Volkswagen Golf / Golf GTI / Golf Variant. Manual - part 523

1 - Clutch Housing
2 - Oil Deflector Ring
3 - Dished Washer

❑ Removing. Refer to

⇒ Fig. ““Removing the

Dished Washer -A- from

the Output Shaft”“ ,

page 172

❑ Installing. Refer to

⇒ Fig. ““Installing the

Dished Washer into the

Output Shaft”“ ,

page 173

4 - Outer Race/Tapered Roller

Bearing

❑ Removing. Refer to

⇒ Fig. ““Removing the

Outer Race / Tapered

Roller Bearing from the

Clutch Housing”“ ,

page 173

❑ Installing. Refer to

⇒ Fig. ““Installing the

Outer Race/Tapered

Roller Bearing in the

Clutch Housing”“ ,

page 174

5 - Inner Race / Tapered Roller

Bearing

❑ Removing. Refer to

⇒ Fig. ““Removing the

Inner Race/Tapered

Roller Bearing on the

side of the Clutch Hous‐

ing”“ , page 173

❑ Installing. Refer to

⇒ Fig. ““Installing the Inner Race/Tapered Roller Bearing on the Side of the Clutch Housing”“ ,

page 173

6 - Output Shaft

❑ For 1st through 4th gear
❑ There are different versions. Refer to 

⇒ Fig. ““Differentiation of Output Shafts”“ , page 168

❑ Allocate according to the transmission code letters. Refer to the Parts Catalog.
❑ Adjusting. Refer to 

⇒ “2.3 Output Shaft, Adjusting”, page 187

 .

7 - Needle Bearing

❑ For 2nd gear

8 - 2nd Gear Wheel
9 - 2nd Gear Inner Race

❑ Replace if there are wear grooves
❑ Installed position. Refer to

⇒ Fig. ““Installing 2nd Gear Outer Race, Inner Race and Synchronizer Ring”“ , page 177

 .

10 - 2nd Gear Outer Race

❑ Check the inner friction surface for wear. Refer to

⇒ Fig. ““Checking the Inner Contact Surface for Wear on the 1st Gear Outer Ring, the 2nd Gear Outer

Ring, and the 3rd Gear Outer Ring ”“ , page 176

❑ Check the outer friction surface for wear. Refer to

⇒ Fig. ““Checking the Outer Contact Surface for Wear on the 1st Gear Outer Ring, the 2nd Gear Outer

Ring, and the 3rd Gear Outer Ring”“ , page 176

❑ Installed position. Refer to

⇒ Fig. ““Installing 2nd Gear Outer Race, Inner Race and Synchronizer Ring”“ , page 177

 .

11 - 2nd Gear Synchronizer Ring

❑ Check the inner running surface for grooves and radial wear
❑ Installed position. Refer to

⇒ Fig. ““Installing 2nd Gear Outer Race, Inner Race and Synchronizer Ring”“ , page 177

 .

12 - Locking Collar with Synchronizer Hub for 1st and 2nd Gears

❑ After removing the circlip, remove with the 2nd gear wheel. Refer to

⇒ Fig. ““Removing the Locking Collar and the Synchronizer Hub for 1st and 2nd Gear”“ , page 176

 .

❑ Disassembling. Refer to

⇒ Fig. ““Disassembling and Assembling the Locking Collar and the Synchronizer Hub for 1st, 2nd, 3rd

and 4th Gears”“ , page 177

 .

❑ Assembling the locking collar/synchronizer hub. Refer to

⇒ Fig. ““Disassembling and Assembling the Locking Collar and the Synchronizer Hub for 1st, 2nd, 3rd

and 4th Gears”“ , page 177

 and

⇒ Fig. ““Assembling: Locking Collar/Synchronizer Hub for 1st, 2nd, 3rd and 4th Gears”“ , page 177

❑ Installed position. Refer to

⇒ Fig. ““Installed Position: Locking Collar/Synchronizer Hub for 1st and 2nd Gears”“ , page 177

 .

❑ Installing. Refer to

⇒ Fig. ““Warming and Installing the Locking Collar/Synchronizer Hub for 1st and 2nd Gears.”“ ,

page 178

13 - Locking Ring
14 - 1st Gear Synchronizer Ring

❑ Check the inner running surface for grooves and radial wear
❑ Installed position. Refer to

⇒ Fig. ““Installing the Synchronizer Ring for 1st Gear Outer Race and Inner Race”“ , page 178

 .

15 - 1st Gear Outer Race

❑ Check the inner friction surface for wear. Refer to

⇒ Fig. ““Checking the Inner Contact Surface for Wear on the 1st Gear Outer Ring, the 2nd Gear Outer

Ring, and the 3rd Gear Outer Ring ”“ , page 176

❑ Check the outer friction surface for wear. Refer to

⇒ Fig. ““Checking the Outer Contact Surface for Wear on the 1st Gear Outer Ring, the 2nd Gear Outer

Ring, and the 3rd Gear Outer Ring”“ , page 176

❑ Installed position. Refer to

⇒ Fig. ““Installing the Synchronizer Ring for 1st Gear Outer Race and Inner Race”“ , page 178

 .

16 - 1st Gear Inner Race

❑ Replace if there are wear grooves
❑ Installed position. Refer to

⇒ Fig. ““Installing the Synchronizer Ring for 1st Gear Outer Race and Inner Race”“ , page 178

 .

17 - Needle Bearing

❑ For 1st gear

18 - 1st Gear Wheel

❑ Mount on the output shaft. Refer to

⇒ Fig. ““Install 1st Gear Wheel with Needle Roller Bearing”“ , page 178

19 - Thrust Washer

❑ Quantity: 2
❑ For 1st and 4th gears
❑ The tab on the thrust washer must fit into the hole in the output shaft.
❑ Not installed on transmissions with reinforcement measures

20 - Retaining Ring

❑ Holds the thrust washers for the 1st and 4th gear in place on the output shaft
❑ Not installed on transmissions with reinforcement measures

21 - Collar Bushing

❑ For the 4th gear needle bearing
❑ Only installed on transmissions with reinforcement measures. Refer to

⇒ Fig. ““Reinforcement Measures on Manual Transmission 0FB near 4th Gear Wheel”“ , page 167

❑ Allocate according to the transmission code letters. Refer to the Parts Catalog.

22 - Needle Bearing

❑ For 4th gear
❑ There are different versions. Refer to

⇒ Fig. ““Variations of the Needle Bearing and Gear Wheels for 4th Gear”“ , page 168

❑ Allocate according to the transmission code letters. Refer to the Parts Catalog.

23 - 4th Gear Wheel

❑ There are different versions. Refer to

⇒ Fig. ““Variations of the Needle Bearing and Gear Wheels for 4th Gear”“ , page 168

❑ Allocate according to the transmission code letters. Refer to the Parts Catalog.

24 - 4th Gear Synchronizer Ring

❑ Brass or steel
❑ Checking for wear. Refer to 

⇒ Fig. ““Checking the 4th Gear Synchronizer Ring for Wear”“ , page 179

25 - Locking Collar with Synchronizer Hub for 3rd and 4th Gears

❑ After removing the locking ring, remove the 4th gear wheel. Refer to

⇒ Fig. ““Removing the 3rd and 4th Gear Synchronizer Hub/Locking Collar with the 4th Gear Wheel”“ ,

page 175

❑ Disassembling. Refer to

⇒ Fig. ““Disassembling and Assembling the Locking Collar and the Synchronizer Hub for 1st, 2nd, 3rd

and 4th Gears”“ , page 177

 .

❑ Assembling the locking collar/synchronizer hub. Refer to

⇒ Fig. ““Disassembling and Assembling the Locking Collar and the Synchronizer Hub for 1st, 2nd, 3rd

and 4th Gears”“ , page 177

 and

⇒ Fig. ““Assembling: Locking Collar/Synchronizer Hub for 1st, 2nd, 3rd and 4th Gears”“ , page 177

❑ Installed position: locking collar/synchronizer hub. Refer to

⇒ Fig. ““Installed Position: Locking Collar/Synchronizer Hub for 3rd and 4th Gears”“ , page 180

❑ Installing. Refer to

⇒ Fig. ““Warming and Installing the Synchronizer Hub with Locking Collar for 3rd and 4th Gears”“ , page

180

26 - Locking Ring
27 - 3rd Gear Synchronizer Ring

❑ Check the inner running surface for grooves and radial wear
❑ Installed position. Refer to

⇒ Fig. ““Installing the 3rd Gear Synchronizer Ring, Outer Ring and Inner Ring”“ , page 180

 .

28 - 3rd Gear Outer Race

❑ Check the inner friction surface for wear. Refer to

⇒ Fig. ““Checking the Inner Contact Surface for Wear on the 1st Gear Outer Ring, the 2nd Gear Outer

Ring, and the 3rd Gear Outer Ring ”“ , page 176

❑ Check the outer friction surface for wear. Refer to

⇒ Fig. ““Checking the Outer Contact Surface for Wear on the 1st Gear Outer Ring, the 2nd Gear Outer

Ring, and the 3rd Gear Outer Ring”“ , page 176

❑ Installed position. Refer to

⇒ Fig. ““Installing the 3rd Gear Synchronizer Ring, Outer Ring and Inner Ring”“ , page 180

 .

29 - 3rd Gear Inner Race

❑ Replace if there are wear grooves
❑ Installed position. Refer to

⇒ Fig. ““Installing the 3rd Gear Synchronizer Ring, Outer Ring and Inner Ring”“ , page 180

 .

30 - Needle Bearing

❑ For 3rd gear

31 - 3rd Gear Wheel

❑ Mount on the output shaft. Refer to

⇒ Fig. ““Installing the 3rd Gear Wheel with Needle Bearing”“ , page 181

32 - Inner Race / Tapered Roller Bearing

❑ Removing. Refer to

⇒ Fig. ““Remove the Inner Race/Tapered Roller Bearing on the side of the Transmission Housing”“ ,

page 174

❑ Installing. Refer to

⇒ Fig. ““Installing the Inner Race/Tapered Roller Bearing on the side of the Transmission Housing”“ ,

page 174

33 - Locking Ring

❑ Determine again when replacing inner race/tapered roller bearing and output shaft. Refer to

⇒ Fig. ““Selecting the Locking Ring”“ , page 174

34 - Outer Race/Tapered Roller Bearing

❑ Removing. Refer to

⇒ Fig. ““Removing the Outer Race/Tapered Roller Bearing from the Transmission Housing”“ ,

page 175

❑ Installing. Refer to

⇒ Fig. ““Installing the Outer Race/Tapered Roller Bearing into the Transmission Housing”“ , page 175

35 - Shim

❑ Selecting thickness. Refer to 

⇒ “2.3 Output Shaft, Adjusting”, page 187

 .

36 - Transmission Housing

Reinforcement Measures on Manual Transmission 0FB near 4th

Gear Wheel
The following components are affected.
1 - Output Shaft
Characteristics. Refer to

⇒ Fig. ““Differentiation of Output Shafts”“ , page 168

2 - Collar Bushing
Characteristics. Refer to

⇒ Fig. ““Variations of the Needle Bearing and Gear Wheels for 4th

Gear”“ , page 168

3 - Needle Bearing for 4th Gear
Characteristics. Refer to

⇒ Fig. ““Variations of the Needle Bearing and Gear Wheels for 4th

Gear”“ , page 168

4 - 4th Gear Wheel
Characteristics. Refer to

⇒ Fig. ““Variations of the Needle Bearing and Gear Wheels for 4th

Gear”“ , page 168

Note

♦

Never mix parts for reinforced 4th gear transmissions and 4th

gear transmissions without reinforcement. Refer to the Parts

Catalog.

♦

To remove and install modified components, follow instruc‐

tions in repair manual. Refer to

⇒ “2.2.1 Output Shaft, Disassembling and Assembling, 1st to

4th Gears”, page 172

 .