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 3.2 Adjusting differential Special tools and workshop equipment required ♦ Universal dial gauge bracket -VW 387- ♦ End dimension plate - VW 385/17- ♦ Press tool -VW 407- ♦ Thrust plate -30 - 205- ♦ Torque wrench - V.A.G 1331- ♦ -1- Internal puller -Kukko 21/7- ♦ -4- Counter support -Kukko 22/2- ♦ Dial gauge It is necessary to readjust the differential when the following components are renewed: ♦ Gearbox housing ♦ Clutch housing ♦ Differential cage or the ♦ Tapered roller bearing of differential Adjustment overview ⇒ page 195 . Carry out procedure as follows: 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 tapered roller bearing outer race without shim into gearbox housing using thrust piece -30 - 205- ⇒ page 201 . Note Inner and outer tapered roller bearing races are paired. Do not interchange! 204 Rep. Gr.39 - Final drive - differential
– Press outer race of tapered roller bearing into clutch housing using thrust plate -30 - 205- ⇒ page 200 . – Fit differential into clutch housing. – Set gearbox housing in place and tighten 5 bolts to 25 Nm. – Attach dial gauge and set to “0” with 1 mm preload. Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 5-speed manual gearbox 0A4 - Edition 04.2010 – Move differential up and down. Read and note play indicated on dial gauge. (Example: 0.70 mm.) 3.2.1 Determining thickness of shim The specified bearing preload is obtained by adding a constant value for preload (0.25 mm) to the reading obtained. Example: Measured value 0.70 mm + Preload (constant) 0.25 mm Thickness of shim = Example: 0.95 mm Bearing play, measured value Thickness of shim according to table Table of shims 0.70 mm 0.95 mm Bearing play bearing clearance (mm) 0.303 … 0.449 0.450 … 0.499 0.500 … 0.549 0.550 … 0.599 0.600 … 0.649 0.650 … 0.699 0.700 … 0.749 0.750 … 0.799 0.800 … 0.849 0.850 … 0.899 0.900 … 0.949 0.950 … 0.999 1.000 … 1.049 1.050 … 1.099 1.100 … 1.149 Shim Thickness (mm) 0.650 0.700 0.750 0.800 0.850 0.900 0.950 1.000 1.050 1.100 1.150 1.200 1.250 1.300 1.350 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. 1.150 … 1.199 1.400 Note Allocate shims according to ⇒ Electronic parts catalogue “ETKA” . 3. Differential 205
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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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Driving needle bearing in to stop G
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