VOLKSWAGEN JETTA 2005 (13) PDF Document

The identification code and date of manufacture are located on the gearbox. The code follows the format of an identification code, followed by the day, month, and year of manufacture. The gearbox code also appears on the vehicle identification plates.

The manual gearbox capacity is 2.0 liters. For specific data such as individual gear ratios, gear oil specifications, and clutch allocation, refer to the Electronic parts catalogue ETKA.

General repair notes include: Always renew O-rings, seals, and gaskets. When installing oil seals, half-fill the space between sealing lips with sealing grease G 052 128 A1. The open side of the oil seal must face the side with fluid filling. For housing joint surfaces, thoroughly clean and apply a thin, uniform coat of sealant AMV 188 200 03. Ensure breather holes remain free of sealing paste.

For bolts and nuts, loosen and tighten covers and housings diagonally. Torque settings are for unoiled fasteners. Always renew self-locking bolts and nuts. If a bolt thread requires locking fluid, clean the thread with a wire brush and apply AMV 185 100 A1.

Special tools required include release tool T10178 and torque wrench V.A.G 1331. To remove: First, ensure any radio anti-theft codes are obtained, then disconnect the battery with the ignition off. Remove trim and covers below the drive side. Depending on equipment, remove any knee airbag bracket or crash bar. Remove the cable guide and footwell vent. If applicable, remove the damping from the lower clutch pedal mounting bracket area by removing the lock washers and pulling it off. Push the damping upwards in the area of the upper securing nut. Unbolt the clutch pedal by removing the nut and bolt. The pedal remains hooked to the master cylinder operating rod. Swing the clutch pedal down slightly and remove the over-centre spring.

Special equipment includes brake filling and bleeding equipment (VAS 5234 or V.A.G 1869). Prefilling the system is not necessary. Connect the bleeding equipment. If necessary, use a 670 mm bleeder hose V.A.G 1238/B3. Connect the hose to the collector bottle and the bleeder valve. Pressurize the system to 2 bar. Open the bleeder valve and bleed approximately 100 cm3 of brake fluid. Close the valve. Rapidly operate the pedal from stop to stop 10 to 15 times. Open the valve again and bleed an additional 50 cm3 of brake fluid. Close the valve. Depress the clutch pedal several times after completing the process.

Ensure the gearbox is in neutral and the mechanism moves freely. Remove the air filter housing if necessary to access the selector shaft. Pull the locking mechanisms on the gate selector and gear selector cable end-pieces forward to stop, then turn to the left to lock. Secure the selector shaft by pressing it down and inserting locking pin T10027 A until it engages. With the gear lever in neutral, guide locking pin T10027 A through holes A and B to lock the assembly. Turn the cable locking mechanisms clockwise to stop so they snap into their original position. Remove the locking pin. Check that the selector shaft moves freely and conduct a functional check by selecting all gears.

Remove the noise insulation if necessary. Remove the oil plug. The oil level is correct when the gearbox is filled to the lower edge of the filler hole. If filling is required: Fill with gear oil until it reaches the lower edge of the filler hole. Screw in the plug. Start the engine, engage a gear, and allow the gearbox to turn for approximately 2 minutes. Stop the engine, remove the plug again, and top up to the lower edge of the filler hole. Tighten the plug to the specified torque.