Volkswagen Golf / Golf GTI / Golf Variant. Manual — part 598
Installing the Inner Race/Small Tapered Roller Bearing
Removing the 3rd/4th Gear Synchronizer Hub/Locking Collar,
2nd Gear Wheel, 3rd and 4th Gear with Output Shaft Needle
Bearing Sleeve
A - Puller - Quick Action Separating Tool - 22-115mm - Kukko
17/2- , for example.
B - M10 x 20, 17 mm Hex Bolt
Note
Support the separating tool so that the 1st/2nd gear locking collar
does not come off as well.
Removing the Locking Collar with the Synchronizer Hub and
Bearing Mount
– Remove the locking ring -arrow- beforehand.
Removing the Inner Race/Large Tapered Roller Bearing
-A- vise protectors
– Before installing puller, insert a M10 x 20 bolt into the hole in
the output shaft.
Installing the Inner Race/Large Tapered Roller Bearing
-A- thrust washer
– Install the thrust washer before installing the inner race. The
shoulder faces the inner race.
Installed Position of the Inner Race, the Outer Race and the 1st
Gear Synchronizer Ring
– Place inner race -A- on drive gear for 1st gear.
The angled tabs -arrow 1- face the outer race -B-.
– Install the outer race -B-.
The tabs -arrow 2- must lock into the retainers -arrow 3- in the
gear wheel.
– Install the synchronizer ring -C-.
The retainers -arrow 4- lock in the tabs -arrow 1- on the inner race
-A-.
Note
If the parts are not to be replaced, make sure they are reallocated
to their original gear.
Checking Inner Race for 1st Gear and 2nd Gear for Wear
– Install the inner race onto taper of selector gear and then
measure gap dimension -a- with a feeler gauge.
Gap Dimension
-a-
Installation Dimen‐
sion
Wear Limit
1st and 2nd gear
0.75 to 1.25 mm
0.3 mm
Checking 1st Gear and 2nd Gear Synchronizing Ring for Wear
– Install the synchronizer ring, outer race and inner race onto
taper of selector gear and then measure the gap dimension
-a- with a feeler gauge.
Gap Dimension
-a-
Installation Dimen‐
sion
Wear Limit
1st and 2nd gear
1.2 to 1.8 mm
0.5 mm
Disassembling and Assembling Locking Collar and Synchronizer
Hub for 1st and 2nd Gears
1 - Spring
Spring allocation. Refer to the Parts Catalog.
Assembly in conjunction with hollow locking pieces. Refer to
⇒ Fig. ““Assembly: Locking Collar/Synchronizer Hub for 1st and
2nd Gears Together with Locking Pieces That Are Hollow on the
Assembly in conjunction with locking pieces that are not hollow.
Refer to
⇒ Fig. ““Assembly: Locking Collar/Synchronizer Hub for 1st and
2nd Gears Together with locking Pieces That Are Not Hollow”“ ,
.
2 - Locking collar
3 - Synchronizer Hub
4 - Locking piece
Allocate the locking pieces. Refer to the Parts Catalog.
The collar has the same width on both side of the synchronizer
hub.
The Shoulder Has a Chamfer on One Side -arrow B-
The bevel on the synchronizer hub collar and the splines on the
outside of the locking collar -arrow A- face in the same direction
after being assembled.
The notches on the synchronizer hub and locking collar for the
locking pieces -arrow C- must line up.
Assembly: Locking Collar/Synchronizer Hub for 1st and 2nd
Gears Together with Locking Pieces That Are Hollow on the In‐
side
• The locking collar is pushed over the synchronizer hub.
– Install the locking pieces and springs offset by 120°. The an‐
gled end of the spring must engage into the hollow locking
piece.
Assembly: Locking Collar/Synchronizer Hub for 1st and 2nd
Gears Together with locking Pieces That Are Not Hollow
• The locking collar is pushed over the synchronizer hub.
– Install the locking pieces and springs offset by 120°.
• The angled end of the spring must be positioned in front of the
locking pieces -arrows-.
Installed Position: Locking Collar/Synchronizer Hub for 1st and
2nd Gears
The teeth of the locking collar -arrow- point toward the splines of
the 3rd/4th gear synchronizer hub -A-.
Installing the Locking Collar/Synchronizer Hub for 1st and 2nd
Gears.
Turn the synchronizer ring so that the grooves line up with the
locking pieces.
Installed Position of 2nd Gear Outer Race
The tabs -arrows- face 1st gear -A-.
Installed Position: Synchronizer Ring -A- (2nd Gear Inner Race)
The tabs -arrow 1- engage into the holes -arrow 2- inside the
synchronizer ring -B-.
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