Volkswagen Golf / Golf GTI / Golf Variant. Service manual - part 597

13 - Synchronizer Ring

❑ (Inner race for 1st gear)
❑ Installed position. Refer to

⇒ Fig. ““Installed Position of the Inner Race, the Outer Race and the 1st Gear Synchronizer Ring”“ , page

161

❑ Checking for wear. Refer to

⇒ Fig. ““Checking Inner Race for 1st Gear and 2nd Gear for Wear”“ , page 161

❑ Check for scoring

14 - 1st Gear Outer Race

❑ Installed position. Refer to

⇒ Fig. ““Installed Position of the Inner Race, the Outer Race and the 1st Gear Synchronizer Ring”“ , page

161

❑ Checking for wear. Refer to

⇒ Fig. ““Checking 1st Gear and 2nd Gear Synchronizing Ring for Wear”“ , page 161

❑ Replace if there are grooves or scoring

15 - 1st Gear Synchronizer Ring

❑ Installed position. Refer to

⇒ Fig. ““Installed Position of the Inner Race, the Outer Race and the 1st Gear Synchronizer Ring”“ , page

161

❑ Checking for wear. Refer to

⇒ Fig. ““Checking 1st Gear and 2nd Gear Synchronizing Ring for Wear”“ , page 161

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

❑ After removing the locking ring -item 17- 

⇒ Item 17 (page 156)

 , remove with the bearing mount. Refer

to 

⇒ Fig. ““Removing the Locking Collar with the Synchronizer Hub and Bearing Mount”“ , page 160

❑ Disassembling. Refer to

⇒ Fig. ““Disassembling and Assembling Locking Collar and Synchronizer Hub for 1st and 2nd Gears”“ ,

page 162

 .

❑ Assembling operating sleeve/synchronizer hub. Refer to

⇒ Fig. ““Disassembling and Assembling Locking Collar and Synchronizer Hub for 1st and 2nd Gears”“ ,

page 162

 ,

⇒ Fig. ““Assembly: Locking Collar/Synchronizer Hub for 1st and 2nd Gears Together with Locking Pieces

That Are Hollow on the Inside”“ , page 162

 and

⇒ Fig. ““Assembly: Locking Collar/Synchronizer Hub for 1st and 2nd Gears Together with locking Pieces

That Are Not Hollow”“ , page 162

❑ Installed position. Refer to

⇒ Fig. ““Installed Position: Locking Collar/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 163

17 - Circlip
18 - 2nd Gear Synchronizer Ring

❑ Checking for wear. Refer to

⇒ Fig. ““Checking 1st Gear and 2nd Gear Synchronizing Ring for Wear”“ , page 161

❑ Install so that cut-outs engage in engagement pieces of locking collar for 1st and 2nd gear.

19 - 2nd Gear Outer Race

❑ Insert in the 2nd gear synchronizer ring -item 18- 

⇒ Item 18 (page 156)

 .

❑ Installed position. Refer to 

⇒ Fig. ““Installed Position of 2nd Gear Outer Race”“ , page 163

❑ Replace if there are grooves or scoring

20 - Synchronizer Ring

❑ (Inner race for 2nd gear)
❑ Checking for wear. Refer to

⇒ Fig. ““Checking 1st Gear and 2nd Gear Synchronizing Ring for Wear”“ , page 161

❑ Check for scoring
❑ Installed position. Refer to

⇒ Fig. ““Installed Position: Synchronizer Ring -A- (2nd Gear Inner Race)”“ , page 163

21 - 2nd Gear Wheel

❑ Installed position. Refer to 

⇒ Fig. ““Installed Position: 2nd Gear Wheel”“ , page 164

22 - Needle Bearing

❑ For 2nd gear

23 - Thrust Washer
24 - Sleeve

❑ For the 3rd gear needle bearing
❑ Removing with the 2nd gear wheel. Refer to

⇒ Fig. ““Removing the 3rd/4th Gear Synchronizer Hub/Locking Collar, 2nd Gear Wheel, 3rd and 4th Gear

with Output Shaft Needle Bearing Sleeve”“ , page 160

❑ Installing. Refer to 

⇒ Fig. ““Installing the Sleeve for the 3rd Gear Needle Bearing”“ , page 164

25 - Needle Bearing

❑ For 3rd gear

26 - 3rd Gear Wheel
27 - 3rd Gear Synchronizer Ring

❑ Checking for wear. Refer to 

⇒ Fig. ““Checking 3rd/4th Gear Synchronizing Ring for Wear”“ , page 164

28 - Locking Collar with Synchronizer Hub for 3rd and 4th Gears

❑ Remove with 2nd gear wheel and 3rd gear. Refer to

⇒ Fig. ““Removing the 3rd/4th Gear Synchronizer Hub/Locking Collar, 2nd Gear Wheel, 3rd and 4th Gear

with Output Shaft Needle Bearing Sleeve”“ , page 160

❑ Disassembling. Refer to

⇒ Fig. ““Disassembling and Assembling Locking Collar and Synchronizer Hub for 3rd/4th Gears”“ , page

165

 .

❑ Assembling the locking collar/synchronizer hub. Refer to

⇒ Fig. ““Disassembling and Assembling Locking Collar and Synchronizer Hub for 3rd/4th Gears”“ , page

165

 ,

⇒ Fig. ““Assembly: Locking Collar/Synchronizer Hub for 3rd and 4th Gears Together with Locking Pieces

that are Hollow on the Inside”“ , page 165

 and

⇒ Fig. ““Assembly: Locking Collar/Synchronizer Hub for 3rd and 4th Gears Together with Locking Pieces

that are Not Hollow”“ , page 165

 .

❑ Installed position: locking collar/synchronizer hub. Refer to

⇒ Fig. ““Installed Position: Locking Collar/Synchronizer Hub for 3rd and 4th Gears”“ , page 166

❑ Installing. Refer to

⇒ Fig. ““Installing the Synchronizer Hub with Locking Collar for 3rd and 4th Gears”“ , page 166

29 - Sleeve

❑ For the 4th gear needle bearing
❑ Removing with the locking collar and the 3rd/4th gear synchronizer hub. Refer to

⇒ Fig. ““Removing the 3rd/4th Gear Synchronizer Hub/Locking Collar, 2nd Gear Wheel, 3rd and 4th Gear

with Output Shaft Needle Bearing Sleeve”“ , page 160

❑ Installing. Refer to 

⇒ Fig. ““Installing the Sleeve for the 4th Gear Needle Bearing”“ , page 166

30 - Needle Bearing

❑ For 4th gear

31 - 4th Gear Synchronizer Ring

❑ Checking for wear. Refer to 

⇒ Fig. ““Checking 3rd/4th Gear Synchronizing Ring for Wear”“ , page 164

32 - 4th Gear Wheel
33 - Thrust Washer
34 - Needle Bearing

❑ For the output shaft
❑ Removing and installing. Refer to 

⇒ Fig. ““Removing the Needle Bearing”“ , page 121

35 - Transmission Housing
36 - Sleeve

❑ For the needle bearing/output shaft
❑ Removing. Refer to

⇒ Fig. ““Removing the 3rd/4th Gear Synchronizer Hub/Locking Collar, 2nd Gear Wheel, 3rd and 4th Gear

with Output Shaft Needle Bearing Sleeve”“ , page 160

❑ Installing. Refer to 

⇒ Fig. ““Installing the Sleeve for the Needle Bearing/Output Shaft”“ , page 166

37 - 5th Gear Wheel

❑ Removing and installing. Refer to

⇒ “5.10 Transmission Housing Cover and 5th Gear, Removing”, page 101

 .

38 - Plate Spring

❑ Installed position. Refer to

⇒ Fig. ““Installed Position of Plate Springs for 5th Gear Synchronizer Hub and Gear Securing Bolts”“ ,

page 117

39 - Bolt

❑ Replace after removing
❑ Holds in position with the adapter on the plate spring bolt head. Refer to

⇒ Fig. ““Installed Position of Plate Springs for 5th Gear Synchronizer Hub and Gear Securing Bolts”“ ,

page 117

❑ Removing and installing. Refer to

⇒ “5.10 Transmission Housing Cover and 5th Gear, Removing”, page 101

 .

❑ Tightening specification. Refer to

⇒ “5.3 Overview - Transmission Housing Cover and 5th Gear”, page 93

 .

2.2

Output Shaft, Disassembling and As‐

sembling

Special tools and workshop equipment required
♦ Press Piece - Rod - VW407-
♦ Press Piece - Rod - VW412-
♦ Press Piece - Multiple Use - VW512-
♦ Puller - Taper Roller Bearing - VAG1582-
♦ Puller - Taper Roller Bearing - Adapter 4 - VAG1582/4-
♦ Puller - Taper Roller Bearing - Adapter 5 - VAG1582/5-
♦ Press Plate - VW402-
♦ Bearing Installer - Multiple Use - 32-111-
♦ Press Piece - Rod - VW408A-
♦ Press Piece - Rod - VW409-
♦ Support Channels - VW457-
♦ Press Piece - Multiple Use - VW 519-
♦ Press Piece - Multiple Use - VW429-
♦ Press Piece - 60mm - VW415A-
♦ Press Piece - Multiple Use - VW447H-
♦ Press Piece - Multiple Use - VW454-
♦ Press Piece - Multiple Use - VW455-
♦ Press Tube - 41-501-
♦ -1- Puller - Kukko Internal - 36-46mm - 21/6-

♦ -3- Puller - Kukko Quick Action Separating Tool - 22-115mm -

17/2-

♦ -4- Puller - Kukko Counterstay - 22/2-
♦ Inductive Heater - VAS6414-
♦ Feeler Gauge

Caution

This procedure contains mandatory replaceable parts. Refer

to component overview prior to starting procedure.

Mandatory Replacement Parts
♦ Nuts - Bearing Mount
♦ Seals - Bearing Mount Bikts
Remove the Small Outer Race/Tapered Roller Bearing
A - Internal Puller - 37-46mm for example Puller - Kukko Internal

- 36-46mm - Kukko 21/6-
B - Counter Support , for example, Puller - Kukko Counterstay -

Kukko 22/2-

Installing the Small Outer Race/Tapered Roller Bearing

Removing the Inner Race/Small Tapered Roller Bearing
A - Protective jaws/vise
– Attach grip and securely clamp it behind bearing rollers. Then

turn the bearing and apply tension to the grip.