Volkswagen Golf / Golf GTI / Golf Variant. Manual - part 584

5th Gear, Removing Separately
– Cover the openings in the transmission housing with a cloth.
– Move the shift fork -1- into neutral.
– Remove the bolt -2- with the shift jaw for 5th gear.
– Remove both bolts -arrows- for the pivot pin.
– Remove the pivot pin.
– Remove the 5th gear shift fork.
– It is not necessary to remove the spring -3- and the locking

collar -4-.

– Remove the bolts -A- for the synchronizer hub and for the 5th

gear wheel. Do this by engaging 5th gear -arrow 1- and 1st

gear -arrow 2- and -3-.

– The input shaft and the output shaft are blocked after both

gears are engaged. The synchronizer hub and the gear wheel

cannot turn. Both bolts can be loosened now.

Note

Remove any locking compound residue still in the threaded holes

using a thread tap if the shafts are not going to be replaced.

Remove 5th Gear Synchronizer Hub Together with Locking Collar

and Locking Pieces.
To Do This Use the Puller - Transmission Gears - T10309- .

– Insert the Puller - Transmission Gears - Half Shell - T10309/1-

between the 5th gear wheel -A- and the mount for 5th gear

shift fork -B-.

• The Puller - Transmission Gears - Half Shell - T10309/1- must

be placed under the synchronizer ring.

– Press the Puller into the end position, if necessary.
– Rotate the Puller - Transmission Gears - Half Shell - T10309/1-

to the opposite side in direction of -arrow-.

– Install the Puller - Transmission Gears - Threaded Insert -

T10309/3- in the Puller - Transmission Gears - Half Shell .

– Insert the second Puller - Transmission Gears - Half Shell -

T10309/1- and put the Puller - Transmission Gears - Tube -

T10309/2- on the tool.

– Check synchronizer hub after pulling for damage.
– Replace the synchronizer ring.
– Remove the 5th gear selector gear with needle bearing.

– Remove the 5th gear wheel.
– Insert the hook -A-.
B - Puller - Two Arm Thrust Piece - T10040/3- or M10 x 20 bolt,

17 mm

Note

♦

When remove drive gear, make sure the hook does not bend

outward. Check the 5th gear for damage.

♦

Slightly heat 5th gear wheel with Hot Air Blower - VAG1416-

if necessary.

5th gear and transmission housing cover, installing. Refer to

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

page 114

 .

5.11

Transmission, Disassembling and As‐

sembling

Special tools and workshop equipment required
♦ Holding Plate - VW309A-
♦ Transmission Support - VW353-
♦ Bearing/Bushing Installer - Multiple Use - VW295-
♦ Bearing Driver - Multiple Use - VW244B-
♦ For example Hot Air Blower VAG1416 - 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 - T10408-
♦ Puller - Transmission Gears - Thrust Piece - T10408/2-

♦ Spacer Plate - T10408/3-
♦ M7 x 35 hex collar bolt and washer (components of the Puller

- Transmission Gears - T10408- )

♦ Support Bridge - T10323-
♦ Rear Wheel Bearing Kit - Piece 7 - 3253/7-
♦ Press Piece - Multiple Use - VW433-
♦ Torque Wrench 1332 40-200Nm - VAG1332-
♦ -2- Puller - Kukko Puller - 60-150mm Width, 200mm Length -

Kukko 18/1- (quantity 2)

♦ Shop Crane - Drip Tray - VAS6208-
♦ Inductive Heater - VAS6414-
♦ Sealing Compound - AMV 188 200 03-
♦ M8 x 100 mm stud bolt

Caution

This procedure contains mandatory replaceable parts. Refer

to component overview prior to starting procedure.

Mandatory Replacement Parts
♦ Bolts - Plate Spring to Transmission
♦ Nut - Gearshift Lever to Gearshift Unit
Transmission Housing Cover, Transmission Housing, Gearshift

Shaft with Gearshift Cover, Input Shaft, Output Shaft, Differential

and Gearshift Mechanism, Removing and Installing
Transmission, Disassembling
– Remove the clutch release lever, the release bearing and the

guide sleeve. 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-
– Secure the bolt on the Bracket - Multiple Use - 30-211A- with

the nut -A-.

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- .

– Place the Drip Tray underneath.
– Open the oil filler plug and the oil drain plug.
– Drain the transmission fluid.
– Remove the transmission housing cover -arrow-.

Remove the 5th gear shift fork as follows:
– Move the shift fork -1- into neutral.
– Remove the bolt -2- with the shift jaw for 5th gear.
– Remove both bolts -arrows- for the pivot pin.
– Remove the pivot pin.
– Remove the 5th gear shift fork.
– It is not necessary to remove the spring -3- and the locking

collar -4-.

– Engage 5th gear -arrow 1- and 1st gear -arrows 2 and 3- and

then remove the bolts -A- for the synchronizer hub and for the

5th gear wheel.

– The input shaft and the output shaft are blocked after both

gears are engaged. The synchronizer hub and the gear wheel

cannot turn. Both bolts can be loosened now.

Note

Remove any locking compound residue still in the threaded holes

using a thread tap if the shafts are not going to be replaced.

– Remove both bolts -arrows- for the reverse shaft support.