Volkswagen Golf / Golf GTI / Golf Variant. Manual — part 527
Installed Position: Locking Collar/Synchronizer Hub for 3rd and
4th Gears
The wider collar on the synchronizer hub -arrow- faces 3rd gear.
– Place the synchronizer ring for 4th gear on the 4th gear wheel.
Warming and Installing the Synchronizer Hub with Locking Collar
for 3rd and 4th Gears
– Turn the 4th gear synchronizer ring so that the grooves line up
with the locking pieces.
– Install the locking ring.
Installing the 3rd Gear Synchronizer Ring, Outer Ring and Inner
Ring
– Install the synchronizer ring -A- into the 3rd and 4th gear syn‐
chronizer hub.
The tabs -1- lock in the openings -2- in the synchronizer hub.
– Install the outer race -B- in the synchronizer ring.
The tabs -3- face away from the synchronizer ring.
– Install the inner race -C- in the outer race.
The tabs -4- lock in the larger openings -5- in the synchronizer
ring -A-.
Installing the 3rd Gear Wheel with Needle Bearing
• The synchronizer ring -1- and the tabs -arrow A- are inside the
openings in the synchronizer hub -2-.
The pins -arrows B- in the outer race lock in the recesses
-arrows C- in the gear wheel -3-.
Note
♦
Pressing on inner race/tapered roller bearing. Refer to
⇒ Fig. ““Installing the Inner Race/Tapered Roller Bearing on
the side of the Transmission Housing”“ , page 174
.
♦
Selecting the locking ring for the inner race/tapered roller bear‐
ing. Refer to
⇒ Fig. ““Selecting the Locking Ring”“ , page 174
.
2.2.2
Output Shaft, 5th, 6th and Reverse
Gears, Disassembling and Assembling
Special tools and workshop equipment required
♦ Press Plate - VW401-
♦ Press Plate - VW402-
♦ Press Piece - Rod - VW407-
♦ Press Piece - Rod - VW408A-
♦ Press Piece - Multiple Use - VW412-
♦ Press Piece - 60mm - VW415A-
♦ Holding Plate - VW309A-
♦ Transmission Support - VW353-
♦ Press Piece - Multiple Use - VW433-
♦ Press Piece - Multiple Use - VW454-
♦ Support Channels - VW457-
♦ Crankshaft Holding Fixture - VW801-
♦ Press Piece - Multiple Use - VW431-
♦ Press Piece - Multiple Use - VW455-
♦ Press Piece - Multiple Use - VW510-
♦ Press Piece - 42mm - VW516-
♦ Press Piece - Multiple Use - VW519-
♦ Press Piece - Multiple Use - 30-11-
♦ Press Piece - Multiple Use - 40-105-
♦ Bearing Installer - Multiple Use - 40-20-
♦ Slide Hammer - Press Plate - 2050-
♦ Press Piece - Reverse Gear Syncro - 3296-
♦ Puller - Taper Roller Bearing - VAG1582-
♦ Puller - Taper Roller Bearing - Adapter 4 - VAG1582/4-
♦ Puller - Taper Roller Bearing - Adapter 7 - VAG1582/7-
♦ Inductive Heater - VAS6414-
♦ -1- Puller - Kukko Internal - 46-56mm - 21/7-
♦ -3- Puller - Kukko Quick Action Separating Tool - 22-115mm -
17/2-
♦ -4- Puller - Kukko Counterstay - 22/2-
Removing the Outer Race/Tapered Roller Bearing from the
Clutch Housing
A - Counter Support , for example, -22/2-
B - Internal Puller 46 to 58 mm , for example, -21/7-
Note
Check the washer for damage after removing it and replace if
necessary.
Installing the Outer Race/Tapered Roller Bearing in the Clutch
Housing
– Place the washer under the outer race.
– Support the clutch housing with the -40-20- directly under the
bearing mount.
Removing the Outer Race/Tapered Roller Bearing from the
Transmission Housing
A - Counter Support , for example, -22/2-
B - Internal Puller 46 to 58 mm , for example, -Kukko 21/7-
Installing the Outer Race/Tapered Roller Bearing into the Trans‐
mission Housing.
– Support the transmission housing under the bearing mount
using the -2050- .
Disassembling the Output Shaft
Remove the Inner Race/Tapered Roller Bearing on the side of the
Transmission Housing
Note the following before installing the -VAG1582- :
– Remove the inner race/tapered roller bearing locking ring on
the side facing the transmission housing.
– Place the - VW431- and - 40-105- on the output shaft.
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