Volkswagen Golf Variant / Jetta. Manual - part 210

 

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Volkswagen Golf Variant / Jetta. Manual - part 210

 

 

Notes on Performance Test, AWD

– Only test stands with 4 braked rollers should be used for the

performance test.

6. Notes on Performance Test, AWD    

15

General Repair Information

⇒ “7.1 Safety Precautions, Vehicles with Start/Stop System”,

page 16
⇒ “7.2 Contact Corrosion”, page 16
⇒ “7.3 Special Tools”, page 16
⇒ “7.4 Components”, page 16

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 list of general instructions that apply to multiple repair proce‐

dures throughout the repair manual are summarized once here

under the “Components” section. Refer to

⇒ “7.4 Components”, page 16

 . They apply to this repair manual.

7.1

Safety Precautions, Vehicles with Start/

Stop System

WARNING

Risk of injury if the engine starts automatically in vehicles with

a Start/Stop System.

♦ For vehicles with an activated Start/Stop System (recog‐

nizable from a notification in the instrument cluster), the

engine can be started automatically if needed.

♦ Make sure the Start/Stop system is deactivated when

working on the vehicle (turn off ignition and turn the ignition

back on if needed).

7.2

Contact Corrosion

♦ The transmission housing and clutch housing consist of a

magnesium alloy.

♦ Bolts and other components, which come into direct contact

with the transmission, have a surface coating adapted for this.

♦ Contact corrosion occurs when incorrect components (bolts,

nuts, washers, etc.) are used. The transmission housing and

clutch housing are damaged.

♦ Only install components provided in the Parts Catalog.

7.3

Special Tools

Refer to Workshop Equipment and Special Tools for a complete

list of special tools used in the repair manual.

7.4

Components

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.

16

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FWD
♦ Check the transmission fluid level after installation. Refer to

⇒ “8 Transmission Fluid, Checking”, page 192

 .

♦ For capacities, refer to

⇒ “1.2 Codes Letters, Transmission Allocation and Capacities,

FWD”, page 2

 . For specification. Refer to the Parts Catalog.

AWD
♦ After installing the transmission and/or bevel box, check the

transmission fluid level in the manual transmission and the

gear oil level in the bevel box (Manual Transmission. Refer to

⇒ “8 Transmission Fluid, Checking”, page 192

 ), (Bevel Box.

Refer to

⇒ “10 Axle Oil in Bevel Box, Checking or Adding”,

page 218

 ).

♦ For capacities. Refer to

⇒ “2.2 Code Letters, Transmission Allocation and Capacities,

AWD”, page 7

 . For specification. Refer to the Parts Catalog.

O-Rings, Gaskets, Seals and Sealant
♦ Always thoroughly clean the separating surfaces on the hous‐

ing before applying the sealant.

♦ Apply the Sealant - AMV 188 200 03- evenly and not too thick.
♦ Replace the O-rings, seals and gaskets.
♦ Flange shaft, input shaft and selector shaft seals are illustrated

as shaft seals.

♦ Once a shaft seal or gasket has been removed, check the

contact surface on the housing or shaft for burrs and damage

caused by the removal. Repair as necessary.

♦ Before installing the shaft seals, lightly oil the outer circumfer‐

ence and fill the space between the sealing lips -arrow- half‐

way with Grease - G 052 128 A1- .

♦ The open side on the shaft seals faces the fluid to be sealed

off.

♦ Press in new shaft seal, so that the sealing lip does not run on

the same point as the sealing lip of the old shaft seal (use offset

tolerance).

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

rings from being crushed during assembly.

♦ Check the fluid level in the manual transmission after replacing

the seals, O-rings and gaskets (Refer to

⇒ “8 Transmission Fluid, Checking”, page 192

 .) or the fluid

level in the bevel box (Refer to

⇒ “10 Axle Oil in Bevel Box, Checking or Adding”,

page 218

 .)

7. General Repair Information    

17

♦ Do not stretch the circlips.
♦ Installation position for some of the circlips: the circlip is »nar‐

rower at the top« and so is its installation position. This makes

it easier for the pliers to grab the circlip when removing and

installing it.

♦ Replace damaged or overstretched locking ring after remov‐

ing.

♦ 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-.

18

 

 

 

 

 

 

 

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