Volkswagen Golf Variant / Jetta. Manual - part 179

 

  Index      Volkswagen     Volkswagen Golf Variant (2007), Jetta (2005) - service repair manual

 

Search            

 

 

 

 

 

 

 

 

 

Content   ..  177  178  179  180   ..

 

 

Volkswagen Golf Variant / Jetta. Manual - part 179

 

 

– Tighten the bolt -b- to 25 Nm.
– Tighten the bolt -c- to 25 Nm (see upper illustration).

– Install the pivot pin -arrow- for the shift forks. To do this align

shift mechanism using a screwdriver, so that the relevant pivot

pin can be installed.

– Apply the Sealant - AMV 188 200 03- evenly onto the sealing

surface of the cap.

– Install the gearshift shaft cover.

Install the gearshift shaft cover as follows:
– Move the gearshift rail into the neutral position.
– Apply the Sealant - AMV 188 200 03- evenly onto the sealing

surface of the gearshift cover.

– Move the gearshift shaft into neutral.
– Position the selector shaft so that selector finger -arrow- is in‐

serted into the selector rails.

– Tighten the selector shaft selector cover to the specification

-item 17- 

⇒ Item 17 (page 165)

 .

178

Transmission Neutral Position Sensor - G701- -arrow- and

tighten the screw to the tightening specification -item 11-

⇒ Item 11 (page 164)

 .

– Install both flange shafts with springs, thrust washers and ta‐

pered rings. Refer to

⇒ “3.1 Differential, Disassembling and Assembling”,

page 263

 .

7.7.3

5th Gear, Installing

• Pay attention that the Bracket - Multiple Use - 30 - 211 A- and

the Support Bridge - T10323- is installed.

– Secure the bolt on the Bracket - Multiple Use - 30 - 211A- with

the nut -A-.

Installed Position, 5th Gear Wheel
The groove all the way around -arrow- faces the transmission

housing.
– To install, heat the 5th gear wheel to approximately 100 °C

with the Inductive Heater - VAS6414- .

WARNING

Wear safety gloves.

7. Transmission, Disassembling and Assembling    

179

Checking 5th gear synchronizer ring
– Before reinstalling drive gear and synchronizer ring for 5th

gear, press the synchronizer ring onto the taper of the drive

gear and measure the gap dimension -a- using a feeler gauge.

Gap dimension

-a-

Installation Dimen‐

sion

Wear limit

5th Gear

1.1 to 1.7 mm

0.5 mm

– Install 5th gear wheel with needle bearing.
– Place the 5th gear synchronizer ring onto the selector gear.
– If disassembled, assemble the 5th gear synchronizer hub/

locking collar before installing

⇒ Fig. ““5th Gear Locking Collar/Synchronizer Hub Assem‐

bly”“ , page 226

 .

Installed Position of 5th Gear Synchronizer Hub/Locking Collar
The pointed teeth on the locking collar -arrow 1- and the high col‐

lar on the synchronizer hub -arrow 2- face the transmission hous‐

ing.
The notches -arrow 3- on the synchronizer hub must line up with

the cast locking pieces on the synchronizer ring

⇒ Fig. ““5th Gear Synchronizer Ring with Cast Locking Pieces”“ ,

page 180

 lower).

5th Gear Synchronizer Ring with Cast Locking Pieces
– Cover all openings with a cloth to prevent foreign objects from

getting into the transmission.

– To install, heat the 5th gear synchronizer hub to approximately

100 °C (212 °F)with the Inductive Heater - VAS6414- .

WARNING

Wear safety gloves.

180

Note

Make sure there is enough clearance when installing the syn‐

chronizer ring.

– Loosen the support for the input shaft.
– If it has not been done already, clean any locking fluid residue

from the threaded hole for the synchronizer hub bolt and 5th

gear wheel with a thread tap.

Otherwise, there is the danger that the screws could shear off.
– Screw-in new synchronizer hub bolts and 5th gear wheel.

Installed Position of Plate Springs for 5th Gear Synchronizer Hub

and Gear Securing Bolts
The outer diameter -arrows- faces 5th gear.

– Engage 5th gear -arrow 1- and 1st gear -arrows 2- and -3- and

then tighten the bolts -A- for the synchronizer hub and the 5th

gear wheel to the tightening specification. Refer to -item 4-

⇒ Item 4 (page 162)

 .

– The input shaft and the output shaft are blocked after both

gears are engaged. The synchronizer hub and the gear wheel

cannot turn. Both bolts can be loosened now.

– Install the 5th gear shift fork.

7. Transmission, Disassembling and Assembling    

181

 

 

 

 

 

 

 

Content   ..  177  178  179  180   ..