Volkswagen Golf Variant / Jetta. Manual - part 528

 

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Volkswagen Golf Variant / Jetta. Manual - part 528

 

 

⇒ Item 2 (page 159)

9 - Clutch Housing

❑ When replacing: adjust the differential. Refer to 

⇒ “2.2 Differential, Adjusting”, page 178

10 - Input Shaft Seal

❑ Pry out with a screwdriver
❑ Installing. Refer to 

⇒ Fig. ““Installing the Seal for the Input Shaft”“ , page 129

11 - Ball Stud

❑ 20 Nm
❑ Remove grease already present
❑ Grease using the Grease for Clutch Disc Shaft Splines - G 000 100-

12 - Right Flange Shaft Seal

❑ Replace when the transmission is installed. Refer to

⇒ “1.2 Right Flange Shaft Seal, Replacing”, page 171

 .

13 - Sleeve

❑ For seal
❑ Removing. Refer to 

⇒ Fig. ““Sealing Ring Sleeve, Removing”“ , page 129

 .

❑ Installing. Refer to 

⇒ Fig. ““Sealing Ring Sleeve, Pulling In”“ , page 129

 .

14 - Oil Filler Plug

❑ Tightening specification: 

⇒ Fig. ““Different Versions of Fluid Fill and Drain Plugs”“ , page 111

15 - Shim S2

❑ For the differential
❑ Selecting thickness. Refer to 

⇒ “2.2 Differential, Adjusting”, page 178

 .

16 - Outer Race/Tapered Roller Bearing

❑ For the differential
❑ Removing from the clutch housing and installing

⇒ “2.1 Differential, Disassembling and Assembling”, page 173

❑ When replacing: adjust the differential. Refer to 

⇒ “2.2 Differential, Adjusting”, page 178

17 - Bolt

❑ 5 Nm and 90° additional turn
❑ Replace after removing

18 - Outer Race/Tapered Roller Bearing

❑ For the differential
❑ Removing from the transmission housing and installing. Refer to

⇒ “2.1 Differential, Disassembling and Assembling”, page 173

❑ When replacing: adjust the differential. Refer to 

⇒ “2.2 Differential, Adjusting”, page 178

19 - Shim S1

❑ For the differential
❑ Always 1 mm thick
❑ Shim S1 is deleted as of production date 12/04/2006

Refer to

⇒ Fig. ““Shim S1 for the outer race/tapered roller bearing is deleted as of production date 04/12/2006.”“ , page

179

❑ Outer race/tapered roller bearing seat adapted in transmission housing

20 - Alignment Sleeve
21 - Transmission Housing

❑ Shim S1 is deleted as of production date 12/04/2006. Refer to

⇒ Fig. ““Shim S1 for the outer race/tapered roller bearing is deleted as of production date 04/12/2006.”“ ,

page 179

128

⇒ “2.2 Differential, Adjusting”, page 178

22 - Oil Drain Plug

❑ Tightening specification. Refer to 

⇒ Fig. ““Different Versions of Fluid Fill and Drain Plugs”“ , page 111

23 - Seal

❑ For the left flange shaft
❑ Replace when the transmission is installed. Refer to

⇒ “1.1 Left Flange Shaft Seal, Replacing”, page 170

 .

Installing the Seal for the Input Shaft

Sealing Ring Sleeve, Removing
– Place the Press Piece - Multiple Use - Spacer Sleeve -

VW472/2- und Press Piece - Pad - 30-555- on the differential.

-A- = Puller - Kukko Puller - 60-150mm Width, 200mm Length -

18/1-
-B- = Puller - Kukko Quick Action Separating Tool - 12-75mm -

17/1-

Sealing Ring Sleeve, Pulling In
A - Threaded studs from Seal Installer - Driver Set - 3066- instal‐

led in differential threaded piece
B - M12 nut with washer
– Turn the nut -B- and pull the sleeve all the way over the Press

Piece - Pivot Mount Bushing - 3124- .

Note

If transmission is disassembled, press sleeve in onto stop using

Press Piece - Pivot Mount Bushing - 3124- .

7. Transmission Housing and Clutch Housing, Servicing    

129

Gearshift Shaft Sleeve -A-, Installing

130

Shift Unit, Servicing

Special tools and workshop equipment required
♦ Press Piece - Shift Rod/Alternator - VW423-
♦ Torque Wrench 1331 5-50Nm - VAG1331-
♦ Breather Tube Tool - T10203-

1 - Sleeve

❑ For the selector shaft
❑ Removing. Refer to

⇒ Fig. ““Gearshift Shaft

Sleeve -A-, Remov‐

ing”“ , page 130

❑ Installing. Refer to

⇒ Fig. ““Gearshift Shaft

Sleeve -A-, Installing”“ ,

page 130

2 - Gearshift Shaft with Gear‐

shift Cover

❑ replace together

3 - Locking Elbow

❑ For adjusting the shift

mechanism

❑ Removing. Refer to

⇒ Fig. ““Removing the

locking elbow -A- from

the shift cover”“ ,

page 132

 .

❑ Installing. Refer to

⇒ Fig. ““Drive the lock‐

ing elbow in the shift

cover.”“ , page 132

4 - Relay Lever

❑ Installation position. Re‐

fer to

⇒ Fig. ““Selector lever/

relay lever installed po‐

sition”“ , page 70

 .

❑ Plastic relay lever from

05/2007. Refer to

⇒ “1.11 Plastic Relay

Lever”, page 78

 .

5 - Bearing Bushing

❑ Not needed for the plastic relay lever

6 - Seal

❑ For the selector shaft
❑ Pry out with a screwdriver
❑ Inserting. Refer to 

⇒ Fig. ““Insert sealing ring -A- as far as stop”“ , page 132

7 - Cap

❑ For the transmission ventilation

8 - Selector Lever

❑ Installing. Refer to 

⇒ Fig. ““Installing the transmission shift lever”“ , page 69

 .

❑ Can be replaced with the shift mechanism still installed
❑ Installation position. Refer to 

⇒ Fig. ““Selector lever/relay lever installed position”“ , page 70

 .

8. Shift Unit, Servicing    

131

 

 

 

 

 

 

 

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