Volkswagen Golf Variant / Jetta. Manual - part 294

 

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Volkswagen Golf Variant / Jetta. Manual - part 294

 

 

splines on the output shaft -arrow B-.

Warming and Installing the Reverse Gear Synchronizer Hub
– Install the locking ring.
– Mount the reverse gear locking collar on the reverse gear syn‐

chronizer hub.

– Install the reverse gear wheel and the needle bearing.

Installing the Sleeve -A-
• Installed position: wide collar points toward reverse gear se‐

lector gear.

– Install the circlip.

Check the 5th and 6th Gear Synchronizer Ring for Wear

-A- = Brass Synchronizer Ring

Gap Dimension

-a-

Installation Dimen‐

sion

Wear Limit

5th and 6th gear

1.0 to 1.7 mm

0.5 mm

-B- = Steel Synchronizer Ring

Gap Dimension

-a-

Installation Dimen‐

sion

Wear Limit

5th and 6th gear

1.2 to 2.1 mm

0.8 mm

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

351

measure gap dimension -a- using a feeler gauge.

Disassembling and Assembling Locking Collar and Synchronizer

Hub for 5th and 6th Gears
– To disassemble, remove the springs -1-.
1 - Spring
2 - Locking piece
3 - Locking collar
4 - Synchronizer hub
– Slide the locking collar over the synchronizer hub.
• Installed position: The narrow locking piece recesses in the

synchronizer hub align with the recesses in the locking collar.

Assembling Locking Collar/Synchronizer Hub for 5th and 6th

Gears
• The locking collar is pushed over the synchronizer hub.
– Install the locking pieces and springs offset by 120°.
• The angled end of the spring must engage into the hollow

locking piece.

– Install the 6th gear wheel with needle bearing.
– Install the 6th gear synchronizer ring.

Warming and Installing the Locking Collar/Synchronizer Hub for

5th and 6th Gears
On some locking collars, there is a chamfer on the outer diameter.
Installation position: the bevel on the outer diameter of the locking

collar faces toward the 5th gear wheel.
– Turn the 6th gear synchronizer ring so that the grooves line up

with the locking pieces.

– Install the locking ring.
– Install the 5th gear synchronizer ring.
– Install 5th gear wheel with needle bearing.

352

the Transmission Housing
– Choose the correct locking ring. Refer to

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

 and install.

Selecting the Locking Ring
– Choose and install the thickest locking ring that will fit.
– Select the locking ring according to the Table. Part number.

Refer to the Parts Catalog.

Available Locking Rings

Thickness (mm)

1.79

1.89

1.98

1.83

1.92

 

1.86

1.95

 

Installing the Inner Race/Tapered Roller Bearing on the Side of

the Clutch Housing

3.3

Output Shaft, 5th, 6th and Reverse

Gears, Adjusting

⇒ “3.3.1 Determining the Shim”, page 355
⇒ “3.3.2 Shim Table”, page 355
⇒ “3.3.3 Checking Measurement”, page 356

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-

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

353

nents were replaced:
♦ Transmission Housing
♦ Clutch Housing
♦ Output Shaft, 5th, 6th and Reverse 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.
– Install the tapered roller bearing outer race in the transmission

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 5th/6th gears and reverse gear into

the clutch housing.

– Install the transmission housing and tighten the bolts

-A and B- diagonally to the tightening specification.

354

 

 

 

 

 

 

 

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