Volkswagen Golf Variant / Jetta. Manual - part 527

 

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Volkswagen Golf Variant / Jetta. Manual - part 527

 

 

– Install the Back-Up Lamp Switch - F4- -C-.
– Install the mounting pins -B- on the top of the transmission.
– Move the gearshift rail into the neutral position.
– Apply Sealing Paste - AMV 188 200 03- evenly onto the gear‐

shift cover sealing surface.

– Install the selector shaft with the selector cover -A-. Tighten

the bolts -arrows-.

– Transmission on vehicles with Stop/Start system: install the

Transmission Neutral Position Sensor - G701- -arrow- and

tighten the screw to the tightening specification. Refer to

⇒ “6.5 Overview - Input Shaft, Output Shaft, Differential Se‐

lector Mechanism and Shift Rods, Removing and Installing”,

page 116

 .

– Attach the input and output shaft bearing mount with new bolts

-A-.

Note

Tighten to tightening specification diagonally and in stages start‐

ing at the center.

– Tighten shift mechanism (shift forks) hex collar nut -B-.

124

ing surface.

– Tighten the clutch housing to the transmission housing.
– Turn the transmission in the mounting bracket with transmis‐

sion housing upward.

Installed Position of Drive Gear for 5th Gear -1-:
High inner collar -arrow- faces toward transmission housing cov‐

er.
– Position 5th gear wheel -1-.
– Install 5th gear wheel with needle bearing.
– Place the 5th gear synchronizer ring onto the selector gear.
– Position 5th gear synchronizer cover together with locking col‐

lar and stop ring.

– Insert 5th gear shift fork -2- and slide in mounting pins -1- as

far as stop direction of -arrow-.

– Select a new locking ring -arrow-.
– Determine thickest circlip that can still be inserted for input

shaft -3- and output shaft -4- and insert.

For the available circlips. Refer to the Parts Catalog.

Thickness (mm)

2.00
2.10
2.20

– Install the transmission housing cover.

6. Transmission, Disassembling and Assembling    

125

washers and the tapered rings.

– Install the clutch release lever together with release bearing

and guide sleeve. Refer to

⇒ “4.2 Clutch Release Lever with Release Bearing and Guide

Sleeve, Removing and Installing”, page 44

 .

126

Transmission Housing and Clutch

Housing, Servicing

Special tools and workshop equipment required
♦ Press Piece - Rod - VW408A-
♦ Press Piece - Multiple Use Spacer Sleeve - VW472/2-
♦ Centering/Press Pin - 12-551-
♦ Press Piece - Pad - 30-555-
♦ Threaded rod from the Seal Installer - Driver Set - 3066-
♦ Press Piece - Pivot Mount Bushing - 3124-
♦ Centering/Press Pin - 12-551-
♦ Bearing Installer - Crankshaft Needle Bearing Mandrel - 2026-
♦ Seal Installer - Drive axle - T40008-
♦ Torque Wrench 1331 5-50Nm - VAG1331-
♦ Puller - Kukko Puller - 60-150mm Width, 200mm Length -

18/1-

♦ Puller - Kukko Quick Action Separating Tool - 12-75mm - 17/1-

1 - Sleeve

❑ For the selector shaft
❑ Removing. Refer to

⇒ Fig. ““Gearshift Shaft

Sleeve -A-, Remov‐

ing”“ , page 130

❑ Installing. Refer to

⇒ Fig. ““Gearshift Shaft

Sleeve -A-, Installing”“ ,

page 130

2 - Alignment Sleeve
3 - Magnet

❑ Held in place by housing

joint surface

4 - Cap

❑ Apply Sealing Com‐

pound - AMV 188 200

03- to the sealing sur‐

face before installing.

5 - Circlip

❑ insert in roller bearing

groove

6 - Circlip

❑ insert in roller bearing

groove

7 - Cylindrical Roller Bearing

❑ For the input shaft
❑ Removing and installing

-item 21-

⇒ Item 21 (page 151)

8 - Cylindrical Roller Bearing

❑ For the output shaft

7. Transmission Housing and Clutch Housing, Servicing    

127

 

 

 

 

 

 

 

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