VOLKSWAGEN GOLF VARIANT 2010 (06) PDF Document

The 5-speed manual gearbox 0A4 is installed in the Jetta 2005, Bora 2006, VOLKSWAGEN GOLF VARIANT 2007, Bora Sportwagen 2008, VOLKSWAGEN GOLF VARIANT 2010, and Jetta 2011 in conjunction with a 4-cylinder engine.

The gearbox code and production date are indicated by arrow 1 on the manual gearbox 0A4, and the manual gearbox 0A4 itself is indicated by arrow 2.

The example for codes and production date is: FNE 10 11 3, where:

I I I I

Identification code Day Month Year (2003)

of manufacture

Additional data provide information about the production facility. The gearbox code also appears on the vehicle identification plates.

For the VOLKSWAGEN GOLF VARIANT 2010 5-speed manual gearbox 0A4 with identification codes HGR and JCT:

For the VOLKSWAGEN GOLF VARIANT 2010 5-speed manual gearbox 0A4 with identification code KBL, the final drive ratio (Z1 : Z2) is 61 : 18 = 3.389.

The overall ratio calculation example is as follows:

i = Z2 : Z1

iG = Gear ratio = ZG2 : ZG1= 29 : 39 = 0.744

iA = Final drive ratio = ZA2 : ZA1 = 61 : 18 = 3.389

itotal = Overall ratio = iG x iA = 0.744 x 3.389 = 2.521

Z1 = No. of teeth on driving gear, Z2 = No. of teeth on driven gear

• 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 (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 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.

• 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).

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

• Do not interchange synchro-rings. 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.

• 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.

After assembly, check synchromeshed gears of 1st through 5th gear for slight play, or for freedom of movement.

If the clutch slave cylinder is removed with the hydraulic line attached, do not depress the clutch pedal. Otherwise the piston will be pressed out of the slave cylinder.

If the clutch has burnt out, thoroughly clean the clutch housing as well as the friction surface of the flywheel with a cloth to reduce the smell of burnt linings.

The clamp for securing the gear knob to the gear lever should be secured to the gear knob using hose clip pliers -V.A.G 1275-. Always renew the clamp.

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

The torque settings for the crash bar to the steering column mounting bracket are:

• Attachment with 2 bolts: 10 Nm.
• Attachment with 1 bolt: 20 Nm.

Bolts for the crash bar must be renewed.

Use pliers -T10005- to release the retainer for the master cylinder operating rod.

The length of the spacer should be about 40 mm (e.g., a 1/2″ socket).

Secure retainer -2- to the master cylinder operating rod -1-. Press the retainer into the notch in the clutch pedal -3- until it can be heard to engage.

Secure the gear selector cable and gate selector cable to the selector housing using securing clips -2 and 3-. Press the gear selector cable onto the gear lever and the gate selector cable onto the gate selector lever in the selector housing. Securing clips -1 and 4- have been discontinued.

The bolts for the gearbox support to the gearbox bracket and gearbox must be tightened to a specified torque of 20 Nm + 90°.

For a completely dismantled VOLKSWAGEN GOLF VARIANT 2010 5-speed manual gearbox 0A4:

The following points are essential to ensure correct adjustment of the selector mechanism:

• Moving parts of the selector mechanism and elements transferring force must be in proper condition.
• The selector mechanism must move freely.
• The gearbox, clutch, and clutch mechanism must also be in proper condition.
• The gearbox must be in neutral.

With the gearbox in neutral, the selector lever must rest in the selector lever gate for 3rd and 4th gear.

To remove the selector shaft:

• Remove the selector shaft with the selector mechanism cover, placing the selector shaft in the neutral position.
• Then remove bolts (arrows) and pull the selector shaft out of the gearbox housing.

The pointed teeth of the locking collar (arrow 1) and the high shoulder of the synchro-hub (arrow 2) face the gearbox housing. The synchro-hub supports (arrow 3) align with the cast locking pieces of the 5th gear synchro-ring.

The wear limit for the 5th gear synchro-ring gap (-a-) is 0.5 mm. The installation (new) dimension is 1.1 … 1.7 mm.

If the bearing play cannot be measured, but input shaft play is perceptible and the input shaft turns freely, the adjustment is acceptable.

The adjustment overview is on page 195.

Allocate shims according to Electronic parts catalogue “ETKA” .

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:

Carry out procedure as follows:

• Press the small tapered roller bearing outer race together with a 0.65 mm thick shim into the clutch housing to stop.
• Insert the output shaft and tighten nuts for bearing support to 25 Nm, then turn 90° further.
• Turn the output shaft 20 to 30 times in one direction. 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 a dial gauge (3 mm measuring range) and set to “0” with 1 mm preload.
• Move the output shaft up and down and note the dial gauge reading (example: 0.20 mm).
• Remove the output shaft and pull out the small tapered roller bearing outer race.