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Service
Workshop Manual
Golf Variant 2007 ➤
Golf Variant 2010 ➤
Jetta 2005 ➤
Jetta 2011 ➤
6-speed manual gearbox 02Q
Edition 06.2010
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 ➤ Jetta 2011 ➤ 6-speed manual gearbox 02Q Edition 06.2010 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 MEX5R006920...

  • Page 3: Table Of Contents

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 Contents 00 - Technical data ........... .

  • Page 4

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 Removing and installing gearbox in vehicles with turbo diesel engine ....

  • Page 5: Technical Data

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 00 – Technical data Gearbox identification The 6-speed manual gearbox 02Q is installed in the Jetta 2005 ►, in the Golf Variant 2007 ►, in the Golf Variant 2010 ►...

  • Page 6

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 Manual gearbox 6-speed 02Q Identification code Allocation Model Jetta 2005 ► Jetta 2005 ► Jetta 2005 ►...

  • Page 7

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 Manual gearbox 6-speed 02Q Identification code Engine 2.0 l - 100 kW 2.0 l - 147 kW 2.0 l - 125 kW...

  • Page 8

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 Manual gearbox 6-speed 02Q Identification code 69 : 25 = 2.760 72 : 22 = 3.273 70 : 24 = 2.917...

  • Page 9: Overview - Power Transmission

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 Overview - power transmission Designation -Arrows- indicate direction of travel. 1 - Engine 2 - Clutch...

  • Page 10

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 I - 1st gear II - 2nd gear III - 3rd gear IV - 4th gear...

  • Page 11: Calculating Overall Gear Ratio „i

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 Calculating overall gear ratio „i“ Example: 6th gear Final drive Drive gear ZG 1 = 43...

  • Page 12: General Repair Notes

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 General repair notes To ensure flawless and successful gearbox repairs, the greatest care and cleanliness as well as the use of good and proper tools are essential.

  • Page 13

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 4.3.2 O-rings, seals, gaskets and sealants ♦ Thoroughly clean housing joint surfaces before applying seal‐ ant .

  • Page 14

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 4.3.4 Nuts and bolts ♦ Loosen and tighten securing bolts and nuts for covers and housings diagonally.

  • Page 15

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 4.3.7 Synchro-rings ♦ Do not interchange. When reusing synchro-rings, always fit to the same gear. ♦ Check for wear and renew if necessary.

  • Page 16: Clutch

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 30 – Clutch Fault finding, power transmission – Refer to ⇒ Fault finding, power transmission; Rep. gr. 30 ;...

  • Page 17: Repairing Clutch Mechanism

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 Repairing clutch mechanism Overview Note Before disconnecting battery, obtain code for radio units having anti-theft coding.

  • Page 18: Assembly Overview - Pedal Cluster

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 Assembly overview - pedal cluster 1 - Bulkhead ❑ With support for mount‐ ing bracket 2 - Seal ❑...

  • Page 19: Removing And Installing Over-centre Spring

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 ❑ Qty. 3 ❑ For mounting bracket on bulkhead ❑ Always renew 16 - Hexagon nut, 25 Nm ❑...

  • Page 20

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 – With ignition switched off, disconnect battery ⇒ Electrical sys‐ tem; Rep. gr. 27 ; Disconnecting and connecting battery .

  • Page 21

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 – Push damping upwards in area of upper securing nut -1- above clutch pedal -A- in -direction of arrow-.

  • Page 22

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 – Insert over-centre spring -2- in mounting bracket from above while holding end of spring with assembly tool -T10178- in in‐...

  • Page 23: Removing And Installing Clutch Pedal

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 – Install crash bar -1- in front of clutch pedal by screwing on and tightening nuts -2-.

  • Page 24

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 2.4.1 Removing Vehicles with knee airbag Note The installation location of the knee airbag is above the pedal cluster.

  • Page 25

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 – 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 26

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 – Release clutch pedal from master cylinder with pliers - T10005- . – Remove clutch pedal.

  • Page 27: Removing And Installing Mounting Bracket

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 • Receptacle -arrow- for tip -A- of clutch pedal must stand ver‐ tically. – Insert tip -A- of clutch pedal in bearing recess of over-centre spring.

  • Page 28

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 ♦ Hose clamps -3094- ♦ Hose clip pliers -VAS 6362- ♦ Sealing tool -T10249- 2.5.1 Removing –...

  • Page 29

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 Continuation for all Note During the following work, ensure that no brake fluid lands on ♦...

  • Page 30

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 – Remove crash bar -1- from in front of clutch pedal by removing nuts -2-. Continuation for all –...

  • Page 31

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 – Push damping upwards in area of upper securing nut -1- above clutch pedal -A- in -direction of arrow-.

  • Page 32

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 Some cars have damping -arrow- on the clutch pedal mounting bracket. Vehicles without knee airbag – Install crash bar -1- in front of clutch pedal by screwing on and tightening nuts -2-.

  • Page 33: Removing And Installing Master Cylinder

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 Removing and installing master cylinder Special tools and workshop equipment required ♦ Pliers -T10005- 2.6.1 Removing –...

  • Page 34: Removing And Installing Clutch Position Sender G476

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 – Attach retainer -2- to master cylinder operating rod -1-. – Insert spacer -A- between clutch pedal and stop and press clutch pedal to spacer.

  • Page 35

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 ♦ Hose clamps -3094- 2.7.1 Removing – First check whether a coded radio is fitted. If so, obtain anti- theft code.

  • Page 36

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 Continuation for all If a pipe/hose line -1- with a round component is installed directly beneath the master cylinder, the pipe/hose line must be removed.

  • Page 37

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 Note Renew hose clips. ♦ Allocate all components according to ⇒ Electronic parts cata‐ ♦ logue „ETKA“ .

  • Page 38: Assembly Overview - Hydraulics (lhd)

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 Assembly overview - hydraulics (LHD) 1 - Brake fluid reservoir 2 - Spring-type clip ❑ Not fitted in all vehicles 3 - Supply hose ❑...

  • Page 39

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 12 - Plastic line ❑ Allocation ⇒ Electronic parts catalogue „ETKA“ ❑ To remove, remove battery and battery tray ⇒ Electrical system; Rep. gr. 27 ; Removing and installing battery .

  • Page 40: Assembly Overview - Hydraulics (rhd)

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 Retainer identification Dim. „a“ mm Line configuration Plastic line Pipe/hose line Assembly overview - hydraulics (RHD)

  • Page 41: Bleeding Clutch System

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 10 - Bracket ❑ Secured to body ❑ Hidden by engine/gearbox mounting 11 - Pipe line ❑...

  • Page 42

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 ♦ Brake filling and bleeding equipment -VAS 5234- or ♦ Brake filling and bleeding equipment -V.A.G 1869-...

  • Page 43: Repairing Clutch Release Mechanism

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 Repairing clutch release mechanism Special tools and workshop equipment required ♦ Torque wrench -V.A.G 1331- 1 - Gearbox 2 - Input shaft seal ❑...

  • Page 44: Removing Pipe/hose Line And Bleeder From And Installing On Slave Cylinder

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 Slave cylinder -A- with divided supply line The supply line for some slave cylinders is divided in the area of the -arrow-.

  • Page 45: Removing And Installing Pipe/hose Line Or Plastic Line

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 – Release securing clip -2- with a screwdriver or pointed object and pull bleeder -4- off slave cylinder -1-.

  • Page 46

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 Removing – Remove complete air filter housing ⇒ Rep. gr. 23 ; Repairing diesel direct injection system or ⇒ Rep. gr. 24 ; Repairing injection system .

  • Page 47: Renewing Input Shaft Seal

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 – Push pipe/hose line or plastic line -1- with O-ring -2- onto con‐ nection of master cylinder -4- until securing clip -3- engages audibly.

  • Page 48

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 ♦ Thrust piece -T40008- ♦ Sealing grease -G 052 128 A1- Procedure • Remove gearbox. – Remove slave cylinder with release bearing ⇒...

  • Page 49: Repairing Clutch - Vehicles With Turbo Diesel Engine

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 Repairing clutch - vehicles with turbo diesel engine Special tools and workshop equipment required ♦ Counterhold -3067- ♦...

  • Page 50

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 – Remove noise insulation ⇒ General body repairs, exterior; Rep. gr. 50 ; Noise insulation .

  • Page 51: Removing And Installing „sachs" Clutch

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 Rounded outer contour -arrows 1- and a circumferential crease -arrow 2- = LuK clutch = -B- –...

  • Page 52

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 Checking ends of diaphragm spring • Wear to half the thickness of the diaphragm spring -arrows- is permitted.

  • Page 53

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 For engines having a crankshaft of smaller diameter -arrow- or having an needle bearing -arrow- in the crankshaft...

  • Page 54: Repairing „sachs" Clutch

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 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 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 Note Select clutch plate and pressure plate according to engine ♦ code and ⇒ Electronic parts catalogue „ETKA“ .

  • Page 56

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 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 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 Centring clutch disc and removing and installing pressure plate for engines having a crankshaft of smaller diameter or having a...

  • Page 58: Repairing Clutch - Vehicles With Petrol Engine

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 Repairing clutch - vehicles with petrol engine Special tools and workshop equipment required ♦ Counterhold -3067- ♦...

  • Page 59: Repairing Clutch

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 Repairing clutch Note Check whether dowel sleeves for aligning engine and gearbox are fitted in cylinder block and install if nec‐...

  • Page 60

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 – Remove pressure plate and clutch plate. Installing Install in the reverse order of removal, observing the following:...

  • Page 61

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 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 62

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 Centring clutch disc and removing and installing pressure plate for engines having a crankshaft of smaller diameter or having a...

  • Page 63: Controls, Housing

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 34 – Controls, housing Repairing selector mechanism Installation position of selector mechanism Arrow -A- Gear selection movement...

  • Page 64: Overview Of Selector Mechanism

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 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 65

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 ♦ Hose clip pliers -V.A.G 1275- ♦ Torque wrench -V.A.G 1331- 1. Repairing selector mechanism...

  • Page 66: Removing And Installing Gear Knob And Frame

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 Removing and installing gear knob and frame 1 - Emblem ❑ Can be carefully levered off gear knob of plastic...

  • Page 67

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 – 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 68: Repairing Gear Lever And Selector Housing (through 10.06)

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 Repairing gear lever and selector housing (through 10.06) Note Lubricate bearing points and sliding surfaces with grease -G 000 450 02- .

  • Page 69

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 25 - Lock washer ❑ Always renew 26 - Hexagon nut ❑ M8: 25 Nm ❑ M6: 8 Nm ❑...

  • Page 70: Repairing Gear Lever And Selector Housing (from 11.06)

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 Repairing gear lever and selector housing (from 11.06) Note Lubricate bearing points and sliding surfaces with grease -G 000 450 02- .

  • Page 71

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 14 - Bush 15 - Gear lever guide 16 - Hexagon nut ❑ M8: 25 Nm ❑...

  • Page 72

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 – 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 73

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 – Slacken ends -A- and -B- by turning both round to right. • Ends -A- and -B- must point in opposite directions.

  • Page 74

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 – Move gate selector lever back to stop (opposite from mounting holes for gear and gate selector cable) -arrow 1-.

  • Page 75: Assembly Overview - Removing And Installing Selector Cables

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 Assembly overview - removing and installing selector cables Note Lubricate bearing points and sliding surfaces with grease -G 000 450 02- .

  • Page 76

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 ❑ Do not interchange; cable end-pieces for gate selector cable to relay lever and gear selector cable to gearbox selector lever are different ⇒...

  • Page 77

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 Allocation of cable end-pieces The holes in the cable end-pieces have different diameters. Cable end-piece for Dimension „a“...

  • Page 78

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 Installation position of gearbox selector lever and relay lever Gearbox selector lever with damper weight Relay lever engages in guide rail of gearbox selector lever via shoe -arrow-.

  • Page 79: Plastic Relay Lever

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 – Remove securing clip -3- for gear selector cable from gearbox selector lever -1-. – Pull gear selector cable off pin -arrow-.

  • Page 80

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 Relay lever with catch -arrow 1- – Press catch -arrow 1- down to stop and remove relay lever together with cable end-piece.

  • Page 81

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 Relay lever with clip -arrow 1- • Clip -arrow 1- secures relay lever. • Ensure proper engagement of clip.

  • Page 82: Removing And Installing Selector Mechanism

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 • Relay lever has been removed. • Cable end-piece may be pressed only onto bush -arrow-.

  • Page 83

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 – Remove selector housing nuts -arrows-. – Remove complete air filter housing if it is over selector mech‐...

  • Page 84: Removing And Installing Gear Selector Cable And Gate Selector Cable

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 • Distance to body must be same on both sides. Secure selector housing ⇒ Item 26 (page 65) ⇒...

  • Page 85

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 – Bend open tabs -arrows- of selector mechanism cover using a screwdriver and remove cover. – Remove gasket.

  • Page 86: Adjusting Selector Mechanism

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 – Secure gear selector cable and gate selector cable to selector housing using securing clips -2 and 3-.

  • Page 87

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 – Pull locking mechanisms on gate selector cable and gear se‐ lector cable end-pieces forward to stop -direction of arrow 1- and then turn to left to lock -direction of arrow 2-.

  • Page 88: Functional Check

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 – Now turn angled rod -A- back to original position -direction of arrow 2-. • During this procedure, angled rod -A- must be pressed out of gearbox in -direction of arrow 1-.

  • Page 89: Removing And Installing Gearbox In Vehicles With Turbo Diesel Engine

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 Removing and installing gearbox in vehicles with turbo diesel engine Removing gearbox Special tools and workshop equipment required ♦...

  • Page 90

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 ♦ Support elements for gear‐ box (determine when set‐ ting adjustment plate on gearbox support ) ♦...

  • Page 91

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 ♦ Bracket -T10346- ♦ Engine support -3300 A- ♦ Adapter -VW 771/40- ♦ Hose clamps to 25 mm -3094- ♦...

  • Page 92

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 – Remove securing clip -1- for gear selector cable from gearbox selector lever -2- and pull cable off pin -arrow-.

  • Page 93

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 Right-hand drive – Clamp off hose of pipe/hose line -A- to slave cylinder using hose clamp -3094- .

  • Page 94

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 – Set up support bracket -10-222 A- in front of bonnet support. – Use: ♦ Adapter -10-222 A /3- ♦...

  • Page 95

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 – Remove left charge air hose -arrow 1- and -arrow 2- ⇒ Rep. gr. 21 ; Charge air system with turbocharger .

  • Page 96

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 – Remove pendulum support. – Pull connector -1- off oil level and oil temperature sender - G266- .

  • Page 97

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 – Lower gearbox about 40 mm, dimension -a-, by adjusting spin‐ dles attached to engine. Note Observe connecting lines, hoses and radiator when moving en‐...

  • Page 98

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 – Attach bracket -T10346- with bolt -1- to left threaded hole in subframe. -1- = Flange bolt M6 x 20.

  • Page 99

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 Pin -B- must lie flush with guide from gearbox support -3282- at bottom -arrow-. Engine/gearbox connecting bolt -arrow- has been removed.

  • Page 100: Transporting Gearbox

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 – Observe longitudinal member -arrows-. Then carefully lower gearbox. Note Be careful of all lines when lowering gearbox.

  • Page 101: Installing Gearbox

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 – Adjust support beam on sliding piece using locking pin -arrow-. Number of holes visible = 6.

  • Page 102

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 – Attach bracket -T10346- with bolt -1- to left threaded hole in subframe. -1- = Flange bolt M6 x 20.

  • Page 103

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 – Now turn gearbox upwards near differential, using spindle of gearbox support -3282- , and downwards near 6th gear.

  • Page 104

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 – Screw in lower engine/gearbox securing bolts and tighten to specified torque ⇒ page 104 – Remove engine support -3300 A- and bracket -T10346- .

  • Page 105

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 – If small cover plate -A- for flywheel is present, install it -arrows- ⇒ page 104 Note There are threaded inserts, e.g.

  • Page 106

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 – If front vehicle level sender -G78- is present, bolt it onto trans‐ verse link ⇒ Rep. gr. 40 ; Removing and installing front vehicle level sender -G78- .

  • Page 107

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 – Attach earth strap -1- to upper starter bolt. – Push connector -2- onto reversing light switch -F4- .

  • Page 108: Specified Torques

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 – Spread a small amount of grease on pin -arrow- of gearbox selector lever -2-. Allocate grease using ⇒ Electronic parts catalogue (ETKA) .

  • Page 109

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 Item Bolt Quantity M12 x 165 ♦ With short M8 stud ♦ Additionally, starter to gearbox M6 x 8 ♦...

  • Page 110: Removing And Installing Gearbox, Vehicles With Petrol Engine

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 Removing and installing gearbox, ve‐ hicles with petrol engine Removing gearbox Special tools and workshop equipment required ♦...

  • Page 111

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 ♦ Support elements for gear‐ box (determine when set‐ ting adjustment plate on gearbox support ) ♦...

  • Page 112

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 ♦ 2 x brackets -T10346- ♦ Engine support -3300 A- ♦ Adapter -VW 771/40- ♦ Hose clamps to 25 mm -3094- ♦...

  • Page 113

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 – Remove securing clip -1- for gear selector cable from gearbox selector lever -2- and pull cable off pin -arrow-.

  • Page 114

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 Right-hand drive – Clamp off hose of pipe/hose line -A- to slave cylinder using hose clamp -3094- .

  • Page 115

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 – Set up support bracket -10-222 A- in front of bonnet support. – Use: ♦ Adapter -10-222 A /3- ♦...

  • Page 116

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 – Remove cowling -arrow- together with radiator fans ⇒ Rep. gr. 19 ; Parts of cooling system .

  • Page 117

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 – Remove drive shaft heat shield, if present -arrows- ⇒ Running gear, axles, steering; Rep. gr. 40 ; Repairing drive shafts .

  • Page 118

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 – Remove bracket -1- from gearbox -arrows-. – Remove relay lever together with cable end-piece ⇒ page 75 –...

  • Page 119

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 – Attach support elements -A- to adjustment plate as illustrated. – Screw in pin -3282/29- instead of support element -C-.

  • Page 120: Transporting Gearbox

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 – If necessary, turn gearbox further upwards near differential using spindles of gearbox support -3282- .

  • Page 121: Installing Gearbox

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 – Bolt gearbox lifting tackle -3336- to clutch housing. – Adjust support beam on sliding piece using locking pin -arrow-.

  • Page 122

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 – Ensure that intermediate plate is hooked into sealing flange and pushed onto dowel sleeves -arrows-.

  • Page 123

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 – Secure adapter -VW 771/40- in threaded hole of gearbox housing as shown in figure. – Secure gearbox to gearbox support -3282- using bolt (M10x20) -A-.

  • Page 124

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 – Guide gearbox with differential over subframe -A- -in direction of arrow-. – Swing rear of gearbox towards subframe.

  • Page 125

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 – Align engine and gearbox in installation position. To do this, raise sufficiently so that bracket -1- completely contacts left assembly mounting -2-.

  • Page 126

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 – Install drive shaft heat shield, if present -arrows- ⇒ Running gear, axles, steering; Rep. gr. 40 ; Repairing drive shafts .

  • Page 127

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 – Fit charge air hoses -arrow 1- and -arrow 2- and charge air pipe on engine ⇒ Rep. gr. 21 ; Charge air system with turbo‐...

  • Page 128: Specified Torques

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 Allocate grease using ⇒ Electronic parts catalogue (ETKA) . – Renew securing clip -1- each time it is removed.

  • Page 129

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 Item Bolt Quantity M12 x 165 ♦ With short M8 stud ♦ Additionally, starter to gearbox M6 x 8 ♦...

  • Page 130: Checking Gearbox Oil

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 Checking gearbox oil Special tools and workshop equipment required ♦ Torque wrench -V.A.G 1331- ♦ Multi-point bit -3357- Gearbox oil specification ⇒...

  • Page 131

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 Various versions of oil filler and drain plugs I - Oil filler or oil drain plug with multi-point socket head 45 Nm II - Oil filler or oil drain plug with hexagon socket head 30 Nm 4.

  • Page 132: Dismantling And Assembling Gearbox

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 Dismantling and assembling gearbox Overview - rear final drive 1 - Clutch housing 2 - Reverse shaft...

  • Page 133: Assembly Overview

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 Assembly overview l - Removing and installing gearbox housing and selector mechanism ⇒ page 130 ll - Removing and installing in‐...

  • Page 134: Removing And Installing Gearbox Housing And Selector Mechanism

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 Removing and installing gearbox housing and selector mechanism 1 - Countersunk bolt, 33 Nm 2 - Flange shaft with compres‐...

  • Page 135

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 ❑ Repairing ⇒ page 172 ❑ Removing with gearbox installed: ♦ Remove battery and battery tray ⇒ Electrical system; Rep. gr. 27 ; Battery; Removing and installing battery .

  • Page 136: Removing And Installing Input Shaft, Output Shafts, Differential And Selector Rods

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 Removing and installing input shaft, output shafts, differential and selector rods 1 - Output shaft for 1st through 4th gears ❑...

  • Page 137

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 14 - Slave cylinder with clutch release bearing 15 - Bolt ❑ Qty. 3 ❑ Always renew ❑...

  • Page 138: Assembly Order, Gearbox »without« Retaining Ring A For Input Shaft Sealing Cover

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 Assembly order, gearbox »without« retaining ring -A- for input shaft sealing cover Removing and installing gearbox housing, selector mechanism, input shaft, output shafts, differential and selector rods.

  • Page 139

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 ♦ Support bridge -30 - 211 A- ♦ Thrust piece -T10042- ♦ Drift -T10169- ♦ or drift -T10362- ⇒...

  • Page 140

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 5.5.1 Removing – Secure gearbox to assembly stand using bolts -arrows-. Note If one of the bolting holes does not contact the gearbox support , lay a washer between the hole and the gearbox support .

  • Page 141

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 – Remove bolts -B-, which secure gearbox housing to clutch housing. Note One bolt -arrow- is located outside of bolting flange.

  • Page 142

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 Remove retaining ring -C- from deep groove ball bearing of input shaft in gearbox housing as follows: –...

  • Page 143

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 – If present, remove washer -1- from deep groove ball bearing -2-. – If gearbox housing is to be renewed, check whether washer must be re-installed ⇒...

  • Page 144

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 – Insert input shaft -1-, output shaft for 5th and 6th gears -2- together with selector rod -3-, selector fork -4- and reverse shaft -5-.

  • Page 145

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 On some gearboxes, flats -A- are present on the deep groove ball bearing for the input shaft and the bearing support -B-.

  • Page 146

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 – If necessary, lay a washer (outer diameter = 85 mm) -1- on deep groove ball bearing -2-.

  • Page 147

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 – Set gearbox housing in place and tighten new bolts -A-, -B- and -C- to specified torque.

  • Page 148

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 – Now press selector shaft -1- against stop sleeve -2- in -direction of arrow- and guide downwards with selector finger -3- through selector forks to stop.

  • Page 149: Assembly Order, Gearbox »with« Retaining Ring A For Input Shaft Sealing Cover

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 – Drive sealing cover into gearbox housing to stop using thrust piece -T10042- . Assembly order, gearbox »with« retain‐...

  • Page 150

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 Special tools and workshop equipment required ♦ Support plate -VW 309- ♦ Support clamp -VW 313- ♦...

  • Page 151

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 ♦ Support bridge -30-211A- ♦ Thrust piece -T10143- ♦ Drift -T10169- ♦ or drift -T10362- ⇒ page 163 ♦...

  • Page 152

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 Note If one of the bolting holes does not contact the gearbox support , lay a washer between the hole and the gearbox support .

  • Page 153

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 – Gearboxes for vehicles with start-stop system: remove gear‐ box neutral position sender -G701- -arrow-. – Remove bolts -B-, which secure gearbox housing to clutch housing.

  • Page 154

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 – Remove retaining ring -A- for input shaft sealing cover. – Pierce rubber in centre of cover -C- with a screwdriver .

  • Page 155

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 – Screw adapter VW 771/40 into threaded hole of gearbox hous‐ ing. – Heat gearbox housing using hot air blower , e.g. -V.A.G 1416- in vicinity of bearing seat for deep groove ball bearing for input shaft for about 10 minutes to about 100°...

  • Page 156

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 – First insert input shaft -1- and 5th and 6th gear output shaft -2- together with selector rod -3-, selector fork reverse gear -4- and reverse shaft -5-.

  • Page 157

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 – Then insert differential -1-. Note A second mechanic will be required for further installation of shafts in clutch housing.

  • Page 158

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 Note Heating is necessary to avoid damage to deep groove ball ♦ bearing when gearbox housing is installed.

  • Page 159

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 – Now press selector shaft -1- against stop sleeve -2- in -direction of arrow- and guide downwards with selector finger -3- through selector forks to stop.

  • Page 160

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 – Drive sealing cover into gearbox housing to stop of thrust piece. – Secure sealing cover with retaining ring -A-.

  • Page 161: Repairing Gearbox Housing

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 Repairing gearbox housing Special tools and workshop equipment required ♦ Drift sleeve -VW 244 B- ♦ Gearbox support -VW 353- ♦...

  • Page 162

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 ♦ Guide pin -VW 436A- ♦ Guide pin -VW 439- ♦ Multipurpose tool -VW 771- ♦ Support plate -VW 801- ♦...

  • Page 163

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 ♦ Drift -3264- ♦ Assembly tool -3290- ♦ Torque wrench -V.A.G 1331- ♦ Drift -T10168- ♦ Drift -T10169- or drift - T10362- ⇒...

  • Page 164

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 1 - Gearbox housing ❑ If renewed: adjust out‐ put shafts and differen‐ tial ⇒ page 232 ❑...

  • Page 165

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 11 - Shim ❑ For output shaft for 5th, 6th and reverse gears ❑ Adjustment overview ⇒...

  • Page 166

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 Removing angled rod for selector shaft – Break off angled rod in released position. – Insert a screwdriver -A- in hole for angled rod -B-.

  • Page 167

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 Driving in selector shaft bearing bush to stop of tool Pressing stop sleeve -A- out of gearbox housing –...

  • Page 168

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 Drive in stop sleeve with shoulder until tool makes contact • Clutch housing bolted to gearbox housing.

  • Page 169

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 Pulling out selector shaft bearing bush – Use thread adapter from counter support -Kukko 22/1- -arrow-.

  • Page 170

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 Driving in plug -1- – Drive in sealing plug to dimension -a-, about 3 mm below upper edge of housing, using drift -3264- .

  • Page 171: Repairing Clutch Housing

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 Repairing clutch housing Special tools and workshop equipment required ♦ Press tool -VW 407- ♦ Drift -T10168- ♦...

  • Page 172

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 1 - Bearing bush ❑ For selector rods ❑ Renew each time after removing ❑ Pulling out ⇒...

  • Page 173

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 ❑ Removing and installing ⇒ page 187 ❑ If renewed, adjust output shaft for 1st through 4th gears ⇒...

  • Page 174

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 Pulling needle bearing out of clutch housing A - Counter support , e.g. -Kukko 22/2- B - Internal puller, 23.5 … 30 mm , e.g. -Kukko 21/4- Note The needle bearing is destroyed during removal and must be re‐...

  • Page 175

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 Pressing reverse gear selector fork shaft into clutch housing 7. Repairing clutch housing...

  • Page 176: Repairing Selector Unit

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 Repairing selector unit Note Lubricate bearing points and running surfaces with grease -G 000 450 02- .

  • Page 177: Renewing Oil Seal For Selector Shaft

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 10 - Lock washer ❑ For relay lever ❑ Not fitted on plastic relay lever ❑ Always renew 11 - Seal for selector shaft ❑...

  • Page 178

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 Metal relay lever – Pull off securing clip -2- and press relay lever -3- to side out of mounting.

  • Page 179: Repairing Selector Forks

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 Repairing selector forks Special tools and workshop equipment required ♦ Thrust plate -VW 402- ♦ Press tool -VW 411- ♦...

  • Page 180

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 1 - Rubber dampers ❑ Can be removed from and inserted in selector rod by hand...

  • Page 181

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 Through gearbox manufacture date 05 03 6 - pulling out ball sleeve for reverse gear selector fork A - Internal puller, 18 …...

  • Page 182: Gears, Shafts

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 35 – Gears, shafts Input shaft Dismantling and assembling input shaft Special tools and workshop equipment required ♦...

  • Page 183

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 ♦ Thrust piece -VW 454- ♦ Thrust piece -30 - 505- ♦ Thrust plate -40 - 105- ♦...

  • Page 184

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 1 - Retaining ring ❑ For deep groove ball bearing of input shaft ⇒ Item 6 (page 180) ❑...

  • Page 185

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 ❑ Pressing on ⇒ page 181 8 - Input shaft ❑ With gear wheels for 3rd, 4th and 6th gears 9 - Cylindrical roller bearing ❑...

  • Page 186

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 Pressing on deep groove ball bearing Deep groove ball bearing with a rubber ring -arrow- Shoulder -A- faces press tool -VW 412- .

  • Page 187

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 Pulling cylinder roller bearing out of clutch housing – When pulling out, squeeze together retaining ring -arrow- of cylindrical roller bearing, using pliers -C-.

  • Page 188

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 From gearbox date 10 04 6 through around gearbox date 20 01 8 slightly deeper In order for the washer beneath the deep groove ball bearing ⇒...

  • Page 189: Output Shaft For 1st Through 4th Gears

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 Output shaft for 1st through 4th gears Assembly overview - output shaft for 1st through 4th gears Dismantling and assembling output shaft for 1st through 4th gears ⇒...

  • Page 190

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 12 - Locking collar with synchro-hub for 1st and 2nd gears ❑ After removing retaining ring ⇒...

  • Page 191: Dismantling And Assembling Output Shaft For 1st Through 4th Gears

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 30 - Synchromeshed gear for 3rd gear ❑ Installation position ⇒ page 198 31 - Tapered roller bearing inner race ❑...

  • Page 192

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 Special tools and workshop equipment required ♦ Thrust plate -VW 401- ♦ Thrust plate -VW 402- ♦...

  • Page 193

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 ♦ Support plate -VW 309- ♦ Support clamp -VW 313- ♦ Gearbox support -VW 353- ♦ Thrust piece -VW 431- ♦...

  • Page 194

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 ♦ Thrust piece -VW 512- ♦ Tube -VW 516- ♦ Tube -VW 519- ♦ Multipurpose tool -VW 771- ♦...

  • Page 195

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 ♦ Drift sleeve -40-20- ♦ Drift sleeve -40-21- ♦ Thrust piece -2050- ♦ Supplementary set for en‐...

  • Page 196

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 ♦ -1- Internal puller - Kukko 21/7- ♦ -1- Internal puller - Kukko 21/8- ♦ -2- Puller -Kukko 18/2- ♦...

  • Page 197

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 Press on tapered roller bearing inner race on side facing clutch housing Pulling tapered roller bearing outer race out of clutch housing A - Counter support , e.g.

  • Page 198

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 Press on tapered roller bearing inner race on side facing gearbox housing – Determine and install retaining ring ⇒...

  • Page 199

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 Pulling off synchro-hub and locking collar for 3rd and 4th gears with synchromeshed gear for 4th gear –...

  • Page 200

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 1st/2nd gear synchronisation from gearbox date 26 10 9 onwards Synchro-ring -C-, outer ring -B- and inner ring -A- are made of steel.

  • Page 201

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 Installation position of outer ring, inner ring and synchro-ring for 2nd gear – Check lugs -arrows 1- and -arrows 2- for scoring.

  • Page 202

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 Pressing on locking collar and synchro-hub for 1st and 2nd gears Turn synchro-ring so that grooves align with locking pieces.

  • Page 203

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 Checking synchro-ring for 4th gear for wear – Press synchro-ring onto cone of synchromeshed gear and measure gap -a- using feeler gauge.

  • Page 204

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 Installation position of synchro-ring -A- (3rd gear inner ring) Lugs -arrows 1- locate in notches -arrows 2- of synchro-ring -B-.

  • Page 205

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 Check outer friction surface of 1st gear outer ring and 2nd gear outer ring for wear –...

  • Page 206

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 Assembling locking collars and synchro-hubs for 1st and 2nd gears as well as 3rd and 4th gears Locking collar has been pushed over synchro-hub.

  • Page 207

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 Installation of synchro-ring outer ring and 1st gear inner ring – Insert synchro-ring -A- into synchro-hub.

  • Page 208

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 Pressing on synchro-hub with locking collar for 3rd and 4th gears – Turn synchro-ring so that grooves align with locking pieces.

  • Page 209

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 Installation position of synchro-ring -A- (3rd gear inner ring) Lugs -arrows 1- locate in notches -arrows 2- of synchro-ring -B-.

  • Page 210: Adjusting Output Shaft For 1st Through 4th Gears

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 Adjusting output shaft for 1st through 4th gears Special tools and workshop equipment required ♦ Gearbox support -VW 353- ♦...

  • Page 211

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 ♦ Support plate -VW 309- ♦ Thrust piece -2050- ♦ Torque wrench -V.A.G 1331- ♦ Internal puller -1 - Kukko 21/7- ♦...

  • Page 212

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 – Press tapered roller bearing outer race with 1.70 mm thick shim into gearbox housing to stop. In the process, support gearbox housing using thrust piece -2050- directly below bear‐...

  • Page 213

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 Example: Installed shim 1.70 mm - Measured value 0.14 mm + Preload (constant) 0.20 mm Shim thickness 1.76 mm...

  • Page 214

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 – Set up measuring tools and secure to clutch housing using bolt -arrow-. – Set dial gauge (3 mm measuring range) to „0“ with 1 mm pre‐...

  • Page 215: Output Shaft For 5th, 6th And Reverse Gears

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 Output shaft for 5th, 6th and reverse gears Dismantling and assembling output shaft for 5th, 6th and reverse gears...

  • Page 216

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 ♦ Support plate -VW 309- ♦ Gearbox support -VW 353- ♦ Thrust piece -VW 433- ♦ Thrust piece -VW 454- ♦...

  • Page 217

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 ♦ Thrust piece -VW 431- ♦ Installing sleeve -VW 455- ♦ Thrust pad -VW 510- ♦ Tube -VW 516- ♦...

  • Page 218

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 ♦ Thrust plate -40 - 105- ♦ Drift sleeve -40 - 20- ♦ Thrust piece -2050- ♦...

  • Page 219

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 ♦ -1- Internal puller -Kukko 21/7- ♦ -3- Splitter -Kukko 17/2- ♦ -4- Counter support -Kukko 22/2-...

  • Page 220

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 10 - Synchromeshed gear for reverse gear 11 - Sleeve ❑ Press off together with synchromeshed gear for reverse gear ⇒...

  • Page 221

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 Pulling out tapered roller bearing outer race A - Counter support , e.g. -Kukko 22/2- B - Internal puller, 46 … 58 mm , e.g. -Kukko 21/7- Note After pulling out, check washer for damage and renew if neces‐...

  • Page 222

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 Pressing off sleeve -A- together with synchromeshed gear for re‐ verse gear – First remove retaining ring.

  • Page 223

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 Pressing on reverse gear synchro-hub – Install retaining ring. Pressing on sleeve -A- Installation position: Wide collar faces reverse gear synchro‐...

  • Page 224

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 Assembling locking collar with synchro-hub for 5th and 6th gears Locking collar has been pushed over synchro-hub.

  • Page 225

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 Pressing on tapered roller bearing inner race Pulling outer race for tapered roller bearing out of gearbox hous‐...

  • Page 226: Adjusting Output Shaft For 5th, 6th And Reverse Gears

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 Adjusting output shaft for 5th, 6th and reverse gears Special tools and workshop equipment required ♦ Gearbox support -VW 353- ♦...

  • Page 227

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 ♦ Support plate -VW 309- ♦ Thrust piece -2050- ♦ Torque wrench -V.A.G 1331- ♦ -1- Internal puller -Kukko 21/7- ♦...

  • Page 228

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 – Press tapered roller bearing outer race with 1.70 mm thick shim into gearbox housing to stop. In the process, support gearbox housing using thrust piece -2050- directly below bear‐...

  • Page 229

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 - Measured value 0.25 mm + Preload (constant) 0.20 mm Shim thickness 1.65 mm – Determine thickness of shim from table ⇒...

  • Page 230

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 – If the edge of the housing protrudes, put washers with a total thickness of 8 mm on bolt -arrow- for securing assembly de‐...

  • Page 231: Final Drive - Differential

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 39 – Final drive - differential Renewing flange shaft oil seals with gearbox installed Renewing oil seal for left flange shaft...

  • Page 232

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 ♦ Drip tray for workshop hoist -VAS 6208- 1.1.1 Removing – Remove left wheel. – Remove noise insulation ⇒ General body repairs, exterior;...

  • Page 233: Renewing Seal For Right Flange Shaft

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 1.1.2 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 234

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 ♦ Drip tray for workshop hoist -VAS 6208- ♦ Sealing grease -G 052 128 A1- 1.2.1 Removing –...

  • Page 235

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 1.2.2 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 236: Adjustment Overview

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 Adjustment overview Note If repairs have been carried out on the gearbox, it is necessary to...

  • Page 237: Differential

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 Differential Dismantling and assembling differential Special tools and workshop equipment required ♦ Thrust plate -VW 402- ♦...

  • Page 238

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 ♦ Tube -3259- ♦ Tube -3296- ♦ Tube -3345- ♦ Tapered roller bearing pull‐ er -V.A.G 1582- ♦...

  • Page 239

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 1 - Gearbox housing 2 - Shim ❑ For differential ❑ Determining thickness ⇒ page 239...

  • Page 240

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 15 - Thrust washer ❑ Installation position: shoulder faces spring, lugs, if present, face tapered ring 16 - Tapered ring ❑...

  • Page 241

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 Press tapered roller bearing outer race with washer into clutch housing – First insert washer. Note Observe installation position of washer.

  • Page 242

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 Pressing on tapered roller bearing inner race Cage with tapered rollers must be easy to turn during pressing.

  • Page 243: Adjusting Differential

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 Installing differential bevel gears – Lubricate one-piece thrust washer with gear oil and install. – Install both sun wheels and secure (e.g. with flange shaft).

  • Page 244

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 ♦ Tube -3259- ♦ Tube -3345- ♦ Torque wrench -V.A.G 1331- ♦ -1- Internal puller -Kukko 21/7- ♦...

  • Page 245

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 – Press tapered roller bearing outer race, without shim, into gearbox housing. – Fit differential into clutch housing.

  • Page 246

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed manual gearbox 02Q - Edition 06.2010 – Press outer race in again and tighten gearbox housing to specified torque ⇒ Item 11 (page 130) ⇒...

This manual also for:

Golf variant 2010, Jetta 2005, Jetta 2011

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