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. ❑ Seals/O-rings are adapted to configuration of line connection ⇒ page 38 ❑ Allocation ⇒ Electronic parts catalogue “ETKA” 13 - Pipe/hose line ❑ Pipe ⇒ Item 11 (page 39) and hose/pipe line may be in one piece ❑ Allocation ⇒ Electronic parts catalogue “ETKA” ❑ To remove, remove battery and battery tray ⇒ Electrical system; Rep. Gr. 27 ; Removing and installing battery . 14 - Bracket ❑ Secured to retainer for ABS/EDL 15 - Bracket ❑ For ABS/EDL 16 - Seal / O-ring ❑ Pull onto line connection ❑ Insert with brake fluid ❑ Seals/O-rings are adapted to configuration of line connection ⇒ page 38 ❑ Allocation ⇒ Electronic parts catalogue “ETKA” 17 - Clip ❑ Pull out clip to stop to remove and install pipe/hose line 18 - Slave cylinder ❑ Removing and installing ⇒ page 40 19 - Flange bolt, 20 Nm 20 - Bleeder valve ❑ Bleeding clutch system ⇒ page 42 21 - Dust cap 22 - Gearbox 23 - Bracket Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 5-speed manual gearbox 0A4 - Edition 04.2010 24 - Hexagon bolt, 20 Nm 2.10 Removing and installing slave cylinder Special tools and workshop equipment required ♦ Torque wrench -V.A.G 1331- 2.10.1 Removing Carry out procedure as follows: – First check whether a coded radio is fitted. If so, obtain antitheft code. 40 Rep. Gr.30 - Clutch
– With ignition switched off, disconnect battery earth strap ⇒ Electrical system; Rep. Gr. 27 ; Disconnecting and connecting battery . – Remove complete air filter housing if it is near slave cylinder ⇒ Rep. Gr. 23 ; Repairing diesel direct injection system or ⇒ Rep. Gr. 24 ; Repairing injection system . – Remove securing clip -arrow 1- for gear selector cable from gearbox selector lever -A-. – Pull gear selector cable off pin. Metal relay lever – Remove securing clip -arrow 2- for gate selector cable from relay lever -B-. – Pull gate selector cable from pin. – Pull securing clip -arrow 3- off relay lever -B- and remove relay lever. Plastic relay lever – Remove relay lever together with cable end-piece from gearbox ⇒ page 73 . Continuation for all Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 5-speed manual gearbox 0A4 - Edition 04.2010 – Remove gearbox selector lever -A- by removing nut -arrow 4-. – Remove cable support bracket from gearbox -arrows-. – Then tie up gear selector cable and gate selector cable. – Remove retainer -B- from gearbox and pull off from pipe/hose line -A-. – Then remove gearbox support -arrow A-. – Lay a lint-free cloth under slave cylinder. – Pull clip for pipe/hose line out of slave cylinder to stop. 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. – Pull pipe/hose line out of slave cylinder and seal opening. – Remove slave cylinder -arrows B-. Caution Do not operate clutch pedal any more. 2.10.2 Installing Install in the reverse order of removal, observing the following: 2. Repairing clutch mechanism 41
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Page 3 and 4: Golf Variant 2007 ➤ , Golf Varian
Page 13 and 14: 4.1.3 Locking devices ♦ Do not ov
Page 19 and 20: ❑ Qty. 3 ❑ For mounting bracket
Page 23 and 24: Some cars have damping -arrow- on t
Page 29 and 30: The crash bar -1- in front of clutc
Page 35 and 36: - Push pipe/hose line or plastic li
Page 43: Golf Variant 2007 ➤ , Golf Varian
Page 47 and 48: ♦ Brake filling and bleeding equi
Page 49 and 50: ❑ Do not wash out bearing; wipe o
Page 53 and 54: Checking ends of diaphragm spring G
Page 59 and 60: 1 - Flywheel ❑ Removing and insta
Page 73 and 74: - Move gate selector lever back to
Page 77 and 78: Fitting position of cable tie for c
Page 83 and 84: - Bend open tabs -arrows- of select
Page 85 and 86: Carry out procedure as follows: Gol
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Golf Variant 2007 ➤ , Golf Varian
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Protected by copyright. Copying for
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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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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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