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Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ ,
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Passat 2006 ➤ , Passat 2011 ➤ ,
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6-speed manual gearbox 0AJ
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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 K0058970420
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Safety precautions for vehicles with a start-stop system . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.1 Gearbox identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3 Identification codes, assembly allocation, ratios and capacities . . . . . . . . . . . . . . . . . . . . 3
3.1 Identification codes, assembly allocation, gear ratios and capacities, Golf 2004 ► . . . . . . 3
3.2 Identification codes, assembly allocation, gear ratios and capacities, Golf 2009 ► . . . . . . 3
3.3 Identification codes, assembly allocation, ratios and capacities, Golf Plus 2005 ► . . . . . . 5
3.4 Identification codes, assembly allocation, ratios and capacities, Golf Plus 2009 ► . . . . . . 5
3.5 Identification codes, assembly allocation and capacities, Passat 2006 ► . . . . . . . . . . . . . . 6
3.6 Identification code, assembly allocation, transmission ratios and capacities, Passat 2011 ►
........................................................................ 7
3.7 Identification codes, assembly allocation and capacities, Eos 2006 ► . . . . . . . . . . . . . . . . 8
3.8 Identification codes, assembly allocation, ratios and capacities, Scirocco 2009 ► . . . . . . 10
3.9 Identification codes, assembly allocation, ratios and capacities, Touran 2003 ► . . . . . . . . 12
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3.10 Calculation of gear ratios . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4 Overview - power transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
5 General repair instructions . . . . . g.e.n.A.G.. V. o.lk.s.w.ag. e.n.A.G. d. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
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30 - Clutch . . . . . . . . . . . . . .ris.ed.b . . . . . . . . . . . . . . . . . . . . . . u.ar.an.t . . . . . . . . . . . . . . . . . 20
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1 Clutch operation . a.ut.h . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .o.r a. . . . . .
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1.1 Overview - clutch sactuation . . . . . . . . . . . . . . . ................................. 20
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1.2 Assembly overview, pedal cluster with clutch pedal switch F36 , only Touran up to 05.03
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1.3 Only Touran up to 05.03 - removing and installing clutch pedal switch F36 . . . . . . . . . . . . 23
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1.4 Assembly overview, pedal cluster with clutch position sender G476 - Touran from 06.03,
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1.5 Removing and installing over-centre spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
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1.6 Removing and installing clutch pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
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1.7 Removing and installing mounting bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
1.8 Removing and installing master cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
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1.9 Removing and installing clutch position sender G476 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
1.10 Assembly overview - hydraulics (LHD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
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1.11 Assembly overview - hydraulics (RHD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
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1.12 Removing and installing slave cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
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1.13 Bleeding clutch system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
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2 Clutch release mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
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2.1 Assembly overview - clutch release mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
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2.2 Repairing clutch release mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
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3 Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
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3.1 Assembly overview - clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
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3.2 Removing and installing clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
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34 - Controls, housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
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1 Selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
1.1 Installation position of selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
1.2 Overview - selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
1.3 Assembly overview - gear knob and cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
1.4 Removing and installing gear knob with gaiter and noise insulation . . . . . . . . . . . . . . . . . . 141
1.5 Assembly overview - Gear lever and selector housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
1.6 Dismantling and assembling selector mechanism (from 11.06) . . . . . . . . . . . . . . . . . . . . . . 151
1.7 Assembly overview - Selector cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
Contents i
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
1.8 Removing and installing selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
1.9 Adjusting selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
2 Removing and installing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
2.1 Removing and installing gearbox, Touran (except vehicles with 1.2 l engine) . . . . . . . . . . 171
2.2 Removing and installing gearbox, Touran (only vehicles with 1.2 l engine) . . . . . . . . . . . . 185
2.3 Removing and installing gearbox, Golf 2004 ► . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
2.4 Removing and installing gearbox, Golf 2009 ► with 1,2 l engine . . . . . . . . . . . . . . . . . . . . 214
2.5 Removing and installing gearbox, Golf 2009 ► with 1.4 l engine and Passat 2011 ► . . . . 230
2.6 Removing and installing gearbox, Golf Plus with 1,2 l engine . . . . . . . . . . . . . . . . . . . . . . 248
2.7 Removing and installing gearbox, Golf Plus with 1,4 l engine . . . . . . . . . . . . . . . . . . . . . . 261
2.8 Removing and installing gearbox, Passat 2006 ► and Eos . . . . . . . . . . . . . . . . . . . . . . . . 277
2.9 Removing and installing gearbox - Scirocco . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 289
3 Transporting gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305
4 Gear oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 306
4.1 Checking gear oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 306
4.2 Fill with gear oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 307
5 Dismantling and assembling gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 309
5.1 Overview - gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 309
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5.2 Overview - dismantling and assembling gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310
5.3 Assembly overview - Removing and installing cover for gearbox housing and 5th and 6th
gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311
5.4 Assembly overview - removing and installing clutch housing . . . . . . . . . . . . . . . . . . . . . . . . 313
5.5 Assembly overview - removing and installing input shaft, output shaft, differential, selector
mechanism and selector forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 314
5.6 Dismantling and assembling procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 316
6 Gearbox housing and clutch housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 331
6.1 Assembly overview - gearbox housing and clutch housing . . . . . . . . . . . . . . . . . . . . . . . . 331
7 Gearbox housing cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 334
7.1 Assembly overview - gearbox housing cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 334
7.2 Repairing gearbox housing
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8 Selectory Vunit . . . . . . . . . . . . . . . . . . .n.ot.g.u . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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ed overview - selector unit . . . . . . .ra.nt.e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 337
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ut selector unit . . . . . . . . . . . . . . . . . . .or.ac. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 338
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9 Selector forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 340
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9.1 Assembly overview - selector forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 340
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9.2 Repairing selector forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 341
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35 - Gears, shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 345
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1 Input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 345
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1.1 Assembly overview - input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 345
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1.2 Dismantling and assembling input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 348
1.3 Renewing input shaft seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 356
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2 Output shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 358
2.1 Assembly overview - output shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 358
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2.2 Dismantling and assembling output shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 361
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39 - Final drive - differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 367
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1 Oil seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 367
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1.1 Renewing left flange shaft oil seal with gearbox installed . . . . . . . . . . . . . . . . . . . . . . . . . . 367
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1.2 Renewing right flange shaft oil seal with gearbox installed . . . . . . . . . . . . . . . . . . . . . . . . 368
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2 Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 371
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2.1 Assembly overview - differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 371
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2.2 Dismantling and assembling differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 373
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2.3 Adjusting differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 377
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ii Contents
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
00 – Technical data
1 Safety precautions
(VRL009874; Edition 01.2017)
⇒ “1.1 Safety precautions for vehicles with a start-stop system”,
page 1
1.1 Safety precautions for vehicles with a
start-stop system
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♦ In vehicles with the start/stop system activated (identifia‐
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♦ When working on the vehicle, therefore, ensure that the
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start/stop system is deactivated (switch ignition off, then
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1. Safety precautions 1
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
2 Identification
⇒ “2.1 Gearbox identification”, page 2
2.1 Gearbox identification
Configuration of identification codes and construction data on
manual gearbox -arrow-
Code letters and production date of manual gearbox -arrow-
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Example: FVG 12 11 2
I I I I
I I I I
Identification Day Month Year (2002) of
code manufacture
Additional data provide information about the production facility.
Note
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2 Rep. gr.00 - Technical data
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
3 Identification codes, assembly allo‐
cation, ratios and capacities
6-speed manual gearbox 0AJ is installed in following vehicles:
⇒ “3.1 Identification codes, assembly allocation, gear ratios and
capacities, Golf 2004 ►”, page 3
⇒ “3.2 Identification codes, assembly allocation, gear ratios and
capacities, Golf 2009 ►”, page 3
⇒ “3.3 Identification codes, assembly allocation, ratios and ca‐
pacities, Golf Plus 2005 ►”, page 5
⇒ “3.4 Identification codes, assembly allocation, ratios and ca‐
pacities, Golf Plus 2009 ►”, page 5
⇒ “3.5 Identification codes, assembly allocation and capacities,
Passat 2006 ►”, page 6
⇒ “3.6 Identification code, assembly allocation, transmission ra‐
tios and capacities, Passat 2011 ►”, page 7
⇒ “3.7 Identification codes, assembly allocation and capacities,
Eos 2006 ►”, page 8
cardiagn.com
⇒ “3.8 Identification codes, assembly allocation, ratios and ca‐
pacities, Scirocco 2009 ►”, page 10
⇒ “3.9 Identification codes, assembly allocation, ratios and ca‐
pacities, Touran 2003 ►”, page 12
3.1 Identification codes, assembly allocation, gear ratios and capacities, Golf
2004 ►
Manual gearbox 6-speed, 0AJ
Identification code JPG KRG LHX
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Allocation Engine 1.4Vol
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Ratio Final drive utho 74 : 17 = 4.352
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Capacity of manual gear‐ 2.3 l 2.3 l 2.3 l
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Drive shaft flange diame‐ 100 mm 100 mm 100 mm
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The following data can be found in the ⇒ Electronic Parts Cata‐
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♦ Individual gear ratios
♦ Gear oil
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♦ Clutch allocation
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3. Identification codes, assembly allocation, ratios and capacities
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
Manual gearbox 6-speed, 0AJ
Identification code KRG LHY MHS
Allocation Engine 1.4 l - 90 kW 1.4 l - 90 kW 1.2 l - 77 kW
1.2 l - 77 kW
Ratio Final drive 73 : 18 = 4.056 73 : 18 = 4.056 73 : 18 = 4.056
Z2 : Z1
Capacity of manual gear‐ 2.3 l 2.3 l 2.3 l
box
Drive shaft flange diame‐ 100 mm 100 mm 100 mm
ter
The following data can be found in the ⇒ Electronic Parts Cata‐
logue “ETKA” .
♦ Individual gear ratios
♦ Gear oil
♦ Clutch allocation
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Allocation Engine 1.2 l - 77 kW
Ratio Final drive 73 : 18 = 4.056
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Capacity of manual gear‐ 2.3 l
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Drive shaft flange diame‐ 100 mm
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The following data can be found in the ⇒ Electronic Parts Cata‐
logue “ETKA” .
♦ Individual gear ratios
4 Rep. gr.00 - Technical data
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
♦ Gear oil
♦ Clutch allocation
3.3 Identification codes, assembly allocation, ratios and capacities, Golf Plus
2005 ►
Manual gearbox 6-speed, 0AJ
Identification code JPG LHX
Manufac‐ from 07.07 09.08
tured to 09.08 01.09
Allocation Engine 1.4 l - 90 kW 1.4 l - 90 kW
Ratio Final drive 74 : 17 = 4.352 74 : 17 = 4.352
Z2 : Z1
Capacity of manual gear‐ 2.3 l 2.3 l
box
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3.4 Identification codes, assembly allocation, ratios and capacities, Golf Plus
2009 ► t to the co
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Manual gearbox 6-speed, 0AJ
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Identification code LHY MHS MHU
Manufac‐ from 01.09 08.09 08.09
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Allocation Engine 1.2 l - 77 kW 1.2 l - 77 kW 1.2 l - 77 kW
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The following data can be found in the ⇒ Electronic Parts Cata‐
logue “ETKA” .
♦ Individual gear ratios
♦ Gear oil
♦ Clutch allocation
Manual gearbox 6-speed, 0AJ
Identification code LNY NBW NBX
Manufac‐ from 11.09 07.11 07.11
tured to 06.11 11.13 11.13
3. Identification codes, assembly allocation, ratios and capacities 5
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
Manual gearbox 6-speed, 0AJ
Identification code LNY NBW NBX
Allocation Engine 1.2 l - 77 kW 1.2 l - 77 kW 1.2 l - 77 kW
1.2 l - 90 kW
Ratio Final drive 73 : 18 = 4.056 73 : 18 = 4.056 73 : 18 = 4.056
Z2 : Z1
Capacity of manual gear‐ 2.3 l 2.3 l 2.3 l
box
Drive shaft flange diame‐ 100 mm 100 mm 100 mm
ter
The following data can be found in the ⇒ Electronic Parts Cata‐
logue “ETKA” . gen AG
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Identification code PRG PRJ
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Manufac‐ from 05.13 05.13
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Allocation Engine 1.2 l - 77 kW 1.2 l - 77 kW
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Ratio Final drive 73 : 18 = 4.056 73 : 18 = 4.056
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3.5 Identification codes, assembly allocation and capacities, Passat 2006 ►
Manual gearbox 6-speed, 0AJ
Identification code GPN HBL HPB
Manufac‐ from 11.04 06.04 11.04
tured to 12.04 07.04 10.06
Allocation Engine 1.6 l - 85 kW 1.6 l - 85 kW 1.6 l - 85 kW
Ratio Final drive 76 : 15 = 5.067 76 : 15 = 5.067 76 : 15 = 5.067
Z2 : Z1
Capacity of manual gear‐ 2.3 l 2.3 l 2.3 l
box
Drive shaft flange diame‐ 100 mm 100 mm 100 mm
ter
The following data can be found in the ⇒ Electronic Parts Cata‐
logue “ETKA” .
6 Rep. gr.00 - Technical data
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
♦ Individual gear ratios
♦ Gear oil
♦ Clutch allocation
Manual gearbox 6-speed, 0AJ
Identification code JJY JPG LHX
Manufac‐ from 11.06 05.07 11.08
tured to 05.08 11.08 08.10
Allocation Engine 1.6 l - 85 kW 1.4 l - 90 kW 1.4 l - 90 kW
Ratio Final drive 76 : 15 = 5.067 74 : 17 = 4.352 74 : 17 = 4.352
Z2 : Z1
Capacity of manual gear‐ 2.3 l 2.3 l 2.3 l
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Identification code LNY MHS MHT
Manufac‐ from 05.09 08.09 08.09
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Allocation Engine 1.4 l - 90 kW 1.4 l - 90 kW 1.4 l - 90 kW
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Ratio Final drive 73 : 18 = 4.056 73 : 18 = 4.056 74 : 17 = 4.352
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3.6 Identification code, assembly allocation, transmission ratios and capacities,
Passat 2011 ►
Manual gearbox 6-speed, 0AJ
Identification code LHY LNY NBW
Manufac‐ from 08.10 08.10 06.11
tured to 06.11 06.11 12.14
Allocation Engine 1.4 l - 90 kW 1.4 l - 90 kW 1.4 l - 90 kW
Ratio Final drive 74 : 17 = 4.352 73 : 18 = 4.056 73 : 18 = 4.056
Z2 : Z1
3. Identification codes, assembly allocation, ratios and capacities 7
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
Manual gearbox 6-speed, 0AJ
Identification code LHY LNY NBW
Capacity of manual gear‐ 2.3 l 2.3 l 2.3 l
box
Drive shaft flange diame‐ 100 mm 100 mm 100 mm
ter
The following data can be found in the ⇒ Electronic Parts Cata‐
logue “ETKA” .
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Identification code NBX PRG PRJ
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Ratio Final drive 73 : 18 = 4.056 73 : 18 = 4.056 73 : 18 = 4.056
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Capacity of manual gear‐ 2.3 l 2.3 l 2.3 l
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The following data can be found in the ⇒ Electronic Parts Cata‐
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3.7 Identification codes, assembly allocation and capacities, Eos 2006 ►
cted agen
Prote AG.
Manual gearbox 6-speed, 0AJ
Identification code HPB JJY JPG
Manufactured from 05.06 11.06 07.07
to 10.06 11.07 05.08
Allocation Engine 1.6 l - 85 kW 1.6 l - 85 kW 1.4 l - 90 kW
Ratio Final drive 76 : 15 = 5.067 76 : 15 = 5.067 74 : 17 = 4.352
Z2 : Z1
Capacity of manual gearbox 2.3 l 2.3 l 2.3 l
Drive shaft flange diameter 100 mm 100 mm 100 mm
The following data can be found in the ⇒ Electronic Parts Cata‐
logue “ETKA” .
♦ Individual gear ratios
♦ Gear oil
♦ Clutch allocation
8 Rep. gr.00 - Technical data
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
Manual gearbox 6-speed, 0AJ
Identification code KRG LHY LNY
Manufactured from 05.08 11.08 05.09
to 11.08 04.11 04.11
Allocation Engine 1.4 l - 90 kW 1.4 l - 90 kW 1.4 l - 90 kW
Ratio Final drive 73 : 18 = 4.056 73 : 18 = 4.056 73 : 18 = 4.056
Z2 : Z1
Capacity of manual gearbox 2.3 l 2.3 l 2.3 l
Drive shaft flange diameter 100 mm 100 mm 100 mm
The following data can be found in the ⇒ Electronic Parts Cata‐
logue “ETKA” .
♦ Individual gear ratios
♦ Gear oil
♦ Clutch allocation
Manual gearbox 6-speed, 0AJ
cardiagn.com
Identification code MHS MHU NBW
Manufac‐ from 08.09 08.09 06.11
tured to 05.10 05.10 11.13
Allocation Engine 1.4 l - 90 kW 1.4 l - 90 kW 1.4 l - 90 kW
Ratio Final drive 73 : 18 = 4.056 73 : 18 = 4.056
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logue “ETKA” . ility
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♦ Individual gear ratios
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Manual gearbox 6-speed, 0AJ
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Identification code NBX PRG PRJ
Manufac‐ from 06.11 11.13 11.13
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The following data can be found in the ⇒ Electronic Parts Cata‐
cted agen
Prote AG.
logue “ETKA” .
♦ Individual gear ratios
♦ Gear oil
3. Identification codes, assembly allocation, ratios and capacities 9
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Manual gearbox 6-speed, 0AJ
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Identification code PRL
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Manufac‐ from 11.13
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Allocation Engine 1.4 l - 92 kW
Ratio Final drive 73 : 18 = 4.056
Z2 : Z1
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Capacity of manual gear‐ 2.3 l
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Drive shaft flange diame‐ 100 mm
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The following data can be found in the ⇒ Electronic Parts Cata‐
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3.8 Identification codes, assembly allocation, ratios and capacities, Scirocco
2009 ►
Manual gearbox 6-speed, 0AJ
Identification code LHY LNY MHS
Manufactured from 11.08 05.09 08.09
to 06.11 06.11 05.10
Allocation Engine 1.4 l - 90 kW 1.4 l - 90 kW 1.4 l - 90 kW
Ratio Final drive 73 : 18 = 4.056 73 : 18 = 4.056 73 : 18 = 4.056
Z2 : Z1
Capacity of manual gearbox 2.3 l 2.3 l 2.3 l
Drive shaft flange diameter 100 mm 100 mm 100 mm
The following data can be found in the ⇒ Electronic Parts Cata‐
logue “ETKA” .
♦ Individual gear ratios
♦ Gear oil
♦ Clutch allocation
Manual gearbox 6-speed, 0AJ
Identification code MHU NBW NBX
Manufac‐ from 08.09 06.11 06.11
tured to 05.10 11.13 11.13
Allocation Engine 1.4 l - 90 kW 1.2 l - 77 kW 1.2 l - 77 kW
1.4 l - 90 kW 1.4 l - 90 kW
Ratio Final drive 73 : 18 = 4.056 73 : 18 = 4.056 73 : 18 = 4.056
Z2 : Z1
Capacity of manual gear‐ 2.3 l 2.3 l 2.3 l
box
10 Rep. gr.00 - Technical data
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
Manual gearbox 6-speed, 0AJ
Identification code MHU NBW NBX
Drive shaft flange diame‐ 100 mm 100 mm 100 mm
ter
The following data can be found in the ⇒ Electronic Parts Cata‐
logue “ETKA” .
♦ Individual gear ratios
♦ Gear oil
♦ Clutch allocation
Manual gearbox 6-speed, 0AJ
Identification code MYF PRG PRL
Manufac‐ from 05.14 11.13 11.13
tured to 05.14 05.15 05.15
Allocation Engine 1.4 l - 92 kW 1.4 l - 90 kW 1.4 l - 90 kW
Ratio Final drive 73 : 18 = 4.056 73 : 18 = 4.056 73 : 18 = 4.056
cardiagn.com
Z2 : Z1
Capacity of manual gear‐ 2.3 l 2.3 l 2.3 l
box
Drive shaft flange diame‐ 100 mm 100 mm 100 mm
ter
The following data can be found in the ⇒ Electronic Parts Cata‐
logue “ETKA” .
♦ Individual gear ratios
♦ Gear oil
AG. Volkswagen AG d
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Allocation Engine 1.4 l - 90 kW
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Capacity of manual gear‐ 2.3 l
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ter
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The following data can be found in the ⇒ Electronic Parts Cata‐
logue “ETKA” .
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3. Identification codes, assembly allocation, ratios and capacities 11
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
3.9 Identification codes, assembly allocation, ratios and capacities, Touran
2003 ► AG. Volkswagen
agen AG do
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Manual gearbox y Vol 6-speed, 0AJ ot g
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db ran
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Identification code FVG tho
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Allocation Engine 1.6 l - 85 kW 1.6 l - 85 kW 1.6 l - 85 kW
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Drive shaft flange diame‐ 100 mm 100 mm 100 mm
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The following data can be found in the ⇒ Electronic Parts Cata‐
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logue “ETKA” .
♦ Individual gear ratios
ss o
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Identification code GQG GVW HBJ
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Allocation Engine 1.6 l - 85 kW 1.6 l - 85 kW 1.6 l - 85 kW
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Ratio Final drive 76 : 15 = 5.067 76 : 15 = 5.067 76 : 15 = 5.067
Z2 : Z1
Capacity of manual gear‐ 2.3 l 2.3 l 2.3 l
box
Drive shaft flange diame‐ 100 mm 100 mm 100 mm
ter
The following data can be found in the ⇒ Electronic Parts Cata‐
logue “ETKA” .
♦ Individual gear ratios
♦ Gear oil
♦ Clutch allocation
Manual gearbox 6-speed, 0AJ
Identification code JJX LHX MNZ
Manufac‐ from 10.06 05.10 05.10
tured to 01.07 06.11 06.11
Allocation Engine 1.6 l - 85 kW 1.2 l - 77 kW 1.2 l - 77 kW
Ratio Final 76 : 15 = 5.067 74 : 17 = 4.353 74 : 17 = 4.353
Z2 : Z1 drive
Capacity of manual 2.3 l 2.3 l 2.3 l
gearbox
Drive shaft flange diam‐ 100 mm 100 mm 100 mm
eter
12 Rep. gr.00 - Technical data
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
The following data can be found in the ⇒ Electronic Parts Cata‐
logue “ETKA” .
♦ Individual gear ratios
♦ Gear oil
♦ Clutch allocation
Manual gearbox 6-speed, 0AJ
Identification code NBY NBZ PRH
Manufac‐ from 06.11 06.11 11.13
tured to 11.13 11.13 05.15
Allocation Engine 1.2 l - 77 kW 1.2 l - 77 kW 1.2 l - 77 kW
1.2 l - 105 kW 1.2 l - 105 kW
Ratio Final drive 74 : 17 = 4.353 74 : 17 = 4.353 74 : 17 = 4.353
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The following data can be found in the ⇒ Electronic Parts Cata‐
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Manual gearbox 6-speed, 0AJ
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Identification code PRK
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Manufac‐ from 11.13
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Allocation Engine 1.2 l - 77 kW
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♦ Individual gear ratios
♦ Gear oil
♦ Clutch allocation
3.10 Calculation of gear ratios
Example:
6th gear Final drive
Drive gear ZG1 = 46 ZA1 = 24
Driven gear ZG2 = 33 ZA2 = 70
3. Identification codes, assembly allocation, ratios and capacities 13
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
i = ZG2 : ZG1 1)
iG = Gear ratio = ZG2 : ZG1= 33 : 46 = 0.717
iA = Final drive ratio = ZA2 : ZA1 = 70 : 24 = 2.917 n AG. Volkswagen AG do
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1) Z1 = No. of teeth on driving gear, Z2 = No. of teeth
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14 Rep. gr.00 - Technical data
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
4 Overview - power transmission
Designation:
-Arrows- indicate direction of travel.
1 - Engine
2 - Clutch
3 - Manual gearbox
4 - Input shaft
5 - Output shaft
6 - Differential
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4. Overview - power transmission 15
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
I - 1st gear
II - 2nd gear
III - 3rd gear
IV - 4th gear
V - 5th gear
VI - 6th gear
R - Reverse gear
A - Final drive
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16 Rep. gr.00 - Technical data
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
5 General repair instructions
To ensure flawless and successful gearbox repairs, the greatest
care and cleanliness as well as the use of good and proper tools
are essential. Of course, the basic rules for safety also apply dur‐
ing repair work.
A number of general notes on the individual repair procedures,
which can otherwise be found in the relevant sections of the man‐
ual, are summarised here. They apply for this particular workshop
manual.
Gearbox
AG. Volkswagen
♦ When installing the manual gearbox, ensure
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wax and grease.
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♦ Capacity, ⇒ page 3
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Gaskets and seals
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♦ Before installing radial oil seals, half-fill space between sealing
es, in part or in w
lips with sealing grease -arrow-.
t to the co
♦ Allocate grease using ⇒ Electronic parts catalogue (ETKA) .
♦ The open side of the oil seals faces toward the side with fluid
rrectness of i
filling.
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♦ Following installation, check gear oil level ⇒ page 306 .
♦ Lightly oil O-rings before installing; this prevents the rings be‐
nform
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ing crushed when inserted.
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♦ Thoroughly clean parting surfaces and apply sealant - AMV
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♦ Evenly apply a thin coat of sealing paste - AMV 188 200 03- . cted agen
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♦ Breather holes must remain free of sealing paste.
Locking devices
5. General repair instructions 17
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
♦ Renew retaining rings.
♦ Do not overstretch retaining rings.
♦ Retaining rings must locate properly in grooves.
♦ Renew spring pins. Installation position: slot longitudinal to line
of force.
Nuts and bolts
♦ Loosen and tighten securing bolts and nuts for covers and
housings diagonally.
♦ Do not cant especially delicate parts, such as clutch pressure
plates. Loosen and tighten bolts and nuts in stages in a diag‐
onal sequence.
♦ Specified torques given are forVunoiled
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♦ Check pitch of thread, to ensure correct thread chaser is used
hole
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to clean threads and to ensure the threads are not damaged.
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Bearings
♦ Install new tapered roller bearings as supplied and do not lu‐
bricate additionally.
rrectness of i
♦ Install needle bearings with lettered side (thicker metal) to‐
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♦ Tapered roller bearings fitted to one shaft must be renewed as
nform
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a set. Use same make of bearings.
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on
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heater - VAS 6414- before installing.
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ious thicknesses make it possible to achieve the exact shim
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♦ Check for burrs and damage.
♦ Install only flawless shims.
Synchro-rings
18 Rep. gr.00 - Technical data
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
♦ Do not interchange them. When reusing synchro-rings, always
fit to the same synchromeshed gear.
♦ Check for wear and renew if necessary.
♦ Check grooves -arrow 1- of synchro-ring -A- and inner ring for
flat spots (worn grooves). gen AG
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uth is installed, check the outer friction
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surface -arrow 2- andssinner
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friction surface -arrow 3- of this c
intermediate ring for »scoring«, »signs of abnormal wear« and
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»blue discolouration (due to overheating)«.
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♦ Check cone of synchromeshed gear for »scoring« and »signs
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♦ Before installing, clean and heat with the inductive heater -
VAS 6414- to maximum 100° C.
rrectness of i
Synchromeshed gears
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♦ After assembly, check synchromeshed gears for slight play, or
for freedom of movement.
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♦ Ensure that the pressure plate does not cant: loosen and tight‐
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the smell of burnt linings.
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5. General repair instructions 19
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
30 – Clutch
1 Clutch operation
⇒ “1.1 Overview - clutch actuation”, page 20
Removing and installing clutch pedal, Touran up to 05.03
⇒ “1.2 Assembly overview, pedal cluster with clutch pedal switch
F36 , only Touran up to 05.03”, page 22
Removing and installing clutch pedal, Touran from 06.03, Passat,
Eos, Scirocco, Golf, and Golf Plus
⇒ “1.6 Removing and installing clutch pedal”, page 51
⇒ “1.7 Removing and installing mounting bracket”, page 78
⇒ “1.8 Removing and installing master cylinder”, page 114
⇒ “1.12 Removing and installing slave cylinder”, page 125
⇒ “1.13 Bleeding clutch system”, page 127
⇒ “2 Clutch release mechanism”, page 129
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1.1 Overview - clutch actuation
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♦ If the vehicle has a radio with anti-theft coding, obtain code before disconnecting battery.
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♦ Disconnect battery earth strap ⇒ Electrical system; Rep. gr. 27 ; Disconnecting and reconnecting battery .
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♦ When reconnecting battery, refer to ⇒ Electrical system; Rep. gr. 27 ; Disconnecting and connecting battery .
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♦ Grease all bearing points and contact surfaces.
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♦ Allocate grease using ⇒ Electronic parts catalogue (ETKA) .
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rrectness of i
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20 Rep. gr.30 - Clutch
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speedAmanual gearbox 0AJ - Edition 01.2017
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⇒ “1.2 Assembly overview, oris tee
pedal cluster with clutch pedal th or
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switch F36 , only Touran up to ss
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occo, Golf, and Golf Plus”,
t to the co
page 24
II -
rrectness of i
⇒ “1.10 Assembly overview -
hydraulics (LHD)”, page 121
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⇒ “1.11 Assembly overview -
nform
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hydraulics (RHD)”, page 124
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1. Clutch operation 21
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
1.2 Assembly overview, pedal cluster with clutch pedal switch - F36- , only
Touran up to 05.03
1 - Plenum chamber bulkhead
❑ With support for mount‐
ing bracket
2 - Seal
❑ Always renew
❑ Between mounting
bracket and bulkhead
❑ Self-adhesive agen
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❑ From 06.03 discontin‐
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parts catalogue “ETKA”
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⇒ page 24
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❑ Removing and installing
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⇒ page 23
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❑ Remove after removing over-centre spring
10 - Support
❑ To remove and install, separate master cylinder from clutch pedal ⇒ page 114
11 - Seal
❑ Always renew
❑ Between master cylinder and mounting bracket
12 - Master cylinder
❑ Removing and installing ⇒ page 116
13 - Clutch position sender - G476-
❑ Allocation ⇒ Electronic parts catalogue “ETKA”
❑ From 06.03, installed instead of the clutch pedal switch - F36- ⇒ page 24
❑ Can be checked using “guided fault finding” with the vehicle diagnosis, testing and information system -
VAS 5051-
❑ The clutch position sender - G476- is identified as clutch pedal switch - F36- in “guided fault finding”
22 Rep. gr.30 - Clutch
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
14 - Clip
❑ To remove pipe/hose line, pull out clip to stop
❑ Can be pressed in as far as stop before fitting line
15 - Supply hose
16 - Self-locking hexagon nut, 25 Nm
❑ Qty. 3
❑ For mounting bracket to bulkhead
❑ Always renew
17 - Hexagon nut, 25 Nm
❑ Always renew
18 - Stop
❑ For clutch pedal
1.3 Only Touran up to 05.03 - removing and
installing clutch pedal switch - F36-
cardiagn.com
To ensure sufficiently secure seating of clutch pedal switch in
pedal cluster, the pedal switch may be installed only once.
Removing
– Remove storage compartment n AG. Volkswon
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repairs, interior;Vo Rep. gr. 68 ; Compartments,
lks not covers and
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trims; Removing
d b and installing storage compartment
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– Carefully
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– Turn clutch pedal switch -A- on housing 45° anti-clockwise and
pull out of support.
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1. Clutch operation 23
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
Distinguishing between clutch pedal switches
AG. Volkswagen AG d
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Clutchy Vpedal
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-A- = »without light dome«
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– Now insert clutch pedal switch in access hole.
hole
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– To lock clutch pedal switch on housing, turn 45° clockwise.
es, in part or in w
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– Push connector onto clutch pedal switch .
– Renew cut cable ties.
rrectness of i
– Install storage compartment on driver side ⇒ General body
l purpos
repairs, interior; Rep. gr. 68 ; Compartments, covers and
trims; Removing and installing storage compartment on driver
side .
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1.4 Assembly overview, pedal cluster with clutch position sender - G476- -
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Touran from 06.03, Passat, Eos, Scirocco, Golf, and Golf Plus
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❑ Always renew
❑ Between mounting
bracket and bulkhead
❑ Self-adhesive
❑ Bond to mounting
bracket
3 - Mounting bracket
❑ For mounting clutch
pedal
❑ Is provided with damp‐
ing in some equipment
variants ⇒ page 26
❑ Removing and instal‐
ling, Touran
⇒ page 106
❑ Removing and instal‐
ling, Golf 2004 ►
⇒ page 78
❑ Removing and instal‐
ling, Golf 2009 ► left-
hand drive and Scirocco
⇒ page 83
❑ Removing and instal‐
ling, Golf 2009 ► right-
hand drive and Golf Plus
right-hand drive
⇒ page 88
❑ Removing and instal‐
ling, Golf Plus left-hand
drive ⇒ page 93
24 Rep. gr.30 - Clutch
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
❑ Removing and installing, Passat ⇒ page 99 .
❑ Removing and installing, Eos ⇒ page 103
4 - Bolt
5 - Over-centre spring
❑ Removing and installing, Touran from 06.03 ⇒ page 48
❑ Removing and installing, Golf 2004 ► ⇒ page 27
❑ Removing and installing, Golf 2009 ► left-hand drive and Scirocco ⇒ page 31
❑ Removing and installing, Golf 2009 ► right-hand drive ⇒ page 36
❑ Removing and installing, Golf Plus ⇒ page 40
❑ Removing and installing, Passat ⇒ page 45 .
❑ Removing and installing, Eos ⇒ page 45
6 - Bearing bush
7 - Locating pin
8 - Clutch pedal
❑ Removing and installing, Touran ⇒ page 74
❑ Removing and installing, Golf 2004 ► ⇒ page 51
cardiagn.com
❑ Removing and installing, Golf 2009 ► left-hand drive and Scirocco ⇒ page 56
❑ Removing and installing, Golf 2009 ► right-hand drive ⇒ page 62
❑ Removing and installing, Golf Plus ⇒ page 66
❑ Removing and installing, Passat ⇒ page 72 .
❑ Removing and installing, Eos ⇒ page 72
9 - Support
❑ To remove and install, separate master cylinder from clutch pedal (⇒ Removing and installing clutch
pedal)
❑ Touran ⇒ page 74
❑ Golf 2004 ► ⇒ page 51
❑ Golf 2009 ► left-hand drive and Scirocco ⇒ page 56
❑ Golf 2009 ► right-hand drive ⇒ page agen
62
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11 - Master cylinder
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❑ Touran with clutch position sender - G476- (from 06.03), removing and installing after removal of mount‐
spec
ing bracket ⇒ page 117
es, in part or in w
t to the co
❑ Passat, Eos, Scirocco, Golf, and Golf Plus, removing and installing after removal of mounting bracket
⇒ page 114
rrectness of i
12 - Clutch position sender - G476-
❑ Allocation ⇒ Electronic parts catalogue “ETKA”
l purpos
❑ Removing and installing, Touran from 06.03, Passat, Eos, Scirocco, Golf and Golf Plus ⇒ page 119
nform
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❑ Can be checked using “guided fault finding” with the vehicle diagnosis, testing and information system -
VAS 5051-
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1. Clutch operation
AG.
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
14 - Supply hose
❑ Rubber
❑ From 12. 05, plastic ⇒ page 123
❑ Golf 2009 ►, Golf Plus 2009 ► and Scirocco made from plastic ⇒ page 123
15 - Self-locking hexagon nut, 25 Nm
❑ Qty. 3
❑ For mounting bracket to bulkhead
❑ Always renew
16 - Hexagon nut, 25 Nm
❑ Always renew
17 - Stop AG. Volkswagen AG d
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26 Rep. gr.30 - Clutch
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
1.5 Removing and installing over-centre
spring
⇒ “1.5.1 Removing and installing over-centre spring - Golf 2004
►”, page 27
⇒ “1.5.2 Removing and installing over-centre spring - Golf 2009
► left-hand drive and Scirocco”, page 31
⇒ “1.5.3 Removing and installing over-centre spring - Golf 2009
► right-hand drive”, page 36
⇒ “1.5.4 Removing and installing over-centre spring, Golf Plus”,
page 40
⇒ “1.5.5 Removing and installing over-centre spring, Passat,
Eos”, page 45
⇒ “1.5.6 Removing and installing over-centre spring with mount‐
ing bracket removed (Touran up to 05.03)”, page 46
⇒ “1.5.7 Removing and installing over-centre spring with mount‐
ing bracket installed (Touran from 06.03)”, page 48
1.5.1 Removing and installing over-centre
cardiagn.com
spring - Golf 2004 ►
Special tools and workshop equipment required
♦ Release tool - T10178-
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mounting bracket.
28 Rep. gr.30 - Clutch
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
– To do this, remove lock washers -A- for damping.
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inder.
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spring -4- from mounting bracket.
Installing
Install in the reverse order of removal, observing the following:
Note
Renew self-locking nuts.
1. Clutch operation 29
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bracket.
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The crash bar -1- in front of clutch pedal -2- may be secured in
different ways.
Attachment with 2 bolts
30 Rep. gr.30 - Clutch
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bracket (attachment with 1 bolt)
♦ Renew bolts for crash bar
1.5.2 Removing and installing over-centre
spring - Golf 2009 ► left-hand drive and
Scirocco
Special tools and workshop equipment required
♦ Release tool - T10178-
1. Clutch operation 31
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
♦ Torque wrench - V.A.G 1331-
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body repairs, interior; Rep. gr. 68 .
Vehicles with knee airbag
– Remove knee airbag bracket together with crash bar. ⇒ Inte‐
rior equipment; Rep. gr. 69 ; Airbag; Removing and installing
knee airbag bracket (Golf 2009 ►)
Continuation for all
– Remove cable guide -2- from steering column.
– Remove footwell vent -3-. ⇒ Heating, air conditioning; Rep.
gr. 80 ; Repairing heating
Vehicles without knee airbag
32 Rep. gr.30 - Clutch
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1. Clutch operation 33
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus
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Installing
Install in the reverse order of removal, observing the following:
Note
Renew self-locking nuts.
– Insert over-centre spring -2- in mounting bracket from above
while holding end of spring with assembly tool - T10178- in
installation position.
34 Rep. gr.30 - Clutch
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
– Receptacle -arrow- for tip -A- of clutch pedal must stand ver‐
tically.
– Insert tip of clutch pedal -1- in bearing recess of over-centre
spring.
– Depress clutch pedal slightly, push bolt through and tighten
self-locking nut to specified torque.
Some cars have damping -arrow- on the clutch pedal mounting
bracket.
– Return it to installation position.
Vehicles without knee airbag
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1. Clutch operation 35
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
– Mount cable guide -2- on steering column.
– Install foot well vent -3-. ⇒ Rep. gr. 80
Vehicles with knee airbag
– Install knee airbag bracket together with crash bar. ⇒ Interior
equipment; Rep. gr. 69 ; Airbag; Removing and installing knee
airbag bracket (Golf 2009 ►)
Continuation for all
– Install trim and cover below trim on drive side ⇒ General body
repairs, interior; Rep. gr. 68 .
Torque settings
Component Nm
Clutch pedal to mounting bracket 25
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spring - Golf 2009 ► right-hand drive
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36 Rep. gr.30 - Clutch
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
♦ Torque wrench - V.A.G 1331- wage
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– Remove cable guide -2- from steering column.
– Remove crash bar -1- (bolt -2-).
1. Clutch operation 37
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
If fitted, remove damping -arrow- from lower area of clutch pedal
mounting bracket.
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38 Rep. gr.30 - Clutch
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rrectness of i
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tically.
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spring.
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self-locking nut to specified torque.
1. Clutch operation 39
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– Mount cable guide -2- on steering column.
– Install foot well vent -3-. ⇒ Rep. gr. 80
– Install knee airbag bracket. ⇒ Interior equipment; Rep. gr. 69 ;
Airbag; Removing and installing knee airbag bracket (Golf
2009 ►)
– Install trim and cover below trim on drive side ⇒ General body
repairs, interior; Rep. gr. 68 .
Torque settings
Component Nm
Clutch pedal to mounting bracket 25
♦ Renew self-locking nuts
Crash bar to steering column mounting 20
bracket
♦ Renew bolt for crash bar
1.5.4 Removing and installing over-centre
spring, Golf Plus
Special tools and workshop equipment required
40 Rep. gr.30 - Clutch
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
♦ Torque wrench - V.A.G 1331-
Removing
– Push driver seat as far back as possible and put steering wheel
in highest position.
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1. Clutch operation 41
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
– Remove footwell trim by unscrewing nuts -arrows-. wage
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42 Rep. gr.30 - Clutch
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
– Push damping upwards in area of upper securing nut -1-
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1. Clutch operation 43
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
Some cars have damping -arrow- on the clutch pedal mounting
bracket. en AG. V
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– Install crash bar -A-, tighten bolt -B-.
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44 Rep. gr.30 - Clutch
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
– Fit universal joint -2- to steering rack and screw in new bolt
-1- ⇒ Running gear, axles, steering; Rep. gr. 48 ; Assembly
overview - steering .
– Carry out basic setting for steering angle sender - G85- with
vehicle diagnosis, testing and information system - VAS
5051- .
– Install trim and cover below trim on drive side ⇒ General body
repairs, interior; Rep. gr. 68 .
Torque settings
Component Nm
Clutch pedal to mounting bracket 25
♦ Renew self-locking nuts
Crash bar to steering column mounting Bolt M6 = 5
bracket
Crash bar to steering column mounting Bolt M8 = 20
bracket
♦ Renew bolts for crash bar
cardiagn.com
1.5.5 Removing and installing over-centre
spring, Passat, Eos
Special tools and workshop equipment required
♦ Release tool - T10178-
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– Remove mounting bracket, Passat ⇒ page 99 .
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– Remove mounting bracket, Eos ⇒ page 103 .
l purpos
– Carefully clamp lower section of clutch pedal in vice having
protective jaw pads.
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– Separate clutch pedal from master cylinder ⇒ page 114 .
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1. Clutch operation 45
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
– Press over-centre spring from clutch pedal -arrow 1- while
swinging mounting bracket in -direction of arrow 2-.
– Carefully release tension from over-centre spring.
– Swing mounting bracket back to starting position and remove
over-centre spring.
Installing
• Clutch pedal is separated from master cylinder.
– Carefully clamp lower section of clutch pedal in vice having
protective jaw pads.
olkswagen AG
en AG. V
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– Compress over-centre spring -arrow 1-.
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-arrow 2- until over-centre spring can be pressed onto locating
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lug -A- of clutch pedal. orm
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– Connect clutch pedal to master cylinder ⇒ page 114 .
– Install mounting bracket, Passat ⇒ page 99 .
– Install mounting bracket, Eos ⇒ page 103 .
1.5.6 Removing and installing over-centre
spring with mounting bracket removed
(Touran up to 05.03)
Special tools and workshop equipment required
46 Rep. gr.30 - Clutch
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
♦ Release tool - T10178-
AG. Volkswagen AG d
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Removing auth eo
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itte
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protective jaw pads.
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swinging mounting bracket in -direction of arrow 2-.
urposes, in part or in wh
t to the co
– Carefully release tension from over-centre spring.
– Swing mounting bracket back to starting position and remove
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over-centre spring.
Installing
ss o
• Clutch pedal is separated from master cylinder.
cial p
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mer
protective jaw pads.
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1. Clutch operation 47
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
– Compress over-centre spring -arrow 1-.
– At the same time, move mounting bracket downwards
-arrow 2- until over-centre spring can be pressed onto locating
lug -A- of clutch pedal.
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Cover over-centre spring with a cloth.
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Check operation of over-centre spring.
ility
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wit
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– Connect master cylinder to clutch pedal ⇒ page 114 .
t to the co
– Install mounting bracket ⇒ page 106 .
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1.5.7 Removing and installing over-centre
cardiagn.com
spring with mounting bracket installed
ss o
(Touran from 06.03)
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Release tool - T10178-
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Torque wrench - V.A.G 1331-
Removing
– Remove storage compartment on driver side ⇒ General body
repairs, interior; Rep. gr. 68 ; Compartments, covers and
trims; Removing and installing storage compartment on driver
side .
48 Rep. gr.30 - Clutch
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
– Remove crash bar -A- by removing bolt -B- and loosening bolt
-C-.
LHD vehicles
– Unbolt fuse holder and relay carrier and secure to dash panel
⇒ Electrical system; Rep. gr. 97 ; Removing and installing
fuse holders and relay carriers; Removing and installing relay
plate and relay carrier .
– Remove bracket for relay carrier, onboard supply control unit
- J519- and fuse holder. ⇒ Electrical system; Rep. gr. 97 ;
Removing and installing control units; Removing and installing
onboard supply control unit
– To remove over-centre spring from mounting bracket -A-,
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carefully cut through cable tie -arrow-.
Continuation for all AG. Volkswagen AG d
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– Remove steering d b column universal joint from steering
y ara box ⇒
ise nte
Running gear,thor axles, steering; Rep. gr. 48 ; Assembly over‐
eo
view - steering
s au column; Removing and installing steering col‐ ra
c
umn . s
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nl
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es, in part or in w
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– Unbolt clutch pedal -1- from mounting bracket -3- by removing
nf
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nut -2- and pulling out bolt -5-.
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Installing Prote AG.
Note
Renew self-locking nuts.
1. Clutch operation 49
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , wGolf
agenPlus 2005 ➤ A
AG. Volkswagen , G
Golf
doesPlus ...
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6-speed manual gearbox 0AJ - Edition
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– Insert over-centre spring in mountingaubracket
th from above while e or
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holding end of spring with release tool
ss - T10178- in installation
position.
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– Insert tip of clutch pedal in bearing recess of over-centre
y li
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spring.
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self-locking nut. hole
spec
– Attach steering column universal joint to steering box ⇒ Run‐
es, in part or in w
t to the co
ning gear, axles, steering; Rep. gr. 48 ; Assembly overview -
steering column; Removing and installing steering column .
rrectness of i
l purpos
nf
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thi
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– Install crash bar -A-, (bolt -B- and bolt -C-).
iv
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rp
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– Install storage compartment and cover on driver side, ⇒ Gen‐
f
en
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t.
eral body repairs, interior; Rep. gr. 68 ; Compartments, covers
yi Co
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and trims; Removing and installing storage compartment on t. C rig
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driver side . yri
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– Carry out basic setting for steering angle sender - G85- with
agen
Prote AG.
vehicle diagnosis, testing and information system - VAS
5051- .
Torque settings
Component Nm
Clutch pedal to mounting bracket 25
♦ Renew self-locking nuts
Crash strut Bolt M8 = 20
Bolt M6 = 5
♦ Renew bolt for crash bar to steering col‐
umn mounting bracket
50 Rep. gr.30 - Clutch
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
1.6 Removing and installing clutch pedal
⇒ “1.6.1 Removing and installing clutch pedal - Golf 2004 ►”, page
51
⇒ “1.6.2 Removing and installing clutch pedal, Golf 2009 ► left-
hand drive and Scirocco”, page 56
⇒ “1.6.3 Removing and installing clutch pedal - Golf 2009 ► right-
hand drive”, page 62
⇒ “1.6.4 Removing and installing clutch pedal, Golf Plus”,
page 66
⇒ “1.6.5 Removing and installing clutch pedal, Passat, Eos”, page
72
Removing and installing clutch pedal, Touran up to 05.03
⇒ “1.2 Assembly overview, pedal cluster with clutch pedal switch
F36 , only Touran up to 05.03”, page 22
⇒ “1.6.6 Removing and installing clutch pedal, Touran from
06.03”, page 74
1.6.1 Removing and installing clutch pedal -
cardiagn.com
Golf 2004 ►
Special tools and workshop equipment required
AG. Volkswagen AG d
♦ Pliers - T10005- lksw
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♦ Release tool - T10178-
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Cop py
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Prote AG.
1. Clutch operation 51
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
♦ Torque wrench - V.A.G 1331-
AG. Volkswagen AG d
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Removing
wit
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– Push driver seat as far back as possible and put steering wheel
hole
spec
in highest position.
es, in part or in w
t to the co
– Remove trim and cover below trim on drive side ⇒ General
body repairs, interior; Rep. gr. 68 .
rrectness of i
– Remove cable guide -2- from steering column.
cardiagn.com
l purpos
– Remove footwell vent -3-. ⇒ Heating, air conditioning; Rep.
gr. 80 ; Repairing heating
nform
ercia
The crash bar -1- in front of clutch pedal -2- may be secured in
different ways.
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Attachment with 2 bolts
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Prote AG.
– Remove crash bar -1- (1 bolt -2-).
52 Rep. gr.30 - Clutch
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
If fitted, remove damping -arrow- from lower area of clutch pedal
mounting bracket.
– To do this, remove lock washers -A- for damping.
cardiagn.com
– Pull off damping.
– Push damping upwards in area of upper securing nut -1-
above clutch pedal -A- in -direction of arrow-. wage
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53
cted agen
Prote AG.
1. Clutch operation
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
– Unbolt clutch pedal -1- from mounting bracket -3- by removing
nut -2- and pulling out bolt -5-.
– Swing clutch pedal forward slightly and remove over-centre
spring -4- from mounting bracket.
– Release clutch pedal from master cylinder with pliers -
cardiagn.com
T10005- . en AG. V
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Renew self-locking nuts.
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– Attach retainer -2- to master cylinder operating rod -1-.
– Press retainer into notch in clutch pedal -3- until it can be heard
to engage.
rrectness o
cial p
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mer
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Cop py
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54 Rep. gr.30 - Clutch
AG. Volkswagen AG d
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oes ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
ol not
V g6-speed
d by ua
ran manual gearbox 0AJ - Edition 01.2017
rise tee
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– Insert over-centre
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– Receptacle -arrow- for tip -A- of clutch pedal -1- must be ver‐
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self-locking nut to specified torque.
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Some cars have damping -arrow- on the mounting bracket/clutch
pedal.
– Return it to installation position.
The crash bar -1- in front of clutch pedal -2- may be secured in
different ways.
Attachment with 2 bolts
1. Clutch operation 55
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Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 by V➤ , Golf Plus ...
o ot g
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6-speed manual gearbox 0AJ - Edition 01.2017 hor is tee
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bracket (attachment with 2 bolts)
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Crash bar to steering column mounting 20
bracket (attachment with 1 bolt)
♦ Renew bolts for crash bar
1.6.2 Removing and installing clutch pedal,
Golf 2009 ► left-hand drive and Scirocco
Special tools and workshop equipment required
♦ Pliers - T10005-
56 Rep. gr.30 - Clutch
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
♦ Release tool - T10178-
AG. Volkswagen AG d
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ot
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Removing
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– First check whether a coded radio is fitted. If so, obtain anti-
theft code.
– Disconnect battery earth strap ⇒ Electrical system; Rep. gr.
27 ; Disconnecting and reconnecting battery .
Continuation for all
– Push driver seat as far back as possible and put steering wheel
in highest position.
– Remove trim and cover below trim on drive side ⇒ General
body repairs, interior; Rep. gr. 68 .
Vehicles with knee airbag
– Remove knee airbag bracket together with crash bar. ⇒ Inte‐
rior equipment; Rep. gr. 69 ; Airbag; Removing and installing
knee airbag bracket (Golf 2009 ►)
1. Clutch operation 57
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
Continuation for all
– Remove cable guide -2- from steering column.
– Remove footwell vent -3-. ⇒ Heating, air conditioning; Rep.
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– Remove crash bar -1- (bolt -2-).
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Continuation for all
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– To do this, remove lock washers -A- for damping.
– Pull off damping.
58 Rep. gr.30 - Clutch
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
– Push damping upwards in area of upper securing nut -1-
above clutch pedal -A- in -direction of arrow-.
– Unbolt clutch pedal -1- from mounting bracket -3- by removing
cardiagn.com
nut -2- and pulling out bolt -5-.
– Swing clutch pedal forward slightly and remove over-centre
spring -4- from mounting bracket.
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– Release clutch pedal from master cylinder with pliers -
l purpos
T10005- .
– Remove clutch pedal.
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1. Clutch operation 59
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
– Attach retainer -2- to master cylinder operating rod -1-.
– Press retainer into notch in clutch pedal -3- until it can be heard
to engage.
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– Insert over-centre spring -2- in mounting bracket from above
ility
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while holding end of spring with assembly tool - T10178- in
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– Receptacle -arrow- for tip -A- of clutch pedal -1- must be ver‐ copy Vo
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tical. cted agen
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– Insert tip -A- of clutch pedal in bearing recess of over-centre
spring.
– Depress clutch pedal slightly, push bolt through and tighten
self-locking nut to specified torque.
60 Rep. gr.30 - Clutch
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
Some cars have damping -arrow- on the mounting bracket/clutch
pedal.
– Return it to installation position.
Vehicles without knee airbag
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– Install crash bar -1- and tighten bolt -2- to specified torque.
t to the co
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Continuation for all
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– Mount cable guide -2- on steering column.
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Cop py
– Install foot well vent -3-. ⇒ Rep. gr. 80
t. rig
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pyri by
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o
Vehicles with knee airbag by c lksw
cted agen
Prote AG.
– Install knee airbag bracket together with crash bar. ⇒ Interior
equipment; Rep. gr. 69 ; Airbag; Removing and installing knee
airbag bracket (Golf 2009 ►)
Continuation for all
– Install trim and cover below trim on drive side ⇒ General body
repairs, interior; Rep. gr. 68 .
– If disconnected, reconnect battery and perform work required
after connecting battery ⇒ Electrical system; Rep. gr. 27 ;
Disconnecting and connecting battery .
Torque settings
Component Nm
Clutch pedal to mounting bracket 25
♦ Renew self-locking nuts
Crash bar to steering column mounting 20
bracket
♦ Renew bolt for crash bar
1. Clutch operation 61
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
1.6.3 Removing and installing clutch pedal -
Golf 2009 ► right-hand drive
Special tools and workshop equipment required
♦ Pliers - T10005-
♦ Release tool - T10178-
cardiagn.com
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♦ Torque wrench - V.A.G 1331-
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Removing
at
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ion
c
– First check whether a coded radio is fitted. If so, obtain anti-
in t
or
theft code.
his
ate
do
priv
– Disconnect battery earth strap ⇒ Electrical system; Rep. gr.
um
for
27 ; Disconnecting and reconnecting battery .
en
ng
t.
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op
– Push driver seat as far back as possible and put steering wheel
C py
t. rig
gh
in highest position.
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pyri by
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cted
– Remove trim and cover below trim on drive side ⇒ General
agen
Prote AG.
body repairs, interior; Rep. gr. 68 .
62 Rep. gr.30 - Clutch
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
– Remove knee airbag bracket. ⇒ Interior equipment; Rep. gr.
69 ; Airbag; Removing and installing knee airbag bracket (Golf
2009 ►)
– Remove cable guide -2- from steering column.
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– Remove footwell vent -3-. ⇒ Heating, air conditioning; Rep.
ce
le
un
pt
gr. 80 ; Repairing heating
an
d
itte
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– Remove crash bar -1- (bolt -2-).
pe
ility
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wit
, is n
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hole
spec
es, in part or in w
t to the co
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rrectness of i
l purpos
If fitted, remove damping -arrow- from lower area of clutch pedal
nform
ercia
mounting bracket.
m
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tion in
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Cop py
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by
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Prote AG.
– To do this, remove lock washers -A- for damping.
– Pull off damping.
1. Clutch operation 63
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
– Push damping upwards in area of upper securing nut -1-
above clutch pedal -A- in -direction of arrow-.
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t to the co
– Unbolt clutch pedal -1- from mounting bracket -3- by removing
cardiagn.com
rrectness of i
nut -2- and pulling out bolt -5-.
– Swing clutch pedal forward slightly and remove over-centre
l purpos
spring -4- from mounting bracket.
nform
mercia
a
com
tion in
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te o
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s
iva
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cum
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Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Release clutch pedal from master cylinder with pliers -
T10005- .
– Remove clutch pedal.
Installing
Install in the reverse order of removal, observing the following:
Note
Renew self-locking nuts.
64 Rep. gr.30 - Clutch
AG. Volkswagen AG d
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d by ara
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e nte➤ , Golf Plus 2005 ➤ , Golf Plus ...
ho eo
aut 6-speed manual r a gearbox 0AJ -
c
Edition 01.2017
ss
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– Attach retainer -2- to master cylinder operating rod -1-.
un
pt
an
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itte
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– Press retainer into notch in clutch pedal until it can be heard
rm
ab
to engage. pe
ility
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es, in part or in w
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– Insert over-centre spring -2- in mounting bracket from above
nform
ercia
while holding end of spring with assembly tool - T10178- in
m
installation position.
a
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tion in
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te o
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cardiagn.com
Cop py
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pyri by
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by c lksw
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– Receptacle -arrow- for tip -A- of clutch pedal must stand ver‐
tically.
– Insert tip of clutch pedal -1- in bearing recess of over-centre
spring.
– Depress clutch pedal slightly, push bolt through and tighten
self-locking nut to specified torque.
1. Clutch operation 65
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
Some cars have damping -arrow- on the mounting bracket/clutch
pedal.
– Return it to installation position.
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pt
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an
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– Install crash bar -1- and tighten bolt -2- to specified torque.
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es, in part or in w
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– Mount cable guide -2- on steering column.
m
at
om
io
– Install foot well vent -3-. ⇒ Rep. gr. 80
n
c
in t
or
his
e
– Install knee airbag bracket. ⇒ Interior equipment; Rep. gr. 69 ;
at
do
riv
Airbag; Removing and installing knee airbag bracket (Golf
p
cum
or
2009 ►)
f
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– Install trim and cover below trim on drive side ⇒ General body Cop py
ht. rig
repairs, interior; Rep. gr. 68 . rig ht
py by
co Vo
by lksw
– If disconnected, reconnect battery and perform work required Prote
cted AG.
agen
after connecting battery ⇒ Electrical system; Rep. gr. 27 ;
Disconnecting and connecting battery .
Torque settings
Component Nm
Clutch pedal to mounting bracket 25
♦ Renew self-locking nuts
Crash bar to steering column mounting 20
bracket
♦ Renew bolt for crash bar
1.6.4 Removing and installing clutch pedal,
Golf Plus
Special tools and workshop equipment required
66 Rep. gr.30 - Clutch
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
♦ Pliers - T10005-
♦ Torque wrench - V.A.G 1331-
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Removing
erm
ab
ility
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– Push driver seat as far back as possible and put steering wheel
wit
is n
in highest position.
h re
ole,
spec
– Remove trim and cover below trim on drive side ⇒ General
urposes, in part or in wh
body repairs, interior; Rep. gr. 68 .
t to the co
– Remove cable guide -2- from steering column.
– Remove footwell vent -3-. ⇒ Heating, air conditioning; Rep.
rrectne
gr. 80 ; Repairing heating
ss o
cial p
f inform
mer
atio
om
n
c
i
or
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Cop py
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pyri by
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by
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Prote AG.
1. Clutch operation 67
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
– Now remove crash bar -A- in front of clutch pedal by unscrew‐
ing bolt -B-.
– Remove footwell trim by unscrewing nuts -arrows-.
cardiagn.com
– Remove bolt -1- and pull universal joint -2- off steering rack.
AG. Volkswagen AG d
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pt
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es, in part or in w
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at
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c
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Cop py
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by
68
copy Vo
by lksw
Rep. gr.30 - Clutch cted agen
Prote AG.
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
If fitted, remove damping -arrow- from lower area of clutch pedal
mounting bracket.
– To do this, remove lock washers -A- for damping.
cardiagn.com
– Pull off damping.
AG. Volkswagen AG d
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– Push damping upwards in area of upper isedsecuring
b nut -1- ara
nte
above clutch pedal -A- in -direction of horarrow-. eo
aut ra
ss c
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nl
pt
du
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at
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c
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ate
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for
en
ng
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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.
1. Clutch operation 69
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
– Unbolt clutch pedal -1- from mounting bracket -3- by removing
nut -2- and pulling out bolt -5-.
– Swing clutch pedal forward slightly and remove over-centre
spring -4- from mounting bracket.
AG. Volkswagen AG d
agen oes
olksw not
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d by ara
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or eo
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aut ra
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ce
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un
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d
itte
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wit
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spec
urposes, in part or in wh
t to the co
rrectne
– Release clutch pedal from master cylinder with pliers -
cardiagn.com
T10005- .
ss
– Remove clutch pedal.
o
cial p
f in
Installing
form
mer
atio
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n
c
Note
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Renew self-locking nuts.
i
o
pr
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Cop py
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Vo
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– Attach retainer -2- to master cylinder operating rod -1-. by c lksw
cted agen
Prote AG.
– Press retainer into notch in clutch pedal -3- until it can be heard
to engage.
– Insert over-centre spring in mounting bracket from above.
– Receptacle -arrow- for tip -A- of clutch pedal must be vertical.
– Insert tip of clutch pedal in bearing recess of over-centre
spring.
– Depress clutch pedal slightly, push bolt through and tighten
self-locking nut to specified torque.
70 Rep. gr.30 - Clutch
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
Some cars have damping -arrow- on the mounting bracket/clutch
pedal.
– Return it to installation position.
AG. Volkswagen AG d
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d b ara
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urposes, in part or in wh
t to the co
– Install crash bar -A-, tightening bolt -B- to specified torque.
rrectne
cardiagn.com
ss o
cial p
f inform
mer
atio
om
n
c
i
or
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te
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Cop py
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pyri by
Vo
co lksw
by
cted agen
Prote AG.
1. Clutch operation 71
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
– Fit universal joint -2- to steering rack and screw in new bolt
-1-. ⇒ Running gear, axles, steering; Rep. gr. 48 ; Assembly
overview - steering column
– Carry out basic setting for steering angle sender - G85- with
vehicle diagnosis, testing and information system - VAS
5051- .
– Install trim and cover below trim on drive side ⇒ General body
repairs, interior; Rep. gr. 68 .
Torque settings
Component Nm
Clutch pedal to mounting bracket 25
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Crash bar to steering column mounting
oris
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bracket auth
ra
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Crash bar to steering column mounting Bolt M8 = 20
ce
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nl
bracket
pt
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♦ Renew bolts for crash bar
erm
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1.6.5 Removing and installing clutch pedal,
hole
spec
Passat, Eos
es, in part or in w
t to the co
Special tools and workshop equipment required
♦ Pliers - T10005-
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
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ate
do
priv
cum
for
en
ng
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Cop py
t. rig
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pyri by
Vo
♦ Release tool - T10178-
co lksw
by
cted agen
Prote AG.
72 Rep. gr.30 - Clutch
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
♦ Torque wrench - V.A.G 1331-
Removing
– Remove mounting bracket, Passat ⇒ page 99 .
– Remove mounting bracket, Eos ⇒ page 103 .
– Carefully clamp mounting bracket in vice having jaw protec‐
tors. AG. Volkswagen AG d
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– Unbolt clutch pedal -1-isefrom
d b mounting bracket -3- by removing
ua
cardiagn.com
ran
nut -2- and pulling out
thor
bolt -5-. tee
o
u ra
sa c
– Swing clutch pedal
s forward slightly and remove over-centre
ce
le
spring -4- from mounting bracket.
un
pt
an
d
itte
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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
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tion in
– Release clutch pedal from master cylinder with pliers -
r
te o
thi
T10005- .
s
iva
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– Remove clutch pedal.
fo
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Installing
Co
Cop py
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gh
Install in the reverse order of removal, observing the following:
ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Note
Renew self-locking nuts.
1. Clutch operation 73
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
– Attach retainer -2- to master cylinder operating rod -1-.
– Press retainer into notch in clutch pedal -3- until it can be heard
to engage.
– Insert over-centre spring -2- in mounting bracket from above
while holding end of spring with assembly lever -T10178- in
installation position.
– Insert tip of clutch pedal -1- in bearing recess of over-centre
spring.
– Depress clutch pedal slightly, push bolt through and tighten
self-locking nut.
cardiagn.com
– Install mounting bracket, Passat ⇒ page 99 .
– Install mounting bracket, Eos ⇒ page 103 .
Torque setting
Component Nm
Clutch pedal to mounting bracket 25
♦ Renew self-locking nuts
AG. Volkswagen AG d
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1.6.6 Removing and installing clutch pedal,
d
rise nte
tho eo
Touran from 06.03 ss au ra
c
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un
Special tools and workshop equipment required
pt
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♦ Pliers - T10005-
erm
ab
ility
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wit
is n
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ole,
spec
urposes, in part or in wh
t to the co
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cial p
f inform
mer
atio
om
n
c
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or
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Cop py
t. rig
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Vo
co lksw
by
cted agen
Prote AG.
74 Rep. gr.30 - Clutch
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
♦ Release tool - T10178-
♦ Torque wrench - V.A.G 1331-
cardiagn.com
AG. Volkswagen AG d
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d by ara
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or eo
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ut
Removing ss a ra
c
ce
le
– Remove storage compartment on driver side ⇒ General body
un
pt
an
d
repairs, interior; Rep. gr. 68 ; Compartments, covers and
itte
y li
trims; Removing and installing storage compartment on driver
erm
ab
side .
ility
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– Remove crash bar -A- by removing bolt -B- and loosening bolt
h re
ole,
-C-.
spec
urposes, in part or in wh
LHD vehicles
t to the co
– Unbolt fuse holder and relay carrier and secure to dash panel
⇒ Electrical system; Rep. gr. 97 ; Removing and installing
rrectne
fuse holders and relay carriers; Removing and installing relay
plate and relay carrier .
ss
– Remove bracket for relay carrier, onboard supply control unit
o
cial p
- J519- and fuse holder. ⇒ Electrical system; Rep. gr. 97 ;
inform
Removing and installing control units; Removing and installing
mer
onboard supply control unit
atio
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Cop py
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pyri by
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by c lksw
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Prote AG.
1. Clutch operation 75
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
– Carefully cut through cable tie above mounting bracket -A-
-arrow-.
Continuation for all
– Remove steering column universal joint from steering box ⇒
Running gear, axles, steering; Rep. gr. 48 ; Assembly over‐
view - steering column; Removing and installing steering col‐
umn .
AG. Volkswagen AG d
agen oes
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Note
Renew self-locking nuts.
76 Rep. gr.30 - Clutch
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
– Attach retainer -2- to master cylinder operating rod -1-.
– Press retainer into attachment point in clutch pedal -3- until it
can be heard to engage.
– Insert over-centre spring -2- in mounting bracket from above
while holding end of spring with assembly lever -T10178- in
installation position.
– Insert tip of clutch pedal -1- in bearing recess of over-centre
spring.
– Depress clutch pedal slightly, push bolt through and tighten
self-locking nut.
cardiagn.com
– Attach steering column universal joint to steering box ⇒ Run‐
ning gear, axles, steering; Rep. gr. 48 ; Assembly overview -
steering column; Removing and installing steering column .
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Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
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Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
♦ Installation tool for spring-type clips - VAS 5024 A-
♦ Sealing tool - T10249-
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Removing
LHD vehicles
– Remove battery and, if necessary, detach back wall of battery
box ⇒ Electrical system; Rep. gr. 27 ; Removing and installing
battery .
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Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
– In addition to disconnecting, sealing tool - T10249/1- can also
be for sealing (⇒ figure above).
– Release securing clip -2- using screwdriver or a pointed object
and pull pipe/hose assembly or plastic line -1- off clutch master
cylinder.
– Unclip clutch position sender - G476- from master cylinder
-arrow- and remove with electrical connector attached -4-.
Note
When performing work in the footwell, put cloths on the carpet to
protect it from possible brake fluid spills.
– Remove trim and cover below trim on drive side ⇒ General
cardiagn.com
body repairs, interior; Rep. gr. 68 .
– Remove cable guide -2- from steering column.
– Remove footwell vent -3-. ⇒ Heating, air conditioning; Rep.
gr. 80 ; Repairing heating
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– Push damping upwards in area of upper securing nut -1-
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1. Clutch operation 81
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
– Remove securing nuts -1- and -2-.
The upper securing nut -1- is accessible between the relay carrier
and the steering column trim.
– Remove mounting bracket -3-.
Installing
Install in the reverse order of removal, observing the following:
Some cars have damping -arrow- on the clutch pedal mounting
cardiagn.com
bracket.
Note
♦ Renew self-locking nut.
♦ Renew hose clips.
♦ Allocate all components according to ⇒ Electronic parts cata‐
logue “ETKA” .
The crash bar -1- in front of clutch pedal -2- may be secured in
different ways.
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Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
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Crash bar to steering column mounting 10
bracket (attachment with 2 bolts)
Crash bar to steering column mounting 20
bracket (attachment with 1 bolt)
♦ Renew bolts for crash bar
1.7.2 Removing and installing mounting
bracket - Golf 2009 ► left-hand drive and
Scirocco
Special tools and workshop equipment required
♦ Hose clamps to 25 mm - 3094-
1. Clutch operation 83
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
♦ Torque wrench - V.A.G 1331-
♦ Sealing tool - T10249-
cardiagn.com
Removing
– First check whether a coded radio is fitted. If so, obtain anti-
theft code.
– Remove battery and, if necessary, detach back wall of battery
box ⇒ Electrical system; Rep. gr. 27 ; Removing and installing
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84 Rep. gr.30 - Clutch
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
– In addition to disconnecting, sealing tool - T10249/1- can also
be for sealing (⇒ figure above).
– Release securing clip -2- using screwdriver or a pointed object
and pull pipe/hose line or plastic line -3- off master cylinder.
– Unclip clutch position sender - G476- from master cylinder
-arrow- and remove with electrical connector attached -4-.
Note
When performing work in the footwell, put cloths on the carpet to
protect it from possible brake fluid spills.
– Remove trim and cover below trim on drive side ⇒ General
body repairs, interior; Rep. gr. 68 .
Vehicles with knee airbag
Note
The installation location of the knee airbag is above the pedal
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Vehicles without knee airbag
spec
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1. Clutch operation 85
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
If fitted, remove damping -arrow- from lower area of clutch pedal
mounting bracket.
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Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
– Remove securing nuts -1- and -2-.
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Continuation for all
1. Clutch operation 87
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
– Mount cable guide -2- on steering column.
– Install foot well vent -3-. ⇒ Heating, Air conditioning; Rep. gr.
80 ; Repairing heating; Removing and installing left footwell
vent
Vehicles with knee airbag
– Install knee airbag bracket together with crash bar. ⇒ Interior
equipment; Rep. gr. 69 ; Airbag; Removing and installing knee
airbag bracket (Golf 2009 ►)
Continuation for all
– Install trim and cover below trim on drive side ⇒ General body
repairs, interior; Rep. gr. 68 . Volkswa
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♦ hooks - 3438-
88 Rep. gr.30 - Clutch
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27 ; Disconnecting and reconnecting battery .
Continuation for all
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An insulation mat is installed in conjunction with some engines.
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Note
♦ During the following work, ensure that no brake fluid lands on
longitudinal member or gearbox. If this does happen, clean the
affected areas thoroughly.
♦ Place a lint-free cloth under the master cylinder.
– Clamp off supply hose to master cylinder using hose clamp -
3094- .
– Pull supply hose off master cylinder.
– In addition, for disconnecting, you can seal supply hose with
sealing tool - T10249/1- .
1. Clutch operation 89
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ ,AGolf
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6-speed manual gearbox 0AJ - Edition gen G
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When performing work in the footwell, put cloths on the carpet to
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mer
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– Remove cable guide -2- from steering column.
– Remove footwell vent -3-. ⇒ Heating, air conditioning; Rep.
gr. 80 ; Repairing heating
– Remove crash bar -1- (bolt -2-).
90 Rep. gr.30 - Clutch
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
If fitted, remove damping -arrow- from lower area of clutch pedal
mounting bracket.
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1. Clutch operation 91
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
– Remove securing nuts -1- and -2-.
The upper securing nut -1- is accessible between the relay carrier
and the steering column trim.
– Remove mounting bracket -3-.
Installing
Install in the reverse order of removal, observing the following:
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– Install crash bar -1- and tighten bolt -2- to specified torque.
92 Rep. gr.30 - Clutch
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
– Mount cable guide -2- on steering column.
– Install foot well vent -3-. ⇒ Heating, air conditioning; Rep. gr.
80 ; Repairing heating
Golf
– Install bracket for knee airbag ⇒ Interior equipment; Rep. gr.
69 ; Airbag; Removing and installing knee airbag bracket (Golf
2009 ►) .
Continuation for all
– Install trim and cover below trim on drive side ⇒ General body
repairs, interior; Rep. gr. 68 .
– Press pipe/hose line -2- with seal into connection of master
cylinder.
– Engage securing clip -1-.
– Test line by tugging on it.
– Clip clutch position sender - G476- into master cylinder with
electrical connector -3- attached -arrow-.
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– After removing hose clamp - 3094- , return supply hose to its
original position, if necessary.
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– If disconnected, connect battery ⇒ Electrical system; Rep. gr.
27 ; Removing and installing battery .
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1.7.4 Removing and installing mounting
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Special tools and workshop equipment required
1. Clutch operation 93
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
♦ Hose clamps to 25 mm - 3094-
♦ Torque wrench - V.A.G 1331-
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♦ Installation tool for spring-type clips - VAS 5024 A-
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94 Rep. gr.30 - Clutch
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
Note
♦ During the following work, ensure that no brake fluid lands on
longitudinal member or gearbox. If this does happen, clean the
affected areas thoroughly.
♦ Place a lint-free cloth under the master cylinder.
– Clamp off supply hose to master cylinder using hose clamp -
3094- .
– If necessary, loosen spring clip -3- using assembly tool - VAS
5024- .
– In addition to disconnecting, sealing tool - T10249/1- can also
be for sealing (⇒ figure above).
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– Remove driver side compartment and cover ⇒ General body
s
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panels .
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– Carefully cut through cable tie -1-.
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1. Clutch operation 95
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
– Remove crash bar -A- by removing bolt -B-.
– Unbolt fuse holder beneath dash panel on left and lay to side
⇒ Electrical system; Rep. gr. 97 ; Removing and installing
fuse holder .
– Unhook relay carrier beneath dash panel on left and lay to side
⇒ Electrical system; Rep. gr. 97 ; Removing and installing
relay carrier . AG. Volkswagen n AG do
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– To do this, remove lock washers -A- for damping.
– Pull off damping.
96 Rep. gr.30 - Clutch
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
– Push damping upwards in area of upper securing nut -1-
above clutch pedal -A- in -direction of arrow-.
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1. Clutch operation 97
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
Some cars have damping -arrow- on the clutch pedal mounting
bracket.
– Install relay carrier beneath dash panel on left ⇒ Electrical
system; Rep. gr. 97 ; Removing and installing relay carrier .
– Install fuse holder beneath dash panel on left ⇒ Electrical
system; Rep. gr. 97 ; Removing and installing fuse holder .
– Install crash bar -A-, tightening bolt -B- to specified torque.
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– Install footwell vent, cable guide, cover and compartment on
driver side ⇒ General body repairs, interior; Rep. gr. 68 ;
Compartments, covers and trim panels .
– Renew cut cable ties.
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98 Rep. gr.30 - Clutch
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
– Push pipe/hose line -1- with seal -2- onto connection of master
cylinder -4- until securing clip -3- engages audibly.
– Test pipe/hose assembly by tugging on it.
– After removing hose clamp - 3094- , return supply hose to its
original shape, if necessary.
– Bleed clutch system ⇒ page 127 .
– Install battery ⇒ Electrical system; Rep. gr. 27 ; Battery; Re‐
moving and installing .
Torque settings
Component Nm
Mounting bracket to bulkhead 25
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1. Clutch operation 99
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
♦ Installation tool for spring-type clips - VAS 5024 A-
♦ Sealing tool - T10249-
cardiagn.com
Removing
LHD vehicles
– First check whether a coded radio is fitted. If so, obtain anti-
theft code.
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100 Rep. gr.30 - Clutch
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
– If necessary, loosen spring-type clip -3- with assembly tool -
VAS 5024- and pull supply hose off master cylinder.
– Release securing clip -2- with a screwdriver or a pointed object
and pull out of master cylinder to stop.
– Pull pipe/hose line -1- out from master cylinder and seal hose.
– Separate electrical connector -4- at clutch position sender -
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– Remove crash bar -1- by removing bolt -2-.
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1. Clutch operation 101
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
– Remove securing nuts -1- and -2-.
The upper securing nut -1- is accessible through the opening in
the lower-assisted steering column trim.
– Pull mounting bracket -3- off studs on bulkhead.
Installing
Install in reverse order of removal. During this step, observe the
following:
Note
♦ Renew self-locking nut.
♦ Renew hose clips.
♦ Allocate all components according to ⇒ Electronic parts cata‐
logue “ETKA” .
– If present, install retaining clip for front parking aid warning
buzzer - H22- ⇒ Electrical system; Rep. gr. 94 ; Parking aid .
cardiagn.com
– Install crash bar -1- and tighten bolt -2- to specified torque.
– Install lower-assisted steering column trim ⇒ General body
repairs, interior; Rep. gr. 68 ; Compartments, covers and trim
panels .
– Install driver side footwell cover ⇒ General body repairs, in‐
terior; Rep. gr. 68 ; Compartments, covers and trim panels .
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102 Rep. gr.30 - Clutch
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
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♦ Installation tool for spring-type clips - VAS 5024 A-
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1. Clutch operation 103
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
Removing
LHD vehicles
– First check whether a coded radio is fitted. If so, obtain anti-
theft code.
– Remove battery and, if necessary, detach back wall of battery
box ⇒ Electrical system; Rep. gr. 27 ; Removing and installing
battery .
Continuation for all
Note
♦ During the following work, ensure that no brake fluid lands on
longitudinal member or gearbox. If this does happen, clean the
affected areas thoroughly.
♦ Place a lint-free cloth under the master cylinder.
– Clamp off supply hose to master cylinder using hose clamp -
3094- .
cardiagn.com
– It may also be sealed with sealing tool - T10249/1- .
If necessary, loosen spring-type clip -3- with assembly tool - VAS
5024- and pull supply hose off master cylinder.
– Pull supply hose off master cylinder.
– Release securing clip -2- using screwdriver or a pointed object
and pull pipe/hose line -1- off master cylinder.
– Unclip clutch position sender - G476- from master cylinder
-arrow- and remove with electrical connector attached -4-.
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104 Rep. gr.30 - Clutch
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
– Remove crash bar -1- (1 bolt -2-).
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The crash bar -1- in front of clutch pedal -2- may be secured in
different ways.
Attachment with 2 bolts
– Install crash bar -1- and tighten 2 bolts to specified torque.
Attachment with 1 bolt
1. Clutch operation 105
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
– Install crash bar -1- and tighten bolt -2- to specified torque.
– Install trim and cover below trim on drive side ⇒ General body
repairs, interior; Rep. gr. 68 .
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106 Rep. gr.30 - Clutch
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
Special tools and workshop
equipment required
♦ Tensioning strap - T10038-
♦ Hose clamp - 3094-
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Removing
LHD vehicles
– First check whether a coded radio is fitted. If so, obtain anti-
theft code.
– Remove battery and, if necessary, detach back wall of battery
box ⇒ Electrical system; Rep. gr. 27 ; Removing and installing
battery .
1. Clutch operation 107
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– If previously fitted, remove air pipe -arrow- ⇒ Rep. gr. 21 ; itte
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In some vehicles, master cylinder is located behind a line for air
conditioning system -arrow-.
Continuation for all
Note
♦ During the following work, ensure that no brake fluid lands on
longitudinal member or gearbox. If this does happen, clean the
affected areas thoroughly.
♦ Place a lint-free cloth under the master cylinder.
– Clamp off supply hose to master cylinder using hose clamp -
3094- .
– It may also be sealed with sealing tool - T10249/1- .
108 Rep. gr.30 - Clutch
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
– If necessary, loosen spring-type clip -3- with assembly tool -
VAS 5024- and pull supply hose off master cylinder.
– Pull clip -2- for pipe/hose line out of master cylinder to stop.
– Pull pipe/hose line -1- out efrom
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bracket in footwell area ⇒ page 23 .
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♦ This must be removed from mounting bracket in a later step.
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– Push driver seat as far back as possible and put steering wheel
in highest position.
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– Remove storage compartment and cover below on driver side
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cardiagn.com
⇒ General body repairs, interior; Rep. gr. 68 ; Compartments,
covers and trims; Removing and installing storage compart‐
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ment on driver side .
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– Carefully cut through cable tie -1-.
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– Then turn clutch pedal switch -A- 45° anti-clockwise and pull
out of support -arrows-.
1. Clutch operation 109
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
– Remove crash bar -A- by removing bolt -B- and loosening bolt
-C-.
RHD vehicles
cardiagn.com
– Unscrew securing nuts -arrows- for mounting bracket.
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LHD vehicles
– Unbolt fuse holder and relay carrier and secure to dash panel t to the co
⇒ Electrical system; Rep. gr. 97 ; Removing and installing rrectne
fuse holders and relay carriers; Removing and installing relay
plate and relay carrier .
ss
– Remove bracket for relay carrier, onboard supply control unit
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cial p
- J519- and fuse holder. ⇒ Electrical system; Rep. gr. 97 ;
inform
Removing and installing control units; Removing and installing
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– To remove mounting bracket -A-, carefully cut through cable
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110 Rep. gr.30 - Clutch
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
– Press bracket -1- to right -arrow- and secure to steering col‐
umn using wire -2-.
Volkswagen AG
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– Press wiring harness -1- upwards and outwards -arrow- using
extension -2- from -V.A.G 1835- .
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– While doing this, unbolt upper securing nut for mounting brack‐
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– Then unbolt both lower securing nuts for mounting bracket.
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– Untie bracket from steering column.
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– Untie relay carrier from dash panel and lay in foot well.
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1. Clutch operation 111
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
– Secure tensioning strap -arrow 1- to dash panel cross member
-arrow 2- as shown in figure.
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Installing
Install in reverse order of removal. During this step, observe the
rrectness of i
following:
cardiagn.com
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– Renew cut cable ties.
– If previously fitted, install clutch pedal switch - F36-
nform
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⇒ page 23 .
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– If there is no clutch pedal switch - F36- , install clutch position
ion
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sender - G476- ⇒ page 119 .
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– Push pipe/hose line -1- with seal -2- onto connection of master
p
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cylinder -4- until securing clip -3- engages audibly.
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LHD vehicles
– Install relay carrier bracket, onboard supply control unit - J519-
and fuse holder.
– Install onboard supply control unit - J519- (located on left un‐
der dash panel) ⇒ Electrical system; Rep. gr. 97 ; Removing
and installing control unit; Removing and installing onboard
supply control unit .
– Install relay carrier on left under dash panel ⇒ Electrical sys‐
tem; Rep. gr. 97 ; Removing and installing relay carrier;
Removing and installing relay carrier on left under dash panel .
– Install fuse holder on left under dash panel ⇒ Electrical sys‐
tem; Rep. gr. 97 ; Removing and installing fuse holder; Re‐
moving and installing fuse holder on left under dash panel .
Continuation for all
112 Rep. gr.30 - Clutch
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
– Install crash bar -A-, (bolts -B- and -C-).
– Install cover and storage compartment on driver side ⇒ Gen‐
eral body repairs, interior; Rep. gr. 68 ; Compartments, covers
and trims; Removing and installing storage compartment on
driver side .
LHD vehicles
– Install battery ⇒ Electrical system; Rep. gr. 27 ; Battery; Re‐
moving and installing battery .
RHD vehicles
cardiagn.com
– If present, fold heat shield around the pipe/hose assembly
-arrows-.
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– If removed, install air pipe -arrow- ⇒ Rep. gr. 21 ; Super‐
ss
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charging .
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– Bleed clutch system ⇒ page 127 .
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Torque settings
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Component Nm
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Mounting bracket to bulkhead 25
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♦ Renew self-locking nuts.
Crash strut Bolt M8 = 20
rrectness of i
Bolt M6 = 5
♦ Renew bolt for crash bar to steering col‐
l purpos
umn mounting bracket
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1. Clutch operation 113
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
1.8 Removing and installing master cylinder
⇒ “1.8.1 Removing and installing master cylinder, Passat, Eos,
Scirocco, Golf and Golf Plus ”, page 114
⇒ “1.8.2 Removing and installing master cylinder - Touran with
clutch pedal switch F36 (up to 05.03)”, page 116
⇒ “1.8.3 Removing and installing master cylinder - Touran with
clutch position sender G476 (from 06.03)”, page 117
1.8.1 Removing and installing master cylin‐
der, Passat, Eos, Scirocco, Golf and
Golf Plus
Special tools and workshop equipment required
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Removing
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– Remove mounting bracket, Golf 2004 ► ⇒ page 78 .
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– Remove mounting bracket, Golf 2009 ► left-hand drive and
Scirocco ⇒ page 83 .
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– Remove mounting bracket, Golf 2009 ► right-hand drive and
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Golf Plus right-hand drive ⇒ page 88 .
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– Remove mounting bracket, Golf Plus left-hand drive
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– Remove mounting bracket, Passat ⇒ page 99 .
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– Remove mounting bracket, Eos ⇒ page 103 . C py
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– Release retainer for master cylinder operating rod using pliers co Vo
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114 Rep. gr.30 - Clutch
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
– Insert spacer -A- between clutch pedal and stop and press
clutch pedal to spacer.
♦ Length of spacer = about 40 mm (e.g. 1/2" socket)
– Release securing bar -B- and pull master cylinder out of AG. Volkswagen AG d
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– Attach retainer -2- to master cylinder operating rod -1-.
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– Insert spacer -A- between clutch pedal and stop and press
AG.
clutch pedal to spacer.
♦ Length of spacer = about 40 mm (e.g. 1/2" socket)
– Engage master cylinder in mounting bracket -arrow 1- and
-arrow 2-.
1. Clutch operation 115
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
– Press master cylinder operating rod -1- in
-direction of arrow- until retainer -2- engages audibly in clutch
pedal.
– Install mounting bracket, Golf 2004 ► ⇒ page 78 .
– Install mounting bracket, Golf 2009 ► left-hand drive and Scir‐
occo ⇒ page 83 .
– Install mounting bracket, Golf 2009 ► right-hand drive and Golf
Plus right-hand drive ⇒ page 88 .
– Install mounting bracket, Golf Plus left-hand drive
⇒ page 93 .
– Install mounting bracket, Passat ⇒ page 99 .
– Install mounting bracket, Eos ⇒ page 103 .
1.8.2 Removing and installing master cylinder
- Touran with clutch pedal switch - F36-
(up to 05.03)
Special tools and workshopwaequipment
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Removing
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– Remove mounting bracket ⇒ page 106 .
Release master cylinder operating rod from clutch pedal as fol‐
nform
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lows:
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– Release retainer for master cylinder operating rod using pliers
ion in
- T10005- .
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Clutch pedal must not be moved further past rest position.
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Otherwise, over-centre spring will separate from clutch pedal
and mounting bracket.
Cover over-centre spring with a cloth.
– Pull master cylinder plunger in -direction of arrow-; if neces‐
sary, press both sides of retainer together again using pliers -
T10005- .
116 Rep. gr.30 - Clutch
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
– Press catch in -direction of arrow 1-.
– Turn master cylinder to stop in -direction of arrow 2- and re‐
move it from mounting bracket.
Installing
– Renew seal between master cylinder and mounting bracket.
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– Insert master cylinder with shoulder -A- in notch -B- of mount‐
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– Turn master cylinder in -direction of arrow- to stop, ensuring
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– Carefully clamp mounting bracket in vice having jaw protec‐
tors.
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– Insert retainer -1- into clutch pedal as shown.
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– Insert plunger -2- in round notch of retainer.
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– Block plunger behind shoulder -3- with 10 mm open-jaw span‐
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– Install mounting bracket ⇒ page 106 .
1.8.3 Removing and installing master cylinder
- Touran with clutch position sender -
G476- (from 06.03)
Special tools and workshop equipment required
1. Clutch operation 117
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
♦ Pliers - T10005-
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Removing
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– Remove mounting bracket ⇒ page 106 .
– Release retainer for master cylinder operating rod using pliers
- T10005- .
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♦ Length of spacer = about 40 mm (e.g. 1/2" socket) Prote AG.
– Release securing bar -B- and pull master cylinder out of
mounting bracket -arrow 1- and -arrow 2-.
Installing
• Move clutch pedal to rest position at stop.
118 Rep. gr.30 - Clutch
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
– Attach retainer -2- to master cylinder operating rod -1-.
– Insert spacer -A- between clutch pedal and stop and press
clutch pedal to spacer.
♦ Length of spacer = about 40 mm (e.g. 1/2" socket)
– Engage master cylinder in mounting bracket -arrow 1- and
-arrow 2-.
cardiagn.com
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– Press master cylinder operating rod -1- in
t to the co
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pedal.
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– Install mounting bracket ⇒ page 106 .
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1.9 Removing and installing clutch position
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Special tools and workshop equipment required
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1. Clutch operation 119
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
♦ Hose clamps - 3094-
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Removing
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LHD vehicles ot
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– First check whether a coded radio is fitted. If so, obtain anti-
hole
spec
theft code.
es, in part or in w
t to the co
– Remove battery and, if necessary, detach back wall of battery
box ⇒ Electrical system; Rep. gr. 27 ; Removing and installing
cardiagn.com
battery .
rrectness of i
RHD vehicles
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An insulation mat is installed in conjunction with some engines.
Appearance may be different from that illustrated.
nform
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– Remove heat shield from pipe/hose assembly -arrows-.
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Continuation for all
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If a pipe/hose line -1- with a round component is installed directly
beneath the master cylinder, the pipe/hose line must be removed.
Note
During the following work, ensure that no brake fluid lands on
longitudinal member or gearbox. If this does happen, clean the
affected areas thoroughly.
120 Rep. gr.30 - Clutch
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
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– Clamp off supply hose to master d b cylinder using
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– Release securing clip -2- with a screwdriver or a pointed object
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and pull out of master cylinder to stop.
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– Pull pipe/hose line -1- out from master cylinder and seal hose.
Continuation for all
nform
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– Disconnect connector -4-.
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– Unclip clutch position sender - G476- from master cylinder
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♦ Renew hose clips.
♦ Allocate all components according to ⇒ Electronic parts cata‐
logue “ETKA” .
If the pipe/hose assembly was removed:
– Push pipe/hose line -1- with seal -2- onto connection of master
cylinder -4- until securing clip -3- engages audibly.
– Test pipe/hose assembly by tugging on it.
– After removing hose clamp - 3094- , return supply hose to its
original shape, if necessary.
– Bleed clutch system ⇒ page 127 .
LHD vehicles
– Install battery ⇒ Electrical system; Rep. gr. 27 ; Battery; Re‐
moving and installing .
– Reconnect battery and perform work required after connecting
battery ⇒ Electrical system; Rep. gr. 27 ; Disconnecting and
connecting battery .
1.10 Assembly overview - hydraulics (LHD)
1. Clutch operation 121
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
1 - Brake fluid reservoir
2 - Spring-type clip
❑ Not fitted in all vehicles
3 - Supply hose
❑ Rubber
❑ From 12 05, plastic
⇒ page 123
❑ Golf 2009 ► and Sciroc‐
co made from plastic
⇒ page 123
4 - Master cylinder
❑ Touran with clutch pedal
switch - F36- , Remov‐
ing and installing
(to 05. 03) ⇒ page 116
❑ Touran with clutch posi‐
tion sender - G476-
(from 06.03), removing
and installing
⇒ page 117
cardiagn.com
❑ Passat, Eos, Scirocco,
Golf, and Golf Plus, re‐
moving and installing
⇒ page 114
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⇒ Item 9 (page 25)
spec
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t to the co
7 - Clutch pedal
❑ Removing and installing Touran up to 05. 03 ⇒ page 22
❑ Touran from 06.03, Passat, Eos, Scirocco, Golf, and Golf Plus, removing and installing ⇒ page 24
rrectne
8 - Hexagon nut, ⇒ Item 15 (page 26)
ss
9 - Seal / O-ring
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❑ Pull onto line connection
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❑ Seals/O-rings are adapted to configuration of line connection ⇒ page 123
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11 - Holder Prote AG.
❑ Secured to body
12 - Seal / O-ring
❑ Pull onto line connection
❑ Insert with brake fluid
❑ Seals/O-rings are adapted to configuration of line connection ⇒ page 123
122 Rep. gr.30 - Clutch
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
❑ Allocation ⇒ Electronic parts catalogue “ETKA”
13 - Clip
❑ To remove pipe/hose line, pull out clip to stop
❑ Can be pressed in as far as stop before fitting line
14 - Slave cylinder
❑ Removing and installing ⇒ page 125
15 - Dust cap
16 - Bleeder valve
❑ Bleeding clutch system ⇒ page 127
17 - Gearbox
18 - Hexagon bolt ⇒ Item 9 (page 130)
19 - Holder
Seals and O-rings for pipe and hose lines
Item Material of line connection
cardiagn.com
1 Line connection with circumferential groove
-arrow 1-
2 Line connection with shoulder -arrow 2-
3 Line connection with shoulder -arrow 2- and cir‐
cumferential groove -arrow 3-
• For line connection having circumferential groove -arrow 1-
and -arrow 3-, a seal or O-ring must be set there.
Supply hose -1- of plastic agen
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1. Clutch operation 123
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
1.11 Assembly overview - hydraulics (RHD)
1 - Brake fluid reservoir
2 - Seal
❑ For plastic supply hose
❑ The seals must be loca‐
ted in supply hose
3 - Supply hose
❑ Rubber
❑ From 12 05, plastic
⇒ page 123
❑ Golf 2009 ► and Sciroc‐
co made from plastic
⇒ page 123
4 - Master cylinder
❑ Touran with clutch pedal
switch - F36- , Remov‐
ing and installing
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(to 05. 03) ⇒ page 116 AG. Volkswagen AG d
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⇒ page 117
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⇒ page 114
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spec
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❑ Can be pressed in as far
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6 - Seal / O-ring
s
❑ Pull onto line connection
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❑ Insert with brake fluid
inform
❑ Seals/O-rings are adapted to configuration of line connection ⇒ page 123
mer
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❑ Allocation ⇒ Electronic parts catalogue “ETKA”
om
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7 - Retainer ⇒ Item 9 (page 25)
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❑ Secured to body
11 - Pipe/hose line
❑ Allocation ⇒ Electronic parts catalogue “ETKA” .
❑ To remove, remove battery and battery tray ⇒ Electrical system; Rep. gr. 27 ; Removing and installing
battery .
12 - Holder
❑ Secured to retainer for ABS/EDL
❑ Not fitted in all vehicles
124 Rep. gr.30 - Clutch
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
13 - Holder
❑ For ABS/EDL
❑ Not fitted in all vehicles
14 - Seal / O-ring
❑ Pull onto line connection
❑ Insert with brake fluid
❑ Seals/O-rings are adapted to configuration of line connection ⇒ page 123
❑ Allocation ⇒ Electronic parts catalogue “ETKA”
15 - Clip
❑ To remove pipe/hose line, pull out clip to stop
❑ Can be pressed in as far as stop before fitting line
16 - Slave cylinder
❑ Removing and installing ⇒ page 125
17 - Bleeder valve
❑ Bleeding clutch system ⇒ page 127
18 - Dust cap
cardiagn.com
19 - Gearbox
20 - Hexagon bolt ⇒ Item 9 (page 130)
21 - Holder
1.12 Removing and installing
Volkswa
slave cylinder
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– First check whether a coded radio is fitted. If so, obtain anti-
theft code.
nform
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– Disconnect battery earth strap ⇒ Electrical system; Rep. gr.
m
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27 ; Disconnecting and reconnecting battery .
on
c
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– Then remove complete air filter housing if it is over slave cyl‐
his
ate
inder ⇒ Rep. gr. 23 ; Repairing diesel direct injection system
do
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1. Clutch operation 125
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
– Pull gear selector cable off pin.
Metal relay lever
– Remove securing clip -arrow 2- for gate
agenselector cableAfrom
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ss 3- off relay lever -B- and remove relay
ce
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lever.
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box ⇒ page 162 .
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– Remove gearbox selector lever -A- by removing nut
t to the co
-arrow 4-.
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– Remove cable support bracket from gearbox -arrows-.
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– Place a lint-free cloth under slave cylinder.
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– Pull clip -A- for pipe/hose assembly out of slave cylinder to
stop.
– Pull pipe/hose assembly out of support -C-.
– Pull pipe/hose line -B- out of slave cylinder and seal opening.
– Unbolt slave cylinder -arrows- and remove.
Caution
Do not operate clutch pedal any more.
Installing
Install in the reverse order of removal, observing the following:
126 Rep. gr.30 - Clutch
olkswagen AG
en AG. V
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wag does
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byV 6-speed manual
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– Install slave cylinderss aand tighten bolts -arrows- to specified ra
c
torque.
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– Insert pipe/hose assembly -B- into slave cylinder to stop.
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– Press in clip -A- securing pipe/hose assembly as far as stop.
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– Test pipe/hose assembly by tugging on it.
h re
ole,
– Press pipe/hose assembly into mounting -C- on gearbox as
spec
urposes, in part or in wh
far as stop.
t to the co
– Bleed clutch system after installing slave cylinder
⇒ page 127 .
rrectne
Assembling selector mechanism ⇒ page 164 .
Adjust selector mechanism ⇒ page 168 .
ss o
cial p
f
– If removed, install complete air filter housing ⇒ Rep. gr. 23 ;
inform
Repairing diesel direct injection system or ⇒ Rep. gr. 24 ;
mer
Repairing injection system
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n
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– Connect battery earth ⇒ Electrical system; Rep. gr. 27 ; Dis‐
i
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connecting and reconnecting battery .
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Torque setting
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Slave cylinder to gearbox ⇒ Item 9 (page 130)
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1.13 Bleeding clutch system cop Vo
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Special tools and workshop equipment required
♦ Brake filling and bleeding equipment - VAS 5234- or
♦ Brake filling and bleeding unit - V.A.G 1869-
Note
Prefilling system is not necessary!
1. Clutch operation 127
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
Specifications for brake fluid ⇒ Brake systems; Rep. gr. 47 ;
Bleeding brake system .
– Remove complete air filter housing if it blocks access to bleed‐
er valve (-arrow-, figure below) ⇒ Rep. gr. 23 ; Repairing
diesel direct injection system or ⇒ Rep. gr. 24 ; Repairing
injection system
– Connect brake filling and bleeding equipment - VAS 5234- or
-V.A.G 1869- .
To bleed system, use 670 mm bleeder hose - V.A.G 1238/B3- if
necessary.
– Connect bleeder hose to collector bottle of brake bleeding
equipment.
– Push bleeder hose -arrow- onto bleeder valve.
– Pressurise system to 2 bar.
– Open bleeder valve.
– Bleed off about 100 cm3 brake fluid.
– Close bleeder valve.
cardiagn.com
– Quickly press and release pedal from stop to stop 10 to 15
times. gen AG
. Volkswagen AG
d a oes
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– Open bleeder valve. Vol gu
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– Bleed off an additional 50 cm3 brake fluid. tho eo
au ra
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– Close bleeder valve.
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– Depress clutch pedal several times after completion of bleed‐
itte
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128 Rep. gr.30 - Clutch
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
2 Clutch
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⇒ “2.2
s Repairing clutch release mechanism”, page 130
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2.1 Assembly overview - clutch release mechanism
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❑ To remove and install,
spec
remove gearbox
urposes, in part or in wh
t to the co
❑ Remove and install to‐
gether with clutch re‐
lease lever and guide
rrectne
sleeve ⇒ page 130 to
⇒ page 130
s
❑ Do not wash out bear‐
s o
ing; wipe only
cial p
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❑ Renew noisy bearings
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❑ To remove and install,
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AG.
⇒ page 130
❑ Remove old grease
4 - Retaining spring
❑ To remove and install,
remove gearbox
❑ Secure to clutch release
lever
5 - Guide bush
❑ To remove and install,
remove gearbox
❑ Remove and install to‐
gether with release
bearing and clutch re‐
lease lever ⇒ page 130
to ⇒ page 130
6 - Input shaft seal
❑ Renewing ⇒ page 356
7 - Ball-head pin, 20 Nm
❑ To remove and install, remove gearbox
❑ Remove old grease
❑ Lubricate with clutch plate spline grease
❑ Allocate grease using ⇒ Electronic parts catalogue (ETKA) .
2. Clutch release mechanism 129
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
8 - Gearbox
9 - Hexagon bolt, 20 Nm
10 - Holder
11 - Slave cylinder
❑ Removing and installing ⇒ page 125
2.2 Repairing clutch release mechanism
Special tools and work‐
shop equipment re‐
quired
♦ Torque wrench -
V.A.G 1331-
cardiagn.com
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spec
and ball stud.
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Install in reverse order of
removal.
rrectness of i
Removing and installing guide sleeve
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nf
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– Turn guide sleeve -3- about 90° in -direction of arrow- relative
orm
to release bearing -2- until locking lugs of guide sleeve align
m
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– Pull guide sleeve out of release bearing in this position.
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Install in reverse order of removal.
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130 Rep. gr.30 - Clutch
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
Removing and installing release bearing
– Press together retaining hooks -arrows- on back of clutch re‐
lease lever and remove release bearing -A- from clutch re‐
lease lever.
– To install, press release bearing -A- into clutch release lever
until retaining hooks -arrows- engage.
AG. Volkswagen AG d
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2. Clutch release mechanism 131
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
3 Clutch
⇒ “3.1 Assembly overview - clutch”, page 132
⇒ “3.2 Removing and installing clutch”, page 134
Note
♦ Renew clutch plates and pressure plates with damaged or
loose rivet connections.
♦ Renew pressure plate and clutch plate together only.
♦ A clutch manufactured by either “Sachs” or “LuK” may be in‐
stalled.
♦ Select clutch plate and pressure plate according to engine
code and ⇒ Electronic parts catalogue “ETKA” .
♦ Clean splines of drive shaft and, if the clutch plate has been
used, clean the splines of the hub. Remove corrosion and ap‐
ply only a very thin coat of clutch plate spline grease to splines.
Then, move the clutch plate back and forth on the drive shaft
cardiagn.com
until the hub moves easily on the shaft. Remove excess
grease.
♦ Allocate grease using ⇒ Electronic parts catalogue (ETKA) .
♦ Pressure plates are protected against corrosion and greased.
Clean contact surface only. Otherwise, G the service life of the
A . Volkswagen AG d
clutch will be considerably reduced.
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♦ Pressure plate contact surface and clutch plate lining must
db ua
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make full contact withutflywheel.
h or
Only then insert securing bolts. tee
or
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♦ Check whether dowel sleeves for aligning engine and gearbox
s
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are fitted in cylinder block and install if necessary.
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erm
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problems and possible noises from the gearbox (rattling of
ility
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3.1 Assembly overview - clutch
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132 Rep. gr.30 - Clutch
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
1 - Flywheel
❑ Removing and installing
⇒ Engine, mechanics;
Rep. gr. 13 .
❑ Ensure that centring
pins fit tightly
2 - Clutch plate
❑ Allocation ⇒ Electronic
parts catalogue .
❑ Removing and installing
⇒ page 134
❑ Centring for engines
having a crankshaft of
smaller diameter or hav‐
ing needle bearings in
the crankshaft -
⇒ page 137
❑ Installation position: let‐
tering on “gearbox side”
faces pressure plate
cardiagn.com
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❑ Check ends horis of dia‐ nte
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⇒ pages 133
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pt
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⇒ page 134
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❑ Contact surface for
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spec
free of grooves, oil and
es, in part or in w
grease
t to the co
4 - M6 bolt - 13 Nm, M7 bolt -
20 Nm
rrectness of i
❑ Allocation ⇒ Electronic parts catalogue .
l purpos
❑ Loosen or tighten diagonally in small steps
nform
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Check ends of diaphragm spring
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In event of repair, always select clutch plate and pressure plate
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according to engine code and ⇒ Electronic Parts Catalogue .
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3. Clutch 133
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
Check spring connection and riveted fastenings.
– Check spring connection betweenepressure plate
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– If pressure plate has damaged
ris
ed springs or loose rivet connec‐ rante
tions -arrows-, it must
au
t be renewed.
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⇒ page 137 centring
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• Gearbox is removed.
3. Clutch 135
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– Reverse counterhold tool - 3067- for installation.
– To centre clutch plate, use centring mandrel - 3190 A- .
– Tighten bolts in small steps diagonally in order not to damage
centring holes of pressure plate and centring pins of flywheel.
Torque setting ⇒ Item 4 (page 133) .
For engines having a crankshaft of smaller diameter -arrow- or
having an needle bearing -arrow- in the crankshaft
136 Rep. gr.30 - Clutch
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
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⇒ “1.8 Removing and installing selector mechanism”, page 164
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⇒ “1.9 Adjusting selector mechanism”, page 168
1.1 Installation position of selector mechanism
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Arrow -A- Gear selection movement
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2 - Deflector lever
138 Rep. gr.34 - Controls, housing
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
1.2 Overview - selector mechanism
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♦ Remove selector mechanism to renew selector cables ⇒ page 164 .
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♦ Do not kink selector cables.
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1.3 Assembly overview - gear knob and cov‐
er
Special tools and workshop equipment required
1. Selector mechanism 139
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
♦ Removal wedge - 3409-
AG. Volkswagen AG d
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❑ Gear knob and gaiter
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⇒ page 144
❑ Removing and instal‐
ling, Touran
⇒ page 145
3 - Clamp
❑ For securing gear knob
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❑ Always renew
❑ Secure to gear knob us‐
ing hose clip pliers -
V.A.G 1275-
4 - Centre console cover
❑ In some equipment ver‐
sions, forms one part to‐
gether with centre console
5 - Noise insulation
❑ Not fitted in all vehicles
❑ Arrow on noise insulation points in direction of travel
❑ Locking lugs are arranged at varying intervals
❑ Therefore it can be installed in only one position
140 Rep. gr.34 - Controls, housing
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
1.4 Removing and installing gear knob with
gaiter and noise insulation
⇒ “1.4.1 Removing and installing gear knob with gaiter and noise
insulation, Golf, Eos and Scirocco”, page 141
⇒ “1.4.2 Removing and installing gear knob with gaiter and noise
insulation, Golf Plus”, page 142
⇒ “1.4.3 Removing and installing gear knob with gaiter, Passat”,
page 144
⇒ “1.4.4 Removing and installing gear knob with gaiter, Touran”,
page 145
1.4.1 Removing and installing gear knob with
gaiter and noise insulation, Golf, Eos
and Scirocco
Special tools and workshop equipment required
♦ Removal wedge - 3409-
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1. Selector mechanism 141
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
– Fold boot up over gearstick.
– Open clamp -arrow- and pull off gear knob together with gaiter.
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– Install gear knob and gaiter and squeeze new clamp -arrow-
together.
– Then press gaiter into frame of centre console.
1.4.2 Removing and installing gear knob with
gaiter and noise insulation, Golf Plus
Special tools and workshop equipment required
142 Rep. gr.34 - Controls, housing
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
♦ Removal wedge - 3409-
♦ Hose clip pliers - V.A.G 1275-
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– Pull off noise insulation.
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Installing
– First set noise insulation in place.
1. Selector mechanism 143
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
Installation position of noise insulation:
-Arrow A- points in direction of travel.
Catches -arrows B- must engage in centre console.
– Turn gaiter inside out.
The gear knob must be pressed to stop.
– Install gear knob and gaiter and squeeze new clamp -arrow-
together.
– Then press gaiter into centre console.
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1.4.3 Removing and installing gear knob with
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Special tools and workshop equipment required
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♦ Front end hook - 3370-
AG.
144 Rep. gr.34 - Controls, housing
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
Removing
– Open ashtray.
– Press hook for front end - 3370- as far as it will go under the
plastic frame for the gaiter -arrow 1-.
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– Install gear knob and gaiter and squeeze new clamp -arrow-
together.
– Insert back of gaiter with plastic frame first.
1.4.4 Removing and installing gear knob with
gaiter, Touran
Special tools and workshop equipment required
1. Selector mechanism 145
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
♦ Removal wedge - 3409-
AG. Volkswagen AG d
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– Open clamp -arrow- and pull off gear knob together with gaiter.
Installing
– Turn gaiter inside out.
The gear knob must be pressed to stop.
146 Rep. gr.34 - Controls, housing
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
– Install gear knob and gaiter and squeeze new clamp -arrow-
together.
1.5 Assembly overview - Gear lever and se‐
lector housing
⇒ “1.5.1 Assembly overview - selector lever and selector housing
(up to 10.06)”, page 147
⇒ “1.5.2 Assembly overview - selector lever and selector housing
(from 11.06)”, page 150
cardiagn.com
1.5.1 Assembly overview - selector lever and selector housing (up to 10.06)
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1. Selector mechanism 147
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
1 - Lock washer
❑ Removing and installing
⇒ page 151
2 - Bush
3 - Compression spring
4 - Bush
5 - Torx bolt, 5 Nm
6 - Cover
7 - Dampers
8 - Dampers
9 - Bearing shell
10 - Gear lever guide
11 - Damping washer
12 - Seal
❑ Between selector hous‐
ing and underbody
cardiagn.com
❑ Self-adhesive
❑ Bond to selector lever
housing
13 - Gear lever
14 - Selector housing
15 - Bearing bush
16 - Locating pin
17 - Guide bush agen
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❑ Always renew
❑ Fitting ⇒ page 155
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23 - Gate change cable
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❑ Removing and installing ⇒ page 149
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24 - Gear change cable
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148 Rep. gr.34 - Controls, housing
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
28 - Lock washer
❑ Always renew
Removing and installing gate and gear selector cables
– Remove securing clip from gear selector cable -A- and gate
selector cable -B-.
To do this, raise tab using screwdriver -arrow 1- and press off
securing clip -arrow 2-.
– Remove gear selector cable -A- from gear lever pin.
– Remove gate selector cable -B- from pin of gate selector lever.
cardiagn.com
Installing compression spring
Volkswagen AG
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1. Selector mechanism 149
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
1.5.2 Assembly overview - selector lever and selector housing (from 11.06)
Note
♦ Lubricate bearing positions and sliding surfaces.
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❑ Always renew
3 - Gear lever
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❑ Can be removed and in‐
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4 - Damping washer
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❑ Push onto gear lever up
at
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to stop -arrow-
n
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5 - Lock washer
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❑ Lever off gate selector
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lever
❑ Press onto gate selector
lever inside selector
mechanism
❑ Fitting position
⇒ page 138
7 - Bush
8 - Gear change cable
❑ Lever off gear lever
guide
❑ Press onto gear lever
guide inside selector mechanism
❑ Fitting position ⇒ page 138
9 - Dampers
10 - Bearing shell
❑ Is damaged during removal
❑ Always renew
11 - Bush
12 - Lock washer
❑ Removing and installing ⇒ page 151
150 Rep. gr.34 - Controls, housing
n AG. Volkswagen AG do
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13 - Compressionssspring
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15 - Gear lever guide erm
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16 - Hexagon nut M8 25 Nm, hexagon nut M6 8 Nm
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❑ Qty. 4
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17 - Seal
t to the co
❑ Between selector housing and underbody
❑ Self-adhesive
rrectne
❑ Bond to selector lever housing
18 - Selector housing
ss o
❑ With compression spring and gate selector lever
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❑ Compression spring and gate selector lever cannot be removed
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Removing and installing securing clip
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– To remove or install securing clip -arrow A-, press spacer bush
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-arrow B- to stop -in direction of arrow C- using screwdriver
fo
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and pull off securing clip.
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♦ Do not cant spacer bush when pushing down.
♦ Slot in gear lever for securing clip must be visible.
♦ Carefully release tension from spring.
1.6 Dismantling and assembling selector
mechanism (from 11.06)
Special tools and workshop equipment required
♦ Release tool - T10236-
♦ Press piece - VW 412-
♦ Assembly tool - T10178-
♦ Adapter - 10 - 222 A /25-
♦ - 2- = counter support e.g. from -Kukko- , type 16
♦ Wedge - T10357-
1. Selector mechanism 151
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
Thrust block - T10083-
Dismantling
– Remove selector mechanism ⇒ page 164 .
– Bend open tabs -arrows- of base plate for selector mechanism
using screwdriver and remove base plate; (tabs in front area
of base plate are not illustrated).
– Remove seal from selector housing.
– Remove gear and gate selector cables from selector housing
⇒ page 150 .
– Lift upper end -A- of compression spring over tab of gate se‐
cardiagn.com
lector lever.
– Use screwdriver to press catches -arrows- of ball socket to‐
wards bearing ball of gear lever guide; break off catches if
necessary.
– Lever ball socket -A- with gear lever guide -B- out of selector
housing. en AG. V
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– Then press ball socket off bearing ball of gear lever guide and
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remove it.
hole
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• Please pay attention to guides -A- during the further proce‐
es, in part or in w
t to the co
dure.
• They must not be broken off.
rrectness of i
– Lever lower end -arrow 1- of compression spring onto shoulder
l purpos
on gate selector lever as far as stop.
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Prote AG.
152 Rep. gr.34 - Controls, housing
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
– Now pull gear lever guide up to stop and pull ball stud out of
gate selector lever -arrow 2-.
– Then turn gear lever guide in -direction of arrow 1-.
• Pin -arrow 2- must be in notch in selector housing.
– Then swing out gear lever guide with gear lever in
-direction of arrow 3-.
Installing
cardiagn.com
Caution
The lower end of the compression spring (-arrow 1- ⇒ figure
above) can snap off the shoulder of the gate selector lever out
of control during the further procedure.
– Therefore, carefully press it down off shoulder of gate selector
lever. en AG. V
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– Fit gear lever guide in selector housing.
m
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• Pin -arrow 1- is still located in notch in selector housing.
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– Turn gear lever guide in -direction of arrow 2- until ball stud
o
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-A- is located in notch in selector housing.
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1. Selector mechanism 153
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
– Place selector housing with gear lever guide into larger recess
-arrow- in thrust piece - T10083- .
• The gear lever guide must project from the selector housing
up to the stop.
Note
For clarity of illustration, only part of the gate selector lever is
shown.
cardiagn.com
– Insert end -A- of compression spring into guide from above.
– Pull end -B- of compression spring downwards and insert it
next to guide (in direction of ball joint).
– Carefully remove selector housing with gear lever guide from
thrust piece - T10083- .
– Move gate selector lever back to stop (opposite from mounting
holes for gear and gate selector cable) -arrow 1-. AG. Volkswagen A
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– Grease ball stud. by Vol ot g
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– Press ball stud into gate selector leveroris -arrow 2-. tee
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ss to be damaged.
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– Place selector housing with gear lever guide into larger recess
-arrow- in thrust piece - T10083- .
rrectness of i
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Prote AG.
154 Rep. gr.34 - Controls, housing
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
• The gear lever guide must project from the selector housing
up to the stop.
– Lift upper end -A- of compression spring over pin of gate se‐
lector lever.
• Use a new ball socket -B-.
– Grease ball socket and bearing ball of gear lever guide.
– Press ball socket onto bearing ball of gear lever guide up to
stop.
– Remove selector housing from thrust piece - T10083- .
– Press ball socket into selector housing -arrows-.
• All 4 retaining lugs must engage.
– Insert lower end -C- of compression spring into guide.
– Lift upper end -A- of compression spring over pin of gate se‐
lector lever into guide.
– Attach gear selector cable and gate selector cable
⇒ page 150 .
cardiagn.com
– Install base plate ⇒ page 155 .
– Install selector mechanism ⇒ page 164 .
1.6.1 Attaching base plate
Caution
Risk of damage to selector housing and floor plate.
Apply only light pressure to selector housing.
– Fit new seal to base plate.
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– Attach floory Vplate
olks by bending down tabss-arrows-
not
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cumferencesed b of floor plate (only tabs on left side
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are illustrated).
tho
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– Tabs
s can be bent down using wedge - T10357- .
ce
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- A- = counter support e.g. from -Kukko- , type 16
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– Bond new gasket ⇒ Item 17 (page 151) to selector housing.
ility
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1. Selector mechanism
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
1.7 Assembly overview - Selector cables
⇒ “1.7.1 Assembly overview - selector cables (cable support
bracket and metal relay lever )”, page 156
⇒ “1.7.2 Assembly overview - selector cables (cable support
bracket and plastic relay lever)”, page 159 en AG. V
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1.7.1 Assembly overview - selector d bcables (cable support bracket
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♦ Lubricate bearing positions and sliding surfaces.
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♦ Allocate grease using ⇒ Electronic parts catalogue (ETKA) .
h re
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♦ Do not kink selector cables.
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1 - Gear change cable
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❑ Connect to cable end-
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piece
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⇒ Item 11 (page 157) .
❑ Fitting position
nf
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⇒ page 138
orm
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❑ From 11.06, modified
om
attachment to gear lever
n in
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⇒ Item 8 (page 150)
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2 - Gate change cable
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❑ Connect to cable end- ht. rig
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piece py by
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⇒ Item 10 (page 157) .
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❑ Fitting position
⇒ page 138
❑ From 11.06, modified
attachment to gate se‐
lector lever inside selec‐
tor mechanism
⇒ Item 6 (page 150)
3 - Lock washer
❑ Always renew
❑ Discontinued in selector
mechanisms from 11.06
⇒ page 150
4 - Selector housing
5 - Lock washer
❑ Always renew
❑ Do not damage cables
when removing
6 - Hexagon bolt, 20 Nm
❑ Qty. 3
❑ For cable support bracket
7 - Cable support bracket
❑ Metal
❑ After installing, adjust selector mechanism ⇒ page 168
156 Rep. gr.34 - Controls, housing
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
8 - Grommet
❑ Cable support bracket mounting on gearbox
9 - Spacer
10 - Cable end-piece
❑ After installing, adjust selector mechanism ⇒ page 168
❑ For gate selector cable to relay lever
❑ Do not interchange; cable end-pieces for gate selector cable to relay lever and gear selector cable to
gearbox selector lever are different
❑ Secured with securing clip ⇒ Item 12 (page 157)
❑ Allocation ⇒ page 158 .
11 - Cable end-piece
❑ After installing, adjust selector mechanism ⇒ page 168
❑ For gear selector cable to gearbox selector lever
❑ Do not interchange; cable end-pieces for gate selector cable to relay lever and gear selector cable to
gearbox selector lever are different
❑ Allocation ⇒ page 158 .
12 - Lock washer
cardiagn.com
❑ Always renew
13 - Lock washer
❑ Always renew
14 - Bearing bush
15 - Deflector lever
❑ Metal
❑ Greasing ⇒ page 163 . AG. Volkswagen AG d
agen oes
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❑ Allocation ⇒ Electronic d b parts catalogue .
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❑ Fitting position ⇒utpage
ho
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159 eo
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❑ After installing,s adjust selector mechanism ⇒ page 168
s c
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16 - Slide block
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17 - Lock nut
erm
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ility
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❑ ⇒ Item 9 (page 337)
wit
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18 - Gearbox selector lever
ole,
spec
❑ Greasing ⇒ page 163 .
urposes, in part or in wh
t to the co
❑ Installing ⇒ page 158
❑ Fitting position ⇒ page 159
❑ After installing, adjust selector mechanism ⇒ page 168
rrectne
❑ From 06.06, smaller diameter of support pin for cable end-piece ⇒ page 158
s
❑ Touran, from 02.06, smaller diameter of support pin for cable end-piece ⇒ page 158
s o
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by
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Prote AG.
1. Selector mechanism 157
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
Allocation of cable end-pieces
The holes in the cable end-pieces have different diameters.
Touran, cable end-piece for: Dimension “a”
1 - Gear selector cable to gearbox selector lever 8.5 mm
from 02.06
2 - Gear selector cable to gearbox selector lever 10 mm
through 01.06
n AG. Volkswagen AG do
2 - Gate selector cable to metal relay lever olkswage 8 mm es n
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2 - Gate selector cable to plastic relayiselever
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⇒ page 162 ut
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Golf, Golf Plus, Passat, Eos and Scirocco, cable Dimension “a”
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end-piece for:
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1 - Gear selector cable to gearbox selector lever 8.5 mm
erm
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from 06.06
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2 - Gear selector cable to gearbox selector lever 10 mm
h re
ole,
through 05.06
spec
urposes, in part or in wh
2 - Gate selector cable to metal relay lever 8 mm
t to the co
cardiagn.com
2 - Gate selector cable to plastic relay lever 10 mm
⇒ page 162
rrectne
Smaller diameter of support pin for gear selector cable end-piece
ss
Touran, support pin for gear selector cable end- Dimension “a”
o
cial p
f i
piece
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mer
Through 01.06 10 mm
atio
om
From 02.06 8.5 mm
n
c
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Golf, Golf Plus, Passat, Eos and Scirocco, sup‐ Dimension “a”
iv
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pr
port pin for gear selector cable end-piece
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Through 05.06 10 mm
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Install gearbox selector lever
AG.
– When fitting the gearbox selector lever, ensure that the gap
-arrow A- is aligned with the master spline -arrow B-.
158 Rep. gr.34 - Controls, housing
AG. Volkswagen AG d
agen oes
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Eos 2006 ➤ , Golf 2004 ➤ , Golfd b2009
yV ➤ , Golf Plus 2005 ➤ , Golft gPlus
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6-speed
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Installation position of gearbox selector lever/relay lever
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1- Gearbox selector lever
itte
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erm
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2- Relay lever engages in guide rail of gearbox selector lever
ility
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via shoe -arrow-.
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es, in part or in w
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1.7.2 Assembly overview - selector cables (cable support bracket and plastic re‐
f
en
ng
cardiagn.com
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lay lever) Cop py
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Note
AG.
♦ Lubricate bearing positions and sliding surfaces.
♦ Allocate grease using ⇒ Electronic parts catalogue (ETKA) .
♦ Do not kink selector cables.
1. Selector mechanism 159
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
1 - Selector shaft with selector
shaft cover
2 - Slide block
3 - Deflector lever
❑ Plastic
❑ Greasing ⇒ page 163 .
❑ Allocation ⇒ Electronic
parts catalogue .
❑ Fitting position
⇒ page 161
❑ After installing, adjust
selector mechanism
⇒ page 168
❑ Remove and install
plastic relay lever to‐
gether with cable end-
piece ⇒ page 162
4 - Cable end-piece
❑ After installing, adjust
cardiagn.com
selector mechanism
⇒ page 168
❑ For gate selector cable
to relay lever
❑ Do not interchange; ca‐
ble end-pieces for gate
selector cable to relay
lever and gear selector AG. Volkswagen AG d
cable to gearbox selec‐ agen oes
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tor lever are different d by V gu
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❑ Removing from plastic uthor eo
relay lever ⇒ page 162 ss a ra
c
❑ Pressing onto plastic re‐
ce
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un
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lay lever ⇒ page 162
an
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❑ Allocation ⇒ page 158 .
erm
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ility
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5 - Gearbox selector lever
wit
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❑ Greasing ⇒ page 163 .
ole,
spec
❑ Installing ⇒ page 158
urposes, in part or in wh
t to the co
❑ Fitting position ⇒ page 161
❑ After installing, adjust selector mechanism ⇒ page 168
rrectne
6 - Lock nut
❑ ⇒ Item 9 (page 337)
ss o
7 - Cable end-piece
cial p
f in
❑ After installing, adjust selector mechanism ⇒ page 168
form
mer
❑ For gear selector cable to gearbox selector lever
atio
om
❑ Do not interchange; cable end-pieces for gate selector cable to relay lever and gear selector cable to
c
i
or
gearbox selector lever are different
thi
te
sd
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❑ Allocation ⇒ page 158 .
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8 - Lock washer yi
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❑ Always renew
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❑ Always renew Prote AG.
❑ Do not damage cables when removing
160 Rep. gr.34 - Controls, housing
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
10 - Gear change cable
❑ Connect to cable end-piece ⇒ Item 7 (page 160) .
❑ Fitting position ⇒ page 138
11 - Selector housing
12 - Lock washer
❑ Always renew
13 - Gate change cable
❑ Connect to cable end-piece ⇒ Item 4 (page 160) .
❑ Fitting position ⇒ page 138
14 - Lock washer
❑ Always renew
❑ Do not damage cables when removing
15 - Cable support bracket
❑ Plastic
❑ After installing, adjust selector mechanism ⇒ page 168
16 - Hexagon bolt, 20 Nm
cardiagn.com
❑ Qty. 3
❑ For cable support bracket
17 - Grommet
❑ Qty. 3 n AG. Volkswagen AG do
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❑ Cable support bracket mounting
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18 - Spacer oris tee
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❑ Qty. 3 au ac
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19 - Sealing ring
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❑ Renewing ⇒ Item 6 (page 337)
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20 - Fastener
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❑ ⇒ Relay lever with clip ⇒ page 162
h re
hole
spec
es, in part or in w
t to the co
Installation position of gearbox selector lever/relay lever
1- Gearbox selector lever
rrectness of i
2- Relay lever engages in guide rail of gearbox selector lever
via shoe -arrow-.
l purpos
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at
om
ion
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Prote AG.
1. Selector mechanism 161
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
1.7.3 Plastic relay lever
From 05.07, plastic relay lever
• To remove relay lever, first separate cable end-piece from
gate selector cable.
This will avoid damage to the gate selector cable
cardiagn.com
– Pull locking mechanism forward to stop in
-direction of arrow 1-, and then lock it by turning to left in
-direction of arrow 2-.
– Then push relay lever forwards (-in direction of arrow 3-).
Relay lever with catch -arrow 1- (⇒ previous figure).
– Press catch -arrow 1- (⇒ previous figure) down to stop and
remove relay lever together with cable end-piece. In the proc‐
ess, swing it in direction of operation.
Relay lever with clip -arrow 1-
olksw
– Pull off clip -arrow 1- and remove relay slever
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Cable end-piece must be located
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Continuation for all ss
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• The cable end-piece can be removed only with the relay lever
an
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removed ⇒ page 163 .
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162
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Rep. gr.34 - Controls, housing Prote AG.
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
Gate relay lever: thoroughly grease following areas in particular
prior to installation
• Shaft -A- of gate relay lever -arrows-; amount of grease:
0.2 grams.
• Allocate grease using ⇒ Electronic parts catalogue (ETKA) .
Gearbox selector lever: thoroughly grease following areas in par‐
ticular prior to installation
• Guide rail -B- of gearbox selector lever into which gate relay
lever engages.
• Support pin for cable end-piece.
• Allocate grease using ⇒ Electronic parts catalogue
agen
(ETKA)
AG. Volksw. agen AG d
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olks
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• Illustration of gate relay lever and gearboxd b selector lever may
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ac
– Press cable end-piece onto relay
ss lever ⇒ page 164 .
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1. Selector mechanism 163
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
Pressing on cable end-piece
• Relay lever has been removed
• Cable end-piece may be pressed only onto bush -arrow-.
• Cable end-piece must move freely on relay lever.
• It must be located behind catch -arrow 2- ⇒ page 162 .
1.8 Removing and installing selector mech‐
anism
Removing
Special tools and workshop equipment required
♦ Torque wrench - V.A.G 1331-
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– Remove securing bracket for centre console, remove footwell
es, in part or in w
trim from centre console and ashtray or storage compartment
t to the co
for this ⇒ General body repairs, interior; Rep. gr. 68 ; Com‐
partments, covers and trims; Removing and installing centre
console .
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Golf 2009 ►
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– Remove ashtray or storage compartment from centre console
⇒ General body repairs, interior; Rep. gr. 68 ; Compartments,
nf
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covers and trims; Removing and installing centre console .
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164 Rep. gr.34 - Controls, housing
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
The rear footwell duct runs over the centre console securing
bracket on some models.
– Remove rear footwell ducts ⇒ Heater; Rep. gr. 80 , remove
centre console for this ⇒ General body repairs, interior; Rep.
gr. 68 ; Compartments, covers and trims; Removing and in‐
stalling centre console .
Continuation for all Golf 2009 ►
– Remove nuts for centre console securing bracket ⇒ General
body repairs, interior; Rep. gr. 68 ; Compartments, covers and
trims; Removing and installing centre console .
– Remove nuts from selector housing ⇒ page 165 .
– Lower selector housing.
• If the selector housing cannot be lowered, the securing nuts
for the selector housing are under the centre console securing
bracket.
• The securing bracket for the centre console must then be re‐
moved ⇒ General body repairs, interior; Rep. gr. 68 ; Com‐
partments, covers and trims; Removing and installing centre
console .
cardiagn.com
Golf Plus
– Remove upper parts and, if necessary, securing brackets for
centre console ⇒ General body repairs, interior; Rep. gr. 68 ;
Compartments, covers and trims; Removing and installing
centre console
Touran
– Remove ashtray or storage compartment from centre console
⇒ General body repairs, interior; Rep. gr. 68 ; Compartments,
covers and trims; Removing and installing front centre con‐
sole .
Vehicles where centre console securing brackets cannot be re‐
moved as a separate component:
Volkswa AG. gen AG
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– Remove centre olksconsole, ⇒ General body
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t gu interior;
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Continuation
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– If present, remove interior monitoring sensor - G273- from rear
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securing nuts ⇒ Electrical system; Rep. gr. 96 .
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Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
– Remove complete air filter housing if it is over selector mech‐
anism ⇒ Rep. gr. 23 ; Repairing diesel direct injection system
or ⇒ Rep. gr. 24 ; Repairing injection system .
– Remove securing clip -3- for gear selector cable from gearbox
selector lever -1-.
– Pull gear selector cable off pin.
Metal relay lever
– Remove securing clip -4- for gate selector cable from relay
lever -2-.
– Pull gate selector cable from pin.
Plastic relay lever
Releasing cable end-piece from gate selector cable
– Pull locking mechanism forward to stop in
-direction of arrow 1-, and then lock it by turning to left in
-direction of arrow 2-.
– Then push relay lever forwards (-in direction of arrow 3-).
cardiagn.com
– Remove relay lever and cable end-piece together
⇒ page 162 . agen
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– Remove cable support bracket from gearbox -arrows-.
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– Remove noise insulation ⇒ General body repairs, exterior;
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Rep. gr. 50 ; Noise insulation
spec
urposes, in part or in wh
– Remove underbody panels ⇒ General body repairs, exterior;
t to the co
Rep. gr. 50 .
– Remove tunnel cross members with exhaust pipe in the fore
rrectne
area below the selector mechanism ⇒ Rep. gr. 26 ; Exhaust
system .
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– Unhook rear exhaust system and remove front heat shield ⇒
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inform
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– Swing selector lever housing down and remove with selector
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166 Rep. gr.34 - Controls, housing
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
– Route cables -1- from selector mechanism -2- to gearbox as
follows:
• Bowden cables must lie parallel to each other and must not
cross.
• Bowden cables must be laid in the intended indentation in heat
shield -3-.
Note
In the close-up, the heat shield is shown from above.
Clip -A- holds cables and heat shield together in position.
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lever -1- and relay lever -2-.
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– Renew securing clip -3- and, for metal relay lever, securing
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clip -4- each time they are removed.
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– Secure gear selector cable with securing clip -3- and gate se‐
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lector cable with securing clip -4-.
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Cable end-piece to plastic relay lever
– Fit relay lever and cable end-piece together ⇒ page 162 .
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– Insert gate selector cable in cable end-piece.
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1. Selector mechanism 167
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
Continued for all selector mechanisms
– If present, place interior monitoring sensor - G273- on rear
securing nuts ⇒ Electrical system; Rep. gr. 96 .
– Install centre console securing bracket and centre console ⇒
General body repairs, interior; Rep. gr. 68 ; Compartments,
covers and trims .
– Renew clamp -arrow-.
– Install gaiter with gear knob and noise insulation, Passat
⇒ page 144 , Golf, Eos and Scirocco ⇒ page 141 , Golf Plus
⇒ page 142 .
– Install underbody panels ⇒ General body repairs, exterior;
Rep. gr. 50 .
– Assemble exhaust system free of tension and attach tunnel
cross-piece ⇒ Rep. gr. 26 ; Exhaust system .
Adjust selector mechanism ⇒ page 168 .
– If removed, install complete air filter housing ⇒ Rep. gr. 23 ;
Repairing diesel direct injection system or ⇒ Rep. gr. 24 ;
Repairing injection system
cardiagn.com
– Follow procedure after connecting battery ⇒ Electrical system;
Rep. gr. 27 ; Battery; Disconnecting and connecting battery .
1.8.1 Torque settings
Component Nm
Selector housing to body Nuts M8 = 8
Nuts M6 = 25
Cable support bracket to gear‐ 20 Nm
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168 Rep. gr.34 - Controls, housing
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
Note
♦ The following points are essential to ensure correct adjust‐
ment of selector mechanism:
♦ Moving parts of operating elements and elements transferring
force must be in proper condition.
♦ Selector mechanismwamust
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– Remove air filter housing if it blocks access to angled rod for
itte
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fixing selector shaft and to securing mechanism for gear se‐
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lector cable and gate selector cable ⇒ Rep. gr. 23 ; Repairing
ot
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diesel direct injection system or ⇒ Rep. gr. 24 ; Repairing
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injection system .
hole
spec
– Pull locking mechanisms on gate selector cable and gear se‐
es, in part or in w
t to the co
lector cable end-pieces forward to stop -direction of arrow 1-
cardiagn.com
and then turn to left to lock -direction of arrow 2-.
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selector shaft.
AG.
– Remove gaiter and, if present, noise insulation from frame for
centre console, Passat ⇒ page 144 , Golf, Eos and Scirocco
⇒ page 141 , Golf Plus ⇒ page 142 , Touran ⇒ page 145
– If noise insulation is present, remove it.
Set gear stick as follows:
– Select neutral using gear lever.
– Guide locking pin - T10027 A- through hole -A- into hole -B-.
1. Selector mechanism 169
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
– Check that gate and selector cables -B- are inserted, free of
tension, into locking devices -A-.
– Now turn locking mechanisms on gear selector cable and gate
selector cable end pieces clockwise to stop
-direction of arrow 1-.
The spring presses the locking mechanism into original position
-direction of arrow 2-.
– Now turn angled rod -A- back to original position
-direction of arrow-.
Note
The angled rod -A- must be pressed out of selector housing to
stop and point straight up. swa
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– Pull locking pin out of holes -A- and -B-.
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– Install gaiter and, if it was removed, noise insulation, Passat
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⇒ page 144 , Golf, Eos and Scirocco ⇒ page 141 , Golf Plus
h re
hole
⇒ page 142 , Touran ⇒ page 145 .
spec
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– Check that selector shaft moves freely.
t to the co
– Check operation of selector mechanism ⇒ page 170 .
– If removed, install complete air filter housing ⇒ Rep. gr. 23 ;
rrectness of i
Repairing diesel direct injection system or ⇒ Rep. gr. 24 ;
l purpos
Repairing injection system
nform
mercia
1.9.1 Functional check
at
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• With gearbox in neutral, gear lever must rest in gate for 3rd
o
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and 4th gears.
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attempts, repeat adjustment procedure of selector mechanism
AG.
⇒ page 168 .
170 Rep. gr.34 - Controls, housing
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
2 Removing and installing gearbox
⇒ “2.1 Removing and installing gearbox, Touran (except vehicles
with 1.2 l engine)”, page 171
⇒ “2.2 Removing and installing gearbox, Touran (only vehicles
with 1.2 l engine)”, page 185
⇒ “2.3 Removing and installing gearbox, Golf 2004 ►”,
page 200
⇒ “2.4 Removing and installing gearbox, Golf 2009 ► with 1,2 l
engine”, page 214
⇒ “2.5 Removing and installing
AG. Vgearbox, Golf 2009 ► with 1.4 l
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engine and Passat o2011 agen
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⇒ “2.6 Removingise and installing gearbox, Golf Plus with
d ran 1,2 l en‐
tee
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h248
u or
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⇒ “2.7 Removing and installing gearbox, Golf Plus with 1,4 l en‐
ce
le
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gine”, page 261
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⇒ “2.8 Removing and installing gearbox, Passat 2006 ► and Eos”,
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page 277
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⇒ “2.9 Removing and installing gearbox - Scirocco”, page 289
h re
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2.1 Removing and installing gearbox, Tour‐
urposes, in part or in wh
t to the co
an (except vehicles with 1.2 l engine)
⇒ “2.1.1 Removing gearbox”, page 173
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⇒ “2.1.2 Installing gearbox”, page 178
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Way to tell difference on vehicles: headlight contour has been
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In this connection, the bolting surface of the wings (required for
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Special tools and workshop equipment required
♦ To 11.06: small headlights -arrow 1-: adapter - 10-222A/22-
⇒ page 175 .
2. Removing and installing gearbox 171
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
♦ From 11.06 to 05.10: large headlights with curvature
-arrow 2-: adapter - 10-222A/26- ⇒ page 175 .
♦ Support - 10-222 A-
♦ Gearbox support - 3282-
♦ Adjustment plate - 3282/31-
♦ Support elements for gear‐
box (determine when set‐
cardiagn.com
ting adjustment plate on
gearbox support )
♦ Gearbox lifting tackle -
3336- for transporting gear‐
box
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172
AG.
Rep. gr.34 - Controls, housing
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
♦ Torque wrench - V.A.G
1331-
♦ Torque wrench - V.A.G
1332-
♦ Engine and gearbox jack -
V.A.G 1383 A-
♦ Grease for splines
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2.1.1 Removing gearbox
AG.
– First check whether a coded radio is fitted. If so, obtain anti-
theft code.
– Disconnect battery earth strap ⇒ Electrical system; Rep. gr.
27 ; Disconnecting and reconnecting battery .
– Remove engine cover with air filter ⇒ Rep. gr. 24 ; Repairing
injection system; Removing and installing air filter housing .
– Remove camshaft housing cover if lifting eye -arrow- is not
accessible ⇒ Rep. gr. 15 ; Cylinder head, valve gear .
– Remove battery and battery tray ⇒ Electrical system; Rep. gr.
27 ; Battery; Removing and installing battery .
– Remove securing clip -arrow 1- for gear selector cable from
gearbox selector lever -A-.
2. Removing and installing gearbox 173
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
– Pull gear selector cable off pin.
Metal relay lever
– Remove securing clip -arrow 2- for gate selector cable from
relay lever -B-.
– Pull gate selector cable from pin.
– Pull securing clip -arrow 3- off relay lever -B- and remove relay
lever.
Plastic relay lever
– Remove relay lever together with cable end-piece
⇒ page 162 .
Continuation for all
– Remove gearbox selector lever -A- by removing nut
-arrow 4-.
– Remove cable support bracket from gearbox -arrows-.
cardiagn.com
– Then raise and secure gear selector cable and gate selector
cable.
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– Pull pipe/hose line -A- out of support -B- on gearbox.
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– Remove slave cylinder -arrows-, lay to side and secure with
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Caution
Do not operate clutch pedal any more.
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– Gearboxes for vehicles with start-stop system: pull connector
com
tio
-arrow- off gearbox neutral position sender - G701- .
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– Remove earth strap at upper engine/gearbox connecting bolt.
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– Remove upper engine/gearbox connecting bolts.
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– Then remove upper securing bolt on starter. t. Cop py
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– Remove both foam pieces from upper edge of left and right yri
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Prote AG.
– If there are hose and cable connections in area of engine sup‐
port eyes for support bracket - 10-222 A- , remove these now.
174 Rep. gr.34 - Controls, housing
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
To 11.06: vehicles with small headlights
– Place support bracket - 10-222 A- with adapters - 10-222 A/
22- behind bonnet stay.
From 11.06 to 05.10: vehicles with large headlights with curvature
– Place support bracket - 10-222A- with adapters - 10-222A/26-
behind bonnet stay.
Continuation for all
– Take up weight of engine/gearbox assembly on spindles.
– Raise vehicle on lift.
cardiagn.com
– Remove noise insulation ⇒ General body repairs, exterior;
Rep. gr. 50 ; Noise insulation; Assembly overview - noise in‐
sulation .
– Remove front left wheel housing liner ⇒ General body repairs,
exterior; Rep. gr. 66 ; Removing and installing wheel housing
liner; Front wheel housing liner.
– Pull off connector -1- for reversing light switch - F4- .
– Remove nut -2-.
– Remove starter (bolt -3-) ⇒ Electrical system; Rep. gr. 27 ;
Starter; Removing and installing starter, manual gearbox .
AG. Volkswagen AG d
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– Remove drive shaft heat shield, if present -arrows- ⇒ Running
rm
ab
gear, axles, steering; Rep. gr. 40 ; Repairing drive shafts; Re‐
pe
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moving and installing drive shafts .
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– Separate exhaust system at flange and unbolt exhaust pipe
hole
spec
bracket from subframe ⇒ Rep. gr. 26 ; Exhaust system .
es, in part or in w
t to the co
– Remove drive shafts from flange shafts, raise as high as pos‐
sible and secure. Do not damage the surface protection ⇒
Running gear, axles, steering; Rep. gr. 40 ; Repairing drive
rrectness of i
shafts; Removing and installing drive shafts .
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Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
– Remove engine/gearbox connecting bolt -A- above right
flange shaft.
– Remove pendulum support, remove bolts -arrows A, B- and
-C- for this.
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– Remove gearbox bracket by removing bolts -arrows 2-.
AG.
Gearbox support - 3282- is aligned with adjustment plate -
3282/31- for removal of gearbox.
– Insert gearbox support - 3282- in engine and gearbox jack -
V.A.G 1383 A- .
– Fit adjustment plate - 3282/31- on gearbox support - 3282-
( adjustment plate fits in only one position).
– Align arms of gearbox support according to holes in adjust‐
ment plate .
176 Rep. gr.34 - Controls, housing
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
– Attach support elements -A- to adjustment plate as illustrated.
– Screw in support hook - 3282/49- instead of support element
-C-.
– Position engine and gearbox jack under vehicle. Arrow -B- on
adjustment plate points in direction of vehicle travel.
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– Insert support hook - 3282/49- in notch in differential below
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flange shaft -arrow-.
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figure).
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– Press gearbox off dowel sleeves.
– Observe intermediate plate on engine.
– Have a second mechanic press engine forwards.
2. Removing and installing gearbox 177
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
– Turn gearbox downwards and towards front end by lowering
near 6th gear cover as shown -arrow 1-.
– At the same time, ensure that engine/gearbox connecting
bolts -arrow 2- contact exhaust system.
– Then carefully guide gearbox with right flange shaft -A- past
flywheel and intermediate plate as shown.
– Lower gearbox being careful of subframe.
– When lowering gearbox, change position of gearbox using
spindles of gearbox support - 3282- .
Note
cardiagn.com
Be careful of all lines when lowering gearbox.
2.1.2 Installing gearbox
Note
Refer to procedure “Removing gearbox” for required special tools
⇒ page 171 .
– All threaded holes into which self-locking bolts are to be . Volkswagen AG
screwed must be cleaned of residual locking fluid with aathread
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– Check whether dowel sleeves for aligning s engine and gearbox
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– Ensure that intermediate plate is correctly seated on engine.
hole
spec
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– Clean input shaft splines and apply thin coat of grease for
t to the co
clutch plate splines .
The clutch plate must slide easily to and fro on the input shaft.
rrectness of i
Gearbox support - 3282- is aligned with adjustment plate -
3282/31- for installation of gearbox.
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V.A.G 1383 A- .
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– Fit adjustment plate - 3282/31- on gearbox support - 3282-
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Rep. gr.34 - Controls, housing Prote
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Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
– Screw in support elements -A- to adjustment plate as illustra‐
ted.
– Screw in support hook - 3282/49- instead of support element
-C-.
– Place gearbox on engine and gearbox jack .
– Insert support hook - 3282/49- in notch in differential below
flange shaft -arrow-.
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– Align adjustment plate and gearbox parallel to one another.
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– Position engine and gearbox jack under vehicle. Arrow -B- on
adjustment plate points in direction of vehicle travel.
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– Using spindles of gearbox support - 3282- , tilt gearbox in vi‐
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2. Removing and installing gearbox 179
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
– Turn gearbox upwards in vicinity of 6th gear cover as shown
-arrow 1- and towards subframe.
– At the same time, ensure that engine/gearbox connecting
bolts -arrow 2- contact exhaust system.
• The gearbox must be aligned parallel to the engine.
– Insert gearbox while screwing in bolts -arrow- and tighten to
specified torque ⇒ page 184 .
– Screw in connecting bolt for engine and gearbox -arrow- and
tighten to specified torque ⇒ page 184 .
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– Then screw in lower connecting bolts for engine and gearbox
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-arrows- and tighten to specified torque ⇒ page 184 .
– After gearbox has been bolted to engine, remove engine and
rrectness of i
gearbox jack from gearbox.
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– Align engine and gearbox in installation position. To do this,
tighten both spindles on the support bracket - 10-222 A- .
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– Now install hexagon bolts -arrows- for engine mounting in right
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180 Rep. gr.34 - Controls, housing
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
– Install slave cylinder -1- and tighten bolts to specified torque
⇒ Item 9 (page 130) .
– Press pipe/hose assembly -A- into retainer -B- on gearbox.
– Install left assembly mounting -2- using new hexagon bolts
-arrows- and tighten to specified torque ⇒ page 184 .
WARNING
Do not remove support bracket - 10-222 A- until the bolts se‐
curing the left and right assembly mountings have been tight‐
ened to specified torque.
– Remove both foam pieces from upper edge of left and right
wings ⇒ Body, front; Rep. gr. 50 .
– Install earth strap at upper engine/gearbox connecting bolt.
– Insert upper engine/gearbox securing bolts and tighten to tor‐
que specification ⇒ page 184 .
– Install pendulum support -arrows A, B- and -C- ⇒ Running
cardiagn.com
gear, axles, steering; Rep. gr. 40 ; Torque settings for front
axle .
– Use new bolts for securing.
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Installs engine and gearbox mounting free of tension ⇒ Rep.
s c gr.
10 ; Removing and installing engine .
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– Attach drive shafts to gearbox ⇒ Running gear, axles, steer‐
erm
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ing; Rep. gr. 40 ; Repairing drive shaft; Removing and instal‐
ot p
ling drive shafts .
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– Install drive shaft heat shield, if present -arrows- ⇒ Running
urposes, in part or in wh
gear, axles, steering; Rep. gr. 40 ; Repairing drive shafts; Re‐
t to the co
moving and installing drive shafts .
– Assemble exhaust system without stresses ⇒ Rep. gr. 26 ;
rrectne
Exhaust system .
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– Install starter with bolt -3- and nut -2- ⇒ Electrical system; Rep.
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gr. 27 ; Starter; Removing and installing starter, manual gear‐
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– Push connector -1- onto reversing light switch - F4- .
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2. Removing and installing gearbox 181
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
– Gearboxes for vehicles with start-stop system: join connector
-arrow- to gearbox neutral position sender - G701- .
– Check for correct installation position of vacuum hose for
brake system, install vacuum hose if necessary ⇒ Rep. gr.
47 .
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– Install cable support bracket on gearbox and tighten bolts
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-arrows- to specified torque ⇒ Item 6 (page 156) .
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182 Rep. gr.34 - Controls, housing
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
– Install gearbox selector lever -A- ⇒ page 158 and tighten nut
-arrow 4- to specified torque ⇒ Item 9 (page 337) .
Metal relay lever
Note
♦ When installing, lubricate bearing positions and sliding surfa‐
ces.
♦ Allocate grease using ⇒ Electronic parts catalogue (ETKA) .
– Insert relay lever -B- into mounting of selector cover.
– At the same time, swing relay lever so that shoe engages in
guide of gearbox selector lever.
– Secure relay lever with new securing clip -arrow 3-.
Plastic relay lever
– Install relay lever together with cable end-piece ⇒ page 162 .
Continuation for all
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– Spread a small amount of grease on pin of gearbox
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– Connect gear selector cable to sgearbox selector lever
ce
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-arrow 1-.
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– Adjust selector mechanism ⇒ page 168 .
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– Check gear oil ⇒ page 306 .
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Gear oil ⇒ Electronic Parts Catalogue “ETKA” .
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spec
urposes, in part or in wh
– Install front left wheel housing liner ⇒ General body repairs,
t to the co
exterior; Rep. gr. 66 ; Removing and installing wheel housing
liners; Front wheel housing liners .
– Install noise insulation ⇒ General body repairs, exterior; Rep.
gr. 50 ; Noise insulation; Assembly overview - noise insula‐ rrectne
tion .
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– Set both foam pieces on upper edge of left and right wings ⇒
cial p
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Body, front; Rep. gr. 50 .
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– If camshaft housing cover was removed, install it ⇒ Rep. gr.
atio
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15 ; Cylinder head, value gear .
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– Install engine cover with air filter ⇒ Rep. gr. 24 ; Repairing
t
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injection system; Removing and installing air filter housing .
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– Install battery tray, battery cover and battery ⇒ Electrical sys‐
en
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tem; Rep. gr. 27 ; Removing and installing battery . t. Cop py
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– Follow procedure after connecting battery ⇒ Electrical system; yri
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Rep. gr. 27 ; Battery; Disconnecting and connecting battery .
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Prote AG.
2. Removing and installing gearbox 183
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
2.1.3 Torque settings
Gearbox to engine with 2 bolts in upper area of clutch housing.
Item Bolt Quantity Nm
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5 M 10 x 60 2 40
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Item -A- dowel sleeves for centring
Gearbox to engine with 3 bolts in upper area of clutch housing.
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Item Bolt Quantity Nm
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1 M12 x 65 3 80
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Item -A- dowel sleeves for centring Prote AG.
Gearbox bracket to gearbox
– Renew bolts.
Bolts -arrows 2- 40 Nm + 90°
Gearbox bracket to body
– Renew bolts.
Bolts -arrows 1- 60 Nm + 90°
Note
Install engine and gearbox mounting free of tension ⇒ Rep. gr.
10 ; Removing and installing engine .
Pendulum support to subframe and gearbox ⇒ Running gear,
axles, steering; Rep. gr. 40 ; Torque settings for front axle .
Drive shaft to flange shaft ⇒ Running gear, axles, steering; Rep.
gr. 40 ; Repairing drive shaft; Removing and installing drive
shafts .
Assemble exhaust pipe without stresses ⇒ Rep. gr. 26 ; Exhaust
system .
184 Rep. gr.34 - Controls, housing
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
2.2 Removing and installing gearbox, Tour‐
an (only vehicles with 1.2 l engine)
⇒ “2.2.1 Removing gearbox”, page 188
⇒ “2.2.2 Installing gearbox”, page 194
• -Arrow 1- can be disregarded!
Way to tell difference on vehicles: headlight contour has been
modified
In this connection, the bolting surface of the wings (required for
supporting the adapters for the support bracket - 10-222A- ) has
been modified.
Therefore, the adapters have been modified.
It is essential to watch out for the different adapters .
cardiagn.com
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♦ From 11.06 to 05.10: large headlights with curvature
an
d
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-arrow 2-: adapter - 10-222A/26- ⇒ page 190 .
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2. Removing and installing gearbox 185
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
From 06.10: Large headlights without round profile -arrow 3-
adapter - 10-222A/8- ⇒ page 190
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186 Rep. gr.34 - Controls, housing
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009
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♦ Gearbox lifting tackle -
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2. Removing and installing gearbox 187
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
♦ Torque wrench - V.A.G
1331-
♦ Torque wrench - V.A.G
1332-
♦ Engine and gearbox jack -
V.A.G 1383 A-
♦ Grease for splines
♦ Allocate grease using ⇒
Electronic parts catalogue
(ETKA) .
♦ Allocate grease using ⇒
Electronic parts catalogue
(ETKA) .
AG. Volkswagen AG d
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At a later point, support bracket - 10-222 A- will be put onto lon‐
gitudinal members with adapters - 10 - 222 A /8- .
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cover indicated area of both adapters - 10 - 222 A /8- with self-
his
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adhesive fabric tape -arrows- ⇒ Electronic Parts Catalogue
do
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2.2.1 Removing gearbox
– First check whether a coded radio is fitted. If so, obtain anti-
theft code.
– Disconnect battery earth strap ⇒ Electrical system; Rep. gr.
27 ; Disconnecting and reconnecting battery .
– If the lifting eyes of the engine for support bracket - 10 - 222
A- are blocked by the cover or the air filter, it must be removed
188 Rep. gr.34 - Controls, housing
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
now. ⇒ Rep. gr. 23 ; Repairing diesel direct injection system
or ⇒ Rep. gr. 24 ; Repairing injection system
– Remove complete air filter housing if it is over the gearbox ⇒
Rep. gr. 23 ; Repairing diesel direct injection system or ⇒
Rep. gr. 24 ; Repairing injection system
– Remove battery and battery tray ⇒ Electrical system; Rep. gr.
27 ; Battery; Removing and installing battery .
– Remove securing clip -arrow 1- for gear selector cable from
gearbox selector lever -B-.
– Pull gear selector cable off pin.
– Remove relay lever -A- together with cable end-piece
⇒ page 162 .
– Remove gearbox selector lever -B- by removing nut
-arrow 2-.
cardiagn.com
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– Remove cable support bracket from gearbox -arrows-.
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– Then raise and secure gear selector cableautand gate selector
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– Pull line between master and slave cylinders -A- out of support
-B-, if present, on gearbox.
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2. Removing and installing gearbox 189
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
– Gearboxes for vehicles with start-stop system: pull connector
-arrow- off gearbox neutral position sender - G701- .
– Remove earth strap at upper securing bolt for starter or at
subframe.
– Remove upper securing bolt from starter.
– Remove upper engine/gearbox connecting bolts.
– If there are hose and cable connections in area of engine sup‐
port eyes for support bracket - 10 - 222 A- , remove these now.
From 11.06 to 05.10: vehicles with large headlights with curvature
– Place support bracket - 10-222A- with adapters - 10-222A/26-
behind bonnet stay.
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-arrow- on bolt-on surface for wing.
– Bolt together support bracket - 10-222A- and adapter -
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10-222A/8- with hexagon bolt -B-.
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-B- = Hexagon bolt M12 X 60, commercially available with washer
– Connect support bracket - 10-222A- to engine.
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– Take up weight of engine/gearbox assembly on spindles.
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– Raise vehicle on lift.
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– Remove noise insulation ⇒ General body repairs, exterior;
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– Remove front left wheel housing liner ⇒ General body repairs, C py
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exterior; Rep. gr. 66 ; Wheel housing liner .
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190 Rep. gr.34 - Controls, housing
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
– Pull off connector -1- for reversing light switch - F4- .
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– Remove nut -2- if present.
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– Remove starter,
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Starter . auth or
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– Unbolt exhaust pipe from engine ⇒ Rep. gr. 26 ; Exhaust
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– Separate exhaust system -arrows 1- and remove exhaust pipe
bracket from subframe -arrows 2- ⇒ Rep. gr. 26 ; Exhaust
system .
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sible and secure. Do not damage the surface protection ⇒ Prote AG.
Running gear, axles, steering; Rep. gr. 40 ; Repairing drive
shafts; Removing and installing drive shafts .
– Remove pendulum support.
2. Removing and installing gearbox 191
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
– Remove hexagon bolts -arrows 1- for left assembly mounting
from gearbox mounting.
– Tilt engine/gearbox assembly by lowering it via spindles of
support bracket - 10-222 A- .
Note
Be careful of all lines when lowering gearbox.
– Remove gearbox bracket by removing bolts -arrows 2-.
– For vehicles with a sheet metal sump, remove cover plate near
sump.
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frame.
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spec
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-2- = Flange bolt M6 x 20.
– Secure engine support - 3300 A- to bracket .
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Place a cloth between engine support - 3300 A- and oil pan.
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Gearbox support - 3282- is aligned with adjustment plate -
Prote AG.
3282/31- for removal of gearbox.
– Insert gearbox support - 3282- in engine and gearbox jack -
V.A.G 1383 A- .
– Fit adjustment plate - 3282/31- on gearbox support - 3282-
( adjustment plate fits in only one position).
– Align arms of gearbox support according to holes in adjust‐
ment plate .
192 Rep. gr.34 - Controls, housing
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
– Attach support elements -A- to adjustment plate as illustrated.
– Screw in support hook - 3282/49- instead of support element
-C-.
– Position engine and gearbox jack under vehicle. Arrow -B- on
adjustment plate points in direction of vehicle travel.
– Align adjustment plate parallel to gearbox. agen
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– Insert support hook - 3282/49- in one of the recesses in dif‐
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– Remove engine/gearbox connecting bolt (-arrow- in previous
figure).
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2. Removing and installing gearbox 193
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
– Press gearbox off dowel sleeves.
– Press gearbox with 6th gear cover towards front -arrow 1- and
turn it downwards slightly -arrow 2-.
– Observe intermediate plate on engine.
– Then carefully guide gearbox with right flange shaft -A- past
flywheel -B- and intermediate plate as shown.
cardiagn.com
– Carefully guide left flange shaft -A- past subframe bracket
-B- as shown.
– Lower gearbox being careful of subframe.
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2.2.2 Installing gearbox
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Refer to procedure “Removing gearbox” for required special tools
⇒ page 185 .
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– All threaded holes into which self-locking bolts are to be
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– Ensure that intermediate plate is correctly seated on engine.
194 Rep. gr.34 - Controls, housing
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
– Clean input shaft splines and apply thin coat of grease for
clutch plate splines .
The clutch plate must slide easily to and fro on the input shaft.
– If present, unbolt left securing bolt for heat shield -1- from sub‐
frame.
– Attach bracket - T10346- or -T10346/1- with bolt -2- in left n AG. Volkswagen AG do
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– Press engine forwards using spindle of engine support - 3300
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Gearbox support - 3282- is aligned with adjustment plate -
3282/31- for installation of gearbox.
– Insert gearbox support - 3282- in engine and gearbox jack -
V.A.G 1383 A- .
– Fit adjustment plate - 3282/31- on gearbox support - 3282-
( adjustment plate fits in only one position).
– Align arms of gearbox support according to holes in adjust‐
ment plate .
– Screw in support elements -A- to adjustment plate as illustra‐
ted.
– Screw in support hook - 3282/49- instead of support element
-C-.
2. Removing and installing gearbox 195
AG. Volkswagen AG d
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– Place gearbox on engine and gearbox
ss jack .
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– Insert support hook - 3282/49- in one of the recesses in dif‐
pt
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ferential below flange shaft -arrow-.
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– Position engine and gearbox jack under vehicle. Arrow -B- on
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adjustment plate points in direction of vehicle travel.
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– Using spindles of gearbox support - 3282- , tilt gearbox in vi‐
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Be careful of all lines when installing gearbox.
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– Carefully guide gearbox with right flange shaft -A- past fly‐
wheel -B- and intermediate plate as shown.
– Carefully guide left flange shaft -A- past subframe bracket
-B- as shown.
– Turn gearbox to installation position.
• The gearbox must be aligned parallel to the engine.
– Insert gearbox.
196 Rep. gr.34 - Controls, housing
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– Screw in connecting bolt for engine and gearbox -arrow- and
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tighten to specified torque ⇒ page 200 .
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– Then screw in lower connecting bolts for engine and gearbox
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-arrows- and tighten to specified torque ⇒ page 200 .
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– After bottom of gearbox and engine are bolted together, re‐
n
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– Remove engine support - 3300 A- and bracket .
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– Screw in all lower engine/gearbox connecting bolts and tighten
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them to specified torque ⇒ page 200 .
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– For vehicles with a sheet metal sump, fit cover plate near sump
-arrows- ⇒ page 200 .
– Align engine and gearbox in installation position.
– Install slave cylinder -1- and tighten bolts to specified torque
⇒ Item 9 (page 130) .
– Press pipe/hose assembly -A- into retainer -B- on gearbox.
– Install left assembly mounting -2- using new hexagon bolts
-arrows- and tighten to specified torque ⇒ page 200 .
WARNING
Do not remove support bracket - 10 - 222 A- until the bolts
securing the left and right assembly mountings have been
tightened to specified torque.
– Insert upper engine/gearbox securing bolts and tighten to tor‐
que specification.
2. Removing and installing gearbox 197
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
– Install starter bolt -3- and, if present, nut -2- ⇒ Electrical sys‐
tem; Rep. gr. 27 ; Starter .
– Push connector -1- onto reversing light switch - F4- .
– Install pendulum support ⇒ Running gear, axles, steering;
Rep. gr. 40 ; Assembly overview - Subframe, anti-roll bar,
suspension links .
– Use new bolts for securing.
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Install engine and gearbox mounting free of tension ⇒ Rep. gr.
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10 ; Removing and installing engine .
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– Reassemble exhaust system ⇒ Rep. gr. 26 ; Exhaust system .
ility
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– Attach drive shafts to gearbox ⇒ Running gear, axles, steer‐
h re
hole
ing; Rep. gr. 40 ; Repairing drive shaft; Removing and instal‐
spec
ling drive shafts .
es, in part or in w
t to the co
– Attach connector -1- to oil level and oil temperature sender -
G266- .
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-arrow- to gearbox neutral position sender - G701- .
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– Attach vacuum hose from brake servo to engine ⇒ Rep. gr.
t.
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47 . t. Cop py
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Prote AG.
198 Rep. gr.34 - Controls, housing
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
– Install cable support bracket on gearbox and tighten bolts
-arrows- to specified torque ⇒ Item 6 (page 156) .
– Install gearbox selector lever -B- and tighten hexagon nut
-arrow 2- to specified torque ⇒ Item 17 (page 157) .
– Install relay lever -A- together with cable end-piece
⇒ page 162 .
– Spread a small amount of grease on pin of gearbox selector
lever -B-.
Allocate grease using ⇒ Electronic parts catalogue (ETKA) .
cardiagn.com
– Connect gear selector cable to gearbox selector lever
-arrow 1-.
– Adjust selector mechanism ⇒ page 168 .
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– If corrosionoris protection was damaged, repair usinganmaterials
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– Install lower part of front left wheel housing liner ⇒ General
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body repairs, exterior; Rep. gr. 66 ; Wheel housing liner .
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– Install noise insulation ⇒ General body repairs, exterior; Rep.
ab
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gr. 50 ; Noise insulation .
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– If camshaft housing cover was removed, install it ⇒ Rep. gr.
h re
ole,
15 ; Cylinder head, value gear .
spec
urposes, in part or in wh
– If removed, reinstall engine cover and air filter housing ⇒ Rep.
t to the co
gr. 23 ; Repairing diesel direct injection engine or ⇒ Rep. gr.
24 ; Repairing injection system
rrectne
– Install battery tray, battery cover and battery ⇒ Electrical sys‐
tem; Rep. gr. 27 ; Removing and installing battery .
ss
– Follow procedure after connecting battery ⇒ Electrical system;
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Rep. gr. 27 ; Battery; Disconnecting and connecting battery .
inform
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2. Removing and installing gearbox 199
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
2.2.3 Torque settings
Gearbox to engine
Item Bolt Quantity Nm
1 M12 x 50 3 80
2 M12 x 55 1 80
♦ Starter to gearbox
3 M12 x 150 1 80
♦ Additionally, start‐
er to gearbox
4 M12 x 60 2 80
5 M 10 x 30 2 40
Item -A- dowel sleeves for centring
Gearbox bracket to gearbox
– Renew bolts.
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Install engine and gearbox mounting free of tension ⇒ Rep. gr.
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10 ; Removing and installing engine .
spec
es, in part or in w
t to the co
Pendulum support to subframe and gearbox ⇒ Running gear,
axles, steering; Rep. gr. 40 ; Assembly overview - subframe, anti-
roll bar, suspension links .
rrectness of i
Drive shaft to flange shaft ⇒ Running gear, axles, steering; Rep.
l purpos
gr. 40 ; Repairing drive shaft; Removing and installing drive
shafts .
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Exhaust system ⇒ Rep. gr. 26 ; Exhaust system .
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⇒ “2.3.2 Installing gearbox”, page 207 t. Cop py
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200 Rep. gr.34 - Controls, housing
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
Special tools and workshop
equipment required
♦ Support - 10 - 222 A-
♦ Adapter - 10 - 222 A /8-
♦ Gearbox support - 3282-
♦ Adjustment plate - 3282/31-
♦ Support elements for gear‐
box (determine when set‐
ting adjustment plate on
gearbox support )
♦ Gearbox lifting tackle -
3336- for transporting gear‐
box
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2. Removing and installing gearbox 201
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
cardiagn.com
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♦ Allocate grease using ⇒ Electronic parts catalogue (ETKA) .
♦ Allocate grease using ⇒ Electronic parts catalogue (ETKA) .
rrectne
2.3.1 Removing gearbox
s
– First check whether a coded radio is fitted. If so, obtain anti-
s o
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theft code.
inform
mer
– Disconnect battery earth strap ⇒ Electrical system; Rep. gr.
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27 ; Disconnecting and reconnecting battery .
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– If the lifting eyes of the engine for support bracket - 10 - 222
thi
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A- are blocked by the cover or the air filter, it must be removed
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– Remove complete air filter housing if it is over the gearbox ⇒ C py
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Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
– Remove camshaft housing cover if lifting eye -arrow- is not
accessible ⇒ Rep. gr. 15 ; Cylinder head, valve gear .
– Remove battery and battery tray ⇒ Electrical system; Rep. gr.
27 ; Battery; Removing and installing battery .
– Remove securing clip -arrow 1- for gear selector cable from
gearbox selector lever -A-.
– Pull gear selector cable off pin.
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2. Removing and installing gearbox 203
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
– Pull line between master and slave cylinders -A- out of support
-B-, if present, on gearbox.
– Remove slave cylinder -arrows-, lay to side and secure with
wire. Do not disconnect pipes.
Note
Do not depress clutch pedal.
– Remove earth strap at upper engine/gearbox connecting bolt.
– Remove upper engine/gearbox connecting bolts.
– Then remove upper securing bolt on starter.
– If there are hose and cable connections in area of engine sup‐
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– Remove noise insulation ⇒ General body repairs, exterior;
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Rep. gr. 50 ; Noise insulation .
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– Remove lower part of front left wheel housing liner ⇒ General
body repairs, exterior; Rep. gr. 66 ; Wheel housing liner .
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– Pull off connector -1- for reversing light switch - F4- .
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– Separate exhaust system -arrows 1- and remove exhaust pipe
bracket from subframe -arrows 2- ⇒ Rep. gr. 26 ; Exhaust
system .
204 Rep. gr.34 - Controls, housing
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
– Pull connector -1- off oil level and oil temperature sender -
G266- .
– Remove drive shafts from flange shafts, raise as high as pos‐
sible and secure. Do not damage the surface protection ⇒
Running gear, axles, steering; Rep. gr. 40 ; Repairing drive
shafts; Removing and installing drive shafts .
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– Remove hexagon bolts -arrows 1- for left assembly mounting
from gearbox mounting.
– Tilt engine/gearbox assembly by lowering it via spindles of
support bracket - 10-222 A- .
– Remove gearbox bracket by removing bolts -arrows 2-.
Gearbox support - 3282- is aligned with adjustment plate -
3282/31- for removal of gearbox.
– Insert gearbox support - 3282- in engine and gearbox jack -
V.A.G 1383 A- .
– Fit adjustment plate - 3282/31- on gearbox support - 3282-
( adjustment plate fits in only one position).
– Align arms of gearbox support according to holes in adjust‐
ment plate .
2. Removing and installing gearbox 205
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
– Attach support elements -A- to adjustment plate as illustrated.
– Screw in support hook - 3282/49- instead of support element
-C-.
– Position engine and gearbox jack under vehicle. Arrow -B- on
adjustment plate points in direction of vehicle travel.
– Align adjustment plate parallel to gearbox.
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– Remove engine/gearbox connecting bolt (-arrow- in previous
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– Disconnect wire to lambda probe ⇒ Rep. gr. 21 ; Turbocharg‐
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– Remove lambda probe wire from wire guides ⇒ Rep. gr. 21 ;
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206 Rep. gr.34 - Controls, housing
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
– Press gearbox with 6th gear cover towards front -arrow 1- and
turn it downwards slightly -arrow 2-.
– Observe intermediate plate on engine.
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– When lowering gearbox, change position of gearbox using
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2.3.2 Installing gearbox
Note
Refer to procedure “Removing gearbox” for required special tools
⇒ page 202 .
– All threaded holes into which self-locking bolts are to be
screwed must be cleaned of residual locking fluid with a thread
chaser.
– Always renew self-locking nuts and bolts.
– Check whether dowel sleeves for aligning engine and gearbox
are fitted in cylinder block and install if necessary.
If dowel sleeves are not fitted, difficulties shifting gears, clutch
problems and possible noises from the gearbox (rattling of gears
which are not engaged) could occur.
– Ensure that intermediate plate is correctly seated on engine.
2. Removing and installing gearbox 207
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
– Clean input shaft splines and apply thin coat of grease for
clutch plate splines .
The clutch plate must slide easily to and fro on the input shaft.
Gearbox support - 3282- is aligned with adjustment plate -
3282/31- for installation of gearbox.
– Insert gearbox support - 3282- in engine and gearbox jack -
V.A.G 1383 A- .
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– Align adjustment plate and gearbox parallel to one another.
– Position engine and gearbox jack under vehicle. Arrow -B- on
adjustment plate points in direction of vehicle travel.
– Using spindles of gearbox support - 3282- , tilt gearbox in vi‐
cinity of 6th gear.
– Have a second mechanic press engine forwards.
– Then raise gearbox carefully and guide past subframe.
Note
Be careful of all lines when installing gearbox.
208 Rep. gr.34 - Controls, housing
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
– Carefully guide gearbox with right flange shaft -A- past fly‐
wheel -B- and intermediate plate as shown.
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• The gearbox must be aligned parallel to the engine.
– Insert gearbox while screwing in bolts -arrow- and tighten to
specified torque ⇒ page 213 .
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– Screw in connecting bolt for engine and gearbox -arrow- and
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– Then screw in lower connecting bolts for engine and gearbox
-arrows- and tighten to specified torque ⇒ page 213 .
– After bottom of gearbox and engine are bolted together, re‐
move gearbox support - 3282- from gearbox.
– Remove engine support - 3300 A- and bracket .
– Screw in all lower engine/gearbox connecting bolts and tighten
them to specified torque ⇒ page 213 .
– Align engine and gearbox in installation position. To do this,
tighten both spindles on the support bracket - 10-222 A- .
2. Removing and installing gearbox 209
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
– Install slave cylinder -1- and tighten bolts to specified torque
⇒ Item 9 (page 130) .
– Press pipe/hose assembly -A- into retainer -B- on gearbox.
– Install left assembly mounting -2- using new hexagon bolts
-arrows- and tighten to specified torque ⇒ page 213 .
WARNING
Do not remove support bracket - 10 - 222 A- until the bolts
securing the left and right assembly mountings have been
tightened to specified torque.
– Set both foam pieces on upper edge of left and right wings ⇒
Body, front; Rep. gr. 50 .
– Insert upper engine/gearbox securing bolts and tighten to tor‐
que specification.
– Install pendulum support -arrows A-, -B- and -C- ⇒ Running
gear, axles, steering; Rep. gr. 40 ; Assembly overview - sub‐
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– Reassemble exhaust system ⇒ Rep. gr. 26 ; Exhaust system .
wit
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– Attach drive shafts to gearbox ⇒ Running gear, axles, steer‐
hole
ing; Rep. gr. 40 ; Repairing drive shaft; Removing and instal‐
spec
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ling drive shafts .
t to the co
– Install starter with bolt -3- and, if present, nut -2- ⇒ Electrical
system; Rep. gr. 27 ; Starter .
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– Check for correct installation position of vacuum hose for by c lksw
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brake system, install vacuum hose if necessary ⇒ Rep. gr.
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47 .
– Attach connector -1- to oil level and oil temperature sender -
G266- .
210 Rep. gr.34 - Controls, housing
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
– Install cable support bracket on gearbox and tighten bolts
-arrows- to specified torque ⇒ Item 6 (page 156) .
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2. Removing and installing gearbox 211
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
– Install gearbox selector lever -A- ⇒ page 158 and tighten nut
-arrow 4- to specified torque ⇒ Item 17 (page 157) .
Metal relay lever
Note
♦ When installing, lubricate bearing positions and sliding surfa‐
ces.
♦ Allocate grease using ⇒ Electronic parts catalogue (ETKA) .
– Insert relay lever -B- into mounting of selector cover.
– At the same time, swing relay lever so that shoe engages in
guide of gearbox selector lever.
– Secure relay lever with new securing clip -arrow 3-.
Plastic relay lever
– Install relay lever together with cable end-piece ⇒ page 162 .
Continuation for all
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– Spread a small amount of grease on pin of gearbox selector
lever -A-. agen
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– Install lower part of front left wheel housing liner ⇒ General
t to the co
body repairs, exterior; Rep. gr. 66 ; Wheel housing liner .
– Install noise insulation ⇒ General body repairs, exterior; Rep.
rrectness of i
gr. 50 ; Noise insulation .
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– If camshaft housing cover was removed, install it ⇒ Rep. gr.
15 ; Cylinder head, value gear .
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– If removed, reinstall engine cover and air filter housing ⇒ Rep.
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24 ; Repairing injection system
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– Install battery tray, battery cover and battery ⇒ Electrical sys‐
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212 Rep. gr.34 - Controls, housing
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
2.3.3 Torque settings
Gearbox to engine with 2 bolts in upper area of clutch housing.
Item Bolt Quantity Nm
1 M12 x 50 2 80
2 M12 x 55 1 80
♦ Additionally, start‐
er to gearbox
3 M12 x 150 1 80
♦ Additionally, start‐
er to gearbox
4 M12 x 60 2 80
5 M10 x 50 2 40
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Install engine and gearbox mounting free of tension ⇒ Rep. gr.
10 ; Removing and installing engine .
Pendulum support to subframe and gearbox ⇒ Running gear,
axles, steering; Rep. gr. 40 ; Assembly overview - subframe, anti-
roll bar, suspension links .
Drive shaft to flange shaft ⇒ Running gear, axles, steering; Rep.
gr. 40 ; Repairing drive shaft; Removing and installing drive
shafts .
Exhaust system ⇒ Rep. gr. 26 ; Exhaust system .
2. Removing and installing gearbox 213
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
AG. Volkswagen AG d
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⇒ “2.4.2 Installing gearbox”, page 223
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♦ Support - 10 - 222 A-
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♦ Adapter - 10 - 222 A /8-
♦ Adapter - 10 - 222 A /3-
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214 Rep. gr.34 - Controls, housing
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
♦ Support bridge - 3300 A-
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2. Removing and installing gearbox 215
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
♦ Gearbox support - 3282-
♦ Adjustment plate - 3282/31-
♦ Support elements for gear‐
box (determine when set‐
ting adjustment plate on
gearbox support )
♦ Gearbox lifting tackle -
3336- for transporting gear‐
box
cardiagn.com
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216 Rep. gr.34 - Controls, housing
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
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♦ Torque wrench - V.A.G 1331-
♦ Torque wrench - V.A.G 1332-
♦ Engine and gearbox jack - V.A.G 1383 A-
♦ Grease for splines
♦ Allocate grease using ⇒ Electronic parts catalogue (ETKA) .
♦ Allocate grease using ⇒ Electronic parts catalogue (ETKA) .
♦ Flange bolt M6 x 80
♦ Flange bolt M6 x 20
At a later point, support bracket - 10-222 A- will be put onto lon‐
gitudinal members with adapters - 10 - 222 A /8- .
2. Removing and installing gearbox 217
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
• To prevent damage to edges of wings, cover bottom area of
both adapters - 10 - 222 A /8- with self-adhesive fabric tape
-arrow- ⇒ Electronic parts catalogue (ETKA chemical sub‐
stances) .
2.4.1 Removing gearbox
– First check whether a coded radio is fitted. If so, obtain anti-
theft code.
– Disconnect battery earth strap ⇒ Electrical system; Rep. gr.
27 ; Disconnecting and reconnecting battery .
– If the lifting eyes of the engine for support bracket - 10 - 222
cardiagn.com
A- are blocked by the cover or the air filter, it must be removed
now. ⇒ Rep. gr. 23 ; Repairing diesel direct injection system
or ⇒ Rep. gr. 24 ; Repairing injection system
– Remove complete air filter housing if it is over the gearbox ⇒
Rep. gr. 23 ; Repairing diesel direct injection system or ⇒
Rep. gr. 24 ; Repairing injection system
– Remove battery and battery tray ⇒ Electrical system; Rep. gr.
27 ; Battery; Removing and installing battery .
– Remove securing clip -arrow 1- for gear selector cable from
gearbox selector lever -B-.
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– Remove relay lever -A- together with
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– Remove gearbox selector lever -B- by removing nut
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– Remove cable support bracket from gearbox -arrows-.
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– Then raise and secure gear selector cable and gate selector
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218 Rep. gr.34 - Controls, housing
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
– Pull line between master and slave cylinders -A- out of support
-B-, if present, on gearbox.
– Remove slave cylinder -arrows-, lay to side and secure. Do
not disconnect pipes.
Caution
Do not operate clutch pedal any more.
– To prevent damage to vacuum hose from brake servo to en‐
gine, it must be removed from engine⇒ Rep. gr. 47 .
– Gearboxes for vehicles with start-stop system: pull connector
-arrow- off gearbox neutral position sender - G701- .
– Remove earth strap at upper securing bolt for starter or at
subframe.
cardiagn.com
– Remove upper engine/gearbox connecting bolts.
– Bolt bracket - T10346- or -T10346/1- to rear of the three
mounting holes for battery tray.
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– Set up support bracket - 10-222 A- in front of bonnet support.
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♦ Adapter - 10 - 222 A /3-
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♦ Adapter - 10 - 222 A /8-
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– Position adapter - 10 - 222 A /8- :
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• On longitudinal members, at top, directly before the elevation
(-arrow 1-) next to bolt (-arrow 2-)
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– Connect left support eye on engine to support bracket .
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– Connect bracket - T10346- or -T10346/1- to support bracket .
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– Take up weight of engine/gearbox assembly and support
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– Raise vehicle on lift.
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– Remove lower part of front left wheel housing liner ⇒ General
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body repairs, exterior; Rep. gr. 66 ; Wheel housing liner . Prote AG.
2. Removing and installing gearbox 219
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
– Pull off connector -1- for reversing light switch - F4- .
– Remove nut -2- if present.
– Remove starter bolt -3- ⇒ Electrical system; Rep. gr. 27 ;
Starter .
The starter can be left on the gearbox.
– Unbolt exhaust pipe from engine ⇒ Rep. gr. 26 ; Exhaust
system .
– Separate exhaust system -arrows 1- and remove exhaust pipe
bracket from subframe -arrows 2- ⇒ Rep. gr. 26 ; Exhaust
system .
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– Pull connector -1- off oil level and oil temperature sender
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– Remove drive shafts from flange shafts, raise as high as pos‐
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– Remove left bracket -arrow- ⇒ Running gear, axles, steering;
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Rep. gr. 40 ; Assembly overview: subframe, anti-roll bar, sus‐
hole
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pension links to make space for engine and gearbox jack or
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– Remove pendulum support.
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220 Rep. gr.34 - Controls, housing
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
– Remove hexagon bolts -arrows 1- for left assembly mounting
from gearbox mounting.
– Tilt engine/gearbox assembly by lowering it via the spindle of
support bracket - 10-222 A- that is connected to engine.
Note
Be careful of all lines when lowering gearbox.
– Remove gearbox bracket by removing bolts -arrows 2-.
– For vehicles with a sheet metal sump, remove cover plate near
sump.
– Unbolt left securing bolt for heat shield -1- from subframe.
– Bolt on bracket - T10346- or -T10346/1- using bolt -2-.
cardiagn.com
-2- = Flange bolt M6 x 20.
– Secure engine support - 3300 A- to bracket .
Place a cloth between engine support - 3300 A- and oil pan.
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– Press engine forwards using spindle of engine support - 3300
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• The air conditioning compressor -2- must not contact -arrow-
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the refrigerant line -1-.
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• The alternator must not contact the refrigerant line.
• The pressure pipe must not contact the radiator.
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Gearbox support - 3282- is aligned with adjustment plate -
3282/31- for removal of gearbox.
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– Insert gearbox support - 3282- in engine and gearbox jack -
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– Fit adjustment plate - 3282/31- on gearbox support - 3282-
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( adjustment plate fits in only one position).
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2. Removing and installing gearbox 221
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
– Attach support elements -A- to adjustment plate as illustrated.
– Screw in support hook - 3282/49- instead of support element
-C-.
– Position engine and gearbox jack under vehicle. Arrow -B- on
adjustment plate points in direction of vehicle travel.
– Align adjustment plate parallel to gearbox.
cardiagn.com
– Insert support hook - 3282/49- in one of the recesses in dif‐
ferential below flange shaft -arrow-.
– Remove engine/gearbox connecting bolt (-arrow- in previous
figure).
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– Remove engine/gearbox connecting bolt -A- above right
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– Press gearbox off dowel sleeves.
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222 Rep. gr.34 - Controls, housing
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
– Press gearbox with 6th gear cover towards front -arrow 1- and
turn it downwards slightly -arrow 2-.
– Observe intermediate plate on engine.
– Then carefully guide gearbox with right flange shaft -A- past
flywheel -B- and intermediate plate as shown.
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– Carefully guide left flange shaft -A- past subframe
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– Lower gearbox being careful of subframe.
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– When lowering gearbox, change position of gearbox using
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– When lowering gearbox, change position of gearbox using
spindles of gearbox support - 3282- .
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– Always renew self-locking nuts and bolts.
– Check whether dowel sleeves for aligning engine and gearbox
are fitted in cylinder block and install if necessary.
If dowel sleeves are not fitted, difficulties shifting gears, clutch
problems and possible noises from the gearbox (rattling of gears
which are not engaged) could occur.
– Ensure that intermediate plate is correctly seated on engine.
2. Removing and installing gearbox 223
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
– Clean input shaft splines and apply thin coat of grease for
clutch plate splines .
The clutch plate must slide easily to and fro on the input shaft.
– Unbolt left securing bolt for heat shield -1- from subframe.
– Bolt on bracket - T10346- or -T10346/1- using bolt -2-.
-2- = Flange bolt M6 x 20.
– Secure engine support - 3300 A- to bracket .
Place a cloth between engine support - 3300 A- and oil pan.
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– Press engine forwards using spindle of engine
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• The pressure pipe must not contact the radiator.
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– Insert gearbox support - 3282- in engine and gearbox jack -
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– Fit adjustment plate - 3282/31- on gearbox support - 3282-
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– Align arms of gearbox support according to holes in adjust‐
ment plate .
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– Screw in support hook - 3282/49- instead of support element
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224 Rep. gr.34 - Controls, housing
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
AG. Volkswagen AG d
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– Insert support hook - 3282/49- in one of the recesses in dif‐
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ferential below flange shaft -arrow-. se
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– Align adjustment plate and gearbox parallel to one another.
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– Position engine and gearbox jack under vehicle. Arrow -B- on
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– Using spindles of gearbox support - 3282- , tilt gearbox in vi‐
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– Then raise gearbox carefully and guide past subframe.
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– Carefully guide left flange shaft -A- past subframe bracket
-B- as shown.
– Turn gearbox to installation position.
• The gearbox must be aligned parallel to the engine.
– Insert gearbox.
2. Removing and installing gearbox 225
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
– Screw in connecting bolt for engine and gearbox -arrow- and
tighten to specified torque ⇒ page 229 .
– Then screw in lower connecting bolts for engine and gearbox
-arrows- and tighten to specified torque ⇒ page 229 .
– After bottom of gearbox and engine are bolted together, re‐
move gearbox support - 3282- from gearbox.
– Remove engine support - 3300 A- and bracket .
– Screw in all lower engine/gearbox connecting bolts and tighten
them to specified torque ⇒ page 229 .
cardiagn.com
– For vehicles with a sheet metal sump, fit cover plate near sump
-arrows- ⇒ page 229 .
– Align engine and gearbox in installation position using spindle
of support bracket - 10 - 222 A- that is connected to engine.
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– Install slave cylinder -1- and tighten bolts to specified torque
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⇒ Item 9 (page 130) .
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– Press pipe/hose assembly -A- into retainer -B- on gearbox.
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– Install left assembly mounting -2- using new hexagon bolts
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-arrows- and tighten to specified torque ⇒ page 229 .
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WARNING
Do not remove support bracket - 10 - 222 A- until the bolts
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securing the left and right assembly mountings have been
tightened to specified torque.
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– Insert upper engine/gearbox securing bolts and tighten to tor‐
que specification.
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Rep. gr.34 - Controls, housing
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6-speed manual r a gearbox 0AJ -
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– Install starter bolt -3- and, if present, nut -2- ⇒ Electrical sys‐
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tem; Rep. gr. 27 ; Starter .
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– Push connector -1- onto reversing light switch - F4- .
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– Install pendulum support ⇒ Running gear, axles, steering;
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Rep. gr. 40 ; Assembly overview - Subframe, anti-roll bar,
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suspension links .
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– Use new bolts for securing.
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Install engine and gearbox mounting free of tension ⇒ Rep. gr. t. C rig
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10 ; Removing and installing engine . pyri by
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– Reassemble exhaust system ⇒ Rep. gr. 26 ; Exhaust system .
– Attach drive shafts to gearbox ⇒ Running gear, axles, steer‐
ing; Rep. gr. 40 ; Repairing drive shaft; Removing and instal‐
ling drive shafts .
– Attach connector -1- to oil level and oil temperature sender -
G266- .
– Gearboxes for vehicles with start-stop system: join connector
-arrow- to gearbox neutral position sender - G701- .
– Attach vacuum hose from brake servo to engine ⇒ Rep. gr.
47 .
2. Removing and installing gearbox 227
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
– Install cable support bracket on gearbox and tighten bolts
-arrows- to specified torque ⇒ Item 6 (page 156) .
– Install gearbox selector lever -B- and tighten hexagon nut
-arrow 2- to specified torque ⇒ Item 17 (page 157) .
– Install relay lever -A- together with cable end-piece
⇒ page 162 .
– Spread a small amount of grease on pin of gearbox selector
lever -B-.
Allocate grease using ⇒ Electronic parts catalogue (ETKA) .
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– Adjust selector mechanism ⇒ page 168 . rised
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– Check gear oil ⇒ page 306 . ss a ra
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– If corrosion protection was damaged, repair using materials
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specified by manufacturer ⇒ Paint workshop manual .
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– Install lower part of front left wheel housing liner ⇒ General
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body repairs, exterior; Rep. gr. 66 ; Wheel housing liner .
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– Install noise insulation ⇒ General body repairs, exterior; Rep.
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gr. 50 ; Noise insulation .
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– If camshaft housing cover was removed, install it ⇒ Rep. gr.
15 ; Cylinder head, value gear .
– If removed, reinstall engine cover and air filter housing ⇒ Rep.
rrectness of i
gr. 23 ; Repairing diesel direct injection engine or ⇒ Rep. gr.
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24 ; Repairing injection system
– Install battery tray, battery and battery cover ⇒ Electrical sys‐
nform
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tem; Rep. gr. 27 ; Removing and installing battery .
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– Follow procedure after connecting battery ⇒ Electrical system;
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Rep. gr. 27 ; Battery; Disconnecting and connecting battery .
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228 Rep. gr.34 - Controls, housing
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
2.4.3 Torque settings
Gearbox to engine with 2 bolts in upper area of clutch housing.
Item Bolt Quantity Nm
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Item -A- dowel sleeves for centring
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Gearbox to engine with 3 bolts in upper area of clutch housing.
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Item Bolt Quantity Nm
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1 M12 x 50 3 80
2 M12 x 55 1 80
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Gearbox bracket to gearbox
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Bolts -arrows 2- 40 Nm + 90°
Gearbox bracket to body
– Renew bolts.
Bolts -arrows 1- 60 Nm + 90°
Note
Install engine and gearbox mounting free of tension ⇒ Rep. gr.
10 ; Removing and installing engine .
Pendulum support to subframe and gearbox ⇒ Running gear,
axles, steering; Rep. gr. 40 ; Assembly overview - subframe, anti-
roll bar, suspension links .
Drive shaft to flange shaft ⇒ Running gear, axles, steering; Rep.
gr. 40 ; Repairing drive shaft; Removing and installing drive
shafts .
Exhaust system ⇒ Rep. gr. 26 ; Exhaust system .
2. Removing and installing gearbox 229
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
2.5 Removing and installing gearbox, Golf
2009 ► with 1.4 l engine and Passat
2011 ►
⇒ “2.5.1 Removing gearbox”, page 234
⇒ “2.5.2 Installing gearbox”, page 241
Special tools and workshop
equipment required
♦ Support - 10 - 222 A-
♦ Golf: adapter - 10 - 222 A /
8-
♦ Passat: Rack - 10 - 222 A /
1-
♦ Adapter - 10 - 222 A /3-
♦ Holder - T10346-
♦ or bracket - T10346/1-
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Rep. gr.34 - Controls, housing
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2. Removing and installing gearbox 231
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
♦ Gearbox support - 3282-
♦ Adjustment plate - 3282/31-
♦ Support elements for gear‐
box (determine when set‐
ting adjustment plate on
gearbox support )
♦ Gearbox lifting tackle -
3336- for transporting gear‐
box
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Rep. gr.34 - Controls, housing
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
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♦ Torque wrench - V.A.G 1331-
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♦ Torque wrench - V.A.G 1332-
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♦ Engine and gearbox jack - V.A.G 1383 A-
♦ Grease for splines
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♦ Allocate grease using ⇒ Electronic parts catalogue (ETKA) .
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♦ Allocate grease using ⇒ Electronic parts catalogue (ETKA) .
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♦ Flange bolt M6 x 80
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2. Removing and installing gearbox 233
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
• To prevent damage to edges of wings, cover bottom area of
both adapters - 10 - 222 A /8- with self-adhesive fabric tape
-arrow- ⇒ Electronic parts catalogue (ETKA chemical sub‐
stances) .
Continuation for all
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– First check whether a coded radio is fitted. If so, obtain anti-
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– Disconnect battery earth strap ⇒ Electrical system; Rep. gr.
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– If the lifting eyes of the engine for support bracket - 10 - 222
hole
spec
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A- are blocked by the cover or the air filter, it must be removed
es, in part or in w
now. ⇒ Rep. gr. 23 ; Repairing diesel direct injection system
t to the co
or ⇒ Rep. gr. 24 ; Repairing injection system
– Remove complete air filter housing if it is over the gearbox ⇒
rrectness of i
Rep. gr. 23 ; Repairing diesel direct injection system or ⇒
Rep. gr. 24 ; Repairing injection system
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– Remove camshaft housing cover if lifting eye -arrow- is not
accessible ⇒ Rep. gr. 15 ; Cylinder head, valve gear .
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– Remove battery and battery tray ⇒ Electrical system; Rep. gr.
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27 ; Battery; Removing and installing battery .
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– Remove securing clip -arrow 1- for gear selector cable from
gearbox selector lever -B-.
– Pull gear selector cable off pin.
– Remove relay lever -A- together with cable end-piece
⇒ page 162 .
– Remove gearbox selector lever -B- by removing nut
-arrow 2-.
234 Rep. gr.34 - Controls, housing
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– Remove cable support bracket from gearbox and lay to side
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– Then raise and secure gear selector cable and gate selector
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-B-, if present, on gearbox.
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– Remove slave cylinder -arrows-, lay to side and secure. Do
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– Gearboxes for vehicles with start-stop system: pull connector
-arrow- off gearbox neutral position sender - G701- .
– Remove earth strap at upper securing bolt for starter or at
subframe.
– Then remove upper securing bolt on starter.
– Remove upper engine/gearbox connecting bolts -arrows- (bolt
heads may differ from depiction in figure).
2. Removing and installing gearbox 235
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
Golf
– Bolt bracket - T10346- or -T10346/1- to rear of the three
mounting holes for battery tray.
– To do this, use a collar bolt M 6 x 80 or a securing bolt for
battery tray.
– If there are hose and cable connections in area of engine sup‐
port eyes for support bracket - 10 - 222 A- , remove these now.
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– Set up support bracket - 10-222 A- in front of bonnet support.
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♦ Adapter - 10 - 222 A /8-
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– Position adapter - 10 - 222 A /8- :
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• On longitudinal members, at top, directly before the elevation
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(-arrow 1-) next to bolt (-arrow 2-)
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– Connect left support eye on engine to support bracket .
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– Connect bracket - T10346- or -T10346/1- to support bracket .
– Take up weight of engine/gearbox assembly and support
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236 Rep. gr.34 - Controls, housing
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
Passat
– Bolt bracket - T10346- or -T10346/1- to rear of the three
mounting holes for battery tray.
– To do this, use a collar bolt M 6 x 80 or a securing bolt for
battery tray. en AG. V
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– Remove both foamy V pieces from upper edge of left
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wings ⇒ Body,
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– Set up support bracket - 10-222 A- in front of bonnet support.
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♦ Adapter - 10-222 A /3-
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♦ Shackle - 10-222 A /12-
– Position rack feet - 10 - 222 A /1- :
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• on upper longitudinal members,
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• directly next to plenum chamber cover,
• behind bolts -arrow 1- and -arrow 2-.
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– Attach spindle in left engine support eye.
– Connect bracket - T10346- or -T10346/1- to support bracket
using shackle - 10-222 A /12- .
– Take up weight of engine/gearbox assembly and support
bracket on spindles.
Continuation for all
– Raise vehicle on lift.
– Remove noise insulation ⇒ General body repairs, exterior;
Rep. gr. 50 ; Noise insulation .
– Remove lower part of front left wheel housing liner ⇒ General
body repairs, exterior; Rep. gr. 66 ; Wheel housing liner .
2. Removing and installing gearbox 237
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
– Pull off connector -1- for reversing light switch - F4- .
– Remove nut -2- if present.
– Remove starter (bolt -3-) ⇒ Electrical system; Rep. gr. 27 ;
Starter .
– Disconnect cable from Lambda probe ⇒ Rep. gr. 21 ; Turbo‐
charging/supercharging .
– Remove line for lambda probe from retainer for electrical lines
on starter and from guides on charge air pipe ⇒ Rep. gr. 21 ; AG. Volkswagen AG d
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– Disconnect exhaust system from engine ⇒ Rep. gr. 26 ; Ex‐ ss
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haust system .
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– Separate exhaust system -arrows 1- and remove exhaust pipe
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bracket from subframe -arrows 2- ⇒ Rep. gr. 26 ; Exhaust
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– Pull connector -1- off oil level and oil temperature sender -
G266- .
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– Remove drive shafts from flange shafts, raise as high as pos‐
sible and secure. Do not damage the surface protection ⇒
Running gear, axles, steering; Rep. gr. 40 ; Repairing drive
shafts; Removing and installing drive shafts .
– Remove engine/gearbox connecting bolt -A- above right
flange shaft.
238 Rep. gr.34 - Controls, housing
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
– Remove pendulum support.
– Remove hexagon bolts -arrows 1- for left assembly mounting
from gearbox mounting.
– Tilt engine/gearbox assembly by lowering it via the spindle of
support bracket - 10-222 A- that is connected to engine.
Note
cardiagn.com
Be careful of all lines when lowering gearbox.
– Remove gearbox bracket by removing bolts -arrows 2-.
– Unbolt right securing bolt for heat shield -1- from subframe.
– Bolt on bracket - T10346- or -T10346/1- using bolt -2-.
-2- = Flange bolt M6 x 20.
– Secure engine support - 3300 A- to bracket .
– Place a cloth between engine support - 3300 A- and oil pan.
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– Press engine forwards using spindle of engine support - 3300
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• The air conditioning compressor -2- must not contact -arrow-
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the refrigerant line -1-.
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• The pressure pipe must not contact the radiator.
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t to the co
Gearbox support - 3282- is aligned with adjustment plate -
3282/31- for removal of gearbox.
rrectness of i
– Insert gearbox support - 3282- in engine and gearbox jack -
V.A.G 1383 A- .
l purpos
– Fit adjustment plate - 3282/31- on gearbox support - 3282-
( adjustment plate fits in only one position).
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– Align arms of gearbox support according to holes in adjust‐
m
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Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
– Attach support elements -A- to adjustment plate as illustrated.
– Screw in support hook - 3282/49- instead of support element
-C-.
– Position engine and gearbox jack under vehicle. Arrow -B- on
adjustment plate points in direction of vehicle travel.
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– Insert support hook - 3282/49- in one of the recesses in dif‐
es, in part or in w
t to the co
ferential below flange shaft -arrow-.
– Remove engine/gearbox connecting bolt (-arrow- in previous
figure).
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– Remove lower bolts -arrows-.
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240 Rep. gr.34 - Controls, housing
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
– Press gearbox off dowel sleeves.
– Press gearbox with 6th gear cover towards front -arrow 1- and
turn it downwards slightly -arrow 2-.
– Observe intermediate plate on engine.
– Then carefully guide gearbox with right flange shaft -A- past
flywheel -B- and intermediate plate as shown.
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– Carefully guide left flange shaft -A- past subframe bracket
ole,
-B- as shown.
spec
urposes, in part or in wh
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– Lower gearbox being careful of subframe.
– When lowering gearbox, change position of gearbox using
spindles of gearbox support - 3282- .
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Refer to procedure “Removing gearbox” for required special tools
⇒ page 230 .
– All threaded holes into which self-locking bolts are to be
screwed must be cleaned of residual locking fluid with a thread
chaser.
– Always renew self-locking nuts and bolts.
– Check whether dowel sleeves for aligning engine and gearbox
are fitted in cylinder block and install if necessary.
If dowel sleeves are not fitted, difficulties shifting gears, clutch
problems and possible noises from the gearbox (rattling of gears
which are not engaged) could occur.
– Ensure that intermediate plate is correctly seated on engine.
2. Removing and installing gearbox 241
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
– Clean input shaft splines and apply thin coat of grease for
clutch plate splines .
The clutch plate must slide easily to and fro on the input shaft.
– Unbolt right securing bolt for heat shield -1- from subframe.
– Bolt on bracket - T10346- or -T10346/1- using bolt -2-. wage
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– Secure engine support - 3300 A- to bracket . auth or
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– Place a cloth between engine support - 3300 A- and oil pan.
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– Press engine forwards using spindle of engine support - 3300
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– Insert gearbox support - 3282- in engine and gearbox jack -
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– Fit adjustment plate - 3282/31- on gearbox support - 3282-
( adjustment plate fits in only one position).
– Align arms of gearbox support according to holes in adjust‐
ment plate .
– Screw in support elements -A- to adjustment plate as illustra‐
ted.
– Screw in support hook - 3282/49- instead of support element
-C-.
– Place gearbox on engine and gearbox jack .
242 Rep. gr.34 - Controls, housing
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
– Insert support hook - 3282/49- in one of the recesses in dif‐
ferential below flange shaft -arrow-.
– Align adjustment plate and gearbox parallel to one another.
– Position engine and gearbox jack under vehicle. Arrow -B- on
adjustment plate points in direction of vehicle travel.
– Using spindles of gearbox support - 3282- , tilt gearbox in vi‐
cinity of 6th gear.
– Have a second mechanic press engine forwards.
cardiagn.com
– Then raise gearbox carefully and guide past subframe.
Note
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– Carefully guide sgearbox with right flange shaft -A- past fly‐
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– Carefully guide left flange shaft -A- past subframe bracket
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– Turn gearbox to installation position.
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• The gearbox must be aligned parallel to the engine.
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Prote AG.
2. Removing and installing gearbox 243
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
– Insert gearbox while screwing in bolts -arrows- and tighten to
specified torque ⇒ page 247 .
– Screw in connecting bolt for engine and gearbox -arrow- and
tighten to specified torque ⇒ page 247 .
cardiagn.com
– Then screw in lower connecting bolts for engine and gearbox
-arrows- and tighten to specified torque ⇒ page 247 .
– After all lower connecting boltsGfor. Volengine and gearbox have
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– Align engineuthand ee
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– Install slave cylinder -1- and tighten bolts to specified torque
spec
⇒ Item 9 (page 130) .
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– Press pipe/hose assembly -A- into retainer -B- on gearbox.
– Install left assembly mounting -2- using new hexagon bolts
rrectness of i
-arrows- and tighten to specified torque ⇒ page 247 .
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Do not remove support bracket - 10 - 222 A- until the bolts
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244 Rep. gr.34 - Controls, housing
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
– Install starter with bolt -3- and, if present, nut -2- ⇒ Electrical
system; Rep. gr. 27 ; Starter .
– Push connector -1- onto reversing light switch - F4- .
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– Install pendulum support ⇒ Running gear, axles,ed
by V steering; ua
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Rep. gr. 40 ; Assembly overview - Subframe,
horis anti-roll bar, tee
suspension links . aut or
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– Use new bolts for securing.
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Install engine and gearbox mounting free of tension ⇒ Rep. gr.
hole
10 ; Removing and installing engine .
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t to the co
– Reassemble exhaust system ⇒ Rep. gr. 26 ; Exhaust system .
– Push line for lambda probe into retainer for electrical lines on
rrectness of i
starter and into guides on charge air pipe ⇒ Rep. gr. 21 ;
Turbocharging/supercharging .
l purpos
– Connect wire of lambda probe ⇒ Rep. gr. 21 ; Supercharging .
nform
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– Attach drive shafts to gearbox ⇒ Running gear, axles, steer‐
ing; Rep. gr. 40 ; Repairing drive shaft; Removing and instal‐
m
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ling drive shafts .
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– Attach connector -1- to oil level and oil temperature sender -
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– Gearboxes for vehicles with start-stop system: join connector
-arrow- to gearbox neutral position sender - G701- .
– Check for correct installation position of vacuum hose for
brake system, install vacuum hose if necessary ⇒ Rep. gr.
47 .
2. Removing and installing gearbox 245
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
– Install cable support bracket on gearbox and tighten bolts
-arrows- to specified torque ⇒ Item 6 (page 156) .
– Install gearbox selector lever -B- and tighten hexagon nut
-arrow 2- to specified torque ⇒ Item 17 (page 157) .
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– Install relay lever -A- together with cable end-piece byV
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⇒ page 162 . ir se
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– Spread a small amount of grease on pin of gearbox selector
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lever -B-.
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– Connect gear selector cable to gearbox selector lever
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– Adjust selector mechanism ⇒ page 168 .
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– Check gear oil ⇒ page 306 .
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If the gearbox comes in contact with other components, repair
surface protection with manufacturer-approved materials ⇒ Paint
workshop manual .
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– Install lower part of front left wheel housing liner ⇒ General
s
body repairs, exterior; Rep. gr. 66 ; Wheel housing liner .
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– Install noise insulation ⇒ General body repairs, exterior; Rep.
nform
gr. 50 ; Noise insulation .
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– If camshaft housing cover was removed, install it ⇒ Rep. gr.
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15 ; Cylinder head, value gear .
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– If removed, reinstall engine cover and air filter housing ⇒ Rep.
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gr. 23 ; Repairing diesel direct injection engine or ⇒ Rep. gr. um
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– Install battery tray, battery and battery cover ⇒ Electrical sys‐ t. C rig
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– Follow procedure after connecting battery ⇒ Electrical system; Prote AG.
Rep. gr. 27 ; Battery; Disconnecting and connecting battery .
246 Rep. gr.34 - Controls, housing
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
2.5.3 Torque settings
Gearbox to engine with 2 bolts in upper area of clutch housing.
Item Bolt Quantity Nm
1 M12 x 50 2 80
2 M12 x 55 1 80
♦ Additionally, start‐
er to gearbox
3 M12 x 150 1 80
♦ Additionally, start‐
er to gearbox
4 M12 x 60 2 80
5 M10 x 50 2 40
Item -A- dowel sleeves for centring
Gearbox to engine with 3 bolts in upper area of clutch housing.
Item Bolt Quantity Nm
cardiagn.com
1 M12 x 50 3 80
2 M12 x 55 1 80
♦ Additionally, start‐
er to gearbox
3 M12 x 150 1 80
♦ Additionally, start‐
er to gearbox
4 M12 x 60 2 80
5 M10 x 50 2 40 agen
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Install engine and gearbox mounting free of tension ⇒ Rep. gr.
10 ; Removing and installing engine .
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Pendulum support to subframe and gearbox ⇒ Running gear,
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axles, steering; Rep. gr. 40 ; Assembly overview - subframe, anti-
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roll bar, suspension links .
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Drive shaft to flange shaft ⇒ Running gear, axles, steering; Rep.
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shafts .
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2. Removing and installing gearbox 247
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
2.6 Removing and installing gearbox, Golf
Plus with 1,2 l engine
⇒ “2.6.1 Removing gearbox”, page 249
⇒ “2.6.2 Installing gearbox”, page 255
Special tools and workshop
equipment required
♦ Support - 10 - 222 A-
♦ Adapter - 10 - 222 A /8-
♦ Gearbox support - 3282- AG. Volkswagen AG d
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248 Rep. gr.34 - Controls, housing
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
♦ Holder - T10346-
♦ or bracket - T10346/1-
♦ Engine support - 3300 A-
♦ Gearbox lifting tackle -
3336- for transporting gear‐
box
♦ Torque wrench -
V.A.G 1331-
♦ Torque wrench -
V.A.G 1332-
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♦ Flange bolt M6 x 20
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2.6.1 Removing gearbox
– First check whether a coded radio is fitted. If so, obtain anti-
theft code.
– Disconnect battery earth strap ⇒ Electrical system; Rep. gr.
27 ; Disconnecting and reconnecting battery .
– If the lifting eyes of the engine for support bracket - 10 - 222
A- are blocked by the cover or the air filter, it must be removed
2. Removing and installing gearbox 249
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
now. ⇒ Rep. gr. 23 ; Repairing diesel direct injection system
or ⇒ Rep. gr. 24 ; Repairing injection system
– Remove complete air filter housing if it is over the gearbox ⇒
Rep. gr. 23 ; Repairing diesel direct injection system or ⇒
Rep. gr. 24 ; Repairing injection system
– Remove battery and battery tray ⇒ Electrical system; Rep. gr.
27 ; Battery; Removing and installing battery .
– Remove securing clip -arrow 1- for gear selector cable from
gearbox selector lever -B-.
– Pull gear selector cable off pin.
– Remove relay lever -A- together with cable end-piece
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– Remove gearbox selector lever -B- by removing ed nut
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-arrow 2-. ut
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– Remove cable support bracket from gearbox -arrows-.
es, in part or in w
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– Then raise and secure gear selector cable and gate selector
cable.
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– Pull line between master and slave cylinders -A- out of support
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-B-, if present, on gearbox.
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– Remove slave cylinder -arrows-, lay to side and secure with
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Caution
Do not operate clutch pedal any more.
– Remove earth strap at upper engine/gearbox connecting bolt.
– Remove upper engine/gearbox connecting bolts.
– Then remove upper securing bolt on starter.
– If there are hose and cable connections in area of engine sup‐
port eyes for support bracket - 10 - 222 A- , remove these now.
– To prevent damage to vacuum hose from brake servo to en‐
gine, it must be removed from engine⇒ Rep. gr. 47 .
250 Rep. gr.34 - Controls, housing
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
– Gearboxes for vehicles with start-stop system: pull connector
-arrow- off gearbox neutral position sender - G701- .
– Remove both foam pieces from upper edge of left and right
wings ⇒ Body, front; Rep. gr. 50 .
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– Insert fenderaut base plates - T10311- between wing mounting
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flange ands apron underneath on both sides of vehicle.
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“R” -1- denotes right side of vehicle.
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– Set up support bracket - 10-222 A- in front of bonnet support.
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♦ Adapter - 10-222 A /8-
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– Connect left support eye on engine to support bracket . co Vo
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– Take up weight of engine/gearbox assembly on spindles.
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– Raise vehicle on lift.
– Remove noise insulation ⇒ General body repairs, exterior;
Rep. gr. 50 ; Noise insulation .
– Remove lower part of front left wheel housing liner ⇒ General
body repairs, exterior; Rep. gr. 66 ; Wheel housing liner .
– Pull off connector -1- for reversing light switch - F4- .
– Remove nut -2- if present.
– Remove starter (bolt -3-) ⇒ Electrical system; Rep. gr. 27 ;
Starter .
2. Removing and installing gearbox 251
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
– Separate exhaust system -arrows 1- and remove exhaust pipe
bracket from subframe -arrows 2- ⇒ Rep. gr. 26 ; Exhaust
system .
– Pull connector -1- off oil level and oil temperature sender -
G266- .
– Remove drive shafts from flange shafts, raise as high as pos‐
sible and secure. Do not damage the surface protection ⇒
Running gear, axles, steering; Rep. gr. 40 ; Repairing drive
shafts; Removing and installing drive shafts .
cardiagn.com
– Remove pendulum support.
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– Remove hexagon bolts -arrows 1- for left assembly mounting
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– Tilt engine/gearbox assembly by lowering it via spindles of
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– Remove gearbox bracket by removing bolts -arrows 2-.
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– Unbolt left securing bolt for heat shield -1- from subframe.
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– Bolt on bracket - T10346- or -T10346/1- using bolt -2-.
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-2- = Flange bolt M6 x 20.
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1. Secure engine support - 3300 A- to bracket .
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252 Rep. gr.34 - Controls, housing
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
Place a cloth between engine support - 3300 A- and oil pan.
– Press engine forwards using spindle of engine support - 3300
A- . In the process, observe the following points in particular:
• The air conditioning compressor -2- must not contact -arrow-
the refrigerant line -1-.
• The alternator must not contact the refrigerant line.
• The pressure pipe must not contact the radiator.
cardiagn.com
Gearbox support - 3282- is aligned with adjustment plate -
3282/31- for removal of gearbox.
– Insert gearbox support - 3282- in engine and gearbox jack -
V.A.G 1383 A- .
– Fit adjustment plate - 3282/31- on gearbox support - 3282-
( adjustment plate fits in only one position).
– Align arms of gearbox support according to holes in adjust‐
ment plate .
– Attach support elements
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adjustment plate points in direction of vehicle travel.
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2. Removing and installing gearbox 253
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
– Insert support hook - 3282/49- in one of the recesses in dif‐
ferential below flange shaft -arrow-.
– Remove engine/gearbox connecting bolt (-arrow- in previous
figure).
– Remove engine/gearbox connecting bolt -A- above right
flange shaft.
cardiagn.com
– For vehicles with a sheet metal sump, remove cover plate near
sump -arrows-.
– Disconnect wire to lambda probe ⇒ Rep. gr. 21 ; Turbocharg‐
ing/supercharging
– Press gearbox off dowel sleeves.
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– Press gearbox with 6th gear cover towards front -arrow 1- and
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254 Rep. gr.34 - Controls, housing
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
– Then carefully guide gearbox with right flange shaft -A- past
flywheel -B- and intermediate plate as shown.
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– Carefully ed guide left flange shaft -A- past subframe
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– When lowering gearbox, change position of gearbox using
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2.6.2 Installing gearbox
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– All threaded holes into which self-locking bolts are to be
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– Always renew self-locking nuts and bolts.
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– Check whether dowel sleeves for aligning engine and gearbox
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are fitted in cylinder block and install if necessary.
If dowel sleeves are not fitted, difficulties shifting gears, clutch
problems and possible noises from the gearbox (rattling of gears
which are not engaged) could occur.
– Ensure that intermediate plate is correctly seated on engine.
– Clean input shaft splines and apply thin coat of grease for
clutch plate splines .
The clutch plate must slide easily to and fro on the input shaft.
– Unbolt left securing bolt for heat shield -1- from subframe.
– Bolt on bracket - T10346- or -T10346/1- using bolt -2-.
-2- = Flange bolt M6 x 20.
– Secure engine support - 3300 A- to bracket .
2. Removing and installing gearbox 255
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
– Place a cloth between engine support - 3300 A- and oil pan.
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– Press engine forwards using spindle of engine support - 3300
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the refrigerant line -1-.
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• The alternator must not contact the refrigerant line.
• The pressure pipe must not contact the radiator.
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cardiagn.com
Gearbox support - 3282- is aligned with adjustment plate -
3282/31- for installation of gearbox.
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– Insert gearbox support - 3282- in engine and gearbox jack -
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– Fit adjustment plate - 3282/31- on gearbox support - 3282-
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– Place gearbox on engine and gearbox jack .
– Insert support hook - 3282/49- in one of the recesses in dif‐
ferential below flange shaft -arrow-.
256 Rep. gr.34 - Controls, housing
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
– Align adjustment plate and gearbox parallel to one another.
– Position engine and gearbox jack under vehicle. Arrow -B- on
adjustment plate points in direction of vehicle travel.
– Using spindles of gearbox support - 3282- , tilt gearbox in vi‐
cinity of 6th gear.
– Then raise gearbox carefully and guide past subframe.
Note
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– Carefully guide gearbox with right flange shaft -A-
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wheel -B- and intermediate plate as shown. s a u ra
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– Carefully guide left flange shaft -A- past subframe bracket
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– Turn gearbox to installation position.
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• The gearbox must be aligned parallel to the engine.
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tighten to specified torque ⇒ page 260 .
2. Removing and installing gearbox 257
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
– Then screw in lower connecting bolts for engine and gearbox
-arrows- and tighten to specified torque ⇒ page 260 .
– After bottom of gearbox and engine are bolted together, re‐
move gearbox support - 3282- from gearbox.
– Remove engine support - 3300 A- and bracket .
– Screw in all lower engine/gearbox connecting bolts and tighten
them to specified torque ⇒ page 260 .
– For vehicles with a sheet metal sump, fit cover plate near sump
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⇒ Item 9 (page 130) .
– Press pipe/hose assembly -A- into retainer -B- on gearbox.
– Install left assembly mounting -2- using new hexagon bolts rrectne
-arrows- and tighten to specified torque ⇒ page 260 .
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– Remove wing supports - T10311- on both sides of vehicle.
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– Insert upper engine/gearbox securing bolts and tighten to tor‐
que specification.
258 Rep. gr.34 - Controls, housing
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
– Install pendulum support ⇒ Running gear, axles, steering;
Rep. gr. 40 ; Assembly overview - Subframe, anti-roll bar,
suspension links .
– Use new bolts for securing.
Note
Install engine and gearbox mounting free of tension ⇒ Rep. gr.
10 ; Removing and installing engine .
– Reassemble exhaust system ⇒ Rep. gr. 26 ; Exhaust system .
– Attach drive shafts to gearbox ⇒ Running gear, axles, steer‐
ing; Rep. gr. 40 ; Repairing drive shaft; Removing and instal‐
ling drive shafts .
– Install starter with bolt -3- and, if present, nut -2- ⇒ Electrical
system; Rep. gr. 27 ; Starter .
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– Push connector -1- onto reversing light switch - F4- .
– Attach connector -1- to oil level and oil temperature AG.sender
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– Gearboxes for vehicles with start-stop system: join connector
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-arrow- to gearbox neutral position sender - G701- .
– Attach vacuum hose from brake servo to engine ⇒ Rep. gr.
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2. Removing and installing gearbox 259
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
– Install cable support bracket on gearbox and tighten bolts
-arrows- to specified torque ⇒ Item 6 (page 156) .
– Install gearbox selector lever -B- ⇒ page 158 and tighten hex‐
agon nut -arrow 2- to specified torque ⇒ Item 17 (page 157) .
– Install relay lever -A- together with cable end-piece
⇒ page 162 .
– Spread a small amount of grease on pin of gearbox selector
lever -B-.
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body repairs, exterior; Rep. gr. 66 ; Wheel housing liner .
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– Install noise insulation ⇒ General body repairs, exterior; Rep.
gr. 50 ; Noise insulation .
– If removed, reinstall engine cover and air filter housing ⇒ Rep.
rrectness of i
gr. 23 ; Repairing diesel direct injection engine or ⇒ Rep. gr.
24 ; Repairing injection system
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– Install battery tray, battery and battery cover ⇒ Electrical sys‐
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4 M12 x 60 2 80
5 M 10 x 50 or M 10 x 2 40
30
Item -A- dowel sleeves for centring
260 Rep. gr.34 - Controls, housing
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
Gearbox to engine with 3 bolts in upper area of clutch housing.
Item Bolt Quantity Nm
1 M12 x 50 3 80
2 M12 x 55 1 80
♦ Starter to gearbox
3 M12 x 150 1 80
♦ Additionally, start‐
er to gearbox
4 M12 x 60 2 80
5 M 10 x 50 or M 10 x 2 40
30
Item -A- dowel sleeves for centring
Gearbox bracket to gearbox
– Renew bolts.
Bolts -arrows 2- 40 Nm + 90°
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Gearbox bracket to body
– Renew bolts.
Bolts -arrows 1- 60 Nm + 90°
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2. Removing and installing gearbox 261
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
Special tools and workshop
equipment required
♦ Support - 10 - 222 A-
♦ Adapter - 10 - 222 A /8-
♦ Gearbox support - 3282-
♦ Adjustment plate - 3282/31-
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262 Rep. gr.34 - Controls, housing
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
♦ Holder - T10346-
♦ or bracket - T10346/1-
♦ Engine support - 3300 A-
♦ Gearbox lifting tackle -
3336- for transporting gear‐
box
♦ Torque wrench -
V.A.G 1331-
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2.7.1 Removing gearbox
– First check whether a coded radio is fitted. If so, obtain anti-
theft code.
– Disconnect battery earth strap ⇒ Electrical system; Rep. gr.
27 ; Disconnecting and reconnecting battery .
– If the lifting eyes of the engine for support bracket - 10 - 222
A- are blocked by the cover or the air filter, it must be removed
2. Removing and installing gearbox 263
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
now. ⇒ Rep. gr. 23 ; Repairing diesel direct injection system
or ⇒ Rep. gr. 24 ; Repairing injection system
– Remove complete air filter housing if it is over the gearbox ⇒
Rep. gr. 23 ; Repairing diesel direct injection system or ⇒
Rep. gr. 24 ; Repairing injection system
– Remove camshaft housing cover if lifting eye -arrow- is not
accessible ⇒ Rep. gr. 15 ; Cylinder head, valve gear .
– Remove battery and battery tray ⇒ Electrical system; Rep. gr.
27 ; Battery; Removing and installing battery .
– Remove securing clip -arrow 1- for gear selector cable from
gearbox selector lever -A-.
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– Pull securing clip -arrow 3- off relay lever -B- and remove relay
lever.
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– Remove relay lever together with cable end-piece
⇒ page 162 .
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– Remove gearbox selector lever -A- by removing nut
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264 Rep. gr.34 - Controls, housing
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
– Pull line between master and slave cylinders -A- out of support
-B-, if present, on gearbox.
– Remove slave cylinder -arrows-, lay to side and secure with
wire. Do not disconnect pipes.
Caution
Do not operate clutch pedal any more.
– Remove earth strap at upper engine/gearbox connecting bolt.
– Remove upper engine/gearbox connecting bolts.
– Then remove upper securing bolt on starter.
– If there are hose and cable connections in area of engine sup‐
port eyes for support bracket - 10 - 222 A- , remove these now.
– Gearboxes for vehicles with start-stop system: pull connector
-arrow- off gearbox neutral position sender - G701- .
– Remove both foam pieces from upper edge of left and right
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2. Removing and installing gearbox 265
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
– Set up support bracket - 10-222 A- in front of bonnet support.
– Use:
♦ Adapter - 10-222 A /8-
– Take up weight of engine/gearbox assembly on spindles.
– Raise vehicle on lift.
– Remove noise insulation ⇒ General body repairs, exterior;
Rep. gr. 50 ; Noise insulation .
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– Separate exhaust system -arrows 1- and remove exhaust pipe
bracket from subframe -arrows 2- ⇒ Rep. gr. 26 ; Exhaust
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– Pull connector -1- off oil level and oil temperature sender -
G266- .
– Remove drive shafts from flange shafts, raise as high as pos‐
sible and secure. Do not damage the surface protection ⇒
Running gear, axles, steering; Rep. gr. 40 ; Repairing drive
shafts; Removing and installing drive shafts .
266 Rep. gr.34 - Controls, housing
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– Remove engine/gearbox
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– Remove pendulum support.
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– Remove hexagon bolts -arrows 1- for left assembly mounting
from gearbox mounting.
– Tilt engine/gearbox assembly by lowering it via spindles of
support bracket - 10-222 A- .
– Remove gearbox bracket by removing bolts -arrows 2-.
Note
Be careful of all lines when lowering gearbox.
– Unbolt right securing bolt for heat shield -1- from subframe.
– Bolt on bracket - T10346- or -T10346/1- using bolt -2-.
-2- = Flange bolt M6 x 20.
– Secure engine support - 3300 A- to bracket .
– Place a cloth between engine support - 3300 A- and oil pan.
2. Removing and installing gearbox 267
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
– Press engine forwards using spindle of engine support - 3300
A- . In the process, observe the following pointsnin
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– Align arms of gearbox support according to holes in adjust‐
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– Attach support elements -A- to adjustment plate as illustrated.
– Screw in support hook - 3282/49- instead of support element
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– Position engine and gearbox jack under vehicle. Arrow -B- on
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– Align adjustment plate parallel to gearbox.
– Insert support hook - 3282/49- in one of the recesses in dif‐
ferential below flange shaft -arrow-.
– Remove engine/gearbox connecting bolt (-arrow- in previous
figure).
– Disconnect wire to lambda probe ⇒ Rep. gr. 21 ; Turbocharg‐
ing/supercharging
– Remove lambda probe wire from wire guides ⇒ Rep. gr. 21 ;
Turbocharging/supercharging .
268 Rep. gr.34 - Controls, housing
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
– Separate exhaust system so that lower bolts -arrows- may be
removed.
– Press gearbox off dowel sleeves.
– Press gearbox with 6th gear cover towards front -arrow 1- and
turn it downwards slightly -arrow 2-.
– Observe intermediate plate on engine.
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– Carefully guide left flange shaft -A- past subframe bracket
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spindles of gearbox support - 3282- .
2. Removing and installing gearbox 269
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– All threaded holes into which self-locking bolts are to be
screwed must be cleaned of residual locking fluid with a thread
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– Check whether dowel sleeves for aligning engine and gearbox
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– Unbolt right securing bolt for heat shield -1- from subframe.
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– Bolt on bracket - T10346- or -T10346/1- using bolt -2-.
-2- = Flange bolt M6 x 20.
– Secure engine support - 3300 A- to bracket .
– Place a cloth between engine support - 3300 A- and oil pan.
– Press engine forwards using spindle of engine support - 3300
A- . In the process, observe the following points in particular:
• The air conditioning compressor -2- must not contact -arrow-
the refrigerant line -1-.
• The alternator must not contact the refrigerant line.
• The pressure pipe must not contact the radiator.
Gearbox support - 3282- is aligned with adjustment plate -
3282/31- for installation of gearbox.
– Insert gearbox support - 3282- in engine and gearbox jack -
V.A.G 1383 A- .
– Fit adjustment plate - 3282/31- on gearbox support - 3282-
( adjustment plate fits in only one position).
– Align arms of gearbox support according to holes in adjust‐
ment plate .
270 Rep. gr.34 - Controls, housing
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
– Screw in support elements -A- to adjustment plate as illustra‐
ted.
– Screw in support hook - 3282/49- instead of support element
-C-.
– Place gearbox on engine and gearbox jack .
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– Insert support hook - 3282/49- in one of the recesses in dif‐ le
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– Align adjustment plate and gearbox parallel to one another.
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– Position engine and gearbox jack under vehicle. Arrow -B- on
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– Using spindles of gearbox support - 3282- , tilt gearbox in vi‐
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Be careful of all lines when installing gearbox.
– Carefully guide gearbox with right flange shaft -A- past fly‐
wheel -B- and intermediate plate as shown.
2. Removing and installing gearbox 271
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
– Carefully guide left flange shaft -A- past subframe bracket
-B- as shown.
– Turn gearbox to installation position.
• The gearbox must be aligned parallel to the engine.
– Screw in connecting bolt for engine and gearbox -arrow- and
tighten to specified torque ⇒ page 276 .
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– Then screw in lower connecting bolts for engine and gearbox
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-arrows- and tighten to specified torque ⇒ page 276 .
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– After bottom of gearbox and engine are bolted together, re‐
spec
urposes, in part or in wh
move gearbox support - 3282- from gearbox.
t to the co
– Remove engine support - 3300 A- and bracket .
– Screw in all lower engine/gearbox connecting bolts and tighten
rrectne
them to specified torque ⇒ page 276 .
– Align engine and gearbox in installation position. To do this,
ss
tighten both spindles on the support bracket - 10-222 A- .
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– Install slave cylinder -1- and tighten bolts to specified torque
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⇒ Item 9 (page 130) .
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– Press pipe/hose assembly -A- into retainer -B- on gearbox.
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– Install left assembly mounting -2- using new hexagon bolts
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-arrows- and tighten to specified torque ⇒ page 276 . t. Cop py
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WARNING
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Do not remove support bracket - 10 - 222 A- until the bolts
securing the left and right assembly mountings have been
tightened to specified torque.
272 Rep. gr.34 - Controls, housing
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
– Set both foam pieces on upper edge of left and right wings ⇒
Body, front; Rep. gr. 50 .
– Remove wing supports - T10311- on both sides of vehicle.
– Insert upper engine/gearbox securing bolts and tighten to tor‐
que specification.
– Install pendulum support ⇒ Running gear, axles, steering;
Rep. gr. 40 ; Assembly overview - Subframe, anti-roll bar,
cardiagn.com
suspension links .
– Use new bolts for securing.
Note
Install engine and gearbox mounting free of tension ⇒ Rep. gr.
10 ; Removing and installing engine . gen AG
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– Reassemble exhaust system ⇒ Rep. gr. ri26 se ; Exhaust system .
db ara
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– Attach drive shafts to gearbox ⇒ Running
au gear, axles, steer‐ ra
c
ss
ing; Rep. gr. 40 ; Repairing drive shaft; Removing and instal‐ ce
le
ling drive shafts .
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– Install starter with bolt -3- and, if present, nut -2- ⇒ Electrical
ility
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system; Rep. gr. 27 ; Starter .
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2. Removing and installing gearbox 273
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– Push connector -1- onto reversing light switch - F4- .
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– Attach connector -1- to oil level and oil temperature sender -
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– Gearboxes for vehicles with start-stop system: join connector
-arrow- to gearbox neutral position sender - G701- .
nf
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– Check for correct installation position of vacuum hose for
m
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brake system, install vacuum hose if necessary ⇒ Rep. gr.
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– Install cable support bracket on gearbox and tighten bolts
-arrows- to specified torque ⇒ Item 6 (page 156) .
274 Rep. gr.34 - Controls, housing
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
– Install gearbox selector lever -A- ⇒ page 158 and tighten nut
-arrow 4- to specified torque ⇒ Item 17 (page 157) .
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♦ Allocate grease using ⇒ Electronic parts catalogue (ETKA) .
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– Insert relay lever -B- into mounting of selector cover.
hole
spec
es, in part or in w
– At the same time, swing relay lever so that shoe engages in
t to the co
guide of gearbox selector lever.
– Secure relay lever with new securing clip -arrow 3-.
rrectness of i
Plastic relay lever
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– Install relay lever together with cable end-piece ⇒ page 162 .
Continuation for all
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– Spread a small amount of grease on pin of gearbox selector
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lever -A-.
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Allocate grease using ⇒ Electronic parts catalogue (ETKA) .
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– Connect gear selector cable to gearbox selector lever
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-arrow 1-.
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– Adjust selector mechanism ⇒ page 168 . C py
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– Check gear oil ⇒ page 306 .
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If the gearbox comes in contact with other components, repair
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surface protection with manufacturer-approved materials ⇒ Paint
workshop manual .
– Install lower part of front left wheel housing liner ⇒ General
body repairs, exterior; Rep. gr. 66 ; Wheel housing liner .
– Install noise insulation ⇒ General body repairs, exterior; Rep.
gr. 50 ; Noise insulation .
– If camshaft housing cover was removed, install it ⇒ Rep. gr.
15 ; Cylinder head, value gear .
– If removed, reinstall engine cover and air filter housing ⇒ Rep.
gr. 23 ; Repairing diesel direct injection engine or ⇒ Rep. gr.
24 ; Repairing injection system
– Install battery tray, battery and battery cover ⇒ Electrical sys‐
tem; Rep. gr. 27 ; Removing and installing battery .
– Follow procedure after connecting battery ⇒ Electrical system;
Rep. gr. 27 ; Battery; Disconnecting and connecting battery .
2. Removing and installing gearbox 275
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
2.7.3 Torque settings
Gearbox to engine with 2 bolts in upper area of clutch housing.
Item Bolt Quantity Nm
1 M12 x 50 2 80
2 M12 x 55 1 80
♦ Additionally, start‐
er to gearbox
3 M12 x 150 1 80
♦ Additionally, start‐
er to gearbox
4 M12 x 60 2 80
5 M 10 x 50 or M 10 x 2 40
30
Item -A- dowel sleeves for centring
Gearbox to engine with 3 bolts in upper area of clutch housing.
cardiagn.com
Item Bolt Quantity Nm
1 M12 x 50 3 80
2 M12 x 55 1 80
♦ Additionally, start‐
er to gearbox
3 M12 x 150 1 80
♦ Additionally, start‐
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Bolts -arrows 2- 40 Nm + 90°
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Gearbox bracket to body
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– Renew bolts.
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Bolts -arrows 1- 60 Nm + 90°
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Install engine and gearbox mounting free of tension ⇒ Rep. gr.
m
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10 ; Removing and installing engine .
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Pendulum support to subframe and gearbox ⇒ Running gear,
t
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axles, steering; Rep. gr. 40 ; Assembly overview - subframe, anti-
o
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roll bar, suspension links .
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Drive shaft to flange shaft ⇒ Running gear, axles, steering; Rep. Cop py
t. rig
gr. 40 ; Repairing drive shaft; Removing and installing drive yri
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Exhaust system ⇒ Rep. gr. 26 ; Exhaust system .
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276 Rep. gr.34 - Controls, housing
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
2.8 Removing and installing gearbox, Pas‐
sat 2006 ► and Eos
⇒ “2.8.1 Removing gearbox”, page 278
⇒ “2.8.2 Installing gearbox”, page 282
Special tools and workshop
equipment required
♦ Support - 10-222 A-
♦ Adapter - 10-222 A /8-
♦ Gearbox support - 3282-
♦ Adjustment plate - 3282/46-
♦ Support elements for gear‐
box (determine when set‐
ting adjustment plate on
gearbox support )
♦ Gearbox lifting tackle -
3336- for transporting gear‐
cardiagn.com
box
♦ Engine and gearbox jack -
V.A.G 1383 A-
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♦ Torque wrench - V.A.G 1331-
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♦ Torque wrench - V.A.G 1332- C py
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2. Removing and installing gearbox 277
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
♦ Grease for splines
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2.8.1 Removing gearbox
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– First check whether a coded radio
ss is fitted. If so, obtain anti-
theft code.
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– Disconnect battery earth strap ⇒ Electrical system; Rep. gr.
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rm
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27 ; Disconnecting and reconnecting battery .
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– Remove engine cover with air filter ⇒ Rep. gr. 24 ; Repairing
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injection system .
hole
spec
– Remove camshaft housing cover if lifting eye -arrow- is not
es, in part or in w
t to the co
accessible ⇒ Rep. gr. 15 ; Cylinder head, valve gear .
– Remove battery and battery tray ⇒ Electrical system; Rep. gr.
27 ; Battery; Removing and installing battery .
rrectness of i
– Remove securing clip -arrow 1- for gear selector cable from
l purpos
gearbox selector lever -A-.
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– Pull gear selector cable off pin.
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Metal relay lever t. Cop py
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– Remove securing clip -arrow 2- for gate selector cable from pyri by
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relay lever -B-.
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– Pull gate selector cable from pin.
– Pull securing clip -arrow 3- off relay lever -B- and remove relay
lever.
Plastic relay lever
– Remove relay lever together with cable end-piece
⇒ page 162 .
Continuation for all
– Remove gearbox selector lever -A- by removing nut
-arrow 4-.
– Remove cable support bracket from gearbox -arrows-.
– Then raise and secure gear selector cable and gate selector
cable.
278 Rep. gr.34 - Controls, housing
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
– Pull pipe/hose line -A- out of support -B- on gearbox.
Volkswa
– Remove slave cylinder -arrows-, lay toswside
agen and secure with
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Do not depress clutch pedal.
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If an earth strap is bolted to the centre hex stud of the left assem‐
wit
bly mounting, it must be removed.
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ole,
– Remove upper engine/gearbox connecting bolts.
spec
urposes, in part or in wh
– Then remove upper securing bolt on starter.
t to the co
– Gearboxes for vehicles with start-stop system: pull connector
rrectne
-arrow- off gearbox neutral position sender - G701- .
– Remove both foam pieces from upper edge of left and right
ss
wings ⇒ Body, front; Rep. gr. 50 .
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cial p
f in
– If there are hose and cable connections in area of engine sup‐
form
mer
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port eyes for support bracket - 10-222 A- , remove these now.
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– Set up support bracket - 10-222 A- together with adapters -
rig by
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10-222 A /8- in front of support for bonnet.
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– Set up support bracket - 10-222 A- together with adapters -
10-222 A /8- in front of support for bonnet.
Continuation for all
– Take up weight of engine/gearbox assembly on spindles.
– Raise vehicle on lift.
– Remove noise insulation ⇒ General body repairs, exterior;
Rep. gr. 50 ; Noise insulation
– Remove front part of front left wheel housing liner ⇒ General
body repairs, exterior; Rep. gr. 66 ; Assembly overview -
wheel housing liners .
2. Removing and installing gearbox 279
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
– Pull connector -1- off reversing light switch - F4- .
– Remove nut -2-.
– Remove starter (bolt -3-) ⇒ Electrical system; Rep. gr. 27 ;
Starter .
– Separate exhaust system at flange and unbolt exhaust pipe
bracket from subframe ⇒ Rep. gr. 26 ; Exhaust system .
– Remove drive shafts from flange shafts, raise as high as pos‐
sible and secure. Do not damage the surface protection ⇒
Running gear, axles, steering; Rep. gr. 40 ; Repairing drive
shafts; Removing and installing drive shafts .
– Remove engine/gearbox connecting bolt -A- above right
flange shaft.
cardiagn.com
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– Remove pendulum support. ut
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Prote AG.
280 Rep. gr.34 - Controls, housing
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
– Remove hexagon bolt and centre-hex stud -arrows 1- of left
assembly mounting from gearbox mounting.
– Tilt engine/gearbox assembly by lowering it via spindles of
support bracket - 10-222 A- .
Note
Be careful of all lines when lowering gearbox.
– Remove gearbox bracket by removing bolts -arrows 2-.
Gearbox support - 3282- is aligned with adjustment plate -
3282/46- for removal of gearbox.
– Insert gearbox support - 3282- in engine and gearbox jack -
V.A.G 1383 A- .
– Fit adjustment plate - 3282/46- on gearbox support - 3282-
( adjustment plate fits in only one position).
– Align arms of gearbox support according to holes in adjust‐
ment plate .
cardiagn.com
– Screw support elements into adjustment plate as illustrated.
– Position engine and gearbox jack - V.A.G 1383 A- under ve‐
hicle. Arrow on adjustment plate points in direction of vehicle
travel.
– Align adjustment plate parallel to gearbox.
The pin -arrow 1- ⇒ (next fig.) must be flush with the guide of the
gearbox support .
– Screw pin - 3282/29- into rear hole in gearbox for securing bolt
of pendulum support.
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– Secure pin - 3282/45- to gearbox using an M8 nut -arrow 2-.
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– Remove engine/gearbox connecting bolt -A-.
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2. Removing and installing gearbox 281
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
– Remove engine/gearbox connecting bolts -arrows- in vicinity
of sump (bolts on engine remain).
– Press gearbox off dowel sleeves.
– Observe intermediate plate on engine.
– Have a second mechanic press engine forwards.
– Turn gearbox upwards near differential using spindles of gear‐
box support - 3282- .
– Turn gearbox downwards in vicinity of 6th gear cover as shown
-arrow 1-.
– At the same time, ensure that engine/gearbox connecting
bolts -arrow 2- contact exhaust system.
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– Then carefully guide gearbox with right flange shaft past fly‐
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wheel and intermediate plate -arrow 2- as shown.
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– Lower gearbox, being careful of subframe -arrow 1-.
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– When lowering gearbox, change position of gearbox using
hole
spec
spindles of gearbox support - 3282- .
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Note
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Be careful of all lines when lowering gearbox.
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2.8.2 Installing gearbox
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Refer to procedure “Removing gearbox” for required special tools
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⇒ page 278 .
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– All threaded holes into which self-locking bolts are to be yri
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screwed must be cleaned of residual locking fluid with a thread
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– Always renew self-locking nuts and bolts.
– Check whether dowel sleeves for aligning engine and gearbox
are fitted in cylinder block and install if necessary.
If dowel sleeves are not fitted, difficulties shifting gears, clutch
problems and possible noises from the gearbox (rattling of gears
which are not engaged) could occur.
– Ensure that intermediate plate is correctly seated on engine.
– Clean input shaft splines and apply thin coat of grease for
clutch plate splines .
282 Rep. gr.34 - Controls, housing
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
The clutch plate must slide easily to and fro on the input shaft.
Gearbox support - 3282- is aligned with adjustment plate -
3282/46- for removal of gearbox.
– Insert gearbox support - 3282- in engine and gearbox jack -
V.A.G 1383 A- .
– Fit adjustment plate - 3282/46- on gearbox support - 3282-
( adjustment plate fits in only one position).
– Align arms of gearbox support according to holes in adjust‐
ment plate .
– Screw support elements into adjustment plate as illustrated.
Note
♦ The support elements are represented symbolically on the ad‐
justment plate .
♦ The arrow on the adjustment plate points in direction of travel.
– Place gearbox on engine and gearbox jack - V.A.G 1383 A- .
cardiagn.com
The pin -arrow 1- must be flush with the guide of the gearbox
support .
– Screw pin - 3282/29- into rear hole in gearbox for securing bolt
of pendulum support.
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– Secure pin - 3282/45- to gearbox using an M8 nut -arrow 2-.
t to the co
– Align adjustment plate and gearbox parallel to one another.
– Now turn gearbox upwards in vicinity of differential using spin‐
rrectness of i
dles of gearbox support - 3282- .
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– Then turn gearbox slightly downwards in vicinity of 6th gear.
– Position engine and gearbox jack - V.A.G 1383 A- under ve‐
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2. Removing and installing gearbox 283
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– Screw in engine/gearbox connecting bolt -A- and tighten to
specified torque ⇒ page 288 .
– Then screw in lower connecting bolts for engine and gearbox
-arrows- and tighten to specified torque ⇒ page 288 .
– After gearbox has been bolted to engine, remove engine and
gearbox jack from gearbox.
284 Rep. gr.34 - Controls, housing
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
– Install slave cylinder -1- and tighten bolts to specified torque
⇒ Item 9 (page 130) .
– Press pipe/hose assembly -A- into retainer -B- on gearbox.
– Install left assembly mounting -2- using new hexagon bolts
and new centre hex stud -arrows- and tighten to specified tor‐
que ⇒ page 288 .
WARNING
Do not remove support bracket - 10 - 222 A- until the bolts
securing the assembly mounting have been tightened to speci‐
fied torque.
– Set both foam pieces on upper edge of left and right wings ⇒
Body, front; Rep. gr. 50 .
– If present, attach earth strap to centre hex stud of left assembly
mounting. wage
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Install engine and gearbox mounting free of tension ⇒ Rep. gr.
10 ; Removing and installing engine .
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– Attach drive shafts to gearbox ⇒ Running gear, axles, steer‐
l purpos
ing; Rep. gr. 40 ; Repairing drive shaft; Removing and instal‐
ling drive shafts .
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– Install exhaust pipe bracket on subframe. ⇒ Rep. gr. 26 ;
Exhaust system
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2. Removing and installing gearbox 285
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
– Gearboxes for vehicles with start-stop system: join connector
-arrow- to gearbox neutral position sender - G701- .
– Check for correct installation position of vacuum hose for
brake system, install vacuum hose if necessary ⇒ Rep. gr.
47 .
– Install cable support bracket on gearbox and tighten bolts
-arrows- to specified torque ⇒ Item 6 (page 156) .
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286 Rep. gr.34 - Controls, housing
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
– Install gearbox selector lever -A- ⇒ page 158 and tighten nut
-arrow 4- to specified torque ⇒ Item 17 (page 157) .
Metal relay lever
Note
♦ When installing, lubricate bearing positions and sliding surfa‐
ces.
♦ Allocate grease using ⇒ Electronic parts catalogue (ETKA) .
– Insert relay lever -B- into mounting of selector cover.
– At the same time, swing relay lever so that shoe engages in
guide of gearbox selector lever.
– Secure relay lever with new securing clip -arrow 3-.
Plastic relay lever
– Install relay lever together with cable end-piece ⇒ page 162 .
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Gear oil ⇒ Electronic Parts Catalogue “ETKA” .
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– Install front part of front left wheel housing liner ⇒ General
body repairs, exterior; Rep. gr. 66 ; Assembly overview -
wheel housing liners .
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– Install noise insulation ⇒ General body repairs, exterior; Rep.
l purpos
gr. 50 ; Noise insulation. .
– Install engine cover with air filter ⇒ Rep. gr. 24 ; Repairing
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2. Removing and installing gearbox 287
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
2.8.3 Torque settings
Gearbox to engine
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Item Bolt Quantity Nm
1 M12 x 60 2 80
2 M12 x 55 1 80
♦ Additionally, start‐
er to gearbox
3 M12 x 150 1 80
♦ Additionally, start‐
er to gearbox
4 M12 x 60 2 80
5 M10 x 50 2 40
Item -A- dowel sleeves for centring
288 Rep. gr.34 - Controls, housing
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
Gearbox to 1.6 l engine with 3 bolts in upper area of clutch hous‐
ing.
Item Bolt Quantity Nm
1 M12 x 60 3 80
2 M12 x 55 1 80
♦ Additionally, start‐
er to gearbox
3 M12 x 170 1 80
♦ Additionally, start‐
er to gearbox
4 M12 x 70 2 80
5 M10 x 50 2 40
Item -A- dowel sleeves for centring
Gearbox bracket to gearbox
– Renew bolts.
Bolts -arrows 2- 40 Nm + 90°
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Gearbox bracket to body
– Renew bolts.
Bolts -arrows 1- 60 Nm + 90°
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Installssengine and gearbox mounting free of tension ⇒ Rep.
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Assemble exhaust pipe without stresses. ⇒ Rep. gr. 26 ; Exhaust
system
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2.9 Removing and installing gearbox - Scir‐
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⇒ “2.9.1 Removing gearbox”, page 292
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⇒ “2.9.2 Installing gearbox”, page 299
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2. Removing and installing gearbox 289
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
Special tools and workshop
equipment required
♦ Support - 10 - 222 A-
♦ Rack - 10 - 222 A /1-
♦ Adapter - 10-222 A /3-
♦ Holder - T10346-
♦ or bracket - T10346/1-
♦ Flange bolt M6 x 80
♦ Support elements for gear‐
box (determine when set‐
ting adjustment plate on
gearbox support )
♦ not required: shackle - 10 -
222 A /12-
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290 Rep. gr.34 - Controls, housing
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
♦ Gearbox support - 3282-
♦ Adjustment plate - 3282/31-
♦ Support elements for gear‐
box (determine when set‐
ting adjustment plate on
gearbox support )
♦ Gearbox lifting tackle -
3336- for transporting gear‐
box
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2. Removing and installing gearbox 291
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
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♦ Grease for splines Prote AG.
♦ Allocate grease using ⇒ Electronic parts catalogue (ETKA) .
♦ Allocate grease using ⇒ Electronic parts catalogue (ETKA) .
2.9.1 Removing gearbox
– Disconnect battery earth strap ⇒ Electrical system; Rep. gr.
27 ; Disconnecting and reconnecting battery .
– If the lifting eyes of the engine for support bracket - 10 - 222
A- are blocked by the cover or the air filter, it must be removed
now. ⇒ Rep. gr. 23 ; Repairing diesel direct injection system
or ⇒ Rep. gr. 24 ; Repairing injection system
– Remove complete air filter housing if it is over the gearbox ⇒
Rep. gr. 23 ; Repairing diesel direct injection system or ⇒
Rep. gr. 24 ; Repairing injection system
292 Rep. gr.34 - Controls, housing
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
– Remove camshaft housing cover if lifting eye -arrow- is not
accessible ⇒ Rep. gr. 15 ; Cylinder head, valve gear .
– Remove battery and battery tray ⇒ Electrical system; Rep. gr.
27 ; Battery; Removing and installing battery .
– Remove securing clip -arrow 1- for gear selector cable from
gearbox selector lever -B-.
– Pull gear selector cable off pin.
– Remove relay lever -A- together with cable end-piece
⇒ page 162 .
– Remove gearbox selector lever -B- by removing nut
-arrow 2-.
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– Remove cable support bracket from gearbox and lay to side
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– Pull line between master and slave cylinders -A- out of support
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2. Removing and installing gearbox 293
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
– Gearboxes for vehicles with start-stop system: pull connector
-arrow- off gearbox neutral position sender - G701- .
– Remove earth strap at upper securing bolt for starter or at
subframe.
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– Then remove upper securing bolt on starter.
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– Remove upper engine/gearbox connecting bolts -arrows- (bolt
heads may differ from depiction in figure).
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– Remove camshaft housing cover. ⇒ Rep. gr. 15 ; Cylinder Prote
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head, valve gear
294 Rep. gr.34 - Controls, housing
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
– Set up support bracket - 10-222 A- behind bonnet support.
– Use:
♦ Rack feet - 10 - 222 A /1-
♦ Adapter - 10-222 A /3-
– Position rack feet - 10 - 222 A /1- :
• on upper longitudinal members (-arrows-)
• directly next to plenum chamber cover.
– Pull off seal -1- for plenum chamber cover -2- near both rack
feet - 10 - 222 A /1- if they cannot be set in place as shown.
– Observe line -3-.
Caution
The rack feet - 10 - 222 A /1- must not be placed on the bolted
on sheet metal of the wings, or these might be damaged.
cardiagn.com
– Attach spindle in engine support eye.
– Take up weight of engine/gearbox assembly and support
bracket on spindles.
– Raise vehicle on lift.
– Remove noise insulation ⇒ General body repairs, exterior;
Rep. gr. 50 ; Noise insulation .
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– Remove front left wheel housing liner ⇒ General
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– If front vehicle level sender - sG78-
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– Pull off connector -1- for reversing light switch - F4- .
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– Remove starter (bolt -3-) ⇒ Electrical system; Rep. gr. 27 ;
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Starter .
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2. Removing and installing gearbox 295
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
– Separate exhaust system -arrows 1- and remove exhaust pipe
bracket from subframe -arrows 2- ⇒ Rep. gr. 26 ; Exhaust
system .
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– Remove drive shafts from flange shafts, raise as high as pos‐
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sible and secure. Do not damage the surface protection ⇒
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t to the co
Running gear, axles, steering; Rep. gr. 40 ; Repairing drive
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– Remove engine/gearbox connecting bolt -A- above right
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– Remove pendulum support.
296 Rep. gr.34 - Controls, housing
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
– Remove hexagon bolts -arrows 1- for left assembly mounting
from gearbox mounting.
– Tilt engine/gearbox assembly by lowering it via the spindle of
support bracket - 10-222 A- that is connected to engine.
Note
Be careful of all lines when lowering gearbox.
– Remove gearbox bracket by removing bolts -arrows 2-.
Gearbox support - 3282- is aligned with adjustment plate -
3282/31- for removal of gearbox.
– Insert gearbox support - 3282- in engine and gearbox jack -
V.A.G 1383 A- .
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– Insert support hook - 3282/49- in one of the recesses in dif‐
ferential below flange shaft -arrow-.
– Remove engine/gearbox connecting bolt (-arrow- in previous
figure).
– Disconnect cable from Lambda probe ⇒ Rep. gr. 21 ; Turbo‐
charging/supercharging .
2. Removing and installing gearbox 297
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
– Separate exhaust system from engine so that lower bolts
-arrows- may be removed.
– Have a second mechanic press engine forwards.
– Press gearbox off dowel sleeves.
– Press gearbox with 6th gear cover towards front -arrow 1- and
turn it downwards slightly -arrow 2-.
– Observe intermediate plate on engine.
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– Then carefully guide gearbox with right flange shaft -A- past s
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flywheel -B- and intermediate plate as shown.
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– Carefully guide left flange shaft -A- past subframe bracket
-B- as shown.
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– Lower gearbox being careful of subframe.
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– When lowering gearbox, change position of gearbox using
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spindles of gearbox support - 3282- .
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– When lowering gearbox, change position of gearbox using
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spindles of gearbox support - 3282- .
298 Rep. gr.34 - Controls, housing
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
2.9.2 Installing gearbox
Note
Refer to procedure “Removing gearbox” for required special tools
⇒ page 289 .
– All threaded holes into which self-locking bolts are to be
screwed must be cleaned of residual locking fluid with a thread
chaser.
– Always renew self-locking nuts and bolts.
– Check whether dowel sleeves for aligning engine and gearbox
are fitted in cylinder block and install if necessary.
If dowel sleeves are not fitted, difficulties shifting gears, clutch
problems and possible noises from the gearbox (rattling of gears
which are not engaged) could occur.
– Ensure that intermediate plate is correctly seated on engine.
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– Clean input shaft splines and Vol apply thin coat of grease for
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The clutch plate must
sa
uslide easily to and fro on the input shaft. or
ac
s
ce
Gearbox support - 3282- is aligned with adjustment plate -
le
un
pt
3282/31- for installation of gearbox.
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– Insert gearbox support - 3282- in engine and gearbox jack -
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ility
V.A.G 1383 A- .
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– Fit adjustment plate - 3282/31- on gearbox support - 3282-
hole
( adjustment plate fits in only one position). spec
es, in part or in w
t to the co
– Align arms of gearbox support according to holes in adjust‐
ment plate .
– Screw in support elements -A- to adjustment plate as illustra‐
rrectness of i
ted.
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– Screw in support hook - 3282/49- instead of support element
-C-.
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– Place gearbox on engine and gearbox jack .
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– Insert support hook - 3282/49- in one of the recesses in dif‐
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2. Removing and installing gearbox 299
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
– Align adjustment plate and gearbox parallel to one another.
– Position engine and gearbox jack under vehicle. Arrow -B- on
adjustment plate points in direction of vehicle travel.
– Using spindles of gearbox support - 3282- , tilt gearbox in vi‐
cinity of 6th gear.
– Have a second mechanic press engine forwards.
– Then raise gearbox carefully and guide past subframe.
Note
Be careful of all lines when installing gearbox.
– Carefully guide gearbox with right flange shaft -A- past fly‐
wheel -B- and intermediate plate as shown.
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– Carefully guide left flange shaft -A- past subframe bracket
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-B- as shown.
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– Turn gearbox to installation position.
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• The gearbox must be aligned parallel to the engine.
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– Insert gearbox while screwing in bolts -arrows- and tighten to
nform
ercia
specified torque ⇒ page 304 .
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300 Rep. gr.34 - Controls, housing
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
– Screw in connecting bolt for engine and gearbox -arrow- and
tighten to specified torque ⇒ page 304 .
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– Then screw in lower connecting bolts for engine and gearbox
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le
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-arrows- and tighten to specified torque ⇒ page 304 .
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been bolted on with specified torque, ⇒ page 304 , remove
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– Align engine and gearbox in installation position using spindle
spec
of support bracket - 10 - 222 A- that is connected to engine.
es, in part or in w
t to the co
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rrectness of i
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– Install slave cylinder -1- and tighten bolts to specified torque
⇒ Item 9 (page 130) .
nform
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– Press pipe/hose assembly -A- into retainer -B- on gearbox.
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– Install left assembly mounting -2- using new hexagon bolts
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-arrows- and tighten to specified torque ⇒ page 260 .
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Do not remove support bracket - 10 - 222 A- until the bolts
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– Insert upper engine/gearbox securing bolts and tighten to tor‐
que specification.
– Install starter with bolt -3- and, if present, nut -2- ⇒ Electrical
system; Rep. gr. 27 ; Starter .
– Push connector -1- onto reversing light switch - F4- .
2. Removing and installing gearbox 301
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
– Install pendulum support. ⇒ Running gear, axles, steering;
Rep. gr. 40 ; Assembly overview - Subframe, anti-roll bar,
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– Use new bolts
ris for securing.
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Note
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Install engine and gearbox mounting free of tension ⇒ Rep. gr.
erm
ab
10 ; Removing and installing engine .
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– Reassemble exhaust system ⇒ Rep. gr. 26 ; Exhaust system .
hole
spec
– Attach drive shafts to gearbox ⇒ Running gear, axles, steer‐
es, in part or in w
t to the co
ing; Rep. gr. 40 ; Repairing drive shaft; Removing and instal‐
ling drive shafts .
rrectness of i
– Attach front vehicle level sender - G78- ⇒ Rep. gr. 40 ; Re‐
moving and installing front left vehicle level sender - G78- .
l purpos
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or
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– Attach connector -1- to oil level and oil temperature sender - Prote
cted AG.
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G266- .
– Gearboxes for vehicles with start-stop system: join connector
-arrow- to gearbox neutral position sender - G701- .
302 Rep. gr.34 - Controls, housing
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
– Install cable support bracket on gearbox and tighten bolts
-arrows- to specified torque ⇒ Item 6 (page 156) .
– Install gearbox selector lever -B- and tighten hexagon nut
-arrow 2- to specified torque ⇒ Item 17 (page 157) .
– Install relay lever -A- together with cable end-piece
⇒ page 162 .
– Spread a small amount of grease on pin of gearbox selector
lever -B-.
Allocate grease using ⇒ Electronic parts catalogue (ETKA) .
cardiagn.com
– Connect gear selector cable to gearbox selector lever
-arrow 1-.
– Adjust selector mechanism ⇒ page 168 .
– Check gear oil ⇒ page 306 .
If the gearbox comes in contact with other components, repair
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– Install front left wheel housing liner s⇒
au General body repairs, ac
exterior; Rep. gr. 66 ; Wheel housings liner .
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nl
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– Install noise insulation ⇒ General body repairs, exterior; Rep.
an
itte
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gr. 50 ; Noise insulation .
erm
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ility
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– If camshaft housing cover was removed, install it ⇒ Rep. gr.
wit
, is n
15 ; Cylinder head, value gear . h re
hole
spec
– Install battery tray, battery and battery cover ⇒ Electrical sys‐
es, in part or in w
tem; Rep. gr. 27 ; Removing and installing battery .
t to the co
– Follow procedure after connecting battery ⇒ Electrical system;
Rep. gr. 27 ; Battery; Disconnecting and connecting battery .
rrectness of i
– Check headlight adjustment of vehicles with front vehicle level
sender - G78- .
l purpos
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or
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Prote AG.
2. Removing and installing gearbox 303
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017 . Volkswage AG n AG d
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2.9.3 Torque settings ise
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Gearbox to engine with 2 bolts in upper area of sclutch
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Item Bolt Quantity Nm
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1 M12 x 50 2 80
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2 M12 x 55 1 80
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3 M12 x 150 1
es, in part or in w 80
t to the co
♦ Additionally, start‐
er to gearbox
rrectness of i
4 M12 x 60 2 80
5 M10 x 50 2 40
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Item -A- dowel sleeves for centring
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Gearbox to engine with 3 bolts in upper area of clutch housing.
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Item Bolt Quantity Nm
or
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1 M12 x 50 3 80
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4 M12 x 60 2 80
5 M10 x 50 2 40
Item -A- dowel sleeves for centring
Gearbox bracket to gearbox
– Renew bolts.
Bolts -arrows 2- 40 Nm + 90°
Gearbox bracket to body
– Renew bolts.
Bolts -arrows 1- 60 Nm + 90°
Note
Install engine and gearbox mounting free of tension ⇒ Rep. gr.
10 ; Removing and installing engine .
Pendulum support to subframe and gearbox ⇒ Running gear,
axles, steering; Rep. gr. 40 ; Assembly overview - subframe, anti-
roll bar, suspension links .
Drive shaft to flange shaft ⇒ Running gear, axles, steering; Rep.
gr. 40 ; Repairing drive shaft; Removing and installing drive
shafts .
Exhaust system ⇒ Rep. gr. 26 ; Exhaust system .
304 Rep. gr.34 - Controls, housing
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
3 Transporting gearbox
Special tools and workshop equipment required
♦ Gearbox mounting support - 3336-
AG. Volkswagen AG d
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– Bolt gearbox lifting tackle - 3336- to clutch housing. s
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es, in part or in w
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– Adjust support beam on sliding piece using locking pin
-arrow-.
nf
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orm
No. of holes visible = 5
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– Lift gearbox using workshop crane and gearbox lifting tackle -
n in
or c
3336- .
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– Set gearbox aside, for example in a transport container.
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3. Transporting gearbox 305
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤sw, aGolf G. Volk...
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⇒ “4.1 Checking gear oil level”, page 306
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⇒ “4.2 Fill with gear oil”, page 307
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4.1 Checking gear oil level
h re
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spec
Special tools and workshop equipment required
es, in part or in w
t to the co
♦ Socket bit - 3357- for oil filler plug with multi-point socket head
bolt
rrectness of i
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♦ Torque wrench - V.A.G 1331- C py
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Gear oil ⇒ Electronic Parts Catalogue “ETKA” .
– Remove noise insulation ⇒ General body repairs, exterior;
Rep. gr. 50 ; Noise insulation; Assembly overview - noise in‐
sulation .
– To check gear oil, remove oil plug -arrow-.
Oil level is correct when gearbox is filled to lower edge of filler
hole.
– Tighten oil plug -arrow- to specified torque.
306 Rep. gr.34 - Controls, housing
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
Various versions of oil filler and drain plugs
I - Oil filler plug/oil drain plug with multi-point socket head, 25 Nm
II - Oil filler plug/oil drain plug with hexagon socket head, 30 Nm
– Install noise insulation ⇒ General body repairs, exterior; Rep.
gr. 50 ; Noise insulation; Assembly overview - noise insula‐
tion .
4.2 Fill with gear oil
Special tools and workshop equipment required
♦ Socket bit - 3357- for oil filler plug with multi-point socket head
bolt
cardiagn.com
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♦ Torque wrench - V.A.G d1331-
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Gear oil ⇒ Electronic Parts Catalogue “ETKA” .
l purpos
– Remove noise insulation ⇒ General body repairs, exterior;
Rep. gr. 50 ; Noise insulation; Assembly overview - noise in‐
nf
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sulation .
orm
m
– Remove plug -arrow-.
atio
om
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c
– Top-up gearbox oil to lower edge of filler plug drilling.
or
thi
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– Screw in plug -arrow-.
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– Start engine, engage gear and allow gearbox to turn for ap‐
f
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– Stop engine and remove plug -arrow-.
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– Top up with gear oil to lower edge of filler hole. cted agen
Prote AG.
– Tighten oil plug -arrow- to specified torque.
4. Gear oil 307
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
Various versions of oil filler and drain plugs
I - Oil filler plug/oil drain plug with multi-point socket head, 25 Nm
II - Oil filler plug/oil drain plug with hexagon socket head, 30 Nm
– Install noise insulation ⇒ General body repairs, exterior; Rep.
gr. 50 ; Noise insulation; Assembly overview - noise insula‐
tion .
cardiagn.com
AG. Volkswagen AG d
agen oes
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ility
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es, in part or in w
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Prote AG.
308 Rep. gr.34 - Controls, housing
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
5 Dismantling and assembling gearbox
⇒ “5.1 Overview - gearbox”, page 309
⇒ “5.2 Overview - dismantling and assembling gearbox”,
page 310
⇒ “5.3 Assembly overview - Removing and installing cover for
gearbox housing and 5th and 6th gears”, page 311
⇒ “5.4 Assembly overview - removing and installing clutch hous‐
ing”, page 313
⇒ “5.5 Assembly overview - removing and installing input shaft,
output shaft, differential, selector mechanism and selector forks”,
page 314
⇒ “5.6 Dismantling and assembling procedure”, page 316
5.1 Overview - gearbox lksw
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1 - 1st gear aut
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2 - 2nd gear
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3 - 3rd gear
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4 - 4th gear
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5 - 5th gear
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6 - 6th gear
spec
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t to the co
7 - Gearbox housing cover
8 - Gearbox housing
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9 - Reverse gear wheel
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10 - Selector mechanism
❑ (Selector forks)
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11 - Clutch housing
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12 - Input shaft
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13 - Output shaft
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14 - Differential
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Prote AG.
5. Dismantling and assembling gearbox 309
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
5.2 Overview - dismantling and assembling gearbox
l - Assembly overview - dis‐
mantling and assembling gear‐
box ⇒ page 311
ll - Assembly overview - remov‐
ing and installing clutch hous‐
ing ⇒ page 313
lII - Assembly overview - re‐
moving and installing input
shaft, output shaft, differential,
selector mechanism and se‐
lector forks ⇒ page 314
Assembly sequence
⇒ page 316
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310 Rep. gr.34 - Controls, housing
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
5.3 Assembly overview - Removing and installing cover for gearbox housing
and 5th and 6th gears
1 - Gearbox housing
❑ Servicing ⇒ page 331
2 - Gear wheel for 5th gear
❑ Fitting position
⇒ page 327
❑ Must be pressed off and
pressed on in gearbox‐
es for 1.4l engine
⇒ page 327 .
3 - Sleeve
4 - Gear wheel for 6th gear
❑ Fitting position
⇒ page 329
5 - Cylindrical roller bearing in‐
ner race
cardiagn.com
❑ For output shaft
❑ Mark before removing
❑ Do not interchange with
inner race for cylindrical
roller bearing of input
shaft
6 - Bolt
❑ M 8: 30 Nm and turn 90° agen
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❑ M10: 75 Nm then turn rise
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h re
hole
bearings for input and
spec
output shafts
es, in part or in w
t to the co
❑ Servicing ⇒ page 334
8 - Bolt, 5 Nm + turn 90° further
rrectness of i
❑ Always renew
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9 - Bolt
❑ M 8: 30 Nm and turn 90° further
nform
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❑ M10: 75 Nm then turn 45° further
m
❑ For input shaft
com
tion in
❑ Self-locking
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❑ Always renew
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10 - Cylindrical roller bearing inner race
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❑ Do not interchange with inner race for cylindrical roller bearing of output shaft
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Prote AG.
5. Dismantling and assembling gearbox 311
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
11 - Thrust washer
12 - Inner race for cylindrical roller bearing with thrust washer
❑ For input shaft
❑ Installed in some gearboxes
❑ Allocate according to ⇒ Electronic parts catalogue “ETKA”
13 - Synchromeshed gear for 6th gear
14 - Synchro-ring for 6th gear
15 - Needle bearing
❑ One-piece design.
❑ For 6th gear
❑ Allocate according to ⇒ Electronic
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17 - Sleeve
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❑ For 6th gear needle bearing
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❑ Renew together with needle bearing. t to the co
18 - Locking collar with synchro-hub for 5th and 6th gear
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❑ Dismantling and assembling ⇒ page 345
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19 - Selector fork for 5th and 6th gear
20 - Locating pin
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312 Rep. gr.34 - Controls, housing
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
5.4 Assembly overview - removing and installing clutch housing
1 - Countersunk bolt
❑ Specified torque
⇒ page 371
2 - Flange shaft with compres‐
sion spring
❑ Removing and installing
⇒ page 316
❑ Assembling
⇒ page 371
3 - Bolt, 5 Nm + turn 90° further
❑ Always renew
4 - Clutch housing
❑ Servicing ⇒ page 331
5 - Gearbox housing
❑ Servicing ⇒ page 331 AG. Volkswagen AG d
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❑ With guide sleeve and rise nte
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⇒ page 129
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5. Dismantling and assembling gearbox 313
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
5.5 Assembly overview - removing and installing input shaft, output shaft, dif‐
ferential, selector mechanism and selector forks
1 - Differential
❑ Dismantling and assem‐
bling ⇒ page 371 . Volkswagen AG
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3 - Oil drain plug,
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⇒ page 307
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⇒ page 316
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⇒ page 371
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5 - Countersunk bolt
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❑ Specified torque
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⇒ page 371
6 - Bolt, 5 Nm + turn 90° further
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⇒ Item 18 (page 315) .
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7 - Hexagon flange nut, 23 Nm
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❑ Always renew
8 - O-ring
❑ Always renew
9 - Pivot pin
10 - Bolt, 5 Nm + turn 90° further
❑ Always renew
11 - Selector shaft with selector shaft cover
❑ (Selector unit)
❑ Servicing ⇒ page 337
12 - Bolt, 5 Nm + turn 90° further
❑ Always renew
13 - Bolt, 6 Nm
14 - Gearbox neutral position sender - G701-
❑ for vehicles with start/stop system
15 - Reversing light switch - F4- , 20 Nm
❑ Switch without seal: clean thread of switch if necessary
❑ Switch without seal: install switch with sealant if necessary
❑ For allocation of sealant, refer to ⇒ Electronic parts catalogue (ETKA) .
314 Rep. gr.34 - Controls, housing
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
❑ Switch with encapsulated seal: renew switch
❑ Switch with separate seal: renew seal
❑ Lightly coat lug with MoS2 grease
❑ Remove noise insulation with gearbox installed ⇒ General body repairs, exterior; Rep. gr. 66 ; Noise
insulation; Assembly overview – noise insulation .
16 - Sealing ring
❑ Not fitted in all gearboxes
17 - Selector mechanism
❑ (Selector forks)
❑ Servicing ⇒ page 340
18 - Input shaft and output shaft with bearing mounting and deep groove ball bearing
❑ If bearing support is separated agefrom
n AG.gearbox housing,
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or input shaft ⇒ page 345 eo
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❑ Dismantling and ss assembling output shaft ⇒ page 358 c
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21 - Bolt, 25 Nm + turn 45° further
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❑ Always renew
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❑ For securing shaft for reverse gear
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22 - Oil collector
23 - Magnet
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24 - Oil guide
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5. Dismantling and assembling gearbox 315
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
5.6 Dismantling and assembling procedure AG. Volkswagen AG d
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Removing and installing gearbox housing cover, clutch housing, by V o gu
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Special tools and workshop
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♦ Support clamp - VW 313-
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♦ Pressure plate - VW 401-
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♦ Pressure plate - VW 402-
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♦ Press piece - VW 412-
♦ Adapter - T10235-
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Prote AG.
316 Rep. gr.34 - Controls, housing
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
♦ Press piece - VW 407-
♦ Tube - VW 418 A-
♦ Press tool - T10080-
♦ Thrust block - T10083-
♦ Shim - T10083/1-
♦ Drip tray - V.A.G 1306-
♦ Gearbox for 1.6 l engine
♦ Thrust washer - 3074-
♦ Gearbox for 1.4 l engine
♦ Thrust washer - T10375-
♦ Engine and gearbox sup‐ n AG. Volkswagen AG do
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c
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for
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Cop py
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Prote AG.
5. Dismantling and assembling gearbox 317
AG. Volkswagen AG d
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Eos 2006 ➤ , Golf d by V2004 ➤ , Golf 2009 ➤ , Golf Plus gu 2005 ➤
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6-speed manual
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♦ Torque wrench -
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♦ -1- Three arm puller - Kuk‐
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♦ -3- Two-arm puller - Kukko
es, in part or in w
204/2-
t to the co
♦ Hexagon socket head bolts
M8 x 15
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♦ Puller - T10309-
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♦ Half-sleeve - T10309/4-
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♦ If pulling off is not possible
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♦ Half-sleeve - T10309/4A-
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♦ Adapter - T10309/5-
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♦ Sealant - AMV 188 200 03-
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318 Rep. gr.34 - Controls, housing
AG. Volkswagen AG d
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Eos 2006 ➤ , Golf 2004 r➤ ise , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf
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6-speed manual gearbox 0AJ - Edition 01.2017
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5.6.1 Removing
un
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– Secure gearbox to repair stand Engine and gearbox support -
rm
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VW 540- -arrows-.
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– Place drip tray - V.A.G 1306- underneath.
h re
hole
spec
– Drain gear oil.
es, in part or in w
t to the co
rrectness of i
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– Remove clutch release lever -A- together with release bearing
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and guide sleeve -arrows-.
n in
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– Remove right flange shaft securing bolt -B-.
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– To do this, screw two bolts into flange and counterhold flange
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shaft using a lever.
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– Remove flange shaft along with spring, thrust washer and ta‐ t. C rig
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– Unbolt gearbox housing cover -arrow- and carefully pull it off.
– Pull out pivot pin -1- for 5th and 6th gear selector fork -2- and
remove selector fork.
5. Dismantling and assembling gearbox 319
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
– Remove bolts -A- for inner bearing races from input and output
shafts, engaging 5th gear -arrow 1- and 1st gear -arrow 2- and
-arrow 3-.
– Input shaft and output shaft are locked when both gears are
engaged. Both bolts can now be loosened.
Note
♦ If the shafts are to be reused, clean residual locking material
out of threaded holes using a thread chaser.
♦ Pull off gear wheel for 6th gear with three arm puller - Kukko
30/1- .
♦ If necessary, gear wheel for 6th gear can be pulled off to stop
on spindle with two arm puller - Kukko 204/2- . Then pull off
further with three arm puller - Kukko 30/1- .
– Pull off gear wheel for 6th gear with inner race of cylindrical
roller bearing for output shaft.
A - Three-arm puller - Kukko 30/1-
cardiagn.com
B - Hexagon socket-head bolt - M8 x 15-
Adhere to the sequence for pulling off the following components:
• Synchromeshed gear for 6th gear: pull off together with inner
race of cylindrical roller bearing for input shaft.
• Synchro-hub for 5th and 6th gear: pull off together with inner
race for 6th gear needle bearing. agen
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Synchromeshed gear for 6th gear: pull off together with inner
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of cylindrical roller bearing for input shaft.
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– First insert half-sleeve - T10309/4A- .
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• The half-sleeve must be positioned beneath the synchromesh‐
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wit
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– If necessary, half sleeve must be pressed to end position.
hole
spec
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– Position adapter - T10309/5- .
– Set threaded insert - T10309/3- in half-sleeve and lightly t to the co
clamp. rrectness of i
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c
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do
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for
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t.
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Cop py
t. rig
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pyri by
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by c lksw
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Prote AG.
320 Rep. gr.34 - Controls, housing
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
– Now, install second half-sleeve - T10309/4A- , and fit tube -
T10309/2- onto assembly.
AG. Volkswagen AG d
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Then, pull off synchro-hub for 5th and 6th gear together with inner
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race for needle bearing for 6th gear synchromeshed gear.
wit
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– First insert half-sleeve - T10309/4A- .
hole
spec
es, in part or in w
• Half sleeve must be positioned beneath synchro-ring.
t to the co
– If necessary, half sleeve must be pressed to end position.
– Position adapter - T10309/5- .
rrectness of i
– Set threaded insert - T10309/3- in half-sleeve and lightly
l purpos
clamp.
nform
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at
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c
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do
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Cop py
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– Now, install second half-sleeve - T10309/4A- , and fit tube - cop Vo
by lksw
T10309/2- onto assembly.
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Prote AG.
Note
The synchro-ring for 5th gear must always be renewed after it is
pulled off.
– Remove synchromeshed gear for 5th gear.
5. Dismantling and assembling gearbox 321
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
– Remove flange shaft securing bolt -1- by screwing 2 bolts into
flange and counter holding flange shaft with a lever.
– Pull out flange shaft with compression spring.
– Remove sleeve -2- and needle bearing -4-.
– Unscrew hexagon flange nut -5-agfor
en Asecuring
G. Volkswareverse
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– Remove bearing mounting
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Gearbox for 1.6 l engine
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– Remove gear wheel for 5th gear -3-.
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Gearbox for 1.4 l engine
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– The gear wheel for 5th gear -3- will be pressed off later when
h re
hole
the bearing support for the deep groove ball bearing
spec
⇒ page 351 .
es, in part or in w
t to the co
Continuation for all
– Turn gearbox in support bracket so that clutch housing is up‐
rrectness of i
wards.
cardiagn.com
l purpos
– Remove securing bolts from clutch housing side for securing
clutch housing to gearbox housing.
nform
ercia
– Remove clutch housing, if necessary carefully levering up all
around along protruding housing flange and alternating be‐
m
a
tween sides, being careful not to damage sealing surfaces.
com
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– Do not cant the clutch housing. This prevents damage to roller
thi
s
bearings and their bearing seats on the input and output
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shafts.
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– Remove differential -A- from gearbox housing. Cop py
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Prote AG.
322 Rep. gr.34 - Controls, housing
AG. Volkswagen AG d
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V gu 6-speed manual gearbox 0AJ - Edition 01.2017
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– Then sremove
au oil collector -A- and oil guide -B- with magnet ra
c
from gearbox housing.
s
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spec
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– Gearboxes for vehicles with start-stop system: remove gear‐
ss
box neutral position sender - G701- -arrow-.
o
cial p
f inform
mer
atio
om
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c
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sd
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Cop py
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Prote AG.
– Remove selector shaft with selector cover -A-. Place selector
shaft in neutral. Then remove bolts -arrows- and pull selector
shaft out of gearbox housing.
– Remove pivot pins -B- located on underside of gearbox.
– Screw out reversing light switch - F4- -C-.
– Remove bolt -A- for securing reverse gear wheel shaft.
– Remove pivot pins -B- located on bottom of gearbox.
Note
Do not remove sealing cover -arrow- when dismantling gearbox.
Gearbox for 1.6 l engine
5. Dismantling and assembling gearbox 323
agen AG olksw
Eos 2006 ➤ , Golf 2004
wage ➤ , Golf 2009 ➤ d,oGolf
n AG. V
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olks
6-speed manual
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V o
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– Press out input
au shaft, output shaft with bearing mounting, se‐or a
t
c
lector mechanism
ss (selector forks) and reverse gear together.
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pt
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itte
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Note
erm
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ility
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♦ Position gearbox housing so that dowel sleeves in the gearbox
, is n
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will not be damaged.
hole
spec
♦ When pressing out, get help from second mechanic to ensure
es, in part or in w
t to the co
components do not fall out.
Gearbox for 1.4 l engine
rrectness of i
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– Press out input shaft, output shaft with gear wheel for 5th gear
-A-, bearing mounting, selector mechanism (selector forks)
and reverse gear together.
nf
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♦ Position gearbox housing so that dowel sleeves in the gearbox
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♦ When pressing out, get help from second mechanic to ensure
t.
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Continuation for all Prote
cted AG.
agen
– Press input and output shafts with deep groove ball bearing
and, as appropriate, gear wheel for 5th gear off bearing mount‐
ing ⇒ Item 14 (page 346) .
5.6.2 Installing
Note
♦ If bearing mounting with deep groove ball bearing was re‐
moved, press onto input shaft and output shaft ⇒ page 355 .
♦ If needle roller bearing bushing for synchromeshed gear for
5th gear was removed, press onto input shaft ⇒ page 355 .
Gearbox for 1.4 l engine, if gear wheel for 5th gear was not press‐
ed off.
– Position assembled components, input shaft -2- and output
shaft -1- with bearing mounting for deep groove ball bearing,
in thrust piece - T10080- .
– Insert selector mechanism (selector forks) -4- in the shaft lock‐
ing collars.
– Install reverse gear shaft -3- with reverse gear.
– Screw guide pin - T10079- onto stud (secures reverse gear)
-arrow-.
324 Rep. gr.34 - Controls, housing
Eos 2006 ➤ , Golf 2004
agen➤ , Golf 2009A➤
AG. Volkswagen G d, Golf Plus 2005 ➤ , Golf Plus ...
oes
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by
Vol 6-speed manual gearbox
not
gu 0AJ - Edition 01.2017
ara
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Gearbox for 1.6 l engine au
th e or
ac
ss
Gearbox for 1.4 l engine, if gear wheel for 5th gear was pressed
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off.
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– Position assembled components, input shaft -2- and output
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ility
shaft -1- with bearing mounting for deep groove ball bearing,
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in thrust piece - T10080- .
, is n
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hole
– Insert selector mechanism (selector forks) -4- in the shaft lock‐
spec
ing collars.
es, in part or in w
t to the co
– Install reverse gear shaft -3- with reverse gear.
– Screw guide pin - T10079- onto stud (secures reverse gear)
rrectness of i
-arrow-.
l purpos
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at
om
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Continuation for all
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– Insert components together into gearbox while guiding guide
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pin - T10079- through hole to secure selector mechanism in
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gearbox housing.
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– Remove guide pin - T10079- .
op Vo
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Prote AG.
Note the following before pressing in:
♦ Selector forks engage correctly in locking collars.
♦ Check dimension -a- for output shaft teeth.
Note
♦ Due to different spline heights, dimension -a-, output shafts of
individual gearboxes have different lengths.
♦ A shim - T10083/1- (3 mm thick) may have to be fitted on the
input shaft to ensure that the input shaft and the output shaft
are always pressed in evenly.
♦ This is the reason why dimension -a- for output shaft teeth
must be measured.
Dimension -a- = 30.6 mm
Fit washer - T10083/1- onto input shaft ⇒ next figure.
5. Dismantling and assembling gearbox 325
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
Place shim - T10083/1- onto input shaft and carefully press in
bearing mounting together with input shaft and output shaft to
stop
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– Screw in reversing light switch - F4- -C-.
– Install pivot pin -B- in top of gearbox.
– Place selector plates in neutral.
– Apply sealant - AMV 188 200 03- evenly to sealing surface of
selector mechanism cover.
– Install selector shaft with selector cover -A-. Then tighten bolts
-arrows-.
326 Rep. gr.34 - Controls, housing
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
– Gearboxes for vehicles with Start/Stop system: fit gearbox
neutral position sender - G701- -arrow- and tighten securing
bolt to specified torque ⇒ Item 13 (page 314) .
– Using new bolts -A-, tighten bearing mounting for input andwagen AG. Volkswagen AG doe
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Fitting position for pressing on gear wheel for 5th gear and 5th
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Gearbox for 1.6 l engine
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– Set bushing on gear wheel for 5th gear item -2-.
Continuation for all
– Set 5th gear synchromeshed gear with needle bearing in place
item -3-.
– Place 5th gear synchro-ring on synchromeshed gear.
5. Dismantling and assembling gearbox 327
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
Installation position of synchro-hub/locking collar for 5th and 6th
gears
The high shoulder -arrow- faces 5th gear and gearbox housing.
– Press on synchro-hub and locking collar for 5th and 6th gear
⇒ page 327 .
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– Install synchromeshed gear for 6th gear with needle bearing
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– Heat cylindrical roller bearing inner race -B- to maximum 100°
C and press onto input shaft.
328 Rep. gr.34 - Controls, housing
Eos a2006
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– Heat gear wheel for 6th gear to maximum 100°C.
– Press on gear wheel for 6th gear, being careful that teeth of
ss
gear wheel -B- and synchronised gear for 6th gear -C- mesh.
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– Heat cylindrical roller bearing inner race -A- to maximum 100°
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– Then insert oil collector -A- in notch -1- and in hole -2- of gear‐
box housing.
– Now insert oil guide -B- into gearbox housing.
– The magnet is inserted into the oil guide -B-.
5. Dismantling and assembling gearbox 329
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– Insert selector fork for 5th and 6th gears -2- and push pivot pin
-1- in to stop -direction of arrow-.
– Apply sealant - AMV 188 200 03- evenly to sealing surface.
– Tighten gearbox housing cover.
– Install both flange shafts with springs, thrust washers and ta‐
pered rings.
– Install clutch release lever together with release bearing and
guide sleeve ⇒ page 130 .
330 Rep. gr.34 - Controls, housing
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
6 Gearbox housing and clutch housing
⇒ “6.1 Assembly overview - gearbox housing and clutch housing”,
page 331
6.1 Assembly overview - gearbox housing and clutch housing
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6. Gearbox housing and clutch housing 331
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
1 - Clutch housing
❑ If renewed, adjust differ‐
ential ⇒ page 377
2 - Input shaft seal
❑ Removing and installing
⇒ page 356
3 - Ball pin
❑ Removing and installing
⇒ Item 7 (page 129)
4 - Oil seal for right flange shaft
❑ Renewing with gearbox
installed ⇒ page 368
5 - Oil filler plug, torque setting
⇒ page 307
6 - Shim
❑ For differential
❑ Determining thickness
⇒ page 377
cardiagn.com
7 - Tapered roller bearing outer
race
❑ For differential
❑ Pressing out of and into
clutch housing
⇒ page 371
❑ If renewed, adjust differ‐
ential ⇒ page 377
8 - Bolt, 5 Nm + turn 90° further
❑ Always renew
9 - Tapered roller bearing outer wage
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12 - Oil drain plug, torque setting ⇒ page 307
t to the co
13 - Oil seal for left flange shaft
❑ Renewing with gearbox installed ⇒ page 367
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14 - Sleeve
s
❑ For selector shaft
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❑ Driving out ⇒ Fig. ⇒ page 333
inform
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❑ Driving in ⇒ page 333
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15 - Sealing cover
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332 Rep. gr.34 - Controls, housing
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
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20 - Plugs
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Driving in selector shaft sleeve -A- to stop
6. Gearbox housing and clutch housing 333
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
7 Gearbox housing cover
⇒ “7.1 Assembly overview - gearbox housing cover”, page 334
⇒ “7.2 Repairing gearbox housing cover”, page 335
7.1 Assembly overview - gearbox housing cover
1 - Countersunk head bolt,
2 Nm
❑ Tighten diagonally and
alternately.
2 - Mounting plate
❑ For securing cylindrical
roller bearings
❑ Installation position:
countersinks for coun‐
tersunk head bolts face
gearbox housing
❑ Not used with all gear‐
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4 - Cylindrical roller bearing
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❑ For output shaft
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334 Rep. gr.34 - Controls, housing
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
7.2 Repairing gearbox housing cover
Special tools and workshop
equipment required
♦ Press piece - VW 412-
♦ Drift sleeve - 40-21-
♦ Support bridge - 2011-
♦ -1- Internal puller - Kukko
21/5-
♦ -4- Counter support - Kukko
22/2-
♦ E.g. hot-air blower - V.A.G
1416-
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7. Gearbox housing cover 335
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
olkswagen AG
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- V.A.G 1416- to about 100 °C
ut in vicinity of bearing seat.
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– Insert cylindrical roller bearing
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in heated housing and press in
ce
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– Securing cylindrical roller bearings.
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Different locking elements for cylindrical roller bearings
The cover was adapted.
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1. - Securing with mounting plate 6
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336 Rep. gr.34 - Controls, housing
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
8 Selector unit
⇒ “8.1 Assembly overview - selector unit”, page 337
⇒ “8.2 Repairing selector unit”, page 338
8.1 Assembly overview - selector unit
Note
♦ Lubricate bearing positions and sliding surfaces.
♦ Allocate grease using ⇒ Electronic parts catalogue (ETKA) .
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⇒ page 333
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3 - Angled rod
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mechanism
❑ Removing ⇒ page 338
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❑ Driving in ⇒ page 339
s
4 - Deflector lever
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inform
⇒ page 159
mer
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❑ From 05.07, plastic re‐
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lay lever ⇒ page 162
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5 - Bearing bush
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❑ Installing ⇒ page 339
7 - Cap
❑ For gearbox breather
8 - Gearbox selector lever
❑ Install so that master
spline aligns with selec‐
tor shaft
❑ Can be renewed with the selector mechanism installed
❑ Fitting position ⇒ page 159
9 - Lock nut
❑ Self-locking, 23 Nm
10 - Lock washer
❑ Always renew
8. Selector unit 337
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
❑ Not required for plastic relay lever
8.2 Repairing selector unit
Special tools and work‐
shop equipment re‐
quired
♦ Tube - T10203-
cardiagn.com
♦ Tube - VW 423-
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– Then carefully lever
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338 Rep. gr.34 - Controls, housing
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
Drive angled rod -A- into selector shaft cover
Installation position:
Marking -1- aligns with marking -2- on selector cover.
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8. Selector unit 339
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
9 Selector forks
⇒ “9.1 Assembly overview - selector forks”, page 340
⇒ “9.2 Repairing selector forks”, page 341
9.1 Assembly overview - selector forks
Note
It is not necessary to dismantle the selector fork group in order to dismantle and assemble detent segments,
lock washers and angular contact ball bearings.
1 - Selector fork group with se‐
lector plate
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❑ Press inner race into
es, in part or in w
outer race ⇒ page 344
t to the co
❑ Installing ⇒ page 344
4 - Retainer
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❑ Always renew
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❑ Removing ⇒ page 343
❑ Installing ⇒ page 343
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6 - Selector fork for 5th and 6th
gears with selector segments
❑ Selector segment is per‐
manently connected to
selector fork.
❑ Identification ⇒ page 342
7 - Locating pin
❑ For selector fork for 5th and 6th gears
340 Rep. gr.34 - Controls, housing
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
9.2 Repairing selector forks
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♦ Press tool - 3290/1-
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♦ Press tool - VW 431-
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spec
♦ Spacer sleeve - VW 472/2-
urposes, in part or in wh
t to the co
♦ Drift - 10-206-
rrectness o
cial p
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mer
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9. Selector forks 341
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
♦ Release lever -
80-200-
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♦ Assembly mandrel -
10-508-
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Identification of selector
segments and selector
fork for 5th and 6th gear
with selector segments
Dimension -a-
1- Selector segment
for 1st and 2nd
gears = 10.0 mm
2- Selector segment
for 3rd and 4th
gears = 78.6 mm
3- Selector fork for 5th
and 6th gears with
selector segments
= 79.5 mm
342 Rep. gr.34 - Controls, housing
olkswagen AG
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Selector fork for 1st and 2nd gears
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Dimension -a- = 78 mm
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Removing lock washer
– Clamp selector fork in vice with protective jaw covers -B-.
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– Lever off lock washer -A- in -direction of arrow-.
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Installing lock washer
– Press lock washer into groove of detent segment using socket
and spinner handle.
Note
After lock washer is installed, detent segment must still rotate
freely.
A - Spinner handle with 10 mm socket
B - Vice clamp
Removing angular contact ball bearing
Note
When removing and installing angular contact ball bearing, do not
bend selector forks.
9. Selector forks 343
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
Pressing inner race -A- of angular contact ball bearing into outer
race
Inner race must engage in outer race.
Pulling angular contact ball bearing into selector fork to stop
Depression in thrust piece - 3290/1- faces ball bearing.
cardiagn.com
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344 Rep. gr.34 - Controls, housing
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
35 – Gears, shafts
1 Input shaft
⇒ “1.1 Assembly overview - input shaft”, page 345
⇒ “1.2 Dismantling and assembling input shaft”, page 348
⇒ “1.3 Renewing input shaft seal”, page 356
1.1 Assembly overview - input shaft
Note
♦ When installing new gears or new input shaft, refer to ⇒ Electronic Parts Catalogue “ETKA” and technical
data.
♦ Install all bearings, synchromeshed gears and synchro-rings on input shaft with gear oil.
♦ Do not interchange synchro-rings. When reusing always fit to the original gear.
cardiagn.com
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❑ Removing andriseinstalling
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⇒ page 311utho eo
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s
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❑ Combined with thrust
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washer ⇒ page 311
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hole
spec
inner race for cylindrical
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roller bearing of output
t to the co
shaft
❑ Removing and installing
⇒ page 316
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3 - Thrust washer
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❑ Combined with inner
race of cylindrical roller
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bearing ⇒ page 311
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5 - Synchro-ring for 6th gear
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⇒ page 352
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❑ For 6th gear
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❑ Replace together with
Prote AG.
bushing.
❑ Two-part ⇒ page 311
7 - Sleeve
❑ For 6th gear needle
bearing
❑ Renew together with
needle bearing.
❑ Removing and installing ⇒ page 316
1. Input shaft 345
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
8 - Locking collar with synchro-hub for 5th and 6th gear
❑ Removing and installing ⇒ page 316
❑ Dismantling ⇒ page 355
❑ Assembling locking collar and synchro-hub for 5th and 6th gears ⇒ page 355 and ⇒ page 355
❑ Fitting position ⇒ page 355
9 - Synchro-ring for 5th gear
❑ Will be damaged during removal of input shaft
❑ Always renew
❑ Checking ⇒ page 352
10 - Synchromeshed gear, 5th gear
11 - Needle bearing
❑ For 5th gear
❑ Renew together with sleeve
12 - Sleeve
❑ For 5th gear needle bearing
❑ Renew together with needle bearing
cardiagn.com
❑ Press off with bearing mounting with deep groove ball bearing
❑ Pressing on ⇒ page 355
13 - Gearbox housing
❑ Servicing ⇒ page 331
14 - Bearing mounting with deep groove ball bearing
❑ Renew deep groove ball bearing only together with bearing mounting
❑ If bearing support is separated from gearbox housing, the support must always be renewed
❑ Gearbox for 1.6 l engine: press off without gear wheel for 5th gear ⇒ page 351
❑ Gearbox for 1.4 l engine: press off with gear wheel for 5th gear ⇒ page 351
❑ Pressing on ⇒ page 355
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❑ Clean residual locking fluid from
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17 - Synchromeshed gear for 3rd gear
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18 - Synchro-ring for 3rd gear
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19 - Locking collar with synchro-hub for 3rd and 4th gear
spec
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❑ Press off with 3rd gear synchromeshed gear ⇒ page 351
t to the co
❑ Dismantling ⇒ page 352
❑ Installation position, locking collar and synchro-hub ⇒ page 352
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❑ Assembling ⇒ page 352 .
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❑ Pressing on ⇒ page 353
20 - Sleeve
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❑ For 4th gear needle bearing
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❑ Press off with 3rd gear synchromeshed gear ⇒ page 351
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346 Rep. gr.35 - Gears, shafts
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
AG. Volkswagen AG d
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23 - Synchromeshed gear for 4th gear ss a c
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24 - Thrust washer
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25 - Cylindrical roller bearing inner race
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❑ Pressing off ⇒ page 351
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❑ Pressing on ⇒ page 353
h re
hole
spec
26 - Locking ring
es, in part or in w
❑ Renewing
t to the co
❑ Determining thickness ⇒ page 354
27 - Cylindrical roller bearing
rrectness of i
❑ With retaining ring
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❑ Removing ⇒ page 350
❑ Pressing in ⇒ page 351 .
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❑ Installation position: retaining ring in bearing faces input shaft
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28 - Clutch housing
o
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❑ Servicing ⇒ page 331
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29 - Spring
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❑ Fitting position ⇒ page 355
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30 - 3rd and 4th gear locking collar
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31 - 3rd and 4th gear synchro-hub by c lksw
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32 - Locking pieces (qty. 3)
33 - Spring
❑ Fitting position ⇒ page 352
34 - Locking pieces (qty. 3)
35 - Synchro-hub for 5th and 6th gears
36 - Locking collar for 5th and 6th gears
1. Input shaft 347
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
1.2 Dismantling and assembling input shaft
Special tools and workshop
equipment required
♦ Pressure plate - VW 401-
♦ Pressure plate - VW 402-
♦ Press piece - VW 407-
♦ Press piece - VW 412-
♦ Tube - VW 415 A-
♦ Tube - VW 422-
cardiagn.com
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348 Rep. gr.35 - Gears, shafts
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
♦ Spacer sleeve - VW 472/2-
♦ Tube - VW 516-
♦ Extension - 30-23-
♦ Drift sleeve - 30-100-
♦ Press tool - T10080-
♦ Press tool - T10081-
cardiagn.com
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♦ Shim - T10083/1-
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1. Input shaft 349
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
♦ Thrust block - T10083-
♦ Pressure plate - T10084 A-
♦ -1- Internal puller - Kukko AG. Volkswagen AG d
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Pulling cylindrical roller bearing out of clutch housing
– When pulling out, squeeze together retaining ring -arrow- of
cylindrical roller bearing, using pliers -C-.
A - Counter support , e.g. -Kukko 22/1-
B - Internal puller, 30…37 mm , e.g. -Kukko 21/5-
350 Rep. gr.35 - Gears, shafts
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
Pressing cylindrical roller bearing into clutch housing
– Support gearbox housing with tube - VW 415 A- (not visible in
figure) directly below bearing support.
– When pressing in, squeeze together retaining ring -arrow- for
cylindrical roller bearing using pliers -A-.
– Remove pliers before cylindrical roller bearing is in installation
position. Retaining ring must engage in groove of clutch hous‐
ing.
Gearbox for 1.4 l engine
Pressing off bearing mounting with deep groove ball bearing and
gear wheel for 5th gear -A-
– Slide locking collar for 1st and 2nd gear towards 2nd gear.
– Then slide thrust plate - T10084 A- sideways onto input shaft
to stop.
Gearbox for 1.6 l engine
cardiagn.com
Pressing off bearing mounting with deep groove ball bearing
– Slide locking collar for 1st and 2nd gear towards 2nd gear.
AG. Volkswagen AG d
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– Then slide thrust plate - T10084 A- sideways onto input shaft olks
w not
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to stop. se
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Continuation for all utho eo
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Pressing off cylindrical roller bearing inner race
es, in part or in w
t to the co
– Remove retaining ring.
– Press off cylindrical roller bearing inner race together with
thrust washer, 4th gear synchromeshed gear with needle rrectness of i
bearing, locking collar and synchro-hub for 3rd and 4th gear
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1. Input shaft 351
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6-speed manual gearbox 0AJ - Edition 01.2017
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Dismantling and assembling 3rd and 4th gears locking collar and
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synchro-hub
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3- Synchro-hub
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spec
4- Locking piece
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t to the co
– Slide locking collar over synchro-hub.
Deeper notches -arrow A- for locking pieces in synchro-hub and
rrectness of i
notches -arrow B- in locking collar must align.
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Assembling locking collar and synchro-hub for 3rd and 4th gears
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– Insert locking pieces in deeper notches -arrows- and install yri
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springs offset 120°. Angled end of spring must locate in hollow
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locking piece.
Prote AG.
Installation position of locking collar with synchro-hub for 3rd and
4th gear
Groove on top -arrow- faces 4th gear.
Checking synchro-ring
– Press synchro-ring onto cone of synchromeshed gear and
measure gap -a- using feeler gauge.
– Measure gap size -a- at 3 points offset by 120° using feeler
gauge.
– Make a note of average value.
Gap -a- Installation dimen‐ Wear limit
sion
3rd, 4th, 5th and 1.1 … 1.7 mm 0.5 mm
6th gear
352 Rep. gr.35 - Gears, shafts
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
Pressing on synchro-hub with locking collar for 3rd and 4th gears
Installation position: high inside collar faces 3rd gear synchro‐
meshed gear.
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Pressing on sleeve -A- for 4th gear needle bearing
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– After pressing on bushing -A-, fit 4th gear needle bearing, syn‐
h re
hole
chromeshed gear for 4th gear and thrust washer.
spec
es, in part or in w
t to the co
rrectness of i
cardiagn.com
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Pressing on inner race -A- for cylindrical roller bearing
co Vo
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Prote AG.
1. Input shaft 353
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
Determining thickness of retaining ring AG. Volkswagen AG d
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s
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ing ring -A- using feeler gauge -C-.
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– Remove retaining ring (only used for measuring purposes).
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spec
Note
es, in part or in w
t to the co
Allocate retaining rings according to ⇒ Electronic parts catalogue
“ETKA” .
rrectness of i
The following securing clips are available:
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Measured value Retaining ring thick‐ Axial play (mm)
(mm) ness (mm)
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0.05 … 0.14 2.0 0.05 … 0.15
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0.15 … 0.24 2.1 0.05 … 0.15
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rig
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Note
♦ Due to different spline heights, dimension -a-, output shafts of
individual gearboxes have different lengths (shown here with
shafts installed).
♦ To ensure that bearing support is always evenly pressed onto
shafts, it is necessary for shafts always to be inserted evenly
into thrust block - T10083- .
♦ If necessary, insert a shim - T10083/1- (3 mm thick) into
mounting hole for input shaft ⇒ page 354 .
♦ This is the reason why dimension -a- for output shaft teeth
must be measured.
Dimension -a- = 30.6 mm
Insert shim - T10083/1- ⇒ next figure.
Fit shim - T10083/1- .
354 Rep. gr.35 - Gears, shafts
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
Pressing on bearing support
WARNING
Wear protective gloves.
Pressing on sleeve -A- for 5th gear needle bearing
cardiagn.com
Dismantling and assembling locking collar and synchro-hub for
5th and 6th gear
1- Spring
2- Sliding sleeve
3- Synchro-hub
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– Slide locking collar over synchro-hub.
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ss
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notches -arrow B- in locking collar must align.
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Assembling locking collar and synchro-hub for 5th and 6th gears
rrectne
• Locking collar has been pushed over synchro-hub.
– Insert locking pieces in deeper notches -arrows- and install
ss o
springs offset 120°.
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• Angled end of spring must locate in hollow locking piece.
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Prote AG.
1. Input shaft 355
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
1.3 Renewing input shaft seal
Special tools and workshop equipment required
♦ Oil seal extractor lever - T20143/1-
♦ Press tool - T40008-
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♦ Sealing grease
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and guide sleeve ⇒ page 130 .
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t to the co
Do not damage running surface of input shaft for oil seal.
– Half-fill space between sealing lip and dust lip -arrow- with
rrectness of i
sealing grease .
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– Lightly moisten outer circumference of oil seal with gear oil.
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356 Rep. gr.35 - Gears, shafts
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
AG. Volkswagen AG d
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Driving in input shaftrise oil seal flush nte
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– Install clutch
s release lever together with release bearing and c
s
guide sleeve ⇒ page 130 .
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1. Input shaft 357
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
2 Output shaft
⇒ “2.1 Assembly overview - output shaft”, page 358
⇒ “2.2 Dismantling and assembling output shaft”, page 361
2.1 Assembly overview - output shaft
Note
♦ When installing new gears or new output shaft, refer to ⇒ Electronic Parts Catalogue “ETKA” and technical
data.
♦ Install all bearings, synchromeshed gears and synchro-rings on output shaft with gear oil.
♦ Do not interchange synchro-rings. When reusing always fit to the original gear.
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❑ Servicing ⇒ page
ss 331
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2 - Cylindrical roller bearing
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3 - Output shaft
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4 - Gear wheel for 4th gear
❑ Installation position:
shoulder faces 3rd gear
⇒ page 363
5 - Locking ring
6 - Locking ring
7 - Gear wheel for 3rd gear
❑ Installation position: shoulder faces 4th gear ⇒ page 363
8 - Locking ring
9 - Synchromeshed gear, 2nd gear
10 - Needle bearing
❑ For 2nd gear
358 Rep. gr.35 - Gears, shafts
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
11 - Inner ring for 2nd gear
❑ Check lugs for scoring
❑ Installation position ⇒ page 364
❑ Checking synchro-ring, outer ring and inner ring together for wear ⇒ page 363
12 - Outer bearing race for 2nd gear
❑ Installation position ⇒ page 364
❑ Check for scoring or signs of abnormal wear
❑ Checking synchro-ring, outer ring and inner ring together for wear ⇒ page 363
13 - Synchro-ring for 2nd gear
❑ Installation position ⇒ page 364
❑ Checking synchro-ring, outer ring and inner ring together for wear ⇒ page 363
14 - Locking collar with synchro-hub for 1st and 2nd gear
❑ After removing retaining ring, press off with 2nd gear synchromeshed gear ⇒ page 363
❑ Dismantling ⇒ page 364
❑ Assembling locking collar and synchro-hub ⇒ page 364 and ⇒ page. V364
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❑ Pressing on ⇒ page 365 b
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❑ Installing ⇒ page 365
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❑ Assemble so that notches engage in locking pieces of locking collar.
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17 - Outer ring for 1st gear
❑ Check for scoring or signs of abnormal wear
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❑ Checking synchro-ring, outer ring and inner ring together for wear ⇒ page 363
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❑ Fitting position ⇒ page 365
❑ Insert in synchro-ring
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❑ Fitting position ⇒ page 366
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21 - Bearing mounting with deep groove ball bearing
❑ Renew deep groove ball bearing only together with bearing mounting
❑ If bearing support is separated from gearbox housing, the support must always be renewed
❑ Press off without gear wheel for 5th gear ⇒ page 351
❑ Press off with gear wheel for 5th gear ⇒ page 351
❑ Pressing on ⇒ page 355
22 - Gearbox housing
❑ Servicing ⇒ page 331
23 - Bolt
❑ Removing and installing ⇒ page 311
2. Output shaft 359
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
. Volkswagen AG
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24 - Cylindrical roller bearing inner race olks
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❑ Removing and installing ⇒ page 316
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25 - Gear wheel for 6th gear
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❑ Installation position: ⇒ page 329 .
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26 - Sleeve
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❑ Removing and installing ⇒ page 316
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27 - Gear wheel for 5th gear
❑ Fitting position ⇒ page 327
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❑ Must be pressed off and pressed on in gearboxes for the 1.4 l engine ⇒ page 327
28 - Spring
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❑ Fitting position ⇒ page 364
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29 - Sliding sleeve
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30 - Synchro-hub
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31 - Locking pieces (qty. 3)
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360 Rep. gr.35 - Gears, shafts
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
2.2 Dismantling and assembling output shaft
Special tools and workshop
equipment required
♦ Pressure plate - VW 402-
♦ Press piece - VW 407-
♦ Tube - VW 415 A-
♦ Press tool - VW 432-
♦ Drift sleeve - 30-100-
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2. Output shaft 361
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
♦ -1- Internal puller -
Kukko 21/5-
♦ -4- Counter support -
Kukko 22/1-
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Pressing cylindrical roller bearing into clutch housing
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figure) directly below bearing support.
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– When pressing in, squeeze together retaining ring -arrow- for
cylindrical roller bearing using pliers -A-.
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Pressing retaining ring -1- out of groove
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A - Protective gloves
WARNING
Ensure retaining ring does not spring out uncontrolled.
362 Rep. gr.35 - Gears, shafts
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
Pressing off 1st and 2nd gear locking collar and synchro-hub
– After removing retaining ring, press off synchromeshed gear
for 2nd gear together with locking collar and synchro-hub.
Installation position of 3rd gear and 4th gear
– Install gear wheel for 4th gear -A- on output shaft.
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– Install gear wheel for 3rd gear -B- on output shaft.
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Checking 1st and 2nd gear synchro-ring, outer ring and inner ring
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t to the co
– Press synchro-ring, outer ring and inner ring onto cone of syn‐
chromeshed gear and measure gap -a- at 3 points offset by
rrectness of i
120° using a feeler gauge.
– Make a note of average value.
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1st and 2nd gears 1.1 … 1.8 mm 0.5 mm
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2. Output shaft 363
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
Installation position of outer ring, inner ring and synchro-ring for
2nd gear
– Place inner ring -A- on 2nd gear synchromeshed gear.
Angled lugs -arrow 1- face outer ring -B-.
– Fit outer ring -B-.
Lugs -arrow 2- engage in notches -arrow 3- of synchromeshed
gear.
– Fit synchro-ring -C-.
Notches -arrow 4- engage in lugs -arrow 1- of inner ring -A-.
Dismantling and assembling locking collar and synchro-hub for
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1st and 2nd gears
1- Spring
2- Sliding sleeve agen
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urposes, in part or in wh
notches -arrow E- in locking collar must align.
t to the co
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Assembling locking collar with synchro-hub for 1st and 2nd gears
ss o
• Locking collar has been pushed over synchro-hub.
cial p
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– Insert locking pieces in deeper cut-outs -arrows- and install
mer
springs offset 120°. Angled end of spring must locate in hollow
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locking piece.
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364 Rep. gr.35 - Gears, shafts
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
Pressing on locking collar and synchro-hub for 1st and 2nd gears
Installation position:
AG. Volkswagen AG d
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Groove in locking collar forolkselector
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– Place 1st gear synchro-ring in locking collar/synchro-hub.
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Installation position of 1st gear outer ring
Lugs -arrows- face towards reverse gear teeth.
Installation position of 1st gear inner ring -A-
Lugs -arrow 1- engage in notches -arrow 2- in synchro-ring -B-.
2. Output shaft 365
AG. Volkswagen AG d
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Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus oris2005 ➤ , Golf Plus ... nte
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6-speed manual gearbox 0AJ - Edition 01.2017 s au ra
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Installation position of synchromeshed gear for 1st gear
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Higher shoulder -A- faces 2nd gear -B-. Notches in shoulder
erm
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ility
-arrows- engage in lugs of outer ring ⇒ page 365 .
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– Press bearing mounting with deep groove ball bearing onto
h re
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input shaft and output shaft, from ⇒ page 355
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366 Rep. gr.35 - Gears, shafts
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
39 – Final drive - differential
1 Oil seals
⇒ “1.1 Renewing left flange shaft oil seal with gearbox installed”,
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1.1 Renewing left flange shaft oil seal with gearbox installed
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Special tools and workshop
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♦ Multipurpose tool - VW
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spec
771-
urposes, in part or in wh
t to the co
♦ Extractor hook - VW
771/37-
♦ Press tool - T10160-
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♦ Torque wrench -
s
V.A.G 1331-
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♦ Sealing grease
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Electronic parts catalogue
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Removing
– Remove left wheel.
– Remove noise insulation ⇒ General body repairs, exterior;
Rep. gr. 50 ; Noise insulation
– Turn steering to left lock.
– Unbolt drive shaft from flange shaft ⇒ Running gear, axles,
steering; Rep. gr. 40 ; Repairing drive shaft; Removing and
installing drive shafts .
1. Oil seals 367
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
– If possible, lift drive shafts clear and tie in place; do not damage
surface protection.
– Place drip tray under gearbox.
– Remove flange shaft securing bolt by screwing two bolts into
flange and counter holding flange shaft with a lever.
– Pull out flange shaft with compression spring.
– Pull out flange shaft oil seal using multi-purpose tool - VW 771-
and puller hooks - VW 771/37- .
Installing
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– Drive in new seal to stop, being careful not to cant seal.
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– Insert flange shaft.
spec
es, in part or in w
– Secure flange shaft using countersunk bolt and tighten to
t to the co
25 Nm.
– Bolt drive shaft to flange shaft ⇒ Running gear, axles, steering;
rrectness of i
Rep. gr. 40 ; Repairing drive shaft; Removing and installing
drive shafts .
l purpos
– Check gear oil level and top up to lower edge of oil filler hole
if necessary ⇒ page 306 .
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– Install noise insulation ⇒ General body repairs, exterior; Rep.
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gr. 50 ; Noise insulation. .
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1.2 Renewing right flange shaft oil seal with gearbox installed
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Prote AG.
368 Rep. gr.39 - Final drive - differential
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
Special tools and workshop
equipment required
♦ Multipurpose tool - VW
771-
♦ Extractor hook - VW
771/37-
♦ Press tool - T10160-
♦ Torque wrench -
V.A.G 1331-
♦ Sealing grease
♦ Allocate grease using ⇒
Electronic parts catalogue
(ETKA) .
cardiagn.com
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Removing
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Rep. gr. 50 ; Noise insulation
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– Remove drive shaft heat shield, if present -arrows- ⇒ Running
tion in
gear, axles, steering; Rep. gr. 40 ; Repairing drive shafts; Re‐
r
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thi
moving and installing drive shafts .
s
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– Unbolt drive shaft from flange shaft ⇒ Running gear, axles,
rp
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steering; Rep. gr. 40 ; Repairing drive shaft; Removing and
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– Place drip tray under gearbox.
1. Oil seals 369
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
. Volkswagen AG
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– Remove flange shaft securing bolt by screwing
Vol
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a
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– Pull out flange shaft oil seal using multi-purpose tool - VW 771-
rrectness of i
and puller hooks - VW 771/37- or prise out using a lever.
Installing
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or
thi
te
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r
rp
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m
f
en
ng
t.
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Cop py
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– Drive in new seal to stop, being careful not to cant seal.
gh ht
pyri by
Vo
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by
– Half-fill space between sealing lip and dust lip with sealing cted agen
Prote AG.
grease .
– Insert flange shaft.
– Secure flange shaft using countersunk bolt and tighten to
25 Nm.
– Bolt drive shaft to flange shaft ⇒ Running gear, axles, steering;
Rep. gr. 40 ; Repairing drive shaft; Removing and installing
drive shafts .
– Install drive shaft heat shield, if present -arrows- ⇒ Running
gear, axles, steering; Rep. gr. 40 ; Repairing drive shafts; Re‐
moving and installing drive shafts .
– Check gear oil level and top up to lower edge of oil filler hole
if necessary ⇒ page 306 .
– Install noise insulation ⇒ General body repairs, exterior; Rep.
gr. 50 ; Noise insulation. .
370 Rep. gr.39 - Final drive - differential
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
2 Differential
⇒ “2.1 Assembly overview - differential”, page 371
⇒ “2.2 Dismantling and assembling differential”, page 373
⇒ “2.3 Adjusting differential”, page 377
AG. Volkswagen AG d
agen
2.1 Assembly overview - differentialby Volksw oes
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1 - Countersunk bolt, 25 Nm au ra
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ss
❑ Renew after removal
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❑ Screw in together with
itte
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threaded piece rm
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ility
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2 - Right flange shaft
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, is n
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3 - Compression spring for
hole
spec
flange shaft
es, in part or in w
t to the co
❑ Installed behind flange
shafts
cardiagn.com
4 - Thrust washer
rrectness of i
❑ Installation position:
l purpos
shoulder towards spring
5 - Tapered ring
nform
ercia
❑ Installation position:
m
taper towards differen‐
a
com
tio
tial cage
n in
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te o
thi
6 - Locking ring
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iva
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❑ Holds tapered ring,
rp
cum
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thrust washer and
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spring in position when
Co
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flange shaft is removed
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ht ht
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7 - Large differential bevel gear
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❑ Availability ⇒ Electronic
AG.
Parts Catalogue (ETKA)
❑ Installing ⇒ page 377
8 - Threaded piece
❑ Availability ⇒ Electronic
Parts Catalogue (ETKA)
❑ Installing ⇒ page 377
9 - Differential pinion pin
❑ Availability ⇒ Electronic Parts Catalogue (ETKA)
❑ To remove, shear off spring pin ⇒ page 377
❑ Installing ⇒ page 377
10 - Small differential bevel gear
❑ Availability ⇒ Electronic Parts Catalogue (ETKA)
❑ Installing ⇒ page 377
11 - One-piece thrust washer
❑ Availability ⇒ Electronic Parts Catalogue (ETKA)
❑ Coat with gear oil when installing
2. Differential 371
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
12 - Left flange shaft
13 - Oil seal for left flange shaft
❑ Renewing with manual gearbox installed ⇒ page 367 .
14 - Tapered roller bearing outer race
❑ Removing ⇒ page 375
❑ Pressing in ⇒ page 376 .
15 - Tapered roller bearing inner race
❑ Pulling off ⇒ page 376
❑ Pressing on ⇒ page 376
16 - Differential cage
❑ With final drive gear
17 - Retaining sleeve
❑ Availability ⇒ Electronic Parts Catalogue (ETKA)
❑ For securing differential pinion pin
❑ Will be sheared off when removed ⇒ page 377
18 - Tapered roller bearing inner race
cardiagn.com
❑ Pulling off ⇒ page 376
❑ Pressing on ⇒ page 376
19 - Tapered roller bearing outer race
❑ Pressing out ⇒ page 376 .
❑ Pressing in ⇒ page 377 .
20 - Shim
❑ For differential
❑ Determining thickness ⇒ page 377
AG. Volkswagen AG d
21 - Oil seal for right flange shaft lksw
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not
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❑ Renewing with manual gearbox ed installed ⇒ page 368 .
b y ara
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22 - Clutch housing aut or
ac
ss
❑ Servicing ⇒ page 331
ce
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un
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an
23 - Gearbox housing
d
itte
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erm
ab
❑ Servicing ⇒ page 331
ility
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f inform
mer
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n thi
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pr
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fo
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ng
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Cop py
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rig ht
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by lksw
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Prote AG.
372 Rep. gr.39 - Final drive - differential
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
2.2 Dismantling and assembling differential
Special tools and workshop
equipment required
♦ Pressure plate - VW 402-
♦ Pressure plate - VW 401-
♦ Press piece - VW 408 A-
AG. Volkswagen AG d
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♦ Press piece - VW 412- olksw not
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d by ara
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♦ Tube - VW 418 A- horis nte
eo
aut ra
♦ Thrust plate - 30-205- ss c
ce
le
un
pt
an
d
itte
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erm
ab
ility
ot p
wit
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ole,
spec
urposes, in part or in wh
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rrectness o
cial p
f inform
mer
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n
c
i
or
n thi
te
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pr
cum
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fo
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ng
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Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
2. Differential 373
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
AG. Volkswagen AG d
agen oes
olksw not
V
♦ Installing sleeve - VW 455- ed by gu
ara
ris nte
o
♦ Spacer sleeve - VW 472/2- aut
h eo
ra
ss c
♦ Drift sleeve - 40-21-
ce
le
un
pt
an
d
♦ Tube - 30-14-
itte
y li
rm
ab
♦ Tube - 2040-
pe
ility
ot
wit
, is n
♦ Press tool - 3002-
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
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r
te o
thi
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r
rp
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fo
en
ng
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Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
374 Rep. gr.39 - Final drive - differential
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
♦ Retainer - 3067-
♦ Tube - 3259-
♦ Tapered roller bearing pull‐
er - V.A.G 1582-
♦ Grip tool - V.A.G 1582/3-
♦ -1- Internal puller - Kukko
21/7-
♦ -4- Counter support - Kukko
22/2-
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
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cardiagn.com
s
ce
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un
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an
d
itte
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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
l purpos
nform
mercia
a
com
tion in
r
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Note
s
iva
do
r
rp
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fo
♦ Heat tapered roller bearing inner races to 100 °C before in‐
en
ng
t.
stalling.
yi Co
Cop py
ht. rig
♦ Always renew both tapered roller bearings together as a set. rig ht
py by
co Vo
by lksw
♦ If tapered roller bearings, differential cage, gearbox housing cted agen
Prote AG.
or clutch housing is renewed, adjust differential ⇒ page 377 .
Pulling outer race for tapered roller bearing out of gearbox hous‐
ing
A - Counter support , e.g. -Kukko 22/2-
B - Internal puller, 46…58 mm , e.g. -Kukko 21/7-
2. Differential 375
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
Pressing tapered roller bearing outer race into gearbox housing
– Support gearbox housing with tube - 3259- directly below
bearing support.
Pulling off tapered roller bearing and inner race
Note
Both tapered roller bearing inner races are pulled off the differ‐
ential cage in the same way.
cardiagn.com
olkswagen AG
en AG. V
Pressing on tapered roller bearingolinner
ksw race
ag does
not
V gu
by ara
– Support inner race on opposite
ris
ed side using installing sleeve - nte
VW 455- . tho eo
au ra
c
ss
Shoulder of installing sleeve - VW 455- faces towards differential
ce
le
un
pt
cage.
an
d
itte
y li
rm
ab
pe
ility
Note
ot
wit
, is n
h re
hole
Both tapered roller bearing inner races are pressed onto the dif‐
spec
ferential cage in the same way.
es, in part or in w
t to the co
Pressing tapered roller bearing outer race -A- out of clutch hous‐
rrectness of i
ing
B - Internal puller, 46…58 mm , e.g. -Kukko 21/7-
l purpos
– Clamp internal puller securely behind tapered roller bearing
nform
ercia
outer race.
m
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
376 Rep. gr.39 - Final drive - differential
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
Pressing tapered roller bearing outer race into clutch housing
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
Pressing out differential pinion pin
du
an
itte
y li
erm
When pressed out, spring pin will be sheared off.
ab
ility
ot p
– Drive remainder of spring pin out of differential cage.
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
cardiagn.com
rrectness of i
l purpos
nform
ercia
Installing differential bevel gears
m
– Lubricate one-piece thrust washer with gear oil and install.
at
om
ion
c
– Install both sun wheels and secure (e.g. with flange shaft).
in t
or
his
ate
– Insert planet pinions offset 180° and pivot into position.
do
priv
cum
or
– Press in differential pinion pin (-arrow A-) to first planet pinion.
f
en
ng
t.
yi Co
op
– Place threaded pieces -arrows B- in sun gears. C py
t. rig
gh ht
yri by
– Drive differential pinion pin into final position and secure with cop Vo
by lksw
spring pin. cted agen
Prote AG.
2.3 Adjusting differential
2. Differential 377
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
Volkswagen AG
Special tools and workshopswagen AG. does
equipment required by Volk not
gu
ara
d
se nte
♦ End dimension hoplate -
ri eo
ut
VW 385/17-
ss
a ra
c
ce
le
♦ Universal dial gauge holder
un
pt
an
- VW 387-
d
itte
y li
rm
ab
♦ Pressure plate - VW 402-
pe
ility
ot
wit
♦ Pressure plate - VW 401-
, is n
h re
hole
♦ Press piece - VW 408-
spec
es, in part or in w
♦ Press piece - VW 412-
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tio
cardiagn.com
n 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.
378 Rep. gr.39 - Final drive - differential
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
♦ Thrust plate - 30-205-
♦ Tube - 30-14-
♦ Tube - 2040-
♦ Tube - 3259-
♦ Torque wrench -
V.A.G 1331-
♦ -1- Internal puller - Kukko
21/7-
♦ Dial gauge
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
cardiagn.com
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
It is necessary to readjust the differential when the following com‐
r
rp
cum
fo
ponents are renewed:
en
ng
t.
yi Co
op
♦ Gearbox housing C py
t. rig
gh ht
yri
♦ Clutch housing
p by
co Vo
by lksw
cted agen
♦ Differential cage
Prote AG.
or the
♦ Tapered roller bearing of differential
Requirement:
• Sealing surfaces of clutch and gearbox housings must be free
of sealant.
2. Differential 379
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
6-speed manual gearbox 0AJ - Edition 01.2017
– Pressing tapered roller bearing outer race (gear wheel slide)
into gearbox housing.
Note
Inner and outer tapered roller bearing races are paired. Do not
interchange!
– Press tapered roller bearing outer race (opposite gear wheel)
with no shim into gearbox housing.
– Insert differential in gearbox housing.
– Fit clutch housing and tighten 5 bolts to specified torque.
cardiagn.com
– Attach dial gauge and set to “0” with 1 mm preload.
A - 30 mm dial gauge extension
– Set dial gauge to “0” with 1 mm preload for bearing.
– Move differential up and down. Read and note play indicated
on dial gauge. (Example: 1.50 mm)
Determining thickness of shimgen AG. Volkswagen AG d
a oes
lksw no
The specified bearing db
ypreload
Vo is obtained by adding a tconstant
gu
ara
value for preloador(0.35
ise mm) to the reading obtained. nte
e th or
Example: au ac
ss
ce
le
un
pt
Measured value 1.50 mm
an
d
itte
y li
+ Preload (constant) 0.35 mm
erm
ab
ility
Thickness of shim = 1.85 mm
ot p
wit
is n
h re
ole,
– Remove clutch housing and press out tapered roller bearing
spec
urposes, in part or in wh
outer race -A-.
t to the co
B - Internal puller, 46…58 mm , e.g. -Kukko 21/7-
– Allocate shim(s) using ⇒ Electronic Parts Catalogue “ETKA” .
rrectne
The various thicknesses make it possible to achieve the exact
shim thickness required.
ss o
cial p
If the size of shim required is larger than those listed in the ⇒
inform
Electronic Parts Catalogue “ETKA” , insert two shims totalling the
mer
correct figure.
atio
om
– Insert correct shim (in example 1.85 mm) and press tapered
c
i
or
roller bearing outer race into clutch housing again.
thi
te
sd
iva
– Fit clutch housing and tighten bolts to specified torque.
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
380 Rep. gr.39 - Final drive - differential
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