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Workshop Manual
Jetta 2006
Golf Variant 2008
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Service
List of Workshop Manual Repair GroupsList of Workshop Manual
Repair GroupsList of Workshop Manual Repair Groups
Repair Group
00 - Technical data
30 - Clutch
34 - Controls, housing
35 - Gears, shafts
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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.
MEX5R007420
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gearbox identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Location on gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Identification codes, assembly allocation, capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Overview - power transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Calculating overall gear ratio i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General repair notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
3
5
6
6
30 - Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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1
2
2.1
2.2
2.3
2.4
2.5
2.6
2.7
2.8
2.9
2.10
3
4
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1
1.1
1.2
2
3
4
4.1
9
10
10
11
12
14
16
19
21
24
25
27
29
31
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5.6
1
2
2.1
2.2
2.3
2.4
2.5
2.6
2.7
2.8
2.9
3
3.1
3.2
3.3
3.4
4
5
5.1
5.2
5.3
5.4
5.5
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34 - Controls, housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Contents
34
35
35
38
38
40
42
47
50
51
54
57
59
64
65
70
72
74
74
75
76
77
78
79
89
94
97
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1
1.1
2
2.1
102
102
113
113
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Contents
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1.1
1.2
2
2.1
2.2
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Technical data
Gearbox identification
1.1
Location on gearbox
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I
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Day
11
3
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Month Year (2003) of
manufacture
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Manual gearbox
Identification code
Manufac
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Allocation
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Model
FVH
5-speed 0AF
JHT
05.05
11.06
Jetta 2006
Golf Variant 2008
Jetta 2006
Golf Variant 2008
1. Gearbox identification
FVH
5-speed 0AF
JHT
1.6 l - 75 kW
68 : 15 = 4.533
1.6 l - 75 kW
68 : 15 = 4.533
2.0 l
2.0 l
100 mm
100 mm
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Clutch allocation
Designation
-Arrows- indicate direction of travel.
1 - Engine
2 - Clutch
4 - Input shaft
5 - Output shaft
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6 - Differential
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Gears
-Arrows- indicate direction of travel.
II - 2nd gear
III - 3rd gear
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IV - 4th gear
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V - 5th gear
R - Reverse gear
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Drive gear
Final drive
ZG1 = 49
ZG2 = 38
ZA1 = 16
ZA2 = 67
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- eEdition
08.2007
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4.1
Components
4.1.1
Gearbox
G
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When installing mounting brackets
orn Awaxed
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surfaces must be free oof
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ris
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Capacities page 1
4.1.2
Locking devices
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Allocate bolts andssother
components using Electronic parts
catalogue ETKA .
4.1.4
Loosen and tighten securing bolts and nuts for covers and
housings diagonally.
Do not cant especially delicate parts, such as clutch pressure
plates. Loosen and tighten bolts and nuts in stages in a diag
onal sequence.
Torque settings are specified for unoiled bolts and nuts.
Always renew self-locking bolts and nuts.
Ensure with threaded connections that contact surfaces as
well as nuts and bolts are rewaxed only after assembly, if nec
essary.
Use a thread chaser to clear residual locking fluid from all
threaded holes into which self-locking bolts are to be screwed.
Otherwise there is a danger of bolts shearing when subse
quently being removed.
4.1.5
Bearings
4.1.6
Synchro-rings
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Measure shims at several points with a micrometer.
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h exact shim
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4.1.8
Gear wheels
Before installing, clean and heat with the inductive heater VAS 6414- to maximum 100 C.
4.1.9
Synchromeshed gears
4.1.10
Clutch
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If the clutch has burnt out,rithoroughly
clean the bell housing
se
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as well as the friction surface
of
flywheel
with a cloth to reduce
u
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the smell of burnt linings.
ss
30
Clutch
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Refer to Fault finding, power transmission;ksRep.
wage Gr. 30 ;
l
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Complaints about clutch and clutch mechanism
and Fault
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finding, power transmission; Rep. Gr.rise34
; Complaints about
tho
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2.1
Overview
Note
Before disconnecting battery, obtain code for radio units having anti-theft coding.
n AG. Volkswagen A
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With ignition switched off, disconnect
earth strap.G does no
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Electrical system; Rep. Gr.
te
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battery .
Lubricate all bearings and contact surfaces with grease -G 000 450 02- .
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When reconnecting battery,
refer to Electrical system; Rep. Gr. 27 ; Disconnecting
and connecting
c
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2.2
1 - Bulkhead
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2 - Seal
au
ss
Always renew
Between mounting
bracket and bulkhead
Self-adhesive
Bond to mounting
bracket
3 - Mounting bracket
For mounting clutch
pedal
Removing and installing
page 16
4 - Bolt
6 - Bearing bush
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9 - Retainer
To remove and install,
separate master cylin
der from clutch pedal.
page 14
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8 - Clutch pedal
Removing and installing
page 14
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7 - Pivot pin
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5 - Over-centre spring
Removing and installing
page 12
10 - Seal
Always renew
Between master cylinder and mounting bracket
11 - Master cylinder
Removing and installing after removal of mounting bracket page 19
12 - Clutch position sender -G476 Removing and installing page 21
Can be checked in guided fault finding of vehicle diagnosis, testing and information system -VAS 5051 The clutch position sender -G476- is identified as clutch pedal switch -F36- in guided fault finding.
13 - Clip
Pull out clip to stop to remove and install pipe/hose line or plastic line
14 - Supply hose
Rubber
From 12.05, plastic in some vehicles page 25
15 - Self-locking hexagon nut, 25 Nm
Qty. 3
For mounting bracket on bulkhead
Always renew
11
2.3
2.3.1
Removing
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in highest position.
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Remove trim and cover below trim on drive sideris
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body repairs, interior; Rep. Gr. 68 .
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Now unbolt crash bar -1- from in front of clutch pedal -2-.
2.3.2
Installing
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Insert tip of clutch pedal in bearing recess
au of over-centre
s
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spring.
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Install trim and cover below trim on drive side General body
repairs, interior; Rep. Gr. 68 .
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2.3.3
Torque settings
Component
Nm
25
10
2.4
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Removing
Push driver seat as far back as possible and put steering wheel
in highest position.
Remove trim and cover below trim on drive side General
body repairs, interior; Rep. Gr. 68 .
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15
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Insert tip of clutch
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repairs, interior; Rep. Gr. 68 .
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Component
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Depress sclutch
pedal slightly, push bolt through and tighten
self-locking nut.
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First check whether a coded radio is fitted. If so, obtain antitheft code.
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Note
During the following work, ensure that no brake fluid lands on
17
Now unbolt crash bar -1- from in front of clutch pedal -2-.
The upper securing nut -1- is accessible between the relay carrier
and the steering column trim.
Remove mounting bracket -3-.
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2.5.2
Installing
18
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Push pipe/hose line or plastic line -1- with seal -2- onto con
nection of master cylinder -4- until securing clip -3- engages
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2.6.1
Removing
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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).
Release securing bar -B- and pull master cylinder out of
mounting bracket -arrow 1- and -arrow 2-.
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20
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2.6.2
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-.
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until retainer -2- engages audibly
in clutch pedal.
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21
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Removing
First check whether a coded radio is fitted. If so, obtain antitheft code.
Remove complete air filter housing if it is near battery Rep.
Gr. 24 ; Repairing injection system .
Remove battery, battery cover and battery tray Electrical
system; Rep. Gr. 27 ; Removing and installing battery .
If a pipe/hose line or plastic line -1- with a round component is
installed directly beneath the master cylinder, the pipe/hose line
or plastic line must be removed.
Note
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23
pe
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Jetta 2006 , Golf
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5-speed manual
gearbox 0AF - Edition 08.2007
h
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2 - Spring-type clip
3 - Supply hose
Rubber
From 12.05, plastic in
some vehicles
page 25
4 - Master cylinder
Removing and installing
page 19
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6 - Retainer
To remove and install,
separate master cylin
der from clutch pedal.
page 14
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5 - Clip
Pull clip out to stop to re
move or install line be
tween master and slave
cylinders
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7 - Clutch pedal
Removing and installing
page 14
8 - Self-locking hexagon nut,
25 Nm
Mounting bracket to
body
Always renew
9 - O-ring
Pull onto line connection
Insert with brake fluid
Seals, O-rings depending on configuration of line connections page 25
Allocation Electronic parts catalogue ETKA
10 - Seal
Pull onto line connection
Insert with brake fluid
Seals, O-rings depending on configuration of line connections page 25
Allocation Electronic parts catalogue ETKA
11 - Pipe/hose line
Allocation Electronic parts catalogue ETKA
To remove, remove battery and battery tray Electrical system; Rep. Gr. 27 ; Removing and installing
battery .
12 - Retainer
For pipe/hose line Item 11 (page 24)
Secured to body.
13 - Plastic line
Allocation Electronic parts catalogue ETKA
To remove, remove battery and battery tray Electrical system; Rep. Gr. 27 ; Removing and installing
battery .
24
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19 - Hexagon bolt, 20 Nm
20 - Retainer
For pipe/hose line Item 11 (page 24)
Seals and O-rings for pipe/hose line or plastic line
-1-
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-2-
2.9
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18 - Gearbox
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17 - Bleeder valve
Bleeding clutch system page 27
25
2.9.1
Removing
First check whether a coded radio is fitted. If so, obtain antitheft code.
With ignition switched off, disconnect battery Electrical sys
tem; Rep. Gr. 27 ; Disconnecting and connecting battery .
Remove complete air filter housing if it is near slave cylinder
Rep. Gr. 24 ; Repairing injection system .
Remove securing clip for gear selector cable -arrow 1- from
gearbox selector lever -A-.
Pull gear selector cable from pin.
Metal relay lever
Remove securing clip -arrow 2- for gate selector cable from
relay lever -B-.
Pull gate selector cable from pin.
Pull securing clip -arrow 3- off relay lever -B- and remove relay
lever.
Plastic relay lever
Remove relay lever together with cable end-piece from gear
box page 50 .
Continuation for all
Remove gearbox selector lever -A- by removing nut
-arrow 4-.
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Pull clip -A- for line between master and slave cylinders out of
slave cylinder to stop.
Pull line between master and slave cylinders out of support
-C-.
Pull line between master and slave cylinders -B- out of slave
cylinder and seal opening.
AG.
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26
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2.9.2
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27
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To bleed system, use 670 mm
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ris
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28
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1 - Release bearing
Remove and install to
gether with clutch re
lease lever
Item 3 (page 29)
and guide sleeve
Item 5 (page 29)
page 30 to
page 30
Do not wash out bear
ing; wipe only
Renew noisy bearings
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4 - Retaining spring
Secure to clutch release
lever
5 - Guide sleeve
Remove and install to
gether with release
bearing
Item 1 (page 29) and
guide sleeve
Item 5 (page 29)
page 30 to page 30
6 - Input shaft seal
Removing and installing page 89
7 - Ball stud, 20 Nm
Remove old grease
3. Repairing clutch release mechanism
29
wa
Removing and installing clutch release lever with release
ksbearing
Vol
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and guide sleeve
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Pull clutch release lever with release bearing and guide sleeve
off input shaft and ball stud.
30
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Check whether dowel sleeves for aligning engine and gearbox are fitted in cylinder block and install if nec
essary.
If dowel sleeves are not fitted, difficulties shifting gears, clutch problems and possible noises from the gear
Replace clutch plates and pressure plates with damaged or loose rivets.
Allocation Electronic parts catalogue ETKA .
4. Repairing clutch
31
pe
rm
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wit
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Note
4 - Bolt, 20 Nm
Allocation Electronic parts catalogue ETKA
Loosen or tighten diagonally and in steps
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 damage to the pressure plate centring hole and
the flywheel centring pins.
32
AG.
3 - Pressure plate
Removing and installing
page 32 .
Check ends of dia
phragm spring
page 33
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2 - Clutch plate
Allocation Electronic
parts catalogue ETKA
Installation position with
two-part flywheel: short
er end of hub faces
pressure plate
Text
Getriebeseite (gear
box side) always faces
pressure plate and
gearbox
Installation position with
single piece flywheel:
spring cage faces pres
sure plate
Centring page 32 .
Lightly grease splines
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1 - Flywheel
Ensure that centring
pins fit tightly
Contact surface for
clutch lining must be
free of grooves, oil and
grease
Removing and installing
Rep. Gr. 13
un
le
es, in part or in w
l purpos
hole
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, is n
m
m
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4. Repairing clutch
33
34
Controls, housing
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2.1
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C - Heat shield
Remove before remov
ing gear selector mech
anism
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35
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Prote
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ment.
For work on selector mechanism in engine compartment, remove complete air filter housing if it is located
36
AG.
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rig
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37
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Prote
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2.2
1 - Emblem
Can be carefully levered
off selector lever knob of
plastic or leather
2 - Selector lever knob
With gaiter
Selector lever knob and
gaiter cannot be sepa
rated from one another
Always renew together
Removing and installing
page 38
3 - Clamp
For securing selector
lever knob to selector
lever
Always renew
rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit
2.3
ility
ab
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5 - Noise insulation
Not fitted in all vehicles
Arrow on noise insula
tion points in direction of
travel
Locking lugs are ar
ranged at varying inter
vals
Therefore it can be in
stalled in only one posi
tion
AG. Volkswagen AG d
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38
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2.3.1
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AG.
Install selector lever knob and gaiter and squeeze new clamp
-arrow- together.
When selector lever knob is pushed on, it must engage in cir
cumferential groove in selector lever.
Then press gaiter into frame of centre console.
39
2.4
Lubricate bearing positions and sliding surfaces with grease -G 000 450 02- .
1 - Securing clip
Removing and installing
page 41
2 - Bush
3 - Compression spring
4 - Bush
5 - Torx screw, 5 Nm
6 - Cover
7 - Damping
8 - Damping
9 - Ball socket
10 - Selector lever guide
11 - Damping washer
12 - Seal
Between selector lever
housing and underbody
Self-adhesive
Bond to selector lever
housing
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Selector lever housing
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Bearing bushss a
13 - Selector lever
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15 -
es, in part or in w
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14 -
16 - Pivot pin
17 - Guide bush
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
18 - Compression spring
Installing page 41
19 - Gate selector lever
20 - Torx screw, 5 Nm
21 - Seal
Always renew
22 - Base plate
Bend open tabs to remove
Always renew
AG.
Prote
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40
do
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To do this, raise tab using screwdriver -arrow 1- and press
ris off
ho
t
securing clip -arrow 2-.
au
ss
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pe
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spec
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com
AG.
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Prote
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Note
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41
2.5
w
Lubricate bearing points and sliding surfaces with grease
olks -G 000 450 02- .
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7 - Bush
8 - Gear selector cable
Lever off selector lever
guide
Press onto selector lev
er inside selector mechanism
Installation position page 35
9 - Damping
10 - Ball socket
Will be damaged when removed.
Always renew
11 - Bush
12 - Securing clip
Removing and installing page 41
13 - Compression spring
Removing and installing page 41
42
AG.
do
c
um
en
5 - Securing clip
Do not damage cables
when removing
Always renew
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4 - Damping washer
Push onto selector lever
up to stop -arrow-
Prote
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by c
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C
op
yi
3 - Selector lever
Can be removed and in
stalled with selector lev
er guide
Item 15 (page 43)
installed
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
2 - Seal
Always renew
ility
ab
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an
pt
ce
1 - Base plate
Bend open tabs to re
move
Always renew
43
not
gu
ara
nte
eo
ra
c
ht
rig
py
Co
t.
b
ed
ris page
mechanism
o
h
t
au
ss
2.5.1
es, in part or in w
l purpos
hole
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, is n
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43
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Lever ball socket -A- with selector lever guide
wage -B- out of se does n
s
k
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o
lector lever housing.
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Then press ball socket off bearing ball of selector lever guide
and remove it.
agen
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44
ht
rig
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Co
t.
Now pull selector lever guide up to stop and pull ball stud out
of gate selector lever -arrow 2-.
do
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spec
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wit
es, in part or in w
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ercia
, is n
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n AG. Volkswagen AG do
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ir se
tee
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or
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ac
a
ss
The selector lever guide must project from the selector lever
housing up to the stop.
45
AG. Volkswagen AG d
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The selector lever guide must project from the selector lever
housing up to the stop.
c
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46
Prote
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by
AG.
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2.6
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agen
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AG.
Prote
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by
5 - Securing clip
Always renew
Do not damage cables
when removing
c
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t
.
C
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ht
rig
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Co
t.
3 - Securing clip
Always renew
do
c
um
en
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
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s
es, in part or in w
l purpos
hole
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com
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Lubricate bearing positions and sliding surfaces with grease -G 000 450 02- .
6 - Hexagon bolt, 20 Nm
Qty. 3
For support bracket
7 - Support bracket
May be made from plastic or metal
8 - Grommet
Support bracket mounting on gearbox
9 - Spacer
10 - Cable end-piece
After installing, adjust selector mechanism page 54
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 13 (page 48)
From 05.07, fitted in conjunction with plastic relay lever page 50
Removing from plastic relay lever page 50
Pressing onto plastic relay lever page 50
2. Repairing selector mechanism
47
agen
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Vo
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AG.
Prote
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by
c
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py
rig
ht
.
C
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thi
sd
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en
48
rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit
ility
ab
y li
an
pt
ce
es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
o
c
erm
or
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t
a
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du
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f
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ng
AG. Volkswagen AG d
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16 - Shoe
Dimension a
8.5 mm
10 mm
8 mm
10 mm
. Volkswagen AG
gen AG
d
Dimension a oes not g
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10 mm
tee
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8.5 mm
a
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Support pin for gear selector cable end-piece
Vol
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db
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r
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s
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nf
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spec
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n in
wit
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hole
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t
a
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f
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ng
Through 05.06
From 06.06
ht
rig
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49
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AG.
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or
Variant
u 2008
ac
a
ss
2.7
r
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c
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C
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Prote
cted
by
The cable end-piece can be removed only with the relay lever
removed page 51 .
Note
To fit, lubricate bearing points and sliding surfaces with grease G 000 450 02- .
Press cable end-piece onto relay lever page 51 .
Insert relay lever together with cable end-piece.
50
agen
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ht
rig
py
Co
t.
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
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c
um
en
urposes, in part or in wh
ole,
cial p
is n
mer
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or
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t
a
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v
i
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p
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2.8
2.8.1
Removing
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form
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thi
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urposes, in part or in wh
ole,
cial p
is n
mer
m
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or
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t
a
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p
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AG. Volkswagen AG d
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Jetta
2006
,
Golf
Variant
2008
o
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h
ut
ra
a
5-speed
manual
gearbox
0AF
Edition
08.2007
c
s
s
Grease -G 000 450 02 First check whether a coded radio is fitted. If so, obtain antitheft code.
With ignition switched off, disconnect battery earth strap
Electrical system; Rep. Gr. 27 ; Removing and installing bat
tery .
2. Repairing selector mechanism
51
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AG. Volkswagen AG d
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52
2.8.2
Installing
n Gd
AG
Fit relay lever and cable end-piece
page
agen together A
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Nm
Prote
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Nuts M6 = 8
Nuts M8 = 25
20 Nm
AG.
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Component
Torque settings
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2.8.3
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53
2.9
Note
The following points are essential to ensure correct adjust
condition.
ss
does
not
gu
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ra
c
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54
ht
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Co
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fo
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s
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form
spec
atio
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n
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thi
sd
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um
en
urposes, in part or in wh
ole,
cial p
is n
mer
m
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o
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erm
or
e
t
a
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v
i
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d
p
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ab
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ce
un
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o
Pull locking mechanisms on gate selector
cable and gear se
yV
db
e
lector cable forward to stop -direction
of
arrow
1- and then turn
is
r
tho
to left to lock -direction of arrow
au 2-.
ht
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spec
atio
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wit
Check that gate and selector cables -B- are inserted, free of
stress, into locking device -A-.
thi
sd
o
cu
m
en
es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
o
c
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or
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t
a
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AG. Volkswagen AG d
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c
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2.9.1
Functional check
With gearbox in neutral, selector lever must rest in gate for 3rd
and 4th gear.
Operate clutch.
Select all gears several times. Pay particular attention to op
eration of reverse gear lock.
55
ht
rig
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56
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
om
c
r
erm
o
e
t
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Torque wrench -V.A.G 1331 Torque wrench -V.A.G 1332 Engine and gearbox jack -V.A.G 1383 A Grease for clutch plate splines -G 000 100 Grease -G 000 450 02-
3.1
Removing gearbox
First check whether a coded radio is fitted. If so, obtain antitheft code.
With ignition switched off, disconnect battery Electrical sys
tem; Rep. Gr. 27 ; Disconnecting and connecting battery .
If the lifting eyes of the engine for support bracket -10 - 222 Aare covered by a component, for example the air filter, it must
be removed now. Rep. Gr. 24 ; Repairing injection system
Remove complete air filter housing if it is over the gearbox
Rep. Gr. 24 ; Repairing injection system .
Remove battery and battery tray Electrical system; Rep.
Gr. 27 ; Removing and installing battery .
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Lower gearbox, being careful of subframe -arrow 1-.
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For vehicles with a sheet metal sump, install cover plate near
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axles, steer
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system; Rep. Gr. 27 ; Starter .
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To fit, lubricate bearing points and sliding surfaces with grease G 000 450 02- .
Insert relay lever -B- into mounting of selector cover.
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3.4
Gearbox to engine
Item
Bolt
Quantity
Nm
1
2
M 12 x 65
M 12 x 135
Additionally, start
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2
2
80
80
3
4
M 10 x 60
M 12 x 90
3
1
40
80
70
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40 Nm + 90
60 Nm + 90
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To check gear oil, remove oil plug -arrow-.
Oil level is correct when gearbox is filled to lower edge of filler
hole.
Tighten oil plug -arrow- to specified torque page 73 .
When filling with oil, note the following:
Remove oil plug -arrow-.
Fill with gear oil to lower edge of filler hole.
Screw in plug -arrow-.
Start engine, engage gear and allow gearbox to turn for ap
prox. 2 minutes.
Stop engine and remove plug -arrow-.
Top up with gear oil to lower edge of filler hole.
Tighten oil plug -arrow- to specified torque page 73 .
72
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5.1
Overview - gearbox
1 - 1st gear
2 - 2nd gear
3 - 3rd gear
4 - 4th gear
5 - 5th gear
6 - Gearbox housing cover
7 - Gearbox housing
8 - Reverse gear
9 - Selector mechanism
(Selector forks)
10 - Clutch housing
11 - Input shaft
12 - Output shaft
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5.2
Assembly overview
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5.3
Assembly overview - removing and installing cover for gearbox housing and
5th gear
1 - Gearbox housing
Repairing page 89
2 - Gear wheel for 5th gear
Removing and installing
page 79
3 - Retaining ring
Renew
Determining thickness
page 88
4 - Seal
5 - Gearbox housing cover
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5.4
1 - Countersunk bolt, 25 Nm
2 - Flange shaft with compres
sion spring
Removing and installing
page 79
Assembling
page 124
3 - Bolt, 5 Nm then turn 90 fur
ther
Always renew
4 - Clutch housing
Repairing page 89
5 - Gearbox housing
Repairing page 89
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page 29
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5.5
Assembly overview - removing and installing input shaft, output shaft (drive
pinion), differential, selector mechanism and selector forks
1 - Differential
Dismantling and assem
bling page 124
2 - Gearbox housing
Repairing page 89
Shim S1 for outer race
of tapered roller bearing
for differential from
gearbox build date
04 12 6 is discontinued
page 134
Bearing seat for tapered
roller bearing outer race
adapted in gearbox
housing
3 - Oil drain plug, tightening
torque page 73
4 - Flange shaft with compres
sion spring
Removing and installing
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Remove flange shaft alongsswith
spring, thrust washer and ta
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Pull out pivot pin -1- for 5th gear -2- and remove selector fork.
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Remove clutch housing, ifonecessary
carefully levering up all
ris
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around along protrudingauhousing
flange and alternating be
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tween sides, being careful
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Press needle roller bearing inner race for 5th gear synchro
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85
Prote
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Install selector shaft with selector cover -A-. Then tighten bolts
-arrows-.
86
AG.
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Turn gearbox in support bracket
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upwards.
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87
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Thickness (mm)
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Prote
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9 - Clutch housing
If renewed, adjust differ
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AG.
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6 - Retaining ring
Insert in groove of cylin
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5 - Retaining ring
Insert in groove of cylin
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ility
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4 - Sealing cover
Apply sealant -AMV 188
200 03- before bolting
on.
un
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3 - Magnet
Held in place by housing
joint surface
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91
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differential.
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92
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3 - Retaining pin
For adjusting shift
mechanism
Removing page 95
Driving in page 96
un
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4 - Relay lever
Installation position
page 49
From 05.07, plastic re
lay lever page 50
5 - Bearing bush
Not required for plastic
relay lever
6 - Seal
Lever out with a screw
driver
Installing page 96
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7 - Cap
For gearbox breather
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9 - Hexagon nut, 23 Nm
Always renew
10 - Securing clip
Always renew
Not required for plastic relay lever
Removing retaining pin -A- from selector shaft cover
Remove outer part of retaining pin.
Then carefully lever out retaining pin using a screwdriver.
95
n AG. Volkswagen AG do
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do
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a
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97
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AG. Volkswagen AG d
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Jetta 2006 , Golf Variant
Vol2008
by
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5-speed manual gearbox
0AF - Edition 08.2007
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Note
It is not necessary to dismantle the selector fork group Item 1 (page 99) in order to dismantle and assemble
selector segments, lock washers and angular contact ball bearings.
98
es, in part or in w
l purpos
hole
ercia
, is n
m
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99
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AG. Volkswagen AG d
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Clamp selector fork in vice with protective
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-B-.
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Lever off lock washer -A- in adirection
of arrow.
c
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AG.
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100
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Pressing inner race -A- of angular contact ball bearing into outer
race
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101
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35
Gears, shafts
Input shaft
1.1
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102
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AG.
AG. Volkswagen AG d
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Install all bearings, synchromeshed gears and synchro-rings on input shaft with gear oil.
Do not interchange synchro-rings. When reusing always fit to the original gear.
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7 - Gearbox housing
Repairing page 89
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6 - Sleeve
For 5th gear needle
bearing
Renew together with
Item 5 (page 105)
Press off with bearing
mounting with deep
groove ball bearing
page 107
Pressing on.
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9 - Input shaft
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20 - Retaining ring
Renew
Determining thickness page 110
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Repairing page 89
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23 - Spring
Installation position page 108
24 - 3rd and 4th gear locking collar
31 - Stop ring
Prevents the locking pieces from drifting out.
Removing page 111
Installing page 112
106
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27 - Spring
Installation position page 108
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Slide locking collar for 1st and 2nd gear towards 2nd gear.
Then slide pressure plate -T10084 A- onto input shaft to stop
from side.
Insert thrust piece -T10081- centralizing pins into holes in input
and output shafts.
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Pulling off sleeve for cylindrical roller bearing with 4th gear syn
chromeshed gear
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1. Input shaft
107
Dismantling and assembling 3rd and 4th gear locking collar and
synchro-hub
1-
Spring
2-
Locking collar
3-
Synchro-hub
4-
Locking piece
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Deeper notches -arrow A- for locking
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Assembling locking collar and synchro-hub for 3rd and 4th gears
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108
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Wear limit
1.11.7 mm
0.5 mm
Pressing on synchro-hub with locking collar for 3rd and 4th gears
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Checking synchro-ring for wear
db
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Press synchro-ring onto cone of synchromeshed
gear and
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measure gap -a- using feeler gauge.
s
1. Input shaft
109
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1. Input shaft
111
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112
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Tube -VW 415 A Thrust piece -VW 432 Drift sleeve -30 - 100-
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2. Output shaft
113
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.
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3 - Output shaft
If an inner race as bear
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roller bearing
Item 2 (page 114) is
present, it cannot be re
moved from output shaft
Check bearing seat or
inner race for cylindrical
roller bearing for scoring
and damage.
If cylindrical roller bear
ing inner race or bearing
seat is damaged or
scored, renew output
shaft and cylindrical roll
er bearing together
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114
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15 - Retaining ring
Pressing out page 116
Installing page 119
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2. Output shaft
115
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116
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Pressing off 1st and 2nd gear locking collar and synchro-hub
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Install retaining ringd b-1-.
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Wear limit
0.751.25 mm
0.3 mm
1.21.8 mm
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2. Output shaft
117
Spring
2-
Locking collar
3-
Synchro-hub
4-
Locking piece
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Assembling locking collar with synchro-hub for 1st and 2nd sgears
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Pressing on locking collar and synchro-hub for 1st and 2nd gears
Installation position:
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Groove in locking collar for selector fork faces 1st gear and teeth
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1.1
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Pull out flange shaft oil seal using multi-purpose tool -VW 771and puller hooks -VW 771/37- .
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1.1.2
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121
1.1.3
Torque settings:
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Torque settings:
123
Differential
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2. Differential
125
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126
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page 132 .
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If tapered roller bearings, differential cage, gearbox housing or clutch housing is renewed, adjust differential
2. Differential
127
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7 - Sun wheel
Installing
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14 - Shim S1
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For differential
Always 1 mm thick
Shim S1 discontinued as of gearbox date 04 12 6 page 134
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Bearing seat for tapered roller bearing outer race adapted in gearbox housing
Allocation Electronic parts catalogue (ETKA)
15 - Tapered roller bearing outer race
Pulling out page 129
Pressing in page 129
16 - Tapered roller bearing inner race
Pulling off page 130
Pressing on page 130
128
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Determining thickness page 132
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Repairing page 89
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2. Differential
129
Both tapered roller bearing inner races are pulled off the differ
ential cage in the same way.
130
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Drive differential pinion pin into final position and secure with
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131
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2.2
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2. Differential
133
Shim S1
15.2 mm
16.2 mm
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Prote
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2.2.1
Determining shim S2
134
1.50 mm
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0.35 mm
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2. Differential
135
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