Volkswagen Golf / Golf GTI / Golf Variant. Manual - part 599

Installed Position: 2nd Gear Wheel
The higher collar -A- faces toward 1st gear -B-. The notches in

the collar -arrow- lock into the tabs on the outer race. Refer to

⇒ Fig. ““Installed Position of 2nd Gear Outer Race”“ , page 163

 .

Installing the Sleeve for the 3rd Gear Needle Bearing

Checking 3rd/4th Gear Synchronizing Ring for Wear
– Press synchronizer ring onto taper of the gear wheel and

measure gap dimension -a- using a feeler gauge.

Gap Dimension

-a-

Installation Dimen‐

sion

Wear limit

3rd and 4th gear

1.0 to 1.7 mm

0.5 mm

Disassembling and Assembling Locking Collar and Synchronizer

Hub for 3rd/4th Gears
1 - Spring
Allocate the correct springs. 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

Inside”“ , page 162

 .

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”“ ,

page 162

 .

2 - Locking piece
Allocate the locking pieces. Refer to the Parts Catalog.
3 - Locking collar
4 - Synchronizer Hub
– Slide the locking collar over the synchronizer hub.
The notches for the locking pieces on the synchronizer hub and

locking collar must line up with each other.

Assembly: Locking Collar/Synchronizer Hub for 3rd and 4th

Gears Together with Locking Pieces that are Hollow on the Inside
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 3rd and 4th

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 an‐

gled end of the spring must be positioned in front of the locking

pieces -arrows-.

Installed Position: Locking Collar/Synchronizer Hub for 3rd and

4th Gears
The bevel -arrow- faces 4th gear.

Installing the Synchronizer Hub with Locking Collar for 3rd and

4th Gears

Installing the Sleeve for the 4th Gear Needle Bearing

Installing the Sleeve for the Needle Bearing/Output Shaft

2.3

Output Shaft, Adjusting

(Selecting the correct adjusting shim for the output shaft)
Special tools and workshop equipment required
♦ Dial Gauge Holder - VW387-
♦ Measuring Set - Magnetic Plate - 50mm - VW385/17-
♦ Press Piece - Multiple Use - VW512-

♦ Door Alignment Device - Replacement Stud - 3114/2-
♦ Press Piece - Rod - VW407-
♦ Torque Wrench 1331 5-50Nm - VAG1331-
♦ Dial Gauge
♦ -1- Puller - Kukko Internal - 36-46mm - 21/6-
♦ -4- Puller - Kukko Counterstay - 22/2-
It is necessary to adjust the output shaft if the following compo‐

nents were replaced:
♦ Output Shaft
♦ Clutch Housing
or
♦ Tapered roller bearing
Adjustment overview. Refer to

⇒ “3 Adjustment Overview”, page 198

 .

Requirements:
• Remove any sealant remaining on the sealing surfaces on the

clutch and transmission housings.

– Press the outer race/small tapered roller bearing with the ad‐

justment shim 0.65 mm into the clutch housing as far as the

stop. Refer to

⇒ Fig. ““Installing the Small Outer Race/Tapered Roller Bear‐

ing”“ , page 159

 .

– Install the output shaft and tighten the nuts for the bearing

mount.

– Rotate the output shaft 20 to 30 times in one direction.

Note

♦

For this reason, it must be rotated in one direction so the ta‐

pered roller bearing rollers are seated in one direction.

♦

Therefore, it must also be rotated 20 to 30 times in one direc‐

tion.

♦

Otherwise the measurements will be incorrect.