5-speed manual gearbox 0A4.pdf

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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. Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 5-speed manual gearbox 0A4 - Edition 04.2010 ♦ Inductive heater -VAS 6414- Note ♦ The output shaft is dismantled as follows: position separating device under 2nd gear synchromeshed gear ⇒ Item 21 (page 172) and press off as described in ⇒ page 174 . Remove retaining ring ⇒ Item 17 (page 172) . Then press off locking collar with synchro-hub for 1st and 2nd gear as described in ⇒ page 174 . ♦ When installing new gears or new input shaft, refer to ⇒ Electronic parts catalogue “ETKA” and technical data ⇒ page 2 . ♦ 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. 170 Rep. Gr.35 - Gears, shafts
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 5-speed manual gearbox 0A4 - Edition 04.2010 1 - Hexagon nut, 25 Nm and then turn 90° further ❑ 4 nuts for bearing support ❑ Always renew 2 - Clutch housing 3 - Shim ❑ For output shaft ❑ Adjustment overview ⇒ page 195 4 - Small tapered roller bearing outer race ❑ Removing ⇒ page 173 ❑ Pressing in ⇒ page 173 5 - Tapered roller bearing inner race small ❑ Pulling off ⇒ page 174 ❑ Pressing on ⇒ page 174 6 - Output shaft ❑ Adjusting ⇒ page 180 7 - Tapered roller bearing inner race large ❑ Pulling off ⇒ page 175 ❑ Pressing on ⇒ page 175 8 - Seal ❑ Place sealing rings (Qty. 4) on bearing support bolts ❑ Always renew 9 - Bearing support ❑ With large tapered roller bearing outer race and bolts ❑ Change outer race only together with large tapered roller bearing and bearing support 10 - Thrust washer ❑ Shoulder of thrust washer faces tapered roller bearing 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. 11 - Synchromeshed gear for 1st gear 12 - Needle bearing ❑ For 1st gear 13 - Synchro-ring ❑ (Inner ring for 1st gear) ❑ Installation position ⇒ page 175 ❑ Check for wear ⇒ page 175 ❑ Check lugs for scoring 14 - Outer ring for 1st gear ❑ Installation position ⇒ page 175 ❑ Check for wear ⇒ page 176 ❑ Renew if scored 2. Output shaft 171
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Golf Variant 2007 ➤ , Golf Varian
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4.1.3 Locking devices ♦ Do not ov
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❑ Qty. 3 ❑ For mounting bracket
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Some cars have damping -arrow- on t
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The crash bar -1- in front of clutc
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♦ Brake filling and bleeding equi
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❑ Do not wash out bearing; wipe o
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Checking ends of diaphragm spring G
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Carry out procedure as follows: Gol
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♦ Support bracket -10 - 222 A- Go
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5-speed manual gearbox 0A4.pdf

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