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 Pulling off small tapered roller bearing inner race A - Vice with protective jaw covers – Fit adapter and tighten behind bearing rollers, then turn bearing and retighten gripping device. Pressing on small tapered roller bearing inner race Pressing off 3rd and 4th gear synchro-hub and locking collar, 2nd, 3rd and 4th gear synchromeshed gears with sleeve for gearbox housing needle bearing A - Splitter, 22 … 115 mm , e.g. -Kukko 17/2- B - Hexagon bolt M10 x 20, 17 mm AF Note Support splitter so that the 1st and 2nd gear locking collar is not pulled off at the same time. Pressing off locking collar with synchro-hub and bearing support – First remove retaining ring -arrow-. 174 Rep. Gr.35 - Gears, shafts
Pulling of large tapered roller bearing inner race -A- Vice jaw protectors Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 5-speed manual gearbox 0A4 - Edition 04.2010 – Before fitting puller, insert a M10 × 20 hexagon bolt in the output shaft drilling. Pressing on large tapered roller bearing inner race -A- Thrust washer – Fit thrust washer before pressing on inner race. Shoulder faces inner race. Installation position of outer ring, inner ring and synchro-ring for 1st gear – Place inner ring -A- on synchromeshed gear for 1st gear. Angled lugs -arrows 1- face outer ring -B-. – Fit outer ring -B-. Lugs -arrows 2- engage in notches -arrows 3- of synchromeshed gear. – Fit synchro-ring -C-. Notches -arrows 4- engage in lugs -arrows 1- of inner ring -A-. Note 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. If components are not to be renewed, ensure that they are matched with their original gears. Checking 1st and 2nd gear inner ring for wear – Press inner ring onto cone of synchromeshed gear and measure gap -a- using a feeler gauge. Gap -a- Installation (new) dimension Wear limit 1st and 2nd gears 0.75 … 1.25 mm 0.3 mm 2. Output shaft 175
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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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- Push pipe/hose line or plastic li
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- With ignition switched off, disco
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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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1 - Flywheel ❑ Removing and insta
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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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♦ Support bracket -10 - 222 A- Go
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- Remove cables -1- from transporta
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If dowel sleeves are not fitted, di
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Page 181 and 182: Assembly of 1st and 2nd gear lockin
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Page 209 and 210: - Press outer race of tapered rolle
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