6-Speed Manual Gearbox 02Q

Service
Workshop Manual
db i e
Golf Variant 2007 Golf Variant 2010 AG olk w g AG d a n o n Jettay 2005 olk rs Jetta 2011 ut
V
ge sw
.V
s a en
6-speed manual gearbox 02Q

Edition 06.2010
urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p
un le
a ss
ho
es ot g ua ran tee or ac
ility ab y li an pt ce
rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en
r fo ng
Service Department. Technical Information
ht rig py Co t.
agen lksw Vo by
AG.
Prote cted by
c o p yri gh t. C op yi
Service
List of Workshop Manual Repair GroupsList of Workshop Manual Repair GroupsList of Workshop Manual Repair Groups
Repair Group
00 - Technical data 30 - Clutch 34 - Controls, housing 35 - Gears, shafts 39 - Final drive - differential
es, in part or in w l purpos hole ercia , is n m ot com
pe rm itte d
un le
AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h ut ra a c s s
rrectness of i t to the co nform spec a t i h re o n in wit thi s
r te o iva r rp fo g n
do c um en
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 2010 Volkswagen AG, Wolfsburg MEX5R006920
agen lksw Vo by
AG.
ht rig py Co t.
Prote cted by c o py rig ht . C op yi
es, in part or in w l purpos hole ercia , is n m m ot p o c erm or e t a itte iv r du rp o nl f e ng
n AG. Volkswagen AG do es n wage s k l ot g o yV ua b ran ed s i tee2005 , Jetta 2011 r GolfhVariant 2007 , Golf Variant 2010 , Jetta o t or u ac a 6-speed manual gearbox 02Q - Edition 06.2010 ss
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
rrectness of i t to the co nf o r m spec atio h re n in wit
1
1 1 1 5 7 8 8 8 8 12 13 13 14 15 19 23 29 30 34 36 37 39 40 40 41 43 45 45 47 50 50 53 54 55 55 59 59 60 62 62 64 66 71 75 78 80 82
1 1.1 1.2 2 3 4 4.1 4.2 4.3 1 2 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9 2.10 3 3.1 3.2 3.3 3.4 4 4.1 4.2 4.3 4.4 4.5 5 5.1 5.2 1 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 1.10 1.11
Gearbox identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Location on gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Identification code, assembly allocation and capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . Overview - power transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Calculating overall gear ratio i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General repair notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Contact corrosion! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fault finding, power transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Repairing clutch mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly overview - pedal cluster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing over-centre spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing clutch pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing mounting bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing master cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing clutch position sender G476 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly overview - hydraulics (LHD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly overview - hydraulics (RHD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bleeding clutch system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Repairing clutch release mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing pipe/hose line and bleeder from and installing on slave cylinder . . . . . . . . . . . . Removing and installing slave cylinder with release bearing . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing pipe/hose line or plastic line . . . . . . . . . . . . . . . . . . . . . . . . . . . . Renewing input shaft seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Repairing clutch - vehicles with turbo diesel engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Determining clutch manufacturer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing Sachs clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Repairing Sachs clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing LuK clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Repairing LuK clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Repairing clutch - vehicles with petrol engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Repairing clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Repairing selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation position of selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Overview of selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing gear knob and frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing gaiter with gear knob and noise insulation . . . . . . . . . . . . . . . . . . Repairing gear lever and selector housing (through 10.06) . . . . . . . . . . . . . . . . . . . . . . . . Repairing gear lever and selector housing (from 11.06) . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly overview - removing and installing selector cables . . . . . . . . . . . . . . . . . . . . . . Plastic relay lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing gear selector cable and gate selector cable . . . . . . . . . . . . . . . . Adjusting selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Contents
ht rig py Co t.
thi sd o cu m en
30 - Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
34 - Controls, housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
agen lksw Vo by
AG.
Prote cted by
c o p yri gh t . C op yi
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed manual gearbox 02Q - Edition 06.2010 2 2.1 2.2 2.3 2.4 3 3.1 3.2 3.3 3.4 4 5 5.1 5.2 5.3 5.4 5.5 5.6 6 7 8 8.1 9 1 1.1 2 2.1 2.2 2.3 3 3.1 3.2 1 1.1 1.2 2 3 3.1 3.2 Removing and installing gearbox in vehicles with turbo diesel engine . . . . . . . . . . . . . . . . Removing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transporting gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Specified torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing gearbox, vehicles with petrol engine . . . . . . . . . . . . . . . . . . . . . . Removing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transporting gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Specified torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking gearbox oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dismantling and assembling gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Overview - rear final drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing gearbox housing and selector mechanism . . . . . . . . . . . . . . . . . . Removing and installing input shaft, output shafts, differential and selector rods . . . . . . . . Assembly order, gearbox without retaining ring A for input shaft sealing cover . . . . . . . . Assembly order, gearbox with retaining ring A for input shaft sealing cover . . . . . . . . . . Repairing gearbox housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . olkswagen AG en AG. V sn Repairing clutch housing . . . . . .ol.ks .w .a.g. . . . . . . . . . . . . . d . o.e. . o. . . . . . . . . . . . . . . . . . . . . . t gu V y b d e Repairing selector unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ar.an .t . . . . . . . . . . . . . . . . . s ri ee o h t Renewing oil seal for selector shaft . . . . . . . . . . . . . . . . . . . . . . . . . . .or.a. . . . . . . . . . . . . . u a c ss Repairing selector forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
35 - Gears, shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178

Input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dismantling and assembling input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Output shaft for 1st through 4th gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly overview - output shaft for 1st through 4th gears . . . . . . . . . . . . . . . . . . . . . . . . Dismantling and assembling output shaft for 1st through 4th gears . . . . . . . . . . . . . . . . . . Adjusting output shaft for 1st through 4th gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Output shaft for 5th, 6th and reverse gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dismantling and assembling output shaft for 5th, 6th and reverse gears . . . . . . . . . . . . . . Adjusting output shaft for 5th, 6th and reverse gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Renewing flange shaft oil seals with gearbox installed . . . . . . . . . . . . . . . . . . . . . . . . . . . . Renewing oil seal for left flange shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Renewing seal for right flange shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjustment overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dismantling and assembling differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjusting differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
do c um en
ht rig py Co t.
es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g n
85 85 96 97 104 106 106 116 117 124 126 128 128 129 130 132 134 145 157 167 172 173 175 178 178 185 185 187 206 211 211 222 227 227 229 232 233 233 239
39 - Final drive - differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
rrectness of i t to the co nform spec at i h re o n wit in t his
ii
Contents
agen lksw Vo by
AG.
Prote cted by
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 lkswagen A 6-speed manual gearbox 02Q n AG. Vo G do - Edition 06.2010 e wage
00
1
Technical data
The 6-speed manual gearbox 02Q is installed in the Jetta 2005 , in the Golf Variant 2007 , in the Golf Variant 2010 and in the Jetta 2011 in conjunction with a 4-cylinder engine. Allocation page 1
pe rm itte d
Gearbox identification
un le
ss
ks Vol by d e ris ho t au
s no t gu ara nte eo ra c
1.1
Location on gearbox
Code letters and date of manufacture -arrow 1- manual gearbox 02Q -arrow 2-
do c um en
Manual gearbox 02Q -arrow 2-
Identification code and date of gearbox manufacture -arrowExample: GRF 25 11 I I I I I I Identification Day Month code 3 I I Year (2003) of 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

GRF from to 05.05 11.05 6-speed 02Q GVT 05.05 11.05 GXC 07.06 07.06
1. Gearbox identification
Manual gearbox Identification code Manufactured
ht rig py Co t.
agen lksw Vo by
AG.
Prote cted by c o p yri gh t. C op yi
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed manual gearbox 02Q - Edition 06.2010 Manual gearbox Identification code Allocation Model 6-speed 02Q GVT Jetta 2005 Golf Variant 2007 2.0 l - 147 kW turbo FSI 71 : 18 = 3.944 71 : 23 = 3.087 2.3 l 107 mm
GRF Jetta 2005 Golf Variant 2007 Engine 2.0 l - 103 kW turbo diesel 69 : 20 = 3.450 Final drive I1) 69 : 25 = 2.760 Final drive II2) 2.3 l 107 mm
GXC Jetta 2005 Golf Variant 2007 2.0 l - 125 kW turbo diesel 71 : 18 = 3.944 71 : 23 = 3.087 2.3 l 107 mm
Ratio: Z2 : Z1
Capacity of manual gearbox Drive shaft flange

1) 2)
Final drive for 1st to 4th gears Final drive for 5th and 6th gears and reverse gear The following data can be found in the Electronic parts catalogue ETKA . Individual gear ratios Specification for gear oil Allocation of clutch plate and pressure plate
Manual gearbox Identification code Manufactured Allocation
HDV
6-speed 02Q HVS
KNQ 02.08 11.08 Golf Variant 2007 1.9 l - 77 kW turbo diesel 1.6 l - 77 kW turbo diesel 72 : 17 = 4.235 72 : 22 = 3.273 2.3 l 107 mm
Ratio: Z2 : Z1
from 05.05 07.06 . Volkswagen AG to G A n e does wag not olks Jetta 2005 gu Jetta 2005 y VModel b ara d e Golf Variant 2007 Golf 2007 ntVariant is r ee o h or ut Engine 2.0 l 96 kW 2.0 l 125 kW a a c ss turbo diesel turbo diesel 2.0 l - 100 kW turbo diesel 2.0 l - 103 kW turbo diesel 1) 69 : 20 = 3.450 70 : 19 = 3.684 Final drive I
un le
Final drive Capacity of manual gearbox Drive shaft flange

1) 2)
II2)
69 : 25 = 2.760 2.3 l 107 mm
70 : 24 = 2.917 2.3 l 107 mm
r fo ng
Allocation
Rep. gr.00 - Technical data
AG.
Manufactured
from to Model
11.07 10.08 Jetta 2005 Golf Variant 2007 Golf Variant 2010
agen lksw Vo by
Manual gearbox Identification code
KNS
11.07 02.09 Jetta 2005 Golf Variant 2007
ht rig py Co t.
6-speed 02Q KNU
KNY 02.08 10.08 Jetta 2005
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed manual gearbox 02Q - Edition 06.2010 Manual gearbox Identification code 6-speed 02Q KNU
Ratio: Z2 : Z1
Final
n AG. Volkswagen AG do es n kW wage kW Engine 2.0 o llk -s100 2.0 l - 147 ot g yV ua b turbo diesel 2.0 l 155 kW d ran e tee ris 2.0 l - 103 kW o h t or u turbo diesel ac a ss 1) 69 : 20 = 3.450 71 : 18 = 3.944 drive I
un le
KNS
KNY 2.0 l - 125 kW turbo diesel 70 : 19 = 3.684 70 : 24 = 2.917 2.3 l 107 mm

1) 2)
II2)
69 : 25 = 2.760 2.3 l 107 mm
71 : 23 = 3.087 2.3 l 107 mm
Final drive for 1st to 4th gears Final drive for 5th and 6th gears and reverse gear The following data can be found in the Electronic parts catalogue ETKA . Individual gear ratios Specification for gear oil
Allocation of clutch plate and pressure plate
KRM 05.07 07.10 Jetta 2005 Golf Variant 2010 2.0 l - 103 kW turbo diesel 69 : 20 = 3.450 69 : 25 = 2.760 2.3 l 107 mm
6-speed 02Q KXZ 05.09 Jetta 2005 Golf Variant 2007 2.0 l - 125 kW turbo diesel 70 : 19 = 3.684 70 : 24 = 2.917 2.3 l 107 mm
AG.
ht rig py Co t.
KZS
from to Model
r fo ng
05.09
Engine Ratio: Z2 : Z1
Final drive I1)
Jetta 2005 Golf Variant 2007 Jetta 2011 2.0 l - 155 kW 2.0 l - 147 kW 70 : 19 = 3.684 70 : 24 = 2.917 2.3 l 107 mm
Final drive II2) Capacity of manual gearbox Drive shaft flange

1) 2)
Manual gearbox Identification code Manufactured Allocation from to Model
LHD 10.08
6-speed 02Q LNN 06.09 Golf Variant 2010
Ratio: Z2 : Z1
Jetta 2005 Golf Variant 2007 Golf Variant 2010 Jetta 2011 Engine 2.0 l - 100 kW turbo diesel 1) 69 : 20 = 3.450 Final drive I
1.6 l - 77 kW turbo diesel 72 : 17 = 4.235
agen lksw Vo by
NFN 05.09 Jetta 2005
2.0 l - 125 kW turbo diesel 70 : 19 = 3.684

1. Gearbox identification
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed manual gearbox 02Q - Edition 06.2010 Manual gearbox Identification code Final drive Capacity of manual gearbox Drive shaft flange
1) 2)
LHD II2) 69 : 25 = 2.760
6-speed 02Q LNN 72 : 22 = 3.273
NFN 70 : 24 = 2.917 2.3 l 107 mm

or ac
Specification for gear oil
Individual gear ratios
un le
ris Final drive for 1st to 4th gears tho ureverse a Final drive for 5th and 6th gears and gear ss The following data can be found in the Electronic parts catalogue ETKA .
2.3 l 2.3 l n AG AG. Volkswage does agen ksw not l o 107 mm 107 mm gu yV
b ed
ara nte e
Allocation of clutch plate and pressure plate
NFP
6-speed 02Q MDL 11.09 Jetta 2011 2.0 l - 155 kW 70 : 19 = 3.684 70 : 24 = 2.917
ht rig py Co t.
Ratio: Z2 : Z1
from 05.10 to Model Golf Variant 2010 Engine 2.0 l - 103 kW turbo diesel 1) 69 : 20 = 3.450 Final drive I
r fo ng
Individual gear ratios Specification for gear oil Allocation of clutch plate and pressure plate
agen lksw Vo by
1) 2)
Final drive for 1st to 4th gears Final drive for 5th and 6th gears and reverse gear The following data can be found in the Electronic parts catalogue ETKA .
AG.
II2)
69 : 25 = 2.760 2.3 l 107 mm
2.3 l 107 mm
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed manual gearbox 02Q - Edition 06.2010
2
Designation
Overview - power transmission
-Arrows- indicate direction of travel. 1 - Engine 2 - Clutch 3 - Manual gearbox 4 - Input shaft 5 - Output shaft for 5th, 6th and reverse gears 6 - Output shaft for 1st through 4th gears 7 - Differential
pe rm itte d
un le
n AG. Volkswagen AG do es n wage s k l ot g o yV ua b ran ed s i tee r o h t or u ac a ss
Gears -Arrows- indicate direction of travel.

ht rig py Co t.
do c um en
agen lksw Vo by
AG.
Prote cted by
2. Overview - power transmission
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed manual gearbox 02Q - Edition 06.2010 I - 1st gear II - 2nd gear III - 3rd gear IV - 4th gear V - 5th gear VI - 6th gear A - Final drive
AG. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o eo h t u ra a c s s
R - Reverse gear
thi sd o cu m en
ht rig py Co t.
agen lksw Vo by
AG.
Prote cted by
3
Example:
Calculating overall gear ratio i

6th gear Final drive ZA1 = 25 ZA2 = 69
Drive gear Driven gear i = ZG2 : ZG1 1)
ZG1 = 43 ZG2 = 35
iG = Gear ratio = ZG2: ZG1= 35 : 43 = 0.814 iA = Final drive ratio = ZG2 : ZG1 = 69 : 25 = 2.760 itotal = Overall ratio = iG x iA = 0.814 x 2.760 = 2.247 Volkswa
gen AG n AG. does wage not 1) Z1 = No. of teeth on driving gear, Z2 = V No. of teeth on driven gear olks gu y b ara d e nte ris o eo h t u ra a c ss
pe rm itte d
un le
do c um en
ht rig py Co t.
agen lksw Vo by
AG.
Prote cted by
3. Calculating overall gear ratio i
General repair notes
To ensure flawless and successful gearbox repairs, the greatest care and cleanliness as well as the use of good and proper tools are essential. Of course, the basic rules for safety also apply dur ing repair work. A number 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 8 . They apply to this workshop manual.
4.1
Contact corrosion!
The gearbox housing and clutch housing are made of a mag nesium alloy. Bolts and other components in direct contact with the gearbox AG. Volkswagen AG d agen oes have a surface matched to it. w s k n l
db e If the incorrect components (bolts, nuts, washers and so on) ris o h are used, contact corrosion will develop. The gearbox housing t u a and clutch housing will ss be damaged.
o yV
ot g ua ran tee or ac
Always install parts listed in the Electronic parts catalogue ETKA .
4.2 4.3 4.3.1
Special tools Components Gearbox
For a complete list of special tools used in this workshop manual, see Workshop equipment and special tools .
When installing the manual gearbox, ensure that the dowel sleeves between the engine and gearbox are correctly seated. When installing mounting brackets or waxed components, clean the contact surfaces. Contact surfaces must be free of wax and grease. Allocate bolts and other components using Electronic parts catalogue ETKA . Capacity page 1 .
ht rig py Co t.
thi sd o cu m en
Following installation, check gear oil level page 126 .

agen lksw Vo by
Prote cted by
AG.
4.3.2
O-rings, seals, gaskets and sealants

. Volkswagen AG gen AG does not gu ara nte eo ra c
Thoroughly clean housing joint surfaces before applying seal ant . Always renew O-rings, seals and gaskets.
y db ise r tho au s contact surface s
un le
a ksw Apply sealant -AMV 188 200 03- uniformly but not too thick. Vol
Before installing radial shaft seals, lightly oil outer diameter and half-fill space between sealing lips -arrow- with sealing grease -G 052 128 A1- . The open side of the oil seal faces the side with fluid filling. Press in new oil seals so that sealing lip does not contact the shaft in the same place as the old seal (make use of insertion depth tolerances). Lightly oil O-rings before installing; this prevents the rings be ing crushed when inserted. After renewing seals and gaskets, check oil level in gearbox and replenish if necessary page 126 .
When seals have been removed, check on housings or shafts for burrs and damage and rectify as nec essary.
4.3.3
Locking devices
Do not overstretch retaining rings.
Retaining rings must locate properly in grooves.
AG.
Prote cted by
Renew spring pins. Installation position: slit -A- should be in line with the line of force -arrow-.
4. General repair notes
ht rig py Co t.
Always renew retaining rings which have been damaged or overstretched.

agen lksw Vo by
r fo ng
4.3.4
Nuts and bolts
Loosen and tighten securing bolts and nuts for covers and housings diagonally. Do not cant especially delicate parts, such as clutch pressure plates. Loosen and tighten bolts and nuts in stages in a diag onal sequence. Torque settings are specified for unoiled bolts and nuts. Always renew self-locking bolts and nuts. Ensure with threaded connections that contact surfaces as well as nuts and bolts are rewaxed only after assembly, if nec essary. Threads of bolts secured with locking fluid must be cleaned with a wire brush. Then insert bolts with locking fluid AMV 185 101 A1- . Clean threaded holes in which self-locking bolts or bolts with locking fluid have been inserted, e.g. with a thread chaser. Otherwise there is a danger that the bolts may shear when removed again.
4.3.5
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. olkswagen AG en AG. V
ol Do not interchange outer or inner y V races of bearings of the db e same size. The bearings are ris matched in pairs.
ag ksw
4.3.6
Shims
tho au s s
does not gu ara nte eo ra c

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.

thi sd o cu m en
10
ht rig py Co t.
agen lksw Vo by
AG.
4.3.7
Synchro-rings
Do not interchange. When reusing synchro-rings, always fit to the same gear. Check for wear and renew if necessary. Check grooves -arrow 1- of synchro-ring -A- and inner ring for flat spots (worn grooves). If synchro-rings are coated, coating must not be damaged. If an intermediate ring -B- is installed, check the outer friction surface -arrow 2- and inner friction surface -arrow 3- of this intermediate ring for scoring and signs of abnormal wear. . Volkswage
n AG wage
n AG d oe
s no olks for scoring and signs Check cone of synchromeshed gear t gu yV b ara d of abnormal wear. e n s i
un le
t Moisten synchromesh mechanism with gear oil before instal au ss ling.
r ho
tee or ac
4.3.8
Gears, synchro-hubs, inner races for synchromeshed gears
Heat inner races for synchromeshed gear to about 100 C with the inductive 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. Heat gears with inductive heater -VAS 6414- to approx. 100 C before installing. Press in to stop when installing so there is no axial clearance. Observe installation position.
r fo ng
4.3.9 4.3.10
Synchromeshed gears Clutch

ht rig py Co t.
Ensure that the pressure plate does not cant: loosen and tight en bolts diagonally and in several gradual stages. If the clutch has burnt out, thoroughly clean the clutch housing as well as the friction surface of flywheel with a cloth to reduce the smell of burnt linings.
agen lksw Vo by
After assembly, check synchromeshed gears for slight play, or for freedom of movement.
AG.
Prote cted by
4. General repair notes
11
30
1
Clutch
Fault finding, power transmission
Refer to Fault finding, power transmission; Rep. gr. 30 ; Complaints about clutch and clutch mechanism and Fault finding, power transmission; Rep. gr. 34 ; Complaints about selector mechanism

thi sd o cu m en
12
Rep. gr.30 - Clutch
ht rig py Co t.
agen lksw Vo by
AG.
Prote cted by
2
2.1
Note
Repairing clutch mechanism

Overview
When reconnecting battery, refer to Electrical system; Rep. gr. 27 ; Disconnecting and connecting battery . Lubricate all bearings and contact surfaces with grease -G 000 450 02- . I - Assembly overview - pedal cluster page 14 II - Assembly overview - hy draulics (LHD) page 34 III - Assembly overview - hy draulics (RHD) page 36
AG. Volkswagen AG d agen oes ksw not l o gu yV b ara Before disconnecting battery, coding. d obtain code for radio units having anti-theft e nte is r o eo h t u disconnect battery Electrical system; Rep.r a With ignition switched a off, gr. 27 ; Disconnecting c ss necting battery .
and con
do c um en
ht rig py Co t.
agen lksw Vo by
AG.
2. Repairing clutch mechanism
13
2.2
wa Assembly overview - pedal cluster olks yV
2 - Seal Always renew Between mounting bracket and bulkhead Self-adhesive Bond to mounting bracket
1 - Bulkhead With support for mount ing bracket
ss
b ed ris o th au

3 - Mounting bracket For mounting clutch pedal Is provided with damp ing in some equipment variants page 15 Removing and installing page 23 4 - Bolt 5 - Over-centre spring Removing and installing page 15 6 - Bearing bush 7 - Pivot pin 8 - Clutch pedal Removing and installing page 19 9 - Retainer To remove and install, separate master cylin der from clutch pedal page 19
thi sd o cu m en
10 - Seal Always renew Between master cylinder and mounting bracket 11 - Master cylinder Removing and installing after removal of mounting bracket page 29 12 - Clutch position sender -G476 Removing and installing page 30 Can be checked using guided fault finding of vehicle diagnostic tester The clutch position sender -G476- is identified as clutch pedal switch -F36- in guided fault finding 13 - Clip Pull out clip to stop to remove and install pipe/hose line 14 - Supply hose Rubber From 12.05, plastic page 35 15 - Hexagon nut, 25 Nm Self-locking
14
Rep. gr.30 - Clutch
ht rig py Co t.
agen lksw Vo by
AG.
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed manual gearbox 02Q - Edition 06.2010 Qty. 3 For mounting bracket on bulkhead Always renew gen AG. Volkswagen AG
a lksw
o 16 - Hexagon nut, y V 25 Nm b ed s i r Always renew tho

ss 17 - Stop For clutch pedal
au

Mounting bracket with damping -arrows-

thi sd o cu m en
Special tools and workshop equipment required Release tool -T10178-
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 antitheft code.
AG.
2.3
Removing and installing over-centre spring
ht rig py Co t.
agen lksw Vo by
Prote cted by
15
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed manual gearbox 02Q - Edition 06.2010 With ignition switched off, disconnect battery Electrical sys tem; Rep. gr. 27 ; Disconnecting and connecting battery . Continuation for all Push driver seat as far back as possible and put steering wheel in highest position. Remove driver side footwell cover and driver side left trim panel General body repairs, interior; Rep. gr. 68 ; Com partments, covers and trim panels . Vehicles with knee airbag Remove bracket for knee airbag together with crash bar Interior equipment; Rep. gr. 69 ; Airbag; Removing and in stalling knee airbag bracket . Vehicles without knee airbag Remove crash bar -1- from in front of clutch pedal by removing nuts -2-. Continuation for all
AG. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte is r o eo h ut ra a c s s
If fitted, remove damping -arrow- from lower area of clutch pedal mounting bracket.
thi sd o cu m en
To do this, remove lock washers -A- for damping. Pull off damping.
16
Rep. gr.30 - Clutch
ht rig py Co t.
agen lksw Vo by
AG.
Push damping upwards in area of upper securing nut -1above clutch pedal -A- in -direction of arrow-.
un le
AG. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o eVariant h t or Golf Variant 2007 , Golf u ac a s s
2010 , Jetta 2005 , Jetta 2011 6-speed manual gearbox 02Q - Edition 06.2010
r fo ng
Unbolt clutch pedal -1- from mounting bracket -3- by removing nut -2- and pulling out bolt -5-. Note
agen lksw Vo by
AG.
Prote cted by
The clutch pedal remains hooked to operating rod of master cyl inder.
Swing clutch pedal down slightly and remove over-centre spring -4- from mounting bracket.
2.3.2
Installing
Install in the reverse order of removal, observing the following: Note
Renew self-locking nuts.
ht rig py Co t.
17
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed manual gearbox 02Q - Edition 06.2010 Insert over-centre spring -2- in mounting bracket from above while holding end of spring with assembly tool -T10178- in in stallation position.
Depress clutch pedal slightly, push bolt through and tighten self-locking nut to specified torque page 19 .
pe rm itte d
Insert tip -A- of clutch pedal in bearing recess of over-centre spring.

un le
AG. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte ver Receptacleo-arrowfor tip -A- of clutch pedal must stand ris eo h ra tically. aut c s s
Some cars have damping -arrow- on the clutch pedal mounting bracket. Return it to installation position. Vehicles without knee airbag
do c um en
18
Rep. gr.30 - Clutch
ht rig py Co t.
agen lksw Vo by
AG.
G. Volkswagen AG d n Aand Install crash bar -1- in front of clutch pedal by screwing on oes wage s k not l o tightening nuts -2-. gu yV
Vehicles with knee airbag
Continuation for all
Install bracket for knee airbag bar Inte rior equipment; Rep. gr. 69 ; Airbag; Removing and installing knee airbag bracket .
un le
b ed ris o th au ss with crash together
ara nte e
or ac
Install driver side footwell cover and driver side left trim panel General body repairs, interior; Rep. gr. 68 ; Compartments, covers and trim panels . If disconnected, connect battery Electrical system; Rep. gr. 27 ; Removing and installing battery .
2.3.3
Component
Specified torques
Nm 25 10
Clutch pedal to mounting bracket Renew self-locking nuts
Crash bar to steering column mounting bracket

Special tools and workshop equipment required Pliers -T10005-
Release tool -T10178-
ht rig py Co t.
2.4
Removing and installing clutch pedal

r fo ng
agen lksw Vo by
Prote cted by
AG.
19
2.4.1
Removing
Vehicles with knee airbag Note

AG. Volkswagen AG d The installation location of the knee airbag is above the pedal agen oes ksw not l cluster. o g yV
With ignition switched off, disconnect battery earth strap Electrical system; Rep. gr. 27 ; Disconnecting and connecting battery . Continuation for all Push driver seat as far back as possible and put steering wheel in highest position. Remove driver side footwell cover and driver side left trim panel General body repairs, interior; Rep. gr. 68 ; Com partments, covers and trim panels . Vehicles with knee airbag Remove bracket for knee airbag together with crash bar Interior equipment; Rep. gr. 69 ; Airbag; Removing and in stalling knee airbag bracket . Vehicles without knee airbag Remove crash bar -1- from in front of clutch pedal by removing nuts -2-.
First check whether a coded radio is fitted. If theft code.
b ed ris o h t so, obtain antiau ss
ua ran tee
or ac

do c um en
20
Rep. gr.30 - Clutch
ht rig py Co t.
agen lksw Vo by
AG.
Prote cted by
n AG. Volkswagen AG do es n wage s k l ot g o To do this, bremove lock washers -A- for damping. yV ua ran ed s i tee r o Pull off h damping. t or u ac a ss
Push damping upwards in area of upper securing nut -1above clutch pedal -A- in -direction of arrow-.
thi sd o cu m en
Unbolt clutch pedal -1- from mounting bracket -3- by removing nut -2- and pulling out bolt -5-. Swing clutch pedal forward slightly and remove over-centre spring -4- from mounting bracket.
ht rig py Co t.
agen lksw Vo by
AG.
Prote cted by
21
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed manual gearbox 02Q - Edition 06.2010 Release clutch pedal from master cylinder with pliers T10005- . Remove clutch pedal.
2.4.2
Installing
Install in the reverse order of removal, observing the following: Note
Renew self-locking nuts.

Attach retainer -2- to master cylinder operating rod -1-. Press retainer into notch in clutch pedal -3- until it can be heard to engage.
Insert over-centre spring -2- in mounting bracket from above lkswagen A o while holding end of spring with assembly tool -T10178- in in yV db e stallation position. ris
tho au s s
G. Volkswagen AG d oes not gu ara nte eo ra c


do c um en
AG.
22
Rep. gr.30 - Clutch
ht rig py Co t.
agen lksw Vo by
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed manual gearbox 02Q - Edition 06.2010 Receptacle -arrowfor tip -A- of clutch pedal must stand ver tically.
Insert tip -A- of clutch pedal in bearing recess of over-centre spring. Depress clutch pedal slightly, push bolt through and tighten self-locking nut to specified torque page 23 .
Some cars have damping -arrow- on the mounting bracket/clutch pedal. Return it to installation position. Vehicles without knee airbag
un le
Install crash bar -1- in front of clutch pedal by screwing on and tightening nuts -2-. Vehicles with knee airbag Install bracket for knee airbag together with crash bar Inte rior equipment; Rep. gr. 69 ; Airbag; Removing and installing knee airbag bracket . Continuation for all Install driver side footwell cover and driver side left trim panel General body repairs, interior; Rep. gr. 68 ; Compartments, covers and trim panels .
r fo ng
Component Clutch pedal to mounting bracket Renew self-locking nuts Crash bar to steering column mounting bracket
Nm 25 10
2.5
Removing and installing mounting bracket
Special tools and workshop equipment required
AG.
2.4.3
Specified torques
ht rig py Co t.
agen lksw Vo by
23
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed manual gearbox 02Q - Edition 06.2010 Hose clamps -3094-
Hose clip pliers -VAS 6362-
Sealing
un le
AG. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o eo h t u ra a -T10249tool c s s
2.5.1
LHD
Removing
First check whether a coded radio is fitted. If so, obtain antitheft code. With ignition switched off, disconnect battery earth strap Electrical system; Rep. gr. 27 ; Disconnecting and connecting battery .
r fo ng
agen lksw Vo by
Remove complete air filter housing if it is near battery Rep. gr. 23 ; Repairing diesel direct injection system or Rep. gr. 24 ; Repairing injection system . Remove battery and battery tray Electrical system; Rep. gr. 27 ; Battery; Removing and installing battery .
AG.
Prote cted by
24
Rep. gr.30 - Clutch
ht rig py Co t.
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed manual gearbox 02Q - Edition 06.2010 Continuation for all Note During the following work, ensure that no brake fluid lands on Place a lint-free cloth under the master cylinder. Clamp off supply hose to master cylinder using hose clamp to 25 mm -3094- .
longitudinal member or gearbox. If this does happen, clean the affected areas thoroughly.
If necessary, loosen spring-type clip -3- with hose clip pliers VAS 6362- and pull supply hose off master cylinder. In addition, for disconnecting, you can close it with the sealing tool -T10249/1- ( figure above).
wag Release securing clip -2- using screwdriver aepointed object n AG d AG. Volksor agen oes ksw line -1- off master cylinder. not and pull pipe/hose line or plastic l o V
e Unclip clutch position rissender -G476- from master cylinder thowith electrical connector attached -4-. -arrow- and remove u a
y db
When performing work in the footwell, put cloths on the carpet to protect it from possible brake fluid spills.
Remove driver side footwell cover and driver side left trim panel General body repairs, interior; Rep. gr. 68 ; Com partments, covers and trim panels . Vehicles with knee airbag Remove bracket for knee airbag together with crash bar Interior equipment; Rep. gr. 69 ; Airbag; Removing and in stalling knee airbag bracket . Vehicles without knee airbag
Note
un le
ss
gu ara nte eo ra c
r fo ng
ht rig py Co t.
agen lksw Vo by
AG.
Prote cted by
25
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed manual gearbox 02Q - Edition 06.2010 Remove crash bar -1- from in front of clutch pedal by removing nuts -2-. Continuation for all
un le
To do this, remove lock washers -A- for damping. Pull off damping.
r fo ng
26
Rep. gr.30 - Clutch
ht rig py Co t.
agen lksw Vo by
AG.
Prote cted by
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed manual gearbox 02Q - Edition 06.2010 Push damping upwards in area of upper securing nut -1above clutch pedal -A- in -direction of arrow-.
Remove nuts -2-.
Remove mounting bracket -1-.
do c um en
2.5.2
Installing
Install in the reverse order of removal, observing the following: Note Renew self-locking nuts. Renew hose clips. Allocate all components according to Electronic parts cata
logue ETKA .
ht rig py Co t.
agen lksw Vo by
AG.
Prote cted by
27
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed manual gearbox 02Q - Edition 06.2010 Some cars have damping -arrow- on the clutch pedal mounting bracket. Vehicles without knee airbag
pe rm itte d
un le
Install crash bar -1- in front of clutch pedal by screwing on and tightening nuts -2-. Vehicles with knee airbag Install bracket for knee airbag together with crash bar Inte rior equipment; Rep. gr. 69 ; Airbag; Removing and installing knee airbag bracket . Install driver side footwell cover and driver side left trim panel General body repairs, interior; Rep. gr. 68 ; Compartments, covers and trim panels . Push pipe/hose line or plastic line -1- with seal -2- onto con nection of master cylinder -4- until securing clip -3- engages audibly. Test line by tugging on it. After removing hose clamp up to 25 mm -3094- , return supply hose to its original shape, if necessary. Bleed clutch system page 37 . LHD Install battery tray and battery Electrical system; Rep. gr. 27 ; Removing and installing battery . Remove complete air filter housing if it is near battery Rep. gr. 23 ; Repairing diesel direct injection system or Rep. gr. 24 ; Repairing injection system . Reconnect battery and perform work required after connecting battery Electrical system; Rep. gr. 27 ; Disconnecting and connecting battery .
agen lksw Vo by
AG.
do c um en
2.5.3
Component
Specified torques
Nm 25 10
Mounting bracket to body Renew self-locking nuts. Crash bar to steering column mounting bracket
28
Rep. gr.30 - Clutch
ht rig py Co t.
2.6
Removing and installing master cylinder
Special tools and workshop equipment required Pliers -T10005AG. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o eo h t u ra a c s s
2.6.1
Removing
Remove mounting bracket page 23 . Release retainer for master cylinder operating rod using pliers -T10005- .
do c um en
Length of spacer = about 40 mm (e.g. 1/2" socket). Release securing bar -B- and pull master cylinder out of mounting bracket -arrow 1- and -arrow 2-.
2.6.2
Installing
Move clutch pedal to rest position at stop.
AG.
Insert spacer -A- between clutch pedal and stop and press clutch pedal to spacer.
Prote cted by
ht rig py Co t.
agen lksw Vo by
29
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed manual gearbox 02Q - Edition 06.2010 Attach retainer -2- to master cylinder operating rod -1-.
Insert spacer -A- between clutch pedal and stop and press clutch pedal to spacer. Length of spacer = about 40 mm (e.g. 1/2" socket). Engage master cylinder in mounting bracket -arrow 1- and -arrow 2-.
pe rm itte d
un le
do c um en
Install mounting bracket page 23 .
2.7
Removing and installing clutch position sender -G476-
30
Rep. gr.30 - Clutch
AG.
Press master cylinder operating rod -1- in -direction of arrow- until retainer -2- engages audibly in clutch pedal.
ht rig py Co t.
agen lksw Vo by
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed manual gearbox 02Q - Edition 06.2010 Hose clamps -3094-
2.7.1
LHD
Removing
First check whether a coded radio is fitted. If so, obtain antitheft code. With ignition switched off, disconnect battery earth strap . Volkswagen AG gen AG does Electrical system; Rep. gr. 27 ; Disconnecting and connecting a ksw not l o V battery . gu by a
r Remove complete air filter housing if it is near battery Rep. ho ut a gr. 23 ; Repairing diesel direct injection system or Rep. gr. s s 24 ; Repairing injection system .
d ise
ran tee or ac
Remove battery and battery tray Electrical system; Rep. gr. 27 ; Battery; Removing and installing battery .
Right-hand drive
pe rm itte d
un le
In vehicles with particle filter, remove shielding -A- from parti cle filter Rep. gr. 26 ; Parts of exhaust system; Assembly overview - front exhaust pipe with particle filter . An insulation mat is installed in conjunction with some engines.
Remove heat shield from pipe/hose line -arrows-.

ht rig py Co t.
do c um en
agen lksw Vo by
AG.
31
If a pipe/hose line -1- with a round component is installed directly beneath the master cylinder, the pipe/hose line must be removed. Note
un le
n AG. Volkswagen AG do es n wage s k l ot g o yV ua b ran ed s i tee r Variant 2010 , Jetta 2005 , Jetta 2011 Golf Variant 2007 , Golf o h t or u ac a 6-speed manual gearbox 02Q Edition 06.2010 ss
During the following work, ensure that no brake fluid lands on longitudinal member or gearbox. If this does happen, clean the affected areas thoroughly.
Place a lint-free cloth under the master cylinder.
r fo ng
Clamp off supply hose to master cylinder using hose clamp to 25 mm -3094- .
agen lksw Vo by
AG.
Prote cted by
Release securing clip -2- with a screwdriver or a pointed object and pull out of master cylinder to stop. Pull pipe/hose line -1- or plastic line out from master cylinder and seal. Disconnect electrical connector -4-. Unclip clutch position sender -G476- from master cylinder -arrow- and remove. Note
Disregard item -3-.
2.7.2
Installing
Install in the reverse order of removal, observing the following:
32
Rep. gr.30 - Clutch
ht rig py Co t.
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed manual gearbox 02Q - Edition 06.2010 Note Renew hose clips. Allocate all components according to Electronic parts cata
logue ETKA .
If the pipe/hose line was removed Push pipe/hose line -1- or plastic line with seal -2- onto con nection of master cylinder -4- until securing clip -3- engages audibly. Test pipe/hose line by tugging on it. After removing hose clamp up to 25 mm -3094- , return supply hose to its original shape, if necessary. Bleed clutch system page 37 . Right-hand drive
In vehicles with particle filter, install shielding -A- on particle filter Rep. gr. 26 ; Parts of exhaust system; Assembly over view - front exhaust pipe with particle filter . AG. Volkswagen AG d agen o LHD
ksw Vol by d e ris tho Install battery tray and battery Electrical usystem; Rep. 27 ; Removing and installing battery . ss a
gr.
es n ot g ua ran tee or ac
Reconnect battery and perform work required after connecting battery Electrical system; Rep. gr. 27 ; Disconnecting and connecting battery .
pe rm itte d
Remove complete air filter housing if it is near battery Rep. gr. 23 ; Repairing diesel direct injection system or Rep. gr. 24 ; Repairing injection system .
un le
do c um en
ht rig py Co t.
agen lksw Vo by
AG.
Prote cted by
33
2.8
Assembly overview - hydraulics (LHD)
1 - Brake fluid reservoir 2 - Spring-type clip Not fitted in all vehicles 3 - Supply hose Rubber From 12 05, plastic page 35 4 - Master cylinder Removing and installing page 29 5 - Clip Pull out clip to stop to re move and install pipe/ hose line or plastic line Pulled out to side on some master cylinders 6 - Seal / O-ring Pull onto line connection Insert with brake fluid Seals/O-rings are adap ted to configuration of line connection page 35 Allocation Electronic AG. Volkswagen AG d parts catalogue ETKA agen oes ksw n
b 7 - Retainer ed ris o h t To remove au and install, ssmaster cylin separate der from clutch pedal page 19
ol yV
8 - Clutch pedal Removing and installing page 19 9 - Hexagon nut, 25 Nm Self-locking Qty. 3 For mounting bracket on bulkhead Always renew
pe rm itte d
un le
10 - Pipe/hose line Allocation Electronic parts catalogue ETKA To remove, remove battery and battery tray Electrical system; Rep. gr. 27 ; Removing and installing battery . Removing and installing page 41
do c um en
34
Rep. gr.30 - Clutch
ht rig py Co t.
agen lksw Vo by
AG.
11 - Bracket For pipe/hose line Item 10 (page 34) Secured to body Hidden by engine/gearbox mounting Retainer identification page 36
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed manual gearbox 02Q - Edition 06.2010 olkswagen A G en AG. V 12 - Plastic line Allocation Electronic parts catalogue sstray Electrical system; Rep. gr. 27 ; Removing and installing To remove, remove battery and battery battery . Removing and installing page 41
ag ksw Vol y b ed ris o h ETKA t au
13 - Bracket For plastic line Item 12 (page 34) Secured to body Hidden by engine/gearbox mounting Retainer identification page 36 14 - Seal / O-ring Pull onto line connection Insert with brake fluid Seals/O-rings are adapted to configuration of line connection page 35 Allocation Electronic parts catalogue ETKA 15 - Breather Removing and installing page 40
un le
19 - Slave cylinder Can be renewed only with gearbox removed Removing and installing page 39 20 - Gearbox Seals and O-rings for pipe/hose line or plastic line Item 1 2 Material of line connection Line connection with circumferential groove -arrow 1Line connection with shoulder -arrow 2-
Supply hose -1- of plastic The seals -2- must be located in supply hose housing.
AG.
18 - Dust cap
agen lksw Vo by
17 - Bleeder valve Bleeding clutch system page 37
ht rig py Co t.
16 - Clip Pull out clip to stop to remove and install pipe/hose line or plastic line or bleeder
r fo ng
35
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed manual gearbox 02Q - Edition 06.2010 Retainer identification Dim. a mm 8 6 Line configuration Plastic line Pipe/hose line
2.9
Assembly overview - hydraulics (RHD)
1 - Brake fluid reservoir 2 - Seal For plastic supply hose The seals must be loca ted in supply hose 3 - Supply hose Made of plastic page 35 May be made of rubber 4 - Master cylinder Removing and installing page 29 5 - Clip Pull clip out to stop to re move or install pipe line Pulled out to side on some master cylinders 6 - Seal / O-ring Pull onto line connection Insert with brake fluid Seals/O-rings are adap ted to configuration of line connection page 35 Allocation Electronic parts catalogue ETKA 7 - Retainer To remove and install, separate master cylin der from clutch pedal page 19 8 - Clutch pedal Removing and installing page 19 9 - Hexagon nut, 25 Nm Self-locking Qty. 3 For mounting bracket on bulkhead Always renew

thi sd o cu m en
36
Rep. gr.30 - Clutch
ht rig py Co t.
agen lksw Vo by
AG.
wage 10 - Bracket olks V by Secured to body ed ris o th Hidden by engine/gearbox mounting au
11 - Pipe line Pipe and hose/pipe line Item 13 (page 37) may be in one piece Removing and installing page 41 Allocation Electronic parts catalogue ETKA To remove, remove battery and battery tray Electrical system; Rep. gr. 27 ; Removing and installing battery .
pe rm itte d
un le
ss
n AG. Volkswagen AG do es n ot g ua ran tee or ac
12 - Seal / O-ring Pull onto line connection Insert with brake fluid Seals/O-rings are adapted to configuration of line connection page 35 Allocation Electronic parts catalogue ETKA
13 - Pipe/hose line Pipe Item 11 (page 37) and hose/pipe line may be in one piece Removing and installing page 41 Allocation Electronic parts catalogue ETKA To remove, remove battery and battery tray Electrical system; Rep. gr. 27 ; Removing and installing battery .
do c um en
15 - Seal / O-ring Pull onto line connection Insert with brake fluid Seals/O-rings are adapted to configuration of line connection page 35 Allocation Electronic parts catalogue ETKA 16 - Clip Pull out clip to stop to remove and install pipe/hose line or bleeder. 17 - Bleeder valve Bleeding clutch system page 37 18 - Dust cap 19 - Bleeder connection Removing and installing page 40 20 - Seal / O-ring Pull onto line connection Insert with brake fluid Seals/O-rings are adapted to configuration of line connection page 35 Allocation Electronic parts catalogue ETKA 21 - Slave cylinder Can be renewed only with gearbox removed Removing and installing page 39 22 - Gearbox
AG.
2.10
Bleeding clutch system
agen lksw Vo by
14 - Retainer Secured to body
ht rig py Co t.
37
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed manual gearbox 02Q - Edition 06.2010 Brake filling and bleeding equipment -VAS 5234- or
Brake filling and bleeding equipment -V.A.G 1869-
Note
Prefilling system is not necessary!
Remove complete air filter housing if it is near battery Rep. gr. 23 ; Repairing diesel direct injection system or Rep. gr. 24 ; Repairing injection system . Connect brake filling and bleeding equipment -VAS 5234- or -V.A.G 1869- . 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 -A- to bleeder -arrow-. Pressurise system to 2 bar. Open bleeder valve about 1/4 turn.
Specifications for brake fluid Brake systems; Rep. gr. 47 ; Bleeding brake system .
Move clutch pedal 15 to 20 times quickly by hand from stop to stop. After completing bleeding procedure, when the pressure of 2 bar is released, operate clutch pedal ten more times by foot.
AG.
Prote cted by
thi sd o cu m en
Remove complete air filter housing if it is near battery Rep. gr. 23 ; Repairing diesel direct injection system or Rep. gr. 24 ; Repairing injection system .
38
Rep. gr.30 - Clutch
ht rig py Co t.
agen lksw Vo by
Close bleeder valve.
Repairing clutch release mechanism
Special tools and workshop equipment required Torque wrench -V.A.G 1331-
un le
1 - Gearbox
2 - Input shaft seal Renewing page 43 3 - Slave cylinder with clutch release bearing Are one unit and can be renewed together only Do not wash out bear ing; wipe only Renew noisy bearings together with slave cyl inder For some slave cylin ders, divided supply line page 40 Removing and installing page 40
r fo ng
5 - O-ring Pull onto line connection Insert with brake fluid Allocation Electronic parts catalogue ETKA
AG.
Prote cted by
4 - Bolt Qty. 3 Always renew Without locking fluid 12 Nm (only slave cylin ders with metal housing) With locking fluid 15 Nm (for plastic slave cylin ders) Carefully tighten diago nally in small steps so that the bolting eyes of the slave cylinder do not break off
3. Repairing clutch release mechanism
ht rig py Co t.
agen lksw Vo by
39
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed manual gearbox 02Q - Edition 06.2010 Slave cylinder -A- with divided supply line
en AG. The supply line for some slave cylinders is divided in the area of ag ksw l o V the -arrow-. by
Volkswagen AG does not gu ara nte eo ra c
Allocation Electronic parts catalogue ETKA thori u

a ss
d se
3.1
Removing pipe/hose line and bleeder from and installing on slave cylinder
Removing pipe/hose line or plastic line from and installing on bleeder To remove, release securing clip -2- with a screwdriver or pointed object and pull pipe/hose line or plastic line -4- off bleeder -1-. To install pipe/hose line or plastic line, push onto bleeder con nection with O-ring -3- until securing clip engages audibly. Test line by tugging on it.
thi sd o cu m en
To install, check O-ring -3- on slave cylinder. Press bleeder onto slave cylinder connection until securing clip engages au dibly. Check by pulling on bleeder. Bleed clutch system page 37 .
3.2
Removing and installing slave cylinder with release bearing

Note
Slave cylinder and release bearing are a single component and can be renewed only together.
Removing Remove gearbox.
40
Rep. gr.30 - Clutch
agen lksw Vo by
To remove, release securing clip -2- with a screwdriver or pointed object and pull bleeder -4- off slave cylinder -1-.
AG.
Removing bleeder from and installing on slave cylinder
ht rig py Co t.
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed manual gearbox 02Q - Edition 06.2010 Release securing clip -2- with a screwdriver or pointed object and pull bleeder -4- off slave cylinder -1-.
Remove bolts -arrows-. Remove slave cylinder together with release bearing -A-. Installing
A G do agen Install in the reverse order of removal, observing the A following: es n lksw
G. Volkswagen
b The securing bolts for is the ed slave cylinder must be tightened r o only in small stages. h ut
o yV
Bolt on slave cylinder with release bearing Item 4 (page 39) .
un le
Otherwise, the tabs swith the bolt holes may break off.
sa
Check O-ring -3- on slave cylinder for damage. Press bleeder -4- onto slave cylinder connection -1- until se curing clip -2- engages audibly. Check by pulling on bleeder. Install gearbox. Bleed clutch system page 37 .
r fo ng
3.3
AG.
Prote cted by
Hose clamps to 25 mm -3094-
agen lksw Vo by
ht rig py Co t.
Removing and installing pipe/hose line or plastic line

41
Remove complete air filter housing Rep. gr. 23 ; Repairing diesel direct injection system or Rep. gr. 24 ; Repairing injection system . Note
Removing
un le
AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 ut ra a c s 6-speed manual gearbox 02Q - Edition 06.2010 s
During the following work, ensure that no brake fluid lands on longitudinal member or gearbox. If this does happen, clean the affected areas thoroughly.
Clamp off supply hose to master cylinder using hose clamp -3094- . Remove pipe/hose line or plastic line from master cylinder as fol lows:
r fo ng
Release securing clip -3- using screwdriver or pointed object and pull off line -1- with O-ring -2-. Caution
Do not depress clutch pedal after removing slave cylinder.

Remove pipe/hose line or plastic line from bleeder as follows:
Release securing clip -2- using screwdriver or pointed object and pull line -4- with O-ring -3- off bleeder -1-. Installing Install in the reverse order of removal, observing the following:
42
Rep. gr.30 - Clutch
ht rig py Co t.
agen lksw Vo by
AG.
Push pipe/hose line or plastic line -1- with O-ring -2- onto con nection of master cylinder -4- until securing clip -3- engages audibly. Test line by tugging on it.
AG. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o eo h tGolf Variant 2007 , Golf Variant 2010 , Jetta u ra a c s s
2005 , Jetta 2011 6-speed manual gearbox 02Q - Edition 06.2010


do c um en
After removing hose clamp up to 25 mm -3094- , return supply hose to its original shape, if necessary. Bleed clutch system page 37 . Install complete air filter housing Rep. gr. 23 ; Repairing diesel direct injection system or Rep. gr. 24 ; Repairing injection system
3.4
Renewing input shaft seal
Special tools and workshop equipment required extractor lever -T20143/1-
AG.
Test line by tugging on it.
agen lksw Vo by
Push line with O-ring -3- onto bleeder connection until secur ing clip engages audibly.
Prote cted by
ht rig py Co t.
43
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed manual gearbox 02Q - Edition 06.2010 Thrust piece -T40008-
Sealing grease -G 052 128 A1 Remove gearbox.

un le
Procedure
Remove slave cylinder with release bearing page 40 . Lever out seal for input shaft using lever -T20143/1- . Note
Do not damage running surface of input shaft for oil seal.
Drive seal in flush using thrust piece -T40008- . Install slave cylinder with release bearing page 40 . Install gearbox.
44
Rep. gr.30 - Clutch
ht rig py Co t.
Lightly moisten outer circumference of oil seal with gear oil.

agen lksw Vo by
r fo ng
Half-fill space between sealing lip and dust lip -arrow- with sealing grease -G 052 128 A1- .
AG.
Repairing clutch - vehicles with turbo diesel engine
Special tools and workshop equipment required Counterhold -3067 Torque wrench -V.A.G 1331 Centring mandrel -T10097 Grease for clutch plate splines -G 000 100-
pe rm itte d
un le
For engines having a crankshaft of smaller diameter or having needle bearings in the crankshaft - page 49 centring man drel -3176ht rig py Co t.
do c um en
4.1
Determining clutch manufacturer
A clutch manufactured by either Sachs or LuK may be instal led. The make of the clutch can be determined as follows with the clutch installed:
4. Repairing clutch - vehicles with turbo diesel engine
agen lksw Vo by
AG.
Prote cted by
45
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed manual gearbox 02Q - Edition 06.2010 Remove noise insulation General body repairs, exterior; Rep. gr. 50 ; Noise insulation . Remove noise insulation from engine sump if necessary. Some notches -arrows- are located in lower region of sump be tween engine -A- and gearbox -B-. Check outer contour of flywheel through these notches.
In addition, a small cover plate -A- can be removed -arrowsto enable inspection of flywheel's outer contour.
Round outer contour -arrows- = Sachs clutch = -A Removing and installing Sachs clutch page 47 . Repairing Sachs clutch page 50 .
ht rig py Co t.
do c um en
Outer contour with edges -arrows 1- and, in addition, a circum ferential crease -arrow 2- = LuK clutch = -Bor
agen lksw Vo by
AG.
46
Rep. gr.30 - Clutch
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed manual gearbox 02Q - Edition 06.2010 Rounded outer contour -arrows 1- and a circumferential crease -arrow 2- = LuK clutch = -B Removing and installing LuK clutch page 50 . Repairing LuK clutch page 53 .
4.2
Removing
Removing and installing Sachs clutch
Remove gearbox page 85 . Use counterhold -3067- to loosen bolts. Loosen bolts in small steps and diagonally. As bolts are removed, stop -2- with pin -1- must loosen. If stop does not loosen, press pin towards dual-mass flywheel. Remove pressure plate and clutch plate. Installing Install in the reverse order of removal, observing the following: Note

un le
n AG. Volkswagen AG do es n wage s k l ot g o Select clutch to engine y V plate and pressure plate according ua b ran ed Electronic parts catalogue ETKA s code and i t. r ee o th or ac gearbox au Check whether dowel sleeves for aligning engine and ss
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.
Installation position of clutch plate
Lettering Getriebeseite and protruding spring cage face gearbox.
r fo ng
ht rig py Co t.
agen lksw Vo by
AG.
Prote cted by
47
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed manual gearbox 02Q - Edition 06.2010 Checking ends of diaphragm spring Wear to half the thickness of the diaphragm spring -arrows- is permitted.
Checking spring connections and riveted connections
Check spring connections between pressure plate and cover for cracks as well as rivet connections for secure seating. A pressure plate with damaged spring connections or with loose rivet connections -arrows- must be renewed. Note
Renew clutch plates and pressure plates with damaged or
loose rivet connections.
Select clutch plate and pressure plate according to engine
do c um en
code and Electronic parts catalogue ETKA .
Pressure plates are protected against corrosion and greased.
Clean contact surface only. Otherwise, the service life of the clutch will be considerably reduced.
Pressure plate contact surface and clutch plate lining must
make full contact with flywheel. Only then insert securing bolts.
Reverse counterhold tool -3067- for installation.
48
Rep. gr.30 - Clutch
agen lksw Vo by
AG.
Prote cted by
splines; remove corrosion and apply only a very thin coat of clutch plate spline grease -G 000 100- to splines. Then move clutch plate to and fro on input shaft until hub moves freely on shaft. Remove excessive grease.
ht rig py Co t.
Clean input shaft splines and, on used clutch plates, clean hub
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed manual gearbox 02Q - Edition 06.2010 For engines having a crankshaft of smaller diameter -arrow- or having an needle bearing -arrow- in the crankshaft
needle bearing -arrow- in the crankshaft Note
AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h Centring clutch disc and removing and installing pressure plate ut ra a c s s or having a for engines having a crankshaft of smaller diameter
Disregard arrows -A- and -B-.

Push pressure plate onto centralizing pins.
Tighten all bolts evenly by hand until bolt heads contact pres sure plate. Tighten bolts in small steps diagonally in order not to damage centring holes of pressure plate and centring pins of dualmass flywheel Item 4 (page 50) . Install gearbox page 85 .
thi sd o cu m en
ht rig py Co t.
agen lksw Vo by
AG.
49
4.3
Repairing Sachs clutch
1 - Dual-mass flywheel Removing and installing Rep. gr. 13 Ensure that centring pins fit tightly Contact surface for clutch lining must be free of grooves, oil and grease 2 - Clutch plate Allocation Electronic parts catalogue ETKA Renew only together with pressure plate Removing and installing page 47 Installation position page 47 3 - Thrust plate With adjusting mecha nism Allocation Electronic parts catalogue ETKA Renew only together with clutch plate. Removing and installing page 47 Check ends of dia phragm spring page 48 Check spring connec tions and riveted con nections page 48 .
4 - M6 bolt, 13 Nm, M7 bolt, 20 Nm Allocation Electronic parts catalogue ETKA Loosen or tighten diagonally in small steps
4.4
Removing
Removing and installing LuK clutch
Remove gearbox page 85 . Use counterhold -3067- to loosen bolts. Remove pressure plate and clutch plate. Installing
Loosen bolts in small steps and diagonally.
do c um en
50
Rep. gr.30 - Clutch
ht rig py Co t.
agen lksw Vo by
AG.
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed manual gearbox 02Q - Edition 06.2010 Note Select clutch plate and pressure plate according to engine
Check whether dowel sleeves for aligning engine and gearbox
Installation position of clutch plate Lettering Getriebeseite (gearbox side) faces gearbox.
Checking ends of diaphragm spring Wear to half the thickness of the diaphragm spring -arrows- is permitted.
pe rm itte d
Check spring connections -arrows A- for damage and riveted connections -arrows B- for secure seating.
un le
Checking
AG. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o eo h t u ra a c s s connections and riveted connections spring
do c um en
ht rig py Co t.
agen lksw Vo by
AG.
Prote cted by
51
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed manual gearbox 02Q - Edition 06.2010 Checking position of adjusting mechanism with new pressure plates only Both edges -A- of the adjuster ring must be located between the two notches -arrows B-. If the adjuster ring takes up a different position in new pressure plates, the pressure plate and clutch plate are not allowed to be installed. The adjuster ring may take up a position outside the notches in used clutches. Note Renew clutch plates and pressure plates with damaged or
Renew pressure plate and clutch plate together only. Select clutch plate and pressure plate according to engine
splines; remove corrosion and apply only a very thin coat of clutch plate spline grease -G 000 100- to splines. Then move clutch plate to and fro on input shaft until hub moves freely on shaft. Remove excessive grease. Clean contact surface only. Otherwise, the service life of the clutch will be considerably reduced.
Pressure plates are protected against corrosion and greased. Pressure plate contact surface and clutch plate lining must
pe rm itte d
un le
For engines having a crankshaft of smaller diameter -arrow- or having an needle bearing -arrow- in the crankshaft
do c um en
52
Rep. gr.30 - Clutch
ht rig py Co t.
agen lksw Vo by
AG.
Prote cted by
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed manual gearbox 02Q - Edition 06.2010 Centring clutch disc and removing and installing pressure plate for engines having a crankshaft of smaller diameter or having a needle bearing -arrow- in the crankshaft Note

Push pressure plate onto centralizing pins. Tighten all bolts evenly by hand until bolt heads contact pres sure plate. Tighten bolts in small steps diagonally in order not to damage centring holes of pressure plate and centring pins of dualmass flywheel Item 4 (page 53) . Install gearbox page 85 .
4.5
Repairing LuK clutch
3 - SAC pressure plate SAC means self-ad justing clutch. Renew only together with clutch plate. Allocation Electronic parts catalogue ETKA Removing and installing page 50 Check ends of dia phragm spring page 51 Check spring connec tions and riveted con nections page 51 . 4 - M6 bolt, 13 Nm, M7 bolt, 20 Nm Loosen or tighten diagonally in small steps
agen lksw Vo by
AG.
Prote cted by
2 - Clutch plate Allocation Electronic parts catalogue ETKA Removing and installing page 50 Renew only together with SAC pressure plate. Installation position: page 51 .
ht rig py Co t.
1 - Dual-mass flywheel Removing and installing Rep. gr. 13 Ensure that centring pins fit tightly Contact surface for clutch lining must be free of grooves, oil and grease
do c um en
53
Repairing clutch - vehicles with petrol engine
Special tools and workshop equipment required Counterhold -3067 Centring mandrel -T10097 Torque wrench -V.A.G 1331 Grease for clutch plate splines -G 000 100-
un le
For engines having a crankshaft of smaller diameter or having needle bearings in the crankshaft - page 58 centring man drel -3176-
r fo ng
54
Rep. gr.30 - Clutch
ht rig py Co t.
agen lksw Vo by
AG.
5.1
Note
Repairing clutch
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.
1 - Dual-mass flywheel Removing and installing Rep. gr. 13 Ensure that centring pins fit tightly Contact surface for clutch lining must be free of grooves, oil and grease 2 - Clutch plate Allocation Electronic parts catalogue ETKA Removing and installing AG. Volkswagen AG d agen oes ksw not l page 55 o V gu y b ara d Renew only together nte ise r o eo h t with SAC pressure u ra a c s plate. s Installation position: page 56 . 3 - SAC pressure plate SAC means self-ad justing clutch. Renew only together with clutch plate. Allocation Electronic parts catalogue ETKA Removing and installing page 55 Check ends of dia phragm spring page 56 Checking spring con nections and riveted connections page 56 4 - M6 bolt, 13 Nm, M7 bolt, 20 Nm Loosen or tighten diagonally in small steps

do c um en
Removing Remove gearbox page 85 . Use counterhold -3067- to loosen bolts. Loosen bolts in small steps and diagonally.
AG.
5.2
Removing and installing clutch
5. Repairing clutch - vehicles with petrol engine
ht rig py Co t.
agen lksw Vo by
Prote cted by
55
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed manual gearbox 02Q - Edition 06.2010 Remove pressure plate and clutch plate. Installing
V by ed s i r ho ut a ss
wag the following: Install in the reverse order of removal, observing olks
Note
olkswagen AG en AG. V does not gu ara nte eo ra c

Select clutch plate and pressure plate according to engine
Check whether dowel sleeves for aligning engine and gearbox
Installation position of clutch plate Lettering Getriebeseite -arrow- faces gearbox.
Checking ends of diaphragm spring Wear to half the thickness of the diaphragm spring -arrows- is permitted.
thi sd o cu m en
Checking spring connections and riveted connections Check spring connections -arrows A- for damage and riveted connections -arrows B- for secure seating.
56
Rep. gr.30 - Clutch
ht rig py Co t.
agen lksw Vo by
AG.
Prote cted by
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed manual gearbox 02Q - Edition 06.2010 Checking position of adjusting mechanism with new pressure plates only Both edges -A- of the adjuster ring must be located between the two notches -arrows B-. If the adjuster ring takes up a different position in new pressure plates, the pressure plate and clutch plate are not allowed to be installed.
r ho ut a ss
olks The adjuster ring may take up a position outside the notches yV b d in used clutches. ise
un le
Note
n AG. Volkswagen AG do es n wage ot g ua ran tee or ac

Renew clutch plates and pressure plates with damaged or
Always renew pressure plate and clutch plate together. Select clutch plate and pressure plate according to engine
If clutch has burnt out, thoroughly clean clutch housing, fly
wheel and parts of engine facing gearbox to reduce smell of burnt linings. splines; remove corrosion and apply only a very thin coat of clutch plate spline grease -G 000 100- to splines. Then move clutch plate to and fro on input shaft until hub moves freely on shaft. Remove excessive grease. Clean contact surface only. Otherwise, the service life of the clutch will be considerably reduced.
r fo ng
Pressure plates are protected against corrosion and greased. Pressure plate contact surface and clutch plate lining must
For engines having a crankshaft of smaller diameter -arrow- or having an needle bearing -arrow- in the crankshaft
5. Repairing clutch - vehicles with petrol engine
AG.
Prote cted by
ht rig py Co t.
agen lksw Vo by
57
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed manual gearbox 02Q - Edition 06.2010 Centring clutch disc and removing and installing pressure plate for engines having a crankshaft of smaller diameter or having a needle bearing -arrow- in the crankshaft Note

Continuation for all Push pressure plate onto centralizing pins. Tighten all bolts evenly by hand until bolt heads contact pres sure plate. Tighten bolts in small steps diagonally in order not to damage centring holes of pressure plate and centring pins of dualmass flywheel Item 4 (page 55) . Install gearbox page 85 .

do c um en
58
Rep. gr.30 - Clutch
ht rig py Co t.
agen lksw Vo by
AG.
Prote cted by
34
1
1.1
Controls, housing
Repairing selector mechanism
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 - Relay lever
un le
r fo ng
1. Repairing selector mechanism
ht rig py Co t.
agen lksw Vo by
AG.
59
1.2
Note
Overview of selector mechanism
Note radio code for vehicles with coded radio. Before working on selector mechanism in engine compartment, disconnect earth strap from battery Elec
trical system; Rep. gr. 27 ; Disconnecting and connecting battery . 27 ; Disconnecting and connecting battery .
When reconnecting battery, perform work required after connecting battery Electrical system; Rep. gr. To work on selector mechanism in engine compartment, remove complete air filter housing if it is located
over selector mechanism Rep. gr. 23 ; Repairing diesel direct injection system or Rep. gr. 24 ; Repairing injection system .
Remove selector mechanism to renew selector cables page 78 . Do not kink selector cables. I - Removing and installing gear knob and frame page 62 II - Repairing gear lever and selector housing (through 10.06) page 64 II - Repairing gear lever and selector housing (from 11.06) page 66 III - Assembly overview - re moving and installing selector cables page 71
un le
r fo ng
Removing and installing selector mechanism page 78 Adjust selector mechanism page 82 . Special tools and workshop equipment required
60
Rep. gr.34 - Controls, housing
ht rig py Co t.
agen lksw Vo by
AG.
Prote cted by
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed manual gearbox 02Q - Edition 06.2010 Hose clip pliers -V.A.G 1275-
Torque wrench -V.A.G 1331-
un le
r fo ng
ht rig py Co t.
agen lksw Vo by
AG.
Prote cted by
61
1.3
Removing and installing gear knob and frame
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 Removing and installing page 62 3 - Clamp For securing gear knob to gear lever Secure to gear knob wagen AG. Volkswagen AG does ks not Item 2 (page 62)yusing Vol gu b ara d hose clip pliers -V.A.G nte ise r o eo h 1275t u ra a c s s Always renew 4 - Frame for centre console In some equipment ver sions, forms one part to gether with centre con sole 5 - Noise insulation Not fitted in all vehicles Arrow on noise insula tion points in direction of travel Locking lugs are ar ranged at varying inter vals Therefore it can be installed in only one position
1.4
Pull or carefully prise gaiter with frame for centre console up wards out of centre console -arrows-. Note
AG.
With some equipment variations, the gaiter must be levered off along the front section.
62
agen lksw Vo by
Prote cted by
1.4.1
Removing
ht rig py Co t.
Removing and installing gaiter with gear knob and noise insulation
do c um en
Golf
Open clamp -arrow- and pull off gear knob together with gaiter. In some versions, the centre console frame remains in the centre console. If necessary pull off, or carefully lever off, centre console frame.
Pull gaiter with frame for centre console upwards, inside out over gear knob.
AG. Volkswagen AG d agen oes ksw not l o gu yV b a d , Golf Variant 2010 , Jetta 2005 Variant 2007 ran, Jetta 2011 e is tee r o h 6-speed manual gearbox 02Q Edition 06.2010 t or u ac a ss
Pull off noise insulation -1-.
do c um en
1.4.2
Installing
First set noise insulation in place. Installation position of noise insulation -Arrow A- points in direction of travel. Catches -arrows B- must engage in centre console.
If necessary, press frame into centre console. Then turn gaiter inside out. The gear knob must be pressed to stop.
Install gear knob with frame and gaiter and squeeze new clamp -arrow- together. Then press gaiter with frame into centre console or gaiter into frame.
ht rig py Co t.
agen lksw Vo by
AG.
63
1.5
Note
Repairing gear lever and selector housing (through 10.06)
Lubricate bearing points and sliding surfaces with grease -G 000 450 02- .
1 - Lock washer Removing and installing page 65 2 - Bush 3 - Compression spring 4 - Bush 5 - Torx screw, 6 - Cover 7 - Damping 8 - Damping
AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r 5 Nm o eo h ut ra a c s s
9 - Ball socket
10 - Gear lever guide 11 - Damping washer 12 - Seal Between selector hous ing and underbody Self-adhesive Bond to selector hous ing 13 - Selector lever 14 - Selector housing 15 - Bearing bush 17 - Guide bush
ht rig py Co t.
do c um en
16 - Pivot pin
19 - Gate selector lever 20 - Torx screw, 5 Nm 21 - Seal Always renew 22 - Base plate Bend open tabs to remove Always renew 23 - Gate selector cable On gate selector lever Removing and installing page 65 24 - Gear selector cable Removing from and attaching to gear lever guide page 65
64
agen lksw Vo by
AG.
18 - Compression spring Installing page 65
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed manual gearbox 02Q - Edition 06.2010 25 - Lock washer Always renew 26 - Hexagon nut M8: 25 Nm M6: 8 Nm Qty. 4 27 - Bearing bush Fits in one position only 28 - Lock washer Always renew
n AG. Volkswagen AG do es n wage s k l ot g o yV ua b Removing and installing gate and gear selector cables ran ed s i tee r o h t or u Remove securing clip from gear selector cable -A- and gate ac a s s selector cable -B-.
pe rm itte d
To do this, raise tab using screwdriver -arrow 1- and press off securing clip -arrow 2-.
Remove gear selector cable -A- from gear lever retainer. Remove gate selector cable -B- from retainer of gate selector lever.
un le
Do not cant spacer bush when pushing down. Carefully release tension from spring. Installing compression spring
Slot in gear lever for securing clip must be visible.
Insert compression spring so that extension -A- lies on top of pin -arrow-. Then pull extension -B- down so that it sits below pin -arrow-.
AG.
Prote cted by
Note
ht rig py Co t.
To remove or install securing clip -arrow A-, press spacer bush -arrow B- to stop -in direction of arrow C- using screwdriver and pull off securing clip.
agen lksw Vo by
Removing and installing securing clip
do c um en
65
1.6
Note
Repairing gear lever and selector housing (from 11.06)
y Dismantling and assembling selectoremechanism page 67 . db
AG. Volkswagen AG Lubricate bearing points and sliding surfacesw with 450 doe 02- . agen grease -G 000
ks Vol
1 - Base plate Bend open tabs to re move Always renew 2 - Seal Always renew
ris ho ut a ss
3 - Selector lever Can be removed and in stalled with gear lever guide Item 15 (page 67) installed
4 - Damping washer Push onto gear lever up to stop -arrow5 - Securing clip Do not damage cables when removing Always renew
thi sd o cu m en
7 - Bush 8 - Gear selector cable Lever off gear lever guide Press onto gear lever guide inside selector mechanism Installation position page 59 9 - Damping 10 - Ball socket Will be damaged when removed Always renew 11 - Bush 12 - Lock washer Removing and installing page 65 13 - Compression spring Removing and installing page 65
66
agen lksw Vo by
AG.
6 - Gate selector cable Lever off gate selector lever Press onto gate selector lever inside selector mechanism Installation position page 59
ht rig py Co t.
14 15 -
16 M8: 25 Nm M6: 8 Nm Qty. 4
AG. Volkswagen AG d agen oes ksw not l o gu Bush yV b ara d e nte is r o eo Gear lever guide h ut ra a c s s Hexagon nut
17 - Seal Between selector housing and underbody Self-adhesive Bond to selector housing 18 - Selector lever housing With compression spring and gate selector lever Compression spring and gate selector lever cannot be removed
1.6.1
Dismantling and assembling selector mechanism

ht rig py Co t.
thi sd o cu m en
Special tools and workshop equipment required thrust piece -T10083Dismantling
Remove selector mechanism page 78 .
Bend open tabs -arrows- of base plate for selector mechanism using screwdriver and remove base plate; (tabs in front area of base plate are not illustrated). Remove seal from selector housing. Remove gear and gate selector cables from selector housing page 71 .
agen lksw Vo by
AG.
67
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed manual gearbox 02Q - Edition 06.2010 Lift upper end -A- of compression spring over tab of gate se lector lever. Use screwdriver to press catches -arrows- of ball socket to wards bearing ball of gear lever guide; break off catches if necessary.
un le
AG. Volkswagen AG d agen oes ksw not l o Lever ball socket -A- with gear lever guide -B- out of selector V gu by ara d e housing. nte is r o eo h t ra au Then press ball socket off bearing ball of gear lever sguide and c s
remove it.
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-.
r fo ng
ht rig py Co t.
Then swing out gear lever guide with gear lever in -direction of arrow 3-. Assembling Caution
The lower end of the compression spring (-arrow 1- figure above) can snap off the shoulder of the gate selector lever out of control during the further procedure.
Therefore, carefully press it down off shoulder of gate selector lever. The ends of the compression spring then become tensioned di agonally with a loud noise.
68
AG.
Pin -arrow 2- must be in notch in selector housing.
agen lksw Vo by
Then turn gear lever guide in -direction of arrow 1-.
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed manual gearbox 02Q - Edition 06.2010 Slacken ends -A- and -B- by turning both round to right. Ends -A- and -B- must point in opposite directions.
Fit gear lever guide with gear lever 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. AG. Volkswagen A
n wage olks V by ed ris o th au
The gear lever guide must project from the selector housing up to the stop.
pe rm itte d
un le
ss
G do es n ot g ua ran tee or ac
Note
For clarity of illustration, only part of the gate selector lever is shown.
Insert end -A- of compression spring into guide from above. Pull end -B- of compression spring downwards and insert it next to guide (in direction of ball joint). Please pay attention to guides ( figure above) during the fur ther procedure.
They must not be broken off.
Carefully remove selector housing with gear lever guide from thrust piece -T10083- .
ht rig py Co t.
do c um en
agen lksw Vo by
AG.
69
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed manual gearbox 02Q - Edition 06.2010 Move gate selector lever back to stop (opposite from mounting holes for gear and gate selector cable) -arrow 1-. Grease ball stud. Press ball stud into gate selector lever -arrow 2-. Guides -A- and tabs -B- are not allowed to be damaged.
Place selector housing with gear lever guide into larger recess -arrow- in thrust piece -T10083- .
pe rm itte d
un le
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- . Lift upper end -A- of compression spring over pin of gate se lector lever into guide. Press ball socket into selector housing -arrows-. Attach gear lever, gear selector cable, gate selector cable and base plate page 66 . Install selector mechanism page 78 .
AG.
Insert lower end -C- of compression spring into guide.
do c um en
70
agen lksw Vo by
All locking lugs must clip in.
ht rig py Co t.
1.7
Note
Assembly overview - removing and installing selector cables
Lubricate bearing points and sliding surfaces with grease -G 000 450 02- .
1 - Gear selector cable Connect to cable endpiece Item 18 (page 72) Installation position page 59 From 11.06, modified attachment to gear lever inside selector mecha nism Item 8 (page 66) 2 - Gate selector cable Connect to cable endpiece Item 11 (page 71) Installation position page 59 From 11.06, modified attachment to gate se lector lever inside selec tor mechanism Item 6 (page 66) 3 - Lock washer Always renew Discontinued in selector mechanisms from 11.06 page 66 4 - Lock washer Do not damage cables when removing Always renew 5 - Selector housing 6 - Hexagon bolt, 20 Nm For cable support bracket Qty. 2
un le
pe rm itte d
7 - Cable support bracket May be made from plastic or metal
8 - Grommet Cable support bracket mounting on gearbox 9 - Spacer 10 - Nut, 20 Nm For cable support bracket
do c um en
ht rig py Co t.
agen lksw Vo by
AG.
11 - Cable end-piece For gate selector cable to relay lever After installing, adjust selector mechanism page 82
71
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed manual gearbox 02Q - Edition 06.2010 Do not interchange; cable end-pieces for gate selector cable to relay lever and gear selector cable to gearbox selector lever are different page 73 From 05.07, fitted in conjunction with plastic relay lever page 75 Removing from plastic relay lever page 75 Pressing onto plastic relay lever page 75 Allocation page 73 12 - Relay lever Installation position page 74 After installing, adjust selector mechanism page 82 May be made from plastic or metal Metal relay lever is mounted in bearing bush Item 13 (page 72) and secured with securing clip Item 14 (page 72) From 05.07, plastic relay lever Remove and install plastic relay lever together with cable end-piece page 75 Bearing bushes and securing clip not required for plastic relay lever 13 - Bearing bush Discontinued on relay levers made from plastic 14 - Lock washer Always renew Discontinued on relay levers made from plastic 15 - Shoe 16 - Gearbox selector lever With damper weight Install so that master After installing, adjust selector mechanism page 82 Installation position page 74 From 06.06, smaller diameter of support pin for cable end-piece page 73
AG. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte is r o eo h ut ra a c s s spline aligns with selector shaft
17 - Hexagon nut, 23 Nm Self-locking Always renew
18 - Cable end-piece For gear selector cable to gearbox selector lever After installing, adjust selector mechanism page 82 Do not interchange; cable end-pieces for gate selector cable to relay lever and gear selector cable to gearbox selector lever are different page 73
do c um en
72
ht rig py Co t.
agen lksw Vo by
AG.
Allocation of The holes in
Cable end-piece for 1 - Gear selector cable to gearbox selector lever from 06.06 2 - Gear selector cable to gearbox selector lever through 05.06 2. - Gate selector cable to metal relay lever 2. - Gate selector cable to plastic relay lever page 75
k Vol by d cable ise rend-pieces tho u a the ss cable end-pieces
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 . Volkswagen AG 6-speed manual gearbox 02Q - Edition 06.2010 gen AG does swa have different
not gu ara nte eo ra c diameters.
Dimension a 8.5 mm 10 mm 8 mm 10 mm

thi sd o cu m en
From 06.06, smaller diameter of support pin for gear selector ca ble end-piece Through 05.06 From 06.06 10 mm 8.5 mm
ht rig py Co t.
Support pin for gear selector cable end-piece

Dimension a
agen lksw Vo by
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.
Prote cted by
73
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed manual gearbox 02Q - Edition 06.2010 Installation position of gearbox selector lever and relay lever 12Gearbox selector lever with damper weight Relay lever engages in guide rail of gearbox selector lever via shoe -arrow-.
Renewing cable end-pieces Pull locking mechanisms of end-pieces of gate selector cable and gear selector cable forward to stop -arrow 1- and then turn to left to lock -arrow 2-.
thi sd o cu m en
74
ht rig py Co t.
agen lksw Vo by
AG.
Prote cted by
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed manual gearbox 02Q - Edition 06.2010 Remove securing clip -3- for gear selector cable from gearbox selector lever -1-. Pull gear selector cable off pin -arrow-. Metal relay lever Remove securing clip -4- for gate selector cable from relay lever -2-. Pull gate selector cable from pin. Plastic relay lever Remove relay lever together with cable end-piece page 75 . Carefully pry off cable end-piece page 77 . Continued for all selector mechanisms Spread a small quantity of grease -G 000 450 02- on pin -arrows- of gearbox selector lever -1- and, as needed, relay lever pin -2-. Renew securing clip -3- and, for metal relay lever, securing . Volkswagen AG clip -4- each time they are removed. gen AG d
t gu metal V Secure gear selector cable with securing clip -3- and, for by ara ed nte s i relay lever, gate orselector cable with securing clip -4-. e
wa olks
oes no
th au ss
or ac
Note
If a plastic relay lever is installed, it must be mounted together with the cable end-piece page 75 .
Adjust selector mechanism page 82 .
1.8
Plastic relay lever
From 05.07, relay lever is made from plastic. 2 versions may be installed. Relay lever with catch or Relay lever with clip Comply with the following during removal and installation work: To remove relay lever, first separate cable end-piece from gate selector cable.
thi sd o cu m en
This will avoid damage to the gate selector cable

ht rig py Co t.
Then push relay lever forwards (-in direction of arrow 3-).

AG.
Prote cted by
agen lksw Vo by
Pull locking mechanism forward to stop in -direction of arrow 1- and then lock by turning to left in -direction of arrow 2-.
75
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed manual gearbox 02Q - Edition 06.2010 Relay lever with catch -arrow 1 Press catch -arrow 1- down to stop and remove relay lever together with cable end-piece. In the process, swing it in di rection of operation.
Relay lever with clip -arrow 1 Pull clip -arrow 1- off and remove relay lever together with ca ble end-piece. n AG. Volkswagen A Continuation for all Cable end-piece must be located
wage olks V y db ise or behindthcatch -arrow 2-. au s s
Note
The cable end-piece can be removed only with the relay lever removed page 77 .
un le
To fit, lubricate bearing points and sliding surfaces with grease G 000 450 02- .
Press cable end-piece onto relay lever page 77 . Install relay lever together with cable end-piece to stop. Relay lever with catch -arrow 1 Ensure proper engagement.
Catch -arrow 1- secures relay lever. Cable end-piece must be located behind catch -arrow 2-.
r fo ng
76
ht rig py Co t.
agen lksw Vo by
AG.
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed manual gearbox 02Q - Edition 06.2010 Relay lever with clip -arrow 1 Clip -arrow 1- secures relay lever. Ensure proper engagement of clip. Cable end-piece must be located behind catch -arrow 2-.
pe rm itte d
Levering gate selector cable end-piece off plastic relay lever Relay lever has been removed.
un le
Insert a flat-blade screwdriver -A- between bush -B- and relay lever.
do c um en
agen lksw Vo by
Pressing on cable end-piece

AG.
ht rig py Co t.
77
. Volkswagen AG gen AG does swa k not l o Golf Variant 2007 gu 2005 y V , Golf Variant 2010 , Jetta b a d e 6-speed manual gearbox 02Q - Edition 06.2010 rante is r o eo th ra au c s s has been removed. Relay lever
, Jetta 2011
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 -arrow 2-.

thi sd o cu m en
Grease -G 000 450 02-
1.9.1
Removing
First check whether a coded radio is fitted. In this case, obtain anti-theft code. With ignition switched off, disconnect battery Electrical sys tem; Rep. gr. 27 ; Disconnecting and connecting battery . Remove gaiter with selector knob and noise insulation page 62 . Remove centre console and securing bracket for centre con sole General body repairs, interior; Rep. gr. 68 ; Compart ments, covers and trims .
78
AG.
agen lksw Vo by
ht rig py Co t.
1.9
Removing and installing selector mech anism
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed manual gearbox 02Q - Edition 06.2010 Remove selector housing nuts -arrows-. Remove complete air filter housing if it is over selector mech anism Rep. gr. 23 ; Repairing diesel direct injection system or Rep. gr. 24 ; Repairing injection system .
Remove securing clip -3- for gear selector cable from gearbox selector lever -1-. Pull gear selector cable off pin -arrow-. Metal relay lever Remove securing clip -4- for gate selector cable from relay lever -2-. Pull gate selector cable off pin -arrow-. Plastic relay lever
Releasing cable end-piece from gate selector cable

To avoid damage to gate selector cable, separate cable endpiece from gate selector cable before removal.
Pull locking mechanism forward to stop in -direction of arrow 1- and then lock by turning to left in -direction of arrow 2-. Then push relay lever forwards (-in direction of arrow 3-). Remove relay lever together with cable end-piece page 75 . Continued for all selector mechanisms
un le
Remove cable support bracket from gearbox -arrows-. Remove noise insulation General body repairs, exterior; Rep. gr. 50 ; Noise insulation . Remove tunnel cross member Rep. gr. 26 ; Removing and installing parts of exhaust system .
ht rig py Co t.
Remove underbody panels General body repairs, exterior; Rep. gr. 50 . Separate front exhaust system at double clamp and detach from subframe Rep. gr. 26 ; Removing and installing parts of exhaust system .
r fo ng
Remove rear exhaust system and heat shield Rep. gr. 26 ; Removing and installing parts of exhaust system . Swing selector housing down and remove with selector ca bles.
1.9.2
Installing
Install in the reverse order of removal, observing the following: Align selector housing parallel to body.
agen lksw Vo by
AG.
79
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed manual gearbox 02Q - Edition 06.2010 Distance to body must be same on both sides.
Secure selector housing Item 26 (page 65) or Item 16 (page 67) . Install cable support bracket on gearbox and tighten bolts to specified torques Item 6 (page 71) and Item 10 (page 71) . The holes in the cable end-pieces have different diameters. Allocation of cable end-pieces page 73 Spread a small quantity of grease -G 000 450 02- on pin -arrows- of gearbox selector lever -1- and, as needed, relay lever pin -2-. Renew securing clip -3- and, for metal relay lever, securing clip -4- each time they are removed. Secure gear selector cable with securing clip -3- and gate se lector cable with securing clip -4-. Cable end-piece to plastic relay lever Fit relay lever and cable end-piece together page 75 . Insert gate selector cable in cable end-piece. Continued for all selector mechanisms
AG. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o eo h t u ra a centre console c and s s
Install gaiter with selector knob and noise insulation page 62 . Install underbody panels General body repairs, exterior; Rep. gr. 50 . Install heat shield. Assemble exhaust system free of tension and attach tunnel cross member Rep. gr. 26 ; Removing and installing parts of exhaust system . Adjust selector mechanism page 82 . If complete air filter housing was removed, install it Rep. gr. 23 ; Repairing diesel direct injection system or Rep. gr. 24 ; Repairing injection system .
pe rm itte d
Install centre console securing bracket General body repairs, interior; Rep. gr. 68 ; Compartments, covers and trims .
un le
Follow procedure after connecting battery Electrical system; Rep. gr. 27 ; Battery; Disconnecting and connecting battery .
ht rig py Co t.
do c um en
Remove selector mechanism page 78 .
80
AG.
1.10.1
Removing
agen lksw Vo by
Prote cted by
1.10
Removing and installing gear selector cable and gate selector cable
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed manual gearbox 02Q - Edition 06.2010 Bend open tabs -arrows- of selector mechanism cover using n AG. Volkswagen AG do es n wage a screwdriver and remove cover. o olks Remove gasket.
yV db ise r tho au s s
t gu ara nte eo ra c
un le
Pull off securing clips -1 4-. Note
Securing clips -1 and 4- have been discontinued on selector mechanisms from 11.06.
Prise gear selector cable off gear lever and gate selector cable off gate selector lever with e.g. a screwdriver if necessary.
r fo ng
Pull gear selector cable and gate selector cable from selector housing. Release locks -A- for gear and gate selector cables -B- as follows:
AG.
ht rig py Co t.
Turn sliding sleeve to right to stop -arrow 2- until it engages. Remove locking mechanism from Bowden cables.
Pull off securing clips -1- and -2-. Remove cable support bracket from Bowden cables.
1.10.2
Installing
agen lksw Vo by
Prote cted by
Push sliding sleeve forward to stop -arrow 1-.
81
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed manual gearbox 02Q - Edition 06.2010 Secure gear selector cable and gate selector cable to selector housing using securing clips -2 and 3-. Press gear selector cable onto gear lever and gate selector cable onto gate selector lever in selector housing and secure with clips -1 and 4Note
Securing clips -1 and 4- have been discontinued on selector mechanisms from 11.06.
Fit seal and secure selector mechanism cover by pressing down tabs -arrows-. Install selector mechanism page 79 . Adjust selector mechanism page 82 .
1.11
Adjusting selector mechanism
Locking pin -T10027 ANote

swagen AG The following points are essential to ensure e correct adjust n AG. Volk
ment of selector mechanism:
Gearbox, clutch and clutch mechanism must also be in proper
condition.
pe rm itte d
un le
Selector mechanism must move freely.
does ag ksw not Vol gu y b ara d nte Moving parts of selector mechanism ise and elements transferring r o eo h t force must be in proper condition. u ra a c s s
Gearbox must be in neutral.
Remove complete air filter housing if bracket -A- to secure gear selector cable and gate selector cable are not accessible Rep. gr. 23 ; Repairing diesel direct injection system or Rep. gr. 24 ; Repairing injection system .
do c um en
82
ht rig py Co t.
agen lksw Vo by
AG.
Prote cted by
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed manual gearbox 02Q - Edition 06.2010 Pull locking mechanisms on gate selector cable and gear se lector cable end-pieces forward to stop -direction of arrow 1and 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, turn angled rod -A- in -direction of arrow 3- upwards and at the same time press it in -direction of arrow 2- until it engages in selector shaft. Remove gaiter with selector knob and frame page 62 . If noise insulation is present, remove it.
Now secure gear lever as follows: Select neutral using gear lever. Guide locking pin -T10027 A- through
un le
AG. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte hole -Ainto hole -B-. is r o eo h ut ra a c s s
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 -direction of arrow 1-. The spring presses the locking mechanism into original position -direction of arrow 2-.
r fo ng
ht rig py Co t.
agen lksw Vo by
AG.
83
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed manual gearbox 02Q - Edition 06.2010 Now turn angled rod -A- back to original position -direction of arrow 2-. During this procedure, angled rod -A- must be pressed out of gearbox in -direction of arrow 1-.
Pull locking pin -T10027 A- out of holes -A- and -B-. If noise insulation was present, install it. Install gaiter with selector knob and frame page 62 . Check that selector shaft moves freely. If removed, reinstall complete air filter housing Rep. gr. 23 ;Volk by d e; Repairing diesel direct injection system or Rep. gr. 24 ris ho Repairing injection system ut
pe rm itte d
. Volkswagen AG gen AG does swa not gu ara nte eo ra c
1.11.1
Functional check
un le
a ss
With gearbox in neutral, gear lever must rest in gate for 3rd and 4th gear.
Operate clutch.
Select all gears several times. Pay particular attention to op eration of reverse gear lock. If it continues to be difficult to engage a gear after repeated attempts, repeat adjustment procedure of selector mechanism page 82 .
do c um en
84
ht rig py Co t.
agen lksw Vo by
AG.
Prote cted by
Removing and installing gearbox in vehicles with turbo diesel engine

Removing gearbox
2.1
Special tools and workshop equipment required Support bracket -10 - 222 A Adapter -10-222 A /8 Adapter -10-222 A /3
n AG. Volkswagen AG do es n wage s k l ot g o ua Adapter -10-222 A /18- ed by V ran s i tee r o h t or Gearbox support -3282u ac a ss

do c um en
2. Removing and installing gearbox in vehicles with turbo diesel engine
ht rig py Co t.
agen lksw Vo by
AG.
Prote cted by
85
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed manual gearbox 02Q - Edition 06.2010 Support elements for gear box (determine when set ting adjustment plate on gearbox support ) Adjustment plate -3282/33 Gearbox lifting tackle -3336- for transporting gearbox Torque wrench -V.A.G 1331 Torque wrench -V.A.G 1332 Engine and gearbox jack V.A.G 1383 A-
pe rm itte d
un le
do c um en
86
ht rig py Co t.
agen lksw Vo by
AG.
Prote cted by
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed manual gearbox olkswag02Q en AG- Edition 06.2010 en AG. V Bracket -T10346 Adapter -VW 771/40 Hose clamps to 25 mm -3094 Grease for clutch plate splines -G 000 100 Allocate grease using Electronic parts catalogue (ETKA) . Flange bolt M6 X 20 Flange bolt M6 X 80 Hexagon head bolt M10 x 20
Engine support -3300 A-
ss
ag ksw Vol y b ed ris o h t au

do c um en
At a later point, support bracket -10-222 A- will be put onto lon gitudinal members with adapters -10 - 222 A /8- . To prevent damage to edges of wings, cover bottom area of both adapters -10 - 222 A /8- with self-adhesive fabric tape -arrow- Electronic parts catalogue (ETKA chemical sub stances) .
Removing Check whether a coded radio is fitted. If so, obtain anti-theft code. With ignition switched off, disconnect battery earth strap Electrical system; Rep. gr. 27 ; Disconnecting and connecting battery . At a later point, the support bracket -10-222 A- will be connected to the lifting eyes of engine. If engine cover blocks access, remove engine cover. Remove complete air filter housing if it is located close to the battery Rep. gr. 23 ; Repairing diesel direct injection sys tem . Remove battery, battery cover and battery tray Electrical system; Rep. gr. 27 ; Removing and installing battery .
ht rig py Co t.
agen lksw Vo by
AG.
87
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed manual gearbox 02Q - Edition 06.2010 Remove securing clip -1- for gear selector cable from gearbox selector lever -2- and pull cable off pin -arrow-.
Releasing cable end-piece from gate selector cable To avoid damage to gate selector cable, separate cable endpiece from gate selector cable before removal.
Pull locking mechanism forward to stop in -direction of arrow 1- and then lock by turning to left in -direction of arrow 2-. Then push relay lever forwards (-in direction of arrow 3-). The relay lever is removed together with the cable end-piece at a later point.
Remove cable support bracket from gearbox -arrows-, lay to side and secure with wire.
thi sd o cu m en
LHD Clamp off supply hose to master cylinder using hose clamp -3094- .
88
ht rig py Co t.
agen lksw Vo by
AG.
Right-hand drive
AG. Volkswagen AG d agen oes ksw not l o gu Variant 2010 , Jetta 2005 , Jetta 2011 yV Golf Variant 2007 , Golf b ara d e nte is r 6-speed o e o manual gearbox 02Q - Edition 06.2010 h ut ra a c s s
Clamp off hose of pipe/hose line -A- to slave cylinder using hose clamp -3094- . Continuation for all
Pull out clip -arrowfor pipe/hose line or plastic line to stop. Pull pipe/hose line or plastic line out from slave cylinder bleed er and seal. Caution
Do not operate clutch pedal any more.
Remove earth strap -1- from top starter bolt. Separate electrical connector -2- for reversing light switch F4- . Remove connector and wire from starter.
ht rig py Co t.
thi sd o cu m en
Remove upper engine/gearbox connecting bolts -arrows-. Then remove upper securing bolt on starter.
Bolt bracket -T10346- to rear of the 3 mounting holes for bat tery tray. To do this, use a collar bolt M 6 x 80 or a securing bolt for battery tray. If there are hose and cable connections in area of engine sup port eye for support bracket -10-222 A- , remove these now.
agen lksw Vo by
AG.
89
AG do agen Set up support bracket -10-222 A- in lfront ksw of bonnet support. es n
AG. Volkswagen
Use: Adapter -10-222 A /3 Adapter -10-222 A /8 Adapter -10-222 A /18
Position adapter -10-222 A /8- : On upper longitudinal carrier, directly before the elevation (-arrow 1-) next to bolt (-arrow 2-)
Vo by ed s i r ho ut a ss
Connect bracket -T10346- to support bracket . Attach spindles in left engine support eyes. Take up weight of engine/gearbox assembly and support bracket on spindles.
The left drive shaft will be removed in a later step. With vehicle standing on its wheels, loosen front left flange bolt -arrow- 90 at most, or wheel bearing will be damaged Running gear, axles, steering; Rep. gr. 40 ; Removing and installing drive shafts .
ht rig py Co t.
do c um en
Remove noise insulation General body repairs, exterior; Rep. gr. 50 ; Noise insulation .
agen lksw Vo by
Remove lower part of front left wheel housing liner General body repairs, exterior; Rep. gr. 66 ; Wheel housing liner .
AG.
Prote cted by
Gearboxes for vehicles with start-stop system: pull connector -arrow- off gearbox neutral position sender -G701- .
If front vehicle level sender -G78- is present, unbolt it from transverse link Rep. gr. 40 ; Removing and installing front vehicle level sender -G78- . Remove bracket from starter. Remove starter Electrical system; Rep. gr. 27 ; Starter .
90
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed manual gearbox 02Q - Edition 06.2010 Remove left charge air hose -arrow 1- and -arrow 2- Rep. gr. 21 ; Charge air system with turbocharger . Remove charge air pipe from engine Rep. gr. 21 ; Charge air system with turbocharger . Remove right charge air hose from charge air cooler Rep. gr. 21 ; Charge air system with turbocharger .
Remove cowling -arrow- together with radiator fans Rep. gr. 19 ; Parts of cooling system .
Remove exhaust system Rep. gr. 26 ; Removing and installing parts of exhaust system .
n AG. Volkswagen AG do es n wage s k l ot g o yV ua b ran ed s i tee r o h t or u ac a bracket from subframe -arrows ss
Separate exhaust system at double clamp -arrows-. Raise and secure front exhaust pipe or rest it on tunnel bridge.
thi sd o cu m en
ht rig py Co t.
agen lksw Vo by
AG.
Prote cted by
91
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed manual gearbox 02Q - Edition 06.2010 Remove pendulum support.
Pull connector -1- off oil level and oil temperature sender G266- . Remove left coupling rod from anti-roll bar and lay to side Running gear, axles, steering; Rep. gr. 40 ; Repairing front wheel suspension . Remove left drive shaft Running gear, axles, steering; Rep. gr. 40 ; Removing and installing drive shafts .
Remove right drive shaft from gearbox, raise and secure it Running gear, axles, steering; Rep. gr. 40 ; Removing and installing drive shafts .
AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h ut Running ra Remove drive shaft heat shield, if present -arrowsa c s gear, axles, steering; Rep. gr. 40 ; Repairing sdrive shafts .
Remove hexagon bolts -arrows- on left engine/gearbox mounting -2- from bracket -1-.
do c um en
92
ht rig py Co t.
agen lksw Vo by
AG.
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed manual gearbox 02Q - Edition 06.2010 Lower gearbox about 40 mm, dimension -a-, by adjusting spin dles attached to engine. Note
Observe connecting lines, hoses and radiator when moving en gine/gearbox assembly.
Remove bracket -1- from gearbox -arrows-. Remove relay lever together with cable end-piece page 75 . Remove gearbox selector lever from selector shaft.
pe rm itte d
If small cover plate -A- for flywheel is present, remove it -arrows-.
un le
Remove lower engine/gearbox connecting bolt -1-. Note
Loosen engine/gearbox connecting bolt -3- and leave it installed just hand-tight.
ht rig py Co t.
do c um en
agen lksw Vo by
AG.
Prote cted by
93
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed manual gearbox 02Q - Edition 06.2010 Attach bracket -T10346- with bolt -1- to left threaded hole in subframe. -1- = Flange bolt M6 x 20. Secure engine support -3300 A- to bracket -T10346- . Place a cloth between engine support -3300 A- and oil pan.
Press engine forwards using spindle of engine support -3300 A- . In the process, observe the following points in particular: The air conditioning compressor -2- must not contact -arrowthe refrigerant line -1-. The alternator must not contact the refrigerant line. The pressure pipe must not contact the radiator.
pe rm itte d
un le
To remove gearbox 02Q, set up gearbox support -3282- with adjustment plate -3282/33- . Insert gearbox support -3282- in engine and gearbox jack V.A.G 1383 A- . Align arms of gearbox support according to holes in adjust ment plate . Attach support elements -A- to adjustment plate as illustrated. Screw in pin -3282/29- in place of support element -C-.
ht rig py Co t.
do c um en
Attach adapter -VW 771/40- in threaded hole of gearbox hous ing as shown in illustration. Then screw pin -3282/29- into hole on gearbox for securing bolt of pendulum support. Secure gearbox to gearbox support -3282- using bolt (M10x20) -A-.
94
AG.
Align adjustment plate parallel to gearbox.
agen lksw Vo by
Position engine and gearbox jack -V.A.G 1383 A- under vehi cle. Arrow -B- on adjustment plate points in direction of vehicle travel.
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed manual gearbox 02Q - Edition 06.2010 Pin -B- must lie flush with guide from gearbox support -3282- at bottom -arrow-. Engine/gearbox connecting bolt -arrow- has been removed.
Remove connecting bolt for engine/gearbox -C- as well as lower connecting bolts for engine/gearbox. Press gearbox away from engine, off dowel sleeves. Tilt gearbox in area of differential using spindles of gearbox support -3282- . Differential must face upwards.
Right -2-.
un le
AG. Volkswagen AG d agen oes ksw not l o V guof engine flange shaft by -1- must be guided past bolt hole ara d e nte is r o eo h ut ra a c s s
Guide gearbox with differential -A- over subframe and swing out.
r fo ng
ht rig py Co t.
agen lksw Vo by
AG.
95
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed manual gearbox 02Q - Edition 06.2010 Observe longitudinal member -arrows-. Then carefully lower gearbox. Note
Be careful of all
AG. Volkswagen AG d agen oes ksw not l o V gu lines when lowering gearbox. by ara d e nte is r o eo h ut ra a c s s
2.2
Transporting gearbox
Special tools and workshop equipment required Gearbox mounting support -3336-
do c um en
Workshop hoist -VAS 6100-
Bolt gearbox lifting tackle -3336- to clutch housing.
96
ht rig py Co t.
agen lksw Vo by
AG.
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed manual gearbox 02Q - Edition 06.2010 Adjust support beam on sliding piece using locking pin -arrow-. Number of holes visible = 6. Lift gearbox using workshop crane and gearbox lifting tackle -3336- . Set gearbox aside, for example in a transport container.
2.3
Note
Installing gearbox
Refer to procedure Removing gearbox for required special
tools page 85 .
Renew self-locking nuts and bolts. Renew bolts which must be tightened further to a torque angle. All cable ties which were opened or cut during removal must
be renewed at the same points.
Clean input shaft splines and, on used clutch plate, hub
splines. Remove corrosion and apply only a very thin coat of clutch plate spline grease -G 000 100- to splines. Then move clutch plate to and fro on input shaft until hub moves freely on shaft. Remove excessive grease.
If the gearbox is to be renewed, the gearbox selector lever swageand olk n AG d en AG. V ag oes w relay lever must be transferred to the o new gearbox. s k no l
ed All threaded holes into which self-locking bolts are to be ris o h screwed must be cleaned of residual locking fluid carefully with t u a a thread tap. ss
V by
t gu ara nte eo ra c
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 hooked into sealing flange and pushed onto dowel sleeves -arrows-. Check release bearing for wear. If necessary, renew slave cylinder with release bearing page 40 .

thi sd o cu m en
ht rig py Co t.
agen lksw Vo by
AG.
Prote cted by
97
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed manual gearbox 02Q - Edition 06.2010 Attach bracket -T10346- with bolt -1- to left threaded hole in subframe. -1- = Flange bolt M6 x 20. Secure engine support -3300 A- to bracket -T10346- . Place a cloth between engine support -3300 A- and oil pan.
pe rm itte d
un le
To install gearbox 02Q, set up gearbox support -3282- with ad justment plate -3282/33- . Align arms of gearbox support according to holes in adjust ment plate .
Attach support elements -A- to adjustment plate as illustrated. Screw in pin -3282/29- in place of support element -C-. Place gearbox on engine and gearbox jack -V.A.G 1383 A- . Align adjustment plate and gearbox parallel to one another.
agen lksw Vo by
do c um en
Secure adapter -VW 771/40- in threaded hole of gearbox housing as shown in figure. Secure gearbox to gearbox support -3282- using bolt (M10x20) -A-. Pin -B- must lie flush with guide from gearbox support -3282- at bottom -arrow-. Position engine and gearbox jack -V.A.G 1383 A- under vehi cle. Arrow on adjustment plate points in direction of vehicle travel. Note
Be careful of all lines when installing gearbox.

Then carefully raise gearbox.
98
AG.
Prote cted by
Screw pin -3282/29- into hole on gearbox for securing bolt of pendulum support.
ht rig py Co t.
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed manual gearbox 02Q - Edition 06.2010 Now turn gearbox upwards near differential, using spindle of gearbox support -3282- , and downwards near 6th gear. Guide gearbox with differential -A- over subframe.
The right flange shaft must then be guided past the flywheel -arrow 2-; observe the intermediate plate -arrow 1-.
un le
Right flange shaft -2-.
n AG. Volkswagen AG do es n wage s k l ot g o yV ua b ran ed s i tee r o h t or u -1- must be guided past bolt hole of engine ac a ss
When doing this, use spindles of gearbox support -3282- to adjust position of gearbox so that longitudinal member -arrows- is not touched. Then turn gearbox to installation position via spindles of gear box support -3282- . Align gearbox on engine dowel sleeves and join.
ht rig py Co t.
Screw in engine/gearbox connecting bolt -C- and tighten to specified torque page 104 .
agen lksw Vo by
r fo ng
AG.
Prote cted by
99
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed manual gearbox 02Q - Edition 06.2010 Screw in lower engine/gearbox securing bolts and tighten to specified torque page 104 . Remove engine support -3300 A- and bracket -T10346- .
Screw in engine/gearbox connecting bolt -arrow- and tighten to specified torque page 104 . After bottom of gearbox and engine are bolted together, re move gearbox support -3282- from gearbox. Insert upper engine/gearbox securing bolts and tighten to tor que specification page 104 . Attach gearbox selector lever to selector shaft of gearbox page 73 and tighten hexagon nut to specified torque Item 17 (page 72) . Install relay lever together with cable end-piece page 75 . Install bracket -1- on gearbox using new hexagonal bolts -arrows- and tighten to specified torque page 104 .
ht rig py Co t.
thi sd o cu m en
Align engine and gearbox in installation position. To do this, raise sufficiently so that bracket -1- completely contacts left assembly mounting -2-. Screw new hexagon bolts -arrows- for left assembly mounting -2- into bracket -1- and tighten to specified torque page 104 . 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 all bolts se curing the assembly mounting have been tightened to speci fied torque.
100
agen lksw Vo by
AG.
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed manual gearbox 02Q - Edition 06.2010 If small cover plate -A- for flywheel is present, install it -arrows- page 104 .
Note There are threaded inserts, e.g. HeliCoil in the bolting holes
for the pendulum support. -arrow-.
Distinguishing feature: shoulder along beginning of thread
Install pendulum support Running gear, axles, steering; Rep. gr. 40 ; Assembly overview - Subframe, anti-roll bar, suspension links . Then install drive shafts Running gear, axles, steering; Rep. gr. 40 ; Removing and installing drive shafts .
pe rm itte d
un le
n AG. Volkswagen AG do es n wage s k l ot g o y V torque ua Note corresponding securing bolts and specified b ran ed s i tee Running gear, axles, steering; Rep. gr. 40 r ; Assembly over o h t or u links . view - subframe, anti-roll bar, suspension ac a ss
Install left coupling rod Running gear, axles, steering; Rep. gr. 40 ; Repairing front suspension .
ht rig py Co t.
Install drive shaft heat shield, if present -arrows- Running gear, axles, steering; Rep. gr. 40 ; Repairing drive shafts .
do c um en
agen lksw Vo by
AG.
Prote cted by
101
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed manual gearbox 02Q - Edition 06.2010 If front vehicle level sender -G78- is present, bolt it onto trans verse link Rep. gr. 40 ; Removing and installing front vehicle level sender -G78- .
Attach connector -1- to oil level and oil temperature sender G266- . Assemble exhaust system and attach exhaust system bracket to subframe Rep. gr. 26 ; Removing and installing parts of exhaust system .
Install cowling -arrow- together with radiator fans Rep. gr. 19 ; Parts of cooling system Install charge air pipe on engine Rep. gr. 21 ; Charge air system with turbocharger . Install left charge air hose -arrow 1- and -arrow 2- G . VRep. gr. olkswa gen AG does 21 ; Charge air system with turbochargerlk .swagen A n
Vo by ed s i r ho ut a ss
Fit right charge air hose to charge air cooler Rep. gr. 21 ; Charge air system with turbocharger . Then install starter and secure with lower bolt Electrical system; Rep. gr. 27 ; Starter . Secure wiring retainer to lower starter bolt. Install upper starter bolt; attach connector and wiring to starter Electrical system; Rep. gr. 27 ; Starter .

thi sd o cu m en
102
ht rig py Co t.
agen lksw Vo by
AG.
Prote cted by
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed manual gearbox 02Q - Edition 06.2010 Attach earth strap -1- to upper starter bolt. Push connector -2- onto reversing light switch -F4- .
pe rm itte d
un le
AG. Volkswagen AG d agen oes ksw not l o V gu y b ara connector d Gearboxes nte ise for vehicles with start-stop system: join r o -arrowto gearbox neutral position sender -G701. e or h t u ac a s s pipe/hose line or plastic line -A- to stop into slave cylinder Push
breather and press down clip -arrow-.
Test line by tugging on it. Remove hose clamp -3094- from supply hose. After removing hose clamp -3094- , return supply hose to its original shape, if necessary. Bleed clutch system page 37 .
do c um en
Check for correct installation position of vacuum hose for brake system, install vacuum hose if necessary Rep. gr. 47 . Bolt selector cable support brackets to gearbox and tighten bolts and nuts -arrows- to specified torque Item 6 (page 71) and Item 10 (page 71) . Insert gate selector cable in cable end-piece.
AG.
Prote cted by
ht rig py Co t.
agen lksw Vo by
103
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed manual gearbox 02Q - Edition 06.2010 Spread a small amount of grease on pin -arrow- of gearbox selector lever -2-. Allocate grease using Electronic parts catalogue (ETKA) . Renew securing clip -1- each time it is removed. Adjust selector mechanism page 82 . Install battery tray, battery cover and battery Electrical sys tem; Rep. gr. 27 ; Removing and installing battery . If complete air filter housing was removed, install it Rep. gr. 23 . If necessary, install engine cover. Connect battery and followA procedure after connecting battery G. Volkswagen AG d agen gr. 27 ; Disconnecting oes Electrical system; Rep. ksw not and con l o gu necting battery . yV b a d
ho Check gear ut oil page 126 .
e ris
s Install lower part of front left wheel housing liner General body repairs, exterior; Rep. gr. 66 ; Wheel housing liner .
sa
ran tee or ac
Install noise insulation General body repairs, exterior; Rep. gr. 50 ; Noise insulation .
un le
For vehicles with front vehicle level sender -G78- , check headlight adjustment Electrical system; Rep. gr. 94 ; Lights, lamps, switches - exterior .
2.4
Specified torques
Gearbox to engine
r fo ng
1 2 3 4 5 6
M12 x 55 With short M8 stud M12 x 55 With long M8 stud
M12 x 65 M10 x 50 M10 x 105 M12 x 165 With short M8 stud Additionally, starter to gearbox
104
AG.
Item
Bolt
ht rig py Co t.
agen lksw Vo by
Quantity 1 1 1 2 1 1
Nm 80 80 80 40 40 80
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed manual gearbox 02Q - Edition 06.2010 Item 7 Bolt M12 x 165 With short M8 stud
by ed ris o th au
Quantity 1
Nm 80
Volkswato gen AG Additionally, AG.starter does agen ksw gearbox not l o V g
ss
M6 x 8 Small flywheel cover plate (not on all en gines)
ua ran t 1 ee
or ac
10
Items -A- and -B-: dowel sleeves Renew bolts -1- to -5-. Small cover plate for flywheel on intermediate plate: 10 Nm. Gearbox bracket -1- to gearbox. Renew bolts. Bolts -arrows-: 60 Nm and turn 90 further.
thi sd o cu m en
Bolts -arrows-: 60 Nm and turn 90 further. Note
AG.
Renew bolts.
agen lksw Vo by
Gearbox to body
ht rig py Co t.
105
Removing and installing gearbox, ve hicles with petrol engine

Removing gearbox
3.1
Special tools and workshop equipment required Support bracket -10 - 222 A Adapter -10-222 A /8 Adapter -10-222 A /3 Adapter -10-222 A /18 Gearbox support -3282-
pe rm itte d
un le
do c um en
106
ht rig py Co t.
agen lksw Vo by
AG.
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed manual gearbox 02Q - Edition 06.2010 Support elements for gear box (determine when set ting adjustment plate on gearbox support )
. Volkswagen AG Adjustment plate -3282/33gen AG d
yV Gearbox lifting btackle ed s i -3336- for o transporting r th gearbox au

pe rm itte d
wa olks
Torque wrench -V.A.G 1331es, in part or in w l purpos hole ercia , is n m ot com
Torque wrench -V.A.G 1332 Engine and gearbox jack V.A.G 1383 A-
un le
ss
oes not gu ara nte eo ra c

do c um en
3. Removing and installing gearbox, vehicles with petrol engine
ht rig py Co t.
agen lksw Vo by
AG.
Prote cted by
107
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed manual gearbox 02Q - Edition 06.2010 2 x brackets -T10346 Engine support -3300 A Adapter -VW 771/40 Hose clamps to 25 mm -3094 Grease for clutch plate splines -G 000 100 Allocate grease using Electronic parts catalogue (ETKA) . Flange bolt M6 X 20. Flange bolt M6 X 80 Hexagon head bolt M10 x 20
At a later point, support bracket -10-222 A- will be put onto lon gitudinal members with adapters -10 - 222 A /8- . To prevent damage to edges of wings, cover bottom area of both adapters -10 - 222 A /8- with self-adhesive fabric tape -arrow- Electronic parts catalogue (ETKA chemical sub stances) .
First check whether a coded radio is fitted. If so, obtain antitheft code. With ignition switched off, disconnect battery earth strap Electrical system; Rep. gr. 27 ; Disconnecting and connecting battery . At a later point, the support bracket -10-222 A- will be connected to the lifting eyes of engine. If engine cover blocks access, remove engine cover. Remove complete air filter housing if it is located close to the battery Rep. gr. 24 ; Repairing injection system . Remove battery, battery cover and battery tray Electrical system; Rep. gr. 27 ; Removing and installing battery .
agen lksw Vo by
AG.
Prote cted by
do c um en
108
ht rig py Co t.
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed manual gearbox 02Q - Edition 06.2010 Remove securing clip -1- for gear selector cable from gearbox selector lever -2- and pull cable off pin -arrow-.
Releasing cable end-piece from gate selector cable To avoid damage to gate selector cable, separate cable endpiece from gate selector cable before removal.
Pull locking mechanism forward to stop in -direction of arrow 1- and then lock by turning to left in -direction of arrow 2-. Then push relay lever forwards (-in direction of arrow 3-). The relay lever is removed together with the cable end-piece at a later point.
Remove cable support bracket from gearbox -arrows-, lay to side and secure with wire.
pe rm itte d
LHD
un le
Clamp off supply hose to master cylinder using hose clamp -3094- .
do c um en
ht rig py Co t.
agen lksw Vo by
AG.
109
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed manual gearbox 02Q - Edition 06.2010 Right-hand drive Clamp off hose of pipe/hose line -A- to slave cylinder using hose clamp -3094- . Continuation for all Pull out clip -arrowfor pipe/hose line or plastic line to stop. Pull pipe/hose line or plastic line out from slave cylinder bleed er and seal. Caution
Do not operate clutch pedal any more.

Remove earth strap -1- from top starter bolt. Separate electrical connector -2- for reversing light switch F4- . Remove connector and wire from starter.
un le
Remove upper
n AG. Volkswagen AG do es n wage s k l ot g o yV ua b ran ed s i tee r o h t or u ac a s s engine/gearbox connecting bolts -arrows-.
Then remove upper securing bolt on starter. Bolt bracket -T10346- to rear of the 3 mounting holes for bat tery tray. To do this, use a collar bolt M 6 x 80 or a securing bolt for battery tray.
ht rig py Co t.
Remove both foam pieces from upper edge of left and right wings Body, front; Rep. gr. 50 .
agen lksw Vo by
If there are hose and cable connections in area of engine sup port eye for support bracket -10 - 222 A- , remove these now.
AG.
Prote cted by
110
r fo ng
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed manual gearbox 02Q - Edition 06.2010 Set up support bracket -10-222 A- in front of bonnet support. Use: Adapter Adapter
n AG. Volkswagen AG do es n wage s k l ot g o yV ua b d ran -10-222 rA ise/3tee o h t or u ac a -10-222 A /8ss
Adapter -10-222 A /18
Position adapter -10-222 A /8- : On upper longitudinal carrier, directly before the elevation (-arrow 1-) next to bolt (-arrow 2-)
Connect engine and bracket -T10346- to support bracket . Take up weight of engine/gearbox assembly and support bracket on spindles.
The left drive shaft will be removed in a later step. With vehicle standing on its wheels, loosen front left flange bolt -arrow- 90 at most, or wheel bearing will be damaged Running gear, axles, steering; Rep. gr. 40 ; Removing and installing drive shafts .
ht rig py Co t.
do c um en
agen lksw Vo by
AG.
Prote cted by
If front vehicle level sender -G78- is present, unbolt it from transverse link Rep. gr. 40 ; Removing and installing front vehicle level sender -G78- . Remove bracket from starter. Remove starter Electrical system; Rep. gr. 27 ; Starter . Remove left charge air hose -arrow 1- and -arrow 2- and charge air pipe from engine Rep. gr. 21 ; Charge air system with turbocharger .
Remove right charge air hose -arrow 2- Rep. gr. 21 ; Charge air system with turbocharger
111
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed manual gearbox 02Q - Edition 06.2010 Remove cowling -arrow- together with radiator fans Rep. gr. 19 ; Parts of cooling system .
Disconnect front exhaust pipe from turbocharger (-arrow-) Rep. gr. 26 ; Removing and installing parts of exhaust system and secure it.
Remove pendulum support.
Pull connector -1- off oil level and oil temperature sender G266- . Remove left coupling rod from anti-roll bar and lay to side Running gear, axles, steering; Rep. gr. 40 ; Repairing front wheel suspension .
ht rig py Co t.
thi sd o cu m en
Remove left drive shaft Running gear, axles, steering; Rep. gr. 40 ; Removing and installing drive shafts .
agen lksw Vo by
AG.
112
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed manual gearbox 02Q - Edition 06.2010 Remove drive shaft heat shield, if present -arrows- Running gear, axles, steering; Rep. gr. 40 ; Repairing drive shafts . Remove right drive shaft from gearbox, raise and secure it Running gear, axles, steering; Rep. gr. 40 ; Removing and installing drive shafts .
If small cover plate -A- for flywheel is present, remove it -arrows-.
Remove hexagon bolts -arrows- on left engine/gearbox mounting -2- from bracket -1-.
pe rm itte d
un le
Lower gearbox about 60 mm, dimension -a-, by adjusting spin dles attached to engine. Note
Observe connecting lines, hoses and radiator when moving en gine/gearbox assembly.
do c um en
ht rig py Co t.
agen lksw Vo by
AG.
Prote cted by
113
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed manual gearbox 02Q - Edition 06.2010 Remove bracket -1- from gearbox -arrows-. Remove relay lever together with cable end-piece AG. Volkswagen AG d page 75 . agen o
w olks
yV Remove gearbox eselector lever from selector shaft. db
ris tho u a ss
Remove engine/gearbox connecting bolt -1-. Note
Loosen engine/gearbox connecting bolts -2- and leave them in stalled just hand-tight.
Attach bracket -T10346- with bolt -1- to left threaded hole in subframe. In the process, position bracket -T10346- at the same angle as the engine. -1- = Flange bolt M6 x 20. Secure engine support -3300 A- to bracket -T10346- .
agen lksw Vo by
Prote cted by
do c um en
To remove gearbox 02Q, set up gearbox support -3282- with adjustment plate -3282/33- . Insert gearbox support -3282- in engine and gearbox jack V.A.G 1383 A- . Align arms of gearbox support according to holes in adjust ment plate .
114
ht rig py Co t.
AG.
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed manual gearbox 02Q - Edition 06.2010 Attach support elements -A- to adjustment plate as illustrated. Screw in pin -3282/29- instead of support element -C-.
does wa Position engine and gearbox notvehi olks jack -V.A.G 1383 A- under gu yV b ara cle. Arrow -B- on adjustment plate points in direction of vehicle d e nte s i r travel. o e h
. Volkswagen AG gen AG
pe rm itte d
un le
ss plate parallel to gearbox. Align adjustment
t au
or ac
Secure adapter -VW 771/40- in threaded hole of gearbox housing as shown in figure. Then screw pin -3282/29- into hole on gearbox for securing bolt of pendulum support. Secure gearbox to gearbox support -3282- using bolt (M10x20) -A-. Pin -B- must lie flush with guide from gearbox support -3282- at bottom -arrow-. Remove connecting bolt -C- and lower connecting bolts.
Press gearbox away from engine, off dowel sleeves. Right flange shaft -1- must be guided past bolt hole of engine -2-.
agen lksw Vo by
do c um en
Then the right flange shaft -1- must be guided past the notch -arrow- in the intermediate plate and the flywheel. Tilt gearbox in area of differential using spindles of gearbox support -3282- . Differential must face upwards. Guide gearbox with differential over subframe -A- and swing out.
ht rig py Co t.
AG.
115
g oes , Jetta 2011 Golf Variant 2007 , Golf 2010 , Jettad2005 swa kVariant not Vol gu y b ara 6-speed manual gearbox 02Q Edition 06.2010 d e
olkswagen AG en AG. V
If necessary, turn further upwards near differential using spindles of gearbox support -3282- .
ris tho u a gearbox ss
nte eo ra c
Swivel gearbox further out and carefully lower. Note
Be careful of all lines when lowering gearbox.
thi sd o cu m en
3.2
Transporting gearbox
Special tools and workshop equipment required Gearbox mounting support -3336-
Workshop hoist -VAS 6100-
116
ht rig py Co t.
agen lksw Vo by
AG.
Prote cted by
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed manual gearbox 02Q - Edition 06.2010 Bolt gearbox lifting tackle -3336- to clutch housing.
Adjust support beam on sliding piece using locking pin -arrow-. Number of holes visible = 6. Lift gearbox using workshop crane and gearbox lifting tackle -3336- . Set gearbox aside, for example in a transport container.
3.3
Note
Installing gearbox AG. Volkswagen AG d agen o

w olks yV b ed ris ho t au ss
tools page 106 .
Renew self-locking nuts and bolts. Renew bolts which must be tightened further to a torque angle. All cable ties which were opened or cut during removal must
Refer to procedure Removing gearbox for required special
be renewed at the same points.
splines; remove corrosion and apply only a very thin coat of clutch plate spline grease -G 000 100- to splines. Then move clutch plate to and fro on input shaft until hub moves freely on shaft. Remove excessive grease.
If the gearbox is to be renewed, the gearbox selector lever and relay lever must be transferred to the new gearbox. All threaded holes into which self-locking bolts are to be screwed must be cleaned of residual locking fluid carefully with a thread tap.
ht rig py Co t.
thi sd o cu m en
Check whether dowel sleeves for aligning engine and gearbox are fitted in cylinder block and install if necessary.
agen lksw Vo by
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.
AG.
Prote cted by
117
Check release bearing for wear. If necessary, renew slave cylinder with release bearing page 40 . Attach bracket -T10346- with bolt -1- to left threaded hole in subframe. In the process, position bracket -T10346- at the same angle as the engine. -1- = Flange bolt M6 x 20.
Ensure that intermediate plate is hooked into sealing flange and pushed onto dowel sleeves -arrows-.
un le
n AG. Volkswagen AG do es n wage s k l ot g Vo y ua b Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 ran ed s i tee r o 6-speed manual gearbox 02Q - Edition 06.2010 h t or u ac a ss
Secure engine support -3300 A- to bracket -T10346- .
r fo ng
To install gearbox 02Q, set up gearbox support -3282- with ad justment plate -3282/33- . Align arms of gearbox support according to holes in adjust ment plate . Attach support elements -A- to adjustment plate as illustrated. Screw in pin -3282/29- instead of support element -C-. Place gearbox on engine and gearbox jack -V.A.G 1383 A- . Align adjustment plate and gearbox parallel to one another. Screw pin -3282/29- into hole on gearbox for securing bolt of pendulum support.
118
ht rig py Co t.
agen lksw Vo by
AG.
Prote cted by
a es n 2005 , Jetta 2011 Golf Variant 2007V ,w Golf Variant 2010 ,oJetta ot g olks ua by d ran - Edition 06.2010 6-speed manual gearbox 02Q e is
. Volkswagen AG gen AG d
Secure adapter -VW 771/40housing as shown in figure.
r ho ut a inss threaded
hole of gearbox
tee or ac
Secure gearbox to gearbox support -3282- using bolt (M10x20) -A-. Pin -B- must lie flush with guide from gearbox support -3282- at bottom -arrow-. Position engine and gearbox jack -V.A.G 1383 A- under vehi cle. Arrow on adjustment plate points in direction of vehicle travel. Note
Be careful of all lines when installing gearbox.

Now turn gearbox in area of differential -in direction of arrowusing spindles of gearbox support -3282- . Then carefully raise gearbox.
thi sd o cu m en
Guide gearbox with differential -A- over subframe.
Observe longitudinal member -arrows-.
ht rig py Co t.
agen lksw Vo by
AG.
119
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed manual gearbox 02Q - Edition 06.2010 Guide gearbox with differential over subframe -A-in direction of arrow-. Swing rear of gearbox towards subframe. Then the right flange shaft -1- must be guided past the flywheel and the notch -arrow- in the intermediate plate.
Then turn gearbox to installation position via spindles of gear box support -3282- . Align gearbox on engine dowel sleeves and join.
Screw in engine/gearbox connecting bolt -C- and tighten to specified torque page 124 . AG. Volkswagen AG do agen
t gu yV Screw in engine/gearbox connecting bolt -arrow- and tighten ara db e nte s i r to specified torque page 124 . o e
w olks
es n o
th au s s
or ac
Remove engine support -3300 A- and bracket -T10346- . Screw in lower engine/gearbox securing bolts and tighten to specified torque page 124 . After bottom of gearbox and engine are bolted together, re move gearbox support -3282- from gearbox. Insert upper engine/gearbox securing bolts and tighten to tor que specification page 124 . Attach gearbox selector lever to selector shaft of gearbox page 73 and tighten hexagon nut to specified torque Item 17 (page 72) .
ht rig py Co t.
do c um en
Install relay lever together with cable end-piece page 75 . Install bracket -1- on gearbox using new hexagonal bolts -arrows- and tighten to specified torque page 124 .
agen lksw Vo by
AG.
Prote cted by
120
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed manual gearbox 02Q - Edition 06.2010 Align engine and gearbox in installation position. To do this, raise sufficiently so that bracket -1- completely contacts left assembly mounting -2-. Screw new hexagon bolts -arrows- for left assembly mounting -2- into bracket -1- and tighten to specified torque page 124 . Note
un le
WARNING
pe rm itte d
Do not remove support bracket -10-222 A- until all bolts se curing the assembly mounting have been tightened to speci fied torque.
If small cover plate -A- for flywheel is present, install it -arrows- page 124 .
do c um en
Note
There are threaded inserts, e.g. HeliCoil in the bolting holes
for the pendulum support.
Identification: shoulder along beginning of thread -arrow-. Note corresponding securing bolts and specified torque
Running gear, axles, steering; Rep. gr. 40 ; Assembly over view - subframe, anti-roll bar, suspension links .
Install pendulum support Running gear, axles, steering; Rep. gr. 40 ; Assembly overview - Subframe, anti-roll bar, suspension links . Assemble exhaust system Rep. gr. 26 ; Removing and installing parts of exhaust system . Then install drive shafts Running gear, axles, steering; Rep. gr. 40 ; Removing and installing drive shafts .
ht rig py Co t.
agen lksw Vo by
AG.
121
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed manual gearbox 02Q - Edition 06.2010 Install drive shaft heat shield, if present -arrows- Running gear, axles, steering; Rep. gr. 40 ; Repairing drive shafts . . Volkswage
ks steering; Rep. Install left coupling rod Running gear, y axles, Vol b d gr. 40 ; Repairing front suspension .ise
n AG wage
r ho ut a ss
n AG d oes not gu ara nte eo ra c

If front vehicle level sender -G78- is present, bolt it onto trans verse link Rep. gr. 40 ; Removing and installing front vehicle level sender -G78- .
do c um en
Install cowling -arrow- together with radiator fans Rep. gr. 19 ; Parts of cooling system .
122
ht rig py Co t.
Attach connector -1- to oil level and oil temperature sender G266- .
agen lksw Vo by
AG.
Prote cted by
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed manual gearbox 02Q - Edition 06.2010 Fit charge air hoses -arrow 1- and -arrow 2- and charge air pipe on engine Rep. gr. 21 ; Charge air system with turbo charger . Then install starter and secure with lower bolt Electrical system; Rep. gr. 27 ; Starter . Secure wiring retainer to lower starter bolt. Install upper starter bolt; attach connector and wiring to starter Electrical system; Rep. gr. 27 ; Starter .
Attach earth strap -1- to upper starter bolt. Push connector -2- onto reversing light switch -F4- . Push pipe/hose line or plastic line -A- to stop into slave cylinder lksw-arrow-. breather and pressedown clip agen AG n AG. Vo
ag ksw Vol y b ed ris o h t au ss
Test line by tugging on it. Remove hose clamp -3094- from supply hose.
After removing hose clamp -3094- , return supply hose to its original shape, if necessary. Bleed clutch system page 37 .
Check for correct installation position of vacuum hose for brake system, install vacuum hose if necessary Rep. gr. 47 .
ht rig py Co t.
thi sd o cu m en
Bolt selector cable support brackets to gearbox and tighten bolts and nuts -arrows- to specified torque Item 6 (page 71) and Item 10 (page 71) . Insert gate selector cable in cable end-piece.
AG.
Spread a small amount of grease on pin -arrow- of gearbox selector lever -2-.
agen lksw Vo by
Prote cted by
123
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed manual gearbox 02Q - Edition 06.2010 Allocate grease using Electronic parts catalogue (ETKA) . Renew securing clip -1- each time it is removed. Adjust selector mechanism page 82 . Install battery tray, battery cover and battery Electrical sys tem; Rep. gr. 27 ; Removing and installing battery . If removed, install complete air filter housing Rep. gr. 24 ; Repairing injection system . Install plenum chamber cover with seal. Glazing; Rep. gr. 64 ; Assembly overview - plenum chamber cover Set both foam pieces on upper edge of left and right wings Body, front; Rep. gr. 50 . If necessary, install engine cover. Connect battery and follow procedure after connecting battery Electrical system; Rep. gr. 27 ; Disconnecting and con necting battery . Check gear oil page 126 . Install lower part of front left wheel housing liner General body repairs, exterior; Rep. gr. 66 ; Wheel housing liner . n AG. Volkswagen A
olk Install noise insulation General bodybrepairs, exterior; Rep. yV d e gr. 50 ; Noise insulation . ris
ge swa
3.4
Specified torques
u For vehicles with front vehicle slevel sender -G78- , check sa headlight adjustment Electrical system; Rep. gr. 94 ; Lights, lamps, switches - exterior .
tho
un le
Gearbox to engine
Item 1 2 3 4 5 6
Bolt
Quantity
ht rig py Co t.
Nm 80 80 80 40 40 80
M12 x 55 With short M8 stud M12 x 55 With long M8 stud

r fo ng
1
agen lksw Vo by
1
AG.
M12 x 65 M10 x 50 M10 x 105 M12 x 165 With short M8 stud
1 2 1 1
Additionally, starter to gearbox
124
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed manual gearbox 02Q - Edition 06.2010 Item 7 Bolt M12 x 165 With short M8 stud Additionally, starter to gearbox AG. Volkswagen AG d agen oes 1 ksw M6 x 8 not l o gu y VSmall flywheel cover b ara d e nte ris plate (not on all en eo ho ut ra gines) a c s s
Quantity 1
Nm 80
10
Items -A- and -B-: dowel sleeves Renew bolts -1- to -5-. Small cover plate for flywheel on intermediate plate: 10 Nm. Gearbox bracket -1- to gearbox. Renew bolts. Bolts -arrows-: 60 Nm and turn 90 further.
un le
Note
AG.
Bolts -arrows-: 60 Nm and turn 90 further.
agen lksw Vo by
Renew bolts.
ht rig py Co t.
Gearbox to body
r fo ng
125
Checking gearbox oil

o yV db e ris tho au

agen Torque wrench -V.A.G 1331lksw
AG. Volkswagen AG d oes not gu ara nte eo ra c
ss
Multi-point bit -3357-
do c um en
Gearbox oil specification Electronic parts catalogue ETKA . Remove noise insulation General body repairs, exterior; Rep. gr. 50 ; Noise insulation . To check gear oil, remove oil plug -arrow-. Oil level is correct when gearbox is filled to lower edge of filler hole. Screw in plug -arrow- with new seal. Tighten bolt -arrow- to specified torque page 127 . When filling with oil, note the following: Remove oil plug -arrow-. Fill with gear oil to lower edge of filler hole. Screw in plug -arrow- with new seal. Tighten bolt -arrow- to specified torque page 127 .
AG.
126
ht rig py Co t.
agen lksw Vo by
kswagen AG n AG. Vol2010 Golf Variant 2007 , Golf Variant , Jetta does 2005 , Jetta 2011 age ksw not l o V 6-speed manual gearbox 02Q gu - Edition 06.2010 y b a
Various versions of oil filler and
II - Oil filler or oil drain plug with hexagon socket head 30 Nm

pe rm itte d
un le
I - Oil filler or oil drain plug with multi-point socket head 45 Nm
ed ris o h t drain plugs au ss
ran tee or ac
do c um en
ht rig py Co t.
agen lksw Vo by
AG.
Prote cted by
4. Checking gearbox oil
127
5
5.1
Dismantling and assembling gearbox

Overview - rear final drive
1 - Clutch housing 2 - Reverse shaft 3 - Output shaft for 5th, 6th and reverse gears 4 - Slave cylinder with clutch release bearing 5 - Input shaft 6 - Output shaft for 1st through 4th gears 7 - Differential 8 - Right flange shaft 9 - Left flange shaft 10 - Synchromeshed gear for 2nd gear 11 - Synchromeshed gear for 1st gear
pe rm itte d
un le
12 - Synchromeshed gear for 4th gear 13 - Synchromeshed gear for 3rd gear 14 - Synchromeshed gear for 5th gear 15 - Synchromeshed gear for 6th gear 16 - Synchromeshed gear for reverse gear 17 - Gearbox housing
do c um en
128
ht rig py Co t.
agen lksw Vo by
AG.
5.2
Assembly overview
l - Removing and installing gearbox housing and selector mechanism page 130 ll - Removing and installing in put shaft, output shafts, differ ential and selector rods page 132
pe rm itte d
un le
Note
do c um en
Assembly order, gearbox without retaining ring -A- for input shaft sealing cover page 134
AG.
Prote cted by
Assembly order, gearbox with retaining ring -A- for input shaft sealing cover page 145
ht rig py Co t.
From gearbox date 21 01 8, sealing cover for input shaft is se cured with a retaining ring -A-.
agen lksw Vo by
5. Dismantling and assembling gearbox
129
5.3
Removing and installing gearbox housing and selector mechanism

2 - Flange shaft with compres sion spring Removing and installing page 227 Assembling page 233 3 - Retaining ring For sealing cover Item 4 (page 130) Fitted from gearbox date 21 01 8 4 - Cover plate Secured with retaining ring from gearbox date 21 01 8 Allocate components according to Elec tronic parts catalogue ETKA . 5 - Retaining ring For deep groove ball bearing of input shaft Item 1 (page 180)
1 - Countersunk bolt, 33 Nm

do c um en
6 - Reversing light switch -F4- , 20 Nm Changed to captive seal shortly after introduction of gearbox Item 7 (page 130) . 7 - Seal Not fitted in all gearbox es Always renew 8 - Oil drain plug Torque setting page 127 9 - Seal Always renew 10 - Locking bolt, 45 Nm For selector shaft 11 - Bolt, 15 Nm + turn 90 further Bolt with captive washer only as replacement part Always renew; allocate shim according to Electronic parts catalogue ETKA Allocation of bolts as replacement part page 131 12 - Bolt, 15 Nm + turn 90 further Without washer Always renew; allocate shim according to Electronic parts catalogue ETKA Allocation of bolts as replacement part page 131 13 - Selector unit (Selector shaft with selector shaft cover)
130
ht rig py Co t.
agen lksw Vo by
AG.
Prote cted by
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed manual gearbox 02Q - Edition 06.2010 Repairing page 172 . Removing with gearbox installed: Remove battery and battery tray Electrical system; Rep. gr. 27 ; Battery; Removing and installing battery . The angled rod Item 6 (page 160) for adjusting the selector mechanism must not be engaged.
. gen AG Remove selector cables and gearbox selector lever s page 71 wa
Remove locking screw Item 10 14 - Bolt, 20 Nm Always renew 15 - O-ring Always renew
y db (page 130)se and ri o th au ss
k Vol
Volkswagen AG
pull out selector
does not gu ara mechanism nte eo ra c

16 - Clutch housing Repairing page 167 . 17 - Gearbox housing Repairing page 157 .
Allocation of bolts as replacement parts A - Bolt with captive washer B - Bolt without washer C - Bolt with captive washer
thi sd o cu m en
ht rig py Co t.
agen lksw Vo by
AG.
Prote cted by
131
5.4
Removing and installing input shaft, output shafts, differential and selector rods
1 - Output shaft for 1st through 4th gears Dismantling and assem bling page 187 Installation position page 133 2 - Selector rod with selector fork for 1st and 2nd gears Installation position page 133 3 - Selector rod with selector fork for 3rd and 4th gears Installation position page 133 4 - Output shaft for 5th, 6th and reverse gears Dismantling and assem bling page 211 Installation position page 133 5 - Selector rod with selector fork for 5th and 6th gears Installation position page 133 6 - Selector fork for reverse gear Installation position page 133 Distinguishing page 176 Repairing page 175 .
pe rm itte d
un le
do c um en
8 - Reverse shaft With thrust washer 9 - Thrust washer 10 - Breather Connect to slave cylinder Item 14 (page 132) 11 - Clutch housing Repairing page 167 . 12 - Input shaft seal Renewing page 167 13 - O-ring Pull onto line connection Moisten with brake fluid before installing
132
AG.
7 - Input shaft Dismantling and assem bling page 178 Always renew deep groove ball bearing on input shaft Item 6 (page 180) .
ht rig py Co t.
agen lksw Vo by
Prote cted by
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed manual gearbox 02Q - Edition 06.2010 14 - Slave cylinder with clutch release bearing 15 - Bolt Qty. 3 Always renew Without locking fluid 12 Nm (only slave cylinders with metal housing) With locking fluid 15 Nm (for plastic slave cylinders) Carefully tighten diagonally in small steps so that the bolting eyes of the slave cylinder do not break off 16 - Countersunk bolt, 33 Nm
n AG d nA oes wage kscompression not 17 - Flange shaft with spring l o V gu y b ara d Removing nte ise and installing page 227 r o eo h t u ra Assembling page 233 a c
G. Volkswage
18 - Differential Dismantling and assembling page 233

un le
ss
Installation position of shafts and selector rods in gearbox 1 - Input shaft 2 - Output shaft for 1st through 4th gears 3 - Output shaft for 5th, 6th and reverse gear 4 - Reverse shaft A - Selector rod for 3rd and 4th gears B - Selector rod for 1st and 2nd gears C - Selector rod for 5th and 6th gears D - Selector fork for reverse gear 1)
1)
In some gearboxes, mounting of reverse gear selector fork on selector rod for selector fork for 5th and 6th gears - C - . Distin guishing between reverse gear selector forks page 176 .
r fo ng
ht rig py Co t.
agen lksw Vo by
AG.
Prote cted by
133
5.5
Assembly order, gearbox without retaining ring -A- for input shaft sealing cover
Removing and installing gearbox housing, selector mechanism, input shaft, output shafts, differential and selector rods. Special tools and workshop equipment required Support plate -VW 309 Support clamp -VW 313 Gearbox support -VW 353 Sleeve -VW 455- or sleeve -3160 Multipurpose tool -VW 771 -1- Internal puller -Kukko 21/01 -3- Splitter -Kukko 17/0 -4- Counter support -Kukko 22/1AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h ut ra a c s s

do c um en
134
ht rig py Co t.
agen lksw Vo by
AG.
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed manual gearbox 02Q - Edition 06.2010 Support bridge -30 - 211 A Thrust piece -T10042 Drift -T10169 or drift -T10362 page 163 Thrust piece -T40008 Torque wrench -V.A.G 1331 Hot air blower -V.A.G 1416-
Drip tray for workshop hoist -VAS 6208-
un le
r fo ng
ht rig py Co t.
agen lksw Vo by
AG.
135
5.5.1
Removing
Secure gearbox to assembly Note
If one of the bolting holes does not contact the gearbox support , lay a washer between the hole and the gearbox support .
Rotate gearbox on assembly stand so that oil drain plug is below. Place drip tray underneath. Drain gear oil.
AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d bolts -arrows-. stand using e nte is r o eo h ut ra a c s s
Remove slave cylinder with clutch release bearing -arrows-.
do c um en
Move selector shaft to neutral. Remove reversing light switch -F4- -1-. Remove locking bolt -2-. Then remove bolts -3-. Pull selector shaft with selector shaft cover -4- out of gearbox housing.
Remove securing bolt for left and right flange shaft by screwing two bolts into flange and counterholding using a lever. Pull out flange shafts with compression spring.
136
AG.
During the following steps, ensure that the selector shaft is not blocked by the angled rod -arrow-.
ht rig py Co t.
agen lksw Vo by
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed manual gearbox 02Q - Edition 06.2010 Remove bolts -B-, which secure gearbox housing to clutch housing. Note
One bolt -arrow- is located outside of bolting flange.

Lock input shaft as follows: The lengths of the splines on the input shaft differ to those of the gearbox. Set either installing sleeve -VW 455- over input shaft on clutch housing
or set sleeve -3160- over input shaft on clutch housing Clamp splitter -A-, e.g. -Kukko 17/0- , behind notch in splines of input shaft. The back side of the splitter must rest against installing sleeve VW 455- or sleeve -3160- without play.
thi sd o cu m en
Pull cover plate out of gearbox housing. A - Counter support , e.g. -Kukko 22/1-
AG.
B - Internal puller, 8 12 mm , e.g. -Kukko 21/01-
ht rig py Co t.
Pierce rubber in centre of cover -C- with a screwdriver.

agen lksw Vo by
137
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed manual gearbox 02Q - Edition 06.2010 Remove retaining ring -C- from deep groove ball bearing of input shaft in gearbox housing as follows: Hold one end of retaining ring with screwdriver -A-. Using a screwdriver , -B-, lever other end out of groove in deep groove ball bearing -direction of arrow-. Using screwdriver -B-, lever out securing ring further.
If present, remove washer -1- from gearbox housing -2-. If gearbox housing is to be renewed, check whether washer must be installed page 141 .
Remove securing bolts -A- for gearbox housing to clutch hous ing. Volkswa
AG. agen ksw l o yV db ise r tho au s s
gen AG does not gu ara nte eo ra c

pe rm itte d
un le
Screw adapter -VW 771/40- into threaded hole of gearbox housing. Heat gearbox housing using hot air blower , e.g. -V.A.G 1416in vicinity of bearing seat for deep groove ball bearing for input shaft for about 10 minutes to about 100 C. Using multi-purpose tool -VW 771/1- , pull gearbox housing off clutch housing in -direction of arrow-. Note
138
ht rig py Co t.
If necessary, carefully apply lever on alternating sides at over hanging housing shoulders along perimeter, being careful not to damage sealing surfaces.
agen lksw Vo by
do c um en
AG.
Prote cted by
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed manual gearbox 02Q - Edition 06.2010 If present, remove washer -1- from deep groove ball bearing -2-. If gearbox housing is to be renewed, check whether washer must be re-installed page 141 .
Remove splitter -A- and installing sleeve VW 455 (fig.) or sleeve -3160- from input shaft.
To remove shafts from clutch housing, a second mechanic is re quired.
pe rm itte d
un le
At same time, second mechanic lifts input shaft, reverse shaft and output shaft for reverse, 5th and 6th gears -3- together with selector rods out of clutch housing -arrow B-.
agen lksw Vo by
With left hand, raise differential -1-. With right hand, lift output shaft for 1st to 4th gear together with selector rods -2-arrow A-.
do c um en
Note
After shafts are lifted, differential may be set back in clutch hous ing if desired.
Remove input shaft oil seal. Note
AG.
Always renew deep groove ball bearing on input shaft Item 6 (page 180) .
5.5.2
Installing
A new deep groove ball bearing has been pressed onto the input shaft Item 6 (page 180) .
ht rig py Co t.
139
Insert input shaft -1-, output shaft for 5th and 6th gears -2together with selector rod -3-, selector fork -4- and reverse shaft -5-.
un le
AG. Volkswagen AG d agen oes ksw not l o V gu y b ara d Golf Variant 2007 , Golf Variant 2010 , Jettari2005 , Jetta 2011 nte se o eo h t 6-speed manual gearbox 02Q - Edition 06.2010 u ra a c s s
Then insert differential -1-. Note
r fo ng
A second mechanic will be required for further installation of shafts in clutch housing.
Take output shaft for 1st through 4th gears -3- with selector rods -4- in the right hand as shown in figure. With the left hand, lift differential -1- slightly.
ht rig py Co t.
At the same time, a 2nd mechanic must slightly lift input shaft and output shaft for 5th and 6th gears and reverse gear -2together with reverse gear shaft. Now insert output shaft for 1st through 4th gears in -direction of arrow-.
The teeth of the input shaft, the output shafts and the final drive input gear of differential must mesh.
Now, together with a second mechanic, place shafts and dif ferential in their bearing seats. Secure support bridge -30 - 211 A- for input shaft to clutch housing. Note
For clarity of illustration, clutch housing is shown turned 180.

Screw in bolt -A- until input shaft rises slightly.
140
agen lksw Vo by
AG.
Prote cted by
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed manual gearbox 02Q - Edition 06.2010 On some gearboxes, flats -A- are present on the deep groove ball bearing for the input shaft and the bearing support -B-. Volkswa
lksw and gearbox hous Check deep groove ball bearing for input shaft o yV b d ing. se
u Deep groove ball bearing fors a input shaft and gearbox
AG. agen
ri tho
No flats on deep groove ball bearing -A- or on bearing support -B- page 141 Flats on deep groove ball bearing -A- and on bearing support -B- page 142 From gearbox date 10 04 6 through around gearbox date 20 01 8: A washer is installed above and one below the deep groove ball bearing for the input shaft Item 6 (page 180) . Upper washer Lower washer Outer diameter Outer diameter 78.6 mm 85 mm
un le
gen AG does not gu ara nte eo ra housing c

Measure distance above seat for deep groove ball bearing. Distance above deep groove ball bearing Dimension a 10 mm
Upper washer no yes

agen lksw Vo by
ht rig py Co t.
Through gearbox date 09 04 6 From gearbox date 10 04 6
r fo ng
10.7 mm
In the gearbox housing, the area below the seat for the deep groove ball bearing is also modified -arrowArea below bearing seat Through gearbox date 09 04 6 From gearbox date 10 04 6 Not further ma chined Machined slightly deeper Lower washer no yes
AG.
141
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed manual gearbox 02Q - Edition 06.2010 If necessary, lay a washer (outer diameter = 85 mm) -1- on deep groove ball bearing -2-.
For some gearboxes: Flats -A- on deep groove ball bearing for input shaft and on bear ing support -B No washers may be laid above or below the deep groove ball AG. Volkswagen AG d bearing. agen oe
V by and on bearing support Flats -A- on deep groove ball bearing ed s i r up. -B- in gearbox housing must line ho
w olks
Transfer markings to upper area of deep groove ball bearing and to upper area of bearing support of gearbox housing ( next figure). Heat gearbox housing for about 10 minutes to 100 C in vicinity of seat for deep groove ball bearing of input shaft using -hot air blower- , e.g. -V.A.G 1416- .
pe rm itte d
un le
Mark flats with coloured marks. ss
t au
Note
Heating is necessary to avoid damage to deep groove ball
bearing when gearbox housing is installed.

Line up marking on deep groove ball bearing -A- with marking
on gearbox housing -B- and set gearbox housing in place.
do c um en
142
agen lksw Vo by
Apply sealant -AMV 188 200 03- evenly to sealing surface of clutch housing.
AG.
Prote cted by
ht rig py Co t.
For all gearboxes, heat gearbox housing for about 10 minutes to 100 C in vicinity of seat for deep groove ball bearing of input shaft using -hot air blower- , e.g. -V.A.G 1416- .
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed manual gearbox 02Q - Edition 06.2010 Set gearbox housing in place and tighten new bolts -A-, -Band -C- to specified torque. Allocation of bolts: A - Bolt with captive washer B - Bolt without washer C - Bolt with captive washer
If a washer was laid on the deep groove ball bearing before the gearbox housing was set in place, a washer -1- (outer di ameter = 78.6 mm) must also be placed above the deep groove ball bearing -2- page 141 .
If stop sleeve for selector shaft has been removed, now drive it in to stop of tool page 163 . Turn gearbox in repair stand with opening for selector shaft upwards.
. Volkswagen AG gen AG does swa k not bearing of l o Install retaining gu y V ring -1- for deep groove ball b ara shaft. ised nte r o eo h ut ra Remove support bridge -30 211 Afor input shaft. a c s s
input
Insert selector shaft -1- in lower bearing -2- and in selector forks -3-. Note
For better clarity, sealing cover is removed in illustration.
do c um en
ht rig py Co t.
agen lksw Vo by
AG.
143
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed manual gearbox 02Q - Edition 06.2010 Now press selector shaft -1- against stop sleeve -2- in -direction of arrow- and guide downwards with selector finger -3- through selector forks to stop. Selector shaft cover -4- must be parallel to bolting surface on gearbox housing. Selector shaft must move freely in gate selection direction (upwards and downwards). Note
If selector shaft cover is tilted relative to bolting surface, selector shaft is not inserted in lower bearing.
Tighten bolts -3- for selector shaft cover -4-. Screw in locking bolt -2-, ensuring that angled rod -arrow- is not engaged. Install reversing light switch -F4- -1-. Install left and right flange shaft with springs, thrust washers and tapered rings.
Drive in input shaft oil seal.
Install slave cylinder with release bearing and tighten bolts -arrows- to specified torque Item 4 (page 39) . Shift through all gears.
pe rm itte d
un le
do c um en
AG.
144
ht rig py Co t.
agen lksw Vo by
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed manual gearbox 02Q - Edition 06.2010 Drive sealing cover into gearbox housing to stop using thrust piece -T10042- .
5.6
Assembly order, gearbox with retain ing ring -A- for input shaft sealing cover
Removing and installing gearbox housing, selector mechanism, input shaft, output shafts, differential and selector rods.

do c um en
ht rig py Co t.
agen lksw Vo by
AG.
Prote cted by
145
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed manual gearbox 02Q - Edition 06.2010 Special tools and workshop equipment required Support plate -VW 309 Support clamp -VW 313 Gearbox support -VW 353 Sleeve -VW 455- or sleeve -3160 Multipurpose tool -VW 771 -1- Internal puller -Kukko AG. Volkswagen AG d 21/01agen oes ksw not l o V gu y b ara d -3- Splitter -Kukko is 17/0e n
un le
t -4- Counter support -Kukko au ss 22/1urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p
r ho
tee or ac
r fo ng
146
ht rig py Co t.
agen lksw Vo by
AG.
Prote cted by
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed manual gearbox 02Q - Edition 06.2010 Support bridge -30-211A Thrust piece -T10143 Drift -T10169 or drift -T10362 page 163 Thrust piece -T40008 Torque wrench -V.A.G 1331 Hot air blower -V.A.G 1416-
5.6.1
Removing
Secure gearbox to assembly stand using bolts -arrows-.
thi sd o cu m en
ht rig py Co t.
agen lksw Vo by
AG.
147
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed manual gearbox 02Q - Edition 06.2010 Note
If one of the bolting holes does not contact the gearbox support , lay a washer between the hole and the gearbox support .
Rotate gearbox on assembly stand so that oil drain plug is below. Place drip tray underneath. Drain gear oil. Remove slave cylinder with clutch release bearing -arrows-.
During the following steps, ensure that the selector shaft is not blocked by the angled rod -arrow-. Move selector shaft to neutral. Remove reversing light switch -F4- -1-. Remove locking bolt -2-. Then remove bolts -3-. Pull selector shaft with selector housing.
AG. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o eo h t u ra a cover -4- out of gearbox shaft c s s
Remove securing bolt for left and right flange shaft by screwing two bolts into flange and counterholding using a lever. Pull out flange shafts with compression spring.

do c um en
148
ht rig py Co t.
agen lksw Vo by
AG.
Prote cted by
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed manual gearbox 02Q - Edition 06.2010 Gearboxes for vehicles with start-stop system: remove gear box neutral position sender -G701- -arrow-.
Remove bolts -B-, which secure gearbox housing to clutch housing. Note
AG. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o eo h t u ra a outside of bolting flange. c located s s
un le
One bolt -arrow- is
The lengths of the splines on the input shaft differ to those of the gearbox. Set either installing sleeve -VW 455- over input shaft on clutch housing
Lock input shaft as follows:
The back side of the splitter must rest against installing sleeve VW 455- or sleeve -3160- without play.
AG.
Prote cted by
agen lksw Vo by
Clamp splitter -A-, e.g. -Kukko 17/0- , behind notch in splines of input shaft.
ht rig py Co t.
or set sleeve -3160- over input shaft on clutch housing

r fo ng
149
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed manual gearbox 02Q - Edition 06.2010 Remove retaining ring -A- for input shaft sealing cover.
Pierce rubber in centre of cover -C- with a screwdriver . Pull sealing cover out of gearbox housing. A - Counter support , e.g. -Kukko 22/1B - Internal puller, 8 12 mm , e.g. -Kukko 21/01-
Remove retaining ring -C- from deep groove ball bearing of input shaft in gearbox housing as follows: Hold one end of retaining ring with screwdriver -A-. Using a screwdriver , -B-, lever other end out of groove in deep groove ball bearing -direction of arrow-. Using screwdriver -B-, lever out securing ring further.
Remove securing bolts -A- for gearbox housing to clutch hous ing.
un le
r fo ng
AG.
150
ht rig py Co t.
agen lksw Vo by
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed manual gearbox 02Q - Edition 06.2010 Screw adapter VW 771/40 into threaded hole of gearbox hous ing. Heat gearbox housing using hot air blower , e.g. -V.A.G 1416in vicinity of bearing seat for deep groove ball bearing for input shaft for about 10 minutes to about 100 C. Using multi-purpose tool VW 771/1 , pull gearbox housing off clutch housing in -direction of arrow-. Note
If necessary, carefully apply assembly lever on alternating sides at overhanging housing shoulders along perimeter, being careful not to damage sealing surfaces.
Remove splitter -A- and installing sleeve VW 455 or sleeve -3160- from input shaft. To remove shafts from clutch housing, a second mechanic is re quired.
With left hand, raise differential -1-. With right hand, lift output shaft for 1st to 4th gear together with selector rods -2-arrow A-. At same time, second mechanic lifts input shaft, reverse shaft and output shaft for reverse, 5th and 6th gears -3- together with selector rods out of clutch housing -arrow B-. G. Volkswagen Note
nA wage olks V by ed ris o h ut sa s be set back in clutch hous
Remove input shaft oil seal. Note
After shafts are lifted, differential may ing if desired.
AG do es n ot g ua ran tee or ac
Always renew deep groove ball bearing on input shaft Item 6 (page 180) .
5.6.2
Installing
A new deep groove ball bearing has been pressed onto the input shaft Item 6 (page 180) .
do c um en
ht rig py Co t.
agen lksw Vo by
AG.
Prote cted by
151
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed manual gearbox 02Q - Edition 06.2010 First insert input shaft -1- and 5th and 6th gear output shaft -2- together with selector rod -3-, selector fork reverse gear -4- and reverse shaft -5-. Note different mounting for reverse gear selector fork.
Reverse gear selector fork -1- is mounted on shaft -2- behind se lector rod for 5th and 6th gear -3-.
Reverse gear selector fork -1- is mounted on selector rod with selector fork for 5th and 6th gear -2-.
un le
r fo ng
152
ht rig py Co t.
agen lksw Vo by
AG.
Prote cted by
Then insert Note
A second mechanic will be required for further installation of shafts in clutch housing.
Take output shaft for 1st through 4th gears -3- with selector rods -4- in the right hand as shown in figure. With the left hand, lift differential slightly. At the same time, a 2nd mechanic must slightly lift input shaft and output shaft for 5th and 6th gears and reverse gear -2together with reverse gear shaft. Now insert output shaft for 1st through 4th gears in -direction of arrow-. The teeth of the input shaft, the output shafts and the final drive input gear of differential must mesh.
un le
wa olks yV b differential -1-. ed ris ho t au ss
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 . Volkswage 6-speed manual gearbox 02Q - Edition 06.2010 n AG d gen AG
oes not gu ara nte eo ra c
Now, together with a second mechanic, place shafts and dif ferential in their bearing seats.
ht rig py Co t.
Secure support bridge -30-211A- for input shaft to clutch hous ing.
Prote cted by
For clarity of illustration, clutch housing is shown turned 180.

Screw in bolt -A- until input shaft rises slightly.
Deep groove ball bearing of input shaft fits into gearbox housing in only one position. There is a flat section on deep groove ball bearing and on the bearing support for the deep groove ball bearing. If the flats -A- and -B- are present, no washer must be placed above or below the deep groove ball bearing page 183 . Flats -A- on deep groove ball bearing and on bearing support -B- in gearbox housing must line up.
Mark flats with coloured marks. Transfer markings to upper area of deep groove ball bearing and to upper area of bearing support of gearbox housing ( next figure). Heat gearbox housing for about 10 minutes to 100 C in vicinity of seat for deep groove ball bearing of input shaft using -hot air blower- , e.g. -V.A.G 1416- .
AG.
Note
agen lksw Vo by
r fo ng
153
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed manual gearbox 02Q - Edition 06.2010 Note Heating is necessary to avoid damage to deep groove ball
bearing when gearbox housing is installed. clutch housing.
Apply sealant -AMV 188 200 03- evenly to sealing surface of Line up marking on deep groove ball bearing -A- with marking
on gearbox housing -B- and set gearbox housing in place.
Set gearbox housing in place and tighten new bolts -A-, -Band -C- to specified torque. Allocation of bolts: A - Bolt with captive washer. B - Bolt without washer. C - Bolt with captive washer.
un le
Install retaining ring -1- for deep groove ball bearing of input shaft. Install support bridge -30 - 211 A- for input shaft. If stop sleeve for selector shaft has been removed, now drive it in to stop of tool page 163 . Turn gearbox in repair stand with opening for selector shaft upwards.
r fo ng
Note
For better clarity, sealing cover is removed in illustration.
154
agen lksw Vo by
Insert selector shaft -1- in lower bearing -2- and in selector forks -3-.
AG.
ht rig py Co t.
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed manual gearbox 02Q - Edition 06.2010 Now press selector shaft -1- against stop sleeve -2- in -direction of arrow- and guide downwards with selector finger -3- through selector forks to stop. Selector shaft cover -4- must be parallel to bolting surface on gearbox housing. Selector shaft must move freely in gate selection direction (upwards and downwards). Note
Tighten bolts -3- for selector shaft cover -4-. Screw in locking bolt -2-, ensuring that angled rod -arrow- is not engaged. Install reversing light switch -F4- -1-.
n AG. Volkswagen AG do es n wage s k l ot g o yV ua b If selector shaft cover is tilted ed relative to bolting surface, selectorran s i tee r o shaft is not inserted in lower bearing. h or ut ac a ss
Gearboxes for vehicles with start-stop system: fit gearbox neutral position sender -G701- -arrow- and tighten securing bolt to 6 Nm.
thi sd o cu m en
Drive in input shaft oil seal flush. Install slave cylinder with release bearing page 39 . Shift through all gears.
ht rig py Co t.
agen lksw Vo by
AG.
Prote cted by
155
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed manual gearbox 02Q - Edition 06.2010 Drive sealing cover into gearbox housing to stop of thrust piece.
Secure sealing cover with retaining ring -A-.
thi sd o cu m en
Install flange shafts together with springs, thrust washers and tapered rings.
ht rig py Co t.
156
agen lksw Vo by
AG.
Prote cted by
Repairing gearbox housing
Special tools and workshop equipment required Drift sleeve -VW 244 B Gearbox support -VW 353a ksw Thrust plate -VW Vol 401. Volkswagen AG gen AG does not gu y b ara d e nte is -VW 402Thrust plate r o eo h ut ra a c s Press s tool -VW 407-
Tube -VW 416 B-
un le
r fo ng
ht rig py Co t.
agen lksw Vo by
AG.
6. Repairing gearbox housing
157
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed manual gearbox 02Q - Edition 06.2010 Guide pin -VW 436A Guide pin -VW 439 Multipurpose tool -VW 771 Support plate -VW 801 Guide pin -10 - 15 Thrust piece -3124-
pe rm itte d
un le
do c um en
158
ht rig py Co t.
agen lksw Vo by
AG.
Prote cted by
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed manual gearbox 02Q - Edition 06.2010 Drift -3264 Assembly tool -3290 Torque wrench -V.A.G 1331 Drift -T10168 Drift -T10169- or drift T10362- page 163 Thrust piece -T10203-
pe rm itte d
un le
do c um en
-1- Internal puller -Kukko 21/4 -4- Counter support -Kukko 22/2-
AG.
-1- Internal puller -Kukko 21/2-
ht rig py Co t.
agen lksw Vo by
Prote cted by
159
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed manual gearbox 02Q - Edition 06.2010 1 - Gearbox housing If renewed: adjust out put shafts and differen tial page 232 Changes in area of sup port for deep groove ball bearing for input shaft Item 3 (page 180) . Allocation of compo nents via Electronic parts catalogue (ETKA) 2 - Cover plate Removing page 161 Driving in page 161 3 - Oil drain plug Torque setting page 127 4 - Seal Always renew, if part of original equipment 5 - Oil filler plug Torque setting page 127 6 - Angled rod AG. Volkswagen AG d agen oes For adjusting selector ksw not l o V 82 gu mechanism dpage by ara e nte is r o Can be renewed with eo h ut ra a gearbox assembled c s s Removing page 162 Installation position page 162 Driving in page 162
7 - Bearing bush For selector rods Pulling out page 162 Driving in page 163 8 - Stop sleeve Pressing out with gearbox dismantled page 163 Pressing out with gearbox assembled page 163 Stop sleeve identification page 163 Drive in stop sleeve with shoulder page 164 Drive in stop sleeve without shoulder page 164 9 - Needle bearing For reverse shaft Renew each time after removing Pulling out page 164 Pressing in page 164
AG.
thi sd o cu m en
10 - Tapered roller bearing outer race For output shaft for 5th, 6th and reverse gears Removing and installing page 211 If renewed, adjust output shaft for 5th, 6th and reverse gears page 222
160
ht rig py Co t.
agen lksw Vo by
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed manual gearbox 02Q - Edition 06.2010 11 - Shim For output shaft for 5th, 6th and reverse gears Adjustment overview page 232 12 - Tapered roller bearing outer race For output shaft for 1st through 4th gears Removing and installing page 187 If renewed, adjust output shaft for 1st through 4th gears page 206 13 - Shim For output shaft for 1st through 4th gears Adjustment overview page 232
swagen AG 14 - Tapered roller bearing G. Volkrace n Aouter does wage s k not l o For differential gu yV b ara d e nte Removing and installing page 233 ris o eo h t u ra a If renewed, adjust differential page 232 c ss
15 - Shim For differential Adjustment overview page 232 16 - Bearing bush For selector shaft Pulling out page 165 Driving in page 165 17 - Plug Driving out page 165 Driving in page 166 18 - Seal Renewing page 227 Removing sealing cover -A-
Pierce centre of sealing cover using screwdriver -B- and lever out cover -in direction of arrow-.
ht rig py Co t.

do c um en
Driving in sealing cover to stop
agen lksw Vo by
AG.
Prote cted by
161
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed manual gearbox 02Q - Edition 06.2010 Removing angled rod for selector shaft Break off angled rod in released position. Insert a screwdriver -A- in hole for angled rod -B-. Lever out angled rod in -direction of arrow-.
Installation position of angled rod Marking on angled rod -arrow- must face slave cylinder con nection -1-. Dimension -a- must be about 45.
Note
Drive in angled rod for selector shaft -arrow- to stop of tool.
Angled rod must be released while it is being driven in.
Pulling out selector rod bearing bush A - Internal puller, 14.5 18.5 mm , e.g. -Kukko 21/2B - Counter support , e.g. -Kukko 22/2-
do c um en
162
ht rig py Co t.
agen lksw Vo by
AG.
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed manual gearbox 02Q - Edition 06.2010 Driving in selector shaft bearing bush to stop of tool
Pressing stop sleeve -A- out of gearbox housing

age on thrust platesd oes 401- and -VW 402 Set gearbox o housing -VW ksw n t V l sleeves in gearbox housingoare gu not damaged. y so that dowel ara db
e ris tho u a ss
n AG. Volkswagen AG
nte eo ra c
Driving stop sleeve out of assembled gearbox using guide pin -10 - 15 Remove locking screw and selector shaft. Turn gearbox so that stop sleeve does not fall in gearbox.
do c um en
Stop sleeve identification

agen lksw Vo by
Following stop sleeves can be installed:

AG.
Prote cted by
Stop sleeve with shoulder -arrow 1- page 164 . Stop sleeve without shoulder -arrow 2- page 164 . Allocate components according to Electronic parts catalogue ETKA .
ht rig py Co t.
163
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 swagen AG G. Volk A does agen ksw not 6-speed manual gearbox 02Q - Edition 06.2010 l o V Drive in stop sleeve with shoulder until tool makes Clutch housing bolted to gearbox housing.
y db ise r contact tho au s s
gu ara nte eo ra c
Drive in stop sleeve without shoulder until tool makes contact Clutch housing bolted to gearbox housing.
do c um en
A - Internal puller, 23.5 30 mm , e.g. -Kukko 21/4B - Counter support , e.g. -Kukko 22/2Note
The needle bearing is destroyed during removal and must be re newed.
Pressing needle bearing -A- into gearbox housing Before pressing in, lay reverse shaft thrust washer -B- on nee dle bearing. Support gearbox housing with tube -VW 416 B- directly below bearing support.
164
AG.
Pulling reverse shaft needle bearing out of gearbox housing
ht rig py Co t.
agen lksw Vo by
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed manual gearbox 02Q - Edition 06.2010 Pulling out selector shaft bearing bush Use thread adapter from counter support -Kukko 22/1-arrow-. Hold spindle of assembly tool -3290- securely and turn nut -B-. A - Internal puller, 14.5 18.5 mm , e.g. -Kukko 21/2-
Driving in selector shaft bearing bush -A- to stop of tool.
Driving out plug -1-
Drive in plug -1- outwards from inside gearbox housing.
thi sd o cu m en
ht rig py Co t.
agen lksw Vo by
AG.
165
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed manual gearbox 02Q - Edition 06.2010 Driving in plug -1 Drive in sealing plug to dimension -a-, about 3 mm below upper edge of housing, using drift -3264- .

do c um en
166
ht rig py Co t.
agen lksw Vo by
AG.
Repairing clutch housing
Special tools and workshop equipment required Press tool -VW 407 Drift -T10168 Thrust piece -T40008 -1- Internal puller -Kukko 21/2 -1- Internal puller -Kukko 21/4 -4- Counter support -Kukko 22/1 -4- Counter support -Kukko 22/2n AG. Volkswagen AG do es n wage s k l ot g o yV ua b ran ed s i tee r o h t or u ac a ss
pe rm itte d
un le
do c um en
ht rig py Co t.
agen lksw Vo by
AG.
Prote cted by
7. Repairing clutch housing
167
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed manual gearbox 02Q - Edition 06.2010 1 - Bearing bush For selector rods Renew each time after removing Pulling out page 169 Driving in page 169 2 - Reverse gear selector fork axle Axle cannot be removed with workshop tools If a new clutch housing is used, a new axle must be pressed in page 171 Place reverse gear se lector fork onto shaft page 152 If shaft is not present, mounting on selector rod for selector fork for 5th and 6th gear page 152 Allocation of compo nents via Electronic parts catalogue (ETKA) 3 - Needle bearing For reverse shaft Renew each time after removing Pulling out page 170 Pressing in page 170 4 - Dowel sleeve Qty. 2
n AG. Volkswagen AG do es n wage s k l ot g o yV ua b ran ed s i tee r o h housing t or u ac a ss
6 - Input shaft seal Removing page 170 Driving in page 170 7 - Seal Renewing page 229
un le
5 - Clutch If renewed: adjust output shafts and differential page 232
8 - Washer For differential Installation position: shoulder on inner circumference faces seal Item 7 (page 168) 9 - Tapered roller bearing outer race For differential Removing and installing page 233 If renewed, adjust differential page 239 10 - Oil deflector ring Installation position: shoulder on hole faces output shaft
ht rig py Co t.
11 - Tapered roller bearing outer race For output shaft for 1st through 4th gears
Prote cted by
AG.
168
agen lksw Vo by
r fo ng
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed manual gearbox 02Q - Edition 06.2010 Removing and installing page 187 If renewed, adjust output shaft for 1st through 4th gears page 206 12 - Tapered roller bearing outer race For output shaft for 5th, 6th and reverse gears Removing and installing page 211 If renewed, adjust output shaft for 5th, 6th and reverse gears page 222 13 - Washer For output shaft for 5th, 6th and reverse gears Always 0.65 mm thick 14 - Cylindrical roller bearing For input shaft Removing and installing page 178 15 - Magnet Held in place by housing joint surface 16 - Cap Not fitted in all clutch housings Pulling out selector rod bearing bush A - Counter support , e.g. -Kukko 22/1B - Internal puller, 14.5 18.5 mm , e.g. -Kukko 21/2AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h ut ra a c s s
Driving in selector shaft bearing bush to stop of tool
un le
r fo ng
ht rig py Co t.
agen lksw Vo by
AG.
169
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed manual gearbox 02Q - Edition 06.2010 Pulling needle bearing out of clutch housing A - Counter support , e.g. -Kukko 22/2B - Internal puller, 23.5 30 mm , e.g. -Kukko 21/4Note
swa must be re The needle bearing is destroyed during removal olkand yV b newed. d se
Pressing needle bearing -A- into clutch housing Before pressing in, lay reverse shaft thrust washer -B- on nee dle bearing.
un le
ri tho u a ss
Removing input shaft oil seal Note
r fo ng
When gearbox is removed, oil seal can be removed with drift.

ht rig py Co t.
Driving in input shaft oil seal flush
170
agen lksw Vo by
AG.
Prote cted by
Pressing reverse
pe rm itte d
un le
ol yV db e gear o selector fork ris h ut a ss
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 AG. Volkswagen AG d 6-speed manual gearbox 02Q - Edition 06.2010 agen oes ksw n shaft into clutch
ot g ua ran housing tee or ac
do c um en
ht rig py Co t.
agen lksw Vo by
AG.
171
8
Note
Repairing selector unit
Lubricate bearing points and running surfaces with grease -G 000 450 02- .
1 - Hexagon nut, 23 Nm Self-locking Always renew 2 - Gearbox selector lever Install so that master spline aligns with selec tor shaft Can be renewed with the selector mechanism installed Installation position page 74 After installing, adjust selector mechanism page 82 3 - Shoe Clip into relay lever Item 5 (page 172) 4 - Bearing bush Not required for plastic relay lever 5 - Relay lever Installation position page 74 After installing, adjust selector mechanism, page 82 From 05.07, plastic re lay lever page 75
pe rm itte d
un le
6 - Selector unit Consists of selector shaft and selector shaft cover Components cannot be separated from each other Can be removed and installed with gearbox installed 7 - Bearing bush For selector shaft Removing and installing Item 16 (page 161) 8 - O-ring Insert in peripheral groove of selector mechanism cover Coat with gear oil when installing Always renew
do c um en
172
ht rig py Co t.
agen lksw Vo by
AG.
9 - Cap For gearbox breather
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed manual gearbox 02Q - Edition 06.2010 10 - Lock washer For relay lever Not fitted on plastic relay lever Always renew 11 - Seal for selector shaft Renewing page 173
8.1
Renewing oil seal for selector shaft
Special tools and workshop equipment required Tube -VW 423-
Oil seal extractor lever -T20143/1-
Sealing grease -G 052 128 A1-
Remove complete air filter housing if it is over selector shaft Rep. gr. 23 ; Repairing diesel direct injection system or Rep. gr. 24 ; Repairing injection system

thi sd o cu m en
8. Repairing selector unit
ht rig py Co t.
agen lksw Vo by
AG.
173
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed manual gearbox 02Q - Edition 06.2010 Metal relay lever Pull off securing clip -2- and press relay lever -3- to side out of mounting.
AG. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o eo h t If relay lever cannot be removed due to gearbox u bracket, remove ra a c s gate selector cable from relay lever. Guide shoe out of gearbox s
Note
Plastic relay lever
Remove relay lever together with cable end-piece page 75 . Continued for all selector mechanisms Remove nuts -4- and remove gearbox selector lever -1-. Lever out seal using oil seal extractor lever -T20143/1- .
selector lever.

do c um en
Drive in seal using thrust piece -VW 423- . Carry out further installation in the reverse sequence noting the following points: Install gearbox selector lever on selector shaft of gearbox and tighten hexagon nut to specified torque Item 1 (page 172) . Note
The gearbox selector lever can be installed in only one position.

Adjust selector mechanism page 82 . If removed, install complete air filter housing Rep. gr. 23 ; Repairing diesel direct injection system or Rep. gr. 24 ; Repairing injection system .
174
AG.
Fill space between sealing lip and dust lip -arrow- with sealing grease -G 052 128 A1- .
agen lksw Vo by
Prote cted by
Lightly oil outer circumference of new oil seal.
ht rig py Co t.
Repairing selector forks
Special tools and workshop equipment required Thrust plate -VW 402 Press tool -VW 411 Tube -VW 426 Thrust piece -VW 431 -1- Internal puller -Kukko 21/3 -4- Counter support -Kukko 22/1-

do c um en
ht rig py Co t.
agen lksw Vo by
AG.
Prote cted by
9. Repairing selector forks
175
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed manual gearbox 02Q - Edition 06.2010 1 - Rubber dampers Can be removed from and inserted in selector rod by hand 2 - Selector rod with selector fork for 1st and 2nd gears 3 - Selector rod with selector fork for 3rd and 4th gears 4 - Selector rod with selector fork for 5th and 6th gears 5 - Selector fork for reverse gear Is mounted on shaft for reverse gear selector fork page 152 From gearbox manufac ture date 06 03 6, ball sleeve Item 6 (page 176) is discontinued Gradually discontinued Reverse gear selector fork is modified If shaft for reverse gear selector fork is not present, mounting on selector rod for selector fork for 5th and 6th gear page 152 Distinguishing between reverse gear selector forks page 176 Allocation of compo nents via Electronic parts catalogue (ETKA)
pe rm itte d
un le
do c um en
Distinguishing between reverse gear selector forks Dim. a mm 24 18 15 Selector fork for re verse gear Mounting
With ball sleeve On reverse gear se lector fork shaft Without ball sleeve page 152 Without ball sleeve On selector rod with selector fork for 5th and 6th gears page 152
176
AG.
6 - Ball sleeve Pulling out page 177 Pressing in page 177 From gearbox manufacture date 06 03 6, ball sleeve is discontinued Gradually discontinued
ht rig py Co t.
agen lksw Vo by
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed manual gearbox 02Q - Edition 06.2010 Through gearbox manufacture date 05 03 6 - pulling out ball sleeve for reverse gear selector fork A - Internal puller, 18 23 mm , e.g. -Kukko 21/3B - Counter support , e.g. -Kukko 22/1AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h ut ra a c s s
Through gearbox manufacture date 05 03 6 - pressing in ball sleeve for reverse gear selector fork

do c um en
9. Repairing selector forks
ht rig py Co t.
agen lksw Vo by
AG.
177
35
1
1.1
Gears, shafts
Input shaft
Dismantling and assembling input shaft
Special tools and workshop equipment required Thrust plate -VW 401 Thrust plate -VW 402 Press tool -VW 407 Press tool -VW 412 Thrust piece -VW 431 Thrust piece -VW 432urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p
un le
r fo ng
178
Rep. gr.35 - Gears, shafts
ht rig py Co t.
agen lksw Vo by
AG.
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed manual gearbox 02Q - Edition 06.2010 Thrust piece -VW 454 Thrust piece -30 - 505pe rm itte d
Tube -2040-
-1- Internal puller -Kukko 21/5 -2- Puller -Kukko 18/1 -3- Splitter -Kukko 17/1 -3- Splitter -Kukko 17/2 -4- Counter support -Kukko 22/2-
un le
Thrust plate -40 - 105-
do c um en
Note Install all bearings on input shaft with gear oil. Always renew deep groove ball bearing Item 6 (page 180) .
ht rig py Co t.
agen lksw Vo by
AG.
Prote cted by
1. Input shaft
179
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed manual gearbox 02Q - Edition 06.2010 1 - Retaining ring For deep groove ball bearing of input shaft Item 6 (page 180) Removing and installing page 134 2 - Washer Outer diameter = 78.6 mm May be used only in modified gearbox hous ings (from gearbox date 10 04 6 through around gearbox date 20 01 8) page 183 Allocation of compo nents via Electronic parts catalogue (ETKA)
pe rm itte d
un le
4 - Washer Outer diameter = 85 mm May be used only in modified gearbox housings (from gearbox date 10 04 6 through around gearbox date 20 01 8) page 183 Allocation of components via Electronic parts catalogue (ETKA) 5 - Retaining ring If deep groove ball bearing Item 6 (page 180) and input shaft Item 8 (page 181) are renewed, redetermine page 182 6 - Deep groove ball bearing Always renew Pulling off page 181 Installation position page 182 Pressing on page 182 From around gearbox date 21 01 8, flats on deep groove ball bearing and on bearing support for deep groove ball bearing page 184 7 - Gear wheel for 5th gear Offered as replacement part together with input shaft Pressing off page 181 Installation position: peripheral groove -arrow- faces deep groove ball bearing Item 6 (page 180)
AG.
180
ht rig py Co t.
agen lksw Vo by
3 - Gearbox housing From gearbox date 10 04 6 through around gearbox date 20 01 8, modified in vicinity of seat for deep groove ball bearing Item 6 (page 180) , washers Item 2 (page 180) and Item 4 (page 180) , page 183 From around gearbox date 21 01 8, flats on deep groove ball bear ing and on bearing sup port for deep groove ball bearing page 183 Allocation of compo nents via Electronic parts catalogue (ETKA)
do c um en
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed manual gearbox 02Q - Edition 06.2010 Pressing on page 181 8 - Input shaft With gear wheels for 3rd, 4th and 6th gears 9 - Cylindrical roller bearing With retaining ring Pulling out page 183 Pressing in page 183 Installation position: retaining ring in bearing faces input shaft 10 - Clutch housing Pulling off deep groove ball bearing First remove retaining ring from input shaft. Before setting up pulling device, set thrust piece -VW 431- and thrust plate -40 - 105- on input shaft. Apply splitter -B- to peripheral groove for retaining ring in bear ing. A - Puller , e.g. -Kukko 18/1B - Splitter, 12 75 mm , e.g. -Kukko 17/1-
Pressing off 5th gear wheel A - Splitter, 22 115 mm , e.g. -Kukko 17/2AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h ut ra a c s s
un le
Pressing on gear wheel for 5th gear
Groove -arrow- in wheel must face upwards.
r fo ng
1. Input shaft
ht rig py Co t.
agen lksw Vo by
AG.
181
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed manual gearbox 02Q - Edition 06.2010 Pressing on deep groove ball bearing Deep groove ball bearing with a rubber ring -arrowShoulder -A- faces press tool -VW 412- .
Installation position of deep groove ball bearing
Groove for retaining ring faces upwards -arrow A- and shoulder -arrow B- must face gear wheel for 5th gear. Determine and install retaining ring page 182 .
thi sd o cu m en
Determining thickness of retaining ring Insert a 1.86 mm thick retaining ring -A- in groove of input shaft and press upwards. Measure distance between deep groove ball bearing -B- and installed retaining ring -A- using feeler gauge -C-. Remove retaining ring used for measuring purposes. Determine retaining ring from table. Note
Allocate retaining rings according to Electronic parts catalogue ETKA .

The following retaining rings are available: Measured value (mm) 0.010.05 0.050.07 0.070.10 0.100.13 0.130.16 Retaining ring thick ness (mm) 1.86 1.89 1.92 1.95 1.98 Axial play (mm) 0.010.05 0.010.05 0.010.05 0.010.05 0.010.05
182
ht rig py Co t.
agen lksw Vo by
AG.
Prote cted by
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed manual gearbox 02Q - Edition 06.2010 Pulling cylinder roller bearing out of clutch housing When pulling out, squeeze together retaining ring -arrow- of cylindrical roller bearing, using pliers -C-. A - Counter support , e.g. -Kukko 22/2B - Internal puller, 30 37 mm , e.g. -Kukko 21/5-
Pressing cylindrical roller bearing into clutch housing When pressing in, squeeze together retaining ring -arrow- of cylinder 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. olksw
n AG. V wage olks V by ed ris o th au ss
agen AG does not gu ara nte eo ra c
1.1.1
Modification in area of deep groove ball bearing
From gearbox date 10 04 6 through around gearbox date 20 01 8: One washer above and one below bearing seat for deep groove ball bearing Item 6 (page 180) . Above bearing seat: Bearing seat Washer above bear ing seat no yes
AG.
Beneath bearing seat:
ht rig py Co t.
agen lksw Vo by
Through gearbox Dimension a = 10 date 09 04 6 mm From gearbox date Dimension a = 10 04 6 10.7 mm through around gearbox date 20 01 8: From around gear Below bearing seat: box date 21 01 8 flat for deep groove ball bearing
Prote cted by
thi sd o cu m en
no
1. Input shaft
183
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed manual gearbox 02Q - Edition 06.2010 From gearbox date 10 04 6 through around gearbox date 20 01 8 slightly deeper In order for the washer beneath the deep groove ball bearing Item 6 (page 180) to fit, the bearing seat for the deep groove ball bearing -arrow- is machined out slightly. Beneath bearing seat: Through gearbox Not further ma date chined 09 04 6 From gearbox date Machined slightly 10 04 6 deeper through around gearbox date 20 01 8: From around gear Flat -B- for deep box date 21 01 8 groove ball bearing -AWasher beneath bearing seat no yes
no
From around gearbox date 21 01 8, flats on deep groove ball wagen AG. Volkswagen AG doe s no olks bearing -A- and on bearing support -B- of gearbox housing t gu yV
ris If the flats are present, no washer must be placed above or tho u below the deep groove ball bearing. a s
pe rm itte d
b ed
ara nte e
un le
or ac
do c um en
184
ht rig py Co t.
agen lksw Vo by
AG.
Prote cted by
2
2.1
Output shaft for 1st through 4th gears

Assembly overview - output shaft for 1st through 4th gears
Dismantling and assembling output shaft for 1st through 4th gears page 187 . Note If output shaft or tapered roller bearings have been renewed, adjust output shaft page 206 . Always renew both tapered roller bearings together as a set. 1 - Clutch housing 2 - Oil deflector ring
n AG. 3 - Dished washer wage olks V by page 192 Pulling out ed ris o Pressing th in au 192 page ss
Volkswagen AG

4 - Tapered roller bearing outer race Pulling out page 193 Pressing in page 193 5 - Tapered roller bearing inner race Pressing off page 192 Pressing on page 193 6 - Output shaft For 1st through 4th gears Adjusting page 206 7 - Needle bearing For 2nd gear

do c um en
9 - Synchro-ring (inner ring for 2nd gear) 1st/2nd gear synchronisation modified from gearbox date 26 10 9, differentiation page 195 10 - Outer ring for 2nd gear 1st/2nd gear synchronisation modified from gearbox date 26 10 9, differentiation page 195 11 - Synchro-ring for 2nd gear 1st/2nd gear synchronisation modified from gearbox date 26 10 9, differentiation page 195
2. Output shaft for 1st through 4th gears
ht rig py Co t.
agen lksw Vo by
AG.
8 - Synchromeshed gear for 2nd gear 1st/2nd gear synchroni sation modified from gearbox date 26 10 9, differentiation page 195
Prote cted by
185
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed manual gearbox 02Q - Edition 06.2010 12 - Locking collar with synchro-hub for 1st and 2nd gears After removing retaining ring Item 13 (page 186) , press off with synchromeshed gear for 2nd gear page 195 Dismantling page 197 Assembling locking collar and synchro-hub page 197 1st/2nd gear synchronisation modified from gearbox date 26 10 9, differentiation page 195 13 - Retaining ring 14 - Synchro-ring for 1st gear 1st/2nd gear synchronisation modified from gearbox date 26 10 9, differentiation page 195 15 - Outer ring for 1st gear 1st/2nd gear synchronisation modified from gearbox date 26 10 9, differentiation page 195 16 - Synchro-ring (inner ring for 1st gear) 1st/2nd gear synchronisation modified from gearbox date 26 10 9, differentiation page 195 17 - Needle bearing For 1st gear 18 - Synchromeshed gear for 1st gear 1st/2nd gear synchronisation modified from gearbox date 26 10 9, differentiation page 195 19 - Thrust washer For 1st through 4th gears Qty. 2 . Volkswagen AG gen AG does swa k not l o Insert lugs of thrust washer in holes of output gu y V shaft
ris 20 - Washer ho ut a s Holds thrust washers Item 19 s (page 186) in position on output shaft
b ed
ara nte e
or ac
21 - Needle bearing For 4th gear
22 - Synchromeshed gear for 4th gear 23 - Synchro-ring for 4th gear Check for wear page 199
24 - Locking collar with synchro-hub for 3rd and 4th gears After removing retaining ring Item 25 (page 186) , pull off with 4th gear synchromeshed gear page 195 Dismantling page 197 Installation position, locking collar and synchro-hub page 199 Assembling locking collar and synchro-hub page 197 and page 197 Pressing on page 199 25 - Retaining ring 26 - Synchro-ring for 3rd gear Check for wear page 196
do c um en
29 - Needle bearing For 3rd gear
186
AG.
28 - Synchro-ring (inner ring for 3rd gear) Check for wear page 196 Check lugs for scoring Installation position page 198
ht rig py Co t.
agen lksw Vo by
27 - Outer ring for 3rd gear Insert in synchro-ring Item 26 (page 186) ; installation position page 198 Renew if scored
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed manual gearbox 02Q - Edition 06.2010 30 - Synchromeshed gear for 3rd gear Installation position page 198 31 - Tapered roller bearing inner race Pulling off page 193 Pressing on page 194 32 - Retaining ring If tapered roller bearing Item 31 (page 187) and output shaft Item 6 (page 185) are renewed, rede termine page 194 33 - Tapered roller bearing outer race Pulling out page 194 Pressing in page 194
age 34 - Shim ksw Vol y d b thickness page 206 Determining se
n AG. Volkswagen AG do es n ot g ua ran tee or ac
t 35 - Gearbox au housing
un le
ss
ri ho
2.2
Dismantling and assembling output shaft for 1st through 4th gears
1st/2nd gear synchronisation modified from gearbox date 26 10 9, distinguishing page 195
r fo ng
ht rig py Co t.
agen lksw Vo by
AG.
Prote cted by
187
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed manual gearbox 02Q - Edition 06.2010 Special tools and workshop equipment required Thrust plate -VW 401 Thrust plate -VW 402 Press tool -VW 407 Press tool -VW 408A Press tool -VW 412 Tube -VW 415A-

thi sd o cu m en
188
ht rig py Co t.
agen lksw Vo by
AG.
Prote cted by
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed manual gearbox 02Q - Edition 06.2010 Support plate -VW 309 Support clamp -VW 313 Gearbox support -VW 353 Thrust piece -VW 431 Thrust piece -VW 433 Thrust piece -VW 454-
pe rm itte d
un le
do c um en
ht rig py Co t.
agen lksw Vo by
AG.
Prote cted by
189
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed manual gearbox 02Q - Edition 06.2010 Thrust piece -VW 512 Tube -VW 516 Tube -VW 519 Multipurpose tool -VW 771 Support plate -VW 801 Thrust plate -40-105-
pe rm itte d
un le
do c um en
190
ht rig py Co t.
agen lksw Vo by
AG.
Prote cted by
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed manual gearbox 02Q - Edition 06.2010 Drift sleeve -40-20 Drift sleeve -40-21 Thrust piece -2050 Supplementary set for en gine and gearbox support VW 540/1 B Tapered roller bearing pull er -V.A.G 1582 Adapter -V.A.G 1582/7AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h ut ra a c s s
un le
r fo ng
ht rig py Co t.
agen lksw Vo by
AG.
191
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed manual gearbox 02Q - Edition 06.2010 -1- Internal puller Kukko 21/7-
-1- Internal puller Kukko 21/8 -2- Puller -Kukko 18/2 -3- Splitter -Kukko 17/2 -4- Counter support Kukko 22/2Pulling dished washer -A- out of output shaft Pressing dished washer into output shaft Dimension a = 2 mm
Press off tapered roller bearing inner race on side facing clutch housing A - Splitter, 22 115 mm , e.g. -Kukko 17/2-
do c um en
192
ht rig py Co t.
agen lksw Vo by
AG.
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed manual gearbox 02Q - Edition 06.2010 Press on tapered roller bearing inner race on side facing clutch housing
AG. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o e h Pullingutapered roller bearing outer race out of clutch housing t or ac a s s
A - Counter support , e.g. -Kukko 22/2-
B - Internal puller, 56 70 mm , e.g. -Kukko 21/8-
Pressing tapered roller bearing outer race into clutch housing
Support clutch housing with drift sleeve -40-20- directly below bearing support.
thi sd o cu m en
Pull off tapered roller bearing inner race on side facing gearbox housing Before setting up tapered roller bearing puller : Remove retaining ring for tapered roller bearing inner race on side facing clutch housing. Insert press tool -VW 431- into output shaft and place thrust plate -40-105- on that.
AG.
ht rig py Co t.
agen lksw Vo by
Prote cted by
193
Determine and install retaining ring page 194 .
un le
e ris ho t Press on tapered roller bearing inner race on side facing au gearbox ss housing
n AG 2011 n AG do Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 ,e Jetta es n wag ot g olks V 6-speed manual gearbox 02Q - Edition 06.2010 d by ua r
. Volkswage
an tee or ac
Determining thickness of retaining ring
Determine thickest retaining ring which will still fit and install it. Note
r fo ng
Allocate retaining rings using Electronic parts catalogue (ET KA) .

The following retaining rings are available: Thickness (mm) 1.79 1.92 1.83 1.95 1.86 1.98
ht rig py Co t.
Pulling outer race for tapered roller bearing out of gearbox hous ing A - Counter support , e.g. -Kukko 22/2B - Internal puller, 46 58 mm , e.g. -Kukko 21/7-
Pressing tapered roller bearing outer race into gearbox housing Fit shim under outer race. Support gearbox housing with thrust piece -2050- below bear ing support. Dismantle output shaft. Note
Pull off tapered roller bearing inner race on side facing clutch housing page 193 .
194
AG.
1.89
agen lksw Vo by
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed manual gearbox 02Q - Edition 06.2010 Pulling off synchro-hub and locking collar for 3rd and 4th gears with synchromeshed gear for 4th gear First remove retaining ring. A - Puller , e.g. -Kukko 18/2B - Splitter, 22 115 mm , e.g. -Kukko 17/2-
Pressing off locking collar and synchro-hub for 1st and 2nd gears After removing retaining ring, press off synchromeshed gear for 2nd gear together with locking collar and synchro-hub.
2.2.1
Distinguishing 1st/2nd gear synchroni sation
Up to gearbox date 25 10 9 page 195 From gearbox date 26 10 9 onwards page 196 1st/2nd gear synchronisation up to gearbox date 25 10 9 Synchro-ring -C- and inner ring -A- are made of brass. Outer ring -B- is made of steel. Assembling 1st to 4th gear output shaft up to gearbox date 25 10 9 page 196
thi sd o cu m en
ht rig py Co t.
agen lksw Vo by
AG.
195
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed manual gearbox 02Q - Edition 06.2010 1st/2nd gear synchronisation from gearbox date 26 10 9 onwards Synchro-ring -C-, outer ring -B- and inner ring -A- are made of swagen AG. Volkswagen AG does not olk steel. gu yV ara db e nte isdate r Assembling 1st to 4th gear output shaft - from gearbox o eo h ut ra 26 10 9 onwards page 200 a c s
pe rm itte d
un le
2.2.2
Assembling 1st to 4th gear output shaft up to gearbox date 25 10 9

Checking inner ring for 1st, 2nd and 3rd gears for wear Check projections on inner ring for scoring. Press inner ring onto cone of synchromeshed gear and meas ure gap -a- using a feeler gauge. Gap -a1st, 2nd 3rd gears Installation dimen sion 0.75 1.25 mm Wear limit 0.3 mm
do c um en
Checking synchro-rings for 1st, 2nd and 3rd gear 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 -a1st, 2nd 3rd gears Installation dimen sion 1.2 1.8 mm Wear limit 0.5 mm
Install 2nd gear synchromeshed gear with needle bearing.
196
ht rig py Co t.
agen lksw Vo by
AG.
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed manual gearbox 02Q - Edition 06.2010 Installation position of outer ring, inner ring and synchro-ring for 2nd gear
lkswagen AG . Vo AG Check lugs -arrows 1- and -arrows 2for scoring. do agen
w olks
t gu V Renew inner ring, outered ring by and synchro-ring in case of scor ara nte s i r ing. e ho
es n o
Fit outer ring -B-. Lugs -arrows 2- engage in notches -arrows 3- of synchromeshed gear. Fit synchro-ring -C-. Notches -arrows 4- engage in lugs -arrows 1- of inner ring -A-.
Angled lugs -arrows 1- face outer ring -B-.
un le
Place inner ring -Ass on synchromeshed gear for 2nd gear.
t au
or ac
Dismantling and assembling locking collars and synchro-hubs of 1st and 2nd gears as well as 3rd and 4th gears 1234Spring Locking piece Locking collar
ht rig py Co t.
Slide locking collar over synchro-hub.

agen lksw Vo by
In 3rd and 4th gear, wide collar of synchro-hub and, if present, shoulder on locking collar point in one direction.
AG.
Prote cted by
Notches for locking pieces in synchro-hub and locking collar must align. Assembling locking collars and synchro-hubs for 1st and 2nd gears as well as 3rd and 4th gears Locking collar has been pushed over synchro-hub. Insert locking pieces and install springs offset 120. Angled end of spring must locate in hollow locking piece.
Installation position of locking collar with synchro-hub for 1st and 2nd gears Identification groove -arrow 1- and narrow collar -arrow 2- of syn chro-hub face 1st gear.
Synchro-hub
r fo ng
197
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed manual gearbox 02Q - Edition 06.2010 Pressing on locking collar and synchro-hub for 1st and 2nd gears Turn synchro-ring so that grooves align with locking pieces. Install retaining ring. Insert synchro-ring for 1st gear.
Installation position of 1st gear outer ring Lugs -arrows- face synchro-hub and locking collar -A-.
pe rm itte d
un le
n AG. Volkswagen AG do es n wage s k l ot g o yV ua b d ran e s i Installation position of synchro-ring -A- (1st gear inner ring) tee r o h t or u ac a s of synchro-ring -B-. Lugs -arrows 1- locate in notches -arrows s2-
Installing synchromeshed gear for 1st gear with needle bearing Higher shoulder -A- faces 2nd gear -B-. Notches in shoulder -arrows- engage in lugs of outer ring page 198 . Install thrust washers for 1st and 4th gears Item 19 (page 186) and Item 20 (page 186) .
Install 4th gear synchromeshed gear with needle bearing.
do c um en
198
ht rig py Co t.
agen lksw Vo by
AG.
Prote cted by
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed manual gearbox 02Q - Edition 06.2010 Checking synchro-ring for 4th gear for wear Press synchro-ring onto cone of synchromeshed gear and measure gap -a- using feeler gauge. Gap -a4th gear Installation dimen sion 1.0 1.7 mm Wear limit 0.5 mm
Installation position of locking collar with synchro-hub for 3rd and 4th gears
gen A a Wider shoulder of synchro-hub -arrow- faces 3rd gear. lksw
pe rm itte d
un le
ss
o yV db e ris tho au
G. Volkswagen AG d oes not gu ara nte eo ra c

Pressing on synchro-hub with locking collar for 3rd and 4th gears Turn synchro-ring so that grooves align with locking pieces. Install retaining ring. Place 3rd gear synchro-ring on locking collar with synchro-hub for 3rd and 4th gears.
do c um en
Lugs -arrows- face synchro-hub and locking collar -A-.

agen lksw Vo by
ht rig py Co t.
Installation position of 3rd gear outer ring

AG.
199
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed manual gearbox 02Q - Edition 06.2010 Installation position of synchro-ring -A- (3rd gear inner ring) Lugs -arrows 1- locate in notches -arrows 2- of synchro-ring -B-.
AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is of 3rd gear synchromeshed gear r Installation position o eo h ut ra a s Higher shoulder -A- faces 4th gear -B-. Notches in shoulder c s
-arrows- engage in lugs of outer ring page 198 .
Install 3rd gear synchromeshed gear with needle bearing. Note
Press on tapered roller bearing inner race page 194 .
Determine retaining ring for tapered roller bearing inner race
page 194 .
2.2.3
Assembling 1st to 4th gear output shaft - from gearbox date 26 10 9 onwards
Check inner friction surface of 1st gear outer ring and 2nd gear outer ring for wear Place inner ring -1- on cone of synchromeshed gear. Press outer ring -2- on cone of inner ring. Measure gap size -a- at 3 points offset by 120 using feeler gauge. Make a note of average value.
agen lksw Vo by
thi sd o cu m en
Gap -a-
1st and 2nd gears
1.00 1.80 mm
200
AG.
Installation dimen sion
Wear limit 0.3 mm
ht rig py Co t.
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed manual gearbox 02Q - Edition 06.2010 Check outer friction surface of 1st gear outer ring and 2nd gear outer ring for wear Check inner surface of synchro-ring -arrowfor scoring and radial contact scoring, renew if necessary. Place inner ring, outer ring and synchro-ring on cone of inner ring. Press on synchro-ring with outer ring whilst turning at same time in order to seat them. Measure gap size -a- at 3 points offset by 120 using feeler gauge. Make a note of average value. Gap -a1st and 2nd gears Installation dimen sion 1.00 1.80 mm Wear limit 0.8 mm
Install 2nd gear synchromeshed gear with needle bearing. Installation of outer ring, inner ring and synchro-ring for 2nd gear Place inner ring -A- on synchromeshed gear. Lugs -1- point away from synchromeshed gear. Fit outer ring -B-. Lugs -2- engage in notches -3- of synchromeshed gear. Fit synchro-ring -C-. Larger notches -4- engage in lugs -1- of inner ring -A-.
Dismantling and assembling locking collars and synchro-hubs of 1st and 2nd gears as well as 3rd and 4th gears 1234Spring Locking piece Locking collar Synchro-hub
Slide locking collar over synchro-hub. In 3rd and 4th gear, wide collar of synchro-hub and, if present, shoulder on locking collar point in one direction. Notches for locking pieces in synchro-hub and locking collar must align.
do c um en
ht rig py Co t.
agen lksw Vo by
AG.
201
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed manual gearbox 02Q - Edition 06.2010 Assembling locking collars and synchro-hubs for 1st and 2nd gears as well as 3rd and 4th gears Locking collar has been pushed over synchro-hub. Insert locking pieces and install springs offset 120. Angled end of spring must locate in hollow locking piece.
Identification groove -arrow 1- and narrow collar -arrow 2- of syn chro-hub face 1st gear.
Installation position of locking collar with synchro-hub for 1st and 2nd gears
un le
Pressing on locking collar and synchro-hub for 1st and 2nd gears Pins -A- of synchro-ring engage in notches -B- of synchro-hub. Install retaining ring.
r fo ng
202
ht rig py Co t.
agen lksw Vo by
AG.
Installation of
Lugs -1- engage in notches -2- of synchro-hub. Insert outer ring -B- into synchro-ring. Lugs -3- point away from synchro-ring. Insert inner ring -C- into outer ring. Lugs -4- engage in larger notches -5- of synchro-ring -A-.
un le
Insert synchro-ring -A- into synchro-hub.
b ed ris o th outer synchro-ring au ss
wagen olk AG. V Golf Variant 2007 , sGolf Variant AG do 2010 , Jetta 2005 , Jetta 2011 agen es n ksw l ot g o 6-speed manual gearbox 02Q - Edition 06.2010 V y u
ring and 1st gear inner ring
ara nte e
or ac
Installing synchromeshed gear for 1st gear with needle bearing

ht rig py Co t.
Synchro-ring -1- is located with lugs -arrow A- in notches of synchro-hub -2-.

agen lksw Vo by
Pins -arrows B- of outer ring engage in notches -arrows C- of synchromeshed gear -3-. Install thrust washers for 1st and 4th gears Item 19 (page 186) and Item 20 (page 186) .
AG.
Install 4th gear synchromeshed gear with needle bearing.
Checking synchro-ring for 4th gear for wear Press synchro-ring onto cone of synchromeshed gear and measure gap -a- using feeler gauge. Gap -a4th gear Installation dimen sion 1.0 1.7 mm Wear limit 0.5 mm
Installation position of locking collar with synchro-hub for 3rd and 4th gears Wider shoulder of synchro-hub -arrow- faces 3rd gear.
r fo ng
203
Turn synchro-ring so that grooves align with locking pieces. Install retaining ring.
Pressing on synchro-hub with locking collar for 3rd and 4th gears
AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d Golf Variant 2007 , Golf Variant 2010 s ,eJetta 2005 , Jetta 2011 nte i r o eo 6-speed manual gearbox 02Q - Edition u 06.2010 th ra a c s s
Checking inner ring for 3rd gear for wear
Press inner ring onto cone of synchromeshed gear and meas ure gap -a- using a feeler gauge. Gap -a3rd gear Installation dimen sion 0.75 1.25 mm Wear limit
ht rig py Co t.
thi sd o cu m en
Checking synchro-ring for 3rd gear 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 -a3rd gear Installation dimen sion 1.2 1.8 mm Wear limit 0.5 mm
Place 3rd gear synchro-ring on locking collar with synchro-hub for 3rd and 4th gears.
Installation position of 3rd gear outer ring Lugs -arrows- face synchro-hub and locking collar -A-.
204
agen lksw Vo by
AG.
0.3 mm
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed manual gearbox 02Q - Edition 06.2010 Installation position of synchro-ring -A- (3rd gear inner ring) Lugs -arrows 1- locate in notches -arrows 2- of synchro-ring -B-.
Installation position of 3rd gear synchromeshed gear Higher shoulder -A- faces 4th gear -B-. Notches in shoulder -arrows- engage in lugs of outer ring page 198 . Install 3rd gear synchromeshed gear with needle bearing. Note Press on tapered roller bearing inner race page 194 . Determine retaining ring for tapered roller bearing inner race
page 194 .

thi sd o cu m en
ht rig py Co t.
agen lksw Vo by
AG.
Prote cted by
205
pe rm itte d
2.3
Adjusting output shaft for 1st through 4th gears
un le
AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o e o , Jetta h 2007 , Golf Variant 2010 , Jetta 2005 Golf Variant ut ra a c s 6-speed s manual gearbox 02Q - Edition 06.2010
2011
Special tools and workshop equipment required Gearbox support -VW 353 Universal dial gauge brack et -VW 387 Press tool -VW 407 Thrust piece -VW 433 Assembly tool -VW 792 Support plate -VW 801r te o iva r rp fo g n
do c um en
206
ht rig py Co t.
agen lksw Vo by
AG.
AG. Volkswagen AG Golf Variant 2007 , Golf Variant 2010 , Jetta 2011 doe agen , Jetta 2005 s no ksw l o t gu 06.2010 V manual gearbox 02Q - Edition 6-speed y b a
Torque wrench -V.A.G 1331 Internal puller -1 - Kukko 21/7 Counter support -4 - Kukko 22/2-
Thrust piece -2050-
un le
Support plate -VW 309-
ed ris o h t au ss
ran tee or ac
r fo ng
(Determining shim for output shaft) It is necessary to readjust the output shaft when the following components are renewed: Gearbox housing Clutch housing Output shaft for 1st to 4th gear or Tapered roller bearing for output shaft Adjustment overview page 232 Prerequisites: Sealing surfaces of clutch and gearbox housings must be free of sealant. When taking measurements, install only the output shaft to be measured.
ht rig py Co t.
agen lksw Vo by
AG.
Prote cted by
207
Set complete output shaft for 1st through 4th gears in clutch housing.
pe rm itte d
shim into gearbox housing to stop. In the process, support gearbox housing using thrust piece -2050- directly below bear ing support.
un le
AG. Volkswagen AG d agen oes ksw not l o V , Jetta 2005 , Jetta 2011 Golf Variant 2007 , Golf Variant 2010 gu by ara d e nte 6-speed manual gearbox 02Q - o Edition 06.2010 ris eo h ut ra a c s s race with 1.70 mm thick Press tapered roller bearing outer
Set gearbox housing in position and tighten bolts -A- as well as -B- alternately and diagonally to specified torque.
do c um en
Set up measuring tools and secure to clutch housing using bolt -arrow-. Set dial gauge (3 mm measuring range) to 0 with 1 mm pre load. Loosen clutch housing/gearbox housing securing bolts diag onally until the bolts release the gearbox housing or output shaft. Read and note value on dial gauge (example: 0.14 mm). Note If no value is indicated when clutch housing/gearbox housing
securing bolts are loosened: urement.
Install 1.95 mm shim or, if necessary, 2.20 mm shim for meas Allocate shims using Electronic parts catalogue (ETKA) .
2.3.1
Determining thickness of shim
Specified bearing preload is obtained as follows: Subtracting measured value (0.14 mm) from inserted shim (1.70 mm). Add a constant value for preload (0.20 mm).
208
ht rig py Co t.
agen lksw Vo by
AG.
Example:
Installed shim - Measured value + Preload (constant) Shim thickness
ss
n wage olks V by ed ris o th au
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed wagen A manual gearbox 02Q - Edition 06.2010 AG. Volks 1.70 mm 0.14 mm 0.20 mm 1.76 mm
Determine thickness of shim from table page 209 . Remove gearbox housing and pull tapered roller bearing outer race from gearbox housing. A - Counter support , e.g. -Kukko 22/2B - Internal puller, 46 58 mm , e.g. -Kukko 21/7 Remove inserted shim (1.70 mm thick) from gearbox housing.
do c um en
2.3.2
1.45 1.50 1.55 1.60 1.65 1.70
Table of shims
agen lksw Vo by
The various thicknesses make it possible to achieve the exact shim thickness required. Determine part number of shim according to Electronic parts catalogue ETKA . Press in tapered roller bearing outer race together with correct shim (in example 1.75 mm). In the process, support gearbox housing using thrust piece -2050- directly below bearing sup port.
2.3.3
Carrying out check measurement
Determined shim installed.
AG.
Thickness (mm) 1.75 1.80 1.85 1.90 1.95 2.00
2.05 2.10 2.15 2.20 2.25
ht rig py Co t.
209
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed manual gearbox 02Q - Edition 06.2010 Set up measuring tools and secure to clutch housing using bolt -arrow-. Set dial gauge (3 mm measuring range) to 0 with 1 mm pre load. Loosen clutch housing/gearbox housing securing bolts diag onally until the bolts release the gearbox housing or output shaft. If correct shim has been selected, dial gauge will indicate a value between 0.15 mm to 0.25 mm.
pe rm itte d
un le
do c um en
210
ht rig py Co t.
agen lksw Vo by
AG.
Prote cted by
Output shaft for 5th, 6th and reverse gears

Dismantling and assembling output shaft for 5th, 6th and reverse gears
3.1
Special tools and workshop equipment required Thrust plate -VW 401 Thrust plate -VW 402 Press tool -VW 407
AG. Volkswagen AG d agen oes ksw not l o V gu Press tool -VW 408 Ay b ara d nte ise r eo Press tool -VW 412- utho ra a c s Tube -VW 415 A- s
pe rm itte d
un le
do c um en
3. Output shaft for 5th, 6th and reverse gears
ht rig py Co t.
agen lksw Vo by
AG.
Prote cted by
211
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed manual gearbox 02Q - Edition 06.2010 Support plate -VW 309 Gearbox support -VW 353 Thrust piece -VW 433 Thrust piece -VW 454 Support rail -VW 457 Support plate -VW 801n AG. Volkswagen AG do es n wage s k l ot g o yV ua b ran ed s i tee r o h t or u ac a ss

thi sd o cu m en
212
ht rig py Co t.
agen lksw Vo by
AG.
Prote cted by
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed manual gearbox 02Q - Edition 06.2010 Thrust piece -VW 431 Installing sleeve -VW 455 Thrust pad -VW 510 Tube -VW 516 Tube -VW 519pe rm itte d
Thrust plate -30 - 11-
un le
do c um en
ht rig py Co t.
agen lksw Vo by
AG.
213
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed manual gearbox 02Q - Edition 06.2010 Thrust plate -40 - 105 Drift sleeve -40 - 20 Thrust piece -2050 Tube -3296 Tapered roller bearing pull er -V.A.G 1582 Adapter -V.A.G 1582/4-
Adapter -V.A.G 1582/7-
thi sd o cu m en
214
ht rig py Co t.
agen lksw Vo by
AG.
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed manual gearbox 02Q - Edition 06.2010 -1- Internal puller -Kukko 21/7-
-3- Splitter -Kukko 17/2 -4- Counter support -Kukko Note
If output shaft or tapered roller bearings have been renewed, adjust output shaft page 222 . Always renew both tapered roller bearings together as a set. 1 - Clutch housing
pe rm itte d
un le
AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo 22/2- uth ra a c s s
2 - Washer Always 0.65 mm thick
6 - Reverse gear synchro-hub Pressing off page 218 Installation position page 218 Pressing on page 219 7 - Retaining ring 8 - Reverse gear locking collar With synchro-ring 9 - Needle bearing For synchromeshed gear for reverse gear
AG.
5 - Output shaft For 5th, 6th and reverse gears Adjusting page 222
ht rig py Co t.
agen lksw Vo by
4 - Tapered roller bearing inner race Pulling off page 218 Pressing on page 221
3 - Tapered roller bearing outer race Pulling out page 217 Pressing in page 217
do c um en
215
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed manual gearbox 02Q - Edition 06.2010 10 - Synchromeshed gear for reverse gear 11 - Sleeve Press off together with synchromeshed gear for reverse gear page 218 Installation position: wide shoulder of sleeve faces synchromeshed gear for reverse gear Pressing on page 219 12 - Retaining ring 13 - Needle bearing For 6th gear 14 - Synchromeshed gear for 6th gear
AG. 15 - Synchro-ring for 6th gear agen ksw l o V Check for wear by page 219 ed
Volkswagen AG does not gu ara nte synchro-hub for 5th and 6th gears e or a c
tho with 16 - Locking collar au s After s removing retaining ring Item 17 (page 216) , press off with synchromeshed gear for 6th gear page 217 Dismantling page 219 Assembling locking collar and synchro-hub page 219 and page 220 Pressing on page 220
ris
17 - Retaining ring 18 - Needle bearing For 5th gear 19 - Synchro-ring for 5th gear Check for wear page 219 20 - Synchromeshed gear for 5th gear 21 - Tapered roller bearing inner race Pulling off page 217 Pressing on page 220
22 - Retaining ring If tapered roller bearing Item 21 (page 216) and output shaft Item 5 (page 215) are renewed, rede termine page 220
agen lksw Vo by
thi sd o cu m en
24 - Shim Determining thickness page 222 25 - Gearbox housing 26 - Spring Installation position page 220 27 - Locking collar 28 - Synchro-hub 29 - Locking pieces (Qty. 3) Installation position page 219
216
AG.
23 - Tapered roller bearing outer race Pulling out page 221 Pressing in page 221
ht rig py Co t.
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed manual gearbox 02Q - Edition 06.2010 Pulling out tapered roller bearing outer race A - Counter support , e.g. -Kukko 22/2B - Internal puller, 46 58 mm , e.g. -Kukko 21/7Note
After pulling out, check washer for damage and renew if neces sary.
Pressing tapered roller bearing outer race into clutch housing Fit washer under outer race.
pe rm itte d
un le
n AG. Volkswagen AG do es n wage s k l ot g o yV ua b ran ed -40 - 20- directly below s Support clutch housing with drift sleeve i tee r o h t or bearing support. u ac a ss
Pulling off tapered roller bearing inner race First remove retaining ring. Before setting up pulling device, set thrust piece -VW 431- and thrust plate -40 - 105- on output shaft.
do c um en
Pressing off synchro-hub and locking collar for 5th and 6th gears with synchromeshed gear for 6th gear
AG.
Prote cted by
First remove retaining ring.
ht rig py Co t.
agen lksw Vo by
217
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed manual gearbox 02Q - Edition 06.2010 Pressing off sleeve -A- together with synchromeshed gear for re verse gear First remove retaining ring.
Pressing off reverse gear synchro-hub First remove retaining ring. A - Splitter, 22 115 mm , e.g. -Kukko 17/2-
Pulling off tapered roller bearing inner race Before setting up pulling device, set thrust plate -30 - 11- on output shaft.
Stop of reverse gear locking collar -arrow A- faces teeth of output shaft -arrow B-.
Installation position of reverse gear synchro-hub

thi sd o cu m en
AG.
Prote cted by
218
ht rig py Co t.
agen lksw Vo by
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed manual gearbox 02Q - Edition 06.2010 Pressing on reverse gear synchro-hub Install retaining ring.
Pressing on sleeve -AInstallation position: Wide collar faces reverse gear synchro meshed gear. Install retaining ring.
Checking synchro-rings for 5th and 6th gear for wear Press synchro-ring onto cone of synchromeshed gear and measure gap -a- using feeler gauge. Gap -aInstallation (new) di mension 1.0 1.7 mm Wear limit 0.5 mm
pe rm itte d
un le
5. and 6th gear
1234-
Spring
Dismantling and assembling locking collar and synchro-hub for 5th and 6th gears Locking piece Locking collar Synchro-hub
do c um en
Notches for locking pieces in synchro-hub and locking collar must align.
AG.
Slide locking collar over synchro-hub.
ht rig py Co t.
agen lksw Vo by
Prote cted by
219
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed manual gearbox 02Q - Edition 06.2010 Assembling locking collar with synchro-hub for 5th and 6th gears Locking collar has been pushed over synchro-hub. Insert locking pieces and install springs offset 120. Angled end of spring must locate in hollow locking piece.
Pressing on locking collar and synchro-hub for 5th and 6th gears Install retaining ring.
Pressing on tapered roller bearing inner race Determine and install retaining ring page 220 .
Determining thickness of retaining ring
pe rm itte d
un le
Determine thickest retaining ring which will still fit and install it. Determine retaining ring from table. Part number Electronic parts catalogue ETKA . Available retaining rings Thickness (mm) 1.79 1.83 1.86 1.89 1.92 1.95
1.98
do c um en
220
ht rig py Co t.
agen lksw Vo by
AG.
Prote cted by
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed manual gearbox 02Q - Edition 06.2010 Pressing on tapered roller bearing inner race
Pulling outer race for tapered roller bearing out of gearbox hous ing A - Counter support , e.g. -Kukko 22/2B - Internal puller, 46 58 mm , e.g. -Kukko 21/7-
Pressing tapered roller bearing outer race into gearbox housing Support gearbox housing with thrust piece -2050- below bear ing support.

thi sd o cu m en
ht rig py Co t.
agen lksw Vo by
AG.
Prote cted by
221
3.2
Adjusting output shaft for 5th, 6th and reverse gears
Special tools and workshop equipment required Gearbox support -VW 353 Universal dial gauge brack et -VW 387 Press tool -VW 407pe rm itte d
Assembly tool -VW 792 Support plate -VW 801es, in part or in w l purpos hole ercia , is n m ot com
un le
Thrust piece -VW 433-
do c um en
222
ht rig py Co t.
agen lksw Vo by
AG.
Prote cted by
Support plate -VW 309es, in part or in w l purpos hole ercia , is n m ot com
Thrust piece -2050 Torque wrench -V.A.G 1331 -1- Internal puller -Kukko 21/7 -4- Counter support -Kukko 22/2-
pe rm itte d
un le
AG. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 eo h t u ra a c 6-speed manual gearbox 02Q - Edition 06.2010 s s
do c um en
It is necessary to readjust the output shaft when the following components are renewed: Gearbox housing Clutch housing Output shaft for 5th, 6th and reverse gears or Tapered roller bearing for output shaft Adjustment overview page 232 . Prerequisites: Sealing surfaces of clutch and gearbox housings must be free of sealant. When taking measurements, install only the output shaft to be measured.
ht rig py Co t.
agen lksw Vo by
AG.
Prote cted by
223
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed manual gearbox 02Q - Edition 06.2010 Press tapered roller bearing outer race with 1.70 mm thick shim into gearbox housing to stop. In the process, support gearbox housing using thrust piece -2050- directly below bear ing support. Set complete 5th, 6th and reverse gear output shaft in clutch housing.
Set gearbox housing in position and tighten bolts -Aas -B- alternately and diagonally to specified torque. Set up measuring tools.
n AG. Volkswagen AG do es n wage s k l ot g o yV ua b ran ed s i tee r as well o h t or u ac a ss

thi sd o cu m en
Read and note value on dial gauge (example: 0.25 mm). Note If dial gauge indicates no value when clutch housing/gearbox
housing securing bolts are loosened, install a 1.95 mm shim or, if necessary, a 2.20 mm shim. KA .
Allocate shims according to Electronic parts catalogue ET
3.2.1
Determining thickness of shim
The specified bearing preload will be attained by subtracting the measured value (0.25 mm) from the inserted shim (1.70 mm) and adding a constant value for preload (0.20 mm). Example: Installed shim 1.70 mm
224
AG.
Prote cted by
Loosen clutch housing/gearbox housing securing bolts diag onally until the bolts release the gearbox housing or output shaft.
agen lksw Vo by
Set dial gauge (3 mm measuring range) to 0 with 1 mm pre load.
ht rig py Co t.
If the edge of the housing protrudes, put washers with a total thickness of 8 mm on bolt -arrowfor securing assembly de vice -VW 792- to clutch housing.
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed manual gearbox 02Q - Edition 06.2010 - Measured value + Preload (constant) Shim thickness 0.25 mm 0.20 mm 1.65 mm
Determine thickness of shim from table page 225 . Remove gearbox housing and pull tapered roller bearing outer race from gearbox housing. A - Counter support , e.g. -Kukko 22/2B - Internal puller, 46 58 mm , e.g. -Kukko 21/7 Remove inserted shim (1.70 mm thick) from gearbox housing.
3.2.2
1.50 1.55 1.60 1.65 1.70 1.75
Table of shims
Thickness (mm) 1.80 1.85 1.90 1.95 2.00 2.05
2.10 2.15 2.20 2.25
Part numbers Electronic parts catalogue ETKA . The various thicknesses make it possible to achieve the exact shim thickness required. Press in tapered roller bearing outer race together with correct shim (in example 1.65 mm). In the process, support gearbox housing using thrust piece -2050- directly below bearing sup port.
do c um en
3.2.3
Carrying out check measurement
Determined shim installed.
Set up measuring tools.
ht rig py Co t.
agen lksw Vo by
AG.
225
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed manual gearbox 02Q - Edition 06.2010 If the edge of the housing protrudes, put washers with a total thickness of 8 mm on bolt -arrowfor securing assembly de vice -VW 792- to clutch housing. Set dial gauge (3 mm measuring range) to 0 with 1 mm pre load. Loosen clutch housing/gearbox housing securing bolts diag onally until the bolts release the gearbox housing or output shaft. If correct shim has been selected, dial gauge will indicate a value between 0.15 mm to 0.25 mm.
pe rm itte d
un le
do c um en
226
ht rig py Co t.
agen lksw Vo by
AG.
39
1
Final drive - differential

Renewing flange shaft oil seals with gearbox installed
Renewing oil seal for left flange shaft
1.1
Special tools and workshop equipment required Multipurpose tool -VW 771 Puller hooks -VW 771/37 Thrust piece -3305 Torque wrench V.A.G 1331 Torque wrench V.A.G 1332 Sealing grease -G 052 128 A1 Drip tray
un le
r fo ng
1. Renewing flange shaft oil seals with gearbox installed
ht rig py Co t.
agen lksw Vo by
AG.
227
un le
n AG. Volkswagen AG do es n wage s k l ot g Vo y ua b Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 ran ed , Jetta 2011 s i tee r o 6-speed manual gearbox 02Q - Edition 06.2010 th or u ac a ss
1.1.1
Removing
Remove left wheel.
ht rig py Co t.
Place drip tray under gearbox. Remove flange shaft securing bolt by screwing two bolts into flange and counterholding flange shaft with a lever. Pull out flange shaft with compression spring.
Remove flange shaft oil seal.
228
Rep. gr.39 - Final drive - differential
agen lksw Vo by
AG.
Prote cted by
Remove left drive shaft Running gear, axles, steering; Rep. gr. 40 ; Repairing drive shafts; Removing and installing drive shafts .
r fo ng
1.1.2
Installing
Drive in new seal to stop, being careful not to cant seal. Half-fill space between sealing lip and dust lip with sealing grease -G 052 128 A1- .
Insert flange shaft. Secure flange shaft using countersunk bolt and tighten to specified torque Item 10 (page 235) . Install left drive shaft Running gear, axles, steering; Rep. gr. 40 ; Repairing drive shafts; Removing and installing drive shafts . Install lower part of front left wheel housing liner General body repairs, exterior; Rep. gr. 66 ; Wheel housing liner . Install wheel Running gear, axles, steering; Rep. gr. 44 ; Torque settings for mounting wheels . Check gear oil page 126 .
AG. Volkswagen AG d agen oes ksw not l o V gu Install noise insulation General body repairs, exterior; Rep. y b ara d nte gr. 50 ; Noise insulation . orise eo h t u ra a c s s
1.2
Renewing seal for right flange shaft
Special tools and workshop equipment required Thrust piece -3305-
do c um en
ht rig py Co t.
agen lksw Vo by
AG.
Prote cted by
229
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed manual gearbox 02Q - Edition 06.2010 Drip tray for workshop hoist -VAS 6208-
Sealing grease -G 052 128 A1-
1.2.1
Removing
Remove noise insulation General body repairs, exterior; Rep. gr. 50 ; Noise insulation . Remove drive shaft heat shield from engine -arrows-, if fitted.
lkswagen AG AG. Vo-Anshaft Removing right drive shaft from gearbox flange doe wage
by Secure drive shafts with wire, taking ed care not to damage sur ris face protection. o th
ks Vol
Note
With some engines, the drive shaft cannot be raised and se
cured high enough that the flange shaft can be pulled out. ing; Rep. gr. 40 ; Removing and installing drive shafts .
au ss
In that case, remove drive shaft Running gear, axles, steer Place drip tray under gearbox. Remove flange shaft securing bolt by screwing two bolts into flange and counterholding flange shaft with a lever. Pull out flange shaft with compression spring. Pry seal out using assembly lever.
do c um en
230
ht rig py Co t.
agen lksw Vo by
AG.
1.2.2

Secure flange shaft -A- using countersunk bolt and tighten to specified torque Item 10 (page 235) .
AG. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise careful not to cant seal. Drive in new seal to stop, being r o eo h t u ra a c s Half-fill space between sealing lip and dust lip with sealing s
Installing
grease -G 052 128 A1- .
Attach right drive shaft to gearbox flange shaft -A- Running gear, axles, steering; Rep. gr. 40 ; Repairing drive shaft; Re moving and installing drive shafts .
thi sd o cu m en
Install drive shaft heat shield, if present, on engine. Tighten bolts -arrows- to specified torque Running gear, axles, steering; Rep. gr. 40 ; Repairing drive shafts . Check gear oil page 126 .
AG.
ht rig py Co t.
agen lksw Vo by
Prote cted by
231
2
Note
Adjustment overview
If repairs have been carried out on the gearbox, it is necessary to readjust output shaft for 1st through 4th gear, output shaft for 5th, 6th and reverse gear or differential only if components have been renewed which have a direct effect on the adjustment of the gear box. To prevent unnecessary adjustments, refer to the following table:
To be adjusted: Output shaft Output shaft Differential for 1st for 5th, 6th page 239 through 4th and reverse gears gears page 206 page 222 x x x x x x x x x x x x
Parts renewed:
Gearbox housing Clutch housing Output shaft for 1st through 4th gears Output shaft for 5th, 6th and reverse gears Differential cage Tapered roller bearings for 1st to 4th gear output shaft Tapered roller bearings for 5th, 6th and reverse gear output shaft Tapered roller bearing for differen tial

do c um en
AG.
Prote cted by
232
ht rig py Co t.
agen lksw Vo by
3
3.1
Differential
Dismantling and assembling differential
Special tools and workshop equipment required Thrust plate -VW 402 Press tool -VW 408 A Press tool -VW 412 Tube -VW 415 A Thrust plate -40 - 105 Thrust plate -3005n AG. Volkswagen AG do es n wage s k l ot g o yV ua b ran ed s i tee r o h t or u ac a ss

thi sd o cu m en
ht rig py Co t.
agen lksw Vo by
AG.
Prote cted by
3. Differential
233
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed manual gearbox 02Q - Edition 06.2010 Tube -3259 Tube -3296 Tube -3345 Tapered roller bearing pull er -V.A.G 1582 Adapter -V.A.G 1582/6A -1- Internal puller -Kukko 21/7 -2- Puller -Kukko 18/1 -3- Splitter -Kukko 17/1 -4- Counter support -Kukko 22/2-
pe rm itte d
un le
Note
Heat tapered roller bearing inner race to approx. 100 C before installing. Always renew both tapered roller bearings together as a set. If tapered roller bearings, differential cage, gearbox housing or clutch housing is renewed, adjust differential
ht rig py Co t.
do c um en
234
agen lksw Vo by
AG.
Prote cted by
page 239 .
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed manual gearbox 02Q - Edition 06.2010 1 - Gearbox housing 2 - Shim For differential Determining thickness page 239 3 - Tapered roller bearing outer race Pulling out page 238 Pressing in page 238 4 - Tapered roller bearing inner race Pulling off page 237 Pressing on page 237 5 - Differential cage With riveted final drive gear 6 - Tapered roller bearing inner race Pulling off page 237 Pressing on page 238 7 - Tapered roller bearing outer race Pulling out page 236 Pressing in page 237

do c um en
9 - Clutch housing 10 - Countersunk bolt, 33 Nm Screw into threaded piece Item 22 (page 236) 11 - Right flange shaft 12 - Protective ring Pry protective ring off flange shaft with a screwdriver, alternating sides Item 11 (page 235) Install with indentation facing away from threaded hole in flange shaft Push on protective ring to stop by hand Protective ring must engage in flange shaft 13 - Seal For right flange shaft Allocation Electronic parts catalogue ETKA Renewing with gearbox installed page 229 14 - Compression spring for flange shaft Installed behind flange shaft
agen lksw Vo by
AG.
Prote cted by
8 - Washer Installation position: shoulder on inner cir cumference faces seal Item 13 (page 235) Allocation Electronic parts catalogue ETKA
3. Differential
ht rig py Co t.
235
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed manual gearbox 02Q - Edition 06.2010 15 - Thrust washer Installation position: shoulder faces spring, lugs, if present, face tapered ring
n 16 - Tapered ring wage olks V by Installation position: taper towards differential ed cage
is or
19 - Differential pinion pin Drive out using drift Installing page 239
pe rm itte d
18 - Sun wheel Installing page 239
un le
th 17 - Retaining ring au ss Holds tapered ring, thrust washer and spring in position when flange shaft is removed
AG. Volkswagen AG d oes not gu ara nte eo ra c

20 - Spring pin For securing differential pinion pin Removing and installing page 238 21 - Planet pinion Installing page 239 22 - Threaded piece Installing page 239
23 - One-piece thrust washer Coat with gear oil when installing
24 - Protective ring Pry protective ring off flange shaft with a screwdriver, alternating sides Item 25 (page 236) Install with indentation facing away from threaded hole in flange shaft Push on protective ring to stop by hand Protective ring must engage in flange shaft 25 - Left flange shaft 26 - Seal For left flange shaft Allocation Electronic parts catalogue ETKA Renewing with gearbox installed page 227 Pulling tapered roller bearing outer race out of clutch housing A - Counter support , e.g. -Kukko 22/2B - Internal puller, 46 58 mm , e.g. -Kukko 21/7Note
ht rig py Co t.
do c um en
After pulling out, renew washer.
236
agen lksw Vo by
AG.
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed manual gearbox 02Q - Edition 06.2010 Press tapered roller bearing outer race with washer into clutch housing First insert washer. Note Observe installation position of washer.
gen AG . gen AG does housing. Shoulder on inner circumference faces seal in clutch swa
by ed ris o th au ss
Volkswa
k Vol
Pulling off tapered roller bearing inner race

un le
not gu ara nte eo ra c

Before setting up pulling device, set thrust plate -40 - 105- on differential housing.
Pressing on tapered roller bearing inner race
r fo ng
Pulling off tapered roller bearing inner race A - Puller , e.g. -Kukko 18/1B - Splitter, 12 75 mm , e.g. -Kukko 17/1-
ht rig py Co t.
agen lksw Vo by
AG.
Prote cted by
3. Differential
237
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed manual gearbox 02Q - Edition 06.2010 Pressing on tapered roller bearing inner race Cage with tapered rollers must be easy to turn during pressing.
Pulling outer race for tapered roller bearing out of gearbox hous ing A - Counter support , e.g. -Kukko 22/2B - Internal puller, 46 58 mm , e.g. -Kukko
AG. Volkswagen AG d agen oes ksw not l o gu yV b ara 21/7d e nte is r o eo h ut ra a c s s
un le
pe rm itte d
Pressing tapered roller bearing outer race into gearbox housing Support gearbox housing with tube -3345- directly below bear ing support.
do c um en
Removing and installing spring pin for differential pinion pin Removing Cover tapered roller bearing inner race to avoid possible dam age and entry of metal particles. Drive out spring pin with chisel, inserting chisel into circum ferential groove. Installing Drive into differential cage to stop.
ht rig py Co t.
238
agen lksw Vo by
AG.
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed manual gearbox 02Q - Edition 06.2010 Installing differential bevel gears Lubricate one-piece thrust washer with gear oil and install. Install both sun wheels and secure (e.g. with flange shaft). Insert planet pinions offset 180 and pivot into position.
Volkswa k l o yV d b -arrows B- in sun gears. Place threaded pieces ise r tho Installation position: au shoulder to sun gear s s
gen AG . gen AG A-) to first Press in differential pinion pin (-arrow planet does pinion. swa
not gu ara nte eo ra c

3.2
pe rm itte d
Drive differential pinion pin into final position and secure with spring pin.
Adjusting differential
un le
Special tools and workshop equipment required Gearbox support -VW 353 End dimension plate VW 385/17 Universal dial gauge brack et -VW 387 Thrust plate -VW 402 Thrust plate -3005ht rig py Co t.
Press tool -VW 408 A-
do c um en
agen lksw Vo by
AG.
3. Differential
239
g swa 2011 Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 ,lk Jetta o yV b d 6-speed manual gearbox 02Q - Edition 06.2010 se
Torque wrench -V.A.G 1331 -1- Internal puller -Kukko 21/7 -4- Counter support -Kukko 22/2-
pe rm itte d
Tube -3345-
un le
Tube -3259-
ri ho ut a ss
olkswagen AG en AG. V does not gu ara nte eo ra c

do c um en
It is necessary to readjust the differential when the following com ponents are renewed: Gearbox housing Clutch housing Differential cage or Tapered roller bearing of differential Adjustment overview page 232 . Press tapered roller bearing outer race with washer into clutch housing. Note Observe installation position of washer. Shoulder on inner circumference faces seal in clutch housing.
240
ht rig py Co t.
agen lksw Vo by
AG.
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed manual gearbox 02Q - Edition 06.2010 Press tapered roller bearing outer race, without shim, into gearbox housing. Fit differential into clutch housing. Fit gearbox housing and tighten 5 bolts to specified torque Item 11 (page 130) and Item 12 (page 130) . Press differential in direction of clutch housing while turning it eight times. Press differential in direction of gearbox housing while turning it eight times.
Attach dial gauge and set to 0 with 1 mm preload. A - 30 mm dial gauge extension Move differential up and down. Read and note play indicated on dial gauge. (Example: 0.70 mm)
3.2.1
Example:
es n ksw thickness of shim ot g Determining Vol u by

d se
AG. Volkswagen AG d agen o
tee ri The specified bearing preload is obtained by adding a constant ho or ut (0.25 mm) to the reading obtained. ac a value for preload s
ara n
Measured value + Preload (constant) Thickness of shim =
0.70 mm 0.25 mm 0.95 mm
Remove gearbox housing. Pull tapered roller bearing outer race out of gearbox housing. A - Counter support , e.g. -Kukko 22/2B - Internal puller, 46 58 mm , e.g. -Kukko 21/7 Determine part number of shim according to Electronic parts catalogue ETKA . Insert shims of determined thickness, thickest shim first. The following shims are available: Shim thickness (mm)
ht rig py Co t.
thi sd o cu m en
If the size of shim required is larger than those listed in the table, insert two shims totalling the correct figure. When using two shims, install the thicker one first. The various thicknesses make it possible to achieve the exact shim thickness required.
agen lksw Vo by
AG.
0.65 0.70 0.75 0.80
0.85 0.90 0.95 1.00
1.05 1.10 1.15 1.20
1.25
3. Differential
241
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed manual gearbox 02Q - Edition 06.2010 Press outer race in again and tighten gearbox housing to specified torque Item 11 (page 130) and Item 12 (page 130) .
pe rm itte d
un le
do c um en
242
ht rig py Co t.
agen lksw Vo by
AG.
Prote cted by

6-Speed Manual Gearbox 02Q

Загружено:

Сведения о документе

Авторское право

Доступные форматы

Поделиться этим документом

Поделиться или встроить документ

Параметры публикации

Этот документ был вам полезен?

Это неприемлемый материал?

Авторское право:

Доступные форматы

6-Speed Manual Gearbox 02Q

Загружено:

Авторское право:

Доступные форматы

Service

6-speed manual gearbox 02Q

urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p

rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en

Service Department. Technical Information

es, in part or in w l purpos hole ercia , is n m ot com

AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h ut ra a c s s

rrectness of i t to the co nform spec a t i h re o n in wit thi s

Prote cted by c o py rig ht . C op yi

es, in part or in w l purpos hole ercia , is n m m ot p o c erm or e t a itte iv r du rp o nl f e ng

35 - Gears, shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178

es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g n

39 - Final drive - differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227

rrectness of i t to the co nform spec at i h re o n wit in t his

rrectness of i t to the co nform spec a t i h re o n in wit thi s

Manual gearbox 02Q -arrow 2-

Additional data provide information about the production facility. Note

The gearbox code also appears on the vehicle identification plates.

Identification code, assembly allocation and capacities

Manual gearbox Identification code Manufactured

Prote cted by c o p yri gh t. C op yi

Capacity of manual gearbox Drive shaft flange

Manual gearbox Identification code Manufactured Allocation

6-speed 02Q HVS

urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p

rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en

Final drive Capacity of manual gearbox Drive shaft flange

69 : 25 = 2.760 2.3 l 107 mm

70 : 24 = 2.917 2.3 l 107 mm

Rep. gr.00 - Technical data

Prote cted by c o py rig ht . C op yi

Manual gearbox Identification code

11.07 02.09 Jetta 2005 Golf Variant 2007

6-speed 02Q KNU

KNY 02.08 10.08 Jetta 2005

urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p

KNY 2.0 l - 125 kW turbo diesel 70 : 19 = 3.684 70 : 24 = 2.917 2.3 l 107 mm

Final drive Capacity of manual gearbox Drive shaft flange

69 : 25 = 2.760 2.3 l 107 mm

71 : 23 = 3.087 2.3 l 107 mm

rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en

Allocation of clutch plate and pressure plate

Manual gearbox Identification code Manufactured Allocation

Final drive I1)

Final drive II2) Capacity of manual gearbox Drive shaft flange

Manual gearbox Identification code Manufactured Allocation from to Model

6-speed 02Q LNN 06.09 Golf Variant 2010

1.6 l - 77 kW turbo diesel 72 : 17 = 4.235

NFN 05.09 Jetta 2005

2.0 l - 125 kW turbo diesel 70 : 19 = 3.684

LHD II2) 69 : 25 = 2.760

6-speed 02Q LNN 72 : 22 = 3.273

NFN 70 : 24 = 2.917 2.3 l 107 mm

Specification for gear oil

urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p

Individual gear ratios

rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en

Allocation of clutch plate and pressure plate

Manual gearbox Identification code Manufactured Allocation

Rep. gr.00 - Technical data

Prote cted by c o p yri gh t. C op yi

Final drive Capacity of manual gearbox Drive shaft flange

69 : 25 = 2.760 2.3 l 107 mm

Overview - power transmission