Volkswagen Golf / Golf GTI / Golf Variant. Manual — part 597
13 - Synchronizer Ring
❑ (Inner race for 1st gear)
❑ Installed position. Refer to
❑ 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
❑ 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
❑ 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-
, 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”“ ,
❑ Assembling operating sleeve/synchronizer hub. Refer to
⇒ Fig. ““Disassembling and Assembling Locking Collar and Synchronizer Hub for 1st and 2nd Gears”“ ,
That Are Hollow on the Inside”“ , page 162
and
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-
❑ 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
❑ Assembling the locking collar/synchronizer hub. Refer to
⇒ Fig. ““Disassembling and Assembling Locking Collar and Synchronizer Hub for 3rd/4th Gears”“ , page
that are Hollow on the Inside”“ , page 165
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
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
⇒ 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
39 - Bolt
❑ Replace after removing
❑ Holds in position with the adapter on the plate spring bolt head. Refer to
❑ 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.
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