VOLKSWAGEN JETTA 2011 (04) PDF Document

The 5-speed manual gearbox 0A4 is installed in the VOLKSWAGEN JETTA 2011 in conjunction with a 4-cylinder engine.

Codes and production date -arrow 1- manual gearbox 0A4 -arrow 2- are located on the gearbox.

Example of Codes and production date of gearbox:

The gearbox code also appears on the vehicle identification plates.

For the VOLKSWAGEN JETTA 2011, the following codes are relevant:

For the VOLKSWAGEN JETTA 2011, another relevant code is:

For the VOLKSWAGEN JETTA 2011, another relevant code is:

For the 5th gear example:

i = Z2 : Z1

iG = Gear ratio = ZG2 : ZG1= 29 : 39 = 0.744

iA = Final drive ratio = ZA2 : ZA1 = 61 : 18 = 3.389

itotal = Overall ratio = iG x iA = 0.744 x 3.389 = 2.521

Z1 = No. of teeth on driving gear, Z2 = No. of teeth on driven gear

General repair notes for the gearbox in the VOLKSWAGEN JETTA 2011:

To ensure flawless and successful gearbox repairs, the greatest care and cleanliness as well as the use of good and proper tools are essential. Of course, the basic rules for safety also apply during repair work.

A number of instructions generally applicable to the various repair procedures – which were previously repeated a number of times at various places in the workshop manual are summarised under the topic “components”. They apply to this workshop manual.

Gearbox capacity, gearbox completely dismantled is 1.9 l.

Gearbox capacity, gearbox partially dismantled is 1.7 l.

O-rings, seals, gaskets and sealants:

• Thoroughly clean housing joint surfaces before applying sealant.
• Apply sealant -AMV 188 200 03- uniformly but not too thick.
• Renew O-rings, seals and gaskets.
• After removing gaskets and seals, always inspect contact surface of housing or shaft for burrs resulting from removal or for other signs of damage.
• Before installing radial shaft seals, lightly oil outer diameter and half-fill space between sealing lips -arrow- 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 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 oil level in gearbox and replenish if necessary.

Locking devices:

• 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-.

Nuts and bolts:

• Loosen nuts or bolts in the order opposite to the tightening sequence.
• Securing bolts and securing nuts 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- .
• Threaded holes into which self-locking bolts or bolts coated with locking fluid are screwed, must be cleaned (e.g. with a thread chaser). Otherwise there is a danger of bolts shearing when subsequently being removed.

Bearings:

• 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.

Shims:

• 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.

Synchro-rings:

• Do not interchange. When reusing synchro-rings, always fit to the same synchromeshed 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 the cone of the synchromeshed gear for scoring and signs of abnormal wear.
• Moisten synchromesh mechanism with gear oil before installing.

Gears, synchro-hubs, inner races for needle bearings:

• Heat inner races for needle bearings 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.

Synchromeshed gears:

• After assembly, check synchromeshed gears of 1st through 5th gear for slight play, or for freedom of movement.

Clutch:

• When removing gearbox, remove slave cylinder without disconnecting pipes.
• If the clutch slave cylinder is removed with the hydraulic line attached, do not depress clutch pedal. Otherwise the piston will be pressed out of the slave cylinder.
• 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.

Special tools and workshop equipment required for removing the over-centre spring:

• Release tool -T10178-

Procedure for Vehicles with knee airbag (The installation location of the knee airbag is above the pedal cluster):

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

With ignition switched off, disconnect battery earth strap.

Push driver seat as far back as possible and move steering wheel to highest position.

Remove trim and cover below trim on drive side.

Remove bracket for knee airbag together with crash bar.

Remove cable guide -2- from steering column.

Remove footwell vent -3-.

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

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

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

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

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

Renew self-locking nuts.

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

Receptacle -arrow- for tip -A- of clutch pedal must stand vertically.

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

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

If some cars have damping -arrow- on the mounting bracket/clutch pedal, return this to installation position.

For Vehicles without knee airbag:

The crash bar -1- in front of clutch pedal -2- may be secured in different ways.

Attachment with 2 bolts: Install crash bar -1- and tighten 2 bolts to specified torque.

Attachment with 1 bolt: Install crash bar -1- and tighten bolt -2- to specified torque.

Continuation for all:

Mount cable guide -2- on steering column.

Install footwell vent -3-.

Vehicles with knee airbag: Install bracket for knee airbag together with crash bar.

Continuation for all: Install trim and cover below trim on drive side.

If disconnected, connect battery.

Specified torques for clutch pedal components on the VOLKSWAGEN JETTA 2011:

Procedure to remove the clutch pedal for the VOLKSWAGEN JETTA 2011:

Carry out procedure as follows for Vehicles with knee airbag (Note: The installation location of the knee airbag is above the pedal cluster):

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

With ignition switched off, disconnect battery earth strap.

Continuation for all:

Push driver seat as far back as possible and move steering wheel to highest position.

Remove trim and cover below trim on drive side.

Vehicles with knee airbag:

Remove bracket for knee airbag together with crash bar.

Continuation for all:

Remove cable guide -2- from steering column.

Remove footwell vent -3-.

Vehicles without knee airbag:

The crash bar -1- in front of clutch pedal -2- may be secured in different ways. Crash bar may look different from as shown in following illustrations.

Attachment with 2 bolts: Remove crash bar -1- (2 bolts).

Attachment with 1 bolt: Remove crash bar -1- (1 x bolt -2-).

Continuation for all:

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

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

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

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

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

Remove clutch pedal.

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

Note: Renew self-locking nuts.

Secure retainer -2- to master cylinder operating rod -1-.

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

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

Receptacle -arrow- for tip -A- of clutch pedal must stand vertically.

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

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

If some cars have damping -arrow- on the mounting bracket/clutch pedal, return this to installation position.

Vehicles without knee airbag:

The crash bar -1- in front of clutch pedal -2- may be secured in different ways.

Attachment with 2 bolts: Install crash bar -1- and tighten 2 bolts to specified torque.

Attachment with 1 bolt: Install crash bar -1- and tighten bolt -2- to specified torque.

Continuation for all:

Mount cable guide -2- on steering column.

Install footwell vent -3-.

Vehicles with knee airbag: Install bracket for knee airbag together with crash bar.

Continuation for all: Install trim and cover below trim on drive side.

If disconnected, connect battery.

Special tools and workshop equipment required:

• Pliers -T10005-
• Release tool -T10178-

Procedure to remove the mounting bracket for the VOLKSWAGEN JETTA 2011 clutch master cylinder:

Carry out procedure as follows for Vehicles with knee airbag (Note: The installation location of the knee airbag is above the pedal cluster):

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

With ignition switched off, disconnect battery earth strap.

Continuation for all:

Push driver seat as far back as possible and move steering wheel to highest position.

Remove trim and cover below trim on drive side.

Vehicles with knee airbag:

Remove bracket for knee airbag together with crash bar.

Continuation for all:

Remove cable guide -2- from steering column.

Remove footwell vent -3-.

Vehicles without knee airbag:

The crash bar -1- in front of clutch pedal -2- may be secured in different ways. Crash bar may look different from as shown in following illustrations.

Attachment with 2 bolts: Remove crash bar (2 bolts).

Attachment with 1 bolt: Remove crash bar -1- (1 x bolt -2-).

Continuation for all:

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

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

Remove securing nuts -1- and -2-. The upper securing nut -1- is accessible between the relay carrier and the steering column trim.

Remove mounting bracket -3-.

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

Some cars have damping -arrow- on the clutch pedal mounting bracket. Return this to installation position.

Vehicles without knee airbag:

The crash bar -1- in front of clutch pedal -2- may be secured in different ways.

Attachment with 2 bolts: Install crash bar -1- and tighten 2 bolts to specified torque.

Attachment with 1 bolt: Install crash bar -1- and tighten bolt -2- to specified torque.

Continuation for all:

Mount cable guide -2- on steering column.

Install footwell vent -3-.

Vehicles with knee airbag: Install bracket for knee airbag together with crash bar.

Continuation for all: Install trim and cover below trim on drive side.

If disconnected, connect battery.

Specified torques for mounting bracket components on the VOLKSWAGEN JETTA 2011:

Special tools and workshop equipment required:

• Hose clamps -3094-

Procedure to remove the clutch position sender -G476- for LHD VOLKSWAGEN JETTA 2011:

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

With ignition switched off, disconnect battery earth strap.

Remove complete air filter housing if it is near battery.

Remove battery and battery tray.

Clamp off supply hose to master cylinder with hose clamps up to ∅ 25 mm -3094- .

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

In addition, for disconnecting, you can close it with the sealing tool -T10249/1-.

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

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

Remove trim and cover below trim on drive side.

For Vehicles with knee airbag (Note: The installation location of the knee airbag is above the pedal cluster):

Remove bracket for knee airbag together with crash bar.

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

Note: Allocate all components according to Electronic parts catalogue “ETKA” .

If the pipe/hose line was removed:

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

Test pipe/hose line by tugging on it.

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

Bleed clutch system.

For LHD:

Install battery tray and battery.

If removed, install complete air filter housing.

Connect battery and follow procedure after connecting battery.

Special tools and workshop equipment required for removing and installing slave cylinder:

• Torque wrench -V.A.G 1331-

Procedure to remove the slave cylinder for VOLKSWAGEN JETTA 2011:

Carry out procedure as follows:

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

With ignition switched off, disconnect battery earth strap.

Remove complete air filter housing if it is near slave cylinder.

Remove securing clip -arrow 1- for gear selector cable from gearbox selector lever -A-.

Pull gear selector cable off pin.

Metal relay lever:

• Remove securing clip -arrow 2- for gate selector cable from relay lever -B-.
• Pull gate selector cable from pin.
• Pull securing clip -arrow 3- off relay lever -B- and remove relay lever.

Plastic relay lever:

Remove relay lever together with cable end-piece.

Continuation for all:

Remove gearbox selector lever -A- by removing nut -arrow 4-.

Remove cable support bracket from gearbox -arrows-.

Then tie up gear selector cable and gate selector cable.

Remove retainer -B- from gearbox and pull off from pipe/hose line -A-.

Then remove gearbox support -arrow A-.

Lay a lint-free cloth under slave cylinder.

Pull clip for pipe/hose line out of slave cylinder to stop.

Pull pipe/hose line out of slave cylinder and seal opening.

Remove slave cylinder -arrows B-.

Caution: Do not operate clutch pedal any more.

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

Install slave cylinder and tighten bolts -arrows B- to specified torque.

Insert pipe/hose line into slave cylinder to stop.

Push securing clip into pipe/hose line to stop.

Test pipe/hose line by tugging on it.

Then mount gearbox support -arrow A-.

Bleed clutch system after installing slave cylinder.

Assembling selector mechanism.

Adjust selector mechanism.

If removed, install complete air filter housing.

Connect battery earth.

Specified torques for slave cylinder connections on the VOLKSWAGEN JETTA 2011:

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.
• Tighten bolts to specified torque.

Bolts -arrows-: 20 Nm + 90°

Special tools and workshop equipment required for bleeding the clutch system:

• Brake filling and bleeding equipment -VAS 5234- or Brake filling and bleeding equipment -V.A.G 1869-

Prefilling system is not necessary!

Specifications for brake fluid refer to Brake systems; Rep. Gr. 47 ; Bleeding brake system.

Procedure to bleed the system for the VOLKSWAGEN JETTA 2011:

Remove complete air filter housing if it blocks access to bleeder valve -arrow-.

Connect brake filling and bleeding equipment -VAS 5234- or -V.A.G 1869- .

To bleed system, use 670 mm bleeder hose -V.A.G 1238/B3- if necessary.

Connect bleeder hose to collector bottle of brake bleeding equipment.

Connect bleeder hose to bleeder valve -arrow-.

Pressurise system to 2 bar.

Open bleeder valve.

Allow about 100 cm3 of brake fluid to flow out.

Close bleeder valve.

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

Open bleeder valve again.

Allow another 50 cm3 of brake fluid to flow out.

Close bleeder valve.

Depress clutch pedal several times after completion of bleeding process.

If removed, install complete air filter housing.

Install noise insulation.

Special tools and workshop equipment required for removing the selector mechanism:

• Torque wrench -V.A.G 1331-

Procedure to remove the selector mechanism for the VOLKSWAGEN JETTA 2011:

Carry out procedure as follows:

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

With ignition switched off, disconnect battery earth strap.

Remove gaiter with selector knob and noise insulation.

Remove centre console and securing bracket for centre console.

Remove selector housing nuts -arrows-.

Remove complete air filter housing if it is over selector mechanism.

Remove securing clip -3- for gear selector cable from gearbox selector lever -1-. Pull gear selector cable off pin.

Metal relay lever:

• Remove securing clip -4- for gate selector cable from relay lever -2-.
• Pull gate selector cable from pin.

Plastic relay lever:

Remove relay lever together with cable end-piece.

Continued for all selector mechanisms:

Remove gearbox selector lever -A- by removing nut -arrow 4-.

Remove cable support bracket from gearbox -arrows-.

Then tie up gear selector cable and gate selector cable.

Remove retainer -B- from gearbox and pull off from pipe/hose line -A-.

Then remove gearbox support -arrow A-.

Remove selector mechanism.

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

Align selector housing parallel to body.

Distance to body must be same on both sides.

Secure selector housing.

Route cables -1- from selector mechanism -2- to gearbox as follows:

• After cables cross over -arrow-, they must be routed parallel to one another as far as cable support bracket on gearbox.
• Make sure that cable tie -arrow- for securing cables is installed correctly. Installation position.
• Cables must be laid in the intended indentation in heat shield -3-.

In the close-up, the heat shield is shown from above.

Clip -A- holds cables and heat shield together in position.

Install cable support bracket on gearbox and tighten bolts to specified torques.

Spread a small quantity of grease on pins -arrows- of gearbox selector lever -1- and of relay lever -2-.

Renew securing clips -3- and, for metal relay lever, securing clip -4- each time they are removed.

Secure gear selector cable with securing clip -3- and gate selector cable, if necessary with securing clip -4-.

Cable end-piece to plastic relay lever:

• Mounting relay lever together with cable end-piece.
• Insert gate selector cable in cable end-piece.

Continued for all selector mechanisms:

Install centre console.

Install gaiter with selector knob and noise insulation.

Install heat shield beneath selector mechanism. If removed, reinstall underbody panels.

Assemble exhaust system free of tension and attach tunnel cross member.

Adjust selector mechanism.

If removed, install complete air filter housing.

Follow procedure after connecting battery.

Procedure to remove the gear selector cable and gate selector cable for the VOLKSWAGEN JETTA 2011:

Carry out procedure as follows:

Remove selector mechanism.

Bend open tabs -arrows- of selector mechanism cover using a screwdriver and remove cover.

Remove gasket.

Pull off securing clips -2 and 3-. Securing clips -1 and 4- are no longer present.

Prise gear selector cable off gear lever and gate selector cable off gate selector lever with e.g. a screwdriver if necessary.

Pull gear selector cable and gate selector cable from selector housing.

Release locks -A- for gear and gate selector cables -B- as follows:

• Push sliding sleeve forward to stop -arrow 1-.
• Turn sliding sleeve to right to stop -arrow 2- until it engages.

Remove locking mechanism from Bowden cables.

Pull off securing clips -1- and -2-.

Remove cable support bracket from Bowden cables.

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

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

Press gear selector cable onto gear lever and gate selector cable onto gate selector lever in selector housing. (Securing clips -1 and 4- have been discontinued.)

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

Install selector mechanism.

Adjust selector mechanism.

Special tools and workshop equipment required for adjusting the selector mechanism:

• Locking pin -T10027 A

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

• Moving parts of selector mechanism and elements transferring force must be in proper condition.
• Selector mechanism must move freely.
• Gearbox, clutch and clutch mechanism must also be in proper condition.
• Gearbox must be in neutral.

Procedure to adjust the selector mechanism for the VOLKSWAGEN JETTA 2011:

Carry out procedure as follows:

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

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

Secure selector shaft as follows:

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

Remove gaiter with selector knob and cover.

If noise insulation is present, remove it.

Secure selector lever as follows:

• Select neutral using gear lever.
• Guide locking pin -T10027 A- through hole -A- into hole -B-.

Gate and selector cables -B- must be inserted, free of tension, into locking devices -A-.

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

Then turn angled rod -A- back to original position in -direction of arrow-.

The angled rod -A- must be pressed out of selector housing to stop and point to rear.

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

If noise insulation was present, install it.

Install gaiter with selector knob and cover.

Check selector shaft can move freely.

If removed, install complete air filter housing.

Functional check:

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

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

Special tools and workshop equipment required for removing and installing the gearbox on the VOLKSWAGEN JETTA 2011 are:

Other required equipment includes:

• Adjustment plate -3282/39-
• Support elements for gearbox (determine when setting adjustment plate on gearbox support )
• 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 for clutch plate splines -G 000 100-
• Pin -3282/29-

Torque settings for the gearbox on a petrol engine for the VOLKSWAGEN JETTA 2011:

Item -A- dowel sleeves for centring.

Gearbox bracket -A- to gearbox:

• Renew bolts.
• Screw in all bolts hand-tight.
• Tighten bolts to specified torque.

Bolts -arrows-: 40 Nm + 90°

Gearbox mounting to body:

• Renew bolts.
• Screw in all bolts hand-tight.
• Tighten bolts to specified torque.

Bolts -arrows-: 60 Nm + 90°

Gearbox support to gearbox bracket and gearbox:

• Renew bolts.
• Screw in all bolts hand-tight.
• Tighten bolts to specified torque.

Bolts -arrows-: 20 Nm + 90°

Torque settings for the gearbox on a diesel engine for the VOLKSWAGEN JETTA 2011:

Item -A- dowel sleeves for centring.

Gearbox bracket -A- to gearbox:

• Renew bolts.
• Screw in all bolts hand-tight.
• Tighten bolts to specified torque.

Bolts -arrows-: 40 Nm + 90°

Gearbox mounting to body:

• Renew bolts.
• Screw in all bolts hand-tight.
• Tighten bolts to specified torque.

Bolts -arrows-: 60 Nm + 90°

Gearbox support to gearbox bracket and gearbox:

• Renew bolts.
• Screw in all bolts hand-tight.
• Tighten bolts to specified torque.

Bolts -arrows-: 20 Nm + 90°

Special tools and workshop equipment required for transporting the gearbox:

• Gearbox mounting support -3336-

Procedure for transporting the gearbox on the VOLKSWAGEN JETTA 2011:

Bolt gearbox lifting tackle -3336- to clutch housing.

Adjust support beam on sliding piece using locking pin -arrow-.

Number of holes visible = 5.

Lift gearbox using workshop crane and gearbox lifting tackle -3336- .

Set gearbox aside, for example in a transport container.

It is not possible to check the gear oil level by unscrewing the oil filler plug.

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:

Special tools and workshop equipment required:

• Torque wrench -V.A.G 1331-
• Hose (approx. 600 mm long, external diameter 10 mm) with funnel, commercially available.

Preparation:

Gearbox oil specification.

Remove complete air filter housing.

Remove noise insulation.

Draining gear oil:

Use a clean container with a scale and a 3-litre capacity to catch the oil which runs out.

Selector shaft is locked in place.

Drain gear oil by removing oil drain plug -arrow 1- and pivot pin -arrow 2-.

Install pivot pin -arrow 2- with a new O-ring.

Screw in oil drain plug -arrow 1-.

Now turn angled rod -A- back to original position -direction of arrow- so that selector shaft can move again.

Filling with gear oil:

Top up gear oil in container to 1.7 l.

Gearbox oil specification.

Remove reversing light switch -F4- -arrow-.

Connect a hose (approx. 600 mm long, external diameter 10 mm) with a funnel, commercially available.

Insert hose into mounting hole of reversing light switch -F4- (2nd mechanic) and pour in gear oil.

Install reversing light switch -F4- -arrow- again.

Check function of selector mechanism.

Install complete air filter housing.

Install noise insulation.

Capacity of manual gearbox (gearbox completely dismantled) is 1.9 l.

Capacity of manual gearbox (gearbox partially dismantled) is 1.7 l.

Table for “Checking and topping up gear oil” for the VOLKSWAGEN JETTA 2011 5-speed manual gearbox 0A4:

Procedure to dismantle the gearbox for the VOLKSWAGEN JETTA 2011:

Carry out procedure as follows:

Remove clutch release lever, release bearing and guide sleeve.

Bearings of input shaft and output shaft must not be damaged when 5th gear is removed and installed.

Therefore, following tools must be mounted for support at this stage during attachment of gearbox to gearbox support -VW 353- :

Underneath input shaft:

• Support bridge -30-211A-
• Thrust piece -32 – 111-
• Thrust piece -T10030/4-

Lock bolt of support bridge -30-211A- with nut -A-.

Underneath bearing support for output shaft:

• Support device -T10323-
• Assembly tool -3253/7-
• Thrust piece -VW 433-

Secure gearbox on gearbox support -VW 353- .

Place drip tray underneath.

Remove oil filler plug and oil drain plug.

Drain gear oil.

Remove gearbox housing cover -arrow-.

Remove selector fork for 5th gear as follows:

• Cover openings in gearbox housing using a cloth.
• Move selector fork -1- to neutral position.
• Remove bolt -2- with selector fork for 5th gear.
• Then remove both bolts -arrows- for pivot pins.
• Pull out pivot pin.
• Remove 5th gear selector fork.

Spring -3- and locking collar -4- do not need to be removed.

Remove bolts -A- for synchro-hub and gear wheel for 5th gear. To do this, engage 5th gear -arrow 1- and 1st gear -arrows 2- and -3-. Input shaft and output shaft are locked when both gears are engaged. Synchro-hub and gear wheel cannot turn. Both bolts can now be loosened.

If shafts are not to be renewed, carefully clean residual locking material out of threaded holes using a thread chaser.

Remove both bolts -arrows- for reverse shaft support bracket.

Now remove 3rd bolt -arrow- for reverse shaft support bracket.

Gearboxes for vehicles with start-stop system: remove gearbox neutral position sender -G701- -arrow-.

Remove selector shaft with selector mechanism cover, placing selector shaft in neutral position. Then remove bolts -arrows and pull selector shaft out of gearbox housing.

Remove cover plate -A- and pivot pins -B- from underside of gearbox.

Remove reverse gear -A-, input shaft -B- and output shaft -C- one after the other from clutch housing.

Remove differential.

Procedure to assemble the gearbox for the VOLKSWAGEN JETTA 2011:

Install differential.

Always renew sealing rings -arrows- for output shaft bearing support.

Insert input shaft -1- and output shaft -2- together.

Tighten nuts for output shaft bearing support to specified torque.

Place reverse gear wheel -3- on needle bearing in clutch housing. The shoulder -arrow- faces away from the clutch housing.

Check that reverse shaft -4- is complete; do not yet fit reverse shaft support to reverse shaft.

Fit reverse shaft into clutch housing.

Clean locking fluid from all threaded holes in reverse shaft support; a thread chaser may be used.

Install reverse shaft support.

Attach reverse gear selector fork -1- with support for reverse gear selector fork -2-, spring -3- and sliding piece -4-.

Installation position, reverse gear:

• Bolt on reverse gear selector mechanism -A-.
• Install selector forks -B- together with selector plates. Reverse gear support -C- is located in front of selector plates.

Screw M8 x 100 mm stud -A- into reverse shaft support so that shaft is aligned after gearbox housing is fitted.

Align selector plates.

Note: The selector segments must be positioned in the grooves on the locking collars.

Apply sealant -AMV 188 200 03- evenly to sealing surface of clutch housing.

Fit gearbox housing.

Install reverse shaft support bolts -arrow- as follows:

• Install bolt -a-.
• Remove stud -A-.
• Install bolt -c-.

Tightening sequence:

• Tighten bolt -a- to 30 Nm.
• Tighten bolt -b- to 25 Nm.
• Tighten bolt -c- to 25 Nm.

Install pivot pin -arrow- for selector forks. Do this by aligning selector mechanism with a screwdriver so that respective pivot pin can be installed.

Apply sealant -AMV 188 200 03- evenly to sealing surface of cover plate.

Fit selector shaft cover.

Install selector shaft with selector shaft cover plate as follows:

• Place selector plates in neutral.
• Apply sealant -AMV 188 200 03- evenly to sealing surface of selector mechanism cover.
• Move selector shaft to neutral.
• Position selector shaft so that selector finger -arrow- is inserted in selector plates.
• Bolt on selector shaft cover to specified torque.
• Gearboxes for vehicles with start-stop system: fit gearbox neutral position sender -G701- -arrow- and tighten securing bolt to specified torque.

Install both flange shafts with compression springs, thrust washers and tapered rings.

Ensure that support bridge -30-211A- and support device -T10323- are attached.

Lock bolt of support bridge -30-211A- with nut -A-.

Installation position, 5th gear wheel: The circumferential groove -arrow- faces gearbox housing.

Heat gear wheel for 5th gear to about 100 °C with inductive heater -VAS 6414- before installing. Wear protective gloves!

Drive on gear wheel for 5th gear.

Install cover for gearbox housing and tighten bolts to specified torques.

Fit clutch release lever and release bearing.

Fill with gear oil.

Procedure to adjust 5th gear on the VOLKSWAGEN JETTA 2011 5-speed manual gearbox 0A4:

Engage 5th gear. Loosen bolt -1-. Press locking collar and selector jaw in -direction of arrow-. Then tighten bolt -1- to 25 Nm.

Check measurement: It must not be possible to slide a 0.2 mm feeler gauge between locking collar and gear wheel. If necessary, repeat adjustment.

Disengage 5th gear. Locking collar must now be in the neutral position. Synchro-ring must move freely.

Shift through all gears.

Install gearbox housing cover.

Fit release bearing guide sleeve.

Fit clutch release lever and release bearing.

Fill with gear oil.

Procedure to determine input shaft shim for the VOLKSWAGEN JETTA 2011 5-speed manual gearbox 0A4:

Press tapered roller bearing outer race into gearbox housing to stop.

Press tapered roller bearing outer race without shim into gearbox housing to stop.

Install input shaft in clutch housing and set gearbox housing in place. Tighten hexagon head bolts to 25 Nm and then turn 90° further.

Fit measuring appliance and dial gauge in clutch housing.

Before taking any measurements, rotate input shaft to allow bearings to settle. Set dial gauge to “0” with 1 mm preload.

This step must be repeated for each subsequent measurement, or the dial gauge will not return to the starting position.

Press input shaft in direction of dial gauge -direction of arrow-.

Read and note play on dial gauge (example: 1.21 mm).

Dial gauge does not return to original position.

Determining thickness of shim (Example):

Table of shims for input shaft adjustment:

Remove input shaft and press outer race of tapered roller bearing out of gearbox housing using thrust plate -VW 447 i- .

Insert shims of 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.

Press outer race of tapered roller bearing together with the shim into gearbox housing using thrust pad -VW 510- .

Procedure for carrying out check measurement after adjusting input shaft shim on the VOLKSWAGEN JETTA 2011 5-speed manual gearbox 0A4:

Set gearbox housing in place and tighten hexagon head bolts to 25 Nm and then turn 90° further.

Set up measuring appliance and dial gauge.

Rotate input shaft so that tapered roller bearings settle.

Press input shaft in -direction of arrow-.

Bearing play should be min. 0.01 … max. 0.09 mm.

If the bearing play cannot be measured, but input shaft play is perceptible and the input shaft turns freely, the adjustment is acceptable.

Special tools and workshop equipment required for output shaft service on the VOLKSWAGEN JETTA 2011 5-speed manual gearbox 0A4:

Inductive heater -VAS 6414-

Note on output shaft dismantling:

• The output shaft is dismantled as follows: position separating device under 2nd gear synchromeshed gear and press off as described in. Remove retaining ring. Then press off locking collar with synchro-hub for 1st and 2nd gear as described in.
• When installing new gears or new input shaft, refer to Electronic parts catalogue “ETKA” and technical data.
• Always renew both tapered roller bearings together as a set.
• Heat inner races, gear wheels and synchro-hubs to about 100 °C with the inductive heater -VAS 6414- before installing. Wear protective gloves to do this.

Adjustment overview for the output shaft on the VOLKSWAGEN JETTA 2011 5-speed manual gearbox 0A4 refers to page 195.

Requirement:

Sealing surfaces of clutch and gearbox housings must be free of sealant.

Procedure to determine thickness of shim:

Press small tapered roller bearing outer race together with a 0.65 mm thick shim into clutch housing to stop.

Insert output shaft and tighten nuts for bearing support to 25 Nm, then turn 90° further.

Turn output shaft 20 to 30 times in one direction.

Note:

• The shaft must be turned in one direction so that the rollers of the tapered roller bearing settle in one direction.
• It is necessary to turn the shaft 20 to 30 times to achieve this.
• Otherwise the resulting reading will be incorrect.

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

Move output shaft up and down and note dial gauge reading (example: 0.20 mm).

Determining thickness of shim (Example):

Example for Bearing play calculation:

Table of shims for output shaft adjustment:

Remove output shaft and pull out small tapered roller bearing outer race.

Press in small tapered roller bearing outer race together with the shim (1.00 mm in example) into gearbox housing using thrust pad -VW 510- .

Procedure to adjust the differential for the VOLKSWAGEN JETTA 2011 5-speed manual gearbox 0A4:

Press tapered roller bearing outer race without shim into gearbox housing using thrust plate -30 – 205-.

Fit differential into clutch housing.

Set gearbox housing in place and tighten 5 bolts to 25 Nm.

Attach dial gauge and set to “0” with 1 mm preload.

Move differential up and down. Read and note play indicated on dial gauge. (Example: 0.70 mm.)

Determining thickness of shim (Example):

Example for Bearing play calculation:

Table of shims for differential adjustment:

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

Insert shims of determined thickness, thickest shim first.

Press in outer race of tapered roller bearing again and bolt gearbox housing tight.