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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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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 ........... .
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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...
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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...
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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...
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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...
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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.
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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.
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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.
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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 ❑...
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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 .
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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.
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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‐...
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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)
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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;...
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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.
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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.
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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 –...
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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 –...
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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.
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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‐...
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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-.
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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.
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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.
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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.
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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.
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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 ❑...
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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”...
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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.
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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 ❑...
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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- ♦...
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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 ⇒...
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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 ❑...
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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 ⇒...
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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‐...
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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...
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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- .
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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- .
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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 ❑...
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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.
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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- .
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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 ⇒...
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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...