5-Speed Manual Gearbox 0A4 PDF

Service
Workshop Manual
Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Passat 2006
5-speed manual gearbox 0A4
Edition 04.2010
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Service Department. Technical Information
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List of Workshop Manual Repair GroupsList of Workshop Manual Repair GroupsList of Workshop Manual Repair Groups
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Repair Group
30 - Clutch 35 - Gears, shafts
00 - Technical data
34 - Controls, housing
39 - Final drive - differential
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Technical information should always be available to the foremen and mechanics, because their careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a matter of course, be observed.
All rights reserved. No reproduction without prior agreement from publisher. Copyright 2010 Volkswagen AG, Wolfsburg K0058990420
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00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1 1.1 1.2 1.3 1.4 1.5 1.6 2 3 4 4.1 1 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 1.10 1.11 1.12 1.13 1.14 1.15 1.16 1.17 1.18 1.19 1.20 1.21 2 2.1 2.2 2.3 3 4 5 5.1 5.2 5.3 5.4 5.5 6 Gearbox identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Location on gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Identification codes, assembly allocation, capacities, Golf 2004 . . . . . . . . . . . . . . . . . . Identification codes, assembly allocation, capacities, Golf 2009 . . . . . . . . . . . . . . . . . . Identification codes, assembly allocation, capacities, Golf Plus 2005 . . . . . . . . . . . . . . Identification codes, assembly allocation, capacities, Golf Plus 2009 . . . . . . . . . . . . . . Identification codes, assembly allocation and capacities, Passat 2006 . . . . . . . . . . . . . . Overview - power transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Calculating overall gear ratio i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General repair notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Repairing clutch mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly overview - pedal cluster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing over-centre spring, Golf 2004 . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing over-centre spring, Golf 2009 LHD . . . . . . . . . . . . . . . . . . . . . . Removing and installing over-centre spring, Golf 2009 RHD . . . . . . . . . . . . . . . . . . . . . . Removing and installing over-centre spring, Golf Plus . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing over-centre spring, Passat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing clutch pedal, Golf 2004 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing clutch pedal, Golf 2009 LHD . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing clutch pedal, Golf 2009 RHD . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing clutch pedal, Golf Plus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing clutch pedal, Passat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing mounting bracket, Golf 2004 . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing mounting bracket, Golf 2009 LHD . . . . . . . . . . . . . . . . . . . . . . Removing and installing mounting bracket, Golf 2009 right-hand drive and Golf Plus righthand drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing mounting bracket, Golf Plus left-hand drive . . . . . . . . . . . . . . . . Removing and installing mounting bracket, Passat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing master cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing clutch position sender G476 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly overview - hydraulics (LHD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly overview - hydraulics (RHD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing slave cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Torque settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bleeding clutch system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Repairing clutch release mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Repairing clutch, in conjunction with dual-mass flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . Identifying make of clutch, vehicles with 1.9 l - 66 kW turbo diesel engine and vehicles with 1.9 l - 77 kW turbo diesel engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing Sachs clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Repairing Sachs clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing LuK clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Repairing LuK clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Repairing clutch, in conjunction with one-piece flywheel . . . . . . . . . . . . . . . . . . . . . . . . . .
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Contents
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30 - Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
15 15 16 18 22 27 32 37 38 44 49 54 59 61 67 73 79 84 88 90 94 96 98 98 99 99 101 103 105 105 107 109 109 112 113
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Contents
Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010
34 - Controls, housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116

1 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 1.10 1.11 1.12 2 2.1 2.2 3 3.1 3.2 4 4.1 4.2 5 5.1 5.2 6 6.1 6.2 7 8 8.1 8.2 8.3 9 9.1 9.2 9.3 9.4 9.5 9.6 9.7 10 11 12 1 1.1 1.2 2 2.1 2.2 Repairing selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation position of selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Overview of selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . n. AG AG n. Removing and installing gear knob and cover . w .a .g .e. .. .V .o.lk.sw .a .g .e. . .do . e. . . . . . . . . . . . . . . s no s k l o t gu V Removing and installing gaiter with gear knob .a. . . . . . . . . . by and noise insulation, Golf . . . d ra e s i Removing and installing gaiter with gear ....... r knob and noise insulation, Golf Plus . .nt. ee o h t o u Removing and installing gaiter withs a selector lever knob and noise insulation, Passat r ac . . . . s Repairing gear lever and selector housing (through 10.06) . . . . . . . . . . . . . . . . . . . . . . . . Repairing gear lever and selector housing (from 11.06) . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly overview - removing and installing selector cables . . . . . . . . . . . . . . . . . . . . . . Plastic relay lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjusting selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing gearbox, Golf 2004 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing gearbox, Golf 2009 with turbo diesel engine . . . . . . . . . . . . . . Removing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing gearbox, Golf 2009 with petrol engine . . . . . . . . . . . . . . . . . . . . Removing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing gearbox, Golf Plus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing gearbox, Passat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transporting gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking and topping up gear oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Draining gear oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fill with gear oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dismantling and assembling gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Overview - gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing cover for gearbox housing and 5th gear . . . . . . . . . . . . . . . . . . . . Removing and installing gearbox housing and selector mechanism . . . . . . . . . . . . . . . . . . Removing and installing input shaft, output shaft, differential and selector forks . . . . . . . . Assembly sequence - removing and installing cover for gearbox housing and 5th gear . . Assembly sequence - Dismantling and assembling gearbox completely . . . . . . . . . . . . . . Repairing gearbox housing and clutch housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Repairing selector unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dismantling and assembling selector forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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116 116 117 118 118 120 121 123 125 131 134 136 139 143 144 150 156 157 163 171 173 180 188 189 196 205 207 212 219 220 220 221 222 223 223 224 225 226 227 228 234 248 255 258 263 263 270 275 275 287
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35 - Gears, shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263

Input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dismantling and assembling input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjusting input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Output shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dismantling and assembling output shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjusting output shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 3 3.1 1 1.1 1.2 1.3 1.4 2 3 3.1 3.2 Reverse shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291 Dismantling and assembling reverse shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291 Renewing flange shaft oil seals with gearbox installed . . . . . . . . . . . . . . . . . . . . . . . . . . . . Renewing oil seal for left flange shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Distinguishing seals for right flange shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Renewing seal (two-part seal and sleeve for right flange shaft) . . . . . . . . . . . . . . . . . . . . . . Renewing seal and sleeve together (one-piece seal and sleeve for right flange shaft) . . . . Adjustment overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dismantling and assembling differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjusting differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294 294 295 296 299 302 303 303 311
39 - Final drive - differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294

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Contents
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1
Technical data
Gearbox identification
5-speed manual gearbox 0A4 is installed in following vehicles: Allocation, Golf 2004 page 2 Allocation, Golf 2009 page 4 Allocation, Golf Plus 2005 page 5 Allocation, Golf Plus 2009 page 6 Allocation, Passat 2006 page 6
1.1
Location on gearbox
Codes and production date -arrow 1- manual gearbox 0A4 -arrow 2-
Manual gearbox 0A4 -arrow 2AG. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte is r o eo h ut ra a c s s
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Codes and production date of gearbox Example: FNE 10 11 I I I I I I Identification Day Month code
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3 I I Year (2003) of manufacture
Additional data provide information about the production facility. Note
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The gearbox code is also included on the vehicle data stickers.

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1. Gearbox identification
1.2
Identification codes, assembly allocation, capacities, Golf 2004

FNE from to Engine 08.03 08.03 1.9 l - 77 kW turbo diesel 61 : 18 = 3.389 1.9 l 1.7 l 100 mm 5-speed 0A4 GQQ 08.03 08.06 1.9 l - 77 kW turbo diesel 61 : 18 = 3.389 1.9 l 1.7 l 100 mm HGR 03.05 08.06 2.5 l - 110 kW 62 : 17 = 3.647 1.9 l 1.7 l 100 mm
Manual gearbox Identification code Manufactured Allocation
Ratio Final drive Z1 : Z2 Capacity of manual gearbox (gear box completely dismantled) Capacity of manual gearbox page 220 (gearbox partially dis mantled) Drive shaft flange
The following data can be found in the Electronic parts cata logue ETKA . Individual gear ratios Gear oil Clutch allocation
Manual gearbox Identification code Manufactured from to Engine Final drive
HDR
5-speed 0A4 GTB
JCT 05.06 06.08 2.5 l - 110 kW 62 : 17 = 3.647 1.9 l 1.7 l 108 mm
Allocation Ratio ed Z1 : Z2 ris ho t Capacity of manual gearbox (gear au box completely dismantled) ss Capacity of manual gearbox page 220 (gearbox partially dis mantled) Drive shaft flange
01.05 08.03 08.06 03.04 2.0 l 85 kW 2.5 l - 110 kW k s l w o agen AG n AG. V does wage s k n l ot= o : 17 = 3.647 62 : 17 3.647 V62 gu by 1.9 l 1.7 l 100 mm 1.9 l 1.7 l 108 mm
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JCR 05.06 06.08 1.9 l - 66 kW turbo diesel 1.9 l - 77 kW turbo diesel

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5-speed 0A4 JCU 05.06 06.08 2.0 l - 85 kW

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JCV
from to Engine
05.06 06.08 1.8 l - 110 kW
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Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 Manual gearbox Identification code Ratio Final drive Z1 : Z2 Capacity of manual gearbox (gear box completely dismantled) Capacity of manual gearbox page 220 (gearbox partially dis mantled) Drive shaft flange The following data can be found logue ETKA . Individual gear ratios
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JCR 61 : 18 = 3.389 1.9 l 1.7 l 108 mm
5-speed 0A4 JCU 72 : 17 = 4.235 1.9 l 1.7 l 100 mm
JCV 63 : 16 = 3.938 1.9 l 1.7 l 108 mm
Clutch allocation
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Gear oil
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FNC from to Engine 05.06 12.06 1.9 l - 77 kW turbo diesel 61 : 18 = 3.778 1.9 l 1.7 l 100 mm
5-speed 0A4 HJK 05.06 12.06 1.8 l - 110 kW 63 : 16 = 3.938 1.9 l 1.7 l 100 mm
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KCL
12.06 06.08 1.9 l - 77 kW turbo diesel 61 : 18 = 3.778 1.9 l 1.7 l
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100 mm
The following data can be found in the Electronic parts cata logue ETKA .
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Gear oil Clutch allocation
Manual gearbox Identification code Manufactured Allocation from to Engine
07.07 06.08 1.9 l - 77 kW turbo diesel 61 : 18 = 3.778 1.9 l 1.7 l 100 mm
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Individual gear ratios
KBL
5-speed 0A4 KCD 05.07 12.07 2.5 l - 125 kW 62 : 17 = 3.647 1.9 l 1.7 l 100 mm
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JQP 07.07 06.08 1.8 l - 118 kW 62 : 17 = 3.647 1.9 l 1.7 l 100 mm

Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 The following data can be found in the Electronic parts cata logue ETKA . Individual gear ratios Gear oil Clutch allocation
Manual gearbox Identification code Manufac tured Allocation from to Engine
KPF
5-speed 0A4 LHW
Ratio Z1 : Z2 Capacity of manual gear box (gearbox completely dismantled) Capacity of manual gear box page 220 (gearbox partially dismantled) Drive shaft flange
07.07 04.08 . Volkswagen AG gen AG d 06.08 06.08 a o e w s no olks t gu y Vl - 125 kW b 2.5 1.9 l - 77 kW ara d e nte is r turbo diesel o eo h ut r a Final drive ss 61 : 18 = 3.778 62 : 17 = 3.647 ac 1.9 l 1.7 l 100 mm 1.9 l 1.7 l 100 mm
1.3
Identification codes, assembly allocation, capacities, Golf 2009

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KQM
Ratio Final drive Z1 : Z2 Capacity of manual gear box (gearbox completely dismantled) Capacity of manual gear box page 220 (gearbox partially dismantled) Drive shaft flange
61 : 18 = 3.778 1.9 l 1.7 l 100 mm
61 : 18 = 3.778 1.9 l 1.7 l 100 mm
The following data can be found in the Electronic parts cata logue ETKA . Individual gear ratios Gear oil
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Manufac tured Allocation
from to Engine
06.08 05.09 1.9 l - 81 kW turbo diesel
08.08
2.0 l - 81 kW turbo diesel
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Manual gearbox Identification code
5-speed 0A4 LLL
LHW 05.09 1.6 l - 66 kW turbo diesel 1.6 l - 77 kW turbo diesel 62 : 17 = 3.647 1.9 l 1.7 l 100 mm
Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 Clutch allocation
LUB 05.09 1.9 l - 77 kW turbo diesel 62 : 17 = 3.647 1.9 l 1.7 l 100 mm
5-speed 0A4 KCD 08.09 09.09 2.5 l - 125 kW 62 : 17 = 3.647 1.9 l 1.7 l 100 mm
KPF 08.09 05.10 2.5 l - 125 kW 61 : 18 = 3.778 1.9 l 1.7 l 100 mm
The following data can be found in the Electronic parts cata logue ETKA .
age w Individual gear ratios olks
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MDZ 11.09 1.9 l - 77 kW turbo diesel 61 : 18 = 3.778 1.9 l 1.7 l 100 mm
5-speed 0A4 LEA

05.10 08.10 2.5 l - 125 kW 61 : 18 = 3.778 1.9 l 1.7 l
The following data can be found in the Electronic parts cata logue ETKA . Gear oil
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100 mm
Individual gear ratios Clutch allocation

AG.
1.4
Identification codes, assembly allocation, capacities, Golf Plus 2005

HNV from to 11.04 05.06 5-speed 0A4 JCX 05.06 01.09 KBL 11.07 01.09
Manual gearbox Identification code Manufactured
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HNV 1.9 l - 66 kW turbo diesel 1.9 l - 77 kW turbo diesel 62 : 17 = 3.647 1.9 l 1.7 l 100 mm
KBL 1.9 l - 77 kW turbo diesel 61 : 18 = 3.778 1.9 l 1.7 l 100 mm
Ratio Final drive Z1 : Z2 Capacity of manual gearbox Capacity of manual gearbox page 220 (gearbox partially dis mantled) Drive shaft flange
The following data can be found in the Electronic parts cata en AG. Volkswagen AG does wag logue ETKA . not olks Individual gear ratios Gear oil
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1.5
Identification codes, assembly allocation, capacities, Golf Plus 2009

KQM 01.09 5-speed 0A4 LHW 02.09 1.6 l - 66 kW turbo diesel 1.6 l - 77 kW turbo diesel 62 : 17 = 3.647 1.9 l 1.7 l 100 mm
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from to Engine
100 mm
100 mm
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1.6
Identification codes, assembly allocation and capacities, Passat 2006

HNV from to 01.05 05.06 5-speed 0A4 JCX 05.06 11.08 JQP 05.07 11.08
Manual gearbox Identification code Manufac tured
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Ratio Final drive Z1 : Z2 Capacity of manual gearbox Capacity of manual gearbox page 220 (gearbox partially dis mantled) Drive shaft flange
61 : 18 = 3.778 1.9 l 1.7 l
62 : 17 = 3.647 1.9 l 1.7 l
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Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 Manual gearbox Identification code Allocation Engine 5-speed 0A4 JCX 1.9 l - 66 kW turbo diesel 1.9 l - 77 kW turbo diesel 62 : 17 = 3.647 1.9 l 1.7 l 100 mm
HNV 1.9 l - 77 kW turbo diesel 62 : 17 = 3.647 1.9 l 1.7 l 100 mm
JQP 1.8 l - 118 kW
Ratio Final drive Z1 : Z2 Capacity of manual gear box (gearbox completely dismantled) Capacity of manual gear box page 220 (gear box partially dismantled) Drive shaft flange
62 : 17 = 3.647 1.9 l 1.7 l 107 mm
The following data can be found in the Electronic parts cata logue ETKA . Individual gear ratios Gear oil Clutch allocation Manual gearbox Identification code Manufac tured Allocation
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KJF 12.07 2.0 l - 85 kW turbo diesel 62 : 17 = 3.647 1.9 l 1.7 l
Ratio Final Z1 : Z2 drive Capacity of manual gearbox (gearbox com pletely dismantled) Capacity of manual gearbox page 220 (gearbox partially dis mantled) Drive shaft flange
Engine
2.0 l - 85 kW 72 : 17 = 4.235 1.9 l 1.7 l
1.9 l - 77 kW turbo diesel 62 : 17 = 3.647 1.9 l 1.7 l

100 mm
100 mm
100 mm
The following data can be found in the Electronic parts cata logue ETKA . Individual gear ratios
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Gear oil
Manufac tured Allocation
from to Engine
01.08
AG.
KBL
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Clutch allocation
5-speed 0A4 LHP 11.08 08.09 2.0 l - 81 kW turbo diesel 1.6 l - 77 kW turbo diesel
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Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 Manual gearbox Identification code Ratio Final Z1 : Z2 drive Capacity of manual gearbox (gearbox com pletely dismantled) Capacity of manual gearbox page 220 (gearbox partially dis mantled) Drive shaft flange 61 :
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1.9 l 1.7 l
1.9 l 1.7 l
1.9 l 1.7 l
100 mm
100 mm
100 mm
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Designation
Overview - power transmission
-Arrows- indicate direction of travel. 1 - Engine 2 - Clutch 3 - Manual gearbox 4 - Input shaft
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Gears -Arrows- indicate direction of travel.
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2. Overview - power transmission
Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 I - 1st gear II - 2nd gear IV - 4th gear V - 5th gear R - Reverse gear A - Final drive
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Example:
Calculating overall gear ratio i

5th gear Final drive ZA1 = 18 ZA2 = 61
Drive gear Driven gear i = Z2 : Z1 1)
ZG1 = 39 ZG2 = 29
1) Z1 = No. of teeth on driving gear, Z2 = No. of teeth on driven gear
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iG = Gear ratio = ZG2 : ZG1= 29 : 39 = 0.744

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General repair notes
To ensure flawless and successful gearbox repairs, the greatest care and cleanliness as well as the use of good and proper tools are essential. Of course, the basic rules for safety also apply dur ing repair work. A number of instructions generally applicable to the various repair procedures - which were previously repeated a number of times at various places in the workshop manual are summarised under the topic components page 12 . They apply to this workshop manual.
4.1 4.1.1
Components Gearbox
When installing the manual gearbox, ensure that the dowel sleeves between the engine and gearbox are correctly seated. When installing mounting brackets or waxed components, clean the contact surfaces. Contact surfaces must be free of wax and grease. Allocate bolts and other components using Electronic parts catalogue ETKA . If the gearbox is repaired, fill with gear oil. Capacity, gearbox completely Capacity, gearbox partially dis dismantled mantled page 220 1.9 l 1.7 l
4.1.2
Seals and sealing rings

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Before installing oil seal, half-fill space between sealing lips with sealing grease -G 052 128 A1- -arrow-.
wag The open side of the oil seal faces the side with fluid olks filling.
ed After installing, check oil level page 220 . ris
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Thoroughly clean parting surfaces and apply sealant -AMV 188 200 03- . Apply sealant uniformly but not too thick.
a Lightly oil O-rings before installing; this ss prevents the ing crushed when inserted.
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4.1.3
Sealant
Thoroughly clean housing joint surfaces before applying seal ing paste. Evenly apply a thin coat of sealing paste -AMV 188 200 03- . Breather holes must remain free of sealing paste.
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4.1.4
Locking devices
Renew retaining rings. Do not overstretch retaining rings. Retaining rings must locate properly in grooves.
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4.1.5
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Nuts and bolts
Loosen and tighten securing bolts and nuts for covers and housings diagonally.
Do not cant especially delicate parts, such as clutch pressure plates. Loosen and tighten bolts and nuts in stages in a diag onal sequence. Torque settings are specified for unoiled bolts and nuts. Always renew self-locking bolts and nuts.
Ensure with threaded connections that contact surfaces as well as nuts and bolts are rewaxed only after assembly, if nec essary. Use a thread chaser to clear residual locking fluid from all threaded holes into which self-locking bolts are to be screwed. Otherwise there is a danger of bolts shearing when subse quently being removed.
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4.1.6
Bearings
Install new tapered roller bearings as supplied and do not lu bricate additionally. Install needle bearings with lettered side (thicker metal) to wards fitting tool. Tapered roller bearings fitted to one shaft must be renewed as a set. Use same make of bearings. Heat inner races to about 100 C with the inductive heater VAS 6414- before installing. Do not interchange outer or inner races of bearings of the same size. The bearings are matched in pairs.
AG.
4.1.7
Shims
Measure shims at several points with a micrometer. The var ious thicknesses make it possible to achieve the exact shim thickness required. Check for burrs and damage. Install only flawless shims.
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4. General repair notes
13
4.1.8
Synchro-rings
Do not interchange. When reusing synchro-rings, always fit to the same synchromeshed gear. Check for wear and renew if necessary. Check grooves -arrow 1- of synchro-ring -A- and inner ring for flat spots (worn grooves). If synchro-rings are coated, coating must not be damaged. If an intermediate ring -B- is installed, check the outer friction surface -arrow 2- and inner friction surface -arrow 3- of this intermediate ring for scoring, signs of abnormal wear and blue discolouration (due to overheating). Check cone of synchromeshed gear for scoring and signs of abnormal wear. Moisten synchromesh mechanism with gear oil before instal ling.
4.1.10 4.1.11
Synchromeshed gears Clutch
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Before installing, clean and heat with the inductive heater VAS 6414- to maximum 100 C.
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4.1.9
Gear wheels
After assembly, check synchromeshed gears for slight play, or for freedom of movement.
Ensure that the pressure plate does not cant: loosen and tight en bolts diagonally and in several gradual stages. If the clutch has burnt out, thoroughly clean the clutch housing as well as the friction surface of flywheel with a cloth to reduce the smell of burnt linings.
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30
1
1.1
Note
Clutch
Repairing clutch mechanismlkswagen AG. Volkswagen AG does no
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Before disconnecting battery, obtain code for radio having anti-theft coding.
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With ignition switched off, disconnect battery Electrical system; Rep. Gr. 27 ; Disconnecting and con
necting battery . battery .
When reconnecting battery, refer to Electrical system; Rep. Gr. 27 ; Disconnecting and connecting Grease all bearing points and contact surfaces. Allocate grease using Electronic parts catalogue (ETKA) . I - Assembly overview - pedal cluster page 16 II - Assembly overview - hy draulics (LHD) page 94 III - Assembly overview - hy draulics (RHD) page 96
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15
1.2
Assembly overview - pedal cluster

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age 1 - Bulkhead ksw Vol y b mount With support for ed ris o ing bracket h t
ss 2 - Seal Always renew Between mounting bracket and bulkhead Self-adhesive Bond to mounting bracket
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4 - Bolt 5 - Over-centre spring Removing and installing, Golf 2004 page 18 Removing and installing, Golf 2009 LHD page 22 Removing and installing, Golf 2009 RHD page 27 Removing and installing, Golf Plus page 32 Removing and installing, Passat page 37 6 - Bearing bush 7 - Pivot pin 8 - Clutch pedal Removing and installing, Golf 2004 page 38 Removing and installing, Golf 2009 LHD page 44 Removing and installing, Golf 2009 RHD page 49 Removing and installing, Golf Plus page 54 Removing and installing, Passat page 59 9 - Retainer To remove and install, separate master cylinder from clutch pedal ( Removing and installing clutch pedal)
16
Rep. Gr.30 - Clutch
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3 - Mounting bracket For mounting clutch pedal Is provided with damp ing in some equipment variants page 17 Removing and instal ling, Golf 2004 page 61 Removing and instal ling, Golf 2009 LHD page 67 Removing and instal ling, Golf 2009 righthand drive, and Golf Plus right-hand drive page 73 Removing and instal ling, Golf Plus left-hand drive page 79 Removing and instal ling, Passat page 84
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Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 Golf 2004 page 38 Golf 2009 LHD page 44 Golf 2009 RHD page 49 Golf Plus page 54 . Passat page 59
10 - Seal Always renew Between master cylinder and mounting bracket 11 - Master cylinder Removing and installing after removal of mounting bracket page 88 12 - Clutch position sender -G476 Removing and installing page 90 Can be checked in guided fault finding of vehicle diagnosis, testing and information system -VAS 5051- . The clutch position sender -G476- is identified as clutch pedal switch -F36- in guided fault finding. 13 - Clip Pull out clip to stop to remove and install pipe/hose line 14 - Supply hose Rubber From 12. 05, plastic page 95 n AG. Volkswagen AG do es n wage s k l ot g Golf 2009 and Golf Plus 2009 plasticy Vo page 95 u
ris 15 - Self-locking hexagon nut, 25 Nm tho u a Qty. 3 ss For mounting bracket to bulkhead Always renew
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16 - Hexagon nut, 25 Nm Always renew 17 - Stop For clutch pedal
Mounting bracket with damping -arrows-
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1.3
is Special tools and hworkshop equipment required or

Removing and installing over-centre . Volkswagen AG gen AG does a w not spring, Golf olks 2004 g yV
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Release tool ss -T10178-
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Torque wrench -V.A.G 1331-
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1.3.1
Removing
Push driver seat as far back as possible and put steering wheel in highest position. Remove trim and cover below trim on drive side General body repairs, interior; Rep. Gr. 68 . Remove cable guide -2- from steering column. Remove footwell vent -3-. Heating, air conditioning; Rep. Gr. 80 ; Repairing heating The crash bar -1- in front of clutch pedal -2- may be secured in different ways. Attachment with 2 bolts
18
Rep. Gr.30 - Clutch
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Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 Remove crash bar -1- (2 bolts). Attachment with 1 bolt
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Remove crash bar -1- (1 bolt -2-).
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To do this, remove lock washers -A- for damping. Pull off damping.
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If fitted, remove damping -arrow- from lower area of clutch pedal mounting bracket.
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19
Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 Push damping upwards in area of upper securing nut -1above clutch pedal -A- in -direction of arrow-.
Unbolt clutch pedal -1- from mounting bracket -3- by removing nut -2- and pulling out bolt -5-. Note
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The clutch pedal remains hooked to operating rod of master cyl inder.
Swing clutch pedal down slightly and remove over-centre spring -4- from mounting bracket.
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Install in the reverse order of removal, observing the following: Note

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Renew self-locking nuts.
20
Rep. Gr.30 - Clutch
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1.3.2
Installing
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Receptacle -arrow- for tip -A- of clutch pedal must stand ver tically. Insert tip of clutch pedal in bearing recess of over-centre spring. Depress clutch pedal slightly, push bolt through and tighten self-locking nut to specified torque page 22 .
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Some cars have damping -arrow- on the clutch pedal mounting bracket. Return it to installation position. The crash bar -1- in front of clutch pedal -2- may be secured in different ways. Attachment with 2 bolts
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Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 Install crash bar -1- and tighten the 2 bolts to specified torque page 22 . Attachment with 1 bolt
Install crash bar -1- and tighten bolt -2- to specified torque page 22 . Install trim and cover below trim on drive side General body repairs, interior; Rep. Gr. 68 .
1.3.3
Torque settings
Component
Nm 25 10 20
Clutch pedal to mounting bracket Renew self-locking nuts. Crash bar to steering column mounting bracket (attachment with 2 bolts) Crash bar to steering column mounting bracket (attachment with 1 bolt) Renew bolts for crash bar
1.4
Removing and installing over-centre spring, Golf 2009 LHD
Special tools and workshop equipment required Release tool -T10178ht rig py Co t.
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Rep. Gr.30 - Clutch
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Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 Torque wrench -V.A.G 1331-
1.4.1
Removing
Vehicles with knee airbag Note

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With ignition switched off, disconnect battery Electrical sys tem; Rep. Gr. 27 ; Disconnecting and connecting battery . Continuation for all Push driver seat as far back as possible and put steering wheel in highest position. Remove trim and cover below trim on drive side General body repairs, interior; Rep. Gr. 68 . Vehicles with knee airbag Remove bracket for knee airbag together with crash bar Interior equipment; Rep. Gr. 69 ; Airbag; Removing and in stalling knee airbag bracket (Golf 2009 ) . Continuation for all Remove cable guide -2- from steering column. Remove footwell vent -3-. Heating, air conditioning; Rep. Gr. 80 ; Repairing heating
First check theft code.
ed ris ho t whether au a coded ss
radio is fitted. If so, obtain anti-
ran tee or ac

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Vehicles without knee airbag
23
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Continuation for all
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Remove crash bar -1- (bolt -2-).
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2009 , Pass ...
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Rep. Gr.30 - Clutch
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Swing clutch pedal down slightly and remove over-centre spring -4- from mounting bracket. AG. Volkswagen AG d agen o
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1.4.2
Installing
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Receptacle -arrow- for tip -A- of clutch pedal must stand ver tically. Insert tip of clutch pedal -1- in bearing recess of over-centre spring. Depress clutch pedal slightly, push bolt through and tighten self-locking nut to specified torque page 27 .
Some cars have damping -arrow- on the clutch pedal mounting . Volkswagen AG bracket. gen AG d
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Rep. Gr.30 - Clutch
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26
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Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 Install crash bar -1- and tighten bolt -2- to specified torque page 27 . Continuation for all
Mount cable guide -2- on steering column. Install foot well vent -3-. Rep. Gr. 80 Vehicles with knee airbag Install bracket for knee airbag together with crash bar Inte rior equipment; Rep. Gr. 69 ; Airbag; Removing and installing knee airbag bracket (Golf 2009 ) . Continuation for all Install trim and cover below trim on drive side General body repairs, interior; Rep. Gr. 68 . . Volkswag
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Component
1.4.3
Torque settings
Nm 25 20
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Clutch pedal to mounting bracket Renew self-locking nuts. Crash bar to steering column mounting bracket Renew bolt for crash bar
1.5
Removing and installing over-centre spring, Golf 2009 RHD
Special tools and workshop equipment required Pliers -T10005-
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27
Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 Release tool -T10178-
1.5.1
Removing
First check whether a theft code.
Push driver seat as far back as possible and put steering wheel in highest position. Remove trim and cover below trim on driver side Body Re pairs; Rep. Gr. 68 . Remove bracket for knee airbag Interior equipment; Rep. Gr. 69 ; Airbag; Removing and installing knee airbag bracket (Golf 2009 ) . Remove footwell vent -3-. Heating, air conditioning; Rep. Gr. 80 ; Repairing heating
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With ignition switched off, disconnect battery Electrical sys tem; Rep. Gr. 27 ; Disconnecting and connecting battery .
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28
Rep. Gr.30 - Clutch
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Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 Remove cable guide -2- from steering column. Remove crash bar -1- (bolt -2-).

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Swing spring
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1.5.2
Installing
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Rep. Gr.30 - Clutch
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Receptacle -arrow- for tip -A- of clutch pedal must stand ver tically. Insert tip of clutch pedal -1- in bearing recess of over-centre spring. Depress clutch pedal slightly, push bolt through and tighten self-locking nut to specified torque page 32 .
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31
Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 Install crash bar -1- and tighten bolt -2- to specified torque page 32 .
Install foot well vent -3-. Rep. Gr. 80 Install bracket for knee airbag Interior equipment; Rep. Gr. 69 ; Airbag; Removing and installing knee airbag bracket (Golf 2009 ) . Install trim and cover below trim on drive side General body repairs, interior; Rep. Gr. 68 . If disconnected, connect battery Electrical system; Rep. Gr. 27 ; Removing and installing battery .
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Mount cable guide -2- on steering column.
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1.5.3
Component
Torque settings
Nm 25 20
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Clutch pedal to mounting bracket Renew self-locking nuts
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Crash bar to steering column mounting bracket Renew bolt for crash bar
1.6
Removing and installing over-centre spring, Golf Plus
Special tools and workshop equipment required Torque wrench -V.A.G 1331-
1.6.1
Removing
Push driver seat as far back as possible and put steering wheel in highest position.
32
Rep. Gr.30 - Clutch
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Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 Remove trim and cover below trim on drive side General body repairs, interior; Rep. Gr. 68 . Carefully cut through cable tie -1-. Remove cable guide -2- from steering column. Remove footwell vent -3-. Heating, air conditioning; Rep. Gr. 80 ; Repairing heating
Now remove crash bar -A- from in front of clutch pedal by re moving bolt -B-. G. Volkswagen
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Remove footwell trim by removing nuts -arrows-.
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Remove bolt -1- and pull universal joint -2- from steering box.
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33
Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 If fitted, remove damping -arrow- from lower area of clutch pedal mounting bracket.
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Push damping upwards in area of upper securing nut -1above clutch pedal -A- in -direction of arrow-.
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34
Rep. Gr.30 - Clutch
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Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 Unbolt clutch pedal -1- from mounting bracket -3- by removing nut -2- and pulling out bolt -5-. Note
The clutch pedal remains hooked to operating rod of master cyl inder. . Volkswag
Swing spring
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1.6.2
Installing

Insert over-centre spring in mounting bracket from above. Receptacle -arrow- for tip -A- of clutch pedal must be vertical.
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Insert tip of clutch pedal in bearing recess of over-centre spring.

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Depress clutch pedal slightly, push bolt through and tighten self-locking nut to specified torque page 36 .
AG.
35
Return it to installation position.
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Some cars have damping -arrow- on the clutch pedal mounting bracket.
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Fit universal joint -2- to steering box and screw in new bolt -1- Running gear, axles, steering; Rep. Gr. 48 ; Assembly overview - Steering . Carry out basic setting for steering angle sender -G85- with vehicle diagnosis, testing and information system -VAS 5051- . Install trim and cover below trim on drive side General body repairs, interior; Rep. Gr. 68 .
1.6.3
Component
Torque settings
Nm 25 Bolt M6 = 5
Clutch pedal to mounting bracket Renew self-locking nuts Crash bar to steering column mounting bracket
36
Rep. Gr.30 - Clutch
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Install crash bar -A-, tightening bolt -B- page 36 .
Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 Component Crash bar to steering column mounting bracket Renew bolts for crash bar Nm Bolt M8 = 20
1.7
Removing and installing over-centre spring, Passat
Special tools and workshop equipment required Release tool -T10178-
1.7.1
Removing
Remove mounting bracket page 84 .
Carefully clamp lower section of clutch pedal in vice having protective jaw pads. Separate clutch pedal from master cylinder page 59 . Press over-centre spring from clutch pedal -arrow 1- while swinging mounting bracket in -direction of arrow 2-. Carefully release tension from over-centre spring. Swing mounting bracket back to starting position and remove over-centre spring.
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Clutch pedal is separated from master cylinder.
Carefully clamp lower section of clutch pedal in vice having protective jaw pads. Insert over-centre spring in mounting bracket.
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1.7.2
Installing
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37
Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 Receptacle -arrow- for tip -A- of clutch pedal must stand ver tically. Apply release tool -T10178- to middle of over-centre spring and swing up mounting bracket.
Compress over-centre spring -arrow 1-. At the same time, move mounting bracket downwards -arrow 2- until over-centre spring can be pressed onto locating lug -A- of clutch pedal. WARNING
If over-centre spring is improperly installed, it will jump uncon trolled out of mounting bracket. Place a cloth over over-centre spring.
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Install mounting bracket, Passat page 84 .
1.8
Connect clutch pedal to master cylinder page 59 .
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Removing and installing clutch pedal, Golf 2004
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38
Rep. Gr.30 - Clutch
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Release tool -T10178-
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1.8.1
Removing
Push driver seat as far back as possible and put steering wheel in highest position. Remove trim and cover below trim on drive side General body repairs, interior; Rep. Gr. 68 . Remove cable guide -2- from steering column. Remove footwell vent -3-. Heating, air conditioning; Rep. Gr. 80 ; Repairing heating The crash bar -1- in front of clutch pedal -2- may be secured in different ways. Attachment with 2 bolts
Remove crash bar -1- (2 bolts). Attachment with 1 bolt
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39
Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 Remove crash bar -1- (1 bolt -2-).
To do this, remove Pull off damping.
. Volkswagen AG gen AG does swa k not l o lock washers V -A- for damping. gu y ara db e nte is r o eo h ut ra a c s s

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40
Rep. Gr.30 - Clutch
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Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 Push damping upwards in area of upper securing nut -1AG. Volkswagen AG d agen oes ksw not above clutch pedal -A- in -direction of arrow-. l o V g
ss
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Unbolt clutch pedal -1- from mounting bracket -3- by removing nut -2- and pulling out bolt -5-. Swing clutch pedal forward slightly and remove over-centre spring -4- from mounting bracket.
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Release clutch pedal from master cylinder with pliers T10005- . Remove clutch pedal.
1.8.2
Installing
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41
Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 Attach retainer -2- to master cylinder operating rod -1-. Press retainer into notch in clutch pedal -3- until it can be heard to engage.
ag Insert over-centre spring -2- in mounting bracket from above ksw Vol y b while holding end of spring with assembly tool -T10178in in ed ris stallation position. ho
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Insert tip -A- of clutch pedal in bearing recess of over-centre spring. Depress clutch pedal slightly, push bolt through and tighten self-locking nut to specified torque page 43 .
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Receptacle -arrow- for tip -A- of clutch pedal -1- must be ver tical.
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42
Rep. Gr.30 - Clutch
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Golf 2004 , Golf
Some cars have damping -arrow- on the clutch pedal mounting bracket. Return it to installation position. The crash bar -1- in front of clutch pedal -2- may be secured in different ways. Attachment with 2 bolts
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Attachment with 1 bolt
Install crash bar -1- and tighten bolt -2- to specified torque page 43 . Install trim and cover below trim on drive side General body repairs, interior; Rep. Gr. 68 .
1.8.3
Component
Torque settings
Nm 25 10 20
Clutch pedal to mounting bracket Renew self-locking nuts. Crash bar to steering column mounting bracket (attachment with 2 bolts) Crash bar to steering column mounting bracket (attachment with 1 bolts) Renew bolts for crash bar
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Install crash bar -1- and tighten the 2 bolts to specified torque page 43 .
43
1.9
Removing and installing clutch pedal, Golf 2009 LHD
Release tool -T10178AG. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o eo h t u ra a c s s
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Vehicles with knee airbag Note
The installation location of the knee airbag is above the pedal cluster.
First check whether a coded radio is fitted. If so, obtain antitheft code. With ignition switched off, disconnect battery Electrical sys tem; Rep. Gr. 27 ; Disconnecting and connecting battery .
44
Rep. Gr.30 - Clutch
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1.9.1
Removing
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Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 Continuation for all Push driver seat as far back as possible and put steering wheel in highest position. Remove trim and cover below trim on drive side General body repairs, interior; Rep. Gr. 68 . Vehicles with knee airbag Remove bracket for knee airbag together with crash bar Interior equipment; Rep. Gr. 69 ; Airbag; Removing and in stalling knee airbag bracket (Golf 2009 ) . Continuation for all Remove cable guide -2- from steering column. Remove footwell vent -3-. Heating, air conditioning; Rep. Gr. 80 ; Repairing heating Vehicles without knee airbag
Remove crash bar -1- (bolt -2-). Continuation for all
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Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... olkswag en AG 04.2010 AG. V0A4 5-speed manual gearbox Edition do agen washers -A- for
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46
Rep. Gr.30 - Clutch
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Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 Release clutch pedal from master cylinder with pliers T10005- . Remove clutch pedal.
1.9.2
Installing

Attach retainer -2- to master cylinder operating rod -1-. Press retainer into notch in clutch pedal -3- until it can be heard to engage.
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Insert over-centre spring -2- in mounting bracket from above while holding end of spring with assembly tool -T10178- in in stallation position.
AG.
47
Insert tip -A- of clutch pedal in bearing recess of over-centre spring. Depress clutch pedal slightly, push bolt through and tighten self-locking nut to specified torque page 49 .
Receptacle -arrow- for tip -A- of clutch pedal -1- must be ver tical.
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Some cars have damping -arrow- on the clutch pedal mounting bracket. Return it to installation position. Vehicles without knee airbag
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Install crash bar -1- and tighten bolt -2- to specified torque page 49 . Continuation for all
Mount cable guide -2- on steering column. Install foot well vent -3-. Rep. Gr. 80 Vehicles with knee airbag Install bracket for knee airbag together with crash bar Inte rior equipment; Rep. Gr. 69 ; Airbag; Removing and installing knee airbag bracket (Golf 2009 ) . Continuation for all Install trim and cover below trim on drive side General body repairs, interior; Rep. Gr. 68 . If disconnected, connect battery Electrical system; Rep. Gr. 27 ; Removing and installing battery .
48
Rep. Gr.30 - Clutch
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Prote cted by
1.9.3
Component
Torque settings
Nm 25 20
Clutch pedal to mounting bracket Renew self-locking nuts Crash bar to steering column mounting bracket Renew bolt for crash bar
1.10
Removing and installing clutch pedal, Golf 2009 RHD
Special tools and workshop equipment required Pliers -T10005AG. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o eo h t u ra a c s s
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Torque wrench -V.A.G 1331ht rig py Co t.
1.10.1
Removing
First check whether a coded radio is fitted. If so, obtain antitheft code.
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Prote cted by
49
Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 With ignition switched off, disconnect battery Electrical sys tem; Rep. Gr. 27 ; Disconnecting and connecting battery . Push driver seat as far back as possible and put steering wheel in highest position. Remove trim and cover below trim on drive side General body repairs, interior; Rep. Gr. 68 . Remove bracket for knee airbag Interior equipment; Rep. Gr. 69 ; Airbag; Removing and installing knee airbag bracket (Golf 2009 ) . Remove cable guide -2- from steering column.
Remove footwell vent -3-. Heating, air conditioning; Rep. Gr. 80 ; Repairing heating Remove crash bar -1- (bolt -2-).
pe rm itte d
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50
Rep. Gr.30 - Clutch
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Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 To do this, remove lock washers -A- for damping. Pull off damping.
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51
Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 Release clutch pedal from master cylinder with pliers T10005- . Remove clutch pedal.
1.10.2
Installing

Attach retainer -2- to master cylinder operating rod -1-. Press retainer into notch in clutch pedal until it can be heard to engage.
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stallation position.
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52
Rep. Gr.30 - Clutch
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Prote cted by
Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 Receptacle -arrow- for tip -A- of clutch pedal must stand ver tically. Insert tip of clutch pedal -1- in bearing recess of over-centre spring. Depress clutch pedal slightly, push bolt through and tighten self-locking nut to specified torque page 54 .
Some cars have damping -arrow- on the clutch pedal mounting n AG. Volkswagen AG do bracket. e wage Return it to installation position.
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Install crash bar -1- and tighten bolt -2- to specified torque page 54 .
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Mount cable guide -2- on steering column. Install foot well vent -3-. Rep. Gr. 80 Install bracket for knee airbag Interior equipment; Rep. Gr. 69 ; Airbag; Removing and installing knee airbag bracket (Golf 2009 ) . Install trim and cover below trim on drive side General body repairs, interior; Rep. Gr. 68 .
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53
1.10.3
Component
Torque settings
Nm 25 20
Clutch pedal to mounting bracket Renew self-locking nuts Crash bar to steering column mounting bracket Renew bolt for crash bar
1.11
Removing and installing clutch pedal, Golf Plus

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1.11.1
Removing
Push driver seat as far back as possible and put steering wheel in highest position. Remove trim and cover below trim on drive side General body repairs, interior; Rep. Gr. 68 . Remove cable guide -2- from steering column. Remove footwell vent -3-. Heating, air conditioning; Rep. Gr. 80 ; Repairing heating
54
Rep. Gr.30 - Clutch
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AG.
Now remove crash bar -A- from in front of clutch pedal by re moving bolt -B-.
n AG. Volkswagen AG do es n wage s k l ot g o yV ua b ran ed s i tee r o h Golf 2004 , Golf 2009 , Golf Plus 2005 t or , Golf Plus u ac a 5-speed manual gearbox 0A4 ss
2009 , Pass ... - Edition 04.2010

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Remove footwell trim by removing nuts -arrows-.

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Remove bolt -1- and pull universal joint -2- from steering box.
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AG.
55
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56
Rep. Gr.30 - Clutch
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AG.
Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 Unbolt clutch pedal -1- from mounting bracket -3- by removing nut -2- and pulling out bolt -5-. Swing clutch pedal forward slightly and remove over-centre spring -4- from mounting bracket.
pe rm itte d
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1.11.2
Installing
Note

Attach retainer -2- to master cylinder operating rod -1-. Press retainer into notch in clutch pedal until it can be heard to engage. Insert over-centre spring in mounting bracket from above.
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AG.
Prote cted by
57
Insert tip of clutch pedal in bearing recess of over-centre spring. Depress clutch pedal slightly, push bolt through and tighten self-locking nut to specified torque page 59 .
Receptacle -arrow- for tip -A- of clutch pedal must be vertical.
AG. Volkswagen AG d agen oes ksw not l o V gu y b Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ara ... d nte ise r o 5-speed manual gearbox 0A4 Edition 04.2010 eo h t u ra a c s s
Some cars have damping -arrow- on the clutch pedal mounting bracket. Return it to installation position.
do c um en
Install crash bar -A-, tightening bolt -B- to specified torque page 59 .
58
Rep. Gr.30 - Clutch
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AG.
Prote cted by
Fit universal joint -2- to steering box and screw in new bolt -1- Running gear, axles, steering; Rep. Gr. 48 ; Assembly overview - Steering . Carry out basic setting for steering angle sender -G85- with vehicle diagnosis, testing and information system -VAS 5051- .
n AG. Volkswagen AG do es n wage s k l ot g o yV u, b arGolf Golf 2004 , Golf 2009 Plus 2005 , Golf Plus an ed s i tee r o 5-speed manual gearbox 0A4 h t o ra au c ss
2009 , Pass ... - Edition 04.2010
Install trim and cover below trim on drive side General body repairs, interior; Rep. Gr. 68 .
1.11.3
Torque settings
Nm 25 Bolt M6 = 5
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Component Clutch pedal to mounting bracket Renew self-locking nuts Crash bar to steering column mounting bracket Crash bar to steering column mounting bracket Renew bolts for crash bar
Prote cted by
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Bolt M8 = 20
1.12
Removing and installing clutch pedal, Passat
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59
1.12.1
Removing
Remove mounting bracket page 84 . Carefully clamp mounting bracket in vice having protective jaw pads. Unbolt clutch pedal -1- from mounting bracket -3- by removing nut -2- and pulling out bolt -5-. Swing clutch pedal forward slightly and remove over-centre spring -4- from mounting bracket.
do c um en
1.12.2
Installing
60
Rep. Gr.30 - Clutch
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AG.
Prote cted by
Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 Attach retainer -2- to master cylinder operating rod -1-. Press retainer into notch in clutch pedal -3- until it can be heard to engage.
Insert over-centre spring -2- in mounting bracket from above while holding end of spring with assembly tool -T10178- in in stallation position. Insert tip of clutch pedal -1- in bearing recess of over-centre AG. Volkswagen AG d n oes wage spring. not olks
ed through and tighten Depress clutch pedal slightly, push bolt ris o h t self-locking nut. au
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Install mounting bracket page 84 .
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1.12.3
Component
Torque setting
Nm 25
Clutch pedal to mounting bracket Renew self-locking nuts
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1.13
AG.
Prote cted by
Hose clamps to 25 mm -3094-
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Special tools and workshop equipment required
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Removing and installing mounting bracket, Golf 2004

61
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Spring-type clip pliers -VAS 5024 A-
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Sealing tool -T10249-
1.13.1
LHD
Removing
First check whether a coded radio is fitted. If so, obtain antitheft code. With ignition switched off, disconnect battery Electrical sys tem; Rep. Gr. 27 ; Disconnecting and connecting battery . Remove complete air filter housing if it is near battery Rep. Gr. 23 ; Repairing diesel direct injection system or Rep. Gr. 24 ; Repairing injection system . Remove battery and battery tray Electrical system; Rep. Gr. 27 ; Battery; Removing and installing battery .
62
Rep. Gr.30 - Clutch
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AG.
Prote cted by
Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 Continuation for all Note During the following work, ensure that no brake fluid lands on Place a lint-free cloth under the master cylinder. Clamp off supply hose to master cylinder using hose clamp -3094- .
AG do agen clip -3- with If necessary, loosen spring-type assembly tool es n ksw ot g Vol y VAS 5024- and pull supply hose off master cylinder. ua db
longitudinal member or gearbox. If this does happen, clean the affected areas thoroughly.
AG. Volkswagen
Unclip clutch position sender -G476- from master cylinder -arrow- and remove with electrical connector attached -4-. Note
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Release securing clip -2- using screwdriver or a pointed object and pull pipe/hose line -1- off master cylinder.
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ran e tee ris ho t o au disconnecting, you can close it with the sealingr ac In addition, sfor s
tool -T10249/1- ( figure above).
When performing work in the footwell, put cloths on the carpet to protect it from possible brake fluid spills.
do c um en
Remove cable guide -2- from steering column.

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AG.
Remove footwell vent -3-. Heating, air conditioning; Rep. Gr. 80 ; Repairing heating
The crash bar -1- in front of clutch pedal -2- may be secured in different ways. Attachment with 2 bolts
Unbolt crash bar (2 bolts). Attachment with 1 bolt
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Remove trim and cover below trim on drive side General body repairs, interior; Rep. Gr. 68 .
63
G do agen Golf 2004 , Golf 2009 ,sGolf ksw , Golf Plus 2005 e not Plus 2009 , Pass ... Vol gu y b 5-speed manual gearbox 0A4 Edition 04.2010 ara d e
AG. Volkswagen A
Remove
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(1 bolt -2-).
nte eo ra c
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64
Rep. Gr.30 - Clutch
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AG.
Prote cted by
Remove securing nuts -1- and -2-. The upper securing nut -1- is accessible between the relay carrier and the steering column trim. Remove mounting bracket -3-.
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1.13.2
Installing
Install in the reverse order of removal, observing the following:
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AG.
Prote cted by
65
Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 Some cars have damping -arrow- on the clutch pedal mounting bracket. Note Renew self-locking nuts. Renew hose clips.
AG. Volkswagen AG d agen oes ksw not l o V gu y b to Electronic parts cata ara Allocate all components according d nte ise r logue ETKA . o eo h t u ra a c s s
The crash bar -1- in front of clutch pedal -2- may be secured in different ways. Attachment with 2 bolts
Install crash bar -1- and tighten the 2 bolts to specified torque page 67 . Attachment with 1 bolt
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Install trim and cover below trim on drive side General body repairs, interior; Rep. Gr. 68 .
AG.
66
Rep. Gr.30 - Clutch
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Prote cted by
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Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 Push pipe/hose line -1- with seal -2- onto connection of master cylinder -4- until securing clip -3- engages audibly. Test pipe/hose line by tugging on it. After removing hose clamp -3094- , return supply hose to its original position, if necessary. Bleed clutch system page 101 . LHD Install battery Electrical system; Rep. Gr. 27 ; Removing and installing battery . Remove complete air filter housing if it is near battery Rep. Gr. 23 ; Repairing diesel direct injection system or Rep. Gr. 24 ; Repairing injection system .
1.13.3
Component
Torque settings
Crash bar to steering column mounting bracket (attachment with 2 bolts) Crash bar to steering column mounting bracket (attachment with 1 bolt) Renew bolts for crash bar
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Mounting bracket to bulkhead Renew self-locking nuts.
AG. Volkswagen AG d agen oes ksw not l o gu yV Nm b ara d e nte is r o eo h 25 ut ra a c s s
10 20
1.14
Removing and installing mounting bracket, Golf 2009 LHD
Special tools and workshop equipment required Hose clamps to 25 mm -3094-
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AG.
67
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AG. Volkswagen A
Torque wrench -V.A.G 1331urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p
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1.14.1
Removing
First check whether a coded radio is fitted. If so, obtain antitheft code. With ignition switched off, disconnect battery Electrical sys tem; Rep. Gr. 27 ; Disconnecting and connecting battery . Remove complete air filter housing if it is near battery Rep. Gr. 23 ; Repairing diesel direct injection system or Rep. Gr. 24 ; Repairing injection system . Remove battery and battery tray Electrical system; Rep. Gr. 27 ; Removing and installing battery . Note During the following work, ensure that no brake fluid lands on Place a lint-free cloth under the master cylinder. Clamp off supply hose to master cylinder using hose clamp -3094- . Pull supply hose -1- off master cylinder.
68
Rep. Gr.30 - Clutch
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Prote cted by
Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 In addition, for disconnecting, you can close it with the sealing tool -T10249/1- ( figure above). Release securing clip -2- using screwdriver or a pointed object and pull pipe/hose line or plastic line -3- off master cylinder. Unclip clutch position sender -G476- from master cylinder -arrow- and remove with electrical connector attached -4-. Note
Remove trim and cover below trim on drive side General body repairs, interior; Rep. Gr. 68 . Vehicles with knee airbag Note
does wag The installation location not the pedal olks of the knee airbag is above gu yV b cluster. ara ed
olkswagen AG en AG. V
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ris ho ut a ss bracket Remove
for knee airbag together with crash bar Interior equipment; Rep. Gr. 69 ; Airbag; Removing and in stalling knee airbag bracket (Golf 2009 ) .
nte eo ra c
Remove footwell vent -3-. Heating, air conditioning; Rep. Gr. 80 ; Repairing heating Vehicles without knee airbag
Remove crash bar -1- (bolt -2-). Continuation for all

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69
To do this, remove lock washers -A- for damping.

Pull off damping.
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70
Rep. Gr.30 - Clutch
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AG.
Prote cted by
Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 Remove securing nuts -1- and -2-. The upper securing nut -1- is accessible between the relay carrier and the steering column trim. Remove mounting bracket -3-.
1.14.2
Installing

Some cars have damping -arrow- on the clutch pedal mounting bracket. Vehicles without knee airbag
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Install crash bar -1- and tighten bolt -2- to specified torque page 72 . Continuation for all
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71
Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 Mount cable guide -2- on steering column. Install footwell vent -3-. Heating, Air conditioning; Rep. Gr. 80 ; Repairing heating; Removing and installing left footwell vent Vehicles with knee airbag Install bracket for knee airbag together with crash bar Inte rior equipment; Rep. Gr. 69 ; Airbag; Removing and installing knee airbag bracket (Golf 2009 ) . Continuation for all Install trim and cover below trim on drive side General body repairs, interior; Rep. Gr. 68 . Push pipe/hose line or plastic line -1- with seal -2- onto con nection of master cylinder -4- until securing clip -3- engages audibly. Test line by tugging on it. After removing hose clamp -3094- , return supply hose to its n AG. Volkswagen AG do original position, if necessary. e wage Bleed clutch system page 101 .
Install battery Electrical and installing battery .
olks yV db e ris ho Rep. Gr. system; ut a ss
27 ; Removing
If removed, install complete air filter housing Rep. Gr. 23 ; Repairing diesel direct injection system or Rep. Gr. 24 ; Repairing injection system
1.14.3
Component
Torque settings
Nm 25 20
Mounting bracket to bulkhead Renew self-locking nuts.
Crash bar to steering column mounting bracket Renew bolt for crash bar
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72
Rep. Gr.30 - Clutch
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1.15
Removing and installing mounting bracket, Golf 2009 right-hand drive and Golf Plus right-hand drive
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Special tools and workshop equipment required Hose clamps to 25 mm -3094 Sealing tool -T10249 Hook -3438-
1.15.1
Removing
Vehicles with knee airbag
Remove shielding -A- from particle filter Rep. Gr. 26 ; Parts of exhaust system; Assembly overview - front exhaust pipe with particle filter . Continuation for all A heat shield is installed in conjunction with some engines. Ap pearance may be different from that illustrated.
AG.
Vehicles with turbo diesel engine and particle filter
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With ignition switched off, disconnect battery Electrical sys tem; Rep. Gr. 27 ; Disconnecting and connecting battery .
Prote cted by
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73
Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 Remove heat shield from pipe/hose line -arrows-.
Note During the following work, ensure that no brake fluid lands on Place a lint-free cloth under the master cylinder. Clamp off supply hose to master cylinder using hose clamp -3094- . Pull supply hose 3 off master cylinder. In addition, for disconnecting, you can seal supply hose with sealing tool -T10249/1- . Release securing clip -1- with a screwdriver or pointed object Pull pipe/hose line -2- off master cylinder. Unclip clutch position sender -G476from master cylinder n AG. Volkswagen AG do es -3-. wage connector attached -arrow- and remove with electrical s k no l o Note
V by ed s i r ho ut a ss
Remove trim and cover below trim on drive side General body repairs, interior; Rep. Gr. 68 . Golf Remove bracket for knee airbag Interior equipment; Rep. Gr. 69 ; Airbag; Removing and installing knee airbag bracket (Golf 2009 ) . Note
The installation location of the knee airbag is above the pedal cluster.
thi sd o cu m en
74
Rep. Gr.30 - Clutch
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Prote cted by
Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 Remove cable guide -2- from steering column by cutting cable tie -1- if necessary. Remove footwell vent -3-. Heating, air conditioning; Rep. Gr. 80 ; Repairing heating
Remove crash bar -1- (bolt -2-).
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Prote cted by
75
Remove securing nuts -1- and -2-.
The upper securing nut -1- is accessible between the relay carrier and the steering column trim. Remove mounting bracket -3-.
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1.15.2
Installing
76
Rep. Gr.30 - Clutch
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Some cars bracket.
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Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 AG. Volkswagen the clutch
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Fit cable guide -2- onto steering column, secure with cable tie -1- if necessary. Install footwell vent -3-. Heating, air conditioning; Rep. Gr. 80 ; Repairing heating Golf Install bracket for knee airbag Interior equipment; Rep. Gr. 69 ; Airbag; Removing and installing knee airbag bracket (Golf 2009 ) . Continuation for all Install trim and cover below trim on drive side General body repairs, interior; Rep. Gr. 68 . Press pipe/hose line -2- with seal into connection of master cylinder.
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Prote cted by
77
Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 Clip in securing clip -1-. Test line by tugging on it. Clip clutch position sender -G476- into master cylinder with electrical connector -3- attached -arrow-. Hook -3438- can be used for installing pipe/hose line -2- and clutch position sender -3-. After removing hose clamp -3094- , return supply hose to its original position, if necessary. . Volkswagen AG gen AG
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If present, fold heat shield around the pipe/hose line -arrows-. Vehicles with particle filter
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If disconnected, connect battery Electrical system; Rep. Gr. 27 ; Removing and installing battery .
1.15.3
Component
Torque settings
Nm 25 20
Mounting bracket to bulkhead Renew self-locking nuts Crash bar to steering column mounting bracket Renew bolt for crash bar
78
Rep. Gr.30 - Clutch
AG.
Bleed clutch system page 101 .
Prote cted by
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Install shielding -A- onto particle filter Rep. Gr. 26 ; Parts of exhaust system; Assembly overview - front exhaust pipe with particle filter .
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1.16
Removing and installing mounting bracket, Golf Plus left-hand drive
Special tools and workshop equipment required Hose clamps -3094 Torque wrench -V.A.G 1331 Spring-type clip pliers -VAS 5024 A Hose clamp -3094-
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1.16.1
Removing
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With ignition switched off, disconnect battery Electrical sys tem; Rep. Gr. 27 ; Disconnecting and connecting battery . Remove complete air filter housing if it is near battery Rep. Gr. 23 ; Repairing diesel direct injection system or Rep. Gr. 24 ; Repairing injection system .
AG.
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79
Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 Remove battery, battery cover and battery tray Electrical system; Rep. Gr. 27 ; Removing and installing battery . Note During the following work, ensure that no brake fluid lands on Place a lint-free cloth under the master cylinder. Clamp off supply hose to master cylinder using hose clamp -3094- . If necessary, loosen spring clip -3- using assembly tool -VAS 5024- . In addition, for disconnecting, you can close it with the sealing tool -T10249/1- ( figure above). Pull off supply hose.
AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d Pull clip -2- for pipe/hose line out of master cylinder to stop. e nte is r o eo h ut hose. ra Pull pipe/hose line -1- out from master cylinder and seal a c s s
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Unclip clutch position sender -G476- from master cylinder -arrow- and remove with electrical connector attached -4-.
Note
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Push driver seat as far back as possible and put steering wheel in highest position. Remove driver side compartment and cover General body repairs, interior; Rep. Gr. 68 ; Compartments, covers and trim panels . Carefully cut through cable tie -1-.
Remove footwell vent -3-. Heating, air conditioning; Rep. Gr. 80 ; Repairing heating
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80
Rep. Gr.30 - Clutch
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AG.
Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 Remove crash bar -A- by removing bolt -B-. Unbolt fuse holder beneath dash panel on left and lay to side Electrical system; Rep. Gr. 97 ; Removing and installing fuse holder . Unhook relay carrier beneath dash panel on left and lay to side Electrical system; Rep. Gr. 97 ; Removing and installing relay carrier .
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81
Remove mounting bracket securing nuts -arrows- as follows: Wrap tape around universal joint from socket set -V.A.G 1835- .
en AG n AG Press wiring harness -1and left d -arrowusing ex ageupwards oes ksw not l o V tension -2- from gu by-V.A.G 1835- . a
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Then unbolt both lower securing nuts for mounting bracket and remove mounting bracket.
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1.16.2
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Installing
Install in reverse order of removal. During this step, observe the following:
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82
Rep. Gr.30 - Clutch
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Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 Some cars have damping -arrow- on the clutch pedal mounting bracket. Volkswa
AG. agen
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es n w Install relay carrier beneath dash panel on left o olks t guElectrical yV b ara carrier . d system; Rep. Gr. 97 ; Removing and installing relay e n s
t holder beneath dash panel on left Electrical or Install fuse ac au ss Rep. Gr. 97 ; Removing and installing fuse holder system; .
ri ho
tee
Install crash bar -A-, tightening bolt -B- to specified torque page 84 . Install footwell vent, cable guide, cover and compartment on driver side General body repairs, interior; Rep. Gr. 68 ; Compartments, covers and trim panels .
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Renew cut cable ties.

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Push pipe/hose line -1- with seal -2- onto connection of master cylinder -4- until securing clip -3- engages audibly. Test pipe/hose line by tugging on it. After removing hose clamp -3094- , return supply hose to its original shape, if necessary. Bleed clutch system page 101 . Install battery tray, battery cover and battery Electrical sys tem; Rep. Gr. 27 ; Removing and installing battery . If removed, install complete air filter housing Rep. Gr. 23 ; Repairing diesel direct injection system or Rep. Gr. 24 ; Repairing injection system
AG.
83
1.16.3
Component
Torque settings
AG. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte s i r Golf 2004 , Golf 2009 , Golf Plus 2005th o , Golf Plus 2009 , Pass ... eo u ra a 5-speed manual gearbox 0A4 - Edition 04.2010 c s s
Nm 25
Mounting bracket to bulkhead Renew self-locking nuts
Crash bar to steering column mounting bracket Crash bar to steering column mounting bracket Renew bolts for crash bar
Bolt M6 = 5
Bolt M8 = 20
1.17
Removing and installing mounting bracket, Passat
Special tools and workshop equipment required Hose clamps to 25 mm -3094-
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Spring-type clip pliers -VAS 5024 A-
84
Rep. Gr.30 - Clutch
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Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 Sealing tool -T10249-
1.17.1
LHD
Removing
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Remove lower steering column trim General body repairs, interior; Rep. Gr. 68 ; Compartments, covers and trim panels . With ignition switched off, disconnect battery Electrical sys tem; Rep. Gr. 27 ; Disconnecting and connecting battery . Remove complete air filter housing if it is near battery Rep. Gr. 23 ; Repairing diesel direct injection system or Rep. Gr. 24 ; Repairing injection system . Remove battery and battery tray Electrical system; Rep. Gr. 27 ; Battery; Removing and installing battery . Continuation for all Note
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First check theft code.
AG. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte is r o eo h ut ra a c s whethersa coded radio is fitted. If so, obtain anti-
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During the following work, ensure that no brake fluid lands on Place a lint-free cloth under the master cylinder.
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If necessary, loosen spring-type clip -3- with assembly tool VAS 5024- and pull supply hose off master cylinder.
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Clamp off supply hose to master cylinder using hose clamp -3094- .
AG.
85
Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 In addition, for disconnecting, you can close it with the sealing tool -T10249/1- ( figure above). Release securing clip -2- with a screwdriver or a pointed object and pull out of master cylinder to stop. Pull pipe/hose line -1- out from master cylinder and seal hose. Separate electrical connector -4- at clutch position sender G476- . Remove driver side footwell cover General body repairs, interior; Rep. Gr. 68 ; Compartments, covers and trim panels .
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Remove crash bar -1- by removing bolt -2-.
If present, remove retaining clip -1- and swing front parking aid warning buzzer -H22- -2- in -direction of arrow-.
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Pull off damping if lower securing bolt for mounting bracket is covered, -arrows-.
86
Rep. Gr.30 - Clutch
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AG.
Prote cted by
Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 Remove securing nuts -1- and -2-. The upper securing nut -1- is accessible through the opening in the lower steering column trim. Pull mounting bracket -3- off studs on body.
1.17.2
Installing
Install in reverse order of removal. During this step, observe the following: Note
Renew self-locking nuts. Renew hose clips. Allocate all components according to Electronic parts cata
logue ETKA .
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Install lower steering column trim General body repairs, in terior; Rep. Gr. 68 ; Compartments, covers and trim panels . Install driver side footwell cover General body repairs, in terior; Rep. Gr. 68 ; Compartments, covers and trim panels .
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If present, install retaining clip for front parking aid warning buzzer -H22- Electrical system; Rep. Gr. 94 ; Parking aid .
87
Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 Push pipe/hose line -1- with seal -2- onto connection of master cylinder -4- until securing clip -3- engages audibly. Test line by tugging on it. After removing hose clamp -3094- , return supply hose to its original shape, if necessary. Bleed clutch system page 101 . LHD
AG. Volkswagen AG d agen oes ksw not l o V sys Install battery tray, battery cover and battery Electrical gu y b ara d e tem; Rep. Gr. 27 ; Removing and installing battery nte is. r o eo h t u ra a Rep. Gr. 23 ; If removed, install complete air filter housing c s s
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Repairing diesel direct injection system or Rep. Gr. 24 ; Repairing injection system
Reconnect battery and perform work required after connecting battery Electrical system; Rep. Gr. 27 ; Disconnecting and connecting battery .
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1.17.3
Component
Torque settings
Nm 25 20
Mounting bracket to bulkhead Renew self-locking nuts. Crash bar Renew bolt for crash bar
1.18
Removing and installing master cylinder

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1.18.1
Removing
Remove mounting bracket, Golf 2004 page 61 . Remove mounting bracket, Golf 2009 LHD page 67 . Remove mounting bracket, Golf 2009 right-hand drive and Golf Plus right-hand drive page 73 . Remove mounting bracket, Golf Plus left-hand drive page 79 . Remove mounting bracket, Passat page 84
88
Rep. Gr.30 - Clutch
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AG.
Prote cted by
Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 Release retainer for master cylinder operating rod using pliers -T10005- .
Insert spacer -A- between clutch pedal and stop and press clutch pedal to spacer. Length of spacer = about 40 mm (e.g. 1/2 socket). Release securing bar -B- and pull master cylinder out of mounting bracket -arrow 1- and -arrow 2-.
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1.18.2
Installing
Move clutch pedal to rest position at stop.
Attach retainer -2- to master cylinder operating rod -1-.
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Prote cted by
89
Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 Insert spacer -A- between clutch pedal and stop and press clutch pedal to spacer. Length of spacer = about 40 mm (e.g. 1/2 socket). Engage master cylinder in mounting bracket -arrow 1- and -arrow 2-.
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Press master cylinder operating rod -1- in direction of arrow until retainer -2- engages audibly in clutch pedal. Install mounting bracket, Golf 2004 page 61 . Install mounting bracket, Golf 2009 LHD page 67 . Install mounting bracket, Golf 2009 right-hand drive and Golf Plus right-hand drive page 73 . Install mounting bracket, Golf Plus left-hand drive page 79 . Install mounting bracket, Passat page 84
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1.19
1.19.1
LHD
Removing
First check whether a coded radio is fitted. If so, obtain antitheft code. With ignition switched off, disconnect battery Electrical sys tem; Rep. Gr. 27 ; Disconnecting and connecting battery .
90
Rep. Gr.30 - Clutch
AG.
Prote cted by
Hose clamps -3094-
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Removing and installing clutch position sender -G476c o p yri gh t. C op yi
Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 Remove complete air filter housing if it is near battery Rep. Gr. 23 ; Repairing diesel direct injection system or Rep. Volkswagen AG Gr. 24 ; Repairing injection system .gen AG. does swa
y db Remove battery and battery tray Electrical system; Rep. ise r Gr. 27 ; Battery; Removing and installing battery . tho
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RHD
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not gu ara nte eo ra c

In vehicles with particle filter, remove shielding -A- from parti cle filter Rep. Gr. 26 ; Parts of exhaust system; Assembly overview - front exhaust pipe with particle filter . An insulation mat is installed in conjunction with some engines. Appearance may be different from that illustrated.
Remove heat shield from pipe/hose line -arrows-.
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Continuation for all If a pipe/hose line -1- with a round component is installed directly beneath the master cylinder, the pipe/hose line must be removed. Note During the following work, ensure that no brake fluid lands on Place a lint-free cloth under the master cylinder.
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91
Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 Clamp off supply hose to master cylinder using hose clamp -3094- .
Release securing clip -2- with a screwdriver or a pointed object and pull out of master cylinder to stop. Pull pipe/hose line -1- out from master cylinder and seal hose. . Volkswag Disconnect electrical connector -4-. Unclip clutch position sender -arrow- and remove.
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1.19.2
Installing
Install in reverse order of removal. During this step, observe the following: Note Renew hose clips.
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Allocate all components according to Electronic parts cata

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logue ETKA .
92
Rep. Gr.30 - Clutch
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AG.
Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 If the pipe/hose line was removed Push pipe/hose line -1- with seal -2- onto connection of master cylinder -4- until securing clip -3- engages audibly. Test pipe/hose line by tugging on it. After removing hose clamp -3094- , return supply hose to its original position, if necessary. Bleed clutch system page 101 . Right-hand drive
In vehicles with particle filter, install shielding -A- on particle filter Rep. Gr. 26 ; Parts of exhaust system; Assembly overview - front exhaust pipe with particle filter . LHD Install battery tray and battery Electrical system; Rep. Gr. 27 ; Removing and installing battery .
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If removed, install complete air filter housing Rep. Gr. 23 ; Repairing diesel direct injection system or Rep. Gr. 24 ; Repairing injection system Reconnect battery and perform work required after connecting battery Electrical system; Rep. Gr. 27 ; Disconnecting and connecting battery .
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Prote cted by
93
1.20
Assembly overview - hydraulics (LHD)
1 - Brake fluid reservoir 2 - Spring-type clip Not fitted in all vehicles 3 - Supply hose Rubber From 12. 05, plastic page 95 Golf 2009 and Golf Plus 2009 plastic page 95 4 - Master cylinder Removing and installing page 88 5 - Clip Pull out clip to stop to re move and install pipe/ hose line 6 - Retainer To remove and install, separate master cylin der from clutch pedal, Golf 2004 page 38 , Golf 2009 page 44 , Golf Plus page 54 , Passat page 59
7 - Clutch pedal Removing and instal ling, Golf 2004 page 38 Removing and instal ling, Golf 2009 page 44 Removing and instal ling, Golf Plus page 54 Removing and installing, Passat page 59 8 - Hexagon nut, Item 15 (page 17) 9 - Seal / O-ring Pull onto line connection Insert with brake fluid Seals/O-rings are adapted to configuration of line connection page 95 Allocation Electronic parts catalogue ETKA

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10 - Pipe/hose line Allocation Electronic parts catalogue ETKA To remove, remove battery and battery tray Electrical system; Rep. Gr. 27 ; Removing and installing battery . 11 - Retainer Secured to body 12 - Seal / O-ring Pull onto line connection Insert with brake fluid.
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AG.
94
Rep. Gr.30 - Clutch
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Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 Seals/O-rings are adapted to configuration of line connection page 95 AG. Volkswagen AG d agen oes w s Allocation Electronic parts catalogue ETKA k not l Vo
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e 13 - Clip ris tho u Pull out clip to stop to remove s a and install pipe/hose line
gu ara nte eo ra c
15 - Hexagon bolt Item 9 (page 104) 16 - Bleeder valve Bleeding clutch system page 101 17 - Dust cap 18 - Gearbox 19 - Retainer
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14 - Slave cylinder Removing and installing page 98
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20 - Hexagon bolt, 20 Nm Seals and O-rings for pipe and hose lines 1 2 3 Line connection with circumferential groove -arrow 1Line connection with shoulder -arrow 2Line connection with shoulder -arrow 2- and cir cumferential groove -arrow 3AG.
Prote cted by
Item
Material of line connection
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For line connection having circumferential groove -arrow 1and -arrow 3-, a seal or O-ring must be set there.
Supply hose -1- of plastic The seals -2- must be located in supply hose.
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95
1.21
Assembly overview - hydraulics (RHD)
1 - Brake fluid reservoir 2 - Seal For plastic supply hose The seals must be loca ted in supply hose 3 - Supply hose Made of plastic May be made of rubber Item 3 (page 94) 4 - Master cylinder Removing and installing page 88 5 - Clip Pull clip out to stop to re move or install pipe Is also pulled out to side in some master cylin ders. 6 - Seal / O-ring Pull onto line connection Insert with brake fluid. Seals/O-rings are adap ted to configuration of line connection page 95 Allocation Electronic parts catalogue ETKA
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8 - Clutch pedal Removing and installing, Golf 2004 page 38 Removing and installing, Golf 2009 page 49 Removing and installing, Golf Plus page 54 Removing and installing, Passat page 59 9 - Hexagon nut, Item 15 (page 17) 10 - Retainer Secured to body 11 - Pipe line Pipe and hose/pipe line Item 13 (page 97) may be in one piece Allocation Electronic parts catalogue ETKA
96
Rep. Gr.30 - Clutch
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Prote cted by
7 - Retainer To remove and install, separate master cylin der from clutch pedal ( Removing and installing clutch pedal) Golf 2004 page 38 Golf 2009 page 49 Golf Plus page 54 Passat page 59
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Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 To remove, remove battery and battery tray Electrical system; Rep. Gr. 27 ; Removing and installing battery . 12 - Seal / O-ring Pipe Item 11 (page 96) and hose/pipe line may be in one piece Pull onto line connection Insert with brake fluid Seals/O-rings are adapted to configuration of line connection page 95 Allocation Electronic parts catalogue ETKA 13 - Pipe/hose line Pipe Item 11 (page 96) and hose/pipe line may be in one piece Allocation Electronic parts catalogue ETKA To remove, remove battery and battery tray Electrical system; Rep. Gr. 27 ; Removing and installing battery . 14 - Retainer Secured to retainer for ABS/EDL 15 - Retainer For ABS/EDL 16 - Seal / O-ring Pull onto line connection Insert with brake fluid. Seals/O-rings are adapted to configuration of line connection page 95 Allocation Electronic parts catalogue ETKA 17 - Clip Pull out clip to stop to remove and install pipe/hose line 18 - Slave cylinder Removing and installing page 98 19 - Hexagon bolt Item 9 (page 104) 20 - Bleeder valve Bleeding clutch 21 - Dust cap 22 - Gearbox 23 - Retainer
AG. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte is 101 r system page o eo h ut ra a c s s
24 - Hexagon bolt, 20 Nm

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97
Removing and installing slave cylin der
With ignition switched off, disconnect battery Electrical sys tem; Rep. Gr. 27 ; Disconnecting and connecting battery . Remove complete air filter housing if it hinders access to slave cylinder Rep. Gr. 23 ; Repairing diesel direct injection sys tem or Rep. Gr. 24 ; Repairing injection system . Remove securing clip -arrow 1- for gear selector cable from gearbox selector lever -A-. Pull gear selector cable off pin. Metal relay lever Remove securing clip -arrow 2- for gate selector cable from relay lever -B-. Pull gate selector cable from pin.
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2.1
Removing
Pull securing clip -arrow 3- off relay lever -B- and remove relay lever. Remove relay lever together with cable end-piece from gear box page 134 . Remove gearbox selector lever -A- by removing nut -arrow 4-.
AG.
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98
Rep. Gr.30 - Clutch
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Prote cted by
Plastic relay lever
Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 Remove cable support bracket from gearbox -arrows-. Then raise and secure gear selector cable and gate selector cable. Remove bracket -B- from gearbox and pull it off pipe/hose line -A-.
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Then remove gearbox support -arrow A-. Place a lint-free cloth under slave cylinder. Pull clip for pipe/hose line out of slave cylinder to stop. Pull pipe/hose line out of slave cylinder and seal opening. Remove slave cylinder -arrows B-. Caution
Install in the reverse order of removal, observing the following: Install slave cylinder and tighten bolts -arrows B- to specified torque. Insert pipe/hose line into slave cylinder to stop. Test pipe/hose line by tugging on it. Push retaining clip into pipe/hose line to stop. Then install gearbox support -arrows A-. Bleed clutch system after installing slave cylinder page 101 . Assembling selector mechanism page 131 . Adjusting selector mechanism page 139 . If removed, install complete air filter housing Rep. Gr. 23 ; Repairing diesel direct injection system or Rep. Gr. 24 ; Repairing injection system Connect battery earth Electrical system; Rep. Gr. 27 ; Bat tery; Disconnecting and connecting battery .
2.3
Torque settings
Slave cylinder to gearbox Item 9 (page 104)
2. Removing and installing slave cylinder
AG.
2.2
Installing
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Do not operate clutch pedal any more.
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99
Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 Gearbox support to gearbox bracket and gearbox Renew bolts. Screw in all bolts hand-tight. Tighten bolts to specified torque. Bolts -arrows20 Nm + 90
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100
Rep. Gr.30 - Clutch
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Prote cted by
Bleeding clutch system
Special tools and workshop equipment required Brake filling and bleeding equipment -VAS 5234- or
Brake filling and bleeding equipment -V.A.G 1869-
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Note
Prefilling system is not necessary!
Specifications for brake fluid Brake systems; Rep. Gr. 47 ; Bleeding brake system .
Remove complete air filter housing if it blocks access to bleed er connection (-arrow-, figure below) Rep. Gr. 23 ; Repair ing diesel direct injection system or Rep. Gr. 24 ; Repairing injection system Connect brake filling and bleeding equipment -VAS 5234- or -V.A.G 1869- . To bleed system, use 670 mm bleeder hose -V.A.G 1238/B3- if necessary. Connect bleeder hose to collector bottle of brake bleeding equipment.
3. Bleeding clutch system
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101
Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 Connect bleeder hose to bleeder -arrow-. Pressurise system to 2 bar. Open bleeder valve. Bleed off about 100 cm3 brake fluid. Close bleeder valve. Rapidly operate pedal from stop to stop 10 to 15 times. Open bleeder valve. Bleed off an additional 50 cm3 brake fluid. Close bleeder valve. Depress clutch pedal several times after completion of bleed ing process. If removed, install complete air filter housing Rep. Gr. 23 ; Repairing diesel direct injection system or Rep. Gr. 24 ; Repairing injection system

thi sd o cu m en
102
Rep. Gr.30 - Clutch
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Repairing clutch release mechanism
1 - Gearbox 2 - Ball stud, 25 Nm To remove and install, remove gearbox . Volkswagen AG gen AG does Remove old grease wa s k not l Vo gu fromdcontact surface of by ara e release lever nte clutch ris o eo h t u ra s a Lubricate with grease c s G 000 1003 - Input shaft seal To remove and install, remove gearbox Renewing Item 12 (page 251) 4 - Guide sleeve To remove and install, remove gearbox With vulcanised O-ring If O-ring is damaged, re new guide sleeve and O-ring together 5 - Retaining spring To remove and install, remove gearbox Secure to clutch release lever 7 - Clutch release lever To remove and install, remove gearbox Remove and install to gether with release bearing page 104 Remove old grease
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8 - Release bearing To remove and install, remove gearbox Do not wash out bearing; wipe only
4. Repairing clutch release mechanism
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6 - Socket head bolt, 20 Nm

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103
Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 Renew noisy bearings Removing from and inserting in clutch release lever page 104 Lubricate contact surface of release lever with MoS2 grease AG. Volkswagen 9 - Hexagon bolt, 20 Nm 10 - Slave cylinder Removing and installing page 98 11 - Plunger
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12 - Assembly bolt Secures clutch release lever when gearbox is installed. Remove after gearbox has been installed Note
Removing and installing release lever together with release bear ing Unhook spring -arrow 1-. Pull off release lever -arrow 2- and release bearing. Install in reverse order of removal.
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Removing and installing release bearing
Press together retaining hooks -arrows- on back of clutch re lease lever and remove release bearing -A- from clutch re lease lever. To install, press release bearing -A- into clutch release lever until retaining hooks -arrows- engage.
104
Rep. Gr.30 - Clutch
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Repairing clutch, in conjunction with dual-mass flywheel
Special tools and workshop equipment required Counterhold -3067 Centring mandrel -3190 A Torque wrench -V.A.G 1331 Grease for clutch plate splines -G 000 100-
5.1
Identifying make of clutch, vehicles with 1.9 l - 66 kW turbo diesel engine and ve hicles with 1.9 l - 77 kW turbo diesel engine
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The make of the clutch can be determined as follows with the clutch installed: Remove noise insulation General body repairs, exterior; Rep. Gr. 50 ; Noise insulation .
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5. Repairing clutch, in conjunction with dual-mass flywheel
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105
Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 Some notches -arrows- are located in lower region of sump be tween engine -A- and gearbox -B-. Check outer contour of flywheel through these notches.
In addition, a small cover plate -A- can be removed to enable inspection of flywheel's outer contour. Round outer contour -arrows- = Sachs clutch = -A Removing and installing Sachs clutch page 107 .
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wa . Repairing Sachs clutch page 109 ks Vol
or
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106
Rep. Gr.30 - Clutch
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Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 Rounded outer contour -arrows 1- and a circumferential crease -arrow 2- = LuK clutch = -B Removing and installing LuK clutch page 109 . Repairing LuK clutch page 112 .
5.2 5.2.1
Removing and installing Sachs clutch Removing
Remove gearbox.
Use counterhold -3067- to loosen bolts. Loosen bolts in small steps and diagonally. As bolts are removed, stop -2- with pin -1- must loosen. If stop does not loosen, press pin towards dual-mass flywheel. Remove pressure plate and clutch plate.
5.2.2
Installing
Install in the reverse Note
Renew pressure plate and clutch plate together only. Select
clutch plate and pressure plate according to engine code and Electronic parts catalogue ETKA . are fitted in cylinder block and install if necessary.
n AG. Volkswagen AG do es n wage s k l ot Vo y b order of e removal, observing the following: guara d nte s i r eo tho u ra a c ss
Check whether dowel sleeves for aligning engine and gearbox If dowel sleeves are not fitted, difficulties shifting gears, clutch
problems and possible noises from the gearbox (rattling of gears which are not engaged) could occur.
Installation position of clutch plate Lettering Getriebeseite (gearbox side) faces gearbox.
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107
Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 Checking ends of diaphragm spring n AG. Volkswagen A
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Checking spring connections and riveted connections Check spring connections between pressure plate and cover for cracks as well as rivet connections for secure seating. Note
Renew clutch plates and pressure plates with damaged or
loose rivet connections.

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Always renew pressure plate and clutch plate together. Select clutch plate and pressure plate according to engine If clutch has burnt out, thoroughly clean clutch housing, fly
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wheel and parts of engine facing gearbox to reduce smell of burnt linings.
Clean input shaft splines and, on used clutch plates, clean hub
splines; remove corrosion and apply only a very thin coat of clutch plate spline grease -G 000 100- to splines. Then move clutch plate to and fro on input shaft until hub moves freely on shaft. Remove excessive grease. Clean contact surface only. Otherwise, the service life of the clutch will be considerably reduced.
Pressure plates are protected against corrosion and greased. Pressure plate contact surface and clutch plate lining must
make full contact with flywheel. Only then insert securing bolts.
Reverse counterhold tool -3067- for installation. Push pressure plate onto dowel pins. To centre clutch plate, use centring mandrel -3190 A- . Tighten all bolts evenly by hand until bolt heads contact pres sure plate. Tighten bolts in small steps diagonally in order not to damage centring holes of pressure plate and centring pins of dualmass flywheel. Torque setting Item 4 (page 109) Install gearbox.
108
Rep. Gr.30 - Clutch
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code and Electronic Parts Catalogue (ETKA) .

Golf 2004 , Golf
5.3
Repairing Sachs clutch
1 - Dual-mass flywheel Removing and installing Rep. Gr. 13 Ensure that centring pins fit tightly Contact surface for clutch lining must be free of grooves, oil and grease 2 - Clutch plate Allocation Electronic parts catalogue ETKA Removing and installing page 107 Renew only together with pressure plate Installation position page 107 3 - Pressure plate Allocation Electronic parts catalogue ETKA With adjusting mecha nism Removing and installing page 107 Check ends of dia phragm spring page 108 Checking spring con nections and riveted connections page 108 Renew only together with clutch plate
AG. Volkswagen AG d agen oes ksw not l o V gu y b ara d e nte ... 2009 , o Golf ris Plus 2005 , Golf Plus 2009 , Pass eo h t u ra a 5-speed manual gearbox 0A4 - Edition 04.2010 c s s

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4 - M6 bolt, 13 Nm, M7 bolt, 20 Nm Loosen or tighten diagonally in small steps
5.4 5.4.1
Removing and installing LuK clutch Removing
Remove gearbox.
Use counterhold -3067- to loosen bolts. Loosen bolts in small steps and diagonally. Remove pressure plate and clutch plate.
5.4.2
Installing
Install in the reverse order of removal, observing the following:
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109
Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 Note Renew pressure plate and clutch plate together only. Select
clutch plate and pressure plate according to engine code and Electronic parts catalogue ETKA . are fitted in cylinder block and install if necessary.
Check whether dowel sleeves for aligning engine and gearbox If dowel sleeves are not fitted, difficulties shifting gears, clutch
problems and possible noises from the gearbox (rattling of gears which are not engaged) could occur.
Installation position of clutch plate Lettering Getriebeseite (gearbox side) faces gearbox.
Checking ends of diaphragm spring Wear to half the thickness of the diaphragm spring -arrows- is permitted.
Checking spring connections and riveted connections

. Volkswagand en AG AG Check spring connections -arrows a Afor damage riveted gen does kswseating. not l connections -arrows B- for secure o V g
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110
Rep. Gr.30 - Clutch
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Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 Checking position of adjusting mechanism with new pressure plates only Both edges -A- of the adjuster ring must be located between the two notches -arrows B-. If the adjuster ring takes up a different position in new pressure plates, the pressure plate and clutch plate are not allowed to be installed. The adjuster ring may take up a position outside the notches in used clutches. Note Renew clutch plates and pressure plates with damaged or
loose rivet connections.
Renew pressure plate and clutch plate together only. Select clutch plate and pressure plate according to engine
code and Electronic parts catalogue ETKA .
If clutch has burnt out, thoroughly clean clutch housing, fly
wheel and parts of engine facing gearbox to reduce smell of burnt linings. splines; remove corrosion and apply only a very thin coat of . Volkswagen AG clutch plate spline grease -G 000 100- to splines. Then move gen AG does swa k not l o clutch plate to and fro on input shaft until hub moves V freely on gu y ara db e shaft. Remove excessive grease. nt ris
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Clean input shaft splines and, on used clutch plates, clean hub
u Pressure plates are protected against corrosion and greased. sa

s Clean contact surface only. Otherwise, the service life of the clutch will be considerably reduced.
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Pressure plate contact surface and clutch plate lining must
make full contact with flywheel. Only then insert securing bolts.
Reverse counterhold tool -3067- for installation. Push pressure plate onto dowel pins. To centre clutch plate, use centring mandrel -3190 A- . Tighten all bolts evenly by hand until bolt heads contact pres sure plate. Tighten bolts in small steps diagonally in order not to damage centring holes of pressure plate and centring pins of dualmass flywheel. Torque setting Item 4 (page 112) Install gearbox.
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111
5.5
Repairing LuK clutch
1 - Dual-mass flywheel Removing and installing Rep. Gr. 13 Ensure that centring pins fit tightly Contact surface for clutch lining must be free of grooves, oil and grease 2 - Clutch plate Allocation Electronic parts catalogue ETKA Removing and installing page 109 Renew only together with SAC pressure plate Installation position: page 110 3 - SAC pressure plate SAC means self-ad justing clutch Renew only together with clutch plate Allocation Electronic parts catalogue ETKA Removing and installing page 109 Check ends of dia AG. Volkswagen AG d phragm spring agen oes ksw not l o V page 110 gu by ara d e nte is r Checking spring con o eo h ut ra nections and riveted a c s s connections page 110 Checking position of adjusting mechanism with new pressure plates only page 111 4 - M6 bolt, 13 Nm, M7 bolt, 20 Nm Loosen or tighten diagonally in small steps

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112
Rep. Gr.30 - Clutch
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Repairing clutch, in conjunction with one-piece flywheel
Special tools and workshop equipment required Counterhold -3067 Centring mandrel -3190 A Torque wrench V.A.G 1331 Grease for clutch plate splines -G 000 100-
Remove gearbox. Note
Renew clutch plates and pressure plates with damaged or loose rivets.
Select clutch plate and pressure plate according to Electronic parts catalogue (ETKA) and engine code. Check whether dowel sleeves for aligning engine and gearbox are fitted in cylinder block and install if nec If dowel sleeves are not fitted, difficulties shifting gears, clutch problems and possible noises from the gear
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essary.
box (rattling of gears which are not engaged) could occur.

AG.
6. Repairing clutch, in conjunction with one-piece flywheel
113
Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 1 - Flywheel Removing and installing Rep. Gr. 13 Ensure that centring pins fit tightly Keep contact surface for clutch lining free of grooves, oil and grease. 2 - Clutch plate Allocation Electronic parts catalogue (ETKA) Installation position: spring cage faces pres sure plate Centring page 114 Lightly grease splines Note 3 - Pressure plate Removing and installing page 114 Check ends of dia phragm spring page 115 Checking spring con nections and riveted connections page 115 Note

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Centring clutch plate and removing and installing pressure plate Loosen or tighten bolts diagonally in stages. Reverse position of counterhold -3067- when removing. Note
Pressure plate contact surface and clutch plate lining must make full contact with flywheel. Tighten securing bolts diagonally and evenly to prevent damage to the pressure plate centring hole and the flywheel centring pins.
114
Rep. Gr.30 - Clutch
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Prote cted by
4 - M6 bolt, 13 Nm, M7 bolt, 20 Nm Determine according to Electronic parts catalogue (ETKA) Loosen or tighten diagonally and in steps
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Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 Checking ends of diaphragm spring Wear up to half the thickness of the diaphragm spring is per mitted.
Checking spring connections and riveted connections Check spring connections between pressure plate and cover for cracks as well as rivet connections for secure seating. A pressure plate with damaged spring connections or with loose rivet connections -arrows- must be renewed.

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6. Repairing clutch, in conjunction with one-piece flywheel
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Prote cted by
115
34
1
1.1
Controls, housing
Repairing selector mechanism
Installation position of selector mechanism
-Arrow A- Gear selection movement -Arrow B- Gate selection movement A - Gear selector cable B - Gate selector cable C - Heat shield Remove before remov ing gear selector mech anism 1 - Gearbox selector lever 2 - Relay lever
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116
Rep. Gr.34 - Controls, housing
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1.2
Note
Overview of selector mechanism
Note radio code for vehicles with coded radio. Before working on selector mechanism in engine compartment, disconnect earth strap from battery Elec
trical system; Rep. Gr. 27 ; Disconnecting and connecting battery . 27 ; Disconnecting and connecting battery .
When reconnecting battery, perform work required after connecting battery Electrical system; Rep. Gr. To work on selector mechanism in engine compartment, remove complete air filter housing if it is located
nte rismechanism to renew selector cables page Remove selector e 136 . tho
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ag; Volksw en AG do n AG. Gr. over selector mechanism w Rep. 23 Repairing diesel direct injection system or Rep. Gr. 24 ; age es n s k l ot g o Repairing injection system . V y u
b ed
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Do not kinkssselector cables. I - Removing and installing gear knob and cover page 118 II - Repairing gear lever and selector housing (through 10.06) page 123 II - Repairing gear lever and selector housing (from 11.06) page 125 III - Assembly overview - re moving and installing selector cables page 131 Removing and installing selec tor mechanism page 136
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Adjusting selector mechanism page 139 .

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1. Repairing selector mechanism
117
1.3
Removing and installing gear knob and cover
1 - Emblem Can be carefully levered off gear knob of plastic or leather 2 - Gear knob With gaiter Gear knob and gaiter cannot be separated from one another Always renew together Removing and instal ling, Golf page 118 Removing and instal ling, Golf Plus page 120 Removing and instal ling, Passat page 121
3 - Clamp For securing to gear lever Secure to gear knob Item 2 (page 118) us ing hose clip pliers V.A.G 1275 Always renew
AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h ut ra a gear knob c s s
4 - Centre console cover In some equipment ver sions, forms one part to gether with centre con sole 5 - Noise insulation Not fitted in all vehicles Arrow on noise insulation points in direction of travel Locking lugs are arranged at varying intervals Therefore it can be installed in only one position
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AG.
118
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1.4
Removing and installing gaiter with gear knob and noise insulation, Golf
Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 Hose clip pliers -V.A.G 1275-
Removing Pull or carefully lever gaiter upwards out of centre console frame -arrows-. With some equipment variations, the gaiter must be levered off along the front section.
Pull gaiter upwards, inside out over gear knob. n AG. Volkswagen A
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tethe r In some versions, the centre console frame remains in e o centre ho ut ra a console. c s s
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Then pull off, or carefully lever off, centre console frame -arrow 1-. Pull off noise insulation -arrow 2-. Installing First set noise insulation in place.
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119
Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 Installation position of noise insulation:
wag -Arrow A- points in direction of travel. olks
Catches Then
The gear knob must be pressed to stop.
Then turn gaiter inside out.
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olkswagen AG en AG. V does not gu yV b ara d e nte -arrows B- must engage in centre console. is r o eo h ut ra a press framessinto centre console. c
Install gear knob and gaiter and squeeze new clamp -arrowtogether. Then press gaiter into frame of centre console.
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1.5
Hose clip pliers -V.A.G 1275-
Removing Pull or carefully lever gaiter upwards out of centre console frame -arrows-. With some equipment variations, the gaiter must be levered off along the front section.
120
AG.
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Removing and installing gaiter with gear knob and noise insulation, Golf Plus
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es n w Pull gaiter V upwards, inside out over gear oknob. olks tg
AG. Volkswagen AG d agen o
nte with gaiter. ris Open clamp -arrow- and pull off gear knob together e ho
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Installing First set noise insulation in place.
Installation position of noise insulation: -Arrow A- points in direction of travel. Catches -arrows B- must engage in centre console. Turn gaiter inside out.
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Install gear knob and gaiter and squeeze new clamp -arrowtogether. When gear knob is pushed on, it must engage in circumferential groove in gear lever. Then press gaiter into centre console.
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AG.
1.6
Removing and installing gaiter with se lector lever knob and noise insulation, Passat
Special tools and workshop equipment required Hose clip pliers -V.A.G 1275-
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121
Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 Front-end hooks -3370AG. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o eo h t u ra a c s s
Removing Open ashtray.
Pull gaiter with plastic frame out of centre console frame -1-arrow-. Hold centre console frame securely -1-. It must not be pulled along. Connections for various switches may be accidentally pulled apart. Pull gaiter upwards, inside out over gear knob.
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Open clamp -arrow- and pull off gear knob together with gaiter. Pull off noise insulation. Installing First set noise insulation in place.
Installation position of noise insulation -Arrow A- points in direction of travel. Catches -arrows B- must engage in centre console. Turn gaiter inside out. The gear knob must be pressed to stop.
122
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Prote cted by
Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 Install gear knob and gaiter and squeeze new clamp -arrowtogether. Insert back of gaiter with plastic frame first.
1.7
Note
Repairing gear lever and selector housing (through 10.06)
Lubricate bearing positions and sliding surfaces. Allocate grease using Electronic parts catalogue (ETKA) . 1 - Securing clip n AG. Volkswagen AG do es n wage s k l ot g o Removing and installing yV ua b ran page 126 ed s i tee r o h t or u ac a 2 - Bush s 4 - Bush 6 - Cover 7 - Damping 8 - Damping
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3 - Compression spring 5 - Torx bolt, 5 Nm
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9 - Ball socket
10 - Gear lever guide 11 - Damping washer 12 - Seal Between selector hous ing and underbody Self-adhesive Bond to selector hous ing
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16 - Pivot pin 17 - Guide bush 18 - Compression spring Installing page 124
AG.
15 - Bearing bush
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14 - Selector housing
Prote cted by
13 - Gear lever
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123
Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 19 - Gate selector lever 20 - Torx bolt, 5 Nm 21 - Seal Always renew 22 - Base plate Bend open tabs to remove Always renew 23 - Gate selector cable On gate selector lever Removing and installing page 124 24 - Gear selector cable Removing from and attaching to gear lever guide page 124 25 - Securing clip Always renew 26 - Hexagon nut M8, 25 Nm, hexagon nut M 6, 8 Nm Qty. 4 27 - Bearing bush Fits in one position only 28 - Securing clip Always renew
Remove securing clip from gear selector cable -A- and gate selector cable -B-. To do this, raise tab using screwdriver -arrow 1- and press off securing clip -arrow 2-. Remove gear selector cable -A- from gear lever retainer. Remove gate selector cable -B- from retainer of gate selector lever.
Removing and installing gate and gear selector cables

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Then pull extension -B- down so that it sits below pin -arrow-.
AG.
124
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Insert compression spring so that extension -A- lies on top of pin -arrow-.
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Installing compression spring
1.8
Note
Repairing gear lever and selector housing (from 11.06)
Lubricate bearing positions and sliding surfaces. Allocate grease using Electronic parts catalogue (ETKA) . Dismantling and assembling selector mechanism page 126 . 1 - Base plate Bend open tabs to re move Always renew 2 - Seal Always renew 3 - Gear lever Can be removed and in stalled with gear lever guide Item 15 (page 126) installed
4 - Damping washer Push onto gear lever up to stop -arrow5 - Securing clip Do not damage cables when removing Always renew
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6 - Gate selector cable Lever off gate selector lever Press onto gate selector lever inside selector mechanism Installation position page 116 7 - Bush
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9 - Damping 10 - Ball socket Will be damaged when removed. Always renew 11 - Bush 12 - Securing clip Removing and installing page 126
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AG.
Prote cted by
8 - Gear selector cable Lever off gear lever guide Press onto gear lever guide inside selector mechanism Installation position page 116
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125
Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 13 - Compression spring 14 - Bush 15 - Gear lever guide 16 - Hexagon nut M8, 25 Nm, hexagon nut M 6, 8 Nm Qty. 4 17 - Seal Between selector housing and underbody Self-adhesive Bond to selector housing 18 - Selector housing With compression spring and gate selector lever Compression spring and gate selector lever cannot be removed Removing and installing securing clip To remove or install securing clip -arrow A-, press spacer bush -arrow B- to stop in direction of arrow -arrow C- using screw driver and pull off securing clip. Note Do not cant spacer bush when pushing down.
e Carefully release otension from spring. ris
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Special tools and workshop equipment required Thrust piece -T10083Dismantling Remove selector mechanism page 136 .
1.8.1
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Dismantling and assembling selector mechanism
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126
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Prote cted by
Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 Bend open tabs -arrows- of base plate for selector mechanism using screwdriver and remove base plate; (tabs in front area of base plate are not illustrated). Remove seal from selector housing. Remove gear and gate selector cables from selector housing page 125 . Lift upper end -A- of compression spring over tab of gate se AG. Volkswagen AG d agen oes lector lever. n lksw
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Use screwdriver to press catches -arrows- of ball socket to wards bearing ball of gear lever guide; break off catches if necessary. Lever ball socket -A- with gear lever guide -B- out of selector housing.
ss
Then press ball socket off bearing ball of gear lever guide and remove it. Please pay attention to guides -A- during the further proce dure. They must not be broken off.
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Lever lower end -arrow 1- of compression spring onto shoulder on gate selector lever as far as stop.
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AG.
Now pull gear lever guide up to stop and pull ball stud out of gate selector lever -arrow 2-.
127
Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 Then turn gear lever guide in -direction of arrow 1-. Pin -arrow 2- must be in notch in selector housing Then swing out gear lever guide with gear lever in -direction of arrow 3-. Assembling Caution
The lower end of the compression spring (-arrow 1- figure above) can snap off the shoulder of the gate selector lever out of control during the further procedure.
Therefore, carefully press it down off shoulder of gate selector lever. The ends of the compression spring then become tensioned di agonally with a loud noise. Slacken ends -A- and -B- by turning both round to right. Ends -A- and -B- must point in opposite directions. AG. Volkswagen AG d agen o
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Fit gear lever guide in selector housing. Pin -arrow 1- is still located in notch in selector housing. Turn gear lever guide in -direction of arrow 2- until ball stud -A- is located in notch in selector housing.
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128
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Place selector housing with gear lever guide into larger recess -arrow- in thrust piece -T10083- .
AG.
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does wag 2005 , Golf Plus Golf 2004 , Golf 2009 , Golf Plus 2009 not , Pass ... olks gu yV b ara 04.2010 d5-speed manual gearbox 0A4 - Edition e n s
olkswagen AG en AG. V
Note
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The gear lever guide must project from up to the stop.
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housing
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For clarity of illustration, only part of the gate selector lever is shown.
Insert end -A- of compression spring into guide from above. Pull end -B- of compression spring downwards and insert it next to guide (in direction of ball joint). Please pay attention to guides ( figure above) during the fur ther procedure. They must not be broken off.
Move gate selector lever back to stop (opposite from mounting holes for gear and gate selector cable) -arrow 1-. Grease ball stud. Press ball stud into gate selector lever -arrow 2-.
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Carefully remove selector housing with gear lever guide from thrust piece -T10083- .
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Place selector housing with gear lever guide into larger recess -arrow- in thrust piece -T10083- .
AG.
Guides -A- and tabs -B- are not allowed to be damaged.
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129
agen Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 ksw , Pass ... Vol y b 5-speed manual gearbox 0A4 - Edition 04.2010 ed
Use a new ball socket -B-.
Lift upper end -A- of compression spring over pin of gate se lector lever. Grease ball socket and bearing ball of gear lever guide. Press ball socket onto bearing ball of gear lever guide up to stop. Remove selector housing from thrust piece -T10083- . Insert lower end -C- of compression spring into guide. Lift upper end -A- of compression spring over pin of gate se lector lever into guide. Press ball socket into selector housing -arrows-. All 4 locking lugs must engage.
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The gear lever guide must project from the selector up to the stop.
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Fit gear lever, gear selector cable, gate selector cable and base plate page 125 .
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Install selector mechanism page 136 .
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Note
Lubricate bearing positions and sliding surfaces. Allocate grease using Electronic parts catalogue (ETKA) . 1 - Gear selector cable Connect to cable endpiece Item 11 (page 132) Installation position page 116 Use cable tie to fix onto gate selector cable page 134 From 11.06, modified attachment to gear lever inside selector mecha nism Item 8 (page 125) 2 - Gate selector cable Connect to cable endpiece Item 10 (page 131) Installation position page 116 Use cable tie to fix onto gear selector cable page 134 From 11.06, modified attachment to gate se lector lever inside selec tor mechanism Item 6 (page 125) 3 - Securing clip Always renew Discontinued in selector mechanisms from 11.06 page 125 4 - Selector housing 5 - Securing clip Always renew Do not damage cables when removing 6 - Hexagon bolt, 20 Nm Qty. 3 For cable support bracket 7 - Cable support bracket May be made from plastic or metal 8 - Grommet Cable support bracket mounting on gearbox 9 - Spacer
1.9
Assembly overview - removing and installing selector cables

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Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 10 - Cable end-piece After installing, adjust selector mechanism page 139 For gate selector cable to relay lever Do not interchange; cable end-pieces for gate selector cable to relay lever and gear selector cable to gearbox selector lever are different For metal relay lever, secured with securing clip Item 12 (page 132) From 05.07, fitted in conjunction with plastic relay lever page 134 Removing from plastic relay lever page 134 Pressing onto plastic relay lever page 134 n AG. Volkswagen AG do es n wage s k l ot g o Allocation page 133 yV u
nte ris 11 - Cable end-piece eo tho u ra a c After installing, adjust selector mechanism page 139 ss For gear selector cable to gearbox selector lever Do not interchange; cable end-pieces for gate selector cable to relay lever and gear selector cable to gearbox selector lever are different Allocation page 133
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12 - Securing clip Always renew Not required for plastic relay lever 13 - Securing clip Always renew Not required for plastic relay lever 14 - Bearing bush Not required for plastic relay lever
15 - Relay lever Installation position page 134 After installing, adjust selector mechanism page 139 May be made from plastic or metal Metal relay lever is mounted in bearing bush Item 14 (page 132) and secured with securing clip Item 13 (page 132) From 05.07, plastic relay lever Remove and install plastic relay lever together with cable end-piece page 134 Bearing bushes and securing clip not required for plastic relay lever
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16 - Shoe 17 - Gearbox selector lever Installing page 133 Installation position page 134 After installing, adjust selector mechanism page 139 From 06.06, smaller diameter of support pin for cable end-piece page 133 18 - Self-locking hexagon nut, 23 Nm Always renew
132
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Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 Allocation of cable end-pieces The holes in the cable end-pieces have different diameters. Cable end-piece for 1 - Gear selector cable to gearbox selector lever from 06.06 2 - Gear selector cable to gearbox selector lever through 05.06 2. - Gate selector cable to metal relay lever 2. - Gate selector cable to plastic relay lever page 134 Dimension a 8.5 mm 10 mm 8 mm 10 mm
From 06.06, smaller diameter of support pin for gear selector ca ble end-piece Support pin for gear selector cable end-piece Through 05.06 From 06.06 Dimension a 10 mm 8.5 mm
Installing gearbox selector lever
When setting gearbox selector lever in place, ensure that gap in teeth -arrow A- is over the partial tooth on the selector shaft -arrow B-
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Installation
2 - Relay lever engages in guide rail of gearbox selector lever via shoe -arrow-.
1 - Gearbox selector lever
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1.10
Plastic relay lever
From 05.07, plastic relay lever To remove relay lever, first separate cable end-piece from gate selector cable.
134
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Wind cable tie -arrow- around the selector cables in a figure eight and secure them as shown in figure.
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Fitting position of cable tie for cables
Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 This will avoid damage to the gate selector cable Pull locking mechanism forward to stop in -direction of arrow 1- and then lock by turning to left in -direction of arrow 2-.
. gen AG Then push relay lever forwards (-in direction of arrow 3-). swa
Relay lever with catch -arrow 1- ( previous
Relay lever with clip -arrow 1-
Press catch -arrow 1- ( previous figure) and remove relay lever together with cable end-piece. In the proc ess, swing it in direction of operation.
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Pull clip -arrow 1- off and remove relay lever together with ca ble end-piece. Continuation for all Cable end-piece must be located behind catch -arrow 2-. The cable end-piece can be removed only with the relay lever removed page 135 . Note
When installing, lubricate bearing positions and sliding surfa
ces.
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Allocate grease using Electronic parts catalogue (ETKA) . Press cable end-piece onto relay lever page 136 .
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Ensure proper engagement. Cable end-piece must be located behind catch -arrow 2- ( previous figure).
Levering gate selector cable end-piece off plastic relay lever Relay lever has been removed Insert a flat-blade screwdriver -A- between bush -B- and relay lever.
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Fastener -arrow 1- secures relay lever ( previous figure).
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Install relay lever together with cable end-piece to stop.
135
Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 Pressing on cable end-piece Relay lever has been removed Cable end-piece may be pressed only onto bush -arrow-. Cable end-piece must move freely on relay lever. It must be located behind catch -arrow 2- page 134 .
1.11
Removing and installing selector mech . Volkswage n AG d AG agen oes anism ksw not l o V
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1.11.1
Removing
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First check whether a coded radio is fitted. If so, obtain antitheft code. With ignition switched off, disconnect battery earth strap Electrical system; Rep. Gr. 27 ; Removing and installing bat tery .
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Install gaiter with gear knob and noise insulation. Golf page 118 , Golf Plus page 120 , Passat page 121 Golf 2004
Remove securing bracket for centre console, remove footwell trim from centre console and ashtray or storage compartment for this General body repairs, interior; Rep. Gr. 68 ; Com partments, covers and trims; Removing and installing centre console . Golf 2009 Remove ashtray or storage compartment and securing brack et for centre console General body repairs, interior; Rep. Gr. 68 ; Compartments, covers and trims; Removing and in stalling centre console .
136
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Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 Remove rear footwell ducts, if fitted Heater; Rep. Gr. 80 , remove centre console for this General body repairs, inte rior; Rep. Gr. 68 ; Compartments, covers and trims; Removing and installing centre console . Golf Plus Remove upper parts and, if necessary, securing brackets for centre console General body repairs, interior; Rep. Gr. 68 ; Compartments, covers and trims; Removing and installing centre console Vehicles where centre console securing brackets cannot be re moved as a separate component: Remove centre console, General body repairs, interior; Rep. Gr. 68 ; Compartments, covers and trims . Continuation for all Remove selector housing nuts -arrows-. Remove complete air filter housing if it is over selector mech anism Rep. Gr. 23 ; Repairing diesel direct injection system or Rep. Gr. 24 ; Repairing injection system . Remove securing clip -3- for gear selector cable from gearbox selector lever -1-.
Pull gear selector cable off pin. Metal relay lever Remove securing clip -4- for gate selector cable from relay lever -2-. Pull gate selector cable from pin. Plastic relay lever
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137
Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 Releasing cable end-piece from gate selector cable Pull locking mechanism forward to stop in -direction of arrow 1- and then lock by turning to left in -direction of arrow 2-. Then push relay lever forwards (-in direction of arrow 3-). Remove relay lever together with cable end-piece page 134 . Continued for all selector mechanisms
Remove cable support bracket from gearbox -arrows-; if nec essary, unclip hose -A- from bracket -B- first. Remove noise insulation General body repairs, exterior; Rep. Gr. 50 ; Noise insulation . Remove tunnel cross member Rep. Gr. 26 ; Removing and olkswagen AG installing parts of exhaust system . en AG. V
o Separate front exhaust system at double clamp andbdetach yV d e s from subframe Rep. Gr. 26 ; Removing and installing parts ri tho of exhaust system . u a
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Unhook exhaust system Rep. Gr. 26 ; Removing and in stalling parts of exhaust system .
Remove underbody panels General body repairs, exterior; Rep. Gr. 50 . Swing selector housing down and remove with selector ca bles.
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1.11.2
Installing
Install in the reverse order of removal, observing the following: Align selector housing parallel to body. Distance to body must be same on both sides.
Secure selector housing Item 26 (page 124) or Item 16 (page 126) . Route cables -1- from selector mechanism -2- to gearbox as follows:
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After cables cross over -arrow-, they must be routed parallel to one another as far as cable support bracket on gearbox.
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Make sure that cable tie -arrow- for securing cables is installed correctly. Installation position page 134 . Cables must be laid in the intended indentation in heat shield -3-. Note
In the close-up, the heat shield is shown from above.
138
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Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 Clip -A- holds cables and heat shield together in position. The holes in the cable end-pieces have different diameters. Allocation of cable end-pieces page 133
Spread a small quantity of grease on pins -arrows- of gearbox selector lever -1- and relay lever -2-. Allocate grease using Electronic parts catalogue (ETKA) . Renew securing clip -3- and, for metal relay lever, securing clip -4- each time they are removed. Secure gear selector cable with securing clip -3- and gate se lector cable with securing clip -4-. Cable end-piece to plastic relay lever Fit relay lever and cable end-piece together page 134 . Insert gate selector cable in cable end-piece. Continued for all selector mechanisms Install centre console General body repairs, interior; Rep. Gr. 68 ; Compartments, covers and trims .
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Assemble exhaust system free of tension and attach tunnel cross member Rep. Gr. 26 ; Removing and installing parts of exhaust system . Adjusting selector mechanism page 139 . If removed, install complete air filter housing Rep. Gr. 23 ; Repairing diesel direct injection system or Rep. Gr. 24 ; Repairing injection system Follow procedure after connecting battery Electrical system; Rep. Gr. 27 ; Battery; Disconnecting and connecting battery .
or General body repairs, exterior; Install underbody panels th u a Rep. Gr. 50 . ss
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1.11.3
Component
Torque settings
Selector lever housing to body Item 26 (page 124) or Item 16 (page 126) Selector cables support bracket to gearbox Item 6 (page 131)
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1.12
Adjusting selector mechanism
139
Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 Locking pin -T10027 An AG. Volkswagen AG do es n wage s k l ot g o yV ua b ran ed s i tee r o h t or u ac a ss
Note
The following points are essential to ensure correct adjust
ment of selector mechanism:
Moving parts of operating elements and elements transferring
force must be in proper condition.
Selector mechanism must move freely. Gearbox, clutch and clutch mechanism must also be in proper
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condition.
Pull locking mechanisms on gate selector cable and gear se lector cable end-pieces forward to stop -direction of arrow 1and then turn to left to lock -direction of arrow 2-.
140
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Remove air filter housing if bracket -A- and securing mecha nism for gear selector cable and gate selector cable are not accessible Rep. Gr. 23 ; Repairing diesel direct injection system or Rep. Gr. 24 ; Repairing injection system .
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Gearbox must be in neutral.
Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 Secure selector shaft as follows:
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-direction of arrow 2- upwards and at the same time press it in until it engages in selector shaft.
Install gaiter with gear knob and noise insulation. Golf page 118 , Golf Plus page 120 , Passat page 121 If noise insulation is present, remove it. Now secure gear lever as follows: Select neutral using gear lever. Guide locking pin -T10027 A- through hole -A- into hole -B-.

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Now turn locking mechanisms on gear selector cable and gate selector cable end-pieces clockwise to stop -direction of arrow-. Spring presses locking mechanism into original position.
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Now turn angled rod -A- back to original position -direction of arrow-.
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141
Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 Note
The angled rod -A- must be pressed out of selector housing to stop and point to rear.
Install gaiter with gear knob and noise insulation. Golf page 118 , Golf Plus page 120 , Passat page 121 Check that selector shaft moves freely. If necessary, install complete air filter housing Rep. Gr. 23 or Rep. Gr. 24
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1.12.1
Functional check
With gearbox in neutral, selector lever must rest in gate for 3rd and 4th gear.
Operate clutch.
Select all gears several times. Pay particular attention to op eration of reverse gear lock.
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If it continues to be difficult to engage a gear after repeated attempts, repeat adjustment procedure of selector mechanism page 139 .
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142
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Removing and installing gearbox, Golf 2004
Special tools and workshop equipment required Support bracket -10 - 222 A Adapter -10 - 222 A / 8 Hook - 10 - 222 A /2 Adapter -10 - 222 A /3 Adapter -10 - 222 A /16 Gearbox support -3282 Rear left engine support eye points towards side page 146 shackle -10-222 A /12-
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143
Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 Adjustment plate -3282/39 Support elements for gear box (determine when set ting adjustment plate on gearbox support ) Engine and gearbox jack V.A.G 1383A Torque wrench -V.A.G 1331 Torque wrench -V.A.G 1332 Gearbox lifting tackle -3336- for transporting gearbox Grease for clutch plate splines -G 000 100 Allocate grease using Electronic parts catalogue (ETKA) .
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2.1
Removing gearbox
First check whether a coded radio is fitted. If so, obtain antitheft code. With ignition switched off, disconnect battery Electrical sys tem; Rep. Gr. 27 ; Disconnecting and connecting battery . If the lifting eyes of the engine for support bracket -10 - 222 Aare covered by a component, for example the air filter, it must be removed now. Rep. Gr. 23 ; Repairing diesel direct in jection system or Rep. Gr. 24 ; Repairing injection system Remove complete air filter housing if it is near battery Rep. Gr. 23 ; Repairing diesel direct injection system or Rep. Gr. 24 ; Repairing injection system . Remove battery and battery tray Electrical system; Rep. Gr. 27 ; Removing and installing battery .
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144
AG.
Remove securing clip -arrow 1- for gear selector cable from gearbox selector lever -A-.
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Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 Pull gear selector cable off pin. Metal relay lever Remove securing clip -arrow 2- for gate selector cable from relay lever -B-. Pull gate selector cable from pin. Pull securing clip -arrow 3- off relay lever -B- and remove relay lever. Plastic relay lever Remove relay lever together with cable end-piece page 134 . Continuation for all Remove gearbox selector lever -A- by removing nut n AG. Volkswagen AG do es n wage -arrow 4-. o olks
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Remove bracket -B- from gearbox and pull it off pipe/hose line -A-.
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Then remove gearbox support -arrow A-.
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Remove earth strap at upper engine/gearbox connecting bolt.
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Caution
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Remove slave cylinder -arrow B-, lay to side and secure with wire. Do not disconnect pipes.
AG.
145
Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 Pull connector -arrow 1- off reversing light switch -F4- . Now remove connector -arrow 2- and wire -arrow 3- from starter. Then remove upper securing bolt on starter. Remove upper engine/gearbox connecting bolts. If there are hose and cable connections in area of engine sup port eye for support bracket -10 - 222 A- , remove these now.
Set up support bracket -10 - 222 A- together with adapters -10 - 222 A /8- , adapter -10 - 222 A /3- and adapter -10 - 222 A / 16- before support for bonnet. Attach hook -10 - 222 A /10- at front right of engine.
Rear left engine support eye points towards side -arrow Attach shackle -10-222 A /12- at rear left of engine -arrow-. Attach hook - 10-222 A /2- in shackle -10-222 A /12- . Then connect hook -10-222 A /2- using adapter -10-222 A / 16- .
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146
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Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 Rear left engine support eye points upwards -arrow-: Insert hook - 10-222 A /2- . Then connect hook -10-222 A /2- using adapter -10-222 A / 16- . Continuation for all Take up weight of engine/gearbox assembly on spindles. Raise vehicle. Remove noise insulation General body repairs, exterior; Rep. Gr. 50 ; Noise insulation . Remove lower part of front left wheel housing liner General body repairs, exterior; Rep. Gr. 66 ; Wheel housing liner .
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Separate exhaust system at double clamp and unbolt exhaust pipe bracket from subframe Rep. Gr. 26 ; Exhaust system . Disconnect drive shafts from flange shafts and tie up as high as possible, being careful not to damage surface protection.
n AG. Volkswagen AG do es n ot g V ua by d ran e s i tee r o Remove drive shaft heat shield, if present -arrows Running h or ut ac a gear, axles, steering; Rep. Gr. 40 ; Repairing drive shafts; ss
Removing and installing drive shafts .
Remove pendulum support -arrows A-, -B- and -C-.
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Remove hexagon bolts -arrows- for left assembly mounting from gearbox mounting.
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147
Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus e 2009. V ,sPass ... wagen A olk G do g n AG es n 5-speed manual gearbox 0A4 - Edition 04.2010 Volkswa ot Tilt engine/gearbox assembly by lowering it support bracket -10 - 222 A- . Note
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Lower threaded spindle of adapter -10 - 222 A /16- using wing
ed nut, but not more than until spindle is flush with nut -arrow-.
Be careful of all lines when lowering gearbox.
Securing bolts -arrows- for gearbox bracket -A- must be ac cessible.
Remove gearbox bracket -A- -arrows-.
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If small cover plate -A- for flywheel behind the right flange shaft -arrows- is installed, remove it.
Remove exhaust system strut -1- from gearbox -arrow-. Remove starter Electrical system; Rep. Gr. 27 ; Starter . To remove gearbox 0A4, set up gearbox support -3282- with adjustment plate -3282/39- . Insert gearbox support -3282- in engine and gearbox jack V.A.G 1383A- . Align arms of gearbox support according to holes in adjust ment plate .
148
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Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 Screw in support elements -A - and -C- on adjustment plate as shown. Position engine and gearbox jack under vehicle. Arrow -B- on adjustment plate points in direction of vehicle travel.
Align adjustment plate parallel to gearbox and lock safety sup port on gearbox. Then screw pin -3282/29- into hole on gearbox for securing bolt of pendulum support. Remove lower engine/gearbox connecting bolts. Separate exhaust system if lower bolts -arrows- cannot be re moved.
k Rep. Gr. 26 ; Removing and installing parts of the Vol exhaust by d e system ris
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Press gearbox off dowel sleeves and carefully swing towards subframe. Turn gearbox downwards in vicinity of differential. Have a second mechanic push engine forwards slightly.
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149
Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 Carefully lower gearbox, guiding right-hand flange shaft -Apast intermediate plate and flywheel as shown. AG. Volkswagen
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2.2
Note
Installing gearbox
Refer to procedure Removing gearbox for required special tools page 143 .
Observe the following table on the subject of checking and top ping up gear oil. Checking and topping up gear oil
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Partially dismantled (Gear box housing and clutch housing were not separa ted.)
X after instal lation page 220
All threaded holes into which self-locking bolts are to be screwed must be cleaned of residual locking fluid carefully with a thread tap. Always renew self-locking bolts and nuts. Check whether dowel sleeves for aligning engine and gearbox are fitted in cylinder block and install if necessary. If dowel sleeves are not fitted, difficulties shifting gears, clutch problems and possible noises from the gearbox (rattling of gears which are not engaged) could occur. Ensure that intermediate plate is correctly seated on engine. Clean input shaft splines and apply thin coat of grease for clutch plate splines -G 000 100- .
150
AG.
X before in stallation Item 3 (page 250) oil capacity page 2
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Gearbox
Original part No oil loss Completely dismantled
No X X
Yes
Yes
Golf
To install gearbox 0A4, set up gearbox support -3282- with ad justment plate -3282/39- . Align arms of gearbox support according to holes in adjust ment plate . Screw in support elements -A - and -C- ( pin -3282/29- ) on adjustment plate as shown. Place gearbox on engine and gearbox jack . Align adjustment plate and gearbox parallel to one another.
The clutch plate must slide easily to and fro on the input shaft.
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2009 , Pass ... - Edition 04.2010

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Using spindles of gearbox support -3282- , tilt gearbox down wards in vicinity of differential.
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Then carefully raise gearbox, guiding with right flange shaft -A- past flywheel and intermediate plate as shown. Using spindles of gearbox support -3282- , tilt gearbox up wards in vicinity of differential. Raise gearbox to engine. Have a second mechanic push engine forwards slightly. Align gearbox to engine and join. Screw in lower engine/gearbox securing bolts and tighten to specified torque page 154 . After gearbox has been bolted to engine, remove engine and gearbox jack from gearbox. If small cover plate had been installed behind the right-hand flange shaft -A-, install it -arrows-. Screw in upper engine/gearbox securing bolts and tighten to specified torque page 154 .
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Position engine and gearbox jack under vehicle. -Arrow B- on adjustment plate points in direction of vehicle travel.
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Screw pin -3282/29- into hole on gearbox for securing bolt of pendulum support.
151
Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 Install bracket -A- on gearbox using new hexagonal bolts -arrows- and tighten to specified torque page 154 .
Align engine and gearbox in installation position using both spindles of support bracket -10 - 222 A- . Install new bolts -arrows- for left assembly mounting in gear box mounting and tighten to specified torque page 154 . WARNING
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Do not remove support bracket -10 - 222 A- until the curing the left and right assembly mountings have been tight ened to specified torque.
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Note
Install engine and gearbox mounting free of tension Rep. Gr. 10 ; Removing and installing engine .
Install slave cylinder and tighten bolts -arrows B- to specified torque Item 9 (page 104) . Then install gearbox support -arrow A- and tighten to specified torque page 154 .
Attach drive shafts to gearbox Running gear, axles, steer ing; Rep. Gr. 40 ; Repairing front suspension .
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152
AG.
Install drive shaft heat shield, if present -arrows- Running gear, axles, steering; Rep. Gr. 40 ; Repairing drive shafts; Removing and installing drive shafts .
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Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 Install pendulum support with new bolts -arrows A-, -B- and -C- Running gear, axles, steering ; Rep. Gr. 40 ; Repairing front suspension . Assemble exhaust system and attach exhaust system bracket to subframe Rep. Gr. 26 ; Exhaust system .
Bolt exhaust system strut -1- onto gearbox and tighten bolt -arrow- to specified torque Rep. Gr. 26 ; Exhaust system .
Push connector -1- onto reversing light switch -F4- .
AG. Volkswagen AG d agen oes ksw not l o V gu y b ara Install starter, push on connector -arrow 2- and bolt oned wire nte is r -arrow 3- Electrical system; Rep. Gr. 27 ; Starter . o eo h t u ra a c s s Install earth strap at upper engine/gearbox connecting bolt.
Attach support -B- to gearbox.
Press pipe/hose line -A- into retainer -B- on gearbox. Install cable support bracket on gearbox and tighten bolts -arrows- to specified torque Item 6 (page 131) .
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153
Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 Install gearbox selector lever -A-. Tighten hexagon nut -arrow 4- to specified torque Item 18 (page 132) . Spread a small amount of grease on pin of gearbox selector lever -A-. Allocate grease using Electronic parts catalogue (ETKA) . Connect gear selector cable to gearbox selector lever -arrow 1-. Metal relay lever Install relay lever -B- and secure with securing clip -arrow 3-. Spread a small amount of grease on pin of relay lever -B-. Allocate grease using Electronic parts catalogue (ETKA) . Connect gate selector cable to relay lever -arrow 2-. Plastic relay lever Install relay lever together with cable end-piece page 134 . Continuation for all
olks . Adjust selector mechanism page 139 yV
Reconnect battery and perform work required after connecting battery Electrical system; Rep. Gr. 27 ; Disconnecting and connecting battery . Install lower part of front left wheel housing liner General body repairs, exterior; Rep. Gr. 66 ; Wheel housing liner . Install noise insulation General body repairs, exterior; Rep. Gr. 50 ; Noise insulation .
Install engine cover and air filter housing Rep. Gr. 23 or Rep. Gr. 24
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2.2.1
Item 1 2
Torque settings
Bolt Quantity 2 1 Nm 80 80
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Gearbox to petrol engine
4 5 6
M 10 x 50 M 12 x 85 M6x8 Small cover plate for flywheel
3 1 1
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Item -A- dowel sleeves for centring
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Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 Gearbox to diesel engine Item 1 2 Bolt M 12 x 55 M 12 x 150 Additionally, start er to gearbox M10 x 50 M12 x 60 M6 x 8 Small flywheel cover plate Quantity 2 2 Nm 80 80
3 4 5
3 1 1
40 80 10
Item -A- dowel sleeves for centring Gearbox bracket to gearbox Renew bolts. Screw in all bolts hand-tight. Tighten bolts to specified torque. Bolts -arrows40 Nm + 90
Gearbox mounting to body Renew bolts. Screw in all bolts hand-tight.

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Removing and installing gearbox, Golf 2009 with turbo diesel engine
Special tools and workshop equipment required Support bracket -10 - 222 A Adapter -10-222 A /8 Adapter -10 - 222 A /18 Adjustment plate -3282/39 Support elements for gear box (determine when set ting adjustment plate on gearbox support ) Gearbox support -3282AG. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o eo h t u ra a c s s
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Gearbox lifting tackle -3336- for transporting gearbox Grease for clutch plate splines -G 000 100 Flange bolt M6 x 20 Flange bolt M6 x 80
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At a later point, support bracket -10-222 A- will be put onto lon gitudinal members with adapters -10 - 222 A /8- . To prevent damage to edges of wings, cover bottom area of both adapters -10 - 222 A /8- with self-adhesive fabric tape -arrow- Electronic parts catalogue (ETKA chemical sub stances) .
3.1
Removing gearbox
First check whether a coded radio is fitted. If so, obtain antitheft code. With ignition switched off, disconnect battery Electrical sys tem; Rep. Gr. 27 ; Disconnecting and connecting battery . If the lifting eyes of the engine for support bracket -10 - 222 Aare covered by a component, for example the air filter, it must
3. Removing and installing gearbox, Golf 2009 with turbo diesel engine
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Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 be removed now. Rep. Gr. 23 ; Repairing diesel direct in jection system or Rep. Gr. 24 ; Repairing injection system Remove complete air filter housing if it is near battery Rep. Gr. 23 ; Repairing diesel direct injection system or Rep. Gr. 24 ; Repairing injection system . Remove battery and battery tray Electrical system; Rep. Gr. 27 ; Removing and installing battery . Remove securing clip -arrow 1- for gear selector cable from Volkswa gen AG . gen AG gearbox selector lever -A-. does swa Pull gear selector cable off pin. Release end-piece from gate selector
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The relay lever was secured with a clip shortly after start of pro duction page 135 .
Remove gearbox selector lever -A- by removing nut -arrow 3-. Remove cable support bracket from gearbox -arrows-. Then raise and secure gear selector cable and gate selector cable. Remove bracket -B- from gearbox and pull it off pipe/hose line -A-.
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Then remove gearbox support -arrow A-. Remove slave cylinder -arrow B-, lay to side and secure with wire. Do not disconnect pipes. Caution
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Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 Pull connector -arrow 1- off reversing light switch -F4- . Now remove connector -arrow 2- and wire -arrow 3- from starter. Remove earth strap at upper engine/gearbox connecting bolt. Then remove upper securing bolt on starter. Remove upper engine/gearbox connecting bolts.
Bolt bracket -T10346- to rear of the three mounting holes for battery tray. To do this, use a collar bolt M 6 x 80 or a securing bolt for battery tray. If there are hose and cable connections in area of engine sup port eye for support bracket -10 - 222 A- , remove these now.
Set up support bracketG -10-222 A- in front of bonnet support. . Volkswage Use:

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On upper longitudinal carrier, directly before the elevation (-arrow 1-) next to bolt (-arrow 2-)
Connect bracket -T10346- to support bracket . Attach spindles in left engine support eyes. Take up weight of engine/gearbox assembly and support bracket on spindles. Raise vehicle.
Remove noise insulation General body repairs, exterior; Rep. Gr. 50 ; Noise insulation .
Remove lower part of front left wheel housing liner General body repairs, exterior; Rep. Gr. 66 ; Wheel housing liner . Then remove all lines from gearbox.
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159
Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 Gearboxes for vehicles with start-stop system: pull connector -arrow- from gearbox neutral position sender -G701- .
Remove starter Electrical system; Rep. Gr. 27 ; Starter . If front vehicle level sender -G78- is present, unbolt it from transverse link Rep. Gr. 40 ; Removing and installing front vehicle level sender -G78- .
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Remove drive shaft heat shield, if present -arrows- Running gear, axles, steering; Rep. Gr. 40 ; Repairing drive shafts; Removing and installing drive shafts .
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Remove pendulum support.
160
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Separate exhaust system at double clamp and unbolt exhaust pipe bracket from subframe Rep. Gr. 26 ; Exhaust system .
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Remove drive shafts from flange shafts, raise as high as pos sible and secure. Do not damage the surface protection Running gear, axles, steering; Rep. Gr. 40 ; Removing and installing drive shafts .
Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 Remove hexagon bolts -arrows- for left assembly mounting from gearbox mounting. Tilt engine/gearbox assembly by lowering it via spindles of AG. Volkswagen AG d agen oes support bracket -10 - 222 A- . n lksw
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Secure engine support -3300 A- to bracket -T10346- .
Place a cloth between engine support -3300 A- and oil pan.
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-1- = Flange bolt M6 x 20.
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Attach bracket -T10346- with bolt -1- to left threaded hole in subframe.
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Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 Press engine forwards using spindle of engine support -3300 A- . In the process, observe the following points in particular: The air conditioning compressor -2- must not contact -arrowthe refrigerant line -1olkswagen AG en AG. V
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Insert gearbox support -3282- in engine and gearbox jack V.A.G 1383A- . Align arms of gearbox support according to holes in adjust ment plate . Screw in support elements -A - and -C- on adjustment plate as shown. Position engine and gearbox jack under vehicle. Arrow -B- on adjustment plate points in direction of vehicle travel.
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Remove lower engine/gearbox connecting bolts.
Separate exhaust system if lower bolts -arrows- cannot be re moved.
Rep. Gr. 26 ; Removing and installing parts of the exhaust system
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Then screw pin -3282/29- into hole on gearbox for securing bolt of pendulum support.
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Align adjustment plate parallel to gearbox and lock safety sup port on gearbox.
Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 Press gearbox off dowel sleeves and carefully swing towards subframe. Turn gearbox downwards in vicinity of differential.
Carefully lower gearbox, guiding right-hand flange shaft -Apast dowel sleeve -arrow- in cylinder block as shown.
Guide left flange shaft -B- past subframe bracket -arrow- as shown. When lowering gearbox, change position of gearbox using spindles of gearbox support -3282- . Note
3.2
Installing gearbox
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Observe the following table on the subject of checking and top ping up gear oil. Checking and topping up gear oil No Yes Yes
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Note
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X After instal lation page 220
All threaded holes into which self-locking bolts are to be screwed must be cleaned of residual locking fluid carefully with a thread tap. Always renew self-locking bolts and nuts. Check whether dowel sleeves for aligning engine and gearbox are fitted in cylinder block and install if necessary. If dowel sleeves are not fitted, difficulties shifting gears, clutch problems and possible noises from the gearbox (rattling of gears which are not engaged) could occur. Ensure that intermediate plate is correctly seated on engine. Clean input shaft splines and apply thin coat of grease for clutch plate splines -G 000 100- . The clutch plate must slide easily to and fro on the input shaft. Attach bracket -T10346- with bolt -1- to left threaded hole in subframe. In the process, position bracket -T10346- at the same angle as the engine. -1- = Flange bolt M6 x 20. Secure engine support -3300 A- to bracket -T10346- .
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Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 Press engine forwards using spindle of engine support -3300 A- . In the process, observe the following points in particular: The air conditioning compressor -2- must not contact -arrowthe refrigerant line -1The alternator must not contact the refrigerant line. The pressure pipe must not contact the radiator.
To install gearbox 0A4, set up gearbox support -3282- with ad justment plate -3282/39- . Align arms of gearbox support according to holes in adjust ment plate . Screw in support elements -A - and -C- ( pin -3282/29- ) on adjustment plate as shown. Place gearbox on engine and gearbox jack . Align adjustment plate and gearbox parallel to one another.
Screw pin -3282/29- into hole on gearbox for securing bolt of pendulum support. Position engine and gearbox jack under vehicle. -Arrow B- on adjustment plate points in direction of vehicle travel. Using spindles of gearbox support -3282- , tilt gearbox down AG. Volkswagen AG d wards in vicinityaof differential. gen o
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Carefully lift gearbox, guiding right-hand flange shaft -A- past dowel sleeve in cylinder block -arrow- as shown.
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165
Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 Guide left flange shaft -B- past subframe bracket -arrow- as shown. Using spindles of gearbox support -3282- , tilt gearbox up wards in vicinity of differential. Raise gearbox to engine. Align gearbox to engine and join. Screw in lower engine/gearbox securing bolts and tighten to specified torque page 169 . After gearbox has been bolted to engine, remove engine and gearbox jack from gearbox. Remove engine support -3300 A- and bracket -T10346- . If small cover plate had been installed behind the right-hand flange shaft -A-, install it -arrows-. Screw in upper engine/gearbox securing bolts and tighten to specified torque page 169 .
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Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 Align engine and gearbox in installation position using both spindles of support bracket -10 - 222 A- . Install new bolts -arrows- for left assembly mounting in gear swspecified agen AG AG. Volk n box mounting and tighten to doetorque page 169 . wage
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Do not remove support bracket -10 - 222 A- until the bolts se curing the left and right assembly mountings have been tight ened to specified torque.
Note
Then install drive shafts Running gear, axles, steering; Rep. Gr. 40 ; Removing and installing drive shafts .
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Install pendulum support Running gear, axles, steering; Rep. Gr. 40 ; Repairing front suspension . Assemble exhaust system and attach exhaust system bracket to subframe Rep. Gr. 26 ; Exhaust system .
If front vehicle level sender -G78- -arrows- is present, install it Rep. Gr. 40 ; Removing and installing front vehicle level sender -G78- .
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167
Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 Gearboxes for vehicles with start-stop system: join connector -arrow- to gearbox neutral position sender -G701- .
Install slave cylinder and tighten torque Item 9 (page 104) .
Then install gearbox support -arrow A- and tighten to specified torque page 169 .
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Push connector -1- onto reversing light switch -F4- . Install starter, push on connector -arrow 2- and bolt on wire -arrow 3- Electrical system; Rep. Gr. 27 ; Starter . Install earth strap at upper engine/gearbox connecting bolt.
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Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 Install gearbox selector lever -A- page 133 . Tighten hexagon nut -arrow 3- to specified torque Item 18 (page 132) . Spread a small amount of grease on pin of gearbox selector lever -A-. Allocate grease using Electronic parts catalogue (ETKA) . Connect gear selector cable to gearbox selector lever -arrow 1-. Install relay lever together with cable end-piece page 134 . Adjusting selector mechanism page 139 . Install battery tray, battery cover and battery Electrical sys tem; Rep. Gr. 27 ; Removing and installing battery . Install engine cover and air filter housing Rep. Gr. 23 or Rep. Gr. 24 Reconnect battery and perform work required after connecting battery Electrical system; Rep. Gr. 27 ; Disconnecting and connecting battery . Install lower part of front left wheel housing liner General body repairs, exterior; Rep. Gr. 66 ; Wheel housing liner . Install noise insulation General body repairs, exterior; Rep. Gr. 50 ; Noise insulation . For vehicles with front vehicle level sender -G78- , check headlight adjustment Electrical system; Rep. Gr. 94 ; Lights, lamps, switches - exterior .
3.2.1
Item 1 2
Torque settings
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Gearbox to engine Bolt
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M10 x 50 M12 x 60 M6 x 8 Small flywheel cover plate
3 1 1
40 80 10
Item -A- dowel sleeves for centring Gearbox bracket to gearbox Renew bolts. Screw in all bolts hand-tight. Tighten bolts to specified torque. Bolts -arrows40 Nm + 90
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Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 Gearbox mounting to body Renew bolts. Screw in all bolts hand-tight. Tighten bolts to specified torque.
Bolts -arrows-
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Gearbox support to gearbox bracket and gearbox Renew bolts. Screw in all bolts hand-tight. Tighten bolts to specified torque. Bolts -arrows-
20 Nm + 90
Drive shaft to flange shaft Running gear, axles, steering; Rep. Gr. 40 ; Repairing drive shaft; Removing and installing drive shafts .
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170
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Special tools and workshop equipment required Support bracket -10 - 222 A Adapter -10-222 A /8 Adapter -10 - 222 A /18 Adjustment plate -3282/39 Support elements for gear box (determine when set ting adjustment plate on gearbox support ) Gearbox support -3282-
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2009 , Pass ... - Edition 04.2010
Removing and installing gearbox, Golf 2009 with petrol engine

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Shackle -T10419-
4. Removing and installing gearbox, Golf 2009 with petrol engine
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Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 Shackle -10-222 A /12-
Engine and gearbox jack V.A.G 1383A Engine support -3300 A Torque wrench -V.A.G 1331 Torque wrench -V.A.G 1332 Gearbox lifting tackle -3336- for transporting gearbox Grease for clutch plate splines -G 000 100 Allocate grease using Electronic parts catalogue (ETKA) . 2 x hexagon socket head bolt M 6 20 Flange bolt M6 x 80 Support -T10036 A or support -T10036urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p
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Dimension -a- = 11 mm Dimension -b- = 98 mm Dimension -c- = 70 mm
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At a later point, support bracket -10-222 A- will be put onto lon gitudinal members with adapters -10 - 222 A /8- . To prevent damage to edges of wings, cover bottom area of both adapters -10 - 222 A /8- with self-adhesive fabric tape -arrow- Electronic parts catalogue (ETKA chemical sub stances) .
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With ignition switched off, disconnect battery Electrical sys tem; Rep. Gr. 27 ; Disconnecting and connecting battery . Then remove engine cover with air filter Rep. Gr. 24 ; Re pairing injection system . Remove battery and battery tray Electrical system; Rep. Gr. 27 ; Removing and installing battery . Release end-piece from gate selector cable page 134 . Pull clip -arrow 1- off and remove relay lever together with ca ble end-piece. Remove securing clip -arrow 2- for gear selector cable from gearbox selector lever -A-. Pull gear selector cable off pin. Remove gearbox selector lever -A- by removing nut -arrow 3-.
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Removing gearbox
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Remove bracket -B- from gearbox and pull it off pipe/hose line -A-.
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Now remove connector -arrow 2- and wire -arrow 3- from starter. Then remove upper securing bolt on starter. Remove upper engine/gearbox connecting bolts.
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To prevent damage to vacuum hose from brake servo to en gine, it must be removed from engine -arrow- Rep. Gr. 47 .
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Pull connector -arrow 1- off reversing light switch -F4- .

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Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 Note At a later point, support bracket -10-222 A- is connected to
engine to lower engine/gearbox. back -arrow-.
Some engines have a secondary air inlet valve -N112- on the Both upper threaded holes for securing bolts of secondary air inlet valve are needed for attaching engine to support bracket -10-222 A- -arrows- in figure below. Therefore, secondary air inlet valve must be removed Rep. Gr. 26 ; Secondary air system .
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Attach lug -T10419- to rear of engine -direction of arrow-. Volkswa
Screw lug tightly into threaded holes, -arrows-. Torque setting: 10 Nm WARNING
Always tighten bolts to specified torque.
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Remove transport eye -arrow B- and remove it from retaining eye -arrow A-, without disconnecting line connections Rep. Gr. 15 ; Cylinder head, valve gear .
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In addition, retaining eye -arrow A-, at front of engine, is needed for catching engine.
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175
Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 Set up support bracket -10-222 A- in front of bonnet support. Use: Adapter -10-222 A /8 Adapter -10-222 A /18 Position adapter -10-222 A /8- : On upper longitudinal carrier, directly before the elevation (-arrow 1-) next to bolt (-arrow 2-)
Attach shackle -10-222 A /12- at front left of engine. Connect lug -T10419- and shackle -10-222 A /12- to support bracket . Take up weight of engine/gearbox assembly on spindles. Raise vehicle. Remove noise insulation General body repairs, exterior; Rep. Gr. 50 ; Noise insulation . Remove lower part of front left wheel housing liner General body repairs, exterior; Rep. Gr. 66 ; Wheel housing liner . Then remove all lines from gearbox. Remove starter Electrical system; Rep. Gr. 27 ; Starter . If front vehicle level sender -G78- is present, unbolt it from transverse link Rep. Gr. 40 ; Removing and installing front vehicle level sender -G78- .
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Remove drive shaft heat shield, if present -arrows- Running gear, axles, steering; Rep. Gr. 40 ; Repairing drive shafts; Removing and installing drive shafts . Remove drive shafts from flange shafts, raise as high as pos sible and secure. Do not damage the surface protection Running gear, axles, steering; Rep. Gr. 40 ; Removing and installing drive shafts .
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176
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Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 Remove front exhaust pipe -1- from manifold by removing 4 nuts -2- and bolts -3- Rep. Gr. 26 ; Exhaust system .
Remove hexagon bolts -arrows- for left assembly mounting from gearbox mounting. Tilt engine/gearbox assembly by lowering it via spindles of support bracket -10 - 222 A- . Securing bolts -arrows- for gearbox bracket -A- must be ac cessible.
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177
Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 If heat shield is installed, remove it from subframe -arrows-.
Screw support -T10036- or support -T10036 A- tightly onto subframe using 2 hexagon socket head bolts M6 20 -arrows-.
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Secure engine support -3300 A- onto support -A-.
The pressure pipe must not contact the radiator.
To remove gearbox 0A4, set up gearbox support -3282- with adjustment plate -3282/39- . Insert gearbox support -3282- in engine and gearbox jack V.A.G 1383A- . Align arms of gearbox support according to holes in adjust ment plate .
178
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The alternator must not contact the refrigerant line.
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The air conditioning compressor -2- must not contact -arrowthe refrigerant line -1-.
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Press engine forwards using spindle of engine support -3300 A- . In the process, observe the following points in particular:
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Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 Screw in support elements -A - and -C- on adjustment plate as shown. Position engine and gearbox jack under vehicle. Arrow -B- on adjustment plate points in direction of vehicle travel.
Align adjustment plate parallel to gearbox and lock safety sup port on gearbox. Then screw pin -3282/29- into hole on gearbox for securing bolt of pendulum support. Remove lower engine/gearbox connecting bolts.
Press gearbox off dowel sleeves and carefully swing towards subframe.
Guide right flange shaft past flywheel -arrow 2- ( figure above).
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Then guide right flange shaft past recess -arrow 1-.
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179
Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 Guide left flange shaft -B- past subframe bracket -arrow- as shown. When lowering gearbox, change position of gearbox using spindles of gearbox support -3282- . Note

4.2
Note
Installing gearbox
Observe the following table on the subject of checking and top ping up gear oil. Checking and topping up gear oil No X X X Before in stallation Item 3 (page 250) Oil capacity page 2
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Yes
Yes
Gearbox
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All threaded holes into which self-locking bolts are to be screwed must be cleaned of residual locking fluid carefully with a thread tap. Always renew self-locking bolts and nuts. Check whether dowel sleeves for aligning engine and gearbox are fitted in cylinder block and install if necessary. If dowel sleeves are not fitted, difficulties shifting gears, clutch problems and possible noises from the gearbox (rattling of gears which are not engaged) could occur. Ensure that intermediate plate is correctly seated on engine. Clean input shaft splines and apply thin coat of grease for clutch plate splines -G 000 100- .
180
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X After instal lation page 220
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Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 The clutch plate must slide easily to and fro on the input shaft. If heat shield is installed, remove it from subframe -arrows-.
Screw support -T10036- or support -T10036 A- tightly onto subframe using 2 hexagon socket head bolts M6 20 -arrows-.
Secure engine support -3300 A- onto support -A-.
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Press engine forwards using spindle of engine support -3300 A- . In the process, observe the following points in particular:
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The air conditioning compressor -2- must not contact -arrowthe refrigerant line -1-. The pressure pipe must not contact the radiator.
AG.
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To install gearbox 0A4, set up gearbox support -3282- with ad justment plate -3282/39- . Align arms of gearbox support according to holes in adjust ment plate .
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The alternator must not contact the refrigerant line.

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181
Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 Screw in support elements -A - and -C- ( pin -3282/29- ) on adjustment plate as shown. Place gearbox on engine and gearbox jack . Align adjustment plate and gearbox parallel to one another.
Screw pin -3282/29- into hole on gearbox for securing bolt of pendulum support. Position engine and gearbox jack under vehicle. -Arrow B- on adjustment plate points in direction of vehicle travel. Raise gearbox carefully.
Guide right flange shaft past flywheel
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Guide left flange shaft -B- past subframe bracket -arrow- as shown. Then guide right flange shaft past recess -arrow 1- previous figure. Raise gearbox to engine. Align gearbox to engine and join.
Screw in lower engine/gearbox securing bolts and tighten to specified torque page 186 .
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After gearbox has been bolted to engine, remove engine and gearbox jack from gearbox. Remove engine support -3300 A- and support .
182
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Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 If heat shield was removed, bolt it onto subframe, -arrows-. Screw in upper engine/gearbox securing bolts and tighten to specified torque page 186 .
Align engine and gearbox in installation position using both spindles of support bracket -10 - 222 A- . Install new bolts -arrows- for left assembly mounting in gear box mounting and tighten to specified torque page 186 .
AG. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte is r Do not remove support bracket -10 - 222 A- until the bolts se o eo h utbeen tight ra curing the left and right assembly mountings have a c s s ened to specified torque.
WARNING
Note
Then install drive shafts Running gear, axles, steering; Rep. Gr. 40 ; Removing and installing drive shafts . Install drive shaft heat shield, if present -arrows- Running gear, axles, steering; Rep. Gr. 40 ; Repairing drive shafts; Removing and installing drive shafts .
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183
Assemble exhaust system and attach exhaust system bracket to subframe Rep. Gr. 26 ; Exhaust system .
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Rep. Gr. 40 ; Repairing front suspension .
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AG. Volkswagen AG d agen oes ksw not l o V 2009 , Golf Plus 2005 , Golf 2004 , Golf Golf gu Plus 2009 by ara d e nte 5-speed manual gearbox 0A4 Edition 04.2010 is r o eo h ut ra a c s s Install pendulum support Running gear, axles, steering;
, Pass ...
If front vehicle level sender -G78- -arrows- is present, install it Rep. Gr. 40 ; Removing and installing front vehicle level sender -G78- .
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Install vacuum hose -arrow- Rep. Gr. 47 .
Install slave cylinder and tighten bolts -arrows B- to specified torque Item 9 (page 104) . Then install gearbox support -arrow A- and tighten to specified torque page 186 .
184
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Push connector -1- onto
Install earth strap at upper engine/gearbox connecting bolt.
Install starter, push on connector -arrow 2- and bolt on wire -arrow 3- Electrical system; Rep. Gr. 27 ; Starter .
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-F4- .
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Install gearbox selector lever -A- page 133 .
Tighten hexagon nut -arrow 3- to specified torque Item 18 (page 132) . Spread a small amount of grease on pin of gearbox selector lever -A-. Allocate grease using Electronic parts catalogue (ETKA) . Connect gear selector cable to gearbox selector lever. Renew securing clip -arrow 2- each time it is removed. Install relay lever together with cable end-piece page 134 . Clip -arrow 1- secures relay lever Ensure proper engagement of clip.
Connect gate selector cable to cable end-piece. Adjust selector mechanism page 139 . Remove shackle -10-222 A /12- from engine. Insert transport eye into retaining eye of engine -arrow A- and screw it tight -arrow B- Rep. Gr. 15 ; Cylinder head, valve gear .
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185
Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 Remove lug -T10419- from back of engine. olkswag yV
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If secondary air inlet valve -N112- -arrow- was removed, install it on engine Rep. Gr. 26 ; Secondary air system . Install battery tray, battery cover and battery Electrical sys tem; Rep. Gr. 27 ; Removing and installing battery . Then remove engine cover with air filter Rep. Gr. 24 ; Re pairing injection system . Reconnect battery and perform work required after connecting battery Electrical system; Rep. Gr. 27 ; Disconnecting and connecting battery .
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Install lower part of front left wheel housing liner General body repairs, exterior; Rep. Gr. 66 ; Wheel housing liner .
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Install noise insulation General body repairs, exterior; Rep. Gr. 50 ; Noise insulation .
AG.
For vehicles with front vehicle level sender -G78- , check headlight adjustment Electrical system; Rep. Gr. 94 ; Lights, lamps, switches - exterior .
4.2.1
Item 1 2
Torque settings
Bolt M12 x 65 M12 x 170 Additionally, start er to gearbox M12 x 170 Additionally, start er to gearbox M10 x 65 M12 x 95 M6 x 8 Small flywheel cover plate (not present here) Quantity 2 1 Nm 80 80
Gearbox to engine
4 5 6
186
80
3 1 1
40 80 10
Golf 2004 , Golf 2009

Gearbox bracket to gearbox Renew bolts. Screw in all bolts hand-tight. Tighten bolts to specified torque. Bolts -arrows-
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AG. Volkswagen AG d agen oes ksw not l o V gu y b ara d n ise r , tGolf Plus 2005 , Golf Plus 2009 , Passte ... eo ho u a5-speed manual gearbox 0A4 - Edition 04.2010 r ac s s
40 Nm + 90
Gearbox mounting to body Renew bolts. Screw in all bolts hand-tight. Tighten bolts to specified torque. Bolts -arrows-
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60 Nm + 90
187
Removing and installing gearbox, Golf Plus
Special tools and workshop equipment required Support bracket -10 - 222 A Adapter -10 - 222 A / 8 Hook - 10 - 222 A /2 Adapter -10 - 222 A /3 Adapter -10 - 222 A /16 Gearbox support -3282 Rear left engine support eye points towards side page 192 shackle -10-222 A /12-
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188
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Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 Adjustment plate -3282/39 Support elements for gear box (determine when set ting adjustment plate on gearbox support ) Engine and gearbox jack V.A.G 1383A Retainer -T10346 Engine support -3300 A Wing supports -T10311 Torque wrench -V.A.G 1332 Grease for clutch plate splines -G 000 100 Allocate grease using Electronic parts catalogue (ETKA) . Flange bolt M6 x 20
5.1
Removing gearbox
Check whether a coded radio is fitted. If so, obtain anti-theft code. With ignition switched off, disconnect battery Electrical sys tem; Rep. Gr. 27 ; Disconnecting and connecting battery . Remove cover from engine.
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Remove complete air filter housing -1- with intake hose -2- Rep. Gr. 23 ; Repairing diesel direct injection .
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Remove battery -3-, battery cover and battery tray Electrical system; Rep. Gr. 27 ; Removing and installing battery . Remove bolt -arrow- and valve block -4- from front wall of ple num chamber. Remove noise insulation -5- from front wall of plenum cham ber. Remove front wall of plenum chamber General body re pairs, exterior; Rep. Gr. 50 ; Noise insulation . Remove securing clip -arrow 1- for gear selector cable from gearbox selector lever -A-.
AG.
5. Removing and installing gearbox, Golf Plus
189
Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 Pull gear selector cable off pin. Metal relay lever Remove securing clip -arrow 2- for gate selector cable from relay lever -B-.
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Remove relay lever together with cable end-piece page 134 . Continuation for all Remove gearbox selector lever -A- by removing nut -arrow 4-. Remove cable support bracket from gearbox -arrows-. Then raise and secure gear selector cable and gate selector cable. Remove bracket -B- from gearbox and pull it off pipe/hose line -A-.
Plastic relay lever
n AG. Volkswagen AG do es n ot g yV ua b ran ed 3- off relay lever -B- and remove relay Pull securing clip -arrow s i tee r o h lever. t or u ac a ss

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190
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Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 Pull off reversing light connector -arrow 1-.
is or
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th Then removeau upper securing bolt on starter.

Remove upper engine/gearbox connecting bolts.
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If there are hose and cable connections in area of engine sup port eye for support bracket -10 - 222 A- , remove these now.
Insert wing supports -T10311- between wing flange and mounting plate for wing on both sides of vehicle. Installation position: R (-1-) means right side of vehicle. L is not illustrated, but means left side of vehicle. Arrow -2- points in direction of travel. Note
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Hole -3- can be used to pull out wing supports .

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Set up support bracket -10 - 222 A- in front of bonnet support. Use: Adapter -10-222 A /3 Adapter -10-222 A /8 Adapter -10-222 A /16 Then attach spindle in right engine support eye.
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Prote cted by
191
Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 Rear left engine support eye points towards side -arrow Attach shackle -10-222 A /12- at rear left of engine -arrow-. Attach hook - 10-222 A /2- in shackle -10-222 A /12- . Then connect hook -10-222 A /2- using adapter -10-222 A / 16- .
Rear left engine support eye points upwards -arrow-: n AG. Volkswagen AG Insert hook - 10-222 A /2- . Then connect hook 16- . Continuation for all Raise vehicle.
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-10-222 A
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Take up weight of engine/gearbox assembly on spindles. Remove noise insulation General body repairs, exterior; Rep. Gr. 50 ; Noise insulation . Remove lower part of front left wheel housing liner General body repairs, exterior; Rep. Gr. 66 ; Wheel housing liner . Then remove all lines from gearbox. Gearboxes for vehicles with start-stop system: pull connector -arrow- from gearbox neutral position sender -G701- .

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Separate connection -arrow 1- or -arrow 2- on charge air hose Rep. Gr. 21 ; Charge air system with turbocharger .
192
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Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 Remove drive shaft heat shield, if present -arrows- Running gear, axles, steering; Rep. Gr. 40 ; Repairing drive shafts; Removing and installing drive shafts .
oe wa not as pos Remove drive shaftsV from high olks flange shafts, raise as s gu y b not damage the surface protection ara sible and secure.ed Do nte s i r Running gear, axles, steering; Rep. Gr. 40 ; Removing and o eo h t u ra installing drive c s a shafts .
Separate exhaust system at double clamp and remove ex haust pipe bracket from subframe Rep. Gr. 26 ; Removing and installing parts of exhaust system .
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Tilt engine/gearbox assembly by lowering it via spindles of support bracket -10 - 222 A- . Note Lower threaded spindle of adapter -10 - 222 A /16- using wing
ed nut, but not more than until spindle is flush with nut -arrow-.
Be careful of all lines when lowering gearbox. Securing bolts -arrows- for gearbox bracket -A- must be ac cessible.
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Remove hexagon bolts -arrows- for left assembly mounting from gearbox mounting.
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193
Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 Remove gearbox bracket -A- -arrows-.
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-1- = Flange bolt M6 x 20. Secure engine support -3300 A- to bracket -T10346- .
Place a cloth between engine support -3300 A- and oil pan.
194
AG.
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Remove starter Electrical system; Rep. Gr. 27 ; Starter .
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If exhaust system strut -1- is fitted, remove it from gearbox -arrow-.

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5-speed manual n AG. Volkswagen AG do es n wage s k l ot g o V ua by forwards using spindle of engine ran Press engine support -3300 ed tee ris o A- . In hthe process, observe the following points in particular: t o ra au c ss The air conditioning compressor -2- must not contact -arrowthe refrigerant line -1-. The alternator must not contact the refrigerant line. The pressure pipe must not contact the radiator.
Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... gearbox 0A4 - Edition 04.2010
Note
Check that adapters -10 - 222 A /8- are completely located on
longitudinal members -arrows-. of support bracket -10-222 A- .
If necessary, correct position of adapters using front spindle To remove gearbox 0A4, set up gearbox support -3282- with adjustment plate -3282/39- .
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Insert gearbox support -3282- in engine and gearbox jack V.A.G 1383A- . Align arms of gearbox support according to holes in adjust ment plate . Screw in support elements -A - and -C- on adjustment plate as shown. Position engine and gearbox jack under vehicle. Arrow -B- on adjustment plate points in direction of vehicle travel.
AG.
Align adjustment plate parallel to gearbox and lock safety sup port on gearbox. Then screw pin -3282/29- into hole on gearbox for securing bolt of pendulum support. Remove lower engine/gearbox connecting bolts. Separate exhaust system if lower bolts -arrows- cannot be re moved.
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195
Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 Rep. Gr. 26 ; Removing and installing parts of the exhaust system
Press gearbox off dowel sleeves and carefully swing towards subframe. Turn gearbox downwards in vicinity of differential.
Carefully lower gearbox, guiding right-hand flange shaft -Apast dowel sleeve -arrow- in cylinder block as shown.
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Guide left flange shaft -B- past subframe bracket -arrow- as shown. When lowering gearbox, change position of gearbox using spindles of gearbox support -3282- . Note
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5.2
Note
Installing gearbox
196
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Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 Observe the following table on the subject of checking and top ping up gear oil. Checking and topping up gear oil Gearbox Original part No oil loss Completely dismantled No X X X Before in stallation Item 3 (page 250) Oil capacity page 5 X After instal lation AG. Volkswagen AG d agen oes ksw not l o V gu by page 220 ara d e Yes Yes
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All threaded holes into which self-locking bolts are to be screwed must be cleaned of residual locking fluid carefully with a thread tap. Always renew self-locking bolts and nuts. Check whether dowel sleeves for aligning engine and gearbox are fitted in cylinder block and install if necessary. If dowel sleeves are not fitted, difficulties shifting gears, clutch problems and possible noises from the gearbox (rattling of gears which are not engaged) could occur. Ensure that intermediate plate is correctly seated on engine.
Clean input shaft splines and apply thin coat of grease for clutch plate splines -G 000 100- . The clutch plate must slide easily to and fro on the input shaft.
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In the process, position bracket -T10346- at the same angle as the engine. -1- = Flange bolt M6 x 20. Secure engine support -3300 A- to bracket -T10346- .
197
Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 Press engine forwards using spindle of engine support -3300 A- . In the process, observe the following points in particular: AG. Volkswagen
ks The air conditioning compressor -2- musty not Vol contact -arrowb d e the refrigerant line -1-. ris
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The pressure pipe must not contact the radiator.
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Note
Check that adapters -10 - 222 A /8- are completely located on
longitudinal members -arrows-. of support bracket -10-222 A- .
If necessary, correct position of adapters using front spindle To install gearbox 0A4, set up gearbox support -3282- with ad justment plate -3282/39- . Align arms of gearbox support according to holes in adjust ment plate . Screw in support elements -A - and -C- ( pin -3282/29- ) on adjustment plate as shown. Align adjustment plate and gearbox parallel to one another.
AG.
Prote cted by
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Place gearbox on engine and gearbox jack .
Screw pin -3282/29- into hole on gearbox for securing bolt of pendulum support. Position engine and gearbox jack under vehicle. -Arrow B- on adjustment plate points in direction of vehicle travel. Using spindles of gearbox support -3282- , tilt gearbox down wards in vicinity of differential.
198
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n AG d en AG Carefully lift gearbox, guiding flange shaft agright-hand oes -A- past ksw not l o V block -arrow- as shown. gu dowel sleeve in cylinder y b a
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Guide left flange shaft -B- past subframe bracket -arrow- as shown. Using spindles of gearbox support -3282- , tilt gearbox up wards in vicinity of differential. Raise gearbox to engine. Align gearbox to engine and join.
Screw in lower engine/gearbox securing bolts and tighten to specified torque page 203 .
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After gearbox has been bolted to engine, remove engine and gearbox jack from gearbox. Remove engine support -3300 A- and bracket -T10346- .
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If small cover plate had been installed behind the right-hand flange shaft -A-, install it -arrows-. Screw in upper engine/gearbox securing bolts and tighten to specified torque page 203 .
199
Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 Align engine and gearbox in installation position using both spindles of support bracket -10 - 222 A- . Install new bolts -arrows- for left assembly mounting in gear box mounting and tighten to specified torque page 203 . WARNING
Do not remove support bracket -10 - 222 A- until the bolts se curing the left and right assembly mountings have been tight ened to specified torque.
AG. Volkswagen AG d agen oes ksw not l o gu yV Note b ara d e nte is r o eo th ra Install engine and gearbox mounting free sof au tension Rep. Gr. c s 10 ; Removing and installing engine .
Install slave cylinder and tighten bolts -arrows B- to specified torque Item 9 (page 104) . Then install gearbox support -arrow A- and tighten to specified torque page 203 . Then install drive shafts Running gear, axles, steering; Rep. Gr. 40 ; Removing and installing drive shafts .
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Install pendulum support Running gear, axles, steering; Rep. Gr. 40 ; Repairing front suspension . Assemble exhaust system and attach exhaust system bracket to subframe Rep. Gr. 26 ; Removing and installing parts of exhaust system .
200
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Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 If exhaust system strut -1- was removed, bolt it onto gearbox and tighten bolt -arrow- to specified torque Rep. Gr. 26 ; Exhaust system .
Install charge air hose -arrow 1- or -arrow 2- Rep. Gr. 21 ; Charge air system with turbocharger .
Gearboxes for vehicles with start-stop system: join connector -arrow- to gearbox neutral position sender -G701- .
Reconnect reversing light connector -arrow 1-. Install starter, push on connector -arrow 2- and bolt on wire -arrow 3- Electrical system; Rep. Gr. 27 ; Starter . Install earth strap at upper engine/gearbox connecting bolt.

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Prote cted by
201
Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 Attach support -B- to gearbox. Press pipe/hose line -A- into retainer -B- on gearbox. Install cable support bracket on gearbox and tighten bolts -arrows- to specified torque Item 6 (page 131) .
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Install gearbox selector lever -A-. Tighten hexagon nut -arrow 4- to specified torque Item 18 (page 132) . Spread a small amount of grease on pin of gearbox selector lever -A-. Allocate grease using Electronic parts catalogue (ETKA) . Connect gear selector cable to gearbox selector lever -arrow 1-.
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Metal relay lever
Install relay lever -B- and secure with securing clip -arrow 3-. Allocate grease using Electronic parts catalogue (ETKA) . Connect gate selector cable to relay lever -arrow 2-. Plastic relay lever Install relay lever together with cable end-piece page 134 . Continuation for all Adjust selector mechanism page 139 . Install front wall of plenum chamber General body repairs, exterior; Rep. Gr. 50 ; Noise insulation .
AG.
202
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Spread a small amount of grease on pin of relay lever -B-.
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Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 Install noise insulation -5- on front wall of plenum chamber. Install valve block -4- on front wall of plenum chamber -arrow-. Install battery tray, battery cover and battery -3- Electrical system; Rep. Gr. 27 ; Removing and installing battery . Install complete air filter housing -1- with intake hose -2- Rep. Gr. 23 . Install engine cover. Reconnect battery and perform work required after connecting battery Electrical system; Rep. Gr. 27 ; Disconnecting and connecting battery . Install lower part of front left wheel housing liner General body repairs, exterior; Rep. Gr. 66 ; Wheel housing liner . Install noise insulation General body repairs, exterior; Rep. Gr. 50 ; Noise insulation .
5.2.1
Item 1 2
Torque settings
Bolt M 12 x 55 M 12 x 150 Additionally, start er to gearbox
Gearbox to engine
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n AG. Volkswagen AG do es n wage s k l ot g o yV ua b ran ed s i tee r o Quantity Nm h t or u ac a ss 2 80
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80
3 4 5
M10 x 50 M12 x 60 M6 x 8 Small flywheel cover plate
3 1 1
40 80 10
Item -A- dowel sleeves for centring Gearbox bracket to gearbox Renew bolts.
Tighten bolts to specified torque. Bolts -arrows-
Screw in all bolts hand-tight.
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40 Nm + 90
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203
Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 Gearbox mounting to body Renew bolts. Screw in all bolts hand-tight. Tighten bolts to specified torque. Bolts -arrows60 Nm + 90
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204
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Removing and installing gearbox, Passat
Special tools and workshop equipment required Support bracket -10 - 222 A Adapter -10 - 222 A /8 Gearbox support -3282-
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6. Removing and installing gearbox, Passat
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205
Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... swagen A04.2010 lkEdition . Vo5-speed manual gearbox 0A4 Gd gen AG Adapter -10
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206
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Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 Adjustment plate -3282/39 Support elements for gear box (determine when set ting adjustment plate on gearbox support ) Engine and gearbox jack V.A.G 1383A Torque wrench -V.A.G 1331 Torque wrench -V.A.G 1332 Gearbox lifting tackle -3336- for transporting gearbox Grease for clutch plate splines -G 000 100 Allocate grease using Electronic parts catalogue (ETKA) .
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6.1
Removing gearbox
First check whether a coded radio is fitted. If so, obtain antitheft code. With ignition switched off, disconnect battery Electrical sys tem; Rep. Gr. 27 ; Disconnecting and connecting battery . If the lifting eyes of the engine for support bracket -10 - 222 Aare covered by a component, for example the air filter, it must be removed now. Rep. Gr. 23 ; Repairing diesel direct in jection system or Rep. Gr. 24 ; Repairing injection system
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Then remove complete air filter housing Rep. Gr. 23 or Rep. Gr. 24 .
AG.
Remove battery, battery cover and battery tray Electrical system; Rep. Gr. 27 ; Removing and installing battery . Remove securing clip -arrow 1- for gear selector cable from gearbox selector lever -A-.
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207
ks Vol by d e Pull gear selector cable ris ho t u alever Metal relay ss
Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... lkswag n AG d 04.2010 5-speed manual gearbox -e Edition n AG. Vo0A4 oe wage off pin.
Remove securing clip -arrow 2- for gate selector cable from relay lever -B-. Pull gate selector cable from pin.
Pull securing clip -arrow 3- off relay lever -B- and remove relay lever. Plastic relay lever Remove relay lever together with cable end-piece page 134 . Continuation for all Remove gearbox selector lever -A- by removing nut -arrow 4-.
Remove cable support bracket from gearbox -arrows-. Then raise and secure gear selector cable and gate selector cable. Remove bracket -B- from gearbox and pull it off pipe/hose line -A-.
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208
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AG.
Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 Pull off reversing light connector -arrow 1-. Now remove connector -arrow 2- and wire -arrow 3- from starter. Then remove upper securing bolt on starter. Remove upper engine/gearbox connecting bolts. If there are hose and cable connections in area of engine sup port eye for support bracket -10 - 222 A- , remove these now.
Set up support bracket -10 - 222 A- together with adapters -10 - 222 A /3- and adapters -10 - 222 A /8- in front of bonnet struts. Take up weight of engine/gearbox assembly on spindles. Raise vehicle.
AG. Volkswagen AG d agen oes ksw not l o gu exterior; Remove noisebinsulation General body repairs, yV ara d nte Rep. Gr. 50 ise; Noise insulation . r o eo h t u ra a lower part of front left wheel housing liner General Remove c s s
body repairs, exterior; Rep. Gr. 66 ; Wheel housing liner .
Then remove all lines from gearbox.
Gearboxes for vehicles with start-stop system: pull connector -arrow- from gearbox neutral position sender -G701- .
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Remove drive shaft heat shield, if present -arrows- Running gear, axles, steering; Rep. Gr. 40 ; Repairing drive shafts; Removing and installing drive shafts . Disconnect drive shafts from flange shafts and tie up as high as possible, being careful not to damage surface protection. Separate exhaust system at double clamp and remove ex haust pipe bracket from subframe Rep. Gr. 26 ; Removing and installing parts of exhaust system .
AG.
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209
Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 If front vehicle level sender -G78- -arrows- is present, remove it Rep. Gr. 40 ; Removing and installing front left vehicle level sender -G78- . Remove left and right coupling rods from anti-roll bar.
Unscrew nuts -arrows- for swivel joint and suspension links.
Remove steering box from subframe raise and tie. Fix position of subframe prior to removal Running gear, axles, steering; Rep. Gr. 40 ; Assembly overview - subframe, anti-roll bar, suspension links; Fixing position of subframe and brackets . Remove subframe with pendulum support, anti-roll bar and suspension links Running gear, axles, steering; Rep. Gr. 40 ; Assembly overview - subframe, anti-roll bar, suspension links . Remove hexagon bolts -arrows- for left assembly mounting from gearbox mounting. Tilt engine/gearbox assembly by lowering it via spindles of support bracket -10 - 222 A- . Securing bolts -arrows- for gearbox bracket -A- must be ac cessible.
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Remove pendulum support from gearbox, bolt -2- and bolt -3-.
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Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 Remove gearbox bracket -A- -arrows-.
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Remove exhaust system strut -1-, if present, from gearbox and, as necessary, from exhaust system -arrow- (attachment to exhaust system is not visible in figure). Remove starter Electrical system; Rep. Gr. 27 ; Starter . To remove gearbox 0A4, set up gearbox support -3282- with adjustment plate -3282/39- .
Insert gearbox support -3282- in engine and gearbox jack V.A.G 1383A- .
Align arms of gearbox support according to holes in adjust ment plate .
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Screw in support elements -A - and -C- on adjustment plate as shown.

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Position engine and gearbox jack under vehicle. Arrow -B- on adjustment plate points in direction of vehicle travel.
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211
Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 Align adjustment plate parallel to gearbox and lock safety sup port on gearbox. Then screw pin -3282/29- into hole on gearbox for securing bolt of pendulum support. Remove lower engine/gearbox connecting bolts. Separate exhaust system if lower bolts -arrows- cannot be re moved.
Rep. Gr. 26 ; Removing and installing parts of the exhaust system Press gearbox off dowel sleeves and carefully lower. When lowering gearbox, change position of gearbox using spindles of gearbox support -3282- . Note

6.2
Note
Installing gearbox
Observe the following table on the subject of checking and top ping up gear oil . Checking and topping up gear oil No X X X Before in stallation Item 3 (page 250) Oil capacity page 6 X After instal lation page 220
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Yes
Yes
Gearbox
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th Always renew self-locking bolts and aunuts.
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Check whether dowel sleeves for aligning engine and gearbox are fitted in cylinder block and install if necessary. If dowel sleeves are not fitted, difficulties shifting gears, clutch problems and possible noises from the gearbox (rattling of gears which are not engaged) could occur. Ensure that intermediate plate is correctly seated on engine. Clean input shaft splines and apply thin coat of grease for clutch plate splines -G 000 100- . The clutch plate must slide easily to and fro on the input shaft. To install gearbox 0A4, set up gearbox support -3282- with ad justment plate -3282/39- . Align arms of gearbox support according to holes in adjust ment plate . Screw in support elements -A - and -C- ( pin -3282/29- ) on adjustment plate as shown. Place gearbox on engine and gearbox jack . Align adjustment plate and gearbox parallel to one another.
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Screw pin -3282/29- into hole on gearbox for securing bolt of pendulum support. Position engine and gearbox jack under vehicle. -Arrow B- on adjustment plate points in direction of vehicle travel. Raise gearbox to engine. Have a second mechanic push engine forwards slightly. Align gearbox to engine and join. Screw in lower engine/gearbox securing bolts and tighten to specified torque page 217 . After gearbox has been bolted to engine, remove engine and gearbox jack from gearbox. If small cover plate -A- had been installed behind the right flange shaft -arrows-, install it. Screw in upper engine/gearbox securing bolts and tighten to specified torque page 217 .
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213
Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 Install bracket -A- on gearbox using new hexagonal bolts -arrows- and tighten to specified torque page 217 .
Align engine and gearbox in installation position using both spindles of support bracket -10 - 222 A- . Install new bolts -arrows- for left assembly mounting in gear box mounting and tighten to specified torque page 217 . WARNING
Do not remove support bar -10-222 A- until all bolts securing the left and right assembly mountings have been tightened to specified torque.
Note
Attach drive shafts to gearbox Running gear, axles, steer ing; Rep. Gr. 40 ; Repairing front suspension .
s olkRunning Install drive shaft heat shield, if present -arrows-y V b d gear, axles, steering; Rep. Gr. 40 ; Repairing e drive shafts; ris Removing and installing drive shafts . utho
Attach steering box to subframe Running gear - front and four-wheel drive; Rep. Gr. 48 .
Install subframe and suspension links s with pendulum support Running gear, axles, steering; Rep. Gr. 40 ; Assembly overview - subframe, anti-roll bar, suspension links .
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Attach pendulum support to gearbox bolt -2- and bolt -3- Running gear, axles, steering; Rep. Gr. 40 ; Repairing front wheel suspension .
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Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 If front vehicle level sender -G78- -arrows- is present, install it Rep. Gr. 40 ; Removing and installing front left vehicle level sender -G78- . Assemble exhaust system and attach exhaust system bracket to subframe Rep. Gr. 26 ; Removing and installing parts of exhaust system .
Attach exhaust system strut -1-, if present, to gearbox and ex haust system and tighten bolts -arrow- to specified torque (attachment to exhaust system is not visible in figure). Rep. Gr. 26 ; Removing and installing parts of exhaust system . wagen AG. Volkswagen AG doe
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Gearboxes for vehicles with start-stop system: join connector -arrow- to gearbox neutral position sender -G701- .
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Then install gearbox support -arrow A- and tighten to specified torque page 217 .
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Install slave cylinder and tighten bolts -arrows B- to specified torque Item 9 (page 104) .
215
Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 Reconnect reversing light connector -arrow 1-. Install starter, push on connector -arrow 2- and bolt on wire -arrow 3- Electrical system; Rep. Gr. 27 ; Starter . Install earth strap at upper engine/gearbox connecting bolt.
Install cable support bracket on gearbox and tighten bolts -arrows- to specified torque Item 6 (page 131) .
Press pipe/hose line -A- into retainer -B- on gearbox.
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Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 Install gearbox selector lever -A-. Tighten hexagon nut -arrow 4- to specified torque Item 18 (page 132) . n AG. Volkswagen A
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Connect gear selector cable to gearbox selector lever -arrow 1-.
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Install relay lever -B- and secure with securing clip -arrow 3-. Spread a small amount of grease on pin of relay lever -B-. Allocate grease using Electronic parts catalogue (ETKA) . Connect gate selector cable to relay lever -arrow 2-. Plastic relay lever Continuation for all Install relay lever together with cable end-piece page 134 . Adjust selector mechanism page 139 . Install battery tray, battery cover and battery Electrical sys tem; Rep. Gr. 27 ; Removing and installing battery .
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Install engine cover.
Install lower part of front left wheel housing liner General body repairs, exterior; Rep. Gr. 66 ; Wheel housing liner . Install noise insulation General body repairs, exterior; Rep. Gr. 50 ; Noise insulation . For vehicles with front vehicle level sender -G78- , check headlight adjustment Electrical system; Rep. Gr. 94 ; Lights, lamps, switches - exterior .
6.2.1
Item 1 2
Torque settings
Bolt M 12 x 55 M 12 x 150 Additionally, start er to gearbox M10 x 50 M12 x 60 M6 x 8 Small flywheel cover plate Quantity 2 2 Nm 80 80
Gearbox to engine
3 4 5
3 1 1
40 80 10
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Reconnect battery and perform work required after connecting battery Electrical system; Rep. Gr. 27 ; Disconnecting and connecting battery .
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Install complete air filter housing Rep. Gr. 23 or Rep. Gr. 24

217
Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 Gearbox bracket to gearbox Renew bolts. Screw in all bolts hand-tight. Tighten bolts to specified torque. Bolts -arrows40 Nm + 90
Gearbox mounting to body Renew bolts. Screw in all bolts hand-tight. Tighten bolts to specified torque. Bolts -arrowsAG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h ut ra a c s s
60 Nm + 90
Gearbox support to gearbox bracket and gearbox Renew bolts. Screw in all bolts hand-tight. Bolts -arrows-
Tighten bolts to specified torque.
20 Nm + 90
Drive shaft to flange shaft Running gear, axles, steering; Rep. Gr. 40 ; Repairing drive shaft; Removing and installing drive shafts .
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Transporting gearbox
Special tools and workshop equipment required Gearbox mounting support -3336-
Bolt gearbox lifting tackle -3336- to clutch housing.
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Adjust support beam on sliding piece using locking pin -arrow-. Raise gearbox using workshop crane and gearbox lifting tack le -3336- .
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Number of holes visible = 5.

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Set gearbox aside, for example in a transport container.

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7. Transporting gearbox
219
Checking and topping up gear oil
It is not possible to check the gear oil level by unscrewing the oil filler plug.
The angle of the engine/gearbox unit means the lower edge of the fill hole -arrow 1- is below the oil level -arrow 2-. The oil level in the gearbox can only be checked by completely draining the gear oil and then refilling:
Hose (approx. 600 mm long, external diameter 10 mm) with funnel, commercially available.
8.1
Preparation
Gear oil specification for manual gearboxes Electronic parts catalogue ETKA . Remove complete air filter housing Rep. Gr. 23 or Rep. Gr. 24 . Remove noise insulation General body repairs, exterior; Rep. Gr. 50 ; Noise insulation .
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220
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Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 Clean gearbox. Caution
To drain gear oil, a pivot pin for the selector forks in the gearbox must be removed. To prevent the positions of the selector forks from being changed, e.g. due to accidental operation of the selector mech anism, the selector shaft must be locked in position. AG. Volkswagen AG d agen o
Secure selector shaft as follows:
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Press selector shaft down -direction of arrow 1-.

While pressing down selector shaft, turn angled rod -A- in -direction of arrow 2- upwards and at the same time press it in until it engages in selector shaft.
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8.2
Draining gear oil

Use a clean container with a scale and a 3-litre capacity to catch the oil which runs out. Selector shaft is locked in place page 221
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Drain gear oil by removing oil drain plug -arrow 1- and then pivot pin -arrow 2-.
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Install pivot pin -arrow 2- with a new O-ring Item 7 (page 226) .
Screw in oil drain plug -arrow 1- Item 17 (page 251) . Now turn angled rod -A- back to original position -direction of arrow- so that selector shaft can move again.
AG.
8. Checking and topping up gear oil
221
8.3
Fill with gear oil
Top up oil in container to 1.7 litres. Gear oil specification for manual gearboxes Electronic parts catalogue ETKA . Remove reversing light switch -F4- -arrow-. Connect hose (approx. 600 mm long, external diameter 10 mm) to commercially available funnel. Insert hose in fitting hole for reversing light switch (2nd me AG. Volkswagen AG d agen oes chanic) and fill gear oil. n lksw
b ed-arrow Install reversing light switch -F4ris o h Item 2 (page 256) . ut
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Install complete air filter housing Rep. Gr. 23 or Rep. Gr. 24
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s Check operation of selector mechanism page 142 .
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9
9.1
1 - 1st gear 2 - 2nd gear 3 - 3rd gear 4 - 4th gear 5 - 5th gear
Dismantling and assembling gearbox

Overview - gearbox
6 - Gearbox housing cover 7 - Gearbox housing 8 - Selector mechanism (Selector forks) 9 - Reverse gear 10 - Clutch housing 11 - Input shaft 12 - Output shaft 13 - Differential

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9. Dismantling and assembling gearbox
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9.2
Assembly overview
Dismantling and assembling procedure page 234 I - Removing and installing cover for gearbox housing and 5th gear page 225 . II - Removing and installing gearbox housing and selector mechanism page 226 III - Removing and installing in put shaft, output shaft, differ ential and selector forks page 227
ag Assembly sequence - remov ksw Vol y ing and installing cover for b ed gearbox housing and 5th gear horis t page 228 . au
Assembly sequence - Disman tling and assembling gearbox completely page 234 .
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9.3
Removing and installing cover for gearbox housing and 5th gear
1 - Bolt, 18 Nm For gearbox housing cover. 2 - Gearbox housing cover Note 3 - Seal 4 - Bolt, 80 Nm + turn 90 fur ther Always renew Fitted section of bolt head holds dished spring washer in posi tion Clean residual locking fluid from threaded holes for synchro-hub securing bolts and 5th gear wheel with a thread chaser. Otherwise the bolts may shear. 5 - Dished washer Installing page 246
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7 - Pivot pin
6 - Socket head bolt, 25 Nm For pivot pin to gearbox housing
8 - 5th gear selector fork Dismantling and assem bling page 258 Adjusting page 247 9 - Spring Version with bent ends. Installing page 270 10 - Locking collar for 5th gear Installation position page 269 Adjusting page 247 11 - Locking pieces (Qty. 3) Installation position page 269
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12 - Synchro-hub with synchromeshed gear and synchronizing ring for 5th gear Pull off together with gearbox housing page 234 Pull off individually page 228 Dismantling and assembling page 269 13 - Needle bearing 14 - Gear wheel for 5th gear Pull off together with gearbox housing page 234 Pull off individually page 228
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Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 Installation position page 245
9.4
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1 - Countersunk bolt, 25 Nm 2 - Flange shaft with compres sion spring Removing and installing page 294 Assembling page 303 3 - Torx socket head bolt, 25 Nm For reverse shaft sup port. Self-locking Always renew 4 - Torx socket head bolt, 30 Nm For reverse shaft sup port Self-locking Always renew 5 - O-ring Always renew 6 - Pivot pin 7 - Bolt, 25 Nm 8 - Bolt, 25 Nm 9 - Cover plate 10 - Multi-point socket head bolt 25 Nm For reverse shaft sup port. Always renew 11 - Bolt, 5 Nm 12 - Gearbox neutral position sender -G701 for vehicles with start/stop system 13 - Gearbox housing Pull off together with 5th gear page 234 Repairing page 248 14 - Clutch housing Repairing page 248 15 - Hexagon bolt, 25 Nm and turn 90 further Always renew 16 - Selector shaft with selector shaft cover (Selector unit) Repairing page 255 17 - Multi-point socket head bolt 25 Nm
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9.5
Removing and installing input shaft, output shaft, differential and selector forks
1 - Differential Dismantling and assem bling page 303 2 - Seal Qty. 4 Always renew 3 - Output shaft Dismantling and assem bling page 275 4 - Reverse shaft support Dismantling and assem bling page 291 5 - Reverse shaft Dismantling and assem bling page 291 6 - Input shaft Dismantling and assem bling page 263 7 - Selector fork for reverse gear Dismantling and assem bling page 258 Installation position page 241 8 - Torx socket head bolt, 25 Nm

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10 - Clutch housing Repairing page 248 11 - Hexagon nut, 25 Nm and then turn 90 further 4 nuts for bearing support. Always renew 12 - Flange shaft with compression spring Removing and installing page 294 Assembling page 303 13 - Countersunk bolt, 25 Nm
AG.
9 - Selector mechanism (Selector forks) Dismantling and assem bling page 258
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9.6
Assembly sequence - removing and in stalling cover for gearbox housing and 5th gear
Note
Follow the working procedure described below if only the 5th
gear has to be removed:
Special tools and workshop equipment required Support plate -VW 309 Gearbox support -VW 353 Drift -VW 295 Drift sleeve -VW 244 B Hot air blower -V.A.G 1416 Torque wrench -V.A.G 1331 -Zweiarmabzieher Kukko 210.1 -Stehbolzen M 8 x 100 mmr fo ng
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228
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Support bridge -30-211A Thrust piece -32 - 111 Thrust piece from assembly tool -T10030/4 Tube -VW 416 B Puller -T10309 Two arm puller -T10040 With puller hooks T10040/2A Thrust piece -T10040/3-
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229
Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 Support device -T10323 Assembly tool -3253/7 Thrust piece -VW 433 Thrust plate -40 - 105 Torque wrench -V.A.G 1332-
Remove clutch release lever and release bearing page 103 .
9.6.1
Removing

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Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 Bearings of input shaft and output shaft must not be damaged when 5th gear is removed and installed. Therefore, following tools must be mounted for support at this stage during attachment of gearbox to gearbox support -VW 353- :
Underneath input shaft: Support bridge -30-211A Thrust piece -32 - 111 Thrust piece -T10030/4 The input shaft can be supported by the thrust piece -32 - 111only at a later point.
Underneath bearing support for output shaft: Support device -T10323 Assembly tool -3253/7 Thrust piece -VW 433 Secure gearbox on gearbox support
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Remove gearbox housing cover -arrow-.
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231
Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 Check whether puller hooks -T10040/2A- can be inserted cor rectly under 5th gear wheel. Puller hooks -T10040/2A- cannot be inserted correctly. -APuller hooks -T10040/2A- make contact too soon with: gearbox housing wall ribs in gearbox housing under gear wheel -BPuller hooks -T10040/2A- come into contact with ribs in gearbox housing below gear wheel. Puller hooks -T10040/2A- cannot be inserted correctly. 5th gear can be removed separately, from page 232 Removing 5th gear separately Cover openings with a cloth. Move selector fork -1- to neutral position. Remove bolt -2- with selector fork for 5th gear. Then remove both bolts -arrows- for pivot pins. Pull out pivot pins. Remove selector fork. Spring -3- and locking collar -4- do not need to be removed. olkswagen AG en AG. V
ag ksw Vol y b ed ris Remove bolts -A- for synchro-hub and gear wheel for 5th gear. o h t u To do this, engage 5th gear -arrow 1and 1st gear a ss -arrows 2- and -3does not gu ara nte eo ra c
Removal of synchro-hub for 5th gear, gear wheel for 5th gear and gearbox housing together page 234
After both gears are engaged, the input shaft and output shaft are locked. The synchro-hub and gear wheel cannot turn. Both bolts can now be loosened. Note
If shafts are not to be renewed, carefully clean residual locking material out of threaded holes using a thread chaser.
Pull off synchro-hub for 5th gear together with locking collar and locking pieces. Use puller -T10309- . First set half sleeve -T10309/1- between 5th gear wheel -Aand support for selector fork for 5th gear -B-.
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Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 The half sleeve -T10309/1- must be positioned beneath the synchro-ring.
If necessary, half sleeve must be pressed to end position. Then turn half sleeve -T10309/1- to opposite side -direction of arrow-.
Set threaded insert -T10309/3- in half shell . Now fit second half shell -T10309/1- and set tube -T10309/2n AG. Volkswagen AG do over assembly. e wage
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Remove 5th gear synchromeshed gear with needle bearing.
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Pull off gear wheel for 5th gear. (Shown here on another gear box.) First set up puller hooks -A-.
B - Thrust plate -40 - 105Note
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When pulling off gear wheel, ensure that hooks do not bend out wards. After pulling off gear wheel for 5th gear, examine for damage.
9.6.2
Installing
Install 5th gear page 244 . Apply sealant -AMV 188 200 03- evenly to sealing surface of gearbox cover. Install gearbox housing cover page 225 . Fit clutch release lever and release bearing page 103 . Top up gear oil page 150 .
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233
9.7
Assembly sequence - Dismantling and assembling gearbox completely
Removing and installing gearbox housing cover, gearbox hous ing, selector shaft with selector mechanism cover, input shaft, output shaft, differential and selector mechanism. Special tools and workshop equipment required Support plate -VW 309 Gearbox support -VW 353 Drift -VW 295 Drift sleeve -VW 244 Bpe rm itte d
Torque wrench V.A.G 1331 -Stehbolzen M 8 x 100 mm-
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Hot air blower -V.A.G 1416-
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Thrust piece -32 - 111 Thrust piece from assembly tool -T10030/4 Tube -VW 416 B Puller plate -T10408 Thrust pieces -T10408/2 Grips -T10408/3 Hexagon bolts M7 x 35 with washers Puller - 2 Kukko 18/1-
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Support bridge -30-211A-
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Support device -T10323 Assembly tool -3253/7 Thrust piece -VW 433 Torque wrench -V.A.G 1332-
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9.7.1

Removing
Remove clutch release lever, release bearing and guide sleeve page 103 . Bearings of input shaft and output shaft must not be damaged when 5th gear is removed and installed. Therefore, following tools must be mounted for support at this stage during attachment of gearbox to gearbox support -VW 353- :
Underneath input shaft: Support bridge -30-211A Thrust piece -32 - 111 Thrust piece -T10030/4 Lock bolt of support bridge -30-211A- with nut -A-. Underneath bearing support for output shaft: Support device -T10323 Assembly tool -3253/7 Thrust piece -VW 433-
236
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Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 Secure gearbox on gearbox support -VW 353- . Place drip tray -V.A.G 1306- underneath. Remove oil filler plug and oil drain plug. Drain gear oil.
Remove gearbox housing cover -arrow-.
Remove selector fork for 5th gear as Cover openings with a cloth.
Remove bolt -2- with selector fork for 5th gear. Then remove both bolts -arrows- for pivot pins. Pull out pivot pins. Remove selector fork.
Move selector fork -1- to neutral position.
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Spring -3- and locking collar -4- do not need to be removed. Remove bolts -A- for synchro-hub and gear wheel for 5th gear. To do this, engage 5th gear -arrow 1- and 1st gear -arrows 2- and -3-. After both gears are engaged, the input shaft and output shaft are locked. The synchro-hub and gear wheel cannot turn. Both bolts can now be loosened. Note
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If shafts are not to be renewed, carefully clean residual locking material out of threaded holes using a thread chaser.
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237
Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 Remove both bolts -arrows- for reverse shaft support bracket.
Now remove 3rd bolt -arrow- for reverse shaft support bracket.
Gearboxes for vehicles with start-stop system: remove gear box neutral position sender -G701- -arrow-.
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Remove selector shaft with selector mechanism cover, placing selector shaft in neutral position. Then remove bolts -arrowsand pull selector shaft out of gearbox housing.
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gen AG . en AG-B Remove cover plate -A- and pivot from underside does of agpins ksw not l o V gearbox. gu y b a
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Remove pivot pins -A- on top side of gearbox and securing bolts -B- for gearbox housing to clutch housing in area of dif ferential.
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Note
Do not remove nuts -B- for output shaft bearing support.
Remove both flange shafts. Remove flange shafts together with springs, thrust washers and tapered rings.
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Remove bolts -A- from clutch housing side for securing clutch housing to gearbox housing.
AG.
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Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 Pull off following components together with gearbox housing: Synchro-hub for 5th gear Gear wheel for 5th gear Both grips -T10408/3- must be secured on gear wheel for 5th gear. The grips must always be positioned above the two housing ribs, which are located opposite each other -arrows-.
AG. Volkswagen AG d agen oes ksw not l o gu yV b Note ara d e nte is r o eo h ut ra a There is a needle bearing beneath the gear wheel for 5th gear. c s s
Secure the grips so that the bearing does not come in contact
with the gear wheel for 5th gear when the gearbox housing is pulled off.
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Use puller plate -T10408- in conjunction with following special tools: Thrust pieces -T10408/2 Grips -T10408/3 Puller Kukko 18/1
Screw puller plate -T10408- firmly into threaded holes for gearbox housing cover. A - Hexagon bolts M7 x 35 with washers Torque setting 18 Nm Place thrust pieces -T10408/2- on shafts.
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Install pullers Kukko 18/1 -A-.
240
AG.
Heat gear wheel for 5th gear slightly with hot air blower V.A.G 1416- if necessary.
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Pull off 5th gear synchro-hub, gear wheel for 5th gear and gearbox housing by alternately tightening spindles -A- approx. 12 turn.
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Unbolt reverse gear selector mechanism -B-.
Remove selector forks -A- together with selector plates.
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AG. Volkswagen AG d agen oes ksw not l o gu yV b ar d e Golf 2004 nte Plus is , Golf 2009 , Golf Plus 2005 ,aGolf r o eo h 5-speed manual gearbox ut r a0A4 a c s s
2009 , Pass ... - Edition 04.2010
Remove nuts -B- for output shaft bearing support.
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Remove reverse gear -A-, input shaft -B- and output shaft -C- one after the other from clutch housing. Remove differential.
9.7.2
Installing
Install differential. Always renew sealing rings -arrows- for output shaft bearing support. Note
The figure shows only 3 of the 4 sealing rings.
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241
Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 Insert input shaft -1- and output shaft -2- together.
AG. Volkswagen AG d agen oes ksw not l o V gu Tighten nuts for output shaft bearing support to specified tor by ara d e nte is que Item 11 (page 227) . r o eo h ut ra a c s Set reverse gear wheel -3- on needle bearing in clutch hous s
ing.
The shoulder -arrow- faces away from the clutch housing. Ensure that reverse shaft -4- is complete page 291 ; do not yet fit reverse shaft support to reverse shaft. Fit reverse shaft into clutch housing. Clean locking fluid from all threaded holes in reverse shaft support; a thread chaser may be used. Install reverse shaft support.
Attach reverse gear selector fork -1- with support for reverse gear selector fork -2-, spring -3- and sliding piece -4-.
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Installation position, reverse gear
Bolt on reverse gear selector mechanism -A-. Install selector forks -B- together with selector plates. Reverse gear support -C- is located in front of selector plates.
242
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Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 Screw M 8 x 100 mm studs -A- into reverse shaft support so that shaft is aligned after gearbox housing is fitted. Align selector plates. Note
The selector segments must be positioned in the grooves on the locking collars.
Apply sealant -AMV 188 200 03- evenly to sealing surface of clutch housing. Fit gearbox housing. Install reverse shaft support bolts -arrow- as follows: Install bolt -a-. Remove stud -A- ( figure above). Install bolt -c-. Tightening sequence: Tighten bolt -a- to 30 Nm. Tighten bolt -b- ( figure below) to 25 Nm.
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Tighten bolt -c- to 25 Nm.
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Install pivot pin -arrow- for selector forks. Do this by aligning selector mechanism with a screwdriver so that respective pivot pin can be installed.
Apply sealant -AMV 188 200 03- evenly to sealing surface of cover plate. Fit selector shaft cover plate.
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243
Move selector shaft to neutral. Position selector shaft so that selector finger -arrow- is inser ted in selector plates. Bolt on selector shaft cover to specified torque Item 17 (page 226) . Gearboxes for vehicles with start-stop system: fit gearbox neutral position sender -G701- -arrow- and tighten securing bolt to specified torque Item 11 (page 226) .
agen AG AG. V does agen ksw not l o V gu Install selector shaft with selector shaft cover plate as follows: y ara db e nte is r o eo h Place selector plates in neutral. ut ra a c s s
Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 olksw
Apply sealant -AMV 188 200 03- evenly to sealing surface of selector shaft cover.

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Install both flange shafts with springs, thrust washers and ta pered rings page 224 .
AG.
9.7.3
Installing 5th gear
Ensure that support bridge -30-211A- and support device T10323- are attached.
Lock bolt of support bridge -30-211A- with nut -A-.
244
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Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 Installation position, gear wheel for 5th gear The circumferential groove -arrow- faces gearbox housing.
Drive on gear wheel for 5th gear.
Checking 5th gear synchro-ring Before installing synchromeshed gear and synchro-ring for 5th gear, press synchro-ring onto cone of synchromeshed gear and measure gap -a- with a feeler gauge. Gap -a5th gear Installation (new) di mension 1.1 1.7 mm
pe rm itte d
Wear limit
Place 5th gear synchro-ring on synchromeshed gear.

If synchro-hub and locking collar for 5th gear are dismantled, assemble before installing page 269 . Installation position 5th gear synchro-hub and locking collar The pointed teeth of the locking collar -arrow 1- and the high shoulder of the synchro-hub -arrow 2- face the gearbox housing. The synchro-hub supports -arrow 3- align with the cast locking pieces of the 5th gear synchro-ring ( page 246 , bottom).
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Install 5th gear synchromeshed gear with needle bearing.
AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo 0.5 mm h ut ra a c s s
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245
Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 5th gear synchro-ring with cast locking pieces Cover all openings in gearbox housing with a cloth to prevent foreign bodies from entering gearbox.
Drive on 5th gear synchro-hub. Note
When driving on synchro-ring, ensure that it moves freely.
Loosen support for input shaft. WARNING
Wear protective gloves!
Clean residual locking fluid from threaded holes for synchrohub securing bolts and 5th gear wheel with a thread chaser. Otherwise the bolts may shear. Screw in securing bolts for synchro-hub and gear wheel for 5th gear.
Installation position of dished springs for securing bolts for gear wheel and synchro-hub for 5th gear The outer circumference -arrows- faces 5th gear. Tighten securing bolts for synchro-hub and gear wheel for 5th gear to specified torque. page 225
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246
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Prote cted by
Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 Tighten bolts -A- for synchro-hub and 5th gear wheel to speci fied torque Item 4 (page 225) . To do this, engage 5th gear -arrow 1- and 1st gear -arrows 2- and -3-. After both gears are engaged, the input shaft and output shaft are locked. The synchro-hub and gear wheel cannot turn. Now both bolts can be tightened. Install 5th gear selector fork.
Adjusting 5th gear Engage 5th gear. Loosen bolt -1-. Push locking collar and se lector jaw in direction of arrow and then tighten bolt -1- to 25 Nm. Check measurement: It must not be possible to slide a 0.2 mm feeler gauge between locking collar and gear wheel. If neces sary, repeat adjustment.
Disengage 5th gear. Locking collar must now be in the neutral position. Synchro-ring must move freely. Shift through all gears. Install gearbox housing cover page 225 . Fit release bearing guide sleeve page 103 . Fit clutch release lever and release bearing page 103 . Top up gear oil, Golf 2004 page 150 Top up gear oil, Golf 2009 with turbo diesel engine page 163 Top up gear oil, Golf 2009 with petrol engine page 180 Top up gear oil, Golf Plus page 197 . Top up gear oil, Passat page
AG. Volkswagen AG d agen oes ksw not l o V gu 212 . by ara d e nte is r o eo h ut ra a c s s

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247
10
Repairing gearbox housing and clutch housing
Special tools and workshop equipment required Drift -VW 295 Adapter -VW 295 A Thrust pad -VW 447 H Thrust pad -VW 512 Tube -2040 Thrust piece -VW 454-

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248
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Puller -VW 228 B- (is not required for this gearbox) Drift -VW 222 A- (not re quired with this gearbox) Assembly device -3066(Spindle from assembly de vice) Thrust piece -3124- (for two-part seal and sleeve) Multipurpose tool -VW 771(for one-piece seal and sleeve) Extractor hooks VW 771/37- (for one-piece seal and sleeve)
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AG. Volkswagen AG d agen oes ksw not l o V g by ara Plus 2005 , Golf Plus d Golf 2004 , Golf 2009 ,uGolf e nte is r o e o manual gearbox 0A4 h 5-speed ut ra a c s s
2009 , Pass ... - Edition 04.2010
Multipurpose tool -T10148- (for one-piece seal and sleeve)
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10. Repairing gearbox housing and clutch housing
249
2 - Needle bearing For output shaft Removing page 252 Installing and securing page 252 . 3 - Oil filler plug, 35 Nm The oil level cannot be checked by removing the oil filler plug If the gearbox was dis mantled, it must be filled prior to installation Capacities, Golf 2004 page 2 Capacities, Golf 2009 page 4
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ag ksw Vol y b - Gearbox housing ed ris o h t out If renewed: adjust au put shaft and differential ss
Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... wagen AG 5-speed manual gearbox 0A4e-nEdition AG. Volks04.2010
page 302

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Capacities, Passat page 6 4 - Tapered roller bearing outer race For output shaft Removing and installing page 275 If replaced: adjust out put shaft page 287 5 - Shim For output shaft Adjustment overview page 302 6 - Shim For input shaft Adjustment overview page 270 7 - Tapered roller bearing outer race For input shaft Removing and installing page 263 If renewed: adjust input shaft page 270 8 - Tapered roller bearing outer race For input shaft Removing and installing page 263 If renewed: adjust input shaft page 270 9 - Needle bearing Removing and installing page 291 10 - Dowel sleeve Qty. 2
250
AG.
Prote cted by
Capacities, Golf Plus 2009 page 6 page 5
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Capacities, Golf Plus 2005 page 5
11 - Clutch housing When renewing, adjustment overview page 302 12 - Guide sleeve With input shaft seal and vulcanised O-ring Driving out oil seal page 252 Driving in oil seal page 252 Remove guide sleeve to change oil seal If O-ring is damaged, renew guide sleeve and O-ring together 13 - Socket head bolt Removing and installing Item 6 (page 103) 14 - Seal Renewing page 296 15 - Sleeve For seal Item 14 (page 251) Removing page 253 Installing page 253
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AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h Golf 2004 , Golf 2009 , Golf Plus 2005 ut r ac a s s
, Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010
17 - Oil drain plug, 35 Nm 18 - Tapered roller bearing outer race For differential Removing and installing page 303 If renewed, adjust differential page 311 19 - Magnet Held in place by housing joint surface 20 - Oil collector Installing oil collector in gearbox housing page 254 21 - Tapered roller bearing outer race For differential Removing and installing page 303 If renewed, adjust differential page 311 22 - Shim For differential Adjustment overview page 302 23 - Seal Renewing page 294
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16 - One-piece seal and sleeve If seal is damaged, renew seal and sleeve together Removing page 253 Installing page 253
AG.
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251
Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 Driving out needle roller bearing
Driving needle bearing in to stop Secure needle bearing in gearbox housing at three points (120 offset) using a punch.
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Driving oil seal out of guide sleeve
Driving oil seal into guide sleeve to stop
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252
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Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 Levering out sleeve -arrowusing screwdriver
Pulling in sleeve
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Screw spindle -A- of assembly device -3066- into threaded piece of differential. Pull sleeve in to stop using thrust piece -3124- by turning nut -B-. Note
With gearbox dismantled, press sleeve in to stop using thrust piece -3124- .
Pulling out sleeve and seal
There is a shoulder in the inner diameter of the sleeve.

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To pull out seal and sleeve, apply extractor hooks -VW 771/37behind shoulder in sleeve.
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Press extractor hooks -VW 771/37- forcefully into sleeve while pulling.
AG.
Pulling in sleeve and seal Clean seat for seal in gearbox. Screw spindle -A- of assembly device -3066- into threaded piece of differential. Pull sleeve in to stop using thrust piece -T10148- by turning nut -B-. Note
With gearbox dismantled, press sleeve in to stop using thrust piece -T10148- .
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253
Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 Installing oil collector -A- in gearbox housing Insert oil collector in hole -arrow 1- and groove -arrow 2- si multaneously.

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AG.
254
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11
n AG. Volkswagen AG do es n wage s k l ot g o yV ua b ran ed s i tee r o h t or , Golf Plus u Golf 2004 , Golf 2009 , Golf Plus 2005 ac a ss 5-speed manual gearbox 0A4
2009 , Pass ... - Edition 04.2010
Repairing selector unit
Special tools and workshop equipment required Tube -T10203-
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Tube -VW 423-
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11. Repairing selector unit
255
Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 1 - Selector unit Consists of selector shaft and selector shaft cover Components cannot be separated from each other 2 - Reversing light switch -F4 Tighten to 20 Nm Lightly coat lug with MoS2 grease. 3 - Angled rod For adjusting selector mechanism Removing page 257 Pressing in page 257 4 - Relay lever Installation position page 134 From 05.07, plastic re lay lever page 134 5 - Bearing bush Not required for plastic relay lever 6 - Seal Lever out with a screw driver Installing page 257 7 - Hexagon nut, 23 Nm Self-locking Always renew
8 - Gearbox selector lever Install so that master spline aligns with selector shaft Can be renewed with the selector mechanism installed Installation position page 134 9 - Cap For gearbox breather
10 - Securing clip Always renew Not required for plastic relay lever 11 - Cover plate
12 - Spring Not installed in all gearboxes. Reinstall if part of original equipment.
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256
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Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 Removing angled rod -A- from selector shaft cover Remove outer part of angled rod. Then carefully lever out angled rod using a screwdriver.
Pressing angled rod -AInstallation position:
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Marking -arrow- points to upper part of selector shaft.
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AG. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o eo h into selector shaft cover t u ra a c s s
Inserting oil seal to stop
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11. Repairing selector unit
257
12
Dismantling and assembling selector forks

Special tools and workshop equipment required Thrust plate -VW 402 Thrust piece -3290/1 Thrust piece -VW 431es, in part or in w l purpos hole ercia , is n m ot com
Spacer sleeve -VW 472/2 Drift -10 - 206-
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Assembly tool -3301-
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Removal lever -80200-
258
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Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 Drift -10 - 508-
Clamp -2070-
Note
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12. Dismantling and assembling selector forks
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It is not necessary to dismantle the selector fork group ( Item 7 (page 260) ) in order to remove and install selector segments, lock washers and angular contact ball bearings.
259
Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 1 - 5th gear selector segment Identification page 261 After lock washer is in stalled, selector seg ment must still rotate freely. 2 - Lock washer Always renew Removing page 261 Installing page 261 3 - 5th gear selector fork Adjusting. 4 - Bolt, 25 Nm 6 - Angular contact ball bearing Qty. 4 Removing page 261 Press inner race into outer race page 262 Installing page 262 7 - Selector fork group with se lector plate 8 - Selector segment for 1st and 2nd gears Identification page 261 After lock washer is in stalled, segment must still rotate freely
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5 - 5th gear selector jaw
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11 - Spring 12 - Selector fork for reverse gear 13 - Support for reverse gear selector fork 14 - Retaining ring
260
AG.
10 - Sliding piece
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9 - Selector segment for 3rd and 4th gears Identification page 261 After lock washer is installed, segment must still rotate freely
Prote cted by
Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 Identifying selector segments Dimension -a1 - 1st and 2nd gear selector segments = 11.4 mm 2 - 3rd and 4th gear selector segments = 7.7 mm 3 - 5th gear selector segments = 12.1 mm
Removing lock washer

Volkswagen AG G.vice Clamp selector fork in with protective jaw covers -B-. gen A does swa
y ua Leversoff d b lock washer -A- in direction of arrow. ran i e te or

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Installing lock washer
Press lock washer into groove of selector segment using sock et and spinner handle. Note
After lock washer is installed, selector segment must still rotate freely.
A - Spinner handle with 10 mm socket B - Protective jaw covers Removing angular contact ball bearing Note
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When removing and installing angular contact ball bearing, do not bend selector forks.
AG.
12. Dismantling and assembling selector forks
261
Pressing inner race -A- of angular contact ball bearing into outer race Inner race must engage in outer race.
AG. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte s i r Golf 2004 , Golf 2009 , Golf Plus 2005th o , Golf Plus 2009 , Pass ... eo u ra a 5-speed manual gearbox 0A4 - Edition 04.2010 c s s
Pulling angular contact ball bearing into selector fork to stop Depression in thrust piece -3290/1- faces ball bearing.
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Selector fork with selector segments installed Dim. -a- (mm) 1st/2nd gear selector fork 3rd/4th gear selector fork Selector segment assignment page 261 87.2 87.4 93.6 93.8
262
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35
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Gears, AG. Volkswagen AG d nshafts oe wage

Input shaft
1.1
Dismantling and assembling input shaft
Special tools and workshop equipment required Press tool -VW 407 Thrust pad -VW 447 H Press tool -VW 412 Tube -VW 422 Thrust plate -VW 401 Thrust plate -VW 402 Press tool -VW 408 A-
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1. Input shaft
263
Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 Tube -VW 421 Thrust piece -VW 454 Thrust pad -VW 447 i Thrust pad -VW 510 Drift sleeve -41-501 -3- Splitter -Kukko 17/1n AG. Volkswagen AG do es n wage s k l ot g o yV ua b ran ed s i tee r o h t or u ac a ss

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Note When installing new gear wheels or input shaft, consult technical data page 2 and Electronic parts
catalogue ETKA .
If the position of the tapered roller bearings is affected when parts are exchanged, the input shaft must be
readjusted. See adjustment overview page 302 .
264
Rep. Gr.35 - Gears, shafts
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Prote cted by
Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 1 - Clutch housing 2 - Tapered roller bearing outer race Pressing out page 266 Pressing in page 266 3 - Tapered roller bearing inner race Pressing off page 267 Pressing on page 267 4 - Input shaft Adjusting page 270
5 - Gear wheel for 3rd gear Installation position: shoulder faces 4th gear Pressing off page 267 Pressing on page 268 6 - Retaining ring Always renew
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8 - Tapered roller bearing inner race Pressing off with gear wheel and sleeve for 4th gear page 267 Pressing on page 268 9 - Thrust washer 10 - Tapered roller bearing outer race Pressing out page 269 Pressing in page 269 11 - Shim Determining thickness page 270 12 - Gearbox housing 13 - Sleeve For needle bearing Press off with gear wheel for 4th gear and tapered roller bearing inner race page 267 Pressing on page 268 Set thrust washer Item 9 (page 265) in place before installing
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7 - Gear wheel for 4th gear Pressing off with ta pered roller bearing out er race and sleeve page 267 Pressing on page 268 Collar faces 3rd gear
1. Input shaft
265
oes wa no Golf 2004 , Golf 2009 ,VGolf 2009 olks Plus 2005 , Golf Plus t gu , Pass ... y b ara d 5-speed manual gearbox 0A4 Edition 04.2010 e n is
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14 - Needle bearing
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tee or ac
16 - Synchro-ring for 5th gear With cast locking pieces page 246 Check for wear page 245
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15 - Synchromeshed gear for 5th gear
17 - Spring Installation position page 269 After gearbox construction date 05 11 1: Bent ends on springs page 270 18 - Locking pieces (Qty. 3) Installation position page 269 19 - Synchro-hub for 5th gear Pulling off, from page 234 .
20 - Locking collar for 5th gear Pulling off with synchro-hub for 5th gear, from page 234 . 21 - Dished washer Installation position page 246
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22 - Bolt Item 4 (page 225) Always renew Fitted section of bolt head holds dished spring in position page 246 . Pressing out tapered roller bearing outer race
AG.
Pressing in tapered roller bearing outer race
266
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Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 Pressing off tapered roller bearing inner race A - Splitter -Kukko 17/1AG. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o eo h t u ra a c s s
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Pressing on tapered roller bearing inner race
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Pressing off gear wheel for 4th gear with tapered roller bearing and sleeve
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Pressing off gear wheel for 3rd gear
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1. Input shaft
267
Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 Pressing on gear wheel for 3rd gear
Pressing on gear wheel for 4th gear Shoulder faces 3rd gear
Pressing on tapered roller bearing inner race

Pressing on sleeve for needle bearing
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Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 Pressing out tapered roller bearing outer race
Pressing in tapered
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Install with shim after adjusting input shaft.

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AG. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o eo h t u ra a roller bearing outer race c s s
5th gear synchronization 1234Springs for lock pieces Locking collar with 3 recesses -arrows A- for the locking pieces -item 4Synchro-hub
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Assembling 5th gear locking collar/synchro-hub Slide locking collar over synchro-hub. Pointed teeth -A- and shoulder -B- of synchro-hub face in same direction. The recesses for the locking pieces in locking collar and synchro-hub must be aligned ( page 269 ). Insert locking pieces (installation position page 269 ). Install springs below shoulder -C-, offset 120. Springs must seat with angled ends in front of locking pieces -arrows-.
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Locking pieces - installation position: thin extension -arrow B- faces the pointed teeth of the locking collar -2agen lksw Vo by
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Prote cted by
1. Input shaft
269
Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 Installing springs with bent ends -AThese springs are installed on both sides. Spring are installed only in conjunction with locking pieces which are hollow on the inner side. Insert locking pieces (installation position page 269 ).
Installation position of springs: Install springs offset 120.
Angled end -A- of spring must locate in hollow locking piece. It must be located under shoulder -B- of locking piece. Bent ends always face away from synchro-hub -direction of arrow-.
1.2
Adjusting input shaft
(Determining input shaft shim)
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270
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Prote cted by
Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 Special tools and workshop equipment required Universal dial gauge brack et -VW 387 End dimension plate . Volkswagen AG VW 385/17gen AG d
V 510 Thrust padd-VW by
ho Thrust ut pad -VW 447 ie ris
wa olks
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Torque wrench -V.A.G 1331 Dial gauge
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Press tool -VW 407-
a ss

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It is necessary to readjust the input shaft only when the following components are renewed: Gearbox housing Clutch housing Input shaft Gear wheel for 4th gear or the Tapered roller bearings Adjustment overview page 302 Requirement: Sealing surfaces of clutch and gearbox housings must be free of sealant.
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1. Input shaft
271
Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 Press tapered roller bearing outer race into gearbox housing to stop.
Install input shaft in clutch housing and set gearbox housing in place. Tighten hexagon head bolts to 25 Nm and then turn 90 further.
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Fit measuring appliance and dial gauge in clutch housing. Before taking any measurements, rotate input shaft to allow bearings to settle. Set dial gauge to 0 with 1 mm preload. Note
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Press input shaft in direction of dial gauge -direction of arrow-.
Read and note play on dial gauge (example: 1.21 mm). Note
Dial gauge does not return to original position.
1.2.1
Example:
Determining thickness of shim
Bearing play, measured value Thickness of shim according to table 1.21 mm 1.175 mm
272
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This step must be repeated for each subsequent measurement, or the dial gauge will not return to the starting position.
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AG.
Table of shims
Bearing play Measured value (mm) 0.6710.699 0.7000.724 0.7250.749 0.7500.774 0.7750.799 0.8000.824 0.8250.849 0.8500.874 0.8750.899 0.9000.924 0.9250.949 0.9500.974 0.9750.999 1.0001.024 1.0251.049 1.0501.074 1.0751.099 1.1001.124 1.1251.149 1.1501.174 11751.199 1.2001.224 1.2251.249 1.2501.274. 1.2751.229 1.3001.324 1.3251.349 1.3501.374 1.3751.399 1.4001.424 1.4251.449 1.4501.474 1.4751.499 1.5001.524 1.5251.549 1.5501.574 1.5751.599 1.6001.624 1.6251.649 1.6501.674 1.6751.699 1.7001.724 Note
n AG. Volkswagen AG do es n wage s k l ot g o yV ua b d ra e Golf 2004 , Golf 2009 , Golf Plus 2005 nte , Golf Plus s i r o eo h t 5-speed manual gearbox 0A4 u ra a c ss
2009 , Pass ... - Edition 04.2010
Shim Thickness (mm) 0.650 0.675 0.700 0.725 0.750 0.775 0.800 0.825 0.850 0.875 0.900 0.925 0.950 0.975 1.000 1.025 1.050 1.075 1.100 1.125 1.150 1.175 1.200 1.225 1.250 1.275 1.300 1.325 1.350 1.375 1.400 1.425 1.450 1.475 1.500 1.525 1.550 1.575 1.600 1.625 1.650 1.675

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Allocate shims according to Electronic parts catalogue ETKA .

Remove input shaft and press outer race of tapered roller bearing out of gearbox housing using thrust plate -VW 447 i- . Insert shims of determined thickness, thickest shim first. If the size of shim required is larger than those listed in the table, insert two shims totalling the correct figure. Press outer race of tapered roller bearing together with the shim (1.175 mm in example) into gearbox housing using thrust pad -VW 510- .
1. Input shaft
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273
Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 Set gearbox housing in place and tighten hexagon head bolts to 25 Nm and then turn 90 further.
1.2.2
Carrying out check measurement
Set up measuring appliance and dial gauge. Rotate input shaft so that tapered roller bearings settle. Press input shaft in -direction of arrow-. Bearing play should be min. 0.01 ... max. 0.09 mm. Note
If the bearing play cannot be measured, but input shaft play is perceptible and the input shaft turns freely, the adjustment is ac ceptable.

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274
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2
2.1
Output shaft
Dismantling and assembling output shaft
Special tools and workshop equipment required Press tool -VW 407 Press tool -VW 412 Thrust pad -VW 512 Puller -V.A.G 1582 Adapter -V.A.G 1582/4 Adapter -V.A.G 1582/5-
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2. Output shaft
275
Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 Thrust plate -VW 402 Thrust piece -32 - 111 Press tool -VW Press tool -VW Tube -VW 519es, in part or in w l purpos hole ercia , is n m ot com
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Support rails -VW 457un le
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276
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Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 Thrust ring -VW 429 Tube -VW 415 A Thrust pad -VW 447 H Thrust piece -VW 454 Installing sleeve -VW 455 Drift sleeve -41-501-
Internal puller -1-Kukko 21/6-
Counter support -4-Kukko 22/2 Splitter -3-Kukko 17/2-
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2. Output shaft
277
Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 Note The output shaft is dismantled as follows: position separating device under 2nd gear synchromeshed gear
Item 21 (page 279) and press off as described in page 281 . Remove retaining ring Item 17 (page 279) . Then press off locking collar with synchro-hub for 1st and 2nd gear as described in page 282 . data page 2 .
When installing new gears or new input shaft, refer to Electronic parts catalogue ETKA and technical Always renew both tapered roller bearings together as a set. 1 - Hexagon nut, 25 Nm and then turn 90 further 4 nuts for bearing sup port. Always renew 2 - Clutch housing 3 - Shim For output shaft Adjustment overview page 302 4 - Small tapered roller bearing outer race Removing page 280 Pressing in page 281
5 - Tapered roller bearing inner race small Pulling off page 281 Pressing on page 281 6 - Output shaft Adjusting page 287
7 - Tapered roller bearing inner race large Pulling off page 282 Pressing on page 282 8 - Seal Place sealing rings (Qty. 4) on bearing support bolts
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9 - Bearing support With large tapered roller bearing outer race and bolts Change outer race only together with large tapered roller bearing and bearing support 10 - Thrust washer Shoulder of thrust washer faces tapered roller bearing 11 - Synchromeshed gear for 1st gear 12 - Needle bearing For 1st gear
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278
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Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 13 - Synchro-ring (Inner ring for 1st gear) Installation position page 282 Check for wear page 283 Check lugs for scoring 14 - Outer ring for 1st gear Installation position Check for wear page 283 Renew if scored
15 - Synchro-ring for 1st gear Installation position page 282 Check for wear page 283
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16 - Locking collar with synchro-hub for 1st and 2nd gears After removing retaining ring, pull off together with bearing support page 282 Item 17 (page 279) Dismantling page 283 Assembling locking collar and synchro-hub page 283 , page 284 and page 284 Installation position page 284 Pressing on page 284 17 - Retaining ring 18 - Synchro-ring for 2nd gear Check for wear page 283 Assemble so that notches engage in locking pieces of locking collar Item 16 (page 279)
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20 - Synchro-ring (Inner ring for 2nd gear) Check for wear page 283 Check lugs for scoring Installation position page 285
21 - Synchromeshed gear for 2nd gear Installation position page 285 22 - Needle bearing For 2nd gear 23 - Thrust washer 24 - Sleeve for 3rd gear needle bearing Pressing off with synchromeshed gear for 2nd gear page 281 Pressing on page 285 25 - Needle bearing For 3rd gear 26 - Synchromeshed gear for 3rd gear 27 - Synchro-ring for 3rd gear Check for wear page 286 28 - Locking collar with synchro-hub for 3rd and 4th gears Press off with synchromeshed gears for 2nd gear Item 21 (page 279) and 3rd gear Item 26 (page 279) page 281 .
2. Output shaft
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19 - Outer ring for 2nd gear Insert in synchro-ring Item 18 (page 279) . Installation position page 285 Renew if scored
279
Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 Dismantling page 286 Assembling locking collar and synchro-hub page 286 , page 286 and page 286 Installation position, locking collar and synchro-hub page 287 Pressing on page 287
29 - Sleeve . Volkswagen AG does For needle bearing kswagen AG not l o V gu y b alocking Press off with 3rd and 4th gear Item 28 (page 279) collar and synchro-hub page 281 . d ran e is tee r o h Pressing on or ut page 287
s 30 - Needle bearing For 4th gear
sa
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31 - Synchro-ring for 4th gear Check for wear page 286 32 - Synchromeshed gear for 4th gear 33 - Thrust washer 34 - Needle bearing For output shaft Removing and installing page 252 35 - Gearbox housing 36 - Sleeve For output shaft needle bearing Pressing off page 281 Pressing on page 287

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Pulling out small tapered roller bearing outer race A - Internal puller, 37...46 mm , e.g. -Kukko 21/6B - Counter support , e.g. -Kukko 22/2-
280
AG.
39 - Bolt Item 4 (page 225) Always renew Removing and installing page 234
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38 - Dished washer Installation position page 246
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37 - Gear wheel for 5th gear Removing and installing page 234
Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 Pressing in small tapered roller bearing outer race
Pulling off small tapered roller bearing inner race A - Vice with protective jaw covers Fit adapter and tighten behind bearing rollers, then turn bear ing and retighten gripping device.
Pressing on small tapered roller bearing inner race
Pressing off 3rd and 4th gear synchro-hub and locking collar, 2nd, 3rd and 4th gear synchromeshed gears with sleeve for gearbox housing needle bearing A - Splitter, 22...115 mm , e.g. -Kukko 17/2B - Hexagon bolt M10 x 20, 17 mm AF Note
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2. Output shaft
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Support splitter so that the 1st and 2nd gear locking collar is not pulled off at the same time.
281
Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 Pressing off locking collar with synchro-hub and bearing support First remove retaining ring -arrow-.
Pulling off large tapered roller bearing inner race A - Protective jaws Before fitting puller, insert a M 10 x 20 hexagon bolt in the output shaft drilling.
Pressing on large tapered roller bearing inner race -A- Thrust washer Fit thrust washer before pressing on inner race. faces inner race.
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Installation position of outer ring, inner ring and synchro-ring for 1st gear Place inner ring -A- on synchromeshed gear for 1st gear. Angled lugs -arrow 1- face outer ring -B-. Fit outer ring -B-.
Lugs -arrow 2- engage in notches -arrow 3- of synchromeshed gear. Fit synchro-ring -C-. Notches -arrow 4- engage in lugs -arrow 1- of inner ring -A-.
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Note
282
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If components are to be reused, ensure that they are matched with their original gears.
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Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 Checking 1st and 2nd gear inner ring for wear Press inner ring onto cone of synchromeshed gear and meas ure gap -a- using a feeler gauge. Gap -a1st and 2nd gears Installation (new) di mension 0.75 1.25 mm Wear limit 0.3 mm
Checking 1st and 2nd gear synchro-ring for wear Press synchro-ring, outer ring and inner ring onto cone of syn chromeshed gear and measure gap -a- using a feeler gauge. Gap -a1st and 2nd gears Installation (new) di mension 1.2 1.8 mm Wear limit 0.5 mm
Dismantling and assembling locking collar and synchro-hub for 1st and 2nd gears 1 - Spring Allocate springs according to Electronic parts catalogue ET KA . Installation with hollow locking pieces page 284 . Installation with solid locking pieces page 284 . 2 - Locking collar 3 - Synchro-hub 4 - Locking piece
Allocate locking pieces according to Electronic parts catalogue ETKA . Collar is equally wide on both sides of synchro-hub. Collar has chamfer on one side -arrow B-. Chamfer on collar of synchro-hub and outer teeth of locking collar -arrow A- face in same direction after assembly. Notches -arrow C- in synchro-hub and sliding collar for locking pieces must align.

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2. Output shaft
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Assembly of 1st and 2nd gear locking collar and synchro-hub with solid locking pieces Locking collar has been pushed over synchro-hub. Insert locking pieces and install springs offset 120. Springs must seat with angled ends in front of locking pieces -arrows-.
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Pressing on locking collar and synchro-hub for 1st and 2nd gears Turn synchro-ring so that grooves align with locking pieces.
284
AG.
Teeth of locking collar -arrow- face splines for 3rd and 4th gear synchro-hub -A-.
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Installation position of locking collar with synchro-hub for 1st and 2nd gears
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Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 Installation position of 2nd gear outer ring Lugs -arrows- face 1st gear -A-.
Installation position of synchro-ring (2nd gear inner ring) -Alksw

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Installation position of synchromeshed gear for 2nd gear Higher shoulder -A- faces 1st gear -B-. Notches in shoulder -arrows- engage in lugs of outer ring page 285 .
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Pressing on sleeve for 3rd gear needle bearing

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2. Output shaft
285
Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 Checking synchro-rings for 3rd and 4th gear for wear Press synchro-ring onto cone of synchromeshed gear and measure gap -a- using feeler gauge. Gap -a1st gear 3rd gear 4th gear Installation (new) di mension 1.0 ... 1.7 mm 1.0 ... 1.7 mm 1.0 ... 1.7 mm Wear limit 0.5 mm
Dismantling and assembling 3rd and 4th gear locking collar and synchro-hub 1 - Spring Allocate springs according to Electronic parts catalogue ET KA . Installation with hollow locking pieces page 284 . Installation with solid locking pieces page 284 . 2 - Locking piece Allocate locking pieces according to Electronic parts catalogue ETKA . 3 - Locking collar 4 - Synchro-hub Slide locking collar over synchro-hub. Notches for locking pieces in synchro-hub and locking collar must align.
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Assembly of 3rd and 4th gear locking collar and synchro-hub with solid locking pieces Locking collar has been pushed over synchro-hub. Insert locking pieces and install springs offset 120. Springs must seat with angled ends in front of locking pieces -arrows-.
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AG.
286
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Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 Installation position of locking collar and synchro-hub for 3rd and . Volkswagen AG 4th gears gen AG d Chamfer -arrow- faces 4th gear.
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Pressing on synchro-hub with locking collar for 3rd and 4th gears
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Pressing on sleeve for output shaft needle bearing
2.2
Adjusting output shaft
(Determining shim for output shaft)
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Pressing on sleeve for 4th gear needle bearing
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2. Output shaft
287
Universal dial gauge brack et -VW 387 End dimension plate VW 385/17 Thrust pad -VW 512 Straightening tool -3114/2 Press tool -VW 407 Torque wrench V.A.G 1331 Dial gauge
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...
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Counter support -4-Kukko 22/2It is necessary to readjust the output shaft when the following components are renewed: Output shaft Clutch housing or Tapered roller bearings
288
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Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 Adjustment overview page 302 Prerequisites: Sealing surfaces of clutch and gearbox housings must be free of sealant.
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s Turn output shaft 20 to 30 times in one direction.
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The shaft must be turned in one direction so that the rollers of
the tapered roller bearing settle in one direction.
It is necessary to turn the shaft 20 to 30 times to achieve this. Otherwise the resulting reading will be incorrect.
Set up dial gauge (3 mm measuring range) and set to 0with 1 mm preload. Move output shaft up and down. Read and note play indicated on dial gauge.
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The specified bearing preload will be attained if the determined measured value is added to the 0.65 mm shim already installed. Example: Bearing play = Thickness of shim according to (0.65 mm table plus determined measured val ue) 0.740 mm Table of shims Bearing play = (0.65 mm plus determined measured val ue) 0.650 0.660 0.689 0.690 0.739 0.740 0.789 0.790 0.839 0.840 0.889 0.890 0.939 0.940 0.989 Shim thickness (mm) 0.750 0.800 0.850 0.900 0.950 1.000 1.050 1.100 0.900 mm
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2.2.1
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2. Output shaft
289
Bearing play = (0.65 mm plus determined measured val ue) 0.990 1.039 1.040 1.089 1.090 1.139 1.140 1.189 1.190 1.239 1.240 1.289 1.290 1.339 1.340 1.389 1.390 1.429 Note
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...
Shim thickness (mm) 1.150 1.200 1.250 1.300 1.350 1.400 1.450 1.500 1.550
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Remove output shaft and pull out small tapered roller bearing outer race page 280 . Insert shims of determined thickness, thickest shim first.
AG.
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If the previously used 0.65 mm shim is to be reinstalled, check it for damage.
If the size of shim required is larger than those listed in the table, insert two shims totalling the correct figure. The various thicknesses make it possible to achieve the exact shim thickness required. Press in outer race of small tapered roller bearing together with the calculated shim (0.70 mm in example) page 281 and install output shaft. Tighten bearing support nuts in clutch housing to 25 Nm and then turn 90 further.
290
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3
3.1
Reverse shaft
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Thrust piece -VW 454 Thrust pad -VW 447 H Press tool -VW 411 Centring mandrel -12 - 551 Thrust plate -VW 401 Press tool -VW 408 A-

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-1- Internal puller -Kukko 21/2-
-4- Counterhold -Kukko 22/1-
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3. Reverse shaft
291
After dismantling, always renew needle bearing in clutch housing and reverse shaft support.
1 - Clutch housing
2 - Needle bearing Pulling out page 292 Pressing in page 293 3 - Reverse gear wheel 4 - Retaining ring Always renew after re moving 5 - Synchromeshed gear for re verse gear Remove retaining ring before renewing Shoulder faces reverse gear wheel 6 - Reverse shaft Removing page 234 7 - Needle bearing Pressing out page 293 Pressing in page 293 8 - Reverse shaft support Removing and installing page 234
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Note
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Pulling needle bearing out of clutch housing A - Counter support , e.g. -Kukko 22/1B - Internal puller, 14.5 18.5 mm , e.g. -Kukko 21/2Note
The needle bearing is destroyed during removal and must be re newed.
292
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Pressing needle bearing out of reverse shaft support
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Pressing needle bearing into reverse shaft support

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293
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Renewing flange shaft oil seals with gearbox installed

Renewing oil seal for left flange shaft
39
Final drive - differential
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1.1
Special tools and workshop equipment required Multipurpose tool -VW 771 Puller hooks -VW 771/37 Thrust piece -T10160 Drip tray -V.A.G 1306 Torque wrench V.A.G 1331-
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1.1.1
Removing
Remove left wheel. Remove noise insulation General body repairs, exterior; Rep. Gr. 50 ; Noise insulation . Remove lower part of front left wheel housing liner General body repairs, exterior; Rep. Gr. 66 ; Wheel housing liner . Turn steering to left lock. Disconnect drive shaft from flange shaft Running gear, axles, steering; Rep. Gr. 40 ; Repairing drive shaft; Removing and installing drive shafts .
294
Rep. Gr.39 - Final drive - differential
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Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 Raise drive shaft as high as possible and secure. Take care n AG. Volkswagen AG do not to damage paint on drive shaft in the process. es wage Place drip tray under gearbox.
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Pull out flange shaft with compression spring.
Pull out flange shaft oil seal using multipurpose tool -VW 771and puller hooks -VW 771/37- .
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1.1.2
Installing
Drive in new seal to stop, being careful not to cant seal. Half-fill space between sealing lip and dust lip with sealing grease -G 052 128 A1- . Insert flange shaft. Secure flange shaft with countersunk bolt. Attach drive shafts to gearbox Running gear, axles, steer ing; Rep. Gr. 40 ; Repairing drive shaft; Removing and instal ling drive shafts . Check gear oil page 220 . Install lower part of front left wheel housing liner General body repairs, exterior; Rep. Gr. 66 ; Wheel housing liner . Install noise insulation General body repairs, exterior; Rep. Gr. 50 ; Noise insulation . Install wheel Running gear, axles, steering; Rep. Gr. 44 ; Torque settings for mounting wheels .
1.1.3 1.2
Torque setting Distinguishing seals for right flange shaft
Flange shaft to gearbox (countersunk bolt) Item 12 (page 306)
The seal -1- for the right flange shaft is located in a sleeve -2-.
1. Renewing flange shaft oil seals with gearbox installed
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295
Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 There are different versions. Seal -1- and sleeve -2- are two parts. Identification: notches along circumference of sleeve -arrow-. Renew seal page 296 . Seal -1- and sleeve -2- are one piece. Identification: no notches in sleeve. Renew seal and sleeve together page 299 .
1.3
Renewing seal (two-part seal and sleeve for right flange shaft)
Special tools and workshop equipment required Drip tray -V.A.G 1306n AG. Volkswagen AG do es n wage s k l ot g o yV ua b ran ed s i tee r o h t or u ac a ss
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Thrust piece -T10160-
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Assembly tool -3253/2-
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1.3.1
Removing
Remove noise insulation General body repairs, exterior; Rep. Gr. 50 ; Noise insulation . Turn steering to right to full lock. Remove drive shaft heat shield, if present -arrows- Running gear, axles, steering; Rep. Gr. 40 ; Repairing drive shafts; Removing and installing drive shafts .
Disconnect drive shaft -1- from flange shaft. Raise drive shaft as high as possible and secure. Take care not to damage paint on drive shaft in the process. Place drip tray under gearbox and engine.
Unbolt turbocharger oil return line from engine -arrow- Rep. Gr. 21 ; Charge air system for turbocharger; Removing and installing turbocharger with ancillaries . Place drip tray under gearbox.
Remove flange shaft securing bolt by screwing two bolts into flange and counterholding flange shaft with a lever. Pull out flange shaft with compression spring.
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297
Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 Lever out seal using screwdriver -A- supporting screwdriver on assembly tool -3253/2- . Note
. gen AG Do not damage sleeve. Otherwise, leaks will occur. swa
Replace sleeve if damaged
1.3.2
Installing
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Drive in new seal to stop, being careful not to cant seal. Half-fill space between sealing lip and dust lip with sealing grease -G 052 128 A1- . Insert flange shaft. Secure flange shaft with countersunk bolt.
Install drive shaft heat shield, if present -arrows- Running gear, axles, steering; Rep. Gr. 40 ; Repairing drive shafts; Removing and installing drive shafts . Check and top up gear oil page 220 . Install noise insulation General body repairs, exterior; Rep. Gr. 50 ; Noise insulation .
298
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AG.
Bolt drive shaft -1- to flange shaft Running gear, axles, steering; Rep. Gr. 40 ; Repairing drive shaft; Removing and installing drive shafts .
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If turbocharger oil return line was unbolted from engine, bolt it on again now -arrow- Rep. Gr. 21 ; Charge air system for turbocharger; Removing and installing turbocharger with an cillaries .
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1.3.3 1.4
Torque setting Renewing seal and sleeve together (one-piece seal and sleeve for right flange shaft)
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Special tools and workshop equipment required Thrust piece -T10148 Spindle from assembly tool -3066 Multipurpose tool -VW 771 Puller hooks -VW 771/37-
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299
Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 Drip tray -V.A.G 1306-
1.4.1
Removing
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Remove noise insulation General body repairs, exterior; Rep. Gr. 50 ; Noise insulation . Turn steering to right to full lock. Remove drive shaft heat shield, if present -arrows- Running gear, axles, steering; Rep. Gr. 40 ; Repairing drive shafts; Removing and installing drive shafts .
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Raise drive shaft as high as possible and secure. Take care not to damage paint on drive shaft in the process. Place drip tray under gearbox and engine.
AG.
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Unbolt turbocharger oil return line from engine -arrow- Rep. Gr. 21 ; Charge air system for turbocharger; Removing and installing turbocharger with ancillaries .
Remove flange shaft securing bolt by screwing two bolts into flange and counterholding flange shaft with a lever. Pull out flange shaft with compression spring.
300
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Disconnect drive shaft -1- from flange shaft.
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Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 Pull out seal and sleeve together. There is a shoulder in the inner diameter of the sleeve. Apply puller hooks -VW 771/37- directly behind shoulder in sleeve. Press extractor hooks -VW 771/37- forcefully into sleeve while pulling.
1.4.2
Installing
Clean seat for seal in gearbox. Pull in seal and sleeve together. A - Screw spindle of assembly tool -3066- into threaded piece of differential. B - Nut M12
n AG. Volkswagen AG do Pull in seal with sleeve to stop using thrust piece -T10148- by es n wage s k l ot g o turning nut -B-. yV u
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Secure flange shaft with countersunk bolt.
If turbocharger oil return line was unbolted from engine, bolt it on again now -arrow- Rep. Gr. 21 ; Charge air system for turbocharger; Removing and installing turbocharger with an cillaries . Bolt drive shaft -1- to flange shaft Running gear, axles, steering; Rep. Gr. 40 ; Repairing drive shaft; Removing and installing drive shafts .
Insert flange shaft.
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1.4.3
Torque setting
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Check and top up gear oil page 220 .
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301
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Note
Adjustment overview
nents have been renewed which have a direct effect on the adjustment of the gearbox. To prevent unnecessary adjustments, refer to the following table:
AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r If repairs have been carried out to the gearbox, it is necessary to o eo th u ra a adjust the input shaft, output shaft or differential only if compo c s s
Parts renewed:
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Gearbox housing Clutch housing Input shaft Output shaft Differential cage Tapered roller bearings for input shaft Tapered roller bearing for output shaft Tapered roller bearing for differen tial Gear wheel for 4th gear
To be adjusted: Input shaft Output shaft Differential page 270 page 287 page 311 x x x x x x x x x x
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3
3.1
Differential
Dismantling and assembling differential
Special tools and workshop equipment required Tapered roller bearing pull er -V.A.G 1582 Adapter -V.A.G 1582/3 Press tool -VW 412 Thrust plate -VW 401 Thrust plate -VW 402-

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3. Differential
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Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 Press tool -VW 408 A Thrust piece -VW 473 Thrust plate -30 - 205 Sleeve -3144 Torque 1332 Thrust piece -2007AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is wrench -V.A.G r o eo h ut ra a c s s

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Counter support -4-Kukko 22/2-
304
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Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 Note Heat tapered roller bearing inner race to 100 C before installing. Always renew both tapered roller bearings together as a set. If tapered roller bearings, differential cage, gearbox housing or clutch housing are renewed, adjust differ
ential page 302 .
1 - Gearbox housing 2 - Shim For differential Determining thickness page 311 3 - Tapered roller bearing outer race Pulling out page 308 n AG. Volkswagen AG do Pressing in es n wage s k l ot g page 308 by Vo ua
r 4 - Tapered roller ho bearing inner ut a race ss Pulling off page 307 Pressing on page 307
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5 - Differential cage With final drive gear Differential cage adap ted to one-piece thrust washer page 309 Hole for spring pin adap ted to length of spring pin page 308 Allocate according to Electronic parts cata logue ETKA . 6 - Tapered roller bearing inner race Pulling off page 307 Pressing on page 307
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8 - Clutch housing 9 - Sleeve For seating oil seal Item 10 (page 305) Removing and installing page 248 10 - Seal Renewing oil seal for left flange shaft with gearbox installed page 294 Renewing seal for right flange shaft with gearbox installed (two-part seal and sleeve for right flange shaft) page 296
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7 - Tapered roller bearing outer race Pressing out page 307 Pressing in page 307
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3. Differential
305
Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 11 - One-piece seal and sleeve If seal is damaged, renew seal and sleeve together page 299
n AG 12 - Countersunk bolt, 25 Nm wage olks V y Screw into threaded piece Iteme20 d b (page 306)
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14 - Compression spring for flange shaft Installed behind flange shafts 15 - Thrust washer Installation position page 310 16 - Tapered ring With grooves to engage in thrust washer Installation position: taper towards differential cage
th 13 - Flange shaft au ss Removing and installing page 294
is or

17 - Retaining ring Holds tapered ring, thrust washer and spring in position when flange shaft is removed 18 - One-piece thrust washer Coat with gear oil when installing One-piece thrust washer has shoulder in some gearboxes page 309 19 - Large differential bevel gear Installing page 310 20 - Threaded piece Installing page 310
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22 - Spring pin For securing differential pinion pin Spring pins of different lengths have been installed Spring pin identification page 308 Removing and installing short spring pin page 309 Long spring pin is sheared off when removed page 309 Installing long spring pin page 309 23 - Small differential bevel gear Installing page 310 24 - Large differential bevel gear Installing page 310
306
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21 - Differential pinion pin Removing in conjunction with shorter spring pin page 309 Removing in conjunction with longer spring pin page 309 Installing page 310
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Pressing tapered roller bearing outer race out of

First remove seating sleeve for flange shaft seal.

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Pressing tapered roller bearing outer race into clutch housing No shim is installed in the clutch housing end.
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Pulling off tapered roller bearing inner race
Before fitting extractor, position thrust plate -40 - 105- on dif ferential cage. Note
Both tapered roller bearing inner races are pulled off the differ ential cage in the same way.
Pressing on tapered roller bearing inner race Note
Both tapered roller bearing inner races are pressed onto the dif ferential cage in the same way.
3. Differential
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Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 Pulling outer race for tapered roller bearing out of gearbox hous ing A - Counter support , e.g. -Kukko 22/2B - Internal puller, 46...58 mm , e.g. -Kukko 21/7-
Pressing tapered roller bearing outer race into gearbox housing Fit shim under outer race.
AG. Volkswagen AG d agen oes ksw not l o V gu y b directly below bearing mounting ara Support gearbox housing us d e nte ing sleeve -3144- th .oris eo u ra a c s s
Spring pin identification Dim. a mm Identification Circumferential groove -arrowsNo circumferential groove 28.5 (short spring pin) Removing and installing page 309 36.0 (long spring pin), Removing page 309 , Installing page 309
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Check hole for spring pin in differential cage.

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The hole in the differential cage was modified for the longer spring pin. Hole -A-A- and -BLength of spring pin (mm) 28.5 (short spring pin) 36.0 (long spring pin)
308
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Allocation of differential cages

Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 Removing and installing spring pin with circumferential groove (short spring pin) Removing Cover tapered roller bearing inner race and speedometer drive gear to avoid possible damage and ingress of metal particles. Drive out spring pin with chisel, inserting chisel into circum ferential groove. Installing Drive into differential cage to stop. Removing spring pin without circumferential groove (long spring pin): pressing out differential pinion pin When pressed out, spring pin will be sheared off. Drive remainder of spring pin out of differential cage.
Drive in new spring pin with drift -1- until dimension -a- = 3.0 mm is attained. The spring pin must not come in contact with gears with dif ferential cage installed.
Align hole in differential pinion pin with hole in differential cage.
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In some gearboxes, the one-piece thrust washer has a shoulder -A- near the holes In this case, the differential cage has a circumferential groove -B-. Lubricate one-piece thrust washer with gear oil and install.
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Install one-piece thrust washer so that it engages in groove -B- in differential cage.
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3. Differential
309
Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 Installing differential bevel gears and differential pinion pin Lubricate one-piece thrust washer with gear oil and install. Install both sun wheels and secure (e.g. with flange shaft). Insert planet pinions offset 180 and pivot into position. Press in differential pinion pin (-arrow A-) to first planet pinion. . Volkswage
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ss pin into final position and Drive differential pinion spring pin.
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Installation position of thrust washer for tapered ring -1-. The shoulder -arrow- points towards spring -B-. Some gearboxes have lugs -A-. Lugs -A- face tapered ring -1-.
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3.2
Adjusting differential
Special tools and workshop equipment required Universal dial gauge brack et -VW 387 End dimension plate VW 385/17 Press tool -VW 407 Thrust plate -30 - 205 Torque wrench V.A.G 1331 Internal puller -1 - Kukko 21/7 Counter support -4 - Kukko 22/2 Dial gauge
It is necessary to readjust the differential when the following com ponents are renewed: Gearbox housing Clutch housing Differential cage or the tapered roller bearing of differential Adjustment overview page 302 . Press outer race of tapered roller bearing without shim into gearbox housing using thrust piece -30 - 205- page 308
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Inner and outer tapered roller bearing races are paired. Do not interchange!
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3. Differential
311
Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 Press outer race of tapered roller bearing into clutch housing using thrust plate -30 - 205- page 307 . Fit differential into clutch housing. Set gearbox housing in place and tighten 5 bolts to 25 Nm. Attach dial gauge and set to 0 with 1 mm preload. Move differential up and down. Read and note play indicated on dial gauge. (Example: 0.70 mm.)
3.2.1
Example:
Bearing play, measured value Thickness of shim according to table 0.70 mm Table of shims Bearing play Measured value (mm) 0.303 0.449 0.450 0.499 0.500 0.549 0.550 0.599 0.600 0.649 0.650 0.699 0.700 0.749 0.750 0.799 0.800 0.849 0.850 0.899 0.900 0.949 0.950 0.999 1.000 1.049 1.050 1.099 1.100 1.149 1.150 1.199 Note 0.95 mm
312
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Shim Thickness (mm) 0.650 0.700 0.750 0.800 0.850 0.900 0.950 1.000 1.050 1.100 1.150 1.200 1.250 1.300 1.350 1.400
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Golf 2004 , Golf 2009 , Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010 Remove gearbox housing and pull tapered roller bearing outer race from gearbox housing. Pulling outer race for tapered roller bearing out of gearbox hous ing A - Counter support , e.g. -Kukko 22/2B - Internal puller 46 . 58 mm , e.g. -Kukko 21/7- . Insert shims of determined thickness, thickest shim first. If the size of shim required is larger than those listed in the table, insert two shims totalling the correct figure. The various thicknesses make it possible to achieve the exact shim thickness required. Press in outer race of tapered roller bearing again page 308 and bolt gearbox housing tight.

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3. Differential
313

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Service

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Service Department. Technical Information

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39 - Final drive - differential

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34 - Controls, housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116

rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en

35 - Gears, shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263

39 - Final drive - differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294

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Codes and production date -arrow 1- manual gearbox 0A4 -arrow 2-

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3 I I Year (2003) of manufacture

Additional data provide information about the production facility. Note

The gearbox code is also included on the vehicle data stickers.

Identification codes, assembly allocation, capacities, Golf 2004

Manual gearbox Identification code Manufactured Allocation

Manual gearbox Identification code Manufactured from to Engine Final drive

5-speed 0A4 GTB

JCT 05.06 06.08 2.5 l - 110 kW 62 : 17 = 3.647 1.9 l 1.7 l 108 mm

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Manual gearbox Identification code Manufactured Allocation

JCR 05.06 06.08 1.9 l - 66 kW turbo diesel 1.9 l - 77 kW turbo diesel

5-speed 0A4 JCU 05.06 06.08 2.0 l - 85 kW

05.06 06.08 1.8 l - 110 kW

Rep. Gr.00 - Technical data

JCR 61 : 18 = 3.389 1.9 l 1.7 l 108 mm

5-speed 0A4 JCU 72 : 17 = 4.235 1.9 l 1.7 l 100 mm

JCV 63 : 16 = 3.938 1.9 l 1.7 l 108 mm

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Manual gearbox Identification code Manufactured Allocation

12.06 06.08 1.9 l - 77 kW turbo diesel 61 : 18 = 3.778 1.9 l 1.7 l

Gear oil Clutch allocation

Manual gearbox Identification code Manufactured Allocation from to Engine

07.07 06.08 1.9 l - 77 kW turbo diesel 61 : 18 = 3.778 1.9 l 1.7 l 100 mm

Individual gear ratios

JQP 07.07 06.08 1.8 l - 118 kW 62 : 17 = 3.647 1.9 l 1.7 l 100 mm

Manual gearbox Identification code Manufac tured Allocation from to Engine

5-speed 0A4 LHW

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Identification codes, assembly allocation, capacities, Golf 2009

61 : 18 = 3.778 1.9 l 1.7 l 100 mm

61 : 18 = 3.778 1.9 l 1.7 l 100 mm