Volkswagen Golf Variant / Jetta. Manual - part 289

 

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Volkswagen Golf Variant / Jetta. Manual - part 289

 

 

Outer race and on the 2nd Gear Outer Race
– Check the synchronizer ring -arrow- on the inner running sur‐

face for grooves and radial wear, and replace if necessary.

– Install the inner race, the outer race and the synchronizer ring

on the cone on the inner race.

– Press on the synchronizer ring with the outer race and turn it

evenly so that the synchronizer ring settles in.

– Measure 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

0.8 mm

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

Installing 2nd Gear Outer Race, Inner Race and Synchronizer

Ring
– Install the inner race -A- in the gear wheel.
The tabs -1- face away from the gear wheel.
– Install the outer race -B-.
The tabs -2- engage in grooves -3- on the gear wheel.
– Install the synchronizer ring -C-.
The larger openings -4- lock in the tabs -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.

2. 1st through 4th Gear Output Shaft    

331

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.

Installation Position of Locking Collar/Synchronizer Hub for 1st

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.
The pins -A- on the synchronizer ring lock into the recesses -B-

in the synchronizer hub.
– Install the locking ring.

332

Race
– Install the synchronizer ring -A- in the synchronizer hub.
The tabs -1- lock in the openings -2- in the synchronizer hub.
– Install the outer race -B- in the synchronizer ring.
The tabs -3- face away from the synchronizer ring.
– Install the inner race -C- in the outer race.
The tabs -4- lock in the larger openings -5- in the synchronizer

ring -A-.

Installing 1st Gear Wheel with Needle Bearing
• The synchronizer ring -1- and the tabs -arrow A- are inside the

openings in the synchronizer hub -2-.

The pins -arrows B- in the outer race lock in the recesses

-arrows C- in the gear wheel -3-.
– 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.
– Place the synchronizer ring for 4th gear on the 4th gear wheel.

2. 1st through 4th Gear Output Shaft    

333

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

locking pieces.

– Install the locking ring.

Checking the 3rd Gear Inner Race for Wear
– 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

3rd Gear

0.75 to 1.25 mm

0.3 mm

Checking Synchronizer Ring for 3rd Gear for Wear
– Install the synchronizer ring, outer race and inner race onto

taper of selector gear and then measure the gap dimension

-a- with a feeler gauge.

Gap dimension

-a-

Installation Dimen‐

sion

Wear Limit

3rd Gear

1.2 to 1.8 mm

0.5 mm

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

locking collar for 3rd and 4th gears.

Installed Position: 3rd Gear Outer Race
The tabs -arrows- face the synchronizer hub/locking collar -A-.

334

 

 

 

 

 

 

 

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