5-speed manual gearbox 0A4.pdf

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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 5-speed manual gearbox 0A4 - Edition 04.2010 4 General repair notes 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” ⇒ page 8 . They apply to this workshop manual. 4.1 Components 4.1.1 Gearbox ♦ 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 ⇒ Electronic parts catalogue “ETKA” . ♦ Capacity ⇒ page 2 ♦ If the gearbox is repaired, fill with gear oil. Capacity, gearbox completely dismantled Gearbox capacity, gearbox partially dismantled ⇒ page 112 1.9 l 1.7 l 4.1.2 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. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by Volkswagen AG. Volkswagen AG does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by Volkswagen AG. ♦ 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 ⇒ page 112 . 8 Rep. Gr.00 - Technical data
4.1.3 Locking devices ♦ Do not overstretch retaining rings. ♦ Always renew retaining rings which have been damaged or overstretched. ♦ Retaining rings must locate properly in grooves. Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 5-speed manual gearbox 0A4 - Edition 04.2010 ♦ Renew spring pins. Installation position: slit -A- should be in line with the line of force -arrow-. 4.1.4 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- . Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by Volkswagen AG. Volkswagen AG does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by Volkswagen AG. ♦ 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. 4.1.5 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. 4. General repair notes 9
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- Move gate selector lever back to
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Fitting position of cable tie for c
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- Bend open tabs -arrows- of select
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Carry out procedure as follows: Gol
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If dowel sleeves are not fitted, di
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♦ Inductive heater -VAS 6414- Gol
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Installation position, reverse gear
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Driving needle bearing in to stop G
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Identifying selector segments Dimen
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Pulling of large tapered roller bea
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Assembly of 1st and 2nd gear lockin
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Dismantling and assembling 3rd and
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Special tools and workshop equipmen
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- Press outer race of tapered rolle
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