Volkswagen Golf / Golf GTI / Golf Variant. Manual - part 524

Differentiation of Output Shafts

Output Shaft

-1- with Reinforce‐

ment Measures

-2- without Reinforce‐

ment Measures

Dimension -a-

40.1 mm

42.0 mm

-Arrow A-

Groove for collar

bushing position

-21-

⇒ Item 21

(page 166)

-

-Arrow B-

-

2 opposite holes and

circular groove for the

thrust washer mounts

-19-

⇒ Item 19 (page 165)

Variations of the Needle Bearing and Gear Wheels for 4th Gear

4th Gear Wheel

-1- with Reinforce‐

ment Measures

-2- without Reinforce‐

ment Measures

Dimension -a-

52.0 mm

48.0 mm

4th Gear Wheel

Needle Bearing

-3- with Reinforce‐

ment Measures

-4- without Reinforce‐

ment Measures

Dimension -b-

52.0 mm

48.0 mm

• The needle bearing -3- is fitted on the collar bushing -5- on

transmissions with reinforcement measures.

2.1.2

Overview - Output Shaft, 5th/6th and Reverse Gears

Note

♦

Secure the transmission on the assembly stand. Refer to

⇒ “7 Securing on Engine and Transmission Holder”, page 141

 .

♦

To install, warm the inner races/tapered roller bearing and synchronizer hub to approximately 100 °C (212

°F) using Inductive Heater - VAS6414- . Wear protective gloves.

♦

Adjust the output shaft if it or the tapered roller bearing are being replaced. Refer to

⇒ “2.3.2 Output Shaft, 5th, 6th and Reverse Gears, Adjusting”, page 190

 .

♦

Replace both tapered roller bearings together.

1 - Clutch Housing
2 - Washer

❑ Always 0.65 mm thick

3 - Outer Race/Tapered Roller

Bearing

❑ Removing. Refer to

⇒ Fig. ““Removing the

Outer Race/Tapered

Roller Bearing from the

Clutch Housing”“ ,

page 182

❑ Installing. Refer to

⇒ Fig. ““Installing the

Outer Race/Tapered

Roller Bearing in the

Clutch Housing”“ ,

page 183

4 - 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 184

❑ Installing. Refer to

⇒ Fig. ““Installing the In‐

ner Race/Tapered Roll‐

er Bearing on the side of

the Clutch Housing”“ ,

page 187

5 - Output Shaft

❑ For 5th, 6th and reverse

gears

❑ Adjusting. Refer to

⇒ “2.3.2 Output Shaft,

5th, 6th and Reverse Gears, Adjusting”, page 190

 .

6 - Reverse Gear Synchronizer Hub

❑ Removing. Refer to 

⇒ Fig. ““Removing the Reverse Gear Synchronizer Hub”“ , page 184

❑ Installed position. Refer to 

⇒ Fig. ““Installed Position: Reverse Gear Synchronizer Hub”“ , page 185

 .

❑ Installing. Refer to 

⇒ Fig. ““Warming and Installing the Reverse Gear Synchronizer Hub”“ , page 185

7 - Locking Ring
8 - Reverse Gear Locking Collar

❑ With synchronizer ring

9 - Needle Bearing

❑ For reverse gear wheel

10 - Reverse Gear Wheel
11 - Sleeve

❑ Remove with the reverse gear wheel. Refer to

⇒ Fig. ““Removing the Sleeve -A- together with the Reverse Gear Wheel”“ , page 184

❑ Installed position: The wider sleeve collar faces the reverse gear wheel
❑ Installing. Refer to 

⇒ Fig. ““Installing the Sleeve -A- ”“ , page 185

12 - Locking Ring
13 - Needle Bearing

❑ For 6th gear

14 - 6th Gear Wheel
15 - Synchronizer Ring for 6th Gear

❑ Brass or steel
❑ Checking for wear. Refer to

⇒ Fig. ““Checking 5th and 6th Gear Synchronizer Ring for Wear”“ , page 185

16 - Locking Collar with Synchronizer Hub for 5th and 6th Gears

❑ After removing the securing ring, remove with the 6th gear wheel. Refer to

⇒ Fig. ““Removing the 5th and 6th Gear Synchronizer Hub/Locking Collar with the 6th Gear Wheel”“ ,

page 184

❑ Disassembling. Refer to

⇒ Fig. ““Disassembling and Assembling Locking Collar and Synchronizer Hub for 5th and 6th Gears”“ ,

page 186

 .

❑ Assembling the locking collar/synchronizer hub. Refer to

⇒ Fig. ““Disassembling and Assembling Locking Collar and Synchronizer Hub for 5th and 6th Gears”“ ,

page 186

 and

⇒ Fig. ““Assembling Locking Collar/Synchronizer Hub for 5th and 6th Gears”“ , page 186

❑ Installing. Refer to

⇒ Fig. ““Installing the Locking Collar/Synchronizer Hub for 5th and 6th Gears”“ , page 186

17 - Locking Ring
18 - Needle Bearing

❑ For 5th gear

19 - Synchronizer Ring for 5th Gear

❑ Brass or steel
❑ Checking for wear. Refer to

⇒ Fig. ““Checking 5th and 6th Gear Synchronizer Ring for Wear”“ , page 185

20 - 5th Gear Wheel
21 - Inner Race / Tapered Roller Bearing

❑ Removing. Refer to

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

page 183

❑ Installing. Refer to

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

page 187

22 - Locking Ring

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

⇒ Fig. ““Selecting the Locking Ring”“ , page 187

23 - Outer Race/Tapered Roller Bearing

❑ Removing. Refer to

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

page 183

❑ Installing. Refer to

⇒ Fig. ““Installing the Outer Race/Tapered Roller Bearing into the Transmission Housing.”“ , page 183

24 - Shim

❑ Selecting thickness. Refer to

⇒ “2.3.2 Output Shaft, 5th, 6th and Reverse Gears, Adjusting”, page 190

 .

25 - Transmission Housing
26 - Spring

❑ Installed position. Refer to

⇒ Fig. ““Assembling Locking Collar/Synchronizer Hub for 5th and 6th Gears”“ , page 186

 .

27 - Locking Collar
28 - Synchronizer Hub
29 - Locking Piece

❑ Quantity: 3
❑ Installed position. Refer to

⇒ Fig. ““Disassembling and Assembling Locking Collar and Synchronizer Hub for 5th and 6th Gears”“ ,

page 186

 .