Volkswagen Golf / Golf GTI / Golf Variant. Manual — part 595
Installation of Offset Springs -A-
These springs are installed on both sides.
– Springs are only installed in conjunction with hollow locking
pieces.
– Insert locking pieces (installed position: Refer to
⇒ Fig. ““5th Gear Synchronizing”“ , page 147
Spring installed position:
– Install the spring offset by 120°.
– Angled end -A- of spring must engage into the hollow locking
piece.
The spring must be located below the tab -B- of the locking pieces.
The offset end always faces away from the synchronizer hub in
direction of -arrow-.
1.3
Input Shaft, Adjusting
Special tools and workshop equipment required
♦ Dial Gauge Holder - VW387-
♦ Measuring Set - Magnetic Plate - 50mm - VW385/17-
♦ Press Piece - Multiple Use - VW510-
♦ Press Piece - VW447i-
♦ Press Piece - Rod - VW407-
♦ Torque Wrench 1331 5-50Nm - VAG1331-
♦ Dial Gauge
A new input shaft adjustment is required when the following com‐
ponents have been replaced:
♦ Transmission Housing
♦ Clutch Housing
♦ Input Shaft
♦ 4th Gear Wheel
or the
♦ Tapered roller bearing
Adjustment overview. Refer to
⇒ “3 Adjustment Overview”, page 198
Requirement:
• Remove any sealant remaining on the sealing surfaces on the
clutch and transmission housings.
– Press the taper roller bearing outer race into the clutch housing
all the way.
– Install the outer race/tapered roller bearing all the way into the
transmission housing without the adjusting shim.
– Install the input shaft into the clutch housing and mount the
transmission housing. Install the hex bolts. Refer to
⇒ “5.4 Overview - Transmission Housing and Selector Mech‐
.
– Install the measuring device and the dial gauge in the clutch
housing.
– Rotate the input shaft before measuring so the tapered roller
bearing settles. Set the dial gauge with 1 mm pretension to “0”.
Note
Repeat this process each time a measurement is taken otherwise
the dial gauge will not go back to its start setting.
– Press the input shaft toward the dial gauge direction of
-arrow-.
– Read and make note of the play on the dial gauge (example:
1.21 mm).
Note
The dial gauge does not return to its starting position.
Determining the Shim
Example:
Bearing Clearance Measured
Value
Adjustment Shim Thickness
According To the Table
1.21 mm
1.175 mm
Shim Table
Bearing Play
Shim
Measured Value (mm)
Thickness (mm)
0.671 to 0.699
0.700 to 0.724
0.725 to 0.749
0.650
0.675
0.700
0.750 to 0.774
0.775 to 0.799
0.800 to 0.824
0.725
0.750
0.775
0.825 to 0.849
0.850 to 0.874
0.875 to 0.899
0.800
0.825
0.850
0.900 to 0.924
0.925 to 0.949
0.950 to 0.974
0.875
0.900
0.925
0.975 to 0.999
1.000 to 1.024
1.025 to 1.049
0.950
0.975
1.000
1.050 to 1.074
1.075 to 1.099
1.100 to 1.124
1.025
1.050
1.075
1.125 to 1.149
1.150 to 1.174
1.175 to 1.199
1.100
1.125
1.150
1.200 to 1.224
1.225 to 1.249
1.250 to 1.274
1.175
1.200
1.225
1.275 to 1.229
1.300 to 1.324
1.325 to 1.349
1.250
1.275
1.300
1.350 to 1.374
1.375 to 1.399
1.400 to 1.424
1.325
1.350
1.375
1.425 to 1.449
1.450 to 1.474
1.475 to 1.499
1.400
1.425
1.450
1.500 to 1.524
1.525 to 1.549
1.550 to 1.574
1.475
1.500
1.525
1.575 to 1.599
1.600 to 1.624
1.625 to 1.649
1.550
1.575
1.600
1.650 to 1.674
1.675 to 1.699
1.700 to 1.724
1.625
1.650
1.675
Note
Allocate the shims. Refer to the Parts Catalog.
– Remove the drive axle and pry out the outer race/tapered roller
bearing using the Press Piece - VW447i- from the transmis‐
sion housing.
– Install the shim with the correct thickness, thickest shim first.
If the measured shim thickness is larger than those listed in the
Table, then install two shims that add up to the necessary thick‐
ness.
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