Volkswagen Golf / Golf GTI / Jetta. Manual — part 320

35-68

A - Separating device 22 to 115 mm,
e.g. Kukko 17/2

Fig. 7

Pressing off reverse
gear synchro-hub

- Remove securing clip.

Fig. 8

Pulling off tapered roller
bearing inner race

- Before mounting extractor, set

thrust plate 30-11 on output shaft.

Output shaft for 5th, 6th and reverse gear, disassembling and assembling

35-69

Reverse gear locking collar stop
(arrow -A-) faces toothing of output
shaft (arrow -B-).

Fig. 9

Installation position of
reverse gear synchro-
hub

Fig. 10 Pressing on reverse

gear synchro-hub

- Install securing clip.

Output shaft for 5th, 6th and reverse gear, disassembling and assembling

35-70

Installation position: Wide collar
faces reverse gear.

Fig. 11 Pressing on sleeve -A-

- Install securing clip.

Fig. 12 Checking synchro-ring

for 5th and 6th gear for
wear

- Press synchro-ring onto gear

cone and measure gap "a" with
feeler gauge.

Gap "a"

New

dimension

Wear

limit

5th and

6th gear

1.0 ... 1.7

mm

0.5

mm

Output shaft for 5th, 6th and reverse gear, disassembling and assembling

35-71

Fig. 13 Disassembling and

assembling 5th and 6th
gear locking collar and
synchro-hub

1 - Spring

2 - Locking piece

3 - Locking collar

4 - Synchro-hub

- Slide locking collar over synchro-

hub.

Recesses for locking pieces in

synchro-hub and locking collar
must align.

The locking collar has been pushed
over the synchro-hub.

Fig. 14 Assembling 5th and 6th

gear locking
collar/synchro-hub

- Insert locking pieces and install

springs 120 offset. Angled end
of spring must locate in hollow
locking piece.

Output shaft for 5th, 6th and reverse gear, disassembling and assembling