Volkswagen Golf Variant / Jetta. Manual - part 534

❑ Installation position. Refer to

⇒ Fig. ““5th Gear Locking Collar/Synchronizer Hub Assembly”“ , page 157

 .

28 - Locking Pieces

❑ Quantity: 3

29 - 5th Gear Synchronizer Hub
30 - 5th Gear Locking Collar
31 - Stop ring

❑ Prevents locking pieces from moving off
❑ Removing. Refer to 

⇒ Fig. ““Stop Ring, Removing”“ , page 156

❑ Installing. Refer to 

⇒ Fig. ““Stop Ring, Installing”“ , page 157

 .

Remove the Roller Bearing from the Clutch Housing
– Compress the cylindrical roller bearing locking ring -arrow-

with pliers -C- and remove it.

A - for example Puller - Kukko Counterstay - 22/1-
B - for example Puller - Kukko Internal - 28-37mm - 21/5-

Pressing Cylindrical Roller Bearing into Clutch Housing.
– Support the clutch housing with the Press Piece - 60mm -

VW415A- (not illustrated) directly below bearing mount.

– Compress the cylindrical roller bearing locking ring -arrow-

with pliers -A- and install it.

– Remove the pliers before the cylindrical roller bearing gets into

its installed position. The locking ring must lock into the groove

on the clutch housing.

Remove the Bearing Mount and Grooved Ball Bearing
– Slide the locking collar for 1st and 2nd gear to 2nd gear.
– Slide the Bearing Installer - Bearing Press Plate - T10084A-

sideways all the way into input shaft.

– Insert the centering pins in Press Piece - T10081- into holes

in input and output shaft.

152

ing
– Remove the circlip using the Circlip Pliers - VW161A- .
– Remove the cylindrical roller bearing bearing inner race to‐

gether with the: thrust washer, 4th gear wheel with needle

bearing, 3rd and 4th gear locking collar/synchronizer hub and

3rd gear wheel.

Disassembling and Assembling Locking collar and Synchronizer

Hub for 3rd/4th Gears
1 - Spring
2 - Locking collar
3 - Synchronizer Hub
4 - Locking piece
– Slide the locking collar over the synchronizer hub.
The deeper recesses -arrow A- for the locking pieces inside the

synchronizer hub and the recesses -arrow B- inside the locking

collar must align.

Assembling Locking Collar/Synchronizer Hub for 3rd and 4th

Gears.
• The locking collar is pushed over the synchronizer hub.
– Insert locking pieces in deep recesses -arrows- and install

springs offset by 120°. The angled end of the spring must en‐

gage into the hollow locking piece.

Installed Position: Locking Collar/Synchronizer Hub for 3rd and

4th Gears
The groove on the front side -arrow- points to the 4th gear.

1. Input Shaft    

153

measure gap dimension -a- using a feeler gauge.

Gap dimension

-a-

Installation Dimen‐

sion

Wear limit

3rd 4th and 5th

Gear

1.1 to 1.7 mm

0.5 mm

Installing the Synchronizer Hub with Locking Collar for 3rd and

4th Gears

Install the 4th Gear Needle Bearing Sleeve -A-.
– Install the 4th gear needle bearing, the 4th gear wheel syn‐

chronizer ring and the thrust washer after installing the sleeve

-A-

Installing the Bearing Inner Race -A- for the Cylindrical Roller

Bearing

154

press upward -arrow-.

– Measure between the bearing inner race -B- and the installed

locking ring -A- with a feeler gauge -C-.

– Remove the locking ring used for the measurement.
– Select the locking ring according to the Table.

Note

Allocate the correct locking rings. Refer to the Parts Catalog.

Available Locking Rings

Measured value

(mm)

Circlip thickness

(mm)

Axial play (mm)

0.05 to 0.14

2.0

0.05 to 0.15

0.15 to 0.24

2.1

0.05 to 0.15

0.25 to 0.34

2.2

0.05 to 0.15

0.35 to 0.44

2.3

0.05 to 0.15

0.45 to 0.51

2.4

0.05 to 0.10

Install the bearing mount with grooved ball bearing onto the input

and output shafts.

Note

♦

Due to the varying spline height, the output shafts of individual

transmissions have different -a- lengths (illustrated here with

front shaft installed).

♦

So that the bearing mount is always pressed in the same on

the shafts, the shafts must always be inserted evenly in the

Press Piece - Block - T10083- .

♦

if necessary a Press Piece - Block - Washer - T10083/1- (3

mm thick) must be placed in the Input shaft locating bore. Re‐

fer to

⇒ Fig. ““Insert the Press Piece - Block - Washer -T10083/1-

”“ , page 156

 .

♦

For this reason the splines on the output shaft dimension -a-

must be measured.

Dimension -a- = 30.6 mm

Insert the Press Piece - Block - Washer - T10083/1- ⇒ next il‐

lustration

1. Input Shaft    

155