Volkswagen Golf Variant / Jetta. Manual - part 290

 

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Volkswagen Golf Variant / Jetta. Manual - part 290

 

 

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

 .

2.2.4

Output Shaft for 1st through 4th gears,

Assembling - from Transmission Manu‐

facture Date 5/25/00

Inner Friction Surface on 1st Gear Outer Race, 2nd Gear Outer

Race and 3rd Gear Outer Race, Checking for Wear
– 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, 2nd gear, and 3rd

gear

0.4 mm

2. 1st through 4th Gear Output Shaft    

335

Race and 3rd Gear Outer Race, Checking for Wear
– 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, 2nd gear, and 3rd

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.

336

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.

2. 1st through 4th Gear Output Shaft    

337

ner 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

-A- = Brass Synchronizer Ring

Gap Dimension

-a-

Installation Dimen‐

sion

Wear Limit

4th Gear

1.0 to 1.7 mm

0.5 mm

-B- = Steel Synchronizer Ring

Gap Dimension

-a-

Installation Dimen‐

sion

Wear Limit

4th Gear

1.3 to 2.4 mm

0.8 mm

338

 

 

 

 

 

 

 

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