Volkswagen 2015 Golf GTI Operating instructions

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Repair Manual
Golf 2015 ➤
Golf Variant 2015 ➤
Manual Transmission
Edition 02.2016
Service
Service Department. Technical Information
ProCarManuals.com

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List of Workshop Manual Repair Groups
Repair Group
00 - General, Technical Data
30 - Clutch
34 - Controls, Housing
35 - Gears, Shafts
39 - Final Drive, Differential
Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.
Service
All rights reserved.
No reproduction without prior agreement from publisher.
Copyright © 2016 Volkswagen AG, Wolfsburg D4B804111B5
ProCarManuals.com

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Contents
00 - General, Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Transmission Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.1 Road Test with Testing Equipment Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.2 Start/Stop System Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3 Repair Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3.1 General Repair Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3.2 Contact Corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4.1 Transmission/Engine Allocation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4.2 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4.3 Gear Ratio Calculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
5 Overview - Powertrain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
5.1 Overview - Powertrain, Front Wheel Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
6 Electrical Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
6.1 Overview - Electrical Components Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
7 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
30 - Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1 Clutch Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.1 Overview - Component Location, Clutch Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.2 Overview - Pedal Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.3 Overview - Clutch Hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1.4 Overview - Clutch Release Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
1.5 Over-Center Spring, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
1.6 Return Spring, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
1.7 Clutch Pedal, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
1.8 Mounting Bracket, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
1.9 Bearing Bushing, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
1.10 Clutch Master Cylinder, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
1.11 Clutch Slave Cylinder with Release Bearing, Removing and Installing . . . . . . . . . . . . . . . . 33
1.12 Clutch Mechanism Lines, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
1.13 Bleeder, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
1.14 Clutch Master and Clutch Slave Cylinder, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
1.15 Clutch Position Sensor G476 , Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . 37
1.16 Clutch Mechanism, Bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
1.17 Clutch Release Mechanism, Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
2 Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
2.1 Clutch Manufacturers, Differentiating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
2.2 Overview - Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
2.3 Clutch, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
3 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
34 - Controls, Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
1 Selector Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
1.1 Selector Mechanism Installation Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
1.2 Overview - Selector Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
1.3 Overview - Shift Lever Knob and Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
1.4 Gearshift Knob, Removing and Installingg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
1.5 Selector Mechanism, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
1.6 Selector Mechanism, Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Golf 2015 ➤ , Golf Variant 2015 ➤
Manual Transmission - Edition 02.2016
Contents i
ProCarManuals.com

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1.7 Gearshift Mechanism, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
1.8 Selector Shaft Seal, Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
2 Transmission, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
2.1 Transmission, Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
2.2 Transmission, Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
2.3 Transmission Tightening Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
3 Subframe Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
3.1 Overview - Subframe Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
4 Transmission, Transporting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
4.1 Transmission, Transporting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
5 Transmission, Disassembling and Assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
5.1 Overview - Schematic, Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
5.2 Overview - Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
5.3 Overview - Transmission Housing and Selector Mechanism . . . . . . . . . . . . . . . . . . . . . . . . 111
5.4 Overview - Shift Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
5.5 Overview - Input Shaft, Output Shafts, Differential, Shift Lever Rods . . . . . . . . . . . . . . . . 114
5.6 Overview - Shift Forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
5.7 Transmission, Disassembling and Assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
6 Transmission Housing and Clutch Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
6.1 Overview - Transmission Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
6.2 Overview - Clutch Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
6.3 Transmission Housing, Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
6.4 Clutch Housing, Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
7 Securing on Engine and Transmission Holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
7.1 Securing on Engine and Transmission Holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
8 Transmission Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
8.1 Transmission Fluid Level, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
9 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
35 - Gears, Shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
1 Input Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
1.1 Overview - Input Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
1.2 Input Shaft, Disassembling and Assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
1.3 Input Shaft Seal, Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
2 Output Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
2.1 Overview - Output Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
2.2 Output Shaft, Disassembling and Assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
2.3 Output Shaft, Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
3 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
39 - Final Drive, Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
1 Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
1.1 Overview - Component Location, Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
1.2 Left Seal, Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
1.3 Right Seal, Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
2 Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
2.1 Overview - Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
2.2 Differential, Disassembling and Assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
2.3 Differential, Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
3 Adjustment Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
3.1 Overview - Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
4 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
5 Revision History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
Golf 2015 ➤ , Golf Variant 2015 ➤
Manual Transmission - Edition 02.2016
ii Contents
ProCarManuals.com

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00 – General, Technical Data
1 Identification
(Edition 02.2016)
⇒ 1.1 Transmission Identification, page 1
1.1 Transmission Identification
Code Letters and Production Date -arrow 1-, Manual Transmis‐
sion 02Q -arrow 2-
Manual Transmission 02Q: 02Q -arrow 2-
Transmission Codes and Production Date -arrow-
Example: NYG 11 01 2
I I I I
I I I I
Code letters Day Month Year (2012)
of manufacture
For additional data and information contact the factory.
Note
♦
The transmission code is also listed in the vehicle data plates.
♦ The manual transmission 0FB has reinforcement measures
near the output shaft for 1st to 4th gear and is designed for a
tightening specification up to 380 Nm.
♦ The manual transmission 0FB can only be identified using the
transmission code.
Golf 2015 ➤ , Golf Variant 2015 ➤
Manual Transmission - Edition 02.2016
1. Identification 1
ProCarManuals.com

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2 Safety Precautions
⇒ 2.1 Road Test with Testing Equipment Safety Precautions,
page 2
⇒ 2.2 Start/Stop System Safety Precautions, page 2
2.1 Road Test with Testing Equipment
Safety Precautions
If testing equipment must be used during a road test, note the
following:
WARNING
Distraction and testing equipment that is not secured properly
can cause accidents.
The passenger airbag could pose a risk if it deploys in a colli‐
sion.
• Operating testing equipment while driving causes it to shift
position.
• There is an increased risk of injury due to unsecured test‐
ing equipment.
♦ Always secure testing equipment on the rear seat using a
strap and have a second person in the rear seat operate
it.
Caution
Risk of damaging electronic components when disconnecting
the battery.
♦ Complete the steps for disconnecting the battery.
♦ Always turn off the ignition before disconnecting the bat‐
tery.
To prevent personal injury and damage to electrical and electronic
components, observe the following:
♦ Connect and disconnect test equipment only when the ignition
is off.
– Disconnect the battery. Refer to ⇒ Electrical Equipment; Rep.
Gr. 27 ; Battery; Battery, Disconnecting and Connecting .
2.2 Start/Stop System Safety Precautions
WARNING
Danger of injury through automatic motor starting with vehicles
with the Start/Stop System.
♦ Deactivate the Start-Stop system when working on the
vehicle. Turn off the ignition.
♦ Only switch the ignition on briefly when necessary.
Golf 2015 ➤ , Golf Variant 2015 ➤
Manual Transmission - Edition 02.2016
2 Rep. Gr.00 - General, Technical Data
ProCarManuals.com

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3 Repair Information
⇒ 3.1 General Repair Information, page 3
⇒ 3.2 Contact Corrosion, page 6
3.1 General Repair Information
Special tools and workshop equipment required
♦ Inductive Heater - VAS6414-
Carefulness, cleanliness and the correct tools are required for
transmission repairs to be successful. The usual basic safety pre‐
cautions apply when making vehicle repairs.
Some general repair information that applies to several proce‐
dures throughout this manual is summarized. They apply to this
repair manual.
Special Tools and Equipment
For a complete list of special tools used in the Repair Manual refer
to Workshop Equipment and Special Tools.
Transmission
♦ Make sure that the alignment sleeves between the engine and
transmission are positioned correctly when installing the trans‐
mission.
♦ Clean the contact surfaces when installing brackets as well as
parts that have been waxed. Contact surfaces must be free of
grease and wax.
♦ For the correct bolts and other components. Refer to the Parts
Catalog.
♦ Fill with transmission fluid when repairing the manual trans‐
mission.
Seals, Sealing Rings
♦ Always thoroughly clean the separating surfaces on the hous‐
ing before applying the sealant.
♦ Flange shaft, input shaft and gearshift shaft seals are also il‐
lustrated as radial shaft seals.
♦ Once a shaft 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 shaft seals, lightly oil the outer circumfer‐
ence and fill the space between the sealing lips -arrow- half‐
way with Grease - G 052 128 A1- .
♦ The open side of the gaskets point toward the fluid to be sealed
in.
♦ Lightly lubricate the O-rings before inserting to prevent the
rings from being crushed during assembly.
Sealant
♦ Always thoroughly clean the separating surfaces on the hous‐
ing before applying the Sealant .
♦ Apply the Sealing Compound - AMV 188 200 03- evenly and
not too thick.
♦ Do not allow any Sealing Compound to get into the ventilation
holes.
Golf 2015 ➤ , Golf Variant 2015 ➤
Manual Transmission - Edition 02.2016
3. Repair Information 3
ProCarManuals.com

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Fasteners
♦ Do not stretch the circlips.
♦ Installation position for some of the circlips: The circlip is »nar‐
rower at the top« and so is its installation position. This makes
it easier for the pliers to grab the circlip when removing and
installing it.
♦ Replace damaged or overstretched locking ring after remov‐
ing.
♦ The circlips must rest at the bottom of the groove.
♦ Replace the adapter sleeves. Installation position: the slot
-A- should align with the line of force -arrow-.
Golf 2015 ➤ , Golf Variant 2015 ➤
Manual Transmission - Edition 02.2016
4 Rep. Gr.00 - General, Technical Data
ProCarManuals.com

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Bolts and Nuts
♦ Always loosen or tighten bolts and nuts on covers and hous‐
ings 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
in a diagonal sequence.
♦ The tightening specifications stated apply to non-oiled nuts
and bolts.
♦ Replace self-locking nuts and bolts after removing them.
♦ 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 the bolts that were
installed with locking fluid. Then insert the bolts with Locking
Fluid - AMV 185 101 A1- .
♦ If self-locking bolts were installed or if regular bolts were in‐
stalled with locking fluid, then the threaded holes must be
cleaned, for example with a thread tap. Otherwise the bolts
could shear the next time they are removed.
♦ Please make sure that the thread pitch is correct so that the
proper thread cutter is used during cleaning, and the thread
does not get damaged.
Bearings
♦ Insert the bearings with transmission fluid.
♦ Install the new tapered roller bearings. It is not necessary to
oil them.
♦ Install needle bearings with lettered side (thicker metal) racing
the fitting tool.
♦ Replace all the tapered roller bearings that are on the same
shaft. Use tapered roller bearings from the same manufactur‐
er.
♦ To install, warm the inner races/tapered roller bearing to ap‐
proximately 100 °C (212 °F) with -VAS6414- .
♦ Do not interchange outer and inner bearing races with those
from other bearing of the same size. The bearings are paired.
Adjusting Shims
♦ Measure the shims at several locations with a micrometer cal‐
iper. It is possible to measure the necessary shim thickness
by the different tolerances.
♦ Check for burrs and damage.
♦ Only install perfect shims.
Synchronizer Rings
Golf 2015 ➤ , Golf Variant 2015 ➤
Manual Transmission - Edition 02.2016
3. Repair Information 5
ProCarManuals.com

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♦ Do not interchange them. When reusing synchronizer rings,
always install to the same gear wheel.
♦ 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 intermediate
ring on the outer contact surface -arrow 2- and inner contact
surface -arrow 3- for grooves, scoring and blue coloring (from
overheating).
♦ Check taper of drive gear for grooves and scoring.
♦ Coat the synchronizing with transmission fluid and then install.
Toothed Gears, Synchronizer Hubs
♦ Clean before installing. Warm using the -VAS6414- to a max‐
imum 100 °C (212 °F).
♦ 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 di‐
agonally 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.
3.2 Contact Corrosion
♦ The transmission housing and clutch housing consist of a
magnesium alloy.
♦ Bolts and other components, which come into direct contact
with the transmission, have a surface coating adapted for this.
♦ Contact corrosion occurs when incorrect components (bolts,
nuts, washers, etc.) are used. The transmission housing and
clutch housing are damaged.
♦ Only install components provided in the Parts Catalog.
Golf 2015 ➤ , Golf Variant 2015 ➤
Manual Transmission - Edition 02.2016
6 Rep. Gr.00 - General, Technical Data
ProCarManuals.com

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4 Technical Data
⇒ 4.1 Transmission/Engine Allocation, page 7
⇒ 4.2 Capacities, page 8
⇒ 4.3 Gear Ratio Calculation, page 8
4.1 Transmission/Engine Allocation
⇒ 4.1.1 Transmission/Engine Allocation, Golf, page 7
⇒ 4.1.2 Transmission/Engine Allocation, Golf Wagon,
page 7
4.1.1 Transmission/Engine Allocation, Golf
Manual Transmission 6-Speed 02Q
Codes NBL PFN
Manufactured from
through
06/2014 03/2014
Allocation Engine 2.0L - 155 KW 2.0L - 110 KW
Turbo diesel
Ratio
Z1 : Z2 Final drive I 1) 68 : 21 = 3.238 69 : 20 = 3.450
Final drive II 2) 68 : 26 = 2.615 69 : 25 = 2.760
Driveshaft Flange Diameter 107 mm 107 mm
1) Final drive for 1st through 4th gear
2) Final drive for 5th gear, 6th gear and reverse gear
• Refer to the Parts Catalog for the following information:
♦ The individual gear ratios
♦ Transmission fluid specification
♦ Clutch plate and pressure plate allocation
4.1.2 Transmission/Engine Allocation, Golf Wagon
Manual Transmission 6-Speed 02Q
Codes PFN
Manufactured from
through
03/2014
Allocation Engine 2.0L - 110 KW
Turbo diesel
Ratio
Z1 : Z2 Final drive I 1) 69 : 20 = 3.450
Final drive II 2) 69 : 25 = 2.760
Driveshaft Flange Diameter 107 mm
1) Final drive for 1st through 4th gear
2) Final drive for 5th gear, 6th gear and reverse gear
• Refer to the Parts Catalog for the following information:
♦ The individual gear ratios
♦ Transmission fluid specification
♦ Clutch plate and pressure plate allocation
Golf 2015 ➤ , Golf Variant 2015 ➤
Manual Transmission - Edition 02.2016
4. Technical Data 7
ProCarManuals.com

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4.2 Capacities
Manual Transmis‐
sion Capacity
Refer to ⇒ Fluid Capacity Tables; Rep.
Gr. 03
4.3 Gear Ratio Calculation
Example
6. Gear Final drive
Drive gear ZG1 = 46 ZA1 = 24
Driven gear ZG2 = 33 ZA2 = 70
i = Z2 : Z1 (Z1 = number of teeth on the drive gear, Z2 = number
of teeth on the driven gear)
iG = gear ratio = ZG2 : ZG1 = 33 : 46 = 0.717
iA= axle ratio = ZA2 : ZA1 = 70 : 24= 2.917
itotal = total ratio = iG x iA = 0.717 x 2.917 = 2.091
Golf 2015 ➤ , Golf Variant 2015 ➤
Manual Transmission - Edition 02.2016
8 Rep. Gr.00 - General, Technical Data
ProCarManuals.com

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5 Overview - Powertrain
⇒ 5.1 Overview - Powertrain, Front Wheel Drive, page 9
5.1 Overview - Powertrain, Front Wheel Drive
Name
The -arrows- point in the direction of travel.
1 - Engine
2 - Clutch
3 - Manual Transmission
4 - Input Shaft
5 - 5th, 6th and Reverse Gear
Output Shaft
6 - 1st through 4th Gear Output
Shaft
7 - Differential
Ratio
The -arrows- point in the direction of travel.
Golf 2015 ➤ , Golf Variant 2015 ➤
Manual Transmission - Edition 02.2016
5. Overview - Powertrain 9
ProCarManuals.com

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I - 1st Gear
II - 2nd Gear
III - 3rd Gear
IV - 4th Gear
V - 5th Gear
VI - 6th Gear
R - Reverse Gear
A - Final Drive
Golf 2015 ➤ , Golf Variant 2015 ➤
Manual Transmission - Edition 02.2016
10 Rep. Gr.00 - General, Technical Data
ProCarManuals.com

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6 Electrical Components
⇒ 6.1 Overview - Electrical Components Location, page 11
6.1 Overview - Electrical Components Lo‐
cation
⇒ 6.1.1 Overview - Electrical Components Location, Manual
Transmission, page 11
⇒ 6.1.2 Overview - Electrical Components Location, Clutch
Mechanism, page 11
6.1.1 Overview - Electrical Components Location, Manual Transmission
1 - Transmission Neutral Posi‐
tion Sensor - G701-
❑ Installed location: in the
area of the shift unit un‐
der the selector shaft
bracket.
❑ Removing and instal‐
ling. Refer to
⇒ 5.3 Overview - Trans‐
mission Housing and
Selector Mechanism,
page 111 .
2 - Back-Up Lamp Switch - F4-
❑ Installed location: In the
area of the shift unit un‐
der the selector shaft
bracket.
❑ Removing and instal‐
ling. Refer to
⇒ 5.3 Overview - Trans‐
mission Housing and
Selector Mechanism,
page 111 .
6.1.2 Overview - Electrical Components Lo‐
cation, Clutch Mechanism
Clutch Position Sensor - G476- -arrow-
Installed location: in the passenger compartment on the clutch
master cylinder.
Clutch Position Sensor - G476- , removing and installing. Refer
to
⇒ 1.15 Clutch Position Sensor G476 , Removing and Installing,
page 37 .
Golf 2015 ➤ , Golf Variant 2015 ➤
Manual Transmission - Edition 02.2016
6. Electrical Components 11
ProCarManuals.com

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7 Special Tools
Special tools and workshop equipment required
♦ Inductive Heater - VAS6414-
Golf 2015 ➤ , Golf Variant 2015 ➤
Manual Transmission - Edition 02.2016
12 Rep. Gr.00 - General, Technical Data
ProCarManuals.com

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30 – Clutch
1 Clutch Mechanism
⇒ 1.1 Overview - Component Location, Clutch Mechanism,
page 13
⇒ 1.2 Overview - Pedal Assembly, page 15
⇒ 1.3 Overview - Clutch Hydraulics, page 17
⇒ 1.4 Overview - Clutch Release Mechanism, page 21
⇒ 1.5 Over-Center Spring, Removing and Installing, page 22
⇒ 1.6 Return Spring, Removing and Installing, page 24
⇒ 1.7 Clutch Pedal, Removing and Installing, page 27
⇒ 1.8 Mounting Bracket, Removing and Installing, page 28
⇒ 1.9 Bearing Bushing, Removing and Installing, page 32
⇒ 1.10 Clutch Master Cylinder, Removing and Installing,
page 32
⇒ 1.11 Clutch Slave Cylinder with Release Bearing, Removing
and Installing, page 33
⇒ 1.12 Clutch Mechanism Lines, Removing and Installing, page
34
⇒ 1.13 Bleeder, Removing and Installing, page 36
⇒ 1.14 Clutch Master and Clutch Slave Cylinder, Checking,
page 36
⇒ 1.15 Clutch Position Sensor G476 , Removing and Installing,
page 37
⇒ 1.16 Clutch Mechanism, Bleeding, page 37
⇒ 1.17 Clutch Release Mechanism, Servicing, page 38
1.1 Overview - Component Location, Clutch Mechanism
Golf 2015 ➤ , Golf Variant 2015 ➤
Manual Transmission - Edition 02.2016
1. Clutch Mechanism 13
ProCarManuals.com

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I - Refer to
⇒ 1.2 Overview - Pedal As‐
sembly, page 15
II - Refer to
⇒ 1.3.1 Overview - Clutch Hy‐
draulics, page 17
III - Refer to
⇒ 1.3.2 Overview - Clutch Hy‐
draulics, RHD, page 19
Golf 2015 ➤ , Golf Variant 2015 ➤
Manual Transmission - Edition 02.2016
14 Rep. Gr.30 - Clutch
ProCarManuals.com

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1.2 Overview - Pedal Assembly
1 - Clutch Master Cylinder
❑ Removing and instal‐
ling. Refer to
⇒ 1.10 Clutch Master
Cylinder, Removing and
Installing, page 32 .
2 - Bearing Bushing
❑ Removing and instal‐
ling. Refer to
⇒ 1.9 Bearing Bushing,
Removing and Instal‐
ling, page 32 .
❑ Do not lubricate
3 - Clamp
❑ The clamp must be re‐
moved in order to re‐
move/install the hose/
line assembly
4 - Seal
❑ Self-adhesive
❑ Replace after removing
the clutch master cylin‐
der
❑ Glue to clutch master
cylinder
5 - Clutch Position Sensor -
G476-
❑ Can be checked in Gui-
ded Fault Finding
using Vehicle Diagnosis
Tester
❑ Allocation. Refer to the
Parts Catalog.
❑ Removing and instal‐
ling. Refer to ⇒ 1.15 Clutch Position Sensor G476 , Removing and Installing, page 37 .
6 - Bearing Axle
❑ Replace after removing
❑ Do not lubricate
7 - Rubber Stop
8 - Nut
❑ 25 Nm
❑ Replace after removing
❑ Quantity: 3
❑ Self-locking
❑ For the mounting bracket to the bulkhead
9 - Bearing Shell
❑ Quantity: 2
❑ Installed on both sides
❑ Installed in connection with over-center spring only
❑ Do not lubricate
Golf 2015 ➤ , Golf Variant 2015 ➤
Manual Transmission - Edition 02.2016
1. Clutch Mechanism 15
ProCarManuals.com

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10 - Bracket
❑ For the clutch pedal
❑ Removing and installing. Refer to ⇒ 1.8 Mounting Bracket, Removing and Installing, page 28 .
❑ Use a Piston Pin Drift - VW207- to drive the bushings into the holes for the mounting bracket pins on the
bulkhead.
11 - Return Spring
❑ Installed depending on the date of manufacture
❑ Removing and installing. Refer to ⇒ 1.6 Return Spring, Removing and Installing, page 24 .
❑ Do not grease the mount on the bracket.
12 - Mounting Pin
❑ For the clutch master cylinder
❑ Replace after removing
❑ Do not lubricate
13 - Over-Center Spring
❑ Installed depending on the date of manufacture
❑ There are different versions. For the correct allocation. Refer to the Parts Catalog.
❑ Removing and installing. Refer to ⇒ 1.5 Over-Center Spring, Removing and Installing, page 22 .
❑ Do not lubricate
14 - Bearing Bushing
❑ Do not lubricate
15 - Slide Bushing
❑ Installed depending on the date of manufacture
❑ For return spring mounting
❑ Install on clutch pedal
❑ Lubricate to the return spring mount
❑ Grease. Refer to the Parts Catalog.
16 - Mounting Pin
❑ For plunger/clutch master cylinder
❑ Replace after removing
❑ Do not lubricate
17 - Clutch Pedal
❑ Removing and installing. Refer to ⇒ 1.7 Clutch Pedal, Removing and Installing, page 27 .
❑ Do not lubricate
18 - Pedal Rubber
19 - Bearing Bushing
❑ Do not lubricate
20 - Tension Spring
❑ For the clutch pedal
❑ Installed depending on the date of manufacture
❑ Removing and installing over-center spring. Refer to
⇒ 1.5 Over-Center Spring, Removing and Installing, page 22 .
21 - Damping Element
❑ Installed in connection with tension spring only
❑ Do not lubricate
Golf 2015 ➤ , Golf Variant 2015 ➤
Manual Transmission - Edition 02.2016
16 Rep. Gr.30 - Clutch
ProCarManuals.com