Volkswagen Golf / Golf GTI / Golf Variant. Manual - part 526

Removing the Locking Collar and the Synchronizer Hub for 1st

and 2nd Gear
After removing the circlip, press off the gear wheel for 2nd gear

and locking collar/synchronizer hub together.
Assemble the Output Shaft

Note

Heat the inner races of the tapered roller bearing and synchron‐

izer hub to approximately 100 °C (212 °F) with the -VAS6414-

before installing. Press on as far as the stop so there is no axial

play.

Checking the Inner Contact Surface for Wear on the 1st Gear

Outer Ring, the 2nd Gear Outer Ring, and the 3rd Gear Outer

Ring
– Install the inner race -1- on the cone on the gear wheel.
– Install the outer race -2- on the cone on the inner race. Meas‐

ure the gap -a- with a feeler gauge at 3 locations at 120°.

– Note the average value.

Wear Limit Dimension -a-

1st gear, 2nd gear, and 3rd

gear

0.4 mm

Checking the Outer Contact Surface for Wear on the 1st Gear

Outer Ring, the 2nd Gear Outer Ring, and the 3rd Gear Outer

Ring
– Check the synchronizer ring -arrow- on the inner running sur‐

face for grooves and radial wear, and replace if necessary.

– Install the inner race, the outer race and the synchronizer ring

on the cone on the inner race.

– Press on the synchronizer ring with the outer race and turn it

evenly so that the synchronizer ring settles in.

– Measure the gap -a- with a feeler gauge at 3 locations at 120°.
– Note the average value.

Wear Limit Dimension -a-

1st gear, 2nd gear, and 3rd

gear

0.8 mm

– Install the 2nd gear wheel with the needle bearing.

Installing 2nd Gear Outer Race, Inner Race and Synchronizer

Ring
– Place inner race -A- on drive gear for 2nd gear.
The tabs -1- face away from the gear wheel.
– Install the outer race -B-.
The tabs -2- engage in grooves -3- on the gear wheel.
– Install the synchronizer ring -C-.
The larger openings -4- lock in the tabs -1- on the inner race

-A-.

Disassembling and Assembling the Locking Collar and the Syn‐

chronizer Hub for 1st, 2nd, 3rd and 4th Gears
1 - Spring
2 - Locking piece
3 - Locking collar
4 - Synchronizer hub
– Slide the locking collar over the synchronizer hub.
In 3rd and 4th gear, the wide collar on the synchronizer hub and

the locking collar face in one direction.
The notches for the locking pieces on the synchronizer hub and

locking collar must line up with each other.

Assembling: Locking Collar/Synchronizer Hub for 1st, 2nd, 3rd

and 4th Gears
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.

Installed Position: Locking Collar/Synchronizer Hub for 1st and

2nd Gears
The identification groove -arrow 1- and the narrow collar

-arrow 2- on the synchronizer hub face 1st gear.

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Warming and Installing the Locking Collar/Synchronizer Hub for

1st and 2nd Gears.
The pins -A- on the synchronizer ring lock into the recesses -B-

in the synchronizer hub.
– Install the locking ring.

Installing the Synchronizer Ring for 1st Gear Outer Race and In‐

ner Race
– Install the synchronizer ring -A- into the 1st and 2nd gear syn‐

chronizer hub.

The tabs -1- lock in the openings -2- in the synchronizer hub.
– Install the outer race -B- in the synchronizer ring.
The tabs -3- face away from the synchronizer ring.
– Install the inner race -C- in the outer race.
The tabs -4- lock in the larger openings -5- in the synchronizer

ring -A-.

Install 1st Gear Wheel with Needle Roller Bearing
• The synchronizer ring -1- and the tabs -arrow A- are inside the

openings in the synchronizer hub -2-.

The pins -arrows B- in the outer race lock in the recesses

-arrows C- in the gear wheel -3-.
– Install the 1st and 4th gear thrust washers in the output shaft

-Item 19- 

⇒ Item 19 (page 165)

 and -Item 20-

⇒ Item 20 (page 165)

 .

On Transmissions with Reinforcement Measures, Install Collar

Bushing -A- to Stop.

Note

Allocate transmission via code letters:

• Installation position of the collared sleeve -A-: The collar

-arrow- points to the 1st gear wheel.

– Then install the 4th gear wheel with needle bearing.

Checking the 4th Gear Synchronizer Ring for Wear

-A- = Brass Synchronizer Ring

Gap Dimension

-a-

Installation Dimen‐

sion

Wear Limit

4th Gear

1.0 to 1.7 mm

0.5 mm

-B- = Steel Synchronizer Ring

Gap Dimension

-a-

Installation Dimen‐

sion

Wear Limit

4th Gear

1.3 to 2.4 mm

0.8 mm

– Press synchronizer ring onto taper of the gear wheel and

measure gap dimension -a- using a feeler gauge.