Volkswagen Golf 2015 Repair Manual
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Volkswagen Golf 2015 Repair Manual

Manual transmission
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Service
Repair Manual
Golf 2015 ➤
Golf Variant 2015 ➤
Manual Transmission
Edition 12.2014
Service Department. Technical Information

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Summary of Contents for Volkswagen Golf 2015

  • Page 1 Service Repair Manual Golf 2015 ➤ Golf Variant 2015 ➤ Manual Transmission Edition 12.2014 Service Department. Technical Information...
  • Page 2 In addition, the normal basic safety precautions for working on motor vehicles must, as a matter of course, be observed. All rights reserved. No reproduction without prior agreement from publisher. Copyright © 2015 Volkswagen AG, Wolfsburg D4B8041661E...

  • Page 3: Table Of Contents

    Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 Contents 00 - General, Technical Data ..........
  • Page 4 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 Transmission Tightening Specifications ........
  • Page 5 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 Revision History ............204...
  • Page 6 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 Contents...

  • Page 7: General, Technical Data

    Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 00 – General, Technical Data Safety Precautions (Edition 12.2014) ⇒ 1.1 Start/Stop System Safety Precautions , page 1 Start/Stop System Safety Precautions WARNING There is a risk of injury if the engine starts automatically in ve‐...

  • Page 8: Identification

    Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 Identification ⇒ 2.1 Transmission Identification , page 2 Transmission Identification Code Letters and Build Date -arrow 1- Manual Transmission 0A4 -arrow 2- Manual Transmission 0A4 -arrow 2-...

  • Page 9: Repair Information

    Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 Repair Information ⇒ 3.1 General Repair Information , page 3 General Repair Information Carefulness, cleanliness and the correct tools are required for transmission repairs to be successful. The usual basic safety pre‐...
  • Page 10 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 Fasteners ♦ Replace the circlips. ♦ Do not overstretch the circlips. ♦ The circlips must fit completely inside the groove. ♦ Replace the adapter sleeves. Installed position: slot is length‐...
  • Page 11 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 Adjusting Shims ♦ Measure the shims at several locations with a micrometer cal‐ iper. It is possible to measure the necessary shim thickness by the different tolerances.

  • Page 12: Technical Data

    Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 Technical Data ⇒ 4.1 Transmission/Engine Allocation , page 6 ⇒ 4.2 Capacities , page 6 ⇒ 4.3 Gear Ratio Calculation , page 7 Transmission/Engine Allocation ⇒ 4.1.1 Transmission/Engine Allocation, Golf , page 6 ⇒...

  • Page 13: Gear Ratio Calculation

    Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 Gear Ratio Calculation Example: 6th Gear Final Drive Drive gear ZG 1 = 47 ZA 1 = 18 Driven gear ZG 2 = 31 ZA 2 = 61...

  • Page 14: Overview - Powertrain

    Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 Overview - Powertrain ⇒ 5.1 Overview - Powertrain, Front Wheel Drive , page 8 Overview - Powertrain, Front Wheel Drive Name The -arrows- point in the direction of travel.
  • Page 15 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 I - 1st Gear II - 2nd Gear III - 3rd Gear IV - 4th Gear V - 5th Gear R - Reverse Gear A - Final Drive...

  • Page 16: Electrical Components

    Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 Electrical Components ⇒ 6.1 Component Location Overview - Electrical Components , page 10 Component Location Overview - Electri‐ cal Components ⇒ 6.1.1 Component Location Overview - Electrical Components, Manual Transmission , page 10 ⇒...

  • Page 17: Clutch

    Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 30 – Clutch Clutch Mechanism ⇒ 1.1 Component Location Overview - Clutch Mechanism , page ⇒ 1.2 Overview - Pedal Assembly , page 13 ⇒ 1.3 Overview - Clutch Hydraulics , page 15 ⇒...
  • Page 18 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 I - Refer to ⇒ 1.2 Overview - Pedal As‐ sembly , page 13 II - Refer to ⇒ 1.3.1 Overview - Clutch Hy‐ draulics , page 15 III - Refer to ⇒...

  • Page 19: Overview - Pedal Assembly

    Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 Overview - Pedal Assembly 1 - Clutch Master Cylinder ❑ Removing and instal‐ ling. Refer to ⇒ 1.10 Clutch Master Cylinder, Removing and Installing , page 29 2 - Bearing Bushing ❑...
  • Page 20 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 10 - Bracket ❑ For the clutch pedal ❑ Removing and installing. Refer to ⇒ 1.9 Mounting Bracket, Removing and Installing , page 26 ❑ Use a Piston Pin Drift - VW207- to drive sockets into the holes for the bracket mounting pins on the bulkhead.

  • Page 21: Overview - Clutch Hydraulics

    Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 Overview - Clutch Hydraulics ⇒ 1.3.1 Overview - Clutch Hydraulics , page 15 1.3.1 Overview - Clutch Hydraulics 1 - Hex Bolt ❑ Tightening specifica‐ tion. Refer to ⇒...
  • Page 22 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 ❑ Seals/O-rings suitable for the line connection material. Refer to ⇒ Fig. Sealing Rings/O-Rings for Hose/Line Assembly or Pipe , page 16 ❑ Allocation. Refer to the Parts Catalog.
  • Page 23 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 1.3.2 Overview - Clutch Hydraulics, RHD 1 - Clutch Slave Cylinder ❑ Removing and Instal‐ ling. Refer to ⇒ 1.11 Clutch Slave Cylinder, Removing and Installing , page 30 2 - Bleed Valve ❑...

  • Page 24: Overview - Clutch Release Mechanism

    Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 13 - Clamp ❑ The clamp must be removed in order to remove/install the hose/line assembly 14 - Hex bolt ❑ Tightening specification. Refer to ⇒ 1.4 Overview - Clutch Release Mechanism , page 18...

  • Page 25: Clutch Pedal, Removing And Installing

    Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 ❑ Removing from and installing in the clutch release lever ⇒ Fig. Removing and Installing the Release Bearing , page 35 ❑ Lubricate release lever contact surface with MoS 2 grease 9 - Hex Bolt ❑...

  • Page 26: Bearing Bushing, Removing And Installing

    Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 Installing Install in reverse order of removal. Note the following: -1- = 14 mm internal socket wrench A 14 mm hex socket wrench can also be used instead of a 14 mm internal socket wrench.

  • Page 27: Over-Center Spring, Removing And Installing

    Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 – Remove the bearing bushing -A- from the openings -1-. Installing – Turn the valve fitter such that the openings -1- or pin -2- are visible. The openings -1- and the pin -2- face in the same direction.
  • Page 28 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 – Remove the Data Bus on Board Diagnostic Interface - J533- -1- from the bracket. Refer to ⇒ Electrical Equipment; Rep. Gr. 97 ; Control Modules; Component Location Overview - Control Modules and push it aside.

  • Page 29: Return Spring, Removing And Installing

    Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 Installing Install in reverse order of removal. Note the following: • The bearing shells -arrows- for the pins -1- are installed. – Pull the clutch pedal into the passenger compartment (⇒ in direction of -arrow A- in the previous illustration).
  • Page 30 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 Continuation for All – Remove driver side footwell vent -1-. Refer to ⇒ Heating, Ventilation and Air Conditioning; Rep. Gr. 87 ; Air Routing; Driver Side Footwell Vent, Removing and Installing .
  • Page 31 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 – Move the clutch pedal in direction of -arrow-, unclip the return spring -1- and remove. Installing Install in reverse order of removal. Note the following: •...

  • Page 32: Mounting Bracket, Removing And Installing

    Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 Mounting Bracket, Removing and Instal‐ ling Special tools and workshop equipment required ♦ Hose Clamps - Up To 25 mm - 3094- ♦ Torque Wrench 1331 5-50Nm - VAG1331- ♦...
  • Page 33 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 – Remove the Data Bus on Board Diagnostic Interface - J533- -1- from the bracket. Refer to ⇒ Electrical Equipment; Rep. Gr. 97 ; Control Modules; Component Location Overview - Control Modules and push it aside.
  • Page 34 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 – Remove the clutch master cylinder return hose and seal with the Sealing Tool - T10249/1- . Note When working inside the footwell, cover the carpet with cloths to protect it from leaking brake fluid.

  • Page 35: Clutch Master Cylinder, Removing And Installing

    Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 – Connect hose/line assembly -1- with connection ⇒ Fig. Disconnect and Connect Clutch Mechanism Wires , page 16 – Connect the supply hose -2- to the clutch master cylinder.

  • Page 36: Clutch Slave Cylinder, Removing And Installing

    Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 1.11 Clutch Slave Cylinder, Removing and Installing Special tools and workshop equipment required ♦ Hose Clamps - Up To 25 mm - 3094- ♦ Torque Wrench 1331 5-50Nm - VAG1331- Caution This procedure contains mandatory replaceable parts.

  • Page 37: Clutch Mechanism Lines, Removing And Installing

    Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 – Place a lint-free cloth under the clutch slave cylinder. – Release the clamp -A- with a screwdriver and remove the hose/line assembly -B- from the connection.
  • Page 38 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 ♦ Hose Clamps - Up To 25 mm - 3094- Removing – Remove the entire air filter housing if the clutch mechanism lines are not accessible. Refer to ⇒ Engine Mechanical, Fuel Injection and Ignition;...

  • Page 39: Clutch Mechanism, Bleeding

    Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 Installing Install in reverse order of removal. Note the following: – Connect the hose/line assembly -1- with the connection on the clutch master cylinder and the clutch slave cylinder.

  • Page 40: Clutch Master And Clutch Slave Cylinder, Checking

    Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 – Return clutch pedal to the rest position. – Remove cap from the bleed valve -arrow-. – Connect the Brake Charger/Bleeder Unit - VAS5234- . – Connect the bleed hose with the collector bottle pressure hose.

  • Page 41: Clutch Release Mechanism, Servicing

    Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 – Release the Clutch Position Sensor - G476- -2- on the clutch master cylinder -1- in direction of -arrow- and remove it. Installing Install in reverse order of removal. Note the following: •...

  • Page 42: Clutch

    Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 Clutch ⇒ 2.1 Overview - Clutch , page 36 ⇒ 2.2 Clutch, Removing and Installing , page 39 Overview - Clutch ⇒ 2.1.1 Overview - Clutch, with Dual Mass Flywheel, Sachs , page 36 ⇒...
  • Page 43 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 ❑ M 7: 20 Nm ❑ Loosen and tighten in small steps and in diagonal sequence ❑ Allocation. Refer to the Parts Catalog. 2.1.2 Overview - Clutch, with Dual Mass Flywheel, LuK 1 - Flywheel ❑...
  • Page 44 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 2.1.3 Overview - Clutch, with Single Flywheel 1 - Flywheel ❑ Removing and instal‐ ling. Refer to ⇒ Rep. Gr. 13 ; Cylinder Block, Transmission Side; Fly‐...

  • Page 45: Clutch, Removing And Installing

    Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 Clutch, Removing and Installing ⇒ 2.2.1 Clutch, Removing and Installing, with Dual Mass Fly‐ wheel, Sachs , page 39 ⇒ 2.2.2 Clutch, Removing and Installing, with Dual Mass Fly‐...
  • Page 46 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 • When loosening, the stop -2- and the bolt -1- must loosen up together. – If the stop does not loosen: push the bolt toward the dual mass flywheel.
  • Page 47 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 Check the Ends of the Diaphragm Spring • Wear up to half the thickness of the diaphragm spring -arrows- is permitted. Checking the Spring Connections and Rivet Connections I - Pull-spring OK •...
  • Page 48 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 When Installing, Tighten Bolts as Follows so Clutch Pressure Plate Does Not Distort (Causing Shuddering On Acceleration): – Make sure the stop pin (position sensor) -arrow- moves easily.
  • Page 49 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 – Remove the clutch pressure plate and clutch plate. Installing Install in reverse order of removal. Note the following: Note Allocate clutch pressure plate and clutch plate according to the ♦...
  • Page 50 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 Check the Ends of the Diaphragm Spring • Wear up to half the thickness of the diaphragm spring -arrows- is permitted. Note Allocate clutch pressure plate and clutch plate according to the engine code.
  • Page 51 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 Only Check Position of Adjustment Mechanism with New Pres‐ sure Plates • Both edges -A- of the adjusting ring must be located between both notches -arrows B-.
  • Page 52 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 – Insert the Flywheel Retainer - 3067- to loosen the bolts. When Removing, Loosen the Bolts as Follows So That the Clutch Pressure Plate Does Not Distort (Causing Shuddering on Accel‐...
  • Page 53 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 Check the Ends of the Diaphragm Spring • Wear up to half the thickness of the diaphragm spring -arrows- is permitted. Check the Spring Connection and Rivet Connections –...
  • Page 54 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 Checking the Metal Ring – Check the metal ring in the clutch pressure plate -arrow- for damage. • Replace any clutch pressure plates that have a broken metal ring.

  • Page 55: Special Tools

    Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 Special Tools Special tools and workshop equipment required ♦ Flywheel Retainer - 3067- ♦ Alignment Tool - Clutch Plate - 3190A- ♦ Torque Wrench 1331 5-50Nm - VAG1331- ♦...
  • Page 56 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 ♦ Brake Charger/Bleeder Unit - VAG1869- ♦ Brake Charger/Bleeder Unit - VAS5234- or ♦ Hose Clamps - Up To 25 mm - 3094- Rep. Gr.30 - Clutch...

  • Page 57: Controls, Housing

    Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 34 – Controls, Housing Selector Mechanism ⇒ 1.1 Selector Mechanism Installation Position , page 51 ⇒ 1.3 Overview - Selector Mechanism , page 53 ⇒ 1.2 Overview - Gearshift Knob and Cover , page 52 ⇒...

  • Page 58: Overview - Gearshift Knob And Cover

    Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 Overview - Gearshift Knob and Cover 1 - Gearshift Housing with Gearshift Lever 2 - Nut ❑ M6: 8 Nm ❑ M8: 25 Nm 3 - Bracket ❑...

  • Page 59: Overview - Selector Mechanism

    Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 Overview - Selector Mechanism Note Lubricate the bearing areas and the sliding surfaces. ♦ Grease allocation. Refer to the Parts Catalog. ♦ 1 - Gearshift Shaft with Gear‐...

  • Page 60: Gearshift Knob, Removing And Installing

    Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 6 - Lock Washer ❑ Replace after removing 7 - Lock Washer ❑ Replace after removing ❑ Be careful not to damage the cables when removing them 8 - Selector Cable ❑...
  • Page 61 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 ♦ Hose Clip Pliers - VAG1275A- ♦ Wedge Set - T10383- ♦ Wedge Set - Wedge 1 - T10383/1- ♦ or the equivalent equipment, Backrest Panel Tool - 3370- Caution This procedure contains mandatory replaceable parts.

  • Page 62: Selector Mechanism, Removing And Installing

    Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 Selector Mechanism, Removing and In‐ stalling Special tools and workshop equipment required ♦ Torque Wrench 1331 5-50Nm - VAG1331- Caution This procedure contains mandatory replaceable parts. Refer to component overview prior to starting procedure.
  • Page 63 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 Installed Position of Gearshift Housing Nuts -arrows-. – Remove the nuts -arrows-. – Remove center console and center console mounting bracket. Refer to ⇒ Body Interior; Rep. Gr. 68 ; Center Console; Over‐...
  • Page 64 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 Remove the Relay Lever and the Cable Retainer. – Remove the clip -arrow 1- and then remove the relay lever together with the cable retainer -arrow 2-.
  • Page 65 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 With the Relay Lever Removed: Pry the Selector Cable Retainer Off of the Relay Lever. – Insert a screwdriver -A- between the bushing -B- and the relay lever.
  • Page 66 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 – Route the cables -1- from the gearshift mechanism -2- to the transmission as follows: ♦ After the cables cross each other diagonally -arrow-, they must run parallel to each other up to the cable mounting bracket on the transmission.
  • Page 67 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 Selector Lever/Relay Lever Installed Position 1 - Gearshift lever 2 - The relay lever fits into the sliding rail on the transmission se‐ lector lever via the sliding shoe -arrow-.
  • Page 68 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 Installing the Transmission Shift Lever – When positioning the transmission shift lever, make sure the tooth gap -arrow A- is placed over the missing selector shaft teeth -arrow B-.

  • Page 69: Selector Mechanism, Adjusting

    Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 Selector Mechanism, Adjusting Special tools and workshop equipment required ♦ Connecting Pin - T10027A- Adjusting Requirements • Operating and transfer elements of shift mechanism must be in proper condition.
  • Page 70 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 – Remove the boot and, if possible, the noise insulation from the center console. Refer to ⇒ 1.4 Gearshift Knob, Removing and Installing , page 54 Secure the gearshift shaft as follows: –...

  • Page 71: Selector Mechanism, Checking

    Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 – Remove the Locking Pin from the noise insulation -A- and the holes -B and C-. – Install the boot and if the insulation (if equipped). Refer to ⇒...
  • Page 72 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 – Lightly oil new seal on outer circumference. – Fill the space between the sealing and dust lip -arrow- halfway with Sealing Grease - G 052 128 A1- .

  • Page 73: Transmission, Removing And Installing

    Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 Transmission, Removing and Instal‐ ling ⇒ 2.1 Transmission, Removing , page 67 ⇒ 2.2 Transmission, Installing , page 77 ⇒ 2.3 Transmission Tightening Specifications , page 86...
  • Page 74 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 ♦ Bolt - Pendulum Support to Subframe ♦ Bolts - Transmission Bracket to Transmission ♦ Bolts - Transmission Mount to Transmission Bracket ♦ Lock Washer - Cable Retainer ♦...
  • Page 75 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 – Remove the transmission support -A arrows-. – Remove the clutch slave cylinder -B arrows- lay aside and se‐ cure with wire. Do not open the line system.
  • Page 76 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 – Unclip the right mount -1- for the engine cover from the bracket -2-. – Attach the Engine Support Bridge - 10-222A- as follows: The following are needed: ♦...
  • Page 77 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 – If present, remove wires from the front area of both longitudinal members -arrow-. Do not disconnect line system. – Place the Engine Support Brackets - T40093/3-6- on both lon‐...
  • Page 78 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 – Remove all wires from the transmission. – Transmission on vehicles with Start/Stop System: disconnect the connector -arrow- from the Transmission Neutral Position Sensor - G701- .
  • Page 79 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 – Install the two bolts into the flange and counterhold the flange shaft with the pry lever to remove the right flange shaft bolt -arrow-. – Remove the flange shaft.
  • Page 80 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 – Disconnect the exhaust system at the clamping sleeve -arrow-. Refer to ⇒ Rep. Gr. 26 ; Exhaust Pipes/Mufflers; Overview - Muffler . – Remove bolts -1 through 3- and remove pendulum support.
  • Page 81 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 – Remove the left assembly mounting hex bolts -arrows- from the transmission mounting. – Turn the spindles on the Engine Support Bridge - 10-222A- and lower the transmission to dimension -a-.
  • Page 82 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 – Align the Adjusting Plate so that it is parallel to the transmis‐ sion and secure the safety support to the transmission. – Install the Transmission Support - Pins 29 - 3282/29- into the rear hole for the pendulum support bolt on the transmission.

  • Page 83: Transmission, Installing

    Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 – Carefully lower the transmission with the Engine and Gearbox Jack - VAS6931- , while making sure that the right flange shaft seal -1- is guided through without any damage to the pressure plate -arrow-.
  • Page 84 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 ♦ Lock Washer - Gearshift Cable ♦ Nut - Coupling Rod to Stabilizer Bar ♦ Bolts - CV Boot to Inner CV Joint ♦ Seals - Transmission...
  • Page 85 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 – Clean the drive axle splines and grease lightly with Grease For Clutch Disc Shaft Splines - G 000 100- . It must be possible to slide the clutch plate back and forth on the input shaft.
  • Page 86 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 – Tip the transmission over the adjusting spindle for the Trans‐ mission Support - 3282- in the direction of -arrow-. – Push the engine forward slightly with a second technician.
  • Page 87 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 – Reinsert the right flange shaft and tighten the bolt -arrow- to the tightening specification. Refer to ⇒ 1.3 Right Seal, Replacing , page 185 – Install upper engine/transmission connecting bolts and tight‐...
  • Page 88 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 – If equipped install the ground cable on the transmission mount -arrow-. – Install the pendulum support with new bolts -1 to 3-. Refer to ⇒ Engine Mechanical, Fuel Injection and Ignition; Rep. Gr.
  • Page 89 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 – Install the coupling rod -3- on both side of the stabilizer bar -2-. Refer to ⇒ Engine Mechanical, Fuel Injection and Ignition; Rep. Gr. 10 ; Subframe Mount; Overview - Subframe Mount .
  • Page 90 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 – Connect the connector -1- to the Back-Up Lamp Switch - F4- . – Install the starter, connect the connector -arrow 2- and attach the wire -arrow 3-. Refer to ⇒ Electrical Equipment; Rep. Gr.
  • Page 91 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 – Install the transmission shift lever -A-. Refer to ⇒ Fig. Installing the Transmission Shift Lever , page 62 – Tighten the hex nut -arrow 3-. Refer to ⇒...

  • Page 92: Transmission Tightening Specifications

    Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 – Install the left charge air hose -A- -arrows-. Refer to ⇒ Engine Mechanical, Fuel Injection and Ignition; Rep. Gr. 21 ; Charge Air System; Overview - Charge Air System .

  • Page 93: Subframe Mount

    Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 Subframe Mount ⇒ 3.1 Overview - Subframe Mount , page 87 Overview - Subframe Mount 1 - Bolt ❑ 20 Nm +90° ❑ Replace after removing ❑ Transmission support to...
  • Page 94 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 9 - Transmission Bracket 10 - Transmission Mount ❑ Check the adjustment. Refer to ⇒ Engine Mechanical, Fuel Injection and Ignition; Rep. Gr. 10 ; Subframe Mount; Subframe Mount, Checking Adjustment ❑...

  • Page 95: Transmission, Transporting

    Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 Transmission, Transporting Special tools and workshop equipment required ♦ Transmission Support Jig - 3336- ♦ Shop Crane - VAS6100- – Attach the Transmission Support Jig - 3336- to the clutch housing.

  • Page 96: Transmission, Disassembling And Assembling

    Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 Transmission, Disassembling and Assembling ⇒ 5.1 Schematic Overview - Transmission , page 90 ⇒ 5.2 Overview - Transmission , page 92 ⇒ 5.3 Overview - Transmission Housing Cover and 5th Gear , page 93 ⇒...
  • Page 97 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 1 - 1st Gear 2 - 2nd Gear 3 - 3rd Gear 4 - 4th Gear 5 - 5th Gear 6 - Transmission Housing Cov‐ 7 - Transmission Housing 8 - Selector Mechanism ❑...

  • Page 98: Overview - Transmission

    Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 Overview - Transmission I - Refer to ⇒ 5.3 Overview - Transmis‐ sion Housing Cover and 5th Gear , page 93 II - Refer to ⇒ 5.4 Overview - Transmis‐...

  • Page 99: Overview - Transmission Housing Cover And 5Th Gear

    Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 Overview - Transmission Housing Cover and 5th Gear 1 - Bolt ❑ 18 Nm ❑ Cover to transmission housing ❑ Quantity: 5 2 - Transmission Housing Cov‐...
  • Page 100 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 ❑ Adjusting. Refer to ⇒ Fig. Adjusting 5th Gear , page 118 11 - Locking Pieces (quantity: 3) ❑ Installed position. Refer to ⇒ Fig. 5th Gear Synchronizing , page 147 12 - Synchronizer Hub with Gear Wheel and 5th Gear Synchronizer Ring ❑...

  • Page 101: Overview - Transmission Housing And Selector Mechanism

    Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 Overview - Transmission Housing and Selector Mechanism 1 - Bolt ❑ 25 Nm 2 - Flange Shaft with Pressure Spring ❑ Removing and instal‐ ling. Refer to ⇒...

  • Page 102: Overview - Shift Unit

    Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 ❑ Replace after removing 16 - Gearshift Shaft with Gearshift Cover ❑ (Shift unit) ❑ Servicing. Refer to ⇒ 5.8 Shift Unit, Servicing , page 99 17 - Internal Multi-Point Bolt ❑...

  • Page 103: Overview - Input Shaft, Output Shafts, Differential, Gearshift Rods

    Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 10 - Cap 11 - Spring ❑ Not installed in all transmissions ❑ Install if present Overview - Input Shaft, Output Shafts, Differential, Gearshift Rods 1 - Differential ❑...

  • Page 104: Overview - Shift Forks

    Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 ❑ Quantity: 4 12 - Flange Shaft with Pressure Spring ❑ Removing and installing. Refer to ⇒ 1.3 Right Seal, Replacing , page 185 ❑ Assembling. Refer to ⇒...

  • Page 105: Shift Unit, Servicing

    Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 ❑ Installing. Refer to ⇒ Fig. Installing the Angular Contact Ball Bearing into the Shift Fork , page 101 7 - Shift Fork Group with Gearshift Rails 8 - 1st/2nd Gear Shift Segment ❑...

  • Page 106: Shift Forks, Servicing

    Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 Shift Forks, Servicing Special tools and workshop equipment required ♦ Press Plate - VW402- ♦ Subframe Support Tool - Press Piece - 3290/1- ♦ Press Piece - Multiple Use - VW431- ♦...

  • Page 107: Transmission Housing Cover And 5Th Gear, Removing

    Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 Removing the Angular Contact Ball Bearing Note Be careful not to bend the shift forks when removing and installing the angular contact ball bearing. Installing the Angular Contact Ball Bearing Inner Race -A- into the Outer Race The bearing inner race must engage with outer race.
  • Page 108 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 ♦ Bearing/Bushing Installer - Multiple Use - VW295- ♦ Bearing Driver - Multiple Use - VW244B- ♦ For example Hot Air Blower - VAG1416- ♦ Torque Wrench 1331 5-50Nm - VAG1331- ♦...
  • Page 109 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 • Be careful not to damage the bearing for the input and output shafts when removing and installing 5th gear. • When securing the transmission to the Transmission Support...
  • Page 110 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 5th Gear, Removing Separately – Cover the openings in the transmission housing with a cloth. – Move the shift fork -1- into neutral. – Remove the bolt -2- with the shift jaw for 5th gear.

  • Page 111: Transmission, Disassembling And Assembling

    Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 – Install the Puller - Transmission Gears - Threaded Insert - T10309/3- in the Puller - Transmission Gears - Half Shell . – Insert the second Puller - Transmission Gears - Half Shell - T10309/1- and put the Puller - Transmission Gears - Tube - T10309/2- on the tool.
  • Page 112 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 ♦ Spacer Plate - T10408/3- ♦ M7 x 35 hex collar bolt and washer (components of the Puller - Transmission Gears - T10408- ) ♦ Support Bridge - T10323- ♦...
  • Page 113 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 – Secure the transmission on the Transmission Support - VW353- . – Place the Drip Tray underneath. – Open the oil filler plug and the oil drain plug.
  • Page 114 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 – Remove the third bolt -arrow- from the reverse shaft support. – Transmission on vehicles with Stop/Start system: remove the Transmission Neutral Position Sensor - G701- -arrow-.
  • Page 115 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 – Remove pivot pins -A- on top side of transmission and bolts -B- for transmission housing to clutch housing in area of dif‐ ferential. – Remove the bolts -A- that connect the clutch and transmission housing.
  • Page 116 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 Use the Puller - Transmission Gears - T10408- with the Following Special Tools: ♦ Puller - Transmission Gears - Thrust Piece - T10408/2- ♦ Spacer Plate - T10408/3- ♦...
  • Page 117 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 – Remove the shift forks -A- together with the gearshift rails. – Remove the gearshift mechanism/reverse gear -B-. – Remove the reverse gear -A-, the input shaft -B- and the output shaft -C-, one after the other, from the clutch housing.
  • Page 118 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 – Install the reverse gear shift fork -1- with the support for the reverse gear shift fork -2-, the spring -3- and the sliding piece -4-. Reverse gear location –...
  • Page 119 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 – Install the bolt -c-. Tightening sequence: – Tighten the bolt -a- (⇒ upper illustration). – Tighten the bolt -b-. – Tighten the bolt -c- (⇒ upper illustration).

  • Page 120: Transmission Housing Cover And 5Th Gear, Installing

    Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 – Transmission on vehicles with Stop/Start system: install the Transmission Neutral Position Sensor - G701- -arrow- and tighten the screw. – Install both flange shafts with springs, thrust washers and ta‐...
  • Page 121 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 Refer to ⇒ 5.10 Transmission Housing Cover and 5th Gear, Removing , page 101 , Transmission Housing Cover and 5th Gear, Remov‐ ing to get a list of the special tools needed.
  • Page 122 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 Checking 5th Gear Synchronizer Ring – Before re-installing the gear wheel and the 5th gear synchron‐ izer ring push the synchronizer ring onto the taper of the drive gear.
  • Page 123 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 – Loosen the support for the input shaft. If it has not been done already, locking fluid residue from the threaded holes for the synchronizer hub bolts and 5th gear wheel must be cleaned with a thread tap.
  • Page 124 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 Adjusting 5th Gear – Engage 5th gear. Loosen the bolt -1-. Push the locking collar and the shift jaw in direction of -arrow-. Tighten the bolt -1- to the tightening specification.

  • Page 125: Transmission Housing And Clutch Housing

    Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 Transmission Housing and Clutch Housing ⇒ 6.1 Overview - Transmission Housing and Clutch Housing , page 119 ⇒ 6.2 Transmission Housing, Servicing , page 121 ⇒ 6.3 Clutch Housing, Servicing , page 122...
  • Page 126 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 ❑ Adjustment overview. Refer to ⇒ 3 Adjustment Overview , page 198 7 - Outer Race/Tapered Roller Bearing ❑ For the input shaft ❑ Removing and installing. Refer to ⇒...

  • Page 127: Transmission Housing, Servicing

    Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 21 - Seal ❑ For the left flange shaft ❑ Replacing. Refer to ⇒ 1.3 Right Seal, Replacing , page 185 Transmission Housing, Servicing Special tools and workshop equipment required ♦...

  • Page 128: Clutch Housing, Servicing

    Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 Removing the Seal from the Guide Sleeve Installing the Seal All the Way Into the Guide Sleeve Installing the Oil Catch Tray -A- into the Transmission – Insert the oil catch tray into the hole -arrow 1- and groove -arrow 2- at the same time.
  • Page 129 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 Installing the Sleeve and Seal – Clean the seal seat inside the transmission. – Attach the spindle -A- for the Seal Installer - Driver Set - 3066- into the threaded piece on the differential.

  • Page 130: Securing On Engine And Transmission Holder

    Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 Securing on Engine and Transmis‐ sion Holder Special tools and workshop equipment required ♦ Holding Plate - VW309- ♦ or Holding Plate - VW309A- ♦ Transmission Support - VW353- –...

  • Page 131: Transmission Fluid

    Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 Transmission Fluid ⇒ 8.1 Transmission Fluid Level, Checking , page 125 ⇒ 8.2 Transmission Fluid, Draining and Filling , page 125 Transmission Fluid Level, Checking It is not possible to check the transmission fluid level by removing oil filler plug.
  • Page 132 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 Clean the transmission. Caution To drain gear oil, journal for shift forks in transmission must be removed. To avoid that the position of the shift forks is changed, for ex‐...
  • Page 133 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 – Remove the Back-Up Lamp Switch - F4- -arrow-. – Hose (approximately 600 mm (23.6 in.) long, outside diameter 10 mm) with commercially available funnel. – Insert the hose into the hole in the Back-Up Lamp Switch - F4- (seconded technician) and fill the transmission fluid.

  • Page 134: Special Tools

    Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 Special Tools Special tools and workshop equipment required ♦ Transmission Support - Mounting Plate 39 - 3282/39- ♦ Transmission Support Ele‐ ments (determine when mounting the Adjustment...
  • Page 135 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 ♦ Engine Support Bridge - 10-222A- ♦ Engine Support Bridge - Gearbox Adapter - 10-222A/29- ♦ Engine Support Bridge - Engine Support 18 - 10-222A/18- ♦ Engine/Gearbox Support Shackle (2 pc.) - 10-222A/...
  • Page 136 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 ♦ Bearing/Bushing Installer - Multiple Use - VW295- ♦ Bearing/Bushing Installer - Multiple Use - VW295A- ♦ Press Piece - Multiple Use - VW447H- ♦ Press Piece - Multiple Use - VW512- ♦...
  • Page 137 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 ♦ Holding Plate - VW309A- ♦ or Holding Plate - VW309A- ♦ Transmission Support - VW353- ♦ Bearing/Bushing Installer - Multiple Use - VW295- ♦ Bearing Driver - Multiple Use - VW244B- ♦...
  • Page 138 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 ♦ Press Plate - VW402- ♦ Subframe Support Tool - Press Piece - 3290/1- ♦ Press Piece - Multiple Use - VW431- ♦ Subframe Bushing Tool Kit - 3301- ♦...
  • Page 139 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 ♦ Bracket - Multiple Use - 30-211A- ♦ Bearing Installer - Multiple Use - 32-111- ♦ Assembly Tool Kit - Press Piece 2 - T10030/4- from the Hydraulic Press - Bush‐...
  • Page 140 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 ♦ Support Bridge - T10323- ♦ Rear Wheel Bearing Kit - Piece 7 - 3253/7- ♦ Press Piece - Multiple Use - VW433- ♦ Press Piece - Multiple Use - 40-105- ♦...
  • Page 141 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 ♦ Bracket - Multiple Use - 30-211A- ♦ Bearing Installer - Multiple Use - 32-111- ♦ Assembly Tool Kit - Press Piece 2 - T10030/4- from the Hydraulic Press - Bush‐...
  • Page 142 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 ♦ Seal Installer - One-Piece Seal - T10148- ♦ Breather Tube Tool - T10203- ♦ Wedge Set - T10383- ♦ Engine Support - Basic Set Square Pipe - T40091/1- (quantity ♦...
  • Page 143 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 ♦ Engine Support - Supplement Kit Spindle - T40093/3- (quan‐ tity 2) from the Engine Support - Supplement Kit - T40093A- ♦ Engine Support Brackets - T40093/3-6- (quantity 2) ♦...
  • Page 144 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 ♦ Shop Crane - Drip Tray - VAS6208- ♦ Inductive Heater - VAS6414- ♦ Press Piece - Shift Rod/Alternator - VW423- ♦ Slide Hammer Set - VW771-...
  • Page 145 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 ♦ Slide Hammer Set - Hook - VW771/37- ♦ -2- Puller - Kukko Puller - 60-150mm Width, 200mm Length - Kukko 18/1- (quantity 2) ♦ Engine Support Bridge - Special Hook (2 pc.) - 10-222A/20- ♦...
  • Page 146 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 ♦ Pry Lever - 80-200- ♦ Spring Strut Compressor - 2070- ♦ Spindle from the Seal Installer - Driver Set - 3066- or M8 x 105 bolt ♦...

  • Page 147: Gears, Shafts

    Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 35 – Gears, Shafts Input Shaft ⇒ 1.1 Overview - Input Shaft , page 141 ⇒ 1.2 Input Shaft, Disassembling and Assembling , page 143 ⇒ 1.3 Input Shaft, Adjusting , page 148 ⇒...
  • Page 148 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 1 - Clutch Housing 2 - Outer Race/Tapered Roller Bearing ❑ Removing. Refer to ⇒ Fig. Removing the Outer Race/Tapered Roller Bearing , page 144 ❑ Installing. Refer to ⇒...

  • Page 149: Input Shaft, Disassembling And Assembling

    Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 12 - Transmission Housing 13 - Sleeve ❑ For the 5th gear needle bearing ❑ Pressing off with 4th gear drive gear and the inner race/tapered roller bearing. Refer to ⇒...
  • Page 150 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 ♦ Press Piece - 28x100mm - VW421- ♦ Press Piece - VW447i- ♦ Press Piece - Multiple Use - VW454- ♦ Press Piece - Multiple Use - VW510- ♦...
  • Page 151 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 Installing the Inner Race/Tapered Roller Bearing Removing the 4th Gear Wheel with the Tapered Roller Bearing and Sleeve Removing the 3rd Gear Wheel Installing 3rd Gear Wheel...
  • Page 152 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 Removing 4th Gear Wheel The shoulder faces 3rd gear. Installing the Inner Race/Tapered Roller Bearing Installing the Needle Bearing Sleeve Removing the Outer Race/Tapered Roller Bearing Rep. Gr.35 - Gears, Shafts...
  • Page 153 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 Installing the Outer Race/Tapered Roller Bearing – Install with shim after adjusting input shaft. 5th Gear Synchronizing Springs for Locking Pieces Locking Collar with 3 Notches -arrow A- for Locking Pieces...

  • Page 154: Input Shaft, Adjusting

    Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 Installation of Offset Springs -A- These springs are installed on both sides. – Springs are only installed in conjunction with hollow locking pieces. – Insert locking pieces (installed position: Refer to ⇒...
  • Page 155 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 – Press the taper roller bearing outer race into the clutch housing all the way. – Install the outer race/tapered roller bearing all the way into the transmission housing without the adjusting shim.
  • Page 156 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 – Press the input shaft toward the dial gauge direction of -arrow-. – Read and make note of the play on the dial gauge (example: 1.21 mm).
  • Page 157 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 Shim Table Bearing Play Shim Measured Value (mm) Thickness (mm) 0.671 to 0.699 0.650 0.700 to 0.724 0.675 0.725 to 0.749 0.700 0.750 to 0.774 0.725 0.775 to 0.799 0.750...

  • Page 158: Input Shaft Seal, Replacing

    Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 – Press the outer race/tapered roller bearing and the selected shim (1.175 mm in the example) into the transmission housing using the Press Piece - Multiple Use - VW510- .
  • Page 159 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 – Fill the space between the sealing and dust lip -arrow- halfway with Sealing Grease - G 052 128 A1- . – Coat the outer circumference of the seal lightly with transmis‐...

  • Page 160: Output Shaft

    Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 Output Shaft ⇒ 2.1 Overview - Output Shaft , page 154 ⇒ 2.2 Output Shaft, Disassembling and Assembling , page 158 ⇒ 2.3 Output Shaft, Adjusting , page 166...
  • Page 161 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 1 - Nut ❑ 4 nuts for the bearing mount ❑ Replace after removing ❑ Tightening specifica‐ tion. Refer to ⇒ 5.6 Overview - Input Shaft, Output Shafts,...
  • Page 162 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 13 - Synchronizer Ring ❑ (Inner race for 1st gear) ❑ Installed position. Refer to ⇒ Fig. Installed Position of the Inner Race, the Outer Race and the 1st Gear Synchronizer Ring , page ❑...
  • Page 163 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 21 - 2nd Gear Wheel ❑ Installed position. Refer to ⇒ Fig. Installed Position: 2nd Gear Wheel , page 164 22 - Needle Bearing ❑ For 2nd gear...

  • Page 164: Output Shaft, Disassembling And Assembling

    Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 35 - Transmission Housing 36 - Sleeve ❑ For the needle bearing/output shaft ❑ Removing. Refer to ⇒ Fig. Removing the 3rd/4th Gear Synchronizer Hub/Locking Collar, 2nd Gear Wheel, 3rd and 4th Gear with Output Shaft Needle Bearing Sleeve , page 160 ❑...
  • Page 165 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 ♦ -3- Puller - Kukko Quick Action Separating Tool - 22-115mm - 17/2- ♦ -4- Puller - Kukko Counterstay - 22/2- ♦ Inductive Heater - VAS6414- ♦ Feeler Gauge Caution This procedure contains mandatory replaceable parts.
  • Page 166 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 Installing the Inner Race/Small Tapered Roller Bearing Removing the 3rd/4th Gear Synchronizer Hub/Locking Collar, 2nd Gear Wheel, 3rd and 4th Gear with Output Shaft Needle Bearing Sleeve A - Puller - Quick Action Separating Tool - 22-115mm - Kukko 17/2- , for example.
  • Page 167 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 Installing the Inner Race/Large Tapered Roller Bearing -A- thrust washer – Install the thrust washer before installing the inner race. The shoulder faces the inner race. Installed Position of the Inner Race, the Outer Race and the 1st Gear Synchronizer Ring –...
  • Page 168 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 Disassembling and Assembling Locking Collar and Synchronizer Hub for 1st and 2nd Gears 1 - Spring Spring allocation. Refer to the Parts Catalog. Assembly in conjunction with hollow locking pieces. Refer to ⇒...
  • Page 169 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 Installed Position: Locking Collar/Synchronizer Hub for 1st and 2nd Gears The teeth of the locking collar -arrow- point toward the splines of the 3rd/4th gear synchronizer hub -A-.
  • Page 170 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 Installed Position: 2nd Gear Wheel The higher collar -A- faces toward 1st gear -B-. The notches in the collar -arrow- lock into the tabs on the outer race. Refer to ⇒...
  • Page 171 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 Disassembling and Assembling Locking Collar and Synchronizer Hub for 3rd/4th Gears 1 - Spring Allocate the correct springs. Refer to the Parts Catalog. Assembly in conjunction with hollow locking pieces. Refer to ⇒...

  • Page 172: Output Shaft, Adjusting

    Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 Installed Position: Locking Collar/Synchronizer Hub for 3rd and 4th Gears The bevel -arrow- faces 4th gear. Installing the Synchronizer Hub with Locking Collar for 3rd and 4th Gears...
  • Page 173 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 ♦ Door Alignment Device - Replacement Stud - 3114/2- ♦ Press Piece - Rod - VW407- ♦ Torque Wrench 1331 5-50Nm - VAG1331- ♦ Dial Gauge ♦ -1- Puller - Kukko Internal - 36-46mm - 21/6- ♦...
  • Page 174 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 – Install dial gauge (3 mm measuring range) and set to 0 with 1 mm pre-load. – Move the input shaft up and down, check the play on the dial gauge and make a note of it.
  • Page 175 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 – Tighten the nut for the bearing mount in the clutch housing. Tightening Specifications ♦ Bearing mount to the clutch housing. Refer to ⇒ 5.6 Overview - Input Shaft, Output Shafts, Differential, Gearshift Rods , page 97 2.

  • Page 176: Reverse Shaft

    Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 Reverse Shaft ⇒ 3.1 Overview - Reverse Shaft , page 170 ⇒ 3.2 Reverse Shaft, Disassembling and Assembling , page 170 Overview - Reverse Shaft Note Always replace the needle sleeve after removing it from the clutch housing or from the reverse shaft support.
  • Page 177 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 ♦ Press Piece - Multiple Use - VW454- ♦ Press Piece - Multiple Use - VW447H- ♦ Press Piece - Rod - VW411- ♦ Centering/Press Pin - 12-551- ♦...
  • Page 178 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 Installing the Needle Sleeve into the Reverse Shaft Support Rep. Gr.35 - Gears, Shafts...

  • Page 179: Special Tools

    Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 Special Tools ♦ Press Piece - Multiple Use - VW429- ♦ Press Piece - 60mm - VW415A- ♦ Press Piece - Multiple Use - VW447H- ♦ Press Piece - Multiple Use - VW454- ♦...
  • Page 180 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 ♦ Press Piece - Rod - VW407- ♦ Press Piece - Multiple Use - VW447H- ♦ Press Piece - Rod - VW412- ♦ Press Piece - Shift Rod/Al‐...
  • Page 181 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 ♦ Press Piece - Rod - VW407- ♦ Press Piece - Rod - VW412- ♦ Press Piece - Multiple Use - VW512- ♦ Puller - Taper Roller Bear‐...
  • Page 182 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 ♦ Press Plate - VW402- ♦ Bearing Installer - Multiple Use - 32-111- ♦ Press Piece - Rod - VW408A- ♦ Press Piece - Rod - VW409- ♦...
  • Page 183 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 Special tools and workshop equipment required ♦ Press Piece - Multiple Use - VW454- ♦ Press Piece - Multiple Use - VW447H- ♦ Press Piece - Rod - VW411- ♦...
  • Page 184 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 ♦ Dial Gauge Holder - VW387- ♦ Measuring Set - Magnetic Plate - 50mm - VW385/17- ♦ Press Piece - Multiple Use - VW510- ♦ Press Piece - VW447i- ♦...
  • Page 185 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 ♦ Dial Gauge Holder - VW387- ♦ Measuring Set - Magnetic Plate - 50mm - VW385/17- ♦ Press Piece - Multiple Use - VW512- ♦ Door Alignment Device -...
  • Page 186 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 ♦ Press Piece - 28x100mm - VW421- ♦ Press Piece - VW447i- ♦ Press Piece - Multiple Use - VW454- ♦ Press Piece - Multiple Use - VW510- ♦...
  • Page 187 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 ♦ Bearing/Bushing Installer - Multiple Use - VW295- ♦ Bearing/Bushing Installer - Multiple Use - VW295A- ♦ Press Plate - VW402- ♦ Press Piece - Multiple Use - VW454-...
  • Page 188 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 ♦ -1- Puller - Kukko Internal - 36-46mm - 21/6- ♦ -3- Puller - Kukko Quick Action Separating Tool - 22-115mm - 17/2- ♦ -4- Puller - Kukko Counterstay - 22/2- ♦...

  • Page 189: Final Drive, Differential

    Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 39 – Final Drive, Differential Seals ⇒ 1.1 Component Location Overview - Seals , page 183 ⇒ 1.2 Left Seal, Replacing , page 183 ⇒ 1.3 Right Seal, Replacing , page 185...
  • Page 190 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 ♦ Torque Wrench 1331 5-50Nm - VAG1331- ♦ Sealing Grease - G 052 128 A1- Caution This procedure contains mandatory replaceable parts. Refer to component overview prior to starting procedure.

  • Page 191: Right Seal, Replacing

    Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 Installing – Lightly oil new seal on outer circumference. – Fill the space between the sealing and dust lip -arrow- halfway with Sealing Grease - G 052 128 A1- .
  • Page 192 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 Right Flange Shaft Seal, Replacing Note The seal -1- and the sleeve -2- are a single part. ♦ The seal and the sleeve can only be replaced together.
  • Page 193 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 The seal is located in a metal housing. – Remove the seal and the sleeve together. A ridge is located on the internal diameter of the sleeve.
  • Page 194 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 – Attach the drive axle heat shield -arrows- (if equipped). Refer to ⇒ Suspension, Wheels, Steering; Rep. Gr. 40 ; Drive Axle; Drive Axle Heat Shield, Removing and Installing .

  • Page 195: Differential

    Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 Differential ⇒ 2.1 Overview - Differential , page 189 ⇒ 2.2 Differential, Disassembling and Assembling , page 190 ⇒ 2.3 Differential, Adjusting , page 194 Overview - Differential...

  • Page 196: Differential, Disassembling And Assembling

    Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 ❑ For the right flange shaft ❑ If the seal is damaged, then replace both the seal and sleeve. Refer to ⇒ 1.3 Right Seal, Replacing , page 185 10 - Bolt ❑...
  • Page 197 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 Note Heat the inner race / tapered roller bearing to 100 °C (212 °F) ♦ before installing. Replace both tapered roller bearings together. ♦ Adjust the differential when replacing the tapered roller bear‐...
  • Page 198 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 Removing the Outer Race/Tapered Roller Bearing from the Transmission Housing A - Counter Support , for example, Puller - Kukko Counterstay - 22/2- B - Internal Puller 46 to 58 mm , for example, Puller - Kukko In‐...
  • Page 199 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 Spring Pin with Surrounding Groove (Short Spring Pin): Remov‐ ing and Installing Removing – Cover the inner race/tapered roller bearing in order to prevent possible damage and entry of shavings.

  • Page 200: Differential, Adjusting

    Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 Installing the Differential Planetary Gears and Differential Bevel Gear Axle – Insert thrust washer union with transmission fluid. – Install and secure both large differential planetary gears, for example, with a flange shaft.
  • Page 201 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 ♦ Differential tapered roller bearing Adjustment Overview. Refer to ⇒ 3 Adjustment Overview , page 198 – Press tapered roller bearing outer race into transmission hous‐ ing without shim, using Press Piece - Multiple Use - 30-205- .
  • Page 202 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 – Attach the Dial Gauge Holder - VW387- and set the dial gauge to 0 with 1 mm preload. – Move differential up and down, read off play on dial gauge and note.
  • Page 203 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 – Remove the transmission housing and remove the tapered roller bearing outer race from the transmission housing. A - Counter Support , for example, Puller - Kukko Counterstay -...

  • Page 204: Adjustment Overview

    Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 Adjustment Overview Note A re-adjustment of the drive axle, output shaft or differential is only required only required if components, which have a direct influ‐ ence on transmission adjustment, have been replaced. Note the...

  • Page 205: Special Tools

    Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 Special Tools ♦ Press Piece - Rod - VW408A- ♦ Press Piece - Multiple Use - VW 473- ♦ Press Piece - Multiple Use - 30-205- ♦ Bearing Installer - Wheel Bearing - 3144- ♦...
  • Page 206 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 Special tools and workshop equipment required ♦ Dial Gauge Holder - VW387- ♦ Measuring Set - Magnetic Plate - 50mm - VW385/17- ♦ Press Piece - Rod - VW407- ♦...
  • Page 207 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 ♦ Seal Installer - One-Piece Seal - T10148- ♦ Spindle from the Seal In‐ staller - Driver Set - 3066- ♦ Slide Hammer Set - VW771- ♦ Slide Hammer Set - Hook - VW771/37- ♦...
  • Page 208 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 ♦ Puller - Taper Roller Bear‐ ing - VAG1582- ♦ Puller - Taper Roller Bear‐ ing - Adapter 3 - VAG1582/3- ♦ Press Piece - Multiple Use - VW412- ♦...
  • Page 209 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 ♦ Slide Hammer Set - VW771- ♦ Slide Hammer Set - Hook - VW771/37- ♦ Seal Installer - Flange Shaft Oil Seal - T10160- ♦ Used Oil Collection and Ex‐...
  • Page 210 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 12.2014 Revision History DRUCK NUMBER: K0059240221 Fac‐ Edit Notes Quality tory Edi‐ Type ed‐ Checke Edi‐ tion d By tion 12.2 8/14/ Edi‐ Jim H 2015 torial Re‐...
  • Page 211 All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other intellectual property rights of Volkswagen of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice. No part of this document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the publisher.
  • Page 212 All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other intellectual property rights of Volkswagen of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice. No part of this document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the publisher.
  • Page 213 All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other intellectual property rights of Volkswagen of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice. No part of this document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the publisher.

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