Volkswagen Golf 2015 Repair Manual
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Volkswagen Golf 2015 Repair Manual

Manual transmission
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Repair Manual
Golf 2015 ➤
Golf Variant 2015 ➤
Manual Transmission
Edition 02.2016
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 02.2016 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 © 2016 Volkswagen AG, Wolfsburg D4B804111B5...

  • Page 3: Table Of Contents

    Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 Contents 00 - General, Technical Data ..........
  • Page 4 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 Gearshift Mechanism, Checking ..........

  • Page 5: General, Technical Data

    Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 00 – General, Technical Data Identification (Edition 02.2016) ⇒ 1.1 Transmission Identification , page 1 Transmission Identification Code Letters and Production Date -arrow 1-, Manual Transmis‐ sion 02Q -arrow 2-...

  • Page 6: Safety Precautions

    Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 Safety Precautions ⇒ 2.1 Road Test with Testing Equipment Safety Precautions , page 2 ⇒ 2.2 Start/Stop System Safety Precautions , page 2 Road Test with Testing Equipment...

  • Page 7: Repair Information

    Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 Repair Information ⇒ 3.1 General Repair Information , page 3 ⇒ 3.2 Contact Corrosion , page 6 General Repair Information Special tools and workshop equipment required ♦ Inductive Heater - VAS6414- Carefulness, cleanliness and the correct tools are required for transmission repairs to be successful.
  • Page 8 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 Fasteners ♦ Do not stretch the circlips. ♦ Installation position for some of the circlips: The circlip is »nar‐ rower at the top« and so is its installation position. This makes it easier for the pliers to grab the circlip when removing and installing it.
  • Page 9 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 Bolts and Nuts ♦ Always loosen or tighten bolts and nuts on covers and hous‐ ings diagonally with a tightening sequence. ♦ Especially delicate parts, such as clutch pressure plates, must not be distorted.

  • Page 10: Contact Corrosion

    Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 ♦ Do not interchange them. When reusing synchronizer rings, always install to the same gear wheel. ♦ Check for wear and replace if necessary. ♦ Check the grooves -arrow 1- on the synchronizer ring -A- and the inner race for flat areas (grooves are worn).

  • Page 11: Technical Data

    Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 Technical Data ⇒ 4.1 Transmission/Engine Allocation , page 7 ⇒ 4.2 Capacities , page 8 ⇒ 4.3 Gear Ratio Calculation , page 8 Transmission/Engine Allocation ⇒ 4.1.1 Transmission/Engine Allocation, Golf , page 7 ⇒...

  • Page 12: Capacities

    Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 Capacities Manual Transmis‐ Refer to ⇒ Fluid Capacity Tables; Rep. sion Capacity Gr. 03 Gear Ratio Calculation Example 6. Gear Final drive Drive gear ZG 1 = 46...

  • Page 13: Overview - Powertrain

    Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 Overview - Powertrain ⇒ 5.1 Overview - Powertrain, Front Wheel Drive , page 9 Overview - Powertrain, Front Wheel Drive Name The -arrows- point in the direction of travel.
  • Page 14 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 I - 1st Gear II - 2nd Gear III - 3rd Gear IV - 4th Gear V - 5th Gear VI - 6th Gear R - Reverse Gear A - Final Drive Rep.

  • Page 15: Electrical Components

    Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 Electrical Components ⇒ 6.1 Overview - Electrical Components Location , page 11 Overview - Electrical Components Lo‐ cation ⇒ 6.1.1 Overview - Electrical Components Location, Manual Transmission , page 11 ⇒...

  • Page 16: Special Tools

    Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 Special Tools Special tools and workshop equipment required ♦ Inductive Heater - VAS6414- Rep. Gr.00 - General, Technical Data...

  • Page 17: Clutch

    Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 30 – Clutch Clutch Mechanism ⇒ 1.1 Overview - Component Location, Clutch Mechanism , page 13 ⇒ 1.2 Overview - Pedal Assembly , page 15 ⇒ 1.3 Overview - Clutch Hydraulics , page 17 ⇒...
  • Page 18 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 I - Refer to ⇒ 1.2 Overview - Pedal As‐ sembly , page 15 II - Refer to ⇒ 1.3.1 Overview - Clutch Hy‐ draulics , page 17 III - Refer to ⇒...

  • Page 19: Overview - Pedal Assembly

    Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 Overview - Pedal Assembly 1 - Clutch Master Cylinder ❑ Removing and instal‐ ling. Refer to ⇒ 1.10 Clutch Master Cylinder, Removing and Installing , page 32 2 - Bearing Bushing ❑...
  • Page 20 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 10 - Bracket ❑ For the clutch pedal ❑ Removing and installing. Refer to ⇒ 1.8 Mounting Bracket, Removing and Installing , page 28 ❑ Use a Piston Pin Drift - VW207- to drive the bushings into the holes for the mounting bracket pins on the bulkhead.

  • Page 21: Overview - Clutch Hydraulics

    Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 Overview - Clutch Hydraulics ⇒ 1.3.1 Overview - Clutch Hydraulics , page 17 ⇒ 1.3.2 Overview - Clutch Hydraulics, RHD , page 19 1.3.1 Overview - Clutch Hydraulics 1 - Clutch Slave Cylinder ❑...
  • Page 22 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 12 - Clamp ❑ The clamp must be removed in order to remove/install the hose/line assembly 13 - Seal/O-Ring ❑ Replace if damaged ❑ Install on the line connection ❑...
  • Page 23 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 Sealing Rings/O-Rings for Hose/Line Assembly or Pipe Item Line Connection Version Line connection with a groove all the way around -arrow 1- Line connection with a shoulder -arrow 2-...
  • Page 24 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 8 - Supply Hose 9 - Brake Fluid Reservoir 10 - Seals ❑ Must be located inside the supply hose. 11 - Clutch Master Cylinder ❑ Removing and installing. Refer to ⇒...

  • Page 25: Overview - Clutch Release Mechanism

    Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 Overview - Clutch Release Mechanism 1 - Clutch Slave Cylinder with Release Bearing ❑ Must be replaced to‐ gether because they are a single unit ❑ Do not wash the bear‐...

  • Page 26: Over-Center Spring, Removing And Installing

    Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 Release Bearing with Additional Plastic Washer Identified by the tabs -arrow- on the plastic washer. Only for Release Bearings with Additional Plastic Washer; Where the Pressure Plate Diaphragm Springs -arrows- have a Slightly Lower Installation Height.
  • Page 27 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 Continuation for All – Remove driver side footwell vent -1-. Refer to ⇒ Heating, Ventilation and Air Conditioning; Rep. Gr. 87 ; Air Routing; Overview - Air Routing and Air Distribution in Passenger Com‐...

  • Page 28: Return Spring, Removing And Installing

    Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 – If present, push the clutch pedal in the direction of -arrow B- to disengage and remove the tension spring -1-. – Bring clutch pedal to the rest position.
  • Page 29 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 Vehicles with a Knee Airbag – Remove the driver side knee airbag -1-. Refer to ⇒ Body In‐ terior; Rep. Gr. 69 ; Knee Airbags; Overview - Knee Airbag .
  • Page 30 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 – Press the retainers together in the direction of -arrows- and remove the mounting pin -1- for the valve lifter/clutch master cylinder to the right. – Move the clutch pedal in the direction of -arrow-, unclip the return spring -1- and remove.

  • Page 31: Clutch Pedal, Removing And Installing

    Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 – Insert the crash bolster -1- and tighten the bolt -2-. Refer to ⇒ Body Interior; Rep. Gr. 70 ; Instrument Panel; Overview - In‐ strument Panel .

  • Page 32: Mounting Bracket, Removing And Installing

    Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 Installing Install in reverse order of removal. Note the following: Item -1- is a 14 mm internal socket wrench A 14 mm hex socket wrench can also be used instead of a 14 mm internal socket wrench.
  • Page 33 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 Vehicles with a Knee Airbag – Remove the driver side knee airbag -1-. Refer to ⇒ Body In‐ terior; Rep. Gr. 69 ; Knee Airbags; Overview - Knee Airbag .
  • Page 34 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 – Remove bolt -2-, unclip the crash bolster -1- and push aside. – Remove the entire air filter housing if the clutch mechanism lines are not accessible.
  • Page 35 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 Note When working inside the footwell, cover the carpet with cloths to protect it from leaking brake fluid. – Disconnect the connector -2- from the Clutch Position Sensor - G476- .

  • Page 36: Bearing Bushing, Removing And Installing

    Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 Bearing Bushing, Removing and Instal‐ ling Removing Disconnect the battery ground cable. Refer to ⇒ Electrical Equip‐ ment; Rep. Gr. 27 ; Battery; Battery, Disconnecting and Con‐...

  • Page 37: Clutch Slave Cylinder With Release Bearing, Removing And Installing

    Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 – Remove the bracket. Refer to ⇒ 1.8 Mounting Bracket, Removing and Installing , page 28 – Remove the Clutch Position Sensor - G476- . Refer to ⇒...

  • Page 38: Clutch Mechanism Lines, Removing And Installing

    Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 – Remove the bolts -arrows-. – Remove the clutch slave cylinder together with the release bearing -A-. Installing Install in the reverse order of removal while noting the following: •...
  • Page 39 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 Caution Danger of leaking brake fluid. ♦ Be careful not to get any brake fluid on the longitudinal member or on the transmission when performing the fol‐...

  • Page 40: Bleeder, Removing And Installing

    Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 – Push the hose/line assembly -4- with the O-ring -3- onto the bleeder connection -1- until the clip -2- audibly locks into place. – Pull on the line to make sure it is secure.

  • Page 41: Clutch Position Sensor G476 , Removing And Installing

    Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 1.15 Clutch Position Sensor - G476- , Re‐ moving and Installing Removing – Move the driver seat as far back as possible. – Disconnect the connector -arrow- from the Clutch Position Sensor - G476- .

  • Page 42: Clutch Release Mechanism, Servicing

    Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 – Remove the air filter housing if it makes the bleeder inacces‐ sible. Vehicles with a Turbo Diesel Engine Refer to ⇒ Engine Mechanical, Fuel Injection and Glow Plug;...
  • Page 43 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 – Remove and attach the clutch slave cylinder with the release bearing -arrows-. Clutch Slave Cylinder -A- with Divided Supply Line The supply line is divided in area with -arrows- on some clutch slave cylinders Allocation.

  • Page 44: Clutch

    Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 Clutch Only for Vehicles with 2.0L Turbo Diesel Engine ⇒ 2.1 Clutch Manufacturers, Differentiating , page 40 ⇒ 2.2 Overview - Clutch , page 41 ⇒ 2.3 Clutch, Removing and Installing , page 45 Clutch Manufacturers, Differentiating Only for Vehicles with 2.0L Turbo Diesel Engine.

  • Page 45: Overview - Clutch

    Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 Round Outer Contour -arrows- is a Clutch Made By Sachs = – Remove and install clutch Sachs . Refer to ⇒ 2.3.1 Clutch, Removing and Installing, with Dual Mass Fly‐...
  • Page 46 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 1 - Dual Mass Flywheel ❑ Make sure it fits secure‐ ly on the centering pins ❑ Keep the clutch lining contact surface free of grooves, oil and grease.
  • Page 47 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 2.2.2 Overview - Clutch, with Dual Mass Flywheel, LuK 1 - Dual Mass Flywheel ❑ Make sure it fits secure‐ ly on the centering pins ❑ Keep the clutch lining contact surface free of grooves, oil and grease.
  • Page 48 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 2.2.3 Overview - Clutch, with Single Flywheel 1 - Flywheel ❑ Make sure it fits secure‐ ly on the centering pins ❑ Keep the clutch lining contact surface free of grooves, oil and grease ❑...

  • Page 49: Clutch, Removing And Installing

    Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 Clutch, Removing and Installing ⇒ 2.3.1 Clutch, Removing and Installing, with Dual Mass Fly‐ wheel, Sachs , page 45 ⇒ 2.3.2 Clutch, Removing and Installing, with Dual Mass Fly‐...
  • Page 50 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 • 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 51 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 Check the Ends of the Diaphragm Spring • Wear up to half the thickness of the diaphragm spring -arrows- is permitted. Checking the Pull-Springs and Rivet Connection I - Pull-spring OK •...
  • Page 52 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 Engines Having a Crankshaft with A Smaller Diameter -arrow-, or Engines Having A Needle Bearing -arrow- in the Crankshaft Centering the Clutch Disc, Removing and Installing the Pressure Plate On Engines with a Crankshaft with a Smaller Diameter, or Engines with a Needle Bearing in the Crankshaft.
  • Page 53 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 er Diameter, or Engines with a Needle Bearing in the Crank‐ shaft. , page 48 -3176- . Removing Transmission removed. – Insert the -3067- to loosen the bolts.
  • Page 54 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 Check the Ends of the Diaphragm Spring • Wear up to half the thickness of the diaphragm spring -arrows- is permitted. Checking the Pull-Springs and Rivet Connection I - Pull-spring OK •...
  • Page 55 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 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 56 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 Centering the Clutch Disc, Removing And Installing the Pressure Plate on Engines with a Crankshaft with a Smaller Diameter, or Engines with a Needle Bearing in the Crankshaft.
  • Page 57 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 Installing Note Allocate clutch pressure plate and clutch plate according to the ♦ engine code. Refer to the Parts Catalog. Clean the input shaft splines and (on used clutch plates) the ♦...
  • Page 58 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 Check the Spring Connection and Rivet Connections – Check the spring connection between the pressure plate and the cover for cracks and make sure the rivet connections are tight.
  • Page 59 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 – Use the -3067- when installing. – Tighten the bolt diagonally in small steps. – Install the transmission. Refer to ⇒ 2.2 Transmission, Installing , page 92 Tightening Specifications ♦...

  • Page 60: Special Tools

    Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 Special Tools Special tools and workshop equipment required ♦ Flywheel Retainer - 3067- ♦ Alignment Tool - Clutch Plate - T10097- ♦ Torque Wrench 1331 5-50Nm - VAG1331- ♦...
  • Page 61 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 ♦ Torque Wrench 1331 5-50Nm - VAG1331- ♦ Brake Charger/Bleeder Unit - VAG1869- ♦ Brake Charger/Bleeder Unit - VAS5234- or ♦ Hose Clamps - Up To 25mm - 3094-...
  • Page 62 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 ♦ Centering Pin - 3176- . Rep. Gr.30 - Clutch...

  • Page 63: Controls, Housing

    Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 34 – Controls, Housing Selector Mechanism ⇒ 1.1 Selector Mechanism Installation Position , page 59 ⇒ 1.2 Overview - Selector Mechanism , page 60 ⇒ 1.3 Overview - Shift Lever Knob and Cover , page 62 ⇒...

  • Page 64: Overview - Selector Mechanism

    Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 Overview - Selector Mechanism Note Lubricate the bearing areas and the sliding surfaces. ♦ Grease allocation. Refer to the Parts Catalog. ♦ 1 - Shift Lever Shaft with Shift...
  • Page 65 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 8 - Nut ❑ 20 Nm ❑ For the cable bracket 9 - Grommet ❑ Quantity: 3 ❑ Cable mounting bracket to transmission 10 - Spacer ❑ Quantity: 3 11 - Lock Washer ❑...

  • Page 66: Overview - Shift Lever Knob And Cover

    Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 ❑ Relay lever and cable retainer, removing and installing. Refer to ⇒ Fig. Relay Lever with Cable Retainer, Removing and Installing , page 66 20 - Sliding Shoe...

  • Page 67: Selector Mechanism, Removing And Installing

    Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 ♦ Hose Clip Pliers - VAG1275A- ♦ Wedge Set - T10383- ♦ -T10383/1- ♦ or the equivalent equipment, Backrest Panel Tool - 3370- Removing – Use the -T10383/1- to carefully pry out the selector lever boot from the center console insert in direction of -arrows-.
  • Page 68 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 Caution This procedure contains mandatory replaceable parts. Refer to component overview prior to starting procedure. Mandatory Replacement Parts ♦ Nut - Selector Lever to Shift Lever Shaft with Shift Lever Cover ♦...
  • Page 69 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 Installed Position of Gearshift Housing Nuts -arrow- – Remove the shift lever housing nuts -arrows-. – Remove center console and center console mounting bracket. Refer to ⇒ Body Interior; Rep. Gr. 68 ; Center Console; Over‐...
  • Page 70 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 Disconnecting the Cable Retainer from the Selector Cable – Pull the securing mechanism all the way forward in direction of -arrow 1- and then unlock to the left in direction of -arrow 2-.
  • Page 71 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 With the Selector Relay Lever Removed: Pry the Selector Cable Retainer Out of the Selector Relay Lever. • The relay lever is removed. – Insert a screwdriver -A- between the bushing -B- and the relay lever.
  • Page 72 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 Cable Retainer Allocation These holes have different diameters. Cable Retainer for: Dimension a -1-: Shift cable to shift lever 8.5 mm -2-: Selector cable to relay lever...
  • Page 73 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 Relay Lever: Lubricate the Following Areas Very Carefully when Installing. • Shaft -A- on the relay lever in the direction of -arrows-; quantity of grease: 0.2 grams •...
  • Page 74 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 A clip -A- holds the cables and heat shield to each other in place. – Mount the cable bracket on the transmission and tighten the bolts -2- and nuts -1-.

  • Page 75: Selector Mechanism, Adjusting

    Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 – Install the boot with the selector knob and, if necessary, the noise insulation. Refer to ⇒ 1.4 Gearshift Knob, Removing and Installingg , page 62 – Replace the clamp -arrow-.
  • Page 76 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 Vehicles with a Gasoline Engine – Refer to ⇒ Engine Mechanical, Fuel Injection and Ignition; Rep. Gr. 24 ; Air Filter; Air Filter Housing, Removing and In‐...
  • Page 77 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 Secure the shift lever shaft as follows: – Install the shift lever in neutral and, if necessary, press the shift lever to the left and hold. – Guide the -T10027A- through the noise insulation -A-, hole -B- and into hole -C-.

  • Page 78: Gearshift Mechanism, Checking

    Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 – Remove the -T10027A- from the noise insulation -A- and the holes -B and C-. – Install the boot and the noise insulation (if equipped). Refer to ⇒...
  • Page 79 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 – Remove the seal using the -T20143/1- – 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 80: Transmission, Removing And Installing

    Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 Transmission, Removing and Instal‐ ling ⇒ 2.1 Transmission, Removing , page 76 ⇒ 2.2 Transmission, Installing , page 92 ⇒ 2.3 Transmission Tightening Specifications , page 104 Transmission, Removing ⇒...
  • Page 81 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 – If the -10-222A- does not yet have a hole with an -arrow- marked on it, do so now. • Dimension -a- = 225mm • Hole diameter = 12.5 mm –...
  • Page 82 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 – Remove nut -1- and bolts -2- and set the cable bracket and cables off to the side. Note Brake fluid must not come into contact with the longitudinal mem‐...
  • Page 83 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 – Attach the -10-222A- as follows: The following are needed: ♦ -10-222A/31-1- ♦ -10-222A/31-2- ♦ -10-222A/12- ♦ -T40091/1- ♦ -T40091/3- ♦ -T40093A/3- ♦ -T40093/3-6- – Remove caps above the front suspension strut bolted con‐...
  • Page 84 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 – Remove fuel filter and set off to the side. Do not open the line system. Refer to ⇒ Fuel Supply System; Rep. Gr. 20 ; Fuel Delivery Unit/Fuel Level Sensor;...
  • Page 85 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 – Remove the drive axle heat shield -arrows- (if equipped). Re‐ fer to ⇒ Suspension, Wheels, Steering; Rep. Gr. 40 ; Drive Axle; Drive Axle, Removing and Installing .
  • Page 86 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 – Remove the bolts -arrows- and then remove the transmission bracket from the transmission. – Remove the bolts -2- from the transmission/engine connec‐ tion. The transmission to engine connection bolts -1 and 3- will be re‐...
  • Page 87 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 – Remove the last transmission to engine connecting bolt -arrow-. – Separate the transmission from the engine (alignment sleeves). – Carefully lower the transmission while guiding the right flange shaft past the hole -arrow 1- on the intermediate plate and the flywheel -arrow 2-.
  • Page 88 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 ♦ Engine Sling - Engine Bracket - 2024A/1- from Engine Sling - 2024A- ♦ Grease for Clutch Plate Shaft Splines - G 000 100- ♦ Allocate the grease for gearshift mechanism. Refer to the Parts Catalog.
  • Page 89 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 – Remove the cable retainer from the selector cable. • To avoid damage to the selector cable, the cable retainer must be disconnected from the selector lever before removal.
  • Page 90 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 – Remove the upper engine/transmission connecting bolts -arrows-. – Disconnect any hoses and cables in the area of the -10-222A- lifting eyes on the engine. – Attach the -10-222A- as follows: The following are needed: ♦...
  • Page 91 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 – If present, remove wires from the front area of both longitudinal members -arrow-. Do not disconnect line system. – Place the -T40093/3-6- on both longitudinal members (the right longitudinal member is illustrated here).
  • Page 92 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 – Remove the fan shroud with the coolant fan -arrow-. Refer to ⇒ Engine Mechanical, Fuel Injection and Ignition; Rep. Gr. 19 ; Radiator/Coolant Fan; Fan Shroud, Removing and Instal‐...
  • Page 93 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 – Move the left suspension strut to the outside and support it with the hook -2024A/1- as illustrated. WARNING There is the risk of an accident due to loose support parts.
  • Page 94 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 – Remove the bolts -arrows- from the transmission mount. – Turn the spindles on the -10-222A- and lower the transmission to dimension -a-. • Dimension -a- = approximately 60 mm –...
  • Page 95 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 Align the -3282- with the -3282/33- in order to install the trans‐ mission. – Align the arms of the -3282- so that they match up with the holes in the Adjustment Plate .

  • Page 96: Transmission, Installing

    Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 – Guide the transmission and the differential over the subframe and swing them out. – Be careful of the longitudinal member -arrow 1- and of the subframe -arrow 2-.
  • Page 97 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 ♦ Bolt - Pendulum Support to Transmission ♦ Bolt - Transmission Bracket to Transmission Note Refer to Transmission, Removing to get a list of the special ♦...
  • Page 98 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 – Install the -3282/29- into the rear hole in the transmission for the pendulum support bolt. – Secure the -VW771/40- inside the threaded hole in the trans‐...
  • Page 99 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 – Install transmission bracket -1- with new bolts -arrows-. Refer ⇒ 3.1 Overview - Subframe Mount , page 105 Caution Risk of damaging threads in transmission bracket by inserting bolts crooked.
  • Page 100 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 – Mount the cable bracket on the transmission and tighten the bolts and nuts -arrows-. Refer to ⇒ 1.2 Overview - Selector Mechanism , page 60 – Install the selector cable in the cable retainer.
  • Page 101 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 Note Threaded inserts (for example, Heli Coil ) are found in the pen‐ dulum support fastening holes on some transmissions. Refer to ⇒ Fig. Transmission with Threaded Insert (for example Heli Coil) for Attaching the Pendulum Support , page 107 –...
  • Page 102 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 ♦ Hose Clamp up to 25mm - 3094- Caution This procedure contains mandatory replaceable parts. Refer to component overview prior to starting procedure. Mandatory Replacement Parts ♦ Nut - Selector Lever to Shift Lever Shaft with Shift Lever Cover ♦...
  • Page 103 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 Engage the intermediate plate on the sealing flange and push it onto the alignment sleeves -arrows-. – Check the release bearing for wear. Replace the clutch slave cylinder with release bearing if necessary.
  • Page 104 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 – Guide the transmission with the differential -arrow 2- over the subframe. – Pay attention to the longitudinal member -arrow 1-. • After that, the right flange shaft -1- must be guided past the flywheel and the opening -arrow- in the intermediate plate.
  • Page 105 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 – Tighten the -10-222A- spindles until the transmission bracket -1- touches the transmission mount -2- to align the engine/ transmission assembly in its installed position. – Install new bolts -arrows- and tighten. Refer to ⇒...
  • Page 106 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 – Install the selector cable in the cable retainer. – Apply a small amount of grease on the pins -arrow- for the shift lever -2-. Grease allocation. Refer to the Parts Catalog.
  • Page 107 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 – Install pendulum support with new bolts. Refer to ⇒ Engine Mechanical, Fuel Injection and Ignition; Rep. Gr. 10 ; Sub‐ frame Mount; Overview - Subframe Mount .

  • Page 108: Transmission Tightening Specifications

    Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 – Connect the connector -1- to the Oil Level Thermal Sensor - G266- . – Gear oil level in manual transmission, checking. Refer to ⇒ 8.1 Transmission Fluid Level, Checking , page 142 –...

  • Page 109: Subframe Mount

    Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 Subframe Mount ⇒ 3.1 Overview - Subframe Mount , page 105 Overview - Subframe Mount 1 - Bolt ❑ Ttightening specifica‐ tion. Refer to ⇒ Engine Mechanical, Fuel Injec‐...
  • Page 110 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 10 - Bolt ❑ For pendulum support to transmission ❑ Refer to ⇒ Engine Mechanical, Fuel Injection and Ignition; Rep. Gr. 10 ; Subframe Mount; Overview - Subframe Mount .
  • Page 111 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 Transmission with Threaded Insert (for example Heli Coil ) for Attaching the Pendulum Support Note There are threaded inserts (for example Heli Coil ) in the pen‐...

  • Page 112: Transmission, Transporting

    Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 Transmission, Transporting ⇒ 4.1 Transmission, Transporting , page 108 Transmission, Transporting Special tools and workshop equipment required ♦ Transmission Support Jig - 3336- ♦ Shop Crane - VAS6100- –...

  • Page 113: Transmission, Disassembling And Assembling

    Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 Transmission, Disassembling and Assembling ⇒ 5.1 Overview - Schematic, Transmission , page 109 ⇒ 5.2 Overview - Transmission , page 110 ⇒ 5.3 Overview - Transmission Housing and Selector Mecha‐...

  • Page 114: Overview - Transmission

    Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 Overview - Transmission l - Refer to ⇒ 5.3 Overview - Transmis‐ sion Housing and Selector Mechanism , page 111 l - Refer to ⇒ 5.4 Overview - Shift Unit ,...

  • Page 115: Overview - Transmission Housing And Selector Mechanism

    Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 Overview - Transmission Housing and Selector Mechanism 1 - Bolt ❑ Removing and instal‐ ling. Refer to ⇒ 2.1 Overview - Differ‐ ential , page 212 2 - Left Flange Shaft ❑...
  • Page 116 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 12 - Locking Bolt ❑ Metal locking bolt: 45 Nm ❑ Plastic locking bolt: 30 Nm ❑ Replace locking bolt after removing ❑ For the selector shaft ❑...

  • Page 117: Overview - Shift Unit

    Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 Overview - Shift Unit 1 - Bearing Bushing ❑ For the selector shaft ❑ Removing and instal‐ ling. Refer to ⇒ 6.1 Overview - Trans‐ mission Housing ,...

  • Page 118: Overview - Input Shaft, Output Shafts, Differential, Shift Lever Rods

    Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 Overview - Input Shaft, Output Shafts, Differential, Shift Lever Rods 1 - Output Shaft, 1st to 4th Gears ❑ Disassembling and as‐ sembling. Refer to ⇒ 2.1 Overview - Out‐...
  • Page 119 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 9 - Reverse Shaft 10 - Thrust Washer 11 - Bleeder ❑ Connect with clutch slave cylinder 12 - Clutch Housing ❑ Servicing. Refer to ⇒ 6 Transmission Housing and Clutch Housing , page 130 13 - Input Shaft Seal ❑...

  • Page 120: Overview - Shift Forks

    Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 Overview - Shift Forks 1 - Insulation Mat ❑ Remove from the shift lever rod by hand and install. 2 - Shift Lever Rod with Shift Fork for 1st Gear and 2nd Gear...
  • Page 121 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 ♦ Bracket - Multiple Use - 30-211A- ♦ Seal Installer - Drive Flange - T10143- or Seal Installer - Out‐ put Shaft Oil Seal - T10180- ♦ Locking Sleeve Drift - T10169- ♦...
  • Page 122 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 – Remove the right flange shaft (the illustration shows the left flange shaft). – Remove the flange shaft and the pressure spring. – Remove the clutch slave cylinder with the release bearing -arrows-.
  • Page 123 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 Note Use the -80-200- to press against the spring force of the securing bushing direction of -arrow- so that the shift lever shaft -1- does not touch the securing bushing -2- when removing.
  • Page 124 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 – Or place the -3160- over the input shaft on the clutch housing. – Tension the Separating Tool - 5-60mm -A-, for example -17/0- , tightly behind the splines on the input shaft.
  • Page 125 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 Note Pry the cap -1- off with a screwdriver -2-. Plastic Cover Carefully remove all tabs -A-. Do not damage the transmission housing when doing so. – Remove the cap -A-.
  • Page 126 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 – Remove the bolts -A- that attach the transmission housing to the clutch housing. – Install -VW771/40- into the threaded hole in the transmission housing. – Heat the transmission housing in the area near the bearing seat for the grooved ball bearing/input shaft to approximately 100 °C (212 °F) for approximately 10 minutes using a Hot Air...
  • Page 127 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 – Lift the differential -1- with the left hand. With the right hand, lift the output shaft for 1st to 4th gear together with the shift lever rods -2- -arrow A-.
  • Page 128 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 – Then install the differential -1-. Note A second technician is needed to help install the shafts into the clutch housing. – Hold 1st through 4th gear output shaft -3- with the shift lever rods -4- in the right hand as illustrated.
  • Page 129 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 Note It is necessary to heat the transmission housing so that the ♦ grooved ball bearing is not damaged when the housing is be‐ ing installed. Apply Sealing Paste - AMV 188 200 03- evenly onto the seal‐...
  • Page 130 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 – Install the grooved ball bearing/input shaft locking ring -1-. – Remove the -30-211A- for the input shaft. – If the retaining sleeve for the shift lever shaft was removed, then install it now all the way onto the tool.
  • Page 131 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 – Tighten the bolts -3- for the shift lever cover -4-. – Install the locking bolt -2-, lock elbow -arrow- must not be in‐ stalled when doing so.
  • Page 132 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 Allocation Mounting Area for the Cov‐ Cover Installation -Arrow A- is at vertical Made of Refer to metal ⇒ Fig. Metal Cov‐ er , page 128 -Arrow B- is at an angle...
  • Page 133 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 – Install the flange shafts with the springs, thrust washers and tapered rings. Tightening Specifications ♦ Refer to ⇒ 1.4 Overview - Clutch Release Mechanism , page 21 ♦...

  • Page 134: Transmission Housing And Clutch Housing

    Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 Transmission Housing and Clutch Housing ⇒ 6.1 Overview - Transmission Housing , page 130 ⇒ 6.2 Overview - Clutch Housing , page 132 ⇒ 6.3 Transmission Housing, Servicing , page 134 ⇒...
  • Page 135 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 ❑ Removing. Refer to ⇒ Fig. Removing the Shift Rod Bearing Bushing , page 135 ❑ Installing. Refer to ⇒ Fig. Installing the Shift Rod Bearing Bushing all the way onto the Tool , page 136 8 - Retaining Sleeve ❑...

  • Page 136: Overview - Clutch Housing

    Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 17 - Plugs ❑ Removing. Refer to ⇒ Fig. Removing the Plug -1- , page 138 ❑ Installing. Refer to ⇒ Fig. Installing the Plug -1- , page 139 18 - Seal ❑...
  • Page 137 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 9 - Outer Race/Tapered Roller Bearing ❑ For the differential ❑ Removing and installing. Refer to ⇒ 2.2 Differential, Disassembling and Assembling , page 214 ❑ When replacing: Adjusting the differential. Refer to ⇒...

  • Page 138: Transmission Housing, Servicing

    Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 Transmission Housing, Servicing Special tools and workshop equipment required ♦ Bearing Driver - Multiple Use - VW244B- ♦ Transmission Support - VW353- ♦ Press Plate - VW401- ♦...
  • Page 139 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 Removing the Locking Elbow for the Shift Lever Shaft – Break off the bracket in its unlocked position. – Insert a screwdriver -A- into the hole in the locking bracket -B-.
  • Page 140 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 Installing the Shift Rod Bearing Bushing all the way onto the Tool Removing the Retaining Sleeve -A- from the Transmission Hous‐ – Place transmission housing on Press Plate - VW401- and press plate -VW402- in such a way so that the alignment sleeves inside the transmission housing do not get damaged.
  • Page 141 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 Drive in Lock Sleeve with Shoulder as Far as Stop on Tool • The transmission housing is bolted to the clutch housing. Drive in Lock Sleeve without Shoulder as far as Stop on Tool •...
  • Page 142 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 Removing the Selector Shaft Bearing Bushing – Use the thread adapter from -Kukko 22/1- -arrow-. – Hold the spindle on the -3290- steady and turn the nut -B-.

  • Page 143: Clutch Housing, Servicing

    Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 Installing the Plug -1- – Using the -3264- , drive in the sealing plugs to dimension -a- approximately 3 mm below the upper edge of the housing.
  • Page 144 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 Removing the Needle Sleeve from the Clutch Housing A - Counter Support , for example, -22/2- B - Internal Puller 23.5 to 30 mm , for example -21/4-...

  • Page 145: Securing On Engine And Transmission Holder

    Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 Securing on Engine and Transmis‐ sion Holder ⇒ 7.1 Securing on Engine and Transmission Holder , page 141 Securing on Engine and Transmission Holder Special tools and workshop equipment required ♦...

  • Page 146: Transmission Fluid

    Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 Transmission Fluid ⇒ 8.1 Transmission Fluid Level, Checking , page 142 Transmission Fluid Level, Checking Special tools and workshop equipment required ♦ For oil filler plug with multi-point fitting Triple Square Socket Driver - 3357- .

  • Page 147: Special Tools

    Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 Special Tools ♦ Slide Hammer Set - Adapt‐ er 40 - VW771/40- ♦ Engine Support Brackets - T40093/3-6- (quantity 2) ♦ Engine Support Bridge - Special Hook (2 pc.) - 10-222A/20- ♦...
  • Page 148 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 Special tools and workshop equipment required ♦ Bearing Driver - Multiple Use - VW244B- ♦ Transmission Support - VW353- ♦ Press Plate - VW401- ♦ Press Plate - VW402- ♦...
  • Page 149 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 ♦ Guide Pin - VW436A- ♦ Press Piece - Guide Pin - VW439- ♦ Slide Hammer Set - VW771- ♦ Crankshaft Holding Fixture - VW801- ♦ Guide Pins - 10 - 15- ♦...
  • Page 150 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 ♦ Bearing Installer - Crank‐ shaft Pilot Bearing - 3264- ♦ Subframe Support Tool - 3290- ♦ Torque Wrench 5-50Nm - VAG1331- ♦ Bushing Driver - Selector Shaft - T10168- ♦...
  • Page 151 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 ♦ Holding Plate - VW309A- ♦ or Holding Plate - VW 309A- ♦ Holding Fixture - VW 313- ♦ Transmission Support - VW353- ♦ Press Piece - Multiple Use...
  • Page 152 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 Special tools and workshop equipment required ♦ Press Piece - Rod - VW407- ♦ Bushing Driver - Selector Shaft - T10168- ♦ Seal Installer - Driveshaft - T40008- ♦...
  • Page 153 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 ♦ Transmission Support - Mounting Plate 33 - 3282/33- ♦ Support Elements for trans‐ mission (determine when mounting the Mounting Plate on the Transmission Support ) ♦ Transmission Support Jig - 3336- to transport the transmission.
  • Page 154 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 ♦ Bracket - Multiple Use - 30-211A- ♦ Seal Installer - Drive Flange - T10143- or Seal Installer - Output Shaft Oil Seal - T10180- ♦ Locking Sleeve Drift - T10169- ♦...
  • Page 155 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 ♦ Engine Support Bridge - 10-222A- ♦ Engine/Gearbox Support Shackle (2 pc.) - 10-222A/ ♦ Engine Support Bridge - Engine Support 31 - Adapt‐ er 1 - 10-222A/31-1- ♦...
  • Page 156 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 Special tools and workshop equipment required ♦ Engine Support Bridge - 10-222A- ♦ Engine Support Bridge - Engine Support 29 - 10-222A/29- ♦ Engine Support Bridge -...
  • Page 157 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 ♦ Connecting Pin - T10027A- ♦ Wedge Set - T10383- ♦ Puller - Crankshaft/Power Steering Seal 1 - T20143/1- ♦ Hose Clip Pliers - VAG1275A- 9. Special Tools...
  • Page 158 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 ♦ Engine and Gearbox Bracket - VAS6095A- ♦ Shop Crane - VAS6100- ♦ Engine Bung Set - VA 6122- ♦ Shop Crane - Drip Tray - VAS6208-...
  • Page 159 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 ♦ Press Piece - Shift Rod/Alternator - VW423- ♦ -1- Puller - Kukko Internal - 14-19mm - 21/2- ♦ -1- Puller - Kukko Internal - 20-30mm - 21/4- ♦...
  • Page 160 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 ♦ Transmission Support Jig - 3336- ♦ Triple Square Socket Driver - 3357- . ♦ Backrest Panel Tool - 3370- Rep. Gr.34 - Controls, Housing...

  • Page 161: Gears, Shafts

    Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 35 – Gears, Shafts Input Shaft ⇒ 1.1 Overview - Input Shaft , page 157 ⇒ 1.2 Input Shaft, Disassembling and Assembling , page 158 ⇒ 1.3 Input Shaft Seal, Replacing , page 161...

  • Page 162: Input Shaft, Disassembling And Assembling

    Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 ❑ Installing. Refer to ⇒ Fig. Grooved Ball Bearing Installation Location and Installing the Grooved Ball Bearing , page 160 5 - 5th Gear Wheel ❑ Available as a replacement part together with the input shaft ❑...
  • Page 163 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 Input Shaft, Disassembling – Remove the grooved ball bearing locking ring. Removing the Grooved Ball Bearing – Mount the Separating Tool 22-115mm -A- into the groove in the ball bearing for the locking ring.
  • Page 164 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 Grooved Ball Bearing Installation Location and Installing the Grooved Ball Bearing • Grooved ball bearing installed position: The groove for the locking ring faces up -arrow A- and the collar -arrow B- must face the 5th gear wheel.

  • Page 165: Input Shaft Seal, Replacing

    Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 Pressing Cylindrical Roller Bearing into Clutch Housing. – Compress the cylindrical roller bearing locking ring -arrow- with pliers -C- and install it. – Remove the pliers before the cylindrical roller bearing gets into its installed position.
  • Page 166 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 – Fill the space with the new seal between the sealing and dust lip halfway with Sealing Grease - G 052 128 A1- . – Coat the outer circumference of the seal lightly with transmis‐...

  • Page 167: Output Shaft

    Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 Output Shaft ⇒ 2.1 Overview - Output Shaft , page 163 ⇒ 2.2 Output Shaft, Disassembling and Assembling , page 172 ⇒ 2.3 Output Shaft, Adjusting , page 187 Overview - Output Shaft ⇒...
  • Page 168 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 1 - Clutch Housing 2 - Oil Deflector Ring 3 - Dished Washer ❑ Removing. Refer to ⇒ Fig. Removing the Dished Washer -A- from the Output Shaft , page 172 ❑...
  • Page 169 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 ❑ Installed position. Refer to ⇒ Fig. Installing 2nd Gear Outer Race, Inner Race and Synchronizer Ring , page 177 11 - 2nd Gear Synchronizer Ring ❑ Check the inner running surface for grooves and radial wear ❑...
  • Page 170 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 21 - Collar Bushing ❑ For the 4th gear needle bearing ❑ Only installed on transmissions with reinforcement measures. Refer to ⇒ Fig. Reinforcement Measures on Manual Transmission 0FB near 4th Gear Wheel , page 167 ❑...
  • Page 171 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 31 - 3rd Gear Wheel ❑ Mount on the output shaft. Refer to ⇒ Fig. Installing the 3rd Gear Wheel with Needle Bearing , page 181 32 - Inner Race / Tapered Roller Bearing ❑...
  • Page 172 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 Differentiation of Output Shafts Output Shaft -1- with Reinforce‐ -2- without Reinforce‐ ment Measures ment Measures Dimension -a- 40.1 mm 42.0 mm -Arrow A- Groove for collar...
  • Page 173 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 1 - Clutch Housing 2 - Washer ❑ Always 0.65 mm thick 3 - Outer Race/Tapered Roller Bearing ❑ Removing. Refer to ⇒ Fig. Removing the Outer Race/Tapered...
  • Page 174 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 14 - 6th Gear Wheel 15 - Synchronizer Ring for 6th Gear ❑ Brass or steel ❑ Checking for wear. Refer to ⇒ Fig. Checking 5th and 6th Gear Synchronizer Ring for Wear , page 185 16 - Locking Collar with Synchronizer Hub for 5th and 6th Gears ❑...
  • Page 175 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 27 - Locking Collar 28 - Synchronizer Hub 29 - Locking Piece ❑ Quantity: 3 ❑ Installed position. Refer to ⇒ Fig. Disassembling and Assembling Locking Collar and Synchronizer Hub for 5th and 6th Gears , page 186 2.

  • Page 176: Output Shaft, Disassembling And Assembling

    Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 Output Shaft, Disassembling and As‐ sembling ⇒ 2.2.1 Output Shaft, Disassembling and Assembling, 1st to 4th Gears , page 172 ⇒ 2.2.2 Output Shaft, 5th, 6th and Reverse Gears, Disassem‐...
  • Page 177 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 Installing the Dished Washer into the Output Shaft Dimension a = 2 mm Removing the Inner Race/Tapered Roller Bearing on the side of the Clutch Housing A - Separating Tool 22-115mm , for example, -17/2-...
  • Page 178 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 Installing the Outer Race/Tapered Roller Bearing in the Clutch Housing – Support the clutch housing with the -40-20- directly under the bearing mount. Remove the Inner Race/Tapered Roller Bearing on the side of the...
  • Page 179 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 Removing the Outer Race/Tapered Roller Bearing from the Transmission Housing A - Counter Support , for example, -22/2- B - Internal Puller 46 to 58 mm , for example, -21/7- Installing the Outer Race/Tapered Roller Bearing into the Trans‐...
  • Page 180 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 Removing the Locking Collar and the Synchronizer Hub for 1st and 2nd Gear After removing the circlip, press off the gear wheel for 2nd gear and locking collar/synchronizer hub together.
  • Page 181 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 Installing 2nd Gear Outer Race, Inner Race and Synchronizer Ring – Place inner race -A- on drive gear for 2nd gear. The tabs -1- face away from the gear wheel.
  • Page 182 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 Warming and Installing the Locking Collar/Synchronizer Hub for 1st and 2nd Gears. The pins -A- on the synchronizer ring lock into the recesses -B- in the synchronizer hub.
  • Page 183 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 On Transmissions with Reinforcement Measures, Install Collar Bushing -A- to Stop. Note Allocate transmission via code letters: • Installation position of the collared sleeve -A-: The collar -arrow- points to the 1st gear wheel.
  • Page 184 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 Installed Position: Locking Collar/Synchronizer Hub for 3rd and 4th Gears The wider collar on the synchronizer hub -arrow- faces 3rd gear. – Place the synchronizer ring for 4th gear on the 4th gear wheel.
  • Page 185 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 Installing the 3rd Gear Wheel with Needle Bearing • The synchronizer ring -1- and the tabs -arrow A- are inside the openings in the synchronizer hub -2-.
  • Page 186 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 2.2.2 Output Shaft, 5th, 6th and Reverse Gears, Disassembling and Assembling Special tools and workshop equipment required ♦ Press Plate - VW401- ♦ Press Plate - VW402- ♦...
  • Page 187 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 Installing the Outer Race/Tapered Roller Bearing in the Clutch Housing – Place the washer under the outer race. – Support the clutch housing with the -40-20- directly under the bearing mount.
  • Page 188 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 Removing the 5th and 6th Gear Synchronizer Hub/Locking Collar with the 6th Gear Wheel – Remove the locking ring beforehand. Removing the Sleeve -A- together with the Reverse Gear Wheel –...
  • Page 189 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 Installed Position: Reverse Gear Synchronizer Hub • The stop -arrow A- on the reverse gear locking collar faces the splines on the output shaft -arrow B-. Warming and Installing the Reverse Gear Synchronizer Hub –...
  • Page 190 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 – Press synchronizer ring onto taper of the gear wheel and measure gap dimension -a- using a feeler gauge. Disassembling and Assembling Locking Collar and Synchronizer Hub for 5th and 6th Gears To disassemble, remove the springs -1-.

  • Page 191: Output Shaft, Adjusting

    Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 Installing the Inner Race/Tapered Roller Bearing on the side of the Transmission Housing – Choose the correct locking ring. Refer to ⇒ Fig. Selecting the Locking Ring , page 187 and install.
  • Page 192 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 ♦ Slide Hammer - Press Plate - 2050- ♦ Torque Wrench 1331 5-50Nm - VAG1331- ♦ Puller - Kukko Internal - 46-56mm - 21/07- ♦ Puller - Kukko Counterstay - 22/2- ♦...
  • Page 193 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 – Position the measuring tools on the clutch housing and secure them with a bolt -arrow-. – Set the dial gauge (3 mm range) with 1 mm preload to 0 .
  • Page 194 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 – Install the outer race/tapered roller bearing with the selected shim (in the example: 1.75 mm). Support transmission hous‐ ing directly beneath bearing mount using -2050- .
  • Page 195 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 Requirements • Remove any sealant still on the sealing surfaces on the clutch and transmission housings. • Install the output shaft that is going to be measured.
  • Page 196 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 – Attach the measuring tools to the clutch housing. In the case of protruding housing edges: – Place washers (total thickness: 8 mm) under the -VW792- -arrow-.
  • Page 197 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 – Remove the transmission housing and remove the tapered roller bearing outer race from the transmission housing. A - Counter Support , for example, -22/2- B - Internal Puller 46 to 58 mm , for example, -21/7- –...

  • Page 198: Special Tools

    Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 Special Tools Special tools and workshop equipment required ♦ Press Plate - VW401- ♦ Press Plate - VW402- ♦ Press Piece - Rod - VW407- ♦ Press Piece - Rod - VW408A- ♦...
  • Page 199 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 ♦ Holding Plate - VW309A- ♦ Transmission Support - VW353- ♦ Press Piece - Multiple Use - VW433- ♦ Press Piece - Multiple Use - VW454- ♦ Support Channels - VW457- ♦...
  • Page 200 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 ♦ Holding Plate - VW309A- ♦ Holding Fixture - VW313- ♦ Transmission Support - VW353- ♦ Press Piece - Multiple Use - VW431- ♦ Press Piece - Multiple Use - VW433- ♦...
  • Page 201 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 ♦ Press Piece - Multiple Use - VW512- ♦ Press Piece - 42mm - VW516- ♦ Press Piece - Multiple Use - VW519- ♦ Slide Hammer Set - VW771- ♦...
  • Page 202 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 ♦ Transmission Support - VW353- ♦ Dial Gauge Holder - VW387- ♦ Press Piece - Rod - VW407- ♦ Press Piece - Multiple Use - VW433- ♦ Seal Installer - Stator - VW792- ♦...
  • Page 203 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 ♦ Press Piece - Multiple Use - VW431- ♦ Press Piece - Multiple Use - VW455- ♦ Press Piece - Multiple Use - VW510- ♦ Press Piece - 42mm - VW516- ♦...
  • Page 204 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 ♦ Holding Plate - VW 09A- ♦ Slide Hammer - Press Plate - 2050- ♦ Torque Wrench 1331 5-50Nm - VAG1331- ♦ -1- Internal Puller - VAS251615- ♦...
  • Page 205 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 ♦ Transmission Support - VW353- ♦ Dial Gauge Holder - VW387- ♦ Press Piece - Rod - VW407- ♦ Press Piece - Multiple Use - VW433- ♦ Seal Installer - Stator - VW792- ♦...
  • Page 206 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 ♦ Press Piece - Multiple Use - 40-105- ♦ Bearing Installer - Multiple Use - 40-20- ♦ Slide Hammer - Press Plate - 2050- ♦ Press Piece - Reverse Gear Syncro - 3296- ♦...
  • Page 207 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 ♦ Press Plate - VW401- ♦ Press Plate - VW402- ♦ Press Piece - Rod - VW407- ♦ Press Piece - Rod - VW408A- ♦ Press Piece - Multiple Use - VW412- ♦...
  • Page 208 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 ♦ Bearing Installer - Multiple Use - 40-20- ♦ Bearing Installer - Differen‐ tial Bearing - 40-21- ♦ Press Piece - Multiple Use - 2050- ♦ Holding Fixture - Spacers - VW540/1B- ♦...
  • Page 209 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 ♦ Puller - Crankshaft/Power Steering Seal - T20143/1- ♦ Puller - Taper Roller Bearing - Adapter 7 - VAG1582/7- ♦ Dial Indicator - VAS6080A- ♦ Inductive Heater - VAS6414-...
  • Page 210 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 ♦ Press Piece - Bushing - 50mm Diameter - VW432- ♦ -1- Puller - Kukko Internal - 28-37mm - 21/5- ♦ -3- Puller - Kukko Quick Action Separating Tool - 22-115mm - 17/2- ♦...

  • Page 211: Final Drive, Differential

    Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 39 – Final Drive, Differential Seals ⇒ 1.1 Overview - Component Location, Seals , page 207 ⇒ 1.2 Left Seal, Replacing , page 207 ⇒ 1.3 Right Seal, Replacing , page 209...
  • Page 212 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 ♦ Shop Crane - Drip Tray - VAS6208- or Used Oil Collection and Extraction Unit - SMN372500- ♦ Sealing Grease - G 052 128 A1- Removing – Remove the left wheel.

  • Page 213: Right Seal, Replacing

    Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 – Install the seal all the way in without tilting it. – Fill the space between the sealing and dust lip -arrow- halfway with Sealing Grease - G 052 128 A1- .
  • Page 214 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 – Remove the heat shield above the right drive axle -arrows-, if equipped. – Remove the right drive axle from the transmission flange shaft -A-. Refer to ⇒ Suspension, Wheels, Steering; Rep. Gr. 40 ;...
  • Page 215 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 – Install the seal all the way in without tilting it. – Install the seal all the way in without tilting it. – Push the flange shaft -A- toward the transmission and secure.

  • Page 216: Differential

    Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 Differential ⇒ 2.1 Overview - Differential , page 212 ⇒ 2.2 Differential, Disassembling and Assembling , page 214 ⇒ 2.3 Differential, Adjusting , page 218 Overview - Differential Note Secure the transmission on the assembly stand.
  • Page 217 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 wheel 6 - Inner Race / Tapered Roller Bearing ❑ Removing. Refer to ⇒ Fig. Removing the Inner Race/Tapered Roller Bearing , page 216 ❑ Installing. Refer to ⇒...

  • Page 218: Differential, Disassembling And Assembling

    Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 21 - Small Differential Bevel Gear ❑ Availability. Refer to the Parts Catalog. ❑ Installing. Refer to ⇒ Fig. Installing the Differential Bevel Gears , page 217 22 - Threaded Piece ❑...
  • Page 219 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 Caution This procedure contains mandatory replaceable parts. Refer to component overview prior to starting procedure. Mandatory Replacement Parts ♦ Seal - Right Flange Shaft Removing the Outer Race/Tapered Roller Bearing from the...
  • Page 220 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 Heat the Inner Race/Tapered Roller Bearing and Press On It The cage wit the tapered rollers must rotate easily when being installed. WARNING Wear safety gloves. Removing the Inner Race/Tapered Roller Bearing...
  • Page 221 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 Installing Outer Race/Tapered Roller Bearing into the Transmis‐ sion Housing – Support the transmission housing directly under the bearing mount using the - 3345- . Removing the Spring Pin for the Differential Bevel Gear Axle –...

  • Page 222: Differential, Adjusting

    Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 Installing the Spring Pin for the Differential Bevel Gear Axle – Align the hole in the differential bevel gear axle to the hole in the differential housing.
  • Page 223 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 – Install the outer race/tapered roller bearing without adjustment shim into transmission housing. – Insert differential into clutch housing. – Mount transmission housing and tighten five bolts.
  • Page 224 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 – Install the outer race again and the tighten the transmission housing to the tightening specification. Tightening Specifications ♦ Transmission housing to clutch housing. Refer to ⇒ 5.3 Overview - Transmission Housing and Selector Mech‐...

  • Page 225: Adjustment Overview

    Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 Adjustment Overview ⇒ 3.1 Overview - Adjustment , page 221 Overview - Adjustment Note When performing repairs on the transmission, readjustment of the output shaft for 1st to 4th gears, output shaft for 5th/6th gear and...

  • Page 226: Special Tools

    Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 Special Tools Special tools and workshop equipment required ♦ Press Plate - VW402- ♦ Press Piece - Rod - VW408A- ♦ Press Piece - Multiple Use - VW412- ♦...
  • Page 227 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 ♦ Slide Hammer Set - VW771- ♦ Slide Hammer Set - Hook - VW 771/37- ♦ Seal Installer - Flange Shaft - 3305- ♦ Torque Wrench 1331 5-50Nm - VAG1331- ♦...
  • Page 228 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 ♦ Measuring Set - Magnetic Plate - 50mm - VW385/17- ♦ Dial Gauge Holder - VW387- ♦ Press Plate - VW402- ♦ Press Piece - Rod - VW408A- ♦...
  • Page 229 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 Special tools and workshop equipment required ♦ Press Piece - Bushing - 3259- ♦ Press Piece - Reverse Gear Syncro - 3296- ♦ Bearing Installer - Wheel Bearing - 3345- ♦...
  • Page 230 Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 ♦ Inductive Heater - VAS6414- ♦ -1- Puller - Kukko Internal - 46-56mm - 21/7- ♦ -4- Counter Support - VAS 251 623- Rep. Gr.39 - Final Drive, Differential...

  • Page 231: Revision History

    Golf 2015 ➤ , Golf Variant 2015 ➤ Manual Transmission - Edition 02.2016 Revision History DRUCK NUMBER: K0059240421 Fac‐ Edit Notes Quality tory Edi‐ Type Checke Edi‐ tion d By tion 02.2 3/30/ Fac‐ Fac‐ Remove tool names from Jim H...
  • Page 232 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 233 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 234 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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