Volkswagen Golf Variant / Jetta. Manual - part 284

 

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Volkswagen Golf Variant / Jetta. Manual - part 284

 

 

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date 4/10/06 through approximately 1/20/08. Refer to

⇒ “1.2.1 Grooved Ball Bearing Changes”, page 315

 .

❑ Flattened areas on grooved ball bearing and bearing seat approximately from transmission build date

1/21/2008. Refer to 

⇒ “1.2.1 Grooved Ball Bearing Changes”, page 315

 .

❑ Refer to the Parts Catalog.

4 - Washer

❑ Outer diameter = 85 mm
❑ Only insert with the changed transmission housing (from transmission production date 04/10/2006

through approximately 01/20/2008). Refer to 

⇒ “1.2.1 Grooved Ball Bearing Changes”, page 315

 .

❑ Refer to the Parts Catalog.

5 - Circlip

❑ Select when replacing the grooved ball bearing -item 6- 

⇒ Item 6 (page 311)

 and the input shaft

-item 8- 

⇒ Item 8 (page 311)

 . Refer to

⇒ Fig. ““Determining the Grooved Ball Bearing Locking Ring on the Input Shaft”“ , page 314

6 - Grooved Ball Bearing

❑ Replace after removing
❑ Removing. Refer to 

⇒ Fig. ““Removing the Grooved Ball Bearing”“ , page 312

 .

❑ Installation position. Refer to

⇒ Fig. ““Grooved Ball Bearing Installation Location and Installing the Grooved Ball Bearing”“ ,

page 313

 .

❑ Installing. Refer to

⇒ Fig. ““Grooved Ball Bearing Installation Location and Installing the Grooved Ball Bearing”“ ,

page 313

 .

❑ Flattened areas on grooved ball bearing and bearing seat approximately from transmission build date

1/21/2008. Refer to

⇒ Fig. ““Flattened Areas on the Grooved Ball Bearing -A- and Bearing Seat -B- in the Transmission

Housing Approximately from Transmission Build Date 2/21/08.”“ , page 316

 .

7 - 5th Gear Wheel

❑ Available as a replacement part together with the input shaft
❑ Removing. Refer to 

⇒ Fig. ““Removing the 5th Gear Wheel”“ , page 312

 .

❑ Installed position: the surrounding groove -arrow- points toward grooved ball bearing -item 6-

⇒ Item 6 (page 311)

❑ Installing. Refer to 

⇒ Fig. ““Warming the 5th Gear Wheel and Installing”“ , page 313

 .

8 - Input Shaft

❑ With 3rd/4th and 6th gear wheel

9 - Cylindrical Roller Bearing

❑ With circlip
❑ Removing. Refer to

⇒ Fig. ““Removing the Cylindrical Roller Bearing from the Clutch Housing”“ , page 314

 .

❑ Installing. Refer to 

⇒ Fig. ““Pressing Cylindrical Roller Bearing Into Clutch Housing.”“ , page 314

 .

❑ Installed position: the circlip in bearing points to input shaft

10 - Clutch Housing

1.2

Input Shaft, Disassembling and Assem‐

bling

Special tools and workshop equipment required
♦ Press Plate - VW401-
♦ Press Plate - VW402-
♦ Press Piece - Rod - VW407-
♦ Press Piece - Rod - VW408A-

1. Input Shaft    

311

17/2-

♦ Puller - Kukko Counterstay - 22/2-
♦ Feeler Gauge
Input Shaft, Disassembling
– Remove the grooved ball bearing locking ring.
Removing the Grooved Ball Bearing
– Mount the Separating Tool -A- into the groove in the ball bear‐

ing for the locking ring.

A - 22 to 115 mm Separating Tool , for example Puller - Kukko

Quick Action Separating Tool - 22-115mm - 17/2-
– The grooved ball bearing and 5th gear wheel can also be re‐

moved together. To do this, place the Separating Tool -A- as

shown in the following illustration under the 5th gear wheel.

Removing the 5th Gear Wheel
A - 22 to 115 mm Separating Tool , for example Puller - Kukko

Quick Action Separating Tool - 22-115mm - 17/2-
Input Shaft, Assembling

312

Grooved Ball Bearing Installation Location and Installing the

Grooved Ball Bearing
• Grooved ball bearing installation location: the groove for the

circlip faces up -arrow A-. The collar -arrow B- must face the

5th gear wheel.

– Install the grooved ball bearing securing ring on the input shaft

(⇒ next figure).

1. Input Shaft    

313

Shaft
– Insert a 1.86 mm locking ring -A- into groove in the input shaft

and press it upward.

– Measure the gap between the grooved ball bearing -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.

The following locking rings are available:

Measured Value

(mm)

Circlip Thickness

(mm)

Axial Play (mm)

0.01 to 0.05

1.86

0.01 to 0.05

0.05 to 0.07

1.89

0.01 to 0.05

0.07 to 0.10

1.92

0.01 to 0.05

0.10 to 0.13

1.95

0.01 to 0.05

0.13 to 0.16

1.98

0.01 to 0.05

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

with pliers -C- and remove it.

A - Counter Support , for example, Puller - Kukko Counterstay -

22/2-
B - Internal Puller 30 to 37 mm , for example, Puller - Kukko In‐

ternal - 28-37mm - 21/5-

Pressing Cylindrical Roller Bearing Into Clutch Housing.
– Compress the cylindrical roller bearing locking ring -arrow-

with pliers -C- 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.

314

 

 

 

 

 

 

 

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