Volkswagen Golf Variant / Jetta. Manual - part 286

 

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Volkswagen Golf Variant / Jetta. Manual - part 286

 

 

❑ 1st/2nd gear synchronizing, from transmission build date 10/26/2009. Refer to

⇒ “2.2.1 Differentiating 1st/2nd Gear Synchronization, Differentiating 3rd Gear Synchronization”,

page 325

 .

12 - Locking Collar with Synchronizer Hub for 1st and 2nd Gears

❑ After removing circlip -item 13- 

⇒ Item 13 (page 319)

 , remove the 2nd gear wheel. Refer to

⇒ Fig. ““Removing the Locking Collar and the Synchronizer Hub for 1st and 2nd Gear”“ , page 324

❑ Disassembling. Refer to

⇒ Fig. ““Disassembling and Assembling the Locking Collar and the Synchronizer Hub for 1st, 2nd, 3rd

and 4th Gears”“ , page 327

 .

❑ Assembling locking collar/synchronizer hub. Refer to

⇒ Fig. ““Disassembling and Assembling the Locking Collar and the Synchronizer Hub for 1st, 2nd, 3rd

and 4th Gears”“ , page 327

❑ 1st/2nd gear synchronizing, from transmission build date 10/26/2009. Refer to

⇒ “2.2.1 Differentiating 1st/2nd Gear Synchronization, Differentiating 3rd Gear Synchronization”,

page 325

 .

13 - Circlip
14 - 1st Gear Synchronizer Ring

❑ 1st/2nd gear synchronizing, from transmission build date 10/26/2009. Refer to

⇒ “2.2.1 Differentiating 1st/2nd Gear Synchronization, Differentiating 3rd Gear Synchronization”,

page 325

 .

15 - 1st Gear Outer Race

❑ 1st/2nd gear synchronizing, from transmission build date 10/26/2009. Refer to

⇒ “2.2.1 Differentiating 1st/2nd Gear Synchronization, Differentiating 3rd Gear Synchronization”,

page 325

 .

16 - Synchronizer Ring for 1st Gear

❑ 1st/2nd gear synchronizing, from transmission build date 10/26/2009. Refer to

⇒ “2.2.1 Differentiating 1st/2nd Gear Synchronization, Differentiating 3rd Gear Synchronization”,

page 325

 .

17 - Needle Bearing

❑ For 1st gear

18 - 1st Gear Wheel

❑ 1st/2nd gear synchronizing, from transmission build date 10/26/2009. Refer to

⇒ “2.2.1 Differentiating 1st/2nd Gear Synchronization, Differentiating 3rd Gear Synchronization”,

page 325

 .

19 - Thrust Washer

❑ For 1st and 4th gears
❑ Quantity: 2
❑ The tab on the thrust washer must fit into the hole in the output shaft.

20 - Washer

❑ Holds the thrust washers -item 19- 

⇒ Item 19 (page 319)

 in place on the output shaft

21 - Needle Bearing

❑ For 4th gear

22 - 4th Gear Wheel
23 - 4th Gear Synchronizer Ring

❑ Brass or steel
❑ Checking for wear. Refer to 

⇒ Fig. ““Checking the 4th Gear Synchronizer Ring for Wear”“ , page 329

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

❑ After removing locking ring -item 25- 

⇒ Item 25 (page 320)

 , remove the 4th gear wheel. Refer to

⇒ Fig. ““Removing the 3rd and 4th Gear Synchronizer Hub/Locking Collar with the 4th gear Wheel”“ ,

page 324

2. 1st through 4th Gear Output Shaft    

319

⇒ Fig. ““Disassembling and Assembling the Locking Collar and the Synchronizer Hub for 1st, 2nd, 3rd

and 4th Gears”“ , page 327

 .

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

⇒ Fig. ““Installed Position: Locking Collar/Synchronizer Hub for 3rd and 4th Gears”“ , page 329

❑ Assembling the locking collar/synchronizer hub. Refer to

⇒ Fig. ““Disassembling and Assembling the Locking Collar and the Synchronizer Hub for 1st, 2nd, 3rd

and 4th Gears”“ , page 327

 and

⇒ Fig. ““Assembling the Locking Collar/Synchronizer Hub for 1st, 2nd, 3rd and 4th Gears”“ , page 327

❑ Installing. Refer to

⇒ Fig. ““Installing the Synchronizer Hub with Locking Collar for 3rd and 4th Gears”“ , page 329

 .

25 - Circlip
26 - 3rd Gear Synchronizer Ring

❑ Modified 3rd gear synchronizing from transmission manufacture date 5/25/2000, differentiation. Refer to

⇒ “2.2.1 Differentiating 1st/2nd Gear Synchronization, Differentiating 3rd Gear Synchronization”,

page 325

 .

27 - 3rd Gear Outer Race

❑ Modified 3rd gear synchronizing from transmission manufacture date 5/25/2000, differentiation. Refer to

⇒ “2.2.1 Differentiating 1st/2nd Gear Synchronization, Differentiating 3rd Gear Synchronization”,

page 325

 .

28 - Synchronizer Ring for 3rd Gear

❑ Modified 3rd gear synchronizing from transmission manufacture date 5/25/2000, differentiation. Refer to

⇒ “2.2.1 Differentiating 1st/2nd Gear Synchronization, Differentiating 3rd Gear Synchronization”,

page 325

 .

29 - Needle Bearing

❑ For 3rd gear

30 - 3rd Gear Wheel

❑ Modified 3rd gear synchronizing from transmission manufacture date 5/25/2000, differentiation. Refer to

⇒ “2.2.1 Differentiating 1st/2nd Gear Synchronization, Differentiating 3rd Gear Synchronization”,

page 325

 .

31 - Inner Race / Tapered Roller Bearing

❑ Removing. Refer to

⇒ Fig. ““Remove the Inner Race/Tapered Roller Bearing on the Side of the Transmission Housing”“ ,

page 323

❑ Installing. Refer to

⇒ Fig. ““Installing the Inner Race/Tapered Roller Bearing on the Side of the Transmission Housing”“ ,

page 323

 .

32 - Circlip

❑ Select the correct one when replacing the tapered roller bearing -item 31- 

⇒ Item 31 (page 320)

 and the

output shaft -item 6- 

⇒ Item 6 (page 318)

 . Refer to 

⇒ Fig. ““Selecting The Locking Ring”“ , page 323

33 - Outer Race/Tapered Roller Bearing

❑ Removing. Refer to

⇒ Fig. ““Removing the Outer Race/Tapered Roller Bearing from the Transmission Housing”“ ,

page 324

 .

❑ Installing. Refer to

⇒ Fig. ““Installing the Outer Race/Tapered Roller Bearing into the Transmission Housing.”“ ,

page 324

 .

34 - Shim

❑ Selecting thickness. Refer to 

⇒ “2.3 Output Shaft 1st through 4th Gear, Adjusting”, page 340

 .

35 - Transmission Housing

320

Output Shaft, 1st to 4th Gears, Disas‐

sembling and Assembling

⇒ “2.2.1 Differentiating 1st/2nd Gear Synchronization, Differenti‐

ating 3rd Gear Synchronization”, page 325

 .

⇒ “2.2.1 Differentiating 1st/2nd Gear Synchronization, Differenti‐

ating 3rd Gear Synchronization”, page 325
⇒ “2.2.3 Output Shaft for 1st through 4th Gears, Assembling -

from Transmission Manufacture Date 10/26/09 through Trans‐

mission Manufacture Date 5/24/00”, page 330
⇒ “2.2.4 Output Shaft for 1st through 4th gears, Assembling - from

Transmission Manufacture Date 5/25/00”, page 335

Special tools and workshop equipment required
♦ Press Plate - VW401-
♦ Press Plate - VW402-
♦ Press Piece - Rod - VW407-
♦ Press Piece - Rod - VW408A-
♦ Press Piece - Multiple Use - VW412-
♦ Press Piece - 60mm - VW415A-
♦ Holding Plate - VW309A-
♦ Holding Fixture - VW313-
♦ Transmission Support - VW353-
♦ Press Piece - Multiple Use - VW431-
♦ Press Piece - Multiple Use - VW433-
♦ Press Piece - Multiple Use - VW454-
♦ Press Piece - Multiple Use - VW512-
♦ Press Piece - 42mm - VW516-
♦ Press Piece - Multiple Use - VW519-
♦ Slide Hammer Set - Hammer - VW771-
♦ Crankshaft Holding Fixture - VW801-
♦ Press Piece - Multiple Use - 40-105-
♦ Bearing Installer - Multiple Use - 40-20-
♦ Bearing Installer - Differential Bearing - 40-21-
♦ Slide Hammer - Press Plate - 2050-
♦ Holding Fixture - Spacers - VW540/1B-
♦ Puller - Taper Roller Bearing - VAG1582-
♦ Puller - Taper Roller Bearing - Adapter 7 - VAG1582/7-
♦ Inductive Heater - VAS6414-
♦ Puller - Kukko Internal - 46-56mm - 21/7-
♦ Puller - Kukko Internal - 56-70mm - 21/8-
♦ Puller - Kukko Puller - 60-200mm Width, 250mm Length -

18/2-

♦ Puller - Kukko Quick Action Separating Tool - 22-115mm -

17/2-

♦ Puller - Kukko Counterstay - 22/2-

2. 1st through 4th Gear Output Shaft    

321

Installing the Dished Washer into the Output Shaft
Dimension “a” = 2 mm

Removing the Inner Race/Tapered Roller Bearing on the Side of

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

Quick Action Separating Tool - 22-115mm - 17/2-

Installing the Inner Race/Tapered Roller Bearing on the Side of

the Clutch Housing

Removing the Outer Race / Tapered Roller Bearing from the

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

22/2-
B - Internal Puller 56 to 70 mm , for example, Puller - Kukko In‐

ternal - 56-70mm - 21/8-

322

 

 

 

 

 

 

 

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