Volkswagen Golf Variant / Jetta. Manual - part 291

 

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Volkswagen Golf Variant / Jetta. Manual - part 291

 

 

measure gap dimension -a- using a feeler gauge.

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.

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.

Installing the 3rd Gear Synchronizer Ring, Outer Ring and Inner

Ring
– 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-.

2. 1st through 4th Gear Output Shaft    

339

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 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

 .

2.3

Output Shaft 1st through 4th Gear, Ad‐

justing

⇒ “2.3.1 Determining the Shim”, page 341
⇒ “2.3.2 Shim Table”, page 342
⇒ “2.3.3 Checking Measurement”, page 342

Special tools and workshop equipment required
♦ Transmission Support - VW353-
♦ Dial Gauge Holder - VW387-
♦ Press Piece - Rod - VW407-
♦ Press Piece - Multiple Use - VW433-
♦ Seal Installer - Stator - VW792-
♦ Crankshaft Holding Fixture - VW801-
♦ Holding Plate - VW309A-
♦ Slide Hammer - Press Plate - 2050-
♦ Torque Wrench 1331 5-50Nm - VAG1331-
♦ -1- Puller - Kukko Internal - 46-56mm - 21/7-
♦ -4- Puller - Kukko Counterstay - 22/2-
(Selecting the correct adjusting shim for the output shaft)
It is necessary to adjust the output shaft if the following compo‐

nents were replaced:
♦ Transmission housing
♦ Clutch housing
♦ Output shaft for 1st to 4th gears or
♦ Output shaft tapered roller bearing
Adjustment overview. Refer to

⇒ “4 Overview - Adjustment”, page 393

 .

Requirements
• Remove any sealant remaining on the sealing surfaces on the

clutch and transmission housing.

• Install the output shaft that is going to be measured.

340

housing with a 1.70 mm shim. Support transmission housing

directly beneath bearing mount using Slide Hammer - Press

Plate - 2050- .

– Install the output shaft for 1st through 4th gears into the clutch

housing.

– Install the transmission housing and tighten the bolts

-A and B- diagonally to the tightening specification.

– Position the measuring tools on the clutch housing and secure

them with a bolt -arrow-.

– Set the dial gauge (3 mm range) with 1 mm preload to “0”.
– Loosen securing bolts for clutch housing/transmission housing

in diagonal sequence until bolts the clear transmission hous‐

ing or the output shaft.

– Read measured value on dial indicator and note (example:

0.14 mm).

Note

The measured value will not be displayed when loosening the

bolts that connect the clutch housing to the transmission hous‐

ing.

Install a 1.95 mm shim or, if necessary, a 2.20 mm shim in

place of the 1.70 mm shim for measuring.

Allocate the shims. Refer to the Parts Catalog.

2.3.1

Determining the Shim

The required bearing tension is reached as follows:
The specified bearing pre-load is reached when determined

measured value (0.14 mm) is subtracted from inserted adjust‐

ment shim (1.70 mm).

2. 1st through 4th Gear Output Shaft    

341

Inserted shim

1.70 mm

- Measured value

0.14 mm

+ Preload (constant value)

0.20 mm

Shim thickness

1.76 mm

– Select the correct shim thickness according to the table. Refer

to 

⇒ “2.3.2 Shim Table”, page 342

 .

– Remove the transmission housing and remove the tapered

roller bearing outer race from the 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-
– Remove the inserted shim (1.70 mm) from the transmission

housing.

2.3.2

Shim Table

 

Thickness (mm)

 

1.45

1.75

2.05

1.50

1.80

2.10

1.55

1.85

2.15

1.60

1.90

2.20

1.65

1.95

2.25

1.70

2.00

 

Tolerance variations make it possible to find the exact shim thick‐

ness required.
– Shim part number. Refer to the Parts Catalog.
– Install the outer race/tapered roller bearing with the selected

shim (in the example: 1.75 mm) Support transmission housing

directly beneath bearing mount using Slide Hammer - Press

Plate - 2050- .

2.3.3

Checking Measurement

• The selected adjusting shim is installed.

342

 

 

 

 

 

 

 

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