VOLKSWAGEN GOLF VARIANT 2010 (11) PDF Document

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.

A number of instructions generally applicable to the various repair procedures are summarised under the topic “components” on page 8. They apply to this manual.

When installing the manual gearbox for 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”.

If the gearbox is repaired, fill with gear oil.

The capacity specifications for the gearbox are as follows:

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.

After removing gaskets and seals, always inspect contact surface of housing or shaft for burrs resulting from removal or for other signs of damage.

Before installing radial shaft seals, lightly oil outer diameter and half-fill space between sealing lips -arrow- with sealing grease -G 052 128 A1- .

The open side of the oil seal faces the side with fluid filling.

Press 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, refer to page 99.

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-.

Loosen nuts or bolts in the order opposite to the tightening sequence.

Nuts and bolts which secure covers and housings should be loosened and tightened diagonally in stages if no tightening sequence is specified.

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.

Threads of bolts secured with locking fluid must be cleaned with a wire brush. Then insert bolts with locking fluid -AMV 185 101 A1- .

Clean threaded holes in which self-locking bolts or bolts with locking fluid have been inserted, e.g. with a thread chaser. Otherwise there is a danger that the bolts may shear when removed again.

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

Lubricate all gearbox bearings with gear oil before installing.

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.

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.

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.

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

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

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

Observe installation position.

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

When removing gearbox, remove slave cylinder without disconnecting pipes.

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

Ensure that the pressure plate does not cant: loosen and tighten bolts diagonally and in several gradual stages.

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

Refer to Fault finding, power transmission; Rep. Gr. 30; Complaints about clutch and clutch mechanism and Fault finding, power transmission; Rep. Gr. 34; Complaints about selector mechanism.

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

With ignition switched off, disconnect battery earth strap, refer to Electrical system; Rep. Gr. 27; Disconnecting and connecting battery.

When reconnecting battery, refer to Electrical system; Rep. Gr. 27; Disconnecting and connecting battery.

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

The components are:

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, refer to page 15; Removing and installing, refer to page 25)

4 – Bolt

5 – Over-centre spring (Removing and installing, refer to page 15)

6 – Bearing bush

7 – Pivot pin

8 – Clutch pedal (Removing and installing, refer to page 20)

9 – Retainer (To remove and install, separate master cylinder from clutch pedal, refer to page 20)

10 – Seal (Always renew; Between master cylinder and mounting bracket)

11 – Master cylinder (Removing and installing after removal of mounting bracket, refer to page 25)

12 – Clutch position sender -G476- (Removing and installing, refer to page 33; 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, refer to page 38)

15 – Hexagon nut, 25 Nm (Self-locking)

16 – Hexagon nut, 25 Nm (Qty. 3; For mounting bracket on bulkhead; Always renew)

17 – Stop (For clutch pedal)

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

For attachment with 2 bolts, the specified torque is 10 Nm. For attachment with 1 bolt, the specified torque is 20 Nm. Renew bolts for crash bar.

The required special tool is the Release tool -T10178- .

First check whether a coded radio is fitted. If so, obtain anti-theft code.

Disconnect battery earth strap with ignition switched off, refer to Electrical system; Rep. Gr. 27; Disconnecting and connecting battery.

Push driver seat as far back as possible and put steering wheel in highest position.

Remove trim and cover below trim on drive side, refer to General body repairs, interior; Rep. Gr. 68.

For vehicles with knee airbag, remove bracket for knee airbag together with crash bar, refer to Interior equipment; Rep. Gr. 69; Airbag; Removing and installing knee airbag bracket.

For all vehicles, remove cable guide -2- from steering column.

Remove footwell vent -3-, refer to Heating, air conditioning; Rep. Gr. 80; Repairing heating.

For vehicles without knee airbag, the crash bar -1- in front of clutch pedal -2- may be secured in different ways:

Attachment with 2 bolts: Remove crash bar -1- (2 bolts).

Attachment with 1 bolt: Remove crash bar -1- (1 bolt -2-).

If fitted, remove damping -arrow- from lower area of clutch pedal mounting bracket by removing lock washers -A- for damping and pulling 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 down slightly and remove over-centre spring -4- from mounting bracket.

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

Renew self-locking nuts.

Insert over-centre spring -2- in mounting bracket from above while holding end of spring with assembly tool -T10178- in installation position.

Receptacle -arrow- for tip -A- of clutch pedal must stand vertically.

Insert tip of clutch pedal in bearing recess of over-centre spring.

Depress clutch pedal slightly, push bolt through and tighten self-locking nut to specified torque, refer to page 20.

If present, return damping to installation position. If damping was on the clutch pedal mounting bracket, return it to installation position.

For vehicles without knee airbag, secure the crash bar -1- in front of clutch pedal -2- according to previous attachment method (2 bolts or 1 bolt) to specified torque, refer to page 20.

Mount cable guide -2- on steering column.

Install footwell vent -3-, refer to Heating, air conditioning; Rep. Gr. 80; Repairing heating.

For vehicles with knee airbag, install bracket for knee airbag together with crash bar, refer to Interior equipment; Rep. Gr. 69; Airbag; Removing and installing knee airbag bracket.

Install trim and cover below trim on drive side, refer to General body repairs, interior; Rep. Gr. 68.

If disconnected, connect battery, refer to Electrical system; Rep. Gr. 27; Removing and installing battery.

Obtain anti-theft code if a coded radio is fitted.

Disconnect battery earth strap with ignition switched off, refer to Electrical system; Rep. Gr. 27; Disconnecting and connecting battery.

Push driver seat as far back as possible and put steering wheel in highest position.

Remove trim and cover below trim on drive side, refer to General body repairs, interior; Rep. Gr. 68.

For vehicles with knee airbag, 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.

Disconnect battery earth strap with ignition switched off, refer to Electrical system; Rep. Gr. 27; Disconnecting and connecting battery.

Remove cable guide -2- from steering column.

Remove footwell vent -3-, refer to Heating, air conditioning; Rep. Gr. 80; Repairing heating.

For vehicles without knee airbag, the crash bar -1- in front of clutch pedal -2- may be secured in different ways:

Attachment with 2 bolts: Remove crash bar -1- (2 bolts).

Attachment with 1 bolt: Remove crash bar -1- (1 bolt -2-).

If fitted, remove damping -arrow- from lower area of clutch pedal mounting bracket by removing lock washers -A- for damping and pulling 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 down slightly and remove over-centre spring -4- from mounting bracket.

Release clutch pedal from master cylinder with pliers -T10005- .

Remove clutch pedal.

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

Renew self-locking nuts.

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, refer to page 25.

If some cars have damping -arrow- on the mounting bracket/clutch pedal, return it to installation position.

For vehicles without knee airbag, install crash bar -1- in front of clutch pedal -2- according to previous attachment method (2 bolts or 1 bolt) to specified torque, refer to page 25.

Mount cable guide -2- on steering column.

Install footwell vent -3-, refer to Heating, Air conditioning; Rep. Gr. 80; Repairing heating; Removing and installing left footwell vent.

For vehicles with knee airbag, install bracket for knee airbag together with crash bar, refer to Interior equipment; Rep. Gr. 69; Airbag; Removing and installing knee airbag bracket.

Install trim and cover below trim on drive side, refer to General body repairs, interior; Rep. Gr. 68.

If disconnected, connect battery, refer to Electrical system; Rep. Gr. 27; Removing and installing battery.

Component | Nm

Renew self-locking nuts for clutch pedal to mounting bracket. Renew bolts for crash bar.

The required special tools are Pliers -T10005- and Release tool -T10178- .

First check whether a coded radio is fitted. If so, obtain anti-theft code.

With ignition switched off, disconnect battery earth strap, refer to Electrical system; Rep. Gr. 27; Disconnecting and connecting battery.

Continue for all:

Push driver seat as far back as possible and put steering wheel in highest position.

Remove trim and cover below trim on drive side, refer to General body repairs, interior; Rep. Gr. 68.

For vehicles with knee airbag, 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.

With ignition switched off, disconnect battery earth strap, refer to Electrical system; Rep. Gr. 27; Disconnecting and connecting battery.

Continue for all:

Remove cable guide -2- from steering column.

Remove footwell vent -3-, refer to Heating, air conditioning; Rep. Gr. 80; Repairing heating.

For vehicles without knee airbag, the crash bar -1- in front of clutch pedal -2- may be secured in different ways:

Attachment with 2 bolts: Remove crash bar -1- (2 bolts).

Attachment with 1 bolt: Remove crash bar -1- (1 bolt -2-).

If fitted, remove damping -arrow- from lower area of clutch pedal mounting bracket by removing lock washers -A- for damping and pulling 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 down slightly and remove over-centre spring -4- from mounting bracket.

Release clutch pedal from master cylinder with pliers -T10005- .

Remove clutch pedal.

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

Renew self-locking nuts.

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, refer to page 25.

If some cars have damping -arrow- on the mounting bracket/clutch pedal, return it to installation position.

For vehicles without knee airbag, install crash bar -1- in front of clutch pedal -2- according to previous attachment method (2 bolts or 1 bolt) to specified torque, refer to page 25.

Mount cable guide -2- on steering column.

Install footwell vent -3-, refer to Heating, air conditioning; Rep. Gr. 80; Repairing heating.

For vehicles with knee airbag, install bracket for knee airbag together with crash bar, refer to Interior equipment; Rep. Gr. 69; Airbag; Removing and installing knee airbag bracket.

Install trim and cover below trim on drive side, refer to General body repairs, interior; Rep. Gr. 68.

If disconnected, connect battery, refer to Electrical system; Rep. Gr. 27; Removing and installing battery.

No special tools are explicitly listed for this section, but reference is made to page 25 for installation/removal steps of the crash bar which may require tools shown previously.

The required special tool is Pliers -T10005- .

Remove mounting bracket, refer to page 25.

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-.

Move clutch pedal to rest position at stop.

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, refer to page 25.

The required special tool is Hose clamps -3094- .

First check whether a coded radio is fitted. If so, obtain anti-theft code.

With ignition switched off, disconnect battery earth strap, refer to Electrical system; Rep. Gr. 27; Disconnecting and connecting battery.

Remove complete air filter housing if it is near battery, refer to Rep. Gr. 23; Repairing diesel direct injection system or Rep. Gr. 24; Repairing injection system.

Remove battery and battery tray, refer to Electrical system; Rep. Gr. 27; Battery; Removing and installing battery.

For all vehicles, during the following work, ensure that no brake fluid lands on longitudinal member or gearbox. If this does happen, clean the affected areas thoroughly.

Place a lint-free cloth under the master cylinder.

Clamp off supply hose to master cylinder using hose clamp to 25 mm ∅ -3094- .

If necessary, loosen spring-type clip -3- with hose clip pliers -VAS 6362- and pull supply hose off master cylinder.

For disconnecting, you can close it with the sealing tool -T10249/1- (refer to figure above).

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-.

When performing work in the footwell, put cloths on the carpet to protect it from possible brake fluid spills.

Remove trim and cover below trim on drive side, refer to General body repairs, interior; Rep. Gr. 68.

For vehicles with knee airbag, remove bracket for knee airbag together with crash bar, refer to Interior equipment; Rep. Gr. 69; Airbag; Removing and installing knee airbag bracket.

Remove cable guide -2- from steering column.

Remove footwell vent -3-, refer to Heating, air conditioning; Rep. Gr. 80; Repairing heating.

For vehicles without knee airbag, the crash bar -1- in front of clutch pedal -2- may be secured in different ways:

Attachment with 2 bolts: Unbolt crash bar (2 bolts).

Attachment with 1 bolt: Remove crash bar -1- (1 bolt -2-).

If fitted, remove damping -arrow- from lower area of clutch pedal mounting bracket by removing lock washers -A- for damping and pulling off damping.

Push damping upwards in area of upper securing nut -1- above clutch pedal -A- in direction of arrow.

Remove securing nuts -1- and -2-. The upper securing nut -1- is accessible between the relay carrier and the steering column trim.

Remove mounting bracket -3-.

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, refer to page 42.

For LHD models:

Install battery, refer to Electrical system; Rep. Gr. 27; Removing and installing battery.

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

Reconnect battery and perform work required after connecting battery, refer to Electrical system; Rep. Gr. 27; Disconnecting and connecting battery.

For right-hand drive vehicles with particle filter, install shielding -A- on particle filter, refer to Rep. Gr. 26; Parts of exhaust system; Assembly overview – front exhaust pipe with particle filter.

If a pipe/hose line -1- with a round component is installed directly beneath the master cylinder, the pipe/hose line must be removed.

Clamp off supply hose to master cylinder using hose clamp to 25 mm ∅ -3094- .

Release securing clip -2- with a screwdriver or a pointed object and pull out of master cylinder to stop.

Pull pipe/hose line -1- or plastic line out from master cylinder and seal.

Disconnect electrical connector -4-.

Unclip clutch position sender -G476- from master cylinder -arrow- and remove.

Install mounting bracket, refer to page 25.

Install damping if it was removed.

If damping was removed from the lower area of the clutch pedal mounting bracket, install it by pushing damping downwards in the area of upper securing nut -1- above clutch pedal -A- in direction of arrow, removing lock washers -A- for damping and then pulling off damping, and then pushing damping upwards in area of upper securing nut -1- above clutch pedal -A- in direction of arrow.

Install securing nuts -1- and -2-.

Install mounting bracket -3-.

Install cable support bracket on gearbox and tighten bolts to specified torque, refer to Item 6 (page 70).

Install trim and cover below trim on drive side, refer to General body repairs, interior; Rep. Gr. 68.

Reconnect battery and perform work required after connecting battery, refer to Electrical system; Rep. Gr. 27; Disconnecting and connecting battery.

Install gearbox selector lever -A-.

Tighten hexagon nut -arrow 4- to specified torque, refer to Item 18 (page 71).

Spread a small amount of grease -G 000 450 02- on pin of gearbox selector lever -A-.

Connect gear selector cable to gearbox selector lever -arrow 1-.

For Metal relay lever, install relay lever -B- and secure with securing clip -arrow 3-. Spread a small amount of grease -G 000 450 02- on pin of relay lever -B-. Connect gate selector cable to relay lever -arrow 2-.

For Plastic relay lever, install relay lever together with cable end-piece, refer to page 73.

For all, adjust selector mechanism, refer to page 80.

Install battery tray and battery, refer to Electrical system; Rep. Gr. 27; Removing and installing battery.

If engine cover and complete air filter housing were removed, reinstall them, refer to Rep. Gr. 23; Repairing diesel direct injection engine or Rep. Gr. 24; Repairing injection system.

Reconnect battery and perform work required after connecting battery, refer to Electrical system; Rep. Gr. 27; Disconnecting and connecting battery.

Install lower part of front left wheel housing liner, refer to General body repairs, exterior; Rep. Gr. 66; Wheel housing liner.

Install noise insulation, refer to General body repairs, exterior; Rep. Gr. 50; Noise insulation.

1 – Brake fluid reservoir

2 – Spring-type clip

3 – Supply hose (Rubber; From 12.05, plastic in some vehicles, refer to page 38)

4 – Master cylinder (Removing and installing, refer to page 31)

5 – Clip (Pull out clip to stop to remove and install pipe/hose line)

6 – Retainer (To remove and install, separate master cylinder from clutch pedal, refer to page 20)

7 – Clutch pedal (Removing and installing, refer to page 20)

8 – Hexagon nut, 25 Nm (Self-locking; Qty. 3; For mounting bracket on bulkhead; Always renew)

9 – Seal / O-ring (Pull onto line connection; Insert with brake fluid; Seals/O-rings are adapted to configuration of line connection, refer to page 38; Allocation, refer to Electronic parts catalogue “ETKA”)

10 – Pipe/hose line (Allocation, refer to Electronic parts catalogue “ETKA”; To remove, remove battery and battery tray, refer to Electrical system; Rep. Gr. 27; Removing and installing battery.)

11 – Bracket (Secured to body)

12 – Seal / O-ring (Pull onto line connection; Insert with brake fluid; Seals/O-rings are adapted to configuration of line connection, refer to page 38; Allocation, refer to Electronic parts catalogue “ETKA”)

13 – Clip (Pull out clip to stop to remove and install pipe/hose line)

14 – Slave cylinder (Removing and installing, refer to page 40)

15 – Hexagon bolt, 20 Nm

16 – Bleeder valve (Bleeding clutch system, refer to page 42)

17 – Dust cap

18 – Gearbox

19 – Bracket

20 – Hexagon bolt, 20 Nm

Item | Material of line connection

For some vehicles from 12.05, there is a plastic supply hose -1- where the seals -2- must be located in the supply hose.

1 – Brake fluid reservoir

2 – Seal (For plastic supply hose; The seals must be located in supply hose)

3 – Supply hose (Rubber; From 12.05, plastic in some vehicles, refer to page 38)

4 – Master cylinder (Removing and installing, refer to page 31)

5 – Clip (Pull clip out to stop to remove or install pipe line; Pulled out to side on some master cylinders)

6 – Seal / O-ring (Pull onto line connection; Insert with brake fluid; Seals/O-rings are adapted to configuration of line connection, refer to page 38; Allocation, refer to Electronic parts catalogue “ETKA”)

7 – Retainer (To remove and install, separate master cylinder from clutch pedal, refer to page 20)

8 – Clutch pedal (Removing and installing, refer to page 20)

9 – Hexagon nut, 25 Nm (Self-locking; Qty. 3; For mounting bracket on bulkhead; Always renew)

10 – Bracket (Secured to body)

11 – Pipe line (Pipe and hose/pipe line, Item 13 (page 40) may be in one piece; Allocation, refer to Electronic parts catalogue “ETKA”; To remove, remove battery and battery tray, refer to Electrical system; Rep. Gr. 27; Removing and installing battery.)

12 – Seal / O-ring (Pipe, Item 11 (page 39) and hose/pipe line may be in one piece; Pull onto line connection; Insert with brake fluid; Seals/O-rings are adapted to configuration of line connection, refer to page 38; Allocation, refer to Electronic parts catalogue “ETKA”)

13 – Pipe/hose line (Pipe, Item 11 (page 39) and hose/pipe line may be in one piece; Allocation, refer to Electronic parts catalogue “ETKA”; To remove, remove battery and battery tray, refer to Electrical system; Rep. Gr. 27; Removing and installing battery.)

14 – Bracket (Secured to retainer for ABS/EDL)

15 – Bracket (For ABS/EDL)

16 – Seal / O-ring (Pull onto line connection; Insert with brake fluid; Seals/O-rings are adapted to configuration of line connection, refer to page 38; Allocation, refer to Electronic parts catalogue “ETKA”)

17 – Clip (Pull out clip to stop to remove and install pipe/hose line)

18 – Slave cylinder (Removing and installing, refer to page 40)

19 – Flange bolt, 20 Nm

20 – Bleeder valve (Bleeding clutch system, refer to page 42)

21 – Dust cap

22 – Gearbox

23 – Bracket

24 – Hexagon bolt, 20 Nm

The required special tool is Torque wrench -V.A.G 1331- .

First check whether a coded radio is fitted. If so, obtain anti-theft code.

With ignition switched off, disconnect battery earth strap, refer to Electrical system; Rep. Gr. 27; Disconnecting and connecting battery.

Remove complete air filter housing if it is over slave cylinder, refer to Rep. Gr. 23; Repairing diesel direct injection system or Rep. Gr. 24; Repairing injection system.

Remove securing clip -arrow 1- for gear selector cable from gearbox selector lever -A-.

Pull gear selector cable from pin.

For Metal relay lever: Remove securing clip -arrow 2- for gate selector cable from relay lever -B-. Pull gate selector cable from pin. Pull securing clip -arrow 3- off relay lever -B- and remove relay lever.

For Plastic relay lever: Remove relay lever together with cable end-piece, refer to page 73.

Continuation for all:

Remove gearbox selector lever -A- by removing nut -arrow 4-.

Remove cable support bracket from gearbox -arrows-.

Then raise and secure gear selector cable and gate selector cable.

Remove retainer -B- from gearbox and pull it off pipe/hose line -A-.

Then remove gearbox support -arrow A-.

Place a lint-free cloth under slave cylinder.

Pull clip for pipe/hose line out of slave cylinder to stop.

Pull pipe/hose line out of slave cylinder and seal opening.

Remove slave cylinder -arrows B-.

Caution: Do not operate clutch pedal any more.

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

Install slave cylinder and tighten bolts -arrows B- to specified torque.

Insert pipe/hose line into slave cylinder to stop.

Push securing clip into pipe/hose line to stop.

Test pipe/hose line by tugging on it.

Then install gearbox support -arrows A-.

Bleed clutch system after installing slave cylinder, refer to page 44.

Assembling selector mechanism, refer to page 70.

Adjust selector mechanism, refer to page 80.

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

Connect battery earth, refer to Electrical system; Rep. Gr. 27; Disconnecting and reconnecting battery.

Slave cylinder to gearbox, refer to Item 9 (page 45).

Gearbox selector lever to selector shaft, refer to Item 18 (page 71).

Selector cable support bracket to gearbox, refer to Item 6 (page 70).

Gearbox support to gearbox bracket and gearbox:

Renew bolts.

Screw in all bolts hand-tight.

Tighten bolts to specified torque: Bolts -arrows- 20 Nm + 90°

Prefilling system is not necessary!

Specifications for brake fluid refer to Brake systems; Rep. Gr. 47; Bleeding brake system.

Remove complete air filter housing if it blocks access to bleeder connection -arrow-, figure below, refer to Rep. Gr. 23; Repairing diesel direct injection system or Rep. Gr. 24; Repairing injection system.

Connect brake filling and bleeding equipment -VAS 5234- or -V.A.G 1869- .

To bleed system, use 670 mm bleeder hose -V.A.G 1238/B3- if necessary.

Connect bleeder hose to collector bottle of brake bleeding equipment.

Connect bleeder hose to bleeder -arrow-.

Pressurise system to 2 bar.

Open bleeder valve.

Bleed off about 100 cm3 brake fluid.

Close bleeder valve.

Rapidly operate pedal from stop to stop 10 to 15 times.

Open bleeder valve.

Bleed off an additional 50 cm3 brake fluid.

Close bleeder valve.

Depress clutch pedal several times after completion of bleeding process.

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

The torque wrench specification is -V.A.G 1331- .

Ball stud is 25 Nm.

Unhook spring -arrow 1-.

Pull off release lever -arrow 2- and release bearing.

Install in reverse order of removal.

Press together locking lugs -arrows- on back of clutch release lever and remove release bearing -A- from clutch release lever.

To install, press release bearing -A- into clutch release lever until locking lugs -arrows- engage.

For the Dual-mass flywheel: Removing and installing is in Rep. Gr. 13. Ensure that centring pins fit tightly. Contact surface for clutch lining must be free of grooves, oil and grease.

For the Clutch plate: Allocation refers to Electronic parts catalogue “ETKA”. Removing and installing, refer to page 48. Renew only together with pressure plate. Installation position, refer to page 48.

For the Pressure plate: Allocation refers to Electronic parts catalogue “ETKA”. If it has an adjusting mechanism, Removing and installing, refer to page 48. Check ends of diaphragm spring, refer to page 49. Check spring connections and riveted connections, refer to page 49. Renew only together with clutch plate.

For Bolt M6, 13 Nm, Bolt M7, 20 Nm: Loosen or tighten diagonally in small steps.

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

To install: Reverse counterhold tool -3067- for installation. Push pressure plate onto centralizing pins. To centre clutch plate, use centring mandrel -3190 A- . Tighten all bolts evenly by hand until bolt heads contact pressure plate. Tighten bolts in small steps diagonally in order not to damage centring holes of pressure plate and centring pins of dual mass flywheel. Install gearbox, refer to page 92.

For the Dual-mass flywheel: Removing and installing, refer to Rep. Gr. 13. Ensure that centring pins fit tightly. Contact surface for clutch lining must be free of grooves, oil and grease.

For the Clutch plate: Allocation refers to Electronic parts catalogue “ETKA”. Removing and installing, refer to page 50. Renew only together with SAC pressure plate. Installation position, refer to page 51.

For the SAC pressure plate: SAC means “self-adjusting clutch”. Renew only together with clutch plate. Allocation refers to Electronic parts catalogue “ETKA”. Removing and installing, refer to page 50. Check ends of diaphragm spring, refer to page 51. Checking spring connections and riveted connections, refer to page 51. Checking position of adjusting mechanism with new pressure plates only, refer to page 52.

For Bolt M6, 13 Nm, Bolt M7, 20 Nm: Loosen or tighten diagonally in small steps.

Removing:

Remove gearbox, refer to page 84.

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:

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

Check whether dowel sleeves for aligning engine and gearbox are fitted in cylinder block and install if necessary. If dowel sleeves are not fitted, difficulties shifting gears, clutch problems and possible noises from the gearbox (rattling of gears which are not engaged) could occur.

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

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.

Checking position of adjusting mechanism with new pressure plates only:

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.

Renew clutch plates and pressure plates with damaged or loose rivet connections.

Renew pressure plate and clutch plate together only.

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.

Push pressure plate onto centralizing pins.

To centre clutch plate, use centring mandrel -3190 A- .

Tighten all bolts evenly by hand until bolt heads contact pressure plate.

Tighten bolts in small steps diagonally in order not to damage centring holes of pressure plate and centring pins of dual mass flywheel.

Install gearbox, refer to page 92.

The required special tools and workshop equipment are:

Counterhold -3067-

Centring mandrel -3190 A-

Torque wrench -V.A.G 1331-

Grease for clutch plate splines -G 000 100-

Renew clutch plates and pressure plates with damaged or loose rivets.

Select clutch plate and pressure plate according to Electronic parts catalogue “ETKA” and engine codes.

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.

Loosen or tighten bolts diagonally in stages.

Reverse position of counterhold -3067- when removing.

Tighten bolts diagonally and evenly to prevent damage to the centring holes in the pressure plate housing and the centring pins in the flywheel.

Install gearbox, refer to page 92.

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

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

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

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.

Note radio code for vehicles with coded radio.

Before working on selector mechanism in engine compartment, disconnect earth strap from battery, refer to Electrical system; Rep. Gr. 27; Disconnecting and connecting battery.

When reconnecting battery, perform work required after connecting battery, refer to Electrical system; Rep. Gr. 27; Disconnecting and connecting battery.

To work on selector mechanism in engine compartment, remove complete air filter housing if it is located over selector mechanism, refer to Rep. Gr. 23; Repairing diesel direct injection system or Rep. Gr. 24; Repairing injection system.

Remove selector mechanism to renew selector cables, refer to page 75.

Do not kink selector cables.

1 – Gearbox selector lever with damper weight

2 – Relay lever engages in guide rail of gearbox selector lever via shoe -arrow-.

Cable end-piece for | Dimension “a”

Support pin for gear selector cable end-piece | Dimension “a”

Wind cable tie -arrow- around the selector cables in a figure eight and secure them as shown in figure.

To remove relay lever, first separate cable end-piece from gate selector cable to avoid damage to the gate selector cable.

Pull locking mechanism forward to stop in -direction of arrow 1- and then lock by turning to left in -direction of arrow 2-.

Then push relay lever forwards (-in direction of arrow 3-).

If the relay lever has a catch -arrow 1- : Press catch -arrow 1- down to stop and remove relay lever together with cable end-piece. In the process, swing it in direction of operation.

If the relay lever has a clip -arrow 1- : Pull clip -arrow 1- off and remove relay lever together with cable end-piece. The cable end-piece can be removed only with the relay lever removed, refer to page 75.

To fit, lubricate bearing points and sliding surfaces with grease -G 000 450 02- .

Press cable end-piece onto relay lever, refer to page 75.

Install relay lever together with cable end-piece to stop.

Remove securing clip from gear selector cable -A- and gate selector cable -B- by raising tab using screwdriver -arrow 1- and pressing off securing clip -arrow 2-.

Remove gear selector cable -A- from gear lever retainer.

Remove gate selector cable -B- from retainer of gate selector lever.

To remove or install securing clip -arrow A-, press spacer bush -arrow B- to stop in direction of arrow -arrow C- using screwdriver and pull off securing clip.

Do not cant spacer bush when pushing down.

Slot in gear lever for securing clip must be visible.

Carefully release tension from spring.

Insert compression spring so that extension -A- lies on top of pin -arrow-.

Then pull extension -B- down so that it sits below pin -arrow-.

Obtain anti-theft code if a coded radio is fitted.

Disconnect battery earth strap with ignition switched off, refer to Electrical system; Rep. Gr. 27; Removing and installing battery.

Remove gaiter with selector knob and noise insulation, refer to page 61.

Remove centre console and securing bracket for centre console, refer to General body repairs, interior; Rep. Gr. 68; Compartments, covers and trims.

Remove selector housing nuts -arrows-.

Remove complete air filter housing if it is over selector mechanism, refer to Rep. Gr. 23; Repairing diesel direct injection system or Rep. Gr. 24; Repairing injection system.

Remove securing clip -3- for gear selector cable from gearbox selector lever -1-.

Pull gear selector cable off pin.

For Metal relay lever: Remove securing clip -4- for gate selector cable from relay lever -2-. Pull gate selector cable from pin.

For Plastic relay lever: Remove relay lever together with cable end-piece, refer to page 73.

Continuation for all selector mechanisms:

Remove cable support bracket from gearbox -arrows-; if necessary, unclip pipe/hose -A- from bracket -B- first.

Remove noise insulation, refer to General body repairs, exterior; Rep. Gr. 50; Noise insulation.

Remove tunnel cross member, refer to Rep. Gr. 26; Removing and installing parts of exhaust system.

Separate front exhaust system at double clamp and detach from subframe, refer to Rep. Gr. 26; Removing and installing parts of exhaust system.

Remove rear exhaust system and heat shield, refer to Rep. Gr. 26; Removing and installing parts of exhaust system.

Remove underbody panels, refer to General body repairs, exterior; Rep. Gr. 50.

Swing selector housing down and remove with selector cables.

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

Align selector housing parallel to body. Distance to body must be same on both sides.

Secure selector housing, refer to Item 26 (page 64) or Item 16 (page 66).

Route cables -1- from selector mechanism -2- to gearbox as follows: After cables cross over -arrow-, they must be routed parallel to one another as far as cable support bracket on gearbox. Make sure that cable tie -arrow- for securing cables is installed correctly. Installation position, refer to page 73. Cables must be laid in the intended indentation in heat shield -3-.

Clip -A- holds cables and heat shield together in position.

Install cable support bracket on gearbox and tighten bolts to specified torques, refer to Item 6 (page 70).

Spread a small quantity of grease -G 000 450 02- on pins -arrows- of gearbox selector lever -1- and relay lever -2-.

Renew securing clips -3- and -4- each time they are removed.

Secure gear selector cable with securing clip -3- and gate selector cable with securing clip -4-.

Cable end-piece to plastic relay lever: Fit relay lever and cable end-piece together, refer to page 73. Insert gate selector cable in cable end-piece.

Continued for all selector mechanisms:

Install centre console, refer to General body repairs, interior; Rep. Gr. 68; Compartments, covers and trims.

Install gaiter with selector knob and noise insulation, refer to page 61.

Install heat shield.

If removed, reinstall underbody panels, refer to General body repairs, exterior; Rep. Gr. 50.

Assemble exhaust system free of tension and attach tunnel cross member, refer to Rep. Gr. 26; Removing and installing parts of exhaust system.

Adjust selector mechanism, refer to page 80.

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

Follow procedure after connecting battery, refer to Electrical system; Rep. Gr. 27; Battery; Disconnecting and connecting battery.

Moving parts of selector mechanism and elements transferring force must be in proper condition.

Selector mechanism must move freely.

Gearbox, clutch and clutch mechanism must also be in proper condition.

Gearbox must be in neutral.

Press selector shaft down -direction of arrow 1-.

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

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

Operate clutch.

Select all gears several times. Pay particular attention to operation of reverse gear lock.

If it continues to be difficult to engage a gear after repeated attempts, repeat adjustment procedure of selector mechanism, refer to page 80.

For vehicles with turbo diesel engines and vehicles with 2.0l – 110 kW petrol engines:

Hook – 10 – 222 A /2-

Adapter -10 – 222 A /3-

Adapter -10 – 222 A /16-

Hook -10 – 222 A /10-

For all vehicles:

Support bracket -10 – 222 A-

Adapter -10 – 222 A /8-

Pin -3282/29-

Gearbox support -3282-

Adjustment plate -3282/39-

Engine and gearbox jack -V.A.G 1383A-

Torque wrench -V.A.G 1331-

Torque wrench -V.A.G 1332-

Gearbox mounting support -3336-

Grease -G 000 450 02-

Grease for clutch plate splines -G 000 100-

First check whether a coded radio is fitted. If so, obtain anti-theft code.

With ignition switched off, disconnect battery earth strap, refer to Electrical system; Rep. Gr. 27; Disconnecting and connecting battery.

Remove engine cover if engine lifting eye arrow -10 – 222 A is not accessible.

Remove complete air filter housing if it is near battery, refer to Rep. Gr. 23; Repairing diesel direct injection system or Rep. Gr. 24; Repairing injection system.

Remove battery and battery tray, refer to Electrical system; Rep. Gr. 27; Battery; Removing and installing battery.

Remove securing clip -arrow 1- for gear selector cable from gearbox selector lever -A-.

Pull gear selector cable from pin.

For Metal relay lever: Remove securing clip -arrow 2- for gate selector cable from relay lever -B-. Pull gate selector cable from pin. Pull securing clip -arrow 3- off relay lever -B- and remove relay lever.

For Plastic relay lever: Remove relay lever together with cable end-piece, refer to page 73.

Continuation for all:

Remove gearbox selector lever -A- by removing nut -arrow 4- (refer to previous figure).

Remove cable support bracket from gearbox -arrows-.

Then raise and secure gear selector cable and gate selector cable.

Remove retainer -B- from gearbox and pull it off pipe/hose line -A-.

Then remove gearbox support -arrow A-.

Remove slave cylinder -arrow B-, lay to side and secure with wire. Do not disconnect pipes.

Caution: Do not operate clutch pedal any more.

Remove earth strap at upper engine/gearbox connecting bolt.

Pull connector -arrow 1- off reversing light switch -F4- .

Now remove connector -arrow 2- and wire -arrow 3- from starter.

Then remove upper securing bolt on starter.

Remove upper engine/gearbox connecting bolts.

If there are hose and cable connections in area of engine support eye for support bracket -10 – 222 A- , remove these now.

For Vehicles with 1.4 l petrol engine: Set up support bracket -10 – 222 A- together with adapters -10 – 222 A /8- in front of gas struts for bonnet.

For Vehicles with turbo diesel engines and vehicles with 2.0 l – 110 kW petrol engines: Set up support bracket -10 – 222 A- together with adapters -10 – 222 A /8- , adapter -10 – 222 A /3- and adapter -10 – 222 A /16- in front of gas struts for bonnet. Attach hook -10 – 222 A /10- at front right of engine.

Now attach hook -10 – 222 A /2- at rear left of engine -arrow-.

Then connect hook -10 – 222 A /2- using adapter -10 – 222 A /16- .

Continuation for all vehicles:

Position adapter -10 – 222 A /8- directly over wing bolting points.

Take up weight of engine/gearbox assembly on spindles.

Raise vehicle.

Remove noise insulation, refer to General body repairs, exterior; Rep. Gr. 50; Noise insulation.

Remove lower part of front left wheel housing liner, refer to General body repairs, exterior; Rep. Gr. 66; Wheel housing liner.

Then remove all lines from gearbox.

Remove drive shaft heat shield from engine -arrows-, if fitted.

For Vehicles with 1.4 l petrol engine: Separate exhaust system -arrows 1-, remove front exhaust pipe and unscrew front exhaust pipe bracket from subframe -arrows 2-, refer to Rep. Gr. 26; Parts of exhaust system.

For Vehicles with turbo diesel engines and vehicles with 2.0 l – 110 kW petrol engines: Separate exhaust system at double clamp and remove exhaust pipe bracket from subframe, refer to Rep. Gr. 26; Removing and installing parts of exhaust system.

Disconnect drive shafts from flange shafts and tie up as high as possible, being careful not to damage surface protection.

Press gearbox off dowel sleeves and carefully swing towards subframe.

Turn gearbox downwards in vicinity of differential.

Have a second mechanic push engine forwards slightly.

Carefully lower gearbox, guiding with right flanged shaft -A- past intermediate plate of flywheel as shown.

When lowering gearbox, change position of gearbox using spindles of gearbox support -3282- . Be careful of all lines when lowering gearbox.

Adjust support beam on sliding piece using locking pin -arrow-.

Lift gearbox using workshop crane and gearbox lifting tackle -3336- .

Set gearbox aside, for example in a transport container.

Gearbox to 1.4 l petrol engine:

Item -A- are dowel sleeves for centring.

Gearbox to 2.0 l/100 kW petrol engine:

Item -A- are dowel sleeves for centring.

Gearbox to turbo diesel engine:

Item -A- are dowel sleeves for centring.

Renew bolts.

Screw in all bolts hand-tight.

Tighten bolts to specified torque: Bolts -arrows- 40 Nm + 90°

Renew bolts.

Screw in all bolts hand-tight.

Tighten bolts to specified torque: Bolts -arrows- 60 Nm + 90°

Renew bolts.

Screw in all bolts hand-tight.

Tighten bolts to specified torque: Bolts -arrows- 20 Nm + 90°

It is not possible to check the gear oil level by unscrewing the oil filler plug.

The angle of the engine/gearbox unit means the lower edge of the fill hole -arrow 1- is below the oil level -arrow 2-.

The oil level in the gearbox can only be checked by completely draining the gear oil and then refilling.

Special tools and workshop equipment required: Torque wrench -V.A.G 1331- and Hose (approx. 600 mm long, external diameter 10 mm) with funnel, commercially available.

Gear oil for manual gearboxes refers to Electronic parts catalogue “ETKA”.

Remove complete air filter housing, refer to Rep. Gr. 23; Repairing diesel direct injection system or Rep. Gr. 24; Repairing injection system.

Remove noise insulation, refer to General body repairs, exterior; Rep. Gr. 50; Noise insulation.

Clean gearbox.

Caution: To drain gear oil, a pivot pin for the selector forks in the gearbox must be removed.

To prevent the positions of the selector forks from being changed, e.g. due to accidental operation of the selector mechanism, the selector shaft must be locked in position.

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

Use a clean container with a scale and a 3-litre capacity to catch the oil which runs out.

Selector shaft is locked in place, refer to page 100.

Drain gear oil by removing oil drain plug -arrow 1- and then pivot pin -arrow 2-.

Install pivot pin -arrow 2- with a new O-ring, refer to Item 5 (page 107).

Screw in oil drain plug -arrow 1-, refer to Item 17 (page 135).

Now turn angled rod -A- back to original position -direction of arrow- so that selector shaft can move again.

Top up oil in container to 1.9 litres.

Gearbox oil specification refers to Electronic parts catalogue “ETKA”.

Remove reversing light switch -F4- -arrow-.

Connect hose (approx. 600 mm long, external diameter 10 mm) to commercially available funnel.

Insert hose in fitting hole for reversing light switch -F4- (2nd mechanic) and fill gear oil.

Install reversing light switch -F4- -arrow-, refer to Item 2 (page 143).

Check operation of selector mechanism, refer to page 82.

Install complete air filter housing, refer to Rep. Gr. 23; Repairing diesel direct injection system or Rep. Gr. 24; Repairing injection system.

Install noise insulation, refer to General body repairs, exterior; Rep. Gr. 50; Noise insulation.

1 – 1st gear

2 – 2nd gear

3 – 3rd gear

4 – 4th gear

5 – 5th gear

6 – 6th gear

7 – Gearbox housing cover

8 – Gearbox housing

9 – Selector mechanism (Selector forks)

10 – Reverse gear wheel

11 – Clutch housing

12 – Input shaft

13 – Output shaft

14 – Differential

Assembly sequence – Removing and installing cover for gearbox housing and 5th and 6th gear, refer to page 109.

Assembly sequence – Dismantling and assembling gearbox completely, refer to page 115.

I – Removing and installing cover for gearbox housing and 5th and 6th gears, refer to page 104.

II – Removing and installing gearbox housing and shift mechanism, refer to page 107.

III – Removing and installing input shaft, output shaft, differential and selector forks, refer to page 108.

1 – Gearbox housing (Pull off together with 5th and 6th gears, refer to page 115. Repairing, refer to page 132.)

2 – Gear wheel for 5th gear (Pull off individually, refer to page 109. Pull off together with gearbox housing, refer to page 115)

3 – Sleeve

4 – Gear wheel for 6th gear (Pull off individually, refer to page 109. Pull off together with gearbox housing, refer to page 115)

5 – Cylindrical roller bearing inner race (For output shaft; Mark before removing; Do not interchange with inner race for cylindrical roller bearing of input shaft; Larger outer diameter from gearbox date 21 08 6; Allocation, refer to page 106)

6 – Bolt (For output shaft; Allocation of bolts, refer to page 106; To gearbox date 20 08 6: 40 Nm and 180° further; From gearbox date 21 08 6: 80 Nm and then turn 90° further; Self-locking; Always renew; Clean residual locking fluid from threaded holes for securing bolts for synchro-hub for 5th and 6th gears and gear wheel for 6th gear with a thread chaser. Otherwise the bolts may shear.)

7 – Gearbox housing cover (With cylindrical roller bearings for input and output shafts; Cylindrical roller bearings for input and output shafts from gearbox date 21 08 6 with larger outer diameter, refer to page 140. Repairing, refer to page 138.)

8 – Bolt, 18 Nm (Qty. 5; For gearbox housing cover.)

9 – Bolt (For input shaft)

10 – Cylindrical roller bearing inner race (For input shaft; Mark before removing; Do not interchange with cylinder roller bearing inner race of output shaft; From gearbox date 21 08 6, combined with thrust washer in one component, refer to Item 12 (page 105); Allocation of inner race for cylindrical roller bearing, refer to page 106)

11 – Thrust washer (Through gearbox date 20 08 6)

12 – Inner race for cylindrical roller bearing with thrust washer (For input shaft; From gearbox date 21 08 6; Allocation of inner race for cylindrical roller bearing, refer to page 106)

13 – Sleeve (For 6th gear needle bearing; Renew together with needle bearing; Larger diameter from gearbox date 21 08 6; Allocate components according to Electronic parts catalogue “ETKA” .)

14 – Needle bearing (For 6th gear; Renew together with sleeve; Larger diameter from gearbox date 21 08 6; Allocate components according to Electronic parts catalogue “ETKA” .)

15 – Synchromeshed gear for 6th gear (Adapted to sleeve and needle bearing from gearbox date 21 08 6; Allocate components according to Electronic parts catalogue “ETKA” .)

16 – Wave spring washer (From gearbox date 26 05 8; Allocate according to Electronic parts catalogue “ETKA”)

17 – Synchro-ring for 6th gear

18 – Locking collar with synchro-hub for 5th and 6th gears (Pull off individually, refer to page 109; Pull off together with gearbox housing, refer to page 115; Dismantling and assembling, refer to page 157 and page 157; From gearbox date 12 06 6, locking collar modified, refer to page 157; Adjusting, through gearbox date 11 06 6, refer to page 130; Adjusting, from gearbox date 12 06 6, refer to page 131; Installation of springs with angled ends for locking pieces, refer to page 158)

19 – Synchro-ring for 5th gear (Will be damaged during removal of input shaft; Always renew)

20 – Wave spring washer (From gearbox date 26 05 8; Allocate according to Electronic parts catalogue “ETKA”)

21 – Synchromeshed gear for 5th gear, refer to Item 15 (page 105)

22 – Needle bearing (For 5th gear; Renew together with sleeve)

23 – Sleeve, refer to Item 13 (page 105) (For 6th gear needle bearing. Renew together with needle bearing)

Puller hooks -T10040/2A- can be checked for correct insertion under the 5th gear wheel.

If puller hooks -T10040/2A- make contact too soon with gearbox housing wall or ribs in gearbox housing under 5th gear wheel, removal of “synchro-hub 5th/6th gear”, “6th gear wheel”, “5th gear wheel” and “gearbox housing” together is required, refer to page 115.

If puller hooks -T10040/2A- come into contact with ribs in gearbox housing below gear wheel, 5th/6th gear can be removed individually, refer to page 113.

Remove selector fork for 5th and 6th gears as follows:

Cover openings with a cloth.

Engage 5th gear -arrows 1- and -2-.

Remove selector jaw for 5th and 6th gears -bolt A-.

Then remove both bolts -B- for pivot pins.

Pull out pivot pins.

Remove selector fork for 5th and 6th gears.

Remove -bolts A- for inner bearing races from input and output shafts, engaging 5th gear -arrow 1- and 1st gear -arrow 2- and -arrow 3- for this. Input shaft and output shaft are locked when both gears are engaged. Both bolts can now be loosened.

If the shafts are to be reused, clean residual locking material out of threaded holes using a thread chaser.

Remove both bolts -arrows- for reverse shaft support bracket.

Now remove 3rd bolt -arrow- for reverse shaft support bracket.

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

Remove cover plate -A- and pivot pins -B- from underside of gearbox.

Remove pivot pins -A- on top side of gearbox and securing bolts -B- for gearbox housing to clutch housing in area of differential.

Remove bolts -A- from clutch housing side for securing clutch housing to gearbox housing. Do not remove nuts -B- for output shaft bearing support.

Remove both flange shafts, together with springs, thrust washers and tapered rings.

Pull off following components together with gearbox housing: Synchro-hub for 5th/6th gears, Gear wheel for 6th gear, Gear wheel for 5th gear.

Use puller plate -T10408- in conjunction with following special tools: Thrust pieces -T10408/2-, Puller Kukko 18/1 (Qty. 2). Screw puller plate -T10408- firmly into threaded holes for gearbox housing cover. Hexagon bolts M7 x 35 with washers, Torque setting 18 Nm.

Place thrust pieces -T10408/2- on shafts. Install puller Kukko 18/1.

Pull off 5th and 6th gear synchro-hub, 6th gear wheel, 5th gear wheel and gearbox housing by alternately tightening spindles -A- (1/2 rotation) of pullers Kukko 18/2.

Heat 5th and 6th gear wheels slightly with hot air blower -V.A.G 1416- if necessary.

Set threaded insert -T10309/3- in half shell.

Now fit second half shell -T10309/1- and set tube -T10309/2- over assembly.

After parts are pulled off, check synchro-hub for damage.

Renew synchro-ring for 5th gear.

Now remove sleeve from gear wheel for 5th gear.

Pull off gear wheel for 5th gear.

First set up puller hooks -A-. Thrust piece -T10040/3- or Thrust plate -40 – 105-.

When pulling off gear wheel, ensure that hooks do not bend outwards. After pulling off 5th gear wheel, examine for damage.

Heat gear wheel slightly with hot air blower -V.A.G 1416- if necessary.

Installing 5th/6th gears, refer to page 123.

Apply sealant -AMV 188 200 03- evenly to sealing surface of gearbox housing cover.

Install cover for gearbox housing and tighten bolts to specified torques, refer to page 104.

Fit clutch release lever and release bearing, refer to page 44.

Fill with gear oil, refer to page 92.

Removing and installing gearbox housing cover, clutch housing, selector shaft with selector mechanism cover, input shaft, output shaft, differential and selector mechanism.

Support plate -VW 309-

Gearbox support -VW 353-

Drift -VW 295-

Drift sleeve -VW 244 B-

Hot air blower -V.A.G 1416-

Torque wrench -V.A.G 1331-

-Zweiarmabzieher Kukko 210.1-

-Stehbolzen M 8 x 100 mm

Support bridge -30-211A-

Thrust piece -32 – 111-

Thrust piece from assembly tool -T10030/4-

Tube -VW 416 B-

Puller -T10309-

Two arm puller -T10040- or two arm puller -Kukko 20/10-

With puller hooks -T10040/2A-

Thrust piece -T10040/3-

Bearings of input shaft and output shaft must not be damaged when 5th and 6th gears are removed and installed.

The following tools must be mounted for support at this stage during attachment of gearbox to gearbox support -VW 353- :

Underneath input shaft:

Support bridge -30-211A-

Thrust piece -32 – 111-

Thrust piece -T10030/4-

The input shaft can be supported by the thrust piece -32 – 111- only at a later point.

Underneath bearing support for output shaft:

Support device -T10323-

Assembly tool -3253/7-

Thrust piece -VW 433-

Secure gearbox on gearbox support -VW 353- .

Remove gearbox housing cover -arrow-.

Remove cover, if necessary carefully levering up all around along protruding housing flange and alternating between sides, being careful not to damage sealing surfaces.

Remove selector fork for 5th and 6th gears as follows:

Cover openings with a cloth.

Engage 5th gear -arrows 1- and -2-.

Remove selector jaw for 5th and 6th gears -bolt A-.

Then remove both bolts -B- for pivot pins.

Pull out pivot pins.

Remove selector fork for 5th and 6th gears.

Remove -bolts A- for inner bearing races from input and output shafts, engaging 5th gear -arrow 1- and 1st gear -arrow 2- and -arrow 3- for this. Input shaft and output shaft are locked when both gears are engaged. Both bolts can now be loosened.

If the shafts are to be reused, clean residual locking material out of threaded holes using a thread chaser.

Remove both bolts -arrows- for reverse shaft support bracket.

Support device -T10323-

Assembly tool -3253/7-

Thrust piece -VW 433-

Torque wrench -V.A.G 1332-

Mounting -2 Kukko 18/1- (Qty. 2)

Hexagon bolts M7 x 35 with washers

It is necessary to readjust the input shaft only when the following components are renewed: Gearbox housing, Clutch housing, Input shaft, Gear wheel for 4th gear, or the Tapered roller bearing. Adjustment overview, refer to page 192.

Requirement: Sealing surfaces of clutch and gearbox housings must be free of sealant.

Press tapered roller bearing outer race into gearbox housing to stop.

Press tapered roller bearing outer race without shim into gearbox housing to stop.

Install input shaft in clutch housing and set gearbox housing in place. Tighten hexagon head bolts to 25 Nm and then turn 90° further.

Fit measuring appliance and dial gauge in clutch housing.

Before taking any measurements, rotate input shaft to allow bearings to settle. Set dial gauge to “0” with 1 mm preload.

Note: This step must be repeated for each subsequent measurement, or the dial gauge will not return to the starting position.

Press input shaft in direction of dial gauge -direction of arrow-.

Read and note play on dial gauge (example: 1.21 mm).

Note: Dial gauge does not return to original position.

Determining thickness of shim (Example):

Installed shim: 0.65 mm

+ Measured value: 0.20 mm

+ Preload (constant): 0.15 mm

Shim thickness: 1.00 mm

Example for determining shim thickness from bearing play (Bearing play = 0.65 mm shim plus determined measured value):

Table of shims (Bearing play = 0.65 mm shim plus determined measured value):

Allocate shims according to Electronic parts catalogue “ETKA”.

Remove input shaft and press outer race of tapered roller bearing out of gearbox housing using thrust plate -VW 447 i- .

Insert shims of determined thickness, thickest shim first. If the size of shim required is larger than those listed in the table, insert two shims totalling the correct figure. The various thicknesses make it possible to achieve the exact shim thickness required.

Press in outer race of tapered roller bearing together with the shim (1.175 mm in example) into gearbox housing using thrust pad -VW 510- .

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

Set up measuring appliance and dial gauge.

Rotate input shaft so that tapered roller bearings settle.

Press input shaft in -direction of arrow-.

Bearing play should be min. 0.01 … max. 0.09 mm.

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

Universal dial gauge bracket -VW 387-

End dimension plate -VW 385/17-

Thrust pad -VW 510-

Thrust pad -VW 447 i-

Press tool -VW 407-

Torque wrench -V.A.G 1331-

Dial gauge

Internal puller -1- Kukko 21/8-

Counter support -4- Kukko 22/2-

Puller -2- Kukko 18/0- (threaded spindle)

It is necessary to readjust the output shaft when the following components are renewed:

Output shaft

Clutch housing

Tapered roller bearing

Adjustment overview, refer to page 192.

Requirement: Sealing surfaces of clutch and gearbox housings must be free of sealant.

Press small tapered roller bearing outer race together with a 0.65 mm thick shim into clutch housing to stop, refer to page 170.

Insert output shaft and tighten nuts for bearing support to 25 Nm, then turn 90° further.

Turn output shaft 20 to 30 times in one direction. Note: The shaft must be turned in one direction so that the rollers of the tapered roller bearing settle in one direction. It is necessary to turn the shaft 20 to 30 times to achieve this. Otherwise the resulting reading will be incorrect.

Set up dial gauge (3 mm measuring range) and set to “0” with 1 mm preload. -A- = threaded spindle from puller -Kukko 18/0- .

Move output shaft up and down and note dial gauge reading (example: 0.20 mm).

The specified bearing preload is obtained by adding a constant preload figure (0.10 … 0.15 mm) to the reading obtained (0.20 mm) and the thickness of the shim installed (0.65 mm).

Example:

Installed shim: 0.65 mm

+ Measured value: 0.20 mm

+ Preload (constant): 0.15 mm

Shim thickness: 1.00 mm

Example for determining shim thickness from bearing play (Bearing play = 0.65 mm shim plus determined measured value):

Table of shims:

Allocate shims according to Electronic parts catalogue “ETKA”.

Remove output shaft and pull out small tapered roller bearing outer race, refer to page 169.

Insert shims of determined thickness, thickest shim first. If the size of shim required is larger than those listed in the table, insert two shims totalling the correct figure. The various thicknesses make it possible to achieve the exact shim thickness required.

Press in small tapered roller bearing outer race together with the correct shim (in example 1.00 mm), refer to page 170 and install output shaft. Tighten bearing support nuts in clutch housing to 25 Nm and then turn 90° further.

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

Set up measuring appliance and dial gauge.

Rotate input shaft so that tapered roller bearings settle.

Press input shaft in -direction of arrow-.

Bearing play should be min. 0.01 … max. 0.09 mm.

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

Thrust piece -VW 454-

Thrust pad -VW 447 H-

Press tool -VW 411-

Centring mandrel -12 – 551-

Pressure plate -VW 401-

Press tool -VW 408 A-

Internal puller -1- Kukko 21/2-

Counter support -4- Kukko 22/1-

After dismantling, always renew needle bearing in clutch housing and reverse shaft support.

A – Counter support , e.g. -Kukko 22/1-

B – Internal puller, 14.5 … 18.5 mm , e.g. -Kukko 21/2-

Note: The needle bearing is destroyed during removal and must be renewed.

Secure needle bearing in gearbox housing at three points (120° offset) using a punch.

Lubricate one-piece thrust washer with gear oil and install.

Install one-piece thrust washer so that it engages in groove -B- in differential cage.

Table of shims:

Allocate shims according to Electronic parts catalogue “ETKA”.

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- .

Insert shims of determined thickness, thickest shim first. If the size of shim required is larger than those listed in the table, insert two shims totalling the correct figure. The various thicknesses make it possible to achieve the exact shim thickness required.

Press in tapered roller bearing outer race together with the correct shim (in example 0.95 mm) again, refer to page 198 and bolt gearbox housing tight.

It is necessary to readjust the differential when the following components are renewed: Gearbox housing, Clutch housing, Differential cage, or the Tapered roller bearing of differential. Adjustment overview, refer to page 192.

Press tapered roller bearing outer race without shim into gearbox housing using thrust piece -30 – 205-, refer to page 198.

Note: Inner and outer tapered roller bearing races are paired. Do not interchange!

Press outer race of tapered roller bearing into clutch housing using thrust plate -30 – 205-, refer to page 197.

Fit differential into clutch housing.

Set gearbox housing in place and tighten 5 bolts to 25 Nm.

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)

Determining thickness of shim (Example):

Measured value: 0.70 mm

+ Preload (constant): 0.25 mm

Thickness of shim = 0.95 mm

Example for determining shim thickness from bearing play:

Table of shims:

Allocate shims according to Electronic parts catalogue “ETKA”.

Remove gearbox housing and pull tapered roller bearing outer race from gearbox housing.

Insert shims of determined thickness, thickest shim first. If the size of shim required is larger than those listed in the table, insert two shims totalling the correct figure. The various thicknesses make it possible to achieve the exact shim thickness required.

Press in tapered roller bearing outer race together with the correct shim (in example 0.95 mm) again, refer to page 198 and bolt gearbox housing tight.