Volkswagen Golf / Golf GTI / Golf Variant. Manual — part 559
Fasteners
♦ Replace the circlips.
♦ Do not overstretch the circlips.
♦ The circlips must fit completely inside the groove.
♦ Replace the adapter sleeves. Installed position: slot is length‐
wise to line of force.
Bolts and Nuts
♦ Always loosen or tighten bolts and nuts on covers and hous‐
ings diagonally.
♦ 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 bolts and nuts after removing them.
♦ Make sure the contact surfaces and visible surfaces on the
nuts and bolts are waxed after assembling.
♦ Use a thread cutter to clean all threaded holes containing self-
locking bolts to remove any locking compound residue. Oth‐
erwise 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 Inductive Heater -
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 this intermediate
ring on the outer friction surface -arrow 2- and inner friction
surface -arrow 3- for »grooves«, »wear grooves« 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 and warm to maximum 100 °C (212 °F) using the In‐
ductive Heat Unit - VAS6414- before installing.
♦ 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.
4
Technical Data
⇒ “4.1 Transmission/Engine Allocation”, page 6
⇒ “4.2 Capacities”, page 6
⇒ “4.3 Gear Ratio Calculation”, page 7
4.1
Transmission/Engine Allocation
4.1.1
Transmission/Engine Allocation, Golf
Manual Transmission
5-Speed Manual Transmission 0A4
Codes
NZA
Manufactured
from
through
06/2013
Allocation
Engine
1.8L - 125 kW
Ratio
Z1 : Z2
Final Drive
61 : 18 = 3.389
Drive axle flange diameter
100 mm
Refer to the Parts Catalog for the following information:
♦ The individual gear ratios
♦ Transmission fluid
♦ Clutch allocation
4.1.2
Transmission/Engine Allocation, Golf Wagon
Manual Transmission
5-Speed Manual Transmission 0A4
Codes
QSY
Manufactured
from
through
11/2014
Allocation
Engine
1.8L - 125 kW
Ratio
Z1 : Z2
Final Drive
61 : 18 = 3.389
Drive Axle flange diameter
100 mm
Refer to the Parts Catalog for the following information:
♦ The individual gear ratios
♦ Transmission fluid
♦ Clutch allocation
4.2
Capacities
Manual transmission capacity
(transmission completely disas‐
sembled)
Refer to ⇒ Fluid Capacity Tables; Rep. Gr. 03
Manual transmission capacity
(transmission partly disassembled)
Refer to ⇒ Fluid Capacity Tables; Rep. Gr. 03
4.3
Gear Ratio Calculation
Example:
6th Gear
Final Drive
Drive gear
ZG1 = 47
ZA1 = 18
Driven gear
ZG2 = 31
ZA2 = 61
i = Z2 : Z1 (Z1 = number of teeth drive gear, Z2 = number of teeth
driven gear)
iG = gear ratio = ZG2 : ZG1 = 31 : 47 = 0.660
iA= axle ratio= ZA2 : ZA1= 61 : 18= 3.389
itotal = total ratio = iG x iA = 0.660 x 3.389 = 2.237
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