Volkswagen Golf Variant / Jetta. Manual - part 137

 

  Index      Volkswagen     Volkswagen Golf Variant (2007), Jetta (2005) - service repair manual

 

Search            

 

 

 

 

 

 

 

 

 

Content   ..  135  136  137  138   ..

 

 

Volkswagen Golf Variant / Jetta. Manual - part 137

 

 

General Repair Information

⇒ “5.1 Components”, page 10

The highest level of care and cleanliness along with tools that

function properly are required to ensure a proper and successful

transmission repair. Of course the general safety precautions also

apply when carrying out repair work.
A number of generally applicable instructions for individual repair

procedures, which are otherwise mentioned at various points in

the Repair Manual, are summarized here under the topic “Com‐

ponents”. Refer to 

⇒ “5.1 Components”, page 10

 . They apply

to this repair manual.

5.1

Components

⇒ “5.1.1 Transmission”, page 10
⇒ “5.1.2 O-Rings, Gaskets, Seals and Sealant”, page 11
⇒ “5.1.3 Retainers”, page 11
⇒ “5.1.4 Bolts and Nuts”, page 12
⇒ “5.1.5 Bearings”, page 12
⇒ “5.1.6 Shims”, page 12
⇒ “5.1.7 Synchronizer Rings”, page 13
⇒ “5.1.8 Gear Wheels, Synchronizer Hubs and Needle Bearing

Inner Races”, page 13
⇒ “5.1.9 Selector Gears”, page 13
⇒ “5.1.10 Clutch”, page 13

5.1.1

Transmission

♦ Make sure that the alignment bushings between the engine

and transmission are positioned correctly when installing the

manual transmission.

♦ Clean the contact surfaces when installing brackets and

waxed components. Contact surfaces must be free of wax and

grease.

♦ Allocate the bolts and other components. Refer to the Parts

Catalog.

♦ Capacities. Refer to

⇒ “2.3 Codes, Transmission Allocation and Capacities”, page

3

 .

♦ Fill the transmission fluid when repairing the manual trans‐

mission.

Capacity, Transmission Com‐

pletely Disassembled

Capacity, Transmission Parti‐

ally Disassembled. Refer to

⇒ “6 Transmission Fluid,

Checking and Filling”,

page 157

Refer to ⇒  Fluid Capacity Ta‐

bles; Rep. Gr.  03

Refer to ⇒  Fluid Capacity Ta‐

bles; Rep. Gr.  03

10

O-Rings, Gaskets, Seals and Sealant

♦ Clean the housing separating surfaces thoroughly before ap‐

plying the sealant .

♦ Apply the Sealant - AMV 188 200 03- evenly and not too thick.
♦ Replace the O-rings, seals and gaskets.
♦ After removing gaskets, examine the contact surface on hous‐

ing/shaft for burrs resulting from removal or for other damage.

♦ Before installing the radial shaft seals lightly oil the outer cir‐

cumference and fill the space between the sealing lips

-arrow- halfway with Grease - G 052 128 A1- .

♦ The open side of the gaskets point toward the fluid to be sealed

in.

♦ When installing the new shaft seals, make sure the sealing lip

does not run on the same point as the sealing lip of the old

seal (use insertion depth tolerances).

♦ Lightly lubricate the O-rings before inserting to prevent the

rings from being crushed during assembly.

♦ After replacing the seals and sealing rings, check the trans‐

mission fluid level and fill if necessary. Refer to

⇒ “6 Transmission Fluid, Checking and Filling”, page 157

 .

5.1.3

Retainers

♦ Do not stretch the circlips.
♦ Always replace damaged or stretched circlips.
♦ The circlips must rest at the bottom of the groove.
♦ Replace the adapter sleeves. Installation position: the slot

-A- should align with the line of force -arrow-.

5. General Repair Information    

11

Bolts and Nuts

♦ Loosen the bolts and nuts opposite the tightening sequence.
♦ Nuts and bolts which secure covers and housings should be

loosened and tightened diagonally and in steps if no tightening

sequence is specified.

♦ Especially delicate parts, such as clutch pressure plates, must

not be distorted. Loosen and tighten bolts and nuts in stages

in a diagonal sequence.

♦ The tightening specifications given apply to unoiled bolts and

nuts.

♦ Always replace self-locking bolts and nuts.
♦ Use a wire brush to clean the threads of the bolts that were

installed with locking fluid. Then insert the bolts with Locking

Fluid - AMV 185 101 A1- .

♦ Clean the threaded holes for the self-locking bolts or for the

bolts coated with locking fluid. (for example with a thread tap).

Otherwise there is the risk that the bolts could break off the

next time they are removed.

5.1.5

Bearings

♦ Install needle bearings with the lettered side (thicker metal)

facing the fitting tool.

♦ Insert all the bearings in transmission with gear oil.
♦ Replace all the tapered roller bearings that are on the same

shaft, and use tapered roller bearings from the same manu‐

facturer.

♦ To install, heat the bearing inner races to approximately 100°

C (212 °F) with Inductive Heater - VAS6414- .

♦ Do not interchange outer and inner bearing races with those

from other bearing of the same size. The bearings are paired.

5.1.6

Shims

♦ Measure the shims at several locations with a micrometer cal‐

iper. Tolerance variations make it possible to find the exact

shim thickness required.

♦ Check for burrs or damage.
♦ Only install perfect shims.

12

Synchronizer Rings

♦ Do not interchange them. When reusing synchronizer rings,

always install on the same gear wheel.

♦ Check for wear and replace if necessary.
♦ Check the grooves -arrow 1- on the synchronizer ring -A- and

the inner race for flat areas (grooves are worn).

♦ The coating on the synchronizer rings must not be damaged.
♦ If an intermediate ring -B- is installed, check the outer friction

surface -arrow 2- and the inner friction surface -arrow 3- for

»grooves« and »scoring«.

♦ Check taper of drive gear for »grooves« and »scoring«.
♦ Coat the synchronizing with transmission fluid and then install.

5.1.8

Gear Wheels, Synchronizer Hubs and

Needle Bearing Inner Races

♦ To install, warm the needle bearing inner race to approximate‐

ly 100 °C (212 °F) with Inductive Heater - VAS6414- .

♦ Heat the synchronizer hub to approximately 100 °C (212 °F)

with the Inductive Heat Unit - VAS6414- before installing.

Press on as far as the stop when installing so there is no axial

play.

♦ Heat the gears to approximately 100 °C (212 °F) with the In‐

ductive Heat Unit - VAS6414- before installing. Press on as far

as the stop when installing so there is no axial play.

♦ Pay attention to the installed location.

5.1.9

Selector Gears

♦ After installing, check 1st through 5th gear for minimal amount

of axial clearance and for ease of movement.

5.1.10

Clutch

♦ When removing transmission, remove the clutch slave cylin‐

der without opening the lines.

♦ If the clutch slave cylinder is removed with the hydraulic line

attached, do not depress clutch pedal. Otherwise the piston

will be pressed out of the clutch slave cylinder.

♦ Do not tilt the clutch pressure plate. Loosen and tighten it di‐

agonally and in small steps.

♦ To reduce odor caused by a burnt clutch, thoroughly clean the

clutch housing and the flywheel running surface with a clean

cloth.

5. General Repair Information    

13

 

 

 

 

 

 

 

Content   ..  135  136  137  138   ..