VOLKSWAGEN JETTA 2005 (14) PDF Document

To ensure flawless and successful gearbox repairs for the VOLKSWAGEN JETTA 2005, 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“.

The gearbox housing and clutch housing are made of a magnesium alloy.

Bolts and other components in direct contact with the gearbox have a surface matched to it.

If the incorrect components (bolts, nuts, washers and so on) are used, contact corrosion will develop, which will damage the gearbox housing and clutch housing.

Always install parts listed in the Electronic parts catalogue „ETKA“.

Thoroughly clean housing joint surfaces before applying sealant.

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

Always renew O-rings, seals, and gaskets.

When seals have been removed, check the contact surface on housings or shafts for burrs and damage and rectify as necessary.

Before installing radial shaft seals, lightly oil the outer diameter and half-fill the space between the sealing lips 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 the 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 the oil level in the 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 and tighten securing bolts and nuts for covers and housings diagonally.

Do not cant especially delicate parts, such as clutch pressure plates. Loosen and tighten bolts and nuts in stages in a diagonal sequence.

Torque settings are specified for unoiled bolts and nuts.

Always renew self-locking bolts and nuts.

Ensure with threaded connections that contact surfaces as well as nuts and bolts are rewaxed only after assembly, if necessary.

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

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

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.

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.

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

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

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

If fitted, remove damping -arrow- from the lower area of the clutch pedal mounting bracket. To do this, remove lock washers -A- for damping and pull off damping.

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

Unbolt the clutch pedal -1- from the mounting bracket -3- by removing nut -2- and pulling out bolt -5-.

Swing the clutch pedal down slightly and remove the over-centre spring -4- from the mounting bracket.

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

Remove the clutch pedal.

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

Renew self-locking nuts.

Attach retainer -2- to the master cylinder operating rod -1-.

Press the retainer into the notch in the clutch pedal -3- until it can be heard to engage.

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

The receptacle -arrow- for the tip -A- of the clutch pedal must stand vertically.

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

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

If the vehicle has damping -arrow- on the mounting bracket/clutch pedal, return it to the installation position.

For vehicles without a knee airbag, install the crash bar -1- in front of the clutch pedal by screwing on and tightening nuts -2-.

For vehicles with a knee airbag, install the bracket for the knee airbag together with the crash bar.

Install the driver side footwell cover and driver side left trim panel.

If disconnected, connect the battery.

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

The specified torque for the crash bar to the steering column mounting bracket is 10 Nm.

The special tools required for removing and installing the mounting bracket are Hose clamps -3094-, Hose clip pliers -VAS 6362-, and Sealing tool -T10249-.

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

With ignition switched off, disconnect the battery earth strap.

Remove the complete air filter housing if it is near the battery.

Remove the battery and battery tray.

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

Place a lint-free cloth under the master cylinder.

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

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

If necessary, close the line for disconnecting with the sealing tool -T10249/1-.

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

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

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

Remove the driver side footwell cover and driver side left trim panel.

For vehicles with a knee airbag, remove the bracket for the knee airbag together with the crash bar.

For vehicles without a knee airbag, remove the crash bar -1- from in front of the clutch pedal by removing nuts -2-.

If fitted, remove damping -arrow- from the lower area of the clutch pedal mounting bracket. To do this, remove lock washers -A- for damping and pull off damping.

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

Remove nuts -2-.

Remove the mounting bracket -1-.

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

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

Renew self-locking nuts.

Renew hose clips.

Allocate all components according to the Electronic parts catalogue „ETKA“.

If the vehicle has damping -arrow- on the clutch pedal mounting bracket, return it to the installation position.

For vehicles without a knee airbag, install the crash bar -1- in front of the clutch pedal by screwing on and tightening nuts -2-.

For vehicles with a knee airbag, install the bracket for the knee airbag together with the crash bar.

Install the driver side footwell cover and driver side left trim panel.

Push the pipe/hose line or plastic line -1- with seal -2- onto the connection of the master cylinder -4- until the securing clip -3- engages audibly.

Test the line by tugging on it.

After removing the hose clamp up to 25 mm ∅ -3094-, return the supply hose to its original shape, if necessary.

Bleed the clutch system.

For LHD vehicles, install the battery tray and battery.

For LHD vehicles, remove the complete air filter housing if it is near the battery.

Reconnect the battery and perform the work required after connecting the battery.

Component Nm

Renew self-locking nuts for the mounting bracket to body.

Remove the mounting bracket.

Release the retainer for the master cylinder operating rod using pliers -T10005-.

Insert spacer -A- between the clutch pedal and the stop and press the clutch pedal to the spacer. The length of the spacer should be about 40 mm (e.g. 1/2″ socket).

Release the securing bar -B- and pull the master cylinder out of the mounting bracket -arrow 1- and -arrow 2-.

Move the clutch pedal to the rest position at the stop.

Attach the retainer -2- to the master cylinder operating rod -1-.

Insert spacer -A- between the clutch pedal and the stop and press the clutch pedal to the spacer. The length of the spacer should be about 40 mm (e.g. 1/2″ socket).

Engage the master cylinder in the mounting bracket -arrow 1- and -arrow 2-.

Press the master cylinder operating rod -1- in the direction of the arrow until the retainer -2- engages audibly in the clutch pedal.

Install the mounting bracket.

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

With the ignition switched off, disconnect the battery earth strap.

For LHD vehicles: Remove the complete air filter housing if it is near the battery. Remove the battery and battery tray.

For Right-hand drive vehicles with a particle filter, remove shielding -A- from the particle filter. An insulation mat is installed in conjunction with some engines. Remove the heat shield from the pipe/hose line -arrows-.

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

Place a lint-free cloth under the master cylinder.

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

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

If necessary, close the line for disconnecting with the sealing tool -T10249/1-.

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

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

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

Remove the driver side footwell cover and driver side left trim panel.

For vehicles with a knee airbag, remove the bracket for the knee airbag together with the crash bar.

For vehicles without a knee airbag, remove the crash bar -1- from in front of the clutch pedal by removing nuts -2-.

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

Renew hose clips.

Allocate all components according to the Electronic parts catalogue „ETKA“.

If the pipe/hose line was removed: Push the pipe/hose line -1- or plastic line with seal -2- onto the connection of the master cylinder -4- until the securing clip -3- engages audibly. Test the pipe/hose line by tugging on it. After removing the hose clamp up to 25 mm ∅ -3094-, return the supply hose to its original shape, if necessary. Bleed the clutch system.

For Right-hand drive: In vehicles with a particle filter, install shielding -A- on the particle filter. Install the complete air filter housing if it is near the battery.

For LHD vehicles: Install the battery tray and battery. Remove the complete air filter housing if it is near the battery. Reconnect the battery and perform the work required after connecting the battery.

Check whether a coded radio is fitted. If so, obtain the anti-theft code.

With ignition switched off, disconnect the battery earth strap.

If the engine cover blocks access, remove the engine cover.

Remove the complete air filter housing if it is located close to the battery.

Remove the battery, battery cover, and battery tray.

Remove the left charge air hose -arrow 1- and -arrow 2- and the charge air pipe from the engine.

Remove the right charge air hose from the charge air cooler.

Remove the cowling -arrow- together with the radiator fans.

Remove the exhaust system bracket from the subframe -arrows-.

Separate the exhaust system at the double clamp -arrows-.

Raise and secure the front exhaust pipe or rest it on the tunnel bridge.

Remove the pendulum support.

Pull the connector -1- off the oil level and oil temperature sender -G266-.

Remove the left coupling rod from the anti-roll bar and lay it to the side.

Remove the left drive shaft.

Remove the drive shaft heat shield, if present -arrows-.

Remove the right drive shaft from the gearbox, raise, and secure it.

Remove the hexagon bolts -arrows- on the left engine/gearbox mounting -2- from the bracket -1-.

Lower the gearbox about 40 mm, dimension -a-, by adjusting the spindles attached to the engine. Observe connecting lines, hoses, and the radiator when moving the engine/gearbox assembly.

Remove bracket -1- from the gearbox -arrows-.

Remove the relay lever together with the cable end-piece.

Remove the gearbox selector lever from the selector shaft.

If a small cover plate -A- for the flywheel is present, remove it -arrows-.

Remove the lower engine/gearbox connecting bolt -1-.

Loosen the engine/gearbox connecting bolts -2- and leave them installed just hand-tight.

Attach bracket -T10346- with bolt -1- to the left threaded hole in the subframe. Bolt -1- is a Flange bolt M6 x 20.

Secure the engine support -3300 A- to bracket -T10346-.

Place a cloth between the engine support -3300 A- and the oil pan.

Press the engine forwards using the spindle of the engine support -3300 A-. Observe the following points in particular: The air conditioning compressor -2- must not contact the refrigerant line -1-. The alternator must not contact the refrigerant line. The pressure pipe must not contact the radiator.

To remove gearbox „02Q“, set up the gearbox support -3282- with adjustment plate -3282/33-.

Insert the gearbox support -3282- in the engine and gearbox jack -V.A.G 1383 A-.

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

Attach support elements -A- to the adjustment plate as illustrated.

Screw in pin -3282/29- in place of support element -C-.

Position the engine and gearbox jack -V.A.G 1383 A- under the vehicle. Arrow -B- on the adjustment plate points in the direction of vehicle travel.

Align the adjustment plate parallel to the gearbox.

Attach adapter -VW 771/40- in the threaded hole of the gearbox housing as shown in the illustration.

Screw pin -3282/29- into the hole on the gearbox for the securing bolt of the pendulum support.

Secure the gearbox to the gearbox support -3282- using bolt (M10x20) -A-.

Pin -B- must lie flush with the guide from the gearbox support -3282- at the bottom -arrow-.

Position the engine and gearbox jack -V.A.G 1383 A- under the vehicle. Arrow on the adjustment plate points in the direction of vehicle travel.

Now turn the gearbox upwards near the differential, using the spindle of the gearbox support -3282-, and downwards near the 6th gear.

Guide the gearbox with differential -A- over the subframe.

The right flange shaft must then be guided past the flywheel -arrow 2-; observe the intermediate plate -arrow 1-.

The right flange shaft -1- must be guided past the bolt hole of the engine -2-.

When doing this, use the spindles of the gearbox support -3282- to adjust the position of the gearbox so that the longitudinal member -arrows- is not touched.

Turn the gearbox to the installation position via the spindles of the gearbox support -3282-.

Align the gearbox on the engine dowel sleeves and join.

Screw in the engine/gearbox connecting bolt -C- and tighten to the specified torque.

Screw in the lower engine/gearbox securing bolts and tighten to the specified torque.

Remove the engine support -3300 A- and bracket -T10346-.

Screw in the engine/gearbox connecting bolt -arrow- and tighten to the specified torque.

After the bottom of the gearbox and engine are bolted together, remove the gearbox support -3282- from the gearbox.

Insert the upper engine/gearbox securing bolts and tighten to the torque specification.

Attach the gearbox selector lever to the selector shaft of the gearbox and tighten the hexagon nut to the specified torque.

Install the relay lever together with the cable end-piece.

Install bracket -1- on the gearbox using new hexagonal bolts -arrows- and tighten to the specified torque.

Align the engine and gearbox in the installation position. To do this, raise sufficiently so that bracket -1- completely contacts the left assembly mounting -2-.

Screw the new hexagon bolts -arrows- for the left assembly mounting -2- into bracket -1- and tighten to the specified torque.

Install the engine and gearbox mounting free of tension.

If a small cover plate -A- for the flywheel is present, install it -arrows-.

If there are threaded inserts, e.g. „HeliCoil“ in the bolting holes for the pendulum support, note the corresponding securing bolts and specified torque.

Install the pendulum support.

Then install the drive shafts.

Install the drive shaft heat shield, if present -arrows-.

Install the left coupling rod.

The specified torque for the engine/gearbox connecting bolt -C- is detailed on page 104.

The specified torque for the lower engine/gearbox securing bolts is detailed on page 104.

The required special tools and workshop equipment are Torque wrench -V.A.G 1331- and Multi-point bit -3357-.

The oil level is correct when the gearbox is filled to the lower edge of the filler hole.

The torque setting for the oil filler or oil drain plug with a multi-point socket head is 45 Nm.

The torque setting for the oil filler or oil drain plug with a hexagon socket head is 30 Nm.

The table below indicates which adjustments are necessary based on renewed components:

If repairs have been carried out on the gearbox, it is necessary to readjust the output shaft for 1st through 4th gear, output shaft for 5th, 6th and reverse gear, or differential only if components have been renewed which have a direct effect on the adjustment of the gearbox. To prevent unnecessary adjustments, refer to the table.

The specified torque for the Countersunk bolt (1) is 33 Nm.

The specified torque for the Reversing light switch -F4- (6) is 20 Nm.

The specified torque for Bolt (11) is 15 Nm + turn 90° further. Always renew; allocate shim according to Electronic parts catalogue „ETKA“.

The specified torque for Bolt (12) is 15 Nm + turn 90° further. Always renew; allocate shim according to Electronic parts catalogue „ETKA“.

The specified torque for the Locking bolt (10) for the selector shaft is 45 Nm.

The specified torque for Bolt (14) is 20 Nm. Always renew.

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

Secure the gear selector cable and gate selector cable to the selector housing using securing clips -2 and 3-.

Press the gear selector cable onto the gear lever and the gate selector cable onto the gate selector lever in the selector housing and secure with clips -1 and 4-.

Fit the seal and secure the selector mechanism cover by pressing down the tabs -arrows-.

Install the selector mechanism.

Adjust the selector mechanism.

The following points are essential to ensure correct adjustment of the selector mechanism:

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

The selector mechanism must move freely.

The gearbox, clutch, and clutch mechanism must also be in proper condition.

The gearbox must be in neutral.

Remove the complete air filter housing if the bracket -A- to secure the gear selector cable and gate selector cable are not accessible.

Pull the locking mechanisms on the gate selector cable and gear selector cable end-pieces forward to stop in the direction of arrow 1- and then turn to the left to lock in the direction of arrow 2-.

Secure the selector shaft as follows: Press the selector shaft down in the direction of arrow 1-. While pressing down the selector shaft, turn the angled rod -A- upwards in the direction of arrow 3- and at the same time press it in the direction of arrow 2- until it engages in the selector shaft.

Remove the gaiter with the selector knob and frame, and if noise insulation is present, remove it.

Now secure the gear lever as follows: Select neutral using the gear lever. Guide the locking pin -T10027 A- through hole -A- into hole -B-.

Check that the gate and selector cables -B- are inserted, free of tension, into the locking devices -A-.

Now turn the locking mechanisms on the gear selector cable and gate selector cable end pieces clockwise to stop in the direction of arrow 1-. The spring presses the locking mechanism into the original position in the direction of arrow 2-.

Now turn the angled rod -A- back to the original position in the direction of arrow 2-. During this procedure, the angled rod -A- must be pressed out of the gearbox in the direction of arrow 1-.

Pull the locking pin -T10027 A- out of holes -A- and -B-.

If noise insulation was present, install it.

Install the gaiter with the selector knob and frame.

Check that the selector shaft moves freely.

If removed, reinstall the complete air filter housing.

Perform a functional check.

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

Operate the clutch.

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

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

The torque specifications for the gearbox to engine are:

Items -A- and -B- are dowel sleeves.

Small cover plate for flywheel on intermediate plate: 10 Nm.

Gearbox bracket -1- to gearbox: Renew bolts. Bolts -arrows-: 60 Nm and turn 90° further.

Gearbox to body: Renew bolts. Bolts -arrows-: 60 Nm and turn 90° further.

Install engine and gearbox mounting free of tension.

WARNING: Do not remove support bracket -10-222 A- until all bolts securing the assembly mounting have been tightened to specified torque.

Refer to the procedure „Removing gearbox“ for required special tools.

Renew self-locking nuts and bolts.

Renew bolts which must be tightened further to a torque angle.

All cable ties which were opened or cut during removal must be renewed at the same points.

Clean input shaft splines and, on used clutch plate, hub splines. Remove corrosion and apply only a very thin coat of clutch plate spline grease -G 000 100- to splines. Then move the clutch plate to and fro on the input shaft until the hub moves freely on the shaft. Remove excessive grease.

If the gearbox is to be renewed, the gearbox selector lever and relay lever must be transferred to the new gearbox.

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

Check whether dowel sleeves for aligning the engine and gearbox are fitted in the 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 the intermediate plate is hooked into the sealing flange and pushed onto the dowel sleeves -arrows-.

Check the release bearing for wear. If necessary, renew the slave cylinder with release bearing.

Attach bracket -T10346- with bolt -1- to the left threaded hole in the subframe. -1- is a Flange bolt M6 x 20.

Secure the engine support -3300 A- to bracket -T10346-.

Press the engine forwards using the spindle of the engine support -3300 A-. Observe the following points in particular: The air conditioning compressor -2- must not contact the refrigerant line -1-. The alternator must not contact the refrigerant line. The pressure pipe must not contact the radiator.

To install gearbox „02Q“, set up the gearbox support -3282- with adjustment plate -3282/33-.

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

Attach support elements -A- to the adjustment plate as illustrated.

Screw in pin -3282/29- in place of support element -C-.

Place the gearbox on the engine and gearbox jack -V.A.G 1383 A-. Align the adjustment plate and gearbox parallel to one another.

Screw pin -3282/29- into the hole on the gearbox for the securing bolt of the pendulum support.

Secure the gearbox to the gearbox support -3282- using bolt (M10x20) -A-.

Pin -B- must lie flush with the guide from the gearbox support -3282- at the bottom -arrow-.

Position the engine and gearbox jack -V.A.G 1383 A- under the vehicle. Arrow on the adjustment plate points in the direction of vehicle travel.

Be careful of all lines when installing the gearbox.

Now turn the gearbox in the area of the differential -in direction of arrow- using the spindles of the gearbox support -3282-.

Then carefully raise the gearbox.

Guide the gearbox with differential -A- over the subframe.

Observe the longitudinal member -arrows-.

If a small cover plate -A- for the flywheel is present, install it -arrows-.

Install the pendulum support.

Then install the drive shafts.

Install the drive shaft heat shield, if present -arrows-.

Install the left coupling rod.

If the front vehicle level sender -G78- is present, bolt it onto the transverse link.

Attach the connector -1- to the oil level and oil temperature sender -G266-.

Assemble the exhaust system and attach the exhaust system bracket to the subframe.

Install the cowling -arrow- together with the radiator fans.

Install the charge air pipe on the engine.

Install the left charge air hose -arrow 1- and -arrow 2-.

Fit the right charge air hose to the charge air cooler.

Then install the starter and secure it with the lower bolt.

Secure the wiring retainer to the lower starter bolt.

Install the upper starter bolt; attach the connector and wiring to the starter.

Attach the earth strap -1- to the upper starter bolt.

Push the connector -2- onto the reversing light switch -F4-.

Push the pipe/hose line or plastic line -A- to stop into the slave cylinder breather and press down the clip -arrow-.

Test the line by tugging on it.

Remove the hose clamp -3094- from the supply hose.

After removing the hose clamp -3094-, return the supply hose to its original shape, if necessary.

Bleed the clutch system.

Check for the correct installation position of the vacuum hose for the brake system, install the vacuum hose if necessary.

Bolt the selector cable support brackets to the gearbox and tighten the bolts and nuts -arrows- to the specified torque.

Insert the gate selector cable in the cable end-piece.

Spread a small amount of grease on the pin -arrow- of the gearbox selector lever -2-.

Allocate grease using the Electronic parts catalogue (ETKA).

Renew securing clip -1- each time it is removed.

Adjust the selector mechanism.

Install the battery tray, battery cover, and battery.

If the complete air filter housing was removed, install it.

If necessary, install the engine cover.

Connect the battery and follow the procedure after connecting the battery.

Check the gear oil.

Install the lower part of the front left wheel housing liner.

Install the noise insulation.

For vehicles with the front vehicle level sender -G78-, check the headlight adjustment.

The specified torques for the gearbox to engine connection are as follows:

Items -A- and -B- are dowel sleeves.

Small cover plate for flywheel on intermediate plate: 10 Nm.

Gearbox bracket -1- to gearbox: Renew bolts. Bolts -arrows-: 60 Nm and turn 90° further.

Gearbox to body: Renew bolts. Bolts -arrows-: 60 Nm and turn 90° further.

Note: Install engine and gearbox mounting free of tension.

If the output shaft or tapered roller bearings have been renewed, adjust the output shaft. Always renew both tapered roller bearings together as a set.

Check the inner surface of the synchro-ring -arrow- for scoring and radial contact scoring, renew if necessary.

Place the inner ring, outer ring, and synchro-ring on the cone of the inner ring.

Press on the synchro-ring with the outer ring whilst turning at the same time in order to seat them.

Measure the gap size -a- at 3 points offset by 120° using a feeler gauge.

Make a note of the average value.

Install the 2nd gear synchromeshed gear with a needle bearing.

Check the projections on the inner ring for scoring.

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

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

The identification groove -arrow 1- and the narrow collar -arrow 2- of the synchro-hub face the 1st gear.

The lugs -arrows- face the synchro-hub and locking collar -A-.

Lugs -arrows 1- locate in the notches -arrows 2- of synchro-ring -B-.

The higher shoulder -A- faces the 4th gear -B-. Notches in the shoulder -arrows- engage in the lugs of the outer ring.

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

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

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

Prerequisites include ensuring that sealing surfaces of the clutch and gearbox housings are free of sealant. When taking measurements, install only the output shaft to be measured.

Press the tapered roller bearing outer race with a 1.70 mm thick shim into the gearbox housing to the stop. During this process, support the gearbox housing using thrust piece -2050- directly below the bearing support.

Set the complete output shaft for 1st through 4th gears in the clutch housing.

Set the gearbox housing in position and tighten bolts -A- as well as -B- alternately and diagonally to the specified torque.

Set up measuring tools and secure to the clutch housing using bolt -arrow-.

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

Loosen the clutch housing/gearbox housing securing bolts diagonally until the bolts release the gearbox housing or output shaft.

Read and note the value on the dial gauge (example: 0.14 mm).

If no value is indicated when the clutch housing/gearbox housing securing bolts are loosened, install a 1.95 mm shim or, if necessary, a 2.20 mm shim.

Allocate shims using the Electronic parts catalogue (ETKA).

Specified bearing preload is obtained by subtracting the measured value (e.g., 0.14 mm) from the inserted shim (1.70 mm) and adding a constant value for preload (0.20 mm).

Determine the thickness of the shim from the table.

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

Remove the inserted shim (e.g., 1.70 mm thick) from the gearbox housing.

Determine the part number of the shim according to the Electronic parts catalogue „ETKA“.

Press the tapered roller bearing outer race together with the correct shim (e.g., 1.75 mm) into the gearbox housing. During this process, support the gearbox housing using thrust piece -2050- directly below the bearing support.

Carry out check measurement: Determined shim installed. Set up measuring tools.

If the output shaft or tapered roller bearings have been renewed, readjust the output shaft for 5th, 6th, and reverse gears.

Prerequisites: Sealing surfaces of clutch and gearbox housings must be free of sealant. When taking measurements, install only the output shaft to be measured.

Press the tapered roller bearing outer race with a 1.70 mm thick shim into the gearbox housing to the stop. During this process, support the gearbox housing using thrust piece -2050- directly below the bearing support.

Set the complete 5th, 6th, and reverse gear output shaft in the clutch housing.

Set the gearbox housing in position and tighten bolts -A- as well as -B- alternately and diagonally to the specified torque.

Set up measuring tools.

If the edge of the housing protrudes, put washers with a total thickness of 8 mm on bolt -arrow- for securing assembly device -VW 792- to the clutch housing.

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

Loosen the clutch housing/gearbox housing securing bolts diagonally until the bolts release the gearbox housing or output shaft.

If the correct shim has been selected, the dial gauge will indicate a value between 0.15 mm to 0.25 mm.

The specified bearing preload is obtained by subtracting the measured value (e.g., 0.25 mm) from the inserted shim (1.70 mm) and adding a constant value for preload (0.20 mm).

Determine the thickness of the shim from the table.

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

Remove the inserted shim (e.g., 1.70 mm thick) from the gearbox housing.

Determine the part number of the shim according to the Electronic parts catalogue „ETKA“.

Press the tapered roller bearing outer race together with the correct shim (e.g., 1.65 mm) in. During this process, support the gearbox housing using thrust piece -2050- directly below the bearing support.

Carry out check measurement: Determined shim installed. Set up measuring tools.

Lubricate the 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 the differential pinion pin -arrow A- to the first planet pinion.

Place threaded pieces -arrows B- in the sun gears. Installation position: shoulder to sun gear.

Drive the differential pinion pin into the final position and secure with the spring pin.

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

Gearbox housing

Clutch housing

Differential cage or

Tapered roller bearing of differential

Adjustment overview.

Press the tapered roller bearing outer race with a washer into the clutch housing. Note: Observe the installation position of the washer. The shoulder on the inner circumference faces the seal in the clutch housing.

Press the tapered roller bearing outer race, without shim, into the gearbox housing.

Fit the differential into the clutch housing.

Fit the gearbox housing and tighten 5 bolts to the specified torque.

Press the differential in the direction of the clutch housing while turning it eight times.

Press the differential in the direction of the gearbox housing while turning it eight times.

Attach the dial gauge and set it to “0” with 1 mm preload. Move the differential up and down. Read and note the play indicated on the dial gauge (Example: 0.70 mm).

The specified bearing preload is obtained by adding a constant value for preload (0.25 mm) to the reading obtained.

Remove the gearbox housing.

Pull the tapered roller bearing outer race out of the gearbox housing.

Determine the part number of the shim according to the Electronic parts catalogue „ETKA“.

Insert shims of the determined thickness, thickest shim first. If the size of the shim required is larger than those listed in the table, insert two shims totalling the correct figure. When using two shims, install the thicker one first.