FREE REPAIR MANUALS & LABOR GUIDES 1982-2013 Vehicles
Courtesy of Operation CHARM: Car repair manuals for everyone.
Home >> Volkswagen >> 2010 >> Jetta GLI (1K2) L4-2.0L Turbo (CCTA) >> Repair and Diagnosis >> Transmission and Drivetrain >> Manual Transmission/Transaxle >> Description and Operation >> General Repair Information >> Components

Components







Components

Transmission

• Make sure that the alignment sleeves between the engine and transmission are positioned correctly when installing the transmission.

• Clean the contact surfaces when installing the brackets as well as any waxed components. Contact surfaces must be free of grease and wax.

• For the correct bolt allocation, refer to the Parts Catalog.

• Check the transmission fluid level. Refer to => [ Transmission Fluid, Checking ] Service and Repair.

• For the correct capacity refer to => [ Codes Letters, Transmission Allocation and Capacities ] Codes Letters, Transmission Allocation and Capacities

O-rings, Gaskets, Seals and Sealant

• Clean the housing separating surfaces thoroughly before applying the sealant.

• Apply the sealing paste (AMV 188 200 03) evenly and not too thick.

• Replace the O-rings, seals and gaskets.

• Once a seal or gasket has been removed, check the contact surface on the housing or shaft for burrs and damage caused by the removal. Repair as necessary.

• Before installing the radial shaft seals, lightly lubricate the outer circumference and fill the space between the sealing lips - arrow - halfway with sealing grease for seal (G 052 128 A1).






• The open side of the shaft seals point toward the fluid to be sealed in.

• Press in the new shaft seal, so that the sealing lip does not run on the same point as the sealing lip of the old shaft seal (use insertion depth tolerances).

• Lightly lubricate O-rings before installing to prevent them from being crushed when inserting.

• After replacing the seals and O-rings, check the transmission fluid level and fill if necessary. Refer to => [ Transmission Fluid, Checking ] Service and Repair.

Fasteners






• Do not overstretch the circlips.

• Always replace damaged or stretched circlips.

• The circlips must fit completely inside the groove.

• Replace the roll pins. Installed position: the slit - A - should align with the line of force- arrow -.

Bolts and Nuts






• Always loosen or tighten bolts and nuts for covers and housings 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 and in a diagonal sequence.

• The tightening specifications stated apply to non-lubricated nuts and bolts.

• Always replace self-locking nuts and bolts.

• 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 bolts that were installed with locking compound. Install the bolts using liquid locking fluid (AMV 185 101 A1).

• Clean the threaded holes for the self-locking bolts or for the bolts coated with locking fluid. Otherwise the bolts could shear the next time they are removed.

Bearings

• Install needle bearings with the lettered side (thicker metal) facing the installation tool.

• Insert all the bearings in the transmission using transmission fluid.

• Replace all the tapered roller bearings that are on the same shaft. Use tapered roller bearings from the same manufacturer.

• To install, heat the inner race to approximately 100 °C (212 °F) using the inductive heat unit (VAS 6414).

• Do not interchange the outer and inner bearing races with those from other bearing of the same size. The bearings are paired.

Adjusting Shims






• Measure the adjusting shims at several locations with a micrometer caliper. Tolerance variations make it possible to find the exact shim thickness required.

• 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.

• 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 outer friction surface - arrow 2 - and the inner friction surface - arrow 3 - for grooves and scoring.

• Check the taper of the drive gear for grooves and scoring.

• Coat the synchronizer ring with transmission fluid and then install.

Gears, Synchronizer Hubs and Needle Bearing Sleeve

• Warm the needle bearing sleeves to approximately 100 °C (212 °F) using the inductive heat unit (VAS 6414).

• Heat the synchronizer hub to approximately 100 °C (212 °F) using the inductive heat unit (VAS 6414) before installing. Press on as far as the stop when installing so there is no axial play.

• Heat the gears to approximately 100 °C (212 °F) using the inductive heat unit (VAS 6414) before installing. Press on to the stop when installing, so there is no axial clearance.

• 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 diagonally 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.

pro multis Credits:Operation CHARM About Operation CHARM