VOLKSWAGEN JETTA 2006 (01) PDF Document

The code letters and date of manufacture for the 5-speed manual gearbox 0AF are located directly on the gearbox. The gearbox code also appears on the vehicle identification plates.

When performing repairs on your VOLKSWAGEN JETTA 2006, ensure the following:

When installing the manual gearbox, ensure that the dowel sleeves between the engine and gearbox are correctly seated.

When installing mounting brackets or waxed components, clean the contact surfaces. Contact surfaces must be free of wax and grease.

Allocate bolts and other components using the electronic parts catalogue.

When changing a gearbox, fill with gear oil to the lower edge of the filler hole.

Always renew self-locking bolts and nuts.

Torque settings are specified for unoiled bolts and nuts.

Use a thread chaser to clear residual locking fluid from all threaded holes into which self-locking bolts are to be screwed to avoid the danger of bolts shearing.

When installing new tapered roller bearings, install them as supplied and do not lubricate them additionally.

With the gearbox in neutral, the selector lever must rest in the gate for 3rd and 4th gear. Operate the clutch and select all gears several times, paying particular attention to the operation of the reverse gear lock.

Prefilling the system is not necessary. Connect brake filling and bleeding equipment (VAS 5234 or V.A.G 1869). If necessary, use a 670 mm bleeder hose (V.A.G 1238/B3).

1. Connect the bleeder hose to the collector bottle of the brake bleeding equipment.

2. Connect the bleed hose to the bleeder valve.

3. Pressurise the system to 2 bar.

4. Open the bleeder valve and bleed off about 100 cm3 of brake fluid.

5. Close the bleeder valve.

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

7. Open the bleeder valve and bleed off an additional 50 cm3 of brake fluid.

8. Close the bleeder valve.

9. Depress the clutch pedal several times after completion of the bleeding process.

To check the gear oil, remove the oil plug. The oil level is correct when the gearbox is filled to the lower edge of the filler hole.

When filling with oil:

1. Remove the oil plug.

2. Fill with gear oil to the lower edge of the filler hole.

3. Screw in the plug.

4. Start the engine, engage a gear, and allow the gearbox to turn for approximately 2 minutes.

5. Stop the engine and remove the plug.

6. Top up with gear oil to the lower edge of the filler hole.

7. Tighten the oil plug to the specified torque.

1. Ensure the gearbox is in neutral.

2. Remove the air filter housing if necessary to access the selector mechanism.

3. Pull the locking mechanisms on the gate selector cable and gear selector cable forward to the stop (direction of arrow 1) and then turn to the left to lock (direction of arrow 2).

4. Set the selector shaft by pressing the selector shaft down (direction of arrow 1). While pressing down, turn the locking pin (A) (direction of arrow 2) and press it carefully in until it engages in the selector shaft.

5. Remove the gaiter with the selector lever knob and noise insulation.

6. Move the selector lever to neutral.

7. Guide the locking pin (T10027 A) through hole (A) into hole (B).

8. Ensure the gate and selector cables are inserted, free of stress, into the locking device.

9. Turn the locking mechanisms on the gear selector cable and gate selector cable clockwise to the stop (direction of arrow 1).

10. Turn the angled rod (A) back to its original position.

11. Pull the locking pin out of holes (A) and (B).