Gear Oil, Checking and Filling

Gear Oil, Checking and Filling

Checking gear oil level using the familiar method is no longer possible.





Engine/transmission inclination was changed

Lower edge of filler hole - arrow 1 - is therefore located beneath new oil level - arrow 2 -.





Gear oil level can only be checked if gear oil is drained completely and then filled up again:

Special tools, testers and auxiliary items required

• Torque wrench 5 to 50 Nm (V.A.G 1331)

• Hose (approximately 600 mm long, outside diameter 10 mm) with commercially available funnel

Preparation

- Disconnect battery ground (GND) cable with ignition switched off.

- Remove battery and battery tray.

- Disconnect intake air duct - 1 - and connector - 2 - from Mass Air Flow (MAF) sensor.





- Remove bolts - 3 - and - 4 -.

- Remove complete air filter.

- Remove center section of noise insulation below engine/transmission.

Clean transmission.





CAUTION!
To drain gear oil, journal for shift forks in transmission must be removed.

To avoid that the position of the shift forks is changed, e.g. by involuntarily operating shift mechanism, shift rod must be secured.

Secure Shift Rod as Follows

- Press down shift rod - direction of arrow 1 -.





- While pressing down shift rod, rotate bracket - A - upward in - direction of arrow 2 - and simultaneously press it carefully in until it engages in shift rod.

Gear Oil, Draining

Use a clean container (3.0 liters capacity) with scale to collect gear oil.

• Shift rod is secured.

- Drain gear oil by removing oil drain plug - arrow 1 - and then removing journal - arrow 2 -.





- Install journal - arrow 2 - with new O-ring => [ (Item 7) Bolt, 25 Nm ] Transmission Housing and Shift Mechanism Assembly Overview.

- Install oil drain plug - arrow 1 - => [ (Item 17) Oil drain plug, 30 Nm ] Transmission and Clutch Housing Assembly Overview.

- Now rotate angle - A - back into initial position - direction of arrow - to let shift rod move freely again.





Gear Oil, Filling

Fill up gear oil in collect container to 1.7 liters.

- Remove backup light switch (F4) - arrow -.





- Connect hose (approximately 600 mm long, outside diameter 10 mm) to commercially available funnel.

- Insert hose into mounting hole of backup light switch (second mechanic) and fill up gear oil.

- Install backup light switch (F4) - arrow - => [ (Item 2) ] Shift Mechanism Assembly Overview.

- Check switching function.

- Install battery tray and battery.

- Install complete air filter housing.

- Connect battery and note work steps after connecting battery.

- Install center section of noise insulation below engine/transmission.