Volkswagen Golf 2007 User Manual

Service

Workshop Manual

Golf Variant 2007

Golf Variant 2010

Jetta 2005

6-speed manual gearbox 02S

Edition 07.2009

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Service Department. Technical Information

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Service

List of Workshop Manual Repair GroupsList of Workshop Manual Repair GroupsList of Workshop Manual Repair Groups

Repair Group

00 - Technical data

30 - Clutch

34 - Controls, housing

35 - Gears, shafts

39 - Final drive - differential

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Technical information should always be available to the foremen and mechanics, because their

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careful and constant adherence to thepinstructions is essential to ensure vehicle roadC-worthiness and

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matter of course, be observed.

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All rights reserved.

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No reproduction without prior agreement from publisher.

Copyright © 2010 Volkswagen AG, Wolfsburg

MEX5R007520

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						Golf Variant 2007 , Golf Variant 2010 , Jetta 2005
																6-speed manual gearbox 02S - Edition 07.2009
																Contents
00 - Technical data . . . . . . . .		. . .			.			.				.			.	. . . . .	.		. .	.		.		.	.	.	.		. . . . . . .	. .	.	.		.	.		.		.	.		.	.	.	. .	. .						1
1	Gearbox identification .	. . .		.			.		.			.			.	. . . . . .	.	.	. .	.	.		.		. .	.	.		. . . . . . . . .	. .	.	.	.	.		.	.	.		.	.	.		. .	. . .	. .							1
1.1	Location on gearbox . .	. . .		.			.		.				.		.	. . . . . .	.	.	. .		. .		.		.	. .	n.		A.G...V.ol.ks.w.a.g.en.		A.	G.	.	.	.		.	.	.		. .		.	.	. . .	. .							1
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1.2																									a													o.t															1
	Identification code, assembly allocation and capacitiesV																											.	. . . . . . . .	. .	.	.	.		e	.	.			.	. .			. .	. . .	. .
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2	Overview - power transmission															r		d																							a			n.t									5
													.		.		e. .		. .		. .		.		.	. .		.	. . . . . . . .	. .	.	.	.	.	.		.	.	.		. .	r			. . .	. .
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3	Calculating overall gear ratio “i”															th																													e								7
															. . .s. . . .		.	.	. .	.	.		.	.	.	.	.		. . . . . . . . .	. .	.	.	.	.		.	.	.		.	. .			. .	. . . . .c
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4	General repair notes														u	le																														e	a						8
		. . .		.			.		.				.			n. . . . . .	.	.	. .		. .		.	.		. .		.	. . . . . . . .	. .	.	.	.	.	.		.	. .			. .		.	.	. . .
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4.1	Components										t		e	d																																				i			8
		. . .		.		.			.						.	. . . . . .	.	.	. .		. .		. .			. .		.	. . . . . . . .	. .	.	.	.	.	.		.	. .			. .		.	.	. . .	. .
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30 - Clutch							e																																												b
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		. .		.		.				.				.		. . . . .	.	.	.	.	.		. .			. .			. . . . . . .	. .	.	.		.	.		.	.		.	.		.	.	. .	. .				12w
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1			n													. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .																																			12				i
	Fault finding, power transmission,																																																								e
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2		l																																																	13
	Repairing clutch mechanismh					.			.				.		.	. . . . . .	.	.	. .		. .		. .			. .		.	. . . . . . . .	. .	.	.	.	.	.		.	. .			. .		.	.	. . .	. .											e
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2.1	Overview	w																																																	13						t
		i. . .			.	.					.			.		. . . . . .	.	.	. .	.	.		. .		.	.		.	. . . . . . . . .	.	.	. .		.	.		.	. .			. .		.	.	. . .	. .											o
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2.2																																																			14
	Assembly overview - pedal cluster															. . . . .	.	.	. .	.	.	.	. .			.	.		. . . . . . . . .	. .	.	.	.	.		.	.	. .			. .			. .	. . .	. .
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2.3		a																																																	15						c
	Removing and installingnover-centre spring																		. .	.	.	.	.		.	.	.		. . . . . . . . .	. .		. .		.	.	.		. .			. .		.	.	. . .	. .											r
2.4		p																																																	20						o
	Removing and installing clutch pedal . . .																.	.	. .	.	.	.	. .			.	.		. . . . . . . . .	. .	.	.	.	.		. .		. .			. .			. .	. . .	. .											t
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		s																																																							c
2.5		e																																																	25						e
	Removing and installing omounting bracket																	.	. .	.	.		. .		.	.	.		. . . . . . . . .	. .	.	.	.	.		. .		. .			. .			. .	. . .	. .
		s																																																							n
2.6		p										cylinder																																							31						s
	Removing and installing masterp																.		. . .		. .		. .			.	.		. . . . . . . . .	. .		. .		.	.	.		. .			. .		.	.	. . .	. .											f
		r																																																							s
2.7		u							position sender G476																																										33						o
	Removing and installing clutchc																										.		. . . . . . . . .	.	.	. .		.	.	.		. .			. .		.	.	. . .	. .											f
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2.8		r																																																	37
	Assembly overview - hydraulics (LHD vehicles)																				.		. .	.		.	.		. . . . . . . . .	. .	.	.	.	.		. .		. .			. .			. .	. . .	. .											r
		e																																																							m
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2.9	Assembly overview - hydraulics (RHD vehicles)																				.		. .			. .		.	. . . . . . . .	. .	.	.	.		.	.		. .		.	.		.	.	. . .	. .					39 o
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2.10 Removing and installing slave cylinder . .																	.	.	. .	.	.		. .	.		.		.	. . . . . . . .	. .	.	.	.	.	.	.		. .			. .		.	.	. . .	. .
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2.11	Bleeding clutch system	. . . . .v
															.	. . . . . .	.	.	. .		. .		. .	.		.		.	. . . . . . . .	. .	.	.	.	.	.	.		. .			. .			. .	. . .	. .					d42
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3									i																																								c		44
												p
	Repairing clutch release mechanism . . . .																.		. .	.	. .		. .			. .		.	. . . . . . . .	. .	.	.	.	.	.	.		. .			. .			. .	. . .	. .		u
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4																n																													C	n					46
	Repairing clutch, in conjunction with dual-mass flywheel																												. . . . . . . .	. .		. .		.	.	.		. .			. .		.	.		t. .
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4.1	Determining clutch manufacturer															o																																			46
																. . . . .th.	.	.	. .	.	.		. .	.		.		.	. . . . . . . . .	.	.	. .		.	.	.		. .			. .		.	gi. . . .		. .
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4.2																	i																					o													48
	Removing and installing Sachs clutch . . . . .o.c																			.	. .		. .			.	.		. . . . . . . . .	. .		. .		.	.	.					. .		t.	.	. . .	. .
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4.3	Repairing Sachs clutch																			y	b	d		t c.e.to.r						A.n.eg							kl		V												50
																																				s
		. . .		.		.			.				.		.	. . . . . .	.	.	. .		. .		.						. . . . . . . .						w. .			. .			. .			. .	. . .	. .
																							e					P		.G				a
4.4	Removing and installing LuK clutch																																																		50
																		.	. .	.	.		. .	.		.	.		. . . . . . . . .	.	.	. .		.	.	.		. .			. .		.	.	. . .	. .
4.5	Repairing LuK clutch . .	. . .			.	.				.			.		.	. . . . . .	.		. . .		. .		. .			. .		.	. . . . . . . .	. .	.	.	.	.	.	.		. .			. .		.	.	. . .	. .					53
5	Repairing clutch, in conjunction with one-piece flywheel																												. . . . . . . .	. .	.	.	.		.	.		. .		.	.		.	.	. . .	. .					54
34 - Controls, housing . . . . . .		. . .				.			.				.		.	. . . . .	.		. .	.	.		. .			.		.	. . . . . . .	. .	.	.		.	.	.		.		.	.		.	.	. .	. .				57
1	Fault finding, power transmission															. . . . . .	.	.	. .	.	.		. .	.		.		.	. . . . . . . . .	.	.	.	.	.	.	.		. .			. .		.	.	. . .	. .					57
2	Repairing selector mechanism											.		.		. . . . . .	.	.	. .	.	.		. .	.		.		.	. . . . . . . . .	.	.	. .		.	.	.		. .			. .		.	.	. . .	. .					58
2.1	Installation position of selector mechanism																		. . .		. .		. .			. .			. . . . . . . . .	. .	.	.		.	.	.		. .			. .		.	.	. . .	. .					58
2.2	Overview of selector mechanism															. . . . . .	.	.	. .	.	.		. .	.		.		.	. . . . . . . . .	.	.	. .		.	.	.		. .			. .		.	.	. . .	. .					59
2.3	Removing and installing gear knob and frame																			.	.	.	.	.		.	.		. . . . . . . . .	.	.	. .		.	.	.		. .			. .		.	.	. . .	. .					61
2.4	Removing and installing gaiter with gear knob and noise insulation																													. .		. .		.	.	.		. .			. .		.	.	. . .	. .					61
2.5	Repairing gear lever and selector housing (through 10.06) . . . . . .																													. .	.	.	.		.	.		. .		.	.		.	.	. . .	. .					63
2.6	Repairing gear lever and selector housing (from 11.06)																												. . . . . . . .	. .	.	.	.		.	. .		.		.	.		.	.	. . .	. .					65
2.7	Assembly overview - removing and installing selector cables . . . .																													. .	.	.	.		.	. .		.		.	.		.	.	. . .	. .					70
2.8	Plastic relay lever . . . .	. . .	.			.			.			.		.		. . . . . .	.	.	. .	.	.		. .	.		.		.	. . . . . . . .	. .	.	.	.	.	.	.		. .			. .		.	.	. . .	. .					73
2.9	Removing and installing selector mechanism .																				. .		. .			. .		.	. . . . . . . .	. .	.	.	.		.	.		. .		.	.		.	.	. . .	. .					75
2.10 Removing and installing gear selector cable and gate selector cable																															.	.	.	.		. .		. .			. .			.	. . .	. .					78
2.11	Adjusting selector mechanism										.			.		. . . . . . .		.	. .	.	.		. .	.		.	.		. . . . . . . . .	.	.	. .		.	.	.		. .			. .		.	.	. . .	. .					80
3	Removing and installing gearbox															. . . . . .	.	.	. .	.	.		. .	.		.		.	. . . . . . . . .	.	.	. .		.	.	.		. .			. .		.	.	. . .	. .					84
3.1	Removing gearbox . . .	. . .	.			.		.				.		.		. . . . . . .		.	. .	.	.	.	. .			.	.		. . . . . . . . .	. .	.	.	.	.		. .		. .			. .			. .	. . .	. .					85
3.2	Installing gearbox . . . .	. . .	.			.			.			.		.		. . . . . .	.	.	. .	.	.		. .	.		.		.	. . . . . . . .	. .	.	.	.	.	.	.		. .			. .		.	.	. . .	. .					92
4	Checking and topping up gear oil															. . . . . .	.	.	. .	.	.		. .	.		.		.	. . . . . . . . .	.	.	.	.	.	.	.		. .			. .		.	.	. . .	. .					99
4.1	Preparation . . . . . . . . .	. . .	.			.			.			.		.		. . . . . .	.	.	. .	.	.		. .	.		.	.		. . . . . . . . .	. .	.	.	.	.		. .		. .			. .			. .	. . .	. .					99
																																													Contents								i

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Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 6-speed manual gearbox 02S - Edition 07.2009

4.2	Draining gear oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	100
4.3	Filling with gear oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	101
5	Dismantling and assembling gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	102
5.1	Overview - gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	102
5.2	Assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	103
5.3	Removing and installing cover for gearbox housing and 5th and 6th gear . . . . . . . . . . . .	104
5.4	Removing and installing gearbox housing and shift mechanism . . . . . . . . . . . . . . . . . . . .	107
5.5	Removing and installing input shaft, output shaft, differential and selector forks . . . . . . . .	108
5.6	Assembly sequence - Removing and installing cover for gearbox housing and 5th and 6th
	gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	109
5.7	Assembly sequence - Dismantling and assembling gearbox completely . . . . . . . . . . . . . .	115
6	Repairing gearbox housing and clutch housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	132
7	Repairing gearbox housing cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	138
8	Repairing selector unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	142
9	Dismantling and assembling selector forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	145

35 - Gears, shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150

1	Input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	150
1.1	Dismantling and assembling input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	150
1.2	Adjusting input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	158
2	Output shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	163
2.1	Dismantling and assembling output shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	163
2.2	Adjusting output shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	176
3	Reverse shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	181
3.1	Dismantling and assembling reverse shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	181

39 - Final drive - differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184

1

1.1

1.2

1.3

1.4

2

3

3.1

3.2

Renewing flange shaft oil seals with gearbox installed . . . . . . . . . . . . . . . . . . . . . . . . . . . .

184

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184

Renewing oil seal for left flange shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Distinguishing seals for right flange shaft

. . . . . . . . . . . . . a. . . . . . . . . . . . . . . . . . . . . . . . . 185

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186

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flange shaft) . . . .

189

Renewing sealsand sleeve together (one-piece seal and sleeve for rightc

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Adjustment overviewu

192

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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .h. . . . . . . . . . . .

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ii Contents

Downloaded from www.Manualslib.com manuals search engine

Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 6-speed manual gearbox 02S - Edition 07.2009

G.

00 –

Technical data

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1

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Gearbox identifications

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in the Jetta 2005 ,

The 6-speed manual gearbox 02S is installede d

t

Variant 2010 in con

i

t

in the Golf Variant 2007 and in the Golfm

junction with a 4-cylinder engine.

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Allocation page 1 .

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is

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1.1

l

o

Location on gearboxh

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i

-arrow 1- Manual gearbox

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Code letters and date of manufactureo

02S -arrow 2-

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Manual gearbox 02S -arrow 2-

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Identification code and date of gearbox manufacture

Example:	FNG	12	11	3
	I	I	I	I
	I	I	I	I
	Identification	Day	Month	Year (2003)
	code			of manufacture

Additional data provide information about the production facility.

Note

The gearbox code also appears on the vehicle identification plates.

1.2Identification code, assembly allocation and capacities

	Manual gearbox			6-speed 02S
	Identification code		FNG	HYG	GQM
	Manufactured	from	05.05	05.06	05.05
		to	05.05	09.06
	Allocation	Model	Jetta 2005	Jetta 2005	Jetta 2005
			Golf Variant 2007	Golf Variant 2007	Golf Variant 2007
					1. Gearbox identification 1
Downloaded from www.Manualslib.com manuals search engine

Golf Variant 2007 , Golf Variant 2010 , Jetta 2005

6-speed manual gearbox 02S - Edition 07.2009

Manual gearbox

6-speed 02S

Identification code

FNG

HYG

GQM

Engine

1.9 l - 74 kW

1.4 l - 103 kW

1.9 l - 74 kW

turbo diesel

turbo diesel

1.9 l - 77 kW

1.9 l - 77 kW

turbo diesel

turbo diesel

Ratio

Final drive

61 : 18 = 3.389

62 : 17 = 3.647

61 : 18 = 3.389

Z1 : Z2

Capacity of manual gearbox (gear

2.1 l

2.1 l

2.1 l

box completely dismantled)

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AG

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1.9 l

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1.9 l

1.9 l

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Capacity of manual gearboxV

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ar

page 99 (gearboxepartially dis

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a

mantled)

i

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ee

th

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a

s

c

Drive shaft flanges

100 mm

c

100 mm

100 mm

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• The followingd

data can be found in the

n

Electronic parts catalogue “ETKA” .

t

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i

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♦ Individualr

gear ratios

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♦ Specification for gear oil

t

s

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of clutch plate and pressure plate

,

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s

♦ Allocationl

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w

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6-speed 02S r

Manual gearbox

i

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,

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Identificatione

code

GQP

GXV

t

JAU

s

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p

from

05.05

05.05

s

11.05

r

s

Manufacturedu

p

to

07.05

08.06

o

07.06

f

l

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r

Model

Jetta 2005

Jetta 2005

Jetta 2005

Allocation

m

m

Golf Variant 2007

Golf Variant 2007ta

Golf Variant 2007

m

i

o

Engine

2.0 l - 110 kW

n

o

1.4 l - 125 kW

c

r

2.0 l - 110ikW

o

h

t

n

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i

t

Ratio

Final drive

62 : 17 = 3.647

63 : 16 =s

3.938

62 : 17 = 3.647

a

Z1 : Z2

v

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2.1 l

2.1 l

2.1 l

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Capacity of manual gearbox (gear

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.

oC

box completelyodismantled)

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Capacity of manualgirgearbox

1.9 l

h

1.9 l

1.9 l

t

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b

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y

page 99 (gearbox partiallyoc

dis

V

o

mantled)

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etcet

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or

Drive shaft flange

P

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100 mm

107 mm

100 mm

• The following data can be found in the

Electronic parts catalogue “ETKA” .

♦Individual gear ratios

♦Specification for gear oil

♦Allocation of clutch plate and pressure plate

Manual gearbox			6-speed 02S
Identification code		JYL	JCL	JCN
Manufactured	from	09.06	05.06	05.06
	to		09.06	09.06
Allocation	Model	Jetta 2005	Jetta 2005	Jetta 2005
		Golf Variant 2007	Golf Variant 2007	Golf Variant 2007
	Engine	2.0 l - 110 kW	1.9 l - 77 kW	2.0 l - 110 kW
			turbo diesel
Ratio	Final drive	63 : 16 = 3.938	61 : 18 = 3.389	62 : 17 = 3.647
Z1 : Z2

2Rep. Gr.00 - Technical data

Downloaded from www.Manualslib.com manuals search engine

Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 6-speed manual gearbox 02S - Edition 07.2009

Manual gearbox

6-speed 02S

Identification code

JYL

JCL

JCN

Capacity of manual gearbox (gear

2.1 l

2.1 l

2.1 l

box completely dismantled)

Capacity of manual gearbox

1.9 l

1.9 l

1.9 l

page 99 (gearbox partially dis

mantled)

Drive shaft flange

100 mm

100 mm

100 mm

•

The following data can be found in the

Electronicg

parts catalogueG

“ETKA” .

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♦

Individual gear ratios

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♦ Specification for gear oil

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plate

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♦ Allocation of clutch plate and pressurele

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Identification code

e

JCP

JCQ

JYG

p

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Manufactured

w

from

05.06

05.06

09.06

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to

09.06

09.06

t

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t

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Allocation

r

Model

Jetta 2005

Jetta 2005

a

Jetta 2005 r

c

p

Golf Variant 2007

Golf Variant 2007

o

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Golf Variant 2007

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Engine

2.0 l - 110 kW

1.4 l - 125 kW

1.4 l - 125 kW

e

t

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Ratio

p

drive

63 : 16 = 3.938

62 : 17 = 3.647

s

Finalp

62 : 17 = 3.647f

r

s

Z1 : Z2

u

o

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(gear

2.1 l

2.1 l

2.1 l

Capacity of manual gearboxm

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box completely

dismantled)

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1.9 l

1.9 l

Capacity of manual gearboxo

1.9t nl

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page 99 (gearbox partially dis

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mantled)

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Drive shaft flange

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100 mm

100 mm

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Electronic parts catalogue “ETKA” .

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The following data can be found in the

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♦

Individual gear ratios

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♦ Allocation of clutch plate and pressure plate

Manual gearbox

6-speed 02S

Identification code

JXP

JXR

KWB

Manufactured

from

09.06

09.06

07.08

to

Allocation

Model

Jetta 2005

Jetta 2005

Jetta 2005

Golf Variant 2007

Golf Variant 2007

Golf Variant 2007

Golf Variant 2010

Engine

1.4 l - 103 kW

2.0 l - 110 kW

1.4 l - 118 kW

Ratio

Final drive

62 : 17 = 3,647

Z1 : Z2

Capacity of manual gearbox (gear

2.1 l

box completely dismantled)

Capacity of manual gearbox

1.9 l

page 99 (gearbox partially dis

mantled)

Drive shaft flange

100 mm

1. Gearbox identification 3

Downloaded from www.Manualslib.com manuals search engine

Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 6-speed manual gearbox 02S - Edition 07.2009

Manual gearbox				6-speed 02S
Identification code			JXP	JXR	KWB
•	The following data can be found in the		Electronic parts catalogue “ETKA” .
♦	Individual gear ratios
♦	Specification for gear oil
♦	Allocation of clutch plate and pressure plate

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4Rep. Gr.00 - Technical data

Downloaded from www.Manualslib.com manuals search engine

Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 6-speed manual gearbox 02S - Edition 07.2009

2Overview - power transmission

Designation

-Arrows- indicate direction of travel.

1 - Engine

2 - Clutch

3 - Manual gearbox

4 - Input shaft

G.V

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5 - Output shaftb

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Ratio

-Arrows- indicate direction of travel.

2. Overview - power transmission 5

Downloaded from www.Manualslib.com manuals search engine

Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 6-speed manual gearbox 02S - Edition 07.2009

I - 1st gear

II - 2nd gear

III - 3rd gear

IV - 4th gear

V - 5th gear

VI - 6th gear

R - Reverse gear

A - Final drive

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6Rep. Gr.00 - Technical data

Downloaded from www.Manualslib.com manuals search engine

Golf Variant 2007 , Golf Variant 2010 , Jetta 2005

6ol-kspeeds

manual gearbox 02S - Edition 07.2009

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6th gear

Final drive

a

t

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e

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ZG1 = 45

ZA1 = 18

b

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ZA

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t

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: ZA

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c

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2

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Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 6-speed manual gearbox 02S - Edition 07.2009

4General 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. Of course, the basic rules for safety also apply dur ing repair work.

Anumberofinstructionsgenerallyapplicabletothevariousrepair procedures - which were previously repeated a number of times at various places in the workshop manual are summarised under the topic “components” page 8 . They apply to this workshop manual.

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When installing mounting brackets or waxed components,

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Gearbox capacity, gearbox

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inspect contact sur

♦ After removing gaskets and seals, always.

face of housing or shaft for burrs resulting from removal or for

other signs of damage.

♦ Before installing radial shaft seals, lightly oil outer diameter and half-fill space between sealing lips -arrow- with sealing grease -G 052 128 A1- .

♦ The open side of the oil seal faces the side with fluid filling.

♦ Press in new oil seals so that sealing lip does not contact the shaft in the same place as the old seal (make use of insertion depth tolerances).

♦ Lightly oil O-rings before installing; this prevents the rings be ing crushed when inserted.

♦ After renewing seals and gaskets, check oil level in gearbox and replenish if necessary page 99 .

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8Rep. Gr.00 - Technical data

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Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 6-speed manual gearbox 02S - Edition 07.2009

4.1.3Locking devices

♦Do not overstretch retaining rings.

♦Always renew retaining rings which have been damaged or overstretched.

♦Retaining rings must locate properly in grooves.

♦Renew spring pins. Installation position: slit -A- should be in line with the line of force -arrow-.

4.1.4Nuts and bolts

♦ Loosen nuts or bolts in the order opposite to the tightening

sequence.

♦ Nuts and bolts which secure covers and housings should be

loosened and tightened diagonally in stages if no tighteningn

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bolts and nuts.

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locking fluid must be cleaned

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Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 6-speed manual gearbox 02S - Edition 07.2009

4.1.6Shims

♦Measure shims at several points with a micrometer. The var ious thicknesses make it possible to achieve the exact shim thickness required.

♦Check for burrs and damage.

♦Install only flawless shims.

4.1.7Synchro-rings

♦Do not interchange. When reusing synchro-rings, always fit to the same gear.

♦Check for wear and renew if necessary.

♦Check grooves -arrow 1- of synchro-ring -A- and inner ring for flat spots (worn grooves).

♦If synchro-rings are coated, coating must not be damaged.

♦If an intermediate ring -B- is installed, check the outer friction surface -arrow 2- and inner friction surface -arrow 3- of this intermediate ring for “scoring” and “signs of abnormal wear”.

♦Check cone of synchromeshed gear for “scoring” and “signs of abnormal wear”.

♦Moisten synchromesh mechanism with gear oil before instal ling.

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♦ When removing gearbox, remove slave cylinder without dis

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Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 6-speed manual gearbox 02S - Edition 07.2009

♦Ensurethatthepressureplatedoesnotcant:loosenandtight en bolts diagonally and in several gradual stages.

♦If the clutch has burnt out, thoroughly clean the clutch housing as well as the friction surface of flywheel with a cloth to reduce the smell of burnt linings.

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4. General repair notes 11

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Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 6-speed manual gearbox 02S - Edition 07.2009

30 – Clutch

1Fault finding, power transmission

–Refer to Fault finding, power transmission; Rep. Gr. 30 ; Complaints about clutch and clutch mechanism and Fault finding, power transmission; Rep. Gr. 34 ; Complaints about selector mechanism

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12 Rep. Gr.30 - Clutch

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Repairing clutch mechanism

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♦ Before disconnecting battery, obtain code for radio units having anti-theft coding.

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;Disconnecting

♦ With ignition switched off, disconnect battery earth strap Electrical system; Rep.Gr. 27s

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and connectinglbattery .

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♦ When reconnecting battery, refer to

Electrical system; Rep.Gr. 27 ;Disconnecting and connecting

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♦ Lubricate all bearings and contact surfaces with grease -G 000 450 02- .

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I - Assembly overview - pedaln

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III - Assembly overview - hy

draulics (RHD) page 39

2. Repairing clutch mechanism 13

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Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 6-speed manual gearbox 02S - Edition 07.2009

2.2Assembly overview - pedal cluster

1 - Bulkhead

With support for mount ing bracket

2 - Seal

Always renew

Between mounting

bracket and bulkhead

Self-adhesive

Bond to mounting

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3 - Mounting bracket

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For mounting clutche

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6 - Bearing bush

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7 - Pivot pin

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8 - Clutch pedal

Removing andpage 20

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9 - Retainer

To remove and install, separate master cylin der from clutch pedalpage 20

10 - Seal

Always renew

Between master cylinder and mounting bracket

11 - Master cylinder

Removing and installing after removal of mounting bracket page 25 12 - Clutch position sender -G476-

Removing and installing page 33

Can be checked using “guided fault finding” of vehicle diagnostic tester

The clutch position sender -G476- is identified as clutch pedal switch -F36- in “guided fault finding”.

13 - Clip

Pull out clip to stop to remove and install pipe/hose line 14 - Supply hose

Rubber

From 12.05, plastic page 38

15 - Hexagon nut, 25 NmSelf-locking

14 Rep. Gr.30 - Clutch

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16 - Hexagon nut, 25 Nm

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17 - Stop

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For clutchn pedal

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Mounting bracket with damping -arrows-

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2.3Removing and installing over-centre spring

Special tools and workshop equipment required ♦ Release tool -T10178-

2.3.1Removing

Vehicles with knee airbag

Note

The installation location of the knee airbag is above the pedal cluster.

–First check whether a coded radio is fitted. If so, obtain antitheft code.

2. Repairing clutch mechanism 15

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Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 6-speed manual gearbox 02S - Edition 07.2009

–With ignition switched off, disconnect battery earth strap Electricalsystem;Rep.Gr. 27;Disconnectingandconnecting battery .

Continuation for all

–Pushdriverseatasfarbackaspossibleandputsteeringwheel in highest position.

–Remove trim and cover below trim on drive side General body repairs, interior; Rep. Gr. 68 .

Vehicles with knee airbag

–Remove bracket for knee airbag together with crash bar Interior equipment; Rep. Gr. 69 ; Airbag; Removing and in stalling knee airbag bracket .

Continuation for all

–Remove cable guide -2- from steering column.

–Remove footwell vent -3- Heating, air conditioning; Rep. Gr. 80 ; Repairing heating .

Vehicles without knee airbag

The crash bar -1- in front of clutch pedal -2- may be secured in different ways.

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Attachment withs 2 bolts

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– Removeucrash bar -1- (2 bolts).

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Attachment with 1 bolt

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– Remove crash bar -1- (1 bolt -2-).

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16 Rep. Gr.30 - Clutch

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Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 6-speed manual gearbox 02S - Edition 07.2009

– If fitted, remove damping -arrow- from lower area of clutch

pedal mounting bracket.

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– Tordo this, remove lock washers -A- for damping.

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– Pull off damping.

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–Push damping upwards in area of upper securing nut -1- above clutch pedal -A- in -direction of arrow-.

2. Repairing clutch mechanism 17

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Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 6-speed manual gearbox 02S - Edition 07.2009

–Unboltclutchpedal-1-frommountingbracket-3-byremoving nut -2- and pulling out bolt -5-.

Note

The clutch pedal remains hooked to operating rod of master cyl inder.

–Swing clutch pedal down slightly and remove over-centre spring -4- from mounting bracket.

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2.3.2

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Installingl

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order of removal, observing the following:

Install in the reversew

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Note

a

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s

o

Renew self-locking nuts.

p

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u

p

l

a

i

– Insert over-centre spring -2- in mounting bracket from above

c

r

e

while holding end of spring with assembly tool -T10178- in in

m

stallation position.

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•Receptacle -arrow- for tip -A- of clutch pedal must stand ver tically.

–Insert tip of clutch pedal in bearing recess of over-centre spring.

–Depress clutch pedal slightly, push bolt through and tighten self-locking nut to specified torque page 20 .

18 Rep. Gr.30 - Clutch

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w

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Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 6-speed manual gearbox 02S - Edition 07.2009

Some cars have damping -arrow- on the clutch pedal mounting bracket.

– Return it to installation position. Vehicles without knee airbag

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The crash bar -1- inr front of clutch pedal -2- may be secured in

i

different ways.

o

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t

a

p

Attachment with 2,bolts

n

i

s

– Install crash bar -1- and tighten the 2 bolts to specified torque

e

s

page 20 .

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Attachment with 1 bolt

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C

-2- to specified torque

– Install crash bar -1- and tighten bolti

.

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page 20 .

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Continuation for all

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et

P

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g

or

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A

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e	m

–Mount cable guide -2- on steering column.

–Install footwell vent -3- Heating, air conditioning; Rep. Gr. 80 ; Repairing heating .

Vehicles with knee airbag

–Install bracket for knee airbag together with crash bar Inte rior equipment; Rep. Gr. 69 ; Airbag; Removing and installing knee airbag bracket .

Continuation for all

–Install trim and cover below trim on drive side General body repairs, interior; Rep. Gr. 68 .

–Ifdisconnected,connectbattery Electricalsystem;Rep.Gr. 27 ; Removing and installing battery .

2. Repairing clutch mechanism 19

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Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 6-speed manual gearbox 02S - Edition 07.2009

2.3.3Specified torques

Component

Nm

Clutch pedal to mounting bracket

25

♦ Renew self-locking nuts

Crash bar to steering column mounting

10

bracket (attachment with 2 bolts)

Crash bar to steering column mounting

wag

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20

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bracket (attachment with 1 bolt)

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♦

Renew bolts for crash bar

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is

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u

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s

s

2.4

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Removingd u and installing clutch pedal

n

i

t

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equipment required

Special tools and workshopr m

♦

Pliers -T10005-

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m

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♦

Release tool -T10178-

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2.4.1Removing

Vehicles with knee airbag

Note

The installation location of the knee airbag is above the pedal cluster.

–First check whether a coded radio is fitted. If so, obtain antitheft code.

–With ignition switched off, disconnect battery earth strap Electricalsystem;Rep.Gr. 27;Disconnectingandconnecting battery .

20 Rep. Gr.30 - Clutch

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Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 6-speed manual gearbox 02S - Edition 07.2009

Continuation for all

– Pushdriverseatasfarbackaspossibleandputsteeringwheel

in highest position.

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ge

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General

s

– Remove trim and cover below trim on drive side

o

V

y

body repairs, interior; Rep. Gr. 68 .r

b

d

e

is

o

Vehicles with knee airbag

th

s

u

a

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le

d

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e

Note

t

t

m

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p

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t

The installation location ofn

the knee airbag is above the pedal

o

cluster.

s

,

i

e

l

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w

– First check whetheria coded radio is fitted. If so, obtain anti-

theft code.

n

o

r

t

r

a

off, disconnect battery earth strap

– With ignition switchedn

p

Electricalsystem;Rep.Gr. 27;Disconnectingandconnecting

i

,

battery .

s

s

e

o

Continuation for all

p

p

r

u

– Remove cable guider-2- from steering column.

l

a

i

c

e

Heating, air conditioning; Rep.

– Remove footwell ventm-3-

m

Gr. 80 ; Repairing heating .

o

c

r

o

Vehicles without knee airbagv

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a

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p

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f

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t o

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c o r r e c t n e s s o f i n

The crash bar -1- in front of clutch pedal -2- may be secured in different ways.

Attachment with 2 bolts

– Remove crash bar -1- (2 bolts).

Attachment with 1 bolt

– Remove crash bar -1- (1 bolt -2-). Continuation for all

2. Repairing clutch mechanism 21

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Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 6-speed manual gearbox 02S - Edition 07.2009

G.V

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a

w

– If fitted, remove damping -arrow- fromyVlower area of

s

pedal mounting bracket.

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l

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m

m

– To do this, remove lock washers -A- for damping.

o

c

r

– Pull off damping.

o

v

e

t

a

i

r

p

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o

f

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–Push damping upwards in area of upper securing nut -1- above clutch pedal -A- in -direction of arrow-.

oita

22 Rep. Gr.30 - Clutch

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Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 6-speed manual gearbox 02S - Edition 07.2009

–Unboltclutchpedal-1-frommountingbracket-3-byremoving nut -2- and pulling out bolt -5-.

–Swing clutch pedal down slightly and remove over-centre spring -4- from mounting bracket.

–Release clutch pedal from master cylinder with pliers - T10005- .

–Remove clutch pedal.

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2.4.2

Installing

e

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Install in the reverse order of removal, observing the following:

c

t

n

t

i

o

o

h

t

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a

c

p

Note

o

s

c

n

r

i

r

,

e

e

t

n

s

o

Renew self-locking nuts.

e

r

s

p

s

u

o

p

f

l

i

i

– Attach retainer -2- to master cylinder operating rod -1-.

n

e

r

a

f

r

o

c

m

o– Pressretainerintonotchinclutchpedal-3-untilitcanbeheard

a

oi

m

t

m

to engage.

n

n

o

i

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t

t

i

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a

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w

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et

g

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or

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2. Repairing clutch mechanism 23

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Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 6-speed manual gearbox 02S - Edition 07.2009

.V

olks

wag

en

n

AG

A

G

ge

d

a

e

w

s

k

s

– Insert over-centre spring -2- in mountingl

bracket from above

o

n

V

ot

y

assembly tool -T10178- in in

gua

while holding end of springdwithb

e

r

stallation position.

is

a

r

o

th

u

a

s

s

le

d

u

n

e

t

t

m

i

p

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n

s

i

,

e

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o

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p

l

a

i

c

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m

m

o

• Receptacle c-arrow- for tip -A- of clutch pedal must stand ver

tically.

r

o

e

t

a

v

i

r

– Insert tip -A- of clutch pedal in bearing recess of over-centre

spring.

p

r

o

f

g

n

i

y

p

– Depress clutch pedal oslightly, push bolt through and tighten

C

torque page 25 .

self-locking nut to specified.th

g

i

t

r

y

b

p

o

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y

y

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b

d

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a

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et

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or

P

A

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.G

Some cars have damping -arrow- on the mounting bracket/clutch pedal.

– Return it to installation position. Vehicles without knee airbag

tam

24 Rep. Gr.30 - Clutch

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Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 6-speed manual gearbox 02S - Edition 07.2009

The crash bar -1- in front of clutch pedal -2- may be secured in different ways.

Attachment with 2 bolts

–Install crash bar -1- and tighten the 2 bolts to specified torquepage 25 .

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wag

en

n

AG

A

G

ge

d

o

a

e

w

s

s

n

lk

ot

o

V

g

y

b

u

d

a

e

r

s

a

i

n

r

t

o

e

th

e

Attachment with 1sbolt

c

u

o

r

a

a

s

le

– Install crashu bar -1- and tighten bolt -2- to specified torque

n

page 25itt

d

.

m

e

r

for all

Continuationp

e

n

o

t

s

i

,

e

l

o

h

w

n

i

r

o

t

r

a

p

n

i

,

s

e

s

o

– Mount cable guide -2- on steering column.

p

r

u

–

p

Heating, air conditioning; Rep. Gr.

Install footwell vent -3-

l

i

80 ; Repairing heating .

c

r

e

m

Vehicles with knee airbag

m

o

c

–

r

for knee airbag together with crash bar Inte

Install bracketa

o

e

t

rior equipment; Rep. Gr. 69 ; Airbag; Removing and installing

v

i

r

knee airbagfbracket .

p

r

o

g

oC

Continuation for allo

n

i

y

p

C

p

.

y

–

r

Install trim and coverirbelow trim on drive side General bodyt

t

h

g

g

y

h

i

68 .

kl

b

repairs, interior; Rep. Gr.y

y

p

o

c

V

b

d

e

s

o

w

a

t

c

et

g

–

or

A

n

Ifdisconnected,connectbattery Electricalsystem;Rep.Gr.

P

.G

27 ; Removing and installing battery .

n e

2.4.3	Specified torques
Component		Nm
Clutch pedal to mounting bracket		25
♦ Renew self-locking nuts
Crash bar to steering column mounting		10
bracket (attachment with 2 bolts)
Crash bar to steering column mounting		20
bracket (attachment with 1 bolts)
♦ Renew bolts for crash bar

2.5Removing and installing mounting bracket

Special tools and workshop equipment required

2. Repairing clutch mechanism 25

Downloaded from www.Manualslib.com manuals search engine

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olks

wag

en

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AG

A

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Golf Variant 2007 , Golf Variant 2010 , Jetta 2005r

o

e

th

e

o

u

a

a

l6es-speed manual gearbox 02S - Edition 07.2009

e

s

c

n

c

t

u

p

d

clamps to 25 mm Ø -3094-

a

a

♦ Hosei

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t

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m

i

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e

b

t

p

i

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i

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i

r

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t

r

a

p

n

i

,

s

e

s

o

p

r

u

p

l

a

i

c

♦m Hose clip pliers -VAS 6362-

r

e

m

o

c

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t

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n f o r

♦ Sealing tool -T10249-

2.5.1Removing

LHD

–First check whether a coded radio is fitted. If so, obtain antitheft code.

–With ignition switched off, disconnect battery earth strap Electricalsystem;Rep.Gr. 27;Disconnectingandconnecting battery .

–Remove complete air filter housing if it is near battery Rep. Gr. 23 ; Repairing diesel direct injection system or Rep. Gr. 24 ; Repairing injection system .

–Remove battery and battery tray Electrical system; Rep. Gr. 27 ; Battery; Removing and installing battery .

26 Rep. Gr.30 - Clutch

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