Volkswagen Golf Variant / Jetta. Manual - part 287

 

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Volkswagen Golf Variant / Jetta. Manual - part 287

 

 

Housing
– Support the clutch housing with the Bearing Installer - Multiple

Use - 40-20- directly under the bearing mount.

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

the Transmission Housing
Before installing the Tapered Roller Bearing Puller :
– Remove the inner race/tapered roller bearing locking ring on

the side facing the transmission housing.

– Place the Press Piece - Multiple Use - VW431- in the output

shaft and place the Press Piece - Multiple Use - 40-105- on

top.

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

the Transmission Housing
– Choose the correct locking ring. Refer to

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

 and install.

Selecting The Locking Ring
– Choose and install the thickest locking ring that will fit.

Note

Allocate the circlips. Refer to the Parts Catalog.

The following locking rings are available:

Thickness (mm)

1.79

1.83

1.86

1.89

1.92

1.95

1.98

 

2. 1st through 4th Gear Output Shaft    

323

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

22/2-
B - Internal Puller 46 to 58 mm , for example, Puller - Kukko In‐

ternal - 46-56mm - 21/7-

Installing the Outer Race/Tapered Roller Bearing into the Trans‐

mission Housing.
– Install the adjusting shim under the outer race.
– Support the transmission housing under the bearing mount

using the Slide Hammer - Press Plate - 2050- .

Disassembling the Output Shaft

Note

Remove the inner race/tapered roller bearing on the side of the

transmission housing. Refer to

⇒ Fig. ““Remove the Inner Race/Tapered Roller Bearing on the

Side of the Transmission Housing”“ , page 323

 .

Removing the 3rd and 4th Gear Synchronizer Hub/Locking Collar

with the 4th gear Wheel
– Remove the locking ring beforehand.
A - Puller , for example, Puller - Kukko Puller - 60-200mm Width,

250mm Length - 18/2-
B - 22 to 115 mm Separating Tool , for example Puller - Kukko

Quick Action Separating Tool - 22-115mm - 17/2-
– Remove the thrust washers for 1st and 4th gears -item 19-

⇒ Item 19 (page 319)

 and -item 20- 

⇒ Item 20 (page 319)

 .

– Remove the 1st gear wheel -item 18- 

⇒ Item 18 (page 319)

 .

Removing the Locking Collar and the Synchronizer Hub for 1st

and 2nd Gear
After removing the circlip, press off the gear wheel for 2nd gear

and locking collar/synchronizer hub together.

324

Differentiating 1st/2nd Gear Synchroni‐

zation, Differentiating 3rd Gear Syn‐

chronization

1st/2nd Gear Synchronization through Transmission Manufac‐

ture Date 10/25/2009 and 3rd Gear Synchronization through

Transmission Manufacture date 5/24/2000

The Synchronizer Ring -C-

and Inner Ring -A- are Made

of Brass.

The Outer Ring -B- is Made of

Steel.

Transmission

Manufacture

Date

Assembling

the Output

Shaft, 1st to

4th Gears

1st/2nd gear synchronization

Through

10/25/09

Refer to

⇒ “2.2.2 Out‐

put Shaft for

1st through 4th

Gears, Assem‐

bling, through

Transmission

Production

Date

10/25/2009”,

page 326

3rd gear synchronization

Through

5/24/2000

Refer to

⇒ “2.2.3 Out‐

put Shaft for

1st through 4th

Gears, Assem‐

bling - from

Transmission

Manufacture

Date 10/26/09

through Trans‐

mission Manu‐

facture Date

5/24/00”,

page 330

2. 1st through 4th Gear Output Shaft    

325

Date 10/26/2009 and 3rd Gear Synchronization from Transmis‐

sion Manufacture Date 5/25/2000

The Synchronizer Ring -C-,

the Outer Ring -B- and

the Inner Ring -A- are Made of

Steel.

Transmission

Manufacture

Date

Assembling

the Output

Shaft, 1st to

4th Gears

1st/2nd gear synchronization

From

10/26/2009

Refer to

⇒ “2.2.3 Out‐

put Shaft for

1st through 4th

Gears, Assem‐

bling - from

Transmission

Manufacture

Date 10/26/09

through Trans‐

mission Manu‐

facture Date

5/24/00”,

page 330

 or

⇒ “2.2.4 Out‐

put Shaft for

1st through 4th

gears, Assem‐

bling - from

Transmission

Manufacture

Date 5/25/00”,

page 335

 .

3rd gear synchronization

From

5/25/2000

Refer to

⇒ “2.2.4 Out‐

put Shaft for

1st through 4th

gears, Assem‐

bling - from

Transmission

Manufacture

Date 5/25/00”,

page 335

2.2.2

Output Shaft for 1st through 4th Gears,

Assembling, through Transmission Pro‐

duction Date 10/25/2009

Checking the Inner Race for 1st, 2nd and 3rd Gear for Wear
– Check the tabs on the inner race for scoring.
– 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 2nd and 3rd

gear

0.75 to 1.25 mm

0.3 mm

326

 

 

 

 

 

 

 

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