Assembling

WARNING: This page does not describe the selected car, but rather 8 other vehicles, including the 2005 Volkswagen Jetta, 2005 Volkswagen GTI, 2004 Volkswagen Jetta, 2004 Volkswagen GTI, and 2003 Volkswagen Jetta. However, it is still accessible from the selected car via links, so may be relevant.

Fig 1: Identifying 5th, 6th And Reverse Gear Output Shaft, Selector Rod & Reverse Shaft

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Install differential -1-.
Install 5th, 6th and reverse gear output shaft -2- together with reverse selector fork, 5th, 6th and reverse gear selector rod -3- and reverse shaft -4-.

Fig 2: Taking 1st-4th Gear Output Shaft With Selector Rods In Right Hand

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Take 1st-4th gear output shaft -3- with selector rods -5- in right hand as illustrated.
With left hand, lift differential slightly.
At same time, have a second technician slightly lift 5th, 6th and reverse gear output shaft together with reverse shaft -4-.
Insert 1st-4th gear output shaft in direction of arrow.

Toothing of output shafts and final drive gear/differential must mesh.

Together with second technician, place shafts in their bearing seats.

Fig 3: Setting Input Shaft In Clutch Housing

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Set input shaft in clutch housing and swing in (arrow).
Install transmission housing.

For transmissions from build date 06 04 0

Fig 4: Identifying Locking Plate Bolt

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Insert locking plate (arrow) in outer race/tapered roller bearing recess for input shaft.
Tighten new bolt to tightening torque. Refer to Input shaft, output shafts (pinion shafts), differential and selector rods, disassembling and assembling , item Input shaft, output shafts (pinion shafts), differential and selector rods, disassembling and assembling

Continued for all vehicles

Install transmission housing.

Installing selector shaft

Bring selector rods into neutral position.

Fig 5: Identifying Cover Plate, Lower Selector Shaft Bearing & Bolt

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Insert selector shaft -1-.
Position selector shaft so that shift fingers are inserted in selector rods. See Figure .
When doing this, align lower selector shaft bearing (arrow) through drilling for cover plate.
Bolt cover plate -A- to lower selector shaft bearing -1- with bolt -2-, M8 x 60 mm.

Fig 6: Identifying Cover Plate, Selector Shaft Cover & Bolts

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Hand tighten cover plate -A- by alternately tightening (1/2 turn) bolts (arrows).
Remove bolt -2- and hand tighten original bolt in its place.
Install selector shaft cover -B- and tighten hex bolts -4- to torque.
Tighten cover plate hex bolts.

Insert locking bolt -3- for selector shaft gate with locking fluid D 000 600 A2.
Install switch for back-up light.
Install both flanged shafts with springs, thrust washers and tapered rings.
Install speedometer sensor.

Fig 7: Pressing In Input Shaft Oil Seal Using T40008

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Press in input shaft oil seal.
Install slave cylinder with release bearing.