Volkswagen Golf Variant / Jetta. Manual - part 270

 

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Volkswagen Golf Variant / Jetta. Manual - part 270

 

 

Note

A second technician is needed to help install the shafts into the

clutch housing.

– Hold the output shaft for 1st through 4th gear -3- and the gear‐

shift rods -4- with the right hand.

– Slightly lift the differential with the left hand.
– Have the second technician lift the input shaft, the 5th/6th gear

output shaft and reverse gear -2- together with the reverse

shaft slightly at the same time.

– Install the 1st to 4th gear output shaft in direction of -arrow-.
• Places of input shaft, output shafts and final drive gear/differ‐

ential must engage.

– Together with a second technician, now displace shafts and

differential in their bearing seats.

– Secure the Bracket - Multiple Use - 30-211A- for the input shaft

to the clutch housing.

Note

The clutch housing is shown in the illustration rotated 180°.

– Install the bolt -A- just far enough until the input shaft starts to

lift.

The Grooved Ball Bearing/Input Shaft Only Fits in One Position

in the Transmission Housing.
There is a flattened area on the grooved ball bearing and the

bearing mount.
• If the flattened areas -A and B- are present, do not insert any

washers above and below the grooved ball bearing. Refer to

⇒ “1.2.1 Grooved Ball Bearing Changes”, page 315

 .

• The flattened sides -A- on the grooved ball bearing and on the

bearing mount -B- must align in the transmission housing.

– Mark the flattened side with color.
– Transfer the markings to the upper area of the grooved ball

bearing and to the upper area of the transmission housing

bearing mount (⇒ next figure).

– Heat the transmission housing in the area near the bearing

seat for the grooved ball bearing/input shaft to approximately

100 °C (212 °F) for approximately 10 minutes using a Hot Air

Blower , for example, Hot Air Blower - VAG1416- .

11. Transmission, Disassembling and Assembling    

255

It is necessary to heat the transmission housing so that the

grooved ball bearing is not damaged when the housing is be‐

ing installed.

Apply Sealing Paste - AMV 188 200 03- evenly onto the seal‐

ing surface of the clutch housing.

Align the marking on the grooved ball bearing -A- with the

marking on the transmission housing -B- and mount the trans‐

mission housing.

– Install the transmission housing and tighten the new bolts

-A, B and C- to the tightening specification.

If the steel bolts (out hex head) are the replacement part, pay

attention to the allocation:
A - Bolt with permanent washer
B - Bolt without washer
C - Bolt with permanent washer

– Install the grooved ball bearing/input shaft locking ring -1-.
– Remove the Bracket - Multiple Use - 30-211A- for the input

shaft.

– Install the selector shaft lock sleeve all the way onto the tool.

Refer to 

⇒ Fig. ““Lock Sleeve Differentiation”“ , page 266

 .

– Turn the transmission with opening for selector shaft in as‐

sembly stand upward.

Note

Use the Pry Lever - 80-200- to press against the spring force of

the securing bushing direction of -arrow- when installing so that

the gearshift shaft -1- does not touch the securing bushing -2-

when removing.

256

the shift forks -3-.

Note

The cover is not shown in the illustration -item 2-

⇒ Item 2 (page 262)

 .

– Push the gearshift shaft -1- against the retaining sleeve -2- in

direction of -arrow- and guide is through the shift fork all the

way down using the shift finger -3-.

• The gearshift cover -4- must stand parallel to the bolting sur‐

face on the transmission housing.

• It must be possible to move the gearshift shaft easily (forward

and backward).

Note

If the gearshift cover is at an angle to the bolting surface, then the

gearshift shaft is not installed into the lower bearing.

– Tighten the bolts -3- on the gearshift cover -4-.
– Install the locking bolt -2-, lock elbow -arrow- must not be in‐

stalled when doing so.

– Install the Back-Up Lamp Switch - F4- -1-.

– Transmission on vehicles with Start/Stop System: Install the

Transmission Neutral Position Sensor - G701- -arrow- and

tighten the bolt to 6 Nm.

11. Transmission, Disassembling and Assembling    

257

⇒ “2 Clutch Release Mechanism, Servicing”, page 50

 .

– Move the gearshift lever (selector lever) through all the gears.
– Install the cover as follows:

Cover Differentiation
-I- = metal cover; secured with securing ring -A-.
-II- = plastic cover; without securing ring.

Allocation

Mounting Area for

the Cover

Cap

Installation

-Arrow A- = vertical

Made of metal

Refer to

⇒ Fig. ““Metal Cov‐

er”“ , page 259

-Arrow B- = at an

angle

Plastic

Refer to

⇒ Fig. ““Plastic Cov‐

er”“ , page 259

258

 

 

 

 

 

 

 

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