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Volkswagen Golf Variant 2007 Service Manual

6-speed manual gearbox 02s.
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Service
Workshop Manual
Golf Variant 2007 ➤
Golf Variant 2010 ➤
Jetta 2005 ➤
6-speed manual gearbox 02S
Edition 07.2009
Service Department. Technical Information

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   Summary of Contents for Volkswagen Golf Variant 2007

  • Page 1

    Service Workshop Manual Golf Variant 2007 ➤ Golf Variant 2010 ➤ Jetta 2005 ➤ 6-speed manual gearbox 02S Edition 07.2009 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 © 2010 Volkswagen AG, Wolfsburg MEX5R007520...

  • Page 3: Table Of Contents

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 Contents 00 - Technical data ........... .

  • Page 4

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 Draining gear oil ............100 Filling with gear oil .

  • Page 5: Technical Data

    Technical data Gearbox identification The 6-speed manual gearbox 02S is installed in the Jetta 2005 ▸, in the Golf Variant 2007 ▸ and in the Golf Variant 2010 ▸ in con‐ junction with a 4-cylinder engine. Allocation ⇒ page 1...

  • Page 6

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 Manual gearbox 6-speed 02S Identification code Engine 1.9 l - 74 kW 1.4 l - 103 kW 1.9 l - 74 kW...

  • Page 7

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 Manual gearbox 6-speed 02S Identification code Capacity of manual gearbox (gear‐ 2.1 l 2.1 l 2.1 l box completely dismantled) Capacity of manual gearbox 1.9 l...

  • Page 8

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 Manual gearbox 6-speed 02S Identification code • The following data can be found in the ⇒ Electronic parts catalogue “ETKA” .

  • Page 9: Overview - Power Transmission

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 Overview - power transmission Designation -Arrows- indicate direction of travel. 1 - Engine 2 - Clutch 3 - Manual gearbox...

  • Page 10

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 I - 1st gear II - 2nd gear III - 3rd gear IV - 4th gear V - 5th gear...

  • Page 11: Calculating Overall Gear Ratio "i

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 Calculating overall gear ratio “i” Example: 6th gear Final drive Drive gear ZG 1 = 45 ZA 1 = 18...

  • Page 12: General Repair Notes

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 General repair notes To ensure flawless and successful gearbox repairs, the greatest care and cleanliness as well as the use of good and proper tools are essential.

  • Page 13

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 4.1.3 Locking devices ♦ Do not overstretch retaining rings. ♦ Always renew retaining rings which have been damaged or overstretched.

  • Page 14

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 4.1.6 Shims ♦ Measure shims at several points with a micrometer. The var‐ ious thicknesses make it possible to achieve the exact shim thickness required.

  • Page 15

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 ♦ Ensure that the pressure plate does not cant: loosen and tight‐ en bolts diagonally and in several gradual stages.

  • Page 16: Clutch

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 30 – Clutch Fault finding, power transmission – Refer to ⇒ Fault finding, power transmission; Rep. Gr. 30 ; Complaints about clutch and clutch mechanism and ⇒ Fault finding, power transmission;...

  • Page 17: Repairing Clutch Mechanism

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 Repairing clutch mechanism Overview Note Before disconnecting battery, obtain code for radio units having anti-theft coding. ♦ With ignition switched off, disconnect battery earth strap ⇒ Electrical system; Rep. Gr. 27 ; Disconnecting ♦...

  • Page 18: Assembly Overview - Pedal Cluster

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 Assembly overview - pedal cluster 1 - Bulkhead ❑ With support for mount‐ ing bracket 2 - Seal ❑ Always renew ❑...

  • Page 19: Removing And Installing Over-centre Spring

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 ❑ Qty. 3 ❑ For mounting bracket on bulkhead ❑ Always renew 16 - Hexagon nut, 25 Nm ❑ Always renew 17 - Stop ❑...

  • Page 20

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 – With ignition switched off, disconnect battery earth strap ⇒ Electrical system; Rep. Gr. 27 ; Disconnecting and connecting battery .

  • Page 21

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 – If fitted, remove damping -arrow- from lower area of clutch pedal mounting bracket. – To do this, remove lock washers -A- for damping.

  • Page 22

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 – Unbolt clutch pedal -1- from mounting bracket -3- by removing nut -2- and pulling out bolt -5-. Note The clutch pedal remains hooked to operating rod of master cyl‐...

  • Page 23

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 Some cars have damping -arrow- on the clutch pedal mounting bracket. – Return it to installation position. Vehicles without knee airbag The crash bar -1- in front of clutch pedal -2- may be secured in different ways.

  • Page 24: Removing And Installing Clutch Pedal

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 2.3.3 Specified torques Component Clutch pedal to mounting bracket ♦ Renew self-locking nuts Crash bar to steering column mounting bracket (attachment with 2 bolts)

  • Page 25

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 Continuation for all – Push driver seat as far back as possible and put steering wheel in highest position. – Remove trim and cover below trim on drive side ⇒ General body repairs, interior;...

  • Page 26

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 – If fitted, remove damping -arrow- from lower area of clutch pedal mounting bracket. – To do this, remove lock washers -A- for damping.

  • Page 27

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 – Unbolt clutch pedal -1- from mounting bracket -3- by removing nut -2- and pulling out bolt -5-. – Swing clutch pedal down slightly and remove over-centre spring -4- from mounting bracket.

  • Page 28

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 – Insert over-centre spring -2- in mounting bracket from above while holding end of spring with assembly tool -T10178- in in‐...

  • Page 29: Removing And Installing Mounting Bracket

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 The crash bar -1- in front of clutch pedal -2- may be secured in different ways. Attachment with 2 bolts –...

  • Page 30

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 ♦ Hose clamps to 25 mm Ø -3094- ♦ Hose clip pliers -VAS 6362- ♦ Sealing tool -T10249- 2.5.1 Removing –...

  • Page 31

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 Continuation for all Note During the following work, ensure that no brake fluid lands on ♦ longitudinal member or gearbox. If this does happen, clean the affected areas thoroughly.

  • Page 32

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 – Remove bracket for knee airbag together with crash bar ⇒ Interior equipment; Rep. Gr. 69 ; Airbag; Removing and in‐...

  • Page 33

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 – To do this, remove lock washers -A- for damping. – Pull off damping. – Push damping upwards in area of upper securing nut -1- above clutch pedal -A- in -direction of arrow-.

  • Page 34

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 Some cars have damping -arrow- on the clutch pedal mounting bracket. Note Renew self-locking nuts. ♦ Renew hose clips. ♦...

  • Page 35: Removing And Installing Master Cylinder

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 – Push pipe/hose line or plastic line -1- with seal -2- onto con‐ nection of master cylinder -4- until securing clip -3- engages audibly.

  • Page 36

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 – Release retainer for master cylinder operating rod using pliers -T10005- . – Insert spacer -A- between clutch pedal and stop and press clutch pedal to spacer.

  • Page 37: Removing And Installing Clutch Position Sender G476

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 – Insert spacer -A- between clutch pedal and stop and press clutch pedal to spacer. ♦ Length of spacer = about 40 mm (e.g.

  • Page 38

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 – Remove complete air filter housing if it is near battery ⇒ Rep. Gr. 23 ; Repairing diesel direct injection system or ⇒ Rep.

  • Page 39

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 – Clamp off supply hose to master cylinder using hose clamp to 25 mm ∅ -3094- . – Release securing clip -2- with a screwdriver or a pointed object and pull out of master cylinder to stop.

  • Page 40

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 If the pipe/hose line was removed – Push pipe/hose line -1- or plastic line with seal -2- onto con‐ nection of master cylinder -4- until securing clip -3- engages audibly.

  • Page 41: Assembly Overview - Hydraulics (lhd Vehicles)

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 Assembly overview - hydraulics (LHD vehicles) 1 - Brake fluid reservoir 2 - Spring-type clip 3 - Supply hose ❑ Rubber ❑...

  • Page 42

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 15 - Hexagon bolt, 20 Nm 16 - Bleeder valve ❑ Bleeding clutch system ⇒ page 42 17 - Dust cap...

  • Page 43: Assembly Overview - Hydraulics (rhd Vehicles)

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 Assembly overview - hydraulics (RHD vehicles) 1 - Brake fluid reservoir 2 - Seal ❑ For plastic supply hose ❑ The seals must be loca‐...

  • Page 44: Removing And Installing Slave Cylinder

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 ❑ Insert with brake fluid ❑ Seals/O-rings are adapted to configuration of line connection ⇒ page 38 ❑ Allocation ⇒ Electronic parts catalogue “ETKA”...

  • Page 45

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 – With ignition switched off, disconnect battery earth strap ⇒ Electrical system; Rep. Gr. 27 ; Disconnecting and connecting battery .

  • Page 46: Bleeding Clutch System

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 2.10.2 Installing Install in the reverse order of removal, observing the following: – Install slave cylinder and tighten bolts -arrows B- to specified torque.

  • Page 47

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 ♦ Brake filling and bleeding equipment -V.A.G 1869- Note Prefilling system is not necessary! Specifications for brake fluid ⇒ Brake systems; Rep. Gr. 47 ;...

  • Page 48: Repairing Clutch Release Mechanism

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 Repairing clutch release mechanism Special tools and workshop equipment required ♦ Torque wrench -V.A.G 1331- 1 - Gearbox 2 - Ball stud, 25 Nm ❑...

  • Page 49

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 ❑ Renew noisy bearings ❑ Removing from and inserting in clutch release lever ⇒ page 45 ❑ Lubricate contact surfaces of release lever with MoS 2 grease.

  • Page 50: Repairing Clutch, In Conjunction With Dual-mass Flywheel

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 Repairing clutch, in conjunction with dual-mass flywheel Special tools and workshop equipment required ♦ Counterhold -3067- ♦ Centring mandrel -3190 A- ♦...

  • Page 51

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 Some notches -arrows- are located in lower region of sump be‐ tween engine -A- and gearbox -B-. – Check outer contour of flywheel through these notches.

  • Page 52: Removing And Installing Sachs Clutch

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 Rounded outer contour -arrows 1- and a circumferential crease -arrow 2- = LuK clutch = -B- – Removing and installing LuK clutch ⇒...

  • Page 53

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 Checking ends of diaphragm spring • Wear to half the thickness of the diaphragm spring -arrows- is permitted. Checking spring connections and riveted connections –...

  • Page 54: Repairing Sachs Clutch

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 Repairing Sachs clutch 1 - Dual-mass flywheel ❑ Removing and installing ⇒ Rep. Gr. 13 ❑ Ensure that centring pins fit tightly ❑...

  • Page 55

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 Note Renew pressure plate and clutch plate together only. Select ♦ clutch plate and pressure plate according to engine code and ⇒...

  • Page 56

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 Checking position of adjusting mechanism with new pressure plates only • Both edges -A- of the adjuster ring must be located between the two notches -arrows B-.

  • Page 57: Repairing Luk Clutch

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 Repairing LuK clutch 1 - Dual-mass flywheel ❑ Removing and installing ⇒ Rep. Gr. 13 ❑ Ensure that centring pins fit tightly ❑...

  • Page 58: Repairing Clutch, In Conjunction With One-piece Flywheel

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 Repairing clutch, in conjunction with one-piece flywheel Special tools and workshop equipment required ♦ Counterhold -3067- ♦ Centring mandrel -3190 A- ♦...

  • Page 59

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 1 - Flywheel ❑ Removing and installing ⇒ Rep. Gr. 13 ❑ Ensure that centring pins fit tightly ❑ Keep contact surface for clutch lining free of grooves, oil and grease.

  • Page 60

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 Checking ends of diaphragm spring • Wear up to half the thickness of the diaphragm spring is per‐ mitted. Checking spring connections and riveted connections –...

  • Page 61: Controls, Housing

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 34 – Controls, housing Fault finding, power transmission – Refer to ⇒ Fault finding, power transmission; Rep. Gr. 30 ;...

  • Page 62: Repairing Selector Mechanism

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 Repairing selector mechanism Installation position of selector mechanism Arrow -A- Gear selection movement Arrow -B- Gate selection movement A - Gear selector cable...

  • Page 63: Overview Of Selector Mechanism

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 Overview of selector mechanism Note Note radio code for vehicles with coded radio. ♦ Before working on selector mechanism in engine compartment, disconnect earth strap from battery ⇒ Elec‐...

  • Page 64

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 ♦ Hose clip pliers -V.A.G 1275- ♦ Torque wrench -V.A.G 1331- Rep. Gr.34 - Controls, housing...

  • Page 65: Removing And Installing Gear Knob And Frame

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 Removing and installing gear knob and frame 1 - Emblem ❑ Can be carefully levered off gear knob of plastic...

  • Page 66

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 – Pull gaiter with frame for centre console upwards, inside out over gear knob. – Open clamp -arrow- and pull off gear knob together with gaiter.

  • Page 67: Repairing Gear Lever And Selector Housing (through 10.06)

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 Repairing gear lever and selector housing (through 10.06) Note Lubricate bearing points and sliding surfaces with grease -G 000 450 02- .

  • Page 68

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 25 - Securing clip ❑ Always renew 26 - Hexagon nut ❑ M8: 25 Nm ❑ M6: 8 Nm ❑ Qty. 4 27 - Bearing bush ❑...

  • Page 69: Repairing Gear Lever And Selector Housing (from 11.06)

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 Repairing gear lever and selector housing (from 11.06) Note Lubricate bearing points and sliding surfaces with grease -G 000 450 02- .

  • Page 70

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 14 - Bush 15 - Gear lever guide 16 - Hexagon nut ❑ M8: 25 Nm ❑ M6: 8 Nm ❑...

  • Page 71

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 – Lift upper end -A- of compression spring over tab of gate se‐ lector lever. – Use screwdriver to press catches -arrows- of ball socket to‐...

  • Page 72

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 – Slacken ends -A- and -B- by turning both round to right. • Ends -A- and -B- must point in opposite directions.

  • Page 73

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 – Move gate selector lever back to stop (opposite from mounting holes for gear and gate selector cable) -arrow 1-.

  • Page 74: Assembly Overview - Removing And Installing Selector Cables

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 Assembly overview - removing and installing selector cables Note Lubricate bearing points and sliding surfaces with grease -G 000 450 02- .

  • Page 75

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 9 - Spacer 10 - Cable end-piece ❑ For gate selector cable to relay lever ❑ After installing, adjust selector mechanism ⇒...

  • Page 76

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 Allocation of cable end-pieces The holes in the cable end-pieces have different diameters. Cable end-piece for Dimension “a” 1 - Gear selector cable to gearbox selector lever 8.5 mm...

  • Page 77: Plastic Relay Lever

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 Fitting position of cable tie for cables – Wind cable tie -arrow- around the selector cables in a figure eight and secure them as shown in figure.

  • Page 78

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 Relay lever with clip -arrow 1- – Pull clip -arrow 1- off and remove relay lever together with ca‐ ble end-piece.

  • Page 79: Removing And Installing Selector Mechanism

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 Levering gate selector cable end-piece off plastic relay lever • Relay lever has been removed. – Insert a flat-blade screwdriver -A- between bush -B- and relay lever.

  • Page 80

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 ♦ Torque wrench -V.A.G 1331- ♦ Grease -G 000 450 02- – First check whether a coded radio is fitted. If so, obtain anti- theft code.

  • Page 81

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 Releasing cable end-piece from gate selector cable – Pull locking mechanism forward to stop in -direction of arrow 1- and then lock by turning to left in -direction of arrow 2-.

  • Page 82: Removing And Installing Gear Selector Cable And Gate Selector Cable

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 Clip -A- holds cables and heat shield together in position. – Install cable support bracket on gearbox and tighten bolts to specified torques ⇒...

  • Page 83

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 – Bend open tabs -arrows- of selector mechanism cover using a screwdriver and remove cover. – Remove gasket. – Pull off securing clips -2 and 3-. (Securing clips -1 and 4- have been discontinued.) Lever gear selector cable off gear lever...

  • Page 84: Adjusting Selector Mechanism

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 – Secure gear selector cable and gate selector cable to selector housing using securing clips -2 and 3-. – Press gear selector cable onto gear lever and gate selector cable onto gate selector lever in selector housing.

  • Page 85

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 – Remove complete air filter housing if bracket -A- to secure gear selector cable and gate selector cable are not accessible ⇒...

  • Page 86: Functional Check

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 – Check that gate and selector cables -B- are inserted, free of tension, into locking devices -A-. – Now turn locking mechanisms on gear selector cable and gate selector cable end pieces clockwise to stop -direction of arrow 1-.

  • Page 87

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 – If it continues to be difficult to engage a gear after repeated attempts, repeat adjustment procedure of selector mechanism ⇒...

  • Page 88: Removing And Installing Gearbox

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 Removing and installing gearbox Special tools and workshop equipment required ♦ Vehicles with turbo diesel engines and vehicles with 2.0l - 110 kW petrol engines ♦...

  • Page 89: Removing Gearbox

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 ♦ Adjustment plate -3282/39- ♦ Engine and gearbox jack - V.A.G 1383A- ♦ Torque wrench -V.A.G 1331- ♦ Torque wrench -V.A.G 1332- ♦...

  • Page 90

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 – Pull gear selector cable from pin. Metal relay lever – Remove securing clip -arrow 2- for gate selector cable from relay lever -B-.

  • Page 91

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 – Pull connector -arrow 1- off reversing light switch -F4- . – Now remove connector -arrow 2- and wire -arrow 3- from starter.

  • Page 92

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 – Now attach hook -10 - 222 A /2- at rear left of engine -arrow-. – Then connect hook -10 - 222 A /2- using adapter -10 - 222 A / 16- .

  • Page 93

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 – Remove pendulum support. First remove bolt -arrow A- and then bolts -B- and -C-. – Remove hexagon bolts -arrows- for left assembly mounting from gearbox mounting.

  • Page 94

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 – If small cover plate -A- for flywheel behind the right flange shaft -arrows- is installed, remove it. – Remove exhaust system strut -1-, if present, from gearbox -arrow-.

  • Page 95: Transporting Gearbox

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 – Press gearbox off dowel sleeves and carefully swing towards subframe. – Turn gearbox downwards in vicinity of differential. – Have a second mechanic push engine forwards slightly.

  • Page 96: Installing Gearbox

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 – Adjust support beam on sliding piece using locking pin -arrow-. Number of holes visible = 5. – Lift gearbox using workshop crane and gearbox lifting tackle -3336- .

  • Page 97

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 The clutch plate must slide easily to and fro on the input shaft. To install gearbox “02S”, set up gearbox support -3282- with ad‐...

  • Page 98

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 – Install bracket -A- on gearbox using new hexagonal bolts -arrows- and tighten to specified torque ⇒ page 96 – Align engine and gearbox in installation position using both spindles of support bracket -10-222A- .

  • Page 99

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 – Install pendulum support with new bolts -arrows A-, -B- and -C- ⇒ Running gear, axles, steering ; Rep. Gr. 40 ; Repairing front suspension .

  • Page 100: Specified Torques

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 – Install gearbox selector lever -A-. – Tighten hexagon nut -arrow 4- to specified torque ⇒ Item 18 (page 71) –...

  • Page 101

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 Gearbox to 2.0 l/100 kW petrol engine Item Bolt Quantity M12 x 65 M12 x 150 ♦ Additionally, start‐ er to gearbox M12 x 165 ♦...

  • Page 102

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 Gearbox mounting to body – Renew bolts. – Screw in all bolts hand-tight. – Tighten bolts to specified torque. Bolts -arrows- 60 Nm + 90°...

  • Page 103: Checking And Topping Up Gear Oil

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 Checking and topping up gear oil It is not possible to check the gear oil level by unscrewing the oil filler plug.

  • Page 104: Draining Gear Oil

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 Clean gearbox. Caution To drain gear oil, a pivot pin for the selector forks in the gearbox must be removed.

  • Page 105: Filling With Gear Oil

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 Filling with gear oil Top up oil in container to 1.9 litres. Gearbox oil specification ⇒ Electronic parts catalogue “ETKA” .

  • Page 106: Dismantling And Assembling Gearbox

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 Dismantling and assembling gearbox Overview - gearbox 1 - 1st gear 2 - 2nd gear 3 - 3rd gear 4 - 4th gear...

  • Page 107: Assembly Overview

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 Assembly overview Assembly sequence - Removing and installing cover for gearbox housing and 5th and 6th gear ⇒ page 109 Assembly sequence - Dismantling and assembling gearbox com‐...

  • Page 108: Removing And Installing Cover For Gearbox Housing And 5th And 6th Gear

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 Removing and installing cover for gearbox housing and 5th and 6th gear 1 - Gearbox housing ❑ Pull off together with 5th and 6th gears ⇒...

  • Page 109

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 ❑ Allocation of bolts ⇒ page 106 ❑ To gearbox date 20 08 6: 40 Nm and 180° further ❑ From gearbox date 21 08 6: 80 Nm and then turn 90° further ❑...

  • Page 110

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 20 - Wave spring washer ❑ From gearbox date 26 05 8 ❑ Allocate according to ⇒ Electronic parts catalogue “ETKA”...

  • Page 111: Removing And Installing Gearbox Housing And Shift Mechanism

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 Removing and installing gearbox housing and shift mechanism 1 - Countersunk bolt, 25 Nm 2 - Flange shaft with compres‐...

  • Page 112: Removing And Installing Input Shaft, Output Shaft, Differential And Selector Forks

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 Removing and installing input shaft, output shaft, differential and selector forks 1 - Differential ❑ Dismantling and assem‐ bling ⇒ page 193 2 - Seal ❑...

  • Page 113: Gear

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 Assembly sequence - Removing and in‐ stalling cover for gearbox housing and 5th and 6th gear Note Follow the working procedure described below if only the 5th ♦...

  • Page 114

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 ♦ Support bridge -30-211A- ♦ Thrust piece -32 - 111- ♦ Thrust piece from assembly tool -T10030/4- ♦ Tube -VW 416 B- ♦...

  • Page 115

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 ♦ Support device -T10323- ♦ Assembly tool -3253/7- ♦ Thrust piece -VW 433- ♦ Thrust plate -40 - 105- ♦ Torque wrench -V.A.G 1332- 5.6.1...

  • Page 116

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 • Bearings of input shaft and output shaft must not be damaged when 5th and 6th gears are removed and installed.

  • Page 117

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 – Check whether puller hooks -T10040/2A- can be inserted cor‐ rectly under 5th gear wheel. Puller hooks -T10040/2A- cannot be inserted correctly.

  • Page 118

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 – Pull off gear wheel for 6th gear with inner race of cylindrical roller bearing for output shaft. A - Two arm puller , e.g. -Kukko 20/10-...

  • Page 119: Assembly Sequence - Dismantling And Assembling Gearbox Completely

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 – Set threaded insert -T10309/3- in half shell . – Now fit second half shell -T10309/1- and set tube -T10309/2- over assembly.

  • Page 120

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 Special tools and workshop equipment required ♦ Support plate -VW 309- ♦ Gearbox support -VW 353- ♦ Drift -VW 295- ♦...

  • Page 121

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 ♦ Support bridge -30-211A- ♦ Thrust piece -32 - 111- ♦ Thrust piece from assembly tool -T10030/4- ♦ Tube -VW 416 B- ♦...

  • Page 122

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 ♦ Support device -T10323- ♦ Assembly tool -3253/7- ♦ Thrust piece -VW 433- ♦ Torque wrench -V.A.G 1332- ♦ Mounting -2 Kukko 18/1- (Qty. 2) ♦...

  • Page 123

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 • Bearings of input shaft and output shaft must not be damaged when 5th and 6th gears are removed and installed.

  • Page 124

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 – Remove selector fork for 5th and 6th gears as follows: – Cover openings with a cloth. – Engage 5th gear -arrows 1- and -2-.

  • Page 125

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 – Now remove 3rd bolt -arrow- for reverse shaft support bracket. – Remove selector shaft with selector mechanism cover, placing selector shaft in neutral position.

  • Page 126

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 – Remove bolts -A- from clutch housing side for securing clutch housing to gearbox housing. Note Do not remove nuts -B- for output shaft bearing support.

  • Page 127

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 – Remove selector forks -A- together with selector plates. – Unbolt reverse gear selector mechanism -B-. – Remove nuts -B- for output shaft bearing support.

  • Page 128

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 – Insert input shaft -1- and output shaft -2- together. – Tighten nuts for output shaft bearing support to specified tor‐...

  • Page 129

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 – Screw M8 x 100 mm studs -A- into reverse shaft support so that shaft is aligned after gearbox housing is fitted.

  • Page 130

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 Install selector shaft with selector shaft cover plate as follows: – Place selector plates in neutral. – Apply sealant -AMV 188 200 03- evenly to sealing surface of selector mechanism cover.

  • Page 131

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 Checking 5th gear synchro-ring and 6th gear synchro-ring – Before installing synchromeshed gears and synchro-rings for 5th and 6th gear, press synchro-rings onto cones of synchro‐...

  • Page 132

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 – Drive on synchro-hub for 5th and 6th gear. Note When driving on, ensure that synchro-ring moves freely. – Heat inner race of cylindrical roller bearing for 6th gear syn‐...

  • Page 133

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 Installation position of gear wheel for 6th gear: Groove -B- faces away from sleeve -A-. “Or” groove -arrow 1- near shoulder -arrow 2- faces away from sleeve -A- see previous figure).

  • Page 134

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 – To tighten securing bolts -A-, engage 2 gears -arrows 1- through -3-. – Install selector forks for 5th and 6th gears.

  • Page 135

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 Adjusting 5th and 6th gear from gearbox manufacture date 12 06 6 – Engage 5th gear. – Loosen bolt -1-.

  • Page 136: Repairing Gearbox Housing And Clutch Housing

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 Repairing gearbox housing and clutch housing Special tools and workshop equipment required ♦ Drift -VW 295- ♦ Adapter -VW 295 A- ♦...

  • Page 137

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 ♦ Puller -VW 228 B- (is not required for this gearbox) ♦ Drift -VW 222 A- (not re‐ quired with this gearbox) ♦...

  • Page 138

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 1 - Gearbox housing ❑ If renewed: adjust input shaft and differential ⇒ page 192 2 - Needle bearing ❑ For output shaft ❑...

  • Page 139

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 ❑ Remove guide sleeve to change oil seal ❑ If O-ring is damaged, renew guide sleeve and O-ring together 13 - Socket head bolt, 20 Nm ❑...

  • Page 140

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 Driving needle bearing in to stop – Secure needle bearing in gearbox housing at three points (120° offset) using a punch.

  • Page 141

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 Pulling in sleeve – Clean sleeve seat in gearbox. – Screw spindle -A- of assembly device -3066- into threaded piece of differential.

  • Page 142: Repairing Gearbox Housing Cover

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 Repairing gearbox housing cover Special tools and workshop equipment required ♦ Pressure plate -VW 401- ♦ Pressure plate -VW 402- ♦...

  • Page 143

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 1 - Cylindrical roller bearing ❑ For output shaft ❑ Do not interchange with cylindrical roller bearing for input shaft ❑...

  • Page 144

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 Pulling cylindrical roller bearing out of gearbox housing cover A - Internal puller, 30 … 37 mm , e.g. -Kukko 21/5- B - Counter support , e.g.

  • Page 145

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 Secure cylindrical roller bearing in gearbox housing cover by pe‐ ening -arrows-. 7. Repairing gearbox housing cover...

  • Page 146: Repairing Selector Unit

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 Repairing selector unit Special tools and workshop equipment required ♦ Tube -T10203- ♦ Tube -VW 423- ♦ Torque wrench -V.A.G 1331-...

  • Page 147

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 1 - Selector unit ❑ Consists of selector shaft and selector shaft cover ❑ Components cannot be separated from each other 2 - -Schalter für Rückfahr‐...

  • Page 148

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 Removing angled rod -A- from selector shaft cover – Remove outer part of angled rod. – Then carefully lever out angled rod using a screwdriver.

  • Page 149: Dismantling And Assembling Selector Forks

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 Dismantling and assembling selector forks Special tools and workshop equipment required ♦ Pressure plate -VW 402- ♦ Thrust piece -3290/1- ♦...

  • Page 150

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 ♦ Drift -10 - 508- ♦ Clamp -2070- Note It is not necessary to dismantle the selector fork group ( ⇒...

  • Page 151

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 1 - Selector segment for 5th and 6th gears ❑ Identification ⇒ page 148 ❑ After lock washer is in‐...

  • Page 152

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 Identifying selector segments Dimension -a- 1 - 1st and 2nd gear selector segments = 11.4 mm 2 - 3rd and 4th gear selector segments = 7.7 mm 3 - 5th and 6th gear selector segments = 12.1 mm...

  • Page 153

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 Pressing inner race -A- of angular contact ball bearing into outer race Inner race must engage in outer race. Pulling angular contact ball bearing into selector fork to stop Depression in thrust piece -3290/1- faces ball bearing.

  • Page 154: Gears, Shafts

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 35 – Gears, shafts Input shaft Dismantling and assembling input shaft Special tools and workshop equipment required ♦ Press tool -VW 407- ♦...

  • Page 155

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 ♦ Drift sleeve -41 - 501- ♦ Thrust pad -VW 447 i- ♦ Drift sleeve -30 - 100- ♦ Thrust pad -VW 510- ♦...

  • Page 156

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 1 - Clutch housing 2 - Tapered roller bearing outer race ❑ Pressing out ⇒ page 154 ❑ Pressing in ⇒...

  • Page 157

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 16 - Wave spring washer ❑ From gearbox date 26 05 8 ❑ Allocate according to ⇒ Electronic parts catalogue “ETKA”...

  • Page 158

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 Pressing out tapered roller bearing outer race Pressing in tapered roller bearing outer race Pressing off tapered roller bearing inner race...

  • Page 159

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 Pressing off gear wheel for 4th gear with tapered roller bearing and sleeve Pressing off gear wheel for 3rd gear...

  • Page 160

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 Pressing on tapered roller bearing inner race Pressing on sleeve for needle bearing Pressing out tapered roller bearing outer race Pressing in tapered roller bearing outer race –...

  • Page 161

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 Deeper notches in both sides of locking collar for 5th and 6th gears -arrows- from gearbox date 12 06 6...

  • Page 162: Adjusting Input Shaft

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 Installing springs with bent ends -A- The modified springs are installed on both sides. – Spring are installed only in conjunction with locking pieces which are hollow on the inner side.

  • Page 163

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 Special tools and workshop equipment required ♦ Universal dial gauge brack‐ et -VW 387- ♦ End dimension plate - VW 385/17- ♦...

  • Page 164

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 – Press tapered roller bearing outer race into gearbox housing to stop. – Press tapered roller bearing outer race without shim into gear‐...

  • Page 165

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 Table of shims Bearing play Shim Measured value (mm) Thickness (mm) 0.671…0.699 0.650 0.700…0.724 0.675 0.725…0.749 0.700 0.750…0.774 0.725 0.775…0.799 0.750...

  • Page 166

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 – Set gearbox housing in place and tighten hexagon head bolts to 25 Nm and then turn 90° further. 1.2.2 Carrying out check measurement –...

  • Page 167: Output Shaft

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 Output shaft Dismantling and assembling output shaft Special tools and workshop equipment required ♦ Press tool -VW 407- ♦ Press tool -VW 412- ♦...

  • Page 168

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 ♦ Pressure plate -VW 402- ♦ Thrust piece -32 - 111- ♦ Press tool -VW 408 A- ♦ Press tool -VW 409- ♦...

  • Page 169

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 ♦ Drift sleeve -30 - 100- ♦ Tube -VW 415 A- ♦ Thrust pad -VW 447 H- ♦ Thrust piece -VW 454- ♦...

  • Page 170

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 ♦ Internal puller -1- Kukko 21/6- ♦ Counter support -4- Kukko 22/2- ♦ Splitter -3- Kukko 17/2- Note The output shaft is dismantled as follows: position separating device under 2nd gear synchromeshed gear ♦...

  • Page 171

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 1 - Hexagon nut, 25 Nm and then turn 90° further ❑ 4 nuts for bearing sup‐ port ❑ Always renew...

  • Page 172

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 ❑ Check for wear ⇒ page 172 16 - Locking collar with synchro-hub for 1st and 2nd gears ❑ After removing retaining ring ⇒...

  • Page 173

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 31 - Synchro-ring for 4th gear ❑ Check for wear ⇒ page 175 32 - Synchromeshed gear for 4th gear...

  • Page 174

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 Pressing in small tapered roller bearing outer race Pulling off small tapered roller bearing inner race A - Vice with protective jaws –...

  • Page 175

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 Pressing off locking collar with synchro-hub and bearing support – First remove retaining ring -arrow-. Pulling off large tapered roller bearing inner race A - Protective jaws –...

  • Page 176

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 Checking 1st and 2nd gear inner ring for wear – Press inner ring onto cone of synchromeshed gear and meas‐...

  • Page 177

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 Assembly of 1st and 2nd gear locking collar and synchro-hub with hollow locking pieces • Locking collar has been pushed over synchro-hub.

  • Page 178

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 Installation position of 2nd gear outer ring Lugs -arrows- face 1st gear -A-. Installation position of synchro-ring (2nd gear inner ring) -A- Lugs -arrow 1- engage in notches -arrow 2- in synchro-ring -B-.

  • Page 179

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 Checking synchro-rings for 3rd and 4th gear for wear – Press synchro-ring onto cone of synchromeshed gear and measure gap -a- using feeler gauge.

  • Page 180: Adjusting Output Shaft

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 Installation position of locking collar with synchro-hub for 3rd and 4th gears Chamfer -arrow- faces 4th gear. Pressing on synchro-hub with locking collar for 3rd and 4th gears...

  • Page 181

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 Special tools and workshop equipment required ♦ Universal dial gauge brack‐ et -VW 387- ♦ End dimension plate - VW 385/17- ♦...

  • Page 182

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 ♦ Adapter -VW 771/15- It is necessary to readjust the output shaft when the following components are renewed: ♦ Output shaft ♦...

  • Page 183

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 – Set up dial gauge (3 mm measuring range) and set to “0”with 1 mm preload. -A- = threaded spindle from puller --Kukko 18/0- .

  • Page 184

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 Bearing play = Shim (0.65 mm shim thickness (mm) plus determined measured val‐ 1.290 … 1.339 1.450 1.340 … 1.389 1.500...

  • Page 185: Reverse Shaft

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 Reverse shaft Dismantling and assembling reverse shaft Special tools and workshop equipment required ♦ Thrust piece -VW 454- ♦ Thrust pad -VW 447 H- ♦...

  • Page 186

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 Note After dismantling, always renew needle bearing in clutch housing and reverse shaft support. 1 - Clutch housing 2 - Needle bearing ❑...

  • Page 187

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 Pressing needle bearing -A- into clutch housing Pressing needle bearing out of reverse shaft support Pressing needle bearing into reverse shaft support...

  • Page 188: Final Drive - Differential

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 39 – Final drive - differential Renewing flange shaft oil seals with gearbox installed Renewing oil seal for left flange shaft...

  • Page 189: Distinguishing Seals For Right Flange Shaft

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 – Raise drive shaft as high as possible and secure. Take care not to damage paint on drive shaft in the process.

  • Page 190: Renewing Seal (two-part Seal And Sleeve For Right Flange Shaft)

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 There are different versions. Seal -1- and sleeve -2- are two parts. Identification: notches along circumference of sleeve -arrow-. Renew seal ⇒...

  • Page 191

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 ♦ Torque wrench -V.A.G 1331- 1.3.1 Removing – Remove noise insulation ⇒ General body repairs, exterior; Rep. Gr. 50 ; Noise insulation .

  • Page 192

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 1.3.2 Installing – Drive in new seal to stop, being careful not to cant seal. – Half-fill space between sealing lip and dust lip with sealing grease -G 052 128 A1- .

  • Page 193: Renewing Seal And Sleeve Together (one-piece Seal And Sleeve For Right Flange Shaft)

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 1.3.3 Torque setting Flange shaft to gearbox (countersunk bolt) ⇒ Item 12 (page 195) Renewing seal and sleeve together (one-piece seal and sleeve for right...

  • Page 194

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 ♦ Drip tray for workshop hoist -VAS 6208- 1.4.1 Removing – Remove noise insulation ⇒ General body repairs, exterior; Rep. Gr. 50 ; Noise insulation .

  • Page 195

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 1.4.2 Installing – Clean seat for seal in gearbox. – Pull in seal and sleeve together. A - Screw spindle of assembly tool -3066- into threaded piece of differential.

  • Page 196: Adjustment Overview

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 Adjustment overview Note If repairs have been carried out to the gearbox, it is necessary to adjust the input shaft, output shaft or differential only if compo‐...

  • Page 197: Differential

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 Differential Dismantling and assembling differential Special tools and workshop equipment required ♦ Tapered roller bearing pull‐ er -V.A.G 1582- ♦ Adapter -V.A.G 1582/3- ♦...

  • Page 198

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 ♦ Press tool -VW 408 A- ♦ Thrust piece -VW 473- ♦ Thrust plate -30 - 205- ♦ Sleeve -3144- ♦...

  • Page 199

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 Note Heat tapered roller bearing inner race to 100° C before installing. ♦ Always renew both tapered roller bearings together as a set.

  • Page 200

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 12 - Countersunk bolt, 25 Nm ❑ Screw into threaded piece ⇒ Item 20 (page 196) 13 - Flange shaft ❑...

  • Page 201

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 Pressing tapered roller bearing outer race into clutch housing No shim is installed in the clutch housing end. Pulling off tapered roller bearing inner races –...

  • Page 202

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 Pressing tapered roller bearing outer race into gearbox housing – Fit shim under outer race. – Support gearbox housing directly below bearing mounting us‐...

  • Page 203

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 Removing spring pin without circumferential groove (long spring pin); pressing out differential pinion pin When pressed out, spring pin will be sheared off.

  • Page 204: Adjusting Differential

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 Installation position of thrust washer for tapered ring -1-. The shoulder -arrow- points towards spring -B-. Some gearboxes have lugs -A-.

  • Page 205

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 It is necessary to readjust the differential when the following com‐ ponents are renewed: ♦ Gearbox housing ♦ Clutch housing ♦...

  • Page 206

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S - Edition 07.2009 Bearing play Shim 0.303 … 0.449 0.650 0.450 … 0.499 0.700 0.500 … 0.549 0.750 0.550 … 0.599 0.800 0.600 … 0.649 0.850...

This manual also for:

Golf variant 2010, Jetta 2005

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  • Pyay Thar Jan 07, 2016 06:52:
    Help! me volkswagen service manual.