Manua-0AJ.pdf

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

Service
List of Workshop Manual Repair Groups
AG. Volkswagen AG d
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Repair Gssr o u p
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00 - Technical data
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30 - Clutch
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34 - Controls, housing
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35 - Gears, shafts
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39 - Final drive - differential
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Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.
All rights reserved.

No reproduction without prior agreement from publisher.
Copyright © 2017 Volkswagen AG, Wolfsburg D4B8033B594

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

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

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

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

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

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

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

plates.
1.2 Identification code, assembly allocation and capacities

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

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

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

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

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

Jetta 2013 ➤ , Jetta 2015 ➤
4 General repair instructions

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

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♦ Renew O-rings, seals and gaskets.

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

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

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

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

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and replenish if necessary ⇒ page 111 .

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

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

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

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

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

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

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

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

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»blue discolouration (due to overheating)«.

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

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

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

ling.
rrectness of i
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nform
ercia
4.1.9 Gear wheels

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

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

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

um
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there is no axial clearance.

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

Jetta 2013 ➤ , Jetta 2015 ➤
4.1.10 Synchromeshed gears

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

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

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

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

cluster ⇒ page 12
II - Assembly overview - hy‐
draulics (LHD) ⇒ page 51
III - Assembly overview - hy‐
draulics (RHD) ⇒ page 54
AG. Volkswagen AG d
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t to the co
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cial p
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mer
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Prote AG.
2. Repairing clutch mechanism 11

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

s o
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❑ Between clutch master cylinder and mounting bracket

inform
mer
11 - Clutch master cylinder

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

o
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12 - Clutch position sender - G476-

te
sd
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❑ Removing and installing ⇒ page 48

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

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

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

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

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Prote AG.

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

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

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

un
pt
and installing knee airbag bracket.

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

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

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

rrectness o
cial p
f inform
mer
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Prote AG.

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

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

f
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– Pull off damping. Cop py
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Prote AG.

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

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

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

p
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spring -4- from mounting bracket.

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

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

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

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

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

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

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

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

spec
installing knee airbag bracket .

es, in part or in w
t to the co

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

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

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

rm
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atio
om
n in
c
2.3.3 Specified torques

or
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te
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Component Nm
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f
en
ng
Clutch pedal to mounting bracket 25

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

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

spring (right-hand drive)

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

Jetta 2013 ➤ , Jetta 2015 ➤

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

– Pull off damping.

Jetta 2013 ➤ , Jetta 2015 ➤

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

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

Jetta 2013 ➤ , Jetta 2015 ➤

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

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

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

atio
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or
2.5 Removing and installing clutch pedal

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

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

cluster.

theft code.
trims .

Jetta 2013 ➤ , Jetta 2015 ➤

different ways.
– Remove crash bar -1- (2 bolts).
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
Attachment with 1 bolt ss
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ce
e

nl
pt
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itte
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ility
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos

mounting bracket.
nf
ercia
orm
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or c
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Prote AG.

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

– Swing clutch pedal forward slightly and remove over-centre

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

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

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

Jetta 2013 ➤ , Jetta 2015 ➤

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

Component Nm

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

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

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

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

pedal.

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

bracket
2.7 Removing and installing mounting

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

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

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

cluster.



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


mounting bracket. agen
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Prote AG.

Jetta 2013 ➤ , Jetta 2015 ➤

– Remove securing nuts -1- and -2-.

The upper securing nut -1- is accessible between the relay
carrier and the steering column trim.
– Remove mounting bracket -3-.
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♦ Renew self-locking nut.

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♦ Allocate all components according to ⇒ Electronic parts cata‐

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

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

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

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

bracket (attachment with 1 bolt)
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Prote AG.

Jetta 2013 ➤ , Jetta 2015 ➤
Special tools and workshop

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

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

protect it from possible brake fluid spills.

trims .
Note

cluster.

Jetta 2013 ➤ , Jetta 2015 ➤

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

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

trims .

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

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

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

bracket
2.9 Removing and installing clutch master

cylinder

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

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

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

sender - G476-
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Cop py
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Prote AG.

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

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

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

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

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

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

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

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

Jetta 2013 ➤ , Jetta 2015 ➤
1 - Brake fluid reservoir

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

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7 - Clutch pedal
h re
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spec

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

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

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

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

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10 - Pipe/hose or plastic line

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

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

m
1 Line connection with circumferential groove
a
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2 Line connection with shoulder -arrow 2-
s
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3 Line connection with shoulder -arrow 2- and cir‐
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Supply hose -1- of plastic

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

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

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

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

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

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

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

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

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

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

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

t to the co
rrectness of i
2.13.2 Installing
l purpos

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

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

Jetta 2013 ➤ , Jetta 2015 ➤
3 Bleeding clutch mechanism

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

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

y li
erm
ab
moving and installing air filter .

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

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

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

Jetta 2013 ➤ , Jetta 2015 ➤
4 Repairing clutch release mechanism
4.1 Assembly overview - clutch release mechanism
1 - Release bearing
❑ Remove and install to‐
gether with clutch re‐
lease lever
and guide sleeve
⇒ page 61
❑ Do not wash out bear‐
ing; wipe only gen AG
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❑ Renew noisy bearings yV
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2 - Bolt, 5 Nm + turnth90°
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3 - Clutch release lever pt

du
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❑ Remove and install to‐ y li

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

h re
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spec

es, in part or in w
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⇒ page 61
❑ Remove old grease
rrectness of i
4 - Retaining spring
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❑ Secure to clutch release

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

ion
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gether with release

in t
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his
ate
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⇒ Item 1 (page 60) and

p
clutch release lever

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

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

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

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

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

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

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

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

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

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

l purpos
nf
ercia
Remove and install release bearing.

rm
m
atio
m
• Clutch release lever removed.

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

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

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Jetta 2013 ➤ , Jetta 2015 ➤ ed b ara
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ris
6-speed manual gearbox 0AJ - Edition 06.2017 ut
ho eo
ra
s a c
s
ce
e
nl
pt
5 Repairing clutch
du
an
itte
y li
erm
ab
ility
ot p
Special tools and workshop
wit
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equipment required
h re
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spec
es, in part or in w
t to the co
rrectness of i
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nform
mercia
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c
in t
or
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ate
do
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Cop py
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rig ht
py by
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Prote AG.
♦ Counterhold tool - 3067-

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

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

or
thi
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pressure plate and

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

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

used clutch plates, hub splines. Re‐
move corrosion and apply only a
very thin coat of grease for clutch
plate splines - G 000 100- to the in‐
put shaft splines. Then, move the
clutch plate back and forth on the
drive shaft until the hub moves easi‐
ly on the shaft. Remove excess
grease.
5. Repairing clutch 63
Jetta 2013 ➤ , Jetta 2015 ➤
3 - Thrust plate
❑ Removing and installing for engines having a crankshaft wage
nof
AGsmaller
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en AG
doesor having needle bearings
in the crankshaft - ⇒ page 65 Volks not
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❑ Check ends of diaphragm spring ⇒ page 65 oris
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th eo
❑ Checking spring connections and riveted a connections ⇒ page 65
u ra
c
ss
❑ Contact surface for clutch lining must be free of grooves, oil and grease
ce
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un
pt
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Note
rm
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ility
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Pressure plates are protected
wit
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against corrosion and greased.
h re
hole
Clean contact surface only; other‐
spec
wise the service life of the clutch will
es, in part or in w
t to the co
be considerably reduced.
4 - Bolt
rrectness of i
❑ M6: 13 Nm
l purpos
❑ M7: 20 Nm
nform
ercia
❑ Loosen or tighten diagonally in small steps

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

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

having an needle bearing -arrow- in the crankshaft

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

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

Arrow -A- Gear selection movement
Arrow -B- Gate selection movement
A - Gear selector cable

B - Gate selector cable
C - Heat shield
❑ Remove before remov‐
ing selector mecha‐
nism.
1 - Gearbox selector lever
2 - Deflector lever
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66 Rep. gr.34 - Controls, housing

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

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lector cables ⇒ page 77 Prote
cted AG.
agen
Removing and installing selector mechanism ⇒ page 82 .

Adjust selector mechanism ⇒ page 89 .
1. Repairing selector mechanism 67

Jetta 2013 ➤ , Jetta 2015 ➤
1.3 Assembly overview - gear knob and cover
1 - Emblem
❑ Can be carefully levered
off gear knob of plastic
or leather
2 - Gear knob
❑ With gaiter
❑ Gear knob and gaiter
cannot be separated
from one another
❑ Always renew together
⇒ page 68
3 - Clamp
❑ For securing gear knob
to gear lever
❑ Secure to gear knob us‐
ing hose clip pliers -
V.A.G 1275-
4 - Frame for centre console
❑ In some equipment ver‐
sions, forms one part to‐
gether with upper centre
console
5 - Noise insulation
❑ Not fitted in all vehicles
❑ Arrow on noise insula‐
tion points in direction of
travel
❑ Because the locking lkswage es n
lugs are irregularly d byV
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Язык

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Похожие издания

Service

6-speed manual gearbox 0AJ

Service Department. Technical Information

39 - Final drive - differential

All rights reserved.

Copyright © 2017 Volkswagen AG, Wolfsburg D4B8033B594

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

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

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

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

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

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

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

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

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

00 – Technical data lkswage

1.1 Location on gearbox

The gearbox code also appears on the vehicle identification

1.2 Identification code, assembly allocation and capacities

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

2 Overview - power transmission

2. Overview - power transmission 3

4 Rep. gr.00 - Technical data

3. Calculating overall gear ratio “i” 5

4 General repair instructions

4.1.2 O-rings, seals and gaskets

♦ Renew O-rings, seals and gaskets.

referred to as oil seals.

tact surface on housings or shafts for burrs and damage and

♦ Before installing shaft seals, lightly oil outer circumference and

- G 052 128 A1- .

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

and replenish if necessary ⇒ page 111 .

ing crushed when inserted.

6 Rep. gr.00 - Technical data

4.1.4 Locking devices

♦ Do not overstretch retaining rings.

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

♦ Retaining rings must locate properly in grooves.

line with the line of force -arrow-.

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

4. General repair instructions 7

♦ If synchro-rings are coated, coating must not be damaged.

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

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

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

»blue discolouration (due to overheating)«.

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

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

♦ Moisten synchromesh mechanism with gear oil before instal‐

4.1.9 Gear wheels

ductive heater - VAS 6414- before installing.

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

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

there is no axial clearance.

8 Rep. gr.00 - Technical data

4.1.10 Synchromeshed gears

4.1.11 Clutch olksw