Volkswagen Golf / Golf GTI / Golf Variant. Manual — part 510

12 - Locking Bolt

❑ Metal locking bolt: 45 Nm
❑ Plastic locking bolt: 30 Nm
❑ Replace locking bolt after removing
❑ For the selector shaft
❑ Metal or plastic locking bolt

13 - Bolt

❑ 15 Nm +180°
❑ Replace after removing
❑ M9 aluminum bolt

14 - Bolt

❑ 15 Nm +180°
❑ Replace after removing
❑ M9 aluminum bolt

15 - Shift Lever Unit

❑ (Shift lever shaft with shift lever cover). Refer to

⇒ “5.4 Overview - Shift Unit”, page 113

.

❑ Removing and installing with the transmission installed:

♦ For vehicles with a turbo diesel engine, remove the entire air filter housing. Refer to ⇒ Engine Mechanical,

Fuel Injection and Glow Plug; Rep. Gr. 24 ; Air Filter; Air Filter Housing, Removing and Installing .

♦ For vehicles with a gasoline engine, remove the entire air filter housing. Refer to ⇒ Engine Mechanical, Fuel

Injection and Ignition; Rep. Gr. 24 ; Air Filter; Air Filter Housing, Removing and Installing .

♦ Remove the battery and the battery tray if necessary. Refer to ⇒ Electrical Equipment; Rep. Gr. 27 ; Battery;

Battery Tray, Removing and Installing .

♦ The lock elbow -Item 6-

⇒ Item 6 (page 130)

, for adjusting the shift mechanism must not be engaged

♦ Remove the cables and shift lever.
♦ Remove the locking screw.
♦ If equipped, remove the Transmission Neutral Position Sensor - G701- .
♦ Remove the bolts and shift unit.
♦ Install in reverse order of removal. Replace the O-ring and bolts.
16 - Bolt

❑ 20 Nm
❑ Replace after removing

17 - O-Ring

❑ Replace after removing

18 - Clutch Housing

❑ Servicing. Refer to

⇒ “6 Transmission Housing and Clutch Housing”, page 130

.

19 - Transmission Housing

❑ Servicing. Refer to

⇒ “6 Transmission Housing and Clutch Housing”, page 130

.

5.4

Overview - Shift Unit

1 - Bearing Bushing

❑ For the selector shaft
❑ Removing and instal‐

ling. Refer to

⇒ “6.1 Overview - Trans‐

mission Housing”,

page 130

.

2 - Shift Lever Unit

❑ Consisting of the shift

lever shaft and the shift

lever cover

❑ The components cannot

be separated from each

other

❑ Can be removed and in‐

stalled with the trans‐

mission installed. Refer

to

⇒ “5.3 Overview - Trans‐

mission Housing and

Selector Mechanism”,

page 111

3 - O-Ring

❑ Insert in the groove in

the shift cover

❑ Install with transmission

fluid

❑ Replace after removing

4 - Cap

❑ For the transmission

ventilation

5 - Bolt

❑ For the shift unit to the

transmission housing

❑ Tightening specification. Refer to

⇒ “5.3 Overview - Transmission Housing and Selector Mechanism”, page 111

.

❑ Replace after removing

6 - Shift Lever Shaft Seal

❑ Replacing. Refer to

⇒ “1.8 Selector Shaft Seal, Replacing”, page 74

.

5.5

Overview - Input Shaft, Output Shafts, Differential, Shift Lever Rods

1 - Output Shaft, 1st to 4th

Gears

❑ Disassembling and as‐

sembling. Refer to

⇒ “2.1 Overview - Out‐

put Shaft”, page 163

.

❑ Installed position. Refer

to

⇒ Fig. ““Installation Lo‐

cation of Shafts and

Shift Lever Rods in

Transmission”“ ,

page 115

.

2 - Shift Lever Rod with Shift

Fork for 1st Gear and 2nd Gear

❑ Installed position. Refer

to

⇒ Fig. ““Installation Lo‐

cation of Shafts and

Shift Lever Rods in

Transmission”“ ,

page 115

.

3 - Shift Lever Rod with Shift

Fork for 3rd Gear and 4th Gear

❑ Installed position. Refer

to

⇒ Fig. ““Installation Lo‐

cation of Shafts and

Shift Lever Rods in

Transmission”“ ,

page 115

.

4 - Output Shaft, 5th/6th and

Reverse Gears

❑ Disassembling and as‐

sembling. Refer to

⇒ “2.2.2 Output Shaft,

5th, 6th and Reverse

Gears, Disassembling and Assembling”, page 182

.

❑ Installed position. Refer to

⇒ Fig. ““Installation Location of Shafts and Shift Lever Rods in Transmission”“ , page 115

.

5 - Shift Lever Rod with Shift Fork for 5th Gear and 6th Gear

❑ Installed position. Refer to

⇒ Fig. ““Installation Location of Shafts and Shift Lever Rods in Transmission”“ , page 115

.

6 - Reverse Gear Shift Fork

❑ Installed position. Refer to

⇒ Fig. ““Installation Location of Shafts and Shift Lever Rods in Transmission”“ , page 115

.

7 - Input Shaft

❑ Installed position. Refer to

⇒ Fig. ““Installation Location of Shafts and Shift Lever Rods in Transmission”“ , page 115

.

❑ Disassembling and assembling. Refer to

⇒ “1.1 Overview - Input Shaft”, page 157

.

❑ Replace grooved ball bearing on drive axle after removing. Refer to

⇒ “1.1 Overview - Input Shaft”, page 157

.

8 - Thrust Washer

❑ Place on the reverse shaft

9 - Reverse Shaft
10 - Thrust Washer
11 - Bleeder

❑ Connect with clutch slave cylinder

12 - Clutch Housing

❑ Servicing. Refer to

⇒ “6 Transmission Housing and Clutch Housing”, page 130

.

13 - Input Shaft Seal

❑ Replacing. Refer to

⇒ “1.3 Input Shaft Seal, Replacing”, page 161

.

14 - O-Ring

❑ Install on the line connection
❑ Coat with brake fluid before installing

15 - Clutch Slave Cylinder with Release Bearing
16 - Bolt

❑ Replace after removing
❑ Quantity: 3
❑ Removing and installing. Refer to

⇒ “1.4 Overview - Clutch Release Mechanism”, page 21

.

17 - Bolt

❑ Tightening specification. Refer to

⇒ “2.1 Overview - Differential”, page 212

.

18 - Right Flange Shaft

❑ With pressure spring and tapered ring
❑ Removing and installing. Refer to

⇒ “1.3 Right Seal, Replacing”, page 209

.

❑ Assembling. Refer to

⇒ “2.1 Overview - Differential”, page 212

.

19 - Differential

❑ Disassembling and assembling. Refer to

⇒ “2.1 Overview - Differential”, page 212

.

Installation Location of Shafts and Shift Lever Rods in Transmis‐

sion
1 - Input Shaft
2 - Output Shaft, 1st to 4th Gears
3 - Output Shaft, 5th/6th and Reverse Gears
4 - Reverse Shaft
A - 3rd and 4th Gear Shift Lever Rod
B - 1st and 2nd Gear Shift Lever Rod
C - 5th and 6th Gear Shift Lever Rod
D - Reverse Gear Shift Fork
The Reverse Gear Shift Fork -D- is Mounted on the 5th and 6th

Gear Gearshift Rod -C-.