Volkswagen Golf Variant 2007 User Manual
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Service
Workshop Manual
Golf Variant 2007 ➤
Golf Variant 2010 ➤
Jetta 2005 ➤
Jetta 2011 ➤
6-speed manual gearbox 02Q
Edition 06.2010
Service Department. Technical Information
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Service
List of Workshop Manual Repair GroupsList of Workshop Manual
Repair GroupsList of Workshop Manual Repair Groups
Re pa ir G ro up
00 - Technical data
30 - Clutch
34 - Controls, housing
35 - Gears, shafts
39 - Final drive - differential
Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. 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
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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Gearbox identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Location on gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Identification code, assembly allocation and capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Overview - power transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3 Calculating overall gear ratio „i“ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4 General repair notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4.1 Contact corrosion! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4.2 Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4.3 Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
30 - Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1 Fault finding, power transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2 Repairing clutch mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.2 Assembly overview - pedal cluster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.3 Removing and installing over-centre spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.4 Removing and installing clutch pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.5 Removing and installing mounting bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
2.6 Removing and installing master cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
2.7 Removing and installing clutch position sender G476 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Contents
6-speed manual gearbox 02Q - Edition 06.2010
2.8 Assembly overview - hydraulics (LHD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
2.9 Assembly overview - hydraulics (RHD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
2.10 Bleeding clutch system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
3 Repairing clutch release mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
3.1 Removing pipe/hose line and bleeder from and installing on slave cylinder . . . . . . . . . . . . 40
3.2 Removing and installing slave cylinder with release bearing . . . . . . . . . . . . . . . . . . . . . . . . 40
3.3 Removing and installing pipe/hose line or plastic line . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
3.4 Renewing input shaft seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
4 Repairing clutch - vehicles with turbo diesel engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
4.1 Determining clutch manufacturer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
4.2 Removing and installing „Sachs“ clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
4.3 Repairing „Sachs“ clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
4.4 Removing and installing „LuK“ clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
4.5 Repairing „LuK“ clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
5 Repairing clutch - vehicles with petrol engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
5.1 Repairing clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
5.2 Removing and installing clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
34 - Controls, housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
1 Repairing selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
1.1 Installation position of selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
1.2 Overview of selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
1.3 Removing and installing gear knob and frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
1.4 Removing and installing gaiter with gear knob and noise insulation . . . . . . . . . . . . . . . . . . 62
1.5 Repairing gear lever and selector housing (through 10.06) . . . . . . . . . . . . . . . . . . . . . . . . 64
1.6 Repairing gear lever and selector housing (from 11.06) . . . . . . . . . . . . . . . . . . . . . . . . . . 66
1.7 Assembly overview - removing and installing selector cables . . . . . . . . . . . . . . . . . . . . . . 71
1.8 Plastic relay lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
1.9 Removing and installing selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
1.10 Removing and installing gear selector cable and gate selector cable . . . . . . . . . . . . . . . . 80
1.11 Adjusting selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Contents i
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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤
6-speed manual gearbox 02Q - Edition 06.2010
2 Removing and installing gearbox in vehicles with turbo diesel engine . . . . . . . . . . . . . . . . 85
2.1 Removing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
2.2 Transporting gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
2.3 Installing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
2.4 Specified torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
3 Removing and installing gearbox, vehicles with petrol engine . . . . . . . . . . . . . . . . . . . . . . 106
3.1 Removing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
3.2 Transporting gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
3.3 Installing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
3.4 Specified torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
4 Checking gearbox oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
5 Dismantling and assembling gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
5.1 Overview - rear final drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
5.2 Assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
5.3 Removing and installing gearbox housing and selector mechanism . . . . . . . . . . . . . . . . . . 130
5.4 Removing and installing input shaft, output shafts, differential and selector rods . . . . . . . . 132
5.5 Assembly order, gearbox »without« retaining ring A for input shaft sealing cover . . . . . . . . 134
5.6 Assembly order, gearbox »with« retaining ring A for input shaft sealing cover . . . . . . . . . . 145
6 Repairing gearbox housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
7 Repairing clutch housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
8 Repairing selector unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
8.1 Renewing oil seal for selector shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
9 Repairing selector forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
35 - Gears, shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
1 Input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
1.1 Dismantling and assembling input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
2 Output shaft for 1st through 4th gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
2.1 Assembly overview - output shaft for 1st through 4th gears . . . . . . . . . . . . . . . . . . . . . . . . 185
2.2 Dismantling and assembling output shaft for 1st through 4th gears . . . . . . . . . . . . . . . . . . 187
2.3 Adjusting output shaft for 1st through 4th gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
3 Output shaft for 5th, 6th and reverse gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
3.1 Dismantling and assembling output shaft for 5th, 6th and reverse gears . . . . . . . . . . . . . . 211
3.2 Adjusting output shaft for 5th, 6th and reverse gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
39 - Final drive - differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
1 Renewing flange shaft oil seals with gearbox installed . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
1.1 Renewing oil seal for left flange shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
1.2 Renewing seal for right flange shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229
2 Adjustment overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
3 Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
3.1 Dismantling and assembling differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
3.2 Adjusting differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
ii Contents
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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤
00 – Technical data
1 Gearbox identification
The 6-speed manual gearbox 02Q is installed in the Jetta 2005 ►,
in the Golf Variant 2007 ►, in the Golf Variant 2010 ► and in the
Jetta 2011 ► in conjunction with a 4-cylinder engine.
Allocation ⇒ page 1
1.1 Location on gearbox
Code letters and date of manufacture -arrow 1- manual gearbox
02Q -arrow 2-
Manual gearbox 02Q -arrow 2-
6-speed manual gearbox 02Q - Edition 06.2010
Identification code and date of gearbox manufacture -arrow-
Example: GRF 25 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.
1.2 Identification code, assembly allocation and capacities
Manual gearbox 6-speed 02Q
Identification code GRF GVT GXC
Manufactured from
to
05.05
11.05
05.05
11.05
07.06
07.06
1. Gearbox identification 1
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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 GRF GVT GXC
Allocation Model Jetta 2005 ►
Golf Variant 2007 ►
Engine 2.0 l - 103 kW
turbo diesel
Ratio: Z2 : Z
1
Final drive I
Final drive II
1)
69 : 20 = 3.450 71 : 18 = 3.944 71 : 18 = 3.944
2)
69 : 25 = 2.760 71 : 23 = 3.087 71 : 23 = 3.087
Jetta 2005 ►
Golf Variant 2007 ►
2.0 l - 147 kW
turbo FSI
Jetta 2005 ►
Golf Variant 2007 ►
2.0 l - 125 kW
turbo diesel
Capacity of manual gearbox 2.3 l 2.3 l 2.3 l
Drive shaft flange ∅ 107 mm 107 mm 107 mm
1)
Final drive for 1st to 4th gears
2)
Final drive for 5th and 6th gears and reverse gear
• 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 02Q
Identification code HDV HVS KNQ
Manufactured from
to
Allocation Model Jetta 2005 ►
Ratio: Z2 : Z
Capacity of manual gearbox 2.3 l 2.3 l 2.3 l
Drive shaft flange ∅ 107 mm 107 mm 107 mm
1)
Final drive for 1st to 4th gears
2)
Final drive for 5th and 6th gears and reverse gear
• 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
1
Manual gearbox 6-speed 02Q
Identification code KNS KNU KNY
Manufactured from
Engine 2.0 l - 96 kW
Final drive I
Final drive II
Golf Variant 2007 ►
1)
2)
to
Allocation Model Jetta 2005 ►
Golf Variant 2007 ►
05.05 07.06 02.08
2.0 l - 100 kW
2.0 l - 103 kW
69 : 20 = 3.450 70 : 19 = 3.684 72 : 17 = 4.235
69 : 25 = 2.760 70 : 24 = 2.917 72 : 22 = 3.273
turbo diesel
turbo diesel
turbo diesel
11.07
10.08
Jetta 2005 ►
Golf Variant 2007 ►
2.0 l - 125 kW
turbo diesel
11.07
02.09
Golf Variant 2007 ►
Jetta 2005 ►
11.08
1.9 l - 77 kW
turbo diesel
1.6 l - 77 kW
turbo diesel
02.08
10.08
Jetta 2005 ►
Golf Variant 2007 ►
Golf Variant 2010 ►
2 Rep. gr.00 - Technical data
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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 KNS KNU KNY
Ratio: Z2 : Z
Capacity of manual gearbox 2.3 l 2.3 l 2.3 l
Drive shaft flange ∅ 107 mm 107 mm 107 mm
1)
Final drive for 1st to 4th gears
2)
Final drive for 5th and 6th gears and reverse gear
• 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 02Q
Identification code KRM KXZ KZS
1
Final drive II
Manufactured from
Allocation Model Jetta 2005 ►
Engine 2.0 l - 100 kW
Final drive I
1)
2)
to
Engine 2.0 l - 103 kW
turbo diesel
2.0 l - 103 kW
turbo diesel
69 : 20 = 3.450 71 : 18 = 3.944 70 : 19 = 3.684
69 : 25 = 2.760 71 : 23 = 3.087 70 : 24 = 2.917
Golf Variant 2010 ►
turbo diesel
Ratio: Z2 : Z
1
Final drive I
Final drive II
1)
69 : 20 = 3.450 70 : 19 = 3.684 70 : 19 = 3.684
2)
69 : 25 = 2.760 70 : 24 = 2.917 70 : 24 = 2.917
05.07
07.10
2.0 l - 147 kW
2.0 l - 155 kW
05.09 05.09
Jetta 2005 ►
Golf Variant 2007 ►
2.0 l - 125 kW
turbo diesel
turbo diesel
Jetta 2005 ►
Golf Variant 2007 ►
Jetta 2011 ►
2.0 l - 155 kW
2.0 l - 147 kW
2.0 l - 125 kW
Capacity of manual gearbox 2.3 l 2.3 l 2.3 l
Drive shaft flange ∅ 107 mm 107 mm 107 mm
1)
Final drive for 1st to 4th gears
2)
Final drive for 5th and 6th gears and reverse gear
• 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 02Q
Identification code LHD LNN NFN
Manufactured from
10.08 06.09 05.09
to
Allocation Model Jetta 2005 ►
Golf Variant 2010 ► Jetta 2005 ►
Golf Variant 2007 ►
Golf Variant 2010 ►
Jetta 2011 ►
Ratio: Z2 : Z
1
Engine 2.0 l - 100 kW
1)
Final drive I
69 : 20 = 3.450 72 : 17 = 4.235 70 : 19 = 3.684
turbo diesel
1.6 l - 77 kW
turbo diesel
2.0 l - 125 kW
turbo diesel
1. Gearbox identification 3
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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 LHD LNN NFN
Final drive II
Capacity of manual gearbox 2.3 l 2.3 l 2.3 l
Drive shaft flange ∅ 107 mm 107 mm 107 mm
1)
Final drive for 1st to 4th gears
2)
Final drive for 5th and 6th gears and reverse gear
• 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 02Q
Identification code NFP MDL
Manufactured from
Allocation Model Golf Variant 2010 ► Jetta 2011 ►
Ratio: Z2 : Z
1
Final drive I
Final drive II
Capacity of manual gearbox 2.3 l 2.3 l
Drive shaft flange ∅ 107 mm 107 mm
1)
Final drive for 1st to 4th gears
2)
Final drive for 5th and 6th gears and reverse gear
• The following data can be found in the ⇒ Electronic parts catalogue „ETKA“ .
2)
69 : 25 = 2.760 72 : 22 = 3.273 70 : 24 = 2.917
05.10 11.09
to
Engine 2.0 l - 103 kW
turbo diesel
1)
69 : 20 = 3.450 70 : 19 = 3.684
2)
69 : 25 = 2.760 70 : 24 = 2.917
2.0 l - 155 kW
♦ Individual gear ratios
♦ Specification for gear oil
♦ Allocation of clutch plate and pressure plate
4 Rep. gr.00 - Technical data
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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤
6-speed manual gearbox 02Q - Edition 06.2010
2 Overview - power transmission
Designation
-Arrows- indicate direction of travel.
1 - Engine
2 - Clutch
3 - Manual gearbox
4 - Input shaft
5 - Output shaft for 5th, 6th and
reverse gears
6 - Output shaft for 1st through
4th gears
7 - Differential
Gears
-Arrows- indicate direction of travel.
2. Overview - power transmission 5
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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
V - 5th gear
VI - 6th gear
R - Reverse gear
A - Final drive
6 Rep. gr.00 - Technical data
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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤
6-speed manual gearbox 02Q - Edition 06.2010
3 Calculating overall gear ratio „i“
Example:
6th gear Final drive
Drive gear ZG1 = 43 ZA1 = 25
Driven gear ZG2 = 35 ZA2 = 69
i = ZG2 : ZG1
1)
iG = Gear ratio = ZG2: ZG1= 35 : 43 = 0.814
iA = Final drive ratio = ZG2 : ZG1 = 69 : 25 = 2.760
i
= Overall ratio = iG x iA = 0.814 x 2.760 = 2.247
total
1) Z1 = No. of teeth on driving gear, Z2 = No. of teeth on driven gear
3. Calculating overall gear ratio „i“ 7
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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤
6-speed manual gearbox 02Q - Edition 06.2010
4 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. Of course, the basic rules for safety also apply dur‐
ing repair work.
A number of instructions generally applicable to the various repair
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.
4.1 Contact corrosion!
♦ The gearbox housing and clutch housing are made of a mag‐
nesium alloy.
♦ Bolts and other components in direct contact with the gearbox
have a surface matched to it.
♦ If the incorrect components (bolts, nuts, washers and so on)
are used, contact corrosion will develop. The gearbox housing
and clutch housing will be damaged.
♦ Always install parts listed in the ⇒ Electronic parts catalogue
„ETKA“ .
4.2 Special tools
For a complete list of special tools used in this workshop manual,
see ⇒ Workshop equipment and special tools .
4.3 Components
4.3.1 Gearbox
♦ When installing the manual gearbox, ensure that the dowel
sleeves between the engine and gearbox are correctly seated.
♦ When installing mounting brackets or waxed components,
clean the contact surfaces. Contact surfaces must be free of
wax and grease.
♦ Allocate bolts and other components using ⇒ Electronic parts
catalogue „ETKA“ .
♦ Following installation, check gear oil level ⇒ page 126 .
♦ Capacity ⇒ page 1 .
8 Rep. gr.00 - Technical data
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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 .
♦ Apply sealant -AMV 188 200 03- uniformly but not too thick.
♦ Always renew O-rings, seals and gaskets.
♦ When seals have been removed, check contact surface on
housings or shafts for burrs and damage and rectify as nec‐
essary.
♦ 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 126 .
4.3.3 Locking 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. General repair notes 9
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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.
♦ Do not cant especially delicate parts, such as clutch pressure
plates. Loosen and tighten bolts and nuts in stages in a diag‐
onal sequence.
♦ Torque settings are specified for unoiled bolts and nuts.
♦ Always renew self-locking bolts and nuts.
♦ Ensure with threaded connections that contact surfaces as
well as nuts and bolts are rewaxed only after assembly, if nec‐
essary.
♦ Threads of bolts secured with locking fluid must be cleaned
with a wire brush. Then insert bolts with locking fluid AMV 185 101 A1- .
♦ Clean threaded holes in which self-locking bolts or bolts with
locking fluid have been inserted, e.g. with a thread chaser.
Otherwise there is a danger that the bolts may shear when
removed again.
4.3.5 Bearings
♦ Install needle bearings with lettered side (thicker metal) to‐
wards fitting tool.
♦ Lubricate all gearbox bearings with gear oil before installing.
♦ Tapered roller bearings fitted to one shaft must be renewed as
a set. Use same make of bearings.
♦ Heat inner races to about 100° C with the inductive heater -
VAS 6414- before installing.
♦ Do not interchange outer or inner races of bearings of the
same size. The bearings are matched in pairs.
4.3.6 Shims
♦ 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.
10 Rep. gr.00 - Technical data
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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.
♦ 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.
4.3.8 Gears, synchro-hubs, inner races for
♦ Heat inner races for synchromeshed gear to about 100° C with
the inductive heater -VAS 6414- before installing.
♦ Heat synchro-hub with inductive heater -VAS 6414- to approx.
100 °C before installing. Press in to stop when installing so
there is no axial clearance.
♦ Heat gears with inductive heater -VAS 6414- to approx. 100 °
C before installing. Press in to stop when installing so there is
no axial clearance.
♦ Observe installation position.
synchromeshed gears
4.3.9 Synchromeshed gears
♦ After assembly, check synchromeshed gears for slight play, or
for freedom of movement.
4.3.10 Clutch
♦ Ensure that the pressure plate does not cant: loosen and tight‐
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.
4. General repair notes 11
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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤
6-speed manual gearbox 02Q - Edition 06.2010
30 – Clutch
1 Fault 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
12 Rep. gr.30 - Clutch
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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤
2 Repairing clutch mechanism
2.1 Overview
6-speed manual gearbox 02Q - Edition 06.2010
Note
♦
Before disconnecting battery, obtain code for radio units having anti-theft coding.
♦
With ignition switched off, disconnect battery ⇒ Electrical system; Rep. gr. 27 ; Disconnecting and con‐
necting battery .
♦
When reconnecting battery, refer to ⇒ Electrical system; Rep. gr. 27 ; Disconnecting and connecting battery .
♦
Lubricate all bearings and contact surfaces with grease -G 000 450 02- .
I - Assembly overview - pedal
cluster ⇒ page 14
II - Assembly overview - hy‐
draulics (LHD) ⇒ page 34
III - Assembly overview - hy‐
draulics (RHD) ⇒ page 36
2. Repairing clutch mechanism 13
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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤
6-speed manual gearbox 02Q - Edition 06.2010
2.2 Assembly 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
bracket
3 - Mounting bracket
❑ For mounting clutch
pedal
❑ Is provided with damp‐
ing in some equipment
variants ⇒ page 15
❑ Removing and installing
⇒ page 23
4 - Bolt
5 - Over-centre spring
❑ Removing and installing
⇒ page 15
6 - Bearing bush
7 - Pivot pin
8 - Clutch pedal
❑ Removing and installing
⇒ page 19
9 - Retainer
❑ To remove and install,
separate master cylin‐
der from clutch pedal
⇒ page 19
10 - Seal
❑ Always renew
❑ Between master cylinder and mounting bracket
11 - Master cylinder
❑ Removing and installing after removal of mounting bracket ⇒ page 29
12 - Clutch position sender -G476-
❑ Removing and installing ⇒ page 30
❑ 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 35
15 - Hexagon nut, 25 Nm
❑ Self-locking
14 Rep. gr.30 - Clutch
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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤
❑ Qty. 3
❑ For mounting bracket on bulkhead
❑ Always renew
16 - Hexagon nut, 25 Nm
❑ Always renew
17 - Stop
❑ For clutch pedal
Mounting bracket with damping -arrows-
2.3 Removing and installing over-centre spring
6-speed manual gearbox 02Q - Edition 06.2010
Special tools and workshop equipment required
♦ Release tool -T10178-
2.3.1 Removing
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 anti-
theft code.
2. Repairing clutch mechanism 15
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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 .
Continuation for all
– Push driver seat as far back as possible and put steering wheel
in highest position.
– Remove driver side footwell cover and driver side left trim
panel ⇒ General body repairs, interior; Rep. gr. 68 ; Com‐
partments, covers and trim panels .
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 .
Vehicles without knee airbag
– Remove crash bar -1- from in front of clutch pedal by removing
nuts -2-.
Continuation for all
– If fitted, remove damping -arrow- from lower area of clutch
pedal mounting bracket.
– To do this, remove lock washers -A- for damping.
– Pull off damping.
16 Rep. gr.30 - Clutch
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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤
– Push damping upwards in area of upper securing nut -1-
– Unbolt clutch pedal -1- from mounting bracket -3- by removing
The clutch pedal remains hooked to operating rod of master cyl‐
above clutch pedal -A- in -direction of arrow-.
nut -2- and pulling out bolt -5-.
Note
6-speed manual gearbox 02Q - Edition 06.2010
inder.
– Swing clutch pedal down slightly and remove over-centre
spring -4- from mounting bracket.
2.3.2 Installing
Install in the reverse order of removal, observing the following:
Note
Renew self-locking nuts.
2. Repairing clutch mechanism 17
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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‐
stallation position.
• Receptacle -arrow- for tip -A- of clutch pedal must stand ver‐
tically.
– Insert tip -A- of clutch pedal in bearing recess of over-centre
– Depress clutch pedal slightly, push bolt through and tighten
Some cars have damping -arrow- on the clutch pedal mounting
bracket.
– Return it to installation position.
Vehicles without knee airbag
spring.
self-locking nut to specified torque ⇒ page 19 .
18 Rep. gr.30 - Clutch
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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-.
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 driver side footwell cover and driver side left trim panel
⇒ General body repairs, interior; Rep. gr. 68 ; Compartments,
covers and trim panels .
– If disconnected, connect battery ⇒ Electrical system; Rep. gr.
27 ; Removing and installing battery .
2.3.3 Specified torques
Component Nm
Clutch pedal to mounting bracket
♦ Renew self-locking nuts
Crash bar to steering column mounting
bracket
2.4 Removing and installing clutch pedal
Special tools and workshop equipment required
♦ Pliers -T10005-
25
10
♦ Release tool -T10178-
2. Repairing clutch mechanism 19
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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.
– First check whether a coded radio is fitted. If so, obtain anti-
theft code.
– With ignition switched off, disconnect battery earth strap ⇒
Electrical system; Rep. gr. 27 ; Disconnecting and connecting
battery .
Continuation for all
– Push driver seat as far back as possible and put steering wheel
in highest position.
– Remove driver side footwell cover and driver side left trim
panel ⇒ General body repairs, interior; Rep. gr. 68 ; Com‐
partments, covers and trim panels .
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 .
Vehicles without knee airbag
– Remove crash bar -1- from in front of clutch pedal by removing
nuts -2-.
Continuation for all
– If fitted, remove damping -arrow- from lower area of clutch
pedal mounting bracket.
20 Rep. gr.30 - Clutch
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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤
– 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-.
6-speed manual gearbox 02Q - Edition 06.2010
– Unbolt clutch pedal -1- from mounting bracket -3- by removing
nut -2- and pulling out bolt -5-.
– Swing clutch pedal forward slightly and remove over-centre
spring -4- from mounting bracket.
2. Repairing clutch mechanism 21
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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.
2.4.2 Installing
Install in the reverse order of removal, observing the following:
Note
Renew self-locking nuts.
– Attach retainer -2- to master cylinder operating rod -1-.
– Press retainer into notch in clutch pedal -3- until it can be heard
to engage.
– Insert over-centre spring -2- in mounting bracket from above
while holding end of spring with assembly tool -T10178- in in‐
stallation position.
22 Rep. gr.30 - Clutch
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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.
– Depress clutch pedal slightly, push bolt through and tighten
self-locking nut to specified torque ⇒ page 23 .
Some cars have damping -arrow- on the mounting bracket/clutch
pedal.
– Return it to installation position.
Vehicles without knee airbag
– Install crash bar -1- in front of clutch pedal by screwing on and
tightening nuts -2-.
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 driver side footwell cover and driver side left trim panel
⇒ General body repairs, interior; Rep. gr. 68 ; Compartments,
covers and trim panels .
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
2.5 Removing and installing mounting
bracket
Special tools and workshop equipment required
2. Repairing clutch mechanism 23
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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
LHD
– First check whether a coded radio is fitted. If so, obtain anti-
theft code.
– With ignition switched off, disconnect battery earth strap ⇒
Electrical system; Rep. gr. 27 ; Disconnecting and connecting
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 .
24 Rep. gr.30 - Clutch
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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
longitudinal member or gearbox. If this does happen, clean the
affected areas thoroughly.
♦
Place a lint-free cloth under the master cylinder.
– Clamp off supply hose to master cylinder using hose clamp to
25 mm ∅ -3094- .
– If necessary, loosen spring-type clip -3- with hose clip pliers -
VAS 6362- and pull supply hose off master cylinder.
– In addition, for disconnecting, you can close it with the sealing
tool -T10249/1- (⇒ figure above).
– Release securing clip -2- using screwdriver or a pointed object
and pull pipe/hose line or plastic line -1- off master cylinder.
– Unclip clutch position sender -G476- from master cylinder
-arrow- and remove with electrical connector attached -4-.
Note
When performing work in the footwell, put cloths on the carpet to
protect it from possible brake fluid spills.
– Remove driver side footwell cover and driver side left trim
panel ⇒ General body repairs, interior; Rep. gr. 68 ; Com‐
partments, covers and trim panels .
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 .
Vehicles without knee airbag
2. Repairing clutch mechanism 25
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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
– If fitted, remove damping -arrow- from lower area of clutch
pedal mounting bracket.
– To do this, remove lock washers -A- for damping.
– Pull off damping.
26 Rep. gr.30 - Clutch
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