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 4.1 Removing gearbox, Jetta 2011 with 2.5 l - 125 kW engine . . . . . . . . . . . . . . . . . . . . . . . . 98 4.2 Installing gearbox, Jetta 2011 with 2.5 l - 125 kW engine . . . . . . . . . . . . . . . . . . . . . . . . . . 104 5 Transporting gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111 6 Checking and topping up gear oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112 6.1 Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112 6.2 Draining gear oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113 6.3 Filling with gear oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114 7 Dismantling and assembling gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115 7.1 Overview - gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115 7.2 Assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116 7.3 Removing and installing cover for gearbox housing and 5th gear . . . . . . . . . . . . . . . . . . . . 117 7.4 Removing and installing gearbox housing and selector mechanism . . . . . . . . . . . . . . . . . . 118 7.5 Removing and installing input shaft, output shaft, differential and selector forks . . . . . . . . 119 7.6 Assembly sequence - removing and installing cover for gearbox housing and 5th gear . . 120 7.7 Assembly sequence - Dismantling and assembling gearbox completely . . . . . . . . . . . . . . 126 8 Repairing gearbox housing and clutch housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141 9 Repairing selector unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147 10 Dismantling and assembling selector forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150 35 - Gears, shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155 1 Input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155 1.1 Dismantling and assembling input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155 1.2 Adjusting input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162 2 Output shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167 2.1 Dismantling and assembling output shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167 2.2 Adjusting output shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180 3 Reverse shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184 3.1 Dismantling and assembling reverse shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184 39 - Final drive - differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187 1 Renewing flange shaft oil seals with gearbox installed . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187 1.1 Renewing oil seal for left flange shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187 1.2 Distinguishing seals for right flange shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189 1.3 Renewing seal (two-part seal and sleeve for right flange shaft) . . . . . . . . . . . . . . . . . . . . . . 189 1.4 Renewing seal and sleeve together (one-piece seal and sleeve for right flange shaft) . . . . 192 2 Adjustment overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195 3 Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196 3.1 Dismantling and assembling differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196 3.2 Adjusting differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204 ii Contents
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. 00 – Technical data 1 Gearbox identification The 5-speed manual gearbox 0A4 is installed in the Jetta 2005 ▸, Bora 2006 ▸, Golf Variant 2007 ▸, Bora Sportwagen 2008 ▸, Golf Variant 2010 ▸ and Jetta 2011 ▸ in conjunction with a 4-cylinder engine. Allocation ⇒ page 2 . 1.1 Location on gearbox Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 5-speed manual gearbox 0A4 - Edition 04.2010 Codes and production date -arrow 1- manual gearbox 0A4 -arrow 2- Manual gearbox 0A4 -arrow 2- Codes and production date of gearbox Example: FNE 10 11 3 I I I I I I I I Identification code Day Month Year (2003) of manufacture Additional data provide information about the production facility. Note The gearbox code also appears on the vehicle identification plates. 1. Gearbox identification 1
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Page 13 and 14: 4.1.3 Locking devices ♦ Do not ov
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1 - Flywheel ❑ Removing and insta
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Golf Variant 2007 ➤ , Golf Varian
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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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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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