VOLKSWAGEN JETTA 2005 (15) PDF Document

To ensure flawless and successful gearbox repairs for the VOLKSWAGEN JETTA 2005 6-speed manual gearbox 02S, 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.

When installing the manual gearbox on the VOLKSWAGEN JETTA 2005 6-speed manual gearbox 02S, ensure that the dowel sleeves between the engine and gearbox are correctly seated. When installing mounting brackets or waxed components, clean the contact surfaces; they 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 of the VOLKSWAGEN JETTA 2005 6-speed manual gearbox 02S completely dismantled is 2.1 l. The capacity when partially dismantled is 1.9 l (refer to Gearbox capacity, gearbox partially dismantled).

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 the contact surface of the housing or shaft for burrs resulting from removal or for other signs of damage. 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 new oil seals in 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 (refer to Oil capacity, gearbox partially dismantled).

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. The installation position for the spring pin is such that the 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 the lettered side (thicker metal) towards the 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 the 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 synchro-rings. When reusing synchro-rings, always fit them 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, the 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 the 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 the synchro-hub with the inductive heater -VAS 6414- to approximately 100° C before installing, pressing in to stop when installing so there is no axial clearance. Heat gears with the inductive heater -VAS 6414- to approximately 100° C before installing, pressing in to stop when installing so there is no axial clearance. Observe the installation position. After assembly, check the synchromeshed gears for slight play or for freedom of movement.

When removing the gearbox, remove the slave cylinder without disconnecting the pipes. If the clutch slave cylinder is removed with the hydraulic line attached, do not depress the clutch pedal; otherwise, the piston will be pressed out of the slave cylinder. Ensure that the pressure plate does not cant by loosening and tightening 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 the flywheel with a cloth to reduce the smell of burnt linings.

Refer to Fault finding, power transmission in Repair Group 30 for complaints about the clutch and clutch mechanism, and refer to Fault finding, power transmission in Repair Group 34 for complaints about the selector mechanism.

The pedal cluster components for the VOLKSWAGEN JETTA 2005 6-speed manual gearbox 02S include:

• 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. Qty. 3 for mounting bracket on bulkhead; always renew.
• 16 – Hexagon nut, 25 Nm: Always renew. For mounting bracket on bulkhead.
• 17 – Stop: For clutch pedal.

The specified torque for the clutch pedal to mounting bracket on the VOLKSWAGEN JETTA 2005 6-speed manual gearbox 02S is 25 Nm. Renew self-locking nuts.

The specified torques for the crash bar attachments on the VOLKSWAGEN JETTA 2005 6-speed manual gearbox 02S system are:

Renew bolts for crash bar.

The special tool required for removal of the over-centre spring is Release tool -T10178-.

The steps for removal are:

First check whether a coded radio is fitted. If so, obtain anti-theft code. With ignition switched off, disconnect the battery earth strap. Push the driver seat as far back as possible and put the steering wheel in the highest position. Remove trim and cover below trim on the drive side. For vehicles with a knee airbag, remove the bracket for the knee airbag together with the crash bar. Remove the cable guide -2- from the steering column. Remove the footwell vent -3-. For vehicles without a knee airbag, the crash bar -1- in front of the clutch pedal -2- may be secured in different ways.

For attachment with 2 bolts, remove the crash bar -1- (2 bolts). For attachment with 1 bolt, remove the crash bar -1- (1 bolt -2-).

For all vehicles, if fitted, remove damping -arrow- from the lower area of the clutch pedal mounting bracket by removing lock washers -A- for damping and pulling off damping. Then push damping upwards in the area of the upper securing nut -1- above the clutch pedal -A- in the -direction of 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. 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. Ensure the receptacle -arrow- for the tip -A- of the clutch pedal stands 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 (refer to Specified torques). If some cars have damping -arrow- on the mounting bracket/clutch pedal, return it to the installation position. For vehicles without a knee airbag, the crash bar -1- in front of the clutch pedal -2- may be secured in different ways. For attachment with 2 bolts, install the crash bar -1- and tighten the 2 bolts to the specified torque (refer to page 31). For attachment with 1 bolt, install the crash bar -1- and tighten bolt -2- to the specified torque (refer to page 20). For all vehicles, mount the cable guide -2- on the steering column. Install the footwell vent -3- (refer to Heating, air conditioning; Rep. Gr. 80; Repairing heating). For vehicles with a knee airbag, install the bracket for the knee airbag together with the crash bar (refer to Interior equipment; Rep. Gr. 69; Airbag; Removing and installing knee airbag bracket). For all vehicles, install the trim and cover below the trim on the drive side (refer to General body repairs, interior; Rep. Gr. 68). If disconnected, connect the battery (refer to Electrical system; Rep. Gr. 27; Removing and installing battery).

The specified torques for the clutch pedal to mounting bracket on the VOLKSWAGEN JETTA 2005 6-speed manual gearbox 02S are:

Renew self-locking nuts.

The special tools and workshop equipment required for removing and installing the clutch pedal on the VOLKSWAGEN JETTA 2005 6-speed manual gearbox 02S are Pliers -T10005- and Release tool -T10178-.

For vehicles with a knee airbag on the VOLKSWAGEN JETTA 2005 6-speed manual gearbox 02S, the installation location of the knee airbag is above the pedal cluster. First check whether a coded radio is fitted. If so, obtain the anti-theft code. With ignition switched off, disconnect the battery earth strap. Push the driver seat as far back as possible and put the steering wheel in the highest position. Remove trim and cover below the trim on the drive side. Remove the bracket for the knee airbag together with the crash bar. Remove the cable guide -2- from the steering column. Remove the footwell vent -3-. The crash bar -1- in front of the clutch pedal -2- may be secured in different ways. For attachment with 2 bolts, remove the crash bar -1- (2 bolts). For attachment with 1 bolt, remove the crash bar -1- (1 bolt -2-). If fitted, remove damping -arrow- from the lower area of the clutch pedal mounting bracket by removing lock washers -A- for damping and pulling off damping. Push damping upwards in the area of the upper securing nut -1- above the clutch pedal -A- in the -direction of 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. Ensure the receptacle -arrow- for the tip -A- of the clutch pedal stands 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 (refer to page 25). If some cars have 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- and tighten the 2 bolts to the specified torque (refer to page 25) or install the crash bar -1- and tighten bolt -2- to the specified torque (refer to page 25). For all vehicles, mount the cable guide -2- on the steering column. Install the footwell vent -3- (refer to Heating, Air conditioning; Rep. Gr. 80; Repairing heating; Removing and installing left footwell vent). For vehicles with a knee airbag, install the bracket for the knee airbag together with the crash bar (refer to Interior equipment; Rep. Gr. 69; Airbag; Removing and installing knee airbag bracket). For all vehicles, install the trim and cover below the trim on the drive side (refer to General body repairs, interior; Rep. Gr. 68). If disconnected, connect the battery (refer to Electrical system; Rep. Gr. 27; Removing and installing battery).

The specified torques for clutch components on the VOLKSWAGEN JETTA 2005 6-speed manual gearbox 02S are:

Renew self-locking nuts and bolts for the crash bar.

The special tool required is Pliers -T10005-.

For LHD vehicles, first check whether a coded radio is fitted. If so, obtain the 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. Clamp off the supply hose to the master cylinder using hose clamp -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 disconnecting, you can close the hose 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 it with the electrical connector attached -4-. Remove trim and cover below the trim on the drive side. For vehicles with a knee airbag, remove the bracket for the knee airbag together with the crash bar. Remove the cable guide -2- from the steering column. Remove the footwell vent -3-. For vehicles without a knee airbag, the crash bar -1- in front of the clutch pedal -2- may be secured in different ways. For attachment with 2 bolts, unbolt the crash bar (2 bolts). For attachment with 1 bolt, remove the crash bar -1- (1 bolt -2-). For all vehicles, if fitted, remove damping -arrow- from the lower area of the clutch pedal mounting bracket by removing lock washers -A- for damping and pulling off damping. Push damping upwards in the area of the upper securing nut -1- above the clutch pedal -A- in the -direction of arrow-. Remove securing nuts -1- and -2-. Remove the mounting bracket -3-. To install, 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 (refer to page 42). For LHD, install the battery. If the complete air filter housing was removed, install it. Press 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 (refer to page 42). Install the battery tray and battery. If the complete air filter housing was removed, install it. Reconnect the battery and perform work required after connecting the battery. 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 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 (refer to page 42).

For LHD vehicles, first check whether a coded radio is fitted. If so, obtain the 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. For right-hand drive vehicles with a particle filter, remove shielding -A- from the particle filter. Remove the heat shield from the pipe/hose line -arrows-. 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. Clamp off the supply hose to the master cylinder using a hose clamp -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 disconnecting, you can close it 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 it with the electrical connector attached -4-. For vehicles with a knee airbag, remove the bracket for the knee airbag together with the crash bar. Remove the cable guide -2- from the steering column. Remove the footwell vent -3-. For vehicles without a knee airbag, the crash bar -1- in front of the clutch pedal -2- may be secured in different ways. For attachment with 2 bolts, unbolt the crash bar (2 bolts). For attachment with 1 bolt, remove the crash bar -1- (1 bolt -2-). For all vehicles, if fitted, remove damping -arrow- from the lower area of the clutch pedal mounting bracket by removing lock washers -A- for damping and pulling off damping. Push damping upwards in the area of the upper securing nut -1- above the clutch pedal -A- in the -direction of arrow-. Remove securing nuts -1- and -2-. Remove the mounting bracket -3-. To install, 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 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 (refer to page 42). For LHD, install the battery tray and battery. If the complete air filter housing was removed, install it. Reconnect the battery and perform work required after connecting the battery. 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 (refer to page 42). For right-hand drive vehicles with a particle filter, install shielding -A- on the particle filter. For LHD, install the battery tray and battery. If the complete air filter housing was removed, install it. Reconnect the battery and perform work required after connecting the battery.

The assembly overview for hydraulics (LHD vehicles) on the VOLKSWAGEN JETTA 2005 6-speed manual gearbox 02S includes:

• 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.

The material of the line connection for seals and O-rings on the VOLKSWAGEN JETTA 2005 6-speed manual gearbox 02S hydraulics (LHD) is as follows:

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

The assembly overview for hydraulics (RHD vehicles) on the VOLKSWAGEN JETTA 2005 6-speed manual gearbox 02S includes:

• 1 – Brake fluid reservoir.
• 2 – Seal: For plastic supply hose; the seals must be located in the 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 special tool required for removing and installing the slave cylinder on the VOLKSWAGEN JETTA 2005 6-speed manual gearbox 02S is Torque wrench -V.A.G 1331-.

First check whether a coded radio is fitted. If so, obtain the anti-theft code. With ignition switched off, disconnect the battery earth strap. Remove the complete air filter housing if it is over the slave cylinder. Remove the securing clip -arrow 1- for the gear selector cable from the gearbox selector lever -A-. Pull the gear selector cable from the pin. For the metal relay lever, remove the securing clip -arrow 2- for the gate selector cable from the relay lever -B-. Pull the gate selector cable from the pin. Pull the securing clip -arrow 3- off the relay lever -B- and remove the relay lever. For the plastic relay lever, remove the relay lever together with the cable end-piece (refer to page 73). For all selector mechanisms, remove the gearbox selector lever -A- by removing nut -arrow 4-. Remove the cable support bracket from the gearbox -arrows-. Then raise and secure the gear selector cable and gate selector cable. Remove the retainer -B- from the gearbox and pull it off the pipe/hose line -A-. Then remove the gearbox support -arrow A-. Place a lint-free cloth under the slave cylinder. Pull the clip for the pipe/hose line out of the slave cylinder to stop. Pull the pipe/hose line out of the slave cylinder and seal the opening. Remove the slave cylinder -arrows B-. Caution: Do not operate the clutch pedal any more.

Install in the reverse order of removal, observing the following: Install the slave cylinder and tighten the bolts -arrows B- to the specified torque. Insert the pipe/hose line into the slave cylinder to stop. Push the securing clip into the pipe/hose line to stop. Test the pipe/hose line by tugging on it. Then install the gearbox support -arrows A-. Bleed the clutch system after installing the slave cylinder (refer to page 44). Assemble the selector mechanism (refer to page 70). Adjust the selector mechanism (refer to page 80). If the complete air filter housing was removed, install it. Connect the battery earth (refer to Electrical system; Rep. Gr. 27; Disconnecting and reconnecting battery).

The specified torques for the slave cylinder to gearbox connection on the VOLKSWAGEN JETTA 2005 6-speed manual gearbox 02S are:

• 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, and tighten bolts to the specified torque. Bolts -arrows- are 20 Nm + 90°.

The special tools and workshop equipment required for bleeding the clutch system on the VOLKSWAGEN JETTA 2005 6-speed manual gearbox 02S are Brake filling and bleeding equipment -VAS 5234- or Brake filling and bleeding equipment -V.A.G 1869-.

Prefilling the system is not necessary. Refer to Specifications for brake fluid in Brake systems; Rep. Gr. 47; Bleeding brake system.

Remove the complete air filter housing if it blocks access to the bleeder connection. Connect the brake filling and bleeding equipment -VAS 5234- or -V.A.G 1869-. To bleed the system, use a 670 mm bleeder hose -V.A.G 1238/B3- if necessary. Connect the bleeder hose to the collector bottle of the brake bleeding equipment. Connect the bleeder hose to the bleeder -arrow-. Pressurise the system to 2 bar. Open the bleeder valve. Bleed off about 100 cm3 of brake fluid. Close the bleeder valve. Rapidly operate the pedal from stop to stop 10 to 15 times. Open the bleeder valve. Bleed off an additional 50 cm3 of brake fluid. Close the bleeder valve. Depress the clutch pedal several times after completion of the bleeding process. If the complete air filter housing was removed, install it.

The repair overview for the clutch release mechanism on the VOLKSWAGEN JETTA 2005 6-speed manual gearbox 02S includes:

• 1 – Gearbox: Torque wrench -V.A.G 1331- required.
• 2 – Ball stud, 25 Nm: To remove and install, remove gearbox. Remove old grease from the contact surface of the clutch release lever. Grease with clutch plate spline grease -G 000 100-.
• 3 – Input shaft seal: To remove and install, remove gearbox. Renewing (refer to Item 12 (page 134)).
• 4 – Guide sleeve: To remove and install, remove gearbox. With vulcanised O-ring. If the O-ring is damaged, renew the guide sleeve and O-ring together.
• 5 – Retaining spring: To remove and install, remove gearbox. Secure to clutch release lever.
• 6 – Socket head bolt, 20 Nm.
• 7 – Clutch release lever: To remove and install, remove gearbox. Remove and install together with the release bearing (refer to page 45). Remove old grease.
• 8 – Release bearing: To remove and install, remove gearbox. Do not wash out the bearing; wipe only. Renew noisy bearings. Removing from and inserting in the clutch release lever (refer to page 45). Lubricate contact surfaces of the release lever with MoS2 grease.
• 9 – Flange bolt, 20 Nm.
• 10 – Slave cylinder: Removing and installing (refer to page 40).
• 11 – Plunger.
• 12 – Assembly bolt: Secures the clutch release lever when the gearbox is installed. Remove after the gearbox has been installed.

To remove the release lever together with the release bearing:

Unhook the spring -arrow 1-. Pull off the release lever -arrow 2- and the release bearing. Install in the reverse order of removal.

To remove and install the release bearing: Press together the locking lugs -arrows- on the back of the clutch release lever and remove the release bearing -A- from the clutch release lever. To install, press the release bearing -A- into the clutch release lever until the locking lugs -arrows- engage.

The special tools and workshop equipment required for repairing the clutch in conjunction with a dual-mass flywheel on the VOLKSWAGEN JETTA 2005 6-speed manual gearbox 02S are Counterhold -3067-, Centring mandrel -3190 A-, Torque wrench -V.A.G 1331-, and Grease for clutch plate splines -G 000 100-.

The make of the clutch on the VOLKSWAGEN JETTA 2005 6-speed manual gearbox 02S can be determined as follows with the clutch installed: Remove the noise insulation (refer to General body repairs, exterior; Rep. Gr. 50; Noise insulation). Check the outer contour of the flywheel through the notches located in the lower region of the sump between the engine -A- and gearbox -B-. A small cover plate -A- can be removed to enable inspection of the flywheel’s outer contour. A round outer contour -arrows- indicates a Sachs clutch (-A-). An outer contour with edges -arrows 1- and, in addition, a circumferential crease -arrow 2- indicates a LuK clutch (-B-).

The removal procedure for the Sachs clutch when in conjunction with a dual-mass flywheel on the VOLKSWAGEN JETTA 2005 6-speed manual gearbox 02S is:

Remove gearbox (refer to page 84). Use counterhold -3067- to loosen bolts. Loosen bolts in small steps and diagonally. As bolts are removed, stop -2- with pin -1- must loosen. If the stop does not loosen, press the pin towards the dual-mass flywheel. Remove the pressure plate and clutch plate.

The installation guidelines for the pressure plate and clutch plate when installing the Sachs clutch on the VOLKSWAGEN JETTA 2005 6-speed manual gearbox 02S are:

• Renew the pressure plate and clutch plate together only. Select the clutch plate and pressure plate according to the engine code and Electronic parts catalogue “ETKA”.
• Check whether the 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.
• The lettering “Getriebeseite” (gearbox side) on the clutch plate faces the gearbox.

When repairing the Sachs clutch on the VOLKSWAGEN JETTA 2005 6-speed manual gearbox 02S, the check for the ends of the diaphragm spring involves ensuring that wear to half the thickness of the diaphragm spring -arrows- is permitted.

When repairing the Sachs clutch on the VOLKSWAGEN JETTA 2005 6-speed manual gearbox 02S, check the spring connections between the pressure plate and cover for cracks, as well as the rivet connections for secure seating. Renew clutch plates and pressure plates with damaged or loose rivet connections. Always renew the pressure plate and clutch plate together. Select the clutch plate and pressure plate according to the engine code and the Electronic parts catalogue “ETKA”. If the clutch has burnt out, thoroughly clean the clutch housing, flywheel, and parts of the engine facing the gearbox to reduce the smell of burnt linings. Clean the input shaft splines and, on used clutch plates, clean the hub splines; remove corrosion and apply only a very thin coat of clutch plate spline grease -G 000 100- to the splines. Then move the clutch plate to and fro on the input shaft until the hub moves freely on the shaft. Remove excessive grease. Pressure plates are protected against corrosion and greased; clean the contact surface only. Otherwise, the service life of the clutch will be considerably reduced. The pressure plate contact surface and clutch plate lining must make full contact with the flywheel; only then insert the securing bolts. Reverse the counterhold tool -3067- for installation. Push the pressure plate onto the centralizing pins. To centre the clutch plate, use the centring mandrel -3190 A-. Tighten all bolts evenly by hand until the bolt heads contact the pressure plate. Tighten the bolts in small steps diagonally in order not to damage the centring holes of the pressure plate and the centring pins of the dual-mass flywheel. Install the gearbox (refer to page 92).

The removal procedure for the LuK clutch when in conjunction with a dual-mass flywheel on the VOLKSWAGEN JETTA 2005 6-speed manual gearbox 02S is:

Remove gearbox (refer to page 84). Use counterhold -3067- to loosen bolts. Loosen bolts in small steps and diagonally. Remove the pressure plate and clutch plate.

Install the LuK clutch on the VOLKSWAGEN JETTA 2005 6-speed manual gearbox 02S in the reverse order of removal, observing the following: Renew the pressure plate and clutch plate together only. Select the clutch plate and pressure plate according to the engine code and the Electronic parts catalogue “ETKA”. Check whether the 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. The lettering “Getriebeseite” (gearbox side) on the clutch plate faces the gearbox.

Note the following when repairing the clutch on the VOLKSWAGEN JETTA 2005 6-speed manual gearbox 02S with the gearbox removed:

• Renew clutch plates and pressure plates with damaged or loose rivets.
• Select the clutch plate and pressure plate according to the Electronic parts catalogue “ETKA” and engine codes.
• 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.

For the flywheel when repairing the clutch with a one-piece flywheel on the VOLKSWAGEN JETTA 2005 6-speed manual gearbox 02S:

• 1 – Flywheel: Removing and installing (refer to Rep. Gr. 13). Ensure that centring pins fit tightly. Keep the contact surface for the clutch lining free of grooves, oil, and grease.

For the clutch plate when repairing the clutch with a one-piece flywheel on the VOLKSWAGEN JETTA 2005 6-speed manual gearbox 02S:

• 2 – Clutch plate: Allocation (refer to Electronic parts catalogue “ETKA”). Installation position: spring cage faces the pressure plate. Centring (refer to page 55). Lightly grease splines.

For the pressure plate when repairing the clutch with a one-piece flywheel on the VOLKSWAGEN JETTA 2005 6-speed manual gearbox 02S:

• 3 – Pressure plate: Removing and installing (refer to page 55). Check ends of diaphragm spring (refer to page 56). Check spring connections and riveted connections (refer to page 56).

The torque settings for the bolts when repairing the clutch with a one-piece flywheel on the VOLKSWAGEN JETTA 2005 6-speed manual gearbox 02S are: Bolt M6, 13 Nm, Bolt M7, 20 Nm. Loosen or tighten diagonally in small steps.

To center the clutch plate and install the pressure plate when repairing the clutch with a one-piece flywheel on the VOLKSWAGEN JETTA 2005 6-speed manual gearbox 02S, loosen or tighten the bolts diagonally in stages. Reverse the position of the counterhold -3067- when removing. The pressure plate contact surface and clutch plate lining must make full contact with the flywheel. Tighten the bolts diagonally and evenly to prevent damage to the centring holes in the pressure plate housing and the centring pins in the flywheel. Install the gearbox (refer to page 92).

When repairing the clutch with a one-piece flywheel on the VOLKSWAGEN JETTA 2005 6-speed manual gearbox 02S, wear up to half the thickness of the diaphragm spring -arrows- is permitted.

Check the spring connections -arrows A- for damage and riveted connections -arrows B- for secure seating. A pressure plate with damaged spring connections or with loose rivet connections -arrows- must be renewed.

When repairing the clutch with a one-piece flywheel on the VOLKSWAGEN JETTA 2005 6-speed manual gearbox 02S 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.

Refer to Fault finding, power transmission in Repair Group 30 for complaints about the clutch and clutch mechanism, and refer to Fault finding, power transmission in Repair Group 34 for complaints about the selector mechanism.

The installation position of the selector mechanism on the VOLKSWAGEN JETTA 2005 6-speed manual gearbox 02S is defined by:

• Arrow -A- indicates Gear selection movement.
• Arrow -B- indicates Gate selection movement.
• A – Gear selector cable.
• B – Gate selector cable.
• C – Heat shield (Remove before removing the gear selector mechanism).
• 1 – Gearbox selector lever.
• 2 – Relay lever.

Before working on the selector mechanism in the engine compartment of the VOLKSWAGEN JETTA 2005 6-speed manual gearbox 02S, note the radio code for vehicles with a coded radio. Disconnect the earth strap from the battery. When reconnecting the battery, perform work required after connecting the battery. To work on the selector mechanism in the engine compartment, remove the complete air filter housing if it is located over the selector mechanism. Remove the selector mechanism to renew the selector cables (refer to page 75). Do not kink the selector cables. The overview shows procedures for:

• I – Removing and installing gear knob and frame (refer to page 61).
• II – Repairing gear lever and selector housing (through 10.06) (refer to page 63).
• II – Repairing gear lever and selector housing (from 11.06) (refer to page 65).
• III – Assembly overview – removing and installing selector cables (refer to page 70).

Removing and installing the selector mechanism (refer to page 75). Adjusting the selector mechanism (refer to page 80).

The components for removing and installing the gear knob and frame on the VOLKSWAGEN JETTA 2005 6-speed manual gearbox 02S are:

• 1 – Emblem: Can be carefully levered off the gear knob of plastic or leather.
• 2 – Gear knob: With gaiter. Gear knob and gaiter cannot be separated from one another. Always renew together. Removing and installing (refer to page 61).
• 3 – Clamp: For securing the gear knob to the gear lever. Secure to the gear knob (refer to Item 2 (page 61)) using hose clip pliers -V.A.G 1275-. Always renew.
• 4 – Frame for centre console: In some equipment versions, forms one part together with the centre console.
• 5 – Noise insulation: Not fitted in all vehicles. Arrow on the noise insulation points in the direction of travel. Locking lugs are arranged at varying intervals, so it can be installed in only one position.

To remove the gaiter with gear knob and noise insulation on the VOLKSWAGEN JETTA 2005 6-speed manual gearbox 02S, pull or carefully prise the gaiter with the frame for the centre console upwards out of the centre console -arrows-. With some equipment variations, the gaiter must be levered off along the front section. Pull the gaiter with the frame for the centre console upwards, inside out, over the gear knob. Open the clamp -arrow- and pull off the gear knob together with the gaiter. In some versions, the centre console frame remains in the centre console. If necessary, pull off or carefully lever off the centre console frame. Pull off the noise insulation -1-.

To install the gaiter with gear knob and noise insulation on the VOLKSWAGEN JETTA 2005 6-speed manual gearbox 02S, first set the noise insulation in place. For installation position of noise insulation, arrow A points in the direction of travel, and catches -arrows B- must engage in the centre console. If necessary, press the frame into the centre console. Then turn the gaiter inside out. The gear knob must be pressed to the stop. Install the gear knob with the frame and gaiter and squeeze the new clamp -arrow- together. Then press the gaiter with the frame into the centre console or the gaiter into the frame.

The components for repairing the gear lever and selector housing (through 10.06) on the VOLKSWAGEN JETTA 2005 6-speed manual gearbox 02S are:

Lubricate bearing points and sliding surfaces with grease -G 000 450 02- during repair.

The components for repairing the gear lever and selector housing (from 11.06) on the VOLKSWAGEN JETTA 2005 6-speed manual gearbox 02S are:

Lubricate bearing points and sliding surfaces with grease -G 000 450 02- during repair.

The procedure for dismantling the selector mechanism when dealing with the gear lever and selector housing (from 11.06) on the VOLKSWAGEN JETTA 2005 6-speed manual gearbox 02S is: Remove the selector mechanism (refer to page 75). Bend open the tabs -arrows- of the base plate for the selector mechanism using a screwdriver and remove the base plate (tabs in the front area of the base plate are not illustrated). Remove the seal from the selector housing. Remove the gear and gate selector cables from the selector housing (refer to page 78). Lift the upper end -A- of the compression spring over the tab of the gate selector lever. Use a screwdriver to press the catches -arrows- of the ball socket towards the bearing ball of the gear lever guide; break off the catches if necessary. Lever the ball socket -A- with the gear lever guide -B- out of the selector housing. Then press the ball socket off the bearing ball of the gear lever guide and remove it. Pay attention to the guides -A- during the further procedure; they must not be broken off. Lever the lower end -arrow 1- of the compression spring onto the shoulder on the gate selector lever as far as the stop. Now pull the gear lever guide up to the stop and pull the ball stud out of the gate selector lever -arrow 2-. Then turn the gear lever guide in the -direction of arrow 1-. Pin -arrow 2- must be in the notch in the selector housing. Then swing out the gear lever guide with the gear lever in the -direction of arrow 3-. For assembling, carefully press the lower end of the compression spring (arrow 1) down off the shoulder of the gate selector lever, as it can snap off the shoulder during the further procedure. The ends of the compression spring then become tensioned “diagonally” with a loud noise. Move the gate selector lever back to stop (opposite from the mounting holes for the gear and gate selector cable) -arrow 1-. Grease the ball stud. Press the ball stud into the gate selector lever -arrow 2-. Guides -A- and tabs -B- are not allowed to be damaged. Place the selector housing with the gear lever guide into the larger recess -arrow- in the thrust piece -T10083-. The gear lever guide must project from the selector housing up to the stop. Lift the upper end -A- of the compression spring over the pin of the gate selector lever. Use a new ball socket -B-. Grease the ball socket and the bearing ball of the gear lever guide. Press the ball socket onto the bearing ball of the gear lever guide up to the stop. Remove the selector housing from the thrust piece -T10083-. Insert the lower end -C- of the compression spring into the guide. Lift the upper end -A- of the compression spring over the pin of the gate selector lever into the guide. Press the ball socket into the selector housing -arrows-. All locking lugs must clip in. Attach the gear lever, gear selector cable, gate selector cable, and base plate (refer to page 65). Install the selector mechanism (refer to page 75).

The assembly overview for removing and installing selector cables on the VOLKSWAGEN JETTA 2005 6-speed manual gearbox 02S is:

Lubricate bearing points and sliding surfaces with grease -G 000 450 02- during assembly overview.

The allocation of cable end-pieces based on their dimension “a” for the VOLKSWAGEN JETTA 2005 6-speed manual gearbox 02S is:

For the gear selector cable end-piece on the VOLKSWAGEN JETTA 2005 6-speed manual gearbox 02S:

To fit the selector cables with a cable tie on the VOLKSWAGEN JETTA 2005 6-speed manual gearbox 02S, wind the cable tie -arrow- around the selector cables in a figure eight and secure them as shown in the figure.

To remove the plastic relay lever on the VOLKSWAGEN JETTA 2005 6-speed manual gearbox 02S (From 05.07), first separate the cable end-piece from the gate selector cable to avoid damage to the gate selector cable. Pull the locking mechanism forward to the stop in the -direction of arrow 1- and then lock by turning to the left in the -direction of arrow 2-. Then push the relay lever forwards (-in the direction of arrow 3-).

For a relay lever with a catch -arrow 1-, press the catch -arrow 1- down to the stop and remove the relay lever together with the cable end-piece, swinging it in the direction of operation in the process.

For a relay lever with a clip -arrow 1-, pull the clip -arrow 1- off and remove the relay lever together with the cable end-piece. The cable end-piece must be located behind the catch -arrow 2-. The cable end-piece can be removed only with the relay lever removed (refer to page 75).

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

Press the cable end-piece onto the relay lever (refer to page 75). Install the relay lever together with the cable end-piece to the stop.

To remove the gate selector cable end-piece off the plastic relay lever on the VOLKSWAGEN JETTA 2005 6-speed manual gearbox 02S, the relay lever must have been removed. Insert a flat-blade screwdriver -A- between the bush -B- and the relay lever.

The relay lever must have been removed. The cable end-piece may be pressed only onto the bush -arrow-. The cable end-piece must move freely on the relay lever. It must be located behind catch -arrow 2-.

The procedure for removing the selector mechanism when dealing with the gear lever and selector housing on the VOLKSWAGEN JETTA 2005 6-speed manual gearbox 02S is: Remove the complete air filter housing if 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 -direction of arrow 1- and then turn to the left to lock -direction of arrow 2-. Secure the selector shaft as follows: Press the selector shaft down -direction of arrow 1-. While pressing down the selector shaft, turn the angled rod -A- in the -direction of arrow 2- upwards and at the same time press it in until it engages in the selector shaft. Remove the gaiter with the selector knob and frame (refer to page 61). If noise insulation is present, remove it. 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 -direction of arrow 1-. The spring presses the locking mechanism into the original position -direction of arrow 2-. Now turn the angled rod -A- back to the original position -direction of arrow-. Note: The angled rod -A- must be pressed out of the selector housing to the stop and point to the rear. Pull the locking pin out of holes -A- and -B-. If noise insulation was present, install it. Install the gaiter with the selector knob and frame (refer to page 61). Check that the selector shaft moves freely. If removed, reinstall the complete air filter housing. Follow the procedure after connecting the battery.

For the functional check after adjusting the selector mechanism on the VOLKSWAGEN JETTA 2005 6-speed manual gearbox 02S: 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 (refer to page 80).

The special tools and workshop equipment required for removing and installing the gearbox on the VOLKSWAGEN JETTA 2005 6-speed manual gearbox 02S are:

• 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-.

The procedure for removing the gearbox on the VOLKSWAGEN JETTA 2005 6-speed manual gearbox 02S is:

First check whether a coded radio is fitted. If so, obtain the anti-theft code. With ignition switched off, disconnect the battery earth strap. Remove the engine cover if the engine lifting eye arrow -10 – 222 A is not accessible. Remove the complete air filter housing if it is near the battery. Remove the battery and battery tray. Remove the securing clip -arrow 1- for the gear selector cable from the gearbox selector lever -A-. Pull the gear selector cable from the pin.

For the metal relay lever: Remove the securing clip -arrow 2- for the gate selector cable from the relay lever -B-. Pull the gate selector cable from the pin. Pull the securing clip -arrow 3- off the relay lever -B- and remove the relay lever. For the plastic relay lever, remove the relay lever together with the cable end-piece (refer to page 73).

For all selector mechanisms: Remove the gearbox selector lever -A- by removing nut -arrow 4-. Remove the cable support bracket from the gearbox -arrows-. Then raise and secure the gear selector cable and gate selector cable. Remove the retainer -B- from the gearbox and pull it off the pipe/hose line -A-. Then remove the gearbox support -arrow A-. Remove the slave cylinder -arrow B-, lay it to the side, and secure it with wire; do not disconnect the pipes. Caution: Do not operate the clutch pedal any more. Remove the earth strap at the upper engine/gearbox connecting bolt. Pull the connector -arrow 1- off the reversing light switch -F4-. Now remove connector -arrow 2- and wire -arrow 3- from the starter. Then remove the upper securing bolt on the starter. Remove the upper engine/gearbox connecting bolts. If there are hose and cable connections in the area of the engine support eye for the support bracket -10 – 222 A-, remove these now.

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

For vehicles with turbo diesel engines and vehicles with 2.0 l – 110 kW petrol engines: Set up the 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 the gas struts for the bonnet. Attach hook -10 – 222 A /10- at the front right of the engine. Now attach hook -10 – 222 A /2- at the rear left of the engine -arrow-. Then connect hook -10 – 222 A /2- using adapter -10 – 222 A /16-.

For all vehicles: Position adapter -10 – 222 A /8- directly over the wing bolting points. Take up the weight of the engine/gearbox assembly on spindles. Raise the vehicle. Remove the noise insulation. Remove the lower part of the front left wheel housing liner. Then remove all lines from the gearbox. Remove the drive shaft heat shield from the engine -arrows-, if fitted. For vehicles with 1.4 l petrol engine: Separate the exhaust system -arrows 1-, remove the front exhaust pipe, and unscrew the front exhaust pipe bracket from the subframe -arrows 2-. For vehicles with turbo diesel engines and vehicles with 2.0 l – 110 kW petrol engines: Separate the exhaust system at the double clamp and remove the exhaust pipe bracket from the subframe. For all vehicles: Disconnect the drive shafts from the flange shafts and tie them up as high as possible, being careful not to damage the surface protection. Remove the pendulum support. First remove bolt -arrow A- and then bolts -B- and -C-. Remove the hexagon bolts -arrows- for the left assembly mounting from the gearbox mounting. Tilt the engine/gearbox assembly by lowering it via the spindles of the support bracket -10 – 222 A-. Lower the gearbox carefully, guiding it with the right flanged shaft -A- past the flywheel and intermediate plate as shown. When lowering the gearbox, change the position of the gearbox using the spindles of the gearbox support -3282-. Press the gearbox off the dowel sleeves and carefully swing it towards the subframe. Turn the gearbox downwards in the vicinity of the differential. Have a second mechanic push the engine forwards slightly.

For transporting the gearbox on the VOLKSWAGEN JETTA 2005 6-speed manual gearbox 02S, bolt the gearbox lifting tackle -3336- to the clutch housing. Adjust the support beam on the sliding piece using the locking pin -arrow-. The number of visible holes is 5. Lift the gearbox using a workshop crane and the gearbox lifting tackle -3336-. Set the gearbox aside, for example, in a transport container.

When installing the gearbox on the VOLKSWAGEN JETTA 2005 6-speed manual gearbox 02S, observe the following:

• 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 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 correctly seated on the engine.
• Clean the input shaft splines and apply a thin coat of grease for clutch plate splines -G 000 100-.
• Install the gearbox selector lever -A-. Tighten the hexagon nut -arrow 4- to the specified torque (refer to Item 18 (page 71)). Spread a small amount of grease -G 000 450 02- on the pin of the gearbox selector lever -A-. Connect the gear selector cable to the gearbox selector lever -arrow 1-. For the metal relay lever, install the relay lever -B- and secure it with securing clip -arrow 3-. Spread a small amount of grease -G 000 450 02- on the pin of the relay lever -B-. Connect the gate selector cable to the relay lever -arrow 2-. For the plastic relay lever, install the relay lever together with the cable end-piece (refer to page 73). For all selector mechanisms, adjust the selector mechanism (refer to page 80). Install the battery tray and battery. If the engine cover and complete air filter housing were removed, reinstall them. Reconnect the battery and perform work required after connecting the battery. Install the lower part of the front left wheel housing liner. Install the noise insulation.

The specified torques for the gearbox to 1.4 l petrol engine connection on the VOLKSWAGEN JETTA 2005 6-speed manual gearbox 02S are:

Item -A- are dowel sleeves for centring.

The specified torques for the gearbox to turbo diesel engine connection on the VOLKSWAGEN JETTA 2005 6-speed manual gearbox 02S are:

Item -A- are dowel sleeves for centring.

For the gearbox bracket to gearbox connection: Renew bolts. Screw in all bolts hand-tight. Tighten bolts to the specified torque: Bolts -arrows- are 40 Nm + 90°.

For the gearbox mounting to the body on the VOLKSWAGEN JETTA 2005 6-speed manual gearbox 02S, renew bolts, screw in all bolts hand-tight, and tighten bolts to the specified torque. Bolts -arrows- are 60 Nm + 90°.

For the gearbox support to the gearbox bracket and gearbox on the VOLKSWAGEN JETTA 2005 6-speed manual gearbox 02S, renew bolts, screw in all bolts hand-tight, and tighten bolts to the specified torque. Bolts -arrows- are 20 Nm + 90°.

It is not possible to check the gear oil level by unscrewing the oil filler plug on the VOLKSWAGEN JETTA 2005 6-speed manual gearbox 02S because 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.

The special tools and workshop equipment required are Torque wrench -V.A.G 1331- and a Hose (approx. 600 mm long, external diameter 10 mm) with funnel, commercially available. Gear oil for manual gearboxes refers to the Electronic parts catalogue “ETKA”.

Preparation steps include: Remove the complete air filter housing. Remove the noise insulation.

To drain the gear oil, use a clean container with a scale and a 3-litre capacity to catch the oil which runs out. The selector shaft is locked in place (refer to page 100). Drain gear oil by removing the oil drain plug -arrow 1- and then the pivot pin -arrow 2-. Install the pivot pin -arrow 2- with a new O-ring (refer to Item 5 (page 107)). Screw in the oil drain plug -arrow 1- (refer to Item 17 (page 135)). Now turn the angled rod -A- back to the original position -direction of arrow- so that the selector shaft can move again.

To fill with gear oil, top up the oil in the container to 1.9 litres. Gearbox oil specification refers to the Electronic parts catalogue “ETKA”. Remove the reversing light switch -F4- -arrow-. Connect a hose (approx. 600 mm long, external diameter 10 mm) to a commercially available funnel. Insert the hose in the fitting hole for the reversing light switch -F4- (2nd mechanic) and fill the gear oil. Install the reversing light switch -F4- -arrow- (refer to Item 2 (page 143)). Check the operation of the selector mechanism (refer to page 82). Install the complete air filter housing. Install the noise insulation. After work, clean the 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 the selector shaft as follows: Press the selector shaft down -direction of arrow 1-. While pressing down the selector shaft, turn the angled rod -A- in the -direction of arrow 2- upwards and at the same time press it in until it engages in the selector shaft.

The special tools and workshop equipment required for dismantling and assembling the input shaft for the VOLKSWAGEN JETTA 2005 6-speed manual gearbox 02S are Press tool -VW 407-, Thrust pad -VW 447 H-, Press tool -VW 412-, Tube -VW 422-, Pressure plate -VW 401-, Pressure plate -VW 402-, and Press tool -VW 408 A-.

If installing new gears, refer to the Electronic parts catalogue “ETKA” and technical data (refer to page 1). If the position of the tapered roller bearings is affected when parts are exchanged, the input shaft must be readjusted (see adjustment overview (refer to page 192)). Requirement: Sealing surfaces of the clutch and gearbox housings must be free of sealant.

Press the tapered roller bearing outer race into the gearbox housing to stop. Press the tapered roller bearing outer race without shim into the gearbox housing to stop. Install the input shaft in the clutch housing and set the gearbox housing in place. Tighten the hexagon head bolts to 25 Nm and then turn 90° further. Fit the measuring appliance and dial gauge in the clutch housing. Before taking any measurements, rotate the input shaft to allow the bearings to settle. Set the 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 the input shaft in the direction of the dial gauge -direction of arrow-. Read and note the play on the dial gauge (example: 1.21 mm). Note: The dial gauge does not return to the original position.

To determine the thickness of the shim (Example): Installed shim is 0.65 mm. + Measured value is 0.20 mm. + Preload (constant) is 0.15 mm. Shim thickness is 1.00 mm. Bearing play = (0.65 mm shim plus determined measured value). Bearing play 0.850 mm corresponds to a Shim thickness according to table of 1.000 mm.

Remove the output shaft and pull out the small tapered roller bearing outer race (refer to page 169). Insert shims of the 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 the small tapered roller bearing outer race together with the correct shim (1.175 mm in example) (refer to page 170) and install the output shaft. Tighten the bearing support nuts in the clutch housing to 25 Nm and then turn 90° further.

The steps for output shaft adjustment (Determining thickness of shim) on the VOLKSWAGEN JETTA 2005 6-speed manual gearbox 02S are:

Set up the dial gauge (3 mm measuring range) and set to “0” with 1 mm preload. -A- is the threaded spindle from puller -Kukko 18/0-. Move the output shaft up and down and note the 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 for Shim thickness calculation: Installed shim is 0.65 mm. + Measured value is 0.20 mm. + Preload (constant) is 0.15 mm. Shim thickness is 1.00 mm. Example for Shim thickness from table: Bearing play = (0.65 mm shim plus determined measured value). Bearing play 0.850 mm corresponds to a Shim thickness according to table of 1.000 mm. Remove the output shaft and pull out the small tapered roller bearing outer race (refer to page 169). Insert shims of the 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 the small tapered roller bearing outer race together with the correct shim (1.00 mm in example) (refer to page 170) and install the output shaft. Tighten the bearing support nuts in the clutch housing to 25 Nm and then turn 90° further.

To press the tapered roller bearing outer race into the gearbox housing when adjusting the differential on the VOLKSWAGEN JETTA 2005 6-speed manual gearbox 02S, fit the shim under the outer race. Support the gearbox housing directly below the bearing mounting using sleeve -3144-. Fit the gearbox housing and tighten 5 bolts to 25 Nm. Attach the dial gauge and set 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 special tools and workshop equipment required for dismantling and assembling the differential on the VOLKSWAGEN JETTA 2005 6-speed manual gearbox 02S are Tapered roller bearing puller -V.A.G 1582-, Adapter -V.A.G 1582/3-, Press tool -VW 412-, Pressure plate -VW 401-, and Pressure plate -VW 402-.

Note: Heat the tapered roller bearing inner race to 100° C before installing. Always renew both tapered roller bearings together as a set. If tapered roller bearings, differential cage, gearbox housing, or clutch housing are renewed, adjust the differential (refer to page 192).

The components are:

Pressing the tapered roller bearing outer race out of the clutch housing: First remove the seating sleeve for the flange shaft seal.

The steps for pressing the tapered roller bearing outer race into the clutch housing when dismantling and assembling the differential on the VOLKSWAGEN JETTA 2005 6-speed manual gearbox 02S are: No shim is installed in the clutch housing end.

To pull off the tapered roller bearing inner races when dismantling and assembling the differential on the VOLKSWAGEN JETTA 2005 6-speed manual gearbox 02S: Before fitting the extractor, position the thrust plate -40 – 105- on the differential cage. Note: Both tapered roller bearing inner races are pulled off the differential cage in the same way.

To press on the tapered roller bearing inner race when dismantling and assembling the differential on the VOLKSWAGEN JETTA 2005 6-speed manual gearbox 02S, note that the inner races of tapered roller bearings for the gearbox housing and clutch housing are pressed on with the same press tools.

To pull the outer race for the tapered roller bearing out of the gearbox housing when dismantling and assembling the differential on the VOLKSWAGEN JETTA 2005 6-speed manual gearbox 02S, use Counter support -A- e.g., -Kukko 22/2- and Internal puller -B-, 46 … 58 mm, e.g., -Kukko 21/7-.

The steps for pressing the tapered roller bearing outer race into the gearbox housing when adjusting the differential on the VOLKSWAGEN JETTA 2005 6-speed manual gearbox 02S are:

Fit shim under the outer race. Support the gearbox housing directly below the bearing mounting using sleeve -3144-.

Spring pin identification:

Allocation of differential cages: Check the hole for the spring pin in the differential cage. The hole in the differential cage was modified for the longer spring pin.

Removing and installing spring pin with circumferential groove (short spring pin): Removing: Cover the tapered roller bearing inner race and speedometer drive gear to avoid possible damage and ingress of metal particles. Drive out the spring pin with a chisel, inserting the chisel into the circumferential groove. Installing: Drive into the differential cage to the stop.

Removing spring pin without circumferential groove (long spring pin); pressing out differential pinion pin: When pressed out, the spring pin will be sheared off. Drive the remainder of the spring pin out of the differential cage and the differential pinion pin.

Installing spring pin without circumferential groove (long spring pin): Align the hole in the differential pinion pin with the hole in the differential cage. Drive in the new spring pin with drift -1- until dimension -a- = 3.0 mm is attained. Note: The spring pin must not come in contact with gears with the differential cage installed.

In some gearboxes, the one-piece thrust washer has a shoulder -A- near the holes. In this case, the differential cage has a circumferential groove -B-. Lubricate the one-piece thrust washer with gear oil and install. Install the one-piece thrust washer so that it engages in groove -B- in the differential cage.

Installing differential bevel gears and differential pinion pin: Lubricate the one-piece thrust washer with gear oil and install. Install both sun wheels and secure (e.g., with the 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 on the VOLKSWAGEN JETTA 2005 6-speed manual gearbox 02S when the following components are renewed: Gearbox housing, Clutch housing, Differential cage, or the Tapered roller bearing of differential. Adjustment overview is provided (refer to page 192).

Press the tapered roller bearing outer race without shim into the 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 the outer race of the tapered roller bearing into the clutch housing using thrust plate -30 – 205- (refer to page 197). Fit the differential into the clutch housing. Set the gearbox housing in place and tighten 5 bolts to 25 Nm. Attach the dial gauge and set 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).

Determining thickness of shim (The specified bearing preload is obtained by adding a constant value for preload (0.25 mm) to the reading obtained):

Example for Shim thickness from table: Bearing play = (0.65 mm shim plus determined measured value). Bearing play 0.70 mm corresponds to a Shim thickness according to table of 0.95 mm.

Table of shims:

Allocate shims according to the Electronic parts catalogue “ETKA”. Remove the gearbox housing and pull the tapered roller bearing outer race from the gearbox housing. Insert shims of the 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 the tapered roller bearing outer race together with the correct shim (1.175 mm in example) (refer to page 198) and bolt the gearbox housing tight.