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)

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

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.