Volkswagen Golf / Golf GTI / Golf Variant. Manual - part 583

5.9

Shift Forks, Servicing

Special tools and workshop equipment required
♦ Press Plate - VW402-
♦ Subframe Support Tool - Press Piece - 3290/1-
♦ Press Piece - Multiple Use - VW431-
♦ Subframe Bushing Tool Kit - 3301-
♦ Press Piece - Multiple Use Spacer Sleeve - VW472/2-
♦ Valve Guide/Clutch Release Push Rod Seal Drift - 10-206-
♦ Pry Lever - 80-200-
♦ Assembly Mandrel for Gear Selector Rod - 10-508-
♦ Spring Strut Compressor - 2070-
Shift Segment Identification
Dimension -a-
1 - 1st and 2nd gear shift segments = 11.4 mm
2 - 3rd gear and 4th gear selector segments = 7.7 mm
3 - 5th gear shift segments = 12.1 mm

Removing the Lock Washer
– Secure shift fork in vise with protective jaws -B-.
– Pry off the lock washer -A- in the direction of -arrow-.

Installing the Lock Washer
– Press the lock washer in the groove in the shift segment using

a socket wrench

Note

The shift segment must still rotate easily after the lock washer is

installed.

A - 10 mm socket wrench
B - Protective Jaws

Removing the Angular Contact Ball Bearing

Note

Be careful not to bend the shift forks when removing and installing

the angular contact ball bearing.

Installing the Angular Contact Ball Bearing Inner Race -A- into the

Outer Race
The bearing inner race must engage with outer race.

Installing the Angular Contact Ball Bearing into the Shift Fork
The recess in the Subframe Support Tool - Press Piece - 3290/1-

point to the ball bearing.

Shift Fork with the Shift Segments Installed
 

Dimension -a- (mm)

1st/2nd gear shift fork

87.2 to 87.4

3rd/4th gear shift fork

93.6 to 93.8

Shift segment allocation

⇒ Fig. ““Shift Segment Identification”“ , page 100

5.10

Transmission Housing Cover and 5th

Gear, Removing

Special tools and workshop equipment required
♦ Holding Plate - VW309A-
♦ or Holding Plate - VW309A-
♦ Transmission Support - VW353-

♦ Bearing/Bushing Installer - Multiple Use - VW295-
♦ Bearing Driver - Multiple Use - VW244B-
♦ For example Hot Air Blower - VAG1416-
♦ Torque Wrench 1331 5-50Nm - VAG1331-
♦ Bracket - Multiple Use - 30-211A-
♦ Bearing Installer - Multiple Use - 32-111-
♦ Assembly Tool Kit - Press Piece 2 - T10030/4- from the Hy‐

draulic Press - Bushing Tool Kit - T10030-

♦ Press Piece - 37mm - VW416B-
♦ Puller - Transmission Gears - T10309-
♦ Puller - Two Arm - T10040-
♦ With the Puller - Two Arm w/Thrust Piece - T10040/2A-
♦ Puller - Two Arm Thrust Piece - T10040/3-
♦ Support Bridge - T10323-
♦ Rear Wheel Bearing Kit - Piece 7 - 3253/7-
♦ Press Piece - Multiple Use - VW433-
♦ Press Piece - Multiple Use - 40-105-
♦ Torque Wrench 1332 40-200Nm - VAG1332-

Caution

This procedure contains mandatory replaceable parts. Refer

to component overview prior to starting procedure.

Mandatory Replacement Parts
♦ Bolts - Plate Spring to Transmission
5th Gear and Transmission Housing Cover, Installing. Refer to

⇒ “5.12 Transmission Housing Cover and 5th Gear, Installing”,

page 114

 .

Note

♦

If only 5th has to be removed, follow this procedure:

♦

Pay attention to the work procedure if the transmission hous‐

ing must be removed. Refer to

⇒ “5.11 Transmission, Disassembling and Assembling”, page

105

 .

– Remove the clutch release lever and release bearing. Refer

to 

⇒ “1.16 Clutch Release Mechanism, Servicing”, page 35

 .

• Be careful not to damage the bearing for the input and output

shafts when removing and installing 5th gear.

• When securing the transmission to the Transmission Support

- VW353- , install the following tools for support:

Under the Input Shaft:
♦ Bracket - Multiple Use - 30-211A-
♦ Bearing Installer - Multiple Use - 32-111-
♦ Assembly Tool Kit - Press Piece 2 - T10030/4-
• Input shaft may be supported by Bearing Installer - Multiple

Use - 32-111- only at a later time.

Under the Output Shaft Bracket
♦ Support Bridge - T10323-
♦ Rear Wheel Bearing Kit - Piece 7 - 3253/7-
♦ Press Piece - Multiple Use - VW433-

– Secure the transmission on the Transmission Support -

VW353- .

– Remove the transmission housing cover -arrow-.

– Make sure the Puller - Two Arm w/Thrust Piece - T10040/2A-

can be installed correctly under the 5th gear wheel.

Puller - Two Arm w/Thrust Piece - T10040/2A- cannot be In‐

stalled Correctly.

-A-

Puller - Two Arm w/Thrust Piece -

T10040/2A- prematurely touch

the:

♦ Transmission housing wall
♦ The ribbing in the transmission

housing under the 5th gear

wheel

“Combined” removal of the:

“5th gear synchronizer

hub”, “5th gear wheel” and

“transmission housing”.

Refer to

⇒ “5.11 Transmission, Dis‐

assembling and Assem‐

bling”, page 105

 .

The-B-

Puller - Two Arm w/Thrust Piece -

T10040/2A- touch the ribs in the

transmission housing under the

5th gear wheel.

Puller - Two Arm w/Thrust Piece - T10040/2A- can be Installed

Correctly.

5th gear is removed individually ⇒

⇒ Fig. ““5th Gear, Removing Separately”“ , page 104