Volkswagen Golf / Golf GTI / Golf Variant. Manual - part 594

♦ Press Piece - 28x100mm - VW421-
♦ Press Piece - VW447i-
♦ Press Piece - Multiple Use - VW454-
♦ Press Piece - Multiple Use - VW510-
♦ Press Tube - 41-501-
♦ -3- Puller - Kukko Quick Action Separating Tool - 12-75mm -

Kukko 17/1-

♦ Press Plate - VW402-
♦ Inductive Heater - VAS6414-

Caution

This procedure contains mandatory replaceable parts. Refer

to component overview prior to starting procedure.

Mandatory Replacement Parts
♦ Circlip - Input Shaft
Removing the Outer Race/Tapered Roller Bearing

Installing the Outer Race/Tapered Roller Bearing

Removing the Inner Race/Tapered Roller Bearing
A - Puller - Quick Action Separating Tool - 12-75mm -Kukko 17/1-

Installing the Inner Race/Tapered Roller Bearing

Removing the 4th Gear Wheel with the Tapered Roller Bearing

and Sleeve

Removing the 3rd Gear Wheel

Installing 3rd Gear Wheel

Removing 4th Gear Wheel
The shoulder faces 3rd gear.

Installing the Inner Race/Tapered Roller Bearing

Installing the Needle Bearing Sleeve

Removing the Outer Race/Tapered Roller Bearing

Installing the Outer Race/Tapered Roller Bearing
– Install with shim after adjusting input shaft.

5th Gear Synchronizing
1 - Springs for Locking Pieces
2 - Locking Collar with 3 Notches -arrow A- for Locking Pieces

-4-

3 - Synchronizer Hub
4 - Locking pieces - installed position: the extension -arrow B-

faces toward the pointed teeth of the locking collar -2-

5th Gear Locking Collar/Synchronizer Hub Assembly
– Slide the locking collar over the synchronizer hub.
The pointed teeth -A- and the shoulder -B- on the synchronizer

hub face in the same direction. Recesses for locking pieces in

locking collar and synchronizer hub must line up. (Refer to

⇒ Fig. ““5th Gear Synchronizing”“ , page 147

 ).

– Insert locking pieces (installed position: Refer to

⇒ Fig. ““5th Gear Synchronizing”“ , page 147

 ).

– Install the springs offset by 120° under the tabs -C-.
Installed Position of the Springs with Locking Pieces that are Not

Hollow Inside:
The angled end of the spring must be positioned in front of the

locking pieces -arrows-.
Installed Position of the Springs with Locking Pieces that are Hol‐

low Inside:
– The angled end of the spring must engage into the hollow

locking piece (⇒ illustration following the next one).