Golf Mk4: Power transmission
Also for this vehicle: Golf (5K1) L4-2.0L DSL Turbo (CJAA) (2011), Golf (5K1) L5-2.5L (CBUA) (2011), Golf GL L4-2.0L (AEG) (2001), Golf GL L4-2.0L (AVH) (2002), Golf GL L4-2.0L (AZG) (2001), Golf GLS L4-1.8L Turbo (AWW) (2001), Golf GLS L4-2.0L (AEG) (2001), Golf GLS L4-2.0L (AVH) (2002), Golf GLS L4-2.0L (AZG) (2001), Golf GTI L4-1781cc 1.8L SOHC (HT) (1985), Golf GTI L4-1781cc 1.8L SOHC (RD) (1987), Golf GTI L4-1984cc 2.0L DOHC (9A) (1990), Golf GTI L4-2.0L (ABA) (1997), Golf GTI V6-2792cc 2.8L DOHC (AAA) SFI (1998), Golf III L4-1984cc 2.0L SOHC (1993), Golf III L4-2.0L (ABA) (1995), Golf L4-1.8L Turbo (AWD) (2000), Golf L4-1.8L Turbo (AWW) (2003), Golf L4-1.9L DSL Turbo (AHU) (1997), Golf L4-1.9L DSL Turbo (ALH) (1999), Golf L4-1.9L DSL Turbo (BEW) (2004), Golf L4-1588cc 1.6L DSL SOHC (1987), Golf L4-1588cc 1.6L DSL SOHC Turbo (1985), Golf L4-1781cc 1.8L SOHC (1987), Golf L4-1781cc 1.8L SOHC (ACC) Can (1993), Golf L4-1781cc 1.8L SOHC (RV) (1990), Golf L4-1781cc 1.8L SOHC (RV, PF) (1989), Golf L4-1896cc 1.9L DSL Turbo (1Z) (1997), Golf L4-2.0L (ABA) (1996), Golf L4-2.0L (AEG) (1999), Golf L4-2.0L (AVH) (2003), Golf L4-2.0L (AZG) (2004), Golf L4-2.0L (BEV) (2004), Golf L4-2.0L DSL Turbo (CJAA) (2010), Golf L5-2.5L (CBUA) (2010), Golf Mk1, Golf Mk2, Golf Mk3, Golf Mk5, Golf Mk6.
Steering & suspension
Body & interior
Engine
General
Transmission
Heating & A/C
Choose Sections to see everything in a chapter, or a chapter title to start at its first page.
Automatic gearbox 01M176 pages
Technical data85 pages
- Suggestions and criticism of this workshop manual
Further information on "automatic gearbox 01M”4 pages
- Gearbox identification
- Identification codes, engine allocation, ratios, equipment
Repair with an exchange component10 pages
Fault finding for the automatic 4-speed gearbox48 pages
- Vehicle cannot drive forwards or backwards
- Vehicle will not drive forwards
- Vehicle will not reverse
- Gearbox oily
- Oil or ATF leaks around torque converter
- Visible fouling of ATF and/or engine coolant
- ATF level too low, final drive oil level too high (or vice versa) - no external leaks in gearbox
- Gearbox oily only near breather - no other external leaks in gearbox
- ATF escaping from breather (only for longitudinally installed gearbox 01N)
- Selector mechanism does not move freely
- Not all selector lever positions can be selected; selected drive ranges do not function
- Parking lock does not engage
- Parking lock disengages "with a jolt” (selector lever sometimes difficult to move from "P” to "R”)
- Final drive noisy
- Performance - jolting in neutral or during certain engine and gearbox movements
- Engine speed drops when driving range is selected
- Vehicle does not start at all or also starts in "R-D-3-2-1”
- Vehicle does not start or engine stalls after a short time
- Selector lever can be moved from "N” or "P” without brake being operated
- Selector lever cannot be moved from "N” or "P” although brake is operated
- Shifts occur sporadically or not at all
- All shifts are "hard or jolting”
- One particular shift is "hard or jolting”
- Shift from 3rd to 4th gear takes "too long” in vehicles through 12.92 having economy/sport switch
- Shifts take "too long”
- Hard shifts immediately after repair
- Gearbox downshifts at constant vehicle speed without apparent reason
- Gearbox does not downshift for kickdown
- Gearbox does not shift until it warms up
- Gearbox switches to emergency running
- Selector lever position "1”, gearbox does not shift to 1st gear (no power transfer in 1st gear)
- Selector lever position "D”, "3” or "2”, gearbox does not shift to 1st gear
- Selector lever position "D”, "3” or "2”, automatic gearbox does not shift to 2nd gear (no power transfer)
Selector lever position "D” or "3” does not shift to 3rd gear, hydraulic (3H)4 pages
Selector lever position "D” or "3” does not shift to 3rd gear, mechanical (3M)3 pages
Selector lever position "D” or "3” does not shift to 3rd gear (not gearbox 001)2 pages
Selector lever position "D” does not shift to 4th gear2 pages
Selector lever position "D” does not shift to 4th gear, mechanical (4M)2 pages
- Selector lever position "R”, automatic gearbox does not shift to reverse gear
Automatic gearbox, control, assembly, housing53 pages
- Connecting Volkswagen tester and selecting functions
- Carry out basic setting
- Electrical and electronic components and their locations
Repairing selector mechanism19 pages
- Checking selector mechanism
- Checking operation of the ignition key withdrawal lock
- Dismantling and assembling shift mechanism
Removing and installing selector lever handle3 pages
- Removing and installing selector lever
- Removing and installing selector lever lock solenoid N110 and wiring for selector lever illumination
Removing, installing and adjusting locking cable for ignition key withdrawal lock4 pages
- Measuring main pressure
Removing and installing gearbox - required tools12 pages
Dismantling and assembling gearbox18 pages
- Removing and installing ATF cooler and ATF filler tube
- Overview - dismantling and assembling planetary gearbox
- I - Removing and installing ATF pump to support tube
- II - Removing and installing reverse clutch -K2- to large sun gear
- III - Removing and installing freewheel and reverse gear brake -B1-
- IV - Planet carrier and gearbox housing with input gear and cover
- Assembling planetary gearbox
- Installing exchange component
- Overview - all planetary gearbox adjustments
- Adjusting planet carrier
- Adjusting reverse gear brake -B1-
- Adjusting clutch play between -K1- and -K2-
Adjusting 2nd and 4th gear brake -B2-2 pages
- Adjusting 2nd and 4th gear brake -B2-
- Adjusting 2nd and 4th gear brake -B2-
Automatic gearbox, gears, control14 pages
- Dismantling and assembling ATF pump
- Dismantling and assembling freewheel with -B1- piston
- Dismantling and assembling 1st to 3rd gear clutch -K1-
- Dismantling and assembling reverse gear clutch -K2-
- Dismantling and assembling 3rd and 4th gear clutch -K3- with turbine shaft
- Removing and installing oil pan
- Removing and installing ATF strainer
- Removing and installing gearbox oil temperature sender G93
Removing and installing valve body5 pages
- Dismantling and assembling parking lock
Final drive, differential, differential lock18 pages
Checking gear oil in final drive3 pages
5-speed manual gearbox 02J56 pages
Technical data5 pages
Clutch, control9 pages
Gearbox mechanics,operation, construction,diff.27 pages
Servicing gear selector mechanism up to 05.997 pages
Servicing gear selector mechanism from 05.997 pages
- Removing and installing gearbox
- Checking gear oil
Dismantling and assembling gearbox7 pages
- Servicing gearbox housing and clutch housing
- Dismantling and assembling gearbox selector mechanism up to 05.99
- Dismantling and assembling gearbox selector mechanism from 05.99
- Dismantling and assembling selector forks
Gearbox,mechanics,gears,shafts,internal operation9 pages
Dismantling and assembling input shaft2 pages
Dismantling and assembling output shaft2 pages
- Adjusting output shaft
- Dismantling and assembling reverse shaft
Final drive, differential, differential lock6 pages
Renewing oil seals for flanged shafts with gearbox installed3 pages
- Dismantling and assembling differential
- Adjustment overview
- Adjusting differential
5-speed automatic gearbox 09A111 pages
Technical data20 pages
Torque converter › Torque converter5 pages
Automatic gearbox, control, assembly, housing46 pages
- Connecting Volkswagen tester and selecting functions
Repairing selector mechanism23 pages
- Checking selector mechanism
- Checking operation of the ignition key withdrawal lock
Dismantling and assembling shift mechanism4 pages
- Checking gearbox
Removing and installing gearbox6 pages
- Removing gearbox
Transportation of automatic gearbox, securing gearbox to repair stand2 pages
- Installing gearbox
- Torque settings
- Gearbox repair
- Position of selector elements
- Assembling gearbox
Removing and installing ATF cooler4 pages
Automatic gearbox, gears, control30 pages
Housing cover for planetary gearbox5 pages
1st through 3rd gear clutch "K1”3 pages
Reverse gear clutch "K2” and 3rd through 5th gear clutch "K3”4 pages
5th gear clutch "K4”3 pages
Valve body7 pages
Removing and installing valve body6 pages
- Renewing oil seal for selector shaft
Removing, installing and adjusting multifunction switch F1253 pages
Final drive, differential, differential lock › Renewing oil seals for flange shafts10 pages
- Assembly overview
Renewing oil seal for left flange shaft4 pages
Renewing seal for right flange shaft4 pages
5-speed automatic gearbox 09A self-diagnosis › Self diagnosis, V.A.G Inspection Service21 pages
Self-diagnosis function4 pages
- Locations of electrical/electronic components
- Fault table
- Erasing fault memory
- Initiating basic setting
Gearbox: Electrical check3 pages
- Definitions
Automatic gearbox 01M self-diagnosis › Self diagnosis, V.A.G Inspection Service17 pages
5-speed manual gearbox 02K92 pages
Technical data17 pages
- Overview - power transmission
- Calculating overall gear ratio "i”
General repair notes10 pages
Clutch, control26 pages
Repairing clutch mechanism21 pages
- Overview
- Assembly overview - pedal cluster
- Distinguishing between clutch pedal switches F36
Removing and installing clutch pedal switch F36 with rectangular housing3 pages
Removing and installing clutch pedal switch F36 with round housing3 pages
- Assembly overview - hydraulic system
- Bleeding clutch system
Repairing clutch5 pages
Gearbox mechanics,operation, construction,diff.36 pages
Repairing selector mechanism18 pages
- Installation position of selector mechanism
- Assembly overview - selector lever housing and selector lever
Removing and installing selector lever and selector rod4 pages
Removing selector lever from and installing in selector lever housing4 pages
Adjusting selector mechanism5 pages
Removing and installing gearbox5 pages
- Checking gearbox oil
Dismantling and assembling gearbox9 pages
- Repairing gearbox housing and selector shaft
- Repairing clutch housing
- Repairing gearbox housing cover
Gearbox,mechanics,gears,shafts,internal operation5 pages
Final drive, differential, differential lock8 pages
Renewing flange shaft oil seals (gearbox installed)4 pages
- Adjustment overview
5 and 6-speed manual gearbox 02M111 pages
Technical data15 pages
Gearbox identification3 pages
- Overview - power transmission
- Calculating overall gear ratio "i"
General repair notes10 pages
Clutch, control24 pages
- Fault finding, power transmission
Repairing clutch mechanism21 pages
- Overview
- Assembly overview - pedal cluster
- Distinguishing between clutch pedal switchesF36
Removing and installing clutch pedal switchF36 with rectangular housing3 pages
Removing and installing clutch pedal switchF36 with round housing3 pages
- Assembly overview - hydraulic system
- Bleeding clutch system
- Repairing clutch release mechanism
- Repairing clutch
Gearbox mechanics,operation, construction,diff.46 pages
- Fault finding, power transmission
Repairing selector mechanism14 pages
- Installation position of selector mechanism
- Removing and installing gear knob and cover
- Separating gaiter from gear lever and assembling with gear knob
- Repairing gear lever and selector housing
- Assembly overview - removing and installing selector cables
Adjusting selector mechanism, gearbox with retaining pin (through gearbox date 18 05 3)2 pages
- Adjusting selector mechanism, gearbox with angled rod from gearbox date 19 05 3)
- Functional check
Removing and installing gearbox5 pages
- Checking gear oil
Dismantling and assembling gearbox13 pages
- Overview - gearbox
- Assembly overview
- Removing and installing gearbox housing and selector mechanism through gearbox date 18 05 3
- Removing and installing gearbox housing and selector mechanism from gearbox date 19 05 3
- Removing and installing input shaft, output shafts, differential and selector rods
- Installing to engine and gearbox support
Dismantling and assembling procedure for gearboxes through gearbox date 18 05 33 pages
Dismantling and assembling procedure for gearboxes from gearbox date 19 05 33 pages
Repairing gearbox housing3 pages
Repairing clutch housing3 pages
Dismantling and assembling selector mechanism on gearbox side3 pages
Repairing selector forks3 pages
Gearbox,mechanics,gears,shafts,internal operation15 pages
Input shaft6 pages
- Dismantling and assembling input shaft, through gearbox date 18 05 3
Adjusting input shaft (through gearbox date 18 05 3)3 pages
- Dismantling and assembling input shaft, from gearbox date 19 05 3
Output shaft for 1st through 4th gears6 pages
- Dismantling and assembling output shaft for 1st through 4th gears
Adjusting output shaft for 1st through 4th gears4 pages
Output shaft for 5th, 6th and reverse gears3 pages
Final drive, differential, differential lock11 pages
Renewing flange shaft oil seals with gearbox installed7 pages
- Adjustment overview
5-speed manual gearbox 02T40 pages
Technical data5 pages
Clutch, control10 pages
Gearbox mechanics,operation, construction,diff.18 pages
Gearbox,mechanics,gears,shafts,internal operation2 pages
Final drive, differential, differential lock5 pages
Renewing oil seals for flanged shafts3 pages
- Dismantling and assembling differential
- Adjusting differential
5-speed manual gearbox 02C, four-wheel drive122 pages
Technical data12 pages
Clutch, control18 pages
Repairing clutch mechanism14 pages
- Assembly overview - pedal cluster
- Distinguishing between clutch pedal switches F36
Removing and installing clutch pedal switch F36 with rectangular housing3 pages
Removing and installing clutch pedal switch F36 with round housing3 pages
- Removing and installing over-centre spring
- Removing and installing clutch pedal
- Assembly overview - hydraulic system
- Removing and installing master cylinder
- Bleeding clutch system
Gearbox mechanics,operation, construction,diff.31 pages
- Connecting VAS 5051 and selecting functions
Electrical and electronic components and their locations4 pages
- Electrical check of Haldex coupling
Removing and installing gearbox5 pages
- Removing and installing bevel box
- Checking gear oil in manual gearbox with bevel box
Dismantling and assembling gearbox7 pages
- Overview - gearbox
- Assembly overview
- Removing and installing cover for gearbox housing and 5th gear
- Removing and installing gearbox housing and selector mechanism
- Removing and installing input shaft, output shaft, differential and selector forks
- Procedure for removing and installing gearbox housing cover, gearbox housing, selector mechanism, input shaft, output shaft, dif
- Assembly overview - Repairing gearbox housing and clutch housing
Dismantling and assembling selector mechanism on gearbox side2 pages
- Dismantling and assembling selector forks
Gearbox,mechanics,gears,shafts,internal operation12 pages
Dismantling and assembling input shaft3 pages
Adjusting input shaft4 pages
- Adjusting output shaft
Dismantling and assembling output shaft3 pages
- Dismantling and assembling reverse shaft
Final drive, differential, differential lock49 pages
Renewing oil seals for flange shafts or right-hand drive flange (gearbox installed)3 pages
- Renewing bevel box output flange oil seal (bevel box removed)
- Modifying gearbox support VW 353
- Adjustment overview
- Checking gear oil in rear final drive and topping up
- Adjusting differential
- Removing and installing rear final drive
- Renewing propshaft flange oil seal on rear final drive (final drive removed)
Dismantling and assembling bevel box3 pages
- Renewing flange shaft oil seals (final drive installed)
- Renewing needle bearing (polygon bearing) for right output shaft or for right flange shaft
- Renewing O-ring between Haldex coupling and pinion housing (final drive removed)
- Renewing O-rings for rear final drive housing cover (final drive installed)
Dismantling and assembling rear final drive7 pages
- Assembly overviews - rear final drive
- Removing and installing cover for Haldex coupling and plates
- Removing and installing pinion housing
- Removing and installing differential and bevel gear with stub shaft
- Removing and installing cover for Haldex coupling from plate housing
- Assembly overview - Removing and installing Haldex coupling cover with plate housing, set of plates, pinion housing with shaft b
Repair shaft bevel gear mounting3 pages
Repairing bearings for bevel gear with stub shaft3 pages
Adjusting shaft bevel gear and bevel gear with stub shaft (final drive gear set)8 pages
6-speed manual gearbox 02M, 02Y, all-wheel drive271 pages
Technical data22 pages
Gearbox identification3 pages
Identifying rear final drive4 pages
- Overview - power transmission
Clutch, control24 pages
- Fault finding, power transmission
Repairing clutch mechanism21 pages
- Overview
- Assembly overview - pedal cluster
- Distinguishing between clutch pedal switchesF36
Removing and installing clutch pedal switchF36 with rectangular housing3 pages
Removing and installing clutch pedal switchF36 with round housing3 pages
- Assembly overview - hydraulic system
- Bleeding clutch system
- Repairing clutch release mechanism
- Repairing clutch
Gearbox mechanics,operation, construction,diff.90 pages
Vehicle diagnosis, testing and information systemVAS 50512 pages
Electrical and electronic components and their locations11 pages
Removing and installing electrical and electronic components7 pages
Checking Haldex coupling11 pages
Electrical check of Haldex coupling10 pages
- Fault finding, power transmission
Repairing selector mechanism14 pages
- Installation position of selector mechanism
- Removing and installing gear knob and cover
- Separating gaiter from gear lever and assembling with gear knob
- Repairing gear lever and selector housing
- Assembly overview - removing and installing selector cables
Adjusting selector mechanism, gearbox with retaining pin (through gearbox date 18 05 3)2 pages
- Adjusting selector mechanism, gearbox with angled rod from gearbox date 19 05 3)
- Functional check
Removing and installing gearbox16 pages
Removing and installing gearbox (vehicles with 4-cylinder engine)5 pages
Removing and installing gearbox (vehicles with 5-cylinder engine)5 pages
Removing and installing gearbox (vehicles with 6-cylinder engine)5 pages
Removing and installing bevel box9 pages
Removing and installing bevel box (vehicles with 4-cylinder engine)4 pages
Removing and installing bevel box (vehicles with 5 and 6-cylinder engines)4 pages
- Checking gear oil
Dismantling and assembling gearbox13 pages
- Overview - gearbox
- Assembly overview
- Removing and installing gearbox housing and selector mechanism through gearbox date 18 05 3
- Removing and installing gearbox housing and selector mechanism from gearbox date 19 05 3
- Removing and installing input shaft, output shafts, differential, bevel box and selector rods
- Installing to engine and gearbox support
Dismantling and assembling procedure for gearboxes through gearbox date 18 5 33 pages
Dismantling and assembling procedure for gearboxes from gearbox date 19 05 33 pages
Repairing gearbox housing3 pages
Repairing clutch housing3 pages
Dismantling and assembling selector mechanism on gearbox side3 pages
Repairing selector forks3 pages
Gearbox,mechanics,gears,shafts,internal operation18 pages
Input shaft6 pages
- Dismantling and assembling input shaft, through gearbox date 18 05 3
Adjusting input shaft (through gearbox date 18 05 3)3 pages
- Dismantling and assembling input shaft, from gearbox date 19 05 3
Output shaft for 1st through 4th gears6 pages
- Dismantling and assembling output shaft for 1st through 4th gears
Adjusting output shaft for 1st through 4th gears4 pages
Output shaft for 5th, 6th and reverse gears6 pages
- Dismantling and assembling output shaft for 5th, 6th and reverse gears
Adjusting output shaft for 5th, 6th and reverse gears4 pages
Final drive, differential, differential lock117 pages
Propshaft14 pages
Renewing flange shaft oil seals with gearbox and bevel box installed7 pages
- Checking function of Haldex coupling
Oil seals7 pages
Renewing propshaft flange oil seal on rear final drive (final drive removed)3 pages
Differential for manual gearbox3 pages
Renew O-rings9 pages
Renewing O-ring between Haldex coupling and pinion housing (final drive removed)4 pages
Renewing O-rings for rear final drive housing cover (final drive installed)4 pages
- Adjustment overview - manual gearbox
Bevel box6 pages
Dismantling and assembling bevel box5 pages
Removing and installing rear final drive4 pages
- Check gear oil in rear final drive
Renewing needle bearing5 pages
Renewing needle bearing (polygon bearing) for right output shaft drive flange4 pages
Checking oil level or changing oil in Haldex coupling6 pages
Dismantling and assembling rear final drive10 pages
- Dismantling and assembling rear final drive
- Removing and installing cover for Haldex coupling and plates
- Removing and installing pinion housing
- Removing and installing differential and bevel gear with stub shaft
- Removing and installing cover for Haldex coupling from plate housing
Dismantling and assembling procedure4 pages
Differential for rear final drive6 pages
Dismantling and assembling differential5 pages
Repairing shaft bevel gear bearing6 pages
Repairing bearing for bevel gear with stub shaft5 pages
Adjusting shaft bevel gear and bevel gear with stub shaft (final drive gear set)23 pages
- General notes
- Adjustment and marking of final drive gear sets
- Position of shims
- Adjustment overview - rear final drive
- Recommended sequence for new adjustment of final drive gear set
Adjusting shaft bevel gear7 pages
Adjusting bevel gear (with stub shaft)10 pages
- Adjusting preload of tapered roller bearing for bevel gear (with stub shaft)
- Example:
- Determining thickness of shim S1*
- Example:
- Measuring backlash
- Example:
- Determining thickness of shim S2
- Example:
- Available shims for S2
- Determining thickness of shim S1
- Available shims for S1
- Carrying out control measurement - measuring backlash