VW Golf Mk5 2004 2009, Golf Plus Mk5 2005 2009,Passat 2006 5-speed manual gearbox 0A4 - Workshop Manual

1.1 Location on gearbox......Page 7
1.2 Identification codes, assembly allocation, capacities, Golf 2004 ▸......Page 8
1.3 Identification codes, assembly allocation, capacities, Golf 2009 ▸......Page 10
1.4 Identification codes, assembly allocation, capacities, Golf Plus 2005 ▸......Page 11
1.6 Identification codes, assembly allocation and capacities, Passat 2006 ▸......Page 12
2 Overview - power transmission......Page 15
3 Calculating overall gear ratio “i”......Page 17
4.1.3 Sealant......Page 18
4.1.7 Shims......Page 19
4.1.11 Clutch......Page 20
1.1 Overview......Page 21
1.2 Assembly overview - pedal cluster......Page 22
1.3.1 Removing......Page 24
1.3.2 Installing......Page 26
1.4 Removing and installing over-centre spring, Golf 2009 ▸ LHD......Page 28
1.4.1 Removing......Page 29
1.4.2 Installing......Page 31
1.5 Removing and installing over-centre spring, Golf 2009 ▸ RHD......Page 33
1.5.1 Removing......Page 34
1.5.2 Installing......Page 36
1.6.1 Removing......Page 38
1.6.2 Installing......Page 41
1.6.3 Torque settings......Page 42
1.7.2 Installing......Page 43
1.8 Removing and installing clutch pedal, Golf 2004 ▸......Page 44
1.8.1 Removing......Page 45
1.8.2 Installing......Page 47
1.8.3 Torque settings......Page 49
1.9.1 Removing......Page 50
1.9.2 Installing......Page 53
1.10.1 Removing......Page 55
1.10.2 Installing......Page 58
1.11.1 Removing......Page 60
1.11.2 Installing......Page 63
1.12 Removing and installing clutch pedal, Passat......Page 65
1.12.2 Installing......Page 66
1.13 Removing and installing mounting bracket, Golf 2004 ▸......Page 67
1.13.1 Removing......Page 68
1.13.2 Installing......Page 71
1.14 Removing and installing mounting bracket, Golf 2009 ▸ LHD......Page 73
1.14.1 Removing......Page 74
1.14.2 Installing......Page 77
1.14.3 Torque settings......Page 78
1.15.1 Removing......Page 79
1.15.2 Installing......Page 82
1.15.3 Torque settings......Page 84
1.16.1 Removing......Page 85
1.16.2 Installing......Page 88
1.17 Removing and installing mounting bracket, Passat......Page 90
1.17.1 Removing......Page 91
1.17.2 Installing......Page 93
1.18.1 Removing......Page 94
1.18.2 Installing......Page 95
1.19.1 Removing......Page 96
1.19.2 Installing......Page 98
1.20 Assembly overview - hydraulics (LHD)......Page 100
1.21 Assembly overview - hydraulics (RHD)......Page 102
2.1 Removing......Page 104
2.3 Torque settings......Page 105
3 Bleeding clutch system......Page 107
4 Repairing clutch release mechanism......Page 109
5.1 Identifying make of clutch, vehicles with 1.9 l - 66 kW turbo diesel engine and vehicles with 1.9 l - 77 kW turbo diesel e
gine......Page 111
5.2.2 Installing......Page 113
5.4.2 Installing......Page 115
5.5 Repairing LuK clutch......Page 118
6 Repairing clutch, in conjunction with one-piece flywheel......Page 119
1.1 Installation position of selector mechanism......Page 122
1.2 Overview of selector mechanism......Page 123
1.4 Removing and installing gaiter with gear knob and noise insulation, Golf......Page 124
1.5 Removing and installing gaiter with gear knob and noise insulation, Golf Plus......Page 126
1.6 Removing and installing gaiter with selector lever knob and noise insulation, Passat......Page 127
1.7 Repairing gear lever and selector housing (through 10.06)......Page 129
1.8 Repairing gear lever and selector housing (from 11.06)......Page 131
1.8.1 Dismantling and assembling selector mechanism......Page 132
1.9 Assembly overview - removing and installing selector cables......Page 137
1.10 Plastic relay lever......Page 140
1.11.1 Removing......Page 142
1.11.2 Installing......Page 144
1.12 Adjusting selector mechanism......Page 145
1.12.1 Functional check......Page 148
2 Removing and installing gearbox, Golf 2004 ▸......Page 149
2.1 Removing gearbox......Page 150
2.2 Installing gearbox......Page 156
2.2.1 Torque settings......Page 160
3 Removing and installing gearbox, Golf 2009 ▸ with turbo diesel engine......Page 162
3.1 Removing gearbox......Page 163
3.2 Installing gearbox......Page 169
3.2.1 Torque settings......Page 175
4 Removing and installing gearbox, Golf 2009 ▸ with petrol engine......Page 177
4.1 Removing gearbox......Page 179
4.2 Installing gearbox......Page 186
4.2.1 Torque settings......Page 192
5 Removing and installing gearbox, Golf Plus......Page 194
5.1 Removing gearbox......Page 195
5.2 Installing gearbox......Page 202
5.2.1 Torque settings......Page 209
6 Removing and installing gearbox, Passat......Page 211
6.1 Removing gearbox......Page 213
6.2 Installing gearbox......Page 218
6.2.1 Torque settings......Page 223
7 Transporting gearbox......Page 225
8.1 Preparation......Page 226
8.2 Draining gear oil......Page 227
8.3 Fill with gear oil......Page 228
9.1 Overview - gearbox......Page 229
9.2 Assembly overview......Page 230
9.3 Removing and installing cover for gearbox housing and 5th gear......Page 231
9.4 Removing and installing gearbox housing and selector mechanism......Page 232
9.5 Removing and installing input shaft, output shaft, differential and selector forks......Page 233
9.6 Assembly sequence - removing and installing cover for gearbox housing and 5th gear......Page 234
9.6.1 Removing......Page 236
9.6.2 Installing......Page 239
9.7 Assembly sequence - Dismantling and assembling gearbox completely......Page 240
9.7.1 Removing......Page 242
9.7.2 Installing......Page 247
10 Repairing gearbox housing and clutch housing......Page 254
11 Repairing selector unit......Page 261
12 Dismantling and assembling selector forks......Page 264
1.1 Dismantling and assembling input shaft......Page 269
1.2 Adjusting input shaft......Page 276
1.2.1 Determining thickness of shim......Page 278
1.2.2 Carrying out check measurement......Page 280
2.1 Dismantling and assembling output shaft......Page 281
2.2 Adjusting output shaft......Page 293
2.2.1 Determining thickness of shim......Page 295
3.1 Dismantling and assembling reverse shaft......Page 297
1.1.1 Removing......Page 300
1.2 Distinguishing seals for right flange shaft......Page 301
1.3 Renewing seal (two-part seal and sleeve for right flange shaft)......Page 302
1.3.1 Removing......Page 303
1.3.2 Installing......Page 304
1.4 Renewing seal and sleeve together (one-piece seal and sleeve for right flange shaft)......Page 305
1.4.1 Removing......Page 306
1.4.3 Torque setting......Page 307
2 Adjustment overview......Page 308
3.1 Dismantling and assembling differential......Page 309
3.2 Adjusting differential......Page 317
3.2.1 Determining thickness of shim......Page 318