5-speed manual gearbox 0A4.pdf

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• Half sleeve -T10309/1- must be positioned beneath synchroring.
– If necessary, half sleeve must be pressed to end position.
– Turn half sleeve -T10309/1- to opposite side
-direction of arrow-.
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤
5-speed manual gearbox 0A4 - Edition 04.2010
– Set threaded insert -T10309/3- in half shell .
– Fit second half shell -T10309/1- now and set tube -T10309/2-
onto assembly.
– After pulling off synchro-hub, examine for damage.
– Renew 5th gear synchro-ring.
– Remove 5th gear synchromeshed gear with needle bearing.
– Pull off gear wheel for 5th gear (here shown on a different
gearbox).
– First insert puller hook -A-.
B - Thrust plate -40 - 105- or hexagon bolt M10 x 20, 17 mm AF
Note
♦ When pulling off gear wheel, ensure that hooks do not bend
outwards. After pulling off 5th gear wheel, examine for damage.
♦ Heat gear wheel slightly with hot air blower -V.A.G 1416- if
necessary.
7.6.2 Installing cover for gearbox housing and
5th gear
Install 5th gear ⇒ page 137 .
– Install cover for gearbox housing and tighten bolts to specified
torques ⇒ page 117 .
– Fit clutch release lever and release bearing ⇒ page 44 .
– Fill with gear oil ⇒ page 92 .
7. Dismantling and assembling gearbox 125