Transmission Component Overview
Transmission Component Overview
l - => [ Transmission Housing and Shift Unit ]
ll - GTI through 2009 => [ Input Shaft, Output Shaft, Differential and Selector Rods ]
ll - Eos, Golf/GTI from 2010, Passat, Passat CC and CC => [ Input Shaft, Output Shafts, Differential and Shift Rods ]
• From transmission build date 21 January 2008, the input shaft cap is secured with a circlip - A -.
Transmission, without Input Shaft Cap Circlip - A -, disassembly and assembly. Refer to => [ Transmission, Without Cap/Input Shaft Circlip ] Transmission, Without Cap/Input Shaft Circlip.
Transmission, with Input Shaft Cap Circlip - A -, disassembly and assembly. Refer to => [ Transmission, with Cap/Input Shaft Circlip ] Transmission, With Cap/Input Shaft Circlip.
Transmission Housing and Shift Unit
1 Countersunk Bolt
• Removing and installing, refer to - item 12 -=> [ Countersunk Bolt ] Differential.
2 Flange Shaft with Spring
• Removing and installing, refer to => [ Left Flange Shaft Seal ] Left Flange Shaft Seal.
• Disassembly and assembly, refer to => [ Differential ] Differential.
3 Circlip
• For the sealing cap - item 4 -.
• Installed from transmission build date 21 January 2008.
4 Sealing Cap
• Secured with a circlip from transmission build date 21 January 2008.
5 Securing Ring
• For the grooved ball bearing/input shaft - item 6 -=> [ Grooved Ball Bearing ] Input Shaft Overview.
6 Backup Lamp Switch (F4)
• 20 Nm
• Short after series introduction of transmission with permanent seal.
7 Oil Seal
• Not on all transmissions.
8 Oil Drain Plug
• Tightening specification, refer to => [ Different Versions of
the Oil Fill and Oil Drain Plugs ] Service and Repair.
9 Oil Seal
• Always replace.
10 Bolt
• 6 Nm
11 Transmission Neutral Position Sensor (G701)
• For vehicles with the start/stop system.
12 Locking Screw
• 45 Nm
• For the selector shaft.
13 Bolt
• Always replace.
• Note the different bolts and their related tightening specifications
• Round head socket bolt = to transmission build date 9 December 2006, M8 aluminum bolt = 8 Nm + 180° (1/2) additional turn.
• Round head socket bolt = from transmission build date 10 December 2006, M9 aluminum bolt = 15 Nm + 180° (1/2) additional turn.
• Hex head steel bolt = 15 Nm + 90° (1/4) additional turn.
• Allocation of steel bolts as a replacement part, refer to => [ For steel bolts (hex
head) as a replacement part, note the allocation: ] Transmission, Without Cap/Input Shaft Circlip.
14 Bolt
• Always replace.
• Note the different bolts and their related tightening specifications
• Round head socket bolt = to transmission build date 19 December 2006, M8 aluminum bolt = 8 Nm + 180° (1/2) additional turn.
• Round head socket bolt = from transmission build date 10 December 2006, M9 aluminum bolt = 15 Nm + 180° (1/2) additional turn.
• Hex head steel bolt = 15 Nm + 90° (1/4) additional turn.
• Allocation of steel bolts as a replacement part, refer to => [ For steel bolts (hex
head) as a replacement part, note the allocation: ] Transmission, Without Cap/Input Shaft Circlip.
15 Shift Unit
• Overview, refer to => [ Shift Unit Overview ] Shift Unit Overview.
• Removing with transmission installed:
• Remove the battery and battery tray.
• The locking pin - item 6 -=> [ Locking Pin ] Transmission Housing for adjusting the shift mechanism must not be engaged.
• Remove the cables and transmission shift lever. Refer to => [ Shift and Selector Cables ] Shift Mechanism Overview.
• Remove the locking screw - item 12 - and remove the shift unit.
16 Bolt
• 20 Nm
• Always replace
17 O-ring
• Always replace
18 Clutch Housing
• Disassembling and assembling, refer to => [ Clutch Housing ] Clutch Housing.
19 Transmission Housing
• Disassembling and assembling, refer to => [ Transmission Housing ] Transmission Housing.
Input Shaft, Output Shaft, Differential and Selector Rods
1 Output Shaft, 1st to 4th Gears
• Disassembling and assembling, refer to => [ Output Shaft, 1st to 4th Gears ] Output Shaft, 1st to 4th Gears.
• Installed position, refer to => [ Shafts and Selector Rods, Installed Positions ] Shafts and Selector Rods, Installed Positions.
2 Selector Rod with Shift Fork for 1st and 2nd Gear
• Installed position, refer to => [ Shafts and Selector Rods, Installed Positions ] Shafts and Selector Rods, Installed Positions.
3 Selector Rod with Shift Fork for 3rd and 4th Gear
• Installed position, refer to => [ Shafts and Selector Rods, Installed Positions ] Shafts and Selector Rods, Installed Positions.
4 Output Shaft, 5th, 6th and Reverse Gears
• Disassembling and assembling, refer to => [ Output Shaft, 5th, 6th and Reverse Gears ] Output Shaft, 5th, 6th and Reverse Gears.
• Installed position, refer to => [ Shafts and Selector Rods, Installed Positions ] Shafts and Selector Rods, Installed Positions.
5 Selector Rod with Shift Fork for 5th and 6th Gear
• Installed position, refer to => [ Shafts and Selector Rods, Installed Positions ] Shafts and Selector Rods, Installed Positions.
6 Reverse Gear Shift Fork
• Installed position, refer to => [ Shafts and Selector Rods, Installed Positions ] Shafts and Selector Rods, Installed Positions.
• Differences, refer to => [ Reverse Gear Shift
Fork Differentiation ] Shift Forks.
• disassembling and assembling, refer to => [ Shift Forks ] Shift Forks.
7 Input Shaft
• Disassembling and assembling. refer to => [ Input Shaft Overview ] Input Shaft Overview.
• Always replace the grooved ball bearings on input shaft - item 6 -=> [ Grooved Ball Bearing ] Input Shaft Overview.
8 Reverse Shaft
• With the thrust washer.
9 Thrust Washer
10 Breather
• Connected with the slave cylinder.
11 Clutch Housing
• Disassembling and assembling, refer to => [ Clutch Housing ] Clutch Housing.
12 Input Shaft Seal
• Replacing, refer to => [ Input Shaft Seal ] Input Shaft Seal.
13 O-ring
• Install onto the line connection.
• Lubricate with brake fluid before installing.
14 Slave Cylinder with Release Bearing
15 Bolt
• Quantity: 3
• Always replace
• Removing and installing, refer to - item 4 -=> [ Bolt ] Clutch Release Mechanism Overview.
16 Countersunk Bolt
• Removing and installing, refer to - item 12 -=> [ Countersunk Bolt ] Differential.
17 Stub Shaft with Spring
• Removing and installing, refer to => [ Right Stub Shaft Seal, through 31 October 2004, Transmission Installed ].
• Assembling, refer to => [ Differential ] Differential.
• As of transmission build date 4 November 2001, replaced by a flange shaft - item 15 -=> [ Right Flange Shaft ] Differential.
• Flange shaft, removing and installing, refer to => [ Right Flange Shaft Seal, from November 1 2004 ] Right Flange Shaft Seal, From November 1 2004.
• Disassembling and assembling the flange shaft, refer to => [ Differential ] Differential.
18 Differential
• Disassembling and assembling, refer to => [ Differential ] Differential.
Input Shaft, Output Shafts, Differential and Shift Rods
1 Output Shaft, 1st to 4th Gears
• Installed position, refer to => [ Shafts and Selector Rods, Installed Positions ] Shafts and Selector Rods, Installed Positions.
• Disassembling and assembling, refer to => [ Output Shaft, 1st to 4th Gears ] Output Shaft, 1st to 4th Gears.
2 Selector Rod with Shift Fork for 1st and 2nd Gear
• Installed position, refer to => [ Shafts and Selector Rods, Installed Positions ] Shafts and Selector Rods, Installed Positions.
• Disassembling and assembling, refer to => [ Shift Forks ] Shift Forks.
3 Selector Rod with Shift Fork for 3rd and 4th Gear
• Installed position, refer to => [ Shafts and Selector Rods, Installed Positions ] Shafts and Selector Rods, Installed Positions.
• Disassembling and assembling, refer to => [ Shift Forks ] Shift Forks.
4 Output Shaft, 5th, 6th and Reverse Gears
• Installed position, refer to => [ Shafts and Selector Rods, Installed Positions ] Shafts and Selector Rods, Installed Positions.
• Disassembling and assembling, refer to => [ Output Shaft, 5th, 6th and Reverse Gears ] Output Shaft, 5th, 6th and Reverse Gears.
5 Selector Rod with Shift Fork for 5th and 6th Gear
• Installed position, refer to => [ Shafts and Selector Rods, Installed Positions ] Shafts and Selector Rods, Installed Positions.
• Disassembling and assembling, refer to => [ Shift Forks ] Shift Forks.
6 Reverse Gear Shift Fork
• Installed position, refer to => [ Shafts and Selector Rods, Installed Positions ] Shafts and Selector Rods, Installed Positions.
• Differences, refer to => [ Reverse Gear Shift
Fork Differentiation ] Shift Forks.
• Disassembling and assembling, refer to => [ Shift Forks ] Shift Forks.
7 Input Shaft
• Installed position, refer to => [ Shafts and Selector Rods, Installed Positions ] Shafts and Selector Rods, Installed Positions.
• Disassembling and assembling, refer to => [ Input Shaft Overview ] Input Shaft Overview.
• Always replace grooved ball bearings on input shaft - item 6 -=> [ Grooved Ball Bearing ] Input Shaft Overview.
8 Reverse Shaft
• With the thrust washer.
9 Thrust Washer
10 Breather
• Connected with the slave cylinder.
11 Clutch Housing
• Disassembling and assembling, refer to => [ Clutch Housing ] Clutch Housing.
12 Input Shaft Seal
• Replacing, refer to => [ Input Shaft Seal ] Input Shaft Seal.
13 O-ring
• Installed onto the line connection.
• Lubricate with brake fluid before installing.
14 Slave Cylinder with Release Bearing
15 Bolt
• Quantity: 3
• Always replace
• Removing and installing, refer to - item 4 -=> [ Bolt ] Clutch Release Mechanism Overview.
16 Countersunk Bolt
• Removing and installing, refer to - item 12 -=> [ Countersunk Bolt ] Differential
17 Flange Shaft with Spring
• Removing and installing, refer to => [ Right Flange Shaft Seal, from November 1 2004 ] Right Flange Shaft Seal, From November 1 2004.
• Disassembling and assembling, refer to => [ Differential ] Differential.
18 Differential
• Disassembling and assembling, refer to => [ Differential ] Differential.