Volkswagen Golf Variant 2007 User Manual
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Service
Workshop Manual
Golf Variant 2007 ➤
Golf Variant 2010 ➤
Jetta 2005 ➤
6-speed manual gearbox 0AJ
Edition 07.2009
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 MEX5R009620
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Contents
6-speed manual gearbox 0AJ - Edition 07.2009
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3 Calculating overall gear ratio “i” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4 General repair notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4.1 Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
30 - Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1 Fault finding, power transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2 Repairing clutch mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.2 Assembly overview - pedal cluster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.3 Removing and installing over-centre spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.4 Removing and installing clutch pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
2.8 Assembly overview - hydraulics (LHD vehicles) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
2.9 Assembly overview - hydraulics (RHD vehicles) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
2.10 Removing and installing slave cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
3 Bleeding clutch system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
4 Repairing clutch release mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
4.1 Assembly overview - clutch release mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
4.2 Removing and installing clutch release lever, release bearing and guide sleeve . . . . . . . . 43
5 Repairing clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
34 - Controls, housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
1 Repairing selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
1.1 Installation position of selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
1.2 Overview of selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
1.3 Assembly overview - gear knob and frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
1.4 Removing and installing gaiter with gear knob and noise insulation . . . . . . . . . . . . . . . . . . 49
1.5 Assembly overview - selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
1.6 Assembly overview - selector cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
1.7 Removing cable end-piece from relay lever and installing . . . . . . . . . . . . . . . . . . . . . . . . . . 59
1.8 Removing and installing selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
1.9 Removing and installing gear selector cable and gate selector cable . . . . . . . . . . . . . . . . 65
1.10 Adjusting selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
2 Removing and installing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
2.1 Removing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
2.2 Installing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
3 Transporting gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
4 Checking gear oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
5 Dismantling and assembling gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
5.1 Overview - gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
5.2 Assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
5.3 Removing and installing cover for gearbox housing and 5th and 6th gear . . . . . . . . . . . . 90
5.4 Removing and installing clutch housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Contents i
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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
6-speed manual gearbox 0AJ - Edition 07.2009
5.5 Removing and installing input shaft, output shaft, differential, selector mechanism and
selector forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
5.6 Dismantling and assembling procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
6 Repairing gearbox housing and clutch housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
7 Repairing gearbox housing cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
8 Repairing selector unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
9 Dismantling and assembling selector forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
35 - Gears, shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
1 Input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
1.1 Dismantling and assembling input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
2 Output shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
2.1 Dismantling and assembling output shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
39 - Final drive - differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
1 Renewing flange shaft oil seals with gearbox installed . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
1.1 Renewing oil seal for left flange shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
1.2 Renewing seal for right flange shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
2 Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
2.1 Dismantling and assembling differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
2.2 Adjusting differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
ii Contents
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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
6-speed manual gearbox 0AJ - Edition 07.2009
00 – Technical data
1 Gearbox identification
The 6-speed manual gearbox 0AJ is installed in the Jetta 2005 ▸,
in the Golf Variant 2007 ▸ and in the Golf Variant 2010 ▸ in con‐
junction with a 4-cylinder injection engine.
Allocation ⇒ page 1 .
1.1 Location on gearbox
Code letters and date of gearbox manufacture -arrow-
Identification code and date of gearbox manufacture -arrow-
Example: FVG 12 11 2
Additional data provide information about the production facility.
The gearbox code also appears on the vehicle identification
plates.
1.2 Identification code, assembly allocation and capacities
Manual gearbox
Identification code KRG LHY
Note
Identification
I I I I
I I I I
Day Month Year (2002) of
code
Manufactured from
to
Allocation Model Jetta 2005 ▸ and Golf Var‐
Ratio
Final drive 73 : 18 = 4.056 73 : 18 = 4.056
Engine 1.4 l - 90 kW 1.4 l - 90 kW
Z1 : Z2
Capacity of manual gearbox 2.0 l 2.0 l
Drive shaft flange ∅ 100 mm 100 mm
manufacture
07.08 12.08
Jetta 2005 ▸, Golf Variant 2007 ▸ and
iant 2007 ▸
Golf Variant 2010 ▸
The following data can be found in the ⇒ Electronic parts cata‐
logue “ETKA” .
♦ Individual gear ratios
1. Gearbox identification 1
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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
6-speed manual gearbox 0AJ - Edition 07.2009
♦ Gear oil
♦ Clutch allocation
2 Rep. Gr.00 - Technical data
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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
6-speed manual gearbox 0AJ - Edition 07.2009
2 Overview - power transmission
Designation
-Arrows- indicate direction of travel.
1 - Engine
2 - Clutch
3 - Manual gearbox
4 - Input shaft
5 - Output shaft
6 - Differential
Gears
-Arrows- indicate direction of travel.
2. Overview - power transmission 3
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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
6-speed manual gearbox 0AJ - 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
4 Rep. Gr.00 - Technical data
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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
6-speed manual gearbox 0AJ - Edition 07.2009
3 Calculating overall gear ratio “i”
Example:
6th gear Final drive
Drive gear ZG1 = 49 ZA1 = 15
Driven gear ZG2 = 38 ZA2 = 76
i = Z2 : Z1
1)
iG = Gear ratio = ZG2: ZG1= 38 : 49 = 0.776
iA = Final drive ratio = ZA2 : ZA1 = 76 : 15 = 5.067
i
= Overall ratio = iG x iA = 0.776 x 5.067 = 3.932
total
1) Z1 = No. of teeth on driving gear, Z2 = No. of teeth on driven gear
3. Calculating overall gear ratio “i” 5
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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
6-speed manual gearbox 0AJ - Edition 07.2009
4 General repair notes
To ensure perfect 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 6 . They apply to this workshop
manual.
4.1 Components
4.1.1 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.
♦ Following installation, check gear oil level ⇒ page 86 .
♦ Capacity ⇒ page 1 .
4.1.2 O-rings, seals and gaskets
♦ Always renew O-rings, seals and gaskets.
♦ Before installing oil seal, half-fill space between sealing lips
with sealing grease -G 052 128 A1- -arrow-.
♦ The open side of the oil seal faces the side with fluid filling.
♦ Following installation, check gear oil level ⇒ page 86 .
♦ Lightly oil O-rings before installing; this prevents the rings be‐
ing crushed when inserted.
♦ Thoroughly clean parting surfaces and apply sealant -AMV
188 200 03- .
♦ Apply sealant uniformly but not too thick.
4.1.3 Sealant
♦ Thoroughly clean housing joint surfaces before applying seal‐
ing paste.
♦ Evenly apply a thin coat of sealing paste -AMV 188 200 03- .
♦ Breather holes must remain free of sealing paste.
6 Rep. Gr.00 - Technical data
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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
6-speed manual gearbox 0AJ - Edition 07.2009
4.1.4 Locking devices
♦ Always renew retaining rings which have been damaged or
overstretched.
♦ Do not overstretch retaining rings.
♦ Retaining rings must locate properly in grooves.
♦ Renew spring pins. Installation position: slot longitudinal to line
of force.
4.1.5 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
100 A1.
♦ All threaded holes into which self-locking bolts are to be
screwed must be cleaned of residual locking fluid using a
thread chaser. Otherwise there is a danger of bolts shearing
when subsequently being removed.
4.1.6 Bearings
♦ Install new tapered roller bearings as supplied and do not lu‐
bricate additionally.
♦ Install needle bearings with lettered side (thicker metal) to‐
wards fitting tool.
♦ Tapered roller bearings fitted to one shaft must be renewed as
a set. Use same make of bearings.
♦ Heat bearing inner races to max. 100° C with the inductive
heater -VAS 6414- before installing.
♦ Do not interchange outer or inner bearing races of the same
size. The bearings are matched in pairs.
4. General repair notes 7
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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
6-speed manual gearbox 0AJ - Edition 07.2009
4.1.7 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.
4.1.8 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”, “signs of abnormal wear” and
“blue discolouration (due to overheating)”.
♦ If the synchro-rings are coated, check cone of synchromeshed
gear for “scoring” and “signs of abnormal wear”.
♦ Moisten synchromesh mechanism with gear oil before instal‐
ling.
4.1.9 Gear wheels
♦ Before installing, clean and heat with the inductive heater -
VAS 6414- to maximum 100° C.
4.1.10 Synchromeshed gears
♦ After assembly, check synchromeshed gears for slight play, or
for freedom of movement.
4.1.11 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 bell housing
as well as the friction surface of flywheel with a cloth to reduce
the smell of burnt linings.
♦ When removing gearbox, remove slave cylinder without dis‐
connecting pipes.
♦ If the clutch slave cylinder is removed with the hydraulic line
attached, do not depress clutch pedal. Otherwise the piston
will be pressed out of the slave cylinder.
8 Rep. Gr.00 - Technical data
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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
6-speed manual gearbox 0AJ - Edition 07.2009
30 – Clutch
1 Fault finding, power transmission
Please note:
♦ ⇒ Fault finding, power transmission; Rep. Gr. 30 ; Complaints
regarding clutch and clutch actuation
♦ ⇒ Fault finding, power transmission; Rep. Gr. 34 ; Complaints
regarding selector mechanism
1. Fault finding, power transmission 9
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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
6-speed manual gearbox 0AJ - Edition 07.2009
2 Repairing clutch mechanism
2.1 Overview
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 11
II - Assembly overview - hy‐
draulics (LHD vehicles)
⇒ page 35
III - Assembly overview - hy‐
draulics (RHD vehicles)
⇒ page 37
10 Rep. Gr.30 - Clutch
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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
6-speed manual gearbox 0AJ - Edition 07.2009
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 12
❑ Removing and installing
⇒ page 23
4 - Bolt
5 - Over-centre spring
❑ Removing and installing
⇒ page 12
6 - Bearing bush
7 - Pivot pin
8 - Clutch pedal
❑ Removing and installing
⇒ page 17
9 - Retainer
❑ To remove and install,
separate master cylin‐
der from clutch pedal
⇒ “2.4 Removing and installing clutch pedal”, page 17
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 31
❑ 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 or plastic line
14 - Supply hose
❑ Made of plastic ⇒ page 36
15 - Hexagon nut, 25 Nm
❑ Self-locking
❑ Qty. 3
2. Repairing clutch mechanism 11
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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
6-speed manual gearbox 0AJ - Edition 07.2009
❑ 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
Special tools and workshop equipment required
♦ Release tool -T10178-
Torque wrench -V.A.G 1331-
12 Rep. Gr.30 - Clutch
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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
6-speed manual gearbox 0AJ - Edition 07.2009
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.
– 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 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 ⇒
General body repairs, interior; Rep. Gr. 69 ; Airbag; Removing
and installing 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.
Attachment with 2 bolts
– Remove crash bar -1- (2 bolts).
2. Repairing clutch mechanism 13
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.
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
6-speed manual gearbox 0AJ - Edition 07.2009
Attachment with 1 bolt
– Remove crash bar -1- (1 bolt -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.
14 Rep. Gr.30 - Clutch
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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
6-speed manual gearbox 0AJ - Edition 07.2009
– Push damping upwards in area of upper securing nut -1-
above clutch pedal -A- in -direction of arrow-.
– Unbolt clutch pedal -1- from mounting bracket -3- by removing
nut -2- and pulling out bolt -5-.
Note
The clutch pedal remains hooked to operating rod of master cyl‐
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 15
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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
6-speed manual gearbox 0AJ - Edition 07.2009
– 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 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 17 .
Some cars have damping -arrow- on the clutch pedal mounting
bracket.
– Reinstall in original position.
Vehicles without knee airbag
16 Rep. Gr.30 - Clutch
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.
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
6-speed manual gearbox 0AJ - 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 torque
⇒ page 17 .
Attachment with 1 bolt
– Install crash bar -1- and tighten bolt -2- to specified torque
⇒ page 17 .
Continuation for all
– 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 ⇒ Gen‐
eral body repairs, interior; 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 .
– Reconnect battery and perform work required after connecting
battery ⇒ Electrical system; Rep. Gr. 27 ; Disconnecting and
connecting battery .
2.3.3 Torque settings
Component Nm
Clutch pedal to mounting bracket
♦ Renew self-locking nuts
Crash bar to steering column mounting
bracket (attachment with 2 bolts)
Crash bar to steering column mounting
bracket (attachment with 1 bolt)
♦ Renew bolts for crash bar
2.4 Removing and installing clutch pedal
25
10
20
Special tools and workshop equipment required
2. Repairing clutch mechanism 17
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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
6-speed manual gearbox 0AJ - Edition 07.2009
♦ Pliers -T10005-
♦ Release tool -T10178-
Torque wrench -V.A.G 1331-
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 trim and cover below trim on drive side ⇒ General
body repairs, interior; Rep. Gr. 68 .
18 Rep. Gr.30 - Clutch
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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
6-speed manual gearbox 0AJ - Edition 07.2009
Vehicles with knee airbag
– Remove bracket for knee airbag together with crash bar ⇒
General body repairs, interior; Rep. Gr. 69 ; Airbag; Removing
and installing 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.
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 19
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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
6-speed manual gearbox 0AJ - Edition 07.2009
If fitted, remove damping -arrow- from lower area of clutch pedal
mounting bracket.
– To do this, remove lock washers -A- for damping.
– Pull off damping.
– Push damping upwards in area of upper securing nut -1-
above clutch pedal -A- in -direction of arrow-.
20 Rep. Gr.30 - Clutch
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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
6-speed manual gearbox 0AJ - Edition 07.2009
– 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.
– 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.
2. Repairing clutch mechanism 21
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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
6-speed manual gearbox 0AJ - Edition 07.2009
– 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
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 clutch pedal mounting
bracket.
– Reinstall in original position.
Vehicles without knee airbag
22 Rep. Gr.30 - Clutch
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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
6-speed manual gearbox 0AJ - 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 torque
⇒ page 23 .
Attachment with 1 bolt
Continuation for all
– Install crash bar -1- and tighten bolt -2- to specified torque
⇒ page 23 .
Continuation for all
– 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 ⇒ Gen‐
eral body repairs, interior; 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 .
– Reconnect battery and perform work required after connecting
battery ⇒ Electrical system; Rep. Gr. 27 ; Disconnecting and
connecting battery .
2.4.3 Torque settings
Component Nm
Clutch pedal to mounting bracket
♦ Renew self-locking nuts
Crash bar to steering column mounting
bracket (attachment with 2 bolts)
Crash bar to steering column mounting
bracket (attachment with 1 bolts)
♦ Renew bolts for crash bar
2.5 Removing and installing mounting bracket
Special tools and workshop equipment required
25
10
20
2. Repairing clutch mechanism 23
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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
6-speed manual gearbox 0AJ - Edition 07.2009
♦ Hose clamps to 25 mm -3094-
♦ Torque wrench -V.A.G 1331-
♦ Hose clip pliers -VAS 6362-
♦ Sealing tool -T10249-
2.5.1 Removing
Left-hand drive
– First check whether a coded radio is fitted. If so, obtain anti-
theft code.
24 Rep. Gr.30 - Clutch
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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
6-speed manual gearbox 0AJ - Edition 07.2009
– 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 located close to the
battery ⇒ Rep. Gr. 24 ; Repairing injection system .
– Remove battery and battery tray ⇒ Electrical system; Rep.
Gr. 27 ; Battery; Removing and installing battery .
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
-3094- .
– If necessary, loosen spring-type clip -3- with hose clip pliers -
VAS 6362- and pull supply hose off master cylinder.
– In addition, seal supply hose with sealing tool -T10249/1- .
– Release securing clip -2- using screwdriver or 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 trim and cover below trim on drive side ⇒ General
body repairs, interior; Rep. Gr. 68 .
Vehicles with knee airbag
Note
The installation location of the knee airbag is above the pedal
cluster.
– Remove bracket for knee airbag together with crash bar ⇒
General body repairs, interior; Rep. Gr. 69 ; Airbag; Removing
and installing knee airbag bracket .
Continuation for all
2. Repairing clutch mechanism 25
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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
6-speed manual gearbox 0AJ - Edition 07.2009
– 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.
Attachment with 2 bolts
– Unbolt crash bar (2 bolts).
Attachment with 1 bolt
– Remove crash bar -1- (1 bolt -2-).
Continuation for all
If fitted, remove damping -arrow- from lower area of clutch pedal
mounting bracket.
26 Rep. Gr.30 - Clutch
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