Volkswagen Golf / Golf GTI / Golf Variant. Service manual - part 527

Installed Position: Locking Collar/Synchronizer Hub for 3rd and

4th Gears
The wider collar on the synchronizer hub -arrow- faces 3rd gear.
– Place the synchronizer ring for 4th gear on the 4th gear wheel.

Warming and Installing the Synchronizer Hub with Locking Collar

for 3rd and 4th Gears
– Turn the 4th gear synchronizer ring so that the grooves line up

with the locking pieces.

– Install the locking ring.

Installing the 3rd Gear Synchronizer Ring, Outer Ring and Inner

Ring
– Install the synchronizer ring -A- into the 3rd and 4th gear syn‐

chronizer hub.

The tabs -1- lock in the openings -2- in the synchronizer hub.
– Install the outer race -B- in the synchronizer ring.
The tabs -3- face away from the synchronizer ring.
– Install the inner race -C- in the outer race.
The tabs -4- lock in the larger openings -5- in the synchronizer

ring -A-.

Installing the 3rd Gear Wheel with Needle Bearing
• The synchronizer ring -1- and the tabs -arrow A- are inside the

openings in the synchronizer hub -2-.

The pins -arrows B- in the outer race lock in the recesses

-arrows C- in the gear wheel -3-.

Note

♦

Pressing on inner race/tapered roller bearing. Refer to

⇒ Fig. ““Installing the Inner Race/Tapered Roller Bearing on

the side of the Transmission Housing”“ , page 174

 .

♦

Selecting the locking ring for the inner race/tapered roller bear‐

ing. Refer to

⇒ Fig. ““Selecting the Locking Ring”“ , page 174

 .

2.2.2

Output Shaft, 5th, 6th and Reverse

Gears, Disassembling and Assembling

Special tools and workshop equipment required
♦ Press Plate - VW401-
♦ Press Plate - VW402-
♦ Press Piece - Rod - VW407-
♦ Press Piece - Rod - VW408A-
♦ Press Piece - Multiple Use - VW412-
♦ Press Piece - 60mm - VW415A-
♦ Holding Plate - VW309A-
♦ Transmission Support - VW353-
♦ Press Piece - Multiple Use - VW433-
♦ Press Piece - Multiple Use - VW454-
♦ Support Channels - VW457-
♦ Crankshaft Holding Fixture - VW801-
♦ Press Piece - Multiple Use - VW431-
♦ Press Piece - Multiple Use - VW455-
♦ Press Piece - Multiple Use - VW510-
♦ Press Piece - 42mm - VW516-
♦ Press Piece - Multiple Use - VW519-
♦ Press Piece - Multiple Use - 30-11-
♦ Press Piece - Multiple Use - 40-105-
♦ Bearing Installer - Multiple Use - 40-20-
♦ Slide Hammer - Press Plate - 2050-
♦ Press Piece - Reverse Gear Syncro - 3296-
♦ Puller - Taper Roller Bearing - VAG1582-
♦ Puller - Taper Roller Bearing - Adapter 4 - VAG1582/4-
♦ Puller - Taper Roller Bearing - Adapter 7 - VAG1582/7-
♦ Inductive Heater - VAS6414-
♦ -1- Puller - Kukko Internal - 46-56mm - 21/7-
♦ -3- Puller - Kukko Quick Action Separating Tool - 22-115mm -

17/2-

♦ -4- Puller - Kukko Counterstay - 22/2-
Removing the Outer Race/Tapered Roller Bearing from the

Clutch Housing
A - Counter Support , for example, -22/2-
B - Internal Puller 46 to 58 mm , for example, -21/7-

Note

Check the washer for damage after removing it and replace if

necessary.

Installing the Outer Race/Tapered Roller Bearing in the Clutch

Housing
– Place the washer under the outer race.
– Support the clutch housing with the -40-20- directly under the

bearing mount.

Removing the Outer Race/Tapered Roller Bearing from the

Transmission Housing
A - Counter Support , for example, -22/2-
B - Internal Puller 46 to 58 mm , for example, -Kukko 21/7-

Installing the Outer Race/Tapered Roller Bearing into the Trans‐

mission Housing.
– Support the transmission housing under the bearing mount

using the -2050- .

Disassembling the Output Shaft

Remove the Inner Race/Tapered Roller Bearing on the side of the

Transmission Housing
Note the following before installing the -VAG1582- :
– Remove the inner race/tapered roller bearing locking ring on

the side facing the transmission housing.

– Place the - VW431- and - 40-105- on the output shaft.