VOLKSWAGEN GOLF 2004 (10) PDF Document

To ensure flawless and successful gearbox repairs for the VOLKSWAGEN GOLF 2004, the greatest care and cleanliness, as well as the use of good and proper tools, are essential. Basic safety rules also apply during repair work.

Instructions generally applicable to various repair procedures, previously repeated in the manual, are summarized under the topic “components” which applies to this manual.

• 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 the Electronic parts catalogue “ETKA”.
• If the gearbox is repaired, fill with gear oil.

The capacity of the manual gearbox (gearbox completely dismantled) is 1.9 l, and the capacity of the partially dismantled gearbox is 1.7 l.

• Before installing the oil seal, half-fill the space between the sealing lips with sealing grease -G 052 128 A1-.
• The open side of the oil seal faces the side with fluid filling.
• After installing, check the oil level.
• Lightly oil O-rings before installing; this prevents the rings being crushed when inserted.
• Thoroughly clean parting surfaces and apply sealant -AMV 188 200 03-.
• Apply sealant uniformly but not too thick.

• Thoroughly clean housing joint surfaces before applying sealing paste.
• Evenly apply a thin coat of sealing paste -AMV 188 200 03-.
• Breather holes must remain free of sealing paste.

• Renew retaining rings.
• Do not overstretch retaining rings.
• Retaining rings must locate properly in grooves.
• Renew spring pins. Installation position: slot must be in line with direction of force.

• 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 diagonal 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 necessary.
• Use a thread chaser to clear residual locking fluid from all threaded holes into which self-locking bolts are to be screwed. Otherwise there is a danger of bolts shearing when subsequently being removed.

• Install new tapered roller bearings as supplied and do not lubricate additionally.
• Install needle bearings with lettered side (thicker metal) towards fitting tool.
• 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.

• Measure shims at several points with a micrometer. The various thicknesses make it possible to achieve the exact shim thickness required.
• Check for burrs and damage.
• Install only flawless shims.

• Do not interchange. When reusing synchro-rings, always fit to the same synchromeshed gear.
• Check for wear and renew if necessary.
• Check grooves -arrow 1- of synchro-ring -A- and inner ring for flat spots (worn grooves).
• If synchro-rings are coated, coating must not be damaged.
• If an intermediate ring -B- is installed, check the outer friction surface -arrow 2- and inner friction surface -arrow 3- of this intermediate ring for scoring, signs of abnormal wear and blue discolouration (due to overheating).
• Check cone of synchromeshed gear for scoring and signs of abnormal wear.
• Moisten synchromesh mechanism with gear oil before installing.

Before installing, clean and heat gear wheels with the inductive heater -VAS 6414- to maximum 100° C.

After assembly, check synchromeshed gears for slight play, or for freedom of movement.

• Ensure that the pressure plate does not cant: loosen and tighten 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.

Before disconnecting the battery, obtain the code for the radio having anti-theft coding.

With the ignition switched off, disconnect the battery. Refer to Electrical system; Rep. Gr. 27 ; Disconnecting and connecting battery. When reconnecting the battery, refer to the same section.

Grease all bearing points and contact surfaces. Allocate grease using the Electronic parts catalogue (ETKA).

Remove the cable guide -2- from the steering column.

The torque setting for the clutch pedal to the mounting bracket is 25 Nm. Self-locking nuts must be renewed.

The torque setting for the crash bar to the steering column mounting bracket (attachment with 2 bolts) is 10 Nm. Bolts for the crash bar must be renewed.

The torque setting for the crash bar to the steering column mounting bracket (attachment with 1 bolt) is 20 Nm. Bolts for the crash bar must be renewed.

Install in the reverse order of removal, observing that self-locking nuts must be renewed.

Insert the over-centre spring -2- in the mounting bracket from above while holding the end of the spring with assembly tool -T10178- in installation position. The receptacle -arrow- for the tip -A- of the clutch pedal must stand vertically. Insert the tip of the clutch pedal in the bearing recess of the over-centre spring. Depress the clutch pedal slightly, push the bolt through and tighten the self-locking nut to the specified torque. If some cars have damping -arrow- on the clutch pedal mounting bracket, return it to the installation position. Install the crash bar -1- and tighten the 2 bolts to the specified torque. If only one bolt is used for the crash bar, tighten bolt -2- to the specified torque. Install the trim and cover below the trim on the drive side.

The special tools required are the Release tool -T10178- and the Torque wrench -V.A.G 1331-.

Push the driver seat as far back as possible and put the steering wheel in the highest position. Remove the trim and cover below the trim on the drive side. Remove the cable guide -2- from the steering column. Remove the footwell vent -3-. The crash bar -1- in front of the clutch pedal -2- may be secured in different ways. If attached with 2 bolts, remove the crash bar -1- (2 bolts). If attached with 1 bolt, remove the crash bar -1- (1 bolt -2-). If fitted, remove damping -arrow- from the lower area of the clutch pedal mounting bracket by removing lock washers -A- for damping and pulling off the damping. Push the damping upwards in the area of the upper securing nut -1- above the clutch pedal -A- in the direction of the arrow. Unbolt the clutch pedal -1- from the mounting bracket -3- by removing nut -2- and pulling out bolt -5-. The clutch pedal remains hooked to the operating rod of the master cylinder. Swing the clutch pedal down slightly and remove the over-centre spring -4- from the mounting bracket. Release the clutch pedal from the master cylinder with pliers -T10005- and remove the clutch pedal.

Install in the reverse order of removal, observing that self-locking nuts must be renewed. Attach the retainer -2- to the master cylinder operating rod -1-. Press the retainer into the notch in the clutch pedal -3- until it can be heard to engage. Insert the over-centre spring -2- in the mounting bracket from above while holding the end of the spring with assembly tool -T10178- in installation position. The receptacle -arrow- for the tip -A- of the clutch pedal -1- must be vertical. Insert the tip -A- of the clutch pedal in the bearing recess of the over-centre spring. Depress the clutch pedal slightly, push the bolt through and tighten the self-locking nut to the specified torque. If some cars have damping -arrow- on the clutch pedal mounting bracket, return it to the installation position. Install the crash bar -1- and tighten the 2 bolts to the specified torque. If only one bolt is used, install the crash bar -1- and tighten bolt -2- to the specified torque. Install the trim and cover below the trim on the drive side.

Self-locking nuts must be renewed. Bolts for the crash bar must be renewed.

The special tools required are the Release tool -T10178- and the Torque wrench -V.A.G 1331-.

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. With the ignition switched off, disconnect the battery. Push the driver seat as far back as possible and put the steering wheel in the highest position. Remove the trim and cover below the trim on the drive side. Remove the bracket for the knee airbag together with the crash bar. Remove the cable guide -2- from the steering column. Remove the footwell vent -3-.

First check whether a coded radio is fitted. If so, obtain anti-theft code. With the ignition switched off, disconnect the battery. Push the driver seat as far back as possible and put the steering wheel in the highest position. Remove the trim and cover below the trim on the drive side. Remove the cable guide -2- from the steering column. Remove the footwell vent -3-. Remove the crash bar -1- (bolt -2-). If fitted, remove damping -arrow- from the lower area of the clutch pedal mounting bracket by removing lock washers -A- for damping and pulling off the damping. Push the damping upwards in the area of the upper securing nut -1- above the clutch pedal -A- in the direction of the arrow. Unbolt the clutch pedal -1- from the mounting bracket -3- by removing nut -2- and pulling out bolt -5-. The clutch pedal remains hooked to the operating rod of the master cylinder. Swing the clutch pedal forward slightly and remove the over-centre spring -4- from the mounting bracket.

Install in the reverse order of removal, observing that self-locking nuts must be renewed.

Insert the over-centre spring -2- in the mounting bracket from above while holding the end of the spring with assembly tool -T10178- in installation position. The receptacle -arrow- for the tip -A- of the clutch pedal must stand vertically. Insert the tip of the clutch pedal -1- in the bearing recess of the over-centre spring. Depress the clutch pedal slightly, push the bolt through and tighten the self-locking nut to the specified torque. If some cars have damping -arrow- on the clutch pedal mounting bracket, return it to the installation position. Install the crash bar -1- and tighten the 2 bolts to the specified torque. If only one bolt is used, install the crash bar -1- and tighten bolt -2- to the specified torque. Mount the cable guide -2- on the steering column. Install the foot well vent -3-. If a bracket for the knee airbag was removed, install it together with the crash bar. Install the trim and cover below the trim on the drive side. If the battery was disconnected, connect it.

Self-locking nuts must be renewed. The bolt for the crash bar must be renewed.

The special tool required is Pliers -T10005-.

The special tools required are Release tool -T10178- and Torque wrench -V.A.G 1331-.

First check whether a coded radio is fitted. If so, obtain anti-theft code. With the ignition switched off, disconnect the battery. Push the driver seat as far back as possible and put the steering wheel in the highest position. Remove the trim and cover below the trim on the drive side. Remove the bracket for the knee airbag. Remove the footwell vent -3-. Remove the cable guide -2- from the steering column. Remove the crash bar -1- (bolt -2-). If fitted, remove damping -arrow- from the lower area of the clutch pedal mounting bracket by removing lock washers -A- for damping and pulling off the damping. Push the damping upwards in the area of the upper securing nut -1- above the clutch pedal -A- in the direction of the arrow. Unbolt the clutch pedal -1- from the mounting bracket -3- by removing nut -2- and pulling out bolt -5-. The clutch pedal remains hooked to the operating rod of the master cylinder. Swing the clutch pedal forward slightly and remove the over-centre spring -4- from the mounting bracket.

Install in the reverse order of removal, observing that self-locking nuts must be renewed.

Insert the over-centre spring -2- in the mounting bracket from above while holding the end of the spring with assembly tool -T10178- in installation position. The receptacle -arrow- for the tip -A- of the clutch pedal must stand vertically. Insert the tip of the clutch pedal -1- in the bearing recess of the over-centre spring. Depress the clutch pedal slightly, push the bolt through and tighten the self-locking nut to the specified torque. If some cars have damping -arrow- on the clutch pedal mounting bracket, return it to the installation position. Install the crash bar -1- and tighten the bolt -2- to the specified torque. Mount the cable guide -2- on the steering column. Install the foot well vent -3-. Install the bracket for the knee airbag together with the crash bar. Install the trim and cover below the trim on the drive side. If the battery was disconnected, connect it.

Self-locking nuts must be renewed. The bolt for the crash bar must be renewed.

The special tool required is the Torque wrench -V.A.G 1331-.

Push the driver seat as far back as possible and put the steering wheel in the highest position. Remove the trim and cover below the trim on the drive side. Remove the cable guide -2- from the steering column. Remove the footwell vent -3-.

Install in the reverse order of removal, observing that self-locking nuts must be renewed.

Insert the over-centre spring in the mounting bracket from above. The receptacle -arrow- for the tip -A- of the clutch pedal must be vertical. Insert the tip of the clutch pedal in the bearing recess of the over-centre spring. Depress the clutch pedal slightly, push the bolt through and tighten the self-locking nut to the specified torque. If some cars have damping -arrow- on the clutch pedal mounting bracket, return it to the installation position. Install the crash bar -A-, tightening bolt -B- to the specified torque. Fit the universal joint -2- to the steering box and screw in the new bolt -1-. Carry out the basic setting for the steering angle sender -G85- with the vehicle diagnosis, testing and information system -VAS 5051-. Install the trim and cover below the trim on the drive side.

Self-locking nuts must be renewed. Bolts for the crash bar must be renewed.

The special tool required is the Release tool -T10178-.

Remove the mounting bracket. Carefully clamp the lower section of the clutch pedal in a vice having protective jaw pads. Separate the clutch pedal from the master cylinder. Press the over-centre spring from the clutch pedal -arrow 1- while swinging the mounting bracket in the direction of arrow 2-. Carefully release the tension from the over-centre spring. Swing the mounting bracket back to the starting position and remove the over-centre spring.

The clutch pedal is separated from the master cylinder. Carefully clamp the lower section of the clutch pedal in a vice having protective jaw pads. Insert the over-centre spring in the mounting bracket.

The receptacle -arrow- for the tip -A- of the clutch pedal must stand vertically. Apply the release tool -T10178- to the middle of the over-centre spring and swing up the mounting bracket. Compress the over-centre spring -arrow 1-. At the same time, move the mounting bracket downwards -arrow 2- until the over-centre spring can be pressed onto the locating lug -A- of the clutch pedal. WARNING: If the over-centre spring is improperly installed, it will jump uncontrolled out of the mounting bracket. Place a cloth over the over-centre spring. Check the operation of the over-centre spring by moving the mounting bracket up and down a few times. Connect the clutch pedal to the master cylinder. Install the mounting bracket.

The special tool required is Pliers -T10005-.

Push the damping upwards in the area of the upper securing nut -1- above the clutch pedal -A- in the direction of the arrow. Unbolt the clutch pedal -1- from the mounting bracket -3- by removing nut -2- and pulling out bolt -5-. The clutch pedal remains hooked to the operating rod of the master cylinder. Swing the clutch pedal forward slightly and remove the over-centre spring -4- from the mounting bracket. Release the clutch pedal from the master cylinder with pliers -T10005- and remove the clutch pedal.

Install in the reverse order of removal, observing that self-locking nuts must be renewed.

Push the damping upwards in the area of the upper securing nut -1- above the clutch pedal -A- in the direction of the arrow. Attach the retainer -2- to the master cylinder operating rod -1-. Press the retainer into the notch in the clutch pedal -3- until it can be heard to engage. Insert the over-centre spring -2- in the mounting bracket from above while holding the end of the spring with assembly tool -T10178- in installation position. The receptacle -arrow- for the tip -A- of the clutch pedal -1- must be vertical. Insert the tip -A- of the clutch pedal in the bearing recess of the over-centre spring. Depress the clutch pedal slightly, push the bolt through and tighten the self-locking nut to the specified torque. If some cars have damping -arrow- on the clutch pedal mounting bracket, return it to the installation position. Install the crash bar -1- and tighten the 2 bolts to the specified torque. If only one bolt is used, install the crash bar -1- and tighten bolt -2- to the specified torque. Install the trim and cover below the trim on the drive side.

Self-locking nuts must be renewed. Bolts for the crash bar must be renewed.

The special tools required are Pliers -T10005-, Release tool -T10178-, and Torque wrench -V.A.G 1331-.

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. With the ignition switched off, disconnect the battery. Push the driver seat as far back as possible and put the steering wheel in the highest position. Remove the trim and cover below the trim on the drive side. Remove the bracket for the knee airbag. Remove the cable guide -2- from the steering column. Remove the footwell vent -3-. Remove the crash bar -1- (bolt -2-). If fitted, remove damping -arrow- from the lower area of the clutch pedal mounting bracket by removing lock washers -A- for damping and pulling off the damping. Push the damping upwards in the area of the upper securing nut -1- above the clutch pedal -A- in the direction of the arrow. Unbolt the clutch pedal -1- from the mounting bracket -3- by removing nut -2- and pulling out bolt -5-. The clutch pedal remains hooked to the operating rod of the master cylinder. Swing the clutch pedal forward slightly and remove the over-centre spring -4- from the mounting bracket. Release the clutch pedal from the master cylinder with pliers -T10005- and remove the clutch pedal.

Install in the reverse order of removal, observing that self-locking nuts must be renewed.

Push the damping upwards in the area of the upper securing nut -1- above the clutch pedal -A- in the direction of the arrow. Attach the retainer -2- to the master cylinder operating rod -1-. Press the retainer into the notch in the clutch pedal -3- until it can be heard to engage. Insert the over-centre spring -2- in the mounting bracket from above while holding the end of the spring with assembly tool -T10178- in installation position. The receptacle -arrow- for the tip -A- of the clutch pedal must stand vertically. Insert the tip -A- of the clutch pedal in the bearing recess of the over-centre spring. Depress the clutch pedal slightly, push the bolt through and tighten the self-locking nut to the specified torque. If some cars have damping -arrow- on the clutch pedal mounting bracket, return it to the installation position. Install the crash bar -1- and tighten bolt -2- to the specified torque. Mount the cable guide -2- on the steering column. Install the foot well vent -3-. If a bracket for the knee airbag was removed, install it together with the crash bar. Install the trim and cover below the trim on the drive side. If the battery was disconnected, connect it.

The special tools required are Pliers -T10005-, Release tool -T10178-, and Torque wrench -V.A.G 1331-.

First check whether a coded radio is fitted. If so, obtain anti-theft code. With the ignition switched off, disconnect the battery. Push the driver seat as far back as possible and put the steering wheel in the highest position. Remove the trim and cover below the trim on the drive side. Remove the bracket for the knee airbag. Remove the cable guide -2- from the steering column. Remove the footwell vent -3-. Remove the crash bar -1- (bolt -2-). If fitted, remove damping -arrow- from the lower area of the clutch pedal mounting bracket by removing lock washers -A- for damping and pulling off the damping. Push the damping upwards in the area of the upper securing nut -1- above the clutch pedal -A- in the direction of the arrow. Unbolt the clutch pedal -1- from the mounting bracket -3- by removing nut -2- and pulling out bolt -5-. The clutch pedal remains hooked to the operating rod of the master cylinder. Swing the clutch pedal forward slightly and remove the over-centre spring -4- from the mounting bracket. Release the clutch pedal from the master cylinder with pliers -T10005- and remove the clutch pedal.

Install in the reverse order of removal, observing that self-locking nuts must be renewed.

Insert the over-centre spring -2- in the mounting bracket from above while holding the end of the spring with assembly tool -T10178- in installation position. The receptacle -arrow- for the tip -A- of the clutch pedal must stand vertically. Insert the tip of the clutch pedal -1- in the bearing recess of the over-centre spring. Depress the clutch pedal slightly, push the bolt through and tighten the self-locking nut to the specified torque. If some cars have damping -arrow- on the clutch pedal mounting bracket, return it to the installation position. Install the crash bar -1- and tighten bolt -2- to the specified torque. Mount the cable guide -2- on the steering column. Install the foot well vent -3-. If a bracket for the knee airbag was removed, install it together with the crash bar. Install the trim and cover below the trim on the drive side. If the battery was disconnected, connect it.

Self-locking nuts must be renewed. The bolt for the crash bar must be renewed.

The special tools required are Pliers -T10005- and Torque wrench -V.A.G 1331-.

Push the driver seat as far back as possible and put the steering wheel in the highest position. Remove the trim and cover below the trim on the drive side. Remove the cable guide -2- from the steering column. Remove the footwell vent -3-.

Install in the reverse order of removal, observing that self-locking nuts must be renewed.

Push the damping upwards in the area of the upper securing nut -1- above the clutch pedal -A- in the direction of the arrow. Unbolt the clutch pedal -1- from the mounting bracket -3- by removing nut -2- and pulling out bolt -5-. The clutch pedal remains hooked to the operating rod of the master cylinder. Swing the clutch pedal forward slightly and remove the over-centre spring -4- from the mounting bracket. Fit the universal joint -2- to the steering box and screw in the new bolt -1-. Carry out the basic setting for the steering angle sender -G85- with the vehicle diagnosis, testing and information system -VAS 5051-. Install the trim and cover below the trim on the drive side.

Self-locking nuts must be renewed. Bolts for the crash bar must be renewed.

The special tools required are Pliers -T10005- and Release tool -T10178-.

Remove the mounting bracket. Carefully clamp the mounting bracket in a vice having protective jaw pads. Unbolt the clutch pedal -1- from the mounting bracket -3- by removing nut -2- and pulling out bolt -5-. Swing the clutch pedal forward slightly and remove the over-centre spring -4- from the mounting bracket. Release the clutch pedal from the master cylinder with pliers -T10005- and remove the clutch pedal.

Install in the reverse order of removal, observing that self-locking nuts must be renewed.

Attach the retainer -2- to the master cylinder operating rod -1-. Press the retainer into the notch in the clutch pedal -3- until it can be heard to engage. Insert the over-centre spring -2- in the mounting bracket from above while holding the end of the spring with assembly tool -T10178- in installation position. The receptacle -arrow- for the tip -A- of the clutch pedal must be vertical. Insert the tip of the clutch pedal -1- in the bearing recess of the over-centre spring. Depress the clutch pedal slightly, push the bolt through and tighten the self-locking nut. Install the mounting bracket.

Self-locking nuts must be renewed.

The special tool required is Pliers -T10005-.

Remove the mounting bracket for the VOLKSWAGEN GOLF 2004. Release the retainer for the master cylinder operating rod using pliers -T10005-. Insert spacer -A- between the clutch pedal and stop and press the clutch pedal to the spacer. The length of the spacer should be about 40 mm (e.g., 1/2 socket). Release the securing bar -B- and pull the master cylinder out of the mounting bracket -arrow 1- and -arrow 2-.

Move the clutch pedal to the rest position at stop. Attach retainer -2- to the master cylinder operating rod -1-.

Insert the spacer -A- between the clutch pedal and stop and press the clutch pedal to the spacer. The length of the spacer should be about 40 mm (e.g., 1/2 socket). Engage the master cylinder in the mounting bracket -arrow 1- and -arrow 2-. Press the master cylinder operating rod -1- in the direction of the arrow until retainer -2- engages audibly in the clutch pedal. Install the mounting bracket for the VOLKSWAGEN GOLF 2004.

The special tool required is Hose clamps -3094-.

First check whether a coded radio is fitted. If so, obtain anti-theft code. With the ignition switched off, disconnect the battery. Remove the complete air filter housing if it is near the battery. Remove the battery and battery tray. In RHD vehicles with a particle filter, remove the shielding -A- from the particle filter. An insulation mat may be installed with some engines. Remove the heat shield from the pipe/hose line -arrows-. Clamp off the supply hose to the master cylinder using hose clamp -3094-. Pull the supply hose -3- off the master cylinder. For disconnecting, close it with the sealing tool -T10249/1-. Release the securing clip -2- using a screwdriver or pointed object and pull the pipe/hose line or plastic line -3- off the master cylinder. Unclip the clutch position sender -G476- from the master cylinder -arrow- and remove it with the electrical connector attached -4-. Remove the trim and cover below the trim on the drive side. Remove the bracket for the knee airbag. Remove the cable guide -2- from the steering column. Remove the footwell vent -3-. Remove the crash bar -1- (bolt -2-). If fitted, remove damping -arrow- from the lower area of the clutch pedal mounting bracket by removing lock washers -A- for damping and pulling off the damping. Push the damping upwards in the area of the upper securing nut -1- above the clutch pedal -A- in the direction of the arrow. Remove the securing nuts -1- and -2-. The upper securing nut -1- is accessible between the relay carrier and the steering column trim. Remove the mounting bracket -3-.

Install in the reverse order of removal, observing that self-locking nuts and hose clips must be renewed. Allocate all components according to the Electronic parts catalogue “ETKA”.

Push the damping upwards in the area of the upper securing nut -1- above the clutch pedal -A- in the direction of the arrow. Remove the securing nuts -1- and -2-. The upper securing nut -1- is accessible between the relay carrier and the steering column trim. Remove the mounting bracket -3-. Install the mounting bracket. Install the crash bar -1- and tighten the bolt -2- to the specified torque. Fit the cable guide -2- onto the steering column. Install the foot well vent -3-. If a bracket for the knee airbag was removed, install it together with the crash bar. Install the trim and cover below the trim on the drive side. Push the pipe/hose line or plastic line -1- with seal -2- onto the connection of the master cylinder -4- until the securing clip -3- engages audibly. Test the line by tugging on it. After removing the hose clamp -3094-, return the supply hose to its original position, if necessary. Bleed the clutch system. Install the battery tray, battery cover and battery. If the complete air filter housing was removed, install it. Clip the clutch position sender -G476- into the master cylinder with the electrical connector -3- attached -arrow-. Clip in the securing clip -1-. Test the line by tugging on it. Attach the support -B- to the gearbox. Press the pipe/hose line -A- into the retainer -B- on the gearbox. Install the cable support bracket on the gearbox and tighten the bolts -arrows- to the specified torque. Install the gearbox selector lever -A-. Tighten the hexagon nut -arrow 4- to the specified torque. Spread a small amount of grease on the pin of the gearbox selector lever -A-. Connect the gear selector cable to the gearbox selector lever -arrow 1-. Install the relay lever -B- and secure with the securing clip -arrow 3-. Spread a small amount of grease on the pin of the relay lever -B-. Connect the gate selector cable to the relay lever -arrow 2-. Adjust the selector mechanism. Install the front wall of the plenum chamber.

The special tool required is Hose clamps to 25 mm -3094-.

First check whether a coded radio is fitted. If so, obtain anti-theft code. With the ignition switched off, disconnect the battery. Remove the complete air filter housing if it is near the battery. Remove the battery and battery tray. Clamp off the supply hose to the master cylinder using hose clamp -3094-. If necessary, loosen the spring-type clip -3- with assembly tool -VAS 5024- and pull the supply hose off the master cylinder. For disconnecting, close it with the sealing tool -T10249/1-. Release the securing clip -2- using a screwdriver or a pointed object and pull the pipe/hose line or plastic line -3- off the master cylinder. Unclip the clutch position sender -G476- from the master cylinder -arrow- and remove with the electrical connector attached -4-. Remove the trim and cover below the trim on the drive side. If present, remove the retaining clip -1- and swing the front parking aid warning buzzer -H22- -2- in the direction of the arrow. Pull off damping if the lower securing bolt for the mounting bracket is covered, -arrows-. Push the damping upwards in the area of the upper securing nut -1- above the clutch pedal -A- in the direction of the arrow. Remove the securing nuts -1- and -2-. The upper securing nut -1- is accessible between the relay carrier and the steering column trim. Remove the mounting bracket -3-.

Install in the reverse order of removal, observing that self-locking nuts must be renewed. Hose clips must be renewed. All components must be allocated according to the Electronic parts catalogue “ETKA”.

If present, install the retaining clip for the front parking aid warning buzzer -H22-. Install the crash bar -1- and tighten bolt -2- to the specified torque. Install the lower steering column trim. Install the driver side footwell cover. Install the trim and cover below the trim on the drive side. Attach the support -B- to the gearbox. Press the pipe/hose line -A- into the retainer -B- on the gearbox. Install the cable support bracket on the gearbox and tighten the bolts -arrows- to the specified torque. Push the pipe/hose line -1- with seal -2- onto the connection of the master cylinder -4- until the securing clip -3- engages audibly. Test the line by tugging on it. After removing the hose clamp -3094-, return the supply hose to its original position, if necessary. Bleed the clutch system. Install the battery tray, battery cover and battery. If the complete air filter housing was removed, install it.

The special tools required are Hose clamps to 25 mm -3094-, Sealing tool -T10249-, Hook -3438-, and Torque wrench -V.A.G 1331-.

Vehicles with knee airbag: First check whether a coded radio is fitted. If so, obtain anti-theft code. With the ignition switched off, disconnect the battery. Vehicles with turbo diesel engine and particle filter: Remove shielding -A- from the particle filter. Continuation for all: A heat shield may be installed in conjunction with some engines. Remove the heat shield from the pipe/hose line -arrows-. During the following work, ensure that no brake fluid lands on the longitudinal member or gearbox. If this does happen, clean the affected areas thoroughly. Place a lint-free cloth under the master cylinder. Clamp off the supply hose to the master cylinder using hose clamp -3094-. Pull supply hose -3- off the master cylinder. For disconnecting, seal the supply hose with sealing tool -T10249/1-. Release securing clip -1- with a screwdriver or pointed object and pull the pipe/hose line -2- off the master cylinder. Unclip the clutch position sender -G476- from the master cylinder -arrow- and remove with the electrical connector attached -3-. When performing work in the footwell, put cloths on the carpet to protect it from possible brake fluid spills. Remove the trim and cover below the trim on the drive side. Golf: Remove the bracket for the knee airbag. Continuation for all: Remove the cable guide -2- from the steering column. Remove the footwell vent -3-. Remove the crash bar -1- (bolt -2-). If fitted, remove damping -arrow- from the lower area of the clutch pedal mounting bracket by removing lock washers -A- for damping and pulling off the damping. Push the damping upwards in the area of the upper securing nut -1- above the clutch pedal -A- in the direction of the arrow. Remove the securing nuts -1- and -2-. The upper securing nut -1- is accessible between the relay carrier and the steering column trim. Remove the mounting bracket -3-.

Install in the reverse order of removal, observing that self-locking nuts must be renewed.

Push the damping upwards in the area of the upper securing nut -1- above the clutch pedal -A- in the direction of the arrow. Remove the securing nuts -1- and -2-. The upper securing nut -1- is accessible between the relay carrier and the steering column trim. Remove the mounting bracket -3-. Install the mounting bracket. Install the crash bar -1- and tighten bolt -2- to the specified torque. Fit the cable guide -2- onto the steering column. Install the foot well vent -3-. If a bracket for the knee airbag was removed, install it together with the crash bar. Install the trim and cover below the trim on the drive side. Press the pipe/hose line -2- with seal into the connection of the master cylinder -4- until the securing clip -3- engages audibly. Test the line by tugging on it. After removing the hose clamp -3094-, return the supply hose to its original position, if necessary. Bleed the clutch system. Install the battery tray and battery. If the complete air filter housing was removed, install it. Reconnect the battery and perform the work required after connecting the battery.

The special tools required are Hose clamps -3094-, Torque wrench -V.A.G 1331-, Spring-type clip pliers -VAS 5024 A-, and Hose clamp -3094- (Sealing tool -T10249- is also mentioned).

First check whether a coded radio is fitted. If so, obtain anti-theft code. With the ignition switched off, disconnect the battery. Remove the complete air filter housing if it is near the battery. Remove the battery, battery cover and battery tray. During the following work, ensure that no brake fluid lands on the longitudinal member or gearbox. If this does happen, clean the affected areas thoroughly. Place a lint-free cloth under the master cylinder. Clamp off the supply hose to the master cylinder using hose clamp -3094-. If necessary, loosen the spring clip -3- using assembly tool -VAS 5024- and pull the supply hose off the master cylinder. For disconnecting, close it with the sealing tool -T10249/1-. Pull off the supply hose. Pull clip -2- for the pipe/hose line out of the master cylinder to stop. Pull the pipe/hose line -1- out from the master cylinder and seal the hose. Unclip the clutch position sender -G476- from the master cylinder -arrow- and remove with the electrical connector attached -4-. When performing work in the footwell, put cloths on the carpet to protect it from possible brake fluid spills. Remove the trim and cover below the trim on the drive side. Carefully cut through cable tie -1-. Remove the cable guide -2- from the steering column. Remove the footwell vent -3-. Remove the crash bar -1- by removing bolt -2-. If fitted, remove damping -arrow- from the lower area of the clutch pedal mounting bracket by removing lock washers -A- for damping and pulling off the damping. Push the damping upwards in the area of the upper securing nut -1- above the clutch pedal -A- in the direction of the arrow. Remove the securing nuts -1- and -2-. The upper securing nut -1- is accessible between the relay carrier and the steering column trim. Remove the mounting bracket -3-.

Install in the reverse order of removal, observing that self-locking nuts must be renewed and hose clips must be renewed. Allocate all components according to the Electronic parts catalogue “ETKA”.

If present, install the retaining clip for the front parking aid warning buzzer -H22-. Install the crash bar -1- and tighten bolt -2- to the specified torque. Install the lower steering column trim. Install the driver side footwell cover. Push the pipe/hose line -1- with seal -2- onto the connection of the master cylinder -4- until the securing clip -3- engages audibly. Test the line by tugging on it. After removing the hose clamp -3094-, return the supply hose to its original position, if necessary. Bleed the clutch system. Install the battery tray and battery. If the complete air filter housing was removed, install it. Install the bracket -A- on the gearbox using new hexagonal bolts -arrows- and tighten to the specified torque. Align the engine and gearbox in the installation position using both spindles of the support bracket -10 – 222 A-. Install the new bolts -arrows- for the left assembly mounting in the gearbox mounting and tighten to the specified torque. WARNING: Do not remove the support bracket -10 – 222 A- until the bolts securing the left and right assembly mountings have been tightened to the specified torque. Install the engine and gearbox mounting free of tension. Attach the drive shafts to the gearbox. Install the drive shaft heat shield, if present -arrows-. Install the pendulum support. Assemble the exhaust system and attach the exhaust system bracket to the subframe.

The special tool required is Release tool -T10178-.

Remove the mounting bracket. Carefully clamp the mounting bracket in a vice having protective jaw pads. Separate the clutch pedal from the master cylinder. Press the over-centre spring from the clutch pedal -arrow 1- while swinging the mounting bracket in the direction of arrow 2-. Carefully release the tension from the over-centre spring. Swing the mounting bracket back to the starting position and remove the over-centre spring.

Install in the reverse order of removal.

Carefully clamp the lower section of the clutch pedal in a vice having protective jaw pads. Insert the over-centre spring in the mounting bracket. The receptacle -arrow- for the tip -A- of the clutch pedal must stand vertically. Apply the release tool -T10178- to the middle of the over-centre spring and swing up the mounting bracket. Compress the over-centre spring -arrow 1-. At the same time, move the mounting bracket downwards -arrow 2- until the over-centre spring can be pressed onto the locating lug -A- of the clutch pedal. WARNING: If the over-centre spring is improperly installed, it will jump uncontrolled out of the mounting bracket. Place a cloth over the over-centre spring. Check the operation of the over-centre spring by moving the mounting bracket up and down a few times. Connect the clutch pedal to the master cylinder. Install the mounting bracket.

The capacity of the manual gearbox (gearbox completely dismantled) for identification code FNE is 1.9 l, and the capacity of the partially dismantled gearbox is 1.7 l.

The capacity of the manual gearbox (gearbox completely dismantled) for identification code GQQ is 1.9 l, and the capacity of the partially dismantled gearbox is 1.7 l.

The capacity of the manual gearbox (gearbox completely dismantled) for identification code HGR is 1.9 l, and the capacity of the partially dismantled gearbox is 1.7 l.

The capacity of the manual gearbox (gearbox completely dismantled) for identification code HDR is 1.9 l, and the capacity of the partially dismantled gearbox is 1.7 l.

The capacity of the manual gearbox (gearbox completely dismantled) for identification code GTB is 1.9 l, and the capacity of the partially dismantled gearbox is 1.7 l.

The capacity of the manual gearbox (gearbox completely dismantled) for identification code JCT is 1.9 l, and the capacity of the partially dismantled gearbox is 1.7 l.

The capacity of the manual gearbox (gearbox completely dismantled) for identification code JCR is 1.9 l, and the capacity of the partially dismantled gearbox is 1.7 l.

The capacity of the manual gearbox (gearbox completely dismantled) for identification code JCU is 1.9 l, and the capacity of the partially dismantled gearbox is 1.7 l.

The capacity of the manual gearbox (gearbox completely dismantled) for identification code JCV is 1.9 l, and the capacity of the partially dismantled gearbox is 1.7 l.

The capacity of the manual gearbox (gearbox completely dismantled) for identification code FNC is 1.9 l, and the capacity of the partially dismantled gearbox is 1.7 l.

The capacity of the manual gearbox (gearbox completely dismantled) for identification code HJK is 1.9 l, and the capacity of the partially dismantled gearbox is 1.7 l.

The capacity of the manual gearbox (gearbox completely dismantled) for identification code KCL is 1.9 l, and the capacity of the partially dismantled gearbox is 1.7 l.

The capacity of the manual gearbox (gearbox completely dismantled) for identification code KBL is 1.9 l, and the capacity of the partially dismantled gearbox is 1.7 l.

The capacity of the manual gearbox (gearbox completely dismantled) for identification code KCD is 1.9 l, and the capacity of the partially dismantled gearbox is 1.7 l.

The capacity of the manual gearbox (gearbox completely dismantled) for identification code JQP is 1.9 l, and the capacity of the partially dismantled gearbox is 1.7 l.

The capacity of the manual gearbox (gearbox completely dismantled) for identification code KPF is 1.9 l, and the capacity of the partially dismantled gearbox is 1.7 l.

The capacity of the manual gearbox (gearbox completely dismantled) for identification code LHW is 1.9 l, and the capacity of the partially dismantled gearbox is 1.7 l.

The capacity of the manual gearbox (gearbox completely dismantled) for identification code KQM is 1.9 l, and the capacity of the partially dismantled gearbox is 1.7 l.

The capacity of the manual gearbox (gearbox completely dismantled) for identification code LLL is 1.9 l, and the capacity of the partially dismantled gearbox is 1.7 l.

The capacity of the manual gearbox (gearbox completely dismantled) for identification code LHW is 1.9 l, and the capacity of the partially dismantled gearbox is 1.7 l.

The capacity of the manual gearbox (gearbox completely dismantled) for identification code LUB is 1.9 l, and the capacity of the partially dismantled gearbox is 1.7 l.

The capacity of the manual gearbox (gearbox completely dismantled) for identification code MDZ is 1.9 l, and the capacity of the partially dismantled gearbox is 1.7 l.

The capacity of the manual gearbox (gearbox completely dismantled) for identification code LEA is 1.9 l, and the capacity of the partially dismantled gearbox is 1.7 l.

The capacity of the manual gearbox (gearbox completely dismantled) for identification code HNV is 1.9 l, and the capacity of the partially dismantled gearbox is 1.7 l.

The capacity of the manual gearbox (gearbox completely dismantled) for identification code JCX is 1.9 l, and the capacity of the partially dismantled gearbox is 1.7 l.

The capacity of the manual gearbox (gearbox completely dismantled) for identification code KBL is 1.9 l, and the capacity of the partially dismantled gearbox is 1.7 l.

The capacity of the manual gearbox (gearbox completely dismantled) for identification code KQM is 1.9 l, and the capacity of the partially dismantled gearbox is 1.7 l.

The capacity of the manual gearbox (gearbox completely dismantled) for identification code LHW is 1.9 l, and the capacity of the partially dismantled gearbox is 1.7 l.

The capacity of the manual gearbox (gearbox completely dismantled) for identification code LUB is 1.9 l, and the capacity of the partially dismantled gearbox is 1.7 l.

The capacity of the manual gearbox (gearbox completely dismantled) for identification code HNV is 1.9 l, and the capacity of the partially dismantled gearbox is 1.7 l.

The capacity of the manual gearbox (gearbox completely dismantled) for identification code JCX is 1.9 l, and the capacity of the partially dismantled gearbox is 1.7 l.

The capacity of the manual gearbox (gearbox completely dismantled) for identification code JQP is 1.9 l, and the capacity of the partially dismantled gearbox is 1.7 l.

The capacity of the manual gearbox (gearbox completely dismantled) for identification code JVF is 1.9 l, and the capacity of the partially dismantled gearbox is 1.7 l.

The capacity of the manual gearbox (gearbox completely dismantled) for identification code KBM is 1.9 l, and the capacity of the partially dismantled gearbox is 1.7 l.

The capacity of the manual gearbox (gearbox completely dismantled) for identification code KJF is 1.9 l, and the capacity of the partially dismantled gearbox is 1.7 l.

The capacity of the manual gearbox (gearbox completely dismantled) for identification code KBL is 1.9 l, and the capacity of the partially dismantled gearbox is 1.7 l.

The capacity of the manual gearbox (gearbox completely dismantled) for identification code LHP is 1.9 l, and the capacity of the partially dismantled gearbox is 1.7 l.

The capacity of the manual gearbox (gearbox completely dismantled) for identification code MDM is 1.9 l, and the capacity of the partially dismantled gearbox is 1.7 l.

The components are: 1 – Engine, 2 – Clutch, 3 – Manual gearbox, 4 – Input shaft, 5 – Output shaft, and 6 – Differential. The arrows indicate the direction of travel.

The gears are: I – 1st gear, II – 2nd gear, III – 3rd gear, IV – 4th gear, V – 5th gear, R – Reverse gear, and A – Final drive. The arrows indicate the direction of travel.

The overall gear ratio is calculated as i = Z2 : Z1, where iG (Gear ratio) = ZG2 : ZG1 and iA (Final drive ratio) = ZA2 : ZA1. The Overall ratio is iG x iA. For example, using 5th gear where ZG1 = 39, ZA1 = 18, ZG2 = 29, and ZA2 = 61: iG = 29 : 39 = 0.744; iA = 61 : 18 = 3.389; Overall ratio = 0.744 x 3.389 = 2.521. Z1 is the number of teeth on the driving gear, and Z2 is the number of teeth on the driven gear.

To ensure flawless and successful gearbox repairs, the greatest care and cleanliness as well as the use of good and proper tools are essential. Basic safety rules also apply during repair work. A number of instructions generally applicable to the various repair procedures are summarized under the topic “components” which applies to this manual.

The codes and production date are located on the manual gearbox 0A4, indicated by arrow 1. The gearbox code is also included on the vehicle data stickers.

The format for the codes and production date is: Identification code | Day | Month | Year (2003) of manufacture. For example: FNE 10 11 3.

The overview covers:

I – Removing and installing gear knob and cover (see page 118).

II – Repairing gear lever and selector housing (through 10.06) (see page 123).

II – Repairing gear lever and selector housing (from 11.06) (see page 125).

III – Assembly overview – removing and installing selector cables (see page 131).

Removing and installing selector mechanism (see page 136).

Adjusting selector mechanism (see page 139).

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

The dimension “a” for the support pin for the gear selector cable end-piece from 06.06 is 8.5 mm. Through 05.06, the dimension was 10 mm.

Remove the selector mechanism to renew selector cables, refer to page 136.

Instructions for adjusting the selector mechanism can be found on page 139.

The procedure for removing and installing the gearbox on the VOLKSWAGEN GOLF 2004 is on page 144 for removal and page 150 for installation.

The oil level in the gearbox can only be checked by completely draining the gear oil and then refilling. The oil capacity for a completely dismantled gearbox is 1.9 l, and for a partially dismantled gearbox is 1.7 l.

To drain gear oil, the selector shaft must be locked in place. Press the selector shaft down in the direction of arrow 1. While pressing down the selector shaft, turn the angled rod -A- upwards in the direction of arrow 2 and at the same time press it in until it engages in the selector shaft. Drain the gear oil by removing the oil drain plug -arrow 1- and then the pivot pin -arrow 2-. Install the pivot pin -arrow 2- with a new O-ring. Screw in the oil drain plug -arrow 1-. Now turn the angled rod -A- back to the original position so that the selector shaft can move again.

To fill with gear oil, top up oil in the container to 1.7 litres. Remove the reversing light switch -F4- -arrow-. Connect a hose (approx. 600 mm long, external diameter 10 mm) to a commercially available funnel. Insert the hose in the fitting hole for the reversing light switch (2nd mechanic) and fill the gear oil. Install the reversing light switch -F4- -arrow-. Check the operation of the selector mechanism. Install the complete air filter housing. Install the noise insulation.

The main sections for dismantling and assembling the gearbox are:

I – Removing and installing cover for gearbox housing and 5th gear (see page 225).

II – Removing and installing gearbox housing and selector mechanism (see page 226).

III – Removing and installing input shaft, output shaft, differential and selector forks (see page 227).

Assembly sequence – removing and installing cover for gearbox housing and 5th gear (see page 228).

Assembly sequence – Dismantling and assembling gearbox completely (see page 234).

Removing and installing the gearbox housing and selector mechanism is detailed on page 226. Repairing the gearbox housing and clutch housing is on page 248.

Adjustment is necessary if the following components are renewed:

The oil level can only be checked by completely draining the gear oil and then refilling.

For a completely dismantled gearbox, oil capacity must be checked before installation. For a partially dismantled gearbox, oil capacity must be checked after installation (see page 220).

All threaded holes into which self-locking bolts are to be screwed must be cleaned of residual locking fluid carefully with a thread tap. Always renew self-locking bolts and nuts. Check whether dowel sleeves for aligning engine and gearbox are fitted in cylinder block and install if necessary. If dowel sleeves are not fitted, difficulties shifting gears, clutch problems and possible noises from the gearbox (rattling of gears which are not engaged) could occur. Ensure that the intermediate plate is correctly seated on the engine. Clean input shaft splines and apply a thin coat of grease for clutch plate splines -G 000 100-. The clutch plate must slide easily to and fro on the input shaft.

The special tools required are: Press tool -VW 407-, Thrust pad -VW 447 H-, Press tool -VW 412-, Tube -VW 422-, Thrust plate -VW 401-, Thrust plate -VW 402-, and Press tool -VW 408 A-.

If components are renewed that affect the input shaft position, readjustment is necessary. First, press the tapered roller bearing outer race into the gearbox housing to stop. Install the input shaft in the clutch housing and set the gearbox housing in place. Tighten the hexagon head bolts to 25 Nm and then turn 90° further. Fit the measuring appliance and dial gauge in the clutch housing. Before taking any measurements, rotate the input shaft to allow the bearings to settle. Set the dial gauge to “0” with 1 mm preload. Press the input shaft in the direction of the arrow. Read and note the play on the dial gauge (example: 1.21 mm). Determine the thickness of the shim using the table based on the bearing play. For example, if the bearing play (measured value) is 1.21 mm, the thickness of the shim is 1.175 mm. The shim thickness is determined by adding the measured value to 0.65 mm (the initially installed shim) and finding the corresponding shim thickness in the table. Remove the input shaft and press the outer race of the tapered roller bearing out of the gearbox housing using the thrust plate -VW 447 i-. Insert the shims of the determined thickness, thickest shim first. Press the outer race of the tapered roller bearing together with the shim into the gearbox housing using the thrust pad -VW 510-. Set the gearbox housing in place and tighten the hexagon head bolts to 25 Nm and then turn 90° further. Set up the measuring appliance and dial gauge. Rotate the input shaft so that the tapered roller bearings settle. Press the input shaft in the direction of the arrow. The bearing play should be min. 0.01 … max. 0.09 mm. If the bearing play cannot be measured, but input shaft play is perceptible and the input shaft turns freely, the adjustment is acceptable.

If the size of shim required is larger than those listed in the table, insert two shims totalling the correct figure.

The specified bearing preload will be attained if the determined measured value is added to the 0.65 mm shim already installed. The adjustment overview is on page 302. Prerequisites: Sealing surfaces of clutch and gearbox housings must be free of sealant. Press the outer ring of the small tapered roller bearing to stop with 0.65 mm shim into the clutch housing. Insert the output shaft and tighten the nuts for the bearing support to 25 Nm, then turn 90° further. Turn the output shaft 20 to 30 times in one direction, ensuring the rollers of the tapered roller bearing settle in one direction (this may take 20 to 30 turns). Set up the dial gauge (3 mm measuring range) and set to “0” with 1 mm preload. Move the output shaft up and down. Read and note the play indicated on the dial gauge (example: 1.21 mm). Determine the thickness of the shim using the table based on the bearing play calculation: Bearing play = (0.65 mm + determined measured value). For example, if the bearing play is 0.740 mm, the shim thickness according to the table is 0.900 mm. Allocate shims according to the Electronic parts catalogue “ETKA”. Remove the output shaft and pull out the small tapered roller bearing outer race. Insert shims of the determined thickness, thickest shim first. If the required shim size is larger than listed, insert two shims totalling the correct figure. Press the outer race of the tapered roller bearing together with the calculated shim (0.70 mm in example) into the gearbox housing using the thrust pad -VW 510- and install the output shaft. Tighten the bearing support nuts in the clutch housing to 25 Nm and then turn 90° further.

It is necessary to readjust the differential when the following components are renewed: Gearbox housing, Clutch housing, Differential cage, or the tapered roller bearing of the differential. The adjustment overview is on page 302.

The procedure is: Press the outer race of the tapered roller bearing without shim into the gearbox housing using thrust piece -30 – 205-. Fit the differential into the clutch housing. Set the gearbox housing in place and tighten 5 bolts to 25 Nm. Attach the dial gauge and set to “0” with 1 mm preload. Move the differential up and down. Read and note the play indicated on the dial gauge (Example: 0.70 mm). Determine the thickness of the shim using the table based on the bearing play calculation: Bearing play = (0.65 mm + determined measured value). For example, if the bearing play is 0.70 mm, the shim thickness according to the table is 0.95 mm. Allocate shims according to the Electronic parts catalogue “ETKA”. Press the outer race of the tapered roller bearing together with the shim (1.175 mm in example) into the gearbox housing using the thrust pad -VW 510-.

The adjustment is acceptable if the bearing play is perceptible and the input shaft turns freely. The procedure involves pressing the outer race of the tapered roller bearing into the clutch housing using thrust plate -30 – 205-. Fit the differential into the clutch housing. Set the gearbox housing in place and tighten 5 bolts to 25 Nm. Attach the dial gauge and set to “0” with 1 mm preload. Move the differential up and down. Read and note the play indicated on the dial gauge (Example: 0.70 mm). Determine the thickness of the shim using the table based on the bearing play calculation. Press in the outer race of the tapered roller bearing again and bolt the gearbox housing tight.

The special tools required are: Thrust piece -VW 454-, Thrust pad -VW 447 H-, Press tool -VW 411-, Centring mandrel -12 – 551-, Thrust plate -VW 401-, Press tool -VW 408 A-, Internal puller -1-Kukko 21/2-, and Counterhold -4-Kukko 22/1-.

After dismantling, always renew the needle bearing in the clutch housing and reverse shaft support.

Check the hole for the spring pin in the differential cage. The hole in the differential cage was modified for the longer spring pin.