Volkswagen Golf Variant / Jetta. Manual - part 194

 

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Volkswagen Golf Variant / Jetta. Manual - part 194

 

 

taper of selector gear and then measure the gap dimension

-a- with a feeler gauge.

Gap dimension

-a-

Installation Dimen‐

sion

Wear limit

1st and 2nd gear

1.2 to 1.8 mm

0.5 mm

Disassembling and Assembling Locking Collar and Synchronizer

Hub for 1st and 2nd Gears
1 - Spring
Allocate the correct springs. Refer to the Parts Catalog
Installing with the hollow locking pieces. Refer to

⇒ Fig. ““Assembly: Locking Collar/Synchronizer Hub for 1st and

2nd Gears Together with Locking Pieces that are Hollow on the

Inside”“ , page 238

 .

Installing with the locking pieces that are not hollow. Refer to

⇒ Fig. ““Assembly: Locking Collar/Synchronizer Hub for 1st and

2nd Gears Together with Locking Pieces that are not Hollow”“ ,

page 239

 .

2 - Locking collar
3 - Synchronizer Hub
4 - Locking piece
Allocate the locking pieces. Refer to the Parts Catalog.
The collar has the same width on both side of the synchronizer

hub.
The shoulder has a chamfer on one side -arrow B-
The bevel on the synchronizer hub collar and the splines on the

outside of the locking collar -arrow A- face in the same direction

after being assembled.
The notches on the synchronizer hub and locking collar for the

locking pieces -arrow C- must line up.

Assembly: Locking Collar/Synchronizer Hub for 1st and 2nd

Gears Together with Locking Pieces that are Hollow on the Inside
• The locking collar is pushed over the synchronizer hub.
– Install the locking pieces and springs offset by 120°. The an‐

gled end of the spring must engage into the hollow locking

piece.

238

Gears Together with Locking Pieces that are not Hollow
• The locking collar is pushed over the synchronizer hub.
– Install the locking pieces and springs offset by 120°. The an‐

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

pieces -arrows-.

Installed Position: Locking Collar/Synchronizer Hub for 1st and

2nd Gears
The teeth on the locking collar -arrow- point toward the splines for

the 3rd/4th gear synchronizer hub -A-.

Installing the Locking Collar/Synchronizer Hub for 1st and 2nd

Gears.
Turn the synchronizer ring so that the grooves line up with the

locking pieces.

Installed Position of 2nd Gear Outer Race
The tabs -arrows- face 1st gear -A-.

2. Output Shaft    

239

synchronizer ring -B-.

Installed position: 2nd gear wheel
The higher collar -A- faces toward 1st gear -B-. The notches in

the collar -arrow- lock into the tabs on the outer race. Refer to

⇒ Fig. ““Installed Position of 2nd Gear Outer Race”“ , page 239

 .

Installing the Sleeve for the 3rd Gear Needle Bearing

Checking 3rd/4th Gear Synchronizing Ring for Wear
– Press synchronizer ring onto taper of the gear wheel and

measure gap dimension -a- using a feeler gauge.

Gap dimension

-a-

Installation Dimen‐

sion

Wear limit

3rd and 4th gear

1.0 to 1.7 mm

0.5 mm

240

Hub for 3rd/4th Gears
1 - Spring
Allocate the correct springs. Refer to the Parts Catalog
Installing with the hollow locking pieces. Refer to

⇒ Fig. ““Assembly: locking collar/synchronizer hub for 3rd and 4th

gears together with locking pieces that are hollow on the inside”“ ,

page 241

 .

Installing with the locking pieces that are not hollow. Refer to

⇒ Fig. ““Assembly: Locking Collar/Synchronizer Hub for 3rd and

4th Gears Together with Locking Pieces that are not Hollow”“ ,

page 241

 .

2 - Locking piece
Allocate the locking pieces. Refer to the Parts Catalog.
3 - Locking collar
4 - Synchronizer Hub
– Slide the locking collar over the synchronizer hub.
The notches for the locking pieces on the synchronizer hub and

locking collar must line up with each other.

Assembly: locking collar/synchronizer hub for 3rd and 4th gears

together with locking pieces that are hollow on the inside
The locking collar is pushed over the synchronizer hub.
– Install the locking pieces and springs offset by 120°. The an‐

gled end of the spring must engage into the hollow locking

piece.

Assembly: Locking Collar/Synchronizer Hub for 3rd and 4th

Gears Together with Locking Pieces that are not Hollow
• The locking collar is pushed over the synchronizer hub.
– Install the locking pieces and springs offset by 120°. The an‐

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

pieces -arrows-.

2. Output Shaft    

241

 

 

 

 

 

 

 

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