Volkswagen Golf Variant / Jetta. Manual - part 175

Cover for Transmission Housing and 5th Gear, Removing and Installing

1 - Bolt

❑ 18 Nm
❑ Cover to transmission

housing

2 - Transmission Housing Cov‐

er

❑ With magnet from

11/2010. Refer to

⇒ Fig. ““Transmission

Housing Cover with a

Magnet -A- ”“ ,

page 163

Note

♦

If transmission housing cover is

removed and installed with

transmission installed, drain and

fill gear oil. Refer to

⇒ “6 Transmission Fluid, Check‐

ing and Filling”, page 157

 .

♦

Please note that a small amount

of oil escapes when removing

cover.

3 - Seal
4 - Bolt

❑ 80 Nm plus 90° addition‐

al turn

❑ Always replace.
❑ Hold with the adapter on

the plate spring bolt

head in position

❑ Remove locking com‐

pound residue from the

threaded holes for the

synchronizer hub and 5th gear drive gear bolts using a thread tap. Otherwise, there is the danger that

the screws could shear off.

5 - Plate Spring

❑ Installing. Refer to

⇒ Fig. ““Installed Position of Plate Springs for 5th Gear Synchronizer Hub and Gear Securing Bolts”“ ,

page 181

 .

6 - Cylinder Bolt

❑ 25 Nm
❑ For the pivot pin to the transmission housing

7 - Pivot Pin
8 - 5th Gear Shift Fork

❑ Disassembling and Assembling. Refer to

⇒ “10 Shift Forks, Disassembling and Assembling”, page 191

 .

❑ Adjusting. Refer to 

⇒ Fig. ““Adjusting the 5th Gear”“ , page 182

 .

9 - Spring

❑ Offset version
❑ Installing. Refer to 

⇒ Fig. ““Installation of Offset Springs -A- ”“ , page 226

162

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10 - 5th Gear Locking Collar

❑ Installation position. Refer to

⇒ Fig. ““5th Gear Locking Collar/Synchronizer Hub Assembly”“ , page 226

 .

❑ Adjusting. Refer to 

⇒ Fig. ““Adjusting the 5th Gear”“ , page 182

 .

11 - Locking Pieces

❑ Quantity: 3
❑ Installation position. Refer to 

⇒ Fig. ““5th Gear Synchronizing”“ , page 225

 .

12 - Synchronizer Hub with Gear Wheel and 5th Gear Synchronizer Ring

❑ Remove together with the transmission housing. Refer to

⇒ “7.7 Transmission, Assembly Sequence, Disassembling and Assembling”, page 170

❑ Remove individually. Refer to

⇒ “7.6 Assembly Sequence, Transmission Housing Cover and 5th Gear, Removing and Installing”, page

166

❑ Disassembling and Assembling. Refer to

⇒ Fig. ““5th Gear Locking Collar/Synchronizer Hub Assembly”“ , page 226

 .

13 - Needle Bearing
14 - 5th Gear Wheel

❑ Remove together with the transmission housing. Refer to

⇒ “7.7 Transmission, Assembly Sequence, Disassembling and Assembling”, page 170

❑ Remove individually. Refer to

⇒ “7.6 Assembly Sequence, Transmission Housing Cover and 5th Gear, Removing and Installing”, page

166

❑ Installation position. Refer to 

⇒ Fig. ““Installed Position, 5th Gear Wheel”“ , page 179

 .

Transmission Housing Cover with a Magnet -A-
The magnet can be inserted only into a cover with a recess

-arrow-.
The magnet is held in place by the bolt for the 5th gear shift fork

pivot pin when the cover is installed.

7. Transmission, Disassembling and Assembling    

163

Transmission Housing and Shift Mechanism, Removing and Installing

1 - Bolt

❑ 25 Nm

2 - Flange Shaft with Pressure

Spring

❑ Removing and Instal‐

ling. Refer to

⇒ “1.2 Left Flange Shaft

Seal, Replacing”,

page 255

 .

❑ Assembling. Refer to

⇒ “3 Differential”,

page 263

 .

3 - Inner TORX® Bolt

❑ 25 Nm
❑ For the reverse shaft

support

❑ Self-locking
❑ Always replace.

4 - TORX® Socket Bolt

❑ 30 Nm
❑ For the reverse shaft

support

❑ Self-locking
❑ Always replace.

5 - O-Ring

❑ Always replace.

6 - Pivot Pin
7 - Bolt

❑ 25 Nm

8 - Bolt

❑ 25 Nm

9 - Cap
10 - Internal Multipoint Bolt

❑ 25 Nm
❑ For the reverse shaft support
❑ Always replace.

11 - Bolt

❑ 5 Nm

12 - Transmission Neutral Position Sensor - G701-

❑ For vehicles with the Start/Stop System

13 - Transmission Housing

❑ Remove together with 5th gear. Refer to

⇒ “7.7 Transmission, Assembly Sequence, Disassembling and Assembling”, page 170

 .

❑ Servicing. Refer to 

⇒ “8 Transmission Housing and Clutch Housing, Servicing”, page 183

 .

14 - Clutch Housing

❑ Servicing. Refer to 

⇒ “8 Transmission Housing and Clutch Housing, Servicing”, page 183

 .

164

❑ 25 Nm and 90° additional turn
❑ Always replace.

16 - Gearshift Shaft with Gearshift Cover

❑ Shift unit
❑ Servicing. Refer to 

⇒ “9 Shift Unit, Servicing”, page 189

 .

17 - Internal Multipoint Bolt

❑ 25 Nm

7.5

Input Shaft, Output Shaft, Differential and Shift Rods, Removing and In‐

stalling

1 - Differential

❑ Disassembling and As‐

sembling. Refer to

⇒ “3 Differential”,

page 263

 .

2 - Seal

❑ Quantity: 4
❑ Always replace.

3 - Output Shaft

❑ Disassembling and As‐

sembling. Refer to

⇒ “2.1 Output Shaft, Dis‐

assembling and Assem‐

bling”, page 231

 .

4 - Reverse Shaft Support

❑ Disassembling and As‐

sembling. Refer to

⇒ “3 Reverse Shaft”,

page 246

 .

5 - Reverse Shaft

❑ Disassembling and As‐

sembling. Refer to

⇒ “3 Reverse Shaft”,

page 246

 .

6 - Input Shaft

❑ Disassembling and As‐

sembling. Refer to

⇒ “1 Input Shaft”,

page 220

 .

7 - Reverse Gear Shift Fork

❑ Disassembling and As‐

sembling. Refer to

⇒ “10 Shift Forks, Dis‐

assembling and Assem‐

bling”, page 191

 .

❑ Installation position. Refer to 

⇒ “7.7.2 Assembling the Transmission”, page 176

 .

8 - Inner TORX® Bolt

❑ 25 Nm

9 - Selector Mechanism

❑ Shift forks

7. Transmission, Disassembling and Assembling    

165