Volkswagen Golf / Golf GTI / Jetta. Manual — part 311

35-36

Fig. 7

Pressing off 1st and 2nd
gear locking collar and
synchro-hub

- After removing securing ring

press 2nd selector gear and
locking collar/synchro-hub off
together.

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

Fig. 8

Pulling off tapered roller
bearing inner race

Output shaft, 1st-4th gear, disassembling and assembling

35-37

Fig. 9

Pressing on tapered
roller bearing inner race

Fig. 10 Checking 1st, 2nd and

3rd gear inner ring for
wear

- Press inner ring onto gear wheel

cone and measure gap "a" with a
feeler gauge.

Gap "a"

New

dimension

Wear

limit

1st, 2nd

and 3rd

gear

0.75 ... 1.25

mm

0.3

mm

Output shaft, 1st-4th gear, disassembling and assembling

35-38

Fig. 11 Checking 1st, 2nd and

3rd gear synchro-rings
for wear

- Press synchro-ring, outer-ring and

inner-ring onto selector gear cone
and measure gap "a" with feeler
gauge.

Gap "a"

New

dimension

Wear

limit

1st, 2nd

and 3rd

gear

1.2 ... 1.8

mm

0.5

mm

Fig. 12 Installation position of

outer ring, inner ring
and 2nd gear synchro
ring

- Place inner ring -A- on 2nd gear

wheel.

Angled lugs (arrow -1-) point

toward outer ring -B-.

- Install outer ring -B-.

Lugs (arrow -2-) engage in gear

wheel recesses (arrow -3-).

- Install synchro-ring -C-.

Recesses (arrow -4-) engage in

lugs (arrow -1-) of inner ring -A-.

Output shaft, 1st-4th gear, disassembling and assembling

35-39

Fig. 13 Disassembling and

assembling 1st and 2nd
as well as 3rd and 4th
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 1st and 2nd

as well as 3rd and 4th
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, 1st-4th gear, disassembling and assembling