Volkswagen Golf Variant / Jetta. Manual - part 193

 

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

 

Search            

 

 

 

 

 

 

 

 

 

Content   ..  191  192  193  194   ..

 

 

Volkswagen Golf Variant / Jetta. Manual - part 193

 

 

❑ Installation position. Refer to 

⇒ Fig. ““Installed position: 2nd gear wheel”“ , page 240

 .

22 - Needle Bearing

❑ For 2nd gear

23 - Thrust Washer
24 - 3rd Gear Needle Bearing Sleeve

❑ Removing with the 2nd gear wheel. Refer to

⇒ Fig. ““3rd/4th Gear Synchronizer Hub/Locking Collar, 2nd, 3rd and 4th Gear Wheel with Output Shaft

Needle Bearing Sleeve, Removing”“ , page 236

❑ Installing. Refer to 

⇒ Fig. ““Installing the Sleeve for the 3rd Gear Needle Bearing”“ , page 240

25 - Needle Bearing

❑ For 3rd gear

26 - 3rd Gear Wheel
27 - 3rd Gear Synchronizer Ring

❑ Checking for wear 

⇒ Fig. ““Checking 3rd/4th Gear Synchronizing Ring for Wear”“ , page 240

28 - Locking Collar with Synchronizer Hub for 3rd and 4th Gears

❑ Remove with 2nd gear wheel -item 21- 

⇒ Item 21 (page 234)

 and 3rd gear -item 26-

⇒ Item 26 (page 234)

⇒ Fig. ““3rd/4th Gear Synchronizer Hub/Locking Collar, 2nd, 3rd and 4th Gear Wheel with Output Shaft

Needle Bearing Sleeve, Removing”“ , page 236

❑ Disassembling. Refer to

⇒ Fig. ““Disassembling and Assembling Locking Collar and Synchronizer Hub for 3rd/4th Gears”“ , page

241

 .

❑ Assembling operating sleeve/synchronizer hub. Refer to

⇒ Fig. ““Disassembling and Assembling Locking Collar and Synchronizer Hub for 3rd/4th Gears”“ , page

241

 ,

⇒ Fig. ““Assembly: locking collar/synchronizer hub for 3rd and 4th gears together with locking pieces that

are hollow on the inside”“ , page 241

 and

⇒ Fig. ““Assembly: Locking Collar/Synchronizer Hub for 3rd and 4th Gears Together with Locking Pieces

that are not Hollow”“ , page 241

❑ Installed position: locking collar/synchronizer hub. Refer to

⇒ Fig. ““Installed Position: Locking Collar/Synchronizer Hub for 3rd and 4th Gears”“ , page 242

❑ Installing. Refer to

⇒ Fig. ““Installing the Synchronizer Hub with Locking Collar for 3rd and 4th Gears”“ , page 242

29 - Sleeve

❑ For the 4th gear needle bearing
❑ Removing with the locking collar and the 3rd/4th gear synchronizer hub -item 28-

⇒ Item 28 (page 234)

 . Refer to

⇒ Fig. ““3rd/4th Gear Synchronizer Hub/Locking Collar, 2nd, 3rd and 4th Gear Wheel with Output Shaft

Needle Bearing Sleeve, Removing”“ , page 236

❑ Installing. Refer to 

⇒ Fig. ““Installing the Sleeve for the 4th Gear Needle Bearing”“ , page 242

30 - Needle Bearing

❑ For 4th gear

31 - 4th Gear Synchronizer Ring

❑ Checking for wear. Refer to 

⇒ Fig. ““Checking 3rd/4th Gear Synchronizing Ring for Wear”“ , page 240

32 - 4th Gear Wheel
33 - Thrust Washer
34 - Needle Bearing

❑ For the output shaft
❑ Removing and Installing. Refer to -item 2- 

⇒ Item 2 (page 184)

 .

234

❑ For the needle bearing/output shaft
❑ Removing. Refer to

⇒ Fig. ““3rd/4th Gear Synchronizer Hub/Locking Collar, 2nd, 3rd and 4th Gear Wheel with Output Shaft

Needle Bearing Sleeve, Removing”“ , page 236

❑ Installing. Refer to 

⇒ Fig. ““Installing the Sleeve for the Needle Bearing/Output Shaft”“ , page 242

37 - 5th Gear Wheel

❑ Remove individually. Refer to

⇒ “7.6 Assembly Sequence, Transmission Housing Cover and 5th Gear, Removing and Installing”, page

166

❑ Remove with the transmission housing. Refer to

⇒ “7.7 Transmission, Assembly Sequence, Disassembling and Assembling”, page 170

 .

38 - Plate Spring

❑ Installation position. Refer to

⇒ Fig. ““Installed Position of Plate Springs for 5th Gear Synchronizer Hub and Gear Securing Bolts”“ ,

page 181

 .

39 - Screw -item 4- 

⇒ Item 4 (page 162)

❑ Always replace.
❑ Removing and Installing. Refer to

⇒ “7.7 Transmission, Assembly Sequence, Disassembling and Assembling”, page 170

 .

Remove the Small Outer Race/Tapered Roller Bearing
A - Internal Puller - 37-46mm for example Puller - Kukko Internal

- 36-46mm -Kukko 21/6-
B - Counter Support , for example, Puller - Kukko Counterstay -

Kukko 22/2-

Outer Race/Small Tapered Roller Bearing, Installing

2. Output Shaft    

235

Then rotate the bearing and apply tension to the grip.

Bearing Inner Race/Small Tapered Roller Bearing, Installing

3rd/4th Gear Synchronizer Hub/Locking Collar, 2nd, 3rd and 4th

Gear Wheel with Output Shaft Needle Bearing Sleeve, Removing
A - 22 to 115 mm Separating Tool , for example Puller - Kukko

Quick Action Separating Tool - 22-115mm -Kukko 17/2-
B - M10 x 20, 17 mm hex bolt

Note

Support the separating tool so that the 1st/2nd gear locking collar

does not come off as well.

Removing the Locking Collar with the Synchronizer Hub And

Bearing Mount
– Remove the locking ring -arrow- beforehand.

236

the output shaft.

Installing the Bearing Inner Race/Large Tapered Roller Bearing
-A- thrust washer
– Install the thrust washer before installing the bearing inner

race. The shoulder faces the inner race.

Installed Position of the Inner Race, the Outer Race and the 1st

Gear Synchronizer Ring
– Place inner race -A- on drive gear for 1st gear.
The angled tabs -arrows 1- face the outer race -B-.
– Install the outer race -B-.
The tabs -arrows 2- must lock into the retainers -arrows 3- in the

gear wheel.
– Install the synchronizer ring -C-.
The retainers -arrows 4- lock in the tabs -arrows 1- on the inner

race -A-.

Note

If the parts are not to be replaced, make sure they are reallocated

to their original gear.

Checking Inner Race for 1st Gear and 2nd Gear for Wear
– Install the inner race onto taper of selector gear and then

measure gap dimension -a- with a feeler gauge.

Gap dimension

-a-

Installation Dimen‐

sion

Wear limit

1st and 2nd gear

0.75 to 1.25 mm

0.3 mm

2. Output Shaft    

237

 

 

 

 

 

 

 

Content   ..  191  192  193  194   ..