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 – Remove lower part of front left wheel housing liner or front left wheel housing liner ⇒ General body repairs, exterior; Rep. Gr. 66 ; Wheel housing liner . – Turn steering to left lock. – Disconnect drive shaft from flange shaft ⇒ Running gear, axles, steering; Rep. Gr. 40 ; Repairing drive shaft; Removing and installing drive shafts . – Raise drive shaft as high as possible and secure. Take care not to damage paint on drive shaft in the process. – Place drip tray under gearbox. – Remove flange shaft securing bolt by screwing 2 bolts into flange and counterholding flange shaft with a lever. – Pull out flange shaft with compression spring. – Pull out flange shaft oil seal using multipurpose tool -VW 771- and puller hooks -VW 771/37- . 1.1.2 Installing – Drive in new seal to stop, being careful not to cant seal. – Half-fill space between sealing lip and dust lip with sealing grease -G 052 128 A1- . – Insert flange shaft. – Secure flange shaft with countersunk bolt. – Attach drive shafts to gearbox ⇒ Running gear, axles, steering; Rep. Gr. 40 ; Repairing drive shaft; Removing and installing drive shafts . – Check gear oil ⇒ page 112 . – Install lower part of front left wheel housing liner or front left wheel housing liner ⇒ General body repairs, exterior; Rep. Gr. 66 ; Wheel housing liner . – Install noise insulation ⇒ General body repairs, exterior; Rep. Gr. 50 ; Noise insulation . – Install wheel ⇒ Running gear, axles, steering; Rep. Gr. 44 ; Torque settings for mounting wheels . 188 Rep. Gr.39 - Final drive - differential
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. 1.1.3 Torque setting Flange shaft to gearbox (countersunk bolt) ⇒ Item 12 (page 199) 1.2 Distinguishing seals for right flange shaft The seal -1- for the right flange shaft is located in a sleeve -2-. There are different versions. Seal -1- and sleeve -2- are two parts. Identification: notches along circumference of sleeve -arrow-. Renew seal ⇒ page 189 . Seal -1- and sleeve -2- are one piece. Identification: no notches in sleeve. Renew seal and sleeve together ⇒ page 192 . Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 5-speed manual gearbox 0A4 - Edition 04.2010 1.3 Renewing seal (two-part seal and sleeve for right flange shaft) Special tools and workshop equipment required ♦ Thrust piece -T10160- ♦ Assembly tool -3253/2- 1. Renewing flange shaft oil seals with gearbox installed 189
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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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♦ Inductive heater -VAS 6414- Gol
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Installation position, reverse gear
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