Golf 4 manual transmission do it yourself

In detail: golf 4 manual transmission do-it-yourself repair from a real master for the site my.housecope.com.

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Repair sequence (not detailed) Volkswagen Golf 4 gearbox type 02K (DUU, DUW, DLP) in pictures.

General form Gearbox Golf with engine 1.4-1.6

Removing the fifth gear cover Checkpoint

Unscrewing the fifth gear mounting bolt Gearbox Golf with the help of a special device locking the coupling.

Loosening the selector drive nuts Checkpoint.

Unscrewing the selection mechanism plug Manual transmission

Removing the gear retainer Checkpoint

Removing the body bolts gearboxes Golf-4

Removing the upper part of the case Checkpoint

Output shaft gears and input shaft assembly

Main pair without gears

Reverse gear Checkpoint on the axis.

Major malfunctions Manual transmission Golf-4 type 02K.

Differential rivet break. This malfunction often leads to the destruction of the case. Checkpoint.

This breakdown is typical for a Volkswagen. Volkswagen Golf-4 gearbox.To eliminate it, we use the original repair kit 02k498088.

Destruction of the output shaft bearing will damage the teeth of the final drive.

The assembly is carried out in the reverse order, taking into account the adjustment of the bearings and the installation of the housing elements on the sealing compound.

Video (click to play).

In general, the disassembly sequence Volkswagen Golf-2,3 gearbox practically no different from the above repair sequence Manual transmission Golf-4.

professional repair with a quality guarantee of mechanical gearboxes of cars of the Volkswagen Golf 4 IV brand on all model range 1.2 1.4 1.6 1.8 1.9 2.0 2.3 2.5 2.8 Moscow the Russian Federation

Gearbox REPAIR VOLKSWAGEN Golf 4 IV 1.2 1.4 1.6 1.8 1.9 2.0 2.3 2.5 2.8
MEKHANINDIVIDUAL GEARBOXES VOLKSWAGEN GOLF 4 IV
installation replacement buy all modifications 1.2 1.4 1.6 1.8 1.9 2.0 2.3 2.5 2.8
repair and restoration of shafts argon welding of the manual transmission body
Moscow city

Artem 8 965 126 13 83 Vadim 8 925 675 78 75

Full car diagnostics during repair - free of charge!

Possessing a high level of professionalism, extensive experience in the repair of manual transmissions, and our own warehouse of spare parts, we carry out diagnostics, sale, replacement and repair of all types of manual transmissions for the Volkswagen Golf 4 IV car. Box repair begins with an initial, obligatory free diagnostics.

consulting by a repairman / by phone free of charge /
delivery of the car for repair / within the city of Moscow 3,000 rubles. From the Moscow region and other regions of the Russian Federation - by agreement /
complex car diagnostics / determination of the presence of a malfunction of the engine, manual transmission, ABS, brake system; checking the electrical circuits of the car for corrosion, checking the kinematic destruction of the unit, checking the level of transmission oil, checking the operability of the clutch hydraulic system / - during repairs free of charge
visual inspection, checking the integrity of the hull
checking the transmission oil content for steel, aluminum or bronze chips
opening the pallet / if necessary /
removal from the car
disassembly, flushing of parts and assemblies
troubleshooting / presence of the car owner - required /
agreement with the car owner on the cost of full repair and the date of completion of the repair
receipt of spare parts from the warehouse / rem. kit, consumables, units /
repair / argon welding / gearbox housing if necessary
assembly
clutch replacement / at the request of the car owner /
installation on a car
filling with gear oil
output diagnostics and tested drive of the car

Warranty from 3 to 24 months or 60,000 km. mileage.

We have a fund remanufactured gearboxes VW Golf 4 IV 1.2 1.4 1.6 1.8 1.9 2.0 2.3 2.5 2.8 / see article replacement / ... If the car owner wishes, we can replace the faulty one with one that has been sorted out from the exchange fund, which is often more economically expedient.

Complex troubleshooting of manual transmission (disassembly - assembly) without repair

Removal and installation (as separate work)

Replacing the clutch with the box removed

economy - from 3,000 to 8,000 rubles / use, at the request of the car owner, only used parts to reduce the cost of repairs /
business - from 8,000 to 28,000 rubles. / replacement only of directly damaged parts in the unit /
representative - from 28,000 to 60,000 rubles. / replacement regardless of damage with a set: oil seals, bearing bearings, needle bearings, synchronizers, stoppers, coupling hub locks - plus directly affected parts /

Own warehouse of spare parts necessary for the repair of manual transmissions. Bearings, oil seals, gears, synchronizers, gear couplings, shafts, differentials, manual transmission housings are available and on order for all brands of cars.

Gearboxes of a Volkswagen Golf 4 IV come for repair in 9 out of 10 cases due to the characteristic noises emitted by the bearing bearings on the gearbox and differential shafts. An example of such a box VOLKSWAGEN Golf 4 IV in the photos below. Change three bearing bearings (one each: primary, secondary shaft, differential); new gearbox oil seals (input shaft, differential, gear selection unit), we wash the manual transmission housing with nefras, the inside, to remove steel chips and old gear oil:

Similar work on the VW Golf 4 IV gearbox. Replacing the bearing bearings (input shaft, output shaft, differential), oil seals (input shaft and differential), flushing the housing with oil (from steel chips and old oil).

A small video from the channel to allow you to get distracted from the problem of car repair:

Diagram of the gearbox of the VOLKSWAGEN Golf 4 IV gearbox

gear selection unit (gearbox forks)

A small video from the channel to allow you to get distracted from the problem of car repair:

replacement and repair of transmissions VOLKSWAGEN Golf 4 IV

replacement and repair of manual transmission VOLKSWAGEN Golf 4 IV

replacement and repair of the VOLKSWAGEN Golf 4 IV gearbox

change of transmission oil

clutch replacement VOLKSWAGEN Golf 4 IV

replacement release bearing VOLKSWAGEN Golf 4 IV

Replacing the rear oil seal and crankshaft bearing VOLKSWAGEN Golf 4 IV

replacement of the input shaft oil seal and drive oil seals VOLKSWAGEN Golf 4 IV

replacement of the input shaft of the manual transmission VOLKSWAGEN Golf 4 IV

replacement of the secondary shaft of the manual transmission VOLKSWAGEN Golf 4 IV

VOLKSWAGEN Golf 4 IV gearbox backstage repair

repair (argon welding) of the VOLKSWAGEN Golf 4 IV manual transmission housing

repair of the secondary shaft of the VOLKSWAGEN Golf 4 IV gearbox

replacement of the fifth gear of the manual transmission (without removing the gearbox from the car) VOLKSWAGEN Golf 4 IV

repair of 1st and 2nd gears of VOLKSWAGEN Golf 4 IV

repair of 3rd and 4th gears of VOLKSWAGEN Golf 4 IV

repair of 5 gears VOLKSWAGEN Golf 4 IV

buy gearbox VOLKSWAGEN Golf 4 IV

buy manual transmission VOLKSWAGEN Golf 4 IV

buy gearbox VOLKSWAGEN Golf 4 IV

Call us to choose a time for manual transmission diagnostics and repairs in a gearbox repair workshop. An appointment in advance will allow you to find the most convenient solution, we are always ready to meet the wishes of the client.In our specialized repair shops for manual transmissions of Volkswagen Golf 4 IV manual transmissions, high-quality service, diagnostics and repairs of all types of transmissions are carried out. We offer an honest service for your repair. Your presence is obligatory at all stages of diagnostics and repair of the Volkswagen Golf 4 IV gearbox; all work and accessories are coordinated. The term for overhaul of the gearbox is from 0.5 to 1 working days (if the necessary parts are available).We have round-the-clock line consultations on the repair of manual transmissions of gearboxes (8 965 126 13 83) and delivery for repair on a tow truck (8 926 167 15 40).A tow truck for manual transmission repairs is provided for a fee (within the MKAD - 3000, outside the MKAD by agreement).The cost of work during the overhaul of the Volkswagen Golf 4 IV gearbox is 10,000 rubles (input and output diagnostics, removal and installation of the gearbox, disassembly and assembly, test drive exit) + cost of components.Input diagnostics is carried out with the obligatory presence of the owner of the car within 30 - 40 minutes after removing the gearbox from the car (inspection, disassembling the manual gearbox, flushing the inner case of the gearbox from metal shavings, disassembling the shafts).Removal of the gearbox from the car, disassembly and troubleshooting takes place on the day of the request for repair.Warranty for the repair of the gearbox of the Volkswagen Golf 4 IV gearbox from 1 to 12 months or 60,000 km of run (set individually for each car - depending on the components during the repair).

the structure, installed on the assembly line, was fastened with two bolts unscrewed towards the receiving pipe

unscrewing them, you can remove the entire bracket

in these places (1 and 2) both axles and bushings wear out, backlash appears

and also often the axle is acidified 2

in the design of this part of the stage VAG made minor changes

they are completely interchangeable, only longer bolts are required, and nuts for them

when installing, it is easier to insert the bolts from the side of the wheel, and tighten the nuts from the side of the muffler

the rods on the hinges are conveniently clicked on with the help of "crocodiles"

note that no lubrication is required, but a rubber ring is required to keep dirt out
Remove the rocker arm from the axle, connect it to the rod

we put the rocker on the axle

put on the retaining ring

after replacing worn-out parts with new ones, no adjustments are usually required

in the other replaceable part of the stage, souring most often occurs, due to which the lever of the stage moves with difficulty

it is attached in the area of the steering rack, to the subframe, with only three bolts

Changes were also made to its design, and I was faced with the fact that the balance beam at the end, with a certain movement of the stage lever, rests on the thrust.

So when ordering this part, you need to immediately order a new, modernized rod (the one with S-shaped ends and a weight in the middle), or be ready for a "file revision"

Transmission repair Volkswagen Golf 4 1.6 l. 2001 at.

Customer complaints: Extraneous noise when driving, slowly fading out when the gas is released. In fifth gear, a strong hum is heard, and it also flies out after switching on.

Troubleshooting showed: The gearbox suffered a standard problem, which ripped rivets from the attachment of the differential gear to the gearbox. While driving, rivets got caught between the manual transmission housing and the differential ring, which led to a hole in the front housing (bell) and crumbled the teeth of the main pair. Oil leaked out and 5th (fifth) gear burned out.

It is necessary to replace: The main pair, fifth gear, a set of bearings, a set of oil seals, a manual transmission housing, put the original differential bolts.

Deadline: 1 business day.

Manual transmission parts price: 19,000 p

Manual transmission repair: 4 900 p

Golf 4 gearbox repair with spare parts: 23 900 p

Specifications, 5-Speed 012

Do not lubricate the gear lever linkage.

GEAR LEVER LEVER, ADJUSTMENT / CHECK

Installation is carried out in the reverse order of removal.

Please note the following when installing:

- check that the centering sleeves are installed correctly.
- install the clutch slave cylinder in place using the lever so that the bolt can be inserted easily. Warning

The bolt for the clutch slave cylinder has a pointed end to facilitate installation.

Tightening torques for screw connections

FIXING THE TRANSMISSION TO THE ENGINE

1 = bolt M12 x 70
2 = bolt M12 x 85
3 = bolt M12 x 100
4 = bolt M8 x 15

1 = bolt M12 x 70
2 = bolt M12 x 80
3 = bolt M12 x 90
4 = bolt M12 x 100
5 = bolt M11 x 120
6 = bolt M10 x 50
7 = bolt M10 x 40
8 = bolt M8 x 40

Location of centering sleeves: points A and B

If you need to replace the final drive housing or the tapered roller bearing of the pinion gear or hollow shaft and the deviation r is not indicated on the bevel gear, the installation position of the pinion gear must be determined before removing the gearbox housing (it is necessary to measure the actual deviation).

Before installing the transmission case, check that the guide bushings are installed in the transmission case.

Handle the transmitting device of the speedometer very carefully. Do not drop it, otherwise the speedometer reading may be inaccurate.

Final drive mechanism

The speedometer drive1 can be replaced without removing the gearbox.

Differential 2 can be removed without removing the gearbox housing.

Remove O-ring 3 using VW tool 681.

Seal the final drive cover 4 with AMV 188 200 03.

Always replace circlips 6 and 23.

Install the drive shaft flange using VW tool 295.

The side of the concave washer 10 with a smaller diameter faces the guide sleeve (concave side).

Mark the retaining rings 11, 13 after removal.

Drive shaft flange O-ring - Remove with VW tool 681 and install (5mm below the surface of the final drive housing) with tool VW 195.

Final drive housing 15: Drive shaft flange O-ring - remove with VW tool 681. Install (5 mm below the surface of the final drive housing) with tool VW 195. 3rd / 4th gear shift rod bushing - install with tools VW 295 and VW 295А. Seal with AMV 188 200 03.

Gear lever channel cover 18 - tighten the mounting bolt to 20 N.m.

The lock for 5th gear and reverse gear 22 can be replaced without removing the gearbox. The beveled side of the plastic bushing faces the shift shaft. Tightening torque for the mounting bolts: 10 N.m.

1. Internal shift rod
2. Shift rod of 1st, 2nd, 5th gear and reverse gear with a shift fork
3. Hollow shaft drive gear
4. Transmission housing
5. Socket head bolt - 25 N.m.
6. Socket head bolt for reverse gear axis - 35 N.m.
7. Socket head bolt - 25 N.m.
8. Lock
9. Socket head bolt - 40 N.m.
10. Washer
11. Shifting shaft

Remove the O-ring of the inner shift rod 1 using the VW 681 tool and install it flush with the VW 460/2 tool. On the installed gearbox, carefully remove the O-ring with a screwdriver and install with the VW 423 tool. First, remove the exhaust pipes and the shift rod gear to get free space.

1st, 2nd, 5th and reverse gear shift rod with shift fork 2 - for disassembly / assembly, remove / install spring pins. 1st / 2nd gear shift forks can be replaced individually. Replace the 5th / reverse shift fork only with the shift ring and shift rod.

Socket head bolt for reverse gear axle 6 - 35 N.m.The reverse gear axle does not need to be removed to remove the reverse gear.

Socket head bolt 7-25 N.m. The inside of the head faces the spring / lock safety mechanism.

Install the lock 8 after installing the selector shaft 11 and the inner selector rod.

3rd / 4th gear shift rod and shift fork: The shift rod or shift fork can be individually replaced. Replace the shift rod bearing if worn.

Removing the shift shaft bolts

Volkswagen produces reliable, inexpensive cars with German quality and comfort. More and more people around the world are choosing this brand. Since 1999, Volkswagen sales have increased by 20% annually. Since 2009, Volkswagen has been one of the largest car manufacturing companies in the world. The concern consists of more than three hundred companies. Audi, Bentley, Porsche, Skoda, Seat, Bugatti, Lamborghini, Scania - all these are parts of the Volkswagen concern. Cheap Volkswagen car options are popular. In Russia, they are usually brought to technological perfection and do not have "childhood" diseases.

For their cars, Volkswagen uses the usually popular and reliable automatic transmissions. Most of them are able to honestly leave the entire reasonable service life of the car, if, of course, they are serviced on time and are not exposed to unnecessary loads. Volkswagen automatic transmission repair is rarely required, is well studied and does not pose serious problems for service station specialists.

Volkswagen Passat B4 car

For the Passat B4 and Golf model with automatic transmission 096, the following repair features are characteristic:

It is better to order original gaskets and oil seals for Passat B4 and Golf, the rest are of poor quality, except for budget products from Atok.
Rubber pads on pistons lose their properties over time and begin to hold pressure poorly. The entire set of pistons must be replaced or the vehicle has been in service for more than ten years.
As a result of exposure of the hydraulic plate to contaminated oil, the pressure regulator, the torque converter lock-up solenoid, the pressure control valve, and the solenoid valve may fail. After 150,000 runs on the Passat B4, it is necessary to clean the automatic transmission valve body from dirty oil.
After ten years of operation of the Passat B4 and Golf, the properties of the wiring change, the resistance increases and the computer may start giving errors. Therefore, together with the solenoids and sensors, during overhaul, their wiring also changes.
From old age or excessive load, the return springs may fail, which will lead to the inability to engage reverse gear. After ten years, their condition should definitely be checked.

Automatic transmission 096 for Volkswagen Passat B4 and Golf

For the Passat B5 models with automatic transmission 01M, the following repair features are characteristic:

DO NOT SPEND MONEY ON REPAINING!
Now you yourself can remove any scratch from the body of your car in just 5 seconds.

It is better to take only original compression rings for Passat B5. The only analogue is only from the Atok company.
Rubber on the Passat B5 is made of poor quality, in the cold it quickly loses its properties, dries out over time. After a few years, oil begins to leak. At the first sign, you need to change the pistons. This usually applies to machines that have been in operation for more than 10 years.
The sliding bearing on the Passat B5, mounted on the front drum, is made of plastic. Over time, it loses its characteristics and at one point it simply scatters, damaging the machine gun with its remains. You can check its integrity by examining the pallet, if it is strewn with plastic fragments - it's time to change the bearing.

Volkswagen Passat B5 with automatic transmission 01M

The solenoids are quite reliable. Over time, the pressure regulator and ball-type solenoids may fail. Their normal lifespan is about ten years.

After 200,000, or better before, it is necessary to flush and clean the valve body from dirt. Dirty oil has the ability to abrasively process the insides of the valve body and "eat up" the metal of the valves and spools.The wear of the plate with dirty oil can be so severe that it must be replaced as an assembly.

Automatic transmission 01M for Volkswagen Passat B5For the Passat B6 model with automatic transmission 09G, the following repair features are characteristic: The Passat B6 automatic transmission is not demanding on completely clean oil, filters are used with an outdated design, however, they serve up to 200,000, after several oil changes and washes. However, when repairing after overheating of the box, it is better to replace the filter with a new one. When overheated, it will take away the remnants of the clutches and their glue, which will be impossible to get out of the filter. When installing such a filter back, the remnants of the clutches will fall into the box. 09G automatic transmission Volkswagen Passat B6 and SharanVolkswagen Passat B6 with automatic transmission 09GFor the Passat B6 and Sharan models with automatic transmission 5HP19 EYF, the following repair features are characteristic:

The 5HP19 EYF automatic transmission on Sharan lives well over 200,000 kilometers. This box forgives both slippage and overheating, but does not like dirty oil or its low level. Oil starvation is capable of destroying everything in the boxes. From valve body to clutches.

For the 5HP19 EYF service staff, Sharan is known primarily for its torque converters. Their forced blocking eats up the friction linings, which leads to severe oil contamination and subsequent repairs.

Automatic transmission 5HP19 EYF Volkswagen Passat B6 and SharanVolkswagen Sharan with automatic transmission 5HP19EYFRepair and diagnostic procedures for automatic transmissions require special equipment and knowledge. However, Volkswagen transmissions are well studied and if you have the means and desire, you can try to repair them yourself. But, most likely, it will be cheaper to give this business to professionals. Repair of a Volkswagen Tuareg automatic transmission in Rostov, for example, will cost from 12,000 rubles in a normal service. Trained and experienced service employees will handle the repairs much faster and better.

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blog of photo reports about car repair GOLF 3

The gearbox was sorted out for a number of reasons: 1. The gearbox lever dangled from 3rd to 1st gear, that is, it did not spring to the left, but only sprung towards the 5th gear, without taking a neutral position (opposite to 3rd and 4th gears). 2. Whistle in fifth gear. 3.The gear selector oil seal and the oil seal on the right flange were leaking. By the way, the oil seals on the flanges were changed a couple of years ago, even when buying a car (before that there were still native oil seals), but one again began to leak, most likely, as always, due to the crooked hands of the servicemen.

PERFORMANCE ORDER

Clean the transmission from dirt

In this photo report, removal of the checkpoint mechanics, as well as clutch drive repair on Volkswagen Golf III (Volkswagen Golf 3) due to the fact that there was breakdown in the clutch drive mechanism.

The beginning in this situation was laid by the fact that the car clutch burnedbut the necessary repairs were continually delayed, eventually causing the clutch pedal to fail.

So, to do the work, you need an assistant, a pit, a lift or a jack, whichever is available, and also, be sure to disconnect the battery terminal.

The gearbox converts the torque transmitted from the engine in magnitude and direction. The gearbox and final drive along with the differential are located in a separate housing and are bolted to the engine block. The gearbox is lubricated independently of the engine.

The gear shift drive consists of two cable drives. In this case, less vibration is transmitted to the gear lever and the vibration of the machine does not affect gear changes. Also, the gearshift mechanism is virtually maintenance-free.

When a gear is engaged, a choice is made between lateral movement (gear selection movement) in the idle position and the actual shift movement. Both movements, each through its own shift cable, are transmitted to the shift shaft of the gearbox. In this case, the gear shift cable rotates the shift shaft around its own axis, while the gear selection cable through the bypass lever changes the position of the shift shaft along the axis.

Video (click to play).

Manual or automatic transmission can be removed without removing the engine. The gearbox must be removed when replacing the clutch disc or the gearbox itself.

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