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) ⇒...

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Golf variant 2010 Jetta 2005 Jetta 2011

Volkswagen Golf Variant 2007 Workshop Manual

Technical Data

Clutch

Controls, Housing

Gears, Shafts

Final Drive - Differential

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