VOLKSWAGEN JETTA 2005 (10) PDF Document

The 5-speed manual gearbox 0A4 is installed in the VOLKSWAGEN JETTA 2005 in conjunction with a 4-cylinder engine.

To ensure flawless and successful gearbox repairs, the greatest care and cleanliness as well as the use of good and proper tools are essential. Of course, the basic rules for safety also apply during repair work.

A number of instructions generally applicable to the various repair procedures which were previously repeated a number of times at various places in the workshop manual are summarised under the topic “components” . They apply to this workshop manual.

Thoroughly clean housing joint surfaces before applying sealant.

Apply sealant -AMV 188 200 03- uniformly but not too thick.

Renew O-rings, seals and gaskets.

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

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

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

Press in new oil seals so that sealing lip does not contact the shaft in the same place as the old seal (make use of insertion depth tolerances).

Lightly oil O-rings before installing; this prevents the rings being crushed when inserted.

After renewing seals and gaskets, check oil level in gearbox and replenish if necessary .

Do not overstretch retaining rings.

Always renew retaining rings which have been damaged or overstretched.

Retaining rings must locate properly in grooves.

Renew spring pins. Installation position: slit -A- should be in line with the line of force -arrow-.

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

Securing bolts and securing nuts 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- .

Threaded holes into which self-locking bolts or bolts coated with locking fluid are screwed, must be cleaned (e.g. with a thread chaser). Otherwise there is a danger of bolts shearing when subsequently being removed.

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 synchromeshed gear.

Check for wear and renew if necessary.

Check grooves -arrow 1- of synchro-ring -A- and inner ring for flat spots (worn grooves).

If synchro-rings are coated, coating must not be damaged.

If an intermediate ring -B- is installed, check the outer friction surface -arrow 2- and inner friction surface -arrow 3- of this intermediate ring for “scoring” and “signs of abnormal wear”.

Check the cone of the synchromeshed gear for “scoring” and “signs of abnormal wear”.

Moisten synchromesh mechanism with gear oil before installing.

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

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

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

Observe installation position.

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

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 having anti-theft coding.

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

If reconnecting battery, follow procedure after connecting battery Electrical system; Rep. Gr. 27; Disconnecting and connecting battery .

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

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

Push driver seat as far back as possible and move steering wheel to highest position.

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

Remove bracket for knee airbag together with crash bar General body repairs, interior; Rep. Gr. 69; Airbag; Removing and installing knee airbag bracket.

Remove cable guide -2- from steering column.

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

If fitted, remove damping -arrow- from lower area of clutch pedal mounting bracket.

To do this, remove lock washers -A- for damping.

Pull off insulation.

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-.

The clutch pedal remains hooked to operating rod of master cylinder.

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 .

Carry out procedure as follows:

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

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

Push driver seat as far back as possible and move steering wheel to highest position.

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

Vehicles with knee airbag:

Remove bracket for knee airbag together with crash bar General body repairs, interior; Rep. Gr. 69; Airbag; Removing and installing knee airbag bracket.

Continuation for all:

Remove cable guide -2- from steering column.

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

Vehicles without knee airbag:

The crash bar -1- in front of clutch pedal -2- may be secured in different ways. Crash bar may look different from as shown in following illustrations.

Attachment with 2 bolts:

Remove crash bar -1- (2 bolts).

Attachment with 1 bolt:

Remove crash bar -1- (1 x bolt -2-).

Continuation for all:

If fitted, remove damping -arrow- from lower area of clutch pedal mounting bracket.

To do this, remove lock washers -A- for damping.

Pull off insulation.

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.

Secure 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 .

Some cars have damping -arrow- on the mounting bracket/clutch pedal.

Return this to installation position.

Vehicles without knee airbag:

The crash bar -1- in front of clutch pedal -2- may be secured in different ways.

Attachment with 2 bolts:

Install crash bar -1- and tighten 2 bolts to specified torque .

Attachment with 1 bolt:

Install crash bar -1- and tighten bolt -2- to specified torque .

Continuation for all:

Mount cable guide -2- on steering column.

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

Vehicles with knee airbag:

Install bracket for knee airbag together with crash bar General body repairs, interior; Rep. Gr. 69; Airbag; Removing and installing knee airbag bracket .

Continuation for all:

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

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

Carry out procedure as follows:

LHD:

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

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

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

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

Clamp off supply hose to master cylinder with hose clamps up to ∅ 25 mm -3094- .

If present, 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- (⇒ figure above).

Release securing clip -2- using screwdriver or a pointed object and pull pipe/hose line -1- or plastic line -1- off master cylinder.

Unclip clutch position sender -G476- from master cylinder -arrow- and remove with electrical connector attached -4-.

Note

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 General body repairs, interior; Rep. Gr. 68 .

Vehicles with knee airbag:

Note

The installation location of the knee airbag is above the pedal cluster.

Remove bracket for knee airbag together with crash bar General body repairs, interior; Rep. Gr. 69; Airbag; Removing and installing knee airbag bracket.

Continuation for all:

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-.

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

Some cars have damping -arrow- on the clutch pedal mounting bracket.

Return this to installation position.

Vehicles without knee airbag:

The crash bar -1- in front of clutch pedal -2- may be secured in different ways.

Attachment with 2 bolts:

Install crash bar -1- and tighten 2 bolts to specified torque .

Attachment with 1 bolt:

Install crash bar -1- and tighten bolt -2- to specified torque .

Continuation for all:

Mount cable guide -2- on steering column.

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

Vehicles with knee airbag:

Install bracket for knee airbag together with crash bar General body repairs, interior; Rep. Gr. 69; Airbag; Removing and installing knee airbag bracket .

Continuation for all:

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

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

Carry out procedure as follows:

LHD:

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

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

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

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

Right-hand drive:

In vehicles with particle filter, remove shielding -A- from particle filter Rep. Gr. 26; Parts of exhaust system; Assembly overview – front exhaust pipe with particle filter .

An insulation mat is installed in conjunction with some engines.

Remove the insulation mat from the hose/pipe line -arrows-.

Continuation for all:

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 with hose clamps up 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 in the reverse order of removal, observing the following:

Note

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 contour, if necessary.

Bleed clutch system .

Right-hand drive:

In vehicles with particle filter, mount shielding -A- on particle filter Rep. Gr. 26; Parts of exhaust system; Assembly overview – front exhaust pipe with particle filter .

LHD:

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

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

Connect battery and follow procedure after connecting battery Electrical system; Rep. Gr. 27; Disconnecting and connecting battery .

Carry out procedure as follows:

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

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

Remove complete air filter housing if it is near slave cylinder 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 off pin.

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.

Plastic relay lever:

Remove relay lever together with cable end-piece .

Continuation for all:

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

Remove cable support bracket from gearbox -arrows-.

Then tie up gear selector cable and gate selector cable.

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

Then remove gearbox support -arrow A-.

Lay 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 mount gearbox support -arrow A-.

Bleed clutch system after installing slave cylinder .

Assembling selector mechanism .

Adjust selector mechanism .

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

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

Slave cylinder to gearbox Item 9 (page 45)

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

Selector cable support bracket to gearbox 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°

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

Prefilling system is not necessary!

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

Carry out procedure as follows:

Remove complete air filter housing if it blocks access to bleeder valve -arrow- 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 valve -arrow-.

Pressurise system to 2 bar.

Open bleeder valve.

Allow about 100 cm3 of brake fluid to flow out.

Close bleeder valve.

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

Open bleeder valve again.

Allow another 50 cm3 of brake fluid to flow out.

Close bleeder valve.

Depress clutch pedal several times after completion of bleeding process.

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

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.

The make of the clutch can be determined as follows with the clutch installed:

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

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 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 or

Remove gearbox.

Use counter-hold tool -3067- to loosen bolts.

Loosen bolts in small steps and diagonally.

As bolts are removed, stop -2- with pin -1- must loosen.

If stop does not loosen: Press bolt towards two-piece flywheel.

Remove pressure plate and clutch plate.

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.

Wear to half the thickness of the diaphragm spring -arrows- is permitted.

Check spring connections between thrust plate and cover for cracks and make sure rivet fastenings are seated tightly.

Reverse position of counterhold tool -3067- when installing.

Put pressure plate onto centring 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.

Torque setting: .

Install gearbox.

Remove gearbox.

Use counter-hold tool -3067- to loosen bolts.

Loosen bolts in small steps and diagonally.

Remove pressure plate and clutch plate.

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.

1 – Dual-mass flywheel:

Removing and installing .

Ensure that centring pins fit tightly.

Contact surface for clutch lining must be free of grooves, oil and grease.

2 – Clutch plate:

Allocation Electronic parts catalogue “ETKA” .

Removing and installing .

Renew only together with pressure plate.

Installation position .

3 – Pressure plate:

Allocation Electronic parts catalogue “ETKA” .

With adjusting mechanism.

Removing and installing .

Check ends of diaphragm spring .

Check spring connections and riveted connections .

Renew only together with clutch plate.

4 – M6 bolt, 13 Nm, M7 bolt, 20 Nm:

Loosen or tighten diagonally in small steps.

Wear to half the thickness of the diaphragm spring -arrows- is permitted.

Check spring connections -arrows A- for damage and riveted connections -arrows B- for secure seating.

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.

Pull or carefully prise gaiter with centre console cover upwards out of centre console -arrows-.

With some equipment variations, the gaiter must be levered off along the front section.

Pull gaiter with centre console cover upwards, inside out over gear knob.

Open clamp -arrow- and pull off gear knob together with gaiter.

In some versions, centre console cover remains in the centre console.

If necessary, pull or carefully price off centre console cover.

Pull off noise insulation -1-.

First insert noise insulation.

Installation position of noise insulation:

-Arrow A- points in direction of travel.

– Catches -arrows B- must engage in centre console.

If necessary, press centre console cover into centre console.

Then turn gaiter inside out.

The gear knob must be pressed to stop.

Install selector lever knob with cover and gaiter and squeeze new clamp -arrow- together.

Then press gaiter with cover into centre console or press gaiter into cover.

Remove securing clip from gear selector cable -A- and gate selector cable -B-.

To do this, raise tab using screwdriver -arrow 1- and press 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.

Removing and installing securing clip:

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

Note:

Do not cant spacer bush when pushing down.

Slot in gear lever for securing clip must be visible.

Carefully release tension from spring.

Installing compression 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-.

Carry out procedure as follows:

Remove selector mechanism .

Bend open tabs -arrows- of selector mechanism base plate using a screwdriver and remove base plate. Tabs in front area of base plate are not illustrated.

Remove seal from selector housing.

Remove gear selector cable and gate selector cable from selector housing .

Lift upper end -A- of compression spring over tab of gate selector lever.

Use screwdriver to press catches -arrows- of ball socket towards bearing ball of gear lever guide; break off catches if necessary.

Lever ball socket -A- with gear lever guide -B- out of selector housing.

Then press ball socket off bearing ball of gear lever guide and remove it.

Please pay attention to guides -A- during the further procedure.

They must not be broken off.

Lever lower end -arrow 1- of compression spring onto shoulder on gate selector lever as far as stop.

Now pull gear lever guide up to stop and pull ball stud out of gate selector lever -arrow 2-.

Then turn selector lever in -direction of arrow 1-.

Pin -arrow 2- must be in notch in selector housing.

Then swing out gear lever guide with gear lever in -direction of arrow 3-.

Assembling selector mechanism:

Caution

The lower end of the compression spring (-arrow 1- figure above) can snap off the shoulder of the gate selector lever out of control during the further procedure.

Therefore, carefully press lower end off shoulder of gate selector lever.

The ends of the compression spring then become tensioned “diagonally” with a loud noise.

Gate and selector cables -B- must be inserted, free of tension, into locking devices -A-.

Now turn locking mechanisms on gear selector cable and gate selector cable end pieces clockwise to stop -direction of arrow 1-.

The spring presses the locking mechanism into original position -direction of arrow 2-.

Then turn angled rod -A- back to original position in -direction of arrow-.

Note

The angled rod -A- must be pressed out of selector housing to stop and point to rear.

Pull locking pin out of holes -A- and -B-.

If noise insulation was present, install it.

Install gaiter with selector knob and cover .

Check selector shaft can move freely.

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

Functional check:

With gearbox in neutral, selector lever must rest in selector lever 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 .

Clamp selector fork in vice with protective jaw covers -B-.

Lever off lock washer -A- in -direction of arrow-.

Press lock washer into groove of selector segment using socket and spinner handle.

Note

After lock washer is installed, selector segment must still rotate freely.

Note

When removing and installing angular contact ball bearing, do not bend selector forks.

Inner race must engage in outer race.

Depression in thrust piece -3290/1- faces ball bearing.

Press inner ring onto cone of synchromeshed gear and measure gap -a- using a feeler gauge.

Press inner race -A- of angular contact ball bearing into outer race.

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 .

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

Install pivot pin -arrow 2- with a new O-ring Item 5 (page 118) .

Screw in oil drain plug -arrow 1- Item 17 (page 144) .

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

Top up gear oil in container to 1.7 l.

Gearbox oil specification Electronic parts catalogue “ETKA” .

Remove reversing light switch -F4- -arrow-.

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

Insert hose into mounting hole of reversing light switch -F4- (2nd mechanic) and pour in gear oil.

Install reversing light switch -F4- -arrow- again Item 2 (page 148) .

Check function of selector mechanism .

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

Install noise insulation 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 – Gearbox housing cover

7 – Gearbox housing

8 – Selector mechanism (Selector forks)

9 – Reverse gear wheel

10 – Clutch housing

11 – Input shaft

12 – Output shaft

13 – Differential

I – Removing and installing cover for gearbox housing and 5th gear .

II – Removing and installing gearbox housing and selector mechanism .

III – Removing and installing input shaft, output shaft, differential and selector forks .

1.1 Renewing oil seal for left flange shaft:

Multipurpose tool -VW 771-

Thrust piece -T10160-

Torque wrench -V.A.G 1331-

1.3 Renewing seal (two-part seal and sleeve for right flange shaft):

Thrust piece -T10160-

Assembly tool -3253/2-

Bolts -arrows- 40 Nm + 90°

Bolts -arrows- 60 Nm + 90°

Bolts -arrows- 20 Nm + 90°

Before installation Item 3 (page 143) Oil capacity .

After installation .

All threaded holes into which self-locking bolts are to be screwed must be cleaned of residual locking fluid carefully with a thread chaser.

Always renew self-locking bolts and nuts.

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.

Ensure that intermediate plate is correctly seated on engine.

Clean input shaft splines and apply thin coat of grease for clutch plate splines -G 000 100- .

The clutch plate must slide easily to and fro on the input shaft.

To install gearbox “0A4”, set up gearbox support -3282- with adjustment plate -3282/39- .

Align arms of gearbox support according to holes in adjustment plate .

Screw in support elements -A – and -C- ( pin -3282/29- ) on adjustment plate as shown.

Place gearbox on engine and gearbox jack .

Align adjustment plate and gearbox parallel to one another.

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.

Example:

When installing new gears or new input shaft, consult technical data and Electronic parts catalogue “ETKA” .

The output shaft is dismantled as follows: position separating device under 2nd gear synchromeshed gear and press off as described in . Remove retaining ring . Then press off locking collar with synchro-hub for 1st and 2nd gear as described in .

Carry out procedure as follows:

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

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 dial gauge (3 mm measuring range) and set to “0” with 1 mm preload.

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

Example:

Installed shim 0.65 mm

+ Measured value 0.20 mm

+ Preload (constant) 0.15 mm

Shim thickness 1.00 mm

Example:

Remove output shaft and pull out small tapered roller bearing outer race .

Note

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

Pulling needle bearing out of clutch housing:

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.

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.

Installation position of thrust washer for tapered ring -1-.

The shoulder -arrow- points towards spring -B-.

Some gearboxes have lugs -A-.

Lugs -A- face tapered ring -1-.

Carry out procedure as follows:

Press tapered roller bearing outer race without shim into gearbox housing using thrust plate -30 – 205- .

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.)

Example:

Measured value 0.70 mm

+ Preload (constant) 0.25 mm

Thickness of shim = 0.95 mm

Example:

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-

Fit shim under outer race.

Support gearbox housing directly below bearing mounting using sleeve -3144- .