K0050366020-5-Speed Manual Gearbox 0AH

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Service Department. Technical Information

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List of Workshop Manual Repair Groups
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00 - Technical data
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30 - Clutch
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34 - Controls, housing
35 - Gears, shafts
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39 - Final drive - differential

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Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.
All rights reserved.

No reproduction without prior agreement from publisher.
Copyright © 2016 Volkswagen AG, Wolfsburg K0050366020

Caddy 2004 ➤ , Caddy 2011 ➤
5-speed manual gearbox 0AH - Edition 06.2016
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Identification . . . . . . . . . . . . n. A. G. ..V.ol.ks. w. a.g.en. A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
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1.1 Gearbox identificationVol.ks.w.a. . . . . . . . . . . . . . . . .oe.s.n.ot. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
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2 Overview - power ris transmission . . . . . . . . . . . . . . . . . . . .nt.ee. . . . . . . . . . . . . . . . . . . . . . . . .
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2.1 Overview - powerau
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transmission . . . . . . . . . . . . . . . . . . . . . .o.r a. . . . . . . . . . . . . . . . . . . . . . . 2
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3 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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3.1 Calculating overall gear ratio “i” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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3.2 Allocation gearbox - engine/capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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4 Repair notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
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4.1 General repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
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30 - Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
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1 Clutch operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.1 Assembly overview - pedal cluster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.2 Assembly overview - clutch hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
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1.3 Assembly overview - clutch release mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
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1.4 Removing and installing over-centre spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

1.5 Removing and installing clutch pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
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1.6 Removing and installing mounting bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

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1.7 Removing and installing clutch master cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
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1.8 Removing and installing clutch position sender G476 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
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1.9 Removing and installing clutch slave cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
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1.10 Bleeding clutch mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

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1.11 Repairing clutch release mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

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2 Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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2.1 Assembly overview - clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
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2.2 Removing and installing clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
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34 - Controls, housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
1 Selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
1.1 Installation position - selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
1.2 Assembly overview - Selector cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
1.3 Assembly overview - gear knob and cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
1.4 Assembly overview - Selector lever and selector housing, ►06.2010 . . . . . . . . . . . . . . . . 41
1.5 Assembly overview - Selector lever and selector housing, 07.2010► . . . . . . . . . . . . . . . . 43
1.6 Dismantling and assembling selector mechanism, 07.2010► . . . . . . . . . . . . . . . . . . . . . . 44
1.7 Removing and installing gear knob . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
1.8 Removing and installing selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
1.9 Adjusting selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
1.10 Removing and installing relay lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
2 Removing and installing gearbox. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
2.1 Specified torques for gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
2.2 Removing gearbox, vehicles ►07.2010 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
2.3 Removing gearbox, from 08.2010► . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
2.4 Installing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
3 Transporting gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
3.1 Transporting gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
4 Gear oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
4.1 Checking gear oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
5 Dismantling and assembling gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
5.1 Schematic overview - gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
5.2 Assembly overview - selector unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Contents i
Caddy 2004 ➤ , Caddy 2011 ➤
5.3 Assembly overview - selector forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

5.4 Assembly overview - gearbox housing/5th gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
5.5 Assembly overview - input shaft, output shafts, differential, selector unit . . . . . . . . . . . . . . 89
5.6 Repairing selector unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
5.7 Repairing selector forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
5.8 Dismantling and assembling gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
6 Gearbox housing, clutch housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
6.1 Assembly overview - gearbox housing/clutch housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
6.2 Assembly overview - clutch housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
6.3 Repairing gearbox housing/clutch housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
35 - Gears, shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

1 Input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
1.1 Assembly overview - input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
1.2 Dismantling and assembling input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
2 Output shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
2.1 Assembly overview - output shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
2.2 Dismantling and assembling output shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
39 - Final drive - differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126

1 Oil seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
1.1 Renewing left oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
1.2 Renewing right oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
2 Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
2.1 Assembly overview - differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
2.2 Dismantling and assembling differential . . . . . . . . . . G. ..V.o.lk.sw. a. g.e.n. . . . . . . . . . . . . . . . . . . . . 132
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2.3 Adjusting differential . . . . . . . . . . . . . . . . . o. lk.s.w.ag. . . . . . . . . . . . . . . d.o.es. n.o. . . . . . . . . . . . . . 137
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ii Contents
Caddy 2004 ➤ , Caddy 2011 ➤
00 – Technical data
1 Identification
(VRL009270; Edition 06.2016)
⇒ “1.1 Gearbox identification”, page 1
1.1 Gearbox identification AG. Volkswagen AG d

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Codes and production date of gearbox
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Identification Day Month Year (2004)
code of manufacture
Additional data provide information about the production facility.
Note
The gearbox code is also included on the vehicle data stickers.
1. Identification 1
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2 Overview - power transmission

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Ratio
Arrows indicate direction of travel.
2 Rep. gr.00 - Technical data

Caddy 2004 ➤ , Caddy 2011 ➤
I - 1st gear
II - 2nd gear
III - 3rd gear
IV - 4th gear
V - 5th gear
R - Reverse gear
A - Final drive
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2. Overview - power transmission 3

Caddy 2004 ➤ , Caddy 2011 ➤
3 Technical data
⇒ “3.1 Calculating overall gear ratio i ”, page 4
⇒ “3.2 Allocation gearbox - engine/capacities”, page 4
3.1 Calculating overall gear ratio “i”

Example:
5th gear Final drive
Drive gear ZG1 = 37 ZA1 = 14
Driven gear ZG2 = 50 ZA2 = 69
i = Z2 : Z1 1)
iG = Gear ratio = ZG2 : ZG1= 37 : 50 = 0.740
iA = Final drive ratio = ZA2 : ZA1 = 69 : 14 = 4.929
itotal = Overall ratio = iG x iA = 0.740 x 4.929 = 3.647
1) Z1 = No. of teeth on driving gear, Z2 = No. of teeth on driven gear
3.2 Allocation gearbox - engine/capacities

Manual gearbox 5-speed 0AH
Identification code FZS FZT FZU
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♦ Specification for gear oil

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Identification code JJS JJT JJV
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Identification code JJW KBQ KHH
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Identification code KHS KLK LBP
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3. Technical data 5
Caddy 2004 ➤ , Caddy 2011 ➤

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Identification code LBR LBS LBT
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Identification code LBU LBV LBW

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Identification code LJL LSQ LSP
Manufac‐ from 06.09 09.10 09.10
tured to
Engine 2.0 l - 80 kW 1.2 l - 63-77 kW 1.2 l - 77 kW

Caddy 2004 ➤ , Caddy 2011 ➤
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Manual gearbox yV
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Identification code oris LJL teeLSQ LSP
th or
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Drive shaft flange diameter
ss
a 100 mm 100 ammc 100 mm
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logue (ETKA) :
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s
Identification code MBQ MBR MBS
s o
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Manufac‐ from 10.09 10.09 10.09
nform
tured to
mer
atio
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The following data can be found in the ⇒ Electronic parts cata‐ Prote AG.
logue (ETKA) :
Identification code MBT MBU MHR
Manufac‐ from 10.09 10.09 04.10
tured to
diesel diesel

logue (ETKA) :
3. Technical data 7
Caddy 2004 ➤ , Caddy 2011 ➤
4 Repair notes
⇒ “4.1 General repair instructions”, page 8
4.1 General repair instructions
4.1.1 Drive
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.
♦ When installing the manual gearbox, ensure that the dowel
sleeves between the engine and gearbox are correctly seated.
♦ When installing mounting brackets or waxed components,
clean the contact surfaces. Contact surfaces must be free of
wax and grease.
♦ Allocate bolts and other components using ⇒ Electronic parts
catalogue (ETKA) . AG. Volkswagen AG d
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♦ When changing a gearbox, fill with gear oil to the lower dedgeby V gu
ara
of the filler hole ⇒ page 83 . orise nte
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♦ Capacities and specifications ⇒ page 4 . ss a c
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un
4.1.2 Gaskets and seals
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♦ Before installing oil seal, half-fill space between sealing lips
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ility
with sealing grease - G 052 128 A1- -arrow-.
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♦ The open side of the oil seals faces toward the side with fluid
hole
filling.
spec
es, in part or in w
t to the co
♦ Lightly oil O-rings before installing; this prevents the rings be‐
ing crushed when inserted.
♦ After installing, check oil level ⇒ page 83 .
rrectness of i
♦ Renew O-rings
l purpos
♦ Apply sealant uniformly but not too thick.
nform
mercia
4.1.3 Sealant
com
tion in
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thi
♦ Thoroughly clean housing joint surfaces before applying seal‐

s
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ing paste.
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♦ Apply sealing paste - AMV 188 200 03- uniformly but not too
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♦ Breather holes must remain free of sealing paste.
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Caddy 2004 ➤ , Caddy 2011 ➤
4.1.4 Locking devices

♦ Renew retaining rings.
♦ Do not overstretch retaining rings.
♦ Retaining rings must locate properly in grooves.
♦ Renew spring pins. Installation position: slot longitudinal to line
of force.
4.1.5 Nuts and bolts

♦ Loosen and tighten bolts and securing 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 in a diag‐
onal sequence.
♦ Torque settings are specified
agen
AG. Volkswfor
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n AG d bolts and nuts.
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♦ Always renew
db
y V self-locking nuts and bolts. ua
ran
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♦ Ensure
uth with threaded connections that contact surfaces
o
or as
well
ss as nuts and bolts are rewaxed only after assembly,
a ac
if nec‐
essary.
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♦ Residual locking agent must be removed from all threaded

itte
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erm
holes into which self-locking bolts are screwed; this is done

ab
ility
with a screw tap. Otherwise there is a danger of bolts shearing

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when subsequently being removed.

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hole
4.1.6 Bearings
spec
es, in part or in w
t to the co
♦ Install new tapered roller bearings as supplied and do not lu‐

bricate additionally.
rrectness of i
♦ Install needle bearings with lettered side (thicker metal) to‐

wards fitting tool.
l purpos
♦ Tapered roller bearings fitted to one shaft must be renewed as

a set. Use same make of bearings.
nform
ercia
♦ Heat inner races to maximum 100°C before installing.

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at
om
io
♦ Do not interchange outer or inner races of bearings of the

n
c
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same size. The bearings are matched in pairs.

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ate
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4.1.7 Shims
p
cum
for
en
ng
♦ Measure shims at several points with a micrometer. The var‐

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ious thicknesses make it possible to achieve the exact shim
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thickness required.
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♦ Check for burrs and damage. cted agen
Prote AG.
♦ Install only flawless shims.
4. Repair notes 9
Caddy 2004 ➤ , Caddy 2011 ➤
4.1.8 Synchro-rings
♦ Do not interchange them. When reusing synchro-rings, always
fit to the same synchromeshed gear.
♦ Check for wear and renew if necessary.
♦ Check grooves -arrow 1- of synchro-ring -A- and inner ring for
flat spots (worn grooves).
♦ If synchro-rings are coated, coating must not be damaged.
♦ If an intermediate ring -B- is installed, check the outer friction
surface -arrow 2- and inner friction surface -arrow 3- of this
intermediate ring for »scoring«, »signs of abnormal wear« and
»blue discolouration (due to overheating)«.
♦ Check the cone of the synchromeshed gear for »scoring« and
»signs of abnormal wear«.
♦ Moisten synchromesh mechanism with gear oil before instal‐
ling.
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4.1.9 Gear wheels
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♦ Before installing, clean and heat on a hot plate to maximum
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100°C.
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♦ The temperature can be checked with thermometer -
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V.A.G 1558- , ignition tester - V.A.G 1767- or diesel tester -
hole
spec
V.A.G 1743- .
es, in part or in w
t to the co
4.1.10 Synchromeshed gears
♦ After assembly, check synchromeshed gears for slight play, or
rrectness of i
for freedom of movement.
l purpos
4.1.11 Clutch
♦ Ensure that the pressure plate does not cant: loosen and tight‐
nform
ercia
en bolts diagonally and in several gradual stages.

m
at
om
♦ If the clutch has burnt out, thoroughly clean the clutch housing ion
c
as well as the friction surface of flywheel with a cloth to reduce

in t
or
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the smell of burnt linings.

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Prote AG.

Caddy 2004 ➤ , Caddy 2011 ➤
30 – Clutch
1 Clutch operation
⇒ “1.1 Assembly overview - pedal cluster”, page 11
⇒ “1.2 Assembly overview - clutch hydraulics”, page 13
⇒ “1.3 Assembly overview - clutch release mechanism”,
page 15
⇒ “1.4 Removing and installing over-centre spring”, page 16
⇒ “1.5 Removing and installing clutch pedal”, page 18
⇒ “1.6 Removing and installing mounting bracket”, page 20
⇒ “1.7 Removing and installing clutch master cylinder”,
page 25
⇒ “1.8 Removing and installing clutch position sender G476 ”,
page 27
⇒ “1.9 Removing and installing clutch slave cylinder”, page 27
⇒ “1.10 Bleeding clutch mechanism”, page 29
⇒ “1.11 Repairing clutch release mechanism”, page 30
1.1 Assembly overview - pedal cluster
Note
Lubricate all bearing and contact surfaces with grease - G 000

450 02- .
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es, in part or in w
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nf
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orm
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or c
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1. Clutch operation 11
Caddy 2004 ➤ , Caddy 2011 ➤
1 - Plenum chamber bulkhead

❑ With support for mount‐
ing bracket
2 - Seal
❑ Renew after removal
❑ Self-adhesive
❑ Bond to mounting n AG. Volkswagen AG do
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❑ Between mounting d b ua
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bracket and
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3 - Mounting sbracket
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❑ For mounting clutch
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❑ Removing and installing
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⇒ page 20
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4 - Bolt
hole
spec
es, in part or in w
5 - Over-centre spring
t to the co
⇒ page 16
rrectness of i
6 - Sleeve bearing
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7 - Locating pin
8 - Clutch pedal
nform
ercia

m
⇒ page 18
at
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ion
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9 - Support
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❑ Remove to remove
a
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clutch pedal, removing

p
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or
and installing
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⇒ page 18 .
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10 - Seal
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❑ Between master cylinder and mounting bracket
11 - Master cylinder
❑ Removing and installing after removal of mounting bracket ⇒ page 25
12 - Clutch position sender - G476-
❑ Can be checked with ⇒ Vehicle diagnostic tester
❑ In the ⇒ Vehicle diagnostic tester, the clutch position sender - G476- is referred to as clutch pedal switch
- F36- .
❑ Removing and installing ⇒ page 27
13 - Clip
❑ Pull out clip to stop to remove and install pipe/hose line
14 - Supply hose
15 - Nut
❑ 25 Nm
16 - Nut
❑ 25 Nm
12 Rep. gr.30 - Clutch

Caddy 2004 ➤ , Caddy 2011 ➤
17 - Stop
❑ For clutch pedal
AG. Volkswagen AG d
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Assembly overview - clutch hydraulics
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Note
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Lubricate all bearing and contact surfaces with grease - G 000
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1 - Brake fluid reservoir
t to the co
2 - Spring-type clip
rrectne
3 - Supply hose
❑ Rubber
ss
❑ From 12 05, plastic
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⇒ page 14
inform
mer
4 - Master cylinder
atio
m

o
n
c
i
after removal of mount‐
or
n thi
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ing bracket
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sd
va
⇒ page 25
i
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5 - Clip
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❑ Pull clip out to stop to re‐
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6 - Support
❑ To remove and install,
separate master cylin‐
der from clutch pedal
⇒ page 18
7 - Clutch pedal
⇒ page 18
8 - Nut
❑ 25 Nm
9 - Sealing ring
❑ Fit on line connection
❑ Insert with brake fluid
❑ Seals, O-rings depend‐
ing on material of line
connections ⇒ page 14
❑ Allocation ⇒ Electronic parts catalogue (ETKA)
10 - Pipe/hose line
11 - Holder
12 - Sealing ring
❑ Fit on line connection
❑ Insert with brake fluid
❑ Seals, O-rings depending on material of line connections ⇒ page 14
Caddy 2004 ➤ , Caddy 2011 ➤
❑ Allocation ⇒ Electronic parts catalogue
AG. Volkswagen A(ETKA)
agen G do
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13 - Clip by Vol ot g
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ed ran
❑ Pull out clip
ho
risto stop to remove and install pipe/hose line tee
t or
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14 - Slave cylinder
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15 - Dust cap
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16 - Bleeder valve
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❑ Bleeding clutch mechanism ⇒ page 29
h re
hole
spec
17 - Drive
es, in part or in w
t to the co
18 - Bolt
❑ 20 Nm
rrectness of i
19 - Holder
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Seals and O-rings for pipe and hose lines
nf
ercia
orm
Item Material of line connection
m
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om
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1 Line connection with circumferential groove
or c
thi
-arrow 1-
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2 Line connection with shoulder -arrow 2-

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3 Line connection with shoulder -arrow 2- and cir‐

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cumferential groove -arrow 3-
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• For line connection having circumferential groove -arrow 1-
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and -arrow 3-, a seal or O-ring must be set there. Prote
cted AG.
agen
Supply hose -1- of plastic

• The seals -2- must be located in supply hose housing.

Caddy 2004 ➤ , Caddy 2011 ➤
1.3 Assembly overview - clutch release mechanism
1 - Release bearing
❑ Remove and install to‐
gether with clutch re‐
lease lever
⇒ Item 3 (page 15)
and guide sleeve
⇒ page 30
❑ Do not wash out bear‐
ing; wipe onlyagen AG. Volkswagen AG do
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❑ Renew Vol
by noisy bearings
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2 - Bolt
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❑ss Renew after removal
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❑ 5 Nm +90°
pt
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3 - Clutch release lever
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gether with release
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bearing
hole
spec
⇒ Item 1 (page 15) and
es, in part or in w
guide sleeve
⇒ Item 5 (page 15) t to the co
⇒ page 30
rrectness of i
4 - Retaining spring
❑ Secure to clutch release
l purpos
lever
5 - Guide bush
nf
ercia
or

m
m
atio
gether with release

om
n in
bearing
or c
⇒ Item 1 (page 15) and

thi
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sd
a
clutch release lever

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⇒ page 30
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6 - Sealing ring t. C rig
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❑ For input shaft cop Vo
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❑ Lever out using screwdriver Prote AG.
❑ Installing ⇒ Fig. ⇒ page 107

7 - Ball pin
❑ Lubricate with MoS2 grease.
❑ 20 Nm
8 - Drive
9 - Bolt
❑ 20 Nm
10 - Holder
11 - Slave cylinder
❑ Grease plunger head with MoS2 grease
Caddy 2004 ➤ , Caddy 2011 ➤
1.4 Removing and installing over-centre

spring
Special tools and workshop equipment required
♦ Release tool - T10178-
AG. Volkswagen AG d
agen oes
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♦ Torque wrench - V.A.G 1331- ss c
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Removing nform
ercia
– Push driver seat as far back as possible and move steering

wheel to highest position.
m
a
com
tion in
– Remove driver side compartment and cover ⇒ General body

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te o
thi
repairs, interior; Rep. gr. 68 ; Compartments, covers .

s
iva
do
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– Remove crash bar -A-. First remove bolt -B- and then bolt
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-C-.
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– Remove steering column universal joint from steering rack ⇒
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Running gear, axles, steering; Rep. gr. 48 .
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Prote AG.
Note
♦ The steering column must be released to facilitate the removal

of bolt -5- ⇒ Running gear, axles, steering; Rep. gr. 48 .
♦ Make sure that over-centre spring does not spring out uncon‐
trolled.

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tee Caddy 2004 ➤ , Caddy 2011 ➤
o
auth 5-speed or manual gearbox 0AH - Edition 06.2016
ac
ss
ce
le
– Unbolt clutch pedal -1- from mounting bracket -3- by removing
un
pt
an
nut -2- and pulling out bolt -5-.
d
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ility
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Note
wit
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ole,
spec
The clutch pedal remains hooked to operating rod of master cyl‐
inder.
t to the co
– Swing clutch pedal down slightly and remove over-centre
spring -4- from mounting bracket.
rrectne
Installing
ss
Install in reverse order of removal, observing the following:
o
cial p
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mer
atio
om
n
c
i
or
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te
sd
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– Insert over-centre spring in mounting bracket from above while

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holding end of spring with release tool - T10178- in installation
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position.
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– Insert tip of clutch pedal in bearing recess of over-centre
by lksw
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spring.
AG.
– Depress clutch pedal slightly, push bolt through and tighten

self-locking nut.
– Install steering column universal joint on steering rack ⇒ Run‐
ning gear, axles, steering; Rep. gr. 48 .
– Install crash bar -A-, (bolt -B- and bolt -C-).

– Install cover and storage compartment on driver side ⇒ Gen‐
eral body repairs, interior; Rep. gr. 68 ; Compartments, cov‐
ers .
– Carry out basic setting for steering angle sender - G85- using
⇒ Vehicle diagnostic tester.
Torque settings
♦ ⇒ “1.1 Assembly overview - pedal cluster”, page 11
Component Torque setting
Crash strut Bolt M 8 = 20 Nm
Bolt M 6 = 5 Nm
Caddy 2004 ➤ , Caddy 2011 ➤
1.5 Removing and installing clutch pedal

♦ Pliers - T10005-
♦ Release tool - T10178-
♦ Torque wrench - V.A.G 1331- AG. Volkswagen AG d

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Removing
rrectne

ss o
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mer
atio
om
n
c
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or
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Prote AG.

Caddy 2004 ➤ , Caddy 2011 ➤
– Remove crash bar -A- by removing bolt -B- and loosening bolt
-C-.
– Remove steering column universal joint from steering rack ⇒
Running gear, axles, steering; Rep. gr. 48 .
AG. Volkswagen AG d
agen oes
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– Unbolt clutch pedal -1- from mounting bracket -3- by removing
wit
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nut -2- and pulling out bolt -5-.
h re
hole
spec
– Swing clutch pedal forward slightly and remove over-centre
es, in part or in w
spring -4- from mounting bracket.
t to the co
rrectness of i
l purpos
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tion in
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– Release clutch pedal from master cylinder with pliers -
cted agen
Prote AG.
T10005- .
– Remove clutch pedal.
Installing
Caddy 2004 ➤ , Caddy 2011 ➤
– Attach retainer -2- to master cylinder operating rod -1-.

– Press retainer into notch in clutch pedal until it can be heard
to engage.
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– Insert over-centre spring in mounting bracket from above while

un
pt
an
d
holding end of spring in installation position with release tool -

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T10178- .
rm
ab
pe
ility
– Insert tip of clutch pedal in bearing recess of over-centre
ot
wit
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spring.
h re
hole
spec
– Depress clutch pedal slightly, push bolt through and tighten
es, in part or in w
self-locking nut.
t to the co
– Install steering column universal joint on steering rack ⇒ Run‐
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
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rp
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fo
en
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– Install crash bar -A-, (bolt -B- and bolt -C-).

n
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Cop py
– Install cover and storage compartment on driver side ⇒ Gen‐
t. rig
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eral body repairs, interior; Rep. gr. 68 ; Compartments, cov‐
p by
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ers .
by
cted agen
Prote AG.
– Perform basic setting in guided fault finding - G85- with ⇒ Ve‐
hicle diagnostic tester.
Torque settings
Bolt M 6 = 5 Nm
1.6 Removing and installing mounting bracket

Caddy 2004 ➤ , Caddy 2011 ➤
Special tools and workshop

equipment required
♦ Tensioning strap - T10038-
♦ Hose clamps to 25 mm -
3094-
♦ Torque wrench - V.A.G n AG. Volkswagen AG do
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1331- byV
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♦ Socket set - V.A.G 1835-uth o tee
or
s a ac
♦ Installation tool for spring-
s
ce
e
type clips - VAS 5024 A-

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es, in part or in w
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at
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ion
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ate
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Removing
– With ignition switched off, disconnect battery earth strap ⇒
Electrical system; Rep. gr. 27 ; Disconnecting and connecting
battery .
– Remove complete air filter housing ⇒ Rep. gr. 23 or ⇒ Rep.
gr. 24 .
– Remove battery, battery cover and battery tray ⇒ Electrical
system; Rep. gr. 27 ; Battery; Removing and installing battery .
– Lay a lint-free cloth under master cylinder.
– Clamp off supply hose to brake fluid reservoir using hose
clamps up to 25 mm - 3094- .
– Pull supply hose off master cylinder.
– In addition, for disconnecting, supply hose can be sealed with
sealing tool - T10249/1- .
Caddy 2004 ➤ , Caddy 2011 ➤
– Release securing clip -1- with a screwdriver or pointed object.

– Pull off pipe/hose assembly or plastic line -2- from master cyl‐
inder.
– Unclip clutch position sender - G476- from master cylinder
-arrow- and remove with electrical connector attached -3-.
Note
When performing work in the footwell, put cloths on the carpet to

protect it from possible brake fluid spills.
– Then remove clutch position sender - G476- ⇒ page 27 .

– Push driver seat as far back as possible and move steering
wheel to highest position.
– Carefully cut through cable tie -1-.

– Remove cable guide -2- from steering column, if fitted.
– Remove footwell vent -3-. AG. Volkswagen AG d
agen oes
– Remove crash bar -A-. olksw not
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– Remove bolt -B- and loosen bolt -C-.
hole
spec
– Release relay carrier on left under dash panel ⇒ Electrical
es, in part or in w
t to the co
system; Rep. gr. 97 .
– Separate relay carrier bracket, onboard supply control unit -
J519- and fuse holder.
rrectness of i
l purpos
Note
nf
ercia
To separate relay carrier bracket and onboard supply control unit

rm
m
- J519- , it may be necessary first to separate data bus diagnostic

atio
m
interface - J533- .
o
n in
or c
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rig ht
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Prote AG.

AG. Volkswagen AG d
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d by Caddy 2004 ➤ , Caddy 2011
gu
ara ➤
ise nte
5-speed
thor manual gearbox 0AH - Edition 06.2016 eo
au ra
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– To remove mounting bracket -A-, carefully cut through cable
ce
le
un
pt
tie -arrow-.
an
d
itte
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erm
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ility
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is n
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ole,
spec
t to the co
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cial p
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mer
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n
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– Press bracket -1- to right -arrow- and secure to steering col‐
en
ng
t.
yi
umn using wire -2-.
Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Remove mounting bracket securing nuts -arrows- as follows:

– Wrap the U-joint from the socket set - V.A.G 1835- with tape.
Caddy 2004 ➤ , Caddy 2011 ➤
– Press wiring harness -1- upwards and left -arrow- using ex‐
tension -2- from -V.A.G 1835- .
– While doing this, unbolt upper securing nut for mounting brack‐
et.
– Then unbolt both lower securing nuts for mounting bracket.
– Free bracket from steering column.
n AG. Volkswagen A
– Unscrew relay carrier from dash panel
olks
wagand
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put it down inGfoot‐
does
not
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hole
spec
es, in part or in w
t to the co
– Secure tensioning strap - T10038- -arrow 1- to dash panel
cross member -arrow 2- as shown in figure.
rrectness of i
l purpos
nf
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orm
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op
– Secure tensioning strap - T10038- to bracket -1-. C py
ht. rig
rig ht
py by
co Vo
by lksw
cted
Note
agen
Prote AG.
It may be necessary to separate data bus control unit in order to

separate bracket for relay carrier and onboard supply control unit.
– Carefully pull bracket -1- towards back using tensioning strap

- T10038- far enough that you can pull mounting bracket off
studs on bulkhead.
Installing
– Renew cut cable ties.

Caddy 2004 ➤ , Caddy 2011 ➤
– Push pipe/hose line -1- with new seal -2- onto connection of
master cylinder -4- until securing clip -3- engages audibly.
– Check pipe/hose line by tugging on it.
– Secure relay carrier bracket, onboard supply
gen AG control unit
. Volkswagen AG-
does
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J519- and fuse holder. yV
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ed nte
– Secure relay carrier on left
tho
runder
is dash panel ⇒ Electrical sys‐ e or
tem; Rep. gr. 97 . s au ac
s
ce
le
– Install crash bar.
un
pt
an
d
itte
– Install footwell vent, cable guide, cover and storage compart‐
y li
rm
ab
ment on driver side ⇒ General body repairs, interior; Rep. gr.
pe
ility
68 ; Compartments, covers .
ot
wit
, is n
h re
– Install battery carrier, battery cover and battery ⇒ Electrical
hole
spec
es, in part or in w
t to the co
– Bleed clutch mechanism after installing master cylinder
⇒ page 29 .
Torque settings
rrectness of i
l purpos
nform
ercia

Bolt M 6 = 5 Nm
m
a
com
tion in
r
te o
thi
1.7 Removing and installing clutch master
s
iva
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cylinder
r
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Co
Cop py
ht. rig
♦ Pliers - T10005- rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Removing
– Remove mounting bracket ⇒ page 20 .
– Release retainer for master cylinder operating rod using pliers
- T10005- .
Caddy 2004 ➤ , Caddy 2011 ➤
5-speed manual gearbox
en AG0AH
. Volk-swEdition
agen AG06.2016
ag does
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y Vol gu
– Insert spacer -A-sebetween
db clutch pedal and stop and press
ara
nte
clutch pedal tothorspacer.
i
eo
au ra
c
♦ s
Length of sspacer = about 40 mm (e.g. 1/ " socket) 2
ce
e
nl
pt
du
an
– Release securing bar -B- and pull master cylinder out of
itte
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mounting bracket -arrows 1- and -2-.
erm
ab
ility
ot p
Installing
wit
, is n
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hole
spec
• Move clutch pedal to rest position at stop.
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
– Attach retainer -2- to master cylinder operating rod -1-.
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
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by
cted agen
Prote AG.
– Insert spacer -A- between clutch pedal and stop and press
clutch pedal to spacer.
♦ Length of spacer = about 40 mm (e.g. 1/2" socket)
– Engage master cylinder in mounting bracket -arrow 1- and

-arrow 2-.

Caddy 2004 ➤ , Caddy 2011 ➤
– Press master cylinder operating rod -1- in direction of arrow

until retainer -2- engages audibly in clutch pedal.
– Install mounting bracket ⇒ page 20 .
Volkswa AG. gen AG
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ility
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wit
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ole,
1.8 Removing and installing clutch position
spec
sender - G476-
t to the co
Removing
rrectne
– With ignition switched off, disconnect battery ⇒ Electrical sys‐
tem; Rep. gr. 27 ; Battery: Disconnecting and connecting
battery .
ss o
cial p
f
inform
gr. 24 .
mer
atio
om
system; Rep. gr. 27 ; Battery; Removing and installing battery . n

c
i
or
n thi
te
– Disconnect connector -4-.

sd
iva
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pr
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– Unclip clutch position sender - G476- from master cylinder

fo
en
ng
-arrow- and remove.

t.
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Cop py
ht. rig
rig ht
py by
o Vo
Note by c lksw
cted agen
Prote AG.
Disregard items -1- to -3-.
Installing
Install in reverse order of removal.
1.9 Removing and installing clutch slave

cylinder
Caddy 2004 ➤ , Caddy 2011 ➤
♦ Torque wrench - V.A.G 1331-
Removing
gr. 24 .
– Remove securing clip -arrow 1- for gear selector cable from
gearbox selector lever -A-.
– Remove securing clip -arrow 2- for gate selector cable from
relay lever -B-.
– Pull gate selector cable and gear selector cable off pins.
– Pull securing clip -arrow 3- from relay lever -B- and remove
relay lever.
– Remove gearbox selector lever -A- by removing nut
-arrow 4-.
AG. Volkswagen AG d
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– Remove cable support bracket from gearbox -arrows-.

ole,
spec
– Then raise and secure gear selector cable and gate selector
t to the co
cable.
– Place a lint-free cloth under slave cylinder.
rrectness o
cial p
f inform
mer
atio
om
n
c
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or
n thi
te
sd
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Caddy 2004 ➤ , Caddy 2011 ➤
– Pull clip -A- for pipe/hose line out of slave cylinder to stop.
– Pull pipe/hose line out of retainer -C- on gearbox.
– Pull pipe/hose line -B- out of slave cylinder and seal off open‐
ing.
– Unbolt slave cylinder -arrows- and remove it.
Note
Do not depress clutch pedal.

AG. Volkswagen AG d
agen
Installing olksw
oes
not
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Install in reverse orisorder of removal, observing the following:
e nte
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– Greaseshead of plunger with MoS2.
s a c
ce
le
un
pt
an
d
– Install slave cylinder and tighten bolts -arrows-.

itte
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erm
ab
– Press clip -A- into slave cylinder onto stop.
ility
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is n
– Insert pipe/hose line -B-, with a new seal, into slave cylinder
h re
ole,
to stop until securing clip -A- engages audibly in slave cylinder.
spec
– Check pipe/hose line by tugging on it.
t to the co
– Press pipe/hose line into retainer -C- on gearbox.
– Bleed clutch mechanism after installing slave cylinder
⇒ page 29 . rrectnes
Assemble selector mechanism ⇒ page 49 .

s o
cial p
Check selector mechanism and adjust as necessary

inform
⇒ page 52 .
mer
atio
m
– Then install complete air filter housing ⇒ Rep. gr. 23 or ⇒

o
n
c
Rep. gr. 24 .
i
or
n thi
te
sd
a
Torque settings
iv
o
pr
cum
r
fo
♦ ⇒ “1.2 Assembly overview - clutch hydraulics”, page 13

en
ng
t.
yi Co
Cop py
. rig
1.10 Bleeding clutch mechanism
ht ht
rig by
copy Vo
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cted
agen
Prote AG.
♦ Brake filling and bleeding equipment - VAS 5234- or
Caddy 2004 ➤ , Caddy 2011 ➤
♦ Brake filling and bleeding unit - V.A.G 1869-
Note
Prefilling system is not necessary!
Brake fluid specifications ⇒ Brake systems; Rep. gr. 47

AG. Volkswagen AG d
– Remove complete air filter housing ⇒ Rep. gr.lks23
wagor
en ⇒ Rep. oes
not
gr. 24 . db
y Vo gu
ara
e nte
ris
– Connect brake filling and bleeding equipment
ut
ho - VAS 5234- or eo
ra
-V.A.G 1869- . ss
a c
ce
e
nl
To bleed system, use 670 mm bleeder hose - V.A.G 1238/B3- if
pt
du
an
necessary.
itte
y li
erm
ab
– To do this, connect the bleeder hose to the collector bottle of
ility
ot p
the brake bleeding device.
wit
, is n
h re
– Connect bleeder hose to bleeder -arrow-.
hole
spec
es, in part or in w
– Pressurise system to 2 bar.
t to the co
– Open bleeder valve.
– Bleed off about 100 cm3 brake fluid. rrectness of i
– Close bleeder valve.

l purpos
– Rapidly operate pedal cluster from stop to stop 10 to 15 times.

nform
ercia
– Open bleeder valve.

m
at
om
– Bleed off an additional 50 cm3 brake fluid.

ion
c
in t
or
– Close bleeder valve.

his
ate
do
riv
– Depress clutch pedal several times after completion of bleed‐

p
cum
or
ing process.
f
en
ng
t.
yi Co
Cop py
. rig
1.11 Repairing clutch release mechanism
t
gh ht
pyri by
Vo
co lksw
by
cted
agen
Prote AG.

Caddy 2004 ➤ , Caddy 2011 ➤
• Gearbox removed
Removing and installing clutch release lever with release bearing
and guide sleeve
– Remove bolts -arrow-.
– Pull clutch release lever with release bearing and guide sleeve
off input shaft and ball stud.
Removing and installing guide sleeve

– Push guide sleeveag-3-
en Aupwards
G. Volkswaout ofG release
gen A
do bearing -2-.
w es n
olks ot
– Turn guide ed
bsleeve
yV -3- about 90° in direction ofguarrow
ara relative
to release or bearing -2- until locking lugs of guide sleeve
is nte
eo align
th
withs augrooves -4- of release bearing. ra
c
s
– Pull guide sleeve out of release bearing in this position.
ce
le
un
pt
an
d
itte

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ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
Removing and installing release bearing

t to the co
– Press together locking lugs -arrows- on back of clutch release

lever and remove release bearing -A- from clutch release lev‐
rrectness of i
er.
l purpos
– To install, press release bearing -A- into clutch release lever

until retaining lugs -arrows- engage.
nform
ercia
Torque settings
m
♦ ⇒ “1.3 Assembly overview - clutch release mechanism”, page

com
tio
15
n in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Caddy 2004 ➤ , Caddy 2011 ➤
2 Clutch
⇒ “2.1 Assembly overview - clutch”, page 32
⇒ “2.2 Removing and installing clutch”, page 33
olkswagen AG
en AG. V
2.1 Assembly overview
yV
olks
wag - clutch does
not
gu
b ara
ed nte
oris eo
th
Note au ra
c
ss
ce
e
nl
pt
du
♦ Check whether dowel sleeves for aligning engine and gearbox are fitted in cylinder block and install if nec‐
an
itte
essary.
y li
erm
ab
ility
♦ If dowel sleeves are not fitted, difficulties shifting gears, clutch problems and possible noises from the gear‐
ot p
wit
box (rattling of gears which are not engaged) could occur.
, is n
h re
hole
♦ Renew clutch plates and pressure plates with damaged or loose rivets.
spec
es, in part or in w
♦ Allocation ⇒ Electronic parts catalogue (ETKA)
t to the co
rrectness of i
1 - Flywheel
l purpos
❑ Ensure that centring

pins fit tightly
❑ Contact surface for
nf
ercia
o
clutch lining must be
rm
m
free of grooves, oil and

atio
m
grease
o
n in
or c
thi

te
sd
a
⇒ Rep. gr. 13
iv
o
r
rp
cu
o
2 - Clutch plate
f
en
ng
t.
yi Co
❑ Installation position with Cop py
t. rig
two-part flywheel: short‐ yri
gh by
ht
er end of hub faces cop Vo
by lksw
pressure plate
cted agen
Prote AG.
❑ Text
“Getriebeseite” (gear‐
box side) always faces
pressure plate and
gearbox
❑ Installation position with
single piece flywheel:
spring cage faces pres‐
sure plate
❑ Centring on vehicles
with a 1.4 l petrol engine
⇒ page 34
❑ Centring on vehicles
with a 1.6 l petrol engine
or a diesel engine
⇒ page 34 .
❑ Lightly grease splines
❑ Allocation ⇒ Electronic
parts catalogue (ETKA)
❑ Clean input shaft
splines and, on used
clutch plates, hub
splines; remove corrosion and apply only a very thin coat of grease - G 000 100- to the input shaft splines.

Caddy 2004 ➤ , Caddy 2011 ➤
Then, move the clutch plate back and forth on the drive shaft until the hub moves easily on the shaft.
Remove excess grease.
3 - Pressure plate
❑ Removing and installing on vehicles with a 1.4 l petrol engine ⇒ page 34
❑ Removing and installing on vehicles with a 1.6 l petrol engine or a diesel engine ⇒ page 34 .
❑ Check ends of diaphragm spring ⇒ page 34
Pressure plates are protected against corrosion and greased. Clean contact surface only; otherwise the service
life of the clutch will be considerably reduced. gen AG
. Volkswagen AG
d a oes
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Vol gu
4 - Bolt db
y ara
rise nte
❑ Renew after removal tho eo
au ra
c
❑ Loosen or tighten diagonally ands in steps
s
ce
le
un
pt
an
d
itte
y li
❑ 20 Nm
rm
ab
pe
ility
ot
wit
, is n
h re
2.2 Removing and installing clutch
hole
spec
es, in part or in w
t to the co
equipment required
rrectness of i
♦ Retainer - 3067-
l purpos
♦ Torque wrench - V.A.G

1331-
nform
ercia
♦ Required in addition for ve‐

hicles with 1.6 l petrol en‐
m
a
com
ti
gine and for vehicles with a
on in
diesel engine: centring
r
te o
thi
mandrel - 3190 A-
s
iva
do
r
rp
c
♦ Required in addition for ve‐
um
fo
en
g
hicles with a 1.4 l petrol en‐

n
t.
yi Co
gine: centring drift - t. Cop py
T10086-
rig
gh ht
pyri by
Vo
o
by c
♦ Grease - G 000 100-
lksw
cted agen
Prote AG.
• Gearbox removed
2. Clutch 33
Caddy 2004 ➤ , Caddy 2011 ➤
Vehicles with 1.4 l petrol engine

Centring clutch plate and removing and installing pressure plate
– Loosen or tighten bolts diagonally in stages.
– Reverse position of counterhold - 3067- when removing.
Note
♦ Pressure plate contact surface and clutch plate lining must

make full contact with flywheel.
♦ Tighten securing bolts diagonally and evenly to prevent dam‐
age to pressure plate centring hole and flywheel centring pins.
Vehicles with 1.6 l petrol engine and vehicles with a diesel engine
Centring clutch plate and removing and installing pressure plate

– Loosen or tighten bolts diagonally in stages.
– Reverse position of counterhold - 3067- when removing. agen AG. Volkswagen AG do
lksw es n
o ot g
yV ua
edb ran
ris tee
Note ut
ho or
a ac
ss
Pressure plate contact surface and clutch plate lining must make
ce
e
nl
pt
du
full contact with flywheel. Tighten bolts diagonally and evenly to
an
itte
prevent damage to the centring holes in the pressure plate hous‐
y li
erm
ab
ing and the centring pins in the flywheel.
ility
ot p
wit
, is n
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hole
Checking ends of diaphragm spring -arrows-
spec
es, in part or in w
• Wear up to half the thickness of the diaphragm spring is per‐
t to the co
mitted.
Torque settings
rrectness of i
♦ ⇒ “2.1 Assembly overview - clutch”, page 32
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
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rp
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o
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f
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ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Caddy 2004 ➤ , Caddy 2011 ➤
5-speed
gen AG. Volkmanual gearbox
swagen AG
d
0AH - Edition 06.2016
wa oes
olks not
byV gu
ara
ed
34 – Controls, housing
ris nte
tho eo
au ra
c
ss
ce
le
un
pt
1 Selector mechanism
an
d
itte
y li
erm
ab
⇒ “1.1 Installation position - selector mechanism”, page 35
ility
ot p
wit
is n
⇒ “1.2 Assembly overview - Selector cables”, page 37
h re
ole,
⇒ “1.3 Assembly overview - gear knob and cover”, page 39
spec
t to the co
⇒ “1.4 Assembly overview - Selector lever and selector housing,
►06.2010”, page 41
⇒ “1.5 Assembly overview - Selector lever and selector housing,
rrectne
07.2010►”, page 43
⇒ “1.6 Dismantling and assembling selector mechanism,
ss o
07.2010►”, page 44
cial p
f inform
⇒ “1.7 Removing and installing gear knob”, page 48
mer
atio
m
⇒ “1.8 Removing and installing selector mechanism”, page 49

o
n
c
i
or
n
⇒ “1.9 Adjusting selector mechanism”, page 52
thi
te
sd
iva
o
⇒ “1.10 Removing and installing relay lever”, page 55
pr
cum
r
fo
en
ng
1.1 Installation position - selector mechanism

t.
yi Co
Cop py
t. rig
gh
Arrow -A- = gear selection movement
ht
pyri by
Vo
co lksw
by
Arrow -B- = gate selection movement
cted agen
Prote AG.
1. Selector mechanism 35
Caddy 2004 ➤ , Caddy 2011 ➤
A - Gear selector cable

B - Gate selector cable
C - Heat shield
❑ Remove before remov‐
ing selector mecha‐
nism.
1 - Gearbox selector lever
2 - Deflector lever
AG. Volkswagen AG d
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olksw not
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, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
36 Rep. gr.34 - Controls, housing

Caddy 2004 ➤ , Caddy 2011 ➤
1.2 Assembly overview - Selector cables
Note
Lubricate bearing positions and sliding surfaces with grease - G 000 450 02- .
1 - Gear change cable

❑ Connect to cable end-
piece
❑ Fitting position
⇒ page 35
2 - Gate change cable
❑ Connect to cable end-
piece
⇒ page 35
3 - Lock washer
4 - Selector housing
5 - Lock washer
❑ Do not damage cables
when removing
6 - Bolt
❑ For cable support brack‐
et agen
AG. Volkswagen AG d
oes
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❑ 20 Nm d byV gu
ar
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7 - Cable support bracket
ut
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8 - Grommet
ce
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nl
pt
du
❑ Cable support bracket

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itte
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mounting on gearbox
erm
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ility
ot p
9 - Distance piece
wit
, is n
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10 - Cable end-piece
hole
spec
❑ After installing, adjust

es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
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thi
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iva
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f
en
ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Caddy 2004 ➤ , Caddy 2011 ➤
selector mechanism
⇒ page 52
❑ For gate selector cable to relay lever
❑ Do not interchange; cable end-pieces for gate selector cable to relay lever and gear selector cable to
gearbox selector lever are different
❑ For metal relay lever, secured with securing clip ⇒ Item 12 (page 38)
❑ From 05.07, fitted in conjunction gen AG
with
. Volkplastic
swagen Arelay
G do lever ⇒ page 55
swa es n
❑ Removing from plastic y V relay lever ⇒ page 55
o lk ot g
ua
d b ran
❑ Pressing onto plastic
oris
e
relay lever ⇒ page 57 tee
th or
❑ Allocation ⇒ss page 38 .
au ac
ce
le
11 - Cable end-piece
un
pt
an
d
itte
❑ For gear selector cable to gearbox selector lever
y li
rm
ab
❑ Do not interchange; cable end-pieces for gate selector cable to relay lever and gear selector cable to
pe
ility
gearbox selector lever are different ⇒ page 38
ot
wit
, is n
h re
12 - Lock washer
hole
spec
es, in part or in w
t to the co
13 - Lock washer
rrectness of i
14 - Sleeve bearing
l purpos
15 - Deflector lever
❑ Fitting position ⇒ page 39
nform
ercia
16 - Slide block
m
a
com
tio
17 - Nut
n in
r
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❑ 23 Nm
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❑ With damper weight
C py
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rig ht
❑ Install so that master spline aligns with selector shaft
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❑ After installing, adjust selector mechanism ⇒ page 52
Allocation of cable end-pieces

The holes in the cable end-pieces have different diameters.
Cable end-piece for Dimension “a”
1. - Gate selector cable to gearbox selector lever 8.5 mm
from 02.06
2 - Gate selector cable to gearbox selector lever 10 mm
to 01.06
2. - Gate selector cable to metal relay lever 8 mm
2. - Gate selector cable to plastic relay lever 10 mm
⇒ page 55

Caddy 2004 ➤ , Caddy 2011 ➤
AG. Volkswagen
Smaller diameter of support pin for
lksw
agegear
n
selector cable end-piece
AG do
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Vo ot g
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Support pin for gear selector
or
ise
d
cable end-piece Dimension “a”rante
th eo
To 01. 06 ss
au 10 mm ra
c
ce
From 02.06 nl
e 8.5 mm
pt
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hole
spec
es, in part or in w
t to the co
Install gearbox selector lever
rrectness of i
– When fitting the gearbox selector lever, ensure that the gap
-arrow A- is aligned with the master spline -arrow B-.
l purpos
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ercia
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Prote AG.
Installation position of gearbox selector lever/relay lever

1- Gearbox selector lever with damper weight
2- Relay lever engages in guide rail of gearbox selector lever
via shoe -arrow-.
1.3 Assembly overview - gear knob and cover
Caddy 2004 ➤ , Caddy 2011 ➤
1 - Gear knob
❑ With gaiter
❑ Gear knob and gaiter
cannot be separated
from one another
⇒ page 48
2 - Gaiter
3 - Clamp
❑ To secure gear knob on
selector lever
4 - Noise insulation
❑ Not fitted in all vehicles
❑ Locking lugs are ar‐
ranged at varying inter‐
vals
Volkswagen AG
❑ Therefore it can be in‐ swagen AG. does
stalled in only one posi‐
by Volk not
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ed
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spec
es, in part or in w
t to the co
rrectness of i
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Cop py
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Prote AG.

Caddy 2004 ➤ , Caddy 2011 ➤
1.4 Assembly overview - Selector lever and selector housing, ►06.2010
Note
Lubricate bearing positions and sliding surfaces with grease - G 000 450 02- .
1 - Lock washer
⇒ page 42
2 - Bush
3 - Compression spring
4 - Bush
5 - Bolt
❑ 5 Nm
6 - Cover
7 - Dampers
8 - Dampers
9 - Bearing shell
10 - Gear lever guide AG. Volkswagen AG d
agen oes
ksw
11 - Damping washer byV
ol not
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12 - Seal hor eo
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❑ Between selectorshous‐
s c
ing and underbody
ce
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un
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❑ Self-adhesive
itte
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❑ Bond to selector lever

pe
ility
housing
ot
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13 - Gear lever
hole
spec
es, in part or in w
t to the co
15 - Sleeve bearing
16 - Locating pin
rrectness of i
17 - Guide bush
l purpos
❑ Installing ⇒ page 43
nform
ercia
19 - Gate selector lever

m
a
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tion in
20 - Bolt
r
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❑ 5 Nm
s
iva
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21 - Seal
um
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22 - Floor panel opy
rig by
Vo
ht
❑ Renew after removal by c lksw

cted agen
Prote AG.
❑ Bend open tabs to remove
❑ On gate selector lever
Caddy 2004 ➤ , Caddy 2011 ➤

❑ Removing from and attaching to selector lever guide ⇒ page 42
25 - Lock washer
26 - Nut
❑ M8: 25 Nm
❑ M6: 8 Nm
27 - Sleeve bearing
❑ Fits in one position only
28 - Lock washer
AG. Volkswagen AG d
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olksw not
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Removing and installing gate and gear selector cables rised
nte
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– Remove securing clip from gear selector cable -A-
ss a and gate ra
c
selector cable -B-.
ce
le
un
pt
an
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To do this, raise tab using screwdriver -arrow 1- and press off

itte
y li
securing clip -arrow 2-.
erm
ab
ility
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– Remove gear selector cable -A- from gear lever retainer.
wit
is n
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– Remove gate selector cable -B- from retainer of gate selector
ole,
spec
lever.
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
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Removing and installing securing clip
thi
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– To remove or install securing clip -arrow A-, press spacer bush

i
o
pr
cum
r
fo
-arrow B- to stop in direction of -arrow C- using screwdriver

en
ng
t.
and pull off securing clip. Cop
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Note
c by lksw
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Prote AG.
♦ Do not cant spacer bush when pushing down.

♦ Slot in gear lever for securing clip must be visible.
♦ Carefully release tension from spring.

Caddy 2004 ➤ , Caddy 2011 ➤
Installing compression spring

– Insert compression spring so that extension -A- lies on top of
pin -arrow-.
– Then pull extension -B- down so that it sits below pin -arrow-.
1.5 Assembly overview - Selector lever and selector housing, 07.2010►
Note
♦ Lubricate bearing positions and sliding surfaces.

♦ Allocate grease using ⇒ Electronic
wage
nparts
AG. Vocatalogue
lkswagen AG(ETKA) .
doe
ks s no
Vol t
♦ Dismantling and assembling
ed
by selector mechanism ⇒ page 44
gu.
ara
ris nte
utho eo
ra
a c
ss
1 - Floor panel
ce
e
nl
pt
du
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itte
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ab
❑ Bend open tabs to re‐
ility
ot p
move
wit
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2 - Seal h re
hole
spec
es, in part or in w
t to the co
3 - Gear lever
❑ Can be removed and in‐
stalled with gear lever
rrectness of i
guide
l purpos
installed
nf
ercia
4 - Damping washer
orm
❑ Push onto gear lever up

m
atio
m
to stop -arrow-
o
n in
or c
5 - Lock washer
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❑ Do not damage cables

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when removing
Co
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❑ Lever off gate selector
by
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lever
AG.
❑ Press onto gate selector

lever inside selector
mechanism
⇒ page 35
7 - Bush
❑ Lever off gear lever
guide
Caddy 2004 ➤ , Caddy 2011 ➤
❑ Press onto gear lever
guide inside selector mechanism
9 - Dampers
10 - Bearing shell
❑ Is damaged during removal
11 - Bush
12 - Lock washer
14 - Bush
15 - Gear lever guide
16 - Nut
❑ M8: 25 Nm
❑ M6: 8 Nm
17 - Seal
❑ Between selector housing and underbody
❑ Self-adhesive
❑ Bond to selector lever housing
❑ With compression spring and gate selector lever
❑ Compression spring and gate selector lever cannot be removed
1.6 Dismantling and assembling selector

mechanism, 07.2010► AG. Volkswagen AG d
agen oes
Special tools and workshop equipment required olksw not
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♦ rise nte
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Thrust block - T10083- ss c
ce
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un
pt
Dismantling
an
d
itte
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rm
– Remove selector mechanism ⇒ page 49 .

ab
pe
ility
ot
wit
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
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tion in
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Cop py
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pyri by
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44
c by lksw
cted agen
Rep. gr.34 - Controls, housing Prote AG.
Caddy 2004 ➤ , Caddy 2011 ➤
– Bend open tabs -arrows- of base plate for selector mechanism

using screwdriver and remove base plate; (tabs in front area
of base plate are not illustrated).
– Remove seal from selector housing.
– Remove gear and gate selector cables from selector housing
⇒ page 43 .
– Lift upper end -A- of compression spring over tab of gate se‐
lector lever.
– Use screwdriver to press catches -arrows- of ball socket to‐

wards bearing ball of gear lever guide; break off catches if
necessary.
– Lever ball socket -A- with gear lever guide -B- out of selector
housing.
– Then press ball socket off bearing ball of gear lever guide and
remove it.
• Please pay attention to guides -A- during the further proce‐
dure.
• They must not be broken off. AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
e
– Lever lower end -arrow 1- of compression spring ontohorisshoulder nte
eo
on gate selector lever as far as stop. s aut ra
c
s
ce
e
nl
pt
du
an
itte
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erm
ab
ility
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– Now pull gear lever guide up to stop and pull ball stud out of
wit
, is n
h re
gate selector lever -arrow 2-.
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
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by c lksw
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Prote AG.
Caddy 2004 ➤ , Caddy 2011 ➤
– Then turn gear lever guide in -direction of arrow 1-.

• Pin -arrow 2- must be in notch in selector housing
– Then swing out gear lever guide with gear lever in
-direction of arrow 3-.
Installing
Caution
The lower end of the compression spring (-arrow 1- ⇒ figure

above) can snap off the shoulder of the gate selector lever out
of control during the further procedure.
– Therefore, carefully press it down off shoulder of gate selector

lever.
The ends of the compression spring then become tensioned “di‐
agonally” with a loud noise.
– Slacken ends -A- and -B- by turning both round to right.
• Ends -A- and -B- must point in opposite directions.
AG. Volkswagen AG d
agen oes
olksw not
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d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
h re
hole
– Fit gear lever guide in selector housing.

spec
es, in part or in w
t to the co
• Pin -arrow 1- is still located in notch in selector housing.

– Turn gear lever guide in -direction of arrow 2- until ball stud
-A- is located in notch in selector housing.
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
riv
– Place selector housing with gear lever guide into larger recess
p
cum
or
-arrow- in thrust piece - T10083- .

f
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
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Prote AG.

Caddy 2004 ➤ , Caddy 2011 ➤
• The gear lever guide must project from the selector housing
up to the stop.
– Insert end -A- of compression spring into guide from above.
– Pull end -B- of compression spring downwards and insert it
next to guide (in direction of ball joint).
• Please pay attention to guides (⇒ figure above) during the fur‐
ther procedure.
• They must not be broken off.
Note
For clarity of illustration, only part of the gate selector lever is

shown.
– Carefully remove selector housing with gear lever guide from

thrust piece - T10083- .
– Move gate selector lever back to stop (opposite from mounting

holes for gear and gate selector cable) -arrow 1-.
– Grease ball stud.
– Press ball stud into gate selector lever -arrow 2-.
• Guides -A- and tabs -B- are not allowed to be damaged.
– Place selector housing with gear lever guide into larger recess
-arrow- in thrust piece - T10083- .
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
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aut ra
ss c
ce
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nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
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47
op Vo
by c lksw
Prote
cted AG.
agen 1. Selector mechanism
lkswage es n
o ot g
byV ua
ed ran
Caddy 2004 ➤ , Caddy 2011 hor ➤
is tee
t or
5-speed manual gearbox au0AH - Edition 06.2016 ac
ss
ce
e
nl
• The gear lever guide must project from the selector housing
pt
du
an
itte
up to the stop.
y li
erm
ab
– Lift upper end -A- of compression spring over pin of gate se‐
ility
ot p
lector lever.
wit
, is n
h re
• Use a new ball socket -B-. hole
spec
es, in part or in w
– Grease ball socket and bearing ball of gear lever guide.
t to the co
– Press ball socket onto bearing ball of gear lever guide up to
stop.
rrectness of i
– Remove selector housing from thrust piece - T10083- .
l purpos
– Insert lower end -C- of compression spring into guide.

– Lift upper end -A- of compression spring over pin of gate se‐
nform
ercia
lector lever into guide.

m
at
om
i
– Press ball socket into selector housing -arrows-.
on
c
in t
or
• All locking lugs must clip in.
his
ate
do
priv
c
– Attach gear lever, gear selector cable, gate selector cable and
um
for
base plate ⇒ page 43 .
en
ng
t.
yi Co
op
– Install selector mechanism ⇒ page 49 .
C py
t. rig
gh ht
yri by
Torque settings cop Vo
by lksw
cted agen
Prote AG.
♦ ⇒ “1.5 Assembly overview - Selector lever and selector hous‐
ing, 07.2010►”, page 43
1.7 Removing and installing gear knob

♦ Removal wedge - 3409-
♦ Hose clip pliers - V.A.G 1275-

Caddy 2004 ➤ , Caddy 2011 ➤
Removing
– Lever gaiter upwards out of centre console frame -arrows-.
– Fold boot up over gearstick.
– Open clamp -arrow- and pull off gear knob together with gaiter.
AG. Volkswagen A
n G do
wage es n
Installing Volks ot g
by ua
ed ran
ris
Install in reverse order ofthoremoval, observing the following: tee
u or
a ac
– Turn gaiter inside sout.
s
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Install gear knob and gaiter and squeeze new clamp -arrow-
together.
rrectness of i
When gear knob is pushed on, it must engage in circumferential
groove in gear lever.
l purpos
nform
mercia
a
com
tion in
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thi
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1.8 Removing and installing selector mech‐
Cop py
t. rig
gh ht
anism pyri by
Vo
co lksw
by
cted agen
Prote
AG.
♦ Grease - G 000 450 02-
Caddy 2004 ➤ , Caddy 2011 ➤
Removing
battery .
– Remove gaiter with gear knob ⇒ page 48 .
– If noise insulation is present, pull it off.
– Remove front centre console, ⇒ General body repairs, interi‐
or; Rep. gr. 68 ; Compartments, covers .
– Remove selector lever housing nuts -arrows-.
gr. 24 .
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
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aut ra
ss c
ce
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un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Remove securing clip -3- for gear selector cable from gearbox
selector lever -1-.
– Pull gear selector cable off pin.
rrectness of i
Metal relay lever

l purpos
– Remove securing clip -4- for gate selector cable from relay
lever -2-.
nform
ercia
– Pull gate selector cable from pin.

m
a
com
tion in
Plastic relay lever

r
te o
thi
s
iva
do
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rp
cum
fo
en
ng
Releasing cable end-piece from gate selector cable

t.
yi Co
Cop py
.
• To avoid damage to gate selector cable, separate cable end-
ht rig
rig ht
by
piece from gate selector cable before removal. copy Vo
by lksw
cted agen
Prote
– Pull locking mechanism forward to stop in
AG.
-direction of arrow 1-, and then lock it by turning to left in

-direction of arrow 2-.
– Then push relay lever forwards (-in direction of arrow 3-).
– Remove relay lever and cable end-piece together
⇒ page 55 .
Continued for all selector mechanisms

Caddy 2004 ➤ , Caddy 2011 ➤
– Remove cable support bracket from gearbox -arrows-; if nec‐

essary unclip hoses first.
– Remove noise insulation ⇒ General body repairs, exterior;
Rep. gr. 66 ; Noise insulation .
– Remove tunnel cross members ⇒ Rep. gr. 26 ; Exhaust sys‐
tem/silencers .
– Separate exhaust system at front at double clamp and unhook
rear of exhaust system; remove front heat shield ⇒ Rep. gr.
26 ; Exhaust system/silencers .
– Swing selector lever housing down and remove with selector
cables.
Installing
– Align selector lever housing parallel to body.
• Distance to body must be same on both sides.
Secure selector housing ⇒ Item 26 (page 42) or
⇒ Item 16 (page 44) .
– Route cables -1- from selector mechanism -2- to gearbox as

follows:
• Bowden cables must lie parallel to each other and must not n AG. Volkswagen AG do
cross. olks
wage es n
o V t gu
by ara
• Bowden cables must be laid in the intended indentationrisin
ed heat nte
shield -3-. utho eo
ra
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ss
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
Clip -A- holds cables and heat shield together in position.

nform
ercia
The holes in the cable end-pieces have different diameters.

m
at
Allocation of cable end-pieces ⇒ page 38

om
ion
c
in t
or
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ate
do
priv
cum
for
en
ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Caddy 2004 ➤ , Caddy 2011 ➤
– Spread a small quantity of grease on pins of gearbox selector

lever -1- and relay lever -2-.
• Allocate grease using ⇒ Electronic parts catalogue (ETKA) .
– Renew securing clip -3- and, for metal relay lever, securing
clip -4- each time they are removed.
olkswagen AG
en AG. V
– Secure gear selector cable owith ksw securing clip -3- and gate
ag does se‐
not
V l
lector cable, if necessary
ed b with securing clip -4-.
y gu
ara
ris nte
Cable end-piece to plastic
au
tho relay lever eo
ra
ss c
– Install relay lever and cable end-piece together ⇒ page 55 .
ce
e
nl
pt
du
an
– Insert gate selector cable in cable end-piece.
itte
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erm
ab
Continued for all selector mechanisms
ility
ot p
wit
, is n
– Install front centre console ⇒ General body repairs, interior;
h re
Rep. gr. 68 ; Compartments, covers .
hole
spec
es, in part or in w
t to the co
– Renew clamp -arrow-.
– Install front heat shield.
rrectness of i
– Assemble exhaust system free of tension and attach tunnel
cross-piece ⇒ Rep. gr. 26 ; Exhaust system/silencers .
l purpos
– Adjust selector mechanism ⇒ page 52 .
nf
ercia
– Install complete air filter housing ⇒ Rep. gr. 23 or ⇒ Rep. gr.
orm
24 .
m
atio
om
– Follow procedure after connecting battery ⇒ Electrical system;

n in
or c
Rep. gr. 27 ; Battery; Disconnecting and connecting battery .

thi
te
sd
iva
Torque settings
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rp
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o
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f
en
ng

t.
yi Co
op
ing, ►06.2010”, page 41 C py
t. rig
gh ht
yri
p by
co Vo
by lksw
ing, 07.2010►”, page 43 Prote
cted AG.
agen
♦ ⇒ “1.2 Assembly overview - Selector cables”, page 37
1.9 Adjusting selector mechanism

♦ Pin - T10027-

Caddy 2004 ➤ , Caddy 2011 ➤
Note
♦ The following points are essential to ensure correct adjust‐

ment of selector mechanism:
♦ The moving parts of the selector mechanism and the elements
that transfer force must function correctly
♦ Selector mechanism must move freely
♦ Gearbox, clutch and clutch mechanism must also be in proper
condition
• Gearbox must be in neutral

– Remove air filter housing if angled rod -A- and securing mech‐
anism for gear selector cable and gate selector cable are not
accessible ⇒ Rep. gr. 23 or ⇒ Rep. gr. 24 .
– Pull locking mechanisms on gate selector cable and gear se‐

lector cable forward to stop -direction ofG.arrow
nA Volksw1-
ageand
n AGthen turn
to left to lock -direction of arrow wage
olks 2-.
does
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ility
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spec
es, in part or in w
t to the co
Secure selector shaft as follows:

– Press selector shaft down in direction of -arrow 1-.
rrectness of i
– While pressing down selector shaft, turn locking pin -A- in di‐
rection of -arrow 2- press it carefully in until it engages in
l purpos
selector shaft.
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
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cum
fo
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ng
t.
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Cop py
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rig ht
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by lksw
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Prote AG.
Caddy 2004 ➤ , Caddy 2011 ➤
– Lever gaiter upwards out of centre console cover -arrows-.

– Remove noise insulation, if fitted.
Set gear stick as follows: agen

AG. Volkswagen AG d
oes
olksw not
V
– Move gear lever to neutral. d by gu
ara
rise nte
o eo
– Guide locking pin - T10027- through hole -A- into
aut hole -B-.
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ss c
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nl
pt
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erm
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ility
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spec
es, in part or in w
t to the co
– Check that gate and selector cables -B- are inserted, free of
tension, into locking devices -A-.
rrectness of i
– Now turn locking mechanisms on gear selector cable and gate
l purpos
selector cable clockwise to stop in direction of -arrow 1-.

The spring presses the locking mechanism into original position
nform
ercia
in direction of -arrow 2-.

m
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ion
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ate
do
priv
cum
for
en
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op py
– Now turn angled rod -A- back to original position t. C rig
gh ht
-direction of arrow-. yri
p by
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by lksw
cted agen
Prote AG.

Caddy 2004 ➤ , Caddy 2011 ➤
– Pull locking pin - T10027- out of holes -A- and -B-.

– Install noise insulation, if previously fitted.
– Press gaiter into centre console.
– Install air filter housing ⇒ Rep. gr. 23 or ⇒ Rep. gr. 24 if
necessary.
Function
• With gearbox in neutral, selector lever must rest in selector
lever gate for 3rd and 4th gear.
– Operate clutch.
– Shift through all gears several times. Pay particular attention
to operation of reverse gear lock.
– If it continues to be difficult to engage a gear after repeated
attempts, repeat adjustment procedure of selector mecha‐
. Volkswagen AG
nism. w agen AG does
ks n ol ot g
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edb ran
1.10 Removing and installing relay lever
tho
ris tee
or
au ac
ss
From 05.07, plastic relay lever
ce
e
nl
pt
du
an
• To remove relay lever, first separate cable end-piece from
itte
y li
gate selector cable.
erm
ab
ility
ot p
wit
, is n
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spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
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at
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ion
c
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This will avoid damage to the gate selector cable.

at
do
priv
– Pull locking mechanism forward to stop in

um
for
-direction of arrow 1-, and then lock it by turning to left in

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ng
t.
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-direction of arrow 2-. . Cop py
rig
ht ht
rig
– Then push relay lever forwards (-in direction of arrow 3-). py by
co Vo
by lksw
cted
Relay lever with catch -arrow 1- (⇒ previous figure).
agen
Prote AG.
– Press catch -arrow 1- (⇒ previous figure) down to stop and

remove relay lever together with cable end-piece. Move it in
operating direction when doing this.
Caddy 2004 ➤ , Caddy 2011 ➤
Relay lever with clip -arrow 1-

– Pull off clip -arrow 1- and remove relay lever together with ca‐
ble end-piece.
Cable end-piece must be located behind catch -arrow 2-.
Continuation for all
• The cable end-piece can be removed only with the relay lever
removed ⇒ page 56 .
Note
♦ When installing, lubricate bearing positions and sliding surfa‐

ces.
♦ Allocate grease using ⇒ Electronic parts catalogue (ETKA) .
– Press cable end-piece onto relay lever ⇒ page 57 .

– Install relay lever together with cable end-piece to stop.
Relay lever with catch -arrow 1- (⇒ previous figure).
• Fastener -arrow 1- secures relay lever (⇒ previous figure).
• Ensure proper engagement.
• Cable end-piece must be locatednbehind
AG. Volkscatch -arrow 2- (⇒
wagen A
previous figure). olks
wage
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Relay lever with clip -arrow
ris
ed 1- (⇒ previous figure). nte
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• Clip -arrow 1- secures
ss
au relay lever (⇒ previous figure). ra
c
ce
le
• Ensure proper engagement of clip.

un
pt
an
d
itte
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• Cable end-piece must be located behind catch -arrow 2- (⇒

rm
ab
previous figure).
pe
ility
ot
wit
, is n
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Levering gate selector cable end-piece off plastic relay lever

hole
spec
• Relay lever has been removed

es, in part or in w
t to the co
– Insert flat-blade screwdriver -A- between bush -B- and relay

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

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agen oes
olksw not
byV gu
ara
ed
ris nte
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ho Caddy 2004 ➤ , Caddy e o 2011 ➤
ra
a
ss 5-speed manual gearbox 0AH - Edition 06.2016 c
ce
le
un
pt
Pressing on cable end-piece
an
d
itte
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rm
ab
• Relay lever has been removed
pe
ility
ot
wit
• Cable end-piece may be pressed only onto bush -arrow-.
, is n
h re
hole
• Cable end-piece must move freely on relay lever.
spec
es, in part or in w
• It must be located behind catch -arrow 2- ⇒ page 55 .
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Caddy 2004 ➤ , Caddy 2011 ➤
2 Removing and installing gearbox.

⇒ “2.1 Specified torques for gearbox”, page 58
⇒ “2.2 Removing gearbox, vehicles ►07.2010”, page 59
⇒ “2.3 Removing gearbox, from 08.2010►”, page 66
⇒ “2.4 Installing gearbox”, page 76
2.1 Specified torques for gearbox

Gearbox to engine
Vehicles with 1.4 l engine
Item Bolt Quantity Nm
1 M 12 x 65 3 80
2 1) M 12 x 55 1
3 2) M 12 x 170 1 80
4 M 12 x 80 2 80
5 M 10 x 60 2 40
1)⇒ Electrical system; Rep. gr. 27 ; Starter; Removing and in‐
stalling starter
2)Also starter to gearbox
Item -A- dowel sleeves for centring
Vehicles with 1.6 l engine

1 M 12 x 65 2 80
2 1) M 12 x 150 1 80
3 1) M 12 x 170
agen
AG. Volkswa1
gen AG
do 80
w es n
olks ot g
4 Md b10
y V x 60 3 u40
ara
e n
4 ris
utho M 12 x 90 1 80 tee o
ra
a c
1) ss
⇒ Electrical system; Rep. gr. 27 ; Starter; Removing and in‐
ce
e
nl
stalling starter
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
Vehicles with diesel engine

h re
hole
spec

es, in part or in w
t to the co
1 M 12 x 55 2 80
2 1) M 12 x 150 2 80
rrectness of i
3 M 10 x 60 3 40
4 M 12 x 65 1 80
l purpos
1)⇒ Electrical system; Rep. gr. 27 ; Starter; Removing and in‐

nform
ercia
stalling starter
m
2)Also
at
starter to gearbox
om
ion
c
in t

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ate
do
priv
cum
for
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ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
58
cted agen
Prote AG.
Rep. gr.34 - Controls, housing
Caddy 2004 ➤ , Caddy 2011 ➤
Gearbox bracket to gearbox and gearbox to body.

Torque settings
Bolts -arrows 1- 2) 60 Nm +90°
Bolts -arrows 2- 2) 40 Nm +90°
2) Renew bolts.
Note
olkswagen AG
en AG. V
Install engine and gearbox mounting
Vol
ksw free of tension ⇒ Rep.
ag does
notgr.
10 ; Removing and installing
ed by engine . gu
ara
ris nte
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ra
Torque settings ss
a c
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le
♦ ⇒ “1.2 Assembly overview - Selector cables”, page 37

un
pt
an
d
itte
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♦ ⇒ “1.2 Assembly overview - clutch hydraulics”, page 13
erm
ab
ility
ot p
♦ ⇒ “5.2 Assembly overview - selector unit”, page 86
wit
is n
h re
ole,
2.2 Removing gearbox, vehicles ►07.2010
spec
t to the co
♦ Support - 10-222 A-
rrectne
♦ shackles - 10-222 A /12-
s
♦ Gearbox lifting tackle -
s o
3336- for transporting gear‐
cial p
f in
box
form
mer
atio
om
n
c
i
or
n thi
te
sd
iva
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pr
cum
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en
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Cop py
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cted agen
Prote AG.
2. Removing and installing gearbox. 59

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gen AG does
Caddy 2004 ➤ , Caddy 2011 ➤ olks
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5-speed manual gearbox 0AH - Edition
ise
d b06.2016 ara
nte
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aut ra
ss c
ce
le
un
pt
♦ Gearbox support - 3282-
an
d
itte
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♦ Adjustment plate - 3282/46-
erm
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ility
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♦ Support elements for gear‐
wit
is n
box (determine when set‐
h re
ole,
ting adjustment plate on
spec
gearbox support ) urposes, in part or in wh
t to the co
♦ Torque wrench -
V.A.G 1331-
rrectne
♦ Torque wrench -
V.A.G 1332-
ss
♦ Engine and gearbox jack -
o
cial p
f
V.A.G 1383 A-
inform
mer
♦ Grease for splines -
atio
m
G 000 100-
o
n
c
i
or
n
♦ Allocate grease using ⇒
thi
te
sd
a
Electronic parts catalogue

iv
o
pr
c
(ETKA) .
um
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
♦ Additionally required for vehicles with a diesel engine: hook -

10–222 A/2-

battery .
– If engine cover panel is fitted, remove it.
gr. 24 .

Caddy 2004 ➤ , Caddy 2011 ➤

– Remove securing clip for gear selector cable -arrow 1- from
Metal relay lever
– Remove securing clip for gate selector cable -arrow 2- from
relay lever -B-.
– Pull securing clip -arrow 3- off relay lever -B- and remove relay
lever.
Plastic relay lever
– Removing relay lever together with cable end-piece
⇒ page 55 .
-arrow 4- (⇒ previous figure).

– Use cable tie to tie up gear selector cable and gate selector
cable.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
– Pull clip -A- for pipe/hose assembly out of slave cylinder to

an
itte
y li
stop.
erm
ab
ility
ot p

wit
, is n
h re
– Pull pipe/hose line -B- out of slave cylinder and seal opening.
hole
spec
es, in part or in w
t to the co
Note
Do not depress clutch pedal.

rrectness of i
l purpos
nform
ercia
– Remove earth strap from upper starter bolt -1-.

m
at
– Remove connector -2- and cable -3- from starter.

om
ion
c
in t
r
– Remove upper engine/gearbox connecting bolts.

o
his
ate
do
riv
– Then remove upper securing bolt on starter.

p
cum
for
– Remove filler pieces from upper edge of left and right wings.
en
ng
t.
yi Co
op py
– If there are hose and cable connections in area of engine sup‐ t. C rig
gh ht
port eyes for support bracket - 10-222A- , remove these now. pyri by
Vo
o
by c lksw
cted
Vehicles with petrol engine
agen
Prote AG.

Caddy 2004 ➤ , Caddy 2011 ➤
– Set up support bracket - 10-222A- together with adapters -

10-222A/22- behind gas strut for bonnet.
– Use shackle - 10-222 A /12- to attach spindle to engine on left
(gearbox side).

10-222A/22- , adapter - 10-222A/3- and adapter - 10-222A/16-
behind gas strut for bonnet.
– Attach hook - 10-222A/10- at front right of engine.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
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– Attach additional hook - 10-222A/2- to rear left of engine
s au ra
c
-arrow-. s
ce
e
nl
pt
du
– Connect hook - 10-222A/2- using adapter - 10-222A/16- .
an
itte
y li
erm
ab
Continuation for all vehicles
ility
ot p
wit
– Take up weight of engine/gearbox assembly on spindles.
, is n
h re
hole
– Raise vehicle on lift.

spec
es, in part or in w
– Remove noise insulation and front left wheel housing liner ⇒ t to the co
General body repairs, exterior; Rep. gr. 66 ; Removing and
installing wheel housing liner; Front wheel housing liner .
rrectness of i
l purpos
– Pull off connector -3- for reversing light.

– Unscrew nut -1- and remove bracket -2- for electrical cables.
nform
ercia
– Remove starter ⇒ Electrical system; Rep. gr. 27 ; Starter;

m
at
om
Removing and installing starter .

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

Caddy 2004 ➤ , Caddy 2011 ➤
– Remove protective cap for drive shaft, if fitted, from engine

-arrows-.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
– Separate exhaust system at double clamp and unbolt exhaust
es, in part or in w
pipe bracket from subframe -arrows-. ⇒ Rep. gr. 26 ; Exhaust
t to the co
system/silencers
– Disconnect drive shafts from flange shafts and tie up as high
rrectness of i
as possible, being careful not to damage surface protection.
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
g
Note
n
t.
yi Co
Cop py
t. rig
Check to see if a cover plate -A- is installed above the right flange
gh ht
pyri by
shaft.
co Vo
by lksw
cted agen
Prote AG.
– This cover plate must be removed now -arrows-.
– Remove pendulum support. Unscrew bolts -arrows A, B- and

-C- to do this.
– If fitted, remove intake manifold between lock carrier and in‐
take air guide ⇒ Rep. gr. 24 ; Intake manifold .

Caddy 2004 ➤ , Caddy 2011 ➤
– Remove bolts -arrows- for engine mounting on right.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
– Remove hexagon bolts -arrows 1- for left assembly mounting
ility
ot p
from gearbox mounting.
wit
, is n
h re
– Tilt engine/gearbox assembly by lowering it via spindles of
hole
spec
support bracket - 10-222A- .
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
c
Note
or
thi
te
sd
iva
♦ In vehicles with a diesel engine, lower threaded spindle from

r
rp
cu
o
adapter - 10-222A/16- using winged nut, but not more than

f
en
ng
t.
until top of spindle is flush with top of nut -arrow-.
yi Co
Cop py
t. rig
♦ All vehicles, when lowering gearbox assembly, observe cool‐
gh ht
yri by
ant hose between engine and heat exchanger being careful
op Vo
by c lksw
cted
not to stretch it.
agen
Prote AG.
♦ Be careful of all lines when lowering gearbox.
– Remove gearbox bracket by unscrewing bolts -arrows 2-.

To remove gearbox “0AH”, set up gearbox support - 3282/46- with
adjustment plate - 3282/46- .
– Insert gearbox support - 3282- in engine and gearbox jack -
V.A.G 1383A- .
– Align arms of gearbox support according to holes in adjust‐
ment plate .

Caddy 2004 ➤ , Caddy 2011 ➤
– Attach support elements -A- to adjustment plate as illustrated.

– Position engine and gearbox jack under vehicle. Arrow -B- on
adjustment plate points in direction of vehicle travel.
– Align adjustment plate parallel to gearbox.

– Secure adapter - 3282/45- on gearbox using M8 nut -arrow-.
– Screw pin - 3282/29- into hole on gearbox for securing bolt of
pendulum support.
– Remove engine/gearbox connecting bolts -arrows- in vicinity

of sump (bolts remain on engine when exhaust system is in
front of bolts).
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
– Remove last engine/gearbox connecting bolt -arrow-.

, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Caddy 2004 ➤ , Caddy 2011 ➤
wage es n
Note yV
olks ot g
ua
d b ran
ir se tee
For 1.4 l petrol engines, the engine/gearbox
utho
connecting bolt -A- or
is above right-hand flange shaft.
a ac
ss
ce
e
nl
pt
du
an
– Press gearbox off dowel sleeves.
itte
y li
erm
ab
– Observe intermediate plate on engine.
ility
ot p
wit
, is n
– Have a second mechanic press engine forwards.
h re
hole
spec
es, in part or in w
t to the co
– Carefully guide gearbox with right-hand flange shaft -A- past
flywheel and intermediate plate as shown.
rrectness of i
– Using spindles of gearbox support - 3282- , tilt gearbox up‐
wards in vicinity of differential.
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
– Swivel gearbox forwards towards front end at clutch housing. Cop py
t. rig
Ensure sufficient clearance between right flange shaft -A- and yri
gh by
ht
clutch pressure plate. cop Vo
by lksw
cted agen
Prote AG.
– Carefully lower gearbox and ensure sufficient clearance be‐
tween left flange shaft -B- and subframe.
– At the same time, ensure that engine/gearbox connecting

bolts -arrows- contact the exhaust system when it is located in
the area of the bolts.
– When lowering gearbox, if necessary change position of gear‐
box using spindles of gearbox support - 3282- .
Note
Be careful of all lines when lowering gearbox.
2.3 Removing gearbox, from 08.2010►

Caddy 2004 ➤ , Caddy 2011 ➤

equipment required
♦ Support - 10-222A-
♦ Adapter - 10-222A/30-
♦ Adapter - 10-222A/3-
♦ Hooks - 10-222A/2-
♦ Adapter - 10-222A/16-
♦ Hook - 10 - 222 A /10-
♦ Pin - 3282/29-
♦ Pin - 3282/48-
♦ Support - 3282/59-
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
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aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Caddy 2004 ➤ , Caddy 2011 ➤

♦ Adjustment plate - 3282/46-
AG. Volkswagen AG d
agen
♦ Support elements for gear‐ Volksw
oes
not
gu
box (determine when set‐ d by ara
ting adjustment plate on rise nte
tho eo
gearbox support ) s au ra
c
s
ce
le
♦ Torque wrench -
un
pt
V.A.G 1331-
an
d
itte
y li
rm
ab
♦ Torque wrench -
pe
ility
V.A.G 1332-
ot
wit
, is n
h re
♦ Engine and gearbox jack -
hole
spec
V.A.G 1383 A-
es, in part or in w
t to the co
♦ Grease for splines -
G 000 100-
♦ Allocate grease using ⇒
rrectness of i
Electronic parts catalogue
l purpos
(ETKA) .
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
♦ Only vehicles with 1.0 l TSI petrol engine and 1.2 l TSI petrol
engine:

Caddy 2004 ➤ , Caddy 2011 ➤
♦ Additionally required for vehicles with a diesel engine: hook -

10–222 A/2-

battery .
– Remove engine cover panel from engine.
gr. 24 . en AG. V
olkswagen AG
ag does
lksw not
– Remove battery, battery cover and battery
db
y V tray ⇒ Electrical
o gu
ara
system; Rep. gr. 27 ; Battery; Removing
or
ise and installing battery . nte
h eo
ut ra
– Remove securing clip for gear
ss selector cable -arrow 1- from
a c
ce
e
nl
pt
du
an
itte
y li
erm
ab
Metal relay lever
ility
ot p
wit
, is n
– Remove securing clip for gate selector cable -arrow 2- from
h re
relay lever -B-.
hole
spec
es, in part or in w
t to the co
– Pull securing clip -arrow 3- off relay lever -B- and remove relay
lever.
rrectness of i
Plastic relay lever
l purpos
– Removing relay lever together with cable end-piece

⇒ page 55 .
nform
ercia

m
at
om

ion
c
-arrow 4- (⇒ previous figure).

in t
or
his
ate
do
riv

p
cum
for
en
g
– Use cable tie to tie up gear selector cable and gate selector
n
t.
yi Co
op
cable. C py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Caddy 2004 ➤ , Caddy 2011 ➤
– Pull clip -A- for pipe/hose assembly out of slave cylinder to

stop.
– Pull pipe/hose line -B- out of slave cylinder and seal opening.
Note
♦ There is no need to remove slave cylinder with securing bolts

-arrows-.
♦ Do not depress clutch pedal.
– Remove earth strap from upper starter bolt -1-.

– Remove connector -2- and cable -3- from starter.
– Remove upper engine/gearbox connecting bolts.
– Then remove upper securing bolt on starter.
– Remove filler pieces from upper edge of left and right wings.
– If there are hose and cable connections in area of engine sup‐
port eyes for support bracket - 10-222A- , remove these now.
AG. Volkswagen AG d
agen
Vehicles with 1.2 l TSI petrol engine Volksw
oes
not
by gu
d ara
rise nte
tho eo
au ra
– Set up support bracket - 10-222A-
ss together with adapters - c
10-222A/30- in front of support for bonnet.
ce
e
nl
pt
du
an
itte
– Hook in bracket - 10-222A/32- with shackle - 10 - 222 A /32-1- .

y li
erm
ab
ility
Other vehicles with petrol engines
ot p
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, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
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nf
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orm
m
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Prote AG.

Caddy 2004 ➤ , Caddy 2011 ➤
. Volkswagen AG
a gen AG d
– Set up support bracketVol - 10-222A- together with adapters
ksw
oes
not
gu
-
10-222A/30- in front
ed by of support for bonnet. ara
n is tee
or
– Use shackleaut-h 10-222 A /12- to attach spindle to engine on left
or
ac
(gearbox side).
ss
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spec
es, in part or in w
t to the co
rrectness of i
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nform
mercia
a
com
ti
on in
10-222A/30- , adapter - 10-222A/3- and adapter - 10-222A/16-
r
te o
thi
behind gas strut for bonnet.
s
iva
do
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rp
c
– Attach hook - 10-222A/10- at front right of engine.
um
fo
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ng
t.
yi
– Attach additional hook - 10-222A/2- to rear left of engine
Co
op py
-arrow-.
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by
cted agen
Prote AG.
– Then connect hook - 10-222A/2- using adapter - 10-222A/16- .

Continuation for all vehicles
– Take up weight of engine/gearbox assembly on spindles.
– Raise vehicle on lift.
– Remove noise insulation and front left wheel housing liner ⇒
General body repairs, exterior; Rep. gr. 66 ; Removing and
installing wheel housing liner; Front wheel housing liner .

Caddy 2004 ➤ , Caddy 2011 ➤
– Pull off connector -3- for reversing light.

– Unscrew nut -1- and remove bracket -2- for electrical cables.
– Remove starter ⇒ Electrical system; Rep. gr. 27 ; Starter;
– Remove protective cap for drive shaft, if fitted, from engine

-arrows-.
– Separate exhaust system at double clamp and unbolt exhaust

pipe bracket from subframe -arrows-. ⇒ Rep. gr. 26 ; Exhaust
system/silencers
– Disconnect drive shafts from flange shafts n Aand
G. Votie up
lkswageas
n Ahigh
G do
lkswage surface protection.
as possible, being careful not to damage es n
Vo ot g
by ua
ed ran
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th or
au ac
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ility
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wit
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hole
spec
Note
es, in part or in w
t to the co
Check to see if a cover plate -A- is installed above the right flange
shaft.
rrectness of i
– This cover plate must be removed now -arrows-.

l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
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ng
t.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.

Caddy 2004 ➤ , Caddy 2011 ➤
– Remove pendulum support. Unscrew bolts -arrows A, B- and

-C- to do this.
– If fitted, remove intake manifold between lock carrier and in‐
take air guide ⇒ Rep. gr. 24 ; Intake manifold .
n AG. Volkswagen AG
– Remove bolts -arrows-
olkfor
ge
swa engine mounting on
doright.
es n
o
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db ara
rise nte
tho eo
au ra
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pt
du
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itte
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ab
ility
ot p
wit
, is n
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hole
spec
es, in part or in w
t to the co
– Remove hexagon bolts -arrows 1- for left assembly mounting
from gearbox mounting.
rrectness of i
– Tilt engine/gearbox assembly by lowering it via spindles of
l purpos
support bracket - 10-222A- .

nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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rig ht
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Vo
Note
co lksw
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cted agen
Prote AG.
♦ In vehicles with a diesel engine, lower threaded spindle from

adapter - 10-222A/16- using winged nut, but not more than
until top of spindle is flush with top of nut -arrow-.
♦ All vehicles, when lowering gearbox assembly, observe cool‐
ant hose between engine and heat exchanger being careful
not to stretch it.
♦ Be careful of all lines when lowering gearbox.

Caddy 2004 ➤ , Caddy 2011 ➤
– Remove gearbox bracket by unscrewing bolts -arrows 2-.

To remove gearbox “0AH”, set up gearbox support - 3282/46- with
adjustment plate - 3282/46- .
– Insert gearbox support - 3282- in engine and gearbox jack -
V.A.G 1383A- .
ment plate .
– Attach support elements -A- to adjustment plate as illustrated.

– Position engine and gearbox jack under vehicle. Arrow -B- on
adjustment plate points in direction of vehicle travel.
AG. Volkswagen AG d
agen oes
olksw not
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– Align adjustment plate parallel to gearbox.
h re
ole,
spec
– Secure adapter - 3282/45- on gearbox using M8 nut -arrow-.
t to the co
– Then screw pin - 3282/29- into hole on gearbox for securing
bolt of pendulum support.
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
e
– Remove engine/gearbox connecting bolts -arrows- in vicinity

t
sd
va
of sump (bolts remain on engine when exhaust system is in

i
o
pr
cum
r
front of bolts).
fo
en
ng
t.
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pyri by
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o
by c lksw
cted agen
Prote AG.

Caddy 2004 ➤ , Caddy 2011 ➤
n AG. Volkswagen AG do5-speed manual gearbox 0AH - Edition 06.2016
lkswage es n
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– Remove last engine/gearbox
ir se
d b connecting bolt -arrow-. aran
o tee
h
aut or
ac
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e
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pt
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itte
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ility
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spec
es, in part or in w
t to the co
rrectness of i
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Note
For 1.4 l petrol engines, the engine/gearbox connecting bolt -A-
nf
ercia
o
rm
m
atio
om
n in
– Press gearbox off dowel sleeves.
or c
thi
e
– Observe intermediate plate on engine.

t
sd
iva
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cu
– Have a second mechanic press engine forwards.
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co
– Carefully guide gearbox with right-hand flange shaft -A- past
by lksw
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flywheel and intermediate plate as shown.
Prote AG.
– Using spindles of gearbox support - 3282- , tilt gearbox up‐

wards in vicinity of differential.
– Now swivel gearbox forwards towards front end at clutch hous‐

ing. Ensure sufficient clearance between right flange shaft
-A- and clutch pressure plate.
– Carefully lower gearbox and ensure sufficient clearance be‐
tween left flange shaft -B- and subframe.

Caddy 2004 ➤ , Caddy 2011 ➤

– When lowering gearbox, if necessary change position of gear‐
box using spindles of gearbox support - 3282- .
Note
Be careful of all lines when lowering gearbox.
2.4 Installing gearbox

– All threaded holes into which self-locking bolts are to be
screwed must be cleaned of residual locking fluid with a thread
chaser.
– Always renew self-locking nuts and bolts.
– Check whether dowel sleeves for aligning engine and gearbox
are fitted in cylinder block and install if necessary.
– Ensure that intermediate plate is correctly seated on engine.
– Clean input shaft splines and apply thin coat of grease for
clutch plate splines - G 000 100- .
AG. Volkswagen A
The clutch plate must slide easilylkto and
swa
gen fro on the input
G dshaft.
oes
n
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yV
To install gearbox “0AH”, set ed bup gearbox support - 3282/46- withuara
ris nte
adjustment plate - 3282/46-
utho . eo
ra
s a c
s
ce
le
ment plate .
un
pt
an
d
itte
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– Screw in support elements -A- to adjustment plate as illustra‐

erm
ab
ted.
ility
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– Place gearbox on engine and gearbox jack - V.A.G 1383 A- .

h re
ole,
spec
– Align adjustment plate and gearbox parallel to one another.

t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
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or
n thi
te
sd
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Cop py
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pyri by
Vo
co lksw
by
cted agen
Prote AG.

Caddy 2004 ➤ , Caddy 2011 ➤
– Then screw pin - 3282/29- into hole on gearbox for securing

bolt of pendulum support.
– Secure adapter - 3282/45- to gearbox using am M8 nut
-arrow-.
– Position engine and gearbox jack - V.A.G 1383 A- under ve‐
hicle; -arrow B- on adjustment plate points in direction of travel.
– Now turn gearbox upwards, near differential, using spindles of
gearbox support - 3282- .
– Position engine and gearbox jack - V.A.G 1383 A- under ve‐
hicle. Arrow on adjustment plate points in direction of vehicle
travel.
– Carefully lift gearbox.
Note
AG. Volkswagen AG d
agen oes
lksw not
Be careful of all lines when installing gearbox. d by Vo gu
ara
rise nte
tho eo
– Have a second mechanic press engine forwards. s au ra
c
s
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un
pt
– Then carefully guide gearbox and left-hand flange shaft -B-
an
d
itte
past subframe and guide right-hand flange shaft -A- past
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ab
clutch pressure plate.
ility
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wit
– Turn gearbox to installation position via spindles of gearbox
is n
h re
support - 3282- .
ole,
spec
t to the co
rrectness o
cial p
f in
– At the same time, carefully guide gearbox with right-hand
form
mer
flange shaft -A- past flywheel and intermediate plate as shown.
atio
om
n
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i
or
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te
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t.
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Cop py
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co lksw
by
cted agen
Prote AG.


Caddy 2004 ➤ , Caddy 2011 ➤
– Install gearbox, insert bolts (-arrows- in upper figure and lower

figure) and tighten to specified torque ⇒ page 58 .
Note
For 1.4 l petrol engines, the engine/gearbox connecting bolt -A-

– After gearbox has been bolted to engine, remove engine and

gearbox jack - V.A.G 1383 A- from gearbox.
– Install gearbox bracket using new bolts -arrows 2- and tighten

to specified torque ⇒ page 58 .
– Align engine and gearbox in installation
n AGposition
. Volkswagusing
en AG spin‐
dles of support bracket - 10-222A-
lkswag.e does
not
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– Screw in new bolts -arrows
or
ise 1- for the left engine/gearbox nte
eo
mounting and tighten
authto specified torque ⇒ page 58 . ra
ss c
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ility
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– Now install hexagon bolts -arrows- for engine mounting in right

es, in part or in w
assembly mounting and tighten to specified torque ⇒ Rep. gr.

t to the co
10 ; Removing and installing engine .

rrectness of i
WARNING
l purpos
Do not remove support bar - 10 - 222 A- until all bolts securing

the left and right assembly mountings have been tightened to
specified torque.
nform
mercia
a
com
tion in
– Insert upper engine/gearbox securing bolts and tighten to tor‐

r
te o
que specification ⇒ page 58 .

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co lksw
by
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Prote AG.

Caddy 2004 ➤ , Caddy 2011 ➤
– Install pendulum support with bolts -arrows A, B- and -C- and

tighten to specified torque ⇒ Running gear, axles, steering;
Rep. gr. 40 ; Subframe .
– Use new bolts for securing.
AG. Volkswagen AG d
agen oes
olksw not
Note d by V gu
ara
rise nte
tho eo
Install engines aand gearbox mounting free of tension ⇒ Rep. gr.r ac
u
10 ; Removing and installing engine .
s
ce
le
un
pt
an
d
itte
– Install intake pipe between lock carrier and intake air duct ⇒
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erm
ab
Rep. gr. 24 ; Intake manifold .
ility
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– Install flywheel cover plate -A- located behind right-hand
h re
ole,
flange shaft -arrows-
spec
– Fit drive shafts to gearbox ⇒ Running gear, axles, steering;
t to the co
Rep. gr. 40 ; Drive shafts; Removing and installing drive
shafts .
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
e
– Bolt exhaust pipe bracket onto subframe -arrows- ⇒ Rep. gr.

t
sd
iva
26 ; Exhaust system/silencers .
pr
cum
r
fo
en
ng
– Assemble exhaust system and set up free of tension ⇒ Rep.

t.
yi Co
op
gr. 26 ; Exhaust system/silencers . C py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Install drive shaft shield, if present, on engine -arrows- ⇒ Run‐

– Install starter motor ⇒ Electrical system; Rep. gr. 27 ; Starter;

Caddy 2004 ➤ , Caddy 2011 ➤
– Install bracket -2- for electrical wiring and tighten nut -1-.
– Attach connector -3- for reversing light.
lks wage es n
o ot g
byV ua
d ran
ir se
– Then install upper securing bolt for starter and
tho tighten to speci‐ tee
or
fied torque ⇒ page 58 . au ac
ss
ce
e
– Reconnect earth strap to upper starter bolt -1-.

nl
pt
du
an
itte
– Reconnect connector -2- and cable -3- to starter.
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
– Press clip -A- into slave cylinder onto stop.
l purpos
– Insert pipe/hose line -B- with a new seal into slave cylinder to
stop until securing clip -A- engages audibly in slave cylinder.
nform
ercia
– Test pipe/hose assembly by tugging on it.

m
at
om
io
– Press pipe/hose assembly into retainer -C- on gearbox.
n
c
in t
or
his
e
– Bleed clutch mechanism after installing pipe/hose assembly

at
do
riv
⇒ page 29 .
p
cum
for
en
ng
t.
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t. rig
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pyri by
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co lksw
by
cted agen
– Install cable support bracket on gearbox and tighten bolts Prote AG.
-arrows-.

Caddy 2004 ➤ , Caddy 2011 ➤
– Install gearbox selector lever -A- and tighten hexagon nut

-arrow 4-.
Volkswagen AG
– Insert relay lever -B- into mounting of selector cover.
swa
gen AG
.
does
olk not
yV gu
– At the same time, swing relay lever so thatseshoe
d b engages in ara
nte
guide of gearbox selector lever -A-. ho
ri eo
aut ra
c
– Secure relay lever with new securingssclip -arrow 3-.
ce
e
nl
pt
du
– Spread a small quantity of grease - G 000 450 02- on pins
an
itte
y li
arrows of gearbox selector lever -A- and relay lever -B-.
erm
ab
ility
ot p
– Secure gear selector cable with a new securing clip
wit
-arrow 1- and gate selector cable with a new securing clip
, is n
h re
-arrow 2-.
hole
spec
– Adjust selector mechanism ⇒ page 52 .
es, in part or in w
t to the co
– Check gear oil ⇒ page 83 .
– Install front left wheel housing liner ⇒ General body repairs,
rrectness of i
exterior; Rep. gr. 66 ; Removing and installing wheel housing
liners; Front wheel housing liners .
l purpos
– Install noise insulation beneath engine/gearbox ⇒ General

body repairs, exterior; Rep. gr. 66 ; Noise insulation .
nf
ercia
orm
– Install battery tray, battery cover and battery ⇒ Electrical sys‐
m
atio
m
tem; Rep. gr. 27 ; Battery; Removing and installing battery .

o
n in
or c
thi
– Install complete air filter housing ⇒ Rep. gr. 23 or ⇒ Rep. gr.
te
sd
a
24 .
iv
o
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rp
cu
o
m
– Install engine cover.
f
en
ng
t.
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op
– Follow procedure after connecting battery ⇒ Electrical system;
C py
t. rig
gh
Rep. gr. 27 ; Battery; Disconnecting and connecting battery .
ht
pyri by
Vo
co lksw
by
Torque settings
cted agen
Prote AG.
♦ ⇒ “2.1 Specified torques for gearbox”, page 58

Caddy 2004 ➤ , Caddy 2011 ➤
3 Transporting gearbox
⇒ “3.1 Transporting gearbox”, page 82
3.1 Transporting gearbox

– Bolt gearbox lifting tackle - 3336- to clutch housing.
– Adjust support beam on sliding piece using locking pin

-arrow-.
No. of holes visible = 5
– Lift gearbox using workshop crane and gearbox lifting tackle -
3336- .
– Set gearbox aside, for example in a transport container.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
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d
itte
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
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fo
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.

Caddy 2004 ➤ , Caddy 2011 ➤
4 Gear oil
⇒ “4.1 Checking gear oil level”, page 83
4.1 Checking gear oil level

lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
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un
pt
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d
itte
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ility
ot p
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is n
♦ Multi-point bit - 3357-
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
Gear oil specification ⇒ Electronic parts catalogue (ETKA) .⇒

sd
iva
o
pr
cum
r
– Remove noise insulation beneath engine/gearbox ⇒ General

fo
en
ng

t.
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Cop py
– To check gear oil level, remove oil filler plug -arrow-.
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The oil level is correct, when the gearbox is filled to lower edge
by lksw
cted agen
Prote
of filler hole.
AG.
– Tighten bolt -arrow-.

When filling with oil, note the following:
– Unscrew and remove bolt -arrow- to check gear oil level.
– Top-up gearbox oil to lower edge of filler plug drilling.
– Screw in bolt -arrow- for checking gear oil level.
– Start engine, engage gear and allow gearbox to turn for ap‐
prox. 2 minutes.
– Stop engine and remove bolt -arrow-.
– Top up with gear oil to lower edge of filler hole.
– Tighten bolt -arrow-.
4. Gear oil 83
Caddy 2004 ➤ , Caddy 2011 ➤
Various versions of oil filler and drain plugs

I - Oil filler plug/oil drain plug with multi-point socket head, 25 Nm
II - Oil filler plug/oil drain plug with hexagon socket head, 30 Nm
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
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nl
pt
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itte
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
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t.
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Cop py
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rig ht
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co Vo
by lksw
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Prote AG.

agen
AG. Volkswagen AG d
oes
Caddy 2004 ➤ , Caddy 2011 ➤
olksw 5-speed not manual gearbox 0AH - Edition 06.2016
V g
by ua
ed ran
oris tee
th or
u
5 Dismantling and assembling gearbox ss
a ac
ce
e
nl
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⇒ “5.1 Schematic overview - gearbox”, page 85
an
itte
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⇒ “5.2 Assembly overview - selector unit”, page 86
ility
ot p
⇒ “5.3 Assembly overview - selector forks”, page 87
wit
, is n
h re
hole
⇒ “5.4 Assembly overview - gearbox housing/5th gear”,
spec
page 88
es, in part or in w
t to the co
⇒ “5.5 Assembly overview - input shaft, output shafts, differential,
selector unit”, page 89
rrectness of i
⇒ “5.6 Repairing selector unit”, page 90
l purpos
⇒ “5.7 Repairing selector forks”, page 92

⇒ “5.8 Dismantling and assembling gearbox”, page 95
nf
ercia
o
5.1 Schematic overview - gearbox
rm
m
atio
om
n in
or c
thi
1 - 1st gear
te
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2 - 2nd gear
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3 - 3rd gear
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4 - 4th gear rig ht
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5 - 5th gear Prote
cted AG.
agen
6 - Gearbox housing cover

7 - Gearbox housing
8 - Reverse gear wheel
9 - Selector mechanism
❑ (Selector forks)
10 - Clutch housing
11 - Input shaft
12 - Output shaft
13 - Differential
5. Dismantling and assembling gearbox 85

Caddy 2004 ➤ , Caddy 2011 ➤
5.2 Assembly overview - selector unit
1 - Sleeve
❑ For selector shaft
❑ Driving in and out
⇒ page 107
2 - Selector shaft with selector
shaft cover
❑ Renew together
3 - Retaining pin
❑ For adjusting selector
mechanism
❑ Removing ⇒ page 91
❑ Installing ⇒ Fig.
⇒ page 91 AG. Volkswagen AG d
agen oes
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4 - Deflector lever d by
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❑ Fitting position hor eo
ut
⇒ page 39 ss a ra
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5 - Sleeve bearing
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6 - Sealing ring
erm
ab
❑ Lever out with a screw‐
ility
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driver.
wit
is n
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ole,
spec
7 - Cap t to the co
❑ For gearbox breather
rrectne
❑ Install so that master

spline aligns with selec‐
s
tor shaft
s o
cial p
❑ Can be renewed with

inform
the selector mechanism

mer
installed
atio
om
c
i
or
⇒ page 39
thi
te
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9 - Nut
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ng
❑ Renew after removal yi

t.
Co
op
❑ 23 Nm
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Prote AG.

Caddy 2004 ➤ , Caddy 2011 ➤
5.3 Assembly overview - selector forks
Note
It is not necessary to dismantle the selector fork group ⇒ Item 1 (page 87) in order to dismantle and assemble
selector segments, lock washers and angular contact ball bearings.
1 - Selector fork group with se‐

lector plate
2 - Selector segment for 3rd
and 4th gear
❑ Identification
⇒ page 94
❑ After installation, selec‐
tor segment must still ro‐
tate freely
3 - Angular contact ball bearing
❑ Press inner race into
outer race ⇒ page 95
❑ Installing ⇒ page 95 AG. Volkswagen AG d
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4 - Retainer by
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❑ Removing s⇒
s page 94
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5 - 1st/2nd gear selector seg‐

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ment
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❑ Identification
wit
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⇒ page 94
h re
hole
spec
❑ After lock washer is in‐

es, in part or in w
stalled, segment must

t to the co
still rotate freely

❑ Selector fork with selec‐
tor segment
rrectness of i
⇒ page 94
l purpos
6 - 5th gear selector fork with

selector segment
nform
ercia
❑ Selector segment is per‐

manently connected to
m
at
om
selector fork.
ion
c
in t
r
❑ Identification ⇒ page 93
o
his
ate
do
riv
7 - Locating pin
p
cum
or
❑ For 5th gear selector fork.

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Caddy 2004 ➤ , Caddy 2011 ➤
5.4 Assembly overview - gearbox housing/5th gear
1 - Gearbox housing
2 - Gear wheel for 5th gear
⇒ page 103
3 - Locking ring
❑ Determining thickness AG. Volkswagen AG d
⇒ page 103 lksw
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4 - Seal rised ara
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5 - Gearbox housing cover aut ra
ss c
ce
le
If gearbox housing cover is in‐
un
pt
stalled with gearbox installed,
an
d
itte
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check oil level and top up with
erm
ab
gear oil ⇒ page 83 .
ility
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wit
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6 - Bolt
h re
ole,
spec
❑ 5 Nm +90°
t to the co
7 - Locking ring
rrectne
❑ Determining thickness
⇒ page 103
ss o
cial p
f
8 - Synchro-hub with locking
inform
collar and stop ring for 5-speed
mer
gearbox
atio
om
❑ Dismantling and assem‐
n
c
i
or
n
bling ⇒ page 111
thi
te
sd
va
9 - Synchro-ring for 5th gear

i
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pr
cum
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10 - Synchromeshed gear, 5th

t.
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gear Cop py
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11 - Needle bearing p by
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cted
❑ for 5th gear
agen
Prote AG.
12 - 5th gear selector fork

❑ Dismantling and assembling ⇒ page 87
13 - Locating pin
❑ for 5th gear selector fork.

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2004 ➤ , Caddy 2011 ➤
ra
c
s
s 5-speed manual gearbox 0AH - Edition 06.2016
ce
le
un
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d
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5.5 Assembly overview - input shaft, output shafts, differential, selector unit
y li
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ility
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1 - Differential
h re
ole,
❑ Dismantling and assem‐
spec
bling ⇒ page 132
t to the co
2 - Gearbox housing
❑ Servicing ⇒ page 104
rrectne
3 - Oil drain plug
s
❑ 25 Nm
s o
cial p
f
4 - Flange shaft with compres‐
inform
sion spring
mer
atio
❑ Assembling
om
n
⇒ page 132
c
i
or
n thi
e

t
sd
va
⇒ page 95
i
o
pr
cum
r
fo
en
ng
5 - Countersunk bolt yi
t.
Co
op
❑ 25 Nm
C py
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6 - Bolt
op Vo
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cted agen
❑ Renew after removal Prote AG.
❑ To secure bearing
mounting with deep
groove ball bearing for
input and output shafts
⇒ Item 16 (page 90) .
❑ 5 Nm +90°
7 - Nut
❑ For selector mechanism
⇒ Item 15 (page 89) .
❑ 23 Nm
8 - O-ring
9 - Pivot pin
10 - Bolt
❑ 5 Nm +90°
11 - Selector shaft with selector shaft cover
❑ (Selector unit)
12 - Bolt
❑ 5 Nm +90°
13 - Reversing light switch
❑ Changed to captive seal shortly after introduction of gearbox.
❑ 20 Nm
14 - Sealing ring
❑ If fitted, renew after removal
15 - Selector mechanism
❑ (Selector forks)

Caddy 2004 ➤ , Caddy 2011 ➤
16 - Input shaft and output shaft with bearing mounting and deep groove ball bearing
❑ If bearing support is separated from gearbox housing, the support must always be renewed
❑ Pressing bearing mounting off and on ⇒ Item 8 (page 110) .
❑ Dismantling and assembling input shaft ⇒ page 111
❑ Dismantling and assembling output shaft ⇒ page 121
17 - Reverse gear shaft
18 - Reverse gear wheel agen
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19 - Bolt byV gu
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❑ Renew after removal utho eo
ra
a c
❑ For reverse gear shaft. ss
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un
❑ 25 Nm +90°
pt
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d
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20 - Oil collector
erm
ab
ility
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21 - Magnet
wit
is n
h re
❑ Insert in oil guide ⇒ Item 22 (page 90) .
ole,
spec
22 - Oil guide
t to the co
5.6 Repairing selector unit
rrectness
o
cial p
f
equipment required
inform
mer
♦ Tube - VW 423-
atio
om

n
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or
1331-
thi
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Cop py
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py by
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Prote AG.

Caddy 2004 ➤ , Caddy 2011 ➤
♦ Tube - T10203- lkswage es n
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Removing retaining pin -A- from selector shaft cover
ss
ce
e
nl
pt
– Remove outer part of retaining pin.
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– Then carefully lever out retaining pin using a screwdriver.
erm
ab
ility
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hole
spec
es, in part or in w
t to the co
rrectness of i
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Drive retaining pin -A- into selector shaft cover
nf
ercia
Installation position:
orm
m
Marking -1- aligns with marking -2- on selector cover.
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Prote AG.
Inserting oil seal -A- onto stop

Caddy 2004 ➤ , Caddy 2011 ➤
5.7 Repairing selector forks

equipment required
♦ Pressure plate - VW 402-
♦ Press tool - 3290/1-
♦ Press tool - VW 431-
♦ Assembly tool - 3301-
♦ Thrust piece with spacer
sleeve - VW 472-
AG. Volkswagen AG d
♦ Drift - 10 - 206- agen oes
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ility
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hole
spec
es, in part or in w
t to the co
rrectness of i
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nf
ercia
orm
m
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om
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Prote AG.

Caddy 2004 ➤ , Caddy 2011 ➤
♦ Assembly mandrel - 10 -
508- agen
AG. Volkswagen AG d
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♦ Release lever - 80–200- d by gu
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♦ Clamp - 2070- auth eo
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ility
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es, in part or in w
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rrectness of i
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nform
mercia
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ion
c
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or
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ate
do
priv
cum
for
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Cop py
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co lksw
by
cted agen
Prote AG.
Identification of selector segments and selector fork for 5th gear

with selector segments
Dimension -a-
1- Selector segment for 1st and 2nd gears = 10.2 mm
2- Selector segment for 3rd and 4th gears = 78.6 mm
3- 5th gear selector fork with selector segments = 79.5 mm

Caddy 2004 ➤ , Caddy 2011 ➤
Selector fork 1st/2nd gear with selector segments

Dimension -a- = 75 mm
Removing lock washer

– Clamp selector fork in vice with protective jaw covers -B-.
– Lever off lock washer -A- in direction of arrow.
AG. Volkswagen AG d
Installing lock washer agen oes
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– Press lock washer into groove of detent segment
rise
d
using socket nte
o
and spinner handle. auth eo
ra
ss c
ce
le
un
pt
Note
an
d
itte
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erm
After lock washer is installed, detent segment must still rotate ab

ility
ot p
freely. wit
is n
h re
ole,
spec
A - Spinner handle with 10 mm socket
t to the co
B - Vice clamp
Removing angular contact ball bearing

rrectnes
Note
s o
cial p
f inform
When removing and installing angular contact ball bearing, do not

mer
bend selector forks.

atio
om
n
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Prote AG.

Caddy 2004 ➤ , Caddy 2011 ➤
Pressing inner race -A- of angular contact ball bearing into outer
race
Inner race must engage in outer race.
Pulling angular contact ball bearing into selector fork to stop

Depression in thrust piece - 3290/1- faces ball bearing.
5.8 Dismantling and assembling gearbox
AG. Volkswagen AG d
agen oes
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d by ara
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nl
pt
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ab
ility
ot p
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
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n in
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Prote AG.

Caddy 2004 ➤ , Caddy 2011 ➤

equipment required
♦ Support clamp - VW 313-
AG. Volkswagen AG d
♦ Pressure plate - VW 402- agen oes
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♦ Press piece - VW 412- rised
nte
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ut
♦ Adapter - T10235- ss a ra
c
ce
♦ Guide bolt - T10079- le
un
pt
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rm
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pe
ility
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es, in part or in w
t to the co
rrectness of i
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mercia
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tion in
r
te o
thi
s
iva
do
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rp
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fo
en
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t.
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Cop py
ht. rig
rig ht
py by
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by lksw
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Prote AG.

Caddy 2004 ➤ , Caddy 2011 ➤
♦ Engine and gearbox sup‐

port - VW 540-
♦ Drip tray - V.A.G 1306-
1331-
♦ Thrust block - T10083-
AG. Volkswagen AG d
agen oes
♦ Press tool - T10085- Volksw not
gu
d by ara
e
♦ Sealant - AMV 188 200 03- horis nte
eo
aut ra
ss c
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nl
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ab
ility
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, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
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or c
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Prote AG.
Removing and installing gearbox housing cover, clutch housing,

selector shaft with selector mechanism cover, input shaft, output
shaft, differential and selector mechanism
Removing
– Secure gearbox to repair stand Engine and gearbox support -
VW 540- -arrows-.
– Place drip tray - V.A.G 1306- underneath.
– Drain gear oil.

Caddy 2004 ➤ , Caddy 2011 ➤
– Remove clutch release lever -A- together with release bearing

and guide sleeve -arrows-.
– Remove right flange shaft securing bolt -B-.
– Screw 2 bolts into flange and counterhold flange shaft using a
lever.
– Remove flange shaft along with spring, thrust washer and ta‐
pered ring.
– Unbolt gearbox housing cover -arrow- and carefully pull it off.
– Pull out pivot pin -1- for 5th gear -2- and remove selector fork.
olkswagen AG
en AG. V
– Remove securing clipolk-3-
swafor 5th gear synchro-hub.
g does
not
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by a
– Remove locking oris collar with synchro-hub, synchromeshedntgear
ed ra
ee
for 5th gearauwith
th synchro-ring and needle bearing from outputor
ac
shaft. ss
ce
le
un
pt
– Remove securing clip -4- for gear wheel for 5th gear and re‐
an
d
itte
move gear wheel.

y li
erm
ab
ility
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wit
is n
h re
ole,
spec
t to the co
– Remove bearing mounting securing bolts -A- from input and

output shafts.
rrectne
– Unscrew hexagon collared nut -B- for securing reverse gear

selector mechanism.
s
– Remove securing bolt for left flange shaft -C- by screwing two
s o
cial p
bolts into flange and counterholding flange shaft with a lever.

f inform
mer
– Pull out flange shaft -C- with spring.

atio
m
– Turn gearbox in support bracket so that clutch housing is up‐

o
n
c
i
or
wards.
thi
te
sd
va
– Remove securing bolts from clutch housing side for securing

i
o
pr
cum
clutch housing to gearbox housing.

r
fo
en
ng
t.
yi Co
– Remove clutch housing, if necessary carefully levering up all Cop py
around along protruding housing flange and alternating be‐
t. rig
gh ht
yri
tween sides, being careful not to damage sealing surfaces.
p by
o Vo
by c lksw
cted agen
– Do not cant the clutch housing. This prevents damage to roller
Prote AG.
bearings and their bearing seats on the input and output

shafts.

Caddy 2004 ➤ , Caddy 2011 ➤
– Remove differential -A- from gearbox housing.
– Then remove oil collector -A- and oil guide -B- with magnet
from gearbox housing.
AG. Volkswagen AG d
agen oes
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V gu
d by ara
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ss c
– Remove selector shaft with selector cover -A-. Place selector
ce
e
nl
pt
shaft in neutral. Then remove bolts -arrows- and pull selector

du
an
itte
shaft out of gearbox housing.

y li
erm
ab
ility
– Remove pivot pins -B- located on underside of gearbox.

ot p
wit
, is n
– Remove reversing light switch -C-.

h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
– Remove bolt -A- for securing reverse gear wheel shaft.

nform
ercia
– Remove pivot pins -B- located on bottom of gearbox.

m
at
om
ion
c
in t
r
Note
o
his
ate
do
priv
Do not remove sealing cover -arrow- when dismantling gearbox.

um
for
en
ng
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Cop py
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by c lksw
cted agen
Prote AG.

Caddy 2004 ➤ , Caddy 2011 ➤
– Press out input shaft, output shaft with bearing mounting, se‐
lector mechanism (selector forks) and reverse gear together.
Note
♦ Position gearbox housing so that dowel sleeves in the gearbox

will not be damaged.
♦ When pressing out, get help from second mechanic to ensure
components do not fall out. agen
AG. Volkswagen AG d
oes
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a
– Press input shaft andrisoutput shaft off bearing mounting with rante
ed
deep groove ball bearing
tho ⇒ page 114 . eo
s au ra
c
s
Installing
ce
e
nl
pt
du
an
itte
y li
erm
ab
Note
ility
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♦ Press bearing mounting with deep groove ball bearing onto
h re
input shaft and output shaft ⇒ page 117 .
hole
spec
es, in part or in w
♦ Press needle roller bearing sleeve for synchromeshed gear for
t to the co
5th gear onto input shaft ⇒ page 117 .
rrectness of i
– Position assembled components, input shaft -2- and output
shaft -1- with bearing mounting for deep groove ball bearing,
l purpos
in thrust piece - T10085- .

– Insert selector mechanism (selector forks) -4- in the shaft lock‐ nf
ercia
o
ing collars.
rm
m
atio
m
– Install reverse gear shaft -3- with reverse gear.

o
n in
or c
thi
– Screw guide pin - T10079- onto stud (secures reverse gear)

te
sd
a
-arrow-.
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Cop py
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rig ht
py by
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by lksw
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Prote AG.

Caddy 2004 ➤ , Caddy 2011 ➤
– Insert components together in gearbox housing. To do this,

guide guide pin - T10079- through hole for attachment of se‐
lector mechanism in gearbox housing.
– Remove guide pin - T10079- .
– Before pressing in bearing mounting, check selector forks are
engaged correctly in locking collar.
– Carefully press in bearing mounting together with input shaft

and output shaft to stop.
lkswage es n
o ot g
byV ua
d ran
ir se tee
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u or
a ac
ss ce
le
un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
– Install bolt -A- for securing reverse gear wheel shaft.

es, in part or in w
t to the co
– Install pivot pin -B- in bottom of gearbox.

rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
– Install reversing light switch -C-.

r
rp
cum
fo
en
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– Install pivot pin -B- in top of gearbox.

n
t.
yi Co
Cop py
– Place selector plates in neutral.
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pyri by
Vo
co
– Apply sealant - AMV 188 200 03- evenly to sealing surface of
by lksw
cted agen
Prote
selector mechanism cover.
AG.
– Install selector shaft with selector cover -A-. Then tighten bolts
-arrows-.

Caddy 2004 ➤ , Caddy 2011 ➤
– Using new bolts -A-, tighten bearing mounting for input and
output shafts.
Note
Tighten bolts to specified torque, working from centre outwards

using alternate sequence.
– Tighten hexagon flange nut -B- for securing selector mecha‐

nism (selector forks).
– Then insert oil collector -A- in notch -1- and in hole -2- of gear‐
box housing.
– Now insert oil guide -B- into gearbox housing.

– The magnet is inserted into the oil guide -B-.
AG. Volkswagen AG d
agen oes
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rise nte
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an
d
itte
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erm
ab
ility
ot p
– Install differential -A-.

wit
is n
h re
– Apply sealant - AMV 188 200 03- evenly to sealing surface.

ole,
spec
– Secure clutch housing to gearbox housing.

t to the co
– Turn gearbox in support bracket so that gearbox housing is

upwards.
rrectness o
cial p
f inform
mer
atio
om
n
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Cop py
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pyri by
Vo
co lksw
by
cted agen
Prote AG.

Caddy 2004 ➤ , Caddy 2011 ➤
– Install gear wheel for 5th gear -1-.

Installation position of 5th gear wheel:
The high shoulder -arrow- faces gearbox housing cover.
– Install synchromeshed gear for 5th gear with needle bearing.
– Place 5th gear synchro-ring on synchromeshed gear.
– Install 5th gear synchro-hub complete with locking collar and
stop ring.
– Insert 5th gear selector fork -2- and push in pivot pin -1- to stop
in direction of -arrow-.
– Determine new retaining ring -arrow-.
– Determine thickest possible retaining rings which will still fit for
input shaft -3- and output shaft -4- and install them.
Available circlips
Thickness (mm) Article number
2.00 085 311 187
2.10 085 311 187 A
2.20 085 311 187 B
– Tighten gearbox housing cover.
G. Volkswagen
– Install both flange shafts with springs,
wage
n A thrust washers
AG do
eand
s no ta‐
olks
pered rings. d by V t gu
a
e ran
ris tee
– Install clutch release
ut
ho lever together with release bearing and or
guide sleeve ⇒ spage
s a 30 . ac
ce
e
nl
pt
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an
itte
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erm
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ility
ot p
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, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Caddy 2004 ➤ , Caddy 2011 ➤
6 Gearbox housing, clutch housing

⇒ “6.1 Assembly overview - gearbox housing/clutch housing”,
page 104
⇒ “6.2 Assembly overview - clutch housing”, page 106
⇒ “6.3 Repairing gearbox housing/clutch housing”, page 107
6.1 Assembly overview - gearbox housing/clutch housing

AG. Volkswagen AG d
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1 - Clutch housing d by V gu
ara
ise nte
❑ If renewed, hor adjust differ‐ eo
ut
entialss⇒ page 137
a ra
c
ce
le
2 - Input shaft seal

un
pt
an
d
itte
❑ Lever out with a screw‐
y li
rm
ab
driver.
pe
ility
❑ Installing ⇒ Fig.
ot
wit
, is n
⇒ page 107
h re
hole
spec
3 - Ball pin
es, in part or in w
t to the co
❑ Lubricate with MoS2
grease.
❑ 20 Nm
rrectness of i
4 - Oil seal for right flange shaft
l purpos
❑ Renewing with gearbox

installed ⇒ page 127
nform
ercia
5 - Hydraulic fluid filler plug

m
a
com
❑ 30 Nm
ion in
r
te o
6 - Shim S2
thi
s
iva
do
❑ For differential
r
rp
cum
fo
en
ng
t.
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⇒ page 137
Co
Cop py
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gh
7 - Tapered roller bearing outer
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Prote AG.
❑ Pressing out of and into
clutch housing
⇒ page 132
❑ If renewed, adjust differ‐
ential ⇒ page 137
8 - Bolt
❑ 5 Nm +90°
9 - Tapered roller bearing outer race
❑ Pulling out of and pressing into clutch housing ⇒ page 132
❑ If renewed, adjust differential ⇒ page 137
10 - Shim S1
❑ Discontinued without substitute
11 - Dowel sleeve
12 - Gearbox housing
❑ If renewed, adjust differential ⇒ page 137

Caddy 2004 ➤ , Caddy 2011 ➤
13 - Oil drain plug

AG. Volkswagen AG d
❑ 25 Nm lksw
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14 - Oil seal for left flange shaft rised ara
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❑ Renewing with gearbox installed a⇒ ut page 126
h
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15 - Sleeve
ce
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nl
pt
du
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❑ For selector shaft
itte
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ab
❑ Driving in and out ⇒ page 107
ility
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16 - Sealing cover
wit
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h re
❑ Apply sealant - AMV 188 200 03- before bolting on.
hole
spec
es, in part or in w
17 - Locking ring
t to the co
❑ Insert in groove of cylindrical roller bearing
18 - Locking ring
rrectness of i
❑ Insert in groove of cylindrical roller bearing
l purpos
19 - Cylindrical roller bearing

❑ For input shaft
nform
ercia
❑ Pulling out and pressing in ⇒ Item 21 (page 110)

m
at
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i
on
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or
❑ For output shaft
his
ate
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❑ Pulling out and pressing in ⇒ Item 2 (page 119)

p
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for
21 - Plugs
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❑ Insert into hole in clutch housing. C py
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by c lksw
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Prote AG.
6. Gearbox housing, clutch housing 105

Caddy 2004 ➤ , Caddy 2011 ➤
6.2 Assembly overview - clutch housing
1 - Countersunk bolt
❑ 25 Nm
2 - Flange shaft with compres‐
sion spring
❑ Assembling
⇒ page 132
⇒ page 95
3 - Bolt
❑ 5 Nm +90°
4 - Clutch housing
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gen AG does
5 - Gearbox housingVolkswa not
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❑ Servicingris ⇒ page 104
ed nte
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6 - Clutchssrelease
au lever ra
c
❑ With guide sleeve and
ce
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nl
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release bearing
an
itte
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erm
ab
⇒ page 95
ility
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7 - Bolt
h re
hole

spec
es, in part or in w
❑ 5 Nm +90°
t to the co
rrectness of i
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ate
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for
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Cop py
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Vo
co lksw
by
cted agen
Prote AG.

Caddy 2004 ➤ , Caddy 2011 ➤
6.3 Repairing gearbox housing/clutch housing

equipment required
♦ Centring pin - 12 - 551-
♦ Pin - 2026-
♦ Press tool - T40008-
1331-
♦ Sealant - AMV 188 200 03-
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Driving in input shaft oil seal flush

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pyri by
Vo
co lksw
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cted agen
Prote AG.
6. Gearbox housing, clutch housing 107

Caddy 2004 ➤ , Caddy 2011 ➤
Driving out selector shaft sleeve -A-
Driving in selector shaft sleeve -A- to stop
AG. Volkswagen AG d
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cial p
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Prote
108
AG.
Rep. gr.34 - Controls, housing
wage e
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olks Caddy 2004 ➤ , Caddys n2011ot g ➤
b ua
5-speed ir se manual gearbox 0AH - Edition 06.2016
d ran
tee
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ss
35 – Gears, shafts
ce
le
un
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d
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1 Input shaft
ility
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is n
h re
⇒ “1.1 Assembly overview - input shaft”, page 109
ole,
spec
⇒ “1.2 Dismantling and assembling input shaft”, page 111
t to the co
1.1 Assembly overview - input shaft
rrectne
Note
ss o
♦ When installing new gear wheels, consult technical data ⇒ page 4 and ⇒ Electronic parts catalogue (ETKA) .
cial p
f inform
♦ Install all bearings, synchromeshed gears and synchro-rings on input shaft with gear oil.
mer
atio
m
♦ Do not interchange synchro-rings. When reusing always fit to the original gear.
o
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pr
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1 - Locking ring
um
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t.
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op py
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⇒ page 103 p by
co Vo
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2 - 5th gear locking collar with Prote AG.
synchro-hub
⇒ page 117
❑ Assembling 5th gear
locking collar and syn‐
chro-hub ⇒ page 118
❑ Dismantling
⇒ page 117
⇒ page 95
❑ Check for wear
⇒ page 115
4 - Synchromeshed gear, 5th
gear
5 - Needle bearing
❑ for 5th gear
❑ Renew together with
6 - Sleeve
❑ for 5th gear needle
bearing
❑ Renew together with
❑ Press off with bearing
support and deep
groove ball bearing
⇒ page 114
❑ Pressing on ⇒ page 117
1. Input shaft 109

Caddy 2004 ➤ , Caddy 2011 ➤
7 - Gearbox housing
8 - Bearing mounting with deep groove ball bearing
❑ Renew deep groove ball bearing only together with bearing support
❑ Pressing off ⇒ page 114
9 - Input shaft
10 - Needle bearing
❑ for 3rd gear
11 - Synchromeshed gear, 3rd gear
12 - Synchro-ring for 3rd gear
❑ Check for wear ⇒ page 115
13 - Locking collar with synchro-hub for 3rd and 4th gear
❑ Installation position, locking collar and synchro-hub ⇒ page 115
❑ Press off with 3rd gear synchromeshed gear ⇒ page 114
❑ Dismantling ⇒ page 114
❑ Assembling ⇒ page 115 .
AG. Volkswagen AG d
15 - Synchromeshed gear, 4th gear agen oes
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16 - Sleeve rised
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❑ for 4th gear needle bearing aut ra
c
ss
❑ Renew together with ⇒ Item 17 (page 110)
ce
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nl
pt
du
❑ Press off with 3rd gear synchromeshed gear ⇒ page 114
an
itte
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ility
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17 - Needle bearing
wit
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❑ for 4th gear
hole
spec
❑ Renew together with ⇒ Item 16 (page 110)
es, in part or in w
t to the co
18 - Thrust washer
19 - Inner race for cylindrical roller bearing rrectness of i
l purpos

20 - Locking ring
nform
ercia

m
at
❑ Determining thickness ⇒ page 116

om
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ate
❑ With retaining ring

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❑ Installation position: retaining ring in bearing faces input shaft

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❑ Pressing in ⇒ page 114 .
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22 - Clutch housing
by
cted agen
Prote AG.
23 - Spring
110 Rep. gr.35 - Gears, shafts

Caddy 2004 ➤ , Caddy 2011 ➤
24 - 3rd and 4th gear locking collar

25 - 3rd and 4th gear synchro-hub
26 - Locking pieces
27 - Spring
28 - Locking pieces
29 - Synchro-hub for 5th gear n AG. Volkswagen AG do
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30 - Locking collar for 5th gear ir se
d b ran
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31 - Stop ring aut or
ac
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❑ Prevents locking pieces from drifting out
ce
le
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1.2 Dismantling and assembling input shaft
spec
t to the co
equipment required
rrectne
s
s o
cial p
f in
♦ Press piece - VW 407-
form
mer
atio
om
n
c
♦ Tube - VW 415 A-
i
or
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te
sd
a
♦ Tube - VW 422-
iv
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t.
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Prote AG.
1. Input shaft 111

Caddy 2004 ➤ , Caddy 2011 ➤
♦ Thrust piece with spacer

sleeve - VW 472-
♦ Tube - VW 516-
♦ Extension - 30 - 23-
♦ Drift sleeve - 30 - 100-
AG. Volkswagen AG d
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t to the co
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cial p
f inform
mer
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c
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or
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ng
t.
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Cop py
t. rig
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pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Caddy 2004 ➤ , Caddy 2011 ➤
♦ Circlip pliers - VW 161 A-

♦ Tube - 2010-
♦ Thrust block - T10083-
♦ Pressure plate - T10084A-
♦ -1- internal puller, e.g.
KUKKO 21-5 - VAS 251
611-
♦ -4- counter support, e.g.
KUKKO 22-2 - VAS 251
623-
♦ -Feeler gauge-
AG. Volkswagen AG d
agen oes
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ris nte
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Pulling cylindrical roller bearing out of clutch housing

un
pt
an
d
itte
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– When pulling out, squeeze together retaining ring -arrow- of

rm
ab
cylindrical roller bearing, using pliers -C-.

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ility
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A - Counter support , e.g. -Kukko 22/2-

h re
hole
B - Internal puller, 30 … 37 mm , e.g. -Kukko 21/5-

spec
es, in part or in w
t to the co
rrectness of i
l purpos
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tion in
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te o
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en
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t.
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Cop py
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rig ht
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co Vo
by lksw
cted agen
Prote AG.
1. Input shaft 113

Caddy 2004 ➤ , Caddy 2011 ➤
Pressing cylindrical roller bearing into clutch housing

– Support gearbox housing with tube - VW 415 A- (not visible
here) directly below bearing support.
– When pressing in, squeeze together retaining ring -arrow- for
cylindrical roller bearing using pliers -A-.
– Remove pliers before cylindrical roller bearing is in installation
position. Retaining ring must engage in groove of clutch hous‐
ing.
Pressing off bearing mounting with deep groove ball bearing

n AG. Volkswagen AG
wa oe ge d
– Slide locking collar for 1st and olks gear towards 2nd gear.s not g
V2nd
by ua d ran
ise
– Then slide thrust plate t-hoT10084/A-
r sideways onto input shaft tee
or
to stop. ss au ac
ce
le
– Insert centring pins in thrust piece - T10081- into holes in input

un
pt
an
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and output shafts.

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spec
es, in part or in w
t to the co
Pressing off cylindrical roller bearing inner race
– First remove circlip with circlip pliers - VW 161 A- .
– Press off inner race for cylindrical roller bearing together with rrectness of i
l purpos
thrust washer, synchromeshed gear for 4th gear with needle

bearing, locking collar and synchro-hub for 3rd and 4th gears
and gear wheel for 3rd gear.
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
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rp
cum
fo
en
ng
t.
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Dismantling and assembling 3rd and 4th gear locking collar and Cop py
t. rig
synchro-hub gh ht
pyri by
Vo
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by
1- Spring Prote
cted AG.
agen
2- Sliding sleeve
3- Synchro-hub
4- Locking piece
– Slide locking collar over synchro-hub.
Deeper notches -arrow A- for locking pieces in synchro-hub and
notches -arrow B- in locking collar must align.

lkswage es n
o ot g
byV ua
d ran
ho
ir se tee Caddy 2004 ➤ , Caddy 2011 ➤
t or
au 5-speed manual
ac gearbox 0AH - Edition 06.2016
ss
ce
le
un
Assembling locking collar and synchro-hub for 3rd and 4th gear
pt
an
d
itte
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• Locking collar has been pushed over synchro-hub.
erm
ab
ility
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– Insert locking pieces in deeper notches -arrows- and install
wit
is n
springs with an offset of 120°. Angled end of spring must locate
h re
ole,
in hollow locking piece.
spec
t to the co
rrectness o
cial p
f i
Installation position of locking collar with synchro-hub for 3rd and
nform
4th gear
mer
atio
m
Groove on front -arrow- faces 4th gear.

o
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i
or
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te
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t.
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Cop py
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cted agen
Prote AG.
Checking synchro-ring for wear

– Press synchro-ring onto cone of synchromeshed gear and
measure gap -a- using feeler gauge.
Gap -a- Installation dimen‐ Wear limit
sion
3rd, 4th and 5th 1.1…1.7 mm 0.5 mm
gear
Pressing on synchro-hub with locking collar for 3rd and 4th gears
1. Input shaft 115

Caddy 2004 ➤ , Caddy 2011 ➤
Pressing on sleeve -A- for 4th gear needle bearing

– After pressing on sleeve -A-, fit 4th gear needle bearing, 4th
gear synchro-ring with synchromeshed gear and thrust wash‐
er.
lkswage es n
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byV ua
d ran
ir se tee
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nl
pt
du
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itte
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ility
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hole
spec
Pressing on inner race -A- for cylindrical roller bearing
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
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or
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ate
do
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Determining thickness of retaining ring

um
for
en
ng
t.
– Insert a 2.0 mm thick retaining ring -A- in groove of input shaft
yi Co
op py
and press upwards -arrow-. t. C rig
gh ht
pyri by
– Measure distance between inner race -B- and installed circlip
co Vo
by lksw
cted
-A- using feeler gauge -C-.
agen
Prote AG.
– Remove circlip (only used for measuring purposes).

– Determine retaining ring from table.
Note
Allocate circlips using ⇒ Electronic parts catalogue (ETKA) .
Available circlips
Measured value Retaining ring thick‐ Axial play (mm)
(mm) ness (mm)
0.05…0.10 2.0 0.05…0.15
0.15…0.20 2.1 0.05…0.15
0.25…0.30 2.2 0.05…0.15
0.35…0.40 2.3 0.05…0.15
0.45…0.50 2.4 0.05…0.10

Caddy 2004 ➤ , Caddy 2011 ➤
Pressing on bearing mounting with deep groove ball bearing

– Heat inner bearing mounting to approx. 100°C before pressing
on.
WARNING
Wear protective gloves.
Pressing on sleeve -A- for 5th gear needle bearing
Removing stop ring

– Using a screwdriver, unclip hooks -A- of check ring from syn‐
chro-hub.
lkswage es n
o ot g
byV ua
d ran
ir se tee
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a ac
ss
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e
nl
pt
du
an
itte
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ab
Dismantling and assembling 5th gear locking collar and synchro-

ility
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hub
wit
, is n
h re
1- Spring
hole
spec
es, in part or in w
2- Locking piece
t to the co
3- Synchro-hub installation position: groove on face

-arrow A- and wide shoulder -arrow B- must face 5th gear.
rrectness of i
4- Sliding sleeve
l purpos
5- Stop ring
nf
ercia
orm
Deeper notches -arrow C- for locking pieces in synchro-hub and

m
atio
m
notches -arrow D- in locking collar must align.

o
n in
or c
thi
te
sd
iva
o
r
rp
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f
en
ng
t.
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Cop py
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gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
1. Input shaft 117

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
Caddy 2004 ➤ , Caddy 2011 ➤ oris nte
eo
th
5-speed manual gearbox 0AH - Edition 06.2016 s au ra
c
s
ce
e
nl
pt
Assembling 5th gear locking collar/synchro-hub
du
an
itte
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erm
ab
ility
ot p
– Install locking pieces in deeper notches -arrows- and install
wit
, is n
springs so that they are offset by 120°. Angled end of spring
h re
hole
must locate in hollow locking piece.
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
Installing stop ring
– Press on stop ring using tube - 2010- . mercia
at
om
ion
c
– Insert stop ring together with tube - 2010- into 5th gear syn‐
in t
or
his
chro-hub/locking collar (observe installation position
ate
do
riv
⇒ page 117 ).
p
cum
for
The hooks -arrow 1- lock in the recess -arrow 2- of the synchro-
en
ng
t.
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hub locking pieces.
Co
Cop py
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ht
– Press stop ring downwards until hooks engage.
rig by
copy Vo
by lksw
cted agen
Prote AG.

Caddy 2004 ➤ , Caddy 2011 ➤
2 Output shaft
⇒ “2.1 Assembly overview - output shaft”, page 119
⇒ “2.2 Dismantling and assembling output shaft”, page 121
2.1 Assembly overview - output shaft
Note
♦ When installing new gear wheels or a new output shaft, consult technical data ⇒ page 4 and ⇒ Electronic
parts catalogue (ETKA) .
♦ Install all bearings, synchromeshed gears and synchro-rings on output shaft with gear oil.
♦ Do not interchange synchro-rings. When reusing always fit to the original gear.
1 - Clutch housing
❑ With retaining ring
❑ Installation position: re‐
taining ring in bearing
faces output shaft
❑ Pressing in AG. Volkswagen AG d
agen
⇒ page 122 . V olksw
oes
not
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db ara
3 - Output shaft orise nte
th eo
❑ With inner au race for cylin‐ ra
c
ss
drical roller bearing
ce
e
nl
pt
❑ Inner race cannot be re‐

du
an
itte
moved from output

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erm
ab
shaft.
ility
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❑ If inner race of cylindri‐

wit
, is n
cal roller bearing is dam‐

h re
hole
aged or scored, renew

spec
output shaft and cylin‐

es, in part or in w
t to the co
drical roller bearing to‐

gether.
rrectness of i
❑ Installation position:
l purpos
shoulder faces 3rd gear

⇒ page 122
nf
ercia
5 - Locking ring
orm
m
atio
6 - Locking ring
om
n in
or c
7 - Gear wheel for 3rd gear

thi
te
sd
a
iv
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shoulder faces 4th gear

o
m
f
en
ng
⇒ page 122
t.
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op py
8 - Locking ring
. C rig
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rig by
py Vo
9 - Synchromeshed gear, 2nd gear
co lksw
by
cted agen
Prote AG.
10 - Needle bearing
❑ for 2nd gear
11 - Inner ring for 2nd gear
2. Output shaft 119

Caddy 2004 ➤ , Caddy 2011 ➤
❑ Fitting position ⇒ page 123 AG. Volkswagen AG d
agen oes
ksw
12 - Outer ring for 2nd gear by
Vol not
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ara
ed
❑ Renew if scored horis nte
eo
ut
❑ Set on inner ring ⇒ Item 11 (page 119)
ss a . ra
c
ce
e
nl
pt
du
an
itte
13 - Synchro-ring for 2nd gear
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erm
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ility
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wit
❑ Fitting position ⇒ page 123 , is n
h re
hole
14 - Locking collar with synchro-hub for 1st and 2nd gear
spec
es, in part or in w
❑ After removing retaining ring ⇒ Item 15 (page 120) , press off with 2nd gear synchromeshed gear
t to the co
⇒ page 122
❑ Dismantling ⇒ page 124
rrectness of i
❑ Assembling locking collar and synchro-hub ⇒ page 124
l purpos
nf
ercia
15 - Locking ring
orm
m
❑ Pressing out ⇒ page 122
atio
om
n in
or c
thi
te
16 - Synchro-ring for 1st gear
sd
iva
o
r
rp
cu
o
m
f
en
ng
❑ Assemble so that notches engage in locking pieces of locking collar ⇒ Item 14 (page 120)
t.
yi Co
Cop py
t. rig
17 - Outer ring for 1st gear opyri
gh by
Vo
ht
❑ Insert in synchro-ring ⇒ Item 16 (page 120) . Installation position ⇒ page 125 . by c lksw
cted agen
Prote AG.
❑ Renew if scored
18 - Inner ring for 1st gear
❑ Check lugs for scoring
19 - Needle bearing
❑ for 1st gear
20 - Synchromeshed gear, 1st gear
21 - Bearing mounting with deep groove ball bearing
❑ Renew deep groove ball bearing only together with bearing support
22 - Gearbox housing
❑ Installation position: shoulder faces gearbox housing cover ⇒ page 103
24 - Locking ring
25 - Spring

Caddy 2004 ➤ , Caddy 2011 ➤
AG. Volkswagen AG d
agen 5-speednot manual gearbox 0AH - Edition 06.2016
oes
olksw
y V gu
d b ara
e
26 - Sliding sleeve horis nte
eo
ut ra
a
27 - Synchro-hub s s c
ce
e
nl
pt
28 - Locking pieces
du
an
itte
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erm
ab
ility
ot p
2.2 Dismantling and assembling output shaft
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
equipment required
rrectness of i
l purpos

♦ Tube - VW 415 A-
nform
mercia
♦ Press tool - VW 432-
at
om
ion
c
♦ Drift sleeve - 30 - 100-
in t
or
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ate
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Prote AG.
♦ Internal puller e.g. KUKKO 21-5 - VAS 251 611-

♦ Counter support e.g. KUKKO 22-2 - VAS 251 623-
Pulling cylindrical roller bearing out of clutch housing
– When pulling out, squeeze together retaining ring -arrow- of
cylindrical roller bearing, using pliers -C-.
2. Output shaft 121

Caddy 2004 ➤ , Caddy 2011 ➤
Pressing cylindrical roller bearing into clutch housing

– Support gearbox housing with tube - VW 415 A- (not visible
here) directly below bearing support.
– When pressing in, squeeze together retaining ring -arrow- for
cylindrical roller bearing using pliers -A-.
. Volkswagen AG
does gen AG
– Remove pliers before Vol
kscylindrical
wa roller bearing isnin
ot ginstallation
position. Retaining
ed by ring must engage in groove of clutch
ua hous‐
ran
ing. horis tee
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Pressing retaining ring -1- out of groove
ility
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A - Protective gloves
h re
hole
spec
es, in part or in w
WARNING
t to the co
Ensure retaining ring does not spring out uncontrolled.
rrectness of i
l purpos
nf
ercia
orm
m
atio
m
Pressing off 1st and 2nd gear locking collar and synchro-hub
o
n in
or c
– After removing retaining ring, press off synchromeshed gear

thi
te
sd
a
for 2nd gear together with locking collar and synchro-hub.

iv
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Cop py
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Prote AG.
Installation position of 3rd gear and 4th gear

– Install gear wheel for 4th gear -A- on output shaft.
Collar -arrow 1- faces 3rd gear wheel -B-.
– Install retaining rings -2- and -3-.
– Install gear wheel for 3rd gear -B- on output shaft.
Collar -arrow 2- faces gear wheel for 4th gear -A-.
– Install retaining ring -1-.

Caddy 2004 ➤ , Caddy 2011 ➤
Checking 1st and 2nd gear inner ring for wear

– Press inner ring onto cone of synchromeshed gear and meas‐
ure gap -a- using a feeler gauge.
sion . Volkswagen AG
gen AG
wamm does
1st and 2nd gear 0.75…1.25 mm olk0.3
s not
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Checking 1st and 2nd gear synchro-ring for wear
ility
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wit
is n
– Press synchro-ring, outer ring and inner ring onto cone of syn‐
h re
ole,
chromeshed gear and measure gap -a- using a feeler gauge.
spec
t to the co
sion
1st and 2nd gear 1.2…1.8 mm 0.5 mm
rrectness o
cial p
f inform
mer
atio
m
Installation position of outer ring, inner ring and synchro-ring for

o
n
c
i
or
n
2nd gear
thi
te
sd
va
– Place inner ring -A- on 2nd gear synchromeshed gear.

i
o
pr
cum
r
fo
Angled lugs -arrow 1- face outer ring -B-.
en
ng
t.
yi Co
op py
– Fit outer ring -B-. t. C rig
gh ht
pyri by
Lugs -arrow 2- engage in notches -arrow 3- of synchromeshed
co Vo
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cted
gear.
agen
Prote AG.
– Fit synchro-ring -C-.

Notches -arrow 4- engage in lugs -arrow 1- of inner race -A-.
2. Output shaft 123

Caddy 2004 ➤ , Caddy 2011 ➤
Dismantling and assembling locking

n AG. Vocollar
lkswageand
n AGsynchro-hub for
1st and 2nd gear lkswage does
n
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1- Spring ir se nte
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2- au
Slidingsssleeve ra
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3- Synchro-hub
nl
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4- Locking piece
erm
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ility
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hole
spec
After assembly, the groove on the face -arrow A- and the higher
es, in part or in w
t to the co
shoulder -arrow B- of synchro-hub face outer splines of the lock‐
ing collar -arrow C-.
Deeper notches -arrow D- for locking pieces in synchro-hub and
rrectness of i
notches -arrow E- in locking collar must align.
l purpos
nf
ercia
orm
Assembling locking collar with synchro-hub for 1st and 2nd gear
m
atio
om
n in
or c
thi
e
– Install locking pieces in deeper notches -arrows- and install

t
sd
iva
springs so that they are offset by 120°. Angled end of spring

r
rp
cu
o
must locate in hollow locking piece.

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Prote AG.
Pressing on locking collar and synchro-hub for 1st and 2nd gear
Groove in locking collar for selector fork faces 1st gear and teeth
for reverse gear face 2nd gear.
– Turn synchro-ring so that grooves align with locking pieces.

AG. Volkswagen AG d
agen oes
Volksw Caddy 2004 no➤
t gu, Caddy 2011 ➤
y
rised b
5-speed manual gearbox 0AH - aEdition
ran
tee
06.2016
tho
u or
a ac
Fitting retaining ring ss
ce
le
un
– Place 1st gear synchro-ring in locking collar/synchro-hub.
pt
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pe
ility
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, is n
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hole
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es, in part or in w
t to the co
rrectness of i
l purpos
Installation position of 1st gear outer ring
nform
ercia
Lugs -arrows- face towards reverse gear teeth.

m
a
com
tion in
r
te o
thi
s
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en
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t.
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pyri by
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Prote AG.
Installation position of 1st gear inner ring -A-

Lugs -arrow 1- engage in notches -arrow 2- in synchro-ring -B-.
Installation position of synchromeshed gear for 1st gear

Higher shoulder -A- faces 2nd gear -B-. Notches in shoulder
-arrows- engage in lugs of outer ring (-arrow- ⇒ page 125 ).
2. Output shaft 125

Caddy 2004 ➤ , Caddy 2011 ➤
39 – Final drive - differential

1 Oil seals
⇒ “1.1 Renewing left oil seal”, page 126
⇒ “1.2 Renewing right oil seal”, page 127
1.1 Renewing left oil seal

equipment required
♦ Multipurpose tool - VW
771- AG. Volkswagen AG d
agen oes
olksw not
yV gu
♦ Extractor hook - VW ed b ara
nte
is
771/37- hor eo
aut ra
c
♦ Press tool - T10160- ss
ce
e
nl
pt
du
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itte
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erm
ab
♦ Torque wrench -
ility
ot p
V.A.G 1331-
wit
, is n
h re
♦ Sealing grease - G 052 128
hole
A1-
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
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Prote AG.
Removing
– Remove left wheel.
– Remove front left wheel housing liner ⇒ General body repairs,
liner; Front wheel housing liner .
– Turn steering to left lock.
126 Rep. gr.39 - Final drive - differential

Caddy 2004 ➤ , Caddy 2011 ➤
– Unbolt drive shaft from flange shaft ⇒ Running gear, axles,

steering; Rep. gr. 40 ; Drive shafts; Removing and installing
drive shafts .
– Raise drive shaft as high as possible and secure. Take care
not to damage paint on drive shaft in the process.
– Place drip tray - V.A.G 1306- under gearbox.
– Remove flange shaft securing bolt by screwing 2 bolts into
flange and counterholding flange shaft with a lever.
– Pull out flange shaft with compression spring.
– Pull out flange shaft oil seal using multi-purpose tool - VW 771-
and puller hooks - VW 771/37- .
Installing
AG. Volkswagen AG d
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erm
– Drive in new seal to stop, being careful not to cant seal.

ab
ility
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– Half-fill space between sealing lip and dust lip with sealing
wit
is n
grease - G 052 128 A1- . h re

ole,
spec
– Insert flange shaft.
t to the co
– Secure flange shaft with countersunk bolt and tighten bolt.

– Install drive shaft to flange shaft ⇒ Running gear, axles, steer‐
rrectne
ing; Rep. gr. 40 ; Drive shafts; Removing and installing drive

shafts .
ss
– Mount left wheel ⇒ Running gear, axles, steering; Rep. gr.

o
cial p
44 ; Torque settings for wheel bolts .

inform
mer
– Check gear oil level and top up to lower edge of oil filler hole
atio
if necessary ⇒ page 83 .
om
n
c
i
or
– Install front left wheel housing liner ⇒ General body repairs,

thi
te

sd
iva
o
r
liner; Front wheel housing liner .

p
cum
r
fo
en
ng

t.
yi Co
op
body repairs, exterior; Rep. gr. 66 ; Noise insulation . C py
ht. rig
rig ht
py by
Torque settings co Vo
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Prote
♦ ⇒ “6.2 Assembly overview - clutch housing”, page 106
AG.
1.2 Renewing right oil seal

1. Oil seals 127

Caddy 2004 ➤ , Caddy 2011 ➤
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
♦ Press tool - T10160- s au ra
c
s
ce
le
un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
♦ Sealing grease - G 052 128 A1-
nform
ercia
Removing
m

a
com
tio

n in
r
te o
thi
– Place drip tray - V.A.G 1306- under gearbox.

s
iva
do
r
rp
– Unbolt drive shaft from flange shaft ⇒ Running gear, axles,

um
fo
steering; Rep. gr. 40 ; Drive shafts; Removing and installing

en
ng
t.
yi Co
drive shafts . t. Cop py
rig
gh ht
– Raise drive shaft as high as possible and secure. Take care pyri by
Vo
co
not to damage paint on drive shaft in the process.
by lksw
cted agen
Prote AG.
– Remove flange shaft securing bolt by screwing 2 bolts into
flange and counterholding flange shaft with a lever.
– Pull out flange shaft with compression spring.
– Lever out flange shaft oil seal with assembly lever.
Installing

Caddy 2004 ➤ , Caddy 2011 ➤
– Drive in new seal to stop, being careful not to cant seal.

– Half-fill space between sealing lip and dust lip with sealing
grease - G 052 128 A1- .
– Insert flange shaft.
– Secure flange shaft with countersunk bolt and tighten bolt.
– Install drive shaft to flange shaft ⇒ Running gear, axles, steer‐
ing; Rep. gr. 40 ; Drive shafts; Removing and installing drive
shafts .
– Check gear oil level and top up to lower edge of oil filler hole
if necessary ⇒ page 83 .
Torque settings
AG. Volkswagen AG d
agen oes
olksw not
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nl
pt
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ility
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wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
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en
ng
t.
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co Vo
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cted agen
Prote AG.
1. Oil seals 129

Caddy 2004 ➤ , Caddy 2011 ➤
2 Differential
⇒ “2.1 Assembly overview - differential”, page 130
⇒ “2.2 Dismantling and assembling differential”, page 132
⇒ “2.3 Adjusting differential”, page 137
2.1 Assembly overview - differential
Note
♦ Heat tapered roller bearing inner race to 100°C before installing!

n AG. Volkswagen A ge G do
swa es
♦ Always renew both tapered roller
by
Vol bearings together as a set! ot gu
k n
a d ran
ise
♦ If tapered roller bearings,
tho differential cage, gearbox housing or clutch housing
r tee
o is renewed, adjust differential
⇒ page 137 ! ss
au ra
c
ce
le
un
pt
an
d
itte
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1 - Countersunk bolt
erm
ab
ility
❑ Screw into threaded
ot p
wit
piece
is n
h re
ole,
spec
❑ 25 Nm
t to the co
2 - Flange shaft
❑ right
rrectne
3 - Compression spring for
flange shaft
ss
❑ Installed behind flange
o
cial p
shafts
inform
mer
4 - Thrust washer
atio
m
o
n
c
shoulder towards spring

or
n thi
te
sd
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5 - Tapered ring
i
o
pr
cum
r
fo
en
ng
t.
taper towards differen‐
yi Co
op
tial cage
C py
t. rig
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6 - Locking ring
cop Vo
by lksw
cted agen
❑ Holds tapered ring,
Prote AG.
thrust washer and

spring in position when
flange shaft is removed
7 - Large differential bevel gear
8 - Threaded piece
9 - Differential pinion pin
❑ Drive out using drift
10 - Small differential bevel
gear
11 - One-piece thrust washer
❑ Insert with gear oil ⇒ page 136

Caddy 2004 ➤ , Caddy 2011 ➤
12 - Left flange shaft

13 - Oil seal for left flange shaft
❑ Renewing with manual gearbox installed ⇒ page 126 .
15 - Tapered roller bearing inner race
❑ Pulling off ⇒ page 135
16 - Differential cage
❑ With final drive gear
17 - Retaining sleeve
❑ For securing differential pinion pin agen
AG. Volkswagen AG d
oes
lksw not
❑ Removing ⇒ page 136 d by Vo gu
ara
se nte
❑ Installing ⇒ page 136 thori
eo
au ra
18 - Tapered roller bearing inner race
ss c
ce
le
un
❑ Pulling off ⇒ page 135
pt
an
d
itte
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erm
ab
ility
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wit
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❑ Pressing out ⇒ page 135 .
h re
ole,
spec
t to the co
20 - Shim S2
rrectne
21 - Oil seal for right flange shaft
ss
❑ Renewing with manual gearbox installed ⇒ page 127 .
o
cial p
22 - Gearbox housing f inform

mer

atio
om
n
c
23 - Clutch housing
i
or
n thi
te

sd
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o
pr
cum
r
fo
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.
2. Differential 131
Caddy 2004 ➤ , Caddy 2011 ➤
2.2 Dismantling and assembling differential

equipment required
♦ Tapered roller bearing pull‐
er - V.A.G 1582-
♦ Grip tool - V.A.G 1582/3-
lkswage es n
o ot g
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d ran
ir se tee
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ss
ce
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nl
pt
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itte
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ab
ility
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wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Caddy 2004 ➤ , Caddy 2011 ➤
♦ Installing sleeve - VW 455-

♦ Thrust piece with spacer agen
AG. Volkswagen AG d
oes
sleeve - VW 472- Volksw not
gu
by ara
d
♦ Drift sleeve - 40 - 21- rise nte
tho eo
au ra
♦ Tube - 30 - 14- ss c
ce
e
nl
♦ Tube - 2040-
pt
du
an
itte
y li
♦ Press tool - 3002-
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
2. Differential 133
Caddy 2004 ➤ , Caddy 2011 ➤
♦ Press piece - VW 408 A-

♦ Thrust plate - 30 - 205-
♦ Tube - 3259-
1331-
♦ Internal puller e.g. KUKKO
21-7 - VAS 251 615-
♦ Counter support e.g. KUK‐
KO 22-2 - VAS 251 623- agen
AG. Volkswagen AG d
oes
lksw n o ot g
yV ua
edb ran
ris tee
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au ac
ss
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le
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pt
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d
itte
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
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Cop py
ht. rig
Pulling outer race for tapered roller bearing out of gearbox hous‐ py
rig by
ht
ing co Vo
by lksw
cted agen
Prote
AG.

Caddy 2004 ➤ , Caddy 2011 ➤
AG. Volkswagen AG d
agen oes 5-speed manual gearbox 0AH - Edition 06.2016
olksw not
y V gu
d b ara
Pressing tapered riseroller bearing outer race into gearbox housing nte
tho eo
au ra
– Supports gearbox housing with tube - 3259- directly below c
s
bearing support.
ce
le
un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectne
Pulling off tapered roller bearing inner races
ss o
cial p
f
Note
inform
mer
atio
Both tapered roller bearing inner races are pulled off the differ‐
om
ential cage in the same way.
n
c
i
or
n thi
te
sd
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o
pr
cum
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fo
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
cted
Pressing on tapered roller bearing inner race
agen
Prote AG.
– Support inner race on opposite side using installing sleeve -

VW 455- .
Shoulder of installing sleeve - VW 455- faces towards differential
cage.
Note
Both tapered roller bearing inner races are pressed onto the dif‐
ferential cage in the same way.
Pressing tapered roller bearing outer race -A- out of clutch hous‐
ing
B - Internal puller 46…58 mm , e.g. -Kukko 21/7-
– Clamp internal puller securely behind tapered roller bearing
outer race.
2. Differential 135
Caddy 2004 ➤ , Caddy 2011 ➤
Pressing tapered roller bearing outer race into clutch housing
AG. Volkswagen AG d
agen oes
olksw not
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d by ara
ise nte
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ss c
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ility
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wit
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h re
hole
Removing spring pin for differential pinion pin
spec
es, in part or in w
– Drive spring pin -A- out through hole -B- in differential cage
t to the co
using a 4 mm ∅ drift.
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
Installing spring pin for differential pinion pin

o
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rp
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m
f
en
ng
– Align hole in differential pinion pin with hole in differential cage.

t.
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Cop py
– Drive in new spring pin with drift -1- until dimension -a- = 3.1
t. rig
gh ht
yri
±0.2 mm is attained. p by
o Vo
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cted agen
Prote AG.
Installing one-piece thrust washer

– Lubricate one-piece thrust washer with gear oil.
– Install one-piece thrust washer so that lug -A- engages in
groove -B- in differential cage.

Caddy 2004 ➤ , Caddy 2011 ➤
Installing differential bevel gears

– Install one-piece thrust washer moistened with gear oil
⇒ page 136 . agen
AG. Volkswagen AG d
o w es n
olks o
– Install both sun
ed
bwheels
yV and secure (e.g. with flange
t gu
arashaft).
ris nte
– Insert planet
au
tho pinions offset 180° and pivot into position.e or
a
ss c
– Press in differential pinion pin (-arrow A-) to first planet pinion.
ce
le
un
pt
an
d
– Place threaded pieces -arrows B- in sun wheels.

itte
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erm
ab
– Drive differential pinion pin into final position and secure with
ility
ot p
spring pin ⇒ page 136 .
wit
is n
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ole,
spec
2.3 Adjusting differential
t to the co
equipment required
rrectne
♦ End dimension plate -
s
VW 385/17-
s o
cial p
f i
♦ Universal dial gauge holder
nform
- VW 387-
mer
atio
m

o
n
c
i
or
♦ Pressure plate - VW 402- n thi

te
sd
iva
o
pr

cum
r
fo
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
2. Differential 137
Caddy 2004 ➤ , Caddy 2011 ➤
♦ Thrust plate - 30 - 205-

♦ Tube - 30 - 14-
♦ Tube - 2040-
♦ Tube - 3259-
♦ Torque wrench -
V.A.G 1331-
♦ Internal puller e.g. KUKKO
21-7 - VAS 251 615-
♦ Dial gauge
AG. Volkswagen AG d
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It is necessary to readjust the differential when the following com‐

ility
ot p
ponents are renewed:

wit
, is n
h re
♦ Gearbox housing
hole
spec
♦ Clutch housing
es, in part or in w
t to the co
♦ Differential cage
or the
rrectness of i
♦ Tapered roller bearing of differential

l purpos
– Pressing tapered roller bearing outer race (gear wheel slide)

into gearbox housing.
nf
ercia
orm
m
atio
m
Note
o
n in
or c
thi
e
Inner and outer tapered roller bearing races are paired. Do not
t
sd
iva
interchange!
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f
en
ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Caddy 2004 ➤ , Caddy 2011 ➤
– Press tapered roller bearing outer race (opposite gear wheel)

with no shim into gearbox housing.
– Insert differential in gearbox housing.
en AG. V
olkswagen AG
ag does
ksw not
– Fit clutch housingVol
by and tighten 5 bolts. gu
ara
ed nte
ris
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ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
– Fit dial gauge, and set it to “0” with 1 mm preload.
es, in part or in w
t to the co
A - 30 mm dial gauge extension
– Move differential up and down. Read and note play indicated
on dial gauge. (Example: 1.50 mm)
rrectness of i
Determining shim S2
l purpos
The specified bearing preload is obtained for S2 by adding a con‐
nform
ercia
stant value for preload (0.35 mm) to the measured value.

m
a
Example:
com
tion in
r
Measured value 1.50 mm

te o
thi
s
iva
+ Preload (constant) 0.35 mm

do
r
rp
cum
fo
Thickness of shim S2 = 1.85 mm

en
ng
t.
yi Co
Cop py
ht. rig
– Remove clutch housing and press out tapered roller bearing
rig ht
py by
outer race -A-.
co Vo
by lksw
cted agen
Prote AG.
B - Internal puller 46 … 58 mm , e.g. -Kukko 21/7-
– Allocate shim(s) using ⇒ Electronic parts catalogue (ETKA) .
The various thicknesses make it possible to achieve the exact
shim thickness required.
If the size of shim required is larger than those listed in the ⇒
Electronic parts catalogue (ETKA) , insert two shims totalling the
correct figure.
– Insert correct S2 shim (in example 1.85 mm) and press ta‐
pered roller bearing outer race into clutch housing again.
– Fit clutch housing and tighten bolts.
Torque settings
♦ ⇒ “6.1 Assembly overview - gearbox housing/clutch housing”,
page 104
2. Differential 139

K0050366020-5-Speed Manual Gearbox 0AH

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K0050366020-5-Speed Manual Gearbox 0AH

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Service

Workshop Manual agen

5-speed manual gearbox 0AH

Service Department. Technical Information

39 - Final drive - differential

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Copyright © 2016 Volkswagen AG, Wolfsburg K0050366020

3.1 Calculating overall gear ratio “i” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

4.1 General repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

1.4 Removing and installing over-centre spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

1.6 Removing and installing mounting bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

1.7 Removing and installing clutch master cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

1.9 Removing and installing clutch slave cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

1.10 Bleeding clutch mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

1.11 Repairing clutch release mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

5.3 Assembly overview - selector forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

35 - Gears, shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

39 - Final drive - differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126

1.1 Gearbox identification AG. Volkswagen AG d

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

2 Overview - power transmission

Arrows indicate direction of travel.

2 Rep. gr.00 - Technical data

2. Overview - power transmission 3

3.1 Calculating overall gear ratio “i”

3.2 Allocation gearbox - engine/capacities

Capacity of manual gearbox 2.1 litre 2.1 litre 2.1 litre

Drive shaft flange diameter 100 mm 100 mm 100 mm

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

♦ Ratio of final drive

♦ Individual gear ratios

♦ Specification for gear oil

♦ Clutch plate allocation

Manual gearbox 5-speed 0AH

Identification code GUG GXZ HFN

Manufac‐ from 07.04 - 11.06 11.03 - 11.06 12.03 - 11.06

Allocation Model Caddy 2004 ► Caddy 2004 ► Caddy 2004 ►

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

4 Rep. gr.00 - Technical data

♦ Ratio of final drive

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

♦ Clutch plate allocation

Manual gearbox 5-speed 0AH

Identification code JJW KBQ KHH

Manufac‐ from 06.06 - 05.08 05.06 - 11.06 11.06 - 05.08

Drive shaft flange diameter 100 mm 100 mm 100 mm

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

♦ Ratio of final drive

♦ Individual gear ratios

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

♦ Individual gear ratios

Identification code LBU LBV LBW

Manufac‐ from 05.08 05.08 11.08

Allocation Model Caddy 2004 ► Caddy 2004 ► Caddy 2004 ►

Engine 2.0 l - 51 kW 1.6 l - 75 kW 1.4 l - 59 kW

Capacity of manual gearbox 2.1 litre 2.1 litre 2.1 litre

Drive shaft flange diameter 100 mm 100 mm 100 mm

6 Rep. gr.00 - Technical data

♦ Individual gear ratios

Allocation Model Caddy 2004 ► Caddy 2004 ► Caddy 2004 ►

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

4.1 General repair instructions

4.1.2 Gaskets and seals

♦ Apply sealant uniformly but not too thick.