Volkswagen Jetta 2005 User Manual
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Service
Workshop Manual
Golf Variant 2007 ➤
Golf Variant 2010 ➤
Jetta 2005 ➤
Jetta 2011 ➤
5-speed manual gearbox 0AF
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 - rear 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 D3E801CBF24
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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤
5-speed manual gearbox 0AF - Edition 06.2010
Contents
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1 Fault finding, power transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2 Repairing clutch mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.2 Assembly overview - pedal cluster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.3 Removing and installing over-centre spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.4 Removing and installing clutch pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.5 Removing and installing mounting bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
2.6 Removing and installing master cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
2.7 Removing and installing clutch position sender G476 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
2.8 Assembly overview - hydraulics (LHD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
2.9 Assembly overview - hydraulics (RHD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
2.10 Removing and installing slave cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
3 Bleeding clutch system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
4 Repairing clutch release mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
4.1 Assembly overview - clutch release mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
4.2 Removing and installing clutch release lever, release bearing and guide sleeve . . . . . . . . 44
5 Repairing clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
34 - Controls, housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
1 Repairing selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
1.1 Repairing selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
1.2 Removing and installing gear knob and cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
1.3 Removing and installing gaiter with selector lever knob and noise insulation . . . . . . . . . . 50
1.4 Repairing gear lever and selector housing (through 10.06) . . . . . . . . . . . . . . . . . . . . . . . . 52
1.5 Repairing gear lever and selector housing (from 11.06) . . . . . . . . . . . . . . . . . . . . . . . . . . 55
1.6 Assembly overview - removing and installing selector cables . . . . . . . . . . . . . . . . . . . . . . 61
1.7 Removing and installing selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
1.8 Adjusting selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
1.9 Plastic relay lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
2 Removing and installing gearbox, Jetta 2005 ▸, Golf Variant 2007 ▸ and Golf Variant
2010 ▸ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
2.1 Removing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
2.2 Installing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
3 Removing and installing gearbox, Jetta 2011 ▸ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
3.1 Removing gearbox, Jetta 2011 with 2.0 l - 85 kW engine . . . . . . . . . . . . . . . . . . . . . . . . . . 87
3.2 Installing gearbox, Jetta 2011 with 2.0 l - 85 kW engine . . . . . . . . . . . . . . . . . . . . . . . . . . 93
4 Transporting gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
5 Checking gear oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
6 Dismantling and assembling gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
6.1 Overview - gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
6.2 Assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Contents i
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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤
5-speed manual gearbox 0AF - Edition 06.2010
6.3 Assembly overview - removing and installing cover for gearbox housing and 5th gear . . . . 104
6.4 Assembly overview - removing and installing clutch housing . . . . . . . . . . . . . . . . . . . . . . . . 105
6.5 Assembly overview - removing and installing input shaft, output shaft, differential, selector
mechanism and selector forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
6.6 Dismantling and assembling procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
7 Repairing gearbox housing and clutch housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
8 Repairing selector unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
9 Dismantling and assembling selector forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
35 - Gears, shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
1 Input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
1.1 Dismantling and assembling input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
2 Output shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
2.1 Dismantling and assembling output shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
39 - Final drive - rear differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
1 Renewing flange shaft oil seals with gearbox installed . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
1.1 Renewing oil seal for left flange shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
1.2 Renewing seal for right flange shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
2 Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
2.1 Dismantling and assembling differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
2.2 Adjusting differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
ii Contents
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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤
5-speed manual gearbox 0AF - Edition 06.2010
00 – Technical data
1 Gearbox identification
The 5-speed manual gearbox 0AF 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 production date -arrow 1-, manual gearbox 0AF
-arrow 2-.
Manual gearbox 0AF -arrow 2-
Codes and production date of gearbox
Example: FVH 12 11 3
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 5-speed 0AF
Identification code FVH JHT JHU
Manufac‐
tured
Identification
I I I I
I I I I
Day Month Year (2003) of
code
from
to
05.05 11.06 03.09
manufacture
1. Gearbox identification 1
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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤
5-speed manual gearbox 0AF - Edition 06.2010
Manual gearbox 5-speed 0AF
Identification code FVH JHT JHU
Allocation Model Jetta 2005 ▸
Golf Variant 2007 ▸
Jetta 2005 ▸
Golf Variant 2007 ▸
Jetta 2005 ▸
Golf Variant 2007 ▸
Golf Variant 2010 ▸
Ratio
Engine 1.6 l - 75 kW 1.6 l - 75 kW 1.4 l - 59 kW
Final drive 68 : 15 = 4.533 68 : 15 = 4.533 68 : 15 = 4.533
Z1 : Z2
Capacity of manual gear‐
2.0 l 2.0 l 2.0 l
box
Drive shaft flange ∅ 100 mm 100 mm 90 mm
The following data can be found in the ⇒ Electronic parts cata‐
logue “ETKA” :
♦ Individual gear ratios
♦ Gear oil
♦ Clutch allocation
Manual gearbox 5-speed 0AF
from
to
Identification code LEG LVN LDZ
Manufac‐
tured
Allocation Model Jetta 2005 ▸
Ratio
Engine 1.4 l - 59 kW 1.6 l - 75 kW 2.0 l - 85 kW
Final drive 61 : 14 = 4.357 68 : 15 = 4.533 59: 15 = 3.933
Z1 : Z2
Capacity of manual gear‐
box
Drive shaft flange ∅ 90 mm 100 mm 100 mm
The following data can be found in the ⇒ Electronic parts cata‐
logue “ETKA” :
Golf Variant 2007 ▸
Golf Variant 2010 ▸
♦ Individual gear ratios
♦ Gear oil
06.09 05.09 06.10
2.0 l 2.0 l 2.0 l
Jetta 2005 ▸
Golf Variant 2007 ▸
Golf Variant 2010 ▸
Jetta 2005 ▸
Golf Variant 2007 ▸
Golf Variant 2010 ▸
Jetta 2011 ▸
♦ Clutch allocation
2 Rep. Gr.00 - Technical data
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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤
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
5-speed manual gearbox 0AF - Edition 06.2010
Gears
-Arrows- indicate direction of travel.
2. Overview - power transmission 3
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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤
5-speed manual gearbox 0AF - Edition 06.2010
I - 1st gear
II - 2nd gear
III - 3rd gear
IV - 4th gear
V - 5th 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 ➤ , Jetta 2011 ➤
5-speed manual gearbox 0AF - Edition 06.2010
3 Calculating overall gear ratio “i”
Example:
5th gear Final drive
Drive gear ZG1 = 37 ZA1 = 14
Driven gear ZG2 = 50 ZG2 = 69
i = Z2 : Z1
1)
iG = Gear ratio = ZG2: ZG1= 37 : 50 = 0.740
iA = Final drive ratio = ZA2 : ZA1 = 69 : 14 = 4.929
Overall ratio = total ratio = iG x iA = 0.740 x 4.929 = 3.647
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 ➤ , Jetta 2011 ➤
5-speed manual gearbox 0AF - 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 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.
♦ Allocate bolts and other components using ⇒ Electronic parts
catalogue “ETKA” .
♦ Following installation, check gear oil level ⇒ page 100 .
♦ Capacity ⇒ page 1
4.1.2 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.
♦ 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 100 .
6 Rep. Gr.00 - Technical data
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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤
5-speed manual gearbox 0AF - Edition 06.2010
4.1.3 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-.
4.1.4 Nuts and bolts
♦ Loosen nuts or bolts in the order opposite to the tightening
sequence.
♦ Securing bolts and securing nuts which secure covers and
housings should be loosened and tightened diagonally in
stages if no tightening sequence is specified.
♦ 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- .
♦ Threaded holes into which self-locking bolts or bolts coated
with locking fluid are screwed, must be cleaned (e.g. with a
thread chaser). Otherwise there is a danger of bolts shearing
when subsequently being removed.
4.1.5 Bearings
♦ 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 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. General repair notes 7
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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤
5-speed manual gearbox 0AF - Edition 06.2010
4.1.6 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.
4.1.7 Synchro-rings
♦ Do not interchange. When reusing synchro-rings, always fit to
the same synchromeshed 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 the cone of the synchromeshed gear for “scoring” and
“signs of abnormal wear”.
♦ Moisten synchromesh mechanism with gear oil before instal‐
ling.
4.1.8 Gears, synchro-hubs, inner races for needle bearings
♦ Heat inner races for needle bearings 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.
4.1.9 Synchromeshed gears
♦ After assembly, check synchromeshed gears of 1st through
5th gear for slight play, or for freedom of movement.
4.1.10 Clutch
♦ 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 ➤ , Jetta 2011 ➤
5-speed manual gearbox 0AF - Edition 06.2010
♦ 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 9
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.
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤
5-speed manual gearbox 0AF - 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 .
10 Rep. Gr.30 - Clutch
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.
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤
5-speed manual gearbox 0AF - Edition 06.2010
2 Repairing clutch mechanism
2.1 Overview
Note
♦
Before disconnecting battery, obtain code for radio having anti-theft coding.
♦
With ignition switched off, disconnect battery ⇒ Electrical system; Rep. Gr. 27 ; Disconnecting and con‐
necting battery .
♦
If reconnecting battery, follow procedure after connecting battery ⇒ Electrical system; Rep. Gr. 27 ; Dis‐
connecting and connecting battery .
♦
Grease all bearing points and contact surfaces. Allocate grease according to ⇒ Electronic parts catalogue
“ETKA” .
I - Assembly overview - pedal
cluster ⇒ page 12
II - Assembly overview - hy‐
draulics (LHD) ⇒ page 35
III - Assembly overview - hy‐
draulics (RHD) ⇒ page 37
2. Repairing clutch mechanism 11
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.
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤
5-speed manual gearbox 0AF - 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 13
❑ Removing and installing
⇒ page 24
4 - Bolt
5 - Over-centre spring
❑ Removing and installing
⇒ page 13
6 - Bearing bush
7 - Pivot pin
8 - Clutch pedal
❑ Removing and installing
9 - Retainer
❑ To remove and install,
10 - Seal
❑ Always renew
❑ Between master cylinder and mounting bracket
11 - Master cylinder
❑ Removing and installing after removal of mounting bracket ⇒ page 30
12 - Clutch position sender -G476-
❑ Removing and installing ⇒ page 32
❑ Can be checked in “guided fault finding” of vehicle diagnosis, testing and information system -VAS 5051- .
❑ The clutch position sender -G476- is identified as clutch pedal switch -F36- in “guided fault finding”.
13 - Clip
⇒ page 18
separate master cylin‐
der from clutch pedal
⇒ “2.4 Removing and installing clutch pedal”, page 18
❑ Pull out clip to stop to remove and install pipe/hose line
14 - Supply hose
❑ Made of plastic ⇒ page 36
15 - Hexagon nut, 25 Nm
❑ Self-locking
❑ Qty. 3
12 Rep. Gr.30 - Clutch
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.
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤
❑ For mounting bracket to bulkhead
❑ Always renew
16 - Hexagon nut, 25 Nm
❑ Always renew
17 - Stop
❑ For clutch pedal
Mounting bracket with damping -arrows-
5-speed manual gearbox 0AF - Edition 06.2010
2.3 Removing and installing over-centre
Special tools and workshop equipment required
♦ Release tool -T10178-
Torque wrench -V.A.G 1331-
spring
2. Repairing clutch mechanism 13
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.
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤
5-speed manual gearbox 0AF - Edition 06.2010
2.3.1 Removing
Perform the following steps:
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 move steering
wheel to 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. Crash bar may look different from as shown in
following illustrations.
Attachment with 2 bolts
– Remove crash bar -1- (2 bolts).
14 Rep. Gr.30 - Clutch
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.
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤
5-speed manual gearbox 0AF - Edition 06.2010
Attachment with 1 bolt
– Remove crash bar -1- (1 x bolt -2-).
– If fitted, remove damping -arrow- from lower area of clutch
pedal mounting bracket.
– To do this, remove lock washers -A- for damping.
– Pull off insulation.
2. Repairing clutch mechanism 15
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.
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤
5-speed manual gearbox 0AF - Edition 06.2010
– 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.
16 Rep. Gr.30 - Clutch
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.
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤
5-speed manual gearbox 0AF - 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 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 18 .
Some cars have damping -arrow- on the clutch pedal mounting
bracket.
– Return this to installation position.
Vehicles without knee airbag
2. Repairing clutch mechanism 17
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.
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤
5-speed manual gearbox 0AF - Edition 06.2010
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 2 bolts to specified torque
⇒ page 18 .
Attachment with 1 bolt
– Install crash bar -1- and tighten bolt -2- to specified torque
⇒ page 18 .
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 .
– If disconnected, connect battery ⇒ Electrical system; Rep. Gr.
27 ; Removing and installing battery .
2.3.3 Torque settings
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 bolt)
♦ Renew bolts for crash bar
2.4 Removing and installing clutch pedal
Special tools and workshop equipment required
18 Rep. Gr.30 - Clutch
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.
♦ Pliers -T10005-
♦ Release tool -T10178-
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤
5-speed manual gearbox 0AF - Edition 06.2010
Torque wrench -V.A.G 1331-
2.4.1 Removing
Perform the following steps:
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 move steering
wheel to highest position.
2. Repairing clutch mechanism 19
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.
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤
5-speed manual gearbox 0AF - Edition 06.2010
– 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. Crash bar may look different from as shown in
following illustrations.
Attachment with 2 bolts
– Remove crash bar -1- (2 bolts).
Attachment with 1 bolt
– Remove crash bar -1- (1 x bolt -2-).
Continuation for all
20 Rep. Gr.30 - Clutch
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.
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤
5-speed manual gearbox 0AF - Edition 06.2010
– If fitted, remove damping -arrow- from lower area of clutch
pedal mounting bracket.
– To do this, remove lock washers -A- for damping.
– Pull off insulation.
– Push damping upwards in area of upper securing nut -1-
above clutch pedal -A- in -direction of arrow-.
2. Repairing clutch mechanism 21
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.
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤
5-speed manual gearbox 0AF - Edition 06.2010
– Unbolt clutch pedal -1- from mounting bracket -3- by removing
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.
2.4.2 Installing
Install in the reverse order of removal, observing the following:
Note
Renew self-locking nuts.
– Secure retainer -2- to master cylinder operating rod -1-.
– Press retainer into notch in clutch pedal -3- until it can be heard
to engage.
22 Rep. Gr.30 - Clutch
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.
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤
5-speed manual gearbox 0AF - 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
spring.
– Depress clutch pedal slightly, push bolt through and tighten
self-locking nut to specified torque ⇒ page 24 .
Some cars have damping -arrow- on the clutch pedal mounting
bracket.
– Return this to installation position.
Vehicles without knee airbag
2. Repairing clutch mechanism 23
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.
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤
5-speed manual gearbox 0AF - Edition 06.2010
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 2 bolts to specified torque
⇒ page 24 .
Attachment with 1 bolt
– Install crash bar -1- and tighten bolt -2- to specified torque
⇒ page 24 .
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 .
– If disconnected, connect battery ⇒ Electrical system; Rep. Gr.
27 ; Removing and installing battery .
2.4.3 Torque settings
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
2.5 Removing and installing mounting bracket
Special tools and workshop equipment required
24 Rep. Gr.30 - Clutch
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.
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤
♦ Hose clamps to 25 mm ∅ -3094-
♦ Torque wrench -V.A.G 1331-
♦ Hose clip pliers -VAS 6362-
5-speed manual gearbox 0AF - Edition 06.2010
♦ Sealing tool -T10249-
2.5.1 Removing
Perform the following steps:
LHD
– First check whether a coded radio is fitted. If so, obtain anti-
theft code.
2. Repairing clutch mechanism 25
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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤
5-speed manual gearbox 0AF - Edition 06.2010
– 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.
♦
Lay a lint-free cloth under master cylinder.
– Clamp off supply hose to master cylinder with hose clamps up
to ∅ 25 mm -3094- .
– Then seal supply hose with sealing tool -T10249/1- .
– 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 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.
26 Rep. Gr.30 - Clutch
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