Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed automatic gearbox 09G - Edition 04.2010 General repair notes To ensure flawless and successful gearbox repairs, the greatest care and cleanliness as well as the use of good and proper tools are essential.
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed automatic gearbox 09G - Edition 04.2010 The catalogue is also available on ⇒ CD-ROM and can be ordered the usual way from Bertelsmann.
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed automatic gearbox 09G - Edition 04.2010 1.14 Guided fault finding, vehicle self-diag‐ nosis and testing Before making repairs to the automatic gearbox, determine the cause of the fault as precisely as possible with the aid of “guided...
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed automatic gearbox 09G - Edition 04.2010 37 – Controls, housing Connecting “tester” Volkswagen offers various devices such as ♦ Vehicle diagnosis, testing and information system -VAS 5051- ♦...
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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed automatic gearbox 09G - Edition 04.2010 – Switch on “tester” -arrow-. The “tester” is ready for use when it is possible to choose between...
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed automatic gearbox 09G - Edition 04.2010 Electrical and electronic components and their locations 1 - Control unit for automatic gearbox -J217- ❑ The control unit trans‐...
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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed automatic gearbox 09G - Edition 04.2010 Automatic gearbox control unit -J217- -A- in Jetta 2011 ▸ with 2.0 l - 85 kW engine Location: control unit is located in plenum chamber on right.
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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed automatic gearbox 09G - Edition 04.2010 Wiring harness, 8-pin ♦ Wiring harness for senders ♦ With integrated gearbox oil temperature sender -G93- -arrow- Location: wiring harness is attached to valve body in gearbox.
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed automatic gearbox 09G - Edition 04.2010 – Push lever -3- onto selector shaft -4-. – Use lever -3- to shift gearbox to “P” position, i.e. press lever -3- back (opposite direction of travel) to stop.
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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed automatic gearbox 09G - Edition 04.2010 Carry out procedure as follows: – Place setting gauge on selector shaft -2- and turn multifunction switch -1- until setting gauge engages in lug on multifunction switch connector.
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed automatic gearbox 09G - Edition 04.2010 Selector mechanism up to 02.2009 WARNING Before working on vehicle with engine running, move selector lever into position “P” and apply handbrake.
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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed automatic gearbox 09G - Edition 04.2010 – Remove selector lever cable. Remove selector housing from selector lever cable. Installing Do not grease cable.
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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed automatic gearbox 09G - Edition 04.2010 – Also clip selector lever cable into bracket. Make sure that bracket does not make contact with ATF cooler.
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed automatic gearbox 09G - Edition 04.2010 Checking selector lever cable Brief description To check ease of movement of selector lever cable, it must be removed from the gearbox and the free end must be placed so that it does not bump against anything.
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed automatic gearbox 09G - Edition 04.2010 ♦ Parts of the assembly mounting have been removed and in‐ stalled. ♦ The cable itself or the selector mechanism has been removed and installed.
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed automatic gearbox 09G - Edition 04.2010 – Press yellow plastic part -arrow- from right to left. Lever can now be moved from position “P”.
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed automatic gearbox 09G - Edition 04.2010 In vehicles with button -arrow- at front on knob Button -arrow- is not allowed to be pressed in when knob is being fitted and removed.
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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed automatic gearbox 09G - Edition 04.2010 Selector lever is locked and cannot be shifted out of “P” position when the button is pressed. Solenoid for selector lever lock blocks selector lever.
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– Remove upper engine/gearbox connecting bolts. Bolts may be installed with a socket -T10179- . However, note lower torque setting when tightening ⇒ page 54 6. Removing and installing gearbox, Jetta 2005 ▸, Bora 2006 ▸, Golf Variant 2007 ▸, Jetta Wagon 2008 ▸...
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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed automatic gearbox 09G - Edition 04.2010 – If present, remove earth strap from bracket -A-. – Remove 2 securing bolts for gearbox mounting on bracket -A- and 4 bolts for bracket on gearbox.
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– Remove lower engine/gearbox connecting bolts. – Leave an easily accessible bolt installed for safety. – Start with two lower bolts. 6. Removing and installing gearbox, Jetta 2005 ▸, Bora 2006 ▸, Golf Variant 2007 ▸, Jetta Wagon 2008 ▸...
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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed automatic gearbox 09G - Edition 04.2010 Note On some smaller engines up to 1.6 litres, one of the lower -bolts- can be backed out of the gearbox but not removed from the hole.
Battery, battery carrier, air filter and engine cover are removed “from above”. Engine and gearbox must then be supported so that left assembly mounting can be removed. 6. Removing and installing gearbox, Jetta 2005 ▸, Bora 2006 ▸, Golf Variant 2007 ▸, Jetta Wagon 2008 ▸...
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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed automatic gearbox 09G - Edition 04.2010 Noise insulation is removed and drive shafts are pressed off “from below”. Gearbox is lowered using gearbox jack.
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Before sending back removed gearbox in the usual manner, secure log to gearbox. – Move selector lever to position “P” position. – Raise vehicle. 6. Removing and installing gearbox, Jetta 2005 ▸, Bora 2006 ▸, Golf Variant 2007 ▸, Jetta Wagon 2008 ▸...
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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed automatic gearbox 09G - Edition 04.2010 – Depress brake pedal to remove bolt for left drive shaft -arrow- (second mechanic required). Note After this, do not set vehicle on the ground any more ⇒...
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– Remove noise insulation tray. – Remove lower part of left wheel housing liner. – If present, remove heat shield above right drive shaft -arrows-. 6. Removing and installing gearbox, Jetta 2005 ▸, Bora 2006 ▸, Golf Variant 2007 ▸, Jetta Wagon 2008 ▸...
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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed automatic gearbox 09G - Edition 04.2010 – Unbolt suspension link from wheel bearing housing on both sides. – Press both drive shafts out of gearbox. This procedure is de‐...
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– Turn cap -1- in -direction of arrow- and remove. – Remove six -torque converter nuts- with insert -V/175- . Note Continue turning the engine carefully! 6. Removing and installing gearbox, Jetta 2005 ▸, Bora 2006 ▸, Golf Variant 2007 ▸, Jetta Wagon 2008 ▸...
– Carry out basic settings. To do this – Connect vehicle diagnosis, testing and information system - VAS 5051- and then select “Perform basic settings” under Guided functions 6. Removing and installing gearbox, Jetta 2005 ▸, Bora 2006 ▸, Golf Variant 2007 ▸, Jetta Wagon 2008 ▸...
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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed automatic gearbox 09G - Edition 04.2010 – In order to remove selector lever cable from gearbox, first re‐ lease cable -arrows 1- and then remove it from cable support bracket -arrow 2-.
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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed automatic gearbox 09G - Edition 04.2010 – If present, remove earth strap from bracket -A-. – Remove 2 securing bolts for gearbox mounting on bracket -A- and 4 bolts for bracket on gearbox.
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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed automatic gearbox 09G - Edition 04.2010 – Unbolt suspension link from wheel bearing housing on both sides. Torque settings ⇒ Rep. Gr. 40 ; Assembly overview - subframe, anti-roll bar, suspension links .
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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed automatic gearbox 09G - Edition 04.2010 – Now remove assembly mounting bracket. To do this, lower engine and gearbox slightly via support bracket -10 - 222 A- spindles.
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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed automatic gearbox 09G - Edition 04.2010 – Depress brake pedal to remove bolt for left drive shaft -arrow- (second mechanic required). Note After this, do not set vehicle on the ground any more ⇒...
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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed automatic gearbox 09G - Edition 04.2010 – Press both drive shafts out of gearbox. This procedure is de‐ scribed in ⇒ Rep. Gr. 40 ; Repairing drive shafts; Removing and installing drive shafts .
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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed automatic gearbox 09G - Edition 04.2010 – Remove ⇒ pendulum support, first bolt -A- and then bolts -B-. – Turn cap -1- in direction of arrow and remove.
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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed automatic gearbox 09G - Edition 04.2010 – If present, remove earth strap from bracket -A-. – Remove 2 securing bolts for gearbox mounting on bracket -A- and 4 bolts for bracket on gearbox.
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed automatic gearbox 09G - Edition 04.2010 Transporting gearbox Special tools and workshop equipment required ♦ Shackle -10 - 222 A /12- Shackle 10-222 A/12 can be used to transport the automatic gearbox and set up gearbox support 3282.
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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed automatic gearbox 09G - Edition 04.2010 – Use a small screwdriver to pry out securing bolts of connectors on solenoid valves -2- to -9- carefully and pull off connectors.
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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed automatic gearbox 09G - Edition 04.2010 – Separate connectors -2- and -5-. – Unscrew bracket bolts -3-. – If a connector is damaged, the wiring harness or the gearbox input speed sender -G182- or the gearbox output speed send‐...
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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed automatic gearbox 09G - Edition 04.2010 – Remove selector lever -1- from selector shaft. – In the process, carefully grip selector lever -1- with pliers -2- so that torque is not transferred to multifunction switch -F125- .
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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed automatic gearbox 09G - Edition 04.2010 – When removing valve body, secure damper piston -2- to pre‐ vent it from falling out or remove together with spring if nec‐...
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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed automatic gearbox 09G - Edition 04.2010 Wiring harnesses -1-, -3-, -4- and -5- are not allowed to be trapped by valve body.
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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed automatic gearbox 09G - Edition 04.2010 Cables -3-, -5- and -9- are not allowed to be trapped. – Tighten new bolts -arrows-, -arrows A- and -arrows B- from inside to outside to specified torque ⇒...
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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed automatic gearbox 09G - Edition 04.2010 WARNING Under certain circumstances, interchanging connectors may lead to destruction of the gearbox. If a connector is damaged, the wiring harness or the valve body together with the solenoid valves must be renewed.
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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed automatic gearbox 09G - Edition 04.2010 The mating part of the connectors must bear the same identifica‐ tion as the respective connector itself.
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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed automatic gearbox 09G - Edition 04.2010 – If cables are too short to be bolted on, they have been incor‐ rectly routed or trapped by the valve body. Remove valve body again and route cables correctly.
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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed automatic gearbox 09G - Edition 04.2010 – Use a small screwdriver to pry out securing bolts of connectors on solenoid valves -2- to -9- carefully and pull off connectors.
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed automatic gearbox 09G - Edition 04.2010 39 – Final drive - differential Renewing oil seals for flange shafts (Gearbox installed) Only the left-hand side is described here. Renewing oil seal on right-hand side is nearly identical.