VOLKSWAGEN GOLF VARIANT 2007 (15) PDF Document

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. Of course, the basic rules for safety also apply during repair work.

When installing mounting brackets or waxed components on the VOLKSWAGEN GOLF VARIANT 2007 gearbox, clean the contact surfaces. Contact surfaces must be free of wax and grease.

The capacity of the VOLKSWAGEN GOLF VARIANT 2007 gearbox when completely dismantled is 2.1 l.

The capacity of the VOLKSWAGEN GOLF VARIANT 2007 gearbox when partially dismantled is 1.9 l.

Lightly oil O-rings before installing; this prevents the rings being crushed when inserted.

Before installing radial shaft seals, lightly oil the outer diameter and 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. Press new oil seals in so that the sealing lip does not contact the shaft in the same place as the old seal (make use of insertion depth tolerances).

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-.

Nuts and bolts which secure covers and housings should be loosened and tightened diagonally in stages if no tightening sequence is specified. Loosen nuts or bolts in the order opposite to the tightening sequence.

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.

Install needle bearings with lettered side (thicker metal) towards fitting tool.

Lubricate all gearbox bearings with gear oil before installing.

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.

Check for wear and renew if necessary. Check grooves -arrow 1- of synchro-ring -A- and inner ring for flat spots (worn grooves). 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”.

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

Moisten synchromesh mechanism with gear oil before installing.

Heat inner races for synchromeshed gear to about 100° C with the inductive heater -VAS 6414- before installing.

Heat synchro-hub with inductive heater -VAS 6414- to approx. 100 °C before installing. Press in to stop when installing so there is no axial clearance.

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

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

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.

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

Lubricate all bearings and contact surfaces with grease -G 000 450 02- .

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.

The crash bar -1- in front of clutch pedal -2- may be secured in different ways. For attachment with 2 bolts: Remove crash bar -1- (2 bolts). For attachment with 1 bolt: Remove crash bar -1- (1 bolt -2-).

The specified torque for the Clutch pedal to mounting bracket hexagon nut is 25 Nm. Renew self-locking nuts.

The specified torque for the Crash bar to steering column mounting bracket (attachment with 2 bolts) is 10 Nm. Renew bolts for crash bar.

The specified torque for the Crash bar to steering column mounting bracket (attachment with 1 bolt) is 20 Nm. Renew bolts for crash bar.

The special tools and workshop equipment required for removing and installing the clutch pedal on the VOLKSWAGEN GOLF VARIANT 2007 are:

Pliers -T10005-

Release tool -T10178-

Swing clutch pedal down slightly and remove over-centre spring -4- from mounting bracket.

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.

Release retainer for master cylinder operating rod using pliers -T10005- .

Press master cylinder operating rod -1- in -direction of arrow- until retainer -2- engages audibly in clutch pedal.

The document does not explicitly list special tools for removing and installing the mounting bracket for the VOLKSWAGEN GOLF VARIANT 2007 in section 2.5, but refers to work in other sections which might imply tools used there.

During the following work, ensure that no brake fluid lands on longitudinal member or gearbox. If this does happen, clean the affected areas thoroughly. Place a lint-free cloth under the master cylinder.

Clamp off supply hose to master cylinder using hose clamp to 25 mm ∅ -3094- . If necessary, loosen spring-type clip -3- with hose clip pliers -VAS 6362- and pull supply hose off master cylinder. In addition, for disconnecting, you can close it with the sealing tool -T10249/1- . Release securing clip -2- using screwdriver or a pointed object and pull pipe/hose line or plastic line -1- off master cylinder.

Push pipe/hose line -1- or plastic line with seal -2- onto connection of master cylinder -4- until securing clip -3- engages audibly. Test line by tugging on it.

After removing hose clamp up to 25 mm ∅ -3094- , return supply hose to its original shape, if necessary.

Bleed clutch system.

If complete air filter housing was removed, install it ⇒ Rep. Gr. 23 ; Repairing diesel direct injection system or ⇒ Rep. Gr. 24 ; Repairing injection system.

Install battery tray and battery⇒ Electrical system; Rep. Gr. 27 ; Removing and installing battery .

If fitted, return damping -arrow- from lower area of clutch pedal mounting bracket to installation position. Install crash bar -1- and tighten the 2 bolts to specified torque or Install crash bar -1- and tighten bolt -2- to specified torque.

Then install gearbox support with new bolts -arrow A- and tighten to specified torque.

Then install gearbox support -arrows- and tighten bolts to specified torque.

Fit clutch release lever and release bearing.

The specified torques for the VOLKSWAGEN GOLF VARIANT 2007 gearbox to 1.4 l petrol engine are:

Item -A- are dowel sleeves for centring.

The specified torques for the VOLKSWAGEN GOLF VARIANT 2007 gearbox to 2.0 l/100 kW petrol engine are:

Item -A- are dowel sleeves for centring.

The specified torques for the VOLKSWAGEN GOLF VARIANT 2007 gearbox to turbo diesel engine are:

Item -A- are dowel sleeves for centring.

The torque for Bolts -arrows- securing the Gearbox bracket to gearbox is 40 Nm + 90°. Renew bolts. Screw in all bolts hand-tight. Tighten bolts to specified torque.

The torque for Bolts -arrows- securing the Gearbox mounting to body is 60 Nm + 90°. Renew bolts. Screw in all bolts hand-tight. Tighten bolts to specified torque.

The torque for Bolts -arrows- securing the Gearbox support to gearbox bracket and gearbox is 20 Nm + 90°. Renew bolts. Screw in all bolts hand-tight. Tighten bolts to specified torque.

The oil level in the gearbox can only be checked by completely draining the gear oil and then refilling. To drain gear oil, the selector shaft must be locked in place. Press selector shaft down -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. Drain gear oil by removing oil drain plug -arrow 1- and then pivot pin -arrow 2-. Install pivot pin -arrow 2- with a new O-ring. Screw in oil drain plug -arrow 1-. Now turn angled rod -A- back to original position -direction of arrow- so that selector shaft can move again. To fill with gear oil, top up oil in container to 1.9 litres. Remove reversing light switch -F4- -arrow-. Connect hose (approx. 600 mm long, external diameter 10 mm) to commercially available funnel. Insert hose in fitting hole for reversing light switch -F4- (2nd mechanic) and fill gear oil. Install reversing light switch -F4- -arrow-.

Secure selector shaft as follows: Press selector shaft down -direction of arrow 1-. While pressing down selector shaft, turn angled rod -A- in -direction of arrow 2- upwards and at the same time press it in until it engages in selector shaft.

Drain gear oil by removing oil drain plug -arrow 1- and then pivot pin -arrow 2-. Install pivot pin -arrow 2- with a new O-ring. Screw in oil drain plug -arrow 1-.

Top up oil in container to 1.9 litres. Remove reversing light switch -F4- -arrow-. Connect hose (approx. 600 mm long, external diameter 10 mm) to commercially available funnel. Insert hose in fitting hole for reversing light switch -F4- (2nd mechanic) and fill gear oil. Install reversing light switch -F4- -arrow-.

The assembly sequence is as follows:

I – Removing and installing cover for gearbox housing and 5th and 6th gears.

II – Removing and installing gearbox housing and shift mechanism.

III – Removing and installing input shaft, output shaft, differential and selector forks.

The torque for Bolt 8 securing the gearbox housing cover is 18 Nm. Quantity is 5.

Bolt 9 is for the input shaft.

The torque for Bolt 6 for the output shaft depends on the gearbox date. To gearbox date 20 08 6: 40 Nm and 180° further. From gearbox date 21 08 6: 80 Nm and then turn 90° further. Always renew self-locking bolts.

The torque for Hexagon bolt 13 is 25 Nm and turn 90° further. Always renew.

The torque for Countersunk bolt 1 is 25 Nm.

The torque for Torx socket head bolt 3 for reverse shaft support is 25 Nm and it is self-locking. The torque for Torx socket head bolt 4 for reverse shaft support is 30 Nm and it is self-locking.

The torque for Multi-point socket head bolt 10 for reverse shaft support is 25 Nm. Always renew.

The torque for Bolt 8 is 25 Nm.

The torque for Countersunk bolt 13 is 25 Nm.

The torque for Hexagon nut 11 is 25 Nm and then turn 90° further. 4 nuts for bearing support. Always renew.

When installing new gears, refer to Electronic parts catalogue “ETKA” and technical data page 1.

If the position of the tapered roller bearings is affected when parts are exchanged, the input shaft must be readjusted. See adjustment overview page 192 .

Press tapered roller bearing outer race into gearbox housing to stop. If necessary, heat gearbox housing cover with hot air blower -V.A.G 1416- in vicinity of bearing seat to about 100° C. Insert cylindrical roller bearing in heated housing and press in using workshop press until heat exchange has taken place. Cylindrical roller bearings must be pressed into cover to stop.

Press tapered roller bearing outer race without shim into gearbox housing to stop. Install input shaft in clutch housing and set gearbox housing in place. Tighten hexagon head bolts to 25 Nm and then turn 90° further.

Set gearbox housing in place and tighten hexagon head bolts to 25 Nm and then turn 90° further. 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.

The specified bearing preload is obtained by adding a constant preload figure (0.10 … 0.15 mm) to the reading obtained (e.g., 0.20 mm) and the thickness of the shim installed (0.65 mm). Remove input shaft and press outer race of tapered roller bearing out of gearbox housing using thrust plate -VW 447 i- . Insert shims of determined thickness, thickest shim first. If the size of shim required is larger than those listed in the table, insert two shims totalling the correct figure. Press outer race of tapered roller bearing together with the shim (e.g., 1.175 mm in example) into gearbox housing using thrust pad -VW 510- .

Table of shims for input shaft adjustment on the VOLKSWAGEN GOLF VARIANT 2007:

The document details procedures for pressing out/in tapered roller bearing outer races and inner races, and setting shims for output shaft adjustment, but does not list a single consolidated step-by-step procedure for the entire dismantling and assembly of the output shaft as a whole, rather it points to sub-sections for specific tasks like pressing off/on bearing components.

The adjustment procedure for the output shaft involves setting up the dial gauge with a 1 mm preload, rotating the input shaft to settle bearings, pressing the input shaft in the direction of the dial gauge arrow, and reading the play on the dial gauge. This measured value is then used with the installed shim thickness (0.65 mm) and a constant preload (0.10-0.15 mm) to determine the correct shim thickness from a table.

The constant preload value added to the reading obtained is 0.10 … 0.15 mm.

The specified shim thickness for a bearing play (0.65 mm shim plus determined measured value) of 0.850 mm is 1.000 mm according to the table of shims.

Raise drive shaft as high as possible and secure. Place drip tray under gearbox and engine. Remove flange shaft securing bolt by screwing two bolts into flange and counterholding flange shaft with a lever. Pull out flange shaft with compression spring. Pull out flange shaft oil seal using multipurpose tool -VW 771- and puller hooks -VW 771/37- . Drive in new seal to stop, being careful not to cant seal. Half-fill space between sealing lip and dust lip with sealing grease -G 052 128 A1- . Insert flange shaft. Secure flange shaft with countersunk bolt.

The torque setting for the Flange shaft to gearbox (countersunk bolt) is specified under Item 12 (page 195) in the relevant section.

The procedure involves tasks such as removing/installing tapered roller bearings outer and inner races, pressing components, and adjusting the differential. Install differential. Always renew sealing rings -arrows- for output shaft bearing support.

Attach dial gauge and set to “0” with 1 mm preload.

The specified bearing preload is obtained by adding a constant value for preload (0.25 mm) to the reading obtained. For a measured value of 0.70 mm, the Thickness of shim is 0.95 mm according to the example provided for determining thickness of shim.

Table of shims for differential adjustment on the VOLKSWAGEN GOLF VARIANT 2007:

Check spring connections between pressure plate and cover for cracks as well as rivet connections for secure seating. Renew clutch plates and pressure plates with damaged or loose rivet connections. Always renew pressure plate and clutch plate together.

The lettering “Getriebeseite” (gearbox side) faces gearbox.

Wear to half the thickness of the diaphragm spring -arrows- is permitted.

Reverse counterhold tool -3067- for installation. Push pressure plate onto centralizing pins. To centre clutch plate, use centring mandrel -3190 A- . Tighten all bolts evenly by hand until bolt heads contact pressure plate. Tighten bolts in small steps diagonally in order not to damage centring holes of pressure plate and centring pins of dual mass flywheel.

Install in the reverse order of removal, observing the following:

Renew pressure plate and clutch plate together only. Select clutch plate and pressure plate according to engine code and Electronic parts catalogue “ETKA” .

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.

Installation position of clutch plate: Lettering “Getriebeseite” (gearbox side) faces gearbox.

Remove gearbox. Use counterhold -3067- to loosen bolts. Loosen bolts in small steps and diagonally. As bolts are removed, stop -2- with pin -1- must loosen. If stop does not loosen, press pin towards dual-mass flywheel. Remove pressure plate and clutch plate.

Check spring connections -arrows A- for damage and riveted connections -arrows B- for secure seating.

Both edges -A- of the adjuster ring must be located between the two notches -arrows B-. If the adjuster ring takes up a different position in new pressure plates, the pressure plate and clutch plate are not allowed to be installed. The adjuster ring may take up a position outside the notches in used clutches.

Lettering “Getriebeseite” (gearbox side) faces gearbox.

Wear up to half the thickness of the diaphragm spring -arrows- is permitted.

Removing: Remove gearbox. Use counterhold -3067- to loosen bolts. Loosen bolts in small steps and diagonally. Remove pressure plate and clutch plate. Installing: Install in the reverse order of removal, observing the following.

The selector mechanism consists of the gearbox selector lever (1), relay lever (2), gear selector cable (A), gate selector cable (B), and heat shield (C).

Note radio code for vehicles with coded radio.

Pull or carefully prise gaiter with frame for centre console upwards out of centre console -arrows-. Open clamp -arrow- and pull off gear knob together with gaiter. If necessary pull off, or carefully lever off, centre console frame. Pull off noise insulation -1-.

Installation position of noise insulation: -Arrow A- points in direction of travel. Catches -arrows B- must engage in centre console.

First set noise insulation in place. If necessary, press frame into centre console. Then turn gaiter inside out. The gear knob must be pressed to stop. Install gear knob with frame and gaiter and squeeze new clamp -arrow- together. Then press gaiter with frame into centre console or gaiter into frame.

The Clamp for securing gear knob to gear lever is secured to gear knob using hose clip pliers -V.A.G 1275- and has no specified torque in the description, only that it should be renewed always.

Remove securing clip from gear selector cable -A- and gate selector cable -B-. To do this, raise tab using screwdriver -arrow 1- and press off securing clip -arrow 2-. Remove gear selector cable -A- from gear lever retainer. Remove gate selector cable -B- from retainer of gate selector lever.

To remove or install securing clip -arrow A-, press spacer bush -arrow B- to stop in direction of arrow -arrow C- using screwdriver and pull off securing clip. Do not cant spacer bush when pushing down. Slot in gear lever for securing clip must be visible. Carefully release tension from spring.

Insert compression spring so that extension -A- lies on top of pin -arrow-. Then pull extension -B- down so that it sits below pin -arrow-.

First check whether a coded radio is fitted. If so, obtain anti theft code. With ignition switched off, disconnect battery earth strap. Remove engine cover if engine lifting eye arrow -10 – 222 A is not accessible. Remove complete air filter housing if it is near battery. Remove battery and battery tray. Remove securing clip -arrow 1- for gear selector cable from gearbox selector lever -A-. Pull gear selector cable from pin. Metal relay lever: Remove securing clip -arrow 2- for gate selector cable from relay lever -B-. Pull gate selector cable from pin. Pull securing clip -arrow 3- off relay lever -B- and remove relay lever. Plastic relay lever: Remove relay lever together with cable end-piece. Continuation for all: Remove gearbox selector lever -A- by removing nut -arrow 4-. Remove cable support bracket from gearbox -arrows-. Then raise and secure gear selector cable and gate selector cable. Remove retainer -B- from gearbox and pull it off pipe/hose line -A-. Then remove gearbox support -arrow A-. Remove slave cylinder -arrow B-, lay to side and secure with wire. Do not disconnect pipes. Remove earth strap at upper engine/gearbox connecting bolt. Pull connector -arrow 1- off reversing light switch -F4-. Now remove connector -arrow 2- and wire -arrow 3- from starter. Then remove upper securing bolt on starter. Remove upper engine/gearbox connecting bolts. If there are hose and cable connections in area of engine support eye for support bracket -10 – 222 A- , remove these now. Vehicles with 1.4 l petrol engine: Set up support bracket -10 – 222 A- together with adapters -10 – 222 A /8- in front of gas struts for bonnet. Vehicles with turbo diesel engines and vehicles with 2.0 l – 110 kW petrol engines: Set up support bracket -10 – 222 A- together with adapters -10 – 222 A /8- , adapter -10 – 222 A /3- and adapter -10 – 222 A /16- in front of gas struts for bonnet. Attach hook -10 – 222 A /10- at front right of engine. Now attach hook -10 – 222 A /2- at rear left of engine -arrow-. Then connect hook -10 – 222 A /2- using adapter -10 – 222 A /16- . Continuation for all vehicles: Position adapter -10 – 222 A /8- directly over wing bolting points. Take up weight of engine/gearbox assembly on spindles. Raise vehicle. Remove noise insulation. Remove lower part of front left wheel housing liner. Then remove all lines from gearbox. Remove drive shaft heat shield from engine -arrows-, if fitted. Vehicles with 1.4 l petrol engine: Separate exhaust system -arrows 1-, remove front exhaust pipe and unscrew front exhaust pipe bracket from subframe -arrows 2- . Vehicles with turbo diesel engines and vehicles with 2.0 l – 110 kW petrol engines: Separate exhaust system at double clamp and remove exhaust pipe bracket from subframe. Continuation for all vehicles: Disconnect drive shafts from flange shafts and tie up as high as possible, being careful not to damage surface protection. Remove pendulum support. First remove bolt -arrow A- and then bolts -B- and -C-. Remove hexagon bolts -arrows- for left assembly mounting from gearbox mounting. Tilt engine/gearbox assembly by lowering it via spindles of support bracket -10 – 222 A- . Remove gearbox bracket -A- -arrows-. Press gearbox off dowel sleeves and carefully swing towards subframe. Turn gearbox downwards in vicinity of differential. Have a second mechanic push engine forwards slightly. Carefully lower gearbox, guiding with right flanged shaft -A- past intermediate plate of flywheel as shown. When lowering gearbox, change position of gearbox using spindles of gearbox support -3282- . Then carefully raise gearbox, guiding with right flange shaft -A- past flywheel and intermediate plate as shown. Using spindles of gearbox support -3282- , tilt gearbox upwards in vicinity of differential. Raise gearbox to engine. The engine must still be pushed forwards (2nd mechanic). Align gearbox to engine and join. Screw in lower engine/gearbox securing bolts and tighten to specified torque. After gearbox has been bolted to engine, remove gearbox jack from gearbox. If small cover plate -A- had been installed behind the right flange shaft -arrows-, install it. Screw in upper engine/gearbox securing bolts and tighten to specified torque.

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- . Install gearbox selector lever -A-. Tighten hexagon nut -arrow 4- to specified torque. Spread a small amount of grease -G 000 450 02- on pin of gearbox selector lever -A-. Connect gear selector cable to gearbox selector lever -arrow 1-. Metal relay lever: Install relay lever -B- and secure with securing clip -arrow 3-. Spread a small amount of grease -G 000 450 02- on pin of relay lever -B-. Connect gate selector cable to relay lever -arrow 2-. Plastic relay lever: Install relay lever together with cable end-piece. Continuation for all: Adjust selector mechanism. Install battery tray and battery. If removed, reinstall engine cover and complete air filter housing. Reconnect battery and perform work required after connecting battery. Install lower part of front left wheel housing liner. Install noise insulation.