Volkswagen Golf Variant / Jetta. Manual - part 288

 

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Volkswagen Golf Variant / Jetta. Manual - part 288

 

 

taper of selector gear and then measure the gap dimension

-a- with a feeler gauge.

Gap Dimension

-a-

Installation Dimen‐

sion

Wear Limit

1st 2nd and 3rd

gear

1.2 to 1.8 mm

0.5 mm

– Install the 2nd gear wheel with the needle bearing.

Installed Position: 2nd Gear Outer Race, Inner Race and Syn‐

chronizer Ring
– Check the tabs -arrows 1 and arrows 2- for scoring.
– Replace the inner race, the outer race and the synchronizer

ring if they have grooves or scoring.

– Install the inner race -A- on the 2nd gear wheel.
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-.

Disassembling and Assembling the Locking Collar and the Syn‐

chronizer Hub for 1st, 2nd, 3rd and 4th Gears
1 - Spring
2 - Locking piece
3 - Locking collar
4 - Synchronizer hub
– Slide the locking collar over the synchronizer hub.
In 3rd and 4th gear, the wide collar on the synchronizer hub and

the locking collar face in one direction.
The notches for the locking pieces on the synchronizer hub and

locking collar must line up with each other.

Assembling the Locking Collar/Synchronizer Hub for 1st, 2nd, 3rd

and 4th Gears
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.

2. 1st through 4th Gear Output Shaft    

327

and 2nd Gears
The identification groove -arrow 1- and the narrow collar

-arrow 2- on the synchronizer hub face the 1st gear.

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.
– Install the locking ring.
Install the 1st gear synchronizer ring

Installation Position of 1st Gear Outer Race
The tabs -arrows- face the synchronizer hub/locking collar -A-.

Installed Position: Synchronizer Ring -A- (1st gear inner race)
The tabs -arrows 1- engage into the holes -arrows 2- inside the

synchronizer ring -B-.

328

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

⇒ Fig. ““Installation Position of 1st Gear Outer Race”“ ,

page 328

 .

– Install the thrust washers for 1st and 4th gears -item 19-

⇒ Item 19 (page 319)

 and -item 20- 

⇒ Item 20 (page 319)

 .

– Install the 4th gear wheel with needle bearing.

Checking the 4th Gear Synchronizer 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

4th Gear

1.0 to 1.7 mm

0.5 mm

Installed Position: Locking Collar/Synchronizer Hub for 3rd and

4th Gears
The wider collar on the synchronizer hub -arrow- faces the 3rd

gear.

Installing the Synchronizer Hub with Locking Collar for 3rd and

4th Gears
– Turn the synchronizer ring so that the grooves line up with the

locking pieces.

– Install the locking ring.
– Install the 3rd gear synchronizer ring on the synchronizer hub/

locking collar for 3rd and 4th gears.

2. 1st through 4th Gear Output Shaft    

329

Installed Position: Synchronizer Ring -A- (3rd Gear Inner Race)
The tabs -arrows 1- engage into the holes -arrows 2- inside the

synchronizer ring -B-.

Installed Position: 3rd Gear Wheel
The higher collar -A- faces toward 4th gear -B-. The notches in

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

⇒ Fig. ““Installation Position of 1st Gear Outer Race”“ ,

page 328

 .

– Install the 3rd gear wheel with the needle bearing.

Note

Pressing on inner race/tapered roller bearing. Refer to

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

the Side of the Transmission Housing”“ , page 323

 .

Selecting the locking ring for the inner race/tapered roller bear‐

ing. Refer to

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

 .

2.2.3

Output Shaft for 1st through 4th Gears,

Assembling - from Transmission Manu‐

facture Date 10/26/09 through Trans‐

mission Manufacture Date 5/24/00

Checking the Inner Contact Surface for Wear on the 1st Gear

Outer Race and on the 2nd Gear Outer Race
– Install the inner race -1- on the cone on the gear wheel.
– Install the outer race -2- on the cone on the inner race. Meas‐

ure the gap -a- with a feeler gauge at 3 locations at 120°.

– Note the average value.

Wear Limit Dimension -a-

1st gear and 2nd gear

0.4 mm

330

 

 

 

 

 

 

 

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