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What precautions should be taken regarding contact corrosion for the VOLKSWAGEN GOLF VARIANT 2007?
The gearbox housing and clutch housing for the VOLKSWAGEN GOLF VARIANT 2007 are made of a magnesium alloy.
Bolts and other components in direct contact with the gearbox have a surface matched to it.
If the incorrect components (bolts, nuts, washers and so on) are used, contact corrosion will develop, which will damage the gearbox housing and clutch housing.
Always install parts listed in the Electronic parts catalogue „ETKA“.
What are the general repair notes for the VOLKSWAGEN GOLF VARIANT 2007 gearbox?
To ensure flawless and successful gearbox repairs for the VOLKSWAGEN GOLF VARIANT 2007, the greatest care and cleanliness as well as the use of good and proper tools are essential. 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 should be ensured when installing the manual gearbox for the VOLKSWAGEN GOLF VARIANT 2007?
When installing the manual gearbox for the VOLKSWAGEN GOLF VARIANT 2007, ensure that the dowel sleeves between the engine and gearbox are correctly seated.
What should be done to contact surfaces when installing mounting brackets or waxed components for the VOLKSWAGEN GOLF VARIANT 2007 gearbox?
When installing mounting brackets or waxed components for the VOLKSWAGEN GOLF VARIANT 2007 gearbox, clean the contact surfaces. Contact surfaces must be free of wax and grease.
What is the procedure after renewing seals and gaskets for the VOLKSWAGEN GOLF VARIANT 2007 gearbox?
After renewing seals and gaskets for the VOLKSWAGEN GOLF VARIANT 2007 gearbox, check the oil level in the gearbox and replenish if necessary.
What is the requirement for retaining rings in the VOLKSWAGEN GOLF VARIANT 2007 gearbox repair?
Do not overstretch retaining rings for the VOLKSWAGEN GOLF VARIANT 2007 gearbox.
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-.
How should nuts and bolts be loosened and tightened for covers and housings in the VOLKSWAGEN GOLF VARIANT 2007 gearbox?
Loosen and tighten securing bolts and nuts for covers and housings diagonally for the VOLKSWAGEN GOLF VARIANT 2007 gearbox.
Do not cant especially delicate parts, such as clutch pressure plates. Loosen and tighten bolts and nuts in stages in a diagonal sequence.
What is the requirement for threaded connections secured with locking fluid on the VOLKSWAGEN GOLF VARIANT 2007 gearbox?
Threads of bolts secured with locking fluid must be cleaned with a wire brush. Then insert bolts with locking fluid – AMV 185 101 A1- .
Clean threaded holes in which self-locking bolts or bolts with locking fluid have been inserted, e.g. with a thread chaser. Otherwise there is a danger that the bolts may shear when removed again.
How should tapered roller bearings fitted to one shaft be treated during VOLKSWAGEN GOLF VARIANT 2007 gearbox repair?
Tapered roller bearings fitted to one shaft for the VOLKSWAGEN GOLF VARIANT 2007 gearbox must be renewed as a set. Use the same make of bearings.
What should be done before installing inner races for bearings in the VOLKSWAGEN GOLF VARIANT 2007 gearbox?
Heat inner races to about 100° C with the inductive heater – VAS 6414- before installing for the VOLKSWAGEN GOLF VARIANT 2007 gearbox.
What should be done with bearings of the same size during VOLKSWAGEN GOLF VARIANT 2007 gearbox repair?
Do not interchange outer or inner races of bearings of the same size for the VOLKSWAGEN GOLF VARIANT 2007 gearbox. The bearings are matched in pairs.
What is the procedure for installing radial shaft seals during VOLKSWAGEN GOLF VARIANT 2007 gearbox repair?
Before installing radial shaft seals for the VOLKSWAGEN GOLF VARIANT 2007 gearbox, lightly oil the outer diameter and half-fill the space between the sealing lips -arrow- with sealing grease -G 052 128 A1- .
The open side of the oil seal faces the side with fluid filling.
Press in new oil seals so that the sealing lip does not contact the shaft in the same place as the old seal (make use of insertion depth tolerances).
What is the procedure for installing O-rings before inserting them in the VOLKSWAGEN GOLF VARIANT 2007 gearbox?
Lightly oil O-rings before installing for the VOLKSWAGEN GOLF VARIANT 2007 gearbox; this prevents the rings being crushed when inserted.
What must be ensured regarding the clutch pedal when installing the clutch for the VOLKSWAGEN GOLF VARIANT 2007?
Ensure that the pressure plate for the VOLKSWAGEN GOLF VARIANT 2007 does not cant: loosen and tighten bolts diagonally and in several gradual stages.
What should be done if the clutch has burnt out during VOLKSWAGEN GOLF VARIANT 2007 clutch repair?
If the clutch has burnt out during VOLKSWAGEN GOLF VARIANT 2007 clutch repair, thoroughly clean the clutch housing as well as the friction surface of the flywheel with a cloth to reduce the smell of burnt linings.
What are the steps for checking and servicing synchro-rings during VOLKSWAGEN GOLF VARIANT 2007 gearbox repair?
Check synchro-rings for wear and renew if necessary for the VOLKSWAGEN GOLF VARIANT 2007 gearbox.
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 cone of synchromeshed gear for scoring and signs of abnormal wear.
Moisten synchromesh mechanism with gear oil before installing.
What is the procedure for heating inner races for synchromeshed gears during VOLKSWAGEN GOLF VARIANT 2007 gearbox repair?
Heat inner races for synchromeshed gear to about 100° C with the inductive heater -VAS 6414- before installing for the VOLKSWAGEN GOLF VARIANT 2007 gearbox.
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 should be checked after assembly of synchromeshed gears for the VOLKSWAGEN GOLF VARIANT 2007 gearbox?
After assembly of synchromeshed gears for the VOLKSWAGEN GOLF VARIANT 2007 gearbox, check for slight play, or for freedom of movement.
What should be done before disconnecting the battery when repairing the clutch mechanism for the VOLKSWAGEN GOLF VARIANT 2007?
Before disconnecting the battery when repairing the clutch mechanism for the VOLKSWAGEN GOLF VARIANT 2007, obtain the code for radio units having anti-theft coding.
What should be done to lubricate bearings and contact surfaces when reconnecting the battery during clutch mechanism repair for the VOLKSWAGEN GOLF VARIANT 2007?
When reconnecting the battery during clutch mechanism repair for the VOLKSWAGEN GOLF VARIANT 2007, lubricate all bearings and contact surfaces with grease -G 000 450 02- .
What is the torque setting for the clutch pedal to the mounting bracket on the VOLKSWAGEN GOLF VARIANT 2007?
The torque setting for the clutch pedal to the mounting bracket on the VOLKSWAGEN GOLF VARIANT 2007 is 25 Nm. Renew self-locking nuts.
What is the torque setting for the crash bar to the steering column mounting bracket on the VOLKSWAGEN GOLF VARIANT 2007?
The torque setting for the crash bar to the steering column mounting bracket on the VOLKSWAGEN GOLF VARIANT 2007 is 10 Nm.
What should be noted about the connection of the clutch pedal to the master cylinder operating rod when removing the clutch pedal for the VOLKSWAGEN GOLF VARIANT 2007?
When releasing the clutch pedal from the master cylinder with pliers -T10005- during clutch pedal removal for the VOLKSWAGEN GOLF VARIANT 2007, the clutch pedal remains hooked to the operating rod of the master cylinder.
What should be ensured when installing the clutch pedal for the VOLKSWAGEN GOLF VARIANT 2007?
When installing the clutch pedal for the VOLKSWAGEN GOLF VARIANT 2007, renew self-locking nuts.
What procedure should be followed when installing the over-centre spring during clutch pedal installation for the VOLKSWAGEN GOLF VARIANT 2007?
To install the over-centre spring for the VOLKSWAGEN GOLF VARIANT 2007 clutch pedal, insert the over-centre spring -2- in the mounting bracket from above while holding the end of the spring with assembly tool -T10178- in the 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.
What is the instruction regarding brake fluid during removal of the mounting bracket for the VOLKSWAGEN GOLF VARIANT 2007 clutch master cylinder?
During work related to the master cylinder for the VOLKSWAGEN GOLF VARIANT 2007, 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.
What is the procedure for disconnecting the supply hose to the master cylinder during removal of the clutch master cylinder for the VOLKSWAGEN GOLF VARIANT 2007?
Clamp off the supply hose to the master cylinder using hose clamp to 25 mm ∅ -3094- for the VOLKSWAGEN GOLF VARIANT 2007 clutch master cylinder removal.
If necessary, loosen the spring-type clip -3- with hose clip pliers -VAS 6362- and pull the supply hose off the master cylinder.
For disconnecting, you can close the hose 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 -1- off the master cylinder.
Unclip the clutch position sender -G476- from the master cylinder -arrow- and remove with the electrical connector attached -4-.
What should be done with cloths when performing work in the footwell during clutch master cylinder removal for the VOLKSWAGEN GOLF VARIANT 2007?
When performing work in the footwell during clutch master cylinder removal for the VOLKSWAGEN GOLF VARIANT 2007, put cloths on the carpet to protect it from possible brake fluid spills.
What are the steps for reattaching the supply hose after removing the clutch master cylinder for the VOLKSWAGEN GOLF VARIANT 2007?
Push the pipe/hose line -1- or plastic line with seal -2- onto the connection of the master cylinder -4- until the securing clip -3- engages audibly when installing the supply hose for the VOLKSWAGEN GOLF VARIANT 2007 clutch master cylinder.
Test the line by tugging on it.
After removing the hose clamp up to 25 mm ∅ -3094- , return the supply hose to its original shape, if necessary.
Bleed the clutch system.
What should be done regarding the slave cylinder pipe/hose line when removing the bleeder from the slave cylinder for the VOLKSWAGEN GOLF VARIANT 2007?
To remove the pipe/hose line or plastic line from the bleeder for the VOLKSWAGEN GOLF VARIANT 2007 slave cylinder, release the securing clip -2- with a screwdriver or a pointed object and pull the pipe/hose line or plastic line -4- off the bleeder -1-.
To install the pipe/hose line or plastic line, push it onto the bleeder connection with O-ring -3- until the securing clip engages audibly.
Test the line by tugging on it.
What should be done when removing the bleeder from the slave cylinder for the VOLKSWAGEN GOLF VARIANT 2007?
To remove the bleeder from the slave cylinder for the VOLKSWAGEN GOLF VARIANT 2007, release the securing clip -2- with a screwdriver or a pointed object and pull the bleeder -4- off the slave cylinder -1-.
To install, check the O-ring -3- on the slave cylinder. Press the bleeder onto the slave cylinder connection until the securing clip engages audibly.
Check by pulling on the bleeder.
Bleed the clutch system.
What should be noted about the slave cylinder and release bearing when removing and installing for the VOLKSWAGEN GOLF VARIANT 2007?
The slave cylinder and release bearing for the VOLKSWAGEN GOLF VARIANT 2007 are a single component and can only be renewed together.
What must be observed when tightening the securing bolts for the slave cylinder during installation for the VOLKSWAGEN GOLF VARIANT 2007?
The securing bolts for the slave cylinder for the VOLKSWAGEN GOLF VARIANT 2007 must be tightened only in small stages.
Otherwise, the tabs with the bolt holes may break off.
What is the procedure for installing the slave cylinder with release bearing during VOLKSWAGEN GOLF VARIANT 2007 clutch release mechanism repair?
Bolt on the slave cylinder with release bearing to Item 4.
Check the O-ring -3- on the slave cylinder for damage.
Press the bleeder -4- onto the slave cylinder connection -1- until the securing clip -2- engages audibly.
Check by pulling on the bleeder.
Install the gearbox.
Bleed the clutch system.
What is the purpose of checking the outer contour of the flywheel through notches when determining clutch manufacturer for the VOLKSWAGEN GOLF VARIANT 2007 with turbo diesel engine?
The outer contour of the flywheel through notches is checked to determine clutch manufacturer for the VOLKSWAGEN GOLF VARIANT 2007 with turbo diesel engine.
Round outer contour -arrows- indicates a Sachs clutch = -A-.
Outer contour with edges -arrows 1- and, in addition, a circumferential crease -arrow 2- indicates a LuK clutch = -B-.
What is the procedure for loosening bolts when removing the Sachs clutch for the VOLKSWAGEN GOLF VARIANT 2007 with turbo diesel engine?
Use counterhold -3067- to loosen bolts when removing the Sachs clutch for the VOLKSWAGEN GOLF VARIANT 2007 with turbo diesel engine.
Loosen bolts in small steps and diagonally.
As bolts are removed, stop -2- with pin -1- must loosen.
If the stop does not loosen, press the pin towards the dual-mass flywheel.
What should be checked regarding dowel sleeves when installing the Sachs clutch for the VOLKSWAGEN GOLF VARIANT 2007 with turbo diesel engine?
Check whether dowel sleeves for aligning engine and gearbox are fitted in the cylinder block and install if necessary when installing the Sachs clutch for the VOLKSWAGEN GOLF VARIANT 2007 with turbo diesel engine.
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.
What is the installation position of the clutch plate when installing the Sachs clutch for the VOLKSWAGEN GOLF VARIANT 2007 with turbo diesel engine?
The lettering „Getriebeseite“ (gearbox side) faces the gearbox when installing the clutch plate for the Sachs clutch on the VOLKSWAGEN GOLF VARIANT 2007 with turbo diesel engine.
What is the permitted wear on the ends of the diaphragm spring when repairing the Sachs clutch for the VOLKSWAGEN GOLF VARIANT 2007 with turbo diesel engine?
Wear to half the thickness of the diaphragm spring -arrows- is permitted when checking the ends of the diaphragm spring when repairing the Sachs clutch for the VOLKSWAGEN GOLF VARIANT 2007 with turbo diesel engine.
What should be done if clutch plates and pressure plates have damaged or loose rivet connections when repairing the Sachs clutch for the VOLKSWAGEN GOLF VARIANT 2007 with turbo diesel engine?
Renew clutch plates and pressure plates with damaged or loose rivet connections when repairing the Sachs clutch for the VOLKSWAGEN GOLF VARIANT 2007 with turbo diesel engine.
What is the procedure for cleaning input shaft splines and applying grease when repairing the Sachs clutch for the VOLKSWAGEN GOLF VARIANT 2007 with turbo diesel engine?
Clean input shaft splines and, on used clutch plates, clean hub splines; remove corrosion and apply only a very thin coat of clutch plate spline grease -G 000 100- to splines. Then move the clutch plate to and fro on the input shaft until the hub moves freely on the shaft. Remove excessive grease when repairing the Sachs clutch for the VOLKSWAGEN GOLF VARIANT 2007 with turbo diesel engine.
What should be ensured regarding contact surface and lining when installing the Sachs clutch for the VOLKSWAGEN GOLF VARIANT 2007 with turbo diesel engine?
The pressure plate contact surface and clutch plate lining must make full contact with the flywheel when installing the Sachs clutch for the VOLKSWAGEN GOLF VARIANT 2007 with turbo diesel engine. Only then insert securing bolts.
What should be done regarding the centring pins when checking the dual-mass flywheel during repair of the Sachs clutch for the VOLKSWAGEN GOLF VARIANT 2007 with turbo diesel engine?
Ensure that centring pins fit tightly when checking the dual-mass flywheel during repair of the Sachs clutch for the VOLKSWAGEN GOLF VARIANT 2007 with turbo diesel engine.
What should be checked regarding the contact surface for clutch lining during repair of the Sachs clutch for the VOLKSWAGEN GOLF VARIANT 2007 with turbo diesel engine?
The contact surface for clutch lining must be free of grooves, oil and grease when repairing the Sachs clutch for the VOLKSWAGEN GOLF VARIANT 2007 with turbo diesel engine.
What should be checked regarding spring connections and riveted connections when repairing the Sachs clutch for the VOLKSWAGEN GOLF VARIANT 2007 with turbo diesel engine?
Check spring connections between the pressure plate and cover for cracks as well as rivet connections for secure seating when repairing the Sachs clutch for the VOLKSWAGEN GOLF VARIANT 2007 with turbo diesel engine.
A pressure plate with damaged spring connections or with loose rivet connections -arrows- must be renewed.
What is the procedure for checking the position of the adjusting mechanism with new pressure plates only when repairing the LuK clutch for the VOLKSWAGEN GOLF VARIANT 2007 with turbo diesel engine?
Both edges -A- of the adjuster ring must be located between the two notches -arrows B- when checking the position of the adjusting mechanism with new pressure plates only for the LuK clutch repair on the VOLKSWAGEN GOLF VARIANT 2007 with turbo diesel engine.
If the adjuster ring takes up a different position in new pressure plates, the pressure plate and clutch plate are not allowed to be installed.
The adjuster ring may take up a position outside the notches in used clutches.
What should be done regarding the centring pins when Centring clutch disc and removing and installing pressure plate for engines having a crankshaft of smaller diameter or having a needle bearing in the crankshaft for the VOLKSWAGEN GOLF VARIANT 2007?
Push the pressure plate onto the centralizing pins when Centring clutch disc and removing and installing pressure plate for engines having a crankshaft of smaller diameter or having a needle bearing in the crankshaft for the VOLKSWAGEN GOLF VARIANT 2007.
What is the procedure for tightening bolts evenly by hand when Centring clutch disc and removing and installing pressure plate for engines having a crankshaft of smaller diameter or having a needle bearing in the crankshaft for the VOLKSWAGEN GOLF VARIANT 2007?
Tighten all bolts evenly by hand until the bolt heads contact the pressure plate when Centring clutch disc and removing and installing pressure plate for engines having a crankshaft of smaller diameter or having a needle bearing in the crankshaft for the VOLKSWAGEN GOLF VARIANT 2007.
What should be done regarding dowel sleeves when installing the gearbox after Centring clutch disc and removing and installing pressure plate for engines having a crankshaft of smaller diameter or having a needle bearing in the crankshaft for the VOLKSWAGEN GOLF VARIANT 2007?
Check whether dowel sleeves for aligning engine and gearbox are fitted in the cylinder block and install if necessary when installing the gearbox after Centring clutch disc and removing and installing pressure plate for engines having a crankshaft of smaller diameter or having a needle bearing in the crankshaft for the VOLKSWAGEN GOLF VARIANT 2007.
What should be done to the selector mechanism when installing the gearbox after Centring clutch disc and removing and installing pressure plate for engines having a crankshaft of smaller diameter or having a needle bearing in the crankshaft for the VOLKSWAGEN GOLF VARIANT 2007?
Install the gearbox after Centring clutch disc and removing and installing pressure plate for engines having a crankshaft of smaller diameter or having a needle bearing in the crankshaft for the VOLKSWAGEN GOLF VARIANT 2007.
What is the procedure for removing the gear knob and frame for the VOLKSWAGEN GOLF VARIANT 2007 selector mechanism?
Pull or carefully prise the gaiter with the frame for the centre console upwards out of the centre console -arrows- when removing the gear knob and frame for the VOLKSWAGEN GOLF VARIANT 2007 selector mechanism.
In some equipment variations, the gaiter must be levered off along the front section.
Pull the gaiter with the frame for the centre console upwards, inside out, over the gear knob.
Open the clamp -arrow- and pull off the gear knob together with the gaiter.
If necessary, pull off, or carefully lever off, the centre console frame.
Pull off the noise insulation -1-.
What is the installation position of the noise insulation when installing the gaiter with gear knob and noise insulation for the VOLKSWAGEN GOLF VARIANT 2007 selector mechanism?
First set the noise insulation in place when installing the gaiter with gear knob and noise insulation for the VOLKSWAGEN GOLF VARIANT 2007 selector mechanism.
Installation position of noise insulation:
Arrow A- points in the direction of travel.
Catches -arrows B- must engage in the centre console.
What must be ensured when installing the gaiter with gear knob and noise insulation for the VOLKSWAGEN GOLF VARIANT 2007 selector mechanism?
If necessary, press the frame into the centre console when installing the gaiter with gear knob and noise insulation for the VOLKSWAGEN GOLF VARIANT 2007 selector mechanism.
Then turn the gaiter inside out.
The gear knob must be pressed to the stop.
Install the gear knob with the frame and gaiter and squeeze the new clamp -arrow- together.
Then press the gaiter with the frame into the centre console or the gaiter into the frame.
What is the procedure for removing the gate and gear selector cables during repair of the gear lever and selector housing (through 10.06) for the VOLKSWAGEN GOLF VARIANT 2007?
Remove the securing clip from the gear selector cable -A- and the gate selector cable -B- during removal of gate and gear selector cables during repair of the gear lever and selector housing (through 10.06) for the VOLKSWAGEN GOLF VARIANT 2007.
To do this, raise the tab using a screwdriver -arrow 1- and press off the securing clip -arrow 2-.
Remove the gear selector cable -A- from the gear lever retainer.
Remove the gate selector cable -B- from the retainer of the gate selector lever.
What is the procedure for removing and installing the securing clip when repairing the gear lever and selector housing (through 10.06) for the VOLKSWAGEN GOLF VARIANT 2007?
To remove or install the securing clip -arrow A-, press the spacer bush -arrow B- to the stop -in the direction of arrow C- using a screwdriver and pull off the securing clip when repairing the gear lever and selector housing (through 10.06) for the VOLKSWAGEN GOLF VARIANT 2007.
Do not cant the spacer bush when pushing down.
The slot in the gear lever for the securing clip must be visible.
Carefully release the tension from the spring.
What is the procedure for installing the compression spring when repairing the gear lever and selector housing (through 10.06) for the VOLKSWAGEN GOLF VARIANT 2007?
Insert the compression spring so that extension -A- lies on top of the pin -arrow- when installing the compression spring when repairing the gear lever and selector housing (through 10.06) for the VOLKSWAGEN GOLF VARIANT 2007.
Then pull the extension -B- down so that it sits below the pin -arrow-.
What must be done when attaching the gear selector cable and gate selector cable to the selector housing during installation when repairing the gear lever and selector housing (through 10.06) for the VOLKSWAGEN GOLF VARIANT 2007?
Secure the gear selector cable and gate selector cable to the selector housing using securing clips -2 and 3- when attaching the gear selector cable and gate selector cable to the selector housing during installation when repairing the gear lever and selector housing (through 10.06) for the VOLKSWAGEN GOLF VARIANT 2007.
Press the gear selector cable onto the gear lever and the gate selector cable onto the gate selector lever in the selector housing and secure with clips -1 and 4-.
Securing clips -1 and 4- have been discontinued on selector mechanisms from 11.06.
Fit the seal and secure the selector mechanism cover by pressing down the tabs -arrows-.
Install the selector mechanism.
Adjust the selector mechanism.
What must be done to the locking mechanisms on the gate selector cable and gear selector cable end-pieces during removal of gear selector cable and gate selector cable for the VOLKSWAGEN GOLF VARIANT 2007?
Pull the locking mechanisms on the gate selector cable and gear selector cable end-pieces forward to the stop in the direction of arrow 1- and then turn to the left to lock in the direction of arrow 2- when removing the gear selector cable and gate selector cable for the VOLKSWAGEN GOLF VARIANT 2007.
What is the procedure for removing the gear selector cable and gate selector cable from the selector housing when repairing the gear lever and selector housing (from 11.06) for the VOLKSWAGEN GOLF VARIANT 2007?
Pull the gear selector cable and gate selector cable from the selector housing when repairing the gear lever and selector housing (from 11.06) for the VOLKSWAGEN GOLF VARIANT 2007.
What is the procedure for removing the cable support bracket from the Bowden cables when removing gear selector cable and gate selector cable for the VOLKSWAGEN GOLF VARIANT 2007?
Pull off securing clips -1- and -2- and remove the cable support bracket from the Bowden cables when removing gear selector cable and gate selector cable for the VOLKSWAGEN GOLF VARIANT 2007.
What must be ensured when installing the gear selector cable and gate selector cable during installation when repairing the gear lever and selector housing (from 11.06) for the VOLKSWAGEN GOLF VARIANT 2007?
Install the gear selector cable and gate selector cable in the reverse order of removal, observing the following:
The distance to the body must be the same on both sides.
Secure the selector housing.
Install the cable support bracket on the gearbox and tighten the bolts to the specified torques.
The holes in the cable end-pieces have different diameters.
Spread a small quantity of grease -G 000 450 02- on the pin -arrows- of the gearbox selector lever -1- and, as needed, the relay lever pin -2-.
Renew securing clip -3- and, for the metal relay lever, securing clip -4- each time they are removed.
Secure the gear selector cable with securing clip -3- and, for the metal relay lever, the gate selector cable with securing clip -4-.
For cable end-piece to plastic relay lever: fit the relay lever and cable end-piece together, insert the gate selector cable in the cable end-piece.
For all selector mechanisms: install the centre console securing bracket and centre console, install the gaiter with the selector knob and noise insulation, install the underbody panels, install the heat shield, assemble the exhaust system free of tension and attach the tunnel cross member, remove the rear exhaust system and heat shield, and swing the selector housing down and remove with the selector cables.
Adjust the selector mechanism.
If the complete air filter housing was removed, install it.
Follow the procedure after connecting the battery.
What is the check for the gearbox selector lever and relay lever installation position for the VOLKSWAGEN GOLF VARIANT 2007?
Installation position of gearbox selector lever and relay lever for the VOLKSWAGEN GOLF VARIANT 2007:
1 – Gearbox selector lever with damper weight.
2 – Relay lever engages in the guide rail of the gearbox selector lever via the shoe -arrow-.
What is the procedure for renewing cable end-pieces for the VOLKSWAGEN GOLF VARIANT 2007?
Pull the locking mechanisms of the end-pieces of the gate selector cable and gear selector cable forward to the stop -arrow 1- and then turn to the left to lock -arrow 2- when renewing cable end-pieces for the VOLKSWAGEN GOLF VARIANT 2007.
What should be noted when renewing cable end-pieces for the VOLKSWAGEN GOLF VARIANT 2007 selector mechanism?
The cable end-piece must be located behind the catch -arrow 2- when renewing cable end-pieces for the VOLKSWAGEN GOLF VARIANT 2007 selector mechanism.
The cable end-piece can be removed only with the relay lever removed.
To fit, lubricate the bearing points and sliding surfaces with grease -G 000 450 02- .
Press the cable end-piece onto the relay lever.
Install the relay lever together with the cable end-piece to the stop.
For a relay lever with a catch -arrow 1-, the catch -arrow 1- secures the relay lever. Ensure proper engagement. The cable end-piece must be located behind catch -arrow 2-.
For a relay lever with a clip -arrow 1-, the clip -arrow 1- secures the relay lever. Ensure proper engagement of the clip. The cable end-piece must be located behind catch -arrow 2-.
What is the procedure for levering the gate selector cable end-piece off the plastic relay lever when repairing the selector unit for the VOLKSWAGEN GOLF VARIANT 2007?
When the relay lever has been removed, insert a flat-blade screwdriver -A- between the bush -B- and the relay lever, and lever the gate selector cable end-piece off the plastic relay lever when repairing the selector unit for the VOLKSWAGEN GOLF VARIANT 2007.
What is the procedure for pressing on the cable end-piece when repairing the selector unit for the VOLKSWAGEN GOLF VARIANT 2007?
Press the cable end-piece onto the relay lever when pressing on the cable end-piece when repairing the selector unit for the VOLKSWAGEN GOLF VARIANT 2007.
What must be done to the selector shaft when adjusting the selector mechanism for the VOLKSWAGEN GOLF VARIANT 2007?
Press the selector shaft down in the direction of arrow 1- when securing the selector shaft for the VOLKSWAGEN GOLF VARIANT 2007 selector mechanism adjustment.
While pressing down the selector shaft, turn the angled rod -A- in the direction of arrow 3- upwards and at the same time press it in the direction of arrow 2- until it engages in the selector shaft.
Remove the gaiter with the selector knob and frame. If noise insulation is present, remove it.
Select neutral using the gear lever.
Guide the locking pin -T10027 A- through hole -A- into hole -B-.
Check that the gate and selector cables -B- are inserted, free of tension, into the locking devices -A-.
Now turn the locking mechanisms on the gear selector cable and gate selector cable end pieces clockwise to the stop in the direction of arrow 1-. The spring presses the locking mechanism into the original position in the direction of arrow 2-.
Now turn the angled rod -A- back to the original position in the direction of arrow 2-. During this procedure, the angled rod -A- must be pressed out of the gearbox in the direction of arrow 1-.
Pull the locking pin -T10027 A- out of holes -A- and -B-.
If noise insulation was present, install it.
Install the gaiter with the selector knob and frame.
Check that the selector shaft moves freely.
If removed, reinstall the complete air filter housing.
What is the functional check for the adjusted selector mechanism for the VOLKSWAGEN GOLF VARIANT 2007?
Functional check for the adjusted selector mechanism for the VOLKSWAGEN GOLF VARIANT 2007:
With the gearbox in neutral, the gear lever must rest in the gate for 3rd and 4th gear.
Operate the clutch.
Select all gears several times. Pay particular attention to the operation of the reverse gear lock.
If it continues to be difficult to engage a gear after repeated attempts, repeat the adjustment procedure of the selector mechanism.
What is the procedure for removing the gearbox in vehicles with turbo diesel engine for the VOLKSWAGEN GOLF VARIANT 2007?
Check whether a coded radio is fitted. If so, obtain anti-theft code when removing the gearbox in vehicles with turbo diesel engine for the VOLKSWAGEN GOLF VARIANT 2007.
With ignition switched off, disconnect the battery earth strap.
If the engine cover blocks access, remove the engine cover.
Remove the complete air filter housing if it is located close to the battery.
Remove the battery, battery cover and battery tray.
Remove the left charge air hose -arrow 1- and -arrow 2- and the charge air pipe from the engine.
Remove the right charge air hose from the charge air cooler.
Remove the cowling -arrow- together with the radiator fans.
Remove the exhaust system bracket from the subframe -arrows-.
Separate the exhaust system at the double clamp -arrows-.
Raise and secure the front exhaust pipe or rest it on the tunnel bridge.
Remove the pendulum support.
Pull the connector -1- off the oil level and oil temperature sender -G266- .
Remove the left coupling rod from the anti-roll bar and lay it to the side.
Remove the left drive shaft.
Remove the drive shaft heat shield, if present -arrows-.
Remove the right drive shaft from the gearbox, raise and secure it.
Remove the hexagon bolts -arrows- on the left engine/gearbox mounting -2- from the bracket -1-.
Lower the gearbox about 40 mm, dimension -a-, by adjusting the spindles attached to the engine.
Observe connecting lines, hoses and the radiator when moving the engine/gearbox assembly.
Remove bracket -1- from the gearbox -arrows-.
Remove the relay lever together with the cable end-piece.
Remove the gearbox selector lever from the selector shaft.
If a small cover plate -A- for the flywheel is present, remove it -arrows-.
Remove the lower engine/gearbox connecting bolt -1-.
Loosen the engine/gearbox connecting bolts -2- and leave them installed just hand-tight.
Attach bracket -T10346- with bolt -1- to the left threaded hole in the subframe.
-1- is a Flange bolt M6 x 20.
Secure the engine support -3300 A- to the bracket -T10346- .
Place a cloth between the engine support -3300 A- and the oil pan.
Press the engine forwards using the spindle of the engine support -3300 A- . In the process, observe the following points in particular:
The air conditioning compressor -2- must not contact the refrigerant line -1-.
The alternator must not contact the refrigerant line.
The pressure pipe must not contact the radiator.
To remove gearbox „02Q“, set up the gearbox support -3282- with adjustment plate -3282/33- .
Insert the gearbox support -3282- in the engine and gearbox jack -V.A.G 1383 A- .
Align the arms of the gearbox support according to the holes in the adjustment plate.
Attach support elements -A- to the adjustment plate as illustrated.
Screw in pin -3282/29- in place of support element -C-.
Position the engine and gearbox jack -V.A.G 1383 A- under the vehicle. Arrow -B- on the adjustment plate points in the direction of vehicle travel.
Align the adjustment plate parallel to the gearbox.
Attach the adapter -VW 771/40- in the threaded hole of the gearbox housing as shown in the illustration.
Then screw pin -3282/29- into the hole on the gearbox for the securing bolt of the pendulum support.
Secure the gearbox to the gearbox support -3282- using bolt (M10x20) -A-.
Pin -B- must lie flush with the guide from the gearbox support -3282- at the bottom -arrow-.
Position the engine and gearbox jack -V.A.G 1383 A- under the vehicle. Arrow on the adjustment plate points in the direction of vehicle travel.
Now turn the gearbox upwards near the differential, using the spindle of the gearbox support -3282- , and downwards near the 6th gear.
Guide the gearbox with differential -A- over the subframe.
The right flange shaft must then be guided past the flywheel -arrow 2-; observe the intermediate plate -arrow 1-.
The right flange shaft -1- must be guided past the bolt hole of the engine -2-.
When doing this, use the spindles of the gearbox support -3282- to adjust the position of the gearbox so that the longitudinal member -arrows- is not touched.
Then turn the gearbox to the installation position via the spindles of the gearbox support -3282- .
Align the gearbox on the engine dowel sleeves and join.
Screw in the engine/gearbox connecting bolt -C- and tighten to the specified torque.
Screw in the lower engine/gearbox securing bolts and tighten to the specified torque.
Remove the engine support -3300 A- and bracket -T10346- .
Screw in the engine/gearbox connecting bolt -arrow- and tighten to the specified torque.
After the bottom of the gearbox and engine are bolted together, remove the gearbox support -3282- from the gearbox.
Insert the upper engine/gearbox securing bolts and tighten to the torque specification.
Attach the gearbox selector lever to the selector shaft of the gearbox and tighten the hexagon nut to the specified torque.
Install the relay lever together with the cable end-piece.
Install bracket -1- on the gearbox using new hexagonal bolts -arrows- and tighten to the specified torque.
Align the engine and gearbox in the installation position. To do this, raise sufficiently so that bracket -1- completely contacts the left assembly mounting -2-.
Screw the new hexagon bolts -arrows- for the left assembly mounting -2- into bracket -1- and tighten to the specified torque.
Install the engine and gearbox mounting free of tension.
WARNING: Do not remove the support bracket -10-222 A- until all bolts securing the assembly mounting have been tightened to the specified torque.
If a small cover plate -A- for the flywheel is present, install it -arrows-.
Note: There are threaded inserts, e.g. „HeliCoil“ in the bolting holes for the pendulum support.
Note: Note the corresponding securing bolts and specified torque in Running gear, axles, steering; Rep. gr. 40 ; Assembly overview – subframe, anti-roll bar, suspension links .
Install the pendulum support.
Then install the drive shafts.
Install the drive shaft heat shield, if present -arrows-.
Install the left coupling rod.
What is the procedure for removing the gearbox in vehicles with petrol engine for the VOLKSWAGEN GOLF VARIANT 2007?
Remove the bracket -1- from the gearbox -arrows- when removing the gearbox in vehicles with petrol engine for the VOLKSWAGEN GOLF VARIANT 2007.
Remove the relay lever together with the cable end-piece.
Remove the gearbox selector lever from the selector shaft.
Remove the engine/gearbox connecting bolt -1-.
Note: Loosen the engine/gearbox connecting bolts -2- and leave them installed just hand-tight.
Attach bracket -T10346- with bolt -1- to the left threaded hole in the subframe.
-1- is a Flange bolt M6 x 20.
Secure the engine support -3300 A- to the bracket -T10346- .
Press the engine forwards using the spindle of the engine support -3300 A- . In the process, observe the following points in particular:
The air conditioning compressor -2- must not contact the refrigerant line -1-.
The alternator must not contact the refrigerant line.
The pressure pipe must not contact the radiator.
To remove gearbox „02Q“, set up the gearbox support -3282- with adjustment plate -3282/33- .
Insert the gearbox support -3282- in the engine and gearbox jack -V.A.G 1383 A- .
Align the arms of the gearbox support according to the holes in the adjustment plate.
Attach support elements -A- to the adjustment plate as illustrated.
Screw in pin -3282/29- instead of support element -C-.
Place the gearbox on the engine and gearbox jack -V.A.G 1383 A- .
Align the adjustment plate and gearbox parallel to one another.
Screw pin -3282/29- into the hole on the gearbox for the securing bolt of the pendulum support.
Secure the gearbox to the gearbox support -3282- using bolt (M10x20) -A-.
Pin -B- must lie flush with the guide from the gearbox support -3282- at the bottom -arrow-.
Position the engine and gearbox jack -V.A.G 1383 A- under the vehicle. Arrow on the adjustment plate points in the direction of vehicle travel.
Now turn the gearbox in the area of the differential -in the direction of arrow- using the spindles of the gearbox support -3282- .
Then carefully raise the gearbox.
Guide the gearbox with differential -A- over the subframe.
Observe the longitudinal member -arrows-.
What is the procedure for checking gearbox oil when performing gearbox work on the VOLKSWAGEN GOLF VARIANT 2007?
Remove the noise insulation when checking gearbox oil for the VOLKSWAGEN GOLF VARIANT 2007.
To check the gear oil, remove the oil plug -arrow-.
The oil level is correct when the gearbox is filled to the lower edge of the filler hole.
Screw in the plug -arrow- with a new seal.
Tighten the bolt -arrow- to the specified torque.
What is the procedure for filling with oil when checking gearbox oil for the VOLKSWAGEN GOLF VARIANT 2007?
When filling with oil for the VOLKSWAGEN GOLF VARIANT 2007 gearbox:
Remove the oil plug -arrow-.
Fill with gear oil to the lower edge of the filler hole.
Screw in the plug -arrow- with a new seal.
Tighten the bolt -arrow- to the specified torque.
Install the noise insulation.
What are the specifications for the oil filler or oil drain plug for the VOLKSWAGEN GOLF VARIANT 2007 gearbox?
Various versions of oil filler and drain plugs exist for the VOLKSWAGEN GOLF VARIANT 2007 gearbox:
I – Oil filler or oil drain plug with multi-point socket head 45 Nm.
II – Oil filler or oil drain plug with hexagon socket head 30 Nm.
What is the adjustment overview for the differential when parts are renewed on the VOLKSWAGEN GOLF VARIANT 2007 gearbox?
If repairs have been carried out on the gearbox for the VOLKSWAGEN GOLF VARIANT 2007, it is necessary to readjust the output shaft for 1st through 4th gear, output shaft for 5th, 6th and reverse gear or differential only if components have been renewed which have a direct effect on the adjustment of the gearbox. To prevent unnecessary adjustments, refer to the following table:
| Parts renewed: | Output shaft for 1st through 4th gears ⇒ page 206 | Output shaft for 5th, 6th and reverse gears ⇒ page 222 | Differential ⇒ page 239 |
|---|---|---|---|
| Gearbox housing | x | x | x |
| Clutch housing | x | x | x |
| Output shaft for 1st through 4th gears | x | ||
| Output shaft for 5th, 6th and reverse gears | x | ||
| Differential cage | x | ||
| Tapered roller bearings for 1st to 4th gear output shaft | x | ||
| Tapered roller bearings for 5th, 6th and reverse gear output shaft | x | ||
| Tapered roller bearing for differential | x |
What is the prerequisite regarding sealing surfaces when adjusting the differential for the VOLKSWAGEN GOLF VARIANT 2007?
Sealing surfaces of clutch and gearbox housings must be free of sealant when taking measurements for adjusting the differential for the VOLKSWAGEN GOLF VARIANT 2007.
When taking measurements, install only the output shaft to be measured.
What is the procedure for installing differential bevel gears for the VOLKSWAGEN GOLF VARIANT 2007 differential adjustment?
Lubricate the one-piece thrust washer with gear oil and install it when installing differential bevel gears for the VOLKSWAGEN GOLF VARIANT 2007 differential adjustment.
Install both sun wheels and secure (e.g. with flange shaft).
Insert planet pinions offset 180° and pivot into position.
Press in the differential pinion pin -arrow A- to the first planet pinion.
Place the threaded pieces -arrows B- in the sun gears.
Installation position: shoulder to sun gear.
Drive the differential pinion pin into the final position and secure with the spring pin.
What is the procedure for installing the differential bevel gears for the VOLKSWAGEN GOLF VARIANT 2007 differential adjustment?
Lubricate one-piece thrust washer with gear oil and install it when installing differential bevel gears for the VOLKSWAGEN GOLF VARIANT 2007 differential adjustment.
Install both sun wheels and secure (e.g. with flange shaft).
Insert planet pinions offset 180° and pivot into position.
Press in differential pinion pin -arrow A- to first planet pinion.
Place threaded pieces -arrows B- in sun gears.
Installation position: shoulder to sun gear.
Drive the differential pinion pin into final position and secure with the spring pin.
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