Volkswagen Jetta 2005 Service Manual

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– Set threaded insert -T10309/3- in half shell .
– Now fit second half shell -T10309/1- and set tube -T10309/2-
over assembly.
– After parts are pulled off, check synchro-hub for damage.
– Renew synchro-ring for 5th gear.
– Now remove sleeve from gear wheel for 5th gear.
– Pull off gear wheel for 5th gear.
– First set up puller hooks -A-.
-B- = Thrust piece -T10040/3-
or
Thrust plate -40 - 105-
Note
♦ When pulling off gear wheel, ensure that hooks do not bend
outwards. After pulling off 5th gear wheel, examine for dam‐
age.
♦ Heat gear wheel slightly with hot air blower -V.A.G 1416- if
necessary.
5.6.2 Installing cover for gearbox housing and
5th and 6th gears
Installing 5th/6th gears ⇒ page 123 .
– Apply sealant -AMV 188 200 03- evenly to sealing surface of
gearbox housing cover.
– Install cover for gearbox housing and tighten bolts to specified
torques ⇒ page 104 .
– Fit clutch release lever and release bearing ⇒ page 44 .
– Fill with gear oil ⇒ page 92 .
5.7 Assembly sequence - Dismantling and
assembling gearbox completely
Removing and installing gearbox housing cover, clutch housing,
selector shaft with selector mechanism cover, input shaft, output
shaft, differential and selector mechanism.
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
6-speed manual gearbox 02S - Edition 07.2009
5. Dismantling and assembling gearbox 115

Volkswagen Jetta 2005 Specifications

General

Brand	Volkswagen
Model	Jetta 2005
Category	Automobile
Language	English