Volkswagen Golf / Golf GTI / Golf Variant. Manual — part 483
Fasteners
♦ Do not stretch the circlips.
♦ Installation position for some of the circlips: The circlip is »nar‐
rower at the top« and so is its installation position. This makes
it easier for the pliers to grab the circlip when removing and
installing it.
♦ Replace damaged or overstretched locking ring after remov‐
ing.
♦ The circlips must rest at the bottom of the groove.
♦ Replace the adapter sleeves. Installation position: the slot
-A- should align with the line of force -arrow-.
Bolts and Nuts
♦ Always loosen or tighten bolts and nuts on covers and hous‐
ings diagonally with a tightening sequence.
♦ 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 stated apply to non-oiled nuts
and bolts.
♦ Replace self-locking nuts and bolts after removing them.
♦ Make sure the contact surfaces and visible surfaces on the
nuts and bolts are waxed after assembling.
♦ Use a wire brush to clean the threads of the bolts that were
installed with locking fluid. Then insert the bolts with Locking
Fluid - AMV 185 101 A1- .
♦ If self-locking bolts were installed or if regular bolts were in‐
stalled with locking fluid, then the threaded holes must be
cleaned, for example with a thread tap. 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 lettered side (thicker metal) racing
the fitting tool.
♦ Replace all the tapered roller bearings that are on the same
shaft. Use tapered roller bearings from the same manufactur‐
er.
♦ To install, warm the inner races/tapered roller bearing to ap‐
proximately 100 °C (212 °F) with -VAS6414- .
♦ Do not interchange outer and inner bearing races with those
from other bearing of the same size. The bearings are paired.
Adjusting Shims
♦ Measure the shims at several locations with a micrometer cal‐
iper. It is possible to measure the necessary shim thickness
by the different tolerances.
♦ Check for burrs and damage.
♦ Only install perfect shims.
Synchronizer Rings
♦ Do not interchange them. When reusing synchronizer rings,
always install to 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 the intermediate
ring on the outer contact surface -arrow 2- and inner contact
surface -arrow 3- for grooves, scoring 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 -VAS6414- to a max‐
imum 100 °C (212 °F).
♦ Pay attention to the installed location.
Selector Gears
♦ After assembling, check the selector gears for minimum axial
clearance and ease of movement.
Clutch
♦ Do not tilt the clutch pressure plate. Loosen and tighten it di‐
agonally 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.
3.2
Contact Corrosion
♦ The transmission housing and clutch housing consist of a
magnesium alloy.
♦ Bolts and other components, which come into direct contact
with the transmission, have a surface coating adapted for this.
♦ Contact corrosion occurs when incorrect components (bolts,
nuts, washers, etc.) are used. The transmission housing and
clutch housing are damaged.
♦ Only install components provided in the Parts Catalog.
4
Technical Data
⇒ “4.1 Transmission/Engine Allocation”, page 7
⇒ “4.2 Capacities”, page 8
⇒ “4.3 Gear Ratio Calculation”, page 8
4.1
Transmission/Engine Allocation
4.1.1
Transmission/Engine Allocation, Golf
Manual Transmission
6-Speed 02Q
Codes
NBL
PFN
Manufactured
from
through
06/2014
03/2014
Allocation
Engine
2.0L - 155 KW
2.0L - 110 KW
Turbo diesel
Ratio
Z1 : Z2
Final drive I
1)
68 : 21 = 3.238
69 : 20 = 3.450
Final drive II
2)
68 : 26 = 2.615
69 : 25 = 2.760
Driveshaft Flange Diameter
107 mm
107 mm
1)
Final drive for 1st through 4th gear
2)
Final drive for 5th gear, 6th gear and reverse gear
• Refer to the Parts Catalog for the following information:
♦ The individual gear ratios
♦ Transmission fluid specification
♦ Clutch plate and pressure plate allocation
4.1.2
Transmission/Engine Allocation, Golf Wagon
Manual Transmission
6-Speed 02Q
Codes
PFN
Manufactured
from
through
03/2014
Allocation
Engine
2.0L - 110 KW
Turbo diesel
Ratio
Z1 : Z2
Final drive I
1)
69 : 20 = 3.450
Final drive II
2)
69 : 25 = 2.760
Driveshaft Flange Diameter
107 mm
1)
Final drive for 1st through 4th gear
2)
Final drive for 5th gear, 6th gear and reverse gear
• Refer to the Parts Catalog for the following information:
♦ The individual gear ratios
♦ Transmission fluid specification
♦ Clutch plate and pressure plate allocation
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