
Manual gearbox 0A4 -arrow 2-

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Codes and production date of gearbox

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1. Gearbox identification 1
1.2 Identification codes, assembly allocation, capacities, Golf 2004 ▸

Manual gearbox 5-speed 0A4
Identification code FNE GQQ HGR
Manufactured from 08.03 08.03 03.05
to 08.03 08.06 08.06
Allocation Engine 1.9 l - 77 kW 1.9 l - 77 kW 2.5 l - 110 kW
turbo diesel turbo diesel
Ratio Final drive 61 : 18 = 3.389 61 : 18 = 3.389 62 : 17 = 3.647
Z1 : Z2
Capacity of manual gearbox (gear‐ 1.9 l 1.9 l 1.9 l
box completely dismantled)
Capacity of manual gearbox 1.7 l 1.7 l 1.7 l
⇒ page 220 (gearbox partially dis‐
mantled)
Drive shaft flange ∅ 100 mm 100 mm 100 mm
The following data can be found in the ⇒ Electronic parts cata‐
logue “ETKA” .
♦ Individual gear ratios
♦ Gear oil
♦ Clutch allocation

Identification code HDR GTB JCT
to 08.06 03.04 06.08
Allocation Engine 2.0 l -en85 kW
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2 Rep. Gr.00 - Technical data


Identification code JCR JCU JCV
Z1 : Z2
mantled)
The following data can be found in the ⇒ Electronic wage parts cata‐
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rrectness of i
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♦ Gear oil
AG.

Identification code KBL KCD JQP
to 06.08 12.07 06.08
turbo diesel
Z1 : Z2
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♦ Gear oil

Identification code KPF LHW
Manufac‐ from
07.07 04.08
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Allocation by Vl - 125 kW
2.5 Engine 1.9 l - 77gukW
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Z1 : Z2
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Capacity of manual gear‐ 1.9 l 1.9 l
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Cop py
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turbo diesel turbo diesel turbo diesel
1.6 l - 77 kW
turbo diesel
Z1 : Z2
Capacity of manual gear‐ 1.9 l 1.9 l 1.9 l
dismantled)
logue “ETKA” .
♦ Gear oil


Identification code LUB KCD KPF
Manufac‐ from 05.09 08.09 08.09
tured to 09.09 05.10
turbo diesel
Z1 : Z2
dismantled)
logue “ETKA” .
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ss
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hole
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Allocation Engine 1.9 l - 77 kW 2.5 l - 125 kW

t to the co
turbo diesel
Ratio Final drive 61 : 18 = 3.778 61 : 18 = 3.778
rrectness of i
Z1 : Z2
l purpos

dismantled)
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1.4 Identification codes, assembly allocation, capacities, Golf Plus 2005 ▸

Identification code HNV JCX KBL
to 05.06 01.09 01.09

Identification code HNV JCX KBL
1.9 l - 77 kW 1.9 l - 77 kW
Z1 : Z2
mantled)
The following data can be found in the ⇒ Electronic parts cata‐ en AG. Volkswagen AG
logue “ETKA” . olks
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1.5 Identification codes, assembly allocation, capacities, Golf Plus 2009 ▸
wit
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Identification code KQM LHW LUB
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to
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1.6 l - 77 kW
o
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inform
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atio
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Capacity of manual gearbox 1.9 l 1.9 l 1.9 l i

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♦ Gear oil
1.6 Identification codes, assembly allocation and capacities, Passat 2006 ▸

Identification code HNV JCX JQP
Manufac‐ from 01.05 05.06 05.07
tured to 05.06 11.08 11.08


Identification code HNV JCX JQP
1.9 l - 77 kW
turbo diesel
Z1 : Z2
dismantled)
box ⇒ page 220 (gear‐
box partially dismantled)

logue “ETKA” .
♦ Gear oil
Manual gearbox AG. Volkswagen AG d 5-speed 0A4
agen oes
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Capacity of manual 1.9 l 1.9 l 1.9 l

ole,
gearbox (gearbox com‐

spec
pletely dismantled)
t to the co

gearbox ⇒ page 220
(gearbox partially dis‐
rrectne
mantled)
ss o
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atio
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cum
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Identification code Prote
cted KBL AG.
agen
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Manufac‐ from 01.08 11.08 08.09
tured to 08.09
1.6 l - 77 kW 1.6 l - 77 kW
Manual gearbox n A5-speed

G. Volkswa0A4
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thor 62 : 17 = 3.647 62e o: 17 = 3.647
Z1 : Z2 drive ss
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gearbox (gearbox com‐
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Capacity of manual 1.7 l
ot p 1.7 l 1.7 l
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gearbox ⇒ page 220
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2 Overview - power transmission

Designation
-Arrows- indicate direction of travel.
1 - Engine
2 - Clutch
3 - Manual gearbox
4 - Input shaft
wage es n
5 - Output shaft
yV
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6 - Differential
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Gears
-Arrows- indicate direction of travel.
2. Overview - power transmission 9

I - 1st gear lkswage es n
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II - 2nd gear o
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3 Calculating overall gear ratio “i”

Example:
5th gear Final drive
Drive gear ZG1 = 39 ZA1 = 18
Driven gear ZG2 = 29 ZA2 = 61
i = Z2 : Z1 1)
iG = Gear ratio = ZG2 : ZG1= 29 : 39 = 0.744 n AG. Volkswagen AG do
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ss
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du
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3. Calculating overall gear ratio “i” 11

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 12 . They apply to this workshop
manual.
4.1 Components
4.1.1 Gearbox
♦ When installing the manual gearbox, ensure that the dowel
sleeves between the engine and gearbox are correctly seated.
♦ When installing mounting brackets or waxed components,
clean the contact surfaces. Contact surfaces must be free of
wax and grease.
♦ Allocate bolts and other components using ⇒ Electronic parts
catalogue “ETKA” .
♦ If the gearbox is repaired, fill with gear oil.
Capacity, gearbox completely Capacity, gearbox partially dis‐
dismantled mantled ⇒ page 220
1.9 l 1.7 l
4.1.2 Seals and sealing rings

♦ Before installing oil seal, half-fill space between sealing lips
with sealing grease -G 052 128 A1- -arrow-.
olkswagen AG
en AG. V
♦ The open side of the oil seal faces the side with fluid
olks filling.
wag does
not
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by ara
♦ After installing, check oil level ⇒ page 220 .rised nte
ho eo
ut
♦ Lightly oil O-rings before installing; thisss aprevents the rings be‐ ra
c
ing crushed when inserted.
ce
e
nl
pt
du
an
♦ Thoroughly clean parting surfaces and apply sealant -AMV

itte
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188 200 03- .

erm
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ility
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♦ Apply sealant uniformly but not too thick.

wit
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hole
spec
es, in part or in w
4.1.3 Sealant
t to the co
♦ Thoroughly clean housing joint surfaces before applying seal‐

ing paste.
rrectness of i
♦ Evenly apply a thin coat of sealing paste -AMV 188 200 03- .
l purpos
♦ Breather holes must remain free of sealing paste.

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12
by lksw
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Rep. Gr.00 - Technical data Prote AG.
4.1.4 Locking devices

♦ Renew retaining rings.
♦ Do not overstretch retaining rings.
♦ Retaining rings must locate properly in grooves.
♦ Renew spring pins. Installation position:
AG. Volkswagen AG slot must be in line
agen does
with direction of
Vo force.
lksw not
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4.1.5 Nuts and bolts
wit
is n
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ole,
♦ Loosen and tighten securing bolts and nuts for covers and
spec
housings diagonally.
t to the co
♦ Do not cant especially delicate parts, such as clutch pressure
plates. Loosen and tighten bolts and nuts in stages in a diag‐
onal sequence.
rrectne
♦ Torque settings are specified for unoiled bolts and nuts.
ss
♦ Always renew self-locking bolts and nuts.
o
cial p
♦ Ensure with threaded connections that contact surfaces as f inform

mer
well as nuts and bolts are rewaxed only after assembly, if nec‐
atio
m
essary.
o
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c
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or
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♦ Use a thread chaser to clear residual locking fluid from all

te
sd
a
threaded holes into which self-locking bolts are to be screwed.

iv
o
pr
Otherwise there is a danger of bolts shearing when subse‐

um
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fo
en
ng
quently being removed.

t.
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4.1.6 Bearings
ht. rig
rig ht
py by
co Vo
by lksw
♦ Install new tapered roller bearings as supplied and do not lu‐
cted agen
Prote AG.
bricate additionally.
♦ Install needle bearings with lettered side (thicker metal) to‐
wards fitting tool.
♦ Tapered roller bearings fitted to one shaft must be renewed as
a set. Use same make of bearings.
♦ Heat inner races to about 100 °C with the inductive heater -
VAS 6414- before installing.
♦ Do not interchange outer or inner races of bearings of the
same size. The bearings are matched in pairs.
4.1.7 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. General repair notes 13

4.1.8 Synchro-rings
♦ Do not interchange. When reusing synchro-rings, always fit to
the same synchromeshed 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”, “signs of abnormal wear” and
“blue discolouration (due to overheating)”.
♦ Check cone of synchromeshed gear for “scoring” and “signs
of abnormal wear”.
♦ Moisten synchromesh mechanism with gear oil before instal‐
ling.
AG. Volkswagen AG d
agen oes
olksw not
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4.1.9 Gear wheels ss c
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un
pt
♦ Before installing, clean and heat with the inductive heater -
an
d
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VAS 6414- to maximum 100° C.
rm
ab
pe
ility
4.1.10 Synchromeshed gears
ot
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hole
♦ After assembly, check synchromeshed gears for slight play, or
spec
for freedom of movement.
es, in part or in w
t to the co
4.1.11 Clutch
♦ Ensure that the pressure plate does not cant: loosen and tight‐
rrectness of i
en bolts diagonally and in several gradual stages.
l purpos
♦ If the clutch has burnt out, thoroughly clean the clutch housing
as well as the friction surface of flywheel with a cloth to reduce
nform
ercia
the smell of burnt linings.

m
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com
tion in
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Prote AG.

30 – Clutch
1 Repairing clutch mechanismlkswagen AG. Volkswagen AG does no
o t gu
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1.1 Overview ss
au ra
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Note
rm
ab
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ility
ot
♦ Before disconnecting battery, obtain code for radio having anti-theft coding.
wit
, is n
h re
♦ With ignition switched off, disconnect battery ⇒ Electrical system; Rep. Gr. 27 ; Disconnecting and con‐
hole
spec
necting battery .
es, in part or in w
t to the co
♦ When reconnecting battery, refer to ⇒ Electrical system; Rep. Gr. 27 ; Disconnecting and connecting
battery .
rrectness of i
♦ Grease all bearing points and contact surfaces.
l purpos
♦ Allocate grease using ⇒ Electronic parts catalogue (ETKA) .
nform
ercia
I - Assembly overview - pedal

m
a
cluster ⇒ page 16
com
tion in
r
II - Assembly overview - hy‐

te o
thi
draulics (LHD) ⇒ page 94
s
iva
do
r
rp
cum
III - Assembly overview - hy‐
fo
en
g
draulics (RHD) ⇒ page 96

n
t.
yi Co
Cop py
ht. rig
rig ht
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co Vo
by lksw
cted agen
Prote AG.
1. Repairing clutch mechanism 15

1.2 Assembly overview - pedal cluster

1 - Bulkhead ksw
age es n
y Vol ot g
❑ With supportsedfor
b mount‐ ua
ran
ing bracket
thori tee
or
au ac
2 - Seal ss
ce
e
nl
❑ Always renew
pt
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itte
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❑ Between mounting
erm
ab
bracket and bulkhead
ility
ot p
wit
❑ Self-adhesive
, is n
h re
❑ Bond to mounting
hole
spec
bracket
es, in part or in w
t to the co
3 - Mounting bracket
❑ For mounting clutch
pedal
rrectness of i
❑ Is provided with damp‐
l purpos
ing in some equipment

variants ⇒ page 17
nform
ercia
❑ Removing and instal‐

ling, Golf 2004 ▸
m
at
⇒ page 61
om
ion
c

in t
or
his
e
ling, Golf 2009 ▸ LHD

at
do
riv
⇒ page 67
p
cum
or

f
en
ng
t.
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ling, Golf 2009 ▸ right-
Co
op py
hand drive, and Golf
t. C rig
gh ht
yri
Plus right-hand drive p by
co Vo
⇒ page 73
by lksw
cted agen
Prote AG.
ling, Golf Plus left-hand
drive ⇒ page 79
ling, Passat
⇒ page 84
4 - Bolt
5 - Over-centre spring
❑ Removing and installing, Golf 2004 ▸ ⇒ page 18
❑ Removing and installing, Golf 2009 ▸ LHD ⇒ page 22
❑ Removing and installing, Golf 2009 ▸ RHD ⇒ page 27
❑ Removing and installing, Golf Plus ⇒ page 32
❑ Removing and installing, Passat ⇒ page 37
6 - Bearing bush
7 - Pivot pin
8 - Clutch pedal
❑ Removing and installing, Golf 2009 ▸ LHD ⇒ page 44
❑ Removing and installing, Golf 2009 ▸ RHD ⇒ page 49
9 - Retainer
❑ To remove and install, separate master cylinder from clutch pedal (⇒ Removing and installing clutch
pedal)
16 Rep. Gr.30 - Clutch

❑ Golf 2004 ▸ ⇒ page 38
❑ Golf 2009 ▸ LHD ⇒ page 44
❑ Golf 2009 ▸ RHD ⇒ page 49
❑ Golf Plus ⇒ page 54 .
❑ Passat ⇒ page 59
10 - Seal
❑ Always renew
❑ Between master cylinder and mounting bracket
11 - Master cylinder
❑ Removing and installing after removal of mounting bracket ⇒ page 88
12 - Clutch position sender -G476-
❑ Removing and installing ⇒ page 90
❑ Can be checked in “guided fault finding” of vehicle diagnosis, testing and information system -VAS 5051- .
❑ 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 95 n AG. Volkswagen AG do
wage es n
❑ Golf 2009 ▸ and Golf Plus 2009 ▸ plasticy⇒
Vo page 95
lks ot g
u b ara
ed
15 - Self-locking hexagon nut, 25 Nm ris nte
utho e or
❑ Qty. 3 ss
a ac
ce
e
❑ For mounting bracket to bulkhead

nl
pt
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an
❑ Always renew
itte
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16 - Hexagon nut, 25 Nm
ility
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❑ Always renew
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hole
17 - Stop
spec
es, in part or in w
❑ For clutch pedal
t to the co
rrectness of i
Mounting bracket with damping -arrows-
l purpos
nform
mercia
at
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ion
c
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ate
do
priv
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for
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ng
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Cop py
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Prote AG.

1.3 Removing and installing over-centre

. Volkswagen AG
gen AG
spring, Golf
yV
olks 2004 ▸
w a does
not
g
b ua
ed ran
Special tools and hworkshop
or
is equipment required tee
t or
au ac
♦ Release tool
ss -T10178-
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e
nl
pt
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erm
ab
ility
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hole
spec
es, in part or in w
t to the co
rrectness of i
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♦ Torque wrench -V.A.G 1331-
nform
mercia
at
om
ion
c
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or
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ate
do
priv
cum
for
en
ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
1.3.1 Removing
– 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 .
– Remove cable guide -2- from steering column.
– Remove footwell vent -3-.⇒ Heating, air conditioning; Rep.
Gr. 80 ; Repairing heating
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
AG. Volkswagen AG d
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pt
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ility
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hole
– Remove crash bar -1- (1 bolt -2-).
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
riv
If fitted, remove damping -arrow- from lower area of clutch pedal

p
cum
or
mounting bracket.
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en
ng
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cted agen
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– To do this, remove lock washers -A- for damping.

– Pull off damping.

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

above clutch pedal -A- in -direction of arrow-.
AG. Volkswagen AG d
agen oes
olksw not
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d b ara
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ce
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nl
pt
du
an
itte
– Unbolt clutch pedal -1- from mounting bracket -3- by removing
y li
erm
ab
nut -2- and pulling out bolt -5-.
ility
ot p
wit
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h re
Note
hole
spec
es, in part or in w
The clutch pedal remains hooked to operating rod of master cyl‐
t to the co
inder.
rrectness of i
– Swing clutch pedal down slightly and remove over-centre
spring -4- from mounting bracket.
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
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op py
1.3.2 Installing
t. C rig
gh ht
pyri by
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co
Install in the reverse order of removal, observing the following:
by lksw
cted agen
Prote AG.
Note
Renew self-locking nuts.

– Insert over-centre spring -2- in mounting bracket from above

while holding end of spring with assembly tool -T10178- in in‐
stallation position.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
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au ra
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ce
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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
– Receptacle -arrow- for tip -A- of clutch pedal must stand ver‐
tically.
nf
ercia
o
– Insert tip of clutch pedal in bearing recess of over-centre
rm
m
spring.
atio
om
n in
c
– Depress clutch pedal slightly, push bolt through and tighten

or
thi
e
self-locking nut to specified torque ⇒ page 22 .

t
sd
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cted agen
Prote AG.
Some cars have damping -arrow- on the clutch pedal mounting

bracket.
– Return it to installation position.
different ways.

– Install crash bar -1- and tighten the 2 bolts to specified torque
⇒ page 22 .
– Install crash bar -1- and tighten bolt -2- to specified torque
⇒ page 22 .
– Install trim and cover below trim on drive side ⇒ General body
repairs, interior; Rep. Gr. 68 .
AG. Volkswagen AG d
agen oes
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1.3.3 Torque settings
ce
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nl
pt
du
an
itte
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Component Nm
erm
ab
ility
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Clutch pedal to mounting bracket 25

wit
♦ Renew self-locking nuts.

, is n
h re
hole
spec
Crash bar to steering column mounting 10

es, in part or in w
bracket (attachment with 2 bolts)

t to the co

bracket (attachment with 1 bolt)
rrectness of i
♦ Renew bolts for crash bar

l purpos

nf
ercia
spring, Golf 2009 ▸ LHD

orm
m
atio
m
Special tools and workshop equipment required

o
n in
or c
thi
♦ Release tool -T10178-

te
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t.
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Cop py
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pyri by
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o
by c lksw
cted agen
Prote AG.

1.4.1 Removing
Vehicles with knee airbag
Note
. Volkswag
The installation location of the knee
ksw
airbag
agen AG is above thedpedal
en AG
oes
cluster. by
Vol not
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ed ran
ris tee
ho
– First check whetherau a coded
t
radio is fitted. If so, obtain anti- or
ac
theft code. ss
ce
e
nl
pt
du
– With ignition switched off, disconnect battery ⇒ Electrical sys‐

an
itte
y li
tem; Rep. Gr. 27 ; Disconnecting and connecting battery .
erm
ab
ility
ot p
Continuation for all

wit
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– Push driver seat as far back as possible and put steering wheel h re
hole
spec
es, in part or in w
t to the co

rrectness of i
– Remove bracket for knee airbag together with crash bar ⇒

l purpos
Interior equipment; Rep. Gr. 69 ; Airbag; Removing and in‐

stalling knee airbag bracket (Golf 2009 ▸) .
nform
ercia

m
at
om

ion
c
in t
or

his
ate

do
priv
cum
or
Vehicles without knee airbag

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

lkswage es n
Golf 2004 ➤ by,VGolf 2009 ➤ , Golf Plus 2005 ➤
o ot g
u,a Golf Plus 2009 ➤ , Pass ...
ed ra
5-speed hor manual gearbox 0A4 - Edition 04.2010 ntee
is
t or
au ac
ss
– Remove crash bar -1- (bolt -2-).
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

mounting bracket.
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.




Note

inder.
– Swing clutch pedal down slightly and remove over-centre

spring -4- from mounting bracket. agen
AG. Volkswagen AG d
o
ksw es n
Vol ot g
d by ua
ran
e
ris tee
utho or
a ac
ss
ce
le
un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
1.4.2 Installing
spec
es, in part or in w
t to the co

rrectness of i
Note
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
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pyri by
Vo
co lksw
by
cted agen
Prote AG.


tically.
– Insert tip of clutch pedal -1- in bearing recess of over-centre
spring.

bracket. gen AG
. Volkswagen AG
d wa oes
olks not
db
yV gu
ara
e nte
ris
ut
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ra
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ss
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le
un
pt
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
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
26
cted agen
Prote AG.
Rep. Gr.30 - Clutch
⇒ page 27 .
– Mount cable guide -2- on steering column.

– Install foot well vent -3-.⇒ Rep. Gr. 80
– Install bracket for knee airbag together with crash bar ⇒ Inte‐
rior equipment; Rep. Gr. 69 ; Airbag; Removing and installing
knee airbag bracket (Golf 2009 ▸) .
repairs, interior; Rep. Gr. 68 . . Volkswag AG en AG
sw agen doe
– If disconnected, connectyV
olkbattery ⇒ Electrical system;
s noRep. Gr.
t gu
27 ; Removing and ise
d installing
b battery . ara
n r tee
ho
aut or
ac
ss
ce
e
nl
pt
du
an
Component Nm
itte
y li
erm
ab

ility
ot p

wit
, is n
h re
hole

spec
bracket
es, in part or in w
t to the co
♦ Renew bolt for crash bar

rrectness of i

spring, Golf 2009 ▸ RHD
l purpos

nf
ercia
or
♦ Pliers -T10005-
m
m
atio
om
n in
or c
thi
te
sd
iva
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rp
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en
ng
t.
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Cop py
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pyri by
Vo
co lksw
by
cted agen
Prote AG.

1.5.1 Removing olkswage es n
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byV ua
ed ran
– First check whether a coded radio
oris is fitted. If so, obtain anti- tee
theft code. auth or
ac
ss
ce
le
un
pt

an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
– Remove trim and cover below trim on driver side ⇒ Body Re‐
h re
hole
pairs; Rep. Gr. 68 .

spec
es, in part or in w
– Remove bracket for knee airbag ⇒ Interior equipment; Rep.

t to the co
Gr. 69 ; Airbag; Removing and installing knee airbag bracket

(Golf 2009 ▸) .
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.



mounting bracket.

– Pull off damping. agen
AG. Volkswagen AG d
oes
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y V gu
d b ara
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nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
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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
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iva
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Cop py
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o
29
c by lksw
cted agen
Prote AG. 1. Repairing clutch mechanism


Note

inder.
AG. Volkswagen AG d
agen oes
ksw not
– Swing clutch pedal bdown yV
ol
slightly and remove over-centre gu
ara
spring -4- from mounting
rise
d bracket. nte
tho eo
au 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
1.5.2 Installing
rrectness of i
l purpos
Note
nform
ercia

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.


lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectne
tically.
s
s o
spring.
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
p by
co Vo
by lksw
bracket. Prote
cted AG.
agen

⇒ page 32 .
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
– Install bracket for knee airbag ⇒ Interior equipment; Rep. Gr.
, is n
h re
69 ; Airbag; Removing and installing knee airbag bracket (Golf
hole
spec
2009 ▸) .
es, in part or in w
t to the co
– If disconnected, connect battery ⇒ Electrical system; Rep. Gr.
rrectness of i
27 ; Removing and installing battery .
l purpos
nform
ercia

m
a
com
tio
Component Nm
n in
r
te o
thi
s
iva
do
♦ Renew self-locking nuts
r
rp
cum
fo
en
ng
t.
yi
Co
op py
bracket t. C rig
gh ht
yri by
♦ Renew bolt for crash bar cop Vo
by lksw
cted agen
Prote AG.

spring, Golf Plus
1.6.1 Removing


– Carefully cut through cable tie -1-.
– Now remove crash bar -A- from in front of clutch pedal by re‐
moving bolt -B-. G. Volkswagen A AG do
agen es n
olksw ot g
yV ua
db ran
rise tee
tho or
s au ac
s
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f in
– Remove footwell trim by removing nuts -arrows-.

form
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
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Remove bolt -1- and pull universal joint -2- from steering box.


mounting bracket.

– Pull off damping. 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

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
py by
co Vo
by lksw
cted agen
Prote AG.


Note

inder. . Volkswag AG en AG
agen does
olksw no
– Swing clutch pedal down d bslightly and remove
yV over-centre t guara
spring -4- from mounting rise bracket. nte
tho eo
s au ra
c
s
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
1.6.2 Installing
rrectness of i
l purpos
Note
nform
ercia

m
a
com
tion in
– Insert over-centre spring in mounting bracket from above.
r
te o
thi
s
iva
– Receptacle -arrow- for tip -A- of clutch pedal must be vertical.

do
r
rp
cum
fo

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

AG. Volkswagen AG d
agen oes
olksw not
yV gu
Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 s➤ ed , Golf Plus 2009 ➤ , Pass ...
b ara
nte
ri
ut
ho eo
ra
s a c
s
ce
le
un
pt
bracket.
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
– Install crash bar -A-, tightening bolt -B- ⇒ page 36 .
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– Fit universal joint -2- to steering box and screw in new bolt
-1- ⇒ Running gear, axles, steering; Rep. Gr. 48 ; Assembly
overview - Steering .
– Carry out basic setting for steering angle sender -G85- with
vehicle diagnosis, testing and information system -VAS
5051- .

Component Nm
Crash bar to steering column mounting Bolt M6 = 5

bracket

Component Nm
bracket

spring, Passat
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
1.7.1 Removing
an
itte
y li
erm
ab
– Remove mounting bracket ⇒ page 84 .
ility
ot p
wit
, is n
– Carefully clamp lower section of clutch pedal in vice having
h re
protective jaw pads.
hole
spec
es, in part or in w
– Separate clutch pedal from master cylinder ⇒ page 59 .
t to the co
– Press over-centre spring from clutch pedal -arrow 1- while
swinging mounting bracket in -direction of arrow 2-.
rrectness of i
– Carefully release tension from over-centre spring.
l purpos
– Swing mounting bracket back to starting position and remove

over-centre spring.
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
op
1.7.2 Installing
C py
t. rig
gh ht
pyri by
• Clutch pedal is separated from master cylinder.
o Vo
by c lksw
cted agen
Prote AG.
– Carefully clamp lower section of clutch pedal in vice having
protective jaw pads.
– Insert over-centre spring in mounting bracket.

tically.
– Apply release tool -T10178- to middle of over-centre spring
and swing up mounting bracket.
– Compress over-centre spring -arrow 1-.

– At the same time, move mounting bracket downwards
-arrow 2- until over-centre spring can be pressed onto locating
lug -A- of clutch pedal.
WARNING
If over-centre spring is improperly installed, it will jump uncon‐

trolled out of mounting bracket.
Place a cloth over over-centre spring.
Check operation of over-centre spring.
wage
e
olks s no
t gu
Do this by moving mountingedbracket
by
V
up and down a few times. ara
ris nte
ho eo
aut ra
ss c
– Connect clutch pedal to master cylinder ⇒ page 59 .
ce
e
nl
pt
du
an
– Install mounting bracket, Passat ⇒ page 84 .

itte
y li
erm
ab
ility
ot p
1.8 Removing and installing clutch pedal,

wit
, is n
Golf 2004 ▸
h re
hole
spec

es, in part or in w
t to the co
♦ Pliers -T10005-
rrectness of i
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.

Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ ,G
A Golf
. VolkPlus
swage2009
n AG d➤ , Pass ...
agen oes
5-speed manual
Volksw gearbox 0A4 - Edition n04.2010
ot g
y ua
db ran
rise tee
♦ Release tool -T10178- tho or
s au ac
s
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
co lksw
by
cted agen
Prote AG.
1.8.1 Removing
different ways.
– Remove crash bar -1- (2 bolts).


– Remove crash bar -1- (1 bolt -2-).

mounting bracket.
. Volkswagen AG
gen AG does
swa
– To do this, remove lock washers y V -A- for damping.
o lk not
gu
edb ara
is nte
– Pull off damping. hor eo
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
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.

– Push damping upwards in area of upper securing nut -1- AG. Volkswagen AG d
agen
above clutch pedal -A- in -direction of arrow-. V olksw
oes
not
g y ua
db ran
rise tee
tho or
au ac
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
m

o
n
c
i
or
n thi
– Swing clutch pedal forward slightly and remove over-centre
te
sd
a

iv
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
– Release clutch pedal from master cylinder with pliers -

T10005- .
– Remove clutch pedal.
1.8.2 Installing
Note

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

– Press retainer into notch in clutch pedal -3- until it can be heard
to engage.
olkswagen AG
en AG. V
– Insert over-centre spring -2- in mounting bracket fromolabove
ksw
ag does
not
while holding end of spring with assembly tool -T10178-
ed
by V
in in‐ gu
ara
stallation position. ho
ris nte
eo
t
au ra
c
ss
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
t
– Receptacle -arrow- for tip -A- of clutch pedal -1- must be ver‐
ion in
tical.
r
te o
thi
s
iva
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⇒ page 43 .

Component Nm



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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.


– Remove bracket for knee airbag together with crash bar ⇒

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⇒ page 49 .



Component Nm

bracket

Golf 2009 ▸ RHD
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Torque wrench -V.A.G 1331-

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1.10.1 Removing
theft code.


(Golf 2009 ▸) .
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T10005- .
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Note

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⇒ page 54 .
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2009 ▸) .


Component Nm

bracket
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– Remove bolt -1- and pull universal joint -2- from steering box.


mounting bracket.
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Note

rrectness of i
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nform
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bracket.
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– Install crash bar -A-, tightening bolt -B- to specified torque

⇒ page 59 .

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Passat
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hole
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to engage.

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nform
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Component Nm
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♦ Spring-type clip pliers -VAS 5024 A-

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1.13.1 Removing
LHD
theft code.
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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 .

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 master cylinder.
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-3094- .
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bracket.
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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
pyri by
Vo
co lksw
by
cted agen
Prote AG.
1.14.1 Removing
theft code.
Gr. 27 ; Removing and installing battery .
Note


-3094- .
– Pull supply hose -1- off master cylinder.

– In addition, for disconnecting, you can close it with the sealing

– Release securing clip -2- using screwdriver or a pointed object
and pull pipe/hose line or plastic line -3- off master cylinder.
Note


Note
olkswagen AG
en AG. V
The installation location
olks of the knee airbag is above
wag does
not the pedal
cluster. ed
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ara
ris nte
ho eo
aut ra
ss bracket c
– Remove for knee airbag together with crash bar ⇒
ce
le

un
pt
an
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ab

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ility
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, is n

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hole
spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
ercia

m
a
com
tion in
r
te o
thi
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iva
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rp
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fo
en
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t.
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Cop py
ht. rig
rig ht
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by lksw
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Prote AG.


mounting bracket.
AG. Volkswagen AG d
agen oes
olksw not
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d b ara
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tho eo
au ra
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ce
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un
pt
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
ercia

m

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.


AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
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ris nte
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aut ra
ss c
ce
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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
1.14.2 Installing
rrectness of i
l purpos
nf
ercia
o
Note
rm
m
atio
om
n in
or c
thi
te
sd
iva

o
r
rp
cu
bracket.
o
m
f
en
ng
t.
yi Co
Vehicles without knee airbag ht. Cop py
rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
⇒ page 72 .


– Install footwell vent -3-. ⇒ Heating, Air conditioning; Rep. Gr.
80 ; Repairing heating; Removing and installing left footwell
vent
– 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.
original position, if necessary. wage
e
olks s no
yV t gu
– Bleed clutch system ⇒ page 101 . edb ara
ris nte
– Install battery ⇒ Electrical system; ho Rep. Gr. 27 ; Removing eo
aut ra
and installing battery . ss c
ce
e
nl
pt
– If removed, install complete air filter housing ⇒ Rep. Gr. 23 ;
du
an
itte
Repairing diesel direct injection system or ⇒ Rep. Gr. 24 ;
y li
erm
ab
Repairing injection system
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
Component Nm
Mounting bracket to bulkhead 25
nform
ercia

m
at
om

on
c
bracket
in t
or
his
ate

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.


bracket, Golf 2009 ▸ right-hand drive
and Golf Plus right-hand drive
lkswage es n
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byV ua
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ir se tee
tho
u or
a ac
ss
ce
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un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectne
ss
♦ Hook -3438-
o
cial p
f in
form
mer
atio
1.15.1 Removing
om
n
c
i
or
n
thi
te
sd
iva
o
r

p
cum
r
fo
theft code.
en
ng
t.
yi Co
op
– With ignition switched off, disconnect battery ⇒ Electrical sys‐ C py
t. rig
gh ht
pyri by
Vo
co lksw
by
Vehicles with turbo diesel engine and particle filter cted agen
Prote AG.
– Remove shielding -A- from particle filter ⇒ Rep. Gr. 26 ; Parts

of exhaust system; Assembly overview - front exhaust pipe
with particle filter .
A heat shield is installed in conjunction with some engines. Ap‐
pearance may be different from that illustrated.

– Remove heat shield from pipe/hose line -arrows-.
Note


-3094- .
– Pull supply hose 3 off master cylinder.
– In addition, for disconnecting, you can seal supply hose with
sealing tool -T10249/1- .
Release securing clip -1- with a screwdriver or pointed object

– Pull pipe/hose line -2- off master cylinder.
lkswage connector attached
-arrow- and remove with electrical es -3-.
no
o t gu
yV
db ara
ir se nte
ho eo
Note 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
Golf
es, in part or in w
t to the co

(Golf 2009 ▸) .
rrectness of i
l purpos
Note
nf
ercia
The installation location of the knee airbag is above the pedal

or
cluster.
m
m
atio
om
n in
c

or
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
co lksw
by
cted agen
Prote AG.

– Remove cable guide -2- from steering column by cutting cable

tie -1- if necessary.

mounting bracket.
lkswage es n
o ot g
byV ua
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ir se tee
tho
u or
a ac
ss
ce
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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
co lksw
by
cted agen
Prote AG.

– Push damping upwards in area of upper securing nut -1- AG. Volkswagen AG d
above clutch pedal -A- in -direction of arrow-. lksw
agen oes
not
Vo gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
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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
nf
ercia
or
m
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.
1.15.2 Installing
Note

AG. Volkswagen
n AG do
wage es n
olks ot g
Some cars have damping ed
by-arrow- on
V
the clutch pedal mountingua
ran
bracket. oris tee
th or
au ac
ss
ce
le
un
pt
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
tion in
r
te o
thi
⇒ page 78 .
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.
– Fit cable guide -2- onto steering column, secure with cable tie
-1- if necessary.
– Install footwell vent -3-.⇒ Heating, air conditioning; Rep. Gr.
80 ; Repairing heating
Golf
2009 ▸) .
– Press pipe/hose line -2- with seal into connection of master
cylinder.

– Clip in securing clip -1-.

– Clip clutch position sender -G476- into master cylinder with
electrical connector -3- attached -arrow-.
Hook -3438- can be used for installing pipe/hose line -2- and
clutch position sender -3-.
original position, if necessary. gen AG
. Volkswagen AG
a does
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y Vol gu
b ara
ed nte
oris eo
th
au ra
c
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
– If present, fold heat shield around the pipe/hose line
es, in part or in w
t to the co
-arrows-.
Vehicles with particle filter
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
or
– Install shielding -A- onto particle filter ⇒ Rep. Gr. 26 ; Parts

f
en
ng
of exhaust system; Assembly overview - front exhaust pipe

t.
yi Co
op
with particle filter .
C py
t. rig
gh ht
yri by
Continuation for all cop Vo
by lksw
cted agen
Prote
AG.


Component Nm

bracket


bracket, Golf Plus left-hand drive

♦ Hose clamps -3094-
♦ Hose clamp -3094-
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
Sealing tool -T10249-

an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f in
1.16.1 Removing
form
mer
atio
m

o
n
c
theft code.
i
or
n thi
te
sd
a

iv
o
pr

um
r
fo
en
ng
t.
yi
Co
op py
. C rig
ht ht
rig
Gr. 24 ; Repairing injection system . py by
co Vo
by lksw
cted agen
Prote AG.

– Remove battery, battery cover and battery tray ⇒ Electrical

system; Rep. Gr. 27 ; Removing and installing battery .
Note


-3094- .
– If necessary, loosen spring clip -3- using assembly tool -VAS
5024- .

– Pull off supply hose. AG. Volkswagen AG d
agen oes
olksw not
yV gu
– Pull clip -2- for pipe/hose line out of master cylinder to stop.
ised b ara
nte
or eo
h
– Pull pipe/hose line -1- out from master cylinder and sealaut hose. ra
c
ss
ce
le
un
pt
an
d
itte
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rm
ab
pe
ility
Note
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
– Remove driver side compartment and cover ⇒ General body
l purpos
repairs, interior; Rep. Gr. 68 ; Compartments, covers and trim

panels .
nform
ercia
– Carefully cut through cable tie -1-.

m
a
com
tio
– Remove cable guide -2- from steering column. n 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.

– Remove crash bar -A- by removing bolt -B-.

– Unbolt fuse holder beneath dash panel on left and lay to side
⇒ Electrical system; Rep. Gr. 97 ; Removing and installing
fuse holder .
– Unhook relay carrier beneath dash panel on left and lay to side
⇒ Electrical system; Rep. Gr. 97 ; Removing and installing
relay carrier .
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
mounting bracket.
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
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
– Pull off damping. rig ht
py by
co Vo
by lksw
cted agen
Prote AG.


Remove mounting bracket securing nuts -arrows- as follows:

– Wrap tape around universal joint from socket set -V.A.G
1835- .
. Volkswag
– Press wiring harnesssw-1-
ageupwards
n AG andenleft
AG d-arrow-
oes using ex‐
Volk
tension -2- fromby-V.A.G 1835- . not
gu
a d ran
ise
– While doing ho this, unbolt upper securing nut for mounting brack‐
r tee
ut or
et. ss
a ac
ce
le
– Then unbolt both lower securing nuts for mounting bracket and
un
pt
an
d
remove mounting bracket.

itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
1.16.2 Installing
om
n
c
i
or
Install in reverse order of removal. During this step, observe the

thi
te
sd
a
following:
iv
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.


bracket. Volkswa AG. gen AG
agen do
– Install relay carrier
olksbeneath dash panel on left
w es n
o⇒
t guElectrical
yV
system; Rep. sed Gr.
b 97 ; Removing and installing relay
ara carrier .
n
ri tee
ho
– Install fuse
au
t holder beneath dash panel on left ⇒ Electrical
or
ac
system;
ss Rep. Gr. 97 ; Removing and installing fuse holder .
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
ercia
– Install crash bar -A-, tightening bolt -B- to specified torque

⇒ page 84 .
m
at
om
io
– Install footwell vent, cable guide, cover and compartment on
n
c
in t
r
driver side ⇒ General body repairs, interior; Rep. Gr. 68 ;

o
his
e
Compartments, covers and trim panels .

at
do
priv
cum
– Renew cut cable ties.

for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
original shape, if necessary.
– Install battery tray, battery cover and battery ⇒ Electrical sys‐
tem; Rep. Gr. 27 ; Removing and installing battery .

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
e nte
Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005th➤o , Golf Plus 2009 ➤ , Pass ...
ris
eo
u
ss a ra
c
ce
e
nl
pt
du
an
itte
y li
erm
ab
Component Nm
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
bracket
rrectness of i
bracket
♦ Renew bolts for crash bar l purpos
nform
ercia

bracket, Passat
m
at
om
ion
c
in t
r

o
his
ate
do
riv

p
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

AG. Volkswagen AG d
agen
1.17.1 Removing Volksw
oes
not
gu
d by ara
e
LHD horis nte
eo
aut ra
– First check whethersa coded radio is fitted. If so, obtain anti-
s c
theft code.
ce
le
un
pt
an
d
itte
– Remove lower steering column trim ⇒ General body repairs,
y li
rm
ab
interior; Rep. Gr. 68 ; Compartments, covers and trim panels .
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
Gr. 27 ; Battery; Removing and installing battery .
l purpos

nform
ercia
Note
m
a
com
tion in

r
te o
thi

s
iva

do
r
rp
cum
fo

en
ng
t.
yi Co
Cop py
t. rig
– Clamp off supply hose to master cylinder using hose clamp gh ht
yri by
-3094- .
op Vo
by c lksw
cted agen
Prote AG.
– If necessary, loosen spring-type clip -3- with assembly tool -
VAS 5024- and pull supply hose off master cylinder.


– Release securing clip -2- with a screwdriver or a pointed object
and pull out of master cylinder to stop.
– Pull pipe/hose line -1- out from master cylinder and seal hose.
– Separate electrical connector -4- at clutch position sender -
G476- .
– Remove driver side footwell cover ⇒ General body repairs,
interior; Rep. Gr. 68 ; Compartments, covers and trim panels .
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
– Remove crash bar -1- by removing bolt -2-.
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
– If present, remove retaining clip -1- and swing front parking aid
s
iva
do
warning buzzer -H22- -2- in -direction of arrow-.
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.
– Pull off damping if lower securing bolt for mounting bracket is

covered, -arrows-.


The upper securing nut -1- is accessible through the opening in
the lower steering column trim.
– Pull mounting bracket -3- off studs on body.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
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
1.17.2 Installing
es, in part or in w
t to the co
following:
rrectness of i
l purpos
Note
nform
ercia

m
♦ Renew hose clips.

at
om
ion
c
♦ Allocate all components according to ⇒ Electronic parts cata‐

in t
or
his
e
logue “ETKA” .
at
do
priv
cum
or
– If present, install retaining clip for front parking aid warning

f
en
ng
t.
yi
buzzer -H22- ⇒ Electrical system; Rep. Gr. 94 ; Parking aid .
Co
Cop py
ht. rig
– Install crash bar -1- and tighten bolt -2- to specified torque rig ht
py by
⇒ page 88 .
co Vo
by lksw
cted agen
Prote AG.
– Install lower steering column trim ⇒ General body repairs, in‐
terior; Rep. Gr. 68 ; Compartments, covers and trim panels .
– Install driver side footwell cover ⇒ General body repairs, in‐
terior; Rep. Gr. 68 ; Compartments, covers and trim panels .

original shape, if necessary.
LHD AG. Volkswagen AG d
agen oes
ksw
– Install battery tray, battery cover and battery ⇒ Electrical
by V sys‐
o l not
gu
ara
tem; Rep. Gr. 27 ; Removing and installing batteryris.e d
nte
tho eo
– If removed, install complete air filter housing ⇒
ss a Rep. Gr. 23 ;
u ra
c
ce
le
Repairing injection system un
pt
an
d
itte
y li
– Reconnect battery and perform work required after connecting
rm
ab
pe
battery ⇒ Electrical system; Rep. Gr. 27 ; Disconnecting and
ility
ot
connecting battery .
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
Component Nm
rrectness of i
l purpos
Crash bar 20
nform
ercia

m
a
com
tion in
1.18 Removing and installing master cylinder
r
te o
thi
s
iva
do
r
rp
cum
fo
♦ Pliers -T10005-
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
1.18.1 Removing
– Remove mounting bracket, Golf 2004 ▸ ⇒ page 61 .
– Remove mounting bracket, Golf 2009 ▸ LHD ⇒ page 67 .
– Remove mounting bracket, Golf 2009 ▸ right-hand drive and
Golf Plus right-hand drive ⇒ page 73 .
– Remove mounting bracket, Golf Plus left-hand drive
⇒ page 79 .
– Remove mounting bracket, Passat ⇒ page 84

– 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).
– Release securing bar -B- and pull master cylinder out of

mounting bracket -arrow 1- and -arrow 2-.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
1.18.2 Installing
rrectne
• Move clutch pedal to rest position at stop.
ss 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
pyri by
Vo
co lksw
by
cted agen
Prote AG.

– 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
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
– Press master cylinder operating rod -1- in direction of arrow
spec
until retainer -2- engages audibly in clutch pedal.
t to the co
– Install mounting bracket, Golf 2004 ▸ ⇒ page 61 .
– Install mounting bracket, Golf 2009 ▸ LHD ⇒ page 67 .
rrectne
– Install mounting bracket, Golf 2009 ▸ right-hand drive and Golf
Plus right-hand drive ⇒ page 73 .
ss o
cial p
f
– Install mounting bracket, Golf Plus left-hand drive
inform
⇒ page 79 .
mer
atio
m
– Install mounting bracket, Passat ⇒ page 84

o
n
c
i
or
n thi
te
sd
iva
o
1.19 Removing and installing clutch position
pr
cum
r
fo
en
sender -G476-
ng
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Special tools and workshop equipment required opyri
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♦ Hose clamps -3094-
by
cted agen
Prote AG.
1.19.1 Removing
LHD
theft code.


Volkswagen AG
Gr. 24 ; Repairing injection system .gen AG.
swa does
k not
y Vol gu
– Remove battery and battery d btray ⇒ Electrical system; Rep. ara
ise nte
Gr. 27 ; Battery; Removing
tho
r and installing battery . eo
au ra
c
RHD ss
ce
e
nl
pt
du
– In vehicles with particle filter, remove shielding -A- from parti‐
an
itte
y li
cle filter ⇒ Rep. Gr. 26 ; Parts of exhaust system; Assembly
erm
ab
overview - front exhaust pipe with particle filter .
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An insulation mat is installed in conjunction with some engines.
, is n
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Appearance may be different from that illustrated.
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
– Remove heat shield from pipe/hose line -arrows-.

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at
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ion
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ate
do
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for
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Prote AG.

If a pipe/hose line -1- with a round component is installed directly
beneath the master cylinder, the pipe/hose line must be removed.
Note



-3094- .
– Release securing clip -2- with a screwdriver or a pointed object

and pull out of master cylinder to stop.
– Pull pipe/hose line -1- out from master cylinder and seal hose.
. Volkswag n AG en AG
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– Disconnect electrical connector -4-. y Volks not
gu
db ara
– Unclip clutch position sender -G476- from ise
rmaster cylinder nte
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-arrow- and remove. s au ra
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es, in part or in w
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1.19.2 Installing
nform
ercia

following:
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tion in
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Note
s
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♦ Renew hose clips.

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op
♦ Allocate all components according to ⇒ Electronic parts cata‐
C py
ht. rig
logue “ETKA” . rig ht
py by
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If the pipe/hose line was removed

original position, if necessary.
Right-hand drive
lkswage es n
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u or
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ss
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le
un
pt
an
d
– In vehicles with particle filter, install shielding -A- on particle

itte
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filter ⇒ Rep. Gr. 26 ; Parts of exhaust system; Assembly
erm
ab
ility
overview - front exhaust pipe with particle filter .
ot p
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LHD
h re
ole,
spec
– Install battery tray and battery⇒ Electrical system; Rep. Gr.
27 ; Removing and installing battery . t to the co

rrectne

ss

o
cial p
inform
mer
atio
om
n
c
i
or
n thi
te
sd
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pr
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t.
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Cop py
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gh ht
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co lksw
by
cted agen
Prote AG.

1.20 Assembly overview - hydraulics (LHD)
1 - Brake fluid reservoir

2 - Spring-type clip
❑ Not fitted in all vehicles
3 - Supply hose
❑ Rubber
❑ From 12. 05, plastic
⇒ page 95
❑ Golf 2009 ▸ and Golf
Plus 2009 ▸ plastic
⇒ page 95
4 - Master cylinder
❑ Removing and installing
⇒ page 88
5 - Clip
❑ Pull out clip to stop to re‐
move and install pipe/
hose line
6 - Retainer
❑ To remove and install, agen
AG. Volkswagen AG d
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separate master cylin‐ Volksw not
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der from clutch pedal, d by ara
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Golf 2004 ▸ ⇒ page 38 , hor eo
ut
Golf 2009 ▸ ⇒ page 44 , ss a ra
c
Golf Plus ⇒ page 54 ,
ce
e
nl
Passat ⇒ page 59
pt
du
an
itte
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7 - Clutch pedal
erm
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ility
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ling, Golf 2004 ▸
, is n
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⇒ page 38
hole
spec
es, in part or in w
ling, Golf 2009 ▸

⇒ page 44 t to the co
rrectness of i
ling, Golf Plus ⇒ page 54

l purpos
8 - Hexagon nut, ⇒ Item 15 (page 17)

nform
ercia
9 - Seal / O-ring
m
at
❑ Pull onto line connection

om
ion
c
❑ Insert with brake fluid

in t
or
his
te
❑ Seals/O-rings are adapted to configuration of line connection ⇒ page 95

a
do
priv
❑ Allocation ⇒ Electronic parts catalogue “ETKA”

um
for
en
ng
t.
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10 - Pipe/hose line
Co
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❑ Allocation ⇒ Electronic parts catalogue “ETKA” opyri
gh by
Vo
ht
❑ To remove, remove battery and battery tray ⇒ Electrical system; Rep. Gr. 27 ; Removing and installing by c lksw
cted agen
battery . Prote AG.
11 - Retainer
❑ Secured to body
12 - Seal / O-ring
❑ Insert with brake fluid.

AG. Volkswagen AG d
❑ Allocation ⇒ Electronic parts catalogue sw agen
“ETKA” oes
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13 - Clip ris
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❑ Pull out clip to stop to remove
s a and install pipe/hose line
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s
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14 - Slave cylinder
un
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ab
15 - Hexagon bolt ⇒ Item 9 (page 104) pe
ility
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16 - Bleeder valve
h re
hole
❑ Bleeding clutch system ⇒ page 101
spec
es, in part or in w
17 - Dust cap
t to the co
18 - Gearbox
rrectness of i
19 - Retainer
l purpos
20 - Hexagon bolt, 20 Nm
nform
ercia
Seals and O-rings for pipe and hose lines

m
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tion in
Item Material of line connection
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1 Line connection with circumferential groove
s
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-arrow 1-
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2 Line connection with shoulder -arrow 2-
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3 Line connection with shoulder -arrow 2- and cir‐
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• For line connection having circumferential groove -arrow 1- Prote AG.
and -arrow 3-, a seal or O-ring must be set there.
Supply hose -1- of plastic

• The seals -2- must be located in supply hose.

1.21 Assembly overview - hydraulics (RHD)
1 - Brake fluid reservoir

2 - Seal
❑ For plastic supply hose
❑ The seals must be loca‐
ted in supply hose
3 - Supply hose
❑ Made of plastic
❑ May be made of rubber AG. Volkswagen AG d
⇒ Item 3 (page 94) agen oes
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4 - Master cylinder orise nte
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❑ Removing and installing s au ra
c
⇒ page 88 s
ce
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un
pt
5 - Clip
an
d
itte
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❑ Pull clip out to stop to re‐
ab
pe
ility
move or install pipe
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❑ Is also pulled out to side
h re
in some master cylin‐
hole
spec
ders.
es, in part or in w
t to the co
6 - Seal / O-ring
rrectness of i
❑ Seals/O-rings are adap‐
l purpos
ted to configuration of
line connection
nform
ercia
⇒ page 95
m
❑ Allocation ⇒ Electronic
a
com
ti
parts catalogue “ETKA”
on in
r
te o
thi
7 - Retainer s
iva
do
❑ To remove and install,

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rp
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separate master cylin‐

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t.
der from clutch pedal (⇒
yi Co
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Removing and installing
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❑ Golf 2004 ▸ ⇒ page 38 Prote
cted AG.
agen
❑ Golf 2009 ▸ ⇒ page 49

❑ Golf Plus ⇒ page 54
❑ Passat ⇒ page 59
8 - Clutch pedal
9 - Hexagon nut, ⇒ Item 15 (page 17)
10 - Retainer
❑ Secured to body
11 - Pipe line
❑ Pipe and hose/pipe line ⇒ Item 13 (page 97) may be in one piece

❑ To remove, remove battery and battery tray ⇒ Electrical system; Rep. Gr. 27 ; Removing and installing
battery .
12 - Seal / O-ring
❑ Pipe ⇒ Item 11 (page 96) and hose/pipe line may be in one piece
❑ Insert with brake fluid
13 - Pipe/hose line
❑ Pipe ⇒ Item 11 (page 96) and hose/pipe line may be in one piece
❑ To remove, remove battery and battery tray ⇒ Electrical system; Rep. Gr. 27 ; Removing and installing
battery .
14 - Retainer
❑ Secured to retainer for ABS/EDL
15 - Retainer
❑ For ABS/EDL
16 - Seal / O-ring
17 - Clip
❑ Pull out clip to stop to remove and install pipe/hose line
18 - Slave cylinder
19 - Hexagon bolt ⇒ Item 9 (page 104) AG. Volkswagen AG d
agen oes
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20 - Bleeder valve by
Vol not
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ara
ed
❑ Bleeding clutch system ⇒ page
horis 101 nte
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21 - Dust cap ss c
ce
e
nl
22 - Gearbox
pt
du
an
itte
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23 - Retainer
erm
ab
ility
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hole
spec
es, in part or in w
t to the co
rrectness of i
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nform
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c
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or
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ate
do
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Prote
97
AG.
1. Repairing clutch mechanism
2 Removing and installing slave cylin‐

der
AG. Volkswagen AG d
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2.1 Removing ss a c
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theft code.
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– Remove complete air filter housing if it hinders access to slave

spec
cylinder ⇒ Rep. Gr. 23 ; Repairing diesel direct injection sys‐

tem or ⇒ Rep. Gr. 24 ; Repairing injection system . t to the co
– Remove securing clip -arrow 1- for gear selector cable from

gearbox selector lever -A-.
rrectne
– Pull gear selector cable off pin.

ss
Metal relay lever

o
cial p
f inform
– Remove securing clip -arrow 2- for gate selector cable from

mer
relay lever -B-.

atio
om
– Pull gate selector cable from pin.

c
i
or
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te
– Pull securing clip -arrow 3- off relay lever -B- and remove relay
sd
iva
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lever.
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ng
Plastic relay lever

t.
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Cop py
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– Remove relay lever together with cable end-piece from gear‐
rig
gh ht
yri by
box ⇒ page 134 . cop Vo
by lksw
cted agen
Prote
AG.
– Remove gearbox selector lever -A- by removing nut

-arrow 4-.

– Remove cable support bracket from gearbox -arrows-.

– Then raise and secure gear selector cable and gate selector
cable.
– Remove bracket -B- from gearbox and pull it off pipe/hose line
-A-.
AG. Volkswagen AG d
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spec
t to the co
– Then remove gearbox support -arrow A-.
rrectne
– Place a lint-free cloth under slave cylinder.
ss
– Pull clip for pipe/hose line out of slave cylinder to stop.
o
cial p
f in
– Pull pipe/hose line out of slave cylinder and seal opening.
form
mer
– Remove slave cylinder -arrows B-.
atio
om
n
c
i
or
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Caution
t
sd
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pr
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fo
Do not operate clutch pedal any more.
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t.
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Cop py
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2.2 Installing
by c lksw
cted agen
Prote AG.

– Install slave cylinder and tighten bolts -arrows B- to specified
torque.
– Insert pipe/hose line into slave cylinder to stop.
– Push retaining clip into pipe/hose line to stop.
– Then install gearbox support -arrows A-.
– Bleed clutch system after installing slave cylinder
⇒ page 101 .
Assembling selector mechanism ⇒ page 131 .
Adjusting selector mechanism ⇒ page 139 .
– Connect battery earth ⇒ Electrical system; Rep. Gr. 27 ; Bat‐
tery; Disconnecting and connecting battery .
2.3 Torque settings

Slave cylinder to gearbox ⇒ Item 9 (page 104)
2. Removing and installing slave cylinder 99

Gearbox support to gearbox bracket and gearbox

– Renew bolts.
– Screw in all bolts hand-tight.
– Tighten bolts to specified torque.
Bolts -arrows- 20 Nm + 90°
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
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un
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d
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rm
ab
pe
ility
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wit
, is n
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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
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cum
fo
en
ng
t.
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Cop py
t. rig
gh ht
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Vo
co lksw
by
cted agen
Prote AG.

3 Bleeding clutch system

♦ Brake filling and bleeding equipment -VAS 5234- or
AG. Volkswagen AG d
agen oes
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nl
pt
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ab
ility
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spec
♦ Brake filling and bleeding equipment -V.A.G 1869-
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
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ate
do
priv
cum
for
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t.
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Note
Co
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rig ht
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Prefilling system is not necessary! copy Vo
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cted agen
Prote AG.
Specifications for brake fluid ⇒ Brake systems; Rep. Gr. 47 ;
Bleeding brake system .
– Remove complete air filter housing if it blocks access to bleed‐
er connection (-arrow-, figure below) ⇒ Rep. Gr. 23 ; Repair‐
ing diesel direct injection system or ⇒ Rep. Gr. 24 ; Repairing
injection system
– Connect brake filling and bleeding equipment -VAS 5234- or
-V.A.G 1869- .
To bleed system, use 670 mm bleeder hose -V.A.G 1238/B3- if
necessary.
– Connect bleeder hose to collector bottle of brake bleeding
equipment.
3. Bleeding clutch system 101

– Connect bleeder hose to bleeder -arrow-.

– Pressurise system to 2 bar.
– Open bleeder valve.
– Bleed off about 100 cm3 brake fluid.
– Close bleeder valve.
– Rapidly operate pedal from stop to stop 10 to 15 times.
– Open bleeder valve.
– Bleed off an additional 50 cm3 brake fluid.
– Close bleeder valve.
– Depress clutch pedal several times after completion of bleed‐
ing process.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
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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
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
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cu
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f
en
ng
t.
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Cop py
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rig ht
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by lksw
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Prote AG.

4 Repairing clutch release mechanism

1 - Gearbox
2 - Ball stud, 25 Nm
remove gearbox
. Volkswagen AG
❑ Remove old gen AG
wagrease does
lks not
fromdcontact
by
Vo surface of gu
ara
clutch
oris
e release lever nte
t h eo
❑s a Lubricate with grease -
u ra
c
s G 000 100-
ce
le
un
pt
3 - Input shaft seal

an
d
itte
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erm

ab
ility
remove gearbox
ot p
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is n
❑ Renewing
h re
ole,
⇒ Item 12 (page 251)

spec
4 - Guide sleeve
t to the co

remove gearbox
rrectne
❑ With vulcanised O-ring

❑ If O-ring is damaged, re‐
s
new guide sleeve and

s o
O-ring together
cial p
f inform
5 - Retaining spring
mer
atio
m

o
n
c
remove gearbox
i
or
n thi
e
❑ Secure to clutch release

t
sd
iva
lever
pr
cum
r
fo
en
ng
6 - Socket head bolt, 20 Nm

t.
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Cop py
7 - Clutch release lever
t. rig
gh ht
pyri by
co Vo
by lksw
cted
remove gearbox
agen
Prote AG.
❑ Remove and install to‐

gether with release
bearing ⇒ page 104
❑ Remove old grease
8 - Release bearing
❑ To remove and install, remove gearbox
❑ Do not wash out bearing; wipe only
4. Repairing clutch release mechanism 103

❑ Renew noisy bearings
❑ Removing from and inserting in clutch release lever ⇒ page 104
❑ Lubricate contact surface of release lever with MoS2 grease AG. Volkswagen
n AG do
wage es n
9 - Hexagon bolt, 20 Nm Volks ot g
by ua
ed ran
ris
10 - Slave cylinder tho tee
or
au ac
❑ Removing and installing ⇒ page 98 ss
ce
e
nl
pt
11 - Plunger
du
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itte
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12 - Assembly bolt
erm
ab
ility
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❑ Secures clutch release lever when gearbox is installed.
wit
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❑ Remove after gearbox has been installed
h re
hole
spec
es, in part or in w
Note
t to the co
rrectness of i
Removing and installing release lever together with release bear‐
ing
l purpos
– Unhook spring -arrow 1-.
nform
ercia
– Pull off release lever -arrow 2- and release bearing.

m
at
– Install in reverse order of removal.
om
ion
c
in t
or
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ate
do
priv
cum
for
en
ng
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Removing and installing release bearing by c lksw
cted agen
Prote AG.
– Press together retaining hooks -arrows- on back of clutch re‐
lease lever and remove release bearing -A- from clutch re‐
lease lever.
– To install, press release bearing -A- into clutch release lever
until retaining hooks -arrows- engage.

5 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-
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an
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ab
ility
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5.1 Identifying make of clutch, vehicles with

wit
is n
h re
ole,
1.9 l - 66 kW turbo diesel engine and ve‐

spec
hicles with 1.9 l - 77 kW turbo diesel

t to the co
engine
The make of the clutch can be determined as follows with the
rrectne
clutch installed:
s
– Remove noise insulation ⇒ General body repairs, exterior;

s o
Rep. Gr. 50 ; Noise insulation .

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
pyri by
Vo
co lksw
by
cted agen
Prote AG.
5. Repairing clutch, in conjunction with dual-mass flywheel 105

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.
– In addition, a small cover plate -A- can be removed to enable

inspection of flywheel's outer contour.
Round outer contour -arrows- = Sachs clutch = -A-
– Removing and installing Sachs clutch ⇒ page 107 .
. Volkswagen AG
gen AG does
– Repairing Sachs clutch ⇒ page
Vol
ks109
wa . not
by gu
d ara
Outer contour with edgeso-arrows
ris
e 1- and, in addition, a circum‐ nte
eo
ferential crease -arrowa2-
u = LuK clutch = -B-
th
ra
ss c
or
ce
le
un
pt
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
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Rounded outer contour -arrows 1- and a circumferential crease

-arrow 2- = LuK clutch = -B-
– Removing and installing LuK clutch ⇒ page 109 .
– Repairing LuK clutch ⇒ page 112 .
5.2 Removing and installing Sachs clutch
5.2.1 Removing
• Remove gearbox.
– 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.
5.2.2 Installing wage

es n
lks ot
Vo
Install in the reverse order of eremoval,
d by observing the following: guara
ir s nte
utho eo
ra
a c
ss
Note
ce
e
nl
pt
du
an
itte
♦ Renew pressure plate and clutch plate together only. Select

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erm
ab
clutch plate and pressure plate according to engine code and

ility
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⇒ Electronic parts catalogue “ETKA” .

wit
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♦ Check whether dowel sleeves for aligning engine and gearbox

hole
are fitted in cylinder block and install if necessary.

spec
es, in part or in w
t to the co
♦ If dowel sleeves are not fitted, difficulties shifting gears, clutch

problems and possible noises from the gearbox (rattling of
gears which are not engaged) could occur.
rrectness of i
Installation position of clutch plate

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

nf
ercia
orm
m
atio
om
n in
or c
thi
te
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107
co Vo
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cted 5. Repairing clutch, in conjunction with dual-mass flywheel
agen
Prote AG.
Checking ends of diaphragm spring

n AG. Volkswagen A ge G do
swa es
• Wear to half the thickness
by
Vol of the diaphragm spring -arrows-
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ility
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Checking spring connections and riveted connections
– Check spring connections between pressure plate and cover
rrectne
for cracks as well as rivet connections for secure seating.
ss o
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Note
inform
mer
♦ Renew clutch plates and pressure plates with damaged or
atio
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loose rivet connections.

o
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♦ Always renew pressure plate and clutch plate together.
te
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♦ Select clutch plate and pressure plate according to engine
um
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code and ⇒ Electronic Parts Catalogue (ETKA) .

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♦ If clutch has burnt out, thoroughly clean clutch housing, fly‐
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wheel and parts of engine facing gearbox to reduce smell of
ht
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burnt linings.
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♦ Clean input shaft splines and, on used clutch plates, clean hub
splines; remove corrosion and apply only a very thin coat of
clutch plate spline grease -G 000 100- to splines. Then move
clutch plate to and fro on input shaft until hub moves freely on
shaft. Remove excessive grease.
♦ Pressure plates are protected against corrosion and greased.
Clean contact surface only. Otherwise, the service life of the
clutch will be considerably reduced.
♦ Pressure plate contact surface and clutch plate lining must
make full contact with flywheel. Only then insert securing bolts.
– Reverse counterhold tool -3067- for installation.

– Push pressure plate onto dowel 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.
Torque setting ⇒ Item 4 (page 109)
• Install gearbox.

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5.3 Repairing Sachs clutch
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1 - Dual-mass flywheel
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⇒ Rep. Gr. 13
spec
es, in part or in w
❑ Ensure that centring
t to the co
pins fit tightly
❑ Contact surface for
clutch lining must be
rrectness of i
free of grooves, oil and
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grease
2 - Clutch plate
nform
❑ Allocation ⇒ Electronic mercia
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⇒ page 107
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❑ With adjusting mecha‐
nism
⇒ page 107
❑ Check ends of dia‐
phragm spring
⇒ page 108
❑ Checking spring con‐
nections and riveted
connections
⇒ page 108
with clutch plate
4 - M6 bolt, 13 Nm, M7 bolt, 20 Nm
❑ Loosen or tighten diagonally in small steps
5.4 Removing and installing LuK clutch
5.4.1 Removing
• Remove gearbox.
– Use counterhold -3067- to loosen bolts.
– Loosen bolts in small steps and diagonally.
– Remove pressure plate and clutch plate.
5.4.2 Installing

Note
♦ Renew pressure plate and clutch plate together only. Select

clutch plate and pressure plate according to engine code and
⇒ Electronic parts catalogue “ETKA” .
♦ Check whether dowel sleeves for aligning engine and gearbox
♦ If dowel sleeves are not fitted, difficulties shifting gears, clutch
problems and possible noises from the gearbox (rattling of
gears which are not engaged) could occur.
Installation position of clutch plate

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

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

– Check spring connections -arrows aA- for
gen AGdamage
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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 not allowed to
be installed.
• The adjuster ring may take up a position outside the notches
in used clutches.
Note
♦ Renew clutch plates and pressure plates with damaged or

loose rivet connections.
♦ Renew pressure plate and clutch plate together only.
♦ 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‐
wheel and parts of engine facing gearbox to reduce smell of
burnt linings.
♦ Clean input shaft splines and, on used clutch plates, clean hub
splines; remove corrosion and apply only a very thin coat of
clutch plate spline grease -G 000 100- to splines. Then move
swa
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clutch plate to and fro on input shaft until hub movesy V freely on
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♦ Pressure plate contact surface and clutch plate lining must
erm
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make full contact with flywheel. Only then insert securing bolts.
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– Reverse counterhold tool -3067- for installation.
spec
es, in part or in w
– Push pressure plate onto dowel pins.
t to the co
– To centre clutch plate, use centring mandrel -3190 A- .
– Tighten all bolts evenly by hand until bolt heads contact pres‐ rrectness of i
sure plate.
l purpos
– Tighten bolts in small steps diagonally in order not to damage

centring holes of pressure plate and centring pins of dual-
nform
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mass flywheel.
m
at
Torque setting ⇒ Item 4 (page 112)

om
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5.5 Repairing LuK clutch
1 - Dual-mass flywheel
⇒ Rep. Gr. 13
pins fit tightly
❑ Contact surface for
clutch lining must be
free of grooves, oil and
grease
2 - Clutch plate
⇒ page 109
with SAC pressure plate
❑ Installation position:
⇒ page 110
3 - SAC pressure plate
❑ SAC means “self-ad‐
justing clutch”
with clutch plate
⇒ page 109
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❑ Checking spring con‐ horis nte
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connections ss
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⇒ page 110
nl
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❑ Checking position of adjusting mechanism with new pressure plates only ⇒ page 111
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4 - M6 bolt, 13 Nm, M7 bolt, 20 Nm

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❑ Loosen or tighten diagonally in small steps

h re
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6 Repairing clutch, in conjunction with one-piece flywheel

equipment required
♦ Counterhold -3067-
♦ Centring mandrel -3190 A-
♦ Torque wrench -
V.A.G 1331-
splines -G 000 100-
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• Remove gearbox.
nf
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Note
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♦ Renew clutch plates and pressure plates with damaged or loose rivets.
n in
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♦ Select clutch plate and pressure plate according to ⇒ Electronic parts catalogue (ETKA) and engine code.
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♦ Check whether dowel sleeves for aligning engine and gearbox are fitted in cylinder block and install if nec‐
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essary.
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box (rattling of gears which are not engaged) could occur.
p by
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6. Repairing clutch, in conjunction with one-piece flywheel 113

1 - Flywheel
⇒ Rep. Gr. 13
pins fit tightly
❑ Keep contact surface for
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grooves, oil and grease.
2 - Clutch plate n AG. Volkswagen AG do
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❑ Centring ⇒ page 114
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Note
hole
spec
es, in part or in w
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3 - Pressure plate
⇒ page 114
rrectness of i
l purpos
phragm spring
⇒ page 115
nform
ercia
❑ Checking spring con‐

nections and riveted
m
at
connections
om
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⇒ page 115
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Note
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4 - M6 bolt, 13 Nm, M7 bolt, Cop py
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❑ Determine according to ⇒ Electronic parts catalogue (ETKA)
co Vo
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❑ Loosen or tighten diagonally and in steps
AG.
Centring clutch plate and removing and installing pressure plate

– Loosen or tighten bolts diagonally in stages.
– Reverse position of counterhold -3067- when removing.
Note
Pressure plate contact surface and clutch plate lining must make
full contact with flywheel. Tighten securing bolts diagonally and
evenly to prevent damage to the pressure plate centring hole and
the flywheel centring pins.


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

– 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.
lkswage es n
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6. Repairing clutch, in conjunction with one-piece flywheel 115

34 – Controls, housing
1 Repairing selector mechanism
1.1 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
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116 Rep. Gr.34 - Controls, housing

1.2 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 .
♦ When reconnecting battery, perform work required after connecting battery ⇒ Electrical system; Rep. Gr.
27 ; Disconnecting and connecting battery .
♦ To work on selector mechanism in engine compartment, remove complete air filter housing if it is located
over selector mechanism w⇒ageRep.
n AG. Gr. 23
Volkswag;enRepairing
AG do
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diesel direct injection system or ⇒ Rep. Gr. 24 ;
y Volks
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♦ Remove selector
tho
rismechanism to renew selector cables ⇒ page
nte
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au ac
♦ Do not kinkssselector cables.
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I - Removing and installing
ility
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gear knob and cover
wit
⇒ page 118
is n
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ole,
II - Repairing gear lever and
spec
selector housing (through
t to the co
10.06) ⇒ page 123
II - Repairing gear lever and
selector housing (from 11.06)
rrectne
⇒ page 125
s
III - Assembly overview - re‐
s o
moving and installing selector

cial p
f in
cables ⇒ page 131

form
mer
Removing and installing selec‐

atio
m
tor mechanism ⇒ page 136

o
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Adjusting selector mechanism

sd
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⇒ page 139 .
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1. Repairing selector mechanism 117

1.3 Removing and installing gear knob and cover
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
ling, Golf ⇒ page 118
ling, Golf Plus
⇒ page 120
ling, Passat AG. Volkswagen AG d
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⇒ page 121 olksw
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3 - Clamp orise nte
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❑ For securing gear
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❑ Secure to gear knob

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⇒ Item 2 (page 118) us‐
erm
ab
ing hose clip pliers -

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V.A.G 1275-
wit
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❑ Always renew
hole
spec
4 - Centre console cover

es, in part or in w
t to the co
❑ In some equipment ver‐

sions, forms one part to‐
gether with centre con‐
rrectness of i
sole
l purpos
5 - Noise insulation
❑ Not fitted in all vehicles
nform
ercia
❑ Arrow on noise insulation points in direction of travel

m
❑ Locking lugs are arranged at varying intervals

at
om
ion
❑ Therefore it can be installed in only one position

c
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1.4 Removing and installing gaiter with gear

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knob and noise insulation, Golf Cop py
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Special tools and workshop equipment required co Vo
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♦ Hose clip pliers -V.A.G 1275-
Removing
– Pull or carefully lever gaiter upwards out of centre console
frame -arrows-.
With some equipment variations, the gaiter must be levered off
along the front section.
– Pull gaiter upwards, inside out over gear knob.

n AG. Volkswagen A ge G do
swa es
– Open clampby-arrow-
Vol
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and pull off gear knob together
not
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with gaiter.
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In some versions,
ho
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e o centre
ut
console.
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– Then pull off, or carefully lever off, centre console frame

-arrow 1-.
rrectne
– Pull off noise insulation -arrow 2-.

Installing
ss o
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– First set noise insulation in place.

inform
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Installation position of noise insulation:

olkswagen AG
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-Arrow A- points in direction of travel.
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Catches -arrows B- must engage
rised
in centre console. nte
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ut
– Then press framessinto centre console.
a ra
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– Then turn gaiter inside out.

un
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The gear knob must be pressed to stop.
erm
ab
ility
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– Install gear knob and gaiter and squeeze new clamp -arrow-
together.
rrectne
– Then press gaiter into frame of centre console.
ss o
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atio
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n
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1.5 Removing and installing gaiter with gear
Co
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knob and noise insulation, Golf Plus
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Removing
– Pull or carefully lever gaiter upwards out of centre console
frame -arrows-.
With some equipment variations, the gaiter must be levered off
along the front section.

AG. Volkswagen AG d
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– Pull gaiter Vupwards,
olks
w
inside out over gear
es n
oknob.
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– Open
ho
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nte with gaiter.
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– sPull
s off noise insulation.
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nl
Installing
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Installation position of noise insulation:
rrectness of i
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Catches -arrows B- must engage in centre console.

– Turn gaiter inside out.
nform
mercia
at
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together. by c lksw
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When gear knob is pushed on, it must engage in circumferential
groove in gear lever.
– Then press gaiter into centre console.
1.6 Removing and installing gaiter with se‐

lector lever knob and noise insulation,
Passat

♦ Front-end hooks -3370-
AG. Volkswagen AG d
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Removing
es, in part or in w
t to the co
– Open ashtray.
– Pull gaiter with plastic frame out of centre console frame -1-
rrectness of i
-arrow-.
l purpos
– Hold centre console frame securely -1-.

It must not be pulled along.
nform
ercia
Connections for various switches may be accidentally pulled

m
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apart.
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– Pull gaiter upwards, inside out over gear knob.
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– Open clamp -arrow- and pull off gear knob together with gaiter.
– Pull off noise insulation.
Installing
Installation position of noise insulation

Catches -arrows B- must engage in centre console.
– Turn gaiter inside out.
The gear knob must be pressed to stop.

together.
– Insert back of gaiter with plastic frame first.
1.7 Repairing gear lever and selector housing (through 10.06)
Note
♦ Lubricate bearing positions and sliding surfaces.

1 - Securing clip n AG. Volkswagen AG do

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❑ Removing and installing yV
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⇒ page 126 ir se
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2 - Bush s au ac
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3 - Compression spring
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4 - Bush
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5 - Torx bolt, 5 Nm ility

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6 - Cover
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7 - Damping
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8 - Damping
9 - Ball socket
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10 - Gear lever guide

l purpos
11 - Damping washer
12 - Seal
nform
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❑ Between selector hous‐

m
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com
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❑ Self-adhesive
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❑ Bond to selector hous‐

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13 - Gear lever
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14 - Selector housing gh ht
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15 - Bearing bush Prote
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16 - Pivot pin
17 - Guide bush
❑ Installing ⇒ page 124

19 - Gate selector lever

20 - Torx bolt, 5 Nm
21 - Seal
❑ Always renew
22 - Base plate
❑ Bend open tabs to remove
❑ Always renew
23 - Gate selector cable
❑ On gate selector lever
24 - Gear selector cable
❑ Removing from and attaching to gear lever guide ⇒ page 124
25 - Securing clip
❑ Always renew
26 - Hexagon nut M8, 25 Nm, hexagon nut M 6, 8 Nm
❑ Qty. 4
27 - Bearing bush
❑ Fits in one position only
28 - Securing clip agen
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Removing and installing gate and gear selector cables
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– Remove securing clip from gear selector cable -A- and gate
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selector cable -B-.

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To do this, raise tab using screwdriver -arrow 1- and press off

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securing clip -arrow 2-.

h re
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spec
– Remove gear selector cable -A- from gear lever retainer.

es, in part or in w
t to the co
– Remove gate selector cable -B- from retainer of gate selector

lever.
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Installing compression spring

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

1.8 Repairing gear lever and selector housing (from 11.06)
Note
♦ Lubricate bearing positions and sliding surfaces.

♦ Dismantling and assembling selector mechanism ⇒ page 126 .
1 - Base plate
❑ Bend open tabs to re‐
move
❑ Always renew
2 - Seal
❑ Always renew
3 - Gear lever n AG. Volkswagen AG do
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❑ Can be removed and in‐ byV ua
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stalled with gear lever ir se tee
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guide au or
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⇒ Item 15 (page 126) ss
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installed
un
pt
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4 - Damping washer
erm
ab
ility
❑ Push onto gear lever up
ot p
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to stop -arrow-
is n
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5 - Securing clip
spec
❑ Do not damage cables
t to the co
when removing
❑ Always renew
rrectne
❑ Lever off gate selector
ss
lever
o
cial p
f i
❑ Press onto gate selector
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mer
mechanism
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⇒ page 116
te
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7 - Bush
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❑ Lever off gear lever
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cted
❑ Press onto gear lever
agen
Prote AG.
guide inside selector mechanism
❑ Installation position ⇒ page 116
9 - Damping
10 - Ball socket
❑ Will be damaged when removed.
❑ Always renew
11 - Bush
12 - Securing clip

14 - Bush
15 - Gear lever guide
16 - Hexagon nut M8, 25 Nm, hexagon nut M 6, 8 Nm
❑ Qty. 4
17 - Seal
❑ Between selector housing and underbody
❑ Self-adhesive
❑ Bond to selector housing
18 - Selector housing
❑ With compression spring and gate selector lever
❑ Compression spring and gate selector lever cannot be removed
Removing and installing securing clip

– To remove or install securing clip -arrow A-, press spacer bush
-arrow B- to stop in direction of arrow -arrow C- using screw‐
driver and pull off securing clip.
Note
♦ Do not cant spacer bush when pushing down.

AG. Volkswagen AG d
agen
♦ Slot in gear lever for securing
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♦ Carefully release otension
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1.8.1 Dismantling and assembling selector

un
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♦
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Thrust piece -T10083-

t to the co
Dismantling
– Remove selector mechanism ⇒ page 136 .
rrectness o
cial p
f inform
mer
atio
om
n
c
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or
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Cop py
t. rig
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pyri by
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by
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– Bend open tabs -arrows- of base plate for selector mechanism

using screwdriver and remove base plate; (tabs in front area
of base plate are not illustrated).
– Remove seal from selector housing.
– Remove gear and gate selector cables from selector housing
⇒ page 125 .
– Lift upper end -A- of compressionAGspring
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agen Atab of gate se‐
lector lever. lksw
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pt
– Use screwdriver to press catches -arrows- of ball socket to‐
du
an
itte
wards bearing ball of gear lever guide; break off catches if
y li
erm
ab
necessary.
ility
ot p
wit
– Lever ball socket -A- with gear lever guide -B- out of selector
, is n
h re
housing.
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
– Then press ball socket off bearing ball of gear lever guide and
remove it.
m
at
om
io
• Please pay attention to guides -A- during the further proce‐
n
c
in t
r
dure.
o
his
ate
do
riv
• They must not be broken off.

p
cum
for
en
ng
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– Lever lower end -arrow 1- of compression spring onto shoulder
Co
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on gate selector lever as far as stop.
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cted agen
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– 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.
– Slacken ends -A- and -B- by turning both round to right.
• Ends -A- and -B- must point in opposite directions.

agen
AG. Volkswagen AG d
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Vol ot g
d by ua
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ris tee
tho or
au ac
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nl
pt
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ab
ility
ot p
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, is n
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hole
spec
es, in part or in w
t to the co
– Fit gear lever guide in selector housing.

rrectness of i
• Pin -arrow 1- is still located in notch in selector housing.

– Turn gear lever guide in -direction of arrow 2- until ball stud
l purpos
-A- is located in notch in selector housing.

nform
mercia
at
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ion
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or
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ate
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– Place selector housing with gear lever guide into larger recess t. C rig
gh ht
-arrow- in thrust piece -T10083- . yri
p by
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olkswagen AG
wag en AG. V
Golf 2004 ➤ , Golf 2009 ➤ , Golf
olksPlus 2005 ➤ , Golf Plus 2009
does
not ➤ , Pass ...
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ed5-speed manual gearbox 0A4 - Edition
b ara 04.2010
s n ri tee
ho
ut or
• The gear lever guide must project from the
ss selector
a housing ac
up to the stop.
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rm
ab
Note
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ility
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For clarity of illustration, only part of the gate selector lever is
h re
hole
shown.
spec
es, in part or in w
t to the co
– Insert end -A- of compression spring into guide from above.
– Pull end -B- of compression spring downwards and insert it
rrectness of i
next to guide (in direction of ball joint).
l purpos
• Please pay attention to guides (⇒ figure above) during the fur‐
ther procedure.
nform
ercia
• They must not be broken off.

m
– Carefully remove selector housing with gear lever guide from
a
com
tio
thrust piece -T10083- .
n in
r
te o
thi
s
iva
– Move gate selector lever back to stop (opposite from mounting
do
r
rp
c
holes for gear and gate selector cable) -arrow 1-.
um
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– Grease ball stud.
Co
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– Press ball stud into gate selector lever -arrow 2-. rig ht
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• Guides -A- and tabs -B- are not allowed to be damaged. cted agen
Prote AG.
– Place selector housing with gear lever guide into larger recess
-arrow- in thrust piece -T10083- .

AG. Volkswagen AG d
Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus 2009 agen
ksw ➤ , Pass ...
oes
not
Vol
5-speed manual gearbox 0A4 - Edition 04.2010 ed
by gu
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ris nte
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• The gear lever guide must project from the selector housing
ss
au ra
c
up to the stop.
ce
le
un
pt
an
– Lift upper end -A- of compression spring over pin of gate se‐
d
itte
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lector lever.
erm
ab
ility
ot p
• Use a new ball socket -B-.
wit
is n
h re
– Grease ball socket and bearing ball of gear lever guide.
ole,
spec
– Press ball socket onto bearing ball of gear lever guide up to
t to the co
stop.
– Remove selector housing from thrust piece -T10083- .
rrectne
– Insert lower end -C- of compression spring into guide.
– Lift upper end -A- of compression spring over pin of gate se‐
ss
lector lever into guide.
o
cial p
f inform
– Press ball socket into selector housing -arrows-.
mer
atio
• All 4 locking lugs must engage.
om
n
c
i
or
n
– Fit gear lever, gear selector cable, gate selector cable and
thi
te
sd
base plate ⇒ page 125 .
iva
o
pr
cum
r
– Install selector mechanism ⇒ page 136 .

fo
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Golf 2004 ➤o,lkGolf
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V t gu
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ara 0A4 - Edition 04.2010
ris nte
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1.9 Assembly overview - removing and installing selector cables au ra
ss c
ce
e
nl
pt
du
an
itte
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Note
erm
ab
ility
♦ Lubricate bearing positions and sliding surfaces. ot p
wit
, is n
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hole
spec
es, in part or in w
t to the co
❑ Connect to cable end-
rrectness of i
piece
l purpos

⇒ page 116
nform
ercia
❑ Use cable tie to fix onto

m
at
om
gate selector cable
ion
c
⇒ page 134
in t
or
his
e
❑ From 11.06, modified

at
do
riv
attachment to gear lever

p
cum
or
inside selector mecha‐

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❑ Connect to cable end-
Prote AG.
piece
⇒ page 116
❑ Use cable tie to fix onto
gear selector cable
⇒ page 134
❑ From 11.06, modified
attachment to gate se‐
lector lever inside selec‐
tor mechanism
3 - Securing clip
❑ Always renew
❑ Discontinued in selector
mechanisms from 11.06
⇒ page 125
4 - Selector housing
5 - Securing clip
❑ Always renew
❑ Do not damage cables when removing
❑ 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
9 - Spacer

10 - Cable end-piece
❑ After installing, adjust selector mechanism ⇒ page 139
❑ For gate selector cable to relay lever
❑ Do not interchange; cable end-pieces for gate selector cable to relay lever and gear selector cable to
gearbox selector lever are different
❑ For metal relay lever, secured with securing clip ⇒ Item 12 (page 132)
❑ From 05.07, fitted in conjunction with plastic relay lever ⇒ page 134
❑ Removing from plastic relay lever ⇒ page 134
❑ Pressing onto plastic relay lever ⇒ page 134 n AG. Volkswagen AG do
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❑ Allocation ⇒ page 133 yV
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11 - Cable end-piece ris nte
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❑ After installing, adjust selector mechanism
ss
a ⇒ page 139 c
ce
e
❑ For gear selector cable to gearbox selector lever

nl
pt
du
an
❑ Do not interchange; cable end-pieces for gate selector cable to relay lever and gear selector cable to
itte
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erm
gearbox selector lever are different
ab
ility
ot p
❑ Allocation ⇒ page 133
wit
, is n
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12 - Securing clip
hole
spec
❑ Always renew
es, in part or in w
t to the co
❑ Not required for plastic relay lever
13 - Securing clip
rrectness of i
❑ Always renew
l purpos

14 - Bearing bush
nform
ercia

m
at
15 - Relay lever
om
ion
c
in t
or
his
te

a
do
priv
❑ May be made from plastic or metal

um
for
en
ng
t.
❑ Metal relay lever is mounted in bearing bush ⇒ Item 14 (page 132) and secured with securing clip
yi Co
op
C py
t. rig
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❑ From 05.07, plastic relay lever
p by
co Vo
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cted
❑ Remove and install plastic relay lever together with cable end-piece ⇒ page 134
agen
Prote AG.
❑ Bearing bushes and securing clip not required for plastic relay lever
16 - Shoe
❑ From 06.06, smaller diameter of support pin for cable end-piece ⇒ page 133
18 - Self-locking hexagon nut, 23 Nm
❑ Always renew

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 134
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”
Through 05.06 10 mm
From 06.06 8.5 mm
AG. Volkswagen AG d
agen oes
olksw not
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Installing gearbox selector lever s
ce
e
nl
pt
du
– When setting gearbox selector lever in place, ensure that gap

an
itte
y li
in teeth -arrow A- is over the partial tooth on the selector shaft

erm
ab
-arrow B-
ility
ot p
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
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om
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c
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ate
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priv
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for
en
ng
t.
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Cop py
t. rig
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by
cted agen
Prote AG.

AG. Volkswagen A
Golf 2004 ➤ , Golf 2009 agen
ksw➤ , Golf Plus 2005 ➤ ,eGolf
s no Plus 2009 ➤ , Pass ...
G do
Vol t gu
5-speed manual egearbox
db
y 0A4 - Edition 04.2010 ara
ris nte
tho eo
Installation positionssof
a gearbox
u
selector lever and relay lever ra
c
ce
le
un
pt
an
d
itte
y li
2 - Relay lever engages in guide rail of gearbox selector lever via
erm
ab
shoe -arrow-.
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
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Fitting position of cable tie for cables

i
o
pr
cum
r
fo
en
ng
– Wind cable tie -arrow- around the selector cables in a figure

t.
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eight and secure them as shown in figure. Cop py
t. rig
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pyri by
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by
cted agen
Prote AG.
1.10 Plastic relay lever

From 05.07, plastic relay lever
• To remove relay lever, first separate cable end-piece from
gate selector cable.

This will avoid damage to the gate selector cable

– Pull locking mechanism forward to stop in
-direction of arrow 1- and then lock by turning to left in
Volkswagen AG
– Then push relay lever forwards (-in direction of arrow 3-).
swa
gen AG
.
does
k not
Vol gu
Relay lever with catch -arrow 1- (⇒ previous figure)sed by ara
nte
ri
– Press catch -arrow 1- (⇒ previous figure) and down utho to stop eo
ra
a c
remove relay lever together with cable end-piece. In the proc‐ ss
ce
le
ess, swing it in direction of operation.
un
pt
an
d
itte
y li
erm
ab
ility
Relay lever with clip -arrow 1- ot p
wit
is n
h re
ole,
– Pull clip -arrow 1- off and remove relay lever together with ca‐
spec
ble end-piece.
t to the co
Cable end-piece must be located behind catch -arrow 2-.
rrectne
• The cable end-piece can be removed only with the relay lever
removed ⇒ page 135 .
ss o
cial p
f inform
Note
mer
atio
om
♦ When installing, lubricate bearing positions and sliding surfa‐
n
c
i
or
n
ces.
thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
– Press cable end-piece onto relay lever ⇒ page 136 . t. Cop py
rig
gh ht
– Install relay lever together with cable end-piece to stop. yri
p by
co Vo
by lksw
cted
• Fastener -arrow 1- secures relay lever (⇒ previous figure).
agen
Prote AG.
• Ensure proper engagement.

• Cable end-piece must be located behind catch -arrow 2- (⇒
previous figure).
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

• Relay lever has been removed
• Cable end-piece may be pressed only onto bush -arrow-.
• Cable end-piece must move freely on relay lever.
• It must be located behind catch -arrow 2- ⇒ page 134 .
1.11 Removing and installing selector mech‐ . Volkswage

AG
anism
n AG d
agen oes
olksw not
V y gu
db ara
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1.11.1 Removing
ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
m

o
n
c
theft code. i
or
n thi
te
sd
a
– With ignition switched off, disconnect battery earth strap ⇒

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

p
cum
r
fo
tery .
en
ng
t.
yi Co
op
– Install gaiter with gear knob and noise insulation. Golf
C py
t. rig
gh
⇒ page 118 , Golf Plus ⇒ page 120 , Passat ⇒ page 121
ht
pyri by
Vo
o
by c lksw
Golf 2004 ▸
cted agen
Prote AG.
– Remove securing bracket for centre console, remove footwell

trim from centre console and ashtray or storage compartment
for this ⇒ General body repairs, interior; Rep. Gr. 68 ; Com‐
partments, covers and trims; Removing and installing centre
console .
Golf 2009 ▸
– Remove ashtray or storage compartment and securing brack‐
et for centre console ⇒ General body repairs, interior; Rep.
Gr. 68 ; Compartments, covers and trims; Removing and in‐
stalling centre console .

– Remove rear footwell ducts, if fitted ⇒ Heater; Rep. Gr. 80 ,

remove centre console for this ⇒ General body repairs, inte‐
rior; Rep. Gr. 68 ; Compartments, covers and trims; Removing
and installing centre console .
Golf Plus
– Remove upper parts and, if necessary, securing brackets for
centre console ⇒ General body repairs, interior; Rep. Gr. 68 ;
Compartments, covers and trims; Removing and installing
centre console
Vehicles where centre console securing brackets cannot be re‐
moved as a separate component:
– Remove centre console, ⇒ General body repairs, interior;
Rep. Gr. 68 ; Compartments, covers and trims .
– Remove selector housing nuts -arrows-.

– 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-.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au 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
Metal relay lever

– Remove securing clip -4- for gate selector cable from relay
rrectness of i
lever -2-.
l purpos

Plastic relay lever
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Releasing cable end-piece from gate selector cable

– Pull locking mechanism forward to stop in
-direction of arrow 1- and then lock by turning to left in
– Then push relay lever forwards (-in direction of arrow 3-).
– Remove relay lever together with cable end-piece
⇒ page 134 .
Continued for all selector mechanisms
– Remove cable support bracket from gearbox -arrows-; if nec‐

essary, unclip hose -A- from bracket -B- first.
– Remove tunnel cross member ⇒ Rep. Gr. 26 ; Removing and
installing parts of exhaust system . en AG. V
olkswagen AG
ag does
lksw not
– Separate front exhaust system at double clamp andbdetach
yV
o gu
ara
d
from subframe ⇒ Rep. Gr. 26 ; Removing and installing
rise parts nte
of exhaust system . utho eo
ra
a c
ss
– Unhook exhaust system ⇒ Rep. Gr. 26 ; Removing and in‐
ce
le
un
pt
stalling parts of exhaust system .
an
d
itte
y li
– Remove underbody panels ⇒ General body repairs, exterior;
rm
ab
pe
ility
Rep. Gr. 50 .
ot
wit
, is n
– Swing selector housing down and remove with selector ca‐
h re
hole
bles.
spec
es, in part or in w
t to the co
1.11.2 Installing
rrectness of i
l purpos
– Align selector housing parallel to body.

nform
ercia
• Distance to body must be same on both sides.

m
Secure selector housing ⇒ Item 26 (page 124) or

com
tion in
⇒ Item 16 (page 126) .

r
te o
thi
s
– Route cables -1- from selector mechanism -2- to gearbox as

iva
do
r
follows:
rp
cum
fo
en
ng
♦ After cables cross over -arrow-, they must be routed parallel

t.
yi Co
op
to one another as far as cable support bracket on gearbox.
C py
t. rig
gh ht
yri by
♦ Make sure that cable tie -arrow- for securing cables is installed cop Vo
by lksw
correctly. Installation position ⇒ page 134 . cted agen
Prote AG.
♦ Cables must be laid in the intended indentation in heat shield

-3-.
Note
In the close-up, the heat shield is shown from above.

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

The holes in the cable end-pieces have different diameters.
Allocation of cable end-pieces ⇒ page 133
– Spread a small quantity of grease on pins -arrows- of gearbox

selector lever -1- and relay lever -2-.
• Allocate grease using ⇒ Electronic parts catalogue (ETKA) .
– Renew securing clip -3- and, for metal relay lever, securing
clip -4- each time they are removed.
– Secure gear selector cable with securing clip -3- and gate se‐
lector cable with securing clip -4-.
Cable end-piece to plastic relay lever
– Fit relay lever and cable end-piece together ⇒ page 134 .
– Insert gate selector cable in cable end-piece.
Continued for all selector mechanisms
– Install centre console ⇒ General body repairs, interior; Rep.
Gr. 68 ; Compartments, covers and trims .
en AG . Volkswag
– Install gaiter with gear knob and noise
ksw
aginsulation.
en AG Golf does
not
⇒ page 118 , Golf Plus ⇒ pageby120
Vol , Passat ⇒ page 121 gu
a d ran
ise
– Install underbody panels th⇒or General body repairs, exterior; tee
or
Rep. Gr. 50 . ss
au ac
ce
e
– Assemble exhaust system free of tension and attach tunnel

nl
pt
du
an
cross member ⇒ Rep. Gr. 26 ; Removing and installing parts

itte
y li
of exhaust system .
erm
ab
ility
ot p
Adjusting selector mechanism ⇒ page 139 .

wit
, is n
h re

hole
spec

es, in part or in w

t to the co
– Follow procedure after connecting battery ⇒ Electrical system;

Rep. Gr. 27 ; Battery; Disconnecting and connecting battery .
rrectness of i

l purpos
Component
nform
ercia
Selector lever housing to body ⇒ Item 26 (page 124) or

m
at
om

ion
c
in t
r
Selector cables support bracket to gearbox

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Special tools and workshop equipment required t. C rig
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♦ Locking pin -T10027 A-

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Note
rrectness of i
♦ The following points are essential to ensure correct adjust‐
ment of selector mechanism:
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♦ Moving parts of operating elements and elements transferring

force must be in proper condition.
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orm
♦ Selector mechanism must move freely.
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♦ Gearbox, clutch and clutch mechanism must also be in proper

or
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• Gearbox must be in neutral.
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– Remove air filter housing if bracket -A- and securing mecha‐ C py
t. rig
nism for gear selector cable and gate selector cable are not gh ht
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accessible ⇒ Rep. Gr. 23 ; Repairing diesel direct injection cop Vo
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agen
Prote AG.
– Pull locking mechanisms on gate selector cable and gear se‐

lector cable end-pieces forward to stop -direction of arrow 1-
and then turn to left to lock -direction of arrow 2-.

AG. Volkswagen AG d
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Secure selector shaft as follows: olksw not
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– Press selector shaft down hor-direction
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s c
-direction of arrow 2- upwards and at the same time press it in
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until it engages in selector shaft.
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– If noise insulation is present, remove it.
hole
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Now secure gear lever as follows:
es, in part or in w
t to the co
– Select neutral using gear lever.
– Guide locking pin -T10027 A- through hole -A- into hole -B-.
rrectness of i
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– Now turn locking mechanisms on gear selector cable and gate
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selector cable end-pieces clockwise to stop
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-direction of arrow-.
Spring presses locking mechanism into original position.
– Now turn angled rod -A- back to original position


Note
The angled rod -A- must be pressed out of selector housing to

stop and point to rear.
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– Pull locking pin out of holes -A- and r-B-.
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– If noise insulation was present,ssinstall it.
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– Check that selector shaft moves freely.
ility
ot p
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– If necessary, install complete air filter housing ⇒ Rep. Gr. 23
h re
or ⇒ Rep. Gr. 24
hole
spec
es, in part or in w
t to the co
rrectness of i
1.12.1 Functional check
l purpos
• With gearbox in neutral, selector lever must rest in gate for 3rd
and 4th gear.
nform
ercia
– Operate clutch.
m
at
om
– Select all gears several times. Pay particular attention to op‐ ion
c
in t
r
eration of reverse gear lock.

o
his
ate
do
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– If it continues to be difficult to engage a gear after repeated

p
cum
or
attempts, repeat adjustment procedure of selector mechanism

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en
ng
⇒ page 139 .
t.
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Cop py
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Prote AG.

2 Removing and installing gearbox, Golf 2004 ▸

equipment required
♦ Support bracket -10 - 222
A-
♦ Adapter -10 - 222 A / 8-
♦ Hook - 10 - 222 A /2-
♦ Adapter -10 - 222 A /3-
♦ Adapter -10 - 222 A /16-
♦ Gearbox support -3282-
♦ Rear left engine support
eye points towards side
⇒ page 146 shackle
-10-222 A /12-
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2. Removing and installing gearbox, Golf 2004 ▸ 143

♦ Adjustment plate -3282/39-

♦ Support elements for gear‐
box (determine when set‐
ting adjustment plate on
gearbox support )
♦ Engine and gearbox jack -
V.A.G 1383A-
1331-
1332-
♦ Gearbox lifting tackle
-3336- for transporting
gearbox
splines -G 000 100-
♦ Allocate grease using ⇒
Electronic parts catalogue
(ETKA) .
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2.1 Removing gearbox
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theft code.
rrectness of i
l purpos

– If the lifting eyes of the engine for support bracket -10 - 222 A-
nform
ercia
are covered by a component, for example the air filter, it must

be removed now. ⇒ Rep. Gr. 23 ; Repairing diesel direct in‐
m
a
com
jection system or ⇒ Rep. Gr. 24 ; Repairing injection system

ion in
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Gr. 27 ; Removing and installing battery . t. C rig
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Metal relay lever
relay lever -B-.
lever.
Plastic relay lever
⇒ page 134 .
– Remove gearbox selector lever -A- by removing nut n AG. Volkswagen AG do
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– Remove cable support bracket from gearbox tho-arrows-.
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– Then raise and secure gear selector cable
s and gate selector
ce
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cable.
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– Then remove gearbox support -arrow A-. s
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– Remove slave cylinder -arrow B-, lay to side and secure with
fo
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g
wire. Do not disconnect pipes.

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

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

- 222 A /8- , adapter -10 - 222 A /3- and adapter -10 - 222 A /
16- before support for bonnet.
– Attach hook -10 - 222 A /10- at front right of engine.
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Rear left engine support eye points towards side -arrow-
– Attach shackle -10-222 A /12- at rear left of engine -arrow-.
rrectness of i
– Attach hook - 10-222 A /2- in shackle -10-222 A /12- .
l purpos
– Then connect hook -10-222 A /2- using adapter -10-222 A /

16- .
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Rear left engine support eye points upwards -arrow-:

– Insert hook - 10-222 A /2- .
16- .
– Take up weight of engine/gearbox assembly on spindles.
– Raise vehicle.
– Remove lower part of front left wheel housing liner ⇒ General
body repairs, exterior; Rep. Gr. 66 ; Wheel housing liner .
– Then remove all lines fromolkgearbox.
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– Remove drive shaft horheat
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shield, if present -arrows- ⇒ Running tee
ut or
gear, axles, steering;
ss
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Removing and installing drive shafts .
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– Separate exhaust system at double clamp and unbolt exhaust
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pipe bracket from subframe ⇒ Rep. Gr. 26 ; Exhaust system .
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– Disconnect drive shafts from flange shafts and tie up as high
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– Remove pendulum support -arrows A-, -B- and -C-. rrectness of i
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– Remove hexagon bolts -arrows- for left assembly mounting Prote AG.
from gearbox mounting.

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– Tilt engine/gearbox assembly by lowering it via spindles
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support bracket -10 - 222 A- . s au ra
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ed nut, but not more than until spindle is flush with nut
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-arrow-.
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es, in part or in w
♦ Be careful of all lines when lowering gearbox.
t to the co
• Securing bolts -arrows- for gearbox bracket -A- must be ac‐
cessible.
rrectness of i
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– Remove gearbox bracket -A- -arrows-.
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– If small cover plate -A- for flywheel behind the right flange shaft
-arrows- is installed, remove it.
– Remove exhaust system strut -1- from gearbox -arrow-.

– Remove starter ⇒ Electrical system; Rep. Gr. 27 ; Starter .
To remove gearbox “0A4”, set up gearbox support -3282- with
adjustment plate -3282/39- .
– Insert gearbox support -3282- in engine and gearbox jack -
V.A.G 1383A- .
– Align arms of gearbox support according to holes in adjust‐
ment plate .

– Screw in support elements -A - and -C- on adjustment plate

as shown.
– Position engine and gearbox jack under vehicle. Arrow -B- on
adjustment plate points in direction of vehicle travel.
– Align adjustment plate parallel to gearbox and lock safety sup‐

port on gearbox.
– Then screw pin -3282/29- into hole on gearbox for securing
bolt of pendulum support.
– Remove lower engine/gearbox connecting bolts.
– Separate exhaust system if lower bolts -arrows- cannot be re‐
moved.
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– Press gearbox off dowel sleeves and carefully swing towards
rrectness of i
subframe.
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– Turn gearbox downwards in vicinity of differential.

– Have a second mechanic push engine forwards slightly.
nform
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– Carefully lower gearbox, guiding right-hand flange shaft -A-

past intermediate plate and flywheel as shown.
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– When lowering gearbox, change olks
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spindles of gearbox supportrise-3282- .
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Be careful of all lines when lowering gearbox.
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2.2 Installing gearbox
t to the co
rrectness of i
Note
l purpos
Refer to procedure “Removing gearbox” for required special tools

⇒ page 143 .
nform
ercia
Observe the following table on the subject of “checking and top‐

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at
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ping up gear oil”.
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“Checking and topping up gear oil”

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“No” “Yes” “Yes”
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Gearbox Original X
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No oil loss X
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Completely Prote X AG.
dismantled before in‐
stallation
⇒ Item 3
(page 250)
oil capacity
⇒ page 2
Partially X
dismantled after instal‐
• (Gear‐ lation
box ⇒
housing page 220
and
clutch
housing
were not
separa‐
ted.)
– All threaded holes into which self-locking bolts are to be

screwed must be cleaned of residual locking fluid carefully with
a thread tap.
– Always renew self-locking bolts and nuts.
– Check whether dowel sleeves for aligning engine and gearbox
If dowel sleeves are not fitted, difficulties shifting gears, clutch
problems and possible noises from the gearbox (rattling of gears
which are not engaged) could occur.
– Ensure that intermediate plate is correctly seated on engine.
– Clean input shaft splines and apply thin coat of grease for
clutch plate splines -G 000 100- .

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Golf V 2009 ➤ , Golf Plus 2005 ➤ot ,guGolf Plus
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The clutch plate must slide easily to and fro on the input shaft.
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To install gearbox “0A4”, set up gearbox support -3282- with ad‐
itte
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justment plate -3282/39- .
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ment plate .
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– Screw in support elements -A - and -C- ( pin -3282/29- ) on
es, in part or in w
adjustment plate as shown.
t to the co
– Place gearbox on engine and gearbox jack .
– Align adjustment plate and gearbox parallel to one another.
rrectness of i
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– Screw pin -3282/29- into hole on gearbox for securing bolt of

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– Position engine and gearbox jack under vehicle. -Arrow B- on C py
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– Using spindles of gearbox support -3282- , tilt gearbox down‐ cted agen
Prote AG.
wards in vicinity of differential.
– Then carefully raise gearbox, guiding with right flange shaft

-A- past flywheel and intermediate plate as shown.
– Using spindles of gearbox support -3282- , tilt gearbox up‐
– Raise gearbox to engine.
– Align gearbox to engine and join.
– Screw in lower engine/gearbox securing bolts and tighten to
specified torque ⇒ page 154 .
– After gearbox has been bolted to engine, remove engine and
gearbox jack from gearbox.
– If small cover plate had been installed behind the right-hand

flange shaft -A-, install it -arrows-.
– Screw in upper engine/gearbox securing bolts and tighten to

– Install bracket -A- on gearbox using new hexagonal bolts

-arrows- and tighten to specified torque ⇒ page 154 .
– Align engine and gearbox in installation position using both

spindles of support bracket -10 - 222 A- .
– Install new bolts -arrows- for left assembly mounting in gear‐
box mounting and tighten to specified torque ⇒ page 154 .
AG. Volkswagen AG d
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Do not remove support bracket -10 - 222 A- until the bolts
ss a
se‐ c
curing the left and right assembly mountings have been tight‐
ce
le
un
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ened to specified torque.
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Install engine and gearbox mounting free of tension ⇒ Rep. Gr.
t to the co
10 ; Removing and installing engine .
rrectness of i
torque ⇒ Item 9 (page 104) .
l purpos
– Then install gearbox support -arrow A- and tighten to specified
nform
ercia
torque ⇒ page 154 .

m
– Attach drive shafts to gearbox ⇒ Running gear, axles, steer‐
a
com
tio
ing; Rep. Gr. 40 ; Repairing front suspension .
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– Install drive shaft heat shield, if present -arrows- ⇒ Running cted agen
Prote AG.
gear, axles, steering; Rep. Gr. 40 ; Repairing drive shafts;

– Install pendulum support with new bolts -arrows A-, -B- and
-C- ⇒ Running gear, axles, steering ; Rep. Gr. 40 ; Repairing
front suspension .
– Assemble exhaust system and attach exhaust system bracket
to subframe ⇒ Rep. Gr. 26 ; Exhaust system .
– Bolt exhaust system strut -1- onto gearbox and tighten bolt
-arrow- to specified torque ⇒ Rep. Gr. 26 ; Exhaust system .
– Push connector -1- onto reversing light switch -F4- . agen

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– Install starter, push on connector -arrow 2- and bolt onedwireby gu
ara
-arrow 3- ⇒ Electrical system; Rep. Gr. 27 ; Starter tho.
ris nte
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au ra
– Install earth strap at upper engine/gearbox connecting
ss bolt. c
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pt
du
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erm
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t to the co
– Attach support -B- to gearbox.
rrectness of i
– Press pipe/hose line -A- into retainer -B- on gearbox.
l purpos
– Install cable support bracket on gearbox and tighten bolts

-arrows- to specified torque ⇒ Item 6 (page 131) .
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– Install gearbox selector lever -A-.

– Tighten hexagon nut -arrow 4- to specified torque
⇒ Item 18 (page 132) .
– Spread a small amount of grease on pin of gearbox selector
lever -A-.
Allocate grease using ⇒ Electronic parts catalogue (ETKA) .
– Connect gear selector cable to gearbox selector lever
-arrow 1-.
Metal relay lever
– Install relay lever -B- and secure with securing clip -arrow 3-.
– Spread a small amount of grease on pin of relay lever -B-.
– Connect gate selector cable to relay lever -arrow 2-.
Plastic relay lever
– Install relay lever together with cable end-piece ⇒ page 134 .
wage es n
– Adjust selector mechanism ⇒ pagey V139
olks . ot g
ua
d b ran
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– Install battery tray, battery cover
hori and battery ⇒ Electrical sys‐
s tee
tem; Rep. Gr. 27 ; Removing aut and installing battery . or
ac
ss
– Install engine cover and air filter housing ⇒ Rep. Gr. 23 or ⇒
ce
le
un
pt
Rep. Gr. 24
an
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– Reconnect battery and perform work required after connecting ab

ility
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battery ⇒ Electrical system; Rep. Gr. 27 ; Disconnecting and wit

is n
connecting battery . h re
ole,
– Install lower part of front left wheel housing liner ⇒ General

spec

t to the co
– Install noise insulation ⇒ General body repairs, exterior; Rep.

Gr. 50 ; Noise insulation .
rrectne

ss o
Gearbox to petrol engine

cial p
f inform
mer
Item Bolt Quantity Nm

atio
m
1 M 12 x 65 2 80
o
n
c
i
or
2 M 12 x 150 1 80
thi
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♦ Additionally, start‐
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3 M 12 x 165 Cop
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4 M 10 x 50 3 40
5 M 12 x 85 1 80
6 M6x8 1 10
♦ Small cover plate
for flywheel
Item -A- dowel sleeves for centring

Gearbox to diesel engine

1 M 12 x 55 2 80
2 M 12 x 150 2 80
er to gearbox
3 M10 x 50 3 40
4 M12 x 60 1 80
5 M6 x 8 1 10
♦ Small flywheel
cover plate
Gearbox bracket to gearbox

– Renew bolts.
Gearbox mounting to body

– Renew bolts.
– Tighten bolts to specifiedwtorque.
agen
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es, in part or in w

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Drive shaft to flange shaft ⇒ Running gear, axles, steering; Rep.

Gr. 40 ; Repairing drive shaft; Removing and installing drive
shafts .
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orm
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2. Removing and installing gearbox, Golf 2004 ▸
3 Removing and installing gearbox, Golf 2009 ▸ with turbo diesel engine

equipment required
A-
♦ Adapter -10-222 A /8-
♦ Adapter -10 - 222 A /18-
gearbox support )
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te o
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♦ Adapter -10-222 A /3-

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V.A.G 1383A-
♦ Retainer -T10346-
♦ Engine support -3300 A-
Volkswa AG. gen AG
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♦ Torque wrencholks -V.A.G
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splines -G 000 100-
ole,
spec
♦ Flange bolt M6 x 20
t to the co
♦ Flange bolt M6 x 80
rrectness o
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f inform
mer
atio
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Cop py
ht. rig
rig ht
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co Vo
by lksw
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Prote AG.
At a later point, support bracket -10-222 A- will be put onto lon‐

gitudinal members with adapters -10 - 222 A /8- .
• To prevent damage to edges of wings, cover bottom area of
both adapters -10 - 222 A /8- with self-adhesive fabric tape
-arrow- ⇒ Electronic parts catalogue (ETKA chemical sub‐
stances) .

theft code.
3. Removing and installing gearbox, Golf 2009 ▸ with turbo diesel engine 157

– Remove securing clip -arrow 1- for gear selector cable from Volkswa
gearbox selector lever -A-. swa
gen AG
. gen AG
does
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– Pull gear selector cable off pin. edb ara
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ris
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– Release end-piece from gate selector cable
aut ⇒ page 138 . ra
c
ss
– Press catch -arrow 2- down to stop and remove relay lever
ce
le
un
pt
together with cable end-piece. In the process, swing it in di‐
an
d
itte
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rection of operation.
erm
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ility
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Note
h re
ole,
spec
The relay lever was secured with a clip shortly after start of pro‐
t to the co
duction ⇒ page 135 .
rrectne
-arrow 3-.
ss
o
cial p
f in
form
mer
cable.
atio
om
n
c
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or
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-A-.
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t.
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Cop py
ht. rig
rig ht
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co Vo
by lksw
cted agen
Prote AG.

Caution


starter.
– Bolt bracket -T10346- to rear of the three mounting holes for

battery tray.
– To do this, use a collar bolt M 6 x 80 or a securing bolt for
battery tray.
– Set up support bracketG-10-222 A- in front of bonnet support.

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A n AG d
agen oes
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♦ Adapterhoris -10-222 A /3- nte
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♦ Adapter
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pt
♦ Adapter -10-222 A /18-

an
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rm
ab
pe
ility
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• On upper longitudinal carrier, directly before the elevation

wit
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(-arrow 1-) next to bolt (-arrow 2-)

h re
hole
spec
– Connect bracket -T10346- to support bracket .

es, in part or in w
t to the co
– Attach spindles in left engine support eyes.

– Take up weight of engine/gearbox assembly and support
rrectness of i
bracket on spindles.
l purpos
– Raise vehicle.
nform
ercia

m

a
com
tio

n in
r
te o
thi
– Then remove all lines from gearbox.

s
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fo
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
– Gearboxes for vehicles with start-stop system: pull connector

-arrow- from gearbox neutral position sender -G701- .
AG. Volkswagen AG d
agen oes
olksw not
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d by ara
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pe
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wit
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– If front vehicle level sender -G78- is present, unbolt it from hole
spec
transverse link ⇒ Rep. Gr. 40 ; Removing and installing front
es, in part or in w
vehicle level sender -G78- .
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
– Remove drive shaft heat shield, if present -arrows- ⇒ Running
r
te o
thi
s
iva
do
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rp
cum
fo
– Remove drive shafts from flange shafts, raise as high as pos‐
en
ng
t.
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sible and secure. Do not damage the surface protection ⇒
Co
op py
Running gear, axles, steering; Rep. Gr. 40 ; Removing and t. C rig
gh ht
installing drive shafts . pyri by
Vo
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by c lksw
cted agen
– Separate exhaust system at double clamp and unbolt exhaust Prote AG.
pipe bracket from subframe ⇒ Rep. Gr. 26 ; Exhaust system .
– Remove pendulum support.

– Remove hexagon bolts -arrows- for left assembly mounting

– Tilt engine/gearbox assembly by lowering it via spindles ofAG. Volkswagen
support bracket -10 - 222 A- . lksw
agen AG do
es n
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• Securing bolts -arrows- for gearbox bracketris-A-
ed must be ac‐
b ran
tee
cessible. ut
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or
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ss
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es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
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tion in
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– Attach bracket -T10346- with bolt -1- to left threaded hole in Cop py
subframe.
t. rig
gh ht
pyri by
Vo
co
-1- = Flange bolt M6 x 20.
by lksw
cted agen
Prote AG.
– Secure engine support -3300 A- to bracket -T10346- .
– Place a cloth between engine support -3300 A- and oil pan.
– Press engine forwards using spindle of engine support -3300

A- . In the process, observe the following points in particular:
• The air conditioning compressor -2- must not contact -arrow-
the refrigerant line -1- en AG. V
olkswagen AG
ag does
ksw not
• Vol
The alternator must not contact
by the refrigerant line. d
gu
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• The pressure pipe must
ut
honot contact the radiator.
r eo
ra
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To remove gearbox “0A4”,
s set up gearbox support -3282- with
ce
le

un
pt
an
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ab
V.A.G 1383A- .
pe
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ment plate .
hole
spec
es, in part or in w
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as shown.
rrectness of i
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tion in
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port on gearbox. Cop py
t. rig
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p by
co Vo
by lksw
bolt of pendulum support. Prote
cted AG.
agen

moved.
⇒ Rep. Gr. 26 ; Removing and installing parts of the exhaust

system


subframe.

past dowel sleeve -arrow- in cylinder block as shown.
lkswage es n
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byV ua
d ran
ir se tee
tho
u or
a ac
ss
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nl
pt
du
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ab
ility
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– Guide left flange shaft -B- past subframe bracket -arrow- as

wit
shown.
, is n
h re
hole
– When lowering gearbox, change position of gearbox using

spec
spindles of gearbox support -3282- .

es, in part or in w
t to the co
Note
rrectness of i

l purpos
nf
ercia
orm
m
atio
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n in

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thi
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sd
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o
Note
m
f
en
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t.
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op py
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⇒ page 157 . pyri by
Vo
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by
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Prote AG.

Gearbox Original X
part
No oil loss X
Completely X
dismantled Before in‐
n AG. Volkstallation
swagen AG
kswage does
byV
ol
⇒ Item 3 not
gu
ara
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ed (page 250) nte
utho
Oil capacity eo
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ss
a
⇒ page 2 c
ce
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Partially X
nl
pt
du
an
dismantled After instal‐
itte
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• (Gear‐ lation
erm
ab
ility
box ⇒
ot p
housing page 220
wit
, is n
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and
hole
clutch
spec
housing
es, in part or in w
t to the co
were not
separa‐
ted.)
rrectness of i
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a thread tap.
nf
ercia
or
m
m
atio
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or c

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t.
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Cop py
t. rig
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pyri by
Vo
co
by lksw
cted agen
Prote
AG.
– Attach bracket -T10346- with bolt -1- to left threaded hole in
subframe.
– In the process, position bracket -T10346- at the same angle
as the engine.


the refrigerant line -1-
• The alternator must not contact the refrigerant line.
• The pressure pipe must not contact the radiator.
ment plate .


pendulum support.
– Position engine and gearbox jack under vehicle. -Arrow B- on
– Using spindles of gearbox support -3282- , tilt gearbox down‐
wards in vicinityaof
gendifferential.
AG. Volkswagen AG d
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olks ot g
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ed ran
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nl
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ab
– Carefully lift gearbox, guiding right-hand flange shaft -A- past

ility
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dowel sleeve in cylinder block -arrow- as shown.

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

shown.
– Remove engine support -3300 A- and bracket -T10346- .

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
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un
-arrows- and tighten to specified torque ⇒ page 169 . pt

an
d
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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
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
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do
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fo
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Cop py
t. rig
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by
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box mounting and
wage
ntighten
AG. Volkto
swspecified
agen AG
doetorque ⇒ page 169 .
ks s no
Vol t gu
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Do not remove support bracket -10 - 222 A- until the bolts se‐
ce
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nl
pt
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an
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erm
ab
ility
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wit
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hole
Note
spec
es, in part or in w
t to the co
rrectness of i
– Then install drive shafts ⇒ Running gear, axles, steering; Rep.
Gr. 40 ; Removing and installing drive shafts .
l purpos
– Install drive shaft heat shield, if present -arrows- ⇒ Running
nform
ercia

m
Removing and installing drive shafts . 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
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by
cted agen
Prote AG.
– Install pendulum support ⇒ Running gear, axles, steering;

Rep. Gr. 40 ; Repairing front suspension .
– If front vehicle level sender -G78- -arrows- is present, install it

⇒ Rep. Gr. 40 ; Removing and installing front vehicle level
sender -G78- .
– Gearboxes for vehicles with start-stop system: join connector

-arrow- to gearbox neutral position sender -G701- .
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
– Install slave cylinder and tighten bolts -arrowsoris B- to specified
e nte
torque ⇒ Item 9 (page 104) . aut
h eo
ra
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ce
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nl
pt
du
an
itte
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erm
ab
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es, in part or in w
t to the co
rrectness of i
– Push connector -1- onto reversing light switch -F4- .
l purpos
– Install starter, push on connector -arrow 2- and bolt on wire

-arrow 3- ⇒ Electrical system; Rep. Gr. 27 ; Starter .
nform
ercia
– Install earth strap at upper engine/gearbox connecting bolt.

m
at
om
ion
c
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or
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ate
do
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for
en
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Cop py
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pyri by
Vo
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by c lksw
– Attach support -B- to gearbox. cted agen
Prote AG.


– Install gearbox selector lever -A- ⇒ page 133 .

⇒ Item 18 (page 132) .
lever -A-.
-arrow 1-.
– Adjusting selector mechanism ⇒ page 139 .
– Install engine cover and air filter housing ⇒ Rep. Gr. 23 or ⇒
Rep. Gr. 24
– For vehicles with front vehicle level sender -G78- , check
headlight adjustment ⇒ Electrical system; Rep. Gr. 94 ;
Lights, lamps, switches - exterior .

Gearbox to engine
. Volkswagen AG
Item gen AG
Bolt
olkQuantity
swa Nm does no
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b
1 M 12 x 50 rised 2 80 ara
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2 M 12 x 150aut
h
2 80 ra
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♦ Additionally,
ss
start‐
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er to gearbox
nl
pt
du
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3 M10 x 50 3 40
erm
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ility
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4 M12 x 60 1 80
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5 M6 x 8 1 10
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hole
♦ Small flywheel
spec
cover plate
es, in part or in w
t to the co

rrectness of i

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– Renew bolts.
nform
mercia

at
om
ion
c

in t
or
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ate
do
priv
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for
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t.
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Cop py
t. rig
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pyri by
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by c lksw
cted agen
Prote AG.

– Renew bolts. AG. Volkswagen AG d
agen oes
olksw not
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– Screw in all bolts hand-tight. ed b ara
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– Tighten bolts to specified torque. aut ra
c
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pt
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ab
ility
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spec
t to the co
– Renew bolts.
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ss o
cial p
f
inform
mer
atio
m

o
n
c
shafts .
i
or
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te
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en
ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
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Prote AG.

AG. Volkswagen
agen Golf 2004 ➤A,GGolf
n2009
ot g ➤ , Golf Plus 2005 ➤ , Golf Plus 2009 ➤ , Pass ...
does
olksw
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ran 5-speed manual gearbox 0A4 - Edition 04.2010
d b ua
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oris tee
th or
au ac
ss
4 Removing and installing gearbox, Golf 2009 ▸ with petrol engine
ce
le
un
pt
an
d
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erm
ab
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equipment required
wit
is n
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ole,
spec
A-
t to the co
♦ Adapter -10-222 A /8-
♦ Adapter -10 - 222 A /18-
rrectne
ss
o
cial p
f i
nform
gearbox support )
mer
atio
m

o
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c
i
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Cop py
ht. rig
rig ht
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co Vo
by lksw
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Prote AG.
♦ Shackle -T10419-
4. Removing and installing gearbox, Golf 2009 ▸ with petrol engine 171
♦ Shackle -10-222 A /12-

V.A.G 1383A-
1331-
1332-
gearbox
splines -G 000 100-
(ETKA) .
♦ 2 x hexagon socket head
bolt M 6 × 20
♦ Flange bolt M6 x 80 agen
AG. Volkswagen AG d
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♦ Support -T10036 A- ed byV gu
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♦ or support -T10036- aut
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t to the co
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f inform
mer
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om
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c
i
or
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Cop py
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by
172
copy Vo
by lksw
Rep. Gr.34 - Controls, housing cted agen
Prote AG.
olkswagen AG
en AG. V
– If you are using support -T10036- , apply 2olkholes
swa ∅ 7 mm as
g does
not
shown in illustration. ed
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• Dimension -a- = 11 mm aut
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• Dimension -c- = 70 mm
itte
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At a later point, support bracket -10-222 A- will be put onto lon‐
rrectness of i
gitudinal members with adapters -10 - 222 A /8- .
l purpos
• To prevent damage to edges of wings, cover bottom area of

both adapters -10 - 222 A /8- with self-adhesive fabric tape
-arrow- ⇒ Electronic parts catalogue (ETKA chemical sub‐
nf
ercia
stances) .
orm
m
atio
om
n in
or c
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Cop py
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ht
pyri by
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Prote
AG.
theft code.
– Then remove engine cover with air filter ⇒ Rep. Gr. 24 ; Re‐
pairing injection system .
– Release end-piece from gate selector cable ⇒ page 134 .
– Pull clip -arrow 1- off and remove relay lever together with ca‐
ble end-piece.
-arrow 3-.
. Volkswagen AG
does gen AG
– Remove cable support bracket
Vol
ksw from gearbox -arrows-.
a
not
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– Then raise and secure
oris
e gear selector cable and gate selector
ran
tee
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th or
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pt
-A-.
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ercia
Caution
m
at
om
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ate
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for
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Cop py
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pyri by
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by
– Now remove connector -arrow 2- and wire -arrow 3- from cted agen
Prote AG.
starter.
– To prevent damage to vacuum hose from brake servo to en‐

gine, it must be removed from engine -arrow- ⇒ Rep. Gr. 47 .

Note
♦ At a later point, support bracket -10-222 A- is connected to

engine to lower engine/gearbox.
♦ Some engines have a secondary air inlet valve -N112- on the
back -arrow-.
• Both upper threaded holes for securing bolts of secondary air

inlet valve are needed for attaching engine to support bracket
-10-222 A- ⇒ -arrows- in figure below.
• Therefore, secondary air inlet valve must be removed ⇒ Rep.
Gr. 26 ; Secondary air system .
– Attach lug -T10419- to rear of engine -direction

Volkswa
of arrow-.
AG. gen AG
agen does
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– Screw lug tightly into threaded holes, -arrows-.
Torque setting: 10 Nm
rrectness of i
l purpos
WARNING
Always tighten bolts to specified torque.

nform
mercia
at
om
ion
c
in t
or
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ate
do
priv
cum
for
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t.
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In addition, retaining eye -arrow A-, at front of engine, is needed Cop py
for catching engine.
t. rig
gh ht
pyri by
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co
– Remove transport eye -arrow B- and remove it from retaining
by lksw
cted agen
Prote
eye -arrow A-, without disconnecting line connections ⇒ Rep.
AG.
Gr. 15 ; Cylinder head, valve gear .
– Set up support bracket -10-222 A- in front of bonnet support.

– Use:
♦ Adapter -10-222 A /8-
♦ Adapter -10-222 A /18-
– Position adapter -10-222 A /8- :
• On upper longitudinal carrier, directly before the elevation
(-arrow 1-) next to bolt (-arrow 2-)
– Attach shackle -10-222 A /12- at front left of engine.
– Connect lug -T10419- and shackle -10-222 A /12- to support
bracket .
– Raise vehicle.

– If front vehicle level sender -G78- is present, unbolt it from
transverse link ⇒ Rep. Gr. 40 ; Removing and installing front
vehicle level sender -G78- .
AG. Volkswagen AG d
agen oes
olksw not
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ara
ed
ris nte
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aut ra
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un
pt
an
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ab
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ility
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wit
, is n

h re

hole
spec

es, in part or in w
t to the co
– Remove drive shafts from flange shafts, raise as high as pos‐

sible and secure. Do not damage the surface protection ⇒
Running gear, axles, steering; Rep. Gr. 40 ; Removing and
rrectness of i
installing drive shafts .

l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
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• Ensure proper engagement of clip.
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♦ Adapter -10 - 222 A /3-
♦ Adapter -10 - 222 A /16-
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⇒ page 192 shackle
-10-222 A /12-
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5. Removing and installing gearbox, Golf Plus 189


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♦ Adapter -10-222 A /8-
♦ Adapter -10-222 A /16-
– Then attach spindle in right engine support eye.

Rear left engine support eye points towards side -arrow-

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⇒ page 189 .


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Install engine and gearbox mounting free sof
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– Install pendulum support ⇒ Running gear, axles, steering;

Rep. Gr. 40 ; Repairing front suspension .
to subframe ⇒ Rep. Gr. 26 ; Removing and installing parts of
exhaust system .

– If exhaust system strut -1- was removed, bolt it onto gearbox

and tighten bolt -arrow- to specified torque ⇒ Rep. Gr. 26 ;
Exhaust system .
– Install charge air hose -arrow 1- or -arrow 2- ⇒ Rep. Gr. 21 ;

Charge air system with turbocharger .

AG. Volkswagen AG d
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5. Removing and installing gearbox, Golf Plus

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⇒ Item 18 (page 132) .
ss o
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– Connect gear selector cable to gearbox selector lever i

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cted AG.
agen

Plastic relay lever
– Install front wall of plenum chamber ⇒ General body repairs,
exterior; Rep. Gr. 50 ; Noise insulation .

– Install noise insulation -5- on front wall of plenum chamber.

– Install valve block -4- on front wall of plenum chamber
-arrow-.
– Install battery tray, battery cover and battery -3- ⇒ Electrical
– Install complete air filter housing -1- with intake hose -2- ⇒
Rep. Gr. 23 .
– Install engine cover.

swage es n
Gearbox to engine yV
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Item Bolt Quantity
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1 M 12 x 55 ss 2 80
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2 M 12 x 150 2 80
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♦ Small flywheel
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rrectness of i
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– Renew bolts.
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– Renew bolts.

– Renew bolts.
shafts .
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6 Removing and installing gearbox, Passat

equipment required
A-
♦ Adapter -10 - 222 A /8-
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6. Removing and installing gearbox, Passat 205

5-speed manual gearbox 0A4
gen AG
. Vo-lkEdition
swagen A04.2010
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♦ Adapter -10 - 222
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gearbox support )
V.A.G 1383A-
1331-
1332-
gearbox
splines -G 000 100-
(ETKA) .
AG. Volkswagen AG d
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ss

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– Then remove complete air filter housing ⇒ Rep. Gr. 23 or ⇒
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Plastic relay lever
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⇒ page 134 .
rrectness of i
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-arrow 4-.
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Caution

– Pull off reversing light connector -arrow 1-.

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

- 222 A /3- and adapters -10 - 222 A /8- in front of bonnet struts.
– Raise vehicle. AG. Volkswagen AG d
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– Remove noisebinsulation
yV
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Rep. Gr. 50 orise; Noise insulation .
d
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ss a lower part of front left wheel housing liner ⇒ General c
body repairs, exterior; Rep. Gr. 66 ; Wheel housing liner . ce
e
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– Then remove all lines from gearbox. an

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AG.

– Disconnect drive shafts from flange shafts and tie up as high
as possible, being careful not to damage surface protection.
– Separate exhaust system at double clamp and remove ex‐
haust pipe bracket from subframe ⇒ Rep. Gr. 26 ; Removing
and installing parts of exhaust system .

– If front vehicle level sender -G78- -arrows- is present, remove

it ⇒ Rep. Gr. 40 ; Removing and installing front left vehicle
level sender -G78- .
– Remove left and right coupling rods from anti-roll bar.
– Unscrew nuts -arrows- for swivel joint and suspension links.
AG. Volkswagen AG d
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– Remove pendulum support from gearbox, bolt -2- and bolt s
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-3-.
un
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axles, steering; Rep. Gr. 40 ; Assembly overview - subframe, h re

ole,
anti-roll bar, suspension links; Fixing position of subframe and

spec
brackets .
t to the co
– Remove subframe with pendulum support, anti-roll bar and

suspension links ⇒ Running gear, axles, steering; Rep. Gr.
40 ; Assembly overview - subframe, anti-roll bar, suspension
rrectne
links .
ss

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inform
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– Remove exhaust system strut -1-, if present, from gearbox

ole,
spec
and, as necessary, from exhaust system -arrow- (attachment

to exhaust system is not visible in figure).

t to the co

rrectne

s

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V.A.G 1383A- .
cial p
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port on gearbox.
moved.

system
– Press gearbox off dowel sleeves and carefully lower.
Note

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6.2 Installing gearbox ho
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Note
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⇒ page 207 .
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ping up gear oil”

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Gearbox Original X
part
No oil loss X
nform
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Completely X
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Oil capacity
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AG.
housing page 220

and
clutch
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were not
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pendulum support.
– If small cover plate -A- had been installed behind the right
flange shaft -arrows-, install it.



WARNING
Do not remove support bar -10-222 A- until all bolts securing

the left and right assembly mountings have been tightened to
specified torque.
Note


ing; Rep. Gr. 40 ; Repairing front suspension .
wage es n
– Install drive shaft heat shield, if present -arrows-y V⇒olkRunning
s ot g
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gear, axles, steering; Rep. Gr. 40 ; Repairing ris
e drive shafts;
d b ran
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Removing and installing drive shafts . utho or
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– Install subframe and suspension links swith pendulum support
ce
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⇒ Running gear, axles, steering; Rep. Gr. 40 ; Assembly

un
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overview - subframe, anti-roll bar, suspension links .

itte
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– Attach steering box to subframe ⇒ Running gear - front and

ility
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wit
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– Attach pendulum support to gearbox bolt -2- and bolt -3- ⇒

rrectne
Running gear, axles, steering; Rep. Gr. 40 ; Repairing front

wheel suspension .
ss o
cial p
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mer
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214
AG.
Rep. Gr.34 - Controls, housing

⇒ Rep. Gr. 40 ; Removing and installing front left vehicle level
sender -G78- .
to subframe ⇒ Rep. Gr. 26 ; Removing and installing parts of
exhaust system .
– Attach exhaust system strut -1-, if present, to gearbox and ex‐

haust system and tighten bolts -arrow- to specified torque
(attachment to exhaust system is not visible in figure). ⇒ Rep.
Gr. 26 ; Removing and installing parts of exhaust system . wagen AG. Volkswagen AG doe
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– Reconnect reversing light connector -arrow 1-.

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– Attach support -B- to gearbox. s
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mer
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⇒ Item 18 (page 132) . n AG. Volkswagen A ge G do
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– Spread a small amount of grease on pinby
Voof
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Allocate grease using ⇒ Electronic
ss
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Metal relay lever
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spec
t to the co
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Plastic relay lever
ss o
cial p
f inform
mer
atio
m

o
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c
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– Install complete air filter housing ⇒ Rep. Gr. 23 or ⇒ Rep.

i
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pr
c
Gr. 24
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– Install engine cover.
Co
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connecting battery . Prote AG.


Gearbox to engine
1 M 12 x 55 2 80
2 M 12 x 150 2 80
er to gearbox
3 M10 x 50 3 40
4 M12 x 60 1 80
5 M6 x 8 1 10
♦ Small flywheel
cover plate


– Renew bolts.

– Renew bolts.
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7 Transporting gearbox
♦ Gearbox mounting support -3336-
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cial p
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mer
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– Adjust support beam on sliding piece using locking pin

o
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c
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-arrow-.
thi
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Number of holes visible = 5.

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7. Transporting gearbox 219

8 Checking and topping up gear oil

It is not possible to check the gear oil level by unscrewing the oil
filler plug.
The angle of the engine/gearbox unit means the lower edge of

the fill hole -arrow 1- is below the oil level -arrow 2-.
The oil level in the gearbox can only be checked by completely
draining the gear oil and then refilling:

AG. Volkswagen AG d
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♦ Hose (approx. 600 mm long, external diameter 10 mm) with

hole
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es, in part or in w
t to the co
8.1 Preparation
Gear oil specification for manual gearboxes ⇒ Electronic parts
rrectness of i
l purpos
– Remove complete air filter housing ⇒ Rep. Gr. 23 or ⇒ Rep.

Gr. 24 .
nform
ercia

m
at
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ion
c
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ate
do
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220
cted agen
Prote
AG.
Clean gearbox.
Caution
To drain gear oil, a pivot pin for the selector forks in the gearbox
must be removed.
To prevent the positions of the selector forks from being
changed, e.g. due to accidental operation of the selector mech‐
anism, the selector shaft must be locked in position.agen AG. Volkswagen AG do
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Secure selector shaft as follows: tho or
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an
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ab
pe
ility
-direction of arrow 2- upwards and at the same time press it in
ot
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until it engages in selector shaft.
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hole
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es, in part or in w
t to the co
rrectness of i
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8.2 Draining gear oil
nform
ercia
Use a clean container with a scale and a 3-litre capacity to catch

m
a
com
ti
the oil which runs out.
on in
r
te o
thi
• Selector shaft is locked in place ⇒ page 221
s
iva
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ng
t.
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– Install pivot pin -arrow 2- with a new O-ring
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⇒ Item 7 (page 226) .
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– Screw in oil drain plug -arrow 1- ⇒ Item 17 (page 251) .

– Now turn angled rod -A- back to original position
-direction of arrow- so that selector shaft can move again.
8. Checking and topping up gear oil 221

8.3 Fill with gear oil

Top up oil in container to 1.7 litres.
Gear oil specification for manual gearboxes ⇒ Electronic parts
– Remove reversing light switch -F4- -arrow-.
– Connect hose (approx. 600 mm long, external diameter
10 mm) to commercially available funnel.
– Insert hose in fitting hole for reversing light switch (2nd me‐
AG. Volkswagen AG d
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– Install reversing light switch -F4-
ris
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b ran
tee
⇒ Item 2 (page 256) . ut
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– Check operation of selector
s
mechanism ⇒ page 142 .
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– Install complete air filter housing ⇒ Rep. Gr. 23 or ⇒ Rep.
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9 Dismantling and assembling gearbox
9.1 Overview - gearbox
1 - 1st gear
2 - 2nd gear
3 - 3rd gear
4 - 4th gear
5 - 5th gear
6 - Gearbox housing cover
7 - Gearbox housing
8 - Selector mechanism
❑ (Selector forks)
9 - Reverse gear
10 - Clutch housing AG. Volkswagen AG d
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12 - Output shaft aut ra
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13 - Differential
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9. Dismantling and assembling gearbox 223

9.2 Assembly overview

Dismantling and assembling procedure ⇒ page 234
I - Removing and installing

cover for gearbox housing and
5th gear ⇒ page 225 .
II - Removing and installing
gearbox housing and selector
mechanism ⇒ page 226
III - Removing and installing in‐
put shaft, output shaft, differ‐
ential and selector forks
⇒ page 227
olkswagen AG
en AG. V
Assembly sequence - remov‐ ksw
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⇒ page 228 . au
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Assembly sequence - Disman‐

nl
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completely ⇒ page 234 .
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9.3 Removing and installing cover for gearbox housing and 5th gear
1 - Bolt, 18 Nm
❑ For gearbox housing
cover.
2 - Gearbox housing cover
Note
3 - Seal
4 - Bolt, 80 Nm + turn 90° fur‐
ther
❑ Always renew
❑ Fitted section of bolt
head holds dished
spring washer in posi‐
tion
❑ Clean residual locking
fluid from threaded
holes for synchro-hub
securing bolts and 5th
gear wheel with a thread
chaser. Otherwise the
bolts may shear. n AG. Volkswagen AG do
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5 - Dished washer byV
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❑ Installing ⇒ page 246 ir se tee
tho
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6 - Socket head bolt, 25 Nm ss
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❑ For pivot pin to gearbox

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housing
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7 - Pivot pin
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8 - 5th gear selector fork

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❑ Dismantling and assem‐

spec
bling ⇒ page 258

t to the co
❑ Adjusting ⇒ page 247

9 - Spring
rrectne
❑ Version with bent ends.

ss o
10 - Locking collar for 5th gear

cial p
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11 - Locking pieces (Qty. 3)

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12 - Synchro-hub with synchromeshed gear and synchronizing ring for 5th gear
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❑ Pull off together with gearbox housing ⇒ page 234 t. Cop py
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❑ Pull off individually ⇒ page 228
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13 - Needle bearing
14 - Gear wheel for 5th gear
❑ Pull off together with gearbox housing ⇒ page 234
❑ Pull off individually ⇒ page 228

9.4 Removing and installing gearbox housing and

lksw
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1 - Countersunk bolt, 25 Nm tho or
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2 - Flange shaft with compres‐
ce
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⇒ page 294
pe
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❑ Assembling
wit
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⇒ page 303
hole
spec
3 - Torx socket head bolt, 25
es, in part or in w
Nm
t to the co
❑ For reverse shaft sup‐
port.
rrectness of i
❑ Self-locking
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❑ Always renew
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❑ Self-locking
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7 - Bolt, 25 Nm
AG.
8 - Bolt, 25 Nm
9 - Cover plate
10 - Multi-point socket head
bolt 25 Nm
port.
❑ Always renew
11 - Bolt, 5 Nm
12 - Gearbox neutral position sender -G701-
❑ for vehicles with start/stop system
13 - Gearbox housing
❑ Pull off together with 5th gear ⇒ page 234
❑ Repairing ⇒ page 248
14 - Clutch housing
15 - Hexagon bolt, 25 Nm and turn 90° further
❑ Always renew
16 - Selector shaft with selector shaft cover
❑ (Selector unit)
17 - Multi-point socket head bolt 25 Nm

9.5 Removing and installing input shaft, output shaft, differential and selector
forks
1 - Differential
bling ⇒ page 303
AG. Volkswagen AG d
2 - Seal lksw
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❑ Qty. 4 ed by ara
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❑ Always renew ut
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3 - Output shaft
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bling ⇒ page 275
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4 - Reverse shaft support
wit
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hole
bling ⇒ page 291
spec
es, in part or in w
5 - Reverse shaft
t to the co
bling ⇒ page 291
rrectness of i
6 - Input shaft
l purpos

bling ⇒ page 263
nform
ercia
7 - Selector fork for reverse

gear
m
at
om
io
n
c
in t
r
bling ⇒ page 258

o
his
ate
do
priv
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⇒ page 241
um
for
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9 - Selector mechanism
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❑ (Selector forks)
AG.

bling ⇒ page 258
10 - Clutch housing
11 - Hexagon nut, 25 Nm and then turn 90° further
❑ 4 nuts for bearing support.
❑ Always renew
12 - Flange shaft with compression spring
❑ Assembling ⇒ page 303
13 - Countersunk bolt, 25 Nm

9.6 Assembly sequence - removing and in‐

stalling cover for gearbox housing and
5th gear
Note
♦ Follow the working procedure described below if only the 5th

gear has to be removed: agen
AG. Volkswagen AG d
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If the gearbox housing has tod bbe y V removed, follow the working t gua
o
♦ ran
procedure: Dismantling and oris assembling gearbox completely
e
tee
⇒ page 234 . aut
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equipment required
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♦ Support plate -VW 309-
is n
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ole,
♦ Gearbox support -VW 353-
spec
♦ Drift -VW 295-
t to the co
♦ Drift sleeve -VW 244 B-
rrectne
♦ Hot air blower -V.A.G 1416-
s
1331-
s o
cial p
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♦ -Zweiarmabzieher Kukko
form
mer
210.1-
atio
m
♦ -Stehbolzen M 8 x 100 mm-

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♦ Support bridge -30-211A-
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tool -T10030/4-
spec
es, in part or in w
♦ Tube -VW 416 B-
t to the co
♦ Puller -T10309-
rrectness of i
♦ Two arm puller -T10040-
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♦ With puller hooks -
T10040/2A-
nform
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♦ Thrust piece -T10040/3-
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♦ Support device -T10323-

♦ Assembly tool -3253/7-
♦ Thrust piece -VW 433-
♦ Thrust plate -40 - 105-
1332-
AG. Volkswagen AG d
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9.6.1 Removing ss c
ce
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nl
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du
– Remove clutch release lever and release bearing

an
itte
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⇒ page 103 .
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230
Prote AG.
• Bearings of input shaft and output shaft must not be damaged

when 5th gear is removed and installed.
• Therefore, following tools must be mounted for support at this
stage during attachment of gearbox to gearbox support -VW
353- :
Underneath input shaft:
• The input shaft can be supported by the thrust piece -32 - 111-
only at a later point.
Underneath bearing support for output shaft:
lkswage es n
– Secure gearbox on gearbox support -VW 353-d b. y Vo ot g
ua
ran
ir se tee
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– Remove gearbox housing cover -arrow-.
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Prote AG.

– Check whether puller hooks -T10040/2A- can be inserted cor‐

rectly under 5th gear wheel.
Puller hooks -T10040/2A- cannot be inserted correctly.
-A- Removal of “synchro-hub
Puller hooks -T10040/2A- make for 5th gear”, “gear wheel
contact too soon with: for 5th gear” and “gearbox
♦ gearbox housing wall housing” “together”
⇒ page 234
♦ ribs in gearbox housing under
gear wheel
-B-
Puller hooks -T10040/2A- come
into contact with ribs in gearbox
housing below gear wheel.
Puller hooks -T10040/2A- cannot be inserted correctly.

5th gear can be removed separately, ⇒ from ⇒ page 232
Removing 5th gear separately

– Cover openings with a cloth.
– Move selector fork -1- to neutral position.
– Remove bolt -2- with selector fork for 5th gear.
– Then remove both bolts -arrows- for pivot pins.
– Pull out pivot pins.
– Remove selector fork.
– Spring -3- and locking collar -4- do not need to be removed.
en AG. V
olkswagen AG
ag does
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– Remove bolts -A- for synchro-hub andhogear
ris wheel for 5th gear. nte
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To do this, engage 5th gear -arrows au1-
t
and 1st gear ra
c
-arrows 2- and -3- s
ce
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.
nl
pt
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– After both gears are engaged, the input shaft and output shaft
erm
ab
are locked. The synchro-hub and gear wheel cannot turn. Both
ility
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bolts can now be loosened.

wit
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spec
Note
es, in part or in w
t to the co
If shafts are not to be renewed, carefully clean residual locking

material out of threaded holes using a thread chaser.
rrectness of i
Pull off synchro-hub for 5th gear together with locking collar and
l purpos
locking pieces.
Use puller -T10309- .
nf
ercia
orm
– First set half sleeve -T10309/1- between 5th gear wheel -A-
m
atio
m
and support for selector fork for 5th gear -B-.

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• The half sleeve -T10309/1- must be positioned beneath the

synchro-ring.
– If necessary, half sleeve must be pressed to end position.
– Then turn half sleeve -T10309/1- to opposite side
– Set threaded insert -T10309/3- in half shell .

– Now fit second half shell -T10309/1- and set tube -T10309/2-
over assembly. wage
e ks s no
Vol t
– After parts are pulled
ed
by off, check synchro-hub for damage.
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– Renew synchro-ring.
au
th ra
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– Remove 5th gear synchromeshed gear with needle bearing.
ce
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– Pull off gear wheel for 5th gear. (Shown here on another gear‐
nform
ercia
box.)
m
– First set up puller hooks -A-.

a
com
tion in
B - Thrust plate -40 - 105-

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fo
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When pulling off gear wheel, ensure that hooks do not bend out‐ t. C rig
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wards. After pulling off gear wheel for 5th gear, examine for pyri by
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damage.
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9.6.2 Installing
Install 5th gear ⇒ page 244 .
– Apply sealant -AMV 188 200 03- evenly to sealing surface of
gearbox cover.
– Install gearbox housing cover ⇒ page 225 .
– Fit clutch release lever and release bearing ⇒ page 103 .
– Top up gear oil ⇒ page 150 .

9.7 Assembly sequence - Dismantling and assembling gearbox completely

Removing and installing gearbox housing cover, gearbox hous‐
ing, selector shaft with selector mechanism cover, input shaft,
output shaft, differential and selector mechanism.

equipment required
♦ Support plate -VW 309-
♦ Gearbox support -VW 353- AG. Volkswagen AG d
agen oes
♦ Drift -VW 295- olksw not
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d b ara
♦ Drift sleeve -VW 244 B- rise nte
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♦ Hot air blower -V.A.G 1416- ss c
ce
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un
pt
♦ Torque wrench -
an
d
V.A.G 1331- itte
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rm
ab
pe
ility
♦ -Stehbolzen M 8 x 100 mm-
ot
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es, in part or in w
t to the co
rrectness of i
l purpos
nform
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tion in
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te o
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AG. Volkswagen AG d
agen
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oes ➤ , Golf Plus 2005 ➤ , Golf Plus 2009 ➤ , Pass ...
ol not
V gu5-speed manual gearbox 0A4
d by ara - Edition 04.2010
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♦ Support bridge -30-211A- ss
ce
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pt
an
d
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ab
♦ Thrust piece from assembly
ility
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tool -T10030/4-
wit
is n
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♦ Tube -VW 416 B-
ole,
spec
♦ Puller plate -T10408-
t to the co
♦ Thrust pieces -T10408/2-
♦ Grips -T10408/3-
rrectne
♦ Hexagon bolts M7 x 35 with
washers
ss o
♦ Puller - 2 Kukko 18/1-
cial p
f inform
mer
atio
om
n
c
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Prote AG.

AG. Volkswagen AG d
agen oes
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Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus
aut 2005 ➤ , Golf Plus 2009 ➤ , Pass ...
h
ra
s c
s 04.2010
ce
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pt
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ab
ility
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spec
es, in part or in w
t to the co
1332-
rrectness of i
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nform
mercia
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ion
c
in t
or
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ate
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cum
for
en
ng
t.
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Prote AG.
9.7.1 Removing
– Remove clutch release lever, release bearing and guide
sleeve ⇒ page 103 .
• Bearings of input shaft and output shaft must not be damaged
when 5th gear is removed and installed.
• Therefore, following tools must be mounted for support at this
stage during attachment of gearbox to gearbox support -VW
353- :
Underneath input shaft:
– Lock bolt of support bridge -30-211A- with nut -A-.
Underneath bearing support for output shaft:

– Secure gearbox on gearbox support -VW 353- .

– Place drip tray -V.A.G 1306- underneath.
– Remove oil filler plug and oil drain plug.
– Drain gear oil.
– Remove gearbox housing cover -arrow-.
AG. Volkswagen AG d
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Remove selector fork for 5th gear as follows:sed b ara
nte
ri
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– Cover openings with a cloth. aut
h
ra
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– Move selector fork -1- to neutral position.
ce
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nl
pt
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an
– Remove bolt -2- with selector fork for 5th gear.
itte
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erm
ab
– Then remove both bolts -arrows- for pivot pins.
ility
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– Pull out pivot pins.
h re
hole
spec
– Remove selector fork.
es, in part or in w
t to the co
– Spring -3- and locking collar -4- do not need to be removed.
rrectness of i
– Remove bolts -A- for synchro-hub and gear wheel for 5th gear.
To do this, engage 5th gear -arrow 1- and 1st gear
l purpos
-arrows 2- and -3-.

nf
ercia
are locked. The synchro-hub and gear wheel cannot turn. Both
orm
bolts can now be loosened.

m
atio
om
n in
or c
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Note
t
sd
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If shafts are not to be renewed, carefully clean residual locking

f
en
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t.
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material out of threaded holes using a thread chaser.
Co
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– Remove both bolts -arrows- for reverse shaft support bracket.
– Now remove 3rd bolt -arrow- for reverse shaft support bracket.
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ility
– Gearboxes for vehicles with start-stop system: remove gear‐
ot p
box neutral position sender -G701- -arrow-.
wit
is n
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ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
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– Remove selector shaft with selector mechanism cover, placing

o
n
c
i
or
selector shaft in neutral position. Then remove bolts -arrows-

thi
e
and pull selector shaft out of gearbox housing.

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Volkswa
– Remove cover plate -A- and pivot agpins
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hole
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es, in part or in w
t to the co
– Remove pivot pins -A- on top side of gearbox and securing
bolts -B- for gearbox housing to clutch housing in area of dif‐
rrectness of i
ferential.
l purpos
nform
mercia
a
com
tion in
r
te o
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– Remove bolts -A- from clutch housing side for securing clutch
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Note
Do not remove nuts -B- for output shaft bearing support.
– Remove both flange shafts.

– Remove flange shafts together with springs, thrust washers
and tapered rings.

Pull off following components together with gearbox housing:

♦ Synchro-hub for 5th gear
♦ Gear wheel for 5th gear
• Both grips -T10408/3- must be secured on gear wheel for 5th
gear.
• The grips must always be positioned above the two housing
ribs, which are located opposite each other -arrows-.
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Use puller plate -T10408- in conjunction with following special
ole,
tools:
spec
♦ Thrust pieces -T10408/2-
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♦ Grips -T10408/3-
rrectne
♦ Puller Kukko 18/1
– Screw puller plate -T10408- firmly into threaded holes for
ss
gearbox housing cover.
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A - Hexagon bolts M7 x 35 with washers
form
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Torque setting 18 Nm
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– Place thrust pieces -T10408/2- on shafts.
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– Install pullers Kukko 18/1 -A-.
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– Heat gear wheel for 5th gear slightly with hot air blower -
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V.A.G 1416- if necessary.

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– Remove selector forks -A- together with selector plates.
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– Unbolt reverse gear selector mechanism -B-.
erm
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– Remove nuts -B- for output shaft bearing support.
nform
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atio
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– Remove reverse gear -A-, input shaft -B- and output shaft
-C- one after the other from clutch housing.
– Remove differential.
9.7.2 Installing
– Install differential.
– Always renew sealing rings -arrows- for output shaft bearing
support.
Note
The figure shows only 3 of the 4 sealing rings.

– Insert input shaft -1- and output shaft -2- together. AG. Volkswagen AG d
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– Tighten nuts for output shaft bearing support to specified
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– Set reverse gear wheel -3- on needle bearing
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The shoulder -arrow- faces away from the clutch housing.
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– Ensure that reverse shaft -4- is complete ⇒ page 291 ; do not
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– Fit reverse shaft into clutch housing. hole
spec
es, in part or in w
– Clean locking fluid from all threaded holes in reverse shaft
t to the co
support; a thread chaser may be used.
– Install reverse shaft support.
rrectness of i
– Attach reverse gear selector fork -1- with support for reverse
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gear selector fork -2-, spring -3- and sliding piece -4-.
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Installation position, reverse gear
– Bolt on reverse gear selector mechanism -A-.

– Install selector forks -B- together with selector plates.
Reverse gear support -C- is located in front of selector plates.

– Screw M 8 x 100 mm studs -A- into reverse shaft support so

that shaft is aligned after gearbox housing is fitted.
– Align selector plates.
Note
The selector segments must be positioned in the grooves on the

locking collars.

clutch housing.
– Fit gearbox housing.
Install reverse shaft support bolts -arrow- as follows:
– Install bolt -a-.
– Remove stud -A- (⇒ figure above).
– Install bolt -c-.

Tightening sequence:
– Tighten bolt -a- to 30 Nm.
– Tighten bolt -b- (⇒ figure below) to 25 Nm.
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selector shaft cover.
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– Bolt on selector shaft cover to specified torque
es, in part or in w
⇒ Item 17 (page 226) .
t to the co
– Gearboxes for vehicles with start-stop system: fit gearbox
rrectness of i
neutral position sender -G701- -arrow- and tighten securing
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bolt to specified torque ⇒ Item 11 (page 226) .
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– Install both flange shafts with springs, thrust washers and ta‐
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pered rings ⇒ page 224 .
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9.7.3 Installing 5th gear

• Ensure that support bridge -30-211A- and support device -
T10323- are attached.
– Lock bolt of support bridge -30-211A- with nut -A-.

Installation position, gear wheel for 5th gear

The circumferential groove -arrow- faces gearbox housing.
– Drive on gear wheel for 5th gear.
Checking 5th gear synchro-ring

– Before installing synchromeshed gear and synchro-ring for 5th
gear, press synchro-ring onto cone of synchromeshed gear
and measure gap -a- with a feeler gauge.
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– Place 5th gear synchro-ring on synchromeshed gear.
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Installation position 5th gear synchro-hub and locking collar spec

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The pointed teeth of the locking collar -arrow 1- and the high
t to the co
shoulder of the synchro-hub -arrow 2- face the gearbox housing.

The synchro-hub supports -arrow 3- align with the cast locking
rrectness of i
pieces of the 5th gear synchro-ring ( ⇒ page 246 , bottom).

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5th gear synchro-ring with cast locking pieces

– Cover all openings in gearbox housing with a cloth to prevent
foreign bodies from entering gearbox.
– Drive on 5th gear synchro-hub.
Note
When driving on synchro-ring, ensure that it moves freely.
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– Clean residual locking fluid from threaded holes for synchro-
wit
hub securing bolts and 5th gear wheel with a thread chaser.
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Otherwise the bolts may shear.
spec
es, in part or in w
– Screw in securing bolts for synchro-hub and gear wheel for 5th
t to the co
gear.
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Installation position of dished springs for securing bolts for gear

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The outer circumference -arrows- faces 5th gear.

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gear to specified torque. ⇒ page 225
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– Tighten bolts -A- for synchro-hub and 5th gear wheel to speci‐
fied torque ⇒ Item 4 (page 225) . To do this, engage 5th gear
-arrow 1- and 1st gear -arrows 2- and -3-.
are locked. The synchro-hub and gear wheel cannot turn. Now
both bolts can be tightened.
– Install 5th gear selector fork.
Adjusting 5th gear

– Engage 5th gear. Loosen bolt -1-. Push locking collar and se‐
lector jaw in direction of arrow and then tighten bolt -1- to 25
Nm.
• Check measurement: It must not be possible to slide a 0.2 mm
feeler gauge between locking collar and gear wheel. If neces‐
sary, repeat adjustment.
– Disengage 5th gear. Locking collar must now be in the neutral
position. Synchro-ring must move freely.
– Shift through all gears.
– Install gearbox housing cover ⇒ page 225 .
– Fit release bearing guide sleeve ⇒ page 103 .
– Fit clutch release lever and release bearing ⇒ page 103 .
– Top up gear oil, Golf 2004 ▸ ⇒ page 150
– Top up gear oil, Golf 2009 ▸ with turbo diesel engine
⇒ page 163
– Top up gear oil, Golf 2009 ▸ with petrol engine ⇒ page 180
– Top up gear oil, Golf Plus ⇒ page 197 . AG. Volkswagen AG d
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– Top up gear oil, Passat ⇒ page 212 . d by
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247
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Prote
cted 9. Dismantling and assembling gearbox
AG.
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10 Repairing gearbox housing and clutch housing

equipment required
♦ Drift -VW 295-
♦ Adapter -VW 295 A-
♦ Thrust pad -VW 447 H-
♦ Thrust pad -VW 512-
♦ Tube -2040-
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is n
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♦ Assembly device -3066-
spec
(Spindle from assembly de‐
t to the co
vice)
♦ Thrust piece -3124- (for
two-part seal and sleeve)
rrectne
♦ Multipurpose tool -VW 771-
(for one-piece seal and
ss o
sleeve)
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♦ Extractor hooks -
mer
VW 771/37- (for one-piece
atio
m
seal and sleeve)

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♦ Multipurpose tool -T10148- (for one-piece seal and sleeve)
10. Repairing gearbox housing and clutch housing 249

5-speed manual gearbox 0A4e-nEdition
AG. Volks04.2010
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1 - Gearbox housing ed
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❑ If renewed: adjust au
t out‐
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ra
put shaft and differential
ss c
⇒ page 302
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2 - Needle bearing
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❑ For output shaft
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❑ Removing ⇒ page 252
, is n
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❑ Installing and securing
hole
spec
⇒ page 252 .
es, in part or in w
t to the co
3 - Oil filler plug, 35 Nm
❑ The oil level cannot be
checked by removing
rrectness of i
the oil filler plug
l purpos
❑ If the gearbox was dis‐

mantled, it must be filled
prior to installation
nform
ercia
Capacities, Golf 2004 ▸

m
a
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t
⇒ page 2
ion in
r
te o
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Capacities, Golf 2009 ▸
s
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⇒ page 4
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Capacities, Golf Plus 2005 ▸

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⇒ page 6 ⇒ page 5
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Capacities, Passat ⇒ page 6
4 - Tapered roller bearing outer

race
⇒ page 275
❑ If replaced: adjust out‐
put shaft ⇒ page 287
5 - Shim
❑ Adjustment overview ⇒ page 302
6 - Shim
❑ For input shaft
7 - Tapered roller bearing outer race
❑ For input shaft
❑ If renewed: adjust input shaft ⇒ page 270
❑ For input shaft
❑ If renewed: adjust input shaft ⇒ page 270
9 - Needle bearing
10 - Dowel sleeve
❑ Qty. 2

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11 - Clutch housing
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❑ When renewing, ⇒ adjustment overview ⇒ page 302
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12 - Guide sleeve
is n
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❑ With input shaft seal and vulcanised O-ring
spec
❑ Driving out oil seal ⇒ page 252
t to the co
❑ Driving in oil seal ⇒ page 252
❑ Remove guide sleeve to change oil seal
rrectne
❑ If O-ring is damaged, renew guide sleeve and O-ring together
13 - Socket head bolt
ss o
❑ Removing and installing ⇒ Item 6 (page 103)
cial p
f inform
14 - Seal
mer
atio
❑ Renewing ⇒ page 296
om
n
c
i
or
n
15 - Sleeve
thi
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sd
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❑ For seal ⇒ Item 14 (page 251)

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❑ Installing ⇒ page 253 . Cop py
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16 - One-piece seal and sleeve py by
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❑ If seal is damaged, renew seal and sleeve together cted agen
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17 - Oil drain plug, 35 Nm
❑ For differential
❑ If renewed, adjust differential ⇒ page 311
19 - Magnet
❑ Held in place by housing joint surface
20 - Oil collector
❑ Installing oil collector in gearbox housing ⇒ page 254
❑ If renewed, adjust differential
⇒ page 311
22 - Shim
23 - Seal
❑ Renewing ⇒ page 294

Driving out needle roller bearing
Driving needle bearing in to stop

– Secure needle bearing in gearbox housing at three points
(120° offset) using a punch.
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Driving oil seal into guide sleeve to stop

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Levering out sleeve -arrow- using screwdriver
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Pulling in sleeve
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– Screw spindle -A- of assembly device -3066- into threaded
h re
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piece of differential.
spec
– Pull sleeve in to stop using thrust piece -3124- by turning nut
t to the co
-B-.
rrectne
Note
ss
With gearbox dismantled, press sleeve in to stop using thrust
o
cial p
f
piece -3124- .
inform
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Pulling out sleeve and seal
n
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There is a shoulder in the inner diameter of the sleeve.

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– To pull out seal and sleeve, apply extractor hooks -VW 771/37-
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Pulling in sleeve and seal

– Clean seat for seal in gearbox.
– Screw spindle -A- of assembly device -3066- into threaded
piece of differential.
– Pull sleeve in to stop using thrust piece -T10148- by turning
nut -B-.
Note
With gearbox dismantled, press sleeve in to stop using thrust

piece -T10148- .

Installing oil collector -A- in gearbox housing

– Insert oil collector in hole -arrow 1- and groove -arrow 2- si‐
multaneously.
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11 Repairing selector unit
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♦ Tube -VW 423-

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11. Repairing selector unit 255

1 - Selector unit
❑ Consists of selector
shaft and selector shaft
cover
❑ Components cannot be
separated from each
other
2 - Reversing light switch -F4-
❑ Tighten to 20 Nm
❑ Lightly coat lug with
MoS2 grease.
3 - Angled rod
❑ For adjusting selector
mechanism
❑ Pressing in
⇒ page 257
4 - Relay lever
⇒ page 134
❑ From 05.07, plastic re‐
lay lever ⇒ page 134
5 - Bearing bush
❑ Not required for plastic
relay lever
6 - Seal
❑ Lever out with a screw‐
driver
❑ Installing ⇒ page 257 n AG. Volkswagen AG do
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❑ Install so that master spline aligns with selector shaft

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❑ Can be renewed with the selector mechanism installed

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9 - Cap
spec
es, in part or in w
❑ For gearbox breather

t to the co
10 - Securing clip
❑ Always renew
rrectness of i

l purpos
11 - Cover plate
nform
ercia
12 - Spring
❑ Not installed in all gearboxes.
m
at
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❑ Reinstall if part of original equipment.

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Removing angled rod -A- from selector shaft cover

– Remove outer part of angled rod.
– Then carefully lever out angled rod using a screwdriver.
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Pressing angled rod -A- into selector
utho shaft cover eo
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Installation position: s
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Marking -arrow- points to upper part of selector shaft.
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Inserting oil seal to stop

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11. Repairing selector unit 257

12 Dismantling and assembling selector forks
Special tools and workshop AG. Volkswagen AG d

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♦ Thrust plate -VW 402- rised
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♦ Thrust piece -3290/1- ss a ra
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♦ Assembly tool -3301-

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♦ Spacer sleeve -VW 472/2-
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hole
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♦ Removal lever -80–200-

♦ Drift -10 - 508-
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♦ Clamp -2070-
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Note
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It is not necessary to dismantle the selector fork group

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( ⇒ Item 7 (page 260) ) in order to remove and install selector
f
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segments, lock washers and angular contact ball bearings.
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12. Dismantling and assembling selector forks 259

1 - 5th gear selector segment

❑ Identification
⇒ page 261
❑ After lock washer is in‐
stalled, selector seg‐
ment must still rotate
freely.
2 - Lock washer
❑ Always renew
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4 - Bolt, 25 Nm s au ra
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5 - 5th gear selector jaw
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6 - Angular contact ball bearing
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❑ Qty. 4
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❑ Press inner race into
spec
outer race ⇒ page 262
es, in part or in w
t to the co
7 - Selector fork group with se‐
lector plate
rrectness of i
8 - Selector segment for 1st
l purpos
and 2nd gears

❑ Identification
nform
ercia
⇒ page 261
m
a
❑ After lock washer is in‐
com
tio
stalled, segment must
n in
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still rotate freely
thi
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9 - Selector segment for 3rd
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❑ Identification ⇒ page 261 t. Cop py
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❑ After lock washer is installed, segment must still rotate freely
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Prote AG.
11 - Spring
12 - Selector fork for reverse gear
13 - Support for reverse gear selector fork
14 - Retaining ring

Identifying selector segments

Dimension -a-
1 - 1st and 2nd gear selector segments = 11.4 mm
2 - 3rd and 4th gear selector segments = 7.7 mm
3 - 5th gear selector segments = 12.1 mm
Removing lock washer

Volkswagen AG
– Clamp selector
swa
fork
gen Ain
G.vice with protective
does jaw covers -B-.
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– Leversoff
d b lock washer -A- in direction of arrow.
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Installing lock washer

t to the co
– Press lock washer into groove of selector segment using sock‐

et and spinner handle.
rrectness of i
l purpos
Note
nform
ercia
After lock washer is installed, selector segment must still rotate

freely.
m
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ion
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A - Spinner handle with 10 mm socket

o
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B - Protective jaw covers

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Removing angular contact ball bearing
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cted AG.
agen
When removing and installing angular contact ball bearing, do not

bend selector forks.
12. Dismantling and assembling selector forks 261

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Pressing inner race -A- of angular contact ball bearing into outer
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Inner race must engage in outer race.
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Pulling angular contact ball bearing into selector fork to stop

m
Depression in thrust piece -3290/1- faces ball bearing.
at
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Selector fork with selector segments installed

Dim. -a- (mm)
1st/2nd gear selector fork 87.2 …87.4
3rd/4th gear selector fork 93.6 …93.8
Selector segment assignment ⇒ page 261

35 – Gears,
wage
nshafts
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Input shaft
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1.1 Dismantling and assembling input shaft
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equipment required
h re
ole,
spec
♦ Press tool -VW 407-
t to the co
rrectne
♦ Tube -VW 422-
s
♦ Thrust plate -VW 401-
s o
cial p
f
inform
mer
♦ Press tool -VW 408 A-
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c
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1. Input shaft 263

♦ Tube -VW 421-

♦ Thrust pad -VW 447 i-
♦ Thrust pad -VW 510- n AG. Volkswagen AG do
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♦ Drift sleeve -41-501- d b ua
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♦ -3- Splitter -Kukko 17/1- aut or
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Note
♦ When installing new gear wheels or input shaft, consult technical data ⇒ page 2 and ⇒ Electronic parts
♦ If the position of the tapered roller bearings is affected when parts are exchanged, the input shaft must be
readjusted. See adjustment overview ⇒ page 302 .
264 Rep. Gr.35 - Gears, shafts

1 - Clutch housing
race
❑ Pressing out
⇒ page 266 agen
AG. Volkswagen AG d
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❑ Pressing in d by
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⇒ page 266 orise nte
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3 - Tapered roller bearing inner ss a c
race
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❑ Pressing off
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⇒ page 267
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❑ Pressing on
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⇒ page 267
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4 - Input shaft
spec
es, in part or in w
t to the co
5 - Gear wheel for 3rd gear
❑ Installation position:
rrectness of i
shoulder faces 4th gear
l purpos
❑ Pressing off
⇒ page 267
nf
ercia
❑ Pressing on
or
⇒ page 268
m
m
atio
m
6 - Retaining ring
o
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or c
❑ Always renew
thi
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❑ Pressing off with ta‐ yi

t.
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pered roller bearing out‐ t. Cop py
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rig
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⇒ page 267 op Vo
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❑ Pressing on Prote AG.
⇒ page 268
❑ Collar faces 3rd gear
8 - Tapered roller bearing inner race
❑ Pressing off with gear wheel and sleeve for 4th gear ⇒ page 267
❑ Pressing on ⇒ page 268
9 - Thrust washer
❑ Pressing out ⇒ page 269
❑ Pressing in ⇒ page 269
11 - Shim
❑ Determining thickness ⇒ page 270
13 - Sleeve
❑ For needle bearing
❑ Press off with gear wheel for 4th gear and tapered roller bearing inner race ⇒ page 267
❑ Set thrust washer ⇒ Item 9 (page 265) in place before installing
1. Input shaft 265

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5-speed manual gearboxised0A4
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14 - Needle bearing ss
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15 - Synchromeshed gear for 5th gear
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16 - Synchro-ring for 5th gear
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ab
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❑ With cast locking pieces ⇒ page 246
ot
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❑ Check for wear ⇒ page 245
h re
hole
spec
17 - Spring
es, in part or in w
t to the co
❑ After gearbox construction date 05 11 1: Bent ends on springs ⇒ page 270
rrectness of i
18 - Locking pieces (Qty. 3)
l purpos
19 - Synchro-hub for 5th gear
nform
ercia
❑ Pulling off, from ⇒ page 234 .

m
20 - Locking collar for 5th gear
a
com
tion in
❑ Pulling off with synchro-hub for 5th gear, from ⇒ page 234 .
r
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21 - Dished washer
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22 - Bolt ⇒ Item 4 (page 225)
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❑ Always renew
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❑ Fitted section of bolt head holds dished spring in position ⇒ page 246 .
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Pressing out tapered roller bearing outer race
Pressing in tapered roller bearing outer race

Pressing off tapered roller bearing inner race

AG. Volkswagen AG d
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A - Splitter -Kukko 17/1- Volksw
oes
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Pressing on tapered roller bearing inner race
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Pressing off gear wheel for 4th gear with tapered roller bearing
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Pressing off gear wheel for 3rd gear
1. Input shaft 267

Pressing on gear wheel for 3rd gear
Pressing on gear wheel for 4th gear

Shoulder faces 3rd gear

AG. Volkswagen AG d
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Pressing on sleeve for needle bearing

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Pressing out tapered roller bearing outer race
AG. Volkswagen AG d
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Pressing in tapered roller
ss au
bearing outer race ra
c
ce
le
– Install with shim after adjusting input shaft.

un
pt
an
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ility
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5th gear synchronization

1- Springs for lock pieces
nform
ercia
2- Locking collar with 3 recesses -arrows A- for the locking

m
pieces -item 4- a
com
tion in
r
3- Synchro-hub
te o
thi
s
iva
do
4- Locking pieces - installation position: thin extension

r
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cum
-arrow B- faces the pointed teeth of the locking collar -2-

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Prote AG.
Assembling 5th gear locking collar/synchro-hub

– Slide locking collar over synchro-hub.
Pointed teeth -A- and shoulder -B- of synchro-hub face in same
direction. The recesses for the locking pieces in locking collar and
synchro-hub must be aligned ( ⇒ page 269 ).
– Insert locking pieces (installation position ⇒ page 269 ).
– Install springs below shoulder -C-, offset 120°. Springs must
seat with angled ends in front of locking pieces -arrows-.
1. Input shaft 269

Installing springs with bent ends -A-

These springs are installed on both sides.
– Spring are installed only in conjunction with locking pieces
which are hollow on the inner side.
– Insert locking pieces (installation position ⇒ page 269 ).
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Installation position of springs: o
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– Install springs offset 120°. ss
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– Angled end -A- of spring must locate in hollow locking piece.
pt
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It must be located under shoulder -B- of locking piece.
erm
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ility
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Bent ends always face away from synchro-hub
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hole
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es, in part or in w
t to the co
rrectness of i
1.2 Adjusting input shaft
l purpos
(Determining input shaft shim)
nform
mercia
at
om
ion
c
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equipment required
♦ Universal dial gauge brack‐
et -VW 387-
♦ End dimension plate -
VW 385/17- gen AG
. Volkswagen AG
d
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♦ Thrust padd-VW
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ara
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♦ Thrustuthpad
o -VW 447 i- eo
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1331-
rm
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♦ Dial gauge
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es, in part or in w
t to the co
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It is necessary to readjust the input shaft only when the following

components are renewed:
♦ Gearbox housing
♦ Clutch housing
♦ Input shaft
♦ Gear wheel for 4th gear
or the
♦ Tapered roller bearings
Adjustment overview ⇒ page 302
Requirement:
• Sealing surfaces of clutch and gearbox housings must be free
of sealant.
1. Input shaft 271

– Press tapered roller bearing outer race into gearbox housing

to stop.
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– ut roller bearing outer race without shim into gear‐
Press tapered
a ra
s c
box housing
s to stop.
ce
le
un
pt
– Install input shaft in clutch housing and set gearbox housing
an
d
itte
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in place. Tighten hexagon head bolts to 25 Nm and then turn
erm
ab
90° further.
ility
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wit
is n
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t to the co
rrectne
– Fit measuring appliance and dial gauge in clutch housing.
ss o
cial p
– Before taking any measurements, rotate input shaft to allow

f in
bearings to settle. Set dial gauge to “0” with 1 mm preload.

form
mer
atio
om
n
c
Note
i
or
n thi
te
sd
iva
This step must be repeated for each subsequent measurement,

o
pr
cum
r
fo
or the dial gauge will not return to the starting position.

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Cop py
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– Press input shaft in direction of dial gauge
– Read and note play on dial gauge (example: 1.21 mm).
Note
Dial gauge does not return to original position.
1.2.1 Determining thickness of shim

Example:
Bearing play, measured value Thickness of shim according to
table
1.21 mm 1.175 mm

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Table of shims
nl
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Bearing play Shim
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Measured value (mm) Thickness (mm)
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0.671…0.699 0.650
h re
hole
0.700…0.724 0.675
spec
0.725…0.749 0.700
es, in part or in w
t to the co
0.750…0.774 0.725
0.775…0.799 0.750
0.800…0.824 0.775
rrectness of i
0.825…0.849 0.800
l purpos
0.850…0.874 0.825
0.875…0.899 0.850
0.900…0.924 0.875
nform
ercia
0.925…0.949 0.900
m
0.950…0.974 0.925
at
om
ion
c
0.975…0.999 0.950
in t
or
1.000…1.024 0.975
his
ate
1.025…1.049 1.000
do
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1.050…1.074 1.025
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1.075…1.099 op
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1.100…1.124 1.075
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1.125…1.149 1.100
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cted 1.125 AG.
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1175…1.199 1.150
1.200…1.224 1.175
1.225…1.249 1.200
1.250…1.274. 1.225
1.275…1.229 1.250
1.300…1.324 1.275
1.325…1.349 1.300
1.350…1.374 1.325
1.375…1.399 1.350
1.400…1.424 1.375
1.425…1.449 1.400
1.450…1.474 1.425
1.475…1.499 1.450
1.500…1.524 1.475
1.525…1.549 1.500
1.550…1.574 1.525
1.575…1.599 1.550
1.600…1.624 1.575
1.625…1.649 1.600
1.650…1.674 1.625
1.675…1.699 1.650
1.700…1.724 1.675
Note
Allocate shims according to ⇒ Electronic parts catalogue “ETKA” .
– Remove input shaft and press outer race of tapered roller

bearing out of gearbox housing using thrust plate -VW 447 i- .
– Insert shims of determined thickness, thickest shim first.
If the size of shim required is larger than those listed in the table,
insert two shims totalling the correct figure.
– Press outer race of tapered roller bearing together with the
shim (1.175 mm in example) into gearbox housing using thrust
pad -VW 510- .
1. Input shaft 273

– Set gearbox housing in place and tighten hexagon head bolts

to 25 Nm and then turn 90° further.
1.2.2 Carrying out check measurement

– Set up measuring appliance and dial gauge.
– Rotate input shaft so that tapered roller bearings settle.
– Press input shaft in -direction of arrow-.
– Bearing play should be min. 0.01 ... max. 0.09 mm.
Note
If the bearing play cannot be measured, but input shaft play is

perceptible and the input shaft turns freely, the adjustment is ac‐
ceptable.
AG. Volkswagen AG d
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ility
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es, in part or in w
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Prote AG.

2 Output shaft
2.1 Dismantling and assembling output shaft

equipment required
♦ Puller -V.A.G 1582-
♦ Adapter -V.A.G 1582/4-
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2. Output shaft 275


AG. Volkswagen AG d
♦ Thrust piece -32 - 111- ksw
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♦ Thrust ring -VW 429-

♦ Tube -VW 415 A-
♦ Installing sleeve -VW 455-
♦ Drift sleeve -41-501-
AG. Volkswagen AG d
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♦ Internal puller -1-Kukko 21/6-

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♦ Counter support -4-Kukko 22/2-

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♦ Splitter -3-Kukko 17/2-

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2. Output shaft 277

Note
♦ The output shaft is dismantled as follows: position separating device under 2nd gear synchromeshed gear
⇒ Item 21 (page 279) and press off as described in ⇒ page 281 . Remove retaining ring
⇒ Item 17 (page 279) . Then press off locking collar with synchro-hub for 1st and 2nd gear as described in
⇒ page 282 .
♦ When installing new gears or new input shaft, refer to ⇒ Electronic parts catalogue “ETKA” and technical
data ⇒ page 2 .
♦ Always renew both tapered roller bearings together as a set.
1 - Hexagon nut, 25 Nm and

then turn 90° further
❑ 4 nuts for bearing sup‐
port.
❑ Always renew
2 - Clutch housing
3 - Shim
❑ Adjustment overview AG. Volkswagen AG d
⇒ page 302 agen oes
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4 - Small tapered roller bearing rised
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❑ Removing ⇒ page 280 s
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❑ Pressing in
du
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⇒ page 281
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5 - Tapered roller bearing inner
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❑ Pulling off ⇒ page 281
hole
spec
❑ Pressing on
es, in part or in w
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⇒ page 281
6 - Output shaft rrectness of i
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race large
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❑ Pressing on
m
at
⇒ page 282
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8 - Seal
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❑ Place sealing rings (Qty.

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10 - Thrust washer
❑ Shoulder of thrust washer faces tapered roller bearing
11 - Synchromeshed gear for 1st gear
12 - Needle bearing
❑ For 1st gear

13 - Synchro-ring
❑ (Inner ring for 1st gear)
AG. Volkswagen AG d
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14 - Outer ring for 1st gear rised
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❑ Installation position ⇒ pages au282
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❑ Renew if scored
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15 - Synchro-ring for 1st gear
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16 - Locking collar with synchro-hub for 1st and 2nd gears
es, in part or in w
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❑ After removing retaining ring, pull off together with bearing support ⇒ page 282 ⇒ Item 17 (page 279)
❑ Dismantling ⇒ page 283
rrectness of i
❑ Assembling locking collar and synchro-hub ⇒ page 283 , ⇒ page 284 and ⇒ page 284
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17 - Retaining ring
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18 - Synchro-ring for 2nd gear
com
tion in
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❑ Assemble so that notches engage in locking pieces of locking collar ⇒ Item 16 (page 279)
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19 - Outer ring for 2nd gear
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❑ Insert in synchro-ring ⇒ Item 18 (page 279) .
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❑ Renew if scored
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20 - Synchro-ring
❑ (Inner ring for 2nd gear)
❑ Check lugs for scoring
21 - Synchromeshed gear for 2nd gear
22 - Needle bearing
❑ For 2nd gear
23 - Thrust washer
24 - Sleeve for 3rd gear needle bearing
❑ Pressing off with synchromeshed gear for 2nd gear ⇒ page 281
25 - Needle bearing
❑ For 3rd gear
26 - Synchromeshed gear for 3rd gear
27 - Synchro-ring for 3rd gear
28 - Locking collar with synchro-hub for 3rd and 4th gears
❑ Press off with synchromeshed gears for 2nd gear ⇒ Item 21 (page 279) and 3rd gear
⇒ Item 26 (page 279) ⇒ page 281 .
2. Output shaft 279

❑ Dismantling ⇒ page 286
❑ Assembling locking collar and synchro-hub ⇒ page 286 , ⇒ page 286 and ⇒ page 286
❑ Installation position, locking collar and synchro-hub ⇒ page 287
29 - Sleeve
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❑ For needle bearing kswagen AG does
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❑ Press off with 3rded byand 4th gear ⇒ Item 28 (page 279)gu
alocking
ran collar and synchro-hub ⇒ page 281 .
ris tee
❑ Pressing onut ⇒ page 287
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30 - Needle bearing
s
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❑ For 4th gear
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31 - Synchro-ring for 4th gear
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32 - Synchromeshed gear for 4th gear
hole
spec
33 - Thrust washer
es, in part or in w
t to the co
34 - Needle bearing
rrectness of i
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36 - Sleeve
nform
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❑ For output shaft needle bearing

m
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❑ Pressing off ⇒ page 281

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38 - Dished washer
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❑ Installation position ⇒ page 246 py by
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39 - Bolt ⇒ Item 4 (page 225) Prote AG.
❑ Always renew
Pulling out small tapered roller bearing outer race

A - Internal puller, 37...46 mm , e.g. -Kukko 21/6-
B - Counter support , e.g. -Kukko 22/2-

Pressing in small tapered roller bearing outer race
Pulling off small tapered roller bearing inner race

A - Vice with protective jaw covers
– Fit adapter and tighten behind bearing rollers, then turn bear‐
ing and retighten gripping device.
AG. Volkswagen AG d
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Pressing on small tapered roller bearing inner race Volksw not
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Pressing off 3rd and 4th gear synchro-hub and locking collar, 2nd,
rrectness of i
3rd and 4th gear synchromeshed gears with sleeve for gearbox
housing needle bearing
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A - Splitter, 22...115 mm , e.g. -Kukko 17/2-

nf
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B - Hexagon bolt M10 x 20, 17 mm AF

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Support splitter so that the 1st and 2nd gear locking collar is not
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pulled off at the same time.

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2. Output shaft 281

Pressing off locking collar with synchro-hub and bearing support

– First remove retaining ring -arrow-.
Pulling off large tapered roller bearing inner race

A - Protective jaws
– Before fitting puller, insert a M 10 x 20 hexagon bolt in the
output shaft drilling.
Pressing on large tapered roller bearing inner race

-A- Thrust washer n AG. Volkswagen AG do
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– Fit thrust washer before pressing on inner race. Shoulderir se
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Installation position of outer ring, inner ring and synchro-ring for

1st gear t to the co
– Place inner ring -A- on synchromeshed gear for 1st gear.

rrectness of i
Angled lugs -arrow 1- face outer ring -B-.

l purpos
– Fit outer ring -B-.

nf
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Lugs -arrow 2- engage in notches -arrow 3- of synchromeshed

or
gear.
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– Fit synchro-ring -C-.

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Notches -arrow 4- engage in lugs -arrow 1- of inner ring -A-.

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If components are to be reused, ensure that they are matched p by
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with their original gears.
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Checking 1st and 2nd gear inner ring for wear

– Press inner ring onto cone of synchromeshed gear and meas‐
ure gap -a- using a feeler gauge.
Gap -a- Installation (new) di‐ Wear limit
mension
1st and 2nd gears 0.75 … 1.25 mm 0.3 mm
Checking 1st and 2nd gear synchro-ring for wear

– Press synchro-ring, outer ring and inner ring onto cone of syn‐
chromeshed gear and measure gap -a- using a feeler gauge.
mension
1st and 2nd gears 1.2 … 1.8 mm 0.5 mm
Dismantling and assembling locking collar and synchro-hub for

1st and 2nd gears
1 - Spring
Allocate springs according to ⇒ Electronic parts catalogue “ET‐
KA” .
Installation with hollow locking pieces ⇒ page 284 .
Installation with solid locking pieces ⇒ page 284 . agen
AG. Volkswagen AG d
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2 - Locking collar d by gu
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3 - Synchro-hub auth
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4 - Locking piece
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Allocate locking pieces according to ⇒ Electronic parts catalogue

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“ETKA” .
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Collar is equally wide on both sides of synchro-hub.

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Collar has chamfer on one side -arrow B-.

hole
spec
es, in part or in w
Chamfer on collar of synchro-hub and outer teeth of locking collar

t to the co
-arrow A- face in same direction after assembly.

Notches -arrow C- in synchro-hub and sliding collar for locking
rrectness of i
pieces must align.

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2. Output shaft
Assembly of 1st and 2nd gear locking collar and synchro-hub with
AG. Volkswagen AG d
hollow locking pieces ksw
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• Locking collar has been pushed over synchro-hub.
ise
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– Insert locking pieces and install springs
sa
utoffset 120°. Angled or
ac
end of spring must locate in hollow locking piece.
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Assembly of 1st and 2nd gear locking collar and synchro-hub with
solid locking pieces
rrectness of i
l purpos
– Insert locking pieces and install springs offset 120°. Springs

must seat with angled ends in front of locking pieces
-arrows-.
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Installation position of locking collar with synchro-hub for 1st and
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Teeth of locking collar -arrow- face splines for 3rd and 4th gear
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synchro-hub -A-. Prote AG.
Pressing on locking collar and synchro-hub for 1st and 2nd gears
Turn synchro-ring so that grooves align with locking pieces.

Installation position of 2nd gear outer ring

Lugs -arrows- face 1st gear -A-.
Installation position of synchro-ring (2nd gear inner

lksw
ring) -A-
AG. Vo agen AG
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Lugs -arrow 1- engage in notchesV-arrow
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Installation position of synchromeshed gear for 2nd gear
Higher shoulder -A- faces 1st gear -B-. Notches in shoulder
rrectne
-arrows- engage in lugs of outer ring ⇒ page 285 .
ss o
cial p
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Pressing on sleeve for 3rd gear needle bearing . Cop py
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Prote AG.
2. Output shaft 285

Checking synchro-rings for 3rd and 4th gear for wear

– Press synchro-ring onto cone of synchromeshed gear and
measure gap -a- using feeler gauge.
mension
1st gear 1.0 ... 1.7 mm 0.5 mm
3rd gear 1.0 ... 1.7 mm
4th gear 1.0 ... 1.7 mm
Dismantling and assembling 3rd and 4th gear locking collar and
synchro-hub
1 - Spring
Allocate springs according to ⇒ Electronic parts catalogue “ET‐
KA” .
Installation with hollow locking pieces ⇒ page 284 .
Installation with solid locking pieces ⇒ page 284 .
2 - Locking piece
Allocate locking pieces according to ⇒ Electronic parts catalogue
“ETKA” .
3 - Locking collar
4 - Synchro-hub
– Slide locking collar over synchro-hub.
Notches for locking pieces in synchro-hub and locking collar must
align.
Assembly of 3rd and 4th gear locking

agen collar and synchro-hub
AG. Volkswagen AG d
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hollow locking pieces yV
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Locking collar has been
ho
ris pushed over synchro-hub. tee
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– Insert locking spieces
s and install springs offset 120°. Angled
end of spring must locate in hollow locking piece.
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es, in part or in w
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Assembly of 3rd and 4th gear locking collar and synchro-hub with
solid locking pieces
rrectness of i

l purpos
– Insert locking pieces and install springs offset 120°. Springs

must seat with angled ends in front of locking pieces
nform
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-arrows-.
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286
Prote AG.
Rep. Gr.35 - Gears, shafts
Installation position of locking collar and synchro-hub for 3rd and

4th gears gen AG
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Chamfer -arrow- faces 4th gear. byV gu
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Pressing on synchro-hub with locking collar for 3rd and 4th gears
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Pressing on sleeve for 4th gear needle bearing
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Pressing on sleeve for output shaft needle bearing
2.2 Adjusting output shaft

(Determining shim for output shaft)
2. Output shaft 287

AG. Volkswagen AG d
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Golf 2004 ➤ , Golf 2009 ➤ by
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ol n
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d ara
5-speed manual gearbox ris 0A4 - Edition 04.2010
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ility
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VW 385/17-
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spec
es, in part or in w
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♦ Straightening tool -3114/2-
rrectness of i
♦ Torque wrench -
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V.A.G 1331-
♦ Dial gauge
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It is necessary to readjust the output shaft when the following
components are renewed:
♦ Output shaft
♦ Clutch housing
or
♦ Tapered roller bearings

Adjustment overview ⇒ page 302

Prerequisites:
• Sealing surfaces of clutch and gearbox housings must be free
of sealant.
– Press outer ring of small tapered roller
wagebearing to stop with
0.65 mm shim into clutch n AG. Volks⇒
agehousing page 281
n AG d
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– Insert output isshaft
ed
b and tighten nuts for bearing support
ara to 25
nte
Nm, then uturn
thor
90° further. eo
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– Turn output
s shaft 20 to 30 times in one direction.
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Note
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♦ The shaft must be turned in one direction so that the rollers of
h re
the tapered roller bearing settle in one direction.
ole,
spec
♦ It is necessary to turn the shaft 20 to 30 times to achieve this.
t to the co
♦ Otherwise the resulting reading will be incorrect.
rrectne
– Set up dial gauge (3 mm measuring range) and set to “0”with
1 mm preload.
ss
– Move output shaft up and down. Read and note play indicated
o
cial p
f
on dial gauge.
inform
mer
atio
om
n
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or
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The specified bearing preload will be attained if the determined

measured value is added to the 0.65 mm shim already installed.
Example:
Bearing play = Thickness of shim according to
(0.65 mm table
plus determined measured val‐
ue)
0.740 mm 0.900 mm
Table of shims
Bearing play = Shim
(0.65 mm thickness (mm)
ue)
0.650 0.750
0.660 … 0.689 0.800
0.690 … 0.739 0.850
0.740 … 0.789 0.900
0.790 … 0.839 0.950
0.840 … 0.889 1.000
0.890 … 0.939 1.050
0.940 … 0.989 1.100
2. Output shaft 289

AG. Volkswagen AG d
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Golf 2004 ➤ , Golf 2009aut ➤ , Golf Plus 2005 ➤ , Golf Plus 2009 ➤ , Pass ra
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Bearing play = Shim
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(0.65 mm thickness (mm)
ility
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spec
0.990 … 1.039 1.150
1.040 … 1.089 1.200
t to the co
1.090 … 1.139 1.250
1.140 … 1.189 1.300
1.190 … 1.239 1.350
rrectne
1.240 … 1.289 1.400
1.290 … 1.339 1.450
ss
1.340 … 1.389 1.500
o
cial p
f
1.390 … 1.429 1.550
inform
mer
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om
n
Note
c
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or
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– Remove output shaft and pull out small tapered roller bearing
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op
outer race ⇒ page 280 .
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• If the previously used 0.65 mm shim is to be reinstalled, check
it for damage.
The various thicknesses make it possible to achieve the exact
shim thickness required.
– Press in outer race of small tapered roller bearing together with
the calculated shim (0.70 mm in example) ⇒ page 281 and
install output shaft. Tighten bearing support nuts in clutch
housing to 25 Nm and then turn 90° further.

3 Reverse shaft
G. Volkswage
3.1 Dismantling
olks
wage
nA
and assembling
n AG d
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Special tools
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♦ Centring mandrel -12 - 551-
hole
spec
es, in part or in w
t to the co
rrectness of i
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♦ -1- Internal puller -Kukko 21/2-
♦ -4- Counterhold -Kukko 22/1-
3. Reverse shaft 291

AG. Volkswagen AG d
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olksw not
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Golf 2004 ➤ , rGolf
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5-speed manual
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Note itte
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After dismantling, always renew needle bearing in clutch housing and reverse shaft support.
wit
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h re
hole
spec
es, in part or in w
1 - Clutch housing
t to the co
2 - Needle bearing
❑ Pulling out ⇒ page 292
rrectness of i
❑ Pressing in
l purpos
⇒ page 293
3 - Reverse gear wheel
nf
ercia
o
4 - Retaining ring
rm
m
atio
❑ Always renew after re‐
om
n in
moving
or c
thi
te
5 - Synchromeshed gear for re‐
sd
iva
o
r
verse gear
rp
cu
o
m
f
en
ng
❑ Remove retaining ring

t.
yi Co
before renewing t. Cop py
rig
gh
❑ Shoulder faces reverse
ht
pyri by
Vo
gear wheel
co lksw
by
cted agen
Prote AG.
6 - Reverse shaft
7 - Needle bearing
❑ Pressing out
⇒ page 293
❑ Pressing in
⇒ page 293
8 - Reverse shaft support
⇒ page 234
Pulling needle bearing out of clutch housing

A - Counter support , e.g. -Kukko 22/1-
B - Internal puller, 14.5 … 18.5 mm , e.g. -Kukko 21/2-
Note
The needle bearing is destroyed during removal and must be re‐

newed.

Pressing needle bearing -A- into sclutch
wage housing es
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nl
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, is n
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hole
spec
es, in part or in w
t to the co
Pressing needle bearing out of reverse shaft support
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
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rp
cu
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ng
t.
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op py
Pressing needle bearing into reverse shaft support t. C rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
3. Reverse shaft 293

Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus 2009 G. Volk...
swagen AG
lkswa➤
gen,APass does
not
5-speed manual gearbox 0A4 - Edition 04.2010 d byV
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ris tee
utho or
39 – Final drive - differential

a ac
ss
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e
nl
pt
du
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itte
y li
1 Renewing flange shaft oil seals with
erm
ab
ility
ot p
gearbox installed
wit
, is n
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hole
spec
es, in part or in w
1.1 Renewing oil seal for left flange shaft
t to the co
rrectness of i
equipment required
♦ Multipurpose tool -VW 771- l purpos
nf
ercia
♦ Puller hooks -VW 771/37-
orm
m
♦ Thrust piece -T10160-
atio
om
n in
c
♦ Drip tray -V.A.G 1306-

or
thi
te
sd
a
♦ Torque wrench -
iv
o
r
rp
cu
V.A.G 1331-
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
1.1.1 Removing
– Remove left wheel.
– Turn steering to left lock.
– Disconnect drive shaft from flange shaft ⇒ Running gear,
axles, steering; Rep. Gr. 40 ; Repairing drive shaft; Removing
and installing drive shafts .
294 Rep. Gr.39 - Final drive - differential

– Raise drive shaft as high as possible and secure. Take care

not to damage paint on drive shaft in the process. wage
es
ks not
Vol gu
– Place drip tray under gearbox. ed by ara
nte
ris
– Remove flange shaft securing bolt by screwing two utho bolts into eo
ra
a
flange and counterholding flange shaft with a lever.
ss c
ce
e
nl
pt
– Pull out flange shaft with compression spring.
du
an
itte
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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
– Pull out flange shaft oil seal using multipurpose tool -VW 771-
and puller hooks -VW 771/37- .
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.
1.1.2 Installing
– Drive in new seal to stop, being careful not to cant seal.
– Half-fill space between sealing lip and dust lip with sealing
grease -G 052 128 A1- .
– Insert flange shaft.
– Secure flange shaft with countersunk bolt.
ing; Rep. Gr. 40 ; Repairing drive shaft; Removing and instal‐
ling drive shafts .
– Check gear oil ⇒ page 220 .
– Install wheel ⇒ Running gear, axles, steering; Rep. Gr. 44 ;
Torque settings for mounting wheels .

Flange shaft to gearbox (countersunk bolt)
1.2 Distinguishing seals for right flange

shaft
The seal -1- for the right flange shaft is located in a sleeve -2-.
1. Renewing flange shaft oil seals with gearbox installed 295

There are different versions.

Seal -1- and sleeve -2- are two parts. Identification: notches along
circumference of sleeve -arrow-.
Renew seal ⇒ page 296 .
Seal -1- and sleeve -2- are one piece. Identification: no notches
in sleeve.
Renew seal and sleeve together ⇒ page 299 .
1.3 Renewing seal (two-part seal and

sleeve for right flange shaft)
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
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
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
op py
♦ Assembly tool -3253/2- t. C rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

1.3.1 Removing
– Turn steering to right to full lock.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
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rise nte
tho eo
au ra
ss c
ce
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nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
– Disconnect drive shaft -1- from flange shaft.

hole
spec
es, in part or in w

t to the co
not to damage paint on drive shaft in the process.

– Place drip tray under gearbox and engine.
rrectness of i
– Unbolt turbocharger oil return line from engine -arrow- ⇒ Rep.

l purpos
Gr. 21 ; Charge air system for turbocharger; Removing and

installing turbocharger with ancillaries .
nf
ercia
– Place drip tray under gearbox.

orm
m
atio
om
n in
or c
thi
te
sd
a
– Remove flange shaft securing bolt by screwing two bolts into

iv
o
r
rp
cu

o
m
f
en
ng
t.
yi
Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

– Lever out seal using screwdriver -A- supporting screwdriver

on assembly tool -3253/2- .
Note
Volkswagen AG
♦ Do not damage sleeve. Otherwise, leaks will occur.
swa
gen AG
.
does
k not
Vol gu
♦ Replace sleeve if damaged ⇒ page 253 .ised by ara
nte
r
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
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rm
ab
pe
1.3.2 Installing
ility
ot
wit
, is n
h re
– Drive in new seal to stop, being careful not to cant seal.
hole
spec
– Half-fill space between sealing lip and dust lip with sealing
es, in part or in w
t to the co
grease -G 052 128 A1- .
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
– If turbocharger oil return line was unbolted from engine, bolt it
s
iva
do
r
on again now -arrow- ⇒ Rep. Gr. 21 ; Charge air system for

rp
cum
fo
turbocharger; Removing and installing turbocharger with an‐

en
ng
t.
cillaries .
yi Co
Cop py
t. rig
– Bolt drive shaft -1- to flange shaft ⇒ Running gear, axles,
gh ht
pyri by
steering; Rep. Gr. 40 ; Repairing drive shaft; Removing and
o Vo
by c lksw
cted
agen
Prote AG.

– Check and top up gear oil ⇒ page 220 .


1.4 Renewing seal and sleeve together (one-piece seal and sleeve for right
flange shaft)
AG. Volkswagen AG d
agen oes
olksw not
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au ra
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un
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d
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ab
ility
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wit
is n
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spec
t to the co
rrectness o

cial p
f inform

mer
atio
m
♦ Spindle from assembly tool -3066-

o
n
c
i
or
n thi
♦ Multipurpose tool -VW 771-

te
sd
iva
o
r
♦ Puller hooks -VW 771/37-

p
cum
r
fo
en
ng
t.
♦ Torque wrench -V.A.G 1331- Cop
yi Co
py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

AG. Volkswagen AG d
agen oes
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y V gu
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rise nte
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un
pt
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d
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rm
ab
1.4.1 Removing
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
– Turn steering to right to full lock.
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
– Disconnect drive shaft -1- from flange shaft.
t. rig
gh ht
pyri by
Vo
o
c by lksw
cted agen
not to damage paint on drive shaft in the process. Prote AG.
– Place drip tray under gearbox and engine.

– Unbolt turbocharger oil return line from engine -arrow- ⇒ Rep.
Gr. 21 ; Charge air system for turbocharger; Removing and
installing turbocharger with ancillaries .
– Remove flange shaft securing bolt by screwing two bolts into


– Pull out seal and sleeve together.

There is a shoulder in the inner diameter of the sleeve.
– Apply puller hooks -VW 771/37- directly behind shoulder in
sleeve.
– Press extractor hooks -VW 771/37- forcefully into sleeve while
pulling.
1.4.2 Installing
– Clean seat for seal in gearbox.
– Pull in seal and sleeve together.
A - Screw spindle of assembly tool -3066- into threaded piece of
differential.
B - Nut M12
– Pull in seal with sleeve to stop using thrust piece -T10148- bywagen AG. Volkswagen AG doe
turning nut -B-. yV
olks s no
t gu
b ara
ed nte
– Half-fill space between sealing lip and dust lip withtho
rigrease
s
-G e or
052 128 A1- . s au ac
s
ce
le

un
pt
an
d
itte
y li
erm
ab
ility
ot p
– If turbocharger oil return line was unbolted from engine, bolt it
wit
is n
on again now -arrow- ⇒ Rep. Gr. 21 ; Charge air system for
h re
ole,
turbocharger; Removing and installing turbocharger with an‐
spec
cillaries .
t to the co
– Bolt drive shaft -1- to flange shaft ⇒ Running gear, axles,
steering; Rep. Gr. 40 ; Repairing drive shaft; Removing and
rrectness o
cial p
f inform
mer
atio
om
n
c

or
n thi
e

t
sd
va

i
o
pr
cum
r
fo
en
ng
– Check and top up gear oil ⇒ page 220 .

t.
yi Co
op py
t. C rig
gh ht
yri
Gr. 50 ; Noise insulation . p by
co Vo
by lksw
cted agen
Prote AG.


2 Adjustment overview
AG. Volkswagen AG d
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olksw not
b yV gu
ara
ed
If repairs have been carried out to the gearbox, thor it
is
is necessary to nte
eo
adjust the input shaft, output shaft or differential
s au only if compo‐ ra
c
nents have been renewed which have a direct effect on the
s
ce
e
adjustment of the gearbox. To prevent unnecessary adjustments,
nl
pt
du
an
refer to the following table:
itte
y li
erm
ab
ility
ot p
To be adjusted:
wit
, is n
h re
Input shaft Output shaft Differential
hole
spec
⇒ page 270 ⇒ page 287 ⇒ page 311
es, in part or in w
Parts renewed: Gearbox housing x x
t to the co
Clutch housing x x x
Input shaft x
rrectness of i
Output shaft x
l purpos
Differential cage x
Tapered roller bearings for input x
nf
ercia
o
shaft
rm
m
atio
Tapered roller bearing for output x
om
n in
shaft
or c
thi
e
Tapered roller bearing for differen‐ x

t
sd
iva
o
tial
r
rp
cu
o
m
f
Gear wheel for 4th gear x
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

3 Differential
3.1 Dismantling and assembling differential

equipment required
♦ Tapered roller bearing pull‐
er -V.A.G 1582-
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
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nl
pt
du
an
itte
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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
cted agen
Prote AG.
3. Differential 303

♦ Sleeve -3144-
AG. Volkswagen AG d
agen
♦ Thrust piece -2007- olksw
oes
not
byV gu
ara
d
♦ Torque wrench -V.A.Gorise nte
eo
1332- aut
h
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
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Note
♦ Heat tapered roller bearing inner race to 100° C before installing.

♦ Always renew both tapered roller bearings together as a set.
♦ If tapered roller bearings, differential cage, gearbox housing or clutch housing are renewed, adjust differ‐
ential ⇒ page 302 .
1 - Gearbox housing
2 - Shim
❑ Determining thickness
⇒ page 311
race
❑ Pulling out ⇒ page 308
❑ Pressing in n AG. Volkswagen AG do
lkswage es n
⇒ page 308 by Vo ot g
ua d ran
ise
4 - Tapered roller
ut
ho bearing inner
r tee
or
race ss
a ac
ce

e
nl
pt
du
an
❑ Pressing on
itte
y li
⇒ page 307
erm
ab
ility
ot p
5 - Differential cage
wit
, is n
h re
❑ With final drive gear

hole
spec
❑ Differential cage adap‐

es, in part or in w
ted to one-piece thrust

t to the co
washer ⇒ page 309

❑ Hole for spring pin adap‐
rrectness of i
ted to length of spring

pin ⇒ page 308
l purpos
❑ Allocate according to ⇒
Electronic parts cata‐
nf
ercia
logue “ETKA” .
orm
m

atio
m
race
o
n in
or c
thi

te
sd
iva
❑ Pressing on
o
r
rp
cu
⇒ page 307
o
m
f
en
ng
t.
yi Co
7 - Tapered roller bearing outer Cop py
t. rig
race opyri
gh by
Vo
ht
❑ Pressing out ⇒ page 307

c by lksw
cted agen
Prote AG.
❑ Pressing in ⇒ page 307
8 - Clutch housing
9 - Sleeve
❑ For seating oil seal ⇒ Item 10 (page 305)
10 - Seal
❑ Renewing oil seal for left flange shaft with gearbox installed ⇒ page 294
❑ Renewing seal for right flange shaft with gearbox installed (two-part seal and sleeve for right flange shaft)
⇒ page 296
3. Differential 305
11 - One-piece seal and sleeve

❑ If seal is damaged, renew seal and sleeve together ⇒ page 299
n AG . Volkswagen AG
12 - Countersunk bolt, 25 Nm wage does
Volks not
❑ Screw into threaded piece ⇒ Iteme20
d b (page 306)
y gu
ara
is nte
or
13 - Flange shaft au
th eo
ra
ss c
ce
e
nl
pt
du
14 - Compression spring for flange shaft
an
itte
y li
erm
❑ Installed behind flange shafts
ab
ility
ot p
15 - Thrust washer
wit
, is n
h re
hole
spec
16 - Tapered ring
es, in part or in w
t to the co
❑ With grooves to engage in thrust washer
❑ Installation position: taper towards differential cage
rrectness of i
17 - Retaining ring
l purpos
❑ Holds tapered ring, thrust washer and spring in position when flange shaft is removed
18 - One-piece thrust washer
nform
ercia
❑ Coat with gear oil when installing

m
at
❑ One-piece thrust washer has shoulder in some gearboxes ⇒ page 309
om
ion
c
in t
r
19 - Large differential bevel gear

o
his
ate
do
priv
cum
or
20 - Threaded piece
f
en
ng
t.
yi Co
❑ Installing ⇒ page 310 Cop py
t. rig
gh ht
yri
21 - Differential pinion pin p by
co Vo
by lksw
cted
❑ Removing in conjunction with shorter spring pin ⇒ page 309
agen
Prote AG.
❑ Removing in conjunction with longer spring pin ⇒ page 309

22 - Spring pin
❑ For securing differential pinion pin
❑ Spring pins of different lengths have been installed
❑ Spring pin identification ⇒ page 308
❑ Removing and installing short spring pin ⇒ page 309
❑ Long spring pin is sheared off when removed ⇒ page 309
❑ Installing long spring pin ⇒ page 309
23 - Small differential bevel gear
24 - Large differential bevel gear

. Volkswage
Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus k2005
wage ➤ , Golf Plus 2009
n AG n AG d
oe➤
s no, Pass ...
ol s
5-speed
d by manual gearbox 0A4 - Edition t04.2010
V gu
ar
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ris tee
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Pressing tapered roller bearing outer race out of clutch
au housing
t or
ac
ss
– First remove seating sleeve for flange shaft seal.
ce
le
un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectne
Pressing tapered roller bearing outer race into clutch housing
ss o
No shim is installed in the clutch housing end. 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
py by
co Vo
by lksw
cted agen
Prote AG.
Pulling off tapered roller bearing inner race
– Before fitting extractor, position thrust plate -40 - 105- on dif‐
ferential cage.
Note
Both tapered roller bearing inner races are pulled off the differ‐
ential cage in the same way.
Note
Both tapered roller bearing inner races are pressed onto the dif‐
ferential cage in the same way.
3. Differential 307
Pulling outer race for tapered roller bearing out of gearbox hous‐
ing
B - Internal puller, 46...58 mm , e.g. -Kukko 21/7-
Pressing tapered roller bearing outer race into gearbox housing

– Fit shim under outer race. agen
AG. Volkswagen AG d
oes
olksw not
V
– Support gearbox housing ed b directly below bearing mountingguus‐
y ara
ing sleeve -3144- th.oris nte
eo
au ra
ss c
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
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hole
spec
es, in part or in w
Spring pin identification

t to the co
Dim. “a” mm Identification
rrectness of i
28.5 (short spring pin) Circumferential groove

Removing and installing -arrows-
l purpos
⇒ page 309
36.0 (long spring pin), No circumferential
nform
ercia
Removing ⇒ page 309 , groove

Installing ⇒ page 309
m
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
Allocation of differential cages

en
ng
t.
yi Co
op
– Check hole for spring pin in differential cage.
C py
t. rig
gh ht
yri by
The hole in the differential cage was modified for the longer spring cop Vo
by lksw
pin.
cted agen
Prote AG.
Hole Length of spring pin (mm)

-A- 28.5 (short spring pin)
-A- and -B- 36.0 (long spring pin)

Removing and installing spring pin with circumferential groove

(short spring pin)
Removing
– Cover tapered roller bearing inner race and speedometer drive
gear to avoid possible damage and ingress of metal particles.
– Drive out spring pin with chisel, inserting chisel into circum‐
ferential groove.
Installing
– Drive into differential cage to stop.
Removing spring pin without circumferential groove (long spring

pin): pressing out differential pinion pin
When pressed out, spring pin will be sheared off.
– Drive remainder of spring pin out of differential cage.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
Installing spring pin without circumferential groove
s a (long spring
u ra
c
pin) s
ce
le
un
pt
– Align hole in differential pinion pin with hole in differential cage.
an
d
itte
y li
erm
ab
– Drive in new spring pin with drift -1- until dimension -a- =
ility
ot p
3.0 mm is attained.
wit
is n
h re
• The spring pin must not come in contact with gears with dif‐
ole,
spec
ferential cage installed.
t to the co
rrectne
In some gearboxes, the one-piece thrust washer has a shoulder
ss
-A- near the holes
o
cial p
f inform
In this case, the differential cage has a circumferential groove
mer
-B-.
atio
om
n
c
– Lubricate one-piece thrust washer with gear oil and install.

i
or
n thi
te
sd
a
– Install one-piece thrust washer so that it engages in groove

iv
o
r
-B- in differential cage.

p
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
3. Differential 309
Installing differential bevel gears and differential pinion pin

– Lubricate one-piece thrust washer with gear oil and install.
– Install both sun wheels and secure (e.g. with flange shaft).
– Insert planet pinions offset 180° and pivot into position.
– Press in differential pinion pin (-arrow A-) to first planet pinion.
. Volkswage n AG n AG d
wage oes
– Place threaded pieces -arrows B-
yV
oin
lks sun gears. not
gu
b ara
ed
Installation position: shoulderhoto
ris sun gear nte
eo
t
au ra
– Drive differential pinionss pin into final position and secure with c
spring pin.
ce
le
un
pt
an
d
itte
y li
Installation position of thrust washer for tapered ring -1-.
erm
ab
ility
ot p
The shoulder -arrow- points towards spring -B-.
wit
is n
h re
ole,
Some gearboxes have lugs -A-.
spec
Lugs -A- face tapered ring -1-.
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
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pr
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3.2 Adjusting differential

equipment required
et -VW 387-
VW 385/17-
♦ Torque wrench -
V.A.G 1331-
♦ Internal puller -1 - Kukko
21/7-
♦ Counter support -4 - Kukko
22/2-
♦ Dial gauge
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rm
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ility
It is necessary to readjust the differential when the following com‐

ot
wit
ponents are renewed:

, is n
h re
hole
♦ Gearbox housing
spec
es, in part or in w
♦ Clutch housing
t to the co
♦ Differential cage
rrectness of i
or the
l purpos
♦ tapered roller bearing of differential

Adjustment overview ⇒ page 302 .
nform
ercia
– Press outer race of tapered roller bearing without shim into

m
gearbox housing using thrust piece -30 - 205- ⇒ page 308

a
com
tion in
r
te o
thi
s
iva
Note
do
r
rp
cum
fo
en
Inner and outer tapered roller bearing races are paired. Do not
ng
t.
yi Co
interchange! ht. Cop py
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3. Differential 311
– Press outer race of tapered roller bearing into clutch housing

using thrust plate -30 - 205- ⇒ page 307 .
– Fit differential into clutch housing.
– Set gearbox housing in place and tighten 5 bolts to 25 Nm.
– Attach dial gauge and set to “0” with 1 mm preload.
– Move differential up and down. Read and note play indicated
on dial gauge. (Example: 0.70 mm.) agen
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Example:
Bearing play, measured value Thickness of shim according to
rrectness of i
table
l purpos
0.70 mm 0.95 mm
Table of shims
nform
mercia
Bearing play Shim
at
om
ion
c
Measured value Thickness
in t
or
(mm) (mm)
his
ate
do
riv
0.303 … 0.449 0.650

p
cum
or
0.450 … 0.499 0.700

f
en
ng
t.
0.500 … 0.549 0.750
yi Co
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0.550 … 0.599 0.800 ht. rig
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0.600 … 0.649 0.850 copy Vo
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0.650 … 0.699 0.900 cted agen
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0.700 … 0.749 0.950
0.750 … 0.799 1.000
0.800 … 0.849 1.050
0.850 … 0.899 1.100
0.900 … 0.949 1.150
0.950 … 0.999 1.200
1.000 … 1.049 1.250
1.050 … 1.099 1.300
1.100 … 1.149 1.350
1.150 … 1.199 1.400
Note

– Remove gearbox housing and pull tapered roller bearing outer

race from gearbox housing.
Pulling outer race for tapered roller bearing out of gearbox hous‐
ing
B - Internal puller 46 …. 58 mm , e.g. -Kukko 21/7- .
The various thicknesses make it possible to achieve the exact
shim thickness required.
– Press in outer race of tapered roller bearing again
⇒ page 308 and bolt gearbox housing tight.
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, is n
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spec
es, in part or in w
t to the co
rrectness of i
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nf
ercia
orm
m
atio
om
n in
or c
thi
te
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iva
o
r
rp
cu
o
m
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3. Differential 313

5-Speed Manual Gearbox 0A4 PDF

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5-Speed Manual Gearbox 0A4 PDF

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Service

Service Department. Technical Information

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Copyright © 2010 Volkswagen AG, Wolfsburg K0058990420

3 Calculating overall gear ratio “i” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

1 Repairing clutch mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

1.2 Assembly overview - pedal cluster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

34 - Controls, housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116

1.11 Removing and installing selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136

1.12 Adjusting selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139

2 Removing and installing gearbox, Golf 2004 ▸ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143

4.1 Removing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173

4.2 Installing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180

5.1 Removing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189

8 Checking and topping up gear oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220

35 - Gears, shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263

3 Reverse shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291

39 - Final drive - differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294

1.1 Location on gearbox

Manual gearbox 0A4 -arrow 2-

Codes and production date of gearbox

Additional data provide information about the production facility.

The gearbox code is also included on the vehicle data stickers.

1.2 Identification codes, assembly allocation, capacities, Golf 2004 ▸

Manual gearbox 5-speed 0A4

Capacity of manual gearbox 1.7 l 1.7 l 1.7 l

⇒ page 220 (gearbox partially dis‐

Drive shaft flange ∅ 100 mm 108 mm 108 mm

The following data can be found in the ⇒ Electronic parts cata‐

♦ Individual gear ratios

Manual gearbox 5-speed 0A4

Identification code JCR JCU JCV

Manufactured from 05.06 05.06 05.06

to 06.08 06.08 06.08

Allocation Engine 1.9 l - 66 kW 2.0 l - 85 kW 1.8 l - 110 kW

2 Rep. Gr.00 - Technical data

Manual gearbox 5-speed 0A4

Manual gearbox 5-speed 0A4

Identification code FNC HJK KCL

Manufactured from 05.06 05.06 12.06

box completely dismantled)

Drive shaft flange ∅ 100 mm 100 mm 100 mm

The following data can be found in the ⇒ Electronic parts cata‐

Manual gearbox 5-speed 0A4

The following data can be found in the ⇒ Electronic parts cata‐

Manual gearbox 5-speed 0A4

Capacity of manual gear‐ 1.7 l 1.7 l

♦ Gear oil nform

1.3 Identification codes, assembly allocation, capacities, Golf 2009 ▸

Manual gearbox 5-speed 0A4

4 Rep. Gr.00 - Technical data

Manual gearbox 5-speed 0A4

Manual gearbox 5-speed 0A4

Identification code MDZ LEA

Manufac‐ from 11.09 05.10

Allocation Engine 1.9 l - 77 kW 2.5 l - 125 kW

Capacity of manual gear‐ 1.9 l 1.9 l

Capacity of manual gear‐ 1.7 l 1.7 l

box ⇒ page 220 (gearbox

Drive shaft flange ∅ 100 mm 100 mm

The following data can be found in the ⇒ Electronic parts cata‐

1.4 Identification codes, assembly allocation, capacities, Golf Plus 2005 ▸

Manual gearbox 5-speed 0A4