Volkswagen Golf / Golf GTI / Golf Variant. Manual — part 593
♦ Pry Lever - 80-200-
♦ Spring Strut Compressor - 2070-
♦ Spindle from the Seal Installer - Driver Set - 3066- or M8 x 105
bolt
♦ or the equivalent equipment, Backrest Panel Tool - 3370-
♦ Sealing Compound - AMV 188 200 03-
♦ M8 x 100 mm stud bolt
35 – Gears, Shafts
1
Input Shaft
⇒ “1.1 Overview - Input Shaft”, page 141
⇒ “1.2 Input Shaft, Disassembling and Assembling”, page 143
⇒ “1.3 Input Shaft, Adjusting”, page 148
⇒ “1.4 Input Shaft Seal, Replacing”, page 152
1.1
Overview - Input Shaft
Note
♦
Pay attention to the Parts Catalog and to the Technical data when installing new gear wheels or a new input
shaft. Refer to
♦
The input shaft must be adjusted because the position of the tapered roller bearing is affected when parts
are replaced. Pay attention to the adjustment overview. Refer to
⇒ “3 Adjustment Overview”, page 198
.
♦
Replace both tapered roller bearings together.
♦
Wearing safety gloves, warm the inner race/tapered roller bearing, the gear wheels and the synchronizer
hubs to approximately 100 °C (212 °F) using an Inductive Heat Unit - VAS6414- before installing them.
1 - Clutch Housing
2 - Outer Race/Tapered Roller
Bearing
❑ Removing. Refer to
❑ Installing. Refer to
3 - Inner Race / Tapered Roller
Bearing
❑ Removing. Refer to
❑ Installing. Refer to
4 - Input Shaft
❑ Adjusting. Refer to
5 - 3rd Gear Wheel
❑ Installed position: shoul‐
der faces 4th gear
❑ Removing. Refer to
⇒ Fig. ““Installing 3rd Gear Wheel”“ , page 145
6 - Circlip
❑ Replace after removing
7 - 4th Gear Wheel
❑ Removing with the outer race/tapered roller bearing and sleeve. Refer to
⇒ Fig. ““Removing the 4th Gear Wheel with the Tapered Roller Bearing and Sleeve”“ , page 145
⇒ Fig. ““Removing 4th Gear Wheel”“ , page 146
❑ The shoulder faces 3rd gear
8 - Inner Race / Tapered Roller Bearing
❑ Removing with 4th gear wheel and sleeve. Refer to
⇒ Fig. ““Removing the 4th Gear Wheel with the Tapered Roller Bearing and Sleeve”“ , page 145
⇒ Fig. ““Installing the Inner Race/Tapered Roller Bearing”“ , page 146
9 - Thrust Washer
10 - Outer Race/Tapered Roller Bearing
❑ Removing. Refer to
⇒ Fig. ““Installing the Outer Race/Tapered Roller Bearing”“ , page 147
⇒ Fig. ““Installing the Outer Race/Tapered Roller Bearing”“ , page 147
11 - Shim
❑ Selecting thickness. Refer to
12 - Transmission Housing
13 - Sleeve
❑ For the 5th gear needle bearing
❑ Pressing off with 4th gear drive gear and the inner race/tapered roller bearing. Refer to
⇒ Fig. ““Removing the 4th Gear Wheel with the Tapered Roller Bearing and Sleeve”“ , page 145
❑ Installing. Refer to
⇒ Fig. ““Installing the Needle Bearing Sleeve”“ , page 146
❑ Mount before installing the thrust washer -item 9-
.
14 - Needle Bearing
❑ For 5th gear
15 - 5th Gear Wheel
16 - 5th Gear Synchronizer Ring
❑ With cast locking pieces. Refer to
⇒ Fig. ““5th Gear Synchronizer Ring with Cast Locking Pieces”“ , page 116
❑ Checking for wear. Refer to
⇒ Fig. ““Checking 5th Gear Synchronizer Ring”“ , page 116
17 - Spring
❑ Installation position. Refer to
⇒ Fig. ““5th Gear Locking Collar/Synchronizer Hub Assembly”“ , page 147
and
⇒ Fig. ““Installation of Offset Springs -A- ”“ , page 148
18 - Locking Pieces (quantity: 3)
❑ Installed position. Refer to
⇒ Fig. ““5th Gear Synchronizing”“ , page 147
19 - 5th Gear Synchronizer Hub
❑ Remove. Refer to
⇒ “5.10 Transmission Housing Cover and 5th Gear, Removing”, page 101
20 - 5th Gear Locking Collar
❑ Remove with 5th gear synchronizer hub. Refer to
⇒ “5.10 Transmission Housing Cover and 5th Gear, Removing”, page 101
21 - Plate Spring
❑ Installed position. Refer to
22 - 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
.
1.2
Input Shaft, Disassembling and Assem‐
bling
Special tools and workshop equipment required
♦ Press Piece - Rod - VW407-
♦ Press Piece - Multiple Use - VW447H-
♦ Press Piece - Rod - VW412-
♦ Press Piece - Shift Rod/Alternator - VW422-
♦ Press Plate - VW401-
♦ Press Piece - Rod - VW408A-
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