VOLKSWAGEN GOLF VARIANT 2010 (09) PDF Document

The gearbox identification code and the date of manufacture are located on the gearbox itself. The identification code consists of three letters. The manufacture date includes the day, month, and year of production. You can also find the gearbox code on the vehicle identification plates.

For the manual gearbox in the VOLKSWAGEN GOLF VARIANT 2010, the gear oil capacity is 2.0 liters. Specific data regarding gear oil can be found in the Electronic parts catalogue ETKA.

To ensure successful repairs, cleanliness and the use of proper tools are essential. Basic safety rules must be observed. When installing the manual gearbox, ensure that dowel sleeves are correctly seated. Always renew O-rings, seals, and gaskets. Before installing an oil seal, half-fill the space between the sealing lips with sealing grease G 052 128 A1. The open side of the oil seal must face the side with fluid filling.

Loosen and tighten securing bolts and nuts for covers and housings diagonally. Always renew self-locking bolts and nuts. Torque settings are specified for unoiled bolts and nuts. If bolts are secured with locking fluid, clean the threads with a wire brush and apply new locking fluid AMV 185 100 A1.

To bleed the system, use brake filling and bleeding equipment such as VAS 5234 or V.A.G 1869. Prefilling the system is not necessary. Connect the bleeding equipment, pressurize the system to 2 bar, open the bleeder valve, and bleed off about 100 cm3 of brake fluid. Close the valve, then rapidly operate the clutch pedal from stop to stop 10 to 15 times. Open the valve again to bleed off an additional 50 cm3 of brake fluid, then close it and depress the clutch pedal several times.

First, disconnect the battery and move the seat back. Remove the trim below the steering column. If equipped with a knee airbag, remove the bracket for the airbag and the crash bar. Remove the cable guide and footwell vent. Unbolt the clutch pedal from the mounting bracket by removing the nut and pulling out the bolt. Swing the pedal down to remove the over-centre spring. Use pliers T10005 to release the clutch pedal from the master cylinder and remove it.

The torque for the clutch pedal to the mounting bracket is 25 Nm. The crash bar to the steering column mounting bracket requires 10 Nm for the 2-bolt attachment or 20 Nm for the 1-bolt attachment.

Remove the noise insulation. Remove the oil plug. The oil level is correct when the gearbox is filled to the lower edge of the filler hole. If topping up, fill to the edge of the hole, then start the engine, engage a gear, and let the gearbox turn for approximately 2 minutes. Stop the engine, remove the plug again, and top up to the lower edge of the filler hole before replacing the plug.

There are two versions:

Version I: Oil filler or oil drain plug with multi-point socket head, 25 Nm.

Version II: Oil filler or oil drain plug with hexagon socket head, 30 Nm.

Ensure the gearbox is in neutral. Pull the locking mechanisms on the gear and gate selector cable end-pieces forward to the stop, then turn to the left to lock. Secure the selector shaft by pressing it down and turning the locking pin T10027 A until it engages. In the cabin, move the gear lever to neutral and guide locking pin T10027 A through the holes. Check that the cables are free of tension, then turn the locking mechanisms back to the original position so the springs can engage. Finally, remove the locking pin.

Bolt the gearbox lifting tackle 3336 to the clutch housing. Adjust the support beam on the sliding piece of the tackle to the 5th hole. Use a workshop crane to lift the gearbox and place it in a transport container.

Press the synchro-ring onto the cone of the synchromeshed gear and measure the gap (a) using a feeler gauge.

Insert a 2.0 mm thick retaining ring into the groove of the input shaft and press it upwards. Measure the distance between the inner race and the installed retaining ring using a feeler gauge. Based on this measured value, determine the correct thickness from the following table: