Service: Jetta 2013 Jetta 2015

Service
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6-speed manual gearbox 0AJ
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Service Department. Technical Information

Service
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
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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 © 2017 Volkswagen AG, Wolfsburg D4B8033B594

Jetta 2013 ➤ , Jetta 2015 ➤
6-speed manual gearbox 0AJ - Edition 06.2017
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Identification of gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Location on gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Identification code, assembly allocation and capacities AG. Volkswa.g.en. A ......................... 1
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2 Overview - power transmission . . . y.V.o.l . . . . . . . . . . . . . . . . . . . .s.n.ot.g.u . . . . . . . . . . . . . . . .
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3 Calculating overall gear ratio “i”orise. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . a.nt.ee. . . . . . . . . . . . . 5
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4 General repair instructions ss a. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .r a.c. . . . . . . . . . 6
4.1 Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
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30 - Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
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1 Fault finding, power transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
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2 Repairing clutch mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
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2.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
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2.2 Assembly overview - pedal cluster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
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2.3 Removing and installing over-centre spring (left-hand drive) . . . . . . . . . . . . . . . . . . . . . . . . 13
2.4 Removing and installing over-centre spring (right-hand drive) . . . . . . . . . . . . . . . . . . . . . . 18
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2.5 Removing and installing clutch pedal (LHD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
2.6 Removing and installing clutch pedal (RHD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
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2.7 Removing and installing mounting bracket (LHD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

2.8 Removing and installing mounting bracket (RHD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
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2.9 Removing and installing clutch master cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
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2.10 Removing and installing clutch position sender G476 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
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2.11 Assembly overview - hydraulics (LHD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
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2.12 Assembly overview - hydraulics (RHD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

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2.13 Removing and installing clutch slave cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
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3 Bleeding clutch mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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4 Repairing clutch release mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
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4.1 Assembly overview - clutch release mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
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4.2 Removing and installing clutch release lever, release bearing and guide sleeve . . . . . . . . cted
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5 Repairing clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
34 - Controls, housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
1 Repairing selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
1.1 Installation position of selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
1.2 Overview of selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
1.3 Assembly overview - gear knob and cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
1.4 Removing and installing gaiter with gear knob and noise insulation . . . . . . . . . . . . . . . . . . 68
1.5 Assembly overview - Gear lever and selector housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
1.6 Assembly overview - Selector cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
1.7 Removing cable end-piece from relay lever and installing . . . . . . . . . . . . . . . . . . . . . . . . . . 81
1.8 Removing and installing selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
1.9 Removing and installing gear selector cable and gate selector cable . . . . . . . . . . . . . . . . 87
1.10 Adjusting selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
2 Removing and installing gearbox, Jetta 2011 ► . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
2.1 Removing gearbox, Jetta 2011 with 1.2 l engine and 1.4 l engine . . . . . . . . . . . . . . . . . . . . 92
2.2 Installing gearbox, Jetta 2011 with 1.2 l engine and 1.4 l engine . . . . . . . . . . . . . . . . . . . . 102
3 Transporting gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
4 Checking gear oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
5 Dismantling and assembling gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
5.1 Overview - gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
5.2 Assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Contents i
Jetta 2013 ➤ , Jetta 2015 ➤
5.3 Assembly overview - Removing and installing cover for gearbox housing and 5th and 6th
gears . . . . . . . . . . . . . . . . . . . . . .e.n.A.G.. V. o.lk.s.w.ag. e.n.A.G. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
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5.4 Assembly overview - removing olksand installing clutch housing not . . . . . . . . . . . . . . . . . . . . . . . . 117
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5.5 Assembly overview - removing ris
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mechanism and selector utho forks . . . . . . . . . . . . . . . . . . . . . . . . . .ee. o.r . . . . . . . . . . . . . . . . . . 118
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5.6 Assembly sequence ss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .c . . . . . . . . . . . . . . . . . 120
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Repairing gearbox housing and clutch housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
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7 Assembly overview - gearbox housing cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
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8 Repairing gearbox housing cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
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9 Repairing selector unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
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10 Dismantling and assembling selector forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
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35 - Gears, shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
1 Input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
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1.1 Dismantling and assembling input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
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2 Output shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165

2.1 Dismantling and assembling output shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
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39 - Final drive - differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173

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1 Renewing flange shaft oil seals with gearbox installed . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
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1.1 Renewing oil seal for left flange shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
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1.2 Renewing seal for right flange shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
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2 Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
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2.1 Dismantling and assembling differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177

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2.2 Adjusting differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
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ii Contents
Jetta 2013 ➤ , Jetta 2015 ➤
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1 Identification of gearbox utho
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The 6-speed manual gearbox 0AJ is installed in the Jetta 2011 in
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Allocation
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1.1 Location on gearbox
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Code letters and date of gearbox manufacture -arrow-
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Codes and production date of gearbox -arrow-
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Example: FVG 12 11 2
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I I I I
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Identification Day Month Year (2002) of
code manufacture
Additional data provide information about the production facility.
Note
The gearbox code also appears on the vehicle identification

plates.
1.2 Identification code, assembly allocation and capacities

Manual gearbox 6-speed, 0AJ
Identification code LHX NBW PRJ
Manufac‐ from 11.08 12.10 11.08
tured to 11.08 12.10
Allocation Model Jetta 2011 ► Jetta 2011 ► Jetta 2011 ►
Engine 1.4 l - 90 kW 1.2 l - 77 kW 1.2 l - 77 kW
1.4 l - 90 kW 1.4 l - 90 kW
Ratio Final drive 74 : 17 = 4.352 73 : 18 = 4.056 73 : 18 = 4.056
Z1 : Z2
Capacity of manual gear‐ 2.0 l 2.0 l 2.0 l
box
Drive shaft flange diame‐ 100 mm 100 mm 100 mm
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1. Identification of gearbox 1
Jetta 2013 ➤ , Jetta 2015 ➤
The following data can be found in the ⇒ Electronic parts cata‐

logue (ETKA) :
♦ Individual gear ratios
♦ Gear oil
♦ Clutch allocation
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Rep. gr.00 - Technical data Prote AG.
Jetta 2013 ➤ , Jetta 2015 ➤
2 Overview - power transmission

Designation:
-Arrows- indicate direction of travel.
1 - Engine
2 - Clutch
3 - Manual gearbox
4 - Input shaft
5 - Output shaft
6 - Differential
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-Arrows- indicate direction of travel.
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2. Overview - power transmission 3

Jetta 2013 ➤ , Jetta 2015 ➤
I - 1st gear
II - 2nd gear
III - 3rd gear
IV - 4th gear
V - 5th gear
VI - 6th gear
R - Reverse gear
A - Final drive
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4 Rep. gr.00 - Technical data

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Drive gear ZG1 = 51 ZA1 = 18
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Driven gear ZG2 = 36 ZA2 = 73
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iG = gear ratio = ZG2: ZG1= 36 : 51 = 0.706
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iA = final drive ratio = ZA 2: ZA1 = 73 : 18 = 4.506
itotal = overall ratio = iG x iA = 0.706 x 4.506 = 3.181
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1) Z1 = no. of teeth on driving gear, Z2 = No. of teeth on driven gear
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3. Calculating overall gear ratio “i” 5

Jetta 2013 ➤ , Jetta 2015 ➤
4 General repair instructions

To ensure flawless and successful gearbox repairs, the greatest
care and cleanliness as well as the use of good and proper tools
are essential. Also note the basic rules on safety when performing
repair procedures.
A series of instructions generally applicable to the various repair
procedures - which were previously repeated a number of times
at various places in the workshop manual - are summarised under
the topic “components” ⇒ page 6 . They apply for this particular
workshop manual.
4.1 Components
4.1.1 Gearbox
♦ 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. G. Volkswasurfaces
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♦ Following thinstallation,
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♦ Capacity
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4.1.2 O-rings, seals and gaskets

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♦ Renew O-rings, seals and gaskets.

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♦ Seals for flange shafts, drive shaft and selector shaft are also
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♦ When oil seals and gaskets have been removed, check con‐
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tact surface on housings or shafts for burrs and damage and

rectify as necessary.
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♦ Before installing shaft seals, lightly oil outer circumference and

half-fill space between sealing lips -arrow- with sealing grease
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- G 052 128 A1- .

♦ The open side of the oil seals faces toward the side with fluid
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♦ After renewing seals and gaskets, check oil level in gearbox

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and replenish if necessary ⇒ page 111 .

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♦ Lightly oil O-rings before installing; this prevents the rings be‐
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4.1.3 Sealant
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♦ Thoroughly clean housing joint surfaces before applying seal‐
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♦ Evenly apply a thin coat of sealing paste - AMV 188 200 03- .
♦ Breather holes must remain free of sealing paste.

Jetta 2013 ➤ , Jetta 2015 ➤
4.1.4 Locking devices
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♦ Do not overstretch retaining rings.
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♦ Installation position for retaining rings: At the top, the ring is
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»narrower« and its installation position therefore as well. This
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make it possible for the pliers to gain a better grip during re‐
moval and installation.
♦ Always renew retaining rings which have been damaged or
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♦ Retaining rings must locate properly in grooves.

♦ Renew spring pins. Installation position: slit -A- should be in
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4.1.5 Nuts and bolts
agen
Prote AG.
♦ Loosen nuts or bolts in the order opposite to the tightening

sequence.
♦ Securing bolts and securing nuts which secure covers and
housings should be loosened and tightened diagonally in
stages if no tightening sequence is specified.
♦ Do not cant especially delicate parts, such as clutch pressure
plates. Loosen and tighten bolts and nuts in stages in a diag‐
onal sequence.
♦ Specified torques given are for unoiled nuts, bolts and screws.
♦ 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.
♦ Clean threads of bolts which are to be installed with locking
fluid using a wire brush. Then insert bolts with locking fluid -
AMV 185 101 A1- .
♦ Threaded holes into which self-locking bolts or bolts with lock‐
ing agent have been screwed must be cleaned (e.g. with a
screw tap). Otherwise there is a danger that the bolts will shear
off when refitted.
♦ Check pitch of thread, to ensure correct thread chaser is used
for cleaning and that threads are not damaged.
4. General repair instructions 7

Jetta 2013 ➤ , Jetta 2015 ➤
4.1.6 Bearings
♦ Install needle bearings with lettered side (thicker metal) to‐
wards fitting tool.
♦ Lubricate all gearbox bearings with gear oil before installing.
♦ Tapered roller bearings fitted to one shaft must be renewed as
a set. Use same make of bearings.
♦ Heat inner races to about 100°C with the inductive heater -
VAS 6414- before installing.
♦ Do not interchange outer or inner races of bearings of the
same size. The bearings are matched in pairs.
4.1.7 Shims
♦ Measure shims at several points with a micrometer. The var‐
ious thicknesses make it possible to achieve the exact shim
thickness required.
♦ Check for burrs and damage.
♦ Install only flawless shims.
4.1.8 Synchro-rings
♦ Do not interchange them. When reusing synchro-rings, always
fit to the same synchromeshed gear. n AG. Volkswagen AG age does
ksw not
♦ Check for wear and renew if necessary. by Vol gu
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♦ Check grooves -arrow 1- of synchro-ring
tho -A- and inner ring for eo
flat spots (worn grooves). ss au ra
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♦ If synchro-rings are coated, coating must not be damaged.

nl
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♦ If an intermediate ring -B- is installed, check the outer friction

erm
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surface -arrow 2- and inner friction surface -arrow 3- of this

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intermediate ring for »scoring«, »signs of abnormal wear« and

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»blue discolouration (due to overheating)«.

h re
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spec
♦ If the synchro-rings are coated, check cone of synchromeshed

es, in part or in w
gear for »scoring« and »signs of abnormal wear«.

t to the co
♦ Moisten synchromesh mechanism with gear oil before instal‐

ling.
rrectness of i
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nform
ercia
4.1.9 Gear wheels

m
at
om
♦ Heat sleeves for needle bearings to about 100°C with the in‐
on
c
in t
ductive heater - VAS 6414- before installing.

or
his
ate
♦ Heat synchro-hub with inductive heater - VAS 6414- to approx.

do
priv
100°C before installing. Press in to stop when installing so

um
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there is no axial clearance.

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♦ Heat gears with inductive heater - VAS 6414- to approx. 100°
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C before installing. Press in to stop when installing so there is p by
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no axial clearance.
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♦ Observe installation position

Jetta 2013 ➤ , Jetta 2015 ➤
4.1.10 Synchromeshed gears

♦ After assembly, check synchromeshed gears for slight play, or
for freedom of movement.
4.1.11 Clutch olksw

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AG. Volkswagen AG d
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♦ Ensure that the pressure plate
rise
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en bolts diagonally andut in several gradual stages.
ho eo
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♦ If the clutch has burnt out, thoroughly clean the clutch housing
ce
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nl
as well as the friction surface of flywheel with a cloth to reduce
pt
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the smell of burnt linings.
itte
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♦ When removing gearbox, remove clutch slave cylinder without
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disconnecting pipes.
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♦ Once the clutch slave cylinder has been removed with the hy‐
hole
spec
draulic line attached, do not depress clutch pedal. Otherwise
es, in part or in w
the piston will be pressed out of the clutch slave cylinder.
t to the co
rrectness of i
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4. General repair instructions 9

Jetta 2013 ➤ , Jetta 2015 ➤
30 – Clutch
1 Fault finding, power transmission
Please note:
♦ ⇒ Fault finding, power transmission; Rep. gr. 30 ; Complaints
regarding clutch and clutch actuation
♦ ⇒ Fault finding, power transmission; Rep. gr. 34 ; Complaints
regarding selector mechanism
AG. Volkswagen AG d
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Prote AG.
10 Rep. gr.30 - Clutch

Jetta 2013 ➤ , Jetta 2015 ➤
2 Repairing clutch mechanism
2.1 Overview
Note
♦ If the vehicle has a radio with anti-theft coding, obtain code before disconnecting battery.
♦ Disconnect battery earth strap ⇒ Electrical system; Rep. gr. 27 ; Battery; Disconnecting and connecting
battery .
♦ When reconnecting battery, refer to ⇒ Electrical system; Rep. gr. 27 ; Battery; Disconnecting and connecting
battery .
♦ Grease all bearing points and contact surfaces. Allocate grease using ⇒ Electronic parts catalogue (ETKA) .
I - Assembly overview - pedal

cluster ⇒ page 12
II - Assembly overview - hy‐
draulics (LHD) ⇒ page 51
III - Assembly overview - hy‐
draulics (RHD) ⇒ page 54
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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Prote AG.
2. Repairing clutch mechanism 11

Jetta 2013 ➤ , Jetta 2015 ➤
2.2 Assembly overview - pedal cluster
1 - Bulkhead
❑ With support for mount‐
ing bracket
2 - Seal
❑ Renew after removal
❑ Between mounting
bracket and bulkhead
❑ Self-adhesive
❑ Bond to mounting
bracket
3 - Mounting bracket
❑ For mounting clutch
pedal
❑ Is provided with damp‐
ing in some equipment
variants ⇒ page 13
❑ Removing and installing
⇒ page 34
4 - Bolt
5 - Over-centre spring
(LHD) ⇒ page 13 n AG. Volkswagen AG do
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❑ Removing and installing y Volks ot g
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(RHD) ⇒ page 18 ised b ran
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6 - Bearing bush aut or
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7 - Bearing mounting
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8 - Clutch pedal
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(LHD) ⇒ page 23
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(RHD) ⇒ page 29
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9 - Support
❑ To remove and install, separate clutch master cylinder from clutch pedal
⇒ “2.5 Removing and installing clutch pedal (LHD)”, page 23
rrectne
10 - Seal
s

s o
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❑ Between clutch master cylinder and mounting bracket

inform
mer
11 - Clutch master cylinder

atio
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❑ Removing and installing after removal of mounting bracket ⇒ page 46

o
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12 - Clutch position sender - G476-

te
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❑ Removing and installing ⇒ page 48

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❑ Can be checked in “Guided Fault Finding” using vehicle diagnostic tester

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❑ The clutch position sender - G476- is identified as clutch pedal switch - F36- in “guided fault finding”
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13 - Clip cop Vo
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❑ Pull out clip to stop to remove and install pipe/hose assembly or plastic line Prote AG.
14 - Supply hose
❑ Made of plastic ⇒ page 53

Jetta 2013 ➤ , Jetta 2015 ➤
15 - Hexagon nut, 25 Nm
❑ Self-locking
❑ Qty. 3
❑ For mounting bracket to bulkhead
17 - Stop
❑ For clutch pedal
Mounting bracket with damping -arrows-
AG. Volkswagen AG d
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2.3 Removing and installing over-centre
l purpos
spring (left-hand drive)

Special tools and workshop equipment required
nform
ercia
♦ Release tool - T10178-

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tion in
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Prote AG.

Jetta 2013 ➤ , Jetta 2015 ➤
Torque wrench - V.A.G 1331-
2.3.1 Removing
Vehicles with knee airbag
Note
The installation location of the knee airbag is above the pedal

cluster.
– First check whether a coded radio is fitted. If so, obtain anti-

theft code.
– Disconnect battery earth strap ⇒ Electrical system; Rep. gr.
27 ; Battery; Disconnecting and connecting battery .
Continuation for all
– Push driver seat as far back as possible and put steering wheel
in highest position.
– Remove trim and cover below trim on driver side ⇒ General
body repairs, interior; Rep. gr. 68 ; Compartments, covers andwagen AG. Volkswagen AG doe
trims . yV
olks s no
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ed nte
Vehicles with knee airbag thoris e or
au ac
– Remove bracket for knee airbag together withsscrash bar ⇒
ce
le
General body repairs, interior; Rep. gr. 69 ; Airbag; Removing

un
pt
and installing knee airbag bracket.

an
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itte
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– Remove cable guide -2- from steering column.

is n
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ole,
– Remove footwell vent -3- ⇒ Heating, air conditioning; Rep. gr.

spec
80 ; Repairing heating .
t to the co
Vehicles without knee airbag

rrectness o
cial p
f inform
mer
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Prote AG.

Jetta 2013 ➤ , Jetta 2015 ➤
The crash bar -1- in front of clutch pedal -2- may be secured in
different ways.
Attachment with 2 bolts
– Remove crash bar -1- (2 bolts).
Attachment with 1 bolt

– Remove crash bar -1- (1 bolt -2-).
AG. Volkswagen AG d
agen oes
olksw not
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If fitted, remove damping -arrow- from lower area of clutch pedal s
ce
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nl
mounting bracket.
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ility
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– To do this, remove lock washers -A- for damping.

f
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t.
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– Pull off damping. Cop py
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Prote AG.

Jetta 2013 ➤ , Jetta 2015 ➤
– Push damping upwards in area of upper securing nut -1-

above clutch pedal -A- in -direction of arrow-.
AG. Volkswagen AG d
agen oes
olksw not
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un
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ility
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t to the co
rrectne
– Unbolt clutch pedal -1- from mounting bracket -3- by removing
nut -2- and pulling out bolt -5-.
ss o
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f in
Note
form
mer
atio
m
Clutch pedal remains hooked to operating rod of clutch master

o
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c
cylinder.
i
or
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– Swing clutch pedal down slightly and remove over-centre

p
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spring -4- from mounting bracket.

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Prote AG.
2.3.2 Installing
Install in the reverse order of removal, observing the following.
Note
Renew self-locking nuts.

Jetta 2013 ➤ , Jetta 2015 ➤
– Insert over-centre spring -2- in mounting bracket from above

while holding end of spring with assembly tool - T10178- in
installation position.
• Receptacle -arrow- for tip -A- of clutch pedal must stand ver‐
tically. AG. Volkswagen A gen G do
swa es
– Insert tip -A- of clutchy Vpedal in bearing recess of over-centre
olk not
gu
spring. edb ara
ris nt ee
th o
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– Depress clutch
s au pedal slightly, push bolt through and tighten r ac
self-locking nut to specified torque ⇒ page 18 .
s
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un
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ab
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spec
Some cars have damping -arrow- on the clutch pedal mounting

t to the co
bracket.
– Return it to installation position.
rrectne

ss o
cial p
f inform
mer
atio
om
n
c
i
or
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Cop py
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Vo
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by c lksw
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Prote AG.

Jetta 2013 ➤ , Jetta 2015 ➤
different ways.
– Install crash bar -1- and tighten the 2 bolts to specified torque
⇒ page 18 .

– Install crash bar -1- and tighten bolt -2- to specified torque
⇒ page 18 .
AG. Volkswagen AG d
agen oes
olksw not
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rise nte
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au ra
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– Mount cable guide -2- on steering column. s
ce
e
nl
pt
du
– Install footwell vent -3- ⇒ Heating, air conditioning; Rep. gr.

an
itte
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erm
ab
ility
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wit
, is n
h re
– Install bracket for knee airbag together with crash bar ⇒ Gen‐
hole
eral body repairs, interior; Rep. gr. 69 ; Airbag; Removing and

spec
installing knee airbag bracket .

es, in part or in w
t to the co

– Install trim and cover below trim on drive side ⇒ General body
rrectness of i
repairs, interior; Rep. gr. 68 ; Compartments, covers and

trims .
l purpos
– Reconnect battery and perform work required after connecting

battery ⇒ Electrical system; Rep. gr. 27 ; Battery; Discon‐
nf
ercia
necting and connecting battery .

rm
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atio
om
n in
c
2.3.3 Specified torques

or
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te
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Component Nm
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Clutch pedal to mounting bracket 25

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Crash bar to steering column mounting 10
co Vo
by lksw
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bracket (attachment with 2 bolts)
agen
Prote AG.

bracket (attachment with 1 bolt)
♦ Renew bolts for crash bar
2.4 Removing and installing over-centre

spring (right-hand drive)

Jetta 2013 ➤ , Jetta 2015 ➤
♦ Pliers - T10005-
AG. Volkswagen AG d
agen oes
olksw not
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ara
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tion in
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♦ Torque wrench - V.A.G 1331- Cop py
ht. rig
rig ht
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co Vo
by lksw
cted agen
Prote AG.
2.4.1 Removing
theft code.
body repairs, interior; Rep. gr. 68 ; Compartments, covers and
trims .
– Remove bracket for knee airbag together with crash bar ⇒

Jetta 2013 ➤ , Jetta 2015 ➤

n AG. Volkswagen A age G do
ksw es n
y Vol ot g
ua
b
ed ran
oris tee
th or
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ss
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un
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an
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ility
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– Remove crash bar -1- (bolt -2-).
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n
If fitted, remove damping -arrow- from lower area of clutch pedal
thi
te
sd
a
mounting bracket.
iv
o
pr
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ng
t.
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Cop py
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Vo
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by
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Prote AG.

– Pull off damping.

Jetta 2013 ➤ , Jetta 2015 ➤

AG. Volkswagen AG d
agen oes
olksw not
y V gu
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rise nte
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au ra
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nl
pt
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ility
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es, in part or in w
Note
t to the co
Clutch pedal remains hooked to operating rod of clutch master
cylinder.
rrectness of i
l purpos
– Swing clutch pedal down slightly and remove over-centre

nform
mercia
at
om
ion
c
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ate
do
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2.4.2 Installing
cop Vo
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Prote AG.
Note

Jetta 2013 ➤ , Jetta 2015 ➤

installation position.
lkswage es n
o ot g
byV ua
– Receptacle -arrow- for tip -A- of clutchrispedal
ed must stand ver‐ ran
tee
tically. utho
or
a ac
ss
– Insert tip of clutch pedal -1- in bearing recess of over-centre
ce
le
un
spring.
pt
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d
itte
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– Depress clutch pedal slightly, push bolt through and tighten
erm
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bracket. ss
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Prote AG.

Jetta 2013 ➤ , Jetta 2015 ➤
⇒ page 23 .
– Mount cable guide -2- on steering column.

80 ; Repairing heating . olksw AG. V agen AG
agen does
– Install trim and cover below trim on driveVoside
lksw ⇒ General body not
gu
repairs, interior; Rep. gr. 68 ; Compartments,
ed by covers and ara
nte
trims . oris eo
th
au ra
c
Vehicles with knee airbag ss
ce
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itte
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Component Nm
rrectne
♦ Renew self-locking nuts
ss
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bracket f inform
mer
♦ Renew bolt for crash bar

atio
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2.5 Removing and installing clutch pedal

thi
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(LHD)
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t.
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Cop py
♦ Pliers - T10005-
t. rig
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Prote AG.

Jetta 2013 ➤ , Jetta 2015 ➤
6-speed manual gearbox 0AJag-eEdition
n AG. Volk06.2017
swagen AG
do w es n
olks ot g
yV ua
♦ Release tool - T10178- rised b ran
tee
tho or
s au ac
s
ce
e
nl
pt
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ility
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es, in part or in w
t to the co
rrectness of i
♦ Torque wrench - V.A.G 1331-
l purpos
nform
mercia
at
om
ion
c
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or
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ate
do
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2.5.1 Removing
AG.
Note

cluster.

theft code.
trims .

Jetta 2013 ➤ , Jetta 2015 ➤

different ways.
– Remove crash bar -1- (2 bolts).
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
Attachment with 1 bolt ss
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pt
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ility
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos

mounting bracket.
nf
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orm
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or c
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Prote AG.

Jetta 2013 ➤ , Jetta 2015 ➤
. Volkswagen AG
gen AG does
– To do this, remove lock washers
Vol
ksw -A- for damping.
a
not
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– Pull off damping. rise nte
tho eo
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c
s
ce
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un
pt
an
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ility
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wit
is n
h re
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spec
t to the co
rrectne
ss o
cial p
f inform
mer
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n
c
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or
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te
sd
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Cop py
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Prote AG.

– Swing clutch pedal forward slightly and remove over-centre

Jetta 2013 ➤ , Jetta 2015 ➤
– Release clutch pedal from clutch master cylinder using pliers

- T10005- .
– Remove clutch pedal.
2.5.2 Installing
Note
– Attach retainer -2- to clutch master cylinder operating rod -1-.

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to engage.
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Jetta 2013 ➤ , Jetta 2015 ➤
• Receptacle -arrow- for tip -A- of clutch pedal must stand ver‐
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⇒ page 29 .

Jetta 2013 ➤ , Jetta 2015 ➤

trims .
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battery ⇒ Electrical system; Rep. gr. 27 ; Battery; Discon‐
necting and connecting battery .

Component Nm

bracket (attachment with 1 bolt) en AG. Volkswagen AG
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Jetta 2013 ➤ , Jetta 2015 ➤
AG. Volkswagen AG d
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Jetta 2013 ➤ , Jetta 2015 ➤

– Swing clutch pedal forward slightly and remove over-centre
– Release clutch pedal from clutch master cylinder using pliers

- T10005- .
– Remove clutch pedal.
AG. Volkswagen AG d
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s
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Jetta 2013 ➤ , Jetta 2015 ➤

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installation position. swa
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nform
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Some cars have damping -arrow- on the mounting bracket/clutch

pedal.

Jetta 2013 ➤ , Jetta 2015 ➤
⇒ page 34 . wage
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Component Nm

bracket
2.7 Removing and installing mounting

bracket (LHD)
♦ Hose clamps to 25 mm - 3094-

Jetta 2013 ➤ , Jetta 2015 ➤
♦ Spring-type clip pliers - VAS 6362-
AG. Volkswagen AG d
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Prote AG.
27 ; Battery; Removing and installing battery

Jetta 2013 ➤ , Jetta 2015 ➤
Note
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inder -arrow- and remove with electrical connector attached
l purpos
-4-.
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Note

cluster.



Jetta 2013 ➤ , Jetta 2015 ➤
different ways.
– Unbolt crash bar (2 bolts).


mounting bracket. agen
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Prote AG.

Jetta 2013 ➤ , Jetta 2015 ➤

– Remove securing nuts -1- and -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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♦ Renew self-locking nut.

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♦ Allocate all components according to ⇒ Electronic parts cata‐

logue (ETKA) .
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Rep. gr.30 - Clutch
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Jetta 2013 ➤ , Jetta 2015 ➤

bracket.
different ways.
⇒ page 40 .
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Attachment with 1thbolt
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80 ; Repairing heating; Removing and installing left footwell
nform
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agen
Prote AG.

Jetta 2013 ➤ , Jetta 2015 ➤
– Push pipe/hose assembly or plastic line -1- with seal -2- onto
connection of clutch master cylinder -4- until securing clip -3-
engages audibly.
– Test line by tugging on it.
– After removing hose clamp - 3094- , return supply hose to its
original shape, if necessary.
– Bleed clutch mechanism ⇒ page 58 .
– Install battery ⇒ Electrical system; Rep. gr. 27 ; Battery; Re‐
moving and installing battery .
– If completely removed beforehand, install air filter housing ⇒
Rep. gr. 24 ; Injection system; Removing and installing air
filter .

Component Nm
Mounting bracket to bulkhead 25
♦ Renew self-locking nuts.

bracket (attachment with 1 bolt)
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Prote AG.

Jetta 2013 ➤ , Jetta 2015 ➤
Special tools and workshop

equipment required
AG. Volkswagen AG d
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theft code.
An insulation mat is installed in conjunction with some engines.
Appearance may be different from that illustrated.

Jetta 2013 ➤ , Jetta 2015 ➤
– Remove heat shield from pipe/hose assembly -arrows-.
AG. Volkswagen AG d
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Note
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♦ During the following work, ensure that no brake fluid lands on
spec
longitudinal member or gearbox. If this does happen, clean the
t to the co
affected areas thoroughly.
♦ Place a lint-free cloth under the clutch master cylinder.
rrectne
clamp - 3094- .
ss o
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f
– Pull supply hose off clutch master cylinder.
inform
mer
– In addition, for disconnecting, you can seal supply hose with
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sealing tool - T10249/1- .
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Note
When performing work in the footwell, put cloths on the carpet to

protect it from possible brake fluid spills.

trims .
Note

cluster.

Jetta 2013 ➤ , Jetta 2015 ➤

AG. Volkswagen AG d
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Co
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Jetta 2013 ➤ , Jetta 2015 ➤
– Push damping upwards in area of upper securing nut -1-agen AG. Volkswagen AG do
above clutch pedal -A- in -direction of arrow-. Vol
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– Remove securing nuts -1- and -2-.
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2.8.2 Installing
Note
Renew self-locking nut.

AG. Volkswagen AG d
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6-speed
ed b manual gearbox 0AJ - Edition a06.2017
ran
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Some cars have damping -arrow- on the clutch spedal
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⇒ page 46 .
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ng
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Cop py
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rig ht
py by
co Vo
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Prote AG.

trims .

Jetta 2013 ➤ , Jetta 2015 ➤
– Press pipe/hose assembly -2- with seal into connection of

clutch master cylinder.
– Engage securing clip -1-.
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– Clip clutch position sender - G476- into clutch
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d b ran
tee
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utho
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nl
original position, if necessary.
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-arrows-.
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– If disconnected, connect battery ⇒ Electrical system; Rep. gr.
om
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or c
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Prote AG.

Component Nm
Mounting bracket to bulkhead 25
♦ Renew self-locking nuts.

bracket
2.9 Removing and installing clutch master

cylinder

Jetta 2013 ➤ , Jetta 2015 ➤
♦ Pliers - T10005-
AG. Volkswagen AG d
agen oes
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2.9.1 Removing
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– Remove mounting bracket:
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es, in part or in w
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♦ Right-hand drive vehicles ⇒ page 40
– Release retainer for clutch master cylinder operating rod using
rrectness of i
pliers - T10005- .
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– Insert spacer -A- between clutch pedal and stop and press
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clutch pedal to spacer.
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– Release retaining clip -B-, and pull clutch master cylinder out
of mounting bracket -arrow 1- and -arrow 2-.
2.9.2 Installing
• Move clutch pedal to rest position at stop.

Jetta 2013 ➤ , Jetta 2015 ➤
– Insert spacer -A- between clutch pedal and stop and press
clutch pedal to spacer.
♦ Length of spacer = approx. 40 mm (e.g. 1/2" socket)
– Engage clutch master cylinder in mounting bracket -arrow 1-

and -arrow 2-.
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2.10 Removing and installing clutch position

sender - G476-
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Cop py
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Prote AG.

Jetta 2013 ➤ , Jetta 2015 ➤
♦ Hose clamps to 25 mm ∅ - 3094-
2.10.1 Removing
LHD vehicles
theft code.
27 ; Battery; Disconnecting and connecting battery . AG. Volkswagen AG d
agen oes
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– Completely remove air filter housing if it is located in proximity
ed
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ris
of battery ⇒ Rep. gr. 24 ; Injection system; Removing tho and tee
or
installing air filter . ss
au ac
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– Remove battery and battery tray ⇒ Electrical system; Rep. gr.

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Jetta 2013 ➤ , Jetta 2015 ➤
If a pipe/hose line or plastic line -1- with a round component is

installed directly beneath the clutch master cylinder, the pipe/
hose line or plastic line must be removed.
Note
During the following work,swensure

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– Pull pipe/hose assembly or plastic line -1- out from clutch
AG.
master cylinder and seal hose.

– Disconnect connector -4-.
inder -arrow- and remove.
2.10.2 Installing

Jetta 2013 ➤ , Jetta 2015 ➤
Note
♦ Renew hose clips.

♦ Allocate all components according to ⇒ Electronic parts cata‐
logue (ETKA) .
If the pipe/hose assembly or plastic line was removed:

– Push pipe/hose assembly or plastic line -1- with seal -2- onto
connection of clutch master cylinder -4- until securing clip -3-
engages audibly.
– Test pipe/hose line by tugging on it.
original shape, if necessary.
LHD vehicles
– Install battery tray and battery ⇒ Electrical system; Rep. gr.
27 ; Battery; Removing and installing battery .
filter . agen
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2.11 Assembly overview - hydraulics (LHD)
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Jetta 2013 ➤ , Jetta 2015 ➤
1 - Brake fluid reservoir

2 - Spring-type clip
❑ Not fitted
3 - Supply hose
❑ Made of plastic
⇒ page 53
⇒ page 46
5 - Clip
❑ Pull out clip to stop to re‐
move and install pipe/
hose assembly or plas‐
tic line
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some clutch master cyl‐
inders gen AG
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⇒ “2.5 Removing and in‐

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7 - Clutch pedal
h re
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⇒ page 23
t to the co
8 - Hexagon nut
❑ Note and torque setting:
rrectness of i
⇒ Item 15 (page 13)

l purpos
9 - Seal / O-ring
❑ Pull onto line connection
nform
ercia
❑ Insert with brake fluid

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❑ Seals/O-rings are adapted to configuration of line connection ⇒ page 53

com
tion in
❑ For allocation refer to ⇒ Electronic parts catalogue (ETKA)

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10 - Pipe/hose or plastic line

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❑ To remove, remove battery and battery tray ⇒ Electrical system; Rep. gr. 27 ; Battery; Removing and
Co
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❑ Secured to body
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12 - Seal / O-ring
13 - Clip
❑ Pull out clip to stop to remove and install pipe/hose assembly or plastic line
14 - Clutch slave cylinder

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t or
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ss
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15 - Dust cap
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16 - Bleeder valve
rm
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❑ Bleeding clutch mechanism ⇒ page 58
ot
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h re
17 - Gearbox hole
spec
18 - Hexagon bolt
es, in part or in w
t to the co
❑ Specified torque: ⇒ Item 9 (page 60)
19 - Bracket
rrectness of i
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Seals and O-rings for pipe/hose assemblies or plastic lines
nform
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Item Material of line connection

m
1 Line connection with circumferential groove
a
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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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Supply hose -1- of plastic

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

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6-speed manual gearbox 0AJ - Edition
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2.12 Assembly overview - hydraulics (RHD)
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1 - Brake fluid reservoir
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2 - Seal
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hole
❑ For plastic supply hose
spec
es, in part or in w
❑ The seals must be loca‐
t to the co
ted in supply hose
3 - Supply hose
rrectness of i
❑ Plastic
l purpos

nform
ercia
⇒ page 46
m
5 - Clip
a
com
tion in
❑ Pull out clip to stop to re‐
r
te o
move and install pipe/
thi
s
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hose assembly or plas‐
do
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c
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❑ Pulled out to side on

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some clutch master cyl‐ C py
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❑ Seals/O-rings are adap‐
ted to configuration of
line connection
⇒ page 53
❑ For allocation refer to ⇒
Electronic parts cata‐
logue (ETKA)
7 - Support
❑ To remove and install,
separate clutch master
cylinder from clutch
pedal
⇒ “2.6 Removing and installing clutch pedal (RHD)”, page 29
8 - Clutch pedal
9 - Hexagon nut
❑ Note and torque setting: ⇒ Item 15 (page 13)
10 - Bracket
❑ Secured to body
11 - Pipe/hose or plastic line
❑ To remove, remove battery and battery tray ⇒ Electrical system; Rep. gr. 27 ; Battery; Removing and
installing battery .
12 - Bracket
❑ Secured to retainer for ABS/EDL
13 - Bracket
❑ For ABS/EDL

AG. Volkswagen AG d
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14 - Seal / O-ring ss a c
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15 - Clip
spec
es, in part or in w
❑ Pull out clip to stop to remove and install pipe/hose assembly or plastic line
t to the co
rrectness of i
17 - Bleeder valve l purpos
❑ Bleeding clutch mechanism ⇒ page 58
18 - Dust cap
nform
ercia
19 - Gearbox
m
at
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ion
20 - Hexagon bolt
c
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or
his
e
❑ Specified torque: ⇒ Item 9 (page 60)

at
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21 - Bracket
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2.13 Removing and installing clutch slave
p by
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cylinder
agen
Prote AG.

2.13.1 Removing
theft code.
– Completely remove air filter housing if it is located above clutch
slave cylinder ⇒ Rep. gr. 24 ; Injection system; Removing and
installing air filter .
– Remove relay lever together with cable end-piece from gear‐
box ⇒ page 81 .

Jetta 2013 ➤ , Jetta 2015 ➤
– Remove gearbox selector lever -A- by removing nut

-arrow 4-.
– Remove cable support bracket from gearbox -arrows-.

– Then raise and secure gear selector cable and gate selector
cable.
– Place a lint-free cloth under clutch slave cylinder.
AG. Volkswagen AG d
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– Pull clip -A- for pipe/hose assembly or plastic line out of clutch olks
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slave cylinder as far as it will go. se
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– Pull pipe/hose assembly or plastic line out of retainer -C-.aut ra
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– Pull pipe/hose assembly or plastic line -B- out of clutch slave
ce
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pt
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cylinder, and seal opening.

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– Unbolt clutch slave cylinder -arrows- and remove.
ility
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Caution h re
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spec
es, in part or in w
Do not operate clutch pedal any more.

t to the co
rrectness of i
2.13.2 Installing
l purpos

nf
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Prote AG.

Jetta 2013 ➤ , Jetta 2015 ➤
– Install clutch slave cylinder and tighten bolts -arrows- to speci‐

fied torque ⇒ Item 9 (page 60) .
– Insert pipe/hose assembly or plastic line -B- into clutch slave
cylinder as far as stop.
– Push securing clip -A- into pipe/hose assembly or plastic line
to stop.
– Test pipe/hose line by tugging on it.
– Press pipe/hose assembly or plastic line into retainer -C- to
stop on gearbox.
– Bleed clutch mechanism after installing clutch slave cylinder
⇒ page 58 .
Assembling selector mechanism ⇒ page 82 .
Adjust selector mechanism ⇒ page 89 .
filter .
– Connect battery earth ⇒ Electrical system; Rep. gr. 27 ; Bat‐
tery; Disconnecting and connecting battery .
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Prote AG.

Jetta 2013 ➤ , Jetta 2015 ➤
3 Bleeding clutch mechanism

♦ Brake filling and bleeding equipment - VAS 5234- or
♦ Brake filling and bleeding unit - V.A.G 1869-
Note
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Prefilling system is not necessary! Volksw not
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Specifications for brake fluid ⇒ Brake systems;aut Rep. gr. 47 ;
h eo
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Bleeding brake system . ss c
ce
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nl
pt
– Completely remove air filter housing if it prevents access to

du
an
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clutch slave cylinder ⇒ Rep. gr. 24 ; Injection system; Re‐

y li
erm
ab
moving and installing air filter .

ility
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– Connect brake filling and bleeding equipment - VAS 5234- or

wit
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h re
-V.A.G 1869- .
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
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or c
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58
AG.
Rep. gr.30 - Clutch
Jetta 2013 ➤ , Jetta 2015 ➤
To bleed system, use 670 mm bleeder hose - V.A.G 1238/B3- if

necessary.
– Connect bleeder hose to collector bottle of brake bleeding
equipment.
– Connect bleeder hose to bleeder -arrow-.
– Pressurise system to 2 bar.
– Open bleeder valve.
– Bleed off about 100 cm3 brake fluid.
– Close bleeder valve.
– Rapidly operate pedal from stop to stop 10 to 15 times.
– Open bleeder valve.
– Bleed off an additional 50 cm3 brake fluid.
AG. Volkswagen AG d
– Close bleeder valve. lksw
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– Depress clutch pedal several times after completion of isbleed‐
ed ara
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– If completely removed beforehand, install air filters housing ⇒
ce
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nl
pt
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filter .
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3. Bleeding clutch mechanism 59

Jetta 2013 ➤ , Jetta 2015 ➤
4 Repairing clutch release mechanism
4.1 Assembly overview - clutch release mechanism
1 - Release bearing
❑ Remove and install to‐
gether with clutch re‐
lease lever
and guide sleeve
⇒ page 61
❑ Do not wash out bear‐
ing; wipe only gen AG
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3 - Clutch release lever pt

du
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❑ Remove and install to‐ y li

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gether with release ility
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⇒ Item 1 (page 60) and

h re
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spec

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⇒ page 61
❑ Remove old grease
rrectness of i
4 - Retaining spring
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❑ Secure to clutch release

lever
nform
ercia
5 - Guide bush
m
at
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❑ Remove and install to‐

ion
c
gether with release

in t
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bearing
his
ate
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⇒ Item 1 (page 60) and

p
clutch release lever

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6 - Input shaft seal co Vo
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❑ Lever out with a screwdriver
Prote AG.
❑ Driving in ⇒ page 138

7 - Ball-head pin, 20 Nm
❑ Lubricate with clutch plate spline grease - G 000 100-
8 - Gearbox
9 - Hexagon bolt, 20 Nm
10 - Bracket

Jetta 2013 ➤ , Jetta 2015 ➤
4.2 Removing and installing clutch release

lever, release bearing and guide sleeve
Removing and installing clutch release lever with release bearing

and guide sleeve.
– Unscrew bolts -arrows-.
– Pull clutch release lever with release bearing and guide sleeve
off input shaft and ball stud.
Install in reverse order of removal.
. gen AG Volkswa
gen AG
• Retaining spring ⇒ Item 4 (page 60) must olkbe
swahooked into clutch does no
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release lever. ed
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♦ Note and torque setting: ⇒ Item
au 2 (page 60)
th eo
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Remove and install guide sleeve. an

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• Clutch release lever removed.
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– Push guide sleeve -3- upwards out of release bearing -2-.

h re
hole
– Turn guide sleeve -3- about 90° in -direction of arrow- relative

spec
es, in part or in w
to release bearing -2- until locking lugs of guide sleeve align

t to the co
with grooves -4- of release bearing.

– Pull guide sleeve out of release bearing in this position.
rrectness of i
Install in reverse order of removal.

l purpos
nf
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Remove and install release bearing.

rm
m
atio
m
• Clutch release lever removed.

o
n in
or c
– Press together locking lugs -arrows- on back of clutch release

thi
te
sd
a
lever and remove release bearing -A- from clutch release lev‐
iv
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er.
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– To install, press release bearing -A- into clutch release lever
yi Co
op
until locking lugs -arrows- engage.
C py
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pyri by
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cted agen
Prote AG.
4. Repairing clutch release mechanism 61

AG. Volkswagen AG d
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Jetta 2013 ➤ , Jetta 2015 ➤ ed b ara
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ris
6-speed manual gearbox 0AJ - Edition 06.2017 ut
ho eo
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s a c
s
ce
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nl
pt
5 Repairing clutch
du
an
itte
y li
erm
ab
ility
ot p
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equipment required
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
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ate
do
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for
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Cop py
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rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
♦ Counterhold tool - 3067-

♦ Centring mandrel - 3190 A-
♦ For engines having a crankshaft of smaller diameter or having
needle bearings ⇒ page 64 in the crankshaft - centring man‐
drel - T10086-
♦ Grease for splines - G 000 100-
(Gearbox removed)

Jetta 2013 ➤ , Jetta 2015 ➤
Note
♦ 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‐
box (rattling of gears which are not engaged) could occur.
♦ Renew clutch plates and pressure plates with damaged or loose rivets.
♦ For allocation refer to ⇒ Electronic parts catalogue (ETKA)
lkswage es n
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1 - Flywheel o
ir se
ran
tee
th or
❑ Ensure that centring au ac
ss
pins fit tightly
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pt
❑ Contact surface for
du
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clutch lining must be
y li
erm
ab
free of grooves, oil and
ility
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grease
wit
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h re
hole
⇒ Rep. gr. 13
spec
es, in part or in w
2 - Clutch plate
t to the co
❑ For allocation refer to ⇒
Electronic parts cata‐
rrectness of i
logue (ETKA)
❑ Installation position with
l purpos
dual-mass flywheel:
shorter end of hub faces
nf
ercia
pressure plate.
orm
❑ Text
m
atio
m
“Getriebeseite” (gear‐
o
n in
c
box side) always faces

or
thi
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pressure plate and

t
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❑ Installation position with
f
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t.
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single piece flywheel:
Co
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spring cage faces pres‐
t. C rig
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sure plate p by
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❑ Centring ⇒ page 64
cted agen
Prote AG.
❑ Centring for engines

having a crankshaft of
smaller diameter or hav‐
ing needle bearings in
the crankshaft -
⇒ page 65
❑ Lightly grease splines
Note
Clean input shaft splines and, on

used clutch plates, hub splines. Re‐
move corrosion and apply only a
very thin coat of grease for clutch
plate splines - G 000 100- to the in‐
put shaft splines. Then, move the
clutch plate back and forth on the
drive shaft until the hub moves easi‐
ly on the shaft. Remove excess
grease.
5. Repairing clutch 63
Jetta 2013 ➤ , Jetta 2015 ➤
3 - Thrust plate
❑ Removing and installing for engines having a crankshaft wage
nof
AGsmaller
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en AG
doesor having needle bearings
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❑ Check ends of diaphragm spring ⇒ page 65 oris
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th eo
❑ Checking spring connections and riveted a connections ⇒ page 65
u ra
c
ss
❑ Contact surface for clutch lining must be free of grooves, oil and grease
ce
le
un
pt
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Note
rm
ab
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Pressure plates are protected
wit
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against corrosion and greased.
h re
hole
Clean contact surface only; other‐
spec
wise the service life of the clutch will
es, in part or in w
t to the co
be considerably reduced.
4 - Bolt
rrectness of i
❑ M6: 13 Nm
l purpos
❑ M7: 20 Nm
nform
ercia
❑ Loosen or tighten diagonally in small steps

m
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tion in
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Centring clutch plate and removing and installing pressure plate
thi
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iva
do
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– Loosen and tighten bolts diagonally in small steps to prevent

rp
cum
fo
damage to thrust plate centring holes and flywheel centring
en
ng
t.
yi
pins.
Co
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– Reverse position of counterhold - 3067- when removing.
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
For engines having a crankshaft of smaller diameter -arrow- or

having an needle bearing -arrow- in the crankshaft

Jetta 2013 ➤ , Jetta 2015 ➤
6-speed
gen AG. manual
Volkswagegearbox
n AGd 0AJ - Edition 06.2017
wa oes
olks not
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Centring clutch plate and removing and installing ed pressure plate
b ara
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ris
for engines with a smaller crankshaft diameter,
tho or with a needle eo
bearing in the crankshaft au ra
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ss
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– Loosen or tighten bolts diagonally in stages.
un
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– Reverse position of counterhold - 3067- when removing.
erm
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Note urposes, in part or in wh
t to the co
♦ Pressure plate contact surface and clutch plate lining must
make full contact with flywheel.
rrectne
♦ Tighten securing bolts diagonally and evenly to prevent dam‐
age to pressure plate centring hole and flywheel centring pins.
ss o
cial p
f in
Checking ends of diaphragm spring -arrows-
form
mer
atio
• Wear up to half the thickness of the diaphragm spring is per‐
om
mitted.
n
c
i
or
n thi
te
sd
iva
o
pr
cum
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fo
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ng
t.
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Cop py
t. rig
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pyri by
Vo
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by
cted agen
Prote AG.
Check spring connection and riveted fastenings.

– Check spring connection between pressure plate and cover
for cracks as well as rivet connections for secure seating.
– If pressure plate has damaged springs or loose rivet connec‐
tions -arrows-, it must be renewed.
5. Repairing clutch 65
Jetta 2013 ➤ , Jetta 2015 ➤
34 – Controls, housing
1 Repairing selector mechanism
1.1 Installation position of selector mechanism

Arrow -A- Gear selection movement
Arrow -B- Gate selection movement
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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itte
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erm
ab
ility
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wit
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spec
es, in part or in w
t to the co
rrectness of i
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nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
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f
en
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t.
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Cop py
t. rig
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Vo
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cted agen
Prote AG.
66 Rep. gr.34 - Controls, housing

Jetta 2013 ➤ , Jetta 2015 ➤
6-speed manual n AG. Volk0AJ
gearbox
age
swagen AG
- Edition
does 06.2017
lksw n
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1.2 Overview of selector mechanism tho
ris tee
or
au ac
ss
ce
e
nl
pt
du
Note
an
itte
y li
erm
ab
♦ If the vehicle has a radio with anti-theft coding, obtain code before disconnecting battery.
ility
ot p
wit
, is n
♦ Before working on selector mechanism in engine compartment, disconnect earth strap from battery ⇒ Elec‐
h re
trical system; Rep. gr. 27 ; Battery; Disconnecting and connecting battery .
hole
spec
es, in part or in w
♦ When reconnecting battery, perform work required after connecting battery ⇒ Electrical system; Rep. gr.
t to the co
♦ For work on selector mechanism in engine compartment, remove complete air filter housing if it is located
rrectness of i
over selector mechanism ⇒ Rep. gr. 24 .
♦ Remove selector mechanism to renew selector cables ⇒ page 82 .
l purpos
♦ Do not kink selector cables.
nform
mercia
at
om
i
I - Assembly overview - gear
on
c
in t
lever knob and cover
or
his
e
⇒ page 68
at
do
priv
cum
II - Assembly overview - selec‐
for
en
g
tor lever and selector housing

n
t.
yi Co
⇒ page 70 Cop py
t. rig
gh ht
yri
III - Assembly overview - se‐ p by
o Vo
by c lksw
lector cables ⇒ page 77 Prote
cted AG.
agen
Removing and installing selector mechanism ⇒ page 82 .

1. Repairing selector mechanism 67

Jetta 2013 ➤ , Jetta 2015 ➤
1.3 Assembly overview - gear knob and cover
1 - Emblem
❑ Can be carefully levered
off gear knob of plastic
or leather
2 - Gear knob
❑ With gaiter
❑ Gear knob and gaiter
cannot be separated
from one another
❑ Always renew together
⇒ page 68
3 - Clamp
❑ For securing gear knob
to gear lever
❑ Secure to gear knob us‐
ing hose clip pliers -
V.A.G 1275-
4 - Frame for centre console
❑ In some equipment ver‐
sions, forms one part to‐
gether with upper centre
console
5 - Noise insulation
❑ Not fitted in all vehicles
❑ Arrow on noise insula‐
tion points in direction of
travel
❑ Because the locking lkswage es n
lugs are irregularly d byV
o ot g
ua
placed, noise insulation o
ir se
ran
tee
can be installed in only auth or
ac
one position ss
ce
e
nl
pt
du
an
itte
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erm
ab
1.4 Removing and installing gaiter with gear

ility
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knob and noise insulation

wit
, is n
h re
hole

spec
es, in part or in w
♦ Hose clip pliers - V.A.G 1275-

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
68
co Vo
by lksw
Rep. gr.34 - Controls, housing cted agen
Prote AG.
Jetta 2013 ➤ , Jetta 2015 ➤
Removing
– Pull off, or carefully lever off, gaiter with centre console frame
-arrows-.
Note
With some equipment variations, the gaiter must be levered off

along the front section.
– Pull gaiter with frame upwards, inside out over gear knob.
– Open clamp -arrow- and pull off gear knob together with gaiter.
In some versions, the centre console frame remains in the centre
console.
– Then pull off, or carefully lever off, centre console frame.
AG. Volkswagen AG d
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pt
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erm
ab
– Pull off noise insulation -1-.
ility
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Installing
wit
, is n
h re
hole
– First set noise insulation in place.
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
Installation position of noise insulation:
om
ion
c
in t
r
• -Arrow A- points in direction of travel.

o
his
ate
do
riv
• Catches -arrows B- must engage in centre console.

p
cum
for
– If necessary, then press frame into centre console.

en
ng
t.
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op py
– Then turn gaiter inside out.
. C rig
ht ht
rig by
py
The gear knob must be pressed to stop.
co Vo
by lksw
cted agen
Prote AG.

Jetta 2013 ➤ , Jetta 2015 ➤
– Install gear knob with gaiter and squeeze new clamp -arrow-
together.
– Then press gaiter with frame into centre console or gaiter into
frame.
1.5 Assembly overview - Gear lever and selector housing
Note
♦ Grease all bearing points and contact surfaces. Allocate grease using ⇒ Electronic parts catalogue (ETKA) .
♦ Dismantling and assembling selector mechanism ⇒ page 72 .
1 - Floor panel
❑ Bend open tabs to re‐
move
2 - Seal
3 - Gear lever
❑ Can be removed and in‐
stalled with gear lever
guide
⇒ Item 15 (page 71) n AG. Volkswagen AG do
wage
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4 - Damping washer ho
ir se tee
ut or
❑ Push onto gear lever up ss
a ac
to stop -arrow-
ce
le
un
pt
an
d
5 - Securing clip
itte
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erm
ab
❑ Do not damage cables

ility
ot p
when removing
wit
is n

h re
ole,
spec
6 - Gate change cable

t to the co
❑ Lever off gate selector

lever
❑ Press onto gate selector
rrectne
lever inside selector

mechanism
ss
❑ Fitting position
o
cial p
⇒ page 66
inform
mer
7 - Bush
atio
m
8 - Gear change cable

o
n
c
i
or
n thi
❑ Lever off gear lever

te
sd
a
guide
iv
o
pr
cum
r
❑ Press onto gear lever

fo
en
ng
guide inside selector mechanism

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co
70
by lksw
cted agen
Rep. gr.34 - Controls, housing Prote AG.
Jetta 2013 ➤ , Jetta 2015 ➤
❑ Fitting position ⇒ page 66
9 - Dampers
10 - Ball socket
❑ Is damaged during removal
11 - Bush
olkswagen AG
en AG. V
12 - Securing clip olks
wag does
not
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❑ Removing and installing ⇒ pageise71
d b ara
nte
r
ho eo
13 - Compression spring aut ra
c
ss
14 - Bush
ce
le
un
pt
an
d
itte
15 - Gear lever guide
y li
erm
ab
ility
16 - Hexagon nut
ot p
wit
is n
❑ M6: 8 Nm
h re
ole,
❑ M8: 25 Nm
spec
❑ Qty. 4
t to the co
17 - Seal
❑ Between selector housing and underbody
rrectne
❑ Self-adhesive
❑ Bond to selector lever housing
ss o
cial p
f
18 - Selector housing
inform
mer
❑ With compression spring and gate selector lever
atio
m
❑ Compression spring and gate selector lever cannot be removed

o
n
c
i
or
n thi
te
sd
iva
o
pr
c
Removing and installing securing clip
um
r
fo
en
ng
t.
– To remove or install securing clip -arrow A-, press spacer bush
yi Co
op
-arrow B- to stop -in direction of arrow C- using screwdriver
C py
ht. rig
and pull off securing clip.
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Note
♦ Do not cant spacer bush when pushing down.

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

Jetta 2013 ➤ , Jetta 2015 ➤
1.5.1 Dismantling and assembling selector mechanism

equipment required
AG. Volkswagen AG d
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ab
pe
ility
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wit
, 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
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Cop py
t. rig
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Vo
o
♦ Press piece - VW 412-
c by lksw
cted agen
Prote AG.
♦ Assembly tool - T10178- or steel bar, 200 x 25 x 5 mm
♦ Adapter - 10 - 222 A /25- or steel bar, 350 x 30 x 5 mm
♦ - 4- = Counter support , e.g. -Kukko 22/4-
♦ Wedge - T10357-

Jetta 2013 ➤ , Jetta 2015 ➤
♦ Thrust block - T10083-
AG. Volkswagen AG d
agen oes
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ility
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♦ Allocate grease using ⇒ Electronic parts catalogue (ETKA) .
is n
h re
ole,
Dismantling
spec
– Remove selector mechanism ⇒ page 82 .
t to the co
– Bend open tabs -arrows- of selector mechanism base plate
using a screwdriver and remove base plate. Note that only
rrectne
tabs on left side of base plate are shown in illustration.
– Remove seal from selector housing.
ss o
cial p
f
– Remove gear and gate selector cables from selector housing
inform
⇒ page 87 .
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
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op py
– Lift upper end -A- of compression spring over tab of gate se‐
. C rig
ht ht
rig
lector lever. py by
co Vo
by lksw
cted
– Use screwdriver to press catches -arrows- of ball socket to‐
agen
Prote AG.
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.

Jetta 2013 ➤ , Jetta 2015 ➤
• Please pay attention to guides -A- during the further proce‐

dure.
• They must not be broken off.
– Lever lower end -arrow 1- of compression spring onto shoulder
on gate selector lever as far as stop.
– Now pull gear lever guide up to stop and pull ball stud out of
gate selector lever -arrow 2-.
– 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-.
AG. Volkswagen AG d
agen oes
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un
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itte
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ility
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Installing
wit
is n
h re
ole,
spec
Caution
t to the co
The lower end of the compression spring -arrow 1- can snap
off the shoulder of the gate selector lever out of control during
the further procedure.
rrectness
– Therefore, carefully press it down off shoulder of gate selector

o
cial p
lever.
inform
mer
The ends of the compression spring then become tensioned “di‐

atio
m
agonally” with a loud noise.

o
n
c
i
or
n thi
e
– Slacken ends -A- and -B- by turning both round to right.

t
sd
iva
o
pr
cum
r
• Ends -A- and -B- must point in opposite directions.

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

Jetta 2013 ➤ , Jetta 2015 ➤
– Fit gear lever guide in selector housing.

• 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.
– Place selector housing with gear lever guide into larger recess
-arrow- in thrust piece - T10083- .
Note
To ensure that the selector housing with gear lever guide can be
inserted in the thrust piece , first remove gear lever, if necessary.
lkswage es n
o ot g
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d ran
ir se tee
tho
u or
a ac
ss
ce
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nl
pt
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• The gear lever guide must project from the selector housing
an
itte
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up to the stop.
erm
ab
ility
ot p
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Note h re
hole
spec
For clarity of illustration, only part of the gate selector lever is
es, in part or in w
t to the co
shown.
– Insert end -A- of compression spring into guide from above.

rrectness of i
– Pull end -B- of compression spring downwards and insert it

l purpos
next to guide (in direction of ball joint).

– Carefully remove selector housing with gear lever guide from
nform
ercia
thrust piece - T10083- .

m
at
om
io
– Move gate selector lever back to stop (opposite from mounting

n
c
in t
or
holes for gear and gate selector cable) -arrow 1-.

his
ate
do
riv
– Grease ball stud.

p
cum
for
en
g
– Press ball stud into gate selector lever -arrow 2-.

n
t.
yi Co
Cop py
• Guides -A- and tabs -B- are not allowed to be damaged.
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Jetta 2013 ➤ , Jetta 2015 ➤
– Place selector housing with gear lever guide into larger recess
-arrow- in thrust piece - T10083- .
• The gear lever guide must project from the selector housing
up to the stop.
– Lift upper end -A- of compression spring over pin of gate se‐
lector lever.
• Use a new ball socket -B-.
– Grease ball socket and bearing ball of gear lever guide.
– Press ball socket onto bearing ball of gear lever guide up to
stop.
– Remove selector housing from thrust piece - T10083- .
– Insert lower end -C- of compression spring into guide.
– Lift upper end -A- of compression spring over pin of gate se‐
. Volkswagen AG
lector lever into guide. swagen AG does
k not
Vol gu
– Press ball socket into
se
d b selector housing -arrows-.
y ara
nte
i
th or eo
• All 4 retainingaulugs must engage. ra
c
ss
– If removed, install gear lever in selector housing.
ce
le
un
pt
an
d
itte
y li
– Secure gear selector cable and gate selector cable to selector

erm
ab
housing using securing clips -2- and -3-.

ility
ot p
wit
is n
– Push gear selector cable -1- onto gear lever and gate selector
h re
ole,
cable -4- onto gate change lever in selector housing.

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

Jetta 2013 ➤ , Jetta 2015 ➤
Installing base plate to selector housing

– Fit new seal ⇒ Item 2 (page 70) to base plate.
Caution
Risk of damage to selector housing and floor plate.

AG. Volkswagen AG d
Only lightly tighten selector housing. agen oes
olksw not
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rise nte
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– Secure base plate by bending downs atabs -arrows- around cir‐
u ra
c
cumference of base plate (here only tabs on left side of base s
ce
e
plate are marked). nl
pt
du
an
itte
y li
erm
ab
ility
ot p
Note
wit
, is n
h re
♦ If only one assembly tool - T10178- is available, instead of a
hole
spec
second assembly tool - T10178- , the pin wrench - T10020-
es, in part or in w
may be used.
t to the co
♦ Instead of assembly tool - T10178- , a steel bar, 200 x 25 x
5 mm may be used.
rrectness of i
♦ Instead of adapter - 10 - 222 A /25- , a steel bar, 350 x 30 x
l purpos
5 mm may be used.
nform
ercia
– Tabs can be bent down using wedge - T10357- .

m
- A- = Counter support , e.g. -Kukko 22/4- .
at
om
ion
c
– Bond new seal to selector housing.
in t
or
his
ate
– Install selector mechanism ⇒ page 82 .
do
priv
cum
for
en
ng
t.
1.6 Assembly overview - Selector cables
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
Note cted agen
Prote AG.
Grease all bearing points and contact surfaces. Allocate grease using ⇒ Electronic parts catalogue (ETKA) .

Jetta 2013 ➤ , Jetta 2015 ➤
1 - Gear change cable

❑ Separate from gear lev‐
er guide in selector
mechanism
❑ Press onto gear lever
guide in selector mech‐
anism
❑ Connect to cable end-
piece
⇒ Item 11 (page 79) .
⇒ page 66
⇒ page 87
❑ After installing, adjust
selector mechanism
⇒ page 89
2 - Gate change cable
❑ Separate from gate se‐
lector lever in selector
mechanism
❑ Press onto gate selector
lever in selector mecha‐
nism
❑ Connect to cable end- n AG. Volkswagen AG do
wage
piece olks es n
ot g
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⇒ Item 10 (page 78) . d b ua
ran
ir se tee
❑ Fitting position autho
or
ac
⇒ page 66 ss
ce
e
❑ After installing, adjust

nl
pt
du
an
selector mechanism
itte
y li
⇒ page 89
erm
ab
ility
ot p
3 - Bush for gate selector cable

wit
, is n
4 - Selector housing h re
hole
spec
es, in part or in w
5 - Securing clip
t to the co

❑ Do not damage cables when removing
rrectness of i
6 - Hexagon bolt, 20 Nm
l purpos
❑ Qty. 3
❑ For cable support bracket
nform
ercia
7 - Cable support bracket

m
at
❑ For selector cables

om
ion
c
in t
or
8 - Grommet
his
ate
do
riv
❑ Cable support bracket mounting on gearbox

p
cum
for
9 - Spacer
en
ng
t.
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op
10 - Cable end-piece
C py
t. rig
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❑ For gate selector cable to relay lever
p by
co Vo
by lksw
cted
❑ Do not interchange; cable end-pieces for gate selector cable to relay lever and gear selector cable to
agen
Prote AG.
gearbox selector lever are different
❑ After installing, adjust selector mechanism ⇒ page 89
❑ Remove and install together with relay lever ⇒ Item 13 (page 79)
⇒ “1.7 Removing cable end-piece from relay lever and installing”, page 81
❑ Remove from relay lever ⇒ page 81
❑ Press onto relay lever ⇒ page 81

Jetta 2013 ➤ , Jetta 2015 ➤
❑ Allocation ⇒ page 79 .
11 - Cable end-piece
❑ For gear selector cable to gearbox selector lever
❑ Do not interchange; cable end-pieces for gate selector cable to relay lever and gear selector cable to
gearbox selector lever are different
❑ Allocation ⇒ page 79 . lkswage es n
Vo ot g
y ua
db ran
12 - Securing clip ris
e
tee
tho or
❑ Renew after each removal ⇒ Electronic
ss
au
parts catalogue (ETKA) . ac
ce
e
13 - Deflector lever
nl
pt
du
an
❑ Fitting position ⇒ page 80 itte
y li
erm
ab
ility
ot p
wit
❑ Remove and install together with cable end-piece ⇒ Item 10 (page 78)
, is n
h re
⇒ “1.7 Removing cable end-piece from relay lever and installing”, page 81
hole
spec
❑ Grease before installing ⇒ page 80 .
es, in part or in w
t to the co
14 - Slide block
rrectness of i
❑ Self-locking
l purpos

nform
ercia
❑ Install so that master spline aligns with selector shaft ⇒ page 80

m
at
om
ion
c
in t
or
his
e
❑ From 06.06, smaller diameter of support pin for cable end-piece ⇒ page 80
at
do
priv
c
❑ Grease before installing ⇒ page 81 .
um
for
en
ng
t.
yi Co
Cop py
t. rig
gh
Allocation of cable end-pieces
ht
pyri by
Vo
co lksw
by
cted
The holes in the cable end-pieces have different diameters.
agen
Prote AG.
Cable end-piece for Dimension “a”

1 - Gear selector cable to gearbox selector lever 8.5 mm
2 - Gate selector cable to relay lever 10 mm
⇒ page 81

Jetta 2013 ➤ , Jetta 2015 ➤
Pin diameter for attaching gear selector cable end-piece

Support pin for gear selector cable end-piece Dimension “a”
∅ of support pin 8.5 mm
Install gearbox selector lever

– When fitting the gearbox selector lever, ensure that the gap
-arrow A- is aligned with the master spline -arrow B-.
AG. Volkswagen AG d
agen oes
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Installation position of gearbox
ss selector lever/relay lever c
ce
e
nl
pt
1- Gearbox selector lever

du
an
itte
y li
2- Relay lever engages in guide rail of gearbox selector lever

erm
ab
ility
via shoe -arrow-

ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
Greasing the relay lever.

• Grease the shaft -A- of relay lever all over with great care
nf
ercia
-arrows-, amount of grease: 0.2 grammes.

rm
m
atio
m
• Allocate grease using ⇒ Electronic parts catalogue (ETKA) .

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

Jetta 2013 ➤ , Jetta 2015 ➤
Apply grease to gearbox selector lever

• Apply grease to guide rail -B- of gearbox selector lever in which
the relay lever engages, being especially careful when doing
so.
• Allocate grease using ⇒ Electronic parts catalogue (ETKA) .
1.7 Removing cable end-piece from relay

lever and installing
Removing and installing relay lever
Caution
olkswagen AG
en AG. V
To avoid damage to gate selector cable, separate kswcable end-
ag does
not
Vol
piece from gate selector cable before removal.
ed
by gu
ara
ris nte
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• Gearbox selector level is in neutral position.
ce
le
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– Pull locking mechanism forward to stop in
an
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-direction of arrow 1-, and then lock it by turning to left in
erm
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ility
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– Then push relay lever forwards in -direction of arrow 3-.
h re
ole,
spec
Various means of securing the relay lever on the selector mech‐
anism cover have been fitted.
t to the co
♦ Relay lever with catch
♦ Relay lever with clip
rrectness o
cial p
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Relay lever secured with catch -arrow 1- on selector mechanism

mer
cover
atio
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n
c
– Carefully press down catch -arrow 1- to stop.

i
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– Then move relay lever to and fro (direction of operation) in its

iva
o
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bearing. Carefully pull out relay lever together with cable end-
p
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piece -arrow 2-.

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ng
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• Remove the cable end-piece -arrow 2- only with the relay lever
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removed ⇒ page 82 .
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Prote AG.
Note
Grease all bearing points and contact surfaces. Allocate grease

using ⇒ Electronic parts catalogue (ETKA) .
– Press cable end-piece onto relay lever ⇒ page 82 .

– Insert relay lever together with cable end-piece.
• Catch -arrow 1- secures relay lever.
• Cable end-piece must be located behind catch -arrow 2-.

Jetta 2013 ➤ , Jetta 2015 ➤
Relay lever -arrow 1- secured with clip on selector mechanism

cover
– Pull off clip -arrow 1- and remove relay lever together with ca‐
ble end-piece -arrow 2-.
Note
Before installing, grease bearing points and sliding surfaces. Al‐

locate grease using ⇒ Electronic parts catalogue (ETKA) .
lkswage es n
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Levering cable end-piece for gate selector cable off relay lever
h re
hole
spec
• Relay lever removed.
es, in part or in w
t to the co
– Insert a flat-blade screwdriver -A- between bush -B- and relay
lever.
rrectness of i
l purpos
nform
mercia
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tion in
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te o
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Pressing on cable end-piece
AG.
• Relay lever removed.

• Cable end-piece may be pressed only onto bush -arrow-.
• Cable end-piece must move freely on relay lever.
• It must be located behind catch ⇒ page 81 .
1.8 Removing and installing selector mech‐

anism
1.8.1 Removing selector mechanism


Jetta 2013 ➤ , Jetta 2015 ➤

theft code.
– Remove gear lever gaiter with gear knob and any noise insu‐
lation from frame for centre console ⇒ page 68 .
– Remove centre console and securing bracket for centre con‐
sole ⇒ General body repairs, interior; Rep. gr. 68 ; Compart‐
ments, covers and trims .
– If present, remove interior monitoring sensor - G273- from rear
securing nuts ⇒ Electrical system; Rep. gr. 96 ; Anti-theft
alarm system .
– Remove selector lever housing nuts -arrows-.
– Completely remove air filter housing ⇒ Rep. gr. 24 ; Injection
system; Removing and installing air filter .
Caution
olkswagen AG
en AG. V
To avoid damage to gate selector cable, olksseparate cable end-
wag does
not
piece from gate selector cable before
ed
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erm
ab
ility
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h re
ole,
spec
t to the co
– Pull locking mechanism forward to stop in

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

ss o
cial p
f inform
mer
atio
om
n
c
i
or
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te
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pr
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fo
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t.
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Cop py
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83
co Vo
by lksw
cted 1. Repairing selector mechanism
agen
Prote AG.
Jetta 2013 ➤ , Jetta 2015 ➤
– Remove securing clip -1- for gear selector cable from gearbox
selector lever -2-.
– Pull gear selector cable off pin of gearbox selector lever.
Relay lever -4- secured with clip -3- on selector mechanism cover
– Detach clip -3- from hole in relay lever and pull relay lever
-4- together with cable end-piece out of selector mechanism
cover.

cover
– Carefully press down catch -arrow 1- to stop.
– Then move relay lever to and fro (direction of operation) in its
bearing. Carefully pull out relay lever together with cable end-
piece -arrow 2-.
Continued for all selector mechanisms
AG. Volkswagen AG d
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– Remove cable support bracket from gearbox -arrows-.
ss a c
ce
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nl
– Remove noise insulation ⇒ General body repairs, exterior;
pt
du
an
Rep. gr. 50 ; Noise insulation .
itte
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erm
ab
– Remove tunnel cross-pieces ⇒ General body repairs, exterior;
ility
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Rep. gr. 50 ; Tunnel cross-piece .
wit
, is n
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hole
spec
Caution
es, in part or in w
t to the co
Risk of damage to decoupling element.
♦ Do not allow the decoupling element to kink by more than
rrectness of i
10°.
l purpos
♦ Install decoupling element so that it is not under tension.

♦ Do not damage wire mesh on decoupling element.
nf
ercia
orm
m
atio
om
– Release exhaust system at front from double clamp, and re‐

n in
or c
move it from subframe ⇒ Rep. gr. 26 ; Exhaust system or ⇒

thi
te
sd
Rep. gr. 26 ; Parts of exhaust system .

iva
o
r
rp
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– Detach exhaust system at rear, and secure it to vehicle body

m
f
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ng
t.
using wire or similar. If necessary, remove rear part of exhaust op
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system.
C py
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pyri by
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cted agen
Prote AG.

Jetta 2013 ➤ , Jetta 2015 ➤
– Unscrew nuts -arrows- for underbody cover.

– Unscrew clamping washers -2- and -3-.
– Lower underbody cover on inside until heat shield -1- for cen‐
tre tunnel can be removed.
– Swing down gear lever housing and remove with selector ca‐
bles.
AG. Volkswagen AG d
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1.8.2 Installing selector mechanism aut
ho eo
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ss
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– Align selector lever housing parallel to body.
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• Distance to body must be same on both sides.
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– Tighten nuts -arrows- of selector housing
h re
hole
⇒ Item 16 (page 71) .
spec
es, in part or in w
t to the co
rrectness of i
l purpos
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orm
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atio
om
n in
or c
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– Route cables -1- from selector mechanism -2- to gearbox as

t
sd
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follows: o
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ng
• Bowden cables must lie parallel to each other and must not
t.
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cross. C py
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rig ht
• Bowden cables must be laid in the intended indentation in heat
py by
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shield -3-. Prote
cted AG.
agen
Note
In the close-up, the heat shield is shown from above.

AG. Volkswagen AG d
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Jetta 2013 ➤ , Jetta 2015 ➤ d byV gu
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6-speed manual gearbox 0AJ - Edition 06.2017 horis nte
eo
aut ra
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Clip -A- holds cables and heat shield together in position.
ce
e
nl
pt
du
an
itte
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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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– Secure cable support bracket on gearbox -arrows-
⇒ Item 6 (page 78) .
nform
ercia
The holes in the cable end-pieces have different diameters.
m
at
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ion
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Allocation of cable end-pieces ⇒ page 79
in t
or
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ate
do
priv
cum
for
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Cop py
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rig ht
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Prote AG.
– Spread small amount of grease on pin of gearbox selector

lever -2-.
Allocate grease using ⇒ Electronic parts catalogue (ETKA) .
– Renew securing clip -1- each time after removing.
– Secure gear selector cable with new securing clip -1-.
Relay lever -4- secured with clip -3- on selector mechanism cover
– Spread small amount of grease on pin of relay lever.
– Insert relay lever -4- together with cable end-piece in selector
mechanism cover and secure with clip -3-.

Jetta 2013 ➤ , Jetta 2015 ➤

cover
Note
Before installing, grease bearing points and sliding surfaces. Al‐

locate grease using ⇒ Electronic parts catalogue (ETKA) .
– Insert relay lever together with cable end-piece -arrow 2-.

• Catch -arrow 1- secures relay lever.
Continued for all selector mechanisms
– Insert gate selector cable in cable end-piece.
– If removed beforehand, fit interior monitoring sensor - G273-
on rear securing nuts ⇒ Electrical system; Rep. gr. 96 ; Anti-
theft alarm system .
– Install centre console securing bracket and centre console ⇒
General body repairs, interior; Rep. gr. 68 ; Compartments,
agen
AG. Volkswagen AG d
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covers and trims . yV
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– Renew clamp -arrow-. au
th or
ac
ss
– Install gear lever gaiter with gear knob and, if present, noise
ce
e
nl
pt
insulation ⇒ page 68 .
du
an
itte
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erm
ab
ility
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hole
spec
es, in part or in w
t to the co
rrectness of i
– Install heat shield -1- beneath selector mechanism, and se‐
l purpos
cure it with clamping washers -2- and -3-.

– Secure underbody cover to vehicle body -arrows- ⇒ General
nform
ercia
body repairs, exterior; Rep. gr. 50 ; Underbody cover .

m
at
om
– Install exhaust system free of tension ⇒ Rep. gr. 26 ; Exhaust

on
c
in t
system or ⇒ Rep. gr. 26 ; Parts of exhaust system .

or
his
ate
do
– Install tunnel cross-pieces beneath exhaust system ⇒ General

priv
body repairs, exterior; Rep. gr. 50 ; Tunnel cross-piece .

um
for
en
ng
t.
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Co
Cop py
t. rig
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ht
pyri by
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Rep. gr. 24 ; Injection system; Removing and installing air by c lksw
cted agen
filter . Prote AG.
– Follow procedure after connecting battery ⇒ Electrical system;

Rep. gr. 27 ; Battery; Disconnecting and connecting battery .
1.9 Removing and installing gear selector

cable and gate selector cable

Jetta 2013 ➤ , Jetta 2015 ➤
1.9.1 Removing AG. Volkswagen AG d

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lksw not
– Remove selector mechanism ⇒ page 82 . d by
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– Bend open tabs -arrows- of selector mechanism
ut
ho base plate eo
ra
using a screwdriver and remove base plate.
ss a Note that only c
tabs on left side of base plate are shown in illustration.
ce
le
un
pt
an
d
– Remove seal.
itte
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erm
ab
ility
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is n
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ole,
spec
t to the co
rrectne
– Pull off securing clips -2- and -3-.
ss
– Push gear selector cable -1- and gate selector cable -4- off
o
cial p
f
gear lever and selector lever, e.g. using release tool - T10236-
inform
or a screwdriver.
mer
atio
m
– Pull gear selector cable and gate selector cable from selector
o
n
c
housing. i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
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Cop py
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pyri by
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by c lksw
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Prote AG.
Release locks -A- for gear and gate selector cables -B- as follows:
♦ Push sliding sleeve forward to stop -arrow 1-.
♦ Turn sliding sleeve to right to stop -arrow 2- until it engages.
– Remove locking mechanism from Bowden cables.

Jetta 2013 ➤ , Jetta 2015 ➤
– Pull off securing clips -1- and -2-.

– Remove cable support bracket from Bowden cables.
1.9.2 Installing
– Secure gear selector cable and gate selector cable to selector
housing using securing clips -2- and -3-.
– Push gear selector cable -1- and gate selector cable -4- onto
gear lever and selector lever in selector housing.
– Install new base plate with new seal on selector housing n AG. Volkswagen AG do
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-arrows- ⇒ page 77 . byV
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– Install selector mechanism ⇒ page 85 . tho tee
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– Adjust selector mechanism ⇒ page 89 . ss
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1.10 Adjusting selector mechanism t to the co

rrectness of i

l purpos
♦ Locking pin - T10027 A-

nform
mercia
a
com
tion in
r
te o
thi
s
iva
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fo
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t.
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Cop py
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gh ht
pyri by
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Prote AG.

Jetta 2013 ➤ , Jetta 2015 ➤
Note
The following points are essential to ensure correct adjustment of

selector mechanism:
• Gearbox, clutch and clutch mechanism must be in proper con‐

dition
• Selector mechanism must move freely
• Moving parts of selector mechanism and elements transferring
force must be in proper condition
• Gearbox must be in neutral
– Remove air filter housing if it prevents access to angled rod
for securing selector shaft and locking mechanism for gear
selector cable and gate selector cable ⇒ Rep. gr. 24 ; Injection
– Pull locking mechanisms on gate selector cable and gear se‐
lector cable end-pieces forward to stop -direction of arrow 1-
and then turn to left to lock -direction of arrow 2-.
Secure selector shaft as follows:

– Press selector shaft down -direction of arrow 1-.
– While pressing down selector shaft, agenturn locking pin
AG. Volkswagen AG-A-
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-direction of arrow 2- pressy Vitocarefully in until it engagess ninot gu
selector shaft. ris
ed
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tho or
– Remove gaiter andauany noise insulation from frame for centre ac
ss .
console ⇒ page 68
ce
le
un
pt
Set gear stick as follows:

an
d
itte
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rm
ab
– Select neutral position using gear lever.

pe
ility
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wit
, is n
h re
hole
– Guide locking pin - T10027 A- through hole -A- into hole -B-.
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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cum
fo
en
ng
t.
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Cop py
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pyri by
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by
90
cted agen
Prote AG.
Rep. gr.34 - Controls, housing
Jetta 2013 ➤ , Jetta 2015 ➤
– Check that gate and selector cables -B- are inserted, free of
tension, into locking devices -A-.
– Now turn locking mechanisms on gear selector cable and gate
selector cable end pieces clockwise to stop
The spring presses the locking mechanism into original position
– Now turn angled rod -A- back to original position

-direction of arrow-.
Note
The angled rod -A- must be pressed out of selector housing to

stop and point straight up.
– Pull locking pin out of holes -A- and -B-.

– Install gaiter and, if present, noise insulation ⇒ page 68 .
– Check that selector shaft moves freely.
Rep. gr. 24 ; Injection system; Removing and installing n air
AG. Volkswagen AG d
filter . wage oes
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1.10.1 Function
ility
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• With gearbox in neutral, gear lever must rest in selector lever

hole
gate for 3rd and 4th gear.

spec
es, in part or in w
– Operate clutch.
t to the co
– Select all gears several times. Pay particular attention to op‐

eration of reverse gear lock.
rrectness of i
– If it continues to be difficult to engage a gear after repeated

l purpos
attempts, repeat adjustment procedure of selector mechanism

⇒ “1.10 Adjusting selector mechanism”, page 89 .
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.

Jetta 2013 ➤ , Jetta 2015 ➤
2 Removing and installing gearbox,

Jetta 2011 ►
2.1 Removing gearbox, Jetta 2011 with 1.2 l engine and 1.4 l engine
Special tools and workshop agen

AG. Volkswagen AG d
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equipment required olksw not
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pt
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ab
ility
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wit
, 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
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
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co Vo
by lksw
cted agen
Prote AG.
♦ Support bracket - 10 - 222 A-

♦ Gearbox support - 3282-
♦ Engine and gearbox jack - V.A.G 1383 A-
♦ Tensioning strap - T10038-
♦ Engine support, basic set - T40091-
♦ Engine support, supplement set - T40093-

Jetta 2013 ➤ , Jetta 2015 ➤
♦ Spindle from assembly tool - 3066- or M8x105 mm bolt
♦ Adjustment plate - 3282/31-
AG. Volkswagen AG d
agen oes
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♦ Thrust piece - T10148-
ab
pe
ility
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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
♦ Grease for splines - G 000 100-

tion in
r
te o

thi
s
iva
do
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fo
Note
en
ng
t.
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Cop py
t. rig
The battery earth must be disconnected for the remaining proce‐ yri
gh by
ht
dure. Therefore, first check whether a coded radio is fitted. Then
op Vo
by c lksw
obtain anti-theft coding first if necessary.
cted agen
Prote AG.

– Completely remove air filter housing ⇒ Rep. gr. 24 ; Injection
– Remove battery and battery tray ⇒ Electrical system; Rep. gr.
2. Removing and installing gearbox, Jetta 2011 ► 93

Jetta 2013 ➤ , Jetta 2015 ➤
– Remove securing clip -1- for gear selector cable from gearbox
selector lever -6-.
– Pull gear selector cable -2- off pin of gearbox selector lever.
• To avoid damage to gate selector cable, separate cable end-
piece from gate selector cable before removal.
– Pull locking mechanism of gate selector cable forward as far
as stop in -direction of arrow B- and then lock by turning it in
-direction of arrow C-.
– Push relay lever forwards in direction of -arrow A-, at the same
time pulling out the gate selector cable.
Volkswa
– Pull off clip -4- and remove relay lever -3- together
agen with cable AG does
AG. gen
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end-piece. by
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– Remove gearbox selector lever -6-
tho by undoing nut -5-.
ri tee
or
au ac
ss
– Remove cable support bracket from gearbox and lay to side
ce
e
nl
pt
du
-arrows-.
an
itte
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erm
ab
– Then raise and secure gear selector cable and gate selector
ility
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cable.
wit
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
– Pull line between clutch master and clutch slave cylinder -A-
nform
ercia
out of bracket -B- (if present) on gearbox.

m
at
– Remove clutch slave cylinder -arrows-, lay to side and secure.
om
io
Do not disconnect pipes.
n
c
in t
or
his
ate
do
riv
Caution
p
cum
for
en
ng
t.
Risk of damage to clutch slave cylinder.
yi Co
Cop py
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♦ Make sure you do not press the clutch pedal if the clutch
gh ht
pyri by
slave cylinder is removed from the gearbox with the pipe/
co Vo
by lksw
cted
hose assembly still attached.
agen
Prote AG.
– Remove upper engine/gearbox connecting bolts.

– Remove earth strap at upper securing bolt for starter or at left
subframe.
– Then remove upper securing bolt on starter.
– To prevent damage to vacuum hose leading from brake boos‐
ter to engine, remove vacuum hose from engine ⇒ Brake
system; Rep. gr. 47 ; Brake booster/brake master cylinder;
Assembly overview - brake booster/brake master cylinder .

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
nte Jetta 2013 ➤ , Jetta 2015 ➤
ed
ris
o eo
aut
h
6-speed manual gearbox ra 0AJ - Edition 06.2017
ss c
ce
e
– Gearboxes for vehicles with start-stop system: pull connector
nl
pt
du
an
-arrow- off gearbox neutral position sender - G701- .
itte
y li
erm
ab
– Remove plenum chamber cover ⇒ General body repairs, ex‐
ility
terior; Rep. gr. 50 ; Plenum chamber cover; removing and ot p
wit
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installing plenum chamber cover .
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
– Unscrew bolts -arrows- for lock carrier retaining bracket on left
nf
ercia
o
and right.
rm
m
atio
om
n in
or c
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Cop py
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rig ht
py by
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by lksw
cted agen
Prote AG.
– Unscrew lower supports at adapters - 10 - 222 A /28- and re‐

place with supports -10 - 222 A /28-2- .
– Unscrew bolts -arrows- for securing support bracket to lock
carrier from adapter - 10-222 A /28-2- .
• Use the existing bolts in the supports -10 - 222 A /28-2- for
attachment of the adapters - 10 - 222 A /28- . Do not use se‐
curing bolts for the retaining brackets for this purpose.
– Fit adapter - 10 - 222 A /28- and tighten the bolts -arrows- to

8 Nm.
Caution
A second mechanic is required to place the support bracket on

the vehicle in order to prevent the support bracket from tipping.
– If there are hose and cable connections in area of engine sup‐

port eyes for support bracket - 10 - 222 A- , remove these now.
Vehicles with 1.2 l/77 kW TSI engine

– Fit support bracket - 10 - 222 A- as shown.

Jetta 2013 ➤ , Jetta 2015 ➤
– First push swivel joints -item 2- onto square tube of support

bracket - 10 - 222 A- .
• Securing bolts for swivel joints - T40091/3- -item 2- on -10 -
222 A- face front of vehicle.
– Fit support bracket - 10 - 222 A- on suspension turrets with the
aid of a second mechanic to prevent it from tipping.
– Push -T40091/1- -item 5- on left and right from front through
-10 - 222 A /28- -item 6- and fit swivel joints - T40093/4-
-item 4- on each side.
– Push hole rail - T40091/2- -item 7- with support - T40093/5-
-item 8- into swivel joints - T40093/4- -item 4-.
– Insert locking pin in hole rail - T40091/2- -item 7- and secure
with split pins.
1 - Adapter - 10 - 222 A /31-2-

2 - Swivel joint - T40091/3-
3 - Adapter - 10 - 222 A /31-1-
AG. Volkswagen AG d
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4 - Swivel joint - T40093/4- olksw
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5- Square tube - T40091/1- orise nte
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6- Adapter - 10 - 222
s A /28-
s a c
with -10 - 222 A /28-2-
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7 - Hook rail - T40091/2-
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ab
8 - Support - T40093/5-
ility
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9 - Spindle - 10 - 222 A /11-

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❑ Attach to lifting eye of

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engine -arrow-.
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1.4 l/90 kW TFSI engine and 1.4 l/118 kW TSI engine

– Fit support bracket - 10 - 222 A- as shown.
– First push swivel joints -item 2- onto square tube of support
bracket - 10 - 222 A- .
• Securing bolts for swivel joints - T40091/3- -item 2- on -10 -
222 A- face front of vehicle.

Jetta 2013 ➤ , Jetta 2015 ➤
– Fit support bracket - 10 - 222 A- on suspension turrets with the

aid of a second mechanic to prevent it from tipping.
– Push -T40091/1- -item 5- on left and right from front through
-10 - 222 A /28- -item 6- and fit swivel joints - T40093/4-
-item 4- on each side.
– Push hole rail - T40091/2- -item 7- with support - T40093/5-
-item 8- into swivel joints - T40093/4- -item 4-.
– Insert locking pin in hole rail - T40091/2- -item 7- and secure
with split pins.
1 - Adapter - 10 - 222 A /31-2-

3 - Adapter - 10 - 222 A /31-1-
5 - Square tube - T40091/1-
6 - Adapter - 10 - 222 A /28- Volkswa
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engine -arrow-.
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Continued for all vehicles
– Tighten all threaded connections of support bracket by hand.
When doing this, adjust support bracket via adapters - 10 - 222
A /28- so that it is horizontal.
– Slightly take up weight of engine/gearbox assembly on spindle
of support bracket - 10 - 222 A- ; do not lift.
– Raise vehicle and remove front left wheel.
Rep. gr. 50 ; Assembly overview - noise insulation .

Jetta 2013 ➤ , Jetta 2015 ➤
– Remove front left wheel housing liner ⇒ General body repairs,

exterior; Rep. gr. 66 ; Wheel housing liner; Assembly overview
- front wheel housing liner .
– Pull off connector -1- for reversing light switch - F4- .
– Remove nut -2- if present.
– Remove starter (bolt -3-) ⇒ Electrical system; Rep. gr. 27 ;
Starter; Removing and installing starter .
– Unbolt exhaust pipe from engine ⇒ Rep. gr. 26 ; Removing
and installing parts of exhaust system or ⇒ Rep. gr. 26 ; Parts
of exhaust system .
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10°.
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♦ Install decoupling element so that it is not under tension.
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♦ Do not damage wire mesh on decoupling element.
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t to the co
– Separate exhaust system -arrows 1-, and unbolt exhaust pipe
bracket from subframe -arrows 2- ⇒ Rep. gr. 26 ; Removing
and installing parts of exhaust system or ⇒ Rep. gr. 26 ; Parts
rrectne
of exhaust system .
ss o
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– Pull connector -1- off oil level and oil temperature sender - op
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G266- .
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– Remove drive shafts from flange shafts, raise as high as pos‐ co Vo
by lksw
sible and secure. Do not damage the surface protection ⇒
cted agen
Prote AG.
Running gear, axles, steering; Rep. gr. 40 ; Removing and
installing drive shafts .

Jetta 2013 ➤ , Jetta 2015 ➤
– Remove bolt for right flange shaft. To do this, screw two bolts
into flange and counterhold flange shaft with a lever.
– Remove flange shaft.
Note
Before removing flange shaft, check oil seal for leaks. If oil seal
leaks, it must be renewed during installation.
– Screw spindle -A- from assembly tool - 3066- into threaded

piece of differential.
– Insert thrust piece - T10148- and secure with nut -B-.
Note
♦ The thrust piece - T10148- is intended to protect the right oil

seal and the gearbox against dirt.
♦ Instead of the spindle -A-, an M8x105 mm bolt can be screwed
hand-tight into the threaded piece of the differential.
– Remove pendulum support.
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– Remove hexagon bolts -arrows 1- for left assembly mounting

hole
from gearbox mounting.

spec
es, in part or in w
t to the co
– Tilt engine/gearbox assembly by lowering spindle of support

bracket .
rrectness of i
Note
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Be careful of all lines when lowering gearbox.

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Jetta 2013 ➤ , Jetta 2015 ➤
AG . Volkswagen AG
– Remove gearbox bracket by removing bolts -arrows
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– For vehicles with a sheet metal sump, remove cover plate near
sump.
rrectness of i
To remove gearbox “0AJ”, set up gearbox support - 3282- with
l purpos
adjustment plate - 3282/31- .

– Insert gearbox support - 3282- in engine and gearbox jack -
nform
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V.A.G 1383 A- .
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– Fit adjustment plate - 3282/31- on gearbox support - 3282-
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– Screw a support hook ⇒ page 101 into gearbox support -
by lksw
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3282- instead of support element -C- (pin).
AG.
– Position engine and gearbox jack under vehicle. Arrow -B- on

adjustment plate points in direction of vehicle travel.
– Align adjustment plate - 3282/31- parallel to gearbox.

Jetta 2013 ➤ , Jetta 2015 ➤
– Insert support hook -arrow- into one of notches in gearbox

housing under left flange shaft -A-.
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– Remove engine/gearbox connecting bolt -arrow-.
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– Remove engine/gearbox connecting bolt -A- above removed
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right flange shaft.

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– Press gearbox off dowel sleeves and carefully swing towards

or
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subframe.
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– Press gearbox with gearbox housing cover towards front end

-arrow 1- and turn it downwards slightly -arrow 2-.
– Have a second mechanic push engine forwards slightly.

Jetta 2013 ➤ , Jetta 2015 ➤
– Carefully lower gearbox with engine and gearbox jack - V.A.G

1383 A- , and take the thrust piece - T10148- -1- past the
pressure plate -arrow-.
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– Carefully guide left flange shaft -A- past subframe bracket hole
spec
-B- as shown. Move engine and gearbox jack together with
es, in part or in w
gearbox to the front end.
t to the co
– When lowering the gearbox, change position of gearbox using
spindles of gearbox support - 3282- .
rrectness of i
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– If appropriate, re-insert right flange shaft and tighten counter‐

a
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sunk bolt to specified torque.

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Specified torques
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♦ Flange shaft to gearbox (countersunk bolt) ⇒ page 177 opy
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2.2 Installing gearbox, Jetta 2011 with 1.2 l

engine and 1.4 l engine
Note
Refer to procedure “Removing gearbox” for required special tools

⇒ page 92 .
– 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 bolts and nuts.
– Check whether dowel sleeves for aligning engine and gearbox
are fitted in cylinder block and install if necessary.
If dowel sleeves are not fitted, difficulties shifting gears, clutch
problems and possible noises from the gearbox (rattling of gears
which are not engaged) could occur.
– Ensure that intermediate plate is correctly seated on engine.

Jetta 2013 ➤ , Jetta 2015 ➤
– Clean input shaft splines and apply thin coat of grease for
clutch plate splines - G 000 100- .
The clutch plate must slide easily to and fro on the input shaft.
Volkswa
– Check clutch release bearing for wear andswrenew
agen if necessary.
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To install gearbox “0AJ”, set up gearbox d b support - 3282- with ad‐ ara
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– Insert gearbox support - 3282-
ss
in engine and gearbox jack -
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V.A.G 1383 A- .
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– Fit adjustment plate - 3282/31- on gearbox support - 3282-
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( adjustment plate fits in only one position).
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ment plate .
hole
spec
– Screw in support elements -A- to adjustment plate as illustra‐
es, in part or in w
t to the co
ted.
– Screw a support hook ⇒ page 103 into gearbox support -
3282- instead of support element -C- (pin).
rrectness of i
– Place gearbox on engine and gearbox jack .
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– Insert support hook -arrow- into one of notches in gearbox
o
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housing under left flange shaft -A-.

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– Align adjustment plate - 3282/31- and gearbox parallel to one

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

Jetta 2013 ➤ , Jetta 2015 ➤
AG . Volkswage
– Remove right flange shaft if gearbox kis
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– Check flange shaft oil sealsut
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– Screw spindle -A- of assembly tool - 3066- into threaded piece
of differential.
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– Insert thrust piece - T10148- and secure with nut -B-.
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Note
form
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atio
♦ The thrust piece - T10148- is intended to protect the right oil
om
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seal and the gearbox against dirt.
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♦ Instead of the spindle -A-, an M8x105 mm bolt can be screwed
iva
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hand-tight into the threaded piece of the differential.

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– Using spindles of gearbox support - 3282- , tilt gearbox in vi‐ C py
t. rig
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– Then raise gearbox carefully and guide past subframe. Prote
cted AG.
agen
Note
Be careful of all lines when installing gearbox.
– Carefully lift gearbox with engine and gearbox jack - V.A.G

1383 A- , and take the thrust piece - T10148- -1- past the
pressure plate -arrow-.
– Carefully guide left flange shaft -A- past subframe bracket

-B- as shown.
– Align gearbox to engine and join.

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nl
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– Screw in connecting bolt for engine and gearbox -arrow- and
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tighten to specified torque ⇒ page 108 .
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– Then screw in lower connecting bolts for engine and gearbox

-arrows- and tighten to specified torque ⇒ page 108 .
m
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ion
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ate
do
priv
cum
for
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t.
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Cop py
t. rig
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pyri by
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by c lksw
cted agen
Prote AG.
– Re-insert right flange shaft and tighten countersunk bolt to

specified torque.
– Remove gearbox support - 3282- from gearbox.
– Screw in all lower engine/gearbox connecting bolts and tighten
them to specified torque ⇒ page 108 .
– For vehicles with a sheet metal sump, fit cover plate near sump
-arrows- ⇒ page 108 .
– Align engine/gearbox assembly in installation position via
spindle of support bracket .

Jetta 2013 ➤ , Jetta 2015 ➤
– Install clutch slave cylinder -1- and tighten bolts to specified

torque ⇒ Item 9 (page 60) .
– Press pipe/hose assembly -A- into retainer -B-, if present, on
gearbox.
Caution
Risk of damaging thread in gearbox bracket if bolts are started

at an angle.
♦ To avoid damage to the thread in the gearbox bracket, the
gearbox mounting and console must be aligned parallel to
each other.
– Install left assembly mounting -2- using new hexagon bolts

-arrows- and tighten to specified torque ⇒ page 108 .
Note
Install engine and gearbox mounting free of tension ⇒ Rep. gr.

10 ; Removing and installing engine .
WARNING
Do not remove support bracket - 10 - 222 A- until the bolts

securing the left and right assembly mountings have been
tightened to specified torque.
– Screw in upper engine/gearbox securing bolts and tighten to

specified torque ⇒ page 108 .
– Install bolt -3- for starter and, if present, nut -2- ⇒ Electrical
. Volkswagen AG
system; Rep. gr. 27 ; Starter; Removing and ksw
ainstalling
gen AG starter . does
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– Push connector -1- onto reversingiselight
d b switch - F4- . ara
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d
itte
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rm
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pe
ility
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wit
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hole
spec
es, in part or in w
t to the co
– Attach pendulum support to gearbox with new bolts ⇒ Run‐

ning gear, axles, steering; Rep. gr. 40 ; Assembly overview -
subframe .
rrectness of i
– Assemble exhaust system, and secure exhaust system brack‐

l purpos
et to subframe ⇒ Rep. gr. 26 ; Removing and installing parts

of exhaust system or ⇒ Rep. gr. 26 ; Parts of exhaust system .
nform
ercia
– Attach drive shafts to gearbox ⇒ Running gear, axles, steer‐

ing; Rep. gr. 40 ; Removing and installing drive shafts .
m
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tion in
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s
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106
cted agen
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Rep. gr.34 - Controls, housing
AG.
Jetta 2013 ➤ , Jetta 2015 ➤
– Attach connector -1- to oil level and oil temperature sender -

G266- .
– Gearboxes for vehicles with start-stop system: join connector

-arrow- to gearbox neutral position sender - G701- .
– Connect vacuum hose leading from brake booster to engine
⇒ Brake system; Rep. gr. 47 ; Brake booster/brake master
cylinder; Assembly overview - brake booster/brake master cyl‐
inder .
– Install cable support bracket on gearbox and tighten bolts

-arrows- to specified torque ⇒ Item 6 (page 78) .
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– Install gearbox selector lever -B- and tighten hexagon nut

nl
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an
-arrow 2- to specified torque ⇒ Item 15 (page 79) .

itte
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erm
ab
– Install relay lever -A- together with cable end-piece

ility
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⇒ page 81 .
wit
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– Spread small amount of grease on pin of gearbox selector

hole
spec
lever -B-.
es, in part or in w
t to the co

– Connect gear selector cable to gearbox selector lever
-arrow 1-.
rrectness of i
– Adjust selector mechanism ⇒ page 89 .

l purpos
– Check gear oil ⇒ page 111 .

nform
ercia
If the gearbox comes in contact with other components, repair

surface protection with manufacturer-approved materials ⇒ Paint
m
at
om
workshop manual .
on
c
in t
or
– Install plenum chamber cover ⇒ General body repairs, exte‐

his
ate
rior; Rep. gr. 50 ; Plenum chamber cover; Removing and

do
priv
installing plenum chamber cover .

um
for
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co
107
by lksw
cted agen
Prote 2. Removing and installing gearbox, Jetta 2011 ►
AG.
Jetta 2013 ➤ , Jetta 2015 ➤
– Tighten bolts -arrows- for lock carrier retaining bracket on left

and right to specified torque ⇒ General body repairs, exterior;
Rep. gr. 50 ; Lock carrier; Lock carrier - attachments .
– Install air filter housing ⇒ Rep. gr. 24 ; Injection system; Re‐
moving and installing air filter .
– Install battery tray and battery ⇒ Electrical system; Rep. gr.
27 ; Battery; Removing and installing battery .
– Connect battery and follow procedure after connecting battery
⇒ Electrical system; Rep. gr. 27 ; Disconnecting and con‐
necting battery .
– Install front left wheel housing liner ⇒ General body repairs,
exterior; Rep. gr. 66 ; Wheel housing liner; Front wheel hous‐
ing liner .
– Install noise insulation ⇒ General body repairs, exterior; Rep. n AG. Volkswagen AG do
gr. 50 ; Noise insulation . olks
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– Install wheel ⇒ Running gear, axles, steering; Rep. gr.rise44
d ;
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Specified torque for mounting wheels . ut
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Gearbox to engine with 2 bolts in upper area of clutch housing.
rm
ab
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ility
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Item Bolt Quantity Nm
wit
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hole
1 M12 x 50 2 80
spec
2 M12 x 55 1 80
es, in part or in w
t to the co
♦ Starter to gearbox
3 M12 x 150 1 80
rrectness of i
♦ Additionally, start‐
er to gearbox
l purpos
4 M12 x 60 2 80
nform
ercia
5 M 10 x 30 2 40
m
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Item -A- dowel sleeves for centring
ion in
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Gearbox to engine with 3 bolts in upper area of clutch housing.
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Item Bolt Quantity Nm

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1 M12 x 50 3 80 Cop py
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2 M12 x 55 1 80
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♦ Starter to gearbox by c lksw
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Prote AG.
3 M12 x 150 1 80
♦ Additionally, start‐
er to gearbox
4 M12 x 60 2 80
5 M 10 x 30 2 40
Item -A- dowel sleeves for centring

Jetta 2013 ➤ , Jetta 2015 ➤
Gearbox bracket to gearbox

– Renew bolts.
Bolts -arrows 2- 40 Nm +90°
Gearbox bracket to body
– Renew bolts.
Bolts -arrows 1- 60 Nm +90°
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Cop py
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Jetta 2013 ➤ , Jetta 2015 ➤
3 Transporting gearbox
♦ Gearbox mounting support - 3336-
♦ Workshop hoist - VAS 6100-
AG. Volkswagen AG d
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– Bolt gearbox lifting tackle - 3336- to clutch housing.

spec
es, in part or in w
t to the co
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– Adjust support beam on sliding piece using locking pin

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-arrow-.
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Number of visible holes = 5. t. Cop py
rig
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– Lift gearbox with workshop hoist - VAS 6100- and gearbox lift‐ p by
o Vo
by c
ing tackle - 3336- .
lksw
cted agen
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– Set gearbox aside, for example in a transport container.

Jetta 2013 ➤ , Jetta 2015 ➤
4 Checking gear oil

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Socket - 3357-
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ab
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Gear oil ⇒ Electronic parts catalogue (ETKA)
wit
is n
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ole,
Rep. gr. 50 ; Noise insulation; Assembly overview - noise in‐
spec
sulation .
t to the co
rrectness o
cial p
f inform
mer
– To check gear oil, remove oil plug -arrow-.
atio
om
The oil level is correct when the gearbox is filled to lower edge of
n
c
i
or
n
filler hole.
thi
te
sd
va
– Tighten bolt -arrow- to specified torque ⇒ page 112 .

i
o
pr
cum
r
fo
en
ng
When filling with oil, note the following:

t.
yi Co
op py
– Remove oil plug -arrow-
t. C rig
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– Top-up gearbox oil to lower edge of filler plug drilling.
c by lksw
cted agen
Prote AG.
– 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 bolt -arrow- to specified torque ⇒ page 112 .
4. Checking gear oil 111

Jetta 2013 ➤ , Jetta 2015 ➤
Various versions of oil filler and drain plug

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
– Install noise insulation ⇒ General body repairs, exterior; Rep.
gr. 50 ; Noise insulation; Assembly overview - noise insula‐
tion .
AG. Volkswagen AG d
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nform
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a
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tion in
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iva
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Cop py
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by
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Prote AG.

lkswage es n
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byV ua
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ho
ir se tee Jetta 2013 ➤ , Jetta 2015 ➤
t or
au 6-speed
ac manual gearbox 0AJ - Edition 06.2017
ss
ce
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nl
pt
du
an
5 Dismantling and assembling gearbox
itte
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ility
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5.1 Overview - gearbox
h re
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spec
es, in part or in w
t to the co
1 - 1st gear
2 - 2nd gear
rrectness of i
3 - 3rd gear
l purpos
4 - 4th gear
5 - 5th gear
nf
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6 - 6th gear
m
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7 - Gearbox housing cover
or c
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8 - Gearbox housing
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9 - Reverse gear wheel
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10 - Selector mechanism Cop py
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❑ (Selector forks)
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cted
11 - Clutch housing
agen
Prote AG.
12 - Input shaft
13 - Output shaft
14 - Differential
5. Dismantling and assembling gearbox 113

Jetta 2013 ➤ , Jetta 2015 ➤
5.2 Assembly overview
l - Assembly overview - remov‐

ing and installing cover for
gearbox housing and 5th and
6th gears ⇒ page 115
ll - Assembly overview - remov‐
ing and installing clutch hous‐
ing ⇒ page 117
lII - Assembly overview - re‐
moving and installing input
shaft, output shaft, differential,
selector mechanism and se‐
lector forks ⇒ page 118
Assembly sequence
AG. Volkswagen AG d
⇒ page 120 ksw
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Cop py
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by c lksw
cted agen
Prote AG.

Jetta 2013 ➤ , Jetta 2015 ➤
5.3 Assembly overview - lkRemoving

swa
gen AG and installing
. Volkswagen AG
does
not
cover for gearbox housing
and 5th and 6th sgears Vo g
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1 - Gearbox housing ss
ce
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nl
pt
❑ Repairing ⇒ page 136
du
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itte
y li
2 - Gear wheel for 5th gear
erm
ab
ility
ot p
wit
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⇒ page 132
h re
hole
❑ Must be pressed off
spec
⇒ page 159 and on
es, in part or in w
t to the co
⇒ page 133 on some
gearboxes
3 - Sleeve
rrectness of i
l purpos
⇒ page 134
nform
ercia
5 - Cylindrical roller bearing in‐

m
at
ner race
om
ion
c
❑ For output shaft
in t
or
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❑ Mark before removing

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❑ Do not interchange with
um
for
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inner race for cylindrical

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roller bearing of input Cop py
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6 - Bolt Prote
cted AG.
agen

❑ Self-locking
❑ M8: 30 Nm then turn 90°
further.
❑ M10: 75 Nm then turn
45° further.
❑ With cylindrical roller
bearings for input and
output shafts
❑ Note that there are different securing clips ⇒ page 141
8 - Bolt
❑ 5 Nm and turn 90° further
9 - Bolt
❑ For input shaft
❑ Self-locking
❑ M8: 30 Nm then turn 90° further.
❑ M10: 75 Nm then turn 45° further.
10 - Cylindrical roller bearing inner race
❑ For input shaft
❑ Do not interchange with inner race for cylindrical roller bearing of output shaft

Jetta 2013 ➤ , Jetta 2015 ➤
11 - Thrust washer
12 - Inner race for cylindrical roller bearing with thrust washer
❑ For input shaft
❑ Installed in some gearboxes
❑ Allocate according to ⇒ Electronic parts catalogue (ETKA)
13 - Synchromeshed gear for 6th gear
14 - Synchro-ring for 6th gear
15 - Needle bearing
❑ One-piece
❑ For 6th gear
❑ Replace together with sleeve ⇒ Item 17 (page 116) .
16 - Needle bearing
❑ Two-piece
❑ For 6th gear
❑ Installed in some gearboxes
17 - Sleeve
❑ For 6th gear needle bearing
❑ Renew together with needle bearing
18 - Locking collar with synchro-hub for 5th and 6th gear
❑ Dismantling and assembling ⇒ “1 Input shaft”, page 153wage
es ks not
Vol gu
19 - Selector fork for 5th and 6th gear ed by ara
nte
ris
20 - Bearing mounting utho eo
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ss
❑ For selector fork for 5th and 6th gears
ce
le
un
pt
21 - Synchro-ring for 5th gear an
d
itte
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rm
❑ Will be damaged during removal of input shaft ab

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ility
ot
wit
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22 - Synchromeshed gear, 5th gear

hole
spec
es, in part or in w
23 - Needle bearing
t to the co
❑ For 5th gear

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

Jetta 2013 ➤ , Jetta 2015 ➤
5.4 Assembly overview - removing and installing clutch housing
1 - Countersunk bolt, 25 Nm
2 - Flange shaft with compres‐
sion spring
❑ Removing and installing n AG. Volkswagen AG do
wage
⇒ “5.6 Assembly se‐ olks es n
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quence”, page 120 d b ua
ran
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❑ Assembling autho
or
ac
⇒ “2 Differential”, ss
page 177
ce
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un
pt
an
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itte
3 - Bolt, 5 Nm + turn 90° further
y li
erm
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ility
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4 - Clutch housing
h re
ole,
spec
5 - Gearbox housing
t to the co
6 - Clutch release lever
rrectne
❑ With guide sleeve and
release bearing
ss o
cial p
f in
⇒ page 61
form
mer
7 - Bolt
atio
om
n
c
i
or
n thi
te
sd
iva
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pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Jetta 2013 ➤ , Jetta 2015 ➤
5.5 Assembly overview - removing and installing input shaft, output shaft, dif‐
ferential, selector mechanism and selector forks
1 - Differential
❑ Dismantling and assem‐
bling ⇒ page 177
2 - Gearbox housing
3 - Oil drain plug
❑ Specified torque
⇒ Fig. ““Various ver‐
sions of oil filler and
drain plug”“ , page 112
4 - Flange shaft with compres‐
sion spring
⇒ “5.6 Assembly se‐
quence”, page 120
❑ Assembling
⇒ “2 Differential”,
page 177
5 - Countersunk bolt, 25 Nm
AG. Volkswagen AG d
❑ Self-locking ksw
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❑ Renew after removal ed b y gu
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❑ To secure bearing utho eo
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groove ball bearing for
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input and output shafts

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itte
⇒ Item 18 (page 119) .

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erm
ab
ility
7 - Hexagon flange nut, 23 Nm

ot p
wit
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❑ For selector mechanism

h re
⇒ Item 17 (page 119) .

hole
spec
❑ Self-locking
es, in part or in w
t to the co

8 - O-ring
rrectness of i

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9 - Pivot pin
nf
ercia

rm
m
atio
m
11 - Selector shaft with selector shaft cover

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or c
❑ (Selector unit)
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❑ Renew after removal C py
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13 - Bolt, 6 Nm cop Vo
by lksw
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Prote
14 - Gearbox neutral position sender - G701-
AG.
❑ for vehicles with start/stop system

15 - Reversing light switch - F4- , 20 Nm
❑ Changed to captive seal shortly after introduction of gearbox.

Jetta 2013 ➤ , Jetta 2015 ➤
16 - Seal
❑ Not fitted in all gearboxes
17 - Selector mechanism
❑ (Selector forks)
18 - 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 support off and on: Dismantling and assembling input shaft ⇒ Item 14 (page 157)
❑ Dismantling and assembling input shaft ⇒ “1 Input shaft”, page 153
❑ Dismantling and assembling output shaft ⇒ “2 Output shaft”, page 165
19 - Reverse gear shaft
20 - Reverse gear wheel
❑ For securing shaft for reverse gear
22 - Oil collector
23 - Magnet wage
es n
olks ot g
24 - Oil guide byV ua
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rm
ab
pe
ility
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spec
es, in part or in w
t to the co
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l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
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rp
cum
fo
en
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t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Jetta 2013 ➤ , Jetta 2015 ➤
5.6 Assembly sequence

Removing and installing gearbox housing cover, clutch housing,
selector shaft with selector mechanism cover, input shaft, output
shaft, differential and selector mechanism.

equipment required
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ab
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wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
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pr
cum
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fo
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t.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.
♦ Support clamp - VW 313-

♦ Thrust plate - VW 401-
♦ Adapter - T10235-
♦ Guide bolt - T10079-

Jetta 2013 ➤ , Jetta 2015 ➤
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
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nl
pt
du
an
itte
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ab
ility
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spec
es, in part or in w
t to the co
rrectness of i

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♦ Tube - VW 418 A-
nf
♦ Thrust washer - 3074-

ercia
orm
m

atio
om
n in
c

or
thi
te
sd
a
♦ Shim - T10083/1-
iv
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f
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Jetta 2013 ➤ , Jetta 2015 ➤
AG. Volkswagen AG d
agen oes
olksw not
y V gu
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rise nte
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pt
du
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ab
ility
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♦ Puller - Kukko 18/1- -2-

wit
, is n
h re
♦ Separator - Kukko 17/1- -3-

hole
spec
es, in part or in w
♦ Three arm puller - Kukko 30/1- -1-

t to the co
♦ Two-arm puller - Kukko 204/2- -3-

♦ Sealing paste - AMV 188 200 03-
rrectness of i
♦ Hexagon socket-head bolt - M8 x 15-

l purpos
nf
ercia
orm
m
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f
en
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t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Jetta 2013 ➤ , Jetta 2015 ➤
♦ Thrust washer - T10375-
♦ Engine and gearbox support - VW 540-
lkswage es n
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♦ Drip tray
ility
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wit
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hole
5.6.1 Dismantling gearbox
spec
es, in part or in w
t to the co
– Secure gearbox to repair stand Engine and gearbox support -
VW 540- -arrows-.
– Put a drip tray , e.g. -V.A.G 1306- underneath.
rrectness of i
– Drain gear oil.
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
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f
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– Remove clutch release lever -A- together with release bearing

t.
yi Co
op
and guide sleeve -arrows-.
C py
t. rig
gh ht
yri by
– Remove right flange shaft securing bolt -B-. cop Vo
by lksw
cted agen
Prote AG.

Jetta 2013 ➤ , Jetta 2015 ➤
– To do this, screw two 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 and 6th gear selector fork -2-
-in direction of arrow- andlksremove
wage selector fork. es no
o t gu
yV
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ris nte
tho eo
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itte
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ab
ility
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wit
, is n
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hole
spec
es, in part or in w
t to the co
– Unscrew bolts -A- for inner bearing races from input and output
shafts, engaging 5th gear -arrow 1- and 1st gear (-arrow 2-
and -arrow 3-).
rrectness of i
– Input shaft and output shaft are locked when both gears are
l purpos
engaged. Both bolts can now be loosened.

nform
ercia
Note
m
at
om
ion
c
♦ If shafts are not to be renewed, carefully clean residual locking

in t
or
his
e
material out of threaded holes using a thread chaser.

at
do
priv
♦ Pull off gear wheel for 6th gear with three arm puller - Kukko
um
for
en
30/1- .
ng
t.
yi Co
op py
♦ If necessary, gear wheel for 6th gear can be pulled off to stop
. C rig
ht ht
rig
on spindle with two arm puller - Kukko 204/2- . Then pull off py by
co Vo
further with three arm puller - Kukko 30/1- .
by lksw
cted agen
Prote AG.

Jetta 2013 ➤ , Jetta 2015 ➤
– Pull off gear wheel for 6th gear with inner race of cylindrical
roller bearing for output shaft.
A - Three-arm puller - Kukko 30/1-
B - Hexagon socket-head bolt - M8 x 15-
lkswage es n
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un
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an
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itte
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rm
ab
– Tighten splitter - Kukko 17/1- -A- behind constant mesh teeth
pe
ility
of synchromeshed gear for 6th gear (not dog teeth) -arrow-.
ot
wit
, is n
h re
A - Splitter 12 to 75 mm , e.g. -Kukko 17/1-
hole
spec
es, in part or in w
t to the co
C - Puller , e.g. -Kukko 18/1-
– Pull off gear wheel for 6th gear with inner race of cylindrical
rrectness of i
roller bearing for input shaft and thrust washer.
l purpos
– Remove locking collar for 5th and 6th gears with locking
pieces.
nform
mercia
– Tighten splitter - Kukko 17/1- -A- below synchro-ring for 5th a

com
tion in
gear -1-. This presses synchro-ring against synchro-hub -2-.

r
te o
thi
A - Splitter 12 to 75 mm , e.g. -Kukko 17/1-

s
iva
do
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rp
cum

fo
en
ng
t.
yi Co
C - Puller , e.g. -Kukko 18/1- Cop py
t. rig
gh ht
yri
– Pull off synchro-hub for 5th and 6th gears with sleeve for 6th
p by
co Vo
gear needle bearing and 5th gear synchro-ring.
by lksw
cted agen
Prote AG.
Note
The synchro-ring for 5th gear must always be renewed after it is

pulled off.

Jetta 2013 ➤ , Jetta 2015 ➤
– Remove securing bolt for left flange shaft -1- by screwing two
bolts into flange and counterholding flange shaft with a lever.
– Pull out flange shaft with compression spring.
– Remove sleeve -2- and 5th gear synchromeshed gear with
needle bearing -4-.
– Unscrew hexagon flange nut -5- for securing reverse gear se‐
lector mechanism.
– Remove bearing mounting securing bolts -6- from input and
output shafts.
The gear wheel for 5th gear -3- will be pressed off later when the
bearing support for the deep groove ball bearing ⇒ page 159 .
Note
5th gear wheel can be removed by hand in some gearboxes.
– Turn gearbox in support bracket so that clutch housing is up‐

wards.
– Remove securing bolts from clutch housing side for securing
clutch housing to gearbox housing.
– Remove clutch housing, if necessary carefully levering up all
around along protruding housing flange and alternating be‐
tween sides, being careful not to damage sealing surfaces.
– Do not cant the clutch housing. This prevents damage to roller
bearings and their bearing seats on the input and output
shafts.
– Remove differential -A- from gearbox housing.

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
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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.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Jetta 2013 ➤ , Jetta 2015 ➤
– Then remove oil collector -A- and oil guide -B- with magnet
from gearbox housing.
– Gearboxes for vehicles with start-stop system: remove gear‐

box neutral position sender - G701- -arrow-.
AG. Volkswagen AG d
agen oes
olksw not
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un
pt
an
d
itte
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ab
pe
– Remove selector shaft with selector cover -A-. Place selector
ility
ot
shaft in neutral. Then remove bolts -arrows- and pull selector
wit
, is n
shaft out of gearbox housing.

h re
hole
– Remove pivot pins -B- located on underside of gearbox. spec

es, in part or in w
t to the co
– Screw out reversing light switch - F4- -C-.
rrectness of i
l purpos
nform
mercia
a
com
ti
– Remove bolt -A- for securing reverse gear wheel shaft.

on in
r
te o
thi
– Remove pivot pins -B- located on bottom of gearbox.

s
iva
do
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cum
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en
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Note
n
t.
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Cop py
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gh
Do not remove sealing cover -arrow- when dismantling gearbox.
ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Gearbox on which gear wheel for 5th gear can be removed by
hand.

Jetta 2013 ➤ , Jetta 2015 ➤
. Volkswagen AG
– Press out input shaft, output shaft with bearing mounting, se‐ kswagen AG does
not
lector mechanism (selector forks) and reverse gear together.by Vol gu
ara
ed nte
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Note ss c
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nl
pt
du
an
♦ Position gearbox housing so that dowel sleeves in the gearbox
itte
y li
will not be damaged.
erm
ab
ility
ot p
♦ When pressing out, get help from second mechanic to ensure
wit
, is n
components do not fall out.
h re
hole
spec
es, in part or in w
Gearbox on which gear wheel for 5th gear cannot be removed by
t to the co
hand.
– Press out input shaft, output shaft with gear wheel for 5th gear
rrectness of i
-A-, bearing mounting, selector mechanism (selector forks)
and reverse gear together.
l purpos
nf
ercia
Note
orm
m
atio
m
♦ Position gearbox housing so that dowel sleeves in the gearbox

o
n in
c
will not be damaged.

or
thi
te
sd
a
♦ When pressing out, get help from second mechanic to ensure

iv
o
r
rp
cu
components do not fall out.
o
m
f
en
ng
t.
yi Co
op
C py
t. rig
gh ht
yri by
– Press input and output shafts with deep groove ball bearing
cop Vo
by lksw
cted
and, as appropriate, gear wheel for 5th gear off bearing mount‐
agen
Prote AG.
ing ⇒ Item 14 (page 157) .
5.6.2 Assembling gearbox
Note
♦ If bearing mounting with deep groove ball bearing was re‐

moved, press onto input shaft and output shaft ⇒ page 162 .
♦ If needle roller bearing bushing for synchromeshed gear for
5th gear was removed, press onto input shaft ⇒ page 163 .
If gear wheel for 5th gear was not pressed off:

– Position assembled components, input shaft -2- and output
shaft -1- with bearing mounting for deep groove ball bearing,
in thrust piece - T10080- .
– Insert selector mechanism (selector forks) -4- in the shaft lock‐
ing collars.
– Install reverse gear shaft -3- with reverse gear.
– Screw guide pin - T10079- onto stud (secures reverse gear)
-arrow-.

Jetta 2013 ➤ , Jetta 2015 ➤
If gear wheel for 5th gear was pressed off:

– Position assembled components, input shaft -2- and output
shaft -1- with bearing mounting for deep groove ball bearing,
in thrust piece - T10080- .
– Insert selector mechanism (selector forks) -4- in the shaft lock‐
ing collars. n AG. Volkswagen AG do
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– Install reverse gear shaft -3- with reverse gear. byV
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– Screw guide pin - T10079- onto stud (secures reverse
utho gear) tee
or
-arrow-. ss
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spec
es, in part or in w
t to the co
rrectness of i
– Insert components together into gearbox while guiding guide
l purpos
pin - T10079- through hole to secure selector mechanism in

gearbox housing.
nform
ercia
– Remove guide pin - T10079- .

m
at
Note the following before pressing in:
om
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ate
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Prote AG.
♦ Selector forks engage correctly in locking collars.

♦ Reverse gear selector fork must engage correctly in reverse
gear wheel.
♦ Check dimension -a- for output shaft teeth.
Note
♦ The output shafts of the individual gearboxes are of different

lengths due to the different heights of the teeth -a-
♦ A shim - T10083/1- (3 mm thick) may have to be fitted on the
input shaft to ensure that the input shaft and the output shaft
are always pressed in evenly.
♦ This is the reason why dimension -a- for output shaft teeth
must be measured.

Jetta 2013 ➤ , Jetta 2015 ➤
Dimension -a- mm Fit shim - T10083/1- on input shaft Pressing in input and output shafts
27.6 no ⇒ Fig. ““Carefully press in bearing mounting together with input shaft and output shaft to stop.”“ , page 131
30.6 yes ⇒ Fig. ““Fit shim -T10083/1- on input shaft and carefully press in bearing mounting together with input shaft
and output shaft to stop.”“ , page 131
lkswage es n
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t to the co
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cial p
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mer
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n
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pr
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fo
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t.
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Cop py
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rig ht
py by
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130
by c lksw
cted agen
Prote AG.
Jetta 2013 ➤ , Jetta 2015 ➤
Carefully press in bearing mounting together with input shaft and

output shaft to stop.
Fit shim - T10083/1- on input shaft and carefully press in bearing

mounting together with input shaft and output shaft to stop.
AG. Volkswagen AG d
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es, in part or in w
t to the co
rrectness of i
– Install bolt -A- for securing reverse gear wheel shaft.

l purpos
– Install pivot pin -B- in bottom of gearbox.

nform
mercia
at
om
ion
c
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or
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ate
do
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– Screw in reversing light switch - F4- -C-.
lksw
cted agen
Prote AG.
– Install pivot pin -B- in top of gearbox.
– Place selector plates in neutral.
– Apply sealing paste - AMV 188 200 03- evenly to sealing sur‐
face of selector mechanism cover
– Install selector shaft with selector cover -A-. Then tighten bolts
-arrows-.
131
Jetta 2013 ➤ , Jetta 2015 ➤
– Gearboxes for vehicles with start-stop system: fit gearbox

neutral position sender - G701- and tighten securing bolt
-arrow- to specified torque ⇒ Item 13 (page 118) .
AG. Volkswagen AG d
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ab
– Using new bolts -A-, tighten bearing mounting for input and
ility
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output shafts.
wit
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hole
spec
Note
es, in part or in w
t to the co
Tighten bolts to specified torque, working from centre outwards
using alternate sequence.
rrectness of i
– Tighten hexagon flange nut -B- for securing selector mecha‐
l purpos
nism (selector forks).
nf
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Note
thi
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♦ Before input and output shafts are inserted into thrust block -
cu
o
m
f
T10083- , height of gearing output shaft must be measured
en
ng
t.
yi
⇒ page 129 .
Co
Cop py
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gh
♦ If this dimension is 30.6 mm, insert shim - T10083/1- .
ht
pyri by
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Prote AG.
– Insert input and output shafts together with gearbox housing
into thrust block - T10083- .
Fitting position for pressing on gear wheel for 5th gear and 5th/
6th gear synchro-hub and locking collar:
The high shoulder -arrow- faces gearbox housing cover.
132
Jetta 2013 ➤ , Jetta 2015 ➤
If gear wheel for 5th gear was pressed off:

– Press on gear wheel for 5th gear.
– Set sleeve on gear wheel for 5th gear
⇒ Fig. ““Fitting position for pressing on gear wheel for 5th gear
and 5th/6th gear synchro-hub and locking collar:”“ ,
page 132 item -2-.
– Set 5th gear synchromeshed gear with needle bearing in place
⇒ Fig. ““Fitting position for pressing on gear wheel for 5th gear
and 5th/6th gear synchro-hub and locking collar:”“ ,
page 132 item -3-.
– Place 5th gear synchro-ring on synchromeshed gear.
Installation position of synchro-hub/locking collar for 5th and 6th

gears
The high shoulder -arrow- faces 5th gear and gearbox housing.
– Press on synchro-hub and locking collar for gen5th
AG.and
Volks6th
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⇒ Fig. ““Fitting position for pressing on ol swa wheel for 5th geardoes no
kgear
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and 5th/6th gear synchro-hub and d blocking collar:”“ ,
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ab
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, is n
– Heat sleeve for needle bearing for 6th gear to maximum 100°
h re
hole
C and press on.
spec
es, in part or in w
t to the co
WARNING
Wear protective gloves.

rrectness of i
l purpos
– Install synchromeshed gear for 6th gear with needle bearing

and synchro-ring.
nform
mercia
at
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ion
c
in t
or
– Set thrust washer -A- in place.

his
ate
do
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for
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Note
n
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♦ Do not interchange inner races of cylindrical roller bearings of
rig ht
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Vo
input and output shafts.
co lksw
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cted agen
Prote AG.
♦ For some gearboxes, the thrust washer -A- and the inner race
for the cylindrical bearing -B- are combined in one component.
• They can be pressed on together only.
WARNING
– Heat cylindrical roller bearing inner race -B- to maximum 100°

C and press onto input shaft.
133
Jetta 2013 ➤ , Jetta 2015 ➤
Installation position of 6th gear wheel:

High collar faces bushing.
– Shift locking collar -A- for 5th and 6th gear to freewheel posi‐
tion to enable 6th gear synchromeshed gear to turn while gear
wheel for 6th gear is being pressed on.
WARNING
– Heat gear wheel for 6th gear to maximum 100°C.

– Press on gear wheel for 6th gear, being careful that teeth of
G. Volkswagen AG d
gear wheel -B- and synchronised gear
lkswagfor
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– Heat cylindrical roller bearing
thoris inner race -A- to maximum 100° tee
or
C and press onto output aushaft. ac
ss
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spec
t to the co
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– Then insert oil collector -A- in notch -1- and in hole -2- of gear‐
box housing. ss o
cial p
f inform
mer
atio
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n
c
i
or
n thi
te
sd
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pr
cum
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fo
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t.
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Cop py
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rig ht
py by
co Vo
by lksw
cted agen
– Now insert oil guide -B- into gearbox housing. Prote AG.
– The magnet is inserted into the oil guide -B-.
134
Jetta 2013 ➤ , Jetta 2015 ➤
– Install differential -A-.

face.
– Secure clutch housing to gearbox housing.
– Turn gearbox in support bracket so that gearbox housing is
upwards.
– Before tightening securing bolts -A-, engage 2 gears

-arrow 1- to -arrow 3-.
AG. Volkswagen AG d
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pt
du
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ab
ility
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– Insert selector fork for 5th and 6th gears -2- and push pivot pin
wit
, is n
-1- in to stop -direction of arrow-.
h re
hole
spec
es, in part or in w
face.
t to the co
– Tighten gearbox housing cover.
rrectness of i
l purpos
nf
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orm
m
atio
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n in
c
– Install both flange shafts with springs, thrust washers and ta‐
or
thi
pered rings.
te
sd
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rp
cu
– Install clutch release lever together with release bearing and

o
m
f
guide sleeve ⇒ page 61 .

en
ng
t.
yi Co
Cop py
ht. rig
rig ht
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by lksw
cted agen
Prote AG.
135
Jetta 2013 ➤ , Jetta 2015 ➤
6 Repairing gearbox housing and clutch housing

AG. Volkswagen AG d
Special tools and workshop agen oes
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Cop py
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rig ht
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Prote AG.
♦ Centring mandrel - 12-551-

♦ Drift - 2026-
136
Jetta 2013 ➤ , Jetta 2015 ➤
1 - Clutch housing
❑ If renewed, adjust differ‐
ential ⇒ page 183
2 - Seal
❑ For input shaft n AG. Volkswagen AG do
lkswage es n
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❑ Lever out with a screw‐ byV ua
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driver ir se tee
tho
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❑ Driving in ⇒ page 138 ss
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3 - Ball-head pin, 20 Nm
un
pt
an
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itte
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ab
❑ Lubricate with clutch
ility
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plate spline grease -
wit
is n
G 000 100-
h re
ole,
spec
t to the co
4 - Seal
❑ For right flange shaft
rrectne
❑ Renewing with gearbox
installed ⇒ page 174
ss o
5 - Oil filler plug
cial p
f inform
❑ Specified torque
mer
⇒ “4 Checking gear oil”,
atio
m
page 111
o
n
c
i
or
n thi
6 - Shim
te
sd
iva
o
❑ For differential
pr
cum
r
fo
❑ Determining thickness
en
ng
t.
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⇒ “2.2 Adjusting differ‐ Cop py
ential”, page 183
t. rig
gh ht
pyri by
Vo
o
7 - Tapered roller bearing outer
c by lksw
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race
Prote AG.
❑ Pressing out of and into
clutch housing ⇒ “2 Differential”, page 177
❑ If renewed, adjust differential ⇒ page 183
9 - Tapered roller bearing outer race
❑ Pulling out of and pressing into clutch housing ⇒ “2 Differential”, page 177
10 - Dowel sleeve
❑ Qty. 2
11 - Gearbox housing
12 - Oil drain plug
❑ Specified torque ⇒ “4 Checking gear oil”, page 111
13 - Seal
❑ For left flange shaft
❑ Renewing with gearbox installed ⇒ page 173
6. Repairing gearbox housing and clutch housing 137

Jetta 2013 ➤ , Jetta 2015 ➤
14 - Sleeve
❑ For selector shaft
❑ Driving out ⇒ Fig. ⇒ page 138
15 - Sealing cover
❑ Before bolting on, apply sealing paste - AMV 188 200 03- to sealing surface.
16 - Retaining ring
❑ Insert in groove of cylindrical roller bearing
17 - Retaining ring
❑ Insert in groove of cylindrical roller bearing
18 - Cylindrical roller bearing
❑ For input shaft
❑ Pulling out and pressing in ⇒ “1 Input shaft”, page 153
❑ Pulling out and pressing in ⇒ “2 Output shaft”, page 165
AG. Volkswagen AG d
20 - Plug ksw
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❑ Present on some gearboxes byV gu
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❑ Insert into hole in clutch housing. ut
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Driving in input shaft oil seal flush

itte
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es, in part or in w
t to the co
rrectness of i
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nform
ercia
Driving out selector shaft sleeve -A-

m
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com
tion in
r
te o
thi
s
iva
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fo
en
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.
138
Jetta 2013 ➤ , Jetta 2015 ➤
AG. Volkswagen AG d
Driving in selector shaft sleeve -A- tolksstop
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tion in
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Cop py
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Prote AG.
6. Repairing gearbox housing and clutch housing 139

Jetta 2013 ➤ , Jetta 2015 ➤ agen
AG. Volkswagen AG d
oes
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6-speed manual gearbox
by
V 0AJ - Edition 06.2017
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7 Assembly overview - gearbox housing cover
c a
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pt
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itte
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1 - Bolt
erm
ab
ility
ot p
❑ Tighten diagonally, to‐
wit
gether with bearing
, is n
h re
plate
hole
spec
❑ Note that there are dif‐
es, in part or in w
ferent securing clips
t to the co
⇒ page 141
2 - Mounting plate
rrectness of i
❑ Not fitted in all gearbox‐
l purpos
es
❑ For securing cylindrical
roller bearings
nform
ercia
❑ Installation position:
m
at
om
countersinks for coun‐
ion
c
tersunk bolts face gear‐
in t
or
box housing
his
ate
do
riv
❑ If not present, secure

p
cum
or
with bolts ⇒ page 141

f
en
ng
t.
yi Co
op
3 - Cylindrical roller bearing C py
t. rig
gh ht
❑ For input shaft yri
p by
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by c lksw
❑ Do not interchange with cted agen
Prote AG.
cylindrical roller bearing
for output shaft
❑ Removing ⇒ page 143
❑ Pressing in
⇒ page 143 .
❑ Different locking ele‐
ment ⇒ page 141
❑ Do not interchange with
cylindrical roller bearing
for input shaft
❑ Pressing in ⇒ page 143 .
❑ Different locking element ⇒ page 141
❑ Observe different versions
❑ Allocation ⇒ Electronic parts catalogue (ETKA)
140
Jetta 2013 ➤ , Jetta 2015 ➤
Different locking elements for cylindrical roller bearings

Locking element Threaded
AG. Volkswholes
agen Ain
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agen cover es n
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1. - Securing ris with
ed 6 2ranNm
tee
mounting uth plate -A-
o
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and countersunk
ss
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head bolt M 4 x 14
ce
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un
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-arrows-
an
d
itte
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2. - Securing with 2 2 Nm
erm
ab
ility
countersunk head
ot p
bolt M 4 x 12
wit
is n
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-arrows-
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
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n
c
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sd
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pr
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fo
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t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
7. Assembly overview - gearbox housing cover 141

Jetta 2013 ➤ , Jetta 2015 ➤
8 Repairing gearbox housing cover

equipment required
AG. Volkswagen AG d
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hole
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es, in part or in w
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nf
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orm
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atio
♦ Drift sleeve - 40 - 21-

om
n in
or c
♦ Support bridge - 2011-

thi
te
sd
iva

o
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cu
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en
ng
♦ -1- internal puller, e.g. KUKKO 21-5 - VAS 251 611-

t.
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op py
♦ -4- counter support, e.g. KUKKO 22-1 - VAS 251 621-
. C rig
ht ht
rig by
opy Vo
♦ Hot-air blower - V.A.G 1416- by c lksw
cted agen
Prote AG.
142
Jetta 2013 ➤ , Jetta 2015 ➤
– Remove bolts -arrows-

– If fitted, remove mounting plate -A-. agen
AG. Volkswagen AG d
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ab
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wit
, is n
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spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
Pulling cylindrical roller bearing out of gearbox housing cover

m
A - Internal puller, e.g. KUKKO 21-5 - VAS 251 611-
at
om
ion
c
B - Counter support, e.g. KUKKO 22-1 - VAS 251 621-
in t
or
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ate
do
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for
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ng
t.
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Cop py
t. rig
gh ht
pyri by
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co lksw
by
cted agen
Prote AG.
Pressing cylindrical roller bearing into gearbox housing cover

– Heat gearbox housing cover with hot air blower - V.A.G 1416-
in vicinity of bearing seat to about 100°C.
– Insert cylindrical roller bearing in heated housing and press in
using workshop press until heat exchange has taken place.
Note
Cylindrical roller bearings must be pressed into cover to stop. Do

not use the bolts to pull.
8. Repairing gearbox housing cover 143

Jetta 2013 ➤ , Jetta 2015 ➤
– If fitted, insert mounting plate -A-.

– Secure cylindrical roller bearing with bolts -arrows-.
Specified torques
♦ ⇒ “7 Assembly overview - gearbox housing cover”, page 140
AG. Volkswagen AG d
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es, in part or in w
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l purpos
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mercia
at
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ion
c
in t
or
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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.
144
Jetta 2013 ➤ , Jetta 2015 ➤
6-speed manual
agen AG.gearbox
Volkswage0AJ
n AG d- Edition 06.2017
o
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olks ot g
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9 Repairing selector unit
tee
tho or
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un
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♦ Tube - T10203-
itte
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erm
ab
ility
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t to the co
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mer
♦ Tube - VW 423-
atio
om
n
c
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or
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te
sd
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pr
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fo
en
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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.
Lubricate bearing positions and sliding surfaces.

9. Repairing selector unit 145

Jetta 2013 ➤ , Jetta 2015 ➤
1 - Sleeve
❑ For selector shaft
❑ Driving out ⇒ Fig.
⇒ page 138
2 - Selector shaft with selector
shaft cover
❑ Renew together
3 - Angled rod
❑ For adjusting selector
mechanism
4 - Deflector lever
⇒ page 80
❑ Grease before installing n AG. Volkswagen AG do
⇒ page 80 lkswage es n
o ot g
byV ua
d
5 - Seal o
ir se
ran
tee
th or
❑ For selector shaft au ac
ss
❑ Lever out with a screw‐
ce
le
un
pt
driver
an
d
itte
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❑ Installing ⇒ page 147
erm
ab
ility
ot p
6 - Cap
wit
is n
h re
❑ For gearbox breather
ole,
spec
t to the co
❑ Install so that master
spline aligns with selec‐
tor shaft
rrectne
❑ Can be renewed with
the selector mechanism
s
installed
s o
cial p
f
inform
mer
atio
m
❑ Self-locking
o
n
c
i
or

thi
te
sd
iva
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pr
cum
r
fo
en
ng
t.
Removing angled rod -A- from selector shaft cover
yi Co
Cop py
t. rig
– Remove outer part of angled rod.
gh ht
pyri by
Vo
co lksw
by
– Then carefully lever out angled rod using a screwdriver. Prote
cted AG.
agen
146
Jetta 2013 ➤ , Jetta 2015 ➤
Driving angled rod into selector mechanism cover

Installation position:
Marking -1- aligns with marking -2- on selector cover.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
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pt
du
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Insert oil seal for selector shaft -A- as far as stop.
ility
ot p
wit
, is n
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hole
spec
es, in part or in w
t to the co
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9. Repairing selector unit 147

Jetta 2013 ➤ , Jetta 2015 ➤
AG. Volkswagen AG d
agen oes
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10 Dismantling and assembling selector forks by ara
d
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equipment required
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♦ Thrust piece - 3290/1-
♦ Thrust piece - VW 431-
♦ Assembly tool - 3301-
♦ Spacer sleeve - VW 472/2-
♦ Drift - 10 - 206-
148
Jetta 2013 ➤ , Jetta 2015 ➤
♦ Release lever - 80 - 200-
♦ Assembly mandrel - 10 - 508-
AG. Volkswagen AG d
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♦ Tensioning device - 2070- ility
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Note
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It is not necessary to dismantle the selector fork group ⇒ Item 1 (page 150) in order to dismantle and assemble
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selector segments, lock washers and angular contact ball bearings.

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10. Dismantling and assembling selector forks 149

Jetta 2013 ➤ , Jetta 2015 ➤
1 - Selector fork group with se‐

lector plate
2 - Selector segment for 3rd
and 4th gear
❑ Identification
⇒ page 151
❑ After installation, selec‐
tor segment must still ro‐
tate freely
3 - Angular contact ball bearing
❑ Qty. 4
❑ Press inner race into
outer race ⇒ page 152
❑ Installing ⇒ page 152agen AG. Volkswagen AG do
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4 - Clamping washer db
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❑ Removing
ss ⇒ page 151
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❑ Installing ⇒ page 151 pt

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❑ Identification
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⇒ page 151
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‐
rrectness of i
tor segment
⇒ page 151
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6 - Selector fork for 5th and 6th

gears with selector segments
nf
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❑ Selector segment is per‐

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selector fork.
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❑ Identification ⇒ page 151

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7 - Bearing mounting
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❑ For selector fork for 5th and 6th gears

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Prote AG.
150
Jetta 2013 ➤ , Jetta 2015 ➤
Identification of selector segments and selector fork for 5th and

6th gear with selector segments
Dimension -a-
1- Selector segment for 1st and 2nd gears = 10.0 mm
2- Selector segment for 3rd and 4th gears = 78.6 mm
3- Selector fork for 5th and 6th gears with selector segments
= 79.5 mm
Selector fork for 1st and 2nd gears with selector segments
Dimension -a- = 78 mm
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– Clamp selector fork in vice with protective jaw covers -B-.

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– Lever off lock washer -A- in -direction of arrow-.

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Installing lock washer

– Press lock washer into groove of detent segment using socket
nform
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and spinner handle.

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B - Protective jaw covers cted agen
Prote AG.
10. Dismantling and assembling selector forks 151

Jetta 2013 ➤ , Jetta 2015 ➤
Removing angular contact ball bearing
Note
When removing and installing angular contact ball bearing, do not

bend selector forks.
Pressing inner race -A- of angular contact ball bearing into outer agen AG. Volkswagen AG doe
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Inner race must engage in outer race. oris tee
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Pulling angular contact ball bearing into selector fork to stop
rrectness of i
Depression in thrust piece - 3290/1- faces ball bearing.
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Prote AG.
152
AG. Volkswagen AG d
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byV gu
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6-speed
nte manual gearbox 0AJ - Edition 06.2017
ho eo
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35 – Gears, shafts
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1 Input shaft
ility
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spec
1.1 Dismantling and assembling input shaft
t to the co
rrectne
equipment required
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mer
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Prote AG.

♦ Tube - VW 415 A-
♦ Tube - VW 422-
1. Input shaft 153

Jetta 2013 ➤ , Jetta 2015 ➤
AG. Volkswagen AG d
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♦ Tube - VW 516-
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♦ Extension - 30 - 23-
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Prote AG.
154 Rep. gr.35 - Gears, shafts

Jetta 2013 ➤ , Jetta 2015 ➤
♦ Shim - T10083/1-
♦ Thrust plate - T10084 A-
AG. Volkswagen AG d
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♦ Inductive heater - VAS 6414-
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♦ -1- Internal puller - Kukko 21/5-

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♦ -4- Counter support - Kukko 22/1-

♦ Feeler gauge
Note
♦ When installing new gear wheels or an input shaft, consult technical data ⇒ page 1 and ⇒ Electronic parts
catalogue (ETKA) .
♦ 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.
♦ Before installing, heat synchro-hubs and bearing support with deep groove ball bearing to about 100°C using
the inductive heater - VAS 6414- . Wear protective gloves when doing this.
1. Input shaft 155

Jetta 2013 ➤ , Jetta 2015 ➤
1 - Bolt
⇒ “5.3 Assembly over‐
view - Removing and in‐
stalling cover for gear‐
box housing and 5th and
6th gears”, page 115
2 - Cylindrical roller bearing in‐
ner race
❑ Combined with thrust
washer
AG. Volkswagen AG d
box housing and 5th and ksw
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6th gears”, page 115 by
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❑ Mark before removing horis nte
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❑ Do not interchange with ss a c
inner race for cylindrical
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roller bearing of output
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⇒ “5.6 Assembly se‐
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h re
hole
spec
3 - Thrust washer
es, in part or in w
t to the co
❑ Combined with inner
race of cylindrical roller
bearing
rrectness of i
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box housing and 5th and
nf
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6th gears”, page 115

rm
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4 - Synchromeshed gear for

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6th gear
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❑ Check for wear ⇒ page 160

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6 - Needle bearing t. Cop py
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❑ For 6th gear
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❑ Two-part
⇒ “5.3 Assembly overview - Removing and installing cover for gearbox housing and 5th and 6th gears”,
page 115
7 - Sleeve
❑ Renew together with needle bearing ⇒ Item 6 (page 156) .
❑ Removing and installing ⇒ “5.6 Assembly sequence”, page 120
8 - Locking collar with synchro-hub for 5th and 6th gear
❑ Dismantling ⇒ page 163
❑ Assembling locking collar and synchro-hub for 5th and 6th gears ⇒ page 163 and ⇒ page 164
❑ Will be damaged during removal of input shaft

Jetta 2013 ➤ , Jetta 2015 ➤
10 - Synchromeshed gear, 5th gear
11 - Needle bearing
❑ For 5th gear
AG. Volkswagen AG d
❑ Replace together with sleeve ⇒ Item 12 o(pageagen
lksw 157) .
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12 - Sleeve ris
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❑ For 5th gear needle bearing s aut or
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❑ Press off with bearing mounting and deep groove ball bearing ⇒ Item 14 (page 157) .
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❑ Pressing on ⇒ page 163
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14 - Bearing mounting with deep groove ball bearing
es, in part or in w
t to the co
❑ Renew deep groove ball bearing only together with bearing support
rrectness of i
❑ Press off without gear wheel for 5th gear ⇒ page 159
l purpos
❑ Press off with gear wheel for 5th gear ⇒ page 159
nform
ercia
15 - Input shaft
m
❑ Clean residual locking fluid from threaded hole in input shaft using a thread chaser.
at
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ion
c
16 - Needle bearing
in t
or
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❑ For 3rd gear

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17 - Synchromeshed gear for 3rd gear

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18 - Synchro-ring for 3rd gear Cop py
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19 - Locking collar with synchro-hub for 3rd and 4th gear
agen
Prote AG.
❑ Press off with 3rd gear synchromeshed gear ⇒ page 159

❑ Installation position, locking collar and synchro-hub ⇒ page 160
❑ Assembling ⇒ page 160 .
20 - Sleeve
❑ Press off with 3rd gear synchromeshed gear ⇒ page 159
21 - Needle bearing
❑ For 4th gear
23 - Synchromeshed gear for 4th gear
24 - Thrust washer
❑ Pressing off ⇒ page 159
1. Input shaft 157

Jetta 2013 ➤ , Jetta 2015 ➤
26 - Retaining ring
❑ Renew
❑ Determining thickness ⇒ page 162
❑ With retaining ring
❑ Installation position: retaining ring in bearingwafaces
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28 - Clutch housing ed by ara
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ris
❑ Repairing ⇒ page 136 tho eo
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29 - Spring
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30 - 3rd and 4th gear locking collar
ility
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31 - 3rd and 4th gear synchro-hub
wit
, is n
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hole
32 - Locking pieces (qty. 3)
spec
es, in part or in w
33 - Spring
t to the co
rrectness of i
35 - Synchro-hub for 5th and 6th gears
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36 - Locking collar for 5th and 6th gears
nf
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Pulling cylindrical roller bearing out of clutch housing
om
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– When pulling out, squeeze together retaining ring -arrow- of thi

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cylindrical roller bearing, using pliers -C-.
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A - Counter support , e.g. -Kukko 22/1-

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Prote AG.
Pressing cylindrical roller bearing into clutch housing

– Support gearbox housing with tube - VW 415 A- (not visible in
figure) 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.

Jetta 2013 ➤ , Jetta 2015 ➤
Pressing off bearing mounting with deep groove ball bearing

– Slide locking collar for 1st and 2nd gear towards 2nd gear.
– Then slide thrust plate - T10084 A- sideways onto input shaft
to stop.
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Pressing off bearing mounting with deep groove ball bearing and
ot
wit
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gear wheel for 5th gear -A-
h re
hole
spec
– Slide locking collar for 1st and 2nd gear towards 2nd gear.
es, in part or in w
t to the co
– Then slide thrust plate - T10084 A- sideways onto input shaft
to stop.
rrectness of i
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mercia
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tion in
Pressing off cylindrical roller bearing inner race
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– Remove retaining ring.
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– Press off cylindrical roller bearing inner race together with

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ng
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thrust washer, 4th gear synchromeshed gear with needle
yi Co
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bearing, locking collar and synchro-hub for 3rd and 4th gear
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Dismantling and assembling 3rd and 4th gear locking collar and
synchro-hub
1- Spring
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.
1. Input shaft 159

Jetta 2013 ➤ , Jetta 2015 ➤
Assembling locking collar and synchro-hub for 3rd and 4th

agen
AG.gears
Volkswagen AG
do w es n
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• Locking collar has been pushed over synchro-hub.
ed
by
V ua
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– Insert locking pieces in deeper notches
au
tho -arrows- and install or
ac
springs offset 120°. Angled end ofssspring must locate in hollow
locking piece.
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Installation position of locking collar with synchro-hub for 3rd and
4th gear
rrectness of i
Groove on top -arrow- faces 4th gear.
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Checking synchro-ring for wear
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– Press synchro-ring onto cone of synchromeshed gear and cop Vo
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measure gap -a- using feeler gauge.
cted agen
Prote AG.
Gap -a- Installation dimen‐ Wear limit

sion
3rd, 4th, 5th and 1.1 … 1.7 mm 0.5 mm
6th gear
Pressing on synchro-hub with locking collar for 3rd and 4th gears
Installation position: high inside collar faces 3rd gear synchro‐
meshed gear.

Jetta 2013 ➤ , Jetta 2015 ➤
Pressing on sleeve -A- for 4th gear needle bearing

– After pressing on bushing -A-, fit 4th gear needle bearing, syn‐
chromeshed gear for 4th gear and thrust washer.
Pressing on inner race -A- for cylindrical roller bearing
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Prote AG.
1. Input shaft 161

Jetta 2013 ➤ , Jetta 2015 ➤
Determining thickness of retaining ring

– Insert a 2.0 mm thick retaining ring -A- in groove of input shaft
and press upwards -arrow-.
– Measure distance between inner race -B- and installed retain‐
ing ring -A- using feeler gauge -C-.
– Remove retaining ring (only used for measuring purposes).
– Determine retaining ring from table.
Note
Allocate retaining rings using ⇒ Electronic parts catalogue (ET‐

KA) .
The following securing clips are available:

Measured value Retaining ring thick‐ Axial play (mm)
(mm) ness (mm)
0.05 … 0.14 2.0 0.05 … 0.15
0.15 … 0.24 2.1 0.05 … 0.15
0.25 … 0.34 2.2 0.05 … 0.15
0.35 … 0.44 2.3 0.05 … 0.15
0.45 … 0.51 2.4 0.05 … 0.10
AG. Volkswagen AG d
agen
Press bearing mounting with deep groove ball bearingolksonto input
w oes
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shaft and output shaft as follows: ed
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Note
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♦ Due to different spline heights, dimension -a-, output shafts of

ab
ility
individual gearboxes have different lengths (shown here with
ot p
shafts installed). wit

is n
h re
ole,
♦ To ensure that bearing support is always evenly pressed onto

spec
shafts, it is necessary for shafts always to be inserted evenly

t to the co
into thrust block - T10083- .

♦ If necessary, insert a shim - T10083/1- (3 mm thick) into
mounting hole for input shaft ⇒ page 163 .
rrectne
♦ This is the reason why dimension -a- for output shaft teeth
must be measured.
ss o
cial p
f inform
Dimension -a- mm Fit shim - T10083/1- .

mer
atio
m
27.6 no
o
n
c
i
or
30.6 yes ⇒ page 163

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Cop py
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Prote AG.

Jetta 2013 ➤ , Jetta 2015 ➤
Fit shim - T10083/1- .

– Heat inner bearing mounting to approx. 100°C before pressing
on.
WARNING
– Press on bearing support. AG. Volkswagen AG d

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Pressing on sleeve -A- for 5th gear needle bearing
rrectness of i
l purpos
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mercia
at
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ion
c
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ate
do
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for
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ng
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Dismantling and assembling locking collar and synchro-hub for C py
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5th and 6th gear
gh ht
pyri by
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by
1- Spring Prote
cted AG.
agen
2- Sliding sleeve
3- Synchro-hub
4- Locking piece
Deeper notches -arrow A- for locking pieces in synchro-hub and
notches -arrow B- in locking collar must align.
1. Input shaft 163

Jetta 2013 ➤ , Jetta 2015 ➤
wage es n
Assembling locking collar and synchro-hub for 5th and 6th gears
yV
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ua
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• Locking collar has been pushed over synchro-hub. horis tee
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– Insert locking pieces in deeper notches -arrows- and
ss install
springs offset 120°.
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• Angled end of spring must locate in hollow locking piece.
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Cop py
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Prote AG.

Jetta 2013 ➤ , Jetta 2015 ➤
2 Output shaft
2.1 Dismantling and assembling output shaft

equipment required
AG. Volkswagen AG d
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Prote AG.

♦ Tube - VW 415 A-
♦ Thrust piece - VW 432-
2. Output shaft 165

Jetta 2013 ➤ , Jetta 2015 ➤
AG. Volkswagen AG d
agen oes
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♦ Feeler gauge
m
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Note
his
ate
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♦ When installing new gear wheels or a new output shaft, consult technical data ⇒ page 1 and ⇒ Electronic
for
en
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parts catalogue (ETKA) .

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♦ Install all bearings, synchromeshed gears and synchro-rings on output shaft with gear oil.
t. rig
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♦ Heat gear wheels and synchro-hubs to about 100°C with the inductive heater - VAS 6414- before installing.
c by lksw
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Wear protective gloves to do this.
Prote AG.

Jetta 2013 ➤ , Jetta 2015 ➤
1 - Clutch housing
❑ With retaining ring
❑ Pressing in
⇒ page 169 .
❑ Installation position: re‐
taining ring in bearing
faces output shaft
3 - Output shaft
❑ If an inner race as bear‐
ing seat for cylindrical
roller bearing
⇒ Item 2 (page 167) is
present, it cannot be re‐
moved from output shaft
❑ Check bearing seat or
inner race of cylindrical
roller bearing for scoring
and damage
❑ If cylindrical roller bear‐
ing inner race or bearing
seat is damaged or
AG. Volkswagen AG d
scored, renew output ksw
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4 - Gear wheel for 4th gear ss a ra
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shoulder faces 3rd gear
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⇒ page 170
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5 - Retaining ring
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6 - Retaining ring h re
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spec
7 - Gear wheel for 3rd gear
es, in part or in w
t to the co
❑ Installation position: shoulder faces 4th gear ⇒ page 170

8 - Retaining ring
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9 - Synchromeshed gear, 2nd gear

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10 - Needle bearing
❑ For 2nd gear
nform
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11 - Inner ring for 2nd gear

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12 - Outer bearing race for 2nd gear

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❑ Set on inner ring ⇒ Item 11 (page 167) .

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❑ Fitting position ⇒ page 170 py by
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13 - Synchro-ring for 2nd gear
agen
Prote AG.

14 - Locking collar with synchro-hub for 1st and 2nd gear
❑ After removing retaining ring ⇒ Item 15 (page 168) , press off with 2nd gear synchromeshed gear
⇒ page 169
2. Output shaft 167

Jetta 2013 ➤ , Jetta 2015 ➤
❑ Assembling locking collar and synchro-hub ⇒ page 171 and ⇒ page 171
15 - Retaining ring
❑ Pressing out ⇒ page 169
16 - Synchro-ring for 1st gear
❑ Assemble so that notches engage in locking pieces of locking collar ⇒ Item 14 (page 167) .
17 - Outer ring for 1st gear
❑ Insert in synchro-ring ⇒ Item 16 (page 168) .
❑ Renew if scored
18 - Inner ring for 1st gear
❑ Check lugs for scoring
AG. Volkswagen AG d
❑ Fitting position ⇒ page 172 agen oes
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19 - Needle bearing rised
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❑ For 1st gear aut ra
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20 - Synchromeshed gear, 1st gear
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21 - Bearing mounting with deep groove ball bearing
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❑ Renew deep groove ball bearing only together with bearing support
, is n
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hole
spec
❑ Press off without gear wheel for 5th gear ⇒ page 159
es, in part or in w
t to the co
❑ Press off with gear wheel for 5th gear ⇒ page 159
rrectness of i
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23 - Bolt
nf
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⇒ “5.3 Assembly overview - Removing and installing cover for gearbox housing and 5th and 6th gears”,
atio
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page 115
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❑ Do not interchange with inner race for cylindrical roller bearing of input shaft
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❑ Removing and installing ⇒ “5.6 Assembly sequence”, page 120 C py
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25 - Gear wheel for 6th gear op Vo
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❑ Installation position: collar faces sleeve Prote AG.

26 - Sleeve
❑ Must be pressed off ⇒ page 159 and on ⇒ page 133 on some gearboxes

Jetta 2013 ➤ , Jetta 2015 ➤
28 - Spring
29 - Sliding sleeve
30 - Synchro-hub
Pulling cylindrical roller bearing out of clutch housing

– When pulling out, squeeze together retaining ring -arrow- of
cylindrical roller bearing, using pliers -C-.
B - Internal puller, 30…37 mm , e.g. -Kukko 21/5-
. Volkswagen AG
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Pressing cylindrical roller bearing y V into clutch housing
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– Support gearbox housing horis
with tube - VW 415 A- (not visible in nte
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figure) directly belowaut bearing support. ra
ss c
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– When pressing in, squeeze together retaining ring -arrow- for
e
nl
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cylindrical roller bearing using pliers -A-.

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– Remove pliers before cylindrical roller bearing is in installation ab

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position. Retaining ring must engage in groove of clutch hous‐ wit

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Pressing retaining ring -1- out of groove

rrectness of i
A - Protective gloves
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WARNING
nf
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Ensure retaining ring does not spring out uncontrolled.

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Pressing off 1st and 2nd gear locking collar and synchro-hub
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– After removing retaining ring, press off synchromeshed gear
agen
Prote AG.
for 2nd gear together with locking collar and synchro-hub.
2. Output shaft 169

AG. Volkswagen AG d
agen oes
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Jetta 2013aut ➤ , Jetta 2015 ➤ ra
c
s
6-speeds manual gearbox 0AJ - Edition 06.2017
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un
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Installation position of 3rd gear and 4th gear
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ab
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– Install gear wheel for 4th gear -A- on output shaft.
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hole
spec
Collar -arrow 1- faces 3rd gear wheel -B-.
es, in part or in w
t to the co
– Install retaining rings -2- and -3-.
– Install gear wheel for 3rd gear -B- on output shaft.
rrectness of i
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Collar -arrow 2- faces gear wheel for 4th gear -A-.

– Install retaining ring -1-.
nform
mercia
a
Checking 1st and 2nd gear inner ring for wear
com
tion in
r
– Press inner ring onto cone of synchromeshed gear and meas‐

te o
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ure gap “a” using a feeler gauge.
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Gap “a” Installation dimen‐ Wear limit
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1st and 2nd gears 0.75 … 1.25 mm
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Checking 1st and 2nd gear synchro-rings for wear

– Press synchro-ring, outer ring and inner ring onto cone of syn‐
chromeshed gear and measure gap “a” using a feeler gauge.
Gap “a” Installation dimen‐ Wear limit
sion
1st and 2nd gears 1.2 … 1.8 mm 0.5 mm
Installation position of outer ring, inner ring and synchro-ring for

2nd gear
– Place inner ring -A- on 2nd gear synchromeshed gear.
Angled lugs -arrow 1- face outer ring -B-.
– Fit outer ring -B-.
Lugs -arrow 2- engage in notches -arrow 3- of synchromeshed
gear.
– Fit synchro-ring -C-.
Notches -arrow 4- engage in lugs -arrow 1- of inner race -A-.

Jetta 2013 ➤ , Jetta 2015 ➤
n AG. Volkswagen AG do 6-speed manual gearbox 0AJ - Edition 06.2017
lks wage es n
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Dismantling and assembling
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1- Spring ss
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2- Sliding sleeve
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3- Synchro-hub
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4- Locking piece
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spec
es, in part or in w
t to the co
After assembly, the groove on the face -arrow A- and the higher
shoulder -arrow B- of synchro-hub face outer splines of the lock‐
rrectness of i
ing collar -arrow C-.
l purpos
Deeper notches -arrow D- for locking pieces in synchro-hub and

notches -arrow E- in locking collar must align.
nform
mercia
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in t
Assembling locking collar with synchro-hub for 1st and 2nd gears
or
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• Locking collar has been pushed over synchro-hub.

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– Insert locking pieces in deeper notches -arrows- and install
en
ng
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springs so that they are offset by 120°. Angled end of spring
Co
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must locate in hollow locking piece.
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Prote AG.
Pressing on locking collar and synchro-hub for 1st and 2nd gears
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.
2. Output shaft 171

Jetta 2013 ➤ , Jetta 2015 ➤ AG. Volkswagen AG d
6-speed manual gearbox 0AJ - Edition 06.2017 agen oes
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Fitting retaining ring oris eo
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au ra
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– Place 1st gear synchro-ring in locking collar/synchro-hub.
ss
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ility
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t to the co
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Installation position of 1st gear outer ring
ss
Lugs -arrows- face towards reverse gear teeth.
o
cial p
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mer
atio
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Installation position of 1st gear inner ring -A-
AG.
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 ⇒ page 172 .

lkswage es n
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auth Jetta 2013 ➤ , Jetta or 2015 ➤
ac
ce
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un
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39 – Final drive - differential
erm
ab
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1 Renewing flange shaft oil seals with
ole,
spec
gearbox installed
t to the co
1.1 Renewing oil seal for left flange shaft
rrectness
o
cial p
f i
equipment required
nform
mer
atio
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n
c
i
or
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sd
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pr
cum
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t.
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Cop py
t. rig
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pyri by
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Prote AG.
♦ Multipurpose tool - VW 771-

♦ Extractor hook - VW 771/37-
♦ Drip tray , e.g. -V.A.G 1306-
♦ Sealing grease - G 052 128 A1-
1.1.1 Removing
– Remove left wheel.
1. Renewing flange shaft oil seals with gearbox installed 173

Jetta 2013 ➤ , Jetta 2015 ➤

– Turn steering to left lock.
– Remove drive shaft from flange shaft ⇒ Running gear, axles,
steering; Rep. gr. 40 ; Removing and installing drive shafts .
– If possible, lift drive shafts clear and tie in place; do not damage
surface protection.
– Place drip tray under gearbox.
– Remove flange shaft securing bolt by screwing two bolts into
flange and counter holding flange shaft with a lever.
– Pull out flange shaft oil seal using multi-purpose tool - VW 771-
and puller hooks - VW 771/37- .
AG. Volkswagen AG d
agen oes
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1.1.2 Installing
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– Drive in new seal to stop, being careful not to cant seal.

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– Half-fill space between sealing lip and dust lip with sealing
, is n
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grease - G 052 128 A1- .

hole
spec
– Insert flange shaft.

es, in part or in w
t to the co
– Secure flange shaft using countersunk bolt and tighten to

25 Nm.
rrectness of i
– Screw drive shaft onto flange shaft ⇒ Running gear, axles,

l purpos
– Check gear oil level and top up to lower edge of oil filler hole
if necessary ⇒ page 111 .
nform
ercia

m
at
om
gr. 50 ; Noise insulation .

ion
c
in t
or
– Install wheel ⇒ Running gear, axles, steering; Rep. gr. 44 ;

his
ate
Torque settings for mounting wheels .

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1.2 Renewing seal for right flange shaft

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Cop py
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Prote AG.
174 Rep. gr.39 - Final drive - differential

Jetta 2013 ➤ , Jetta 2015 ➤
Special tools and workshopwagen AG. Volkswagen AG doe

equipment required y Volks s no
t gu
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th or
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ility
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es, in part or in w
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com
tion in
r
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thi
s
iva
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t.
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Cop py
t. rig
gh ht
pyri by
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co lksw
by
cted agen
Prote AG.
♦ Multipurpose tool - VW 771-

♦ Extractor hook - VW 771/37-
♦ Drip tray , e.g. -V.A.G 1306-
♦ Sealing grease - G 052 128 A1-
1.2.1 Removing
– Remove drive shaft from flange shaft ⇒ Running gear, axles,
– If possible, lift drive shafts clear and tie in place; do not damage
surface protection.
– Place drip tray under gearbox.
1. Renewing flange shaft oil seals with gearbox installed 175

Jetta 2013 ➤ , Jetta 2015 ➤
– Remove flange shaft securing bolt by screwing two bolts into

flange and counter holding flange shaft with a lever.
AG. Volkswagen AG d
agen oes
olksw not
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rise nte
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ility
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– Pull out flange shaft oil seal using multi-purpose tool - VW 771-
h re
and puller hooks - VW 771/37- or prise out using a lever.
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
1.2.2 Installing s
iva
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– Drive in new seal to stop, being careful not to cant seal.

fo
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ng
t.
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– Half-fill space between sealing lip and dust lip with sealing Cop py
grease - G 052 128 A1- .
t. rig
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pyri by
Vo
co
– Insert flange shaft.
by lksw
cted agen
Prote AG.
– Secure flange shaft using countersunk bolt and tighten to
25 Nm.
– Screw drive shaft onto flange shaft ⇒ Running gear, axles,
– Check gear oil level and top up to lower edge of oil filler hole
if necessary ⇒ page 111 .
gr. 50 ; Noise insulation .

Jetta 2013 ➤ , Jetta 2015 ➤
2 Differential
2.1 Dismantling and assembling differential

equipment required
AG. Volkswagen AG d
agen oes
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d by ara
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aut ra
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un
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t to the co
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cial p
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mer
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n
c
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or
n thi
te
sd
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pr
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Cop py
t. rig
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by c lksw
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Prote AG.

♦ Press piece - VW 408 A-
♦ Tube - VW 418 A-
♦ Thrust plate - 30 - 205-
2. Differential 177
Jetta 2013 ➤ , Jetta 2015 ➤
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
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aut ra
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♦ Installing sleeve - VW 455-
rrectne
♦ Drift sleeve - 40 - 21- ss o
cial p
♦ Tube - 30 - 14-
inform
mer
♦ Tube - 2040-
atio
om
♦ Thrust piece - 3002-

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pr
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t.
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Cop py
t. rig
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pyri by
Vo
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by c lksw
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Prote AG.

Jetta 2013 ➤ , Jetta 2015 ➤
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
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or eo
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aut ra
ss c
ce
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nl
pt
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ility
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es, in part or in w
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♦ Counterhold tool - 3067-

t.
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Cop py
t. rig
♦ Tube - 3259- opyri
gh by
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ht
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♦ Grip tool - V.A.G 1582/3-
lksw
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Prote AG.
♦ Tapered roller bearing puller - V.A.G 1582-
2. Differential 179
Jetta 2013 ➤ , Jetta 2015 ➤
Note
♦ Heat tapered roller bearing inner races to about 100°C with the inductive heater - VAS 6414- before installing.
Wear protective gloves when doing this.
♦ Always renew both tapered roller bearings together as a set.
♦ If tapered roller bearings, differential, gearbox housing or clutch housing is renewed, adjust differential
⇒ page 183 .
AG. Volkswagen AG d
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1 - Countersunk bolt, 25seNmd b ara
nte
ri
❑ Screw into threaded
aut
ho eo
ra
piece ss c
⇒ Item 8 (page 180) .
ce
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nl
pt
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2 - Right flange shaft

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3 - Compression spring for

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flange shaft
wit
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❑ Installed behind flange

hole
spec
shafts
es, in part or in w
t to the co
4 - Thrust washer
shoulder towards spring
rrectness of i
5 - Tapered ring
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taper towards differen‐
nf
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tial cage
orm
m
atio
6 - Retaining ring
om
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c
❑ Holds tapered ring,

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thi
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thrust washer and

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sd
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spring in position when

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flange shaft is removed

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7 - Large differential bevel gear . Cop py
rig
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❑ Installing ⇒ page 183 rig ht
py by
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8 - Threaded piece cted agen
Prote AG.
9 - Differential pinion pin
❑ To remove, shear off
spring pin
⇒ page 183

Jetta 2013 ➤ , Jetta 2015 ➤
10 - Small differential bevel gear

11 - One-piece thrust washer
AG. Volkswagen AG d
❑ Coat with gear oil when installing agen oes
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12 - Left flange shaft rised
nte
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13 - Seal ss a ra
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❑ For left flange shaft
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❑ Renewing with manual gearbox installed ⇒ page 173 .
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15 - Tapered roller bearing inner race
t to the co
❑ Pulling off ⇒ page 182
rrectness of i
16 - Differential cage
l purpos
❑ With final drive gear

17 - Clamping sleeve
nform
ercia
❑ For securing differential pinion pin

m
at
om
❑ Will be sheared off when removed ⇒ page 183
ion
c
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or
18 - Tapered roller bearing inner race
his
ate
do
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❑ Pulling off ⇒ page 182

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or

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❑ Pressing out ⇒ page 182 . py by
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20 - Shim
❑ Determining thickness ⇒ “2.2 Adjusting differential”, page 183
21 - Seal
❑ For right flange shaft
❑ Renewing with manual gearbox installed ⇒ page 174 .
22 - Clutch housing
Pulling outer race for tapered roller bearing out of gearbox hous‐
ing
2. Differential 181
Jetta 2013 ➤ , Jetta 2015 ➤
Pressing tapered roller bearing outer race into gearbox housing

– Support gearbox housing with tube - 3259- directly
agebelow
es n
bearing support. o lksw ot g
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es, in part or in w
Pulling off tapered roller bearing inner races
t to the co
Note
rrectness of i
l purpos
Both tapered roller bearing inner races are pulled off the differ‐
ential cage in the same way.
nform
mercia
a
com
tion in
r
te o
thi
s
iva
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cum
fo
Pressing on tapered roller bearing inner races
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ng
t.
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op py
– Support inner race on opposite side using installing sleeve - t. C rig
gh ht
VW 455- . yri
p by
co Vo
by lksw
cted
Shoulder of installing sleeve - VW 455- faces towards differential
agen
Prote AG.
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
– Clamp internal puller securely behind tapered roller bearing
outer race.

Jetta 2013 ➤ , Jetta 2015 ➤
. Volkswagen AG
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Pressing tapered roller
Vol bearing outer race into clutch
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oes
not housing
g by ua
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oris tee
th or
au ac
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t to the co
Pressing out differential pinion pin
rrectne
When pressed out, spring pin will be sheared off.
s
– Drive remainder of spring pin out of differential cage.
s o
cial p
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mer
atio
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or
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Installing differential bevel gears yri
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cted
– Lubricate one-piece thrust washer with gear oil and install.
agen
Prote AG.
– Install both sun wheels and secure (e.g. with flange shaft).
– Insert planet pinions offset 180° and pivot into position.
– Press in differential pinion pin (-arrow A-) to first planet pinion.
– Place threaded pieces -arrows B- in sun gears.
– Drive differential pinion pin into final position and secure with
spring pin.
2.2 Adjusting differential
2. Differential 183
Jetta 2013 ➤ , Jetta 2015 ➤

equipment required
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ate
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♦ End dimension plate - VW 385/17- t. C rig
gh ht
pyri by
♦ Universal dial gauge holder - VW 387-
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Prote AG.

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rrectness of i
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♦ Thrust plate - 30 - 205-

♦ Tube - 30 - 14-
♦ Tube - 2040-
♦ Tube - 3259-
♦ Dial gauge , e.g. -VAS 6079-
2. Differential 185
Jetta 2013 ➤ , Jetta 2015 ➤
It is necessary to readjust the differential when the following com‐

ponents are renewed:
♦ Gearbox housing
♦ Clutch housing
♦ Differential cage
or the
♦ Tapered roller bearing of differential
– Pressing tapered roller bearing outer race (gear wheel slide)
into gearbox housing.
Note
Inner and outer tapered roller bearing races are matched in pairs.
Do not interchange!
– Press tapered roller bearing outer race (opposite gear wheel)

with no shim into gearbox housing.
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– Insert differential in gearbox housing.lkswagen A oes
not
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– Fit clutch housing and tightenris5edbolts
b
to specified torque ara
nte
⇒ Item 3 (page 117) . utho eo
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ss
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le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
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hole
spec
– Fit universal dial gauge bracket - VW 387- and set dial gauge
es, in part or in w
t to the co
to “0” with 1 mm preload.

A - 30 mm dial gauge extension
rrectness of i
– Move differential up and down. Read and note play indicated

on dial gauge. (Example: 1.50 mm)
l purpos
nform
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2.2.1 Determining thickness of shim

en
ng
t.
yi Co
op py
The specified bearing preload is obtained by adding a constant t. C rig
gh ht
value for preload (0.35 mm) to the reading obtained. yri
p by
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by lksw
cted
Example:
agen
Prote AG.
Measured value 1.50 mm

+ Preload (constant) 0.35 mm
Thickness of shim = 1.85 mm

Jetta 2013 ➤ , Jetta 2015 ➤
– Remove clutch housing and press out tapered roller bearing

outer race -A-.
– 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 shim (in example 1.85 mm) and press tapered
roller bearing outer race into clutch housing again.
– Fit clutch housing and tighten bolts to specified torque
⇒ Item 3 (page 117) .
AG. Volkswagen AG d
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erm
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ility
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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
atio
om
n in
or c
thi
te
sd
iva
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r
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o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
2. Differential 187

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Service

6-speed manual gearbox 0AJ

Service Department. Technical Information

39 - Final drive - differential

All rights reserved.

Copyright © 2017 Volkswagen AG, Wolfsburg D4B8033B594

2 Repairing clutch mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

2.2 Assembly overview - pedal cluster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

2.7 Removing and installing mounting bracket (LHD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

2.12 Assembly overview - hydraulics (RHD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

3 Bleeding clutch mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 Repairing selector unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145

2 Output shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165

39 - Final drive - differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173

2.1 Dismantling and assembling differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177

00 – Technical data lkswage

1.1 Location on gearbox

The gearbox code also appears on the vehicle identification

1.2 Identification code, assembly allocation and capacities

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

2 Overview - power transmission

2. Overview - power transmission 3

4 Rep. gr.00 - Technical data

3. Calculating overall gear ratio “i” 5

4 General repair instructions

4.1.2 O-rings, seals and gaskets

♦ Renew O-rings, seals and gaskets.

referred to as oil seals.

tact surface on housings or shafts for burrs and damage and

♦ Before installing shaft seals, lightly oil outer circumference and

- G 052 128 A1- .

♦ After renewing seals and gaskets, check oil level in gearbox

and replenish if necessary ⇒ page 111 .

ing crushed when inserted.

6 Rep. gr.00 - Technical data

4.1.4 Locking devices

♦ Do not overstretch retaining rings.

♦ Installation position for retaining rings: At the top, the ring is

♦ Retaining rings must locate properly in grooves.

line with the line of force -arrow-.

♦ Loosen nuts or bolts in the order opposite to the tightening

4. General repair instructions 7

♦ 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)«.

♦ If the synchro-rings are coated, check cone of synchromeshed

gear for »scoring« and »signs of abnormal wear«.

♦ Moisten synchromesh mechanism with gear oil before instal‐

4.1.9 Gear wheels

ductive heater - VAS 6414- before installing.

♦ Heat synchro-hub with inductive heater - VAS 6414- to approx.

100°C before installing. Press in to stop when installing so

there is no axial clearance.

8 Rep. gr.00 - Technical data

4.1.10 Synchromeshed gears

4.1.11 Clutch olksw

as well as the friction surface of flywheel with a cloth to reduce

the piston will be pressed out of the clutch slave cylinder.

4. General repair instructions 9

10 Rep. gr.30 - Clutch

2 Repairing clutch mechanism