Volkswagen Golf / Golf GTI / Golf Variant. Manual — part 522
Grooved Ball Bearing Installation Location and Installing the
Grooved Ball Bearing
• Grooved ball bearing installed position: The groove for the
locking ring faces up -arrow A- and the collar -arrow B- must
face the 5th gear wheel.
– Then select the grooved ball bearing locking ring and install it
on the input shaft. Refer to
⇒ Fig. ““Selecting the Locking Ring”“ , page 160
Selecting the Locking Ring
– Insert a 1.86 mm locking ring -A- into groove in the input shaft
and press it upward.
– Measure the gap between the grooved ball bearing -B- and
the installed locking ring -A- with a feeler gauge -C-.
– Remove the locking ring used for the measurement.
– Select the locking ring according to the Table.
Note
For the correct locking rings. Refer to the Parts Catalog.
The following circlips are available:
Measured Value
(mm)
Circlip Ring Thick‐
ness (mm)
Axial Play (mm)
0.01 to 0.05
1.86
0.01 to 0.05
0.05 to 0.07
1.89
0.01 to 0.05
0.07 to 0.10
1.92
0.01 to 0.05
0.10 to 0.13
1.95
0.01 to 0.05
0.13 to 0.16
1.98
0.01 to 0.05
Removing the Cylindrical Roller Bearing from the Clutch Housing
– Compress the cylindrical roller bearing locking ring -arrow-
with pliers -C- and remove it.
A - Counter Support , for example, -22/2-
B - Internal Puller 30 to 37 mm , for example, -21/5-
Pressing Cylindrical Roller Bearing into Clutch Housing.
– Compress the cylindrical roller bearing locking ring -arrow-
with pliers -C- and install it.
– Remove the pliers before the cylindrical roller bearing gets into
its installed position. The locking ring must lock into the groove
on the clutch housing.
1.3
Input Shaft Seal, Replacing
Special tools and workshop equipment required
♦ Puller - Crankshaft/Power Steering Seal - T20143/1-
♦ Seal Installer - Driveshaft - T40008-
♦ Sealing Grease - G 052 128 A1-
Caution
This procedure contains mandatory replaceable parts. Refer
to component overview prior to starting procedure.
Mandatory Replacement Parts
♦ Grooved Ball Bearing - Input Shaft
– Remove manual transmission.
– Remove the clutch slave cylinder with release bearing. Refer
to
⇒ “1.11 Clutch Slave Cylinder with Release Bearing, Remov‐
– Pry the input shaft seal out.
Note
Be careful not to damage the contact surface for the seal on the
input shaft.
– Fill the space with the new seal between the sealing and dust
lip halfway with Sealing Grease - G 052 128 A1- .
– Coat the outer circumference of the seal lightly with transmis‐
sion fluid.
– Install the input shaft seal so that it is flush.
– Install the clutch slave cylinder with release bearing. Refer to
⇒ “1.11 Clutch Slave Cylinder with Release Bearing, Remov‐
.
– Install manual transmission.
2
Output Shaft
⇒ “2.1 Overview - Output Shaft”, page 163
⇒ “2.2 Output Shaft, Disassembling and Assembling”,
page 172
⇒ “2.3 Output Shaft, Adjusting”, page 187
2.1
Overview - Output Shaft
⇒ “2.1.1 Overview - Output Shaft, 1st to 4th Gears”, page 163
⇒ “2.1.2 Overview - Output Shaft, 5th/6th and Reverse Gears”,
2.1.1
Overview - Output Shaft, 1st to 4th 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.
♦
Install a collar bushing instead of thrust washers -19-
on transmissions with reinforcement measures (manual transmission 0FB). The
output shaft components, 1st through 4th gear, 4th gear wheel and the needle bearing for the 4th gear wheel
were adapted Refer to
⇒ Fig. ““Reinforcement Measures on Manual Transmission 0FB near 4th Gear Wheel”“ , page 167
to the Parts Catalog.
♦
Adjust the output shaft if it or the tapered roller bearing are being replaced. Refer to
⇒ “2.3 Output Shaft, Adjusting”, page 187
♦
Replace both tapered roller bearings together.
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