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