Volkswagen Workshop Manual (6-Speed Manual Gearbox 02U, 0DQ)

Service
Workshop Manual
Rapid India 2011 ➤
Rapid NH 2013 ➤
Rapid NH 2014 ➤
Gearbox 02U, 0DQ
Edition 02.2020
Service Department. Technical Information

Service
List of Workshop Manual Repair Groups
Repair Group
00 - Technical data
30 - Clutch
34 - Controls, housing
35 - Gears, shafts
39 - Final drive - differential
Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.
Rapid India 2011 ➤ , Rapid NH 2013 ➤ , Rapid NH 2014 ➤
Gearbox 02U, 0DQ - Edition 02.2020
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Safety precautions when working on vehicles with start-stop system . . . . . . . . . . . . . . . . 1
1.2 Safety precautions during road tests in which testing and measuring equipment is used . . 1
1.3 General safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.1 Gearbox identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3 Repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.1 General points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.2 Contact corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.3 Seals and sealing rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.4 Screws, nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4.1 Filling capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4.2 Allocation gearbox - engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4.3 Calculation of gear ratios . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
5 Overview of Transmission System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
5.1 Overview of power transmission - front-wheel drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
30 - Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1 Repairing clutch control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.1 Fitting location overview - clutch control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.2 Summary of components - Foot controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.3 Assembly overview - clutch hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
1.4 Assembly overview - clutch release mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
1.5 Removing and installing clutch pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
1.6 Removing and installing over-centre helper spring Rapid NH (vehicles from 08/2013) . . . . 32
1.7 Removing and installing bushing, Rapid NH (vehicles from 08/2013) . . . . . . . . . . . . . . . . 34
1.8 Removing and installing bearing bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
1.9 Removing and installing the master cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
1.10 Removing and installing the slave cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
1.11 Removing and installing cables for clutch control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
1.12 Removing and installing clutch pedal switch F36 , Rapid NH (Vehicles until 08.2013), Rapid
India . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
1.13 Removing and installing clutch position sensor G476 , Rapid NH (vehicles from 08/2013)
........................................................................ 50
1.14 Bleeding the clutch control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
1.15 Checking the master and slave cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
1.16 Repairing the clutch release mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
2 Repairing clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
2.1 Assembly overview - clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
2.2 Removing and installing clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
2.3 Fault finding power transmission - problems with the clutch and clutch control . . . . . . . . . . 60
34 - Controls, housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
1 Shift mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
1.1 Fitting location of shift mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
1.2 Summary of components - gearshift knob and cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
1.3 Summary of components - shift lever and shift housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
1.4 Removing and installing gearshift knob with shift lever collar . . . . . . . . . . . . . . . . . . . . . . 70
1.5 Removing and installing selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
1.6 Repairing shift mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
1.7 Setting the shift mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Contents i
1.8 Inspecting the gearshift mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

1.9 Replacing the sealing ring for the gearshift shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
2 Removing and installing the gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
2.1 Removing the gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
2.2 Installing the gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
2.3 Tightening torques for gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
3 Assembly bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
3.1 Assembly overview - assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
4 Transporting the gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
5 Disassembling and assembling the gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
5.1 Schematic overview - Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
5.2 Summary of components - Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
5.3 Summary of components - input shaft, output shafts, differential gear and shift rods . . . . 110
5.4 Assembly overview - gearbox housing cover and 5th/6th gear . . . . . . . . . . . . . . . . . . . . . . 112
5.5 Summary of components - Gearshift unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
5.6 Assembly overview - shift forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
5.7 Removing and installing switching unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
5.8 Repairing gearshift unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
5.9 Repairing gearshift forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
5.10 Disassembling and assembling the gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
6 Gearbox housing, clutch housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
6.1 Summary of components - Clutch housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
6.2 Summary of components - Gearbox housing and clutch housing . . . . . . . . . . . . . . . . . . . . 136
6.3 Repairing gearbox housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
6.4 Repairing clutch housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
6.5 Repairing gearbox housing cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
7 Attachment at engine and gearbox mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
8 Gear oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
8.1 Checking gear oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
8.2 Draining and filling gearbox oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
35 - Gears, shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145

1 Drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
1.1 Drive shaft - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
1.2 Disassembling and assembling the drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
1.3 Replacing input shaft sealing ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
2 Output shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
2.1 Output shaft - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
2.2 Disassembling and assembling the output shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
39 - Final drive - differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162

1 Sealing rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
1.1 Installation overview - sealing rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
1.2 Replacing left sealing ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
1.3 Replacing right sealing ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
2 Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
2.1 Summary of components - Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
2.2 Disassembling and assembling differential gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
2.3 Adjusting the differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
ii Contents
00 – Technical data
1 Safety instructions
(SRL001532; Edition 02.2020)
⇒ “1.1 Safety precautions when working on vehicles with start-
stop system”, page 1
⇒ “1.2 Safety precautions during road tests in which testing and
measuring equipment is used”, page 1
⇒ “1.3 General safety instructions”, page 1
1.1 Safety precautions when working on ve‐

hicles with start-stop system
Risk of injury as a result of automatic engine start in vehicles with
start/stop system.
In vehicles with the start/stop system activated (identifiable by an
indication in the dash panel insert) the engine can start automat‐
ically if required.
– It is necessary to ensure that the start-stop system is deacti‐
vated when carrying out work on the vehicle (switch ignition
off and if required switch ignition on again).
1.2 Safety precautions during road tests in

which testing and measuring equipment
is used
There is an increased risk of injury or accident from unintended
motion and insufficient securing of testers and measuring instru‐
ments.
There is a risk of injury from the release of the passenger airbag
in the event of an accident.
Operation of test and measuring instruments by the driver while
driving may result in deviating from the direction of travel.
– Fasten test and measurement equipment with a strap on the
rear seat and secure their operation by another person sitting
on the rear seat.
1.3 General safety instructions

Risk of damage to the electronic components when disconnecting
the battery.
• Observe actions for disconnecting the battery ⇒ Electrical
system; Rep. gr. 27 ; Battery; Disconnecting and connecting
the battery .
• Disconnect and connect the measurement and test equipment
with the ignition off.
1. Safety instructions 1
2 Identification
⇒ “2.1 Gearbox identification”, page 2
2.1 Gearbox identification

Manual gearbox 02U and 0DQ.
Differences between gearbox 02U and 0DQ
Manual gearbox 02U Propshafts with flange
Manual gearbox 0DQ Propshafts without flange
Placement of the code letter and production date of the gearbox

-arrow 1- and -arrow 2-.
Manual gearbox 02U -arrow 2-
Manual gearbox 0DQ
2 Rep. gr.00 - Technical data

Codes and production date of gearbox

Example: PPA 22 01 4
I I I I
I I I I
Engine identi‐ Day Month Year (2014)
fication char‐ of manufacture
acters
Additional data provides information about the production facility.
The gearbox identification characters also appear on the vehicle
data sticker.
2. Identification 3
3 Repair instructions
⇒ “3.1 General points”, page 4
⇒ “3.2 Contact corrosion”, page 6
⇒ “3.3 Seals and sealing rings”, page 6
⇒ “3.4 Screws, nuts”, page 7
3.1 General points

To ensure flawless and successful gearbox repairs, the greatest
care and cleanliness as well as the use of good and proper tools
are essential. Also note the basic rules on safety when performing
repair procedures.
A number of generally valid notes for individual repair operations
- which are otherwise listed several times at numerous points in
the workshop manual - are summarised here. They apply for this
particular workshop manual.
Special tools
For a complete list of special tools used in this workshop manual,
see ⇒ Workshop equipment and special tools .
Gearbox
♦ When installing the gearbox, ensure the dowel sleeves are
correctly located between the engine and gearbox.
♦ When installing bearing brackets or waxed components, the
contact surfaces must be cleaned. Contact surfaces must be
free of wax and grease.
♦ Bolts and other attachments should have a classification in the
⇒ Electronic Catalogue of Original Parts .
♦ Following installation, check gear oil level
⇒ “8 Gear oil”, page 143 .
♦ Gearbox oil ⇒ Electronic catalogue of original parts .
♦ Filling capacity ⇒ “4.1 Filling capacity”, page 8 .
Circlips

♦ Do not over-tension the circlips.

♦ Fitting position for some circlips: the ring is »narrower on top«,
as is its installation position. This make it possible for the pliers
to gain a better grip during removal and installation.
♦ Always renew retaining rings which have been damaged or
overstretched.
♦ Circlips must be positioned in the base of the groove.
♦ Replace roll pins. Fitting position: Slot -A- along power flow
-arrow-.
Bearings
♦ Lubricate all bearings with gear oil before installing.
♦ Heat inner races of tapered roller bearings with the inductive
heater - VAS 6414- to approx. 100 °C before installing. Press
in to stop when installing so there is no axial clearance.
♦ Do not mix up the outer and inner rings of bearings of the same
size. The bearings are matched in pairs.
♦ Tapered roller bearings fitted to one shaft must be replaced as
a set. Use same make of bearings.
♦ Install needle bearings, ball sleeves and roller sleeves with
lettered side (thicker metal) towards fitting tool.
Shims
♦ Gauge shims at several points with a micrometer. The various
thicknesses make it possible to achieve the exact shim thick‐
ness required.
♦ Check for burrs and damage.
♦ Install only flawless shims.
Synchro-rings
3. Repair instructions 5
♦ These are not interchangeable. When reusing synchro-rings,

always fit to the same synchromeshed gear.
♦ Check for wear and replace if necessary.
♦ Check grooves -arrow 1- of synchro-ring -A- and inner ring for
flat spots (worn grooves).
♦ If synchro-rings are coated, coating must not be damaged.
♦ If an intermediate ring -B- is installed, check the outer friction
surface -arrow 2- and inner friction surface -arrow 3- of this
intermediate ring for »scoring« and »signs of abnormal wear«.
♦ Check the cone of the synchromesh gear for »scoring« and
»signs of abnormal wear«.
♦ Moisten synchromesh mechanism with gear oil before instal‐
ling.
Gears and synchro-hubs
♦ Heat synchro-hub with inductive heater - VAS 6414- to approx.
100 °C before installing. Press in to stop when installing so
there is no axial clearance.
♦ Heat gears with inductive heater - VAS 6414- to approx. 100
°C before installing. Press in to stop when installing so there
is no axial clearance.
♦ Note installation position.
Synchromeshed gears
♦ After assembly, check synchromesh gears for slight play, or
for freedom of movement.
Clutch
♦ Ensure that the pressure plate does not cant: loosen and tight‐
en bolts diagonally and in several gradual stages.
♦ If the clutch has burnt out, thoroughly clean the clutch housing
and the friction surface of flywheel with a cloth to reduce the
smell of burnt linings.
3.2 Contact corrosion

The gearbox housing and the clutch housing are made out of
magnesium alloy.
Bolts and other components that come into direct contact with the
gearbox have a surface with varying finishes in relation to it.
The use of substitute components causes contact corrosion
(screws. nuts. washers ...). The gearbox housing and clutch hous‐
ing are damaged.
Generally install parts which are indicated in the ⇒ Electronic
Catalogue of Original Parts .
3.3 Seals and sealing rings

Always replace sealing rings and seals.
After removing gaskets and seals, always inspect contact surface
of housing or shaft for burrs resulting from removal or for other
signs of damage.

Before installing radial shaft sealing rings, lightly oil outer diame‐
ter and half-fill space between sealing lips -arrow- with sealing
grease - G 052 128 A1- .
The open side of the sealing rings faces the sealing fluid.
After installing, check oil level and top up
⇒ “8 Gear oil”, page 143 .
Before inserting lightly oil the O-rings, in order to prevent the rings
being squashed during installation.
Sealant
♦ Thoroughly clean housing joint surfaces before applying seal‐
ing paste .
♦ Apply sealing paste - AMV 188 200 03- uniformly but not too
thick.
3.4 Screws, nuts

♦ Loosen and tighten securing bolts and nuts for covers and
housings diagonally.
♦ Do not cant especially delicate parts, such as clutch pressure
plates. Loosen and tighten bolts and nuts in stages crosswise.
♦ Tightening torques are for unlubricated nuts, bolts and screws.
♦ Always replace the self-locking screws and nuts.
♦ It is important to ensure at all bolted connections that the con‐
tact surfaces as well as the nuts and bolts are waxed only after
being installed, should this be necessary.
♦ Clean all threaded holes into which self-locking bolts are in‐
serted, using a thread tap to remove locking agent residues.
Otherwise there is a danger of bolts shearing when subse‐
quently being removed.
♦ Check pitch of thread, to ensure correct thread chaser is used
to clean threads and to ensure the threads are not damaged.
3. Repair instructions 7
4 Technical data
⇒ “4.1 Filling capacity”, page 8
⇒ “4.2 Allocation gearbox - engine”, page 8
⇒ “4.3 Calculation of gear ratios”, page 8
4.1 Filling capacity

Filling capacity 2.2 l
Gear oil ⇒ Electronic Catalogue of Original Parts
4.2 Allocation gearbox - engine

⇒ “4.2.1 Allocation gearbox - engine Rapid NH”, page 8
⇒ “4.2.2 Allocation gearbox - engine Rapid India”, page 8
4.2.1 Allocation gearbox - engine Rapid NH

6 speed manual gearbox 02U
Vehicles with petrol Engine identification characters
engine
1.2 l/77 kW TSI NBU PRN
NTD PRP
6 speed manual gearbox 02U

engine
1.2 l/ 81 kW TSI PRQ
6 speed manual gearbox 0DQ

engine
1.0 l/ 81 kW TSI SEP
4.2.2 Allocation gearbox - engine Rapid India

6 speed manual gearbox 0DQ
engine
1.0 l/ 81 kW TSI UCM
4.3 Calculation of gear ratios

Example:
5th gear Final drive
Drive gear ZG1 = 46 ZA1 = 24
Driven gear ZG2 = 33 ZA2 = 70
8 Rep. gr.00 - Technical data Volkswagen Technical Site: https://vwts.ru

i = ZG2: ZG1 1)
iG = gear ratio = ZG2: ZG1 = 33 : 46 = 0.717
iA = axle drive ratio = ZA2:ZA1 = 70:24 = 2.917
itotal = Total ratio = iG × iA = 0.717 × 2.917 = 2.091
1) Z1 = No. of teeth on driving gear, Z2 = No. of teeth on driven gear
4. Technical data 9
5 Overview of Transmission System

⇒ “5.1 Overview of power transmission - front-wheel drive”, page
10
5.1 Overview of power transmission - front-wheel drive

Identification
-Arrows- in direction of travel
1 - Engine
2 - Clutch
3 - Manual gearbox
4 - Drive shaft
5 - Output shaft
6 - Differential
Gears
-Arrows- in direction of travel

I - 1st gear
II - 2nd gear
III - 3rd gear
IV - 4th gear
V - 5th gear
VI - 6th gear
R - Reverse gear
A - Final drive
5. Overview of Transmission System 11

30 – Clutch
1 Repairing clutch control
⇒ “1.1 Fitting location overview - clutch control”, page 12
⇒ “1.2 Summary of components - Foot controls”, page 14
⇒ “1.3 Assembly overview - clutch hydraulics”, page 18
⇒ “1.4 Assembly overview - clutch release mechanism”,
page 25
⇒ “1.5 Removing and installing clutch pedal”, page 26
⇒ “1.6 Removing and installing over-centre helper spring Rapid
NH (vehicles from 08/2013)”, page 32
⇒ “1.7 Removing and installing bushing, Rapid NH (vehicles from
08/2013)”, page 34
⇒ “1.8 Removing and installing bearing bracket”, page 35
⇒ “1.9 Removing and installing the master cylinder”, page 44
⇒ “1.10 Removing and installing the slave cylinder”, page 46
⇒ “1.11 Removing and installing cables for clutch control”,
page 47
⇒ “1.12 Removing and installing clutch pedal switch F36 , Rapid
NH (Vehicles until 08.2013), Rapid India”, page 49
⇒ “1.13 Removing and installing clutch position sensor G476 ,
Rapid NH (vehicles from 08/2013)”, page 50
⇒ “1.14 Bleeding the clutch control”, page 52
⇒ “1.15 Checking the master and slave cylinder”, page 53
⇒ “1.16 Repairing the clutch release mechanism”, page 55
1.1 Fitting location overview - clutch control
12 Rep. gr.30 - Clutch

I-
⇒ “1.2 Summary of compo‐
nents - Foot controls”,
page 14
II -
⇒ “1.3.1 Summary of compo‐
nents - clutch hydraulics, Rap‐
id NH )left-hand drive vehicles
up to 08.2013)”, page 18
❑
II -
nents - clutch hydraulics, Ra‐
pud NH )left-hand drive vehi‐
cles as of 08.2013)”,
page 20
III -
id NH (right-hand drive up to
08.2013), Rapid India”,
page 22
III -
id NH (right-hand drive vehi‐
cles from 08.2013)”,
page 23
1. Repairing clutch control 13

1.2 Summary of components - Foot controls

⇒ “1.2.1 Summary of components - Foot controls, vehicles to
08/2013, Rapid India”, page 14
⇒ “1.2.2 Summary of components - foot controls, Rapid NH (ve‐
hicles as of 08/2013)”, page 16
1.2.1 Summary of components - Foot controls, vehicles to 08/2013, Rapid India
1 - Front wall
❑ with mount for bearing
bracket and master cyl‐
inder
2 - Bushing
❑ for the top location hole
in the bracket
❑ The bushes for the bot‐
tom location hole in the
bracket are located in
the master cylinder
3 - Bearing bracket
❑ removing and installing
with master cylinder
⇒ “1.8 Removing and in‐
stalling bearing brack‐
et”, page 35
4 - Hexagon nut
❑ Mounting bracket with
clutch pedal and master
cylinder for front wall
❑ 3 units
❑ self-locking
❑ replace after each re‐
moval
❑ 25 Nm
5 - Clutch pedal switch - F36-
❑ applies to vehicles Rap‐
id NH up to 08/2013 and
Rapid India
❑ Difference ⇒ page 50
❑ Removing and installing
⇒ “1.12 Removing and
installing clutch pedal
switch F36 , Rapid NH (Vehicles until 08.2013), Rapid India”, page 49
6 - Crash bar
❑ secured to steering column
❑ Assign components via the ⇒ Electronic catalogue of original parts .
7 - Screw
❑ 20 Nm
8 - Stop
❑ for the clutch pedal
9 - Bearing shaft
❑ replace after each removal

10 - Clutch pedal
❑ removing and installing, left-hand drive
⇒ “1.5.1 Removing and installing clutch pedal, Rapid NH (left-hand drive vehicles up to 08.2013)”, page
26
❑ removing and installing, right-hand drive
⇒ “1.5.3 Removing and installing clutch pedal, Rapid NH (right-hand drive until 08.2013), Rapid India”,
page 29
11 - Bushing
12 - Tension spring with vibration damper
❑ attached to the bearing bracket, position 3 and the clutch pedal
❑ Removing and installing ⇒ page 15
13 - Cap
14 - Retaining clip
❑ only replace if the master cylinder has been removed
❑ Removing ⇒ page 44
❑ push on ⇒ page 44
15 - Master cylinder
⇒ “1.9.1 Removing and installing master cylinder, Rapid NH (Vehicles until 08.2013), Rapid India”, page
44
16 - Clamp
❑ to remove and install the tube-hose line pull out clamp up to the stop
❑ is pulled out from the side on certain slave cylinders
17 - Gasket
❑ always replace
❑ stick onto the master cylinder
18 - Supply hose
19 - Clutch position sender - G476-
❑ for vehicles with start/stop system
❑ does not apply to Rapid India
⇒ “1.13 Removing and installing clutch position sensor G476 , Rapid NH (vehicles from 08/2013)”, page
50
❑ can be inspected with ⇒ Vehicle diagnostic tester in the operating mode “Targeted fault finding”
Removing and installing tension spring

– Insert vibration damper with the recess -arrows- as of the 2nd
spring coil -arrows-.

1.2.2 Summary of components - foot controls, Rapid NH (vehicles as of 08/2013)
1 - Clutch pedal
⇒ “1.5.4 Removing and
installing clutch pedal,
Rapid NH (right-hand
drive vehicles from
08.2013)”, page 31
❑ is not lubricated
2 - Bushing
stalling bushing, Rapid
NH (vehicles from
08/2013)”, page 34
3 - Master cylinder
installing master cylin‐
der, Rapid NH (vehicles
from 08/2013)”,
page 45
4 - Clamp
❑ to remove and install the
tube-hose line pull out
clamp up to the stop
5 - Gasket
❑ self-adhesive
❑ stick onto the master
cylinder
❑ replace after removing
the master cylinder
6 - Clutch position sender -
G476-
⇒ “1.13 Removing and installing clutch position sensor G476 , Rapid NH (vehicles from 08/2013)”, page
50
❑ can be checked with ⇒ Vehicle diagnostic tester system
❑ Assignment ⇒ Electronic Catalogue of Original parts
7 - Bearing shaft
8 - Front wall
❑ with pin bolts for securing the bearing bracket for the clutch pedal and master cylinder
9 - Bushing
❑ for upper mounting bolt
❑ The sockets for lower mounting bolts of the bearing bracket for clutch pedal are in the master cylinder
10 - Hexagon nut
❑ Mounting bracket with clutch pedal and master cylinder for front wall
❑ 3 units
❑ self-locking

❑ 25 Nm
11 - Bearing bracket
❑ for the clutch pedal
⇒ “1.8.3 Removing and installing bearing bracket, Rapid NH (vehicles from 08/2013)”, page 41
12 - Over-centre helper spring
❑ in the bearing bracket for the clutch pedal.
❑ Grease with grease ⇒ Electronic Catalogue of Original Parts .
⇒ “1.6 Removing and installing over-centre helper spring Rapid NH (vehicles from 08/2013)”,
page 32
13 - Bushing
14 - Spring stop
15 - Carrier bolt
❑ for bearing axle of master cylinder
16 - Cap

1.3 Assembly overview - clutch hydraulics

⇒ “1.3.1 Summary of components - clutch hydraulics, Rapid NH )
left-hand drive vehicles up to 08.2013)”, page 18
⇒ “1.3.2 Summary of components - clutch hydraulics, Rapud NH )
left-hand drive vehicles as of 08.2013)”, page 20
⇒ “1.3.3 Summary of components - clutch hydraulics, Rapid NH
(right-hand drive up to 08.2013), Rapid India”, page 22
⇒ “1.3.4 Summary of components - clutch hydraulics, Rapid NH
(right-hand drive vehicles from 08.2013)”, page 23
1.3.1 Summary of components - clutch hydraulics, Rapid NH )left-hand drive ve‐

hicles up to 08.2013)
1 - Brake fluid reservoir

❑ Check for leaks
⇒ “1.15 Checking the
master and slave cylin‐
der”, page 53
2 - Supply hose
3 - Gasket
❑ the gaskets must be lo‐
cated in the return hose
4 - Master cylinder
der, Rapid NH (Vehicles
until 08.2013), Rapid In‐
dia”, page 44
5 - Clamp
6 - Retaining clip
❑ only replace if the mas‐
ter cylinder has been re‐
moved
❑ dismantling
⇒ page 44
7 - Mounting bracket with
clutch pedal
8 - Hexagon nut
❑ Tightening torque
⇒ “1.2 Summary of com‐
ponents - Foot controls”,
page 14 , Pos. 4
9 - Gasket ring/O-ring
❑ fit onto the line connection
❑ insert with brake fluid
❑ Gasket rings/O-rings are adapted to the version of the line connection ⇒ page 19

10 - Tube-hose line
❑ for removal, remove ABS control unit with hydraulic unit ⇒ Brake systems; Rep. gr. 45
11 - Mounting bracket
❑ mounted at the structure
12 - Hexagon bolt
❑ 20 Nm
13 - Clamp
14 - Vent valve
❑ Bleeding the clutch control ⇒ “1.14 Bleeding the clutch control”, page 52
❑ 4.5 Nm
15 - Dust cap
16 - Slave cylinder
❑ Removing and installing ⇒ “1.10 Removing and installing the slave cylinder”, page 46
Seals/O-rings for tube-hose lines

Pos. Material of line connection
1 Line connection with circumferential groove
-arrow 1-
2 Line connection with shoulder -arrow 2-
3 Line connection with shoulder -arrow 2- and cir‐
cumferential groove -arrow 3-
• In case of a line connection with round slot -arrow 1- and
-arrow 3-, a gasket ring/O-ring must be inserted in the nut.

1.3.2 Summary of components - clutch hydraulics, Rapud NH )left-hand drive

vehicles as of 08.2013)
1 - Screw
❑ 20 Nm
2 - Vent valve
❑ Bleeding the clutch con‐
trol
⇒ “1.14 Bleeding the
clutch control”,
page 52
❑ 4.5 Nm
3 - Dust cap
4 - Supply hose
6 - Gasket
❑ must be located at the
return hose
7 - Master cylinder
from 08/2013)”,
page 45
8 - Clamp
❑ Assignment ⇒ Electron‐
ic Catalogue of Original
parts
❑ Gasket rings/O-rings
are adapted to the ver‐
sion of the line connec‐
tion ⇒ page 21
❑ replace if damaged
10 - Tube-hose line
❑ Form of the tube-hose line may vary from that shown in the figure
❑ Removing and installing ⇒ “1.11 Removing and installing cables for clutch control”, page 47
❑ for tube-hose line

13 - Clamp
14 - Slave cylinder
Disconnect the cables for the clutch control and connect

Separate
– Unlock the clip -3- with a screwdriver and disconnect the tube-
hose line -1- from the connection -4- .
Connect
Note
♦ An O-ring can also be installed instead of the gasket ring -2-

⇒ page 21 .
♦ Replace damaged gasket ring -2-.
– Push in the hose line -1- at the connection -4- until the clip
-3- locks audibly into place.
– Pull the hose line and check whether the line is connected
correctly.
Gasket rings/O-rings for hose lines

Position Material of line connection
1 Line connection with circumferential groove
-arrow 1-
2 Line connection with shoulder -arrow 2-
3 Line connection with shoulder -arrow 2- and cir‐
cumferential groove -arrow 3-
• In case of a line connection with round slot -arrow 1- and
-arrow 3- a gasket ring/O-ring must be inserted.

1.3.3 Summary of components - clutch hydraulics, Rapid NH (right-hand drive up

to 08.2013), Rapid India

❑ Check for leaks
⇒ “1.15 Checking the
master and slave cylin‐
der”, page 53
2 - Supply hose
3 - Gasket
❑ the gaskets must be lo‐
cated in the return hose
4 - Master cylinder
der, Rapid NH (Vehicles
until 08.2013), Rapid In‐
dia”, page 44
5 - Clamp
❑ Pull clip out to stop to re‐
move pipe/hose line
6 - Retaining clip
❑ only replace if the mas‐
ter cylinder has been re‐
moved
❑ dismantling
⇒ page 44
7 - Mounting bracket with
clutch pedal
8 - Hexagon nut
ponents - Foot controls”,
page 14 , Pos. 4
9 - Brake lines
❑ Various number
❑ For brake lines and pipe/hose line
12 - Tube-hose line
❑ Sealing rings/O-rings adapted to the material of the line connection ⇒ page 19

14 - Hexagon bolt
❑ 20 Nm
15 - Clamp
16 - Vent valve
❑ 4.5 Nm
17 - Dust cap
18 - Slave cylinder
1.3.4 Summary of components - clutch hydraulics, Rapid NH (right-hand drive

vehicles from 08.2013)
1 - Screw
❑ 20 Nm
2 - Slave cylinder
⇒ “1.10 Removing and
installing the slave cylin‐
der”, page 46
3 - Gearbox
parts
❑ Gasket rings/O-rings
are adapted to the ver‐
sion of the line connec‐
tion ⇒ page 21
❑ fit onto the line connec‐
tion
6 - Gasket
❑ must be located on the
return hose
7 - Supply hose
8 - Master cylinder
from 08/2013)”,
page 45
9 - Clamp

11 - Brake lines
13 - Tube-hose line
❑ Removing and installing ⇒ “1.11 Removing and installing cables for clutch control”, page 47
15 - Clamp
16 - Vent valve
❑ 4.5 Nm
17 - Dust cap

1.4 Assembly overview - clutch release mechanism
1 - Release bearing
❑ To remove and install,
remove gearbox
⇒ “2 Removing and in‐
stalling the gearbox”,
page 81
❑ Remove and install to‐
gether with the clutch re‐
lease lever and guide
bushing ⇒ page 55
❑ Remove the release
bearing from the release
mechanism clutch
⇒ page 56
❑ Do not wash out bear‐
ing; wipe only
❑ replace noisy bearings
2 - Screw
moval
❑ 5 Nm + 90°
3 - Clutch release lever
remove gearbox
⇒ “2 Removing and in‐
stalling the gearbox”,
page 81
❑ Remove and install to‐
gether with the clutch re‐
lease lever and guide
bushing ⇒ page 55
❑ Remove original grease
4 - Retaining spring
remove gearbox
❑ secured to clutch release lever
5 - Guide bushing
❑ To remove and install, remove gearbox
❑ Remove and install together with the clutch release lever and guide bushing ⇒ page 55
❑ Removing and installing release bearing ⇒ page 55
6 - Ball stud
❑ To remove and install, remove gearbox
❑ Remove original grease
❑ Grease contact surface on the ball stud with grease - G 000 100-
❑ 20 Nm
7 - Input shaft seal
❑ Replace ⇒ “1.3 Replacing input shaft sealing ring”, page 154
8 - Gearbox
9 - Screw
❑ 20 Nm

10 - Slave cylinder
1.5 Removing and installing clutch pedal

⇒ “1.5.1 Removing and installing clutch pedal, Rapid NH (left-
hand drive vehicles up to 08.2013)”, page 26
⇒ “1.5.2 Removing and installing clutch pedal, Rapid NH (left-
hand drive vehicles from 08.2013)”, page 28
⇒ “1.5.3 Removing and installing clutch pedal, Rapid NH (right-
hand drive until 08.2013), Rapid India”, page 29
⇒ “1.5.4 Removing and installing clutch pedal, Rapid NH (right-
hand drive vehicles from 08.2013)”, page 31
1.5.1 Removing and installing clutch pedal,

Rapid NH (left-hand drive vehicles up to
08.2013)
Special tools and workshop equipment required
♦ Pliers - T10005-
♦ Hook - 3438-
♦ Socket wrench SW 8, commercially available
Removing
– Removing driver side trim panel ⇒ Body Work; Rep. gr. 70 .
– Remove the footwell vent ⇒ Heating, Air Conditioning; Rep.
gr. 80 .
– Release screw -arrow- and remove crash strut.
– Remove clutch pedal switch - F36-
⇒ “1.12 Removing and installing clutch pedal switch F36 ,
Rapid NH (Vehicles until 08.2013), Rapid India”, page 49 .
– Unhook tension spring with hook - 3438- .

Only observe the right part of the fig. -arrows- when installing.
– Pull clutch pedal slightly into the passenger compartment.

– Press both sides of the support in -direction of arrow- with the

pliers - T10005- towards the inside.
As a result, the operating rod of the master cylinder is undone
from the clutch pedal.
– Use an Allen key SW 8 -1- to turn the bearing axle for clutch
pedal in -direction of arrow-.
Note
The catches -A- are destroyed while turning.
Bolts -B- are horizontal after turning.

– Move the clutch pedal so that the bearing axle can be pulled
out.
– Remove clutch pedal.
Installing
• Install the clutch pedal with a new bearing axle.
– Grease the supports for the tension spring.
– Ensure that the support -2- is located on the actuator rod -1-
of the master cylinder.
Note
Press the support at the operating rod/master cylinder

⇒ page 44
– Set the stud -A- in such a way that it is positioned horizontally.
– Turn the bearing axle to the right in -direction of arrow- using

an allen key SW 8 -1-.
• The detents -B- must engage audibly.
• Bolts -B- are vertical after turning.

– Hook in the tension spring.

– Press the support into the recess on the clutch pedal -3- until
it clicks audibly into place.
– Install the clutch pedal switch - F36-
– Install crash strut and reinstall screw -arrow-.

– Install the footwell vent ⇒ Heating, Air Conditioning; Rep. gr.
80 .
– Installing driver side trim panel ⇒ Body Work; Rep. gr. 70 .
Tightening torques and summaries of components
Note
Replace bolts / nuts that are tightened at an angle of rotation, as

well as replacement components after removal.
♦ Crash strut at module carrier

08/2013, Rapid India”, page 14 .

Rapid NH (left-hand drive vehicles from
08.2013)
Removing
– Push the driver seat as far as possible towards the rear.
– Push steering wheel as far as possible towards the top, while
doing so use the entire adjustment range of the steering col‐
umn.
– Removing the over-centre helper spring
⇒ “1.6 Removing and installing over-centre helper spring Rap‐
id NH (vehicles from 08/2013)”, page 32 .

– Break the two locks -A- with screwdriver -1-.
– Turn the bearing bolts for the clutch pedal in

-direction of arrow- with Polydrive socket (SW 10) -1- to the
stop.
Instead of the socket wrench (SW 10) -1-, you can also use an
Allen key (SW 10).
– Move the clutch pedal so that the pin can be pulled out.
Installing
– Press on the clutch pedal and insert a new bearing bolt as far
as it will go.

stop.
• The catches -A- must click audibly into place.
– Installing the over-centre helper spring

Rapid NH (right-hand drive until
08.2013), Rapid India
♦ Pliers - T10005-
♦ Hook - 3438-
♦ Socket wrench SW 8, commercially available
Note
If only the over-centre helper spring should be removed, the

clutch pedal must not be separated from the master cylinder.
Removing
– Remove mounting bracket with master cylinder
⇒ “1.8.1 Removing and installing bearing bracket, Rapid NH
(vehicles up to 08.2013)”, page 35 .

– Press both sides of the support in -direction of arrow- with the

pliers - T10005- towards the inside.
As a result, the operating rod of the master cylinder is undone
from the clutch pedal.
– Unhook tension spring with hooks - 3438- (sown with bearing

bracket installed).
Only observe the right part of the fig. -arrows- when installing.
– Use an Allen key SW 8 -1- to turn the bearing axle for clutch
pedal in -direction of arrow-.
Note
The catches -A- are destroyed while turning.
Bolts -B- are horizontal after turning.

– Move the clutch pedal so that the bearing axle can be pulled
out.
– Remove clutch pedal.
Installing
• Insert the clutch pedal with a new bearing axle.
– Grease the supports for the tension spring.
– Ensure that the support -2- is located on the actuator rod -1-
of the master cylinder.
Note
Press the support at the operating rod/master cylinder

⇒ page 44
– Set the stud -A- in such a way that it is positioned horizontally.

– Turn the bearing axle to the right in -direction of arrow- using

an allen key SW 8 -1-.
• The detents -B- must engage audibly.
• Bolts -B- are vertical after turning.
– Put the clutch pedal in home position.
– Hook in tension spring with hooks - 3438- (sown with bearing

bracket installed).
– Press the support into the recess on the clutch pedal -3- until
it clicks audibly into place.
– Install mounting bracket with master cylinder
Note

♦ Bearing bracket to front wall


Rapid NH (right-hand drive vehicles
from 08.2013)
Removing
– Removing bracket
(vehicles from 08/2013)”, page 41 .

– Press the catches -arrows- and detach the carrier bolt -1- of
the tappet for master cylinder to the right (shown with bearing
bracket installed).
– Raise the clutch pedal as far as it can go as far towards the
vehicle compartment.
– Remove the over-centre helper spring.
– Break the two locks -A- with screwdriver -1-.

stop.
Instead of the socket wrench (SW 10) -1-, you can also use an
Allen key (SW 10).
– Move the clutch pedal so that the pin can be pulled out.
Installing
– Press on the clutch pedal and insert a new bearing bolt as far
as it will go.

stop.
• The catches -A- must click audibly into place.
– Installing bracket
1.6 Removing and installing over-centre

helper spring Rapid NH (vehicles from
08/2013)
Removing
– Push the driver seat as far as possible towards the rear.

– Push steering wheel as far as possible towards the top, while

doing so use the entire adjustment range of the steering col‐
umn.
– Disconnect battery earth strap ⇒ Electrical System; Rep. gr.
27 .
– Press the catches -arrows- and detach the carrier bolt -1- of
the tappet for master cylinder to the right.
– Remove the over-centre helper spring.
Installing
Installation is carried out in the reverse order. When installing,
observe the following:
– Insert the over-centre helper spring lengthways from the bot‐

tom into the support -A- in the bracket next to the tappet of the
master cylinder and next to the clutch pedal.
• The area of the support -arrow- for the centering pin of the
clutch pedal must be vertical.
– Then press the over-centre helper spring onto the centering

pin of the clutch pedal -arrow-.
• The over-centre helper spring must be directly in the support

-arrow 1- at the carrier to ensure the application on the clutch
pedal -arrow 2- can be carried out correctly, (⇒ also previous
figure).
• Otherwise it will not be possible to install the carrier bolt -1- for
tappet/master cylinder (⇒ next figure).

– Press the clutch pedal so that a new carrier bolt -1- can be
inserted as far as it goes for the tappet/master cylinder.
• The catches -arrows- for carrier bolts -1- should jump into
place.
– Connect battery ⇒ Electrical System; Rep. gr. 27 .
1.7 Removing and installing bushing, Rapid

NH (vehicles from 08/2013)
Removing
– Disconnect battery earth strap ⇒ Electrical System; Rep. gr.
27 .
– Removing the over-centre helper spring
– Turn plunger of master cylinder so that recesses -1- or pin
-2- are visible.
• Recesses -1- and pin -2- are facing the same direction.
– Remove bearing bush -A- from recesses -1-.
Installing
– Turn plunger of master cylinder so that recesses -1- or pin

-2- are visible.
• Recesses -1- and pin -2- are facing the same direction.
– Insert bearing axle -A- into the recesses -1- and put it into the
correct position.

1.8 Removing and installing bearing bracket

⇒ “1.8.1 Removing and installing bearing bracket, Rapid NH (ve‐
hicles up to 08.2013)”, page 35
⇒ “1.8.2 Removing and installing bearing bracket, Rapid India”,
page 38
⇒ “1.8.3 Removing and installing bearing bracket, Rapid NH (ve‐
hicles from 08/2013)”, page 41
1.8.1 Removing and installing bearing brack‐

et, Rapid NH (vehicles up to 08.2013)
♦ Hose clamp - MP7-602 (3094)-
♦ Closing tool - T10249-
♦ Hook - 3438-
Removing
Left-hand drive
– Remove the engine control unit from the end wall ⇒ engine;
Rep. gr. 24 .
Right-hand drive
A heat-protection matting is installed in combination with certain
engines. The appearance may differ from the figure.
– Remove heat-protection matting -arrows-.
Continued for all versions
NOTICE
Risk of brake fluid escaping.
During the following work, ensure that no brake fluid lands on
longitudinal member or gearbox.
– If this is the case, clean the affected area thoroughly.
– Lay a lint-free cloth under master cylinder.
– Disconnect supply hose -2- to the master cylinder with hose

clamp - MP7-602 (3094)- -A-.
If the return hose with hose clamp is disconnected, it will be per‐
manently deformed.
The return hose however is not defective.
• After the hose clamp is removed, the return hose must be re‐
turned to its original form.

After disconnection, the supply hose can be closed -1- with the
lock tool - T10249/1- -3-.
– Detach return hose -1- at master cylinder.

– Unlock locking clip -2- with a screwdriver or a sharp object and
detach tube-hose line -3- at master cylinder.
Note
On certain master cylinders, the locking clip -2- can also be pulled
out from the side.
Vehicles with start-stop system

– With hooks - 3438- undo the latch -arrow A- for clutch position
sender - G476- .
– Remove clutch position sender - G476- in
-direction of arrow B- from the master cylinder.
gr. 80 .


– Unscrew fixing nuts -1- and -2-.

– Remove bracket -3-.
Installing
Installation is carried out in the reverse order; pay attention to the
following points:
♦ Stick new foam seal onto the master cylinder and bearing
bracket.
♦ Replace self-locking nuts.
– Install crash strut. To do so, reinstall fixing screw -arrow-.

80 .

– Insert the clutch position sender - G476- with connected elec‐

trical plug connection up to the stop on the master cylinder.
• The clutch position sender must lock in place -arrow A-.
– For checking, pull at clutch position sender in
-direction of arrow B-.
– Fit return hose -1- on master cylinder.
• After the hose clamp - MP7-602 (3094)- is removed, the return
hose must be returned to its original form.
– Press in tube-hose line -3- onto the connection of the master
cylinder, until the locking clip -2- is heard to click into position.
– For checking, pull on the line.
– Bleed the clutch control
⇒ “1.14 Bleeding the clutch control”, page 52 .
Left-hand drive
– If removed, install the engine control unit at the front wall ⇒
Engine; Rep. gr. 24 .
– If removed, re-install air filter housing ⇒ Engine; Rep. gr. 24 .
Note

♦ Bearing bracket for clutch pedal on front wall


et, Rapid India
♦ Hose clamp - MP7-602 (3094)-
♦ Hook - 3438-

Removing
– Remove heat-protection matting -arrows-.
NOTICE

clamp - MP7-602 (3094)- -A-.
manently deformed.
lock tool - T10249/1- -3-.
– Detach return hose -1- at master cylinder.

– Unlock locking clip -2- with a screwdriver or a sharp object and
detach tube-hose line -3- at master cylinder.
Note
On certain master cylinders, the locking clip -2- can also be pulled
out from the side.

gr. 80 .


– Unscrew fixing nuts -1- and -2-.

– Remove bracket -3-.
Installing
following points:
♦ Stick new foam seal onto the master cylinder and bearing
bracket.
♦ Replace self-locking nuts.
– Install crash strut. To do so, reinstall fixing screw -arrow-.

80 .


– Press in tube-hose line -3- onto the connection of the master
cylinder, until the locking clip -2- is heard to click into position.
– For checking, pull on the line.
Note



et, Rapid NH (vehicles from 08/2013)
♦ Hose clamp - MP7-602 (3094)-
Removing
– Disconnect battery earth strap ⇒ Electrical system; Rep. gr.
27 ; Battery; Disconnecting and connecting battery .
Left-hand drive
– Remove the engine control unit - J623- from the holder on the
end wall and place it aside ⇒ Rep. gr. 24 ; Engine control unit;
Engine control unit - J623- Removing and installing .
Right-hand drive

– Remove clip -4-, gradually release the heat protection mat at

fastening points -1-, -2-, -3- and remove the mat.
Continued for all vehicles
– Remove the clutch position sender - G476- with connected
electrical plug connection from the master cylinder
Rapid NH (vehicles from 08/2013)”, page 50 .
NOTICE

clamp - MP7-602 (3094)- -A-.
manently deformed.
lock tool - T10249/1- -3-.
– Remove the return hose to the master cylinder -1-.

– Unlock the clip -2- with a screwdriver and remove the feed tube
line -3- ⇒ page 21 .
– Close the openings.
– Remove drive shaft ⇒ Chassis, axles, steering; Rep. gr. 48 .

– Unscrew nuts -1-, -2- and -3-.

– Remove bearing bracket for clutch pedal -4-.
Installing
– Replace self-locking nuts and gasket for master cylinder after
removal.
– Install drive shaft ⇒ Chassis, axles, steering; Rep. gr. 48 .
– Push in the tube-hose line -3- at the connection until the clip
-2- locks audibly into place. ⇒ page 21 .
– Install clutch position sender - G476-
Rapid NH (vehicles from 08/2013)”, page 50 .
Left-hand drive
– Install the engine control unit with connected electrical plug
connection into the bracket on the front face ⇒ Rep. gr. 23 ;
Engine control unit .
Right-hand drive
– If present, secure the heat protection mat at positions

-1, 2 and 3-.
– Secure the heat-protection matting with the circlip -4-.
Note


⇒ “1.2.2 Summary of components - foot controls, Rapid NH
(vehicles as of 08/2013)”, page 16 .
♦ Crash strut to module carrier ⇒ Chassis, axles, steering; Rep.
gr. 48 .

1.9 Removing and installing the master cyl‐

inder
⇒ “1.9.1 Removing and installing master cylinder, Rapid NH (Ve‐
hicles until 08.2013), Rapid India”, page 44
⇒ “1.9.2 Removing and installing master cylinder, Rapid NH (ve‐
hicles from 08/2013)”, page 45
1.9.1 Removing and installing master cylin‐

der, Rapid NH (Vehicles until 08.2013),
Rapid India
♦ Pliers - T10005-
Removing
– Remove mounting bracket with master cylinder
– Unlock the clutch pedal with tongs - T10005- from master cyl‐
inder.
– Remove master cylinder from bearing bracket.
Remove the support -A- in -the direction of the arrow-.
Carefully press the actuator rod/master cylinder in the support

-A-
Installing

– Insert the master cylinder in the bracket.

• Ensure that the support -2- is located on the actuator rod -1-.
Note
If the support -2- was removed it will need to be installed first

⇒ page 44
– Press the support -2- into the recess on the clutch pedal -3-
until it clicks audibly into place.
– Install mounting bracket with master cylinder
1.9.2 Removing and installing master cylin‐

der, Rapid NH (vehicles from 08/2013)
Removing
– Remove the bearing bracket for clutch pedal with master cyl‐
inder
– Press the catches for carrier bolts -1- on the tappet for master
cylinder -arrows- (shown here with a built-in bearing bracket).

– Remove the carrier bolts for the tappet/master cylinder from

the clutch pedal -arrows A-.
The master cylinder is locked into the bearing bracket for clutch
pedal with catches -arrows B-.
The figure only shows 2 of the 4 catches -arrows B-
– Push off the catches -arrows B- and remove the master cylin‐
der from the bearing bracket for the clutch pedal.
Installing
following points:
• Replace the carrier bolts -arrow A- (⇒ figure above) after dis‐
assembly.
• The catches for the carrier bolts need to latch.
– Carefully pull on the carrier bolt and check that the latching is
correct.
– Press the master cylinder into the bearing bracket for the
clutch pedal -arrows B- (⇒ figure above) until all latches en‐
gage.
– Check for firm seating by pulling on the master cylinder.
– Install bearing bracket for clutch pedal
1.10 Removing and installing the slave cylin‐

der
♦ Screw plug set - VAS 6122-
Removing
• Before the master cylinder must be replaced due to a fault, first
of all carry out ⇒ Vehicle diagnostic tester with the system.
• If the slave cylinder with the tube-hose line is removed from
the gearbox, do no longer depress the clutch pedal. Other‐
wise, the piston can be pressed out of the slave cylinder and
thus be destroyed.
– With the ignition switched off, disconnect battery earth strap
⇒ Electrical system; Rep. gr. 27 ; Battery; Disconnecting and
connecting battery .
NOTICE
When performing the following work, make sure no brake fluid
comes into contact with the gearbox.
– Lay a lint-free cloth under slave cylinder.

– Pull out the clip -A- up to the stop and detach the tube-hose
line -B-.
– Pull tube-hose line -B- out of the slave cylinder and close
openings.
Close the open lines and connections with clean plugs e.g. from
the plug set - VAS 6122- .
– Unscrew screws -arrows- and remove slave cylinder.
NOTICE
There is a risk of contamination through escaping brake fluid.
– If the tube-hose line is disconnected from the connection, do
no longer depress the clutch pedal.
Installing
following points:
– Push the slave cylinder into the opening in the gearbox and
tighten the screws -arrows-.
– Insert tube-hose line -B- into the slave cylinder up to the stop.
– Press in clip -A- to stop.
– After installing the slave cylinder bleed the clutch control
Note

♦ Slave cylinder to gearbox

1.11 Removing and installing cables for

clutch control
♦ Hose clamp - MP7-602 (3094)-
♦ Screw plug set - VAS 6122-
Removing
Left-hand drive
– Remove the engine control unit with connected electrical plug
connection from the bracket on the front face and place to one
side ⇒ Engine; Rep. gr. 23 .
Right-hand drive
A heat-protection matting is installed with certain engines (ap‐
pearance may vary from what is shown).

– Remove fixing screw -4-.

– Undo the heat-protection matting in stages at the points
-1,2 and 3- and remove upwards.
NOTICE

clamp - MP7-602 (3094)- -A-.
manently deformed.
– Unlock the clip on the connection -1- with a screwdriver and

remove the tube-hose line.
– Pull out the clip -A- up to the stop and detach the hose line
-B- ⇒ page 21 .
Note
Seal the open lines and connections where necessary with a

clean plug from the seal plug set - VAS 6122- .
– Loosen tube line and remove.

Installing

– Connect the tube line -1- with connector at the master cylinder
and at the slave cylinder.
If the return hose with hose clamp - MP7-602 (3094)- is discon‐
nected, it will be permanently deformed.
Left-hand drive
connection into the bracket on the front face ⇒ Engine; Rep.
gr. 23 .
Right-hand drive

-1, 2 and 3-.
1.12 Removing and installing clutch pedal

switch - F36- , Rapid NH (Vehicles until
08.2013), Rapid India
• To ensure sufficiently secure seating in mounting bracket for
clutch pedal, clutch pedal switch - F36- may be installed only
once.
Removing
– Removing the driver side footwell cover ⇒ Body Work; Rep.
gr. 68 .
gr. 80 .
Note
The clutch pedal switch is installed from the front wall.
– Unplug connector from the clutch pedal switch .

– Turn the clutch pedal switch at the bracket 45° in

-direction of arrow- and remove it from the support.
Installing
Please note the different versions of the clutch pedal switch - F36-
Difference between clutch pedal switches - F36-
-A- • The tappet must be pulled
out completely before the
installation.
-B- • The tappet must not be

pulled out before the instal‐
lation.
• Grease the tappet head.

• Assign the grease via the ⇒ Electronic Catalogue of Original
Parts .
• When installing the clutch pedal switch the clutch pedal must
always remain in the off position. Clutch pedal is only allowed
to be touched with plunger head of clutch pedal switch during
entire installation procedure.
Note
The clutch pedal switch is installed from the front wall.
– Insert the clutch pedal switch into the support of the bearing
bracket and turn it 45° in -direction of arrow-.
– Attach connector for the clutch pedal switch .
80 .
– Install the driver side footwell cover ⇒ Body Work; Rep. gr.
68 .
1.13 Removing and installing clutch position

sensor - G476- , Rapid NH (vehicles
from 08/2013)
♦ Hook - 3438-
Removing
– Disconnect battery ⇒ Electrical System; Rep. gr. 27 .

Left-hand drive
– Remove the engine control unit with connected electrical plug
connection from the bracket on the front face and place to one
side ⇒ Engine; Rep. gr. 23 .
Right-hand drive
A heat-protection matting is installed with certain engines (ap‐
pearance may vary from what is shown).
– Remove fixing screw -4-.
– Undo the heat-protection matting in stages at the points
-1,2 and 3- and remove upwards.
– With hooks - 3438- undo the latch -arrow A- for clutch position
sender - G476- .
– Press the clutch position sender - G476- in
-direction of arrow B- remove from the mounting bracket of the
master cylinder and disconnect the plug connection.
Installing
– Insert the clutch position sender - G476- with connected elec‐

trical plug connection up to the stop on the master cylinder.
• The locking device on the clutch position sender - G476-
should lock into place -arrow A-.
– In the -direction of arrow B- pull on the clutch position sender
- G476- and thus check correct seating.
Note
Ignore positions -1-,-2- and -3-.
Left-hand drive
connection back into the bracket on the front face ⇒ Engine;
Rep. gr. 23 .
Right-hand drive


-1, 2 and 3-.
1.14 Bleeding the clutch control

♦ Brake filling and bleeding device - VAS 5234 / VAS 6860-
• The system must be bled after performing work on the hy‐
draulic clutch control.
• When performing the following work, make sure no brake fluid
comes into contact with the gearbox.
• Pre-filling of the system is not necessary!
• Before bleeding, fill brake fluid reservoir up to “max” marking
with brake fluid.
• Specification of brake fluid ⇒ Electronic catalogue of original
parts .
Vehicles up to 08/2014
– Connect the brake filling and bleeding device - VAS 5234 /
VAS 6860- .
– Fit the bleeder hose onto the vent valve -arrow-.
To bleed system, use the hose - V.A.G 1238/B3- (670 mm long)
if necessary.
For vehicles as of 08/2014

– Remove the cap from the air bleed valve and connect the
brake filling and bleeding device or -arrow-.
To bleed system, use the hose - V.A.G 1238/B3- (670 mm long)
if necessary.
– Then connect ventilation hose with the drip bottle of the brake
bleeding device.
– Switch on brake filling and bleeding device .
• Working pressure: overpressure 2.0 bar
– Open vent valve.
– Allow approx. 100 cm3 of brake fluid to flow out.
– Close vent valve.
– Rapidly operate pedal from stop to stop 10 to 15 times.
– Open vent valve.
– Allow approx. 50 cm3 more brake fluid to flow out.
– Close vent valve.
– After completing the bleeding procedure, press the clutch ped‐
al repeatedly.
Note

♦ Vent valve
1.15 Checking the master and slave cylinder

Before the master cylinder or slave cylinder is replaced due to a
presumed fault, first check the hydraulic clutch actuation.
In the event of a fault or malfunction of the hydraulic system, the
following checks must be carried out to determine the exact na‐
ture of the fault:
♦ Inspect clutch pedal.
♦ Inspect the complete hydraulic system for leaks.
Inspect clutch pedal.
Noises when pressing down on the clutch:
♦ Check over-centre spring and, if necessary, tension spring for
noises.
♦ If you hear noises, remove the over-centre helper spring (and
if necessary, the tension spring) and repeat the test.
♦ If the spring is loud, replace the affected component.
Clutch pedal remains on the floor when engaging the clutch (does
not return to the rest position):
If the clutch pedal does not return to the rest position, the self-
vent function of the clutch hydraulics may be compromised be‐
cause the vent hole in the clutch master cylinder can not perform
its function.

The clutch hydraulics can only continuously vent themselves

when the vent hole is free.
The vent hole is built into in the clutch master cylinder and cannot
be seen from the outside.
• Check to see whether the clutch pedal returns fully to the neu‐
tral position, thus freeing the vent hole in the clutch master
cylinder.
• Check to see whether the clutch pedal does not return to rest
due to footwell trim panels or footmats getting jammed.
• Notify the client to ensure that they do not put their foot down
on the clutch pedal.
High pedal force
Mechanical failure of clutch pressure plate or clutch disc.
• The pedal force is approx. 140 N over the full running time of
the clutch.
Inspect the complete hydraulic system for leaks
NOTICE
If the slave cylinder is removed from the transmission during the
leak test of the hydraulic system, do not depress the clutch ped‐
al.
Symptoms of an external leak are, amongst others, traces of

brake fluid on or below the gearbox, as well as on the noise in‐
sulation under the gearbox.
• Check brake fluid level in the brake fluid reservoir.
– Carry out a visual inspection as well as a manual inspection
for leaks on the following components of the hydraulic clutch
actuation:
♦ Return hose between brake fluid reservoir and master cylin‐
der.
♦ Master cylinder.
♦ Tube-hose line between master cylinder and slave cylinder.
♦ Connection points (plug and screw connections).
♦ Slave cylinder.
• If any leaks are detected, the affected component must be re‐
placed.
• Ventilate the clutch control
The clutch does not disengage or does not disengage fully
The error is caused by the following issues:
♦ Air in the hydraulic system.
♦ The clutch disc is sluggish on the drive shaft serration.
♦ Needle bearing for drive shaft is defective (only applies to au‐
tomatic transmission). Replace needle bearing ⇒ Rep. gr. 13 ;
Crankshaft; Replacing the needle bearing in the crankshaft .
♦ Foreign object in the clutch.
♦ Mechanical failure of clutch pressure plate or clutch disc.
♦ Incorrect components installed during repair work, examples:
clutch disc, clutch pressure plate and dual mass flywheel are

not from the same manufacturer. Assignment ⇒ Electronic

Catalogue of Parts .
♦ When removing and reinstalling the gearbox, some compo‐
nents were not installed. The issue is with the intermediate
plate or the dowel sleeves between the engine and gearbox.
♦ When replacing or repairing the clutch, the clutch disc has
been installed the wrong way round.
1.16 Repairing the clutch release mechanism

Remove and install the clutch release lever together with the re‐
lease bearing and guide bushing
• Gearbox removed.
– Unscrew screws -arrows-.
– Separate the clutch release lever -A- together with the release
bearing and guide sleeve from the drive shaft and ball stud.
Installation is carried out in the reverse order.
– Installing the gearbox
⇒ “2 Removing and installing the gearbox”, page 81 .
Remove and install guide bushing from the release bearing

– Remove the clutch release lever together with the clutch re‐
lease bearing and the guide bushing ⇒ page 55 .
– Remove guide bushing -3- from the release bearing -2- up and
out.
– Rotate the guide bushing-3- opposite the release bearing -2-
approx. 90° in the direction of the arrow until the catch pegs of
the guide bushing fit into the slots -4- of the clutch release
bearing accordingly.
– In this position remove the guide bushing from the release
bearing.
Installation is carried out in the reverse order.
– Install clutch release lever together with release bearing and
guide sleeve ⇒ page 55 .

Removing and installing release bearing

lease bearing and the guide bushing ⇒ page 55 .
– Push together the catch pegs -arrows- on the back of the
clutch release lever and remove the release bearing -A- from
the clutch release lever.
– To install, press the release bearing -A- into the clutch release
lever until the catch pegs -arrows- lock into position.
– Grease contact surface on the clutch release lever with grease
- G 000 100- .
guide sleeve ⇒ page 55 .
Note

• ⇒ “1.4 Assembly overview - clutch release mechanism”, page

25

2 Repairing clutch
⇒ “2.1 Assembly overview - clutch”, page 57
⇒ “2.2 Removing and installing clutch”, page 57
⇒ “2.3 Fault finding power transmission - problems with the clutch
and clutch control”, page 60
2.1 Assembly overview - clutch
1 - Flywheel
❑ Removing and Installing
⇒ Engine; Rep. gr. 13
❑ make sure the centering
pins are correctly fitted
❑ The contact surface for
the clutch lining must be
free of grooves, oil and
grease
2 - Clutch disc
parts
❑ Installation position: the
spring cage points to‐
wards the pressure
plate ⇒ page 58
❑ Centre ⇒ page 60
❑ Lightly grease splines
3 - Pressure plate
stalling clutch”,
page 57
❑ Check the extremities of
the membrane springs
⇒ page 59
❑ Check feather joints and
riveted joints
⇒ page 59
❑ The clutch plates are
protected against corro‐
sion and greased. Only
clean the thrust surface
as otherwise the life of
the clutch may be con‐
siderably reduced.
4 - Screw
❑ assign according to the ⇒ Electronic catalogue of original parts .
❑ loosen or tighten gradually and crosswise
❑ M6 = 13 Nm
❑ M7 = 20 Nm
2.2 Removing and installing clutch

2. Repairing clutch 57
♦ Counterholder - MP1-223 (3067)-

♦ Centering mandrel - MP3-475A (3190A)-
♦ Grease for spline ⇒ Electronic catalogue of original parts
Removing
– Removing the gearbox
⇒ “2.1 Removing the gearbox”, page 81 .
NOTICE
Risk of damage to the pressure plate
– In order to avoid a deformation of the pressure plate when
removing it (this leads to jerking during start-up), the bolts
on the pressure plate must be loosened in small stages
crosswise.
• Insert counterholder - MP1-223 (3067)- to slacken the bolts.

– Release bolts in small stages crosswise.
– Remove pressure plate and clutch plate.
Installing
• Check whether the dowel sleeves for centering the gearbox
are present in the cylinder block, insert if necessary.
• If dowel sleeves are not fitted, difficulties shifting gears, clutch
problems and possible noises from the gearbox (rattling of
gears which are not engaged) could occur.
• Replace the clutch discs and pressure plates if the riveting is
damaged or loose.
• Assign the clutch disc and pressure plate via the ⇒ Electronic
catalogue of original parts and in accordance with the engine
identification characters.
• Clean input shaft splines and, on used clutch plates, hub
splines.
• Remove corrosion and only apply a very thin layer of grease
for serration spline - G 000 100- on the drive shaft serration.
• Then move clutch plate to and fro on input shaft until hub
moves freely on shaft.
• Remove all excess grease.
• Pressure plates are protected against corrosion and greased.
Only clean the thrust surface as otherwise the life of the clutch
may be considerably reduced.
Installation location of the clutch disc

• Legend “side of gearbox” points to the gearbox.

Check the extremities of the membrane spring

• Wear is allowed up to half the membrane spring thickness
-arrows-.
Check feather joints and riveted joints

– Check the feather joints between pressure plate and cover for
cracks as well as the riveted joints for firm seating -arrows-.
Check tension springs and riveted joints

I - Tension springs o.k.
II - Tension springs damaged
• Slight bends in the external area -arrow A- are part of the
standard condition
• Clutch plates with strongly bent or broken feather joints
-arrow B- must be replaced.
Check metal plate ring

– Check metal plate ring in the clutch plate -arrow- for damage.
• Replace the clutch plates with the broken metal plate ring.
Centring clutch plate

• The crankshafts have different diameters -arrow-.
• For large diameter engines, use the centring mandrel -
MP3-475A (3190A)- for centering the coupling disc.
• For small diameter engines, use the centring mandrel -
T10086- .
– Insert counterholder - MP1-223 (3067)- -B- to tighten the bolts.

A - Centring mandrel - MP3-475A (3190A)- , -T10086- if required.
B - Counterholder - MP1-223 (3067)-
– Centre clutch disc with centering pin - MP3-475A (3190A)- -
T10086- -A-.
• The disc must be inserted into the correct installation position
⇒ page 58
– Fit the pressure plate onto the centering pins of the flywheel.
• The thrust surface of the pressure plate and the clutch disc
lining must fully rest against the flywheel before the screws are
inserted.
– Screw in all the screws by hand uniformly. until the bolt head
rests against the pressure plate.
– Tighten bolts evenly in small steps diagonally in order not to
damage centring holes of pressure plate and centring pins of
flywheel.
⇒ “2.2 Installing the gearbox”, page 100 .
Note

♦ Pressure plate to flywheel

⇒ “2.1 Assembly overview - clutch”, page 57
2.3 Fault finding power transmission - prob‐

lems with the clutch and clutch control
Note
Check hydraulic clutch control

⇒ “1.15 Checking the master and slave cylinder”, page 53 .
Always check the fault mentioned by the customer first before

repairing the clutch. During this procedure, it must be determined
if indeed there is a fault of the clutch or if the cause is only an
incorrect setting of the shift mechanism.

Fault Possible causes Measure

Clutch pedal does not return to ini‐ ♦ Air in line system. – Vent air from the line system;
tial position. top up with brake fluid.
♦ Line system. master or slave – Replace defective component,
cylinder leaking. vent air from the line system; top
up with brake fluid.
♦ Release bearing on the guide – Replace guide bushing and re‐
bushing is tilted, seizured. lease bearing.
♦ Membrane spring of the pres‐ – Replace pressure plate.

sure plate broken.

Actuating force on the clutch pedal ♦ Retractor spring defect. – Replace retractor spring.
too high.
♦ Clutch release force increased – Inform customer (higher release
due to wear of clutch linings. force with increased wear).
– Replace clutch disc. when the

distance base/rivet is below 0.1
mm.
♦ Release bearing on the guide – Replace defective components.
bushing is tilted, seizured.
♦ Pressure plate with wrong – Assign pressure plate via the ⇒

spring identification. Electronic catalogue of original
parts .
♦ Mechanical fault at the pressure – Replace defective components.
plate or the clutch disc.
♦ Clutch disc on the serration – Check the hub for damage

sluggish/jams. (burrs), if necessary replace
clutch disc.
– Clean the hub and the drive

shaft serration from corrosion
and residues of lubricant and
grease with grease for spline of
clutch disc ⇒ Electronic cata‐
logue of original parts . Move
clutch disc back and forth. re‐
move excess grease.

Noises when operating the clutch. ♦ Release bearing defective, – Always replace noisy release
guide of clutch release bearing bearings.
not in order, contact surface
drained off. – Replace guide bushings if dam‐
aged.
♦ The contact surface of the pres‐ – Replace pressure plate.
sure plate is defective (the tips
of the membrane spring are – Check release bearing and
bent. broken). Release bearing guide bushing, replace if neces‐
is off-centre. sary.
– Check position of clutch release

lever.
– Check dowel sleeves.

♦ Centre displacement of engine/ – Check dowel sleeves.
gearbox.
♦ Clutch disc installed the wrong – Correct installation.

way up.
♦ Wrong clutch disc installed. – Assign clutch disc via the ⇒

Electronic catalogue of original
parts .

Rattling, scratching occurs when ♦ Air in the system. clutch does – Bleed and check system, top up
the forward or reverse gear is en‐ not separate fully. with brake fluid.
gaged, gearshift jams, is sluggish,
shifting is not possible, clutch with‐
out operation.
♦ Master cylinder or slave cylinder – Replace defective component.
is leaking, line is leaking. top up with brake fluid. bleed
system.
♦ The travel of the clutch pedal is – Inform customer.
not sufficient (carpet, foot mat
under the foot controls), clutch is
not fully depressed.
♦ The pressure plate is bent due – Check components, if necessa‐

to incorrect installation, the ry replace, make sure the cen‐
clutch disc is deformed due im‐ tering pins are correctly fitted.
proper handling.
– If scratching still occurs. check
the serration of the clutch disc
on the drive shaft for ease of
movement. if necessary repair
the gearbox.
♦ Tips of membrane spring broken – Replace pressure plate.
or bent (assembly fault, release
bearing moves off-centre). – Check release bearing and
guide bushing, replace if neces‐
sary.
– Check dowel sleeves.

♦ Clutch disc too thick. – Assign clutch disc via the ⇒
parts .
♦ Deposit adhering to the flywheel – Slightly rub down friction surfa‐
(long immobilization time, high ces of the clutch linings or re‐
humidity). place completely the severely
corroded parts.


♦ Clutch disc on the serration – Check the hub for damage, if
sluggish/jams. Corrosion on the necessary replace the clutch
hub, damage during the assem‐ disc.
bly. Hub profile knocked out on
one side. – Remove corrosion from the hub
and the shaft as well as residues
of lubricant. Lightly grease shaft
with grease for spline ⇒ Elec‐
tronic catalogue of original
parts .
– Move clutch disc back and forth.

remove excess grease.
– Check position of the dowel

sleeves on knocked out hub pro‐
file.
– Check release bearing, guide

bushing and pressure plate, re‐
place if necessary.
♦ Lifting of pressure plate too low – Assign pressure plate via the ⇒
(wrong pressure plate installed). Electronic catalogue of original
parts .
♦ Displacement of engine/gear‐ – Insert dowel sleeves before
box too large (dowel sleeves gearbox has been fitted.
missing). support panel of clutch
plate bent through this. – Check clutch disc and pressure
plate for damage. if necessary
replace.
♦ The lining is spalled off because – Replace clutch disc. Inform cus‐
of too high revs (shift back into tomer.
lower gears during high
speeds).
♦ When starting. linings are spal‐
led off through slipping for too
long a time.

Load change jolts when throttle is ♦ Assembly bracket too soft. – Inform customer. Assign hanger
depressed and sudden reduction of via the ⇒ Electronic Catalogue
the engine speed. of Original Parts replace if nec‐
essary.
♦ Irregular engine running. – Check engine power, correct.
♦ Clutch disc with predamper is – Inform customer.

built in against gear rattling.
♦ Centre displacement of engine/ – Test dowel sleeves, and replace

gearbox. if necessary.

Clutch slips through, no or bad pre‐ ♦ Wrong clutch disc fitted, wrong – Assign the clutch disc and pres‐
drive. pressure plate installed. sure plate via the ⇒ Electronic
catalogue of original parts .

♦ Clutch disc worn out, burnt, – Replace clutch disc.
pressure plate overheated,
scoring, pressure plate warped – Replace pressure plate.
through incorrect assembly,
contact pressure of the pressure – Inform customer.
plate too low, driving error, nat‐
ural wear.
♦ Clutch disc, pressure plate, fly‐ – Replace clutch disc.

wheel - oily. Radial shaft seal of
the engine or the gearbox de‐ – Clean contact surfaces of pres‐
fective. Grease on the contact sure plate and flywheel.
surface through excess greas‐
ing of the hub. – Replace radial shaft seal, re‐
move excess grease from the
drive shaft.
♦ Clutch disc installed the wrong – Correct installation. check
way up. clutch disc. replace if necessary.
♦ Flywheel depth too large or ex‐ – Assign the sealing flange via the
cess removal at the base of the ⇒ electronic catalogue of origi‐
thrust surface. nal parts .
– Inspect clutch disc and pressure

plate, replace if necessary.
♦ Slave cylinder leaking. – Replace slave cylinder.

Clutch grabbing, ♦ Air in the system. – Bleed system. check brake fluid
unit shaking. level. check system for tight‐
ness.
– Replace defective part.

♦ Engine does not run clean. – Check engine power, correct.
♦ Driving error. starting speed is – Inform customer.

too low.
♦ Wrong clutch disc installed. – Assign clutch disc via the ⇒

parts .
♦ Assembly bearing too soft, – Assign the assembly bracket via
knocked out. the ⇒ Electronic catalogue of
original parts .
♦ Clutch lining. contact surface of – Check radial shaft seal of the
pressure plate and flywheel oily drive shaft for clutch or check
(oil leakage from the clutch crankshaft. if necessary re‐
housing). place.
– Replace clutch disc. clean pres‐

sure plate and flywheel.
♦ Release bearing is tilted on the – Replace release bearing and
guide bushing (eroded) guide bushing.
(presses on one side onto the
membrane spring of the pres‐ – Check control element and
sure plate). bearing for control elements.


♦ The contact surface of the pres‐ – Check the contact surface of the
sure plate lifts off only unilater‐ clutch lining on the flywheel,
ally due to the tilted release check pressure plate and mem‐
bearing. brane spring, replace pressure
plate if necessary.
♦ Pressure plate housing de‐
formed when installed. Contact – Replace release bearing and
surface of the pressure plate lifts guide bushing.
off only unilaterally.
♦ Drive shaft too heavily greased – Remove grease from pressure

(traces of grease on the clutch plate and flywheel. replace if
disc, pressure plate and fly‐ damaged (traces of wear. traces
wheel). of overheating. grooves).
– Remove traces of grease from

hub and shaft, grease shaft
lightly with grease for spline of
clutch disc ⇒ Electronic cata‐
logue of original parts .
– Move clutch disc back and forth.

remove excess grease.
Fault Possible cause of fault Measure

Acoustic knock »clack« when ♦ Acceleration is assigned to the – Inform customer.
clutch is released. load carrier/drive shaft through
the sudden press of the clutch
pedal. The drive shaft serration
of the pinions in mesh knocks,
this noise is increased for clutch
discs with noise insulation as the
damping reaches the stop.

Noises in idle. ♦ Torsional damper spring kinked. – Replace clutch disc.
♦ Clutch disc fitted without pre‐ – Assign clutch disc via the ⇒
damper (idle rattling). Electronic catalogue of original
parts .
♦ Pressure plate deformed, imbal‐ – Replace pressure plate.
ance.
♦ Irregular engine running. – Check engine power, correct if

necessary.
♦ Displacement of engine/gear‐ – Insert dowel sleeves before
box too large (dowel sleeves gearbox has been fitted.
missing).
♦ Intermediate plate rubs on the – Insert intermediate plate on

flywheel. sealing flange and push onto the
dowel sleeves.
34 – Controls, housing
1 Shift mechanism
⇒ “1.1 Fitting location of shift mechanism”, page 66
⇒ “1.2 Summary of components - gearshift knob and cover”, page
68
⇒ “1.3 Summary of components - shift lever and shift housing”,
page 69
⇒ “1.4 Removing and installing gearshift knob with shift lever col‐
lar”, page 70
⇒ “1.5 Removing and installing selector mechanism”, page 71
⇒ “1.6 Repairing shift mechanism”, page 74
⇒ “1.7 Setting the shift mechanism”, page 77
⇒ “1.8 Inspecting the gearshift mechanism”, page 79
⇒ “1.9 Replacing the sealing ring for the gearshift shaft”,
page 79
1.1 Fitting location of shift mechanism

-Arrow A- shows the gear selection movement and the gear se‐
lector cable.
-Arrow B- shows the gate selection movement and the gate se‐
lector cable.
66 Rep. gr.34 - Controls, housing

A - Linkage for gearshift mech‐

anism
B - Linkage for gate selection
movement
C - Heat shield
❑ Remove before remov‐
ing selector mechanism
1 - Gearshift lever
2 - Relay lever
1. Shift mechanism 67
1.2 Summary of components - gearshift knob and cover
1 - Centre console cover

2 - Clamp
❑ to secure the gear shift
knob to the gear shift
lever
moval
❑ secure to the gear shift
knob with hose binding
claw - V.A.G 1275A-
3 - Gearshift knob
❑ with collar
parts
❑ Gearshift knob and col‐
lar must not be separa‐
ted
❑ Always replace together
stalling gearshift knob
with shift lever collar”,
page 70

1.3 Summary of components - shift lever and shift housing
1 - Gearshift unit
❑ Overview
ponents - Gearshift
unit”, page 114
stalling switching unit”,
page 115
❑ repairing
⇒ “5.8 Repairing gear‐
shift unit”, page 117
2 - Sealing ring
❑ Replace
⇒ “1.9 Replacing the
sealing ring for the gear‐
shift shaft”, page 79
3 - Sliding shoe
4 - Relay lever
❑ Fitting position
⇒ page 76
❑ Distinguishing the cable
locks ⇒ page 75
❑ Remove and install re‐
lay lever together with
cable lock ⇒ page 75
❑ Greasing the relay lever
⇒ page 76
❑ Grease assignment ⇒
Electronic Catalogue of
Original Parts
❑ After installing, set shift
mechanism
⇒ “1.7 Setting the shift
mechanism”, page 77
5 - Cable lock
❑ for selector cable
❑ Distinguishing the cable locks ⇒ page 75
❑ Lock the cable locks ⇒ page 74
❑ remove from relay lever ⇒ page 76
❑ press onto relay lever ⇒ page 76
❑ After installing, set shift mechanism ⇒ “1.7 Setting the shift mechanism”, page 77
6 - Gearshift lever
❑ grease ⇒ page 77
❑ Grease assignment ⇒ Electronic Catalogue of Original Parts
❑ Fitting position with relay lever ⇒ page 76
❑ installing ⇒ page 77
7 - Hexagon nut
❑ 23 Nm
8 - Cable lock
❑ For shifter shaft lever
❑ Distinguishing the cable locks ⇒ page 75
❑ Lock the cable locks ⇒ page 74
9 - Circlip
❑ Replace after disassembly
10 - Selector cable
❑ Fitting position ⇒ “1.1 Fitting location of shift mechanism”, page 66
❑ connected with cable end-piece for selector cable pos. 5
❑ do not kink
❑ Adjust ⇒ “1.7 Setting the shift mechanism”, page 77
11 - Shift cable
❑ Fitting position ⇒ “1.1 Fitting location of shift mechanism”, page 66
❑ connected with cable end-piece for gear shift lever pos. 8
❑ do not kink
❑ Adjust ⇒ “1.7 Setting the shift mechanism”, page 77
12 - Nut
❑ 4 units
❑ 8 Nm
13 - Gasket
❑ stuck onto the shift housing
14 - Shift housing
15 - Locking clips
❑ do not damage cables when removing
16 - Screw
❑ 3 units
❑ 20 Nm
17 - Cable support
18 - Grommet
❑ Mounting of cable support to gearbox
19 - Bushing
20 - Retaining clip
1.4 Removing and installing gearshift knob

with shift lever collar
♦ Release tool - T30098-
♦ Hose strap pliers , e.g. -V.A.G 1275A-

Removing
– Lever the collar frame out of the centre console. To do so, fit
the release tool - T30098- between the collar frame and the
cover of the centre console in the middle of the front side
-arrow 1- and press it forwards in -direction of arrow 2-.
– Pull collar upwards, inside out over gear knob.
– Open clamp -arrow- and pull off gearshift knob together with
the collar.
Installing
– Turn collar inside out.
• The gear knob must be pressed on the gearshift lever up to
the stop.
– Insert gearshift knob and collar and compress new collar

clamp -arrow-.
1.5 Removing and installing selector mech‐

anism
Removing
– Remove battery and battery tray ⇒ Electrical System; Rep.
gr. 27 .
– Remove lock washer -1-.
– Unscrew shift cable -2- from the gearbox shift lever pin-3-.
– Remove locking mechanism for gate selector cable in

-direction of arrow 1- as far as it can go towards the front and
lock to the left in -direction of arrow 2-.
– Press relay lever -4- (in previous figure) in
-direction of arrow 3- towards the front.
– Undo screws -arrows- and remove cable support from the

gearbox.
– Removing collar with gear shift knob
⇒ “1.4 Removing and installing gearshift knob with shift lever
collar”, page 70 .
– Remove the centre console ⇒ General body repairs, interior;
Rep. gr. 68 .
– Unscrew fixing nuts -arrows- attaching the shift housing.

– Lower shift housing.
The switch housing can be lowered onto the heat protection plate.
– If fitted, remove noise insulation ⇒ exterior body work; Rep.
gr. 66 .
– Remove the rear part of the exhaust system ⇒ Exhaust pipes /
muffler; Rep. gr. 26 .
– Remove heat shield ⇒ Exterior body work; Rep. gr. 66 .
When removing the heat protection plate, remove the loose
switch housing at the same time. While doing so, carefully pull the
cables out of the engine compartment.
Installing
following points:

– Route cables -1- from selector mechanism -2- to gearbox as

follows:
♦ The cables must be installed in parallel up to the cable support
bracket on the gearbox.
♦ The cables must be laid in the intended indentation in heat
shield -3-.
On some equipment variants, the linkages and the heat shield are
held with the clip -A- to each other in position.
Note the correct assignment of the cable locks ⇒ page 75 .
– Align shift housing parallel to vehicle body.
• The distance to the vehicle body must be the same on both
sides.
– Installing shift housing on the central console.
– Grease the following areas with grease ⇒ Electronic Cata‐

logue of Original Parts .
• Sliding rail for engaging the relay lever -4- into the gearbox
shift lever ⇒ page 77
• Gearbox shift lever pin -3- and relay lever -4- ⇒ page 76
– Replace safety mechanism -1- for cable lock -2-.
– Install relay lever -4- together with cable end-piece
⇒ page 75 .
– Setting the shift mechanism
⇒ “1.7 Setting the shift mechanism”, page 77 .
– Insert and mount central console ⇒ Body Work; Rep. gr. 68 .
– Installing collar with gear shift knob
– Install heat shield ⇒ exterior body work; Rep. gr. 66 .
– Install the rear part of the exhaust system ⇒ Exhaust pipes /
muffler; Rep. gr. 26 .
– Install the battery and battery tray ⇒ Electrical System; Rep.
gr. 27 .
Note

♦ Selector housing to body

page 69
♦ Cable support to gearbox
page 69
1.6 Repairing shift mechanism

Lock control cable locks
– Push sliding sleeve forwards up to the stop in direction of ar‐
row-1-.
– Turn sliding sleeve to the right up to the stop in direction of
arrow -2- until it locks in place.

Distinguishing the cable locks for the shift cables

The holes in the cable end-pieces have different diameters.
Cable lock: Dimension “a”
1 - Gear selector cable to 8.5 mm
gearbox selector lever
2. - Gate selector cable to 10 mm
relay lever
Removing and installing relay lever with cable end-piece

• To remove relay lever, first detach cable end-piece from gate
selector cable.
– Pull forward the locking mechanism as far as the stop in
-direction of arrow 1-, then lock by turning to the left in
-direction of arrow 2-.
– Press the relay lever in -direction of arrow 3- towards the front.
– Remove the locking clip -arrow 1- and remove the relay lever
together with the cable lock.
• It is only permissible to remove cable end-piece after relay
lever has been removed.
Lever off cable lock for selector cable from relay lever
• The relay lever has been removed.
– Insert a flat-blade screwdriver -A- between bush -B- and relay
lever.
Press cable end-pieces onto relay lever

• The relay lever has been removed.
• The mounting bolt is greased with grease ⇒ Electronic Cata‐
• The cable lock must move freely on the relay lever.
• The cable lock must be located behind the catch.
Greasing the relay lever.

• Apply grease to the entire length and circumference of the
shaft -A- of the relay lever.
• Assignment grease ⇒ Electronic Catalogue of Original Parts .
• Grease quantity: 0.2 grams
Note
The picture of the relay lever may differ from the original part.
Fitting location of gearbox shift lever/relay lever

1- Gearshift lever
2- Relay lever engages in guide rail of gearbox selector lever
via shoe -arrow-.

Install gearbox selector lever

– When positioning the gearshift lever, make sure that the tooth
opening -arrow A- is located above the interrupted spacing of
the teeth for the gearshift shaft -arrow B-.
Note
The picture of the gearbox selector lever may differ from the orig‐
inal part.
Apply grease to gearbox selector lever

• Before installing, great the slide of the gearbox shift lever
-B-.
• Grease quantity: 0.4 grams
• Great the mounting bolt of the cable lock for the shift cable.
• Assignment grease ⇒ Electronic Catalogue of Original Parts .
Note
The picture of the relay lever may differ from the original part.
Installation position of circlips -1- and -2-.
1.7 Setting the shift mechanism

♦ Rig pin - T10027A-
Conditions for setting the gearshift mechanism
• Gearbox, clutch and clutch control in perfect condition
• Shift mechanism operates freely
• Operating and transmission elements of the shift mechanism
are in perfect condition
• Gearbox in Neutral
• Cable end-pieces of gear selector cable and gate selector ca‐

ble must be accessible.
Locking the cable locks
– Pull cable end-piece off gear selector cable and gate selector
cable forward to stop in direction of -arrow 1- and then lock in
direction of -arrow 2-.
Locking the gearshift shaft
– Press down the gearshift shaft in -direction of arrow 1-.

– Press the locking lever -A- inwards and simultaneously in
-direction of the arrow 2- until it clicks into the gearshift shaft.
Secure the shift lever
– Removing shift lever collar
• You do not need to remove the shift lever completely, as re‐
moving the shift cover and pulling the sleeve up over the
gearshift knob is enough.
• Neutral (idling) is engaged; push the shift lever slightly to the
left in order to slide in the rig pin .
– Insert rig pin - T10027A- through hole -A- into hole -B-.
– Tie up the left strap -1- with the shift lever.

• The shift lever is locked with the locking pin - T10027A- -A-.
• The force of the seat belt is transmitted to the shift lever. It is
then pressed and held in the 1st and 2nd gear gate-arrow-.
Clearance in the switching operation is ruled out in this way.

• The gate selector cable and shift cable -B- are installed to the
locking devices -A- free of stress.
– Turn locking mechanism on gear selector cable and gate se‐
lector cable end pieces as far as stop in
The spring presses the locking mechanism back into original po‐
sition -direction of arrow 2-.
– Turn locking angle -A- in -direction of arrow- to the left back to

its initial position.
– Remove seat belt from the gearshift lever.
– Pull rig pin - T10027A- out of hole -A- and -B-.

– Install gear shit knob
– Inspect gearshift mechanism
1.8 Inspecting the gearshift mechanism

• The shift lever must be positioned Neutral in the lever gate of
the 3rd/4th gear.
– Depress clutch.
– Select all gears several times. Pay particular attention to prop‐
er operation of the reverse gear lock.
If the difficulty in engaging a gear persists after repeated attempts,
repeat adjustment procedure of selector mechanism
1.9 Replacing the sealing ring for the gear‐

shift shaft
♦ Extractor - T20143/1-
♦ Pipe section - MP3-479 (VW 423)-
♦ Sealing grease ⇒ Electronic Catalogue of Original Parts
– Remove securing clip -1- for shift cable from gearbox selector
lever.
– Pull off the shift cable from the stud.
– Remove relay lever -A- together with cable lock ⇒ page 75 .
– Unscrew nuts -arrow 2- and remove the gearbox shift lever
-B-.
– Pry sealing ring off with the extractor tool - T20143/1- .
– Fill space between sealing lip and dust lip -arrow- with sealing
grease - G 052 128 A1- .
– Use pipe section - MP3-479 (VW 423)- -A- to drive in seal

-1- up to the stop.
note the following:
– Attach gearbox selector lever to gearbox selector shaft
⇒ page 77 .
– Secure gearbox selector lever by tightening hexagon nut.
Note

♦ Gearshift lever to gearshift unit

⇒ “5.5 Summary of components - Gearshift unit”, page 114

2 Removing and installing the gearbox

⇒ “2.1 Removing the gearbox”, page 81
⇒ “2.2 Installing the gearbox”, page 100
⇒ “2.3 Tightening torques for gearbox”, page 104
2.1 Removing the gearbox

⇒ “2.1.1 Removing gearbox, Rapid NH”, page 81
⇒ “2.1.2 Removing gearbox, Rapid India”, page 91
2.1.1 Removing gearbox, Rapid NH

Gearbox 02U, 0DQ
♦ Supporting device - MP9-200 (10-222A)-
♦ adapter - MP9-200/10 (10-222A/10)- (2 pieces)
♦ strap - T10038- (2 pieces)
♦ Gearbox mount - 3282-
♦ Adjusting plate - 3282/69-
♦ Bolt - 3282/29-
♦ Engine support bracket - T10533-
♦ Engine and gearbox jack , e.g. -V.A.G 1383A- or -VAS 6931-
Gearbox 0DQ
♦ Plug - T10381/1-
Differences between gearbox 02U and 0DQ
Manual gearbox 02U Propshafts with flange
Manual gearbox 0DQ Propshafts without flange
– Remove engine cover ⇒ Engine; Rep. gr. 10 (when present).

gr. 27 .
– Remove air filter housing ⇒ Engine; Rep. gr. 24 .
– Remove circlip -Arrow 1- for gear shift lever.
– Remove cable end piece with gear selector cable from the pin
of gearbox selector lever -B-.
• Before removing the relay lever -A-, first detach the lock from
the selector cable.
2. Removing and installing the gearbox 81

– Push the locking mechanism of the locking device forward in

the -direction of arrow 1- until it stops and then lock the locking
device by turning to the left in the -direction of arrow 2-.
– Press the relay lever towards the front in the
– Pull off safety clamp -1- and remove the relay lever together
with the locking device from the bearing on the switching unit.
When the relay lever is removed, the selector cable is simultane‐
ously pulled off the lock.
– Unscrew nut -arrow 2- and remove the switching unit -B- from
the shifting unit shaft.
– Remove screws -arrows- disconnect cable support bracket

from gearbox and tie it up.

– Remove screws -arrows-, take the slave cylinder A out of the

gearbox housing and tie it to the side.
• Do not disconnect the clutch line.
NOTICE
After removing the slave cylinder, do not operate the clutch
pedal.
– Disconnect electric plug connection -2- at the starter motor.

– Loosen cover -1- and disconnect the electrical lead from the
starter.
– Unscrew fixing screw for starter at the top.
– Remove the screws of the top gearbox -1-.
– Remove Lambda sensor 1 - GX7- and the Lambda sensor 1

before catalyst - GX10- plug connections -arrow- from the
holder on the bulkhead and expose them.
• Do not separate connectors of Lambda probe.
Install interception device to catch the engine/gearbox assembly.

– Remove the foam parts -arrows- for the water box sealing on
the right and left.
• If hose and cable connections are located in the area of the
lifting eyes of the engine for the supporting device , these must
now be removed.
– Place the supporting device - MP9-200 (10-222A)- on the ve‐

hicle and the hook - MP9-200/10 (10-222A/10)- into the eye‐
lets of the motor.
• When installing the lifting hooks of the supporting device, pay
attention to hose and cable connections in the area of the lifting
eyes of the engine to avoid damaging them.
– Secure support bracket -A- to the bonnet hinges on both sides

with the aid of the tensioning strap - T10038- -B-.
– Slightly pre-tension the engine/gearbox unit via the spindles
of the supporting device .
Component Tightening torque

M12 screws supporting device 20 Nm

Continuation Remove transmission

Manual gearbox 0DQ
With manual gearbox 0DQ, the cardan shafts are inserted directly
into the gearbox, these are removed in the further work process.
When the vehicle is still standing on its wheels, the screws for
propshafts -arrow- on both sides of the vehicle must therefore be
partially loosened.
• If the vehicle is standing on the wheels, the cardan shaft bolt
can be released by a maximum of 90°, otherwise the wheel
bearing can be damaged.
– Loosen the screws for the propshafts -arrow- , ⇒ chassis,
axles, steering; Rep. gr. 40 ; Propshaft; Loosen the Propshaft
screw connection and tighten it .
– Remove both front wheels.
– Remove the noise insulation below the engine/gearbox ⇒
Body Work; Rep. gr. 50 .
– Remove left wheelhouse liners ⇒ General body repairs, ex‐
terior; Rep. gr. 66 ; Wheelhouse liner; removing and installing
front wheelhouse liner .
– Disconnect the electrical plug connections.

1 - Transmission neutral sender - G701- (on vehicles with start/
stop system)
2 - Reversing light switch - F4-
3 - Earth lead
– Unbolt earth cable -3-.
– Unscrew the nut -arrow- and remove the bracket for the elec‐
trical cable.
– Remove the starter screw at the bottom and remove the gear‐
box housing.

– Disconnect the connector on the oil level and oil temperature

sender - G266- -1-.
– Release screws -1- and remove heat shield for right drive
shaft.
NOTICE
Risk of damage to the decoupling element of the pre-exhaust
pipe.
The decoupling element must not be bent or kinked by more
than 10°.
– Do not load the decoupling element with tensile stress.
– Do not bend the decoupling element excessively.
• Before loosening the warm-type clamp (separation point be‐

tween catalytic converter and turbocharger), mark the position
of the warm-type clamp.
• Restore the position of the warm-type clamp when assembling
the exhaust pipe.
– Loosen the screw of the warm-type clamp -1- between the ex‐
haust gas turbocharger and catalytic converter.
– Move the warm-type clamp towards the catalytic converter.
– Unscrew the nuts -arrows- and loosen the catalyst in the hold‐
er.
Manual gearbox 0DQ

– Drain out gear oil

⇒ “8.2 Draining and filling gearbox oil”, page 143 .
– Unscrew the nuts -arrows- and pull the arms from the axle joint
on both sides.
– Unscrew nut -1- from both sides of anti-roll bar bracket -3-.
– On both sides, press off the anti-roll bar bracket -3- from the
anti-roll bar -2- and place the anti-roll bar at the rear.
Manual gearbox 02U
– Unscrew screws -arrows- and remove the left and right drive
shaft from the gearbox.

– Tie up both joint shafts as far as possible, for example with

straps - T10038- on the spring leg.
• Ensure that the surface protection of the drive shafts is not
damaged.
• If the left drive shaft is not tied up as far as possible, it will
disrupt the removal of the gearbox later on in the work proce‐
dure.
Manual gearbox 0DQ
– Remove right and left joint shafts ⇒ Running gear, axles,
steering; Rep. gr. 40 ; Drive shaft; Removing and installing
drive shaft .
– Close the openings in the gearbox with plugs - T10381/1- .

– Remove pendulum support.
– Unscrew the lower connection bolts motor/gearbox -2- and the

bolt -4- located above the propshaft from the engine side.
• Only loosen and leave -1- and -3- screwed in, they are only
removed after gearbox mounting.

– Remove the screws -Arrows- from of the gearbox mount.
– Lower engine/gearbox unit sufficiently via the receiving device

spindles until the fixing screws attaching the gearbox mount‐
ing bracket -Arrow- are accessible under the left wheelhouse.
– Screw out screws -arrows- and remove gearbox console -A-.
• When lowering the engine/gearbox unit, make sure the gear‐
box does not touch the assembly carrier.
To make more space when removing the detached gearbox, the
engine / gearbox unit can be pressed down with the engine sup‐
port - T10533- .
– Fix the engine support - T10533- with the flat side -D- -A- onto
the left threaded hole for the right propeller shaft heat protec‐
tion plate on the cylinder block and with screw M10 x 20 -C-.
– Fix the engine support -D- -B-with the high side to the noise
damper threaded hole on the right side of the front axle, with
M8 x 30 screw -e-.
– Using the engine support - T10533- spindle -D-, carefully push
the motor/gearbox unit forward to the radiator wall.
• When swivelling, special care should be taken to prevent the

unit colliding with the front of the vehicle.
• AC compressor -1- must not touch the coolant hose -2-
-arrow-.
• The generator must not touch the refrigerant line.
• The pressure pipe must not touch the radiator.
Install gearbox mount - 3282- with receiving elements on the
gearbox.
– Place the gearbox mount - 3282- onto engine/gearbox jack ,
e.g. -V.A.G 1383A- or -VAS 6931- .
• The gearbox mount - 3282- is set up for the removal of the
gearbox using the adjusting plate - 3282/69- .
• The adjusting plate only fits in one position.
– Align arms of the gearbox mount with the holes in the adjusting
plate .

– Screw the individual adapters -A- to the arms of the gearbox

mount - 3282- , as shown on the adjustment plate .
• The arrow symbol -B- on the adjusting plate points in the di‐
rection of travel.
– Position the engine/gearbox jack below the vehicle.
– Align the Adjustment plate parallel to the gearbox and the in‐
dividual arms of the gearbox mount to the gearbox as shown
in the figure.
– Screw the adapter with bolt - 3282/29- into the threaded hole
for the pendulum support on the gearbox.
• Position the second rear adapter with flat plate under the gear‐
box rib.
– Support the gearbox with engine / gearbox jack from under‐
neath.
– Remove the last engine/gearbox connecting screws -1- and

-3-.

– Press the gear unit off the engine (remove it from the dowel
sleeves -A-) and carefully swing it towards the front of the ve‐
hicle.
– Turn the gearbox in the differential gear area upwards and fully
downwards in the gearbox cover area.
– Lower the gearbox carefully and, if necessary, tilt the spindles
of the gearbox mount - 3282- .
• When lowering the gearbox, pay attention to the unit carrier.
• Observe all lines when lowering the gearbox.
2.1.2 Removing gearbox, Rapid India

♦ Supporting device - MP9-200 (10-222A)-
♦ adapter - MP9-200/10 (10-222A/10)- (2 pieces)
♦ strap - T10038- (2 pieces)
♦ Gearbox mount - 3282-
♦ Adjusting plate - 3282/69-
♦ Bolt - 3282/29-
♦ Engine support bracket - T10533-
♦ Plug - T10381/1-
♦ Engine and gearbox jack , e.g. -V.A.G 1383A- or -VAS 6931-
– Remove engine cover ⇒ Engine; Rep. gr. 10 (when present).
gr. 27 .
– Remove air filter housing ⇒ Engine; Rep. gr. 24 .
– Remove circlip -Arrow 1- for gear shift lever.
– Remove cable end piece with gear selector cable from the pin
of gearbox selector lever -B-.
• Before removing the relay lever -A-, first detach the lock from
the selector cable.

– Push the locking mechanism of the locking device forward in

the -direction of arrow 1- until it stops and then lock the locking
device by turning to the left in the -direction of arrow 2-.
– Press the relay lever towards the front in the
– Pull off safety clamp -1- and remove the relay lever together
with the locking device from the bearing on the switching unit.
When the relay lever is removed, the selector cable is simultane‐
ously pulled off the lock.
– Unscrew nut -arrow 2- and remove the switching unit -B- from
– Remove screws -arrows- disconnect cable support bracket

from gearbox and tie it up.

– Remove screws -arrows-, take the slave cylinder A out of the

gearbox housing and tie it to the side.
• Do not disconnect the clutch line.
NOTICE
After removing the slave cylinder, do not operate the clutch
pedal.
– Disconnect electric plug connection -2- at the starter motor.

– Loosen cover -1- and disconnect the electrical lead from the
starter.
– Unscrew fixing screw for starter at the top.
– Remove the screws of the top gearbox -1-.
– Remove Lambda sensor 1 - GX7- and the Lambda sensor 1

before catalyst - GX10- plug connections -arrow- from the
holder on the bulkhead and expose them.
• Do not separate connectors of Lambda probe.
Install interception device to catch the engine/gearbox assembly.

– Remove the foam parts -arrows- for the water box sealing on
the right and left.
• If hose and cable connections are located in the area of the
lifting eyes of the engine for the supporting device , these must
now be removed.
– Place the supporting device - MP9-200 (10-222A)- on the ve‐

hicle and the hook - MP9-200/10 (10-222A/10)- into the eye‐
lets of the motor.
• When installing the lifting hooks of the supporting device, pay
attention to hose and cable connections in the area of the lifting
eyes of the engine to avoid damaging them.
– Secure support bracket -A- to the bonnet hinges on both sides

with the aid of the tensioning strap - T10038- -B-.
– Slightly pre-tension the engine/gearbox unit via the spindles
of the supporting device .
Component Tightening torque

M12 screws supporting device 20 Nm

Continuation Remove transmission

With manual gearbox 0DQ, the cardan shafts are inserted directly
into the gearbox, these are removed in the further work process.
When the vehicle is still standing on its wheels, the screws for
propshafts -arrow- on both sides of the vehicle must therefore be
partially loosened.
• If the vehicle is standing on the wheels, the cardan shaft bolt
can be released by a maximum of 90°, otherwise the wheel
bearing can be damaged.
– Loosen the screws for the propshafts -arrow- , ⇒ chassis,
axles, steering; Rep. gr. 40 ; Propshaft; Loosen the Propshaft
screw connection and tighten it .
– Remove both front wheels.
– Remove the noise insulation below the engine/gearbox ⇒
Body Work; Rep. gr. 50 .
– Remove left wheelhouse liners ⇒ General body repairs, ex‐
terior; Rep. gr. 66 ; Wheelhouse liner; removing and installing
front wheelhouse liner .
– Disconnect the electrical plug connections.

1 - Transmission neutral sender - G701- (on vehicles with start/
stop system)
3 - Earth lead
– Unbolt earth cable -3-.
– Unscrew the nut -arrow- and remove the bracket for the elec‐
trical cable.
– Remove the starter screw at the bottom and remove the gear‐
box housing.
– Disconnect the connector on the oil level and oil temperature

sender - G266- -1-.

– Release screws -1- and remove heat shield for right drive
shaft.
NOTICE
Risk of damage to the decoupling element of the pre-exhaust
pipe.
The decoupling element must not be bent or kinked by more
than 10°.
– Do not load the decoupling element with tensile stress.
– Do not bend the decoupling element excessively.
• Before loosening the warm-type clamp (separation point be‐

tween catalytic converter and turbocharger), mark the position
of the warm-type clamp.
• Restore the position of the warm-type clamp when assembling
the exhaust pipe.
– Loosen the screw of the warm-type clamp -1- between the ex‐
haust gas turbocharger and catalytic converter.
– Move the warm-type clamp towards the catalytic converter.
– Unscrew the nuts -arrows- and loosen the catalyst in the hold‐
er.
– Drain out gear oil


– Unscrew the nuts -arrows- and pull the arms from the axle joint
on both sides.
– Unscrew nut -1- from both sides of anti-roll bar bracket -3-.
– On both sides, press off the anti-roll bar bracket -3- from the
anti-roll bar -2- and place the anti-roll bar at the rear.
– Remove right and left joint shafts ⇒ Running gear, axles,
steering; Rep. gr. 40 ; Drive shaft; Removing and installing
drive shaft .
– Close the openings in the gearbox with plugs - T10381/1- .
– Remove pendulum support.

– Unscrew the lower connection bolts motor/gearbox -2- and the

bolt -4- located above the propshaft from the engine side.
• Only loosen and leave -1- and -3- screwed in, they are only
removed after gearbox mounting.
– Remove the screws -Arrows- from of the gearbox mount.
– Lower engine/gearbox unit sufficiently via the receiving device

spindles until the fixing screws attaching the gearbox mount‐
ing bracket -Arrow- are accessible under the left wheelhouse.
– Screw out screws -arrows- and remove gearbox console -A-.
• When lowering the engine/gearbox unit, make sure the gear‐
box does not touch the assembly carrier.
To make more space when removing the detached gearbox, the
engine / gearbox unit can be pressed down with the engine sup‐
port - T10533- .
– Fix the engine support - T10533- with the flat side -D- -A- onto
the left threaded hole for the right propeller shaft heat protec‐
tion plate on the cylinder block and with screw M10 x 20 -C-.
– Fix the engine support -D- -B-with the high side to the noise
damper threaded hole on the right side of the front axle, with
M8 x 30 screw -e-.
– Using the engine support - T10533- spindle -D-, carefully push
the motor/gearbox unit forward to the radiator wall.

• When swivelling, special care should be taken to prevent the

unit colliding with the front of the vehicle.
• AC compressor -1- must not touch the coolant hose -2-
-arrow-.
• The generator must not touch the refrigerant line.
• The pressure pipe must not touch the radiator.
Install gearbox mount - 3282- with receiving elements on the
gearbox.
– Place the gearbox mount - 3282- onto engine/gearbox jack ,
e.g. -V.A.G 1383A- or -VAS 6931- .
• The gearbox mount - 3282- is set up for the removal of the
gearbox using the adjusting plate - 3282/69- .
– Align arms of the gearbox mount with the holes in the adjusting
plate .
– Screw the individual adapters -A- to the arms of the gearbox

mount - 3282- , as shown on the adjustment plate .
• The arrow symbol -B- on the adjusting plate points in the di‐
rection of travel.
– Position the engine/gearbox jack below the vehicle.
– Align the Adjustment plate parallel to the gearbox and the in‐
dividual arms of the gearbox mount to the gearbox as shown
in the figure.
– Screw the adapter with bolt - 3282/29- into the threaded hole
for the pendulum support on the gearbox.
• Position the second rear adapter with flat plate under the gear‐
box rib.
– Support the gearbox with engine / gearbox jack from under‐
neath.

– Remove the last engine/gearbox connecting screws -1- and

-3-.
– Press the gear unit off the engine (remove it from the dowel
sleeves -A-) and carefully swing it towards the front of the ve‐
hicle.
– Turn the gearbox in the differential gear area upwards and fully
downwards in the gearbox cover area.
– Lower the gearbox carefully and, if necessary, tilt the spindles
of the gearbox mount - 3282- .
• When lowering the gearbox, pay attention to the unit carrier.
• Observe all lines when lowering the gearbox.
2.2 Installing the gearbox

Required special tools are identical to the section called Remov‐
ing the gearbox ⇒ “2.1 Removing the gearbox”, page 81 .
Installation is carried out in reverse order of removal. When in‐
stalling, note the following:

• Replace the self-locking nuts and screws when undertaking

assembly work.
• Carefully clean all self-locking screws using a thread tap to
remove locking agent residues.
• After removal, replace screws which have been tightened to a
torquing angle as well as gasket rings and seals.
• Secure all hose connections with hose clamps which comply
with the series design ⇒ Electronic Catalogue of Original
Parts .
• All cable straps that are detached or cut when removing should
be attached again in the same place when installing.
• Clean input shaft splines and, on used clutch plates, the hub
splines too. Apply a very thin layer of grease - G 000 100- to
the shaft serration. The clutch plate must slide easily to and
fro on the input shaft.
• Check whether the dowel sleeves -A- for centering the gear‐
box are present in the cylinder block and insert missing
sleeves. If the sleeves are not provided, problems while shift‐
ing and with the clutch could, and the gearbox could be noisy.
• Check that the intermediate plate is seated correctly.
• Watch out for all lines, coolant hoses and the gear selector
cable when raising the gearbox.
• Check clutch release bearing for wear and replace if neces‐
sary
⇒ “1.16 Repairing the clutch release mechanism”, page 55 .
• The engine is tilted using the engine support - T10533- .
• The gearbox is attached using the gearbox mount - 3282- at
the engine / transmission jack .
– Adjust the gearbox via the spindles of the gearbox mount -
3282- upwards in the differential gear area and downwards in
the gearbox cover area.
– Carefully lift the gearbox in the direction of the engine com‐
partment, guide it carefully past the axle and gradually bring it
into the installation position.
• The engine and gearbox must be in line.
• Slide in the engine and gearbox by hand until the engine flange
and the gearbox flange are in contact.
• Do no trap any lines when inserting the gearbox.
– Position the gearbox carefully onto the engine until the gear‐
box flange touches the entire scope of the engine flange.
– Screw the gearbox to the engine with all screws accessible
from below and tighten slightly.
The final tightening to the prescribed torque is only carried out
when the engine/gear unit is attached to the bearing.
– Remove the gearbox mount - 3282- from the gearbox.
– With the engine support - T10533- spindle, put the engine/gear
unit in the initial position and remove the engine support .

– Bolt the console -A- with new fixing screws -arrows- to the
gearbox
⇒ “3.1 Assembly overview - assembly mountings”, page 105
- Pos. 5.
– Evenly lift up the gearbox via the hooks of the supporting de‐
vice to the supporting arm of the gearbox mount.
NOTICE
Risk of damage to thread for gearbox console.
– Before screwing in the screws, the gearbox console and
supporting arm of the gearbox mount must be completely
parallel to each other.

– For example, move the console into the correct position with
a screwdriver, insert new screws -Arrows- and tighten slightly.
• Tighten the gearbox mount screws to final tightening torque,
checking the engine / gearbox unit bearing setting.
– Check assembly bracket ⇒ Rep. gr. 10 ; Assembly bracket;
Checking assembly bracket setting .
– Remove supporting device .
– Screw in all remaining engine/gearbox connecting bolts and
tighten all bolts to the specified torque
⇒ “2.3 Tightening torques for gearbox”, page 104 .
– Install the left and right propeller shafts on the flange shafts on
the gearbox ⇒ Chassis, axles, steering; Rep. gr. 40 ; Propeller
shaft; remove and install propeller shaft .
– Install the pendulum support ⇒ Rep. gr. 10 ; Assembly mount‐
ings; removing and installing the pendulum support .
– Install front exhaust pipe with catalytic converter ⇒ Engine;
Rep. gr. 26 ; Exhaust gas cleaning; Removing and installing
catalytic converter .
– Install heat shield for right drive shaft ⇒ Chassis, axles, steer‐
ing; Rep. gr. 40 ; Drive shaft; removing and installing heat
shield for drive shaft .
– Complete the front axle ⇒ Chassis, axles, steering; Rep. gr.
40 ; Assembly carrier ,
Manual gearbox 0DQ
– Pour in gear oil
Manual gearbox 02U
– Check gear oil level and top up gear oil if necessary
⇒ “8.1 Checking gear oil level”, page 143 .
– Install the left front wheel housing liner ⇒ General body re‐
pairs, exterior; Rep. gr. 66 ; Wheel housing liner; Remove and
install front wheel housing liner .
– Install the front wheels ⇒ Chassis, axles, steering; Rep. gr.
44 ; Wheels, tyres; tightening torque for wheel bolts .
– Install starter ⇒ Electrical system; Rep. gr. 27 ; Starter; Re‐
moving and installing starter .
– Install clutch slave cylinder
⇒ “1.10 Removing and installing the slave cylinder”,
page 46 .
– Attach the shift mechanism to the gearbox
⇒ “1.6 Repairing shift mechanism”, page 74 .
– Install the noise insulation ⇒ General body repairs, exterior;
Rep. gr. 66 ; Noise insulation .
– Install air filter ⇒ Rep. gr. 24 ; Air filter; Removing and instal‐
ling air filter housing .
– Install the battery with battery tray ⇒ Electrical system; Rep.
gr. 27 ; Battery; Removing and installing battery tray .

Note

♦ ⇒ “2.3 Tightening torques for gearbox”, page 104
2.3 Tightening torques for gearbox
Pos. Screw Nm
1 M 12 x 60 80
When using the insertion tool - T10509- 65
2 M 12 x 150 80
Starter fastening bolts at the same time
Screw with threaded pin M 8 x 16
3 M 10 x 55 40
4 M 12 x 70 80
Screw is accessible from the engine side
A Dowel sleeves

3 Assembly bracket
⇒ “3.1 Assembly overview - assembly mountings”, page 105
3.1 Assembly overview - assembly mountings
1 - Screw
❑ Gearbox bracket to
gearbox mounting
❑ 2 units
❑ Replace after disas‐
sembly
❑ 40 Nm + 90°
2 - Screw
❑ Gearbox mount to body
❑ ⇒ Rep. gr. 10 ; Power‐
train mounting; Assem‐
bly overview - power‐
train mounting .
3 - Gearbox mount
train mounting .
4 - Gearbox bracket
5 - Screw
❑ Gearbox bracket to
gearbox
❑ Only 2 pieces unlike il‐
lustration
sembly
❑ 40 Nm + 90°
6 - Pendulum support
train mounting .
7 - Screw
❑ Pendulum support to sub-frame
❑ ⇒ Rep. gr. 10 ; Powertrain mounting; Assembly overview - powertrain mounting .
8 - Screw
❑ Hinged support to gearbox
9 - Engine bracket
10 - Screw
❑ Engine mount to body
❑ 4 units
11 - Screw
❑ Engine bracket to engine
3. Assembly bracket 105

12 - Screw
❑ Engine bracket to engine
❑ 2 units

4 Transporting the gearbox

♦ Transmission suspension - 3336A-
♦ Workshop crane , e.g. -V.A.S 6100-
– Screw on the Transmission suspension - 3336A- -1- to the
clutch housing.
– Adjust supporting arm on sliding bracket with locking pin

-arrow-.
Number of visible holes = 6.
– Raise gearbox with workshop crane and gearbox suspension
device - 3336A- .
4. Transporting the gearbox 107

5 Disassembling and assembling the

gearbox
⇒ “5.1 Schematic overview - Gearbox”, page 108
⇒ “5.2 Summary of components - Gearbox”, page 109
⇒ “5.3 Summary of components - input shaft, output shafts, dif‐
ferential gear and shift rods”, page 110
⇒ “5.4 Assembly overview - gearbox housing cover and 5th/
6th gear”, page 112
⇒ “5.5 Summary of components - Gearshift unit”, page 114
⇒ “5.6 Assembly overview - shift forks”, page 115
⇒ “5.7 Removing and installing switching unit”, page 115
⇒ “5.8 Repairing gearshift unit”, page 117
⇒ “5.9 Repairing gearshift forks”, page 118
⇒ “5.10 Disassembling and assembling the gearbox”, page 120
5.1 Schematic overview - Gearbox
1 - 1st gear
2 - 2nd gear
3 - 3rd gear
4 - 4th gear
5 - 5th gear
6 - 6th gear
7 - Cover for gearbox housing
8 - Gearbox housing
9 - Reverse gear
10 - Shift mechanism
❑ (Gearshift forks)
11 - Clutch housing
12 - Drive shaft
13 - Output shaft
14 - Differential
❑ Manual gearbox 02U -
with flange shafts
(shown here)
❑ Manual transmission
0DQ - without flange
shafts

5.2 Summary of components - Gearbox
I-
⇒ “5.4 Assembly overview -
gearbox housing cover and
5th/6th gear”, page 112 .
II -
⇒ “6 Gearbox housing, clutch
housing”, page 134
III -
nents - input shaft, output
shafts, differential gear and
shift rods”, page 110
III -
nents - Gearshift unit”,
page 114
III -
⇒ “5.6 Assembly overview -
shift forks”, page 115
5. Disassembling and assembling the gearbox 109

5.3 Summary of components - input shaft, output shafts, differential gear and
shift rods
1 - Differential
❑ Overview
ponents - Differential”,
page 169
2 - Gearbox housing
❑ repairing
⇒ “6 Gearbox housing,
clutch housing”,
page 134
3 - Oil drain plug
⇒ page 143
4 - Flange shaft with pressure
spring
❑ only for manual gearbox
02U
⇒ “5.10 Disassembling
and assembling the
gearbox”, page 120
❑ complete
⇒ “2 Differential”,
page 169
5 - Conical screw
❑ only for manual gearbox
02U
page 169
6 - Screw
❑ self-locking
❑ after removing, replace
⇒ Electronic Catalogue of Original Parts
❑ to secure the bearing support with grooved ball bearings for the drive and output shaft
⇒ Item 18 (page 111)
❑ 5 Nm + 90°
7 - Hexagon nut with collar
❑ for gearshift mechanism Pos. 17
❑ self-locking
❑ after removing, replace ⇒ Electronic Catalogue of Original Parts
❑ 23 Nm
8 - O-ring
9 - Bearing shaft
10 - Screw
❑ 5 Nm + 90°

11 - Gearshift unit
❑ repairing ⇒ “5.8 Repairing gearshift unit”, page 117
12 - Screw
❑ 5 Nm + 90°
13 - Screw
❑ 6 Nm
14 - Gearbox neutral position transmitter - G701-
❑ on vehicles with start-stop system
❑ shortly after series introduction with captive seal
❑ 20 Nm
16 - Sealing ring
❑ not present on all gearboxes
❑ if present. always replace ⇒ Electronic Catalogue of Original Parts
17 - Shift mechanism
❑ (Gearshift forks)
❑ repairing ⇒ “5.9 Repairing gearshift forks”, page 118
18 - Drive shaft and output shaft with bearing support/grooved ball bearings
❑ Always replace bearing support after each removal
❑ Remove the bearing support and press it on: Dismantle and assemble the drive shaft
❑ Disassembling and assembling the drive shaft
⇒ “1.2 Disassembling and assembling the drive shaft”, page 147
❑ Disassembling and assembling the output shaft
⇒ “2.2 Disassembling and assembling the output shaft”, page 157
19 - Reverse shaft support
20 - Reverse gear
21 - Screw
❑ for securing the axle for reverse gear sliding gear
❑ M6: 5 Nm + 90°
❑ M8: 25 Nm + 45°

5.4 Assembly overview - gearbox housing cover and 5th/6th gear
1 - Gearbox housing
❑ repairing
clutch housing”,
page 134
2 - Gear wheel for 5th gear
⇒ page 129
❑ must be pressed off on
certain gearboxes
⇒ page 149 and press‐
ed on again
⇒ page 129
3 - Bushing
4 - Gear wheel for 6th gear
⇒ page 131
5 - Inner ring for cylindrical-roll‐
er bearing
❑ for output shaft
❑ identify before removing
❑ do not interchange with
inner ring/cylindrical-
roller bearing of input
shaft
6 - Screw
❑ self-locking
moval
❑ M8: 30 Nm + 90°
❑ M10: 75 Nm + 45°
7 - Cover for gearbox housing
❑ with cylindrical-roller bearing for input and output shaft
❑ Design variants ⇒ page 141
8 - Screw
❑ 5 Nm + 90°
9 - Screw
❑ for drive shaft
❑ self-locking
❑ M8: 30 Nm + 90°
❑ M10: 75 Nm + 45°
10 - Inner ring/cylindrical-roller bearing with thrust washer
❑ for drive shaft

11 - 6th gear sliding gear

12 - 6th gear synchronizer ring
13 - Needle bearing for 6th gear
❑ two-piece
❑ is designed as one piece on certain gearboxes
❑ replace together with bushing position 14
14 - Bushing for 6th gear needle bearing
❑ replace together with needle bearing position 13
15 - Sliding sleeve with 5th and 6th gear synchronizer body
❑ Disassembling and assembling ⇒ page 153
16 - Gearshift fork for 5th/6th gear
17 - Carrier bolt
❑ for 5th gear gearshift fork
❑ is damaged by the drive shaft when removing
20 - 5th gear needle bearing

5.5 Summary of components - Gearshift unit
1 - Bushing
❑ for the gearshift shaft
❑ extracting ⇒ page 118
❑ drive in ⇒ page 118
2 - Gearshift shaft with cover
❑ replace jointly
3 - Locking bolt
❑ for adjusting the shift
mechanism
4 - Relay lever
⇒ page 76
❑ Grease with grease
⇒ page 76
❑ Assignment grease ⇒
Electronic Catalogue of
Original Parts .
5 - Retaining clip
6 - Sealing ring
❑ Replace
7 - Cap
❑ for gearbox bleeder
8 - Gearshift lever
❑ Display may vary from
original part
❑ may be replaced with
the gearshift unit mounted
❑ Thoroughly grease during fitting ⇒ page 77
❑ Assignment grease ⇒ Electronic Catalogue of Original Parts .
❑ Fitting position ⇒ page 77
9 - Hexagon nut
❑ self-locking
❑ 23 Nm

5.6 Assembly overview - shift forks
1 - Gearshift fork group with

shift guides
2 - 3rd/4th gear shift segment
❑ It must still be possible
to rotate the shift seg‐
ment freely once fitted
3 - Ball bearing
❑ 4 units
❑ inserting ⇒ page 120
4 - Circlip
moval
5 - 1st/2nd gear shift segment
❑ Identification
⇒ page 119
❑ It must still be possible
to rotate the segments
freely once the clamping
plates have been fitted
❑ Gearshift fork with shift
segments ⇒ page 119
6 - 5th/6th gear shift fork with
shift segments
❑ Shift segments are con‐
nected inseparably with
the gearshift fork
7 - Bearing shaft
❑ for 5th/6th gear shift fork
5.7 Removing and installing switching unit

Removing
– Remove the battery with battery tray ⇒ Electrical system; Rep.
• The gearshift is in the neutral position.
• The locking lever on the switching unit is not locked

– Remove the circlip -arrow 1- of the lock for shift cable and re‐
move from the pin of the gear shift lever.
– Remove relay lever -A- together with cable lock ⇒ page 75 .
– Remove nut -arrow 2- and remove the switching unit -B- from
– Disconnect the electrical connector for Encoders for gearbox

neutral position - G701- -2-.
Disconnect Switch for reversing lights - F4- -1-
– Remove switching unit screws -arrows-.

The switching unit is glued on with used “sealant”, so it must be
removed with a sudden movement.
– Remove switching unit.
– Clean the sealing surfaces and cover the opening in the gear‐
box.
Installing
Installation is carried out in reverse order of removal. When in‐
stalling, note the following:
• The gearshift shaft is in the neutral position -arrow-

• Gearbox in the neutral position.
• All sealing surfaces are cleaned.
– Even apply sealant on the sealing surface of the switching unit.

– Insert the switching unit in the gearbox and screw on the

screws -arrows-.
– Installing shift mechanism
– Install the battery with battery tray ⇒ Electrical system; Rep.
Note

♦ Switching unit on gearbox

⇒ “5.3 Summary of components - input shaft, output shafts,
differential gear and shift rods”, page 110 .
♦ Gearbox neutral position encoder - G701-
⇒ “5.3 Summary of components - input shaft, output shafts,
differential gear and shift rods”, page 110
5.8 Repairing gearshift unit

♦ Centring mandrel - MP3-463 (12-551)-
♦ Mandrel - MP3-448 (VW 408A)-
♦ Thrust piece - T10203-
♦ Sealant - AMV 188 200 03-
– Removing shift mechanism
Remove locking angle -A- from gearshift cover
– Remove the outer part of the locking angle.
– Carefully lever out locking angle with a screwdriver.

Drive locking angle into the gearshift unit and its fitting position
The marking -1- must face the marking -2- on the gearshift unit.
– Drive locking angle with the thrust piece - T10203- into the
gearshift unit.
– Installing shift mechanism
Drive out the bushing -A- for the gearshift shaft

– Remove the bushing -A- for the shiftgear shaft with centering
pin - MP3-463 (12-551)- .
Insert the bushing -A- for the shift gear shaft

– Drive in the bushing -A- for the shiftgear shaft with mandrel -
MP3-448 (VW 408A)- .
5.9 Repairing gearshift forks

♦ Driver - MP1-304 (10-206)-
♦ Pressure plate - MP3-407 (VW 402)-
♦ Thrust piece - MP3-453 (VW 431)-
♦ Distance sleeve - MP3-458/2 (VW 472/2)-
♦ Assembly tool - MP5-402 (3301)-
♦ Release tool - T10236-
♦ Assembly tool - T30100 (3290)-

Note
The gearshift fork group does not have to be disassembled for

the disassembly and assembly of the shift segments, clamping
plates and angular ball bearings.
Difference between shift segments and 5th/6th gear shift fork with
shift segments
Dimension -a-
1- Shift segments 1st/2nd gear = 10.0 mm
2- Shift segment 3rd/4th gear = 78.6 mm
3- 5th/6th gear shift fork with shift segments = 79.5 mm
1st/2nd gear shift fork with shift segments

Dimension -a- = 78 mm
Removing the circlip

A - Release tool - T10236-
B - -Vice protection jaws-
– Secure the shift fork in a vice fitted with protective jaws -B-.
– Lift off the circlip -A- in -direction of the arrow-.
Fitting the circlip

A - Handle wrench, wrench size 10 mm
B - Protective jaws
– Press the circlip with a handle wrench -A- into the slot of the
shift segment.
Note
It must still be possible to rotate the shift segment freely once the
circlip has been fitted.

Removing the angular ball bearing

• Do not bend the shift forks when removing and installing the
angular ball bearings.
The inner ring must lock with the outer ring.
Insert the angular ball bearing up to the stop into the gearshift fork
5.10 Disassembling and assembling the

gearbox
♦ Extractor - T10309A-
♦ Threaded insert - T10309/3-
♦ Threaded insert - T10309/4A-
♦ Adapter - T10309/5-
♦ Pressure spindle - MP3-423 (VW 407)-
♦ Thrust washer - 3074-
♦ Guide bolt - T10079-
♦ Insert base - T10083-
♦ Supporting plate - T10083/1-
♦ Pipe section - MP3-409 (VW 418A)-
♦ Three-arm extractor e. g. -VAS 251 203- or -Kukko 30-1-
♦ Two-arm extractor e. g. -VAS 251 007- or -Kukko 204-2-
♦ Hexagon socket head bolt - M8 x 15-
♦ Sealant - AMV 188 200 03-
♦ Catch pan

• Gearbox removed.
Dismantling
– Secure the gearbox to the gearbox mount
⇒ “7 Attachment at engine and gearbox mount”, page 142 .
– Position the catch pan under the gearbox.
– Drain out gear oil.
– Remove clutch release lever -A- together with release bearing
and guide sleeve
Manual gearbox 02U
– Release fixing screw for flange shaft.

• To remove the flange shaft, screw in 2 bolts and counterhold
them using the tyre iron.
– Pull out the flange shaft together with pressure spring, stop
disc and conical ring.
– Unscrew the cover -arrow- for the gearbox housing carefully

remove.
– Remove the carrier bolt -1- for the 5th/6th gear shift fork in
-direction of arrow-.
– Remove gearshift fork -2-

– Engage the 5th gear -arrow 1- and 1st gear -arrow 2- and
-arrow 3-.
The input and output shafts are blocked after engaging both
gears. Now you will be able to undo the screws for the inner rings
of the bearing on the input and output shaft -B-.
– Unscrew screws -B- for inner rings of the bearing on the input
and output shaft.
• If the shafts are not replaced, clean the threaded holes using
a thread tap to remove locking agent residues.
The 6th gear can be removed with the three-armed puller , e.g.,
B. -VAS 251 203- or -Kukko 30-1- .
The 6th gear can also be removed with the two-armed puller ,
e.g., B. -VAS 251 007- or -Kukko 204-2- towards the sprindle to
the stop.
Then continue to remove it with the three-armed puller , e.g. -
VAS 251 203- or -Kukko 30-1- .
– Remove 6th gear pinion with inner ring/cylindrical-roller bear‐

ing for output shaft.
A - Three-arm extractor e. g. -VAS 251 203- or -Kukko 30-1-
B - Hexagon socket head bolt - M8 x 15-
Pull off sliding gear of 6th gear with the 5th/6th°gear synchroniser
body together with inner ring for 6th gear needle bearing and
5thgear synchroniser ring.
• To remove, use the extraction device - T10309A- .
• Observe the sequence when removing the following compo‐
nents:
• Remove the 6th gear sliding gear with inner ring for cylindrical-
roller bearings for drive shaft.
• Pull off 5th/6th gear synchroniser body with inner ring for 6th
gear needle bearing.
Remove the 6th gear sliding gear with inner ring for cylindrical-
roller bearings for drive shaft
1 - Threaded insert - T10309/3-
2 - Half-shell - T10309/4A-
3 - Adapter - T10309/5-
– First mount the half-shell - T10309/4A- -2-.
• The half-shell - T10309/4A- -2- must be arranged under the
6th gear wheel.
• Force expenditure to remove the 6th gear shift wheel can be
very high, therefore the half-shell - T10309/4A- must be used.
• If necessary, press the shell - T10309/4A- into the required
position.
– Attach adapter - T10309/5- -3- as shown.
– Insert threaded insert - T10309/3- into the half-shell -
T10309/4A- -2- and pre-tension slightly -1-.

– Install the second part of the shell - T10309/4A- -2- and mount
the pipe section - T10309/2- -3- onto the complete device.
– Switching gear for 6th gear
Pull off 5th/6th gear synchroniser body with inner ring for 6th gear
needle bearing.
1 - Threaded insert - T10309/3-
2 - Half-shell - T10309/4A-
3 - Adapter - T10309/5-
– First mount the half-shell - T10309/4A- -2-.
• The shell - T10309/4A- -2- must be arranged underneath the
synchroniser ring.
• If necessary, press the shell - T10309/4A- into the required
position.
– Attach adapter - T10309/5- -3- as shown.
– Insert threaded insert - T10309/3- into the half-shell -
T10309/4A- -2- and pre-tension slightly -1-.
– Install the second part of the shell - T10309/4A- -2- and mount
the pipe section - T10309/2- -3- onto the complete device.
– Pull off 5th/6th gear synchroniser body with inner ring for 6th
gear needle bearing.
Note
The synchronizer ring for the 5th gear must always be replaced
after it is detached.
– Remove 5th gear wheel.

Manual gearbox 02U

– Undo fixing screw for flange shaft -1-.

• To remove the flange shaft, screw in 2 bolts and counterhold
them using the tyre iron.
– Remove flange shaft -1- together with pressure spring.
– Remove sleeve -2- and needle bearing -4-.
– Unscrew the fixing screws -6- from the bearing support for the
input and output shaft.
The 5th gear pinion can be removed by hand:
– Remove the 5th gear pinion -3-.
The 5th gear pinion cannot be removed by hand:
The 5th gear pinion -3- is later removed when removing the bear‐
ing support for the grooved ball bearings ⇒ page 125 .
– Then turn the gearbox in the assembly stand with the clutch
housing upwards.
– Release fixing screws, that serve to secure the gearbox hous‐
ing from the clutch housing.
– Carefully release the clutch housing from the projecting hous‐
ing lands and make sure the sealing surfaces are not damaged
in the process.
• Clutch housing must not tilt, so that the roller bearing and
bearing assembly on the drive shaft and output shaft are not
damaged.
– Remove the differential gear -A- from the gearbox housing.


– Remove transmission neutral sender - G701- -arrow-.

– Put the gearshift shaft into Neutral.
– Subsequently unscrew screws -arrows- and remove the gear‐

shift unit -A- from the gearbox housing.
– Remove the bearing pins -B- at the top of the gearbox.
– Unscrew the reversing lights switch - F4- -C-.
– Unscrew the screw -A- for securing the shaft for reverse gear.
– Remove the bearing pins -B- at the bottom of the gearbox.
Note
Do not remove the cover -arrow- to disassemble the gearbox.
The 5th gear pinion can be removed by hand
– Press off the input and output shaft together with the bearing
support, gearshift mechanism (shift forks) and reverse gear.
A - Thrust piece - T10080-
B - Pressure spindle - MP3-423 (VW 407)-
C - Pressure plate - MP3-406 (VW 401)-
D - Pressure plate - MP3-407 (VW 402)-
E - Thrust washer - 3074-
• Position the gearbox housing in such a way that the dowel
sleeves in the gearbox housing are not damaged.
• During the pressing off procedure, also request the assistance
of second mechanic to prevent components from falling.
The 5th gear pinion cannot be removed by hand

– Press off the drive shaft and output shaft together with the 5th
°gear pinion -1-, bearing support, shift mechanism (shift forks)
and reverse gear.
A - Thrust piece - T10080-
E - Thrust plate - T10375-
• Position the gearbox housing in such a way that the dowel
sleeves in the gearbox housing are not damaged.
• During the pressing off procedure, also request the assistance
of second mechanic to prevent components from falling.
– Remove drive shaft and output shaft with grooved ball bearing
and, if necessary, with the 5th gear wheel from the bearing
mount.
Assembling gearbox
Note
♦ Pressing the bearing support for grooved ball bearings onto

the drive and output shafts ⇒ page 153 .
♦ Pressing the sleeve of the 5th gear sliding gear needle bearing
onto the drive shaft ⇒ page 153 .
The 5th gear pinion was not removed
– Use the assembled components drive shaft -2-, output shaft

-1- with bearing support and grooved ball bearings in the thrust
piece - T10080- .
– Insert the shift forks -4- in the sliding sleeves of the shafts.
– Insert the shaft for reverse gear -3- with the reverse gear.
– Screw guide bolts - T10079- to the threaded bolts of the re‐
verse gear fitting -arrow-.
The 5th gear pinion was removed

– Place the assembled components drive shaft -2-, output shaft

-1- with bearing support and grooved ball bearings in the thrust
piece - T10080- .
– Insert the shift forks -4- in the sliding sleeves of the shafts.
– Insert the shaft for reverse gear -3- with the reverse gear.
– Screw guide bolts - T10079- to the threaded bolts of the re‐
verse gear fitting -arrow-.
– Insert the components together into the gearbox housing, by

passing the guide bolt - T10079- through the fixing holes of the
gearshift mechanism in the gearbox housing.
– Unscrew guide bolt - T10079- .
• Before pressing on, do not forget the following:
• To click in the shift forks into the sliding sleeves correctly
• Check the measure -a- at the toothing of the output shaft
Check dimension -a-

The drive shafts of the individual gearboxes have different lengths
due to the different heights of the serration, dimension -a-.
In order to press in the drive shaft and the output shaft at the same
time, a 3 mm thick washer - T10083/1- must be positioned onto
the drive shaft, if necessary.
Therefore, the dimension -a- of the output shaft serration must be
measured.
Dimension -a- = 30.6 mm

– Place washer - T10083/1- -B- onto the input shaft

A - Pressure plate - MP3-407 (VW 402)-
B - Thrust plate - T10083/1-
C - Support - T10083-
D - Pressure spindle - MP3-408 (VW 412)-
E - Pressure plate - MP3-406 (VW 401)-
– Carefully press on the bearing support with the drive and out‐
put shaft up to the arrester.
A - Pressure spindle - MP3-408 (VW 412)-
B - Support - T10083-
– Tighten screw -A- for reverse wheel shaft.

– Install the bearing pins -B- at the bottom of the gearbox.
– Screw on the reversing lights switch - F4- -C-.

– Install the bearing pins -B- at the top of the gearbox.
– Put the gearshift forks into Neutral.
– Apply sealant - AMV 188 200 03- uniformly on the sealing sur‐
faces of the cover.
– Fit slave cylinder -A- and tighten screws -arrows-.

– Install transmission neutral sender - G701- -arrow-.

– Use new screws -A- to screw the bearing support to the drive
shaft and output shaft.
• Tighten the screws in small stages starting from the middle
and crosswise.
– Screw in hexagon collar nut -B- for the gearshift mechanism
(shift forks).
– Fit the gearbox housing together with input and output shaft
onto the insert base - T10083- .
Fitting position of the 5th gear pinion

• The high collar -arrow- points to the gearbox housing cover.
– Fit on the 5th gear pinion -position 1- and bushing
-position 2-.
Press on 5th gear pinion, if it has been pressed off

B - Pipe section - MP3-409 (VW 418A)-
C - Thrust plate - T10375-
D - Support - T10083-
– Press on the 5th gear pinion ⇒ page 129 , -pos. 1-.
– Place sleeve on 5th gear ⇒ page 129 . -Pos. 2-.
– Mount the 5th gear sliding gear with 5th gear synchronizer ring
and needle bearing ⇒ page 130 , -Pos. 1-.

Fitting position of the 5th/6th gear synchronizer body/sliding

sleeve
The high collar -arrow- points to the 5th °gear and to the gearbox
housing.
Press on the sliding sleeve and 5th/6th gear synchronizer body,

if the 5th gear sliding gear -position 1- with needle bearing and
synchronizer ring has been mounted.
A - Pipe section - MP3-409 (VW 418A)-
CAUTION
Wear protective gloves!
– Heat the inner ring for the 6th gear needle bearing to max. 100
°C and press on.
– Mount 6th gear synchroniser ring.
– Mount the 6th gear sliding gear with needle bearing.
CAUTION
– Heat up inner ring for cylindrical-roller bearing -A- (to a max.

of 100 °C) and press on.
A - Inner ring for the cylindrical-roller bearing
C - Pipe section - MP3-409 (VW 418A)-
E - Support - T10083-

Fitting position of the 6th gear pinion

• The high collar points to the bushing.
– Shift the sliding sleeve -1- for 5th/6th gear into idle position so
that the 6th gear sliding gear can turn when pressing on the
6th gear pinion.
CAUTION
– Heat the 6th gear pinion to max. 100 °C.

– Press on 6th°gear sliding gear, while doing so ensure that the
serration of the pinion -2- for the 6th gear and the 6th gear
sliding gear -3- are in mesh.
– Heat the inner ring for the cylindrical-roller bearing -1- to max.
100 °C and press onto the output shaft.
– Insert the magnet into the gearbox housing
⇒ “6.2 Summary of components - Gearbox housing and clutch
housing”, page 136 - position 3.
– Insert differential gear -A-.

face.
– Screw down the clutch housing onto the gearbox housing.
– Turn the gearbox in the assembly stand with the clutch hous‐
ing upwards.

• Before tightening the screws, engage the 5th gear -arrow 1-

and 1st gear -arrow 2- and -arrow 3-.
• The input and output shafts are blocked after engaging both
gears.
– Tighten the mounting screws -B-.
– Push in the 5th/6th gear shift fork -2- and push the bearing bolt
-1- up to the stop in the -direction of arrow-.
face.
– Tighten cover for gearbox housing.
Manual gearbox 02U

– Install both flange shafts together with pressure springs, stop

discs and conical rings.
– Install the clutch release lever together with the release bear‐
ing and guide bushing
– Pour in gear oil ⇒ “8 Gear oil”, page 143 .
Note

♦ ⇒ “5.3 Summary of components - input shaft, output shafts,

differential gear and shift rods”, page 110
♦ Gearbox housing to clutch housing
⇒ “6.1 Summary of components - Clutch housing”,
page 134
♦ Cover for gearbox housing
⇒ “5.4 Assembly overview - gearbox housing cover and 5th/
6th gear”, page 112
♦ Flange shaft on gearbox (manual gearbox 02U)
⇒ “2.1.1 Summary of components - Differential, manual gear‐
box 02U”, page 169

6 Gearbox housing, clutch housing

⇒ “6.1 Summary of components - Clutch housing”, page 134
⇒ “6.2 Summary of components - Gearbox housing and clutch
⇒ “6.3 Repairing gearbox housing”, page 140
⇒ “6.4 Repairing clutch housing”, page 140
⇒ “6.5 Repairing gearbox housing cover”, page 141
6.1 Summary of components - Clutch hous‐

ing
⇒ “6.1.1 Summary of components - Clutch housing, manual gear‐
box 02U”, page 134
⇒ “6.1.2 Summary of components - Clutch housing, manual gear‐
box 0DQ”, page 135
6.1.1 Summary of components - Clutch housing, manual gearbox 02U
1 - Conical screw
❑ 25 Nm
2 - Flange shaft with pressure
spring
❑ Overview
page 169
3 - Screw
sembly
❑ 5 Nm + 90°
4 - Clutch housing
❑ repairing
⇒ “6.4 Repairing clutch
5 - Gearbox housing
❑ with guide bushing and
clutch release bearing
❑ Overview
⇒ “1.4 Assembly over‐
view - clutch release
⇒ “1.16 Repairing the
clutch release mecha‐
nism”, page 55
7 - Screw
sembly
❑ 5 Nm + 90°

6.1.2 Summary of components - Clutch housing, manual gearbox 0DQ
1 - Screw
sembly
❑ 5 Nm + 90°
2 - Clutch housing
3 - Gearbox housing
❑ with guide bushing and
clutch release bearing
❑ Overview
⇒ “1.16 Repairing the
clutch release mecha‐
nism”, page 55
5 - Screw
sembly
❑ 5 Nm + 90°
6. Gearbox housing, clutch housing 135

6.2 Summary of components - Gearbox

housing and clutch housing
⇒ “6.2.1 Summary of components - gearbox housing and clutch
housing, manual gearbox 02U”, page 136
⇒ “6.2.2 Summary of components - gearbox housing and clutch
housing, manual gearbox 0DQ”, page 138
6.2.1 Summary of components - gearbox housing and clutch housing, manual

gearbox 02U
1 - Bushing
❑ for gearshift shaft
2 - Fitting sleeve
3 - Magnet
❑ is held in position by the
separator surface of the
housing
4 - Screw cap
❑ Before screwing down
apply sealing agent -
AMV 188 200 03-
5 - Circlip
❑ insert in the cylinder roll‐
er bearing groove
6 - Circlip
❑ insert in the cylinder roll‐
er bearing groove
7 - Cylindrical-roller bearing
❑ for drive shaft
❑ removing ⇒ page 148
8 - Cylindrical-roller bearing
9 - Clutch housing
❑ when replacing, set the
differential
⇒ “2.3 Adjusting the differential”, page 176
10 - Sealing ring
❑ for drive shaft
❑ Replace ⇒ “1.3 Replacing input shaft sealing ring”, page 154
11 - Ball stud
❑ Overview ⇒ “1.4 Assembly overview - clutch release mechanism”, page 25
12 - Seal ring for right flange shaft
❑ replace with installed gearbox ⇒ “1.3 Replacing right sealing ring”, page 166

13 - Bushing
❑ for gasket ring
❑ extracting and inserting ⇒ “6.4 Repairing clutch housing”, page 140
14 - Oil filler plug
❑ Tightening torque ⇒ page 143
15 - Adjusting washer
❑ for differential
❑ Determine thickness ⇒ “2.3 Adjusting the differential”, page 176
16 - Outer ring/tapered-roller bearing
❑ press out of the clutch housing and press into the coupling housing
⇒ “2.1 Summary of components - Differential”, page 169
❑ when replacing, set the differential ⇒ “2.3 Adjusting the differential”, page 176
17 - Screw
❑ 5 Nm + 90°
❑ press out of the clutch housing and press into the coupling housing
19 - Fitting sleeve
20 - Gearbox housing
21 - Oil drain plug
❑ Tightening torque ⇒ page 143
22 - Seal ring for left flange shaft
❑ replace with installed gearbox ⇒ “1.2 Replacing left sealing ring”, page 162

6.2.2 Summary of components - gearbox housing and clutch housing, manual

gearbox 0DQ
1 - Clutch housing
❑ Overview
ponents - Clutch hous‐
ing”, page 134
❑ when replacing, adjust
the differential gear
⇒ “2.3 Adjusting the dif‐
ferential”, page 176
❑ repairing
⇒ “6.4 Repairing clutch
2 - Input shaft seal
sembly
❑ Replace
⇒ “1.3 Replacing input
shaft sealing ring”, page
154
3 - Ball stud
❑ Overview
4 - Sealing ring
❑ for right drive shaft
❑ Replace
⇒ “1.3 Replacing right
sealing ring”, page 166
5 - Oil filler plug
❑ different versions and
tightening torque
⇒ page 143
6 - Sealing ring
7 - Plug
8 - Screw
❑ 5 Nm + 90°
9 - Shielding disc
❑ In the clutch housing

❑ if the bearing is replaced, set the differential gear ⇒ “2.3 Adjusting the differential”, page 176
12 - Screw
❑ 5 Nm + 90°
❑ in gearbox housing
❑ if the bearing is replaced, set the differential gear ⇒ “2.3 Adjusting the differential”, page 176
14 - Fitting sleeve
❑ when replacing, adjust the differential gear ⇒ “2.3 Adjusting the differential”, page 176
❑ repairing ⇒ “6.5 Repairing gearbox housing cover”, page 141
16 - Oil drain plug
❑ different versions and tightening torque ⇒ page 143
17 - Sealing ring
❑ for left flange shaft
❑ Replace ⇒ “1.2 Replacing left sealing ring”, page 162
18 - Bushing
19 - Magnet
❑ is held in position by the separator surface of the housing
20 - Cover
❑ Before screwing down apply sealing agent - AMV 188 200 03-
21 - Circlip
❑ inserted in the cylinder roller bearing groove
22 - Roller bearing
❑ Remove from the clutch housing ⇒ page 157
23 - Circlip
❑ inserted in the cylinder roller bearing groove
24 - Roller bearing
❑ for drive shaft
❑ Remove from the clutch housing ⇒ page 148

6.3 Repairing gearbox housing

♦ Pressure spindle - MP3-448 (VW 408A)-
♦ Centering mandrel - MP3-463 (12-551)-
Drive out the bushing -A- for the gearshift shaft
Insert the bushing -A- for the shift gear shaft
6.4 Repairing clutch housing

♦ Thrust piece - MP3-484 (30-555)-
♦ Extractor e. g. -VAS 251 417- or -Kukko 18-1-
♦ Separating tool e. g. -VAS 251 409- or -Kukko 17-1-
♦ Assembly tool - MP3-434 (3066)-
♦ Thrust piece - MP3-420 (3124)-
Remove bushing for gasket ring
A - Extractor e. g. -VAS 251 417- or -Kukko 18-1-
B - Separating tool e. g. -VAS 251 409- or -Kukko 17-1-
C - Distance sleeve - MP3-458/2 (VW 472/2)-
D - Thrust piece - MP3-484 (30-555)-
– Position the distance sleeve - MP3-458/2 (VW 472/2)- and
thrust piece - MP3-484 (30-555)- on the clutch housing.

Insert bushing for gasket ring

A - Spindle of assembly device - MP3-434 (3066)- is screwed into
the threaded part of the differential gear
B - M12 nut with washer
C - Thrust piece - MP3-420 (3124)-
– By turning nut -B- insert the bushing of the gasket ring over
the thrust piece - MP3-420 (3124)- up to the stop.
Note
If the gearbox is disassembled, press in the bushing of the gasket

ring with the thrust piece - MP3-420 (3124)- up to the stop.
6.5 Repairing gearbox housing cover

There are two variants of the cover for gearboxes.
In the case of gearbox repair, the two variants of the cover can
be used for gearboxes.
It is possible to change the lid variant -2- on the gearbox, to which
the variant -1- is originally attached.
Versions of cover for gearbox housing
1 - Original version with bearing support using a carrier plate -A-
and six countersunk head screws M 4 x 14 -arrows-.
2 - New version of the cover for gearbox housing with bearing
protection using 2 countersunk head screws M 4 x 12 -arrows-.

7 Attachment at engine and gearbox

mount
♦ Engine and gearbox support - VAS 6095- or -VW 313-
♦ Retaining plate - T30012A (3221A nebo 3221B)-
Alter the Retaining plate - T30012 (3221)- in -T30012A (3221A)- .
• Drill a new hole -Arrow- in the gearbox holder -1- to attach the
gearbox.
– Drill a hole ∅ 11.0 mm in the gearbox mount -arrow- according
to the figure below.
Dimensions in mm.
Attachment at engine and gearbox mount

A - Engine and gearbox support - VAS 6095- or -VW 313-
B - Retaining plate - T30012A (3221A nebo 3221B)-
– Place drip tray under the gearbox attached to the engine and
gearbox holder.

8 Gear oil
⇒ “8.1 Checking gear oil level”, page 143
⇒ “8.2 Draining and filling gearbox oil”, page 143
8.1 Checking gear oil level

♦ Socket wrench insert - T30023 (3357)-
Gearbox oil specification ⇒ Electronic Catalogue of Original
Parts .
• Vehicle on level ground.
– Remove the noise insulation ⇒ General body repairs, exterior;
Rep. gr. 66 ; Noise insulation; Summary of components -
noise insulation .
• The control screw must be removed for gear oil control
-arrow-.
• The oil is at the correct level if the gear is filled up to the lower
edge of the oil filler hole.
• If the oil level does not reach the lower edge of the oil filling
hole, then top up the gear oil
Different version and tightening torque of oil filler plug and oil drain
plug
I - Oil filler plug or oil drain plug with internal serration- 25 Nm
II - Oil filler plug or oil drain plug with internal serration- 30 Nm
8.2 Draining and filling gearbox oil

♦ Socket wrench insert - T30023 (3357)-
Draining out gear oil
Use a suitable container with a volume of 3.0 l to collect the leak‐
ing gear oil.
8. Gear oil 143

– Remove the oil drain plug -arrow- and let the gear oil drain off.
– Screw in drain screw again and tighten to the right tightening
torque.
Pour in gear oil
– Unscrew oil filler cap for gear oil -arrow-.

– Fill the gear oil through the filling opening.
• The oil is at the correct level if the gear is filled up to the lower
edge of the oil filler hole.
• If oil should get on gearbox or other components, remove it
immediately.
♦ Oil drain and filler plug ⇒ page 143

35 – Gears, shafts
1 Drive shaft
⇒ “1.1 Drive shaft - Summary of components”, page 145
⇒ “1.2 Disassembling and assembling the drive shaft”,
page 147
⇒ “1.3 Replacing input shaft sealing ring”, page 154
1.1 Drive shaft - Summary of components
1 - Screw
view - gearbox housing
cover and 5th/6th gear”,
page 112
2 - Inner ring/cylindrical-roller
bearing with thrust washer
and assembling the
3 - Sliding gear for 6th gear
❑ check for wear
⇒ page 150
❑ on certain gearboxes
two-piece, assign via
the ⇒ Electronic Cata‐
logue of Original Parts
❑ replace together with
bushing Pos. 6
6 - Bushing for 6th gear needle
bearing
❑ replace together with
needle bearing Pos. 5
and assembling the
7 - Sliding sleeve with 5th/6th
gear synchronizer body
❑ disassembling ⇒ page 153
❑ Assembly of the sliding sleeve/5th/6th gear synchroniser body ⇒ page 153 and ⇒ page 153
❑ is damaged by the drive shaft when removing
❑ check for wear ⇒ page 150
1. Drive shaft 145


10 - 5th gear needle bearing
❑ replace together with needle bearing Pos. 11
❑ replace together with bushing Pos. 10
❑ press off with bearing support/grooved ball bearing ⇒ page 149 , or ⇒ page 148 if necessary
❑ repairing ⇒ “6 Gearbox housing, clutch housing”, page 134
13 - Bearing support with grooved ball bearing
❑ Always replace grooved ball bearing together with the bearing support
❑ the bearing support must be replaced each time after pressing off from the clutch housing ⇒ Electronic
catalogue of original parts
❑ Variants of bearing mount ⇒ “6.5 Repairing gearbox housing cover”, page 141
❑ Gear 5th gear can be removed by hand: press off the 5th gear without the pinion ⇒ page 149
❑ Gear 5th gear cannot be removed by hand: press off the 5th gear with the pinion ⇒ page 148
❑ Bearing mount fastened with screws
⇒ “5.3 Summary of components - input shaft, output shafts, differential gear and shift rods”, page 110 -
position 6
14 - Drive shaft
❑ Clean the threaded hole in the drive shaft e.g. with a thread tap to remove the locking agent residues
15 - Needle bearing for 3rd gear
16 - Sliding gear for 3rd gear
17 - 3rd gear synchronizer ring
18 - Sliding sleeve with 3rd/4th gear synchronizer body
❑ press off with 3rd gear sliding gear ⇒ page 149
❑ Fitting position sliding sleeve/synchronizer body ⇒ page 150
❑ assembling ⇒ page 150
❑ replace together with Pos. 20
❑ press off with 3rd gear sliding gear ⇒ page 149
❑ replace together with Pos. 19
22 - Sliding gear for 4th gear
23 - Thrust washer
24 - Inner ring for cylindrical-roller bearing
❑ remove ⇒ page 149
❑ can only be removed with 4th gear wheel ⇒ page 149
146 Rep. gr.35 - Gears, shafts

25 - Circlip
❑ replace ⇒ Electronic Catalogue of Original Parts
❑ Determine thickness ⇒ page 152
26 - Roller bearing
❑ with circlip
❑ Fitting position: the circlip in the bearing points towards the drive shaft
27 - Clutch housing
28 - Spring
29 - 3rd/4th gear sliding sleeve
30 - 3rd/4th gear synchronizer body
31 - Arrester
❑ (3 pieces)
32 - Spring
33 - Arrester
❑ (3 pieces)
34 - Synchronizer body for 5th/6th gear
35 - 5th/6th gear sliding sleeve
1.2 Disassembling and assembling the

drive shaft
♦ Drive bushing - MP1-316 (30-100)-
♦ Pressure plate - T10084A-
♦ Insertion tool - T30066 (30-23)-
♦ Insert base - T10083-
♦ Supporting plate - T10083/1-
♦ Countersupport , e.g. -VAS 251 621- or -Kukko 22-1-
1. Drive shaft 147

♦ Interior extractor 28 - 40 mm , e.g. -VAS 251 611- or -Kukko

21-5-
♦ Extractor e. g. -VAS 251 417- or -Kukko 18-1-
♦ Separating tool e. g. -VAS 251 409- or -Kukko 17-1-
♦ Circlip pliers - VW 161A-
♦ Induction heater unit , e. g. -VAS 6414-
♦ Feeler gauge
• When installing new pinions or a new drive shaft observe the
instructions ⇒ Electronic Catalogue of Original Parts and the
technical data .
• Insert all bearings, sliding gears and synchronizer rings onto
the drive shaft with gear oil.
• Do not interchange the synchronizer rings, if re-used always
assign to the original sliding gear.
Pull out the cylindrical-roller bearing from the clutch housing
A - Countersupport , e.g. -VAS 251 621- or -Kukko 22-1-
B - Interior extractor 28 - 40 mm , e.g. -VAS 251 611- or -Kukko
21-5-
• When removing compress circlip -arrow- of the cylindrical-roll‐
er bearing with pliers -C-.
Press the cylindrical-roller bearing into the clutch housing

B - Pipe - MP3-414 (VW 516)-
• When inserting compress circlip -arrow- of the cylindrical-roller
bearing with pliers -A-.
• Remove pliers before the cylindrical-roller bearing is in fitting
position.
• The circlip must lock into the clutch housing slot.
If the 5th gear pinion -1- could not be removed by hand:
Press off the bearing support with the grooved ball bearing and
the 5th gear pinion -1-
B - Pressure plate - T10084A-
C - Pressure spindle - MP3-423 (VW 407)-
D - Thrust piece - T10081-
– Sliding sleeve for 1st and 2nd gear to 2nd gear.
– Slide the pressure plate - T10084A- sideways up to stop onto
the drive shaft.
If the 5th gear pinion could be removed by hand:

Detach bearing support with grooved ball bearings

A - Pressure plate - T10084A-
C - Thrust piece - T10081-
– Sliding sleeve for 1st and 2nd gear to 2nd gear.
– Slide the pressure plate - T10084A- sideways up to stop onto
the drive shaft.
Note
Always replace bearing support with bearings ⇒ Electronic Cata‐

Press off inner ring/cylindrical-roller bearing

B - Pressure plate - MP3-406 (VW 401)-
– Removing the circlip.
– Inner ring for cylindrical-roller bearing together with:
♦ Thrust washer,
♦ 4th gear sliding gear with needle bearing,
♦ sliding sleeve/synchronizer body for 3rd/4th gear and
♦ 3rd gear sliding gear must be pressed off.
Disassemble sliding sleeve and synchronizer body for 3rd/4th
gear ⇒ page 150 .
Inner ring for cylindrical-roller bearing can also be detached sep‐

arately, only with 4th gear wheel
A - Extractor e. g. -VAS 251 417- or -Kukko 18-1-
B - Thrust piece - MP3-431 (3002)-
C - Separating tool e. g. -VAS 251 409- or -Kukko 17-1-
D - Protective jaws
– Remove circlip with circlip pliers - VW 161A- .
– Tension the separating device -C- behind the toothing (not
behind the toothed gearing) of the 4th gear.
1. Drive shaft 149

Disassembling and assembling the sliding sleeve and 3rd/4th

1- Spring
2- Sliding sleeve
3- Synchronizer body
4- Arrester
– Slide the sliding sleeve over the synchronizer body.
The deeper recesses -arrow A- of the arresters in the synchron‐
izer body and the recesses -arrow B- in the sliding sleeve must
be positioned above one another.
Assembly of the sliding sleeve and 3rd/4th gear synchronizer

body
• The sliding sleeve is drawn over the synchronizer body.
– Insert the arresters in the deeper recesses -arrows- and mount
the springs with 120° offset.
The angled ends of the springs must grip into the hollow ar‐
resters.
Fitting position of the 3rd/4th gear sliding sleeve/synchronizer

body
The groove on the front side -arrow- points towards the 4th gear.
Check synchronizer ring for wear

– Press the synchronizer ring on the cone of the sliding gear and
measure clearance -a- with a feeler gauge.
Clearance -a- Installation dimension Wear limit
3., 4, 5 and 6th gear 1.1 …1.7 mm 0.5 mm
– Mount the 3rd gear sliding gear with needle bearing and 3rd
gear synchronizer ring.

Press on the synchronizer body with the 3rd/4th gear sliding

sleeve
A - Drive bushing - MP1-316 (30-100)-
B - Pressure plate - MP3-406 (VW 401)-
Fitting position: The high shoulder points to the 3rd gear
Press on the bushing -1- for the 4th °gear needle bearing
B - Cap - T30066 (30-23)-
– Fit on the needle bearing for the 4th gear sliding gear with the
4th gear sliding gear and the thrust washer.
Press on the inner ring -1- for the cylindrical-roller bearing

B - Pipe - MP3-451 (VW 422)-
– Insert determined circlip ⇒ page 152 .
1. Drive shaft 151

Determining the circlip

– Insert circlip -A- with a thickness of 2.0 mm in the slot of the
drive shaft and push upwards -arrow-.
– Measure dimension between inner ring -B- and positioned cir‐
clip -A- using a feeler gauge -C-.
– Remove the circlip used to take the measurement.
– Determine the first circlip required according to the table.
Assign circlips via ⇒ Electronic Catalogue of Original Parts .
Circlips available
Measured value Circlip thickness Axial play (mm)
(mm) (mm)
0.05 … 0.14 2.0 0.05 … 0.15
0.15 … 0.24 2.1 0.05 … 0.15
0.25 … 0.34 2.2 0.05 … 0.15
0.35 … 0.44 2.3 0.05 … 0.15
0.45 … 0.51 2.4 0.05 … 0.10
Pressing the bearing support with grooved ball bearings onto the
drive and output shaft
The drive shafts of the individual gearboxes have different lengths

due to the different heights of the serration, dimension -a-.
– Measure dimension -a-
• In order to press in the bearing support evenly onto the shafts,
it is necessary that the shafts are also positioned evenly on
the insert base - T10083- .
• Use a 3 mm thick washer - T10083/1- into the fastening open‐
ing of the drive shaft, if necessary ⇒ page 152 .
• Therefore, the dimension -a- of the output shaft serration must
be measured.
Dimension -a- = 30.6 mm
Insert washer - T10083/1- ⇒ page 152 .
Insert washer - T10083/1-

B - Thrust plate - T10083/1-
CAUTION

Press on bearing support with grooved ball bearing

B - Thrust piece - T10080-
– Before pressing on the bearing support heat it to max.100 °C.
CAUTION
Press on the bushing -1- for the 5th °gear needle bearing
B - Pipe - MP3-451 (VW 422)-
Disassembling and assembling the sliding sleeve and 5th/6th

1- Spring
2- Arrester
3- Synchroniser body; fitting position: the groove on the front
side -arrow A- and the wide collar -arrow B- point towards
the 5th gear.
4- Sliding sleeve
The deeper recesses -arrow C- of the arresters in the synchron‐
izer body and the recesses -arrow D- in the sliding sleeve must
Assembly of the sliding sleeve/5th/6th°gear synchronizer body

the springs with 120° offset.
• The angled ends of the springs must grip into the hollow ar‐
resters.
1. Drive shaft 153

1.3 Replacing input shaft sealing ring

♦ Extractor - T20143-
♦ Sealing grease - G 052 128 A1-
– Removing the gearbox
lease bearing and the guide bushing
⇒ “1.4 Assembly overview - clutch release mechanism”, page
25 .
– Lever out gasket ring for drive shaft with extractor tool -
T20143- .
• Do not damage the running surface of the gasket ring on drive
shaft.
– Half-fill space between sealing lip and dust lip with sealing
grease - G 052 128 A1- .
– Slightly moisten the outer circumference of the gasket ring with
gearbox oil.
Insert the gasket ring for the drive shaft until flush
guide sleeve
⇒ “1.4 Assembly overview - clutch release mechanism”, page
25 .

2 Output shaft
⇒ “2.1 Output shaft - Summary of components”, page 155
⇒ “2.2 Disassembling and assembling the output shaft”,
page 157
2.1 Output shaft - Summary of components
1 - Clutch housing
❑ repairing
clutch housing”,
page 134
2 - Roller bearing
❑ with circlip
❑ Fitting position: The cir‐
clip in the bearing points
towards the output shaft
3 - Output shaft
❑ if an inner ring is fitted as
a bearing assembly for
the cylindrical-roller
bearing
⇒ Item 2 (page 155) , it
cannot be removed from
the output shaft
❑ Inspect bearing assem‐
bly or inner ring for cy‐
lindrical-roller bearing
for scoring and damage
❑ replace output shaft and
cylindrical-roller bearing
together if there is scor‐
ing or damage on the
bearing pedestal or in‐
ner ring for cylindrical-
roller bearing
4 - 4th gear pinion
❑ Fitting position: Shoul‐
der points to the 3rd
gear ⇒ page 159
5 - Circlip
6 - Circlip
7 - 3rd gear pinion
❑ Fitting position: Shoulder points to the 4th gear ⇒ page 159
8 - Circlip
9 - Sliding gear for 2nd gear
10 - 2nd gear needle bearing
11 - Inner ring for 2nd gear
2. Output shaft 155

12 - Outer ring for 2nd gear

❑ place onto the inner ring Pos. 11
❑ replace if there are any traces of scoring or of friction ⇒ Electronic Catalogue of Original Parts
13 - 2nd gear synchronizer ring
14 - Sliding sleeve with 1st/2nd gear synchronizer body
❑ after removing the circlip pos. 15 press off together with the 2nd gear sliding gear ⇒ page 158
❑ Assembling sliding sleeve/synchronizer body ⇒ page 160 and ⇒ page 160
15 - Circlip
❑ pushing out ⇒ page 158
16 - 1st gear synchronizer ring
❑ insert in such a way that the recesses lock into the arresters of the sliding sleeve Pos. 14
17 - Outer ring for 1st gear
❑ insert into synchronizer ring Pos. 16
❑ replace if there are any traces of scoring or of friction ⇒ Electronic Catalogue of Original Parts
18 - Inner ring for 1st gear
❑ Check pegs for traces of wear
19 - 1st gear needle bearing
20 - Sliding gear for 1st gear
21 - Bearing support with grooved ball bearing
❑ Always replace grooved ball bearing together with the bearing support
❑ the bearing support must be replaced each time after pressing off from the clutch housing ⇒ Electronic
catalogue of original parts
❑ Variants of bearing mount ⇒ “6.5 Repairing gearbox housing cover”, page 141
❑ Gear 5th gear can be removed by hand: press off the 5th gear without the pinion ⇒ page 149
❑ Gear 5th gear cannot be removed by hand: press off the 5th gear with the pinion ⇒ page 148
❑ Bearing mount fastened with screws
⇒ “5.3 Summary of components - input shaft, output shafts, differential gear and shift rods”, page 110 -
position 6
23 - Screw
⇒ “5.4 Assembly overview - gearbox housing cover and 5th/6th gear”, page 112
24 - Inner ring for cylindrical-roller bearing
❑ identify before removing

❑ do not interchange with inner ring/cylindrical-roller bearing of input shaft
❑ Removing and installing ⇒ “5.10 Disassembling and assembling the gearbox”, page 120
25 - 6th gear pinion
26 - Bushing
27 - 5th gear pinion
28 - Spring
29 - Sliding sleeve
30 - Synchronizer body
31 - Arrester
❑ (3 pieces)
2.2 Disassembling and assembling the out‐

put shaft
♦ Drive bushing - MP1-316 (30-100)-
21-5-
♦ Induction heater unit , e. g. -VAS 6414-
• When installing new pinions or a new drive shaft observe the
instructions ⇒ Electronic Catalogue of Original Parts and the
technical data .
• Insert all bearings, sliding gears and synchronizer rings onto
the output shaft with gear oil.
• Do not interchange the synchronizer rings, if re-used always
assign to the original sliding gear.
Pull out the cylindrical-roller bearing from the clutch housing
21-5-
• When removing compress circlip of the cylindrical-roller bear‐
ing -arrow- with pliers -C-.
2. Output shaft 157

Press the cylindrical-roller bearing into the clutch housing

– Support the clutch housing by positioning pipe section -
MP3-450 (VW 415A)- (not visible in figure) directly under the
bearing support.
• When inserting compress circlip -arrow- of the cylindrical-roller
bearing with pliers -A-.
• Remove pliers before the cylindrical-roller bearing is in fitting
position.
• The circlip must lock into the clutch housing slot.
– Remove the bearing support with grooved ball bearings from
the drive shaft and output shaft
⇒ “1.2 Disassembling and assembling the drive shaft”,
page 147 .
Press the circlip -1- out of the slot

• Prevent the circlip from ejecting in an uncontrolled manner -
wear a safety glove -A- while doing so.
Press off sliding sleeve and 1st/2nd gear synchronizer body

– After removing the circlip jointly press off the 2nd gear sliding
gear and the sliding sleeve/synchronizer body.
– Remove circlip -3- take off 3rd gear pinion -B- by hand.
– Remove circlips -2-, -1- and take off 4th gear pinion -A- by
hand.
Assemble output shaft

Fitting position of 3rd/4th gear pinions

– Place the 4th gear pinion -A- on the output shaft.
Fitting position:
The collar -arrow 1- points towards the 3rd gear pinion -B-.
– Insert circlips -1- and -2-.
– Place the 3rd gear pinion -B- on the output shaft.
Fitting position:
The collar -arrow 2- points towards the 4th gear pinion -A-.
– Insert circlip -3-.
Check synchroniser ring for 1st and 2nd gear for wear, outer ring
and inner ring together
– Press the synchronizer ring, outer ring and inner ring on the
cone of the sliding gear and measure clearance -a- at 3 points,
offset 120° with a feeler gauge.
Clearance -a- Installation dimen‐ Wear limit
sion
1st and 2nd gear 1.2 …1.8 mm 0.5 mm
• Always replace inner ring, outer ring and synchroniser ring to‐
gether
Fitting position of the inner ring, outer ring and 2nd gear syn‐
chronizer ring
– Position the inner ring -A- on the 2nd gear sliding gear.
The angled lands -arrow 1- point towards the outer ring -B-.
– Position the outer ring -B-.
Lock the lands -arrows 2- in the recesses -arrows 3- of the
sliding gear.
– Position the synchronizer ring -C-.
The recesses -arrows 4- must be pushed onto the angled
lands -arrows 1- of the inner ring -A-.
2. Output shaft 159

Disassembling and assembling the sliding sleeve and 1st/2nd

1 - Spring
2 - Sliding sleeve
3 - Synchronizer body
4 - Arrester
Fitting position:
After assembly, the groove on the front side -arrow A- and the
higher collar -arrow B- of the synchroniser body point towards the
outer serration of the sliding sleeve -arrow C-.
The deeper recesses -arrow D- of the arresters in the synchron‐
izer body and the recesses -arrow E- in the sliding sleeve must
Assembly of the sliding sleeve and 1st/2nd gear synchronizer

body
the springs with 120° offset. The angled ends of the springs
must grip into the hollow arresters.
Press on the sliding sleeve and 1st/2nd gear synchronizer body

B - Drive bushing - MP1-316 (30-100)-
Fitting position:
The slot for the shift fork in the sliding sleeve points towards the
1st gear, the serration of the reversing gear points towards the
2nd gear.
– Rotate the synchronizer ring in such a way that the slots are
flush with the arresters.

Insert the circlip

– Insert the 1st gear synchronizer ring in the sliding sleeve/syn‐
chronizer body.
Fitting position of the 1st gear outer ring

The pegs -arrows- point towards the reversing gear serration.
Fitting position for 1st gear inner ring -A-

The pegs -arrow 1- lock into the recesses -arrow 2- of the syn‐
chronizer ring -B-.
Fitting position 1st gear sliding gear

The higher collar -A- points towards the 2nd gear -B-. The re‐
cesses in the collar -arrows- are pushed onto the pegs of the outer
ring ⇒ page 161 .
CAUTION
– Pressing the bearing support with grooved ball bearings onto

the drive and output shaft ⇒ page 152 .
– Before pressing on the bearing supports heat it to a max. 100°
C.
2. Output shaft 161

39 – Final drive - differential

1 Sealing rings
⇒ “1.1 Installation overview - sealing rings”, page 162
⇒ “1.2 Replacing left sealing ring”, page 162
⇒ “1.3 Replacing right sealing ring”, page 166
1.1 Installation overview - sealing rings
1 - Sealing ring
❑ for drive shaft
❑ Replace
⇒ “1.3 Replacing input
shaft sealing ring”, page
154
2 - Sealing ring
❑ for right flange shaft
❑ Replace
⇒ “1.3 Replacing right
3 - Sealing ring
❑ Replace
⇒ “1.2 Replacing left
4 - Sealing ring
❑ Replace
1.2 Replacing left sealing ring

⇒ “1.2.1 Replace left seal, manual gearbox 02U”, page 162
⇒ “1.2.2 Replace left seal, manual gearbox 0DQ”, page 164
1.2.1 Replace left seal, manual gearbox 02U

♦ Multi-purpose tool - MP3-419 (VW 771)-
♦ Adapter - MP3-419/37 (VW 771/37)-
162 Rep. gr.39 - Final drive - differential


♦ Catch pan , e.g. -VAS 6208-
Removing
– Remove front left wheel.
– Remove the sound dampening system ⇒ General body re‐
pairs, exterior ; Rep. gr. 66 ; Noise insulation .
– Turn steering to full left lock and raise the vehicle.
– Remove screws -arrow- for left flange shaft.
– Turn the steering to full left lock.
– Unscrew buts -1- for coupling rod -3-.

– Remove coupling rod -3- from the stabiliser -2- and swing out
to one side.
– Remove nuts -arrows- for the left-hand joint of the axle, and
remove the axle link at the bottom of the axle joint.
– Swivel out the wheel-bearing housing.
– Loosen the hinge shaft from the flange shaft and tie it up as
much as possible.
• Avoid damaging the paintwork on the drive shaft during this
operation.
1. Sealing rings 163

– Unscrew the fixing screw for the flange shaft; to do this, insert
two screws in the flange and counterhold the flange shaft using
a tyre iron.
– Remove flange shaft together with pressure spring.
– Pull out the sealing ring for flange shaft with the multi-purpose
tool - MP3-419 (VW 771)- and adapter - MP3-419/37 (VW
771/37)- .
Installing
– Drive in new seal to stop, being careful not to cant seal.

– Fill half the space between the sealing lip and dust lip with
sealing grease - G 052 128 A1- .
– Press flange shaft against the gearbox and secure with a
screw.
– Install drive shaft ⇒ Chassis, axles, steering; Rep. gr. 40 ;
Drive shaft; removing and installing drive shaft .
– Fit coupling rod ⇒ Chassis, axles, steering; Rep. gr. 40 ; As‐
sembly carrier, Summary of components - Assembly carrier .
– Fit bottom axle link to axle joint ⇒ Chassis, axles, steering;
Rep. gr. 40 ; lower steering joint, steering joint; Summary of
components - bottom track control arm, steering joint
– Checking the gear oil level
– Install the engine/gearbox noise insulation ⇒ General body
repairs, exterior ; Rep. gr. 66 ; Noise insulation .
– Install wheel ⇒ Chassis, axles, steering; Rep. gr. 44 ; Wheels,
tyres; wheel change .
Note

♦ Flange shaft to gearbox

1.2.2 Replace left seal, manual gearbox 0DQ



♦ Adapter - MP3-419/37 (VW 771/37)-
The left-hand drive shaft is inserted directly into the gearbox, so
it is necessary to remove it later on.
• The vehicle sits on the wheels.
– Loosen the mounting nut of the joint shaft by max 90 °.
– Remove front left wheel.
– Remove drive left shaft ⇒ Running gear, axles, steering; Rep.
gr. 40 ; Drive shaft; Removing and installing drive shaft .
771/37)- .
Installing

– Fill half the space between the sealing lips and dust lips with
sealing grease -G 052 128 A1- .
– Install drive shaft ⇒ Running gear, axles, steering; Rep. gr.
40 ; Drive shaft; Removing and installing drive shaft .
– Check gear oil level
⇒ “8.1 Checking gear oil level”, page 143 .
noise insulation .
– Fit the front left wheel ⇒ Chassis, axles, steering; Rep. gr.
44 ; Wheels, tyres .

1.3 Replacing right sealing ring

⇒ “1.3.1 Replace right sealing ring, manual gearbox 02U”,
page 166
⇒ “1.3.2 Replace right sealing ring, manual gearbox 0DQ”,
page 167
1.3.1 Replace right sealing ring, manual gear‐

box 02U
♦ Adapter - MP3-419/37 (VW 771/37)-
Removing
– Turn steering to full right lock.
– Undo screws -arrows- and remove heat shield for drive shaft
from the engine (where present).
– Unscrew right drive shaft from the flange shaft ⇒ Chassis,
axles, steering; Rep. gr. 40 ; Drive shaft; removing and in‐
stalling drive shaft .
– Tie up the drive shaft as far as possible. Avoid damaging the
paintwork on the drive shaft during this operation.
– Unscrew the fixing screw for the flange shaft; to do this, insert
two screws in the flange and counterhold the flange shaft using
a tyre iron.
– Remove the flange shaft with pressure spring.

771/37)- .
Installing

– Fill half the space between the sealing lip and dust lip with
sealing grease - G 052 128 A1- .
– Fit flange shaft and press against the gearbox and secure with
a screw
⇒ “2.1 Summary of components - Differential”, page 169 .
– Install right input shaft to the flange shaft ⇒ Chassis, axles,
steering; Rep. gr. 40 ; Drive shaft; removing and installing
drive shaft .
– If present, install heat shield for drive shaft -arrows-.

– Check the gear oil level and top up where necessary
Note

♦ Flange shaft to gearbox

1.3.2 Replace right sealing ring, manual gear‐

box 0DQ
♦ Adapter - MP3-419/37 (VW 771/37)-
The right-hand drive shaft is inserted directly into the gearbox, so
it has to be removed later on.
• The vehicle sits on the wheels.

– Loosen the mounting nut of the left joint shaft by max 90 °.

– Remove right front wheel.
– Remove the right prop shaft ⇒ Chassis, axles, steering; Rep.
gr. 40 ; Prop shaft; removing and installing prop shaft .
771/37)- .
Installing

– Fill half the space between the sealing lips and dust lips with
sealing grease -G 052 128 A1- .
– Install drive shaft ⇒ Running gear, axles, steering; Rep. gr.
40 ; Drive shaft; Removing and installing drive shaft .
– Checking the gear oil level
noise insulation .
– Install the front wheels ⇒ Chassis, axles, steering; Rep. gr.
44 ; Wheels, tyres .

2 Differential
⇒ “2.2 Disassembling and assembling differential gear”,
page 171
⇒ “2.3 Adjusting the differential”, page 176
2.1 Summary of components - Differential

⇒ “2.1.1 Summary of components - Differential, manual gearbox
02U”, page 169
⇒ “2.1.2 Summary of components - Differential, manual gearbox
0DQ”, page 170
2.1.1 Summary of components - Differential, manual gearbox 02U
1 - Conical screw
❑ 25 Nm
2 - Right flange shaft
3 - Pressure spring for the
flange shaft
❑ fitted behind flange
shafts
4 - Thrust washer
❑ Fitting position: Shoul‐
der for compression
spring
5 - Conical ring
❑ Fitting position: Cone for
differential gear housing
6 - Circlip
❑ holds the conical ring.
stop disc and pressure
spring in position when
the flange shaft is re‐
moved
7 - Flange shaft left
8 - Sealing ring
❑ Replace
9 - Outer ring/tapered-roller
bearing
10 - Inner ring/tapered-roller
bearing
11 - Differential
❑ with gear pinion for final drive
2. Differential 169
12 - Inner ring/tapered-roller bearing

❑ pushing out ⇒ page 173
15 - Sealing ring
❑ for right flange shaft
❑ Replace ⇒ “1.3 Replacing right sealing ring”, page 166
16 - Clutch housing
❑ Overview ⇒ “6.1 Summary of components - Clutch housing”, page 134
❑ Overview ⇒ “6.2 Summary of components - Gearbox housing and clutch housing”, page 136
2.1.2 Summary of components - Differential, manual gearbox 0DQ
1 - Sealing ring
❑ for left drive shaft
❑ Replace
2 - Gearbox housing
❑ Overview
ponents - Gearbox
housing and clutch
3 - Shielding disc
sembly
❑ mount, fitting position
⇒ page 172
4 - Outer ring/tapered-roller
bearing
❑ in gearbox housing
❑ pressing off
⇒ page 172
5 - Inner ring/tapered-roller
bearing
❑ on the differential gear
side
6 - Differential housing
❑ with riveted pinion
❑ Assign differential gear
housing and tensioning

sleeve before removal and installation ⇒ page 175

❑ Press out differential bevel gear axis and cut through tensioning sleeve ⇒ page 175
❑ Install differential bevel gears ⇒ page 176
7 - Inner ring/tapered-roller bearing
❑ on the differential cage side
❑ In the clutch housing
❑ pressing off ⇒ page 173
10 - Shielding disc
❑ mount, fitting position ⇒ page 172
11 - Clutch housing
❑ Overview ⇒ “6.1 Summary of components - Clutch housing”, page 134
❑ Overview - Gearbox housing and clutch housing
⇒ “6.2 Summary of components - Gearbox housing and clutch housing”, page 136
12 - Sealing ring
❑ for right drive shaft
❑ Replace ⇒ “1.3 Replacing right sealing ring”, page 166
2.2 Disassembling and assembling differen‐

tial gear
21-7-
♦ Supporting plate - MP3-464 (30-205)-
♦ Pipe section - MP6-419 (3259)-
♦ Pipe section - MP6-408 (30-14)-
♦ Tapered-roller bearing extractor - V.A.G 1582 / V.A.G 1582A-
♦ Tapered-roller bearing extractor - V.A.G 1582/4 / V.A.G
1582/4A-
♦ Tapered-roller bearing extractor - V.A.G 1582/3 / V.A.G
1582/3A-
♦ Pressure spindle - MP3-427 (40-21)-
♦ Press-on sleeve - MP3-412 (VW 455)-
2. Differential 171
♦ Pipe section - T30041 (2040)-

♦ Tube for wheel bearing - T30019 (3345)-
♦ Counterholder - MP1-223 (3067)-
♦ Hot air blower , e.g. -V.A.G 1416-
• Before installing heat the inner ring of the tapered-roller bear‐
ing to 100°C.
• Replace both tapered-roller bearings together.
• When replacing the tapered-roller bearings. the differential
housing. the gearbox housing or the clutch housing. set the
differential gear ⇒ “2.3 Adjusting the differential”, page 176
Remove outer ring/tapered-roller bearing from the gearbox hous‐
ing
21-7-
Manual gearbox 0DQ
Put on shielding disc - 0DQ gearbox

Installation position of the shielding disc:
• The cap -arrow- points towards the housing -A-.
• Shielding disc on gearbox housing side - pos. 3 see
Press in outer ring/tapered-roller bearing in the gearbox housing

B - Thrust plate - MP3-464 (30-205)-
C - Pipe - MP6-419 (3259)-
D - Pipe - MP6-408 (30-14)-
– Support the gearbox housing with a pipe - MP6-419 (3259)-
directly below the bearing support.

Remove inner ring/tapered-roller bearing (on the side of the gear

pinion)
A - Thrust piece - MP3-431 (3002)-
B - Distance sleeve - MP3-458/2 (VW 472/2)-
C - Tapered-roller bearing extractor - V.A.G 1582/3 / V.A.G
1582/3A-
D - Tapered-roller bearing extractor - V.A.G 1582 / V.A.G 1582A-
• Before mounting the tapered roller bearing extractor , place
the spacer - MP3-458/2 (VW 472/2)- -B- and the pressure
piece - MP3-431 (3002)- -A- on the differential housing.
Press on inner ring/tapered-roller bearing (on the side of the gear

pinion)
B - Pressure spindle - MP3-427 (40-21)-
C - Press-on sleeve - MP3-412 (VW 455)-
CAUTION
• Before pressing on e.g. heat the inner ring/tapered-roller bear‐

ing with the hot-air blower - V.A.G 1416- to approx. 100 °C.
• Support the opposite side of the inner ring with an insertion
bushing - MP3-412 (VW 455)- .
• The shoulder of the insertion bushing points to the differential
gear housing.
Press outer ring/tapered-roller bearing -1- out of clutch housing

C - Pipe - T30041 (2040)-
2 - Interior extractor 45 - 58 mm , e.g. -VAS 251 615- or -Kukko
21-7-
• The internal extractor must be clamped behind the outer ring /
tapered roller bearing.
Manual gearbox 0DQ
2. Differential 173

This illustration shows the shielding disc on the gearbox housing
side.
• The cap -arrow- points towards the housing -A-
• Shielding disc on clutch housing side - pos. 10 see
Press outer ring/tapered-roller bearing into the clutch housing

A - Pressure spindle - MP3-448 (VW 408A)-
B - Press-on sleeve - MP3-413 (VW 510)-
C - Pipe for the wheel bearing - T30019 (3345)-
Continued for manual gearbox 02U
• Support the clutch housing with a pipe for wheel bearing -
T30019 (3345)- -C- directly below the bearing support.
Continued for manual gearbox 0DQ
• Clutch housing is placed directly on the pressure plate -
MP3-407 (VW 402)- -D-.
Remove inner ring/tapered-roller bearing (on the side of the dif‐

ferential cage)
A - Thrust piece - MP3-431 (3002)-
B - Distance sleeve - MP3-458/2 (VW 472/2)-
C - Tapered-roller bearing extractor - V.A.G 1582 / V.A.G 1582A-
D - Tapered-roller bearing extractor - V.A.G 1582/4 / V.A.G
1582/4A-
• Before mounting the tapered roller bearing extractor , place
the spacer - MP3-458/2 (VW 472/2)- -B- and the pressure
piece - MP3-431 (3002)- -A- on the differential housing.
Press on inner ring/tapered-roller bearing (on the side of the dif‐

ferential cage)
C - Thrust piece - MP3-411 (VW 454)-
CAUTION
• Before pressing on e.g. heat the inner ring/tapered-roller bear‐

ing with the hot-air blower - V.A.G 1416- to approx. 100 °C.

Assign differential gear housing before installing and removing

the tensioning sleeve
The hole in the differential gear housing was adapted due to the
extension piece of the tensioning sleeve.
Bore Length of tensioning sleeve, Tensioning sleeve

mm
-A- 24.0 (short tensioning sleeve) Removing installing
⇒ Fig. ““Press out dif‐ ⇒ Fig. ““Fit tensioning
ferential bevel gear sleeve in differential
axis and cut through bevel gear axis”“ ,
tensioning sleeve”“ , page 176
page 175
-A- and -B- 36.0 (long tensioning sleeve) Removing installing
⇒ Fig. ““Press out dif‐ ⇒ Fig. ““Fit tensioning
ferential bevel gear sleeve in differential
axis and cut through bevel gear axis”“ ,
tensioning sleeve”“ , page 176
page 175
continuous 36.0 (long tensioning sleeve) Removing installing
⇒ Fig. ““Remove long ⇒ Fig. ““Fit tensioning
tensioning sleeve be‐ sleeve in differential
fore removing the dif‐ bevel gear axis”“ ,
ferential bevel gear page 176
axis”“ , page 175
Press out differential bevel gear axis and cut through tensioning
sleeve
B - Counterholder - MP1-223 (3067)-
C - Pipe - MP3-409 (VW 418A)-
The tensioning sleeve is cut through during pressing out.
– Remove the remaining part of the tensioning sleeve from the
differential gear housing.
Remove long tensioning sleeve before removing the differential

bevel gear axis
– Drive out tensioning sleeve -A- with mandrel -B- ∅ 5 mm from
the bore -arrow- in the differential gear housing.
• If the bore -arrow- is not continuous in the differential gear
housing, the tensioning sleeve must be cut through
⇒ page 175 .
2. Differential 175
Install differential bevel gears

– Install stop disc compound with gearbox oil.
– Insert both large differential bevel gears and secure (e.g. with
flange shaft).
– Insert the small differential bevel gears offset at 180° and slide
in.
– Push in the differential bevel gear shaft -arrow A- up to the first
small differential bevel gear.
– Insert the threaded parts -arrows B- in the large differential
bevel gears.
• Fitting position: paragraph shows the large compensating bev‐
el gears.
– Insert the differential bevel gear shaft up to stop and secure
with new -tensioning sleeve- .
Fit tensioning sleeve in differential bevel gear axis

– Adjust the hole in differential bevel gear shaft at the hole in the
differential gear housing.
– Drive in tensioning sleeve -1- with mandrel onto dimension
-a- = 2.5 mm.
• The tensioning sleeve -1- must not come into contact with the
coupling housing.
2.3 Adjusting the differential

♦ Supporting plate - MP3-464 (30-205)-
♦ Pipe section - MP6-419 (3259)-
♦ Pipe section - MP6-408 (30-14)-
♦ Tube for wheel bearing - T30019 (3345)-
♦ Pipe section - T30041 (2040)-
♦ Universal dial gauge bracket - MP3-447 (VW 387)-
♦ Dial gauge - MP3-405/17- or -VW 385/17-
♦ Dial gauge
21-7-
The differential must be re-set when the following components
are replaced:
♦ Gearbox housing
♦ Clutch housing

♦ Differential housing
♦ Tapered-roller bearings of the differential gear
Manual gearbox 0DQ
The shielding disc is shown here on the gearbox housing side.
• Shielding disc on gearbox housing side - pos. 3 see
– Press the outer ring / taper roller bearing (on the riveted gear
side of the differential gear housing) into the gear housing.
B - Thrust plate - MP3-464 (30-205)-
C - Pipe - MP6-419 (3259)-
D - Pipe - MP6-408 (30-14)-
• Support the gearbox housing with a pipe - MP6-419 (3259)-
directly below the bearing support.
• The inner and outer rings of the tapered-roller bearing are
paired - do not interchange.
– Press the outer ring/tapered-roller bearing (on the differential
cage side) without adjusting washer into the clutch housing.
For the 0DQ manual gearbox, press the outer ring / tapered roller
bearing without the adjusting washer and without the shielding
disc.
A - Pressure spindle - MP3-448 (VW 408A)-
B - Press-on sleeve - MP3-413 (VW 510)-
C - Pipe for the wheel bearing - T30019 (3345)-
Manual gearbox 02U
• Support the clutch housing with a pipe for wheel bearing -
T30019 (3345)- -C- directly below the bearing support.
Manual gearbox 0DQ
• Clutch housing is placed directly on the pressure plate -
MP3-407 (VW 402)- -D-.
– Insert the differential gear housing together with the installed
inner rings/tapered-roller bearings into the gearbox housing.
– Position the clutch housing and tighten 5 screws to the given
tightening torque .
2. Differential 177
– Set the dial gauge with 1 mm preload on “0”.

A - Dial gauge extension 30 mm
– Set the dial gauge to “0” with 1 mm preload.
– Move the differential gear up and down, read and write down
the clearance on the dial gauge (example: 1.50 mm).
• Do not turn the differential while measuring as otherwise the
bearings will settle and the measuring result will be inaccurate.
Determine thickness of the adjusting washer
The prescribed bearing preload is reached by adding to the es‐
tablished measured value (e.g. 1.50 mm) a constant compression
value (0.35 mm).
Example:
measured value 1.50 mm
+ pressure (const. value) 0.35 mm
Thickness of the adjusting washer = 1.85 mm
– Remove the clutch housing and press out the outer ring/ta‐
pered-roller bearing -1-.
C - Pipe - T30041 (2040)-
2 - Interior extractor 45 - 58 mm , e.g. -VAS 251 615- or -Kukko
21-7-
Assign the adjusting washers via the ⇒ Electronic Catalogue of
Original Parts .
The various thicknesses make it possible to achieve the exact
shim thickness required.
If the measured washer thickness is greater than the thickest
washer listed in the spare parts catalogue, 2 washers corre‐
sponding to the measured value may be fitted.
Manual gearbox 0DQ


This illustration shows the shielding disc on the gearbox housing
side.
• Shielding disc on clutch housing side - pos. 10 see
box 0DQ”, page 170 .
– Insert adjusting washer with the required thickness (in this ex‐
ample 1.85 mm) and press the outer ring/tapered-roller bear‐
ing back into the clutch housing.
– Screw down the clutch housing onto the gearbox housing.
Note

♦ Gearbox housing to clutch housing

⇒ “6.1 Summary of components - Clutch housing”, page 134
2. Differential 179

Volkswagen Workshop Manual (6-Speed Manual Gearbox 02U, 0DQ)

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Volkswagen Workshop Manual (6-Speed Manual Gearbox 02U, 0DQ)

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Service

Service Department. Technical Information

1.8 Inspecting the gearshift mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

35 - Gears, shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145

39 - Final drive - differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162

1.1 Safety precautions when working on ve‐

1.2 Safety precautions during road tests in

1.3 General safety instructions

2.1 Gearbox identification

Placement of the code letter and production date of the gearbox

Manual gearbox 02U -arrow 2-

Manual gearbox 0DQ

2 Rep. gr.00 - Technical data

Codes and production date of gearbox

3.1 General points

4 Rep. gr.00 - Technical data

♦ Do not over-tension the circlips.

♦ These are not interchangeable. When reusing synchro-rings,

3.2 Contact corrosion

3.3 Seals and sealing rings

6 Rep. gr.00 - Technical data

3.4 Screws, nuts

4.1 Filling capacity

4.2 Allocation gearbox - engine

4.2.1 Allocation gearbox - engine Rapid NH

6 speed manual gearbox 02U

6 speed manual gearbox 0DQ

4.2.2 Allocation gearbox - engine Rapid India

4.3 Calculation of gear ratios

8 Rep. gr.00 - Technical data Volkswagen Technical Site: https://vwts.ru

5 Overview of Transmission System

5.1 Overview of power transmission - front-wheel drive

10 Rep. gr.00 - Technical data

5. Overview of Transmission System 11

1.1 Fitting location overview - clutch control

12 Rep. gr.30 - Clutch

1. Repairing clutch control 13

1.2 Summary of components - Foot controls

1.2.1 Summary of components - Foot controls, vehicles to 08/2013, Rapid India

14 Rep. gr.30 - Clutch

Removing and installing tension spring

1. Repairing clutch control 15

1.2.2 Summary of components - foot controls, Rapid NH (vehicles as of 08/2013)

16 Rep. gr.30 - Clutch

1. Repairing clutch control 17

1.3 Assembly overview - clutch hydraulics

1.3.1 Summary of components - clutch hydraulics, Rapid NH )left-hand drive ve‐

1 - Brake fluid reservoir

18 Rep. gr.30 - Clutch

Seals/O-rings for tube-hose lines

1. Repairing clutch control 19

1.3.2 Summary of components - clutch hydraulics, Rapud NH )left-hand drive

20 Rep. gr.30 - Clutch

Disconnect the cables for the clutch control and connect

♦ An O-ring can also be installed instead of the gasket ring -2-

Gasket rings/O-rings for hose lines

1. Repairing clutch control 21

1.3.3 Summary of components - clutch hydraulics, Rapid NH (right-hand drive up

1 - Brake fluid reservoir

22 Rep. gr.30 - Clutch

1.3.4 Summary of components - clutch hydraulics, Rapid NH (right-hand drive

1. Repairing clutch control 23

24 Rep. gr.30 - Clutch