Volkswagen Golf / Golf GTI / Golf Variant. Manual - part 595

Installation of Offset Springs -A-
These springs are installed on both sides.
– Springs are only installed in conjunction with hollow locking

pieces.

– Insert locking pieces (installed position: Refer to

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

 ).

Spring installed position:
– Install the spring offset by 120°.
– Angled end -A- of spring must engage into the hollow locking

piece.

The spring must be located below the tab -B- of the locking pieces.
The offset end always faces away from the synchronizer hub in

direction of -arrow-.

1.3

Input Shaft, Adjusting

Special tools and workshop equipment required
♦ Dial Gauge Holder - VW387-
♦ Measuring Set - Magnetic Plate - 50mm - VW385/17-
♦ Press Piece - Multiple Use - VW510-
♦ Press Piece - VW447i-
♦ Press Piece - Rod - VW407-
♦ Torque Wrench 1331 5-50Nm - VAG1331-
♦ Dial Gauge
A new input shaft adjustment is required when the following com‐

ponents have been replaced:
♦ Transmission Housing
♦ Clutch Housing
♦ Input Shaft
♦ 4th Gear Wheel
or the
♦ Tapered roller bearing
Adjustment overview. Refer to

⇒ “3 Adjustment Overview”, page 198

 .

Requirement:
• Remove any sealant remaining on the sealing surfaces on the

clutch and transmission housings.

– Press the taper roller bearing outer race into the clutch housing

all the way.

– Install the outer race/tapered roller bearing all the way into the

transmission housing without the adjusting shim.

– Install the input shaft into the clutch housing and mount the

transmission housing. Install the hex bolts. Refer to

⇒ “5.4 Overview - Transmission Housing and Selector Mech‐

anism”, page 95

 .

– Install the measuring device and the dial gauge in the clutch

housing.

– Rotate the input shaft before measuring so the tapered roller

bearing settles. Set the dial gauge with 1 mm pretension to “0”.

Note

Repeat this process each time a measurement is taken otherwise

the dial gauge will not go back to its start setting.

– Press the input shaft toward the dial gauge direction of

-arrow-.

– Read and make note of the play on the dial gauge (example:

1.21 mm).

Note

The dial gauge does not return to its starting position.

Determining the Shim
Example:

Bearing Clearance Measured

Value

Adjustment Shim Thickness

According To the Table

1.21 mm

1.175 mm

Shim Table

Bearing Play

Shim

Measured Value (mm)

Thickness (mm)

0.671 to 0.699

0.700 to 0.724

0.725 to 0.749

0.650

0.675

0.700

0.750 to 0.774

0.775 to 0.799

0.800 to 0.824

0.725

0.750

0.775

0.825 to 0.849

0.850 to 0.874

0.875 to 0.899

0.800

0.825

0.850

0.900 to 0.924

0.925 to 0.949

0.950 to 0.974

0.875

0.900

0.925

0.975 to 0.999

1.000 to 1.024

1.025 to 1.049

0.950

0.975

1.000

1.050 to 1.074

1.075 to 1.099

1.100 to 1.124

1.025

1.050

1.075

1.125 to 1.149

1.150 to 1.174

1.175 to 1.199

1.100

1.125

1.150

1.200 to 1.224

1.225 to 1.249

1.250 to 1.274

1.175

1.200

1.225

1.275 to 1.229

1.300 to 1.324

1.325 to 1.349

1.250

1.275

1.300

1.350 to 1.374

1.375 to 1.399

1.400 to 1.424

1.325

1.350

1.375

1.425 to 1.449

1.450 to 1.474

1.475 to 1.499

1.400

1.425

1.450

1.500 to 1.524

1.525 to 1.549

1.550 to 1.574

1.475

1.500

1.525

1.575 to 1.599

1.600 to 1.624

1.625 to 1.649

1.550

1.575

1.600

1.650 to 1.674

1.675 to 1.699

1.700 to 1.724

1.625

1.650

1.675

Note

Allocate the shims. Refer to the Parts Catalog.

– Remove the drive axle and pry out the outer race/tapered roller

bearing using the Press Piece - VW447i- from the transmis‐

sion housing.

– Install the shim with the correct thickness, thickest shim first.
If the measured shim thickness is larger than those listed in the

Table, then install two shims that add up to the necessary thick‐

ness.