Volkswagen Golf Variant / Jetta. Manual - part 535

 

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Volkswagen Golf Variant / Jetta. Manual - part 535

 

 

Press in the Bearing Mount
– Warm to approximately 100 °C before installing.

WARNING

Wear safety gloves.

Install the 5th Gear Needle Bearing Sleeve -A-.

Stop Ring, Removing
– Unclip stop ring hook -A- from synchronizer hub with screw‐

driver.

156

and Assembling
1 - Spring
2 - Locking piece
3 - Synchronizer hub - installation location: Groove on rear side

-arrow A- and wide collar -arrow B- face toward 5th gear.

4 - Locking collar
5 - Stop ring
– Slide the locking collar over the synchronizer hub.
The deeper recesses -arrow C- for the locking pieces inside the

synchronizer hub and the recesses -arrow D- inside the locking

collar must align.

5th Gear Locking Collar/Synchronizer Hub Assembly
• The locking collar is pushed over the synchronizer hub.
– Insert the locking pieces in the deep recesses -arrows- and

install springs offset by 120°. The angled end of the spring

must engage into the hollow locking piece.

Stop Ring, Installing
– Press the stop ring onto the Press Piece - Trailing arm - 2010- .
– Insert stop ring together with Press Piece - Trailing arm - 2010-

into 5th gear synchronizer hub/locking collar (note installation

location. Refer to

⇒ Fig. ““Locking Collar and 5th Gear Synchronizer Hub, Dis‐

assembling and Assembling”“ , page 157

 ).

The hooks -arrow 1- engage in recesses -arrow 2- for synchron‐

izer hub locking pieces.
– Press stop ring down until the hooks engage.

1. Input Shaft    

157

Output Shaft

⇒ “2.1 Output Shaft, Disassembling and Assembling”,

page 158

2.1

Output Shaft, Disassembling and As‐

sembling

Special tools and workshop equipment required
♦ Press Plate - VW402-
♦ Press Piece - Rod - VW407-
♦ Press Piece - Multiple Use - VW412-
♦ Press Piece - 60mm - VW415A-
♦ Press Piece - Bushing - 50mm Diameter - VW432-
♦ Press Piece - Press Tube - 30-100-
♦ Puller - Kukko Internal - 28-37mm - 21/5-
♦ Puller - Kukko Counterstay - 22/1-
♦ Inductive Heater - VAS6414-

Note

When installing new gear wheels or a new input shaft. Refer to the technical data. Refer to

⇒ “1.2 Codes, Transmission Allocation and Capacities”, page 2

 and the Parts Catalog.

Insert all bearings, selector gears and synchronizer rings on output shaft with transmission fluid.

Do not exchange synchronizer rings, always allocate to original selector gear when reusing.

Wearing safety gloves, warm the gear wheels and the synchronizer hubs to approximately 100 °C (212 °F)

using an Inductive Heater - VAS6414- before installing them.

158

❑ With circlip
❑ Removing. Refer to

⇒ Fig. ““Remove the

Roller Bearing from the

Clutch Housing”“ ,

page 161

❑ Installing. Refer to

⇒ Fig. ““Pressing Cylin‐

drical Roller Bearing in‐

to Clutch Housing.”“ ,

page 161

❑ Installed position: the

circlip in bearing points

to output shaft

3 - Output Shaft

❑ If an bearing inner race

is available as a bearing

seat for the roller bear‐

ing -item 2-

⇒ Item 2 (page 159)

 ,

this cannot be removed

from the output shaft

❑ Check bearing seat or

cylindrical roller bearing

inner race for grooves

and damage

❑ If there are grooves or

damage on the bearing

inner race on the cylin‐

drical roller bearing,

then replace both the

output shaft and cylin‐

drical roller bearing.

4 - 4th Gear Wheel

❑ Installed position: shoulder faces 3rd gear. Refer to

⇒ Fig. ““Installation Location of 3rd and 4th Gear Drive Gears”“ , page 162

5 - Circlip

❑ Always replace damaged or stretched circlips.

6 - Circlip

❑ Always replace damaged or stretched circlips.

7 - 3rd Gear Wheel

❑ Installed position: shoulder faces 4th gear. Refer to

⇒ Fig. ““Installation Location of 3rd and 4th Gear Drive Gears”“ , page 162

8 - Circlip

❑ Always replace damaged or stretched circlips.

9 - 2nd Gear Wheel
10 - Needle Bearing

❑ For 2nd gear

11 - 2nd Gear Inner Race

❑ Checking for wear. Refer to

⇒ Fig. ““Checking inner race for 1st gear and 2nd gear for wear”“ , page 162

❑ Installation position. Refer to

⇒ Fig. ““Installed position: 2nd gear outer race, inner race and synchronizer ring”“ , page 163

 .

2. Output Shaft    

159

 

 

 

 

 

 

 

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