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What general repair notes apply to the VOLKSWAGEN GOLF VARIANT 2010 workshop manual?
To ensure flawless and successful gearbox repairs for the VOLKSWAGEN GOLF VARIANT 2010, 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.
What should be observed regarding contact corrosion when working on the VOLKSWAGEN GOLF VARIANT 2010 gearbox?
The gearbox housing and clutch housing for the VOLKSWAGEN GOLF VARIANT 2010 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, damaging the gearbox housing and clutch housing.
Always install parts listed in the Electronic parts catalogue “ETKA”.
What should be ensured when installing the manual gearbox on the VOLKSWAGEN GOLF VARIANT 2010?
When installing the manual gearbox on the VOLKSWAGEN GOLF VARIANT 2010, 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 the Electronic parts catalogue “ETKA”.
Following installation, check gear oil level.
What is the procedure for O-rings, seals, gaskets and sealants on the VOLKSWAGEN GOLF VARIANT 2010?
Thoroughly clean housing joint surfaces before applying sealant.
Apply sealant -AMV 188 200 03- uniformly but not too thick.
Always renew O-rings, seals and gaskets.
When seals have been removed, check contact surface on housings or shafts for burrs and damage and rectify as necessary.
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.
What should be observed regarding locking devices on the VOLKSWAGEN GOLF VARIANT 2010?
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 guidelines for nuts and bolts when working on the gearbox of a VOLKSWAGEN GOLF VARIANT 2010?
Loosen and tighten securing bolts and nuts for covers and housings diagonally.
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.
Ensure with threaded connections that contact surfaces as well as nuts and bolts are rewaxed only after assembly, if necessary.
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.
What are the instructions for installing bearings on the VOLKSWAGEN GOLF VARIANT 2010 gearbox?
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.
How should shims be handled when working on the VOLKSWAGEN GOLF VARIANT 2010 gearbox?
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 guidelines for checking synchro-rings on the VOLKSWAGEN GOLF VARIANT 2010 gearbox?
Do not interchange. When reusing synchro-rings, always fit to the same 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 cone of synchromeshed gear for scoring and signs of abnormal wear.
Moisten synchromesh mechanism with gear oil before installing.
What is the procedure for handling gears, synchro-hubs, and inner races for synchromeshed gears on the VOLKSWAGEN GOLF VARIANT 2010 gearbox during assembly?
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.
What should be checked for synchromeshed gears after assembly on the VOLKSWAGEN GOLF VARIANT 2010 gearbox?
After assembly, check synchromeshed gears for slight play, or for freedom of movement.
What is the instruction for the clutch in the VOLKSWAGEN GOLF VARIANT 2010 repair manual?
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 is the note regarding disconnecting the battery when repairing the clutch mechanism on the VOLKSWAGEN GOLF VARIANT 2010?
Before disconnecting battery, obtain code for radio units having anti-theft coding.
With ignition switched off, disconnect battery.
When reconnecting battery, refer to Electrical system; Disconnecting and connecting battery.
Lubricate all bearings and contact surfaces with grease -G 000 450 02- .
What is the assembly overview for the pedal cluster when repairing the clutch mechanism on the VOLKSWAGEN GOLF VARIANT 2010?
1 – Bulkhead with support for mounting bracket
2 – Seal: Always renew; Between mounting bracket and bulkhead; Self-adhesive; Bond to mounting bracket
3 – Mounting bracket: For mounting clutch pedal; Is provided with damping in some equipment variants; Removing and installing page 23
4 – Bolt
5 – Over-centre spring: Removing and installing page 15
6 – Bearing bush
7 – Pivot pin
8 – Clutch pedal: Removing and installing page 19
9 – Retainer: To remove and install, separate master cylinder from clutch pedal page 19
10 – Seal: Always renew; Between master cylinder and mounting bracket
11 – Master cylinder: Removing and installing after removal of mounting bracket page 29
12 – Clutch position sender -G476-: Removing and installing page 30; Can be checked using „guided fault finding“ of vehicle diagnostic tester; The clutch position sender -G476- is identified as clutch pedal switch -F36- in „guided fault finding“
13 – Clip: Pull out clip to stop to remove and install pipe/hose line
14 – Supply hose: Rubber; From 12.05, plastic page 35
15 – Hexagon nut, 25 Nm: Self-locking
16 – Hexagon nut, 25 Nm: For mounting bracket on bulkhead; Always renew
17 – Stop: For clutch pedal
What are the specified torques for the clutch pedal to mounting bracket and crash bar to steering column mounting bracket on the VOLKSWAGEN GOLF VARIANT 2010?
The specified torques for the clutch pedal to mounting bracket are 25 Nm.
The specified torques for the crash bar to steering column mounting bracket are 10 Nm.
What are the special tools and workshop equipment required for removing and installing the over-centre spring on the VOLKSWAGEN GOLF VARIANT 2010?
Release tool -T10178-
What note should be observed regarding the knee airbag when removing the over-centre spring for the VOLKSWAGEN GOLF VARIANT 2010?
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.
What are the continuation steps for all vehicles when removing the over-centre spring for the VOLKSWAGEN GOLF VARIANT 2010?
With ignition switched off, disconnect battery earth strap.
Push driver seat as far back as possible and put steering wheel in highest position.
Remove driver side footwell cover and driver side left trim panel.
What are the specific steps for vehicles with knee airbag when removing the over-centre spring for the VOLKSWAGEN GOLF VARIANT 2010?
Remove bracket for knee airbag together with crash bar.
What are the specific steps for vehicles without knee airbag when removing the over-centre spring for the VOLKSWAGEN GOLF VARIANT 2010?
Remove crash bar -1- from in front of clutch pedal by removing nuts -2-.
What is the continuation for all vehicles after initial steps for removing the over-centre spring on the VOLKSWAGEN GOLF VARIANT 2010?
If fitted, remove damping -arrow- from lower area of clutch pedal mounting bracket.
To do this, remove lock washers -A- for damping.
Pull off damping.
What is the procedure for removing the over-centre spring on the VOLKSWAGEN GOLF VARIANT 2010?
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.
What note applies to installing the over-centre spring on the VOLKSWAGEN GOLF VARIANT 2010?
Renew self-locking nuts.
What is the installation procedure for the over-centre spring on the VOLKSWAGEN GOLF VARIANT 2010?
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.
If equipped, return damping -arrow- on the clutch pedal mounting bracket to its installation position.
For vehicles without knee airbag: Install crash bar -1- in front of clutch pedal by screwing on and tightening nuts -2-.
For vehicles with knee airbag: Install bracket for knee airbag together with crash bar.
Install driver side footwell cover and driver side left trim panel.
If disconnected, connect battery.
What are the special tools and workshop equipment required for removing and installing the clutch pedal on the VOLKSWAGEN GOLF VARIANT 2010?
Pliers -T10005-
Release tool -T10178-
What is the procedure for removing the clutch pedal on the VOLKSWAGEN GOLF VARIANT 2010?
First check whether a coded radio is fitted. If so, obtain anti-theft code.
With ignition switched off, disconnect battery earth strap.
Push driver seat as far back as possible and put steering wheel in highest position.
Remove driver side footwell cover and driver side left trim panel.
For vehicles with knee airbag: Remove bracket for knee airbag together with crash bar.
For vehicles without knee airbag: Remove crash bar -1- from in front of clutch pedal by removing nuts -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 damping.
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 forward slightly and remove over-centre spring -4- from mounting bracket.
Release clutch pedal from master cylinder with pliers -T10005- .
Remove clutch pedal.
What are the notes for installing the clutch pedal on the VOLKSWAGEN GOLF VARIANT 2010?
Renew self-locking nuts.
What is the installation procedure for the clutch pedal on the VOLKSWAGEN GOLF VARIANT 2010?
Install in the reverse order of removal, observing the following:
Attach 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.
If equipped, return damping -arrow- on the mounting bracket/clutch pedal to its installation position.
For vehicles without knee airbag: Install crash bar -1- in front of clutch pedal by screwing on and tightening nuts -2-.
For vehicles with knee airbag: Install bracket for knee airbag together with crash bar.
Install driver side footwell cover and driver side left trim panel.
What are the specified torques for clutch pedal and crash bar to steering column mounting bracket on the VOLKSWAGEN GOLF VARIANT 2010 during clutch pedal installation?
| Component | Nm |
|---|---|
| Clutch pedal to mounting bracket | 25 |
| Crash bar to steering column mounting bracket | 10 |
Renew self-locking nuts.
What are the special tools and workshop equipment required for removing and installing the mounting bracket on the VOLKSWAGEN GOLF VARIANT 2010?
No special tools or workshop equipment are listed for this section in the PDF.
What is the procedure for removing the mounting bracket on the VOLKSWAGEN GOLF VARIANT 2010?
Some cars have damping -arrow- on the clutch pedal mounting bracket.
For vehicles without knee airbag: Install crash bar -1- in front of clutch pedal by screwing on and tightening nuts -2-.
For vehicles with knee airbag: Install bracket for knee airbag together with crash bar.
Install driver side footwell cover and driver side left trim panel.
Push pipe/hose line or plastic line -1- 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.
For LHD vehicles: Install battery tray and battery.
For LHD vehicles: Remove complete air filter housing if it is near battery.
Reconnect battery and perform work required after connecting battery.
Push damping upwards in area of upper securing nut -1- above clutch pedal -A- in -direction of arrow-.
Remove nuts -2-.
Remove mounting bracket -1-.
What are the notes for installing the mounting bracket on the VOLKSWAGEN GOLF VARIANT 2010?
Renew self-locking nuts.
Renew hose clips.
Allocate all components according to Electronic parts catalogue “ETKA”.
What is the procedure for installing the mounting bracket on the VOLKSWAGEN GOLF VARIANT 2010?
Install crash bar -1- in front of clutch pedal by screwing on and tightening nuts -2-.
Install bracket for knee airbag together with crash bar.
Install driver side footwell cover and driver side left trim panel.
Push pipe/hose line or plastic line -1- 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.
For LHD: Install battery tray and battery.
For LHD: Remove complete air filter housing if it is near battery.
Reconnect battery and perform work required after connecting battery.
Some cars have damping -arrow- on the clutch pedal mounting bracket.
Return it to installation position.
Push damping upwards in area of upper securing nut -1- above clutch pedal -A- in -direction of arrow-.
Remove nuts -2-.
Remove mounting bracket -1-.
What are the specified torques for mounting bracket to body and crash bar to steering column mounting bracket on the VOLKSWAGEN GOLF VARIANT 2010 when removing/installing the mounting bracket?
| Component | Nm |
|---|---|
| Mounting bracket to body | 25 |
| Crash bar to steering column mounting bracket | 10 |
Renew self-locking nuts for mounting bracket to body.
What are the special tools and workshop equipment required for removing and installing the master cylinder on the VOLKSWAGEN GOLF VARIANT 2010?
Pliers -T10005-
What is the procedure for removing the master cylinder on the VOLKSWAGEN GOLF VARIANT 2010?
Remove mounting bracket page 23.
Release retainer for master cylinder operating rod using pliers -T10005- .
Insert spacer -A- between clutch pedal and stop and press clutch pedal to spacer.
Length of spacer = about 40 mm (e.g. 1/2″ socket).
Release securing bar -B- and pull master cylinder out of mounting bracket -arrow 1- and -arrow 2-.
What is the note for installing the master cylinder on the VOLKSWAGEN GOLF VARIANT 2010?
Move clutch pedal to rest position at stop.
What is the installation procedure for the master cylinder on the VOLKSWAGEN GOLF VARIANT 2010?
Attach retainer -2- to master cylinder operating rod -1-.
Insert spacer -A- between clutch pedal and stop and press clutch pedal to spacer.
Length of spacer = about 40 mm (e.g. 1/2″ socket).
Engage master cylinder in mounting bracket -arrow 1- and -arrow 2-.
Press master cylinder operating rod -1- in -direction of arrow- until retainer -2- engages audibly in clutch pedal.
Install mounting bracket page 23.
What are the hose clamps and sealing tool required for removing the clutch position sender -G476- on the VOLKSWAGEN GOLF VARIANT 2010?
Hose clamps -3094-
Sealing tool -T10249-
What is the removal procedure for the clutch position sender -G476- on LHD VOLKSWAGEN GOLF VARIANT 2010 vehicles?
First check whether a coded radio is fitted. If so, obtain anti-theft code.
With ignition switched off, disconnect battery earth strap.
Remove complete air filter housing if it is near battery.
Remove battery and battery tray.
What is the removal procedure for the clutch position sender -G476- on Right-hand drive VOLKSWAGEN GOLF VARIANT 2010 vehicles with particle filter?
In vehicles with particle filter, remove shielding -A- from particle filter.
An insulation mat is installed in conjunction with some engines.
Remove heat shield from pipe/hose line -arrows-.
What is the note regarding brake fluid when continuing for all vehicles when removing the clutch position sender -G476- on the VOLKSWAGEN GOLF VARIANT 2010?
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.
What is the procedure for disconnecting the supply hose to the master cylinder when removing the clutch position sender -G476- on the VOLKSWAGEN GOLF VARIANT 2010?
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-.
What is the procedure for disconnecting the pipe/hose line or plastic line and the clutch position sender -G476- from the master cylinder when removing the clutch position sender -G476- on the VOLKSWAGEN GOLF VARIANT 2010?
Release securing clip -2- using screwdriver or a pointed object and pull pipe/hose line or plastic line -1- off master cylinder.
Unclip clutch position sender -G476- from master cylinder -arrow- and remove with electrical connector attached -4-.
What is the note when performing work in the footwell when removing the clutch position sender -G476- on the VOLKSWAGEN GOLF VARIANT 2010?
When performing work in the footwell, put cloths on the carpet to protect it from possible brake fluid spills.
What is the procedure for removing footwell covers and trim panels when removing the clutch position sender -G476- on the VOLKSWAGEN GOLF VARIANT 2010?
Remove driver side footwell cover and driver side left trim panel.
For vehicles with knee airbag: Remove bracket for knee airbag together with crash bar.
For vehicles without knee airbag: Remove crash bar -1- from in front of clutch pedal by removing nuts -2-.
Continue for all vehicles.
If fitted, remove damping -arrow- from lower area of clutch pedal mounting bracket.
To do this, remove lock washers -A- for damping.
Pull off damping.
Push damping upwards in area of upper securing nut -1- above clutch pedal -A- in -direction of arrow-.
Remove nuts -2-.
Remove mounting bracket -1-.
What are the notes for installing the clutch position sender -G476- on the VOLKSWAGEN GOLF VARIANT 2010?
Renew hose clips.
Allocate all components according to Electronic parts catalogue „ETKA“ .
What is the general assembly procedure for the clutch position sender -G476- on the VOLKSWAGEN GOLF VARIANT 2010?
Install crash bar -1- in front of clutch pedal by screwing on and tightening nuts -2-.
Install bracket for knee airbag together with crash bar.
Install driver side footwell cover and driver side left trim panel.
If disconnected, connect battery.
Some cars have damping -arrow- on the clutch pedal mounting bracket.
Return it to installation position.
For vehicles without knee airbag: Install crash bar -1- in front of clutch pedal by screwing on and tightening nuts -2-.
For vehicles with knee airbag: Install bracket for knee airbag together with crash bar.
Continue for all vehicles.
Push pipe/hose line or plastic line -1- 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.
For LHD: Install battery tray and battery.
For LHD: Remove complete air filter housing if it is near battery.
Reconnect battery and perform work required after connecting battery.
What are the specified torques when removing and installing the mounting bracket for the VOLKSWAGEN GOLF VARIANT 2010?
| Component | Nm |
|---|---|
| Mounting bracket to body | 25 |
| Crash bar to steering column mounting bracket | 10 |
What are the special tools and workshop equipment required for removing and installing the clutch pedal on the VOLKSWAGEN GOLF VARIANT 2010?
Pliers -T10005-
Release tool -T10178-
What is the procedure for removing the clutch pedal on the VOLKSWAGEN GOLF VARIANT 2010?
First check whether a coded radio is fitted. If so, obtain anti-theft code.
With ignition switched off, disconnect battery earth strap.
Push driver seat as far back as possible and put steering wheel in highest position.
Remove driver side footwell cover and driver side left trim panel.
For vehicles with knee airbag: Remove bracket for knee airbag together with crash bar.
For vehicles without knee airbag: Remove crash bar -1- from in front of clutch pedal by removing nuts -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 damping.
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 forward 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 note for installing the clutch pedal on the VOLKSWAGEN GOLF VARIANT 2010?
Renew self-locking nuts.
What is the installation procedure for the clutch pedal on the VOLKSWAGEN GOLF VARIANT 2010?
Install in the reverse order of removal, observing the following:
Attach 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.
If equipped, return damping -arrow- on the mounting bracket/clutch pedal to its installation position.
For vehicles without knee airbag: Install crash bar -1- in front of clutch pedal by screwing on and tightening nuts -2-.
For vehicles with knee airbag: Install bracket for knee airbag together with crash bar.
Install driver side footwell cover and driver side left trim panel.
What are the specified torques for clutch pedal to mounting bracket and crash bar to steering column mounting bracket on the VOLKSWAGEN GOLF VARIANT 2010 during clutch pedal installation?
| Component | Nm |
|---|---|
| Clutch pedal to mounting bracket | 25 |
| Crash bar to steering column mounting bracket | 10 |
What are the special tools and workshop equipment required for removing and installing the mounting bracket on the VOLKSWAGEN GOLF VARIANT 2010?
No special tools or workshop equipment are listed for this section in the PDF.
What is the procedure for removing the mounting bracket on the VOLKSWAGEN GOLF VARIANT 2010?
Some cars have damping -arrow- on the clutch pedal mounting bracket.
For vehicles without knee airbag: Install crash bar -1- in front of clutch pedal by screwing on and tightening nuts -2-.
For vehicles with knee airbag: Install bracket for knee airbag together with crash bar.
Install driver side footwell cover and driver side left trim panel.
Push pipe/hose line or plastic line -1- 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.
For LHD vehicles: Install battery tray and battery.
For LHD vehicles: Remove complete air filter housing if it is near battery.
Reconnect battery and perform work required after connecting battery.
Push damping upwards in area of upper securing nut -1- above clutch pedal -A- in -direction of arrow-.
Remove nuts -2-.
Remove mounting bracket -1-.
What are the notes for installing the mounting bracket on the VOLKSWAGEN GOLF VARIANT 2010?
Renew self-locking nuts.
Renew hose clips.
Allocate all components according to Electronic parts catalogue „ETKA“ .
What is the procedure for installing the mounting bracket on the VOLKSWAGEN GOLF VARIANT 2010?
Install crash bar -1- in front of clutch pedal by screwing on and tightening nuts -2-.
Install bracket for knee airbag together with crash bar.
Install driver side footwell cover and driver side left trim panel.
Push pipe/hose line or plastic line -1- 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.
For LHD: Install battery tray and battery.
For LHD: Remove complete air filter housing if it is near battery.
Reconnect battery and perform work required after connecting battery.
Some cars have damping -arrow- on the clutch pedal mounting bracket.
Return it to installation position.
Push damping upwards in area of upper securing nut -1- above clutch pedal -A- in -direction of arrow-.
Remove nuts -2-.
Remove mounting bracket -1-.
What are the specified torques for mounting bracket to body and crash bar to steering column mounting bracket on the VOLKSWAGEN GOLF VARIANT 2010 when removing/installing the mounting bracket?
| Component | Nm |
|---|---|
| Mounting bracket to body | 25 |
| Crash bar to steering column mounting bracket | 10 |
What are the special tools and workshop equipment required for removing and installing the clutch position sender -G476- on the VOLKSWAGEN GOLF VARIANT 2010?
No special tools or workshop equipment are listed for this section in the PDF.
What is the removal procedure for the clutch position sender -G476- on LHD VOLKSWAGEN GOLF VARIANT 2010 vehicles?
First check whether a coded radio is fitted. If so, obtain anti-theft code.
With ignition switched off, disconnect battery earth strap.
Remove complete air filter housing if it is near battery.
Remove battery and battery tray.
What is the removal procedure for the clutch position sender -G476- on Right-hand drive VOLKSWAGEN GOLF VARIANT 2010 vehicles with particle filter?
In vehicles with particle filter, remove shielding -A- from particle filter.
An insulation mat is installed in conjunction with some engines.
Remove heat shield from pipe/hose line -arrows-.
What is the note regarding brake fluid when continuing for all vehicles when removing the clutch position sender -G476- on the VOLKSWAGEN GOLF VARIANT 2010?
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.
What is the procedure for disconnecting the supply hose to the master cylinder when removing the clutch position sender -G476- on the VOLKSWAGEN GOLF VARIANT 2010?
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-.
What is the procedure for disconnecting the pipe/hose line or plastic line and the clutch position sender -G476- from the master cylinder when removing the clutch position sender -G476- on the VOLKSWAGEN GOLF VARIANT 2010?
Release securing clip -2- using screwdriver or a pointed object and pull pipe/hose line or plastic line -1- off master cylinder.
Unclip clutch position sender -G476- from master cylinder -arrow- and remove.
What is the note when performing work in the footwell when removing the clutch position sender -G476- on the VOLKSWAGEN GOLF VARIANT 2010?
When performing work in the footwell, put cloths on the carpet to protect it from possible brake fluid spills.
What is the procedure for removing footwell covers and trim panels when removing the clutch position sender -G476- on the VOLKSWAGEN GOLF VARIANT 2010?
Remove driver side footwell cover and driver side left trim panel.
For vehicles with knee airbag: Remove bracket for knee airbag together with crash bar.
For vehicles without knee airbag: Remove crash bar -1- from in front of clutch pedal by removing nuts -2-.
Continue for all vehicles.
If fitted, remove damping -arrow- from lower area of clutch pedal mounting bracket.
To do this, remove lock washers -A- for damping.
Pull off damping.
Push damping upwards in area of upper securing nut -1- above clutch pedal -A- in -direction of arrow-.
Remove nuts -2-.
Remove mounting bracket -1-.
What are the notes for installing the clutch position sender -G476- on the VOLKSWAGEN GOLF VARIANT 2010?
Renew hose clips.
Allocate all components according to Electronic parts catalogue „ETKA“ .
What is the general assembly procedure for the clutch position sender -G476- on the VOLKSWAGEN GOLF VARIANT 2010?
Install crash bar -1- in front of clutch pedal by screwing on and tightening nuts -2-.
Install bracket for knee airbag together with crash bar.
Install driver side footwell cover and driver side left trim panel.
If disconnected, connect battery.
Some cars have damping -arrow- on the clutch pedal mounting bracket.
Return it to installation position.
For vehicles without knee airbag: Install crash bar -1- in front of clutch pedal by screwing on and tightening nuts -2-.
For vehicles with knee airbag: Install bracket for knee airbag together with crash bar.
Continue for all vehicles.
Push pipe/hose line or plastic line -1- 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.
For LHD: Install battery tray and battery.
For LHD: Remove complete air filter housing if it is near battery.
Reconnect battery and perform work required after connecting battery.
What are the specified torques when removing and installing the mounting bracket for the VOLKSWAGEN GOLF VARIANT 2010?
| Component | Nm |
|---|---|
| Mounting bracket to body | 25 |
| Crash bar to steering column mounting bracket | 10 |
What are the special tools and workshop equipment required for removing and installing the slave cylinder with release bearing on the VOLKSWAGEN GOLF VARIANT 2010?
Hose clamps to 25 mm -3094-
What is the procedure for removing pipe/hose line and bleeder from and installing on slave cylinder on the VOLKSWAGEN GOLF VARIANT 2010?
Removing pipe/hose line or plastic line from and installing on bleeder:
To remove, release securing clip -2- with a screwdriver or pointed object and pull pipe/hose line or plastic line -4- off bleeder -1-.
To install pipe/hose line or plastic line, push onto bleeder connection with O-ring -3- until securing clip engages audibly.
Test line by tugging on it.
Removing bleeder from and installing on slave cylinder:
To remove, release securing clip -2- with a screwdriver or pointed object and pull bleeder -4- off slave cylinder -1-.
To install, check O-ring -3- on slave cylinder. Press bleeder onto slave cylinder connection until securing clip engages audibly.
Check by pulling on bleeder.
Bleed clutch system.
What is the note regarding the slave cylinder with divided supply line on the VOLKSWAGEN GOLF VARIANT 2010?
The supply line for some slave cylinders is divided in the area of the -arrow-.
What is the note regarding the slave cylinder and release bearing when removing and installing slave cylinder with release bearing on the VOLKSWAGEN GOLF VARIANT 2010?
Slave cylinder and release bearing are a single component and can be renewed only together.
What is the removal procedure for the slave cylinder with release bearing on the VOLKSWAGEN GOLF VARIANT 2010?
Remove gearbox.
Release securing clip -2- with a screwdriver or pointed object and pull bleeder -4- off slave cylinder -1-.
Remove bolts -arrows-.
Remove slave cylinder together with release bearing -A-.
What is the note for installing the slave cylinder with release bearing on the VOLKSWAGEN GOLF VARIANT 2010?
The securing bolts for the slave cylinder must be tightened only in small steps.
Otherwise, the tabs with the bolt holes may break off.
What is the installation procedure for the slave cylinder with release bearing on the VOLKSWAGEN GOLF VARIANT 2010?
Bolt on slave cylinder with release bearing page 39.
Check O-ring -3- on slave cylinder for damage.
Press bleeder -4- onto slave cylinder connection -1- until securing clip -2- engages audibly.
Check by pulling on bleeder.
Install gearbox.
Bleed clutch system.
What are the special tools and workshop equipment required for removing and installing pipe/hose line or plastic line on the VOLKSWAGEN GOLF VARIANT 2010?
Hose clamps to 25 mm -3094-
What is the removal procedure for pipe/hose line or plastic line on the VOLKSWAGEN GOLF VARIANT 2010?
Remove complete air filter housing.
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 -3094- .
Remove pipe/hose line or plastic line from master cylinder as follows:
Release securing clip -3- using screwdriver or pointed object and pull off line -1- with O-ring -2-.
Remove pipe/hose line or plastic line from bleeder as follows:
Release securing clip -2- using screwdriver or pointed object and pull line -4- with O-ring -3- off bleeder -1-.
What is the installation procedure for pipe/hose line or plastic line on the VOLKSWAGEN GOLF VARIANT 2010?
Renew hose clips.
Allocate all components according to Electronic parts catalogue „ETKA“ .
If the pipe/hose line was removed:
Push pipe/hose line -1- or plastic line with seal -2- onto connection of master cylinder -4- until securing clip -3- engages audibly.
Test pipe/hose 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.
For Right-hand drive: In vehicles with particle filter, install shielding -A- on particle filter.
For LHD: Install battery tray and battery.
For LHD: Remove complete air filter housing if it is near battery.
Reconnect battery and perform work required after connecting battery.
What are the special tools and workshop equipment required for renewing the input shaft seal on the VOLKSWAGEN GOLF VARIANT 2010?
Extractor lever -T20143/1-
What is the procedure for renewing the input shaft seal on the VOLKSWAGEN GOLF VARIANT 2010?
Thrust piece -T40008-
Sealing grease -G 052 128 A1-
Procedure:
Remove gearbox.
Remove slave cylinder with release bearing page 40.
Lever out seal for input shaft using lever -T20143/1- .
Note: Do not damage running surface of input shaft for oil seal.
Half-fill space between sealing lip and dust lip -arrow- with sealing grease -G 052 128 A1- .
Lightly moisten outer circumference of oil seal with gear oil.
Drive seal in flush using thrust piece -T40008- .
Install slave cylinder with release bearing page 40.
Install gearbox.
What are the special tools and workshop equipment required for repairing the clutch on VOLKSWAGEN GOLF VARIANT 2010 vehicles with a turbo diesel engine?
Counterhold -3067-
Torque wrench -V.A.G 1331-
Centring mandrel -T10097-
Grease for clutch plate splines -G 000 100-
How can the clutch manufacturer be determined on the VOLKSWAGEN GOLF VARIANT 2010 with a turbo diesel engine when the clutch is installed?
A clutch manufactured by either „Sachs“ or „LuK“ may be installed.
The make of the clutch can be determined as follows with the clutch installed:
Remove noise insulation.
Remove noise insulation from engine sump if necessary.
Some notches -arrows- are located in lower region of sump between engine -A- and gearbox -B-.
Check outer contour of flywheel through these notches.
In addition, a small cover plate -A- can be removed -arrows- to enable inspection of flywheel’s outer contour.
Round outer contour -arrows- = Sachs clutch = -A-
Outer contour with edges -arrows 1- and, in addition, a circumferential crease -arrow 2- = LuK clutch = -B-
What is the check for diaphragm spring ends when inspecting a Sachs clutch on the VOLKSWAGEN GOLF VARIANT 2010?
Wear to half the thickness of the diaphragm spring -arrows- is permitted.
What should be checked for spring connections and riveted connections when inspecting a Sachs clutch on the VOLKSWAGEN GOLF VARIANT 2010?
Check spring connections between pressure plate and cover for cracks as well as rivet connections for secure seating.
A pressure plate with damaged spring connections or with loose rivet connections -arrows- must be renewed.
Renew clutch plates and pressure plates with damaged or loose rivet connections.
Select clutch plate and pressure plate according to engine code and Electronic parts catalogue „ETKA“ .
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 clutch plate to and fro on input shaft until hub moves freely on shaft. Remove excessive grease.
Pressure plates are protected against corrosion and greased. Clean contact surface only. Otherwise, the service life of the clutch will be considerably reduced.
Pressure plate contact surface and clutch plate lining must make full contact with flywheel. Only then insert securing bolts.
Reverse counterhold tool -3067- for installation.
What is the instruction for checking the position of the adjusting mechanism with new pressure plates only when repairing a LuK clutch on the VOLKSWAGEN GOLF VARIANT 2010?
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.
What are the notes for inspecting a LuK clutch on the VOLKSWAGEN GOLF VARIANT 2010?
Renew clutch plates and pressure plates with damaged or loose rivet connections.
Always renew pressure plate and clutch plate together.
Select clutch plate and pressure plate according to engine code and Electronic parts catalogue „ETKA“ .
If clutch has burnt out, thoroughly clean clutch housing, flywheel and parts of engine facing gearbox to reduce smell of burnt linings.
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 clutch plate to and fro on input shaft until hub moves freely on shaft. Remove excessive grease.
Pressure plates are protected against corrosion and greased. Clean contact surface only. Otherwise, the service life of the clutch will be considerably reduced.
Pressure plate contact surface and clutch plate lining must make full contact with flywheel. Only then insert securing bolts.
Reverse counterhold tool -3067- for installation.
What is the repair information for the Sachs clutch on the VOLKSWAGEN GOLF VARIANT 2010?
Dual-mass flywheel:
Removing and installing Rep. gr. 13
Ensure that centring pins fit tightly
Contact surface for clutch lining must be free of grooves, oil and grease
Clutch plate:
Allocation Electronic parts catalogue „ETKA“
Renew only together with pressure plate.
Removing and installing page 47
Installation position page 47
Thrust plate:
With adjusting mechanism
Allocation Electronic parts catalogue „ETKA“
Renew only together with clutch plate.
Removing and installing page 47
Check ends of diaphragm spring page 48
Check spring connections and riveted connections page 48 .
M6 bolt, 13 Nm, M7 bolt, 20 Nm:
Allocation Electronic parts catalogue „ETKA“
Loosen or tighten diagonally in small steps
What is the process for removing and installing the LuK clutch on the VOLKSWAGEN GOLF VARIANT 2010?
Removing:
Remove gearbox page 85 .
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:
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.
Checking ends of diaphragm spring:
Wear to half the thickness of the diaphragm spring -arrows- is permitted.
Checking spring connections and riveted connections:
Check spring connections -arrows A- for damage and riveted connections -arrows B- for secure seating.
What is the procedure for checking the position of the adjusting mechanism with new pressure plates only when repairing a LuK clutch on the VOLKSWAGEN GOLF VARIANT 2010?
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.
What are the notes for inspecting a LuK clutch on the VOLKSWAGEN GOLF VARIANT 2010?
Renew clutch plates and pressure plates with damaged or loose rivet connections.
Always renew pressure plate and clutch plate together.
Select clutch plate and pressure plate according to engine code and Electronic parts catalogue „ETKA“ .
If clutch has burnt out, thoroughly clean clutch housing, flywheel and parts of engine facing gearbox to reduce smell of burnt linings.
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 clutch plate to and fro on input shaft until hub moves freely on shaft. Remove excessive grease.
Pressure plates are protected against corrosion and greased. Clean contact surface only. Otherwise, the service life of the clutch will be considerably reduced.
Pressure plate contact surface and clutch plate lining must make full contact with flywheel. Only then insert securing bolts.
Reverse counterhold tool -3067- for installation.
What are the special tools and workshop equipment required for repairing the clutch on VOLKSWAGEN GOLF VARIANT 2010 vehicles with a petrol engine?
Counterhold -3067-
Centring mandrel -T10097-
Torque wrench -V.A.G 1331-
Grease for clutch plate splines -G 000 100-
What is the repair information for the clutch on the VOLKSWAGEN GOLF VARIANT 2010 with a petrol engine?
Dual-mass flywheel:
Removing and installing Rep. gr. 13
Ensure that centring pins fit tightly
Contact surface for clutch lining must be free of grooves, oil and grease
Clutch plate:
Allocation Electronic parts catalogue „ETKA“
Removing and installing page 55
Renew only together with SAC pressure plate.
Installation position page 56 .
SAC pressure plate:
SAC means „self-adjusting clutch“.
Renew only together with clutch plate.
Allocation Electronic parts catalogue „ETKA“
Removing and installing page 55
Check ends of diaphragm spring page 56
Check spring connections and riveted connections page 56 .
M6 bolt, 13 Nm, M7 bolt, 20 Nm:
Loosen or tighten diagonally in small steps
What is the process for removing and installing the clutch on the VOLKSWAGEN GOLF VARIANT 2010 with a petrol engine?
Removing:
Remove gearbox page 85 .
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:
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“ -arrow- faces gearbox.
Checking ends of diaphragm spring:
Wear to half the thickness of the diaphragm spring -arrows- is permitted.
Checking spring connections and riveted connections:
Check spring connections -arrows A- for damage and riveted connections -arrows B- for secure seating.
What is the procedure for checking the position of adjusting mechanism with new pressure plates only when repairing a clutch on the VOLKSWAGEN GOLF VARIANT 2010 with a petrol engine?
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.
What are the notes for checking spring connections and riveted connections when repairing a clutch on the VOLKSWAGEN GOLF VARIANT 2010 with a petrol engine?
Renew clutch plates and pressure plates with damaged or loose rivet connections.
Always renew pressure plate and clutch plate together.
Select clutch plate and pressure plate according to engine code and Electronic parts catalogue „ETKA“ .
If clutch has burnt out, thoroughly clean clutch housing, flywheel and parts of engine facing gearbox to reduce smell of burnt linings.
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 clutch plate to and fro on input shaft until hub moves freely on shaft. Remove excessive grease.
Pressure plates are protected against corrosion and greased. Clean contact surface only. Otherwise, the service life of the clutch will be considerably reduced.
Pressure plate contact surface and clutch plate lining must make full contact with flywheel. Only then insert securing bolts.
Reverse counterhold tool -3067- for installation.
What is the installation procedure for the clutch disc and pressure plate for engines having a crankshaft of smaller diameter or having a needle bearing in the crankshaft when repairing the clutch on the VOLKSWAGEN GOLF VARIANT 2010?
Push pressure plate onto centralizing pins.
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 Item 4 (page 53) .
Install gearbox page 85 .
What is the installation position of the clutch plate when repairing the clutch on the VOLKSWAGEN GOLF VARIANT 2010 with a petrol engine?
Lettering „Getriebeseite“ -arrow- faces gearbox.
What is the procedure for checking the ends of the diaphragm spring when repairing the clutch on the VOLKSWAGEN GOLF VARIANT 2010 with a petrol engine?
Wear to half the thickness of the diaphragm spring -arrows- is permitted.
What is the procedure for checking spring connections and riveted connections when repairing the clutch on the VOLKSWAGEN GOLF VARIANT 2010 with a petrol engine?
Check spring connections -arrows A- for damage and riveted connections -arrows B- for secure seating.
What is the note for checking the position of adjusting mechanism with new pressure plates only when repairing a clutch on the VOLKSWAGEN GOLF VARIANT 2010 with a petrol engine?
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.
What are the notes for repairing the clutch on the VOLKSWAGEN GOLF VARIANT 2010 with a petrol engine?
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.
What is the procedure for centring the clutch disc and removing and installing the pressure plate for engines having a crankshaft of smaller diameter or having a needle bearing in the crankshaft when repairing the clutch on the VOLKSWAGEN GOLF VARIANT 2010 with a petrol engine?
Push pressure plate onto centralizing pins.
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 Item 4 (page 55) .
Install gearbox page 85 .
What are the components for the VOLKSWAGEN GOLF VARIANT 2010 gearbox oil check?
Torque wrench -V.A.G 1331-
Multi-point bit -3357-
What is the procedure for checking gearbox oil on the VOLKSWAGEN GOLF VARIANT 2010?
Remove noise insulation.
To check gear oil, remove oil plug -arrow-.
Oil level is correct when gearbox is filled to lower edge of filler hole.
Screw in plug -arrow- with new seal.
Tighten bolt -arrow- to specified torque.
What is the procedure for filling with oil when checking gearbox oil on the VOLKSWAGEN GOLF VARIANT 2010?
Remove oil plug -arrow-.
Fill with gear oil to lower edge of filler hole.
Screw in plug -arrow- with new seal.
Tighten bolt -arrow- to specified torque.
Install noise insulation.
What are the various versions of oil filler and drain plugs for the VOLKSWAGEN GOLF VARIANT 2010 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 are the components shown in the overview – rear final drive for the VOLKSWAGEN GOLF VARIANT 2010 gearbox?
1 – Clutch housing
2 – Reverse shaft
3 – Output shaft for 5th, 6th and reverse gears
4 – Slave cylinder with clutch release bearing
5 – Input shaft
6 – Output shaft for 1st through 4th gears
7 – Differential
8 – Right flange shaft
9 – Left flange shaft
10 – Synchromeshed gear for 2nd gear
11 – Synchromeshed gear for 1st gear
12 – Synchromeshed gear for 4th gear
13 – Synchromeshed gear for 3rd gear
14 – Synchromeshed gear for 5th gear
15 – Synchromeshed gear for 6th gear
16 – Synchromeshed gear for reverse gear
17 – Gearbox housing
What are the assembly overview components for the VOLKSWAGEN GOLF VARIANT 2010 gearbox dismantling and assembling?
I – Removing and installing gearbox housing and selector mechanism page 130
II – Removing and installing input shaft, output shafts, differential and selector rods page 132
Note:
From gearbox date 21 01 8, sealing cover for input shaft is secured with a retaining ring -A-.
Assembly order, gearbox »without« retaining ring -A- for input shaft sealing cover page 134
Assembly order, gearbox »with« retaining ring -A- for input shaft sealing cover page 145
What are the components for removing and installing the gearbox housing and selector mechanism on the VOLKSWAGEN GOLF VARIANT 2010 gearbox?
1 – Countersunk bolt, 33 Nm
2 – Flange shaft with compression spring: Removing and installing page 227; Assembling page 233
3 – Retaining ring: For sealing cover; Fitted from gearbox date 21 01 8
4 – Cover plate: Secured with retaining ring from gearbox date 21 01 8; Allocate components according to Electronic parts catalogue „ETKA“ .
5 – Retaining ring: For deep groove ball bearing of input shaft page 180
6 – Reversing light switch -F4-, 20 Nm: Changed to captive seal shortly after introduction of gearbox page 130 .
7 – Seal: Not fitted in all gearboxes; Always renew
8 – Oil drain plug: Torque setting page 127
9 – Seal: Always renew
10 – Locking bolt, 45 Nm: For selector shaft
11 – Bolt, 15 Nm + turn 90° further: Bolt with captive washer only as replacement part; Always renew; allocate shim according to Electronic parts catalogue „ETKA“; Allocation of bolts as replacement part page 131
12 – Bolt, 15 Nm + turn 90° further: Without washer; Always renew; allocate shim according to Electronic parts catalogue „ETKA“; Allocation of bolts as replacement part page 131
13 – Selector unit: (Selector shaft with selector shaft cover)
14 – Bolt, 20 Nm: Always renew
15 – O-ring: Always renew
16 – Clutch housing: Repairing page 167 .
17 – Gearbox housing: Repairing page 157 .
What must be done if the gearbox housing is to be renewed when dismantling the gearbox housing and selector mechanism on the VOLKSWAGEN GOLF VARIANT 2010?
If renewed: adjust output shafts and differential page 232
What are the steps for removing the selector mechanism when dismantling the gearbox housing and selector mechanism on the VOLKSWAGEN GOLF VARIANT 2010?
Remove battery and battery tray.
The angled rod page 160 for adjusting the selector mechanism must not be engaged.
Remove selector cables and gearbox selector lever page 71
Remove locking screw page 130 and pull out selector mechanism
What is the note about the selector mechanism when removing the gearbox housing and selector mechanism on the VOLKSWAGEN GOLF VARIANT 2010?
Repairing page 172 .
Removing with gearbox installed:
Remove battery and battery tray.
The angled rod page 160 for adjusting the selector mechanism must not be engaged.
Remove selector cables and gearbox selector lever page 71
Remove locking screw page 130 and pull out selector mechanism
What are the components for removing and installing the input shaft, output shafts, differential and selector rods on the VOLKSWAGEN GOLF VARIANT 2010 gearbox?
1 – Output shaft for 1st through 4th gears: Dismantling and assembling page 187; Installation position page 133
2 – Selector rod with selector fork for 1st and 2nd gears: Installation position page 133
3 – Selector rod with selector fork for 3rd and 4th gears: Installation position page 133
4 – Output shaft for 5th, 6th and reverse gears: Dismantling and assembling page 211; Installation position page 133
5 – Selector rod with selector fork for 5th and 6th gears: Installation position page 133
6 – Selector fork for reverse gear: Installation position page 133; Distinguishing page 176; Repairing page 175 .
7 – Input shaft: Dismantling and assembling page 178; Always renew deep groove ball bearing on input shaft Item 6 (page 180) .
8 – Reverse shaft: With thrust washer
9 – Thrust washer
10 – Breather: Connect to slave cylinder Item 14 (page 132)
11 – Clutch housing: Repairing page 167 .
12 – Input shaft seal: Renewing page 167
13 – O-ring: Pull onto line connection; Moisten with brake fluid before installing
14 – Slave cylinder with clutch release bearing: Always renew; Without locking fluid 12 Nm (only slave cylinders with metal housing); With locking fluid 15 Nm (for plastic slave cylinders); Carefully tighten diagonally in small steps so that the bolting eyes of the slave cylinder do not break off
15 – Bolt: Qty. 3; Always renew
16 – Countersunk bolt, 33 Nm
17 – Flange shaft with compression spring: Removing and installing page 227; Assembling page 233
18 – Differential: Dismantling and assembling page 233
What is the installation position of shafts and selector rods in the gearbox for the VOLKSWAGEN GOLF VARIANT 2010?
1 – Input shaft
2 – Output shaft for 1st through 4th gears
3 – Output shaft for 5th, 6th and reverse gear
4 – Reverse shaft
A – Selector rod for 3rd and 4th gears
B – Selector rod for 1st and 2nd gears
C – Selector rod for 5th and 6th gears
D – Selector fork for reverse gear 1)
1) In some gearboxes, mounting of reverse gear selector fork on selector rod for selector fork for 5th and 6th gears – C – . Distinguishing between reverse gear selector forks page 176 .
What special tools and workshop equipment are required for Assembly order, gearbox »without« retaining ring -A- for input shaft sealing cover on the VOLKSWAGEN GOLF VARIANT 2010?
Support plate -VW 309-
Support clamp -VW 313-
Gearbox support -VW 353-
Sleeve -VW 455- or sleeve -3160-
Multipurpose tool -VW 771-
-1- Internal puller -Kukko 21/01-
-3- Splitter -Kukko 17/0-
-4- Counter support -Kukko 22/1-
What is the procedure for removing the input shaft, output shafts, differential and selector rods when following the Assembly order, gearbox »without« retaining ring -A- for input shaft sealing cover on the VOLKSWAGEN GOLF VARIANT 2010?
Secure gearbox to assembly stand using bolts -arrows-.
Note: If one of the bolting holes does not contact the gearbox support, lay a washer between the hole and the gearbox support.
Rotate gearbox on assembly stand so that oil drain plug is below.
Place drip tray underneath.
Drain gear oil.
Remove slave cylinder with clutch release bearing -arrows-.
During the following steps, ensure that the selector shaft is not blocked by the angled rod -arrow-.
Move selector shaft to neutral.
Remove reversing light switch -F4- -1-.
Remove locking bolt -2-.
Then remove bolts -3-.
Pull selector shaft with selector shaft cover -4- out of gearbox housing.
Remove securing bolt for left and right flange shaft by screwing two bolts into flange and counterholding flange shaft with a lever.
Pull out flange shafts with compression spring.
Remove bolts -B-, which secure gearbox housing to clutch housing.
Note: One bolt -arrow- is located outside of bolting flange.
Lock input shaft as follows:
Set either installing sleeve -VW 455- over input shaft on clutch housing or set sleeve -3160- over input shaft on clutch housing.
Clamp splitter -A-, e.g. -Kukko 17/0- , behind notch in splines of input shaft. The back side of the splitter must rest against installing sleeve -VW 455- or sleeve -3160- without play.
Pierce rubber in centre of cover -C- with a screwdriver.
Pull cover plate out of gearbox housing.
Remove retaining ring -C- from deep groove ball bearing of input shaft in gearbox housing as follows:
Hold one end of retaining ring with screwdriver -A-.
Using a screwdriver , -B-, lever other end out of groove in deep groove ball bearing -direction of arrow-.
Using screwdriver -B-, lever out securing ring further.
If present, remove washer -1- from gearbox housing -2-.
Note: If gearbox housing is to be renewed, check whether washer must be installed page 141 .
Remove securing bolts -A- for gearbox housing to clutch housing.
Heat gearbox housing using hot air blower , e.g. -V.A.G 1416- in vicinity of bearing seat for deep groove ball bearing for input shaft for about 10 minutes to about 100° C.
Using multi-purpose tool -VW 771/1- , pull gearbox housing off clutch housing in -direction of arrow-.
Remove splitter -A- and installing sleeve VW 455 or sleeve -3160- from input shaft.
To remove shafts from clutch housing, a second mechanic is required.
With left hand, raise differential -1-. With right hand, lift output shaft for 1st to 4th gear together with selector rods -2- -arrow A-.
At same time, second mechanic lifts input shaft, reverse shaft and output shaft for reverse, 5th and 6th gears -3- together with selector rods out of clutch housing -arrow B-.
Note: After shafts are lifted, differential may be set back in clutch housing if desired.
Remove input shaft oil seal.
Note: Always renew deep groove ball bearing on input shaft Item 6 (page 180) .
What is the installation procedure for the input shaft, output shafts, differential and selector rods when following the Assembly order, gearbox »without« retaining ring -A- for input shaft sealing cover on the VOLKSWAGEN GOLF VARIANT 2010?
A new deep groove ball bearing has been pressed onto the input shaft Item 6 (page 180) .
Insert input shaft -1-, output shaft for 5th and 6th gears -2- together with selector rod -3-, selector fork -4- and reverse shaft -5-.
Then insert differential -1-.
Note: A second mechanic will be required for further installation of shafts in clutch housing.
Take output shaft for 1st through 4th gears -3- with selector rods -4- in the right hand as shown in figure.
With the left hand, lift differential -1- slightly.
At the same time, a 2nd mechanic must slightly lift input shaft and output shaft for 5th and 6th gears and reverse gear -2- together with reverse gear shaft.
Now insert output shaft for 1st through 4th gears in -direction of arrow-.
The teeth of the input shaft, the output shafts and the final drive input gear of differential must mesh.
Now, together with a second mechanic, place shafts and differential in their bearing seats.
Secure support bridge -30 – 211 A- for input shaft to clutch housing.
Note: For clarity of illustration, clutch housing is shown turned 180°.
Screw in bolt -A- until input shaft rises slightly.
Set gearbox housing in place and tighten new bolts -A-, -B and -C- to specified torque.
If a washer was laid on the deep groove ball bearing before the gearbox housing was set in place, a washer -1- (outer diameter = 78.6 mm) must also be placed above the deep groove ball bearing -2- page 141 .
Install retaining ring -1- for deep groove ball bearing of input shaft.
Remove support bridge -30 – 211 A- for input shaft.
If stop sleeve for selector shaft has been removed, now drive it in to stop of tool page 163 .
Turn gearbox in repair stand with opening for selector shaft upwards.
Insert selector shaft -1- in lower bearing -2- and in selector forks -3-.
Note: For better clarity, sealing cover is removed in illustration.
Now press selector shaft -1- against stop sleeve -2- in -direction of arrow- and guide downwards with selector finger -3- through selector forks to stop.
Selector shaft cover -4- must be parallel to bolting surface on gearbox housing.
Selector shaft must move freely in gate selection direction (upwards and downwards).
Note: If selector shaft cover is tilted relative to bolting surface, selector shaft is not inserted in lower bearing.
Tighten bolts -3- for selector shaft cover -4-.
Screw in locking bolt -2-, ensuring that angled rod -arrow- is not engaged.
Install reversing light switch -F4- -1-.
Install left and right flange shaft with springs, thrust washers and tapered rings.
Drive in input shaft oil seal flush.
Install slave cylinder with release bearing page 39 .
Shift through all gears.
What are the special tools and workshop equipment required for Assembly order, gearbox »with« retaining ring -A- for input shaft sealing cover on the VOLKSWAGEN GOLF VARIANT 2010?
Thrust piece -T10042-
What is the procedure for driving the sealing cover into the gearbox housing to stop using the thrust piece on the VOLKSWAGEN GOLF VARIANT 2010 when following the Assembly order, gearbox »with« retaining ring -A- for input shaft sealing cover?
Drive sealing cover into gearbox housing to stop of thrust piece.
Secure sealing cover with retaining ring -A-.
Install flange shafts together with springs, thrust washers and tapered rings.
What are the special tools and workshop equipment required for repairing the gearbox housing on the VOLKSWAGEN GOLF VARIANT 2010?
Drift sleeve -VW 244 B-
Gearbox support -VW 353-
Thrust plate -VW 401-
Thrust plate -VW 402-
Press tool -VW 407-
Tube -VW 416 B-
What are the special tools required for removing the angled rod for selector shaft on the VOLKSWAGEN GOLF VARIANT 2010 gearbox housing repair?
Guide pin -VW 436A-
Guide pin -VW 439-
Multipurpose tool -VW 771-
Support plate -VW 801-
Guide pin -10 – 15-
Thrust piece -3124-
What is the procedure for removing the angled rod for selector shaft on the VOLKSWAGEN GOLF VARIANT 2010 gearbox housing repair?
Break off angled rod in released position.
Insert a screwdriver -A- in hole for angled rod -B-.
Lever out angled rod in -direction of arrow-.
What is the installation position of the angled rod on the VOLKSWAGEN GOLF VARIANT 2010 gearbox housing repair?
Marking on angled rod -arrow- must face slave cylinder connection -1-.
Dimension -a- must be about 45°.
What is the note when driving in the angled rod for the selector shaft on the VOLKSWAGEN GOLF VARIANT 2010 gearbox housing repair?
Angled rod must be released while it is being driven in.
What are the details for pulling out the selector rod bearing bush on the VOLKSWAGEN GOLF VARIANT 2010 gearbox housing repair?
A – Internal puller, 14.5 … 18.5 mm , e.g. -Kukko 21/2-
B – Counter support , e.g. -Kukko 22/2-
What is the procedure for driving in the selector shaft bearing bush to the stop of the tool on the VOLKSWAGEN GOLF VARIANT 2010 gearbox housing repair?
Drive in selector shaft bearing bush -A- to stop of tool.
What is the procedure for driving out plug -1- on the VOLKSWAGEN GOLF VARIANT 2010 gearbox housing repair?
Drive in plug -1- outwards from inside gearbox housing.
What is the procedure for driving in plug -1- on the VOLKSWAGEN GOLF VARIANT 2010 gearbox housing repair?
Drive in sealing plug to dimension -a-, about 3 mm below upper edge of housing, using drift -3264- .
What is the procedure for pressing the stop sleeve -A- out of the gearbox housing on the VOLKSWAGEN GOLF VARIANT 2010 gearbox housing repair?
Set gearbox housing on thrust plates -VW 401- and -VW 402- so that dowel sleeves in gearbox housing are not damaged.
Remove locking screw and selector shaft.
Turn gearbox so that stop sleeve does not fall in gearbox.
How can stop sleeves be identified for the VOLKSWAGEN GOLF VARIANT 2010 gearbox housing repair?
Stop sleeve with shoulder -arrow 1- page 164 .
Stop sleeve without shoulder -arrow 2- page 164 .
Allocate components according to Electronic parts catalogue „ETKA“ .
What is the procedure for driving the stop sleeve with shoulder until tool makes contact on the VOLKSWAGEN GOLF VARIANT 2010 gearbox housing repair?
Drive in stop sleeve with shoulder until tool makes contact.
Clutch housing bolted to gearbox housing.
What is the procedure for driving in the stop sleeve without shoulder on the VOLKSWAGEN GOLF VARIANT 2010 gearbox housing repair?
Drive in stop sleeve without shoulder until tool makes contact.
Clutch housing bolted to gearbox housing.
What are the details for pulling the reverse shaft needle bearing out of the gearbox housing on the VOLKSWAGEN GOLF VARIANT 2010 gearbox housing repair?
A – Internal puller, 23.5 … 30 mm , e.g. -Kukko 21/4-
B – Counter support , e.g. -Kukko 22/2-
Note: The needle bearing is destroyed during removal and must be renewed.
What is the procedure for pressing the needle bearing -A- into the clutch housing on the VOLKSWAGEN GOLF VARIANT 2010 gearbox housing repair?
Before pressing in, lay reverse shaft thrust washer -B- on needle bearing.
What is the note for removing the input shaft oil seal on the VOLKSWAGEN GOLF VARIANT 2010 gearbox housing repair?
When gearbox is removed, oil seal can be removed with drift.
What is the procedure for pulling out the selector shaft bearing bush on the VOLKSWAGEN GOLF VARIANT 2010 gearbox housing repair?
Use thread adapter from counter support -Kukko 22/1- -arrow-.
Hold spindle of assembly tool -3290- securely and turn nut -B-.
A – Internal puller, 14.5 … 18.5 mm , e.g. -Kukko 21/2-
What is the procedure for driving in the selector shaft bearing bush -A- to stop of tool on the VOLKSWAGEN GOLF VARIANT 2010 gearbox housing repair?
Drive in selector shaft bearing bush -A- to stop of tool.
What is the procedure for driving out plug -1- on the VOLKSWAGEN GOLF VARIANT 2010 gearbox housing repair?
Drive in plug -1- outwards from inside gearbox housing.
What is the procedure for driving in plug -1- on the VOLKSWAGEN GOLF VARIANT 2010 gearbox housing repair?
Drive in sealing plug to dimension -a-, about 3 mm below upper edge of housing, using drift -3264- .
What are the special tools and workshop equipment required for repairing the selector unit on the VOLKSWAGEN GOLF VARIANT 2010?
Tube -VW 423-
Oil seal extractor lever -T20143/1-
Sealing grease -G 052 128 A1-
What is the removal procedure for the oil seal for the selector shaft on the VOLKSWAGEN GOLF VARIANT 2010 when repairing the selector unit?
Remove complete air filter housing if it is over selector shaft.
What is the repair information for the selector unit on the VOLKSWAGEN GOLF VARIANT 2010?
1 – Hexagon nut, 23 Nm: Self-locking; Always renew
2 – Gearbox selector lever: Install so that master spline aligns with selector shaft; Can be renewed with the selector mechanism installed; Installation position page 74; After installing, adjust selector mechanism page 82
3 – Shoe: Clip into relay lever Item 5 (page 172)
4 – Bearing bush: Not required for plastic relay lever
5 – Relay lever: Installation position page 74; After installing, adjust selector mechanism, page 82; From 05.07, plastic relay lever page 75
6 – Selector unit: Consists of selector shaft and selector shaft cover; Components cannot be separated from each other; Can be removed and installed with gearbox installed
7 – Bearing bush: For selector shaft; Removing and installing Item 16 (page 161)
8 – O-ring: Insert in peripheral groove of selector mechanism cover; Coat with gear oil when installing; Always renew
9 – Cap: For gearbox breather
10 – Lock washer: For relay lever; Not fitted on plastic relay lever; Always renew
11 – Seal for selector shaft: Renewing page 173
What is the procedure for removing the oil seal for the selector shaft on the VOLKSWAGEN GOLF VARIANT 2010 when repairing the selector unit?
Remove complete air filter housing if it is over selector shaft.
What is the procedure for removing the oil seal for the selector shaft on the VOLKSWAGEN GOLF VARIANT 2010 when repairing the selector unit?
Metal relay lever:
Pull off securing clip -2- and press relay lever -3- to side out of mounting.
Note: If relay lever cannot be removed due to gearbox bracket, remove gate selector cable from relay lever. Guide shoe out of gearbox selector lever.
Plastic relay lever:
Remove relay lever together with cable end-piece page 75 .
Continued for all selector mechanisms:
Remove nuts -4- and remove gearbox selector lever -1-.
Lever out seal using oil seal extractor lever -T20143/1- .
Lightly oil outer circumference of new oil seal.
Fill space between sealing lip and dust lip -arrow- with sealing grease -G 052 128 A1- .
Drive in seal using thrust piece -VW 423- .
Carry out further installation in the reverse sequence noting the following points:
Install gearbox selector lever on selector shaft of gearbox and tighten hexagon nut to specified torque Item 1 (page 172) .
Note: The gearbox selector lever can be installed in only one position.
Adjust selector mechanism page 82 .
If removed, install complete air filter housing.
What are the special tools and workshop equipment required for repairing selector forks on the VOLKSWAGEN GOLF VARIANT 2010?
Thrust plate -VW 402-
Press tool -VW 411-
Tube -VW 426-
Thrust piece -VW 431-
-1- Internal puller -Kukko 21/3-
-4- Counter support -Kukko 22/1-
What are the components for the selector rods and forks on the VOLKSWAGEN GOLF VARIANT 2010 when repairing selector forks?
1 – Rubber dampers: Can be removed from and inserted in selector rod by hand
2 – Selector rod with selector fork for 1st and 2nd gears
3 – Selector rod with selector fork for 3rd and 4th gears
4 – Selector rod with selector fork for 5th and 6th gears
5 – Selector fork for reverse gear: Is mounted on shaft for reverse gear selector fork page 152; From gearbox manufacture date 06 03 6, ball sleeve Item 6 (page 176) is discontinued; Gradually discontinued; Reverse gear selector fork is modified; If shaft for reverse gear selector fork is not present, mounting on selector rod for selector fork for 5th and 6th gear page 152; Distinguishing between reverse gear selector forks page 176; Allocation of components via Electronic parts catalogue (ETKA)
6 – Ball sleeve: Pulling out page 177; Pressing in page 177; From gearbox manufacture date 06 03 6, ball sleeve is discontinued; Gradually discontinued
What is the distinguishing information between reverse gear selector forks for the VOLKSWAGEN GOLF VARIANT 2010 when repairing selector forks?
| Dim. „a“ mm | Selector fork for reverse gear | Mounting |
|---|---|---|
| 24 | With ball sleeve | On reverse gear selector fork shaft page 152 |
| 18 | Without ball sleeve | |
| 15 | Without ball sleeve | On selector rod with selector fork for 5th and 6th gears page 152 |
What is the procedure for pulling out the ball sleeve for reverse gear selector fork through gearbox manufacture date 05 03 6 on the VOLKSWAGEN GOLF VARIANT 2010 when repairing selector forks?
A – Internal puller, 18 … 23 mm , e.g. -Kukko 21/3-
B – Counter support , e.g. -Kukko 22/1-
What is the procedure for pressing in the ball sleeve for reverse gear selector fork through gearbox manufacture date 05 03 6 on the VOLKSWAGEN GOLF VARIANT 2010 when repairing selector forks?
No specific procedure provided in the PDF for this step alone.
What are the special tools and workshop equipment required for dismantling and assembling the input shaft on the VOLKSWAGEN GOLF VARIANT 2010?
Thrust plate -VW 401-
Thrust plate -VW 402-
Press tool -VW 407-
Press tool -VW 412-
Thrust piece -VW 431-
Thrust piece -VW 432-
What are the special tools and workshop equipment required for dismantling and assembling the input shaft on the VOLKSWAGEN GOLF VARIANT 2010?
Thrust piece -VW 454-
Thrust piece -30 – 505-
Thrust plate -40 – 105-
Tube -2040-
-1- Internal puller -Kukko 21/5-
-2- Puller -Kukko 18/1-
-3- Splitter -Kukko 17/1-
-3- Splitter -Kukko 17/2-
-4- Counter support -Kukko 22/2-
What is the note regarding bearings when working on the input shaft on the VOLKSWAGEN GOLF VARIANT 2010?
Install all bearings on input shaft with gear oil.
Always renew deep groove ball bearing Item 6 (page 180) .
What is the instruction for pressing on the deep groove ball bearing on the input shaft on the VOLKSWAGEN GOLF VARIANT 2010?
Deep groove ball bearing with a rubber ring -arrow Shoulder -A- faces press tool -VW 412- .
What is the installation position of the deep groove ball bearing on the input shaft on the VOLKSWAGEN GOLF VARIANT 2010?
Groove for retaining ring faces upwards -arrow A- and shoulder -arrow B- must face gear wheel for 5th gear.
Determine and install retaining ring page 182 .
What is the procedure for determining the thickness of the retaining ring for the input shaft on the VOLKSWAGEN GOLF VARIANT 2010?
Insert a 1.86 mm thick retaining ring -A- in groove of input shaft and press upwards.
Measure distance between deep groove ball bearing -B- and installed retaining ring -A- using feeler gauge -C-.
Remove retaining ring used for measuring purposes.
Determine retaining ring from table.
Allocate retaining rings using Electronic parts catalogue „ETKA“ .
The following retaining rings are available:
| Measured value (mm) | Retaining ring thickness (mm) | Axial play (mm) |
|---|---|---|
| 0.01…0.05 | 1.86 | 0.01…0.05 |
| 0.05…0.07 | 1.89 | 0.01…0.05 |
| 0.07…0.10 | 1.92 | 0.01…0.05 |
| 0.10…0.13 | 1.95 | 0.01…0.05 |
| 0.13…0.16 | 1.98 | 0.01…0.05 |
What is the procedure for pulling the tapered roller bearing outer race out of the clutch housing on the VOLKSWAGEN GOLF VARIANT 2010 input shaft assembly?
A – Counter support , e.g. -Kukko 22/2-
B – Internal puller, 46 … 58 mm , e.g. -Kukko 21/7-
What is the procedure for pressing the tapered roller bearing outer race into the clutch housing on the VOLKSWAGEN GOLF VARIANT 2010 input shaft assembly?
Support clutch housing with drift sleeve -40-20- directly below bearing support.
What is the procedure for pulling off the tapered roller bearing inner race on the side facing the gearbox housing on the VOLKSWAGEN GOLF VARIANT 2010 input shaft assembly?
Before setting up tapered roller bearing puller:
Remove retaining ring for tapered roller bearing inner race on side facing clutch housing.
Insert press tool -VW 431- into output shaft and place thrust plate -40-105- on that.
What is the procedure for pressing on the tapered roller bearing inner race on the side facing the gearbox housing on the VOLKSWAGEN GOLF VARIANT 2010 input shaft assembly?
Determine and install retaining ring page 194 .
What is the procedure for determining the thickness of the retaining ring for the tapered roller bearing inner race on the VOLKSWAGEN GOLF VARIANT 2010 input shaft assembly?
Determine thickest retaining ring which will still fit and install it.
Determine retaining ring from table. Part number Electronic parts catalogue „ETKA“ .
The following retaining rings are available:
| Thickness (mm) | ||
|---|---|---|
| 1.79 | 1.89 | 1.98 |
| 1.83 | 1.92 | |
| 1.86 | 1.95 |
What is the procedure for pressing on the tapered roller bearing inner race on the side facing the gearbox housing on the VOLKSWAGEN GOLF VARIANT 2010 input shaft assembly?
Determine and install retaining ring page 194 .
What is the procedure for checking the outer friction surface of the 1st gear outer ring and 2nd gear outer ring for wear on the VOLKSWAGEN GOLF VARIANT 2010 output shaft for 1st through 4th gears?
Check inner surface of synchro-ring -arrow- for scoring and radial contact scoring, renew if necessary.
Place inner ring, outer ring and synchro-ring on cone of inner ring.
Press on synchro-ring with outer ring whilst turning at same time in order to seat them.
Measure gap size -a- at 3 points offset by 120° using feeler gauge.
Make a note of average value.
| Gap -a- | Installation dimension | Wear limit |
|---|---|---|
| 1st and 2nd gears | 1.00 … 1.80 mm | 0.8 mm |
Install 2nd gear synchromeshed gear with needle bearing.
What is the installation position of the outer ring, inner ring and synchro-ring for 2nd gear on the VOLKSWAGEN GOLF VARIANT 2010 output shaft for 1st through 4th gears?
Check lugs -arrows 1- and -arrows 2- for scoring.
Renew inner ring, outer ring and synchro-ring in case of scoring.
Place inner ring -A- on synchromeshed gear for 2nd gear.
Angled lugs -arrows 1- face outer ring -B-.
Fit outer ring -B-.
Lugs -arrows 2- engage in notches -arrows 3- of synchromeshed gear.
Fit synchro-ring -C-.
Notches -arrows 4- engage in lugs -arrows 1- of inner ring -A-.
What is the procedure for assembling locking collars and synchro-hubs for 1st and 2nd gears as well as 3rd and 4th gears on the VOLKSWAGEN GOLF VARIANT 2010 output shaft for 1st through 4th gears?
Locking collar has been pushed over synchro-hub.
Insert locking pieces and install springs offset 120°. Angled end of spring must locate in hollow locking piece.
What is the installation position of the locking collar with synchro-hub for 1st and 2nd gears on the VOLKSWAGEN GOLF VARIANT 2010 output shaft for 1st through 4th gears?
Identification groove -arrow 1- and narrow collar -arrow 2- of synchro-hub face 1st gear.
What is the procedure for pressing on the locking collar and synchro-hub for 1st and 2nd gears on the VOLKSWAGEN GOLF VARIANT 2010 output shaft for 1st through 4th gears?
Pins -A- of synchro-ring engage in notches -B- of synchro-hub.
Install retaining ring.
What is the procedure for installing the synchro-ring for 1st gear on the VOLKSWAGEN GOLF VARIANT 2010 output shaft for 1st through 4th gears?
Insert synchro-ring for 1st gear.
What is the installation position of the 1st gear outer ring on the VOLKSWAGEN GOLF VARIANT 2010 output shaft for 1st through 4th gears?
Lugs -arrows- face synchro-hub and locking collar -A-.
What is the installation position of the synchro-ring -A- (1st gear inner ring) on the VOLKSWAGEN GOLF VARIANT 2010 output shaft for 1st through 4th gears?
Lugs -arrows 1- locate in notches -arrows 2- of synchro-ring -B-.
What is the procedure for installing the synchromeshed gear for 1st gear with needle bearing on the VOLKSWAGEN GOLF VARIANT 2010 output shaft for 1st through 4th gears?
Higher shoulder -A- faces 2nd gear -B-. Notches in shoulder -arrows- engage in lugs of outer ring page 198 .
Install thrust washers for 1st and 4th gears Item 19 (page 186) and Item 20 (page 186) .
Install 4th gear synchromeshed gear with needle bearing.
What is the wear check for the synchro-ring for 4th gear on the VOLKSWAGEN GOLF VARIANT 2010 output shaft for 1st through 4th gears?
Press synchro-ring onto cone of synchromeshed gear and measure gap -a- using feeler gauge.
| Gap -a- | Installation dimension | Wear limit |
|---|---|---|
| 4th gear | 1.0 … 1.7 mm | 0.5 mm |
What is the installation position of the locking collar with synchro-hub for 3rd and 4th gears on the VOLKSWAGEN GOLF VARIANT 2010 output shaft for 1st through 4th gears?
Wider shoulder of synchro-hub -arrow- faces 3rd gear.
What is the procedure for pressing on the synchro-hub with locking collar for 3rd and 4th gears on the VOLKSWAGEN GOLF VARIANT 2010 output shaft for 1st through 4th gears?
Turn synchro-ring so that grooves align with locking pieces.
Install retaining ring.
Place 3rd gear synchro-ring on locking collar with synchro-hub for 3rd and 4th gears.
What is the installation position of the 3rd gear outer ring on the VOLKSWAGEN GOLF VARIANT 2010 output shaft for 1st through 4th gears?
Lugs -arrows- face synchro-hub and locking collar -A-.
What is the procedure for checking the inner ring for 3rd gear for wear on the VOLKSWAGEN GOLF VARIANT 2010 output shaft for 1st through 4th gears?
Press inner ring onto cone of synchromeshed gear and measure gap -a- using a feeler gauge.
| Gap -a- | Installation dimension | Wear limit |
|---|---|---|
| 3rd gear | 0.75 … 1.25 mm | 0.3 mm |
What is the procedure for checking the synchro-ring for 3rd gear for wear on the VOLKSWAGEN GOLF VARIANT 2010 output shaft for 1st through 4th gears?
Press synchro-ring, outer ring and inner ring onto cone of synchromeshed gear and measure gap -a- using a feeler gauge.
| Gap -a- | Installation dimension | Wear limit |
|---|---|---|
| 3rd gear | 1.2 … 1.8 mm | 0.5 mm |
Place 3rd gear synchro-ring on locking collar with synchro-hub for 3rd and 4th gears.
What is the procedure for adjusting output shaft for 1st through 4th gears on the VOLKSWAGEN GOLF VARIANT 2010?
Press tapered roller bearing outer race with 1.70 mm thick shim into gearbox housing to stop. In the process, support gearbox housing using thrust piece -2050- directly below bearing support.
Set complete output shaft for 1st through 4th gears in clutch housing.
Set gearbox housing in position and tighten bolts -A- as well as -B- alternately and diagonally to specified torque.
Set up measuring tools and secure to clutch housing using bolt -arrow-.
Set dial gauge (3 mm measuring range) to „0“ with 1 mm preload.
Loosen clutch housing/gearbox housing securing bolts diagonally until the bolts release the gearbox housing or output shaft.
Read and note value on dial gauge (example: 0.14 mm).
Note:
If no value is indicated when clutch housing/gearbox housing securing bolts are loosened: Install 1.95 mm shim or, if necessary, 2.20 mm shim.
Allocate shims using Electronic parts catalogue (ETKA) .
How is the thickness of the shim determined for adjusting the output shaft for 1st through 4th gears on the VOLKSWAGEN GOLF VARIANT 2010?
Specified bearing preload is obtained as follows: Subtracting measured value (0.14 mm) from inserted shim (1.70 mm). Add a constant value for preload (0.20 mm).
Example:
Installed shim 1.70 mm
Measured value 0.14 mm
Preload (constant) 0.20 mm
Shim thickness 1.76 mm
Determine thickness of shim from table page 209 .
Remove gearbox housing and pull tapered roller bearing outer race from gearbox housing.
A – Counter support , e.g. -Kukko 22/2-
B – Internal puller, 46 … 58 mm , e.g. -Kukko 21/7-
Remove inserted shim (1.70 mm thick) from gearbox housing.
The following shims are available:
| Thickness (mm) | ||
|---|---|---|
| 1.45 | 1.75 | 2.05 |
| 1.50 | 1.80 | 2.10 |
| 1.55 | 1.85 | 2.15 |
| 1.60 | 1.90 | 2.20 |
| 1.65 | 1.95 | 2.25 |
| 1.70 | 2.00 |
The various thicknesses make it possible to achieve the exact shim thickness required.
Determine part number of shim according to Electronic parts catalogue „ETKA“ .
Press in tapered roller bearing outer race together with correct shim (in example 1.75 mm). In the process, support gearbox housing using thrust piece -2050- directly below bearing support.
What is the procedure for carrying out the check measurement for adjusting output shaft for 1st through 4th gears on the VOLKSWAGEN GOLF VARIANT 2010?
Determined shim installed.
Set up measuring tools.
Set up measuring tools and secure to clutch housing using bolt -arrow-.
Set dial gauge (3 mm measuring range) to „0“ with 1 mm preload.
Loosen clutch housing/gearbox housing securing bolts diagonally until the bolts release the gearbox housing or output shaft.
If correct shim has been selected, dial gauge will indicate a value between 0.15 mm to 0.25 mm.
What special tools and workshop equipment are required for adjusting output shaft for 5th, 6th and reverse gears on the VOLKSWAGEN GOLF VARIANT 2010?
Gearbox support -VW 353-
Universal dial gauge bracket -VW 387-
Press tool -VW 407-
Thrust piece -VW 433-
Assembly tool -VW 792-
Support plate -VW 801-
When is it necessary to readjust the output shaft for 5th, 6th and reverse gears when components are renewed on the VOLKSWAGEN GOLF VARIANT 2010?
It is necessary to readjust the output shaft when the following components are renewed:
Gearbox housing
Clutch housing
Output shaft for 5th, 6th and reverse gears or
Tapered roller bearing for output shaft
Adjustment overview page 232 .
Prerequisites:
Sealing surfaces of clutch and gearbox housings must be free of sealant.
When taking measurements, install only the output shaft to be measured.
What is the procedure for adjusting the output shaft for 5th, 6th and reverse gears on the VOLKSWAGEN GOLF VARIANT 2010?
Press tapered roller bearing outer race with 1.70 mm thick shim into gearbox housing to stop. In the process, support gearbox housing using thrust piece -2050- directly below bearing support.
Set complete 5th, 6th and reverse gear output shaft in clutch housing.
Set gearbox housing in position and tighten bolts -A- as well as -B- alternately and diagonally to specified torque.
Set up measuring tools.
If the edge of the housing protrudes, put washers with a total thickness of 8 mm on bolt -arrow- for securing assembly device -VW 792- to clutch housing.
Set dial gauge (3 mm measuring range) to „0“ with 1 mm preload.
Loosen clutch housing/gearbox housing securing bolts diagonally until the bolts release the gearbox housing or output shaft.
Read and note value on dial gauge (example: 0.25 mm).
Note:
If dial gauge indicates no value when clutch housing/gearbox housing securing bolts are loosened, install a 1.95 mm shim or, if necessary, a 2.20 mm shim.
Allocate shims according to Electronic parts catalogue „ETKA“ .
How is the thickness of the shim determined for adjusting the output shaft for 5th, 6th and reverse gears on the VOLKSWAGEN GOLF VARIANT 2010?
The specified bearing preload will be attained by subtracting the measured value (0.25 mm) from the inserted shim (1.70 mm) and adding a constant value for preload (0.20 mm).
Example:
Installed shim 1.70 mm
– Measured value 0.25 mm
+ Preload (constant) 0.20 mm
Shim thickness 1.65 mm
Determine thickness of shim from table page 225 .
Remove gearbox housing and pull tapered roller bearing outer race from gearbox housing.
A – Counter support , e.g. -Kukko 22/2-
B – Internal puller, 46 … 58 mm , e.g. -Kukko 21/7-
Remove inserted shim (1.70 mm thick) from gearbox housing.
Table of shims:
| Thickness (mm) | ||
|---|---|---|
| 1.50 | 1.80 | 2.10 |
| 1.55 | 1.85 | 2.15 |
| 1.60 | 1.90 | 2.20 |
| 1.65 | 1.95 | 2.25 |
| 1.70 | 2.00 | |
| 1.75 | 2.05 |
The various thicknesses make it possible to achieve the exact shim thickness required.
Determine part number of shim according to Electronic parts catalogue „ETKA“ .
Press in tapered roller bearing outer race together with correct shim (in example 1.65 mm). In the process, support gearbox housing using thrust piece -2050- directly below bearing support.
What is the procedure for carrying out the check measurement for adjusting the output shaft for 5th, 6th and reverse gears on the VOLKSWAGEN GOLF VARIANT 2010?
Determined shim installed.
Set up measuring tools.
What are the special tools and workshop equipment required for adjusting the differential on the VOLKSWAGEN GOLF VARIANT 2010?
Gearbox support -VW 353-
End dimension plate -VW 385/17-
Universal dial gauge bracket -VW 387-
Thrust plate -VW 402-
Press tool -VW 408 A-
Thrust plate -3005-
What is the procedure for installing the differential bevel gears on the VOLKSWAGEN GOLF VARIANT 2010 when adjusting the differential?
Lubricate one-piece thrust washer with gear oil and install.
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 differential pinion pin into final position and secure with spring pin.
What is the procedure for adjusting the differential on the VOLKSWAGEN GOLF VARIANT 2010?
Press tapered roller bearing outer race with washer into clutch housing.
Note:
Observe installation position of washer.
Shoulder on inner circumference faces seal in clutch housing.
Press tapered roller bearing outer race, without shim, into gearbox housing.
Fit differential into clutch housing.
Fit gearbox housing and tighten 5 bolts to specified torque Item 11 (page 130) and Item 12 (page 130) .
Press differential in direction of clutch housing while turning it eight times.
Press differential in direction of gearbox housing while turning it eight times.
Attach dial gauge and set to „0“ with 1 mm preload.
A – 30 mm dial gauge extension
Move differential up and down. Read and note play indicated on dial gauge. (Example: 0.70 mm)
How is the thickness of the shim determined for adjusting the differential on the VOLKSWAGEN GOLF VARIANT 2010?
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
Remove gearbox housing.
Pull tapered roller bearing outer race out of gearbox housing.
A – Counter support , e.g. -Kukko 22/2-
B – Internal puller, 46 … 58 mm , e.g. -Kukko 21/7-
Determine part number of shim according to Electronic parts catalogue „ETKA“ .
Insert shims of determined thickness, thickest shim first.
The following shims are available:
| Shim thickness (mm) | |||
|---|---|---|---|
| 0.65 | 0.85 | 1.05 | 1.25 |
| 0.70 | 0.90 | 1.10 | |
| 0.75 | 0.95 | 1.15 | |
| 0.80 | 1.00 | 1.20 |
If the size of shim required is larger than those listed in the table, insert two shims totalling the correct figure. When using two shims, install the thicker one first.
The various thicknesses make it possible to achieve the exact shim thickness required.
What is the procedure for carrying out the check measurement for adjusting the differential on the VOLKSWAGEN GOLF VARIANT 2010?
Determined shim installed.
Set up measuring tools.
Press tapered roller bearing outer race with washer into clutch housing.
Note: Observe installation position of washer.
Shoulder on inner circumference faces seal in clutch housing.
Press tapered roller bearing outer race, without shim, into gearbox housing.
Fit differential into clutch housing.
Fit gearbox housing and tighten 5 bolts to specified torque Item 11 (page 130) and Item 12 (page 130) .
Press differential in direction of clutch housing while turning it eight times.
Press differential in direction of gearbox housing while turning it eight times.
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)
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