SM 6

Service
Workshop Manual
Arteon 2018 ➤ , Golf 2017 ➤ ,
GolfVolksVariant
wage 2017es no➤
n AG. Volkswagen AG do
, Polo 2018 ➤ ,
T-Roc 2018 ➤
t gu
d by ara
e nte
ris
ho
t e or
ss
au
6-speed manual gearbox 02Q,
ac
0BB and 0FB, removed
ce
le
un
pt
Edition 03.2019
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.
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
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.
Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.
All rights reserved.

No reproduction without prior agreement from publisher.
Copyright © 2019 Volkswagen AG, Wolfsburg D4B806B8524

Arteon 2018 ➤ , Golf 2017 ➤ , Golf Variant 2017 ➤ , Polo 2018 ➤ , T-Ro ...
6-speed manual gearbox 02Q, 0BB and 0FB, removed - Edition 03.2019
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3.1 Allocation gearbox - engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3.2 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
4 Overview - power transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4.1 Overview - power transmission - front-wheel drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4.2 Overview - power transmission - all-wheel drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
5 Electrical components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
6 Repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
6.1 General repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
30 - Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1 Clutch operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.1 Assembly overview - clutch release mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.2 Checking clutch master cylinder and clutch slave cylinder . . . . . . . . . . . . . . . . . . . . . . . . 13
1.3 Removing and installing clutch slave cylinder together with release bearing . . . . . . . . . . . . 13
1.4 Repairing clutch release mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2 Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.1 Assembly overview - clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.2 Removing and installing clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
34 - Controls, housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
1 Selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . .en. A. G. ..V.o.lk.sw. a. g.e.n .AG.............. 34
s wag does
2 Removing and installing gearbox . . . . . . . . . . .b.y V. o. . . . . . . . . . . . . . . . . . . . . .n.ot.g.u . . . . . .
lk
35
ara
ed
3 Bevel box . . . . . . . . . . . . . . . . . . . . . . . . .ho.ri.s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .n.te.e . . 36
t o
3.1 Distinguishing between different types ofss abevel u
boxes . . . . . . . . . . . . . . . . . . . . . . . . . . .r a.c 36
3.2 Removing bevel box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
ce
e
nl
pt
du
3.3 Installing bevel box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
an
itte
y li
erm
4 Front differential lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
ab
ility
ot p
5 Transporting gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
wit
, is n
5.1 Transporting manual gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

h re
hole
spec
5.2 Transporting front differential lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
es, in part or in w
6 Gear oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 t to the co
7 Securing to engine and gearbox support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

7.1 Installing manual gearbox to engine and gearbox support . . . . . . . . . . . . . . . . . . . . . . . . . . 41
rrectness of i
7.2 Installing bevel box or front differential lock to engine and gearbox support . . . . . . . . . . . . 42
l purpos
8 Dismantling and assembling gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

8.1 Schematic overview - gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
nf
ercia
8.2 Assembly overview - gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

orm
m
8.3 Assembly overview - gearbox housing and selector mechanism . . . . . . . . . . . . . . . . . . . . 50

atio
om
8.4 Assembly overview - shafts, differential, selector mechanism . . . . . . . . . . . . . . . . . . . . . . 52

n in
or c
thi
8.5 Assembly overview - selector forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

te
sd
iva
8.6 Dismantling and assembling gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

o
r
rp
cu
o
9 Gearbox housing, clutch housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

f
en
ng
t.
yi Co
9.1 Assembly overview - gearbox housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . t. Cop py
rig 74
9.2 Assembly overview - clutch housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
gh ht
pyri by
Vo
o
9.3 Repairing gearbox housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
c by lksw
cted agen
Prote
9.4 Repairing clutch housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
AG.
Contents i
35 - Gears, shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
1 Input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
1.1 Assembly overview - input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
1.2 Dismantling and assembling input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
1.3 Renewing input shaft seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
2 Output shaft . . . . . . .w.a.ge. n. A. G. ..V.ol.ks. w. a.g.en. A. G. d. o.e. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
olks s no
2.1 Assembly overview y V - output shaft . . . . . . . . . . . .t g. u.a. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
db ra
2.2 Dismantling oandris assembling output shaft . . . . . . . . . .nt.ee. . . . . . . . . . . . . . . . . . . . . . . . . . . 103
e
th o
2.3 Adjustings aoutput
u shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . .r a. c. . . . . . . . . . . . . . . . . . . . . . . . . 125
s
ce
le
39 - Final drive - differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136

un
pt
an
d
itte
y li
1 Oil seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
rm
ab
pe
ility
1.1 Overview of fitting locations - seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
ot
wit
, is n
2 Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
h re
hole
2.1 Assembly overview - differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
spec
2.2 Dismantling and assembling differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
es, in part or in w
t to the co
2.3 Adjusting differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
3 Adjustment overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
rrectness of i
4 Components of bevel box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
4.1 Assembly overview - components of bevel box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
l purpos
4.2 Renewing bevel box seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166

4.3 Renewing output flange and redetermining thickness of shim . . . . . . . . . . . . . . . . . . . . . . 189
nform
ercia
5 Components of front differential lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191

m
a
com
5.1 Assembly overview - components of front differential lock . . . . . . . . . . . . . . . . . . . . . . . . . . tion in

191
r
5.2 Checking function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192

te o
thi
s
iva
5.3 Renewing seals for front differential lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192

do
r
rp
5.4 Renewing ball bearing for flange shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197

um
fo
en
ng
t.
6 Gear oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
yi Co
Cop py
. rig
7 Oil for front differential lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
ht ht
rig by
copy Vo
by lksw
cted agen
Prote AG.
ii Contents
00 – Technical data
1 Safety information
(VRL012797; Edition 03.2019)
The relevant description can be found in ⇒ Rep. gr. 00 ; Safety
information .
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
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
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
1. Safety information 1
2 Identification
The relevant description can be found in ⇒ Rep. gr. 00 ; Identi‐
fication; Gearbox identification .
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.
2 Rep. gr.00 - Technical data

3 Technical data
⇒ “3.1 Allocation gearbox - engine”, page 3 .
3.1 Allocation gearbox - engine

The relevant description can be found in ⇒ Rep. gr. 00 ; Technical
data; Allocation gearbox - engine .
3.2 Capacities
The relevant description can be found in ⇒ Rep. gr. 00 ; Technical
data; Calculation of transmission ratio .
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.
3. Technical data 3
4 Overview - power transmission

⇒ “4.1 Overview - power transmission - front-wheel drive”,
page 4
⇒ “4.2 Overview - power transmission - all-wheel drive”,
page 6
4.1 Overview - power transmission - front-wheel drive

Designation
-Arrows- point in direction of travel.
1 - Engine
2 - Clutch
3 - Manual gearbox
4 - Input shaft
5 - Output shaft for 5th, 6th and
reverse gears
6 - Output shaft for 1st to 4th
gears
7 - Differential
8 - Front differential lock
❑ Only installed in some
Golf vehicles with front-
wheel drive and 6-
speed manual gearbox
02Q. Allocation ⇒ Elec‐
tronic parts catalogue n AG. Volkswagen AG do
lkswage es n
(ETKA) byV
o ot g
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
Ratio
atio
om
n in
c

or
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

I - 1st gear
II - 2nd gear
III - 3rd gear
IV - 4th gear
V - 5th gear n AG. Volkswagen AG do
lkswage es n
VI - 6th gear byV
o ot g
ua
d ran
ir se
R - Reverse gear utho tee
or
a ac
A - Final drive 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.
4. Overview - power transmission 5

AG. Volkswagen AG d
agen oes
ksw not
Arteon 2018 ➤ , Golf 2017 ➤ , Golf Variant 2017 by V➤ , Polo 2018 ➤ , T-Ro ...
ol
gu
ara
d
6-speed manual gearbox 02Q, 0BB and 0FB, oriseremoved - Edition 03.2019 nte
eo
th
au ra
s c
4.2 Overview - power transmission - all-wheel drive
s
ce
le
un
pt
an
d
Designation
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
1 - Engine
spec
2 - Clutch
t to the co
3 - Manual gearbox
rrectne
4 - Input shaft
s
reverse gears (output shaft II)
s o
cial p
f in
form
mer
gears (output shaft I)
atio
m
7 - Differential
o
n
c
i
or
n thi
e
8 - Bevel box
t
sd
iva
o
pr
c
9 - Propshaft
um
r
fo
en
ng
t.
yi
10 - All-wheel drive coupling
Co
Cop py
t. rig
11 - Rear final drive
gh ht
pyri by
Vo
co lksw
by
12 - Differential cted agen
Prote AG.
Ratio

I - 1st gear
II - 2nd gear
III - 3rd gear
IV - 4th gear
V - 5th gear
VI - 6th gear
R - Reverse gear
A - Final drive
W1 - Front bevel box
W2 - Rear bevel box
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.
4. Overview - power transmission 7

5 Electrical components
The relevant description can be found in ⇒ Rep. gr. 00 ; Electrical
components; Overview of fitting locations - electrical compo‐
nents .
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.

wage
6 Repair instructions lks es n
o ot g
byV ua
d ran
ir se
⇒ “6.1 General repair instructions”,uthpage 9
o tee
or
a ac
ss
6.1 General repair instructions
ce
le
un
pt
an
d
To ensure flawless and successful gearbox repairs, the greatest
itte
y li
rm
care and cleanliness as well as the use of good and proper tools
ab
pe
ility
are essential. Also note the basic rules on safety when performing ot
wit
repair procedures.
, is n
h re
hole
A number of general notes on the individual repair procedures,
spec
which can otherwise be found in the relevant sections of the man‐
es, in part or in w
t to the co
ual, are summarised here. They apply for this particular workshop
manual.
Special tools
rrectness of i
For a complete list of special tools used in this workshop manual,
l purpos
see ⇒ Electronic parts catalogue (ETKA) .

Gearbox
nform
ercia
♦ When installing the manual gearbox, ensure that the dowel

m
a
com
t
sleeves between the engine and gearbox are correctly seated.
ion in
r
te o
♦ The contact surfaces of waxed parts must be cleaned before
thi
s
iva
the parts are installed. Contact surfaces must be free of wax
do
r
rp
c
and grease.
um
fo
en
ng
t.
yi
♦ Allocate bolts and other components using ⇒ Electronic parts
Co
op py
catalogue (ETKA) . t. C rig
gh ht
pyri by
Gaskets and seals
co Vo
by lksw
cted agen
Prote AG.
After removing gaskets and seals, always inspect contact surfa‐
ces of housing and shaft for burrs resulting from removal or for
other signs of damage.
♦ Thoroughly clean joint surfaces and apply sealant .
♦ Allocation ⇒ Electronic parts catalogue (ETKA)
♦ Before installing radial oil seals, half-fill space between sealing
lips with sealing grease -arrow-.
♦ Allocate grease using ⇒ Electronic parts catalogue (ETKA) .
♦ The open side of the oil seals faces toward the side with fluid
filling.
♦ Lightly oil O-rings before installing; this prevents the rings be‐
ing crushed when inserted.
Sealant
♦ Thoroughly clean housing joint surfaces before applying seal‐
ant .
♦ Apply sealant uniformly and not too thickly.
♦ Allocation ⇒ Electronic parts catalogue (ETKA) .
♦ Breather holes must remain free of sealant .
Locking devices
6. Repair instructions 9
lkswage es n
♦ Do not overstretch retaining rings. byV
o ot g
ua
d ran
ir se tee
♦ Installation position for retaining rings: At
u th the top, the ring is
o
or
»narrower« and its installation positionss
a therefore as well. This ac
make it possible for the pliers to gain a better grip during re‐
ce
le
un
pt
moval and installation.
an
d
itte
y li
♦ Renew retaining rings which have been damaged or over‐
erm
ab
ility
stretched after removal.
ot p
wit
is n
♦ Retaining rings must locate properly in grooves.
h re
ole,
spec
♦ Renew spring pins. Installation position: slit -A- should be in
line with the line of force -arrow-.
t to the co
Nuts and bolts
rrectne
♦ Loosen and tighten securing bolts and nuts for covers and
housings alternately and diagonally.
s
♦ Do not cant especially delicate parts, such as clutch pressure
s o
cial p
plates. Loosen and tighten bolts and nuts alternately and in
f in
stages.
form
mer
atio
♦ Specified torques given are for unoiled nuts, bolts and screws.
om
n
c
i
or
n
♦ Renew self-locking bolts and nuts after each removal. thi
te
sd
va
♦ Ensure with threaded connections that contact surfaces as

i
o
pr
cum
well as nuts and bolts are rewaxed only after assembly, if nec‐
r
fo
en
ng
essary.
t.
yi Co
Cop py
♦ Use a thread chaser to clear residual locking fluid from all
t. rig
gh ht
yri
threaded holes into which self-locking bolts are to be screwed.
p by
co Vo
by lksw
Otherwise there is a danger of bolts shearing when subse‐ Prote
cted AG.
agen
quently being removed.
♦ Check pitch of thread, to ensure correct thread chaser is used
to clean threads and to ensure the threads are not damaged.
Mountings
♦ Lubricate all bearings with gear oil before installing.
♦ Heat inner races of tapered roller bearings with the inductive
heater - VAS 6414- to approx. 100 °C before installing. Press
in to stop when installing so there is no axial clearance.
♦ Do not interchange outer or inner races of bearings of the
same size. The bearings are matched in pairs.
♦ Tapered roller bearings fitted to one shaft must be replaced as
a set. Use same make of bearings.
♦ Install needle bearings, ball sleeves and roller sleeves with
lettered side (thicker metal) towards fitting tool.

Shims
♦ Measure shims at several points with a micrometer. The var‐
ious tolerances make it possible to achieve the exact shim
thickness required.
♦ Check for burrs and damage.
♦ Install only flawless shims.
Synchro-rings
♦ Do not interchange them. When reusing synchro-rings, always

fit to the same synchromeshed
olks
wage gear. es n
o V t gu
by
♦ Check for wearrisand
ed renew if necessary.
ara
nte
tho eo
♦ Check groovessa
u -arrow 1- of synchro-ring -A- and inner ring for ra
c
flat spots s(worn grooves).
ce
le
un
pt
♦ If synchro-rings are coated, coating must not be damaged.
an
d
itte
y li
rm
ab
♦ If an intermediate ring -B- is installed, check the outer friction
pe
ility
surface -arrow 2- and inner friction surface -arrow 3- of this
ot
wit
, is n
intermediate ring for »scoring« and »signs of abnormal wear«.
h re
hole
spec
♦ Check the cone of the synchromeshed gear for »scoring« and
es, in part or in w
»signs of abnormal wear«.
t to the co
♦ Moisten synchromesh mechanism with gear oil before instal‐
ling. rrectness of i
Gears and synchro-hubs
l purpos
♦ Heat synchro-hubs to about 100 °C with the inductive heater

- VAS 6414- before installing. Press in to stop when installing
nform
ercia
so there is no axial clearance.

m
♦ Heat gears to about 100°C with the inductive heater - VAS

a
com
tio
6414- before installing. Press in to stop when installing so

n in
r
there is no axial clearance.

te o
thi
s
iva
do
♦ Observe installation position

r
rp
cum
fo
en
Synchromeshed gears
ng
t.
yi Co
op py
♦ After assembly, check synchromeshed gears for slight play, or
. C rig
ht ht
rig
for freedom of movement. py by
co Vo
by lksw
cted agen
Clutch Prote AG.
♦ Ensure that the pressure plate does not cant: loosen and tight‐
en bolts alternately and diagonally and in several gradual
stages.
♦ In order to reduce the smell of a burned clutch, the clutch
housing as well as the stopping face of the flywheel must be
thoroughly cleaned with a cloth.
6. Repair instructions 11
30 – Clutch
1 Clutch operation
⇒ “1.1 Assembly overview - clutch release mechanism”,
page 12
⇒ “1.2 Checking clutch master cylinder and clutch slave cylinder”,
page 13
⇒ “1.3 Removing and installing clutch slave cylinder together with
release bearing”, page 13
⇒ “1.4 Repairing clutch release mechanism”, page 15
Additional descriptions can be found in ⇒ Rep. gr. 30 ; Clutch
mechanism .
1.1 Assembly overview - clutch release mechanism
1 - Clutch slave cylinder with

release bearing
❑ Are one unit; can only be
renewed together
❑ Do not wash out bear‐
ing; wipe only
❑ If bearing is noisy, re‐
new together with clutch
slave cylinder.
❑ Removing and installing
⇒ page 13 n AG. Volkswagen AG do
lkswage es n
Vo ot g
❑ In case of release bear‐ ed
by ua
ran
ing with additionalhoplas‐
ris tee
tic washer ⇒ pages au 13 ,
t or
ac
allocate pressure plate
s
ce
e
⇒ page 13 .
nl
pt
du
an
itte
❑ Allocation ⇒ Electronic
y li
erm
ab
parts catalogue (ETKA)

ility
ot p
wit
2 - Bolt
, is n
h re
❑ Qty. 3
hole
spec
❑ Renew after removal

es, in part or in w
t to the co
❑ Take account of the

thread pitch of bolt for
cleaning threaded hole
rrectness of i
in clutch housing.
l purpos
Note
nf
ercia
Use compressed air to clean hole. If

orm
necessary, screw a clean, removed

m
atio
m
bolt into and out of the hole to loosen

o
n in
c
locking fluid residue.

or
thi
te
sd
iva
❑ Carefully tighten diago‐

o
r
rp
cu
nally in small steps so

o
m
f
en
ng
that the fastening lugs of

t.
yi Co
op
the clutch slave cylinder C py
t. rig
do not break off.
gh ht
pyri by
Vo
o
❑ 12 Nm for clutch slave cylinders made of metal (without locking fluid)
c by lksw
cted agen
Prote AG.
❑ 15 Nm for clutch slave cylinders made of plastic (with locking fluid)
12 Rep. gr.30 - Clutch

3 - Clip
❑ Pull clip out to stop to remove or install pipe line
❑ Push on until clip engages audibly.
4 - Pipe line
❑ To clutch slave cylinder.
5 - O-ring
❑ Renew if damaged
❑ Pull onto line connection
❑ Insert with brake fluid
❑ Allocation ⇒ Electronic parts catalogue (ETKA)
Release bearing with additional plastic washer

Identifying feature: grooves -arrow- on the plastic washer.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
For release bearing with additional
orise plastic disc only: tips of dia‐ nte
eo
phragm springs on pressure
auth plate (-arrows-), slightly lower overall ra
height ss c
ce
le
un
pt
• Release bearing with additional plastic disc and clutch pres‐

an
d
itte
sure plate with tips of diaphragm springs of slightly lower

y li
rm
ab
overall height must only be installed together.

pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
1.2 Checking clutch master cylinder and

l purpos
clutch slave cylinder

nform
ercia
Carry out Guided Fault Finding using ⇒ Vehicle diagnostic

tester before renewing clutch master cylinder due to suspected
m
fault.
com
tion in
r
1.3 Removing and installing clutch slave

te o
thi
s
iva
do
cylinder together with release bearing

r
rp
cum
fo
en
ng
Special tools and workshop equipment required

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
1. Clutch operation 13
♦ Torque wrench - V.A.G 1331-
Note
♦ Clutch slave cylinder and release bearing are a single com‐

ponent and can be renewed only together.
♦ Take account of the thread pitch of securing bolts
gen AGof clutch n AG doe
.V age olksw
swa s
slave cylinder for cleaning threaded hole
by
Vol in clutch housing.
k not
gu
ara
d
se nte
♦ Use compressed air to clean hole. horiIf necessary, screw a clean, eo
removed bolt into and out ofstheut
s a hole to loosen locking fluid
ra
c
residue.
ce
e
nl
pt
du
an
itte
y li
Removing
erm
ab
ility
ot p
• Gearbox has been removed.
wit
, is n
h re
– Release clip -2- with a screwdriver or pointed object and pull
hole
bleeder -4- off clutch slave cylinder -1-.
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
e
– Remove bolts -arrows-

at
do
priv
– Remove clutch slave cylinder together with release bearing

um
for
en
g
-A-.
n
t.
yi Co
op py
Installing
t. C rig
gh ht
pyri by
Vo
Install in reverse order of removal, observing the following:
co lksw
by
cted agen
Prote AG.
• The securing bolts for the clutch slave cylinder must be tight‐
ened only in small stages.
Otherwise, the tabs with the bolt holes may break off.

– Check O-ring -3- on clutch slave cylinder for damage.

– Press in bleeder -4- on clutch slave cylinder connection -1-
until clip -2- engages audibly.
– Check by pulling on bleeder.
– Install gearbox ⇒ Rep. gr. 34 ; Removing and installing gear‐
box .
– Bleed clutch mechanism ⇒ Rep. gr. 30 ; Clutch mechanism;
Bleeding clutch mechanism .
Specified torques
♦ Clutch slave cylinder with geclutch
n AG. Vorelease bearing
lkswagen AG
does to gearbox
swa
⇒ page 12 . y Volk not
gu b ara
ed nte
oris e
1.4 Repairing clutch release mechanism or ac
th
au
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
♦ Grease for splines

om
ion
c
in t

or
his
ate

do
priv
cum
for
– Remove and install clutch slave cylinder with clutch release

en
ng
t.
yi
bearing -A- -arrows-.
Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
1. Clutch operation 15
Clutch slave cylinder -A- with divided supply line

The supply line for some clutch slave cylinders is divided in the
area of the -arrow-.
Allocation ⇒ Electronic parts catalogue (ETKA)
Release bearing with additional plastic washer

Identifying feature: grooves -arrow- on the plastic washer.
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
For release bearing with additional plastic disc only: tips of dia‐
pe
ility
phragm springs on pressure plate (-arrows-), slightly lower overall
ot
wit
, is n
height
h re
hole
• Release bearing with additional plastic disc and clutch pres‐
spec
sure plate with tips of diaphragm springs of slightly lower
es, in part or in w
t to the co
overall height must only be installed together.
rrectness of i
box .
l purpos
– Bleed clutch mechanism ⇒ Rep. gr. 30 ; Clutch mechanism;

Repairing clutch mechanism .
nform
ercia
Specified torques
m
a
com
tion in
♦ Clutch slave cylinder with clutch release bearing to gearbox

r
te o
thi
⇒ page 12 .
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.

AG. Volkswagen AG d
agen oes
ksw
Arteon 2018 by
➤ , Golf 2017 ➤ , Golf Variant
Vol 2017
not
gu ➤ , Polo 2018 ➤ , T-Ro ...
d ara
6-speedrise manual gearbox 02Q, 0BB and 0FB, nremoved
tee - Edition 03.2019
ho
aut or
ac
ss
2 Clutch
ce
e
nl
pt
du
an
itte
y li
⇒ “2.1 Assembly overview - clutch”, page 17
erm
ab
ility
ot p
⇒ “2.2 Removing and installing clutch”, page 20
wit
, is n
h re
For more information, refer to ⇒ Rep. gr. 30 ; Clutch mechanism
hole
spec
and ⇒ Rep. gr. 30 ; Clutch .
es, in part or in w
t to the co
2.1 Assembly overview - clutch
⇒ “2.1.1 Assembly overview - clutch in conjunction with Sachs
rrectness of i
dual-mass flywheel”, page 17
l purpos
⇒ “2.1.2 Assembly overview - clutch in conjunction with LuK dual-

mass flywheel”, page 18
nform
ercia
⇒ “2.1.3 Assembly overview - clutch with simple flywheel”,

page 19
m
at
om
ion
2.1.1 Assembly overview - clutch in conjunction with Sachs dual-mass flywheel
c
in t
or
his
ate
do
priv
cum
1 - Two-part flywheel
for
en
ng
t.
yi
Co
op py
⇒ Rep. gr. 13 ; Cylinder t. C rig
gh ht
block (gearbox end); yri
p by
o Vo
Removing and installing
by c lksw
cted agen
flywheel .
Prote AG.
❑ Ensure that centring

pins fit tightly
❑ Contact surface for
clutch lining must be
free of grooves, oil and
grease
2 - Clutch plate
❑ Renew only together
with pressure plate
⇒ page 20
❑ Fitting position
⇒ page 23
3 - Pressure plate
❑ With adjusting mecha‐
nism
with clutch plate.
⇒ page 20
❑ Check ends of dia‐
phragm spring
⇒ page 23
❑ Check spring connec‐
tions and riveted con‐
nections ⇒ page 23 .
❑ From approx. 05.11: release bearing with additional plastic washer ⇒ page 13 , pressure plate adapted
⇒ page 13
2. Clutch 17
4 - Bolt
❑ Loosen or tighten alternately and diagonally in small steps (1 full turn)
❑ M 6: 13 Nm
❑ M 7: 20 Nm
2.1.2 Assembly overview - clutch in conjunction with LuK dual-mass flywheel
1 - Two-part flywheel
⇒ Rep. gr. 13 ; Cylinder
block (gearbox end);
Removing and installing
flywheel .
❑ Ensure that centring
pins fit tightly
❑ Contact surface for
clutch lining must be
free of grooves, oil and
grease
2 - Clutch plate
⇒ page 24
❑ Renew only together agen
AG. Volkswagen AG d
oes
with SAC pressure olksw not
V gu
by
plate. rised ara
nte
o eo
❑ Installation position: aut
h
ra
⇒ page 26 . ss c
ce
e
nl
3 - SAC pressure plate pt

du
an
itte
❑ SAC means “self-ad‐ y li

erm
ab
justing clutch”. ility
ot p
wit
, is n
h re
with clutch plate.

hole
spec
es, in part or in w

t to the co

⇒ page 24
rrectness of i

phragm spring
l purpos
⇒ page 27
nform
ercia
tions and riveted connections ⇒ page 27 .

m
at
❑ Release bearing with additional plastic disc ⇒ page 13 , pressure plate is matched accordingly
om
io
⇒ page 13
n
c
in t
or
his
e
4 - Bolt
at
do
priv

um
for
en
g
❑ Loosen or tighten alternately and diagonally in small steps (1 full turn)

n
t.
yi Co
op py
❑ M 6: 13 Nm
t. C rig
gh ht
yri by
❑ M 7: 20 Nm
op Vo
by c lksw
cted agen
Prote AG.

2.1.3 Assembly overview - clutch with simple flywheel
1 - Flywheel
⇒ Rep. gr. 13 ; Cylinder
block (gearbox end);
Removing and installing n AG. Volkswagen AG do
swage es n
flywheel . byV
olk ot g
ua
ed ran
❑ Ensure that centringhor is tee
pins fit tightly aut or
ac
ss
❑ Keep contact surface for
ce
le
un
clutch lining free of
pt
an
d
itte
grooves, oil and grease.
y li
erm
ab
2 - Clutch plate
ility
ot p
wit
is n
h re
ole,
spec
❑ Centring ⇒ page 29
t to the co
3 - Pressure plate
rrectne
⇒ page 29
s
phragm spring
s o
⇒ page 31
cial p
f inform
mer
tions and riveted con‐
atio
m
nections ⇒ page 32 .
o
n
c
i
or
n
4 - Bolt
thi
te
sd
va
i
o
pr
cum
r

fo
en
ng
t.
yi
❑ Loosen or tighten alter‐
Co
op py
nately and diagonally in
t. C rig
gh ht
yri
small steps (1 full turn) p by
co Vo
by lksw
❑ M 6: 13 Nm
cted agen
Prote AG.
❑ M 7: 20 Nm
2. Clutch 19
lkswage es n
Arteon 2018 ➤ , Golf 2017 ➤ , Golf Variant 2017 by V➤ , Polo 2018 ➤ , T-Ro ...
o ot g
ua
ed ran
6-speed manual gearbox 02Q, 0BB and 0FB,hor removed - Edition 03.2019
is tee
ut or
a ac
ss
2.2 Removing and installing clutch
ce
e
nl
pt
du
an
itte
⇒ “2.2.1 Removing and installing clutch in conjunction with Sachs
y li
erm
ab
ility
ot p
⇒ “2.2.2 Removing and installing clutch in conjunction with LuK
wit
, is n
h re
hole
spec
⇒ “2.2.3 Removing and installing clutch in connection with simple
es, in part or in w
flywheel”, page 29
t to the co
2.2.1 Removing and installing clutch in conjunction with Sachs dual-mass fly‐
rrectness of i
wheel l purpos
Special tools and workshop
nf
ercia
equipment required
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.
♦ Counter-hold tool - 3067-

♦ Centring pin - T10097-

♦ For engines having a crankshaft of smaller diameter or having

needle bearings in the crankshaft - ⇒ page 24 centring man‐
drel - 3176-
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.
2. Clutch 21
Removing
• Gearbox is removed.
– Use counter-hold tool - 3067- to loosen bolts.
To prevent the pressure plate from becoming distorted during re‐
moval (causes clutch grab when driving off), always keep to the
following procedure when unbolting the pressure plate:
– Loosen all bolts alternately and diagonally in small steps (1 full
turn).
• As bolts are removed, stop -2- with pin -1- must loosen.
– If stop does not loosen, push pin in direction of dual-mass fly‐
wheel.
– Remove pressure plate and clutch plate.
Installing
Install in reverse order of removal, observing the following:
Note
♦ Select clutch pressure plate and pressure plate accordingswto

agen
AG. Volkswagen AG d
oes
engine code and ⇒ Electronic parts catalogue (ETKA)
by
Vo.l
k not
gu
ara
ed
♦ Clean splines of drive shaft and, if the clutch plate
thoris has been nte
eo
used, clean the splines of the hub. Remove corrosion
au and ap‐ ra
c
ss
ply a very thin coat of clutch plate spline grease to splines.
ce
le
Then, move the clutch plate back and forth on the drive shaft
un
pt
an
d
until the hub moves easily on the shaft. Remove excess

itte
y li
grease.
rm
ab
pe
ility
ot
♦ Clutch pressure plates are protected against corrosion and
wit
, is n
greased. With the exception of the friction surface for the
h re
hole
clutch plate, the clutch pressure plate must not be cleaned.
spec
Service life of clutch will otherwise be shortened considerably.
es, in part or in w
t to the co
♦ The friction surface of the clutch pressure plate and the fly‐
wheel must be cleaned (degreased) thoroughly.
rrectness of i
♦ If the clutch has burnt out, thoroughly clean the gearbox hous‐
ing in the clutch area and the engine facing the gearbox in
l purpos
order to reduce the smell of burnt linings.

♦ Blow off dual mass flywheel with compressed air only.
nform
ercia
♦ Clutch plate linings must make full contact with flywheel and
m
a
com
friction surface of clutch pressure plate. Only then insert se‐

ion in
curing bolts.
r
te o
thi
s
iva
♦ Tighten or loosen securing bolts alternately and diagonally in

do
r
small steps (1 full turn) in order not to damage centring holes

rp
cum
fo
of pressure plate and centring pins of flywheel.

en
ng
t.
yi Co
op
♦ Check whether dowel sleeves for aligning engine and gearbox
C py
t. rig
gh
are fitted in cylinder block and install if necessary.
ht
pyri by
Vo
o
by c lksw
♦ If dowel sleeves are not fitted, difficulties shifting gears, clutch
cted agen
Prote AG.
problems and possible noises from the gearbox (rattling of
gears which are not engaged) could occur.

Installation position of clutch plate

• Lettering “Getriebeseite” and protruding spring cage face
gearbox.
Check ends of diaphragm spring

• Wear to half the thickness of the diaphragm spring -arrows- is
permitted.
Checking spring connections and riveted connections

I - Extension springs OK. agen
AG. Volkswagen AG d
oes
olksw not
• Minor kinks on the outside area d by -arrows A- have series pro‐
V gu
ara
duction status. orise nte
eo
h
ut ra
II - Extension springs damaged
ss a c
ce
e
nl
• Renew clutch pressure plates if springs are broken or badly

pt
du
an
bent -arrow B-.

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
– Check spring connections between pressure plate and cover

m
at
om
for cracks and make sure rivet fastenings are seated tightly.
ion
c
in t
or
• A pressure plate with damaged spring connections or with

his
ate
loose rivet connections -arrows- must be renewed.

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.
2. Clutch 23
– Use counterhold tool - 3067- when installing.
For engines having a crankshaft of smaller diameter -arrow- or

having an needle bearing -arrow- in the crankshaft
Centring clutch plate and removing and installing pressure plate

for engines with a smaller crankshaft diameter, or with a needle
bearing in the crankshaft n AG. Volkswagen AG
wage does
olks not
byV gu
ara
ed
Note ho
ris nte
eo
t
au ra
c
ss
Disregard arrows -A- and -B-.
ce
e
nl
pt
du
an
itte
y li
Continued for all

erm
ab
ility
ot p
wit
, is n
h re
hole
spec
Mount pressure plate as follows so it is not deformed during in‐

es, in part or in w
stallation (leads to jolts when moving off):

t to the co
– Make sure that stop pin (position setter) -arrow- can be moved
easily.
rrectness of i
– Push pressure plate onto centring pins.

l purpos
– Tighten all bolts evenly by hand until bolt heads contact pres‐
sure plate.
nf
ercia
or

m
m
atio
turn) and tighten.

om
n in
or c
• Stop pin -arrow- must lift off pressure plate when this is done.
thi
te
sd
iva

o
r
rp
cu
box .
o
m
f
en
ng
t.
yi Co
Specified torques Cop py
t. rig
gh ht
yri
♦ Pressure plate to flywheel ⇒ page 17 . p by
co Vo
by lksw
cted agen
Prote AG.
2.2.2 Removing and installing clutch in conjunction with LuK dual-mass flywheel


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

♦ Grease for splines t to the co
rrectne
♦ For engines having a crankshaft of smaller diameter or having

ss o
needle bearings in the crankshaft - ⇒ page 24 centring man‐

cial p
f in
drel - 3176-
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.
2. Clutch 25
Removing
Gearbox is removed.
turn) and tighten.
Installing
Install in reverse order of removal, observing the following: AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
Note rise nte
tho eo
au ra
s c
♦ Select clutch pressure plate and pressure plate according to
s
ce
le
engine code and ⇒ Electronic parts catalogue (ETKA) .
un
pt
an
d
itte
y li
♦ Clean splines of drive shaft and, if the clutch plate has been
rm
ab
used, clean the splines of the hub. Remove corrosion and ap‐
pe
ility
ot
wit
, is n
h re
hole
spec
grease.
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
m
a
com
tio
n in
r
te o
thi
♦ Blow off dual mass flywheel with compressed air only.
s
iva
do
r
rp
c
um
fo
en
ng
t.
yi
curing bolts.
Co
Cop py
t. rig
gh ht
♦ Tighten or loosen securing bolts alternately and diagonally in yri
p by
o Vo
c by lksw
cted agen
of pressure plate and centring pins of flywheel.
Prote AG.
♦ Check whether dowel sleeves for aligning engine and gearbox

Installation position of clutch plate

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

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
Arteon 2018 ➤ , Golf 2017 ➤ orise, Golf Variant 2017 ➤ , Polo 2018 ➤ , T-Ro nte ...
eo
h
6-speed manual gearbox
s aut
02Q, 0BB and 0FB, removed - Edition 03.2019 ra
c
s
ce
le
un
pt
an
d
itte
y li
erm
ab
permitted.
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f i
Check extension springs and riveted connections
nform
mer
I - Extension springs OK.
atio
om
n
• Minor kinks on the outside area -arrows A- have series pro‐
c
i
or
n thi
duction status.
te
sd
iva
o
r

p
cum
r
fo
en
ng
• Renew clutch pressure plate if springs are broken or badly

t.
yi Co
op
bent -arrow B-. C py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

– Make sure rivet joints -arrows B- on all extension springs
-arrows A- are firmly seated.
• Renew clutch pressure plate if riveting -arrows B- is loose.
2. Clutch 27
Checking position of adjusting mechanism with new pressure

plates only
• Both edges -A- of adjuster ring must be located between 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. n AG. Volkswagen A age G do
ksw es n
y Vol ot g
ua
b
ed ran
oris tee
th or
au ac
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
– Use counterhold tool - 3067- when installing.
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
For engines having a crankshaft of smaller diameter -arrow- or

um
fo
having an needle bearing -arrow- in the crankshaft

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 o
Arteon 2018 ➤Vo, lkGolf
sw 2017 ➤ , Golf Variant 2017
es n
ot g ➤ , Polo 2018 ➤ , T-Ro ...
by ua
6-speed
risedmanual gearbox 02Q, 0BB and 0FB, rremoved
an
t
- Edition 03.2019
ee
tho or
au ac
Centring clutch plate and and installing pressure plate removing
ss
for engines with a smaller crankshaft diameter, or with a needle
ce
le
un
pt
bearing in the crankshaft
an
d
itte
y li
rm
ab
pe
ility
Note
ot
wit
, is n
h re
hole
Disregard arrows -A- and -B-.
spec
es, in part or in w
t to the co
Continued for all
Mount pressure plate as follows so it is not deformed during in‐
rrectness of i
stallation (leads to jolts when moving off):
l purpos
– Push pressure plate onto centring pins.

– Tighten all bolts evenly by hand until bolt heads contact clutch
nform
ercia
pressure plate.
m
a
com
tio
turn) and tighten.
n in
r
te o
thi
s
iva
do
box .
r
rp
cum
fo
en
g
Specified torques
n
t.
yi Co
Cop py
♦ Pressure plate to flywheel ⇒ page 18 .
t. rig
gh ht
pyri by
Vo
co lksw
by
cted
2.2.3 Removing and installing clutch in connection with simple flywheel
agen
Prote AG.
2. Clutch 29

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
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
Removing
orm
m
atio
m

o
n in
or c

thi
te
sd
iva
To prevent the pressure plate from becoming distorted during re‐

r
rp
cu
o
moval (causes clutch grab when driving off), always keep to the
f
en
ng
t.
following procedure when unbolting the pressure plate:
yi Co
Cop py
t. rig
– Consecutively loosen all bolts in clockwise direction in 90° gh ht
yri by
stages until the clutch pressure plate is released. cop Vo
by lksw
cted agen
Prote AG.

Installing
AG. Volkswagen AG d
agen oes
Note olksw not
byV gu
ara
ed
ris nte
♦ Select clutch upressure
tho plate and pressure plate according to eo
ra
engine codess aand ⇒ Electronic parts catalogue (ETKA) . c
ce
le
♦ Clean splines of drive shaft and, if the clutch plate has been
un
pt
an
d
used, clean the splines of the hub. Remove corrosion and ap‐
itte
y li
erm
ab
ility
ot p
wit
is n
h re
grease.
ole,
spec
t to the co
rrectne
ss
o
cial p
f i
nform
mer
atio
m
o
n
c
i
or
n thi
e
curing bolts.
t
sd
iva
o
pr
c
♦ Tighten or loosen securing bolts alternately and diagonally in
um
r
fo
en
ng

t.
yi Co
of pressure plate and centring pins of flywheel. Cop py
ht. rig
rig ht
♦ Check whether dowel sleeves for aligning engine and gearbox py by
co Vo
by lksw
cted agen
Prote AG.

• Installation position of clutch plate: lettering

“Getriebeseite” (gearbox end) or spring cage faces pressure
plate.

permitted.
2. Clutch 31
Check spring connection and riveted fastenings.

– Check spring connection between thrust plate and cover for
cracks and make sure rivet fastenings are seated tightly.
– If pressure plate has damaged springs or loose rivet connec‐
tions -arrows-, it must be renewed.
Check extension springs and riveted connections

I - Extension springs OK.
• Minor kinks on the outside area -arrows A- have series pro‐
duction status.
• Renew clutch pressure plate if springs are broken or badly
bent -arrow B-.
– Check spring connections -arrows A- for damage, and make
sure that rivet joints -arrows B- are firmly seated.
• Renew clutch pressure plate if spring connections are broken
or badly bent, or if riveting is loose.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
e
– Make sure rivet jointshoris-arrows B- on all extension springs nte
eo
-arrows A- are firmly
s aut seated. ra
c
s
– Tighten all bolts one after another (clockwise) to final torque.
ce
le
un
pt
an
d
itte
• Renew clutch pressure plate if riveting -arrow B- is loose.

y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectne
Check metal ring.

s
– Check that metal ring in clutch pressure plate -arrow- is not

s o
damaged.
cial p
f inform
• Renew clutch pressure plate if metal ring is broken.

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.

Arteon 2018 ➤ , Golf 2017ge➤
n A,GGolf
. VolksVariant
wagen AG2017 ➤ , Polo 2018 ➤ , T-Ro ...
doe
wa
6-speed manualy Vgearbox
olks 02Q, 0BB and 0FB,s nremoved
ot g - Edition 03.2019
b ua
ed ran
ris tee
– Use counterhold tool - 3067- when th installing.
o
or
au ac
ss
ce
e
nl
turn) and tighten.
pt
du
an
itte
y li
erm
ab
box .
ility
ot p
wit
, is n
Specified torques
h re
hole
spec
♦ Pressure plate to flywheel ⇒ page 19 .
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. Clutch 33
34 – Controls, housing
1 Selector mechanism
For relevant description, refer to ⇒ Rep. gr. 34 ; Selector mech‐
anism
and ⇒ Rep. gr. 34 ; Dismantling and assembling gearbox 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
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.
34 Rep. gr.34 - Controls, housing

2 Removing and installing gearbox

The relevant description can be found in ⇒ Rep. gr. 34 ; Re‐
moving and installing gearbox .
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.
2. Removing and installing gearbox 35

3 Bevel box
⇒ “3.1 Distinguishing between different types of bevel boxes”,
page 36
⇒ “3.2 Removing bevel box”, page 36 AG. Volkswagen AG d
agen oes
olksw not
yV gu
⇒ “3.3 Installing bevel box”, page 36sed b ara
nte
ri
tho eo
⇒ “4 Components of bevel box”,aupage 162 ra
c
ss
⇒ “4.2 Renewing bevel box seals”, page 166
ce
le
un
pt
an
d
itte
3.1 Distinguishing between different types
y li
rm
ab
of bevel boxes
pe
ility
ot
wit
, is n
h re
Installed is either bevel box “0AV” or bevel box “0CN”
hole
spec
Bevel boxes can be identified by means of the following:
es, in part or in w
t to the co
Area denoted by -arrow- is marked with “0AV” or “0CN”.
Additional distinguishing feature:
rrectness of i
The output flange on the bevel box “0AV” is secured with a hex‐
l purpos
agon nut ⇒ Assembly overview - bevel box, “0AV” ⇒ page 162 .

Output flange on bevel box “0CN” is secured with a twelve-point
nform
ercia
nut ⇒ Assembly overview - bevel box, “0CN” ⇒ page 165 .

m
a
For more information, refer to ⇒ Rep. gr. 34 ; Bevel box .
com
tion in
r
te o
thi
s
iva
do
r
rp
3.2 Removing bevel box cum

fo
en
ng
t.
yi Co
op
For relevant description, refer to ⇒ Rep. gr. 34 ; Bevel box; Re‐ C py
ht. rig
moving bevel box . rig ht
py by
co Vo
by lksw
3.3 Installing bevel box
cted agen
Prote AG.
For relevant description, refer to ⇒ Rep. gr. 34 ; Bevel box; In‐

stalling bevel box .

4 Front differential lock

⇒ “5 Components of front differential lock”, page 191
⇒ “5.3 Renewing seals for front differential lock”, page 192
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.
4. Front differential lock 37

5 Transporting gearbox
⇒ “5.1 Transporting manual gearbox”, page 38
⇒ “5.2 Transporting front differential lock”, page 39
5.1 Transporting manual gearbox

♦ Gearbox lifting tackle - 3336-
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
♦ Workshop hoist - VAS 6100-
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
m
– Bolt gearbox lifting tackle - 3336- to clutch housing.

o
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.

– Adjust support beam on sliding piece using locking pin

-arrow-.
Number of holes visible = 6.
– Lift gearbox using workshop crane and gearbox lifting tackle -
3336- .
– Set gearbox aside, for example in a transport container.
5.2 Transporting front differential lock

• Protect connectors on front differential lock from being dam‐
aged.
– Prepare front differential lock for transport as follows so that
no oil can escape:
• During transport, the pump -V181- -arrows- is in one of the
positions shown in the illustration.
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
o
39
c by lksw
cted agen
Prote AG. 5. Transporting gearbox
6 Gear oil
The relevant description can be found in ⇒ Rep. gr. 34 ; Gear
oil .
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.

7 Securing to engine and gearbox sup‐

port
⇒ “7.1 Installing manual gearbox to engine and gearbox support”,
page 41
⇒ “7.2 Installing bevel box or front differential lock to engine and
gearbox support”, page 42
7.1 Installing manual gearbox to engine and

gearbox support
♦ Support clamp - VW 313-
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
♦ Retainer - VW 309-
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
op
♦ or support plate - VW 309 A- C py
t. rig
gh ht
yri by
♦ Gearbox support - VW 353- cop Vo
by lksw
cted agen
Prote AG.
7. Securing to engine and gearbox support 41

– Secure gearbox on gearbox support - VW 353- -arrows-.

– Place drip tray underneath.
Note
If one of the bolting holes does not contact the gearbox support ,
fit washers between hole and gearbox support .
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
u ra
7.2 Installing bevel box or front differential s a c
s
ce
e
lock to engine and gearbox support

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
♦ Gearbox support - T10108- 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.

– Set bevel box or front differential lock onto hole number -4-
-arrow- in gearbox support - T10108- .
A - Place nuts M12 x 10 (qty. 4) between bevel box and gearbox
support . wage
e ks s no
Vol t gu
– Then, align bevel box or front differential
d b lock with remaining
y ara
3 holes, and secure it. rise nte
ho t 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
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
7. Securing to engine and gearbox support 43

gen AG
. V02Q,
olkswa0BB and
gen AG
d
0FB, removed - Edition 03.2019
wa oes
olks not
byV gu
ara
ed
8 Dismantling and assembling gearbox
ris nte
tho eo
au ra
c
ss
⇒ “8.1 Schematic overview - gearbox”, page 44
ce
le
un
pt
an
d
⇒ “8.2 Assembly overview - gearbox”, page 48

itte
y li
erm
ab
⇒ “8.3 Assembly overview - gearbox housing and selector mech‐
ility
ot p
anism”, page 50
wit
is n
h re
⇒ “8.4 Assembly overview - shafts, differential, selector mecha‐
ole,
spec
nism”, page 52
t to the co
⇒ “8.5 Assembly overview - selector forks”, page 56
⇒ “8.6 Dismantling and assembling gearbox”, page 56
rrectne
Additional descriptions can be found in ⇒ Rep. gr. 34 ; Disman‐
tling and assembling gearbox .
ss o
8.1 Schematic overview - gearbox
cial p
f inform
mer
⇒ “8.1.1 Schematic overview - gearbox, front-wheel drive”,
atio
page 44
om
n
c
i
or
n
⇒ “8.1.2 Schematic overview - front differential lock”, page 46
thi
te
sd
va
⇒ “8.1.3 Schematic overview - gearbox, all-wheel drive”,

i
o
pr
cum
r
page 47
fo
en
ng
t.
yi Co
8.1.1 Schematic overview - gearbox, front-wheel drive
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

1 - Clutch housing
2 - Reverse shaft
reverse gears
release bearing
5 - Input shaft
gears
7 - Differential wage
es n
lks ot g
Vo
8- Right flange shaft d by ua
ran
ir se tee
o
9- Left flange shaft au th or
ac
ss
10 - Synchromeshed gear, 2nd
ce
le
un
pt
gear
an
d
itte
y li
11 - Synchromeshed gear, 1st
rm
ab
pe
ility
gear
ot
wit
, is n
12 - Synchromeshed gear for
h re
hole
4th gear
spec
es, in part or in w
t to the co
3rd gear
14 - Synchromeshed gear, 5th
rrectness of i
gear
l purpos

6th gear
nform
ercia

reverse gear
m
a
com
tio
17 - Gearbox housing
n 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.
8. Dismantling and assembling gearbox 45

8.1.2 Schematic overview - front differential lock

❑ Front differential lock is
installed depending on
equipment level ⇒ Elec‐
tronic parts catalogue
(ETKA)
2 - Multi-plate clutch
3 - Right flange shaft
4 - Differential of gearbox
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.

8.1.3 Schematic overview - gearbox, all-wheel drive
1 - Clutch housing
2 - Reverse shaft
3 - Output shaft for 5th and 6th
gears and reverse gear
release bearing
5 - Input shaft
gears
7 - Differential
8 - Bevel box
10 - Bevel gear with stub shaft
11 - Shaft bevel gear
12 - Output flange
13 - Left flange shaft
gear
15 - Synchromeshed gear, 1st
gear
4th gear
17 - Synchromeshed gear for agen
AG. Volkswagen AG d
oes
3rd gear olksw not
V gu
d by ara
e
18 - Synchromeshed gear, 5th horis nte
eo
gear s aut ra
c
s
ce
e
nl
pt
du
6th gear
an
itte
y li
erm
ab
20 - Synchromeshed gear for reverse gear

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.

8.2 Assembly overview - gearbox

⇒ “8.2.1 Assembly overview - gearbox with front-wheel drive”,
page 48
⇒ “8.2.2 Assembly overview - gearbox with four-wheel drive,
gearbox with front-wheel drive and front differential lock”,
page 49
8.2.1 Assembly overview - gearbox with front-wheel drive
l-
⇒ “8.3 Assembly overview -
gearbox housing and selector
mechanism”, page 50
ll -
⇒ “8.4.1 Assembly overview -
shafts, differential, selector
mechanism, front-wheel
drive”, page 52
ll -
⇒ “8.5 Assembly overview - se‐
lector forks”, page 56
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
48
AG.
Rep. gr.34 - Controls, housing
8.2.2 Assembly overview - gearbox with four-wheel drive, gearbox with front-
wheel drive and front differential lock
l-
⇒ “8.3 Assembly overview -
gearbox housing and selector
ll -
⇒ “8.4.2 Assembly overview -
shafts, differential, gear selec‐
tor, all-wheel drive and front-
wheel drive with front differen‐
tial lock”, page 54
ll -
⇒ “8.5 Assembly overview - se‐
lector forks”, page 56
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.

8.3 Assembly overview - gearbox housing and selector mechanism
1 - Countersunk bolt
⇒ page 138 or
⇒ page 141 .
❑ With compression
spring and tapered ring.
⇒ Rep. gr. 39 ; Oil
seals; Renewing left oil
seal
❑ Front-wheel drive, as‐
sembling ⇒ page 138
❑ All-wheel drive, assem‐
bling ⇒ page 141
3 - Retaining ring
❑ For sheet metal cover
plate
❑ Discontinued for plastic
cover plate
4 - Cap
❑ Allocate components
AG. Volkswagen AG d
using ⇒ Electronic parts ksw
agen oes
not
l
catalogue (ETKA) by
Vo gu
ara
ed
is nte
5 - Retaining ring ut
hor eo
a ra
❑ For deep groove ball ss c
bearing of input shaft
ce
e
nl
pt
du
⇒ page 89
an
itte
y li
❑ Redetermining thick‐
erm
ab
ility
ness ⇒ page 69
ot p
wit
, is n
6 - Reversing light switch - F4-

h re
hole
spec
❑ Switch without seal:

es, in part or in w
clean thread of switch if necessary

t to the co
❑ Switch with encapsulated seal: renew switch

❑ Switch with separate seal: renew seal
rrectness of i
❑ Lightly coat lug with MoS2 grease

l purpos
❑ 20 Nm
7 - Seal
nf
ercia
❑ If fitted, renew after removal

rm
m
atio
❑ Not fitted in all gearboxes

om
n in
or c
8 - Oil drain plug

thi
te
sd
iva
❑ Specified torque ⇒ Rep. gr. 34 ; Gear oil

o
r
rp
cu
o
m
f
9 - Seal
en
ng
t.
yi Co
op
❑ Renew after removal C py
t. rig
gh ht
yri
10 - Bolt
p by
o Vo
by c lksw
cted
❑ 6 Nm
agen
Prote AG.
11 - Gearbox neutral position sender - G701-

❑ for vehicles with start/stop system

12 - Locking bolt
❑ For selector shaft
❑ Locking bolt must be removed for removal and installing of selector shaft
❑ Renew locking bolt after each removal.
❑ Locking bolt made of metal or plastic.
❑ Locking bolt made of metal: 45 Nm
❑ Locking bolt made of plastic: 30 Nm
❑ On gearboxes without oil filler plug, fill oil through threaded hole for locking bolt ⇒ Rep. gr. 34 ; Gear oil
13 - Bolt
❑ Aluminium bolt M9
❑ 15 Nm and turn 180° further
14 - Bolt
❑ Aluminium bolt M9 AG. Volkswagen AG d
agen oes
❑ Renew after removal Volksw not
gu
by ara
❑ 15 Nm and turn 180° further rise
d
nte
tho eo
u
15 - Selector unit ss a ra
c
❑ (Selector shaft with selector mechanism cover) ⇒ Rep. gr. 34 ; Dismantling and assembling gearbox
ce
le
un
pt
an
d
❑ Removing and installing with gearbox installed:

itte
y li
erm
ab
♦ Remove complete air filter housing in vehicles with turbo diesel engine ⇒ Rep. gr. 23 ; Air filter; Removing
ility
ot p
and installing air filter housing .
wit
is n
h re
ole,
♦ Remove complete air filter housing in vehicles with petrol engine ⇒ Rep. gr. 24 ; Air filter; Removing and
spec
installing air filter housing .
t to the co
♦ Remove battery and battery tray, if necessary ⇒ Electrical system; Rep. gr. 27 ; Battery; Removing and
installing battery .
rrectne
♦ Angled rod ⇒ Item 6 (page 74) for adjusting selector mechanism must be disengaged
♦ Detach cables and gearbox selector lever ⇒ Rep. gr. 34 ; Selector mechanism; Assembly overview - selector
s
mechanism .
s o
cial p
f in
♦ Unscrew locking bolt.
form
mer
♦ If fitted, remove gearbox neutral position sender - G701- .

atio
om
n
c
♦ Unscrew bolts and pull out selector unit.

i
or
n thi
te
sd
a
♦ Install in reverse order of removal. Renew O-ring and bolts.

iv
o
pr
cum
r
fo
16 - Bolt
en
ng
t.
yi Co
❑ Renew after removal t. Cop py
rig
gh
❑ 20 Nm
ht
pyri by
Vo
co lksw
by
17 - O-ring
cted agen
Prote AG.
18 - Clutch housing
❑ Repairing ⇒ page 74

8.4 Assembly overview - shafts, differential,

selector mechanism
⇒ “8.4.1 Assembly overview - shafts, differential, selector mech‐
anism, front-wheel drive”, page 52
⇒ “8.4.2 Assembly overview - shafts, differential, gear selector,
all-wheel drive and front-wheel drive with front differential lock”,
page 54
Additional descriptions can be found in ⇒ Rep. gr. 34 ; Disman‐
tling and assembling gearbox .
n AG. Volkswagen A
8.4.1 Assembly overview - shafts, differential, Vol
kswselector mechanism,
age G do
es n front-wheel
ot g
drive by ua
ed ran
ris te
o th eo
s au ra
c
s
ce
e
nl
pt
gears
du
an
itte
y li
❑ Dismantling and assem‐
erm
ab
bling ⇒ page 96
ility
ot p
wit
, is n
h re
⇒ page 53
hole
spec
2 - Selector rod with selector
es, in part or in w
t to the co
fork for 1st and 2nd gears
⇒ page 53
rrectness of i
l purpos
fork for 3rd and 4th gears

nform
ercia
⇒ page 53
m
at
om
io
reverse gears
n
c
in t
or
his
ate
do
riv
bling ⇒ page 116

p
cum
or
f
en
ng
t.
⇒ page 53
yi Co
Cop py
t. rig
gh ht
yri by
fork for 5th and 6th gears cop Vo
by lksw
cted agen
Prote AG.
⇒ page 53
6 - Selector fork for reverse
gear
⇒ page 53
7 - Input shaft
⇒ page 53
bling ⇒ page 89
❑ Renew deep groove ball bearing on input shaft after each removal ⇒ page 89 .
8 - Thrust washer
❑ Place on reverse shaft.

AG. Volkswagen AG d
9 - Reverse shaft agen oes
olksw not
V gu
by ara
10 - Thrust washer rised
nte
ho eo
ut
11 - Bleeder ss a ra
c
❑ Connect to clutch slave cylinder.
ce
le
un
pt
an
d
itte
12 - Clutch housing
y li
rm
ab
pe
ility
ot
wit
, is n
13 - Input shaft seal
h re
hole
❑ Renew after removal ⇒ page 94
spec
es, in part or in w
14 - O-ring
t to the co
❑ Moisten with brake fluid before installing
rrectness of i
15 - Clutch slave cylinder with release bearing l purpos
16 - Bolt
❑ Qty. 3
nform
ercia

m
a
com
tio
❑ Removing and installing ⇒ page 12
n in
r
te o
thi
s
iva
do
r
❑ Specified torque ⇒ page 138

rp
cum
fo
en
g

n
t.
yi Co
op py
❑ With compression spring and tapered ring.
t. C rig
gh ht
yri by
❑ Removing and installing ⇒ Rep. gr. 39 ; Oil seals; Renewing right oil seal
op Vo
by c lksw
cted agen
❑ Assembling ⇒ page 138 Prote AG.
19 - Differential
❑ Dismantling and assembling ⇒ page 144
Installation position of shafts and selector rods in gearbox

1 - Input shaft
2 - Output shaft for 1st to 4th gears
3 - Output shaft for 5th, 6th and reverse gears
4 - Reverse shaft
A - Selector rod for 3rd and 4th gears
B - Selector rod for 1st and 2nd gears
C - Selector rod for 5th and 6th gears
D - Selector fork for reverse gear
Reverse gear selector fork -item D- is mounted on selector rod for
5th and 6th gear -item C-.

8.4.2 Assembly overview - shafts, differential, gear selector, all-wheel drive and
front-wheel drive with front differential lock

gears
bling ⇒ page 103
⇒ page 55
⇒ page 55
⇒ page 55
4 - Output shaft for 5th and 6th
gears and reverse gear
bling ⇒ page 116
❑ Fitting position n AG. Volkswagen AG do
⇒ page 55 olks
wage es n
o V t gu
by ara
ris
ed nte
fork for 5th and 6th gears
tho eo
au ra
c
ss
ce
le
⇒ page 55
un
pt
an
d
itte
y li

rm
ab
gear
pe
ility
ot
wit
, is n
h re
⇒ page 55
hole
spec
7 - Input shaft
es, in part or in w
t to the co
❑ Installation position
⇒ page 55
rrectness of i
bling ⇒ page 89
l purpos
❑ Renew deep groove ball bearing on input shaft after each removal ⇒ page 89 .
8 - Reverse shaft
nform
ercia
❑ With thrust washer.

m
a
com
9 - Thrust washer
ion in
r
te o
10 - Bleeder
thi
s
iva
do
❑ Connect to clutch slave cylinder.

r
rp
cum
fo
en
g
11 - Clutch housing
n
t.
yi Co
op
C py
ht. rig
rig ht
py by
12 - Input shaft seal co Vo
by lksw
cted agen
❑ Renew after removal ⇒ page 94 Prote AG.
13 - O-ring
❑ Moisten with brake fluid before installing

14 - Clutch slave cylinder with release bearing

15 - Bolt
❑ Qty. 3
AG. Volkswagen AG d
agen oes
17 - Bolt Volksw not
gu
by ara
❑ Qty. 4 rised
nte
ho eo
❑ Renew after removal s aut ra
c
s
ce
le
un
pt
an
d
18 - Bevel box for four-wheel drive, front differential for front-wheel drive
itte
y li
rm
ab
❑ Bevel box ⇒ page 162
pe
ility
ot
wit
, is n
h re
❑ Front differential lock is installed depending on equipment level ⇒ Electronic parts catalogue (ETKA)
hole
spec
❑ Front differential lock ⇒ page 37
es, in part or in w
t to the co
❑ Removing ⇒ Rep. gr. 34 ; Front differential lock; Removing front differential lock
❑ Installing ⇒ Rep. gr. 34 ; Front differential lock; Installing front differential lock
rrectness of i
19 - Differential
l purpos
❑ Dismantling and assembling ⇒ page 149
nform
ercia
Installation position of shafts and selector rods in gearbox

m
a
com
ti
1 - Input shaft
on in
r
te o
thi
2 - Output shaft for 1st to 4th gears
s
iva
do
r
rp
c
3 - Output shaft for 5th, 6th and reverse gears
um
fo
en
ng
t.
4 - Reverse shaft
yi Co
Cop py
t. rig
A - Selector rod for 3rd and 4th gears
gh ht
pyri by
Vo
o
by c lksw
B - Selector rod for 1st and 2nd gears Prote
cted AG.
agen
C - Selector rod for 5th and 6th gears

D - Selector fork for reverse gear
Reverse gear selector fork -item D- is mounted on selector rod for
5th and 6th gear -item C-.

8.5 Assembly overview - selector forks
1 - Rubber dampers
❑ Needs to be pulled out
of selector rod/inserted n AG. Volkswagen AG do
swage es n
into selector rod by byV
olk ot g
ua
hand. ir se
d ran
tee
tho
or
2 - Selector rod with selector ss
au ac
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
fork for 5th and 6th gears
h re
ole,
spec
gear
t to the co
❑ Is mounted on selector
rod with selector fork for
5th and 6th gears
rrectne
⇒ page 53 or
⇒ page 55
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
8.6 Dismantling and assembling gearbox

⇒ “8.6.1 Dismantling gearbox”, page 56
⇒ “8.6.2 Assembling gearbox”, page 66
8.6.1 Dismantling gearbox

Removing and installing gearbox housing, selector mechanism,
input shaft, output shafts, differential, selector rods and, if appli‐
cable, bevel box


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
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
♦ Retainer - VW 309- Prote
cted AG.
agen
♦ or support plate - VW 309 A-

♦ Gearbox support - VW 353-
♦ Sleeve - VW 455- or sleeve - 3160-
♦ Multi-purpose tool - VW 771-
♦ Adapter - VW 771/40-
♦ Internal puller - VAS 251 603- , or e.g. internal puller - Kukko
21/01-

♦ Alternative to adapter - VW 771/40- : M8 X 40 stud (locally

manufactured)
♦ Adapter - T10055/3-
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
♦ Splitter - VAS 251 407- or e.g. splitter - Kukko 17/0-
AG.
♦ Counter support - VAS 251 621- , or e.g. counter support -

Kukko 22/1-
♦ Release lever - 80 - 200-
♦ Drip tray - V.A.G 1306-

♦ or 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
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 bridge - 30-211A-
♦ Thrust piece - T10143- or thrust piece - T10180-
♦ Drift - T10169-
♦ or drift - T10362- ⇒ page 83
♦ Press tool - T40008-
♦ Hot-air blower - V.A.G 1416-

♦ Release lever - 80 - 200-
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
g

n
t.
yi Co
op py
♦ Sealant
t. C rig
gh ht
pyri by
Vo
o
♦ Allocation ⇒ Electronic parts catalogue (ETKA) by c lksw
cted agen
Prote AG.
Dismantling gearbox
– Secure gearbox on gearbox support - VW 353- ⇒ page 41 .
– Drain gear oil from gearbox.
Gearbox for four-wheel drive and gearbox for front-wheel drive
with front differential lock
– Remove right flange shaft countersunk bolt with socket .
– Unscrew the 4 securing bolts -arrows- securing bevel box or
front differential lock to manual gearbox (only 3 securing bolts
are shown in illustration).
– Carefully press bevel box or front differential lock off manual
gearbox, taking care that it does not fall.
– Observe notes on transporting front differential lock
⇒ page 39 .

Gearbox for front-wheel drive without front differential lock

– Remove right flange shaft (fig. shows left flange shaft).
– Pull out flange shaft with compression spring.
Continued for all

– Remove clutch slave cylinder with clutch release bearing
-arrows-.
– Gearboxes for vehicles with start-stop system: remove gear‐

box neutral position sender - G701- -arrow-.
G. Volkswage A n AG d
agen oes
ksw not
y Vol gu
b ara
ed nte
oris eo
th
au ra
c
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
During the following steps, ensure that the selector shaft is not
t to the co
blocked by the angled rod -arrow-

– Move selector shaft to neutral.
rrectness of i
– Remove reversing light switch - F4- -1-.

l purpos
– Unscrew locking bolt -2-.

nform
ercia
– Then unscrew bolts -3-.

m
– Pull selector shaft with selector shaft cover -4- out of gearbox
a
com
tio
housing.
n 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.

Note
To ensure that the selector shaft -1- does not bump against the
locating bush -2- on removal, press against spring force of the
locating bush (-direction of arrow-) using removal lever - 80 -
200- .
– Unscrew securing bolt for left flange shaft by screwing 2 bolts

into flange and counterholding flange shaft with a lever.
– Pull out flange shaft with compression spring.
– Remove bolts -B-, which secure gearbox housing to clutch

housing.
AG. Volkswagen AG d
Note lksw
agen oes
not
o
byV gu
ara
ed
One bolt -arrow- is located outside of bolting
horis
flange. nte
eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
– Lock input shaft as follows:

hole
spec
es, in part or in w
The lengths of the splines on the input shaft to the gearbox differ.
t to the co
– Set either installing sleeve - VW 455- over input shaft on clutch

housing
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.

– or set sleeve - 3160- over input shaft on clutch housing.

– Then clamp splitter - VAS 251 407- , -A-, or e.g. splitter - Kukko
17/0- , behind notch in splines of input shaft.
The back side of the splitter must rest againstninstalling
AG. Volkswsleeve
agen AG -
VW 455- or sleeve - 3160- without play. olkswage does
no
yV t gu
db ara
rise nte
tho eo
s au ra
c
s
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
Cover plate identification
h re
ole,
♦ -I- = cover plate with retaining ring -A-, cover plate made of
spec
rubberised sheet metal
t to the co
♦ -II- = cover plate without retaining ring. Cover plate may be
made of plastic or rubberised sheet metal
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
Rubberised cover plate made of sheet metal
Prote AG.
– If present, remove retaining ring -A- for input shaft cover plate.
– Pierce rubber in centre of cover -C- with a screwdriver .
Caution
Risk of damage to components beneath sealing cover.
– Pull sealing cover out of gearbox housing.

A - Counter support - VAS 251 621- , or e.g. counter support -
Kukko 22/1-
B - Internal puller - VAS 251 603- , or e.g. internal puller - Kukko
21/01-

6-speed manual gearbox 02Q, 0BB and 0FB,olksw
removed - Edition 03.2019
AG. V agen AG
agen does
olksw not
yV gu
db ara
ise nte
Note tho
r eo
au ra
c
ss
Sealing cover -1- can also be levered off carefully using a screw‐
ce
le
un
pt
driver -2-.
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
Plastic cover plate
rrectness of i
Carefully remove all lugs -A-. When doing this, do not damage
l purpos
gearbox housing.
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
yri by
– Pry out sealing cover -A-.
op Vo
by c lksw
cted agen
Prote
• When doing this, ensure any sealing cover components are
AG.
removed.
Continued for all

Remove retaining ring -C- from deep groove ball bearing of input
shaft in gearbox housing as follows:
– Hold one end of retaining ring using screwdriver -A-.
– Using screwdriver -B-, lever other end out of groove in deep
groove ball bearing -direction of arrow-.
– Using screwdriver -B-, lever out securing ring further.

– Remove securing bolts -A- for gearbox housing to clutch hous‐

ing.
– Then screw adapter - VW 771/40- into threaded hole of gear‐

agen
AG. Volkswagen AG d
oes
box housing onto stop. Volksw not
g y ua
db ran
As an alternative to adapter - VW 771/40- , the hfollowing
or
ise tool as‐ tee
sembly can be selected: au
t or
ac
ss
– Screw M8 X 40 stud (locally manufactured) into threaded hole
ce
le
un
pt
of gearbox housing onto stop.
an
d
itte
y li
rm
ab
– Screw adapter - T10055/3- onto stud as far as stop.
pe
ility
ot
Continued for all
wit
, is n
h re
hole
– Heat gearbox housing using hot air blower , e.g. -V.A.G 1416-
spec
in vicinity of bearing seat for deep groove ball bearing for input
es, in part or in w
shaft for about 10 minutes to about 100°C.
t to the co
– Using multi-purpose tool VW 771/1 , pull gearbox housing off
clutch housing in -direction of arrow-.
rrectness of i
l purpos
Note
nform
ercia
If necessary, carefully lever off gearbox housing at protruding

shoulders along perimeter alternately using assembly lever. Be
m
a
com
t
careful not to damage sealing surfaces.
ion in
r
te o
thi
s
iva
do
– Remove splitter -A- and installing sleeve VW 455 or sleeve -
r
rp
cum
3160- from input shaft.
fo
en
ng
t.
yi Co
To remove shafts from clutch housing, a second mechanic is re‐ Cop py
t. rig
quired. opyri
gh by
Vo
ht
by c lksw
cted agen
Prote AG.

– With left hand, raise differential -1-. With right hand, lift output
shaft for 1st to 4th gear together with selector rods -2-
-arrow A-.
– At same time, second mechanic lifts input shaft, reverse shaft
and output shaft for 5th and 6th gears and reverse gear -3-
together with selector rod out of clutch housing -arrow B-.
AG. Volkswagen AG d
agen oes
Note olksw not
V gu
d by ara
ise nte
r
After shafts are lifted, set back differential in clutch housing
ut
ho
if eo
ra
necessary. s a c
s
ce
e
nl
pt
du
an
– Remove input shaft oil seal.
itte
y li
erm
ab
ility
ot p
wit
Note
, is n
h re
hole
spec
Renew deep groove ball bearing on input shaft after each removal
es, in part or in w
⇒ page 89 .
t to the co
8.6.2 Assembling gearbox
rrectness of i
l purpos
• A new deep groove ball bearing has been pressed onto the
input shaft ⇒ page 89 .
nf
ercia
• The reverse gear selector fork -1- is mounted on selector rod
or
for 5th and 6th gear -2- ⇒ page 66 .
m
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
– Insert input shaft -1-, output shaft for 5th and 6th gears -2-
together with selector rod for 5th and 6th gears -3-, reverse
gear selector fork -4- and reverse shaft -5-.
• Selector jaw -arrow A- of reverse gear selector fork points to‐
wards outside of gearbox. The selector jaw -arrow B- of se‐
lector rod for 5th and 6th gears must point towards the inside
of gearbox.

– Then insert differential -1-.
Note
A second mechanic will be required for further installation of the

shafts in the clutch housing.
– Take output shaft for 1st to 4th gears -3- with selector rods
-4- in the right hand as shown in illustration.
– Lift differential slightly with left hand.
– At the same time, a 2nd mechanic must slightly lift input shaft
and output shaft for 5th and 6th gears -2- together with reverse
gear shaft.
– Insert output shaft for 1st to 4th gears in direction of -arrow-.
• The teeth of the input shaft, the output shafts and the final drive
input gear of differential must mesh.
– Then, working with second mechanic, place shafts and differ‐
ential in their bearing seats
– Attach support device for input shaft in same way as on clutch

housing (as shown in one of diagrams).
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
o
– Secure support device - T10323-
aut
h . eo
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
– Secure support device - T10323- .

ss o
cial p
f inform
Note
mer
atio
m
For clarity of illustration, clutch housing is shown turned 180°.

o
n
c
i
or
n thi
te
sd
a
– Screw in bolt -A- until input shaft rises slightly.

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

wage e
Deep groove ball bearingyV
olksof input shaft fits into gearbox
s no
t gu housing
in only one position
ised b ara
n r tee
ho
There is a flat
sa
usection
t
on deep groove ball bearing and on theor ac
bearing support for the deep groove ball bearing.
s
ce
e
nl
pt
du
• Flats -A- on deep groove ball bearing and on bearing support
an
itte
y li
-B- in gearbox housing must line up.
erm
ab
ility
ot p
– Mark these flat sections with colour.
wit
, is n
h re
– Transfer markings to upper area of deep groove ball bearing
hole
and to upper area of bearing support of gearbox housing (⇒
spec
es, in part or in w
next illustration).
t to the co
– 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.
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
Note
thi
te
sd
iva
o
r
rp
cu
♦ Heating is necessary to avoid damage to deep groove ball
o
m
f
en
ng
bearing when gearbox housing is installed.

t.
yi Co
Cop py
♦ Apply sealant evenly to sealing surface of clutch housing.
t. rig
gh ht
pyri by
Vo
o
♦ Line up marking on deep groove ball bearing -A- with marking
by c lksw
cted agen
on gearbox housing -B- and set gearbox housing in place.
Prote AG.
– Fit gearbox housing and tighten new bolts -A-, -B- and -C-.

Redetermine retaining ring -1- for deep groove ball bearing of in‐
put shaft -2-:
• Ensure that input shaft with support bridge - 30-211A- is push‐
ed against gearbox housing.
• Determine thickest possible retaining ring that will still fit for
deep groove ball bearing of input shaft, and insert retaining
ring. Make sure to start determining with the thickest available
retaining ring.
Following retaining rings are available - part numbers ⇒ Elec‐
tronic parts catalogue (ETKA) :
Retaining ring thickness (mm)
2.03 2.09 2.15
2.21 2.27
Continued for all
– Install retaining ring -1- for deep groove ball bearing of input
shaft.
– Remove support bridge - 30 - 211 A- for input shaft.
– If stop sleeve for selector shaft was removed, drive it in now
until stop of tool ⇒ page 83 .
– Turn gearbox in repair stand with opening for selector shaft

upwards. wage
e ks s no
Vol t gu
• Selector shaft is in neutral position -arrows-e(shown
db
y here on a ara
different selector unit). thoris nte
eo
au ra
• Selector plates of gearbox are in neutral.
ss c
ce
le
un
pt
• All sealing surfaces are cleaned.

an
d
itte
y li
erm
• Renew securing bolts and O-ring for sealing selector unit to

ab
ility
gearbox.
ot p
wit
is n
• The angled rod for adjusting the selector mechanism must be

h re
ole,
disengaged
spec
t to the co
Note
rrectne
To ensure that the selector shaft -1- does not bump against the
locating bush -2- on installation, press against spring force of the
ss
locating bush (-direction of arrow-) using removal lever - 80 -

o
cial p
200- .
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.

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nt
Arteon 2018 ➤ , Golf 2017
ut
ho ➤ , Golf Variant 2017 ➤ , Polo 2018 ➤ , eT-Ro eo
ra
...
a
ss 02Q, 0BB and 0FB, removed - Edition 03.2019c
ce
le
un
pt
– Insert selector shaft -1- in lower bearing -2- and in selector
an
d
itte
y li
forks -3-.
rm
ab
pe
ility
ot
wit
Note , is n
h re
hole
spec
es, in part or in w
For better clarity, sealing cover ⇒ page 74 is removed in illus‐
t to the co
tration.
rrectness of i
l purpos
nform
ercia
– Now press selector shaft -1- against stop sleeve -2- in

-direction of arrow- and guide downwards with selector finger
m
a
com
ti
-3- through selector forks to stop.
on in
r
te o
thi
• Selector shaft cover -4- must be parallel to bolting surface on
s
iva
gearbox housing.
do
r
rp
cum
fo
• Selector shaft must move freely in gate selection direction
en
ng
t.
yi
(upwards and downwards).
Co
Cop py
ht. rig
rig ht
py by
co Vo
lksw
Note
by
cted agen
Prote AG.
If selector shaft cover is tilted relative to bolting surface, selector

shaft is not inserted in lower bearing.
– Tighten bolts -3- for selector shaft cover -4-.
Manual gearbox “with” oil filler plug

– Screw in new locking bolt -2-, ensuring that angled rod
-arrow- is not engaged.
Manual gearbox “without” oil filler plug
Fill oil through threaded hole for locking bolt -2-.
– Seal threaded hole to prevent ingress of foreign particles into
gearbox.
– Do not screw in new locking bolt -2- until oil has been filled ⇒
Rep. gr. 34 ; Gear oil .
Continued for all
– Install reversing light switch - F4- -1-.
– Gearbox for vehicles with start/stop system: Insert gearbox

neutral position sender - G701- -arrow- and tighten securing
bolt.

– Drive in input shaft oil seal flush.

– Install clutch slave cylinder together with clutch release bear‐
ing ⇒ page 13 .
– Shift through all gears.
Installing sealing cover plate:

• Allocate cover plate using ⇒ Electronic parts catalogue (ET‐
KA) .
AG. Volkswagen AG d
agen oes
olksw not
V gu
I - Cover plate secured with ed byre‐ ara
nte
is
taining ring hor eo
aut ra
c
♦ This cover plate s is made of
s
ce
e
rubberised sheet metal. It is

nl
pt
du
smooth around the circum‐
an
itte
y li
ference and is held in place
erm
ab
by a retaining ring.
ility
ot p
wit
, is n
♦ Installing ⇒ page 72
h re
hole
spec
II - Cover plate made of plastic
es, in part or in w
without retaining ring

♦ The plastic cover plate is t to the co
held in the hole of the gear‐
rrectness of i
box housing by retaining

lugs around the circumfer‐
l purpos
ence. An additional retain‐

ing ring is not required.
nform
ercia
m
at
III - Cover plate with retaining

om
ion
lip -arrow- without retaining

c
in t
or
ring
his
ate
do
riv
♦ This cover plate is made of

p
cum
or
rubberised sheet metal.

f
en
ng
t.
The cover plate features a
yi Co
op py
»retaining lip« around the t. C rig
gh ht
circumference. It engages yri
p by
o Vo
in the groove of the gearbox
by c lksw
cted agen
housing and stops the cov‐
Prote AG.
er plate from working free.

An additional retaining ring
is not required.

Cover plate with retaining ring

– Drive sealing cover plate into gearbox housing to stop of thrust
piece.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
– Secure sealing
horis cover plate with retaining ring -A-. 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
Cover plate made of plastic and cover plate with retaining lip
l purpos
– Drive sealing cover plate into gearbox housing to stop of thrust

piece.
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
Cover plate with retaining lip Prote AG.
– The retaining lip of the cover plate must be in contact with the
groove of the gearbox housing -arrow- around the circumfer‐
ence.
An additional retaining ring is not required.
Cover plate -1-

Continued for all

– Install flange shafts together with springs, thrust washers and
tapered rings.
lkswage es n
o ot g
byV ua
d ran
ir se tee
Gearbox for four-wheel drive uth and gearbox for front-wheel drive
o
or
with front differential lock
ss
a ac
ce
le
un
Install bevel box or front differential lock to manual gearbox as
pt
an
d
follows:
itte
y li
erm
ab
– Observe notes on transporting front differential lock
ility
ot p
⇒ page 39 .
wit
is n
h re
ole,
– Grease splines of manual gearbox differential with grease for
spec
clutch plate splines .
t to the co
Allocate grease using ⇒ Electronic parts catalogue (ETKA) .
– Push bevel box or front differential lock in area of flange shaft
rrectne
completely onto manual gearbox. When doing this, centre and
guide splines of drive shaft/bevel box or front differential lock
together with differential.
ss o
cial p
f
– Align splines of right flange shaft and differential bevel gear,
inform
turning flange shaft if necessary.
mer
– If splines are correctly positioned and shafts are centred, then atio
om
n
the bevel box or front differential lock will slide to stop against
c
i
or
n thi
manual gearbox.
te
sd
iva
o
pr
cum
r
fo
en
ng
Note
t.
yi Co
Cop py
t. rig
Do not use securing bolts to pull bevel box or front differential lock
gh ht
pyri by
onto manual gearbox. Otherwise the unit will cant and bolt holes
co Vo
by lksw
cted
may break off.
agen
Prote AG.
– Tighten the 4 securing bolts -arrows- securing bevel box or

front differential lock to manual gearbox (only 3 securing bolts
are shown in illustration).
– Tighten right flange shaft countersunk bolt with socket .
Specified torques
♦ ⇒ “8.3 Assembly overview - gearbox housing and selector
♦ ⇒ “1.1 Assembly overview - clutch release mechanism”, page
12 .
♦ ⇒ “2.1 Assembly overview - differential”, page 138 .

9 Gearbox housing, clutch housing

⇒ “9.1 Assembly overview - gearbox housing”, page 74
⇒ “9.2 Assembly overview - clutch housing”, page 76
⇒ “9.3 Repairing gearbox housing”, page 77
⇒ “9.4 Repairing clutch housing”, page 85
9.1 Assembly overview - gearbox housing
1 - Gearbox housing
❑ If renewed: adjust out‐
put shafts and differen‐
tial ⇒ page 161
❑ Changes in area of sup‐
port for input shaft cover
⇒ page 50
❑ Refer to the ⇒ Electron‐
ic parts catalogue (ET‐
KA) for component allo‐
cation.
2 - Cap
❑ Removing ⇒ page 80
❑ Driving in ⇒ page 81
3 - Oil drain plug
❑ Specified torque ⇒ Rep.
gr. 34 ; Gear oil
4 - Seal
❑ If fitted, renew after re‐
moval
5 - Oil filler plug
AG. Volkswagen AG d
❑ A number of manual agen oes
olksw not
gearboxes is not fitted byV gu
ara
ed
with an oil filler plug. horis nte
eo
ut ra
❑ If a gearbox without oil ss a c
filler plug has been com‐
ce
le
un
pt
pletely dismantled, fill oil

an
d
itte
before reassembly.
y li
erm
ab
❑ Capacity of manual
ility
ot p
gearbox (gearbox com‐

wit
is n
pletely dismantled)
h re
ole,
spec
♦ 2.3 l
t to the co
❑ If a gearbox without oil

filler plug has been dismantled partially, fill oil after reassembly.
❑ Capacity of manual gearbox (gearbox partially dismantled)
rrectne
♦ 2.15 l
s
❑ Please observe ⇒ Rep. gr. 34 ; Gear oil

s o
cial p
❑ Specified torque ⇒ Rep. gr. 34 ; Gear oil

inform
mer
6 - Angled rod
atio
m
❑ To adjust selector mechanism ⇒ Rep. gr. 34 ; Selector mechanism; Adjusting selector mechanism
o
n
c
i
or
❑ Can be renewed with gearbox assembled

thi
te
sd
va
i
o
pr
cum
r
fo
❑ Fitting position ⇒ page 81

en
ng
t.
yi Co
❑ Driving in ⇒ page 81 ht. Cop py
rig
rig ht
py by
74
co Vo
by lksw
cted
Rep. gr.34 - Controls, housing
agen
Prote AG.
7 - Bearing bush
❑ For selector shafts
8 - Stop sleeve
❑ Pressing out with gearbox dismantled ⇒ page 82
❑ Pressing out with gearbox assembled ⇒ page 82
❑ Stop sleeve identification ⇒ page 83
❑ Drive in ⇒ page 83 to ⇒ page 84
9 - Needle bearing
❑ For reverse shaft
❑ Pressing in ⇒ page 84 .
10 - Tapered roller bearing outer race
❑ For output shaft for 5th, 6th and reverse gears
❑ If renewed, adjust output shaft for 5th, 6th and reverse gears ⇒ page 130
11 - Shim
❑ Adjustment overview ⇒ page 161
❑ For output shaft for 1st to 4th gears
❑ Removing and installing AG. Vo⇒lkspage
wagen96
AG do
agen es
ksw
❑ If renewed,by
Voadjust
l output shaft for 1st ton4th
ot g gears ⇒ page 125
ua
d ran
se
13 - Shimthori tee
or
au ac
❑ For
ss output shaft for 1st to 4th gears
ce
le

un
pt
an
d
itte
y li

rm
ab
pe
ility
❑ For differential
ot
wit
, is n

h re
hole
❑ If renewed, adjust differential ⇒ page 156

spec
es, in part or in w
15 - Shim
t to the co
rrectness of i
16 - Bearing bush
l purpos

nform
ercia
m
a
com
tio
17 - Plug
n in
r
te o
❑ Driving out ⇒ Fig. ⇒ page 85

thi
s
iva
do
r
rp
cum
fo
en
g
18 - Seal
n
t.
yi Co
op
❑ For left flange shaft
C py
ht. rig
rig ht
❑ Renew after removing ⇒ Rep. gr. 39 ; Oil seals; Renewing left oil seal
py by
co Vo
by lksw
cted agen
Prote AG.
9. Gearbox housing, clutch housing 75

9.2 Assembly overview - clutch housing
1 - Bearing bush
❑ For selector shafts
2 - Needle bearing
❑ For reverse shaft
❑ Pressing in
⇒ page 88 .
3 - Dowel sleeve
❑ Qty. 2 AG. Volkswagen AG d
agen oes
lksw not
4 - Clutch housing d byV
o gu
ara
e nte
❑ If renewed: adjust out‐ horis
eo
put shafts and differen‐ aut ra
s c
tial ⇒ page 161 s
ce
e
nl
pt
du
5 - Cover
an
itte
y li
erm
❑ Not fitted in all clutch
ab
ility
housings
ot p
wit
, is n
6 - Input shaft seal
h re
hole
spec
es, in part or in w
⇒ page 94
t to the co
7 - Seal
rrectness of i
❑ Front-wheel drive - for
l purpos
right flange shaft

❑ Front-wheel drive ⇒
Rep. gr. 39 ; Oil seals;
nf
ercia
Renewing right oil seal

rm
m
atio
m
❑ Front-wheel drive with

o
n in
c
front differential lock, between manual gearbox and front differential lock ⇒ Rep. gr. 39 ; Oil seals;
or
thi
Renewing right oil seal

te
sd
iva
❑ All-wheel drive - between gearbox and bevel box.

r
rp
cu
o
m
f
❑ All-wheel drive ⇒ Rep. gr. 39 ; Oil seals; Renewing right oil seal
en
ng
t.
yi Co
op py
8 - Washer
. C rig
ht ht
rig by
❑ For differential copy Vo
by lksw
cted agen
❑ Installation position: shoulder on inner circumference faces seal ⇒ Item 7 (page 76) Prote AG.

❑ Front-wheel drive, removing and installing ⇒ page 144
❑ Front-wheel drive with front differential lock - removing and installing ⇒ page 149 .
❑ All-wheel drive - removing and installing ⇒ page 149 .
❑ If renewed, adjust differential ⇒ page 156
10 - Oil deflector ring
❑ Installation position: shoulder on hole faces output shaft
❑ For output shaft for 1st to 4th gears

❑ If renewed, adjust output shaft for 1st to 4th gears ⇒ page 125
❑ If renewed, adjust output shaft for 5th, 6th and reverse gears ⇒ page 130
13 - Washer
❑ Always 0.65 mm thick
14 - Cylindrical roller bearing
❑ For input shaft
15 - Solenoid
❑ Held in place by housing joint surface
9.3 Repairing gearbox housing

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
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.
♦ Drift sleeve - VW 244 B-


♦ Pressure plate - VW 401-
♦ Press tool - VW 407-
♦ Tube - VW 416 B-
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
♦ Guide pin, shouldered - VW 436A-
Co
Cop py
t. rig
gh ht
♦ Guide pin, shouldered - VW 439- yri
p by
o Vo
by c lksw
cted
agen
Prote AG.
♦ Guide pin - 10 - 15-
♦ Press tool - 3124-

lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, 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.
♦ Drift - 3264-
♦ Assembly tool - 3290-
♦ Drift - T10168-
♦ Drift - T10169- or drift - T10362- ⇒ page 83

wage e
Arteon 2018 ➤ , Golf 2017 ➤ , Golf Variant 2017 yV
o➤ , Polo 2018 ➤ , T-Ro ... s not g
lks
b ua
6-speed manual gearbox 02Q, 0BB and 0FB, ris removed - Edition 03.2019
ed ran
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
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.

21/2-
21/4-
Kukko 22/2-
♦ Threaded adapter from counter support - VAS 251 621- , or
e.g. counter support - Kukko 22/1-
Removing sealing cover -A-
– Pierce centre of sealing cover using screwdriver -B- and lever
out cover -in direction of arrow-.

wage e
Arteon 2018 ➤ , Golfy V2017olks ➤ , Golf Variant 2017 s➤no,t gPolo 2018 ➤ , T-Ro ...
b ua
6-speed manual ris gearbox 02Q, 0BB and 0FB, removednte-eEdition 03.2019
ed ra
tho
or
au ac
Driving in sealing cover to stop 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
Removing angled rod for selector shaft
nf
ercia
– Break off angled rod in released position.
orm
m
– Insert a screwdriver -A- into hole for angled rod -B-
atio
om
n in
c
– Lever out angled rod in -direction of arrow-.

or
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Installation position of angled rod

• Marking on angled rod -arrow- must face clutch slave cylinder
connection -1-.
• Dimension -a- must be about 45°.
Drive in angled rod for selector shaft -arrow- to stop of tool.
Note
Angled rod must be released while it is being driven in.

AG. Volkswagen
Arteon 2018 ➤ , Golf 2017 ➤lks,wGolf
agen Variant 2017 A➤
G d,oPolo 2018 ➤ , T-Ro ...
es n
Vo ot g
6-speed manual gearboxd b 02Q, 0BB and 0FB, removed - Edition
y ua
ra 03.2019 e nte
ris
tho eo
Pulling out selector rod bearing
au bush ra
c
ss
ce
le
A - Internal puller - VAS 251 609- , or internal puller
un
pt
14.5 … 18.5 mm , e.g. -Kukko 21/2-
an
d
itte
y li
erm
ab
B - Counter support - VAS 251 623- , or e.g. counter support -
ility
ot p
Kukko 22/2-
wit
is n
h re
ole,
spec
t to the co
rrectne
Driving in selector shaft bearing bush to stop of tool
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Pressing stop sleeve -A- out of gearbox housing
– Place gearbox housing on thrust plates - VW 401- and -VW
402- in such a way that dowel sleeves in gearbox housing are
not damaged.
Driving stop sleeve out of assembled gearbox using guide pin -

10 - 15-
• Remove locking screw and selector shaft.
– Turn gearbox so that stop sleeve does not fall in gearbox.

Stop sleeve identification
Following stop sleeves can be installed:

Stop sleeve with shoulder -arrow 1-
Stop sleeve without shoulder -arrow 2-
Stop sleeve
With shoulder Without shoulder
Various versions
Driving in ⇒ page 83 Stop sleeve “02T” Stop sleeve “02Q”
⇒ page 83 ⇒ page 83
Allocate components using ⇒ Electronic parts catalogue (ETKA) .
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
nte
Stop sleeve “02T” and ho ris
stop sleeve “02Q” eo
aut ra
Drive in stop sleeve
ss “02T” ⇒ page 84 . c
ce
e
nl
pt
Drive in stop sleeve “02Q” ⇒ page 83 .

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
Drive in stop sleeve with shoulder and stop sleeve “02Q” without
l purpos
shoulder
• Clutch housing bolted to gearbox housing.
nform
ercia
Driving in stop sleeve to stop

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.

Drive in stop sleeve “02T” without shoulder

• Clutch housing bolted to gearbox housing.
Driving in stop sleeve to stop
Pulling reverse shaft needle bearing out of gearbox housing

A - Internal puller - VAS 251 609- , or e.g. internal puller - Kukko
21/4-
B - Counter support - VAS 251 623- , or e.g. counter support -
Kukko 22/2-
Note
The needle bearing is destroyed during removal and must be re‐

newed.
Pressing needle bearing -A- into gearbox housing

– Before pressing in, place reverse shaft thrust washer -B- on
needle bearing.
. Volkswage
– Support gearbox housing
ksw
agewith
n AG tube - VW 416oB-
n AG d
es ndirectly below
bearing support.by Vol ot g
ua
ed ran
ris tee
tho or
au ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
Pulling out selector shaft bearing bush

hole
spec
– Use threaded adapter from counter support - VAS 251 621- ,

es, in part or in w
t to the co
or e.g. counter support - Kukko 22/1- -arrow-.

– Hold spindle of assembly tool - 3290- securely and turn nut
-B-.
rrectness of i
A - Internal puller - VAS 251 605- , or e.g. internal puller - Kukko

l purpos
21/2-
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.

Driving in selector shaft bearing bush -A- to stop of tool.
Driving out plug -1-

– Drive in plug -1- outwards from inside gearbox housing.
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
Driving in plug -1-

wit
, is n
h re
hole
– Drive in sealing plug to dimension -a-, approx. 3 mm below

spec
upper edge of housing, using punch - 3264- .

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
9.4 Repairing clutch housing
agen
Prote AG.


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
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectne
ss o
♦ Drift - T10168-
cial p
f inform

mer
atio
m

o
n
c
21/2-
or
n thi
te
sd
a

iv
o
pr
21/4-
um
r
fo
en
ng
t.
yi
Co
op py
Kukko 22/1-
. C rig
ht ht
rig by
copy Vo
by lksw
cted agen
Prote AG.

♦ Counter support -
VAS 251 623- , or e.g.
counter support -
Kukko 22/2-
Pulling out selector rod

bearing bush AG. Volkswagen AG d
agen oes
lksw not
A - Counter support - byV
o gu
ara
d
VAS 251 621- , or e.g. orise nte
counter support - Kukko aut
h eo
ra
22/1- ss c
ce
le
un
pt
B - Internal puller - VAS
an
d
itte
251 605- , or e.g. internal
y li
erm
ab
puller - Kukko 21/2-
ility
ot p
wit
is n
Driving in selector shaft bearing bush to stop of tool
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
e
Pulling needle bearing out of clutch housing

t
sd
iva
o
pr

um
r
fo
Kukko 22/2-
en
ng
t.
yi Co
op py
B - Internal puller - VAS 251 609- , or internal puller
. C rig
ht ht
rig
23.5 … 30 mm , e.g. -Kukko 21/4- py by
co Vo
by lksw
cted agen
Prote AG.
Note
The needle bearing is destroyed during removal and must be re‐

newed.

Pressing needle bearing -A- into clutch housing

– Before pressing in, place reverse shaft thrust washer -B- on
needle bearing.
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.

35 – Gears, shafts
1 Input shaft
⇒ “1.1 Assembly overview - input shaft”, page 89
⇒ “1.2 Dismantling and assembling input shaft”, page 90
⇒ “1.3 Renewing input shaft seal”, page 94
1.1 Assembly overview - input shaft
Note
♦ Heat gears to about 100°C with the inductive heater - VAS 6414- before installing. Wear protective gloves
when doing this.
♦ Install all bearings on input shaft with gear oil.
. Volkswagen AG
gen AG
♦ Renew deep groove ball after each removal.a does
ksw not
Vol gu
by ara
ed nte
oris eo
th
au ra
1 - Retaining ring ss c
ce
e
❑ For deep groove ball

nl
pt
du
an
bearing of input shaft
itte
y li
erm
ab
ility
ot p
⇒ page 56
wit
, is n
❑ Redetermining thick‐
h re
hole
ness ⇒ page 69
spec
es, in part or in w
2 - Gearbox housing
t to the co
3 - Retaining ring
❑ If deep groove ball bear‐
rrectness of i
ing and input shaft are
l purpos
renewed, redetermine
⇒ page 93 .
nform
ercia
4 - Deep groove ball bearing

❑ To be renewed after
m
at
om
each removal of drive

ion
c
shaft
in t
or
his
te
❑ Pressing off
a
do
riv
⇒ page 92
p
cum
for
en
g
n
t.
yi Co
⇒ page 93 ht. Cop py
rig
❑ Pressing on rig ht
py by
Vo
⇒ page 93
co lksw
by
cted agen
Prote AG.
5 - Gear wheel for 5th gear
❑ Offered as replacement
part together with input
shaft
❑ Pressing off
⇒ page 92
❑ Installation position: pe‐
ripheral groove -arrow-
faces deep groove ball
bearing.
❑ Pressing on
⇒ page 92
1. Input shaft 89
AG. Volkswagen AG d
agen oes
olksw not
yV gu
Arteon 2018 ➤ , Golf 2017 ➤ , Golf ed Variant 2017 ➤ , Polo 2018 ➤ , T-Ro
b ara...
nt
ris
6-speed manual gearbox 02Q,uth0BB and 0FB, removed - Edition 03.2019 ee or
o
a ac
ss
6 - Input shaft
ce
e
nl
pt
du
an
❑ With gear wheels for 3rd, 4th and 6th gears
itte
y li
erm
ab
7 - Cylindrical roller bearing
ility
ot p
wit
❑ With retaining ring
, is n
h re
hole
spec
es, in part or in w
t to the co
❑ Installation position: retaining ring in bearing faces input shaft
8 - Clutch housing
rrectness of i
l purpos
1.2 Dismantling and assembling input shaft
nform
mercia
at
om
io
equipment required
n
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.

♦ Press tool - VW 408 A-
90 Rep. gr.35 - Gears, shafts

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
♦ Tube - 2040-
spec
es, in part or in w

t to the co
♦ Thrust piece - 32 - 111-

rrectness of i
♦ Inductive heater - VAS 6414-

l purpos
♦ Splitter - VAS 251 411- , or e.g. splitter 22 … 115 mm - Kukko

17/2-
nform
ercia

21/5-
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.
1. Input shaft 91

Kukko 22/2-
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
♦ Feeler gauge
t to the co
Dismantling input shaft
– Remove retaining ring for deep groove ball bearing.
rrectne
Pressing off deep groove ball bearing
– Apply splitter -A- to peripheral groove for retaining ring in deep
ss
groove ball bearing.
o
cial p
f inform
A - Splitter - VAS 251 411- , or e.g. splitter 22 … 115 mm - Kukko
mer
17/2-
atio
om
n
– Deep groove ball bearing and gear wheel for 5th gear can also
c
i
or
n
be pressed off together as a unit. To do this, fit splitter -A-
thi
te
sd
a
beneath gear wheel for 5th gear, as shown in illustration.

iv
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
. rig
Pressing off 5th gear wheel
t
gh ht
pyri by
Vo
co
A - Splitter - VAS 251 411- , or e.g. splitter 22 … 115 mm - Kukko
by lksw
cted agen
Prote
17/2-
AG.
Assembling input shaft
Heating and pressing on gear wheel for 5th gear

• Groove -arrow- in gear wheel must face upwards.

Installation position of deep groove ball bearing/pressing on deep

groove ball bearing
• Installation position of deep groove ball bearing: Groove for
retaining ring points upwards -arrow A-. Shoulder -arrow B-
must face gear wheel for 5th gear.
– Determine retaining ring for deep groove ball bearing on input
shaft ⇒ page 93 and install.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
Determining thickness of retaining ring ss
ce
e
nl
pt
du
– Insert a 1.86 mm thick retaining ring -A- in groove of input shaft
an
itte
y li
and press upwards.
erm
ab
ility
ot p
– Measure distance between deep groove ball bearing -B- and
wit
, is n
installed retaining ring -A- using feeler gauge -C-.
h re
hole
– Remove retaining ring (only used for measuring purposes).
spec
es, in part or in w
t to the co
– Determine retaining ring from table.
rrectness of i
Note
l purpos
Allocate retaining rings using ⇒ Electronic parts catalogue (ET‐

KA) .
nf
ercia
orm
The following securing clips are available:
m
atio
om
n in
c
Measured value Retaining ring thick‐ Axial play (mm)

or
(mm) ness (mm) thi

te
sd
iva
o
r
0.01…0.05 1.86 0.01…0.05

rp
cu
o
m
f
en
ng
0.05…0.07 1.89 0.01…0.05

t.
yi Co
op
0.07…0.10 1.92 0.01…0.05
C py
t. rig
gh ht
yri
0.10…0.13 1.95 0.01…0.05
p by
co Vo
by lksw
cted
0.13…0.16 1.98 0.01…0.05
agen
Prote AG.
Pulling cylinder roller bearing out of clutch housing

– When pulling out, squeeze together retaining ring -arrow- of
cylindrical roller bearing, using pliers -C-.
Kukko 22/2-
21/5-
1. Input shaft 93
Pressing cylindrical roller bearing into clutch housing

– When pressing in, squeeze together retaining ring -arrow- of
cylinder roller bearing, using pliers -A-.
– Remove pliers before cylindrical roller bearing is in installation
position. Retaining ring must engage in groove of clutch hous‐
ing.
1.3 Renewing input shaft seal

♦ Extractor hook - T20143/1-
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
tio
♦ Sealing grease
n in
r
te o
thi

s
iva
do
r
rp
– Remove manual gearbox.

um
fo
en
ng
t.
yi
– Remove clutch slave cylinder together with clutch release
Co
op py
bearing ⇒ page 13 .
. C rig
ht ht
rig by
copy Vo
by lksw
cted agen
Prote AG.

– Lever out input shaft seal.
Note
Do not damage oil seal running surface on input shaft.
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
– Half-fill space between sealing lip and dust lip of new seal with
an
itte
y li
sealing grease . erm
ab
ility
ot p
– Lightly moisten outer circumference of oil seal with gear oil.
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
– Drive in input shaft oil seal flush.
orm
m
atio
m
– Install clutch slave cylinder together with clutch release bear‐

o
n in
c
ing ⇒ page 13 .
or
thi
te
sd
– Install manual gearbox ⇒ Rep. gr. 34 ; Removing and instal‐
iva
o
r
ling gearbox .
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.
1. Input shaft 95
2 Output shaft
⇒ “2.1 Assembly overview - output shaft”, page 96
⇒ “2.2 Dismantling and assembling output shaft”, page 103
⇒ “2.3 Adjusting output shaft”, page 125
2.1 Assembly overview - output shaft

⇒ “2.1.1 Assembly overview - output shaft for 1st to 4th gears”,
page 96
⇒ “2.1.2 Assembly overview - output shaft for 5th, 6th and reverse
gears”, page 101 olks
wage es n
o
yV t gu
db ar
2.1.1 Assembly overview
tho
ris - output shaft for 1st to 4th gears
e an
tee
or
au ac
ss
ce
e
nl
Note
pt
du
an
itte
y li
erm
ab
♦ Heat tapered roller bearing inner races and synchro-hub to about 100 °C with the inductive heater - VAS
ility
ot p
6414- before installing. Wear protective gloves when doing this.
wit
, is n
h re
♦ On reinforced gearboxes, a collar bushing is installed instead of thrust washers ⇒ Item 19 (page 98) and
hole
the retaining ring ⇒ Item 20 (page 98) . Following components have been modified: Output shaft for 1st
spec
to 4th gear, synchromeshed gear for 4th gear, and needle bearing for synchromeshed gear for 4th gear
es, in part or in w
t to the co
⇒ page 100 . Refer to the ⇒ Electronic parts catalogue (ETKA) for component allocation.
♦ If output shaft or tapered roller bearings have been renewed, adjust output shaft ⇒ page 125 .
rrectness of i
♦ Always renew both tapered roller bearings together as a set.
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.

1 - Clutch housing
2 - Oil deflector ring
3 - Dished washer
❑ Pressing in
⇒ page 108 .
4 - Tapered roller bearing outer agen
AG. Volkswagen AG d
oes
race Volksw not
gu
by ara
❑ Removing ⇒ page 108 ris ed
nte
ho eo
❑ Pressing in s aut ra
c
⇒ page 109 . s
ce
e
nl
pt
du
5 - Tapered roller bearing inner
an
itte
y li
race
erm
ab
ility
❑ Pressing off
ot p
wit
⇒ page 108
, is n
h re
❑ Pressing on
hole
spec
⇒ page 108
es, in part or in w
t to the co
6 - Output shaft
❑ For 1st to 4th gears
rrectness of i
❑ Note various versions
⇒ page 100
l purpos
❑ For allocation, refer to

gearbox codes given in
nform
ercia
⇒ Electronic Parts
Catalogue (ETKA) .
m
at
om
i
❑ Adjusting ⇒ page 125
on
c
in t
or
7 - Needle bearing
his
ate
do
riv
❑ For 2nd gear

p
cum
for
en
g

n
t.
yi Co
gear Cop py
t. rig
gh ht
yri
9 - Inner ring for 2nd gear p by
o Vo
by c lksw
cted
❑ Check lugs for scoring
agen
Prote AG.

❑ Checking synchro-ring, outer ring and inner ring together for wear ⇒ page 111
10 - Outer bearing race for 2nd gear
❑ Check for scoring or signs of abnormal wear
11 - Synchro-ring for 2nd gear
❑ Check inner surface for scoring and radial contact scoring.
12 - Locking collar with synchro-hub for 1st and 2nd gears
❑ After removing retaining ring, press off with 2nd gear synchromeshed gear ⇒ page 111
❑ Dismantling ⇒ page 112
❑ Assembling locking collar and synchro-hub ⇒ page 112 and ⇒ page 112
❑ Pressing on ⇒ page 113
2. Output shaft 97
13 - Retaining ring
14 - Synchro-ring for 1st gear
❑ Fitting position ⇒ page 113 olkswage es n
ot g
yV
❑ Checking synchro-ring, outer ring and inner ringsetogether
d b for wear ⇒ page 111 ua
ran
ri tee
ho
15 - Outer ring for 1st gear au
t or
ac
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
16 - Inner ring for 1st gear ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
17 - Needle bearing
rrectness of i
❑ For 1st gear
l purpos
18 - Synchromeshed gear, 1st gear

❑ Place on output shaft ⇒ page 113
nform
ercia
19 - Thrust washer
m
a
❑ For 1st and 4th gear
com
tion in
❑ Qty. 2
r
te o
thi
❑ Insert lugs of thrust washer in holes of output shaft
s
iva
do
r
rp
c
❑ Not installed on reinforced gearboxes.
um
fo
en
ng
t.
yi
20 - Retaining ring
Co
Cop py
. rig
❑ Secures thrust washers for 1st and 4th gears in position on output shaft.
t
gh ht
pyri by
Vo
o
❑ Not installed on reinforced gearboxes.
c by lksw
cted agen
Prote AG.
21 - Collar bushing
❑ For 4th gear needle bearing
❑ Installed on reinforced gearboxes only ⇒ page 100
❑ For allocation, refer to gearbox codes given in ⇒ Electronic Parts Catalogue (ETKA) .
22 - Needle bearing
❑ For 4th gear
❑ Note various versions ⇒ page 100
23 - Synchromeshed gear for 4th gear
❑ Note various versions ⇒ page 100
24 - Synchro-ring for 4th gear
❑ Made from sheet brass or steel metal
❑ Check for wear ⇒ page 114
25 - Locking collar with synchro-hub for 3rd and 4th gears
❑ After removing retaining ring, pull off with 4th gear synchromeshed gear ⇒ page 110 .
❑ Installation position, locking collar and synchro-hub ⇒ page 115

26 - Retaining ring
27 - Synchro-ring for 3rd gear
28 - Outer ring for 3rd gear
29 - Inner ring for 3rd gear
AG. Volkswagen AG d
❑ Checking synchro-ring, outer ring oand agen
lksw inner ring together forewear
no ⇒ page 111
o s
yV t gu
db ara
30 - Needle bearing rise nte
tho eo
❑ For 3rd gear au ra
c
ss
31 - Synchromeshed gear for 3rd gear
ce
le
un
pt
an
d
❑ Place on output shaft ⇒ page 115

itte
y li
erm
ab
32 - Tapered roller bearing inner race
ility
ot p
wit
❑ Pulling off ⇒ page 109
is n
h re
ole,
spec
33 - Retaining ring
t to the co
❑ If tapered roller bearing inner race and output shaft are renewed, redetermine ⇒ page 109 .
rrectne
ss o
cial p
f
35 - Shim inform
mer
❑ Determining thickness ⇒ page 125

atio
m
o
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.
2. Output shaft 99
Gearbox with reinforcement measures

Reinforcements in vicinity of synchromeshed gear for 4th gear
Following components are affected:
1- Output shaft
Distinguishing features ⇒ page 100
2- Collar bushing
3- Needle bearing for 4th gear
4- Synchromeshed gear for 4th gear
Note
♦ Under no circumstances may parts of gearboxes with a rein‐

forced 4th gear be installed together with parts of gearboxes
without a reinforced 4th gear. Refer to the ⇒ Electronic parts
catalogue (ETKA) for component allocation.
♦ Removal and installation of modified components
⇒ page 103 . agen
AG. Volkswagen AG d
oes
olksw not
V gu
d by ara
ise nte
Distinguishing between output shaftsuthor eo
a ra
ss c
Output shaft -1- - reinforced -2- - not reinforced ce
e
nl
pt
du
Dimension -a- 40.1 mm 42.0 mm

an
itte
y li
erm
ab
-arrow A- Shoulder for attach‐ - ility
ot p
ing collar bushing

wit
, is n
⇒ Item 21 (page 98)

h re
hole
-arrow B- - 2 opposing bores and

spec
peripheral groove for

es, in part or in w
t to the co
supporting thrust
washers
⇒ Item 19 (page 98)
rrectness of i
Distinguishing needle bearing and synchromeshed gears for 4th

l purpos
gear
nform
ercia
Synchromeshed -1- - reinforced -2- - not reinforced

gear for 4th gear
m
at
om
io
Dimension -a- 52.0 mm 48.0 mm

n
c
in t
or
his
te
Needle bearing for -3- - reinforced -4- - not reinforced

a
do
riv
4th gear synchro‐

p
cum
or
meshed gear
f
en
ng
t.
yi Co
op
Dimension -b- 52.0 mm 48.0 mm C py
t. rig
gh ht
yri
• On reinforced gearboxes, needle bearing -3- is fitted onto p by
o Vo
by c lksw
collar bushing -5-. Prote
cted AG.
agen

. Volkswagen AG
gen AG d
Arteon 2018 ➤ , Golf 2017Vo➤ , aGolf Variant 2017 ➤ o, ePolo
lksw s no 2018 ➤ , T-Ro ...
tg
y
ise
d b 02Q, 0BB and 0FB, removed -uaEdition
ran 03.2019
r tee
ho
ut or
2.1.2 Assembly overview - output shaft for 5th, 6th and reverse gears
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
Note
ab
ility
ot p
wit
, is n
♦ Heat tapered roller bearing inner races and synchro-hub to about 100 °C with the inductive heater - VAS
h re
6414- before installing. Wear protective gloves when doing this.
hole
spec
♦ If output shaft or tapered roller bearings have been renewed, adjust output shaft ⇒ page 130 .
es, in part or in w
t to the co
rrectness of i
1 - Clutch housing
l purpos
2 - Washer
nf
ercia
❑ Always 0.65 mm thick
orm
m
atio
3 - Tapered roller bearing outer
om
race
n in
or c
thi
te
sd
iva
o
❑ Pressing in
r
rp
cu
o
m
⇒ page 121 .
f
en
ng
t.
yi Co
op
4 - Tapered roller bearing inner C py
t. rig
race
gh ht
pyri by
Vo
o
by c
lksw
cted agen
Prote AG.
❑ Pressing on
⇒ page 125
5 - Output shaft
❑ For 5th, 6th and reverse
gears
❑ Adjusting ⇒ page 130
6 - Reverse gear synchro-hub
❑ Pressing off
⇒ page 122
⇒ page 123
❑ Pressing on
⇒ page 123
7 - Retaining ring
8 - Reverse gear locking collar
❑ With synchro-ring
9 - Needle bearing
❑ For synchromeshed
gear for reverse gear
10 - Synchromeshed gear for reverse gear
11 - Sleeve
❑ Press off together with synchromeshed gear for reverse gear ⇒ page 122
❑ Installation position: wide shoulder of sleeve faces synchromeshed gear for reverse gear
12 - Retaining ring
13 - Needle bearing
❑ For 6th gear
2. Output shaft 101

14 - Synchromeshed gear for 6th gear

16 - Locking collar with synchro-hub for 5th and 6th gears
❑ After removing circlip, press off with 6th gear synchromeshed gear ⇒ page 122
17 - Retaining ring
18 - Needle bearing
❑ For 5th gear
20 - Synchromeshed gear, 5th gear lkswage es n
o ot g
yV ua
21 - Tapered roller bearing inner race ir se
d b ran
tee
o
❑ Pulling off ⇒ page 121 auth or
ac
ss
ce
e
nl
pt
du
an
22 - Retaining ring
itte
y li
erm
ab
❑ If tapered roller bearing inner race and output shaft are renewed, redetermine ⇒ page 125 .
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
24 - Shim
❑ Determining thickness ⇒ page 130
rrectness of i
l purpos
26 - Spring
nform
ercia
27 - Sliding sleeve
m
at
om
io
28 - Synchro-hub
n
c
in t
or
his
e
29 - Locking piece
at
do
riv
❑ Qty. 3
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.

2.2 Dismantling and assembling output

shaft
⇒ “2.2.1 Dismantling and assembling output shaft for 1st
olks
wagto
e
4th es n
ot g
gears”, page 103 d byV ua
ran
ir se tee
⇒ “2.2.2 Dismantling and assembling outpututh shaft for 5th, 6th and
o
or
reverse gears”, page 116 ss
a ac
ce
le
un
2.2.1 Dismantling and assembling output shaft for 1st to 4th gears
pt
an
d
itte
y li
erm
ab
ility
Special tools and workshop ot p
wit
is n
equipment required
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.

♦ Tube - VW 415A-
2. Output shaft 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
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.

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.

♦ Tube - VW 516-
♦ Tube - VW 519-
♦ Thrust plate - 40-105-
2. Output shaft 105

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
♦ Drift sleeve - 40-20-
agen
Prote AG.
♦ Drift sleeve - 40-21-

♦ Supplementary set for engine and gearbox support - VW 540/1
B-
♦ Tapered roller bearing puller - V.A.G 1582-
♦ Grip tool - V.A.G 1582/7-

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.

21/7-
♦ Internal puller - VAS 6775- , or e.g. internal puller - Kukko 21/8-
♦ Puller - VAS 251 419- , or e.g. puller - Kukko 18/2-
Kukko 22/2-
Pulling dished washer -A- out of output shaft
2. Output shaft 107

Pressing dished washer into output shaft

Dimension “a” = 2 mm
olksw
Press off tapered roller bearing inner race on sside
wagefacing clutch
n AG. V agen AG
does
housing by
Volk not
gu
d ara
se nte
A - Splitter - VAS 251 411- or e.g. splitter
tho
ri - Kukko 17/2- e 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
Press on tapered roller bearing inner race on side facing clutch
housing
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
op py
Pulling tapered roller bearing outer race out of clutch housing
t. C rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Kukko 22/2- Prote AG.
B - Internal puller - VAS 6775- , or e.g. internal puller - Kukko 21/8-

Pressing tapered roller bearing outer race into clutch housing

– Support clutch housing with drift sleeve - 40-20- directly below
bearing support.
. Volkswagen AG
Pulling off tapered roller bearing inner race on side facing kgearbox
swa
gen AG does
not
housing by
Vol
gu
ara
d
ise nte
Before installing tapered roller bearing puller observe
ho
r
the follow‐ eo
ut
ing: ss a ra
c
ce
le
– Remove retaining ring for tapered roller bearing inner race on

un
pt
an
d
side facing gearbox housing.

itte
y li
erm
ab
– Insert press tool - VW 431- into output shaft and place thrust
ility
ot p
plate - 40-105- on that.
wit
is n
h re
ole,
spec
t to the co
Press on tapered roller bearing inner race on side facing gearbox
housing
rrectne
– Determine and install retaining ring ⇒ page 109 .
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
Determining thickness of retaining ring
t. rig
gh ht
pyri by
Vo
o
– Determine the thickest circlip which will just fit and install it. by c lksw
cted agen
Prote AG.
Note
Allocate retaining rings using ⇒ Electronic parts catalogue (ET‐

KA) .
The following securing clips are available:

Thickness (mm)
1.79 1.83 1.86 1.89
1.92 1.95 1.98
2. Output shaft 109

Pulling outer race for tapered roller bearing out of gearbox hous‐
ing
Kukko 22/2-
21/7-
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
Pressing tapered roller bearing outer race into gearbox housing

un
pt
an
d
itte
– Fit shim under outer race.
y li
rm
ab
pe
ility
– Support gearbox housing with thrust piece - 2050- below bear‐
ot
wit
ing support.
, is n
h re
hole
Dismantling output shaft
spec
es, in part or in w
t to the co
Note
rrectness of i
Pulling off tapered roller bearing inner race on side facing gearbox
housing ⇒ page 109 .
l purpos
nform
ercia
Pulling off synchro-hub and locking collar for 3rd and 4th gears
with synchromeshed gear for 4th gear
m
a
com
tio
– First remove retaining ring.

n in
r
te o
thi
A - Puller - VAS 251 419- , or e.g. puller - Kukko 18/2-

s
iva
do
r
rp
B - Splitter - VAS 251 411- or e.g. splitter - Kukko 17/2-

um
fo
en
ng
t.
yi
– Then remove retaining ring ⇒ Item 20 (page 98) and thrust
Co
op py
washers ⇒ Item 19 (page 98) . t. C rig
gh ht
pyri by
Vo
– Next step is to remove synchromeshed gear for 1st gear with
o
by c lksw
cted agen
synchro-rings. Prote AG.
On reinforced gearboxes, the collar bushing -B- needs to be

pressed off together with the synchromeshed gear for 1st gear
-C-.
A - Splitter - VAS 251 411- or e.g. splitter - Kukko 17/2-
– Apply splitter -A- behind constant meshed teeth of synchro‐
meshed gear for 1st gear.

Pressing off locking collar and synchro-hub for 1st and 2nd gears
After removing retaining ring, press off synchromeshed gear for
2nd gear together with locking collar and synchro-hub.
Assembling output shaft
Note
Heat inner races of tapered roller bearings and synchro-hub with

the inductive heater - VAS 6414- to approx. 100°C and press them
in to stop so there is no axial clearance.
Checking synchro-ring for 1st, 2nd and 3rd gears for wear to‐
gether with outer and inner races
– Check inner contact surface of synchro-ring -arrow- for scoring
and radial contact scoring; if necessary, renew inner race,
outer race and synchro-ring
– Place inner ring, outer ring and synchro-ring on cone of inner
ring.
– Press down and simultaneously rotate synchro-ring to achieve
proper seating.
– Measure gap size -a- at 3 points offset by 120° using feeler
gauge.
AG. Volkswagen AG d
agen
– Make a note of average value.
Vol
ksw
oes
not
gu
y
db ara
se
Gap -a- Installation
tho
ri dimen‐ Wear limit nte
eo
au sion ra
c
ss
1st and 2nd gears 1.2 … 1.8 mm 0.8 mm
ce
e
nl
pt
du
an
itte
y li
Gap -a- Installation dimen‐ Wear limit

erm
ab
sion
ility
ot p
wit
, is n
3rd gear 1.2 … 2.0 mm 0.8 mm

h re
hole
spec
es, in part or in w
t to the co
Note
Always renew inner ring, outer ring and synchro-ring together.

rrectness of i
– Set 2nd gear synchromeshed gear with needle bearing in

l purpos
place.
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.
2. Output shaft 111

Installation of outer ring, inner ring and synchro-ring for 2nd gear
– Place inner ring -A- on synchromeshed gear for 2nd gear.
Lugs -1- point away from synchromeshed gear.
– Fit outer ring -B-.
Lugs -2- engage in notches -3- of synchromeshed
gen AG
. Volkswgear.
agen AG
wa does
olks not
– Fit synchro-ring -C-. byV gu
ara
ed nte
ris
Larger notches -4- engage tho in lugs -1- of inner ring -A-. eo
au ra
c
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
Dismantling and assembling locking collars and synchro-hubs of
rrectness of i
1st and 2nd gears as well as 3rd and 4th gears
l purpos
1- Spring
2- Locking piece
nform
ercia
3- Sliding sleeve
m
a
com
t
4- Synchro-hub
ion in
r
te o
– Slide locking collar over synchro-hub.

thi
s
iva
do
r
In 3rd and 4th gear, wide collar of synchro-hub and, if present,

rp
cum
fo
shoulder on locking collar point in one direction.

en
ng
t.
yi Co
op
Notches for locking pieces in synchro-hub and locking collar must C py
ht. rig
align. rig ht
py by
co Vo
by lksw
cted agen
Prote
Assembling locking collars and synchro-hubs for 1st and 2nd
AG.
gears as well as 3rd and 4th gears

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

2nd gears
Identification groove -arrow 1- and narrow collar -arrow 2- of syn‐
chro-hub face 1st gear.

Heating and pressing on locking collar and synchro-hub for 1st

and 2nd gears
Pins -A- of synchro-ring engage in notches -B- of synchro-hub.
– Install retaining ring.
Installation of synchro-ring outer ring and 1st gear inner ring

– Insert synchro-ring -A- in synchro-hub for 1st gear and 2nd
gear.
Lugs -1- engage in notches -2- of synchro-hub.
– Insert outer ring -B- into synchro-ring.
Lugs -3- point away from synchro-ring. AG. Volkswagen AG d
agen oes
lksw not
– Insert inner ring -C- into outerbring.
yV
o gu
ara
d
ise nte
Lugs -4- engage in larger notches
uthor
-5- of synchro-ring -A-. eo
a 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
Install synchromeshed gear for 1st gear with needle bearing

• Synchro-ring -1- is located with lugs -arrow A- in notches of
rrectne
synchro-hub -2-.
Pins -arrows B- of outer ring engage in notches -arrows C- of
ss o
synchromeshed gear -3-.

cial p
f inform
– Insert thrust washers for 1st and 4th gears into output shaft
mer
⇒ Item 19 (page 98) and ⇒ Item 20 (page 98) .

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 113

On reinforced gearboxes, press on collar bushing -A- as far as

stop.
• Installation position of collar bushing -A-: Collar -arrow- points
towards synchromeshed gear for 1st gear.
– Then fit synchromeshed gear for 4th gear with needle bearing.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
Checking synchro-ring for 4th gear for wear
-A- = Synchro ring made from brass
rrectness of i
l purpos
sion
4th gear 1.0 … 1.7 mm 0.5 mm
nform
ercia
-B- = Synchro ring made from sheet steel

m
a
com
tio
n in
r
te o
sion
thi
s
iva
do
4th gear 1.3 … 2.4 mm 0.8 mm
r
rp
cum
fo
en
ng
– Press synchro-ring onto cone of synchromeshed gear and

t.
yi Co
op
measure gap -a- using feeler gauge. C py
t. rig
gh ht
yri by
– Measure gap size -a- at 3 points offset by 120° using feeler cop Vo
by lksw
gauge. cted agen
Prote AG.

Installation position of locking collar with synchro-hub for 3rd and

4th gears
Wider shoulder of synchro-hub -arrow- faces 3rd gear.
– Place 4th gear synchro-ring on 4th synchromeshed gear.
Heat and press on synchro-hub with locking collar for 3rd and 4th
gears
– Turn synchro-ring for 4th gear so that grooves align with lock‐
ing pieces.
Installation of synchro-ring outer ring and 3rd gear inner ring

– Insert synchro-ring -A- in synchro-hub for 3rd gear and 4th
gear.
Lugs -1- engage in notches -2- of synchro-hub.
– Insert outer ring -B- into synchro-ring.
Lugs -3- point away from synchro-ring.
– Insert inner ring -C- into outer ring. . Volkswagen AG
gen AG does
swa
Lugs -4- engage in larger notches -5- of synchro-ring
yV
olk -A-. not
gu
d b 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
Install synchromeshed gear for 3rd gear with needle bearing

es, in part or in w
t to the co
• Synchro-ring -1- is located with lugs -arrow A- in notches of

synchro-hub -2-.
rrectness of i
Pins -arrows B- of outer ring engage in notches -arrows C- of

synchromeshed gear -3-.
l purpos
nform
ercia
Note
m
at
om
♦ Press on tapered roller bearing inner race ⇒ page 109 .

ion
c
in t
or
♦ Determine retaining ring for tapered roller bearing inner race

his
ate
⇒ page 109 .
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
by
115
copy Vo
by lksw
cted agen 2. Output shaft
Prote AG.
gen Variant 2017 ➤ AG. Volkswagen A
Arteon 2018 ➤ , Golf 2017 o➤ , aGolf
ksw , ePolo
G do
s no 2018 ➤ , T-Ro ...
V l t gu
ed b 02Q, 0BB and 0FB, removed - Edition
y ara 03.2019
ris nte
tho eo
2.2.2 Dismantling and assembling output shaft for 5th, 6th and reverse gears au ra
ss c
ce
e
nl
pt
du
an
itte
y li
Special tools and workshop erm
ab
equipment required
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.

♦ Tube - VW 415 A-

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
op py
t. C rig
gh ht
pyri by
Vo
o
c by lksw
cted agen
Prote AG.
♦ Mounting rail - VW 457-
2. Output shaft 117

AG. Volkswagen AG d
agen oes
olksw not
yV g
Arteon 2018 ➤ , Golf 2017 ➤ s,edGolf Variant 2017 ➤ , Polo 2018 ➤ ,uaT-Ro
b ran ...
ri te
6-speed manual gearbox 02Q,tho 0BB and 0FB, removed - Edition 03.2019e o
au ra
c
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
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.

♦ Installing sleeve - VW 455-
♦ Thrust plate - VW 510-
♦ Tube - VW 516-
♦ Tube - VW 519-
♦ Thrust plate - 30 - 11-

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
♦ Drift sleeve - 40 - 20-
es, in part or in w
t to the co
♦ Tube - 3296- 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.
2. Output shaft 119

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.

21/7-
Kukko 22/2-
Kukko 22/2-
21/7-
Note
After pulling out, check shim for damage and renew if necessary.

Pressing tapered roller bearing outer race into clutch housing

– Fit shim under outer race.
– Support clutch housing with drift sleeve - 40 - 20- directly below
bearing support.
ing
Kukko 22/2-
21/7-

– Support gearbox housing with thrust piece - 2050- below bear‐
ing support.
Dismantling 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
Pulling off tapered roller bearing inner race on side facing gearbox
rm
ab
housing
pe
ility
ot
wit
Before installing tapered roller bearing puller observe the follow‐

, is n
h re
ing:
hole
spec
– Remove retaining ring for tapered roller bearing inner race on

es, in part or in w
t to the co
side facing gearbox housing.

– Place press tool - VW 431- and thrust plate - 40-105- onto
output shaft.
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.
2. Output shaft 121

Pressing off synchro-hub and locking collar for 5th and 6th gears
with synchromeshed gear for 6th gear
Pressing off sleeve -A- together with synchromeshed gear for re‐
verse gear
Pressing off reverse gear synchro-hub

AG. Volkswagen A
A - Splitter - VAS 251 411- orlkse.g.
wagesplitter - Kukko 17/2-
n G do
es n
o o t gu
yV
edb ara
ris nte
tho eo
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
Pulling off tapered roller bearing inner race on side facing clutch
housing
t to the co
– Before setting up pulling device, set thrust plate - 30 - 11- on

output shaft.
rrectne
Assembling output shaft

ss o
cial p
Note
inform
mer
Heat inner races of tapered roller bearings and synchro-hub with

atio
m
the inductive heater - VAS 6414- to approx. 100°C and press them
o
n
c
i
or
in to stop so there is no axial clearance.

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.

. Volkswagen AG
gen AG does
Installation position of reverse gear synchro-hub
Vol
ksw
a
not
by gu
d ara
Stop of reverse gear lockingocollar
ris
e -arrow A- faces teeth of output nte
shaft -arrow B-. auth eo
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
Heat reverse gear synchro-hub and press on
rrectness of i
l purpos
– Place reverse gear locking collar on reverse gear synchro-

hub.
nf
ercia
o
– Put on reverse gear synchromeshed gear with needle bearing.
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
Pressing on sleeve -A-
gh ht
pyri by
Vo
co lksw
by
Installation position: Wide collar faces reverse gear synchro‐ cted agen
Prote AG.
meshed gear.
Checking synchro-rings for 5th and 6th gear for wear

-A- = Synchro ring made from brass
sion
5th and 6th gear 1.0 … 1.7 mm 0.5 mm
-B- = Synchro ring made from sheet steel

sion
5th and 6th gear 1.2 … 2.1 mm 0.8 mm
– Press synchro-ring onto cone of synchromeshed gear and
measure gap -a- using feeler gauge.
– Measure gap size -a- at 3 points offset by 120° using feeler
gauge.
2. Output shaft 123

Dismantling and assembling locking collar and synchro-hub for

5th and 6th gears
1- Spring
2- Locking piece
3- Sliding sleeve
4- Synchro-hub
– Slide locking collar over synchro-hub.
Notches for locking pieces in synchro-hub and locking collar must
align.
Assembling locking collar with synchro-hub for 5th and 6th gears
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.
AG. Volkswagen AG d
agen
– Install synchromeshed
Vol
ksw gear for 6th gear witheneedle
o s
not
g
bearing.
y ua
db ran
– Fit synchro-ring
or
ise for 6th gear. tee
th or
au ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
Pressing on locking collar and synchro-hub for 5th and 6th gears
wit
, is n
h re
hole
Some locking collars have a chamfer on their outer diameter.

spec
es, in part or in w
Installation position: The chamfer on the outer diameter of the

t to the co
sliding sleeve points towards the 5th gear synchromeshed gear.

– Turn synchro-ring so that grooves align with locking pieces.
rrectness of i

l purpos
– Fit synchro-ring for 5th gear.

nf
ercia
– Install 5th gear synchromeshed gear with needle bearing.

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.

olkswagen AG
wag en AG. V
Arteon 2018 V➤olk,s Golf 2017 ➤ , Golf Variant
does
not2017 ➤ , Polo 2018 ➤ , T-Ro ...
gu
6-speed
sed manual gearbox 02Q, 0BB and 0FB,
by ara removed - Edition 03.2019
n
ri tee
ho
ut or
Press on tapered roller bearing
ss
a inner race on side facing gearbox ac
housing
ce
le
un
pt
an
d
– Determine and install retaining ring ⇒ page 125 .
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
Determining thickness of retaining ring

– Determine the thickest circlip which will just fit and install it.
nform
ercia
– Determine retaining ring from table. Part number ⇒ Electronic

m
a
com
t
parts catalogue (ETKA) .
ion in
r
te o
The following retaining rings are available:
thi
s
iva
do
r
rp
c
Thickness (mm)
um
fo
en
ng
t.
1.79 1.89 Cop
yi
1.98 Co
py
1.83 1.92 ht. rig
rig ht
py by
Vo
1.86 1.95
co lksw
by
cted agen
Prote AG.
Press on tapered roller bearing inner race on side facing clutch

housing
2.3 Adjusting output shaft

⇒ “2.3.1 Adjusting output shaft for 1st to 4th gears”, page 125
⇒ “2.3.2 Adjusting output shaft for 5th, 6th and reverse gears”,
page 130
2.3.1 Adjusting output shaft for 1st to 4th gears
2. Output shaft 125


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

s o
cial p
f i

nform
mer
♦ Universal dial gauge holder - VW 387-

atio
om

c
i
or
n thi
te

sd
iva
o
pr
cum
r
♦ Assembly tool - VW 792-

fo
en
ng
t.
yi Co
♦ Retainer - VW 801- 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
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
21/7-
nf
ercia
Kukko 22/2-
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
cted agen
Prote AG.
2. Output shaft 127

♦ Dial gauge - VAS 6080-

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
(Determining shim for output shaft)
It is necessary to readjust the output shaft when the following
rrectness of i
components are renewed:
l purpos
♦ Gearbox housing
♦ Clutch housing
nf
ercia
orm
♦ Output shaft for 1st to 4th gear or
m
atio
om
n in
♦ Tapered roller bearing for output shaft
or c
thi
te
sd
Adjustment overview ⇒ page 161
iva
o
r
rp
cu
Prerequisites:
o
m
f
en
ng
t.
yi Co
• Sealing surfaces of clutch and gearbox housings must be free Cop py
. rig
of sealant .
t
gh ht
pyri by
Vo
co
• When taking measurements, install only the output shaft to be
by lksw
cted agen
Prote
measured.
AG.
– Press tapered roller bearing outer race with 1.70 mm thick

shim into gearbox housing to stop. In the process, support
gearbox housing using thrust piece - 2050- directly below
bearing support.
– Set complete output shaft for 1st to 4th gears in clutch housing.

– Fit gearbox housing in position and tighten bolts -A- as well as

-B- alternately and diagonally.
– Fit measuring tools and secure to clutch housing using bolt

-arrow-.
– Set dial gauge (3 mm measuring range) to “0” with 1 mm pre‐
load.
– Loosen clutch housing/gearbox housing securing bolts diag‐
onally until the bolts release the gearbox housing or output
shaft.
– Read and note value on dial gauge (example: 0.14 mm).
AG. Volkswagen AG d
agen oes
o lksw not
Note byV gu
ara
ed
ris nte
ho eo
ut
♦ If no value is indicated
ss a when clutch housing/gearbox housing ra
c
securing bolts are loosened:
ce
e
nl
pt
du
an
♦ Fit 1.95 mm shim or, if necessary, 2.20 mm shim for the meas‐
itte
y li
urement instead of 1.70 mm shim.

erm
ab
ility
ot p
♦ Allocate shims using ⇒ Electronic parts catalogue (ETKA) .

wit
, is n
h re
hole
Determining thickness of shim

spec
es, in part or in w
t to the co
Specified bearing preload is obtained as follows:

Subtracting measured value (0.14 mm) from inserted shim
(1.70 mm).
rrectness of i
Add a constant value for preload (0.20 mm).

l purpos
Example:
nform
ercia
Installed shim 1.70 mm

m
at
- Measured value 0.14 mm

om
ion
c
+ Preload (constant) 0.20 mm

in t
or
his
te
Shim thickness 1.76 mm

a
do
priv
cum
or
– Determine thickness of shim from table.

f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
2. Output shaft 129

– Remove gearbox housing and pull tapered roller bearing outer

race out from gearbox housing.
Kukko 22/2-
21/7-
– Remove inserted shim (1.70 mm thick) from gearbox housing.
Table of shims
Thickness (mm)
1.45 1.75 2.05
n AG. Volkswagen AG d
1.50 ksw1.80
age
2.10
oes
not
Vol gu
1.55 d by 1.85 2.15 ara
ise nte
or eo
1.60 aut
h 1.90 2.20 ra
ss c
1.65 1.95 2.25
ce
le
un
pt
1.70 2.00
an
d
itte
y li
rm
ab
The various thicknesses make it possible to achieve the exact
pe
ility
shim thickness required.
ot
wit
, is n
h re
– Determine part number of shim according to ⇒ Electronic
hole
spec
parts catalogue (ETKA) .
es, in part or in w
t to the co
– Press in tapered roller bearing outer race together with correct
shim (in example 1.75 mm). In the process, support gearbox
housing using thrust piece - 2050- directly below bearing sup‐
rrectness of i
port.
l purpos
Carrying out check measurement

• Determined shim installed.
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
– Fit measuring tools and secure to clutch housing using bolt Cop py
t. rig
-arrow-. opyri
gh by
Vo
ht
by c lksw
– Set dial gauge (3 mm measuring range) to “0” with 1 mm pre‐ Prote
cted agen
load.
AG.

shaft.
– If correct shim has been selected, dial gauge will indicate a
value between 0.15 mm to 0.25 mm.
Specified torques
♦ Gearbox housing to clutch housing ⇒ page 50
2.3.2 Adjusting output shaft for 5th, 6th and reverse gears


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.

♦ Assembly tool - VW 792-
2. Output shaft 131

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
ercia

m
a
com
tio
n in
r
te o
thi

s
iva
do
r
rp

um
fo
21/7-
en
ng
t.
yi Co
op py
♦ Counter support - VAS 251 623- , or e.g. counter support - t. C rig
gh ht
Kukko 22/2- yri
p by
co Vo
by lksw
cted agen
Prote AG.

♦ Dial gauge - VAS 6080- 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
It is necessary to readjust the output shaft when the following
rrectne
components are renewed:
♦ Gearbox housing
ss o
cial p
♦ Clutch housing
f inform
mer
♦ Output shaft for 5th, 6th and reverse gears or
atio
m
♦ Tapered roller bearing for output shaft

o
n
c
i
or
n thi
e

t
sd
iva
o
pr
c
Prerequisites:
um
r
fo
en
ng
t.
• Sealing surfaces of clutch and gearbox housings must be free
yi Co
op py
of sealant . t. C rig
gh ht
pyri by
• When taking measurements, install only the output shaft to be
co Vo
by lksw
cted
measured.
agen
Prote AG.
– Press tapered roller bearing outer race with 1.70 mm thick

shim into gearbox housing to stop. In the process, support
gearbox housing using thrust piece - 2050- directly below
bearing support.
– Place complete 5th, 6th and reverse gear output shaft in clutch
housing.
2. Output shaft 133

– Fit gearbox housing in position and tighten bolts -A- as well as

-B- alternately and diagonally.
– Fit measuring tools on clutch housing.

In case of protruding housing edges do the following: agen
AG. Volkswagen AG d
oes
olksw not
– Fit washers with a total thickness of 8 mm underneath assem‐ d by V gu
ara
bly tool - VW 792- -arrow-. orise nte
eo
th
u ra
– Set dial gauge (3 mm measuring range) to “0” withss a
1 mm pre‐ c
load.
ce
le
un
pt
an
d

itte
y li
rm
ab
pe
ility
shaft.
ot
wit
, is n
– Read and note value on dial gauge (example: 0.25 mm).
h re
hole
spec
es, in part or in w
t to the co
Note
♦ If no value is indicated when clutch housing/gearbox housing
rrectness of i
securing bolts are loosened:
l purpos
♦ Fit 1.95 mm shim or, if necessary, 2.20 mm shim for the meas‐
urement instead of 1.70 mm shim.
nform
ercia
♦ Allocate shims using ⇒ Electronic parts catalogue (ETKA) .

m
a
com
tio

n in
r
te o
thi
Specified bearing preload is obtained as follows:

s
iva
do
r
rp
Subtracting measured value (0.25 mm) from inserted shim

um
fo
en
g
(1.70 mm).
n
t.
yi Co
op py
Add a constant value for preload (0.20 mm).
t. C rig
gh ht
pyri by
Vo
Example:
co lksw
by
cted agen
Prote AG.
Installed shim 1.70 mm
- Measured value 0.25 mm
Shim thickness 1.65 mm
– Determine thickness of shim from table.

– Remove gearbox housing and pull tapered roller bearing outer

race out from gearbox housing.
Kukko 22/2-
21/7-
– Remove inserted shim (1.70 mm thick) from gearbox housing.
Table of shims
Thickness (mm)
1.50 1.80 2.10
1.55 1.85 2.15
1.60 1.90 2.20
1.65 1.95 2.25
1.70 2.00
1.75 2.05
– Part numbers ⇒ Electronic Parts Catalogue (ETKA) .
– Press in tapered roller bearing outer race together with correct

shim (in example 1.65 mm). In the process, support gearbox
housing using thrust piece - 2050- directly below bearing sup‐
port.
Carrying out check measurement
• Determined shim installed.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
– Fit measuring tools onto clutch housing.

un
pt
an
d
itte
In case of protruding housing edges do the following: y li

erm
ab
ility
ot p
– Fit washers with a total thickness of 8 mm underneath assem‐ wit

is n
bly tool - VW 792- -arrow-.

h re
ole,
– Set dial gauge (3 mm measuring range) to “0” with 1 mm pre‐

spec
load.
t to the co

shaft.
rrectne
– If correct shim has been selected, dial gauge will indicate a

s
value between 0.15 mm to 0.25 mm.

s o
cial p
f i
Specified torques
nform
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.
2. Output shaft 135

39 – Final drive - differential

AG. Volkswagen AG d
1 Oil seals y Volksw
agen oes
not
gu
d b ara
⇒ “1.1 Overview of fitting locations - seals”, page 136 rise nte
tho eo
au ra
⇒ “4.2 Renewing bevel box seals”, page 166 ss c
ce
e
nl
pt
du
an
itte
y li
Additional descriptions can be found in ⇒ Rep. gr. 39 ; Seals;
erm
ab
ility
Overview of fitting locations - seals .
ot p
wit
, is n
1.1 Overview of fitting locations - seals
h re
hole
spec
es, in part or in w
t to the co
1 - Seal
rrectness of i
❑ Four-wheel drive, for
right flange shaft
l purpos
❑ All-wheel drive, renew‐

ing with manual gearbox
nform
ercia
and bevel box installed

⇒ Rep. gr. 39 ; Oil
m
at
seals; Renewing right oil
om
ion
seal
c
in t
or
his
e

at
do
riv
front differential lock, for

p
cum
or
right flange shaft

f
en
ng
t.
yi
Co
op py
front differential lock,
t. C rig
gh ht
yri
with manual gearbox p by
co Vo
and front differential
by lksw
cted agen
Prote
lock installed ⇒ Rep. gr.
AG.
39 ; Oil seals; Renewing

right oil seal
2 - Seal
❑ All-wheel drive only
❑ For bevel box output
flange.
❑ Renew only with bevel
box removed.
❑ Renewing on bevel box
“0AV” ⇒ page 168 .
❑ Renewing on bevel box
“0CN” ⇒ page 180 .
3 - Seal
❑ For input shaft
❑ Renewing ⇒ page 94
4 - Seal
❑ Front-wheel drive, for right flange shaft.
❑ Front-wheel drive, renewing with manual gearbox installed ⇒ Rep. gr. 39 ; Oil seals; Renewing right oil
seal
❑ Front-wheel drive with front differential lock, between manual gear box and front differential lock.
136 Rep. gr.39 - Final drive - differential

❑ Front-wheel drive with front differential lock, renewing with manual gearbox installed and front differential
lock removed ⇒ Rep. gr. 39 ; Oil seals; Renewing right oil seal
❑ Four-wheel drive, between gearbox and bevel box.
❑ All-wheel drive, renewing with manual gearbox installed and bevel box removed ⇒ Rep. gr. 39 ; Oil
seals; Renewing right oil seal
5 - Seal
❑ Renewing with gearbox installed ⇒ Rep. gr. 39 ; Oil seals; Renewing left oil seal
6 - Seal
❑ Renewing ⇒ Rep. gr. 34 ; Selector mechanism; Renewing oil seal for selector shaft
7 - Seal
❑ Four-wheel drive: between bevel box and manual gearbox
❑ Four-wheel drive: renew with bevel box removed ⇒ page 167
❑ Front-wheel drive with front differential lock, between front differential lock and manual gearbox.
❑ Front-wheel drive with front differential lock, renew with front differential lock removed ⇒ page 193
8 - Seal
❑ All-wheel drive, in bevel box for flange shaft ⇒ page 162
❑ With all-wheel drive: renew working from right flange shaft seal end ( ⇒ Item 1 (page 136) ) ⇒ Rep. gr.
39 ; Oil seals; Renewing left oil seal
❑ To renew, remove needle bearings (polygon bearings) ⇒ Rep. gr. 39 ; Components of bevel box
❑ Front-wheel drive with front differential lock: for flange n Ashaft
G. Volkin
swfront
agen Adifferential
G do
lock
wage es n
❑ For front-wheel drive with front differential lock:
yV
olksis renewed working from seal ot guend
( ⇒ Item 7 (page 137) ) ⇒ page 194 ise
db ara
n r tee
ho
aut or
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
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
1. Oil seals 137

2 Differential
⇒ “2.1 Assembly overview - differential”, page 138
⇒ “2.2 Dismantling and assembling differential”, page 144
⇒ “2.3 Adjusting differential”, page 156 n AG. Volkswagen AG do
lks wage es n
2.1 Assembly overview - differential
o ot g
byV ua
d ran
ir se tee
o
⇒ “2.1.1 Assembly overview -adifferential,
uth
front-wheel drive”, page or
ac
138 ss
ce
le
un
pt
⇒ “2.1.2 Assembly overview - differential, four-wheel drive and
an
d
itte
front-wheel drive with front differential lock”, page 141
y li
erm
ab
ility
2.1.1 Assembly overview - differential, front-wheel drive
ot p
wit
is n
h re
ole,
spec
Note
t to the co
♦ Heat tapered roller bearing inner races to about 100°C with the inductive heater - VAS 6414- before installing.
Wear protective gloves when doing this.
rrectne
s
♦ If tapered roller bearings, differential cage, gearbox housing or clutch housing is renewed, adjust differential
s o
⇒ page 156 .
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.

1 - Gearbox housing
2 - Shim
❑ Determining thickness
⇒ page 156
race agen
AG. Volkswagen AG d
oes
lksw not
❑ Removing ⇒ page 148 byV
o gu
ara
ed
❑ Pressing in horis nte
eo
⇒ page 148 . s aut ra
c
s
ce
e
nl
pt
race du
an
itte
y li
erm
ab
ility
ot p
❑ Pressing on
wit
, is n
⇒ page 147
h re
hole
spec
5 - Differential cage
es, in part or in w
❑ With differential bevel
t to the co
gears, one-piece thrust
washer, differential pin‐
ion pin and final drive
rrectness of i
gear
l purpos
❑ Removing differential
bevel gears, one-piece
thrust washer and differ‐
nform
ercia
ential pinion pin

m
⇒ page 149
at
om
ion
❑ Installing differential
c
in t
or
his
ate
do
priv
c
ential pinion pin
um
for
⇒ page 149
en
ng
t.
yi Co
op py
. C rig
ht ht
rig
race py by
co Vo
by lksw
❑ Pulling off ⇒ page 148 cted agen
Prote AG.
8 - Washer
❑ Installation position: shoulder on inner circumference faces seal for right flange shaft.
9 - Clutch housing
10 - Seal
❑ For right flange shaft
❑ Renewing with gearbox installed ⇒ Rep. gr. 39 ; Oil seals; Renewing right oil seal
❑ 33 Nm
2. Differential 139
Arteon 2018 ➤ , Golf 2017 ➤ , Golf Variant 2017 age➤
n A,GPolo
. Volks2018 ➤ ,dT-Ro
wagen AG
oes ...
ksw no
6-speed manual gearbox 02Q, 0BB and b0FB,
y V removed - Edition 03.2019 t gua
ol
ed ran
oris tee
12 - Right flange shaft au
th or
ac
ss
13 - Protective ring
ce
e
nl
pt
du
an
❑ Lever protective ring off right flange shaft with a screwdriver, alternating sides.
itte
y li
erm
ab
❑ Install with indentation facing away from threaded hole in flange shaft
ility
ot p
❑ Push on protective ring to stop by hand ⇒ “2.1 Assembly overview - differential”, page 138
wit
, is n
h re
❑ Protective ring must engage in flange shaft
hole
spec
14 - Compression spring for flange shaft
es, in part or in w
t to the co
❑ Installed behind flange shaft
15 - Thrust washer
rrectness of i
❑ Installation position: shoulder faces spring, lugs, if present, face tapered ring
l purpos
16 - Tapered ring
❑ Installation position: taper towards differential cage
nf
ercia
o
17 - Retaining ring
rm
m
atio
❑ Holds tapered ring, thrust washer and spring in position when flange shaft is removed
om
n in
or c
18 - Protective ring
thi
te
sd
iva
❑ Lever protective ring off left flange shaft with a screwdriver, alternating sides.
o
r
rp
cu
o
m
❑ Install with indentation facing away from threaded hole in flange shaft
f
en
ng
t.
yi Co
❑ Push on protective ring to stop by hand t. Cop py
rig
gh ht
pyri by
Vo
co lksw
by
19 - Left flange shaft cted agen
Prote AG.
20 - Seal

2.1.2 Assembly overview - differential, four-wheel drive and front-wheel drive with
front differential lock
Note
♦ Heat tapered roller bearing inner races to about 100°C with the inductive heater - VAS 6414- before installing.
Wear protective gloves when doing this.
. Volkswagen AG
gen AG
♦ If tapered roller bearings, differential cage, gearbox housing
not or clutch housing is renewed, adjust differential
a oes d
ksw
Vol
⇒ page 156 . ed
by gu
ara
ris nte
tho eo
au ra
c
ss
1 - Gearbox housing
ce
le
un
pt
an
d
itte
2 - Shim
y li
erm
ab
ility
ot p
wit
❑ Determining thickness
is n
h re
⇒ page 156
ole,
spec
t to the co
race
❑ Pressing in
rrectne
⇒ page 155 .
s
s o
race
cial p
f inform
mer
❑ Pressing on atio
m
⇒ page 154
o
n
c
i
or
n thi
e
5 - Differential cage
t
sd
iva
o
r
❑ With differential bevel

p
cum
r
fo
gears, one-piece thrust

en
ng
t.
yi
washer, differential pin‐
Co
op py
ion pin and final drive
. C rig
ht ht
rig
gear py by
co Vo
by lksw
❑ Removing differential
cted agen
Prote AG.
ential pinion pin
⇒ page 156
❑ Installing differential
ential pinion pin
⇒ page 156
race
8 - Washer
Installation position: shoulder on inner circumference faces clutch housing.
2. Differential 141
9 - Clutch housing
10 - Seal
❑ Four-wheel drive, between gearbox and bevel box.
❑ Renewing ⇒ Rep. gr. 39 ; Oil seals; Renewing right oil seal
❑ Front-wheel drive with front differential lock, between manual gear box and front differential lock.
❑ Renewing ⇒ Rep. gr. 39 ; Oil seals; Renewing right oil seal . Volkswage n AG n AG d
wage oe
11 - Seal Vol
ks s no
t gu
d by ara
❑ For right flange shaft orise nte
h eo
❑ With all-wheel drive: renew with bevel box installed
aut ⇒ Rep. gr. 39 ; Oil seals; Renewing right oil
r a seal
ss c
❑ Front-wheel drive with front differential lock: renew front differential lock installed ⇒ Rep. gr. 39 ; Oil
ce
le
un
pt
seals; Renewing right oil seal
an
d
itte
y li
erm
12 - Hexagon bolt
ab
ility
ot p
❑ Qty. 4
wit
is n
h re
ole,
spec
❑ 40 Nm + 90°
t to the co
rrectne
❑ 33 Nm
ss
❑ For all-wheel drive, removing and installing ⇒ Rep. gr. 39 ; Oil seals; Renewing right oil seal
o
cial p
f in
❑ For front-wheel drive with front differential lock, removing and installing ⇒ Rep. gr. 39 ; Oil seals; Re‐
form
mer
newing right oil seal
atio
m
15 - Seal
o
n
c
i
or
n thi
te
sd
va
❑ All-wheel drive, in bevel box for flange shaft ⇒ page 162

i
o
pr
cum
r
fo
❑ With all-wheel drive: renew working from right flange shaft seal end ( ⇒ Item 1 (page 136) ) ⇒ Rep. gr.
en
ng
t.
yi
39 ; Oil seals; Renewing left oil seal
Co
Cop py
t. rig
gh ht
pyri by
Vo
o
❑ Front-wheel drive with front differential lock: for flange shaft in front differential lock
by c lksw
cted agen
Prote AG.
❑ For front-wheel drive with front differential lock: is renewed working from seal end
( ⇒ Item 7 (page 137) ) ⇒ page 194
16 - Needle bearing (polygon bearing)
❑ All-wheel drive only
❑ Renewing ⇒ Rep. gr. 39 ; Components of bevel box
17 - Retaining ring
❑ For four-wheel drive: for needle roller bearing (polygon bearing).
❑ For front-wheel drive with front differential lock: for right flange shaft
18 - Bevel box for four-wheel drive, front differential for front-wheel drive
❑ Four-wheel drive - seals, flange shaft mounting and output flange mounting ⇒ page 162 .
❑ Front differential lock is installed depending on equipment level ⇒ Electronic parts catalogue (ETKA)
❑ Front-wheel drive - renewing oil seals and flange shaft mounting ⇒ page 191 and ⇒ page 192
19 - Seal
❑ Four-wheel drive: between bevel box and manual gearbox
❑ Four-wheel drive: renew with bevel box removed ⇒ page 167
❑ Front-wheel drive with front differential lock, between front differential lock and manual gearbox.
❑ Front-wheel drive with front differential lock, renew with front differential lock removed ⇒ page 193

20 - Retaining ring
❑ Holds tapered ring, thrust washer and spring in position when flange shaft is removed
21 - Tapered ring
❑ With grooves to engage in thrust washer
❑ Installation position: taper towards differential cage
22 - Thrust washer
❑ Installation position: shoulder faces spring, lugs face tapered ring
23 - Compression spring for left flange shaft
❑ Installed behind left flange shaft
❑ Depending on vehicle equipment with protective ring
. Volkswagen AG
gen AG
❑ Allocation olks⇒ Electronic parts catalogue
wa does
not (ETKA)
yV gu
❑ Lever ed b protective ring off left flange shaft with
ara a screwdriver, alternating sides.
nte
oris
❑ au Install with indentation facing away from threaded
th eo
r a hole in flange shaft
ss c
❑ Push on protective ring to stop by hand
ce
e
nl
pt
du
an
itte
y li
erm
25 - Seal
ab
ility
ot p
❑ Renew after removal 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.
2. Differential 143
2.2 Dismantling and assembling differential

⇒ “2.2.1 Dismantling and assembling differential, front-wheel
drive”, page 144
⇒ “2.2.2 Dismantling and assembling differential, four-wheel
drive, front-wheel drive with front differential lock”, page 149
2.2.1 Dismantling and assembling differential, front-wheel drive

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
rrectne

ss o

cial p
f inform

mer
atio
m
♦ Tube - VW 415 A-
o
n
c
i
or
n thi

te
sd
iva
o
r
♦ Thrust plate - 3005-

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

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
♦ Tube - 3259-
h re
ole,
spec
♦ Tube - 3296-
t to the co
♦ Tube - 3345-
rrectne
♦ Grip tool - V.A.G 1582/6A-
ss
21/7-
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.
2. Differential 145
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.

Kukko 22/2-


Kukko 22/2-
21/7-
Note
AG. Volkswagen AG d
agen
♦ Tighten internal puller
Vol -B- between tapered rollerobearing
ksw
oes
n t outer
race and shim
se
d⇒
by Item 8 (page 139) .
g ua
ran
ri tee
♦ utho out,
After pulling check shim for damage and renew, if neces‐
or
a a
sary. ss c
ce
e
nl
pt
♦ Instead of internal puller - VAS 251 615- , or e.g. internal puller
du
an
itte
- Kukko 21/7- , it is also possible to use internal puller - VAS
y li
erm
ab
6775- , or e.g. internal puller 56 … 70 mm - Kukko 21/8- .
ility
ot p
wit
, is n
h re
Press tapered roller bearing outer race with shim into clutch hous‐
hole
spec
ing
es, in part or in w
t to the co
– Before doing so, insert shim ⇒ Item 8 (page 139) into clutch
housing.
rrectness of i
• Installation position of washer: Shoulder on inner circumfer‐
ence faces seal in clutch housing.
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
a
Pulling off tapered roller bearing and inner race

iv
o
r
rp
cu
o
– Before setting up pulling device, set thrust plate - 40 - 105- on

f
en
ng
t.
yi
differential housing.
Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Heating and pressing on the tapered roller bearing inner race

Cage with tapered rollers must be easy to turn during pressing.
WARNING
Wear protective gloves.
2. Differential 147


Cage with tapered rollers must be easy to turn during pressing.
WARNING
ing agen
AG. Volkswagen AG d
oes
olksw not
V
A - Counter support - VAS 251 623- , or e.g. counter support - ed b y gu
ara
Kukko 22/2- thoris nte
eo
au ra
B - Internal puller - VAS 251 615- , or e.g. internal puller s- Kukko
s c
ce
21/7-
le
un
pt
an
d
itte
y li
erm
ab
Note
ility
ot p
wit
is n
h re
Instead of internal puller - VAS 251 615- , or e.g. internal puller -
ole,
Kukko 21/7- , it is also possible to use internal puller - VAS 6775- ,
spec
or e.g. internal puller 56 … 70 mm - Kukko 21/8- .
t to the co
rrectne
– Support gearbox housing with tube - 3345- directly below
bearing support.
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Removing spring pin for differential piniongepin

n AG. Volkswagen AG d
wa oes
olks not
– Drive spring pin -A- out of hole
d b -arrow- in differential housing
yV gu
ara
using a 5 mm diameter drift
orise-B-. nte
eo
th
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
Note
rrectness of i
l purpos
♦ If there is no hole -arrow- in the differential cage, then proceed

as follows in order to drive out the spring pin:
nform
ercia
♦ Cover tapered roller bearing inner race to prevent possible

damage and ingress of metal particles.
m
at
om
io
♦ Drive out spring pin with chisel, inserting chisel into circum‐
n
c
in t
r
ferential groove.
o
his
ate
do
priv
cum
for
en
ng
t.
yi Co
op py
Installing differential bevel gears t. C rig
gh ht
pyri by
– Lubricate one-piece thrust washer with gear oil and install.
o Vo
by c lksw
cted agen
Prote AG.
– Install both sun wheels and secure (e.g. with flange shaft).
– Insert planet pinions offset 180° and pivot into position.
– Press in differential pinion pin (-arrow A-) to first planet pinion.
– Place threaded pieces -arrows B- in sun gears.
• Installation position: shoulder to sun gear
– Drive differential pinion pin into final position and secure with
spring pin ⇒ page 149 .
Installing spring pin for differential pinion pin

– Align hole in differential pinion pin with hole in differential cage.
– Using a drift, drive in spring pin -1- until dimension -a- = 2.5 ±
0.5 mm is attained.
2.2.2 Dismantling and assembling differential,

four-wheel drive, front-wheel drive with
front differential lock
2. Differential 149
Arteon 2018 ➤ , Golf 2017 w➤ ag,enGolf Variant 2017
AG. Volkswagen AG d ➤ , Polo 2018 ➤ , T-Ro ...
oes
ks
by
V 02Q, 0BB and 0FB, removed
ol not
g-u Edition 03.2019
ara
ed nte
oris
♦ Pressure plate - VWau402-
th e 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
rrectne
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

♦ Extension - 30 - 23-
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
♦ Thrust plate - 40-105-
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.
2. Differential 151
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
♦ Tube - 3259-
hole
spec
♦ Tube - 3296-
es, in part or in w
t to the co
♦ Assembly tool - 3301-

♦ Tube - 3345-
rrectness of i

l purpos
21/7-
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
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

Kukko 22/2-
nf
ercia
♦ Two-arm puller - VAS 251 007- , or e.g. puller - Kukko 204/2-

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.
2. Differential 153

Kukko 22/2-
21/7-
– Tighten internal puller -B- between tapered roller bearing outer
race and shim.
Note
♦ Tighten internal puller -B- between tapered roller bearing outer

race and shim ⇒ Item 8 (page 141) .
♦ After pulling out, renew shim ⇒ Item 8 (page 141) .
♦ Instead of internal puller - VAS 251 615- or e.g. 46-58 mm
internal puller - Kukko 21/7- , internal puller - VAS 6775- or
e.g. 56-70 mm internal puller - Kukko 21/8- can be used as
well.
Press tapered roller bearing outer race with shim into clutch hous‐
ing
– First, insert washer ⇒ Item 8 (page 141) .
• Installation position of washer: Shoulder on inner circumfer‐
ence faces seal in clutch housing.
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
– Place thrust plate - 40-105- on differential housing.

erm
ab
ility
ot p
– Clamp puller -A- e.g. two-arm puller - VAS 251 007- , or e.g.
wit
, is n
puller - Kukko 204/2- in area of flat sides of differential cage

h re
beneath inner bearing race.

hole
spec
es, in part or in w
t to the co
Note
When pulling off inner race, ensure that hooks do not bend out‐
rrectness of i
wards, further tightening bolt -arrow- if necessary.

l purpos

nform
mercia
at
om
WARNING
ion
c
in t
or
his
e

at
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.


WARNING
– Set sleeve -3301/3- from assembly tool - 3301- with notch

-arrow- (larger inner diameter) on tapered roller bearing inner
race.
ing
Kukko 22/2-
B - Internal puller - VAS 251 615- , or e.g.aginternal
en AG. V puller
olkswage-nKukko
AG do
es n
21/7- yV
o lksw ot g
b ua
ed ran
oris tee
th or
au ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p

wit
, is n
h re
– Support gearbox housing with tube - 3345- directly below

hole
spec
bearing support.
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. Differential 155
Removing differential pinion pin and spring pin for differential pin‐
ion pin
– Drive out spring pin -A- from hole -arrow- in differential housing
using 5 mm diameter drift pin -B-.
Note
♦ If there is no hole -arrow- in the differential cage, then proceed

as follows in order to drive out the spring pin:
♦ First drive spring pin -1- flush into differential pinion pin -2-.
♦ Set differential under press with spring pin -arrow- facing to‐
wards extension - 30 - 23- .
♦ Then, press out differential pinion pin.
♦ Remove any sheared-off parts of spring pin from differential
housing and differential pinion pin.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
is nte
Installing differential bevel gears hor eo
aut ra
s c
– Lubricate one-piece thrust washer with gear oil and install. s
ce
e
nl
pt
du
– Install both sun wheels and secure (e.g. with flange shaft).
an
itte
y li
erm
ab
– Insert planet pinions offset 180° and pivot into position.

ility
ot p
– Press in differential pinion pin (-arrow A-) to first planet pinion.

wit
, is n
h re
hole
– Drive differential pinion pin into final position and secure with
spec
spring pin ⇒ page 156 .

es, in part or in w
t to the co
rrectness of i
Installing spring pin for differential pinion pin

l purpos
– Align hole in differential pinion pin with hole in differential cage.

nf
ercia
– Using a drift, drive in spring pin -1- until dimension -a- = 2.5 ±
orm
0.5 mm is attained.
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
2.3 Adjusting differential
AG.


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

rrectne
♦ End dimension plate - VW 385/17-

ss

o
cial p
f inform

mer
atio

om
n
c
i
or

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. Differential 157
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, 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.
♦ Tube - 3259-
♦ Tube - 3345-
21/7-
Kukko 22/2-
♦ 30 mm dial gauge extension
It is necessary to readjust the differential if the following compo‐
nents have been renewed:
♦ Gearbox housing
♦ Clutch housing
♦ Differential cage or
♦ Tapered roller bearing of differential

– Press tapered roller bearing outer race with shim into clutch
housing ⇒ page 138 .
Note
♦ Observe installation position of shim.

♦ Shoulder on inner circumference faces seal in clutch housing.
– Press tapered roller bearing outer race, without shim, into

gearbox housing ⇒ page 138 .
– Fit differential into clutch housing.
– Fit gearbox housing and tighten the 5 bolts.
– Press differential in direction of clutch housing while turning it
8 times.
. Volkswagen AG
gen AG d
– Press differential in direction Vofolkgearbox
swa housing while turning
oes
not
it 8 times. e d by gu
ara
is nte
or eo
– Fit measuring tools aonto
ut
h
gearbox housing. ra
ss c
ce
e
nl
pt
du
an
– Set dial gauge to “0” with 1 mm preload.
itte
y li
erm
ab
A - 30 mm dial gauge extension
ility
ot p
wit
, is n
– Move differential up and down. Read and note play indicated

on dial gauge. (Example: 0.70 mm) h re
hole
spec
es, in part or in w

t to the co
The specified bearing preload is obtained by adding a constant

value for preload (0.25 mm) to the reading obtained.
rrectness of i
Example:
l purpos
Measured value 0.70 mm

nform
ercia
Thickness of shim = 0.95 mm

m
at
om
ion
– Remove gearbox housing.

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.
2. Differential 159
– Pulling outer race for tapered roller bearing out of gearbox

housing.
Kukko 22/2-
21/7-
– Determine part number of shim according to ⇒ Electronic
parts catalogue (ETKA) . en AG. V
olkswagen AG
ag does
ksw not
Vol
– Insert shim of determined thickness. gu
by d ara
ise nte
The following shims are available:
ut
ho
r eo
a ra
ss c
Shim thickness (mm)
ce
le
un
pt
0.65 0.85 1.05 1.25
an
d
itte
y li
rm
ab
0.70 0.90 1.10
pe
ility
ot
0.75 0.95 1.15
wit
, is n
h re
0.80 1.00 1.20
hole
spec
es, in part or in w
If the size of shim required is larger than those listed in the table,
t to the co
insert two shims totalling the correct figure. When using two
shims, install the thicker one first.
rrectness of i
l purpos
– Press in outer ring again and bolt on gearbox housing
nform
ercia
⇒ page 50 .
m
Specified torques
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.

3 Adjustment overview
Note
It is necessary to readjust output shaft for 1st to 4th gear, output

shaft for 5th, 6th and reverse gear or differential only if compo‐
nents have been renewed which have a direct effect on the
adjustment of the gearbox. To prevent unnecessary adjustments,
refer to the following table:
,
To be adjusted:
Output shaft Output shaft Differential
for 1st to 4th for 5th, 6th ⇒ page 156
gears and reverse
⇒ page 125 gears
⇒ page 130
Parts renewed: Gearbox housing x x x
Clutch housing x x x
Output shaft for 1st to 4th gears x
Output shaft for 5th, 6th and reverse x
gears
Differential x
Tapered roller bearings for 1st to x
4th gear output shaft
Tapered roller bearings for 5th, 6th x
and reverse gear output shaft
n AGTapered
. Volkswageroller
n AG d bearing for differen‐ x
wage oes
y Volks
tial not
gu
b ara
ed nte
oris e
th or
au 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.
3. Adjustment overview 161

4 Components of bevel box

⇒ “3.1 Distinguishing between different types of bevel boxes”,
page 36 .
⇒ “4.1 Assembly overview - components of bevel box”,
page 162
⇒ “4.2 Renewing bevel box seals”, page 166
⇒ “4.3 Renewing output flange and redetermining thickness of
shim”, page 189
4.1 Assembly overview - components of

bevel box
⇒ “4.1.1 Assembly overview - components of bevel box, 0AV ”,
page 162
⇒ “4.1.2 Assembly overview - components of bevel box, 0CN ”,
page 165
G. Volkswage
4.1.1 Assembly overview - components
olks
waof
genbevel
A
box,n A“0AV”
G do
es n
ot V gu
by ara
(Seals, flange shaft mount, output flange mount
ris in bevel box)
ed nte
tho eo
s au ra
c
s
1 - Seal
ce
e
nl
pt
du
an
itte
y li
erm
ab
❑ Between bevel box and
ility
ot p
gearbox
wit
, is n
❑ Replacing with bevel
h re
hole
box removed
spec
⇒ page 167
es, in part or in w
t to the co
2 - Bevel box
❑ Removing ⇒ Rep. gr.
34 ; Bevel box; Remov‐
rrectness of i
ing bevel box
l purpos
❑ Installing ⇒ Rep. gr.

34 ; Bevel box; Installing
bevel box
nform
ercia
❑ Detaching with gearbox

m
at
om
removed ⇒ page 60
ion
c
in t
r

o
his
e
removed ⇒ page 73
at
do
priv
cum
3 - Oil drain plug

for
en
ng
t.
yi
Co
Cop py
t.
❑ With captive seal
rig
gh ht
pyri by
Vo
❑ 15 Nm
o
by c lksw
cted agen
Prote AG.
4 - Oil filler plug
❑ 15 Nm
5 - Seal
❑ For right flange shaft
❑ Renewing with manual
gearbox and bevel box
installed ⇒ Rep. gr. 39 ;
Oil seals; Renewing right oil seal

6 - Breather pipe
❑ To vent bevel box
❑ Press in until stop is reached
7 - Cap
8 - Breather pipe
10 Nm
9 - Bolt
❑ 5 Nm
AG. Volkswagen AG d
agen oes
10 - Shield Vol
ksw not
gu
by ara
❑ Not fitted in all bevel boxes ris
ed
nte
tho eo
❑ The outline may differ from that shown a in the diagram.
u ra
c
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
12 - Seal
, is n
h re
hole
spec
es, in part or in w
t to the co
❑ Needle bearing (polygon bearing) is difficult to turn with flange shaft removed The fact it is difficult to
rrectness of i
move does not mean that the bearing is defective. An acoustic test can only be performed with the
bearings installed.
l purpos
❑ Inspect for signs of damage to bearings, such as cracking in outer race, and renew if necessary.
nf
ercia
orm
14 - Retaining ring
m
atio
m

o
n in
or c
❑ For needle roller bearing (polygon bearing)
thi
te
sd
iva
❑ Insert in circumferential groove in stub shaft o

r
rp
cu
o
m
f
en
ng
15 - Hexagon nut yi
t.
Co
op
C py
t. rig
gh ht
yri
❑ Removing ⇒ page 174 p by
co Vo
by lksw
cted
❑ Install using locking fluid - D 000 600-
agen
Prote AG.
❑ Installing ⇒ page 180

❑ 480 Nm
16 - Output flange
❑ Renewing ⇒ page 189
17 - Cover
❑ Not fitted in all bevel boxes
❑ Engage with output flange
18 - Shim
❑ Redetermine if output flange is renewed ⇒ page 189 .
19 - Seal
❑ For output flange
4. Components of bevel box 163

❑ Replace only with bevel box removed ⇒ page 168
❑ No replacement part available for this component
21 - Bolt
❑ 25 Nm
22 - Pinion housing
❑ With shaft bevel gear and outer race/tapered roller agen bearing
AG. Volkswagen AG d
oes
lksw not
❑ No replacement parts available for these d bycomponents
Vo gu
ara
e nte
❑ Carefully lever off and drive in alternately
ho ris
eo
ut ra
❑ Observe bolt holes; pinion housingss a
fits only in one position. c
ce
le
un
23 - O-ring
pt
an
d
itte
y li
❑ To renew, unscrew bolts and carefully lever off pinion housing at projecting webs on outside edge.
erm
ab
❑ Do not remove hexagon nut and output flange.
ility
ot p
wit
is n
24 - Shim
h re
ole,
spec
❑ Observe bevel box bolt bores; shim only fits in one position.
t to the co
25 - Cap
❑ Drive in to stop with spacer tube - VW 540 1B- .
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.

4.1.2 Assembly overview - components of bevel box, “0CN”

(Seals, flange shaft mount, output flange mount in bevel box)
1 - Seal
❑ Between bevel box and
gearbox
AG. Volkswagen AG d
❑ Replacing with bevel agen oes
olksw not
box removed d by V gu
ara
⇒ page 167 rise nte
ho e t or
au ac
2 - Bevel box ss
ce
le
❑ Removing ⇒ Rep. gr.

un
pt
an
d
34 ; Bevel box; Remov‐

itte
y li
ing bevel box
erm
ab
ility
ot p
❑ Installing ⇒ Rep. gr.
wit
is n
34 ; Bevel box; Installing
h re
bevel box
ole,
spec
t to the co
removed ⇒ page 60
removed ⇒ page 73
rrectne
3 - Oil drain plug
s
s o
cial p
f
inform
❑ 15 Nm
mer
atio
m
4 - Oil filler plug

o
n
c
i
or
❑ Renew after removal n thi

te
sd
va

i
o
pr
cum
r
fo
❑ 15 Nm
en
ng
t.
yi Co
op
5 - Seal C py
t. rig
gh ht
❑ Renew after removal yri
p by
co Vo
by lksw
❑ For right flange shaft cted agen
Prote AG.
❑ Renewing with manual
gearbox and bevel box
installed ⇒ Rep. gr. 39 ;
Oil seals; Renewing right oil seal
6 - Breather pipe
❑ Press in until stop is reached
7 - Cap
9 - Seal
❑ Needle bearing (polygon bearing) is difficult to turn with flange shaft removed The fact it is difficult to
move does not mean that the bearing is defective. An acoustic test can only be performed with the
bearings installed.
❑ Inspect for signs of damage to bearings, such as cracking in outer race, and renew if necessary.

11 - Retaining ring
❑ For needle roller bearing (polygon bearing)
❑ Insert in circumferential groove in stub shaft
12 - 12-point nut
❑ Install using locking fluid - D 000 600-
❑ Installing ⇒ page 188
❑ Secure nut at three opposing points by peening.
❑ 350 Nm +_15 Nm agen
AG. Volkswagen AG d
o
ksw es n
Vol ot g
13 - Output flange ed by ua
ran
ris
❑ Renewing ⇒ page 189 tho
tee
or
s au ac
14 - Shim s
ce
le
un
pt
❑ Redetermine if output flange is renewed ⇒ page 189 .
an
d
itte
y li
15 - Seal
rm
ab
pe
ility
ot
wit
, is n
❑ For output flange
h re
hole
spec
❑ Replace only with bevel box removed ⇒ page 180
es, in part or in w
t to the co
rrectness of i
17 - Bolt
❑ 38 Nm
l purpos
18 - Pinion housing nform

ercia
❑ With shaft bevel gear and outer race/tapered roller bearing

m
❑ No replacement parts available for these components

a
com
tion in
❑ Carefully lever off and drive in alternately

r
te o
thi
❑ Observe bolt holes; pinion housing fits only in one position.

s
iva
do
r
rp
19 - O-ring
um
fo
en
ng
❑ To renew, unscrew bolts and carefully lever off pinion housing at projecting webs on outside edge.
t.
yi Co
Cop py
❑ Do not remove hexagon nut and output flange.
t. rig
gh ht
pyri by
Vo
o
20 - Shim by c lksw
cted agen
Prote AG.
❑ Observe bevel box bolt bores; shim only fits in one position.
21 - Cap
❑ Drive in to stop with spacer tube - VW 540 1B- .
4.2 Renewing bevel box seals

⇒ “4.2.1 Renewing seal between gearbox and bevel box with
bevel box removed”, page 167
⇒ “4.2.2 Renewing output flange oil seal, bevel box 0AV (bevel
box removed)”, page 168
⇒ “4.2.3 Renewing output flange oil seal, bevel box 0CN (bevel
box removed)”, page 180
For more details, refer to ⇒ Rep. gr. 39 ; Components of bevel
box; Renewing oil seals for bevel box .

4.2.1 Renewing seal between gearbox and

bevel box with bevel box removed
Special tools and workshop equipment required agen
AG. Volkswagen AG d
oes
olksw not
♦ Removal tool - T20143- ed by
V gu
ara
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
rrectne
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted
♦ Sealing grease
agen
Prote AG.

– Remove bevel box ⇒ Rep. gr. 34 ; Bevel box; Removing bevel
box .
– Lever seal out using extractor tool - T20143/1- or extractor tool
- T20143/2- .

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
Arteon 2018 ➤ , Golf 2017 ➤ , Golf Variant
aut 2017 ➤ , Polo 2018 ➤ , T-Ro ... ra
c
s
6-speed manual gearbox 02Q, 0BBsand 0FB, removed - Edition 03.2019
ce
e
nl
pt
du
an
itte
– Fill half of space between sealing lip and dust lip -arrow- with
y li
erm
ab
sealing grease .
ility
ot p
– Lightly oil outer circumference of new oil seal.
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
– Drive in seal to stop.
m
m
atio
m
– Install bevel box ⇒ Rep. gr. 34 ; Bevel box; Installing bevel

o
n in
or c
box .
thi
te
sd
iva
– Check gear oil level in bevel box ⇒ Rep. gr. 39 ; Gear oil .
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.
4.2.2 Renewing output flange oil seal, bevel

box “0AV” (bevel box removed)
• ⇒ “3.1 Distinguishing between different types of bevel boxes”,
page 36


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
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
♦ Tube - VW 516-
o
m
f
en
ng
t.
yi Co
♦ Thrust plate - 40-105- Cop py
t. rig
gh ht
yri
♦ Press tool - T10049- p by
co Vo
by lksw
cted agen
♦ Gearbox support - T10108- Prote AG.
♦ Support plate - T10108/1-

. Volkswagen AG
gen AG d
Arteon 2018 ➤ , Golf V2017
olks ➤ , Golf Variant 2017 ➤
wa oes
no,t Polo 2018 ➤ , T-Ro ...
y gu
6-speed manual igearbox
sed b 02Q, 0BB and 0FB, removed a-raEdition 03.2019
n
r tee
ho
aut or
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
o
by c lksw
cted agen
Prote AG.
♦ Taper roller bearing puller - V.A.G 1582- with short sleeve

♦ Seal located in pinion housing ⇒ page 175 : adapter - V.A.G
1582/6- or adapter - V.A.G 1582/6A-
♦ Two-arm puller - VAS 251 001- , or e.g. two-arm puller - Kukko
20/10-
♦ Seal located on output flange ⇒ page 177 : adapter - V.A.G
1582/13-
♦ Continued for all
♦ Three-arm puller - VAS 251 205- or e.g. three-arm puller -
Kukko 45-2-
♦ Two-arm puller - VAS 251 001- , or e.g. two-arm puller - Kukko
20/10-
♦ Only for seal in pinion housing ⇒ page 175

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
♦ Only for seal in pinion housing ⇒ page 175
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
a
♦ Extractor hook - VW 771/37-

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

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
♦ Seal located on output flange ⇒ page 177

es, in part or in w
t to the co

rrectness of i

l purpos

♦ or thrust plate - VW 402-
nform
ercia
♦ 2 M 8 X 30 mm studs or guide pins M8 - T10273-

m
at
om
io
♦ Not required: pin - VW 460/2-

n
c
in t
or
his
e
♦ Tube - 3296-
at
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.

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
♦ Tube - 3296-
an
d
itte
y li
erm
ab
♦ Crankshaft seal installing tool - VW 204 B-

ility
ot p
wit

is n
h re
ole,

spec

t to the co
♦ Sealing grease
rrectne
♦ Universal grease
ss o
♦ 2 x M10 x 30 bolts
cial p
f inform
♦ 4 x M12 x 10 nuts
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.

Note
♦ The bevel box oil seal for the output flange can only be re‐
newed with the bevel box removed.
♦ The bevel box output flange is provided with a tapered roller
bearing inner race.
♦ This is removed later in the process.
♦ The taper roller bearing for the bevel box output flange and the
shims are not replaced!

box , or detach bevel box from manual gearbox ⇒ page 60 .
– Fit bevel box on gearbox support - T10108- onto hole
-arrow- marked with the number -4-.
A - Lay nuts M12 x 10 (qty. 4) between bevel box and gearbox
support .
– Then align bevel box with remaining 3 holes and secure.
– Drain oil from bevel box.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
Removing hexagon nut for output flange

hole
spec
es, in part or in w
– Lock output flange for bevel box with stop plate - T10108/1- .
t to the co
Screw in M10 x 30 bolts -arrows- to do this.

A - 36 mm socket for 3/4" drive
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
– Swing bevel box so that output flange points upwards.

do
r
rp
cum
fo
– Pull output flange together with tapered roller bearing inner

en
ng
t.
yi
race off shaft bevel gear of bevel box.
Co
Cop py
t. rig
gh
A - Three-arm puller - VAS 251 205- or e.g. three-arm puller -
ht
pyri by
Vo
o
Kukko 45-2-
c by lksw
cted agen
Prote AG.
• Please note different installation positions of seal for output
flange:

Seal -arrow- for output flange is located in pinion housing.

Removing and installing output flange seal in pinion housing
⇒ page 175 .
Seal -arrow- is located on output flange.

Removing and installing output flange seal ⇒ page 177 .
Removing and installing output flange seal in pinion housing:.

Removing seal
– Pull out seal -A- for output flange.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, 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.

• Bearing inner race/taper roller bearing must be detached from

output flange:
Caution
Risk of damage to tapered roller bearing inner race.

● Pull off tapered roller bearing inner race using adapter -
V.A.G 1582/6- or adapter - V.A.G 1582/6A- .
● If tapered roller bearing inner race is damaged, bevel box
must be replaced.
– Fit thrust plate - 40-105- onto output flange.

– Pull inner ring/the tapered roller bearing off output flange using
tapered roller bearing puller .
Note
Adapter - V.A.G 1582/6- may be used in place of adapter - V.A.G

1582/6A- .
Installing seal and output shaft lkswage es n
o ot g
byV ua
d ran
– Cover pinion housing with a lint-free cloth. o
ir se tee
th or
u
– Clean residual locking fluid from thread of shaft bevel
ss
a
gear. ac
ce
e
nl
• If shim -2- was also removed when output flange was re‐
pt
du
an
moved, it has to be reinserted in pinion housing.
itte
y li
erm
ab
• It assures bearing preload of shaft bevel gear -1- in pinion
ility
ot p
housing.
wit
, is n
h re
– Lay existing tapered roller bearing inner race -3- in outer race
hole
spec
in bevel box.
es, in part or in w
t to the co
– Lightly oil outer circumference of new seal -4- for output flange.
rrectness of i
l purpos
nf
ercia
orm
m
atio
m
– Drive in new oil seal with thrust piece - T10049- .

o
n in
or c
thi
• Seal must be flush with upper edge of housing.

te
sd
iva
o
r
– Half-fill space between sealing lip and dust lip with sealing
rp
cu
o
m
f
grease .
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

– Lightly lubricate splines of output shaft with universal grease .

– Pull in output flange using two arm puller -A-.
A - Two-arm puller - VAS 251 001- , or e.g. two-arm puller - Kukko
20/10-
Please note the following:
• Use new or nearly new puller hooks!
• The output flange must not be canted.
• Fit puller hooks as far as they will go onto underside of pinion
housing.
olkswagen AG
en AG. V
• Take up slack on puller hooksksw fully with two arm puller
ag does
not
Vol
-arrows-. ed by gu
ara
ris nte
• Puller hooks should
au
tho not bend outwards. eo
ra
ss c
• Interrupt pulling-on immediately when effort increases notice‐
ce
le
un
able.
pt
an
d
itte
y li
rm
ab
pe
ility
Note
ot
wit
, is n
h re
♦ The puller must only open the flange so far that the nut can be
hole
spec
attached safely.
es, in part or in w
t to the co
♦ The final position of the flange is attained by tightening the nut,
not by the puller.
rrectness of i
Removing and installing output flange seal -arrow-:
l purpos
Removing seal 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.
• Bearing inner race/taper roller bearing must be removed in
order to remove output flange seal.
Caution

V.A.G 1582/13- .
● If tapered roller bearing inner race is damaged, bevel box
must be replaced.
– Fit thrust plate - 40-105- onto output flange.

– Remove seal from output shaft.

Installing seal and output shaft

• To install seal, pinion housing -1- with shaft bevel gear -2- first wagen AG. Volkswagen AG doe
has to be removed: yV
olks s no
t gu
b ara
ed
– Unscrew securing bolts for pinion housing -1-; then carefully
ris nte
tho e
lever pinion housing off cross-wise at projecting edges.
sa
u or
ac
s
– Remove pinion housing with shaft bevel gear -2-.
ce
le
un
pt
an
d
itte
– Clean thread on shaft bevel gear.
y li
rm
ab
pe
ility
• If shim -3- was also removed when output flange was re‐
ot
wit
moved, it has to be reinserted in pinion housing.
, is n
h re
hole
• It assures bearing preload of shaft bevel gear in pinion hous‐
spec
ing.
es, in part or in w
t to the co
– Place existing bearing inner race/tapered roller bearing -1- in
pinion housing.
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
op py
– Press in new oil seal flush. t. C rig
gh ht
pyri by
• The larger diameter of crankshaft seal installing tool - VW 204
co Vo
by lksw
cted agen
B- must face towards seal. Prote AG.
• Half-fill space between sealing lip and dust lip of seal with
sealing grease .
– Place pinion housing and tapered roller bearing inner race on
output flange.
– Press tapered roller bearing inner race ⇒ page 165 onto output
flange as far as it will go.
• The larger diameter of thrust piece - VW 454- must face to‐
wards output flange.
• Press in tapered roller bearing inner race only as far as it will
go.
• Do not expose the tapered roller bearing to higher forces than
necessary.

– Fit shim -2-, tapered roller bearing inner race -3- and pinion
housing -4- onto shaft bevel gear -1-.
• Always reinstall the existing shim -2-.
• It assures bearing preload of shaft bevel gear in pinion hous‐
ing. AG. Volkswagen
n AG do
wage es n
Volks ot g
by ua
ed ran
oris tee
th or
au 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
– Press output flange and pinion housing plus shaft bevel gear
together as far as they will go.
l purpos
• Shoulder -arrow- of installing sleeve - VW 455- faces shaft

bevel gear.
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
– Screw in M 8 X 30 mm stud bolts = -A- or M8 guide bolts -
c by lksw
cted agen
T10273- into final drive housing. Prote AG.
– Lightly moisten new O-ring -1- with gear oil and slide it onto
pinion housing -2-.
Pinion housing -2- and shim -3- only fit in one position.
– Install existing shim -3-.

– Tighten bolts -1- alternately and in small steps. Turn output

flange -2- slightly back and forth while doing so.
– Tighten securing bolts for pinion housing -2- cross-wise.
Continued for all
Coat thread of new hexagon nut with locking fluid D 000 600
– Tighten new hexagon nut for output flange ⇒ page 162 .
A - 36 mm socket for 3/4" drive
Measure radial run-out on output flange/shaft bevel gear.
Note
After the output flange nut has been tightened, agthe

en Aradial
G. Volksrun-out
wagen AG
does
on the centring pin of the shaft bevel gearolksw be checked.
must not
yV gu b ara
ed nte
oris e
– Secure measuring tools withaubolt
th -A- (M8 x 25) on bevel box. or
ac
ss
– Fit dial gauge - VAS 6080- on centring pin of shaft bevel gear
ce
e
nl
pt
-B- and set it to “0” with 1 mm preload.

du
an
itte
y li
erm
– Turn output flange one full turn in -direction of arrow-.

ab
ility
ot p
– Read measured value on dial gauge.

wit
, is n
h re
• Max. radial run-out = 0.05 mm.

hole
spec
es, in part or in w
– Fit bevel box to manual gearbox ⇒ page 60 , or install bevel

t to the co
box.
– Check gear oil level in bevel box ⇒ Rep. gr. 39 ; Gear oil .
rrectness of i
Specified torques
l purpos
♦ ⇒ “4.1.1 Assembly overview - components of bevel box, 0AV

”, page 162
nf
ercia
orm
4.2.3 Renewing output flange oil seal, bevel

m
atio
om
box “0CN” (bevel box removed)

n in
or c
thi
te
sd
a
• ⇒ “3.1 Distinguishing between different types of bevel boxes”,

iv
o
r
rp
cu
page 36
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.


equipment required 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
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.


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
♦ Support rails - VW 457-

ng
t.
yi Co
op py
♦ Tube - 3296- t. C rig
gh ht
pyri by
♦ Gearbox support - T10108-
co Vo
by lksw
cted agen
Prote AG.
♦ Support plate - T10108/1-
♦ Taper roller bearing puller - V.A.G 1582- with short sleeve
♦ Grip tool - V.A.G 1582/13-

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
♦ Crankshaft seal installing tool - VW 204 B- Cop py
ht. rig
rig ht
♦ Universal dial gauge holder - VW 387- py by
co Vo
by lksw
cted agen
♦ Dial gauge - VAS 6080- Prote AG.

♦ Socket, 34 mm - T50019-
♦ 2 M 8 X 30 mm studs or guide pins M8 - T10273-
♦ Sealing grease
♦ Universal grease
♦ 2 x bolts M10 x 30
♦ 4 nuts M12 x 10

Note
♦ The bevel box oil seal for the output flange can only be re‐
newed with the bevel box removed.
♦ The bevel box output flange is provided with a tapered roller
bearing inner race.
♦ This is removed later in the process.
♦ The taper roller bearing for the bevel box output flange and the
shims are not replaced!

box , or detach bevel box from manual gearbox ⇒ page 60 .
– Fit bevel box on gearbox support - T10108- onto hole
-arrow- marked with the number -4-.
A - Place nuts M12 x 10 (qty. 4) between bevel box and gearbox
support .
– Then align bevel box with remaining 3 holes and secure.
– Drain oil from bevel box.
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
– Release peened points -arrows- of twelve-point nut -A- from

an
d
itte
y li
indentations of output flange -B- by driving them inwards.

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
Unscrew twelve-point nut for output flange.

m
com
tio

n in
r
te o
thi
A - Socket, 34 mm - T50019-
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.

– Swing bevel box so that output flange points upwards.

– Unscrew securing bolts -arrows- for pinion housing -A-.
– Fit a suitable flat-bladed screwdriver -B- into the three recess‐

es -arrows- of pinion housing -A- and carefully lever off pinion
housing together with shaft bevel 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
t to the co
rrectness of i
– Position output flange -A- evenly on support rails - VW 457-
l purpos
-arrows-.
– Press shaft bevel gear off output flange -A-.
nform
ercia
• Prevent shaft bevel gear and tapered roller bearing inner race
m
at
from falling down while doing so.

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
– Press output flange -A- out of pinion housing. Prote AG.

Note
Seal -arrow- is located on output flange.
• Bearing inner race/taper roller bearing must be removed in

order to remove output flange seal.
Caution

V.A.G 1582/13- .
. Volkswag
● If tapered roller bearing inner race kis
swadamaged, bevel box
gen AG
en AG
does
must be replaced. by
Vol not
gu
a
ed ran
ris tee
tho or
au ac
– Fit thrust plate - 40-105-
ss onto output flange. ce
le
un
pt
an
d
itte

y li
erm
ab
ility
– Remove seal from output shaft.

ot p
wit
is n
h re
ole,
Installing seal and output shaft

spec
– Place existing bearing inner race/tapered roller bearing -1- in

t to the co
pinion housing.
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
a
– Press in new oil seal flush.

iv
o
pr
cum
r
fo
• The larger diameter of crankshaft seal installing tool - VW 204

en
ng
t.
yi
B- must face towards seal.
Co
Cop py
ht. rig
• Half-fill space between sealing lip and dust lip of seal with
rig ht
py by
o Vo
sealing grease . by c lksw
cted agen
Prote AG.
– Place pinion housing and tapered roller bearing inner race on
output flange.

– Press tapered roller bearing inner race ⇒ page 165 onto output
flange as far as it will go.
• The larger diameter of thrust piece - VW 454- must face to‐
wards output flange.
• Press in tapered roller bearing inner race only as far as it will
go.
• Do not expose the tapered roller bearing to higher forces than
necessary.
– Fit shim -2-, tapered roller bearing inner race -3- and pinion
housing -4- onto shaft bevel gear -1-.
• Always reinstall the existing shim -2-.
AG. Volkswagen AG d
• It assures bearing preload of shaft bevel gearolkin
swpinion
agen hous‐ oes
not
ing. db
y V gu
ara
e nte
ris
utho eo
ra
a 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
– Lightly lubricate splines of output shaft with universal grease .

– Press output flange and pinion housing plus shaft bevel gear
nf
ercia
together as far as they will go.

orm
m
atio
• Shoulder -arrow- of installing sleeve - VW 455- faces shaft
om
n in
bevel gear.
or c
thi
te
sd
• Turn pinion housing while pressing.

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.

– Screw in M 8 X 30 mm stud bolts = -A- or M8 guide bolts -

T10273- into final drive housing.
– Lightly moisten new O-ring -1- with gear oil and slide it onto
pinion housing -2-.
Pinion housing -2- and shim -3- only fit in one position.
– Install existing shim -3-.
– Tighten bolts -1- alternately and in small steps. Turn output

flange -2- slightly back and forth while doing so.
– Tighten securing bolts for pinion housing -2- cross-wise.
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
Tighten new twelve-point nut for output flange.

ility
ot p
wit
, is n
h re

hole
spec
– Tighten new 12-point nut for output flange ⇒ page 165 .

es, in part or in w
t to the co
A - Socket, 34 mm - T50019-
rrectness of i
l purpos
nform
mercia
at
– Secure twelve-point nut -A-

om
ion
c
in t
r
– in indentations (offset by 120°) of output flange -B- by peening

o
his
te
-arrows-.
a
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.

Measure radial run-out on output flange/shaft bevel gear.
Note
After the output flange nut has been tightened, the radial run-out
on the centring pin of the shaft bevel gear must be checked.
– Secure measuring tools with bolt -A- (M8 x 25) on bevel box.
– Fit dial gauge - VAS 6080- on centring pin of shaft bevel gear
-B- and set it to “0” with 1 mm preload.
– Turn output flange one full turn in -direction of arrow-.
– Read measured value on dial gauge.
• Max. radial run-out = 0.05 mm.
– Fit bevel box to manual gearbox ⇒ page 60 , or install bevel
box ⇒ Rep. gr. 34 ; Bevel box; Installing bevel box .
AG. Volkswagen AG d
agen
– Check gear oil level in bevel box ⇒ Rep. gr. 39 ; Gear oil .Volksw oes
not
gu
y
db ara
Specified torques rise nte
tho eo
au ra
♦ ⇒ “4.1.2 Assembly overview - components of bevel
ss box, 0CN c
”, page 165
ce
le
un
pt
an
d
itte
y li
4.3 Renewing output flange and redeter‐
erm
ab
ility
ot p
mining thickness of shim
wit
is n
h re
ole,
• The bevel box is removed.
spec
Adjustment is only necessary if the output flange is renewed. Its
t to the co
purpose is to re-establish the shaft bevel gear tapered roller bear‐
ing preloading.
rrectne
Bevel box “0AV”:
– Remove output flange and pull tapered roller bearing inner
ss
race off output flange ⇒ page 168 .
o
cial p
f in
Bevel box “0CN”:
form
mer
– Remove output flange and pull tapered roller bearing inner
atio
m
race off output flange ⇒ page 180 .

o
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.

Continued for all

– Measure length of old and new output flange shafts and de‐
termine difference.
Example:
Old output flange 42.90 mm
New output flange 43.00 mm
Difference 0.10 mm
If the new output flange is longer, install a shim which is thinner
by the difference.
If the existing output flange is longer, install a shim which is thicker agen
AG. Volkswagen AG d
oes
by the difference. olksw not
V gu
d by ara
ise nte
Allocation ⇒ Electronic parts catalogue (ETKA) hor eo
aut ra
Bevel box “0AV”: ss c
ce
e
nl
pt
– Install output flange ⇒ page 168 . du
an
itte
y li
erm
Bevel box “0CN”:
ab
ility
ot p
– Install output flange ⇒ page 180 .
wit
, is n
h re
Continued for all
hole
spec
es, in part or in w
– Install bevel box ⇒ Rep. gr. 34 ; Bevel box; Installing bevel
t to the co
box .
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.

5 Components of front differential lock

⇒ “5.1 Assembly overview - components of front differential lock”,
page 191
⇒ “5.4 Renewing ball bearing for flange shaft”, page 197
For additional information, refer to ⇒ Rep. gr. 34 ; Front differ‐
ential lock and ⇒ Rep. gr. 39 ; Components of front differential
lock .
5.1 Assembly overview - components of front differential lock

❑ Removing ⇒ Rep. gr. AG. Volkswagen AG d
34 ; Front differential lksw
agen oes
not
lock; Removing front dif‐ d by
Vo gu
ara
ferential lock orise nte
h eo
❑ Installing ⇒ Rep. gr. aut ra
s c
34 ; Front differential s
ce
le
lock; Installing front dif‐

un
pt
an
d
ferential lock
itte
y li
rm
ab
2 - Seal
pe
ility
ot
wit
, is n
h re
❑ For flange shaft in front
hole
spec
differential lock
es, in part or in w
t to the co
❑ Renew with front differ‐
ential lock removed
⇒ page 194
rrectness of i
3 - Support washer
l purpos
❑ No replacement part
4 - Seal
nform
ercia

m
a
com
❑ Between front differen‐

ion in
tial lock and manual

r
te o
thi
gearbox
s
iva
do
❑ Renew with front differ‐

r
rp
cum
fo
ential lock removed

en
ng
t.
⇒ page 193
yi Co
Cop py
t. rig
5 - Bolts
gh ht
pyri by
Vo
o
❑ 9 Nm
by c lksw
cted agen
Prote AG.
6 - Pump -V181-
⇒ Rep. gr. 39 ; Compo‐
nents of front differential
lock
7 - O-ring
❑ For pump -V181-
❑ Moisten O-rings with oil for front differential lock
8 - Axle differential lock control unit - J647-
❑ Removing and installing ⇒ Rep. gr. 39 ; Components of front differential lock
9 - Bolts
❑ 9 Nm
5. Components of front differential lock 191

10 - Ball bearing
❑ For flange shaft in front differential lock
❑ Renew with front differential lock removed ⇒ page 197
11 - Retaining ring
❑ For ball bearing
12 - Seal
❑ For flange shaft
❑ Renewing with front differential lock installed ⇒ Rep. gr. 39 ; Oil seals; Renewing right oil seal
13 - Flange shaft
14 - Retaining ring
❑ For flange shaft in front differential lock
❑ Renew after removal of flange shaft
15 - Bolt AG. Volkswagen AG d
agen oes
❑ With M8 stud olksw not
V gu
d by ara
❑ 40 Nm orise nte
eo
h
ut ra
16 - Bolt ss a c
ce
le
❑ With M8 stud
un
pt
an
d
itte
❑ 40 Nm
y li
erm
ab
17 - Oil drain plug
ility
ot p
wit
is n
h re
ole,
❑ With O-ring
spec
❑ Moisten O-ring with oil for front differential lock
t to the co
Allocate oil for front differential lock via ⇒ Electronic Parts Catalogue (ETKA) .
❑ 15 Nm
rrectne
18 - Oil filler plug
ss
o
cial p
f i
❑ With O-ring
nform
mer
❑ Moisten O-ring with oil for front differential lock atio

om
Allocate oil for front differential lock via ⇒ Electronic Parts Catalogue (ETKA) .
n
c
i
or
n thi
e
❑ 15 Nm
t
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
5.2 Checking function Cop py
t. rig
gh ht
yri by
– After pump -V181- and axle differential lock control unit - J647-
op Vo
by c lksw
cted
have been installed, perform Basic setting using ⇒ vehicle
agen
Prote AG.
diagnostic tester in Guided functions mode.
5.3 Renewing seals for front differential lock

⇒ “5.3.1 Renewing seal between front differential lock and manual
gearbox on front differential lock”, page 193
⇒ “5.3.2 Renewing oil seal for right flange shaft within front dif‐
ferential lock”, page 194
For additional information, refer to ⇒ Rep. gr. 39 ; Components
of front differential lock .

5.3.1 Renewing seal between front differential

lock and manual gearbox on front differ‐
ential lock
♦ Removal tool - T20143-
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
♦ Sealing grease
on
c
in t
or

his
ate
do
riv
Removing
p
cum
for
en
ng
t.
– Remove front differential lock ⇒ Rep. gr. 34 ; Front differential
op
yi Co
lock; Removing front differential lock .
C py
ht. rig
rig ht
py by
– Secure front differential lock to engine and gearbox support
co Vo
by lksw
⇒ page 42 .
cted agen
Prote AG.
As opposed to the illustration, the flange shaft does not need to

be removed.
– Lever out seal.
• Do not damage the plastic container -A- and the support wash‐
er -B-.
The support washer -B- is located right below the seal.

Installing
• When installing oil seal, make sure that support washer -B- is
inserted ⇒ previous fig. and ⇒ page 191 .
sealing grease .
– Drive in new seal to stop, being careful not to cant seal.

– Install front differential lock ⇒ Rep. gr. 34 ;oFront differential
. V lkswagen AG
lock . swa gen AG does
k not
Vol gu
– Check oil level of front differential
ed
by lock ⇒ Rep. gr. 39 ; Com‐ ara
nte
oris lock; Checking oil level .
ponents of front differential eo
th
au ra
c
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
5.3.2 Renewing oil seal for right flange shaft
es, in part or in w
t to the co
within front differential lock
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.
♦ Extractor hook - VW 771/37-

♦ Sealing grease
Removing
⇒ page 42 .
– Supplement multi-purpose tool - VW 771- with supplementary
set for engine and gearbox support - VW 540/1 B- .
-a- = washer AG. Volkswagen AG d
agen oes
ksw not
– Bolt flange shaft
by V to multi-purpose tool - VW 771-
ol
gu and pull
ara
out.
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
Note
t to the co
♦ The flange shaft is secured with a retaining ring -arrow-.

rrectne
♦ Check if the retaining ring -arrow- is present.

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

If necessary, remove the retaining ring from the area of the seal
-1- or of the ball bearing -2-.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
or
Seal is located in theau front differential lock in front of the roller ac
bearing -A- ss
ce
e
nl
pt
du
an
itte
y li
Caution
erm
ab
ility
ot p
Do not damage the roller bearing -A- when removing the seal.
wit
, is n
h re
hole
Installation position of seal:
spec
es, in part or in w
105 mm below upper edge/hollow shaft
t to the co
– Pull out seal using multi-purpose tool - VW 771- and extractor
rrectness of i
hook - VW 771/37- .
l purpos
• Push extractor hook - VW 771/37- firmly into seal

-direction of arrow-.
nform
ercia
Installing
m
at
om
ion
c
in t
or
sealing grease .
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.
Installation position of seal:

• The open side -arrow- faces towards inside of front differential
lock.

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ar
Arteon 2018or➤ is , Golf 2017 ➤ , Golf Variant 2017 ➤ , aPolo
e nte 2018 ➤ , T-Ro ...
h eo
6-speedaut manual gearbox 02Q, 0BB and 0FB, removed r a- Edition 03.2019
c
ss
ce
le
– Drive in new seal to stop, being careful not to cant seal.
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
Renew retaining ring -arrow-.
nform
ercia
– Push in flange shaft to stop by hand.

m
a
com
tion in
– Drive in flange shaft, being careful not to cant it.
r
te o
thi
s
– Install front differential lock ⇒ Rep. gr. 34 ; Front differential
iva
do
r
lock
rp
cum
fo
en
ng
– Fill oil for front differential lock ⇒ Rep. gr. 39 ; Components

t.
yi Co
op
of front differential lock; Draining and filling oil for front differ‐ C py
t. rig
gh
ential lock .
ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
5.4 Renewing ball bearing for flange shaft

♦ Internal puller - VAS 251 627- or internal puller , e.g. -Kukko

21-5-E-
♦ Adapter from sliding hammer -Kukko 22-0-1-

♦ Press tool - VW412-
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
♦ Press tool - VW473-
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
♦ Pressure plate - VW401-
i
or
n thi
te
sd
a
♦ Pressure plate - VW402-

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.
Removing
⇒ page 42 .

– Supplement multi-purpose tool - VW 771- with engine and

gearbox support supplement - VW 540/1 B- .
-a- = washer
– Bolt flange shaft to multi-purpose tool - VW 771- and pull out.
Note
♦ The flange shaft is secured with a retaining ring

agen
AG.-arrow-.
Volkswagen AG
do w es n
olks ot g
♦ Check if the retaining ring -arrow-d bisy Vpresent. ua
ran
e
ris tee
utho or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
If necessary, remove the retaining ring from the area of the seal
hole
spec
-1- or of the ball bearing -2-.
es, in part or in w
t to the co
– Lever out flange shaft seal -1- using assembly lever.
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
– Remove retaining ring in front of ball bearing ⇒ page 191 .

do
priv
cum
or
– Pull out ball bearing for flange shaft.

f
en
ng
t.
yi Co
op
A - Internal puller - VAS 251 627- or internal puller , e.g. -Kukko C py
t. rig
21-5-E-
gh ht
pyri by
Vo
co lksw
by
B - Adapter from sliding hammer -Kukko 22-0-1- cted agen
Prote AG.

Installing
• The smaller end of thrust piece - VW473- points towards ball
bearing.
• Fit press tool - VW473- centrally onto ball bearing.
• Do not damage the plastic container -A-.
– Press in ball bearing for flange shaft to stop.
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
– Drive in new oil seal to stop, being careful not to cant oil seal.
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
– Half-fill space between sealing lip and dust lip -arrow- with
m
sealing grease .
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.
– Renew retaining ring -arrow-.

– Push in flange shaft to stop by hand.
– Drive in flange shaft, being careful not to cant it.
– Install front differential lock ⇒ Rep. gr. 34 ; Front differential
lock; Installing front differential lock .

6 Gear oil
For relevant description, refer to ⇒ Rep. gr. 39 ; Gear oil
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.
6. Gear oil 201

7 Oil for front differential lock

For relevant description, refer to ⇒ Rep. gr. 39 ; Components of
front differential lock; Checking oil level et seqq.
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.

SM 6

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 6

Uploaded by

Copyright:

Available Formats

Service

Service Department. Technical Information

All rights reserved.

Copyright © 2019 Volkswagen AG, Wolfsburg D4B806B8524

3.3 Installing bevel box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

4 Front differential lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

5.1 Transporting manual gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

6 Gear oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 t to the co

7 Securing to engine and gearbox support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

8 Dismantling and assembling gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

8.2 Assembly overview - gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

8.3 Assembly overview - gearbox housing and selector mechanism . . . . . . . . . . . . . . . . . . . . 50

8.4 Assembly overview - shafts, differential, selector mechanism . . . . . . . . . . . . . . . . . . . . . . 52

8.5 Assembly overview - selector forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

8.6 Dismantling and assembling gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

9 Gearbox housing, clutch housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

39 - Final drive - differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136

2.1 Assembly overview - differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138

4.2 Renewing bevel box seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166

5 Components of front differential lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191

5.1 Assembly overview - components of front differential lock . . . . . . . . . . . . . . . . . . . . . . . . . . tion in

5.2 Checking function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192

5.3 Renewing seals for front differential lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192

5.4 Renewing ball bearing for flange shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197

2 Rep. gr.00 - Technical data

3.1 Allocation gearbox - engine

4 Overview - power transmission

4.1 Overview - power transmission - front-wheel drive

-Arrows- point in direction of travel.

4 Rep. gr.00 - Technical data

4. Overview - power transmission 5

gears (output shaft I)

6 Rep. gr.00 - Technical data

4. Overview - power transmission 7

8 Rep. gr.00 - Technical data

A number of general notes on the individual repair procedures,

see ⇒ Electronic parts catalogue (ETKA) .

♦ When installing the manual gearbox, ensure that the dowel

♦ The contact surfaces of waxed parts must be cleaned before

the parts are installed. Contact surfaces must be free of wax

♦ Retaining rings must locate properly in grooves.

line with the line of force -arrow-.

plates. Loosen and tighten bolts and nuts alternately and in

♦ Ensure with threaded connections that contact surfaces as

10 Rep. gr.00 - Technical data

♦ Do not interchange them. When reusing synchro-rings, always

intermediate ring for »scoring« and »signs of abnormal wear«.

»signs of abnormal wear«.

♦ Heat synchro-hubs to about 100 °C with the inductive heater

so there is no axial clearance.

♦ Heat gears to about 100°C with the inductive heater - VAS

6414- before installing. Press in to stop when installing so

there is no axial clearance.

♦ Observe installation position

1.1 Assembly overview - clutch release mechanism

1 - Clutch slave cylinder with

parts catalogue (ETKA)

❑ Renew after removal

❑ Take account of the

Use compressed air to clean hole. If

necessary, screw a clean, removed

bolt into and out of the hole to loosen

locking fluid residue.