Volkswagen Golf Variant / Jetta. Manual - part 536

 

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Volkswagen Golf Variant / Jetta. Manual - part 536

 

 

❑ Lay on inner race -item 11- 

⇒ Item 11 (page 159)

❑ Replace if there are grooves or scoring
❑ Installation position. Refer to

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

 .

13 - 2nd Gear Synchronizer Ring

❑ Checking for wear. Refer to

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

❑ Installation position. Refer to

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

 .

14 - Locking Collar with Synchronizer Hub for 1st and 2nd Gears

❑ After removing the circlip. Refer to -item 15- 

⇒ Item 15 (page 160)

 , remove with the 2nd gear wheel.

Refer to 

⇒ Fig. ““Locking Collar/Synchronizer Hub for 1st and 2nd Gear”“ , page 162

 .

❑ Disassembling. Refer to

⇒ Fig. ““Disassembling and assembling locking collar and synchronizer hub for 1st and 2nd gears”“ ,

page 163

 .

❑ Assembling the locking collar/synchronizer hub. Refer to

⇒ Fig. ““Disassembling and assembling locking collar and synchronizer hub for 1st and 2nd gears”“ ,

page 163

 and 

⇒ Fig. ““Assembling locking collar/synchronizer hub for 1st and 2nd gears.”“ , page 163

❑ Installation position. Refer to

⇒ Fig. ““Disassembling and assembling locking collar and synchronizer hub for 1st and 2nd gears”“ ,

page 163

 .

❑ Installing. Refer to

⇒ Fig. ““Installing the locking collar/synchronizer hub for 1st and 2nd gears.”“ , page 164

15 - Circlip

❑ Press out. Refer to 

⇒ Fig. ““Removing the locking ring -1- ”“ , page 161

❑ Inserting. Refer to 

⇒ Fig. ““Circlip, Installing”“ , page 164

16 - 1st Gear Synchronizer Ring

❑ Checking for wear. Refer to

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

❑ Insert it so that the holes engage into engagement pieces of locking collar. Refer to -item 14-

⇒ Item 14 (page 160)

 .

17 - 1st Gear Outer Race

❑ Install in synchronizer ring. -item 16- 

⇒ Item 16 (page 160)

❑ Installation position. Refer to 

⇒ Fig. ““Installation position of 1st gear outer race”“ , page 164

 .

❑ Replace if there are grooves or scoring

18 - 1st Gear Inner Race

❑ Checking for wear. Refer to

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

❑ Check for scoring
❑ Installation position. Refer to 

⇒ Fig. ““1st gear inner race -A- installed position”“ , page 164

 .

19 - Needle Bearing

❑ For 1st gear

20 - 1st Gear Wheel

❑ Installation position. Refer to 

⇒ Fig. ““Installation location of 1st gear selector gear”“ , page 165

 .

21 - Bearing Mount with Grooved Ball Bearing

❑ Only replace grooved ball bearing together with bearing mount
❑ if bearing mount is removed from transmission housing, it must always be replaced
❑ Removing. Refer to 

⇒ Fig. ““Remove the Bearing Mount and Grooved Ball Bearing”“ , page 152

❑ Installing. Refer to 

⇒ page 155

160

❑ Installed position: the collar faces the transmission housing cover 

⇒ page 125

24 - Circlip

❑ Replace after removing
❑ Selecting thickness. Refer to 

⇒ page 125

 .

25 - Spring

❑ Installation position. Refer to

⇒ Fig. ““Assembling locking collar/synchronizer hub for 1st and 2nd gears.”“ , page 163

 .

26 - Locking Collar
27 - Synchronizer Hub
28 - Locking Pieces

❑ Quantity: 3

Remove the Roller Bearing from the Clutch Housing
– Compress the cylindrical roller bearing locking ring -arrow-

with pliers -C- and remove it.

A - for example Puller - Kukko Counterstay - 22/1-
B - for example Puller - Kukko Internal - 28-37mm - 21/5-

Pressing Cylindrical Roller Bearing into Clutch Housing.
– Support the clutch housing with the Press Piece - 60mm -

VW415A- (not illustrated) directly below bearing mount.

– Compress the cylindrical roller bearing locking ring -arrow-

with pliers -A- and install it.

– Remove the pliers before the cylindrical roller bearing gets into

its installed position. The locking ring must lock into the groove

on the clutch housing.

Removing the locking ring -1-
A - Protective gloves

WARNING

Prevent circlip from jumping away uncontrolled.

2. Output Shaft    

161

gear and the locking collar/synchronizer hub.

Installation Location of 3rd and 4th Gear Drive Gears
– Install the 4th gear wheel -A- onto the output shaft.
Installation position:
The collar -arrow 1- faces the 3rd gear wheel -B-.
– Install the locking rings -2 and 3-.
– Install the 3rd gear wheel -B- on the output shaft.
Installation position:
The collar -arrow 2- faces the 4th gear wheel -A-.
– Install the locking ring -1-.

Checking inner race for 1st gear and 2nd gear for wear
– Install the inner race onto taper of selector gear and then

measure gap dimension -a- with a feeler gauge.

Gap dimension

-a-

Installation Dimen‐

sion

Wear limit

1st and 2nd gear

0.75 to 1.25 mm

0.3 mm

Checking 1st gear and 2nd gear synchronizing ring for wear
– Install the synchronizer ring, outer race and inner race onto

taper of selector gear and then measure the gap dimension

-a- with a feeler gauge.

Gap dimension

-a-

Installation Dimen‐

sion

Wear limit

1st and 2nd gear

1.2 to 1.8 mm

0.5 mm

162

izer ring
– Install the inner race -A- on the 2nd gear wheel.
The angled tabs -arrows 1- face the outer race -B-.
– Install the outer race -B-.
The tabs -arrows 2- must lock into the retainers -arrows 3- in the

gear wheel.
– Install the synchronizer ring -C-.
The retainers -arrows 4- lock in the tabs -arrows 1- on the inner

race -A-.

Disassembling and assembling locking collar and synchronizer

hub for 1st and 2nd gears
1 - Spring
2 - Locking collar
3 - Synchronizer Hub
4 - Locking piece
– Slide the locking collar over the synchronizer hub.
Installation position:
The groove on the front -arrow A- and the higher collar

-arrow B- on the synchronizer hub faces the outer splines on the

locking collar -arrow C-.
Deeper recesses -arrow D- for locking pieces in synchronizer hub

and recesses -arrow E- in locking collar must align.

Assembling locking collar/synchronizer hub for 1st and 2nd gears.
• The locking collar is pushed over the synchronizer hub.
– Insert the locking pieces in the deeper recesses -arrows- and

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

must engage into the hollow locking piece.

2. Output Shaft    

163

 

 

 

 

 

 

 

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