Volkswagen Golf / Golf GTI / Golf Variant. Manual — part 583
5.9
Shift Forks, Servicing
Special tools and workshop equipment required
♦ Press Plate - VW402-
♦ Subframe Support Tool - Press Piece - 3290/1-
♦ Press Piece - Multiple Use - VW431-
♦ Subframe Bushing Tool Kit - 3301-
♦ Press Piece - Multiple Use Spacer Sleeve - VW472/2-
♦ Valve Guide/Clutch Release Push Rod Seal Drift - 10-206-
♦ Pry Lever - 80-200-
♦ Assembly Mandrel for Gear Selector Rod - 10-508-
♦ Spring Strut Compressor - 2070-
Shift Segment Identification
Dimension -a-
1 - 1st and 2nd gear shift segments = 11.4 mm
2 - 3rd gear and 4th gear selector segments = 7.7 mm
3 - 5th gear shift segments = 12.1 mm
Removing the Lock Washer
– Secure shift fork in vise with protective jaws -B-.
– Pry off the lock washer -A- in the direction of -arrow-.
Installing the Lock Washer
– Press the lock washer in the groove in the shift segment using
a socket wrench
Note
The shift segment must still rotate easily after the lock washer is
installed.
A - 10 mm socket wrench
B - Protective Jaws
Removing the Angular Contact Ball Bearing
Note
Be careful not to bend the shift forks when removing and installing
the angular contact ball bearing.
Installing the Angular Contact Ball Bearing Inner Race -A- into the
Outer Race
The bearing inner race must engage with outer race.
Installing the Angular Contact Ball Bearing into the Shift Fork
The recess in the Subframe Support Tool - Press Piece - 3290/1-
point to the ball bearing.
Shift Fork with the Shift Segments Installed
Dimension -a- (mm)
1st/2nd gear shift fork
87.2 to 87.4
3rd/4th gear shift fork
93.6 to 93.8
Shift segment allocation
⇒ Fig. ““Shift Segment Identification”“ , page 100
5.10
Transmission Housing Cover and 5th
Gear, Removing
Special tools and workshop equipment required
♦ Holding Plate - VW309A-
♦ or Holding Plate - VW309A-
♦ Transmission Support - VW353-
♦ Bearing/Bushing Installer - Multiple Use - VW295-
♦ Bearing Driver - Multiple Use - VW244B-
♦ For example Hot Air Blower - VAG1416-
♦ Torque Wrench 1331 5-50Nm - VAG1331-
♦ Bracket - Multiple Use - 30-211A-
♦ Bearing Installer - Multiple Use - 32-111-
♦ Assembly Tool Kit - Press Piece 2 - T10030/4- from the Hy‐
draulic Press - Bushing Tool Kit - T10030-
♦ Press Piece - 37mm - VW416B-
♦ Puller - Transmission Gears - T10309-
♦ Puller - Two Arm - T10040-
♦ With the Puller - Two Arm w/Thrust Piece - T10040/2A-
♦ Puller - Two Arm Thrust Piece - T10040/3-
♦ Support Bridge - T10323-
♦ Rear Wheel Bearing Kit - Piece 7 - 3253/7-
♦ Press Piece - Multiple Use - VW433-
♦ Press Piece - Multiple Use - 40-105-
♦ Torque Wrench 1332 40-200Nm - VAG1332-
Caution
This procedure contains mandatory replaceable parts. Refer
to component overview prior to starting procedure.
Mandatory Replacement Parts
♦ Bolts - Plate Spring to Transmission
5th Gear and Transmission Housing Cover, Installing. Refer to
⇒ “5.12 Transmission Housing Cover and 5th Gear, Installing”,
.
Note
♦
If only 5th has to be removed, follow this procedure:
♦
Pay attention to the work procedure if the transmission hous‐
ing must be removed. Refer to
⇒ “5.11 Transmission, Disassembling and Assembling”, page
.
– Remove the clutch release lever and release bearing. Refer
to
⇒ “1.16 Clutch Release Mechanism, Servicing”, page 35
.
• Be careful not to damage the bearing for the input and output
shafts when removing and installing 5th gear.
• When securing the transmission to the Transmission Support
- VW353- , install the following tools for support:
Under the Input Shaft:
♦ Bracket - Multiple Use - 30-211A-
♦ Bearing Installer - Multiple Use - 32-111-
♦ Assembly Tool Kit - Press Piece 2 - T10030/4-
• Input shaft may be supported by Bearing Installer - Multiple
Use - 32-111- only at a later time.
Under the Output Shaft Bracket
♦ Support Bridge - T10323-
♦ Rear Wheel Bearing Kit - Piece 7 - 3253/7-
♦ Press Piece - Multiple Use - VW433-
– Secure the transmission on the Transmission Support -
VW353- .
– Remove the transmission housing cover -arrow-.
– Make sure the Puller - Two Arm w/Thrust Piece - T10040/2A-
can be installed correctly under the 5th gear wheel.
Puller - Two Arm w/Thrust Piece - T10040/2A- cannot be In‐
stalled Correctly.
-A-
Puller - Two Arm w/Thrust Piece -
T10040/2A- prematurely touch
the:
♦ Transmission housing wall
♦ The ribbing in the transmission
housing under the 5th gear
wheel
“Combined” removal of the:
“5th gear synchronizer
hub”, “5th gear wheel” and
“transmission housing”.
Refer to
.
The-B-
Puller - Two Arm w/Thrust Piece -
T10040/2A- touch the ribs in the
transmission housing under the
5th gear wheel.
Puller - Two Arm w/Thrust Piece - T10040/2A- can be Installed
Correctly.
5th gear is removed individually ⇒
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