5spd Manual Trans 02j Front Wheel Drive

2006 Audi TT
TRANSMISSION 5 Spd. Manual Transmission 02J Front Wheel Drive
TRANSMISSION
5 Spd. Manual Transmission 02J Front Wheel Drive
00 GENERAL, TECHNICAL DATA

TRANSMISSION IDENTIFICATION
Transmission identification
The 5 speed manual transmission 02J is installed in combination with the 4-cylinder
fuel injected engine in the Audi TT from 1999.
Application. Refer to Code letters, transmission application, ratios, capacities.
Fig. 1: Locating Code Letters And Date Of Manufacture On Transmission

Courtesy of VOLKSWAGEN UNITED STATES, INC.
Location on transmission
Code letters and date of manufacture (arrow -1-), manual transmission 02J (arrow -
2-)
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2006 Audi TT
Fig. 2: Identifying Manual Transmission 02J

Manual transmission 02J (arrow -2-)
Fig. 3: Code Letters And Date Of Manufacture Of Transmission

Code letters and date of manufacture of transmission
Example: DZF 15 10 8
I I I I
I I I I
Code Day Month Year (1998) of manufacture
letters
Additional data depends on manufacture.
NOTE: The transmission code letters are also shown on the

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2006 Audi TT
vehicle identification plates.

Code letters, transmission application, ratios, capacities
Manual 5-speed 02J

transmission
Code letters DZF EGZ1) EWV1)
Manufactured from 06.98 09.00 05.00
to 09.00
Application Model Audi TT 1999 Audi TT 1999 Audi TT 1999 >
> >
Engine 1.8 Liter - 132 1.8 Liter - 132 1.8 Liter - 132
kW kW kW
Ratio: Z2 : Z1 Final drive 63 : 16 = 3.938 63 : 16 = 3.938 63 : 16 = 3.938
1st gear 33 : 10 = 3.300 33 : 10 = 3.300 33 : 10 = 3.300
2nd gear 35 : 18 = 1.944 35 : 18 = 1.944 35 : 18 = 1.944
3rd gear 34 : 26 = 1.308 34 : 26 = 1.308 34 : 26 = 1.308
4th gear 30 : 29 = 1.034 30 : 29 = 1.034 30 : 29 = 1.034
5th gear 31 : 37 = 0.838 31 : 37 = 0.838 31 : 37 = 0.838
6th gear - - -
Reverse 17 : 10 x 36 : 17 : 10 x 36 : 20 17 : 10 x 36 : 20
20 = 3.060 = 3.060 = 3.060
Speedometer 13 : 22 = 0.591 13 : 22 = 0.591 13 : 22 = 0.591
1) After 09.00 with changed synchronization for 1st gear and selector mechanism
on transmission
Code letters DZF EGZ1) EWV1)

Capacity 2.0 Liters 2.0 Liters 2.0 Liters
Specification Gear oil: SAE 75 W 90 (synthetic oil)
Part number: G 005 000 (1 Liter)
Clutch control Hydraulic Hydraulic Hydraulic
Clutch plate diameter 219 mm 2) 219 mm 2) 219 mm 2)
Drive flange diameter 108 mm 108 mm 108 mm
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Overall ratio in top gear 3.299 3.299 3.299
1) After 09.00 with changed synchronization for 1st gear and selector mechanism
on transmission
2) With dual-mass flywheel

TRANSMISSION LAYOUT
Transmission layout
Fig. 4: View Of Transmission Layout & Gear Ratios

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Designation
1 - Engine
2 - Clutch
3 - Transmission
4 - Input shaft
5 - Output shaft/pinion shaft

6 - Differential
Arrows point in direction of travel
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Fig. 5: View Of Transmission Layout & Gear Ratios

Gear ratios
I - 1st gear
II - 2nd gear
III - 3rd gear
IV - 4th gear
V - 5th gear
R - Reverse gear
A - Final drive
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T - Speedometer drive
Arrows point in direction of travel

CALCULATING OVERALL RATIO 'I'
Calculating overall ratio 'i'
Example:
5th gear Final drive

Drive gear ZG1 = 31 ZA1 = 16
Driven gear ZG2 = 37 ZA2 = 63
i= Z2 ÷ Z11)
iG = Gear ratio = ZG2 : ZG1 = 31 : 37 = 0.838
iA = Axle ratio = ZA2 : ZA1 = 63 : 16 = 3.938
iov = Overall ratio

= iG x iA = 0.838 x 3.938 = 3.299
1) Z1 = No. of teeth drive gear, Z2 = No. of teeth driven gear

GENERAL REPAIR INSTRUCTIONS
General repair instructions
To ensure successful transmission repairs, always work with particular care and
maintain a high standard of cleanliness. It is also important to use the correct tools
and to make sure they are in good condition. The basic rules for safety must also be
observed during repair work.
A number of generally valid instructions applicable for the various repair

procedures are given in various parts of the article. These are summarized here and
are applicable to this article
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Special tools
Transmission
When installing, make sure that the dowel sleeves between the engine and
transmission are correctly installed.
Thoroughly clean all connections and the surrounding area before
disconnecting.
When replacing a transmission, fill with gear oil to the lower edge of the filler
hole.
Capacities and specifications. Refer to Code letters, transmission
application, ratios, capacities.
NOTE: If gear oil is added with the transmission installed, check

the oil level as follows:
Top off with gear oil to lower edge of filler hole and reinstall filler plug. Start
engine, engage a gear and allow transmission to turn for about 2 minutes.
Switch engine off and again top off gear oil to lower edge of filler hole.
O-rings, seals, gaskets

Always replace O-rings, seals and gaskets.
After removing gaskets and seals, always inspect the contact surface on the
housing or shaft for burrs resulting from removal or for other signs of damage.
Thoroughly clean joint surfaces and apply sealant AMV 188 200 03.
Apply sealant uniformly but not too thickly.
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Fig. 6: Identifying Space Between Oil Seal Sealing Lips

Before installing seals, lightly oil outer circumference and fill space between
sealing lips (arrow) with a small amount of grease.
The open sides of the seals face the oil side.

When replacing seals, always vary the point at which the sealing lips make
contact (use insertion depth tolerances).
Lightly oil O-rings before installing. This prevents the rings from being
pinched when inserting.
Check gear oil level after replacing gaskets and seals. If necessary, top off so
that oil is level is at bottom edge of filler hole. Specification. Refer to Code
letters, transmission application, ratios, capacities.
Locking devices
Do not over-stretch circlips.

Always replace circlips which have been damaged or over-stretched.
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Fig. 7: Identifying Locking Elements

Replace roll pins. Position: slot -A- should be in line with the line of force
(arrow).
Circlips must locate properly in the groove.
Bolts and nuts
Tighten and loosen bolts and nuts for securing covers and housings in a
diagonal sequence.
Especially delicate parts, such as clutch pressure plates, must not be distorted.
Loosen and tighten bolts and nuts in stages in a diagonal sequence.
Tightening torques as specified are for unoiled bolts and nuts.
Replace self-locking bolts and nuts.
Bearings
Install needle bearings with lettered side (thicker metal) toward installation
tool.
Lubricate all transmission bearings with gear oil.
Always replace the tapered roller bearings on one shaft together as a set and
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use new bearings from the same manufacturer.

Heat inner races of tapered roller bearings to approx. 100 ° C (212 ° F) before
installing. Press on up to stop when installing so there is no axial clearance.
Do not interchange outer or inner bearing races of the same size. The bearing
races are matched in pairs.
Shims
Measure shims at several points with a micrometer. With the various tolerances
it is possible to find the exact shim thickness required.
Check for burrs and damage.
Only install undamaged shims.
Synchronizer rings
Do not interchange. When reusing, always reinstall to the same gear.

Check for wear and replace if necessary.
Coat with gear oil before installing.
Gears
Observe installation position.

Before installing, clean and heat on a hot plate to approx. 100 ° C (212 ° F).
Temperature can be checked with VAG1558 temperature tester.
Sliding gears
After installing, check axial clearance of 1st through 5th speed sliding gears.
The gears should have a small amount of axial clearance and should rotate
freely.
Clutch mechanism
When removing the transmission, remove the clutch slave cylinder without
disconnecting lines.
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If the slave cylinder is removed with the hydraulic line attached, do not depress
the clutch pedal. Otherwise the piston will be pressed out of the slave cylinder.
Make sure that the pressure plate is kept straight: loosen and tighten bolts in a
diagonal sequence and in several gradual stages.
To reduce odor caused by a burned clutch, thoroughly clean the bellhousing,
flywheel and the parts of the engine facing the transmission.
30 CLUTCH
CLUTCH CONTROL, SERVICING
Clutch control, servicing
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Fig. 8: Assembly Overview Clutch Control (Pedal Cluster I & Hydraulics II)
I - Assembly overview - pedal cluster. Refer to Pedal cluster, overview
III - Assembly overview - hydraulics. Refer to Hydraulic system, overview
NOTE: Disconnect battery Ground strap.

For vehicles with coded radio obtain radio code.
Lubricate all bearings and contact surfaces with poly
resin grease Part No. G 052 142 A2.
Make sure that no brake fluid escapes into the footwell,
plenum chamber or onto the transmission below. If this
does happen, clean the affected areas thoroughly.
When performing work in the footwell, put cloths on the
carpet to protect it from possible brake fluid spills.
Pedal cluster, overview
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Fig. 9: Exploded View Of Pedal Cluster Components

1 - Bulkhead
With mounting for mounting bracket and master cylinder
2 - Gasket
Always replace
3 - Mounting bracket
For mounting clutch pedal

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4 - Bolt
5 - Mounting bracket
For mounting accelerator pedal and brake pedal
6 - Self-locking hex nut, 25 Nm
Always replace
7 - Connecting plate

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Always replace
9 - Mounting bushing
10 - Fulcrum pin
11 - Clutch pedal
Removing and installing. Refer to Clutch pedal, removing and installing
12 - Retainer
Removing and installing. Refer to Hydraulic system, overview
Always replace
14 - Master cylinder
Removing and installing. Refer to Master cylinder, removing and installing

15 - Supply hose
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16 - Over-center spring
Removing and installing. Refer to Over-center spring, removing and
installing
17 - Over-center spring mounting

Install in mounting bracket
Removing and installing, to replace master cylinder. Refer to Master cylinder,
removing and installing
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18 - Stop
For clutch pedal
Installation position. Refer to Installing
Always replace
Over-center spring, removing and installing
Special tools and workshop equipment required
Fig. 12: T10111 Assembly Device

T10111 Assembly clip

Removing
Remove driver's side lower cover.

Refer to 68 - INTERIOR EQUIPMENT
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Fig. 13: Inserting Assembly Device T10111 In Over-Center Spring From Right
Side
Install assembly clip T10111, from right side, onto over-center spring. Ensure
that assembly clip is correctly seated:
1 - Rear part of assembly clip must be positioned on over-center spring so that

claws fit over web -1-.
2 - Press clutch pedal lightly toward bulkhead. Hook tab -2- of assembly clip into
cut-out of over-center spring
Press clutch pedal as far as possible toward bulkhead until over-center spring
can be removed downward from mountings on bracket and clutch pedal.
Move clutch pedal to rest position.
Fig. 14: Turning Over-Center Spring Together With Assembly Device T10111
& Taking Out Downward
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Turn over-center spring together with assembly clip T10111 in direction of
arrow -A- and remove downward in direction of arrow -B-.
Installing
Pull clutch pedal into passenger compartment.
Fig. 15: Installing Over-Center Spring Together With Assembly Device

T10111 Into Support
Insert over-center spring together with assembly clip T10111 upward (direction
of arrow -A-) into bracket and then turn in direction of arrow -B-.
Fig. 16: Identifying Rear Support & Clutch Pedal Bearing Tab
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Insert over-center spring into rear mounting first (arrow -A-).

Operate clutch pedal unit over-center spring seats on mounting tab (arrow -B-)
of clutch pedal.
Remove assembly clip and place clutch pedal in rest position.
Install driver's side lower cover.

Clutch pedal, removing and installing
Fig. 17: Identifying Pliers T10005

T10005 Pliers
Fig. 18: Torque Wrench V.A.G 1331

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V.A.G 1331 Torque wrench

Removing
Rotate clutch pedal position switch 45 to left and pull out of retainer.
Remove over-center spring. Refer to Over-center spring, removing and
installing.
Separate clutch pedal from master cylinder. Refer to Master cylinder,
removing and installing and push operating rod toward engine compartment
onto stop.
Fig. 19: Clutch Pedal Nut

Remove nut -A-.
Pull bolt out until the clutch pedal can be removed.
Installing
Installation is performed in the reverse sequence. When doing this, note the
following:
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Fig. 20: Identifying Retainer & Clutch Master Cylinder Operating Rod
Retainer -A- must be installed to master cylinder operating rod -B-.
Press clutch pedal in direction of arrow to engage. Make sure it is correctly
located.
Install over-center spring. Refer to Over-center spring, removing and

installing.
Place clutch pedal position switch into retainer and rotate 45 to right. Refer to
Clutch pedal position switch -F194- or Clutch vacuum vent valve switch -
F36- (cruise control switch), removing and installing.
Clutch pedal position switch -F194- or Clutch vacuum vent valve switch -F36- (cruise control switch), removing and
installing
Removing
Remove lower cover on driver's side.

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Fig. 21: Clutch Pedal Position Switch -F194- Or Clutch Vacuum Vent Valve
Switch -F36- Remove/Install Components
Remove connector -1- from interlock switch.

Turn switch -2- in direction of arrow 90 ° to left and remove switch.
Cruise control switch -3- is removed in the same manner.
Installing
following:
Grease cam head of cruise control or interlock switch with poly resin grease
Part No. G 052 142 A2.
NOTE: The cruise control switch must be installed in the upper

assembly opening.
Hydraulic system, overview
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Fig. 22: Exploded View Of Hydraulic System Components

1 - Brake fluid reservoir

2 - Supply hose
3 - Master cylinder
Removing and installing. Refer to Master cylinder, removing and installing
4 - Retainer
Replace only with master cylinder removed

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Removing. See Pry retainer -A- off in direction of arrow

Pressing on. See Press master cylinder operating rod in retainer -A- in
direction of arrow
5 - Clutch pedal
Removing and installing. Refer to Clutch pedal, removing and installing

Always replace

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7 - O-ring
Pull over hose connector
Insert with brake fluid.
8 - Pipe/hose assembly
Disconnecting at master cylinder and installing. Refer to Master cylinder,

Disconnecting and installing at slave cylinder. Refer to Slave cylinder,
Use parts catalog to check correct application
9 - Bracket
Secured to bodywork
10 - Dust cap
11 - Bleed valve
Bleeding clutch system. Refer to Clutch system, bleeding
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12 - Slave cylinder
Removing and installing. Refer to Slave cylinder, removing and installing
13 - Collared securing bolt, 25 Nm
14 - Transmission
15 - Clip
Pull out retaining clip to disconnect pipe. Refer to Master cylinder, removing
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and installing
16 - O-ring
Pull over pipe connection
Insert with brake fluid.

17 - Support bracket
18 - Hose bracket
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Secure to control cable/gear selector cable support bracket
19 - Clip
Pull out retaining clip to disconnect pipe. Refer to Master cylinder, removing
and installing
Pry retainer -A- off in direction of arrow
Fig. 26: Removing Retainer By Prying

Press master cylinder operating rod in retainer -A- in direction of arrow
Fig. 27: Installing Clutch Master Cylinder Operating Rod In Retainer

Master cylinder, removing and installing

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Fig. 28: Identifying Pliers T10005

T10005 Pliers

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Fig. 30: T10111 Assembly Device

T10111 Assembly clip
Fig. 31: Identifying Hose Clamps 3094

3094 Clamps
Removing
NOTE: In order to take out the master cylinder the entire clutch
pedal assembly must be removed.
Fig. 32: Air Filter Housing, MAF Sensor, And Retainers

Release hose clamp -4- and disconnect intake hose and electrical connector -1-
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from Mass Air Flow (MAF) sensor.

Remove hose -5- from air filter housing.
Unscrew bolts -2- and -3-, then remove air cleaner housing (complete).
Fig. 33: Identifying Supply Hose, Clip & Line/Hose Assembly

Clamp return hose -A- (to brake fluid reservoir) with hose clamp 3094.
Pull return hose -A- off of reservoir.
Pull clip -B- for pipe/hose off master cylinder.
Pull pipe/hose assembly -C- out of master cylinder and seal end of pipe/hose
assembly.
Remove driver's side lower cover.

Turn clutch pedal position switch 45 to left and pull out of retainer.
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Fig. 34: Identifying Connecting Plate, Securing Nuts & Support

Unbolt clutch pedal mounting bracket (complete) as follows:

Remove securing nuts (arrows -1-) and take off connecting plate (arrow -A-).
Remove securing nuts (arrows -2-) for mounting bracket -B-.
Take off mounting bracket.
Fig. 35: Inserting Assembly Device T10111 In Over-Center Spring From Right
Side
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Remove over-center spring using assembly clip T10111 as follows:
1 - Rear part of assembly clip must be positioned on over-center spring so that

claws fit over web -1-.
2 - Press clutch pedal lightly toward bulkhead. Hook tab -2- of assembly clip into
cut-out of over-center spring
Fig. 36: Pressing Both Sides Of Mounting Inward Using Pliers T10005
Disengage master cylinder operating rod in front of clutch pedal as follows:
Carefully pull clutch pedal into passenger department.

Push both sides of retainer in with pliers T10005 (arrows).
Fig. 37: Turning Stop Of Clutch Pedal

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Turn stop -A- for clutch pedal in direction of arrow and remove.
Fig. 38: Removing Master Cylinder From Mounting Bracket

Then push slave cylinder in direction of arrow -1- onto stop.
The top of the slave cylinder must not be covered by the over-center spring
mounting (arrow -2-).
Then swing slave cylinder in direction of arrow -3- out of mounting bracket.
Installing
Installation is carried out in the reverse sequence. When doing this, note the
following:
Fig. 39: Identifying Retainer & Clutch Master Cylinder Operating Rod
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Install retainer -A- to master cylinder operating rod -B-.

Press clutch pedal in direction of arrow to engage. Make sure it is correctly
located.
Fig. 40: Identifying Rear Support & Clutch Pedal Bearing Tab
Insert over-center spring into rear mounting first (arrow -A-).

Operate clutch pedal until over-center spring seats on mounting tab (arrow -B-)
of clutch pedal.
Take out assembly clip and place clutch pedal in rest position.
Fig. 41: Installing Stop For Clutch Pedal

Re-install stop -A- for clutch pedal.

Installation position:
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The arm (arrow) points toward master cylinder -B-.

After installing master cylinder, bleed clutch system. Refer to Clutch system,
bleeding.
Install complete air filter housing.
Refer to
24 MULTIPORT FUEL INJECTION (MFI) for 1.8 LITER 4-CYL. 5V

TURBO FUEL INJECTION & IGNITION, ENGINE CODE(S): AMU
TURBO FUEL INJECTION & IGNITION, ENGINE CODE(S): ATC
TURBO FUEL INJECTION & IGNITION, ENGINE CODE(S): AWP
TURBO FUEL INJECTION & IGNITION, ENGINE CODE(S): BEA
24 - MULTIPORT FUEL INJECTION (MFI) for 1.8 LITER 4-CYL. 5V
TURBO GENERIC SCAN TOOL ENGINE CODE(S): AMU, BEA, ATC,
AWP
Slave cylinder, removing and installing
Removing

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Remove hose -5- from air filter housing.
Fig. 43: Unclipping Clutch Slave Cylinder Hose From Selector Cable Support
Bracket, Removing Bolts & Selector Cable Support Bracket From
Transmission
Unbolt support bracket for gear selector cable from transmission and unclip
hose (arrows).
Vehicles up to 06.01
Fig. 44: Identifying Gate Selector Cable, Gear Selector Cable & Nut
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Pull off gate selector cable -A- with relay lever by removing circlip (arrow).
Remove gear selector cable -B- with transmission selector lever by removing
nut.
Tie up selector cable with transmission selector lever and gate selector cable
with relay lever.
Vehicles from 07.01
Fig. 45: Identifying Gear Selector Lever, Relay Lever & Securing Clips
Remove securing clip -3- for gear selector cable from gear selector lever -1-.
Remove securing clip -4- for gate selector cable from relay lever -2-.
Pry gate selector cable and gear selector cable off pin (arrows).
Continuation for all vehicles
Fig. 46: Identifying Slave Cylinder Fasteners

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Remove bolts for slave cylinder (arrows).
Remove slave cylinder.
Fig. 47: Identifying Retaining Clip, Recess On Pipe Aligned With Projection
On Slave Cylinder And Pipe
Pull clip -A- out of slave cylinder. Then pull pipe/hose assembly -C- out of
slave cylinder and close off end of pipe.
Installing
following:
Fig. 48: Identifying Retaining Clip, Recess On Pipe Aligned With Projection
On Slave Cylinder And Pipe
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Press in retaining clip -A- as far as it will go.
Align recess on pipe with projection (arrow -B-) on slave cylinder.
Push pipe -C- into slave cylinder until it engages audibly.
Grease end of plunger with MoS2.
After installing slave cylinder, bleed clutch system. Refer to Clutch system,
bleeding.
Vehicles up to 06.01
Fig. 49: Locating Gap And Missing Teeth Of Selector Shaft

Install transmission selector lever as follows:
Ensure that gap (arrow -A-) is placed over missing teeth (arrow -B-) of selector
shaft.
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Install gear selector cable -B- to transmission selector lever (arrow).

Install gate selector cable -A- to relay lever and secure (arrow).
Vehicles from 07.01
The cable locks have holes for securing them on the gear selector lever or the
relay lever.
The holes in the cable locks have various diameters:
Cable lock for: Dimension "a"

Gear selector cable to gear change lever 10 mm
Gate selector cable to relay lever 8 mm
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Spread a small quantity of polyurea grease on pins (arrows) of gear change
lever -1- and relay lever -2-.
NOTE: Always replace securing clips -3- and -4- after

disassembling.
Secure gear selector cable with securing clip -3- and gate selector cable with
securing clip -4-.
Continued for all vehicles

Install cable support bracket on transmission. If necessary, push hose onto
cable support bracket.
Install air cleaner housing (complete).
Refer to

AWP
Tightening torques
Clutch slave cylinder to transmission 25 Nm

Selector cable support bracket to transmission 25 Nm
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Clutch system, bleeding
Fig. 52: VAS 5234 Brake Filler And Bleeder Unit

VAS 5234 Brake filler and bleeder unit
NOTE: Before bleeding the clutch system, pull up and support

clutch pedal and top off brake fluid reservoir to "Max"
marking with brake fluid.
Brake fluid specifications.

Refer to 47 BRAKES - HYDRAULIC COMPONENTS
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Fig. 53: Pressing Clasp Together And Disconnecting Secondary Air Pipe From
Air Cleaner Housing
Press clasp (arrow -A-) together and disconnect secondary air pipe from air
cleaner housing. Move secondary air pipe upward and out of way.
NOTE: If necessary, use bleed hose V.A.G 1238/B 3 - 670 mm long

to bleed system.
Fig. 54: Bleed Hose Connected To Slave Cylinder

Connect bleed hose to slave cylinder -B- and open bleed valve.
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Depress clutch pedal several times after completion of bleeding process.

Bleed system again if necessary.
CLUTCH RELEASE MECHANISM, SERVICING
Clutch release mechanism, servicing
Fig. 55: View Of Clutch Release Mechanism Components

1 - Transmission
2 - Ball stud, 25 Nm
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Lubricate with MoS2 grease
3 - Input shaft oil seal
Replacing. Refer to Transmission housing and clutch housing, servicing
4 - Guide sleeve
With vulcanized O-ring

If O-ring is damaged, replace guide sleeve and O-ring together
Lubricate guide sleeve with MoS2grease around release bearing
5 - Retaining spring
Secure to clutch release lever
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6 - Securing bolt, 20 Nm
7 - Clutch release lever
8 - Release bearing
Do not wash out bearing, only wipe
Replace noisy bearings
Lubricate surfaces which contact release lever with MoS2 grease
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9 - Collar bolts, 25 Nm
10 - Slave cylinder
11 - Plunger
Grease end of plunger with MoS2grease

12 - Assembly bolt
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Secures clutch release lever when installing transmission

Unscrew after transmission has been installed
NOTE: If the assembly bolt (Item - 12 Clutch release mechanism,

servicing) is not available, an M 8 x 35 bolt can be used.
CLUTCH, SERVICING
Clutch, servicing
(Transmission removed)
Fig. 58: 3190 A Mandrel

3190 A - Mandrel
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Fig. 59: Identifying Flywheel Retainer 3067

3067 - Counter-hold tool
NOTE:
Fig. 60: Identifying Flywheel, Clutch Plate, Pressure Plate &

Bolt
Clutch plates and pressure plates with damaged or

loose rivets must be replaced.
Select correct clutch plate and pressure plate according
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to parts list and engine code.
1 - Flywheel
Make sure centering pins are a tight fit
Contact surface for clutch lining must be free of grooves, oil and grease
Removing and installing
Refer to
13 ENGINE - CRANKSHAFT, CYLINDER BLOCK for 1.8 LITER 4-
CYL. 5V TURBO ENGINE MECHANICAL, ENGINE CODE(S): AMU,
BEA
CYL. 5V TURBO ENGINE MECHANICAL, ENGINE CODE(S): ATC,
AWP
CYL. 5V TURBO FUEL INJECTION & IGNITION, ENGINE CODE(S):
BEA
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Fig. 61: Identifying Flywheel, Clutch Plate, Pressure Plate & Bolt
2 - Clutch plate
Diameter. Refer to Code letters, transmission application, ratios, capacities
Installation position on dual-mass flywheel: shorter hub end (arrow) points
toward pressure plate
Installation position with single piece flywheel: spring cage faces pressure
plate
Centering. See Centering clutch plate and removing and installing pressure
plate
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Lightly grease splines
NOTE: Clean input shaft splines. On used clutch plates, also clean
the hub splines. Remove corrosion and apply only a very
thin coating of grease Part No: G 000 100 to the input shaft
splines. Then move clutch plate up and down input shaft
until hub moves freely on shaft. Excess grease must be
removed.
Fig. 62: Identifying Flywheel, Clutch Plate, Pressure Plate & Bolt
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3 - Pressure plate
Assembly possible only in one position
Removing and installing. See Centering clutch plate and removing and
installing pressure plate
Check ends of diaphragm spring. See Checking ends of the diaphragm
spring
NOTE: Pressure plates are protected against corrosion and

greased. Only the contact surface may be cleaned,
otherwise the service life of the clutch will be considerably
reduced.
4 - Bolt
Select correct type from parts catalog
On dual-mass flywheel:
Hex bolt (M6) - 13 Nm
On single piece flywheel:

Multi-point bolt (M7) - 20 Nm
Loosen and tighten gradually and in diagonal sequence
Centering clutch plate and removing and installing pressure plate
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Fig. 63: Centering Clutch Plate And Removing And Installing Pressure Plate
Loosen and tighten bolts gradually and in diagonal sequence.

Reverse position of retainer 3067 when removing.
NOTE: Pressure plate contact surface and friction material of

clutch plate must make full contact with flywheel. Then
loosely thread in mounting bolts
Pressure plate can only be installed in one position on
the flywheel.
Then insert and tighten bolts evenly and in diagonal
sequence to prevent damage to the centering holes in
the pressure plate housing and to the centering pins in
the flywheel.
Checking ends of the diaphragm spring
Fig. 64: Checking Ends Of Diaphragm Spring

Acceptable wear limit: up to half the thickness of the diaphragm spring

34 MANUAL TRANSMISSION - CONTROLS, HOUSING
GEAR SELECTOR MECHANISM, SERVICING
Installation position of gear selector mechanism
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Fig. 65: Installation Position Of Gear Selector Mechanism

Arrow -A- Gear selection movement

Arrow -B- Gate selection movement
1 - Gear selector cable

For gear selection movement -A-
2 - Gate selector cable
For gate selection movement -B-

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3 - Heat shield
Remove before removing gear selector mechanism.
4 - Relay lever
5 - Gear selector lever (on transmission) with vibration damper weight
Fig. 66: Gear Selector Mechanism Servicing Overviews

I - Removing and installing gear lever knob and boot. Refer to Gear lever knob
and boot, removing and installing
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II - Servicing gear lever. Refer to Gear lever, servicing

III - Assembly overview: Removing and installing selector cables - assembly
diagram. Refer to Selector cables, removing and installing - assembly overview
Removing and installing selector mechanism. Refer to Gear selector mechanism,

Adjusting selector mechanism. Refer to Gear selector mechanism, adjusting
NOTE: Before working on the selector mechanism, disconnect

the Ground strap from the battery in the engine
compartment.
Note radio code on vehicles with coded radio.
Gear lever knob and boot, removing and installing
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Fig. 67: Gear Lever Knob And Boot Remove/Install Components

1 - Selector lever knob
Unscrew to remove.
2 - Bolt
3 - Retainer ring
4 - Cover (boot)
Removing. See Removing gear lever knob and boot

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Removing gear lever knob and boot

Unscrew gear lever knob -1-.
Remove bolts -2-.
Lift off retainer ring -3- and boot -4-.
Gear lever, servicing
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Fig. 69: Gear Lever Remove/Install Components

NOTE: Lubricate all mountings and sliding surfaces with Polyurea

grease Part No. G 052 142 A2.
1 - Torx socket head bolt, 6 Nm
2 - Cover plate
3 - Gear lever
4 - Damper
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5 - Bearing shell
Insert in damper (Item - 4 Gear lever, servicing)
Press onto gear lever (Item 3 Gear lever, servicing) together with damper
(Item - 4 Gear lever, servicing)
Open side of bearing cage faces selector housing

6 - Gasket
Between selector housing and floor

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Self-adhesive
Bond to gear lever housing
7 - Damper
Press onto gear lever housing
8 - Gear lever housing
9 - Bolt, 25 Nm
10 - Bushing
Only fits in one position
11 - Fulcrum pin
12 - Guide bushing
Press onto gear lever housing
13 - Spring
Installing. See Installing spring

14 - Gate selector bracket
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16 - Base plate
Open tabs to remove
Replace
17 - Circlip
Always replace

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On gate selector bracket

Installation position. Refer to Installation position of gear selector
mechanism
On gear lever
20 - Hex nut, 25 Nm
21 - Bushing
22 - Circlip
Removing. See Removing circlip for gate selector bracket

Removing circlip for gate selector bracket
Fig. 72: Removing Circlip For Gate Selector Bracket

Lift tab in direction of (arrow).
Installing spring
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Fig. 73: Installing Spring

Insert spring so that arm -A- is under stud (arrow).
Pull arm -B- up toward gear lever and leave it resting on top of stud (arrow).
Gear selector mechanism, removing and installing

V.A.G 1331 - Torque wrench
Removing
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Release clamp -4- and disconnect intake hose and electrical connector -1- from
Mass Air Flow (MAF) sensor.
Unscrew bolts -2- and -3-.
Where installed, disconnect secondary air pipe -5- from air cleaner housing.
Remove air cleaner housing (complete):
Refer to

AWP
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Transmission
Remove cable support bracket from transmission (arrows). If necessary, unclip
hose at cable support bracket first.
Selector mechanism up to 06.01
Fig. 77: Gate Selector Cable, Gear Selector Cable & Open Jaw Spanner
Pry off gear selector cable -A- and gate selector cable -B- using an open-ended
wrench -1-.
-1- Standard open-ended wrench (13 mm), commercially available

Selector mechanism from 07.01
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Remove securing clip -3- for gear selector cable from gear selector lever -1-.
Remove securing clip -4- for gate selector cable from relay lever -2-.
Pry gate selector cable and gear selector cable off pins (arrows).
Continued for all selector mechanisms


Remove bolts -2-.
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Fig. 80: Switch Panel, Connectors, Tabs and Tray

Lift out switch panel -1- and unplug connectors -2-.

Carefully press tabs -3- forward and lift out tray -4-.
Fig. 81: Selector Housing Securing Nuts

Remove securing nuts (arrows) for selector housing.
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Fig. 82: Cross Support, Braces, Double Clamp And Heat Shields
Where installed, unbolt both braces -A-.

Remove cross support -B- below exhaust system.
Loosen double clamp -C- and separate exhaust pipes.
Remove heat shields (arrows -D- and -E-) for selector cables.
Unscrew two lower retaining bolts for selector housing.

Pull gear lever housing down and remove from behind together with selector
cables.
Installing
Installation is carried out in the reverse sequence. When doing this note the
following:
Selector mechanism up to 06.01
If cables are to be reused, replace cable locking mechanisms.
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Fig. 83: Identifying Recesses Of Cable Locking Mechanism, Gate Cable

Locking Mechanism & Seals
Smear a small amount of polyurea grease in recesses of cable locking

mechanism -A- and gate cable locking mechanism -B-.
NOTE: The seals (arrows) outside the recess must be grease free.
Fig. 84: Pressing Gate Selector Cable Onto Relay Lever

Press gear selector cable onto selector lever and press gate selector cable onto
relay lever (arrows).
Selector mechanism from 07.01

The cable locks have holes for securing them on the gear selector lever or the
relay lever.
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The holes in the cable locks have various diameters.
Fig. 85: Identifying Gap In Gear Selector Cable To Gear Shift Lever & Gate
Selector Cable To Relay Lever
Application
Cable lock for: Dimension "a"
Gear selector cable to gear lever 10 mm
Gate selector cable to relay lever 8 mm
The cable locks no longer need to be replaced following disassembling.
Spread a small quantity of polyurea grease on pins (arrows) of gear change
lever -1- and relay lever -2-.
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NOTE: Always replace securing clips -3- and -4- after

disassembling.
Secure gear selector cable with securing clip -3- and gate selector cable with
securing clip -4-.
Continued for all selector mechanisms
Align gear lever housing parallel to body.
Distance to body must be same on both sides.
Adjusting selector mechanism. Refer to Gear selector mechanism, adjusting.
Install air cleaner housing (complete):
Refer to

AWP
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Fig. 87: Cross Support, Braces, Double Clamp And Heat Shields
Tightening torques
Selector housing to body 25 Nm
Cross-piece -B- to body 20 Nm
Braces -A- to cross-piece1)2) 20 Nm
Clamp for exhaust pipe -C- 40 Nm
1) Only installed on TT Roadster
2) Installation position: drilling (arrow) faces down

Selector cables, removing and installing - assembly overview
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Fig. 88: Exploded View Of Selector Cables Components

NOTE: Lubricate all mountings and sliding surfaces with Polyurea

grease Part No. G 052 142 A2.
Disengaging from selector cable retainer (Item - 12 Selector cables, removing

and installing - assembly overview). Refer to Gear selector mechanism,
adjusting

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Disengaging from selector cable retainer (Item - 12 Selector cables, removing

and installing - assembly overview). Refer to Gear selector mechanism,
adjusting
3 - Circlip
4 - Circlip
When removing do not damage boots on cables
5 - Selector housing

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6 - Support bracket
7 - Bushing
Support bracket mounting to transmission
8 - Distance piece
9 - Hex bolt, 25 Nm
For support bracket
10 - Selector cable retainer
For gate selector cable to relay lever

Releasing retainer in order to adjust selector mechanism. Refer to Gear
selector mechanism, adjusting
Replace after removing from relay lever (Item - 14 Selector cables, removing
and installing - assembly overview)
From 07.01 with hole:
New version does not have to be replaced

Secured with securing clip
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11 - Cable locking mechanism

For gear selector cable to gear change lever
Releasing retainer in order to adjust selector mechanism. Refer to Gear
selector mechanism, adjusting
Renew after removing from transmission selector lever -item- 16 Selector
cables, removing and installing - assembly overview
From 07.01 with hole:

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New version does not have to be replaced

Secured with securing clip
12 - Circlip
Removing. See Removing circlip for gate selector bracket and selector
lever guide/gate selector housing
13 - Bushing
14 - Relay lever
Installation position. See Installation positions of gear selector lever, relay

lever and adjuster pin.
15 - Shoe
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16 - Transmission selector lever

With balance weight
Install so that master spline aligns with selector shaft. See Installing
transmission selector lever.
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After installing adjust gear selector mechanism. Refer to Gear selector

mechanism, adjusting
17 - Hex nut, 20 Nm
For gear selector lever
Always replace
Installation positions of gear selector lever, relay lever and adjuster pin
Fig. 92: Installation Positions Of Gear Selector Lever, Relay Lever And
Adjuster Pin
1 - Retainer for gate selector cable
2 - Retainer for gear selector cable
3 - Transmission selector lever with vibration damper weight
4 - Back-up light switch
5 - Adjuster pin
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To adjust selector mechanism, turn pin so that it points upward.

6 - Relay lever
Locates in guide rail of gear selector lever (arrow) via sliding block;
lubricate with MoS2 grease.

Installing transmission selector lever

Install so that gap of master spline (arrow -A-) aligns with missing teeth on
selector shaft (arrow -B-).
Removing circlip for gate selector bracket and selector lever guide/gate selector housing
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Fig. 94: Removing Circlip For Gate Selector Bracket

Lift tab in direction of arrow.
Gear selector mechanism, adjusting
Fig. 95: Identifying Connecting Pin T10027

T10027 - Retaining pin
NOTE: The following points are essential to ensure correct

selector adjustment:
Moving parts of selector mechanism and transmission elements must be in

proper condition.
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Selector mechanism must move freely.
The transmission, clutch and clutch mechanism must also be in proper condition.
Transmission in neutral position
Disengage retainers for gear selector cable and gate selector cable as follows:
Fig. 96: Pushing Back Collar Ass Far As It Will Go

Push back collar -1- as far as it will go in direction of arrow -2-.
Turn collar -1- as far as it will go in direction of arrow -3- and allow it to
engage.
NOTE: The selector cable -4- must be free to move within the
retainer.
The illustration shows the gate selector cable. The
retainer on the gear selector cable can be disengaged
in the same way.
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Fig. 97: Pushing Selector Lever Downward Into Gate For 1st/2nd Gear And
Turning Adjuster Pin So That It Points Upward Allowing It To Engage
Push selector lever -1- downward into gate for 1st/2nd gear (arrow -A-). At
same time, turn adjuster pin -2- so that it points upward (arrow -B-) and allow
it to engage.
Adjuster pin -2- must point upward


Remove bolts -2-.
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Fig. 99: Locking Gear Lever In Position Using Retaining Pin T10027
Use retaining pin T10027 to lock gear lever in position.
NOTE:
Fig. 100: Gate Selector Cable And Gear Selector Cable

Properly Inserted In Their Retainers
Make sure that gate selector cable -1- and gear selector
cable -2- are properly inserted in their retainers -3- and are
not under tension.
Turn each collar -4 as far as it will go in direction of arrow, then release.
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Fig. 101: Rotating Bracket Back Into Initial Position

Now turn adjuster pin -A- back to original position (direction of arrow).
Adjuster pin -A- must be horizontal
Pull retaining pin T10027 out of selector mechanism.

Install gear lever knob and boot.
Checking operation
Gear lever must rest in 3rd/4th gear gate with transmission in neutral.
Operate clutch.
Select all gears several times. Pay particular attention to operation of reverse
gear lock.
It should only be possible to engage reverse gear after pressing gear lever down
to overcome reverse gear lock.
Should a gear fail to engage smoothly after repeated selection, the selector shaft
play (lift) should be checked as follows:
Engage 1st gear.

Press gear lever to left onto stop and release.
At same time observe selector shaft in transmission (2nd mechanic).
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Fig. 102: Selector Shaft Movement

When moving gear lever selector shaft must move approx. 1 mm (in direction of
arrow).
If gear lever is not correctly adjusted:
Repeat adjustment procedure. Refer to Gear selector mechanism, adjusting.

TRANSMISSION, REMOVING AND INSTALLING
Transmission, removing and installing
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Fig. 103: Identifying Special Tools - Transmission, Removing And Installing (1

Of 2)
10-222 A Support
10-222 A/1 Support
V.A.G 1383 A Transmission jack
3282 Transmission support
3282/8 Adjustment plate

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3282/40 Pin (3x)

3282/59 Support
Fig. 104: Identifying Special Tools - Transmission, Removing And Installing (2

Of 2)
3300 A Engine support

VW 457/1 Support rails (modifying. Refer to Modifying support rail VW
457/1)
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3336 Transmission lifting beam


Modifying support rail VW 457/1
Support rails VW 457/1 are required to remove and install the transmission.
Fig. 105: Identifying Support Rails VW 457/1

To secure support rail VW 457/1 to the subframe, an additional hole is needed

(arrow).
Dimensions given are in mm.
If hole is not already there:
Drill a hole (8.5 mm diameter - see arrow) in support rail VW 457/1.

Transmission, removing
NOTE: Any cable ties which were removed or cut through when the
transmission was removed must be replaced by cable ties
installed in the same positions.
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Fig. 106: Removing Engine Cover Panel Above Cylinder Head

Unscrew bolts (arrows) and remove engine cover.
Fig. 107: Battery Cover

Remove battery cover (arrows).

Obtain code on vehicles with coded radio/integrated radio and navigation
system.
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Fig. 108: Battery Ground Strap

With ignition switched off, disconnect battery Ground strap (arrow).

Where installed, disconnect hose -5- from air cleaner housing.
Refer to

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AWP
Open lid of main fuse box.
Fig. 110: Main Fuse Box Cover And Black Wire

Remove protective cover -2- for wires.
Unscrew black wire -1- from fuse bar.
Remove battery.
Refer to 27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL
Vehicles without battery cover
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Fig. 111: Removing Battery Platform

Remove battery platform (arrows).
Vehicles with battery cover
Fig. 112: Side Wall, Platform And Main Fuse Box

Pull side wall -1- with main fuse box up and out.
Remove battery platform (arrows).
All models
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Transmission
Remove cable support bracket from transmission (arrows). If necessary, unclip
hose at cable support bracket first.
Pull off gate selector cable -A- with relay lever. Remove circlip (arrow) to do
this.
Remove gear selector cable -B- with transmission selector lever. Remove nut
(arrow) to do this.
Tie up selector cable with transmission selector lever and gate selector cable
with relay lever.
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Fig. 115: Identifying Vehicle Speed Sensor & Reverse Light Connector (From
05.99)
Pull connector off vehicle speed sensor (arrow -1-).
Pull off back-up light connector (arrow -2-).

Remove slave cylinder and place to side. Secure with wire. Do not disconnect
pipes.
NOTE: Do not depress clutch pedal.
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Fig. 117: Starter Cable Retainer, Ground Strap And Upper Securing Bolt
Remove cable retainer (arrow -1-) on starter.
Remove upper securing bolt (arrow -2-) on starter.
Remove Ground strap from upper securing bolt between engine and
transmission (arrow -3-).
Remove engine/transmission upper securing bolts.
If there are hoses and cable connections in area of engine mounting eye for
support 10-222A, remove these now.
Install support bar 10-222A together with legs 10-222 A/1.
Fig. 118: Support Bar Set Up On Wheelhousing Panels

Set up support bar on wheelhousing panels (arrows).

Take weight of engine/transmission assembly on spindles.
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Fig. 119: Unbolting Bracket For Headlight Range Control In Left

Wheelhousing
Where installed, unscrew bracket for headlight range control in left
wheelhousing (arrows) and secure upward to side.
Fig. 120: Center Sound Insulation Panel

Remove center sound insulation panel -1...3-.
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Fig. 121: Left Sound Insulation Panel

Remove left sound insulation panel (arrows).
Vehicles with power steering lines on cross-piece pipe
Fig. 122: Power Steering Lines At Cross-Piece Pipe

Disconnect power steering lines from cross-piece pipe (arrows).
Vehicles with power steering lines on transmission
Disconnect power steering line from transmission and pull speed nut off
transmission.
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Fig. 123: Front Cross-Piece Pipe

Where installed, remove front cross-piece pipe (arrows).
Remove starter.
Fig. 124: Subframe Brace

Where installed, remove brace from subframe (arrows).
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Fig. 125: Removing/Installing Protective Cap For Drive Axle (If Present)
Remove protective cover for right hand inner constant velocity joint from
engine.
Turn wheels fully onto left lock.
Disconnect drive shafts from flange shafts and tie up as high as possible. When
doing this do not damage surface protection.
Fig. 126: Removing Small Cover Plate For Flywheel Behind Right Flange
Shaft
Remove flywheel small cover plate -A- behind right-hand flange shaft
(arrows), if so equipped.
Remove front exhaust pipe.
Refer to
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26 EXHAUST SYSTEM, EMISSION CONTROLS for 1.8 LITER 4-CYL.

5V TURBO ENGINE MECHANICAL, ENGINE CODE(S): AMU, BEA
5V TURBO ENGINE MECHANICAL, ENGINE CODE(S): ATC, AWP
26 - EXHAUST SYSTEM, EMISSION CONTROLS for 1.8 LITER 4-CYL.
5V TURBO GENERIC SCAN TOOL ENGINE CODE(S): AMU, BEA, ATC,
AWP
Fig. 127: Identifying Pendulum Support & Bolts

Unbolt swing mounting (arrows).
Fig. 128: Identifying Transmission Support & Hex Bolts

Remove transmission support (arrows -A-) from transmission.
Remove hex bolts (arrows -B-) from left-hand hand assembly mounting.
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NOTE: Do not damage power steering line when moving

engine/transmission assembly.
Lower engine/transmission assembly via two spindles until transmission

console securing bolts -A- are accessible from left-hand wheelhousing.
Remove transmission mount -A- as follows:
Fig. 129: Identifying Transmission Mount

To prevent self locking bolts (arrows) from breaking off when loosening, heat
bolt positions first with hot air blower V.A.G 1416 or equivalent.
Unscrew bolts (arrows) and remove transmission mount -A- from transmission.
Fig. 130: Identifying Support 3300 A, Support Rail VW 457/1 & Hex Bolts
Bolt support rail VW 457/1 to both pendulum support securing holes on

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subframe.
Insert spacers totaling 6 mm between subframe and support rail VW 457/1.
-A- Qty. 2 hex bolts M 8 x 25
Mount support 3300 A and secure (arrows).
Press engine/transmission forward carefully.
NOTE: Do not damage power steering line when moving

engine/transmission assembly.
Assemble transmission jack with transmission support 3282, adjustment plate

3282/8 for "02A" transmission and support elements as follows:
Place adjustment plate 3282/8 on transmission support 3282. (Adjustment plate
only fits in one position).
Align arms of transmission support according to holes in adjustment plate.
Fig. 131: Identifying Support Elements & Symbol On Adjustment Plate

Bolt on support elements -A- as illustrated on adjustment plate.
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Fig. 132: Transmission Jack Positioned Under Vehicle

Place transmission jack under vehicle. Arrow symbol -B-(Refer to Fig. 131 in
Transmission, removing) on adjustment plate points to front of vehicle.
Align adjustment plate parallel to transmission and lock safety supports on

transmission.
Remove lower engine/transmission securing bolt.
Fig. 133: Pressing Transmission Off From Alignment Sleeves And Carefully
Pivot It Toward Subframe
Press transmission off dowels and carefully swing towards sub-frame.

Lower transmission slightly and incline to left via spindles of transmission
support 3282.
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Fig. 134: Right-Hand Flange Shaft In Area Of Flywheel & Left-Hand Flange
Shaft In Area Of Subframe
Then lower transmission carefully. When doing this guide right-hand flange
shaft -A- in area of flywheel as illustrated and guide left-hand flange shaft -B-
in area of subframe.
NOTE: When lowering transmission change position of

transmission using the transmission support 3282
spindles.
Do not damage power steering line when lowering
transmission.
Transporting the transmission
Fig. 135: Securing Transmission Support Jig 3336 To Clutch Housing

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Bolt transmission lifting device 3336 to clutch housing.
Fig. 136: Adjusting Support Arm On Sliding Piece With Locking Pin
Set support arm on sliding piece with locking pin (arrow).
No. of holes visible = 5

Lift transmission with workshop crane and transmission lifting device 3336.
Place transmission, for example, onto transport container.

Transmission, installing
Installing the transmission is carried out in the reverse sequence. When installing
the transmission ensure engine/transmission mountings are installed stress-free.
Refer to
10 ENGINE - ASSEMBLY for 1.8 LITER 4-CYL. 5V TURBO ENGINE

MECHANICAL, ENGINE CODE(S): AMU, BEA
MECHANICAL, ENGINE CODE(S): ATC, AWP
NOTE:
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Fig. 137: Securing Clutch Release Lever With Bolt

Before installing the transmission press clutch release

lever toward transmission housing and secure with
assembly pin, assembly bolt or M 8 x 35 bolt. Remove
after transmission has been installed. The hole will then
be sealed by the 3rd cable support bracket securing
bolt or plugged.
Clean input shaft splines and lightly grease with G 000
100 grease.
The clutch plate must be able to slide freely in both
directions on the input shaft.
Fig. 138: Identifying Sensor For Speedometer

When replacing the transmission, transfer the speedometer sensor (see

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illustration), the gear selector lever and the relay lever to the new transmission.
When replacing the transmission ensure that the intermediate plate is correctly
positioned.
Check whether dowel sleeves for aligning the engine/transmission are installed
in the cylinder block, install if necessary.
Fig. 139: Identifying Support 3300 A, Support Rail VW 457/1 & Hex Bolts
Bolt support rail VW 457/1 to both pendulum support securing holes on

subframe.
Insert spacers totaling 6 mm between subframe and support rail VW 457/1.
-A- Qty. 2 hex bolts M 8 x 25
Mount support 3300 A and secure (arrows).

Press engine forward carefully.
NOTE: Do not damage power steering line.
Assemble transmission jack. Refer to Transmission, removing.

Place transmission on transmission jack. Refer to Transmission, removing.
Incline transmission to left via spindles of transmission mounting 3282.
Install transmission.
NOTE: Do not damage power steering line.

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Install lower engine/transmission securing bolts.

Remove support 3300 A and support rail VW 457/1.

Install transmission mount -A- with new bolts (arrows).

Install upper engine/transmission securing bolts.
Raise engine/transmission assembly via spindles on support bar 10-222A.
Align engine/transmission in installation position.

Secure transmission mount to subframe (left side) with new bolts (arrows -B-).
NOTE: Install engine/transmission mountings stress-free.
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Refer to
Install transmission support (arrows -A-) to transmission.
WARNING: Do not remove support bar 10-222A until the bolts

securing the left-hand transmission mount have
been tightened to the specified torque setting.
Fig. 142: Pendulum Support

Install pendulum support (arrows).
NOTE: Use new bolts for securing the support.
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Fig. 143: Removing/Installing Bolt & Small Cover Plate

Insert cover plate -2- behind right drive flange so that lower tab engages in
cylinder block.
Reconnect exhaust system.
Refer to

5V TURBO ENGINE MECHANICAL, ENGINE CODE(S): AMU, BEA
5V TURBO ENGINE MECHANICAL, ENGINE CODE(S): ATC, AWP
26 - EXHAUST SYSTEM, EMISSION CONTROLS for 1.8 LITER 4-CYL.
5V TURBO GENERIC SCAN TOOL ENGINE CODE(S): AMU, BEA, ATC,
AWP
Install retainer for power steering line on transmission.

Install drive shafts to transmission, replace seals.
Refer to 40 FRONT SUSPENSION
Install protective cap for right-hand inner constant velocity joint on engine.
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Fig. 144: Subframe Brace

When so equipped, install brace.
Installation position
Install with marking "L" to left side of direction of travel.

Foam strip faces down.
Use new bolts and install with locking compound D 000 600 A2.
Install starter.
Fig. 145: Front Cross-Piece Pipe

Where installed, install front cross-piece pipe (arrows).

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Attach power steering lines.
Fig. 146: Left Sound Insulation Panel

Install left sound insulation panel (arrows).
Fig. 147: Unbolting Bracket For Headlight Range Control In Left

Wheelhousing
When so equipped, fasten bracket for headlight range control in left

wheelhousing (arrows).
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Install slave cylinder.

Install transmission selector lever as follows:
Check that gap of master spline -A- aligns with missing teeth of selector shaft -
B-.
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Install gear selector cable -B- with transmission selector lever (arrow).
Install gate selector cable -A- with relay lever and secure (arrow).
Install cable support bracket on transmission. If necessary, push hose onto
cable support bracket.
Adjust gear selector mechanism. Refer to Gear selector mechanism,
adjusting.
Fig. 151: Identifying Speedometer Sensor & Reverse Light Connectors

Attach back-up light connector (arrow -2-). Attach all other electrical
connections and Ground wires to transmission and to engine/transmission
securing bolts.
Attach connector to speedometer sensor (arrow -1-).
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Install engine cover.

Install battery platform and battery.
Install air cleaner housing (complete).
Refer to

AWP
Connect battery.
NOTE: After reconnecting the battery, re-activate the vehicle's

electrical equipment (radio, clock and convenience
functions etc.) and check for proper functioning.
Refer to 01 MAINTENANCE
Check oil level in transmission. Refer to Transmission gear oil, checking.

Install insulation tray below engine/transmission.
Vehicles with automatic headlight range control
Perform basic setting:
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Refer to 01 ON BOARD DIAGNOSTIC (OBD)

Tightening torques
Transmission to engine
Fig. 152: Removing Bolts On Engine/Transmission Flange

Vehicles with 4-Cyl. engine
Item Bolt Qty. Nm

1 M 12 x 55 1 80
21) M 12 x 55 1 80
31) M 12 x 150 1 80
4 M 12 x 150 1 80
5 M 10 x 50 1 45
6 M 10 x 70 1 45
7 M 10 x 50 1 45
8 M 12 x 55 1 80
1) Bolt with headless screw M8
A: Dowel sleeves for centering
Transmission mount -A- to transmission 50 Nm + 90 °
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Replace bolts (arrows).

Transmission to body
Bolts -A- 25 Nm
Bolts -B- 100 Nm
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Replace bolts -B- (arrows).
Fig. 156: Identifying Pendulum Support & Bolts

Pendulum support
Replace bolts.
Bolts -A- 25 Nm
Bolts -B- 50 Nm
Flywheel cover 10 Nm
Cross-piece pipe to body1) 20 Nm
Brace to subframe1)2) 30 Nm + 90
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°
Protective cover for right hand inner constant velocity joint to M8: 20 Nm
engine M10: 35 Nm
Bracket for headlight range control1) 8 Nm
Slave cylinder to transmission 23 Nm
Transmission selector lever to transmission 20 Nm
1) Not installed on all versions

2) Replace with new bolts and install with locking compound D 000 600 A2.
ENGINE/TRANSMISSION MOUNT, REMOVING AND INSTALLING
Engine/transmission mount, removing and installing
Special tools and equipment required
Fig. 157: Identifying Support Assembly 10-222 A With Legs 10-222 A/1
10-222 A Engine support bridge
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Fig. 158: Identifying Shackle 10 - 222 A/12

10-222 A/12 Shackle
Removing
Fig. 159: Removing Engine Cover Panel Above Cylinder Head

Loosen screws (arrows) and remove engine cover.
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Fig. 160: Battery Cover

Remove cover over battery (arrows).

In vehicles with a coded radio/radio navigation system (RNS) coding, check
code or retrieve it, if necessary.
NOTE: Follow appropriate procedures before disconnecting the

battery.
Fig. 161: Battery Ground Strap

With ignition switched off, disconnect battery Ground strap.
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Loosen clamp -4- and disconnect intake hose and electrical connector -1- from
Mass Air Flow (MAF) sensor.
If present, remove hose -5- from air filter housing.
Remove bolts -2- and -3- and remove complete air filter housing.
Refer to

AWP
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Fig. 163: Battery Holder

Remove battery and battery holder (arrows).
Install engine support bridge 10-222A together with brackets 10-222/A1.
Fig. 164: Support Bridge 10-222A

Place engine support bridge on wheel house panel (arrows).
Remove hose and cable connections in area around engine lifting eyelets for
support bridge 10-222A.
Attach hook on spindle over shackle 10-222A/12 on engine lifting eyelet.
Slightly lift engine/transmission assembly with one spindle.
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Remove engine support (arrows -A-) from transmission.
Remove hex bolts (arrows -B-) for left side engine mount.
Fig. 166: Engine Mount And Bolts

Remove parts to gain access to bolts -1- and -2-.

Remove bolts -1- and -2-.
Remove engine mount -A-.
Installing
Installation is carried out in the reverse order of removal. Note the following:
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Fig. 167: Engine Mount And Bolts

Install engine mount -A- (bolts must be replaced).
Bolt -1-, M10 x 55 40 Nm + 90 °

Bolt -2-, M8 x 20 25 Nm
Lift engine with spindle on engine support bridge.
CAUTION: Before tightening the bolts on the transmission

support / transmission mount, the supports and
mount must be absolutely parallel or the threads will
be damaged. If necessary lift the transmission with a
floor jack.

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Tighten transmission mount on left hand engine mount with new bolts -B-.
NOTE: Engine and transmission mountings must be installed

without tension.
Refer to


Install transmission support (arrows -A-) onto transmission.
CAUTION: Only remove the engine support bridge 10-222A

when all of the screws on the engine mount have
been tightened and torqued.
TRANSMISSION GEAR OIL, CHECKING
Transmission gear oil, checking
Gear oil specification. Refer to Code letters, transmission application, ratios,

capacities
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Remove insulation tray below engine/transmission, if fitted.
Fig. 170: Identifying Oil Plug

Remove plug (arrow) to check oil.
The oil level is correct when the transmission is full to the lower edge of the filler
hole.
Install plug (arrow).
Tightening torque
Oil filler plug: 25 Nm
Filling with new oil
Remove plug (arrow).

Top off oil to lower edge of filler hole.
Start engine, engage gear and allow transmission to turn for approx. 2 minutes.
Switch off engine and remove plug (arrow).

Top up oil to lower edge of filler hole again.
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Tightening torque
Oil filler plug: 25 Nm
TRANSMISSION, DISASSEMBLING AND ASSEMBLING
Overview
Fig. 171: Overview Of Transmission Components

1 - 1st gear
2 - 2nd gear
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3 - 3rd gear
4 - 4th gear
5 - 5th gear
6 - Transmission housing
Servicing. Refer to Transmission housing and clutch housing, servicing
7 - Selector mechanism
(Selector forks)
Disassembling and assembling. Refer to Selector forks, disassembling and
assembling
8 - Input gear for 1st and reverse gear
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Fig. 172: Overview Of Transmission Components

9 - Input shaft
Disassembling and assembling. Refer to Input shaft, disassembling and
assembling input
10 - Output shaft
Disassembling and assembling. Refer to Output shaft, disassembling and
assembling
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11 - Differential
Disassembling and assembling. Refer to Differential, disassembling and
assembling
12 - Clutch housing

Assembly overview
Fig. 173: Transmission Assembly Overviews

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Sequence for disassembling and assembling. Refer to Assembly sequence

I - Removing and installing cover for transmission housing and 5th gear. Refer to
Cover for transmission housing and 5th gear, removing and installing
II - Disassembling and assembling transmission housing and shift mechanism.

Refer to Transmission housing and selector mechanism, removing and
installing
III - Disassembling and assembling input shaft, output shaft, differential and
selector forks. Refer to Input shaft, output shaft (pinion shaft), differential and
selector forks, removing and installing
Cover for transmission housing and 5th gear, removing and installing
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Fig. 174: Exploded View Of Cover For Transmission Housing And 5th Gear
Components
1 - Hex bolt, 10 Nm
For transmission housing cover
2 - Transmission housing cover
NOTE: If the transmission cover is fitted with the transmission

installed, check the oil level as follows:
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Fill with oil up to lower edge of filler hole and install filler plug.
Start engine, engage gear and allow transmission to turn for approx. 2 minutes.
Switch off engine and top up transmission oil to lower edge of filler hole again.
Components
3 - Gasket
4 - Torx socket head bolt M10, 80 Nm
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Fitted piece on bolt head holds saucer spring washer in position
5 - Dished spring
Installing. Refer to Fig. 212
6 - Socket head bolt, 25 Nm
For pivot pin to transmission housing

7 - Pivot pin
8 - 5th gear selector fork

assembling
Adjusting. Refer to Fig. 214
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Components
9 - 5th gear locking collar
Installation position. Refer to Fig. 209

10 - Synchro-hub with 5th gear and synchronizing ring
Disassembling and assembling. Refer to 5th gear synchronizer
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11 - Needle roller bearing

12 - 5th speed gear wheel
Transmission housing and selector mechanism, removing and installing
Fig. 177: Transmission Housing And Selector Mechanism Remove/Install

Components
1 - Countersunk head bolt, 25 Nm
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2 - Flange shaft with spring

Removing and installing. Refer to Flange shaft oil seals (transmission
installed), replacing
Complement. Refer to Differential, disassembling and assembling
For reverse shaft support

Self-locking
Always replace
4 - O-ring
Always replace
5 - Pivot pin
6 - Bolt, 25 Nm
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Fig. 178: Transmission Housing And Selector Mechanism Remove/Install

Components
7 - Bolt, 25 Nm
8 - Cover plate
10 - Clutch housing
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11 - Hex bolt, 25 Nm plus 90 ° (1/4 turn) further
Disassembling and assembling. Refer to Transmission selector mechanism,

disassembling and assembling
13 - Hex bolt, 25 Nm
Input shaft, output shaft (pinion shaft), differential and selector forks, removing and installing
Fig. 179: Input Shaft, Output Shaft (Pinion Shaft), Differential And Selector
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Forks Remove/Install Components

1 - Differential
Disassembling and assembling. Refer to Differential, disassembling and

assembling
2 - Oil seal
Qty. 4
Always replace
3 - Output shaft
Disassembling and assembling. Refer to Output shaft, disassembling and

assembling
4 - Reverse shaft support

Disassembling and assembling. Refer to Reverse shaft, disassembling and
assembling
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5 - Reverse shaft
Disassembling and assembling. Refer to Reverse shaft, disassembling and

assembling
6 - Input shaft
Disassembling and assembling. Refer to Input shaft, disassembling and

assembling input
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7 - Reverse gear selector fork

assembling
Installation position. Refer to Assembling
(Selector forks)
assembling
10 - Clutch housing
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11 - Hex nut, 25 Nm plus 90 ° (1/4 turn) further
4 nuts for bearing support
12 - Flange shaft with spring

Assembling. Refer to Differential, disassembling and assembling
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13 - Cone head bolt, 25 Nm

Assembly sequence
Fig. 182: VW 244 B Sleeve, VW 295 Drift, VW 353 Transmission Support And
VW 309 Holding Plate And V. A. G 1416 Hot Air Blower
Transmission housing cover, transmission housing, selector mechanism, input

shaft, output shaft (pinion shaft), differential and selector forks
Special tools and equipment
VW 309 Holding plate

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VW 353 Transmission support

VW 295 Drift
VW 244 B Sleeve
V. A. G 1416 Hot air blower

Studs M 8 x 100 mm
Fig. 183: Identifying Special Tools - Kukko 20/10 Puller Set

1 - Two-arm puller Kukko 20/10 with Matra V170 hooks
Fig. 184: Torque Wrench V.A.G. 1332

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Disassembling
Fig. 185: Identifying Transmission On Repair Stand

Mount transmission on repair stand.

Drain transmission oil.
Remove clutch release lever and release bearing. Refer to Clutch release
mechanism, servicing.
Remove guide sleeve. Refer to Clutch release mechanism, servicing.
Fig. 186: Identifying Transmission Housing Cover

Remove transmission housing cover (arrow).
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Fig. 187: Identifying 5th Gear Selector Fork

Remove 5th gear selector fork (arrow)
Remove spring and locking pieces from locking collar.
Pull off 5th gear selector fork with locking collar.
Then place locking collar without selector fork onto synchro hub.
Fig. 188: Removing Synchronizer Hub And 5th Gear Drive Gear Bolts And
Inserting 5th Gear And 1st Gear
Remove bolts -A- for synchro-hub and 5th gear. To do this select 5th (arrow -
1-) and 1st gear (arrows -2- and -3-).
After engaging both gears the input shaft and output shaft are locked, synchro-hub
and gear wheel cannot turn.
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Both bolts can now be loosened.
Fig. 189: Identifying Two Arm Puller & Hex Bolt

Pull off synchro-hub and 5th gear wheel and remove together with needle
roller bearing.
A - Two arm puller e.g. Kukko 20/10 with Matra V/170 hooks.
B - Hex bolt M10 x 20
Fig. 190: Pulling Off 5th Gear

Pull off 5th gear

A - Two arm puller e.g. Kukko 20/10 with Matra V/170 hooks.
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B - Hex bolt M10 x 20

Removal sequence:
Set up two-arm puller and centralize by turning screw (arrow).
Pull gear wheel off using two-arm puller. Heat with hot air blower V.A.G 1416
or equivalent first if necessary.
NOTE: When pulling off the gear wheel ensure that the hooks do
not bend outward. If necessary tighten screw (arrow). After
5th gear wheel has been removed check for damage.
Fig. 191: Identifying Flange Shafts

Remove both flange shafts.

Remove flange shafts along with springs, thrust washers and tapered rings.
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Fig. 192: Identifying Reverse Shaft Support Bracket Bolts

Remove both reverse shaft support bracket bolts (arrows).
Fig. 193: Identifying Selector Shaft Bolts

Remove selector shaft with selector mechanism cover. To do this place selector
shaft in neutral position. Then remove bolts (arrows) and pull selector shaft out
of transmission housing.
Fig. 194: Transmission Cover Plate And Pivot Pins

Remove cover plate -A- and pivot pins -B- from underside of transmission.
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Fig. 195: Transmission Pivot Pins & Securing Bolts

Remove pivot pins -A- on top side of transmission and transmission housing to
clutch housing securing bolts -B- in area of differential.
Fig. 196: Inside Clutch Housing Bolts & Output Shaft Bearing Support Nuts
Remove bolts -A- from inside clutch housing for securing clutch housing to
transmission housing.
NOTE: Do not remove nuts -B- for output shaft bearing support.
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Fig. 197: Protruding Transmission Housing Flange

Take-off transmission housing. If necessary, carefully pry up all around and

alternating between sides on protruding housing flange (arrows) being careful
not to damage sealing surfaces.
Fig. 198: Identifying Shift Forks & Reverse Gear Selector Mechanism
Remove selector forks -A- together with selector plates.
Unscrew bolt for selector mechanism for reverse gear -B-.

Remove nuts for output shaft bearing support (Item -B-, Fig. 196 : Refer to
Disassembling)
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Fig. 199: Reverse Gear, Input Shaft And Output Shaft

Remove reverse gear -A-, input shaft -B- and output shaft -C- one after another
from clutch housing.
Take out differential.
Assembling
Install differential.
Fig. 200: Identifying Output Shaft Bearing Support Sealing Rings

Replace sealing rings (arrows) for output shaft bearing support.
NOTE: The illustration only shows 3 of the 4 sealing rings.
Install input shaft, output shaft and reverse shaft together.

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Tighten nuts for output shaft bearing support.

Clean locking fluid remnants from threads in reverse shaft support (arrow in
Fig. 203 : Refer to Assembling). Remnants can be removed using a tap.
Install reverse shaft support.
Install reverse gear selector mechanism.
Fig. 201: Reverse Gear Installation Position

Reverse gear installation position
Install selector forks together with selector plates.
Fig. 202: Reverse Shaft Support Studs

Screw M 8 x 100 mm stud -A- into reverse shaft support so that shaft is aligned
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after mounting transmission housing.

Align selector plates.
NOTE: The selector segments must be positioned in the grooves

on the locking collars.
Install transmission housing.
Install reverse shaft support bolts (arrow) as follows:
Fig. 203: Identifying Reverse Shaft Support Bolts

Insert bolt -a-, remove stud (see Fig. 202 ), insert bolt -b- and hand tighten.
Tightening sequence:
1 - Bolt -a- 30 Nm
2 - Bolt -b- 30 Nm
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Fig. 204: Aligning Selector Mechanism With A Screwdriver To Install Pivot

Pin
Install pivot pin (arrow) for selector forks. To do this align selector mechanism
with a screwdriver, so that relevant pivot pin can be installed.
Install selector shaft cover.
Fig. 205: Identifying Selector Shaft & Lug

Install selector shaft as follows:
Place selector plates in neutral.

Locate tab (arrow -1-) in recess in transmission housing. Position selector shaft
so that selector finger (arrow -2-) is inserted in selector plates.
Install selector shaft cover.
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Fig. 206: 5th Gear Circumferential Groove

Installation position of 5th gear wheel
The circumferential groove (arrow) faces the transmission housing.
Fig. 207: Driving On 5th Gear

Drive on 5th gear.
Checking 5th gear synchro-ring
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Fig. 208: Gap Between Syncro-Ring & Cone

Before installing 5th gear wheel and synchro-ring press synchro-ring onto cone
of gear wheel and measure gap -a- with a feeler gauge.
Gap -a- New Wear limit

5th gear 1.1...1.7 mm 0.5 mm
Install 5th gear wheel with needle roller bearing

Place 5th gear synchro-ring on gear wheel
Assemble 5th gear synchro-hub/locking collar before installing. Refer to
Assembling 5th gear locking collar/synchro-hub.
Fig. 209: Identifying Locking Collar, Synchro-Hub & Synchro-Hub Mountings

Installation position of 5th gear synchro-hub/locking collar
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The pointed teeth of the locking collar (arrow -1-) and the high shoulder of the
synchro-hub (arrow -2-) face the transmission housing.
The syncro-hub mountings (arrow -3-) align with the synchro-ring cast locking
pieces (arrows on Fig. 210 ).
Fig. 210: Identifying 5th Gear Synchronizer Ring

5th gear synchro-ring with cast locking pieces (arrows)
Fig. 211: Driving On 5th Gear Synchro-Hub

Drive on 5th gear synchro-hub
NOTE: When driving on ensure synchro-ring is free to move.
Screw-in securing bolts for synchro-hub and 5th gear wheel.

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Fig. 212: Outer Diameter Of Dished Spring Faces 5th Gear

Installation position of dished spring for gear wheel and 5th gear synchro-hub
securing bolts
The outer diameter (concave side -arrows-) faces 5th gear.
Fig. 213: 5th Gear Synchro-Hub And Gear Securing Bolts

Engage two gears before tightening 5th gear synchro-hub and gear-securing
bolts (arrows)
Disengage two gears again after tightening securing bolts.
Install 5th gear selector fork.
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Fig. 214: Pressing Selector Fork Jaws

Adjusting 5th gear
Engage 5th gear. Loosen bolt -1-. Press locking collar and selector fork jaws in
direction of arrow, then tighten bolt -1- to 25 Nm.
Check measurement: It must not be possible to slide a 0.2 mm feeler gauge

between locking collar and gear wheel. If necessary repeat adjustment.
Disengage 5th gear. Locking collar must now be in neutral position. Synchro-
ring must move freely.
Select all gears.
Install transmission housing cover

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Install flange shafts along with springs, thrust washers and tapered rings.
Install release bearing guide sleeve. Refer to Clutch release mechanism,
servicing.
Install clutch release lever and release bearing. Refer to Clutch release
mechanism, servicing.
TRANSMISSION HOUSING AND CLUTCH HOUSING, SERVICING
Transmission housing and clutch housing, servicing
Fig. 216: Identifying Special Tools -- Transmission Housing And Clutch

Housing, Servicing (1 Of 2)
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VW 295 Drift
VW 295a Adapter
VW 447 H Press plate
VW 512 Press disk
2040 Tube
VW 454 Press piece
Fig. 217: Identifying Special Tools -- Transmission Housing And Clutch

Housing, Servicing (2 Of 2)
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VW 222 A Drift
VW 353 Transmission support
3066 Spindle from assembly tool
3124 Press piece

1 - Kukko 21/1 Internal puller
4 - Kukko 22/1 Counter-support
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Fig. 218: Transmission Housing And Clutch Housing Remove/Install

Components
If replaced: Adjust input shaft and differential. Refer to Adjustment overview
For output shaft

Removing. See Driving out needle roller bearing
Installing and securing. See Driving needle roller bearing in onto stop
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3 - Oil filler plug, 30 Nm

Without magnet
4 - Shim
For input shaft

Adjustment overview. Refer to Adjustment overview
5 - Outer race/tapered roller bearing
For input shaft

Removing and installing. Refer to Pressing out tapered roller bearing outer
race
If replaced: Adjust input shaft. Refer to Input shaft, adjusting
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Components
For output shaft

Removing and installing. Refer to Pulling out small tapered roller bearing
outer race
If replaced: Adjust output shaft. Refer to Output shaft, adjusting
7 - Shim
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For output shaft

For input shaft

Removing and installing. Refer to Pressing out tapered roller bearing outer
race
If replaced: Adjust input shaft. Refer to Input shaft, adjusting
9 - Needle bearing
Removing and installing. Refer to Pulling needle roller bearing out of clutch
housing
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Components
10 - Dowel sleeve
(Qty. 2)
11 - Starter bushing
Pulling out. See Pulling out starter bushing

Knocking in. See Driving in starter bushing
Can be replaced without removing transmission
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12 - Clutch housing
If replaced: Refer to Adjustment overview
13 - Guide sleeve
With input shaft seal and a vulcanized O-ring

Driving out oil seal. See Driving oil seal out of guide sleeve
Driving in oil seal. See Driving oil seal into guide sleeve onto stop
Remove guide sleeve to change the oil seal
If O-ring is damaged, replace guide sleeve and O-ring together
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Components
14 - Socket head bolt, 20 Nm
Self-locking
Always replace
15 - Oil seal
Replacing. Refer to Flange shaft oil seals (transmission installed), replacing
16 - Sleeve
For oil seal (Item - 15 Transmission housing and clutch housing, servicing)
Removing. See Pry out sleeve with screwdriver
Installing. See Pulling sleeve in
17 - Speedometer drive
Aluminum: 30 Nm
Plastic: 10 Nm
18 - Oil drain plug, 30 Nm

Without magnet
For differential
Removing and installing. Refer to Differential, disassembling and
assembling
If replaced: Adjust differential. Refer to Differential, adjusting
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Components
20 - Magnet
Held in place by housing joint surface
For differential
Driving in and out. Refer to Differential, disassembling and assembling
If replaced: Adjust differential. Refer to Differential, adjusting
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22 - Shim
For differential
23 - Oil seal

Driving out needle roller bearing
Fig. 223: Driving Out Needle Bearing

Driving needle roller bearing in onto stop
Fig. 224: Driving In Needle Bearing To Stop

Secure needle roller bearing in transmission housing at three points (120 °

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offset) with a punch.

Driving oil seal out of guide sleeve
Fig. 225: Drive Seal Out Of Guide Sleeve

Driving oil seal into guide sleeve onto stop
Fig. 226: Driving Seal Into Guide Sleeve To Stop

Lightly lubricate outside of new oil seal for input shaft.

Fill area between sealing lip and dust lip with lubricant G052 128 A1.
Pulling out starter bushing
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Fig. 227: Pulling Out Starter Bushing

A - Internal extractor 12...14.5 mm, e.g. Kukko 21/1
B - Counter support. e.g. Kukko 22/1

Driving in starter bushing
Fig. 228: Driving In Starter Bushing Using Special Tool VW222A

Pry out sleeve with screwdriver
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Fig. 229: Prying Out Sleeve Using A Screwdriver

Pulling sleeve in
Fig. 230: Pulling Sleeve In

Screw threaded rod -A- from assembly tool 3066 into differential threaded
piece.
-B- = Nut, M12 with washer
Pull sleeve in onto stop with thrust piece 3124 by turning on nut -B-.
NOTE: When transmission is disassembled press sleeve in with

thrust piece 3124 onto stop.
TRANSMISSION SELECTOR MECHANISM, DISASSEMBLING AND ASSEMBLING
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Transmission selector mechanism, disassembling and assembling
Fig. 231: Identifying Special Tools - Transmission Selector Mechanism,

Disassembling And Assembling
VW 439 Guide pin

VW 401 Thrust plate
VW 408 A Press tool
VW 447 i Thrust plate
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3129 Installation tool
Fig. 232: Identifying Kukko Tools

1 - Kukko 21/3 Internal puller
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Fig. 233: Transmission Selector Mechanism Remove/Install Components

1 - Selector shaft
Revised stop sleeve, which guides selector shaft into 4th gear gate when
changing down from 5th to 4th gear, has been introduced as of transmission
build date 04 09 0. See Revised selector cover and selector shaft
From transmission build date 06 08 1 additional locking mechanism in end
cover. See Revised selector shaft and selector cover
2 - Stop ring
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3 - Ball sleeve
Removing. See Removing ball sleeve from selector mechanism cover
Pressing in. See Driving ball sleeve into selector mechanism cover
4 - Selector mechanism cover
With an additional bolt which guides selector shaft into 4th gear gate when
changing down from 5th to 4th gear, which has been introduced as of
transmission build date 04 09 0. See Revised selector cover and selector
shaft

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5 - Switch for back-up lights - 20 Nm
Lightly coat lug with MoS2 grease
6 - Cap
For transmission breather
7 - Relay lever

8 - Bushing
9 - Oil seal
Pry out with screwdriver
Installing. See Installing oil seal onto stop
10 - Circlip
11 - Hex nut, 20 Nm
Self-locking
Always replace
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12 - Transmission selector lever

Install so that master spline aligns with selector shaft. See Installing
transmission selector lever.
Can be replaced with selector mechanism installed
13 - Cover plate
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From transmission build date 06 08 1 with locking mechanism for selector

shaft. See Revised selector shaft and selector cover
Removing ball sleeve from selector mechanism cover
Fig. 236: Removing Ball Sleeve From Selector Mechanism Cover

Before pulling out ball sleeve, destroy plastic cage and remove balls.
A - Internal extractor, e.g. Kukko 21/3, 18.5...23.5 mm
Driving ball sleeve into selector mechanism cover
Fig. 237: Driving Ball Sleeve Into Selector Mechanism Cover

Installing oil seal onto stop
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Fig. 238: Installing Oil Seal Onto Stop

Lightly lubricate outside of oil seal.
Fill area between sealing lip and dust lip with lubricant G052 128 A1.
Installing transmission selector lever

When installing selector lever, ensure that offset spline (arrow -A-) matches
insert on shaft (arrow -B-).
Revised selector cover and selector shaft
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Fig. 240: Revised Selector Cover And Selector Shaft

As of transmission build date 04 09 0 bolt -2- is installed in selector cover -1-.
Tightening torque
15 Nm
In conjunction with this the stop sleeve is fitted with a bridge -3-.
Functional check
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When shifting down from 5th gear to 4th gear the bolt -2- guides the selector shaft
over cam -3- into 4th gear gate.
Revised selector shaft and selector cover
Fig. 241: Revised Selector Shaft And Selector Cover

From transmission build date 06 08 1 the selector shaft is equipped with four
grooves -A-.
The spring clip -B- is inserted in the cover.

Functional check
Selector shaft is locked into cover by inserting a spring clip -B- through one of the
grooves -A-, with a forward gear engaged.
SELECTOR FORKS, DISASSEMBLING AND ASSEMBLING
Selector forks, disassembling and assembling
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Fig. 242: Identifying Special Tools - Selector Forks, Disassembling And

Assembling
VW 408 A Press tool

3290/1 Assembly tool
3301 Assembly tool
VW 431 Press piece
VW 472/2 Spacer sleeve

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10-206 Drift
Fig. 243: Pry Lever 80-200

80-200 Lever
Fig. 244: Identifying Assembly Drift 10 - 508

10-508 Assembly tool

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Fig. 245: Pry Lever 80-200

2070 Compressor tool
NOTE: The selector fork group (item - 7 Selector forks,

disassembling and assembling) does not need to be
disassembled to remove and install the gear segments,
circlips and ball bearings.
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Fig. 246: Selector Forks, Disassembling And Assembling Overview

1 - 5th gear selector segment

Identification. See Identifying selector segments
After installing circlip selector segment must rotate freely
2 - Circlip
Always replace
Removing. See Removing circlip
Installing. See Installing circlip
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3 - 5th gear selector segment

4 - Screw, 25 Nm
5 - 5th gear selector jaw

6 - Ball bearings
Qty. 4
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Removing. See Removing ball bearings

Press inner race into outer race. See Press inner race -A- of ball bearing into
outer race
Installing. See Pulling ball bearing in up to selector fork
7 - Selector fork group with selector segment groove
8 - 1st and 2nd gear selector segment

9 - 3rd and 4th gear selector segment

10 - Sliding piece
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11 - Spring
12 - Reverse selector fork
13 - Support for reverse selector fork

14 - Circlip
Identifying selector segments
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Fig. 249: Identifying Selector Segments

Dimension -a-
1 - 1st and 2nd gear selector segments = 12.1 mm
1st and 2nd gear selector segments with modified synchronization (Refer to 1st
gear synchronization, modified from transmission build date 02 05 0) = 11.4
mm
The shorter selector segments can also be installed in previous transmissions.

2 - 3rd and 4th gear selector segments = 7.7 mm
3 - 5th gear selector segments = 12.1 mm

Removing circlip
Fig. 250: Removing Circlip

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Clamp selector fork in vise using jaw protectors -B-.
Lift circlip -A- in direction of arrow.
Installing circlip
Fig. 251: Installing Circlip

Press circlip into selector segment with nut driver socket.
-A- Nut driver, 10 mm
-B- Jaw protector
NOTE: After installing the circlip the selector segment must rotate
freely
Removing ball bearings
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Fig. 252: Removing Ball Bearings

NOTE: When removing and installing the ball bearings, do not

bend selector fork.
Press inner race -A- of ball bearing into outer race
Fig. 253: Pressing Inner Race Of Ball Bearing Into Outer Race
Inner race must be in contact with outer race.
Pulling ball bearing in up to selector fork
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Fig. 254: Pulling Ball Bearing In Up To Selector Fork

The depression in thrust piece 3290/1 points toward the ball bearing.
Selector fork with installed selector segments
Fig. 255: Selector Fork With Installed Selector Segments

Dimension -a-
(mm)
1st /2nd Gear selector fork 87.2...87.9
1st/2nd Gear with modified synchronization (Refer to 1st gear 88.4...89.1
synchronization, modified from transmission build date 02 96.0...96.7
05 0)
3rd/4th selector gear
Order of gear segments. See Identifying selector segments

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35 MANUAL TRANSMISSION - GEARS, SHAFTS

INPUT SHAFT, DISASSEMBLING AND ASSEMBLING INPUT
Input shaft, disassembling and assembling input
Fig. 256: Identifying Special Tools - Input Shaft, Disassembling And

Assembling Input (1 Of 2)
VW 407 Press tool

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VW 412 Press tool

VW 422 Tube
VW 401 Thrust plate

VW 408 A Press tool
Fig. 257: Identifying Special Tools - Input Shaft, Disassembling And

Assembling Input (2 Of 2)
VW 421 Tube
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VW 454 Press piece

VW 510 Press piece
41-501 Drift sleeve

3 - Kukko 17/1 Puller set
NOTE:
Fig. 258: Input Shaft Remove/Install Components

When installing new gears, consult technical data.

Refer to Code letters, transmission application, ratios,
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capacities.
If the position of the tapered roller bearings is affected
when exchanging parts, the input shaft must be re-
adjusted. Refer to Adjustment overview
1 - Clutch housing
2 - Tapered roller bearing outer race
Removing. See Pressing out tapered roller bearing outer race

Pressing in. See Pressing in tapered roller bearing outer race
3 - Tapered roller bearing inner race
Pressing off of shaft. See Tapered roller bearing inner race, pressing off
Pressing on. See Pressing on tapered roller bearing inner race
4 - Input shaft
Adjusting. Refer to Input shaft, adjusting
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5 - 3rd gear
Shoulder points to 4th gear
Pressing off. See 5
Pressing on. See Pressing on 3rd gear wheel
6 - Circlip
Always replace
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7 - 4th gear
Pressing off with tapered roller bearing outer race and sleeve. See Pressing off
4th gear wheel with tapered roller bearing and sleeve
Pressing on. See Pressing on 4th gear wheel
Collar faces to 3rd gear
Pressing off with 4th gear wheel and sleeve. See Pressing off 4th gear wheel
with tapered roller bearing and sleeve
9 - Thrust washer
Pressing out. See Pressing out tapered roller bearing outer race
Pressing in. See Pressing in tapered roller bearing outer race
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11 - Shim
Determining thickness; adjusting input shaft: Refer to Input shaft, adjusting
13 - Sleeve
For needle roller bearing

Press off with 4th gear wheel and tapered roller bearing inner race. See
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Pressing off 4th gear wheel with tapered roller bearing and sleeve
Pressing on. See Pressing on sleeve for needle roller bearing
Place thrust washer on before installing (item - 9 Input shaft, disassembling
and assembling input)
15 - Selector gear for 5th gear
Pull off together with 5th gear synchro-hub. Refer to Assembly sequence

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16 - 5th gear synchro-ring

With cast locking pieces. See 12
Check for wear. Refer to Fig. 208
17 - Spring
Installation position. See Assembling 5th gear locking collar/synchro-hub

Changed from transmission build date 05 11 1. Refer to Springs for 5th gear
synchro modified from transmission build date 05 11 1
18 - Locking pieces (Qty. 3)

Installation position. See 5th gear synchronizer
From transmission build date 05 03 1 locking pieces are installed that are
hollow on inside.
19 - 5th gear synchro-hub
Removing and installing. Refer to Assembly sequence
20 - 5th gear locking collar
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21 - Dished washer
Fitted piece on bolt head locates dished spring. Refer to Fig. 212
Pressing out tapered roller bearing outer race
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Fig. 263: Pressing Out Tapered Roller Bearing Outer Race

Pressing in tapered roller bearing outer race
Fig. 264: Pressing In Tapered Roller Bearing Outer Race

Tapered roller bearing inner race, pressing off
Fig. 265: Tapered Roller Bearing Inner Race, Pressing Off

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A - Puller set Kukko 17/1
Pressing on tapered roller bearing inner race
Fig. 266: Pressing On Tapered Roller Bearing Inner Race

Pressing off 4th gear wheel with tapered roller bearing and sleeve
Fig. 267: Pressing Off 4th Gear Wheel With Tapered Roller Bearing And
Sleeve
Pressing off 3rd gear wheel
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Fig. 268: Pressing Off 3rd Gear Wheel

Pressing on 3rd gear wheel
Fig. 269: Pressing On 3rd Gear Wheel

Pressing on 4th gear wheel
Fig. 270: Pressing On 4th Gear Wheel

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Shoulder points to 3rd gear.

Pressing on sleeve for needle roller bearing
Fig. 272: Pressing On Sleeve For Needle Roller Bearing

Pressing out tapered roller bearing outer race
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Fig. 273: Pressing Out Tapered Roller Bearing Outer Race

Pressing in tapered roller bearing outer race
Fig. 274: Pressing Tapered Roller Bearing Outer Race Without Adjustment
Shim Into Clutch Housing Up To Stop
Install with shim after adjusting input shaft.

5th gear synchronizer
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Fig. 275: 5th Gear Synchronizer

1 - Springs for lock pieces

2 - Locking collar with 3 recesses (arrows -A-) for locking pieces (item -4-)
3 - Synchro-hub
4 - Locking pieces
Installation position: Thin extension (arrow -B-) faces pointed teeth of locking
collar (item - 2 Input shaft, disassembling and assembling input)
Assembling 5th gear locking collar/synchro-hub
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Fig. 276: Assembling 5th Gear Locking Collar/Synchro-Hub

Push locking collar over synchro-hub.
Pointed teeth -A- and shoulder -B- of synchro-hub face in same direction. Recesses
for locking pieces in locking collar and synchro-hub must be aligned ( 5th gear
synchronizer).
Insert locking pieces (Installation position: 5th gear synchronizer).

Insert springs offset by 120 ° underneath lug -C-. Angled ends of spring must
be directly behind locking pieces (arrows).
Springs for 5th gear synchro modified from transmission build date 05 11 1
Fig. 277: Identifying Offset Springs For 5th Gear Synchronization

The ends -A- of the springs were bent after the above date.
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The modified springs are installed on both sides.

The modified springs can only be installed in previous transmissions together with
locking pieces that are hollow on the inside.
Insert lock pieces (location: 5th gear synchronizer).
Installation location for springs:
Insert springs offset by 120 °.

Angled ends of spring -A- must grip the hollow locking piece (arrow).
Springs must be located under the indentation -B- in the locking pieces.
Bent end of spring always points away from the synchro hub (arrow).
INPUT SHAFT, ADJUSTING
Input shaft, adjusting
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Fig. 278: Identifying Special Tools -- Input Shaft, Adjusting

(Determining input shaft adjustment shim)

Special tools, testers and auxiliary items
VW 387 Universal dial gauge bracket

VW 385/17 End measuring plate
VW 510 Press piece
VW 407 Press tool

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Dial gauge
It is only necessary to readjust the input shaft when the following components are
replaced:
Transmission housing
Clutch housing
Input shaft
4th gear wheel
or the
Tapered roller bearings
Fig. 279: Pressing Tapered Roller Bearing Outer Race Without Adjustment
Shim Into Clutch Housing Up To Stop
Press tapered roller bearing outer race without shim into clutch housing onto
stop using VW 510.
Install input shaft in clutch housing and assemble transmission housing.
Tighten hex head bolts to 25 Nm and then turn 90 ° further.
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Fig. 280: Installing Measuring Device And Dial Gauge In Clutch Housing
Fit measuring appliance and dial indicator in clutch housing (large tapered
roller bearing in transmission housing).
Before taking any measurements, rotate input shaft to allow bearings to settle.
Set dial gauge to "O" with 1 mm preload.
NOTE: This preparation is to be repeated for each subsequent

measurement, otherwise the gauge will not return to the
starting position.
Press input shaft in direction of dial indicator (arrow).

Read and note clearance indicated on dial indicator.
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NOTE: Dial indicator does not return to original position.
Determine thickness of shim from table. Refer to Table of adjustment shims.

Remove input shaft and press tapered roller bearing outer race out of
transmission housing using VW 447i.
Press tapered roller bearing outer race together with 1.175 shim into
transmission housing using VW 510.
Assemble transmission housing and tighten hex head bolts to 25 Nm and then
turn 90 ° further.
Table of adjustment shims
Measured Shim
bearing clearance Thickness (mm) Part No.
(mm)
0.671... 0.699 0.650 02A 311 140
0.700... 0.724 0.675 02A 311 140 A
0.725... 0.749 0.700 02A 311 140 B
0.750... 0.744 0.725 02A 311 140 C
0.775... 0.799 0.750 02A 311 140 D
0.800... 0.824 0.775 02A 311 140 E
0.825... 0.849 0.800 02A 311 140 F
0.850....0.874 0.825 02A 311 140 G
0.875... 0.899 0.850 02A 311 140 H
0.900... 0.924 0.875 02A 311 140 J
0.925... 0.949 0.900 02A 311 140 K
0.950... 0.974 0.925 02A 311 140 L
0.975... 0.999 0.950 02A 311 140 M
1.000... 1.024 0.975 02A 311 140 N
1.025... 1.049 1.000 02A 311 140 P
1.050... 1.074 1.025 02A 311 140 Q
1.075... 1.099 1.050 02A 311 140 R
1.100... 1.124 1.075 02A 311 140 S
1.125... 1.149 1.100 02A 311 140 T
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1.150... 1.174 1.125 02A 311 140 AA

1.175... 1.199 1.150 02A 311 140 AB
Measured Shim
(mm)
1.200... 1.224 1.175 02A 311 140 AC
1.225... 1.249 1.200 02A 311 140 AD
1.250... 1.274 1.225 02A 311 140 AE
1.275... 1.229 1.250 02A 311 140 AF
1.300... 1.324 1.275 02A 311 140 AG
1.325... 1.349 1.300 02A 311 140
02A 311 140
1.350... 1.374 1.325 02A 311 140
02A 311 140 A
1.375... 1.399 1.350 02A 311 140 A
02A 311 140 A
1.400... 1.424 1.375 02A 311 140 A
02A 311 140 B
1.425... 1.449 1.400 02A 311 140 B
02A 311 140 B
1.450... 1.474 1.425 02A 311 140 B
02A 311 140 C
1.475... 1.499 1.450 02A 311 140 C
02A 311 140 C
1.500... 1.524 1.475 02A 311 140 C
02A 311 140 D
Measured Shim
(mm)
1.525... 1.549 1.500 02A 311 140 D
02A 311 140 D
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1.550... 1.574 1.525 02A 311 140 D

02A 311 140 E
1.575... 1.599 1.550 02A 311 140 E
02A 311 140 E
1.600... 1.624 1.575 02A 311 140 E
02A 311 140 F
1.625... 1.649 1.600 02A 311 140 F
02A 311 140 F
1.650... 1.674 1.625 02A 311 140 F
02A 311 140 G
1.675... 1.699 1.650 02A 311 140 G
02A 311 140 G
1.700... 1.724 1.675 02A 311 140 G
02A 311 140 H
1.725... 1.749 1.700 02A 311 140 H
02A 311 140 H
1.750... 1.774 1.725 02A 311 140 H
02A 311 140 J
1.775... 1.791 1.750 02A 311 140 J
02A 311 140 J
Performing measurement check
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Install measuring appliance and dial gauge

Rotate input shaft so that the tapered roller bearings settle.
Press input shaft in direction of arrow.
Bearing play should be min. 0.01... max. 0.09 mm.
NOTE: If the bearing clearance cannot be measured, but input

shaft play is perceptible and the input shaft turns freely, the
adjustment is acceptable.
OUTPUT SHAFT, DISASSEMBLING AND ASSEMBLING
Output shaft, disassembling and assembling
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Fig. 283: Identifying Special Tools -- Output Shaft, Disassembling And

Assembling (1 Of 3)
VW 407 Press tool

VW 412 Press tool
VW 512 Press disk
V.A.G 1582 Puller
V.A.G 1582/4 Grip piece

V.A.G 1582/5 Grip piece
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Assembling (2 Of 3)
VW 402 Thrust plate

32-111 Thrust piece
VW 408 A Press tool
VW 407 Press tool
VW 457 Support rails

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VW 519 Tube

Assembling (3 Of 3)
VW 429 Thrust ring

VW 415 A Tube
VW 454 Press piece
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VW 455 Fitting sleeve

41-501 Drift sleeve

1 - Internal puller Kukko 21/6

4 - Kukko 22/2 Counter support
NOTE:
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Fig. 287: Exploded View Of Output Shaft Components

The output shaft is disassembled as follows:
Position separating device under 2nd gear wheel (item - 19 Output shaft,
disassembling and assembling) and press off.
Remove circlip (item - 15 Output shaft, disassembling and assembling).
Position two-arm puller under bearing support (item - 9 Output shaft,
disassembling and assembling) and pull off locking collar with 1st and 2nd
gear synchro-hub as described in Pressing locking collar with synchro-hub
over bearing support.
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When installing new gears or a new output shaft consult technical data. Refer
to Code letters, transmission application, ratios, capacities.
Both tapered roller bearings must be replaced together as a set.

1 - Hex nut, 25 Nm plus 90 ° further (1/4 turn)
4 nuts for bearing support
2 - Clutch housing
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3 - Shim
For output shaft
4 - Small tapered roller bearing outer race
Removing. See Pulling out small tapered roller bearing outer race
Pressing in. See Pressing in small tapered roller bearing outer race
5 - Small tapered roller bearing inner race
Pulling off. See Pulling off small tapered roller bearing inner race
Pressing on. See Pressing on small tapered roller bearing inner race
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6 - Output shaft
Is paired with final drive gear, always replace together as a set
Adjusting. Refer to Output shaft, adjusting
7 - Large tapered roller bearing inner race
Pulling off. See Pulling off large tapered roller bearing inner race
Pressing on. See Pressing on large tapered roller bearing inner race
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8 - Sealing ring
Place sealing rings (Qty. 4) on bearing support bolts
9 - Bearing support
With large tapered roller bearing outer race and bolts

Only change outer race together with large tapered roller bearing and bearing
support

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10 - Thrust washer
Shoulder on thrust washer faces tapered roller bearing
11 - 1st selector gear
From transmission build date 02 05 0 synchronization for 1st gear has been
modified. Refer to 1st gear synchronization, modified from transmission
build date 02 05 0

For 1st gear
13 - 1st gear synchro-ring

Checking for wear. See Checking synchro-ring for wear
Identification. See Identifying 1st and 2nd gear synchro-rings
build date 02 05 0
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14 - 1st and 2nd gear locking collar with synchro-hub

Pull off via bearing support after removing circlip (item - 15 Output shaft,
disassembling and assembling).
Disassembling. See Disassembling and assembling 1st and 2nd gear locking
collar and synchro-hub
Assembling locking collar/synchro hub. See Disassembling and assembling
1st and 2nd gear locking collar and synchro-hub and Assembling 1st and
2nd gear locking collar/synchro-hub
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Installation position. See Installation position of 1st and 2nd gear locking
collar/synchro-hub
Pressing on. See Pressing on 1st and 2nd gear locking collar/synchro-hub
build date 02 05 0
15 - Securing clip
16 - 2nd gear synchro-ring
Identification. See Identifying 1st and 2nd gear synchro-rings

Checking for wear. See Checking 2nd gear synchro-ring for wear
Assemble so that recesses locate in locking collar (item - 14 Output shaft,
disassembling and assembling) locking pieces
build date 02 05 0
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17 - Outer ring
Insert in synchro-ring (item - 16 Output shaft, disassembling and
assembling). Installation position. See Installation position of outer-ring
Replace if scored
18 - Synchro-ring
(Inner ring)
Checking for wear. See Checking inner ring for wear
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Check lugs for scoring

Installation position. See Installation position of synchro-ring (inner-ring) -
A-
19 - 2nd gear
Installation position. See Installation position of 2nd gear wheel

For 2nd gear
21 - Thrust washer
22 - Sleeve for 3rd gear needle roller bearing
Pressing off with 2nd gear wheel. See Pressing off 3rd and 4th gear synchro-
hub/locking collar, 2nd, 3rd and 4th gear wheels with transmission
housing needle roller bearing sleeve
Pressing on. See Pressing on needle roller bearing sleeve for 3rd gear
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For 3rd gear
24 - Selector gear for 3rd gear
25 - 3rd gear synchro-ring
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26 - Locking collar with 3rd and 4th gear synchro-hub

Press off with 2nd gear wheel (item - 19 Output shaft, disassembling and
assembling) and 3rd gear wheel (item - 24 Output shaft, disassembling and
assembling). See Pressing off 3rd and 4th gear synchro-hub/locking collar,
2nd, 3rd and 4th gear wheels with transmission housing needle roller
bearing sleeve
Disassembling. See and assembling 3rd and 4th gear locking collar and
synchro-hub
Installation position locking collar/synchro-hub. See Installation position 3rd
and 4th gear locking collar/synchro-hub
Assembling locking collar/synchro-hub. See and assembling 3rd and 4th
gear locking collar and synchro-hub and Assembling 3rd and 4th gear
locking collar/synchro-hub
Pressing on. See Pressing on 3rd and 4th gear synchro-hub with locking
collar
27 - Sleeve
For needle roller bearing

Press off with locking collar and 3rd and 4th gear synchro-hub (item - 26
Output shaft, disassembling and assembling). See Pressing off 3rd and 4th
gear synchro-hub/locking collar, 2nd, 3rd and 4th gear wheels with
transmission housing needle roller bearing sleeve
Pressing on. See Pressing on sleeve for 4th gear needle roller bearing
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For 4th gear
29 - 4th gear synchro-ring

30 - Selector gear for 4th gear
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31 - Thrust washer
For output shaft
Removing and installing. Refer to Driving out needle roller bearing
34 - Sleeve
For needle roller bearing / output shaft

Pressing off. See Pressing off 3rd and 4th gear synchro-hub/locking collar,
2nd, 3rd and 4th gear wheels with transmission housing needle roller
bearing sleeve
Pressing on. See Pressing on sleeve for output shaft needle roller bearing
35 - 5th gear
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36 - Dished spring
Fitted portion on bolt head holds saucer spring washer in position

Pulling out small tapered roller bearing outer race
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Fig. 296: Pulling Off Small Outer Race/Tapered Roller Bearing

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

Pressing in small tapered roller bearing outer race
Fig. 297: Pressing In Small Tapered Roller Bearing Outer Race

Pulling off small tapered roller bearing inner race
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Fig. 298: Pulling Off Small Tapered Roller Bearing Inner Race
A - Vice clamps/vice
Mount gripping device and tension behind bearing rollers, then turn bearing
and retension gripping device.
Pressing on small tapered roller bearing inner race
Fig. 299: Pressing On Small Tapered Roller Bearing Inner Race

Pressing off 3rd and 4th gear synchro-hub/locking collar, 2nd, 3rd and 4th gear wheels with transmission housing needle roller
bearing sleeve
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Fig. 300: Pressing Off 3rd And 4th Gear Synchro-Hub/Locking Collar, 2nd,
3rd And 4Th Gear Wheels With Transmission Housing Needle Roller Bearing
Sleeve
A - Separating device 22...115 mm, e.g. Kukko 17/2
B - Hex bolt 17 mm AF - M10 x 20
NOTE: Support separating appliance so that the 1st and 2nd gear
locking collar is not pulled off at the same time.
Pressing locking collar with synchro-hub over bearing support
Fig. 301: Pressing Locking Collar With Synchro-Hub Over Bearing Support
First remove circlip (arrow).
Pulling off large tapered roller bearing inner race
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Fig. 302: Pulling Off Large Tapered Roller Bearing Inner Race
A - protective jaws
Before mounting puller insert a M 10 x 20 hex bolt in output shaft bore.

Pressing on large tapered roller bearing inner race
Fig. 303: Pressing On Large Tapered Roller Bearing Inner Race

A - Thrust washer
Install thrust washer before pressing on inner race. Shoulder faces inner race.
Checking synchro-ring for wear
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Fig. 304: Checking Synchro-Ring For Wear

Press synchro-ring onto gear cone and measure gap "a" with feeler gauge.
Gap "a" New dimension Wear limit

1st gear 1.0...1.7 mm 0.5 mm
3rd gear 1.0...1.7 mm
4th gear 1.0...1.7 mm
Disassembling and assembling 1st and 2nd gear locking collar and synchro-hub
Fig. 305: Disassembling And Assembling 1st And 2nd Gear Locking Collar
And Synchro-Hub
1 - Circlip
2 - Locking collar
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3 - Synchro-hub
4 - Locking piece
Slide locking collar over synchro-hub.
The wide shoulder of the synchro-hub (arrow -A-) and the outer splines of the
locking collar (arrow -B-) face opposite directions after assembly. Recesses for
locking pieces on synchro-hub and locking collar must align.
Assembling 1st and 2nd gear locking collar/synchro-hub
Fig. 306: Assembling 1st And 2nd Gear Locking Collar/Synchro-Hub

Locking collar is pushed over synchro-hub.
Insert locking pieces and install springs 120 ° offset. Angled end of spring
must locate in hollow locking piece.
Installation position of 1st and 2nd gear locking collar/synchro-hub
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Fig. 307: Installation Position Of 1st And 2nd Gear Locking Collar/Synchro-
Hub
The locking collar splines (arrow -1-) point to splines for 3rd/4th gear synchro-hub -
A-.
The wide shoulder of the synchro-hub (arrow -2-) then faces 1st gear -B-.
Pressing on 1st and 2nd gear locking collar/synchro-hub
Fig. 308: Pressing On 1st And 2nd Gear Locking Collar/Synchro-Hub

NOTE: Before pressing on, place 1st gear synchro-ring on 1st gear
wheel.
Identifying 1st and 2nd gear synchro-rings
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Fig. 309: Identifying 1st And 2nd Gear Synchro-Rings

1st gear synchro-ring: 3 ground-down half teeth (arrow)
2nd gear synchro-ring: 3 ground down half teeth (arrow) or 2 ground-down
half teeth
Only the version with 2 ground-down half teeth is available as a spare part for the
2nd gear synchro-ring.
Distinguishing 1st and 2nd gear synchro-rings
Fig. 310: Distinguishing 1st And 2nd Gear Synchro-Rings

1st gear synchro-ring - no recesses

2nd gear synchro-ring - three recesses (arrows)
Checking 2nd gear synchro-ring for wear
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Fig. 311: Checking Synchronizer Rings For 1st, 2nd And 3rd Gears For Wear
Press synchro-ring, outer-ring and inner-ring onto selector gear cone and
measure gap "a" with feeler gauge.

2nd gear 1.2...1.8 mm 0.5 mm
Installation position of outer-ring
Fig. 312: Installation Position Of Outer-Ring

The lugs (arrows) face 1st gear -A-
Checking inner ring for wear
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Fig. 313: Checking Inner Race For 1st Gear, 2nd Gear And 3rd Gear For
Wear
Press inner ring onto 2nd selector gear cone and measure gap "a" with a feeler
gauge.

2nd gear 0.75...1.25 mm 0.3 mm
Installation position of synchro-ring (inner-ring) -A-
Fig. 314: Installation Position Of Synchro-Ring (Inner-Ring)

The lugs (arrow -1-) locate in the recesses (arrow -2-) in the synchro-ring -B-.
Installation position of 2nd gear wheel
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Fig. 315: Installation Position Of 2nd Gear Wheel

The higher shoulder -A- faces 1st gear -B-. The recesses in the shoulder (arrows)
locate with the lugs of the outer ring (arrow. See Installation position of outer-
ring)
Pressing on needle roller bearing sleeve for 3rd gear
Fig. 316: Pressing On Needle Roller Bearing Sleeve For 3rd Gear
Disassembling and assembling 3rd and 4th gear locking collar and synchro-hub
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Fig. 317: Disassembling And Assembling 3rd And 4th Gear Locking Collar
And Synchro-Hub
1 - Spring
2 - Locking piece
3 - Locking collar
4 - Synchro-hub
Slide locking collar over synchro-hub.
The recesses for locking pieces in synchro-hub and locking collar must align.
Assembling 3rd and 4th gear locking collar/synchro-hub
Fig. 318: Assembling 3rd And 4th Gear Locking Collar/Synchro-Hub

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The locking collar has been pushed over the synchro-hub.

Insert locking pieces and install springs 120 ° offset. Angled end of spring
must locate in hollow locking piece.
Installation position 3rd and 4th gear locking collar/synchro-hub
Fig. 319: Installation Position 3rd And 4th Gear Locking Collar/Synchro-Hub
Chamfer (arrow) faces 4th gear.

Pressing on 3rd and 4th gear synchro-hub with locking collar
Fig. 320: Pressing On 3rd And 4th Gear Synchro-Hub With Locking Collar
Pressing on sleeve for 4th gear needle roller bearing
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Fig. 321: Pressing On Sleeve For 4th Gear Needle Roller Bearing
Pressing on sleeve for output shaft needle roller bearing
Fig. 322: Pressing On Sleeve For Output Shaft Needle Roller Bearing
1st gear synchronization, modified from transmission build date 02 05 0
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Fig. 323: Installed Position Of Outer Race, Inner Race And Synchronizer
Ring, 2nd Gear
The following components have been added or modified:
A- Inner ring
B- Outer ring
C- Synchro-ring
with additional recesses -4- for the lugs -1- of inner ring -A-.
1st gear wheel

with additional recesses -3- for the lugs -2- of outer ring -B-.
NOTE: For 2nd gear the same inner ring, outer ring and
synchro ring are installed.
If the components are not replaced, ensure they are
reallocated to the original gear.
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Fig. 324: Installed Position Of Outer Race, Inner Race And Synchronizer
Ring, 2nd Gear
Installation position of inner ring, outer ring and synchro-ring 1st gear
Place inner ring -A- on 1st gear wheel.
Angled lugs (arrow -1-) point toward outer ring -B-.
Install outer ring -B-.

Lugs (arrow -2-) engage in gear wheel recesses (arrow -3-).
Install synchro-ring -C-.
The recesses (arrow -4-) engage in lugs (arrow -1-) of inner ring -A-.
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Fig. 325: Checking Inner Race For 1st Gear, 2nd Gear And 3rd Gear For
Wear
Check 1st gear inner ring for wear

Press inner ring onto gear wheel cone and measure gap "a" with a feeler gauge.

1st gear 0.75...1.25 mm 0.3 mm
Fig. 326: Checking Synchronizer Rings For 1st, 2nd And 3rd Gears For Wear
Check 1st gear synchro-ring and outer ring for wear
Press synchro-ring, outer ring and inner ring onto selector gear cone and
measure gap "a" with feeler gauge.
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1st gear 1.2...1.8 mm 0.5 mm
Fig. 327: Identifying Locking Collar And Locking Pieces With 1st And 2nd
Gear Synchro-Hub Components
Assembling locking collar and locking pieces with 1st and 2nd gear synchro-
hub
1 - Circlip
2 - Locking collar
3 - Synchro-hub
4 - Locking piece
With introduction of the modified 1st gear synchronization the shoulder has the
same width on both sides of synchro-hub.
The shoulder has a chamfer on one side (arrow -B-).

After assembly the shoulder of the synchro-hub and the outer splines of the locking
collar (arrow -A-) face the same direction.
Recesses for locking pieces on the synchro-hub and locking collar (arrow -C-) must
align.
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Fig. 328: Installation Position Of Locking Collar/Synchro-Hub 1st And 2nd

Gear
Installation position of locking collar/synchro-hub 1st and 2nd gear

The locking collar splines (arrow) point to splines for 3rd/4th gear synchro-hub -A-.
Remove 1st gear synchro-hub as described and install again.

OUTPUT SHAFT, ADJUSTING
Output shaft, adjusting
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Fig. 329: Identifying Special Tools -- Output Shaft, Adjusting

(Determining shim for output shaft)


VW 512 Press disk
3114/2 Straightening tool
VW 407 Press tool

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Dial gauge


1 - Internal puller Kukko 21/6
4 - Kukko 22/2 Counter support
It is necessary to readjust the output shaft when the following components are
replaced:
Final drive
Clutch housing
or
Tapered roller bearing

Press small tapered roller bearing outer race together with a 0.65 mm thick
shim fully into clutch housing. Refer to Pressing in small tapered roller
bearing outer race.
Insert output shaft and tighten nuts for bearing support to 25 Nm, then turn 90 °
further.
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2006 Audi TT
Fig. 331: Identifying Special Tools VW385/17, VW387 & 3114/2

Mount dial gauge (3 mm measuring range) and set to "0" with 1 mm preload.
Move output shaft up and down and note dial gauge reading (example: 0.30
mm).
Determining thickness of shim
The specified bearing preload is obtained by adding a constant preload figure of

0.20 mm to the reading obtained (example: 0.30 mm) and the thickness of the shim
installed (0.65 mm).
Example:
Shim installed 0.65 mm

+ Reading 0.30 mm
+ Preload (constant) 0.20 mm
Thickness of shim 1.15 mm
Remove output shaft and pull out small tapered roller bearing outer race. Refer
to Pulling out small tapered roller bearing outer race.
The following adjustment shims are available:
Size (mm) Part No.

0.65 020 311 391 P
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2006 Audi TT
0.70 020 311 391 Q

0.75 020 311 391
0.80 020 311 391 A
0.85 020 311 391 B
0.90 020 311 391 C
0.95 020 311 391 D
1.00 020 311 391 E
1.05 020 311 391 F
1.10 020 311 391 G
1.15 020 311 391 H
1.20 020 311 391 J
1.25 020 311 391 K
1.30 020 311 391 L
1.35 020 311 391 M
1.40 020 311 391 N
Varying tolerances make it possible to obtain the exact shim thickness required.
Press in small tapered roller bearing outer race together with correct shim (in
example: 1.15 mm) (Refer to Pressing in small tapered roller bearing outer
race) and install output shaft. Tighten bearing support nuts in clutch housing to
25 Nm and then turn 90 ° further.
REVERSE SHAFT, DISASSEMBLING AND ASSEMBLING
Reverse shaft, disassembling and assembling
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Fig. 332: Identifying Special Tools - Reverse Shaft, Disassembling And

Assembling
VW 454 Press piece

VW 411 Press tool
12-551 Centering mandrel
VW 401 Thrust plate

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2006 Audi TT
VW 408 A Press tool
NOTE: After disassembling, always replace needle roller bearing in

clutch housing and reverse shaft support.
Fig. 333: Exploded View Of Reverse Shaft Components

1 - Clutch housing
Pulling out. See Pulling needle roller bearing out of clutch housing
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2006 Audi TT
Pressing in. See Pressing needle roller bearing -A- into clutch housing
3 - Reverse gear wheel
4 - Circlip
Always replace after removing
Fig. 334: Exploded View Of Reverse Shaft Components

5 - Reverse sliding gear wheel
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2006 Audi TT
Before replacing remove circlip

Shoulder faces reverse gear wheel
6 - Reverse shaft
Removing. Refer to Assembly sequence
Pressing out. See Pressing needle roller bearing out of reverse shaft
support
Pressing in. See Pressing needle roller bearing into reverse shaft support
8 - Reverse shaft support

Pulling needle roller bearing out of clutch housing
Fig. 335: Pulling Needle Bearing Out Of Clutch Housing

A - Counter support, e.g. Kukko 22/1
B - Internal extractor 14.5...18.5 mm, e.g. Kukko 21/2
NOTE: The needle bearing is destroyed during removal and must

be replaced.
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Pressing needle roller bearing -A- into clutch housing
Fig. 336: Pressing Needle Bearing Into Clutch Housing

Pressing needle roller bearing out of reverse shaft support
Fig. 337: Pressing Needle Roller Bearing Out Of Reverse Shaft Support
Pressing needle roller bearing into reverse shaft support
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Fig. 338: Pressing Needle Roller Bearing Into Reverse Shaft Support
39 FINAL DRIVE, DIFFERENTIAL
FLANGE SHAFT OIL SEALS (TRANSMISSION INSTALLED), REPLACING
Observe general repair instructions. Refer to General repair instructions.
Fig. 339: Slide Hammer-Multi-Purpose Tool Set VW 771

VW 771 Multi-purpose tool
VW 771/37 Puller hooks
Fig. 340: 3106 Drift

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3106 Drift
Removing
Before replacing right-hand oil seal:
Turn steering to right onto full lock stop.
Fig. 341: Removing/Installing Protective Cap For Drive Axle (If Present)
Remove drive shaft protective cap from engine.
Disconnect drive shaft from flange shaft.
Tie-up drive shaft as high as possible. Do not damage paint on drive shaft.
Before replacing left-hand oil seal:
Remove drive shaft.

All models
Place drip tray underneath.
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Remove flange shaft cone head bolt.

Remove flange shaft with spring.
Fig. 343: Pulling Out Seal Using Special Tools VW 771 & VW 771/37
Pull out seal.
NOTE: Do not damage sleeve, otherwise leaks will occur.

Replace sleeve if damaged. Refer to Pry out sleeve with
screwdriver.
Installing
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2006 Audi TT
Fig. 344: Identifying Special Tool VW 3106

Drive seal into sleeve onto stop, when doing this do not tilt seal.
Fill space between sealing lip and dust lip with grease G 052 128 A1.
Insert flange shaft.
Install cone head bolt into flange shaft threaded piece.
Install left-hand drive shaft or attach right-hand drive shaft to flange shaft.
Install drive shaft protective cover if necessary.

Top up transmission oil. Refer to Transmission gear oil, checking.
Tightening torques
Flange shaft to transmission (cone head bolt) 25 Nm

Protective cap / drive shaft to engine M8 20 Nm
M10 35 Nm
DIFFERENTIAL, DISASSEMBLING AND ASSEMBLING
Differential, disassembling and assembling
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Fig. 345: Identifying Special Tools - Differential, Disassembling And

Assembling (1 Of 2)
V.A.G 1582 Puller

V.A.G 1582/3 Grip
VW 412 Press tool
40-105 Thrust plate
VW 401 Thrust plate

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VW 402 Thrust plate
Fig. 346: Identifying Special Tools - Differential, Disassembling And

Assembling (2 Of 2)
VW 408 A Press tool

VW 473 Thrust piece
30-205 Thrust plate
3144 Sleeve
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2007 Thrust pad
NOTE:
Fig. 347: Exploded View Of Differential Components

Heat tapered roller bearing inner race to 100 ° C b efore

installing.
Always replace both tapered roller bearings together as
a set.
If the tapered roller bearings, differential housing,
transmission housing or clutch housing are replaced,
always adjust the differential. Refer to Differential,
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adjusting.
2 - Bolt
3 - Differential cage
Bolt to final drive gear

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4 - Final drive gear wheel

Rivetted in production
Is paired with output shaft, only replace as a set
Pressing off. See Pressing off final drive gear
Installation position. See Installation position of final drive gear wheel
Heat to 100 ° C before installing

Fit to differential housing. See HEATING FINAL DRIVE GEAR WHEEL
TO APPROX. 100 ° C and installing
Bolted. See Bolting final drive gear and differential housing together
5 - Backing plate
6 - Nut, 70 Nm
7 - Shim
For differential
Determining thickness. Refer to Differential, adjusting
Pulling out. See Pulling tapered roller bearing outer race out of
transmission housing
Pressing in. See Pressing tapered roller bearing outer race into
transmission housing
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Pulling off. See Pulling off tapered roller bearing inner race
10 - Differential housing
With riveted final drive gear

When replacing final drive gear drill out rivet heads. See Drilling out rivet
heads
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Attaching final drive gear with bolts. See Bolting final drive gear and
differential housing together
11 - Speedometer drive wheel
Fit onto differential housing as far as stop before pressing on inner race
Pulling off. See Pulling off tapered roller bearing inner race

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2006 Audi TT

Driving out. See Driving tapered roller bearing outer race out of clutch
housing
Pressing in. See Pressing tapered roller bearing outer race into clutch
housing
14 - Clutch housing
15 - Sleeve
Installed in conjunction with springs behind flange shafts

To accept oil seal (item - 16 Differential, disassembling and assembling)
Removing and installing. Refer to Pry out sleeve with screwdriver
16 - Oil seal
17 - Counter-sunk head bolt, 25 Nm
Bolt into threaded piece (item - 25 Differential, disassembling and

assembling)
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18 - Flange shaft
19 - Spring for flange shaft

Installed behind flange shafts
20 - Thrust washer
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Installation position: Shoulder toward spring, tabs to tapered ring

Installation position with modified thrust washer. See Modified thrust washer
for tapered ring
21 - Tapered ring
With grooves to secure thrust washer

Installation position: Taper toward differential housing
22 - Securing clip
Holds tapered ring, thrust washer and spring in position when flange shaft is
removed
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23 - One-piece thrust washer

Coat with transmission oil when installing
24 - Large differential bevel gear
Installing. See Installing differential bevel gears
25 - Threaded piece

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26 - Differential pinion axis shaft

Knock out with drift
27 - Spring pin
For securing differential pinion axis shaft

Removing and installing. See Removing and installing differential pinion
axis shaft spring pin
28 - Small differential bevel gear

29 - Large differential bevel gear

Driving tapered roller bearing outer race out of clutch housing
Fig. 353: Driving Tapered Roller Bearing Outer Race Out Of Clutch Housing
Using Special Tools VW408 & VW473
First remove flange shaft seal mounting sleeve on transmissions with springs
behind flange shaft.
Pressing tapered roller bearing outer race into clutch housing
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Fig. 354: Pressing Tapered Roller Bearing Outer Race Into Clutch Housing
No shim is installed in the clutch housing end.
Pulling off tapered roller bearing inner race
Fig. 355: Pulling Off Tapered Roller Bearing Inner Race

Before mounting extractor position press piece 40-105 on differential housing.
NOTE: both tapered roller bearing inner races are pulled off the
differential housing in the same way.
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2006 Audi TT

NOTE: The tapered roller bearing inner races for the transmission
housing and the clutch housing are pressed on with the
same press tools.
Pulling tapered roller bearing outer race out of transmission housing
Fig. 357: Pulling Tapered Roller Bearing Outer Race Out Of Transmission
Housing
A - Counter support, e.g. Kukko 22/2
B - Internal puller 46...58 mm, e.g. Kukko 21/7

Pressing Tapered Roller Bearing Outer Race Into Transmission Housing
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Fig. 358: Pressing Tapered Roller Bearing Outer Race Into Transmission
Housing
Install Shim Under Outer Race.

Support Transmission Housing With Sleeve 3144 Directly Below Bearing
Mounting.
Both sides of differential housing are chamfered (arrow) to accept tapered rings/springs
Fig. 359: Both Sides Of Differential Housing Are Chamfered To Accept

Tapered Rings/Springs
Drilling out rivet heads
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Fig. 360: Drilling Out Rivet Heads

Drill out rivet heads with 12 mm drill from countersunk side and knock out
with drift.
NOTE: Clean differential before and after drilling. Protect tapered

roller bearing from drillings.
Pressing off final drive gear
Fig. 361: Pressing Off Final Drive Gear

Place thrust piece 40-105 on differential housing.
Installation position of final drive gear wheel
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Fig. 362: Installation Position Of Final Drive Gear Wheel

The circular groove -A- faces bolt-on side of differential.
Heating final drive gear wheel to approx. 100 ° C and installing
Fig. 363: Heating Final Drive Gear Wheel And Installing

Use bolts -A- from repair kit to guide final drive gear into position during
installation.
Bolting final drive gear and differential housing together
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Fig. 364: Bolting Final Drive Gear And Differential Housing Together
Use special bolts with plates and nuts according to parts catalog.
Removing and installing differential pinion axis shaft spring pin
Fig. 365: Removing And Installing Differential Pinion Axis Shaft Spring Pin
Removing
Cover tapered roller bearing inner race and speedometer drive gear to avoid
possible damage and ingress of metal particles.
Drive out spring pin with chisel, inserting chisel into circumferential groove.
Installing
Drive fully into differential cage.

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Installing differential bevel gears
Fig. 366: Installing Differential Bevel Gears

Lubricate one piece thrust washer with transmission oil and install.
Install both large bevel gears and secure (e.g. with flanged shaft).
Insert small bevel gears (180 ° apart) and pivot into position.
Push differential pinion axis shaft (arrow -A-) in until first bevel gear.
Position threaded pieces (arrow -B-) in large bevel gears
Installation position: step toward gear

Drive differential pinion axis shaft into final position and secure with spring
pin.
Modified thrust washer for tapered ring
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Fig. 367: Modified Thrust Washer For Tapered Ring

Installation position:
If there are no tabs -A- , the shoulder should point toward pressure spring -B-.
ADJUSTMENT OVERVIEW
Adjustment overview
NOTE: If repairs have been performed on the transmission it is

only necessary to adjust the input shaft, output shaft or
differential when components have been replaced which
have a direct effect on the adjustments. Refer to the
following table to avoid unnecessary adjustment:
to be adjusted:
Input shaft Output shaft Differential
Refer to Input Refer to Refer to
shaft, Output shaft, Differential,
adjusting adjusting adjusting
Parts Transmission x x
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2006 Audi TT
replaced: housing
Clutch housing x x x
Input shaft x
Output shaft x
(final drive)
Differential x
housing
Input shaft x
tapered roller
bearing
Output shaft x
tapered roller
bearing
Differential x
tapered roller
bearing
4th gear wheel x
DIFFERENTIAL, ADJUSTING
Differential, adjusting
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Fig. 368: Identifying Special Tools - Differential, Adjusting


30-205 Thrust plate
VW 407 Press tool
Dial gauge
The differential must be adjusted, when

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2006 Audi TT
Transmission housing
Clutch housing
Differential housing
or the
Differential tapered roller bearing

have been replaced.

Press tapered roller bearing outer race into clutch housing using thrust plate 30-
205. Refer to Pressing tapered roller bearing outer race into clutch
housing.
NOTE: Tapered roller bearing inner and outer races are paired. Do
not interchange!
Press tapered roller bearing outer race without shim into transmission housing
using thrust piece 30-205. Refer to Pressing tapered roller bearing outer
race into transmission housing.
Press in tapered roller bearing outer race into clutch housing using thrust piece
30-205. Refer to Pressing tapered roller bearing outer race into clutch
housing.
Install differential into clutch housing.
Mount transmission housing and tighten 5 bolts to 25 Nm.
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Fig. 369: Installing Dial Gauge And Set To "0" With 1 mm Pre-Load
Mount dial gauge and "0" with 1 mm preload.
Move differential up and down and recall play indicated on dial gauge
(Example: 0.70 mm)
Determining shim thickness
The specified bearing preload is obtained by adding a constant figure (0.40 mm) to
the reading obtained.
Example:
Reading 0.70 mm
+ Preload (constant figure) 0.40 mm
Thickness of shim = 1.10 mm
Remove transmission housing and pull tapered roller bearing outer race out
from transmission housing. Refer to Pulling tapered roller bearing outer
race out of transmission housing.
Insert shims of correct thickness, thickest shim first.
The following shims are available:
Size (mm) Part No.

0.65 02A 409 210
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2006 Audi TT
0.70 02A 409 210 A

0.75 02A 409 210 B
0.80 02A 409 210 C
0.85 02A 409 210 D
0.90 02A 409 210 E
0.95 02A 409 210 F
1.05 02A 409 210 G
1.05 02A 409 210 H
1.10 02A 409 210 J
1.15 02A 409 210 K
1.20 02A 409 210 L
1.25 02A 409 210 M
If the size of shim required is larger than that listed in the table, insert two shims
totalling the correct figure.
Varying tolerances make it possible by measuring the shims to obtain the exact
shim thickness required.
Drive in outer race again and tighten transmission housing.
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5spd Manual Trans 02j Front Wheel Drive

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5spd Manual Trans 02j Front Wheel Drive

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2006 Audi TT

TRANSMISSION 5 Spd. Manual Transmission 02J Front Wheel Drive

5 Spd. Manual Transmission 02J Front Wheel Drive

00 GENERAL, TECHNICAL DATA

Fig. 1: Locating Code Letters And Date Of Manufacture On Transmission

Fig. 2: Identifying Manual Transmission 02J

Fig. 3: Code Letters And Date Of Manufacture Of Transmission

NOTE: The transmission code letters are also shown on the

vehicle identification plates.

Manual 5-speed 02J

Code letters DZF EGZ1) EWV1)

Overall ratio in top gear 3.299 3.299 3.299

2) With dual-mass flywheel

Fig. 4: View Of Transmission Layout & Gear Ratios

5 - Output shaft/pinion shaft

Arrows point in direction of travel

Fig. 5: View Of Transmission Layout & Gear Ratios

Arrows point in direction of travel

Calculating overall ratio 'i'

5th gear Final drive

iA = Axle ratio = ZA2 : ZA1 = 63 : 16 = 3.938

iov = Overall ratio

1) Z1 = No. of teeth drive gear, Z2 = No. of teeth driven gear

General repair instructions

A number of generally valid instructions applicable for the various repair

NOTE: If gear oil is added with the transmission installed, check

O-rings, seals, gaskets

Fig. 6: Identifying Space Between Oil Seal Sealing Lips

The open sides of the seals face the oil side.

Do not over-stretch circlips.

Fig. 7: Identifying Locking Elements

Bolts and nuts

use new bearings from the same manufacturer.

Do not interchange. When reusing, always reinstall to the same gear.

Observe installation position.

Clutch control, servicing

I - Assembly overview - pedal cluster. Refer to Pedal cluster, overview

III - Assembly overview - hydraulics. Refer to Hydraulic system, overview

NOTE: Disconnect battery Ground strap.

Fig. 9: Exploded View Of Pedal Cluster Components

For mounting clutch pedal

6 - Self-locking hex nut, 25 Nm

Fig. 10: Exploded View Of Pedal Cluster Components

8 - Self-locking hex nut, 25 Nm

Removing and installing. Refer to Clutch pedal, removing and installing

Removing and installing. Refer to Hydraulic system, overview

13 - Self-locking hex nut, 25 Nm

Removing and installing. Refer to Master cylinder, removing and installing

Fig. 11: Exploded View Of Pedal Cluster Components

17 - Over-center spring mounting

Special tools and workshop equipment required

Fig. 12: T10111 Assembly Device

T10111 Assembly clip

Remove driver's side lower cover.

1 - Rear part of assembly clip must be positioned on over-center spring so that

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Pull clutch pedal into passenger compartment.

Fig. 15: Installing Over-Center Spring Together With Assembly Device

Insert over-center spring into rear mounting first (arrow -A-).

Refer to 68 - INTERIOR EQUIPMENT

Special tools and workshop equipment required

Fig. 17: Identifying Pliers T10005

Fig. 18: Torque Wrench V.A.G 1331

V.A.G 1331 Torque wrench