Volkswagen Golf Variant / Jetta. Manual - part 191

 

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Volkswagen Golf Variant / Jetta. Manual - part 191

 

 

hub face in the same direction. Recesses for locking pieces in

locking collar and synchronizer hub must line up. Refer to

⇒ Fig. ““5th Gear Synchronizing”“ , page 225

 .

– Insert locking pieces (installed position. Refer to

⇒ Fig. ““5th Gear Synchronizing”“ , page 225

 ).

– Install the springs offset by 120° under the tabs -C-. The an‐

gled end of the spring must be positioned in front of the locking

pieces -arrows-.

Note

Note the location of the springs when using locking pieces with

hollow interiors. Refer to

⇒ Fig. ““Installation of Offset Springs -A- ”“ , page 226

 .

Installation of Offset Springs -A-
These springs are installed on both sides.
– Springs are only installed in conjunction with hollow locking

pieces.

– Insert locking pieces (installed position. Refer to

⇒ Fig. ““5th Gear Synchronizing”“ , page 225

 ).

Spring Installed Position:
– Install the spring offset by 120°.
– Angled end -A- of spring must engage into the hollow locking

piece.

It must be located below the tab -B- of the locking pieces.
The offset end always faces away from the synchronizer hub di‐

rection of -arrow-.

1.2

Input Shaft, Adjusting

⇒ “1.2.1 Determining the Shim”, page 228
⇒ “1.2.2 Checking Measurement”, page 229

(Choosing the adjusting shim for the input shaft)
Special tools and workshop equipment required
♦ Dial Gauge Holder - VW387-
♦ Measuring Set - Magnetic Plate - 50mm - VW 385/17-
♦ Press Piece - Multiple Use - VW510-
♦ Press Piece - Multiple Use - VW447I-

226

ponents have been replaced:
♦ Transmission Housing
♦ Clutch Housing
♦ Input Shaft
♦ 4th Gear Wheel
or the
♦ Tapered roller bearing
Adjustment overview. Refer to

⇒ “2 Adjustment Overview”, page 262

 .

Requirement:
• Remove any sealant remaining on the sealing surfaces on the

clutch and transmission housing.

– Press the taper roller bearing outer race into the clutch housing

all the way.

– Install the outer race/tapered roller bearing all the way into the

transmission housing without the adjusting shim.

– Install the input shaft into the clutch housing and mount the

transmission housing. Tighten the bolts to 25 Nm with a 90°

additional turn.

– Install the measuring device and the dial gauge in the clutch

housing.

– Rotate the input shaft before measuring so the tapered roller

bearing settles. Set the dial gauge with 1 mm pretension to “0”.

Note

Repeat this process each time a measurement is taken otherwise

the dial gauge will not go back to its start setting.

1. Input Shaft    

227

-arrow-.

– Read and make note of the play on the dial gauge (example:

1.21 mm).

Note

The dial gauge does not return to its starting position.

1.2.1

Determining the Shim

Example:

Bearing clearance measured

value

Adjustment shim thickness ac‐

cording to the table

1.21 mm

1.175 mm

Shim Table

Bearing play

Shim

Measured value (mm)

Thickness (mm)

0.671 to 0.699

0.700 to 0.724

0.725 to 0.749

0.650

0.675

0.700

0.750 to 0.774

0.775 to 0.799

0.800 to 0.824

0.725

0.750

0.775

0.825 to 0.849

0.850 to 0.874

0.875 to 0.899

0.800

0.825

0.850

0.900 to 0.924

0.925 to 0.949

0.950 to 0.974

0.875

0.900

0.925

0.975 to 0.999

1.000 to 1.024

1.025 to 1.049

0.950

0.975

1.000

1.050 to 1.074

1.075 to 1.099

1.100 to 1.124

1.025

1.050

1.075

1.125 to 1.149

1.150 to 1.174

1.175 to 1.199

1.100

1.125

1.150

1.200 to 1.224

1.225 to 1.249

1.250 to 1.274

1.175

1.200

1.225

1.275 to 1.229

1.300 to 1.324

1.325 to 1.349

1.250

1.275

1.300

1.350 to 1.374

1.375 to 1.399

1.400 to 1.424

1.325

1.350

1.375

1.425 to 1.449

1.450 to 1.474

1.475 to 1.499

1.400

1.425

1.450

1.500 to 1.524

1.525 to 1.549

1.550 to 1.574

1.475

1.500

1.525

228

Shim

Measured value (mm)

Thickness (mm)

1.575 to 1.599

1.600 to 1.624

1.625 to 1.649

1.550

1.575

1.600

1.650 to 1.674

1.675 to 1.699

1.700 to 1.724

1.625

1.650

1.675

Note

Allocate the shims. Refer to the Parts Catalog.

– Remove the driveshaft and pry out the outer race/tapered roll‐

er bearing using the Press Piece - VW 447 i- from the trans‐

mission housing.

– Install the shim with the correct thickness, thickest shim first.
If the measured shim thickness is larger than those listed in the

table, then install two shims that add up to the necessary thick‐

ness.
– Press the outer race/tapered roller bearing and the selected

shim (1.175 mm in the example) into the transmission housing

using the Press Piece - Multiple Use - VW510- .

– Assemble the transmission housing and tighten the hex bolts

to 25 Nm plus an additional 90°.

1.2.2

Checking Measurement

– Install the measuring device and the dial gauge.
– Turn the input shaft so that the tapered roller bearings settle.
– Press the input shaft in direction of -arrow-.
– Bearing play should be between 0.01 and 0.09.

Note

The adjustment is OK if it is not possible to measure the bearing

play and yet the input shaft still have a noticeable play and it easy

to turn.

1.3

Input Shaft Seal, Replacing

Special tools and workshop equipment required
♦ Bearing/Bushing Installer - Multiple Use - VW 295-
♦ Bearing/Bushing Installer - Multiple Use - VW 295 A-
♦ Press Piece - Multiple Use - VW454-
♦ Press Piece - Front Control Arm - 2040-
• Transmission is removed.
– Remove the clutch release lever with the release bearing and

guide sleeve. Refer to

⇒ “2 Clutch Release Mechanism, Servicing”, page 45

 .

1. Input Shaft    

229

 

 

 

 

 

 

 

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