Volkswagen Golf / Golf GTI / Golf Variant. Manual — part 524
Differentiation of Output Shafts
Output Shaft
-1- with Reinforce‐
ment Measures
-2- without Reinforce‐
ment Measures
Dimension -a-
40.1 mm
42.0 mm
-Arrow A-
Groove for collar
bushing position
-21-
-
-Arrow B-
-
2 opposite holes and
circular groove for the
thrust washer mounts
-19-
Variations of the Needle Bearing and Gear Wheels for 4th Gear
4th Gear Wheel
-1- with Reinforce‐
ment Measures
-2- without Reinforce‐
ment Measures
Dimension -a-
52.0 mm
48.0 mm
4th Gear Wheel
Needle Bearing
-3- with Reinforce‐
ment Measures
-4- without Reinforce‐
ment Measures
Dimension -b-
52.0 mm
48.0 mm
• The needle bearing -3- is fitted on the collar bushing -5- on
transmissions with reinforcement measures.
2.1.2
Overview - Output Shaft, 5th/6th and Reverse Gears
Note
♦
Secure the transmission on the assembly stand. Refer to
⇒ “7 Securing on Engine and Transmission Holder”, page 141
.
♦
To install, warm the inner races/tapered roller bearing and synchronizer hub to approximately 100 °C (212
°F) using Inductive Heater - VAS6414- . Wear protective gloves.
♦
Adjust the output shaft if it or the tapered roller bearing are being replaced. Refer to
⇒ “2.3.2 Output Shaft, 5th, 6th and Reverse Gears, Adjusting”, page 190
.
♦
Replace both tapered roller bearings together.
1 - Clutch Housing
2 - Washer
❑ Always 0.65 mm thick
3 - Outer Race/Tapered Roller
Bearing
❑ Removing. Refer to
❑ Installing. Refer to
4 - Inner Race / Tapered Roller
Bearing
❑ Removing. Refer to
❑ Installing. Refer to
5 - Output Shaft
❑ For 5th, 6th and reverse
gears
❑ Adjusting. Refer to
5th, 6th and Reverse Gears, Adjusting”, page 190
.
6 - Reverse Gear Synchronizer Hub
⇒ Fig. ““Removing the Reverse Gear Synchronizer Hub”“ , page 184
❑ Installed position. Refer to
⇒ Fig. ““Installed Position: Reverse Gear Synchronizer Hub”“ , page 185
❑ Installing. Refer to
⇒ Fig. ““Warming and Installing the Reverse Gear Synchronizer Hub”“ , page 185
7 - Locking Ring
8 - Reverse Gear Locking Collar
❑ With synchronizer ring
9 - Needle Bearing
❑ For reverse gear wheel
10 - Reverse Gear Wheel
11 - Sleeve
❑ Remove with the reverse gear wheel. Refer to
⇒ Fig. ““Removing the Sleeve -A- together with the Reverse Gear Wheel”“ , page 184
❑ Installed position: The wider sleeve collar faces the reverse gear wheel
❑ Installing. Refer to
⇒ Fig. ““Installing the Sleeve -A- ”“ , page 185
12 - Locking Ring
13 - Needle Bearing
❑ For 6th gear
14 - 6th Gear Wheel
15 - Synchronizer Ring for 6th Gear
❑ Brass or steel
❑ Checking for wear. Refer to
⇒ Fig. ““Checking 5th and 6th Gear Synchronizer Ring for Wear”“ , page 185
16 - Locking Collar with Synchronizer Hub for 5th and 6th Gears
❑ After removing the securing ring, remove with the 6th gear wheel. Refer to
⇒ Fig. ““Removing the 5th and 6th Gear Synchronizer Hub/Locking Collar with the 6th Gear Wheel”“ ,
❑ Disassembling. Refer to
⇒ Fig. ““Disassembling and Assembling Locking Collar and Synchronizer Hub for 5th and 6th Gears”“ ,
❑ Assembling the locking collar/synchronizer hub. Refer to
⇒ Fig. ““Disassembling and Assembling Locking Collar and Synchronizer Hub for 5th and 6th Gears”“ ,
⇒ Fig. ““Assembling Locking Collar/Synchronizer Hub for 5th and 6th Gears”“ , page 186
❑ Installing. Refer to
⇒ Fig. ““Installing the Locking Collar/Synchronizer Hub for 5th and 6th Gears”“ , page 186
17 - Locking Ring
18 - Needle Bearing
❑ For 5th gear
19 - Synchronizer Ring for 5th Gear
❑ Brass or steel
❑ Checking for wear. Refer to
⇒ Fig. ““Checking 5th and 6th Gear Synchronizer Ring for Wear”“ , page 185
20 - 5th Gear Wheel
21 - Inner Race / Tapered Roller Bearing
❑ Removing. Refer to
⇒ Fig. ““Remove the Inner Race/Tapered Roller Bearing on the side of the Transmission Housing”“ ,
❑ Installing. Refer to
22 - Locking Ring
❑ Determine again when replacing inner race/tapered roller bearing and output shaft. Refer to
⇒ Fig. ““Selecting the Locking Ring”“ , page 187
23 - Outer Race/Tapered Roller Bearing
❑ Removing. Refer to
⇒ Fig. ““Removing the Outer Race/Tapered Roller Bearing from the Transmission Housing”“ ,
❑ Installing. Refer to
24 - Shim
❑ Selecting thickness. Refer to
⇒ “2.3.2 Output Shaft, 5th, 6th and Reverse Gears, Adjusting”, page 190
.
25 - Transmission Housing
26 - Spring
❑ Installed position. Refer to
⇒ Fig. ““Assembling Locking Collar/Synchronizer Hub for 5th and 6th Gears”“ , page 186
.
27 - Locking Collar
28 - Synchronizer Hub
29 - Locking Piece
❑ Quantity: 3
❑ Installed position. Refer to
⇒ Fig. ““Disassembling and Assembling Locking Collar and Synchronizer Hub for 5th and 6th Gears”“ ,
.
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