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What vehicles have the VOLKSWAGEN GOLF VARIANT 2007 5-speed manual gearbox 0A4 installed in conjunction with a 4-cylinder engine according to the VOLKSWAGEN GOLF VARIANT 2007 service manual?
The 5-speed manual gearbox 0A4 is installed in the Jetta 2005, Bora 2006, VOLKSWAGEN GOLF VARIANT 2007, Bora Sportwagen 2008, Golf Variant 2010 and Jetta 2011 in conjunction with a 4-cylinder engine.
What are the general repair notes for the VOLKSWAGEN GOLF VARIANT 2007 5-speed manual gearbox 0A4?
To ensure flawless and successful gearbox repairs, the greatest care and cleanliness as well as the use of good and proper tools are essential. Of course, the basic rules for safety also apply during repair work.
A number of instructions generally applicable to the various repair procedures – which were previously repeated a number of times at various places in the workshop manual are summarised under the topic “components”. They apply to this workshop manual.
What are the general notes regarding the gearbox components for the VOLKSWAGEN GOLF VARIANT 2007 5-speed manual gearbox 0A4?
When installing the manual gearbox, ensure that the dowel sleeves between the engine and gearbox are correctly seated.
When installing mounting brackets or waxed components, clean the contact surfaces. Contact surfaces must be free of wax and grease.
Allocate bolts and other components using Electronic parts catalogue “ETKA”.
Capacity is referenced to page 2.
If the gearbox is repaired, fill with gear oil.
What are the gearbox capacities for the VOLKSWAGEN GOLF VARIANT 2007 5-speed manual gearbox 0A4 based on the identification code?
| Identification code | FNE | GQQ | HGR |
|---|---|---|---|
| Capacity of manual gearbox (gearbox completely dismantled) | 1.9 l | 1.9 l | 1.9 l |
| Capacity of manual gearbox (gearbox partially dismantled) | 1.7 l | 1.7 l | 1.7 l |
The table continues for HDR, GTB, JCT, JCR, JCU, KBL, LHW, LUB, KPF, and KQM codes, all showing 1.9 l capacity when completely dismantled and 1.7 l capacity when partially dismantled.
What are the general notes regarding O-rings, seals, gaskets and sealants for the VOLKSWAGEN GOLF VARIANT 2007 5-speed manual gearbox 0A4?
Thoroughly clean housing joint surfaces before applying sealant.
Apply sealant -AMV 188 200 03- uniformly but not too thick.
Renew O-rings, seals and gaskets.
After removing gaskets and seals, always inspect contact surface of housing or shaft for burrs resulting from removal or for other signs of damage.
Before installing radial shaft seals, lightly oil outer diameter and half-fill space between sealing lips with sealing grease -G 052 128 A1-.
The open side of the oil seal faces the side with fluid filling.
Press in new oil seals so that sealing lip does not contact the shaft in the same place as the old seal (make use of insertion depth tolerances).
Lightly oil O-rings before installing; this prevents the rings being crushed when inserted.
After renewing seals and gaskets, check oil level in gearbox and replenish if necessary, referenced to page 112.
What are the instructions for handling locking devices when servicing the VOLKSWAGEN GOLF VARIANT 2007 5-speed manual gearbox 0A4?
Do not overstretch retaining rings.
Always renew retaining rings which have been damaged or overstretched.
Retaining rings must locate properly in grooves.
Renew spring pins. Installation position: slit -A- should be in line with the line of force -arrow-.
What are the instructions for handling nuts and bolts when servicing the VOLKSWAGEN GOLF VARIANT 2007 5-speed manual gearbox 0A4?
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 diagonal sequence.
Torque settings are specified for unoiled bolts and nuts.
Always renew self-locking bolts and nuts.
Threads of bolts secured with locking fluid must be cleaned with a wire brush. Then insert bolts with locking fluid -AMV 185 101 A1-.
Threaded holes into which self-locking bolts or bolts coated with locking fluid are screwed, must be cleaned (e.g. with a thread chaser). Otherwise there is a danger of bolts shearing when subsequently being removed.
What are the instructions for handling bearings when servicing the VOLKSWAGEN GOLF VARIANT 2007 5-speed manual gearbox 0A4?
Install needle bearings with lettered side (thicker metal) towards 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.
What are the instructions for handling shims when servicing the VOLKSWAGEN GOLF VARIANT 2007 5-speed manual gearbox 0A4?
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.
What are the instructions for handling synchro-rings when servicing the VOLKSWAGEN GOLF VARIANT 2007 5-speed manual gearbox 0A4?
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” and “signs of abnormal wear”.
Check the cone of the synchromeshed gear for “scoring” and “signs of abnormal wear”.
Moisten synchromesh mechanism with gear oil before installing.
What are the instructions for handling gears, synchro-hubs, and inner races for needle bearings when servicing the VOLKSWAGEN GOLF VARIANT 2007 5-speed manual gearbox 0A4?
Heat inner races for needle bearings to about 100 °C with the inductive heater -VAS 6414- before installing.
Heat synchro-hub with inductive heater -VAS 6414- to approx. 100 °C before installing. Press in to stop when installing so there is no axial clearance.
Heat gears with inductive heater -VAS 6414- to approx. 100 °C before installing. Press in to stop when installing so there is no axial clearance.
Observe installation position.
What are the instructions for synchromeshed gears when servicing the VOLKSWAGEN GOLF VARIANT 2007 5-speed manual gearbox 0A4?
After assembly, check synchromeshed gears of 1st through 5th gear for slight play, or for freedom of movement.
What are the clutch-related notes for the VOLKSWAGEN GOLF VARIANT 2007 5-speed manual gearbox 0A4?
When removing gearbox, remove slave cylinder without disconnecting pipes.
If the clutch slave cylinder is removed with the hydraulic line attached, do not depress clutch pedal. Otherwise the piston will be pressed out of the slave cylinder.
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.
What are the specified torques for the clutch mechanism components on the VOLKSWAGEN GOLF VARIANT 2007 5-speed manual gearbox 0A4?
| Component | Nm |
|---|---|
| Clutch pedal to mounting bracket (Renew self-locking nuts) | 25 |
| Crash bar to steering column mounting bracket (attachment with 2 bolts) | 10 |
| Crash bar to steering column mounting bracket (attachment with 1 bolt) (Renew bolts for crash bar) | 20 |
What is the procedure to remove the over-centre spring when servicing the clutch mechanism for the VOLKSWAGEN GOLF VARIANT 2007 5-speed manual gearbox 0A4?
Carry out procedure as follows:
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.
With ignition switched off, disconnect battery earth strap, referenced to Electrical system; Rep. Gr. 27; Disconnecting and connecting battery.
Push driver seat as far back as possible and move steering wheel to highest position.
Remove trim and cover below trim on drive side, referenced to General body repairs, interior; Rep. Gr. 68.
Vehicles with knee airbag
Remove bracket for knee airbag together with crash bar, referenced to General body repairs, interior; Rep. Gr. 69; Airbag; Removing and installing knee airbag bracket.
Continuation for all
Remove cable guide -2- from steering column.
Remove footwell vent -3-, referenced to Heating, air conditioning; Rep. Gr. 80; Repairing heating.
Vehicles without knee airbag
The crash bar -1- in front of clutch pedal -2- may be secured in different ways. Crash bar may look different from as shown in following illustrations.
Attachment with 2 bolts
Remove crash bar -1- (2 bolts).
Attachment with 1 bolt
Remove crash bar -1- (1 x bolt -2-).
If fitted, remove damping -arrow- from lower area of clutch pedal mounting bracket.
To do this, remove lock washers -A- for damping.
Pull off insulation.
Push damping upwards in area of upper securing nut -1- above clutch pedal -A- in -direction of arrow-.
Unbolt clutch pedal -1- from mounting bracket -3- by removing nut -2- and pulling out bolt -5-.
Note: The clutch pedal remains hooked to operating rod of master cylinder.
Swing clutch pedal down slightly and remove over-centre spring -4- from mounting bracket.
What is the procedure for installing the over-centre spring when servicing the clutch mechanism for the VOLKSWAGEN GOLF VARIANT 2007 5-speed manual gearbox 0A4?
Install in the reverse order of removal, observing the following:
Note: Renew self-locking nuts.
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 vertically.
Insert tip of clutch pedal in bearing recess of over-centre spring.
Depress clutch pedal slightly, push bolt through and tighten self-locking nut to specified torque, referenced to page 20.
Some cars have damping -arrow- on the clutch pedal mounting bracket.
Return this to installation position.
Vehicles without knee airbag
The crash bar -1- in front of clutch pedal -2- may be secured in different ways.
Attachment with 2 bolts
Install crash bar -1- and tighten 2 bolts to specified torque, referenced to page 20.
Attachment with 1 bolt
Install crash bar -1- and tighten bolt -2- to specified torque, referenced to page 20.
Continuation for all
Mount cable guide -2- on steering column.
Install footwell vent -3-, referenced to Heating, air conditioning; Rep. Gr. 80; Repairing heating.
Vehicles with knee airbag
Install bracket for knee airbag together with crash bar, referenced to General body repairs, interior; Rep. Gr. 69; Airbag; Removing and installing knee airbag bracket.
Continuation for all
Install trim and cover below trim on drive side, referenced to General body repairs, interior; Rep. Gr. 68.
If disconnected, connect battery, referenced to Electrical system; Rep. Gr. 27; Removing and installing battery.
What are the steps to remove the clutch pedal for the VOLKSWAGEN GOLF VARIANT 2007 5-speed manual gearbox 0A4?
Carry out procedure as follows:
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.
With ignition switched off, disconnect battery earth strap, referenced to Electrical system; Rep. Gr. 27; Disconnecting and connecting battery.
Continuation for all
Push driver seat as far back as possible and move steering wheel to highest position.
Remove trim and cover below trim on drive side, referenced to General body repairs, interior; Rep. Gr. 68.
Vehicles with knee airbag
Remove bracket for knee airbag together with crash bar, referenced to General body repairs, interior; Rep. Gr. 69; Airbag; Removing and installing knee airbag bracket.
Continuation for all
Remove cable guide -2- from steering column.
Remove footwell vent -3-, referenced to Heating, air conditioning; Rep. Gr. 80; Repairing heating.
Vehicles without knee airbag
The crash bar -1- in front of clutch pedal -2- may be secured in different ways. Crash bar may look different from as shown in following illustrations.
Attachment with 2 bolts
Remove crash bar -1- (2 bolts).
Attachment with 1 bolt
Remove crash bar -1- (1 x bolt -2-).
If fitted, remove damping -arrow- from lower area of clutch pedal mounting bracket.
To do this, remove lock washers -A- for damping.
Pull off insulation.
Push damping upwards in area of upper securing nut -1- above clutch pedal -A- in -direction of arrow-.
Unbolt clutch pedal -1- from mounting bracket -3- by removing nut -2- and pulling out bolt -5-.
Swing clutch pedal down slightly and remove over-centre spring -4- from mounting bracket.
Release clutch pedal from master cylinder with pliers -T10005-.
Remove clutch pedal.
What is the procedure for installing the clutch pedal for the VOLKSWAGEN GOLF VARIANT 2007 5-speed manual gearbox 0A4?
Install in the reverse order of removal, observing the following:
Note: Renew self-locking nuts.
Secure retainer -2- to master cylinder operating rod -1-.
Press retainer into notch in clutch pedal -3- until it can be heard to engage.
Insert over-centre spring -2- in mounting bracket from above while holding end of spring with assembly tool -T10178- in installation position.
Receptacle -arrow- for tip -A- of clutch pedal must stand vertically.
Insert tip -A- of clutch pedal in bearing recess of over-centre spring.
Depress clutch pedal slightly, push bolt through and tighten self-locking nut to specified torque, referenced to page 25.
Some cars have damping -arrow- on the mounting bracket/clutch pedal.
Return this to installation position.
Vehicles without knee airbag
The crash bar -1- in front of clutch pedal -2- may be secured in different ways.
Attachment with 2 bolts
Install crash bar -1- and tighten 2 bolts to specified torque, referenced to page 25.
Attachment with 1 bolt
Install crash bar -1- and tighten bolt -2- to specified torque, referenced to page 25.
Continuation for all
Mount cable guide -2- on steering column.
Install footwell vent -3-, referenced to Heating, air conditioning; Rep. Gr. 80; Repairing heating.
Vehicles with knee airbag
Install bracket for knee airbag together with crash bar, referenced to General body repairs, interior; Rep. Gr. 69; Airbag; Removing and installing knee airbag bracket.
Continuation for all
Install trim and cover below trim on drive side, referenced to General body repairs, interior; Rep. Gr. 68.
If disconnected, connect battery, referenced to Electrical system; Rep. Gr. 27; Removing and installing battery.
What are the torque settings for the clutch pedal mounting components on the VOLKSWAGEN GOLF VARIANT 2007 5-speed manual gearbox 0A4?
| Component | Nm |
|---|---|
| Clutch pedal to mounting bracket (Renew self-locking nuts) | 25 |
| Crash bar to steering column mounting bracket (attachment with 2 bolts) | 10 |
| Crash bar to steering column mounting bracket (attachment with 1 bolt) (Renew bolts for crash bar) | 20 |
What are the special tools and workshop equipment required for removing and installing the mounting bracket for the VOLKSWAGEN GOLF VARIANT 2007 5-speed manual gearbox 0A4?
Hose clamps to 25 mm Ø -3094-
Hose clip pliers -VAS 6362-
Sealing tool -T10249-
What is the removal procedure for the mounting bracket for the VOLKSWAGEN GOLF VARIANT 2007 5-speed manual gearbox 0A4 (LHD)?
Carry out procedure as follows:
LHD
First check whether a coded radio is fitted. If so, obtain anti theft code.
With ignition switched off, disconnect battery earth strap, referenced to Electrical system; Rep. Gr. 27; Disconnecting and connecting battery.
Remove complete air filter housing if it is near battery, referenced to Rep. Gr. 23; Repairing diesel direct injection system or Rep. Gr. 24; Repairing injection system.
Remove battery and battery tray, referenced to Electrical system; Rep. Gr. 27; Battery; Removing and installing battery.
Continuation for all
During the following work, ensure that no brake fluid lands on longitudinal member or gearbox. If this does happen, clean the affected areas thoroughly.
Lay a lint-free cloth under master cylinder.
Clamp off supply hose to master cylinder with hose clamps up to ∅ 25 mm -3094-.
If present, loosen spring-type clip -3- with hose clip pliers -VAS 6362- and pull supply hose off master cylinder.
In addition, for disconnecting, you can close it with the sealing tool -T10249/1-.
Release securing clip -2- using screwdriver or a pointed object and pull pipe/hose line -1- or plastic line off master cylinder.
Unclip clutch position sender -G476- from master cylinder -arrow- and remove with electrical connector attached -4-.
Note: When performing work in the footwell, put cloths on the carpet to protect it from possible brake fluid spills.
Remove trim and cover below trim on drive side, referenced to General body repairs, interior; Rep. Gr. 68.
Vehicles with knee airbag
Note: The installation location of the knee airbag is above the pedal cluster.
Remove bracket for knee airbag together with crash bar, referenced to General body repairs, interior; Rep. Gr. 69; Airbag; Removing and installing knee airbag bracket.
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-.
What is the installation procedure for the mounting bracket for the VOLKSWAGEN GOLF VARIANT 2007 5-speed manual gearbox 0A4?
Install in the reverse order of removal, observing the following:
Some cars have damping -arrow- on the clutch pedal mounting bracket.
Note: Renew self-locking nuts. Renew hose clips. Allocate all components according to Electronic parts catalogue “ETKA”.
Vehicles without knee airbag
The crash bar -1- in front of clutch pedal -2- may be secured in different ways.
Attachment with 2 bolts
Install crash bar -1- and tighten 2 bolts to specified torque, referenced to page 31.
Attachment with 1 bolt
Install crash bar -1- and tighten bolt -2- to specified torque, referenced to page 31.
Continuation for all
Mount cable guide -2- on steering column.
Install footwell vent -3-, referenced to Heating, Air conditioning; Rep. Gr. 80; Repairing heating; Removing and installing left footwell vent.
Vehicles with knee airbag
Install bracket for knee airbag together with crash bar, referenced to General body repairs, interior; Rep. Gr. 69; Airbag; Removing and installing knee airbag bracket.
Continuation for all
Install trim and cover below trim on drive side, referenced to General body repairs, interior; Rep. Gr. 68.
If disconnected, connect battery, referenced to Electrical system; Rep. Gr. 27; Removing and installing battery.
What are the specified torques for installing the mounting bracket for the VOLKSWAGEN GOLF VARIANT 2007 5-speed manual gearbox 0A4?
| Component | Nm |
|---|---|
| Mounting bracket to bulkhead (Renew self-locking nuts) | 25 |
| Crash bar to steering column mounting bracket (attachment with 2 bolts) | 10 |
| Crash bar to steering column mounting bracket (attachment with 1 bolt) (Renew bolts for crash bar) | 20 |
What are the torque settings for the gearbox to engine connections when installing the gearbox on a petrol engine for the VOLKSWAGEN GOLF VARIANT 2007 5-speed manual gearbox 0A4?
| Item | Bolt | Quantity | Nm |
|---|---|---|---|
| 1 | M12 x 65 | 2 | 80 |
| 2 | M12 x 170 (Additionally, starter to gearbox) | 1 | 80 |
| 3 | M12 x 165 (Additionally, starter to gearbox) | 1 | 80 |
| 4 | M10 x 50 | 3 | 40 |
| 5 | M12 x 85 | 1 | 80 |
| 6 | M6 x 8 (Small flywheel cover plate) | 1 | 10 |
Item -A- indicates dowel sleeves for centring.
What are the torque settings for the gearbox bracket to gearbox and gearbox mounting to body connections when installing the gearbox on a petrol engine for the VOLKSWAGEN GOLF VARIANT 2007 5-speed manual gearbox 0A4?
Gearbox bracket -A- to gearbox bolts are tightened to 40 Nm + 90°.
Gearbox mounting to body bolts are tightened to 60 Nm + 90°.
Gearbox support to gearbox bracket and gearbox bolts are tightened to 20 Nm + 90°.
What are the torque settings for the gearbox to engine connections when installing the gearbox on a diesel engine for the VOLKSWAGEN GOLF VARIANT 2007 5-speed manual gearbox 0A4?
| Item | Bolt | Quantity | Nm |
|---|---|---|---|
| 1 | M12 x 55 | 2 | 80 |
| 2 | M12 x 150 (Additionally, starter to gearbox) | 2 | 80 |
| 3 | M10 x 50 | 3 | 40 |
| 4 | M12 x 60 | 1 | 80 |
| 5 | M6 x 8 (Small flywheel cover plate) | 1 | 10 |
Item -A- indicates dowel sleeves for centring.
What are the torque settings for the gearbox bracket to gearbox and gearbox mounting to body connections when installing the gearbox on a diesel engine for the VOLKSWAGEN GOLF VARIANT 2007 5-speed manual gearbox 0A4?
Gearbox bracket -A- to gearbox bolts are tightened to 40 Nm + 90°.
Gearbox mounting to body bolts are tightened to 60 Nm + 90°.
Gearbox support to gearbox bracket and gearbox bolts are tightened to 20 Nm + 90°.
What should be checked when installing the gearbox on the VOLKSWAGEN GOLF VARIANT 2007 5-speed manual gearbox 0A4 after the gearbox has been bolted to the engine?
After gearbox has been bolted to engine, remove engine and gearbox jack from gearbox.
If small cover plate had been installed behind the right-hand flange shaft -A-, install it -arrows-.
Screw in upper engine/gearbox securing bolts and tighten to specified torque, referenced to page 96.
Install bracket -A- on gearbox using new hexagonal bolts -arrows- and tighten to specified torque, referenced to page 96.
What is the procedure for installing the gearbox on the VOLKSWAGEN GOLF VARIANT 2007 5-speed manual gearbox 0A4?
Align engine and gearbox in installation position using both spindles of support bracket -10 – 222 A-.
Install new bolts -arrows- for left assembly mounting in gearbox mounting and tighten to specified torque, referenced to page 96.
WARNING: Do not remove support bracket -10 – 222 A- until the bolts securing the left and right assembly mountings have been tightened to specified torque.
Note: Install engine and gearbox mounting free of tension, referenced to Rep. Gr. 10; Removing and installing engine.
Install slave cylinder and tighten bolts -arrows B- to specified torque, referenced to Item 15 (page 38).
Then install gearbox support -arrows A- and tighten to specified torque, referenced to page 96.
Attach drive shafts to gearbox, referenced to Running gear, axles, steering; Rep. Gr. 40; Repairing front suspension.
Install drive shaft heat shield, if present -arrows-, referenced to Running gear, axles, steering; Rep. Gr. 40; Repairing drive shafts; Removing and installing drive shafts.
Install pendulum support with new bolts -arrows A-, -B- and -C-, referenced to Running gear, axles, steering; Rep. Gr. 40; Repairing front suspension.
Assemble exhaust system and attach exhaust system bracket to subframe, referenced to Rep. Gr. 26; Exhaust system.
What is the procedure for checking and topping up gear oil on the VOLKSWAGEN GOLF VARIANT 2007 5-speed manual gearbox 0A4?
The oil level in the gearbox can only be checked by completely draining the gear oil and then refilling.
Carry out procedure as follows:
All threaded holes into which self-locking bolts are to be screwed must be cleaned of residual locking fluid carefully with a thread chaser.
Always renew self-locking bolts and nuts.
Check whether dowel sleeves for aligning engine and gearbox are fitted in cylinder block and install if necessary. If dowel sleeves are not fitted, difficulties shifting gears, clutch problems and possible noises from the gearbox (rattling of gears which are not engaged) could occur.
Ensure that intermediate plate is correctly seated on engine.
Clean input shaft splines and apply thin coat of grease for clutch plate splines -G 000 100- . The clutch plate must slide easily to and fro on the input shaft.
To install gearbox “0A4”, set up gearbox support -3282- with adjustment plate -3282/39- .
Align arms of gearbox support according to holes in adjustment plate.
Screw in support elements -A – and -C- ( pin -3282/29- ) on adjustment plate as shown.
Place gearbox on engine and gearbox jack.
Align adjustment plate and gearbox parallel to one another.
Screw pin -3282/29- into hole on gearbox for securing bolt of pendulum support.
Position engine and gearbox jack under vehicle. Arrow -B- on adjustment plate points in direction of vehicle travel.
Screw in support elements -A – and -C- on adjustment plate as shown.
Position engine and gearbox jack under vehicle. Arrow -B- on adjustment plate points in direction of vehicle travel.
Align adjustment plate parallel to gearbox and lock safety support on gearbox.
Then screw pin -3282/29- into hole on gearbox for securing bolt of pendulum support.
Remove lower engine/gearbox connecting bolts.
Press gearbox off dowel sleeves and carefully swing towards subframe.
Turn to lower gearbox in area of differential.
Have a second mechanic push engine forwards slightly.
Carefully lower gearbox, guiding right-hand flange shaft -A- past intermediate plate and flywheel as shown.
When lowering gearbox, change position of gearbox using spindles of gearbox support -3282- .
Be careful of all lines when lowering gearbox.
What is the procedure for draining gear oil from the VOLKSWAGEN GOLF VARIANT 2007 5-speed manual gearbox 0A4?
Clean gearbox.
Caution: To drain gear oil, a pivot pin for the selector forks in the gearbox must be removed. To prevent the positions of the selector forks from being changed, e.g. due to accidental operation of the selector mechanism, the selector shaft must be locked in position.
Secure selector shaft as follows:
Press selector shaft down in -direction of arrow 1-.
While pressing down selector shaft, turn angled rod -A- in -direction of arrow 2- upwards and at the same time press it in until it engages in selector shaft.
Use a clean container with a scale and a 3-litre capacity to catch the oil which runs out.
Selector shaft is locked in place, referenced to page 113.
Drain gear oil by removing oil drain plug -arrow 1- and pivot pin -arrow 2-.
Install pivot pin -arrow 2- with a new O-ring, referenced to Item 5 (page 118).
Screw in oil drain plug -arrow 1-, referenced to Item 17 (page 144).
Now turn angled rod -A- back to original position -direction of arrow- so that selector shaft can move again.
What is the procedure for filling with gear oil in the VOLKSWAGEN GOLF VARIANT 2007 5-speed manual gearbox 0A4?
Top up gear oil in container to 1.7 l.
Gearbox oil specification is referenced to Electronic parts catalogue “ETKA”.
Remove complete air filter housing, referenced to Rep. Gr. 23; Repairing diesel direct injection system or Rep. Gr. 24; Repairing injection system.
Remove noise insulation, referenced to General body repairs, exterior; Rep. Gr. 50; Noise insulation.
Remove reversing light switch -F4- -arrow-.
Connect a hose (approx. 600 mm long, external diameter 10 mm) with a funnel, commercially available.
Insert hose into mounting hole of reversing light switch -F4- (2nd mechanic) and pour in gear oil.
Install reversing light switch -F4- -arrow- again, referenced to Item 2 (page 148).
Check function of selector mechanism, referenced to page 82.
Install complete air filter housing, referenced to Rep. Gr. 23; Repairing diesel direct injection system or Rep. Gr. 24; Repairing injection system.
Install noise insulation, referenced to General body repairs, exterior; Rep. Gr. 50; Noise insulation.
What needs to be checked regarding the input shaft adjustment (Determining input shaft shim) for the VOLKSWAGEN GOLF VARIANT 2007 5-speed manual gearbox 0A4?
It is necessary to readjust the input shaft only when the following components are renewed:
Gearbox housing
Clutch housing
Input shaft
Gear wheel for 4th gear or the Tapered roller bearing
Requirement: Sealing surfaces of clutch and gearbox housings must be free of sealant.
Carry out procedure as follows:
Press small tapered roller bearing outer race together with a 0.65 mm thick shim into clutch housing to stop, referenced to page 173.
Insert output shaft and tighten nuts for bearing support to 25 Nm, then turn 90° further.
Turn output shaft 20 to 30 times in one direction.
Note:
The shaft must be turned in one direction so that the rollers of the tapered roller bearing settle in one direction.
It is necessary to turn the shaft 20 to 30 times to achieve this.
Otherwise the resulting reading will be incorrect.
Set up dial gauge (3 mm measuring range) and set to “0” with 1 mm preload.
Move output shaft up and down and note dial gauge reading (example: 0.20 mm).
What is the example calculation for determining the thickness of shim for input shaft adjustment for the VOLKSWAGEN GOLF VARIANT 2007 5-speed manual gearbox 0A4?
Example:
Installed shim: 0.65 mm
Measured value: 0.20 mm
Preload (constant): 0.15 mm
Shim thickness: 1.00 mm
Example:
| Bearing play = (0.65 mm shim plus determined measured value) | Thickness of shim according to table |
|---|---|
| 0.850 mm | 1.000 mm |
Remove output shaft and pull out small tapered roller bearing outer race, referenced to page 173.
What is the procedure for checking the input shaft bearing play measurement for the VOLKSWAGEN GOLF VARIANT 2007 5-speed manual gearbox 0A4?
Set up measuring appliance and dial gauge.
Rotate input shaft so that tapered roller bearings settle.
Press input shaft in -direction of arrow-.
Bearing play should be min. 0.01 … max. 0.09 mm.
Note: If the bearing play cannot be measured, but input shaft play is perceptible and the input shaft turns freely, the adjustment is acceptable.
What is the procedure for output shaft adjustment (Determining shim for output shaft) for the VOLKSWAGEN GOLF VARIANT 2007 5-speed manual gearbox 0A4?
Requirement: Sealing surfaces of clutch and gearbox housings must be free of sealant.
Carry out procedure as follows:
Press small tapered roller bearing outer race together with a 0.65 mm thick shim into clutch housing to stop, referenced to page 173.
Insert output shaft and tighten nuts for bearing support to 25 Nm, then turn 90° further.
Turn output shaft 20 to 30 times in one direction.
Note:
The shaft must be turned in one direction so that the rollers of the tapered roller bearing settle in one direction.
It is necessary to turn the shaft 20 to 30 times to achieve this.
Otherwise the resulting reading will be incorrect.
Set up dial gauge (3 mm measuring range) and set to “0” with 1 mm preload.
Move output shaft up and down and note dial gauge reading (example: 0.20 mm).
What is the example calculation for determining the thickness of shim for output shaft adjustment for the VOLKSWAGEN GOLF VARIANT 2007 5-speed manual gearbox 0A4?
Example:
Installed shim: 0.65 mm
Measured value: 0.20 mm
Preload (constant): 0.15 mm
Shim thickness: 1.00 mm
Example:
| Bearing play = (0.65 mm shim plus determined measured value) | Thickness of shim according to table |
|---|---|
| 0.850 mm | 1.000 mm |
Remove output shaft and pull out small tapered roller bearing outer race, referenced to page 173.
What is the procedure for adjusting the differential for the VOLKSWAGEN GOLF VARIANT 2007 5-speed manual gearbox 0A4?
Carry out procedure as follows:
Press tapered roller bearing outer race without shim into gearbox housing using thrust plate -30 – 205-, referenced to page 201.
Fit differential into clutch housing.
Set gearbox housing in place and tighten 5 bolts to 25 Nm.
Attach dial gauge and set to “0” with 1 mm preload.
Move differential up and down. Read and note play indicated on dial gauge. (Example: 0.70 mm.)
What is the example calculation for determining the thickness of shim for differential adjustment for the VOLKSWAGEN GOLF VARIANT 2007 5-speed manual gearbox 0A4?
The specified bearing preload is obtained by adding a constant value for preload (0.25 mm) to the reading obtained.
Example:
Measured value: 0.70 mm
Preload (constant): 0.25 mm
Thickness of shim = 0.95 mm
Example:
| Bearing play, measured value | Thickness of shim according to table |
|---|---|
| 0.70 mm | 0.95 mm |
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