VOLKSWAGEN JETTA 2011 (05) PDF Document

The 5-speed manual gearbox 0AF in your VOLKSWAGEN JETTA 2011 has various identification codes, each with specific allocations and capacities. The gearbox code can be found on the gearbox housing and also on the vehicle identification plates. The following tables provide details for different gearbox codes:

Codes: FVH, JHT, JHU

Codes: LEG, LVN, LDZ

For more specific data such as individual gear ratios, gear oil type, and clutch allocation, refer to the Electronic parts catalogue “ETKA”.

The power transmission system for the VOLKSWAGEN JETTA 2011 with a 5-speed manual gearbox 0AF consists of the following main components:

1. Engine

2. Clutch

3. Manual gearbox

4. Input shaft

5. Output shaft

6. Differential

The gears within the manual gearbox are designated as follows:

I – 1st gear

II – 2nd gear

III – 3rd gear

IV – 4th gear

V – 5th gear

R – Reverse gear

A – Final drive

To calculate the overall gear ratio “i” for your VOLKSWAGEN JETTA 2011, you need to know the number of teeth on the drive gear and the driven gear for both the specific gear and the final drive.

The general formula is: i = Z2 : Z1, where Z1 is the number of teeth on the driving gear and Z2 is the number of teeth on the driven gear.

Example Calculation:

Let’s use an example with the following values:

Step 1: Calculate the Gear Ratio (iG)

iG = Gear ratio = ZG2 : ZG1 = 50 : 37 = 1.351 (Note: The PDF shows 37:50 = 0.740, which is the inverse ratio often used in calculations. Let’s follow the PDF’s example.)

iG = 37 : 50 = 0.740

Step 2: Calculate the Final Drive Ratio (iA)

iA = Final drive ratio = ZA2 : ZA1 = 69 : 14 = 4.929

Step 3: Calculate the Overall Ratio (total ratio)

Overall ratio = total ratio = iG x iA = 0.740 x 4.929 = 3.647

When performing repairs on the gearbox of your VOLKSWAGEN JETTA 2011, it is essential to follow these general notes for a successful and safe repair:

• 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 “ETKA”.

• Following installation, always check the gear oil level.

Proper handling of sealing components is critical during gearbox repairs on your VOLKSWAGEN JETTA 2011. Follow these procedures:

• Thoroughly clean housing joint surfaces before applying sealant.

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

• Always renew O-rings, seals, and gaskets.

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

• Before installing radial shaft seals, lightly oil the outer diameter and half-fill the space between the sealing lips with sealing grease -G 052 128 A1-.

• The open side of the oil seal must face the side with fluid filling.

• Press in new oil seals so that the sealing lip does not contact the shaft in the same place as the old seal. Make use of insertion depth tolerances.

• Lightly oil O-rings before installing; this prevents the rings from being crushed when inserted.

• After renewing seals and gaskets, check the oil level in the gearbox and replenish if necessary.

When working on your VOLKSWAGEN JETTA 2011, adhere to the following procedures for locking devices, nuts, and bolts to ensure safety and proper assembly.

Locking Devices (Retaining Rings, Spring Pins):

• Do not overstretch retaining rings.

• Always renew retaining rings that have been damaged or overstretched.

• Retaining rings must locate properly in their grooves.

• Always renew spring pins. For installation, the slit should be in line with the line of force.

Nuts and Bolts:

• Loosen nuts or bolts in the order opposite to the tightening sequence.

• Securing bolts and nuts for covers and housings should be loosened and tightened diagonally in stages if no specific sequence is specified.

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

• Torque settings specified are 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 the appropriate locking fluid (e.g., 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.

Follow these specific guidelines when handling precision components like bearings, shims, and synchro-rings during a gearbox repair on your VOLKSWAGEN JETTA 2011.

Bearings:

• Install needle bearings with the lettered side (thicker metal) towards the fitting tool.

• 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 an inductive heater (e.g., VAS 6414) before installing.

• Do not interchange outer or inner races of bearings of the same size, as they are matched in pairs.

Shims:

• Measure shims at several points with a micrometer to find the exact thickness required.

• Check shims for burrs and damage before installation.

• Install only flawless shims.

Synchro-Rings and Gears:

• Do not interchange synchro-rings. When reusing them, always fit them to the same synchromeshed gear.

• Check synchro-rings for wear and renew if necessary.

• Check the grooves of the synchro-ring and the cone of the synchromeshed gear for “scoring” and “signs of abnormal wear”.

• If synchro-rings are coated, the coating must not be damaged.

• Moisten the synchromesh mechanism with gear oil before installing.

• Heat synchro-hubs and gears to approximately 100 °C before installing. Press them in to the stop so there is no axial clearance.

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

To remove and install the clutch pedal mounting bracket on your VOLKSWAGEN JETTA 2011, follow these steps. Note that during this work, you should place cloths on the carpet to protect it from brake fluid spills.

Removal:

1. First, check if a coded radio is fitted and obtain the anti-theft code if necessary.

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

3. For LHD vehicles, remove the complete air filter housing and the battery with its tray.

4. Lay a lint-free cloth under the master cylinder to catch any spills.

5. Clamp off the supply hose to the master cylinder with hose clamps (e.g., -3094-).

6. Release the securing clip and pull the pipe/hose line off the master cylinder.

7. Unclip the clutch position sender -G476- from the master cylinder and remove it with the connector attached.

8. Inside the vehicle, remove the trim and cover below the driver’s side trim.

9. If equipped, remove the bracket for the knee airbag together with the crash bar.

10. Remove the footwell vent and the cable guide from the steering column.

11. For vehicles without a knee airbag, remove the crash bar in front of the clutch pedal.

12. If fitted, remove the damping material from the lower area of the mounting bracket.

13. Remove the securing nuts holding the mounting bracket to the bulkhead. The upper nut is accessible between the relay carrier and steering column trim.

14. Remove the mounting bracket.

Installation:

1. Installation is the reverse of the removal procedure.

2. Always renew self-locking nuts and hose clips.

3. Push the pipe/hose line onto the master cylinder connection until the securing clip engages audibly. Test the connection by tugging on it.

4. After removing the hose clamp, return the supply hose to its original contour.

5. Bleed the clutch system.

6. Reinstall all components like the crash bar, trims, battery, and air filter.

7. Reconnect the battery.

Torque Settings:

To remove and install the slave cylinder on your VOLKSWAGEN JETTA 2011, follow these steps carefully.

Removal:

1. Disconnect the battery after obtaining the radio code, if applicable.

2. Remove the complete air filter housing if it is located above the slave cylinder.

3. Remove the securing clips for the gear selector cable and gate selector cable from the gearbox selector lever and relay lever.

4. Pull the cables off their respective pins. For a plastic relay lever, follow the specific procedure to release the cable end-piece first.

5. Unbolt and remove the cable support bracket from the gearbox and tie up the selector cables.

6. Lay a lint-free cloth under the slave cylinder.

7. Pull the clip for the hydraulic line out of the slave cylinder to its stop.

8. Pull the hydraulic line out of the slave cylinder and seal the opening.

9. Unbolt and remove the slave cylinder from the gearbox.

Caution: Do not operate the clutch pedal while the slave cylinder or hydraulic line is disconnected.

Installation:

1. Install the new slave cylinder and tighten the bolts to the specified torque (20 Nm).

2. Insert the hydraulic line between the master and slave cylinders into the slave cylinder to the stop.

3. Push the securing clip into the line to the stop and test the connection by tugging on it.

4. Re-install the selector mechanism components.

5. Bleed the clutch system after installing the slave cylinder.

6. Assemble and adjust the selector mechanism.

7. Reinstall the air filter housing if it was removed.

8. Reconnect the battery.

To bleed the clutch system on your VOLKSWAGEN JETTA 2011, you will need a brake filling and bleeding equipment (e.g., VAS 5234 or V.A.G 1869). Prefilling the system is not necessary.

1. Remove the complete air filter housing if it prevents access to the bleeder valve.

2. Connect the brake filling and bleeding equipment to the brake fluid reservoir.

3. If necessary, use a 670 mm bleeder hose (e.g., V.A.G 1238/B3) to connect the bleeder valve to a collector bottle.

4. Pressurise the system to 2 bar.

5. Open the bleeder valve on the slave cylinder.

6. Allow about 100 cm³ of brake fluid to flow out.

7. Close the bleeder valve.

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

9. Open the bleeder valve again.

10. Allow another 50 cm³ of brake fluid to flow out.

11. Close the bleeder valve.

12. After the bleeding process is complete, depress the clutch pedal several times to check for proper operation.

13. Reinstall the air filter housing if it was removed.

To remove and install the gear knob and associated parts on your VOLKSWAGEN JETTA 2011, follow these steps:

Removal:

1. Pull or carefully prise the gaiter with the centre console cover upwards, out of the centre console. For some variations, the gaiter must be levered off along the front section.

2. Pull the gaiter with the centre console cover upwards and turn it inside out over the gear knob.

3. Open the clamp at the base of the gear knob and pull the gear knob and gaiter off together as a single unit.

4. If necessary, remove the centre console cover from the console.

5. If fitted, pull off the noise insulation from the selector lever.

Installation:

1. First, insert the noise insulation if it was removed. Ensure the arrow on the insulation points in the direction of travel and the catches engage in the centre console.

2. If necessary, press the centre console cover into the centre console.

3. Turn the gaiter inside out.

4. Press the gear knob onto the selector lever until it stops.

5. Squeeze the new clamp together to secure the knob.

6. Press the gaiter with its cover back into the centre console until it clicks into place.

Removing the gearbox on your VOLKSWAGEN JETTA 2011 is a complex procedure. Ensure you have the necessary tools and support equipment before starting.

Preparation:

1. Obtain the anti-theft code for the radio.

2. With the ignition off, disconnect the battery. Remove the air filter housing, battery, and battery tray.

3. Disconnect the selector cables from the gearbox levers and tie them up out of the way.

4. Disconnect the hydraulic line from the slave cylinder, remove the slave cylinder, and secure it to the side. Do not disconnect the hydraulic line from the cylinder itself. Caution: Do not operate the clutch pedal.

5. Remove the earth strap and electrical connections from the starter, then remove the upper starter bolt.

6. Remove the upper engine-to-gearbox connecting bolts.

7. Set up an engine support bracket (e.g., -10 – 222 A-) to support the engine and gearbox assembly.

Under the Vehicle:

8. Raise the vehicle and remove the front left wheel and noise insulation tray.

9. Remove the front left wheel housing liner.

10. For vehicles with power steering, unbolt the brackets for the steering line from the gearbox.

11. Disconnect the electrical connector for the reversing light switch.

12. Remove the lower starter bolt and remove the starter.

13. Separate the exhaust system and remove the pipe bracket from the subframe.

14. Remove the heat shield above the right drive shaft.

15. Disconnect both drive shafts from the flange shafts, raise them as high as possible, and secure them.

16. Remove the pendulum support.

17. Remove the engine/gearbox connecting bolt near the right flange shaft.

18. Remove the cover plate, if fitted.

Lowering the Gearbox:

19. Remove the hexagon bolts for the left assembly mounting from the gearbox mounting.

20. Using the engine support bracket, slightly tilt the engine/gearbox assembly downwards to access the gearbox support bolts.

21. Position a gearbox jack (e.g., -V.A.G 1383A-) with a suitable support plate (e.g., -3282- and -3282/31-) under the gearbox.

22. Unbolt the gearbox support from the gearbox.

23. Remove the remaining engine-to-gearbox connecting bolts.

24. Press the gearbox off the engine’s dowel sleeves. Have a second person assist by pushing the engine forwards slightly.

25. Carefully lower the gearbox, guiding it past the subframe and power steering lines.

Installing the gearbox on your VOLKSWAGEN JETTA 2011 requires careful alignment and adherence to torque specifications. Always use new self-locking bolts.

Preparation and Lifting:

1. Clean all threaded holes of any residual locking fluid.

2. Check that the dowel sleeves for aligning the engine and gearbox are fitted in the cylinder block.

3. Ensure the intermediate plate is correctly seated on the engine.

4. Clean the input shaft splines and apply a thin coat of grease for clutch plate splines (-G 000 100-). The clutch plate must slide easily.

5. Place the gearbox on the gearbox jack with the appropriate support plate.

6. Have a second person ready to push the engine forwards slightly.

Installation and Bolting:

7. Carefully raise the gearbox, guiding it past the subframe and power steering line.

8. Align the gearbox to the engine and join them together.

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

10. Install the connecting bolt in the area of the right flange shaft and tighten to the specified torque.

11. After the gearbox is bolted to the engine, remove the gearbox jack.

12. Bolt the gearbox support onto the gearbox with new bolts and tighten to the specified torque.

13. Align the engine and gearbox in its installation position using the engine support bracket.

14. Screw in new hexagon bolts for the left engine/gearbox mounting and tighten. WARNING: Do not remove the engine support bracket until the left and right assembly mountings are tightened to the specified torque.

15. Screw in the upper engine/gearbox securing bolts and tighten.

Final Assembly:

16. Install the pendulum support with new bolts.

17. Attach the drive shafts to the gearbox.

18. Reinstall the starter, heat shields, exhaust system, and any other removed components.

19. Install the slave cylinder and connect the hydraulic line.

20. Install the selector cables, adjust the selector mechanism, and check the gear oil level.

21. Reinstall the wheel housing liner, noise insulation, and wheel.

22. In the engine bay, reinstall the air filter, battery tray, and battery. Connect the battery and follow the required procedure after reconnection.

The specified torques for installing the gearbox on your VOLKSWAGEN JETTA 2011 are as follows:

Gearbox to engine:

Item -A- refers to the dowel sleeves for centring.

Gearbox support to gearbox:

Renew bolts. Tighten to 40 Nm + 90°.

Gearbox support to gearbox mounting:

Renew bolts. Screw in all bolts hand-tight, then tighten to 60 Nm + 90°.

To check or fill the gear oil in your VOLKSWAGEN JETTA 2011, follow these procedures. You will need a torque wrench and a suitable bit (multi-point bit -3357- or a 17 mm Allen key bit, depending on the plug type).

Checking the Oil Level:

1. If necessary, remove the noise insulation panel to access the oil filler plug.

2. To check the gear oil, remove the oil filler plug located on the side of the gearbox.

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

4. If the level is correct, reinstall the oil filler plug and tighten to the specified torque.

Filling with Oil:

1. Remove the oil filler plug.

2. Fill with the correct specification gear oil until the level reaches the lower edge of the filler hole.

3. Screw the plug back in.

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 again.

6. Top up the gear oil to the lower edge of the filler hole, as the level may have dropped.

7. Reinstall the oil filler plug and tighten to the specified torque.

Torque Settings for Oil Filler/Drain Plugs:

• Oil plug with multi-point socket head: 25 Nm

• Oil plug with hexagon socket head: 30 Nm

After completing the check or fill, reinstall the noise insulation panel.

Renewing the flange shaft oil seals with the gearbox still in the vehicle is possible. The procedure is slightly different for the left and right sides.

Renewing Oil Seal for Left Flange Shaft:

1. Remove the left wheel and noise insulation.

2. Remove the lower part of the front left wheel housing liner.

3. Turn the steering to the left lock.

4. Unbolt the drive shaft from the flange shaft and secure it as high as possible.

5. Place a drip tray under the gearbox.

6. Remove the flange shaft securing bolt by screwing two bolts into the flange and counter-holding.

7. Pull out the flange shaft, which is under spring compression.

8. Pull out the old oil seal using a multi-purpose tool (e.g., -VW 771-) with puller hooks.

9. Before installing the new seal, half-fill the space between the sealing lip and dust lip with sealing grease (-G 052 128 A1-).

10. Drive in the new seal to its stop, being careful not to cant it. A tool like -T10082- can be used.

11. Insert the flange shaft.

12. Secure the flange shaft with a countersunk bolt and tighten to 25 Nm.

13. Reassemble the drive shaft, wheel housing liner, noise insulation, and wheel. Check the gear oil level and top up if necessary.

Renewing Seal for Right Flange Shaft:

The procedure is very similar to the left side, with the following differences:

• Turn the steering to the right to full lock.

• A different drift sleeve (e.g., -3158-) may be required to install the new seal.

• If a heat shield for the drive shaft is installed, it must be removed first.

It is necessary to readjust the differential on your VOLKSWAGEN JETTA 2011 when any of the following components are renewed:

• Gearbox housing

• Clutch housing

• Differential cage

• Tapered roller bearings of the differential

The adjustment procedure involves determining the correct thickness for shim S2 to set the correct bearing preload.

Adjustment Procedure:

1. Measure the depth of the bearing seat for the outer race in the gearbox housing. Depending on the depth (15.2 mm or 16.2 mm), a 1 mm shim (S1) may or may not be required under the outer race on the gear wheel side.

2. Press the tapered roller bearing outer races into the gearbox housing and clutch housing (with shim S1 if required).

3. Insert the differential (without shim S2) into the gearbox housing.

4. Fit the clutch housing and tighten 5 bolts to the specified torque.

5. Attach a dial gauge with an extension to measure the axial play of the differential. Set the gauge to “0” with 1 mm of preload.

6. Move the differential up and down and note the play indicated on the dial gauge (e.g., 1.50 mm).

7. Calculate the required thickness for shim S2 by adding a constant preload value to the measured play.

Example Calculation:

Measured value: 1.50 mm

+ Preload (constant): 0.35 mm

= Thickness of shim S2: 1.85 mm

8. Remove the clutch housing. Press out the tapered roller bearing outer race from the clutch housing.

9. Insert the correct S2 shim(s) into the clutch housing and press the tapered roller bearing outer race back in on top of it.

10. Re-fit the clutch housing and tighten the bolts to the specified torque setting.