Service: Golf 2017 Golf Variant 2017 Polo 2018 T-Cross 2019

Service
Workshop Manual
Golf 2017 ➤
Golf Variant 2017olk ➤
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Service Department. Technical Information

Service
List of Workshop Manual Repair Groups
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00 - Technical data
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30 - Clutch
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34 - Controls, housing
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35 - Gears, shafts
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39 - Final drive - differential
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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 © 2019 Volkswagen AG, Wolfsburg D4B806C0E6D

Golf 2017 ➤ , Golf Variant 2017 ➤ , Polo 2018 ➤ , T-Cross 2019 ➤
Removed 5-speed manual gearbox 0A4 - Edition 01.2019
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3.1 Allocation gearbox - engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3.2 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
4 Overview - power transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
5 Electrical components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
6 Repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
6.1 General repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
30 - Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1 Clutch operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.1 Assembly overview - clutch release mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.2 Repairing clutch release mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2 Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.1 Assembly overview - clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.2 Removing and installing clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
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34 - Controls, housing . . . . . . . . . . . . . . . . y.V.ol.ks.w. . . . . . . . . . . . . . .e.s n.ot.g.u . . . . . . . . . . . 28
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1 Selector mechanism . . . . . . . . . . o.ris.e. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . a.n.te.e . . . . . . . . . 28
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2 Removing and installing gearbox ss au . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .r a.c. . . . . . . 29
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3 Transporting gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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4 Gear oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
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5 Securing to engine and gearbox support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
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6 Dismantling and assembling gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
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6.1 Schematic overview - gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
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6.2 Assembly overview - gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
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6.3 Assembly overview - cover for gearbox housing and 5th gear . . . . . . . . . . . . . . . . . . . . . . 36
6.4 Assembly overview - gearbox housing and selector mechanism . . . . . . . . . . . . . . . . . . . . 38
6.5 Assembly overview - selector unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
6.6 Assembly overview - shafts, differential, selector mechanism . . . . . . . . . . . . . . . . . . . . . . rrectness of i 39
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6.7 Assembly overview - selector forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

6.8 Repairing selector forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
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6.9 Removing cover for gearbox housing and 5th gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

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6.10 Dismantling and assembling gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

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6.11 Installing cover for gearbox housing and 5th gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

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7 Gearbox housing, clutch housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

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7.1 Assembly overview - gearbox housing and clutch housing . . . . . . . . . . . . . . . . . . . . . . . . 66

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7.2 Repairing gearbox housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

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7.3 Repairing clutch housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
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35 - Gears, shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
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1 Input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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1.1 Assembly overview - input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

1.2 Dismantling and assembling input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
1.3 Adjusting input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
1.4 Renewing input shaft seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
2 Output shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
2.1 Assembly overview - output shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
2.2 Dismantling and assembling output shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Contents i
2.3 Adjusting output shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

3 Reverse shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
3.1 Assembly overview - reverse shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
3.2 Dismantling and assembling reverse shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
39 - Final drive - differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

1 Oil seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
1.1 Overview of fitting locations - seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
2 Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
2.1 Assembly overview - differential . .w.a.ge. n. A.G. ..V.ol.ks. w. a.g.en. A .G. .do. e. . . . . . . . . . . . . . . . . . . . . . . . . . 112
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2.2 Dismantling and assembling differential y V . . . . . . . . . . . . . . . . o. t.g.ua. . . . . . . . . . . . . . . . . . . . . 113
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2.3 Adjusting differential . . .or.is. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .an. te.e. . . . . . . . . . . . . . . . .
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3 Adjustment overviewss a. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ac. . . . . . . . . . . . . . . 123
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ii Contents
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1 Safety information
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(VRL012607; Edition 01.2019)
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1. Safety information 1
2 Identification
The relevant description can be found in ⇒ Rep. gr. 00 ; Identi‐
fication; Gearbox identification .
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2 Rep. gr.00 - Technical data

3 Technical data
⇒ “3.1 Allocation gearbox - engine”, page 3 .
3.1 Allocation gearbox - engine

The relevant description can be found in ⇒ Rep. gr. 00 ; Technical
data; Allocation gearbox - engine .
3.2 Capacities
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The relevant description can be found in ⇒ Rep. gr. 00 ; Technical
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3. Technical data 3
4 Overview - power transmission

Designation:
-Arrows- point in direction of travel.
1 - Engine
2 - Clutch
3 - Manual gearbox
4 - Input shaft
5 - Output shaft
6 - Differential
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4. Overview - power transmission 5

5 Electrical components
The relevant description can be found in ⇒ Rep. gr. 00 ; Electrical
components; Overview of fitting locations - electrical compo‐
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6 Repair instructions
⇒ “6.1 General repair instructions”, page 7
6.1 General repair instructions agen

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♦ When installing the manual gearbox, ensure that the dowel
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sleeves between the engine and gearbox are correctly seated.

♦ The contact surfaces of waxed parts must be cleaned before
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♦ Thoroughly clean joint surfaces and apply sealant .
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♦ Allocation ⇒ Electronic parts catalogue (ETKA)
♦ Before installing radial oil seals, half-fill space between sealing
lips with sealing grease -arrow-.
♦ Allocate grease using ⇒ Electronic parts catalogue (ETKA) .
♦ The open side of the oil seals faces toward the side with fluid
filling.
♦ Lightly oil O-rings before installing; this prevents the rings be‐
ing crushed when inserted.
Sealant
♦ Thoroughly clean housing joint surfaces before applying seal‐
ant .
♦ Apply sealant uniformly and not too thickly.
♦ Allocation ⇒ Electronic parts catalogue (ETKA) .
♦ Breather holes must remain free of sealant .
Locking devices
6. Repair instructions 7
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♦ Do not overstretch retainingedrings.
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♦ Renew retaining rings which have been damaged or over‐
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♦ Retaining rings must locate properly in grooves.
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♦ Renew spring pins. Installation position: slit -A- should be in
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Nuts and bolts
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♦ Loosen and tighten securing bolts and nuts for covers and
housings alternately and diagonally.
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plates. Loosen and tighten bolts and nuts alternately and in
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quently being removed.
♦ Check pitch of thread, to ensure correct thread chaser is used
to clean threads and to ensure the threads are not damaged.
Mountings
♦ Lubricate all bearings with gear oil before installing.
♦ Heat inner races of tapered roller bearings with the inductive
heater - VAS 6414- to approx. 100 °C before installing. Press
in to stop when installing so there is no axial clearance.
♦ Do not interchange outer or inner races of bearings of the
same size. The bearings are matched in pairs.
♦ Tapered roller bearings fitted to one shaft must be replaced as
a set. Use same make of bearings.
♦ Install needle bearings, ball sleeves and roller sleeves with
lettered side (thicker metal) towards fitting tool.

Shims
♦ Measure shims at several points with a micrometer. The var‐
ious tolerances make it possible to achieve the exact shim
thickness required.
♦ Check for burrs and damage.
♦ Install only flawless shims.
Synchro-rings
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♦ Do not interchange them. When reusing synchro-rings,
ss always c
fit to the same synchromeshed gear.
ce
e
nl
pt
du
an
itte
♦ Check for wear and renew if necessary.
y li
erm
ab
ility
♦ Check grooves -arrow 1- of synchro-ring -A- and inner ring for
ot p
flat spots (worn grooves).
wit
, is n
h re
hole
♦ If synchro-rings are coated, coating must not be damaged.
spec
es, in part or in w
♦ If an intermediate ring -B- is installed, check the outer friction
t to the co
surface -arrow 2- and inner friction surface -arrow 3- of this
intermediate ring for »scoring« and »signs of abnormal wear«.
rrectness of i
♦ Check the cone of the synchromeshed gear for »scoring« and
»signs of abnormal wear«.
l purpos
♦ Moisten synchromesh mechanism with gear oil before instal‐

ling.
nform
ercia
Gears and synchro-hubs

m
at
om
io
♦ Heat synchro-hubs to about 100 °C with the inductive heater
n
c
in t
or
- VAS 6414- before installing. Press in to stop when installing
his
ate
so there is no axial clearance.
do
priv
cum
or
♦ Heat gears to about 100°C with the inductive heater - VAS

f
en
ng
t.
6414- before installing. Press in to stop when installing so
yi Co
op
there is no axial clearance.
C py
t. rig
gh ht
yri by
♦ Observe installation position
op Vo
by c lksw
cted agen
Prote AG.
Synchromeshed gears
♦ After assembly, check synchromeshed gears for slight play, or
for freedom of movement.
Clutch
♦ Ensure that the pressure plate does not cant: loosen and tight‐
en bolts alternately and diagonally and in several gradual
stages.
♦ In order to reduce the smell of a burned clutch, the clutch
housing as well as the stopping face of the flywheel must be
thoroughly cleaned with a cloth.
6. Repair instructions 9
30 – Clutch n AG. Volkswagen AG do

lkswage es n
o ot g
byV ua
1 Clutch operation tho
ir se
d ran
tee
or
au ac
⇒ “1.1 Assembly overview
ss - clutch release mechanism”,
page 10
ce
le
un
pt
an
d
itte
⇒ “1.2 Repairing clutch release mechanism”, page 11
y li
rm
ab
pe
ility
Additional descriptions can be found in ⇒ Rep. gr. 30 ; Clutch
ot
wit
mechanism .
, is n
h re
hole
1.1 Assembly overview - clutch release mechanism
spec
es, in part or in w
t to the co
1 - Gearbox
rrectness of i
2 - Ball-head pin
❑ To remove and install,
l purpos
remove gearbox
❑ Remove old grease
nform
ercia
❑ Grease contact surface

m
of ball-head pin with
a
com
tio
grease for clutch plate
n in
r
splines .
te o
thi
s
iva
❑ Allocate grease using ⇒

do
r
rp
Electronic parts cata‐ cum

fo
en
g
logue (ETKA) .
n
t.
yi Co
op
❑ 25 Nm
C py
t. rig
gh ht
yri by
3 - Input shaft seal cop Vo
by lksw
cted agen
❑ Renew after removal Prote AG.
⇒ page 87
4 - Guide bush
remove gearbox
❑ With vulcanised O-ring
❑ If O-ring is damaged, re‐
new guide sleeve and
O-ring together
5 - Retaining spring
remove gearbox
❑ Secure to clutch release
lever
6 - Socket head bolt
❑ 20 Nm
7 - Clutch release lever
remove gearbox
❑ Remove and install together with release bearing ⇒ page 11
❑ Remove old grease
❑ Grease contact surface of ball-head pin with grease for clutch plate splines .
❑ Allocate grease using ⇒ Electronic parts catalogue (ETKA) .
8 - Release bearing
❑ To remove and install, remove gearbox
❑ Do not wash out bearing; wipe only
10 Rep. gr.30 - Clutch

❑ Renew noisy bearings
❑ Removing from and inserting in clutch release lever ⇒ page 12
❑ Lubricate contact surface of release lever with MoS2 grease
9 - Hexagon bolt
❑ 20 Nm
10 - Clutch slave cylinder
❑ Removing and installing ⇒ Rep. gr. 30 ; Clutch mechanism; Removing and installing clutch slave cylinder
11 - Plunger
12 - Assembly bolt
❑ Secures clutch release lever when gearbox is installed.
❑ Remove after gearbox has been installed.
❑ If assembly bolt is not available, an M 8 x 35 bolt can be used.
1.2 Repairing clutch release mechanism

Special tools and workshop equipment required
♦ Torque wrench - V.A.G 1331-
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
u ra
♦ Grease for splines
ss a c
ce
e
nl

pt
du
an
itte
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• Gearbox has been removed.

erm
ab
ility
ot p
Removing and installing release lever together with release bear‐

wit
, is n
ing
h re
hole
spec
– Unhook spring -arrow 1-.

es, in part or in w
t to the co
– Pull off release lever -arrow 2- and release bearing.

– Install in reverse order of removal.
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
1. Clutch operation 11
Golf 2017 ➤ , Golf Variant 2017 ➤ , Polo 2018 ➤ , T-Cross 2019. V➤
n AG olkswagen AG do
Removed 5-speed manual gearbox 0A4 - Edition 01.2019olks
wage es n
o
yV t gu
db ara
Removing and installing release bearing rise nte
tho eo
au ra
– Press together retaining hooks -arrows- on backs of clutch re‐
s c
lease lever and remove release bearing -A- from clutch re‐
ce
e
nl
pt
du
lease lever.
an
itte
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erm
ab
– To install, press release bearing -A- into clutch release lever
ility
ot p
until retaining hooks -arrows- engage.
wit
, is n
h re
– Install gearbox ⇒ Rep. gr. 34 ; Removing and installing gear‐
hole
box .
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

2 Clutch
⇒ “2.1 Assembly overview - clutch”, page 13
⇒ “2.2 Removing and installing clutch”, page 16
2.1 Assembly overview - clutch

⇒ “2.1.1 Assembly overview - clutch in conjunction with Sachs
dual-mass flywheel”, page 13
⇒ “2.1.2 Assembly overview - clutch in conjunction with LuK dual-
mass flywheel”, page 14
⇒ “2.1.3 Assembly overview - clutch with simple flywheel”,
page 15
2.1.1 Assembly overview - clutch in conjunction with Sachs dual-mass flywheel
1 - Two-part flywheel
❑ Removing and installing
⇒ Rep. gr. 13 ; Cylinder
block (gearbox end);
Removing and installing
flywheel .
❑ Ensure that centring
pins fit tightly
❑ Contact surface for
clutch lining must be
free of grooves, oil and
grease
2 - Clutch plate
❑ Allocation ⇒ Electronic
parts catalogue (ETKA) gen AG
. Volkswagen AG
swa does
❑ Removing and installing yV
olk not
gu
⇒ page 16 rised b ara
nte
o eo
❑ Renew only together
aut
h
ra
with pressure
s plate
s c
ce
e
nl
❑ Fitting position
pt
du
an
⇒ page 18
itte
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erm
ab
3 - Thrust plate
ility
ot p
wit
❑ With adjusting mecha‐

, is n
h re
nism
hole
spec

es, in part or in w
with clutch plate.

t to the co
parts catalogue (ETKA)
rrectness of i

⇒ page 16
l purpos
❑ Check ends of dia‐

phragm spring
nform
ercia
⇒ page 18
m
at
❑ Check spring connec‐

om
io
tions and riveted con‐

n
c
in t
or
nections ⇒ page 18 .
his
ate
do
riv
4 - Bolt
p
cum
for
❑ Allocation ⇒ Electronic parts catalogue (ETKA)

en
ng
t.
yi Co
op
❑ Loosen or tighten alternately and diagonally in small steps (1 full turn) C py
ht. rig
rig ht
❑ M 6: 13 Nm py by
co Vo
by lksw
cted agen
Prote AG.
2. Clutch 13
❑ M 7: 20 Nm
AG. Volkswagen AG d
agen oes
olksw not
V gu
by
2.1.2 Assembly overview - clutch in conjunction with LuK dual-mass flywheel orised ara
nte
eo
h
aut ra
ss c
1 - Flywheel
ce
le
un
pt
an
d
itte
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⇒ Rep. gr. 13 ; Cylinder
rm
ab
pe
block (gearbox end);
ility
ot
Removing and installing
wit
, is n
h re
flywheel .
hole
spec
es, in part or in w
pins fit tightly
t to the co
❑ Contact surface for
clutch lining must be
free of grooves, oil and
rrectness of i
grease
l purpos
2 - Clutch plate
nform
ercia

m
a
com
tio
⇒ page 19
n in
r
te o
thi
s
iva
do
with SAC pressure
r
rp
cum
plate.
fo
en
ng
t.
yi
❑ Installation position:
Co
op py
⇒ page 21 t. C rig
gh ht
pyri by
3 - SAC pressure plate
o Vo
by c lksw
cted agen
Prote
❑ SAC means “self-ad‐
AG.
justing clutch”
with clutch plate.
⇒ page 19
phragm spring
⇒ page 18
❑ Checking spring con‐
nections and riveted connections ⇒ page 18
4 - Bolt
❑ Loosen or tighten alternately and diagonally in small steps (1 full turn)
❑ M 6: 13 Nm
❑ M 7: 20 Nm

2.1.3 Assembly overview - clutch with simple flywheel
1 - Flywheel
❑ Removing and installing lkswage es n
⇒ Rep. gr. 13 ; Cylinder d byV
o ot g
ua
block (gearbox end); o
ir se
ran
tee
Removing and installing auth or
ac
flywheel . ss
ce
le
un
pt
an
d
pins fit tightly
itte
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erm
ab
❑ Keep contact surface for
ility
ot p
clutch lining free of
wit
is n
grooves, oil and grease.
h re
ole,
spec
2 - Clutch plate
t to the co
❑ Centring ⇒ page 23
rrectne
3 - Thrust plate
ss
⇒ page 23
o
cial p
f in
form
mer
phragm spring
atio
⇒ page 26
om
n
c
i
❑ Check spring connec‐
or
n thi
e
tions and riveted con‐

t
sd
va
nections ⇒ page 26 .
i
o
pr
cum
r
fo
en
ng
4 - Bolt
t.
yi Co
op
C py
t. rig
gh
ht
pyri by
Vo
co lksw
by
❑ Loosen or tighten alter‐ Prote
cted AG.
agen
nately and diagonally in
small steps (1 full turn)
❑ M 6: 13 Nm
❑ M 7: 20 Nm
2. Clutch 15
2.2 Removing and installing clutch

⇒ “2.2.1 Removing and installing clutch in conjunction with Sachs
⇒ “2.2.2 Removing and installing clutch in conjunction with LuK
⇒ “2.2.3 Removing and installing clutch in connection with simple
flywheel”, page 23 agen
AG. Volkswagen AG d
oes
olksw not
V
2.2.1 Removing and installing clutch in conjunction with Sachs dual-mass fly‐ by gu
d ara
ise nte
r
wheel ho eo
aut ra
ss c
ce
le
un
pt
an
Special tools and workshop
d
itte
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equipment required
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
♦ Counter-hold tool - 3067-

♦ Centring mandrel - 3190 A-
Removing
• Gearbox is removed.

– Use counter-hold tool - 3067- to loosen bolts.

To prevent the pressure plate from becoming distorted during re‐
moval (causes clutch grab when driving off), always keep to the
following procedure when unbolting the pressure plate:
– Loosen all bolts alternately and diagonally in small steps (1 full

turn).
• As bolts are removed, stop -2- with pin -1- must loosen.
– If stop does not loosen, push pin in direction of dual-mass fly‐
wheel.
– Remove pressure plate and clutch plate.
Installing
Install in reverse order of removal, observing the following:
Note
♦ Select clutch pressure plate and pressure plate according to

engine code and ⇒ Electronic parts catalogue (ETKA) .
AG. Volkswagen AG d
agen oes
♦ Clean splines of drive shaft and, if the clutch plate yhas
Vol been
ksw not
gu
used, clean the splines of the hub. Remove corrosion ed
b and ap‐ ara
nte
ris
ply a very thin coat of clutch plate spline grease
tho to splines. eo
Then, move the clutch plate back and forth ss
auon the drive shaft ra
c
until the hub moves easily on the shaft. Remove excess
ce
le
un
grease.
pt
an
d
itte
y li
♦ Clutch pressure plates are protected against corrosion and
erm
ab
greased. With the exception of the friction surface for the
ility
ot p
clutch plate, the clutch pressure plate must not be cleaned.

wit
is n
Service life of clutch will otherwise be shortened considerably.

h re
ole,
♦ The friction surface of the clutch pressure plate and the fly‐ spec
wheel must be cleaned (degreased) thoroughly.

t to the co
♦ If the clutch has burnt out, thoroughly clean the gearbox hous‐
ing in the clutch area and the engine facing the gearbox in
rrectne
order to reduce the smell of burnt linings.

♦ Blow off dual mass flywheel with compressed air only.
ss o
cial p
♦ Clutch plate linings must make full contact with flywheel and
inform
friction surface of clutch pressure plate. Only then insert se‐

mer
curing bolts.
atio
om
♦ Tighten or loosen securing bolts alternately and diagonally in

c
i
or
small steps (1 full turn) in order not to damage centring holes

thi
te
sd
a
of pressure plate and centring pins of flywheel.

iv
o
pr
cum
r
fo
♦ Check whether dowel sleeves for aligning engine and gearbox

en
ng
t.
yi
are fitted in cylinder block and install if necessary.
Co
Cop py
t. rig
♦ If dowel sleeves are not fitted, difficulties shifting gears, clutch
gh ht
pyri by
problems and possible noises from the gearbox (rattling of
co Vo
by lksw
cted
gears which are not engaged) could occur.
agen
Prote AG.
2. Clutch 17
Installation position of clutch plate

• Lettering “Getriebeseite” (gearbox side) faces gearbox.
Check ends of diaphragm spring

wage es n
• Wear to half the thicknessy Vof o the diaphragm spring -arrows-
lks ot g is
permitted. ir se
d b ua
ran
o tee
th or
au ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
Checking spring connections and riveted connections
I - Extension springs OK. rrectness of i
• Minor kinks on the outside area -arrows A- have series pro‐

l purpos
duction status.
II - Extension springs damaged
nform
ercia
• Renew clutch pressure plate if springs are broken or badly

m
at
bent -arrow B-.

om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Make sure rivet joints -arrows B- on all extension springs

-arrows A- are firmly seated.
• Renew clutch pressure plate if riveting -arrows B- is loose.

– Reverse position of counter-hold tool - 3067- when installing.

– Push clutch pressure plate onto dowel pins.
– Centre clutch plate with centring mandrel - 3190 A- .
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
To prevent the clutch pressure plate from becoming distorted
ce
le
during installation (causes clutch grab when driving off), always un
pt
an
d
adhere to the following procedure when attaching the clutch pres‐
itte
y li
erm
sure plate:
ab
ility
ot p
– Make sure that stop pin (position setter) -arrow- can be moved
wit
is n
easily.
h re
ole,
spec
– Tighten all bolts evenly by hand until bolt heads contact clutch
pressure plate.
t to the co
– Tighten all bolts alternately and diagonally in small steps (1 full
turn).
rrectne
• Stop pin -arrow- must lift off pressure plate when this is done.
ss
o
cial p
f
box .
inform
mer
Specified torques
atio
m
♦ Pressure plate to flywheel ⇒ page 13 .

o
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
2.2.2 Removing and installing clutch in conjunction with LuK dual-mass flywheel
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
2. Clutch 19

equipment required
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
♦ Counter-hold tool - 3067- ht. rig
rig ht
py by
o Vo
♦ Centring mandrel - 3190 A- by c lksw
cted agen
Prote AG.
Removing


turn).
– Remove clutch pressure plate and clutch plate.
Installing
Install in reverse order of removal, observing the following:
Note

♦ Clean splines of drive shaft and, if the clutch plate has been olkswagen AG
used, clean the splines of the hub. Remove corrosion and ap‐ wage
n AG. V does
ply a very thin coat of clutch plate spline grease to splines. Volks not
gu
y
Then, move the clutch plate back and forth on the rdrive d b shaft ara
ise nte
until the hub moves easily on the shaft. Removeuthexcess
o eo
ra
grease. ss
a c
ce
le

un
pt
an
d

itte
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rm
ab
pe
ility
ot
wit
, is n
♦ The friction surface of the clutch pressure plate and the fly‐
h re
hole
spec
es, in part or in w
♦ If the clutch has burnt out, thoroughly clean the gearbox hous‐
t to the co
ing in the clutch area and the engine facing the gearbox in
order to reduce the smell of burnt linings.
rrectness of i
♦ Blow off dual mass flywheel with compressed air only.
l purpos
curing bolts.
nform
ercia

m
a
com
t
ion in
r
te o
thi
s
iva

do
r
rp

um
fo
en
ng
t.
yi Co
op py
problems and possible noises from the gearbox (rattling of t. C rig
gh ht
gears which are not engaged) could occur. yri
p by
co Vo
by lksw
cted agen
Prote AG.
Installation position of clutch plate

• Lettering “Getriebeseite” (gearbox side) faces gearbox.
2. Clutch 21

• Wear to half the thickness of the diaphragm spring -arrows- is
permitted.
Note
Select clutch pressure plate and pressure plate according to en‐

gine code and ⇒ Electronic parts catalogue (ETKA) .
Check extension springs and riveted connections

I - Extension springs OK.
duction status.
II - Extension springs damagedAG. Volkswagen A
gen G do
swa es
• Renew clutch pressure
yV
olk plate if springs are broken
not or badly
gu
bent -arrow B-.edb ara
ris nt ee
tho or
s au ac
s
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
Checking spring connections and riveted connections

rrectne

ss o
cial p
• Renew clutch pressure plate if riveting -arrows B- is loose.

inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Checking position of adjusting mechanism with new pressure

plates only
• Both edges -A- of adjuster ring must be located between two
notches -arrows B-.
• If the adjuster ring takes up a different position in new pressure
plates, the pressure plate and clutch plate are not allowed to
be installed.
• The adjuster ring may take up a position outside the notches
in used clutches.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
– Reverse position of counter-hold tool - 3067- when installing.
hole
spec
– Push clutch pressure plate onto dowel pins.
es, in part or in w
t to the co
– Centre clutch plate with centring mandrel - 3190 A- .
To prevent the clutch pressure plate from becoming distorted
rrectness of i
during installation (causes clutch grab when driving off), always
adhere to the following procedure when attaching the clutch pres‐
l purpos
sure plate:
– Tighten all bolts evenly by hand until bolt heads contact clutch
nform
ercia
pressure plate.
m
at
om
– Tighten all bolts alternately and diagonally in small steps (1 full
ion
c
turn).
in t
or
his
ate

do
priv
box . cum
for
en
ng
t.
yi
Specified torques
Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote
2.2.3 Removing and installing clutch in connection with simple flywheel
AG.
2. Clutch 23

equipment required
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
♦ Counter-hold tool - 3067-

ng
t.
yi Co
op py
♦ Centring mandrel - 3190 A- t. C rig
gh ht
pyri by
o Vo
by c lksw
cted agen
Prote AG.
Removing


turn).
– Remove pressure plate and clutch plate.
Installing
Note

♦ Clean splines of drive shaft and, if the clutch plate has been
used, clean the splines of the hub. Remove corrosion and ap‐
ply a very thin coat of clutch plate spline grease to splines.
Then, move the clutch plate back and forth on the drive shaft
until the hub moves easily on the shaft. Remove excess
grease.
♦ The friction surface of the clutch pressure plate and the fly‐
♦ If the clutch has burntagout,
en AGthoroughly
. Volkswagenclean
AG d the gearbox hous‐
ing in the clutchVoarea
lksw and the engine facing
oes
the
not gearbox in
order to reduce
sed by the smell of burnt linings. gu
ara
n
i tee
or
♦ Blow off
au dual mass flywheel with compressed air only. r a
th o
ss c
ce
e
nl
pt

du
an
itte
curing bolts.
y li
erm
ab
ility

ot p
wit

, is n
h re

hole
spec

es, in part or in w
t to the co

problems and possible noises from the gearbox (rattling of
rrectness of i
gears which are not engaged) could occur.

l purpos
• Installation position of clutch plate: lettering

nform
ercia
“Getriebeseite” (gearbox end) or spring cage faces pressure

plate.
m
at
om
ion
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or
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ate
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Prote AG.
2. Clutch 25

• Wear to half the thickness of the diaphragm spring -arrows- is
permitted.
Check spring connection and riveted fastenings.

– Check spring connection between thrust plate and cover for
cracks and make sure rivet fastenings are seated tightly.
– If pressure plate has damaged springs or loose rivet connec‐
tions -arrows-, it must be renewed.
Check extension springs and riveted connections

I - Extension springs OK.
duction status.
II - Extension springs damaged agen
AG. Volkswagen AG d
oes
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V
• Renew clutch pressure plate if springs are broken or badlyed by gu
ara
bent -arrow B-. horis nte
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– Check spring connections -arrows A- for damage, and
ss make c
ce
sure that rivet joints -arrows B- are firmly seated.
le
un
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an
d
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• Renew clutch pressure plate if spring connections are broken y li

erm
or badly bent, or if riveting is loose. ab

ility
ot p
wit
is n
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ole,
spec
t to the co

rrectne

s
• Renew clutch pressure plate if riveting -arrow B- is loose.

s o
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f inform
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Prote AG.

Check metal ring.

– Check that metal ring in clutch pressure plate -arrow- is not
damaged.
• Renew clutch pressure plate if metal ring is broken.
– To centre clutch plate, use centring mandrel - w3190

agen A- .
AG. Volkswagen AG d
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– Tighten all bolts alternately and diagonally
ed in small steps (1 full
by ara
turn). thoris nte
eo
au ra
– Install gearbox ⇒ Rep. gr. 34 ; Removing
ss and installing gear‐ c
ce
box .
le
un
pt
an
d
itte
Specified torques
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2. Clutch 27
AG. Volkswagen AG d
34 – Controls, housing
agen oes
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h
ut
1 Selector mechanism a ra
ss c
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nl
pt
The relevant description can be found in ⇒ Rep. gr. 34 ; Selector
du
an
itte
mechanism
y li
erm
ab
ility
ot p
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
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or c
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Prote AG.
28 Rep. gr.34 - Controls, housing

2 Removing and installing gearbox

The relevant description can be found in ⇒ Rep. gr. 34 ; Re‐
moving and installing gearbox .
AG. Volkswagen AG d
agen oes
olksw not
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d b ara
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un
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d
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ab
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ot p
wit
is n
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spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
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pr
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Prote AG.
2. Removing and installing gearbox 29

3 Transporting gearbox
♦ Gearbox lifting tackle - 3336-
AG. Volkswagen AG d
agen oes
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un
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ab
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♦ Workshop hoist - VAS 6100-
is n
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ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
– Bolt gearbox lifting tackle - 3336- to clutch housing.
te
sd
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pr
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fo
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t.
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Cop py
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rig ht
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co Vo
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Prote AG.
– Adjust support beam on sliding piece using locking pin

-arrow-.
Number of visible holes = 5.
– Lift gearbox using workshop crane and gearbox lifting tackle -
3336- .
– Set gearbox aside, for example in a transport container.

4 Gear oil
The relevant description can be found in ⇒ Rep. gr. 34 ; Gear
oil .
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
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un
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es, in part or in w
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nform
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Prote AG.
4. Gear oil 31
5 Securing to engine and gearbox sup‐

port
♦ Support clamp - VW 313-
♦ Retainer - VW 309-
♦ or support plate - VW 309 A-
lkswage es n
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♦ Gearbox support - VW 353- ss
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– Secure gearbox on gearbox support - VW 353- .

cial p
f inform
– Place drip tray underneath.

mer
atio
om
n
c
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Cop py
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AG. Volkswagen AG d
agen oes
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Golf 2017 ➤ , GolfdVariant
by
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ara 2019 ➤
e
Removed oris 5-speed manual gearbox 0A4 - Editionnte 01.2019
e
th or
au ac
ss
ce
le
6 Dismantling and assembling gearbox
un
pt
an
d
itte
y li
erm
⇒ “6.1 Schematic overview - gearbox”, page 33
ab
ility
ot p
⇒ “6.2 Assembly overview - gearbox”, page 35
wit
is n
h re
ole,
⇒ “6.3 Assembly overview - cover for gearbox housing and 5th
spec
gear”, page 36
t to the co
⇒ “6.4 Assembly overview - gearbox housing and selector mech‐
anism”, page 38
rrectne
⇒ “6.6 Assembly overview - shafts, differential, selector mecha‐
nism”, page 39
ss
⇒ “6.7 Assembly overview - selector forks”, page 40
o
cial p
f in
⇒ “6.8 Repairing selector forks”, page 41
form
mer
⇒ “6.9 Removing cover for gearbox housing and 5th gear”,
atio
m
page 44
o
n
c
i
or
n thi
e
⇒ “6.10 Dismantling and assembling gearbox”, page 50

t
sd
iva
o
pr
c
⇒ “6.11 Installing cover for gearbox housing and 5th gear”,
um
r
fo
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ng
page 62 yi
t.
Co
op py
Additional descriptions can be found in ⇒ Rep. gr. 34 ; Disman‐
. C rig
ht ht
rig
tling and assembling gearbox . py by
co Vo
by lksw
cted agen
6.1 Schematic overview - gearbox
Prote AG.
6. Dismantling and assembling gearbox 33

1 - 1st gear
2 - 2nd gear
3 - 3rd gear
4 - 4th gear
5 - 5th gear
6 - Gearbox housing cover
7 - Gearbox housing
8 - Selector mechanism
❑ (Selector forks)
9 - Reverse gear wheel
10 - Clutch housing AG. Volkswagen AG d
agen oes
olksw not
y V gu
11 - Input shaft d b ara
rise nte
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12 - Output shaft aut ra
c
ss
13 - Differential
ce
le
un
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an
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itte
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rm
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pe
ility
ot
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, is n
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es, in part or in w
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nform
mercia
a
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tion in
r
te o
thi
s
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Cop py
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by
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Prote AG.

6.2 Assembly overview - gearbox
I-
⇒ “6.3 Assembly overview -
cover for gearbox housing and
5th gear”, page 36
II -
gearbox housing and selector
mechanism”, page 38
III -
shafts, differential, selector AG. Volkswagen AG d
mechanism”, page 39 agen oes
olksw not
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b ara
III - rise
d
nte
⇒ “6.7 Assembly overview - se‐ ut ho eo
ra
lector forks”, page 40 ss a c
ce
le
un
III -
pt
an
d
⇒ “6.8 Repairing selector

itte
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rm
forks”, page 41
ab
pe
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es, in part or in w
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Cop py
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Prote AG.

6.3 Assembly overview - cover for gearbox housing and 5th gear
1 - Bolt
❑ Qty. 5
❑ For gearbox housing
cover
❑ 18 Nm
2 - Gearbox housing cover
❑ With magnet
⇒ page 37
AG. Volkswagen AG d
Note lksw
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not
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d by ara
♦ Please note that oil leaksooutris of
e nte
eo
the installed gearbox when
aut
h
the ra
cover for the gearboxs housing is
s c
ce
le
removed.
un
pt
an
d
itte
♦ Therefore, the gear oil must be
y li
erm
ab
drained and the gearbox refilled
ility
ot p
⇒ page 31 .
wit
is n
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ole,
3 - Seal
spec
❑ Renew if damaged
t to the co
4 - Bolt
❑ Renew after removal
rrectne
❑ Fitted section of bolt
head holds dished
ss
spring washer in posi‐
o
cial p
f
tion
inform
❑ Clean residual locking
mer
fluid from threaded

atio
m
holes for securing bolts

o
n
c
i
or
for 5th gear synchro-

thi
te
hub and for gear wheel

sd
iva
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r
for 5th gear using a

p
cum
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fo
thread tap. Otherwise

en
ng
t.
yi
the bolts may shear.
Co
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❑ 80 Nm and 90°
rig
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5 - Dished spring
lksw
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Prote AG.
❑ Installing ⇒ page 64
❑ For pivot pin to gearbox housing
❑ 25 Nm
7 - Pivot pin
8 - 5th gear selector fork
❑ Dismantling and assembling ⇒ page 41
9 - Spring
❑ Version with bent ends.
10 - Locking collar for 5th gear
❑ Fitting position ⇒ page 82
❑ Adjusting ⇒ page 65

11 - Locking pieces (Qty. 3)

12 - Synchro-hub with synchromeshed gear and synchronizing ring for 5th gear
❑ Pulling off together with gearboxAhousing ⇒ page 50
G. Volkswagen AG d
agen
❑ Pulling off individually ⇒ opage
lksw 44
oes
not
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❑ Dismantling and assembling
ris
ed ⇒ page 82 nte
tho eo
13 - Needle bearing
ss
au ra
c
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e
14 - Gear wheel for 5th gear

nl
pt
du
an
itte
❑ Pulling off together with gearbox housing ⇒ page 50
y li
erm
ab
❑ Pulling off individually ⇒ page 44
ility
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es, in part or in w
Cover for gearbox housing with magnet -A-
t to the co
Magnet can only be inserted in cover with recess -arrow-.
rrectness of i
With the cover fitted, the magnet is held in place by the bolt for
pivot pins of the selector fork for 5th gear.
l purpos
nform
mercia
at
om
ion
c
in t
or
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ate
do
priv
cum
for
en
ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

6.4 Assembly overview - gearbox housing and selector mechanism
1 - Countersunk bolt
❑ 25 Nm
2 - Flange shaft with compres‐
sion spring
⇒ Rep. gr. 39 ; Oil seals
❑ Assembling
⇒ page 112
3 - Torx socket head bolt
❑ For reverse shaft sup‐
port
❑ Self-locking
❑ 25 Nm
❑ For reverse shaft sup‐
port
❑ Self-locking
❑ 30 Nm
5 - O-ring
6 - Pivot pin
7 - Bolt
❑ 25 Nm
8 - Bolt
❑ 25 Nm agen
AG. Volkswagen AG d
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9 - Cap byV gu
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10 - Multi-point socket head aut
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bolt ss c
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nl
❑ For reverse shaft support

pt
du
an
itte

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ab
❑ 25 Nm
ility
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11 - Bolt
h re
hole
❑ 6 Nm
spec
es, in part or in w
12 - Gearbox neutral position sender - G701-

t to the co
❑ for vehicles with start/stop system

13 - Gearbox housing
rrectness of i
❑ Pull off together with 5th gear ⇒ page 50

l purpos
❑ Repairing ⇒ page 66
nform
ercia
14 - Clutch housing
m
at
om
ion
15 - Hexagon bolt
c
in t
or
his
e

at
do
riv
❑ 25 Nm and 90°
p
cum
for
en
ng
t.
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Cop py
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38
copy Vo
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Rep. gr.34 - Controls, housing cted agen
Prote AG.
16 - Selector shaft with selector shaft cover

❑ (Selector unit)
❑ Repairing ⇒ Rep. gr. 34 ; Dismantling and assembling gearbox; Assembly overview - selector unit
17 - Multi-point socket head bolt
❑ 25 Nm
6.5 Assembly overview - selector unit

The relevant description is located in ⇒ Rep. gr. 34 ; Dismantling
and assembling gearbox; Assembly overview - selector unit .
6.6 Assembly overview - shafts, differential, selector mechanism
1 - Differential
❑ Dismantling and assem‐
bling ⇒ page 112
2 - Seal
❑ Qty. 4
3 - Output shaft
❑ ⇒ page 89
4 - Reverse shaft support
❑ ⇒ page 107
5 - Reverse shaft
❑ ⇒ page 107
6 - Input shaft
❑ ⇒ page 75
. Volkswagen AG
a gen AG does
7 - Selector fork Volfor reverse
ksw not
gu
gear ed
by ara
nte
ris
❑ uDismantling
tho and assem‐ eo
ra
ss bling ⇒ page 41
a c
ce
le
❑ Fitting position
un
pt
an
⇒ page 50
d
itte
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pe
ility
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❑ 25 Nm
wit
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9 - Selector mechanism
spec
es, in part or in w
❑ (Selector forks)
t to the co
❑ Dismantling and assem‐

bling ⇒ page 41
rrectness of i
10 - Clutch housing
l purpos
11 - Hexagon nut
nform
ercia
❑ Qty. 4
m

a
com
tion in
❑ 25 Nm and 90°
r
te o
thi
s
12 - Flange shaft with compression spring

iva
do
r
rp
❑ Removing and installing ⇒ Rep. gr. 39 ; Oil seals

um
fo
en
ng
t.
❑ Assembling ⇒ page 112
yi Co
Cop py
t. rig
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Prote AG.

13 - Countersunk bolt
❑ 25 Nm
6.7 Assembly overview - selector forks
Note
♦ It is not necessary to dismantle the selector fork group in order

to dismantle and assemble detent segments, lock washers
and angular contact ball bearings.
♦ Servicing selector forks ⇒ page 41 .
1 - 5th gear selector segment

❑ Identification
⇒ page 42
❑ After lock washer is in‐
stalled, detent segment
must still rotate freely.
2 - Clamping washer
AG. Volkswagen AG d
❑ Renew after removal lksw
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❑ Removing ⇒ page 43 ed b ara
nte
ris
❑ Installing ⇒ page 43 ut
ho eo
ra
s a c
s
3 - 5th gear selector fork
ce
e
nl
pt
du
an
4 - Bolt
itte
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❑ 25 Nm ab
ility
ot p
5 - 5th gear selector jaw wit

, is n
h re
hole
6 - Angular contact ball bearing

spec
es, in part or in w
❑ Qty. 4
t to the co
❑ Removing ⇒ page 43
❑ Press inner race into
rrectness of i
outer race ⇒ page 43

l purpos
7 - Selector fork group with se‐

lector plate
nf
ercia
orm
8 - 1st/2nd gear selector seg‐

m
atio
m
ment
o
n in
or c
❑ Identification
thi
te
⇒ page 42
sd
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❑ After lock washer is in‐

o
m
f
en
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stalled, segment must

t.
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still rotate freely ht. Cop py
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rig ht
9 - Selector segment for 3rd py by
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and 4th gear
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❑ Identification ⇒ page 42
❑ After lock washer is installed, segment must still rotate freely

10 - Sliding piece
11 - Spring
12 - Selector fork for reverse gear
13 - Support for reverse gear selector fork
14 - Retaining ring
6.8 Repairing selector forks

Volkswagen AG
Special tools and workshopswagen AG. does
equipment required by Volk not
gu
ara
ed nte
ris
tho eo
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c
ss
ce
e
nl
pt
du
an
itte
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ab
ility
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wit
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es, in part or in w
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nf
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orm
m
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om
n in
or c
thi
te
sd
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Cop py
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co lksw
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Prote AG.
♦ Thrust plate - VW 402-

♦ Thrust piece - 3290/1-
♦ Assembly tool - 3301-
♦ Press tool - VW 431-
♦ Spacer sleeve - VW 472/2-
♦ Drift - 10 - 206-

♦ Release lever -
80-200-
♦ Assembly mandrel -
10-508-
AG. Volkswagen AG d
agen oes
olksw not
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d b ara
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♦ Tensioning device - utho eo
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2070- ss a c
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un
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es, in part or in w
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rrectness of i
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Identifying selector seg‐

ments
nform
ercia
Dimension -a-
m
1 - 1st and 2nd gear se‐

com
tio
lector segments =
n in
r
te o
11.4 mm
thi
s
iva
do
2 - 3rd and 4th gear se‐

r
rp
cum
fo
lector segments =
en
ng
t.
7.7 mm
yi Co
Cop py
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3 - 5th gear selector seg‐
gh ht
yri by
ments = 12.1 mm
cop Vo
by lksw
cted agen
Prote AG.

Removing lock washer

– Clamp selector fork in vice with protective jaw covers -B-.
– Lever off lock washer -A- in direction of arrow.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
Installing lock washer

itte
y li
rm
ab
– Press lock washer into groove of detent segment using socket
pe
ility
ot
and spinner handle.
wit
, is n
h re
hole
spec
Note
es, in part or in w
t to the co
After lock washer is installed, detent segment must still rotate
freely.
rrectness of i
l purpos
A - Spinner handle with 10 mm socket

B - Vice clamp
nform
ercia
Removing angular contact ball bearing

m
a
com
tion in
r
te o
thi
Note
s
iva
do
r
rp
cum
fo
When removing and installing angular contact ball bearing, do not en

ng
t.
yi
bend selector forks.
Co
Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.
Pressing inner race -A- of angular contact ball bearing into outer
race
Inner race must engage in outer race.

Pulling angular contact ball bearing into selector fork to stop

Depression in thrust piece - 3290/1- faces ball bearing.
Selector fork with detent segments installed

Dim. -a- (mm)
Selector fork for 1st/2nd gear 87.2 to 87.4
Selector fork for 3rd/4th gear 93.6 to 93.8
Selector segment assignment ⇒ page 42
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
ise
6.9 Removing cover for gearbox housing r nte
tho eo
u ra
and 5th gear s a c
s
ce
le
un
pt
Installing cover for gearbox housing and 5th gear ⇒ page 62 .
an
d
itte
y li
rm
ab
pe
ility
ot
Note wit
, is n
h re
hole
♦ Follow the work procedure described below if only the 5th gear
spec
has to be removed:
es, in part or in w
t to the co
♦ If the gearbox housing has to be removed, please refer to the

procedure
⇒ “6.10 Dismantling and assembling gearbox”, page 50 .
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
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cum
fo
en
ng
t.
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Cop py
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equipment required
AG. Volkswagen AG d
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♦ Gearbox support - VW 353-

h re
hole
spec
♦ Drift - VW 295-
es, in part or in w
t to the co
♦ Drift sleeve - VW 244 B-

♦ e.g. hot-air blower - V.A.G 1416-
rrectness of i

l purpos
♦ Stud - M 8 x 100 mm-

nform
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a
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tion in
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te o
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Cop py
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Prote AG.

AG. Volkswagen AG d
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es, in part or in w
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Cop py
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Prote AG.
♦ Support bridge - 30-211A-

♦ Thrust piece - 32 - 111-
♦ Thrust piece from assembly tool - T10030/4-
♦ Tube - VW 416 B-
♦ Puller - T10309-
♦ Two-arm puller - T10040-
♦ With puller hooks - T10040/2A-

AG. Volkswagen AG d
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♦ Support bridge - T10323-

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♦ Assembly tool - 3253/7-

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♦ Thrust piece - VW 433-

hole
spec
♦ Thrust plate - 40 - 105-

es, in part or in w
t to the co

– Remove clutch release lever and release bearing ⇒ page 11 .
rrectness of i
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nform
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at
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ion
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in t
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ate
do
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Cop py
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• Bearings of input shaft and output shaft must not be damaged

when 5th gear is removed and installed.
• Therefore, the following tools must be mounted for support at
this stage during attachment of gearbox to gearbox support -
VW 353- :
Underneath input shaft:
AG. Volkswagen AG d
♦ Press tool - T10030/4- agen oes
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• The input shaft can be supported by the thrust piece
rise
d
- 32 - 111- nte
only at a later point. autho eo
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Underneath bearing support for output shaft:
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es, in part or in w
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– Remove gearbox housing cover -arrow-.
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
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rp
cum
– Check whether puller hooks - T10040/2A- can be inserted
fo
en
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correctly under 5th gear wheel.

t.
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-A- Removal of “synchro-hub Prote
cted AG.
agen
puller hooks - T10040/2A- make for 5th gear”, “gear wheel
contact prematurely with: for 5th gear” and “gearbox
♦ gearbox housing wall housing” “together”
⇒ page 50
♦ ribs in gearbox housing under
gear wheel
-B-
puller hooks - T10040/2A- come
into contact with ribs in gearbox
housing below gear wheel.
Puller hooks - T10040/2A- cannot be inserted correctly.

5th gear can be removed separately, ⇒ from ⇒ page 49

Removing 5th gear separately

– Cover openings with a cloth.
– Move selector fork -1- to neutral position.
– Remove bolt -2- with selector fork for 5th gear.
– Then remove both bolts -arrows- for pivot pins.
– Pull out pivot pins.
– Remove selector fork.
– Spring -3- and locking collar -4- do not need to be removed.
– Remove bolts -A- for synchro-hub and 5th gear wheel. To do

so, engage 5th gear -arrow 1- and 1st gear -arrows 2- and
-3-.
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– Input shaft and output shaft are locked when both gears arey Vo lks ot g
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engaged. Both bolts can now be loosened. ir se
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Note
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If the shafts are to be reused, carefully clean residual locking ma‐
rm
ab
terial out of threaded holes using a thread chaser.
pe
ility
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Pull off synchro-hub for 5th gear together with locking collar and
hole
spec
locking pieces
es, in part or in w
t to the co
Use puller - T10309- .
– First set half sleeve - T10309/1- between 5th gear wheel -A-
rrectness of i
and support for selector fork for 5th gear -B-.
l purpos
• Half sleeve - T10309/1- must be positioned beneath synchro-

ring.
nform
ercia
– If necessary, half-sleeve must be pressed to end position.

m
a
– Turn half sleeve - T10309/1- in -direction of arrow- to opposite
com
tion in
side.
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Prote AG.

– Insert threaded insert - T10309/3- into half sleeve .

– Now, install second half-sleeve - T10309/1- , and fit tube -
T10309/2- onto assembly.
– After pulling off synchro-hub, examine for damage.
– Renew synchro-ring.
– Remove 5th gear synchromeshed gear with needle bearing.
AG. Volkswagen AG d
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– Pull off gear wheel for 5th gear. (Shown here on another gear‐
h re
ole,
box.)
spec
– First insert puller hook -A-.
t to the co
B - Thrust plate - 40 - 105-
Note rrectness o
When pulling off gear wheel, ensure that hooks do not bend out‐
cial p
f in
wards. After pulling off 5th gear wheel, examine for damage.
form
mer
atio
m
⇒ “6.11 Installing cover for gearbox housing and 5th gear”,

o
n
c
page 62
i
or
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6.10 Dismantling and assembling gearbox

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Removing and installing gearbox housing cover, gearbox hous‐
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equipment required
AG. Volkswagen AG d
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spec

es, in part or in w
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♦ Gearbox support - VW 353-

♦ Pin - VW 295-
rrectness of i
♦ Drift sleeve - VW 244 B-

l purpos
♦ e.g. hot-air blower - V.A.G 1416-

nf
ercia

orm
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♦ Stud - M 8 x 100 mm-

atio
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Cop py
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Prote AG.

AG. Volkswagen AG d
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ris nte
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un
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rm
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es, in part or in w
t to the co
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tion in
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Cop py
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Prote AG.

♦ Thrust piece from assembly tool - T10030/4-
♦ Tube - VW 416 B-
♦ Puller plate - T10408-
♦ Press pieces - T10408/2-
♦ Grips - T10408/3-

♦ Hexagon bolts M7 x 35 with washers olkswage es n
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♦ Puller - VAS 251 417- , or e.g. rpuller
ised - Kukko 18/1- ran
tee
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Prote AG.

♦ Drip tray - V.A.G 1306-
♦ or drip tray for workshop hoist - VAS 6208-
Dismantling gearbox
– Remove clutch release lever, release bearing and guide
sleeve ⇒ page 11 .

• Bearings of input shaft and output shaft must not be damaged

when 5th gear is removed and installed.
• Therefore, the following gtools
AG.must
Volkswbe
agemounted
n Gd for support at
a en of gearbox A
this stage during attachment to gearbox
not support -
oes
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VW 353- : ed
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Underneath ainput
ut
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♦ Press tool - T10030/4-
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– Lock bolt of support bridge - 30-211A- with nut -A-.
h re
hole
spec
Underneath bearing support for output shaft:
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
– Place drip tray underneath.

m
at
– Remove oil filler plug and oil drain plug.
om
ion
c
in t
r
– Drain gear oil.

o
his
ate
do
riv
– Remove gearbox housing cover -arrow-.

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Prote AG.
Remove selector fork for 5th gear as follows:

– Cover openings with a cloth.
– Move selector fork -1- to neutral position.
– Remove bolt -2- with selector fork for 5th gear.
– Then remove both bolts -arrows- for pivot pins.
– Pull out pivot pins.
– Remove selector fork.
– Spring -3- and locking collar -4- do not need to be removed.
– Remove bolts -A- for synchro-hub and gear wheel for 5th gear.
To do this, engage 5th gear -arrow 1- and 1st gear
-arrows 2- and -3-.
– Input shaft and output shaft are locked when both gears are
engaged. Both bolts can now be loosened.
Note
If the shafts are to be reused, carefully clean residual locking ma‐

terial out of threaded holes using a thread chaser.

– Remove both bolts -arrows- for reverse shaft support bracket.
– Now remove 3rd bolt -arrow- for reverse shaft support bracket.
AG. Volkswagen AG d
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– Gearboxes for vehicles with start-stop system: remove gear‐
es, in part or in w
t to the co
box neutral position sender - G701- -arrow-.
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
or
– Remove selector shaft with selector mechanism cover, placing

f
en
ng
t.
selector shaft in neutral position. Then remove bolts -arrows-
yi Co
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and pull selector shaft out of gearbox housing. t. C rig
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– Remove cover plate -A- and pivot pins -B- from underside of
gearbox.
AG. Volkswagen AG d
agen oes
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ab
ility
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– Remove pivot pins -A- on top side of gearbox and securing
hole
spec
bolts -B- for gearbox housing to clutch housing in area of dif‐
es, in part or in w
ferential.
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
– Remove bolts -A- from clutch housing side for securing clutch
do
priv
housing to gearbox housing.

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Do not remove nuts -B- for output shaft bearing support.
agen
Prote AG.
– Remove both flange shafts.

– Remove flange shafts together with springs, thrust washers
and tapered rings.

Pull off following components together with gearbox housing:

♦ Synchro-hub for 5th gear
♦ Gear wheel for 5th gear
• Both fish plates - T10408/3- must be secured on gear wheel
for 5th gear.
• The grips must always be positioned above the two housing
ribs, which are located opposite each other -arrows-.
Note
AG. Volkswagen AG d
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♦ There is a needle bearing beneath
Vothe
lksw gear wheel for 5th gear.
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not
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♦ Secure the grips so that the
or bearing does not come in contact
ise tee
with the gear wheel for 5th
au
th gear when the gearbox housing is or
ac
pulled off. ss
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un
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Use extractor plate - T10408- in conjunction with following special
erm
ab
tools:
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♦ Press pieces - T10408/2-
h re
ole,
spec
♦ Grips - T10408/3-
t to the co
♦ Puller - VAS 251 417- , or e.g. puller - Kukko 18/1-
– Secure removal plate - T10408- firmly using threaded holes
for gearbox housing cover.
rrectne
A - Hexagon bolts M7 x 35 with washers
ss
Tightening torque 18 Nm
o
cial p
f inform
– Place pressure pieces - T10408/2- onto shafts.
mer
atio
om
– Mount puller - VAS 251 417- or e.g. puller - Kukko 18/1- -A-.
n
c
i
or
n thi
e
– Pull off 5th gear synchro-hub, gear wheel for 5th gear and
t
sd
va
gearbox housing by alternately tightening spindles -A- approx.

i
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12 turn.
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– If necessary, heat gear wheel for 5th gear slightly using hot air Cop py
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blower - V.A.G 1416- , for example. opyri
gh by
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– Remove nuts -B- for output shaft bearing support.
AG. Volkswagen AG d
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– Remove selector forks -A- together with selector plates.
rm
ab
pe
ility
ot
– Unbolt reverse gear selector mechanism -B-.
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
– Remove reverse gear -A-, input shaft -B- and output shaft
a
com
tio
-C- one after the other from clutch housing.
n in
r
te o
thi
– Remove differential.
s
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Assembling gearbox
um
fo
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t.
– Install differential.
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Cop py
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rig ht
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Prote AG.
– Renew seals -arrows- for output shaft bearing mounting after

removal.
Note
The figure shows only 3 of the 4 seals.

– Insert input shaft -1- and output shaft -2- together.

– Tighten nuts for output shaft bearing support.
– Place reverse gear wheel -3- on needle bearing in clutch
housing.
The shoulder -arrow- faces away from the clutch housing.
– Check whether reverse shaft -4- is complete ⇒ page 108 ; Do
not fit reverse shaft support on reverse shaft yet.
– Fit reverse shaft into clutch housing.
– Clean locking fluid from all threaded holes in reverse shaft
support; a thread chaser may be used.
– Install reverse shaft support.
– Attach reverse gear selector fork -1- with support for reverse
gear selector fork -2-, spring -3- and sliding piece -4-.
lkswage es n
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Installation position, reverse gear

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– Bolt on reverse gear selector mechanism -A-.

nform
ercia
– Install selector forks -B- together with selector plates.

m
at
om
io
Reverse gear support pin -C- is located in front of selector rods.

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ate
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– Screw M8 x 100 mm studs -A- into reverse shaft support so

that shaft is aligned after gearbox housing is fitted.
– Align selector plates.
Note
The detent segments must be positioned in the grooves on the

locking collars.
– Apply sealant evenly to sealing surface of clutch housing.

– Fit gearbox housing.
Install reverse shaft support bolts -arrow- as follows:
– Install bolt -a-.
– Remove stud -A- (⇒ figure above).
– Install bolt -c-.
Tightening sequence:
– Tighten bolt -a- (see illustration above).
– Tighten bolt -b-. n AG. Volkswagen AG do
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– Tighten bolt -c- (see illustration above). ir se
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– Install pivot pin -arrow- for selector forks. Do this by aligning

spec
selector mechanism with a screwdriver so that respective pivot

es, in part or in w
t to the co
pin can be installed.

– Apply sealant evenly to sealing surface of sealing cover.
rrectness of i
– Fit selector shaft cover.

l purpos
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orm
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Rep. gr.34 - Controls, housing
Install selector shaft with selector shaft cover plate as follows:

– Place selector plates in neutral.
– Apply sealant evenly to sealing surface of selector mechanism
cover.
– Move selector shaft to neutral.
– Position selector shaft so that selector finger -arrow- is inser‐
ted in selector plates.
– Install and secure selector shaft cover.
– Gearbox for vehicles with start/stop system: install gearbox

neutral position sender - G701- -arrow- and tighten securing
bolt.
– Install both flange shafts with compression springs, thrust

washers and tapered rings ⇒ page 112 .
Specified torques
AG. Volkswagen AG d
♦ ⇒ “6.4 Assembly overview - gearbox housing and waselector
gen oes
olks not
mechanism”, page 38 db
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♦ Nuts for output shaft bearing mountingut
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ra
⇒ “6.6 Assembly overview - shafts,ssdifferential, selector mech‐
a c
anism”, page 39
ce
e
nl
pt
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♦ Flange shaft to gearbox (countersunk bolt)

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erm
⇒ “2.1 Assembly overview - differential”, page 112

ab
ility
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Installing cover for gearbox housing and 5th gear ⇒ page 62 .

wit
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es, in part or in w
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AG. Volkswagen AG d
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6.11 Installing cover Vol for gearbox housing and
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5th gearthori ed ran
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For special tools required,
ss refer to procedure for “Removing gear‐
box housing cover and 5th gear” ⇒ page 44 .
ce
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un
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an
d
itte
• Ensure that support bridge - 30-211A- and support - T10323-
y li
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ab
are attached.
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– Lock bolt of support bridge - 30-211A- with nut -A-.
is n
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t to the co
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cial p
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mer
atio
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n
c
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Installation position, 5th gear wheel
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The circumferential groove -arrow- faces gearbox housing.
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– Heat gear wheel for 5th gear to about 100 °C with inductive
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heater - VAS 6414- before installing.
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Prote AG.
WARNING
Wear protective gloves.
– Drive on gear wheel for 5th gear.

Checking 5th gear synchro-ring

– Press synchro-ring onto cone of synchromeshed gear, and
measure gap -a- at 3 points offset by 120° using a feeler
gauge.
– Make a note of average value.
Gap -a- Installation dimen‐ Wear limit
sion
5th gear 1.1 - 1.7 mm 0.5 mm
– Install 5th gear synchromeshed gear with needle bearing.
– Place 5th gear synchro-ring on synchromeshed gear.
– If synchro-hub and locking collar for 5th gear are dismantled,
assemble before installing ⇒ page 82 .
Installation position 5th gear synchro-hub and locking collar

The pointed teeth of the locking collar -arrow 1- and the high
shoulder of the synchro-hub -arrow 2- face the gearbox housing.
The synchro-hub supports -arrow 3- align with the cast locking
pieces of the 5th gear synchro-ring ( ⇒ page 63 , bottom).
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5th gear synchro-ring with cast locking pieces y Volks ot g
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– Cover all openings in gearbox housingthowith
ris a cloth to prevent tee
or
foreign bodies from entering gearbox.
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– Drive on 5th gear synchro-hub.

rrectnes
Note
s o
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When driving on, ensure that synchro-ring moves freely.

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01.2019 oes
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– Unfasten support for input shaft. rise nte
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Wear protective gloves.
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Clean residual locking fluid from threaded holes for securing bolts
ole,
spec
for synchro-hub and for 5th gear wheel with a thread chaser.
t to the co
Otherwise the bolts may shear.
– Screw in securing bolts for synchro-hub and gear wheel for 5th
gear.
rrectness o
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mer
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Installation position of dished springs for securing bolts for gear

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wheel and synchro-hub for 5th gear

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The outer circumference -arrows- faces 5th gear.
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– Tighten securing bolts -A- for synchro-hub and gear wheel for
5th gear. To do this, engage 5th gear -arrow 1- and 1st gear
-arrows 2- and -3-.
– Input shaft and output shaft are locked when both gears are
engaged. Now both bolts can be tightened.
– Install 5th gear selector fork.

Adjusting 5th gear

– Engage 5th gear. Loosen bolt -1-. Press locking collar and se‐
lector jaw in direction of arrow. Then tighten bolt -1- to 25 Nm.
• Check measurement: it must not be possible to slide a 0.2 mm
feeler gauge between locking collar and gear wheel. If neces‐
sary, repeat adjustment.
– Disengage 5th gear. Locking collar must now be in the neutral
position. Synchro-ring must move freely.
– Shift through all gears. wage
es n
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– Install gearbox housing cover ⇒ page 36 . ed by ua
ran
ir s tee
o
– Fit release bearing guide sleeve ⇒ pageau 10 .
th or
ac
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– Fit clutch release lever and release bearing ⇒ page 11 .
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– Fill with gear oil ⇒ Rep. gr. 34 ; Gear oil .

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Specified torques
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♦ ⇒ “6.3 Assembly overview - cover for gearbox housing and 5th
h re
gear”, page 36
hole
spec
es, in part or in w
♦ 5th gear selector jaw
t to the co
⇒ “6.7 Assembly overview - selector forks”, page 40 .
rrectness of i
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Golf 2017 ➤ d by, Golf Variant 2017 ➤ , Polo 2018gu➤
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Removed horis5-speed manual gearbox 0A4 - Edition 01.2019 eo
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7 Gearbox housing, clutch housing
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⇒ “7.1 Assembly overview - gearbox housing and clutch housing”,
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⇒ “7.2 Repairing gearbox housing”, page 68
hole
spec
⇒ “7.3 Repairing clutch housing”, page 73
es, in part or in w
t to the co
7.1 Assembly overview - gearbox housing and clutch housing
rrectness of i
1 - Gearbox housing
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❑ Modified output shaft

roller bearing
nf
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❑ When renewing ⇒ ad‐

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justment overview
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⇒ page 123
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2 - Roller sleeve
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bearing with retaining cted agen
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ring
❑ Identifying roller bearing
for output shaft in gear‐
box housing
⇒ page 68
roller bearing without re‐
taining ring
⇒ page 69 .
roller bearing with re‐
taining ring
⇒ page 70 .
3 - Oil filler plug
❑ The oil level cannot be
checked by removing
the oil filler plug
❑ If the gearbox was dis‐
mantled, it must be filled
prior to installation
❑ Capacity of manual
gearbox (gearbox com‐
pletely dismantled)
♦ 2.0 l
❑ Capacity of manual gearbox (gearbox partially dismantled) ⇒ page 31
♦ 1.8 litre
❑ 35 Nm
4 - Tapered roller bearing outer race
❑ ⇒ page 92
❑ If replaced: Adjust output shaft ⇒ page 102 .
5 - Shim

❑ Adjustment overview ⇒ page 123
6 - Shim
❑ For input shaft
❑ Adjustment overview ⇒ page 123
❑ For input shaft
❑ Removing and installing ⇒ page 77
❑ If renewed: adjust input shaft ⇒ page 83
❑ For input shaft
❑ If renewed: adjust input shaft ⇒ page 83
9 - Needle bearing
10 - Dowel sleeve
❑ Qty. 2
11 - Clutch housing
❑ When renewing ⇒ adjustment overview ⇒ page 123
12 - Guide bush
❑ With input shaft seal and vulcanised AGO-ring
. Volkswagen AG
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❑ To remove and install, remove olksw gearbox not
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❑ Renew seal after each ris removal
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❑ Driving out oil seal
s aut ⇒ page 88 . ra
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❑ Driving in oil seal ⇒ page 88 .
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❑ Remove guide sleeve to change oil seal

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❑ If O-ring is damaged, renew guide sleeve and O-ring together

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14 - Seal with sleeve

es, in part or in w
t to the co
❑ Renew seal and sleeve together after removal

❑ Renewing ⇒ page 73
rrectness of i
15 - Oil drain plug

l purpos
❑ 35 Nm
nform
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❑ For differential
m
at
❑ Pressing in and out ⇒ page 112

om
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❑ If renewed, adjust differential ⇒ page 119

in t
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17 - Solenoid
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❑ Held in place by housing joint surface

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18 - Oil collector Cop py
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❑ Installing oil collector in gearbox housing ⇒ page 68
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❑ Pressing in and out ⇒ page 112
❑ If renewed, adjust differential ⇒ page 119
7. Gearbox housing, clutch housing 67

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20 - Shim byV
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❑ For differential horis nte
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❑ Adjustment overview ⇒ page 123 ss a c
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21 - Seal
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❑ Renew after removing ⇒ Rep. gr. 39 ; Oil seals; Renewing left oil seal
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7.2 Repairing gearbox housing hole
spec
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⇒ “7.2.1 Identifying output shaft bearing in gearbox housing”,
t to the co
page 68
⇒ “7.2.2 Removing and installing roller bearing without retaining
rrectness of i
ring”, page 69
l purpos
⇒ “7.2.3 Removing and installing roller bearing with retaining

ring”, page 70
nform
ercia
Installing oil collector -A- in gearbox housing

m
– Insert oil collector in hole -arrow 1- and groove -arrow 2- si‐
a
com
tio
multaneously.
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7.2.1 Identifying output shaft bearing in gear‐
box housing
The following roller bearings for the output shaft are installed:
Roller bearing -1- without retaining ring
A - Gearbox housing with shoulder for outer race
B - Outer race for roller bearing
Removing and installing roller bearing without retaining ring
⇒ page 69 .

AG. Volkswagen AG d
agen oes
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Golf 2017 b➤ y V, Golf Variant 2017 ➤ , Polo 2018
ol
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tho eo
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Roller bearing -1- with retaining ring
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A - Gearbox housing with groove for retaining ring
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B - Retaining ring for roller bearing
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Removing and installing roller bearing with retaining ring
, is n
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⇒ page 70 .
hole
spec
es, in part or in w
t to the co
Note
Allocation of gear oil and roller bearing via ⇒ Electronic parts
rrectness of i
catalogue (ETKA) .
l purpos
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7.2.2 Removing and installing roller bearing

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♦ Pin - VW295-
by lksw
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♦ Thrust pad - VW 447 H-

♦ Thrust pad - VW 512-
Driving out roller bearing

without retaining ring
Driving in roller bearing without retaining ring onto stop

– Secure roller bearing in gearbox housing at three points (120°
offset) using a punch.
AG. Volkswagen AG d
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7.2.3 Removing and installing roller bearing with retaining ring ol not
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equipment required
AG. Volkswagen AG d
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♦ Press tool - VW407-

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t to the co
♦ Press tool - VW412-

♦ Thrust piece from assembly tool - 3301-
rrectness of i
♦ Assembly tool - 3346-

l purpos
♦ Tube - 30-14-
nform
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♦ Press tool - 30-506B-

m
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♦ Thrust plate - VW402-

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♦ Thrust piece - VW442-
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♦ Thrust piece - 3051-
hole
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Removing roller bearing
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with retaining ring
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– When pulling out roller bearing -1-, press together retaining
ring -2- with pliers.

Pressing in roller bearing with retaining ring

– Place gearbox housing in area of roller bearing on tube -
30-14- .
– Press together retaining ring and press in roller bearing until
retaining ring clips into annular groove.
7.3 Repairing clutch housing
AG. Volkswagen AG d
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♦ Puller - VW 228 B- (is not required for this gearbox) Prote AG.

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Golf 2017 ➤ , Golf Variant 2017 ➤ , Polo 2018 d ➤ , T-Cross 2019 ➤
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Removed 5-speed manual gearbox 0A4 - thEdition 01.2019
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♦ Drift - VW 222 A- (not required with this gearbox)
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♦ Assembly device - 3066- (Spindle from assembly device)
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♦ Thrust piece - 3124- (not required with this gearbox)
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♦ Multi-purpose tool - VW 771-
h re
hole
spec
♦ Extractor hook - VW 771/37-
es, in part or in w
t to the co
♦ Thrust piece -
T10148-
rrectness of i
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There is a shoulder in the Prote AG.
inner diameter of the
sleeve.
– Place puller hooks -
VW 771/37- behind
shoulder in sleeve.
– Press extractor
hooks - VW 771/37-
forcefully into sleeve
while pulling.
Pulling in sleeve and seal

– Clean seat for seal in gearbox.
– Screw spindle -A- of assembly tool - 3066- into threaded piece
of differential.
– Pull in sleeve to stop using thrust piece - T10148- by turning
nut -B-.
Note
With gearbox dismantled, press sleeve in to stop using thrust

piece - T10148- .

35 – Gears, shafts
1 Input shaft
⇒ “1.1 Assembly overview - input shaft”, page 75
⇒ “1.2 Dismantling and assembling input shaft”, page 77
⇒ “1.3 Adjusting input shaft”, page 83
⇒ “1.4 Renewing input shaft seal”, page 87
1.1 Assembly overview - input shaft
Note
♦ When installing new gears or new input shaft, refer to ⇒ Electronic parts catalogue (ETKA) and technical
data.
♦ If the position of the tapered roller bearings is affected when parts are exchanged, the input shaft must be
readjusted. See adjustment overview ⇒ page 123 .
1 - Clutch housing
2 - Tapered roller bearing outer
race
❑ Pressing out
⇒ page 79 .
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❑ Pressing in lksw
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⇒ page 79 . by
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3 - Tapered roller bearing
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race ss
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❑ Pressing off
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⇒ page 79
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❑ Pressing on
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⇒ page 79
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4 - Input shaft
h re
hole
spec
es, in part or in w
t to the co
5 - Gear wheel for 3rd gear

❑ Installation position:
shoulder faces towards
rrectness of i
4th gear
l purpos
❑ Pressing off
⇒ page 80
❑ Pressing on
nform
ercia
⇒ page 80
m
at
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6 - Retaining ring
on
c
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❑ Pressing off with ta‐

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pered roller bearing out‐
Co
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⇒ page 80 p by
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❑ Pressing on
agen
Prote AG.
⇒ page 80
❑ Collar faces 3rd gear
1. Input shaft 75
8 - Tapered roller bearing inner race

❑ Pressing off with gear wheel for 4th gear and sleeve ⇒ page 80
❑ Pressing on ⇒ page 81
9 - Thrust washer
❑ Pressing out ⇒ page 81 .
❑ Pressing in ⇒ page 81 . AG. Volkswagen AG d
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11 - Shim by
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❑ Determining thickness ⇒ page horis 83 nte
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12 - Gearbox housing ss c
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13 - Sleeve
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❑ For needle bearing
erm
ab
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❑ Press off with gear wheel for 4th gear and tapered roller bearing inner race ⇒ page 80
ot p
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❑ Fit thrust washer before installing
spec
es, in part or in w
14 - Needle bearing
t to the co
15 - Synchromeshed gear, 5th gear
rrectness of i
16 - Synchro-ring for 5th gear
❑ With cast locking pieces ⇒ page 63
l purpos
❑ Check for wear ⇒ page 63
nform
ercia
17 - Spring
m
❑ Installation position ⇒ page 82 and ⇒ page 82 .
at
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18 - Locking pieces (Qty. 3)

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19 - Synchro-hub for 5th gear

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Co
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20 - Locking collar for 5th gear
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❑ Pull off with synchro-hub for 5th gear, from ⇒ page 44 Prote
cted AG.
agen
21 - Dished spring
22 - Bolt
❑ Fitted section of bolt head holds dished spring in position ⇒ page 64
❑ Specified torque ⇒ page 36
76 Rep. gr.35 - Gears, shafts

1.2 Dismantling and assembling input shaft

equipment required
AG. Volkswagen AG d
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♦ Thrust plate - VW 447 H-

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♦ Tube - VW 422-
n
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♦ Pressure plate - VW 401-
t. C rig
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♦ Pressure plate - VW 402- by c lksw
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♦ Press tool - VW 408 A-
1. Input shaft 77
AG. Volkswagen AG d
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♦ Tube - VW 421- hor eo
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♦ Thrust piece - VW 454- s
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♦ Thrust plate - VW 447 i-

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♦ Drift sleeve - 41-501-

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♦ Do not apply: tools 1-4

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Rep. gr.35 - Gears, shafts Prote
cted AG.
agen
♦ Splitter - VAS 251

409- or e.g. splitter -
Kukko 17/1-
Pressing out tapered

roller bearing outer race
Pressing in tapered roller bearing outer race
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Pressing off tapered roller bearing inner race
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spec
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Pressing on tapered roller bearing inner race

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Cop py
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1. Input shaft 79
Pressing off gear wheel for 4th gear with tapered roller bearing
and sleeve
AG. Volkswagen AG d
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Pressing off gear wheel for 3rd gear
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Pressing on gear wheel for 3rd gear
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Pressing on gear wheel for 4th gear

Shoulder faces 3rd gear

Pressing on tapered roller bearing inner race
Pressing on sleeve for needle bearing
AG. Volkswagen AG d
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Pressing out tapered roller bearing outer race

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es, in part or in w
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Pressing in tapered roller bearing outer race

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thi
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– Install with shim after adjusting input shaft.

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1. Input shaft 81
5th gear synchronization

1- Springs for lock pieces
olkswagen AG
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2- Locking collar with 3 recesses -arrows A- for othe
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3- Synchro-hub autho eo
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4- Locking pieces - installation position: thin extension
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es, in part or in w
t to the co
rrectness of i
l purpos
Assembling 5th gear locking collar/synchro-hub
nform
ercia
– Slide locking collar over synchro-hub.

m
at
om
Pointed teeth -A- and shoulder -B- of synchro-hub face in same
ion
c
direction. The recesses for the locking pieces in locking collar and
in t
or
synchro-hub must be aligned ( ⇒ page 82 ).
his
ate
do
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– Insert locking pieces (installation position ⇒ page 82 ).

p
cum
for
en
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– Install springs offset by 120° below shoulder -C- of the locking op
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piece.
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Installation position of springs in case of solid locking pieces: cop Vo
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Prote
Springs must seat with angled end in front of locking piece
AG.
-arrows-.
Installation position of springs in case of hollow locking pieces:
– Angled end of spring must locate in hollow locking piece
⇒ page 83 .
Installing springs with bent ends -A-

These springs are installed on both sides.
– Spring are installed only in conjunction with hollow locking
pieces.
– Insert locking pieces (installation position ⇒ page 82 ).

Installation position of springs

– Install springs offset 120°.
– Angled end -A- of spring must locate in hollow locking piece.
It must be located under shoulder -B- of locking piece.
Bent ends always face away from synchro-hub
-direction of arrow-.
1.3 Adjusting input shaft

equipment required
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Cop py
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♦ Universal dial gauge holder - VW 387-
by lksw
cted agen
Prote AG.
♦ End measuring plate - VW 385/17-
♦ Thrust plate - VW 447 i-
1. Input shaft 83

♦ Dial gauge
It is necessary to readjust the input shaft only when the following
components are renewed:
♦ Gearbox housing
♦ Clutch housing
♦ Input shaft
♦ Gear wheel for 4th gear
or the
♦ Tapered roller bearing
Adjustment overview ⇒ page 123
Requirement:
• Sealing surfaces of clutch and gearbox housings must be free
of sealant .
– Press tapered roller bearing outer race into gearbox housing
to stop.
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– Press tapered roller bearing outer race without shim into gear‐
ility
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box housing onto stop.

wit
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– Install input shaft in clutch housing and set gearbox housing

hole
spec
in place. Tighten hexagon bolts ⇒ page 38 .

es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
m
– Fit measuring appliance and dial gauge in clutch housing.

o
n in
or c
thi
– Before taking any measurements, rotate input shaft to allow

te
sd
a
bearings to settle. Set dial gauge to “0” with 1 mm preload.

iv
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op
Note C py
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Repeat this step for each subsequent measurement, or the dial by c lksw
cted agen
gauge will not return to the starting position. Prote AG.

– Press input shaft in direction of dial gauge

-direction of arrow-.
– Read and note play on dial gauge (example: 1.21 mm).
Note
Dial gauge does not return to original position.
Determining thickness of shim

Example:
Bearing play, measured value Thickness of shim according to
table
1.21 mm 1.175 mm
AG. Volkswagen AG d
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Cop py
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Prote AG.
1. Input shaft 85
Table of shims
Bearing play Shim
Measured value (mm) Thickness (mm)
0.671 … 0.699 0.650
0.700 … 0.724 AG. Volksw0.675
agen A
0.725 … 0.749 lkswagen 0.700G does no
o t gu
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0.750 … 0.774 db 0.725 ara
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0.775 … 0.799
thor 0.750 eo
0.800 …s 0.824
au 0.775 ra
c
s
0.825 … 0.849 0.800
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0.850 … 0.874 0.825
an
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0.875 … 0.899 0.850
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0.900 … 0.924 0.875
ility
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0.925 … 0.949 0.900
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0.950 … 0.974 0.925
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hole
spec
0.975 … 0.999 0.950
es, in part or in w
1.000 … 1.024 0.975
t to the co
1.025 … 1.049 1.000
1.050 … 1.074 1.025
1.075 … 1.099 1.050
rrectness of i
1.100 … 1.124 1.075
l purpos
1.125 … 1.149 1.100

1.150 … 1.174 1.125
1175 … 1.199 1.150
nf
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orm
1.200 … 1.224 1.175
m
atio
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1.225 … 1.249 1.200

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c
1.250 … 1.274, 1.225

or
thi
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1.275 … 1.229 1.250

t
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1.300 … 1.324 1.275

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1.325 … 1.349 1.300

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t.
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1.350 … 1.374 1.325
Co
Cop py
1.375 … 1.399 1.350
t. rig
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1.400 … 1.424 1.375
p by
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by c lksw
cted
1.425 … 1.449 1.400
agen
Prote AG.
1.450 … 1.474 1.425
1.475 … 1.499 1.450
1.500 … 1.524 1.475
1.525 … 1.549 1.500
1.550 … 1.574 1.525
1.575 … 1.599 1.550
1.600 … 1.624 1.575
1.625 … 1.649 1.600
1.650 … 1.674 1.625
1.675 … 1.699 1.650
1.700 … 1.724 1.675
Note
Allocate shims using ⇒ Electronic parts catalogue (ETKA) .
– Remove input shaft and press outer race of tapered roller

bearing out of gearbox housing using thrust plate - VW 447 i- .
– Insert shims of determined thickness, thickest shim first.
If the size of shim required is larger than those listed in the table,
insert two shims totalling the correct figure.
– Press outer race of tapered roller bearing together with the
shim (1.175 mm in example) into gearbox housing using thrust
pad - VW 510- .

– Fit gearbox housing and tighten hexagon bolts.

Carrying out check measurement
– Set up measuring appliance and dial gauge.

– Rotate input shaft so that tapered roller bearings settle.
– Press input shaft in -direction of arrow-.
– Bearing play should be min. 0.01 … max. 0.09 mm.
Note
If the bearing play cannot be measured, but input shaft play is

perceptible and the input shaft turns freely, the adjustment is ac‐
ceptable.
Specified torques
♦ Gearbox housing to clutch housing ⇒ page 38
1.4 Renewing input shaft seal
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♦ Pin - VW 295-
hole
spec
♦ Adapter - VW 295 A-
es, in part or in w
t to the co

♦ Tube - 2040-
rrectness of i
♦ Sealing grease
l purpos

nform
ercia
♦ Thrust pad - VW 447 H- and thrust pad - VW 512- are not

needed
m
a
com
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– Remove manual gearbox.

n in
r
te o
thi
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Cop py
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Prote AG.
1. Input shaft 87
– Remove clutch release lever together with release bearing

and guide sleeve ⇒ page 11 .
Driving oil seal out of guide sleeve
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– Half-fill space between sealing lip and dust lip -arrow- with
h re
hole
sealing grease .
spec
es, in part or in w
– Lightly moisten outer circumference of oil seal with gear oil.
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
e
Driving oil seal into guide sleeve to stop

at
do
priv
c
– Install clutch release lever with release bearing and guide
um
for
en
g
sleeve ⇒ page 11
n
t.
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op py
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Specified torques Prote AG.
♦ ⇒ “1.1 Assembly overview - clutch release mechanism”, page

10

2 Output shaft
⇒ “2.1 Assembly overview - output shaft”, page 89
⇒ “2.2 Dismantling and assembling output shaft”, page 92
⇒ “2.3 Adjusting output shaft”, page 102
wage
2.1 Assembly overview - output shaft
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♦ The output shaft is dismantled as follows: position splitter under 2nd gear synchromeshed gear
itte
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⇒ Item 21 (page 90) and press off as described in ⇒ page 96 . Remove retaining ring
erm
ab
⇒ Item 17 (page 90) . Then press off locking collar with synchro-hub for 1st and 2nd gear as described in
ility
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⇒ page 96 .
wit
is n
h re
ole,
♦ When installing new gears or new input shaft, refer to ⇒ Electronic parts catalogue (ETKA) and technical
spec
data.
t to the co
♦ Always renew both tapered roller bearings together as a set.
rrectne
1 - Hexagon nut
s
❑ ⇒ page 39
s o
cial p
f i
2 - Clutch housing
nform
mer
3 - Shim
atio
om
n
c
i
or
n thi
❑ Adjustment overview
te
sd
va
⇒ page 123
i
o
pr
cum
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fo
4 - Small tapered roller bearing

en
ng
t.
yi
outer race
Co
Cop py
t. rig
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co
❑ Pressing in
by lksw
cted agen
⇒ page 95 .
Prote AG.
❑ If replaced: Adjust out‐

put shaft ⇒ page 102 .
❑ Note different versions
when adjusting
⇒ page 104
5 - Tapered roller bearing inner
race small
❑ Pulling off ⇒ page 96
❑ Pressing on
⇒ page 96
6 - Output shaft
race large
❑ Pressing on
⇒ page 97
8 - Seal
❑ Place seals (qty. 4) on bearing support bolts
2. Output shaft 89
AG. Volkswagen AG d
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Golf 2017 ➤ , Golf Variant ori2017
s ➤ , Polo 2018 ➤ , T-Cross 2019 ➤ntee
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Removed 5-speed manual
au gearbox 0A4 - Edition 01.2019 ac
ss
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pt
9 - Bearing support
du
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itte
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❑ With large tapered roller bearing outer race and bolts
erm
ab
ility
❑ Change outer race only together with large tapered roller bearing and bearing support
ot p
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10 - Thrust washer , is n
h re
hole
spec
❑ Shoulder of thrust washer faces tapered roller bearing
es, in part or in w
t to the co
11 - Synchromeshed gear, 1st gear
12 - Needle bearing
rrectness of i
❑ For 1st gear
l purpos
13 - Synchro-ring
❑ (Inner ring for 1st gear)
nform
ercia
❑ Check lugs for scoring

m
at
om
ion
❑ Checking synchro-ring, outer ring and inner ring together for wear ⇒ page 98
c
in t
or
his
te
14 - Outer ring for 1st gear

a
do
priv
c
um
for
en
ng
❑ Check for scoring or signs of abnormal wear

t.
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Cop py
❑ Checking synchro-ring, outer ring and inner ring together for wear ⇒ page 98 ht. rig
rig ht
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15 - Synchro-ring for 1st gear by c lksw
cted agen
Prote AG.
16 - Locking collar with synchro-hub for 1st and 2nd gear
❑ Pull off together with bearing support ⇒ page 96 after removing retaining ring ⇒ Item 17 (page 90)
❑ Dismantling ⇒ page 98
❑ Assembling locking collar and synchro-hub ⇒ page 98 , ⇒ page 98 and ⇒ page 99
17 - Retaining ring
18 - Synchro-ring for 2nd gear
❑ Insert so that recesses engage in locking pieces of locking collar for 1st and 2nd gear
19 - Outer bearing race for 2nd gear
❑ Check for scoring or signs of abnormal wear
❑ Insert in 2nd gear synchro-ring ⇒ Item 18 (page 90) .
20 - Synchro-ring
❑ (Inner ring for 2nd gear)
❑ Check lugs for scoring
21 - Synchromeshed gear for 2nd gear
22 - Needle bearing
❑ For 2nd gear

23 - Thrust washer
24 - Sleeve for 3rd gear needle bearing
❑ Pressing off with synchromeshed gear for 2nd gear ⇒ page 96
25 - Needle bearing
❑ For 3rd gear
26 - Synchromeshed gear for 3rd gear
27 - Synchro-ring for 3rd gear
. Volkswagen AG
does gen AG
28 - Locking collar with Vol
kswsynchro-hub for 3rd and
a 4th
not gears
y g
❑ Pressing ed b with 2nd speed selector gear andua3rd
off ran speed selector gear ⇒ page 96
ris tee
ho
❑ Dismantling
aut ⇒ page 101 or
ac
ss
❑ Assembling locking collar and synchro-hub ⇒ page 101 , ⇒ page 101 and ⇒ page 101
ce
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un
pt
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itte
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erm
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29 - Sleeve
ility
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❑ For needle bearing
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❑ Press off with locking collar and synchro-hub for 3rd and 4th gears ⇒ page 96
ole,
spec
t to the co
30 - Needle bearing
❑ For 4th gear
rrectne
31 - Synchro-ring for 4th gear
ss o
32 - Synchromeshed gear for 4th gear

cial p
f inform
33 - Thrust washer
mer
atio
m
34 - Roller sleeve
o
n
c
i
or

thi
te
sd
va
❑ Roller bearing without retaining ring and roller bearing with retaining ring
i
o
pr
cum
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fo
❑ Identifying roller bearing for output shaft in gearbox housing ⇒ page 68

en
ng
t.
yi Co
❑ Removing and installing roller bearing without retaining ring ⇒ page 69 .
t. Cop py
rig
❑ Removing and installing roller bearing with retaining ring ⇒ page 70 .
gh ht
pyri by
Vo
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by c lksw
35 - Gearbox housing cted agen
Prote AG.
36 - Sleeve
❑ For output shaft roller bearing
❑ Pressing off ⇒ page 96
38 - Dished spring
39 - Bolt
❑ Specified torque ⇒ page 36
❑ Fitted section of bolt head holds dished spring in position ⇒ page 64
2. Output shaft 91
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Golf 2017 ➤ hor , Golf Variant 2017 ➤ , Polo 2018 ➤ , T-Cross
is tee 2019 ➤
t or
Removed au5-speed manual gearbox 0A4 - Edition 01.2019 ac
ss
ce
e
nl
pt
2.2 Dismantling and assembling output shaft
du
an
itte
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erm
ab
ility
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wit
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equipment required
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
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Cop py
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by
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Prote AG.

♦ Thrust pad - VW 512-
♦ Puller - V.A.G 1582-
♦ Grip tool - V.A.G 1582/4-

lkswage es n
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ility
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spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
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ate
do
priv
cum
for
en
ng
t.
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Cop py
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Prote AG.

♦ Support rails - VW 457-
♦ Tube - VW 519-
2. Output shaft 93
AG. Volkswagen AG d
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ab
ility
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, is n
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spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
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ate
do
priv
cum
for
en
ng
t.
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Cop py
ht. rig
rig ht
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co Vo
by lksw
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Prote AG.
♦ Thrust ring - VW 429-

♦ Tube - VW 415 A-
♦ Installing sleeve - VW 455-
♦ Drift sleeve - 41-501-
♦ Internal puller - VAS 251 613- , or e.g. internal puller - Kukko

21/6-

♦ Counter support - VAS 251 623- , or e.g. counter support -

Kukko 22/2-
♦ Splitter - VAS 251

411- , or e.g. splitter
22 … 115 mm - Kuk‐
ko 17/2-
AG. Volkswagen AG d
agen oes
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Pulling out small tapered

itte
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roller bearing outer race
erm
ab
ility
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A - Internal puller - VAS
wit
is n
251 613- , or e.g. internal
h re
ole,
puller - Kukko 21/6-
spec
B - Counter support -
t to the co
VAS 251 623- , or e.g.
counter support -Kukko
22/2-
rrectne
Pressing in small tapered roller bearing outer race
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
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cum
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en
ng
t.
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Cop py
t. rig
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pyri by
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by c lksw
cted agen
Prote AG.
2. Output shaft 95
Pulling off small tapered roller bearing inner race

A - Vice with protective jaw covers
– Fit adapter and apply tension to it behind the bearing rollers,
then turn bearing and re-tension adapter.
Pressing on small tapered roller bearing inner race
Pressing off synchro-hub and locking collar for 3rd and 4th gear,
synchromeshed gears for 2nd, 3rd and 4th gear with sleeve for
output shaft needle bearing
A - Splitter - VAS 251 411- , or e.g. splitter 22 … 115 mm - Kukko
17/2-
B - Hexagon bolt M10 x 20, 17 mm AF
AG. Volkswagen AG d
agen
Note Volksw
oes
not
gu
by ara
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Support splitter so that the 1st and 2nd gear locking collar is not
or eo
th
u ra
pulled off at the same stime.
sa c
ce
e
nl
pt
du
an
itte
Pressing off locking collar with synchro-hub and bearing support

y li
erm
ab
ility
– First, remove retaining ring -arrow-.

ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
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Cop py
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co lksw
by
96
cted agen
Prote AG.
Rep. gr.35 - Gears, shafts
Pulling off large tapered roller bearing inner race

A - Protective jaws
– Before fitting puller, insert a M10 x 20 hexagon bolt in the out‐
put shaft drilling.
AG. Volkswagen AG d
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erm
ab
ility
ot p
Pressing on large tapered roller bearing inner race
wit
, is n
h re
-A- Thrust washer
hole
spec
es, in part or in w
– Fit thrust washer before pressing on inner race. Shoulder
t to the co
faces inner race.
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
Installation position of outer ring, inner ring and synchro-ring for
or
his
e
1st gear
at
do
priv
– Place inner ring -A- on synchromeshed gear for 1st gear. cum
for
en
ng
t.
yi
Angled lugs -arrow 1- face outer ring -B-.
Co
Cop py
ht. rig
– Fit outer ring -B-.
rig ht
py by
co Vo
by lksw
cted
Lugs -arrow 2- engage in notches -arrow 3- of synchromeshed
agen
Prote AG.
gear.
– Fit synchro-ring -C-.
Notches -arrow 4- engage in lugs -arrow 1- of inner race -A-.
Note
If components are not renewed, ensure that they are matched

with their original gears.
2. Output shaft 97
Checking 1st and 2nd gear synchro-ring, outer ring and inner ring
together for wear
– Press synchro-ring, outer ring and inner ring onto cone of syn‐
chromeshed gear and measure gap -a- at 3 points offset by
120° using a feeler gauge.
– Make a note of average value. agen
AG. Volkswagen AG d
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olksw not
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Gap -a- Installation dimen‐ d b Wear limit
y ara
ise nte
sion thor eo
au ra
1st and 2nd gear 1.2 - 1.8 mm s s 0.5 mm c
ce
e
nl
pt
du
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itte
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erm
Note
ab
ility
ot p
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Always renew inner ring, outer ring and synchro-ring together.
h re
hole
spec
es, in part or in w
Dismantling and assembling locking collar and synchro-hub for
t to the co
1st and 2nd gears
1 - Spring
rrectness of i
Allocate spring using ⇒ Electronic parts catalogue (ETKA) .
l purpos
Installation with hollow locking pieces ⇒ page 98 .
nf
ercia
Installation with solid locking pieces ⇒ page 99 .
orm
m
2 - Sliding sleeve
atio
om
n in
c
3 - Synchro-hub
or
thi
te
sd
a
4 - Locking piece
iv
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rp
cu
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Allocate locking pieces using ⇒ Electronic Parts Catalogue (ET‐
f
en
ng
t.
yi
KA) .
Co
Cop py
t. rig
Collar is equally wide on both sides of synchro-hub.
gh ht
pyri by
Vo
co lksw
by
The collar has a chamfer on one side -arrow B-. cted agen
Prote AG.
Chamfer on collar of synchro-hub and outer teeth of locking collar

-arrow A- face in same direction after assembly.
Notches -arrow C- in synchro-hub and sliding collar for locking
pieces must align.
Assembly of 1st and 2nd gear locking collar and synchro-hub with
hollow locking pieces
• Locking collar has been pushed over synchro-hub.
– Insert locking pieces and install springs offset 120°. Angled
end of spring must locate in hollow locking piece.

Assembly of locking collar and synchro-hub for 1st and 2nd gear
with solid locking pieces
– Insert locking pieces and install springs offset 120°.
• Springs must seat with angled ends in front of locking pieces
-arrows-.
Installation position of locking collar with synchro-hub for 1st and

2nd gear
Teeth of locking collar -arrow- face towards splines for 3rd and
4th gear synchro-hub -A-.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
ho eo
Pressing on locking collar and synchro-hub for 1st and
s a 2nd gears
ut ra
c
s
Turn synchro-ring so that grooves align with locking pieces.
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
Installation position of 2nd gear outer ring

Lugs -arrows- face 1st gear -A-.
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
2. Output shaft 99
Installation position of synchro-ring (2nd gear inner race) -A-

Lugs -arrow 1- engage in notches -arrow 2- in synchro-ring -B-.
Installation position of synchromeshed gear for 2nd gear

Higher shoulder -A- faces 1st gear -B-. Notches in shoulder
-arrows- engage in lugs of outer ring ⇒ page 99 .
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
Pressing on sleeve for 3rd gear needle bearing utho eo
ra
s a c
s
ce
le
un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectne
Checking synchro-rings for 3rd and 4th gear for wear

ss
– Press synchro-ring onto cone of synchromeshed gear and

o
cial p
f i
measure gap -a- using feeler gauge.

nform
mer
– Measure gap size -a- at 3 points offset by 120° using feeler

atio
m
gauge.
o
n
c
i
or
n thi
– Make a note of average value.

te
sd
iva
o
pr
Gap -a- Installation dimen‐ Wear limit

um
r
fo
en
sion
ng
t.
yi Co
op py
3rd gear / 4th 1.0 - 1.7 mm 0.5 mm
. C rig
ht ht
rig
gear py by
co Vo
by lksw
cted agen
Prote AG.

Dismantling and assembling 3rd and 4th gear locking collar and
synchro-hub
1 - Spring
Allocate spring using ⇒ Electronic Parts Catalogue (ETKA) .
Installation with hollow locking pieces ⇒ page 98 .
Installation with solid locking pieces ⇒ page 99 .
2 - Locking piece
Allocate locking pieces using ⇒ Electronic Parts Catalogue (ET‐
KA) .
3 - Sliding sleeve
4 - Synchro-hub
– Slide locking collar over synchro-hub. agen
AG. Volkswagen AG d
oes
olksw not
V
Notches for locking pieces in synchro-hub
d by and locking collar must gu
ara
align. rise nte
tho eo
au ra
ss c
Assembly of 3rd and 4th gear locking collar and synchro-hub with
ce
e
nl
pt
hollow locking pieces
du
an
itte
y li
Locking collar has been pushed over synchro-hub.
erm
ab
ility
ot p
– Insert locking pieces and install springs offset 120°. Angled
wit
, is n
end of spring must locate in hollow locking piece.
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
Assembly of 3rd and 4th gear locking collar and synchro-hub with nform
ercia
solid locking pieces

m
at

om
ion
c
in t
– Insert locking pieces and install springs offset 120°. Springs

or
his
e
must seat with angled ends in front of locking pieces

at
do
riv
-arrows-.
p
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Pressing on synchro-hub with locking collar for 3rd and 4th gears
♦ Synchro-hub and locking collar are symmetrical
2. Output shaft 101

Pressing on sleeve for 4th gear needle bearing
Pressing on sleeve for output shaft needle bearing
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
2.3 Adjusting output shaft
hole
spec
es, in part or in w
(Determining shim for output shaft)
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.


equipment required
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

♦ End measuring plate - VW 385/17-
♦ Straightening tool - 3114/2-
♦ Dial gauge
2. Output shaft 103


21/6-

Kukko 22/2-
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
It is necessary to readjust the output shaft when the following
t to the co
components are renewed:
♦ Output shaft
rrectness of i
♦ Clutch housing
l purpos
or
nform
ercia
♦ Tapered roller bearing

m

at
om
ion
c
Prerequisites:
in t
or
his
ate
• Sealing surfaces of clutch and gearbox housings must be free

do
priv
of sealant .
um
for
en
ng
t.
yi
Note difference in tapered roller bearings
Co
Cop py
t. rig
♦ I = Tapered roller bearing outer races “without shoulder”
gh ht
pyri by
Vo
co lksw
by
♦ II = Tapered roller bearing outer races “with shoulder” cted agen
Prote AG.
-arrow-
Outer races for tapered roller bearing “without shoulder”
– Press outer race of small tapered roller bearing with “0.60 mm”
shim into clutch housing to stop ⇒ page 95 .
Outer races for tapered roller bearing “with shoulder”
– Press outer race of small tapered roller bearing with “0.65 mm”
shim into clutch housing to stop ⇒ page 95 .

Continuation for all

– Insert output shaft and tighten nuts for bearing mounting
⇒ page 89 .
– Turn output shaft 20 to 30 times in one direction.
Note
♦ The shaft must be turned in one direction so that the rollers of

the tapered roller bearing settle in one direction.
♦ It is necessary to turn the shaft 20 to 30 times to achieve this.
♦ Otherwise, the result of the measurement will be incorrect.
AG. Volkswagen AG d
agen oes
– Set up dial gauge (3 mm measuring range)Vol and set to “0”with
ksw not
gu
1 mm preload. d by ara
ise r nte
ho eo
– Move output shaft up and down.auRead
t
and note play indicated ra
c
on dial gauge. ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
The specified bearing preload will be attained if the determined
ility
ot p
measured value is added to the shim already installed (0.65 mm
wit
or 0.60 mm).
, is n
h re
hole
spec
Outer race for tapered roller bearing “without shoulder” = item
es, in part or in w
-I-
t to the co
Example
rrectness of i
Bearing play = Thickness of shim according to
(0.600 mm shim table
l purpos
+ measured value 0.330 =

0.930 mm)
nf
ercia
0.930 mm 1.000 mm
orm
m
atio
m
Table of shims
o
n in
or c
thi
Calculated measured value Shim

te
sd
iva
thickness (mm)
o
r
rp
cu
o
m
f
... 0.000 0.600

en
ng
t.
yi
0.000… 0.629 0.650
Co
Cop py
t. rig
0.630 … 0.679 gh
0.700
ht
yri by
0.680 … 0.729 0.750
cop Vo
by lksw
0.730 … 0.779 0.800
cted agen
Prote AG.
0.780 … 0.829 0.850

0.830 … 0.879 0.900
0.880 … 0.929 0.950
0.930 … 0.979 1.000
0.980 … 1.029 1.050
1.030 … 1.079 1.100
1.080 … 1.129 1.150
1.130 … 1.179 1.200
1.180 … 1.229 1.250
1.230 … 1.279 1.300
1.280 … 1.329 1.350
1.330 … 1.342 1.400
2. Output shaft 105

Outer race for tapered roller bearing “with shoulder” -arrow- = item
-II-.
Example
Bearing play = Thickness of shim according to
(0.650 mm shim table agen
AG. Volkswagen AG d
oes
+ measured value 0.230 = yV
olksw not
gu
0.880 mm) ised b ara
n r tee
ho
0.880 mm 0.950 mm aut or
ac
ss
ce
le
Table of shims
un
pt
an
d
itte
y li
Calculated measured value Shim
erm
ab
thickness (mm)
ility
ot p
wit
is n
… 0.000 0.650
h re
0.000 … 0.679 0.700
ole,
spec
0.680 … 0.729 0.750

0.730 … 0.779 0.800
t to the co
0.780 … 0.829 0.850
0.830 … 0.879 0.900
rrectne
0.880 … 0.929 0.950
0.930 … 0.979 1.000
s
0.980 … 1.029 1.050
s o
1.030 … 1.079 1.100
cial p
f in
1.080 … 1.129 1.150
form
mer
1.130 … 1.179 1.200
atio
m
1.180 … 1.229 1.250

o
n
c
i
1.230 … 1.279 1.300
or
n thi
te
sd
a
1.280 … 1.329 1.350

iv
o
pr
c
1.330 … 1.379 1.400
um
r
fo
1.380 … 1.429 1.450
en
ng
t.
yi Co
op py
Continuation for all
. C rig
ht ht
rig by
copy Vo
by lksw
cted agen
Prote AG.
Note
Allocate shims using ⇒ Electronic parts catalogue (ETKA) .
– Remove output shaft and pull out small tapered roller bearing
outer race ⇒ page 95 .
• If the previously used shim is to be reinstalled, it must be
checked for damage.
The various thicknesses make it possible to achieve the exact
shim thickness required.
– Press in outer race of small tapered roller bearing together with
the calculated shim ⇒ page 95 and install output shaft.
– Tighten nut for bearing mounting in clutch housing.
Specified torques
♦ Bearing mounting to clutch housing ⇒ page 39

3 Reverse shaft
⇒ “3.1 Assembly overview -oreverse
en AG. V
lkswagen Ashaft”,
G
page 107
ag does
ksw n
Vol
⇒ “3.2 Dismantling and assembling reverse oshaft”,
t gu page 108
by a
ed ran
ris te
3.1 au
tho
Assembly overview - reverse shaft
eo
ra
ss c
ce
e
nl
pt
du
an
Note
itte
y li
erm
ab
ility
After removal, renew needle bearings in clutch housing and in reverse shaft support.
ot p
wit
, is n
h re
hole
spec
1 - Clutch housing
es, in part or in w
t to the co
2 - Needle bearing
rrectness of i
❑ Pressing in
⇒ page 109 .
l purpos
3 - Reverse gear wheel
nform
ercia
4 - Retaining ring
m
❑ Renew after removal at

om
ion
c
in t
5 - Synchromeshed gear for re‐

or
his
e
verse gear
at
do
riv
❑ Remove retaining ring

p
cum
or
before renewing.
f
en
ng
t.
yi Co
❑ Shoulder faces reverse Cop py
t. rig
gear wheel opyri
gh by
Vo
ht
by c lksw
6 - Reverse shaft Prote
cted AG.
agen

⇒ page 50
7 - Needle bearing
❑ Pressing out
⇒ page 110 .
❑ Pressing in
⇒ page 110 .
8 - Reverse shaft support
⇒ page 50
3. Reverse shaft 107

3.2 Dismantling and assembling reverse shaft

equipment required
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du

an
itte
y li
erm

ab
ility
ot p

wit
, is n
h re
♦ Centring mandrel - 12 - 551-

hole
spec
es, in part or in w
♦ Pressure plate - VW 401-

t to the co

rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
by
108
copy Vo
by lksw
Rep. gr.35 - Gears, shafts cted agen
Prote AG.
♦ Internal puller - VAS 251 605- , or e.g. internal puller - Kukko . Volkswage
AG
21/2- ksw
agen
n AG d
oes
n ol ot g
yV ua
edb ran
ris tee
tho or
au ac
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
♦ Counter support -
VAS 251 621- , or e.g.
rrectne
counter support -
Kukko 22/1-
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
Pulling needle bearing py by
co Vo
out of clutch housing
by lksw
cted agen
Prote AG.
A - Counter support -
VAS 251 621- , or e.g.
counter support - Kukko
22/1-
B - Internal puller - VAS
251 605- , or e.g. internal
puller - Kukko 21/2-
Note
The needle bearing is

destroyed during remov‐
al and must be renewed.
Pressing needle bearing -A- into clutch housing
3. Reverse shaft 109

Pressing needle bearing out of reverse shaft support
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
Pressing needle bearing into reverse shaft support
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

39 – Final drive - differential

1 Oil seals
⇒ “1.1 Overview of fitting locations - seals”, page 111
Additional descriptions can be found in ⇒ Rep. gr. 39 ; Seals;
Overview of fitting locations - seals .
1.1 Overview of fitting locations

en AG. V
olkswagen AG- seals
ag does
ksw not
y Vol gu
b ara
ed
1 - Seal oris nte
eo
h
ut
❑ For input
ss
ashaft ra
c
ce
e
nl
pt
du
⇒ page 87
an
itte
y li
erm
ab
2 - Seal
ility
ot p
❑ For right flange shaft
wit
, is n
h re
❑ Renew after removing
hole
⇒ Rep. gr. 39 ; Oil
spec
es, in part or in w
seals; Renewing right oil
t to the co
seal
3 - Seal
rrectness of i
❑ For left flange shaft
l purpos

⇒ Rep. gr. 39 ; Oil
seals; Renewing left oil nform
ercia
seal
m
at
4 - Seal
om
ion
c
❑ For selector shaft

in t
or
his
te

a
do
riv
⇒ Rep. gr. 34 ; Selector

p
cum
or
mechanism; Renewing
f
en
ng
t.
yi
selector shaft seal
Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
1. Oil seals 111

2 Differential
⇒ “2.1 Assembly overview - differential”, page 112
⇒ “2.2 Dismantling and assembling differential”, page 113
⇒ “2.3 Adjusting differential”, page 119
2.1 Assembly overview - differential
1 - Gearbox housing
2 - Shim
❑ Determining thickness
⇒ page 119
3 - Tapered roller bearing outer
race
❑ Pressing in
⇒ page 117 .
race agen
AG. Volkswagen AG d
oes
lksw not
❑ Pulling off ⇒ page 116 d by
Vo gu
ara
e nte
❑ Pressing on horis
eo
⇒ page 116 aut ra
ss c
ce
le
5 - Differential
un
pt
an
d
❑ With final drive gear

itte
y li
rm
ab
pe
ility
ot
race
wit
, is n
h re
hole
spec
❑ Pressing on
es, in part or in w
⇒ page 116
7 - Tapered roller bearing outer t to the co
race
rrectness of i
❑ Pressing out
l purpos
⇒ page 116 .
❑ Pressing in
⇒ page 116 .
nform
mercia
8 - Clutch housing
a
com
tion in
9 - Seal
r
te o
thi
❑ Renew together with

s
iva
do
sleeve after removal

r
rp
cum
fo
❑ For right flange shaft

en
ng
t.
yi Co
op
❑ If seal is damaged, renew seal and sleeve together ⇒ page 73 C py
t. rig
gh ht
yri by
10 - Countersunk bolt op Vo
by c lksw
cted agen
❑ Renew after removal Prote AG.
❑ 25 Nm
11 - Flange shaft
❑ Right flange shaft
❑ Removing and installing ⇒ Rep. gr. 39 ; Oil seals; Renewing right oil seal
❑ Left flange shaft
❑ Removing and installing ⇒ Rep. gr. 39 ; Oil seals; Renewing left oil seal
112 Rep. gr.39 - Final drive - differential

12 - Compression spring for flange shaft

13 - Thrust washer
14 - Tapered ring
❑ With grooves to engage in thrust washer
❑ Installation position: taper towards differential cage
15 - Retaining ring
❑ Holds tapered ring, thrust washer and spring in position when flange shaft is removed
16 - Seal
❑ For left flange shaft
❑ Renew after removing ⇒ Rep. gr. 39 ; Oil seals; Renewing left oil seal
2.2 Dismantling and assembling differential

equipment required
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
♦ Tapered roller bearing puller - V.A.G 1582-
2. Differential 113

lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
yri
♦ Press tool - VW 408 A- p by
co Vo
by lksw
cted agen
♦ Thrust piece - VW 473- Prote AG.

♦ Sleeve - 3144-
♦ Thrust piece - 2007-

♦ Drift sleeve - 40 - 21-
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
♦ Thrust plate - 40-105-
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f in
♦ Internal puller - VAS 251 615- , or e.g. internal puller - Kukko form
mer
21/7-
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Kukko 22/2-
2. Differential 115
Note
♦ Heat tapered roller bearing inner race to 100 C before instal‐

ling.
♦ Always renew both tapered roller bearings together as a set.
♦ If tapered roller bearings, differential cage, gearbox housing
or clutch housing are renewed, adjust differential
⇒ page 123 .
Pressing tapered roller bearing outer race out of clutch housing

– First remove seating sleeve for flange shaft seal.
Pressing tapered roller bearing outer race into clutch housing

No shim is installed in the clutch housing end.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
Pulling off tapered roller bearing
utho inner races eo
ra
s a c
– Before fitting extractor, position thrust plate - 40 - 105- on dif‐ s
ce
le
ferential cage.
un
pt
an
d
itte
y li
erm
ab
ility
ot p
Note
wit
is n
h re
ole,
Both tapered roller bearing inner races are pulled off the differ‐
spec
ential cage in the same way.

t to the co
rrectne
Pressing on tapered roller bearing inner races

ss o
cial p
f inform
Note
mer
atio
m
The inner races of tapered roller bearings for gearbox housing

o
n
c
and clutch housing are pressed on with the same press tools.
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Pulling outer race for tapered roller bearing out of gearbox hous‐
ing
A - Counter support - VAS 251 623- , or e.g. counter support -
Kukko 22/2-
B - Internal puller - VAS 251 615- , or e.g. internal puller - Kukko
21/7-
Pressing tapered roller bearing outer race into gearbox housing

– Fit shim under outer race.
– Support gearbox housing directly below bearing mounting us‐
ing sleeve - 3144- .
Spring pin identification

Dimension “a” mm Distinguishing features
28.5 (short spring pin) Circumferential groove
Removing and installing -arrows-
⇒ page 118
36.0 (long spring pin), No circumferential
Removing ⇒ page 118 , groove
Installing ⇒ page 118
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Allocation of differential cages

un
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The hole in the differential cage was modified for the longer spring
y li
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pin.
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Bore Length of spring pin (mm)

h re
ole,
-A- 28.5 (short spring pin)

spec
-A- and -B- 36.0 (long spring pin)

t to the co
rrectness o
cial p
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mer
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Cop py
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117
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Prote 2. Differential
AG.
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agen oes
Removing and installing spring pin withVcircumferential
olks
w
groove not
gu
y
(short spring pin) sed b ara
nte
ri
ho eo
Removing aut ra
c
ss
– Cover tapered roller bearing inner race and speedometer drive
ce
le
un
pt
gear to avoid possible damage and ingress of metal particles.
an
d
itte
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rm
ab
– Drive out spring pin with chisel, inserting chisel into circum‐
pe
ility
ferential groove.
ot
wit
, is n
h re
Installing
hole
spec
– Drive into differential cage to stop.
es, in part or in w
t to the co
Removing spring pin without circumferential groove (long spring
rrectness of i
pin): pressing out differential pinion pin
l purpos
When pressed out, spring pin will be sheared off.

– Drive remainder of spring pin out of differential cage.
nform
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tion in
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te o
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Cop py
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Installing spring pin without circumferential groove (long spring py by
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pin)
by lksw
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Prote AG.
– Align hole in differential pinion pin with hole in differential cage.
– Drive in new spring pin with drift -1- until dimension
-a- = 3.0 mm has been attained.
• The spring pin must not come in contact with gears with dif‐
ferential cage installed.
In some gearboxes, the one-piece thrust washer has a shoulder

-A- near the holes
In this case, the differential cage has a circumferential groove
-B-.
– Lubricate one-piece thrust washer with gear oil and install.
– Install one-piece thrust washer so that it engages in groove
-B- in differential cage.

Installing differential bevel gears and differential pinion pin

– Lubricate one-piece thrust washer with gear oil and install.
– Install both sun wheels and secure (e.g. with flange shaft).
– Insert planet pinions offset 180° and pivot into position.
– Press in differential pinion pin (-arrow A-) to first planet pinion.
– Place threaded pieces -arrows B- in sun gears.
Installation position: shoulder to sun gear.
– Drive differential pinion pin into final position and secure with
spring pin.
. Volkswagen AG
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Installation position
y Volk of thrust washer for taperednot ring -1-.
gu
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The shoulder
horis
-arrow- points towards spring -B-. eo
aut ra
Somes gearboxes have lugs -A-.
s c
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un
pt
Lugs -A- face tapered ring -1-.
an
d
itte
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pe
ility
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hole
spec
es, in part or in w
t to the co
rrectness of i
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nform
mercia
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tio
2.3 Adjusting differential

n in
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2. Differential 119

equipment required
AG. Volkswagen AG d
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h re
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spec
♦ End dimension plate - VW 385/17-

t to the co

rrectne

♦ Dial gauge
ss o
cial p
♦ Do not apply: tools 1-4

inform
mer
atio
om
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21/7-

Kukko 22/2-
AG. Volkswagen AG d
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It is necessary to readjust the differential when the following
rised com‐ ara
nte
ponents are renewed: ut
ho eo
ra
s a c
♦ Gearbox housing s
ce
le
un
pt
♦ Clutch housing
an
d
itte
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rm
ab
♦ Differential cage
pe
ility
ot
wit
or the
, is n
h re
hole
♦ Tapered roller bearing of differential
spec
es, in part or in w
t to the co
– Press outer race of tapered roller bearing without shim into
gearbox housing using thrust piece - 30 - 205- ⇒ page 117
rrectness of i
l purpos
Note
nform
ercia
Inner and outer tapered roller bearing races are paired. Do not
interchange!
m
a
com
tion in
r
– Press outer race of tapered roller bearing into clutch housing

te o
thi
using thrust plate - 30 - 205- ⇒ page 116 .

s
iva
do
r
rp
cum
– Fit differential into clutch housing.

fo
en
ng
t.
yi Co
– Set gearbox housing in place and tighten 5 bolts to 25 Nm. Cop py
ht. rig
rig ht
py by
co Vo
by lksw
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Prote AG.
2. Differential 121
– Attach dial gauge and set to “0” with 1 mm preload.

– Move differential up and down. Read and note play indicated
on dial gauge. (Example: 0.70 mm.)
Example:
Bearing play, measured value Thickness of shim according to
table
0.70 mm 0.95 mm
Table of shims
Bearing play Shim
bearing clearance Thickness
(mm) (mm)
0.303 … 0.449 0.650
0.450 … 0.499 0.700
0.500 … 0.549 0.750
0.550 … 0.599 0.800
0.600 … 0.649 0.850
0.650 … 0.699 0.900
0.700 … 0.749 0.950
0.750 … 0.799 1.000
0.800 … 0.849 1.050
0.850 … 0.899 1.100
0.900 … 0.949 1.150
0.950 … 0.999 1.200
1.000 … 1.049 1.250
1.050 … 1.099 1.300
1.100 … 1.149 1.350
1.150 to 1.199 1.400
Note lkswage es n
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byV ua
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ir se tee
Allocate shims using ⇒ Electronic parts catalogue
utho (ETKA) . or
a ac
ss
ce
e
– Remove gearbox housing and pull tapered roller bearing outer

nl
pt
du
race out from gearbox housing.

an
itte
y li
erm
ab
ility
Pulling outer race for tapered roller bearing out of gearbox hous‐
ot p
wit
ing
, is n
h re
hole
A - Counter support - VAS 251 623- , or e.g. counter support -

spec
Kukko 22/2-
es, in part or in w
t to the co
B - Internal puller - VAS 251 615- , or e.g. internal puller - Kukko

21/7-
rrectness of i

l purpos
nf
ercia
The various thicknesses make it possible to achieve the exact

orm
shim thickness required.

m
atio
om
n in
– Press in outer race of tapered roller bearing again

or c
⇒ page 117 and bolt gearbox housing tight.

thi
te
sd
iva
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Specified torques
rp
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en
ng
♦ Gearbox housing to clutch housing ⇒ page 38

t.
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Prote AG.

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Golf 2017 ➤ , Golf Variant
olks 2017 ➤ , Polo 2018 ➤ ,s n
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T-Cross
ot g 2019 ➤
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Removeds ed 5-speed manual gearbox 0A4 - Edition
b ua
ran
01.2019
ri tee
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aut or
ac
ss
3 Adjustment overview
ce
le
un
pt
an
d
itte
y li
erm
ab
Note
ility
ot p
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h re
It is necessary to adjust input shaft, output shaft, or differential
ole,
only if components have been renewed which have a direct effect
spec
on the adjustment of the gearbox. To prevent unnecessary ad‐
t to the co
justments, refer to the following table:
To be adjusted:
rrectne
Input shaft Output shaft Differential
⇒ page 83 ⇒ page 102 ⇒ page 119
ss o
cial p
f
Parts renewed: Gearbox housing x x
inform
Clutch housing x x x
mer
atio
m
Input shaft x
o
n
c
i
or
n
Output shaft x
thi
te
sd
a
Differential cage x
iv
o
pr
cum
r
fo
Input shaft tapered roller bearing x
en
ng
t.
yi Co
Tapered roller bearing for output Cop
x py
shaft
ht. rig
rig ht
py by
o Vo
Tapered roller bearing for differen‐ x
by c lksw
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tial Prote AG.
Gear wheel for 4th gear x
3. Adjustment overview 123

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Removed 5-speed manual gearbox 0A4

Service Department. Technical Information

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Copyright © 2019 Volkswagen AG, Wolfsburg D4B806C0E6D

6.7 Assembly overview - selector forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

6.9 Removing cover for gearbox housing and 5th gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

6.10 Dismantling and assembling gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

6.11 Installing cover for gearbox housing and 5th gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

7 Gearbox housing, clutch housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

7.1 Assembly overview - gearbox housing and clutch housing . . . . . . . . . . . . . . . . . . . . . . . . 66

7.2 Repairing gearbox housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

1.1 Assembly overview - input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

2.3 Adjusting output shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

39 - Final drive - differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

2 Rep. gr.00 - Technical data

3.1 Allocation gearbox - engine

4 Overview - power transmission

4 Rep. gr.00 - Technical data

4. Overview - power transmission 5

6 Rep. gr.00 - Technical data

6.1 General repair instructions agen

For a complete list of special tools used in this workshop manual,

sleeves between the engine and gearbox are correctly seated.

the parts are installed. Contact surfaces must be free of wax

Gaskets and seals

After removing gaskets and seals, always inspect contact surfa‐

moval and installation.

stretched after removal.

♦ Do not cant especially delicate parts, such as clutch pressure

♦ Renew self-locking bolts and nuts after each removal.

♦ Ensure with threaded connections that contact surfaces as

8 Rep. gr.00 - Technical data

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

♦ Moisten synchromesh mechanism with gear oil before instal‐

Gears and synchro-hubs

- VAS 6414- before installing. Press in to stop when installing

so there is no axial clearance.

♦ Heat gears to about 100°C with the inductive heater - VAS

30 – Clutch n AG. Volkswagen AG do

⇒ “1.2 Repairing clutch release mechanism”, page 11

1.1 Assembly overview - clutch release mechanism

❑ Grease contact surface

of ball-head pin with

❑ Allocate grease using ⇒

Electronic parts cata‐ cum

10 Rep. gr.30 - Clutch

1.2 Repairing clutch release mechanism

♦ Allocate grease using ⇒ Electronic parts catalogue (ETKA) .

• Gearbox has been removed.

Removing and installing release lever together with release bear‐

– Unhook spring -arrow 1-.

– Pull off release lever -arrow 2- and release bearing.

12 Rep. gr.30 - Clutch

2.1 Assembly overview - clutch