Volkswagen Golf Variant / Jetta. Manual - part 292

 

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Volkswagen Golf Variant / Jetta. Manual - part 292

 

 

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.

• For correctly selected adjustment shim, dial gauge must now

display a value of 0.15 mm to 0.25 mm.

2. 1st through 4th Gear Output Shaft    

343

5th, 6th and Reverse Gear Output

Shaft

⇒ “3.1 Overview - Input Shaft, 5th/6th and Reverse Gears”, page

344
⇒ “3.2 Output Shaft, 5th, 6th and Reverse Gears, Disassembling

and Assembling”, page 348
⇒ “3.3 Output Shaft, 5th, 6th and Reverse Gears, Adjusting”, page

353

3.1

Overview - Input Shaft, 5th/6th and Re‐

verse Gears

Output Shaft, 5th, 6th and Reverse Gears, Disassembling and

Assembling. Refer to

⇒ “3.2 Output Shaft, 5th, 6th and Reverse Gears, Disassembling

and Assembling”, page 348

 .

Note

Secure the transmission on the assembly stand. Refer to

⇒ “7 Transmission, Securing in Engine/Transmission Holder”, page 191

 .

To install, warm the inner races/tapered roller bearing and synchronizer hub to approximately 100 °C (212

°F) using Inductive Heater - VAS6414- . Wear protective gloves.

Adjust the output shaft if it or the tapered roller bearing are being replaced. Refer to

⇒ “3.3 Output Shaft, 5th, 6th and Reverse Gears, Adjusting”, page 353

 .

Replace both tapered roller bearings together.

344

❑ Always 0.65 mm thick

3 - Outer Race/Tapered Roller

Bearing

❑ Removing. Refer to

⇒ Fig. ““Removing the

Outer Race/Tapered

Roller Bearing”“ ,

page 348

 .

❑ Installing. Refer to

⇒ Fig. ““Installing the

Outer Race/Tapered

Roller Bearing in the

Clutch Housing”“ ,

page 349

 .

4 - Inner Race / Tapered Roller

Bearing

❑ Removing. Refer to

⇒ Fig. ““Removing the

Inner Race/Tapered

Roller Bearing on the

Side of the Clutch Hous‐

ing.”“ , page 350

❑ Installing. Refer to

⇒ Fig. ““Installing the In‐

ner Race/Tapered Roll‐

er Bearing on the Side of

the Clutch Housing”“ ,

page 353

 .

5 - Output Shaft

❑ For 5th, 6th and Re‐

verse Gears

❑ Adjusting. Refer to

⇒ “3.3 Output Shaft, 5th,

6th and Reverse Gears,

Adjusting”, page 353

 .

6 - Reverse Gear Synchronizer Hub

❑ Removing. Refer to 

⇒ Fig. ““Removing the Reverse Gear Synchronizer Hub”“ , page 350

 .

❑ Installation position. Refer to 

⇒ Fig. ““Installed Position: Reverse Gear Synchronizer Hub”“ , page 351

 .

❑ Installing. Refer to 

⇒ Fig. ““Warming and Installing the Reverse Gear Synchronizer Hub”“ , page 351

 .

7 - Circlip
8 - Reverse Gear Locking Collar

❑ With synchronizer ring

9 - Needle Bearing

❑ For reverse gear wheel

10 - Reverse Gear Wheel
11 - Sleeve

❑ Remove with the reverse gear wheel. Refer to

⇒ Fig. ““Removing the Sleeve -A- Together with the Reverse Gear Wheel”“ , page 350

❑ Installed position: the wider collar on sleeve points toward reverse gear selector gear
❑ Installing. Refer to 

⇒ Fig. ““Installing the Sleeve -A- ”“ , page 351

 .

12 - Circlip
13 - Needle Bearing

❑ For 6th gear

3. 5th, 6th and Reverse Gear Output Shaft    

345

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G.

14 - 6th Gear Wheel
15 - 6th Gear Synchronizer Ring

❑ Brass or steel
❑ Checking for wear. Refer to

⇒ Fig. ““Check the 5th and 6th Gear Synchronizer Ring for Wear”“ , page 351

16 - Locking Collar with Synchronizer Hub for 5th and 6th Gears

❑ After removing circlip -item 17- 

⇒ Item 17 (page 346)

 , remove the 6th gear wheel. Refer to

⇒ Fig. ““Removing the 5th and 6th Gear Synchronizer Hub/Locking Collar with the 6th Gear Wheel”“ ,

page 350

❑ Disassembling. Refer to

⇒ Fig. ““Disassembling and Assembling Locking Collar and Synchronizer Hub for 5th and 6th Gears”“ ,

page 352

 .

❑ Assembling the locking collar/synchronizer hub. Refer to

⇒ Fig. ““Disassembling and Assembling Locking Collar and Synchronizer Hub for 5th and 6th Gears”“ ,

page 352

 and

⇒ Fig. ““Assembling Locking Collar/Synchronizer Hub for 5th and 6th Gears”“ , page 352

❑ Installing. Refer to

⇒ Fig. ““Warming and Installing the Locking Collar/Synchronizer Hub for 5th and 6th Gears”“ ,

page 352

 .

17 - Circlip
18 - Needle Bearing

❑ For 5th gear

19 - 5th Gear Synchronizer Ring

❑ Brass or steel
❑ Checking for wear. Refer to

⇒ Fig. ““Check the 5th and 6th Gear Synchronizer Ring for Wear”“ , page 351

20 - 5th Gear Wheel
21 - Inner Race / Tapered Roller Bearing

❑ Removing. Refer to

⇒ Fig. ““Remove the Inner Race/Tapered Roller Bearing on the Side of the Transmission Housing”“ ,

page 349

❑ Installing. Refer to

⇒ Fig. ““Installing the Inner Race/Tapered Roller Bearing on the Side of the Transmission Housing”“ ,

page 353

 .

22 - Circlip

❑ Select the correct one when replacing the tapered roller bearing -item 21- 

⇒ Item 21 (page 346)

 and the

output shaft -item 5- 

⇒ Item 5 (page 345)

 

⇒ Fig. ““Selecting the Locking Ring”“ , page 353

23 - Outer Race/Tapered Roller Bearing

❑ Removing. Refer to

⇒ Fig. ““Removing the Outer Race/Tapered Roller Bearing from the Transmission Housing”“ ,

page 349

 .

❑ Installing. Refer to

⇒ Fig. ““Installing the Outer Race/Tapered Roller Bearing into the Transmission Housing.”“ ,

page 349

 .

24 - Shim

❑ Selecting thickness. Refer to 

⇒ “3.3 Output Shaft, 5th, 6th and Reverse Gears, Adjusting”, page 353

 .

25 - Transmission Housing
26 - Spring

❑ Installation position. Refer to

⇒ Fig. ““Assembling Locking Collar/Synchronizer Hub for 5th and 6th Gears”“ , page 352

 .

346

 

 

 

 

 

 

 

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