Service: Manual Transmission

Service
Repair Manual
R32 2004 ➤
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
e
Manual Transmission
ris nte
ho eo
aut ra
ss c
Engine ID BJS
ce
e
nl
pt
du
an
itte
y li
Edition 01.2012
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Service Department. Technical Information

Service
List of Workshop Manual Repair GroupsList of Workshop Manual
Repair GroupsList of Workshop Manual Repair Groups
Repair Group
00 - General, Technical Data
30 - Clutch
34 - Controls, Housing
35 - Gears, Shafts
39 - Final Drive, Differential
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
Technical information should always be available to the foremen and mechanics, because their
c by lksw
cted agen
Prote
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
AG.
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.
All rights reserved.

No reproduction without prior agreement from publisher.
Copyright © 2012 Volkswagen AG, Wolfsburg D3E80081B7C

R32 2004 ➤
Manual Transmission - Edition 01.2012
Contents
00 - General, Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Transmission Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Rear Final Drive Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.3 Notes on Performance Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.4 Overall Transmission Ratio i, Calculating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.5 General Repair Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2 Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.1 Powertrain Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.1 Code Letters, Allocation, Ratios and Capacities, Transmission . . . . . . . . . . . . . . . . . . . . . . 9
3.2 Code Letters, Allocation, Ratios and Capacities, Rear Final Drive . . . . . . . . . . . . . . . . . . 9
30 - Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.1 Clutch Pedal Switch, Differences . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.2 Clutch System, Bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.1 Clutch Pedal Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.2 Hydraulic System Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.1 Fastener Tightening Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4 Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4.1 Clutch Pedal Switch F36, with a Square Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4.2 Clutch Pedal Switch F36, with a Round Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4.3 Over Center Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4.4 Clutch Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4.5 Master Cylinder . . . . . . . . . . . . . . . . .A.G.. .V.ol.ks.w.a.g.en. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
agen AG do
4.6 Clutch Slave Cylinder with Release ksw Bearing . . . . . . . . . e.s.no. t . . . . . . . . . . . . . . . . . . . . . . . . 24
y Vol g
4.7 Clutch . . . . . . . . . . . . . .se.d.b . . . . . . . . . . . . . . . . . . . . . . . . . . . u.a.ra.n . . . . . . . . . . . . . . . . . . . . 25
ri te
o
5 Special Tools . . . . a. u.th. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . e. o.r a. . . . . . . . . . . . . . . . . 28
ss c
34 - Controls, Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
ce
le
un
pt
an
d
itte
y li
rm
ab
1.1 Transmission Fluid, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

pe
ility
ot
wit

, is n
h re
2.1 Electrical and Electronic Components and Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

hole
spec
2.2 Shift Mechanism Installed Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

es, in part or in w
t to the co
2.3 Shift Knob, Boot and Noise Insulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

2.4 Shift Lever and Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
2.5 Shift and Selector Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
rrectness of i
2.6 Shift Unit Adjusting, through Build Date 18 May 2003 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

l purpos
2.7 Shift Unit Adjusting, from Build Date 19 May 2003 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

2.8 Transmission Gear Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
nform
ercia
2.9 Transmission Housing and Shift Mechanism, through Build Date 18 May 2003 . . . . . . . . 47
2.10 Transmission Housing and Shift Mechanism, from Build Date 19 May 2003 . . . . . . . . . . . . 48
m
a
com
ti
2.11 Input Shaft, Output Shafts, Differential, Bevel Box and Selector Rods . . . . . . . . . . . . . . . . 50
on in
r
te o
3 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
thi
s
iva
do

r
rp
cum
fo
4 Diagnosis and Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

en
ng
t.
yi Co
4.1 Vehicle Diagnostic Tester, Connecting and Selecting Functions . . . . . . . . . . . . . . . . . . . .
t. Cop py
rig 56
gh ht
pyri by
Vo
o
i
by c lksw
cted
Contents
agen
Prote AG.
R32 2004 ➤

5.1 All Wheel Drive Control Module J492 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
5.2 Haldex Clutch Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
5.3 Boot, Removing from Shift Lever, Installing with Shift Knob . . . . . . . . . . . . . . . . . . . . . . . . 60
5.4 Shift Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
5.5 Transmission, Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
5.6 Transmission Transporting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
5.7 Transmission, Securing to the Transmission Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
5.8 Transmission, Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
5.9 Bevel Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
6 Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
6.1 Transmission, Through Build Date 18 May 2003 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
6.2 Transmission, From Build Date 19 May 2003 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
6.3 Transmission Housing, Through Build Date 18 May 2003 . . . . . . . . . . . . . . . . . . . . . . . . . . 96
6.4 Transmission Housing, AG.From
VolkswBuild
agen AG Date 19 May 2003 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
agen do
6.5 Clutch Housing, olkswThrough Build Date 18esMay not 2003 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
yV gu
6.6 Clutch isHousing,
ed
b
From Build Date 19 May 2003 ara . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
nte 110
r
6.7 Shift
aut Unit, Transmission Side Through Build Date 18
ho e o May 2003 . . . . . . . . . . . . . . . . . . . .
ra 114
6.8 Shift
ss
Unit, Transmission Side, From Build Date 19 May c
2003 . . . . . . . . . . . . . . . . . . . . . . 116
ce
le
6.9 Selector Forks Through Build Date, 18 May 2003 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118

un
pt
an
d
itte
6.10 Selector Forks From Build Date, 19 May 2003 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

y li 120
rm
ab
7 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
pe
ility
ot
wit
, is n
35 - Gears, Shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129

h re
hole
spec

es, in part or in w
t to the co
1.1 Input Shaft Adjusting, Through Build Date 18 May 2003 . . . . . . . . . . . . . . . . . . . . . . . . . . 129
1.2 Output Shaft 1st to 4th Gears, Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
1.3 Output Shaft, 5th, 6th and Reverse Gears, Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
rrectness of i

l purpos
2.1 Input Shaft, Through Build Date 18 May 2003 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138

2.2 Input Shaft, From Build Date 19 May 2003 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
nform
ercia
2.3 Output Shaft, 1st to 4th Gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147

2.4 Output Shaft, 5th, 6th and Reverse Gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
m
a
com
tio
3 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165

n in
r
te o
thi
s
iva
39 - Final Drive, Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169

do
r
rp
cum
fo

en
ng
t.
yi
1.1 Haldex Clutch Function, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
Co
Cop py
.
1.2 Haldex Clutch Oil Level, Checking and Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
ht rig
rig ht
py by
1.3 Haldex Clutch Oil Filter, Changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
co Vo
by lksw
cted agen
1.4 Rear Final Drive, Transmission Fluid Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Prote
171
AG.

2.1 Adjustment Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
2.2 Bevel Box Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
2.3 Haldex Clutch and Clutch Disc Cover Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
2.4 Pinion Housing Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
2.5 Differential and Head Bevel Gear/Input Shaft Overview . . . . . . . . . . . . . . . . . . . . . . . . . . 180
2.6 Rear Final Drive Differential Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
2.7 Shaft Bevel Gear Bearing Overview, Rear Final Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
2.8 Head Bevel Gear and Input Shaft Bearing Overview, Rear Final Drive . . . . . . . . . . . . . . . . 185
2.9 Differential, Front Final Drive, Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
2.10 Shift and Head Bevel Gear, Front Final Drive, Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . 189
2.11 Shift and Head Bevel Gear, Rear Final Drive, Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . 202
3 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
ii Contents
R32 2004 ➤

4.1 Front Final Drive Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
4.2 Driveshaft and Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
4.3 Rear Final Drive and Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
5.1 Front Final Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242
5.2 Driveshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 256
5.3 Rear Final Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260
6 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Contents iii
lkswage es n
R32 2004 ➤ d byV
o ot g
ua
ran
Manual Transmission - Edition 01.2012 ho
ir se tee
ut or
a ac
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
iv Contents
R32 2004 ➤
00 – General, Technical Data

1 General Information
⇒ “1.1 Transmission Identification“, page 1
⇒ “1.2 Rear Final Drive Identification“, page 2
⇒ “1.3 Notes on Performance Test“, page 2
⇒ “1.4 Overall Transmission Ratio i, Calculating“, page 2
⇒ “1.5 General Repair Information“, page 3
1.1 Transmission Identification

The 6 speed manual transmission 02Y All Wheel Drive (AWD) is
installed with the 6 cylinder engine in the R32 for MY 2004.
Location on Transmission
Code letters and date of manufacture -arrow 1- manual transmis‐
sion 02Y AWD -arrow 2-.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
Manual Transmission 02M -arrow 2- shown, 02Y similar hor eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
Transmission Code Letters and Date of Manufacture -arrow-
l purpos
Example: EEJ 14 01 9
nform
ercia
I I I I
m
I I I I
a
com
tion in
Identification Day Month Year (1999)

r
te o
thi
Code of manufacture
s
iva
do
r
rp
Additional information about the factory

um
fo
en
ng
t.
yi Co
Cop py
t.
Note
rig
gh ht
pyri by
Vo
o
by c lksw
cted
The transmission code is also listed on the vehicle data label.
agen
Prote AG.
1. General Information 1
R32 2004 ➤
1.2 Rear Final Drive Identification

Rear final drive 02D is allocated to the 6 speed manual transmis‐
sion 02Y All Wheel Drive (AWD).
Location on Rear Final Drive
Near the final drive fluid fill plug
or near the connector for the Haldex clutch

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
Final drive code and build date

Example: EHR 14 01 9 t to the co
rrectne
I I I I
I I I I
ss
Identification Day Month Year 1999 of pro‐

o
cial p
Code duction
inform
mer
Additional data depends on the manufacturer.

atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
1.3 Notes on Performance Test

t.
yi Co
Cop py
t. rig
– Only test stands with four braked rollers should be used for the
gh ht
yri by
performance test.
cop Vo
by lksw
cted agen
Prote AG.
1.4 Overall Transmission Ratio i, Calculat‐
ing
Example
5th Gear Final Drive
Drive gear ZG1 = 37 ZA1 = 14
Driven gear ZG2 = 50 ZG2 = 69
i = ZG2 : ZG1 *
iG = gear ratio = ZG2 : ZG1 = 37 : 50 = 0.740
2 Rep. Gr.00 - General, Technical Data

lkswage es n
o ot g
byV ua
d ran
ir se tee
o
auth R32 2004 or
ac ➤
ss Manual Transmission - Edition 01.2012
ce
e
nl
pt
du
an
iA = axle ratio = ZG2 : ZG1 = 69 : 14 = 4.929
itte
y li
erm
ab
itotal = total ratio = iG x iA = 0.740 x 4.929 = 3.647
ility
ot p
wit
, is n
• *Z
h re
1 = number of teeth on the drive gear, Z2 = number of teeth
hole
spec
on the driven gear
es, in part or in w
t to the co
1.5 General Repair Information
Carefulness, cleanliness and proper tools are essential to ensure
rrectness of i
satisfactory and successful transmission repairs. The usual basic
safety precautions also, naturally apply when carrying out vehicle
l purpos
repairs.
A number of generally applicable instructions for individual repair
nform
ercia
procedures, which are otherwise mentioned at various points in
this repair manual, are summarized here.
m
at
om
ion
c
Components
in t
or
his
ate
Transmission
do
priv
cum
or
♦ Make sure that the alignment sleeves between the engine and
f
en
ng
t.
transmission are positioned correctly when installing the trans‐
yi Co
op
mission.
C py
t. rig
gh ht
yri by
♦ Clean the contact surfaces when installing the brackets as well cop Vo
by lksw
as any waxed components. Contact surfaces must be free of
cted agen
Prote AG.
grease and wax.
♦ For the correct bolts and other components, refer to the Parts
Catalog.
♦ The transmission fluid must be filled whenever replacing the
transmission or the bevel box.
♦ For the correct capacity, refer to Fluid Capacity Tables, Rep.
Gr. 03.
♦ When replacing the rear final drive, fill with gear oil and Haldex
clutch oil up to the lower edge of the fill holes.
♦ For the correct capacity, refer to Fluid Capacity Tables, Rep.
Gr. 03..
O-rings and Seals
♦ Thoroughly clean the separation surfaces and apply sealing
paste -AMV 188 200 03- .
♦ Apply the sealing paste evenly and not too thick.
♦ Replace the O-rings.
♦ Radial shaft seals.
R32 2004 ➤
Prior to installing:
Lightly lubricate the outer circumference with oil and then fill the
space between the sealing lips -arrow- halfway with sealing
grease for seal -G 052 128 A1- .
After installing:
♦ Check the fluid level in the transmission and bevel box. Refer
to ⇒ “1.1 Transmission Fluid, Checking“, page 30 .
♦ Check the fluid level in the rear final drive. Refer to
⇒ “1.4 Rear Final Drive, Transmission Fluid Checking“,
page 171 .
Radial Shaft Seals for the Driveshaft Flange and Bevel Box Shaft
on Rear Final Drive
♦ Lubricate the outer circumference and the space between the
sealing lips lightly with high performance gear oil for Haldex
coupling -G 052 175 A1- for the Haldex clutch before installing.
n AG. Volkswagen A ge G do
swa es n
♦ After installing, check the oil level in the Haldex by
Vol clutch. Refer
k ot g
ua
to ris
ed ran
tee
⇒ “1.2 Haldex Clutch Oil Level, Checking ut
ho and Filling“, or
page 169 . ss
a ac
ce
e
nl
Fasteners
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

R32 2004 ➤
♦ Replace the lock rings.

♦ Do not overstretch the lock rings.
♦ The lock rings must fit completely inside the groove. agen
AG. Volkswagen AG d
oes
olksw not
♦ Replace the roll pin. The slot must be longitudinal to ethed b line
yV gu
ara
of force. horis nte
eo
aut ra
Bolts and Nuts ss c
ce
le
un
♦ Always loosen or tighten bolts and nuts for covers and hous‐
pt
an
d
itte
ings diagonally.
y li
rm
ab
pe
♦ The tightening specification stated apply to non-lubricated
ility
ot
nuts and bolts.
wit
, is n
h re
hole
♦ Always replace the self locking nuts and bolts.
spec
es, in part or in w
♦ Make sure the contact surfaces and visible surfaces on the
t to the co
nuts and bolts are waxed after assembling.
♦ Clean all threaded holes with a thread tap to remove any lock‐
rrectness of i
ing fluid residue. Otherwise the bolts could shear the next time
they are removed.
l purpos
Bearings
nform
ercia
♦ Install the new tapered roller bearings. It is not necessary to

oil them.
m
a
com
tio
♦ Install the needle bearings with the lettered side (thicker metal)
n in
r
te o
facing the installation tool.
thi
s
iva
do
♦ Replace all the tapered roller bearings that are on the same
r
rp
cum
shaft. Use tapered roller bearings from the same manufactur‐
fo
en
ng
er.
t.
yi Co
Cop py
. rig
♦ Heat the inner races to approximately 100 °C (212 °F) before
ht ht
rig by
py
installing co Vo
by lksw
cted agen
Prote
♦ Do not interchange the outer and inner bearing races with
AG.
those from other bearing of the same size. The bearings are
paired.
Adjusting Shims
♦ Measure the adjusting shims at several locations with a mirc‐
ometer. Tolerance variations make it possible to find the exact
shim thickness required.
♦ Check for burrs and damage.
♦ Only install perfect shims.
Synchronizer Rings
R32 2004 ➤
♦ Do not interchange them. When reusing synchronizer rings,

always install to the same gear.
♦ Check for wear and replace if necessary.
♦ Check the grooves -arrow 1- on the synchronizer ring -A- and
the inner race for flat areas (grooves are worn).
♦ The coating on the synchronizer rings must not be damaged.
♦ If an intermediate ring -B- is installed, check the outer friction
surface -arrow 2- and the inner friction surface -arrow 3- for
grooves and scoring.
♦ Check the taper on the drive gear for grooves and scoring.
♦ Coat the synchronizer ring with transmission fluid and then in‐
stall.
Gears AG. Volkswagen AG d
agen oes
ksw
♦ Clean the gears band y V heat them to approximately 100
ol not
gu °C (212
ara
°F) before installing.
rised
nte
ho eo
ut
♦ Clean and
ss a heat to a maximum 100 °C (212 °F) using the in‐
ra
c
ductive heat unit -VAS 6414- or equivalent, before installing.
ce
e
nl
pt
du
Guided Fault Finding, On Board Diagnostic (OBD) and Test In‐ an

itte
y li
struments
erm
ab
ility
ot p
♦ Before servicing the Haldex clutch, determine the cause of the

wit
, is n
damage as exact as possible using the vehicle diagnostic

h re
tester and “Guided Fault Finding“, “OBD“ and “Test Instru‐

hole
spec
ments“.
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

R32 2004 ➤
2 Description and Operation

⇒ “2.1 Powertrain Overview“, page 7
2.1 Powertrain Overview

Components
The -arrows- point in the direction of travel.
1 - Engine
2 - Clutch
3 - Manual Transmission
4 - Input Shaft
5 - Output Shaft for 5th, 6th and agen
AG. Volkswagen AG d
oes
Reverse Gears (Output Shaft olksw not
yV gu
II) ised b ara
nte
or eo
h
6 - Output Shaft for 1st to 4th s aut ra
c
Gear (Output Shaft I) s
ce
le
un
pt
7 - Differential
an
d
itte
y li
rm
ab
8 - Bevel Box
pe
ility
ot
wit
9 - Driveshaft
, is n
h re
hole
10 - Haldex Clutch
spec
es, in part or in w
11 - Rear Final Drive
t to the co
12 - Differential
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Gears
The -arrows- point in the direction of travel.
2. Description and Operation 7

R32 2004 ➤
I - 1st Gear
II - 2nd Gear
III - 3rd Gear
IV - 4th Gear
V - 5th Gear
VI - 6th Gear
R - Reverse Gear
A - Final Drive
T - Drive
W1 - Front Final Drive
W2 - Bevel Box
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

R32 2004 ➤
3 Specifications
⇒ “3.1 Code Letters, Allocation, Ratios and Capacities, Trans‐
mission“, page 9
⇒ “3.2 Code Letters, Allocation, Ratios and Capacities, Rear Final
Drive“, page 9
3.1 Code Letters, Allocation, Ratios and Capacities, Transmission

Manual Transmission 6 Speed 02Y All Wheel Drive (AWD)
Identification Code JRZ GQV JNE
Allocation Type R32, MY 2004 R32, MY 2004 R32, MY 2004
Engine 3.2L - 177 kW 3.2L - 177 kW 3.2L - 177 kW
Ratio: Z2 : Z1 Final drive I 72:17 = 4.235 72:17 = 4.235 72:17 = 4.235
Final drive II 72:22 = 3.273 72:22 = 3.273 72:22 = 3.273
1st gear 47:14 = 3.357 47:14 = 3.357 47:14 = 3.357
2nd gear 48:23 = 2.087 48:23 = 2.087 48:23 = 2.087
3rd gear 47:32 = 1.469 47:32 = 1.469 47:32 = 1.469
4th gear 37:34 = 1.088 37:34 = 1.088 37:34 = 1.088
5th gear 41:37 = 1.108 41:37 = 1.108 41:37 = 1.108
6th gear 31:34 = 0.912 31:34 = 0.912 31:34 = 0.912
Reverse gear 23:14 x 34:14 = 3.900 23:14 x 34:14 = 3.900 23:14 x 34:14 = 3.900
Capacity Refer to the Fluid Capacity Tables, Rep. Gr. 03
Drive axle flange diameter 108 mm 108 mm 108 mm
. Volkswagen AG
i total in highest gear
swa
2.985
gen AG does 2.985 2.985
k not
Vol gu
Allocation: rear final drive code let‐ed by FWS FWS ara
nte
FWS
ters tho
ris eo
au ra
c
ss
ce
le
un
pt
an
d
• Final drive I for 1st to 4th gear

itte
y li
erm
ab
• Final drive II for 5th/6th and reverse gears

ility
ot p
wit
is n
Refer to the Parts Catalog for the following information:

h re
ole,
♦ Transmission fluid
spec
t to the co
♦ Clutch plate allocation
3.2 Code Letters, Allocation, Ratios and Capacities, Rear Final Drive
rrectne
Rear Final Drive 02D

s
Identification Code FWS

s o
cial p
f i
Manufactured from through 05.01

nform
mer
Allocation Type R32, MY 2004

atio
m
Engine 3.2L - 177 kW

o
n
c
i
or
n thi
Ratio: Z2 : Z1 Bevel box 17:27 x 27:17 = 1.00

te
sd
a
front / rear
iv
o
pr
cum
r
fo
Final drive capacity Refer to the Fluid Capacity Tables, Rep.

en
ng
t.
Gr. 03
yi Co
Cop py
Specification Gear oil F 052 145 A SAE 75W-90 (syn‐
ht. rig
rig ht
by
thetic oil)
copy Vo
by lksw
cted agen
Haldex clutch capacity Prote Refer to the Fluid Capacity Tables, Rep.
AG.
Gr. 03
Replacement capacity in Haldex clutch Refer to the Fluid Capacity Tables, Rep.
Gr. 03
3. Specifications 9
R32 2004 ➤ AG. Volkswagen AG d
agen o
Manual Transmission
Volksw - Edition 01.2012es not g
y ua
db ran
rise tee
Rear tho
Final Drive or 02D
s au ac
Identification Code s
FWS
ce
le
un
pt
Specification High performance oil for Haldex clutch G
an
d
itte
y li
052 175
erm
ab
ility
Drive axle flange diameter 100 mm
ot p
wit
is n
Allocation manual transmission code letters JRZ, GQV and JNE
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

R32 2004 ➤
30 – Clutch
⇒ “1.1 Clutch Pedal Switch, Differences“, page 11
⇒ “1.2 Clutch System, Bleeding“, page 11
1.1 Clutch Pedal Switch, Differences

-A- = clutch pedal switch with a square housing -arrow-
– Removing and installing, refer to
⇒ “4.1 Clutch Pedal Switch F36, with a Square Housing“, page
18 .
-B- = clutch pedal switch with a round housing -arrow-.
– Removing and installing, refer to
⇒ “4.2 Clutch Pedal Switch F36, with a Round Housing“, page
19 .
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
1.2 Clutch System, Bleeding

ot
wit
, is n
h re
Special tools and workshop equipment required

hole
spec
es, in part or in w
♦ Brake Charger/Bleeder Unit -VAS 5234- or -V.A.G 1869-

t to the co
Brake fluid specification, refer to “Brake System, Bleeding“ in ⇒

Brake System; Rep. Gr. 47 ; General Information .
rrectness of i
l purpos
Note
nform
ercia
It is not necessary to pre-fill the system.

m
a
com
ti
– Connect the brake charger/bleeder unit -VAS 5234- or -V.A.G

on in
1869- .
r
te o
thi
s
iva
– Use the bleeder hose (670 mm) -V.A.G 1238/B3- .

do
r
rp
cum
fo
– Connect the hose to the brake bleeder unit collector bottle.

en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
R32 2004 ➤
– Attach the bleed hose -A- to the breather assembly -arrow-.

– Apply 2 bar pressure to the system.
– Open the breather assembly valve approximately 1/4 rotation.
swa es
– Press the clutch pedal
by
Vol 15 to 20 times rapidly by hand
k not
gufrom stop
ara
to stop. ris
ed
nte
tho eo
– Close the
ss
abreather
u
assembly valve. ra
c
ce
e
– After completing the bleeding procedure, and the pressure has

nl
pt
du
an
dropped from 2 bar, press the clutch pedal an additional 10
itte
y li
times using your foot.
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
12 Rep. Gr.30 - Clutch

R32 2004 ➤

⇒ “2.1 Clutch Pedal Overview“, page 13
⇒ “2.2 Hydraulic System Overview“, page 15
AG. Volkswagen AG d
agen
2.1 Clutch Pedal Overview
oes
ksw not
Vol gu
by ara
ed nte
oris eo
th
au ra
Note ss c
ce
le
un
pt
♦ Obtain the anti-theft code for the radio before disconnecting
an
d
itte
y li
the battery.
rm
ab
pe
ility
♦ Turn off the ignition and disconnect the battery ground cable.
ot
wit
, is n
Refer to ⇒ Electrical Equipment; Rep. Gr. 27 ; Removal and
h re
Installation .
hole
spec
es, in part or in w
♦ Refer to ⇒ Electrical Equipment; Rep. Gr. 27 ; Removal and
t to the co
Installation when connecting the battery.
♦ Lubricate all bearing and contact surfaces with grease -G 000
rrectness of i
450 02- .
l purpos
1 - Bulkhead
nform
ercia
❑ With the studs for the

m
mounting bracket and
a
com
tio
master cylinder.
n in
r
te o
thi
2 - Seal
s
iva
do
r
❑ Always replace.
rp
cum
fo
en
ng
3 - Mounting Bracket
t.
yi Co
op py
❑ For the clutch pedal.
t. C rig
gh ht
pyri by
Vo
4 - Bolt
co lksw
by
cted agen
Prote AG.
5 - Bracket
❑ For the accelerator and
brake pedal.
6 - Self Locking Nut
❑ 25 Nm
❑ Always replace.
7 - Filler Plate
❑ 25 Nm
❑ Always replace.
9 - Bushing
10 - Pin
11 - Clutch Pedal
❑ Removing and instal‐
ling, refer to
⇒ “4.4 Clutch Pedal“,
page 20 .
12 - Mounting
ling, see -item 4- in the
⇒ “2.2 Hydraulic System
Overview“, page 15 .

R32 2004 ➤
AG. Volkswagen
13 - Self Locking Nut wage
n AG do
es n
Volks ot g
❑ 25 Nm d by ua
ran
ir se tee
❑ Always replace. uth o
or
a ac
ss
14 - Master Cylinder
ce
le
un
pt
❑ Removing and installing, refer to ⇒ “4.5 Master Cylinder“, page 21 .
an
d
itte
y li
rm
ab
15 - Supply Hose
pe
ility
ot
16 - Over Center Spring
wit
, is n
h re
❑ Removing and installing, refer to ⇒ “4.3 Over Center Spring“, page 19 .
hole
spec
es, in part or in w
17 - Over Center Spring Mount
t to the co
❑ Installed inside the bracket.
❑ Master cylinder removing and installing. Refer to ⇒ “4.5 Master Cylinder“, page 21 .
rrectness of i
18 - Clutch Pedal Switch -F36-
l purpos
❑ Differences, refer to ⇒ “1.1 Clutch Pedal Switch, Differences“, page 11 .

❑ Clutch pedal switch removing and installing. Refer to one of the following:
nform
ercia
⇒ “4.1 Clutch Pedal Switch F36, with a Square Housing“, page 18 .

m
a
com
tio
⇒ “4.2 Clutch Pedal Switch F36, with a Round Housing“, page 19 .
n in
r
te o
thi
19 - Stop
s
iva
do
r
rp
c
❑ For the clutch pedal.
um
fo
en
ng
❑ Installed position, refer to ⇒ page 23 .

t.
yi Co
Cop py
. rig
t
gh ht
pyri by
Vo
o
❑ 25 Nm
c by lksw
cted agen
Prote AG.
❑ Always replace.

R32 2004 ➤
2.2 Hydraulic System Overview
1 - Brake Fluid Reservoir

2 - Supply Hose
3 - Master Cylinder
ling, refer to
⇒ “4.5 Master Cylinder“,
page 21 .
4 - Mount
❑ Replace only when the
clutch master cylinder is
removed.
❑ Removing, refer to
⇒ page 16 .
❑ Installing, refer to
⇒ page 16 .
5 - Clutch Pedal
ling, refer to
⇒ “4.4 Clutch Pedal“,
page 20 .
❑ 25 Nm
❑ Always replace.
❑ Quantity: 2
7 - Seal/O-ring
AG. Volkswagen AG d
❑ Always replace. lksw
agen oes
not
Vo gu
❑ Installed on the line con‐ ed by ara
nte
nection. horis
eo
ut ra
❑ Install using brake
ss a
fluid. c
ce
le
❑ Seal/O-ring version, re‐

un
pt
an
fer to ⇒ page 16 .
d
itte
y li
rm
ab
❑ Allocation, refer to the

pe
ility
Parts Catalog.
ot
wit
, is n
h re
8 - Hose/Line Assembly
hole
spec
❑ Allocation, refer to the Parts Catalog.

es, in part or in w
t to the co
9 - Clip
❑ Attached to the body.
rrectness of i
10 - Seal/O-ring
l purpos
❑ Always replace.
❑ Installed on the line connection.
nform
ercia
❑ Install using brake fluid.

❑ Seal/O-ring version, refer to ⇒ page 16 .
m
a
com
tio

n in
r
te o
thi
11 - Bleeder
s
iva
do
r
rp
12 - Seal/O-ring
um
fo
en
ng
t.
❑ Always replace.
yi Co
Cop py
t. rig
gh ht
pyri by
❑ Install using brake fluid.
o Vo
by c lksw
cted agen
Prote
❑ Seal/O-ring version, refer to ⇒ page 16 .
AG.

R32 2004 ➤
13 - Clip
❑ The clip must be removed in order to remove/install the hose/line assembly.
14 - Valve
❑ Clutch system, bleeding. Refer to ⇒ “1.2 Clutch System, Bleeding“, page 11 .
15 - Cap
16 - Clip
❑ The clip must be removed in order to remove/install the hose/line assembly.
17 - Clutch Slave Cylinder
AG. Volkswagen AG d
❑ Removing and installing, remove agen
ksw the transmission. Refer
oes to
ol not
byV
⇒ “5.5 Transmission, Removing“, page 63 . gu
ara
ed is nte
or
18 - Clip au
th eo
ra
s c
❑ The clip must bes removed in order to remove/install the hose/line assembly.
ce
le
un
pt
an
d
itte
y li
rm
ab
Prying Off the Mount -A- in the -direction of arrow-.
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
Installing the Master Cylinder Actuator Rod into the Mount -A-
ion in
(-in the direction of arrow-).

r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Seal/O-ring for the Hose/line Assembly

Item Line Connection Version
1 Line connection with a groove all the way around
-arrow 1-
2 Line connection with a shoulder -arrow 2-
3 Line connection with a shoulder -arrow 2- and a
groove all the way around -arrow 3-
• The seal/O-ring must be installed in the grooves
-arrows 1 and 3-.

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
horis R32
nte 2004 ➤
eo
aut Manual Transmission - Edition 01.2012 ra
ss c
ce
le
un
pt
an
d
3 Specifications
itte
y li
erm
ab
ility
ot p
⇒ “3.1 Fastener Tightening Specifications“, page 17
wit
is n
h re
3.1 Fastener Tightening Specifications
ole,
spec
Component Fastener Size Nm
t to the co
Clutch Pedal Bracket to Bulkhead Nut 1, 2 - 25
Clutch Pedal to Bracket Through Bolt Nut 1, 2 - 25
rrectne
Clutch Slave Cylinder with Release Bearing to Transmission Nut 1, 3
ss
– With a Metal Slave Cylinder with Release Bearing Housing - 12
o
cial p
f in
– With a Plastic Slave Cylinder with Release Bearing Housing - 15
form
mer
Connecting Plate to Accelerator/Brake Pedal Bracket and Clutch - 25
atio
m
Pedal Bracket Nut 1, 2

o
n
c
i
or
n thi
Master Cylinder to Bulkhead Nut 1, 2 - 25
te
sd
iva
o
pr
Pressure Plate to Flywheel Bolt 1, 4
cum
r
fo
en
ng
– With a Single Flywheel - 20

t.
yi Co
Cop py
– With a Dual Mass Flywheel - 22
ht. rig
rig ht
py by
co Vo
lksw
•
by
1 Always replace cted agen
Prote AG.
• 2 Self locking
• 3 Carefully tighten diagonally in small stages so that slave cyl‐
inder eyelets do not break off
• 4 Tighten diagonally and in steps
3. Specifications 17
R32 2004 ➤
4 Removal and Installation

⇒ “4.1 Clutch Pedal Switch F36, with a Square Housing“,
page 18
⇒ “4.2 Clutch Pedal Switch F36, with a Round Housing“,
page 19
⇒ “4.3 Over Center Spring“, page 19
⇒ “4.4 Clutch Pedal“, page 20
⇒ “4.5 Master Cylinder“, page 21
⇒ “4.6 Clutch Slave Cylinder with Release Bearing“, page 24
⇒ “4.7 Clutch“, page 25
4.1 Clutch Pedal Switch F36, with a Square

Housing
The clutch pedal switch may be installed only one time. This as‐
sures it will fit securely inside the clutch pedal bracket.
Removing
– Remove the trim under the steering column. Refer to “Storage
Compartments, Covers and Trim“ in ⇒ Body Interior; Rep. Gr.
68 ; Removal and Installation .
– Disconnect the connector from the clutch pedal switch.
– Rotate the clutch pedal switch 90° to the left and remove it.
Note
On some vehicles it may be necessary to rotate the clutch pedal

switch 90° to the right. The bracket has different holes for the
clutch pedal switch.
Installing and Adjusting lkswage es n
o ot g
byV ua
– Pull the plunger all the way out. rised ran
tee
tho
u or
– Press the clutch pedal as farss aas possible all the way down by ac
hand.
ce
e
nl
pt
du
an
– Install the clutch pedal switch and rotate it 90° to the right.
itte
y li
erm
ab
ility
ot p
wit
Note
, is n
h re
hole
spec
On some vehicles it may be necessary to rotate the clutch pedal

es, in part or in w
switch 90° to the left. The bracket has different holes for the clutch
t to the co
pedal switch.
– Release the clutch pedal.

rrectness of i
The clutch pedal must be in its end position.

l purpos
– Install the trim under the steering column. Refer to “Storage

nf

ercia

rm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
18
co Vo
by lksw
Rep. Gr.30 - Clutch cted agen
Prote AG.
R32 2004 ➤
4.2 Clutch Pedal Switch F36, with a Round

Housing
The clutch pedal switch may be installed only one time. This as‐
sures it will fit securely inside the clutch pedal bracket.
Removing
Compartments, Covers and Trim“ in ⇒ Body Interior; Rep. Gr. n AG. Volkswagen AG do
68 ; Removal and Installation . olkswage es n
o V t gu
by ara
– Disconnect the connector -1- from the clutch pedal switch.
ris
ed nte
tho eo
– Rotate the clutch pedal switch -2- 45° to the left and
ss
au remove ra
c
it.
ce
e
nl
pt
du
an
itte
y li
erm
ab
Note
ility
ot p
wit
, is n
The clutch pedal remains in its resting position (not pressed).
h re
hole
spec
Installing
es, in part or in w
t to the co
rrectness of i
Clutch Pedal Switch Differences
l purpos
Clutch pedal switch

-A- = without a cap on the end • It will be necessary to pull
nf
ercia
o
of the plunger -arrow- the plunger all the way out
rm
m
before installing.
atio
om
n in
or c
-B- = with a cap on the end of • Do not pull out the plunger.
thi
te
sd
the plunger -arrow-
iva
o
r
rp
cu
o
m
• The clutch pedal must be in its resting position.
f
en
ng
t.
yi Co
op
– Guide the clutch pedal switch through the hole, push the clutch C py
t. rig
pedal down and rotate the switch 45° to the right.
gh ht
pyri by
Vo
co lksw
by
– Connect clutch pedal switch connector. cted agen
Prote AG.

4.3 Over Center Spring

♦ Assembly Clip -T10111-
Removing
4. Removal and Installation 19

R32 2004 ➤
– Install the assembly clip -T10111- from the right side into the
over center spring.
– At the same time, make sure the assembly clip -T10111- is
correctly seated:
1 - The rear part of the assembly clip -T10111- must be positioned
on the over center spring so that the claws fit over the web -1-.
2 - Gently push the clutch pedal toward the bulkhead. Hook the
lug -2- on the assembly clip -T10111- into the cut out of the over
center spring.
– Press the clutch pedal as far as possible towards the bulkhead
until the over center spring can be removed downwards from
the mount on the bracket and clutch pedal.
– Pull the clutch pedal back to its rest position.
– Turn the over center spring in the -direction of arrow A- using

the assembly clip -T10111- and then remove it in the
-direction of arrow B-.
Installing
– Pull the clutch pedal towards the passenger compartment.
– Install the over center spring into the bracket in the

-direction of arrow A- using the assembly clip -T10111- while
turning it in the -direction of arrow B-.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
– Install the over center spring in the mount -arrow A-.

wit
is n
h re
ole,
– Push the clutch pedal toward the bulkhead until the over center
spec
spring touches the pin -arrow B- on the clutch pedal.

t to the co
– Move the clutch pedal into its rest position and remove the
assembly clip -T10111- .
rrectne

ss o
cial p
f inform
mer
atio
om
n
c
i
or
4.4 Clutch Pedal

thi
te
sd
iva
o
r

p
cum
r
fo
en
ng
♦ Pliers -T10005-
t.
yi Co
Cop py
. rig
♦ Torque Wrench (5-50 Nm) -V.A.G 1331-
ht ht
rig by
copy Vo
by lksw
cted agen
Prote AG.

R32 2004 ➤
Removing lkswage es n
o ot g
yV ua
– Removeristheed clutch pedal switch. Refer to one of rthe
b
an following:
tee
tho
or
⇒ “4.1au Clutch Pedal Switch F36, with a Square Housing“, ac page
ss
18 .
ce
e
nl
pt
du
an
itte
y li
19 .
erm
ab
ility
ot p
– Remove the over center spring. Refer to
wit
, is n
⇒ “4.3 Over Center Spring“, page 19 .
h re
hole
spec
– Remove the clutch pedal from the master cylinder, refer to
es, in part or in w
⇒ “4.5 Master Cylinder“, page 21 and push the actuator rod
t to the co
toward the engine compartment all the way.
– Remove the nut -A-.
rrectness of i
– Pull the bolt out until the clutch pedal can be removed.
l purpos
Installing
Install in the reverse order of removal.
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
– The mounting -A- must be positioned on the master cylinder
gh ht
pyri by
actuator rod -B-.
co Vo
by lksw
cted agen
Prote AG.
– Press the clutch pedal in the -direction of the arrow- to engage;
be sure that the rod is correctly located.
– Install the over center spring. Refer to
⇒ “4.3 Over Center Spring“, page 19 .
– Install the clutch pedal switch. Refer to one of the following:
18 .
19 .
4.5 Master Cylinder

♦ Pliers -T10005-
Removing
– Disconnect the connecting pipe -1-, the connector -2- and the
hose -3- from the Mass Airflow (MAF) sensor.
– Remove the bolts -4 and 5- and remove the air filter housing.
Refer to ⇒ Engine Mechanical, Fuel Injection and Ignition;
Rep. Gr. 24 ; Description and Operation .
with Electronic Stabilization Program (ESP)
– Remove the Anti-lock Brake System (ABS) control module
and the hydraulic unit. Refer to ⇒ Brake System; Rep. Gr.
Continuation for All

R32 2004 ➤
– Disconnect the supply hose -A- from the brake fluid reservoir
and seal it off.
– Remove the hose/line assembly clip -B- from the master cyl‐
inder.
– Remove the hose/line assembly -C- from the master cylinder
and seal it off.
68 ; Removal and Installation
– Remove the clutch pedal switch. Refer to one of the following:
18 .
19 . n AG. Volkswagen A age G do
ksw es n
y Vol ot g
ua
b
ed ran
oris tee
th or
au ac
ss
Remove the actuator rod/master cylinder from the clutch pedal:
ce
le
un
pt
an
– Pull the clutch pedal slightly towards the passenger compart‐
d
itte
y li
ment.
rm
ab
pe
ility
– Compress both sides of the bracket using the pliers -T10005-
ot
wit
, is n
-arrows-.
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
– Remove the complete clutch pedal mounting bracket as fol‐

lows:
nform
ercia
– Remove the filler plate -A- bolts -arrows 1-.

m
a
com
tion in
– Remove the nuts -arrows 2- for the bracket -B-.

r
te o
thi
s
– Remove the mounting bracket.

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

R32 2004 ➤
– Turn the stop -A- in the -direction of the arrow- and remove it.
– Remove the master cylinder all the way out in the

-direction of arrow 1-.
wage es n
It must not be covered in the upper area of the mountVol
ks for over ot g
by ua
center spring -arrow 2-. ris
ed ran
tee
tho or
– Remove it from the bracket in the -direction
sa
u of arrow 3-. ac
s
ce
le
Installing
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– The mounting -A- must be positioned on the master cylinder
rrectness of i
actuator rod -B-.
l purpos
– Pull the piston rod out of the master cylinder and hold it with
pliers.
nform
ercia
– At the same time, push the clutch pedal in the

-direction of the arrow- to engage it.
m
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
yri by
– Install the stop -A-. cop Vo
by lksw
cted agen
Prote
Installed Position
AG.
The clip -arrow- faces the master cylinder -B-.

– Install the clutch pedal switch. Refer to one of the following:
18 .
19 .
Vehicles with ESP
– Install the ABS control module and the hydraulic unit. Refer to
⇒ Brake System; Rep. Gr. 45 ; Removal and Installation .
– Bleed the clutch system. Refer to
⇒ “1.2 Clutch System, Bleeding“, page 11 .

R32 2004 ➤
4.6 Clutch Slave Cylinder with Release

Bearing
♦ Thrust Piece -T40008-
1 - Transmission
2 - Input Shaft Seal
⇒ page 24 .
⇒ page 25 .
3 - Clutch Slave Cylinder with
Release Bearing
❑ Must be replaced to‐
gether because they are
a single unit.
❑ Do not wash the bear‐
ing, just wipe it off.
❑ Replace any loud bear‐
ings together with the
clutch slave cylinder.
4 - Bolt
❑ With a metal housing,
12 Nm.
❑ With a plastic housing,
15 Nm. AG. Volkswagen AG d
agen oes
ksw
❑ Always replace. byV
ol not
gu
ara
ed
❑ Quantity: 3 horis nte
eo
ut
❑ Carefully tighten diago‐ ss a ra
c
nally and in small stages
ce
e
nl
so that slave cylinder

pt
du
an
itte
bolt eyelets do not break

y li
erm
ab
off.
ility
ot p
5 - O-ring
wit
, is n
h re
❑ Always replace.
hole
spec
❑ Installed on the line con‐

es, in part or in w
t to the co
nection.
❑ Lubricate with brake flu‐
id before installing.
rrectness of i
l purpos
Removing the Seal for the Input Shaft

nform
ercia
– Remove the seal using a screwdriver.

m
at
The seal can only be removed using the sleeve -30-21- when the
om
io
transmission is disassembled.
n
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

R32 2004 ➤
Installing the Seal for the Input Shaft
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
4.7 Clutch
spec
es, in part or in w
t to the co
♦ Flywheel Retainer -3067-
rrectness of i
♦ Centering Pin -T10097-
l purpos

♦ Grease for Clutch Plate Splines -G 000 100-
nform
ercia
(Transmission is removed)
m
a
com
tion in
r
te o
thi
Note
s
iva
do
r
rp
cum
fo
♦ Make sure the alignment sleeves for centering the engine and
en
ng
t.
yi
transmission are installed inside the cylinder block. Install
Co
op py
them if necessary.
. C rig
ht ht
rig by
py
♦ If the alignment sleeves are missing, it will be difficult to shift,
co Vo
by lksw
cted
there will be clutch problems and the transmission may make
agen
Prote AG.
noises (loose rattling).
♦ Replace the clutch and pressure plates with damaged or loose
rivets.
♦ Allocation, refer to the Parts Catalog.

R32 2004 ➤
1 - Flywheel
❑ Make sure it fits secure‐
ly on the centering pins.
❑ There must not be no
grooves, oil or grease
on the clutch disc con‐
tact surface.
ling, refer to ⇒ Engine
Mechanical, Fuel Injec‐
tion and Ignition; Rep.
Gr. 13 ; Description and
Operation .
2 - Clutch Disc
Allocation, refer to the Parts
Catalog.
❑ Dual mass flywheel in‐
stalled position, refer to
⇒ page 26 .
❑ Installed position with a
single flywheel: the
spring cage faces to‐
wards the pressure
plate.
❑ Centering, refer to
⇒ page 27 .
❑ Lightly grease the
splines.
Note
3 - Pressure Plate AG. Volkswagen AG d

agen oes
❑ Removing and instal‐ olksw not
yV gu
ling, refer to ed b ara
nte
is
⇒ page 27 . hor eo
aut ra
❑ Checking the ends of the diaphragm
ss spring. Refer to ⇒ page 27 . c
ce
le
un
pt
Note
an
d
itte
y li
rm
ab
pe
ility
4 - Bolt
ot
wit
, is n
h re
❑ 22 Nm.
hole
spec
❑ Always replace.
es, in part or in w
t to the co
❑ Loosen/tighten diagonally and in steps.

rrectness of i
Clutch Disc Installed Position

l purpos
• The word “Getriebeseite“ (transmission side) or “Getr.-

Seite“ (transmission side) -arrow- must always face the pres‐
sure plate and the transmission.
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

R32 2004 ➤
Centering the Clutch Disc and Removing/Installing the Pressure

Plate
– Loosen or tighten the bolts diagonally and in steps.
– Install the flywheel retainer -3067- when removing.
Note
♦ The pressure plate contact surface and the clutch disc lining
must completely touch the flywheel.
♦ Tighten the bolts in a diagonal sequence equally so that the
centering holes of the pressure plate and centering pins of the
flywheel do not become damaged.
Checking the Ends of the Diaphragm Spring

• Wear up to half the thickness of the diaphragmagspring
en AG. Vis per‐
olkswagen AG
does
mitted. Volksw not
g by ua
ed ran
oris tee
th or
au ac
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

R32 2004 ➤
5 Special Tools
♦ Brake Charger/Bleeder Unit -VAS 5234- or
♦ Brake Charger/Bleeder Unit -V.A.G 1869-
♦ Assembly Clip -T10111- agen

AG. Volkswagen AG d
oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
♦ Pliers -T10005-
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

R32 2004 ➤
♦ Flywheel Retainer -3067-

♦ Centering Pin -T10097-
♦ Torque Wrench (5-50 Nm) -
V.A.G 1331-
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
5. Special Tools 29
R32 2004 ➤
34 – Controls, Housing
⇒ “1.1 Transmission Fluid, Checking“, page 30
1.1 Transmission Fluid, Checking

Note
The transmission fluid for the manual transmission and the bevel
box is checked and filled using the transmission fluid fill hole.
For the correct transmission fluid, refer to the Parts Catalog.

– Remove the fill plug -arrow-. agen
AG. Volkswagen AG d
oes
olksw not
V
The level is correct when the fluid comes up to the bottom d b edge
y gu
ara
of the fill hole. rise nte
tho eo
au ra
– Install and tighten the plug -arrow- to specification,
ss see c
ce
-item 5- in the
e
nl
pt
du
⇒ “6.3 Transmission Housing, Through Build Date 18 May
an
itte
y li
2003“, page 96 or the
erm
ab
⇒ “6.4 Transmission Housing, From Build Date 19 May 2003“,
ility
ot p
page 100 .
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
Note the following when filling for the first time:
rrectness of i
– Remove the fill plug -arrow-.
l purpos
– Add the fluid until it reaches the lower edge of the fill hole.
– Install the plug -arrow-.
nform
ercia
– Start the engine, engage any gear and let the transmission
m
turn for approximately 2 minutes.

at
om
ion
c
– Turn off the engine and remove the drain plug -arrow-.
in t
or
his
ate
– Add fluid once more until it reaches the lower edge of the fill
do
priv
hole.
um
for
en
ng
t.
yi
– Tighten the plug -arrow- to specification, see -item 5- in the
Co
op py
⇒ “6.3 Transmission Housing, Through Build Date 18 May t. C rig
gh ht
2003“, page 96 or the yri
p by
o Vo
c by lksw
cted agen
page 100 .
Prote AG.
30 Rep. Gr.34 - Controls, Housing

R32 2004 ➤
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

R32 2004 ➤

⇒ “2.1 Electrical and Electronic Components and Locations“,
page 32
⇒ “2.2 Shift Mechanism Installed Position“, page 35
⇒ “2.3 Shift Knob, Boot and Noise Insulation“, page 36
⇒ “2.4 Shift Lever and Housing“, page 37
⇒ “2.5 Shift and Selector Cables“, page 38
⇒ “2.6 Shift Unit Adjusting, through Build Date 18 May 2003“,
page 41
⇒ “2.7 Shift Unit Adjusting, from Build Date 19 May 2003“,
page 43
⇒ “2.8 Transmission Gear Overview“, page 46
⇒ “2.9 Transmission Housing and Shift Mechanism, through Build
Date 18 May 2003“, page 47
⇒ “2.10 Transmission Housing and Shift Mechanism, from Build
Date 19 May 2003“, page 48
⇒ “2.11 Input Shaft, Output Shafts, Differential, Bevel Box and
Selector Rods“, page 50
2.1 Electrical and Electronic Components and Locations

1 - All Wheel Drive Control
Module -J492-
❑ Installed location, refer
to ⇒ page 33 .
❑ Comprises a unit to‐
gether with the oil pres‐ AG. Volkswagen AG d
agen
sure actuator and hy‐ Volksw
oes
not
draulic temperature ed by gu
ara
sensor. horis nte
eo
ut ra
❑ Removing and instal‐ ss a c
ling, refer to
ce
e
nl
pt
⇒ “5.1 All Wheel Drive

du
an
itte
Control Module J492“,

y li
erm
ab
page 58 .
ility
ot p
wit
2 - Engine Control Module

, is n
h re
❑ Installed location, refer

hole
spec
to ⇒ page 34 .
es, in part or in w
t to the co
❑ The following signals

are transmitted to the all
wheel drive control
rrectness of i
module via the data

BUS:
l purpos
Engine speed
nf
ercia
Accelerator pedal posi‐

orm
tion
m
atio
om
n in
c
Engine torque
or
thi
te
sd
a

iv
o
r
rp
cu
ling, refer to ⇒ Engine

o
m
f
Mechanical, Fuel Injec‐

en
ng
t.
yi
tion and Ignition; Rep.
Co
Cop py
Gr. 24 ; Removal and
t. rig
gh ht
yri
Installation .
p by
o Vo
by c lksw
cted agen
Prote AG.

R32 2004 ➤
3 - ABS Control Module -J104-

❑ Installed location: to the hydraulic unit on the left side of the engine compartment.
❑ The following signals are transmitted to the all wheel drive control module via the data BUS:
Wheel speeds
Longitudinal acceleration
Brake operation
❑ Removing and installing, refer to ⇒ Brake System; Rep. Gr. 45 ; Removal and Installation .
4 - Haldex Clutch Pump -V181-
❑ Installed location, refer to ⇒ page 33 .
❑ Can be checked in “Guided Fault Finding“ using the vehicle diagnostic tester.
❑ Removing and installing,
gen AG
refer
. Volksto
wag⇒en“5.2
AG Haldex Clutch Pump“, page 59 .
a does
lksw n
5 - Diagnostic Connection
by
Vo ot g
ua
ed ra
❑ Installed or location: Inside the center console undernthe
is tee heating and Air Conditioning (A/C) controls.
th o
au ra
6 - Brake sLamp
s Switch -F- c
ce
le
un
❑ Installed location: on the brake pedal.
pt
an
d
itte
y li
❑ Can be checked in “Guided Fault Finding“ using the vehicle diagnostic tester.
erm
ab
❑ Removing and installing, refer to ⇒ Brake System; Rep. Gr. 46 ; Removal and Installation .
ility
ot p
wit
is n
7 - Parking Brake Indicator Lamp Switch -F9-
h re
ole,
❑ Installed location, refer to ⇒ page 34 .

spec
❑ Can be checked in “Guided Fault Finding“ using vehicle diagnostic tester. t to the co
❑ Removing and installing, refer to ⇒ Brake System; Rep. Gr. 46 ; Description and Operation .
rrectne
All Wheel Drive Control Module

ss o
Installed location: The control module -arrow- is located on the

cial p
f i
rear final drive, on the right front side.

nform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Haldex Clutch Pump
Installed location: The Haldex clutch pump -arrow- is located on
the rear final drive in the right front area under the all wheel drive
control module.

R32 2004 ➤
Engine Control Module

Installed location: The engine control module is located in the
plenum chamber.
Parking Brake Indicator Lamp Switch

Installed location: The switch -arrow- is installed on the parking
brake lever.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

R32 2004 ➤
2.2 Shift Mechanism Installed Position

-Arrow A- Shift Lever Movement
-Arrow B- Selector Lever Movement
A - Shift Lever Cable

B - Selector Lever Cable
C - Heat Shield
❑ Remove the shift mech‐
anism before removal.
1 - Shift Lever
2 - Relay Lever
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
35
cted agen
Prote
2. Description and Operation
AG.
R32 2004 ➤
2.3 Shift Knob, Boot and Noise Insulation
Note
♦ Obtain the radio code on vehicles with a coded radio.

♦ Disconnect the battery negative cable before working on the
shift mechanism inside the engine compartment. Refer to ⇒
Electrical Equipment; Rep. Gr. 27 ; Removal and Installation .
AG. Volkswagen AG d
agen
♦ Read the information on what to do after connecting the
Vol bat‐
ksw
oes
not
tery. Refer to ⇒ Electrical Equipment; Rep. Gr. 27 d;bRemoval
y gu
ara
ise
and Installation . tho
r nte
eo
au ra
♦ Remove the air filter housing. Refer to ⇒ Engine
ss Mechanical, c
ce
e
Fuel Injection and Ignition; Rep. Gr. 24 ; Description and Op‐
nl
pt
du
eration .
an
itte
y li
erm
ab
♦ The shift mechanism must be removed in order to replace the
ility
ot p
shift and selector cables. Refer to
wit
, is n
⇒ “5.4 Shift Mechanism“, page 60 .
h re
hole
spec
♦ Do not bend the shift or selector cables.
es, in part or in w
t to the co
1 - Shift Knob
rrectness of i
❑ Remove and install to‐
gether with the boot
l purpos
-item 2-.
2 - Boot
nf
ercia
or
❑ Removing from the shift
m
m
atio
knob, refer to
om
⇒ “5.3 Boot, Removing
n in
or c
from Shift Lever, Instal‐
thi
te
sd
a
ling with Shift Knob“,

iv
o
r
rp
cu
page 60 .
o
m
f
en
ng
❑ Attaching to the shift

t.
yi Co
op
knob before installing, C py
t. rig
refer to
gh ht
yri by
⇒ “5.3 Boot, Removing
cop Vo
by lksw
cted
from Shift Lever, Instal‐
agen
Prote AG.
ling with Shift Knob“,
page 60 .
❑ Remove and install to‐
gether with the shift
knob -item 1-.
3 - Clamping Sleeve
4 - Clamp
❑ For attaching the shift
knob to the shift lever.
❑ Attach to the shift knob
-item 1- using hose
clamp pliers -V.A.G
1275- .
5 - Frame
6 - Noise Insulation

R32 2004 ➤
2.4 Shift Lever and Housing
Note
Lubricate the bearing areas and the sliding surfaces with grease
-G 000 450 02- .
AG. Volkswagen AG d
1 - Lock Washer agen oes
olksw not
yV gu
❑ Removing and instal‐ ised b ara
nte
ling, refer to ut
hor eo
⇒ page 38 . ss a ra
c
ce
e
2 - Bushing
nl
pt
du
an
itte
y li
3 - Pressure Spring erm
ab
ility
ot p
4 - Bushing
wit
, is n
h re
5 - Bolt
hole
spec
❑ 5 Nm
es, in part or in w
t to the co
6 - Cover
7 - Bearing Shell
rrectness of i
8 - Bearing Shell
l purpos
9 - Shift Lever Guide

10 - Damper
nform
ercia
11 - Gasket
m
at
om
io
❑ Between the shift hous‐
n
c
in t
r
ing and the underbody.

o
his
ate
❑ With self-adhesive.
do
priv
cum
or
❑ Installed on the shift

f
en
ng
housing.
t.
yi Co
Cop py
ht. rig
12 - Bolt opy
rig by
Vo
ht
❑ 25 Nm by c lksw
cted agen
Prote AG.
13 - Retaining Plate
❑ Attached to the body.
14 - Nut
❑ 25 Nm
❑ For the retaining plate to
the body.
15 - Shift Lever
16 - Sound Absorber
17 - Shift Housing
18 - Bushing
19 - Pin
20 - Bushing
21 - Pressure Spring
❑ Installing, refer to ⇒ page 38 .
22 - Selector Bracket
23 - Bolt
❑ 5 Nm

R32 2004 ➤
24 - Base Plate
❑ Bend the tabs in order to remove.
25 - Selector Cable
❑ To the selector bracket.
❑ Installed position, refer to ⇒ “2.2 Shift Mechanism Installed Position“, page 35 .
26 - Shift Cable
❑ Pressed onto the shift lever guide.
❑ Installed position, refer to ⇒ “2.2 Shift Mechanism Installed Position“, page 35 .
27 - Lock Washer
28 - Nut
❑ 25 Nm
29 - Bushing
❑ Fits in one position only.
30 - Lock Washer
Lock Washer, Removing and Installing

– Push the bushing -arrow B- all the way down in the
-direction of arrow C- and remove or install the lock washer
-arrow A-.
Note
♦ Do not tilt the bushing when pushing it down.

♦ The slot in the lever for the lock washer must be visible.
Volkswa AG. gen AG
agen does
♦ Carefully release the tension on they Vpressure
olks
w
spring. not
gu
b ara
ed nte
oris eo
th
Pressure Spring, Installing au ra
c
ss
ce
e
– Install the pressure spring -B- so that the leg -A- contacts the
nl
pt
du
an
upper part of the pin -arrow-.

itte
y li
erm
ab
– Pull the leg -B- downward so that it reaches the bottom of the
ility
ot p
pin -arrow-.
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
2.5 Shift and Selector Cables

nf
ercia
orm
Note
m
atio
om
n in
c
Lubricate the bearing areas and the sliding surfaces with grease
or
thi
e
-G 000 450 02- .

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

R32 2004 ➤
1 - Shift Cable
❑ Attaches to the cable re‐
tainer -item 17-.
❑ Installed position, refer n AG. Volkswagen AG do
swage es n
to byV
olk ot g
ua
⇒ “2.2 Shift Mechanism ir se
d ran
tee
Installed Position“,upage
tho
or
35 . ss
a ac
ce
e
nl
2 - Selector Cable
pt
du
an
itte
y li
❑ Attaches to the cable re‐
erm
ab
tainer -item 10-.
ility
ot p
❑ Installed position, refer
wit
, is n
h re
to
hole
⇒ “2.2 Shift Mechanism
spec
Installed Position“, page
es, in part or in w
t to the co
35 .
3 - Lock Washer
rrectness of i
❑ Always replace.
l purpos
4 - Lock Washer
❑ Be careful not to dam‐
age the cables when re‐
nf
ercia
o
moving them.
rm
m
atio
m
❑ Always replace.
o
n in
or c
5 - Shift Housing
thi
te
sd
iva
o
6 - Bolt
r
rp
cu
o
m
f
❑ 25 Nm en
ng
t.
yi Co
op
❑ For the support. C py
t. rig
gh ht
yri by
7 - Support cop Vo
by lksw
cted agen
Prote
8 - Grommet
AG.
❑ For the cable support to

the transmission.
9 - Spacer
10 - Cable Retainer
❑ For attaching the selector cable to the relay lever.
Adjust the shift mechanism after installing, refer to one of the following:
⇒ “2.6 Shift Unit Adjusting, through Build Date 18 May 2003“, page 41 .
⇒ “2.7 Shift Unit Adjusting, from Build Date 19 May 2003“, page 43 .
❑ Replace after prying off.
❑ No longer needs to be replaced.
❑ Attached with a lock washer, refer to ⇒ page 61 .
❑ Allocation, refer to ⇒ page 63 .
11 - Relay Lever

R32 2004 ➤
12 - Bushing
13 - Lock Washer
❑ Always replace.
14 - Sliding Shoe
15 - Shift Lever
❑ With a balance weight
❑ Insert so that the master spline aligns with the shift rod.
AG. Volkswagen
⇒ “2.6 Shift Unit Adjusting, through Build Date 18
lksw
agMay
en 2003“, page 41e.s n
AG do
o ot g
yV ua
db
⇒ “2.7 Shift Unit Adjusting, from BuildoriDate
se 19 May 2003“, page 43 . ran
tee
th or
au ac
16 - Self Locking Nut ss
ce
e
nl
❑ 20 Nm
pt
du
an
itte
❑ Always replace.
y li
erm
ab
ility
17 - Cable Retainer
ot p
wit
, is n
❑ For attaching the shift cable to the transmission shift lever.
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
❑ Replace after prying off.
l purpos
❑ No longer needs to be replaced.

❑ Attached with a lock washer, refer to ⇒ page 61 .
nform
ercia
❑ Allocation, refer to ⇒ page 63 .

m
at
om
ion
c
in t
or
his
e
Shift/Relay Lever Installed Position

at
do
priv
1 - Shift lever with balance weight

um
for
en
ng
t.
yi
2 - The relay lever fits into the sliding rail on the shift lever via the
Co
op py
sliding shoe -arrow-.
t. C rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

R32 2004 ➤
2.6 Shift Unit Adjusting, through Build Date

18 May 2003
A locking pin -arrow- holds the shift unit -A- in place.

♦ Connecting Pin -T10027-
AG. Volkswagen AG d
agen oes
Note olksw not
y V gu
d b ara
rise nte
♦ The following pointsauare
tho
essential to guarantee correct shift eo
ra
unit adjustment: ss c
ce
e
nl
♦ Operating and transfer elements of the shift unit must be in
pt
du
an
proper condition.
itte
y li
erm
ab
♦ The shift unit must move freely.
ility
ot p
wit
, is n
♦ The transmission, clutch and clutch mechanism must also be

in proper condition. h re
hole
spec
es, in part or in w
t to the co
• Transmission is in neutral.
– Pull the locking mechanisms on the shift and selector cables
all the way forward in the -direction of arrow 1- and then lock
rrectness of i
them to the left in the -direction of arrow 2-.

l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
Hold the shift unit secure as follows: gh ht
pyri by
Vo
co lksw
by
– Push the shift unit down in the -direction of arrow 1-. Prote
cted AG.
agen
– While doing this, slide the locking pin -A- into the transmission,
in the -direction of the arrow-until it locks.
This will lock the shift unit so that it can no longer be moved.

R32 2004 ➤
– Carefully pry the cover -arrows- out of the center console.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
Hold the shift lever secure as follows:
s au ra
c
s
ce
– Move the shift lever from neutral to the left and into the 1st/2nd
e
nl
pt
du
gear gate.
an
itte
y li
erm
ab
– Install the connecting pin -T10027- through hole -A- and into
ility
ot p
hole -B-.
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
– Turn the locking mechanisms on the shift and selector cables

all the way to the right in the -direction of the arrow-.
nform
ercia
The spring will push the locking mechanisms into the starting po‐
sition.
m
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Pull the locking pin -A- out in the -direction of the arrow-.

R32 2004 ➤
– Pull the connecting pin -T10027- out of holes -A and B-.

– Clip the cover into the center console.
Function
• The shift lever must rest in the 3rd/4th gear lever gate when
the transmission is in neutral.
– Press the clutch.
– Move the shift lever several times through all the gears. Pay
particular attention to the operation of the reverse gear lock.
– Should a gear fail to engage smoothly after repeated selection,
adjust the shift unit again.
2.7 Shift Unit Adjusting, from Build Date

19 May 2003 Volkswa AG. gen AG
agen does
A locking pin -arrow- hold the shift unit -A-Voinlksplace.
w not
gu
by ara
ed nte
oris eo
th
au ra
c
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
Note
l purpos
♦ The following points are essential to guarantee correct shift

unit adjustment: nform
ercia
♦ Operating and transfer elements of the shift unit must be in

m
proper condition.
com
tion in
♦ The shift unit must move freely.

r
te o
thi
s
iva
do
♦ The transmission, clutch and clutch mechanism must also be

r
rp
cum
in proper condition.
fo
en
ng
t.
yi Co
op py
• Transmission is in neutral. t. C rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

R32 2004 ➤
– Pull the locking mechanisms on the shift and selector cables

all the way forward in the -direction of arrow 1- and lock them
to the left in the -direction of arrow 2- .
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
Hold the shift unit secure as follows:
wit
, is n
h re
– Push the shift unit down in the -direction of arrow 1-.
hole
spec
– While pressing down the shift unit, rotate the lock pin -A- up‐
es, in part or in w
t to the co
ward in the -direction of arrow 3- and simultaneously press it
in, in the -direction of arrow 2- until it engages in the shift unit.
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
– Carefully pry the cover -arrows- off the center console.
n in
or c
thi
e
Hold the shift lever secure as follows:

t
sd
iva
o
r
rp
cu
– Move the shift lever into neutral.
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

R32 2004 ➤
– Install the connecting pin -T10027- through hole -A- and into
hole -B-.
– Turn the locking mechanisms on the shift and selector cables

all the way to the right in the -direction of arrow 1-.
The springs will push the locking mechanisms into the starting
position in the -direction of arrow 2-.
AG. Volkswagen AG d
agen oes
olksw not
V
– Turn the locking pin -A- back into the starting
ed by position gu
ara
-arrow 2-. horis nte
eo
aut ra
The locking pin -A- must get pushed out
s of the transmission in the
s c
ce
le
-direction of arrow 1-.

un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
It must be possible, now to move the shift unit in the

-direction of the arrow-.
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

R32 2004 ➤
– Pull the connecting pin -T10027- out of holes -A and B-.

– Clip the cover into the center console.
Function
• The shift lever must rest in the 3rd/4th gear lever gate when
the transmission is in neutral.
– Press the clutch.
– Move the shift lever several times through all the gears. Pay
particular attention to the operation of the reverse gear lock.
– Should a gear fail to engage smoothly after repeated selection,
adjust the shift unit again.
2.8 Transmission Gear Overview
1 - Clutch Housing
2 - Reverse Shaft
3 - Output Shaft, 5th, 6th and
Reverse Gears
4 - Clutch Slave Cylinder with
Release Bearing
5 - Input Shaft
6 - Output Shaft, 1st to 4th
Gears
7 - Differential
8 - Bevel Box
9 - Right Flange Shaft
10 - Head Bevel Gear with In‐
put Shaft n AG. Volkswagen AG do
swage es n
11 - Shaft Bevel Gear byV
olk ot g
ua
d ran
ir se
12 - Output Flange tho tee
or
au ac
13 - Speedometer Vehicle ss ce
e
Speed Sensor
nl
pt
du
an
itte
y li
14 - Left Flange Shaft
erm
ab
ility
ot p
15 - 2nd Gear
wit
, is n
h re
16 - 1st Gear
hole
spec
17 - 4th Gear
es, in part or in w
t to the co
18 - 3rd Gear
19 - 5th Gear
rrectness of i
20 - 6th Gear
l purpos
21 - Reverse Gear
22 - Transmission Housing
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
46
cted agen
Prote AG.
Rep. Gr.34 - Controls, Housing
R32 2004 ➤
2.9 Transmission Housing and Shift Mechanism, through Build Date 18 May
2003
1 - Bolt
❑ 25 Nm
2 - Flange Shaft with Pressure
Spring
ling, refer to
⇒ “4.1.2 Right Flange
Shaft Seal, Bevel Box
Installed “, page 217 .
❑ Assembling, refer to
⇒ “5.3.2 Differential“, AG. Volkswagen AG d
agen oes
ksw
page 269 . by
Vol not
gu
a d ran
se
3 - Backup Lamp Switch
ho
ri tee
aut or
ac
❑ 20 Nm ss
ce
le
un
4 - Seal
pt
an
d
itte
y li
❑ Always replace.
rm
ab
pe
ility
5 - Oil Drain Plug
ot
wit
, is n
❑ There are different ver‐
h re
hole
sions
spec
es, in part or in w
♦ With a internal multi-point -
t to the co
45 Nm.
♦ With a internal hex - 30 Nm.
rrectness of i
6 - Seal
l purpos
❑ Always replace.
7 - Cap
nform
ercia
8 - Bolt
m
a
com
tio
❑ 20 Nm
n in
r
te o
thi
❑ Always replace.
s
iva
do
r
9 - Bolt
rp
cum
fo
en
g
❑ 20 Nm
n
t.
yi Co
op
❑ For the shift unit -item 14- to the cap.
C py
t. rig
gh ht
yri
❑ Always replace.
p by
o Vo
by c lksw
cted agen
10 - O-ring
Prote AG.
❑ Always replace.
❑ Install into the groove on the cover.
11 - Bolt
❑ 15 Nm
❑ For the slot in the shift unit shaft.
❑ Always replace.
❑ Install using liquid locking fluid -D 000 600 A2- .
12 - Bolt
❑ 25 Nm + an additional 45° (1/8) turn.
❑ With an attached washer.
❑ Always replace.
13 - Bolt

R32 2004 ➤
❑ Without a washer.
❑ Always replace.
14 - Shift Unit
❑ Disassembly and assembly, refer to
⇒ “6.7 Shift Unit, Transmission Side Through Build Date 18 May 2003“, page 114 .
15 - Bolt
❑ 20 Nm
❑ Always replace.
16 - Shift Unit Cover
❑ Disassembly and assembly, refer to lkswage es n
⇒ “6.7 Shift Unit, Transmission Side Through Build
d by VDate 18 May 2003“, page 114 .t gua
o o
e ran
ris tee
17 - Clutch Housing ut
ho or
a ac
❑ Disassembly and assembly, refer to ss
ce
le
⇒ “6.5 Clutch Housing, Through Build Date 18 May 2003“, page 107 .
un
pt
an
d
itte
y li
erm
ab
ility
ot p
⇒ “6.3 Transmission Housing, Through Build Date 18 May 2003“, page 96 .
wit
is n
h re
ole,
spec
2.10 Transmission Housing and Shift Mechanism, from Build Date 19 May 2003
t to the co
rrectne
1 - Bolt
❑ 25 Nm
ss
2 - Flange Shaft with Pressure
o
cial p
f
Spring
inform
mer
atio
ling, refer to
om
n
c
i
or
n
thi
te
sd
a

iv
o
pr
cum
r
❑ Assembling, refer to
fo
en
ng
⇒ “5.1.1 Differential“,
t.
yi Co
op
page 242 . C py
t. rig
gh ht
yri by
3 - Cover cop Vo
by lksw
cted agen
Prote
4 - Locking Ring
AG.
5 - Backup Lamp Switch

❑ 20 Nm
6 - Seal
❑ Always replace.
7 - Oil Drain Plug
sions
45 Nm.
8 - Seal
❑ Always replace.
9 - Locking Screw
❑ 45 Nm
❑ For the shift unit.

R32 2004 ➤
❑ Always replace the lock‐
ing screw. n AG. Volkswagen AG do
lkswage es n
Vo ot g
❑ Made of either d metal or plastic.
by ua
ran
ir se tee
❑ Metal locking
utho screw - 45 Nm. or
a ac
❑ Plastic locking screw - 30 Nm.
ss
ce
e
nl
pt
10 - Bolt
du
an
itte
y li
❑ There are different bolts and tightening specifications.
erm
ab
ility
ot p
❑ Internal hex round head = aluminum bolt: 8 Nm + an additional 180° (1/8) turn.
wit
, is n
❑ Outer hex head = steel bolt: 15 Nm + an additional 90° (1/4) turn.
h re
hole
❑ Always replace, for the correct allocation refer to the Parts Catalog.
spec
es, in part or in w
❑ Steel bolts as a replacement part, refer to ⇒ page 50 .
t to the co
11 - Bolt
❑ There are different bolts and tightening specifications.
rrectness of i
❑ Internal hex round head = aluminum bolt: 8 Nm + an additional 180° (1/2) turn.
l purpos
❑ Outer hex head = steel bolt: 15 Nm + an additional 90° (1/4) turn.

❑ Always replace, for the correct allocation refer to the Parts Catalog.
nf
ercia
o
❑ Steel bolts as a replacement part, refer to ⇒ page 50 .
rm
m
atio
m
12 - Shift Unit
o
n in
or c
thi
te
sd
a
⇒ “6.8 Shift Unit, Transmission Side, From Build Date 19 May 2003“, page 116 .
iv
o
r
rp
❑ Removing with the transmission installed: cu

o
m
f
en
ng
t.
yi Co
♦ Remove the battery and the battery tray. t. Cop py
rig
gh ht
♦ Remove the cables and transmission shift lever yri
p by
co Vo
by lksw
cted
♦ Remove the locking screw -item 9-, remove the shift unit from transmission.
agen
Prote AG.
13 - Bolt
❑ 20 Nm
❑ Always replace.
14 - O-ring
❑ Always replace.
15 - Clutch Housing
❑ Disassembly and assembly, refer to ⇒ “6.6 Clutch Housing, From Build Date 19 May 2003“, page 110 .
⇒ “6.4 Transmission Housing, From Build Date 19 May 2003“, page 100 .

R32 2004 ➤
If the steel bolts (outer hex head) are the replacement part, pay
attention to the allocation:
A - Bolt with a permanent washer
B - Bolt without a washer
C - Bolt with a permanent washer
2.11 Input Shaft, Output Shafts, Differential, Bevel Box and Selector Rods
1 - Output Shaft, 1st to 4th

Gears
❑ Disassembly and as‐
sembly, refer to
⇒ “2.3 Output Shaft, 1st
to 4th Gears“, n AG. Volkswagen AG do
page 147 . olkswage es n
ot g
yV
❑ Installed position, refer ir se
d b ua
ran
to ⇒ page 53 . tho tee
or
au ac
2 - Selector Shaft with Selector ss
ce
e
Fork, 1st and 2nd Gear

nl
pt
du
an
itte

y li
erm
ab
sembly, refer to
ility
ot p
⇒ “6.9 Selector Forks

wit
, is n
Through Build Date,

h re
18 May 2003“,
hole
spec
page 118 .
es, in part or in w
t to the co
❑ Installed position,
through build date
18 May 2003, refer to
⇒ page 53 .
rrectness of i

l purpos
sembly, refer to
From Build Date,
nf
ercia
19 May 2003“,
rm
m
atio
page 120 .
om
n in
c
❑ Installed position, from

or
thi
build date 19 May 2003,

te
sd
a
refer to ⇒ page 53 .
iv
o
r
rp
cu
o
m
f
3 - Selector Shaft with Selector

en
ng
t.
yi
Fork, 3rd and 4th Gear
Co
Cop py
t. rig
❑ Disassembly and as‐ gh ht
yri by
sembly, refer to cop Vo
by lksw
cted agen
Prote AG.
Through Build Date,
18 May 2003“,
page 118 .
❑ Installed position, through build date 18 May 2003, refer to ⇒ page 53 .

R32 2004 ➤
⇒ “6.10 Selector Forks From Build Date, 19 May 2003“, page 120 .
❑ Installed position, from build date 19 May 2003, refer to ⇒ page 53 .
4 - Output Shaft, 5th, 6th and Reverse Gears
❑ Disassembly and assembly, refer to ⇒ “2.4 Output Shaft, 5th, 6th and Reverse Gears“, page 157 .
5 - Selector Shaft with Selector Fork, 5th and 6th Gear
⇒ “6.9 Selector Forks Through Build Date, 18 May 2003“, page 118 .
6 - Selector Fork, Reverse Gear
⇒ “6.9 Selector Forks Through Build Date, 18 May 2003“, page 118 .
7 - Input Shaft
❑ Disassembly and assembly, refer to one of the following:
⇒ “2.1 Input Shaft, Through Build Date 18 May 2003“, page 138
⇒ “2.2 Input Shaft, From Build Date 19 May 2003“, page 143
8 - Reverse Gear Shaft AG. Volkswagen AG d

agen oes
ksw
❑ With the thrust washer. by
Vol not
gu
ara
ed
is nte
9 - Thrust Washer hor eo
aut ra
c
10 - Breather Assembly ss
ce
le
un
❑ Attached to the clutch slave cylinder -item 16-. pt

an
d
itte
y li
11 - Bolt
erm
ab
ility
ot p
❑ 12 Nm wit
is n
❑ Self-locking.
h re
ole,
spec
❑ Always replace.
❑ Installed from build date 06 April 2000.

t to the co
12 - Securing Plate
❑ Secures the outer race/tapered roller bearing for the input shaft.
rrectne
❑ Installed from build date 06 April 2000.

ss
13 - Clutch Housing
o
cial p
f i
❑ From build date 06 April 2000, with an additional hole for the bolt -item 11- and a notch for the securing
nform
plate -item 12-.

mer
atio
m
❑ Disassembly and assembly, refer to one of the following:

o
n
c
i
or
⇒ “6.5 Clutch Housing, Through Build Date 18 May 2003“, page 107 .
thi
te
sd
iva
o
pr
⇒ “6.6 Clutch Housing, From Build Date 19 May 2003“, page 110 .
um
r
fo
en
ng
t.
yi
Co
Cop py
t. rig
gh
Seal can only be removed using the sleeve -30-21- when the transmission is disassembled.
ht
pyri by
Vo
o
by c lksw
cted
❑ Removing and installing, see -item 2- in the
agen
Prote AG.
⇒ “4.6 Clutch Slave Cylinder with Release Bearing“, page 24 .

R32 2004 ➤
15 - O-ring
❑ Lubricate with brake fluid before installing.
16 - Clutch Slave Cylinder with Release Bearing
17 - Bolt
❑ 12 Nm
❑ Quantity: 3
❑ Always replace.
18 - Bolt
❑ 25 Nm
❑ The length of the bolt is matched to the bevel box.
❑ Check the part number of the bevel box.
❑ When replacing the bevel box, allocate the bolt according to the Parts Catalog.
19 - O-ring
❑ Always replace.
20 - Bevel Box
❑ Removing and installing, refer to one of the following:
With the transmission installed. Refer to ⇒ “5.9 Bevel Box“, page 78 .
With the transmission removed. Refer to en AG. Volkswagen AG
⇒ “6.1 Transmission, Through Build oDate
lksw 18 May 2003“, page e82
ag do s .
no
V t gu
by a
❑ Disassembly and assembly, rrefer
ise
d
to ⇒ “5.1.2 Bevel Box“, page 248 . rante
ho eo
ut
21 - Bolt ss
a ra
c
ce
le
un
pt
an
d
❑ Always replace.
itte
y li
erm
ab
22 - Washer
ility
ot p
wit
is n
23 - O-ring
h re
ole,
❑ Always replace.
spec
24 - O-ring
t to the co
❑ Always replace.
25 - Bolt
rrectne
❑ 12 Nm
s
❑ Always replace
s o
cial p
f i
26 - Speedometer Vehicle Speed Sensor

nform
mer
atio
Note
om
n
c
i
or
n thi
te
sd
27 - O-ring
iva
o
pr
❑ Always replace.
um
r
fo
en
ng
t.
yi
28 - Differential
Co
Cop py
t. rig
❑ Disassembly and assembly, refer to ⇒ “5.1.1 Differential“, page 242 .
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

R32 2004 ➤
Installed Position: Input and Output Shaft in Transmission,

through Build Date 18 May 2003
1 - Output shaft for 5th, 6th and reverse gear
2 - Input shaft
3 - Output shaft for 1st through o4th
lksw gears
age es n
ot g
yV ua
4 - Differential db ran
ir se tee
ho
aut or
ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
Installed Position, Shift Unit in Transmission, through Build Date
wit
, is n
18 May 2003
h re
hole
spec
1 - Selector fork for 3rd and 4th gears
es, in part or in w
t to the co
2 - Selector fork for 1st and 2nd gears
3 - Selector fork for reverse gear
rrectness of i
4 - Selector fork for 5th and 6th gears
l purpos
5 - Gear shift shaft

The lower shift unit bearing -arrow- is attached to the transmission
nform
ercia
housing with the cover.

m
at
om
ion
Installed Position: Selector Shafts and Forks in Transmission,
c
in t
or
from Build Date 19 May 2003

his
ate
do
riv
1 - Input shaft
p
cum
for
en
ng
2 - Output shaft, 1st to 4th gears

t.
yi Co
Cop py
. rig
3 - Output shaft 5th, 6th and reverse gear
t
gh ht
pyri by
Vo
co
4 - Reverse shaft
by lksw
cted agen
Prote AG.
A - Selector shaft for 3rd/4th gear
B - Selector shaft for 1st/2nd gear
C - Selector shaft or 5th/6th gear
D - Reverse gear selector fork

R32 2004 ➤
3 Specifications
3.1 Fastener Tightening Specifications

Component Fastener Size Nm
Backup Lamp Switch to Transmission Housing - 20
Bevel Box to Transmission Bolt 1 40 + 45°
Cap to Shift Unit Bolt 1, 2 - 20
Cap to Transmission Housing Bolt 1, 2 - 20
Cover to Shift Housing Bolt - 5
Clutch Slave Cylinder with Release Bearing to Clutch Housing Bolt - 12
1
Drive Axle Heat Shield to Bevel Box Bolt - 25

Flange Shaft Bolt - 25
Hydraulic Line to Transmission - 25
Locking Screw to Transmission Housing 3 - 45
Oil Drain/Fill Plug to Transmission Housing
– With a internal hex - 30
– With a internal multipoint - 45
Retaining Bracket to Body Nut - 25
Retaining Bracket to Shift Housing Bolt - 25
Securing Plate to Clutch Housing Bolt 1 - 12
AG. Volkswagen AG d
agen
Selector Bracket to Pin Bolt olksw
oes
not - 5
byV gu
ara
Shift Housing to Body Nut ris
ed
nt-e 25
ho e
1 ut - or ac 20
Shift Lever to Shift Unit Nut s a
s
Shift Unit Cover to Transmission Housing Bolt 1, 2 - 20
ce
le
un
pt
an
d
itte
Shift Unit to Transmission Housing Bolt 1, 3 - 20

y li
erm
ab
1 - 12
ility
Speedometer Vehicle Speed Sensor to Clutch Housing Bolt

ot p
wit
is n
Support to Transmission Bolt - 25

h re
ole,
1,2 - 25 + 45°
spec
Transmission Housing to Clutch Housing Bolt

Transmission Housing to Clutch Housing Bolt 1,3

t to the co
– Internal hex round head, aluminum bolt - 8 + 180°

– Outer hex head, steel bolt - 15 + 90°
rrectne
Transmission Housing to Shift Unit Bolt 1, 2, 4 - 15

ss o
• 1 Always replace
cial p
f inform
• 2
mer
Through build date 18 May 2003

atio
m
• 3
o
From build date 19 May 2003

n
c
i
or
n thi
e
• 4 Install using locking fluid -D 000 600 A2-

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

R32 2004 ➤
Transmission to Engine Bolts

Item Bolt Quantity Nm
1 M12 x 55 2 80
2 M12 x 80 1 80
31 M10 x 50 3 45
41 M12 x 55 1 80
5 M12 x 65AG. Volkswagen A1 80
G do agen
es n
ksw
• 1 From 08 January y 2001: Install the Vol
bolts
o
witht gpermanent
ua
b
ed ran
washers. or Refer to the Parts Catalog.
is tee
th or
u
– Replace
ss
a
the bolts. ac
ce
e
nl
-A and B- : Alignment sleeves
pt
du
an
itte
y li
erm
ab
Transmission Mount Bracket to Transmission Bolt
ility
ot p
wit
, is n
– Tighten the new bolts -arrows- to 50 Nm + an additional 90°
h re
(1/4) turn.
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
Transmission Mount to Transmission Mount Bracket Bolt

ion
c
in t
or
– Tighten the new bolts -arrows- to 100 Nm

his
ate
do
riv
Bevel Box and Transmission Bracket Bolt

p
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
The following assembly sequence must be followed when instal‐

ling the bracket:
– Install all the bolts hand tight.
– Tighten the bolts -B- (M10 x 22) first to 10 Nm.
– Tighten the bolts -A- (M10 x 50) to 50 Nm.
– Tighten the bolts -B- to 40 Nm.
R32 2004 ➤ n AG. Volkswagen AG do
wage es n
Manual Transmission - Edition 01.2012 yV
olks ot g
d b ua
ran
ir se tee
tho
or
4 Diagnosis and Testing au ac
ss
ce
e
nl
pt
⇒ “4.1 Vehicle Diagnostic Tester, Connecting and Selecting Func‐
du
an
itte
tions“, page 56
y li
erm
ab
ility
4.1 Vehicle Diagnostic Tester, Connecting
ot p
wit
, is n
and Selecting Functions
h re
hole
spec
es, in part or in w
t to the co
♦ Vehicle Diagnosis, Testing and Information System -VAS
5051-
rrectness of i
♦ Diagnostic Cable, 3 m with Power Supply -VAS 5051/1- or
l purpos
♦ Diagnostic Cable, 5 m without Power Supply -VAS 5051/3-
nform
ercia
WARNING
m
at
om
i
♦ During a test drive you must always secure testing and
on
c
in t
measuring equipment on the back seat.
or
his
ate
do
riv
♦ Only the passenger may use the equipment during the

p
c
road test.
um
for
en
ng
t.
yi Co
Cop py
t. rig
gh
– Remove the cover -1- over the diagnostic connection.
ht
pyri by
Vo
co lksw
by
– Turn off the ignition and connect the vehicle diagnostic tester cted agen
Prote AG.
using the diagnostic cable -VAS 5051/1- or -VAS 5051/3- to
the diagnostic connection.

R32 2004 ➤
– Turn on the tester -arrow-.

The tester is ready to be used when it displays a picture of a ve‐
hicle.
– Turn on the ignition.
– Touch the field/button: Guided Fault Finding on the screen.
– Select the following in this sequence:
♦ Brand
♦ Type
♦ Model year
♦ Version
♦ Engine code
– Confirm the information entered.
Wait for the tester to check all the control modules in the vehicle.
– Press the Go to button Aand
G. Voselect “function/component
lkswagen AG do se‐
agen
lection“. Volksw es n
ot
y gu
db a
Follow the displays
or
ise on the screen to start the desiredranfunctions.
te
th eo
s au ra
c
s
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
4. Diagnosis and Testing 57

R32 2004 ➤
Manual Transmission - Edition 01.2012 AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
d
5 Removal and Installation ise nte
or eo
h
aut ra
s c
⇒ “5.1 All Wheel Drive Control Module J492“, page 58 s
ce
e
nl
pt
du
⇒ “5.2 Haldex Clutch Pump“, page 59
an
itte
y li
erm
ab
⇒ “5.3 Boot, Removing from Shift Lever, Installing with Shift
ility
ot p
Knob“, page 60
wit
, is n
h re
⇒ “5.4 Shift Mechanism“, page 60
hole
spec
⇒ “5.5 Transmission, Removing“, page 63
es, in part or in w
t to the co
⇒ “5.6 Transmission Transporting“, page 70
⇒ “5.7 Transmission, Securing to the Transmission Support“,
rrectness of i
page 71
l purpos
⇒ “5.8 Transmission, Installing“, page 71

⇒ “5.9 Bevel Box“, page 78
nf
ercia
or
5.1 All Wheel Drive Control Module J492
m
m
atio
om
n in
♦ The all wheel drive control module is diagnostic capable. This
or c
thi
new generation control module with changed software can
te
sd
a
only be recognized by the control module part number. In case

iv
o
r
rp
cu
of complaints, perform “Guided Fault Finding“ using the vehi‐
o
m
f
en
ng
cle diagnostic tester. yi

t.
Co
op py
. C rig
ht ht
rig by
py Vo
co lksw
by
cted agen
Prote AG.
Removing
– Turn off the ignition.
– Disconnect the connector from the rear final drive and remove
the connector from the bracket.
– Disconnect the connector -arrow 1- for the Haldex clutch

pump.
– Place a drip tray under the final drive.
– Remove the bolts -arrows 2-.
– Remove the control module.
Installing
Install in reverse order of removal.

R32 2004 ➤
Manual n AG. Volkswagen-AEdition
geTransmission es n 01.2012
a G do
ksw
ol ot g
yV ua
db ran
– Replace the O-rings -A and B-, if equipped. ris
e
tee
tho or
au
If a seal (see -item 13- in the ss
ac
⇒ “2.3 Haldex Clutch and Clutch Disc Cover Overview“,
ce
e
nl
pt
page 177 ) is installed, replace it.
du
an
itte
y li
erm
– Install the bolts and tighten them to specification, see
ab
ility
-item 15- in the
ot p
wit
⇒ “2.3 Haldex Clutch and Clutch Disc Cover Overview“, page
, is n
h re
177 .
hole
spec
– Check the oil level in the Haldex clutch. Refer to
es, in part or in w
t to the co
⇒ “1.2 Haldex Clutch Oil Level, Checking and Filling“,
page 169 .
rrectness of i
5.2 Haldex Clutch Pump
l purpos
nf
ercia
orm
m
atio
♦ Slide Hammer-Complete Set -VW 771-
om
n in
or c
Removing
thi
te
sd
iva
– Turn off the ignition.
o
r
rp
cu
o
m
f
– Remove the rear driveshaft flexible disc bolts -arrows- from
en
ng
t.
yi Co
the rear final drive and push it toward the front carefully. Refer Cop py
to ⇒ “4.2.1 Driveshaft“, page 222 . ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– Disconnect the connector -arrow 1- from the Haldex clutch

pump.
– Place a drip tray under the final drive.
– Remove the bolts -arrows 2-.
– Rotate the pump slightly toward right.
– Remove the pump in the -direction of the arrow-

.
Installing

R32 2004 ➤
– Replace the seal -A-.

– Replace the O-rings -B and C-.
– Note the different diameter:
♦ Diameter of O-ring -B- = 31.5 mm
♦ Diameter of O-ring -C- = 33 mm
– Install the pump all the way in.
– Tighten the bolts.
– Check the oil level in the Haldex clutch. Refer to
page 169 .
5.3 Boot, Removing from Shift Lever, Instal‐

ling with Shift Knob
– Turn the boot inside out.
– Push the clamping sleeve with a screwdriver -arrows- and re‐
move the knob.
– Install the shift knob into the cover.
– Install the clamping sleeve onto the shift knob and lock it.
– Install the shift knob and the cover together.
5.4 Shift Mechanism

Removing
♦ Torque Wrench (5-50 Nm) -V.A.G 1331- lkswage es n
o ot g
byV ua
d
♦ Grease -G 000 450 02- o
ir se
ran
tee
th or
u
Shift Mechanism through December 2000
ss
a ac
ce
le
– The cable retainers -A and B- may be pried off using a 13 mm

un
pt
an
d
open end wrench -1- only if the shift cable, the selector cable
itte
y li
or the cable retainer must be removed.

rm
ab
pe
ility
ot
If the components mentioned above are not being removed:

wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Pull the locking mechanisms for the shift and selector cables
all the way forward in the -direction of arrow 1- and then lock
them to the left in the -direction of arrow 2-.
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

R32 2004 ➤
Shift Mechanism from January 2001

– Remove the shift cable lock washer -4- from the transmission
shift lever -1-.
– Remove the selector cable lock washer -3- from the relay lever
-2-.
– Remove the selector and shift cables from the pins -arrows-.
Continuation for All AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
– Remove the support bolts -arrows- from the transmission, if

un
pt
necessary, unclip the hose from the support.
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
– Carefully pry the cover -arrows- off the center console.

inform
mer
– Remove the cover toward the rear.

atio
m
– Remove the noise insulation.

o
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
– Break the clamp -arrow- and remove the shift knob and cover.

R32 2004 ➤
AG. Volkswagen AG d
– Remove the nuts on the front of the shift housing -arrows-.
lksw
agen oes
not
o
yV gu
db ara
ir se nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
– Remove the bolts from the rear of the shift housing -arrows-.
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
– Remove the cross member bolts -arrows- and cross member
t. rig
gh ht
yri by
-1- over the exhaust system. cop Vo
by lksw
cted agen
Prote
– Separate the exhaust system at the double clamp -2- and then
AG.
remove it along with the catalytic converter (a 2nd technician

is needed). Refer to ⇒ Engine Mechanical, Fuel Injection and
Ignition; Rep. Gr. 26 ; Description and Operation .
– Remove the center and front heat shields.
– Remove the driveshaft. Refer to
⇒ “4.2.1 Driveshaft“, page 222 .
– Pivot the shift housing downward and remove it with the ca‐
bles.
Installing
Shift Mechanism through December 2000
Replace any cable retainers that were removed.
– Lubricate the new cable retainers -A and B- with a small

amount of grease -G 000 450 02- before installing.
Note
The seals -arrows- on the outside of the ball socket must not have
any grease on them.

R32 2004 ➤
– Press the shift cable onto the transmission shift lever and the
selector cable onto the relay lever -arrows-
If the cable retainers were not removed
wage es n
– Attach the shift cable (selector cable) to the cable retainers.
yV
olks ot g
ua
b
ed ran
Shift Mechanism from January 2001 horis tee
t or
au ac
The cable retainers have holes that go all thess way through for
attaching to the shift and/or relay levers.
ce
e
nl
pt
du
an
itte
These holes have different diameters.
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
Allocation of Cable Retainers
spec
es, in part or in w
Cable retainer for: Dimension “a“
t to the co
Shift cable to transmission shift lever 10 mm
Selector cable to relay lever 8 mm
rrectness of i
l purpos
The cable retainers no longer need to be replaced after removal.
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
– Apply a small amount of grease -G 000 450 02- on the trans‐
o
r
rp
cu
mission shift lever -1- pin -arrow- and on the relay lever -2- pin
o
m
f
en
ng
-arrow-.
t.
yi Co
Cop py
– Replace the lock washers -3 and 4- each time they are re‐
t. rig
gh ht
yri
moved.
p by
o Vo
by c lksw
cted agen
Prote AG.
– Align the shift housing so that it is parallel to the body.

• The distance on both sides to the body must be equal.
Install the cross member.
Adjust the shift unit. Refer to one of the following:
page 41 .
⇒ “2.7 Shift Unit Adjusting, from Build Date 19 May 2003“,
page 43 .
Tightening Specifications
Shift housing to body nut, see -item 28- in the
⇒ “2.4 Shift Lever and Housing“, page 37 .
Support to transmission bolts, see -item 6- in the
⇒ “2.5 Shift and Selector Cables“, page 38 .
5.5 Transmission, Removing

♦ Engine Support Bridge -10-222 A-
♦ Bracket for Engine - 10-222 A/1-
♦ Additional Hooks (2) -10-222 A/2-
♦ Engine Support Adapter -10-222 A/3-
♦ Hose Clamps Up to 25 mm Dia. -3094-

R32 2004 ➤
♦ Transmission Support -3282-

♦ Adjusting Plate -3282/27-
♦ Transmission Support Jig -3336-
♦ Engine/Gearbox Jack -V.A.G 1383A-
♦ Universal Support -V.A.G 1359/2 -
♦ Step Ladder -VAS 5085-
♦ Adapter -3282/48-
♦ Adjustment Plates -3282/52-
♦ Spring Type Clip Pliers -VAS 5024-
– First, check whether a coded radio is installed. If so, obtain the
anti-theft code.
– Remove the cover from the engine.
– Remove the battery and the battery tray. Refer to ⇒ Electrical
Equipment; Rep. Gr. 27 ; Removal and Installation
– Remove the connecting hose -1- for the crankcase ventilation
(if equipped) from the cylinder head cover.
– Remove the Evaporative Emission (EVAP) canister hose -2-.
– Remove the coolant line bracket from the plenum chamber
-arrows-.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
– Disconnect the connecting pipe -1-, the connector -2- and the
nl
pt
du
an
hose -3- from the Mass Airflow (MAF) sensor.

itte
y li
erm
ab
– Remove the bolts -4 and 5- and then remove the air filter
ility
ot p
housing.
wit
, is n
h re
– Remove the connecting pipe -1-. Refer to ⇒ Engine Mechan‐

hole
spec
ical, Fuel Injection and Ignition; Rep. Gr. 24 ; Description and

es, in part or in w
Operation .
t to the co
rrectness of i
l purpos
– Pull the locking mechanism on the shift and selector cables all
nf
ercia
the way forward in the -direction of arrow 1- and then lock them
orm
to the left in the -direction of arrow 2-.

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

R32 2004 ➤
– Remove the support bolts -arrows- from the transmission.

– Tie up the shift and selector cables.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
– Remove the power steering line clamp nut -arrow 1-. hole
spec
– Remove the lock washer -arrow 2- from the relay lever -A- and
es, in part or in w
then remove the relay lever.
t to the co
– Remove the nut -arrow 3- and remove the transmission shift
lever -B-.
rrectness of i
Use the extension jaws f/Kukko 20-10 (250 mm) -20-10- if nec‐
l purpos
essary.
nf
ercia
orm
m
atio
om
n in
or c
thi
e
– Remove the nut -arrow- and remove the ground cable from the
t
sd
iva
upper engine to transmission bolt.
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
– Disconnect the wire -arrow 1- from the starter.

– Disconnect the connector from the backup lamps -arrow 2-.
– Remove the cable bracket -A- from the starter -arrow 3-.
– Remove the upper bolt for the starter.

R32 2004 ➤
– Clamp off the hose to the clutch slave cylinder using a hose
clamp up to 25 mm dia. -3094- .
– Remove the clamp -arrow- and the hose/line assembly in the
-direction of arrow-.
Note
Do not press the clutch pedal.
– Remove the upper engine to transmission bolts.

– Disconnect any hoses and cables in the area of the lifting eyes
on the engine.
– Install the engine support bridge -10-222 A- with the bracket

for engine -10-222 A/1- , the additional hooks -10-222 A/2- and
the engine support adapter -10-222 A/3- .
– Pretension the engine and transmission subassembly slightly
using the spindles.
– Remove the right wheel.
AG. Volkswagen AG d
– Turn the steering wheel to the left. agen oes
olksw not
y V gu
b ara
– Lift the vehicle. rise
d
nte
tho eo
u
– Remove the noise insulation. ss a ra
c
ce
e
– Remove the radiator and fans. Refer to ⇒ Engine Mechanical,

nl
pt
du
an
Fuel Injection and Ignition; Rep. Gr. 19 ; Removal and Instal‐
itte
y li
lation .
erm
ab
ility
ot p
wit
, is n
– Remove the left noise insulation fasteners -arrows- and noise
h re
insulation.
hole
spec
es, in part or in w
– Remove the right noise insulation.
t to the co
– Remove the right drive axle heat shield.
– Remove the drive axles from the flange shafts and tie them up
rrectness of i
as high as possible. Be careful not to damage the surface pro‐
tection.
l purpos
– Separate the exhaust system, remove the dual catalytic con‐

verter and remove the front exhaust pipe from the exhaust
nform
ercia
manifold. Refer to ⇒ Engine Mechanical, Fuel Injection and

m
at
om
ion
c
in t
– Remove the power steering line from the starter and from the
or
his
e
transmission.
at
do
priv
cum
– Remove the starter. Refer to ⇒ Electrical Equipment; Rep. Gr.

for
en
g

n
t.
yi Co
Cop py
t. rig
gh
– Remove the bevel box transmission support bolts -arrows-
ht
pyri by
Vo
o
from the engine and the bevel box.
c by lksw
cted agen
Prote AG.

R32 2004 ➤
– Remove the bolt -arrow- above the bevel box.

– Remove the rear engine to transmission bolt.
– Remove the pendulum support bolts -arrows A and B-.

– Mark the position of driveshaft flexible disc to the bevel box
flange.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
– Remove the driveshaft flexible disc bolts -arrows- from the
hole
spec
bevel box flange.
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
– Position the engine-/gearbox jack -V.A.G 1383A- with the uni‐

do
priv
c
versal support -V.A.G 1359/2 - under the transmission and
um
for
en
then lift the transmission until it is parallel with the transmission

ng
t.
yi Co
mount. t. Cop py
rig
gh ht
– Remove the power steering fluid reservoir from the engine pyri by
Vo
co
mount but do not loosen the hoses.
by lksw
cted agen
Prote AG.

R32 2004 ➤
– Remove the engine mount to engine mount bracket bolts

-arrows- from the top.
. Volkswagen AG
gen AG does
swa
Note yV
olk not
gu
d b ara
ise nte
r
Use a step ladderaut -VAS 5085- to loosen the bolts.
ho eo
ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
– Remove the transmission mount -2- to transmission mount
spec
bracket -1- bolts -arrows-.
t to the co
Note
rrectne
Use a step ladder -VAS 5085- to loosen the bolts.
ss o
cial p
f
– Remove the engnine-/gearbox jack -V.A.G 1383A- and uni‐
inform
versal support -V.A.G 1359/2 - from under the transmission.
mer
atio
om
n
c
i
or
n thi
te
sd
iva
– Push the engine and transmission carefully forward so that the

pr
cum
r
fo
pin on the driveshaft flange is free.

en
ng
t.
yi Co
op
– Carefully move the transmission into an angled position. Ro‐ C py
ht. rig
tate the spindle on the engine support bridge -10-222 A- down rig ht
py by
approximately 60 mm. co Vo
by lksw
cted agen
Prote AG.
– Remove the transmission mount bracket -1- bolts -arrows-

from the transmission.

R32 2004 ➤
– Lower the engine and transmission approximately 25 cm -a-

by turning the left and right spindles -arrows- on the engine
support bridge -10-222 A- .
– Measure dimension -a- between the bottom of the transmis‐
sion mount -1- and the bolting surface of the transmission
mount bracket on the transmission -2-.
– Be careful of the wiring harness when lowering the engine and
transmission.
AG. Volkswagen AG d
– Remove the lower engine to transmission bolts. agen oes
olksw not
V gu
d by ara
To remove the transmission, the adjustment plate oris -3282/27- must
e nte
be installed on the transmission support -3282-
aut .
h eo
ra
ss c
– Align the arms on the transmission support so that they match
ce
e
nl
pt
up with the holes in the adjustment plate. du
an
itte
y li
erm
ab
– Install the support elements -A- as illustrated on the adjust‐
ility
ot p
ment plate.
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
– Move the engine-/gearbox jack -V.A.G 1383A- under the ve‐
ion
c
hicle. The arrow symbol -B- on the adjustment plate must point
in t
or
his
e
in the direction of travel.

at
do
priv
c
– Align the adjustment plate so that it is parallel to the transmis‐
um
for
sion.
en
ng
t.
yi Co
op py
– Secure the transmission to the transmission support -3282- t. C rig
gh ht
using a bolt -A-. yri
p by
o Vo
by c lksw
cted agen
Prote AG.
– Remove the bracket bolts -arrows- for the secondary air pump
-1- from the engine.
– Remove the engine to transmission bolt -arrow A-.
– Be careful of the lower intermediate plate on the engine.
– Remove the transmission from the alignment sleeves.

R32 2004 ➤
– Turn the spindles on the transmission support -3282- and ro‐

tate the transmission -1- upward near the bevel box -3-.
– Guide the transmission carefully away from the flywheel (start‐
er ring gear) and push it toward the subframe.
– Turn the spindles on the transmission support -3282- to the
left and lower the transmission so that it is at an angle.
– Guide the bevel box past the cylinder block bolt flange
-arrow A- and then past the oil pan -2-, as illustrated
-arrow B-.
– At the same time, carefully push the engine forward with help
from a second technician.
Note
When lowering the engine and transmission subassembly, pay

attention to the connecting lines and hoses.
– Lower the transmission. Pay attention to the subframe when

doing this -arrow-.
n AG. Volkswagen A
– Use the spindles on the transmission
ksw
age support -3282-
G do
esto
noadjust
y Vol
the position of the transmission while lowering it. t gu
db ar
e an
ris tee
utho or
a ac
Note ss
ce
e
nl
pt
du
an
Pay attention to the power steering lines when lowering the trans‐
itte
y li
erm
mission.
ab
ility
ot p
wit
, is n
h re
hole
spec
5.6 Transmission Transporting

es, in part or in w
t to the co
– Attach the transmission support jig -3336- to the transmission

housing.
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
op py
– Move the sliding bar using the locking bolt -arrow-. t. C rig
gh ht
pyri by
Number of visible holes = 9
co Vo
by lksw
cted agen
Prote AG.
– Lift the transmission with a shop crane and the transmission
support jig -3336- .
– Set the transmission down, for example, into the transport
container.

AG. Volkswagen AG d
ksw
agen oes
not
R32 2004 ➤
ol
byV gu Manual Transmission - Edition 01.2012
d ara
ise nte
or eo
h
ut
5.7 Transmission, Securing to the Trans‐
ss a ra
c
mission Support
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
♦ Holding Plate -VW 309-
ot
wit
, is n
h re
♦ Transmission Support -VW 353-
hole
spec
– Attach the transmission to the assembly stand with bolts
es, in part or in w
t to the co
-arrows-.
rrectness of i
Note
l purpos
If one of the bolt holes does not touch the transmission support
place shims between the hole and the transmission support.
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
5.8 Transmission, Installing
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
Note py by
co Vo
by lksw
cted agen
Prote AG.
Refer to ⇒ “5.5 Transmission, Removing“, page 63 for the re‐
quired special tools.
– Clean all threaded holes with a thread tap to remove any lock‐
ing fluid residue.
– Always replace the self locking nuts and bolts.
– Clean the splines on the input shaft and then lightly lubricate
them with grease for clutch plate splines -G 000 100- .
It must be possible to slide the clutch disc back and forth on the
input shaft.
– Make sure the alignment sleeves for centering the engine to
transmission are installed inside the cylinder block. Install
them if necessary.
If the alignment sleeves are missing, it will be difficult to shift, there
will be clutch problems and transmission may make noises (loose
rattling).
– Make sure the intermediate plate fits correctly on the engine.
To install the transmission, the adjustment plate -3282/27- must
be installed on the transmission support -3282- .
– Align the arms on the transmission support so that they match
up with the holes in the adjustment plate.

R32 2004 ➤
– Install the support elements -A- as illustrated on the adjust‐

ment plate. en AG. V
olkswagen AG
ag does
ol ksw n
– Place the transmission bon
y V the engine-/gearbox jack -V.A.G
ot g
ua
1383A- . ris
ed ran
te
ho eo
ut
– Align the adjustment
ss
a plate so that it is parallel to the transmis‐ ra
c
sion.
ce
le
un
pt
an
d
– Secure the transmission to the transmission support -3282-

itte
y li
using a bolt -A-.
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
– Move the engine-/gearbox jack -V.A.G 1383A- under the ve‐
hicle. The arrow symbol -B- on the adjustment plate must point
in the direction of travel.
rrectne
– Turn the spindles on the transmission support -VAS 3282- and
raise the transmission at an angle on the left side near the
s
bevel box.
s o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
– Lift the transmission carefully and guide it past the subframe

-arrows-.
– Carefully push the engine forward with help from a second
technician.
Note
Be careful of the connecting lines and hoses when moving the

engine.
– Guide the bevel box past the cylinder block bolt flange
-arrow A- and the past the oil pan -2-, as illustrated
-arrow B-.
– Rotate the transmission -1- downward near the bevel box by
turning the spindles on the transmission support -3282- and
guide it into the flywheel (starter ring gear).
– Line up the transmission and the engine and install it.

R32 2004 ➤
– Install the engine to transmission bolt -arrow A- and tighten it

to specification. Refer to ⇒ page 77 .
– Position the bracket for the secondary air pump -1- to the en‐
gine and install the bolts -arrows-. Refer to ⇒ Engine Me‐
chanical, Fuel Injection and Ignition; Rep. Gr. 26 ; Exhaust
System; Exhaust System, Removing and Installing .
– Install the lower intermediate plate.
– Install the lower engine to transmission bolts and tighten them
to specifications. Refer to ⇒ page 77 .
– Lift the engine with the transmission carefully. To do this, turn
the spindles on the engine support bridge -10-222 A- .
– Install the transmission mount bracket -1- with new bolts

-arrows- and tighten them to specifications. Refer to
⇒ page 77 .

versal support -V.A.G 1359/2 - under the transmission and olkswagen AG
then lift the transmission until it is parallel with the transmissionswagen AG. V does
mount. by
Volk not
gu
d ara
se nte
– Align the engine and transmission into its installed thposition.
or
i
e or
au ac
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
– Install new bolts -arrows- for the transmission mount -2- to
t to the co
transmission mount bracket -1- and tighten them to specifica‐
tions. Refer to ⇒ page 77 .
rrectne
Note
ss o
cial p
Use a step ladder -VAS 5085- to install the bolts.

inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

R32 2004 ➤
– Install new bolts -arrow- for the engine mount to engine mount
bracket. Refer to ⇒ Engine Mechanical, Fuel Injection and
Ignition; Rep. Gr. 10 ; Specifications .
Note
Use the step ladder -VAS 5085- to install the bolts.
WARNING
Remove the engine support bridge -10-222 A- only after the

bolts for the engine and transmission mounts have been tight‐
ened to specifications.
Note
Install the engine and transmission mount free of tension.
– Attach the power steering fluid reservoir to the engine mount.
– Install the bolt -arrow- above the bevel box and tighten it to
specification. Refer to ⇒ page 77 .
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
– Position the support to the bevel box and transmission an in‐

pt
du
an
stall the bolts -arrows-. Refer to ⇒ page 80 .

itte
y li
erm
ab
– Press the engine and transmission assembly to the bulkhead;

ility
ot p
while doing so, carefully guide the bevel box pin into drive‐
wit
, is n
shaft.
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
o eo
aut
h
ra R32 2004 ➤
s c
s Manual Transmission - Edition 01.2012
ce
le
un
pt
an
d
itte
y li
rm
ab
Note
pe
ility
ot
wit
, is n
♦ The seal in the driveshaft flange must not be damaged when
h re
hole
removing and installing the transmission.
spec
es, in part or in w
♦ Replace the driveshaft if it is damaged.
t to the co
♦ Slip the driveshaft horizontally onto the respective guide pin.
rrectness of i
l purpos
nform
ercia
– Attach the driveshaft flexible disc to the bevel box flange shaft.
m
Install the bolts -arrows- and tighten them to specification, see
a
com
tio
-item 4- in the ⇒ “5.2 Driveshaft“, page 256 .
n in
r
te o
thi
– Attach the front exhaust pipe to the exhaust manifold. Refer to
s
iva
do
⇒ Engine Mechanical, Fuel Injection and Ignition; Rep. Gr.
r
rp
cum
26 ; Description and Operation .
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– Secure the pendulum support to the transmission with new

bolts -arrows A and B- . Refer to ⇒ Suspension, Wheels,
Steering; Rep. Gr. 40 ; Specifications .
– Install the drive axles to the transmission. Refer to ⇒ Suspen‐
sion, Wheels, Steering; Rep. Gr. 40 ; Removal and Installa‐
tion .
– Install the right drive axle heat shield.
– Install the radiator and fans. Refer to ⇒ Engine Mechanical,
Fuel Injection and Ignition; Rep. Gr. 19 ; Removal and Instal‐
lation .
– Install the dual catalytic converter and then assemble the ex‐
haust system. Refer to ⇒ Engine Mechanical, Fuel Injection
and Ignition; Rep. Gr. 26 ; Description and Operation .
– Position the starter and install the lower bolt. Refer to ⇒ Elec‐
trical Equipment; Rep. Gr. 27 ; Removal and Installation .
– Install the bracket for the power steering line to the starter and
to the transmission.
– Insert the upper engine to transmission bolts and tighten them
to specification. Refer to ⇒ page 77 .
– Attach the ground cable to the upper engine to transmission

bolt and install the nut -arrow-.

R32 2004 ➤
– Install the hose/line assembly in the -direction of the arrow-

and push the clamp -arrow- down.
– Remove the hose clamp up to 25 mm dia. -3094- .
– Install the upper bolt for the starter. Refer to ⇒ Electrical
Equipment; Rep. Gr. 27 ; Removal and Installation .
– Attach the cable bracket -A- to the starter -arrow 3-.

– Connect the connectors for the starter -arrow 1- and to the
backup lamp -arrow 2-.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
– Install the transmission shift lever -B- -arrow 3-.
ot
wit
, is n
h re
– Tighten the nut -arrow 3- to specification, see -item 16- in the
hole
spec
⇒ “2.5 Shift and Selector Cables“, page 38 .
es, in part or in w
t to the co
– Install the relay lever -A- and secure it with a lock washer
-arrow 2-.
– Install the power steering line -arrow 1-.
rrectness of i
l purpos
nform
mercia
a
com
tion in
– Attach the support to the transmission and tighten the bolts
r
te o
thi
-arrows- to specification, see -item 6- in the

s
iva
⇒ “2.5 Shift and Selector Cables“, page 38 . Push the hose

do
r
rp
onto the support, if necessary.

um
fo
en
ng
t.
yi
– Attach the shift cable (selector cable) to the cable retainers.
Co
Cop py
t. rig
gh
– Install the battery tray. Refer to ⇒ Electrical Equipment; Rep.
ht
pyri by
Vo
o
Gr. 27 ; Removal and Installation .
c by lksw
cted agen
Prote AG.
– Install the air filter housing and tighten the bolts -4 and 5-.
– Install the connecting pipe -1-.
– Connect the connecting pipe -1-, the connector -2- and the
hose-3- to the Mass Airflow (MAF) sensor. Refer to ⇒ Engine
Mechanical, Fuel Injection and Ignition; Rep. Gr. 24 ; De‐
scription and Operation .
– Install the battery. Refer to ⇒ Electrical Equipment; Rep. Gr.
27 ; Removal and Installation

R32 2004 ➤
– Attach the crankcase ventilation hose -1- to the cylinder head

cover.
– Attach the Evaporative Emission (EVAP) canister hose -2-.
– Push the coolant line bracket onto the pins under the plenum
chamber -arrows-.
– Connect the negative cable to the battery. Refer to ⇒ Electrical
Equipment; Rep. Gr. 27 ; Removal and Installation .
Note
Note the radio code on vehicles with a coded radio.
– Check the fluid level in the manual transmission and bevel box.
Refer to ⇒ “1.1 Transmission Fluid, Checking“, page 30 .
– Bleed the clutch system. Refer to
⇒ “1.2 Clutch System, Bleeding“, page 11 .
– Adjusting the shift unit. Refer to one of the following:
page 41 . en AG. V
olkswagen AG
ag does
lksw not
⇒ “2.7 Shift Unit Adjusting, from Buildy V Date 19 May 2003“,
o gu
db ara
page 43 . ir se nte
ho eo
ut
– Install the noise insulation.ssRefer
a to ⇒ Body Exterior; Rep. Gr. ra
c
50 ; Description and Operation
ce
e
nl
pt
du
an
– Install the engine cover.
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
Transmission to Engine
hole
spec
Item Bolt Quantity Nm
es, in part or in w
t to the co
1 M12 x 55 2 80
2 M12 x 80 1 80
rrectness of i
31 M10 x 50 3 45
l purpos
41 M12 x 55 1 80
5 M12 x 65 1 80
nf
ercia
or
•
m
1From 08 January 2001: Install the bolts with permanent

m
atio
m
washers. Refer to the Parts Catalog.

o
n in
or c
– Replace the bolts.

thi
te
sd
iva
o
r
-A and B- : Alignment sleeves

rp
cu
o
m
f
en
ng
t.
yi Co
Transmission Mount Bracket to Transmission Bolt t. Cop py
rig
gh ht
yri
Bolts -arrows- 50 Nm + an addi‐
p by
co Vo
by lksw
Prote tional 90° (1/4)
cted AG.
agen
turn

R32 2004 ➤
Transmission Mount to Transmission Mount Bracket Bolt

Bolts -arrows- 100 Nm
Hydraulic line to transmission 25 Nm
Drive axle heat shield to bevel box 25 Nm
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
5.9 Bevel Box
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
♦ Hex Extension -V.A.G 1669-
h re
ole,
spec
t to the co
Removing
– Remove the noise insulation (if equipped) under the engine
and transmission. Refer to ⇒ Body Exterior; Rep. Gr. 50 ;
rrectne
Description and Operation .
s
– Mark the position of driveshaft flexible disc to bevel box flange.
s o
cial p
f i
– Remove the driveshaft flexible disc bolts -arrows- from the
nform
bevel box flange.
mer
atio
m
– Remove the right drive axle heat (if equipped).

o
n
c
i
or
n thi
– Remove the right drive axle from the transmission.

te
sd
iva
o
pr
– Tie the drive axle as high up as possible. Be careful not to

cum
r
fo
damage the paint on the drive axle.

en
ng
t.
yi Co
op
– Separate the exhaust system at the double clamp. Refer to ⇒
C py
t. rig
gh
Engine Mechanical, Fuel Injection and Ignition; Rep. Gr. 26 ;
ht
pyri by
Vo
o
c by lksw
cted agen
Prote AG.
– Remove the pendulum support bolts -A arrows- from the sub‐

frame.
– Carefully press the engine and transmission forward.

R32 2004 ➤
– Remove the front driveshaft from the centering pin -arrow-.
Note
Be careful not to damage the seal inside the driveshaft flange

when removing and installing.
lkswage es n
– Remove the bevel box and transmission support byV
o
bolts ot g
ua
-arrows- from the engine and the bevel ed
ir sbox.
ran
o tee
th or
u
– Place a container under transmission
ss
a and engine. ac
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Remove the oil drain plug -arrow A-.
rrectness of i
– Drain the transmission fluid from the bevel box.
l purpos
– Remove the right flange shaft bolt -arrow- using the hex ex‐
tension -V.A.G 1669- or a 6 mm socket .
nform
ercia
– Remove the bevel box to transmission bolts.

m
at
om
ion
– Remove the bevel box from the transmission.
c
in t
or
his
te
– Remove the bevel box.

a
do
priv
cum
or
Installing
f
en
ng
t.
yi Co
Install in the reverse order of removal. t. Cop py
rig
gh ht
– With the transmission installed, lubricate the differential pyri by
Vo
co
splines with grease for clutch plate splines -G 000 100- .
by lksw
cted agen
Prote AG.

R32 2004 ➤
Note
n AG. Volkswagen A
♦ Always replace the O-ring for
olks
wagsealing
e
the bevel Gbox
doesto trans‐
no
mission -arrow A- and bythe O-rings for sealing the sleeves
V t gu
ara
ed
-arrows B and C-.orLubricate the O-rings lightly with oil.
is nte
e h
ut or
♦ Slide the bevel
ss box completely on the transmission, while do‐
a ac
ing this, join the splines of the input shaft/bevel box with the
ce
e
nl
pt
connecting sleeve/differential.
du
an
itte
y li
erm
♦ Bring the right drive axle splines and the differential bevel gear
ab
ility
into alignment. Rotate the flange shaft if necessary.
ot p
wit
, is n
♦ With proper tooth position and central guiding, the bevel box
h re
hole
slips up to the transmission.
spec
es, in part or in w
♦ Install the bevel box and transmission support before installing
t to the co
the engine to transmission bolts.
♦ Do not pull the bevel box with the bolts against the transmis‐
rrectness of i
sion, otherwise the bevel box is tilted and the bolt eyelets can
break off.
l purpos
♦ Take care not to damage the oil seals in the driveshaft flanges
on removal and installation.
nf
ercia
orm
m
atio
om
n in
♦ Slip the driveshaft horizontally onto the respective guide pin.
or c
thi
te
♦ Driveshaft to the bevel box bolts, see -item 4- in the

sd
iva
⇒ “5.2 Driveshaft“, page 256 .

r
rp
cu
o
m
f
en
ng
♦ Replace the driveshaft seal (if equipped). Refer to ⇒ Suspen‐

t.
yi Co
op
sion, Wheels, Steering; Rep. Gr. 40 ; Description and Oper‐ C py
t. rig
ation .
gh ht
pyri by
Vo
co lksw
by
♦ Install the exhaust pipe at the double clamp. Refer to ⇒ Engine cted agen
Prote AG.
Mechanical, Fuel Injection and Ignition; Rep. Gr. 26 ; De‐
scription and Operation .
♦ Check the fluid level in the transmission and bevel box. Refer
to ⇒ “1.1 Transmission Fluid, Checking“, page 30 .
– Install the drive axles to the transmission. Refer to ⇒ Suspen‐

sion, Wheels, Steering; Rep. Gr. 40 ; Removal and Installa‐
tion .
– Install the noise insulation. Refer to ⇒ Body Exterior; Rep. Gr.
Bevel box to transmission, always replace the 40 Nm + an ad‐
bolts ditional 45° (1/8)
turn
Driveshaft flexible disc with heat shield to the bevel box flange,
see -item 4- in the ⇒ “5.2 Driveshaft“, page 256 .
Bevel Box and Transmission Bracket Bolt

R32 2004 ➤
AG. VolkswaManual
gen AG Transmission - Edition 01.2012
agen does
olksw not
The following assembly sequence must by Vfollowed when instal‐
be gu
ara
ed
ling the bracket: horis nte
eo
aut ra
– Install all the bolts hand tight.ss c
ce
e
nl
pt
– Tighten the bolts -B- (M10 x 22) first to 10 Nm.
du
an
itte
y li
– Tighten the bolts -A- (M10 x 50) to 50 Nm.
erm
ab
ility
ot p
– Tighten the bolts -B- to 40 Nm.
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

R32 2004 ➤
6 Disassembly and Assembly

⇒ “6.1 Transmission, Through Build Date 18 May 2003“,
page 82
⇒ “6.2 Transmission, From Build Date 19 May 2003“, page 87
⇒ “6.3 Transmission Housing, Through Build Date 18 May 2003“,
page 96
page 100
⇒ “6.5 Clutch Housing, Through Build Date 18 May 2003“,
page 107
⇒ “6.6 Clutch Housing, From Build Date 19 May 2003“,
page 110
⇒ “6.7 Shift Unit, Transmission Side Through Build Date
18 May 2003“, page 114
⇒ “6.8 Shift Unit, Transmission Side, From Build Date 19 May
2003“, page 116
⇒ “6.9 Selector Forks Through Build Date, 18 May 2003“,
page 118
⇒ “6.10 Selector Forks From Build Date, 19 May 2003“,
page 120
6.1 Transmission, Through Build Date n AG. Volkswagen AG do

wage es n
18 May 2003 olks ot g
byV ua
d ran
ir se tee
Special tools and workshop equipment required utho
or
a ac
ss
ce
le
un
pt
♦ Holding Fixture -VW 313-
an
d
itte
y li
rm
ab
pe
ility
ot
wit
♦ Sleeve -30-21-
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
Disassembly
– Secure the transmission to the assembly stand with bolts
nform
ercia
-arrows-.
m
– Turn the transmission in the assembly stand so that the drain

a
com
tio
plug is facing down.

n in
r
te o
thi
– Place a drip tray underneath.

s
iva
do
r
rp
– Drain the fluid from the transmission and bevel box.

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

R32 2004 ➤
– Remove the right flange shaft bolt using the hex extension -
V.A.G 1669- or a 6 mm socket. .
Note
The right flange shaft stays in the bevel box.
– Remove the four bevel box to transmission bolts -arrows- (only

three are shown in the illustration).
– Remove the clutch slave cylinder with release bearing bolts

-arrows- and slave cylinder.
– Move the shift unit into neutral.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
– Remove the backup lamp switch -1-.
ce
e
nl
pt
du
an
– Remove the bolts -2- for the gear shift cap -A-.
itte
y li
erm
ab
– Carefully remove the cap.

ility
ot p
wit
– Remove the locking screw -3-

, is n
h re
hole
– Remove the bolts -4- and remove the shift unit cover -B-.
spec
es, in part or in w
– Remove the shift unit in the -direction of the arrow- from the
t to the co
transmission housing.
– Remove the left flange shaft.
rrectness of i
l purpos
– Remove the transmission housing to differential housing bolts

-A-.
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
6. Disassembly and Assembly 83

R32 2004 ➤
– Remove the clutch housing to transmission

gen AG
. Volkshousing
wagen AG
dbolts
swa oes
-B-. y Volk not
gu b ara
ed nte
oris e
th or
au
Note ss
ac
ce
le
un
pt
The bolt -arrow- is located outside of the bolting flange. It is in‐
an
d
itte
y li
stalled with a washer.
erm
ab
ility
ot p
wit
– Remove the transmission housing. If necessary, carefully pry
is n
h re
up all around and alternate between sides on the protruding
ole,
spec
flange. Be careful not to damage the sealing surfaces.
t to the co
from Build Date 06 April 2000
rrectne
– Remove the bolt -arrow- for the securing plate (input shaft
outer race/tapered roller bearing).
s
– Remove the securing plate.
s o
cial p
f in
form
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
op py
– Move the input shaft in the -direction of the arrow- and remove
. C rig
ht ht
rig
it. py by
co Vo
by lksw
cted agen
Prote AG.
– Together with a second technician, remove the differential

-1-, the output shafts -2 and 3-, the reverse gear shaft -4- and
the selector forks -5- carefully from the clutch housing.
– Remove the input shaft seal using the sleeve -30-21- .
Assembly

R32 2004 ➤
– Install the differential -1-. agen

AG. Volkswagen AG d
oes
olksw not
– Install the 5th, 6th and reverse gear output d b shaft -2- together
y V gu
ara
with the reverse gear selector fork, the rise5th and 6th gear se‐ nte
ho eo
lector fork -3- and the reverse geara shaft -4-.
ut ra
c
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Hold the output shaft for 1st through 4th gear -3- and the se‐
lector forks -5- with the right hand.
rrectness of i
– Slightly lift the differential with the left hand.
l purpos
– Have the second technician lift the 5th, 6th and reverse gear
output shaft -2- together with the reverse gear shaft -4- slightly
nform
ercia
at the same time.

m
at
– Install the 1st to 4th gear output shaft in the
om
io
n
c
in t
or
his
e
The splines on the output shafts and the final drive/differential

at
do
riv
must engage.
p
cum
for
en
g
– Together with a second technician, now place the shafts in

n
t.
yi Co
their bearing seats. Cop py
t. rig
gh ht
pyri by
Vo
o
– Install the input shaft into the clutch housing -arrow-.
c by lksw
cted agen
Prote AG.
From Build Date 06 April 2000

– Install the securing plate -arrow- and a new bolt into the notch
in the outer race/tapered roller bearing for the input shaft.
– Tighten the new bolt to specification, see -item 11- in the
⇒ “2.11 Input Shaft, Output Shafts, Differential, Bevel Box and
Selector Rods“, page 50 .
– Install the transmission housing.

R32 2004 ➤
Install the Gear Shift Unit as Follows

– Move the selector forks into the neutral position.
– Install the gear shift unit -1-.
swage es n
– Position the shift unit so y Vthat the fingers fit into the selector
olk ot g
ua
forks, refer to ⇒ page ir se 53 .
d b ran
tee
tho
o
– Align the lowers aubearing -arrow- on the shift unit to the hole in r ac
the cap. s
ce
e
nl
pt
du
– Secure the cap -A- with an M8 x 60 mm bolt -2- to the lower
an
itte
y li
bearing on the shift unit-1-.
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
– Install and tighten the bolts -arrows- for the cap -A- alternating
from side to side hand tight (1/2 turn).
nf
ercia
– Remove the M8 x 60 mm bolt -2- and install an original bolt in
orm
its place hand tight.
m
atio
om
n in
– Install the gear shift unit cover -B- and tighten the bolts -4- to
or c
specification.
thi
te
sd
iva
– Install the locking screw -3- for the shift unit using liquid locking
r
rp
cu
o
fluid -D 000 600 A2- .

f
en
ng
t.
yi Co
op
– Install the backup lamp switch. C py
t. rig
gh ht
yri by
– Install the left flange shaft and pressure spring, the thrust cop Vo
by lksw
washer and the tapered ring. cted agen
Prote AG.
– Install the input shaft seal using the thrust piece -T40008- .
– Install the clutch slave cylinder and release bearing.
Install the bevel box as follows:

R32 2004 ➤
AG. Volkswagen AG d
agen oes Manual Transmission - Edition 01.2012
olksw not
byV gu
ara
d
– Always replace the O-ring
oris for sealing the bevel box to trans‐
e nte
eo
mission -arrow A- and
aut the O-rings for sealing the sleeves
h
ra
-arrows B and C-. Lubricate the O-rings lightly with oil.
ss c
ce
le
un
pt
– Lubricate the differential splines with grease for clutch plate
an
d
splines -G 000 100- . itte
y li
erm
ab
ility
– Slide the bevel box completely onto the transmission, while
ot p
wit
doing this, join the splines of the input shaft/bevel box centrally
is n
h re
with the connecting sleeve/differential.
ole,
spec
– Bring the right drive axle splines and the differential bevel gear
t to the co
– With proper tooth position and central guiding, the bevel box
slips up to the stop against the transmission.
rrectne
– Do not pull the bevel box with the bolts against transmission,
s
otherwise the bevel box is tilted and the mounting eyelets can
s o
break off.
cial p
f inform
mer
– Install the four bevel box to transmission bolts -arrows- (only
atio
m

o
n
c
i
or
n
– Tighten the bolt for the right flange shaft using the hex exten‐
thi
te
sd
a
sion -V.A.G 1669- or a 6 mm socket while counter holding the

iv
o
pr
c
flange shaft with a drift.
um
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
6.2 Transmission, From Build Date 19 May

2003
♦ Thrust Tube -VW 455-
♦ Sleeve -30-21-
♦ Bracket -30-211 A-
♦ Drift -T10168-
♦ Heat Gun -V.A.G 1416-
♦ Kukko Puller 12-14.5 mm -21/1-

R32 2004 ➤
♦ Kukko Separating Tool 5-60 mm -17/0-

♦ Kukko Support -22/1-
Disassembly AG. Volkswagen AG d
agen oes
lksw not
– Secure the transmissionby
Vo to the assembly stand with gubolts
ara
-arrows-. rised
nte
ho eo
ut
– Turn the stransmission
s a in the assembly stand so that the drain ra
c
plug is facing down.
ce
e
nl
pt
du
an
itte
y li
erm
ab
– Drain the fluid from the transmission and bevel box.
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
V.A.G 1669- or a 6 mm socket.
rrectness of i
l purpos
Note
The right flange shaft stays in the bevel box.
nf
ercia
orm
m
atio
m
– Remove the four bevel box to transmission bolts -arrows- (only

o
n in
c

or
thi
te
sd
a

iv
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
– Remove the clutch slave cylinder with release bearing bolts

-arrows- and slave cylinder.

R32 2004 ➤
Make sure the shift unit is not blocked by the locking pin -arrow-.
– Move the shift unit into neutral.
– Remove the locking screw -2-.
swage es n
– Remove the bolts -3-. yV
olk ot g
ua
b
ed ran
– Remove the gearshift thunit
or -4- from the transmission housing.
is tee
or
au ac
– Remove the flange shaft and the stub shaft.
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
– Remove the clutch housing to transmission housing bolts
hole
spec
-B-.
es, in part or in w
t to the co
Note
rrectness of i
One bolt -arrow- is located outside of the bolting flange.
l purpos
nform
mercia
a
com
tion in
r
te o
thi
– Secure the input shaft by installing the thrust tube -VW 455-
s
iva
do
r
over the input shaft, onto the clutch housing.

rp
cum
fo
en
ng
– Install the separating tool -A-, for example, Kukko separating

t.
yi Co
op
tool 5-60 mm -17/0- , tightly behind the input shaft splines. C py
t. rig
gh ht
yri by
The back of the separating tool must contact the thrust tube and cop Vo
by lksw
must be free of play. cted agen
Prote AG.
– Pierce the rubber piece -C- in the center using a screwdriver.

– Remove the cover from the transmission housing.
A - Counter support, for example, Kukko support -22/1-
B - Internal puller 8 to 12 mm, for example, Kukko puller 12-14.5
mm -21/1-

R32 2004 ➤
Remove the lock ring -C- from the grooved ball bearing on the
input shaft/transmission housing as follows:
olkswagen AG
en AG. V
– Hold one end of the lock ring secure using a screwdriver
olks -A-.
wag does
not
y V gu
b ara
– Pry the other end out of the groove in the grooved riseball bearing
d
nte
in the -direction of arrow- using a screwdriveraut -B-.
h o eo
ra
ss c
– Pry out the rest of the lock ring using the screwdriver -B-.
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
– Remove the washer -1- from the transmission housing -2-, if
t to the co
equipped.
• If the transmission is replaced, check whether the washer
must be reinstalled. Refer to ⇒ page 92 .
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
– Remove the transmission housing to clutch housing bolts
f
en
ng
t.
yi
-A-.
Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Install the adapter for VW771 slide hammer -VW 771/40- into
the threaded hole in the transmission housing.
– Heat the transmission housing in the area near the bearing
seat for the grooved ball bearing/input shaft to approximately
100 °C (212 °F) for 10 minutes using the heat gun -V.A.G
1416- , or equivalent.
– Remove the transmission housing from the clutch housing in
the -direction of the arrow- using the slide hammer -VW
771/1- .
Note
If necessary, carefully pry up all around and alternate between

sides on the protruding flange. Be careful not to damage the seal‐
ing surfaces.

R32 2004 ➤
– Remove the washer -1- from the grooved ball bearing -2-, if
equipped.
– If the transmission is being replaced, check whether the wash‐
er must be reinstalled. Refer to ⇒ page 93 .
– Remove the separating tool -A- and the thrust tube -VW 455-
from the input shaft.
A second technician is needed to help remove the shafts from the
clutch housing.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
– Lift the differential -1- with the left hand.
erm
ab
ility
ot p
– With the right hand, left the output shaft for 1st to 4th gear
wit
, is n
together with the selector forks -2- -arrow A-.
h re
hole
spec
– At the same time, the 2nd technician lifts the input, reverse
es, in part or in w
and output shaft for 5th and 6th gear -3- together with the se‐
t to the co
lector shaft out of the clutch housing -arrow B-
rrectness of i
Note
l purpos
If necessary, the differential can be shifted again in the clutch

housing after lifting the shafts.
nf
ercia
orm
m
– Remove the input shaft seal using the sleeve -30-21- . atio
om
n in
or c
thi
te
sd
a
Note
iv
o
r
rp
cu
o
m
f
en
ng
Always replace the grooved ball bearing (-item 6- in the

t.
yi Co
⇒ “2.2 Input Shaft, From Build Date 19 May 2003“, page 143 ) on Cop py
t. rig
the input shaft. opyri
gh by
Vo
ht
by c lksw
cted agen
Assembly
Prote AG.
• Press the new grooved ball bearing (-item 6- in the

⇒ “2.2 Input Shaft, From Build Date 19 May 2003“,
page 143 ) onto the input shaft.

R32 2004 ➤
AG. Volkswagen AG d
agen oes
lksw not
– Install the input shaft -1-, 5th, 6th and reverse gear output shaft d by Vo gu
ara
-2- together with the selector shaft -3-, the selector fork -4- and orise nte
the reverse gear shaft -5-. aut
h eo
ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Install the differential -1-.
rrectness of i
l purpos
Note
nform
ercia
A 2nd technician is needed to help install the shafts into the clutch
m
housing.
at
om
ion
c
in t
or
– Hold the output shaft for 1st through 4th gear -3- and the se‐
his
ate
lector forks -4- with the right hand.
do
priv
cum
or
– Slightly lift the differential with the left hand.

f
en
ng
t.
yi Co
op
– Have the second technician lift the input shaft, the 5th and 6th
C py
t. rig
gh
and reverse gear output shaft -2- together with the reverse
ht
pyri by
Vo
gear shaft slightly at the same time.
o
by c lksw
cted agen
Prote AG.
– Install the 1st to 4th gear output shaft in the
• The input shaft, output shafts and final drive gear/differential
must engage.
– Together with a second technician, place the shafts and dif‐
ferential in their bearing seats.
– Install the bracket -30-211 A- for the input shaft to the clutch
housing.
Note
The clutch housing is shown in the illustration rotated 180°.
– Install the bolt -A- just far enough until the input shaft starts to
lift.
Transmission Housing Changed from Build Date 10 April 2006
One washer each is inserted above and below the input shaft
grooved ball bearing
(-item 6- in the
⇒ “2.2 Input Shaft, From Build Date 19 May 2003“, page 143 )
Upper washer Outer diameter 78.6 mm
Lower washer Outer diameter 85 mm
– Check the transmission housing.

R32 2004 ➤
– Measure the shoulder above the grooved ball bearing mount.

wage es n
The shoulder is deeper than the washer mount. yV
olks ot g
ua
d b ran
e
Shoulder above the Dimension “a“ ris
Washer
o tee
th or
Grooved Ball Bear‐ ss
au ac
ing
ce
le
un
pt
From build date 10 10.7 mm yes
an
d
itte
y li
April 2006
erm
ab
ility
ot p
Through build date 10 mm no
wit
is n
09 April 2006
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
Bearing Seat for Grooved Ball Bearing in Transmission housing
atio
Changed from Build Date 10 April 2006
om
n
c
i
or
n
Bearing seat -arrow- for the grooved ball bearing (-2- ⇒ lower il‐
thi
e
lustration) is slightly lower than the washer mount (-1- ⇒ lower

t
sd
iva
o
illustration).
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
From build date 10 April 2006, place a washer (outer diameter =

85 mm) -1- on the grooved ball bearing -2-.
– Heat the transmission housing using the heat gun -V.A.G
1416- or equivalent, in the area of the bearing seat for the
grooved ball bearing/input shaft to 100 °C (212 °F) for approx‐
imately 10 minutes.

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
r
R32 2004 ➤ ut
ho eo
ra
a
Manual Transmission - Editions 01.2012
s c
ce
le
un
pt
an
– Install the transmission housing and tighten the bolts
d
itte
y li
-A, B and C- to specification.
rm
ab
pe
ility
If the steel bolts (outer hex head) are the replacement part, pay
ot
wit
, is n
attention to the allocation:
h re
hole
spec
Allocation of bolts:
es, in part or in w
t to the co
A - Bolt with a permanent washer
B - Bolt without a washer
rrectness of i
C - Bolt with a permanent washer
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
op
From build date 10 April 2006, install a washer -1- (outer diameter C py
t. rig
= 78.6 mm) above the grooved ball bearing -2-. gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
– Install the grooved ball bearing/input shaft lock ring -1-.

– Remove the bracket -30-211 A- for the input shaft.
– If the shift unit retaining sleeve has been removed, install it

now all the way in using the drift -T10168- .
– Turn the transmission with the opening for the shift unit in the
assembly stand upward.

R32 2004 ➤
– Install the shift unit -1- into the lower bearing -2- and into the
selector forks -3-. The cap is not shown in the illustration.
– Push the shift unit -1- against the retaining sleeve -2- in the
-direction of the arrow- and guide it through the selector fork
all the way down using the shift finger -3-.
• The shift unit cover -4- must be parallel to the bolting surface
on the transmission housing.
• It must be possible to move the shift unit shaft easily (forward
and backward).
Note
If the shift unit cover is at an angle to the bolting surface, then the
shift unit is not installed into the lower bearing.
– Tighten the bolts -3- for the shift unit cover -4-.
– Install the locking screw -2-, the locking pin -arrow- must not
be installed when doing so.
– Install the backup lamp switch -1-.
AG. Volkswagen AG d
agen oes
– Install the flange shaft and stub shaft,othe
lksw pressure springs, not
yV gu
the thrust washers and the taperedse
d rings.
b ara
nte
ri
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
– Install the input shaft seal so that it is flush using the thrust
wit
, is n
h re
piece -T40008- .
hole
spec
– Install the clutch slave cylinder with release bearing.

es, in part or in w
t to the co
– Move the shift lever through all the gears.

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

R32 2004 ➤
– Drive the cap into the transmission housing until seated using
the thrust piece -T10042-
Install the bevel box to the transmission as follows:
– Always replace the O-ring for sealing the bevel box to the
transmission -arrow A- and the O-rings for sealing the sleeves
-arrows B and C-. Lubricate the O-rings lightly with oil.
– Slide the bevel box completely on the transmission, while do‐
ing this, join the splines of the input shaft/bevel box centrally
with the connecting sleeve/differential.
– Bring the right drive axle splines and the differential bevel gear
– With proper tooth position and central guiding, the bevel box
slips up to the stop against the transmission.
lkswage es n
o ot g
Note d byV ua
ran
ir se tee
tho
Do not pull the bevel
au box with the bolts against the transmission, or a
ss c
otherwise the bevel box is tilted and the mounting eyelets can
ce
le
break off.
un
pt
an
d
itte
y li
erm
ab
ility
– Tighten the 4 bevel box bolts -arrows- (only 3 are shown in

ot p
wit
illustration) to the transmission.

is n
h re
ole,
– Tighten the bolt on the right flange shaft using the hex exten‐
spec
sion -V.A.G 1669- or a 6 mm socket while counter holding the

t to the co
flange shaft with a drift.

rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
6.3 Transmission Housing, Through Build
c by lksw
cted agen
Prote AG.
Date 18 May 2003
♦ Punch -VW 407-
♦ Tube 37 mm Dia. -VW 416 B-

R32 2004 ➤

♦ Centering Mandrel -12-551-
♦ Seal Driver -3129-
♦ Centering Mandrel -3176-
♦ Kukko Extractor 23.5-30 mm -21/4-
♦ Kukko Extractor 14.5-18.5 mm -21/2-
❑ When replacing: adjust
the input shaft, output
shaft and the differen‐
tial, refer to
⇒ “2.1 Adjustment Over‐
view“, page 172 .
2 - Seal
❑ Always replace, if equip‐
ped.
3 - Oil Drain Plug
❑ 30 Nm
❑ Always replace.
4 - Retaining Sleeve AG. Volkswagen AG d
agen
❑ Removing, refer Volkswto oes
not
gu
⇒ page e98 d .
b y ara
nte
ris
❑ Installing,
utho refer to eo
ra
⇒sspage
a
99 . c
ce
e
nl
5 - Oil Fill Plug

pt
du
an
itte
y li
❑ 30 Nm
erm
ab
❑ Always replace.
ility
ot p
wit
, is n
6 - Locking Pin
h re
hole
❑ Push the shift unit into

spec
es, in part or in w
the slotted guide rail to

t to the co
adjust the shift unit. Re‐

fer to
⇒ “2.6 Shift Unit Adjust‐
rrectness of i
ing, through Build Date

18 May 2003“, page 41 .
l purpos
⇒ page 99 .
nform
ercia
m
⇒ page 99 .
at
om
ion
c
7 - Bushing
in t
or
his
e
❑ For the selector shafts.

at
do
priv
❑ Replace after removing.

um
for
en
g
❑ Removing, refer to ⇒ page 99 .

n
t.
yi Co
op py
t. C rig
gh ht
pyri by
Vo
8 - Needle Sleeve
co lksw
by
cted agen
Prote
❑ For the reverse gear shaft, replace after removing.
AG.


R32 2004 ➤
9 - Adjusting Shim
❑ For the input shaft.
❑ Adjustment overview, refer to ⇒ “2.1 Adjustment Overview“, page 172 .
10 - Outer Race/Tapered Roller Bearing
❑ Removing and installing, refer to ⇒ “2.1 Input Shaft, Through Build Date 18 May 2003“, page 138 .
❑ When replacing: adjust the input shaft. Refer to
⇒ “1.1 Input Shaft Adjusting, Through Build Date 18 May 2003“, page 129 .
❑ For the output shaft, 5th, 6th and reverse gears. . Volkswagen AG
gen AG does
❑ Removing and installing, refer to ⇒ “2.4 Output ol swa
kShaft, 5th, 6th and Reverse notGears“, page 157 .
y V gu
b a
❑ When replacing: adjust the output shaftrisfor
e 5th, 6th and reverse gears. Refer toran
d
tee
⇒ “1.3 Output Shaft, 5th, 6th and Reverse
au
tho
Gears, Adjusting“, page 134 . or
a
ss c
12 - Adjusting Shim
ce
e
nl
pt
du
❑ For the output shaft, 5th, 6th and reverse gears.
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
❑ For the output shaft, 1st to 4th gears.
hole
spec
❑ Removing and installing, refer to ⇒ page 157 .
es, in part or in w
t to the co
❑ Adjust, if the output shaft for 1st to 4th gears is replaced. Refer to
⇒ “1.2 Output Shaft 1st to 4th Gears, Adjusting“, page 132 .
14 - Adjusting Shim
rrectness of i
l purpos

nform
ercia
❑ For the differential.

m
at
om
io
❑ Removing and installing, refer to ⇒ “5.1.1 Differential“, page 242 .
n
c
in t
or
❑ When replacing: adjust the differential. Refer to his

ate
⇒ “2.9 Differential, Front Final Drive, Adjusting“, page 187 .

do
priv
cum
or
16 - Adjusting Shim
f
en
ng
t.
yi Co
❑ For the differential. t. Cop py
rig
gh
ht
pyri by
Vo
co lksw
by
17 - Seal
cted agen
Prote AG.
❑ Removing and installing, refer to ⇒ “4.1.2 Right Flange Shaft Seal, Bevel Box Installed “, page 217 .
Retaining Sleeve, Removing

R32 2004 ➤
Retaining Sleeve, Installing

– Install the retaining sleeve using a 13 mm socket -A- and a
plastic hammer.
Locking Pin, Removing
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
Locking Pin, Installing
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
Selector Shaft Bushing, Removing
atio
m
A - Internal puller 14.5 to 18.5 mm, for example, Kukko extractor

o
n
c
i
or
n
14.5-18.5 mm -21/2-
thi
te
sd
va
B - Counter support, for example, Kukko support -22/2-

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

R32 2004 ➤
Selector Shaft Bushing, Installing
Needle Sleeve, Removing

A - Internal puller 23.5 to 30 mm, for example, Kukko extractor
23.5-30 mm -21/4-
Note
The needle sleeve will get damaged when it is removed and must
be replaced.
Needle Sleeve, Installing

– While installing, place the thrust washer -B- for the reverse gar
shaft onto the needle sleeve -A- .
– Support the transmission housing beneath the bearing mount
using tube 37 mm dia. -VW 416 B- .
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
6.4 Transmission Housing, From Build Date

pe
ility
ot
19 May 2003
wit
, is n
h re
hole

spec
es, in part or in w
t to the co
♦ Driving Sleeve -VW 244 B-

rrectness of i
♦ Thrust Plate -VW 401-

l purpos

♦ Punch -VW 407-
nform
ercia

m
a
com
tio
♦ Guide Pin -VW 436 A-

n in
r
te o
thi
♦ Guide Pin -VW 439-

s
iva
do
r
rp

um
fo
en
ng
t.
yi Co
Cop py
t. rig
♦ Guide Bolt -10-15-
gh ht
pyri by
Vo
o
by c lksw
♦ Thrust Pad -3124- cted agen
Prote AG.

R32 2004 ➤
♦ Bearing Driver -3264-

♦ Subframe Support Assem. Device -3290-
♦ Drift -T10168-
♦ Drift -T10169- or -T10362-
the output shaft and dif‐
ferential. Refer to
view“, page 172 .
❑ From build date 10 April
2006, change in the
grooved ball bearing/in‐
put shaft mount area,
see -item 3- in the
⇒ “2.2 Input Shaft, From
Build Date 19 May
2003“, page 143 .
❑ Allocate the parts using
the Parts Catalog.
2 - Cover
⇒ page 103 .
⇒ page 103 . n AG. Volkswagen AG do
lkswage es n
3 - Oil Drain Plug byV
o ot g
ua
ed ran
❑ There are different ver‐ horis tee
sions, refer to aut or
ac
⇒ page 103 . ss
ce
e
nl
pt
du

an
itte
y li
45 Nm.
erm
ab
ility
ot p

wit
, is n
h re
4 - Seal
hole
spec
❑ Always replace, if equip‐

es, in part or in w
ped.
t to the co
5 - Fluid Fill Plug

rrectness of i
sions, refer to
l purpos
⇒ page 103 .
♦ With a internal multi-point - 45 Nm.
nf
ercia

rm
m
atio
m
6 - Locking Elbow
o
n in
or c
❑ For adjusting the shift unit. Refer to

thi
te
sd
iva
o
r
rp
cu
❑ Can be replaced with the transmission assembled.

o
m
f
en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
101
co Vo
by lksw
cted 6. Disassembly and Assembly
agen
Prote AG.
R32 2004 ➤
7 - Bushing
8 - Retaining Sleeve
❑ Removing when the transmission is disassembled, refer to ⇒ page 105 .
❑ Removing when the transmission is assembled, refer to ⇒ page 105 .
❑ Different retaining sleeves, refer to ⇒ page 105 .
❑ Installing a retaining sleeve with a shoulder, refer to ⇒ page 105 .
❑ Installing a retaining sleeve without a shoulder, refer to ⇒ page 106 .
9 - Needle Sleeve agen
AG. Volkswagen AG d
oes
lksw not
❑ For the reverse gear shaft. d by
Vo gu
ara
e nte
❑ Replace after removing. horis
eo
ut ra
❑ Removing, refer to ⇒ page 106 . ss a c
ce
le

un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
❑ Removing and installing, refer to ⇒ “2.4 Output Shaft, 5th, 6th and Reverse Gears“, page 157 .
h re
hole
❑ When replacing: adjust the output shaft for 5th, 6th and reverse gear. Refer to
spec
⇒ “1.3 Output Shaft, 5th, 6th and Reverse Gears, Adjusting“, page 134 .
es, in part or in w
t to the co
11 - Adjusting Shim
❑ For the output shaft for 5th, 6th and reverse gear.
rrectness of i
l purpos

nform
ercia
❑ Removing and installing, refer to ⇒ “2.3 Output Shaft, 1st to 4th Gears“, page 147 .
m
❑ Adjust, if the output shaft for 1st to 4th gears is replaced. Refer to a
com
tio
n in
r
te o
thi
13 - Adjusting Shim
s
iva
do
r
rp

um
fo
en
g

n
t.
yi Co
Cop py
t. rig
gh ht
pyri by
o Vo
by c lksw
cted agen
Prote
AG.
❑ When replacing: adjust the differential. Refer to ⇒ “2.1 Adjustment Overview“, page 172 .
15 - Adjusting Shim
16 - Bushing
❑ For the gear shift unit.
17 - Plug

R32 2004 ➤
18 - Seal
Cover, Removing
– Pierce the rubber cover -A- in the center with a screwdriver
-B- and pry it out in the -direction of the arrow-.
Cover, Installing n AG. Volkswagen AG do

lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
Oil Fill and Drain Plugs, Different Versions
rrectness of i
I - Oil fill or drain plug with a multi-point socket head
l purpos
II - Oil fill or drain plug with a hex socket head
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
.
Locking Pin for the Shift Unit, Removing
t rig
gh ht
pyri by
Vo
co
– Remove the pin in its unlocked position.
by lksw
cted agen
Prote AG.
– Guide a screwdriver -A- into hole of lock elbow -B-.
– Pry out the locking pin in the -direction of the arrow-.

R32 2004 ➤
Locking Pin, Installed Position

– The mark on the locking pin -arrow- must point toward the
connection on the clutch slave cylinder -1-.
Dimension -a- must be approximately 45°.
Drive the Shift Unit Locking Pin -arrow- in Up to The Tool Stop
Note
The locking pin must be unlocked when being installed.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte

y li
erm
ab
ility
ot p
14.5-18.5 mm -21/2-
wit
, is n
h re
hole
B - Counter support, for example, Kukko support -22/2- spec

es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia

m
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

R32 2004 ➤
Retaining Sleeve, Removing

– Position the transmission housing on the thrust plates -VW
401- and -VW 402- so that the retaining sleeve -A- inside the
transmission housing does not get damaged.
Retaining Sleeve, Removing, Transmission Assembled, Using

Guide Bolt -10-15-
– Remove the retaining sleeve and shift unit.
– Turn the transmission so that the retaining sleeve cannot fall
into the transmission.
Retaining Sleeve Differentiation

A retaining sleeve with a shoulder -arrow 1-, refer to
⇒ page 105 or without a shoulder -arrow 2-, refer to
⇒ page 106 can be installed.
For the correct allocation, refer to the Parts Catalog.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
Driving in the Retaining Sleeve with Shoulder as Far as the Tool

pt
du
an
Stop
itte
y li
erm
ab
• The transmission housing is bolted to the clutch housing.

ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
105
by lksw
cted agen
Prote AG.
6. Disassembly and Assembly
R32 2004 ➤
Driving in Retaining Sleeve without a Shoulder as Far as the Tool

Stop
• The transmission housing is bolted to the clutch housing.

A - Internal puller 23.5 to 30 mm, for example, Kukko extractor
23.5-30 mm -21/4-
Note
be replaced. wage
e ks s no
Vol t gu
d by ara
e nte
ris
tho eo
Needle Sleeve, Installing au ra
c
ss
ce
le
– Place the thrust washer -B- for the reverse gear shaft onto the
un
pt
an
d
needle sleeve -A-.

itte
y li
erm
– Support the transmission housing beneath the bearing mount ab

ility
ot p
using the tube 37 mm dia. -VW 416 B- . wit

is n
h re
ole,
spec
t to the co
rrectne

ss o
cial p
– Hold the spindle on the subframe support assm. device -3290-

inform
and turn the nut -B-.

mer
atio
m

o
n
c
14.5-18. 5 mm -21/2-
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

R32 2004 ➤
Shift Unit Bushing -A-, Installing
Plug -1-, Removing

– Remove the plug -1- from the inside of the transmission hous‐
ing toward the outside.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
Plug -1-, Installing rise nte
tho eo
au ra
– Using the bearing
ss driver -3264- , drive in the plug approxi‐ c
ce
e
mately 3 mm -a- below the upper edge of the housing.

nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
e
6.5 Clutch Housing, Through Build Date

t
sd
iva
o
r
rp
cu
18 May 2003
o
m
f
en
ng
t.
yi Co
Special tools and workshop equipment required t. Cop py
rig
gh ht
♦ Punch -VW 407- pyri by
Vo
co lksw
by
cted agen
♦ Sleeve -30-21- Prote AG.

R32 2004 ➤

1 - Bushing
⇒ page 109 .
⇒ page 110 .
2 - Selector Shaft for the Re‐
verse Gear Selector Fork
❑ The shaft cannot be re‐
moved with shop tools.
❑ A new shaft must be in‐
stalled when using a
new clutch housing. Re‐
3 - Needle Sleeve
⇒ page 110 .
⇒ page 110 .
4 - Alignment Sleeve AG. Volkswagen AG d
agen
❑ Quantity: 2 olksw
oes
not
byV gu
ara
d
5 - Clutch Housing orise nte
eo
h
ut
❑ Beginning with build ss a ra
c
date 06 April 2002, the
ce
e
nl
securing plate has an

pt
du
an
additional hole and

itte
y li
erm
notch for securing the

ab
ility
outer race/tapered roller

ot p
wit
bearing for the input

, is n
h re
shaft -item 14- .

hole
spec
❑ When replacing: see the

es, in part or in w
adjustment overview.
t to the co
Refer to ⇒ “2.1 Adjustment Overview“, page 172 .

rrectness of i
Seal can only be removed using the sleeve -30-21- when the transmission is disassembled.
l purpos

nform
ercia
7 - Oil Guide
m
at
om
❑ Pry out with a screwdriver.

on
c
in t
or

his
ate
do
riv
8 - Washer
p
cum
for

en
ng
t.
yi Co
op
❑ Allocate the parts according to the Parts Catalog. C py
ht. rig
rig ht
py by
co Vo
by lksw
108
cted agen
Prote AG.
Rep. Gr.34 - Controls, Housing
AG. Volkswagen AG d
agen oes
ksw not
by Vol
gu
ara
R32 2004 ➤
d
orise nte
eo
th
au ra
s c
9 - Outer Race/Tapered Roller Bearing s
ce
e
nl
pt
du
an
itte
y li
❑ Removing and installing, refer to ⇒ “5.1.1 Differential“, page 242 .
erm
ab
ility
❑ When replacing: adjust the differential. Refer to
ot p
wit
, is n
h re
hole
10 - Oil Deflector Washer
spec
es, in part or in w
❑ Installed position: The shoulder on the hole faces the output shaft.
t to the co
rrectness of i
l purpos
nf
ercia
o
rm
m
atio
om
n in
c
❑ Removing and installing, refer to ⇒ “2.4 Output Shaft, 5th, 6th and Reverse Gears“, page 157 .
or
thi
te
❑ When replacing: adjust the output shaft for 5th, 6th and reverse gears. Refer to
sd
iva
o
r
rp
cu
o
m
f
en
ng
13 - Washer
t.
yi Co
op py
❑ For the output shaft.
t. C rig
gh ht
yri by
❑ Always 0.65 mm thick. cop Vo
by lksw
cted agen
Prote
AG.
❑ Bolt - 12 Nm.
❑ Removing and installing, refer to ⇒ “2.1 Input Shaft, Through Build Date 18 May 2003“, page 138 .
❑ When replacing: adjust the input shaft. Refer to
⇒ “1.1 Input Shaft Adjusting, Through Build Date 18 May 2003“, page 129 .
❑ Secured by the securing plate and bolt from build date 06 April 2000.
❑ Always replace.
15 - Magnet
❑ Held in place by the housing joint surface.
16 - Cap
❑ Not present on all clutch housings.

B - Internal puller 14.5 to 18.5 mm, for example, Kukko extractor
14.5-18.5 mm -21/2-

R32 2004 ➤

B - Internal puller 23.5 to 30 mm, for example, Kukko extractor
23.5-30 mm -21/4-
Note
. Volkswag
The needle sleeve will get damaged when
lksw
agen it is removedAand
AG en G
doemust
s no
be replaced. by
Vo t gu
a
ed ran
ris tee
tho or
au ac
ss
ce

le
un
pt
an
d
itte
– While installing, place the thrust washer -B- for the reverse
y li
rm
ab
gear shaft onto the needle sleeve -A-.

pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
Selector Shaft for the Reverse Gear Selector Fork, Installing

nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
6.6 Clutch Housing, From Build Date

19 May 2003
♦ Punch -VW 407-
♦ Sleeve -30-21-
♦ Drift -T10168-

n AG. Volkswagen AG R32 2004 ➤
wage does
Manual
y Volks Transmission - Edition n01.2012
ot g
db ua
ran
ir se tee
♦ Thrust Piece -T40008- utho
or
a ac
ss
♦ Kukko Extractor 14.5018.5 mm -21/2-
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
1 - Bushing
hole
spec
es, in part or in w
t to the co
⇒ page 112 .
rrectness of i
⇒ page 112 .
l purpos
2 - Selector Shaft for the Re‐
verse Gear Selector Fork
nform
ercia
❑ The shaft cannot be re‐
moved with shop tools.
m
at
om
io
❑ A new shaft must be in‐
n
c
in t
or
stalled when using a
his
te
new clutch housing. Re‐

a
do
riv

p
cum
for
en
ng
3 - Needle Sleeve
t.
yi Co
Cop py
❑ For the reverse gear
t. rig
gh ht
yri
shaft. p by
co Vo
by lksw
cted
agen
Prote AG.
❑ Removing, Refer to
⇒ page 113 .
❑ Installing, Refer to
⇒ page 113 .
4 - Alignment Sleeve
❑ Quantity: 2
5 - Clutch Housing
the output shaft and dif‐
ferential. Refer to
view“, page 172 .
Seal can only be removed us‐
ing the sleeve -30-21- when
the transmission is disassembled.
7 - Oil Guide
❑ Pry out with a screwdriver.
8 - Washer
❑ Allocate the parts according to the Parts Catalog.
❑ Installed position: If the inner diameter has a shoulder, then it faces away from the outer race/tapered
roller bearing -item 9-.

R32 2004 ➤
❑ When replacing: adjust the differential. Refer to
❑ Installed position: The shoulder on the hole faces the output shaft.
❑ Removing and installing, refer to ⇒ “2.3 Output Shaft, 1st to 4th Gears“, page 147 .
❑ When replacing: adjust the output shaft for 5th, 6th and reverse gears. Refer to
13 - Washer
❑ Always 0.65 mm thick.
14 - Roller Bearing olkswagen AG
en AG. V
❑ For the input shaft. olkswag does
not
y V gu
❑ Removing, referiseto d b⇒ page 113 . ara
nte
or
❑ Installing, refer
au to ⇒ page 114 .
th eo
ra
ss c
15 - Magnet
ce
e
nl
pt
du
❑ Held in place by the housing joint surface.

an
itte
y li
erm
ab
16 - Cap
ility
ot p
❑ Not present on all clutch housings.

wit
, is n
h re
hole
spec
es, in part or in w

t to the co

rrectness of i
B - Internal puller 14.5 to 18.5 mm, for example, Kukko extractor

14.5-18.5 -21/2-
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
Installing the Selector Shaft Bushing, Installing

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

R32 2004 ➤

B - Internal puller 23.5 to 30Vomm, for example, Kukko extractor
lkswagen AG
23.5-30 mm -21/4-swagen AG. does
olk not
yV gu
edb ara
ris nte
tho
Note eo
au ra
c
ss
ce
le
un
pt
be replaced.
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
– While installing, place thrust washer -B- for the reverse gear
shaft onto the needle sleeve -A-.
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
e
Selector Shaft for the Reverse Gear Selector Fork, Installing

t
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Roller Bearing, Removing
– Compress the roller bearing lock ring -arrow- with pliers -C-
and remove it.
B - Internal puller 30 to 37 mm, for example, Kukko extractor
30-37 mm -21/5-

R32 2004 ➤
Roller Bearing, Installing

and install it.
– Remove the pliers before the roller bearing gets into its instal‐
led position. The lock ring must lock into the groove on the
clutch housing.
wage
6.7 Shift Unit, Transmission Side Through lks es n
o ot g
byV ua
d
Build Date 18 May 2003
ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
rm
♦ Thrust Disc -VW 412-
ab
pe
ility
ot
♦ Tube 28 mm Dia 100 mm -VW 421-
wit
, is n
h re
♦ Sleeve -VW 423-
hole
spec
es, in part or in w
♦ Arbor 50 mm Dia. -VW 432-
t to the co
♦ Press Support -3118-
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

R32 2004 ➤
AG. Volkswagen AG d Manual Transmission - Edition 01.2012
agen oes
olksw not
V
1 - Self LockingedNutby gu
ara
ris nte
❑ 20 Nm ut
ho eo
ra
a
❑ Always replace.
ss c
ce
e
nl
pt
2 - Shift Lever
du
an
itte
y li
❑ Install so that the master
erm
ab
spline aligns with the
ility
ot p
shift unit shaft.
wit
, is n
h re
❑ Can be replaced with
hole
spec
the shift unit still instal‐
es, in part or in w
led.
t to the co
to ⇒ page 40 .
rrectness of i
3 - Sliding Shoe
l purpos
❑ Attached into the relay

lever -item 6-.
nf
ercia
4 - Lock Washer
orm
m
atio
m
⇒ page 116 .
o
n in
or c
thi
5 - Bushing
te
sd
iva
o
r
rp
cu
6 - Relay Lever
o
m
f
en
ng

t.
yi Co
op
to ⇒ page 40 . C py
ht. rig
rig ht
7 - Shift Unit Cover
py by
co Vo
by lksw
cted agen
8 - Ball Sleeve
Prote AG.
❑ For the shift unit

⇒ page 116 .
⇒ page 116 .
9 - Shift Unit Shaft
10 - O-ring
❑ Always replace.
11 - O-ring
❑ Always replace.
12 - Cap
13 - Seal
❑ Pry out with a screwdriver
14 - Cap
❑ For the shift unit shaft.
15 - Cap
❑ For the transmission ventilation

R32 2004 ➤
Relay Lever Lock Washer, Removing

– Lift the clamp in the -direction of the arrow-.
Ball Sleeve, Removing

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
Ball Sleeve -A-, Installing
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
or
Seal, Installing
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
6.8 Shift Unit, Transmission Side, From

Build Date 19 May 2003
♦ Tube 28 mm Dia. 100 mm -VW 421-

R32 2004 ➤

❑ 20 Nm
❑ Always replace.
2 - Shift Lever
❑ Install so that the master
spline aligns with the
shift unit shaft.
❑ Can be replaced with
the shift unit still instal‐
led.
AG. Volkswagen AG d
to ⇒ page 40 . ksw
agen oes
not
Vol
by gu
3 - Sliding Shoe ised ara
nte
or
❑ Attached into the relay aut
h eo
ra
lever -item 5-. ss c
ce
e
nl
pt
4 - Bushing
du
an
itte
y li
5 - Relay Lever
erm
ab
ility
ot p
wit
, is n
to ⇒ page 40 .
h re
hole
spec
6 - Shift Unit
es, in part or in w
❑ With the shift unit cover.
t to the co
❑ Can be removed and in‐
stalled with the trans‐
rrectness of i
mission installed.
l purpos
7 - Bushing
❑ For the shift unit
nf
ercia
or
⇒ page 99 .
m
m
atio
m
o
n in
c
⇒ page 100 .
or
thi
te
sd
iva
8 - O-ring
o
r
rp
cu
o
❑ Install in the groove in the shift unit cover.

f
en
ng
t.
yi Co
❑ Install using transmission fluid. t. Cop py
rig
❑ Always replace.
gh ht
pyri by
Vo
o
by c lksw
9 - Cap cted agen
Prote AG.
❑ For the transmission ventilation.
10 - Lock Washer
❑ For the relay lever.
11 - Seal
❑ Remove using a screwdriver.

R32 2004 ➤
Relay Lever Lock Washer, Removing

– Lift the clamp in the -direction of the arrow-.
Seal, Installing
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
6.9 Selector Forks Through Build Date,

nl
pt
du
an
itte
18 May 2003
y li
erm
ab
ility
ot p

wit
, is n
h re

hole
spec
♦ Punch -VW 411-

es, in part or in w
t to the co
♦ Tube Trans. Drivshaft -VW 426-

♦ Thrust Pad 16.5/28 mm Dia. -VW 431-
rrectness of i

l purpos

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

R32 2004 ➤
1 - Selector Shaft and Selector

Fork, 5th and 6th Gear
4 - Selector Fork, Reverse
Gear
5 - Ball Sleeve
⇒ page 119 .
⇒ page 120 .
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tio
Ball Sleeve for Reverse Gear Selector Fork, Removing
n in
r
te o
thi
A - Internal puller 18 to 23 mm, for example, Kukko extractor 18.5
s
iva
do
-23.5 mm -21/3-
r
rp
cum
fo

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

R32 2004 ➤
Ball Sleeve for Reverse Gear Selector Fork, Installing
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
6.10 Selector Forks From Build Date, 19 May
ility
ot p
2003
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
♦ Punch -VW 411-
rrectness of i
♦ Tube Trans. Driveshaft -VW 426-
l purpos

nform
ercia

m
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

AG. Volkswagen AG d
agen oes R32 2004 ➤
olksw not
V
ed by Manual Transmission
gu
ara - Edition 01.2012
ris nte
tho eo
1 - Insulation Mat ss au ra
c
❑ Can be removed and in‐
ce
e
nl
pt
du
stalled by hand.
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
Fork, 5th and 6th Gear
5 - Selector Fork, Reverse
rrectness of i
Gear
l purpos
❑ From build date

06 March 2006, the ball
sleeve -item 6- has been
nform
ercia
omitted.
m
at
❑ Sliding omission.
om
ion
c
❑ Reverse gear selector
in t
or
fork is adapted.
his
ate
do
riv
❑ Reverse gear selector

p
cum
or
fork differentiation, refer

f
en
ng
t.
to ⇒ page 121 .
yi Co
Cop py
t. rig
6 - Ball Sleeve
gh ht
pyri by
Vo
o
c by lksw
cted agen
⇒ page 122 .
Prote AG.
⇒ page 122 .
❑ From build date
06 March 2006, the ball
sleeve has been omit‐
ted.
❑ Sliding omission.
Reverse Gear Selector Fork Differentiation

Dimension “a“ mm Transmission Build Date
24 through 05 March 2006
18 from 06 March 2006

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
R32 2004 ➤ autho eo
ra
Manual Transmission - Edition 01.2012 ss c
ce
e
nl
pt
du
an
Removing the Reverse Gear Selector Fork Ball Sleeve, Through
itte
y li
Build Date 05 March 2006
erm
ab
ility
ot p
A - Internal puller 18 to 23 mm, for example, Kukko extractor
wit
, is n
18.5-23.5 mm -21/3-
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
Installing the Reverse Gear Selector Fork Ball Sleeve, Through
orm
Build Date 05 March 2006
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

agen
AG. Volkswagen AG d
oes R32 2004 ➤
ksw
y Vol Manual Transmission
not
gua - Edition 01.2012
db ran
rise te
tho eo
au ra
7 Special Tools ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
♦ Multi-Meter -V.A.G 1526/A-
spec
es, in part or in w
♦ Connector Test Set -V.A.G 1594 C-
t to the co
♦ Adapter -3282/48-
rrectness of i
♦ Adjustment Plates -3282/52-
l purpos
♦ Universal Support -V.A.G 1359/2 -

♦ Punch -VW 407-
nform
ercia
♦ Sleeve -30-21-
m
a
com
t
ion in
r
te o
♦ Drift -T10168-
thi
s
iva
do
r

rp
cum
fo
en
g
♦ Punch -VW 411-

n
t.
yi Co
Cop py
t.
♦ Tube Trans. Drivshaft -VW 426-
rig
gh ht
pyri by
Vo
o
by c
lksw
cted agen
Prote AG.
♦ Bracket -30-211 A-
♦ Heat Gun -V.A.G 1416-
♦ Punch -VW 407-
♦ Seal Driver -3129-
♦ Guide Pin -VW 436 A-
♦ Guide Pin -VW 439-
♦ Guide Bolt -10-15-
♦ Thrust Pad -3124-
♦ Bearing Driver -3264-
♦ Subframe Support Assem. Device -3290-
♦ Drift -T10169- or -T10362-
♦ Tube 28 mm Dia 100 mm -VW 421-
♦ Sleeve -VW 423-
7. Special Tools 123

R32 2004 ➤
♦ Hose Clamp Pliers -V.A.G 1275-

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi
♦ Vehicle Diagnosis, Testing and Information System -VAS
Co
Cop py
5051-
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
♦ Spring Type Clip Pliers -VAS 5024-

R32 2004 ➤
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
♦ -1- Kukko Puller 12-14.5 mm -21/1-
ot p
wit
is n
♦ -1- Kukko Extractor 23.5-30 mm -21/4-
h re
ole,
spec
♦ -1- Kukko Extractor 14.5-18.5 mm -21/2-
t to the co
♦ -1- Kukko Extractor 18.5-23.5 mm -21/3-
♦ -3- Kukko Separating Tool 5-60 mm -17/0-
rrectne
♦ -4- Kukko Support -22/1-
s
s o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

R32 2004 ➤
♦ Engine Support Bridge

-10-222 A-
♦ Bracket for Engine - 10-222
A/1-
♦ Additional Hooks (2)
-10-222 A/2-
♦ Engine Support Adapter AG. Volkswagen AG d
agen oes
ksw
-10-222 A/3- by
Vol not
gu
ara
ed
is nte
♦ Hose Clamps Up to 25 mm hor eo
ut
Dia. -3094- ss a ra
c
ce
e
♦ Transmission Support
nl
pt
du
an
-3282-
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

R32 2004 ➤
♦ Adjustment Plate -3282/27-

♦ Transmission Support Jig
-3336-
V.A.G 1331-
♦ Torque Wrench (40-200
Nm) -V.A.G 1332-
♦ Engine/Gearbox Jack -
V.A.G 1383A-
♦ Step Ladder -VAS 5085-
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

R32 2004 ➤

♦ Holding Fixture -VW 313- AG. Volkswagen AG d
agen oes
lksw not
♦ Transmission Support -VW d byV
o gu
ara
353- orise nte
h eo
ut ra
♦ Thrust Tube -VW 455- ss a c
ce
e
nl
♦ Slide Hammer-Complete
pt
du
an
Set -VW 771- itte
y li
erm
ab
♦ Sleeve -30-21-
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

R32 2004 ➤
35 – Gears, Shafts
⇒ “1.1 Input Shaft Adjusting, Through Build Date 18 May 2003“,
page 129
Volkswa
⇒ “1.2 Output Shaft 1st to 4thswGears,
agen
AG.Adjusting“, page
gen AG
does132
o lk not
yV gu
⇒ “1.3 Output Shaft, 5th, d b6th and Reverse Gears, Adjusting“, page
ara
ise nte
134 thor eo
au ra
s c
1.1 s
Input Shaft Adjusting, Through Build
ce
le
un
pt
Date 18 May 2003
an
d
itte
y li
erm
ab
(Choosing the adjusting shim for the input shaft)
ility
ot p
wit
is n
h re
ole,
Note
spec
t to the co
♦ The instructions for adjusting apply only to a transmission with
a built date, through 18 May 2003 (input shaft with tapered
roller bearings).
rrectne
♦ As of transmission build date 19 May 2003, the bearings on
the input shaft have been changed. Refer to
s
⇒ “2.2 Input Shaft, From Build Date 19 May 2003“,
s o
cial p
f
page 143 . Adjusting is no longer necessary.
inform
mer
Special tools and workshop equipment required atio

om
n
c

or
n thi
te
sd
a

iv
o
pr
cum
r
fo
♦ Magnetic Plate 50 mm Dia. -VW 385/17-

en
ng
t.
yi Co
op
♦ Dial Gauge Holder -VW 387-
C py
t. rig
gh ht
yri by
♦ Punch -VW 407- cop Vo
by lksw
cted agen
Prote
♦ Thrust Pad Con. 8/65 -VW 433-
AG.

♦ Kukko Extractor 46-58 mm -21/7-
A new input shaft adjustment is required when the following com‐
ponents have been replaced:
♦ Transmission housing
♦ Clutch housing
♦ Input shaft
or the
♦ Tapered roller bearing
Adjustment overview. Refer to
⇒ “2.1 Adjustment Overview“, page 172 .
• The chosen adjusting shims for both output shafts are instal‐
led.

R32 2004 ➤
– Install the outer race/tapered roller bearing all the way into the
transmission housing without the adjusting shim.
– Install both output shafts and the input shaft into the clutch
housing and then assemble the transmission housing. Tighten
the bolts to specification, see -item 13- in the
⇒ “2.9 Transmission Housing and Shift Mechanism, through
Build Date 18 May 2003“, page 47 .
– Install the measuring device and the dial gauge in the clutch
housing.
– Rotate the input shaft before measuring so the tapered roller
bearing settles. Set the dial gauge with a 1 mm preload to “0“.
Note
Repeat this process each time a measurement is taken otherwise

the dial gauge will not go back to its start setting.
– Pull the input shaft toward the dial gauge.

– Read and make note of the play on the dial gauge (example:
0.63).
– Choose the adjusting shim thickness from the table, refer to
⇒ page 131 (example: 1.55). For the correct part numbers,
refer to the Part Catalog.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
130 Rep. Gr.35 - Gears, Shafts

R32 2004 ➤
– Remove the transmission housing and then remove the outer

race/tapered roller bearing.
46-58 mm -21/7-
– Press the tapered roller bearing outer race together with the
1.55 shim into the transmission housing.
– Install the transmission housing and tighten the new bolts to
specification, see -item 13- in the
Adjustment Shim Table
Bearing Play Adjusting Shim
Measured value (mm) Thickness (mm)
1.480 … 1.524 1.40
1.525 … 1.574 1.45
1.575 … 1.624 1.50
1.625 … 1.674 1.55
1.675 … 1.724 1.60
1.725 … 1.774 1.65
1.775 … 1.824 1.70
1.825 … 1.874 1.75
1.875 … 1.924 1.80
1.925 … 1.974 1.85
1.975 … 2.024 1.90
2.025 … 2.074 1.95
2.075 … 2.124 2.00
Bearing Play agen Adjusting Shim

AG. Volkswagen AG d
oes
lksw not
Measured value (mm) d by Vo
Thickness (mm) gu
ara
ise nte
2.125 … 2.174tho r 2.05 eo
au ra
2.175 …2.224
ss 2.10 c
ce
le
2.225 …2.274 2.15

un
pt
an
d
itte
y li
2.275 …2.324 2.20

erm
ab
ility
2.325 …2.374 2.25

ot p
wit
is n
h re
Checking the Measurement

ole,
spec
– Install the measuring device and the dial gauge.

t to the co
– Turn the input shaft so that the tapered roller bearings settle.
rrectne
– Pull the input shaft toward the dial gauge.

– Bearing play should be between 0.065 and 0.150 mm.
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
131
c by lksw
cted agen
Prote AG. 1. Description and Operation
R32 2004 ➤
1.2 Output Shaft 1st to 4th Gears, Adjusting

♦ Punch -VW 407-
♦ Installation Arbor -VW 792-
♦ Thrust Plate -2050-
(Selecting the correct adjusting shim for the output shaft)
It is necessary to adjust the output shaft if the following compo‐
nents were replaced: en AG. V
olkswagen AG
ag does
ksw not
♦ Transmission housing y Vol gu
b ara
ed nte
ris
♦ Clutch housing tho eo
au ra
c
♦ Output shaft, 1st to 4th ss
gears ce
e
nl
pt
du
♦ Output shaft tapered roller bearing an

itte
y li
erm
ab
ility
ot p

wit
, is n
h re
Requirements
hole
spec
• Remove any sealant still on the sealing surfaces of the clutch

es, in part or in w
t to the co
and transmission housings.

• Install the output shaft that is going to be measured.
rrectness of i
– Install the tapered roller bearing outer race in the transmission

housing with a 1.70 mm adjustment shim. Support the trans‐
l purpos
mission housing directly under the bearing mount using the

thrust plate -2050- .
nf
ercia
– Install the output shaft for 1st through 4th gears into the clutch
rm
m
housing.
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

R32 2004 ➤

-A and B- diagonally to specification, see -item 13- in the
Build Date 18 May 2003“, page 47 or -item 10- in the
⇒ “2.10 Transmission Housing and Shift Mechanism, from
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
– Position the measuring tools on the clutch housing and secure
d
itte
y li
them with the bolt -arrow-.
rm
ab
pe
ility
– Set the dial gauge (3 mm range) with a 1 mm preload to “0“.
ot
wit
, is n
h re
– Loosen the bolts for the clutch housing to transmission hous‐
hole
spec
ing in a diagonal sequence until the bolts clear the transmis‐
es, in part or in w
sion housing and output shaft.
t to the co
– Read the measured value on the dial indicator and note (ex‐
ample: 0.14 mm).
rrectness of i
l purpos
Note
nform
ercia
♦ The dial gauge will not display a value when the clutch housing
to transmission housing bolts are loosened. Install a 1.95 mm
m
a
or 2.20 mm adjusting shim for the measuring.
com
tion in
r
♦ For the correct adjusting shim, refer to the parts catalog.

te o
thi
s
iva
do
r
rp
c
Determining Shim Thickness
um
fo
en
ng
t.
yi
The specified bearing preload is obtained by adding a constant
Co
op py
preload figure of (0.20 mm) to the reading obtained (0.14 mm)
t. C rig
gh ht
yri
and the thickness of the shim installed (1.70 mm). p by
co Vo
by lksw
cted agen
Example Prote AG.
Inserted adjusting shim 1.70 mm

- measured value 0.14 mm
+ Preload (constant value) 0.20 mm
Adjusting shim thickness 1.76 mm
– Select the correct adjusting shim thickness according to the
table. Refer to ⇒ page 134 .
– For the correct part number, refer to the Parts Catalog.

R32 2004 ➤
– Remove the transmission housing and remove the tapered

roller bearing outer race from the transmission housing.
A - Counter-support, for example, Kukko support -22/2-
46-58 mm -21/7-
– Remove the adjusting shim (1.70 mm) from the transmission
housing.
Thickness (mm)
1.45 1.75 2.05
1.50 1.80 2.10
1.55 1.85 2.15
1.60 1.90 2.20
1.65 1.95 2.25
1.70 2.00
Tolerance variations make it possible to find the exact shim thick‐
ness required.
– Install the outer race/tapered roller bearing with the selected

adjusting shim (in the example: 1.75 mm). Support the trans‐
• The selected adjusting shim is installed.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
– Position the measuring tools on the clutch housing and secure

nl
pt
du
an
them with the bolt -arrow-.

itte
y li
erm
ab

ility
ot p
wit
, is n

h re

hole
spec

es, in part or in w
t to the co
– For a correctly selected adjustment shim, dial gauge must now

display a value of 0.15 mm to 0.25 mm.
rrectness of i
l purpos
1.3 Output Shaft, 5th, 6th and Reverse

nform
ercia
Gears, Adjusting
m
at
om
ion
c

in t
or
his
te

a
do
priv
cum
or

f
en
ng
t.
yi Co
♦ Punch -VW 407- Cop py
t. rig
gh ht
yri
♦ Thrust Pad Con. 8/65 -VW 433- p by
o Vo
by c lksw
cted agen
♦ Installation Arbor -VW 792- Prote AG.

R32 2004 ➤

It is necessary to adjust the output shaftVifolthe following compo‐
kswagen AG
nents were replaced: swa
gen AG
.
does
k not
y Vol gu
se
db ara
nte
ri
ho eo
♦ Clutch housingaut ra
c
ss
♦ Output shaft, 5th, 6th and reverse gears
ce
e
nl
pt
du
an
itte
or
y li
erm
ab
♦ Tapered roller bearing
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
Requirements
t to the co
• Remove any sealant still on the sealing surfaces on the clutch
and transmission housings.
rrectness of i
• Install the shaft that is going to be measured.
l purpos
– Install the tapered roller bearing outer race in the transmission

housing with a 1.70 mm adjustment shim. Support the trans‐
nform
ercia

m
at
om
io
– Install the output shaft for 5th, 6th and reverse gear into the
n
c
in t
or
clutch housing.
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

-A and B- diagonally to specification, see -item 13- in the

R32 2004 ➤
– Install the measuring tools. Place several washers on the

clutch housing (total thickness: 8 mm) for the bolt -arrow- being
used to secure the installation arbor -VW 792- .
– Read the measured value on the dial indicator and note (ex‐
ample: 0.27 mm). n AG. Volkswagen A age G do
ksw es n
y Vol ot g
ua
b
ed ran
Note horis tee
t or
s au ac
The dial gauge will not display
s
a value when the clutch housing/
ce
le
transmission housing bolts are loosened. Install a 1.95 mm or

un
pt
an
d
2.20 mm adjusting shim for the measuring. Refer to the parts cat‐
itte
y li
rm
alog.
ab
pe
ility
ot
wit
, is n
Determining Shim Thickness
h re
hole
spec
The specified bearing preload is obtained by adding a constant
es, in part or in w
preload figure of (0.20 mm) to the reading obtained (0.27 mm)
t to the co
and the thickness of the shim installed (1.70 mm).
Example
rrectness of i
Inserted adjusting shim 1.70 mm
l purpos
- measured value 0.27 mm

+ Preload (constant) 0.20 mm
nform
ercia
Adjusting shim thickness 1.63 mm

m
a
com
tio
– For the correct part number, refer to the Parts Catalog.
n in
r
te o
thi
– Select the correct adjusting shim thickness according to the

s
iva
do
table. Refer to ⇒ page 136 .

r
rp
cum
fo
en
ng
t.
yi
– Remove the transmission housing and remove the tapered
Co
op py
roller bearing outer race from the transmission housing.
t. C rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
46-58 mm -21/7-
– Remove the adjusting shim (1.70 mm) from the transmission
housing.
Thickness (mm)
1.50 1.80 2.10
1.55 1.85 2.15
1.60 1.90 2.20
1.65 1.95 2.25
1.70 2.00
1.75 2.05
ness required.

R32 2004 ➤
– Install the outer race/tapered roller bearing with the selected

adjusting shim (in the example: 1.65 mm) Support the trans‐
• The selected adjusting shim is installed.
– Install the measuring tools. Place several washers on the

clutch housing (total thickness: 8 mm) for the bolt -arrow- being
used to secure the installation arbor -VW 792- .
– For a correctly selected adjustment shim, dial gauge must now
display a value of 0.15 mm to 0.25 mm.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

R32 2004 ➤

⇒ “2.1 Input Shaft, Through Build Date 18 May 2003“,
page 138
⇒ “2.2 Input Shaft, From Build Date 19 May 2003“, page 143
⇒ “2.3 Output Shaft, 1st to 4th Gears“, page 147
⇒ “2.4 Output Shaft, 5th, 6th and Reverse Gears“, page 157
2.1 Input Shaft, Through Build Date 18 May

2003
♦ Punch -VW 407-
♦ Punch -VW 408 A- AG. Volkswagen AG d
agen oes
lksw not
♦ Thrust Disc -VW 412- by Vo gu
ara
d
ise nte
♦ Tube 37 mm Dia. -VW 416 B- uthor eo
a ra
s c
♦ Thrust Pad Con. 8/65 -VW 433- s
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
♦ Tapered Roller Bearing Puller -V.A.G 1582-
, is n
h re
hole
♦ Grip -V.A.G 1582/7-
spec
es, in part or in w

♦ Kukko Separating Tool 22-115 mm -17/2- t to the co
rrectness of i
l purpos
♦ Thrust Piece -40-105-

♦ Mounting Universal Joint -41-501-
nform
ercia
♦ Press Tube -2040-

m
a
com

ion in
r
te o
♦ Pressure Washer -3074-

thi
s
iva
do
r
♦ Thrust Piece -3161-

rp
cum
fo
en
ng
t.
yi Co
op py
Note
t. C rig
gh ht
pyri by
Vo
co lksw
by
♦ The input shaft must be adjusted because the position of the cted agen
Prote AG.
tapered roller bearing is affected when parts are replaced. Pay
attention to the adjustment overview. Refer to
♦ Replace both tapered roller bearings together.

R32 2004 ➤
2 - Adjusting Shim
❑ Determining the thick‐
ness, refer to
⇒ “1.1 Input Shaft Ad‐ AG. Volkswagen AG d
agen
justing, Through Build Volksw
oes
not
gu
Date 18 May 2003“, d by ara
page 129 . rise nte
tho eo
au ra
3 - Outer Race/Tapered Roller ss c
ce
e
Bearing
nl
pt
du
an
itte
y li
erm
⇒ page 140 .
ab
ility
ot p
wit
, is n
⇒ page 140 .
h re
hole
spec
4 - Lock Ring
es, in part or in w
❑ Determine replacement
t to the co
when replacing the ta‐
pered roller bearing
-item 5- and input shaft
rrectness of i
-item 8-. Refer to
l purpos
⇒ page 142 .
5 - Inner Race/Tapered Roller
nf
ercia
Bearing
orm
m
atio
m
⇒ page 141 .
o
n in
or c
thi
te
sd
⇒ page 142 .
iva
o
r
rp
cu
6 - 5th Gear
o
m
f
en
ng
t.
yi
Co
Cop py
⇒ page 140 .
t. rig
gh ht
yri by
❑ Installing, refer to cop Vo
by lksw
cted
⇒ page 142 .
agen
Prote AG.
7 - 3rd, 4th and 6th Gear

⇒ page 141 .
8 - Input Shaft
❑ Adjusting, refer to ⇒ “1.1 Input Shaft Adjusting, Through Build Date 18 May 2003“, page 129 .
9 - Inner Race/Tapered Roller Bearing
❑ Secured by the securing plate and bolt as of build date 06 April 2000. Refer to ⇒ page 143 .
❑ Bolt - 12 Nm
❑ Always replace
11 - Clutch Housing
❑ Beginning with build date 06 April 2002, the securing plate has an additional threaded hole and notch
for securing the outer race/tapered roller bearing -item 10- for the input shaft.

R32 2004 ➤ . Volkswagen AG
gen AG
Manual Transmission - Edition
Volk01.2012
swa does
not
by gu
ara
ed nte
Transmission Housing oris
Outer Race/Tapered Roller Bearing, Re‐ eo
th
moving ss
au ra
c
ce
e
nl
pt
du
an
itte
y li
B - Internal puller 46 to 58 mm, for example, Kukko extractor erm
ab
46-58 mm -21/7-
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
Transmission Housing Outer Race/Tapered Roller Bearing, In‐
l purpos
stalling
– Support the transmission housing directly beneath the bearing
nf
ercia
mount using the thrust plate -2050- .
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Inner Race/Tapered Roller Bearing, Removing Prote AG.
-A- Vice jaw protectors

– Remove the lock ring beforehand.
– Position the thrust piece -3161- and the thrust piece -40-105-
on the input shaft before installing the tapered roller bearing
puller -V.A.G 1582- and the grip -V.A.G 1582/7- .
5th Gear, Removing

A - Separating tool 22 to 115 mm, for example, Kukko separating
tool 22-115 mm -17/2-

R32 2004 ➤
3rd, 4th and 6th Gear, Removing

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
Inner Race/Tapered Roller Bearing, Removing
tool 22-115 mm -17/2-
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
3rd, 4th and 6th Gear, Installing

t.
yi Co
Cop py
– Heat the gear to approximately 100 °C (212 °F).
t. rig
gh ht
pyri by
Vo
o
– Install the gear quickly so that no heat transfers onto the input by c lksw
cted agen
shaft.
Prote AG.
Inner Race/Tapered Roller Bearing, Installing

R32 2004 ➤
5th Gear, Installing

– Choose the correct lock ring, refer to ⇒ page 142 and install
it.
Determining the Lock Ring

olksw
– Choose and install the thickest lock
swa
ring
gen Athat
G. V will afit.
gen AG
does
olk not
V
– Select the lock ring according d by to the table. For the correct part guar
e an
numbers, refer to the part ris
tho catalog.
tee
u or
a ac
Available Lock Rings ss
ce
e
nl
pt
du
Thickness (mm)
an
itte
y li
erm
ab
1.79 1.89 1.98

ility
ot p
1.83 1.92
wit
, is n
h re
1.86 1.95
hole
spec
es, in part or in w
t to the co
Clutch Housing Outer Race/Tapered Roller Bearing, Removing

rrectness of i

46-58 mm -21/7-
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

R32 2004 ➤
Outer Race/Tapered Roller Bearing in Clutch Housing, Installed

Position
From build date 06 April 2000
The notches on the outer race/tapered roller bearing -arrow A-
and the clutch housing -arrow B- for the securing plate for the
( ⇒ page 143 ) must align.
Outer Race/Tapered Roller Bearing, Installing, From Build Date

06 April 2000
– Make sure the securing plate -A- can be installed into the
notch.
The securing plate can be installed and tightened only after in‐
stalling the input shaft.
2.2 Input Shaft, From Build Date 19 May

2003
olkswagen AG
♦ Thrust Plate -VW s402-
wage
n AG. V does
k not
Vol gu
♦ Punch -VW ed407-
by ara
nte
ris
ho eo
♦ ThrustautDisc -VW 412- ra
c
ss
ce
le
un
pt
an
d
itte

y li
erm
ab

ility
ot p
wit
is n
♦ Locking Pin -30–505-

h re
ole,
spec

t to the co

rrectne

ss o
cial p
♦ Kukko Puller 65-160 mm -18/1-

inform
mer

atio
om
n
c
i
or
n thi
e
Note
t
sd
iva
o
pr
cum
r
fo
Install all input shaft bearings using transmission fluid.

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

R32 2004 ➤
1 - Lock Ring
2 - Washer
❑ Outer diameter = 78.6
mm.
❑ May only be implemen‐
ted with changed trans‐
mission housings. (from
build date 10 April wagen AG. Volkswagen AG doe
2006). Refer to yV
olks s no
t gu
⇒ page 145 sed.b ara
nte
ori
❑ Allocateaut the parts using
h eo
ra
the Parts
ss Catalog. c
ce
e
nl
pt
du
an
itte
y li
❑ From build date 10 April
erm
ab
2006, adapted in area of
ility
ot p
grooved ball bearing
wit
, is n
-item 6-, the washers
h re
hole
-items 2 and 4-. Refer to
spec
⇒ page 145 and to
es, in part or in w
t to the co
⇒ page 145 .
the Parts Catalog.
rrectness of i
4 - Washer
l purpos
❑ Outer diameter = 85 mm
❑ May only be implemen‐
nform
ercia
ted with changed trans‐

mission housings. (from
m
at
om
build date 10 April

ion
c
2006). Refer to
in t
or
his
e
⇒ page 145 .
at
do
riv

p
cum
or
the Parts Catalog.

f
en
ng
t.
yi Co
op
5 - Lock Ring C py
t. rig
gh ht
yri
❑ Determine replacement p by
co Vo
when replacing the
by lksw
cted agen
Prote
grooved ball bearing -item 6- and the input shaft -item 8-. Refer to ⇒ page 146 .
AG.
6 - Grooved Ball Bearing

❑ Always replace.
7 - 5th Gear
❑ Installed position: The surrounding groove -arrow- faces the grooved ball bearing -item 6-.
8 - Input Shaft
❑ With the 3rd, 4th and 6th gear.
9 - Roller Bearing
❑ With a lock ring.
❑ Installed position: The lock ring inside the bearing faces the input shaft
10 - Clutch Housing

R32 2004 ➤
Changed Area Above Grooved Ball Bearing, From Build Date 10

April 2006
So that the washer (-item 2- in the overview above) can be re‐
moved, the area above the grooved ball bearing (-item 6- in the
overview above) is deeper
Area Above Grooved Ball Bearing Dimension “a“
From build date 10 April 2006 10.7 mm
Through build date 09 April 2006 10 mm
Changed Grooved Ball Bearing Seat, From Build Date 10 April

2006
The bearing seat for the grooved ball bearing (see -item 6- in the
overview above) is slightly deeper for the washer (see -item 4- in
the overview above) -arrow-. swa
gen AG
. Volkswagen AG
does
k not
Vol gu
d by ara
e nte
ris
utho eo
ra
a c
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
Grooved Ball Bearing, Removing
h re
hole
spec
– Remove the lock ring from the input shaft beforehand.
es, in part or in w
t to the co
– Mount the thrust pad 16.5/28 mm dia. -VW 431- and the thrust
piece -40-105- on the input shaft before mounting the puller.
– Position the separating tool -B- in the surrounding groove in‐
rrectness of i
side the bearing for the lock ring.

l purpos
A - Puller, for example, Kukko puller 65-160 mm -18/1-

B - Separating tool 12 to 75 mm, for example, Kukko separating
nform
ercia
tool 12-75 mm -17/1-

m
at
om
ion
c
in t
or
5th Gear, Removing

his
ate
do
riv

p
cum
or
tool 22-115 mm -17/2-

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

R32 2004 ➤
5th Gear, Installing

The groove -arrow- on the gear must face up.
Grooved Ball Bearing, Installing

The groove for the lock ring faces up -arrow A- and the collar
-arrow B- must face the 5th gear.
– Choose the correct lock ring ⇒ page 146 and install.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
– Insert a 1.86 mm lock ring -A- into the groove in the input shaft
t to the co
and press it upward.
– Measure the gap between the grooved ball bearing -B- and
rrectness of i
the installed lock ring -A- with a feeler gauge -C-.
l purpos
– Remove the lock ring used for the measurement.

– Select the lock ring according to the table.
nform
mercia
at
om
Note
on
c
in t
or
his
te
For the correct lock rings, refer to the parts catalog.

a
do
priv
cum
for
en
g
The following locking rings are available:

n
t.
yi Co
Cop py
.
Measured Value Lock Ring Thick‐ Axial Play (mm)
t rig
gh ht
yri by
(mm) ness (mm) cop Vo
by lksw
cted agen
Prote
0.01 … 0.05 1.86 0.01 … 0.05
AG.
0.05 … 0.07 1.89 0.01 … 0.05

0.07 … 0.10 1.92 0.01 …0.05
0.10 … 0.13 1.95 0.01 … 0.05
0.13 … 0.16 1.98 0.01 … 0.05

R32 2004 ➤
Clutch Housing Roller Bearing, Removing

and remove it.
B - Internal puller 30 to 37 mm, for example, Kukko
n AG. Volkswagextractor
en AG
30-37 mm -21/5- lkswage does
not
Vo gu
by ara
ed nte
oris eo
th
au ra
c
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
Clutch Housing Roller Bearing, Installing
ot p
wit
, is n
h re
hole
and install it.
spec
es, in part or in w
– Remove the pliers before the roller bearing gets into its instal‐
t to the co
led position. The lock ring must lock into the groove on the
clutch housing.
rrectness of i
l purpos
nf
ercia
orm
m
atio
m
2.3 Output Shaft, 1st to 4th Gears

o
n in
or c
thi
te

sd
iva
o
r
rp
cu

o
m
f
en
ng
t.
yi Co
♦ Thrust Plate -VW 402- t. Cop py
rig
gh ht
yri
♦ Punch -VW 407- p by
co Vo
by lksw
cted agen
♦ Punch -VW 408 A- Prote AG.

♦ Tube 60 mm Dia. -VW 415 A-
♦ Thrust Pad -VW 512-
♦ Tube 42 mm Dia. -VW 516-
♦ Sleeve -VW 519-
♦ Sleeve -40-20-
♦ Sleeve -40-21-

R32 2004 ➤
♦ Spacers -VW 540/1 B-

gen AG
. Volkswagen AG
wa does
olks not
♦ Grip -V.A.G 1582/7- byV gu
ara
ed nte
ris
♦ Kukko Extractor 46-58tho mm -21/7- eo
au ra
c
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
Note
t to the co
♦ Adjust the output shaft if it or the tapered roller bearing are
being replaced. Refer to
rrectness of i
l purpos
nf
ercia
orm
m
1 - Clutch Housing
atio
om
n in
c

or
thi
te
sd
a
3 - Concave Washer
iv
o
r
rp
cu
o
m
f
en
ng
⇒ page 150 .
t.
yi Co
op py
❑ Installing, refer to t. C rig
gh ht
⇒ page 151 . yri
p by
co Vo
by lksw
cted
4 - Outer Race/Tapered Roller
agen
Prote AG.
Bearing
⇒ page 151 .
⇒ page 151 .
Bearing
⇒ page 151 .
⇒ page 156 .
6 - Output Shaft
❑ For 1st through 4th
gear.
❑ Adjusting, refer to
⇒ “1.2 Output Shaft 1st
to 4th Gears, Adjusting“,
page 132 .
7 - Needle Bearing
❑ For 2nd gear.
8 - 2nd Gear
9 - Synchronizer Ring
❑ (Inner race for 2nd gear)
❑ Checking for wear, refer to ⇒ page 153 .
❑ Check for scoring.

R32 2004 ➤
10 - 2nd Gear Outer Race

❑ Install on the synchronizer ring -item 9-.
❑ Replace if there are grooves or scoring.
11 - 2nd Gear Synchronizer Ring
12 - Synchronizer Hub with Operating Sleeve, 1st and 2nd Gears
❑ After removing the lock ring -item 13-, remove with the 2nd gear. Refer to ⇒ page 152 .
❑ Disassembling, refer to ⇒ page 153 .
❑ Assembling, refer to ⇒ page 153 .
❑ Installed position, refer to ⇒ page 154
13 - Lock Ring
Volkswa
14 - Synchronizer Ring for 1st Gear agen
AG. gen AG
does
olksw not
❑ Checking for wear, refer to ⇒ page 153 . edb
y V gu
ara
is nte
❑ Insert it so that the holes engage into the engagement
ut
hor
pieces of the synchronizer hub with operating
eo
sleeve -item 12-. ss a ra
c
ce
e
15 - 1st Gear Outer Race

nl
pt
du
an
itte
❑ Install into the synchronizer ring -item 14-, installed position. Refer to ⇒ page 154 .
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
❑ (Inner race for 1st gear)
spec
es, in part or in w
t to the co
rrectness of i
17 - Needle Bearing
l purpos
❑ For 1st gear.

18 - 1st Gear
nform
ercia

m
at
om
io
19 - Thrust Washer
n
c
in t
or
❑ For 1st and 4th gears. his

ate
do
riv
❑ The tabs on the thrust washer must fit into the hole in the output shaft.
p
cum
for
en
g
20 - Washer
n
t.
yi Co
op
❑ Holds the thrust washer -item 19- on the output shaft.
C py
t. rig
gh ht
yri by
21 - Needle Bearing
op Vo
by c lksw
cted agen
❑ For 4th gear. Prote AG.
22 - 4th Gear
23 - 4th Gear Synchronizer Ring
24 - Synchronizer Hub with Operating Sleeve, 3rd and 4th Gears
❑ After removing the lock ring -item 25- remove over the 4th gear -item 22-.
❑ Disassembling, refer to ⇒ page 153 .
❑ Assembling, refer to ⇒ page 153 and to ⇒ page 154 .
25 - Lock Ring

R32 2004 ➤
AG. Volkswagen AG d
agen oes
lksw not
26 - Synchronizer Ring for 3rd Gear d by
Vo gu
ara
e nte
❑ Checking for wear, refer to ⇒ page 153tho.ris
eo
au ra
27 - 3rd Gear Outer Race ss c
ce
le
un
❑ Install into the synchronizer ring -item 26-, installed position, refer to ⇒ page 154 .
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
❑ (3rd gear inner race)
h re
ole,
spec
t to the co
29 - Needle Bearing
rrectne
❑ For 3rd gear.
ss
30 - 3rd Gear
o
cial p
f i
nform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
c
32 - Lock Ring
um
r
fo
en
ng
❑ Select the correct one when replacing the tapered roller bearing -item 31- and the output shaft -item 6-.
t.
yi Co
op
Refer to ⇒ page 156 . C py
t. rig
gh ht
yri
p by
o Vo
by c lksw
cted
agen
Prote AG.

34 - Adjusting Shim
❑ Determining thickness, refer to ⇒ “1.2 Output Shaft 1st to 4th Gears, Adjusting“, page 132 .
Concave Washer -A- from the Output Shaft, Removing

R32 2004 ➤
Concave Washer to the Output Shaft, Installing

-a- = 2 mm
Outer Race/Tapered Roller Bearing, Removing

56-70 mm -21/8-
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
s c
Clutch Housing Outer Race/Tapered Roller Bearing, Installing s
ce
le
un
pt
– Support the clutch housing using the sleeve -40-20- directly

an
d
itte
y li
under the bearing mount.

erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness

o
cial p
f inform

mer
atio
– Mount the thrust pad 16.5/28 mm dia. -VW 431- in the output
om
shaft and lay the thrust piece -40-105- on top of it before in‐
c
i
or
stalling the puller.

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

R32 2004 ➤
3rd and 4th Gear Synchronizer Hub Operating Sleeve over 4th
Gear, Removing
A - Puller, for example, Kukko puller 80-210 mm -18/2-
. Volkswagen AG
gen AG does
B - Separating tool 22 to 115 mm, for example, VKukko
olks
wa separating not
tool 22-115 mm -17/2- ed by gu
ara
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
Locking Collar and Synchronizer Hub for 1st and 2nd Gear, Re‐
wit
is n
moving
h re
ole,
spec
After removing the lock ring, remove the selector gear for 2nd
gear and the synchronizer hub operating sleeve.
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
a

iv
o
pr
c
tool 22-115 mm -17/2-
um
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

R32 2004 ➤
Checking the Inner Race for 1st, 2nd and 3rd Gear for Wear
– Press the inner race onto the taper on the gear and measure
the gap dimension -a- with a feeler gauge.
Gap Dimension Installed Dimension Wear Limit
“a“
1st, 2nd and 3rd 0.75 to 1.25 mm 0.3 mm
gear
Checking the 1st, 2nd and 3rd Gear Synchronizer Rings for Wear
– Install the synchronizer ring, outer race and inner race onto
the taper of the selector gear and then measure the gap di‐
mension -a- with a feeler gauge.
-a-
1st, 2nd and 3rd 1.2
swato
gen1.8
AG.mm
Volkswagen AG
doe0.5
s no
mm
gear byV
olk t gu
d a ran
e
ris tee
utho or
a ac
ss
ce
le
un
pt
an
d
2nd Gear Outer Race, Inner Race and Synchronizer Ring, Instal‐
itte
y li
rm
led Position
ab
pe
ility
ot
– Install the inner race -A- onto the 2nd gear.

wit
, is n
h re
The angled tabs -arrows 1- face the outer race -B-.

hole
spec
es, in part or in w
– Install the outer race -B-.

t to the co
The tabs -arrows 2- must lock into the retainers -arrows 3- in the
gear.
rrectness of i
– Install the synchronizer ring -C-.

l purpos
The retainers -arrows 4- lock in the tabs -arrows 1- on the inner

race -A-.
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
op
Synchronizer Hub with Operating Sleeve for 1st, 2nd, 3rd and 4th
C py
t. rig
Gears, Disassembling and Assembling
gh ht
pyri by
Vo
co lksw
by
1- Spring cted agen
Prote AG.
2- Locking pieces
3- Locking collar
4- Synchronizer hub
– Slide the locking collar over the synchronizer hub.
The notches for the locking pieces on the synchronizer hub with
operating sleeve must line up with each other.

R32 2004 ➤
Assembly: Synchronizer Hub with Operating Sleeve for 1st, 2nd,

3rd and 4th Gears
The locking collar is pushed over the synchronizer hub.
– Install the locking pieces and springs offset by 120°. The an‐
gled end of the spring must engage into the hollow locking
piece.
Installed Position: Synchronizer Hub with Operating Sleeve for

1st and 2nd Gears
The identification groove -arrow 1- and the narrow collar
-arrow 2- on the synchronizer hub face 1st gear.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
Synchronizer Hub with Operating
orise
Sleeve for 1st and 2nd Gears, nte
eo
Installing aut
h
ra
ss c
– Install the lock ring.
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectne
Outer Race for 1st and 3rd Gear, Installed Position

The tabs -arrows- face the synchronizer hub with operating sleeve
ss o
-A-.
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

R32 2004 ➤
Synchronizer Ring -A- (Inner Race for 1st and 3rd Gear), Installed
Position
The tabs -arrows 1- engage into the holes -arrows 2- inside the
synchronizer ring -B-.
1st and 3rd Gear, Installed Position

The higher collar -A- points to 2nd and 4th gear -B-. The notches
in the collar -arrows- lock into the tabs on the outer race, refer to
⇒ page 154 .
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
Locking Collar/Synchronizer Hub for 3rd and 4th Gears, Installed
ot p
wit
Position
is n
h re
ole,
The wider collar on the synchronizer hub -arrow- faces 3rd gear.
spec
t to the co
rrectness o
cial p
f inform
mer
atio
m
Synchronizer Hub with Operating Sleeve for 3rd and 4th Gears
o
n
c
i
or
n thi
e

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

R32 2004 ➤
Checking the 4th Gear Synchronizer Ring for Wear

– Press the synchronizer ring onto the taper of the gear and
measure the gap dimension -a- with a feeler gauge.
-a-
4th gear 1.0 to 1.7 mm 0.5 mm

– Choose the correct lock ring, refer to ⇒ page 156 and install.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
Determining the Lock Ring s au ra
c
s
ce
e
– Choose and install the thickest lock ring that will fit.
nl
pt
du
an
itte
– Select the lock ring according to the table. For the correct part
y li
erm
ab
numbers, refer to the parts catalog
ility
ot p
wit
Available Lock Rings
, is n
h re
hole
Thickness (mm)
spec
es, in part or in w
1.79 1.89 1.98 t to the co

1.83 1.92
1.86 1.95
rrectness of i
l purpos
Transmission Housing Outer Race/Tapered Roller Bearing, Re‐

moving
nform
ercia

m
at
om

ion
c
46-58 mm -21/7-
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

R32 2004 ➤
Transmission Housing Outer Race/Tapered Roller Bearing, In‐

stalling
– Install the adjusting shim under the outer race.
– Support the transmission housing under the bearing mount
using the thrust plate -2050- .
2.4 Output Shaft, 5th, 6th and Reverse

Gears
♦ Punch -VW 407-
♦ Punch -VW 408 A-
olkswagen AG
en AG. V
olks
wag does
not
byV gu
ara
♦ Tube 60 mm orisDia. -VW 415 A-
ed
nte
th eo
u ra
♦ HoldingssPlate
a -VW 309- c
ce
e

nl
pt
du
an
itte
y li

erm
ab
ility
ot p

wit
, is n
h re
♦ Support Channels -VW 457-

hole
spec

es, in part or in w
t to the co

rrectness of i

l purpos

nform
ercia
♦ Sleeve -VW 519-

m
♦ Thrust Pad -30-11-

at
om
ion
c

in t
or
his
ate
♦ Sleeve -40-20-
do
priv
cum
or

f
en
ng
t.
yi Co
op
♦ Tube -3296- C py
t. rig
gh ht
yri by
♦ Tapered Roller Bearing Puller -V.A.G 1582- cop Vo
by lksw
cted agen
Prote
♦ Attachment to VAG 1582 -V.A.G 1582/4-
AG.
♦ Grip -V.A.G 1582/7-


R32 2004 ➤
Note
♦ Adjust the output shaft if it or the tapered roller bearing are

being replaced. Refer to
⇒ “1.3 Output Shaft, 5th, 6th and Reverse Gears, Adjusting“,
page 134 .
1 - Clutch Housing
2 - Washer
❑ Always 0.65 mm thick.
3 - Outer Race/Tapered Roller
Bearing
⇒ page 159 .
⇒ page 160 .
Bearing
⇒ page 160 . swage
es n
olk ot g
❑ Installing, refer to d byV ua
ran
⇒ page 163 . o
ir se tee
th or
u
5 - Output Shaft ss
a ac
ce
e
❑ For 5th, 6th and reverse

nl
pt
du
an
gears.
itte
y li
erm
ab
❑ Adjusting, refer to
ility
ot p
⇒ “1.3 Output Shaft, 5th,
wit
6th and Reverse Gears,
, is n
h re
Adjusting“, page 134 .
hole
spec
6 - Reverse Gear Synchronizer
es, in part or in w
t to the co
Hub
⇒ page 161 .
rrectness of i
l purpos
to ⇒ page 161 .
⇒ page 161 .
nform
mercia
7 - Lock Ring
at
om
io
❑ Always replace.
n
c
in t
or
his
e
8 - Reverse Gear Locking Collar

at
do
priv
❑ With a synchronizer ring.

um
for
en
ng
t.
yi
9 - Needle Bearing
Co
Cop py
.
❑ For the reverse gear.
t rig
gh ht
pyri by
Vo
co
10 - Reverse Gear
by lksw
cted agen
Prote AG.
11 - Sleeve
❑ Remove over the reverse gear, refer to ⇒ page 160 .
❑ Installed position: The wider sleeve collar faces the reverse gear.
12 - Lock Ring
❑ Always replace.

R32 2004 ➤
13 - Needle Bearing
❑ For 6th gear.
14 - 6th Gear
15 - Synchronizer Ring for 6th Gear
16 - Synchronizer Hub with Operating Sleeve, 5th and 6th Gears
❑ After removing the lock ring -item 17-, remove AG. Vowith
lkswathe 6th
gen AG dogear. Refer to ⇒ page 160 .
agen es n
ksw
❑ Disassembling, refer to ⇒ pageby162 Vo l . ot g
ua
ed ran
❑ Assembling, refer to ⇒ page horis 162 . tee
ut or
❑ Installing, refer to ⇒ page
ss
a 163 . ac
ce
le
17 - Lock Ring
un
pt
an
d
itte
y li
18 - Needle Bearing
rm
ab
pe
ility
❑ For 5th gear.
ot
wit
, is n
19 - 5th Gear Synchronizer Ring
h re
hole
spec
es, in part or in w
t to the co
20 - 5th Gear
rrectness of i
l purpos
22 - Lock Ring
nform
ercia
❑ Select the correct one when replacing the tapered roller bearing -item 21- and the output shaft -item 5-.
Refer to ⇒ page 163 .
m
a
com
tio
n in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
g
24 - Adjusting Shim
n
t.
yi Co
op py
❑ Determining thickness, refer to ⇒ “1.3 Output Shaft, 5th, 6th and Reverse Gears, Adjusting“, page 134 .
. C rig
ht ht
rig by
py
co Vo
by lksw
cted agen
Prote AG.
26 - Spring
27 - Locking Collar
28 - Synchronizer Hub
29 - Locking Pieces (quantity: 3)
Outer Race/Tapered Roller Bearing, Removing

46-58 mm -21/7-
Note
Check the washer for damage after removing it and replace if

necessary.

R32 2004 ➤
Clutch Housing Outer Race/Tapered Roller Bearing, Installing

– Place the washer under the outer race.
– Support the clutch housing using the sleeve -40-20- directly
under the bearing mount.

wage
e ks s no
Vol t gu
ed
by ara
is nte
or eo
– Mount the thrust pad 16.5/28
au mm dia. -VW 431- and the thrust
th ra
piece -40-105- on the output
ss shaft before mounting the puller. c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
5th and 6th Gear Synchronizer Hub with Operating Sleeve and
6th Gear, Removing
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
op
Sleeve -A- over the Reverse Gear, Removing
C py
t. rig
gh ht
yri by
– Remove the lock ring beforehand. cop Vo
by lksw
cted agen
Prote AG.

R32 2004 ➤
Reverse Gear Synchronizer Hub, Removing

tool 22-115 mm -17/2-
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
– Mount the thrust pad -30-11- on the output shaft before re‐
wit
is n
moving the puller.
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
Reverse Gear Synchronizer Hub, Installed Position
atio
om
n
c
The stop -arrow A- on the reverse gear locking collar faces the
i
or
n thi
splines on the output shaft -arrow B-.
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Reverse Gear Synchronizer Hub, Installing


R32 2004 ➤
Sleeve -A-, Installing

Installed position: The wide collar points toward reverse gear se‐
lector gear.
Checking 5th and 6th Gear Synchronizing Ring for Wear

– Press the synchronizer ring onto the taper of the gear and
measure the gap dimension -a- with a feeler ggauge.
en AG. V
olkswagen AG
d wa oes
olks not
Gap Dimension Installed Dimension
ed
by
V
Wear Limit gu
ara
-a- ho
ris nte
eo
aut ra
5th and 6th gear 1.0 to 1.7ss mm 0.5 mm c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
Synchronizer Hub with Operating Sleeve for 5th and 6th Gears,
es, in part or in w
Disassembling and Assembling
t to the co
1- Spring
2- Locking piece
rrectness of i
3- Locking collar
l purpos
4- Synchronizer hub
nform
ercia
– Slide the locking collar over the synchronizer hub.

m
at
om
The notches for the locking pieces on the synchronizer hub with
ion
c
operating sleeve must line up with each other.

in t
or
his
ate
do
priv
um
for
en
Assembling
ng
t.
yi Co
op py
The locking collar is pushed over the synchronizer hub. t. C rig
gh ht
pyri by
– Install the locking pieces and springs offset by 120°. The an‐
o Vo
by c lksw
cted agen
gled end of the spring must engage into the hollow locking Prote AG.
piece.

lkswage es n
o ot g
byV ua
d ran
ho
ir se R32
tee 2004 ➤
t or
au Manual Transmission - Edition 01.2012
ac
ss
ce
e
nl
pt
du
an
itte
Installing
y li
erm
ab
On some locking collars, there is a chamfer on the outer diameter
ility
ot p
wit
, is n
Installed position: The chamfer on the outer diameter of the lock‐
h re
hole
ing collar faces toward the 5th gear selector gear
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
– Choose the correct locking ring ⇒ page 163 and install it.
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

The following lock rings are available:
– Select the lock ring according to the table. For the correct part
numbers, refer to the parts catalog.
Available Lock Rings
Thickness (mm)
1.79 1.89 1.98
1.83 1.92
1.86 1.95

R32 2004 ➤
Transmission Housing Outer Race/Tapered Roller Bearing, Re‐

moving
46-58 mm -21/7-
lkswage es n
o ot g
byV ua
d ran
ir se tee
ho
Transmission Housing au Outer Race/Tapered Roller Bearing, In‐
t or
ac
stalling ss
ce
le
un
pt
– Support the transmission housing under the bearing mount
an
d
itte
y li
using the thrust plate -2050- .
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

R32 2004 ➤
3 Special Tools
♦ Torque Wrench (5-50 Nm) -V.A.G 1331-gen AG. Volkswagen AG d
a oes
ksw not
♦ Installation Arbor -VW 792- Vol gu
d by ara
e nte
ris
♦ Thrust Plate -2050- tho eo
au ra
c
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos

♦ Locking Pin -30–505-
nf
ercia
o
rm
m
atio
m

o
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
♦ Sleeve -VW 519-
gh ht
pyri by
Vo
o
by c lksw
♦ Slide Hammer-Complete Set -VW 771- Prote
cted AG.
agen
♦ Sleeve -40-20-
♦ Sleeve -40-21-
♦ Spacers -VW 540/1 B-
♦ Tube -3296-

R32 2004 ➤
♦ Grip -V.A.G 1582/7-
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
♦ -1- Kukko Extractor 46-58 mm -21/7-
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
♦ -2- Kukko Puller 80-210 mm -18/2-
hole
spec
♦ -2- Kukko Puller 65-160 mm -18/1-
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

R32 2004 ➤

♦ Transmission Support -VW
AG. Volkswagen AG d
agen
353- Volksw
oes
not
g
y ua
db ran
♦ Magneticris Plate 50 mm Dia.
e
tee
ho
-VWau385/17-
t or
ac
ss
♦ Dial Gauge Holder -VW
ce
e
nl
pt
387-
du
an
itte
y li
erm
♦ Punch -VW 407-
ab
ility
ot p
♦ Thrust Pad Con. 8/65 -VW
wit
, is n
433-
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

R32 2004 ➤
♦ Thrust Piece -40 - 105-

♦ Mounting Universal Joint
-41-501-
♦ Pressure Washer -3074-
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

R32 2004 ➤
39 – Final Drive, Differential

⇒ “1.1 Haldex Clutch Function, Checking“, page 169
⇒ “1.2 Haldex Clutch Oil Level, Checking and Filling“, page 169
⇒ “1.3 Haldex Clutch Oil Filter, Changing“, page 171
page 171
1.1 Haldex Clutch Function, Checking

– Drive the vehicle with the front wheels on a dynamometer.
WARNING
Keep the area in front of the vehicle open. Be careful when

testing to prevent damage.
– Shift into 1st gear and accelerate slowly.

• If the vehicle doeswanot
gentry
AG.to
Vodrive off
lkswagen Aof
G dthe
oes dynamometer at
1500 RPM, thenyV
olksthe Haldex clutch is faulty. not
g
b ua
ed ran
oris tee
h
ut or
sNote
sa ac
ce
e
nl
pt
du
♦ The moving front wheels and the stationary rear wheels lock
an
itte
y li
the Haldex clutch. This means the rear wheels are being driv‐
erm
ab
en as well.
ility
ot p
wit
♦ Only at a speed, which is slightly higher than the idle speed

, is n
h re
when 1st gear is engaged, can the Haldex clutch compensate

hole
spec
for the difference in speeds without locking up.

es, in part or in w
t to the co
1.2 Haldex Clutch Oil Level, Checking and

Filling
rrectness of i
Checking
l purpos

nf
ercia

rm
m
atio
m
♦ Vehicle Diagnostic, Testing, and Information System. -VAS

o
n in
c
5051-
or
thi
te
sd
a

iv
o
r
rp
cu
o

f
en
ng
t.
yi Co
op
– Connect the vehicle diagnostic tester. C py
t. rig
gh ht
yri
– Select “Suspension (Repair Group 01; 40 ... 49)“ on the dis‐
p by
co Vo
by lksw
play. Prote
cted AG.
agen
– Select “AWD with Haldex clutch“.

– Select “01 - OBD-capable systems“.
– Select “AWD Haldex“.
– Select “Electrical Components“.
– Select “oil temperature“.

R32 2004 ➤
• The oil temperature must be between 20 - 40 °C (68 - 104 °F).

• The oil temperature can be reached by driving the vehicle for
awhile.
– Remove the oil fill plug -arrow-.
The oil level is correct if the Haldex clutch is filled to the lower
edge of the fill hole or up to 3 mm below the fill hole.
– Install and tighten the plug -arrow- to specification. Refer to
⇒ “2.4 Pinion Housing Overview“, page 178 .
– If the oil level is not correct, then change the oil. Refer to
⇒ “1.3 Haldex Clutch Oil Filter, Changing“, page 171 .
Filling

♦ Cartridge Gun -V.A.G 1628-
5051-
♦ Diagnostic Cable, 3 m with Power Supply -VAS 5051/1- or Di‐
agnostic Cable, 5 m without Power supply -VAS 5051/3-
♦ High Performance Gear Oil for Haldex Coupling -G 052 175
A1-
– Connect the vehicle diagnostic tester.

– Select “Suspension (Repair Group 01; 40 ... 49)“ on the dis‐ wage
es n
play. yV
olks ot g
u b ara
ed nte
– Select “AWD with Haldex clutch“. thoris e or
au ac
– Select “01 - OBD-capable systems“. ss
ce
e
nl
pt
– Select “AWD Haldex“.
du
an
itte
y li
erm
– Select “Electrical Components“.

ab
ility
ot p
– Select “oil temperature“.

wit
, is n
h re
• The oil temperature must be between 20 and 40 °C (68 - 104
hole
spec
°F).
es, in part or in w
t to the co
• The oil temperature can be reached by driving the vehicle for

awhile.
rrectness of i

l purpos
– Remove the oil drain plug -arrow- and drain the oil completely.
– Insert the oil cartridge into the cartridge gun -V.A.G 1628- .
nform
ercia
– Keep the drain plug with a new seal ready and close at hand.
m
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
170 Rep. Gr.39 - Final Drive, Differential

R32 2004 ➤
– Insert the cartridge gun -V.A.G 1628- vertically into the drain
hole -arrow-.
– Pump all the oil into the Haldex clutch.
– Remove the cartridge gun -V.A.G 1628- and immediately in‐
stall the drain plug with a new seal and tighten it to specifica‐
tion. Refer to wage
e
⇒ “2.3 Haldex Clutch and Clutchy DiscVolks Cover Overview“, page s not gu
177 . ise
d b ara
n r tee
ho
– Check the oil level in the
sa
uHaldex
t
clutch. or
ac
s
ce
e
nl
pt
du
an
itte
y li
erm
ab
1.3 Haldex Clutch Oil Filter, Changing
ility
ot p
wit
, is n
h re
hole
spec
♦ Wrench -T10066-
es, in part or in w
t to the co
Removing
rrectness of i
– Remove the oil filter using the wrench -T10066- .
l purpos
Installed position: The oil filter -A- is located on the right side of
the vehicle near the front bracket -B-.
nform
ercia
Installing
m
at
om
i
– Coat the O-ring on the new filter with Haldex clutch oil.
on
c
in t
or
– Install the oil filter -A- and tighten it to specification, (see
his
ate
do
-item 9- in the ⇒ “2.4 Pinion Housing Overview“, page 178 )
priv
using the wrench -T10066- . cum

for
en
ng
t.
yi
– Check the oil level. Refer to
Co
Cop py
t. rig
gh ht
yri
page 169 . Change the oil if necessary. p by
co Vo
by lksw
cted agen
Prote AG.
1.4 Rear Final Drive, Transmission Fluid

Checking
For the transmission fluid specification, refer to the Fluid Capacity
Tables, Rep. Gr. 03.
– Remove the fill plug -arrow- to check the rear final drive fluid
level.
The oil level is correct when the rear final drive is filled to the lower
edge of the fill hole.
– Tighten the plug -arrow- to specification, (see -item 4- in the
⇒ “2.5 Differential and Head Bevel Gear/Input Shaft Over‐
view“, page 180 ).
Note the following when filling for the first time:
– Remove the plug -arrow-.
– Add transmission fluid until it reaches the lower edge of the fill
hole.
– Install and tighten the plug -arrow- to specification.

R32 2004 ➤

⇒ “2.1 Adjustment Overview“, page 172
⇒ “2.2 Bevel Box Overview“, page 173
⇒ “2.3 Haldex Clutch and Clutch Disc Cover Overview“,
page 177
⇒ “2.4 Pinion Housing Overview“, page 178
⇒ “2.5 Differential and Head Bevel Gear/Input Shaft Overview“,
page 180
⇒ “2.6 Rear Final Drive Differential Overview “, page 182
⇒ “2.7 Shaft Bevel Gear Bearing Overview, Rear Final Drive“,
page 183
⇒ “2.8 Head Bevel Gear and Input Shaft Bearing Overview, Rear
Final Drive“, page 185
⇒ “2.9 Differential, Front Final Drive, Adjusting“, page 187
⇒ “2.10 Shift and Head Bevel Gear, Front Final Drive, Adjusting“,
page 189
⇒ “2.11 Shift and Head Bevel Gear, Rear Final Drive, Adjusting“,
page 202
2.1 Adjustment Overview
Note
When performing repairs on the transmission, adjustment of the

input shaft for 1st to 4th gears, output shaft for 5th, 6th and reverse
gears or the differential is only required if components, which
have a direct influence on transmissionwage adjustment, have
n AG. Volkswagen AG do been
es n
replaced. Refer to the table btoy Vavoid
olks any unnecessary adjusting. ot g
u ara
ed nte
oris e
th o
au to be adjusted:
ra
c
ss
Input shaft only Output shaft, 1st to Output shaft, 5th, 6th Differential, re‐
ce
le
un
pt
through transmis‐ 4th gears. Refer to and reverse gears. fer to

an
d
itte
sion date of manu‐ ⇒ “1.2 Output Shaft Refer to ⇒ “2.9 Differen‐

y li
rm
ab
facture 18 May 1st to 4th Gears, Ad‐ ⇒ “1.3 Output Shaft, tial, Front Final
pe
ility
2003 (with tapered justing“, page 132 . 5th, 6th and Reverse Drive, Adjust‐
ot
wit
, is n
roller bearings). Re‐ Gears, Adjusting“, ing“, page 187 .

h re
fer to page 134 .

hole
spec
⇒ “1.1 Input Shaft

es, in part or in w
Adjusting, Through
t to the co
Build Date 18 May

2003“, page 129 .
rrectness of i
Re‐ Transmission x x x x
placed housing
l purpos
part:
Clutch hous‐ x x x x
nform
ercia
ing
Input shaft x
m
a
com
tio
Output shaft, x
n in
r
te o
1st to 4th
thi
s
iva
gears
do
r
rp
cum
Output shaft, x
fo
en
g
5th, 6th and

n
t.
yi Co
op
reverse gears C py
t. rig
gh ht
yri
Differential x
p by
co Vo
housing
by lksw
cted agen
Prote AG.

R32 2004 ➤
Output shaft x
tapered roller
bearing
Output shaft x
tapered roller
bearing, 1st to
4th gears
Output shaft x
tapered roller
bearing, 5th,
6th and re‐
verse gears
Differential ta‐ x
pered roller
bearing
2.2 Bevel Box Overview

Disassembly and assembly, refer to
⇒ “5.1.2 Bevel Box“, page 248
wage.
e
olks s no
yV tg
♦ *Adjustments are ed necessary when these parts are replaced.
b ua
ran
oris
Refer to ⇒ “2.10.3 Adjustment Overview“, page 191 . tee
th o
au ra
c
ss
ce
le
1 - Bolt
un
pt
an
d
itte
❑ 25 Nm
y li
erm
ab
❑ For the right flange shaft

ility
ot p
to threaded piece/differ‐
wit
is n
ential.
h re
ole,
spec
❑ The length of the bolt is

matched to the bevel

t to the co
box.
❑ Check the part number
of the bevel box.
rrectne
❑ When replacing the bev‐

el box, allocate the bolt
ss
according to the Parts

o
cial p
f i
Catalog.
nform
mer

atio
om
n
c
i
or
⇒ page 249 .
thi
te
sd
va
i
o
pr
cum
⇒ page 253 .
r
fo
en
ng
t.
❑ Remove and install with
yi Co
op py
the transmission instal‐ . C rig
ht ht
led. Refer to
rig by
opy Vo
⇒ “4.1.2 Right Flange by c lksw
cted agen
Prote AG.

3 - Needle Bearing (Polygon
Bearing)
❑ Quantity: 2
ling, refer to
Shaft Needle Bearing“,
page 220 .

R32 2004 ➤
4 - Lock Ring
❑ Always replace.
5 - Seal
❑ Install completely using the thrust piece -T10049- . Refer to ⇒ page 256 .
❑ Replace when the transmission is installed. Refer AG.to
Volkswagen AG
⇒ “4.1.2 Right Flange Shaft Seal, Bevel Boxagen do
olksw Installed “, page 217e.s not
V y gu
db ara
6 - Stud Bolt rise nte
tho eo
❑ 45 Nm au ra
c
ss
❑ M10/ M8.
ce
le
un
pt
an
d
7 - Washer
itte
y li
rm
ab
❑ For the stud bolt -item 6-.
pe
ility
ot
wit
8 - Bolt
, is n
h re
hole
❑ 25 Nm
spec
es, in part or in w
❑ M8
t to the co
9 - Bolt
❑ 45 Nm
rrectness of i
❑ M10
l purpos
10 - Oil Drain Plug

❑ 60 Nm
nform
ercia
❑ With a magnet and seal.

m
a
com
ti
11 - Large Cover *
on in
r
te o
thi
s
iva
do
❑ Do not tilt when installing, tighten the bolts diagonally and in steps.
r
rp
cum
fo
en
12 - O-ring
ng
t.
yi Co
op
❑ Always replace, if equipped. C py
t. rig
gh ht
yri by
13 - Oil Deflector Ring
op Vo
by c lksw
cted agen
❑ Pay attention to the installed position, refer to ⇒ page 253 . Prote AG.
❑ Installed on some transmission between adjusting shim S1 -item 14- and the large tapered roller bearing/
head bevel gear -item 15-.
14 - Adjusting Shim S1
❑ Pay attention to the thickness.
❑ Installed on some transmissions between the oil deflector ring -item 13- and the large cover -item 11-.
❑ Adjustment overview, refer to ⇒ “2.10.3 Adjustment Overview“, page 191 .
15 - Large Tapered Roller Bearing for the Bearing/Head Bevel Gear*
Inner race:
Outer race:
16 - Head Bevel Gear with Input Shaft*
❑ Paired with the shaft bevel gear -item 29-.
❑ Cannot be removed from the input shaft.
❑ Adjusting, refer to ⇒ “2.10.7 Head Bevel Gear, Adjusting“, page 198 .

R32 2004 ➤
17 - Final Drive Housing *

❑ Drain the oil and then tension the bevel box in the assembly stand using the gearbox support -T10108- .
Refer to ⇒ “5.1.2 Bevel Box“, page 248 .
18 - Sleeve for the Oil Supply
19 - O-ring
❑ Always replace.
20 - Small Tapered Roller Bearing for the Bearing/Head Bevel Gear *
Inner race:
AG. Volkswagen AG d
agen
❑ Sits loosely on Vothe
lksw input shaft.
oes
not
gu
by ara
❑ Removing, ris refer to ⇒ page 251 .
ed
nte
ho eo
❑ Installing,
au
t refer to ⇒ page 254 . ra
c
ss
Outer race:
ce
le
un
pt
an
d
itte
❑ Sits loosely in the final drive housing.
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
21 - Bolt
spec
es, in part or in w
❑ 25 Nm
22 - O-ring t to the co
❑ Always replace.
rrectness of i
❑ Must fit into the groove completely.

l purpos
23 - Small Cover *
nform
ercia
m
a
com
tio
24 - O-ring
n in
r
te o
thi
❑ Always replace.
s
iva
do
r
rp
cum
fo
en
g

n
t.
yi Co
op py
t. C rig
gh ht
pyri by
26 - O-ring
o Vo
by c lksw
cted agen
Prote
❑ Always replace.
AG.
27 - Sleeve for the Oil Supply

28 - Roller Sleeve
29 - Shaft Bevel Gear
❑ Paired with the head bevel gear.
❑ Clean the threads.
❑ Grease the splines on the output flange with multipurpose grease.
❑ Adjusting, refer to ⇒ “2.10.6 Shaft Bevel Gear, Adjusting“, page 193 .
30 - Large Tapered Roller Bearing for the Shaft Bevel Gear*
Inner race:

R32 2004 ➤
❑ Mount on the shaft bevel gear -item 29-.
Outer race:
31 - Output Flange*
❑ Grease the splines with multipurpose grease.
32 - Nut
❑ 475 Nm
❑ Always replace.
❑ Install using liquid locking fluid -D 000 600- .
❑ Mount on the shaft bevel gear -item 29- before installing the inner race for the small tapered roller bearing
-item 20-.
34 - Seal
❑ Replace only when the bevel box is removed. Refer to
⇒ “4.1.3 Bevel Box Output
agen Flange Seal,
AG. Volkswagen AG Bevel
doe Box Removed“, page 218 .
ksw s no
* Vol tg
35 - Small Tapered
ed Roller Bearing for the Shaft Bevel Gear
by ua
ran
is tee
or
Outer race: auth or
ac
ss
ce
le
un
pt
an

d
itte
y li
rm
ab
Inner race:
pe
ility
ot
wit
❑ Remove from the output flange, refer to ⇒ page 250 .

, is n
h re
hole
❑ Insert into the outer race.

spec
es, in part or in w
36 - Bolt
t to the co
❑ 25 Nm
❑ Install using sealant -AMV 188 200- .
rrectness of i
37 - Pinion Housing *
l purpos

nform
ercia
m
a
com
tio
n in
r
te o
thi

s
iva
do

r
rp
cum
fo
❑ Lubricate both sides using sealant -AMV 188 200- before installing.
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

R32 2004 ➤
2.3 Haldex Clutch and Clutch Disc Cover Overview
1 - Nut
❑ 220 Nm
⇒ page 262 .
⇒ page 269 .
❑ Install using liquid lock‐
ing fluid -D 000 600- .
2 - Flange, for Driveshaft
❑ Removing, refer to AG. Volkswagen AG d
agen oes
ksw
⇒ page 262 . by Vol not
gu
ara
d
ise nte
3 - Bolt thor eo
au ra
❑ 50 Nm ss c
ce
e
nl
4 - Oil Drain Plug
pt
du
an
itte
y li
❑ 15 Nm
erm
ab
ility
❑ For the Haldex clutch
ot p
wit
oil.
, is n
h re
hole
5 - Seal
spec
es, in part or in w
❑ Always replace.
t to the co
6 - Haldex Clutch Cover
❑ Remove together with
rrectness of i
the housing.
l purpos
❑ For installation, sepa‐

rate from the disc hous‐
ing, refer to
nf
ercia
⇒ page 265 .
orm
m
atio
7 - O-ring
om
n in
c
❑ Always replace.
or
thi
te
sd
❑ Lubricate with high per‐

iva
o
r
formance oil for the Hal‐

rp
cu
o
dex clutch.
f
en
ng
t.
yi Co
op
8 - Ring
C py
t. rig
gh ht
yri
❑ Install in the pinion housing. p by
co Vo
by lksw
cted agen
9 - Roller Prote AG.
❑ Quantity: 3
10 - Roller
❑ Quantity: 6
11 - Washer
❑ Pay attention to the installed position, refer to ⇒ page 267 .
12 - O-ring
❑ Quantity: 3
❑ Always replace
❑ Install in the Haldex clutch cover.
13 - Seal
❑ Always replace.
❑ Some final drives may have also have O-rings installed. Refer to ⇒ page 59 , Fig. N01-0234
14 - All Wheel Drive Control Module -J492-
❑ Removing and installing, refer to ⇒ “5.2 Haldex Clutch Pump“, page 59 .

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
R32 2004 ➤ rised
nte
o eo
Manual Transmission - Edition aut01.2012
h
ra
ss c
ce
e
15 - Bolt
nl
pt
du
an
itte
❑ 6 Nm
y li
erm
ab
ility
16 - Clutch Disc Pack
ot p
wit
, is n
❑ Pay attention to the installed position of the outer and inner clutch discs, refer to ⇒ page 266 .
h re
hole
spec
17 - Hub es, in part or in w
t to the co
18 - Thrust Washer
❑ Pay attention to the installed position, refer to ⇒ page 266 .
rrectness of i
19 - Axial Needle Bearing
❑ With a thrust washer for the axial needle bearing.
l purpos
nform
ercia
20 - Haldex Clutch Pump -V 181-

m
❑ Removing and installing, refer to ⇒ “5.2 Haldex Clutch Pump“, page 59 .
at
om
ion
c
21 - Bolt
in t
or
his
e
❑ 6 Nm
at
do
priv
cum
22 - Seal
for
en
ng
t.
yi
❑ Always replace.
Co
Cop py
ht. rig
23 - O-ring rig ht
py by
co Vo
❑ Always replace.
by lksw
cted agen
Prote AG.
24 - O-ring
❑ Always replace.
25 - Pinion Housing
2.4 Pinion Housing Overview

♦ * Adjusting will be necessary when replacing these parts, refer
to ⇒ “2.11.3 Adjustment Overview“, page 206 .

R32 2004 ➤
1 - Bolt
❑ 10 Nm
2 - Cover
❑ For the pinion housing.
❑ An additional seal on
aluminum covers, refer
to ⇒ page 180 .
❑ Plastic covers have a
cured seal, refer to
⇒ page 180 .
❑ Allocate according to
the transmission code
letters. Refer to
⇒ “3.2 Code Letters, Al‐
location, Ratios and Ca‐
pacities, Rear Final AG. Volkswagen AG d
Drive“, page 9 and the lksw
agen oes
not
Parts Catalog. d byV
o gu
ara
ise nte
r
3 - Seal ut
ho eo
ra
a
❑ Always replace. ss c
ce
e
nl
❑ Made from different ma‐
pt
du
an
terials. Allocate accord‐
itte
y li
erm
ing to the parts catalog.
ab
ility
ot p
4 - Oil Fill Plug
wit
, is n
h re
❑ 30 Nm
hole
spec
5 - Magnet
es, in part or in w
t to the co
❑ Install inside the cover
-item 2-.
rrectness of i
6 - Seal
❑ Not on plastic covers.
l purpos
7 - Nut
nf
ercia
❑ 45 Nm
orm
m
atio
om
n in
❑ Always replace.
or c
thi
te
sd
iva
o
r
rp
cu

o
m
f
en
ng
t.
yi Co
Cop py
❑ Shaft bevel gear bearing overview. Refer to
ht. rig
rig ht
by
⇒ “2.7 Shaft Bevel Gear Bearing Overview, Rear Final Drive“, page 183 . copy Vo
by lksw
cted agen
❑ The sealing surface was enlarged when the plastic cover was introduced. Refer to ⇒ page 180 . Prote AG.
❑ Refer to the Parts Catalog.

9 - Oil Filter
❑ 35 Nm
10 - O-ring
❑ Always replace.
❑ Install using Haldex clutch oil.
11 - O-ring
❑ Always replace.
❑ Install using transmission fluid.
❑ Removing and installing, refer to
⇒ “4.3.5 O-ring, Cover and Rear Axle Housing, Final Drive Removed“, page 237 .

R32 2004 ➤
13 - Rear Final Drive Housing *
❑ Remove any locking fluid from the threads on the stud bolts that attach the pinion housing.
Different Versions of the Pinion Housing Cover

I - Aluminum cover -A- and an extra seal -B-
II - Plastic cover with a cured seal -arrow 1-
Note
♦ Oil fill plug seal -arrow 2-; refer to the Parts Catalog.
♦ Use the plastic cover only on a pinion housing that has the
enlarged sealing surface. Refer to ⇒ page 180 .
Enlarged Sealing Surface on the Pinion Housing

Width of sealing surfaces for plastic drive pinion housing -arrow-
cover dimension -a- = 7 mm gen AG
. Volkswagen AG
a does
lksw not
Width of the sealing surface for an aluminum piniondb
yhousing
Vo cover gu
ara
-a- = 5 mm or
ise nte
th eo
au ra
c
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
2.5 Differential and Head Bevel Gear/Input

es, in part or in w
Shaft Overview
t to the co
♦ * Adjusting will be necessary when replacing these parts. Refer

rrectness of i

l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

R32 2004 ➤

2 - Stud
❑ 10 Nm
3 - Oil Drain Plug
❑ 25 Nm
❑ With a magnet.
4 - Oil Fill Plug
❑ 25 Nm
❑ Capacities and specifi‐
cations, refer to
⇒ “3.2 Code Letters, Al‐
location, Ratios and Ca‐
pacities, Rear Final
Drive“, page 9 .
❑ Check the transmission
fluid in the rear final
drive. Refer to
⇒ “1.4 Rear Final Drive,
Transmission Fluid
Checking“, page 171 .
5 - Ventilation Elbow
❑ Remove from the rear fi‐
nal drive housing AG. Volkswagen AG d
-item 1- before remov‐ agen oes
olksw not
ing the differential. d by
V gu
ara
ise nte
r
6 - Bracket ut
ho eo
ra
s a c
❑ For the connector/wiring s
ce
e
harness.
nl
pt
du
an
itte
❑ Different versions.
y li
erm
ab
❑ Refer to the Parts Cata‐
ility
ot p
log.
wit
, is n
h re
7 - Bolt
hole
spec
❑ 10 Nm
es, in part or in w
t to the co
❑ Quantity: 2
8 - O-ring rrectness of i
❑ Always replace.
l purpos

❑ Replace when the rear final drive is installed.
nf
ercia
9 - Differential
rm
m
atio
❑ Remove with the cover, refer to ⇒ page 264 .

om
n in
c
❑ Install with the cover; tighten the bolts -item 16- diagonally and in steps. Refer to ⇒ page 265 .
or
thi
te
❑ Disassembling and assembling, refer to ⇒ “5.3.2 Differential“, page 269 .

sd
iva
o
r
rp
cu
10 - Bolt
o
m
f
en
ng
t.
yi
❑ 25 Nm
Co
Cop py
t. rig
gh
ht
pyri by
Vo
o
by c
lksw
cted agen
Prote AG.
❑ Use a plastic hammer to install.
12 - Lock Ring
❑ Always replace.

R32 2004 ➤
13 - Head Bevel Gear/Input Shaft *

❑ The head bevel gear is paired with the shaft bevel gear.
❑ Allocate according to the transmission code letters. Refer to
⇒ “3.2 Code Letters, Allocation, Ratios and Capacities, Rear Final Drive“, page 9 and the Parts Catalog.
❑ Head bevel gear and input shaft bearing overview. Refer to
⇒ “2.8 Head Bevel Gear and Input Shaft Bearing Overview, Rear Final Drive“, page 185 .
14 - O-ring
❑ Always replace
❑ Replace when the rear final drive is installed. Refer to
⇒ “4.3.5 O-ring, Cover and Rear Axle Housing, Final Drive Removed“, page 237 .
15 - Cover *
16 - Bolt
❑ 25 Nm
17 - Lock Ring
❑ Always replace.
❑ Use a plastic hammer to install
AG. Volkswagen AG d
agen oes
olksw not
Removing the Old Lock Ring d byfrom
V the Groove in the Flange Shaft
gu
ara
Using the New Lock Ring orise-A- nte
eo
th
au ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
2.6 Rear Final Drive Differential Overview

rrectness of i
l purpos

⇒ “5.3.2 Differential“, page 269 .
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

R32 2004 ➤
1 - Differential Housing
2 - Differential Bevel Gear
Shaft
❑ Secure with the roll pin.
3 - Expansion Pin
❑ For securing the differ‐
ential bevel gear shaft.
❑ Removing, refer to AG. Volkswagen AG d
⇒ page 270 . agen oes
olksw not
y V gu
b ara
4 - Lock Ring rise
d
nte
ho eo
❑ Always replace.aut ra
c
ss
5 - Ball Bearing
ce
le
un
pt
an
d
itte
y li
⇒ page 270 .
erm
ab
ility
ot p
wit
is n
⇒ page 271 .
h re
ole,
6 - Cover
spec
❑ Remove with the differ‐
t to the co
ential.
❑ Install with the differen‐
rrectne
tial.
❑ Remove from the differ‐
s
ential, refer to
s o
⇒ page 270 .
cial p
f inform
❑ Installing on the differ‐
mer
ential, refer to
atio
m
⇒ page 271 .
o
n
c
i
or
7 - Lock Ring
thi
te
sd
va
❑ Always replace.
i
o
pr
cum
r
fo
en
ng
8 - Seal yi
t.
Co
op
❑ Pry out with a pry bar.
C py
t. rig
gh ht
yri
❑ Install using the arbor -VW 195- . p by
co Vo
by lksw
cted agen
9 - Small Differential Bevel Gear Prote AG.

10 - Large Differential Bevel Gear
11 - Thrust Washer Union
2.7 Shaft Bevel Gear Bearing Overview,

Rear Final Drive
⇒ “5.3.3 Shaft Bevel Gear Bearing“, page 271 .

R32 2004 ➤
Note
There is an approximately 4 mm hole in the bottom of the pinion

housing, near the bolting flange on the pinion housing
⇒ page 185 . If oil leaks out, replace the seals -item 5-.
1 - Twelve Point Nut for the

Shaft Bevel Gear
⇒ page 272 .
⇒ page 275 .
ing fluid -D 154 000 A1- .
olkswagen AG
en AG. V
2 - Small inner Race/Tapered ksw
ag does
not
* Vol
Roller Bearing ed
by gu
ara
ris nte
❑ Removing, refer to tho eo
⇒ page 272 . au ra
c
ss
ce
le
un
pt
⇒ page 275 .
an
d
itte
y li
erm
ab
3 - Small Outer Race/Tapered
ility
ot p
Roller Bearing *
wit
is n
h re
ole,
⇒ page 272 .
spec
t to the co
⇒ page 273 .
rrectne
ing fluid -D 154 000 A1- .
ss

o
cial p
f i
ling, refer to
nform
⇒ “2.4 Pinion Housing

mer
atio

om
n
c
5 - Seals
or
n thi
te
sd
a
❑ For the shaft bevel gear.

iv
o
pr
cum
r
fo
en
ng
⇒ page 273 .
t.
yi Co
op py
❑ Assembling, refer to t. C rig
gh ht
⇒ page 274 . yri
p by
o Vo
by c lksw
❑ Insert in installed position, refer to ⇒ page 274 . cted agen
Prote AG.
6 - Large Outer Race/Tapered Roller Bearing *
7 - Large Inner Race/Tapered Roller Bearing *
8 - Spacer
❑ Always replace.

R32 2004 ➤
9 - Shaft Bevel Gear *

❑ Paired with the head bevel gear.
❑ Clean any locking fluid off the threads.
Hole -arrow- in the Pinion Housing

– Replace the shaft bevel gear seals if oil leaks out of the hole
-arrow-.
2.8 Head Bevel Gear and Input Shaft Bear‐

ing Overview, Rear Final Drive
AG. Volkswagen AG d
agen
♦ Driving Sleeve -32-109- Volksw
oes
not
by gu
d ara
♦ Kukko Separating Tool 22-115 mm -17/2- orise nte
eo
th
u ra
Disassembly and assembly, refer to ss a c
⇒ “5.3.4 Head Bevel Gear and Input Shaft Bearing“, page 276 .
ce
le
un
pt
an
d

itte
y li
erm
to ⇒ “2.11.3 Adjustment Overview“, page 206 . ab

ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

R32 2004 ➤

⇒ page 264 .
❑ Use a plastic hammer to AG. Volkswagen AG d
install. agen oes
olksw not
byV gu
ara
2 - Dust Plate rised
nte
ho eo
❑ For the flange shaft. aut ra
c
ss
ce
e
nl
⇒ page 187 .
pt
du
an
itte
y li
erm
ab
⇒ page 187 .
ility
ot p
wit
, is n
3 - Seal
h re
❑ Install completely using hole
spec
the arbor -VW 195- .
es, in part or in w
t to the co
4 - Cover *
rrectness of i
⇒ page 264 .
l purpos
⇒ page 265 .
nform
mercia
at
om
ion
c
❑ Pay attention to the
in t
or
thickness.
his
ate
do
riv
❑ Adjustment overview,
p
cum
or
refer to
f
en
ng
t.
⇒ “2.11.3 Adjustment
yi Co
op
C py
ht. rig
rig ht
py by
7 - Small Outer Race/Tapered
co Vo
by lksw
cted
Roller Bearing *
agen
Prote AG.
⇒ page 277 .
⇒ page 278 .
8 - Small Inner Race/Tapered Roller Bearing *
9 - Head Bevel Gear/Input Shaft *
❑ The head bevel gear is paired with the shaft bevel gear.
10 - Large Inner Race/Tapered Roller Bearing *
11 - Large Outer Race/Tapered Roller Bearing *

R32 2004 ➤
Removing the Dust Plate

tool 22-115 mm -17/2-
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
Installing the Dust Plate
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
2.9 Differential, Front Final Drive, Adjusting
en
ng
t.
yi Co
Cop py
. rig
ht ht
rig by
copy Vo
by lksw
cted agen
Prote AG.
♦ Tube - 3259-
♦ Press Tool -3345-
It is necessary to adjust the differential if the:
♦ Clutch housing
♦ Differential housing
or the
♦ Differential tapered roller bearing

R32 2004 ➤
have been replaced.

– Install the outer race/tapered roller bearing into the clutch
housing with a 0.65 mm shim.
Note
Bearing inner and outer race of the tapered roller bearing are
paired. Do not interchange them.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
– Install the outer race/tapered roller bearing without a adjust‐ du
an
itte
ment shim into the transmission housing.
y li
erm
ab
ility
– Insert the differential into the clutch housing.
ot p
wit
, is n
– Position the transmission housing and tighten the 5 bolts to
h re
hole
specification, (see -items 12 and 13- in the
spec
es, in part or in w
t to the co
Build Date 18 May 2003“, page 47 or -items 10 and 11- in the
Build Date 19 May 2003“, page 48 ) .
rrectness of i
– Press the differential in the direction of the clutch housing and
rotate it eight times at the same time.
l purpos
– Press the differential in the direction of the transmission hous‐
nf
ercia
ing and rotate it eight times at the same time.
orm
m
atio
m
– Install the dial gauge and set it to “0“ with a 1 mm preload.

o
n in
or c
A - 30 mm dial gauge extension
thi
te
sd
iva
o
r
– Move the differential up and down, read off the play on the dial
rp
cu
o
m
gauge and note. (example: 0.70 mm).
f
en
ng
t.
yi Co
op
Determining Shim Thickness C py
ht. rig
rig ht
by
The specified bearing preload is obtained by adding a constant copy Vo
by lksw
preload figure of 0.30 mm to the reading obtained. cted agen
Prote AG.
Example
Measured value 0.70 mm
+ Preload (constant) 0.30 mm
Adjusting shim thickness = 1.00 mm
– Remove the transmission housing.

R32 2004 ➤
– Remove the tapered roller bearing outer race from the trans‐
mission housing.
46-58 mm -21/7-
– Select the correct adjusting shim Athickness
G. Volkswagaccording
en AG to the
table. agen does
olksw not
V y gu
db ara
– For the correct part
or
isenumber, refer to the parts catalog. nte
h eo
ut r
– Install the shim
ss with the correct thickness, thickest
a shim first. ac
ce
le
The following adjusting shims are available:

un
pt
an
d
itte
y li
Adjusting Shim Thickness (mm)
erm
ab
ility
ot p
0.65 0.85 1.05 1.25
wit
is n
h re
0.70 0.90 1.10
ole,
spec
0.75 0.95 1.15
t to the co
0.80 1.00 1.20
If the measured shim thickness is larger than those listed in the
rrectne
table, then install two shims that add up to the necessary thick‐
ness.
ss o
cial p
f in
ness required.
form
mer
– Install the outer race again and the tighten the transmission
atio
om
housing bolts to specification, (see -item 13- in the n

c
i
or
n
thi
te

sd
iva
o
r

p
cum
r
fo
Build Date 19 May 2003“, page 48 ) .

en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
2.10 Shift and Head Bevel Gear, Front Final

Drive, Adjusting
General Information
Careful adjustment of the drivetrain is important for service life
and smooth running of angle transmission. During manufacture
the shaft bevel gear and the head bevel gear are matched and
checked on testing machines to ensure correct mesh pattern and
silent running. The position for quietest running is obtained by
moving the shaft bevel gear axially and, at the same time, main‐
taining the backlash within the specified tolerances. Replace the
gear set (shift and head bevel gear) together!

R32 2004 ➤
⇒ “2.10.1 Gear Set, Adjusting the Mark“, page 190

⇒ “2.10.2 Adjusting Shim Position“, page 191
⇒ “2.10.3 Adjustment Overview“, page 191
⇒ “2.10.4 Sequence for Readjusting Final Drive Set“, page 192
⇒ “2.10.5 Adjusting Shim "S 4", Selecting When Replacing Output
Flange“, page 192
⇒ “2.10.6 Shaft Bevel Gear, Adjusting“, page 193
⇒ “2.10.7 Head Bevel Gear, Adjusting“, page 198
2.10.1 Gear Set, Adjusting the Mark
A - Head Bevel Gear

B - Shaft Bevel Gear
C - Actual Dimension Between
the Head Bevel Gear and the
Back of the Shaft Bevel Gear
(inner race for the large ta‐
pered bearing) at Point with
Quietest Running for this Gear
Set. 65.50 mm. n AG. Volkswagen A ge G do
swa es n
1 - Drivetrain Pairing y Number
Vol
k ot g
ua
-561-. edb ran
ris tee
tho or
2 - Shaft Bevel
ss
au Gear Dimen‐ ac
sion (D = +10)
ce
e
nl
pt
du
❑ Can be between 0 and

an
itte
y li
+0.35 (in the example

erm
ab
+0.10 mm).
ility
ot p
❑ Must be added to the di‐

wit
, is n
h re
mension -C-.
hole
spec
3 - Backlash (Sd = 0.20)

es, in part or in w
t to the co
❑ Check dimension.
S - Step Dimension
rrectness of i
❑ The dimension between

the ground back side/
l purpos
spline and the contact

surface of the inner
race/taper roller bearing
nf
ercia
and/or the adjusting

rm
m
atio
shim S4 on the shaft

om
n in
bevel gear.
or c
thi
e
❑ This dimension is writ‐

t
sd
iva
ten on the front -arrow-

o
r
rp
cu
of the shaft bevel gear

o
m
f
en
ng
(in the example: 3.95).

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

R32 2004 ➤
2.10.2 Adjusting Shim Position
S1 - Adjusting Shim for the

Friction Torque/Tapered Roll‐
er Bearing - Head Bevel Gear
Friction Torque and for Posi‐
tioning the Head Bevel Gear
Shaft Bevel Gear
Friction Torque/TaperedaRoll‐
gen AG
. Volkswagen AG
does
er Bearing - Shaft Bevel
Volksw Gear not
g
y ua
db ran
rise tee
tho or
au ac
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
2.10.3 Adjustment Overview
o
by c lksw
cted agen
Prote AG.
Note
When working on the transmission, the shaft bevel gear, head

bevel gear or complete gear set only needs to be adjusted if com‐
ponents were replaced which directly influence the final drive.
Refer to the table to avoid any unnecessary adjusting.
to be adjusted:
Shaft bevel gear (S3 Head bevel gear
and S4). Refer to (S1 and S2). Refer to
⇒ “2.10.6 Shaft Bevel ⇒ “2.10.7 Head Bev‐
Gear, Adjusting“, el Gear, Adjusting“,
page 193 . page 198 .
Replaced part: Final drive housing x1 x
Large cover x
Small cover x

R32 2004 ➤
Drivetrain (shift and head bevel x x

gear with driveshaft)
Shaft bevel gear tapered roller x
bearing
Head bevel gear tapered roller x
bearing
Pinion housing x
Output flange x2
• 1 Only S3. The shaft bevel gear is removed together with the
wage
pinion housing. The adjusting shim S4 remains unchanged. es n
olks ot
yV gu
db ara
• 2Only S4 via the difference measurement. se
Refer to
ri nte
tho eo
⇒ “2.10.5 Adjusting Shim "S 4", Selecting
ss au When Replacing ra
c
Output Flange“, page 192 .
ce
e
nl
pt
du
an
itte
y li
erm
ab
2.10.4 Sequence for Readjusting Final Drive
ility
ot p
wit
, is n
Set
h re
hole
spec
When the shaft bevel gear and the head bevel gear have to be
es, in part or in w
adjusted, in the interests of a rational sequence, keep to the fol‐
t to the co
lowing order:
1. Adjusting the shaft bevel gear (S3 and S4)
rrectness of i
– Select the adjusting shim thickness "S4" and install it. The
l purpos
shim adjusts the preload on the tapered roller bearing for the
shaft bevel gear.
nf
ercia
o
– Select the adjusting shim thickness "S3 “ and install it. This
rm
m
atio
secures the shaft bevel gear axially, that the dimension from
om
n in
the center of head bevel gear to the back of the shaft bevel
or c
gear corresponds to the installation dimension “ C" determined
thi
te
sd
a
during production.
iv
o
r
rp
cu
o
2. Adjusting the head bevel gear (S1 and S2)

f
en
ng
t.
yi Co
op
– Adjusting the preload on the tapered roller bearing for the head
C py
ht. rig
bevel gear using Stotal.
rig ht
py by
co Vo
by lksw
cted
– Adjust the torsional backlash. Select the adjusting shim thick‐
agen
Prote AG.
ness "S1 “ and “ S2" so that the specified torsional backlash
is present between the shaft bevel gear and the head bevel
gear.
– Check the torsional backlash.
The goal is to reach the position of quietest running that was es‐
tablished in production. To reach this result it is absolutely nec‐
essary to perform any assembling and measuring with the
greatest care and cleanliness.
2.10.5 Adjusting Shim "S 4", Selecting When

Replacing Output Flange
This adjustment is necessary whenever the output flange is being
replaced. This creates the preload on the tapered roller bearing
for the shaft bevel gear.

R32 2004 ➤
– Measure the length of the shaft on the old and new output
flange to get the difference.
Example AG. Volkswagen AG d
agen oes
ksw not
Old output flange 43.50
by V mm
ol
gu
ara
ed
New output flange hori43.30
s mm nte
eo
ut ra
Difference ss a 0.20 mm c
ce
le
un
pt
If the new output flange is longer - install a thinner S4 that matches
an
d
itte
the difference.
y li
rm
ab
pe
ility
If the old output flange is longer - install a thicker S4 that matches
ot
wit
, is n
the difference.
h re
hole
– Allocate adjustment shim(s) according to the Parts Catalog.
spec
es, in part or in w
t to the co
rrectness of i
l purpos
2.10.6 Shaft Bevel Gear, Adjusting
nform
ercia

m
a
com
t
ion in
r
te o
thi
♦ Universal Measuring Tool -VW 385-
s
iva
do
r

rp
cum
fo
en
ng

t.
yi Co
Cop py
. rig
ht ht
rig by
copy Vo
♦ Thrust Pad -VW 472/1-
by lksw
cted agen
Prote AG.
♦ Washer -3253/7-
♦ Tube -3296-
♦ Transmission Holder -T10108-
♦ Stop Plate -T10108/1-
♦ Digital Depth Gauge -VAS 6087-
♦ Torque Wrench -V.A.G 1601-
♦ Feeler Gauge with 0.03 mm Graduation
♦ Dial Gauge
♦ Standard Torque Gauge 0 to 600 Ncm
It is necessary to readjust the shaft bevel gear when:
♦ Final drive housing
♦ Shaft bevel gear tapered roller bearing
♦ Drive train
or the
♦ Pinion housing
is being replaced.
Adjustment overview, refer to
⇒ “2.10.3 Adjustment Overview“, page 191 .

R32 2004 ➤
Adjusting Shim Thickness "S4", Selecting

• The output flange seal is removed
– Install the outer race on the large tapered roller bearing for the
shaft bevel gear into the pinion housing using the washer
-3253/7- . Refer to ⇒ page 255 .
– Install the outer race on the small tapered roller bearing for the
shaft bevel gear into the pinion housing using the thrust pad -
VW 472/1- . Refer to ⇒ page 254 .
– Mount the large tapered roller bearing inner race on the shaft
AG. Volkswagen AG d
bevel gear. ksw
agen oes
n ol ot g
yV ua
– Install the inner race for the small tapered roller bearing ed on the
b ran
ris
output flange. ut
ho tee
or
a ac
– Install the shaft bevel gear. ss
ce
e
nl
pt
du
– Lay the thickest adjusting shim "S4" = 2.5 mm (allocate ac‐
an
itte
y li
cording to the parts catalog) on the shaft bevel gear.
erm
ab
ility
ot p
– Install the output flange and inner race and tighten the nut.
wit
, is n
h re
– Install an M10 bolt -A- as an abutment.
hole
spec
Socket -B-
es, in part or in w
t to the co
rrectness of i
Protectors -C-
l purpos
– Tighten the nut to 50 Nm, remove the bolt -A-.

– Push the shaft bevel gear toward the larger taper roller bearing
nf
ercia
outer race and turn it eight times while doing this.
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

R32 2004 ➤

– Move the shaft bevel gear up and down
(-direction of the arrow-).
– Check the play on the dial gauge and select S4
Example
Adjusting shim 2.50 mm
- Preload (constant value) 0.20 mm
- Play (from the dial gauge) 0.35 mm
Adjusting shim S4 = 1.95 mm
Note
For the correct adjusting shims, refer to the Parts Catalog
Adjusting Shims Available for S4
Adjusting Shim Thickness (mm) . Volkswagen AG

gen AG does
swa
1.30 1.65 2.00 y V 2.35
olk not
gu
db ara
1.35 1.70 2.05 orise 2.40 nte
eo
th
1.40 1.75 2.10 s au 2.45 ra
c
s
1.45 1.80 2.15 2.50
ce
e
nl
pt
du
an
1.50 1.85 2.20
itte
y li
erm
ab
1.55 1.90 2.25
ility
ot p
1.60 1.95 2.30
wit
, is n
h re
hole
– Install the adjusting shim S4 instead of the 2.50 mm shim.
spec
es, in part or in w
– Attach the pinion housing to the final drive housing with an
t to the co
adjusting shim S3.
rrectness of i
Note
l purpos
When attaching the pinion housing it is necessary to install an

adjusting shim S3 (for example, 1.2 mm) so that the shaft bevel
nform
ercia
gear does not touch the final drive housing.

m
at
om
ion
c
in t
or
– Secure the bevel box output flange using the stop plate -
his
ate
T10108/1- .
do
priv
cum
or
– Tighten the nut on the output flange to specification, see

f
en
ng
t.
yi
-item 32- in the ⇒ “2.2 Bevel Box Overview“, page 173 .
Co
Cop py
t. rig
gh
-A- - socket for 3/4 inch drive
ht
pyri by
Vo
o
by c lksw
• The input shaft and the head bevel gear is removed
cted agen
Prote AG.

R32 2004 ➤
– Measure the friction torque.

-A- Standard torque gauge 0 to 0.600 Ncm
Socket -B-
-C- Adapter, 1/2 inch to 3/4 inch
Friction Torques To Be Adjusted
New Bearing Worn Bearing 1
100 to 240 Ncm 30 to 50 Ncm
• 1 Run for at least 50 km
Use a thinner (more friction torque) or thicker (less friction torque)
adjusting shim S4 to correct.
Determining thickness of adjustment shim S3
• The input shaft and the head bevel gear is removed
• The outer race/tapered roller bearing for the head bevel gear/
input shaft are installed.
– Set the adjusting ring on the -VW 385/1- to dimension “a“ = 32

mm.
– Set the adjusting ring to “b“ = 70 mm.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
ut ra
– Assemble the -VW 385/1- as illustrated. ss a c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
– Place the -VW 385/3- in the outer race for the small tapered
roller bearing.
nform
ercia
– Install the -VW 385/1- . The tabs on the adjusting ring must
m
lock into the groove -arrow- on the centering washer.

at
om
ion
c
– Install the large cover and tighten the bolts.

in t
or
his
ate
– Using the moveable adjusting ring, pull the centering washer

do
priv
toward the outside until it is not possible to turn it by hand.

um
for
en
ng
t.
yi
Dimension A, Determining
Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

R32 2004 ➤
– Using a digital depth gauge (for example digital depth gauge

-VAS 6087- ) from the bolting surface on the pinion housing to
the highest point on the universal measuring bar.
In the example, the dimension is 72.50 mm
– To this dimension add half of the dimension of the -VW 385/1- .
This value is 16.00 mm.
Example
Value reading on depth gauge 72.50 mm
Half of the diameter universal mandrel + 16.00 mm
Dimension -A- = 88.50 mm
Dimension B, Determining
The 1st value is the step dimension -s- and is 3.95 mm in the
example. This value is written on the front of the shaft bevel gear
-arrow-.
• Tighten the nut on the output flange to specification, see
-item 32- in the ⇒ “2.2 Bevel Box Overview“, page 173 .
The 2nd value is the measurement between the outer race/large

tapered roller bearing (installed in the pinion housing) on the back
of the shaft bevel gear.
– Measure this gap dimension “f“ with a feeler gauge. V-A-.
olkswage AG n AG d
agen oes
olksw not
yV gu
db ara
Note rise nte
tho eo
s au ra
c
Use a feeler gauge that has 0.03
s mm graduation.
ce
le
un
pt
an
d
itte
In this example, 0.95 mm.

y li
rm
ab
pe
ility
– Remove the shaft bevel gear from the pinion housing to meas‐
ot
wit
ure the 3rd value.

, is n
h re
hole
spec
– Using a digital depth gauge (for example digital depth gauge

es, in part or in w
-VAS 6087- ) measure from the outer race/large tapered roller

t to the co
bearing -A- to the bolting surface on the pinion housing.

– Note the value -e- in the example: 20.10 mm
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

R32 2004 ➤
Example
written step dimension -s- 3.95 mm
Gap dimension -f- determined using a feeler + 0.95 mm
gauge
Value -e- determined with a depth gauge + 20.10 mm
Slump “C“ with shaft bevel gear dimension + 65.60 mm
“D“ (C + D)
Dimension -B- = 90.60 mm
Determining Thickness of Adjustment Shim S 3

S3 = dimension “B“ - dimension “A“
Dimension -B- 90.60 mm

Dimension -A- - 88.50 mm
Adjusting shim S3 thickness = 2.10 mm
Note
For the correct adjusting shims, refer to the Parts

wage
n AG. VCatalog
olkswagen AG
doe
ks s no
Vol t gu
by ara
Adjusting Shims Available for Sor3ised
nte
th eo
au ra
Adjusting Shim
ss Thickness (mm) c
ce
e
nl
pt
1.20 1.50 1.80 2.10

du
an
itte
y li
125 1.55 1.85 2.15

erm
ab
ility
1.30 1.60 1.90 2.20

ot p
wit
, is n
1.35 1.65 1.95

h re
hole
1.40 1.70 2.00

spec
es, in part or in w
1.45 1.75 2.05

t to the co
– Tolerance variations make it possible to find the exact shim

thickness required.
rrectness of i
l purpos
2.10.7 Head Bevel Gear, Adjusting

nf
ercia
orm

m
atio
om
n in
♦ Magnetic Plate 50 mm Dia -VW 385/17-

or c
thi
te

sd
iva
o
r
rp
cu
♦ Measuring Lever -VW 388-

o
m
f
en
ng
t.
yi Co
♦ Crown Wheel Adjustment Device -VW 521- t. Cop py
rig
gh ht
♦ Transmission Holder -T10108- pyri by
Vo
o
by c lksw
cted agen
♦ Dial Gauge Prote AG.

R32 2004 ➤
It is necessary to readjust the head bevel gear when the:

♦ Final drive housing
♦ Cover
♦ Head bevel gear tapered roller bearing/driveshaft
or the
♦ Drivetrain
is being replaced.
Head Bevel Gear Tapered Roller Bearing Preload, Adjusting Fric‐
tion Torque
The shaft bevel gear is removed.
– Install the head bevel gear/input shaft -5- in the final drive
. Volkswagen AG
housing. swa
gen AG does
k not
Vol g
– Mount the by
dinner race/tapered roller bearing -3-uon
ara the head
ise nte
bevel tgear/input
ho
r shaft. eo
au ra
c
– Place
ss a 1.75 mm adjusting shim into the seat of the outer race
ce
le
for the small tapered roller bearing (S2 side) in the small cover
un
pt
an
d
-2-.
itte
y li
erm
ab
A 1.75 mm thick adjusting shim S2 is used temporarily for the

ility
ot p
initial measurement. It is designated as ○S2 * in the following.

wit
is n
h re
S2 * is replaced by the final adjusting shim S2 after the torsional

ole,
spec
backlash is determined.
t to the co
– Install the small cover and tighten the bolts to specification,

see -item 21- in the ⇒ “2.2 Bevel Box Overview“, page 173 .
rrectne
Note
ss o
cial p
The adjusting shim S1 is between the oil deflector ring and the
inform
large cover on some transmissions. The oil deflector ring must be

mer
removed and a temporary adjusting shim S1 must be installed,

atio
om
which has the same thickness as the oil deflector ring, for exam‐
n
c
i
or
ple, 0.75 mm. For the replacement part number, refer to the parts
thi
te
sd
catalog.
iva
o
pr
cum
r
fo
en
ng
– Install the cover with the outer race for the large taper roller
t.
yi Co
bearing outer race with the drive flange seal and without ad‐
Cop py
t. rig
justing shim S1. gh ht
pyri by
Vo
o
by c lksw
– Push the head bevel gear/input shaft toward the large cover
cted agen
Prote AG.
and turn it eight times at the same time.
– Push the head bevel gear/input shaft toward the small taper
roller bearing outer race and turn it eight times while doing this.

R32 2004 ➤

– Move the head bevel gear/input shaft up and down
(-direction of the arrow-)
– Check the play on the dial gauge and determine Stotal
Example
"Stotal” = S2 * + measurement result + preload
Installed adjusting shim(s) S2 * 1.75 mm

Measurement result (example) + 0.75 mm
Preload (constant value) + 0.20 mm
Stotal = 2.70 mm
Adjusting Shim S1 *, Determining Thickness

lkswage es n
o ot g
byV ua
Note ir se
d ran
tee
tho
u or
a ac
♦ The temporary *
adjusting shim S1 is replaced with final shim
ss
ce
le
S1 after the backlash has been determined.

un
pt
an
d
itte
y li
♦ Total shim thickness "Stotal." remains unchanged.
rm
ab
pe
ility
ot
wit
, is n
S1 * = Stotal - S2 *
h re
hole
spec
Example
es, in part or in w
Total shim thickness "Stotal." 2.70 mm t to the co

Installed adjusting shim(s) S2 - 1.75 mm
rrectness of i

l purpos
nform
ercia
Note
m
a
com
For the correct adjusting shims, refer to the parts catalog.

ion in
r
te o
thi
Available adjusting shims for S1 , refer to ⇒ page 202 .

s
iva
do
r
rp
cum
fo
Torsional Backlash, Measuring

en
ng
t.
yi Co
Pinion housing with shaft bevel gear and S3 installed Cop py
t. rig
gh ht
yri by
Installing the head bevel gear/driveshaft: S1 * is on the large side cop Vo
by lksw
cted agen
of the cover, S2 * is on the small side of the cover. Prote AG.

R32 2004 ➤
– Install the measuring tools.

♦ “a“ = 43.5 mm
♦ Turn the measuring lever -VW 388- so that the dial gauge ex‐
tension is at a right angle to the measuring surface.
– Turn the head bevel gear/input shaft all the way. The shaft
bevel gear must not move. Set dial gauge to zero, turn back
head bevel gear/input shaft and read off backlash. Write down
the value.
– Loosen the clamping screw for the roll pin and repeat three
more times after turning head bevel gear/input shaft an addi‐ AG. Volkswagen AG d
tional 90°. Add the four measured values and then calculate agen oes
olksw not
the average torsional backlash. ed by
V gu
ara
ris nte
Calculating the Average Torsional Backlash aut
ho eo
ra
ss c
Example
ce
le
un
pt
an
d
1. Measurement 0.30 mm
itte
y li
erm
ab
+ 2. Measurement 0.31 mm
ility
ot p
wit
is n
h re
ole,
spec
Total 1.20 mm
t to the co
Average backlash: 1.20 mm : 4 = 0.30 mm.
rrectne
Shim Thickness S2, Determining
s
= Inserted adjusting shim
s
S2 *
o
cial p
f in
- Average torsional back‐
form
mer
lash
atio
m
+ Lift (constant value)

o
n
c
i
or
n thi
e
Lift = 0.20 mm
t
sd
iva
o
pr
c
Example
um
r
fo
en
ng
t.
yi
S2 * Inserted adjusting shim 1.75 mm
Co
Cop py
t. rig
gh ht
- Average torsional back‐ 0.30 mm
yri
p by
o Vo
lash by c lksw
cted agen
Prote AG.
1.45 mm
+ Lift (constant value) 0.20 mm
S2 = 1.65 mm
Note
For the correct adjusting shims, refer to the Parts Catalog

1.45 175 2.05 2.35
1.50 1.80 2.10 2.40
1.55 1.85 2.15 2.45
1.60 1.90 2.20 2.50
1.65 195 2.25
1.70 2.00 2.30

R32 2004 ➤
– Install the calculated adjusting shim S2 instead of S2 *.

Table, then install two shims that add up to the necessary thick‐
ness.
thickness required.
– Install the outer race and the head bevel gear/input shaft.
S1 = Stotal - S2
Example:
S1 = 2.70 mm - 1.65 mm
S1 = 1.05 mm
Note
AG. Volkswagen AG d
agen oes
lksw not
d by Vo gu
ara
rise nte
tho eo
Adjusting Shims Available for S1 s au ra
c
s
ce
e
nl
pt
du
an
itte
y li
0.65 0.85 1.05 1.25
erm
ab
ility
ot p
0.70 0.90 1.10 1.30
wit
, is n
0.75 0.95 1.15 1.35
h re
hole
spec
0.80 1.00 1.20 1.40
es, in part or in w
t to the co
table, then install two shims that add up to the necessary thick‐
ness.
rrectness of i
– Install the adjusting shim S1.
l purpos
nform
ercia
Note
m
at
om
ion
c
large cover on some transmissions. Replace the replacement ad‐

in t
or
his
e
justing shim with the oil deflector ring originally installed in the
at
do
riv
same location.
p
cum
for
en
ng
t.
yi
– Install the outer race.
Co
Cop py
t. rig
gh
– Install the large cover.
ht
pyri by
Vo
co lksw
by
Performing Measurement Check - Measuring Torsional Backlash cted agen
Prote AG.
– It must be 0.15 to 0.20 mm.
2.11 Shift and Head Bevel Gear, Rear Final

Drive, Adjusting
General Information
Careful adjustment of the drive train is important for service life
and smooth running of angle transmission. During manufacture
the shaft bevel gear and the head bevel gear are matched and
checked on testing machines to ensure correct mesh pattern and
silent running. The position for quietest running is obtained by

R32 2004 ➤
Manual
agen AG.Transmission
Volkswagen AG - Edition 01.2012
do
w es n
olks ot g
yV ua
moving the shaft bevel gear axially and, at the sameristime,
ed
b
main‐ ran
tee
taining the backlash within the specified tolerances.
utho Replace the or
gear set (shift and head bevel gear) together! ss a ac
ce
le
⇒ “2.11.1 Gear Set, Adjusting the Marking“, page 203
un
pt
an
d
itte
y li
⇒ “2.11.2 Adjusting Shim Position“, page 206
rm
ab
pe
ility
⇒ “2.11.3 Adjustment Overview“, page 206
ot
wit
, is n
h re
⇒ “2.11.4 Sequence for Readjusting Final Drive Set“, page 207
hole
spec
⇒ “2.11.5 Shaft Bevel Gear, Adjusting“, page 207
es, in part or in w
t to the co
⇒ “2.11.6 Head Bevel Gear, Adjusting“, page 211
2.11.1 Gear Set, Adjusting the Marking
rrectness of i
l purpos
A - Head Bevel Gear
nform
ercia
A - Shaft Bevel Gear

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

R32 2004 ➤
1 - Drivetrain Pairing Number

❑ In the example: 5050
2 - Shaft Bevel Gear Dimen‐
sion (D = +2)
❑ Adjustment dimension
for standard production.
3 - Backlash (Sd = 0.12)
AG. Volkswagen AG d
❑ Check dimension. agen oes
olksw not
y V gu
d b ara
4 - Dimension “R“: Actual Di‐ orise nte
mension Between the Head auth eo
ra
Bevel Gear and Face of the ss c
Shaft Bevel Gear in Position of
ce
le
un
pt
Quietest Running for this Gear
an
d
itte
y li
Set.
erm
ab
ility
❑ In the example: R =
ot p
wit
43.14 means R = 43.14
is n
h re
mm
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

R32 2004 ➤
C - Actual Dimension Between

the Head Bevel Gear and the
Back of the Shaft Bevel Gear
at Point with Quietest Running
for this Gear set. 70.00 mm
Ro - Length of Test Machine
Master Gauge used “Ro“ = AG. Volkswagen AG d
agen oes
ksw
42.70 mm by Vol not
gu
ara
d
ise nte
r - Determine this Dimension thor eo
“r“ First, refer to ⇒ page 210 . ss au ra
c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

R32 2004 ➤
2.11.2 Adjusting Shim Position

Friction Torque/Tapered Roll‐
er Bearing - Head Bevel Gear
Head Bevel Gear
Shaft Bevel Gear
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
c
2.11.3 Adjustment Overview

or
thi
te
sd
iva
o
r
rp
cu
o
m
f
Note
en
ng
t.
yi Co
Cop py
t. rig
When working on the rear final drive, the shaft bevel gear, head gh ht
yri by
bevel gear or complete gear set only needs to be adjusted if com‐ cop Vo
by lksw
ponents were replaced which directly influence the final drive.
cted agen
Prote AG.
Refer to the table to avoid any unnecessary adjusting.
to be adjusted:
Shaft bevel gear (S3) via Head bevel gear
dimension “r“. Refer to (S1 and S2). Refer to
⇒ “2.11.5 Shaft Bevel ⇒ “2.11.6 Head Bev‐
Gear, Adjusting“, el Gear, Adjusting“,
page 207 . page 211 .
Replaced part: Pinion housing x
Rear final drive housing x x
Drivetrain (shift and head bevel x x
gear with driveshaft)

R32 2004 ➤
Shaft bevel gear tapered roller x

bearing
Head bevel gear tapered roller x
bearing
Cover (head bevel gear side) x1
• 1 Adjust only S1 using the total friction torque measured ear‐
lier.
2.11.4 Sequence for Readjusting Final Drive

Set
When the shaft bevel gear and the head bevel gear have to be
adjusted, in the interests of a rational sequence, keep to the fol‐
lowing order:
1. Adjusting the friction torque and the shaft bevel gear (S3)
– Adjusting the preload on the tapered roller bearing for the shaft
bevel gear using the friction torque measurement.
– Select the adjusting shim thickness "S3 “ and install it. This
secures the shaft bevel gear axially, that the dimension from
the center of head bevel gear to the face of shaft bevel gear
corresponds to the installation dimension “R" determined dur‐
ing production.
– Perform a check measurement on S3.
2. Adjusting the head bevel gear (S1 and S2)
– Adjusting the preload on the tapered roller bearing for the head
bevel gear suing Stotal.
– Adjust the torsional backlash. Select the adjusting shim thick‐
ness “S1“ and “ S2 “ so that the specified torsional backlash is
AG. Volkswagen AG d
present between the shaft bevel gear and swagenhead bevel gear.
the oes
olk not
V gu
by ara
– Check the torsional backlash. orised nte
h eo
ut
The goal is to reach the position
ss of quietest running that was es‐
a ra
c
tablished in production. To reach this result it is absolutely nec‐
ce
le
un
pt
essary to perform any assembling and measuring with the

an
d
itte
greatest care and cleanliness.

y li
erm
ab
ility
2.11.5 Shaft Bevel Gear, Adjusting

ot p
wit
is n
h re

ole,
spec

t to the co

rrectne
♦ Counter-Hold Tool -T10114-

ss

o
cial p
f in
♦ Dial Gauge
form
mer
♦ Standard Torque Gauge 0 to 600 Ncm

atio
om
n
c
It is necessary to readjust the shaft bevel gear when:

or
n thi
te
sd
a
♦ Pinion housing
iv
o
pr
cum
r
fo
♦ Rear final housing

en
ng
t.
yi Co
op
♦ Shaft bevel gear tapered roller bearing
C py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
207
Prote AG.
2. Description and Operation
R32 2004 ➤ n AG. Volkswagen AG do
wage es n
Manual Transmission - Edition 01.2012 yV
olks ot g
d b ua
ran
ir se tee
or the utho
or
a ac
ss
♦ Drivetrain
ce
e
nl
pt
du
an
is being replaced.
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
Friction Torque, Adjusting
hole
spec
– Install the twelve point nut for the shaft bevel gear.
es, in part or in w
t to the co
– Tighten the twelve point nut to 120 Nm, then measure the fric‐
tion torque, refer to ⇒ page 275 . It may be necessary to
increase the tightening specification until the specified friction
rrectness of i
torque is reached.
l purpos
A - Tighten with 3/4" drive

– Turn the torque wrench (40-200 Nm) -V.A.G 1332- to the right
nform
ercia
to tighten.
m
at
om
i
– Use an adapter from 1/2" to 3/4" .
on
c
in t
or
his
ate
do
riv
Note
p
cum
for
en
ng
t.
yi
Increase the torque slowly and read the friction torque several
Co
op py
times. If the specified friction torque is exceeded, then the spacer t. C rig
gh ht
sleeve must be replaced and the adjustment must be performed pyri by
Vo
co
again. If a spacer sleeve was squeezed together once too far, it
by lksw
cted agen
Prote
can no longer be used.
AG.

200 to 250 Ncm 30 to 50 Ncm
A - standard torque gauge, 0 to 600 Ncm
B - Adapter from 1/2" to 3/4" drive

Determining Thickness of Adjustment Shim S3
– Install the pinion housing with the shaft bevel gear and a tem‐
porary adjusting shim S3 * (1.3 mm thick).
Note
Insert adjusting shim S3 (1.30 mm) temporarily as a initial meas‐

urement. It is designated as S3 * in the following. S3 * is replaced
by the final adjusting shim S3 after “e“ has been determined.
– Do not install the O-ring.

R32 2004 ➤
– Set the adjusting ring of the universal measuring tool -VW 385-
to dimension -a- = 38 mm.
– Set the adjusting ring to -b- = 35 mm.
– Assemble the universal measuring tool -VW 385- according to

the illustration. -VW 385/16- = 12.3 mm long. Adjust the -VW
385/30- to Ro = 42.70 mm.
– Set the dial gauge to zero with 2 mm preload.
– -VW 385/39- Install all the way after removing the master
gauge.
– Mount the final dimension plate onto the head of the shaft
bevel gear.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
– Install the universal mandrel.
hole
spec
es, in part or in w
– Install the cover and tighten the bolts.

t to the co
– Pull the centering plate using the adjustable ring far enough to
the outside so that it is still possible to turn the mandrel by
hand.
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

R32 2004 ➤
– Measure dimension “e“. Turn the universal mandrel until the

dial gauge extension touches the magnetic plate and displays
the maximum runout (return point). Dimension “e“ (black num‐
ber range) is the measured value. Example: 0.28 mm
– Remove the universal measuring device.
Note
Make sure one more time, with the -VW 385/30- mounted, the dial
gauge is at “0“ with 2 mm preload, otherwise repeat the meas‐
urement.
Determining Thickness of Adjustment Shim S3
S3 = S3 * + r + e
(“e“ in black numbered area)
S3 = S3 * + r + e
(“e“ in black numbered area)
Note
♦ If measured in red numbered area, measured value “e“ must

be subtracted.
♦ If measured in black numbered area, measured value “e“ must
be added.
♦ Determine dimension “r“ from the master gauge “Ro“ following
agen
AG. Volkswagen AG d
this formula. o
olks
w es n
ot g
byV ua
ed ran
ris tee
Formula: r = R - Ro tho or
au ac
ss
R - Inscribed value on the head bevel gear (in the example: 43.14
ce
e
nl
mm).
pt
du
an
itte
y li
- Ro- Length of test machine master gauge used

erm
ab
ility
ot p
r = 43.14 mm - 42.70 mm
wit
, is n
h re
r = 0.44 mm
hole
spec
Example
es, in part or in w
t to the co
Value “e“ on the dial gauge 0.28 mm

Calculated dimension “r“ for this drive train + 0.44 mm
rrectness of i
Adjusting shim S3 * already installed + 1.30 mm

l purpos
Shim thickness "S3" = 2.02 mm

nform
mercia
Note
at
om
ion
c
in t
or

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

R32 2004 ➤

1.30 1.69 2.08
1.33 1.72 2.11
1.36 1.75 2.14
1.39 1.78 2.17
1.42 1.81 2.20
1.45 1.84 2.23
1.48 1.87 2.26
1.51 1.90 2.29
1.54 n AG1.93
. Volkswagen AG 2.32
wage does
olks not
1.57 d by V 1.96 2.35
gu
ara
ise n
1.60 thor 1.99 2.38 tee o
au ra
1.63
ss 2.02 2.41 c
ce
e
nl
1.66 2.05 2.44
pt
du
an
itte
y li
– Remove the complete pinion housing with the shaft bevel gear
erm
ab
ility
and 1.3 mm adjusting shim
ot p
wit
, is n
– Install the adjusting shim S3
h re
hole
spec
Two adjusting shims that add up to the measured value may be
es, in part or in w
used. t to the co
Performing Measurement Check, Checking Dimension “r“
rrectness of i
Insert universal mandrel and measure dimension “r“.

l purpos
If adjustment shims were determined correctly, dial indicator must

indicate the determined dimension “r“ with a tolerance of + 0.04
mm (reading counterclockwise in red number display).
nform
mercia
at
2.11.6 Head Bevel Gear, Adjusting

om
ion
c
in t
or

his
ate
do
riv

p
cum
for
en
g

n
t.
yi Co
Cop py
.
t rig
gh ht
pyri by
Vo
co
by lksw
cted agen
Prote AG.
♦ Crown Wheel Adjustment Device -VW 521-
♦ Dial Gauge
It is necessary to readjust the head bevel gear when:
♦ Rear final drive housing
♦ Head bevel gear tapered roller bearing/driveshaft
♦ Cover
or the
♦ Drivetrain
is being replaced.

lkswage es n
R32 2004 ➤ byV
o ot g
ua
ed ran
Manual Transmission - Edition hor01.2012
is tee
ut or
a ac
ss
Head Bevel Gear Tapered Roller Bearing Preload, Adjusting
ce
e
nl
pt
du
The shaft bevel gear is removed.
an
itte
y li
erm
ab
– Insert a 1.0 mm adjusting shim in the seat of the outer race for
ility
ot p
the small tapered roller bearing (S2 side).
wit
, is n
h re
A 1.00 mm thick adjusting shim S2 is used temporarily for the hole
spec
initial measurement. It is designated as ○S2 * in the following.
es, in part or in w
t to the co
S2 * is replaced by the final adjusting shim S2 after the torsional
backlash is determined.
rrectness of i
– Install the outer race. Refer to ⇒ page 278 .
l purpos
– Install the head bevel gear/input shaft with the tapered roller
bearing.
nform
ercia
– Install the cover with the outer race for the large taper roller
bearing outer race with the flange shaft seal and with out ad‐
m
at
justing shim S1.
om
ion
c
in t
or
his
ate
do
riv
– Move the head bevel gear/input shaft up and down

p
cum
or
(-direction of the arrow-)

f
en
ng
t.
yi Co
op
– Check the play on the dial gauge and determine Stotal C py
t. rig
gh ht
yri by
Example cop Vo
by lksw
cted agen
Prote AG.
"Stotal” = S2 + measurement result + preload
Installed adjusting shim(s) S2 * 1.00 mm

Measurement result (example) + 0.90 mm
Preload (constant value) + 0.30 mm
Stotal = 2.20 mm
Adjusting Shim S1 *, Determining Thickness
Note
♦ The temporary adjusting shim S1 * is replaced with final shim

S1 after the backlash has been determined.
♦ Total shim thickness "Stotal." remains unchanged.
S1 = Stotal - S2 *
Example
Total shim thickness "Stotal." 2.20 mm
Installed adjusting shim(s) S2 - 1.00 mm
Available adjusting shims for S1 ⇒ Table, refer to ⇒ page 214 .

Torsional Backlash, Measuring
Pinion housing with shaft bevel gear and S3 installed
Installing the head bevel gear/driveshaft: S1 * is on the cover side,

S2 * in installed in the rear final drive housing.

R32 2004 ➤
– Install the measuring tools.

♦ “a“ = 43.5 mm
♦ Turn the measuring lever -VW 388- so that the dial gauge ex‐
tension is at a right angle to the measuring surface.
– Turn the head bevel gear/input shaft all the way. Set dial gauge
to zero, turn back head bevel gear/input shaft and read off
backlash. Write down the value.
– Loosen clamping screw for the roll pin and repeat three more
times after turning head bevel gear/input shaft an additional
90°. Add the four measured values and then calculate the
average torsional backlash.
Calculating the Average Torsional Backlash
Example
1. Measurement 0.30 mm
+ 2. Measurement 0.31 mm AG. Volkswagen AG d
agen oes
olksw not
+ 3. Measurement e0.30 d b mm
y V gu
ara
is nte
+ 4. Measurement
uthor
0.29 mm eo
a ra
Total ss 1.20 mm c
ce
le
un
pt
an
d
itte
y li
Average backlash: 1.20 mm : 4 = 0.30 mm.
erm
ab
ility
ot p

wit
is n
h re
ole,
S2 * = Inserted adjusting shim spec

- Average torsional backlash

t to the co
+ Lift (constant value)

Lift = 0.20 mm
rrectne
Example
ss o
S2 * Inserted adjusting shim 1.00 mm

cial p
f inform
- Average torsional backlash 0.30 mm

mer
atio
0.70 mm
om
n
c
+ Lift (constant value) 0.20 mm

or
n thi
te
sd
a
S2 = 0.90 mm
iv
o
pr
cum
r
fo
en
ng
t.
yi Co
op
Note C py
t. rig
gh ht
pyri by
Vo
o
c by lksw
cted agen
Prote AG.
Adjusting Shims Available for r S2

0.65 0.90 1.15
0.70 0.95 1.20
0.75 1.00 1.25
0.80 1.05
0.85 1.10
– Install the calculated adjusting shim S2 instead of S2 *.

used.

R32 2004 ➤

thickness required.
– Install the outer race and the head bevel gear/input shaft.
S1 = Stotal - S2
Example:
S1 = 2.20 mm - 0.90 mm
S1 = 1.30 mm
Note
Adjusting Shims Available for r S1

0.65 0.90 1.15
wage
es n
olks ot g
0.70 0.95 d byV 1.20 ua
ran
ir se
0.75 1.00 utho 1.25 tee
or
a ac
0.80 1.05
ss
ce
le
un
0.85 1.10
pt
an
d
itte
y li
rm
– Allocate adjustment shim(s) according to the parts catalog.
ab
pe
ility
ot
– Install the adjusting shim S1.
wit
, is n
h re
hole

used. spec
es, in part or in w
t to the co
thickness required.
rrectness of i
– Install the outer race.

l purpos
– Install the cover.

Performing Measurement Check - Measuring Torsional Backlash
nform
ercia
– It must be 0.12 to 0.20 mm.

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

R32 2004 ➤
3 Specifications
3.1 Fastener
agen
AGTightening
. Volkswagen AG Specifications
do
ksw es n
Vol ot g
ed by Component ua
ran Fastener Size Nm
ris tee
utho Drive Control
All Wheel Module to Haldex Clutch Cover or Bolt - 6
a ac
ss
Bevel Box to Clutch Housing Bolt 1 - 40 + 45°
ce
e
nl
pt
du
Bracket to Rear Final Drive Housing Bolt - 10
an
itte
y li
erm
ab
Cover to Pinion Housing Bolt - 10
ility
ot p
Cover to Rear Final Drive Housing Bolt - 25
wit
, is n
h re
Differential to Rear Final Drive Housing Bolt - 25
hole
spec
Drive Axle Shield to Bevel Box Bolt - 25
es, in part or in w
t to the co
Flange to Rear Driveshaft Tube Bolt - 45
Flange to Haldex Clutch Cover Nut 2 - 220
rrectness of i
Flange Shaft Bolt - 25
l purpos
Flexible Disc with Heat Shield to Bevel Box Flange Bolt - 60

Flexible Disc with Heat Shield to Front Driveshaft Tube Bolt - 60
nform
ercia
Flexible Disc with Vibration Damper to Haldex Clutch Flange Bolt - 60

m
at
Flexible Disc with Vibration Damper to Rear Driveshaft Tube Bolt - 60

om
ion
c
Front Driveshaft Tube to Constant Velocity Joint with Boot Bolt - 40

in t
or
his
te
Haldex Clutch Cover to Pinion Housing Bolt - 50

a
do
priv
cum
Haldex Clutch Pump to Pinion Housing Bolt - 6

for
en
ng
t.
yi
Intermediate Bearing to Underbody Bolt - 25
Co
Cop py
t. rig
Large Cover to Final Drive Housing Bolt
gh
M8 25
ht
pyri by
Vo
o
Large Cover to Final Drive Housing Bolt M10 45
c by lksw
cted agen
Prote AG.
Large Cover to Final Drive Housing Stud Bolt M8/M10 45
Oil Fill Plug to Cover - 30
Oil Filter to Pinion Housing - 35
Oil Drain/Fill Plug to Rear Final Drive Housing Bolt - 25
Oil Drain Plug to Large Cover - 60
Oil Drain Plug to Haldex Clutch Cover - 15
Output Flange to Shaft Bevel Gear Nut 1, 2 - 475
Pinion Housing to Final Drive Housing Bolt 3 - 25
Pinion Housing to Rear Final Drive Housing Nut 1 - 45
Plate to Final Drive Gear/Differential Housing Nut 1 - 40 + 45°
Small Cover to Final Drive Housing Bolt - 25
Stud to Rear Final Drive Housing - 10
• 1 Always replace
• 2 Install using liquid locking fluid -D 000 600-
• 3 Install using sealant -AMV 188 200-
R32 2004 ➤
4 Removal and Installation

⇒ “4.1 Front Final Drive Components“, page 216
⇒ “4.2 Driveshaft and Components“, page 222AG. Volkswagen
n AG do
wage es n
olks page 230
⇒ “4.3 Rear Final Drive and Components“, ot g
yV ua
db ran
ise
4.1 Front Final Drive
au
tho
r
Components tee
or
ac
ss
⇒ “4.1.1 Left Flange Shaft Seal, Bevel Box Installed“, page 216
ce
e
nl
pt
du
an
⇒ “4.1.2 Right Flange Shaft Seal, Bevel Box Installed “,
itte
y li
page 217
erm
ab
ility
ot p
⇒ “4.1.3 Bevel Box Output Flange Seal, Bevel Box Removed“,
wit
, is n
page 218
h re
hole
spec
⇒ “4.1.4 Right Flange Shaft Needle Bearing“, page 220
es, in part or in w
t to the co
4.1.1 Left Flange Shaft Seal, Bevel Box In‐
stalled
rrectness of i
l purpos

♦ Additional Part for VW 771 -VW 771/37-
nf
ercia
orm
m
atio
om
n in
c

or
thi
te
sd
a

iv
o
r
rp
cu
o
♦ Sealing Grease -G 052 128 A1-

f
en
ng
t.
yi Co
op
Removing C py
t. rig
gh ht
yri
– Remove the wheel.
p by
co Vo
by lksw
cted agen
– Remove the center and left part of the noise insulation under
Prote AG.
the engine/transmission, if equipped. Refer to ⇒ Body Exte‐

rior; Rep. Gr. 50 ; Description and Operation .
– Turn the steering wheel to the left.
– Remove the drive axle from the flange shaft.
– Mark the installed position of the lower ball joint bolts -1-.
– Remove the bolts -1-. Refer to ⇒ Suspension, Wheels, Steer‐
ing; Rep. Gr. 40 ; Removal and Installation .
– Remove the flange shaft bolt. To do this, install two bolts into
the flange and counter hold the flange shaft using a pry bar.
– Place a drip tray under the transmission.
– Remove the flange shaft and the pressure spring.

lkswage es n
o ot g
byV ua
d ran
ir se
tho tee
or R32 2004 ➤
u
ss
a
Manual Transmission
ac
- Edition 01.2012
ce
le
un
pt
– Remove the flange shaft seal using the slide hammer - com‐
an
d
itte
y li
plete set -VW 771- and the additional part for VW 771
rm
ab
-771/37- .
pe
ility
ot
wit
Installing , is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
– Install the seal completely, without tilting it using the thrust

piece -3305- .
m
a
com
tio
– Fill the space between the sealing and dust lips half way with
n in
r
te o
sealing grease for seal -G 052 128 A1- .
thi
s
iva
do
– Install the flange shaft.
r
rp
cum
fo
en
g
– Secure the flange shaft with the bolt and tighten it to specifi‐
n
t.
yi Co
op
cation, see -item 20- in the ⇒ “5.1.1 Differential“, page 242 . C py
t. rig
gh ht
yri
– Install the ball joint to the control arm with new nuts. Refer to
p by
co Vo
by lksw
⇒ Suspension, Wheels, Steering; Rep. Gr. 40 ; Removal and Prote
cted AG.
agen
Installation .
– Install the left drive axle to the flange shaft. Refer to ⇒ Sus‐
pension, Wheels, Steering; Rep. Gr. 40 ; Removal and In‐
stallation .
– Install the wheel. Refer to ⇒ Suspension, Wheels, Steering;
Rep. Gr. 44 ; Specifications .
– Check the transmission fluid level in the transmission and
bevel box. Refer to
⇒ “1.1 Transmission Fluid, Checking“, page 30 .
– Install the noise insulation, if equipped. Refer to ⇒ Body Ex‐
terior; Rep. Gr. 50 ; Description and Operation .
4.1.2 Right Flange Shaft Seal, Bevel Box In‐

stalled
♦ Puller -T10037-
Removing
– Remove the center and right part of the noise insulation under
the engine/transmission, if equipped. Refer to ⇒ Body Exte‐
rior; Rep. Gr. 50 ; Description and Operation .
– Turn the steering wheel as far as possible toward the right.
– Remove the drive axle shield from the bevel box if applicable.

R32 2004 ➤

– Attach the puller -T10037- to the flange shaft.
– Align the puller with the -T10037/1- and the lower support
-A- parallel to the flange.
– Remove the flange shaft.
– Pry out the seal with a lever.
Installing
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
– Install the seal completely, without tilting it using the thrust
ce
le
un
piece -T10049- .
pt
an
d
itte
y li
rm
ab
pe
sealing grease fro seal -G 052 128 A1- .
ility
ot
wit
, is n
– Carefully install the flange shaft while rotating it at the same
h re
hole
time.
spec
es, in part or in w
– Secure the flange shaft with the bolt and tighten it to specifi‐
t to the co
cation, see -item 20- in the ⇒ “5.1.1 Differential“, page 242 .
– Install the right drive axle to the flange shaft. Refer to ⇒ Sus‐
rrectness of i
stallation .
l purpos
– Install the drive axle shield to the bevel box and tighten the
bolts to 25 Nm.
nform
ercia

m
a
bevel box. Refer to
com
tion in
r
te o
thi
s
– Install the noise insulation, if equipped. Refer to ⇒ Body Ex‐
iva
do
r
terior; Rep. Gr. 50 ; Description and Operation .

rp
cum
fo
en
ng
t.
yi Co
4.1.3 Bevel Box Output Flange Seal, Bevel Cop py
ht. rig
rig ht
Box Removed py by
co Vo
by lksw
cted agen
Prote
AG.

♦ 2-Arm Puller -20/10-
♦ 3-Arm Puller -45-2 -

R32 2004 ➤
Note
The seal for the driveshaft output flange inside the bevel box can
be replaced only when the bevel box is removed.
Removing
– Remove the bevel box. Refer to ⇒ “5.9 Bevel Box“, page 78 .
– Mount the bevel box on the hole in the transmission holder
marked with the number -4- -arrow-. G. Volkswage nA n AG d
wage oes
– Align the bevel box to the remaining 3 holes and Vol secure. M12
ks not
gu
by
x 10 nuts -A- (quantity: 4) ise
d ara
nte
r
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
T10108/1- .
– Remove the nut for the output flange.
rrectness of i
l purpos
– Remove the output flange with the seal and bearing inner race.
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
-A- - 3-arm puller -45-2 -

en
ng
t.
yi Co
op py
– Place the thrust pad -40-105- on the output flange t. C rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
– Remove the bearing inner race from the output flange using
the tapered roller bearing puller.
– Remove the seal from the output flange.
– Clean any locking fluid residue on the thread on the shaft bevel
gear.
Installing

R32 2004 ➤
– Swivel the bevel box so that the pinion housing -1- faces up‐
ward.
– Install the small inner race/tapered roller bearing for the shaft
bevel gear.
– Install the new output flange seal using the thrust piece -
T10049- .
– Grease the splines on the output flange and on the shaft bevel
gear with multipurpose grease.
– Install the output flange.
-A- - 2-arm puller -20/10-

– Mount the hooks on the bottom of the pinion housing.
– Coat the threads on the nut and on the shaft bevel gear with
liquid locking fluid -D 000 600- .
– Tighten the new nut on the output flange to specification, see
-item 32- in the ⇒ “2.2 Bevel Box Overview“, page 173 . AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
– Install the bevel box. Refer to ⇒ “5.9 Bevel Box“, page 78 .
wit
, is n
h re
hole
bevel box. Refer to
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
4.1.4 Right Flange Shaft Needle Bearing

m
at
om
ion
c

in t
or
his
ate

do
priv
cum
or

f
en
ng
t.
yi Co
op
♦ Punch -VW 407- C py
t. rig
gh ht
yri by
op Vo
by c lksw
cted agen
Prote
♦ Wheel Bearing Assembly Set -3253-
AG.
♦ Assembly Tool -T10047-

♦ Puller -T10037-
Removing
– If equipped, remove the center and right part of insulation be‐
low engine/transmission. Refer to ⇒ Body Exterior; Rep. Gr.

R32 2004 ➤
– Turn the steering wheel as far as possible toward the right.

– Remove the drive axle shield from the bevel box if applicable.
– Attach the puller -T10037- to the flange shaft.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
nte
Install the assembly tool -T10047-
horis
as follows: eo
aut ra
– Arrange both parts ofs the tool so that the marks “B“ face each
s c
ce
e
other.
nl
pt
du
an
itte
– The depressions -arrows- must be under the bearing.

y li
erm
ab
ility
– Attach both halves.
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
– Remove the needle bearing lock ring -A-.

l purpos
– So that the bearing contact surface on the shaft is not dam‐

aged, the shaft must be rotated during the procedure
nf
ercia
-arrow-.
orm
m
atio
Installing
om
n in
or c
– Install the assembly tool -T10047- , refer to ⇒ page 221 .

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

R32 2004 ➤
– So that the bearing contact surface on the shaft is not dam‐

aged, the shaft must be rotated during the procedure
-arrow-.
– Secure the bearing with a new lock ring.
– Carefully install the right flange shaft while rotating it at the
same time.
– Secure the flange shaft with a new bolt and tighten it to spec‐
ification, see -item 20- in the
⇒ “5.1.1 Differential“, page 242 .
– Install the right drive axle to the flange shaft. Refer to ⇒ Sus‐
stallation .
– Install the drive axle heat shield, if equipped, to the bevel box.
bevel box. Refer to
– Install the noise insulation, if equipped.
Shield/drive axle to bevel box 25 Nm
4.2 Driveshaft and Components

⇒ “4.2.1 Driveshaft“, page 222
⇒ “4.2.2 Front Flexible Disc“, page 226
⇒ “4.2.3 Rear Flexible Disc“, page 227
4.2.1 Driveshaft
Special tools and workshop equipment required AG. Volkswagen AG d
agen oes
lksw not
♦ Torque Wrench (5-50 Nm) -V.A.G 1331- by
Vo gu
ara
ed
is nte
♦ Torque Wrench (40-200 Nm) -V.A.G 1332- ut
hor eo
a ra
s c
Removing s
ce
le
un
A twin post hoist should be used when working on the driveshaft. pt

an
d
itte
y li
rm
ab
pe
ility
ot
Note wit
, is n
h re
hole
♦ Mark the position of all the parts to each other before removing
spec
them. Install in the same position otherwise the imbalance will

es, in part or in w
t to the co
be excessive and the bearings could get damaged causing

rumbling noises.
♦ Do not kink the driveshaft, only store and move it when fully
rrectness of i
extended.
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

R32 2004 ➤
– Remove the support bracket nuts -arrows- and support brack‐

et -1- from over the exhaust system.
– Remove the center and front heat shields.
olkswagen AG
en AG. V
– Remove the front flexible disc with heat shield olkbolts
swa -arrow-
g does
not
from the front driveshaft (only one of the three
d by V bolts is shown). gu
ara
e nte
ris
tho eo
au ra
c
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Remove the pendulum support bolts -arrows A- from the sub‐
frame.
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
– Remove the front driveshaft bolts -arrows- from the Constant rig ht
py by
Velocity (CV) joint with boot. co Vo
by lksw
cted agen
Prote AG.
– Carefully press the engine/transmission forward.
– Remove the front driveshaft from the centering pin.

R32 2004 ➤
Note
Take care not to damage the oil seals in the driveshaft flanges on
removal and installation.
– Tip the front driveshaft down and remove it.
– Remove the rear driveshaft flexible disc and vibration damp‐

ener bolts -arrows- from the Haldex clutch flange.
– Remove the intermediate bearing bolts from the vehicle un‐
derbody.
– Remove the rear driveshaft from the centering pin.
Note
♦ The flexible disc and the vibration damper cannot be separa‐

ted from each other.
♦ Do not tilt the driveshaft when removing, pull it off from the
centering pin in a horizontal position. Be careful not to damage
the seal/centering sleeve -arrow- otherwise the driveshaft will
have to be replaced. swa
gen AG
. Volkswagen AG
does
olk not
yV gu
db ara
Installing ris
e nte
tho eo
au ra
Install in reverse sorder
s of removal. c
ce
e
nl
pt
du
an
itte
y li
erm
ab
Note
ility
ot p
wit
, is n
♦ The seals in the driveshaft flanges -arrow- must not be dam‐

h re
aged when removing and installing.

hole
spec
es, in part or in w

t to the co
♦ Do not tilt the front and rear driveshafts. Install them horizon‐
tally onto each guide pin.
rrectness of i
Installed Position of the Rear Flexible Disc

l purpos
♦ The three tabs on the Haldex clutch flange align with the holes
in the flexible disc.
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
224
by lksw
cted agen
Rep. Gr.39 - Final Drive, Differential Prote AG.
R32 2004 ➤
– Align the driveshaft to the Haldex clutch flange so that the

marks -arrows- align.
As of 06.96, balancing discs -arrows- and new bolts were installed

to secure the flexible disc to the flange.
The new bolts have a 12 point socket head.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
Two of the new bolts can be installed with each balancing disc.
wit
, is n
h re
– Always replace the balancing discs with washers -A-. For the
hole
spec
correct part number, refer to the parts catalog.
es, in part or in w
t to the co
Installing the Intermediate Bearing Without Tension
– Align the intermediate bearing in its elongated holes so the
driveshaft is not under stress.
rrectness of i
– Tighten the bolts for the intermediate bearing after installing

l purpos
the driveshaft.
nform
ercia
Note
m
at
om
ion
c
in t
♦ If droning noises are audible while driving, do the following:

or
his
ate
♦ Remove the driveshaft flexible disc from the flange on the Hal‐
do
priv
dex clutch and rotate it one hole relative to the flange and
um
for
en
g
attach it again.
n
t.
yi Co
op py
♦ If droning sounds can still be heard, the driveshaft can be ro‐
t. C rig
gh ht
yri
tated back in offset by one hole. p by
co Vo
by lksw
cted agen
Prote AG.

R32 2004 ➤
Pendulum support to subframe bolts -arrows A-. Refer to ⇒ Sus‐

pension, Wheels, Steering; Rep. Gr. 40 ; Specifications .
Intermediate bearing to body bolts, see -item 18- in the
Front flexible disc with heat shield to bevel box flange, see
Rear flexible disc with vibration dampener to Haldex clutch flange,
see -item 20- in the ⇒ “5.2 Driveshaft“, page 256 .
Front driveshaft to CV joint bolts, see -item 6- in the
Flexible disc and heat shield to front driveshaft, see -item 2- in the
Flexible disc with vibration damper to rear driveshaft, see
4.2.2 Front Flexible Disc

Note
them. Install them in the same AG.position
Volkswageotherwise
n AG d the imbal‐
ance will be excessive olkswand
agenthe bearings could oeget
s n damaged
ot g
causing rumbling d b noises.
yV ua
r
e an
ris tee
♦ Do not bend
ut the driveshaft.
ho or
a ac
ss
ce
e
A twin post hoist should be used when working on the driveshaft.

nl
pt
du
an
itte
y li
Removing
erm
ab
ility
ot p
– Remove the front flexible disc with heat shield bolts -arrow-
wit
from the front driveshaft (only one of the three bolts is shown).
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

R32 2004 ➤
wage es n
– Remove the flexible disc to bevel box olks
y V flange bolts -arrows-.
ot g
d b ua
e ran
– Separate the exhaust system that
o the double clamp. Refer to ⇒
ris tee
or
Engine Mechanical, Fuel Injection
au and Ignition; Rep. Gr. 26 ; ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
frame.
l purpos
– Carefully press the engine/transmission forward.

– Carefully remove the flexible disc.
nform
ercia
Installing
m
at
om
io
Install in reverse order of removal.
n
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
Installed Position of the Front Flexible Disc pyri by
Vo
co lksw
by
cted agen
♦ The heat shield -arrow- faces the intermediate bearing. Prote AG.
♦ Each of the three tabs on the bevel box flange align with the
flexible disc holes.
Note
♦ Slide the driveshaft horizontally onto the guide pin.
For the correct tightening specifications refer to ⇒ page 225 .
4.2.3 Rear Flexible Disc

♦ Gearbox Holder -2004-
♦ Engine-/Gearbox Jack -V.A.G 1383A-

R32 2004 ➤
♦ Universal Transmission Support -V.A.G 1359/2-

A twin post hoist should be used when working on the driveshaft.
Note
them. Install them in the same position otherwise the imbal‐
ance will be excessive and the bearings could get damaged
causing rumbling noises.
♦ Do not bend the driveshaft.
Removing agen
AG. Volkswagen AG d
oes
olksw not
V
– Remove the flexible disc with vibration damper bolts ed by gu
ara
-arrows- from the Haldex clutch flange. horis nte
eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
– Remove the support bracket bolts -arrows- and support brack‐
et -1- from above the exhaust system
l purpos
nform
ercia

m
at
om
io
– Remove the center heat shield.
n
c
in t
or
his
e
– Remove the intermediate bearing bolts from the vehicle un‐

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

versal transmission support -V.A.G 1359/2- and a block of
wood under the rear driveshaft.

R32 2004 ➤
– Push the engine/transmission carefully forward and at the

same time move the pendulum support in front of the subframe
-arrow-.
– Attach the pendulum support to the subframe with a bolt -1-
(8 x 80 mm) and nut -2-.
– Touch up any paint damage as follows: remove grease resi‐
due using nitro thinner -L 001 600- . Apply 2-component acrylic
paint -ALN 769 041- with hardener -ALZ 009 001- .
– Secure the driveshaft to the transmission jack with a strap

-A- to keep it from falling down.
– Push the rear driveshaft forward.
– Attach the gearbox holder -2004- to the flexible disc with vi‐
bration damper using a bolt -B- and M10 nut and support it on
the rear driveshaft flange -arrow-.
– Lower the driveshaft slightly and remove the flexible disc.
Installing
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
♦ Take care not to damage the oil seals in the driveshaft
s au flanges ra
c
on removal and installation. s
ce
e
nl
pt
du
an
itte
y li
erm
ab
♦ Slide the rear driveshaft horizontally onto the guide pin.
ility
ot p
wit
Installed Position of the Rear Flexible Disc
, is n
h re
hole
♦ The three tabs on the Haldex clutch flange align with the holes
in the flexible disc. spec
es, in part or in w
t to the co
rrectness of i
l purpos
– Attach the driveshaft to the Haldex clutch flange so that the

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

R32 2004 ➤

Two of the new bolts can be installed with each balancing disc
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
– Always replace the balancing discs with washers -A-.
pt
du
an
itte
y li
For the correct washer, refer to the parts catalog.
erm
ab
ility
ot p
wit
, is n
h re
For the correct tightening specifications refer to ⇒ page 225 .
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
4.3 Rear Final Drive and Components
mercia
at
⇒ “4.3.1 Haldex Clutch Cover, from Disc Housing“, page 230
om
ion
c
in t
r
⇒ “4.3.2 Haldex Clutch Flange Shaft and Seal, Final Drive Re‐
o
his
te
moved“, page 232

a
do
priv
cum
or
⇒ “4.3.3 Rear Final Drive Flange Shaft Seal“, page 234

f
en
ng
t.
yi Co
⇒ “4.3.4 Pinion Housing O-ring and Haldex Clutch, Final Drive Cop py
Removed“, page 235
t. rig
gh ht
pyri by
Vo
co
⇒ “4.3.5 O-ring, Cover and Rear Axle Housing, Final Drive Re‐
by lksw
cted agen
Prote
moved“, page 237
AG.
⇒ “4.3.6 Rear Final Drive“, page 238
4.3.1 Haldex Clutch Cover, from Disc Housing

♦ Punch -VW 407-
♦ Extractor Lever -VW 681-
♦ Mounting Universal Joint -41-501-
♦ Assembly Tool -3253/1-
♦ Tube -3296-

R32 2004 ➤
1 - Seal
❑ For the flange.
ling, refer to
⇒ “4.3.2 Haldex Clutch
Flange Shaft and Seal,
Final Drive Removed“,
page 232 .
2 - Lock Ring
3 - Ball Bearing
⇒ page 232 .
⇒ page 232 .
4 - Haldex Clutch Cover
❑ Refer to the Parts Cata‐
log.
5 - Concave Washer
❑ Installed position: The
larger diameter (con‐
cave) side faces the disc
housing -item 15-.
❑ There are different lkswage es n
thicknesses. d byV
o ot g
ua
ran
❑ Refer to the Parts Cata‐ ir se tee
tho
or
log au ac
ss
ce
e
6 - Disc for Axial (Thrust) Bear‐

nl
pt
du
ing
an
itte
y li
erm
ab
ility
ot p
ing
wit
, is n
h re
hole
spec
ing
es, in part or in w
t to the co
9 - Axial (Thrust) Bearing
rrectness of i
l purpos
12 - Thrust Washer
13 - Thrust Washer
nf
ercia
or
14 - Thrust Washer
m
m
atio
m
15 - Disc Housing
o
n in
or c
thi
❑ Remove from the Haldex clutch cover, refer to ⇒ page 265 .

te
sd
iva
o
r
16 - Needle Bearing
rp
cu
o
m
f
en
ng

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

R32 2004 ➤
Removing the Ball Bearing from the Haldex Clutch Cover

lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
Installing the Ball Bearing into the Haldex Clutch Cover
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
Removing the Needle Bearing from the Disc Housing
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
B - Internal puller 14.5 to 18.5 mm, for example, Kukko extractor Cop py
14.5-18.5 mm -21/2-
t. rig
gh ht
pyri by
Vo
co
C - Protective jaws
by lksw
cted agen
Prote AG.
Installing the Needle Bearing into the Disc Housing
4.3.2 Haldex Clutch Flange Shaft and Seal,

Final Drive Removed

R32 2004 ➤

Removing
For mounting the rear final drive, transmission support -VW 353-
must be modified on the assembly stand.
Dimensions are in mm.
– Transfer the hole -arrow 1- according to the illustration.
– Drill a 13 mm diameter hole -arrow 1- into the transmission
support -VW 353- .
– Enlarge the hole -arrow 2- to 13 mm.
– Clamp the rear final drive in the assembly fixture .
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
– Remove the flange nut.

, is n
h re
hole
A - M10 x 20 bolts
spec
es, in part or in w
t to the co
Note
rrectness of i
Counter hold the flange by the tube -C- using the gearbox holder
-2004- when loosening the nut (2nd technician needed).
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

R32 2004 ➤
– Remove the flange. Use a three arm puller, for example, 3-arm
. Volkswagen AG
puller -45-2 - -A- as needed. swa
gen AG does
k not
Vol gu
– Remove the seal using extractor lever -VW 681- . sed by ara
nte
ri
Installing utho eo
ra
a c
ss
– Lubricate the outer diameter of the new Haldex clutch seal and
ce
le
un
pt
between the sealing lips with high performance gear oil for
an
d
itte
y li
Haldex coupling -G 052 175 A1- before installing it.
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Install the new seal flush using thrust piece -T10019- .
– Install the flange.
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi
– Install a new nut using liquid locking fluid -D 000 600- and
Co
op py
tighten it to specification.
t. C rig
gh ht
pyri by
Vo
o
A - M10 x 20 bolts
c by lksw
cted agen
Prote AG.
Note
-2004- when tightening the nut (2nd technician needed).
– Install the rear final drive. Refer to

⇒ “4.3.6 Rear Final Drive“, page 238 .
– Check the transmission fluid level in the Haldex clutch. Refer
to
page 169 .
– Specifications, refer to the Fluid Capacity Tables, Rep. Gr. 03.
4.3.3 Rear Final Drive Flange Shaft Seal

♦ Puller -T10037-
♦ Arbor -VW 195-
Note
All illustrations show the right side of the final drive. Removing
and installing the left flange shaft and seal is identical.

R32 2004 ➤
Removing
– Remove the left drive axle and tie it to the lower transverse
link.
– Remove the right driveshaft and tie it between the upper and
lower transverse links.
– Install the lower support from the puller -T10037- into the
housing -arrow- and remove the flange shaft.
– Pry out the seal with a lever.
Installing
– Install the new seal flush using arbor -VW 195- . AG. Volkswagen AG d
agen oes
ksw
– Fill the space between the sealing and dust lips by
Vhalf way with
ol not
gu
sealing grease for seal -G 052 128 A1- . rise d ara
nte
ho eo
ut
– Clamp the flange shaft in a vise with sjaw
s a protectors. ra
c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Remove the old lock ring from the groove in the flange shaft
using the new lock ring -A-.
rrectness of i
– Install the flange shaft using a plastic hammer.
l purpos
– Replace the flange shaft seal (peel off the protective film and
attach the seal to the joint).
nform
ercia
– Install the drive axle. Refer to ⇒ Suspension, Wheels, Steer‐

ing; Rep. Gr. 42 ; Removal and Installation .
m
a
com
tion in
– Check the transmission fluid level in the rear final drive. Refer
r
te o
thi
to
s
iva

do
r
rp
page 171 .
um
fo
en
ng
t.
yi
Co
Cop py
t. rig
gh ht
yri by
4.3.4 Pinion Housing O-ring and Haldex
op Vo
by c lksw
cted agen
Prote
Clutch, Final Drive Removed
AG.


R32 2004 ➤
Removing
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
– Remove all the nuts -arrows- for the pinion housing.
t to the co
Note
rrectness of i
l purpos
The illustration only shows 3 nuts.

nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
g
– Remove the pinion housing. When doing this install the bolts
n
t.
yi Co
-A- evenly so that the housing does not tilt. Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
– Remove the O-ring -A-.

Installing

R32 2004 ➤
– Install the O-ring -A- using transmission fluid.

swa es
– Install adjusting
by
Voshim(s)
lk -B- with the same thickness.
not
gu
a
d ran
se
– The nuts
thoare provided with the sealant -197 300 A1- .e o
ri te
au ra
c
– Checkss the transmission fluid level in the rear final drive. Refer
ce
le
to
un
pt
an
d
itte
y li
page 171 .
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
to
t to the co
page 169 .
rrectne
s
Pinion housing to the rear final drive housing, refer to
s o
⇒ “2.4 Pinion Housing Overview“, page 178 .
cial p
f inform
mer
4.3.5 O-ring, Cover and Rear Axle Housing,
atio
om
n
Final Drive Removed
c
i
or
n thi
te
sd
a

iv
o
pr
cum
r
fo

en
ng
t.
yi Co
op
Removing
C py
t. rig
gh ht
yri by
– Drain the transmission fluid. cop Vo
by lksw
cted agen
Prote
– Remove the left/right flange shaft.
AG.
– Remove the vent -arrow- from the rear final drive housing.
Note
The illustration shows the rear final drive removed.
– Remove the right or left cover. When doing this, install the bolts
-A- evenly so that the cover does not tilt.
– Remove the right cover and the differential.
– Remove the O-ring -A-.

Installing
– Install the O-ring -A- using transmission fluid.
– Add transmission fluid until it reaches the lower edge of the fill
hole.
to
page 171 .
Cover to the rear final drive housing, see -item 16- in the
page 180 .

R32 2004 ➤
4.3.6 Rear Final Drive

♦ Engine-/Gearbox Jack -V.A.G 1383A-
♦ Multipoint Socket -T10035-
Removing
– Remove the rear section of the exhaust system. Refer to ⇒
Engine Mechanical, Fuel Injection and Ignition; Rep. Gr. 26 ;
– Remove the heat shield under the luggage compartment.
– Mark the position of the rear driveshaft to the Haldex clutch
flange in color.
– Remove the rear driveshaft flexible disc and vibration damper
bolts -arrow- from the flange.
– Remove the right drive axle and tie it between the upper and
lower transverse links.
– Remove the left drive axle and tie it to the lower transverse
link.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
– Remove the bolts -A and B- from the front bracket/final drive.

du
an
itte
y li
erm
– Remove the bolts -C- on the front bracket/final drive from the
ab
ility
frame using the multipoint socket -T10035- .

ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
– Place the engine-/gearbox jack -V.A.G 1383A- with the uni‐

versal support -1359/2- under the final drive only and then
m
at
secure it to the final drive.

om
ion
c
in t
r
– Remove the right and left bolts form the frame (-arrow A-).
o
his
ate
do
riv
– Remove rear final drive right bracket, right and left bolts
p
cum
or
(-arrow B-).
f
en
ng
t.
yi Co
Cop py
ht. rig
Note rig ht
py by
co Vo
by lksw
cted agen
Prote
Only one of the two bolts is shown in the illustration.
AG.
– Disconnect the connector from the Haldex clutch (-arrow C-).

R32 2004 ➤
– Remove the right and left vent tube from the carrier -arrow-.
Note
Only the left vent tube is shown in the illustration.
– Lower the final drive slightly and remove it from the frame
carefully using the engine-/gearbox jack -V.A.G 1383A- .
– Lower the final drive.
lkswage es n
o ot g
b yV ua
d ran
– Remove the final drive from the bracket -A- or if it has to be re‐
ise
tee
placed or mounted in an assembly stand. auth or
ac
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
– Replace the left -A- (400 mm) and right -B- (300 mm) vent tube
l purpos
if the final drive is being replaced.

Installing
nform
ercia

m
a
com
ti
♦ Always use new bolts.
on in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
– There are different bolts for the front bracket/final drive. cted agen
Prote AG.
Bolts -A- M10 x 40

Bolts -B- M10 x 55

R32 2004 ➤
♦ Push the driveshaft horizontally onto the guide pins on the final
drive. A second technician will needed.
♦ Slide the rear driveshaft horizontally onto the guide pin.
– Align the driveshaft to the Haldex clutch flange so that the


Two of the new bolts can be installed with each balancing disc
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

R32 2004 ➤
– Always replace the balancing discs with washers -A-.

For the correct washer, refer to the parts catalog.
Note
♦ If droning noises are audible while driving, do the following:

♦ Remove the driveshaft flexible disc with vibration damper from
the Haldex clutch flange and rotate one hole relative to the
flange and attach again.
♦ If droning sounds can still be heard, the driveshaft can be ro‐
tated back offset by one hole.
to
page 171 .
to
page 169 .
– Specification, refer to the Fluid Capacity Tables, Rep. Gr. 03. AG. Volkswagen AG d
agen oes
lksw not
Tightening Specifications by Vo gu
ara
d
ise nte
Front mounting bracket to rear final drive uthor eo
a ra
s c
Front mounting bracket to subframe s
ce
le
un
pt
Rear mounting bracket to rear final drive
an
d
itte
y li
rm
ab
Rear mounting bracket to subframe
pe
ility
ot
wit
For All Above Components
, is n
h re
hole
Refer to ⇒ Suspension, Wheels, Steering; Rep. Gr. 42 ; Speci‐
spec
fications .
es, in part or in w
t to the co
Drive axle to flange shaft. Refer to ⇒ Suspension, Wheels, Steer‐
ing; Rep. Gr. 42 ; Specifications .
rrectness of i
Flexible disc with vibration dampener to Haldex clutch flange, see
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

R32 2004 ➤

⇒ “5.1 Front Final Drive“, page 242
⇒ “5.2 Driveshaft“, page 256
⇒ “5.3 Rear Final Drive“, page 260
5.1 Front Final Drive

⇒ “5.1.1 Differential“, page 242
⇒ “5.1.2 Bevel Box“, page 248
5.1.1 Differential
♦ Punch -VW 407-
♦ Tube -3259-
♦ Tube -3296-
agen
AG. Volkswagen AG d
o w es n
olks ot g
♦ Tapered Roller Bearing Pullered-V.A.G
by
V
1582- ua
ran
ris tee
♦ Attachment to VAG 1582au-V.A.G
tho 1582/6- or
ac
ss
ce
le
un
pt
an
d

itte
y li
erm
ab

ility
ot p
wit
is n
♦ Kukko Support -22/2 -

h re
ole,
spec
Note
t to the co
♦ Heat the inner race/tapered roller bearing to 100 °C (212 °F)

before installing.
rrectne

ss
♦ Adjust the differential, refer to

o
cial p
f i
⇒ “2.9 Differential, Front Final Drive, Adjusting“, page 187

nform
when replacing tapered roller bearing, differential housing,

mer
atio
transmission housing and clutch housing.

om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

R32 2004 ➤
2 - Bolt
❑ The final drive gear
-item 4- and the differ‐
ential housing -item 3-
are only available as‐
sembled.
❑ Single parts
-items 2, 3, 4, 5 and 6-
have been discontin‐
ued.
3 - Differential Housing
sembled.
❑ Single parts
-items 2, 3, 4, 5 and 6-
ued.
4 - Final Drive Gear
sembled.
❑ Single parts
-items 2, 3, 4, 5 and 6-
ued.
5 - Plate
AG. Volkswagen AG d
ential housing -item 3- ksw
agen oes
not
l
are only available as‐ by Vo gu
ara
sembled. rise
d
nte
ho eo
❑ Single parts -items 2, 3, 4, 5
sa
uand 6- have been discontinued.
t ra
c
s
6 - Nut
ce
le
un
pt
an
d

itte
y li
rm
ab
❑ Always replace.
pe
ility
ot
❑ The final drive gear -item 4- and the differential housing -item 3- are only available assembled.
wit
, is n
h re
❑ Single parts -items 2, 3, 4, 5 and 6- have been discontinued.

hole
spec
7 - Clutch Housing
es, in part or in w
t to the co
8 - Adjusting Shim
rrectness of i
❑ Determining thickness, refer to ⇒ “2.9 Differential, Front Final Drive, Adjusting“, page 187 .
l purpos

nform
ercia

m
a
com

ion in
r

te o
thi
s
iva

do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
243
c by lksw
cted agen
Prote AG. 5. Disassembly and Assembly
R32 2004 ➤ lkswage es n
o ot g
Manual Transmission - Edition 01.2012 byV ua
d ran
ir se tee
tho
u or
11 - Differential Housing ss
a ac
ce
e
nl
pt
du
an
itte
❑ Remove before removing the sleeve -item 15-.
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
14 - Adjusting Washer
rrectness of i
❑ Allocate the parts according to the Parts Catalog.
l purpos
15 - Sleeve
❑ Installed on the differential housing.
nform
ercia
❑ Remove and install only when the differential housing is removed.

m
at
om
ion
c
in t
r

o
his
ate
do
riv
16 - Seal
p
cum
or
❑ For the right flange shaft.

f
en
ng
t.
yi Co
❑ The left and right seal diameters are different. Cop py
t. rig
gh
❑ Replace when the transmission is installed. Refer to
ht
pyri by
Vo
o
⇒ “4.1.2 Right Flange Shaft Seal, Bevel Box Installed “, page 217 .
c by lksw
cted agen
Prote AG.
17 - Bevel Box
❑ Removing and installing, refer to one of the following:
with the transmission installed. Refer to ⇒ “5.9 Bevel Box“, page 78 .
with the transmission removed. Refer to ⇒ page 83 .
18 - Bolt
❑ Always replace.
19 - Washer
20 - Bolt
❑ 25 Nm
❑ Install with a threaded piece -item 29-.
22 - O-ring
❑ Always replace.
23 - O-ring
❑ Always replace.
24 - O-ring
❑ Always replace.
25 - Large Differential Bevel Gear
26 - Differential Bevel Gear Shaft
❑ Remove using a drift.

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
horis nte
eo R32 2004 ➤
aut Manual Transmission
ra - Edition 01.2012
ss c
ce
le
un
pt
27 - Expansion Pin
an
d
itte
y li
❑ For securing the differential bevel gear shaft.
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
28 - Small Differential Bevel Gear
es, in part or in w
t to the co
29 - Threaded Piece
rrectness of i
l purpos
nform
ercia
30 - Thrust Washer Union

m
a
com
tio
n in
r
te o
thi
31 - Lock Ring
s
iva
do
r
❑ Holds the tapered ring, the thrust washer and the pressure spring when the flange shaft is removed.
rp
cum
fo
en
ng
32 - Tapered Ring
t.
yi Co
Cop py
❑ With grooves for the thrust washer. ht. rig
rig ht
py by
❑ Installed position: differential housing taper. co Vo
by lksw
cted agen
Prote AG.
33 - Thrust Washer
❑ Installed position: Collar towards spring, tab toward tapered ring.
34 - Flange Shaft Pressure Spring
❑ Installed behind the flange shafts.
❑ With a ring as of transmission date of manufacture 19 May 2003.
❑ The ring protects the seal from dirt.
❑ Pry the ring off using a screwdriver alternating from side to side.
❑ Installed position: The depression faces away from the threaded holes in the flange shaft.
❑ Install the ring all the way by hand.
❑ The ring must lock into the flange shaft.
36 - Seal
❑ For the left flange shaft.
❑ The left and right diameters are different
❑ Replace when the transmission is installed. Refer to
⇒ “4.1.1 Left Flange Shaft Seal, Bevel Box Installed“, page 216 .
Removing the Outer Race/Tapered Roller Bearing from the

Clutch Housing
46-58 mm -21/7-
Note
Check the washer for damage after removing it and replace if

necessary.

R32 2004 ➤
Installing the Outer Race/Tapered Roller Bearing into the Clutch

Housing
– Install the washer beforehand.
AG. Volkswagen AG d
agen oes
lksw not
Removing the Inner Races/Tapered Rollerd bBearings
yV
o gu
ara
ise nte
r
– Before installing the puller, set theuththrust piece -40-105- onto
o eo
ra
the differential housing. ss a c
ce
e
nl
pt
du
an
itte
Note
y li
erm
ab
ility
ot p
Both tapered roller bearing inner races are removed from the dif‐
wit
, is n
ferential housing in the same way.
h re
hole
spec
es, in part or in w
t to the co
Installing the Inner Races/Tapered Roller Bearings
rrectness of i
l purpos
Note
nform
ercia
The inner race/tapered roller bearing for the transmission housing

m
and clutch housing are installed using the same pressing tools.
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
by
Removing the Outer Race/Tapered Roller Bearing from the copy Vo
by lksw
Transmission Housing cted agen
Prote AG.

46-58 mm -21/7-

R32 2004 ➤
Installing the Outer Race/Tapered Roller Bearing into the Trans‐

mission Housing
– Support the transmission housing directly under the bearing
mount using the press tool -3345- .
Removing and Installing the Expansion Pin for the Differential

Bevel Gear Shaft
Removing
– Cover the inner race/tapered roller bearing in order to prevent
possible damage and entry of shavings.
– Remove the roll pin using a punch.
Installing AG. Volkswagen AG d
agen oes
ksw
– Drive into the differential housing up to the by Vstop.
ol not
gu
ara
d
rise nte
tho eo
au ra
ss c
ce
e
nl
Differential Planetary Gears, Installing
pt
du
an
itte
y li
– Insert the thrust washer union with transmission fluid.
erm
ab
ility
ot p
– Install both large differential bevel gears and secure them (for
wit
, is n
example, with the flange shaft).
h re
hole
spec
– Insert the small differential planetary gears 180° offset and
es, in part or in w
pivot them into position.
t to the co
– Press the differential bevel gear (-arrow A-) up to the first small
differential bevel gear.
– Install the threaded pieces (-arrows B-) in the large differential rrectness of i
l purpos
bevel gears: the collar faces the differential bevel gear

– Drive differential planetary gear axle into final position and se‐
nform
ercia
cure with the roll pin.

m
at
om
Remove the Connecting Sleeve -A-

ion
c
in t
or
B - Puller, for example, Kukko puller 65-160 mm -18/1-

his
ate
do
riv
C - Separating tool 12 to 75 mm, for example, Kukko separating

p
cum
or
tool 12-75 mm -17/1-

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

R32 2004 ➤
Attaching the Connecting Sleeve -A- for the Bevel Box
5.1.2 Bevel Box

♦ Thrust Plate -VW 402- AG. Volkswagen AG d
agen oes
ksw
♦ Punch -VW 408 A- byV
ol not
gu
d ara
ise nte
♦ Punch -VW 409- hor eo
aut ra
c
♦ Thrust Disc -VW 412- ss
ce
le
un
pt
♦ Thrust Shells for Drive Pinion Bearing -VW 470/1-
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
♦ Sleeve -30-21-
t to the co
♦ Drift -3138- rrectness of i
l purpos
♦ Tube -3259-
nform
ercia
♦ Puller -T10037-
m
a
com

ion in
r
te o
♦ 3 Arm Puller -45-2-

thi
s
iva
do

r
rp
cum
fo
en
g

n
t.
yi Co
Cop py
♦ Torque Wrench (5-50 Nm) -V.A.G 1331- ht. rig
rig ht
py by
o Vo
by c lksw
cted agen
Prote AG.
♦ Internal Puller -21/02-
♦ Internal Puller -21/89-
♦ 2 Arm Puller -20/10- with

R32 2004 ➤
♦ Puller Hooks w/Tensioner -V/170-

♦ Punch -VW 407-
AG. Volkswagen AG d
agen oes
♦ Transmission Holder -T10108- Volksw not
gu
d by ara
e
♦ Stop Plate -T10108/1- horis nte
eo
aut ra
Disassembly ss c
ce
le
un
– Drain the transmission fluid.
pt
an
d
itte
y li
– Mount the bevel box to the hole in the transmission holder erm
ab
marked with the number -4- -arrow-.
ility
ot p
wit
is n
– Then align bevel box to the remaining 3 holes and secure.
h re
ole,
spec
M12 x 10 nut -A- (quantity: 4)
t to the co
rrectness o
cial p
f inform
mer
atio
m
T10108/1- .
o
n
c
i
or
n thi
– Remove the nut from the output flange.
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
– Attach the puller -T10037- to the right flange shaft.

– Remove the seal if necessary.

R32 2004 ➤
– Remove the output flange with the seal and bearing inner race.
A - Three-arm puller, for example, 3-arm puller -45-2-
– Place the thrust piece -40-105- on the output flange
– Remove the bearing inner race from the output flange using
the tapered roller bearing puller.
– Remove the seal from the output flange.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
– Swivel the bevel box so that the pinion housing -1- faces up‐
un
pt
an
ward.
d
itte
y li
rm
ab
– Remove the bolts that connect the pinion housing to the final
pe
ility
drive housing.
ot
wit
, is n
h re
– Remove the pinion housing.
hole
spec
A - Two-arm puller, for example, 2-arm puller -20/10- , with puller
es, in part or in w
t to the co
hooks w/tensioner -V/170-
– Remove the adjusting shim S3
rrectness of i
– Remove the shaft bevel gear with adjusting shim S4 and the
l purpos
inner race for the large tapered bearing from the final drive
housing.
nform
ercia
– Clean any locking fluid residue on the thread on the shaft bevel
gear.
m
a
com
tion in
r
te o
thi
Note
s
iva
do
r
rp
cum
♦ The pinion housing can be removed and installed wit the out‐
fo
en
ng
put flange still installed.

t.
yi Co
Cop py
. rig
♦ Clean any sealant still on the sealing surfaces of the pinion
ht ht
rig by
py
housing, final drive housing and adjusting shim S3. co Vo
by lksw
cted agen
Prote AG.
♦ Clean the threaded holes in the final drive housing as well as
the bolts for attaching the pinion housing.

R32 2004 ➤
– Remove the small taper roller bearing outer race from the pin‐
ion housing.
– Remove the large taper roller bearing outer race from the pin‐
ion housing.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
– Remove the four bolts -1- from the small cover -2-.
h re
ole,
spec
– Remove the small cover with the outer race/tapered roller
bearing and adjusting shim S2.
t to the co
– Remove the inner race/tapered roller bearing -3- from the
head bevel gear/driveshaft -5-.
rrectnes
Note
s o
cial p
f in
The inner race can be removed by hand. If necessary, after re‐ form
mer
moving the large cover, carefully lift at the head bevel gear/input
atio
m
shaft and remove the inner race.

o
n
c
i
or
n thi
te
– Remove the large cover -4-.

sd
iva
o
pr
cum
r
– Remove the head bevel gear with the input shaft -5-.
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
– Remove the outer race on the large taper roller bearing from
the large cover.
B - Internal puller 56 to 110 mm , for example, internal puller
-21/89-

R32 2004 ➤
– Remove the inner race on the large tapered bearing from the
head bevel gear.
tool 22-115 mm -17/2-
– Remove the roller sleeve from the final drive housing.

A - Internal puller 22 to 28 mm, for example, Kukko extractor
23.5-30 mm -21/4- swa
gen AG
. Volkswagen AG
does
olk not
yV gu
edb ara
ris nte
tho eo
au ra
c
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
– Remove the sleeves for the oil supply.
es, in part or in w
t to the co
B - Internal puller 14.5 to 18.5 mm , for example, Kukko extractor
rrectness of i
14.5-18.5 mm -21/2-
l purpos
(for removing the large sleeve)

C - Internal puller 8 to 12 mm , for example, internal puller -21/02-
nform
ercia
(for removing the small sleeve)

m
at
om
ion
c
in t
or
Note
his
ate
do
priv
It is also possible to remove when the bevel box is not disassem‐

um
for
en
bled.
ng
t.
yi Co
Cop py
ht. rig
Assembly
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Note


R32 2004 ➤
Installing the Sleeves for the Oil Supply

– Carefully install all the way in.
Note
♦ Installed position: Lettered side faces the punch

♦ The sleeves can also be installed when the bevel box is as‐
sembled using the punch -VW 409- .
Installing the Roller Sleeve in the Final Drive Housing

– Install the roller sleeve all the way into the final drive housing
using sleeve -30-21- .
Note
The lettering faces the press tool.
– Install the inner race on the large tapered bearing on the head
bevel gear.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
– Mount the oil deflector ring in the large cover with the opening
y li
erm
ab
-arrow A- over the tab -arrow B-.

ility
ot p
wit
, is n
h re
Note
hole
spec
es, in part or in w
t to the co
large cover on some transmissions. The adjusting shim must be
installed in this location again.
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

R32 2004 ➤
– Install adjusting shim S1 into the large cover and then install
the outer race for the large taper roller bearing.
– Install the head bevel gear/input shaft -1- in the final drive
housing.
– Coat the new O-ring with oil and install it in the large cover
-2-.
Note
Some transmission do not have an O-ring. Apply sealant -AMV

. Volkswagen AG
188 200- on the sealing surface. lkswagen AG does
n
o ot g
yV ua
edb ran
– Tighten the bolts -3, 4 andho 5- diagonally,
ris see -item 9- in the tee
⇒ “2.2 Bevel Box Overview“,
aut page 173 . or
ac
ss
ce
e
nl
pt
– Rotate the bevel box 180°.

du
an
itte
y li
– Mount the inner race/tapered roller bearing -A- on the head

erm
ab
ility
bevel gear/input shaft.

ot p
wit
, is n
– Place the outer race/tapered roller bearing -B- and the adjust‐
h re
hole
ing shim S2 -C- on that.

spec
es, in part or in w
– Place a new O-ring -arrow- on the sealing surface of the small

t to the co
cover -D-.
– Install the cover and tighten the bolts -E-, see -item 21- in the
rrectness of i
⇒ “2.2 Bevel Box Overview“, page 173 .

l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
– Install the outer race on the small taper roller bearing into the
yi Co
op py
pinion housing. . C rig
ht ht
rig by
py
When installing, the tab -arrow- on the pinion housing must be in
co Vo
by lksw
cted
front of the thrust plate -VW 402- .
agen
Prote AG.

R32 2004 ➤
– Install the outer race on the large taper roller bearing into the
pinion housing.
– Install the shaft bevel gear with adjusting shim S4 and the inner
race for the large tapered bearing in the final drive housing.
– Coat both sides of the adjusting shim S3 with sealant and
mount it on the final drive housing.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
– Coat the bolts with sealant and install the pinion housing -1-.
y li
erm
ab
ility
– Install the small inner race/tapered roller bearing for the shaft
ot p
bevel gear.
wit
is n
h re
ole,
– Install the new output flange seal using the thrust piece -
spec
T10049- .
t to the co
– Fill the space between the sealing and dust lip half way with
rrectne
– Grease the splines on the output flange and on the shaft bevel
gear with multipurpose grease.
ss o
cial p
f inform
mer
Installing the Output Flange
atio
m
A - Two-arm puller , for example, 2-arm puller -20/10-

o
n
c
i
or
n thi
e
– Mount the hooks on the bottom of the pinion housing.

t
sd
iva
o
pr
c
– Coat the threads on the nut and on the shaft bevel gear with
um
r
fo
liquid locking fluid -D 000 600- .
en
ng
t.
yi Co
op py
– Tighten the new nut on the output flange to tightening speci‐ t. C rig
gh ht
fication, see -item 13- in the yri
p by
o Vo
⇒ “2.9 Transmission Housing and Shift Mechanism, through by c lksw
cted agen
Prote AG.

R32 2004 ➤
– Install the new seal in the right flange shaft.

– Fill the space between the sealing and dust lip half way with
– Carefully install the right flange shaft while rotating it at the

same time.
– Make sure the flange shaft can turn after installing it.
– If necessary, hit the opposite side of the flange shaft with a
rubber hammer. agen
AG. Volkswagen AG d
o w es n
olks ot g
byV ua
ed ran
ris tee
tho or
au ac
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
5.2 Driveshaft
ot
wit
, is n
h re
hole
spec
es, in part or in w
♦ Puller -VW 391-
t to the co
rrectness of i
l purpos
♦ Punch -VW 407-

nform
ercia

m
a
com
ti
♦ Sleeve-Press Tool -VW 522-

on in
r
te o
thi
♦ Press Block -40-204 A-

s
iva
do
r

rp
cum
fo
en
ng

t.
yi Co
Cop py
. rig
♦ Circlip Pliers -VW 161 A-
t
gh ht
pyri by
Vo
co
♦ Kukko Puller -18/0-
by lksw
cted agen
Prote AG.

R32 2004 ➤
Note
♦ The entire driveshaft was balanced during manufacture In or‐

der to achieve the quietest possible running. It is not possible
to balance the entire driveshaft or the individual driveshaft
tubes with workshop equipment. The entire driveshaft must
always be replaced if the front or rear driveshaft tubes are
damaged.
♦ Do not kink the driveshaft, only store and move when fully ex‐
tended.
them. Install in the same position otherwise the imbalance will
be excessive and the bearings could get damaged causing
rumbling noises.
1 - Manual Transmission with

Bevel Box
2 - 12 Point Collar Bolt
❑ 60 Nm
AG. Volkswagen AG d
3 - Flexible Disc with Heat lksw
agen oes
not
Shield d byV
o gu
ara
ise nte
❑ Removing and installing hor eo
⇒ “4.2.2 Front Flexible aut ra
s c
Disc“, page 226 . s
ce
le
un
pt
an
d
itte
to ⇒ page 227 .
y li
rm
ab
pe
ility
ot
wit
, is n
❑ 60 Nm
h re
hole
spec
5 - Front Driveshaft Tube
es, in part or in w
❑ Do not damage the cen‐
t to the co
tering sleeve and seal
when removing and in‐
stalling.
rrectness of i
6 - Bolt
l purpos
❑ 40 Nm
nform
ercia
7 - Lock Plate
m
8 - Clamp
com
tion in
❑ Tensioning, refer to
r
te o
thi
⇒ page 259 .
s
iva
do
r
rp
9 - Constant Velocity (CV)

um
fo
Joint Boot
en
ng
t.
yi Co
op
❑ Remove with the man‐ C py
ht. rig
drel before removing the rig ht
py by
CV joint.
co Vo
by lksw
cted agen
❑ Check for damage.
Prote AG.
10 - Concave Washer
❑ Splined on the inner diameter.
❑ Installed position: Larger diameter makes contact on CV joint.
11 - Seal
❑ Replace, remove protective foil and adhere in CV joint.
12 - Constant Velocity (CV) Joint

R32 2004 ➤
❑ Filling with grease: press 25 g G-6.3 grease -G6.3- on each side (total 50 g) into the joint. Add grease
to the joint if the CV boot was replaced.
13 - Lock Ring
❑ Remove and install using snap ring pliers -VW 161 A- .
14 - Bolt
❑ 45 Nm
15 - Washer
❑ Always replace.
16 - Flange
17 - Intermediate Bearing
❑ Installed position, refer to ⇒ page 260 . n AG. Volkswagen AG do
wage es n
❑ Installing, refer to ⇒ page 260 . yV
olks ot g
ua
b
ed ran
18 - Bolt horis tee
ut or
❑ 25 Nm ss
a ac
ce
le
19 - Rear Driveshaft Tube

un
pt
an
d
itte
❑ Do not damage the centering sleeve and seal when removing and installing.
y li
erm
ab
ility
ot p
wit
is n
❑ 60 Nm
h re
ole,
❑ Two of the new bolts can be installed with a balancing washer in place of a mounting washer.
spec
21 - Flexible Disc with Vibration Damper
t to the co
❑ Removing and installing, refer to ⇒ “4.2.3 Rear Flexible Disc“, page 227 .
rrectne
s
❑ 60 Nm s o
cial p
❑ Change: As of 09.02, some driveshafts have new bolts with balancing nuts and washers.
inform
mer
❑ Two of the new bolts with the balancing nut and washer can be installed.
atio
m
❑ If the bolts were loosened, then the balancing washer and balancing nut cannot be installed again.
o
n
c
i
or
n thi
te
Note
sd
iva
o
pr
cum
r
fo
en
ng
23 - Rear Final Drive

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

R32 2004 ➤
Installing the CV Joint

– Install carefully.
– Tighten press block -40-204 A- , the driveshaft must not be
pressed downward in the press block -40-204 A- , otherwise
there may be damage to paint.
– Touch up any paint damage as follows: remove grease resi‐
due using nitro thinner -L 001 600- . Apply 2-component acrylic
paint -ALN 769 041- with hardener -ALZ 009 001- .
Tensioning the Clamp

For the correct clamp refer to the parts catalog.
Removing the Flange
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
Installing the Flange

wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

AG. Volkswagen AG d
agen oes
olksw not
R32 2004 ➤ d by
V gu
ara
e nte
horis
eo
aut ra
ss c
Intermediate Bearing, Removing
ce
e
nl
pt
du
an
– Cut through the rubber guide for the center bearing and re‐
itte
y li
move the metal jacket.
erm
ab
ility
ot p
A - Separating device 12 to 75 mm, for example, Kukko separat‐
wit
, is n
ing tool 12-75 mm -17/1-
h re
hole
spec
B - Puller, for example, Kukko puller -18/0- es, in part or in w
t to the co
rrectness of i
l purpos
Intermediate Bearing, Installed Position
nf
ercia
o
The longer brace -A- points in direction of travel -arrow- to the left.
rm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Intermediate Bearing, Installing

– Install the center bearing.
5.3 Rear Final Drive

⇒ “5.3.1 Rear Final Drive“, page 260
⇒ “5.3.2 Differential“, page 269
⇒ “5.3.3 Shaft Bevel Gear Bearing“, page 271
⇒ “5.3.4 Head Bevel Gear and Input Shaft Bearing“, page 276
5.3.1 Rear Final Drive


R32 2004 ➤

♦ Pry Lever - Rmv Outside Mirror -80-200-
♦ Additional Part for VW 771 -771/37-
AG. Volkswagen AG d
♦ Wheel Bearing Assembly Set -3253- agen oes
olksw not
byV gu
ara
d
♦ Hook -3438- orise nte
h eo
ut ra
♦ Thrust Piece -T10019- ss a c
ce
le
♦ Puller -T10037-
un
pt
an
d
itte
y li
♦ Wrench -T10066-
erm
ab
ility
ot p
wit
is n
h re
Disassembly
ole,
spec
For mounting the rear final drive, transmission support -VW 353-
t to the co
must be modified.
Dimensions are in mm.
rrectne
– Transfer the hole -arrow 1- according to the illustration.
– Drill a 13 mm diameter hole -arrow 1- into the transmission
ss
support -VW 353- .
o
cial p
f inform
– Enlarge the hole -arrow 2- to 13 mm.
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
– Remove the bracket -arrow- from the rear final drive.

fo
en
ng
t.
yi Co
– Drain the transmission fluid and the high performance oil for . Cop py
the Haldex clutch.
ht rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

R32 2004 ➤

– Use a M12 bolt with 1.5 mm threads to secure the clamp.
AG. Volkswagen AG d
agen oes
ksw
– Remove the nut for the flange. by
Vol not
gu
ara
ed
is nte
A - M10 x 20 bolts hor eo
aut ra
ss c
ce
le
un
pt
Note
an
d
itte
y li
rm
ab
pe
ility
-2004- when loosening the nut (2nd technician needed).
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Remove the flange
. rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
yri
– Disconnect the connector -1- from the Haldex clutch pump. p by
o Vo
by c lksw
cted agen
– Remove the bolts -arrows A-. Prote AG.
– Remove the Haldex clutch control module -2-.

– Remove the bolts -arrows B- for the pump -3-.
– Turn the pump slightly to the right (clockwise).
– Remove the pump using, for example, slide hammer-complete
set -VW 771- and additional part for VW 771 -VW 771/37- .
Refer to ⇒ page 59 , Fig. N01-0424.
– Remove the oil filter -4- using the wrench -T10066- .

R32 2004 ➤
– Remove the cover -A- bolts -arrows- from the pinion housing.
– Remove the bolts that connect the cover/Haldex clutch to the
pinion housing.
– Insert the screwdriver -A- into the openings -arrow- in the cov‐
AG. Volkswagen AG d
agen
er and remove the cover. Volksw
oes
not
y gu
db ara
– Remove the cover together with the disc housing
ris
e from the pin‐ nte
ho eo
ion housing. au
t ra
ss c
– Remove the 6 rollers and the 3 rollers from the pinion housing.
ce
le
un
pt
an
d
– Remove the thrust washer, the clutch disc pack, the hub and
itte
y li
erm
the thrust washer.
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
– Remove the axial needle bearing from the disc and the pinion
housing using the hook -3438- .
rrectne
– Remove all the nuts from the pinion housing.
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
op
– Remove the pinion housing. When doing this install the bolts C py
ht. rig
-A- evenly so that the housing does not tilt. rig ht
py by
co Vo
by lksw
– Remove the adjusting shim S3 cted agen
Prote AG.

R32 2004 ➤
– Install the lower support from the puller -T10037- into the left
cover -arrow- (the illustrations shows the final drive installed)
and remove the left flange shaft.
– Install the lower support from the puller -T10037- into the
housing -arrow- and remove the right flange shaft.
wage es n
– Remove the vent -arrow- from the rear final drive housing. yV
olks ot g
b ua
ed ran
– Install the bolts -A- evenly so that the cover does not tilt,hoand
ris tee
remove the cover (next to the oil fill plug). au t or
ac
ss
– Remove the right cover and the differential.
ce
le
un
pt
an
d
itte
– Remove the left cover.
y li
rm
ab
pe
ility
ot
wit
, is n
Note
h re
hole
spec
Removal is identical to removing the right cover, refer to
es, in part or in w
⇒ page 264 .
t to the co
rrectness of i
– Remove the head bevel gear with the input shaft.
Assembly
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

R32 2004 ➤
– Remove the disc housing from the Haldex clutch cover.
– Install the head bevel gear with the input shaft.

– Install the left cover with a new O-ring.
– Lubricate the O-ring with transmission fluid.
– Tighten the bolts to specification, see -item 10- in the
⇒ “2.5 Differential and Head Bevel Gear/Input Shaft Over‐
view“, page 180 .
AG. gen Volkswa

– Install the right cover with the differential agena new O-ring AG does
and
olksw not
-A- (lubricate with transmission fluid)
ed b and tighten the bolts di‐
yV gu
ara
agonally. horis nte
e t or
au ac
– Tighten the bolts to specification,
ss see -item 10- in the
⇒ “2.5 Differential and Head Bevel Gear/Input Shaft Over‐ ce
le
un
pt
view“, page 180 . an
d
itte
y li
erm
ab
– Push the vent into the rear final drive housing.
ility
ot p
wit
is n
h re
ole,
spec
t to the co
Remove the old lock ring from the groove in the flange shaft using
rrectne
the new lock ring -A-.

– Install the right and left flange shaft using a plastic hammer.
ss o
– Install the adjusting shim S3

cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

R32 2004 ➤
– Install the new O-ring -A- into the groove all around the pinion
housing and then lubricate it with transmission fluid.
– Install the pinion housing and shaft bevel gear.
Installed position:
The oil filler mount is located above the fluid filler plug.
– Install the nuts with liquid locking fluid -D 197 300 A1- and then
tighten them diagonally to specification, see -item A7- inolkthe
G. V swagen AG
⇒ “2.4 Pinion Housing Overview“, page 178 sw. agen does
olk no t gu
yV
db ara
rise nte
tho eo
s au ra
c
s
ce
e
– Install the disc -1- for the axial needle bearing into the pinion
nl
pt
du
an
housing with the collar facing the axial needle bearing -2-
itte
y li
-arrow A-.
erm
ab
ility
ot p
– Install the axial needle bearing -2-.
wit
, is n
h re
– Install the thrust washer -3- with the larger flat surface
hole
spec
-arrow B- facing the hub -4-.
es, in part or in w
t to the co
– Slide the hub -4- onto the shaft bevel bear with the 3 holes
-arrow C- facing up.
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
– Install the first clutch disc -2- into the pinion housing -1-.
t.
yi Co
op py
– Install the first externally toothed plate -3- and then install the
t. C rig
gh ht
yri
remaining 6 internally and 6 externally toothed plates. p by
co Vo
by lksw
cted agen
Prote AG.

R32 2004 ➤
– Make sure the cam track is remains visible when installing the
cam disc -A-.
Installed position:
The 3 smaller teeth -arrows- must fit into the opposite teeth in the
hub.
– Turn the -arrows- the toothed plate housing -A- and guide the
housing all the way onto the cam disc/clutch disc pack.
– Install the 3 rollers -B- into the openings in the toothed plate
housing.
olkswagen AG
en AG. V
– Install the 6 rollers -C- likewise ointo
lksw the toothed plate housing.
ag does
no
yV t gu
db ara
rise nte
tho eo
Note s au ra
c
s
ce
le
un
The rollers can be installed in only one position in the opening
pt
an
d
inside the toothed plate housing.

itte
y li
erm
ab
ility
ot p
– Install the ring -D-.
wit
is n
h re
ole,
– Place the thicker thrust washers -A- on the rollers and rollers
spec
inside the toothed plate housing.
t to the co
– Install the axial needle bearing -B- and the thin thrust washers
-C-.
rrectne
Note
ss o
cial p
f i
♦ These individual axial needle bearing packs 1 through 3 are

nform
according to the piston diameters inside the Haldex clutch

mer
atio
cover.
om
n
c
♦ Make sure the gap -arrow- between axial needle bearing

or
n thi
e
packs 2 and 3 is equal all the way around.

t
sd
iva
o
pr
cum
r
fo
– Install the plate spring -4- with the large diameter (concave
en
ng
t.
yi
side) facing the ring, refer to ⇒ page 267 , Fig. N39-1043.
Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Coat the O-rings -arrows A-and -arrow B- with high perform‐

ance fluid for the Haldex clutch and install them in the Haldex
clutch cover.
– Pull the center piston -arrow C- approximately 5 mm evenly
above the entire circumference.

R32 2004 ➤
– Place the Haldex clutch cover -1- carefully on the pinion hous‐
ing -2-.
– Install the bolts -arrows- 1/2 turn in steps and diagonally.
– The gap -arrow A- must get smaller evenly.
Note
Bolts must not get stuck in the gap. They could slide into the axial
needle bearing packs for the piston. Remove the cover again and
align the axial needle bearing again.
– Tighten the bolts to specification, see -item 3- in the

177 .
– Secure the cover -A- with new seal (note the different versions,
refer to ⇒ page 180 ) on the drive pinion housing -arrows-.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
– Install the oil filter -4- and tighten it to specification, see
wit
is n
-item 9- in the ⇒ “2.4 Pinion Housing Overview“, page 178 .
h re
ole,
spec
– Install the Haldex clutch pump -3- and the Haldex clutch con‐
trol module -2-. Tighten the bolts -arrows A and B- to specifi‐
t to the co
cation, see -item 15- in the
177 .
rrectne
– Connect the connector -1- to the pump.
ss
– Coat the outer diameter of the new Haldex clutch seal and
o
cial p
f
between the sealing lips with high performance gear oil for
inform
Haldex coupling -G 052 175 A1- before installing it.
mer
atio
om
n
c
– Install the new seal flush.

i
or
n thi
te
sd
a
– Install the flange.

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

R32 2004 ➤
– Install the new nut using liquid locking fluid -D 000 600- and
tighten it to specification, see -item 1-
in the
177 .
olkswagen AG
en AG. V
A - M10 x 20 Bolts olkswag does
not
yV gu
db ara
rise nte
tho eo
Note
s au ra
c
s
ce
e
nl
Counter hold the flange by the tube -C- using the gearbox support
pt
du
an
-2004- when tightening the nut (2nd technician needed).
itte
y li
erm
ab
ility
ot p
– Remove the rear final drive from the assembly stand.
wit
, is n
h re
hole
– Attach the bracket -arrow- to the rear final drive.
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
5.3.2 Differential
r
rp
cu
o
m
f
en
ng
t.
yi
Co
Cop py
ht. rig
♦ Thrust Plate -VW 401- rig ht
py by
co Vo
by lksw
♦ Thrust Plate -VW 402- cted agen
Prote AG.
♦ Punch -VW 407-

♦ Punch -VW 411-
♦ Tube 31.5 mm Dia. -VW 418 A-
♦ Press Appliance -VW 459-
♦ Press Support-R&I Wheel Brg's -3144-
♦ Tube -3296-
Disassembly
– Pry out the seal with a pry lever.
– Remove the small lock ring.

R32 2004 ➤
– Remove the cover from the differential.

– Remove the large lock ring.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
– Remove the ball bearing from the cover.
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
– Shear off the expansion pin and remove the shaft for the small
m
a
com
ti
differential bevel gear.
on in
r
te o
thi
– Remove the rest of the adapter sleeve from the differential
s
iva
bevel gear shaft and the differential housing.
do
r
rp
cum
fo
– Remove the small differential bevel gears and the thrust wash‐
en
ng
t.
yi
er union.
Co
Cop py
t. rig
gh
– Remove the large differential bevel gears from the openings
ht
pyri by
in the side of the differential housing.
co Vo
by lksw
cted agen
Prote AG.
Assembly
– Insert thrust washer union with transmission fluid.
– Install both large differential bevel gears and secure them (for
example, with the flange shaft).
– Install the small differential bevel gears spaced 180° apart and
move them by turning one of the two flange shafts.
– Drive differential planetary gear shaft into final position and
secure with the expansion pin.

R32 2004 ➤
– Install the ball bearing in the cover.

– Secure it with the large lock ring.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
– Install the cover on the differential.
wit
, is n
h re
– Secure it with the small lock ring.
hole
spec
es, in part or in w
– Install the new seal flush. Refer to
t to the co
⇒ “4.3.3 Rear Final Drive Flange Shaft Seal“, page 234 .
rrectness of i
l purpos
nform
mercia
at
om
ion
c
5.3.3 Shaft Bevel Gear Bearing
in t
or
his
ate
do
riv

p
cum
for
en
g
♦ Fitting Sleeve -VW 192-

n
t.
yi Co
op py
t. C rig
gh ht
pyri by
Vo
o
♦ Thrust Plate -VW 401- by c lksw
cted agen
Prote AG.
♦ Attachment Part for VW 771 -VW 771/37-
♦ Sleeve -40 - 103-
♦ Sleeve -2010-
♦ Drift -3138-
♦ Adapter -V.A.G 1582/1-
♦ Punch -VW 407-

R32 2004 ➤

AG. Volkswagen AG d
♦ Kukko Extractor 56-70 mm -21/8- agen oes
olksw not
byV gu
ara
d
The drive pinion housing is removed orisfrom the rear final drive
e nte
housing. Refer to ⇒ “2.4 Pinion Housing
aut
h Overview“, page 178 . eo
ra
ss c
Disassembly
ce
e
nl
pt
du
an
– Mount the pinion housing, as illustrated (oil filter = -arrow B-),
itte
y li
on the hole -arrow A- marked with the number -1- from under‐
erm
ab
ility
neath.
ot p
wit
, is n
– Then align pinion housing to the remaining 3 holes and secure.
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
o
– Remove the twelve point nut for shaft bevel gear.
rm
m
atio
m
A - Ratchet with 3/4" drive

o
n in
or c
thi
te
sd
iva
Note
o
r
rp
cu
o
m
f
en
ng
t.
♦ Protect shaft bevel gear from falling down when removing the
yi Co
op py
twelve point nut.
. C rig
ht ht
rig by
py
♦ If the loosening torque is very large, then use an extension on
co Vo
by lksw
cted
the ratchet.
agen
Prote AG.
– It may be necessary to remove the shaft bevel gear from the

inner race/tapered roller bearing caused by the overlap (tight
fit or loose fit)
– Remove the inner race/small tapered roller bearing and the
spacer.
– Remove the small taper roller bearing outer race from the pin‐
ion housing.

R32 2004 ➤
– Remove the outer race -A- on the large tapered roller bearing
from the pinion housing.
56-70 mm -21/8-
shaft bevel gear.
– Clean the threads on the nut.
– Remove the shaft bevel gear seals from the pinion housing.
AG. Volkswagen AG d
Assembling agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
Note aut ra
ss c
ce
le
un
Clean any locking fluid still on the seats on the outer race/outer
pt
an
d
itte
race inside the pinion housing.

y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Coat the outer race for the small taper roller bearing/shaft
bevel gear with liquid locking fluid -D 154 000 A1- and then
install it into the pinion housing.
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted
273
agen
Prote AG.
5. Disassembly and Assembly
R32 2004 ➤
– Coat the outer race for the large taper roller bearing/shaft bev‐
el gear with liquid locking fluid -D 154 000 A1- and then install
it into the pinion housing.
– Assemble the shaft bevel gear seals as follows:

– Place the new seals on top of each other (-arrows A-). The
tabs -arrows- on the seal are offset to each other.
– Twist the seals (-arrow B-), until the tabs -arrows- engage into
one another -arrow C-.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Install the shaft bevel gear seals -A- into the pinion housing.
rrectness of i
Installed position:
l purpos
The seal with the smaller outer diameter -arrow- faces the pinion
housing.
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
– Install the shaft bevel gear seals all the way into the pinion py by
co Vo
housing.
by lksw
cted agen
Prote AG.

AG. Volkswagen AG d
agen oes
olksw not
d by
V gu
ara R32 2004 ➤
e nte
horis Manual e oTransmission - Edition 01.2012
aut ra
ss c
– Install the inner race on the large tapered bearing on the shaft
ce
e
nl
bevel gear.
pt
du
an
itte
y li
– Lubricate the seals with high performance gear oil for Haldex
erm
ab
coupling -G 052 175 A1- .
ility
ot p
wit
, is n
– Install the shaft bevel gear in the pinion housing.
h re
hole
spec
– Install the new spacer sleeve.
es, in part or in w
t to the co
rrectness of i
l purpos
– Install the inner race on the small tapered bearing on the shaft
bevel gear.
nf
ercia
orm
m
atio
om
n in
Note
or c
thi
te
sd
a
It may be necessary to push the inner race onto the shaft bevel
iv
o
r
rp
cu
gear by hand due to the overlap.
o
m
f
en
ng
t.
yi Co
op
– Secure the pinion housing to the gearbox support -T10108- .
C py
t. rig
gh
Refer to ⇒ page 272 .
ht
pyri by
Vo
o
by c lksw
cted
– Coat the threads on the twelve point nut with liquid locking fluid
agen
Prote AG.
-D 154 000 A1- .
– Install the twelve-point nut for shaft bevel gear.
– Tighten the twelve point nut to 120 Nm, then measure the fric‐
tion torque, refer to ⇒ page 275 . It may be necessary to
increase the tightening specification until the specified friction
torque is reached.
A - Tighten with 3/4" drive
– Turn the torque wrench (40-200 Nm) -V.A.G 1332- to the right
to tighten.
– Use an adapter from 1/2" to 3/4" .
Note
Increase the torque slowly and read the friction torque several
times. If the specified friction torque is exceeded, then the spacer
sleeve must be replaced and the adjustment must be performed
again. If a spacer sleeve was squeezed together once too far, it
can no longer be used.

200 to 250 Ncm 30 to 50 Ncm
A - Standard torque gauge, 0 to 600 Ncm

R32 2004 ➤
B - Adapter from 1/2" to 3/4" drive
5.3.4 Head Bevel Gear and Input Shaft Bear‐

ing
♦ Punch -VW 407-
♦ Punch -VW 409-
AG. Volkswagen AG d
agen oes
♦ Thrust Pad -VW 447 i- olksw not
byV gu
ara
ed
♦ Press Appliance -VW 459- horis nte
eo
aut ra
♦ Thrust Ring -VW 470- ss c
ce
le
un
pt
♦ Thrust Piece & Sleeve -VW 472-
an
d
itte
♦ Thrust Plate -2050- y li

erm
ab
ility
ot p
♦ Drift -3138- wit

is n
h re
ole,

spec
♦ Tube -3296-
t to the co
♦ Rubber Sleeve Tool -3416/3-

rrectne
♦ 2 Arm Puller -20/10-

ss

o
cial p
f inform
Disassembly
mer
atio
The head bevel gear/input shaft is removed from the rear final
om
drive housing. Refer to

c
i
or

thi
te
sd
a
page 180 .
iv
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

R32 2004 ➤
head bevel gear.
tool 22-115 mm -17/2-
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
– Remove the inner race on the small tapered bearing from the
d
itte
y li
input shaft.
rm
ab
pe
ility
ot
wit
, is n
tool 22-115 mm -17/2-
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
– Remove the outer race on the large taper roller bearing from
the cover.
m
a
com
tion in
A - Two-arm puller, for example, 2-arm puller -20/10- with puller
r
te o
thi
hooks w/tensioner -V/170-
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– Remove the outer race on the small taper roller bearing from
the rear final drive housing.
Note
The differential is removed.
Assembly

R32 2004 ➤
– Install the outer race on the small taper roller bearing into the
rear final drive housing.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
– Install the inner race on the large tapered bearing on the head
ility
ot p
bevel gear.
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
– Install the inner race for the small tapered bearing on the input
om
shaft.
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– Install the outer race for the large taper roller bearing in the
cover.

R32 2004 ➤
6 Special Tools
♦ Cartridge Gun -V.A.G 1628-
♦ Diagnostic Cable, 3 m with Power Supply -VAS 5051/1-
♦ Diagnostic Cable, 5 m without
gen AG
Power
. VolkswaSupply
gen AG -VAS 5051/3-
wa does
olks not
♦ Tube - 3259- byV gu
ara
ed nte
ris
♦ Press Toolut-3345-
ho eo
ra
a c
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
♦ Washer -3253/7-
t to the co
♦ Tube -3296-
rrectne
ss o
♦ Digital Depth Gauge -VAS 6087-
cial p
f inform
mer
atio
m
♦ Crown Wheel Adjustment Device -VW 521-

o
n
c
i
or
n thi

te
sd
iva
o
r

p
cum
r
fo
en
ng

t.
yi Co
Cop py
. rig
t
gh ht
pyri by
Vo
co lksw
♦ Driving Sleeve -32-109-
by
cted agen
Prote AG.
♦ Puller -T10037-
♦ 2-Arm Puller -20/10-
♦ Punch -VW 407-
♦ Assembly Tool -T10047-
♦ Engine/Transmission Jack -V.A.G 1383A-
♦ Universal Transmission Support -V.A.G 1359/2-
♦ Arbor -VW 195-

R32 2004 ➤
♦ Multipoint Socket -T10035-

♦ Tube -3259-
♦ Punch -VW 409-
♦ Thrust Shells for Drive Pinion Bearing -VW 470/1- wagen AG. Volkswagen AG does
olks not
♦ Thrust Pad -VW 472/1- yV gu
edb ara
ris nte
♦ Tube 42 mm Dia. -VW 516- tho eo
au ra
c
ss
♦ Sleeve -30-21-
ce
e
nl
pt
du
an
itte
y li
erm
ab
♦ Drift -3138-
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
♦ Puller -VW 391-
rrectness of i
♦ Sleeve-Press Tool -VW 522-
l purpos
♦ Press Block -40-204 A-

nf
ercia
or
♦ Circlip Pliers -VW 161 A-
m
m
atio
om
♦ Pry Lever - Rmv Outside Mirror -80-200-
n in
or c
thi
e
♦ Hook -3438-
t
sd
iva
o
r
rp
cu
♦ Punch -VW 411-
o
m
f
en
ng
t.
yi
♦ Tube 31.5 mm Dia. -VW 418 A-
Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted
agen
Prote AG.

♦ Press Support-R&I Wheel Brg's -3144-
♦ Fitting Sleeve -VW 192-
♦ Sleeve -40 - 103-
♦ Sleeve -2010-
♦ Adapter -V.A.G 1582/1-
♦ Thrust Pad -VW 447 i-
♦ Thrust Ring -VW 470-
♦ Thrust Piece & Sleeve -VW 472-
♦ Rubber Sleeve Tool -3416/3-

R32 2004 ➤

5051-
AG. Volkswagen AG d
agen oes
olksw not
V
♦ Wrench -T10066- d by gu
ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i

l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

R32 2004 ➤
♦ Transmission Support -VW

353-
♦ Magnetic Plate 50 mm Dia.
-VW 385/17-
♦ Dial Gauge Holder -VW
387-
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

R32 2004 ➤
♦ Slide Hammer-Complete AG. Volkswagen

Set -VW 771- lksw
agen AG do
es n
o ot g
yV ua
♦ Additional Part
ris
ed for VW 771
b ran
tee
-VW 771/37-
ut
ho
or
sa ac
♦ ThrustsPiece -3305-
ce
le
un
pt
an
d
itte
y li
V.A.G 1331-
erm
ab
ility
ot p
♦ Torque Wrench (40-200
wit
is n
Nm) -V.A.G 1332-
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

R32 2004 ➤
♦ Mounting Universal Joint

-41-501-
♦ Assembly Tool -3253/1-
♦ Tube -3296-
♦ -1- Kukko Extractor
14.5-18.5 mm -21/2-
♦ -1- Kukko Extractor 46-58
mm -21/7-
AG. Volkswagen AG d
agen
♦ -1- Internal Puller -21/02- olksw
oes
not
byV gu
ara
d
♦ -1- Kukko Extractor 23.5-30 orise nte
eo
mm -21/4- aut
h
ra
ss c
♦ -1- Internal Puller -21/89-
ce
le
un
pt
an
♦ -1- Kukko Extractor 56-70 d
itte
y li
rm
mm -21/8-
ab
pe
ility
ot
♦ -2- 2 Arm Puller -20/10-
wit
, is n
h re
♦ -2- Kukko Puller 65-160
hole
spec
mm -18/1-
es, in part or in w
t to the co
♦ -2- Kukko Puller -18/0-
♦ -3- Kukko Separating Tool
rrectness of i
12-75 mm -17/1-
l purpos
♦ -3- Kukko Separating Tool

22-115 mm -17/2-
nform
ercia

m
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Edition 05.23.2012

Cautions & Warnings
Please read these WARNINGS and CAUTIONS before proceeding with maintenance
and repair work. You must answer that you have read and you understand these
WARNINGS and CAUTIONS before you will be allowed to view this information.
•= If you lack the skills, tools and equipment, or a suitable workshop for any procedure described in this manual, we
suggest you leave such repairs to an authorized Volkswagen retailer or other qualified shop. We especially urge
you to consult an authorized Volkswagen retailer before beginning repairs on any vehicle that may still be covered
wholly or in part by any of the extensive warranties issued by Volkswagen.
•= Disconnect the battery negative terminal (ground strap) whenever you work on the fuel system or the electrical
system. Do not smoke or work near heaters or other fire hazards. Keep an approved fire extinguisher handy.
•= Volkswagen is constantly improving its vehicles and sometimes these changes, both in parts and specifications,
are made applicable to earlier models. Therefore, part numbers listed in this manual are for reference only. Always
check with your authorized Volkswagen retailer parts department for the latest information.
•= Any time the battery has been disconnected on an automatic transmission vehicle, it will be necessary to
reestablish Transmission Control Module (TCM) basic settings using the VAG 1551 Scan Tool (ST).
•= Never work under a lifted vehicle unless it is asolidly . Volkswage on

gen AG supportedn AG dstands
oes
designed for the purpose. Do not support
l sw
kother not under continuous load. Never work under a
a vehicle on cinder blocks, hollow tilesyor Vo props that may crumble gu
b ara
vehicle that is supported solely byrisaedjack. Never work under the vehicle while nt the engine is running. ee
tho or
s au ac
•= For vehicles equipped with radio, be sure of the correct radio an
s anti-theft
code before disconnecting the activation
ce
le
un
battery or removing the radio. If the wrong code is entered when the power is restored, the radio may lock up and
pt
an
d
itte
become inoperable, even if the correct code is used in a later attempt. y li

erm
ab
ility
ot p
•= If you are going to work under a vehicle on the ground, make sure that the ground is level. Block the wheels to wit
is n
keep the vehicle from rolling. Disconnect the battery negative terminal (ground strap) to prevent others from
h re
ole,
starting the vehicle while you are under it.

spec
t to the co
•= Do not attempt to work on your vehicle if you do not feel well. You increase the danger of injury to yourself and
others if you are tired, upset or have taken medicine or any other substances that may impair you or keep you from
being fully alert.
rrectne
•= Never run the engine unless the work area is well ventilated. Carbon monoxide (CO) kills.
ss o
cial p
•=
i
Always observe good workshop practices. Wear goggles when you operate machine tools or work with acid. Wear
nform
goggles, gloves and other protective clothing whenever the job requires working with harmful substances.
mer
atio
om
•=
n
Tie long hair behind your head. Do not wear a necktie, a scarf, loose clothing, or a necklace when you work near
c
i
or
n thi
machine tools or running engines. If your hair, clothing, or jewelry were to get caught in the machinery, severe
te
sd
va
injury could result.

i
o
pr
cum
r
fo
en
ng
•=
t.
Do not re-use any fasteners that are worn or deformed in normal use. Some fasteners are designed to be used op
yi Co
py
only once and are unreliable and may fail if used a second time. This includes, but is not limited to, nuts, bolts,
gh
t. C rig
ht
pyri
washers, circlips and cotter pins. Always follow the recommendations in this manual - replace these fasteners with by
Vo
co lksw
by
new parts where indicated, and any other time it is deemed necessary by inspection. cted agen
Prote AG.
Page 1 of 3
© 2002 Volkswagen of America, Inc.
All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other intellectual property rights of
Volkswagen of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice. No part of this document may be reproduced, stored in a
retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, nor may these materials be modified or reposted to other sites, without
the prior expressed written permission of the publisher.
Version 1.0
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
ss aut Cautions & Warnings ra
c
ce
e
nl
•=
pt
Illuminate the work area adequately but safely. Use a portable safety light for working inside or under the vehicle.
du
an
itte
y li
Make sure the bulb is enclosed by a wire cage. The hot filament of an accidentally broken bulb can ignite spilled
erm
ab
fuel or oil.
ility
ot p
wit
, is n
•=
h re
Friction materials such as brake pads and clutch discs may contain asbestos fibers. Do not create dust by
hole
spec
grinding, sanding, or by cleaning with compressed air. Avoid breathing asbestos fibers and asbestos dust.
es, in part or in w
Breathing asbestos can cause serious diseases such as asbestosis or cancer, and may result in death.
t to the co
•= Finger rings should be removed so that they cannot cause electrical shorts, get caught in running machinery, or be
crushed by heavy parts.
rrectness of i
l purpos
•= Before starting a job, make certain that you have all the necessary tools and parts on hand. Read all the
instructions thoroughly; do not attempt shortcuts. Use tools that are appropriate to the work and use only
nf
replacement parts meeting Volkswagen specifications. Makeshift tools, parts and procedures will not make good
ercia
or
repairs.
m
m
atio
om
n in
•=
c
Catch draining fuel, oil or brake fluid in suitable containers. Do not use empty food or beverage containers that
or
thi
e
might mislead someone into drinking from them. Store flammable fluids away from fire hazards. Wipe up spills at
t
sd
iva
once, but do not store the oily rags, which can ignite and burn spontaneously.
o
r
rp
cu
o
m
f
en
ng
t.
•=
i
Use pneumatic and electric tools only to loosen threaded parts and fasteners. Never use these tools to tighten py Co
Co py
fasteners, especially on light alloy parts. Always use a torque wrench to tighten fasteners to the tightening torque
rig
ht. rig
ht
by
listed. copy Vo
lksw
by
cted agen
Prote AG.
•= Keep sparks, lighted matches, and open flame away from the top of the battery. If escaping hydrogen gas is
ignited, it will ignite gas trapped in the cells and cause the battery to explode.
•= Be mindful of the environment and ecology. Before you drain the crankcase, find out the proper way to dispose of
the oil. Do not pour oil onto the ground, down a drain, or into a stream, pond, or lake. Consult local ordinances that
govern the disposal of wastes.
•= The air-conditioning (A/C) system is filled with a chemical refrigerant that is hazardous. The A/C system should be
serviced only by trained automotive service technicians using approved refrigerant recovery/recycling equipment,
trained in related safety precautions, and familiar with regulations governing the discharging and disposal of
automotive chemical refrigerants.
•= Before doing any electrical welding on vehicles equipped with anti-lock brakes (ABS), disconnect the battery
negative terminal (ground strap) and the ABS control module connector.
•= Do not expose any part of the A/C system to high temperatures such as open flame. Excessive heat will increase
system pressure and may cause the system to burst.
•= When boost-charging the battery, first remove the fuses for the Engine Control Module (ECM), the Transmission
Control Module (TCM), the ABS control module, and the trip computer. In cases where one or more of these
components is not separately fused, disconnect the control module connector(s).
•= Some of the vehicles covered by this manual are equipped with a supplemental restraint system (SRS), that
automatically deploys an airbag in the event of a frontal impact. The airbag is operated by an explosive device.
Handled improperly or without adequate safeguards, it can be accidentally activated and cause serious personal
injury. To guard against personal injury or airbag system failure, only trained Volkswagen Service technicians
should test, disassemble or service the airbag system.
Page 2 of 3
Version 1.0
Cautions & Warnings
•= Do not quick-charge the battery (for boost starting) for longer than one minute, and do not exceed 16.5 volts at the
battery with the boosting cables attached. Wait at least one minute before boosting the battery a second time.
•= Never use a test light to conduct electrical tests of the airbag system. The system must only be tested by trained
Volkswagen Service technicians using the VAG 1551 Scan Tool (ST) or an approved equivalent. The airbag unit
must never be electrically tested while it is not installed in the vehicle.
•= Some aerosol tire inflators are highly flammable. Be extremely cautious when repairing a tire that may have been
inflated using an aerosol tire inflator. Keep sparks, open flame or other sources of ignition away from the tire repair
area. Inflate and deflate the tire at least four times before breaking the bead from the rim. Completely remove the
tire from the rim before attempting any repair. G. Volkswage
nA n AG d
wage oes
Volks not
gu
•= When driving or riding in an airbag-equipped vehicle, nevered by
hold test equipment in your hands aror
an lap while the
oris tee
vehicle is in motion. Objects between you and the airbag
th can increase the risk of injury in an accident. or
au ac
ss
ce
le
un
pt
an
d
itte
I have read and I understand these Cautions and Warnings.
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Page 3 of 3
Version 1.0

Service: Manual Transmission

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Service: Manual Transmission

Uploaded by

Copyright:

Available Formats

Service

Service Department. Technical Information

All rights reserved.

Copyright © 2012 Volkswagen AG, Wolfsburg D3E80081B7C

00 - General, Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1.1 Transmission Fluid, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

2 Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

2.1 Electrical and Electronic Components and Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

2.2 Shift Mechanism Installed Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

2.3 Shift Knob, Boot and Noise Insulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

2.6 Shift Unit Adjusting, through Build Date 18 May 2003 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

2.7 Shift Unit Adjusting, from Build Date 19 May 2003 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

3.1 Fastener Tightening Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

4 Diagnosis and Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

5 Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

6.9 Selector Forks Through Build Date, 18 May 2003 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118

6.10 Selector Forks From Build Date, 19 May 2003 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

35 - Gears, Shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129

1 Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129

2 Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138

2.1 Input Shaft, Through Build Date 18 May 2003 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138

2.3 Output Shaft, 1st to 4th Gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147

3 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165

39 - Final Drive, Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169

1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169

2 Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172

4 Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216

00 – General, Technical Data

1.1 Transmission Identification

Identification Day Month Year (1999)

Additional information about the factory

1.2 Rear Final Drive Identification

or near the connector for the Haldex clutch

Final drive code and build date

Identification Day Month Year 1999 of pro‐

Additional data depends on the manufacturer.

1.3 Notes on Performance Test

2 Rep. Gr.00 - General, Technical Data

4 Rep. Gr.00 - General, Technical Data

♦ Replace the lock rings.

♦ Make sure the contact surfaces and visible surfaces on the

♦ Install the new tapered roller bearings. It is not necessary to

facing the installation tool.

♦ Do not interchange them. When reusing synchronizer rings,

Guided Fault Finding, On Board Diagnostic (OBD) and Test In‐ an

♦ Before servicing the Haldex clutch, determine the cause of the

damage as exact as possible using the vehicle diagnostic

tester and “Guided Fault Finding“, “OBD“ and “Test Instru‐

6 Rep. Gr.00 - General, Technical Data

2 Description and Operation

2.1 Powertrain Overview

11 - Rear Final Drive

2. Description and Operation 7

8 Rep. Gr.00 - General, Technical Data

3.1 Code Letters, Allocation, Ratios and Capacities, Transmission

• Final drive I for 1st to 4th gear

• Final drive II for 5th/6th and reverse gears

Refer to the Parts Catalog for the following information:

♦ Clutch plate allocation

Rear Final Drive 02D

Identification Code FWS

Manufactured from through 05.01

Allocation Type R32, MY 2004