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. icremmocroetavirprofgniypoCla rup op s e s , i n p a r t o r in w hole, isnotpermittedunlessauthorisedbyVolkswagen AG Volkswagen AGdoesnotguaranteeoracceptanyliabilitywith respect t o t h e c o r r e c t n e ss o f niGAnegawskloVybthgirypoC.tnemucodsihtninoitamrof

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Gearbox code letters: 2H2Y4K4S4T4Y6G7A7G 8A9AACDAENAGBAUGCHBDGGFD FFFFZFHFJFKFMFNFO

List of Workshop Manual Repair Groups

5 speed manual Gearbox 020 Edition 10.87

Repair GroupTechnical Bulletins

00 Technical data

30 Clutch

34 Controls, housing

35 Gears, shafts

39 Final drive - differential

Technical Information should always be available to all foremen and mechanics, because their com- pliance with the instructions given is essential to ensure vehicle roadworthiness and safety. In the normal safety precautions to be observed when working on motor vehicles are also applicable.

00 Technical data

Gearbox identification .

- Speedometter drive pinions .

- Code letters, gearbox allocation, ratios, oil capacities (up to 07.82)

- Code letters, gearbox allocation, ratios, oil capacities (up to 07.82)

- Code letters, gearbox allocation, ratios, oil capacities (up to 07.82)

- Code letters, gearbox allocation, ratios, oil capacities (from 8.82) (up to 07.83)

- Code letters, gearbox allocation, ratios, oil capacities (from 8.82 up to 07.83)

- Code letters, gearbox allocation, ratios, oil capacities (from 8.82 up to 7.83)

- Code letters, gearbox allocation, ratios, oil capacities (from 8.83)

- Code letters, gearbox allocation, ratios, oil capacities (from 8.83)

- Code letters, gearbox allocation, ratios, oil capacities (from 8.83)

- Code letters, gearbox allocation, ratios, oil capacities (from 8.83)

- Transmission layout

30 Clutch Page Clutch

- Repairs to the clutch mechanism

- Clutch cable chafing against brake fluid reservoir.

- Repairs to clutch (190/200 mm dia.)

34 Controls, housing Page Controls, Housing

- Operation of shift mechanism

- Repair shift linkage

- Adjusting gearshift linkage

- Adjusting selector shaft retaining screw

- Adjusting retaining screw for 5th gear

- Selector shaft lever self-locking nut

- Removing and installing bonded rubber bushes for gearbox carrier

- Removing and installing gearbox

- General view

- Dismantling and assembling gearbox

- Dismantling and assembling gearbox

- Dismantling and assembling gearbox

- Dismantling and assembling gearbox

- Dismantling and assembling gearbox

- Dismantling and assembling gearbox

- Vehicles with gearchange and consumption indicator

- Additional bearing for output shaft

- Gearbox breather relocation

- TDC sensor adapter in clutch housing

- Spring for the reverse gear relay lever

- Modified locating and mounting of the selector shaft in the gearbox

- Additionally securing magnet in clutch housing with sealing compound

- Selector shaft cover modified

35

- Dismantling and assembling input shaft

- Dismantling and assembling output shaft

- Adjusting output shaft

- Synchronizer hub for 5th gear with retaining ring for locking keys

- Dismantling and assembling output shaft (pinion shaft)

39 Final drive - differential

- Removing and installing drive flange oil seal

- Dismantling and assembling differential

- Adjustment table

- Adjusting differential

- Play free location of drive flange shafts

- Differential with cones: dismantling and assembling

.34-72

- Differential bevel gear shaft secured with extended rivets

Gearboxidentification

Gearboxcodelettersanddateofmanufacture(Arrow1)

Gearbox020(Arrow2)

00-1

- Gearboxcodelettersanddateofmanufacture

Example: FO 18 04 9 ||| | Code letters Day Month Yearof manufacture(79) - 5speedmanualgearbox020

Speedometterdrivepinions

Bellowisalistofspeedometerdrivepinionsat presentbeingfittedtoourmodelsinProduction. Model Pinioncolour PartNo. Teeth

CitiGolf Sport Red 171957 821B 15

Pick-Up Sport White 171957 821A 16

TDCsensoradapterinclutchhousing=>page34-76

Codeletters,gearboxallocation,ratios,oilcapacities(upto07.82)

Codeletters

Oilcapacities 2.0ltrs.

Specification GearoilGL4(MIL-L2105)SAE80

Clutchcontrol mechanical

Clutchplatedia 190mm(Dieselfrom12.80200mm)

Driveflangedia 90mm

Tyres:Dynamicrollcircumference approx.1.75

Overallratiointopgear

(upto7.8035.6Km/h)

Remarks: Inputshaft bearing: 66mmdiam 4+E GCI 4) 4+E

1) Upto7.80-31:32=0.969

2) Upto7.80-44:58=0.759

3) Speedopinionmilk-grey Inputshaftbearing:68mmdiam.

4) GCI:GearchangeandConsumptionIndicator

00-5

Codeletters,gearboxallocation,ratios,oilcapacities(upto07.82)

Allocation Model Golf,Jetta Scirocco Engine 1.6l.-63Kw 81Kw

Ratios

Z2:Z1

Finaldrive 74:19=3.89

1stgear 38:11=3.45 2ndgear 35:18=1.94

3rdgear 36:28=1.29 4thgear 30:33=0.909 1) 5thgear 27:38=0.711 2) Reverse 38:12=3.17 Speedo 16:7=2.29 3)

Oilcapacities 2.0ltrs.

Specification GearoilGL4(MIL-L2105)SAE80

Codeletters

Clutchcontrol Mechanical

Clutchplatedia. 63Kw:190mm81Kw:200mm

Clutchflangedia. 63Kw:90mm81Kw:100mm

Tyres:Dynamicrollcircumference approx.1.75

Overallratiointopgear 2.766(upto7.802.953)

Speedintopgearat 37.96Km/h

1000rpm (upto7.8035.6Km/h)

Remarks:

1) Upto7.80-31:32=0.969

2) Upto7.80-44:58=0.759

3) Speedopinionmilky-grey

4) Cones,SeeW.BNo.3=>page2

5) GCI:GearchangeandConsumptionIndicator

Cones 4) 4+E 81Kw from8.81

Codeletters,gearboxallocation,ratios,oilcapacities(upto07.82)

Cones 4) 4+E GCI 5)

Allocation Model Golf,Jetta Scirocco Sciroccoupto12.80 Engine Engine 1.6l-81Kw

Ratios

Z2:Z1 Finaldrive 74:19=3.89

1stgear 38:11=3.45 2ndgear 36:17=2.12

3rdgear 39:27=1.44

4thgear 35:31=1.13 5thgear 31:34=0.912

Reverse 38:12=3.17

Speedo 16:7=2.29 1)

Codeletters

Oilcapacities 2.0ltrs.

Specification GearoilGL4(MIL-L2105)SAE80

Clutchcontrol mechanical

Clutchplatedia 200mm

Driveflangedia 100mm

Tyres:Dynamicrollcircumference approx.1.75m

Overallratiointopgear 3.548

Speedintopgearat

1000rpm 29.59Km/h

Remarks: 1) Speedopinionmilky-grey 2) Cones,SeeW.BNo.3=>page2 3) GCI:GearchangeandConsumptionIndicator

Codeletters,gearboxallocation,ratios,oilcapacities(from8.82)(upto07.83)

Codeletters

Allocation

Model Golf,Jetta Rabbit Scirocco Golf,Jetta

Engine

Ratios Z2:Z1

Jetta

1.5l/l.6l 51/55KW 40KW Diesel

51KwTurboDiesel 1.5/l.6/1.7l 51-57KW 40KWDiesel 51KwTurboDiesel(USA) 1.6l 63Kw

Finaldrive 74:19=3.89

1stgear 38:11=3.45

2ndgear 35:18=1.94

3rdgear 36:28=1.29

4thgear 30:33=0.909

5thgear 27:38=0.711

Reverse 38:12=3.17 Speedo 16:7=2.29 1)

Codeletters

Oilcapacities 2.0ltrs.

Specification GearoilGL4(MIL-L2105)SAE80

Clutchcontrol mechanical

Clutchplatedia 190mm (Diesel200mm)

Driveflangedia 90mm

Tyres:Dynamicrollcircumference approx.1.75m

Overallratiointopgear

Speedintopgearat 1000rpm 37.96Km/h

Remarks:

1) Speedopinionmilky-grey

2) GCI:GearchangeandConsumptionIndicator

3) Cones,SeeW.BNo.3=>page2

Codeletters,gearboxallocation,ratios,oilcapacities(from8.82upto07.83)

Codeletters

3rdgear 36:28=1.29

4thgear 30:33=0.909

5thgear 27:38=0.711 Reverse 38:12=3.17

16:7=2.29 1) 15:7=2.14 2)

Oilcapacities 2.0ltrs.

Specification GearoilGL4(MIL-L2105)SAE80

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Codeletters FJ

Clutchcontrol mechanical

Clutchplatedia 200mm

Driveflangedia 90mm

Tyres:Dynamicrollcircumference approx.1.75m

Overallratiointopgear 2.766 2.959

Speedintopgearat1000rpm 37.96Km/h 35.48Km/h

Remarks:

1) Speedopinionred

2) Speedopinionmilky-grey

3) GCI:GearchangeandConsumptionIndicator

4) Cones,SeeW.BNo.3=>page2

3) Cones 4) 4+E

Codeletters,gearboxallocation,ratios,oilcapacities(from8.82upto7.83)

Codeletters

1stgear

2ndgear

4thgear 35:31=1.13

5thgear 31.34=0.912 Reverse 38:12=3.17

15:7=2.14 2) 16:7=2.29 1)

Oilcapacities 2.0ltrs.

Specification GearoilGL4(MIL-L2105)SAE80

Codeletters 7G 2H

Clutchcontrol mechanical

Clutchplatedia. 210mm

Driveflangedia 100mm

Tyres:Dynamicrollcircumference approx.1.75m

Overallratiointopgear 3.329 3.591

Speedintopgearat1000rpm 31.54Km/h 29.24Km/h

Remarks:

1) Speedopinionred

2) Speedopinionmilky-grey

3) GCI:GearchangeandConsumptionIndicator

4) Cones,SeeW.BNo.3=>page2

GCI 3) Cones 4) 00-15

Codeletters,gearboxallocation,ratios,oilcapacities(from8.83)

from:

to:

Allocation Model Golf 1) ,Jetta 1) Pickup 1) Caddy Scirocco Golfconvertible Rabbit, Jetta Engine 1.8l.70Kw 1.6l.55Kw 1.6l.51Kw 1.6l.55Kw 1.8l.66Kw

1.6l40Kw Diesel

1.6l.51Kw TurboDiesel

1.7l.57Kw

1.5l.51Kw

1.6l.55Kw

1.6l.63Kw

Ratios Z2:Z1

Oilcapacities 2.0ltrs.

Specification GearoilGL4(MIL-L2105)SAE80

Clutchcontrol mechanical

Clutchplatedia.

Driveflangedia 90mm

Tyres:Dynamicrollcircumference approx.1.75m

Remarks:

1) SouthAfrica

2) Speedopinionmilky-grey

3) Speedopinionred

4) Cones,SeeW.BNo.3=>page2

5) GCI:GearchangeandConsumptionIndicator

Cones 4) Cones 4) USA,Japan Canada

Cones 4) GCI 5) 00-17 Codeletters,gearboxallocation,ratios,oilcapacities(from8.83)

2)

Specification GearoilGL4(MIL-L2105)SAE80

Clutchcontrol mechanical Clutchplatedia. 210mm

Driveflangedia 100mm 90mm 100mm

Tyres:Dynamicrollcircumference approx.1.75m

Overallratiointopgear

Remarks:

1) Speedopinionred

2) Speedopinionmilky-grey

3) Cones,SeeW.BNo.3=>page2

4) GCI:GearchangeandConsumptionIndicator

USA,Japan, Canada Cones 3)

SouthAfrica GCI 4) Cones 3)

USA GCI 4) Cones 3) 00-19

Codeletters,gearboxallocation,ratios,oilcapacities(from8.83)

Specification GearoilGL4(MIL-L2105)SAE80

Clutchcontrol mechanical Clutchplatedia. 190mm 200mm 210mm Driveflangedia. 90mm 100mm

Tyres:Dynamicrollcircumference approx.1.75m

Overallratiointopgear

Remarks:

1) DesignationforCaddyinUSAand Canada

2) Speedopinionmilky-grey

3) Speedopinionred

4) Cones,SeeW.BNo.3=>page2

5) GCI:GearchangeandConsumptionIndicator

GCI 5) Cones 4) GCI 5) USA,Japan Canada Cones 4) GCI 5) 00-21

Codeletters

Speedo 15:7=2.143 2)

Oilcapacities 2.0ltrs.

Specification GearoilGL4(MIL-L2105)SAE80

Clutchcontrol mechanical

Clutchplatedia. 210mm

Driveflangedia. 90mm 100mm

Tyres:Dynamicrollcircumference approx.1.77m

Overallratiointopgear

Remarks:

1) DesignationforCaddyinSouthAfrica

2) Speedopinionred

3) Cones,SeeW.BNo.3=>page2

Codeletters

Speedo 15:7=2.14 1)

Oilcapacities 2.0ltrs.

Specification GearoilGL4SAE80or G50SAE75W-90(syntheticoil)

Clutchcontrol mechanical Clutchplatedia. 210mm Driveflangedia 100mm

Codeletters AUG CHB DGG/FFZ

Tyres:Dynamicrollcircumference approx.1.77m

Overallratiointopgear 3.278

Speedintopgearat1000rpm 32Km/h

Remarks:

1) Speedopinionred

00-25

Transmissionlayout

Designation

1-Engine

2-Clutch

3-Gearbox

4-Inputshaft

5-Outputshaft

6-Differential

Ratios I-1stgear II-2ndgear III-3rdgear IV-4thgear

V-5thgear

R-Reversegear A-Finaldrive T-Speedodrive

Calculatingratios"i"

Z22) :Z11) =i

1) Z1=No.ofteethondrivinggear

2) Z2=No.ofteethondrivengear

Example 1stgear Finaldrive

Drivinggear

ZG1=11 ZA1=19

Drivengear ZG2=38 ZA2=74

Gearratio "iG"

Axleratio"iA" Overallratio "ioverall"

ZG2:ZG1=iG ZA2:ZA1 (ZG2:ZG1)x (ZA2:ZA1)=ioverall

38:11=3.45 74:29=3.89 (38:11)x(74:29)= 13.45

00-27

Clutch

Repairstotheclutchmechanism

Releaseshaft,releaselever,return spring,clutchclever,andrelease bearing

removingandinstalling=>page 34-68

Removingandinstallingclutchcable Removesecuringpartsontherelease shaftandpullcableoutofrubbergrommet.Unhookcableatpedalandpullit out.Wheninstallinggreasecableat joints.

1-O-ring

2-Clutchcable

♦ Adjusting=>fig. 3

3-Retainingwasher

4-Grommet

5-Pinforbrakeandclutchpedal -Lubricatewithmulti-purpose grease 30-1

6-Buffer

7-Bracket

8-Rubberstop

9-Clutchpedal

10-Bush

♦ Removingandinstalling=>fig. 1

11-Gearbox

12-Releaseshaft

♦ Removingandinstalling =>page 34-21

13-Securingpartsforclutchcable

14-Rubberwasher

♦ Position=>fig. 2

15-Rubberguide

16-Adjustingdisc

17-Nut

♦ Lockafteradjusting

Fig.2Installingrubberwasher

Therubberwasher-1-mustbefittedwiththesealinglip-2-paralleltotheendcap-3-.Otherwisethe gearboxbreather(abovetheendcap)cangetdirty andblocked.Thiswouldleadtogearboxleakage. 30-3

Fig.3Adjustingclutchplay 15-25mmatclutchpedal,6mmatreleaseshaft.

Clutchcablechafingagainstbrakefluid reservoir.

Whenproblemsareexperiencedwheretheclutch cablechafesagainstthebrakefluidreservoir,a plasticclipPartNo.172611449whichisavailable fromourPDdepartment,istobefittedonthebrake mastercylindertoensurethataclearanceismaintainedbetweenclutchcableandreservoir.

Forfittingseephotobelow:

U30-0006

1-Clutchcable.

2-Mastercylinder

3-Clipsecuredtomastercylinder

30-5

Repairstoclutch(190/200 mmdia.)

Note:

Whenrepairsarerequiredtothe clutch,thegearboxmustberemoved =>page 34-15

TDCsensoradapterinclutchhous-ing=>page34-76

Whenremovingandinstallingthe clutchinadditiontothenotesinthe Workshopmanualthefollowingshould benoted:

Cleaninputshaftsplinesandwithused clutchplatescleanhubsplines,remove corrosionandapplyaverythincoatof G000100greasetotheinputshaft, untilthehubmovefreelyontheshaft. Removesurplusgreasewithoutfail.

Caution!

Assembleclutchsothatthecenteringpinsinflywheelengagethe centeringholesorslotsinthe pressureplate.OtherwisetheTDC markonflywheelwillnolonger becorrect.

1-Flywheel

♦ Removingandinstalling-Fig.1

♦ Ensurethatcenteringpinsare tight,contactsurfaceforplate mustbefreeofgrooves,oil andgrease.

2-Clutchplate

♦ Centering-Fig.2 checkingforlateralrun-outFig.3 coatsplineslightlywithMolykoteorMolyspray.

3-Retainingring

♦ Leveroutwithscrewdriver watchposition-Fig.4

4-Releaseplate

♦ Coatcontactsurfaceandsocketforclutchpushrodlightly withlithiumgrease.

5-ScrewM10x1x20

♦ Renew,InstalledwithD6lockingfluid

♦ Withshoulder100Nm

♦ Withoutshoulder75Nm 30-7

6-Packingplate

7-Pressureplate

♦ Removingandinstalling Checking-Fig.6,pressure plateswithdamagedorloose rivetsshouldberenewed.

8-Releaseplate

♦ For200mmdia.clutchcoat surfaceandsocketforclutch pushrodlightlywithlithium grease.

9-Retainingring

♦ For200mmdia,clutchlever outwithscrewdriver,watch position-Fig.5

10-Screw

♦ M7x40,20Nm

11-Clutchpushrod

♦ Greaseatbushlocationin driveshaft.

Fig.2Installingclutchplate

Tightenscrewsalternatelyanddiagonallyto20Nm

30-9

Fig.3Removingandinstallingpressureplate

Note: Tofitthe200mmclutchtheretainerVW558must bereworkedasshowninFig.9.

Fig.4Installingretainingring(190mmclutch) Watchpositionofringends.

Fig.5Installingretainingring(200mmclutch) Watchpositionofringends.

Fig.6Checkingpressureplatefordistortion, cracksandsignsofburning Maximuminwardtaper0,2mm.

30-11

Fig.7Checkspringconnectionsbetweenpressureplateandcoverforcracks,looserivetsand security

Clutcheswithdamagedorlooserivetsshouldberenewed.

Fig.8Checkingclutchplateforlateralrun-out May.0.3mm(measured2.5mmfromouteredge)

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Theshadedareamustbereworkedtodimensions given.

Note:

The200mmdia.clutchcanbeserviceinstalledby replacingthepressureplate,flywheel,clutchplate, releaseplateandretainingring.

30-13

Controls,Housing

Operationofshiftmechanism

A-Shiftpattern

Reversegear:

Downwardpressuresystem(asbefore). Thereversecatchisovercomebypressingthegear leverdownwards.

5thgear:

Sidepressuresystem.

Thecatchfor5thgearisovercomebypressinglever sidewaystotheright(arrowsymbol).

Whenchangingdowninto4thgearnolateralpressuremustbeexertedonthegearleverasotherwise 2ndgearmaybeengagedaccidentally.

Thiswouldcausedamagetotheengineduetoexcessivespeed!

34-1

B-Externallinkage

1-Reversegearcatch

2-5thgearretainingscrew(5th gearsafetycatch)

3-Retainingscrewforselector shaft(geardetent)

C-Internallinkage

1-Selectorshaft

2-Shiftfinger

3-5thgearcatch,adjusting =>page 34-11

4-Geardetent,adjusting=>page 34-11

5-Spring,large,pressestheselectorshaftintothe3rdand4thgear plane

6-Spring,small pressestheselectorshaftautomaticallyoutoffthe5thgear plane

7-Reversegearshiftfork

8-1st/2ndgearshiftfork

9-3rd/4thgearshiftfork

10-Shiftlinkfor5thgear

34-3

Repairshiftlinkage

Caution!

Lubricatealljointsandfriction surfaceswithspeciallubricant PartNo.AOS12600006.

1-Connectinglink263.5mmlong -Betweenrelayshaftandselectorshaftlever.Endshavedifferentangles90°and95°.Markarrow-95°endgoesonselectorshaftlever.

2-Relayshaft

3-Relayshaftbracket

4-ProtectiveplateGTI,GLI,models havealargeplate.

5-Relaylever

6-Shiftrodbearing

7-Shiftrod

8-Clip

9-Selectorrod,rear -Beforeremoving,pressclipson plasticendsbackwithscrewdriver.

10-Bellcrank

11-Selectorrod,front -Beforeremoving,pressclipson plasticendsbackwithscrewdriver. -Rodisblack.

12-Selectorshaftlever -Onlyfitsshaftinoneposition. -Freeplayonthegearlever=> page 34-12

13-Retainingscrew/selectorshaft

♦ Adjusting=>page 34-11

14-Retainingscrew5thgear

♦ Adjusting=>page 34-11

15-Relayshaftbracket

16-Selectorlever 34-5

Caution!

Lubricatealljointsandfriction surfaceswithspecialgreasePart No.AOS12600006.

1-Knob

2-Leverbearing

-Dismantleonlytogrease.

♦ Assembly: Placeshellsintherubber guide,presslowerballhalfintoshells(shoulderofrubber guideupwards),insertspring, andupperballhalfbypushing shellsapart.

♦ Pushcompleterubberguide intoleverplate.

3-Spacer

♦ Shouldertowardsleverbearing.

4-Gearlever

♦ Adjusting=>page 34-8

5-Leverhousing

♦ Identificationfor5thgear:depression-arrow-.

♦ Withcoverplateandstop plates.

6-Shiftrod

7-Boot

8-Cap -Drainholemustbeclear.

9-Leverplate ♦ Position:See=>page 34-8

Adjustinggearshiftlinkage

Placeleverinneutral

- Aligncenteringholes-arrows-inleverplateand housingcoverplate.

Note:

Thetappedholesfortheboltsshouldnowbeinthe centreoftheslots-arrowA-.Iftheyarenot,turn leverplate180°.

-Securetheleverbearing

- Loosentheclip.Theselectorlevermustmove easilyontheshiftrod.

-Pullthecapofftheboot.

34-7

- Locatetheshiftfinger-1-inthecentreofthestop plate-2-.

Thedistancesxmustbethesame.

a=15mm

-Setdistance"a"witha15mmwidestripofsheet metal.

-Tightenclipinthisposition.

-Selectallgearsinturnandcheckthattheyengageeasilyandwithoutcatching.Ensurethatreverseand5thgearcatchesareeffective.

-Ifthetoleranceisused,thedimensionforsetting thelinkage -previously15mm-maybe1-2mm less.

-Ifthegearshiftcatchesorjamsdespitebeingadjustcorrectly,thedistanceshouldbesetto13 mm.

Adjustingselectorshaftretainingscrew

Thisisonlynecessaryifgearshiftjamsorisspongy. Modifiedlocatingandmountingoftheselectorshaft inthegearbox=>page 34-72

Vehicleswithgearchangeandconsumptionindicator =>page34-71

-Disconnectlinkagefromselectorshaftlever.

-Placegearboxinneutral.

- Loosenlocknut-2-andturnretainingscrew-1-in untillockingclip-4-liftsoffretainingscrew.

-Turnretainingscrewbackagainuntilclipjust makescontact.

-Tightenlocknut

-Check:Theclipshouldliftassoonasshaft-3-is turnedslightly.

34-9

Adjustingretainingscrewfor5thgear

Thisisnecessaryiftoomuchortoolittleforceisrequiredtoovercomethe5thgearcatch.

Basicsetting

-Placegearboxinneutral. -Takecapofretainingscrew.

- Loosenlocknut-2-andturnretainingscrew-1-in untilthepin-3-juststartstolift.

-Turnretainingscrewback1/3ofaturn. -Lockretainingscrew.

Check:

Theforcerequiredtoovercomethe5thgearcatchis measuredwithaspringgauge.

•Atleverforselectorshaftongearboxspecified: 100N(10kg).

•Atgearleverinvehiclemin.40N(4kg).

Measuredbelowgearleverknob.

Individualsetting: (Tosuitthedriver)

Byliftingthecapandturningadjustingscrew60°in eachcasetheforcetoovercomethe5thgearcatch canbealtered.

Toright - moreforce

Toleft - lessforce

Selectorshaftleverself-lockingnut

Incaseswherecustomercomplaintsarereceivedon difficultgearselectionduetoexcessivefreeplayon thegearlever,itispossiblethattheselectorshaft levernutcouldbeloose(seeillustrationbelow).

Shouldthisnutbeloose,itmustbereplacedwitha self-lockingnut,partnumberN90292001,available fromourPADepartament.

1-Selectorshaftlever

2-LocknutN90292001

Removingandinstallingbondedrubber bushesforgearboxcarrier (gearboxin)

Removing -Detachcarrierfromgearboxandbody. - Cutthemetaloutershellwithanarrowhacksaw bladetoreducetensionandknockbushout. -Donotdamagecarrier.

34-13

Installing - Pressbushinflush.

- Installbushsothatarrowpointsupwardswhen carrierisinstalled. -Installcarrier.

Removingandinstallinggearbox

Removing

- Detachearthstrap-1-frombattery. -Installandtensionliftingappliance-2-. -Detachleftgearboxmountings-3-.

34-15

- Disconnectreversinglightwires-4-.

-Disconnectspeedocable-5-andsealholewith rubbercaptopreventoilfromrunningoutwhen gearboxistakenout.

-Disconnectclutchcable-6-. -Removeupperboltsattachinggearboxtoengine7-. -Removestarter-8-.

- Disconnectconnectinglink-9-.

-Disconnectrearselectorrod-10-. -Removefromselectorrod-11-complete(see sketch).

-Disconnectearthstrapfromgearbox. -Detachtorquestrutfromgearboxandbody.

- Detachexhaustpipebracket-12-.

-Detachreargearboxmounting-13-frombodyand gearbox.

-Detachleftdriveshaft-14-andhangitupwitha wirehook.

- Detachrightdriveshaft-15-andhangitupwitha wirehook.

-Removescrews-16-securinglargecoverplate. Platestaysonengine.

-Removescrew-17-securingsmallcoverplate andtakeplateoff.

-Removebolt-18-.

-Pressgearboxoffdowelsleevesandtakeitout downwards(2mechanicsrequired).

-Thegearboxcanalsobetakenoutwithaspecial appliance(suchasgearboxlifterV.A.G1383)

Installing

Installbyreversingtheremovalsequence.

Ensurethatengine/gearboxmountingsaresecured freeoftension.

Note:

♦ Cleansplinesofinputshaftandlubricatelightly withMoly-pasteorMoly-spray.

♦ Wheninsertingthegearboxensurethatthe largecoverplateislocatedcorrectly.

♦ Checkclutchplay.Itshouldbe15-25mmat clutchpedal.

Tighteningtorques:

Securingpoints

7,1880Nm

8,13,14,15 45Nm

34-17

Generalview

5speedmanualgearbox020

♦ Dismantlingandassemblinggearbox=>page 34-21

1-Bearinghousing

2-Differential

♦ Dismantlingandassembling =>page 39-3

3-Outputshaft

♦ Dismantlingandassembling =>page 35-15

4-Inputshaft

♦ Dismantlingandassembling =>page 35-1

5-1stspeedgear

6-Reversegear

7-2ndspeedgear

34-19

8-Coverforgearboxhousing

9-5thspeedgear

10-4thspeedgear

11-3rdspeedgear

12-Gearboxhousing

Dismantlingandassembling gearbox

Worksequence=>page 34-29

Vehicleswithgearchangeandconsumptionindicator=>page 34-66

Additionalbearingforoutputshaft =>page34-72

1-M8x25 screw -(4off)25Nm

2-Gearboxhousingcover

♦ Repairing=>page 34-62

3-M17 screw -150Nm -Renew,coatnewscrewwith lockingcompoundD6.

4-Sleeve/Synchrohubfor5thgear

♦ D+A=> page 35-1

♦ Synchronizerhubfor5thgear withretainingringforlocking keys=>page 35-30

5-5thgearsynchronizerring

34-21

♦ Checkforwear=>page 35-6

6-5thspeedgear

7-Needlebearingfor5thgear

8-Thrustwasher

♦ Fittingposition:chamferon outer diametertowardsgearbox housing.

9-M7x24 screw

♦ 15Nm

10-M8x28 screw

♦ Securesreverseshaft

♦ 30Nm

11-Gearboxhousing

♦ Repairing=>page 34-58

12-Selectorshaft -Selectorshaftcovermodified =>page 34-77

13-Spring

♦ Pressesselectorshaftand gearleverintothe3rd/4thgear plane.

14-Endcap

15-M8x35 screw

♦ (2off)screwinbelowtheretainingscrews.

♦ 25Nm

16-Shim

♦ Adjustmenttable=>page 39-12

17-Clutchpushrod

♦ Greaseatbushindriveshaft

18-Inputshaft,outputshaftanddifferential

♦ R+I=> page 34-26

♦ Theinputshaftinthe5speed manualgearbox020doesnot needadjusting.

♦ Itishoweverimportanttoensurethattheshimfittedin productionisinstalledagain afterrepairing.

Note: Itmaybefoundthatnoshimisfitted. Inthiscase,assembleagainwithout shim.

19-Gasket

♦ Renew.

34-23

20-Retainingscrewforselector shaft

♦ Adjusting=>page 34-11

21-Retainingscrewfor5thgear

♦ Adjusting=>page 34-11

22-Reversinglightswitch

23-Driveflange

24-M8x50 screw

♦ (12off)25Nm

25-Dishedwasher

26-Circlip

♦ Renew,mustfitproperlyin groove.

27-Cap

♦ Renew.

28-5thspeedgear

♦ Position:Grooveupwards

29-Circlip

♦ Renew,mustfitproperlyin groove.

30-Lockplate

♦ renew

31-Spacersleeve

-Upto12.79renewandpeen, preventsshifttubefromturning.

32-5thgearshiftfork

♦ Adjusting=>page 34-47

33-Gasket

♦ Renew.

34-M8x62 screw

♦ (2off)25Nm

34-25

Dismantlingandassembling gearbox

Removingandinstallinginputshaft, outputshaftanddifferential Worksequence=>page 34-40

1-Circlip

♦ Renew,mustisproperlyin groove.

2-4thspeedgear

♦ Position:shoulderupwards

3-Circlip

♦ Findthickness=>page 34-39

4-3rdspeedgear

♦ Position:shouldertowards 2ndspeedgear.

5-2ndspeedgear

6-Needlebearingfor2ndspeed gear

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7-Sleeve/synchrohubfor1st/2nd gear

8-1stspeedgear

9-Inputshaft

♦ D+A=> page 35-1

10-Rodforselectorforks

♦ Oneofthespigotsattheends theshiftforkrodhasbeendeleted.Wheninstallingtheshift forkset,installrodwithremainingspigotupwards(towardsgearboxhousing).

11-Shiftlinkwithtubefor5thgear

12-3rd/4thgearshiftfork

13-Reverseshiftfork

14-1st/2ndgearshiftfork

15-Shiftforkset

16-Reverseshaft

17-Reversegear

18-Bearinghousing

♦ Repairing=>page 34-51 34-27

19-Cap

♦ Renew.

20-Circlip

♦ Renew,mustfitproperlyin groove.

21-Dishedwasher

22-Driveflange

23-Differential

♦ D+A=> page 39-3

24-Bearingplate

♦ Withouterraceforbearing andstopforreversegear

25-40Nm

26-Thrustwasher

♦ Position:shouldertowards bearingplate

27-Outputshaft,complete

♦ D+Aandrepairandinstallation instructions=>page 35-15

Removinggearboxhousing

- Installinggearboxinrepairstand. -Pullclutchrodoutdownwards.

34-29

- Fittingsupportbarfordriveshaft.

-A-LocknutM12

-LiftVW295aintocontactwithdriveshaftwith screwandlock.

-Removescrewssecuringgearboxhousingcover andtakecoveroffcomplete.

-Removeretainingscrewsforselectorshaftand for5thgearandtakereversinglightswitchout.

- Removeselectorshaftendcap. A-Sparkplugspanner(PartNo.311012205A).

-Moveselectorforkstoneutralandpullselector shaftout.

Note:

Iftheselectorforkscannotbeplacedinneutralthe selectorshaftcannotbepulledout.Shaftcanthen beremovedbyforceasfollows:

- Takeoffcirclip -1-, plate -2-, spring -3-, sleeve -4-, andcirclip-5-.

-Knockshaft-9-out.

-Sheetmetalhousing-6-,andshiftfinger-7-remaininhousing-8-.

-Whenknockingshaftout,placeanutbetween sheetmetalhousing-6-andgearbox-8-toactas support-arrow-.

-Renewdamagedparts(selectorshaft,selector forks).

-Removescrewsecuringthereversegearshaft. -Removecap,circlipandwasherfromdriveflange - Pullflangeoff.

-Screwtwo M8x30 boltsthroughslotsinto flange

- Removescrewholdingsynchronizerhubwitha M12socketheadscrewwrench-A-.

-Engage5thandreversegearstodothis(push frontshiftforkslotdownwards)

34-31

- Presslockingplateforselectortubeclear(from 1.80)(uotrequired)

-Upto12.79:spacerbush.Checkshiftforkfor damageafterscrewingtubeoff.

- Screwselectortubeoutofforkanti-clockwise

Note: Donotpullselectorrodoutoftube.

- Takesynchronizerhuboffcompletewith5th speedgearandfork.

-Removecirclipandthrustwasherfor5thspeed gear.

- Pullgearofforleveritoffwith2tyreleverstakingcarenottodamagehousingsurface.

-A-Twoarmpullere.g.Kukko20/10

- Removeaclampingplateforinputshaftbearing withaM6socketheadscrewwrench. -Removescrewsattachingthegearboxhousing.

34-33

- Pullhousingoff.

-Installinghousing=>page 34-47

34-35

Removinginputshaft

- Pullrodoutofholeinbearinghousingandtake shiftforksetout.

-Takecirclipfor4thspeedgearoffoutputshaft.

- Removeinputshaftcompleteand4thspeedgear together.

Removingoutputshaft

-Removecirclipfor3rdspeedgear. -Takeoff3rdspeedgear,2ndspeedgear,synchronizerringandneedlebearing.

-Removereversegear.

- Pulloffsynchrohub/sleeveand1stspeedgear.

-A-Twoarmpuller

e.g.Kukko20/10with250mmreachhooks.

-Detachbearingplateandtakeoutputshaftout.

34-37

Removingdifferential

-Removecap,circlipandwasher.

- Pullingdriveflangeoff

-A-Screw2Mx30 boltsthroughtheelongated holesintotheflange.

-Takedifferentialout.

Installingdifferential

-Installdifferential

- Installdriveflange

-Fitwasher,circlipandcap.Seatcirclipingroove with30-23if necessary.

Installingoutputshaft

-Insertoutputshaftandsecurebearingplate. -Installthrustwasher,needlebearing,gearand synchroringfor2ndspeed.

- Heatsynchrohub/sleevetoabout120°C,place onshaftandpresshome.

Fittingposition:

Seepage=> 35-22,fig. 3

-Turnsynchroringsothatgroovesarealigned withkeys.

-Installreversegear.

- Driveneedlebearinginnerracefullyhome.

34-39

-Installneedlebearing,synchroringand2ndand 3rdspeedgears.

- Adjustingaxialplayof3rdspeedgear.

-Measureaxialplaywithafeelergaugeandadjust itbyselectingasuitablecirclip.Theplayshould bebetween0and0.20mm.Keepasnearaspossibletolowerlimit.InstallcirclipwithpliersVW 161a.

Circlipsareavailableinthefollowingthickness:

020311381

020311381A2.6black 020311381B2.7bright 020311381C2.8copper 020311381D2.9brass

020311381E 3.0 blue

Installinginputshaft

-Ifshafthasnotbeendismantled,pressbearing off-see=>page 35-21

-Insertcompleteshaftwithoutballbearing.(Shaft isheldwithbar30-211,adaptorVW295aandan M12nutsee=>page 34-31).

-Fit4thspeedgearonoutputshaftandsecure withcirclip.

- Pressinputshaftballbearingintogearboxhousingwithshimsusedpreviously.

-Fittingposition: Wideshoulderoninnerracetowards4thgear.

- Secureclampingplate.

-Assembleshiftforksandinstallasfollows: -Insertlowerspringforselectorrodinbearing.

34-41

- Insert1st/2ndgearshiftforkintheoperating sleeve.

-Liftrodslightlyandswingshiftforksetroundthe outputshaft, guiding3rd/4thgearforkintosleeveandreverse forkintorelaylever.

- Pushselectorrodinandalignshiftforkslots.

Installinggearboxhousing

- Alignreversegearshaft.Spacingxmustbethe same.

Upto22127Hex.headbolt20Nm from23127Torxscrew30Nm Beforeknockinghousingon:

-a-ScrewtwoM8studsintobearinghousing toguidegearbox housing

-b-Ensurethatthedriveshaftisproperlysupportedbybar30-211andadaptorVW295A

- Knockhousingon.

-Installscrewsecuringreversegearshaft. -Installhousingsecuringscrews.

-Screwreversinglightswitchin.

-Tightenballbearingclampingplatescrewsto15 Nm.

34-43

- Fitdriveflange.

-Installwasherandcirclip.

- Presscirclipinandfitcap.

- Heat5thspeedgeartoabout100°Candinstallit.

-Fittingposition:Grooveupwards.

-Fitthrustwasherandcirclip.

- Installsynchrohubcompletewith5thgearand shiftforkandanewlockingplateornewspacer bush.

Note:

Installlockingpartasfollows:

♦ Selectortubewithgroove-spacerbush

♦ Selectortubewithshoulder-lockingplate

-Screwselectortubeclockwiseintoshiftforkwith boxspanner3059.

- Screwtubeoutuntilitprojects5.0mm(x).

Caution!

Donotpulltheselectorrodoutthetube (possiblybytiltingboxspanner)asotherwise theshiftforksingearboxwillfallapartandthe gearboxwillhavetobedismantledagain.If necessaryholdtheroddownwithascrewdriverthroughthesideslotswhentakingbox spanneroff.

- CoatnewsynchrohubscrewwithD6locking solutionandtightenitto150NmwithaM12 socketheadscrewwrench-A-. Select5thgearandreversetodothis,(frontfork slot-arrow-down).

34-45

- Placeshiftforksinneutralandinsertselector shaft.Turngearboxtohorizontalpositiontodo thisandsecuresheetmetalhousingwithwelding wire-A-topreventitfromturning-arrow-. -Installspringandendcap.

-Installretainingscrewsfor5thgearandselector shaftandadjust=>page 34-11

-Toadjust,installlever(fromshiftlinkage)onthe selectorshaft.

Adjusting5thgearshiftfork

Adjustmentmustbedoneverycarefullytoprevent jumpingoutofgear.

- Checkprotectionofselectortube-5.0mm"x" (see=>page 34-46)andadjustifnecessarywith 3059.

- Fitlever-A-onselectorshaftandengage5th gear.(Pullselectorshaftoutfullyandturnitto theleft).

34-47

-Liftoperatingsleeveslightlywithshiftforkto eliminateplayinparts.

- Checkengagementofsleeveincouplingteethon 5thspeedgear.

Specified:Overlap1mm(a).Ifnecessaryadjust byturningtheselectortube.

Important!

Whencheckingoverlap

34-49

Knockingonnewlockingplate

Supportforkwithtoolsapprox.12mmthicke.g.two flatopen-endspanners-A-19mmand24mm.

Upto12.79: Peenspacerbush.

a=19mm

-Peenbushattwoplaceswithabluntchisel19 mmfromupperedgeofselectortube.

Note:

Afterpeening,theselectorrodmustspringback automaticallywhenpresseddown.

-Fitanewgasketandinstallgearboxhousingcovercomplete(withreleasebearing).

-Lubricateclutchpushrodattheendatbush.

-Selectallgearsinturnandcheckthattheyare heldproperly.

Dismantlingandassembling gearbox

Repairingbearinghousing

1-Bearinghousing

♦ Ifreplaced:Adjustoutputshaft =>page 39-13

2-ShimS2

-Always1mmthick

3-Outerracefordifferentialbearing

♦ Removingandinstalling =>page 39-3

♦ Ifreplaced: Adjustdifferential=>page 39-13

4-Magnet

-Isheldbygearboxhousing

♦ Securingmagnetinclutch housing=>page 34-76

5-ShimS3

♦ Seeliston=>page 39-12

6-Outerraceforoutputshaftbearing

♦ Removingandinstalling =>page 34-21 34-51

♦ Ifreplaced: Adjustoutputshaft=>page 35-25

7-Inputshaftneedlebearing

♦ Removingandinstalling=> page 35-1

8-Relaylever -Withplasticinsert -Springforthereversegearrelaylever=>page 34-71

9-Screwwithlockingteeth25Nm

10-Relayleverbracket

11-Starterbush

♦ Pullout=>fig. 3

♦ Knockin=>fig. 34-56 -Canbereplacedwithgearbox insitu.

12-Plug -TDCsensoradapterinclutch housing=>page 34-70

13-Inputshaftoilseal

♦ Pullout=>fig. 1

♦ Knockin=>fig. 34-55 -Fillspacebetweenlipswith multi-purposegreasecanbereplacingwithgearboxout(not dismantled).

14-Driveflangeoilseal

♦ Knockout=>fig. 5

34-53

♦ Knockinuntilitcontactsbearingouterrace=>fig. 34-57 -Fillspacebetweenlipswith multi-purposegrease.

♦ Replacingwithgearboxinsitu =>page 39-1

15-Dowelsleeve(2off)

16-Oildrainplug -Withoutmagnet25Nm

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Fig.2Installinginputshaftoilseal

34-55

Fig.3Removingstarterbush

Fig.4Knockinginstarterbush

34-57

Dismantlingandassembling gearbox

Repairinggearboxhousing

1-Gearboxhousing

♦ Ifreplaced: Adjustdifferential=>page 39-13

2-Dowelsleeve -(2off)

3-Selectorshaftoilseal

-Fillspacebetweenlipswith multi-purposegrease.

♦ Pullout=>fig. 1

♦ Pressin=>fig. 34-60

4-Outputshaftneedlebearing

♦ Removingandinstalling =>page 35-15

5-Bearingouterracefordifferential

♦ Removingandinstalling =>page 39-3

♦ Ifreplaced: Adjustdifferential=>page 39-13

6-ShimS1

♦ See=>page 39-12

7-Driveflangeoilseal -Fillspacebetweenlipswith multi-purposegrease.

♦ Pressout=>fig. 3

♦ Pressinuntilitcontactsbearingouterrace=>fig. 34-61

♦ Replacingwithgearboxinstalled =>page 39-1

34-59

34-61

Dismantlingandassembling gearbox

Repairinggearboxhousingcover Repairstothecovercanbecarriedout withgearboxinstalled.Supportenginegearboxassemblywithbar10-222and detachtorquestrutandreargearbox mountingandlowerassemblyslightly.

1-Endplate -Renewtoremove:pierceand leverout.

♦ Installing=>fig. 34-65

2-Circlips

3-Clutchlever -Fitsshaftinonepositiononly.

4-Returnspring ♦ Position=>fig. 3

5-Releasebearing

♦ Removing:takeoutendplate andremovestopclip,turn shaftandtakebearingout.

6-Releaseshaft

♦ Removing:takeoffstopclip, endplateandcirclips.Pull shaftout.

7-Stopclip -Forshaft

8-Oilsealforreleaseshaft -Fillspacebetweenlipswith multi-purposegrease

♦ Pullingout=>fig. 1

♦ Pressingin=>fig. 34-64 -Canberenewedwithboxinstalledaftertakingshaftout.

9-Gearboxhousingcover

10-Oilfillerplugwithoutmagnet -25Nm 34-63

Vehicleswithgearchangeandconsumptionindicator

(OnlySciroccofromJanuary1981)

Vehicleswiththegearchangeandconsumptionindicator(GCI)haveaspecialswitch-arrow1-inthe gearbox.Thisswitchswitchestheconsumptionindicatoroffinthefirstfourgearsandkeepsthe gearchangeindicatorreadyforaction.Inadditionit takesoverthefunctionofthereversinglightswitch.

Inthisconnectiontheselectorshafthasbeenmodified.Theretainingscrewhasbeendiscontinuedand replacedbyapegbolt-arrow2.Thelocationofthe individualgearsisnowdonebypartsofthenewselectorshaft.

Repairinstruction:

Beforeremovingtheselectorshafttakeoutthepeg boltandtheGCIswitch.

Additionalbearingforoutput shaft

OnlyGTI/GLI

Withtheintroductionofthe1.8litre,82 KWengineitisnecessarytoprovidean additionalbearingfortheoutputshaft. Thenewneedlebearingissecuredaxiallybyaspecialscrew(self-tapping).

1-Oilfillerplug

2-Cover

3-Specialscrew

4-Needlebearing

♦ Pullingout=>fig.1

♦ Drivingin=>fig.2

♦ Fittingdepth=>fig.3

5-5thspeedgear

6-4th speedgear

Fig.1Pullingneedlebearingoutofcover Removespecialscrew.

-A-Extractor18.5-23.5mme.g.Kukko21/3.

Fig.2Installingneedlebearingincover Whatfittingdepth(Fig.3) Placedriftonletteredendofbearing.

34-67

Gearboxbreatherrelocation

Asarunningchangetheoldgearboxbreatherabove thegearshiftshaftcover,hasbeenrelocatedinthe areabetweenthegearshiftshaftpinscrewandthe clutchcableguide.

Ifthegearboxhousingisexchanged,asleeve-Part No.014301473-mustbedrivenintothebreather drillingusingthespecialtool32-106.Thesleeveis thentobefittedwithaplasticcap-PartNo.014301 485-.

Oldgearboxbreather-arrow34-69

Newgearboxbreather-arrow-

TDCsensoradapterinclutchhousing

TheinsertiondepthoftheTDCsensormustbe matchedtothesizeoftheflywheel.Therearethereforetwoadaptersofdifferentcolours:

-Greenadapter-PartNo.020301129Dfor210 mmdiameterclutch(installedinvehicleswith1.8 litreengineandinCaddywithallenginetypes).

-Whiteadapter-PartNo.020301129B/Cfor190 or200mmdiameterclutch(installedinvehicles with1.5and1.6litreengines-exceptCaddy).

Itisessentialtoensurethatthecorrectadapteris usedwhenchangingagearboxorconvertingthe clutch.

Resultsoffittingtheincorrectadapter: 1.Whiteadapter-210mmclutch

-TheTDCsensorwillbedestroyedandthe marksontheflywheeldamaged.Partsofthe TDCsensorwillbefoundintheclutchhousing.

2.Greenadapter-190or200mmclutch

-Thetesterwillshoweithernoindicationoraninaccuratealternatingone.

Springforthereversegearrelaylever

From13087thereversegearrelaylever-A-has beenprovidedwithaspring-B-andthisensurescorrectselectionofthereversegear.

Thespringissupportedbyalocatingpin-C-inthe clutchhousing.

Forthis,thehousinghasbeenprovidedwitharib whichhasarecessintowhichthelocatingpinisinserted-arrow-.

Furthermore,thestrut-D-hasbeenmodifiedtoenabletherelaylever-A-tobeinstalledfreeoftension.

Theearliertypestrutswerebentinslightlyatthe top.Whenusingtheoldtypestrutcorrectfunctioningcannotbeguaranteed.

Note:

Thespringcanonlybeserviceinstalledinconjunctionwiththemodifiedrelaylever,modifiedsupports, andmodifiedclutchhousing.

Modifiedlocatingandmountingofthe selectorshaftinthegearbox

Fromgearboxbuilddate07029thelocatingand mountingoftheselectorshafthasbeenmodified: -Locatingtheselectorshaft

Previously:Theselectorshaft1waslocatedviaa balldetent.

New:

Theselectorshaft1islocatedbythelocatingscrew 2viathedetentelement3.

Thelocatingscrewisinstalledinplaceofthepreviouspegscrew.Todothisthethreadinthegearbox housinghasbeenincreasedin diametertoacceptthelocatingscrew.

Tighteningtorque:20Nm

Note:

Beforereinstallingthelocatingscrew,twothreads aretobecoatedwithsealingcompoundAMV188 20003.

-Selectorshaftmounting

Previously:Slidingmounting

New:

Mountedinbearingsleeves.

Theselectorshaftismountedinthestopcap4and inthegearboxhousingwithbearingsleeves5and6.

Note:

Thebearingsleeve5canonlybeexchangedinconjunctionwiththestopcap4-Fig.1. Removingandinstallingthebearingsleeve6-Fig.2 and3.Fittinglocation-Fig.3.

Theoilseal7hasbeenchangedtosuitthemodified selectorshaftmounting-allocation-Fig.4. Removing:leveroutwiththelever681.

Installing:Fig.5

Note:

Themodified"internalselectormechanism"cannot beinstalledinthepreviousgearboxhousing.

Fig.1Replacingbearingsleevewithstopcap1

Attention!

Theretainingplate2isunderspringpressure. Whenremovingthecirclipholdretaining plate.

Thencarefullyreleasespringpressure.

Fig.2Pullingbearingsleeveoutofgearbox housing

A=Internalpuller18-23mme.g.Kukko22/1

B=Supporte.g.Kukko22/1.

Fig.3Pullingbearingsleeveintothegearbox housing

Pullinontostop-arrowFittingposition:

Thebearingsleeveprotrudesoutoftheholeonthe oilsealside -arrow2-.

34-73

Fig.4Distinguishingoilseals

1-Oilsealuptobuilddate06029

Dimension a=6mm

2-Oilsealfrombuilddate07029

Dimensiona=4.5mm

Note:

Thenewoilsealhasacollarontheinnerdiameterarrow-

Fig.5Installingnewoilsealinthegearbox housing Pullinontostop.

WithgearboxremovedknockinwithVW521/5. Withthegearboxinstalledpullinasshown.

34-75

Additionallysecuringmagnetinclutch housingwithsealingcompound

Toensurethatthemagnet-A-doesnotfalloutofits mountinghole-arrow-andjamtheselectormechanisminthegearbox,themagnetmust,withimmediateeffecttheadditionallysecuredwithsealingcompoundAMV18820003whenevergearboxrepairs arecarriedout.

Note:

Betweeninstallingthemagnetandfillingthegearboxwithoilthereshouldbealapseofapprox.2 hours.

Selectorshaftcovermodified

Fromgearboxdate03079theselectorshaftcoverA-hasbeenprovidedwitharib-arrow1-.

Forthisreason,thegearboxhousinghasbeen providedwithacontactsurface-arrow2-intherib area.

Notes:

Themodifiedcovercanonlybescrewedintogearboxhousingwithacontactsurface.

Thecoverisnotofferedasaservicepartbecause theoldcovercanbescrewedintoallgearboxhousing.

OnsomegearboxesthereisanO-ringfittedinadditionunderthenewcover.

OnthesegearboxesanO-ringmustonceagainbe installedwhenrepairsarecarriedout.

PartNo.903.543.01

34-77

Gears,Shafts

Dismantlingandassembling inputshaft

Synchronizerhubfor5thgearwithretainingringforlockingkeys=>page3536

Note:

Wheninstallingnewgears,seeTechnicalData=>page 00-4

1-M17 screw150Nm ♦ Renew,coatnewscrewwith D6lockingsolution

2-Sleeve

3-Hub

4-Lockingkey -Longsidetowardssynchroring

5-Spring -Wiredia.1.4mm.

6-M7x24 screw-15Nm

7-Gearboxhousing

8-Clampingplate

♦ Securesbearing=>fig. 9 35-1

9-4thspeedgear

10-Synchroringfor4thgear

♦ Checkforwear=>fig. 35-6

11-Sleeve

12-Hub

13-Lockingkey

14-Spring -Wiredia.1.4mm

15-Inputshaft

16-Bushforclutchpushrod

♦ Position=>fig. 35-9

♦ Knockingout=>fig. 12

♦ Knockingin=>fig. 13

17-Needlebearingforinputshaft

♦ Pullingout=>fig. 16

♦ Knockingin=>fig. 17

18-Bearinghousing

19-Sealforclutchpushrod

-Canbereplacedwithgearbox out(notdismantled)

♦ Position=>fig. 35-9

♦ Knockingout=>fig. 11.

♦ PressingIn=>fig. 35-11

20-3rdspeedgear

21-Synchronizingfor3rdgear

♦ Sprayedwithmolybdenum checkforwear=>fig. 35-6

22-Sleeve/hubfor3rd/4thgear

♦ Pressingoff=>fig.2

♦ Pressingoff=>figs.4 - 6

♦ Pressingon=>fig.7

23-Circlip

-Fitnew,donotoverstretch, mustseatproperlyingroove.

35-3

24-Ballbearing

♦ Pressingoff=>fig.1

♦ Pressingintogearboxhousing =>fig.8

-Uptoassemblydate31059: -Whenrenewed,use020311 123G

♦ Pressinnerraceoffandon separately=>fig.35-13 and 19

25-Shimforinputshaft

26-Thrustwasher

♦ Position:Chamferonouter dia. towardsballbearing

27-5thspeedgear

28-Synchroringfor5thgear

♦ Checkforwear=>fig. 35-6

29-Sleeve/hubfor5thgear

♦ Assembling=>fig. 15

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Fig.1Pressingballbearingoff A-Separatingappliance12-75mm-e.g.Kukko 17/1.

Fig.2Pressingoffsleeve/hubwith3rdspeed gear

Fig.3Checkingsynchronizerrings Presssynchroringontogearconeandmeasuregap "a"withfeelers

Gap"a" New wearlimit 3rdspeed 1.15-1.75mm 0.5mm 4th+5thspeed 1.3-1.9mm 0.5mm

Fig.4Assemblingsleeveandhubfor3rd/4th gear

Position:

Thechamferontheinnersplinesofthehub-arrow 1-goestowards3rdgear.

Additionalidentificationgroove-arrow2-goestowards4thgear.

35-5

Fig.5Identificationofhubfor3rd/4thgear

Eitheragroove-withearrow-onhub(4thgearside) oraxialgroovesorthesplines-blackarrow-.

Fig.6Assemblingsleeve/hubfor3rd/4thgear

-Pushsleeveoverhub.Itisnolongernecessaryto assemblethepartsinaparticularposition. -Installkeysandfitsprings120°offset.Thespring withtheangledendmustengageinthehollow key.

Fig.7Pressinghubandsleeveon

Fittingdirection: See=>fig. 4

Turnsynchronizerringsothatgroovesalignwith keys.

35-7

Fig.8Pressingballbearingandshimintothe gearboxhousing

Fittingdirection: Wideshoulderoninnerracetowards4thgear. Securewithclampingplate=>fig. 9

Fig.10Positionofsealandbush -A-Sealforclutchpushrod -B-Bushforclutchpushrod

35-9

Fig.11Pullingsealforclutchpushrodout Canberemovedwithgearboxoutwithoutdismantlingbox

Fig.12Knockingoutbushforclutchpushrod A=10mmrodsuchasanoldpumpshaftfrom automaticgearbox.

Fig.14Installingseal

Pushseal-A-inwiththefittingplug-B-supplied. Takeplugout.Thesealistheninthecorrectposition.(0.8-1.3mmdeep).Oillipsofseal.

35-11

Fig.15Assemblinghubandsleevefor5thgear

-Pushsleeveoverhub.Itisnotnecessarytoassemblethepartsinaparticularposition.

-Insertkeyswithlongsidedownwards(towards synchronizerring).

-Installbothspringsfrombelow120°offset.

-Thespringwiththeangledendmustengagein thehollowkey.

Fig.16Pullingneedlebearingoutofbearing housing

-A-Extractor18.5-23.5mme.g.Kukko21/3 -B-Supporte.g.Kukko22/2

Fig.17Knockingneedlebearingintobearing housing

Fig.18Pressingoff4thspeedgearandballbearinginnerracer

-A-Separatingtool,12-75mme.g.Kukko 17/1.

Onlyuptoassemblydate31059

35-13

Fig.19Pressingonballbearinginnerrace Onlyuptoassemblydate31059.

Dismantlingandassembling outputshaft

Note:

♦ Alwaysrenewbothtaperroller bearingsandthenadjustoutput shaft=>page 35-25

♦ Wheninstallingnewgears,note TechnicalData=>page00-4

♦ Outputshaftgears,removingand installing=>page 34-26

Additionalbearingforoutputshaft =>page 34-67

Pinionshaft=>page 35-33

1-Circlip

♦ Mustfitproperlyingroove

2-Thrustwasher

3-5thspeedgear

♦ Position:Grooveupwards

4-Gearboxhousing

5-Outputshaftneedlebearing

♦ Pullingout=>fig. 11

♦ Pressingin=>fig. 35-24 35-15

6-Circlip

-Fitnew,mustseatproperlyin groove.

7-4thspeedgear

♦ Replacepaironly,heattofit, shoulderupwards.

8-Circlip

-Fitnew,mustseatproperlyin groove.

♦ Findthickness=>page 34-39

9-3rdspeedgear

♦ Adjustaxialplay=>page 34-39

♦ Replacepaironly,heattofit.

♦ Shouldertowards2ndspeed gear

10-2ndspeedgear

11-2ndspeedgearneedlebearing

♦ Lubricatewithgearoil

12-Synchroringfor2ndgear

♦ Sprayedwithmolybdenum checkforwear=>fig. 1

13-Spring -Wiredia.1.4mm

14-Sleeve

15-Hub

16-Lockingkey

17-Sleeve/hubfor1stand2ndgear

♦ Assembling=>fig. 3 and 4 heattofit

18-Synchroringfor1stgear

♦ Checkforwear=>fig. 1

♦ Identification=>fig. 2

19-1stspeedgear

20-Thrustwasher -Shouldertowardstaperroller bearing

35-17

21-ShimS3

♦ See=>page 39-12

22-Outerrace,smallbearing

♦ Pullout=>fig. 9

♦ Knockin=>fig. 10

23-Innerrace,smallbearing

♦ Pressoff=>fig. 6

♦ Bearingisdestroyed,toinstall heatto100°Candpress home=>fig. 7

24-Bearinghousing

25-Outputshaft -Ismatchedtocrownwheel.

♦ Adjustifreplaced=>page 35-25

26-Innerrace,largebearing

♦ Pressoff=>fig. 5

♦ Bearingisdestroyed,toinstall heatto100°Candpress home=>fig.8.

27-Bearingplate

♦ Withbearingouterraceand reversegearstop.

♦ Donotpressbearingraceout.

28-40Nm

Fig.1Checkingsynchronizerrings

Presssynchroringsontogearconesandmeasure gap"a"withfeelers.

Gap"a" New Wearlimit 1stand2ndgear 1.1-1.7mm 0.5mm

Fig.2Markingof1stgearsynchronizerring with110°toothangle

Identification:3x1toothmissing-arrow-. Thisringmustonlybeinstalledon1stgear. Whenrenewing1stgearring: Usering-PartNo.014311295D-withfullteeth. The1stgearsynchronizerringwithfullsplines-Part No.014311295D-shownasaservicepartinthe WorkshopManual,isnolongerbeingsupplied.In caseofrepairthesynchronizerringshowinthe PartsLististobeused.

35-19

Fig.3Assemblinghubandsleevefor1stand 2ndgear

Fittingposition: Identificationgrooveonsplines-arrow1-orend face-arrow2-towards1stgear.

Fig.4Assemblinghubandsleeve

-Pushsleeveoverhub.Itisnolongernecessaryto fitpartsina particularposition.

-Insertkeysandinstallsprings120°offset.The springwiththeangledendmustengageinthe hollowkey.

Fig.5Pressingoffinnerraceoflargebearing A-Partingappliancesuchaskukko17/2-22to115 mm.

Bearingisdestroyedintheprocess.

Fig.6Pressingoffinnerraceofsmallbearing A-Partingappliancesuchaskukko17/2-22to115 mm.

Bearingisdestroyedintheprocess.

Fig.7Heatinnerraceofsmallbearingtoabout 100°C,fitonshaftandpresshome

Fig.8Heatinnerraceoflargebearingtoabout 100°C,fitonshaftandpresshome

35-21

Fig.9Pullingouterraceofsmallbearingoutof bearinghousing

-A-Extractor37-46mm,Kukko21/6 -B-SupportfromKukko22/2

Fig.10Knockingouterraceofsmallbearinginto bearing

housing

Fig.11Knockingneedlebearingoutofgearbox housing

35-23

Fig.12Knockingneedlebearingintogearbox housing

Adjustingoutputshaft

(Findingthicknessof"S3"shim)

Theoutputshaftmustbeadjustedif -Bearinghousing -crownwheelandpinion -oroutputshaftbearings havebeenreplaced.

Seealso"Adjustmentlist",=>page 39-12

- Placea0.65mmshiminthebearinghousingand drivetheouterraceofthesmallbearingin. -Installoutputshaftandtightenendcoverboltsto 40Nm.

35-25

- Insertgauge(3mmrange)andzerowith1mm preload.

-A-Shim0.65mmthick.

-Moveshaftupanddownandrecorddialgauge reading(example:0.30mm).

Caution!

Donotturntheshaftwhenmeasuringbecausethebearingswillthensettleandgivean incorrectreading.

FindingthicknessofS3shim

Thespecifiedbearingpreloadisobtainedbyaddinga constantfigure(0.20mm)tothemeasuredreading (0.30mm)andtheshimthickness(0.65mm)forS3.

Example:

Shiminstalled 0.65mm

+reading0.30mm +preload(constantfigure)0.20mm S3= 1.15mm

- Removeshaftandpullouterraceofsmallbearing out

-A-Extractor37-46mmsuchasKukko21/6. -B-SupportKukko22/2

35-27

Thefollowingshimsareavailable:

Differenttolerancesmakeitpossibletoselecttheexactthicknessofshimsrequired. -Drivethesmallbearingouterraceinwiththeselectedshim"S3"(1.15inexample)andinstalloutputshaft.Tighten coverboltsto 40Nm

A=Torquegauge0-600Ncm

Checkingturningtorque

Thisshouldbe50-150Ncmfornewbearings. Theturningtorqueonbearingswhichhavebeenin useshouldbeatleast30Ncm.

Lubricatebearingsbeforehandwithhypoidgearoil.

35-29

Synchronizerhubfor5thgearwithretainingringforlockingkeys

Thelockingkeysforthesynchronizerunitshave beenstandardized.Thesymmetricalkeysasused for1-4gearsreplacetheasymmetricalkeysused previouslyfor5thgear.The5thgearsynchronizer hubhasbeenmodifiedforthispurposeandaretainingringisfittedtopreventthekeysfrommovingout ofposition.

Note:

Thescrewusedtosecurethesynchronizerhubwithoutcollarshouldalwaysbefittedwithadishedwasher.

Serviceinstallation

Thenewcompletesynchronizerhub (withoperatingsleeve,keys,spring, andretainingring).PartNo.020311 303Dcanbeinstalledinpreviousgearboxes

1-ScrewM17

♦ Renew150Nm

♦ InstallnewscrewwithD6 lockingfluid,tightenwithM 1212pointspanner.

2-Dishedwasher

3-Retainingring(new)

♦ Preventslockingkeysfrom moving.

4-Spring

♦ Wiredia.1.4mm.

5-Operatingsleeve

35-31

♦ Position:Chamferonsplines towards5thspeedgear.

6-Synchronizerhub(modified)

7-Lockingkey(standardized)

8-Installationposition

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34-3011

Tighteningtorqueforbolts-arrow-connectingoutput shaftbearingplatetogearboxhousinghavebeen modified.

New 25Nmandtighten further90°

Old 40Nm

Note:

Thisnewtighteningtorqueisalsovalidretroactively forallexistinggearboxes.

35-33

Finaldrive,Differential

Removingandinstallingdriveflangeoil seal

(Withgearboxinstalled)

Removing

-Detachshaftfromgearboxflange,swingitupwardsandhangitonawirehook.

-Removecirclipanddishedwasher.

- Pulldriveflangeout.

A=ScrewtwoM8x20 boltsthroughtheslots intotheflange.

- Removeoilseal

39-1

Installing

- Packmultipurposegreasebetweenthelipsofthe newsealanddriveitinasfarasitwillgo.

- Installdriveflange.

-Installdishedwasherandcirclip.Presscirclipinto thegroovewith30-23andcheckthatthewasher isconcentric.

-Installdriveshaftandtightenscrewsto45Nm.

-Checkgearboxoillevelandaddoilifnecessary.

Dismantlingandassembling differential

Differentialbevelgearshaftsecured withextendedrivets=>page 39-23

Playfreelocationofdriveflangeshafts =>page 39-16

Caution!

Theinnerandouterracesofthe taperrollerbearingsarematched andmustnotbeinterchanged.

1-Bearinghousing

2-ShimS2 -Isalways1mmthick

3-Outerrace

♦ Pullingout=>fig. 9

♦ Knocking=>fig. 39-10

4-Shaftfordriveflange

♦ Turnslightlywhenpullingout asthrustwashertendsto catch.

♦ Pressincarefullywheninstalling,donotdamagethrust washer.

5-70Nm

39-3

6-Crownwheel -Ismatchedtooutputshaft.

♦ Pressoff=>fig.4

♦ Tofit,heatto100°C=>fig. 39-8

♦ Ifgearsarereplaced,adjust outputshaft=>page 35-15

7-Differentialhousing

♦ Ifreplaced:Adjustdifferential =>page 39-13

8-Serviceparts

♦ Serviceonlyinstalling=>fig. 6

9-Bearinginnerrace

♦ Pulloff=>fig.1

♦ Tofit,heatto100°Cand pressfullyhome=>fig.2

♦ Removeshaftfordriveflange first.

♦ Ifreplaced: Adjustdifferential=>page 39-13

10-Outerrace

♦ Pullingout=>fig. 11

♦ Knockingin=>fig. 39-11

11-ShimS1

♦ Findthickness=>page 39-14

12-Gearboxhousing

13-One-piecethrustwasher

♦ Lubricatewithgearoilbefore installing

14-Differentialpinions

♦ Install=>fig. 39-9

15-Pinionshaft

-Knockoutwithadrift,donot damagethrustwasherwheninstalling

16-Rivet

♦ Productiononlydrillout=>fig. 3

17-Bearinginnerrace

♦ Pressoff=>fig.1

♦ Tofit,heatto100°Cand pressfullyhome=>fig.2

♦ Removeshaftfordriveflange first.

♦ Ifreplaced: Adjustdifferential=>page 39-13

18-Circlip

♦ Findthickness=>fig. 8

Fig.1Pullinginnerraceoff -A-PullersuchasKukko20/1with100mm reachhooks.

39-5

Fig.2Pressinginnerracehome Heatraceto100°firstandinstall.

Fig.3Drillingrivetheads

Drillrivetsoutwith12mmdrillfromthecentre punchedorcountersunksideandknockthemout.

Caution!

Cleandifferentialbeforeandafterdrilling.Protectbearingsfromthedrillchips.

39-7

Fig.5Heatcrownwheeltoabout100°Candinstall

Guidecrownonthehousingwithscrews-A-from repairkit.

Fig.6Boltcrownwheeltohousingwithspecial screws,washersandnuts-PartNo.171498088 (RepairKit).

Fig.7Installingdifferentialpinions

-Lubricateone-piecethrustwasherwithgearoil andinstallit

-Insertsmallpinions,knockspindleinandsecure. -Insertlargepinionsoffset180°andswingin.

Fig.8Findthicknessofcirclip-arrow-

-1-Differentialhousing

-2-Differentialpinionspindle

-3-Differentialpinion

-4-Differentialgear

-5-Driveflangeshaft

-6-Circlip

-Pressshaftagainstdifferentialpinionneedle. -Pressdifferentialgearsagainsthousingandpress thickcirclipintogroove.Ifcirclipjamsatthe sides,installthinnercirclip.

Thefollowingcirclipsareavailable:

Fig.9Knockingdifferentialbearingouterrace outofbearinghousing

Fig.10Knockingdifferentialbearingouterrace intobearinghousing

39-9

Fig.11Knockingdifferentialbearingouterrace outofgearboxhousing

Fig.12Knockingdifferentialbearingouterrace intogearboxhousing

39-11

Adjustmenttable

♦ Whenworkingonthegearboxitisonlynecessarytoadjusttheoutputshaftordifferentialifpartswhichdirectly influencethesettingofthegearboxhavebeenreplaced.Thefollowingtableshouldbenotedinordertoprevent unnecessaryadjustmentsbeingcarriedout.

Partstobeadjusted: ⇒

Partreplaced ↓

Outputshaft =>page 35-25

Differential (S1andS2) =>page 39-13

Gearboxhousing X

Bearinghousing X X

Differentialtaperrollerbearings X

Crownwheelandpinion X

Differentialhousing X

Outputshafttaperrollerbearings X

Adjustingdifferential

(ShimsS1andS2)

Thedifferentialmustbeadjustedifthe: -Gearboxhousing -Bearinghousing -Differentialhousing -orthedifferentialbearings havebeenreplaced.

Seealso"Adjustmenttable"=>page 39-12

- Installouterraceoftaperrollerbearing(endoppositetocrownwheel)inbearinghousingwith shimS2.

-ShimS2isalways1mmthick.

Caution!

Theinnerandouterracesofthetaperroller bearingsarematched.Donotinterchange.

-Driveouterraceofbearing(crownwheelend)intothegearboxhousingwithoutashim.

39-13

-Installdifferentialinthebearinghousing. -Placegearboxhousinginpositionwithagasket andtighten5boltsto25Nm.

- Installdialgaugeandzerowith1mmpreload.

-Movedifferentialupanddownandrecorddial gaugereading(example0.90mm).

Caution!

Donotturnthedifferentialwhenmeasuring becausethebearingswillthensettleandgive anincorrectreading.

FindingthicknessofS1shim

Thespecifiedbearingpreloadisobtainedbyaddinga constantfiguretothemeasuredreadingtofindS1.

Example: measuredreading 0.90mm +preload(constantfigure)0.40mm S1= 1.30mm

- Takegearboxhousingoffandknockbearingouter raceout. -InsertshimS1ofcorrectthicknessasdetermined thicknessshim(1mmifpossible)first. Thefollowingshimsareavailable:

020409231

020409231A0.30

020409231D0.60

020409231E0.70

020409231F0.80

020409298 1.00

Differenttolerancesmakeitpossibletoselectexactlytherequiredshimthickness.

Knockouterraceinagainandinstallgearboxhousing completewithgasket.

39-15

A-Torquegauge,normaltype0-600Ncm

Checkingturningtorque

Thisshouldbe120-350Ncmfornewbearings. Onbearingswhichhavebeeninusethetorque shouldbeatleast30Ncm.

Lubricatebearingsbeforehandwithhypoidgearoil.

Playfreelocationofdriveflangeshafts

Golf,Jetta,Scirocco81kw Jetta,Scirocco63kw (Differentialwithcones)

Toreducenoisethedriveflangeshaftsarenowlocatedfreeofplaybyspringsandtaperedrings.Inthe followingrepairinstructionsonlytheoperations whichhavechangedaredescribed.

Differentialwithcones:dismantlingandassembling

1-Securingkit

♦ Serviceonly

♦ 70Nm

2-Crownwheel

♦ Pressingoff=>fig.6

3-Innerrace

♦ Pullingoff=>fig.5

4-Outerrace

♦ Beforeknockingout: removesleeve

5-ShimS1

6-Oilseal

♦ Pullingout=>fig.1

♦ Installing=>fig.2

7-Taperedring

8-Thrustwasher

9-Spring

10-Driveflange

11-Dishedwasher

12-Circlip

39-17

♦ Renew,mustfitproperlyin groove

13-Sleeve

♦ Removing=>fig.3

♦ Installing=>fig.4

14-Gearboxhousing

15-Differentialhousing

16-Onepiecethrustwasher

♦ Lubricatewithgearoil

17-Pinions

18-Pinionshaft

19-Circlip

20-Rivet

♦ Productiononly

21-Driveflangeshaft

22-ShimS2

23-Bearinghousing

Fig.13Removingdriveflangeoilseal Usehammerassupportsothatsleeveisnotdamaged.

39-19

Fig.15Removingsleeve

Presssleeveinandthenpullitoutwithpliers.Alwaysfitanewsleeve.

39-21

Fig.17Pullingbearinginnerraceoff

A-Pullersuchaskukko20/10with100mmreach hooks

Fromconstructiondate15102

Thebevelgearshaftretensionhasbeenmodified. Thecirclipshavebeendiscontinuedandtheshaftis nowheldinpositionbytwoextendedrivets.

Thismeansthatthetworivetsneartheshaft,ofthe eightrivetssecuringthecrownwheel,havebeenextendedinlength.

Theshaftisavailablewith,orwithoutcirclipgrooves.

Repairinstructions

Whenrepairsarecarriedouttothedifferential wherebytherivetsaredrilledoutandbybolts:

Installshaftwithgrooves-ParNo.020409177Aandsecureinpositionwithcirclips-N0423631-.

Whenrenewingthedifferentialbevelgears: Cutoffbothrivetstothesomelenght(ensuresawdustdoesnotentertaperedrollerbearings).

Securebevelgearshaftwithcirclips.

39-23

Workshop Manual

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List

55 Bonnet, rear lid

57 Front doors, door components, central locking

58 Rear doors, door components

60 Sunroof

63 Bumpers

64 Glazing

66 Exterior equipment

70 Trim, insulation

74 Seat - padding, covers

Groups

Technical Information should always be available to all foremen and mechanics, because their com- pliance with the instructions given is essential to ensure vehicle roadworthiness and safety. In the normal safety precautions to be observed when working on motor vehicles are also applicable.

Contents

55 Bonnet, rear lid Page Bonnet, flaps . .

- Adjusting engine bonnet lock cable - Golf, Jetta

- Renewing tailgate - Golf .

- Boot lock / exploded view - Jetta

- Installing gas - filled spring - Golf

57 Front doors, door components, central lockingPage Front door / exploded view - Golf, Jetta

- Front door / exploded view - Scirocco

58 Rear doors, door components Page Rear door / exploded view - Golf, Jetta

- Stiff window winder operation

60 Sunroof

Sliding roof / exploded view - Golf, Jetta

- Adjustment operations on the sliding roof - Golf, Jetta

- Cleaning water drain hoses - Jetta

- Tilting roof/exploded view - Scirocco

- Removing tilting roof panel - Scirocco

- Installing tilting roof panel and manual drive - Scirocco

- Adjustment operations on the tilting roof - Scirocco

- Cleaning water drain hoses - Scirocco .

63 Bumpers Page

Renewing bumper covering - Golf, Jetta

- Renewing rear bumper side part - Scirocco

- Painting of Citi Golf polypropylene bumpers

64 Glazing Page

Service installation of vent wing - Golf

- Removing and installing knee bar - Jetta

- Removing and installing front door trim panel - Jetta

- Removing and installing rear door trim panel - Jetta

- Removing and installing instrument panel - Scirocco

74 Seat - padding, covers

Renewing rear seat - Golf

Bonnet,flaps

AdjustingenginebonnetlockcableGolf,Jetta

-Removeradiatorgrille=>page 66-8

- Adjustingcatchinlowerpartofflaplockby meansofthePhillipsscrew-arrow-without prestressing.

55-1

Renewingtailgate-Golf

Vehicleswithrearwindowwash/wipesystem. Theholesfortherearwindowwash/wipesystem arenotincludedinthetailgatesuppliedasaspare partandmustbemadeifrequired.

Cuttemplatesforholesfromthedamagedtailgate andusethemtomarkandmakeholesinthenew part.

-Bendendofwireoncecablehasbeenscrewed down.

Note:

Thecablemustbetension-free.

1-Seal

2-Lockcylinderwithhousing

3-Operatingrod

4-Bootlock

5-Lowerpartofbootlock

Adjustinglowerpartofbootlock-Jetta

-Placelowerpartofbootlockinpositionand screwonsothatitisjustfirmlyseated. -Closeboottocentrelowerpartoflock. -Openbootandscrewdownlowerpartoflock. -Adjustingstoprubbersaccordingly.

Installinggas-filledspring-Golf

Thegas-filledspringforthetailgateisinstalledin twostandardversions,bothofthemsuppliedunder PartNo.171827550A.Oneversionhasonegroove onthecylindercasingandtheotherhastwo.

Observetherelevantinstallationhintsinorderto preventmalfunctions,sincethetwotypesofspring aresealedindifferentways.

A-Single-grooveversion

Installation

♦ Securecylindercasingtotailgate

♦ Securepushrodtobody

55-3

Installation

♦ Securecylindercasingtobody

♦ Securepushrodtotailgate Mountingelementsforgas-filledsprings:

2Bolts

PartNo.:171827627

2SpacersPartNo.:171827625

2Lockwashers PartNo.:N12236.2

Caution!

Gas-filledspringsarehighlypressurizedand mustbeopenedinthecorrectmanner.Followingreplacementadiscardedspringmustnot bescrappeduntilthegashasbeenreleasedas prescribed.

SeeSpecialinformationBulletinNo.89.Edition 06/80.

Frontdoor/exploded view-Golf,Jetta

Removeinnumericalorder

Installinreverseorder

1-Boltondoor

♦ Installation:=>Fig.1

♦ Tighteningtorque:45±5Nm

2-Doorcheckstrapwithprotective sleeve

♦ 2hexagonbolts

♦ 2washers

♦ 1pin

♦ 1lockwasher

♦ Installation:=>Fig.2

3-Windowlifter

♦ 4hexagonboltwithdished washers(2xstandardand2x oversized,standardwashers ondrive)

♦ Installation:=>Fig.6

♦ Stiffwindowwinderoperation, =>page 58-8

4-DoorWindow

57-1

♦ 2hexagonboltswithdished washers

♦ Installation:=>Fig.6

5-Cornerwindowwithseal

♦ Installation:=>Fig.7

6-Guiderailwithwindowchannel

♦ 1Phillipsscrewatthetop

♦ 1hollowrivetatthebottom

♦ Installation.=>Fig.7

7-Clips

♦ Sixclipsforwindowslotseals

♦ Installation:=>Fig.8

8-Clips

♦ 3clipsfordoortrim

♦ Installation:=>Fig.3

9-Internalandexternalwindow slotseals

♦ Pressintoclipsforwindow slotseals

♦ Installation:=>Fig.9

10-Windowchannel

♦ Installstartingfromcorner window

♦ Installation:=>Fig.9

11-Fasteningrodwithsecuring sleeve

♦ Insertfasteningrodwithsecuringsleevefromoutside throughrecessandbringinto positionuntilplasticlugson sleevecontact.

♦ Installation:=>Fig.5

12-Tierod

♦ Attachtierodtooperating lever

♦ Installation:=>Fig.5

13-Doorlock

♦ 2hexagonsockethead screws

♦ Installation:=>Fig.4,5 57-3

14-Innerdooroperatingmechanismwithtierod

♦ 2hexagonboltswithdished washers

15-Expandingnutsandclipsfor armrest

♦ Installation:=>Fig.9

16-Windowcrankseal

17-Doorhandle

♦ 2fillisterheadscrews

♦ 2washers

♦ 2packingelementsfordoor handle

♦ 1trimpiece

♦ Installation:=>Fig.11

18-Doorseals

Fig.1Boltingondoor

-Securedoortomountingsusingbolts.

-Tighteningtorque=45±5Nm

Fig.2Installingdoorcheckstrap

-Boltonandgreasedoorcheckstrap. -Insertpinfromaboveandpressonlockwashers frombelow.

57-5

Fig.3Securingclipsfordoortrim(JettaGL)

-Installdoorsealsandsound-absorbingboard. -Installdoortrimclipssothat1=40mm,2=200 mm and3=180mm

Fig.4Installingdoorlock

-Raiseoperatinglever-1-by90°andsecurevia mountinghole-2-usingascrewdriver.

Fig.5Installingdoorlock

-Insertfasteningrodwithsecuringsleeve-1-from outsidethroughrecessandbringintoposition.

-Plasticlugssecuringsleeve-1-mustcontact.

-Attachtierod-2-tooperatinglever.

-Withdrawscrewdriverfrommountinghole.

-Securedoorlockwithhexagonsockethead screws.

Fig.6Installingwindowlifteranddoorwindow a-windowlifter:

-Installwindowlifter-3-frombelowandsecure with4hexagonboltsanddishedwashers

Note:

Usestandarddishedwashersondrive-4-.

-Insertdoorwindowfromabove.

-Screwdoorwindowlooselytogetherwithwindowlifter

-Winddoorwindowrightupsothatitispositioned bythewindowchannelandwindowseals.

-Windwindowdownslightlyandscrewittightly tothewindowlifterthroughthefittingholes.

Note:

Donotsecuredoorwindowuntilcornerwindow, guiderailsandwindowslotsealshavebeeninstalled.

Fig.7Installingcornerwindowandguiderail

-Fitcornerwindowandguiderail.Phillipsscrewat mountingpoint-5-andcompressionrivetat mountingpoint-6-.

-Ascrewisusedatmountingpoint-6-intheevent ofrepairs.

Note:

Lubricatecornerwindowseal.

Fig.8Fittingclipsforwindowslotseals -Insertclipsforwindowslotsealsintorecesses.

Fig.9Installingwindowslotsealsandwindow channel

-Presswindowslotseals-7-intoclips. -Presswindowchannel-8-intoposition,starting fromcornerwindow-arrow9-.

Fig.10Installingexpandingnutsandclipforarmrest

-Fitexpandingnuts-7-andclip-8-forarmrest

Fig.11Installingdoorhandle

-Placedoorhandleinpositionandsecurewith2 fillisterheadscrews-arrows-. -Clipondoorhandletrim.

57-9

Frontdoor/explodedviewScirocco

Repairworkonthedoor-Scirocco

Beforeassemblinganewdoor: Fitsound-absorbingboardanddoor windowsilltrim.

1-Trimstrips

♦ Installationsequence.

♦ Front-button-rear-pushon sleeve-top.

2-Doorwindow

♦ Removeandinstallviawindowslot.

3-Frontguiderail

♦ Removewindowchannelfrom rail,removescrews.

4-Doorwindow-fixed

♦ Lubricateseal.

57-11

1-Windowchannels

♦ Installationsequence:reartop.

2-Doorlock

3-Rearguiderail

♦ Firstwindwindowup

4-Windowlifter

♦ Secureexposedpipeindoor windowsillusingmetalplate.

5-Doorcheckstrap

6-Windowslotseals(innerand outer)

♦ Securetodoorpanelswith clips

Reardoor/exploded view-Golf,Jetta

Removeinnumericalorder

Installinreverseorder

1-Doorhandlewithpacking

♦ 1fillisterheadscrew6x10

♦ 1dishedwasher

♦ 1fillisterheadscrew5x15

♦ 1springwasher

♦ Handlecanbeinstalledandremovedwithinteriortrimin situ.

♦ Removing:=>Fig.1

2-Bellcranklever

♦ Hexagonbolt

♦ 1washer

♦ corrugatedwasher

3-Innerremotecontrolmechanism

♦ 2hexagonbolts

♦ 2dishedwashers

4-Doorlock

58-1

♦ 2hexagonsockethead screws =>Fig.2

5-Securingsleeve

♦ Plasticlugsmustcontact.=> Fig.2

6-Windowchannel

7-Windowslotseals

8-Doorwindow

♦ 2hexagonboltswithoversizeddishedwashers

9-Guiderailwithwindowchannel

♦ 2hexagonboltswithoversizeddishedwashers

♦ 1selftappingscrew

♦ =>Fig.3

10-Cornerwindowwithseal

♦ Lubricatesealbeforeinstallation.

11-Windowlifter

♦ 4hexagonboltswithdished washers

♦ Stiffwindowwinderoperation =>page 58-8

12-Checkflap

♦ =>Fig. 4

13-Windowcrankseal

14-Sealforinnerremotecontrol mechanism

15-Doorcheckstrapwithprotectivesleeve

♦ 2hexagonboltswithwashers

♦ 1pin

♦ 1lockwasher

16-Clips

58-3

♦ Clipsfordoortrimandwindow slotseal

17-Doorretainerbracket

♦ Retainerissecuredwithlower doorbolts

18-Fittingandremovingdoor

♦ Fig.6

♦ Tighteningtorqueofhexagon socketheadbolts-45±5Nm

Fig.1Removingdoorhandle

-Leveroffdoorhandletrim-arrow-.

-Removefillisterheadscrewsandtakeoffdoor handle.

Fig.2Removingdoorlock

-Unlockchildsafetycatch.

-Removehexagonsocketheadscrews. -Partiallypullofflowerpartofdoorlock -Secureoperatinglever-1-viamountingholeusingascrewdriver.

-Detachoperatingrod-2-.

-Removedoorlockfromsecuringsleeve-3-.

58-5

Fig.3Removingguiderail

-Winddownwindowandremovetwohexagon boltswithoversizedishedwashers.

-Removewindowchannelandslotseals.

-Removeself-tappingscrewandhexagonbolts-2fromguiderail.

-Removeguiderailandcornerwindow.

Note:

Lubricatecornerwindowsealbeforeinstallation.

Fig.4Removingcheckflap

-Presscheckflap-3-fordoorventilationinwards toremove.

Fig.5Fittingclipsforwindowslotseals(Jetta

-Installclipsfordoortrimandwindowslotsealsin therecessessothat1=50mm,2=180mm and3=210mm.

Fig.6Fittingandremovingdoor

-Unscrewfourhexagonsocketheadbolts-M8andremovedoor.

-Tighteningtorqueofbolts=45±5Nm.

Note:

Asecondmechanicmustholdthedoorduringfitting andremoving.

58-7

Stiffwindowwinderoperation

Repairprocedure

-1-Removetrimpanel.

-2-LoosenwindowwindermechanismboltsNo 1-6.

SeeFig.1forfrontdoorsandFig.3forreardoors.

-3-Windwindowupfullyandthenloweruntil windowlifterboltsNo.1and2areinlinewithslot indoor.FrontdoorFig.2.ReardoorFig.4

-4-TightenboltsinsequenceasinFig.2for frontdoorandFig.4forreardoors.

-5-Replacetrimpanel.

Fig1Frontdoor

Slidingroof/exploded view-Golf,Jetta

Removeinnumericalorder

1-Trim

♦ Removing:=>Fig.1

2-Frontguide

♦ Removing:=>Fig. 2

3-Leafspring

♦ Removing:=>Fig.3

4-Rearguide

♦ Removing:=>Fig. 4

5-Slidingroofpanel

♦ Removing:=>Figs.2,3,4

♦ Installing:=>Fig.5

6-Crank

7-Cabledrive

♦ Removing:=>Fig.6

8-Fingerplate

♦ Removing:=>Fig.6

9-Draughtdeflector

10-Moulding

♦ Removing:=>Fig.7

60-1

11-Cableguidewithcablesandrear guide

♦ Removing:=>Fig.8

12-Guiderail

-A:Selftappingscrew

-B:Fillisterheadscrew(M4)

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