Service: Fox 2004, Fox 2010, Fox 2014, Spacefox 2006, Spacefox 2011

Service
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Fox 2004 ➤ , Fox 2010 ➤ , Fox 2014 ➤ ,
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5-speed manual gearbox (02T and 0AP)
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Edition 02.2017
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Service Department. Technical Information

Service
List of Workshop Manual Repair Groups
Repair Group
00 - Technical data
30 - Clutch
34 - Controls, housing
35 - Gears, shafts
39 - Final drive - differential
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Technical information should always be available to the foremen and mechanics, because their
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 © 2017 Volkswagen AG, Wolfsburg BRA5R006020

Fox 2004 ➤ , Fox 2010 ➤ , Fox 2014 ➤ , SpaceFox 2006 ➤ , SpaceFox 201 ...
5-speed manual gearbox (02T and 0AP) - Edition 02.2017
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Identification on the gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Prefix, Assignment, gear ratio, filling volume . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2 Transmission assembly scheme . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.1 Nomenclature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.2 Gear ratios . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3 Gearbox ratio “i” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.1 Gearbox ratio “i” - calculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4 General repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4.1 Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4.2 Gaskets and retainers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4.3 Screws, nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4.4 Roller bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4.5 Adjustment shims . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4.6 Synchronizer rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
30 - Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1 Command system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.1 Control mechanism - (version 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.2 Control mechanism - (version 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
2 Clutch drive mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
2.1 Clutch drive mechanism - assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
2.2 Clutch slave cylinder - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
2.3 Clutch drive mechanism - bleed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
3 Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .w.ag. e.n.A.G.. .V.ol.ks.w. a.g.en. A. G. .do. e.s. . . . . . . . . . . . . . . . . 43
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3.1 Clutch - assembly overview . . . . . . . . b.y .Vo. . . . . . . . . . . . . . . . . . . . . . .ot. g.u.a . . . . . . . . . . . . 43
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3.2 Clutch - repair . . . . . . . . . . . . . . .ho. r.is . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .n.tee. . . . . . . . . . 45
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34 - Controls, housing . . . . . . . . . ....
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1 Shift mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
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1.1 Shift mechanism - installation position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

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1.2 Selector mechanism - component overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

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1.3 Drive cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

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1.4 Handle and boot on the gear lever - assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . 59

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1.5 Handle and boot on the gear lever - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
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1.6 Handle and boot on the gear lever - disassemble and assemble . . . . . . . . . . . . . . . . . . . . 61
1.7 Gear shift lever and shifting mechanism - remove and install . . . . . . . . . . . . . . . . . . . . . . 62
1.8 Gearshift lever and mechanism - repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
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1.9 Lever and Gear shifting mechanism - adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

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1.10 Selector and lever - functional check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

2 Transmission - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
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2.1 Gearbox for vehicles with engines (AQZ, ASY, BAH, BJA, BJE, BKR, BLH, BMD, BNM, BNX,
BPA, CCNA, CCRA, CFZA, CHFA, CHFB, CPBA) - remove and install . . . . . . . . . . . . . . 72
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2.2 Gearbox for vehicles with engines (CSEA) - remove and install . . . . . . . . . . . . . . . . . . . . 90
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2.3 Gearbox - transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

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3 Gearbox oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

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3.1 Oil level - check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

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3.2 Oil level - replenish . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
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4 Transmission - repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
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4.1 Gearbox - overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
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4.2 gearbox - assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Contents i
4.3 Gearbox housing cover and 5th gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

4.4 Clutch housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
4.5 Input shaft, planet pinion, differential, selection mechanism and selector forks . . . . . . . . . . 111
4.6 Input shaft, planet pinion, differential, selection mechanism and selector forks - disassemble
and assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
5 Gearbox and clutch housings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
5.1 Transmission and clutch housings - repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
6 Gear selection mechanism - adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
6.1 Gear selection mechanism - disassemble and assemble . . . . . . . . . . . . . . . . . . . . . . . . . . 127
7 Selector forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
7.1 Selector forks - disassemble and assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
35 - Gears, shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136

1 Input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
1.1 Primary shaft - general overview of assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
1.2 Input shaft - disassemble and assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
2 Planet pinion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
2.1 Pinion shaft - general overview of assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
2.2 Planet pinion - disassemble and assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
39 - Final drive - differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157

1 Drive flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
1.1 Left drive flange retainer (left side) - replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
1.2 Drive flange retainer (right side) - replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
2 Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
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2.2 Differential
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2.3 Differential
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ii Contents
00 – Technical data
1 Identification
(VRL010074; Edition 02.2017)
⇒ “1.1 Identification on the gearbox”, page 1
⇒ “1.2 Prefix, Assignment, gear ratio, filling volume”, page 2
1.1 Identification on the gearbox

Prefixes (identification letters) and manufacturing date -arrowA1-.
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Example: KWF 02 03 09
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Prefix Day Month Production year
2009
Supplementary data depend on the manufacturing
Note
♦ Eventual existing additional data are related to the manufac‐

turing process.
♦ Transmission prefixes are also included on the vehicle identi‐
fication plate.
1. Identification 1
1.2 Prefix, Assignment, gear ratio, filling vol‐

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⇒ “1.2.3 Gearbox installed together with engines (CSEA)”,
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BLH, BMD, BNX, BPA, CCNA, CCRA, CFZA, CHFA, CHFB, CPBA)
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Identification letters (prefix) EJY GXS
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Engine 1.0 l - 53 kW 1.6 l - 74 kW 1.6 l - 74 kW

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gearbox ratio Z2: Differential 69 : 14 = 4.929 68 : 15 = 4,533 68 : 15 = 4,533

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Filling capacity 2.0 + 0.1 litres 2.0 + 0.1 litres 2.0 + 0.1 litres
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The following information can be found in: ⇒ Electronic Parts
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♦ Individual gear ratios
♦ Specification of the clutch
♦ Gearbox oil (filling)

Identification letters (prefix) GZK HCS HFG
to 03.07 01.07 05.07
Assignment Model Fox 2005 ► Fox 2005 ► Fox 2004 ►
gearbox ratio Z2: Differential 67 : 16 = 4.188 65 : 18 = 3.611 69 : 14 = 4.929
Z1:
Catalog “ETKA”
Manual gearbox 02T 5-speed

Identification letters (prefix) HSG HUY HZM
to 07.07 03.07 08.07
2 Rep. gr.00 - Technical data


Identification letters (prefix) HSG HUY HZM
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1. Identification 3

Identification letters (prefix) JKE JPU JUR
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Model Fox 2007 ► or
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Identification letters (prefix) KWF KWG

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Assignment Model Fox 2008 ► SpaceFox 2007 ► Fox 2007 ►

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Catalog “ETKA”

Identification letters (prefix) KWJ LNC
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Z1:
Catalog “ETKA”


Identification letters (prefix) LUH LUZ LVC
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Z1:
Catalog “ETKA”
1. Identification 5

Identification letters (prefix) LYL MSK NPW
to 03.13 10.13 09.13
Z1:
Catalog “ETKA”

Identification letters (prefix) QEC QED QEE
to
Engine 1.0 l - 56 kW 1.6 l -
n AG. V74
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wagen AG 1.6 l - 74 kW
swage does
gearbox ratio Z2: Differential 69 : 14 = 4.929by Volk 67 : 16 = 4.188 68
not g: 15 = 4.533
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Filling capacity 2.0 + 0.1
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1.2.2 Gearbox installed together with engines (ASY, BNM)

Identification letters (prefix) HCS JHG KRJ
to 01.07 01.10 04.10
Z1: agen
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1.2.3 Gearbox installed together with engines (CSEA)

Identification letters (prefix) PEL
Manufacturing from 04.13
to
Assignment Model Fox 2014 ►
Engine 1.0 l - 59 kW
gearbox ratio Z2: Differential 69 : 14 = 4.929
Z1:
1. Identification 7

Identification letters (prefix) PEL
Filling capacity 2.1 + 0.1 litres
Catalogue“ETKA” .
♦ Individual gear ratios;
♦ Specification of the clutch;
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2 Transmission assembly scheme

⇒ “2.1 Nomenclature”, page 9
⇒ “2.2 Gear ratios”, page 10
2.1 Nomenclature
1 - Engine
2 - Clutch
3 - Mechanical gearbox
4 - Input shaft/driving shaft
5 - Output shaft/planet pinion
6 - Differential
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Arrows indicate run direction.
2. Transmission assembly scheme 9

2.2 Gear ratios
I - 1st gear
II - 2nd gear
III - 3rd gear
IV - 4th gear
V - 5th gear
R - Reverse gear
A - Sprocket
T - Speedometer control
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3 Gearbox ratio “i”

⇒ “3.1 Gearbox ratio i - calculation”, page 11
3.1 Gearbox ratio “i” - calculation

Example:
5th gear Sprocket
driving gear ZG1 = 50 ZA1 = 18
driven gear ZG2 = 37 ZA2 = 65
i = Z2: Z1
iG = gear gearbox ratio = ZG2: ZG1 = 37 : 50 = 0.740
. Volkswagen AG
iA = differential gear ratio = ZA2 : ZA1 = 65 k:sw
18 =n3.611
age
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itotal = Total gear ratio = iG x iA = 0,740 ed b x 3,611 = 2,672 ara
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1) Z1 = Number of teeth on the drivingsgear Z2 = Number of teeth on the driven
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3. Gearbox ratio “i” 11

4 General repair instructions

⇒ “4.1 Gearbox”, page 12
⇒ “4.2 Gaskets and retainers”, page 12
⇒ “4.3 Screws, nuts”, page 13
⇒ “4.4 Roller bearings”, page 13
⇒ “4.5 Adjustment shims”, page 14
⇒ “4.6 Synchronizer rings”, page 14
4.1 Gearbox
WARNING
For achieving a correct and successful repair of the transmis‐

sion, maximum strictness and cleanliness, as well as accessi‐
ble tools in good conditions, are essential conditions. Obvi‐ agen
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We put together here a series of indications applicable htoor sev‐
is tee
eral operations, which are usually dispersed along the aut Repair or
ac
Manual. These indications apply to this Repair Manual.
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♦ Put the disassembled parts on a clean base and cover
wit
them to prevent dirt. Use transparent film and paper. Do
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not use cloths that fray!
hole
spec
♦ Assemble clean parts only: Remove parts from the pack‐
es, in part or in w
t to the co
aging only immediately before their assembly.
♦ Carefully cover or close open components, in case repair
is not carried out immediately.
rrectness of i
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♦ When assembling the transmission, pay attention on the cor‐

rect seating of guide pins between engine and transmission.
nf
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♦ Whenever the transmission is replaced, fill with oil until the
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lower edge of the filling hole.

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♦ Filling capacity and specification ⇒ page 2 .

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♦ When handling chemicals follow the safety instructions ⇒ cted agen
Prote AG.
Chemical Products Manual; Rep. gr. 00
♦ Assignment of Chemical Materials ⇒ Electronic Parts
Catalogue “ETKA”

♦ Always change O-rings, retainers and gaskets.

♦ After removing the gaskets, check whether the stop surface
has burrs or damage resulting from the assembly.
♦ Before installing the retainers, lubricate slightly the outer di‐
ameter and fill the gap between the sealing lips -arrow- with
Grease - G 052 128 A1- up to half height.
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♦ When handling chemicals follow the safety instructions ⇒
t to the co
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♦ Loosen and tighten cover and case fastening screws or nuts
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♦ The tightening torques indicated apply to non-oiled screws
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and nuts.
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♦ The screw threads with locking paste must be cleaned with

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wire brush. Install screws with Locking paste - AMV 185 100
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♦ All the self-locking screw holes must be cleaned from locking
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WARNING
Always replace self-locking screws/nuts subject to angular tor‐

que.
4.4 Roller bearings

♦ Lubricate all the gearbox roller bearings with gear oil before
installing them
♦ Needle bearings must fit into the labelled part (highest thick‐
ness of the plate), towards the fitting tool.
♦ The tapered roller bearings installed in a same shaft must be
replaced as a set. If possible, they must be supplied by the
same manufacturer.
♦ To install, heat inner rings up to approximately 100 °C
♦ Do not change outside and inner rings on a roller bearing by
the rings from another roller bearing with the same size. Roller
bearings are installed in pairs.
4. General repair instructions 13

4.5 Adjustment shims

♦ Check the shim thicknesses in several places with microme‐
ter. The existence of different tolerances enables calibrating
the required shim thickness with accuracy.
♦ Check for burrs and damages.
♦ Only install adjustment shims in perfect conditions.
4.6 Synchronizer rings

♦ They should not be inverted. When reusing synchronizer
rings, always install them on the same gear pair.
♦ Check for wear, and change them, if required.
♦ Lubricate with gear oil before installing.
♦ Check the splines -arrows- of the synchronizer ring -A- and the
inner track for smooth areas (splines with wear).
♦ In the case of lines synchronizer rings, the lining must not be
damaged.
♦ In an intermediate track -B- is installed, examine it at the outer
friction areas -arrow 2- and inner friction areas -arrow 3-, for
»splines«, »wear signs« and »blue colouring (due to over‐
heating)«
♦ Check the selector gear cone for »splines« and »signs of
wear«.
♦ Install the synchronizer rings with gear oil.
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Rep. gr.00 - Technical data
30 – Clutch
1 Command system
⇒ “1.1 Control mechanism - (version 1)”, page 15
⇒ “1.2 Control mechanism - (version 2)”, page 28
1.1 Control mechanism - (version 1)

⇒ “1.1.1 Command system (version 1) - component overview”,
page 15
⇒ “1.1.2 Command pedals - assembly overview”, page 16
⇒ “1.1.3 Clutch pedal switch F36 with rectangular case - remove
and install”, page 18
⇒ “1.1.4 Clutch pedal switch F36 with round case - remove and
install”, page 19
⇒ “1.1.5 Clutch pedal return spring - remove and install”,
page 20
⇒ “1.1.6 Clutch pedal support - remove and install”, page 21
⇒ “1.1.7 Clutch pedal - remove install”, page 23
⇒ “1.1.8 Hydraulic system - assembly overview”, page 24
⇒ “1.1.9 Transmitting cylinder - clutch hydraulic drive - remove
and install”, page 26
1.1.1 Command system (version 1) - component overview

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1. Command system 15
I - Command pedals - assem‐

bly overview ⇒ page 16
II - Hydraulic system - assem‐
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1.1.2 Command pedals - assembly overview

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Self-locking screws/nuts must be replaced whenever loosened
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and/or removed. Prote AG.
16 Rep. gr.30 - Clutch

1 - Engine compartment's par‐

tition panel
❑ With housing for the
clutch support and mas‐
ter cylinder
2 - Gasket
❑ Replace after every re‐
moval
3 - Pedal support
❑ For the clutch pedal
housing
❑ Remove and install
⇒ page 21
4 - Bolt
5 - Pedal support
❑ For the accelerator and
brake pedal housing
AG. Volkswagen AG d
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6 - Hexagonal nut olksw not
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7 - Clutch pedal switch - F36-
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❑ There are two types
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⇒ page 18
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8 - Pedal return spring
es, in part or in w
t to the co
⇒ page 20
9 - Bearing bush
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10 - Support pin
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11 - Clutch pedal
❑ Remove and install ⇒ page 23
nf
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m
12 - Housing
atio
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❑ Remove and install ⇒ Item 5 (page 25)

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13 - Hexagonal nut
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❑ 25 Nm
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❑ Replace after every removal
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14 - Clutch hydraulic drive transmitting cylinder
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AG.
15 - Lock
16 - Supply hose
17 - Clutch pedal return spring housing
❑ Installation position: the tab -arrow- fits in the transmitting cylinder notch
❑ Install on the housing support
❑ To replace, remove and install the transmitting cylinder of the clutch hydraulic drive ⇒ page 40
18 - Bolt
19 - Limiter stop
❑ For clutch pedal
20 - Hexagonal nut
❑ Self-locking
❑ 25 Nm
Types of Clutch pedal switch - F36-

A - Clutch pedal switch - F36- with rectangular case -arrow-.
- Remove and install ⇒ page 18 .
B - Clutch pedal switch - F36- with round case -arrow-.
- Remove and install ⇒ page 19 .
AG. Volkswagen AG d
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1.1.3 Clutch pedal switch - F36- with rectan‐ th eo
au ra
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gular case - remove and install
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Catalogue “ETKA” rrectness of i
To ensure a seating sufficiently firm on the support, the Clutch

pedal switch - F36- must be mounted only once.
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Removal:
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ercia
– Disconnect connector from Clutch pedal switch - F36- .

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– Turn the Clutch pedal switch - F36- 90° clockwise and remove
tion in
it from support.
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Installation:
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– Pull rod “pivot” to the stop.

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Before installing the Clutch pedal switch - F36- on the support, a Prote
cted AG.
agen
small amount of Polyurea grease - G 052 142 A2- must be applied
on the “pivot” rod of the clutch switch
– Install the clutch pedal switch - F36- of the clutch on the sup‐
port and fasten it by turning it 90° anticlockwise.
– Engage the connector of the Clutch pedal switch - F36- con‐
nector.

1.1.4 Clutch pedal switch - F36- with round

case - remove and install
WARNING
The Clutch pedal switch - F36- must only be removed from the
pedal support with the rod pressed downwards, otherwise the
switch housing will begedamaged.
n AG. Volkswagen AG d
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♦ When handling
db
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chemicals follow the safetyotinstructions
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ara ⇒
Chemical
o
ir se Products Manual; Rep. gr. 00 nte
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ut or
♦ Assignment
ss
a of Chemical Materials ⇒ Electronic Parts
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Removal:
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– Disengage the connector -1- from the Clutch pedal switch -
h re
F36- .
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spec
– Press the rod-3- of the Clutch pedal switch - F36- .
t to the co
– Turn the Clutch pedal switch - F36- -2- 45° in counterclockwise
direction and remove it through the support hole.
rrectne
Note
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The clutch pedal remains in the rest position (not activated).

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mer
atio
m
Installation:
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– Apply the polyurea grease - G 052 142 A2- on the rod, zone
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-A-.
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– Install the Clutch pedal switch - F36- -3- in its respective hous‐
ing, by pressing the activation rod -3- and fastening it by
turning it (45°) clockwise.
Note
The clutch pedal remains in the rest position (not activated).
– Connect the connector -1- of the Clutch pedal switch - F36- .

– After installation, check that it works properly. For some vehi‐
cles, depending on the engine, its working order can be
checked by means of ⇒ Vehicle diagnostic tester.
1.1.5 Clutch pedal return spring - remove and

install
Special tools and workshop equipment required
♦ Pliers - T 10005-
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Removal:
spec
es, in part or in w
t to the co
– Remove the Clutch pedal switch - F36- ⇒ page 18
– Pull clutch pedal slightly towards front seat and press inwards
both sides of the housing with Pliers - T 10005- both sides of
rrectness of i
the housing inwards -arrows-.
l purpos
– Separate the transmitting cylinder stem from the clutch pedal's

hydraulic drive.
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– Press the return spring towards the partition panel -arrow- and
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remove it from downwards.
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Installation:
Prote AG.
– Check that the support -arrow 1- for the pedal return spring is
installed on the support.
Installation position:
– The support tab should be into the gear cylinder notch
-arrow 2-.

– First, install the pedal return spring on the rear part of the sup‐
port.
– Then, press the pedal return spring on the support tab
-arrow-.
– Install the Clutch pedal switch - F36- ⇒ page 18
1.1.6 Clutch pedal support - remove and install
Special tools and workshop

equipment required
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Prote AG.
♦ Clamps (diameter 25 mm) - 3094-

♦ Torque wrench - 5 to 50 Nm ( 1/2” drive) - VAG 1331-
♦ VW 5162 or Standard type clamp pliers - VAS 5024A-
♦ Pliers - T 10005-
Removal:
– Disconnect the Battery - A- ⇒ Electrical equipment; Rep. gr.
27 ; Starter, alternator, battery .
– Pull the harness carefully forwards.
– Place a lint-free cloth sufficiently large under the transmitting
cylinder of the clutch hydraulic drive.
– Install Clamp (diam.25 mm) - 3094- on the return hose -A- and
release it from the transmitting cylinder.
Note
If the hose is secured with a spring clamp, release it with Stand‐

ard-type or VW 5162 clamp pliers - VAS 5024A- .
– Remove clip -B- from the tubing and hose assembly on the
transmitting cylinder.
– Remove tubing and hose assembly -C- from the transmitting
cylinder and cover it.
– Remove the Clutch pedal switch - F36- ⇒ page 18
AG. Volkswagen AG d
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♦ The clutch pedal support is removed with the transmitting cyl‐
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inder. aut ra
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♦ Before removal, it is necessary to separate the transmitting

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cylinder from the clutch pedal.
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– Separate the transmitting cylinder stem from the clutch pedal's t to the co
hydraulic drive.
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– Loosen the fastening nuts -arrow 1- from the housing support

-arrow A-.
– Remove the housing support.
– Remove the cable return spring.
– Remove the return spring housing from the housing support.
– Release the clutch pedal stop.
Installation: AG. Volkswagen AG d
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on the clutch hydraulic drive -B-.
– Press clutch pedal -arrow- to fit the drive stem, make sure the
rrectne
fitting is OK.
– Bleed the clutch system ⇒ page 41 .
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– Remove clutch pedal support ⇒ page 21 .
– Remove the cable return spring ⇒ page 20 .
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Installation:
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– Install cable return spring ⇒ page 20 .

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1.1.8 Hydraulic system - assembly overview

1 - Brake fluid reservoir

2 - Supply hose
❑ Replace whenever AG. Volkswagen AG d
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❑ Push to the stop in order
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to remove and install the
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pipes and hose assem‐
bly
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5 - Housing
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❑ Change only by remov‐

ing the transmitting cyl‐
inder of the clutch hy‐
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draulic drive
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❑ Remove ⇒ page 26
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❑ Install ⇒ page 26
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6 - Clutch pedal
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⇒ page 23
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❑ 25 Nm
AG.

moval
8 - Seal
❑ Fit on cable connection
❑ Lubricate with brake fluid
9 - Pipes and hose assembly
10 - Mounting bracket
❑ Fastened on body
❑ For pipes and hose assembly
❑ Fastened on the slave cylinder of the clutch hydraulic drive
12 - Hexagon socket head bolt
❑ 20 Nm
13 - Clip
❑ Push to the stop in order to remove and install the pipes and hose assembly
14 - Protection cover
15 - Air bleeding valve
❑ Bleed the clutch system ⇒ page 41
16 - Hydraulic clutch slave cylinder
17 - Gearbox
Remove housing -A- by leveraging towards arrow
Install housing -A- on the drive stem of the transmitting cylinder

of the clutch hydraulic drive, towards arrow
Assembly of the flexible plastic tube -1- in some vehicles

• The gaskets -2- must be on the flexible tube.
• Check Assignment in the ⇒ Electronic
agen
AG. VParts
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1.1.9 Transmitting cylinder - clutch hydraulic

spec
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drive - remove and install

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Removal:
– Pull the harness carefully forwards.
– Place a lint-free cloth sufficiently large under the transmitting
cylinder of the clutch hydraulic drive.
– Install Clamp (diam.25 mm) - 3094- on the return hose -A- and
Note
If the hose is secured with a spring clamp, release it with Stand‐

ard-type or VW 5162 clamp pliers - VAS 5024A- .
– Remove clip -B- from the tubing and hose assembly on the
transmitting cylinder.
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– Separate the transmitting cylinder stem from the clutch pedal's

hydraulic drive.
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– Loosen the fastening nuts -arrow 1- from the housing support

-arrow A-.
– Remove the housing support.
– Remove the cable return spring.
– Remove the return spring housing from the housing support.
– Release the clutch pedal stop.
– Remove the transmitting cylinder on the clutch hydraulic drive.
Installation:
– Install cable return spring.

– Press clutch pedal -arrow- to fit the drive stem, make sure the
fitting is OK.
– Bleed the braking system after installing the gear cylinder
⇒ page 41 .
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hole
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⇒ “1.2.2 Command pedals - assembly overview”, page 29
es, in part or in w
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⇒ “1.2.3 Hydraulic system - assembly overview”, page 31
⇒ “1.2.4 Clutch pedal return spring - remove and install”,
rrectness of i
page 33
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⇒ “1.2.5 Clutch pedal support - remove and install”, page 35

⇒ “1.2.6 Clutch pedal - remove and install”, page 37
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1.2.1 Command system (version 2) - component overview

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I - Command pedals - assem‐

II - Hydraulic system - assem‐
bly overview ⇒ page 31 agen
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1.2.2 Command pedals - assembly overview
WARNING
Self-locking screws/nuts must be replaced whenever loosened

and/or removed.

tition panel
❑ With housing for the
clutch support and mas‐
ter gear cylinder
2 - Bushing
❑ For the upper clutch
pedal support housing
❑ Bushings with smaller
assembly holes, located
in the clutch hydraulic
drive gear cylinder
3 - Clutch pedal support
❑ To remove and install
the gear cylinder on the
clutch hydraulic drive
⇒ page 35
4 - Hexagonal nut
❑ Self-locking
❑ 25 Nm
❑ 3 units
moval
5 - Impact absorption bar
❑ Fastened to the steering
column
❑ Assignment: ⇒ Elec‐
tronic Parts
6 - Bolt
❑ 20 Nm
7 - Limiter stop lkswage es n
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11 - Bearing bushes
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12 - Clutch pedal cover

❑ Replace if damaged
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13 - Housing
s
❑ May be removed with the clutch hydraulic drive gear cylinder installed
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14 - Clutch hydraulic drive transmitting cylinder

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15 - Clip
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Rep. gr.30 - Clutch Prote AG.
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17 - Clutch position sensor - G476-
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18 - Piping (plastic)
hole
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❑ Assembly in the flexible plastic tube ⇒ page 26
es, in part or in w
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1.2.3 Hydraulic system - assembly overview
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Assembly overview (plastic piping)
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❑ Assembly in the flexible

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draulic drive.
5 - Clutch pedal
⇒ page 37 .
6 - Hexagonal nut
❑ Self-locking.
❑ 3 units.
❑ 25 Nm.
❑ Replace after each re‐
moval.
7 - Clutch hydraulic drive trans‐
mitting cylinder
⇒ page 40 .
8 - Clip
❑ Push until the stop to re‐
move and install the
pipes.
❑ Assignment: ⇒ Electronic Parts Catalog “ETKA”
❑ Remove and install ⇒ page 40 .
11 - Clip
❑ Push until the stop to remove and install the pipes.
12 - Bolts
❑ 20 Nm.
❑ Replace after each removal.
❑ Bleed the steering system ⇒ page 41 .
14 - Protection cover
15 - Gearbox
Assembly overview (metallic piping and hose)

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4 - Housing
hole
spec
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5 - Clutch pedal
nf
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⇒ page 37 .
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6 - Hexagonal nut
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7 - Clutch hydraulic drive trans‐ Prote
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mitting cylinder
⇒ page 40 .
8 - Clip
❑ Push to the stop in order
to remove and install the
pipes and hose assem‐
bly.
9 - Piping (metallic and hose)
❑ Assignment: ⇒ Electronic Parts Catalog “ETKA”
❑ Fastened on body.
❑ For the piping set.
11 - Bolts
❑ 20 Nm.
❑ Remove and install ⇒ page 40 .

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❑ Bleed the steering system ⇒ page 41 .
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16 - Protection cover ole,
spec
17 - Gearbox
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Remove housing -A- by leveraging towards arrow
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Install housing -A- on the drive stem of the transmitting cylinder
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of the clutch hydraulic drive, towards arrow Prote
cted AG.
agen
Assembly in the flexible plastic tube -1-

• The gaskets -2- must be on the flexible tube.
• Assignment: ⇒ Electronic Parts Catalog “ETKA”
1.2.4 Clutch pedal return spring - remove and

install
olkswagen AG
5-speed manual gearbox (02T and 0AP) - Edition
swa
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Removal
ss
– Release the master cylinder clutch pedal with the Pliers -
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T10005- .
inform
mer
– Remove the pedal support return spring.
atio
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Installation
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– Place the pedal return spring laterally from underneath, along

with the gear cylinder rod and the pedal support -A-.
– Install the pedal return spring in the clutch pedal support

-arrow-.

– Ensure that the housing -2- is located in rod -1-.

– Press the set (housing), until an audible fitting sound is heard
in the clutch pedal crease -3-.
1.2.5 Clutch pedal support - remove and in‐

stall
♦ Clamps (diameter 25 mm) - 3094-
AG. Volkswagen AG d
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♦ Buffer set - T10249-

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Removal:
– Remove the air filter in case of difficulty accessing the master
cylinder ⇒ Engine; Rep. gr. 24 ; Fuel supply - injection sys‐
tem .
Note
♦ For the following operations, ensure that fluid is not spilled

over the gearbox or body. Otherwise, clean
wagen AGthe affected
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♦ Place a lint-free cloth under
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ris nte
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– Install Clamp (diam. 25 mm) - 3094- on the return hose and
ce
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ab
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– Unlock the Clutch position sensor - G476- -arrow A- and
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-arrow B- of the transmitting cylinder.
form
mer
– Remove the Clutch position sensor - G476- from the transmit‐ atio
om
ting cylinder, while the electrical harness is connected.

n
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– Release the fastening clamp -1-, using a screwdriver.

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– Disconnect hose -2- of the transmitting cylinder.

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When performing activities near the feet area (next to the clutch Prote AG.
pedal), protect the floor lining (rug) with cloths in order to prevent
potential brake fluid contamination.
– Remove the fastening nuts -1- and -2-.

– Remove clutch pedal support -3-.
Installation:
Installation is performed in reverse to the removal sequence, ob‐
serving the following:
Note
♦ Replace the sealing applied in the clutch hydraulic drive trans‐

mitting cylinder.
♦ Always replace self-locking nuts.

– Remove the Clamp (diam.25 mm) - 3094- from the return hose
and, if necessary, bend the supply hose -1- back to its original
shape (original contour).
– Press the tube -3- in the cylinder connection until an audible
fastening sound is heard in clamp -2-.
– Install the Clutch position sensor - G476- in the transmitting
cylinder.
– Bleed the clutch system ⇒ page 41 .
– If removed, install the air filter ⇒ Engine; Rep. gr. 24 ; Fuel
supply - injection system .
1.2.6 Clutch pedal - remove and install

♦ Pliers - T10005-
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Note
♦ Always replace the bearing pin ⇒ Item 8 (page 30) .

rrectness of i
♦ If only the return spring must be removed, do not remove the

l purpos
clutch pedal.
nform
ercia
Removal:
m
at
– Remove the air duct for front feet (left side) ⇒ Heating, air
om
ion
conditioning; Rep. gr. 80 ; Heating .

c
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– Remove the fastening bolt -arrow- and remove the impact ab‐
a
do
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sorption bar.
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– Release the master cylinder clutch pedal with the Pliers -

T10005- .
– Remove the clutch pedal support spring.
Remove the clutch pedal bearing pin as detailed below:
– Turn the clutch pedal bearing pin using an Allen wrench

(10 mm) in the direction of the -arrow-.
The locks -arrows 1- will be damaged.
– Move the clutch pedal in order to remove the clutch pedal
bearing pin.
– Remove the clutch pedal.
Installation:
• Install the clutch pedal using a new bearing pin.
– Install the new clutch pedal bearing pin as detailed below:
– Turn the clutch pedal bearing pin using an Allen wrench

(10 mm) in the direction of the -arrow-. wage
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– Install and tighten the fastening bolt -arrow- of the impact ab‐
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2 Clutch drive mechanism

⇒ “2.1 Clutch drive mechanism - assembly overview”, page 39
⇒ “2.2 Clutch slave cylinder - remove and install”, page 40
⇒ “2.3 Clutch drive mechanism - bleed”, page 41
2.1 Clutch drive mechanism - assembly

overview
WARNING
AG. Volkswagen AG d
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♦ When handling chemicals follow the safety instructions
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Chemical Products Manual; Rep. gr. 00ised b ara
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♦ Assignment of Chemical Materialss⇒
au Electronic Parts
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Catalogue “ETKA” s
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1 - Clutch roller bearing
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❑ Remove and install with
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hole
the clutch release lever
spec
⇒ Item 3 (page 39)
es, in part or in w
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and roller bearing guide
bushing
rrectness of i
❑ Do not wash the clutch
roller bearing, just clean
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❑ Change damaged roller
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❑ Remove and install with cted agen
Prote AG.
the clutch roller bearing
⇒ Item 1 (page 39) and
roller bearing's guide
bushing
❑ Lubricate the touching
point on the spherical
pin with Lubricating
grease - G 000 100- .
4 - Lever pressure lever
❑ Fasten on the clutch lev‐
er
5 - Roller bearing's guide bush‐
ing
⇒ page 40
❑ Remove and install with the clutch roller bearing ⇒ Item 1 (page 39) and roller bearing's disengaging
lever ⇒ Item 3 (page 39)
2. Clutch drive mechanism 39

6 - Sealing ring for input shaft

❑ Replace ⇒ page 125
7 - Ball pin
❑ 20 Nm
❑ Lubricate with Lubricating grease - G 000 100- .
8 - Gearbox
9 - Bolt
❑ 20 Nm
11 - Slave cylinder
❑ Lubricate the stem tip with Lubricating grease - G 000 100- .
Removing and installing the clutch lever with the clutch bearing
and bearing guide
– Loosen the bolts -arrows-.
– Separate clutch lever, with the clutch lining and guide bushing,
from input shaft and ball-head pin.
Installation is performed in reverse to removal sequence.
Removing and installing the bearing's guide bushing agen

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– Displace the guide bushing -3- from the clutch lining -2- d bby
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– While securing the collar -2-, turn guide bushings -3- 90° to‐
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– Remove guide bushing from collar. y li

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Removing and installing clutch lining

rrectne
– Compress the fitting edges -arrows- located on the rear part

of the clutch lever, and pull collar -A- out of the lever.
s
– To install collar -A-, engage it on the clutch lever until fitting

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the edges -arrows- .

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– When the air filter is installed behind the Battery - - , the ⇒
rrectness of i
motor of the fuel supply system; Rep. gr. 24 ; Supply system
- fuel injection must also be removed.
l purpos
– Place a sufficiently large lint-free cloth under the clutch slave

cylinder.
nf
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– Remove the clip -A- on the drive receiving cylinder, which fas‐
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tens the tubes and hose.

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– Remove the tubing and hose assembly from the housing -C-
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– Bleed the clutch system after installing the receiving cylinder
⇒ page 41 .
2.3 Clutch drive mechanism - bleed

♦ Brake filling and bleeding equipment - VAS 5234-
2. Clutch drive mechanism 41

♦ Brake bleeding device - V.A.G 1869-
Note
System pre-filling is not required
– When required, use 670-mm long hose - 1238/B3 - .

– Connect the bleeder hose ton A
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hose on the impelling cylinder -arrow- and
or
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open the bleeding valve.
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– Pressurize the system to 2 bar.

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– Open the bleeding valve.

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– Bleed approximately 100 cm3 of brake fluid.

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– Press quickly the pedal from stop to stop, 10 to 15 times.

spec
– Let bleed additional 50 cm3 of brake fluid.

t to the co
– Close the bleeding valve.

rrectne
– Press the clutch pedal several times.

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3 Clutch
⇒ “3.1 Clutch - assembly overview”, page 43
⇒ “3.2 Clutch - repair”, page 45
3.1 Clutch - assembly overview
WARNING

Note
♦ Change clutch plates and plate with damaged or loosened riv‐

eted unions.
♦ The clutch plate and plate must correspond each other ac‐
cording to the ⇒ Electronic Part Catalogue“ETKA” and the
engine prefixes. n AG. Volkswagen AG do
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3. Clutch 43
1 - Flywheel
❑ Pay attention to perfect
fitting of the guide pins
❑ The contact surface of
the clutch plate should
be free of oil and grease,
and should not have
grooves
❑ Remove and install ⇒
Engine; Rep. gr. 13 ;
Crankshaft, pistons
2 - Clutch plate
❑ Installation position: the
spring case should be
facing the clutch plate
❑ Centre the clutch disc
⇒ page 45
❑ Apply a slight coat of
grease on the splines
❑ Clean the splines on the
input shaft and the
clutch plate hub used
❑ Eliminate corrosion and
apply a thin coat of Lu‐
bricating grease - G 000 gen AG
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splines. Move the clutch rised b ara
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plate on the input shaft utho eo
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to one side and other ss a c
until the hub slides
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Eliminate excess
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3 - Clutch plate
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spec
⇒ page 45
es, in part or in w
t to the co
❑ Check the membrane spring ⇒ page 46

❑ The clutch plates are greased and protected against corrosion. Clean the contact surface only; otherwise,
the clutch lifetime will be significantly reduced
rrectness of i
4 - Bolt
l purpos
❑ 20 Nm
❑ Loosen and tighten in a cross and phased pattern
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3.2 Clutch - repair

equipment required
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♦ Lock - 3067-
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♦ Guide pin - 3190A- t. Cop py
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♦ Guide Pin - T 10086-
agen
Prote AG.
Centre the clutch disc using the Guide Pin - T 10086- - remove
and install the clutch plate
or
3. Clutch 45
Centre the clutch disc using the Guide Pin - 3190A- - remove and
install the clutch plate
– Loosen and tighten screws in a cross and ophased
en AG. V
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AG ag does
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– To remove, install Lock - 3067- gu
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♦ The clutch plate and clutch plate contact surfaces must be
itte
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completely seated on the engine's flywheel.
erm
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♦ Tighten evenly the fastening screws, in a cross pattern, to
wit
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prevent damages on the membrane spring of the clutch plate
h re
and the guide pins of the engine's flywheel.
hole
spec
es, in part or in w
t to the co
Check membrane spring height
• Wear until half of the membrane spring thickness is permitted.
rrectness of i
– Install the clutch ⇒ Item 3 (page 44) .
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– Reset centesimal dial gauge to zero in one of the clutch plate cted agen
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membrane spring tabs.
– Measure height of each tab and write down the values.
– Consider the highest and lowest values found.
– The sum of obtained values on the right and left of the zero
point at the centesimal dial gauge should not be higher than
0.80 mm. Otherwise, replace it.

34 – Controls, housing
1 Shift mechanism
⇒ “1.1 Shift mechanism - installation position”, page 47
⇒ “1.2 Selector mechanism - component overview”, page 49
⇒ “1.3 Drive cables”, page 51
⇒ “1.4 Handle and boot on the gear lever - assembly overview”,
page 59
⇒ “1.5 Handle and boot on the gear lever - remove and install”,
page 60
⇒ “1.6 Handle and boot on the gear lever - disassemble and as‐
semble”, page 61
⇒ “1.7 Gear shift lever and shifting mechanism - remove and in‐
stall”, page 62
⇒ “1.8 Gearshift lever and mechanism - repair”, page 66
⇒ “1.9 Lever and Gear shifting mechanism - adjusting”,
page 68
⇒ “1.10 Selector and lever - functional check”, page 70
1.1 Shift mechanism

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-Arrow B- track
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1. Shift mechanism 47
A - Gear selector cable

B - Track selector cable
C - Heat shield
❑ It should be removed
before removing the
shift mechanism
1 - Gearbox selector lever
2 - Inversion lever
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48 Rep. gr.34 - Controls, housing

1.2 Selector mechanism - component over‐

view
⇒ “1.2.1 Selector mechanism - (version 1)”, page 49
1.2.1 Selector mechanism - (version 1)

olkswagen AG
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I - Drive cables olks
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❑ Remove and install ised b ara
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⇒ page 51 . ut
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II - Gear lever handlesand boot
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❑ Assembly overview
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⇒ page 59 .
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⇒ page 60 .
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III - Gear lever and mechanism
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❑ Repair ⇒ page 66 .
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I - Drive cables
⇒ page 53 .
II - Gear lever handle and boot
⇒ page 60 .
⇒ page 60 .
III - Gear lever and mechanism
❑ Repair ⇒ page 66 .
AG. Volkswagen AG d
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I - Drive cables
⇒ page 55 .
II - Gear lever handle and boot
⇒ page 60 .
⇒ page 60 .
AG. Volkswagen AG d
III - Gear lever and mechanism agen oes
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❑ Repair ⇒ page 66 . ed b ara
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1.3 Drive cables
Prote AG.
⇒ “1.3.1 Drive cables (version 1) - remove and install”,

page 51
page 53
page 55
1.3.1 Drive cables (version 1) - remove and

install
WARNING

Note
♦ Lubricate supporting points and sliding surfaces.

♦ Assignment of Lubrication grease - G 000 450 02- ⇒ Elec‐
tronic Parts Catalogue“ETKA” .
1 - Gear selector cable

❑ Press on the gear lever
guide
❑ Installation position
⇒ page 47
❑ For replacement it is
necessary to remove
the gearshift mecha‐
nism case ⇒ page 62
2 - Track selector cable
❑ Connected on the com‐
mand selector
⇒ page 47
necessary to remove
the gearshift mecha‐ AG. Volkswagen AG d
nism case ⇒ page 62 agen oes
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3 - Circlip rised
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❑ Replace after every re‐ aut ra
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4 - Circlip
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❑ Pay attention to prevent
h re
damages on cables dur‐
hole
spec
ing removal
es, in part or in w
5 - Gearshift mechanism case t to the co

⇒ page 62
rrectness of i
6 - Fastening support
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7 - Housing bushing
nf
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8 - Spacer
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❑ 20 ± 2 Nm
or
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❑ For fastening support

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10 - Selector cable fastening

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❑ To fasten the gear selector cable to the selector lever
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❑ Replace after every removal from the gearbox selector lever rig ht
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11 - Selector cable fastening Prote
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agen

❑ Replace after every removal from the gearbox selector lever
12 - Safety washer

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13 - Bearing bush db
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15 - Guide shoe
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❑ Installation position ⇒ page 53
hole
spec
❑ Install in order that the interrupted teeth division fits on the selector lever shaft
es, in part or in w
t to the co
❑ After installation, adjust the gear selection mechanism ⇒ page 68
17 - Hexagonal nut
rrectness of i
❑ Self-locking
❑ 20 ± 2 Nm
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Installation position of the selector lever/inversion lever
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2- Inversion lever. Installed on the selector lever guide by a

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install
WARNING

Note


guide
❑ Installation position agen
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⇒ page 47 olksw not
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❑ For replacement it is oris e nte
necessary to removeaut h eo
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the gearshift mecha‐ ss c
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mand selector
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⇒ page 47
es, in part or in w
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necessary to remove
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3 - Circlip
l purpos

moval
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4 - Circlip
m
at
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5 - Gearshift mechanism case
C py
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❑ Remove and install p by
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⇒ page 62 Prote
cted AG.
agen
7 - Housing bushing
8 - Spacer
❑ 20 ± 2 Nm
❑ For fastening support
12 - Safety washer
13 - Bearing bush
14 - Inversion lever
❑ Installation position ⇒ page 55 .
15 - Guide shoe

5-speedwamanual
gen AG gearbox
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❑ Install in order that the interruptediseteeth division fits on the selector leverarshaft
d b
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❑ After installation, adjust the gearutho selection mechanism ⇒ page 68 or
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17 - Hexagonal nut
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❑ Self-locking
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1- selector lever with balancing weight
2- Inversion lever. Installed on the selector lever guide by a
rrectne
shoe -arrow-.
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Note


guide AG. Volkswagen AG d
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⇒ page 47 rised b ara
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⇒ page 47
t to the co
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3 - Bushing
4 - Circlips
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⇒ page 62
rig ht
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Prote AG.
❑ Different versions ⇒
Electronic Parts
Catalogue“ETKA”
7 - Housing bushing
8 - Spacer
❑ 20 ± 2 Nm
❑ For fastening of the fastening support to the transmission
❑ Location ⇒ page 57
❑ Different versions ⇒ Electronic Parts Catalogue“ETKA”
11 - Safety washer
❑ Location ⇒ page 57
13 - Hexagonal nut
❑ Self-locking
❑ 20 ± 2 Nm


❑ Install in order that the interrupted teeth division fits on the selector lever shaft
❑ After installation, adjust the gear selection mechanism ⇒ page 68
15 - Shoe
16 - Inversion lever
❑ Installation position ⇒ page 57 .
17 - Plastic lock
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Selector cable fastening
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Assignment: ⇒ Electronic Parts Catalog “ETKA”
hole
spec
Locking of cable for: Dimension “a”
es, in part or in w
t to the co
1.- Shift cable to shift lever (locking of shift cable 8.5 mm
with high box)
rrectness of i
2.- Shift cable to shift lever (locking of shift cable 10 mm
with flat box)
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2.- Selector cable to metal inversion lever 8 mm

2.- Selector cable to plastic inversion lever 10 mm
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Removal of selector cable from its fastening
lksw
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– Press the mechanism forward, up to the buffer
-in direction of arrow 1- and then remove it by turning it to the
left -in direction of arrow 2-.
– Then press the lever forward -in direction of arrow 3-.
Inversion lever with clip

Removal:
• To remove the inversion lever, it is necessary to remove the
selector cable from its fastening ⇒ page 57 .
Note
By doing so, it is possible to avoid damage to the selector cable
– Remove the clip -arrow 1- and remove the inversion lever

along with the fastening of the selector cable.
The fastening of the selector cable must be installed -arrow 2-.
Continuation:
• Remove the fastening of the selector cable only with the in‐
version lever removed ⇒ page 58
Installation:
Note
♦ Lubricate supporting pointsagand

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agen AG
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♦ Assignment of theedLubrication
by
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grease - G 000 450 02- g⇒uarElec‐
a
tronic Parts Catalogue“ETKA”
ho
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ss
– Fit via pressure the fastening of the selector cable on the in‐
ce
le
un
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version lever ⇒ page 59 .

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– Insert the inversion lever up to the buffer, along with the fas‐
rm
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tening of the selector cable.

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• The lock -arrow 1- arrests the inverter lever (⇒ previous figure).

h re
hole
spec
• Ensure a safe fit.

es, in part or in w
t to the co
• The fastener of the selector cable must be installed -arrow 2-

(⇒ previous figure).
rrectness of i
Removal of the fastening of the selector cable on the inversion

lever
l purpos
• The inversion lever must be removed

nform
ercia
– Insert a screwdriver -A- between the bushing -B- and the in‐
m
version cable.
a
com
tion in
r
te o
thi
s
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cum
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Prote AG.

Installation of the fastening of the selector cable on the inversion

lever
• The inversion lever must be removed
• Press the fastening of the cable, only via the bushing
-arrow-.
• The fastening of the selector cable must have mobility on the
inversion lever.
1.4 Handle and boot on the gear lever - as‐

sembly overview
⇒ “1.4.1 Handle and boot on the gear lever (version 1) - assembly
overview”, page 59
⇒ “1.4.2 Handle and boot on the gear lever (version 2) - assembly
overview”, page 60
1.4.1 Handle and boot on the gear lever (version 1) - assembly overview
1 - Gear knob
⇒ page 60
boot
2 - Clamp
❑ To fasten handle to gear
lever
moval n AG. Volkswagen AG do
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❑ Fasten with Clamp pli‐ yV
olks ot g
ers or VW 004V - VAG ir se
d b ua
ran
1275- to gear knob tho tee
or
au ac
3 - Bushing ss
ce
le
un
pt
4 - boot with frame

an
d
itte
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rm
ab
pe
ility
the gear knob.

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
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rp
cum
fo
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co
59
by lksw
cted agen
Prote 1. Shift mechanism
AG.
1.4.2 Handle and boot on the gear lever (version 2) - assembly overview
1 - Gear knob
⇒ page 60
boot
2 - boot with frame
the gear lever handle
❑ Disassemble gear lever
handle, by removing the
bushing ⇒ page 61
3 - Bushing
4 - Clamp
❑ To fasten handle to gear
lever
moval AG. Volkswagen AG d
agen
❑ Fasten with Clamp Vopli‐
lksw
oes
not
gu
ers or VW 004V d b- VAG
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1275- to gear
thori knob eo
au ra
c
ss
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nl
pt
du
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itte
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erm
ab
ility
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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
1.5 Handle and boot on the gear lever - re‐

rm
m
atio
m
move and install

o
n in
or c
thi
e

t
sd
iva
o
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rp
cu
♦ Clamp pliers or VW 004V - VAG 1275-

o
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t. rig
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by
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Prote AG.

♦ Spatula - VW 037-
1.5.1 Removal
– Carefully disengage boot from centre console using the scra‐
per - VW 037- .
– Turn boot backwards on top of gear knob.
– Remove trim, if any.
– Remove clamp -arrow- and remove gear lever handle along
with boot.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
1.5.2 Installation
nl
pt
du
an
itte
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– Turn boot lower section outwards.

erm
ab
ility
ot p
– Assemble gear lever handle and boot and put a new clamp
wit
, is n
-arrow-.
h re
hole
spec
When assembling, handle must fit the gear lever groove.

es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
c
1.6 Handle and boot on the gear lever - dis‐

or
thi
te
sd
assemble and assemble

iva
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op
1.6.1 Disassembly
C py
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– Turn cover internal side outwards. by c lksw
cted agen
Prote AG.
– With a screwdriver, carefully force tightening bushing -arrow-

and simultaneously pull gear lever handle out.
lkswage es n
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byV ua
Note o
ir se
d ran
tee
th or
au ac
For some components, screwdriver must be used between pack‐
ss
ce
le
ing and bushing where indicated by the -arrow-.

un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
1.6.2 Assembly
rrectness of i
– Install gear lever handle on boot.
l purpos
– Press tightening bushing on handle and fit.
nform
ercia
1.7 Gear shift lever and shifting mechanism

m
a
- remove and install
com
tion in
r
te o
Special tools and workshop equipment required thi

s
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do

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cum
fo
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t.
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cted agen
Prote AG.

♦ Spatula - VW 037-
1.7.1 Removal
– Disconnect and remove the Battery - A- ⇒ Electrical equip‐
ment; Rep. gr. 27 ; Starter, alternator, battery .
Note
♦ Check whether the vehicle has a coded radio. If so, solicit the
anti-theft code before disconnecting the Battery - A- .
♦ When the Battery - A- ground wire is reconnected, check ve‐
hicle equipment (radio, clock, central locking, electric win‐
dows, etc.) according to the repair manual and/or instructions
for use.
– Remove the console from the Battery - A- ⇒ Electrical equip‐

Continuation to the inversion lever “metal”:
– The fastening elements -A- or -B- must be disengaged by us‐
ing a spanner -1-, only to replace AG. Volkswagen AG d
swagen the gear selectionoes cable,
track selector cable orbyfastening
Vol
k
element. not
gu
d ara
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1- 13 mm spanner
tho
ri e or
au ac
– Install a second
ss open-mouth wrench or suitable pliers -2- be‐
ce
e
low.
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
Note
rrectness of i
If it is not necessary to replace the mentioned components, it is

l purpos
necessary to loosen the fasteners by unlocking their respective

locks -arrow-.
nform
ercia
Continuation to the inversion lever “plastic”:

m
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
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pyri by
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by
cted agen
Prote AG.
– Press the mechanisms forward, up to the buffer

– Then remove the cables from the fastening elements.
Continuation for:
Vehicles with fastening support of the gearbox cable “metal”:
– Loosen fastening screws -arrows- and remove the gearbox

cable fastening support.
Note
For better comprehension, the selector lever, inversion lever and

cable fastening elements are not represented.
Vehicles with fastening support of the gearbox cable “metal”:
– Loosen fastening screws -arrows- and remove the gearbox

cable fastening support.
Continuation:
AG. Volkswagen AG d
agen oes
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ara
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aut ra
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ce
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un
pt
an
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itte
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rm
ab
pe
ility
– Remove carefully the boot on the central console. To facilitate

ot
wit
the operation, use the Scraper - VW 037- with care.

, 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
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cum
fo
en
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t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

– Loosen clamp -arrow- and pull gear lever handle out along with
boot.
– Remove the centre console ⇒ Body - Internal assembly work;
Rep. gr. 68 ; Internal equipment .
– Remove fastening nuts -arrows- from the gearshift mechanism

housing case.
– Remove the engine compartment lower noise insulation, if any
⇒ General body repairs, exteriors; Rep. gr. 50 ; Body - Front
section .
– Remove cross member under the exhaust system.
– Separate the front exhaust pipe from the rear exhaust pipe, by
loosening the double clamp and the sustaining strap of the
intermediate silencer ⇒ Engine; Rep. gr. 26 ; Exhaust system .
lkswage es n
o ot g
byV ua
Note rised ran
tee
tho
u or
a a
Fasteningss nuts and screws of the front exhaust pipe near thecex‐
haust tube, near the catalyst converter
ce
e
nl
pt
du
an
itte
y li
– Remove heat shield.

erm
ab
ility
ot p
– Remove the gearshift mechanism case downwards together

wit
, is n
with the drive cables.

h re
hole
spec
es, in part or in w
1.7.2 Installation
t to the co
WARNING
rrectness of i

l purpos

nf
ercia

or
m
m
atio
om
n in
or c
thi

te
sd
a

iv
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m
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t.
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t. rig
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Prote AG.
Continuation to the inversion lever “metal”:

If the fastening elements of the cables have been removed, they
must be replaced.
– Apply a light coat of lubricating grease on the housings of the
new fastening elements -A- and -B-.
Note
♦ Assignment of the Lubrication grease - G 000 450 02- ⇒ Elec‐

tronic Parts Catalogue“ETKA”
agen
AG.. Volkswagen AG d
o w es n
olks o
♦ The external sealing
ed
by lips -arrows- should be free ofgugrease.
V t
ara
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
– Press the gate selector cable on the selector lever, and the
erm
ab
track selector cable on the inversion lever -arrows-.
ility
ot p
wit
, is n
If the selector cable fastening has not been removed:
h re
hole
– Connect the gear selector cable and the command selector
spec
es, in part or in w
cable with respective fixtures.
t to the co
– Adjust the gearshift mechanism ⇒ page 68 .
Continuation to the inversion lever “plastic”: rrectness of i
The securing elements have different ∅ holes. See placing

l purpos
⇒ page 57
nform
ercia
Note
m
at
om
ion
c
Assignment of the Lubrication grease - G 000 450 02- ⇒ Elec‐

in t
or

his
ate
do
priv
cum
for
en
g
– Apply a light coat of lubrication grease on the housings

n
t.
yi Co
op
-arrows- of the fastening elements -1- and -2- and on the slid‐ C py
ht. rig
ing surfaces. rig ht
py by
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– Install the new metallic lock -arrow- of the fastening element Prote
cted AG.
agen
-2-.
– Connect the gear selector cable and the command selector
cable with respective fixtures.
– Adjust the gear selection mechanism ⇒ page 68 .
1.8 Gearshift lever and mechanism - repair
WARNING


Note

AG. Volkswagen AG d
agen oes
olksw not
y V gu
1 - Gasket ise
d b ara
nte
or
❑ Self-adhesive
auth eo
ra
s c
❑ Install
s on the gearshift
ce
le
mechanism case
un
pt
an
d
itte
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2 - Gear lever
rm
ab
pe
ility
ot
wit
tronic Parts Catalog
, is n
h re
“ETKA”
hole
spec
es, in part or in w
t to the co
⇒ page 62
rrectness of i
4 - Bearing plate
❑ To remove, open locks
l purpos

moval
nform
ercia
❑ At assemble, apply 12 ±
m
2 g. Sealing compound -
a
com
tio
D 176 404 A2- .

n in
r
te o
thi
s
iva
tronic Parts
do
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um
fo
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5 - Circlips
Co
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❑ Replace after each re‐ yri
gh by
ht
moval. cop Vo
by lksw
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6 - Circlip
AG.

moval
⇒ page 47
necessary to remove
the gearshift mechanism case ⇒ page 62
8 - Circlip
❑ For replacement it is necessary to remove the gearshift mechanism case ⇒ page 62
10 - Bushing
11 - Lower bushing
12 - Spring
13 - Upper bushing
14 - Circlip
1.9 Lever and Gear shifting mechanism -

adjusting
♦ Key - T10027A-
Check conditions:
• gearbox in “dead centre”.
• Gear lever and cables in perfect conditions.
• Good operation when engaging gears.
• Gearbox, clutch and drive mechanism in perfect conditions.
wage
e ks s no
Vol t gu
Unlock the fastening elements of the drive cables:
ed
by ara
is nte
or eo
– Release the fastening elements by unlocking
au
th their respective ra
locks -arrow-. ss c
ce
e
nl
pt
du
an
itte
y li
Note
erm
ab
ility
ot p
wit
Selector cable must move on the cable fastening element.

, is n
h re
hole
spec
or depending on the type of fastener:

es, in part or in w
t to the co
rrectness of i
l purpos
– Remove fasteners by removing them from cables in direction

of -arrow 1- until buffer and lock them by turning left in direction
of -arrow 2-.
nf
ercia
or
Lock selector lever:

m
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

– Press selector lever downwards towards -arrow 1- in 1st and

2nd gear, and turn the safety pin -A- by approximately 90° to‐
wards -arrow 2-.
Lock gear lever:
– Remove the gear lever boot from centre console.
– Move slowly the gear lever to left in the 1st and 2nd-gear track.
– Introduce Key - T10027A- in hole -B- through hole -A-.
Note
Check that the selector lever command and the selector cable are
mounted without tension on the cable fastening element.
– Turn to right, to the stop, the gate selector cables' safety

mechanism, towards -arrow-.
The spring returns the safety mechanism to initial position.
or depending on the type of fastener:
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
– Move the gate selector cables' safety mechanism until locking
ility
ot p
them -arrow-.
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
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
– Turn safety pin -A- towards -arrow-, in order to return to its

initial position.
• The safety pin -A- should remain in a vertical position.
– Remove Key - T10027A- from holes -A- and -B-.

– Install the removed components.
AG. Volkswagen A
1.10 Selector and
Vol
klever
swa
gen
- functionalG dcheck
oes
not
y gu
db ar
• Gear lever shouldobe
ris in the “dead centre position”, in 3rd/4thntee
e a
gear track. auth or
a
ss c
– Activate clutch.
ce
e
nl
pt
du
an
– Engage all gears several times. Make sure especially that the
itte
y li
erm
reverse gear blocking is operating correctly.

ab
ility
ot p
When a gear is engaged repetitively and a problem still persists,

wit
, is n
check clearance (travel) of the selector lever, as follows:

h re
hole
spec
– Place the car in first gear.

es, in part or in w
t to the co
– Move gear lever to the left, to the stop, and release it.
– At same time, check the transmission selector lever (2nd me‐
rrectness of i
chanic).
l purpos
– When moving the gear lever, the selector lever should have a
travel of approximately 1 mm -arrow-.
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.

or
– Otherwise, readjust the gear selection lever mechanism
⇒ page 68 .
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
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.
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Cop py
t. rig
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pyri by
Vo
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by
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Prote AG.
2 Transmission - remove and install

⇒ “2.1 Gearbox for vehicles with engines (AQZ, ASY, BAH, BJA,
BJE, BKR, BLH, BMD, BNM, BNX, BPA, CCNA, CCRA, CFZA,
CHFA, CHFB, CPBA) - remove and install”, page 72
⇒ “2.2 Gearbox for vehicles with engines (CSEA) - remove and
install”, page 90
⇒ “2.3 Gearbox - transport”, page 102
2.1 Gearbox for vehicles with engines (AQZ, ASY, BAH, BJA, BJE, BKR, BLH,
BMD, BNM, BNX, BPA, CCNA, CCRA, CFZA, CHFA, CHFB, CPBA) - re‐
move and install

equipment required agen
AG. Volkswagen AG d
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
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
♦ Support or VW 061 - 10-222A-

♦ Support - 10-222 A/1-
♦ Mounting bracket - 3282-
♦ Adjustment plate - 3282/31-
♦ Pin - 3282/48-
♦ Mounting bracket - 3282/59-

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
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

♦ Torque Wrench - 40 to 200 Nm ( 1/2” drive) - VAG 1332-
♦ Gearbox or engine + gearbox set jack or EQ 7081 - VAG
1383A-
2. Transmission - remove and install 73

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
♦ Hooks - 10-222 A/2-
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
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
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cu
o
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f
en
ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

A - -030 103 390 F- (pulley

side). Assignment: ⇒ Electron‐
ic Parts Catalog “ETKA”
B - -030 103 390 G- (flywheel
side). Assignment: ⇒ Electron‐
ic Parts Catalog “ETKA”
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
2.1.1 Removal
es, in part or in w
t to the co
Note
rrectness of i
l purpos

♦ When connecting the Battery - A- , check vehicle equipment
nform
ercia
(radio, clock, electric locks, electric windows, etc.), according

to the repair manual and/or instructions of use
m
at
om
ion
c
in t
or

his
ate

do
priv
cum
or

f
en
ng
t.
ment; Rep. gr. 27 ; Starter, alternator, battery . Cop
yi Co
py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Continuation for vehicles with inversion lever “metal”:

– Unlock the locks -arrow 1- of the cable fastening elements.
Then remove the cables from the fastening elements.
– Loosen the fastening nut -arrow 3- and remove the gearbox
selector lever -B-.
– Remove circlip -arrow 2- from inversion lever -A- and remove
lever.
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
– Remove fastening screws -arrows- from transmission cable

itte
y li
erm
fastening support and remove fastening support from trans‐
ab
ility
mission cables.
ot p
wit
is n
– Remove tubing and hose assembly -A- from support -B- loca‐
h re
ole,
ted on gearbox.
spec
– Remove the slave cylinder on the hydraulic drive -C- without
t to the co
opening the pipes and fasten it.
rrectne
Note
ss
Do not press the clutch pedal.
o
cial p
f inform
mer
or
atio
om
n
c
– Unlock the locks -arrow 1- of the cable fastening elements.
i
or
n thi
e
Then remove the cables from the fastening elements.

t
sd
iva
o
pr
– Loosen the fastening nut -arrow 3- and remove the gearbox

um
r
fo
en
selector lever -B-.

ng
t.
yi Co
op py
– Remove circlip -arrow 2- from inversion lever -A- and remove
. C rig
ht ht
rig
lever. py by
co Vo
by lksw
cted agen
Prote AG.

– Loosen fastening screws -arrows- and remove slave cylinder

from hydraulic drive -1- without opening tubing -2-.
Note
Clutch pedal must not be depressed.
– Loosen securing bolts -arrows- of the gearbox cable mounting

bracket.
– Remove the cables mounting bracket from the gearbox.
Continuation for vehicles with inversion lever “plastic”:
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
– Remove lock -arrow 1- from selector lever cable -B-.

wit
, is n
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– Then remove gear selector cable.

hole
spec
– Remove the hex nut -arrow 2- and remove the selector lever
es, in part or in w
t to the co
-B-.
rrectness of i
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nf
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Prote AG.

– Remove the clip -arrow 1- and remove the inversion lever

along with the fastening of the selector cable.

bracket.
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– Loosen fastening screws
ss -arrows- and remove slave cylinder
ce
le

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pe
Note
ility
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spec
es, in part or in w
Continued for all vehicles:

t to the co
– Remove ground wire from the upper securing bolt of the en‐
gine/gearbox.
rrectness of i
– Remove upper screws fastening the engine to gearbox.

l purpos
– Remove the upper securing bolt of the Starter - B- .

nform
ercia
– Install Bracket or VW 061 - 10-222A- with Support - 10-222 A/

m
1- and sustain slightly the engine/gearbox. Remove the air fil‐

a
com
tio
ter if necessary.
n in
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te o
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t.
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Prote AG.

or
Note
If necessary, use the lifting eyes -030 103 390 F- (on pulley side),
-030 103 390 G- (on inertial flywheel side). Assignment: ⇒ Elec‐
tronic Parts Catalog “ETKA”
– Relieve the weight of the engine/gearbox assembly through

the spindles.
– Lift the vehicle.
AG. Volkswagen AG d
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– Slightly loosen the securing bbolts
y V (left and right) -2- of the drivet gua
ol
shafts with constant velocity
ris
e joint -3- to the transmission drive
d ran
tee
flanges. aut
ho
or
ac
ss
– Remove the left side wheel.
ce
e
nl
pt
du
an
– Remove the left front wheel arch cover ⇒ General body re‐
itte
y li
pairs, exterior; Rep. gr. 66 ; External equipment .
erm
ab
ility
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
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at
om
io
– Disengage connector -1- from reverse gear light switch - F4- .

n
c
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or
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e
– Loosen the securing nut -arrow- and remove the cable support
at
do
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-2- from the Starter - - .

p
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– Remove the Starter - B- ⇒ Electrical system; Rep. gr. 27 ;

n
t.
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op
Starter, alternator, battery . C py
t. rig
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– Remove connectors' bracket.
p by
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Prote AG.
– Remove the fastening screws -arrows A- and -arrows B- and

remove pendulum support.
For vehicles without ABS:

– Disengage connector -1- from the Speed sensor - G22- .

– Remove the front exhaust tube ⇒ Engine; Rep. gr. 26 ; Ex‐
haust system .
– Remove the securing bolts (left and right) -2- of the drive shafts
with constant velocity joint -3- to the transmission drive flang‐
es.
Note AG. Volkswagen AG d

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The drive shafts with constant velocity joint mustornotis be pressed
e nte
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downwards. Otherwise, the internal articulation aut will be damaged
h
ra
due to excessive tilt. Place the drive shafts upwards
ss and fasten c
ce
them with wire on the suspension strut.
e
nl
pt
du
an
itte
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erm
– Mark the installation position of the screws that fasten the low‐
ab
ility
er articulation of the suspension's left wishbone (transversal).
ot p
wit
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hole
spec
es, in part or in w
t to the co
rrectness of i
– Remove the screws -arrows-, consult ⇒ Chassis, axles, steer‐
l purpos
ing; Rep. gr. 40 ; Front suspension .

– Remove the coupling rod -1- from the anti-roll bar.
nform
mercia
at
om
ion
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or
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ate
do
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– Push the suspension strut outwards and support it with a Prote AG.
wooden wedge -1- (for example) and, at the same time, pulling
it away from the (transversal) wishbone.
– Place the final drive with constant velocity joint (left side) up‐
wards and fasten it with wire on the suspension strut.
Note
The drive shaft must not be pressed down. Otherwise, the internal
articulation will be damaged due to excessive tilt.
– Lower the vehicle.

– Remove the securing bolts -arrows- from the engine/gearbox

support (left side).
– Carefully tilt the engine/gearbox aggregate. To do that, turn
the two screws on the Bracket or VW 061 - 10-222A- by ap‐
proximately 90 mm downwards.
Note n AG. Volkswagen AG do

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When lowering the engine/gearbox, make sure the differential
oris is tee
not held on the auxiliary frame (assembly mounting).
auth or
ac
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nl
• Thus, it should be possible accessing the screws -arrows- that
pt
du
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fasten the console -A-.
itte
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ab
ility
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– Remove the fastening screws -arrows- and remove the con‐
wit
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sole -A-.
h re
hole
spec
– Install Bracket - 3282- with Shim - 3282/31- to remove the
es, in part or in w
gearbox.
t to the co
– Install the shift unit arms aligned with the shim holes.
rrectness of i
l purpos
nform
mercia
at
om
ion
The symbols -A- on the Shim - 3282/31- show the supports re‐
c
in t
or
quired, and arrow -B- indicates run direction.
his
ate
do
riv
– Place the Gearbox or engine + gearbox set jack or EQ 7081 -

p
cum
or
VAG 1383A- under the gearbox.

f
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Prote AG.
– Align the shim and engage the safety bracket to the gearbox.
– Fasten the gearbox to the Support - 3282- and remove the
engine/gearbox fastening screw -arrow-.

– Remove the engine/gearbox fastening screw -A- from above

the drive flange (right side).
– For vehicles with crankcase on plate, it is necessary to remove

the fastening screws -arrows- from the cover plate on the en‐
gine crankcase area.
– Remove the lower fastening screws for the engine/gearbox.
– Separate the gearbox from the engine and rotate it carefully
towards the auxiliary frame (assembly mountings).
– Carefully press the engine outwards with the help of a 2nd
operator.
Caution
Prevent the engine/gearbox from touching the electro fan/ra‐

diator during this operation.
AG. Volkswagen AG d
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– Rotate the gearbox downwards by the differential dregion.
by ara
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– Next, carefully lower the gearbox passing the
ss a
right drive flange c
-A- close by the flywheel/intermediate plate, and the left drive
ce
le
un
pt
flange -B- close by the auxiliary frame (assembly mountings).
an
d
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erm
– When lowering, change the gearbox position by the spindle of

ab
ility
the gearbox or engine + gearbox set jack or EQ 7081 - VAG
ot p
1383A- . wit
is n
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spec
t to the co
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2.1.2 Installation
s o
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f in

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mer

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Chemical Products Manual; Rep. gr. 00 p by
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♦ Assignment of Chemical Materials ⇒ Electronic Parts Prote AG.

– Clean primary shaft splines and lubricate them lightly with Lu‐
bricating grease - G 000 100- .
The clutch plate can easily displace from one side to another on
the input shaft.
– Check whether the engine/transmission alignment pins are in‐
stalled on the cylinder block, install them, if absent.
– Make sure the intermediate plate is correctly installed on en‐
gine.
– Install Bracket - 3282- with Shim - 3282/31- to install the gear‐
box.
– Align the plate parallel to the gearbox and engage safety
bracket to the gearbox.
– Fasten gearbox to Support - 3282- .
– Place gearbox or engine + gearbox set jack or EQ 7081 - VAG
1383A- under the vehicle. In such a way that the arrow -B- on
Bracket - 3282- is toward the vehicle driving direction.
– Ask a 2nd operator to carefully push the engine forward.
Caution
AG. Volkswagen AG d
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Prevent the engine/gearbox from d bytouching the electro fan/ra‐
V o gu
ara
diator during this operation. orise nte
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pt
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– Carefully raise the gearbox passing the right drive flange -A-
an
itte
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close by the flywheel/intermediate plate, and the left drive
erm
ab

ility
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– When raising, change the gearbox position by the spindle of

h re
the Gearbox or engine + gearbox set jack or EQ 7081 - VAG

hole
spec
1383A- .
es, in part or in w
t to the co
– Then, rotate the gearbox upward through over the differential

region with the Support´s - 3282- , spindles.
– Install the gearbox.
rrectness of i
l purpos
Note
nf
ercia
Pay attention to prevent damages on the cooling hose, located

rm
m
between engine and radiator, and the power steering pipes.

atio
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– Install and tighten the engine/gearbox fastening screw

iv
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rp
-arrow-.
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pyri by
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Prote AG.

– Install and tighten the engine/gearbox fastening screw -A-

from above the drive flange (right side).
– For vehicles with crankcase on plate, it is necessary to install

a cover plate arrow on the engine crankcase area.
– Install and tighten the lower engine/gearbox fastening screws
-arrow-.
– Install the gearbox console -A- using new bolts -arrows-.

– Align engine/gearbox aggregate, by placing it in assembly po‐
sition. To do that, turn the two screws on the Bracket or VW
061 - 10-222A- upwards.
AG. Volkswagen AG d
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– Install and tighten the securing bolts -arrows- of the engine/

ility
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gearbox support (left side).

wit
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spec
WARNING
t to the co
♦ Do not remove the Support or VW 061 - 10-222A- until the

bolts of the engine/gearbox support have been tightened
(left side).
rrectne
♦ Tighten the engine/gearbox carrier securing bolts free of

s
tension. Refer to ⇒ Engine; Rep. gr. 10 ; Cylinders, cyl‐

s o
inder block, support, protector .

cial p
f inform
mer
atio
m
– Install and tighten the upper screws that fasten the engine to
o
n
c
gearbox.
i
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fo
For vehicles without ABS:

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.

– Connect the connector -1- to Speed sensor - G22- .
– Install pendulum support -arrows A- and -arrow B- by using

new screws.
– Install front exhaust system ⇒ Engine; Rep. gr. 26 ; Exhaust
system .
– Install the screws that fasten the lower articulation of the sus‐
pension's left wishbone. Refer to ⇒ Chassis, axles, steering;
Rep. gr. 40 ; Front suspension . wage
e
olks s no
yV t gu
– Install the coupling rod in the anti-roll bar.
ed
bRefer to ⇒ Chassis, ara
axles, steering; Rep. gr. 40 ; Front hsuspension
or
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t
au ra
c
ss
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– Install the securing bolts (left and right) -2- of the drive shafts
erm
ab
ility
ot p
es. Refer to ⇒ Chassis, axles, steering; Rep. gr. 40 ; Front
wit
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suspension .
h re
hole
spec
– Install the Starter - B- ⇒ Electrical system ; Rep. gr. 27 ;
es, in part or in w
Starter, alternator, battery .
t to the co
– Install connectors on their brackets.
rrectness of i
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– Install the connectors bracket -2- on the securing bolt
t. rig
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-arrow- of the Starter - - . cop Vo
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Prote
– Disengage connector -1- from reverse gear light switch - F4- .
AG.
– Install the ground wire of the upper securing bolt of the engine/
transmission.

– Install the slave cylinder of the hydraulic drive -C-.

– Install tubing and hose assembly -A- on support -B- located
on transmission.
– Install the cable fastening support on transmission -arrows-.
Continuation for vehicles with inversion lever “metal”:
– Install gearbox selector lever -A-.

– Tighten hex nut -arrow 1-. agen
AG. Volkswagen AG d
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– Install inversion lever -B- by fastening ditbywith
V
circlip -arrow 2-. gu
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– Install gate selector cables on the aut corresponding fastening el‐
h o eo
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ements. ss c
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nl
or
pt
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erm
ab
ility
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wit
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hole
spec
es, in part or in w
– Install selector lever -B- and tighten fastening nut -3-.
t to the co
– Install inversion lever -A- by fastening it with a new circlip
-arrow 2-.
rrectness of i
– Install gate selector cables on the corresponding fastening el‐
l purpos
ements.
Continuation for vehicles with inversion lever “plastic”:
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
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cu
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t.
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Cop py
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rig ht
py by
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by lksw
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Prote AG.

– Install selector lever -B- and tighten fastening nut -arrow 2-.
– Install inversion lever -A- by fasteningeitn Awith
G. Vocirclip.
lkswagen AG
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– Install gate selector cables on Vol corresponding fastening el‐ot gu
y the
db ara
ements. rise nte
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Continuation: s au ra
c
s
ce
– Adjust the gear selection mechanism ⇒ page 68 . e
nl
pt
du
an
itte
y li
– Install left front wheel arch cover ⇒ General body repairs, ex‐
erm
ab
terior; Rep. gr. 66 ; External equipment .
ility
ot p
wit
, is n
– Install the left front wheel. Tightening torques, refer to: ⇒ Run‐
h re
ning gear, axles, steering; Rep. gr. 44 ; Vehicle wheels, tires,
hole
spec
measurement .
es, in part or in w
t to the co
– Check gear oil level and fill, if necessary ⇒ page 104 .
– Install the Battery - A- console ⇒ Electrical equipment; Rep.
gr. 27 ; Starter, alternator, battery .
rrectness of i
For vehicles with air filter located behind the Battery - A- :
l purpos
• Install air filter (petrol/ethanol engine) ⇒ Engine; Rep. gr. 24 ;

Supply system - fuel injection .
nform
mercia
• Install air filter (petrol/ethanol engine) ⇒ Engine; Rep. gr. 23 ;
at
om
i
Supply system - fuel injection .
on
c
in t
or
– Install and connect the Battery - - ⇒ Electrical equipment; Rep.
his
ate
do
riv
gr. 27 ; Starter motor, alternator, battery .

p
cum
for
en
ng
t.
2.1.3 Tightening torques
yi Co
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Vehicles with 1.0 L engine p by
co Vo
by lksw
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Prote AG.
Note
♦ Strictly follow the tightening sequence (gearbox to engine)

showed by the illustration
♦ -Pos. A- - Adjustment pins
Po Bolts Tighten‐
si‐ ing tor‐
tio ques
n
1 M 12 x 70 80 Nm
2 M 12 x 65 80 Nm
3 M 12 x 55 80 Nm
4 M 10 x 35 40 Nm
5 M 12 x 125 80 Nm
♦ Also used to fasten the Starter - B-
6 M 10 x 35 40 Nm
7 M 12 x 55 80 Nm
8 M 12 x 125 80 Nm

Vehicles with 1.6 L engine
Note

showed by the illustration agen
AG. Volkswagen AG d
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♦ -Pos. A- - Adjustment dpins
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Po ss Bolts Tighten‐ c
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si‐ ing tor‐
le
un
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ility
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1 M 12 x 70 80 Nm
wit
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2 M 12 x 55 80 Nm
h re
ole,
spec
3 M 12 x 55 80 Nm
4 M 10 x 50 / M 10 x 55 40 Nm
t to the co
2)
5 M 12 x 125 80 Nm
rrectne
6 M 10 x 50 / M 10 x 55 40 Nm
ss
2)
o
cial p
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7 M 12 x 55 80 Nm
form
mer
8 M 12 x 125 80 Nm
atio
m

o
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2) Interchangeable
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ng
Vehicles with 1.2 L engine (40 kW and 47 kW)

t.
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Note
co Vo
by lksw
cted agen
Prote AG.
-Pos. A- - Adjustment pins
Po Bolts Quan Tighten‐

si‐ tity ing tor‐
tio ques
n
1 M 12 x 65 3 80 Nm
2 M 12 x 135 2 80 Nm
3 M 12 x 80 1 80 Nm
4 M 10 x 60 2 40 Nm

Vehicles with 1.4 L engine (55 kW)
Note

AG. Volkswagen AG d
Po Bolts agen Quan Tighten‐oes
olksw not
si‐ d byV tity ing tor‐ gu
ara
tio orise
ques nte
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n aut
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1 M 12 x 55 2 80 Nm
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2 M 12 x 125 2 80 Nm
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itte
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erm
ab
ility
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3 M 12 x 70 1 80 Nm
wit
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4 M 10 x 35 2 40 Nm
hole
spec
5 M 12 x 65 1 80 Nm
es, in part or in w
t to the co
Vehicles with 1.4 L engine (63 kW and 74 kW)
rrectness of i
Note
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nf
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orm
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1 M 12 x 65 3 80 Nm
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2 M 12 x 140 . Cop
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3 M 12 x 80 cted
1 80 Nm
agen
Prote AG.
4 M 10 x 50 / M 10 x 55 2 40 Nm
3)
3) Interchangeable
Vehicles with 1.4 L engine (51 kW - Diesel)
Note

tio ques
n
1 M 12 x 70 2 80 Nm
2 M 12 x 150 2 80 Nm
3 M 10 x 70 3 40 Nm
4 M 12 x 80 1 80 Nm

Console -1- to gearbox:

1 - Console to gearbox
A - 40 Nm + 90° (Replace after every removal)
B - 40 Nm + 90° (Replace after every removal)
Support for power unit - transmission

B - 40 Nm + 90° (Replace after every removal) agen
AG. Volkswagen AG d
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Note ut
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s
Install engine/gearbox mounting without any stress ⇒ Engine;
ce
e
nl
pt
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Rep. gr. 10 ; Cylinders, cylinder block, support, cover .
an
itte
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erm
ab
ility
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Pendulum support (torque restrictor)
spec
es, in part or in w
t to the co
B - 40 Nm + 90° (Replace after every removal)
rrectness of i
For other torques, refer to the respective repair groups
♦ Drive shaft with constant velocity joint to drive flange ⇒ Chas‐
l purpos
sis, axles, steering; Rep. gr. 40 ; Front suspension .
nf
ercia
♦ Lower joint to wishbone (transversal) ⇒ Chassis, axles, steer‐
or
m
m
atio
m
♦ Coupling bar to anti-roll bar ⇒ Chassis, axles, steering; Rep.

o
n in
or c
gr. 40 ; Front suspension .
thi
te
sd
iva
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2.2 Gearbox for vehicles with engines (CSEA) - remove and install cu
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by lksw
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equipment required
AG. Volkswagen AG d
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d by ara
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or eo
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un
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ility
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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
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fo
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ng
t.
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Vo
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by c lksw
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Prote AG.
♦ Support or VW 061 - 10-222A-

♦ Support - 10-222 A/1-
♦ Adjustment plate - 3282/31-
♦ Pin - 3282/48-
♦ Mounting bracket - 3282/59-

AG. Volkswagen AG d
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d by ara
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or eo
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aut ra
ss c
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le
un
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ab
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spec
t to the co
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f inform
mer
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n
c
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te
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fo
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ng
t.
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Cop py
t. rig
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pyri by
Vo
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by c lksw
cted agen
Prote AG.

♦ Gearbox or engine + gearbox set jack or EQ 7081 - VAG
1383A-
2.2.1 Removal
Note
♦ When connecting the Battery - A- , check vehicle equipment
(radio, clock, electric locks, electric windows, etc.), according
to the repair manual and/or instructions of use


– Remove lock -arrow 1- from selector lever cable -B-.

– Then remove gear selector cable.
– Remove the hex nut -arrow 2- and remove the selector lever
-B-.

AG. Volkswagen AG d
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ara
ed
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aut ra
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un
– Remove the clip -arrow 1- and remove the inversion lever pt

an
d
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along with the fastening of the selector cable. y li

erm
ab
ility
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wit
is n
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ole,
spec
t to the co
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f inform
mer
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– Loosen fastening screws -arrows- and remove slave cylinder

Note
– Remove ground wire from the upper securing bolt of the en‐
gine/gearbox.
– Remove upper screws -arrows- fastening the engine to gear‐

box.
– Remove the upper securing bolt of the Starter - B- .
– Install Bracket or VW 061 - 10-222A- with Support - 10-222 A/

1- and sustain slightly the engine/gearbox. Remove the air fil‐
ter if necessary.
– Relieve the weight of the engine/gearbox assembly through
the spindles.
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– Remove the left front wheel arch cover ⇒ General body re‐
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pairs, exterior; Rep. gr. 66 ; External equipment .

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– Loosen the securing nut -arrow- and remove the cable support
-1- from the Starter - - .
– Remove the Starter - B- ⇒ Electrical system; Rep. gr. 27 ;
– Remove connectors' bracket.
– Remove the fastening screws -arrows A- and -arrows B- and

remove pendulum support.
– Remove the securing bolts (left and right) -2- of the drive shafts
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– Remove the securing nuts -arrows-.
– Push the suspension strut outwards and support it with a

wooden wedge -1- (for example) and, at the same time, pulling
it away from the (transversal) wishbone.
Note
The drive shaft must not be pressed down. Otherwise, the internal
articulation will be damagedagdue to. Vexcessive
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When lowering the engine/gearbox, make sure the differential is

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VAG 1383A- under the gearbox.
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– Next, carefully lower the gearbox passing the right drive flange
-A- close by the flywheel/intermediate plate, and the left drive
– When lowering, change the gearbox position by the spindle of
the gearbox or engine + gearbox set jack or EQ 7081 - VAG
1383A- .
2.2.2 Installation

WARNING

que.
– Clean primary shaft splines and lubricate them lightly with Lu‐ wagen AG. Volkswagen AG doe
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– Make sure the intermediate plate is correctly installed on en‐
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hole
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bracket to the gearbox.
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1383A- under the vehicle. In such a way that the arrow -B- on
m
Bracket - 3282- is toward the vehicle driving direction.
a
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– If necessary, request a 2nd operator to carefully push the en‐
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– Carefully raise the gearbox passing the right drive flange -A-
close by the flywheel/intermediate plate, and the left drive
– When raising, change the gearbox position by the spindle of
the Gearbox or engine + gearbox set jack or EQ 7081 - VAG
1383A- .
– Then, rotate the gearbox upward through over the differential
region with the Support´s - 3282- , spindles.
– Install the gearbox.
Note
Pay attention to prevent damages on the cooling hose, located

between engine and radiator, and the power steering pipes.

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– Install and tighten engine/gearbox fasteningssscrews
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– Install the gearbox console -A- using new bolts -arrows-.

– Align engine/gearbox aggregate, by placing it in assembly po‐
sition. To do that, turn the two screws on the Bracket or VW
061 - 10-222A- upwards.
– Install and tighten the securing bolts -arrows- of the engine/

gearbox support (left side).
WARNING
♦ Do not remove the Support or VW 061 - 10-222A- until the

bolts of the engine/gearbox support have been tightened
(left side).
♦ Tighten the engine/gearbox carrier securing bolts free of
tension. Refer to ⇒ Engine; Rep. gr. 10 ; Cylinders, cyl‐
inder block, support, protector .

– Install and tighten upper engine/gearbox fastening screws

-arrow-.
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– Install pendulum support -arrows A- and -arrow B- by using
ss
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– Install the nuts -arrows- that fasten the lower articulation of the
o
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suspension's left wishbone. Refer to ⇒ Chassis, axles, steer‐
inform
mer
atio
m
– Install the coupling rod in the anti-roll bar. Refer to ⇒ Chassis,

o
n
axles, steering; Rep. gr. 40 ; Front suspension .
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– Install the securing bolts (left and right) -2- of the drive shafts
es. Refer to ⇒ Chassis, axles, steering; Rep. gr. 40 ; Front
suspension .
– Install the Starter - B- ⇒ Electrical system ; Rep. gr. 27 ;
– Install connectors on their brackets.

– Install the connectors bracket -1- on the securing bolt

-arrow- of the Starter - - .
– Connect the Reverse gear light switch - F4- connector.
– Install the ground wire of the upper securing bolt of the engine/
transmission.
– Install the slave cylinder of the hydraulic drive -C-.

– Install tubing and hose assembly -A- on support -B- located
on transmission.
– Install the cable fastening support on transmission -arrows-.
– Install selector levern-B- and

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– Install inversion
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– Installho gate selector cables on the corresponding fastening
r tee
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ements.
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Continuation:
un
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– Adjust the gear selection mechanism ⇒ page 68 .

erm
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– Install left front wheel arch cover ⇒ General body repairs, ex‐
wit
is n
terior; Rep. gr. 66 ; External equipment .

h re
ole,
– Install the left front wheel. Tightening torques, refer to: ⇒ Run‐
spec
ning gear, axles, steering; Rep. gr. 44 ; Vehicle wheels, tires,

t to the co
measurement .
rrectne
– Install the Battery - A- console ⇒ Electrical equipment; Rep.

gr. 27 ; Starter, alternator, battery .
ss
– Install and connect the Battery - - ⇒ Electrical equipment; Rep.

o
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gr. 27 ; Starter motor, alternator, battery .

nform
mer
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ss 02.2017 c
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2.2.3 Tightening torques
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Vehicles with 1.0 L engine
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Note
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showed by the illustration
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♦ -Pos. A- - Adjustment pins
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Po Bolts Tighten‐
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1 M 12 x 70 80 Nm
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2 M 12 x 150 80 Nm
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3 M 10 x 55 40 Nm
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7 M 10 x 55 40 Nm
8 M 12 x 150 80 Nm
2.3 Gearbox - transport

♦ Winch 700 - 1200 Kg - VAS 6100-

– Install Bracket - 3336- on the gearbox housing.
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– Adjust thethoarm in the guide with the locking pins -arrow-. tee
or
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Number of visible holes = 5
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3 Gearbox oil level
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⇒ “3.1 Oil level - check”, page 104
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⇒ “3.2 Oil level - replenish”, page 105
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3.1 Oil level - check
hole
spec
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♦ Multi-tooth socket SW 27 - 3357-
rrectness of i
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Note
Gearbox oil specification; check the ⇒ Electronic Parts Catalog

“ETKA” .
– Remove screw (plug) to check oil level -arrow-.
Note
The oil level will be OK if the gearbox has oil up to the lower edge
of the checking hole.
– Install screw (plug) -arrow-.

Bolt tightening torque (plug):

I - Bolt (toothed) = 24 Nm
II - Bolt (hexagonal) = 32 Nm
3.2 Oil level - replenish

AG. Volkswagen AG d
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Note
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Gearbox oil specification; check the ⇒ Electronic Parts Catalog

rp
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3. Gearbox oil level 105

To fill completely the reservoir with new oil:

– Loosen screw (plug) -arrow-.
– Fill with the specified oil up to the lower edge of the checking
hole.
– Install screw (plug) -arrow-.
– Start engine, engage a gear and let the gearbox functioning
by approx. 2 minutes.
– Stop engine and replenish with oil up to the lower edge
wage of the
es n
s
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– Install screw (plug) -arrow-. thoris e or
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Bolt tightening torque (plug):
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I - Bolt (toothed) = 24 Nm
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II - Bolt (hexagonal) = 32 Nm
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4 Transmission - repair
⇒ “4.1 Gearbox - overview”, page 107
⇒ “4.2 gearbox - assembly overview”, page 108
⇒ “4.3 Gearbox housing cover and 5th gear”, page 108
⇒ “4.4 Clutch housing”, page 110
⇒ “4.5 Input shaft, planet pinion, differential, selection mechanism
and selector forks”, page 111
⇒ “4.6 Input shaft, planet pinion, differential, selection mechanism
and selector forks - disassemble and assemble”, page 113
4.1 Gearbox - overview
1 - 1st gear
2 - 2nd gear AG. Volkswagen AG d
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3 - 3rd gear d by V gu
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4 - 4th gear utho eo
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5 - 5th gear
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6 - Gearbox housing cover
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7 - Gearbox housing
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8 - Reverse gear wit

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9 - Selection mechanism spec

❑ Selector forks
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10 - Clutch housing
11 - Input shaft
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12 - Output shaft/planet pinion

ss o
13 - Differential
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4. Transmission - repair 107

4.2 gearbox - assembly overview
I - Gearbox housing cover and

5th gear ⇒ page 108
II - Clutch housing
⇒ page 110
III - Input shaft, planet pinion,
differential, selection mecha‐
nism and selector forks
⇒ page 111
AG. Volkswagen AG d
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4.3 Gearbox housing cover and 5th gear

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Rep. gr.34 - Controls, housing
agen
Prote AG.
1 - Gearbox housing
❑ Assignment ⇒ Electron‐
ic Parts Catalogue “ET‐
KA” . AG. Volkswagen AG d
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❑ Repair ⇒ page o lksw
121 not
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❑ Apply Sealing
orise com‐ nte
pound aut- AMV 188 200
h eo
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03- sevenly on the seal‐
s c
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❑ In case of replacement,
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always adjust differen‐
erm
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2 - 5th gear wheel
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spec
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⇒ page 120
t to the co
3 - Circlip
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⇒ page 120
nf
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4 - Gasket
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❑ Replace if damaged
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5 - Gearbox housing cover
or c
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❑ When installing the cov‐

t
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o
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the oil level

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⇒ page 104 .
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❑ 5 Nm + 90° Prote AG.

moval.
7 - Circlip
❑ Determine thickness ⇒ page 120
8 - Synchronizer with engaging sleeve and stop ring for 5th gear
❑ Disassemble and assemble ⇒ page 136
9 - Synchronizer ring for 5th gear
10 - Selection wheel for 5th gear
❑ Installation position for 5th gear wheel ⇒ page 120
11 - Needle bearing
❑ For 5th gear
12 - Selector fork for 5th gear
13 - Bearing pin
❑ For 5th gear selector fork

4.4 Clutch housing AG. Volkswagen AG d

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♦ When handling chemicals follow the safety
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1 - Countersunk bolt
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❑ 25 Nm
2 - Drive flange with pressure
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spring
3 - Bolt
ss
❑ 5 Nm + 90°
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form
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4 - Clutch housing
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❑ Repair ⇒ page 121

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pound - AMV 188 200 py by
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AG.
tial ⇒ page 173
5 - Gearbox housing
KA” .
pound - AMV 188 200
ing surface.
tial ⇒ page 173
6 - Clutch lever
❑ Remove and install with the roller bearing guide and clutch roller bearing
7 - Bolts
❑ 5 Nm + 90°

4.5 Input shaft, planet pinion, differential,

selection mechanism and selector forks
WARNING

1 - Differential
❑ Disassemble and as‐
semble ⇒ page 164
2 - Gearbox housing
KA” .
pound - AMV 188 200
ing surface.
tial ⇒ page 173
3 - Oil draining screw (plug)
❑ Screw with inner multi-
tooth = 24 Nm
❑ Screw with inner hex = AG. Volkswagen AG d
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4 - Drive flange orise nte
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5 - Countersunk bolt ss a c
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❑ 25 Nm
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7 - Hexagonal nut
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❑ 23 Nm
❑ For the selection mechanism ⇒ Item 15 (page 112)
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13 - Reversing light switch - F4-
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❑ 20 ± 2 Nm
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14 - Sealing ring
es, in part or in w
❑ Only used in some gearbox housings
t to the co
❑ If applicable, replace on installation
15 - Selection mechanism
rrectness of i
❑ Selector forks
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16 - Input shaft and planet pinion with ball bearing support

❑ Clean the threaded holes of the roller bearing support (e.g. Tap M6)
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❑ Removing the roller bearing support ⇒ page 142
n
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❑ Disassemble and assemble the input shaft ⇒ page 136

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❑ Disassemble and assemble the planet pinion ⇒ page 148

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17 - Reverse gear intermediate shaft

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❑ For reverse gear intermediate shaft
❑ M6 = 5 Nm + 90°
❑ M8 = 25 Nm + 90°

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4.6 Input shaft, planet pinion, differential, selection mechanism and selector
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♦ Support for VW643 or VW 643/1 - VW 313- or Rotary stand

for engine and gearbox - VAS 6095-
♦ Plate - VW 401-
♦ Plate - VW 402-
♦ Pressure disc - VW 412-
♦ Guide pin - T 10079-

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♦ Oil collecting tray - VAG 1306-
Modify the bearing of the Support - 3221-
A new hole is required to fasten the mechanical gearbox (02T and
0AP) to the gearbox support.
Dimensions in mm:
– Make a bore of Ø 11.0 mm -arrow- on the Support - 3221- .

4.6.1 Disassembly
– Fasten the gearbox on the Support for VW643 or VW 643/1 -
VW 313- or Rotary stand for engine and gearbox - VAS 6095-
-arrows- as indicated.
– Place the Oil collector - VAG 1306- under the gearbox.
– Drain the gear oil. n AG. Volkswagen A
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– Remove clutch lever -A- with the clutch bearing and bearing
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– Remove the drive flange fastening screw on right side -B-, by

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using two screws to lock the flange with a lever.

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– Remove drive flange.

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– Remove the transmission housing cover -arrow-.

– Remove pin -1- on the 5th gear selector fork bearing -2- and
remove the selector fork.
– Remove circlip -3- and remove the 5th gear synchronizer.
– Remove circlip -4- and remove the 5th gear wheel.
– Remove the fastening screws -A- from the primary and planet
pinion bearings.
– Remove the hex nut -B- from the selection mechanism (re‐
verse gear fastening).
– Remove the drive flange fastening screw on left side -C-, by
using two screws to lock the flange with a lever.
– Remove drive flange.
– Place the gearbox with the clutch housing facing upwards.
– Remove the fastening screws from the clutch housing.
– Remove the clutch housing carefully by leveraging via should‐
ers around the whole case alternately, without damaging the
sealing surfaces. AG. Volkswagen AG d
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– Remove fastening screws -arrows- and remove the selector

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– Remove bearing pins -B- from the upper gearbox part.

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– Remove the reverse gear light switch - F4- -C-.
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– Remove screw -A- that fastens the reverse gear wheel shaft.
– Remove bearing pins -B- from the lower gearbox part.
Note
Do not remove the cover cap -arrow- to disassemble the trans‐

mission.
– Install the gearbox housing over the Plate - VW 401- and Plate
- VW 402- , in order that the case adjustment pins are not
damaged.
– Remove primary and planet pinions simultaneously from the

roller bearing support, with the selection mechanism (selector
fork) and the reverse gear wheel.
Note
During pressing, make sure the parts do not fall; if required, ask
for help from a second mechanic.
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♦ Assignment of Chemical Materials ⇒ Electronic Parts ab

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Catalogue “ETKA” wit

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es, in part or in w
– Simultaneously install the primary drive shaft and the pinion

t to the co
on the bearing support using the Pressure shim - T 10083- and

Pressure shim - T 10080- .
rrectness of i
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– Install input shaft -2-, and planet pinion -1- with the bearing/
ball bearing mounting on the Pressure base - T 10085-
– Install the selection mechanism (selector forks) -4- on the shaft
engaging sleeves.
– Install the reverse gear wheel shaft -3- with gear.
– Install Guide pin - T 10079- on threaded pin (reverse gear fas‐
tening) -arrow-
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– Install all the components in the gearbox case, by directing the

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Guide pin - T 10079- into the case through the gearshift mech‐
itte
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anism's supporting hole.
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– Remove the Guide pin - T 10079- .
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– Before pressing on the roller bearing mounting, check the cor‐
spec
rect fitting of the selector forks on the gearing sleeves.
t to the co
rrectness o
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– Press carefully the roller bearing support with the primary and
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– Install screw -A- on the reverse gear wheel shaft.

– Install bearing pins -B- on the lower transmission part.
– Install the reverse gear light switch - F4- -C-.

– Install the bearing pins -B- in the upper gearbox part.
– Place the selector in the “dead centre” position.
– Apply Sealing compound - AMV 188 200 03- evenly on the
selector cover's surface.
– Install the selector lever shaft with the selector cover -A- and
tighten the screws -arrows-. Tightening torque, see
⇒ Item 12 (page 112) .
– Install bearing supports on the primary and planet pinions by

using new screws -A- tightening in cross and phased pattern,
starting by the middle.
– Install hex nut -B- for theGselection
. Volkswagemechanism (selector forks).
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– Install differential -A-.

h re
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spec
– Apply Sealing compound - AMV 188 200 03- evenly on the

es, in part or in w
sealing surface of the transmission housing.

t to the co
– Install the clutch housing on the gearbox housing and tighten

screws to the specified tightening torque
rrectness of i
⇒ Item 3 (page 110) .

l purpos
– Place the gearbox with the clutch housing facing upwards.

– Install the 5th gear wheel -1- with the needle bearing.
nform
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Installation position for 5th gear wheel

The wide collar -arrow- should point to the gearbox housing cover.
– Install the 5th gear synchronizer ring on the wheel.
– Install the complete 5th gear synchronizer with the gearing
sleeve and stop ring.
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– Install theut5th
ho gear selector fork -2- and push the bearing e o pin
ra
-1- to the
ss a
stop, towards -arrow-. c
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– Determine the new circlip thickness -arrow-

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– Identify and install circlip on the primary -3- and pinion -4-
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Available circlips
hole
spec
es, in part or in w
Thickness (mm) Replacement parts No.
t to the co
2.00 -085 311 187-
2.10 -085 311 187 A-
rrectness of i
2.20 -085 311 187 B-

l purpos
– Install the gearbox housing cover.

nform
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– Install drive flanges.

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– Install clutch lever with bearing and bearing guide ⇒ page 40

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– Fill with gear oil ⇒ page 104 . ht. Cop py
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5 Gearbox and bclutch housings
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⇒ “5.1 Transmission and clutch
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aut ra
5.1 Transmission and clutch housings - repair ss c
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equipment required
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♦ Pressure pin - VW 408A-

♦ Sleeve - VW 472/2-
♦ Centring pin - 12-551-
♦ Pressure disc - 30-555-
♦ Assembly device - 3066-
♦ Pressure plate - 3124-
5. Gearbox and clutch housings 121

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es, in part or in w
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C py
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♦ Pressure tube - T 40008-
♦ -2- Puller 65 - 160 mm - KUKKO 18/1-
♦ -3- Spacer 12 - 75 mm - KUKKO 17/1-
WARNING


1 - Clutch housing
AG. Volkswagen AG d
❑ Assignment ⇒ Electron‐ lksw
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ic Parts Catalogue d by “ET‐
Vo gu
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KA” orise nte
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❑ Apply Sealing aut com‐ ra
s c
pound - AMV
s
188 200
ce
le

un
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an
d
ing surface.
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ility
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ole,
tial ⇒ page 173
spec
2 - Sealing ring for input shaft
t to the co
❑ Remove by leveraging
with screwdriver.
rrectne
❑ Installation ⇒ page 125
3 - Ball pin
ss o
❑ 20 Nm
cial p
f inform
❑ Lubricate with Lubricat‐
mer
ing grease - G 000 100- .
atio
om
n
c
4 - Sealing ring for the right
i
or
n thi
drive flange
te
sd
iva
o
❑ Replace with the gear‐
pr
cum
r
fo
box installed en
ng
t.
⇒ page 157
yi Co
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5 - Bushing
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❑ For the sealing ring
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❑ Removal ⇒ page 125
6 - Oil filling screw (plug)
❑ Screw with inner multi-
tooth = 24 Nm
❑ Screw with inner hex = 32 Nm
7 - O-ring
8 - Speed sensor - G22-
9 - Bolt
❑ 5 Nm + 90°
10 - Adjustment shim S2
❑ For the differential
11 - Outer ring on the tapered roller bearing
❑ If replaced, always adjust differential ⇒ page 173 .
12 - Bolt
❑ 5 Nm + 90°


❑ If replaced, always adjust differential ⇒ page 173 .
❑ Always with 1-mm thickness
Note
Only used on gearbox housings

-02T.301.103.L- and -02T.
301.103.AA-
15 - Adjustment pin
❑ 2 units
16 - Gearbox housing
❑ Assignment ⇒ Electronic Parts Catalogue “ETKA”
❑ Apply Sealing compound - AMV 188 200 03- evenly over the sealing surface of the gearbox housing.
❑ Repair ⇒ page 121 gen AG
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❑ In case of replacement, always adjust differential ⇒ page
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17 - Oil draining screw (plug) thoris e or
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❑ Screw with inner multi-tooth = 24 Nm ss
ac
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❑ Screw with inner hex = 32 Nm

un
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18 - Sealing ring for the left drive flange
rm
ab
pe
❑ Replace with the gearbox installed ⇒ page 157
ility
ot
wit
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19 - Bushing
h re
hole
❑ For the selector lever shaft
spec
es, in part or in w
t to the co
20 - Magnet
rrectness of i
❑ fastened on the case surface
l purpos
21 - Reservoir cap
❑ Apply Sealing compound - AMV 188 200 03- evenly on the sealing surface before installing.
nform
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22 - Circlip
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❑ Install on the tapered roller bearing groove ⇒ Item 25 (page 124) -

n in
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23 - Circlip
s
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❑ Install on the tapered roller bearing groove ⇒ Item 24 (page 124) -

cum
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24 - Tapered roller bearing
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Cop py
❑ For input shaft
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AG.

❑ For planet pinion

Installing the input shaft's sealing ring
Removing the sealing ring bushing

– Sleeve - VW 472/2- and Pressure disc - 30-555- , install on the
differential.
A - Puller 65 - 160 mm - KUKKO 18/1-
B - Spacer 12 - 75 mm - KUKKO 17/1-
AG. Volkswagen AG d
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Installing the sealing ring bushing

nl
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A - Fasten the threaded shaft of the Assembly tool - 3066- to the
erm
ab
threaded part in the differential
ility
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B - M12 nut with washer

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hole
– Install the bushing to the stop with Thrust plate - 3124- by

spec
turning nut -B-.

es, in part or in w
t to the co
Note
rrectness of i
With the gearbox disassembled, press the bushing with Thrust

l purpos
plate - 3124- to the stop.

nform
ercia
Removing the bushing for the selector lever shaft -A-

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Installing the bushing for the selector lever shaft -A-
AG. Volkswagen AG d
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6 Gear selection mechanism - adjust

⇒ “6.1 Gear selection mechanism - disassemble and assemble”,
page 127
6.1 Gear selection mechanism - disassem‐

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♦ Pressure tube - VW 423-
rrectness of i
l purpos
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mercia
at
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ion
c
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or
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for
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rig ht
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by lksw
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Prote AG.
Note
♦ Lubricate supporting points and sliding surfaces with Lubrica‐

tion grease - G 000 450 02- .
♦ Assignment ⇒ Electronic Parts Catalogue “ETKA”
Assembly overview (version 1 and 2):
6. Gear selection mechanism - adjust 127

1 - Bushing
❑ For the selector lever
shaft
2 - Selector lever shaft with se‐
lector cover
❑ Replace as a set
3 - Inversion lever
ing grease - G 000 450
02- .
⇒ page 47
4 - Bearing bushes
02- .
5 - Circlip
6 - Cap
❑ For the gearbox venting
tube
wage es n
7 - Seal yV
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❑ Remove by using a o
ir se
ran
tee
screwdriver auth or
ac
ss
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❑ Install in order that the

ab
ility
grooves are aligned with

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those on the selector

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h re
lever shaft
hole
spec
❑ It can be replaced with

es, in part or in w
the selection mechanism installed

t to the co

rrectness of i
9 - Hexagonal nut
l purpos
❑ Self-locking
❑ 20 ± 2 Nm
nform
ercia

m
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Note
um
for
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♦ Lubricate supporting points and sliding surfaces with Lubrica‐ Cop py
. rig
tion grease - G 000 450 02- .
t
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pyri by
Vo
co
♦ Assignment ⇒ Electronic Parts Catalogue “ETKA”
by lksw
cted agen
Prote AG.

Assembly overview (version 3):
WARNING

1 - Bushing
❑ For the selector lever
shaft
2 - Selector lever shaft with se‐
lector cover
❑ Replace as a set
3 - Inversion lever
⇒ page 47
02- .
4 - Plastic lock
5 - Cap
❑ For the gearbox venting
tube
wage es n
6 - Seal yV
olks ot g
d b ua
❑ Remove by using a o
ir se
ran
tee
screwdriver auth or
ac
❑ Install ⇒ page 130 ss
ce
le
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itte
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rm
❑ Install in order that the

ab
pe
grooves are aligned with ility

ot
those on the selector wit

, is n
h re
lever shaft
hole
spec
❑ It can be replaced with
es, in part or in w
the selection mecha‐

t to the co
nism installed
rrectness of i

KA”
l purpos

8 - Hexagonal nut
nform
ercia
❑ Self-locking
m
a
com
ti
❑ 20 ± 2 Nm
on in
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Prote AG.
6. Gear selection mechanism - adjust 129

Installing sealing ring lkswage es n
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– Install sealing ring -A- to the stop, using therisPressure
ed
b
pipe - ran
tee
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Cop py
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7 Selector forks
⇒ “7.1 Selector forks - disassemble and assemble”, page 131
7.1 Selector forks - disassemble and assemble

equipment required
AG. Volkswagen AG d
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♦ Plate - VW 402-
form
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♦ Pressure pin - VW 408A-

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♦ Pressure base - VW 431-

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♦ Pressure base - VW 447H-

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♦ Pin or VW 010-206 - 10-206-
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7. Selector forks 131

♦ Removal lever - 80-200-
Note
To remove or install the selector segments (skids), circlips and

ball bearings, you are not required to remove the change rail set.
1 - Change rail set with selector

forks
2 - Selector segment of 3rd /
4th gears
❑ Identification
⇒ page 133
❑ After assembling, it
should move freely
❑ Individual selector seg‐ AG. Volkswagen A
ments are mounted agen
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⇒ page 133 orise
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❑ Identification
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al segments
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⇒ page 133
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3 - Ball bearing
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❑ 4 units
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4 - Circlip
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5 - Selector segment of 1st /

inform
2nd gears
mer
❑ Identification
atio
m
⇒ page 133
o
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or
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❑ After assembling, it
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should move freely

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6 - 5th gear selector fork with

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selector segment
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❑ The selector segments yri
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should not be removed from the selector fork cop Vo
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❑ Identification ⇒ page 133 Prote AG.

7 - Bearing pin
❑ For the selector fork for 5th gear
Identification of the selector segments of the 4th gear selector

fork, including the selector segments of the 1st / 2nd gears and
3rd / 4th gears
Dimension -a- = 75 mm AG. Volkswagen AG d
agen oes
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1- Selector segment of 1st / d2nd
by V gears = 10.2 mm gu
ara
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2- Selector segment ofu3rd
tho / 4th gears = 78.6 mm eo
ra
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s
3- Selector fork for 5th gear, including the selector segments
ce
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un
= 79.5 mm
pt
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Individual selector segments of 3rd / 4th gear -A-
ss o
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After assembling the gear selector segments, they should move
inform
freely.
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Only some transmissions have these individual segments.

p
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Cop py
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Prote AG.
Identification of the individual selector segments of the 3rd / 4th

gears
Dimension -a-:
1- Short selector segment of 3rd / 4th gears = 10.2 mm
2- Long selector segment of 3rd / 4th gears = 10.2 mm
Note
When removing or installing internal tracks, do not twist the se‐

lector forks.

Selector fork for 1st/2nd gears, including the selector segments

Dimension -a- = 75 mm
Removing circlip
– Fasten the selector forks to the vice with jaw -B-.
– Remove circlip -A- by leveraging towards -arrow-.
AG. Volkswagen AG d
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Installing circlip
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A - Barrel wrench 10
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hole
spec
B - Jaw
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– Press the circlip on the fork segment groove by using a barrel
wrench.
rrectness of i
Note
l purpos
After installing the circlip, the fork segment should move freely.
nform
mercia
at
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io
Removing ball bearing

n
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or
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ate
do
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Note
um
for
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When removing or installing internal tracks, do not twist the se‐ C py
t. rig
lector forks. gh ht
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Prote AG.

Installation ball bearing
AG. Volkswagen AG d
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mer
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n
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Cop py
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Prote AG.

35 – Gears, shafts y Volkswagen AG.

Volkswagen AG
does
not
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ris
1 Input shaft tho eo
au ra
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⇒ “1.1 Primary shaft - general overview of assembly”, page 136
nl
pt
du
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⇒ “1.2 Input shaft - disassemble and assemble”, page 139
y li
erm
ab
ility
1.1 Primary shaft - general overview of as‐
ot p
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WARNING
rrectness of i
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nform
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Note
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ate
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♦ Install all the roller bearings, gears and synchronizer rings on

p
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or
the input shaft, lubricated with gear oil.

f
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♦ Do not invert the synchronizer rings. When reusing synchron‐ Cop py
izer rings, always install them on the same gear pair.
t. rig
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pyri by
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Prote AG.
136 Rep. gr.35 - Gears, shafts

1 - Circlip
moval.
❑ Determine thickness
⇒ page 120
2 - Engaging sleeve with 5th
gear synchronizer
❑ Disassemble and as‐
semble ⇒ page 146
3 - Synchronizer ring for 5th
gear
❑ Wear check
⇒ page 144
4 - 5th gear wheel
5 - Needle bearing
❑ For 5th gear
❑ Change with bushing
6 - Bushing
❑ For 5th gear needle
bearing
❑ Change with roller bear‐
ing ⇒ Item 5 (page 137)
❑ Remove with ball bear‐
ing support
⇒ page 142
olkswagen AG
en AG. V
7 - Gearbox housing ksw
ag does
not
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❑ Assignment ⇒ Electron‐ isedb ara
nte
ic Parts Catalogue “ET‐ ut
hor eo
KA” ss a ra
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nl
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❑ In case of replacement, always adjust differential ⇒ page 173

itte
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8 - Roller bearing support with ball bearing

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❑ Check and replace whenever damaged

hole
spec
es, in part or in w
t to the co

rrectness of i
9 - Input shaft
l purpos
10 - Needle bearing
❑ For 3rd gear
nf
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or
11 - 3rd gear wheel

m
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atio
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12 - Synchronizer ring for 3rd gear

o
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or c
❑ Wear check ⇒ page 144

thi
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13 - Engaging sleeve with 3rd and 4th gear synchronizer

rp
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❑ Remove with 3rd gear wheel ⇒ page 143 yi

t.
Co
op
C py
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❑ Installation position of the engaging sleeve/synchronizer ring ⇒ page 143 p by
o Vo
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agen
Prote AG.
1. Input shaft 137

14 - Synchronizer ring for 4th gear

❑ Wear check ⇒ page 144 agen
AG. Volkswagen AG d
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15 - 4th gear wheel ed byV gu
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16 - Bushing aut
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❑ For 4th gear needle bearing s
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nl
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❑ Change with needle bearing ⇒ Item 17 (page 138)
du
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❑ Remove with 3rd gear wheel ⇒ page 142
erm
ab
ility
❑ Installation ⇒ page 144 ot p
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17 - Needle bearing
h re
hole
spec
❑ For 4th gear
es, in part or in w
❑ Change with bushing ⇒ Item 16 (page 138)
t to the co
18 - Sealing washer
rrectness of i
19 - Inner ring on the tapered roller bearing
l purpos
nf
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20 - Circlip
orm
m
❑ Replace
atio
om
n in
❑ Thickness determination ⇒ page 145
or c
thi
te
sd
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rp
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❑ With circlip
o
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❑ Installation ⇒ page 142 ht. rig
rig ht
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❑ Installation position: the roller bearing circlip should face the input shaft co Vo
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22 - Clutch housing
23 - Spring
24 - Engaging sleeve for 3rd and 4th gears
25 - Synchronizer for 3rd and 4th gears
26 - Retainers
❑ 3 units
27 - Spring
28 - Retainers
❑ 3 units
29 - Synchronizer for 5th gear
30 - Engaging sleeve for 5th gear
31 - Stop ring
❑ Prevents retainer “escape”

1.2 Input shaft - disassemble and assemble

equipment required
AG. Volkswagen AG d
agen oes
olksw not
y V gu
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rise nte
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ss c ce
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nl
pt
du
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♦ Plate - VW 401-
es, in part or in w
t to the co
♦ Plate - VW 402-
♦ Pressure pin - VW 407-
rrectness of i

l purpos
♦ Pressure tube - VW 415A-

nform
mercia
at
om
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c
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ate
do
priv
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for
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Cop py
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1. Input shaft 139

AG. Volkswagen AG d
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♦ Tube - VW 516-
un
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♦ Tube - 30-100-
erm
ab
ility
ot p
♦ Tube - 2010-
wit
is n
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♦ Pressure base or VW 3002 - 3002-

ole,
spec

t to the co
rrectness o
cial p
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mer
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n
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Cop py
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rig ht
py by
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140
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Prote AG.
Rep. gr.35 - Gears, shafts
AG. Volkswagen AG d
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♦ Pressure plate - T 10084A-

m
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atio
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♦ -1- Puller 30 - 37 mm or VW 020P - Kukko 21/5-

n in
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♦ -2- Puller 65 - 160 mm - KUKKO 18/1-

t
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♦ -3- Spacer 12 - 75 mm - KUKKO 17/1-

o
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♦ -4- Auxiliary support - KUKKO 22/1-
Co
Cop py
ht. rig
♦ Fitting tool - VW 244-
rig ht
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Prote AG.
1. Input shaft 141

Removing tapered roller bearing on clutch housing

A - Auxiliary support - KUKKO 22/1-
n AG. Volkswagen A
B - 30 - 37 mm Puller or oVW
lksw 020P - Kukko 21/5- es no
age G do
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– When removing ris it, compress the bearing circlip -arrow- with
ed ran
tee
pliers -C-. utho
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nl
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Installing tapered roller bearing on clutch housing
es, in part or in w
t to the co
– Support the clutch housing by placing the Pressure pipe - VW
415A- (not shown in fig.) directly under the bearing support.
– When installing, compress the bearing circlip -arrow- with pli‐
rrectness of i
ers -A-.
l purpos
– Remove the pliers just before the bearing is in the correct in‐
stallation position. The circlip shall be locked in the clutch
nf
ercia
housing hole.
orm
m
atio
om
n in
or c
thi
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Removing the bearing support with ball bearings

rp
cu
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en
ng
– Place the car in 2nd gear.

t.
yi Co
Cop py
t.
– Push Thrust plate - T 10084A- laterally to the input shaft stop.
rig
gh ht
pyri by
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co
– Install the centralizing pins of the Pressure shim - T 10081- in
by lksw
cted agen
Prote
the orifices of the input and output shafts.
AG.
Removing the inner ring of the tapered roller bearing with the 4th
gear wheel
A - 65 - 160 mm puller - KUKKO 18/1-
B - 12 - 75 mm separator - KUKKO 17/1-
C - Protection shims
– Remove circlip first.
– Fasten the Spacer 12 - 75 mm - KUKKO 17/1- -B- behind the
helical teeth (not in the gear teeth) of 4th gear.

Fox 2004 ➤ , Fox 2010 ➤ , Fox 2014
AG. Vol➤
ksw, aSpaceFox
gen AG 2006 ➤ , SpaceFox 201 ...
5-speed agen
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does
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Removal of engaging sleeve ris 4th
with 3rdthoand gear synchronizer eo
au ra
c
– After removing the circlip, disengage together the moving gear ss
ce
le
of the 3rd gear and the engaging sleeve with the synchronizer.
un
pt
an
d
itte
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erm
ab
ility
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ole,
spec
t to the co
rrectne
Disassembling and assembling the engaging sleeve and the 3rd
and 4th gear synchroniser
ss o
cial p
f
1 - Spring
inform
mer
2 - Engaging sleeve
atio
om
3 - Synchronizer
n
c
i
or
n thi
e
4 - Retainers
t
sd
iva
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pr
c
– Press the engaging sleeve on the synchronizer.
um
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fo
en
ng
t.
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The deeper grooves -arrow A- for the limiters located on the syn‐
Co
Cop py
chronizer should match the grooves -arrow B- on the engaging ht. rig
rig ht
sleeve. py by
co Vo
by lksw
cted agen
Prote AG.
– Install the retainers in the deeper grooves -arrows-.

• Press the engaging sleeve on the synchronizer
– Install springs -B- and -C- displaced by -a-
Note
-a- = 120°
– The folded end of the spring should fit into the limiter's hole.
Installation position of the 3rd and 4th gear engaging sleeve/syn‐

chronizer
The front face notch -arrow- should face the 4th gear side.
1. Input shaft 143

ks wage es n
Checking the wear on the ysynchronizer
Vol ring ot g
ua
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– Press the synchronizer
horis
ring against the gear cone and meas‐ tee
ure the distance aut-a- with feeler gauge. or
ac
ss
ce
e
Distance -a- New part Wear limit

nl
pt
du
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3rd, 4th and 5th 1.1..1.7 mm 0.5 mm
erm
ab
gears
ility
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hole
spec
es, in part or in w
t to the co
Installation of the synchronizer with the 3rd and 4th gear engaging
rrectness of i
sleeve
l purpos
– When pressing, secure the 3rd gear wheel with the synchron‐
izer ring fitted in the 3rd and 4th engaging sleeve/synchroniz‐
er.
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
yri
Installing the bushing on the needle bearing of 4th gear -A- p by
co Vo
by lksw
cted agen
– Install 4th gear wheel. Prote AG.
Installation of the inner ring on the tapered roller bearing -A-

Determination of the circlip thickness

– Install a circlip with 2.0 mm thickness -A- in the input shaft
groove and press upwards -arrow-.
– Determine the distance between the inner ring -B- and the cir‐
clip installed -A- by using a feeler gauge -C-.
– Remove the circlip used for measurement.
– Use the table to determine the circlip to be installed.
AG. Volkswagen AG d
Note agen oes
olksw not
V gu
d by ara
e
Assignment: ⇒ Electronic Parts Catalogue“ETKA”th.oris nte
eo
au ra
ss c
Available circlips
ce
e
nl
pt
du
an
itte
Value measured Circlip thickness Axial clearance
y li
erm
ab
(mm) (mm) (mm)
ility
ot p
0,05 ... 0.10 2.0 0,05 ... 0.15
wit
, is n
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0,15 ... 0.20 2.1 0,05 ... 0.15
hole
spec
0,25 ... 0.30 2.2 0,05 ... 0.15
es, in part or in w
t to the co
0,35 ... 0.40 2.3 0,05 ... 0.15
0,45 ... 0.50 2.4 0,05 ... 0.10
rrectness of i
l purpos
Installing the bearing support with ball bearings
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
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f
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
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by c lksw
cted agen
Prote AG.
Installing the bushing -A- for the needle bearing of 5th gear
1. Input shaft 145

Removing the stop ring

– Disengage hooks -A- from the stop ring with a screwdriver.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
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ut
Disassembling and assembling the 5th gear engaging sleeves aand ra
c
synchronizer s
ce
le
un
pt
1 - Spring
an
d
itte
y li
rm
ab
2 - Retainers
pe
ility
ot
wit
3 - Synchronizer
, is n
h re
hole
- Installation position: the front face notch -arrow A- and the wide
spec
collar -arrow B- should face the 5th gear.
es, in part or in w
t to the co
4 - Engaging sleeve
5 - Stop ring
rrectness of i
l purpos
The deeper grooves -arrow C- for the limiters located on the syn‐
chronizer should match the grooves -arrow D- on the engaging
nform
ercia
sleeve.
m
a
com
tion in
r
te o
thi
s
iva
do
– Install the retainers in the deeper grooves -arrows-.
r
rp
cum
fo
en
ng
t.
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op py
– Install springs -B- and -C- displaced by -a-.
. C rig
ht ht
rig by
copy Vo
by lksw
cted agen
Prote
Note
AG.
-a- = 120°
– The folded end of the spring should fit into the limiter's hole.

Installing stop ring

AG. Volkswagen AG d
– Fit the ring in Tube - 2010-
lksw
a. gen oes
not
V o gu
y
– Introduce the Tube rise - 2010- with the 5th gear synchroniser ring,
d b ara
nte
observing the ucorrect
tho installation position. The hooks eo
ra
-arrow 1- should
ss a fit in the notches -arrow 2- of the synchronizer c
limiters.
ce
le
un
pt
an
d
– Press the stop ring downwards until locking the hooks.

itte
y li
rm
ab
pe
ility
ot
wit
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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.
1. Input shaft 147

2 Planet pinion
⇒ “2.1 Pinion shaft - general overview of assembly”, page 148
⇒ “2.2 Planet pinion - disassemble and assemble”, page 151
2.1 Pinion shaft - general overview of as‐

G. Volkswagen AG d
sembly olkswagen A oes
not
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db ara
rise nte
WARNING
au
tho eo
ra
ss c
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le

un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
Note
♦ Install all the roller bearings, gears and synchronizer rings on
rrectness of i
the input shaft, lubricated with gear oil.
l purpos
♦ Do not invert the synchronizer rings. When reusing synchron‐

izer rings, always install them on the same gear pair.
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.

. Volkswagen AG
gen AG d
Fox 2004 ➤ , Fox 2010 ➤ , Fox 2014olks ➤ , SpaceFox 2006 ➤ ,sSpaceFox
wa oe
not 201 ...
yV gu
5-speedisemanual gearbox (02T and 0AP) - Edition
d b ara 02.2017
n r tee
ho
ut or
1 - Clutch housing ss
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es, in part or in w
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pound - AMV 188 200
03- evenly over the seal‐
rrectness of i
ing surface of the gear‐
box housing.
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❑ With circlip
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❑ Installation position: the
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planet pinion
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3 - Planet pinion
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also be replaced
⇒ Item 17 (page 166) .
❑ If there is an inner ring
as tapered roller bearing
mounting, this should
not be removed from the
planet pinion.
❑ If scratches or damages
are detected on the roll‐
er bearing mounting or
inner ring, replace the
planet pinion and the ta‐
pered roller bearing as a set.
4 - 4th gear wheel
❑ Installation position: the hub should face the 3rd gear ⇒ page 153
5 - Circlip
6 - Circlip
7 - 3rd gear wheel
❑ Installation position: the hub should face the 4th gear ⇒ page 153
8 - Circlip
9 - 2nd gear wheel
10 - Needle bearing
❑ For 2nd gear
11 - Inner ring for 2nd gear
12 - Outer ring for 2nd gear
❑ Install on inner ring ⇒ Item 11 (page 149)
❑ Change in case of scratches or wear signs
2. Planet pinion 149

13 - Synchronizer ring for 2nd gear

14 - Engaging sleeve with synchronizer for 1st and 2nd gears
❑ Remove with 2nd gear wheel after removing the circlip ⇒ page 153
❑ Disassemble and assemble the engaging sleeve/synchronizer ring ⇒ page 154
15 - Circlip
16 - Synchronizer ring for 1st gear
❑ Install in order that the notches fit in the engaging sleeve limiters ⇒ Item 14 (page 150)
17 - Outer ring for 1st gear
❑ Install on synchroniser ring ⇒ Item 16 (page 150)
❑ Change in case of scratches or wear signs
18 - Inner ring for 1st gear
❑ Check the flanges for wear signs
19 - Needle bearing AG. Volkswagen AG d
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❑ For 1st gear ed by
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20 - 1st gear wheel aut
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❑ Installation position ⇒ page 156 s
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21 - Roller bearing support with ball bearing

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❑ Check and replace whenever damaged

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23 - 5th gear wheel

orm
❑ Installation position: the hub shall face the gearbox housing side ⇒ page 120
m
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24 - Circlip
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25 - Spring
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26 - Engaging sleeve by c lksw
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27 - Synchronizer
28 - Retainers
❑ 3 units

2.2 Planet pinion - disassemble and assemble

equipment required
AG. Volkswagen AG d
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♦ Plate - VW 402-
♦ Pressure tube - VW 415A-
♦ Support tube - 40-21-

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♦ -1- 30 - 37mm Puller or VW 020P - Kukko 21/5-

rm
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Removing tapered roller bearing on clutch housing

hole
spec

es, in part or in w
t to the co
B - 30 - 37 mm Puller or VW 020P - Kukko 21/5-

– When removing it, compress the bearing circlip -arrow- with
rrectness of i
pliers -C-.
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Installing the tapered roller bearing on clutch housing

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– Support the clutch housing by placing the Pressure pipe - VW

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415A- (not shown in fig.) directly under the bearing support.

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– When installing, compress the bearing circlip -arrow- with pli‐
rig
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– Remove the pliers just before the bearing is in the correct in‐
AG.
stallation position. The circlip shall be locked in the clutch

housing hole.

Removing circlip -1- from notch

A - Safety sleeve
WARNING
Carefully remove circlip.

swa
gen AG
. Volkswagen AG
does
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Removing 1st and 2nd engaging sleeve/synchronizer
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– After removing the circlip, disengage together the moving gear
h re
of the 2nd gear and the engaging sleeve with the synchronizer.
hole
spec
es, in part or in w
t to the co
rrectness of i
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Installation position of 3rd and 4th gear wheels
com
tion in
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– Install 4th gear wheel -A- on planet pinion.

thi
s
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do
The collar -arrow 1- shall face the 3rd gear wheel -B-.
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– Install circlips -2- and -3-.

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– Install 3rd gear wheel -B- on planet pinion.
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The hub -arrow 2- shall face the 4th gear wheel -A-.
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Prote AG.
– Install circlip -1-.
Wear check of the inner ring of 1st and 2nd gears

– Press the inner ring against the gear cone and measure the
distance -a- with a feeler gauge.
1st and 2nd gears 0,75 ... 1.25 mm 0.3 mm

AG. Volkswagen AG d
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Fox 2004 ➤ , Fox 2010 ➤ , Fox d by 2014 ➤ , SpaceFox 2006 ➤ , SpaceFox
V gu
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5-speed manual gearbox ho(02T
ris
and 0AP) - Edition 02.2017 eo
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Wear check of the synchronizer ring of 1st and 2nd gears
ce
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pt
an
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– Press the synchroniser ring, internal and external tracks
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against the gear cone and measure the distance -a- with a
erm
ab
feeler gauge.
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1st and 2nd gears 1,2 ... 1.8 mm 0.5 mm
t to the co
rrectness o
Installation position of the outside and inner rings of the 2nd gear
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synchronizer ring
form
mer
– Install inner ring -A- on the 2nd gear wheel. The curve should‐
atio
m
ers -arrow 1- shall face the outer ring -B-.

o
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– Install the outer ring -B- over. The flanges -arrow 2- shall fit in
t
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the grooves -arrow 3- of the gear.

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– Install the synchronizer ring -C- over. The grooves -arrow 4-
ng
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shall fit in the relieves -arrow 1- on inner ring -A-. t. Cop py
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Disassembling and assembling the 1st and 2nd gear engaging

sleeve and synchronizer
1 - Spring
2 - Engaging sleeve
3 - Synchronizer
4 - Retainer
The notch on front face -arrow A- and the wide collar -arrow B-
shall face the external teeth on the engaging sleeve -arrow C-
after installing.
The deeper grooves -arrow D- for the limiters located on the syn‐
chronizer shall match the notches -arrow E- on the engaging
sleeve.
– Install the limiters in the deeper grooves -arrows-.

Assembling 1st and 2nd engaging sleeve/synchronizer

– Install the limiters in the deeper grooves -arrows-.
– Install springs -B- and -C- displaced by -a-
Note
-a- = 120°
AG. Volkswagen AG d
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– The folded end of the spring shall fit into the limiter's hole.
d by
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Installation of 1st and 2nd engaging sleeve/synchronizer
ss a ra
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Installation position: The notch for the selector fork located on the
un
pt
an
lug sleeve must face the 1st gear and the teeth for the reverse d
itte
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gear towards the 2nd gear.
erm
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ility
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– Turn the synchronizer ring in order to match flanges and lim‐
wit
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iters.
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spec
t to the co
rrectness o
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mer
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Installing circlip
i
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– Install the 1st gear circlip on the engaging sleeve/synchroniz‐

t.
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Prote AG.
Installation position of the 1st gear outer ring

The flanges -arrows- shall face the teeth for reverse gear.

AG. Volkswagen AG d
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Installation position of the 1st gear inner ring -A- byV
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The flanges -arrow 1- fit in the notches -arrow 2- on synchronizer
ut
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ring -B-. ss a ra
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Installation position for 1st gear moving wheel
rrectness of i
The tall collar -A- shall face the 2nd gear -B-. The collar notches
l purpos
-arrows- fit on the outer ring flanges -arrow-.
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39 – Finalolkdrive
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1 Drive flange
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⇒ “1.1 Left drive flange retainer (left side) - replace”, page 157
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nl
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⇒ “1.2 Drive flange retainer (right side) - replace”, page 160
itte
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1.1 Left drive flange retainer (left side) - replace
ility
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es, in part or in w
equipment required
t to the co
rrectness of i
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ion
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ate
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♦ Bush and roller bearing puller - VW 771-

♦ Complement - VW 771/37-
♦ Pressure base - T10082-
1. Drive flange 157

1.1.1 Removal
Note
With the gearbox installed.

For diesel engine vehicles:
– Remove the lower engine enoisen AG. Vinsulation
olkswagen A⇒ General body
G do
repairs, exterior; Rep.
olksgr. 50 ; Body - Front section
wag es n .
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Continuation: rise nte
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– Slightly that fasten the drive s au
loosen the screws shaft with con‐ra
c
s
stant velocity joint (left side) to the transmission drive flange.
ce
e
nl
pt
du
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itte
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erm
ab
– Turn the steering wheel to the left stop.
ility
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wit
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– Remove the screws -2- that fasten the drive shaft with constant
h re
velocity joint (left side) -3- to the transmission drive flange.
hole
spec
es, in part or in w
– Mark the installation position of the screws that fasten the low‐
t to the co
er articulation of the suspension's left wishbone (transversal).
Consult ⇒ Chassis, axles, steering; Rep. gr. 40 ; Front sus‐
pension . rrectness of i
Continuation for:
l purpos
Fastening screws:
nf
ercia
orm
m
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– Remove the securing bolts -arrows-. Consult ⇒ Chassis,
Prote AG.
axles, steering; Rep. gr. 40 ; Front suspension .

Fastening nuts:
158 Rep. gr.39 - Final drive - differential

FoxA2004
agen
G. Volk➤
swa, gFox
en AG2010 ➤ , Fox 2014 ➤ , SpaceFox 2006 ➤ ,
does SpaceFox 201 ...
ksw 5-speedgu manual gearbox (02T and 0AP) - Edition 02.2017
ol not
byV ara
ed
ris nte
– Remove
aut
ho
the fastening nuts -arrows-. Consult ⇒ Chassis, eo
ra
axles,
ss steering; Rep. gr. 40 ; Front suspension . c
ce
le
un
pt
an
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erm
ab
ility
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ole,
spec
t to the co
rrectne
– Remove the hex nut -1- from coupling rod -3-.
ss o
– Remove the coupling rod -3- from the stabiliser -2-.
cial p
f inform
– Displace the suspension strut, pulling it away from the wish‐
mer
bone (transversal).
atio
om
n
c
i
or
n thi
e

t
sd
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pr
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fo
en
ng
Note
t.
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Cop py
ht. rig
ht
rig by
opy Vo
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cted agen
due to excessive tilting.
Prote AG.
– Remove the drive flange fastening screw by using two screws

to lock the flange with a lever.
– Remove the drive flange with the spring.
– Remove the drive flange retainer (left side) with the Bush and
bearing puller - VW 771- and the Complement - VW 771/37- .
1. Drive flange 159

1.1.2 Installation
agen
AG. Volkswagen AG d
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byV gu
ara
WARNINGed nte
ris
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s au ra
c
♦ When
s handling chemicals follow the safety instructions ⇒
ce
e

nl
pt
du
an
itte
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erm
ab
ility
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h re
hole
spec
es, in part or in w
t to the co
– Install the new retainer to the stop without tilting it.
– Fill the half space between the sealing lip and the boot with
rrectness of i
Grease - G 052 128 A1- .
l purpos
– Install the drive flange, fastening it with the countersunk bolt.

Tightening torque, see ⇒ Item 1 (page 165) .
nform
ercia
– Install the drive shaft with constant velocity joint (left side) onto
the transmission drive flange. Refer to ⇒ Chassis, axles,
m
at
om
i
steering; Rep. gr. 40 ; Front suspension .
on
c
in t
or

his
ate
do
riv

p
cum
for
en
ng
– Install the lower engine noise insulation ⇒ General body re‐

t.
yi Co
op
pairs, exterior; Rep. gr. 50 ; Body - Front section .
C py
ht. rig
rig ht
py by
– Install the left side wheel. Tightening torque, refer to ⇒ Chas‐ co Vo
by lksw
sis, axles, steering; Rep. gr. 44 ; Vehicle wheels, tyres, cted agen
Prote AG.
measurement .
1.2 Drive flange retainer (right side) - replace


equipment required
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ility
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hole
spec
♦ Bush and roller bearing puller - VW 771-

es, in part or in w
t to the co
♦ Complement - VW 771/37-
♦ Fitting sleeve - 3158-
rrectness of i

l purpos
1.2.1 Removal
nf
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orm
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Note
or c
thi
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sd
iva
With the gearbox installed:

o
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f
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t.
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Cop py
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Vo
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by
– Remove the lower engine noise insulation ⇒ General body cted agen
Prote AG.
repairs, exterior; Rep. gr. 50 ; Body - Front section .
Continuation:
– Turn the steering wheel to the right stop.
1. Drive flange 161

– Remove the screws -2- that fasten the drive shaft with constant
velocity joint (right side) -3- to the gearbox drive flange.
– Place the final drive with constant velocity joint (right side) up‐
Note
due to excessive tilting.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
– Remove the drive flange fastening screw by using two screws ss c
ce
le
to lock the flange with a lever.

un
pt
an
d
itte
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erm
ab
ility
– Remove the drive flange with the spring.
ot p
wit
is n
h re
ole,
spec
t to the co
rrectnes
– Remove the drive flange retainer (right side) with the Bush and
s o
cial p
f
bearing puller - VW 771- and the Complement - VW 771/37- .
inform
mer
atio
m
Note
o
n
c
i
or
n thi
e
♦ Do not damage retainers -A-; otherwise, leaks may occur.

t
sd
iva
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pr
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♦ Replace the retainer, if damaged.

fo
en
ng
t.
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Cop py
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Prote AG.
1.2.2 Installation
WARNING



– Install the new retainer to the stop without tilting it.

– Fill the half space between the sealing lip and the boot with
Grease - G 052 128 A1- .
– Install the drive flange, fastening it with the countersunk bolt.
Tightening torque, see ⇒ Item 1 (page 165) .
– Install the drive shaft with constant velocity joint (right side)
onto the transmission drive flange. Refer to ⇒ Chassis, axles,
steering; Rep. gr. 40 ; Front suspension .
– Install the lower engine noise insulation ⇒ General body re‐
pairs, exterior; Rep. gr. 50 ; Body - Front section .
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
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un
pt
an
d
itte
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erm
ab
ility
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is n
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t to the co
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mer
atio
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n
c
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1. Drive flange 163

2 Differential
⇒ “2.1 Differential - general overview of assembly”, page 164
⇒ “2.2 Differential - disassemble and assemble”, page 167
⇒ “2.3 Differential - adjust”, page 173
2.1 Differential - general overview of assem‐

bly
WARNING

AG. Volkswagen AG d
agen
Note Volksw
oes
not
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d by ara
ise nte
♦ Heat inner ring of the tapered roller bearing to 100 °C before
or eo
h
ut ra
installing. ss a c
ce
le
♦ Always change both tapered roller bearings as a set.

un
pt
an
d
itte
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♦ Adjust the differential when replacing the tapered roller bear‐
erm
ab
ings, differential case, transmission housing or clutch housing
ility
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⇒ page 173 .
wit
is n
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spec
t to the co
rrectness o
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mer
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Prote AG.

1 - Countersunk bolt
❑ 25 Nm
❑ Fasten on the threaded
part
2 - Right drive flange
❑ Do not invert. The right
and left drive flanges are
different
3 - Pressure spring for drive
flange agen
AG. Volkswagen AG d
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❑ Installed behind the d by V gu
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drive flange orise nte
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4 - Sealing washer ss a c
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❑ Installation position: lip
nl
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facing the pressure
itte
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spring
erm
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ility
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5 - Tapered ring
wit
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❑ Installation position:
hole
shoulder facing the dif‐
spec
ferential case
es, in part or in w
t to the co
6 - Circlip
❑ keeps the tapered ring,
rrectness of i
sealing washer and
spring in position when
l purpos
the propelling flange is

removed
nf
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7 - Planetary gear
orm
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c
8 - Flanged shaft nut

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9 - Differential pinion pin
f
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❑ Removal ⇒ page 172 t. Cop py
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10 - Planetary gear cted agen
Prote AG.
11 - Stop cover for planetary gears
❑ Install lubricated with gear oil
12 - Left drive flange
❑ With retainer plate
❑ Do not invert. The right and left drive flanges are different
13 - Retainer for the left drive flange
❑ Left and right diameters are different
❑ Always with 1-mm thickness
❑ Only used on gearbox housings -02T.301.103.L- and -02T.301.103.AA-
2. Differential 165

17 - Differential case
❑ With riveted crown wheel
❑ If replacement is necessary, the planet pinion should also be replaced ⇒ Item 3 (page 149)
18 - Elastic pin
❑ To fasten the differential pinion pin
22 - Retainer for the right drive flange
❑ Left and right diameters are different
. Volkswagen AG
❑ In case of replacement, always adjust differential
swa
gen⇒AG
page 173 does
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24 - Clutch housing db ua
ran
rise tee
❑ Assignment ⇒ Electronic Parts Catalogue
aut
ho
“ETKA” or
ac
❑ Repair ⇒ page 121 ss
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an
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ility
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t to the co
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f inform
mer
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om
n
c
i
or
n thi
te
sd
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Cop py
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Prote AG.

2.2 Differential - disassemble and assemble

wage es n
Special tools and workshop yV
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equipment required ir se
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es, in part or in w
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rrectness of i
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♦ Plate - VW 401-
♦ Plate - VW 402-
♦ Pressure pin - VW 408 A-
♦ Pressure tube - VW 418 A-
2. Differential 167
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ility
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es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
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Cop py
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♦ Fitting tool - VW 455-

♦ Extractor tube - 30-14-
♦ Tube - 2040-
♦ Pressure base or 3002 - VW 3002-

AG. Volkswagen AG d
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ility
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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.
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Cop py
ht. rig
rig ht
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by lksw
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♦ Tube - 3259-
♦ Fitting tool - 3345-
♦ Bearing puller - VAG 1582-
♦ Calliper - VAG 1582/4-
♦ -1- 46 - 56 mm Puller or VW 020T - Kukko 21/7-
2. Differential 169
AG. Volkswagen AG d
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♦ Pressure base or VW 062 - 30-205-

h re
hole
spec
♦ Support tube - 40-21-

es, in part or in w
t to the co

♦ Calliper - VAG 1582/3-
rrectness of i
Removing the outer ring on the tapered roller bearing of the gear‐
box housing
l purpos

nform
ercia
B - 46 - 56mm Puller or VW 020T - Kukko 21/7-

m
at
om
ion
c
in t
r
Note
o
his
ate
do
priv
After removing the outer bearing race, check for the presence of
um
for
adjustment shim S1. This adjustment shim S1 is only used on a

en
ng
t.
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few housings of the gearbox ⇒ Item 14 (page 124) . Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Installing the outer bearing race of the tapered roller bearing on

the gearbox housing
Note
♦ Install adjustment shim S1 (standard 1 mm) below the outer

bearing race in case it has been disassembled.
♦ This adjustment shim S1 is only used on a few housings of the
gearbox ⇒ Item 14 (page 124) .
– Support the gearbox housing by placing the Tube - 3259- di‐

rectly below the bearing support.
Removing the outer race from the tapered roller bearing -A- of the
clutch housing
– Use Puller 46 - 56mm or VW 020T - Kukko 21/7- -B- to remove
the outer race from the tapered roller bearing.
Note
Remove the Speed sensor - G22- before removing the outer race
from the tapered roller bearing.
lkswage es n
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d ran
ir se tee
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u or
Installing the outer race on the tapered roller bearing
ss
a of the clutch ac
housing
ce
le
un
pt
an
d
– Support the clutch housing by placing the Fitter - 3345- directly

itte
y li
below the bearing support.
rm
ab
pe
ility
– Install the Speed sensor - G22- after installing the outer bear‐
ot
wit
, is n
ing race.
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
Removing the inner ring from the tapered roller bearings

– Before installing the puller, install Sleeve - VW 472/2- -
nform
ercia
VW 472/2- and the Pressure base or VW 3002 - 3002- on top

the differential case.
m
a
com
tion in
r
te o
thi
Note
s
iva
do
r
rp
cum
fo
The internal tracks on both roller bearings are removed in an

en
ng
t.
yi
identical way as for the differential case.
Co
Cop py
t. rig
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Prote AG.
2. Differential 171
Installing the inner ring on the tapered roller bearings

– Support the internal track on the opposite side with the press‐
ing bushing -VW 455- .
AG. Volkswagen AG d
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Removing the inner iring
se from the tapered roller bearing
d b ara
nte
or e
h
– Before mounting
s aut
the pulling device, place the Sleeve - VW or ac
472/2- and the
s Pressure base or VW 3002 - 3002- in the plan‐
ce
e
etary gear box.

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
t to the co
Installing the inner ring on the tapered roller bearing rrectness of i
l purpos
– Support the inner ring on the opposite side with the Fitter - VW
455- .
nf
ercia
orm
m
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om
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Cop py
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Removing the differential pinion pin
c by lksw
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Prote AG.
Press the elastic pin until it shears, to remove the shaft.
– Remove the elastic pin remains from the differential case.

Installing the planetary and planetary gears

– Lubricate the stop cover of the planetary gears with gear oil.
– Install the two planetary gears and lock them (for example,
with the drive flange).
– Install the satellite gears displaced by 180°
– Install the differential pinion pin -arrow A- to the first planetary
gear.
– Install nuts -arrows B- on the planetary gears. Installation po‐
sition: edge facing the planetary gear.
– Install the differential pinion pin to the stop and fasten it with
the elastic pin.
2.3 Differential - adjust

equipment required
lkswage es n
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an
d
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rm
ab
pe
ility
ot
wit
, is n
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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
a
com
tion in
r
te o
thi
♦ Measuring disc or VW 385 - VW 385/17-

s
iva
do
r
rp
♦ Mounting bracket - VW 387-

um
fo
en
ng
t.
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♦ Plate - VW 401-
Co
Cop py
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gh
♦ Plate - VW 402-
ht
pyri by
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by
cted agen
Prote AG.
2. Differential 173
wage es n
olks
♦ Pressure pin - VW 408A- ot g
yV b ua
ed ran
♦ Pressure disc - tVW
ho 412-
ris tee
or
au ac
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nl
pt
du
an
itte
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erm
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ility
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, 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.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

♦ Extractor tube - 30-14-
♦ Tube - 2040-
♦ Tube - 3259-
♦ Fitting tool - 3345-
♦ -1- 46 - 56 mm Puller or VW 020T - Kukko 21/7-

AG. Volkswagen AG d
agen oes
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d by ara
ise nte
or eo
h
aut ra
ss c
ce
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nl
pt
du
an
itte
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erm
ab
ility
ot p
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, 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
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or c
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sd
iva
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cu
♦ Pressure base - 30-205-
o
m
f
en
ng
t.
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The differential shall be adjusted when replacing the following Cop py
components:
t. rig
gh ht
pyri by
Vo
o
by c
♦ Gearbox housing
lksw
cted agen
Prote AG.
♦ Clutch housing
♦ Differential case
♦ Tapered roller bearings of the differential
– Installing the outer bearing race (pinion side) on the gearbox
housing ⇒ page 171
Note
The inside and outside tracks of the tapered roller bearings form
an assembly (pairs) and should not be inverted.
2. Differential 175
– Install the outer bearing race (opposite side of pinion) on the

clutch housing without adjustment shim.
– Install the differential on the clutch housing.
– Install the gearbox housing and tighten the 5 screws to the
corresponding tightening torque ⇒ Item 3 (page 110)
AG. Volkswagen AG d
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un
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d
itte
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– Install the measuring device and the dial gauge by using an
erm
ab
ility
extender -A- of approx. 30 mm.
ot p
wit
is n
– Reset the dial gauge to zero with 1-mm pre-tension.
h re
ole,
spec
– Move the differential upwards and downwards, read the clear‐
ance on the dial gauge and write down (in the example: 1.50
t to the co
mm).
Determine adjustment shim thickness S2
rrectne
The pre-tension required for the roller bearing is achieved by
adding a constant pressure value (0.35 mm) to the value achieved
ss
during the measurement for S2.
o
cial p
f inform
Example:
mer
atio
m
Measured value 1.50 mm

o
n
c
i
or
n
+ pressure (constant value) 0.35 mm
thi
te
sd
va
Adjustment shim S2 thickness = 1.85 mm

i
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.

– Remove the clutch housing and the outer bearing race -A-.
B - 46 - 56 mm Puller or VW 020T - Kukko 21/7-
– Install adjustment shim S2 with the corresponding thickness
(in the example, 1.85 mm) and reinstall the outer bearing race
in the clutch housing ⇒ page 171
Adjustment shims:
Thickness (mm) Replacement parts No.
0.65 -02K 409 210-
0.70 -02K 409 210 A- AG. Volkswagen AG d
agen oes
ksw
0.75 -02K 409 by Vo210
l B- not
gu
d ara
0.80 -02Korise 409 210 C- nte
eo
th
0.85 ss a -02K 409 210 D-
u ra
c
0.90 -02K 409 210 E-
ce
e
nl
pt
du
an
0.95 -02K 409 210 F-
itte
y li
erm
ab
1.00 -02K 409 210 G-
ility
ot p
1.05 -02K 409 210 H-
wit
, is n
h re
1.10 -02K 409 210 J-
hole
spec
1.15 -02K 409 210 K-
es, in part or in w
t to the co
1.20 -02K 409 210 L-
1.25 -02K 409 210 M-
rrectness of i
1.30 -02K 409 210 N-
1.35 -02K 409 210 P-
l purpos
1.40 -02K 409 210 Q-
nform
ercia
The existence of different tolerances enables calibrating the re‐

quired shim thickness with accuracy.
m
at
om
io
If the required thickness for the adjustment shim is greater than
n
c
in t
or
that indicated on the table, install 2 shims which thickness sum is

his
ate
equivalent.
do
priv
cum
or
– Install the transmission housing and tighten bolts to the cor‐

f
en
ng
t.
responding tightening torque ⇒ Item 3 (page 110) .
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
2. Differential 177

Service: Fox 2004, Fox 2010, Fox 2014, Spacefox 2006, Spacefox 2011

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What are the different manual gearboxes discussed in the document?

What are the different manual gearboxes discussed in the document?

What information can be found for each gearbox?

What information can be found for each gearbox?

Service

SpaceFox 2006 ➤ , SpaceFox 2011 ➤

Service Department. Technical Information

All rights reserved.

Copyright © 2017 Volkswagen AG, Wolfsburg BRA5R006020

1.1 Shift mechanism - installation position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

1.2 Selector mechanism - component overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

1.3 Drive cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

1.4 Handle and boot on the gear lever - assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . 59

1.9 Lever and Gear shifting mechanism - adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

1.10 Selector and lever - functional check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

2.3 Gearbox - transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

3 Gearbox oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

3.1 Oil level - check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

4.3 Gearbox housing cover and 5th gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

35 - Gears, shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136

39 - Final drive - differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157

1.1 Identification on the gearbox

♦ Eventual existing additional data are related to the manufac‐

1.2 Prefix, Assignment, gear ratio, filling vol‐

⇒ “1.2.3 Gearbox installed together with engines (CSEA)”,

Manufacturing from 08.03 10.03 11.05

to 11.03 07.07 07.07

Assignment Model Fox 2004 ► Fox 2004 ► SpaceFox 2006 ►

Engine 1.0 l - 53 kW 1.6 l - 74 kW 1.6 l - 74 kW

gearbox ratio Z2: Differential 69 : 14 = 4.929 68 : 15 = 4,533 68 : 15 = 4,533

Manual gearbox 5-speed 02T and 0AP

Manual gearbox 02T 5-speed

2 Rep. gr.00 - Technical data

Manual gearbox 02T 5-speed

Manual gearbox AG. Volkswagen

gearbox ratio Z2: Differential 67 : 16 = 4.187 67 : 16 = 4.187 68 : 15 = 4.533

Manual gearbox 5-speed 02T and 0AP

Identification letters (prefix) JHN JJZ

Manufacturing from 01.07 01.07 01.07

Manual gearbox 5-speed 02T and 0AP

The following information can be found in: ⇒ Electronic Parts

Identification letters (prefix) KWF KWG

Manufacturing from 03.08 02.07 03.08

to 02.10 07.11 11.09

Assignment Model Fox 2008 ► SpaceFox 2007 ► Fox 2007 ►

Manual gearbox 5-speed 02T and 0AP

4 Rep. gr.00 - Technical data

Manual gearbox 02T 5-speed

Engine 1.6 l - 74 kW 1.6 l - 74 kW 1.6 l - 74 kW

gearbox ratio Z2: Differential 67 : 16 = 4.187 67 : 16 = 4.187 67 : 16 = 4.187

2.0 + 0.1 litres 2.0 + 0.1 litres 2.0 + 0.1 litres

♦ Individual gear ratios

♦ Specification of the clutch

♦ Gearbox oil (filling)

Manual gearbox 5-speed 02T and 0AP

Identification letters (prefix) LVW LVX LVZ

Manufacturing from 11.09 11.09 11.09

gearbox ratio Z2: Differential 67 : 16 = 4.187 69 : 14 = 4.928 68 : 15 = 4.533

♦ Gearbox oil (filling)