Volkswagen Golf / Golf GTI / Golf Variant. Service manual - part 600

– Install dial gauge (3 mm measuring range) and set to “0” with

1 mm pre-load.

– Move the input shaft up and down, check the play on the dial

gauge and make a note of it.

Determining the Shim
The specified bearing tension is reached when the adjustment

shim (0.65 mm) is added to the measured value.
Example:

Bearing Play =

(Adjustment Shim 0.65 mm

Plus the Measured Value)

Adjustment Shim Thickness

According to the Table

0.740 mm

0.900 mm

Shim Table

Bearing Play =

(Adjustment Shim 0.65 mm

Plus the Measured Value)

Adjustment Shim

Thickness (mm)

0.650

0.660 to 0.689

0.750

0.800

0.690 to 0.739

0.740 to 0.789

0.790 to 0.839

0.850

0.900

0.950

0.840 to 0.889

0.890 to 0.939

0.940 to 0.989

1.000

1.050

1.100

0.990 to 1.039

1.040 to 1.089

1.090 to 1.139

1.150

1.200

1.250

1.140 to 1.189

1.190 to 1.239

1.240 to 1.289

1.300

1.350

1.400

1.290 to 1.339

1.340 to 1.389

1.390 to 1.429

1.450

1.500

1.550

Note

Allocate the shims. Refer to the Parts Catalog.

– Remove the output shaft and then remove the small taper roll‐

er bearing outer race. Refer to

⇒ Fig. ““Remove the Small Outer Race/Tapered Roller Bear‐

ing”“ , page 159

– Install the shim with the correct thickness, thickest shim first.
• If the previous 0.65 mm adjustment shim will be inserted again,

it must be checked for damage.

If the measured shim thickness is larger than those listed in the

Table, then install two shims that add up to the necessary thick‐

ness.
Tolerance variations make it possible to find the exact shim thick‐

ness required.
– Press in the outer race/small tapered roller bearing with de‐

termined shim (0.70 mm as in example). Refer to

⇒ Fig. ““Installing the Small Outer Race/Tapered Roller Bear‐

ing”“ , page 159

 and install output shaft.

– Tighten the nut for the bearing mount in the clutch housing.
Tightening Specifications
♦ Bearing mount to the clutch housing. Refer to

⇒ “5.6 Overview - Input Shaft, Output Shafts, Differential,

Gearshift Rods”, page 97

 .

3

Reverse Shaft

⇒ “3.1 Overview - Reverse Shaft”, page 170
⇒ “3.2 Reverse Shaft, Disassembling and Assembling”,

page 170

3.1

Overview - Reverse Shaft

Note

Always replace the needle sleeve after removing it from the clutch housing or from the reverse shaft support.

1 - Clutch Housing
2 - Needle Sleeve

❑ Removing. Refer to

⇒ Fig. ““Removing the

Needle Sleeve from the

Clutch Housing”“ ,

page 171

❑ Installing. Refer to

⇒ Fig. ““Installing the

Needle Sleeve -A- into

the Clutch Housing”“ ,

page 171

3 - Reverse Drive Gear
4 - Circlip

❑ Replace after removing

5 - Reverse Gear Wheel

❑ Remove before replac‐

ing the locking ring

❑ Collar faces reverse

gear wheel

6 - Reverse Shaft

❑ Removing and instal‐

ling. Refer to

⇒ “5.11 Transmission,

Disassembling and As‐

sembling”, page 105

 .

7 - Needle Sleeve

❑ Removing. Refer to

⇒ Fig. ““Removing the

Needle Sleeve from the

Reverse Shaft Sup‐

port”“ , page 171

❑ Installing. Refer to

⇒ Fig. ““Installing the

Needle Sleeve into the Reverse Shaft Support”“ , page 172

8 - Reverse Shaft Support

❑ Removing and installing. Refer to 

⇒ “5.11 Transmission, Disassembling and Assembling”, page 105

 .

3.2

Reverse Shaft, Disassembling and As‐

sembling

Special tools and workshop equipment required

♦ Press Piece - Multiple Use - VW454-
♦ Press Piece - Multiple Use - VW447H-
♦ Press Piece - Rod - VW411-
♦ Centering/Press Pin - 12-551-
♦ Press Plate - VW401-
♦ Press Piece - Rod - VW408A-
♦ -1- Puller - Kukko Internal - 14-19mm - 21/2-
♦ -4- Puller - Kukko Counterstay - 22/1-

Caution

This procedure contains mandatory replaceable parts. Refer

to component overview prior to starting procedure.

Mandatory Replacement Parts
♦ Needle Sleeve - Reverse Shaft
Removing the Needle Sleeve from the Clutch Housing
A - Puller - Kukko Counterstayt - 22/1- , for example.
B - Puller - Kukko Internal - 14-19mm - 21/2- , for example.

Note

The needle sleeve will get damaged when it is removed and must

be replaced.

Installing the Needle Sleeve -A- into the Clutch Housing

Removing the Needle Sleeve from the Reverse Shaft Support