VW Golf, Golf Plus & Passat 0A4 5-Speed Manual Gearbox Workshop Manual (Edition 04.2010)

Description

VW Golf, Golf Plus & Passat 0A4 5-Speed Manual Gearbox Workshop Manual

This is the genuine Volkswagen Service Department workshop manual (Edition 04.2010) covering the 0A4 5-speed manual gearbox as installed in the Golf 2004 onward, Golf 2009 onward, Golf Plus 2005 onward, Golf Plus 2009 onward, and Passat 2006 onward. If you are working on any of these platforms with a manual transmission, this VW 0A4 5-Speed Manual Gearbox Workshop Manual takes you from clutch pedal to differential with the same repair-group structure VW technicians use in the dealer network.

File Details

• Manual type: Official Volkswagen Service Department Workshop Manual
• Brand/Model: Volkswagen Golf, Golf Plus, Passat — 0A4 5-speed manual gearbox
• Edition: 04.2010
• Language: English
• Page count: 319 pages
• File format: PDF (digital download)

IMAGES PREVIEW

Chapters Covered

• 00 – Technical data
  • Gearbox identification and location codes
  • Identification codes, assembly allocation and capacities for Golf 2004, Golf 2009, Golf Plus 2005, Golf Plus 2009 and Passat 2006
  • Overview – power transmission
  • Calculating overall gear ratio “i”
  • General repair notes and components
• 30 – Clutch
  • Repairing clutch mechanism, pedal cluster and over-centre spring
  • Removing/installing clutch pedal, mounting bracket, master cylinder and clutch position sender G476
  • Hydraulics assembly overview (LHD and RHD)
  • Removing/installing and bleeding slave cylinder, torque settings
  • Repairing clutch release mechanism
  • Repairing clutch with dual-mass flywheel (Sachs and LuK clutch identification, removal, repair)
  • Repairing clutch with one-piece flywheel
• 34 – Controls, housing
  • Repairing selector mechanism — gear knob, gaiter, gear lever and selector housing
  • Removing/installing and adjusting selector cables and mechanism
  • Removing and installing gearbox — separate procedures for Golf 2004, Golf 2009 (turbo diesel and petrol), Golf Plus, and Passat
  • Transporting gearbox
  • Checking, draining and filling gear oil
  • Dismantling and assembling gearbox completely, including cover, housing, input/output shaft, differential and selector forks
  • Repairing gearbox housing, clutch housing and selector unit
  • Dismantling and assembling selector forks
• 35 – Gears, shafts
  • Dismantling, assembling and adjusting input shaft
  • Dismantling, assembling and adjusting output shaft
  • Dismantling and assembling reverse shaft
• 39 – Final drive – differential
  • Renewing flange shaft oil seals with gearbox installed (left and right, one-piece and two-part seals)
  • Adjustment overview
  • Dismantling, assembling and adjusting differential
  Complete PDF Bookmark Tree

  Complete Bookmarks

  The complete bookmarks in the “VW Golf, Golf Plus & Passat 0A4 5-Speed Manual Gearbox Workshop Manual (Edition 04.2010)” are as follows:

  +00 – Technical datap. 7

  +1 Gearbox identificationp. 7

  1.1 Location on gearboxp. 7

  1.2 Identification codes, assembly allocation, capacities, Golf 2004 ▸p. 8

  1.3 Identification codes, assembly allocation, capacities, Golf 2009 ▸p. 10

  1.4 Identification codes, assembly allocation, capacities, Golf Plus 2005 ▸p. 11

  1.5 Identification codes, assembly allocation, capacities, Golf Plus 2009 ▸p. 12

  1.6 Identification codes, assembly allocation and capacities, Passat 2006 ▸p. 12

  2 Overview – power transmissionp. 15

  3 Calculating overall gear ratio “i”p. 17

  +4 General repair notesp. 18

  +4.1 Componentsp. 18

  4.1.1 Gearboxp. 18

  4.1.2 Seals and sealing ringsp. 18

  4.1.3 Sealantp. 18

  4.1.4 Locking devicesp. 19

  4.1.5 Nuts and boltsp. 19

  4.1.6 Bearingsp. 19

  4.1.7 Shimsp. 19

  4.1.8 Synchro-ringsp. 20

  4.1.9 Gear wheelsp. 20

  4.1.10 Synchromeshed gearsp. 20

  4.1.11 Clutchp. 20

  +30 – Clutchp. 21

  +1 Repairing clutch mechanismp. 21

  1.1 Overviewp. 21

  1.2 Assembly overview – pedal clusterp. 22

  +1.3 Removing and installing over-centre spring, Golf 2004 ▸p. 24

  1.3.1 Removingp. 24

  1.3.2 Installingp. 26

  1.3.3 Torque settingsp. 28

  +1.4 Removing and installing over-centre spring, Golf 2009 ▸ LHDp. 28

  1.4.1 Removingp. 29

  1.4.2 Installingp. 31

  1.4.3 Torque settingsp. 33

  +1.5 Removing and installing over-centre spring, Golf 2009 ▸ RHDp. 33

  1.5.1 Removingp. 34

  1.5.2 Installingp. 36

  1.5.3 Torque settingsp. 38

  +1.6 Removing and installing over-centre spring, Golf Plusp. 38

  1.6.1 Removingp. 38

  1.6.2 Installingp. 41

  1.6.3 Torque settingsp. 42

  +1.7 Removing and installing over-centre spring, Passatp. 43

  1.7.1 Removingp. 43

  1.7.2 Installingp. 43

  +1.8 Removing and installing clutch pedal, Golf 2004 ▸p. 44

  1.8.1 Removingp. 45

  1.8.2 Installingp. 47

  1.8.3 Torque settingsp. 49

  +1.9 Removing and installing clutch pedal, Golf 2009 ▸ LHDp. 50

  1.9.1 Removingp. 50

  1.9.2 Installingp. 53

  1.9.3 Torque settingsp. 55

  +1.10 Removing and installing clutch pedal, Golf 2009 ▸ RHDp. 55

  1.10.1 Removingp. 55

  1.10.2 Installingp. 58

  1.10.3 Torque settingsp. 60

  +1.11 Removing and installing clutch pedal, Golf Plusp. 60

  1.11.1 Removingp. 60

  1.11.2 Installingp. 63

  1.11.3 Torque settingsp. 65

  +1.12 Removing and installing clutch pedal, Passatp. 65

  1.12.1 Removingp. 66

  1.12.2 Installingp. 66

  1.12.3 Torque settingp. 67

  +1.13 Removing and installing mounting bracket, Golf 2004 ▸p. 67

  1.13.1 Removingp. 68

  1.13.2 Installingp. 71

  1.13.3 Torque settingsp. 73

  +1.14 Removing and installing mounting bracket, Golf 2009 ▸ LHDp. 73

  1.14.1 Removingp. 74

  1.14.2 Installingp. 77

  1.14.3 Torque settingsp. 78

  +1.15 Removing and installing mounting bracket, Golf 2009 ▸ right-hand drive and Golf Plus right-hand drivep. 79

  1.15.1 Removingp. 79

  1.15.2 Installingp. 82

  1.15.3 Torque settingsp. 84

  +1.16 Removing and installing mounting bracket, Golf Plus left-hand drivep. 85

  1.16.1 Removingp. 85

  1.16.2 Installingp. 88

  1.16.3 Torque settingsp. 90

  +1.17 Removing and installing mounting bracket, Passatp. 90

  1.17.1 Removingp. 91

  1.17.2 Installingp. 93

  1.17.3 Torque settingsp. 94

  +1.18 Removing and installing master cylinderp. 94

  1.18.1 Removingp. 94

  1.18.2 Installingp. 95

  +1.19 Removing and installing clutch position sender -G476-p. 96

  1.19.1 Removingp. 96

  1.19.2 Installingp. 98

  1.20 Assembly overview – hydraulics (LHD)p. 100

  1.21 Assembly overview – hydraulics (RHD)p. 102

  +2 Removing and installing slave cylinderp. 104

  2.1 Removingp. 104

  2.2 Installingp. 105

  2.3 Torque settingsp. 105

  3 Bleeding clutch systemp. 107

  4 Repairing clutch release mechanismp. 109

  +5 Repairing clutch, in conjunction with dual-mass flywheelp. 111

  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 ginep. 111

  +5.2 Removing and installing Sachs clutchp. 113

  5.2.1 Removingp. 113

  5.2.2 Installingp. 113

  5.3 Repairing Sachs clutchp. 115

  +5.4 Removing and installing LuK clutchp. 115

  5.4.1 Removingp. 115

  5.4.2 Installingp. 115

  5.5 Repairing LuK clutchp. 118

  6 Repairing clutch, in conjunction with one-piece flywheelp. 119

  +34 – Controls, housingp. 122

  +1 Repairing selector mechanismp. 122

  1.1 Installation position of selector mechanismp. 122

  1.2 Overview of selector mechanismp. 123

  1.3 Removing and installing gear knob and coverp. 124

  1.4 Removing and installing gaiter with gear knob and noise insulation, Golfp. 124

  1.5 Removing and installing gaiter with gear knob and noise insulation, Golf Plusp. 126

  1.6 Removing and installing gaiter with selector lever knob and noise insulation, Passatp. 127

  1.7 Repairing gear lever and selector housing (through 10.06)p. 129

  +1.8 Repairing gear lever and selector housing (from 11.06)p. 131

  1.8.1 Dismantling and assembling selector mechanismp. 132

  1.9 Assembly overview – removing and installing selector cablesp. 137

  1.10 Plastic relay leverp. 140

  +1.11 Removing and installing selector mechanismp. 142

  1.11.1 Removingp. 142

  1.11.2 Installingp. 144

  1.11.3 Torque settingsp. 145

  +1.12 Adjusting selector mechanismp. 145

  1.12.1 Functional checkp. 148

  +2 Removing and installing gearbox, Golf 2004 ▸p. 149

  2.1 Removing gearboxp. 150

  +2.2 Installing gearboxp. 156

  2.2.1 Torque settingsp. 160

  +3 Removing and installing gearbox, Golf 2009 ▸ with turbo diesel enginep. 162

  3.1 Removing gearboxp. 163

  +3.2 Installing gearboxp. 169

  3.2.1 Torque settingsp. 175

  +4 Removing and installing gearbox, Golf 2009 ▸ with petrol enginep. 177

  4.1 Removing gearboxp. 179

  +4.2 Installing gearboxp. 186

  4.2.1 Torque settingsp. 192

  +5 Removing and installing gearbox, Golf Plusp. 194

  5.1 Removing gearboxp. 195

  +5.2 Installing gearboxp. 202

  5.2.1 Torque settingsp. 209

  +6 Removing and installing gearbox, Passatp. 211

  6.1 Removing gearboxp. 213

  +6.2 Installing gearboxp. 218

  6.2.1 Torque settingsp. 223

  7 Transporting gearboxp. 225

  +8 Checking and topping up gear oilp. 226

  8.1 Preparationp. 226

  8.2 Draining gear oilp. 227

  8.3 Fill with gear oilp. 228

  +9 Dismantling and assembling gearboxp. 229

  9.1 Overview – gearboxp. 229

  9.2 Assembly overviewp. 230

  9.3 Removing and installing cover for gearbox housing and 5th gearp. 231

  9.4 Removing and installing gearbox housing and selector mechanismp. 232

  9.5 Removing and installing input shaft, output shaft, differential and selector forksp. 233

  +9.6 Assembly sequence – removing and installing cover for gearbox housing and 5th gearp. 234

  9.6.1 Removingp. 236

  9.6.2 Installingp. 239

  +9.7 Assembly sequence – Dismantling and assembling gearbox completelyp. 240

  9.7.1 Removingp. 242

  9.7.2 Installingp. 247

  10 Repairing gearbox housing and clutch housingp. 254

  11 Repairing selector unitp. 261

  12 Dismantling and assembling selector forksp. 264

  +35 – Gears, shaftsp. 269

  +1 Input shaftp. 269

  1.1 Dismantling and assembling input shaftp. 269

  +1.2 Adjusting input shaftp. 276

  1.2.1 Determining thickness of shimp. 278

  1.2.2 Carrying out check measurementp. 280

  +2 Output shaftp. 281

  2.1 Dismantling and assembling output shaftp. 281

  +2.2 Adjusting output shaftp. 293

  2.2.1 Determining thickness of shimp. 295

  +3 Reverse shaftp. 297

  3.1 Dismantling and assembling reverse shaftp. 297

  +39 – Final drive – differentialp. 300

  +1 Renewing flange shaft oil seals with gearbox installedp. 300

  +1.1 Renewing oil seal for left flange shaftp. 300

  1.1.1 Removingp. 300

  1.1.2 Installingp. 301

  1.1.3 Torque settingp. 301

  1.2 Distinguishing seals for right flange shaftp. 301

  +1.3 Renewing seal (two-part seal and sleeve for right flange shaft)p. 302

  1.3.1 Removingp. 303

  1.3.2 Installingp. 304

  1.3.3 Torque settingp. 305

  +1.4 Renewing seal and sleeve together (one-piece seal and sleeve for right flange shaft)p. 305

  1.4.1 Removingp. 306

  1.4.2 Installingp. 307

  1.4.3 Torque settingp. 307

  2 Adjustment overviewp. 308

  +3 Differentialp. 309

  3.1 Dismantling and assembling differentialp. 309

  +3.2 Adjusting differentialp. 317

  3.2.1 Determining thickness of shimp. 318

Across its 319 pages, this VW 0A4 5-speed manual gearbox workshop manual gives a technician the complete internal picture of the transmission: identification codes and gearbox capacities by engine variant, clutch and selector servicing, full removal/installation routines tailored to each body style and engine family, and a ground-up teardown of the gearbox internals down to the differential.

What This Manual Lets You Do

With this Golf/Golf Plus/Passat 0A4 gearbox manual in hand, you can correctly identify your exact gearbox variant by its stamped code, confirm the right final drive ratio and oil capacity for your build, and carry out clutch pedal, master cylinder, slave cylinder and hydraulic bleeding work using VW’s specified torque settings. It also walks through full gearbox removal and installation for each specific application — Golf 2004, Golf 2009 turbo diesel, Golf 2009 petrol, Golf Plus and Passat — plus complete internal dismantling, input/output/reverse shaft adjustment, selector fork repair and differential overhaul.

Following the exact VW-specified procedures and torque values in this manual helps avoid mis-adjusted selector mechanisms, incorrect shaft end-float, and premature gearbox wear, which are the most common results of guessing your way through a 5-speed 0A4 rebuild.

This VW Golf, Golf Plus & Passat 0A4 5-Speed Manual Gearbox Workshop Manual is delivered as an instant PDF download — no shipping, no waiting. Read it on a laptop, tablet or phone in the workshop, or print out the pages you need for the job at hand.