VOLKSWAGEN JETTA 2005 (05) PDF Document

To ensure flawless and successful gearbox repairs, the greatest care and cleanliness as well as the use of good and proper tools are essential. Safety rules must be followed during repair work. When installing the gearbox, ensure that dowel sleeves between the engine and gearbox are correctly located. Place removed parts on a clean surface and cover them to prevent soiling. Use plastic sheeting, paper, and lint-free cloths only. Install only clean parts, and do not remove new parts from their packaging until immediately before installation. If repair work cannot be performed immediately, carefully cover or seal the components.

Securing bolts and nuts for covers and housings should be loosened and tightened diagonally. Torque settings are specified for unoiled bolts and nuts. For bolts secured with locking fluid, clean the threads with a wire brush, then insert them using locking fluid AMV 185 100 A1. Use a thread chaser to clear residual locking fluid from all threaded holes into which self-locking bolts are to be screwed to prevent shearing during removal. Always renew self-locking bolts and nuts.

Electrostatic discharge from the human body can disturb the function of electrical components in the gearbox and selector mechanism. Before beginning work on electrical components, touch an earthed object, such as a water pipe or lifting platform. Do not touch connectors or open electronic components directly.

To drain the torque converter, you will need the V.A.G 1358 A oil extraction unit and the V.A.G 1358 A/1 oil extraction probe. Extract the ATF from the torque converter using these tools.

Carefully push the torque converter hub via the oil seal to the first stop. Turn the torque converter towards the gearbox using light pressure until the notch in the hub engages in the follower of the pump gear and the torque converter can be felt to slip in place. The torque converter is properly inserted when it can easily be turned by hand and is seated equally deep in the gearbox around the entire circumference. Note that if the engine and gearbox are brought together with force due to an improperly fitted torque converter, both the gearbox and torque converter will be damaged.

First, ensure the following prerequisites are met: the selector lever cable is disconnected from the selector shaft lever, the selector shaft is set to the N position, the securing bolts for the multifunction switch F125 have been loosened, and the selector shaft lever has been removed. Then, place the setting gauge T10173 on the selector shaft and turn the multifunction switch until the setting gauge engages in the lug on the multifunction switch connector. Secure the setting gauge on the selector shaft with a bolt, tighten the switch securing bolts to 6 Nm, remove the setting gauge, and complete the installation in reverse order.

To check the ease of movement of the selector lever cable, it must be removed from the gearbox and the free end placed so that it does not bump against anything. Move the selector lever repeatedly from P to S and back to P. The selector lever must move easily. Do not grease the connection of the selector lever cable.

With the engine running, screw the adapter for filling oil VAS 6262/2 hand-tight. Add 1 litre of ATF. Pull off the adapter for oil filling VAS 6262 at the quick-release connection and check if ATF flows out of the hole in the adapter. If it does not flow out, add another litre. If ATF flows out, the ATF does not need more topping up; drain the excess until it drips, then fit a new seal to the plug and tighten it to 27 Nm.

Remove the oil pan and the ATF strainer. Draw a sketch of all senders and solenoid valves with their respective connectors. Before separating the connectors at the senders and solenoid valves, the solenoid valve or sender and the respective connector must be identified to ensure they are not interchanged during reinstallation. Use a small screwdriver to pry out the securing bolts of the connectors on the solenoid valves carefully and pull off the connectors. If present, carefully pull off the connectors for the automatic gearbox hydraulic pressure sender 1 G193 and automatic gearbox hydraulic pressure sender 2 G194. Follow additional steps to remove bracket bolts and disconnect wiring harnesses, then loosen the securing bolts for the valve body diagonally and carefully remove it.