Volkswagen Golf / Golf GTI / Golf Variant. Manual — part 587
Checking 5th Gear Synchronizer Ring
– Before re-installing the gear wheel and the 5th gear synchron‐
izer ring push the synchronizer ring onto the taper of the drive
gear. Measure the gap dimension -a- with a feeler gauge.
Gap Dimension
-a-
Installation Dimen‐
sion
Wear Limit
5th Gear
1.1 to 1.7 mm
0.5 mm
– Install 5th gear wheel with needle bearing.
– Place the 5th gear synchronizer ring onto the selector gear.
– If disassembled, assemble the 5th gear synchronizer hub/
locking collar before installing. Refer to
⇒ Fig. ““5th Gear Locking Collar/Synchronizer Hub Assem‐
.
Installed Position of 5th Gear Synchronizer Hub/Locking Collar
The pointed teeth on the locking collar -arrow 1- and the high col‐
lar on the synchronizer hub -arrow 2- face the transmission hous‐
ing.
The notches -arrow 3- on the synchronizer hub must line up with
the cast locking pieces on the synchronizer ring
⇒ Fig. ““5th Gear Synchronizer Ring with Cast Locking Pieces”“ ,
lower).
5th Gear Synchronizer Ring with Cast Locking Pieces
– Cover all openings with a cloth to prevent foreign objects from
getting into the transmission.
– To install, heat the 5th gear synchronizer hub to approximately
100 °C (212 °F) with the Inductive Heater - VAS6414- .
WARNING
Wear safety gloves.
– Install the 5th gear synchronizer hub
Note
Make sure there is enough clearance when installing the syn‐
chronizer ring.
– Loosen the support for the input shaft.
If it has not been done already, locking fluid residue from the
threaded holes for the synchronizer hub bolts and 5th gear wheel
must be cleaned with a thread tap.
Otherwise, there is the danger that the bolts could shear off.
– Screw-in new synchronizer hub bolts and 5th gear wheel.
Installed Position of Plate Springs for 5th Gear Synchronizer Hub
and Gear Securing Bolts
The outer diameter -arrows- faces 5th gear.
– Engage 5th gear -arrow 1- and 1st gear -arrows 2 and 3- and
then tighten the bolts -A- for the synchronizer hub and for the
5th gear wheel.
– The input shaft and the output shaft are blocked after both
gears are engaged. The synchronizer hub and the gear wheel
cannot turn. Both bolts can be loosened now.
– Install the 5th gear shift fork.
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Adjusting 5th Gear
– Engage 5th gear. Loosen the bolt -1-. Push the locking collar
and the shift jaw in direction of -arrow-. Tighten the bolt -1- to
the tightening specification.
• Check measurement: it must not be possible to slide a 0.2 mm
feeler gauge between the locking collar and drive gear. Repeat
the adjusting procedure if necessary.
– Remove 5th gear. The locking collar must be in the neutral
position. The synchronizer ring must move freely.
– Move the gearshift lever (selector lever) through all the gears.
– Install the transmission housing cover. Refer to
⇒ “5.3 Overview - Transmission Housing Cover and 5th Gear”,
.
– Install the release bearing guide sleeve. Refer to
⇒ “1.4 Overview - Clutch Release Mechanism”, page 18
– Install the clutch release lever and release the bearing. Refer
to
⇒ “1.16 Clutch Release Mechanism, Servicing”, page 35
.
– Fill the transmission fluid. Refer to
.
Tightening Specifications
♦ Refer to
⇒ “5.3 Overview - Transmission Housing Cover and 5th Gear”,
♦ Refer to
6
Transmission Housing and Clutch
Housing
⇒ “6.1 Overview - Transmission Housing and Clutch Housing”,
page 119
⇒ “6.2 Transmission Housing, Servicing”, page 121
⇒ “6.3 Clutch Housing, Servicing”, page 122
6.1
Overview - Transmission Housing and Clutch Housing
1 - Transmission Housing
❑ When replacing: adjust
the input shaft and dif‐
ferential. Refer to
2 - Needle Bearing
❑ For the output shaft
❑ Removing. Refer to
❑ Installing and securing.
Refer to
3 - Transmission Fluid Filler
Plug
❑ 35 Nm
❑ The transmission fluid
level cannot be checked
by removing oil filler
plug.
❑ If transmission was dis‐
assembled, it must be
filled before being instal‐
led again.
❑ Manual transmission
capacity (transmission
completely disassem‐
bled). Refer to ⇒ Fluid
Capacity Tables; Rep.
Gr. 03
❑ Manual transmission
capacity (transmission
partly disassembled). Refer to ⇒ Fluid Capacity Tables; Rep. Gr. 03
4 - Outer Race/Tapered Roller Bearing
❑ For the output shaft
❑ Refer to
⇒ “2.2 Output Shaft, Disassembling and Assembling”, page 158
❑ When replacing: adjust the output shaft. Refer to
⇒ “2.3 Output Shaft, Adjusting”, page 166
5 - Shim
❑ For the output shaft
❑ Adjustment overview. Refer to
⇒ “3 Adjustment Overview”, page 198
.
6 - Shim
❑ For the input shaft
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