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 5 Repairing clutch, in conjunction with one-piece flywheel Special tools and workshop equipment required ♦ Counterhold -3067- ♦ Centring mandrel -3190 A- ♦ Torque wrench - V.A.G 1331- ♦ Clutch plate spline grease - G 000 100- (Gearbox removed) Note ♦ Renew clutch plates and pressure plates with damaged or loose rivets. ♦ Select clutch plate and pressure plate according to ⇒ Electronic parts catalogue “ETKA” and engine codes. ♦ Check whether dowel sleeves for aligning engine and gearbox are fitted in cylinder block and install if necessary. ♦ If dowel sleeves are not fitted, difficulties shifting gears, clutch problems and possible noises from the gearbox (rattling of gears which are not engaged) could occur. 54 Rep. Gr.30 - Clutch
1 - Flywheel ❑ Removing and installing ⇒ Rep. Gr. 13 ❑ Ensure that centring pins fit tightly ❑ Keep contact surface for clutch lining free of grooves, oil and grease. 2 - Clutch plate ❑ Allocation ⇒ Electronic parts catalogue “ETKA” ❑ Installation position: spring cage faces pressure plate ❑ Centring ⇒ page 55 ❑ Lightly grease splines Note Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 5-speed manual gearbox 0A4 - Edition 04.2010 3 - Pressure plate ❑ Removing and installing ⇒ page 55 ❑ Check ends of diaphragm spring ⇒ page 56 ❑ Check spring connections and riveted connections ⇒ page 56 . 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. Note 4 - M6 bolt, 13 Nm, M7 bolt, 20 Nm ❑ Allocate according to ⇒ Electronic parts catalogue “ETKA” . ❑ Loosen or tighten diagonally and in steps Centring clutch plate and removing and installing pressure plate – Loosen or tighten bolts diagonally in stages. – Reverse position of counterhold -3067- when removing. Note Pressure plate contact surface and clutch plate lining must make full contact with flywheel. Tighten bolts diagonally and evenly to prevent damage to the centring holes in the pressure plate housing and the centring pins in the flywheel. 5. Repairing clutch, in conjunction with one-piece flywheel 55
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Golf Variant 2007 ➤ , Golf Varian
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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 45 and 46: - With ignition switched off, disco
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
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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
Page 103 and 104: ♦ Support bracket -10 - 222 A- Go
Page 105 and 106: - 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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