VOLKSWAGEN JETTA 2006 (02) PDF Document

The gearbox identification code and date of manufacture are located directly on the gearbox housing. This information also appears on the vehicle identification plates.

Before installing an oil seal, half-fill the space between the sealing lips with sealing grease. The open side of the seal should face the side with the fluid filling. Lightly oil O-rings before installing to prevent them from being crushed. Additionally, thoroughly clean parting surfaces and apply sealant uniformly, ensuring it is not too thick.

Before disconnecting the battery, ensure you have the radio code for units with anti-theft coding. With the ignition switched off, disconnect the battery. Always lubricate bearings and contact surfaces with the specified grease. If the clutch has burnt out, thoroughly clean the bell housing and the friction surface of the flywheel with a cloth to reduce the smell of burnt linings.

Prefilling the system is not necessary. To bleed the system, follow these steps:

Step 1. Connect the brake filling and bleeding equipment to the vehicle.

Step 2. Connect a bleeder hose to the collector bottle of the bleeding equipment.

Step 3. Connect the bleed hose to the bleed valve.

Step 4. Pressurize the system to 2 bar.

Step 5. Open the bleeder valve and bleed off about 100 cm3 of brake fluid.

Step 6. Close the bleeder valve.

Step 7. Rapidly operate the clutch pedal from stop to stop 10 to 15 times.

Step 8. Open the bleeder valve again and bleed off an additional 50 cm3 of brake fluid.

Step 9. Close the bleeder valve and depress the clutch pedal several times.

Ensure the gearbox is in neutral. First, pull the locking mechanisms on the gate selector cable and gear selector cable forward to the stop, then turn them to the left to lock. To set the selector shaft, press the selector shaft down and turn the locking pin until it engages. Move the selector lever to neutral and guide a locking pin through the designated holes to lock it. Check that the cables are inserted free of stress into the locking device, then turn the cable locking mechanisms clockwise to the stop, allowing the spring to return them to the original position. Finally, turn the angled rod back to its original position and remove all locking pins.

The following table lists the torque specifications for the gearbox to engine connection:

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. To fill the oil:

Step 1. Remove the oil plug.

Step 2. Fill with gear oil until it reaches the lower edge of the filler hole.

Step 3. Screw in the plug.

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

Step 5. Stop the engine and remove the plug.

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

Step 7. Tighten the oil plug to the specified torque.

The bearing preload is determined by adding a constant value of 0.35 mm to the measured play. To perform this:

Step 1. Attach a dial gauge and set it to 0 with 1 mm preload.

Step 2. Move the differential up and down and note the play indicated on the dial gauge.

Step 3. Add 0.35 mm to the measured value to get the required thickness for shim S2.

Step 4. Remove the clutch housing and press out the tapered roller bearing outer race.

Step 5. Select the appropriate S2 shim based on the calculated value and press the bearing outer race back into the clutch housing.