SM 22

Service
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
Workshop Manual
ility
ot p
wit
, is n
h re
California 2010 ➤ , Caravelle 2004 ➤ ,
hole
spec
Caravelle 2010 ➤ , Multivan 2004 ➤ ,
es, in part or in w
t to the co
Multivan 2010 ➤ , Sparchassis 2010 ➤ ,
Transporter 2004 ➤ ,
rrectness of i
Transporter 2010 ➤ , Zugkopf 2010 ➤
l purpos
5-speed manual gearbox 02Z
nform
mercia
at
Edition 06.2019
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.
Service Department. Technical Information

Service
List of Workshop Manual Repair Groups
Repair Group
00 - Technical data
30 - Clutch
34 - Controls, housing
35 - Gears, shafts
39 - Final drive - differential
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
Technical information should always be available to the foremen and mechanics, because their
py by
co Vo
by lksw
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
cted agen
Prote AG.
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 © 2019 Volkswagen AG, Wolfsburg K0058980620

California 2010 ➤ , Caravelle 2004 ➤ , Caravelle 2010 ➤ , Multivan 2004 ...
5-speed manual gearbox 02Z - Edition 06.2019
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Gearbox identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.1 Technical data, gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.2 Calculating overall gear ratio “i” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3 Overview - power transmissionagen
AG. Volksw.ag . e.n.A.G. d.o. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
ksw es n
3.1 Overview - power by V transmission . . . . . . . . . . .t g.u.a . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ol o 10
ed ra
4 Repair notes
ho
ris . . . . . . . . . . . . . . . . . . . . . . . . . . . . n. te.e. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
t o
4.1 General
ss
au repair instructions . . . . . . . . . . . . . . . . . . . . .r .ac. . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
ce
5 Electrical components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
e
15
nl
pt
du
an
5.1 Overview of fitting locations - electrical components, manual gearbox . . . . . . . . . . . . . . . . 15
itte
y li
erm
5.2 Overview of fitting locations – electrical components, clutch mechanism . . . . . . . . . . . . . . 15
ab
ility
ot p
wit
30 - Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
, is n
h re
hole
1 Clutch operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
spec
es, in part or in w
1.1 Assembly overview - pedal cluster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
t to the co
1.2 Assembly overview - clutch hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
1.3 Assembly overview - clutch release mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
rrectness of i
1.4 Removing and installing clutch pedal switch F36 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
1.5 Removing and installing mounting bracket for clutch pedal . . . . . . . . . . . . . . . . . . . . . . . . 22
l purpos
1.6 Removing and installing clutch pedal with mounting bracket removed . . . . . . . . . . . . . . . . 24
1.7 Removing and installing over-centre spring with mounting bracket removed . . . . . . . . . . 25
nf
ercia
o
1.8 Removing and installing clutch master cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
rm
m
atio
1.9 Removing and installing clutch slave cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

om
n in
1.10 Bleeding clutch mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

or c
thi
e
2 Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
t
sd
iva
o
r
2.1 Assembly overview - clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

rp
cu
o
m
f
en
2.2 Removing and installing clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

ng
t.
yi Co
Cop py
34 - Controls, housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
ht. rig
rig ht
py by
co Vo
1 Selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
by lksw
cted agen
Prote AG.
1.1 Installation position - selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
1.2 Assembly overview - gear knob and cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
1.3 Assembly overview - Gear lever and selector housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
1.4 Assembly overview - selector lever and selector housing, as of model year 2007 . . . . . . 45
1.5 Assembly overview - selector cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
1.6 Removing and installing selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
1.7 Distinguishing between selector mechanisms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
1.8 Adjusting selector mechanism in neutral, selector gate for 1st and 2nd gears . . . . . . . . . . 52
1.9 Adjusting selector mechanism with 2nd gear engaged . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
1.10 Renewing selector shaft seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
1.11 Removing and installing relay lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
2 Removing and installing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
2.1 Specified torques for gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
2.2 Removing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
2.3 Removing gearbox, 2010► . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
2.4 Installing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
2.5 Installing gearbox, 2010► . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
3 Transporting gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
3.1 Transporting gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
4 Gear oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Contents i
4.1 Checking gear oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

5 Dismantling and assembling gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
5.1 Schematic overview - gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
5.2 Assembly overview - cover for gearbox housing and 5th gear . . . . . . . . . . . . . . . . . . . . . . 90
5.3 Assembly overview - gearbox housing and selector mechanism . . . . . . . . . . . . . . . . . . . . 91
5.4 Assembly overview - selector unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
5.5 Assembly overview - input shaft, output shaft, differential and selector forks . . . . . . . . . . 93
5.6 Assembly overview - selector forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
5.7 Dismantling and assembling gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
5.8 Dismantling and assembling selector unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
5.9 Dismantling and assembling selector forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
5.10 Removing cover for gearbox housing and 5th gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
5.11 Installing cover for gearbox housing and 5th gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
6 Gearbox housing, clutch housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
6.1 Assembly overview - gearbox housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
6.2 Assembly overview - clutch housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
6.3 Repairing gearbox housing . . . . . . . . . . . . . . . . . . . . . . e.n.A.G.. V. o.lk.s.w.ag. e.n.A.G. . . . . . . . . . . . . 127
ag do
6.4 Repairing clutch housing . . . . . . . . . . . . . . . . . . V. o.lk.s.w. . . . . . . . . . . . . . . . . e. s.n.ot.g. . . . . . . 134
by ua
ed ran
ris
35 - Gears, shafts . . . . . . . . . . . . . . . . . . . . u.th. . . . . . . .
o . . . . . . . . . . . . . . . . . . . . . .or. 141
tee
a ac
1 Input shaft . . . . . . . . . . . . . . . . . . . . . .ss. . . . . . . . . . . .
............................ 141
ce
e
nl
1.1 Assembly overview - input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
pt
du
an
itte
1.2 Dismantling and assembling input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
y li
erm
ab
2 Output shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
ility
ot p
wit
2.1 Assembly overview - output shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
, is n
h re
2.2 Dismantling and assembling output shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
hole
spec
2.3 Adjusting output shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
es, in part or in w
t to the co
3 Reverse shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
3.1 Assembly overview - reverse shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
3.2 Dismantling and assembling reverse shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
rrectness of i
l purpos
39 - Final drive - differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171

1 Oil seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
nf
ercia
1.1 Overview of fitting locations - seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
orm
1.2 Renewing left seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
m
atio
m
1.3 Renewing right oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173

o
n in
or c
1.4 Renewing input shaft seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177

thi
te
sd
iva
2 Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
o
r
rp
cu
o
2.1 Assembly overview - differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180

f
en
ng
t.
yi
2.2 Dismantling and assembling differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
Co
Cop py
. rig
2.3 Adjusting differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ht
opy
rig by
Vo
ht
185
3 Adjustment overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
by c lksw
cted agen
Prote AG.
ii Contents
n AG. Volkswagen AG do
lkswage es n
o ot g
yV
00 – Technical data d b ua
ran
ir se tee
tho
u or
a ac
ss
1 Identification
ce
le
un
pt
an
d
itte
y li
(VRL013195; Edition 06.2019)
erm
ab
ility
ot p
⇒ “1.1 Gearbox identification”, page 1
wit
is n
h re
1.1 Gearbox identification
ole,
spec
The 5-speed manual gearbox 02Z is installed in the Transporter
t to the co
2004 ► in conjunction with a 4-cylinder engine.
Codes and production date -arrow 1- manual gearbox 02Z
rrectne
-arrow 2-.
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
Manual gearbox 02Z -arrow 2-.
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Codes and production date of gearbox

Example: FJJ 31 03 3
I I I I
I I I I
Identification Day Month Year 2003 of man‐
code ufacture
Additional data depend on manufacture.
Note
The gearbox code is also included on the vehicle data stickers.
1. Identification 1
2 Technical data
⇒ “2.1 Technical data, gearbox”, page 2
⇒ “2.2 Calculating overall gear ratio i ”, page 8
2.1 Technical data, gearbox

Manual gearbox lks wage es n
ot g
5-speed 02Z
o
yV
Identification code ed
b FJH uara
nte FJJ FJK
ris
ho eo
Manufactured au
t from 03.03 03.03
ra 03.03
ss to 11.04 11.04
c
11.04
ce
le
un
pt
Allocation Model Transporter 2004 ► Transporter 2004 ► Transporter 2004 ►
an
d
itte
y li
Engine 1.9 l - 63 kW 1.9 l - 63 kW 1.9 l - 77 kW
erm
ab
diesel diesel diesel
ility
ot p
wit
Ratio Final drive 74 : 15 = 4.933 73 : 16 = 4.563 74 : 15 = 4.933
is n
h re
1st gear 34 : 09 = 3.7778 34 : 09 = 3.7778 34 : 09 = 3.7778
ole,
spec
2nd gear 33 : 16 = 2.063 33 : 16 = 2.063 29 : 14 = 2.071
3rd gear 30: 24 = 1.25 30: 24 = 1.25 26 : 21 = 1.238
t to the co
4th gear 27 : 32 = 0.844 27 : 32 = 0.844 24 : 29 = 0.828
5th gear 27 : 41 = 0.659 27 : 41 = 0.659 23 : 37 = 0.622
Reverse gear 36 : 20 = 1.8 36 : 20 = 1.8 36 : 20 = 1.8
rrectne
Capacity of manual gearbox 2.0 litres
Drive shaft flange diameter 108 mm 108 mm 108 mm
ss o
cial p
f i
The following data can be found in the ⇒ Electronic parts cata‐
nform
logue (ETKA) :
mer
atio
m
♦ Individual gear ratios

o
n
c
i
or
n thi
♦ Specification for gear oil

te
sd
iva
o
r
♦ Clutch plate allocation

p
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
Manual gearbox 5-speed 02Z
pyri by
Vo
co lksw
by
Identification code FJL FJM FJN
cted agen
Prote AG.
Manufactured from 02.03 01.04 12.03

to 11.04 11.04 11.04
diesel
1st gear 34 : 09 = 3.778 34 : 09 = 3.7778 34 : 09 = 3.7778
2nd gear 29 : 14 = 2.071 33 : 16 = 2.063 33 : 16 = 2.063
3rd gear 26 : 21 = 1.238 31 : 23 = 1.348 31 : 23 = 1.348
4th gear 24 : 29 = 0.828 30 : 29 = 1.034 30 : 29 = 1.034
5th gear 23 : 37 = 0.622 31 : 37 = 0.838 31 : 37 = 0.838
Reverse gear 36 : 20 = 1.8 36 : 20 = 1.8 36 : 20 = 1.8
logue (ETKA) :
2 Rep. gr.00 - Technical data


Identification code GMS GTF GTV
to 11.04 11.04 01.06
AG. Volkswagen AG d
Engine
ksw
agen 1.9 l - 77 kW oes n 2.0 l - 85 kW 1.9 l - 77 kW
by
Vol diesel ot g
ua diesel
ed ran
Ratio Final
tho drive
ris 74 : 15 = 4.933 75
tee : 14 = 5.357
o
73 : 16 = 4.563
a1st
u gear 34 : 09 = 3.778 34r a:c08 = 4.25 34 : 09 = 3.778
ss 2nd gear 29 : 14 = 2.071 34 : 15 = 2.267 29 : 14 = 2.071
ce
le
3rd gear 26 : 21 = 1.238 32 : 22 = 1.455 26 : 21 = 1.238

un
pt
an
d
4th gear 24 : 29 = 0.828 30 : 29 = 1.034 24 : 29 = 0.828

itte
y li
5th gear 23 : 37 = 0.622 31 : 37 = 0.838 23 : 37 = 0.622
erm
ab
ility
Reverse gear 36 : 20 = 1.8 36 : 20 = 1.8 36 : 20 = 1.8
ot p
wit
is n
h re
ole,
spec
t to the co
logue (ETKA) :
rrectne
ss
o
cial p
f inform
mer
atio
m

o
n
c
i
or
n thi
Identification code GTW GTX GTY

te
sd
iva
o
r

p
cum
r
fo
to 01.06 01.06 01.06

en
ng
t.
yi Co
Cop py
t. rig
gh ht
Engine
yri
1.9 l - 77 kW 1.9 l - 77 kW 1.9 l - 63 kW
p by
o Vo
by c
lksw
cted agen
Prote AG.
1st gear 34 : 09 = 3.778 34 : 09 = 3.778 34 : 09 = 3.7778
2nd gear 29 : 14 = 2.071 29 : 14 = 2.071 33 : 16 = 2.063
3rd gear 26 : 21 = 1.238 26 : 21 = 1.238 30 : 24 = 1.25
4th gear 24 : 29 = 0.828 24 : 29 = 0.828 27 : 32 = 0.844
5th gear 23 : 37 = 0.622 23 : 37 = 0.622 27 : 41 = 0.659
Reverse gear 36 : 20 = 1.8 36 : 20 = 1.8 36 : 20 = 1.8
logue (ETKA) :

Identification code GTZ GUA GUB
to 01.06 05.06 05.06
diesel
2. Technical data 3

Identification code GTZ GUA GUB
1st gear 34 : 09 = 3.778 34 : 09 = 3.7778 34 : 09 = 3.7778
2nd gear 33 : 16 = 2.063 33 : 16 = 2.063 33 : 16 = 2.063
3rd gear 30 : 24 = 1.25 31 : 23 = 1.348 31 : 23 = 1.348
4th gear 27 : 32 = 0.844 30 : 29 = 1.034 30 : 29 = 1.034
5th gear 27 : 41 = 0.659 31 : 37 = 0.838 31 : 37 = 0.838
Reverse gear 36 : 20 = 1.8 36 : 20 = 1.8 36 : 20 = 1.8
logue (ETKA) :
♦ Clutch plate allocation n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
o
Manual gearbox auth or5-speed
ac 02Z
ss
Identification code HCW HCX HCY
ce
e
nl
pt
du

an
itte
y li
to 05.06 05.06 05.06

erm
ab
ility
ot p

wit
, is n

h re
hole

spec
1.9 l - 77 kW 1.9 l - 77 kW
es, in part or in w
t to the co
diesel diesel
1st gear 34 : 09 = 3.778 34 : 09 = 3.778 34 : 09 = 3.778
rrectness of i
2nd gear 29 : 14 = 2.071 29 : 14 = 2.071 33 : 16 = 2.063

3rd gear 30 : 24 = 1.25 30 : 24 = 1.25 30 : 24 = 1.25
l purpos
4th gear 27 : 32 = 0.844 27 : 32 = 0.844 27 : 32 = 0.844

5th gear 23 : 37 = 0.622 23 : 37 = 0.622 27 : 41 = 0.659
nform
ercia
Reverse gear 36 : 20 = 1.8 36 : 20 = 1.8 36 : 20 = 1.8

m
at
om
io

n
c
in t
or
his
te

a
do
riv
logue (ETKA) :
p
cum
for
en
ng

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

Identification code HCZ HDC JCC
to 05.06 05.06 08.06


Identification code HCZ HDC JCC
Ratio Final drive 74 : 15 = 4.933 74 : 15 = 4.933 74 : 15 = 4,933
1st gear 34 : 09 = 3.778 34 : 09 = 3.778 34 : 09 = 3.778
2nd gear 33 : 16 = 2.063 29 : 14 = 2.071 33 : 16 = 2.063
3rd gear 30 : 24 = 1.25 30 : 24 = 1.25 30 : 24 = 1.25
4th gear 27 : 32 = 0.844 27 : 32 = 0.844 27 : 32 = 0.844
5th gear 27 : 41 = 0.659 23 : 37 = 0.622 27 : 41 = 0.659
Reverse gear 36 : 20 = 1.8 36 : 20 = 1.8 36 : 20 = 1.8
logue (ETKA) :
♦ Individual gear ratiosagen AG. Volkswagen AG do
w es n
olks ot g
♦ Specification
ed
bfor
y V gear oil ua
ran
is tee
or
♦ Clutchauplate
th allocation or
ac
ss
ce
le
un
pt
an
d
itte

y li
rm
ab
pe
ility
Identification code JCD JCE JCF
ot
wit
, is n

h re
to 08.06 08.06 08.06
hole
spec
es, in part or in w

t to the co

1.9 l - 77 kW 1.9 l - 77 kW
rrectness of i
diesel diesel
l purpos

1st gear 34 : 09 = 3.778 34 : 09 = 3.778 34 : 09 = 3.778
2nd gear 33 : 16 = 2.063 29 : 14 = 2.071 29 : 14 = 2.071
nform
ercia
3rd gear 30 : 24 = 1.25 30 : 24 = 1.25 30 : 24 = 1.25

m
4th gear 27 : 32 = 0.844 27 : 32 = 0.844 27 : 32 = 0.844

a
com
tio
5th gear 27 : 41 = 0.659 23 : 37 = 0.622 23 : 37 = 0.622

n in
r
Reverse gear 36 : 20 = 1.8 36 : 20 = 1.8 36 : 20 = 1.8

te o
thi
s
iva

do
r
rp
cum
fo

en
ng
t.
yi Co
op
C py
t. rig
gh
logue (ETKA) :
ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.


Identification code JCG JCH JCJ
to 08.06 08.06 08.06
diesel
2. Technical data 5

Identification code JCG JCH JCJ
1st gear 34 : 09 = 3.77778 34 : 09 = 3.77778 34 : 09 = 3.778
2nd gear 33 : 16 = 2.063 33 : 16 = 2.063 29 : 14 = 2.071
3rd gear 31 : 23 = 1.348 31 : 23 = 1.348 30 : 24 = 1.25
4th gear 30 : 29 = 1.034 30 : 29 = 1.034 27 : 32 = 0.844
5th gear 31 : 37 = 0.838 31 : 37 = 0.838 23 : 37 = 0.622
Reverse gear 36 : 20 = 1.8 36 : 20 = 1.8 36 : 20 = 1.8
logue (ETKA) :
♦ Clutch plate allocation AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
o
Manual gearbox auth 5-speed 02Z eo
ra
s c
Identification code JQQ s
JQR JQS
ce
e
nl
pt
du
Manufactured from 08:06 08:06 08:06
an
itte
y li
to
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
1.9 l - 63 kW 1.9 l - 63 kW 1.9 l - 77 kW
es, in part or in w
t to the co
1st gear 34 : 09 = 3.778 34 : 09 = 3.778 34 : 09 = 3.778
rrectness of i
2nd gear 33 : 16 = 2.063 33 : 16 = 2.063 29 : 14 = 2.071
3rd gear 30 : 24 = 1.25 30 : 24 = 1.25 30 : 24 = 1.25
l purpos
4th gear 27 : 32 = 0.844 27 : 32 = 0.844 27 : 32 = 0.844

5th gear 27 : 41 = 0.659 27 : 41 = 0.659 23 : 37 = 0.622
Reverse gear 36 : 20 = 1.8 36 : 20 = 1.8 36 : 20 = 1.8
nform
ercia

m
at
om
io
n
c
in t
or
his
te

a
do
riv
logue (ETKA) :
p
cum
for
en
g

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

Identification code JQT JQU JQV
to
Transporter 2010 ► Transporter 2010 ►
diesel
1.9 l - 77 kW
diesel


Identification code JQT JQU JQV
1st gear 34 : 09 = 3.778 34 : 09 = 3.77778 34 : 09 = 3.77778
2nd gear 29 : 14 = 2.071 33 : 16 = 2.063 33 : 16 = 2.063
3rd gear 30 : 24 = 1.25 31 : 23 = 1.348 31 : 23 = 1.348
4th gear 27 : 32 = 0.844 30 : 29 = 1.034 30 : 29 = 1.034
5th gear 23 : 37 = 0.622 31 : 37 = 0.838 31 : 37 = 0.838
Reverse gear 36 : 20 = 1.8 36 : 20 = 1.8 36 : 20 = 1.8
logue (ETKA) :

Identification code JQW swage
n AG. VolkswaLRS
gen AG
does MAG
olk not
V
Manufactured from 08:06
ed
by 08.09 gu
ara 05.11
to tho
ris 05.12 nte
e o 05.12
au ra
Allocation Model Transporter
ss 2004 ► Transporter 2010 ► Transporter
c 2010 ►
ce
e

nl
pt
du
an
itte
y li
2.0 l - 75 kW 2.0 l - 75 kW
erm
ab
diesel diesel
ility
ot p
2.0 l - 84 kW
wit
, is n
h re
diesel
hole
spec
es, in part or in w
1st gear 34 : 09 = 3.778 34 : 09 = 3.7778 34 : 09 = 3.7778
t to the co
2nd gear 29 : 14 = 2.071 35 : 18 = 1.9444 35 : 18 = 1.9444
3rd gear 30 : 24 = 1.25 32 : 27 = 1.185 32 : 27 = 1.185
4th gear 27 : 32 = 0.844 31 : 38 = 0.816 31 : 38 = 0.816
rrectness of i
5th gear 23 : 37 = 0.622 29 : 49 = 0.592 29 : 49 = 0.592
Reverse gear 36 : 20 = 1.8 36 : 20 = 1.8 36 : 20 = 1.8
l purpos

nform
ercia

m
at

om
ion
logue (ETKA) :
c
in t
or
his
te

a
do
priv
cum
or

f
en
ng
t.
yi Co
♦ Clutch plate allocation t. Cop py
rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Identification code MQR MQS MQT
to
diesel
2.0 l - 75 kW
diesel
2. Technical data 7

Identification code MQR MQS MQT
Ratio Final drive 74 : 15 = 4.933 74ag:e15
n AG=. V4.933
olkswagen AG 74 : 15 = 4.933
does
1st gear 34 : 09 = 3.77778 y Vol34 ksw : 09 = 3.77778 34n:ot09
gu = 3.7778
2nd gear 33 : 16 = 2.063 ise d b
33 : 16 = 2.063 35 : 18a= ran1.9444
tee
3rd gear 31 : 23 = 1.348
ut
hor
31 : 23 = 1.348 32 : 27 = 1.185
or
4th gear 30 : 29 = 1.034
ss
a 30 : 29 = 1.034 31 : 38 = 0.816 ac
5th gear 31 : 37 = 0.838 31 : 37 = 0.838 29 : 49 = 0.592
ce
e
nl
pt
Reverse gear 36 : 20 = 1.8 36 : 20 = 1.8 36 : 20 = 1.8
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
logue (ETKA) :
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
Identification code NCX PCA PCB

m
at
om
ion
Manufactured from 05.11 05:12 05:12
c
in t
or
to 05.12
his
ate
do
riv

p
cum
for
en
ng
t.
yi
Co
Cop py
2.0 l - 75 kW
t. rig
gh ht
yri
diesel
p by
co Vo
lksw
2.0 l - 84 kW
by
cted agen
Prote
diesel
AG.

1st gear 34 : 09 = 3.7778 34 : 09 = 3.7778 34 : 09 = 3.7778
2nd gear 35 : 18 = 1.9444 35 : 18 = 1.9444 35 : 18 = 1.9444
3rd gear 32 : 27 = 1.185 32 : 27 = 1.185 32 : 27 = 1.185
4th gear 31 : 38 = 0.816 31 : 38 = 0.816 31 : 38 = 0.816
5th gear 29 : 49 = 0.592 29 : 49 = 0.592 29 : 49 = 0.592
Reverse gear 36 : 20 = 1.8 36 : 20 = 1.8 36 : 20 = 1.8
logue (ETKA) :
2.2 Calculating overall gear ratio “i”

Gear ratios ⇒ page 2
Example:
5th gear Final drive
Drive gear ZG1 = 41 ZA1 = 16
Driven gear ZG2 = 27 ZG2 = 73

AG. Volkswagen AG d
agen oes
lksw not
i = ZG2 : ZG1 1)
byV
o gu
ara
ed
ris nte
iG = gear ratio = ZG2 : ZG1 = 27 : 41 = 0.659 ut
ho eo
ra
s a c
s
iA = final drive ratio = ZG2 : ZG1 = 73 : 16 = 4.563
ce
e
nl
pt
du
an
itte
itotal = overall ratio = iG x iA = 0.659 x 4.563 = 3.007
y li
erm
ab
ility
1) Z1 = No. of teeth on driving gear, Z2 = No. of teeth on driven gear
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.
2. Technical data 9
3 Overview - power transmission

⇒ “3.1 Overview - power transmission”, page 10
3.1 Overview - power transmission

Designation:
Arrows indicate direction of travel.
1 - Engine
2 - Clutch
3 - Manual gearbox
4 - Input shaft
5 - Output shaft
6 - Differential
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
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
Ratio
gh ht
pyri by
Vo
co lksw
by
Arrows indicate direction of travel. cted agen
Prote AG.

I - 1st gear
II - 2nd gear
III - 3rd gear
IV - 4th gear
V - 5th gear
R - Reverse gear
A - Final drive
T - Speedometer drive
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
3. Overview - power transmission 11

4 Repair notes
⇒ “4.1 General repair instructions”, page 12
4.1 General repair instructions
4.1.1 Gearbox
To ensure flawless and successful gearbox repairs, the greatest
care and cleanliness as well as the use of good and proper tools
are essential. Also note the basic rules on safety when performing
repair procedures.
A number of instructions generally applicable to the various repair
procedures are summarised under the topic “components”
⇒ page 12 . They are also repeated at numerous places in the
Workshop Manual. They apply for this particular workshop man‐
ual.
♦ When installing the manual gearbox, ensure that the dowel
sleeves between the engine and gearbox are correctly seated.
n AG. Volkswagen A
♦ When installing mounting brackets
olks
wageor waxed components,
G do
es n
ot g
clean the contact surfaces. by Contact surfaces must be free of
V ua
ed ran
wax and grease. or
is tee
h
ut or
♦ Allocate bolts andssother
a
components using ⇒ Electronic parts ac
catalogue (ETKA) .
ce
le
un
pt
an
d
♦ When changing a gearbox, fill with gear oil to lower edge of

itte
y li
rm
filler hole ⇒ page 87 .

ab
pe
ility
ot
♦ Capacities and specifications ⇒ page 2 .

wit
, is n
h re
4.1.2 Gaskets and seals

hole
spec
es, in part or in w
t to the co
♦ Thoroughly clean parting surfaces, and apply sealant ⇒ Elec‐

tronic Parts Catalogue (ETKA) .
♦ Apply sealant uniformly but not too thick.
rrectness of i
♦ Renew seals.
l purpos
♦ Radial oil seals.

nform
ercia
Before installing:
m
Lightly oil new seals/oil seals on outer diameter. Fill space be‐
com
tio
tween sealing lips -arrow- half full with sealing grease ⇒ Elec‐
n in
r
te o

thi
s
iva
do
After installation:
r
rp
cum
fo
en
g
Check gear oil level; top up oil to lower edge of oil filler hole if
n
t.
yi Co
op
necessary, specification ⇒ page 2 . C py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

4.1.3 Locking devices

♦ Renew retaining rings.
♦ Do not overstretch retaining rings.
♦ Retaining rings must locate properly in grooves.
♦ Renew spring pins. Installation position: slot must be in line
with direction of force.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
s c
4.1.4 Nuts and bolts s
ce
e
nl
pt
du
an
♦ Loosen and tighten bolts and securing nuts for covers and
itte
y li
housings in diagonal sequence.
erm
ab
ility
ot p
♦ Do not cant especially delicate parts, such as clutch pressure
wit
, is n
plates. Loosen and tighten bolts and nuts alternately and in
h re
hole
stages.
spec
es, in part or in w
♦ Specified torques given are for unoiled nuts, bolts and screws.
t to the co
♦ Always renew self-locking bolts and nuts.
rrectness of i
♦ Ensure with threaded connections that contact surfaces as
well as nuts and bolts are rewaxed only after assembly, if nec‐
l purpos
essary.
♦ Residual locking agent must be removed from all threaded
nform
ercia
holes into which self-locking bolts are screwed; this is done

with a screw tap. Otherwise there is a danger of bolts shearing
m
at
om
when subsequently being removed.

ion
c
in t
or
4.1.5 Mountings
his
ate
do
priv
♦ Install new tapered roller bearings as supplied and do not lu‐

um
for
en
bricate additionally.
ng
t.
yi Co
op py
♦ Install needle bearings with lettered side (thicker metal) to‐ t. C rig
gh ht
wards fitting tool. pyri by
Vo
co lksw
by
cted agen
♦ Tapered roller bearings fitted to one shaft must be renewed as Prote AG.
a set. Use same make of bearings.
♦ Heat inner races to maximum 100°C before installing.
♦ Do not interchange outer or inner races of bearings of the
same size. The bearings are matched in pairs.
4.1.6 Shims
♦ Measure shims at several points with a micrometer. The var‐
ious thicknesses make it possible to achieve the exact shim
thickness required.
♦ Check for burrs and damage.
♦ Install only flawless shims.
4. Repair notes 13
4.1.7 Synchro-rings
♦ Do not interchange them. 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)«. Volkswa
AG. gen AG
agen do
♦ Check the cone of the synchromeshed
olks gear for »scoring« and
w es n
ot g
yV
»signs of abnormal wear«. sed b ua
ran
ri tee
ho
♦ Moisten synchromesh mechanism
ut with gear oil before instal‐ or
ac
sa
ling. s
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
4.1.8 Gear wheels
h re
hole
spec
Before installing, clean and heat on a hot plate to maximum 100°
es, in part or in w
C.
t to the co
The temperature can be checked with thermometer -
V.A.G 1558- , ignition tester - V.A.G 1767- or diesel tester -
rrectness of i
V.A.G 1743- .
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.

5 Electrical components
⇒ “5.1 Overview of fitting locations - electrical components, man‐
ual gearbox”, page 15
⇒ “5.2 Overview of fitting locations – electrical components, clutch
mechanism”, page 15
5.1 Overview of fitting locations - electrical

components, manual gearbox
Reversing light switch - F4- -arrow-
Fitting location: in selector unit next to starter.
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
Gearbox neutral position sender - G701- -arrow-
erm
ab
ility
ot p
Fitting location: in area of selector unit beneath reversing light
wit
, is n
switch - F4- next to starter.
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
5.2 Overview of fitting locations – electrical
atio
om
n in
components, clutch mechanism
or c
thi
te
sd
a
Clutch pedal switch - F36- -1-

iv
o
r
rp
cu
o
m
f
Fitting location: on clutch pedal.

en
ng
t.
yi Co
Cop py
t. rig
gh ht
yri
Note
p by
co Vo
by lksw
cted agen
Prote AG.
♦ The clutch pedal switch - F36- is not installed on all vehicles.
♦ The clutch position sender - G476- is installed in vehicles with
start/stop system.
♦ The clutch position sender - G476- and clutch master cylinder
form one unit and cannot be renewed individually ⇒ Electronic
Parts Catalogue (ETKA) .
– Removing and installing clutch pedal switch - F36-

⇒ page 22
– Removing and installing clutch position sender - G476-
⇒ page 26 .
5. Electrical components 15
30 – Clutch
1 Clutch operation
⇒ “1.1 Assembly overview - pedal cluster”, page 16
⇒ “1.2 Assembly overview - clutch hydraulics”, page 18
⇒ “1.3 Assembly overview - clutch release mechanism”,
page 20
⇒ “1.4 Removing and installing clutch pedal switch F36 ”,
page 22
⇒ “1.5 Removing and installing mounting bracket for clutch pedal”,
page 22
⇒ “1.6 Removing and installing clutch pedal with mounting bracket
removed”, page 24
⇒ “1.7 Removing and installing over-centre spring with mounting
bracket removed”, page 25
⇒ “1.8 Removing and installing clutch master cylinder”,
page 26
⇒ “1.9 Removing and installing clutch slave cylinder”, page 31
⇒ “1.10 Bleeding clutch mechanism”, page 34
1.1 Assembly overview - pedal cluster

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
Note orise nte
eo
h
aut ra
s c
♦ Grease all bearing points and contact surfaces. s
ce
le
un
pt
♦ Allocate grease using ⇒ Electronic parts catalogue (ETKA) .
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
16 Rep. gr.30 - Clutch

1 - Bolt
❑ For mounting bracket to
bulkhead
❑ To unscrew, remove
plenum chamber cover.
❑ 25 Nm
2 - Bulkhead
❑ With support for mount‐
ing bracket
3 - Mounting bracket
❑ For mounting clutch
pedal
AG. Volkswagen AG d
❑ Removing and installing agen oes
olksw not
⇒ page 22 byV gu
ara
ed
ris nte
o
4 - Nut aut
h eo
ra
s c
❑ Renew after removal s
ce
le
un
pt
❑ For mounting bracket to
an
d
itte
bulkhead
y li
rm
ab
pe
❑ 25 Nm
ility
ot
wit
, is n
5 - Brake pedal mounting
h re
bracket
hole
spec
❑ Removing and installing
es, in part or in w
t to the co
⇒ Brake system; Rep.
gr. 46 ; Brake pedal;
Removing and installing
rrectness of i
mounting bracket .
l purpos
6 - Nut
❑ Renew after removal
nform
ercia
❑ 25 Nm
m
a
7 - Nut
com
tion in
❑ For connecting plate on
r
te o
clutch pedal mounting thi

s
iva
do
bracket.
r
rp
cum
fo

en
ng
t.
yi Co
❑ 9 Nm . Cop py
rig
ht ht
rig
8 - Nut py by
co Vo
by lksw
❑ For connecting plate on brake pedal mounting bracket. cted agen
Prote AG.
❑ 9 Nm
9 - Connecting plate
10 - Clutch pedal switch - F36-
❑ Not fitted in all vehicles
❑ Removing and installing ⇒ page 22
11 - Clutch pedal
❑ Remove after removing over-centre spring
12 - Support
❑ Removing and installing ⇒ Item 4 (page 19)
13 - Nut
❑ For master cylinder on mounting bracket
1. Clutch operation 17
❑ 25 Nm
14 - Master cylinder
❑ On vehicles with start/stop system, the clutch master cylinder and clutch position sender - G476- form
one unit and cannot be renewed individually ⇒ Electronic Parts Catalogue (ETKA) .
❑ Removing and installing with mounting bracket installed ⇒ page 26
❑ Removing and installing with mounting bracket removed ⇒ page 30
15 - Supply hose
16 - Over-centre spring
17 - Nut
❑ For mounting bracket to bulkhead
❑ 25 Nm
18 - Bolt
19 - Seal
❑ Between mounting bracket and bulkhead
❑ Position on master cylinder.
AG. Volkswagen AG d
agen oes
olksw not
1.2 Assembly overview - clutch hydraulics
yV
b gu
d ara
ise nte
or eo
h
aut ra
ss c
Note
ce
e
nl
pt
du
an
itte
y li
Lubricate all bearings and contact surfaces with grease ⇒ Elec‐

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.

1 - Brake fluid reservoir

2 - Supply hose
3 - Bulkhead
4 - Support
❑ Renew only with master
cylinder removed
❑ Detaching ⇒ page 20
❑ Pressing on
⇒ page 20
5 - Clutch pedal
⇒ page 26
6 - Master cylinder
❑ Removing and installing AG. Volkswagen AG d
agen
⇒ page 30 olksw
oes
not
byV gu
ara
d
7 - Clip orise nte
eo
h
ut
❑ Pull out clip to stop to
ss are‐ ra
c
move and install pipe/
ce
le
un
hose line
pt
an
d
itte
y li
8 - Seal
rm
ab
pe
ility
❑ Renew only if damaged
ot
wit
, is n
❑ Pull onto line connection
h re
hole
❑ Insert with brake fluid
spec
es, in part or in w
t to the co
9 - Pipe/hose line
❑ Allocation ⇒ Electronic
parts catalogue (ETKA)
rrectness of i
10 - Bracket
l purpos
❑ Secured to bulkhead
11 - Bracket
nform
ercia
12 - Bolt
m
a
com
tio
❑ 8 Nm
n in
r
te o
thi
13 - Gearbox
s
iva
do
r
rp
14 - Dust cap
um
fo
en
ng
t.
yi
15 - Bleeder valve
Co
Cop py
. rig
❑ Bleeding clutch mechanism ⇒ page 34
ht ht
rig by
copy Vo
lksw
16 - Bolt
by
cted agen
Prote AG.
❑ 20 Nm
17 - Slave cylinder
18 - Clip
❑ Pull out clip to stop to remove and install pipe/hose line
Lever off retainer -A- in direction of arrow.
Pressing master cylinder operating rod into retainer -A- in

-direction of arrow-
wage
1.3 Assembly overview - clutch release mechanism yV
olks es n
ot g
ua
d b 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
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

1 - Gearbox
2 - Ball-head pin
❑ Grease contact surface
of ball-head pin with
spline grease .
❑ Allocate grease using ⇒
Electronic parts cata‐
logue (ETKA) .
❑ 25 Nm
3 - Input shaft seal
❑ Renewing radial oil seal
for input shaft
⇒ page 177
4 - Guide bush
❑ With vulcanised oil seal
❑ If oil seal is damaged,
renew guide sleeve to‐
gether with oil seal
❑ Lubricate guide sleeve
in area of release bear‐
ing with MoS2 grease.
5 - Retaining spring
❑ Secure to clutch release
lever
6 - Socket head bolt
olks
wage es n
ot g
yV
❑ 18 Nmsed b ua
ran
ri tee
ho
7 - Clutchau release lever
t or
ac
ss
❑ Remove and install to‐
ce
le
un
gether with release

pt
an
d
itte
bearing.
y li
rm
ab
❑ Lubricate surface con‐

pe
ility
tacting ball pin with

ot
wit
, is n
MoS2 grease
h re
hole
spec
8 - Release bearing
es, in part or in w
t to the co
❑ Do not wash out bearing; wipe only

❑ Renew noisy bearings
❑ Lubricate contact surfaces of release lever with MoS2 grease
rrectness of i
l purpos
9 - Bolt
❑ Specified torque ⇒ Item 16 (page 19)
nform
ercia
10 - Slave cylinder
m

com
tion in
11 - Plunger
r
te o
thi
s
iva
❑ Grease plunger head with MoS2 grease

do
r
rp
cum
fo
12 - Assembly bolt
en
ng
t.
yi Co
❑ Secures clutch release lever when gearbox is installed.
Cop py
t. rig
gh
❑ Remove after gearbox has been installed.
ht
pyri by
Vo
co lksw
by
cted agen
Prote
Note
AG.
If the assembly bolt is not available,

an M 8 x 35 bolt can be used in‐
stead.
1.4 Removing and installing clutch pedal

switch - F36-
Note
♦ The clutch pedal switch - F36- is not installed on all vehicles.

♦ The clutch position sender - G476- is installed in vehicles with
start/stop system.
To make sure that the clutch pedal switch - F36- is securely seat‐
ed in the pedal cluster, the clutch pedal switch - F36- may only be
installed once.
Removing
– Remove lower cover on driver side ⇒ General body repairs,
interior; Rep. gr. 68 ; Compartments/covers; Removing and
installing dash panel end trim on driver side .
– Pull connector -1- off clutch pedal switch - F36- .
– Turn clutch pedal switch - F36- on housing 45° anti-clockwise
in direction of -arrow- and pull out of support -2-.
Installing
Install in reverse order of removal, observing the following:
– Pull out plunger of clutch switch - F36- to stop.
• Clutch pedal must be in rest position.
– Now insert clutch pedal switch - F36- into assembly opening.
– To lock clutch pedal switch - F36- on housing,
ageturn
n AG.45°
Volkclock‐
swagen AG
does
wise. olksw not
yV gu b ara
ed
– Push connector onto clutch pedal
tho
riswitch
s - F36- . nte
e or
au ac
– Install lower cover on driver side
ss ⇒ General body repairs, in‐
ce
terior; Rep. gr. 68 ; Compartments/covers; Removing and

e
nl
pt
du
installing dash panel end trim on driver side .

an
itte
y li
erm
ab
ility
1.5 Removing and installing mounting

ot p
wit
, is n
bracket for clutch pedal

h re
hole
spec
Special tools and workshop equipment required

es, in part or in w
t to the co
♦ Hose clamps to 25 mm - 3094-

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
co lksw
by
cted agen
Prote AG.

AG. Volkswagen AG d
♦ Torque wrench - V.A.G 1331- ksw
agen oes
not
Vol
by gu
d 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
Removing
rrectness of i
– Remove battery and battery cover ⇒ Rep. gr. 27 .
l purpos
– Remove dash panel insert ⇒ Rep. gr. 90 .

– Remove lower cover on driver side ⇒ Rep. gr. 70 .
nform
ercia
– Unscrew nut -arrow- for brake pedal mounting bracket through

m
at
om
i
opening of removed dash panel insert.
on
c
in t
or
– Remove plenum chamber cover ⇒ Rep. gr. 64 .
his
ate
do
riv
– Lay a lint-free cloth under master cylinder.

p
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Clamp off supply hose -1- to brake fluid reservoir with hose
clamp to 25 mm - 3094- .
– Unclip supply hose from bracket -arrow- and remove from
master cylinder -2-.
– Pull out clip -3- for pipe/hose line to stop.
– Remove pipe/hose line -4- from master cylinder -2- and seal
it.
– In plenum chamber, pull clip -1- for wiring harness from bolt
-2-.
– Unscrew bolt -2- for clutch pedal mounting bracket.
– Remove clutch pedal switch - F36- ⇒ page 22 .
– Remove connecting plate between clutch pedal mounting
bracket and brake pedal mounting bracket
⇒ Item 9 (page 17) .
– Unscrew nut -arrow- for clutch pedal mounting bracket.
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,
– Unscrew relay carrier with diagnostic connection -1- from dash
spec
panel cross tube and carefully push it upwards.
t to the co
– Pull clutch pedal mounting bracket -2- from stud bolts and
carefully remove.
rrectne
Installing
ss o
cial p
f
– Install clutch pedal switch - F36- ⇒ page 22 .
inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
– Install nut -arrow- of brake pedal mounting bracket.
pr
cum
r
fo
en
ng
– Install dash panel insert ⇒ Electrical system; Rep. gr. 90 ;

t.
yi Co
op
Dash panel insert; Removing and installing dash panel insert . C py
t. rig
gh ht
yri by
– Install lower cover on driver side ⇒ General body repairs, in‐ cop Vo
by lksw
terior; Rep. gr. 70 . cted agen
Prote AG.
– Install plenum chamber cover ⇒ General body repairs, exte‐

rior; Rep. gr. 64 .
– Install battery and battery cover ⇒ Electrical system; Rep. gr.
27 ; Battery; Removing and installing battery .
– Bleed clutch mechanism ⇒ page 34 .
Specified torques
♦ ⇒ “1.2 Assembly overview - clutch hydraulics”, page 18
♦ ⇒ “1.1 Assembly overview - pedal cluster”, page 16
1.6 Removing and installing clutch pedal

with mounting bracket removed
Removing
– Remove clutch pedal mounting bracket ⇒ page 22 .
– Remove over-centre spring ⇒ page 25 .
– Separate clutch pedal from master cylinder ⇒ page 30 .

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
California 2010 ➤uth, Caravelle 2004 ➤ , Caravelle 2010 ➤ , Multivan
o eo
ra
2004 ...
a
ss 5-speed manual gearbox 02Z - Editionc 06.2019
ce
le
un
pt
– Remove nut -A-.
an
d
itte
y li
rm
ab
– Unscrew bolt and remove clutch pedal.
pe
ility
ot
wit
Installing
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
– The retainer -A- must be fitted to the master cylinder operating

rod -B-.
m
a
com
tion in
– Press clutch pedal in -direction of arrow- until it engages. En‐
r
te o
thi
sure that it is properly locked.
s
iva
do
r
– Install over-centre spring ⇒ page 25 .

rp
cum
fo
en
ng
Specified torques
t.
yi Co
Cop py
. rig
ht ht
rig by
copy Vo
by lksw
cted agen
Prote AG.
1.7 Removing and installing over-centre

spring with mounting bracket removed
Removing
– Carefully clamp lower section of mounting bracket/clutch ped‐
al in vice with protective jaw pads.
– Depress clutch pedal down to stop.
– Compress over-centre spring -B- using pliers -A-.
– First remove over-centre spring from bar -C- of mounting
bracket.
– Then guide away from clutch pedal pin.
– Carefully release tension from over-centre spring.
Installing

– Depress clutch pedal down to stop.
– Compress removed over-centre spring -B- using pliers -A-.
• The mounting area for the clutch pedal pin must be horizontal.
– First fit over-centre spring in clutch pedal pin.
– Then lock over-centre spring into mounting bracket extension
-C-.
– Carefully release tension from over-centre spring.
WARNING
If over-centre spring is improperly installed, it will jump uncon‐

trolled out of mounting bracket.
♦ Cover over-centre spring with a cloth.
♦ Check function of over-centre spring.
♦ Operate clutch several times to do so.
Specified torques
1.8 Removing and installing clutch master

cylinder . Volkswage n AG n AG d
wage oes
⇒ “1.8.1 Removing and installing clutch master
yV
olkcylinder
s with not
gu
mounting bracket installed”, page 26 ised b ara
nte
r
ho eo
⇒ “1.8.2 Removing and installing clutch
sa
ut master cylinder with ra
c
mounting bracket removed”, page s30
ce
le
un
pt
1.8.1 Removing and installing clutch master

an
d
itte
y li
erm
cylinder with mounting bracket installed

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

♦ Pliers - T10005-
♦ Sealing tool - T10249-
♦ Torque wrench - V.A.G 1331-
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
Removing
wit
is n
h re
ole,
spec
Note
t to the co
♦ Before replacing the clutch master cylinder due a suspected

defect, use Guided Fault Finding ⇒ Vehicle diagnostic
rrectne
tester.
♦ When performing work in the footwell, put cloths on the floor
ss
covering to protect it from possible brake fluid spills.

o
cial p
f in
♦ On vehicles with start/stop system, the clutch master cylinder

form
mer
and clutch position sender - G476- form one unit and cannot
atio
be renewed individually ⇒ Electronic Parts Catalogue (ET‐

om
KA) .
c
i
or
n thi
te
sd
iva
– Disconnect battery earth strap ⇒ Electrical system; Rep. gr.

o
pr
cum
r
fo
27 ; Battery; Disconnecting and connecting battery .

en
ng
t.
yi Co
– Remove battery and battery cover ⇒ Electrical system; Rep. Cop py
ht. rig
gr. 27 ; Battery; Removing and installing battery . rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– Remove lower dash panel trim on driver side ⇒ General body

repairs, interior; Rep. gr. 68 ; Compartments/covers; Remov‐
ing and installing dash panel trim on driver side .
– If fitted, remove clutch pedal switch - F36- ⇒ page 22 .
Caution
Risk of leaking brake fluid.

♦ During the following work, ensure that no brake fluid lands
on longitudinal member or gearbox. If this does happen,
clean the affected areas thoroughly.
♦ Lay a lint-free cloth under clutch master cylinder.
– To facilitate accessibility to clutch master cylinder, pull off side

battery cover from bulkhead.
– Clamp off supply hose -1- to clutch master cylinder with hose
clamps up to 25 mm - 3094- .
– Pull off supply hose -1- from connection -arrow- of clutch mas‐
ter cylinder -2-. AG. Volkswagen AG d
sw agen oes
k n ol ot g
yV
– Pull out securing
ise
d bclip -3- for pipe/hose assembly to stop.
ua
ran
r tee
ho
– Pull out pipe/hose
sa
ut line -4- from clutch master cylinder -2- and
or
ac
seal. 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
Note
t to the co
♦ Alternatively, sealing tool - T10249/1- can be used to clamp

off the supply hose.
rrectness of i
♦ Clamping off the plastic supply hose with hose clamps up to

l purpos
25 mm - 3094- will cause a permanent deformation.

♦ However, this does not damage the supply hose.
nform
ercia
♦ After removing the hose clamp, up to 25 mm - 3094- , the sup‐

m
at
om
ply hose must be returned to its original shape.

ion
c
in t
or
his
te
– Move clutch pedal to rest position.

a
do
priv
cum
or
Release clutch master cylinder operating rod from clutch pedal

f
en
g
as follows:
n
t.
yi Co
Cop py
t. rig
gh ht
– Press sides of retainer inwards -in direction of arrow- using pyri by
Vo
o
by c
pliers - T10005- .
lksw
cted agen
Prote AG.
Note
To assist clarity, clutch pedal is shown with mounting bracket re‐

moved.
– Pull clutch pedal in direction of retainer -A- for clutch pedal

switch - F36- .

. Volkswagen AG
gen AG d
California 2010 ➤ , Caravelle
Vol
ksw 2004 ➤ , Caravelle 2010
a oes
not ➤ , Multivan 2004 ...
by gu
ised 5-speed manual gearbox 02Z ara- Edition 06.2019
n
r tee
ho
ut or
– If fitted, disconnect electrical connector
ss
a
-1- from clutch position ac
sender - G476- .
ce
e
nl
pt
du
an
– Unclip wiring harness -2- from mounting bracket for clutch
itte
y li
erm
pedal -arrow-.
ab
ility
ot p
wit
, is n
h re
Note
hole
spec
es, in part or in w
The wire for the clutch position sender - G476- is located on the
t to the co
right side of the mounting bracket for the clutch pedal.
rrectness of i
l purpos
– Unscrew securing nuts -2- of clutch master cylinder -1-.

– Pull out clutch master cylinder -1- downwards.
nf
ercia
orm
Installing
m
atio
om
n in
c

or
thi
te
sd
a
Insert clutch master cylinder into retainer.

iv
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.
– Fit new securing nuts -2- for clutch master cylinder -1-, and
tighten them to specified torque ⇒ Item 13 (page 17) .
The retainer -A- must be fitted to the clutch master cylinder op‐
erating rod -B-.
– Push clutch pedal in direction of -arrow- until it engages.
Check that it is engaged securely.
– If fitted, install clutch pedal switch - F36- ⇒ page 22 .
– If present, clip wiring harness -2- for clutch position sender -

G476- to mounting bracket for clutch pedal -arrow-.
– Connect connector -1- to clutch position sender - G476- .
– Install lower dash panel trim on driver side ⇒ General body
repairs, interior; Rep. gr. 68 ; Compartments/covers; Remov‐
ing and installing dash panel trim on driver side .
– Press in pipe/hose line -4- at connection of clutch master cyl‐

inder -2- until securing clip -3- engages audibly.
– Test line by tugging on it.
– Fit supply hose -1- on connection -arrow- of clutch master cyl‐
inder.
– After removing hose clamps up to 25 mm - 3094- , return sup‐
ply hose to its original contour, if necessary.
– If removed, fit side battery cover on stud of bulkhead.
– Install battery and battery cover ⇒ Electrical system; Rep. gr.
27 ; Battery; Removing and installing battery .
Specified torques
1.8.2 Removing and installing clutch master

cylinder with mounting bracket removed
Special tools and workshop equipment required AG. Volkswagen AG d
agen oes
ksw
♦ Pliers - T10005- byV
ol not
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
es, in part or in w
t to the co
rrectness of i
Removing
l purpos

nform
ercia
– Remove over-centre spring ⇒ page 25 .

m
– Move clutch pedal to rest position.

at
om
ion
c
in t
Release clutch master cylinder operating rod from clutch pedal

or
his
e
as follows:
at
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
30
by lksw
cted agen
Rep. gr.30 - Clutch Prote AG.
– Use pliers - T10005- to press sides of mounting inwards in

-direction of arrow-.
– Pull clutch pedal in direction of retainer -A- for clutch pedal
switch - F36- .
– Then unscrew securing nuts for clutch master cylinder on
mounting bracket.
– Pivot retainer on actuator rod/clutch master cylinder by 90°.
– Remove clutch master cylinder from mounting bracket studs.
Installing
– Tighten new nuts securing clutch master cylinder to mounting
bracket to specified torque ⇒ Item 13 (page 17) .
– The retainer -A- must be fitted to the clutch master cylinder

operating rod -B-.
– Press clutch pedal in -direction of arrow- until it engages. En‐
sure that it is properly locked.
– Install over-centre spring ⇒ page 25 .
Specified torques
♦ ⇒ “1.1 Assembly overview - pedal cluster”, page 16 agen
AG. Volkswagen AG d
oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
1.9 Removing and installing clutch slave
an
d
itte
y li
rm
cylinder
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

um
fo
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 oes
olksw not
y V gu
California 2010 ➤ , Caravelle r2004
ise
d b
➤ , Caravelle 2010 ➤ , Multivan 2004 ara
nte ...
5-speed manual gearbox 02Z aut - Edition 06.2019
ho eo
ra
ss c
ce
e
Removing
nl
pt
du
an
itte
y li
erm
ab
Note
ility
ot p
wit
, is n
h re
♦ Before renewing the clutch slave cylinder due to a suspected hole
spec
defect, use Guided fault finding ⇒ Vehicle diagnostic
es, in part or in w
tester.
t to the co
♦ Make sure you do not press (step on) the clutch pedal if the
clutch slave cylinder is removed from the gearbox with the
rrectness of i
pipe/hose assembly still attached. Otherwise the piston will be
pressed out of the clutch slave cylinder and thus destroyed.
l purpos
– Disconnect battery earth strap ⇒ Electrical system; Rep. gr.
nform
ercia

m
– Disconnect connector -1-.
at
om
ion
c
in t
– Pull wiring harness -3- out of coolant expansion tank -2-.
or
his
ate
– Unscrew bolts -4-.
do
priv
cum
or
– Lay coolant expansion tank -2- to one side.

f
en
ng
t.
yi Co
op
Vehicles with diesel engine
C py
t. rig
gh ht
yri by
– Remove connecting hose between intake manifold and charge cop Vo
by lksw
air cooler ⇒ Rep. gr. 21 ; Charge air system; Assembly over‐
cted agen
Prote AG.
view - charge air system hose connections .
Continued for all vehicles
– Remove gear selector cable -A- from gearbox selector lever

by pressing securing clip in direction of arrow -1-.
– Remove gate selector cable -B- from relay lever by pressing
securing clip -arrow 4-.
– Remove cable support bracket -C- from gearbox by pressing
catch in -direction of arrow 3- (pulling back).
– Pull pipe-hose line -2- out of retainer on gearbox -arrow-.

– Remove clutch slave cylinder from gearbox by unscrewing
bolts -3-.
Note
When doing this, pull off connector -1- from reversing light switch
- F4- if necessary.
– Clamp off hose of pipe/hose line -2- to clutch slave cylinder

using hose clamp up to 25 mm - 3094- .
– Lay a lint-free cloth under clutch slave cylinder.

– Pull out securing clip -arrow- for pipe/hose assembly to stop.

– Pull pipe/hose assembly out of clutch slave cylinder and seal
opening.
Caution
Risk of contamination due to brake fluid spill.

♦ Do not operate clutch pedal after pipe/hose line has been
disconnected.
AG. Volkswagen AG d
agen oes
olksw not
Installing d by V gu
ara
rise nte
Install in reverse
utho order of removal, observing the following: eo
ra
s a c
s
ce
le
Seals and O-rings for pipe and hose lines

un
pt
an
d
itte
y li
Item Material of line connection
erm
ab
ility
ot p
1 Line connection with circumferential groove
wit
is n
-arrow 1-
h re
ole,
2 Line connection with shoulder -arrow 2-
spec
3 Line connection with shoulder -arrow 2- and cir‐
t to the co
cumferential groove -arrow 3-
• For line connection having circumferential groove -arrow 1-
rrectne
and -arrow 3-, a seal or O-ring must be set there.
ss o
cial p
– Install clutch slave cylinder, and tighten bolts -3- to specified

inform
torque ⇒ Item 16 (page 19) .

mer
atio
m
– Push retaining clip of pipe/hose assembly to stop into clutch

o
n
c
slave cylinder.
i
or
n thi
te
sd
a
– Insert pipe/hose assembly -2- into clutch slave cylinder onto

iv
o
r
stop.
p
cum
r
fo
en
ng
t.
– Test pipe/hose line by tugging on it.
yi Co
Cop py
t. rig
– Bleed clutch mechanism after installing clutch slave cylinder
gh ht
yri by
⇒ page 34 . cop Vo
by lksw
cted agen
Prote AG.
Fit selector mechanism on gearbox ⇒ page 49 .
Adjust selector mechanism ⇒ page 55 .
– Bolt on coolant expansion tank ⇒ Rep. gr. 19 ; Cooling sys‐
tem/coolant; Overview of fitting locations - cooling system .
– Connect earth strap to battery ⇒ Electrical system; Rep. gr.
Specified torques
♦ ⇒ “1.3 Assembly overview - clutch release mechanism”, page
20
1.10 Bleeding clutch mechanism
Note
♦ Bleeding may only be carried out using the brake filling and
bleeding equipment.
♦ The connection of the bleeder must be free of deposits con‐
taining mineral oil.

♦ Brake filling and bleeding unit - VAS 5234-
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
Brake fluid specifications ⇒ Rep. gr. 47 .
ce
le
un
pt
an
– Connect brake filling and bleeding unit - VAS 5234- .
d
itte
y li
erm
ab
To bleed system, use 670 mm bleeder hose - V.A.G 1238/B3- if
ility
ot p
necessary.
wit
is n
h re
– To do this, connect the bleeder hose to the collector bottle of
ole,
spec
the brake bleeding device.
t to the co
– Connect bleeder hose to bleeder -arrow-.
– Pressurise system to 2 bar.
– Open bleeder valve. rrectne
– Move clutch pedal 15 to 20 times quickly by hand from stop to

ss
stop.
o
cial p
f inform
– Close bleeder valve.

mer
atio
– After completing bleeding procedure, when the pressure of

om
2 bar is released, operate clutch pedal ten more times to its

c
i
or
n thi
limit by foot.
te
sd
iva
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.

2 Clutch
⇒ “2.1 Assembly overview - clutch”, page 35
⇒ “2.2 Removing and installing clutch”, page 37
2.1 Assembly overview - clutch
Note
♦ Check whether dowel sleeves for aligning engine and gearbox are fitted in cylinder block and install if nec‐
essary.
♦ If dowel sleeves are not fitted, difficulties shifting gears, clutch problems and possible noises from the gear‐
box (rattling of gears which are not engaged) could occur.
G. Volkswagen nA AG do
wage e
♦ Renew clutch plates and
y V pressure plates with damaged
olks s no
t gu or loose rivet connections.
b ara
ed
♦ Renew pressure
tho
rplates
is and clutch plates together only. nte
e or
au a
♦ Select clutchss plate and pressure plate according to engine code cand ⇒ Electronic parts catalogue (ETKA) .
ce
le
un
pt
♦ For self-adjusting clutches (with SAC pressure plate), renew clutch and pressure plates or move them to
an
d
itte
another gearbox only as a pair.
y li
erm
ab
ility
ot p
wit
is n
h re
1 - Flywheel
ole,
spec
❑ Ensure that centring
pins fit tightly
t to the co
❑ Contact surface for
clutch lining must be
free of grooves, oil and
rrectne
grease
ss o
⇒ Rep. gr. 13
cial p
f inform
2 - Clutch plate
mer
atio
❑ Allocation ⇒ Electronic
om
parts catalogue (ETKA)

n
c
i
or
n thi
e
❑ Fitting position with two-

t
sd
va
part flywheel: the raised

i
o
pr
cum
r
section of the clutch

fo
en
ng
plate -arrow- faces pres‐

t.
yi Co
op
sure plate. C py
ht. rig
rig ht
❑ Installation position with py by
co Vo
single piece flywheel:
by lksw
cted agen
spring cage faces pres‐
Prote AG.
sure plate
❑ Text
“Getriebeseite” (gear‐
box side), if present,
faces pressure plate or
gearbox
❑ Centring ⇒ page 37
❑ Lightly grease splines
2. Clutch 35
Note
Clean input shaft splines and, on

used clutch plates, hub splines. Re‐
move corrosion. Apply only a very
thin coat of spline grease ⇒ Elec‐
tronic parts catalogue (ETKA) to in‐
put shaft splines. Then, move the
clutch plate back and forth on the
drive shaft until the hub moves easi‐
ly on the shaft. Always remove ex‐
cess grease.
3 - Thrust plate
❑ Check ends of diaphragm spring ⇒ page 38
❑ Checking spring connections and riveted connections ⇒ page 38
❑ Checking position of adjustment mechanism only for new pressure plates from “LuK” ⇒ page 39
Note
Pressure plates are protected

against corrosion and greased.
Clean contact surface only; other‐
wise the service life of the clutch will
be considerably reduced.
4 - Bolt
❑ Allocation ⇒ Electronic parts catalogue (ETKA)
❑ On two-part flywheel
♦ With thread M6 = 13 Nm.
♦ With thread M7 = 22 Nm.
❑ Loosen or tighten diagonally and in steps
❑ On one-piece flywheel: 22 Nm wage es n
olks o t gu
yV
db ara
rise nte
tho eo
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
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
ht. rig
rig ht
py by
co Vo
by lksw
36
cted agen
Prote AG.
Rep. gr.30 - Clutch
2.2 Removing and installing clutch
Special tools and workshop

equipment required
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
♦ Counter-hold tool - 3067-

♦ Centring mandrel - 3190A-
♦ Spline grease ⇒ Electronic parts catalogue (ETKA)
• Gearbox is removed.
Centring clutch plate and removing and installing pressure plate
– Loosen or tighten diagonally and in steps.
– 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 dam‐
age to pressure plate centring hole and flywheel centring pins.
2. Clutch 37
Checking ends of diaphragm spring -arrows-

• Wear up to half the thickness of the diaphragm spring is per‐
mitted. 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
Checking spring connections and riveted connections
es, in part or in w
t to the co
– Check spring connections -arrows A- for damage and riveted
connections -arrows B- for secure seating.
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.

Checking position of adjustment mechanism is necessary only for

new pressure plates from “LuK”.
♦ 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.
Installing
Volkswa
Install in reverse order of removal,
swa
gen AG observingn A
. ge G
thedofollowing:
es k not
Vol gu
d by ara
e nte
ris
Note utho eo
ra
a c
ss
ce
e
♦ Renew clutch plates and pressure plates with damaged or

nl
pt
du
loose rivet connections.
an
itte
y li
erm
ab
♦ Renew pressure plates and clutch plates together only.
ility
ot p
wit
♦ Select clutch plate and pressure plate according to engine
, is n
h re
code and ⇒ Electronic parts catalogue (ETKA) .
hole
spec
♦ If the clutch has burnt out, thoroughly clean the clutch housing,
es, in part or in w
t to the co
flywheel and parts of the engine facing the gearbox in order to
reduce the smell of burnt linings.
♦ Clean input shaft splines and, on used clutch plates, hub
rrectness of i
splines. Remove corrosion. Apply only a very thin coat of
l purpos
spline grease ⇒ Electronic parts catalogue (ETKA) to input

shaft splines. Then, move the clutch plate back and forth on
the drive shaft until the hub moves easily on the shaft. Always
nform
ercia
remove excess grease.

m
at
♦ Remove excess grease.

om
ion
c
in t
r
♦ Pressure plates are protected against corrosion and greased.

o
his
te
Clean contact surface only. Otherwise, the service life of the

a
do
riv
clutch will be considerably reduced.

p
cum
for
en
g
♦ Pressure plate contact surface and clutch plate lining must

n
t.
yi Co
op
make full contact with flywheel. Only then insert securing bolts. C py
t. rig
gh ht
pyri by
Vo
co
Specified torques
by lksw
cted agen
Prote AG.
♦ ⇒ “2.1 Assembly overview - clutch”, page 35
2. Clutch 39
34 – Controls, housing
1 Selector mechanism
⇒ “1.1 Installation position - selector mechanism”, page 40
⇒ “1.2 Assembly overview - gear knob and cover”, page 42
⇒ “1.3 Assembly overview - Gear lever and selector housing”,
page 43
⇒ “1.4 Assembly overview - selector lever and selector housing,
as of model year 2007”, page 45 AG. Volkswagen AG d
agen oes
lksw not
⇒ “1.5 Assembly overview - selector cables”, page 47 byV
o gu
ara
ed
is nte
⇒ “1.6 Removing and installing selector mechanism”, page 49uthor eo
a ra
s c
⇒ “1.7 Distinguishing between selector mechanisms”, page 51
s
ce
le
un
pt
⇒ “1.8 Adjusting selector mechanism in neutral, selector gate for
an
d
itte
y li
1st and 2nd gears”, page 52
erm
ab
ility
ot p
⇒ “1.9 Adjusting selector mechanism with 2nd gear engaged”,
wit
is n
page 55
h re
ole,
⇒ “1.10 Renewing selector shaft seal”, page 59
spec
t to the co
⇒ “1.11 Removing and installing relay lever”, page 60
1.1 Installation position - selector mechanism
rrectne
Arrow -A- gear selection movement
s
Arrow -B- gate selection movement
s 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.
40 Rep. gr.34 - Controls, housing

A - Gear selector cable

B - Gate selector cable
1 - Gearbox selector lever
2 - Deflector lever
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.
1. Selector mechanism 41
1.2 Assembly overview - gear knob and cover
1 - Emblem
2 - Bolt
❑ 6 Nm
3 - Gear knob
❑ Fits onto gear lever in
one position only
4 - Compression spring
5 - Cover with gear lever guide
❑ Fits onto gear lever in
one position only
6 - Gear lever
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
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.

1.3 Assembly overview - Gear lever and selector housing
Note
Lubricate bearing positions and sliding surfaces with grease ⇒ Electronic Parts Catalogue (ETKA) .
1 - Gear lever
❑ There are 2 different
types ⇒ page 44
❑ Allocation ⇒ Electronic AG. Volkswagen AG d
parts catalogue (ETKA) lksw
agen oes
not
o
byV gu
2 - Selector housing rised ara
nte
ho eo
3 - Cable end-piece aut ra
ss c
❑ For gate selector cable
ce
le
un
pt
an
❑ If renewed:
d
itte
y li
erm
ab
♦ Release at cable
ility
ot p
⇒ page 44
wit
is n
h re
♦ Press off ball head of gear
ole,
spec
lever e.g. with an open-jaw
spanner.
t to the co
♦ Insert in cable end-piece
during installation.
rrectne
♦ When adjusting selector
mechanism, engage cable
ss
with cable end-piece
o
cial p
f
⇒ page 52 .
inform
mer
4 - Securing clip
atio
m

o
n
c
i
or
n
❑ For gear selector cable
thi
te
sd
to selector housing
iva
o
pr
cum
r
5 - Guide
fo
en
ng
t.
yi
❑ For long-arm spring
Co
Cop py
⇒ Item 8 (page 43) ht. rig
rig ht
py by
co Vo
by lksw
cted
⇒ page 45
agen
Prote AG.
6 - Bolt
⇒ page 45
❑ 3.5 Nm
7 - Guide pin
8 - Long-arm spring
❑ Note installation position ⇒ page 45
❑ Installing ⇒ page 45
9 - Guide bush
10 - Securing clip
❑ For gate selector cable to selector housing
11 - Gate change cable
❑ Replace together with gear selector cable
12 - Gear change cable

❑ Replace together with gate selector cable
13 - Spacer
14 - Grommet
15 - Bolt
❑ 23 Nm
16 - Plate
17 - Cable end-piece
❑ If renewed:
♦ Release at cable ⇒ page 45
♦ Press off ball head of gear lever e.g. with an open-jaw spanner.
♦ Insert in cable end-piece during installation.
♦ When adjusting selector mechanism, engage cable with cable end-piece ⇒ page 52 .
18 - Clamping sleeve
19 - Bolt
❑ For gear lever to selector housing
❑ 8 Nm +90°
Distinguishing between gear levers

I - Hole -arrow A- for adjusting selector mechanism points towards
driver; adjusting selector mechanism ⇒ page 52 .
AG. Volkswagen AG d
agen oes
II - Hole -arrow B- for adjusting selector mechanism points to‐Volksw not
gu
y
wards front end; adjusting selector mechanism ⇒ page 55 se
d.b ara
nte
ri
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
es, in part or in w
t to the co
rrectness of i
l purpos
Releasing end-piece for gate selector cable

– Pull selector lever sleeve up out of gear lever panel and slip
nform
ercia
over selector lever knob.

m
at
om
– Push down locking mechanism for cable end-piece -A- on gear

on
c
in t
selector cable to stop -arrow-.

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.

Releasing end-piece for gear selector cable

Multivan
– Remove centre left knee padding ⇒ Rep. gr. 70 .
Transporter
– Remove middle footwell trim ⇒ Rep. gr. 70 .
– Push down locking mechanism for cable end-piece -1- on gateolkswage es n
ot g
selector cable to stop -arrow-. db
yV ua
ran
e
ris tee
For clarity of illustration, cable end-piece for gate selectortho cable or
au
is shown with cover beneath gear lever removed. ss ac
ce
le
un
pt
an
Removing and installing long-arm spring guide
d
itte
y li
rm
ab
– Press cable end-piece -2- for gate change cable off selector
pe
ility
lever ball head, e.g. with an open-end spanner.
ot
wit
, is n
h re
– Unscrew bolt -arrow- for long-arm spring guide -1-.
hole
spec
– Remove long-arm spring guide.
es, in part or in w
t to the co
Install in reverse order of removal.
rrectness of i
l purpos
nform
ercia
Installing long-arm spring

m
a
com
t
Installation position:
ion in
r
te o
– Position straight side of long-arm spring with extension -B-
thi
s
iva
pointing towards selector housing.
do
r
rp
cum
fo
– First engage extension -B- of long-arm spring beneath pin
en
ng
t.
-arrow-.
yi Co
Cop py
ht. rig
– Then pull extension -A- up to top of pin -arrow-. rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
1.4 Assembly overview - selector lever and selector housing, as of model year
2007
Note
Lubricate bearing positions and sliding surfaces with grease ⇒ Electronic Parts Catalogue (ETKA) .
1 - Gear lever
2 - Selector housing
3 - Cable end-piece
❑ If renewed:
♦ Release at gate selector
cable ⇒ page 44
♦ Press off ball head of gear
lever e.g. with an open-jaw
spanner.
♦ When installing, connect to
gate selector cable
⇒ page 55
4 - Securing clip
to selector housing
5 - Bearing mounting
6 - Long-arm spring
⇒ page 47
7 - Securing clip
to selector housing
❑ Replace together with
gear selector cable
AG. Volkswagen AG d
agen
9 - Gear change cable Volksw
oes
not
gu
by ara
❑ Replace together with rise
d
nte
gate selector cable utho eo
ra
s a c
s
10 - Spacer
ce
e
nl
pt
du
an
11 - Grommet
itte
y li
erm
ab
12 - Bolt
ility
ot p
❑ 23 Nm
wit
, is n
h re
hole
13 - Nut
spec
es, in part or in w
14 - Cable end-piece
t to the co

❑ If renewed:
rrectness of i
♦ Release at gear selector cable ⇒ page 45

l purpos
♦ Press off ball head of gear lever e.g. with an open-jaw spanner
nf
ercia
♦ When installing, connect to gear selector cable ⇒ page 55

orm
m
15 - Bolt
atio
om
n in
❑ For gear lever to selector housing

or c
thi
e
❑ 8 Nm +90°
t
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
46
AG.
Rep. gr.34 - Controls, housing
Removing and installing long-arm spring

AG. Volkswagen AG d
Removing lksw
agen oes
not
Vo gu
y
Carry out following steps: rise d b ara
nte
tho eo
– Press cable end-piece
s au -3- off selector lever ball head, e.g. with ra
c
an open-jaw spanner.
s
ce
le
un
pt
– Unclip pivot pin -1-.
an
d
itte
y li
erm
ab
– Pull long-arm spring -2- off selector housing.
ility
ot p
wit
Installing
is n
h re
ole,
spec
– First hook grey lug of long-arm spring underneath pin
t to the co
-arrow B-.
– Then hook black lug of long-arm spring above pin -arrow A-.
rrectne
1.5 Assembly overview - selector cables
ss o
cial p
f inform
mer
Note
atio
om
n
c
♦ Lubricate bearing positions and sliding surfaces with grease ⇒ Electronic Parts Catalogue (ETKA) .
i
or
n thi
te
sd
a
♦ Gear selector cable and gate selector cable are one unit and can only be renewed together.
iv
o
pr
cum
r
fo
♦ Do not kink selector cables.

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
o lksw not
byV gu
ara
ed
ris nte
ut
ho 2004 ➤ , Caravelle 2010 ➤ , Multivan e o2004
ra
...
a
5-speed manual gearbox
ss 02Z - Edition 06.2019 c
ce
le
un
pt
1 - Selector housing
an
d
itte
y li
rm
ab
2 - Securing clip
pe
ility
ot
wit
, is n
h re
hole
spec
❑ Press onto relay lever
es, in part or in w
t to the co
⇒ Item 13 (page 48)
❑ Fitting position
⇒ page 40
rrectness of i
4 - Gear change cable
l purpos
❑ Press onto gearbox se‐

lector lever
nform
ercia
⇒ Item 16 (page 49)

m
a
com
ti
⇒ page 40
on in
r
te o
thi
5 - Bolt
s
iva
do
❑ For securing gear and
r
rp
cum
fo
gate selector cables to
en
ng
t.
body
yi Co
Cop py
❑ 23 Nm ht. rig
rig ht
py by
o Vo
6 - Retaining clip
by c lksw
cted agen
Prote AG.
❑ Must be inserted into
groove of end-piece of
each cable
❑ Must be pressed to re‐
move cable end-pieces
⇒ page 50
7 - Cable support bracket
8 - Bolt
❑ For selector cable sup‐
port bracket to gearbox
❑ 25 Nm
9 - Grommet
❑ Cable support bracket mounting on gearbox
10 - Spacer
11 - Securing clip
❑ With relay lever made from plastic securing clip
❑ Always renew securing clip
❑ Renew securing clip if damaged
❑ Removing securing clip ⇒ page 49
12 - Bearing bush
❑ Only with relay lever made from metal
13 - Deflector lever
❑ May be made from plastic or metal
❑ Metal relay lever is mounted in bearing bush ⇒ Item 12 (page 48) and secured with securing clip
⇒ Item 11 (page 48) .
❑ Fitting position ⇒ page 49
❑ Before installing, clean bearing points and sliding surfaces and lubricate with polycarbamide grease ⇒
Electronic Parts Catalogue (ETKA) .

14 - Slide block
15 - Nut
❑ 23 Nm
❑ With damper weight
❑ Install so that master spline aligns with selector shaft
❑ After installing, adjust selector mechanism ⇒ page 52
Installation position of gearbox selector lever/relay lever

1- Gearbox selector lever with damper weight
2- Relay lever engages in guide rail of gearbox selector lever
via shoe -arrow-.
AG. Volkswagen AG d
agen oes
olksw not
V gu
Removing relay lever securing d by
clip ara
rise nte
ho eo
– Lift tab in -direction
aut of arrow-. 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
1.6 Removing and installing selector mech‐

l purpos
anism
nform
ercia

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
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
♦ Grease ⇒ Electronic Parts Catalogue (ETKA)
Removing
– With ignition switched off, disconnect earth strap from battery
⇒ Rep. gr. 27 .
Vehicles with 4-cylinder diesel engine
– Remove connecting hose between intake manifold and charge
air cooler ⇒ Rep. gr. 21 .
by pressing securing clip -arrow 1-.
securing clip -arrow 2- or -arrow 4-.
. Volkswagen AG
gen AG does
– Remove cable support bracket -C- from gearbox
Vol
ksw cable support
a
not
bracket by pulling back catch -arrow 3-.
ed
by gu
ara
ris nte
utho eo
ra
a c
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
– Loosen and fold back floor covering on driver side until bolts
h re
-arrows- are accessible.
hole
spec
es, in part or in w
– Unscrew bolts -arrows- for operating cables on body.
t to the co
– Remove gear and gate selector cable on selector housing:
♦ approx. up to model year 2006 ⇒ page 43
rrectness of i
♦ approx. from model year 2007 onwards ⇒ page 45
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
– Detach selector housing from dash panel cross-member

te
sd
a
-arrows- and remove.

iv
o
r
rp
cu
o
Installing
f
en
ng
t.
yi Co
op
C py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

– Pull back catch of cable support bracket -1- -arrow A- and in‐
sert into gearbox cable support bracket -2- -arrow B-.
AG. Volkswagen A
Catch -1- must engage in ogearbox
lksw
agen cable support Gbracket.
does
no
V t gu
by
– Spread a small quantity
ris
ed of grease on pins of gearbox selector
ara
nte
lever -2- and of
ut
horelay lever -3-. eo
r a ac
ss
ce
e
nl
pt
du
Note
an
itte
y li
erm
ab
Illustration shows version with metal relay lever.
ility
ot p
wit
, is n
h re
– Press gear selector cable -4- onto gearbox selector lever -2-
hole
spec
and gate selector cable -5- onto relay lever -3-.
es, in part or in w
t to the co
– Check that cables are firmly seated on gearbox selector lever
and relay lever.
Securing clip must be engaged.
Vehicles with 4-cylinder diesel engine rrectness of i
l purpos
– Install connecting hose between intake manifold and charge

nf
ercia
orm

m
atio
om
n in
– Fit gear and gate selector cable on selector housing:

or c
thi
te
sd
♦ approx. up to model year 2006 ⇒ page 43

iva
o
r
rp
cu
♦ approx. from model year 2007 onwards ⇒ page 45

o
m
f
en
ng
t.
yi Co
– Adjust selector mechanism ⇒ page 52 . Cop py
t. rig
gh ht
yri
– Install middle footwell trim ⇒ Rep. gr. 70 . p by
co Vo
by lksw
cted agen
– Connect battery. Prote AG.
Observe procedure after connecting battery ⇒ Rep. gr. 27 .

Specified torques
♦ ⇒ “1.5 Assembly overview - selector cables”, page 47
♦ ⇒ “1.3 Assembly overview - Gear lever and selector housing”,
page 43
♦ ⇒ “1.4 Assembly overview - selector lever and selector hous‐
ing, as of model year 2007”, page 45
1.7 Distinguishing between selector mech‐

anisms
The selector mechanism was modified shortly after the start of
series production.
Differentiation in selector mechanism up to model year 2009

The hole in the gear lever for inserting locking pin - T10027- was
moved to the front end.
The locking pin ⇒ Item 2 (page 92) on the selector mechanism
cover of the gearbox has been discontinued.
In order to see version of gear lever, pull out gear lever cover
upwards.
I - Hole -arrow A- for adjusting selector mechanism points towards
driver. If hole is here, selector mechanism must be adjusted fol‐
lowing procedure ⇒ page 52 .
II - Hole -arrow B- in gear lever for adjusting selector mechanism
faces towards front end. If hole is here, selector mechanism must
be adjusted following procedure ⇒ page 55 .
1.8 Adjusting selector mechanism in neu‐

tral, selector gate for 1st and 2nd gears
olkswagen AG
en AG. V
Special tools and workshop equipment required olkswag does
not
V gu
by ara
♦ Pin - T10027- ris
ed nte
tho eo
s au ra
c
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.

Adjustment hole -arrow A- in gear lever points towards driver.

The following points are essential to ensure correct adjustment of
selector mechanism:
♦ Moving parts of operating elements and elements that transfer
force must function correctly.
♦ Selector mechanism must move freely.
♦ Gearbox, clutch and clutch mechanism must also be in proper
condition.
• Gearbox must be in neutral.
Note
Some of the illustrations in the working sequences below show

the selector mechanism of the 6-speed manual gearbox. They are
identical for the 5-speed manual gearbox together with the work‐
ing sequences described here.
Multivan
Transporter AG. Volkswagen AG d
agen oes
olksw not
yV gu
– Remove middle footwell trim ⇒ Rep. gr. is70
e .
d b ara
nte
or eo
h
All vehicles aut ra
c
ss
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
– Push down locking mechanism for cable end-piece -1- on gate

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
o
by c lksw
cted agen
Prote AG.
Secure selector shaft as follows:

– Press selector shaft down in -direction of arrow 1-.
– While pressing selector shaft down, turn angled rod -A- in
-direction of arrow 2-.
This locks the selector shaft and it cannot be moved any more.
Now secure gear lever as follows: olksw

AG. V agen AG
agen does
– Move gear lever inVoneutral
lksw towards left into selector
not gate for
gu
1st and 2nd gears.
sedb
y ara
n i tee
th pin - T10027- through hole of gear lever into or
– Guide locking
au
or
ac
hole of selector
ss
housing.
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
– Now press in -direction of arrow- against lug of securing mech‐

anism for cable end-piece -1- on gate selector cable.
rrectness of i
Spring presses locking mechanism into original position.

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
– Then press in -direction of arrow- against lug of securing Cop py
mechanism for cable end-piece -A- on gear selector cable.
t. rig
gh ht
pyri by
Vo
o
by c
lksw
cted agen
Prote AG.

– Turn angled rod -A- for locking selector shaft back to its initial
position in -direction of arrow-.
n AG. Volkswagen AG
– Pull out locking pin - T10027- from
olks selector lever and selector
wage does
not
housing holes. d byV gu
ara
e nte
ris
Multivan utho eo
ra
a c
ss
– Install centre left knee cushion ⇒ Rep. gr. 70 .
ce
e
nl
pt
du
an
Transporter
itte
y li
erm
ab
– Install middle footwell trim ⇒ Rep. gr. 70 .
ility
ot p
wit
, is n
h re
hole
– Clip selector lever sleeve into gear lever panel.
spec
es, in part or in w
t to the co
Function
• With gearbox in neutral, gear lever must rest in selector lever
gate for 3rd and 4th gear.
rrectness of i
– Depress clutch pedal.
l purpos
– Select all gears several times. Pay particular attention to op‐

eration of reverse gear lock. nf
ercia
orm
Should a gear fail to engage smoothly after repeated selection,

m
atio
m
vertical play of selector shaft should be checked as follows:

o
n in
or c
– Engage 1st gear.

thi
te
sd
iva
– Press gear lever left to stop and release.

r
rp
cu
o
m
f
en
ng
– At the same time, a second mechanic should observe selector

t.
yi Co
op
shaft in gearbox. C py
t. rig
gh ht
pyri by
Vo
o
– When gear lever is moved, selector shaft must have approxi‐
c by lksw
cted agen
mately 1 mm clearance -direction of arrow-.
Prote AG.
– If this is not the case, adjust selector mechanism ⇒ page 52 .
1.9 Adjusting selector mechanism with 2nd

gear engaged
♦ Pin - T10027-
♦ Setting gauge - T10217-
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
Note configuration of selector mechanism in vehicles up to model
erm
ab
year 2009:
ility
ot p
wit
, is n
Adjustment hole -arrow B- in gear lever points towards front end.
h re
hole
spec
If the manual gearbox is equipped with a retaining pin, is it not
es, in part or in w
used to adjust the shift mechanism.

The following points are essential to ensure correct adjustment of t to the co
selector mechanism:
rrectness of i
♦ Moving parts of operating elements and elements that transfer

l purpos
force must function correctly.

♦ Selector mechanism must move freely.
nf
ercia
♦ Gearbox, clutch and clutch mechanism must also be in proper

rm
m
condition.
atio
om
n in
c
• Gearbox in neutral at the start of procedure.

or
thi
te
sd
iva
o
r
rp
cu
Note
o
m
f
en
ng
t.
yi Co
op py
Some of the illustrations in the working sequences below show t. C rig
gh ht
the selector mechanism of the 6-speed manual gearbox. They are pyri by
Vo
o
identical for the 5-speed manual gearbox together with the work‐
c by lksw
cted agen
ing sequences described here.
Prote AG.
Multivan
Transporter
All vehicles


AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
– Push down locking mechanism for cable end-piece -1- on gate
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tio
Engage 2nd gear using gearbox selector lever as follows:
n in
r
te o
thi
– In order to gain access to selector shaft, it may be necessary
s
iva
do
to remove engine cover panel.
r
rp
cum
fo
– Push adjusting gauge - T10217- between gearbox selector
en
ng
t.
yi
lever -A- and selector mechanism cover -B- from in front onto
Co
Cop py
selector shaft to stop. ht. rig
rig ht
py by
o Vo
– At the same time, press gearbox selector lever and selector by c lksw
cted agen
shaft down against adjusting gauge - T10217- to stop in
Prote AG.

– Now shift gearbox selector level to back
– Remove adjusting gauge - T10217- from selector shaft.
Now secure gear lever as follows:

– Move gear lever in neutral towards left into selector gate for
1st and 2nd gears.
– Guide locking pin - T10027- through hole -A- of gear lever into
hole -B- of selector housing.
– Now press in -direction of arrow- against lug of securing mech‐

anism for cable end-piece -1- on gate selector cable.
– Then press in -direction of arrow- against lug of securing

mechanism for cable end-piece -A- on gear selector cable.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
– Pull out locking pin - T10027- from holes of selector lever -A-
ce
le
un
pt
and selector housing -B-.

an
d
itte
y li
– Shift gearbox to neutral position, and check function of selec‐

rm
ab
pe
ility
tor mechanism.
ot
wit
, is n
Multivan
h re
hole
spec
– Install centre left knee cushion ⇒ Rep. gr. 70 .

es, in part or in w
t to the co
Transporter
– Install middle footwell trim ⇒ Rep. gr. 70 .
rrectness of i

l purpos
– Clip selector lever sleeve into gear lever panel.

Function
nform
ercia
• With gearbox in neutral, gear lever must rest in selector lever

m
a
com
gate for 3rd and 4th gear.

ion in
r
te o
– Depress clutch pedal.

thi
s
iva
do
– Select all gears several times. Pay particular attention to op‐

r
rp
cum
fo
eration of reverse gear lock.

en
ng
t.
yi Co
op
Should a gear fail to engage smoothly after repeated selection, C py
t. rig
vertical play of selector shaft should be checked as follows:
gh ht
pyri by
Vo
co lksw
by
– Engage 1st gear. cted agen
Prote AG.
– Press gear lever left to stop and release.

– At the same time, a second mechanic should observe selector
shaft in gearbox.

– When gear lever is moved, selector shaft must have approxi‐

mately 1 mm clearance -in direction of arrow-.
– If this is not the case, adjust selector mechanism ⇒ page 55 .
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
1.10 Renewing selector shaft seal
ot
wit
, is n
h re
hole
spec
es, in part or in w
♦ Tube - VW 423-
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
♦ Sealing grease ⇒ Electronic parts catalogue (ETKA)

Removing
– Remove gearbox selector lever from selector shaft.
– Carefully lever out selector shaft oil seal using a screwdriver.
Installing
– Lightly oil new oil seal on outer diameter. Fill space between
sealing lips -arrow- half full with sealing grease .
– Drive in new oil seal to stop, being careful not to cant oil seal.
– Install gearbox selector lever ⇒ Item 8 (page 92) on selector
shaft.
– Tighten new nut for gearbox selector lever on selector shaft.
– Check gear oil ⇒ page 87 .
Specified torques
♦ ⇒ “5.4 Assembly overview - selector unit”, page 92
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
1.11 ss Removing and installing relay lever
ce
e
nl
pt
du
⇒ “1.11.1 Removing and installing relay lever, metal”, page 60

an
itte
y li
erm
ab
⇒ “1.11.2 Removing and installing relay lever, plastic”,

ility
ot p
page 61
wit
, is n
h re
1.11.1 Removing and installing relay lever,

hole
spec
metal
es, in part or in w
t to the co
Removing
rrectness of i

l purpos

nform
ercia

m
at
Vehicles with 4-cylinder diesel engine

om
ion
c
in t
r

o
his
te

a
do
riv

p
cum
for
en
g

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

– Push locking element -3-, and remove cable -2- while doing
this.
– Remove securing clip -4-.
– Remove relay lever -1-.
Installing
Note
swage es n
♦ If a new plastic relay lever is installed,
byV
olk
the bearing bushes ot g
ua
-5- must be removed. ir se
d ran
tee
tho
or
♦ For the allocation of thessrelay
au lever, refer to ⇒ Electronic Parts ac
Catalogue (ETKA) .
ce
le
un
pt
♦ Before installing, clean bearing points and sliding surfaces and
an
d
itte
y li
lubricate with polycarbamide grease ⇒ Electronic Parts Cata‐
rm
ab
logue (ETKA) .
pe
ility
ot
wit
, is n
h re
Specified torques
hole
spec
es, in part or in w
t to the co
Component Specified torque
Bolts for coolant expansion tank 1.5 Nm
rrectness of i
l purpos
1.11.2 Removing and installing relay lever,

plastic
nform
mercia
a
Removing
com
tion in
r
te o
thi
s
iva
do

r
rp
cum
fo

en
ng
t.
yi Co
op
C py
t. rig
gh ht
yri by
Vehicles with 4-cylinder diesel engine cop Vo
by lksw
cted agen
Prote AG.
– Push locking element -3-, and remove cable -2- while doing
this.
– Remove securing clip -4-.
– Remove relay lever -1-.
Installing
Note
Before installing, clean bearing points and sliding surfaces and

lubricate with polycarbamide grease ⇒ Electronic Parts Cata‐
logue (ETKA) .
Specified torques

Bolts for coolant expansion tank 1.5 Nm
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
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
co lksw
by
cted agen
Prote AG.

2 Removing and installing gearbox

⇒ “2.1 Specified torques for gearbox”, page 63
⇒ “2.2 Removing gearbox”, page 63
⇒ “2.3 Removing gearbox, 2010►”, page 69
⇒ “2.4 Installing gearbox”, page 76
⇒ “2.5 Installing gearbox, 2010►”, page 80
2.1 Specified torques for gearbox

Gearbox to engine
Item Bolt Quantity Nm
AG. V2o lkswagen AG
1 M12 × 150 agen 80 does
ksw
♦ Additional connection of starterby
Vto gear‐
ol not
gu
box ris
ed
ara
nte
tho eo
♦ With M8 stud s au ra
c
s
ce
e
nl
pt
2 M12 × 150 1 80
du
an
itte
♦ With M8 stud
y li
erm
ab
ility
ot p
3 M10 × 50 3 40
wit
, is n
h re
4 M12 × 60 1 80
hole
spec
5 M12 × 55 1 80
es, in part or in w
t to the co
Items -A- and -B-: dowel sleeves for centring
rrectness of i
2.2 Removing gearbox
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.
2. Removing and installing gearbox 63


equipment required
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
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
♦ Support - 10 - 222 A-
t. rig
gh ht
pyri by
Vo
o
by c
♦ Hook - 10 - 222 A /2-
lksw
cted agen
Prote AG.
♦ Adapter - 10 - 222 A /3-
♦ Shackle - 10 - 222 A /12-
♦ Adapter - 10 - 222 A /16-
♦ Adapter - 10 - 222 A /23-
♦ Gearbox support - 3282-

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
♦ Adjustment plate - 3282/41-

erm
ab
ility
ot p
♦ Pin - 3282/34-
wit
is n
h re
♦ Support - 3282/59-
ole,
spec

t to the co

♦ Engine and gearbox jack - V.A.G 1383 A- discontinued
rrectne
♦ Multi-purpose grease ⇒ Electronic Parts Catalogue (ETKA)

s

s o
cial p
f in

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
o
by c lksw
cted agen
Prote AG.

5-speed manual gearboxe02Z - Edition 06.2019
n AG. Volkswagen AG ag does
ksw not
Vol gu
♦ Engine and gearboxedjackby - VAS 6931- ara
nte
oris eo
th
au ra
c
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
– With ignition switched off, disconnect earth strap from battery
⇒ Rep. gr. 27 .
ss o
– Remove plenum chamber cover ⇒ Rep. gr. 64 .
cial p
f inform
– In vehicles with particulate filter, this filter must be removed ⇒
mer
Rep. gr. 26 .
atio
om
n
c
– Unbolt coolant expansion tank and place to side. Do not open
i
or
n thi
e
cooling system.
t
sd
iva
o
pr
c
– Pull off connector -arrow- at coupling point for exhaust gas
um
r
fo
recirculation valve - N18- from bracket for vacuum reservoir en

ng
t.
yi Co
-1-. t. Cop py
rig
gh ht
– Remove connecting hose -2- between intake manifold and yri
p by
o Vo
charge air cooler ⇒ Rep. gr. 21 . by c lksw
cted agen
Prote AG.
– Disconnect connector -arrow- from sender on fuel supply

hose.

securing clip -arrow 2- or -arrow 4-.
– Remove cable support bracket -C- from gearbox cable support
bracket by pulling back catch -arrow 3-.
– Then remove right and left bulkhead panels from plenum
chamber ⇒ Rep. gr. 50 .
– Remove protective caps for suspension struts.

– Place adapter - 10 - 222 A /23- behind suspension strut

-arrow A- and on lock carrier at front -arrow B-.
– If there are hoses and cable connections in area of engine
support eye for support bracket - 10 - 222 A- , remove these
now. n AG. Volkswagen A G do
wage es n
olks ot g
byV ua
ed ran
ris tee
tho or
au ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
– Secure support bracket - 10 - 222 A- in conjunction with adapt‐
wit
, is n
h re
er - 10 - 222 A /3- and adapter - 10 - 222 A /16- to adapter -
hole
10 - 222 A /23- .
spec
es, in part or in w
t to the co
– Hook shackle - 10 - 222 A /12- into retaining eye on front of
engine and then insert spindle - 10 - 222 A /11- in shackle .
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
co lksw
by
cted
– Attach hook - 10 - 222 A /2- in rear lifting eye on engine.
agen
Prote AG.
– Slightly preload engine/gearbox assembly using spindle - 10

- 222 A /11- and adapter - 10 - 222 A /16- .
– Loosen wheel bolts on front left and front right.
– Raise vehicle.
– Remove front wheels.
– If fitted, remove noise insulation ⇒ General body repairs, ex‐
terior; Rep. gr. 66 ; Exterior equipment; Noise insulation .
– Remove subframe, observe fixing of subframe when doing this
⇒ Rep. gr. 40 .
– Unbolt left drive shaft from gearbox and tie it up ⇒ Rep. gr.
40 .

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
California 2010 ➤ , Caravelle 2004au➤
t , Caravelle 2010 ➤ , Multivan 2004 ...
ho eo
ra
5-speed manual gearbox 02Z - Edition
ss 06.2019 c
ce
e
nl
pt
du
an
– Remove right drive shaft -A- from rear torque reaction support
itte
y li
of engine -arrows-.
erm
ab
ility
ot p
– Pull right drive shaft off gearbox stub shaft, raise and secure.
wit
, is n
h re
– Unbolt wiring harness retainer from starter.
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
– Remove earth strap -1- from lower starter bolt -4-.

m
at
om
– Remove connector and wire from starter.
ion
c
in t
or
– Remove lower starter bolt -4-.
his
ate
do
riv
– Remove starter -2- ⇒ Rep. gr. 27 .

p
cum
for
en
g
– Remove engine/gearbox connecting bolt -3-.

n
t.
yi Co
Cop py
– Remove connector from drive for tachograph, if fitted.
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Position engine and gearbox jack - VAS 6931- with universal

support - V.A.G 1359/2- under gearbox, and press against it
slightly.
– Unscrew hexagon bolts -arrows- from left assembly mounting.
– Remove engine and gearbox jack - VAS 6931- with universal
support - V.A.G 1359/2- from beneath gearbox.
– Using adapter - 10 - 222 A /16- and spindle of support bracket

- 10 - 222 A- , lower engine/gearbox approx. 120 mm to di‐
mension -a-.
– Measure dimension -a- between lower side of longitudinal
member -1- and bolting surface of gearbox mounting -2-.
– When lowering engine and gearbox, guide front torque reac‐
tion support with support mounting past body.
– Remove upper engine/gearbox connecting bolts.

– Unplug connector for reversing light -1-.

Note
There is no need to remove slave cylinder with securing bolts

-3-.
– On slave cylinder, unclip line of hydraulic clutch at connector

-arrow- (pull clip) ⇒ page 18 .
Do not depress clutch pedal. agen
AG. Volkswagen AG d
oes
olksw not
To remove gearbox “02Z”, set up gearbox support - 3282/41- d bwith
yV gu
ara
adjustment plate - 3282- . oris e nte
eo
h
aut ra
– Insert gearbox support - 3282- in engine and gearbox
ss jack - c
VAS 6931- .
ce
e
nl
pt
du
an
itte
– Align arms of gearbox support according to holes in adjust‐
y li
erm
ab
ment plate .
ility
ot p
The symbols on the adjusting plate indicate the supports required.
wit
, is n
Arrow points in direction of travel.
h re
hole
spec
es, in part or in w
– Position engine and gearbox jack - VAS 6931- with gearbox
t to the co
support - 3282- under vehicle.
– Lock safety support - 3282/59- -arrow- on gearbox.
rrectness of i
– Remove lower engine/gearbox connecting bolts.
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
– Pull connector -1- off engine.

en
ng
t.
yi Co
op py
– Remove engine/gearbox connecting bolts -arrow A- t. C rig
gh ht
and-arrow B-. yri
p by
o Vo
by c lksw
cted
– Press gearbox away from engine, off dowel sleeves.
agen
Prote AG.
– Then lower gearbox.
2.3 Removing gearbox, 2010►

2.0 l diesel engine (common rail) and 2.0 l petrol engine

AG. Volkswagen AG d
Special tools and workshop agen oes
olksw not
V
equipment required d by gu
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
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.
♦ Support - 10 - 222 A-
♦ Hook - 10 - 222 A /2-
♦ Shackle - 10 - 222 A /12-
♦ Adapter - 10 - 222 A /16-
♦ Adapter - 10 - 222 A /23-

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
♦ Gearbox support - 3282-

♦ Adjustment plate - 3282/41-
♦ Engine and gearbox jack - V.A.G 1383 A- discontinued

♦ Engine and gearbox jack - VAS 6931-

♦ Adapter - 10 - 222 A /23-1-
– Disconnect earth strap at battery with ignition switched off ⇒
Electrical system; Rep. gr. 27 ; Battery; Disconnecting and
connecting battery .
– Remove left and right bulkhead panels from plenum chamber
⇒ General body repairs, exterior; Rep. gr. 50 ; Assembly
overview - bulkhead plenum chamber .
– Remove protective caps for suspension struts.
– Unbolt coolant expansion tank and place to side. Do not open
cooling system.
Vehicles with diesel engine AG. Volkswagen AG d
agen oes
lksw not
– Remove connecting hose between intake manifold and charge d by V o gu
ara
air cooler ⇒ Rep. gr. 21 . orise nte
h eo
ut ra
Continued for all vehicles ss a c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
securing clip -arrow 4-.
h re
hole
spec
– Remove cable support bracket -C- from gearbox cable support
es, in part or in w
bracket by pressing catch in -direction of arrow 3- (pulling
t to the co
back).
– Remove right cover and battery cover ⇒ General body repairs,
rrectness of i
exterior; Rep. gr. 63 ; Front bumper .
l purpos
– Insert end-piece - 10 - 222 A /23-1- in adapter - 10 - 222 A /

23- .
nf
ercia
o
– Place rear adapter - 10 - 222 A /23- suspension strut
rm
m
-arrow A- and front end-piece - 10 - 222 A /23-1- on lock carrier
atio
m
-arrow B-.
o
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.

– Secure support bracket - 10 - 222 A- in conjunction with adapt‐

er - 10 - 222 A /16- on adapter - 10 - 222 A /23- .
Note
♦ To avoid the spindle blocking when the engine/gearbox as‐

sembly is lowered, lubricate spindle and spindle guide of
adapter - 10-222A /16- .
♦ If there are hoses and cable connections in area of engine
support eye for support bracket - 10 - 222 A- , remove these
now.
– Hook shackle - 10 - 222 A /12- into rear retaining eye on engine

and insert hook - 10 - 222 A /2- in on adapter - 10 - 222 A /
16- .
– Take up weight of engine/gearbox assembly on adapter -
10-222 A /16- .
Remove left drive shaft ⇒ Rep. gr. 40 .
– Remove subframe with bracket for rear torque reaction sup‐
port ⇒ Rep. gr. 40 .
of engine -arrows-. wage
e ks s no
Vol t gu
d by ara
e nte
ris
utho eo
ra
a 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
– Remove earth strap -1- from lower starter bolt -4-.

– Remove starter -2- ⇒ Rep. gr. 27 .
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.

– Gearboxes for vehicles with start-stop system: pull connector

-arrow- off gearbox neutral position sender - G701- .
– Remove engine/gearbox connecting bolt -3-.
– If present, disconnect connector for tachograph sender -
G75- .
AG. Volkswagen AG d
agen oes
o lksw not
y V gu
Note ise
d b ara
nte
or eo
th
u ra
Lead seal of tachograph sender - G75- is only allowed to be at‐
s a c
s
tached by authorised specialist workshops ⇒ Electrical system;
ce
le
un
pt
Rep. gr. 90 .
an
d
itte
y li
rm
ab
pe
ility
– Pull off connector for reversing light switch - F4- -1-.
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
– Support gearbox with engine and gearbox support - VAS
r
te o
thi
6931- .
s
iva
do
r
rp
– Unscrew bolts for left assembly mounting -arrows-.

um
fo
en
ng
t.
yi
– Remove engine and gearbox jack - VAS 6931- .
Co
Cop py
t. rig
gh ht
pyri by
Caution
co Vo
by lksw
cted agen
Prote AG.
♦ Make sure that no cables, hoses, etc. are strained or

squashed when the engine/gearbox unit is lowered or
moved.
– Lower engine/gearbox assembly to dimension -a- (approx.

120 mm) using spindle of support bracket - 10 - 222 A- .
– Measure dimension -a- between lower side of longitudinal
member -1- and bolting surface of gearbox mounting -2-.
– When lowering engine and gearbox, guide front torque reac‐
tion support with support mounting past body.
– Remove upper engine/gearbox connecting bolts.

Note
There is no need to remove slave cylinder with securing bolts

-3-.
– Clamp off hose of pipe/hose line -2- to slave cylinder using

hose clamp up to 25 mm - 3094- .
– Pull out clip -arrow- for pipe/hose line onto stop.

– Pull pipe/hose line off slave cylinder.
Caution
Do not depress clutch pedal any longer.
– If present, remove support between particulate filter and gear‐

box ⇒ Rep. gr. 26 . AG. Volkswagen AG d
agen oes
ksw
To remove gearbox “02Z”, set up gearbox support - 3282/41- bywith
Vo l not
gu
ara
adjustment plate - 3282- . rised
nte
ho eo
ut
– Insert gearbox support - 3282- in engine and gearbox
ss a jack - ra
c
VAS 6931- .
ce
le
un
pt
an
d
– Fit adjustment plate - 3282/41- on gearbox support - 3282-

itte
y li
( adjustment plate fits in only one position).
rm
ab
pe
ility
ot
wit
, is n
ment plate .
h re
hole
spec
es, in part or in w
t to the co
support - 3282- under gearbox.
rrectness of i
– Lock safety support -arrow- to gearbox.
l purpos
– Remove bottom engine/gearbox connecting bolts.

nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

– Remove cover plate for flywheel -1-.

– Remove engine/gearbox connecting bolts -arrow-.
– Press gearbox off engine (dowel sleeves) and carefully swing
towards left longitudinal member.
– Then lower gearbox.
2.4 Installing gearbox
Caution
Observe the following points during all installation work, in par‐

ticular in the engine compartment, due to the space limitations:
♦ Route all the various lines and electrical wiring so that they
are in their original positions.
♦ Ensure that there is sufficient clearance to allomoving
ksw
age or es n
hot components. y V l ot g
ua
db e ran
ris tee
utho or
sa ac
If the gearbox is to be renewed, transfersthe following components
ce
e
to new gearbox:
nl
pt
du
an
itte
y li
♦ Relay lever -1-
erm
ab
ility
ot p
♦ Gearbox selector lever -2-
wit
, is n
h re
♦ Gearbox cable support bracket -3-
hole
spec
♦ Bracket -4- for hose-pipe line
es, in part or in w
♦ Tighten gearbox mounting -5- to specified torque t to the co

♦ Speed sender (if installed)
rrectness of i
If current gearbox is re-installed:

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.

5-speed
en AG. V
olkswmanual
agen AG gearbox 02Z - Edition 06.2019
ag does
ksw not
Vol gu
– Renew oil seal -arrow- on stub shaft eond b right.
y ara
nte
oris eo
– Grease right stub shaft splines -2-
au with multi-purpose
th
grease ra
⇒ Electronic Parts Catalogue s(ETKA)
s . c
ce
e
nl
pt
– Clean input shaft splines -1-, and lightly grease them using
du
an
itte
spline grease ⇒ Electronic parts catalogue (ETKA) .
y li
erm
ab
ility
The clutch plate must slide easily to and fro on the input shaft.
ot p
wit
Continued for all gearboxes , is n
h re
hole
spec
– Always renew self-locking bolts and nuts.
es, in part or in w
t to the co
– Check whether dowel sleeves for aligning engine and gearbox
are fitted in cylinder block and install if necessary.
rrectness of i
– Ensure that intermediate plate is correctly seated on engine.
l purpos
To install gearbox “02Z”, set up gearbox support - 3282- with ad‐

justment plate - 3282/41- .
nform
ercia

ment plate .
m
at
om
io
n
c
in t
r

o
his
ate
do
riv
– Place gearbox on engine and gearbox jack - VAS 6931- .

p
cum
for
en
g
– Align adjustment plate and gearbox parallel to one another.

n
t.
yi Co
Cop py
t. rig
gh
ht
pyri by
Vo
o
by c lksw
– Position engine and gearbox jack - VAS 6931- under vehicle.
cted agen
Prote AG.
– Raise gearbox.
– Align gearbox to engine and join.
– Screw in engine/gearbox connecting bolts -arrow A- and

-arrow B- and tighten to specified torque.
– Push connector -1- onto engine.
– After gearbox has been bolted to engine, remove gearbox
support - 3282- from gearbox.
– Screw in lower engine/gearbox connecting bolts and tighten
to specified torque.
– Screw in upper engine/gearbox connecting bolt and tighten to
specified torque.

– Clip line on slave cylinder of hydraulic clutch at connector

-arrow- ⇒ page 18 .
– Insert pipe/hose line for slave cylinder into retainer on gear‐
box.
– Attach connector for reversing light.
– Align engine and gearbox in installation position. To do this,
tighten threaded spindle of adapter - 10 - 222 A /16- and spin‐
dle of support bracket - 10 - 222 A- until gearbox mounting
contacts left longitudinal member.
– When raising engine and gearbox, guide front torque reaction
support with support mounting past body.
– Screw in new hexagon bolts -arrows- for left engine/gearbox

mounting and tighten to specified torque.
Caution
Do not remove support bracket 10-222 A until all bolts of left

subframe mounting are tightened to specified torque.
– Push on connector for tachograph drive, if fitted.

– Install starter -2- ⇒ Rep. gr. 27 . AG. Volkswagen AG d
agen oes
ksw not
– Bolt bracket for wiring harness to upper securingbyV
ol
bolt for start‐ gu
ara
er. rised
nte
ho eo
aut ra
s c
– Attach earth strap -1- to lower starter
s bolt -4-.
ce
le
un
pt
– Screw in engine/gearbox connecting bolt -3- and tighten to
an
d
itte
y li
specified torque.
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness
– Push right drive shaft -A- onto gearbox stub shaft.

o
cial p
f inform
– Screw bolts -arrows- into torque reaction support behind en‐

mer
gine with specified torque ⇒ Rep. gr. 40 .

atio
om
– Screw left drive shaft onto gearbox flange shaft ⇒ Rep. gr.
c
i
or
40 .
thi
te
sd
iva
– Install subframe ⇒ Rep. gr. 40 .

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.

Catch -1- must engage in gearbox cable support bracket.

– Spread a small quantity of grease ⇒ Electronic Parts Cata‐
logue (ETKA) on pins of gearbox selector lever -2- and relay
lever -3-.
– Check that cables are firmly seated on gearbox selector lever
and relay lever.
Securing clip must be engaged.
– Push connector -arrow- onto fuel hose sender.
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
– Push connector -arrow- onto bracket for vacuum reservoir

wit
is n
-1-.
h re
ole,
spec
– Install connecting hose -2- between intake manifold and

charge air cooler ⇒ Rep. gr. 21 .

t to the co
– Then mount right and left bulkhead panels onto plenum cham‐
ber ⇒ Rep. gr. 50 .
rrectne
– Install plenum chamber cover ⇒ Rep. gr. 64 .

ss
– Bolt on coolant expansion tank.

o
cial p
f in

form
mer
– Connect battery.
atio
om
n
c
Observe procedure after connecting battery ⇒ Rep. gr. 27 .

or
n thi
te
sd
a

iv
o
pr
cum
r
fo
– If present, install noise insulation ⇒ General body repairs, ex‐

en
ng
t.
yi
Co
Cop py
t. rig
gh
– Fit the wheels ⇒ Rep. gr. 44 .
ht
pyri by
Vo
co lksw
by
Specified torques
cted agen
Prote AG.

Gearbox to engine
Item Bolt Quantity Nm
1 M12 × 150 2 80
♦ Additional connection of starter to gear‐
box
♦ Stud M8 with hexagon drive.
2 M12 × 150 1 80
3 M10 × 50 3 40
4 M12 × 55 1 80 . Volkswage
en AG
wag80
n AG d
5 M12 × 55 1
Vo lks oes
not
by gu
ara
ed
Items -A- and -B-: dowel sleeves for centring oris nte
eo
th
au ra
c
ss
Gearbox mounting to body
ce
e
nl
pt
du
an
– Renew bolts.
itte
y li
erm
ab
ility
ot p
wit
, is n
Bolts -arrows- 50 Nm +90°
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
Gearbox mounting to gearbox
nform
ercia
– Renew bolts.
m
at
om
io
n
c
in t
or
Bolts -A- 50 Nm +90° 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.
2.5 Installing gearbox, 2010►
Caution
Observe the following points during all installation work, in par‐

ticular in the engine compartment, due to the space limitations:
♦ Route all the various lines and electrical wiring so that they
are in their original positions.
♦ Ensure that there is sufficient clearance to all moving or
hot components.

If current gearbox is re-installed:

– Renew oil seal -arrow- on stub shaft on right.
– Grease right stub shaft splines -2- with grease ⇒ Electronic
Parts Catalogue (ETKA) .
– Clean input shaft splines -1-, and lightly grease them using
spline grease ⇒ Electronic parts catalogue (ETKA) .
. Volkswagen AG
a gen AG does
The clutch plate must slide easily to and fro on the inputVoshaft.
lksw not
gu
by ara
ed
Continued for all gearboxes oris nte
eo
h
ut ra
– Always renew self-locking bolts and nuts.ss a c
ce
le
un
– Check whether dowel sleeves for aligning engine and gearbox
pt
an
d
are fitted in cylinder block and install if necessary.
itte
y li
rm
ab
pe
– Ensure that intermediate plate is correctly seated on engine.
ility
ot
wit
, is n
To install gearbox “02Z”, set up gearbox support - 3282- with ad‐
h re
justment plate - 3282/41- .
hole
spec
es, in part or in w
t to the co
ment plate .
rrectness of i
l purpos
– Place gearbox on engine and gearbox jack - VAS 6931- .

– Align adjustment plate and gearbox parallel to one another.
nform
ercia

m
a
com
tion in
r
te o
thi
support - 3282- under gearbox.
s
iva
do
r
– Raise gearbox.
rp
cum
fo
en
ng
– Align gearbox to engine and join.

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Screw in engine/gearbox connecting bolts -arrows- and tight‐

en to specified torque.
– Install cover plate -1- and tighten securing bolt to 10 Nm.
– After gearbox has been bolted to engine, remove gearbox
support - 3282- from gearbox.
– Screw in top and bottom engine/gearbox connecting bolts and
tighten to specified torque.
– Renew oil seal on slave cylinder line connection if damaged.

– Push pipe/hose line onto slave cylinder to stop and push down
clip -arrow-.
– Remove hose clamps to 25 mm - 3094- .
– Insert pipe/hose line for slave cylinder -2- into retainer on

gearbox -arrow-.
– Push on connector for reversing light switch - F4- -1-.
– Align engine and gearbox in installation position using spin‐
dles of adapter - 10 - 222 A /16- .
– When raising engine and gearbox, guide front torque reaction
support with support mounting past body.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
– Screw in new hexagon bolts -arrows- for left engine/gearbox

nl
pt
du
an
mounting and tighten to specified torque.
itte
y li
erm
ab
ility
ot p
WARNING
wit
, is n
h re
hole
Do not remove support bracket - 10 - 222 A- until the bolts
spec
securing the assembly mountings have been tightened to
es, in part or in w
t to the co
specified torque.
rrectness of i
– If present, connect connector for tachograph sender - G75- .
l purpos
Note
nform
ercia
Lead seal of tachograph sender - G75- is only allowed to be at‐

m
at
om
tached by authorised specialist workshops ⇒ Electrical system;

ion
c
Rep. gr. 90 .
in t
or
his
ate
do
riv
– Install starter -2- ⇒ Rep. gr. 27 .

p
cum
for
en
ng
t.
yi Co
– Gearboxes for vehicles with start-stop system: join connector Cop py
-arrow- to gearbox neutral position sender - G701- .
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

agen
AG.2004
Volksw➤
age,nCaravelle
AG do
es n
2010 ➤ , Multivan 2004 ...
ksw
by Vol 5-speed manual gearbox
ot g
u 02Z - Edition 06.2019
ara
ed nte
oris
– Attach earth strap -1- to loweraustarter
th bolt -4-. e or
ac
ss
– Screw in engine/gearbox connecting bolt -3- and tighten to
ce
e
nl
pt
specified torque.
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

– Screw bolts -arrows- into torque reaction support behind en‐
nform
ercia
gine with specified torque ⇒ Rep. gr. 40 .

m
– Install left drive shaft ⇒ Rep. gr. 40 .
at
om
ion
c
– Install subframe with bracket for rear torque reaction support
in t
or
his
e
⇒ Rep. gr. 40 .
at
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.

Catch -1- must engage in gearbox cable support bracket.

– Spread a small quantity of grease ⇒ Electronic Parts Cata‐
logue (ETKA) on pins of gearbox selector lever -2- and relay
lever -3-.
– Check selector cables are firmly seated on gearbox selector
lever and relay lever.
Securing clips must be engaged.
– Check function of selector mechanism ⇒ page 55 .
Vehicles with diesel engine
– Install connecting hose between intake manifold and charge
– Put on protective caps for suspension struts.
– Then mount right and left bulkhead panels onto plenum cham‐
ber ⇒ Rep. gr. 50 .
– Bolt on coolant expansion tank ⇒ Rep. gr. 19 .
– Connect battery.
– Follow work steps after connecting battery ⇒ Rep. gr. 27 .
Specified torques
Gearbox to engine
. Volkswagen AG
gen AG does
swa
Item Bolt byV
olk Quantity Nm not
gu
d ara
e
1 M12 × 150tho ris
2 80 nte
eo
♦ Additional connections auof starter to gear‐ ra
c
s box
ce
e
nl
pt
du

an
itte
y li
erm
ab
2 M12 × 150 1 80
ility
ot p

wit
, is n
h re
hole
3 M10 × 50 3 40
spec
es, in part or in w
4 M12 × 55 1 80
t to the co
5 M12 × 55 1 80
rrectness of i
Items -A- and -B-: dowel sleeves for centring

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
84
by lksw
cted agen
Rep. gr.34 - Controls, housing Prote AG.
Gearbox mounting to body

– Renew bolts -arrows- each time after removing.
Bolts -arrows- 50 Nm +90°
Gearbox mounting to gearbox n AG. Volkswagen AG do

lkswage es n
o ot g
– Renew bolts -A- each time after removing. d byV ua
ran
ir se tee
o
Component Specified
auth torque or
ac
ss
Bolts -A- 50 Nm +90°
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
co lksw
by
cted agen
Prote AG.

3 Transporting gearbox
⇒ “3.1 Transporting gearbox”, page 86
3.1 Transporting gearbox

Shackle - 3282- may be used in conjunction with hook - 10 - 222
A /12- and workshop crane to transport manual gearbox and to
set up gearbox support - 10-222A/2- .
– Secure clutch release lever with an assembly bolt
⇒ Item 12 (page 21) .
– Fasten shackle - 10 - 222 A /12- to gearbox casing.
– Lift gearbox using workshop crane and hook - 10 - 222 A /2- .
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
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
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

4 Gear oil
⇒ “4.1 Checking gear oil level”, page 87
4.1 Checking gear oil level

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
Gear oil specification ⇒ Electronic parts catalogue (ETKA) .⇒
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
– Remove oil plug -arrow-.
hole
spec
The oil level is correct, when the gearbox is filled to lower edge
es, in part or in w
t to the co
of filler hole.
– Screw in plug -arrow- and tighten.
rrectness of i
When filling with oil, note the following:
l purpos
– Remove oil plug -arrow-

– Fill gearbox oil to lower edge of filler hole.
nform
ercia
– Screw in plug -arrow-.

m
at
om
io
– Start engine, engage gear, and allow gearbox to turn for ap‐
n
c
in t
r
prox. 2 minutes.
o
his
ate
do
riv
– Stop engine and remove plug -arrow-.

p
cum
for
en
g
– Top up with gear oil to lower edge of filler hole.

n
t.
yi Co
op py
– Screw in plug -arrow- and tighten.
t. C rig
gh ht
pyri by
Vo
o
– If present, install noise insulation ⇒ General body repairs, ex‐ by c lksw
cted agen
terior; Rep. gr. 66 ; Exterior equipment; Noise insulation . Prote AG.
Specified torques
♦ ⇒ “6.1 Assembly overview - gearbox housing”, page 124
4. Gear oil 87
5 Dismantling and assembling gearbox

⇒ “5.1 Schematic overview - gearbox”, page 88
⇒ “5.2 Assembly overview - cover for gearbox housing and 5th
gear”, page 90
⇒ “5.3 Assembly overview - gearbox housing and selector mech‐
anism”, page 91
⇒ “5.4 Assembly overview - selector unit”, page 92
⇒ “5.5 Assembly overview - input shaft, output shaft, differential
and selector forks”, page 93
⇒ “5.6 Assembly overview - selector forks”, page 94
⇒ “5.7 Dismantling and assembling gearbox”, page 95 n AG. Volkswagen AG do
lkswage es n
o ot g
⇒ “5.8 Dismantling and assembling selector unit”, page 108 d byV ua
ran
ir se tee
⇒ “5.9 Dismantling and assembling selector forks”, page 109utho
or
a ac
ss
⇒ “5.10 Removing cover for gearbox housing and 5th gear”, page
ce
le
un
113
pt
an
d
itte
y li
⇒ “5.11 Installing cover for gearbox housing and 5th gear”,
rm
ab
pe
page 120
ility
ot
wit
, is n
5.1 Schematic overview - gearbox
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

AG. Volkswagen AG d
agen oes
1 - 1st gear olksw not
y V gu
d b ara
2 - 2nd gear rise nte
tho eo
au ra
3 - 3rd gear ss c
ce
e
nl
pt
4 - 4th gear
du
an
itte
y li
erm
5 - 5th gear
ab
ility
ot p
6 - Gearbox housing cover
wit
, is n
h re
7 - Gearbox housing hole
spec
es, in part or in w
8 - Selector mechanism
t to the co
❑ (Selector forks)
9 - Reverse gear wheel
rrectness of i
10 - Clutch housing
l purpos
11 - Input shaft
nf
ercia
12 - Output shaft
orm
m
atio
13 - Differential
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
co lksw
by
cted agen
Prote AG.
5. Dismantling and assembling gearbox 89

5.2 Assembly overview - cover for gearbox housing and 5th gear
1 - Hexagon bolt
❑ For gearbox housing
cover
❑ 18 Nm
2 - Gearbox housing cover olkswage es n
ot g
byV ua
If gearbox cover is fitted with ir se
d ran
tee
gearbox installed, check oil utho
or
level as follows: ss
a ac
ce
e
nl
pt
– Fill with oil up to lower du
an
itte
edge of filler hole and fit
y li
erm
ab
filler plug.
ility
ot p
wit
, is n
– Start engine, engage
h re
gear, and allow gearbox
hole
spec
to turn for approx. 2 mi‐
es, in part or in w
nutes.
t to the co
– Switch off engine and
top up gear oil to lower
rrectness of i
edge of filler hole again.
l purpos
❑ With magnet
⇒ page 91
nf
ercia
o
3 - Seal
rm
m
atio
m
4 - Torx socket head bolt

o
n in
or c
thi
te
sd
a
❑ Fitted section of bolt

iv
o
r
rp
cu
head holds dished
o
m
f
spring washer in posi‐
en
ng
t.
yi Co
tion t. Cop py
rig
❑ Clean residual locking
gh ht
pyri by
fluid from threaded
co Vo
by lksw
cted
holes for securing bolts
agen
Prote AG.
for 5th gear synchro-
hub and for gear wheel
for 5th gear with a
thread chaser. Otherwise the bolts may shear.
❑ 80 Nm +90°
5 - Dished spring
❑ For pivot pin to gearbox housing
❑ 25 Nm
7 - Pivot pin
8 - 5th gear selector fork
❑ Dismantling and assembling ⇒ page 108
❑ Adjusting ⇒ page 123
9 - 5th gear locking collar with synchro-hub
10 - Synchro-ring for 5th gear
❑ With cast locking pieces ⇒ page 121

11 - Synchromeshed gear, 5th gear

12 - Needle bearing
13 - Gear wheel for 5th gear
Fitting position ⇒ page 120
Cover for gearbox housing with magnet -A-

Magnet can only be fitted in cover with notch -arrow-.
5.3 Assembly overview - gearbox housing and selector mechanism
1 - Countersunk bolt
❑ 25 Nm
2 - Flange shaft with compres‐
sion spring
⇒ page 113
❑ Assembling
⇒ page 182
AG. Volkswagen AG d
agen
3 - Retaining ring Volksw
oes
not
by gu
❑ Must be inserted in pe‐ rised ara
nte
ripheral groove of deep ut
ho eo
ra
groove ball bearing for ss a c
input shaft
ce
e
nl
pt
du
an
4 - Seal
itte
y li
erm
ab

ility
ot p
wit
5 - Bolt
, is n
h re
hole
❑ 8 Nm
spec
es, in part or in w
6 - Pivot pin
t to the co
7 - Bolt
❑ 25 Nm
rrectness of i
8 - Cap
l purpos
9 - Bolt
nform
ercia
❑ For reverse shaft sup‐

port
m
at
om
❑ Note tightening se‐

ion
c
quence when installing

in t
or
his
e
⇒ page 95
at
do
riv
❑ 25 Nm
p
cum
for
en
g
10 - Bolt
n
t.
yi Co
op py
❑ 5 Nm t. C rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

11 - Gearbox neutral position sender - G701-

❑ for vehicles with start/stop system
12 - Gearbox housing
❑ Repairing ⇒ page 91
13 - Clutch housing
14 - Bolt
❑ 25 Nm +90°
16 - Bolt
AG. Volkswagen AG d
❑ 22 Nm lksw
agen oes
not
o
byV gu
ara
ed
ris nte
ho eo
ut ra
5.4 Assembly overview - selector unit ss a c
ce
e
nl
pt
du
an
itte
y li
1 - Selector shaft with selector
erm
ab
shaft cover
ility
ot p
wit
❑ Renew together
, is n
h re
❑ From gearbox date 22
hole
spec
09 3, changed because
es, in part or in w
spring eliminated
t to the co
⇒ Item 12 (page 93) .
2 - Retaining pin
rrectness of i
❑ Discontinued shortly af‐
l purpos
ter start of production

❑ Required for adjusting
selector mechanism of nform
ercia
some gearboxes.
m
at
❑ Removing ⇒ page 108

om
ion
c
❑ Driving in ⇒ page 109

in t
or
his
ate
3 - Cap
do
priv
cum
or
❑ For gearbox breather

f
en
ng
t.
yi Co
4 - Bearing bush Cop py
ht. rig
rig ht
5 - Securing clip py by
co Vo
by lksw
cted agen
6 - Seal Prote AG.
❑ Renewing ⇒ page 59
7 - Nut
❑ 23 Nm
❑ Install so that master
spline aligns with selec‐
tor shaft
❑ Can be renewed with
the selector mechanism
installed

9 - Deflector lever
10 - Reversing light switch AG. Volkswagen AG d
agen oes
ksw
❑ Lightly coat lug with MoS2 grease by Vol not
gu
ara
d
❑ 20 Nm rise nte
tho eo
au ra
11 - Cap ss c
ce
le
un
❑ From gearbox date 22 09 3, changed because spring eliminated ⇒ Item 12 (page 93) .
pt
an
d
itte
y li
12 - Spring
rm
ab
pe
ility
❑ Eliminated beginning gearbox date 22 09 3. ot
wit
, is n
h re
hole
spec
5.5 Assembly overview - input shaft, output shaft, differential and selector forks
es, in part or in w
t to the co
1 - Differential
rrectness of i
❑ Dismantling and assem‐
l purpos
bling ⇒ page 182

2 - Seal
nform
ercia
❑ Qty. 4
m
a
com
tion in
3 - Output shaft
r
te o
thi
s
iva
do
r
rp
c
bling ⇒ page 151
um
fo
en
ng
t.
4 - Reverse shaft support
yi Co
Cop py
t. rig
gh ht
yri
bling
p by
co Vo
by lksw
⇒ Item 10 (page 168) Prote
cted AG.
agen
5 - Reverse shaft
bling ⇒ page 168
6 - Input shaft
bling ⇒ page 141
7 - Selector fork for reverse
gear
bling ⇒ page 108
❑ 25 Nm
❑ (Selector forks)
bling ⇒ page 108
10 - Clutch housing
11 - Nut
❑ 4 nuts for bearing support
❑ 25 Nm +90°
❑ 25 Nm

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
o e
California a2010
ut
h
➤ , Caravelle 2004 ➤ , Caravelle 2010 ➤ o,r aMultivan 2004 ...
s c
s
ce
le
un
pt
an
d
13 - Stub shaft with compression spring
itte
y li
rm
ab
pe
ility
ot
❑ Assembling ⇒ page 182
wit
, is n
h re
hole
spec
es, in part or in w
5.6 Assembly overview - selector forks
t to the co
rrectness of i
Note
l purpos
♦ It is not necessary to dismantle the selector fork group ⇒ Item 7 (page 94) in order to dismantle and
assemble selector segments, lock washers and angular contact ball bearings.
nform
ercia
♦ Sliding piece ⇒ Item 10 (page 94) and spring ⇒ Item 11 (page 95) were entirely deleted shortly after start
m
a
of series production.
com
tion in
r
te o
thi
s
iva
do
1 - 5th gear selector segment
r
rp
cum
fo
❑ Identification
en
ng
t.
yi
⇒ page 111
Co
Cop py
ht. rig
❑ After lock washer is in‐ py
rig by
ht
stalled, detent segment co Vo
by lksw
must still rotate freely.
cted agen
Prote AG.
2 - Clamping washer
3 - 5th gear selector fork
4 - Bolt
❑ 25 Nm
5 - 5th gear selector jaw
6 - Angular contact ball bearing
❑ Press inner race into
outer race ⇒ page 112
❑ Pulling in ⇒ page 112
7 - Selector fork group with se‐
lector plate
09 3, modified holes for
angular contact ball
bearing
⇒ Item 6 (page 94) .
8 - 1st/2nd gear selector seg‐
ment
❑ Identification
⇒ page 111
❑ After lock washer is installed, segment must still rotate freely
9 - Selector segment for 3rd and 4th gear
❑ Identification ⇒ page 111
❑ After lock washer is installed, segment must still rotate freely
10 - Sliding piece
❑ Discontinued shortly after start of production

❑ Installed in some gearboxes
AG. Volkswagen AG d
❑ Old design ⇒ page 111 agen oes
olksw not
y V gu
❑ Current design ⇒ pageise
d111
b ara
n r tee
ho
11 - Spring au
t or
ac
ss
❑ Discontinued shortly after start of production
ce
e
nl
pt
du
❑ Installed in some gearboxes
an
itte
y li
erm
❑ Old design ⇒ page 111
ab
ility
ot p
❑ Current design ⇒ page 111
wit
, is n
h re
12 - Selector fork for reverse gear
hole
spec
13 - Support for reverse gear selector fork
es, in part or in w
t to the co
14 - Retaining ring
rrectness of i
5.7 Dismantling and assembling gearbox
l purpos
Removing and installing gearbox housing cover, clutch housing,
nform
ercia
selector shaft with selector mechanism cover, input shaft, output

shaft, differential and selector mechanism.
m
at
om
ion
c
in t
or
his
ate
equipment required
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.
♦ Retainer - VW 309-

♦ Gearbox support - VW 353-

♦ Drift - VW 295- AG. Volkswagen AG d
agen oes
olksw not
yV gu
♦ Drift sleeve - VW 244 B- ed b ara
nte
ris
ho eo
♦ Hot-air blower - V.A.G 1416- aut 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
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
♦ Support bridge - 30-211A-

♦ Thrust piece - 32 - 111-
♦ Thrust piece from assembly tool - T10030/4-
♦ Tube - VW 416 B-
♦ Puller plate - T10408-
♦ Press pieces - T10408/2-
♦ Hexagon bolts M7 x 35 with washers (form part of puller -
T10408- )
♦ Studs M8 x 100 mm

lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
♦ Support bridge - T10323-
wit
, is n
h re
♦ Assembly tool - 3253/7-
hole
spec
es, in part or in w
♦ Thrust piece - VW 433- t to the co
♦ Thrust plate - 40-105-

rrectness of i
l purpos
♦ Puller, e.g. KUKKO 18-1 - VAS 251 417- (qty. 2)

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.

♦ Drip tray for workshop hoist - VAS 6208-
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
♦ Inductive heater - VAS 6414-
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
a
♦ Sealing paste ⇒ Electronic parts catalogue (ETKA)

iv
o
pr
cum
r
fo
♦ Stud M8 x 100 mm
en
ng
t.
yi Co
Dismantling gearbox Cop py
t. rig
gh ht
yri
– Place drip tray underneath.
p by
o Vo
by c lksw
cted agen
– Remove oil filler plug and oil drain plug.
Prote AG.
– Drain gear oil.
Note
To secure gearbox on gearbox support - VW 353- , it may be

necessary to drill new securing holes into the support.
– Secure gearbox on gearbox support - VW 353- -arrows-.

– Remove clutch release lever -1- together with release bearing.

– When doing so, press on retaining spring -arrow A-.
– Remove securing bolt -arrow B- for right stub shaft -2-.
– Remove stub shaft together with spring, thrust washer and ta‐
pered ring.
– Remove bolts -A- from clutch housing side for securing clutch
housing to gearbox housing.
Caution
♦ Do not remove nuts -B- for output shaft bearing support!
– Unbolt guide sleeve -C-.
lkswage es n
o ot g
byV ua
d ran
ir se tee
o
• Bearings of input shaft and output shaft must not
au be damaged
th or
ac
when 5th gear is removed and installed. ss
ce
le
un
pt
• Therefore, the following tools must be mounted for support
an
d
itte
during attachment of gearbox to gearbox support - VW 353- :
y li
erm
ab
ility
Underneath input shaft:
ot p
wit
is n
♦ Support bridge - 30 - 211A-

h re
ole,
spec
t to the co
♦ Press tool - T10040/3-

– Lock bolt of support bridge - 30 - 211A- with nut -A-.
rrectne
Underneath bearing support for output shaft:

ss o
cial p

inform
mer
♦ Press tool - VW 433-

atio
om
– Place drip tray for workshop hoist - VAS 6208- underneath.

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.

– Drain gear oil.

– Remove gearbox housing cover -arrow-.
Remove selector fork for 5th gear as follows:
– Cover openings with a cloth.

– Move selector fork -1- to neutral position.
– Then remove both bolts -2- for pivot pins.
– Pull out pivot pin in -direction of arrow-.
– Remove selector fork -1-.
– Remove bolts -A- for synchro-hub and 5th gear wheel. To do

this, engage 5th gear -arrow 1- and 1st gear -arrow 2- and
-arrow 3-.
– Input shaft and output shaft are locked when both gears are
engaged. Synchro-hub and gear wheel cannot turn. Now both
bolts can be removed.
Pull off synchro-hub for 5th gear together with locking collar and
locking pieces. G. Volkswagen A AG do
agen es n
ksw
y Vol ot g
ua
b
Note ed ran
oris tee
th or
au ac
Use puller - T10309- . ss
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
– First set half sleeve - T10309/1- between 5th gear wheel -A-
and support for selector fork for 5th gear -B-.
• Half sleeve - T10309/1- must be positioned beneath synchro-
rrectness of i
ring.
l purpos
– If necessary, half-sleeve must be pressed to end position.

– Turn half sleeve - T10309/1- to opposite side
nf
ercia
rm
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
100
cted agen
Prote
Rep. gr.34 - Controls, housing
AG.
– Insert threaded insert - T10309/3- into half sleeve .

Volkswa
– Now, fit second half sleeve - T10309/1-swand
agenplace tube - AG does
AG. gen
T10309/2- on assembly. by
Volk not
gu
a d ran
se
– After pulling off synchro-hub,thcheck
or
i
for damage. tee
or
au ac
ss
ce
e
nl
pt
Note
du
an
itte
y li
erm
ab
The synchro-ring for 5th gear must always be renewed after it is
ility
ot p
pulled off.
wit
, is n
h re
hole
– Remove 5th gear synchromeshed gear with needle bearing.
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
– Remove securing ring -arrow- from deep groove ball bearing

of input shaft in gearbox housing.
m
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.
– Remove selector shaft with selector cover -A-. For this, place
selector shaft in neutral.
– Then remove bolts -1- and pull selector shaft out of gearbox
housing.
– Remove pivot pins -2- located on upper side of gearbox.
– Remove sealing cover -A- and pivot pins -B- from underside
of gearbox.

– Remove bolts -arrows A- through -D- for reverse shaft support.
– Remove securing bolts -A- for gearbox housing to clutch hous‐

ing in area of differential.
– Remove left flange shaft securing bolt. Screw 2 bolts into

flange (see figure) and counterhold flange shaft using a lever.
– Remove flange shaft together with spring, thrust washer and
tapered ring.
Pull off following components together with gearbox housing:
♦ Synchro-hub for 5th gear
♦ Gear wheel for 5th gear n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
Use puller - T10408- in conjunction with following special tools:

un
pt
an
d
itte
y li
♦ Spacers - T10408/1-
erm
ab
ility
ot p
♦ Press pieces - T10408/2-

wit
is n
h re
♦ Puller, e.g. KUKKO 18-1 - VAS 251 417-

ole,
spec
– Tighten 5 spacers - T10408/1- in threaded holes for gearbox

housing cover.
t to the co
– Firmly bolt puller plate - T10408- to spacers - T10408/1- .

rrectne
A - Hexagon bolts M7 x 35 with washers

Specified torque: 18 Nm
ss o
– Place thrust pieces - T10408/2- on shafts.

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
102
by lksw
cted agen
Rep. gr.34 - Controls, housing Prote AG.
– Mount puller, e.g. KUKKO 18-1 - VAS 251 417- .

– Pull off 5th gear synchro-hub, 5th gear wheel and gearbox
housing by alternately tightening spindles -A- (12 rotation) of
puller, e.g. KUKKO 18/-1 - VAS 251 417- .
– Heat gear wheel for 5th gear slightly with hot air blower -
V.A.G 1416- if necessary.
– Remove selector forks -A- together with selector plates.

– Unbolt reverse gear selector mechanism -B-.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
d
– Remove nuts -B- for output
horis shaft bearing support.
e nte
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
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

– Unbolt reverse gear selector mechanism -3- -arrow-.

– Remove input shaft -1- and output shaft -2- together with re‐
verse shaft -4- from clutch housing. AG. Volkswagen
agen AG do
ksw es n
– Remove differential. y Vol ot g
ua
b
ed ran
Assembling thoris tee
or
au ac
– Install differential. ss
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
– Always renew sealing rings -arrows- for output shaft bearing

support.
nform
mercia
at
om
i
Note
on
c
in t
or
his
te
The figure shows only 3 of the 4 seals.

a
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.
– Insert input shaft -1- and output shaft -2- together with reverse
shaft -4- and reverse shaft support in clutch housing.
– Bolt on reverse gear selector mechanism -3- -arrow-.

If clutch housing has been renewed, spring -3- and sliding piece
-4- are no longer installed.
1- Selector fork for reverse gear
2- Securing bolt for reverse gear selector fork.
– Tighten nuts for output shaft bearing support. agen
AG. Volkswagen AG d
oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
– Insert selector forks -A- together with selector plates. In the
process, guide reverse gear selector plate sideways onto re‐ ot
wit
, is n
h re
verse gear selector fork -B-.
hole
spec
– Align selector plates.
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tio
• The selector segments -A- must be positioned in the grooves
n in
r
on the locking collars.

te o
thi
s
iva
do
• Selector rod for reverse gear engages in reverse gear locking
r
rp
cum
collar -arrow-.
fo
en
ng
t.
yi Co
Cop py
t. rig
gh
Note
ht
pyri by
Vo
o
by c lksw
cted agen
♦ Align support for reverse shaft -B- and selector plates.
Prote AG.
♦ The support for reverse shaft -B- in the diagram differs from
the actual genuine part.
– Heat gearbox housing using -hot air blower- , e.g. -V.A.G

1416- in vicinity of bearing seat for deep groove ball bearing
for input shaft for about 10 minutes to about 100°C.
Note
Heating is necessary to avoid damage to deep groove ball bear‐

ing when gearbox housing is installed.
– Apply sealant evenly to sealing surface of clutch housing.

– Carefully fit gearbox housing. In the process, guide selector

plate -1- for 5th gear, deep groove ball bearing for input shaft
-2- and output shaft -3- through holes in gearbox housing.
The output shaft bearing must not be damaged when doing this.
– Likewise move reverse shaft support -4- through hole of seal‐
ing cover for selector shaft.
Holes in gearbox housing -arrows- must align with threaded holes
in reverse gear support.
– Drive on gearbox housing, if necessary, with wheel bearing

tube - 3345- and thrust plate - 3062- . Do not cant gearbox
housing in the process.
– Tighten clutch housing/gearbox housing securing bolts to
specified torque.
lkswage es n
o ot g
byV ua
d ran
ir se te
– Install securing
uth ring -arrow- for deep groove ball bearing ofe o
o
ra
input shaftssin gearbox housing.
a 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
rrectne
Install reverse shaft support bolts -arrows A- to -D- as follows:

ss
– Insert bolts -arrows A- and -B- and tighten hand-tight.

o
cial p
f inform
– Insert bolt -arrow C- and tighten hand-tight.

mer
atio
m
– Insert bolt -arrow D- and tighten to specified torque.

o
n
c
i
or
– Tighten bolt -arrow C- to specified torque.

thi
te
sd
va
– Tighten bolts -arrows A- and -B- to specified torque.

i
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.

– Install pivot pins -arrow- for selector forks in bottom of gearbox.

Do this by aligning selector mechanism with a screwdriver so
that respective pivot pin can be installed.
– Apply sealing paste evenly to sealing surface of sealing cover
for selector shaft. . Volkswage AG n AG d
agen oes
olksw not
yV gu
db ara
rise nte
tho eo
au ra
c
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
– Fit selector shaft cover.
wit
, is n
h re
– Install pivot pins -A- for selector forks in top of gearbox. Do this
hole
spec
by aligning selector mechanism with a screwdriver so that re‐
es, in part or in w
spective pivot pin can be installed.
t to the co
Install selector shaft -B- as follows:
rrectness of i
– Place selector plates in neutral.
– Apply sealing paste evenly to sealing surface of selector
l purpos
mechanism cover.
nform
ercia
– Move selector shaft to neutral.

m
– Position selector shaft so that selector finger -arrow- is inser‐
a
com
tio
ted in selector plates.
n in
r
te o
thi
– Bolt on selector shaft cover.
s
iva
do
r
rp
cum
fo
– Gearbox for vehicles with start/stop system: install gearbox
en
ng
t.
neutral position sender - G701- -arrow- and tighten securing
yi Co
op py
bolt. t. C rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
– Install left flange shaft together with spring, thrust washer and
tapered ring ⇒ page 172 .
– Install right stub shaft together with compression spring, thrust
washer and tapered ring ⇒ page 173 .
– Installing cover for gearbox housing and 5th gear
⇒ page 120 .
Specified torques
♦ ⇒ “5.3 Assembly overview - gearbox housing and selector
♦ ⇒ “2.1 Assembly overview - differential”, page 180

5.8 Dismantling and assembling selector

unit
Special tools and work‐
shop equipment re‐
quired
♦ Thrust piece -
T10203-
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
♦ Torque wrench - horise nte
eo
V.A.G 1331- aut ra
c
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
Removing retaining pin
-A- from selector shaft
ss o
cover
cial p
f inform
– Remove outer part
mer
(angle piece) of re‐

atio
m
taining pin.
o
n
c
i
or
n thi
– Carefully pry out re‐

te
sd
va
taining pin using a

i
o
pr
cum
screwdriver.
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Drive retaining pin -A- into selector shaft cover

Installation position:
Marking -arrow- points to upper part of selector shaft.
5.9 Dismantling and assembling selector forks

equipment required
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
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.
♦ Pressure plate - VW 402-

♦ Thrust piece - 3290/1- from assembly tool - 3290-

♦ Assembly tool - 3301-
♦ Thrust piece - VW 431-
♦ Spacer sleeve - VW 472/2-
♦ Drift - 10 - 206-
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
♦ Assembly mandrel - 10 - 508- cted agen
Prote AG.
♦ Release lever - 80 - 200-

♦ Tensioning device - 2070-

Old design
♦ -1- = selector mechanism
♦ -2- = locking collar
Current design
The selector plate -1- engages directly in the locking collar -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
Identifying selector segments
ole,
spec
Dimension -a-
t to the co
1 - 1st and 2nd gear selector segments = 11.4 mm
2 - 3rd and 4th gear selector segments = 7.7 mm
rrectne
3 - 5th gear selector segments= 12.1 mm
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
e
Removing lock washer

t
sd
iva
o
pr
cum
– Clamp selector fork in vice with protective jaw covers -B-.

r
fo
en
ng
t.
yi
– Lever off lock washer -A- in -direction of arrow-.
Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Installing lock washer

– Press lock washer into groove of detent segment using socket
and spinner handle.
Note
After lock washer is installed, detent segment must still rotate

freely.
A - Spinner handle with 10 mm socket

B - Vice clamps
Removing angular contact ball bearing lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
or
Note ss
au ac
ce
le
un
pt
When removing and installing angular contact ball bearing, do not
an
d
itte
bend selector forks.
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
Pressing inner race -A- of angular contact ball bearing into outer
rrectne
race
Inner race must engage in outer race.
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
Pulling angular contact ball bearing into selector fork to stop yri
p by
co Vo
by lksw
cted
Depression in thrust piece - 3290/1- faces ball bearing.
agen
Prote AG.

Selector fork with detent segments installed

Dim. -a- (mm)
1st/2nd gear selector fork 88.3 to 89.1
3rd/4th gear selector fork 95.9 to 96.7
Selector segment assignment ⇒ page 111
5.10 Removing cover for gearbox housing

and 5th gear
Note
♦ Follow the working procedure described below if only the 5th

gear has to be removed.
♦ If the gearbox housing has to be removed, follow the working
procedure: ⇒ page 95 .
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
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.


equipment required
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
♦ Retainer - VW 309-
♦ Gearbox support - VW 353-
♦ Drift - VW 295-
♦ Drift sleeve - VW 244 B-
♦ Hot-air blower - V.A.G 1416-

lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
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
♦ Support bridge - 30-211A-

rrectness of i

l purpos
♦ Thrust piece from assembly tool - T10030/4-

nf
ercia
♦ Tube - VW 416 B-
orm
m
atio
♦ Puller - T10309-
om
n in
or c
♦ Two-arm puller - T10040-

thi
te
sd
iva
♦ With puller hooks - T10040/2A-

o
r
rp
cu
o
m
f
en
ng
♦ Thrust piece - T10040/3-

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
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
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.
♦ Thrust plate - 40 - 105-
Removing
– Drain gear oil.
Note
To secure gearbox on gearbox support - VW 353- , it may be

necessary to drill new securing holes into the support.
– Remove clutch release lever with release bearing and guide

sleeve ⇒ page 20 .

– Secure gearbox on gearbox support - VW 353- -arrows-.
• Bearings of input shaft and output shaft must not be damaged

when 5th gear is removed and installed.
• Therefore, mount the following tools for support during attach‐
ment of gearbox to gearbox support - VW 353- : AG. Volkswagen A
n G do
wage es n
Underneath input shaft: Volks ot g
by ua
ed ran
♦ Support bridge - 30-211A- oris tee
th or
au ac
♦ Thrust piece - 32 - 111- ss
ce
le
un
pt
♦ Press tool - T10040/3-
an
d
itte
y li
rm
ab
• The input shaft can be supported by the thrust piece - 32 - 111-
pe
ility
only at a later point.
ot
wit
, is n
Underneath bearing support for output shaft:
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
– Remove gearbox housing cover -arrow-.
nform
ercia
Note
m
a
com
tio
Due to changes in the gearbox housing during production, there

n in
r
are various procedures for the removal of the synchromeshed

te o
thi
gear for 5th gear.

s
iva
do
r
rp
cum
fo
en
g
Proceed as follows:
n
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

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

correctly 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 95
♦ ribs in gearbox housing under
5th gear wheel
-B-
Puller hooks - T10040/2A- come
into contact with ribs in gearbox
housing below 5th gear wheel.
Puller hooks - T10040/2A- cannot be inserted correctly.

5th gear can be removed separately, ⇒ from ⇒ page 118
Removing 5th gear separately

– Cover openings in gearbox housing using a cloth.
– Move selector fork -1- to neutral position.
– Then remove both bolts -2- for pivot pins.
– Pull out pivot pin in direction of -arrow-.
– Remove selector fork. 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
– Remove bolts -A- for synchro-hub and 5th gear wheel. To do
pt
du
an
itte
this, engage 5th gear -arrow 1- and 1st gear -arrow 2- and
y li
erm
ab
-arrow 3-.
ility
ot p
– Input shaft and output shaft are locked when both gears are
wit
, is n
h re
hole
bolts can be removed.

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

material out of threaded holes using a thread chaser.
l purpos
Pull off synchro-hub for 5th gear together with locking collar and
nform
ercia
locking pieces.
m
at
om
ion
c
in t
Note
or
his
ate
do
riv
Use puller - T10309- .

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

– First set half sleeve - T10309/1- between 5th gear wheel -A-
and support for selector fork for 5th gear -B-.
• Half sleeve - T10309/1- must be positioned beneath synchro-
ring.
– If necessary, half-sleeve must be pressed to end position.
– Turn half sleeve - T10309/1- to opposite side AG. Volkswagen AG d
-direction of arrow-. 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
– Insert threaded insert - T10309/3- into half sleeve .
erm
ab
ility
ot p
– Now, fit second half sleeve - T10309/1- and place tube -
wit
is n
T10309/2- on assembly.
h re
ole,
spec
– After pulling off synchro-hub, check for damage.
t to the co
Note
rrectne
The synchro-ring for 5th gear must always be renewed after it is
pulled off.
ss o
cial p
f
– Remove 5th gear synchromeshed gear with needle bearing.
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
.
– Pull off gear wheel for 5th gear.
ht rig
rig ht
py by
co Vo
– First install puller hook -A-.
by lksw
cted agen
Prote AG.
B - Hexagon bolt M10 x 20, 17 mm AF
Note
♦ When pulling off gear wheel, ensure that hooks do not bend
outwards. After pulling off 5th gear wheel, examine for dam‐
age.
♦ Heat gear wheel beforehand with hot air blower - V.A.G 1416-
if necessary.
Installing cover for gearbox housing and 5th gear ⇒ page 120 .

AG. Volkswagen
5.11 Installing Vol
kscover
wage
n
for gearbox
AG do
housing
es n
ot g and
5thrisegear
by ua
d ran
te
tho eo
For special stools
sa
u
required, refer to procedure for “Removing gear‐
ra
c
box housing cover and 5th gear” ⇒ page 113 .
ce
le
un
pt
an
• Ensure that support bridge - 30 - 211A- and support device -
d
itte
y li
T10323- are installed.
rm
ab
pe
ility
– Lock bolt of support bridge - 30 - 211A- with nut -A-.
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
Installation position, 5th gear wheel
r
rp
cum
fo
en
g
The circumferential groove -arrow- faces gearbox housing.

n
t.
yi Co
Cop py
t. rig
gh ht
yri
WARNING p by
o Vo
by c lksw
cted agen
Prote AG.
Wear protective gloves.
– Heat gear wheel for 5th gear to about 100°C with inductive
heater - VAS 6414- before installing.
– 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- using a feeler gauge.
Gap -a- Installation dimen‐ Wear limit
sion
5th gear 1.1 - 1.7 mm 0.5 mm
– Install 5th gear synchromeshed gear with needle bearing.
– Place 5th gear synchro-ring on synchromeshed
. Volkswage
gear.
n AG n AG d
wage oe
– If synchro-hub and ylocking
Vol
ks collar for 5th gear ares dismantled,
not
gu
assemble beforeisedinstalling
b ⇒ page 148 . ara
nr tee
ho
aut or
ac
Installation position
ss 5th gear synchro-hub and locking collar
ce
le
un
pt
The pointed teeth of the locking collar -arrow 1- and the high
an
d
itte
shoulder of the synchro-hub -arrow 2- face the gearbox housing.
y li
rm
ab
pe
ility
The supports -arrow 3- for the synchro-hub align with the cast
ot
wit
locking pieces of the gear synchro-ring (-arrows- in figure below).
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
5th gear synchro-ring with cast locking pieces -arrows-

nform
ercia
– Cover all openings in gearbox housing with a cloth to prevent

foreign bodies from entering gearbox.
m
a
com
tion in
WARNING
r
te o
thi
s
iva
do
r
Wear protective gloves.

rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
– Heat synchro-hub for 5th gear to about 100°C using inductive

heater - VAS 6414- before installing.
Note
When driving on, ensure that synchro-ring moves freely.

– Unfasten support for input shaft.

If not already done, clean residual locking fluid from threaded
holes for synchro-hub securing bolts and gear wheel for 5th gear
with a thread tap.
Otherwise the bolts may shear.
– Screw in new securing bolts for synchro-hub and gear wheel
for 5th gear.
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
Installation position of dished springs for securing bolts for gear
t to the co
wheel and synchro-hub for 5th gear
The outer diameter (concave side -arrows-) faces 5th gear.
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
g
– Tighten securing bolts -A- for synchro-hub and gear wheel for
n
t.
yi Co
op
5th gear. To do this, engage 5th gear -arrow 1- and 1st gear C py
t. rig
-arrows 2- and -3-.
gh ht
pyri by
Vo
co lksw
by
– Input shaft and output shaft are locked when both gears are cted agen
Prote AG.
bolts can be tightened to specified torque.
– Install selector fork for 5th gear.

Adjusting 5th gear

– Engage 5th gear. Loosen bolt -1-.
– Press locking collar -2- and selector jaw -3- in direction of
-arrow-. Then, tighten bolt -1-.
– Disengage 5th gear. Locking collar must now be in the neutral
position. Synchro-ring must move freely.
– Shift through all gears.
– Tighten gearbox housing cover.
– Fit a thin protective hose tightly over splines of input shaft.
– Install release bearing guide sleeve ⇒gepage
n AG. V20
olks.wagen AG
a does
ksw not
– Remove insulating sleeve. Vol gu
d by ara
e nte
ris
– Install clutch release lever
tho and release bearing ⇒ page 20 . eo
au ra
c
ss
– Fill with gear oil ⇒ page 87 .
ce
le
un
pt
Specified torques
an
d
itte
y li
erm
ab
ility
ot p
20
wit
is n
h re
♦ ⇒ “5.2 Assembly overview - cover for gearbox housing and 5th
ole,
spec
gear”, page 90
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
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

6 Gearbox housing, clutch housing

⇒ “6.1 Assembly overview - gearbox housing”, page 124
Volkswagen AG
⇒ “6.2 Assembly overview - clutch housing”, pagesw125
agen
AG. does
k not
Vol gu
⇒ “6.3 Repairing gearbox housing”, page s127 d by ara
e nte
ri
ho eo
⇒ “6.4 Repairing clutch housing”, page a 134
ut ra
c
ss
6.1 Assembly overview - gearbox housing
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
1 - Gearbox housing
ility
ot
wit
, is n
❑ If renewed, adjust differ‐
h re
ential ⇒ page 185
hole
spec
es, in part or in w
t to the co
09 3: holes adapted to
sealing cover for selec‐
tor shaft and mounting
of selector fork group
rrectness of i
❑ Note that there are dif‐
l purpos
ferent housing versions

⇒ page 125
nform
ercia
2 - Roller sleeve
m
a
❑ For output shaft
com
tion in
r
te o
thi
⇒ page 127
s
iva
do
r
❑ Note that there are dif‐

rp
cum
fo
ferent bearing versions
en
ng
t.
yi
⇒ page 125
Co
Cop py
t. rig
3 - Oil collector
gh ht
pyri by
Vo
co
❑ Install in gearbox hous‐
by lksw
cted agen
Prote
ing ⇒ page 125 .
AG.
4 - Tapered roller bearing outer

race
❑ For differential
❑ Pulling out and pressing
in ⇒ page 131
❑ If renewed, adjust differ‐
ential ⇒ page 185
5 - Shim
❑ Adjustment overview
⇒ page 190
6 - Oil filler plug
❑ 36 Nm
7 - Seal
❑ For left flange shaft

Distinguishing between output shaft bearings
Note
Allocation of gear oil and roller bearing via ⇒ Electronic parts

catalogue (ETKA) .
Roller bearing -1- with retaining ring

A - Gearbox housing with groove for retaining ring
B - Retaining ring for roller bearing
Removing and installing roller bearing with retaining ring
⇒ page 131 .
Roller bearing -1- without retaining ring AG. Volkswagen AG d

agen oes
lksw not
A - Gearbox housing with shoulder for outer race d byV
o gu
ara
ise nte
r
B - Outer race for roller bearing ut
ho eo
ra
s a c
Removing and installing roller bearing without retaining ring s
ce
le
⇒ page 130 .
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
Insert oil collector -A- in gearbox housing atio

om
– Insert oil collector in hole -arrow 1- and groove -arrow 2- of

c
i
or
n thi
gearbox housing simultaneously.

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.
6.2 Assembly overview - clutch housing
6. Gearbox housing, clutch housing 125

olkswagen AG
en AG. V
California 2010 ➤ , Caravelle o2004
ksw ➤ , Caravelle 2010 ➤
ag does , Multivan 2004 ...
not
V l
5-speed manual gearboxe02Z
d by - Edition 06.2019 gu
ara
ris nte
utho eo
1 - Plug ss
a ra
c
❑ Insert into hole in clutch
ce
le
un
pt
housing.
an
d
itte
y li
❑ Not fitted in all gearbox‐
rm
ab
pe
ility
es
ot
wit
, is n
2 - Ball-head pin
h re
hole
spec
❑ Specified torque
es, in part or in w
⇒ page 20
t to the co
rrectness of i
⇒ page 20
l purpos
4 - Guide bush
❑ With input shaft seal and
nform
ercia
vulcanised oil seal

❑ If O-ring is damaged, re‐
m
a
com
ti
new guide sleeve and
on in
O-ring together
r
te o
thi
s
❑ Renewing radial oil seal
iva
do
r
for input shaft

rp
cum
fo
⇒ page 177
en
ng
t.
yi Co
op
5 - Cylindrical roller bearing
C py
t. rig
gh ht
yri
❑ For input shaft p by
co Vo
by lksw
cted
❑ Pressing out and in
agen
Prote AG.
⇒ page 134
6 - Seal
❑ For right stub shaft.
7 - Drive for tachograph
❑ Installed in vehicles with
tachograph.
❑ 30 Nm
8 - Plug
❑ Installed in vehicles without tachograph.
❑ 30 Nm
9 - Dowel sleeve
❑ Qty. 2
10 - Oil deflector ring
❑ Installation position: shoulder on inner circumference faces oil seal ⇒ Item 6 (page 126)
11 - Tapered roller bearing outer race
❑ Pulling out and pressing in ⇒ page 138
❑ If renewed, adjust differential ⇒ page 185
12 - Oil drain plug
❑ 40 Nm
❑ If replaced: Adjust output shaft ⇒ page 163 .
14 - Shim

❑ Adjustment overview ⇒ page 190
15 - Solenoid
❑ Held in place by housing joint surface
16 - Needle bearing
❑ For reverse shaft
17 - Clutch housing
❑ Adjustment overview ⇒ page 190
AG. Volkswagen AG d
agen oes
lksw not
6.3 Repairing gearbox housing
o
byV gu
ara
ed
ris nte
o eo
⇒ “6.3.1 Removing and installing output
aut
h
shaft bearings in gearbox ra
housing”, page 127 ss c
ce
e
nl
pt
⇒ “6.3.2 Removing and installing differential bearings in gearbox
du
an
itte
housing”, page 131
y li
erm
ab
ility
6.3.1 Removing and installing output shaft
ot p
wit
, is n
bearings in gearbox housing
h re
hole
spec
es, in part or in w
t to the co
Note
♦ No shim is installed in the gearbox housing end.
rrectness of i
♦ Note that there are different bearing versions ⇒ page 125 .
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.


equipment required
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
♦ Thrust plate - VW 401-

ot
wit
, is n
h re

hole
spec
♦ Press tool - VW 408 A-

es, in part or in w
t to the co

♦ Thrust plate - VW 447 H-
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.

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
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
♦ Press tool - VW407-

fo
en
ng
t.
yi Co
♦ Press tool - VW412- t. Cop py
rig
gh ht
♦ Thrust piece from assembly tool - 3301- pyri by
Vo
o
by c lksw
cted agen
♦ Assembly tool - 3346- Prote AG.
♦ Tube - 30-14-
♦ Press tool - 30-506B-

♦ Thrust piece - 3051-
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
♦ Thrust piece -
an
itte
y li
VW442-
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
Driving out roller bearing
m
m
atio
without retaining ring
om
n in
or c
thi
e
Driving in roller bearing without retaining ring onto stop

t
sd
iva
o
r
rp
cu
– Secure outer ring in gearbox housing at 3 points (120° offset)

o
m
f
-arrows- using a punch.

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

Removing roller bearing with retaining ring
– When pulling out roller bearing -1-, press together retaining

ring -2- with pliers. en AG. V
olkswagen AG
ag does
ksw not
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
es, in part or in w
t to the co
Pressing in roller bearing with retaining ring
– Place gearbox housing in area of roller bearing on tube -
30-14- .
rrectness of i
– Press together retaining ring and press in roller bearing until

l purpos
retaining ring clips into annular groove.

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
co lksw
by
cted agen
Prote AG.
6.3.2 Removing and installing differential

bearings in gearbox housing
Note
See adjustment overview ⇒ page 190 .


equipment required
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
♦ Thrust plate - 3062-

h re
hole
spec
♦ Tube - 3146-
es, in part or in w
t to the co
♦ Wheel bearing tube - 3345-

rrectness of i
♦ -1- internal puller, e.g. KUKKO 21-8 - VAS 6775-

l purpos
♦ -4- counter support, e.g. KUKKO 22-2 - VAS 251 623-

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.

AG. Volkswagen AG d
agen oes
olksw not
yV gu
California 2010 ➤ , Caravelle 2004ised b ➤ , Caravelle 2010 ➤ , Multivan 2004
ara ...
nte
r
ut5-speed manual gearbox 02Z - Edition 06.2019
ho eo
a 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
o
♦ Thrust plate -
rm
VW402-
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.
Pulling out tapered roller

bearing outer race
A - Counter support, e.g.
KUKKO 22-2 - VAS 251
623-
B - Internal puller e.g.
KUKKO 21-8 - VAS
6775-

Pressing in tapered roller bearing outer race

– Before pressing in outer race, insert shim of calculated thick‐
ness ⇒ page 185 .
– Support gearbox housing with wheel bearing tube - 3345- di‐
rectly below bearing support.
6.4 Repairing clutch housing

gen AG
. Volkswagen AG
a does
lksw n
⇒ “6.4.1 Removing andbinstalling
yV
o
input shaft bearings inotclutch
gu
ara
d
housing”, page 134orise nte
th eo
⇒ “6.4.2 Removingau and installing output shaft bearings in clutch r ac
ss
ce
e
nl
pt
du
an
⇒ “6.4.3 Removing and installing differential bearings in clutch
itte
y li
erm
ab
ility
ot p
6.4.1 Removing and installing input shaft

wit
, is n
h re
bearings in clutch housing
hole
spec
es, in part or in w
t to the co
Note
rrectness of i
No shim is installed in the clutch housing end.

l purpos

nf
ercia
♦ Thrust plate - VW401- and -VW402-

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.

. Volkswage
California 2010 ➤ , Caravellek2004
wage ➤ , Caravelle 2010
n AG n AG d
oes➤ , Multivan 2004 ...
ol s no
by 5-speed manual gearbox 02Zt g-uEdition
V
ar 06.2019
d e an
ris tee
ho
♦ Tube - 2040- au
t or
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
rrectnes
♦ Sleeve - 30-21-
s 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.
Do not damage dowel sleeves in clutch housing when fitting pres‐

sure plates - VW 401- and -VW 402- .
Cylindrical roller bearing, pressing out
Cylindrical roller bearing, pressing in
Note
♦ Gearbox housing must rest in area of bearing support during

pressing in procedure.
♦ If it is not resting in this area, irreparable damage to the gear‐
box housing may ensue.
– Support clutch housing with suitable tool directly below bear‐

ing support.

6.4.2 Removing and installing output shaft

Note
See adjustment overview ⇒ page 190 .

equipment required
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,
spec
t to the co
rrectnes
♦ End measuring plate - VW 385/17- (for adjusting output shaft

s o
only)
cial p
f inform
♦ Universal dial gauge bracket - VW 387- (for adjusting output

mer
atio
shaft only)
om
n
c

or
n thi
te
sd
a

iv
o
pr
cum
r
fo
♦ Tube - VW 415 A-
en
ng
t.
yi Co
op
♦ Press tool - 30 - 504-
C py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

♦ Internal puller e.g.

KUKKO 21-6 - VAS
251 613-
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
s c
♦ Counter support e.g. s
ce
le
KUKKO 22-2 - VAS

un
pt
an
d
251 623-
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
♦ Pulling ring - 2003/3-
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.

bearing outer race -C-
623-
613-
To prevent damage to
bolting surface for bear‐
ing support in clutch
housing, lay pulling ring -
2003/3- on this surface.

Pressing in tapered roller

bearing outer race
– Before pressing in
outer race, insert
shim of calculated
thickness
⇒ page 163 .
– Support clutch hous‐
ing with tube - VW
415 A- directly below
bearing support.
– Insert outer race.
– Set press tool - 30 - lkswage es n
504- on outer race. d byV
o ot g
ua
ran
ir se tee
– Press in outer race utho
or
using press tool - ss
a ac
VW 407- .
ce
e
nl
pt
du
an
itte
y li
6.4.3 Removing and installing differential
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
Note
es, in part or in w
t to the co
An oil deflector plate is installed in the clutch housing end.
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
co lksw
by
cted agen
Prote AG.

Special tools and work‐

shop equipment re‐
quired
♦ Thrust plate -
VW402-
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
♦ Press tool - VW408A-
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
♦ Internal puller e.g.

KUKKO 21-8 - VAS
6775-

California 2010 ➤ , Caravelle 2004 ➤ , Caravelle 2010AG
➤. V,oMultivan 2004 ...
lkswagen AG
5-speed manual gearbox 02Z - Edition 06.2019 agen does
olksw not
V gu
by ara
ed nte
♦ Counter support e.g. oris eo
th
KUKKO 22-2 - VAS ss
au ra
c
251 623-
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
s
bearing outer race
s o
cial p
f in
form
mer
atio
623-
om
n
c
i
or
n
thi
te
KUKKO 21-8 - VAS
sd
iva
o
r
6775-
p
cum
r
fo
en
ng
t.
yi Co
op py
Note
. C rig
ht ht
rig by
copy Vo
by lksw
After pulling out, check cted agen
Prote AG.
oil deflector ring for dam‐
age and renew if neces‐
sary.
Pressing in tapered roller bearing outer race

– Before pressing in, insert oil deflector plate
⇒ Item 9 (page 181) . Shoulder points to clutch housing.

35 – Gears, shafts
1 Input shaft
⇒ “1.1 Assembly overview - input shaft”, page 141
⇒ “1.2 Dismantling and assembling input shaft”, page 142
1.1 Assembly overview

en AG. V
olks-wainput
gen AG shaft
ag does
ol wheels or new input shaft, oobserve ksw n
When installing newbgear
yV t gu
ara dif‐
ferent versions: rised
nte
ho eo
ut
♦ Technical
ss data ⇒ page 2 .
a ra
c
ce
le
♦ ⇒ Electronic parts catalogue (ETKA)

un
pt
an
d
itte
y li
erm
ab
1 - Cylindrical roller bearing
ility
ot p
wit
❑ Pressing out
is n
h re
⇒ page 145 .
ole,
spec
❑ Pressing in
⇒ page 145 .
t to the co
2 - Clutch housing
rrectne
3 - Retaining ring
4 - Inner race for cylindrical roll‐ ss o
cial p
f i
er bearing
nform
mer
❑ Pressing off
atio
m
⇒ page 145
o
n
c
i
or
❑ Pressing on
thi
e
⇒ page 146
t
sd
iva
o
pr
cum
5 - Input shaft
r
fo
en
ng
t.
yi Co
6 - Gear wheel for 3rd gear . Cop py
rig
ht
❑ Installation position: rig ht
py by
shoulder faces towards
co Vo
by lksw
cted
4th gear
agen
Prote AG.
❑ Pressing off
⇒ page 146
❑ Pressing on
⇒ page 146
7 - Retaining ring
❑ Installation position:
shoulder faces 3rd gear
❑ Pressing off
⇒ page 146
❑ Pressing on
⇒ page 147
9 - Deep groove ball bearing
❑ Pressing off ⇒ page 146
❑ Pressing on ⇒ page 147
1. Input shaft 141

11 - Retaining ring
❑ Insert in peripheral groove of deep groove ball bearing.
12 - Sleeve
❑ For 5th gear needle bearing
13 - Needle bearing
❑ For 5th gear synchromeshed gear
14 - Synchromeshed gear, 5th gear
15 - Synchro-ring for 5th gear AG. Volkswagen AG d
agen oes
❑ With cast locking pieces ⇒ page 113 olksw not
y V gu
d b ara
16 - Spring rise nte
tho eo
u ra
❑ Fitting position ⇒ page 148 ss a c
ce
e
nl
17 - Locking pieces
pt
du
an
itte
y li
erm
ab
ility
18 - Synchro-hub for 5th gear
ot p
wit
, is n
h re
hole
spec
19 - Locking collar for 5th gear
es, in part or in w
t to the co
20 - Dished spring
rrectness of i
l purpos
nform
ercia
❑ Fitted section of bolt head holds dished spring in position ⇒ page 122
❑ Specified torque ⇒ page 90
m
at
om
ion
c
in t
or
his
ate
1.2 Dismantling and assembling input shaft

do
priv
cum
for
en
ng
t.
yi Co
op
Note
C py
t. rig
gh ht
pyri by
Vo
co
♦ Install all bearings on input shaft with gear oil.
by lksw
cted agen
Prote AG.
♦ Heat gear wheels and synchro-hubs to about 100°C with the
inductive heater - VAS 6414- before installing. Wear protective
gloves to do this.
142 Rep. gr.35 - Gears, shafts


equipment required
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
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
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
♦ Tube - VW 420-
♦ Tube - VW 421-
1. Input shaft 143

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,
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
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
♦ Thrust ring - VW 429-

♦ Support rails - VW 457-
♦ Tube - VW 519-
♦ Sleeve - 30 - 21-
♦ Tube - 2040-

AG. Volkswagen AG d
agen oes
ksw
♦ Splitter, e.g. KUKKO byV
ol not
gu
ara
17-0 - VAS 251 407- rised
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
es, in part or in w
t to the co
rrectness of i
♦ Inductive heater -
VAS 6414-
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
Pressing cylindrical roll‐ cted agen
Prote AG.
er bearing out of clutch
housing
Pressing cylindrical roller bearing into clutch housing

Do not damage dowel sleeves in clutch housing when applying
pressure plate - VW 401- .
Cylindrical roller bearing inner ring (clutch side), pressing off

– Before pressing off, remove circlip ⇒ Item 3 (page 141) from
input shaft.
– Now carefully drive inner race for cylindrical roller bearing
about 2 mm off 1st gear splines.
Do not damage 1st gear splines in the process.
– Then apply splitter - VAS 251 407- (e. g. KUKKO 17-0) -A-
behind inner race, and press off inner race.
1. Input shaft 145

Pressing off cylindrical roller bearing inner race

– Then insert circlip ⇒ Item 3 (page 141) in groove of input shaft.
Pressing off gear wheel for 4th gear with deep groove roller bear‐
ing and sleeve
Pressing off gear wheel for 3rd gear

– Before pressing off, remove circlip ⇒ Item 7 (page 141) from
input shaft.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
Pressing on gear wheel for 3rd gear

h re
hole
spec
Shoulder faces upwards (towards gear wheel for 4th gear).

es, in part or in w
t to the co
– Insert circlip ⇒ Item 7 (page 141) in groove of input shaft.

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
co lksw
by
cted agen
Prote AG.

Pressing on gear wheel for 4th gear

Shoulder faces towards gear wheel for 3rd gear.
Installation position of deep groove ball bearing

Retaining ring -arrow- faces towards gear wheel for 4th gear.
Smaller outer diameter of bearing, dimension -a- = 71 mm, must
face synchromeshed gear for 5th gear.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
Pressing on deep groove ball bearing

itte
y li
rm
ab
pe
Observe installation position of deep groove ball bearing

ility
ot
⇒ page 147 .
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
Pressing on sleeve for needle bearing

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
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
1. Input shaft 147

5th gear synchronization

1- Springs for lock pieces
2- Locking collar with 3 recesses -arrows A- for the locking
pieces -item 4-
3- Synchro-hub
4- Locking pieces - installation position: thin extension
-arrow B- faces the pointed teeth of the locking collar -2-
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
or
Assembling 5th gear locking collar/synchro-hub ss
au ac
ce
e
– Slide locking collar over synchro-hub.

nl
pt
du
an
itte
y li
Pointed teeth -C- and shoulder -D- of synchro-hub face in same
erm
ab
direction. The recesses for the locking pieces in locking collar and
ility
ot p
synchro-hub must be aligned ( ⇒ page 148 ).
wit
, is n
h re
– Insert locking pieces (installation position ⇒ page 148 ).
hole
spec
– Fit springs offset 120°.
es, in part or in w
t to the co
– Angled end -A- of spring must locate in hollow locking piece.
It must be located under shoulder -B- of locking piece.
rrectness of i
Bent ends always face away from synchro-hub
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
co lksw
by
cted agen
Prote AG.

2 Output shaft
⇒ “2.1 Assembly overview - output shaft”, page 149
⇒ “2.2 Dismantling and assembling output shaft”, page 151
⇒ “2.3 Adjusting output shaft”, page 163
2.1 Assembly overview - output shaft

When installing new gears or a new output shaft, take account of
difference versions:
♦ Technical data ⇒ page 2 .
♦ ⇒ Electronic parts catalogue (ETKA)
1 - Nut AG. Volkswagen AG d

agen oes
❑ 4 nuts for bearing sup‐ Volksw not
gu
y
port d b ara
ise nte
⇒ Item 9 (page 149) thor eo
au ra
❑ Renew after removal ss c
ce
e
nl
pt
du
an
⇒ page 93
itte
y li
erm
ab
2 - Clutch housing
ility
ot p
wit
, is n
3 - Shim
h re
hole
spec
es, in part or in w
❑ Adjustment overview
t to the co
⇒ page 190
4 - Small tapered roller bearing
rrectness of i
outer race
l purpos
❑ Pressing in
nform
ercia
5 - Small tapered roller bearing

inner race
m
at
om
i
❑ Pressing off
on
c
⇒ page 157
in t
or
his
te
❑ Pressing on
a
do
riv
⇒ page 157
p
cum
for
en
ng
6 - Output shaft
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
7 - Tapered roller bearing inner
c by lksw
cted agen
ring for bearing support Prote AG.
❑ Pulling off ⇒ page 157

❑ Pressing on
⇒ page 158
8 - Seal
❑ Qty. 4
❑ Fit onto bearing support studs
9 - Bearing support
❑ With tapered roller bearing outer race ⇒ Item 7 (page 149)
❑ Change outer race only together with large tapered roller bearing and bearing support
10 - Thrust washer
❑ Shoulder of thrust washer faces tapered roller bearing ⇒ Item 7 (page 149)
2. Output shaft 149

11 - Needle bearing
❑ For 1st gear synchromeshed gear
12 - Synchromeshed gear, 1st gear
13 - Inner synchro-ring for 1st gear
❑ Check for wear ⇒ page 158
14 - Outer ring for 1st gear
15 - Synchro-ring for 1st gear
16 - Locking collar with synchro-hub for 1st and 2nd gear
❑ Fitting position ⇒ page 160 AG. Volkswagen AG d
agen oes
❑ Pressing on ⇒ page 160 olksw not
yV gu b ara
ed
17 - Retaining ring horis nte
e
t or
au a
18 - Synchro-ring for 2nd gear c ss
ce
e
nl
pt
du
an
itte
❑ Assemble so that notches engage in locking pieces of locking collar ⇒ Item 16 (page 150) .
y li
erm
ab
ility
19 - Outer bearing race for 2nd gear
ot p
wit
, is n
h re
hole
spec
20 - Inner synchro-ring for 2nd gear
es, in part or in w
❑ Check for wear ⇒ page 158 t to the co

21 - Synchromeshed gear for 2nd gear
rrectness of i

l purpos
22 - Needle bearing
nf
ercia
❑ For 2nd gear synchromeshed gear

orm
m
23 - Thrust washer
atio
om
n in
c
24 - Sleeve
or
thi
te
❑ For 3rd gear needle bearing

sd
iva
o
r
rp
cu

o
m
f
en
ng

t.
yi Co
Cop py
t. rig
25 - Needle bearing opyri
gh by
Vo
ht
❑ For 3rd gear synchromeshed gear

c by lksw
cted agen
Prote AG.
26 - Synchromeshed gear for 3rd gear
27 - Synchro-ring for 3rd gear
28 - Locking collar with synchro-hub for 3rd and 4th gear
29 - Sleeve
❑ For 4th gear needle bearing

❑ Pressing off ⇒ page 156 agen
AG. Volkswagen AG d
oes
lksw not
❑ Pressing on ⇒ page 163 by Vo gu
a
ed ran
ris
30 - Needle bearing tho tee
or
au ac
❑ For 4th gear ss
ce
e
nl
pt
31 - Synchro-ring for 4th gear
du
an
itte
y li
erm
ab
ility
ot p
32 - Synchromeshed gear for 4th gear
wit
, is n
h re
33 - Thrust washer
hole
spec
34 - Roller sleeve
es, in part or in w
t to the co
rrectness of i
❑ Note that there are different bearing versions ⇒ page 125
l purpos
36 - Inner bearing race of roller bearing
nf
ercia
o
rm
m
atio
om
n in
or c
thi
te
sd
a

iv
o
r
rp
cu
o
m
38 - Dished spring
f
en
ng
t.
yi Co
❑ Fitting position ⇒ page 122 t. Cop py
rig
gh ht
yri
39 - Torx socket head bolt p by
o Vo
by c lksw
cted agen
Prote AG.
❑ Fitted section of bolt head holds dished spring in position ⇒ page 122
❑ Specified torque ⇒ page 90
2.2 Dismantling and assembling output

shaft
Note
♦ Always renew both tapered roller bearings together as a set.

♦ Install all bearings on output shaft with gear oil.
♦ Before installing, heat tapered roller bearing inner races, gear
wheels and synchro-hubs to approx. 100°C using inductive
heater - VAS 6414- (wear protective gloves).
2. Output shaft 151


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

m
a
com

tion in
r
te o
♦ Press tool - 30 - 504-

thi
s
iva
do

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

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
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.

♦ Support rails - VW 457-
♦ Tube - VW 519-
2. Output shaft 153

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
♦ Thrust ring - VW 429-
es, in part or in w
t to the co
♦ Tube - VW 415 A-
rrectness of i
l purpos
♦ Installing sleeve - VW 455-

nf
♦ Drift sleeve - 41 - 501-

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

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c ce
le
un
pt
an
d
itte
y li
rm
ab

pe
ility
ot
wit
, is n
♦ Puller - V.A.G 1582-

h re
hole
spec
♦ Grip tool - V.A.G 1582/4-

es, in part or in w
t to the co
♦ -1- internal puller, e.g. KUKKO 21-6 - VAS 251 613-

rrectness of i
♦ -3- splitter, e.g. KUKKO 17-1 - VAS 251 409-

l purpos
♦ -3- splitter, e.g. KUKKO 17-2 - VAS 251 411-

nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
2. Output shaft 155

♦ Inductive heater -
VAS 6414-
♦ Feeler gauge
Pulling out small tapered
roller bearing outer race
-C-
623-
B - Internal puller e.g. agen
AG. Volkswagen AG d
oes
KUKKO 21-6 - VAS 251 Volksw not
gu
613- ed by ara
nte
ris
ho eo
To prevent damage to aut ra
c
bolting surface for bear‐ ss
ce
le
ing support in clutch

un
pt
housing, lay pulling ring -

an
d
itte
y li
2003/3- on this surface.

erm
ab
ility
ot p
Pressing in small ta‐

wit
is n
pered roller bearing out‐

h re
ole,
er race
spec
– Support clutch hous‐

t to the co
ing with tube - VW

415 A- directly below
bearing support.
rrectne
– Insert outer race.

s
– Set press tool - 30 -

s o
cial p
504- on outer race.

inform
mer
– Press in outer race

atio
using press tool -

om
VW 407- .
c
i
or
n thi
te
sd
va
Pressing off synchro-hub and locking collar for 3rd and 4th gears,
i
o
pr
cum
r
synchromeshed gear for 2nd, 3rd and 4th gears with sleeve for
fo
en
ng
output shaft needle bearing

t.
yi Co
Cop py
A - Splitter, e.g. KUKKO 17-2 - VAS 251 411-
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Note
Support splitter -A- in such a way that 1st and 2nd gear locking
collar is not pulled off at the same time.

ks wage es
Pressing off locking collar ywith
Vol synchro-hub for 1st and 2nd
not gears
gu
as well as bearing support
ris
ed b ara
nt
o ee
th o
– Before pressings au off, remove circlip ⇒ Item 17 (page 150) from r ac
output shaft. 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
Tapered roller bearing inner ring for bearing support, pulling off
rrectness of i
A - Vice clamps
l purpos
– Before fitting puller, insert a M10 × 20 hexagon bolt in the out‐

put shaft drilling.
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
yri by
Pressing off small tapered roller bearing inner race cop Vo
by lksw
cted agen
Prote
A - Splitter, e.g. KUKKO 17-1 - VAS 251 409-
AG.
Pressing on small tapered roller bearing inner race
2. Output shaft 157

California 2010 ➤ , Caravelle 2004 a➤
gen,ACaravelle
G. Volkswag2010
en AG ➤ , Multivan 2004 ...
does
ksw not
5-speed manual gearbox 02Z by V- Edition 06.2019
ol
gu
a
ed ran
oris tee
Tapered roller bearing inner ring
au for bearing
th
support, pressing on or
ac
ss
A - Thrust washer ⇒ Item 10 (page 149)
ce
e
nl
pt
du
an
– Before pressing on, insert thrust washer
itte
y li
erm
⇒ Item 10 (page 149) . Shoulder faces inner race.
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
Installation position of outer ring, inner ring and synchro-ring for

1st gear
nf
ercia
– Place inner ring -A- on synchromeshed gear for 1st gear.
orm
m
atio
Angled lugs -arrow 1- face outer ring -B-.
om
n in
c
– Fit outer ring -B-.

or
thi
te
sd
iva
Lugs -arrow 2- engage in notches -arrow 3- of synchromeshed
o
r
rp
cu
gear.
o
m
f
en
ng
t.
yi
– Fit synchro-ring -C-.
Co
Cop py
t. rig
gh ht
Notches -arrow 4- engage in lugs -arrow 1- of inner race -A-. yri
p by
co Vo
by lksw
cted agen
Prote AG.
Note
If components are not to be renewed, ensure that they are match‐

ed with their original gears.
Checking 1st and 2nd gear inner race for wear

– Press inner ring onto cone of synchromeshed gear and meas‐
ure gap -a- using a feeler gauge.
sion
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.
sion
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 spring using ⇒ Electronic Parts Catalogue (ETKA) .
Installation with hollow locking pieces ⇒ page 159
Installation with solid locking pieces ⇒ page 159
2 - Sliding sleeve
AG. Volkswagen AG d
3 - Synchro-hub ksw
agen oes
not
Vol
y gu
4 - Locking piece ise
d b ara
nte
or e
h
Allocate locking
s aut
pieces using ⇒ Electronic Parts Catalogue o(ET‐ ra
c
KA) . s
ce
e
nl
pt
du
Collar is equally wide on both sides of synchro-hub.
an
itte
y li
erm
ab
Collar has chamfer on one side -arrow B-.
ility
ot p
wit
Chamfer on collar of synchro-hub and outer teeth of locking collar
, is n
h re
-arrow A- face in same direction after assembly.
hole
spec
Notches -arrow C- in synchro-hub and sliding collar for locking
es, in part or in w
t to the co
pieces must align.
Assembly of 1st and 2nd gear locking collar and synchro-hub with
rrectness of i
hollow locking pieces
l purpos
• Locking collar has been pushed over synchro-hub.

– Fit locking pieces and install springs offset 120°. Angled end
nform
ercia
of spring must locate in hollow locking piece.

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
yri
Assembly of locking collar and synchro-hub for 1st and 2nd gear p by
co Vo
with solid locking pieces
by lksw
cted agen
Prote AG.
– Fit locking pieces and install springs offset 120°. Angled ends
of spring must be located in front of locking pieces -arrows-.
2. Output shaft 159

Installation position of locking collar with synchro-hub for 1st and

2nd gear
Teeth of locking collar -arrow- face towards splines for 3rd and
4th gear synchro-hub -A-.
Pressing on locking collar and synchro-hub for 1st and 2nd gears
Turn synchro-ring so that grooves align with locking pieces.
– Insert retaining ring in groove in output shaft.
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
Installation position of 2nd gear outer ring

wit
, is n
h re
Lugs -arrows- face 1st gear -A-.

hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
Installation position of synchro-ring (2nd gear inner race) -A-

in t
or
his
ate
Lugs -arrow 1- engage in notches -arrow 2- in synchro-ring -B-.

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.

Installation position of synchromeshed gear for 2nd gear

Higher shoulder -A- faces 1st gear -B-. Notches in shoulder
-arrows- engage in lugs of outer ring (-arrow- ⇒ page 160 ).
– Place thrust washer on 2nd gear synchromeshed gear.
Pressing on sleeve for 3rd gear needle bearing
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.
Gap -a- Installation dimen‐
AG. Volkswagen AG d Wear limit
agen sion oes
olksw not
V gu
by
3rd gear
ris
ed 1.0…1.7 mm 0.5
ara
mm
nt
4thutgear
ho 1.0…1.7 mm ee
or
a ac
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
Dismantling and assembling 3rd and 4th gear locking collar and
, is n
h re
synchro-hub
hole
spec
1 - Spring
es, in part or in w
t to the co
Allocate spring using ⇒ Electronic Parts Catalogue (ETKA) .

Installation with hollow locking pieces ⇒ page 162
rrectness of i
Installation with solid locking pieces ⇒ page 162

l purpos
2 - Locking piece
nform
ercia
Allocate locking pieces using ⇒ Electronic Parts Catalogue (ET‐

KA) .
m
a
com
tio
3 - Sliding sleeve
n in
r
te o
thi
4 - Synchro-hub
s
iva
do
r
rp
– Slide locking collar over synchro-hub.

um
fo
en
ng
t.
yi
Notches for locking pieces in synchro-hub and locking collar must
Co
op py
align.
t. C rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
2. Output shaft 161

Assembly of 3rd and 4th gear locking collar and synchro-hub with
hollow locking pieces
Locking collar has been pushed over synchro-hub.
– Fit locking pieces and install springs offset 120°. Angled end
of spring must locate in hollow locking piece.
Assembly of 3rd and 4th gear locking collar and synchro-hub with
solid locking pieces
– Fit locking pieces and install springs offset 120°. Angled ends
of spring must be located in front of locking pieces -arrows-.
. Vo wagen AG lks
Installation position of locking collar with synchro-hub agefor
n AG3rd and does
ksw
4th gear by Vol not
gu
ara
ed nte
Chamfer -arrow- faces 4th gear. oris e
th or
au ac
ss
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
Pressing on synchro-hub with locking collar for 3rd and 4th gears
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.

Pressing on sleeve for 4th gear needle bearing
Pressing on sleeve for output shaft needle bearing

– Before pressing on, insert thrust washer
⇒ Item 33 (page 151) .
2.3 Adjusting output shaft

(Determining shim for output shaft)
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,
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
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
2. Output shaft 163


equipment required
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectne
♦ End dimension plate - VW 385/17-
s
♦ Universal dial gauge holder - VW 387-
s o
cial p
f in

form
mer

atio
om
n
c
♦ Tube - VW 415 A-
i
or
n thi
te
sd
a
♦ Press tool - 30 - 504-

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.

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

♦ Door hinge alignment tool - 3114/2-
♦ Dial gauge
It is necessary to readjust the output shaft when the following
components are renewed:
♦ Output shaft
♦ Clutch housing
or the
♦ Tapered roller bearing
Adjustment overview ⇒ page 190
Conditions
• Sealing surfaces of clutch and gearbox housings must be free
of sealant .
2. Output shaft 165

– Press small tapered roller bearing outer race together with a

0.70 mm thick shim into clutch housing to stop.
– Insert output shaft and tighten nuts for bearing mounting.
– Turn output shaft 20 to 30 times in one direction.
Note
♦ The shaft must be turned in one direction so that the rollers of

the tapered roller bearing settle in one direction.
♦ Otherwise, the result of the measurement will be incorrect.
– Set up dial gauge (3 mm measuring range) and set to “0”with

1 mm preload.
– Move output shaft up and down, and note dial gauge reading
(example: 0.25 mm).
Determining thickness of shim
The specified bearing preload is obtained by adding a constant
preload figure (0.10 … 0.15 mm) to the reading obtained (0.25
mm) and the thickness of the shim installed (0.70 mm).
Example:
Installed shim 0.70 mm
+ Measured value 0.25 mm
+ Preload (constant) 0.15 mm
Shim thickness 1.10 mm
Example:
Bearing play = Thickness of shim according to lkswagen AG
(0.70 mm shim tableswagen AG. Vo does
plus determined measured val‐ by Volk not
gu
ue) ris
ed ara
nte
tho eo
0.950 mm s au 1.100 mm ra
c
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 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.

California
agen
AG. Vo2010 ➤ , Caravelle
lkswagen AG
does 2004 ➤ , Caravelle 2010 ➤ , Multivan 2004 ...
ksw not
y Vol
gu5-speed manual gearbox 02Z - Edition 06.2019
db ara
rise nte
– tho
Removeauoutput shaft and pull out small tapered roller bearing
eo
ra
outer race.
ss c
ce
e
nl
pt
A - Counter support, e.g. KUKKO 22-2 - VAS 251 623-
du
an
itte
y li
erm
B - Internal puller e.g. KUKKO 21-6 - VAS 251 613-
ab
ility
ot p
To prevent damage to bolting surface for bearing support in clutch
wit
, is n
housing, lay pulling ring - 2003/3- on this surface.
h re
hole
spec
The following shims are available:
es, in part or in w
t to the co
Bearing play = Shim
(0.70 mm shim thickness (mm)
plus determined measured value)
rrectness of i
≤ … 0.639 0.75
l purpos
0.640 … 0.689 0.80

0.690 … 0.739 0.85
nform
ercia
0.740 … 0.789 0.90

0.790 … 0.839 0.95
m
at
om
0.840 … 0.889 1.0
ion
c
in t
r
0.890 … 0.939 1.05

o
his
e
0.940 … 0.989 1.10

at
do
riv
0.990 … 1.039 1.15

p
cum
for
1.040 … 1.089 1.20

en
ng
t.
yi
1.090 … 1.139 1.25
Co
Cop py
1.140 … 1.189 1.30
t. rig
gh ht
pyri by
1.190 … 1.239 1.35
co Vo
by lksw
cted
1.240 … 1.289 1.40
agen
Prote AG.
1.290 … 1.339 1.45
1.340 … 1.389 1.50
1.390 … 1.429 1.50
Note
Allocate shims using ⇒ Electronic parts catalogue (ETKA) .
– Insert shims of determined thickness, thickest shim first.

• If the previously used 0.70 mm shim is to be reinstalled,
checked the shim for damage.
If the size of shim required is larger than those listed in the table,
insert two shims totalling the correct figure.
The various thicknesses allow for achieving the exact shim thick‐
ness required.
– Press in tapered roller bearing outer race together with correct

shim (in example 1.10 mm).
– Install output shaft and tighten nuts for bearing support in
clutch housing.
Specified torques
♦ ⇒ “5.5 Assembly overview - input shaft, output shaft, differen‐
tial and selector forks”, page 93
2. Output shaft 167

3 Reverse shaft
⇒ “3.1 Assembly overview - reverse shaft”, page 168
⇒ “3.2 Dismantling and assembling reverse shaft”, page 169
3.1 Assembly overview - reverse shaft
Note
After dismantling, always renew needle bearing in clutch housing and reverse shaft support.
1 - Clutch housing
2 - Needle bearing
❑ Pressing in lkswage es n
Vo ot g
y ua
db ran
3 - Reverse shaft orise tee
th or
❑ With reverse
ss
au gear wheel ac
❑ Removing and installing ce
le
un
⇒ page 113 pt
an
d
itte
y li
erm
4 - Reverse gear locking collar ab

ility
ot p
❑ Installation position: dog

wit
is n
teeth face reverse gear

h re
ole,
synchromeshed gear
spec
5 - Washer
t to the co
6 - Needle bearing
❑ For synchromeshed
rrectne
gear for reverse gear

❑ Coat with gear oil when
ss
installing
o
cial p
f in
7 - Synchromeshed gear for re‐

form
mer
verse gear
atio
m
❑ Installation position: dog

o
n
c
i
or
teeth face reverse gear

thi
e
locking collar
t
sd
iva
o
pr
cum
r
8 - Thrust washer
fo
en
ng
t.
yi Co
9 - Needle bearing t. Cop py
rig
gh ht
pyri by
Vo
co
❑ Pressing in
by lksw
cted agen
Prote
⇒ page 170 .
AG.
10 - Reverse shaft support

⇒ page 113

3.2 Dismantling and assembling

agen
Areverse shaft
G. Volkswagen AG d
o
ksw es n
Vol ot g
d by ua
ran
e
Special tools and workshop tho
ris tee
or
equipment required au ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

♦ Drift sleeve - 41 - 501-
3. Reverse shaft 169

Pulling needle bearing out of clutch housing

Note
The needle bearing is destroyed during removal and must be re‐

newed.
Pressing needle bearing into clutch housing

– Position needle bearing in gearbox housing by hand.
– Press in needle bearing using drift sleeve - 41 - 501- . AG. Volkswagen AG d
agen oes
olksw not
V gu
Pulling needle bearing out of reverse shaft support ed by ara
nte
ris
o eo
A - Counter support, e.g. KUKKO 22-1 - VAS 251 621- aut
h
ra
ss c
ce
e
nl
pt
du
an
C - Vice clamps
itte
y li
erm
ab
ility
ot p
wit
, is n
Note
h re
hole
spec
The needle bearing is destroyed during removal and must be re‐
es, in part or in w
newed.
t to the co
rrectness of i
Pressing needle bearing into reverse shaft support
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.

39 – Final drive - differential

1 Oil seals
⇒ “1.1 Overview of fitting locations - seals”, page 171
⇒ “1.2 Renewing left seal”, page 172
⇒ “1.3 Renewing right oil seal”, page 173
⇒ “1.4 Renewing input shaft seal”, page 177
1.1 Overview of fitting locations - seals
1 - Input shaft seal

2 - Seal
❑ For right flange shaft
3 - Seal
❑ For left flange shaft
4 - Seal for selector shaft
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
1. Oil seals 171

1.2 Renewing left seal

equipment required AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
♦ Multi-purpose tool - VW 771-

♦ Extractor hook - VW 771/37-
♦ Thrust piece - T10231-
Removing
– Remove front left wheel bolts.
– Raise vehicle.
– Remove left wheel.
– Remove left drive shaft ⇒ Rep. gr. 40 .
– Place drip tray for workshop hoist - VAS 6208- below gearbox.
172 Rep. gr.39 - Final drive - differential

– Remove flange shaft securing bolts. Screw 2 bolts into flange

and counter hold flange shaft using a lever.
– Pull out flange shaft with compression spring.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
– Pull out flange shaft oil seal using multi-purpose tool - VW 771-
ce
e
nl
pt
and puller hook - VW 771/37- .
du
an
itte
y li
erm
Installing
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
– Lightly oil outer circumference of new oil seal and drive in to
nform
ercia
tool stop.
m
– Half-fill space between sealing lip and dust lip with sealing
at
om
io
grease .
n
c
in t
or
his
e
– Insert flange shaft.

at
do
priv
c
– Secure flange shaft with countersunk bolt and tighten bolt.
um
for
en
ng
t.
yi
– Install left drive shaft ⇒ Rep. gr. 40 .
Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
– If present, install noise insulation ⇒ General body repairs, ex‐ cted agen
Prote AG.
– Fit wheel ⇒ Rep. gr. 44 .
Specified torques
1.3 Renewing right oil seal
1. Oil seals 173


equipment required
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
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
co lksw
by
cted agen
Prote AG.

♦ Drift sleeve - 3158-
♦ Socket insert - T10107 A-
♦ Counter-hold tool - T10140-
♦ Counter-hold tool - T50053-
♦ Assembly mandrel - 3384-

♦ Sealing grease for radial shaft oil seal ⇒ Electronic parts cata‐
logue (ETKA)
♦ Grease for splines of stub shaft ⇒ Electronic Parts Catalogue
(ETKA)
Removing
– Loosen front right wheel bolts.
– Raise vehicle.
– Remove right wheel.
terior; Rep. gr. 66 ; Noise insulation; Assembly overview -
noise insulation .
– Separate threaded connection securing wheel bearing hous‐
ing to lower swivel joint ⇒ Running gear, axles, steering; Rep.
gr. 40 ; Lower suspension link, swivel joint; Assembly over‐
view - lower suspension link, swivel joint
-arrows-.
– Pull right drive shaft off gearbox stub shaft, raise and secure.
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
– Remove O-ring -arrow- from stub shaft.
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
– Remove countersunk bolt for right stub shaft with socket -

tion in
T10107 A- . Counterhold stub shaft with counterhold tool -

r
te o
thi
T10140- or counterhold tool - T50053- when doing this.

s
iva
do
r
– Place drip tray for workshop hoist - VAS 6208- below gearbox.
rp
cum
fo
en
ng
t.
– Remove stub shaft with compression spring. Cop
yi Co
py
t. rig
– Lever out stub shaft oil seal with lever. gh ht
pyri by
Vo
co lksw
by
Installing Prote
cted AG.
agen

– Lightly oil new oil seal on outer diameter.
1. Oil seals 175

– Drive in seal using drift - 3384- to 1 mm below housing surface.

Do not cant oil seal in the process.
Note
If the seal cannot be driven in to a depth of 1 mm below the surface

of the housing, drive in using drift sleeve - 3158- .
– Half-fill space between sealing lip and dust lip -arrow- with
sealing grease .
– Insert stub shaft with spring.
– Screw in countersunk bolt for right stub shaft with socket -

T10107 A- , and tighten it. Counterhold stub shaft using coun‐
terhold tool - T10140- or counterhold tool - T50053- while
doing so.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
– Renew O-ring -arrow- of stub shaft.

nl
pt
du
an
itte
y li
– Grease splines of stub shaft with grease ⇒ Electronic Parts

erm
ab
Catalogue (ETKA) .
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
ht. rig
rig ht
py by
co Vo
176
by lksw
cted agen
Rep. gr.39 - Final drive - differential Prote AG.

– Screw bolts -arrows- into rear torque reaction support to speci‐
fied torque ⇒ Running gear, axles, steering; Rep. gr. 40 ; Drive
shaft; Removing and installing drive shaft .
– Join wheel bearing housing to lower swivel joint ⇒ Running
gear, axles, steering; Rep. gr. 40 ; Lower suspension link,
swivel joint; Assembly overview - lower suspension link, swivel
joint .
– Check gear oil level ⇒ page 87 .
terior; Rep. gr. 66 ; Noise insulation; Assembly overview -
noise insulation .
– Attach wheel ⇒ Running gear, axles, steering; Rep. gr. 44 ;
Wheels, tyres; Specified torque for wheel bolts .
Specified torques
♦ ⇒ “2.1 Assembly overview - differential”, page 180
1.4 Renewing input shaft seal

♦ Drift - VW 295-
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
♦ Adapter - VW 295 A-
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
1. Oil seals 177

♦ Tube - 2040-

• Gearbox has been removed.
– Remove clutch release lever together with release bearing
AG. Volkswagen AG d
and guide sleeve ⇒ page 20 . lksw
agen oes
n o ot g
yV ua
edb ran
ris tee
Note tho or
au ac
ss
ce
e
♦ The oil seal for the input shaft can be replaced individually
nl
pt
du
an
⇒ page 178 .
itte
y li
erm
ab
♦ If the O-ring on the guide sleeve is damaged, the guide sleeve

ility
ot p
must be renewed.
wit
, is n
h re
hole
spec
– Driving oil seal out of guide sleeve

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.

Californiae2010
AG. V➤
olks,wCaravelle
agen AG 2004 ➤ , Caravelle 2010 ➤ , Multivan 2004 ...
ag n does
V olksw 5-speed
not manual gearbox 02Z - Edition 06.2019
y gu
db ara
ise n
– Half-fill space between
tho
r
sealing lip and dust lip -arrow- with tee o
sealing grease s au. ra
c
s
ce
e
– Lightly moisten outer circumference of oil seal with gear oil.
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
– Driving oil seal into guide sleeve to stop
l purpos
– Install clutch release lever together with release bearing and

guide sleeve ⇒ page 20 .
nform
ercia
– Install gearbox ⇒ page 80 .

m
at
om
ion
Specified torques
c
in t
or
his
te

a
do
riv
20 .
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.
1. Oil seals 179

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
orise 2004 ➤ , Caravelle 2010 ➤ , Multivan nte2004 ...
h eo
5-speed manual gearbox aut 02Z - Edition 06.2019 ra
c
ss
ce
e
nl
pt
du
2 Differential
an
itte
y li
erm
ab
ility
⇒ “2.1 Assembly overview - differential”, page 180
ot p
wit
⇒ “2.2 Dismantling and assembling differential”, page 182 , is n
h re
hole
spec
⇒ “2.3 Adjusting differential”, page 185
es, in part or in w
t to the co
2.1 Assembly overview - differential
rrectness of i
Note
l purpos
♦ If tapered roller bearings, differential cage, gearbox housing or clutch housing is renewed, adjust differential
⇒ page 185 .
nform
ercia
♦ For some gearboxes the items -19 … 24- can no longer be ordered as an individual replacement part ⇒
m
at
om
i
Electronic parts catalogue (ETKA) .
on
c
in t
or
his
ate
do
priv
c
1 - Gearbox housing
um
for
en
ng
t.
yi
2 - Shim
Co
Cop py
t.
rig
gh ht
pyri by
Vo
❑ Determining thickness
o
by c lksw
cted agen
⇒ page 185 Prote AG.
3 - Tapered roller bearing outer

race
❑ In gearbox housing
❑ Pressing in
⇒ page 185 .
race
❑ Pressing on
⇒ page 184
5 - Differential cage
❑ With riveted final drive
gear
❑ Final drive gear wheel is
paired with output gear.
Always renew as a set.
6 - Speedometer drive wheel
❑ For vehicles with tacho‐
graph
❑ Fit into differential hous‐
ing to stop before press‐
ing on inner race
race
❑ Pressing on
⇒ page 184
❑ Pressing in ⇒ page 184 .

9 - Oil deflector ring

❑ Installation position: shoulder on inner circumference faces oil seal ⇒ Item 11 (page 181)
10 - Clutch housing
11 - Seal
❑ For stub shaft
❑ Screw into threaded piece ⇒ Item 21 (page 181) .
❑ 25 Nm
13 - Seal
14 - Stub shaft
15 - Compression spring
❑ For flange shaft or stub shaft
❑ Installed behind flange shaft or stub shaft.
16 - Thrust washer
❑ Installation position: shoulder faces spring, lugs face tapered ring
17 - Tapered ring
❑ With grooves to engage in thrust washer
❑ Installation position: taper towards differential cage
18 - Retaining ring n AG. Volkswagen AG do
swage es n
❑ Holds tapered ring,y Vthrust
olk washer and spring in position
ot g
u when flange shaft or stub shaft is removed
b ara
ed nte
19 - One-piece thrust
tho
riswasher e or
u
❑ Coat withssgear
a
oil when installing ac
ce
e
nl
20 - Large differential bevel gear

pt
du
an
itte
y li

erm
ab
ility
ot p
21 - Threaded piece
wit
, is n

h re
hole
spec
22 - Small differential bevel gear

es, in part or in w
t to the co

23 - Clamping sleeve
rrectness of i
❑ For securing differential pinion pin

l purpos

nf
ercia
24 - Differential pinion pin

orm
❑ Drive out using drift

m
atio
om

n in
or c
thi
e
25 - Flange shaft
t
sd
iva
o
r
rp
cu

o
m
f
en
ng
t.
26 - Seal
yi Co
Cop py
❑ For flange shaft
t. rig
gh ht
pyri by
❑ Renewing with gearbox installed ⇒ page 172
co Vo
by lksw
cted agen
Prote AG.
2. Differential 181
2.2 Dismantling and assembling differential

equipment required
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
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.

♦ Support - 40 - 103-

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectne

ss o
cial p
♦ Tube - 3146-
f inform
mer

atio
m
♦ Tapered roller bearing puller - V.A.G 1582-

o
n
c
i
or
n thi
♦ Grip tool - V.A.G 1582/1-

te
sd
iva
o
pr

um
r
fo
en
ng
t.
yi Co
Cop py
t. rig
Pulling tapered roller bearing outer race out of clutch housing
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
B - Internal puller e.g. KUKKO 21-8 - VAS 6775-
Note
After pulling out, check oil deflector ring for damage and renew if
necessary.
2. Differential 183
Pressing tapered roller bearing outer race into clutch housing

– First insert oil deflector ring.
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
Pulling off tapered roller bearing inner races
an
d
itte
y li
– Before setting up extractor, position press tool - 30 - 555- on
erm
ab
ility
differential housing.
ot p
wit
is n
h re
ole,
spec
Note
t to the co
Both tapered roller bearing inner races are pulled off the differ‐
ential cage in the same way.
rrectness o
cial p
f in
Pressing on tapered roller bearing inner race
form
mer
atio
om
n
Note
c
i
or
n thi
te
sd
va
The tapered roller bearing inner races for gearbox housing and
i
o
pr
c
clutch housing are pressed on with the same press tools. um
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Pulling outer race for tapered roller bearing out of gearbox hous‐
ing

Pressing tapered roller bearing outer race into gearbox housing

– Fit shim under outer race.
– Support gearbox housing with wheel bearing tube - 3345- di‐
rectly below bearing support.
Removing spring pin for differential pinion pin

– 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.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
is nte
Installing spring pin for differential pinion pin tho r eo
au ra
s c
– Align hole in differential pinion pin with hole in differential cage. s
ce
le
un
pt
– Drive in spring pin with drift -1- until dimension -a- = 5 ± 0.5
an
d
itte
y li
mm is attained.
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
Installing differential bevel gears rrectness
– Lubricate one-piece thrust washer with gear oil and install.

o
cial p
f in
– Install both sun wheels, and secure them (e.g. with flange shaft
form
mer
and stub shaft).

atio
om
– Insert planet pinions offset 180° and pivot into position.

c
i
or
n thi
e
– Press in differential pinion pin (-arrow A-) to first planet pinion.

t
sd
iva
o
pr
cum
r
– Place threaded pieces -arrows B- in sun gears.

fo
en
ng
t.
yi Co
Installation position: shoulder to sun gear . Cop py
rig
ht ht
rig
– Drive differential pinion pin into final position and secure with py by
co Vo
spring pin.
by lksw
cted agen
Prote AG.
2.3 Adjusting differential

(Determining differential shim)
2. Differential 185

equipment required
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
♦ End dimension plate - VW 385/17-

rrectne
♦ Universal dial gauge holder - VW 387-

s

s o
cial p
f in

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.

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
rrectness of i
l purpos

♦ Tube - 3146-
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
♦ Dial gauge (commercially available) Cop py
t. rig
gh ht
yri
♦ 60 mm dial gauge extension p by
co Vo
by lksw
cted agen
It is necessary to readjust the differential when the following com‐ Prote AG.
ponents are renewed:
♦ Gearbox housing
♦ Clutch housing
♦ Differential cage or
♦ Tapered roller bearing of differential
Adjustment overview ⇒ page 190
2. Differential 187
– Press tapered roller bearing outer race with oil deflector ring
into clutch housing.
Note
Inner and outer tapered roller bearing races are paired. Do not
interchange!
– Press outer ring/taper roller bearing, without shim, into gear‐

box housing.
– Fit differential into clutch housing.
– Set gearbox housing in place and tighten 5 bolts to 25 Nm.
– Fit universal dial gauge bracket - VW 387- and set dial gauge
to “0” with 1 mm preload.
A - 60 mm dial gauge extension
– Move differential up and down. Read and note play indicated
on dial gauge. (Example: 0.70 mm)
Determining thickness of shim
wage es n
The specified bearing preload is obtained by addingVol a constant
ks ot g
by ua
value for preload (0.25 mm) to the reading obtained.
ise
d ran
tee
r
ho
Example: aut or
ac
ss
ce
le
Measured value 0.70 mm

un
pt
an
d
itte
+ Preload (constant) 0.25 mm

y li
erm
ab
Thickness of shim = 0.95 mm

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

. Volkswage
wage 2004 ➤ , Caravelle
n AG n AG d
oes2010 ➤ , Multivan 2004 ...
olks not
d by V 5-speed manual gearbox gu02Z - Edition 06.2019
ar
e an
ris tee
ho
– Remove gearbox housing and pull sa
utapered roller bearing outer
t or
ac
race out from gearbox housing. s
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
– Insert shims of determined thickness, thickest shim first.
, is n
h re
hole
The following shims are available:
spec
es, in part or in w
t to the co
Note
rrectness of i
Allocate shims according to ⇒ Electronic parts catalogue “ETKA” .
l purpos
Bearing play Shim
nform
ercia
bearing clearance Thickness (mm)

(mm)
m
at
om
i
0.325 … 0.449 0.65
on
c
0 … 0.499 0.70
in t
or
his
e
0.500 … 0.549 0.75

at
do
riv
0.550 … 0.599 0.80

p
cum
or
0.600 … 0.649 0.85

f
en
ng
t.
yi
0.650 … 0.699 0.90
Co
Cop py
. rig
0.700 … 0.749 0.95
ht ht
rig by
py
0.750 … 0.799 1.00
co Vo
by lksw
0.800 … 0.849 1.05
cted agen
Prote AG.
0.850 … 0.899 1.10
0.900 … 0.949 1.15
0.950 … 0.999 1.20
1.000 … 1.049 1.25
1.050 … 1.099 1.30
1.100 … 1.149 1.35
1.150 … 1.199 1.40
1.200 … 1.249 0.70 + 0.75
1.250 … 1.299 0.75 + 0.75
1.300 … 1.349 0.75 + 0.80
1.350 … 1.385 0.80 + 0.80
If the size of shim required is larger than those listed in the table,
insert two shims totalling the correct figure.
The various thicknesses make it possible to achieve the exact
shim thickness required.
– Press in outer race again and bolt gearbox housing tight.

Specified torques
2. Differential 189
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
o e
Californiaau2010
th ➤ , Caravelle 2004 ➤ , Caravelle 2010 ➤or ,a Multivan 2004 ...
s c
5-speeds manual gearbox 02Z - Edition 06.2019
ce
le
un
pt
an
d
itte
y li
3 Adjustment overview
rm
ab
pe
ility
ot
wit
, is n
h re
Note
hole
spec
es, in part or in w
t to the co
If repairs have been carried out to the gearbox, it is necessary to
adjust the output shaft or differential only if components have
been renewed which have a direct effect on the adjustment of the
rrectness of i
gearbox. To prevent unnecessary adjustments, refer to the fol‐
lowing table:
l purpos
nform
ercia
Output shaft Differential

⇒ page 163 ⇒ page 185
m
a
com
tio
Parts renewed: Gearbox housing x
n in
r
te o
thi
Clutch housing x x
s
iva
do
Output shaft (final drive) x
r
rp
cum
fo
en
Differential cage x
ng
t.
yi Co
op
Tapered roller bearing for output x
C py
ht. rig
shaft
rig ht
py by
co Vo
by lksw
Prote
cted Tapered roller bearing for differ‐
AG.
agen
x
ential

SM 22

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

SM 22

Uploaded by

Copyright:

Available Formats

Service

5-speed manual gearbox 02Z

Service Department. Technical Information

All rights reserved.

Copyright © 2019 Volkswagen AG, Wolfsburg K0058980620

5.2 Overview of fitting locations – electrical components, clutch mechanism . . . . . . . . . . . . . . 15

1.1 Assembly overview - pedal cluster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

1.9 Removing and installing clutch slave cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

1.10 Bleeding clutch mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

2.1 Assembly overview - clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

2.2 Removing and installing clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

4.1 Checking gear oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

1.1 Assembly overview - input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141

1.2 Dismantling and assembling input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142

39 - Final drive - differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171

1.1 Overview of fitting locations - seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171

1.3 Renewing right oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173

1.4 Renewing input shaft seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177

2.1 Assembly overview - differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180

⇒ “1.1 Gearbox identification”, page 1

The 5-speed manual gearbox 02Z is installed in the Transporter

Codes and production date of gearbox

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

2.1 Technical data, gearbox

3rd gear 30: 24 = 1.25 30: 24 = 1.25 26 : 21 = 1.238

♦ Individual gear ratios

♦ Specification for gear oil

♦ Clutch plate allocation

Manufactured from 02.03 01.04 12.03

2 Rep. gr.00 - Technical data

Manual gearbox 5-speed 02Z

3rd gear 26 : 21 = 1.238 32 : 22 = 1.455 26 : 21 = 1.238

4th gear 24 : 29 = 0.828 30 : 29 = 1.034 24 : 29 = 0.828

Capacity of manual gearbox 2.0 litres

Drive shaft flange diameter 108 mm 108 mm 108 mm

Manual gearbox 5-speed 02Z

Identification code GTW GTX GTY

Manufactured from 11.04 11.04 11.04

to 01.06 01.06 01.06

Manual gearbox 5-speed 02Z

Manual gearbox 5-speed 02Z

Manufactured from 01.06 01.06 01.06

to 05.06 05.06 05.06

Allocation Model Transporter 2004 ► Transporter 2004 ► Transporter 2004 ►

Engine 1.9 l - 75 kW 1.9 l - 75 kW 1.9 l - 62 kW

diesel diesel diesel

2nd gear 29 : 14 = 2.071 29 : 14 = 2.071 33 : 16 = 2.063

4th gear 27 : 32 = 0.844 27 : 32 = 0.844 27 : 32 = 0.844

Reverse gear 36 : 20 = 1.8 36 : 20 = 1.8 36 : 20 = 1.8

Drive shaft flange diameter 108 mm 108 mm 108 mm

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

♦ Individual gear ratios

Manual gearbox 5-speed 02Z

4 Rep. gr.00 - Technical data

Manual gearbox 5-speed 02Z

Manual gearbox 5-speed 02Z

Manufactured from 05.06 05.06 05.06

Allocation Model Transporter 2004 ► Transporter 2004 ► Transporter 2004 ►

Engine 1.9 l - 63 kW 1.9 l - 75 kW 1.9 l - 75 kW

Ratio Final drive 73 : 16 = 4.562 74 : 15 = 4.933 73 : 16 = 4.562

3rd gear 30 : 24 = 1.25 30 : 24 = 1.25 30 : 24 = 1.25

4th gear 27 : 32 = 0.844 27 : 32 = 0.844 27 : 32 = 0.844

5th gear 27 : 41 = 0.659 23 : 37 = 0.622 23 : 37 = 0.622