VOLKSWAGEN JETTA 2011 (07) PDF Document

To ensure flawless and successful gearbox repairs for the VOLKSWAGEN JETTA 2011 manual gearbox, 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.

The gearbox housing and clutch housing on the VOLKSWAGEN JETTA 2011 are made of a magnesium alloy.

Bolts and other components in direct contact with the gearbox have a surface matched to it.

If the incorrect components (bolts, nuts, washers and so on) are used, contact corrosion will develop, which will damage the gearbox housing and clutch housing.

Always install parts listed in the Electronic parts catalogue „ETKA“.

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 and rectify as necessary.

Before installing radial shaft seals, lightly oil the outer diameter and half-fill the space between the 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 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.

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-.

Loosen and tighten securing bolts and nuts for covers and housings diagonally.

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.

Ensure with threaded connections that contact surfaces as well as nuts and bolts are rewaxed only after assembly, if necessary.

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 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.

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. When reusing synchro-rings, always fit 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, 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 cone of synchromeshed gear for scoring and signs of abnormal wear.

Moisten 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 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.

After assembly, check synchromeshed gears for slight play, or for freedom of movement.

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.

Refer to Fault finding, power transmission; Rep. gr. 30 ; Complaints about clutch and clutch mechanism and Fault finding, power transmission; Rep. gr. 34 ; Complaints about selector mechanism.

Before disconnecting the battery, obtain the code for radio units having anti-theft coding.

With ignition switched off, disconnect the battery earth strap.

When reconnecting the battery, refer to Electrical system; Rep. gr. 27 ; Disconnecting and connecting battery.

Lubricate all bearings and contact surfaces with grease -G 000 450 02-.

I – Assembly overview – pedal cluster.

II – Assembly overview – hydraulics (LHD).

III – Assembly overview – hydraulics (RHD).

The specification for the hexagon nut (Item 15) is 25 Nm.

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 put steering wheel in highest position.

Remove driver side footwell cover and driver side left trim panel.

Remove bracket for knee airbag together with crash bar.

If fitted, remove damping -arrow- from lower area of clutch pedal mounting bracket by removing lock washers -A- for damping and pulling off damping.

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.

The required torque for the clutch pedal to mounting bracket is 25 Nm. You must renew self-locking nuts.

The required torque for the crash bar to steering column mounting bracket is 10 Nm.

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

Renew self-locking nuts.

Attach 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 equipped, return damping -arrow- on the clutch pedal mounting bracket to its installation position.

Install crash bar -1- in front of clutch pedal by screwing on and tightening nuts -2-.

Remove the mounting bracket by referring to the procedure for removing the clutch pedal.

Release the retainer for the master cylinder operating rod using pliers -T10005-.

Insert spacer -A- between the clutch pedal and stop and press the clutch pedal to the spacer. The length of the spacer should be about 40 mm (e.g., 1/2″ socket).

Release the securing bar -B- and pull the master cylinder out of the mounting bracket -arrow 1- and -arrow 2-.

Move the clutch pedal to the rest position at the stop.

Attach retainer -2- to the master cylinder operating rod -1-.

Insert spacer -A- between the clutch pedal and stop and press the clutch pedal to the spacer. The length of the spacer should be about 40 mm (e.g., 1/2″ socket).

Engage the master cylinder in the mounting bracket -arrow 1- and -arrow 2-.

Press the master cylinder operating rod -1- in the direction of the arrow until retainer -2- engages audibly in the clutch pedal.

Install the mounting bracket.

No special tools and workshop equipment are explicitly listed for this specific removal/installation in the text, although related sections may imply tools used for the master cylinder or general work.

Clamp off the supply hose to the master cylinder using hose clamp to 25 mm -3094-.

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

For 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-.

During the following work, ensure that no brake fluid lands on the longitudinal member or gearbox. If this does happen, clean the affected areas thoroughly.

Place a lint-free cloth under the master cylinder.

When performing work in the footwell, put cloths on the carpet to protect it from possible brake fluid spills.

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.

Install the supply hose with seal -2- onto the connection of the master cylinder -4- until 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.

Install the battery tray and battery if applicable to LHD vehicles.

Remove the complete air filter housing if it is near the battery.

Reconnect the battery and perform work required after connecting the battery.

Prefilling the system is not necessary.

Remove the complete air filter housing if it is near the battery.

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 -A- to the bleeder -arrow-.

Pressurise the system to 2 bar.

Open the bleeder valve about 1/4 turn.

Move the clutch pedal 15 to 20 times quickly by hand from stop to stop.

Close the bleeder valve.

After completing the bleeding procedure, when the pressure of 2 bar is released, operate the clutch pedal ten more times by foot.

Remove the complete air filter housing if it is near the battery.

To remove, release the securing clip -2- with a screwdriver or pointed object and pull the pipe/hose line or plastic line -4- off the bleeder -1-.

To install, push the pipe/hose line or plastic line onto the bleeder connection with O-ring -3- until the securing clip engages audibly.

Test the line by tugging on it.

Bleed the clutch system.

The slave cylinder and release bearing are a single component and can only be renewed together.

To remove, remove the gearbox.

Release the securing clip -2- with a screwdriver or pointed object and pull the bleeder -4- off the slave cylinder -1-.

Remove the bolts -arrows-.

Remove the slave cylinder together with the release bearing -A-.

To install, tighten the securing bolts for the slave cylinder only in small stages, otherwise the tabs with the bolt holes may break off.

Bolt on the slave cylinder with release bearing as indicated for Item 4.

Check the O-ring -3- on the slave cylinder for damage.

Press the bleeder -4- onto the slave cylinder connection -1- until the securing clip -2- engages audibly.

Check by pulling on the bleeder.

Install the gearbox.

Bleed the clutch system.

The special tools and workshop equipment required are:

• Counterhold -3067-
• Torque wrench -V.A.G 1331-
• Centring mandrel -T10097-
• Grease for clutch plate splines -G 000 100-
• For engines having a crankshaft of smaller diameter or having needle bearings in the crankshaft, centring mandrel -3176-.

A clutch manufactured by either „Sachs“ or „LuK“ may be installed.

The make of the clutch can be determined as follows with the clutch installed:

Remove noise insulation.

Remove noise insulation from engine sump if necessary.

Some notches -arrows- are located in the lower region of the sump between the engine -A- and gearbox -B-.

Check the outer contour of the flywheel through these notches.

In addition, a small cover plate -A- can be removed -arrows- to enable inspection of the flywheel’s outer contour.

If the outer contour is round -arrows- this indicates a Sachs clutch = -A-.

If the outer contour has edges -arrows 1- and, in addition, a circumferential crease -arrow 2- this indicates a LuK clutch = -B-.

The lettering „Getriebeseite“ faces the gearbox.

Wear to half the thickness of the diaphragm spring -arrows- is permitted.

The lettering „Getriebeseite“ (gearbox side) faces the gearbox.

The lettering „Getriebeseite“ -arrow- faces the gearbox.

Check spring connections -arrows A- for damage and riveted connections -arrows B- for secure seating.

Wear to half the thickness of the diaphragm spring -arrows- is permitted.

1 – Gearbox selector lever with damper weight.

2 – Relay lever engages in guide rail of gearbox selector lever via shoe -arrow-.

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

The holes in the cable end-pieces have different diameters.

Table of Cable end-piece dimensions for VOLKSWAGEN JETTA 2011:

For gear selector cable end-piece support pin with smaller diameter from 06.06 on the VOLKSWAGEN JETTA 2011:

When fitting the gearbox selector lever, ensure that the gap -arrow A- is aligned with the master spline -arrow B-.

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

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

Remove the complete air filter housing if the 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 the stop in the direction of arrow 1- and then turn to the left to lock in the direction of arrow 2-.

Secure the selector shaft as follows:

• Press the selector shaft down in the direction of arrow 1-.
• While pressing down the selector shaft, turn the angled rod -A- in the direction of arrow 3- upwards and at the same time press it in the direction of arrow 2- until it engages in the selector shaft.

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 the stop in the direction of arrow 1-. The spring presses the locking mechanism into the original position in the direction of arrow 2-.

Now turn the angled rod -A- back to the original position in the direction of arrow 2-. During this procedure, the angled rod -A- must be pressed out of the gearbox in the direction of arrow 1-.

Pull the locking pin -T10027 A- out of holes -A- and -B-.

If noise insulation was present, install it.

Install the gaiter with the selector knob and frame.

Check that the selector shaft moves freely.

If removed, reinstall the complete air filter housing.

Functional check:

• 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.

The special tools and workshop equipment required are:

• Support bracket -10 – 222 A-
• Adapter -10-222 A /8-
• Adapter -10-222 A /3-
• Adapter -10-222 A /18-
• Gearbox support -3282-

The following are required:

• Support elements for gearbox (determine when setting the adjustment plate on the gearbox support)
• Adjustment plate -3282/33-
• Gearbox lifting tackle -3336- for transporting the gearbox
• Torque wrench -V.A.G 1331-
• Torque wrench -V.A.G 1332-
• Engine and gearbox jack -V.A.G 1383 A-

Set up the support bracket -10-222 A- in front of the bonnet support using adapters -10-222 A /3-, -10-222 A /8-, and -10-222 A /18-.

Position adapter -10-222 A /8- on the upper longitudinal carrier, directly before the elevation (-arrow 1-) next to the bolt (-arrow 2-).

Connect bracket -T10346- to the support bracket.

Attach the spindles in the left engine support eyes.

Take up the weight of the engine/gearbox assembly and support the bracket on the spindles.

With the vehicle standing on its wheels, loosen the front left flange bolt -arrow- 90° at most, or the wheel bearing will be damaged.

Remove the upper engine/gearbox connecting bolts -arrows-.

Then remove the upper securing bolt on the starter.

Bolt bracket -T10346- to the rear of the 3 mounting holes for the battery tray using a collar bolt M 6 x 80 or a securing bolt for the battery tray.

If there are hose and cable connections in the area of the engine support eye for support bracket -10-222 A- , remove these now.

Tilt the gearbox in the area of the differential using the spindles of the gearbox support -3282-.

The differential must face upwards.

Guide the gearbox with the differential -A- over the subframe and swing it out.

Observe the longitudinal member -arrows-.

Then carefully lower the gearbox.

Be careful of all lines when lowering the gearbox.

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

The number of visible holes is 6.

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

Set the gearbox aside, for example in a transport container.

Bolt the gearbox lifting tackle -3336- to the clutch housing.

Refer to the procedure for “Removing gearbox” for required special tools.

Renew self-locking nuts and bolts.

Renew bolts which must be tightened further to a torque angle.

All cable ties which were opened or cut during removal must be renewed at the same points.

Clean the input shaft splines and, on a used clutch plate, 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.

If the gearbox is to be renewed, the gearbox selector lever and relay lever must be transferred to the new gearbox.

All threaded holes into which self-locking bolts are to be screwed must be cleaned of residual locking fluid carefully with a thread tap.

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 hooked into the sealing flange and pushed onto the dowel sleeves -arrows-.

Check the release bearing for wear. If necessary, renew the slave cylinder with release bearing.

Table of Gearbox to Engine Bolt Torques for VOLKSWAGEN JETTA 2011:

For items -A- and -B- (dowel sleeves), renew bolts -1- to -5-.

Small cover plate for flywheel on intermediate plate: 10 Nm.

For the Gearbox bracket -1- to gearbox, renew bolts, and tighten bolts -arrows- to 60 Nm and turn 90° further.

For Gearbox to body, renew bolts, and tighten bolts -arrows- to 60 Nm and turn 90° further.

Install engine and gearbox mounting free of tension.

The special tools and workshop equipment required are:

• Support bracket -10 – 222 A-
• Adapter -10-222 A /8-
• Adapter -10-222 A /3-
• Adapter -10-222 A /18-
• Gearbox support -3282-

Set up the support bracket -10-222 A- in front of the bonnet support using adapters -10-222 A /3-, -10-222 A /8-, and -10-222 A /18-.

Position adapter -10-222 A /8- on the upper longitudinal carrier, directly before the elevation (-arrow 1-) next to the bolt (-arrow 2-).

Connect the bracket -T10346- to the support bracket.

Take up the weight of the engine/gearbox assembly and support the bracket on the spindles.

With the vehicle standing on its wheels, loosen the front left flange bolt -arrow- 90° at most, or the wheel bearing will be damaged.

Remove the bracket -1- from the gearbox -arrows-.

Remove the relay lever together with the cable end-piece.

Remove the gearbox selector lever from the selector shaft.

If a small cover plate -A- for the flywheel is present, remove it -arrows-.

Remove the lower engine/gearbox connecting bolt -1-.

Loosen the engine/gearbox connecting bolts -3- and leave them installed just hand-tight.

Now turn the gearbox upwards near the differential, using the spindle of the gearbox support -3282- , and downwards near the 6th gear.

Guide the gearbox with the differential -A- over the subframe.

The right flange shaft must then be guided past the flywheel -arrow 2-.

Observe the intermediate plate -arrow 1-.

The right flange shaft -1- must be guided past the bolt hole of the engine -2-.

When doing this, use the spindles of the gearbox support -3282- to adjust the position of the gearbox so that the longitudinal member -arrows- is not touched.

Then turn the gearbox to the installation position via the spindles of the gearbox support -3282-.

Table of Gearbox to Engine Bolt Torques for VOLKSWAGEN JETTA 2011:

For items -A- and -B- (dowel sleeves), renew bolts -1- to -5-.

Small cover plate for flywheel on intermediate plate: 10 Nm.

For the Gearbox bracket -1- to gearbox, renew bolts, and tighten bolts -arrows- to 60 Nm and turn 90° further.

For Gearbox to body, renew bolts, and tighten bolts -arrows- to 60 Nm and turn 90° further.

Install engine and gearbox mounting free of tension.

Gearbox oil specification is available in the Electronic parts catalogue „ETKA“.

Remove noise insulation.

To check the gear oil, remove the oil plug -arrow-.

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

Screw in the plug -arrow- with a new seal.

Tighten the bolt -arrow- to the specified torque.

When filling with oil, note the following:

• Remove the oil plug -arrow-.
• Fill with gear oil to the lower edge of the filler hole.
• Screw in the plug -arrow- with a new seal.
• Tighten the bolt -arrow- to the specified torque.

Install the noise insulation.

Various versions of oil filler and drain plugs for the VOLKSWAGEN JETTA 2011 manual gearbox:

If repairs have been carried out on the gearbox, it is necessary to readjust the output shaft for 1st through 4th gear, output shaft for 5th, 6th and reverse gear, or the differential only if components have been renewed which have a direct effect on the adjustment of the gearbox. To prevent unnecessary adjustments, refer to the following table:

Table of Adjustment Requirements for VOLKSWAGEN JETTA 2011 Gearbox Repairs:

Specified bearing preload is obtained as follows:

Subtract the measured value from the inserted shim. Add a constant value for preload (0.20 mm).

Example for VOLKSWAGEN JETTA 2011:

Installed shim: 1.70 mm

Measured value: 0.14 mm

Preload (constant): 0.20 mm

Shim thickness: 1.76 mm

Table of Shim Thicknesses (mm) for VOLKSWAGEN JETTA 2011:

The various thicknesses make it possible to achieve the exact shim thickness required.

Determine the part number of the shim according to the Electronic parts catalogue „ETKA“.

Set up measuring tools and secure to the clutch housing using bolt -arrow-.

Set the dial gauge (3 mm measuring range) to „0“ with 1 mm preload.

Loosen the clutch housing/gearbox housing securing bolts diagonally until the bolts release the gearbox housing or output shaft.

If the correct shim has been selected, the dial gauge will indicate a value between 0.15 mm to 0.25 mm.

The specified bearing preload is attained by subtracting the measured value from the inserted shim and adding a constant value for preload (0.20 mm).

Example for VOLKSWAGEN JETTA 2011:

Installed shim: 1.70 mm

Measured value: 0.25 mm

Preload (constant): 0.20 mm

Shim thickness: 1.65 mm

Table of Shim Thicknesses (mm) for VOLKSWAGEN JETTA 2011:

Determine the part number of the shim according to the Electronic parts catalogue „ETKA“.

Set up measuring tools.

Set the dial gauge (3 mm measuring range) to „0“ with 1 mm preload.

Loosen the clutch housing/gearbox housing securing bolts diagonally until the bolts release the gearbox housing or output shaft.

If the correct shim has been selected, the dial gauge will indicate a value between 0.15 mm to 0.25 mm.

The specified bearing preload is obtained by adding a constant value for preload (0.25 mm) to the reading obtained.

Example for VOLKSWAGEN JETTA 2011:

Measured value: 0.70 mm

Preload (constant): 0.25 mm

Thickness of shim = 0.95 mm

Remove the gearbox housing.

Pull the tapered roller bearing outer race from the gearbox housing.

Determine the part number of the shim according to the Electronic parts catalogue „ETKA“.

Insert shims of the determined thickness, thickest shim first.

Table of Shim Thicknesses (mm) for VOLKSWAGEN JETTA 2011:

If the size of shim required is larger than those listed in the table, insert two shims totalling the correct figure. When using two shims, install the thicker one first.

The various thicknesses make it possible to achieve the exact shim thickness required.

Determined shim installed.

Set up measuring tools.

Press the tapered roller bearing outer race with washer into the clutch housing.

Fit the differential into the clutch housing.

Fit the gearbox housing and tighten 5 bolts to the specified torque.

Press the differential in the direction of the clutch housing while turning it eight times.

Press the differential in the direction of the gearbox housing while turning it eight times.

Attach the dial gauge and set it 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).

Press the outer race in again and tighten the gearbox housing to the specified torque.