General, Technical data

Safety Precautions

Safety Precautions during Road Test with Testing Equipment

If Testing Equipment Must Be Used during a Road Test, Note the Following:

WARNING

Risk of accident due to distractions and testing equipment that is not secured properly.

The front passenger airbag could pose a risk if it deploys in a collision

• Operating testing equipment while driving is a distraction.
• Testing equipment that is not secured properly increases the risk of personal injury.

Always secure testing equipment on the rear seat using a strap and have a second person in the rear seat operate it.

To Prevent Personal Injury and Damage to the Electrical/Electronic Components, Note the Following:

• Only connect and disconnect test equipment when the ignition is off.

Caution

Risk of destroying electronic components when disconnecting the battery.

Follow the steps when disconnecting the battery.

• Disconnect the battery.

Safety Precautions when Working on Start/Stop System

WARNING

Risk of injury if the engine starts automatically in vehicles with the Start/Stop System.

• Deactivate the Start-Stop system when working on the vehicle. Turn off the ignition.
• Only switch the ignition on briefly when necessary.

Identification

Transmission Identification

• Chapter "Transmission Identification, Front Wheel Drive"
• Chapter "Transmission Identification, All Wheel Drive"

Technical Data

Transmission/Engine Allocation

• Chapter "Transmission/Engine Allocation, Golf and Golf Wagon, Manual Transmission 02Q"
• Chapter "Transmission/Engine Allocation, Golf, Manual Transmission 02Q with Front Axle Differential Lock"
• Chapter "Transmission/Engine Allocation, CC, Passat, Golf, Manual Transmission 0FB"
• Chapter "Transmission/Engine Allocation, CC, Manual Transmission 02Q"
• Chapter "Transmission/Engine Allocation, Passat, Manual Transmission 02Q"
• Chapter "Transmission/Engine Allocation, Passat, Manual Transmission 0BB"
• Chapter "Transmission/Engine Allocation, Golf All Wheel Drive, Golf Wagon All Wheel Drive, Manual Transmission 02Q"
• Chapter "Transmission/Engine Allocation, CC All Wheel Drive, Manual Transmission 02Q"
• Chapter "Transmission/Engine Allocation, Passat All Wheel Drive, Manual Transmission 02Q"
• Chapter "Transmission/Engine Allocation, Tiguan All Wheel Drive, Manual Transmission 02Q"

Capacities

Manual Transmission Capacity

Manual transmission capacity

Refer to → Fluid Capacity Tables; Rep. Gr.03

Bevel Box Capacity

Bevel box capacity

Refer to → Fluid Capacity Tables; Rep. Gr.03

Gear Ratio Calculation

Example:

	6th Gear	Final Drive
Drive gear	ZG1 = 46	ZA1 = 24
Driven gear	ZG2 = 33	ZA2 = 70

i = ZG₂ : ZG₁.

i_G = gear ratio = ZG₂ : ZG₁ = 33 : 46 = 0.717

i_A= axle ratio= ZA₂ : ZA₁= 70 : 24= 2.917

i_total = total ratio= i_G x i_A = 0.717 x 2.917 = 2.091

¹⁾ Z₁ = Number of teeth on the drive gear, Z₂ = Number of teeth on the driven gear

Overview - Transmission

Overview - Transmission, Front Wheel Drive

Name

The -arrows- point in the direction of travel.

1. 1
   Engine
2. 2
   Clutch
3. 3
   Manual Transmission
4. 4
   Input Shaft
5. 5
   5th, 6th and Reverse Gear Output Shaft
6. 6
   1st through 4th Gear Output Shaft
7. 7
   Differential
8. 8
   Front Axle Differential Lock

   • With Haldex clutch
   • Installed in connection with gasoline engine depending on the vehicle equipment level.

Ratio

The -arrows- point in the direction of travel.

1. 1
   1st Gear
2. 2
   2nd Gear
3. 3
   3rd Gear
4. 4
   4th Gear
5. 5
   5th Gear
6. 6
   6th Gear

R - Reverse Gear

A - Final Drive

Electrical Components

Component Location Overview - Electrical Components

Component Location Overview - Electrical Components, Manual Transmission

1. 1
   Transmission Neutral Position Sensor -G701-

   • Installed location: in the area of the shift unit under the selector shaft bracket.
   • Removing and installing.
2. 2
   Back-Up Lamp Switch -F4-

   • Installed location: in the area of the shift unit under the selector shaft bracket.
   • Removing and installing.

Component Location Overview - Electrical Components, Clutch Mechanism

Clutch Position Sensor -G476--arrow-, Scirocco, CC, Golf Cabriolet, Passat, Tiguan

Component location: In the engine compartment under the hose -1- on the clutch master cylinder -2- behind the line -3-.

The connector -4- is on the Clutch Position Sensor -G476-.

Clutch Position Sensor -G476-, Removing and installing.

Clutch Position Sensor -G476--arrow-, Golf and Golf Wagon

Installed location: in the passenger compartment on the clutch master cylinder.

Clutch Position Sensor -G476-, Removing and installing.

Repair Information

General Repair Information

The highest level of care and cleanliness along with tools that function properly are required to ensure a proper and successful transmission repair. The usual basic safety precautions apply when making vehicle repairs.

Some general repair information for individual repair procedures, that appear many times throughout the manual, is summarize here. They apply to this repair manual.

Special Tools

Refer to Workshop Equipment and Special Tools for a complete list of special tools used in the repair manual.

Transmission

• Make sure that the alignment bushings between the engine and transmission are positioned correctly when installing the manual transmission.
• Clean the contact surfaces when installing brackets as well as parts that have been waxed. Contact surfaces must be free of wax and grease.
• Allocate the bolts and other components. Refer to the Parts Catalog.
• Fill the transmission fluid when repairing the manual transmission.

Seals and Gaskets

• After removing gaskets, examine the contact surface on housing/shaft for burrs resulting from removal or for other damage.
• Thoroughly clean the separating surfaces and apply Sealant.
• Allocation. Refer to the Parts Catalog.
• Fill the space between the sealing lips halfway with Grease-arrow- before installing the radial shaft seal.
• Grease allocation. Refer to the Parts Catalog.
• The open side of the gaskets point toward the fluid to be sealed in.
• Lightly lubricate the O-rings before inserting to prevent the rings from being crushed during assembly.

Sealant

• Clean the housing separating surfaces thoroughly before applying the Sealant.
• Apply Sealant evenly and not too thick.
• Allocation. Refer to the Parts Catalog.
• Sealant must not go into the bleed holes.

Retainers

• Replace the circlips.
• Do not stretch the circlips.
• The circlips must rest at the bottom of the groove.
• Replace the adapter sleeves. Installed position: slot is lengthwise to line of force.

Bolts and Nuts

• Always loosen or tighten bolts and nuts on covers and housings diagonally.
• Especially delicate parts, such as clutch pressure plates, must not be distorted. Loosen and tighten bolts and nuts in stages in a diagonal sequence.
• The tightening specifications given apply to unoiled bolts and nuts.
• Replace self-locking bolts and nuts after removing them.
• Make sure the contact surfaces and visible surfaces on the nuts and bolts are waxed after assembling.
• Use a thread cutter to clean all threaded holes containing self-locking bolts to remove any locking compound residue. Otherwise the bolts could shear the next time they are removed.
• Please make sure that the thread pitch is correct so that the proper thread cutter is used during cleaning, and the thread does not get damaged.

Bearings

• Insert the bearings with transmission fluid.
• Install the new tapered roller bearings. It is not necessary to oil them.
• Install needle bearings with the lettered side (thicker metal) facing the fitting tool.
• Replace all the tapered roller bearings that are on the same shaft, and use tapered roller bearings from the same manufacturer.
• Do not interchange inner and outer bearing races with those from other bearings of the same size, bearings are paired.

Shims

• Measure the shims at several locations with a micrometer caliper. It is possible to measure the necessary shim thickness by the different tolerances.
• Check for burrs or damage.
• Only install perfect shims.

Synchronizer Rings

• Do not interchange them. When reusing synchronizer rings, always install on the same gear wheel.
• Check for wear and replace if necessary.
• Check the grooves -arrow 1- on the synchronizer ring -A- and the inner race for flat areas (grooves are worn).
• The coating on the synchronizer rings must not be damaged.
• If an intermediate ring -B- is installed, check this intermediate ring on the outer friction surface -arrow 2- and inner friction surface -arrow 3- for "grooves", "wear grooves" and "blue coloring (from overheating)".
• Check taper of drive gear for "grooves" and "scoring".
• Coat the synchronizing with transmission fluid and then install.

Toothed Gears, Synchronizer Hubs

• Clean before installing. Warm using the Inductive Heater -VAS6414- to a maximum 100 ºC (212 ºF).
• Pay attention to the installed location.

Selector Gears

• After assembling, check the selector gears for minimum axial clearance and ease of movement.

Clutch Mechanism

Disconnect the battery. Refer to → Electrical Equipment.

If the battery is to be reconnected: Refer to → Electrical Equipment.

Clutch

• Do not tilt the clutch pressure plate. Loosen and tighten it diagonally and in small steps.
• To reduce odor caused by a burnt clutch, thoroughly clean the clutch housing and the flywheel running surface with a clean cloth.