Volkswagen Golf Variant / Jetta. Manual - part 293

❑ Installation position. Refer to

⇒ Fig. ““Disassembling and Assembling Locking Collar and Synchronizer Hub for 5th and 6th Gears”“ ,

page 352

 .

3. 5th, 6th and Reverse Gear Output Shaft    

347

Output Shaft, 5th, 6th and Reverse

Gears, Disassembling and Assembling

Special tools and workshop equipment required
♦ Press Plate - VW401-
♦ Press Plate - VW402-
♦ Press Piece - Rod - VW407-
♦ Press Piece - Rod - VW408A-
♦ Press Piece - Multiple Use - VW412-
♦ Press Piece - 60mm - VW415A-
♦ Holding Plate - VW309A-
♦ Transmission Support - VW353-
♦ Press Piece - Multiple Use - VW433-
♦ Press Piece - Multiple Use - VW454-
♦ Support Channels - VW457-
♦ Crankshaft Holding Fixture - VW801-
♦ Press Piece - Multiple Use - VW431-
♦ Press Piece - Multiple Use - VW455-
♦ Press Piece - Multiple Use - VW510-
♦ Press Piece - 42mm - VW516-
♦ Press Piece - Multiple Use - VW519-
♦ Press Piece - Multiple Use - 30-11-
♦ Press Piece - Multiple Use - 40-105-
♦ Bearing Installer - Multiple Use - 40-20-
♦ Slide Hammer - Press Plate - 2050-
♦ Press Piece - Reverse Gear Syncro - 3296-
♦ Puller - Taper Roller Bearing - VAG1582-
♦ Puller - Taper Roller Bearing - Adapter 4 - VAG1582/4-
♦ Puller - Taper Roller Bearing - Adapter 7 - VAG1582/7-
♦ Inductive Heater - VAS6414-
♦ -1- Puller - Kukko Internal - 46-56mm - 21/7-
♦ -3- Puller - Kukko Quick Action Separating Tool - 22-115mm -

17/2-

♦ -4- Puller - Kukko Counterstay - 22/2-
Removing the Outer Race/Tapered Roller Bearing
A - Counter Support , for example, Puller - Kukko Counterstay -

22/2-
B - Internal Puller 46 to 58 mm , for example, Puller - Kukko In‐

ternal - 46-56mm - 21/7-

348

Check the washer for damage after removing it and replace if

necessary.

Installing the Outer Race/Tapered Roller Bearing in the Clutch

Housing
– Place the washer under the outer race.
– Support the clutch housing with the Bearing Installer - Multiple

Use - 40-20- directly under the bearing mount.

Removing the Outer Race/Tapered Roller Bearing from the

Transmission Housing
A - Counter Support , for example, Puller - Kukko Counterstay -

22/2-
B - Internal Puller 46 to 58 mm , for example, Puller - Kukko In‐

ternal - 46-56mm - 21/7-

Installing the Outer Race/Tapered Roller Bearing into the Trans‐

mission Housing.
– Support the transmission housing under the bearing mount

using the Slide Hammer - Press Plate - 2050- .

Disassembling the Output Shaft

Remove the Inner Race/Tapered Roller Bearing on the Side of

the Transmission Housing
Before installing the Tapered Roller Bearing Puller :
– Remove the inner race/tapered roller bearing locking ring on

the side facing the transmission housing.

– Place the Press Piece - Multiple Use - VW431- and Press

Piece - Multiple Use - 40-105- on the output shaft.

3. 5th, 6th and Reverse Gear Output Shaft    

349

with the 6th Gear Wheel
– Remove the locking ring beforehand.

Removing the Sleeve -A- Together with the Reverse Gear Wheel
– Remove the locking ring beforehand.

Removing the Reverse Gear Synchronizer Hub
– Remove the locking ring beforehand.
A - 22 to 115 mm Separating Tool , for example Puller - Kukko

Quick Action Separating Tool - 22-115mm - 17/2-

Removing the Inner Race/Tapered Roller Bearing on the Side of

the Clutch Housing.
– Mount the Press Piece - Multiple Use - 30-11- on the output

shaft before removing the puller.

Assemble the Output Shaft.

Note

Heat the tapered bearing inner races and synchronizer hub to

approximately 100 °C (212 °F) with the Inductive Heat Unit -

VAS6414- before installing. Press on to the stop so that there is

no axial clearance when assembling.

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