2003-2008 Volkswagen Golf 4 Door Gears,Shafts User Manual
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Gears,Shafts for Your Volkswagen Golf 4 Door Fifth Generation (2003-2008)

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤  
6-Speed Manual Transmission 02Q - Edition 05.2013  
35 – Gears, Shafts  
1
Input Shaft  
⇒ “1.1 Overview - Input Shaft”, page 310  
⇒ “1.2 Input Shaft, Disassembling and Assembling”, page 311  
1.1  
Overview - Input Shaft  
Note  
♦ Secure the transmission on the assembly stand. Refer to  
⇒ “7 Transmission, Securing in Engine/Transmission Holder”, page 191 .  
♦ Warm the toothed gear to approximately 100 °C (212 °F) using Inductive Heater - VAS6414- . Wear pro‐  
tective gloves.  
♦ Install all input shaft bearings with transmission fluid.  
♦ Replace grooved ball bearing -item 6- ⇒ Item 6 (page 311) after removing.  
1 - Circlip  
❑ For the grooved ball  
bearing/input shaft  
-item 6-  
⇒ Item 6 (page 311) .  
❑ Removing and instal‐  
ling. Refer to  
⇒ “11.8 Assembly Se‐  
quence, Transmission  
without a Securing Ring  
A for the Metal Cover for  
the Input Shaft”,  
page 235 .  
2 - Washer  
❑ Outer circumference =  
78.6 mm  
❑ Only insert with the  
changed transmission  
housing (from transmis‐  
sion production date  
04/10/2006 through ap‐  
proximately  
01/20/2008). Refer to  
⇒ “1.2.1 Grooved Ball  
Bearing Changes”,  
page 315 .  
❑ Refer to the Parts Cata‐  
log.  
3 - Transmission Housing  
❑ Adapted in the grooved  
ball bearing seat area  
-item 6-  
⇒ Item 6 (page 311)  
and washers -item 2-  
⇒ Item 2 (page 310) and  
-item 4-  
⇒ Item 4 (page 311)  
from transmission build  
310  
Rep. Gr.35 - Gears, Shafts  
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤  
6-Speed Manual Transmission 02Q - Edition 05.2013  
date 4/10/06 through approximately 1/20/08. Refer to  
⇒ “1.2.1 Grooved Ball Bearing Changes”, page 315 .  
❑ Flattened areas on grooved ball bearing and bearing seat approximately from transmission build date  
1/21/2008. Refer to ⇒ “1.2.1 Grooved Ball Bearing Changes”, page 315 .  
❑ Refer to the Parts Catalog.  
4 - Washer  
❑ Outer diameter = 85 mm  
❑ Only insert with the changed transmission housing (from transmission production date 04/10/2006  
through approximately 01/20/2008). Refer to ⇒ “1.2.1 Grooved Ball Bearing Changes”, page 315 .  
❑ Refer to the Parts Catalog.  
5 - Circlip  
❑ Select when replacing the grooved ball bearing -item 6- ⇒ Item 6 (page 311) and the input shaft  
-item 8- ⇒ Item 8 (page 311) . Refer to  
⇒ Fig. ““Determining the Grooved Ball Bearing Locking Ring on the Input Shaft”“ , page 314  
6 - Grooved Ball Bearing  
❑ Replace after removing  
❑ Removing. Refer to ⇒ Fig. ““Removing the Grooved Ball Bearing”“ , page 312 .  
❑ Installation position. Refer to  
⇒ Fig. ““Grooved Ball Bearing Installation Location and Installing the Grooved Ball Bearing”“ ,  
page 313 .  
❑ Installing. Refer to  
⇒ Fig. ““Grooved Ball Bearing Installation Location and Installing the Grooved Ball Bearing”“ ,  
page 313 .  
❑ Flattened areas on grooved ball bearing and bearing seat approximately from transmission build date  
1/21/2008. Refer to  
⇒ Fig. ““Flattened Areas on the Grooved Ball Bearing -A- and Bearing Seat -B- in the Transmission  
Housing Approximately from Transmission Build Date 2/21/08.”“ , page 316 .  
7 - 5th Gear Wheel  
❑ Available as a replacement part together with the input shaft  
❑ Removing. Refer to ⇒ Fig. ““Removing the 5th Gear Wheel”“ , page 312 .  
❑ Installed position: the surrounding groove -arrow- points toward grooved ball bearing -item 6-  
⇒ Item 6 (page 311)  
❑ Installing. Refer to ⇒ Fig. ““Warming the 5th Gear Wheel and Installing”“ , page 313 .  
8 - Input Shaft  
❑ With 3rd/4th and 6th gear wheel  
9 - Cylindrical Roller Bearing  
❑ With circlip  
❑ Removing. Refer to  
⇒ Fig. ““Removing the Cylindrical Roller Bearing from the Clutch Housing”“ , page 314 .  
❑ Installing. Refer to ⇒ Fig. ““Pressing Cylindrical Roller Bearing Into Clutch Housing.”“ , page 314 .  
❑ Installed position: the circlip in bearing points to input shaft  
10 - Clutch Housing  
1.2  
Input Shaft, Disassembling and Assem‐  
bling  
Special tools and workshop equipment required  
♦ Press Plate - VW401-  
♦ Press Plate - VW402-  
♦ Press Piece - Rod - VW407-  
♦ Press Piece - Rod - VW408A-  
1. Input Shaft  
311  
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤  
6-Speed Manual Transmission 02Q - Edition 05.2013  
♦ Press Piece - Rod - VW412-  
♦ Press Piece - Multiple Use - VW454-  
♦ Press Piece - Bushing - 50mm Diameter - VW432-  
♦ Locking Pin Driver - 30-505-  
♦ Bearing Installer - Multiple Use - 32-111-  
♦ Inductive Heater - VAS6414-  
♦ Puller - Kukko Internal - 28-37mm - 21/5-  
♦ Puller - Kukko Quick Action Separating Tool - 22-115mm -  
17/2-  
♦ Puller - Kukko Counterstay - 22/2-  
♦ Feeler Gauge  
Input Shaft, Disassembling  
– Remove the grooved ball bearing locking ring.  
Removing the Grooved Ball Bearing  
– Mount the Separating Tool -A- into the groove in the ball bear‐  
ing for the locking ring.  
A - 22 to 115 mm Separating Tool , for example Puller - Kukko  
Quick Action Separating Tool - 22-115mm - 17/2-  
– The grooved ball bearing and 5th gear wheel can also be re‐  
moved together. To do this, place the Separating Tool -A- as  
shown in the following illustration under the 5th gear wheel.  
Removing the 5th Gear Wheel  
A - 22 to 115 mm Separating Tool , for example Puller - Kukko  
Quick Action Separating Tool - 22-115mm - 17/2-  
Input Shaft, Assembling  
312  
Rep. Gr.35 - Gears, Shafts  
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤  
6-Speed Manual Transmission 02Q - Edition 05.2013  
Warming the 5th Gear Wheel and Installing  
The groove -arrow- on the gear wheel must face up.  
•
Grooved Ball Bearing Installation Location and Installing the  
Grooved Ball Bearing  
•
Grooved ball bearing installation location: the groove for the  
circlip faces up -arrow A-. The collar -arrow B- must face the  
5th gear wheel.  
– Install the grooved ball bearing securing ring on the input shaft  
(⇒ next figure).  
1. Input Shaft  
313  
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤  
6-Speed Manual Transmission 02Q - Edition 05.2013  
Determining the Grooved Ball Bearing Locking Ring on the Input  
Shaft  
– Insert a 1.86 mm locking ring -A- into groove in the input shaft  
and press it upward.  
– Measure the gap between the grooved ball bearing -B- and  
the installed locking ring -A- with a feeler gauge -C-.  
– Remove the locking ring used for the measurement.  
– Select the locking ring according to the Table.  
Note  
Allocate the correct locking rings. Refer to the Parts Catalog.  
The following locking rings are available:  
Measured Value  
(mm)  
Circlip Thickness  
(mm)  
Axial Play (mm)  
0.01 to 0.05  
0.05 to 0.07  
0.07 to 0.10  
0.10 to 0.13  
0.13 to 0.16  
1.86  
1.89  
1.92  
1.95  
1.98  
0.01 to 0.05  
0.01 to 0.05  
0.01 to 0.05  
0.01 to 0.05  
0.01 to 0.05  
Removing the Cylindrical Roller Bearing from the Clutch Housing  
– Compress the cylindrical roller bearing locking ring -arrow-  
with pliers -C- and remove it.  
A - Counter Support , for example, Puller - Kukko Counterstay -  
22/2-  
B - Internal Puller 30 to 37 mm , for example, Puller - Kukko In‐  
ternal - 28-37mm - 21/5-  
Pressing Cylindrical Roller Bearing Into Clutch Housing.  
– Compress the cylindrical roller bearing locking ring -arrow-  
with pliers -C- and install it.  
– Remove the pliers before the cylindrical roller bearing gets into  
its installed position. The locking ring must lock into the groove  
on the clutch housing.  
314  
Rep. Gr.35 - Gears, Shafts  
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤  
6-Speed Manual Transmission 02Q - Edition 05.2013  
1.2.1  
Grooved Ball Bearing Changes  
From Transmission Build Date 04.10.2006 through Approximate‐  
ly 01/21/2008  
A washer above and below the grooved ball bearing seat  
-item 6- ⇒ Item 6 (page 311) .  
Above the Bearing Seat  
Bearing Seat  
Washer Above the  
Bearing Seat  
Through transmis‐ Dimension “a” 10  
no  
sion build date  
4/9/06  
mm  
From transmission Dimension “a” 10.7  
yes  
build date 4/10/06  
through approxi‐  
mately 1/20/08  
mm  
approximately from Below the bearing  
no  
transmission build  
date 1/21/2008  
seat  
flattened area for  
the grooved ball  
bearing  
Below the Bearing Seat:  
Slightly Deeper than from Transmission Build Date 10/04/2006  
through Approximately 01/20/2008  
The grooved ball bearing seat -arrow- is slightly deeper to hold  
the washer under the bearing -item 6- ⇒ Item 6 (page 311) .  
Below the Bearing Seat  
Washer Below the  
Bearing Seat  
Through transmis‐  
Not deeper  
no  
sion build date  
04/09/2006  
From transmission  
build date 4/10/06  
through approxi‐  
mately 1/20/08  
Slightly deeper.  
yes  
approximately from Flattened area -B-  
no  
transmission build for the grooved ball  
date 1/21/2008  
bearing -A-  
1. Input Shaft  
315  
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤  
6-Speed Manual Transmission 02Q - Edition 05.2013  
Flattened Areas on the Grooved Ball Bearing -A- and Bearing  
Seat -B- in the Transmission Housing Approximately from Trans‐  
mission Build Date 2/21/08.  
•
If the flattened areas are present, do not insert any washers  
above and below the grooved ball bearing.  
316  
Rep. Gr.35 - Gears, Shafts  
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤  
6-Speed Manual Transmission 02Q - Edition 05.2013  
2
1st through 4th Gear Output Shaft  
⇒ “2.1 Overview - Output Shaft, 1st to 4th Gears”, page 317  
⇒ “2.2 Output Shaft, 1st to 4th Gears, Disassembling and As‐  
sembling”, page 321  
⇒ “2.3 Output Shaft 1st through 4th Gear, Adjusting”, page 340  
2.1  
Overview - Output Shaft, 1st to 4th Gears  
Output Shaft, 1st to 4th Gears, Disassembling and Assembling.  
Refer to  
⇒ “2.2 Output Shaft, 1st to 4th Gears, Disassembling and As‐  
sembling”, page 321 .  
Note  
♦ Secure the transmission on the assembly stand. Refer to  
⇒ “7 Transmission, Securing in Engine/Transmission Holder”, page 191 .  
♦ To install, warm the inner races/tapered roller bearing and synchronizer hub to approximately 100 °C (212  
°F) using Inductive Heater - VAS6414- . Wear protective gloves.  
♦ Adjust the output shaft if it or the tapered roller bearing are being replaced. Refer to  
⇒ “2.3 Output Shaft 1st through 4th Gear, Adjusting”, page 340 .  
♦ Replace both tapered roller bearings together.  
2. 1st through 4th Gear Output Shaft  
317  
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤  
6-Speed Manual Transmission 02Q - Edition 05.2013  
1 - Clutch Housing  
2 - Oil Deflector Ring  
3 - Dished Washer  
❑ Removing. Refer to  
⇒ Fig. ““Removing the  
Dished Washer -A- from  
the Output Shaft”“ ,  
page 322 .  
❑ Installing. Refer to  
⇒ Fig. ““Installing the  
Dished Washer into the  
Output Shaft”“ ,  
page 322 .  
4 - Outer Race/Tapered Roller  
Bearing  
❑ Removing. Refer to  
⇒ Fig. ““Removing the  
Outer Race / Tapered  
Roller Bearing from the  
Clutch Housing”“ ,  
page 322 .  
❑ Installing. Refer to  
⇒ Fig. ““Installing the  
Outer Race/Tapered  
Roller Bearing in the  
Clutch Housing”“ ,  
page 323 .  
5 - Inner Race / Tapered Roller  
Bearing  
❑ Removing. Refer to  
⇒ Fig. ““Removing the  
Inner Race/Tapered  
Roller Bearing on the  
Side of the Clutch Hous‐  
ing”“ , page 322 .  
❑ Installing. Refer to  
⇒ Fig. ““Installing the Inner Race/Tapered Roller Bearing on the Side of the Clutch Housing”“ ,  
page 322 .  
6 - Output Shaft  
❑ For 1st through 4th gear  
❑ Adjusting. Refer to ⇒ “2.3 Output Shaft 1st through 4th Gear, Adjusting”, page 340 .  
7 - Needle Bearing  
❑ For 2nd gear  
8 - 2nd Gear Wheel  
❑ 1st/2nd gear synchronizing, from transmission build date 10/26/2009. Refer to  
⇒ “2.2.1 Differentiating 1st/2nd Gear Synchronization, Differentiating 3rd Gear Synchronization”,  
page 325 .  
9 - Synchronizer Ring (Inner Race for 2nd Gear)  
❑ 1st/2nd gear synchronizing, from transmission build date 10/26/2009. Refer to  
⇒ “2.2.1 Differentiating 1st/2nd Gear Synchronization, Differentiating 3rd Gear Synchronization”,  
page 325 .  
10 - 2nd Gear Outer Race  
❑ 1st/2nd gear synchronizing, from transmission build date 10/26/2009. Refer to  
⇒ “2.2.1 Differentiating 1st/2nd Gear Synchronization, Differentiating 3rd Gear Synchronization”,  
page 325 .  
   
318  
Rep. Gr.35 - Gears, Shafts  
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤  
6-Speed Manual Transmission 02Q - Edition 05.2013  
11 - 2nd Gear Synchronizer Ring  
❑ 1st/2nd gear synchronizing, from transmission build date 10/26/2009. Refer to  
⇒ “2.2.1 Differentiating 1st/2nd Gear Synchronization, Differentiating 3rd Gear Synchronization”,  
page 325 .  
12 - Locking Collar with Synchronizer Hub for 1st and 2nd Gears  
❑ After removing circlip -item 13- ⇒ Item 13 (page 319) , remove the 2nd gear wheel. Refer to  
⇒ Fig. ““Removing the Locking Collar and the Synchronizer Hub for 1st and 2nd Gear”“ , page 324  
❑ Disassembling. Refer to  
⇒ Fig. ““Disassembling and Assembling the Locking Collar and the Synchronizer Hub for 1st, 2nd, 3rd  
and 4th Gears”“ , page 327 .  
❑ Assembling locking collar/synchronizer hub. Refer to  
⇒ Fig. ““Disassembling and Assembling the Locking Collar and the Synchronizer Hub for 1st, 2nd, 3rd  
and 4th Gears”“ , page 327  
❑ 1st/2nd gear synchronizing, from transmission build date 10/26/2009. Refer to  
⇒ “2.2.1 Differentiating 1st/2nd Gear Synchronization, Differentiating 3rd Gear Synchronization”,  
page 325 .  
13 - Circlip  
14 - 1st Gear Synchronizer Ring  
❑ 1st/2nd gear synchronizing, from transmission build date 10/26/2009. Refer to  
⇒ “2.2.1 Differentiating 1st/2nd Gear Synchronization, Differentiating 3rd Gear Synchronization”,  
page 325 .  
15 - 1st Gear Outer Race  
❑ 1st/2nd gear synchronizing, from transmission build date 10/26/2009. Refer to  
⇒ “2.2.1 Differentiating 1st/2nd Gear Synchronization, Differentiating 3rd Gear Synchronization”,  
page 325 .  
16 - Synchronizer Ring for 1st Gear  
❑ 1st/2nd gear synchronizing, from transmission build date 10/26/2009. Refer to  
⇒ “2.2.1 Differentiating 1st/2nd Gear Synchronization, Differentiating 3rd Gear Synchronization”,  
page 325 .  
17 - Needle Bearing  
❑ For 1st gear  
18 - 1st Gear Wheel  
❑ 1st/2nd gear synchronizing, from transmission build date 10/26/2009. Refer to  
⇒ “2.2.1 Differentiating 1st/2nd Gear Synchronization, Differentiating 3rd Gear Synchronization”,  
page 325 .  
19 - Thrust Washer  
❑ For 1st and 4th gears  
❑ Quantity: 2  
❑ The tab on the thrust washer must fit into the hole in the output shaft.  
20 - Washer  
❑ Holds the thrust washers -item 19- ⇒ Item 19 (page 319) in place on the output shaft  
21 - Needle Bearing  
❑ For 4th gear  
22 - 4th Gear Wheel  
23 - 4th Gear Synchronizer Ring  
❑ Brass or steel  
❑ Checking for wear. Refer to ⇒ Fig. ““Checking the 4th Gear Synchronizer Ring for Wear”“ , page 329  
24 - Locking Collar with Synchronizer Hub for 3rd and 4th Gears  
❑ After removing locking ring -item 25- ⇒ Item 25 (page 320) , remove the 4th gear wheel. Refer to  
⇒ Fig. ““Removing the 3rd and 4th Gear Synchronizer Hub/Locking Collar with the 4th gear Wheel”“ ,  
page 324  
2. 1st through 4th Gear Output Shaft  
319  
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤  
6-Speed Manual Transmission 02Q - Edition 05.2013  
❑ Disassembling. Refer to  
⇒ Fig. ““Disassembling and Assembling the Locking Collar and the Synchronizer Hub for 1st, 2nd, 3rd  
and 4th Gears”“ , page 327 .  
❑ Installed position: locking collar/synchronizer hub. Refer to  
⇒ Fig. ““Installed Position: Locking Collar/Synchronizer Hub for 3rd and 4th Gears”“ , page 329  
❑ Assembling the locking collar/synchronizer hub. Refer to  
⇒ Fig. ““Disassembling and Assembling the Locking Collar and the Synchronizer Hub for 1st, 2nd, 3rd  
and 4th Gears”“ , page 327 and  
⇒ Fig. ““Assembling the Locking Collar/Synchronizer Hub for 1st, 2nd, 3rd and 4th Gears”“ , page 327  
❑ Installing. Refer to  
⇒ Fig. ““Installing the Synchronizer Hub with Locking Collar for 3rd and 4th Gears”“ , page 329 .  
25 - Circlip  
26 - 3rd Gear Synchronizer Ring  
❑ Modified 3rd gear synchronizing from transmission manufacture date 5/25/2000, differentiation. Refer to  
⇒ “2.2.1 Differentiating 1st/2nd Gear Synchronization, Differentiating 3rd Gear Synchronization”,  
page 325 .  
27 - 3rd Gear Outer Race  
❑ Modified 3rd gear synchronizing from transmission manufacture date 5/25/2000, differentiation. Refer to  
⇒ “2.2.1 Differentiating 1st/2nd Gear Synchronization, Differentiating 3rd Gear Synchronization”,  
page 325 .  
28 - Synchronizer Ring for 3rd Gear  
❑ Modified 3rd gear synchronizing from transmission manufacture date 5/25/2000, differentiation. Refer to  
⇒ “2.2.1 Differentiating 1st/2nd Gear Synchronization, Differentiating 3rd Gear Synchronization”,  
page 325 .  
29 - Needle Bearing  
❑ For 3rd gear  
30 - 3rd Gear Wheel  
❑ Modified 3rd gear synchronizing from transmission manufacture date 5/25/2000, differentiation. Refer to  
⇒ “2.2.1 Differentiating 1st/2nd Gear Synchronization, Differentiating 3rd Gear Synchronization”,  
page 325 .  
31 - Inner Race / Tapered Roller Bearing  
❑ Removing. Refer to  
⇒ Fig. ““Remove the Inner Race/Tapered Roller Bearing on the Side of the Transmission Housing”“ ,  
page 323  
❑ Installing. Refer to  
⇒ Fig. ““Installing the Inner Race/Tapered Roller Bearing on the Side of the Transmission Housing”“ ,  
page 323 .  
32 - Circlip  
❑ Select the correct one when replacing the tapered roller bearing -item 31- ⇒ Item 31 (page 320) and the  
output shaft -item 6- ⇒ Item 6 (page 318) . Refer to ⇒ Fig. ““Selecting The Locking Ring”“ , page 323  
33 - Outer Race/Tapered Roller Bearing  
❑ Removing. Refer to  
⇒ Fig. ““Removing the Outer Race/Tapered Roller Bearing from the Transmission Housing”“ ,  
page 324 .  
❑ Installing. Refer to  
⇒ Fig. ““Installing the Outer Race/Tapered Roller Bearing into the Transmission Housing.”“ ,  
page 324 .  
34 - Shim  
❑ Selecting thickness. Refer to ⇒ “2.3 Output Shaft 1st through 4th Gear, Adjusting”, page 340 .  
35 - Transmission Housing  
320  
Rep. Gr.35 - Gears, Shafts  
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤  
6-Speed Manual Transmission 02Q - Edition 05.2013  
2.2  
Output Shaft, 1st to 4th Gears, Disas‐  
sembling and Assembling  
⇒ “2.2.1 Differentiating 1st/2nd Gear Synchronization, Differenti‐  
ating 3rd Gear Synchronization”, page 325 .  
⇒ “2.2.1 Differentiating 1st/2nd Gear Synchronization, Differenti‐  
ating 3rd Gear Synchronization”, page 325  
⇒ “2.2.3 Output Shaft for 1st through 4th Gears, Assembling -  
from Transmission Manufacture Date 10/26/09 through Trans‐  
mission Manufacture Date 5/24/00”, page 330  
⇒ “2.2.4 Output Shaft for 1st through 4th gears, Assembling - from  
Transmission Manufacture Date 5/25/00”, page 335  
Special tools and workshop equipment required  
♦ Press Plate - VW401-  
♦ Press Plate - VW402-  
♦ Press Piece - Rod - VW407-  
♦ Press Piece - Rod - VW408A-  
♦ Press Piece - Multiple Use - VW412-  
♦ Press Piece - 60mm - VW415A-  
♦ Holding Plate - VW309A-  
♦ Holding Fixture - VW313-  
♦ Transmission Support - VW353-  
♦ Press Piece - Multiple Use - VW431-  
♦ Press Piece - Multiple Use - VW433-  
♦ Press Piece - Multiple Use - VW454-  
♦ Press Piece - Multiple Use - VW512-  
♦ Press Piece - 42mm - VW516-  
♦ Press Piece - Multiple Use - VW519-  
♦ Slide Hammer Set - Hammer - VW771-  
♦ Crankshaft Holding Fixture - VW801-  
♦ Press Piece - Multiple Use - 40-105-  
♦ Bearing Installer - Multiple Use - 40-20-  
♦ Bearing Installer - Differential Bearing - 40-21-  
♦ Slide Hammer - Press Plate - 2050-  
♦ Holding Fixture - Spacers - VW540/1B-  
♦ Puller - Taper Roller Bearing - VAG1582-  
♦ Puller - Taper Roller Bearing - Adapter 7 - VAG1582/7-  
♦ Inductive Heater - VAS6414-  
♦ Puller - Kukko Internal - 46-56mm - 21/7-  
♦ Puller - Kukko Internal - 56-70mm - 21/8-  
♦ Puller - Kukko Puller - 60-200mm Width, 250mm Length -  
18/2-  
♦ Puller - Kukko Quick Action Separating Tool - 22-115mm -  
17/2-  
♦ Puller - Kukko Counterstay - 22/2-  
2. 1st through 4th Gear Output Shaft  
321  
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤  
6-Speed Manual Transmission 02Q - Edition 05.2013  
Removing the Dished Washer -A- from the Output Shaft  
Installing the Dished Washer into the Output Shaft  
Dimension “a” = 2 mm  
Removing the Inner Race/Tapered Roller Bearing on the Side of  
the Clutch Housing  
A - 22 to 115 mm Separating Tool , for example Puller - Kukko  
Quick Action Separating Tool - 22-115mm - 17/2-  
Installing the Inner Race/Tapered Roller Bearing on the Side of  
the Clutch Housing  
Removing the Outer Race / Tapered Roller Bearing from the  
Clutch Housing  
A - Counter Support , for example, Puller - Kukko Counterstay -  
22/2-  
B - Internal Puller 56 to 70 mm , for example, Puller - Kukko In‐  
ternal - 56-70mm - 21/8-  
322  
Rep. Gr.35 - Gears, Shafts  
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤  
6-Speed Manual Transmission 02Q - Edition 05.2013  
Installing the Outer Race/Tapered Roller Bearing in the Clutch  
Housing  
– Support the clutch housing with the Bearing Installer - Multiple  
Use - 40-20- directly under the bearing mount.  
Remove the Inner Race/Tapered Roller Bearing on the Side of  
the Transmission Housing  
Before installing the Tapered Roller Bearing Puller :  
– Remove the inner race/tapered roller bearing locking ring on  
the side facing the transmission housing.  
– Place the Press Piece - Multiple Use - VW431- in the output  
shaft and place the Press Piece - Multiple Use - 40-105- on  
top.  
Installing the Inner Race/Tapered Roller Bearing on the Side of  
the Transmission Housing  
– Choose the correct locking ring. Refer to  
⇒ Fig. ““Selecting The Locking Ring”“ , page 323 and install.  
Selecting The Locking Ring  
– Choose and install the thickest locking ring that will fit.  
Note  
Allocate the circlips. Refer to the Parts Catalog.  
The following locking rings are available:  
Thickness (mm)  
1.79  
1.92  
1.83  
1.95  
1.86  
1.98  
1.89  
2. 1st through 4th Gear Output Shaft  
323  
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6-Speed Manual Transmission 02Q - Edition 05.2013  
Removing the Outer Race/Tapered Roller Bearing from the  
Transmission Housing  
A - Counter Support , for example, Puller - Kukko Counterstay -  
22/2-  
B - Internal Puller 46 to 58 mm , for example, Puller - Kukko In‐  
ternal - 46-56mm - 21/7-  
Installing the Outer Race/Tapered Roller Bearing into the Trans‐  
mission Housing.  
– Install the adjusting shim under the outer race.  
– Support the transmission housing under the bearing mount  
using the Slide Hammer - Press Plate - 2050- .  
Disassembling the Output Shaft  
Note  
Remove the inner race/tapered roller bearing on the side of the  
transmission housing. Refer to  
⇒ Fig. ““Remove the Inner Race/Tapered Roller Bearing on the  
Side of the Transmission Housing”“ , page 323 .  
Removing the 3rd and 4th Gear Synchronizer Hub/Locking Collar  
with the 4th gear Wheel  
– Remove the locking ring beforehand.  
A - Puller , for example, Puller - Kukko Puller - 60-200mm Width,  
250mm Length - 18/2-  
B - 22 to 115 mm Separating Tool , for example Puller - Kukko  
Quick Action Separating Tool - 22-115mm - 17/2-  
– Remove the thrust washers for 1st and 4th gears -item 19-  
⇒ Item 19 (page 319) and -item 20- ⇒ Item 20 (page 319) .  
– Remove the 1st gear wheel -item 18- ⇒ Item 18 (page 319) .  
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.  
324  
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6-Speed Manual Transmission 02Q - Edition 05.2013  
2.2.1  
Differentiating 1st/2nd Gear Synchroni‐  
zation, Differentiating 3rd Gear Syn‐  
chronization  
1st/2nd Gear Synchronization through Transmission Manufac‐  
ture Date 10/25/2009 and 3rd Gear Synchronization through  
Transmission Manufacture date 5/24/2000  
The Synchronizer Ring -C- Transmission  
and Inner Ring -A- are Made Manufacture  
Assembling  
the Output  
Shaft, 1st to  
4th Gears  
of Brass.  
The Outer Ring -B- is Made of  
Steel.  
Date  
1st/2nd gear synchronization  
Through  
10/25/09  
Refer to  
⇒ “2.2.2 Out‐  
put Shaft for  
1st through 4th  
Gears, Assem‐  
bling, through  
Transmission  
Production  
Date  
10/25/2009”,  
page 326  
3rd gear synchronization  
Through  
Refer to  
5/24/2000  
⇒ “2.2.3 Out‐  
put Shaft for  
1st through 4th  
Gears, Assem‐  
bling - from  
Transmission  
Manufacture  
Date 10/26/09  
through Trans‐  
mission Manu‐  
facture Date  
5/24/00”,  
page 330  
2. 1st through 4th Gear Output Shaft  
325  
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6-Speed Manual Transmission 02Q - Edition 05.2013  
1st/2nd Gear Synchronization from Transmission Manufacture  
Date 10/26/2009 and 3rd Gear Synchronization from Transmis‐  
sion Manufacture Date 5/25/2000  
The Synchronizer Ring -C-, Transmission  
Assembling  
the Output  
Shaft, 1st to  
4th Gears  
the Outer Ring -B- and  
the Inner Ring -A- are Made of  
Steel.  
Manufacture  
Date  
1st/2nd gear synchronization  
From  
Refer to  
10/26/2009  
⇒ “2.2.3 Out‐  
put Shaft for  
1st through 4th  
Gears, Assem‐  
bling - from  
Transmission  
Manufacture  
Date 10/26/09  
through Trans‐  
mission Manu‐  
facture Date  
5/24/00”,  
page 330 or  
⇒ “2.2.4 Out‐  
put Shaft for  
1st through 4th  
gears, Assem‐  
bling - from  
Transmission  
Manufacture  
Date 5/25/00”,  
page 335 .  
3rd gear synchronization  
From  
Refer to  
5/25/2000  
⇒ “2.2.4 Out‐  
put Shaft for  
1st through 4th  
gears, Assem‐  
bling - from  
Transmission  
Manufacture  
Date 5/25/00”,  
page 335  
2.2.2  
Output Shaft for 1st through 4th Gears,  
Assembling, through Transmission Pro‐  
duction Date 10/25/2009  
Checking the Inner Race for 1st, 2nd and 3rd Gear for Wear  
– Check the tabs on the inner race for scoring.  
– Install the inner race onto taper of selector gear and then  
measure gap dimension -a- with a feeler gauge.  
Gap Dimension Installation Dimen‐  
Wear Limit  
-a-  
sion  
1st 2nd and 3rd  
gear  
0.75 to 1.25 mm  
0.3 mm  
326  
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6-Speed Manual Transmission 02Q - Edition 05.2013  
Checking the 1st, 2nd and 3rd Gear Synchronizer Rings for Wear  
– Install the synchronizer ring, outer race and inner race onto  
taper of selector gear and then measure the gap dimension  
-a- with a feeler gauge.  
Gap Dimension Installation Dimen‐  
Wear Limit  
-a-  
sion  
1st 2nd and 3rd  
gear  
1.2 to 1.8 mm  
0.5 mm  
– Install the 2nd gear wheel with the needle bearing.  
Installed Position: 2nd Gear Outer Race, Inner Race and Syn‐  
chronizer Ring  
– Check the tabs -arrows 1 and arrows 2- for scoring.  
– Replace the inner race, the outer race and the synchronizer  
ring if they have grooves or scoring.  
– Install the inner race -A- on the 2nd gear wheel.  
The angled tabs -arrows 1- face the outer race -B-.  
– Install the outer race -B-.  
The tabs -arrows 2- must lock into the retainers -arrows 3- in the  
gear wheel.  
– Install the synchronizer ring -C-.  
The retainers -arrows 4- lock in the tabs -arrows 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 the 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.  
2. 1st through 4th Gear Output Shaft  
327  
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6-Speed Manual Transmission 02Q - Edition 05.2013  
Installation Position of 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 the 1st gear.  
Installing the Locking Collar/Synchronizer Hub for 1st and 2nd  
Gears.  
Turn the synchronizer ring so that the grooves line up with the  
locking pieces.  
– Install the locking ring.  
Install the 1st gear synchronizer ring  
Installation Position of 1st Gear Outer Race  
The tabs -arrows- face the synchronizer hub/locking collar -A-.  
Installed Position: Synchronizer Ring -A- (1st gear inner race)  
The tabs -arrows 1- engage into the holes -arrows 2- inside the  
synchronizer ring -B-.  
328  
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6-Speed Manual Transmission 02Q - Edition 05.2013  
Installing 1st Gear Wheel with Needle Bearing  
The higher collar -A- faces 2nd gear -B-. The notches in the collar  
-arrow- lock into the tabs on the outer race. Refer to  
⇒ Fig. ““Installation Position of 1st Gear Outer Race”“ ,  
page 328 .  
– Install the thrust washers for 1st and 4th gears -item 19-  
⇒ Item 19 (page 319) and -item 20- ⇒ Item 20 (page 319) .  
– Install the 4th gear wheel with needle bearing.  
Checking the 4th Gear Synchronizer Ring for Wear  
– Press synchronizer ring onto taper of the gear wheel and  
measure gap dimension -a- using a feeler gauge.  
Gap dimension Installation Dimen‐  
Wear Limit  
-a-  
sion  
4th Gear  
1.0 to 1.7 mm  
0.5 mm  
Installed Position: Locking Collar/Synchronizer Hub for 3rd and  
4th Gears  
The wider collar on the synchronizer hub -arrow- faces the 3rd  
gear.  
Installing the Synchronizer Hub with Locking Collar for 3rd and  
4th Gears  
– Turn the synchronizer ring so that the grooves line up with the  
locking pieces.  
– Install the locking ring.  
– Install the 3rd gear synchronizer ring on the synchronizer hub/  
locking collar for 3rd and 4th gears.  
2. 1st through 4th Gear Output Shaft  
329  
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6-Speed Manual Transmission 02Q - Edition 05.2013  
Installed Position: 3rd Gear Outer Race  
The tabs -arrows- face the synchronizer hub/locking collar -A-.  
Installed Position: Synchronizer Ring -A- (3rd Gear Inner Race)  
The tabs -arrows 1- engage into the holes -arrows 2- inside the  
synchronizer ring -B-.  
Installed Position: 3rd Gear Wheel  
The higher collar -A- faces toward 4th gear -B-. The notches in  
the collar -arrow- lock into the tabs on the outer race. Refer to  
⇒ Fig. ““Installation Position of 1st Gear Outer Race”“ ,  
page 328 .  
– Install the 3rd gear wheel with the needle bearing.  
Note  
♦ Pressing on inner race/tapered roller bearing. Refer to  
⇒ Fig. ““Installing the Inner Race/Tapered Roller Bearing on  
the Side of the Transmission Housing”“ , page 323 .  
♦ Selecting the locking ring for the inner race/tapered roller bear‐  
ing. Refer to  
⇒ Fig. ““Selecting The Locking Ring”“ , page 323 .  
2.2.3  
Output Shaft for 1st through 4th Gears,  
Assembling - from Transmission Manu‐  
facture Date 10/26/09 through Trans‐  
mission Manufacture Date 5/24/00  
Checking the Inner Contact Surface for Wear on the 1st Gear  
Outer Race and on the 2nd Gear Outer Race  
– 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 and 2nd gear  
0.4 mm  
330  
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6-Speed Manual Transmission 02Q - Edition 05.2013  
Checking the Outer Contact Surface for Wear on the 1st Gear  
Outer race and on the 2nd Gear Outer Race  
– 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 and 2nd gear  
0.8 mm  
– Install the 2nd gear wheel with the needle bearing.  
Installing 2nd Gear Outer Race, Inner Race and Synchronizer  
Ring  
– Install the inner race -A- in the gear wheel.  
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.  
2. 1st through 4th Gear Output Shaft  
331  
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6-Speed Manual Transmission 02Q - Edition 05.2013  
Assembling the 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.  
Installation Position of 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 the 1st gear.  
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.  
332  
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6-Speed Manual Transmission 02Q - Edition 05.2013  
Installing the Synchronizer Ring for 1st Gear Outer race and Inner  
Race  
– Install the synchronizer ring -A- in the synchronizer 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-.  
Installing 1st Gear Wheel with Needle 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 thrust washers for 1st and 4th gears -item 19-  
⇒ Item 19 (page 319) and -item 20- ⇒ Item 20 (page 319) .  
– Install the 4th gear wheel with needle bearing.  
Checking the 4th Gear Synchronizer Ring for Wear  
– Press synchronizer ring onto taper of the gear wheel and  
measure gap dimension -a- using a feeler gauge.  
Gap dimension Installation Dimen‐  
Wear Limit  
-a-  
sion  
4th Gear  
1.0 to 1.7 mm  
0.5 mm  
Installed Position: Locking Collar/Synchronizer Hub for 3rd and  
4th Gears  
The wider collar on the synchronizer hub -arrow- faces the 3rd  
gear.  
– Place the synchronizer ring for 4th gear on the 4th gear wheel.  
2. 1st through 4th Gear Output Shaft  
333  
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6-Speed Manual Transmission 02Q - Edition 05.2013  
Installing the Synchronizer Hub With Locking Collar for 3rd and  
4th Gears  
– Turn the synchronizer ring so that the grooves line up with the  
locking pieces.  
– Install the locking ring.  
Checking the 3rd Gear Inner Race for Wear  
– Install the inner race onto taper of selector gear and then  
measure gap dimension -a- with a feeler gauge.  
Gap dimension Installation Dimen‐  
Wear Limit  
-a-  
sion  
3rd Gear  
0.75 to 1.25 mm  
0.3 mm  
Checking Synchronizer Ring for 3rd Gear for Wear  
– Install the synchronizer ring, outer race and inner race onto  
taper of selector gear and then measure the gap dimension  
-a- with a feeler gauge.  
Gap dimension Installation Dimen‐  
Wear Limit  
-a-  
sion  
3rd Gear  
1.2 to 1.8 mm  
0.5 mm  
– Install the 3rd gear synchronizer ring on the synchronizer hub/  
locking collar for 3rd and 4th gears.  
Installed Position: 3rd Gear Outer Race  
The tabs -arrows- face the synchronizer hub/locking collar -A-.  
334  
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6-Speed Manual Transmission 02Q - Edition 05.2013  
Installed Position: Synchronizer Ring -A- (3rd Gear Inner Race)  
The tabs -arrows 1- engage into the holes -arrows 2- inside the  
synchronizer ring -B-.  
Installed Position: 3rd Gear Wheel  
The higher collar -A- faces toward 4th gear -B-. The notches in  
the collar -arrow- lock into the tabs on the outer race. Refer to  
⇒ Fig. ““Installation Position of 1st Gear Outer Race”“ ,  
page 328 .  
– Install the 3rd gear wheel with the needle bearing.  
Note  
♦ Pressing on inner race/tapered roller bearing. Refer to  
⇒ Fig. ““Installing the Inner Race/Tapered Roller Bearing on  
the Side of the Transmission Housing”“ , page 323 .  
♦ Selecting the locking ring for the inner race/tapered roller bear‐  
ing. Refer to  
⇒ Fig. ““Selecting The Locking Ring”“ , page 323 .  
2.2.4  
Output Shaft for 1st through 4th gears,  
Assembling - from Transmission Manu‐  
facture Date 5/25/00  
Inner Friction Surface on 1st Gear Outer Race, 2nd Gear Outer  
Race and 3rd Gear Outer Race, Checking for Wear  
– 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  
2. 1st through 4th Gear Output Shaft  
335  
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤  
6-Speed Manual Transmission 02Q - Edition 05.2013  
Outer Friction Surface on 1st Gear Outer Race, 2nd Gear Outer  
Race and 3rd Gear Outer Race, Checking for Wear  
– 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  
– Install the inner race -A- in the gear wheel.  
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.  
336  
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6-Speed Manual Transmission 02Q - Edition 05.2013  
Assembling the 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.  
Installation Position of 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 the 1st gear.  
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.  
2. 1st through 4th Gear Output Shaft  
337  
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤  
6-Speed Manual Transmission 02Q - Edition 05.2013  
Installing the Synchronizer Ring for 1st Gear Outer Race and In‐  
ner Race  
– Install the synchronizer ring -A- in the synchronizer 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-.  
Installing 1st Gear Wheel with Needle 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 thrust washers for 1st and 4th gears -item 19-  
⇒ Item 19 (page 319) and -item 20- ⇒ Item 20 (page 319) .  
– Install the 4th gear wheel with needle bearing.  
Checking the 4th Gear Synchronizer Ring for Wear  
-A- = Brass Synchronizer Ring  
Gap Dimension Installation Dimen‐  
Wear Limit  
-a-  
sion  
4th Gear  
1.0 to 1.7 mm  
0.5 mm  
-B- = Steel Synchronizer Ring  
Gap Dimension Installation Dimen‐  
Wear Limit  
-a-  
sion  
4th Gear  
1.3 to 2.4 mm  
0.8 mm  
338  
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– Press synchronizer ring onto taper of the gear wheel and  
measure gap dimension -a- using a feeler gauge.  
Installed Position: Locking Collar/Synchronizer Hub for 3rd and  
4th Gears  
The wider collar on the synchronizer hub -arrow- faces the 3rd  
gear.  
– Place the synchronizer ring for 4th gear on the 4th gear wheel.  
Installing the Synchronizer Hub with Locking Collar for 3rd and  
4th Gears  
– Turn the synchronizer ring so that the grooves line up with the  
locking pieces.  
– Install the locking ring.  
Installing the 3rd Gear Synchronizer Ring, Outer Ring and Inner  
Ring  
– Install the synchronizer ring -A- in the synchronizer 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-.  
2. 1st through 4th Gear Output Shaft  
339  
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6-Speed Manual Transmission 02Q - Edition 05.2013  
Installing the 3rd Gear Wheel with Needle 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 3rd gear wheel with the needle bearing.  
Note  
♦ Pressing on inner race/tapered roller bearing. Refer to  
⇒ Fig. ““Installing the Inner Race/Tapered Roller Bearing on  
the Side of the Transmission Housing”“ , page 323 .  
♦ Selecting the locking ring for the inner race/tapered roller bear‐  
ing. Refer to  
⇒ Fig. ““Selecting The Locking Ring”“ , page 323 .  
2.3  
Output Shaft 1st through 4th Gear, Ad‐  
justing  
⇒ “2.3.1 Determining the Shim”, page 341  
⇒ “2.3.2 Shim Table”, page 342  
⇒ “2.3.3 Checking Measurement”, page 342  
Special tools and workshop equipment required  
♦ Transmission Support - VW353-  
♦ Dial Gauge Holder - VW387-  
♦ Press Piece - Rod - VW407-  
♦ Press Piece - Multiple Use - VW433-  
♦ Seal Installer - Stator - VW792-  
♦ Crankshaft Holding Fixture - VW801-  
♦ Holding Plate - VW309A-  
♦ Slide Hammer - Press Plate - 2050-  
♦ Torque Wrench 1331 5-50Nm - VAG1331-  
♦ -1- Puller - Kukko Internal - 46-56mm - 21/7-  
♦ -4- Puller - Kukko Counterstay - 22/2-  
(Selecting the correct adjusting shim for the output shaft)  
It is necessary to adjust the output shaft if the following compo‐  
nents were replaced:  
♦ Transmission housing  
♦ Clutch housing  
♦ Output shaft for 1st to 4th gears or  
♦ Output shaft tapered roller bearing  
Adjustment overview. Refer to  
⇒ “4 Overview - Adjustment”, page 393 .  
Requirements  
•
Remove any sealant remaining on the sealing surfaces on the  
clutch and transmission housing.  
•
Install the output shaft that is going to be measured.  
340  
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6-Speed Manual Transmission 02Q - Edition 05.2013  
– Install the tapered roller bearing outer race in the transmission  
housing with a 1.70 mm shim. Support transmission housing  
directly beneath bearing mount using Slide Hammer - Press  
Plate - 2050- .  
– Install the output shaft for 1st through 4th gears into the clutch  
housing.  
– Install the transmission housing and tighten the bolts  
-A and B- diagonally to the tightening specification.  
– Position the measuring tools on the clutch housing and secure  
them with a bolt -arrow-.  
– Set the dial gauge (3 mm range) with 1 mm preload to “0”.  
– Loosen securing bolts for clutch housing/transmission housing  
in diagonal sequence until bolts the clear transmission hous‐  
ing or the output shaft.  
– Read measured value on dial indicator and note (example:  
0.14 mm).  
Note  
♦ The measured value will not be displayed when loosening the  
bolts that connect the clutch housing to the transmission hous‐  
ing.  
♦ Install a 1.95 mm shim or, if necessary, a 2.20 mm shim in  
place of the 1.70 mm shim for measuring.  
♦ Allocate the shims. Refer to the Parts Catalog.  
2.3.1  
Determining the Shim  
The required bearing tension is reached as follows:  
The specified bearing pre-load is reached when determined  
measured value (0.14 mm) is subtracted from inserted adjust‐  
ment shim (1.70 mm).  
2. 1st through 4th Gear Output Shaft  
341  
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A constant figure of (0.20 mm) is added to the reading.  
Example  
Inserted shim  
1.70 mm  
0.14 mm  
0.20 mm  
1.76 mm  
- Measured value  
+ Preload (constant value)  
Shim thickness  
– Select the correct shim thickness according to the table. Refer  
to ⇒ “2.3.2 Shim Table”, page 342 .  
– Remove the transmission housing and remove the tapered  
roller bearing outer race from the transmission housing.  
A - Counter Support , for example, Puller - Kukko Counterstay -  
22/2-  
B - Internal Puller 46 to 58 mm , for example, Puller - Kukko In‐  
ternal - 46-56mm - 21/7-  
– Remove the inserted shim (1.70 mm) from the transmission  
housing.  
2.3.2  
Shim Table  
Thickness (mm)  
1.45  
1.50  
1.55  
1.60  
1.65  
1.70  
1.75  
1.80  
1.85  
1.90  
1.95  
2.00  
2.05  
2.10  
2.15  
2.20  
2.25  
Tolerance variations make it possible to find the exact shim thick‐  
ness required.  
– Shim part number. Refer to the Parts Catalog.  
– Install the outer race/tapered roller bearing with the selected  
shim (in the example: 1.75 mm) Support transmission housing  
directly beneath bearing mount using Slide Hammer - Press  
Plate - 2050- .  
2.3.3  
Checking Measurement  
•
The selected adjusting shim is installed.  
342  
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6-Speed Manual Transmission 02Q - Edition 05.2013  
– Position the measuring tools on the clutch housing and secure  
them with a bolt -arrow-.  
– Set the dial gauge (3 mm range) with 1 mm preload to “0”.  
– Loosen securing bolts for clutch housing/transmission housing  
in diagonal sequence until bolts the clear transmission hous‐  
ing or the output shaft.  
•
For correctly selected adjustment shim, dial gauge must now  
display a value of 0.15 mm to 0.25 mm.  
2. 1st through 4th Gear Output Shaft  
343  
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3
5th, 6th and Reverse Gear Output  
Shaft  
⇒ “3.1 Overview - Input Shaft, 5th/6th and Reverse Gears”, page  
344  
⇒ “3.2 Output Shaft, 5th, 6th and Reverse Gears, Disassembling  
and Assembling”, page 348  
⇒ “3.3 Output Shaft, 5th, 6th and Reverse Gears, Adjusting”, page  
353  
3.1  
Overview - Input Shaft, 5th/6th and Re‐  
verse Gears  
Output Shaft, 5th, 6th and Reverse Gears, Disassembling and  
Assembling. Refer to  
⇒ “3.2 Output Shaft, 5th, 6th and Reverse Gears, Disassembling  
and Assembling”, page 348 .  
Note  
♦ Secure the transmission on the assembly stand. Refer to  
⇒ “7 Transmission, Securing in Engine/Transmission Holder”, page 191 .  
♦ To install, warm the inner races/tapered roller bearing and synchronizer hub to approximately 100 °C (212  
°F) using Inductive Heater - VAS6414- . Wear protective gloves.  
♦ Adjust the output shaft if it or the tapered roller bearing are being replaced. Refer to  
⇒ “3.3 Output Shaft, 5th, 6th and Reverse Gears, Adjusting”, page 353 .  
♦ Replace both tapered roller bearings together.  
344  
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6-Speed Manual Transmission 02Q - Edition 05.2013  
1 - Clutch Housing  
2 - Washer  
❑ Always 0.65 mm thick  
3 - Outer Race/Tapered Roller  
Bearing  
❑ Removing. Refer to  
⇒ Fig. ““Removing the  
Outer Race/Tapered  
Roller Bearing”“ ,  
page 348 .  
❑ Installing. Refer to  
⇒ Fig. ““Installing the  
Outer Race/Tapered  
Roller Bearing in the  
Clutch Housing”“ ,  
page 349 .  
4 - Inner Race / Tapered Roller  
Bearing  
❑ Removing. Refer to  
⇒ Fig. ““Removing the  
Inner Race/Tapered  
Roller Bearing on the  
Side of the Clutch Hous‐  
ing.”“ , page 350  
❑ Installing. Refer to  
⇒ Fig. ““Installing the In‐  
ner Race/Tapered Roll‐  
er Bearing on the Side of  
the Clutch Housing”“ ,  
page 353 .  
5 - Output Shaft  
❑ For 5th, 6th and Re‐  
verse Gears  
❑ Adjusting. Refer to  
⇒ “3.3 Output Shaft, 5th,  
6th and Reverse Gears,  
Adjusting”, page 353 .  
6 - Reverse Gear Synchronizer Hub  
❑ Removing. Refer to ⇒ Fig. ““Removing the Reverse Gear Synchronizer Hub”“ , page 350 .  
❑ Installation position. Refer to ⇒ Fig. ““Installed Position: Reverse Gear Synchronizer Hub”“ , page 351 .  
❑ Installing. Refer to ⇒ Fig. ““Warming and Installing the Reverse Gear Synchronizer Hub”“ , page 351 .  
7 - Circlip  
8 - Reverse Gear Locking Collar  
❑ With synchronizer ring  
9 - Needle Bearing  
❑ For reverse gear wheel  
10 - Reverse Gear Wheel  
11 - Sleeve  
❑ Remove with the reverse gear wheel. Refer to  
⇒ Fig. ““Removing the Sleeve -A- Together with the Reverse Gear Wheel”“ , page 350  
❑ Installed position: the wider collar on sleeve points toward reverse gear selector gear  
❑ Installing. Refer to ⇒ Fig. ““Installing the Sleeve -A- ”“ , page 351 .  
12 - Circlip  
13 - Needle Bearing  
❑ For 6th gear  
3. 5th, 6th and Reverse Gear Output Shaft  
345  
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14 - 6th Gear Wheel  
15 - 6th Gear Synchronizer Ring  
❑ Brass or steel  
❑ Checking for wear. Refer to  
⇒ Fig. ““Check the 5th and 6th Gear Synchronizer Ring for Wear”“ , page 351  
16 - Locking Collar with Synchronizer Hub for 5th and 6th Gears  
❑ After removing circlip -item 17- ⇒ Item 17 (page 346) , remove the 6th gear wheel. Refer to  
⇒ Fig. ““Removing the 5th and 6th Gear Synchronizer Hub/Locking Collar with the 6th Gear Wheel”“ ,  
page 350  
❑ Disassembling. Refer to  
⇒ Fig. ““Disassembling and Assembling Locking Collar and Synchronizer Hub for 5th and 6th Gears”“ ,  
page 352 .  
❑ Assembling the locking collar/synchronizer hub. Refer to  
⇒ Fig. ““Disassembling and Assembling Locking Collar and Synchronizer Hub for 5th and 6th Gears”“ ,  
page 352 and  
⇒ Fig. ““Assembling Locking Collar/Synchronizer Hub for 5th and 6th Gears”“ , page 352  
❑ Installing. Refer to  
⇒ Fig. ““Warming and Installing the Locking Collar/Synchronizer Hub for 5th and 6th Gears”“ ,  
page 352 .  
17 - Circlip  
18 - Needle Bearing  
❑ For 5th gear  
19 - 5th Gear Synchronizer Ring  
❑ Brass or steel  
❑ Checking for wear. Refer to  
⇒ Fig. ““Check the 5th and 6th Gear Synchronizer Ring for Wear”“ , page 351  
20 - 5th Gear Wheel  
21 - Inner Race / Tapered Roller Bearing  
❑ Removing. Refer to  
⇒ Fig. ““Remove the Inner Race/Tapered Roller Bearing on the Side of the Transmission Housing”“ ,  
page 349  
❑ Installing. Refer to  
⇒ Fig. ““Installing the Inner Race/Tapered Roller Bearing on the Side of the Transmission Housing”“ ,  
page 353 .  
22 - Circlip  
❑ Select the correct one when replacing the tapered roller bearing -item 21- ⇒ Item 21 (page 346) and the  
output shaft -item 5- ⇒ Item 5 (page 345) ⇒ Fig. ““Selecting the Locking Ring”“ , page 353  
23 - Outer Race/Tapered Roller Bearing  
❑ Removing. Refer to  
⇒ Fig. ““Removing the Outer Race/Tapered Roller Bearing from the Transmission Housing”“ ,  
page 349 .  
❑ Installing. Refer to  
⇒ Fig. ““Installing the Outer Race/Tapered Roller Bearing into the Transmission Housing.”“ ,  
page 349 .  
24 - Shim  
❑ Selecting thickness. Refer to ⇒ “3.3 Output Shaft, 5th, 6th and Reverse Gears, Adjusting”, page 353 .  
25 - Transmission Housing  
26 - Spring  
❑ Installation position. Refer to  
⇒ Fig. ““Assembling Locking Collar/Synchronizer Hub for 5th and 6th Gears”“ , page 352 .  
346  
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6-Speed Manual Transmission 02Q - Edition 05.2013  
27 - Locking Collar  
28 - Synchronizer Hub  
29 - Locking Pieces (quantity: 3)  
❑ Installation position. Refer to  
⇒ Fig. ““Disassembling and Assembling Locking Collar and Synchronizer Hub for 5th and 6th Gears”“ ,  
page 352 .  
3. 5th, 6th and Reverse Gear Output Shaft  
347  
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6-Speed Manual Transmission 02Q - Edition 05.2013  
3.2  
Output Shaft, 5th, 6th and Reverse  
Gears, Disassembling and Assembling  
Special tools and workshop equipment required  
♦ Press Plate - VW401-  
♦ Press Plate - VW402-  
♦ Press Piece - Rod - VW407-  
♦ Press Piece - Rod - VW408A-  
♦ Press Piece - Multiple Use - VW412-  
♦ Press Piece - 60mm - VW415A-  
♦ Holding Plate - VW309A-  
♦ Transmission Support - VW353-  
♦ Press Piece - Multiple Use - VW433-  
♦ Press Piece - Multiple Use - VW454-  
♦ Support Channels - VW457-  
♦ Crankshaft Holding Fixture - VW801-  
♦ Press Piece - Multiple Use - VW431-  
♦ Press Piece - Multiple Use - VW455-  
♦ Press Piece - Multiple Use - VW510-  
♦ Press Piece - 42mm - VW516-  
♦ Press Piece - Multiple Use - VW519-  
♦ Press Piece - Multiple Use - 30-11-  
♦ Press Piece - Multiple Use - 40-105-  
♦ Bearing Installer - Multiple Use - 40-20-  
♦ Slide Hammer - Press Plate - 2050-  
♦ Press Piece - Reverse Gear Syncro - 3296-  
♦ Puller - Taper Roller Bearing - VAG1582-  
♦ Puller - Taper Roller Bearing - Adapter 4 - VAG1582/4-  
♦ Puller - Taper Roller Bearing - Adapter 7 - VAG1582/7-  
♦ Inductive Heater - VAS6414-  
♦ -1- Puller - Kukko Internal - 46-56mm - 21/7-  
♦ -3- Puller - Kukko Quick Action Separating Tool - 22-115mm -  
17/2-  
♦ -4- Puller - Kukko Counterstay - 22/2-  
Removing the Outer Race/Tapered Roller Bearing  
A - Counter Support , for example, Puller - Kukko Counterstay -  
22/2-  
B - Internal Puller 46 to 58 mm , for example, Puller - Kukko In‐  
ternal - 46-56mm - 21/7-  
348  
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6-Speed Manual Transmission 02Q - Edition 05.2013  
Note  
Check the washer for damage after removing it and replace if  
necessary.  
Installing the Outer Race/Tapered Roller Bearing in the Clutch  
Housing  
– Place the washer under the outer race.  
– Support the clutch housing with the Bearing Installer - Multiple  
Use - 40-20- directly under the bearing mount.  
Removing the Outer Race/Tapered Roller Bearing from the  
Transmission Housing  
A - Counter Support , for example, Puller - Kukko Counterstay -  
22/2-  
B - Internal Puller 46 to 58 mm , for example, Puller - Kukko In‐  
ternal - 46-56mm - 21/7-  
Installing the Outer Race/Tapered Roller Bearing into the Trans‐  
mission Housing.  
– Support the transmission housing under the bearing mount  
using the Slide Hammer - Press Plate - 2050- .  
Disassembling the Output Shaft  
Remove the Inner Race/Tapered Roller Bearing on the Side of  
the Transmission Housing  
Before installing the Tapered Roller Bearing Puller :  
– Remove the inner race/tapered roller bearing locking ring on  
the side facing the transmission housing.  
– Place the Press Piece - Multiple Use - VW431- and Press  
Piece - Multiple Use - 40-105- on the output shaft.  
3. 5th, 6th and Reverse Gear Output Shaft  
349  
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6-Speed Manual Transmission 02Q - Edition 05.2013  
Removing the 5th and 6th Gear Synchronizer Hub/Locking Collar  
with the 6th Gear Wheel  
– Remove the locking ring beforehand.  
Removing the Sleeve -A- Together with the Reverse Gear Wheel  
– Remove the locking ring beforehand.  
Removing the Reverse Gear Synchronizer Hub  
– Remove the locking ring beforehand.  
A - 22 to 115 mm Separating Tool , for example Puller - Kukko  
Quick Action Separating Tool - 22-115mm - 17/2-  
Removing the Inner Race/Tapered Roller Bearing on the Side of  
the Clutch Housing.  
– Mount the Press Piece - Multiple Use - 30-11- on the output  
shaft before removing the puller.  
Assemble the Output Shaft.  
Note  
Heat the tapered bearing inner races and synchronizer hub to  
approximately 100 °C (212 °F) with the Inductive Heat Unit -  
VAS6414- before installing. Press on to the stop so that there is  
no axial clearance when assembling.  
350  
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6-Speed Manual Transmission 02Q - Edition 05.2013  
Installed Position: Reverse Gear Synchronizer Hub  
The stop -arrow A- on the reverse gear locking collar faces the  
•
splines on the output shaft -arrow B-.  
Warming and Installing the Reverse Gear Synchronizer Hub  
– Install the locking ring.  
– Mount the reverse gear locking collar on the reverse gear syn‐  
chronizer hub.  
– Install the reverse gear wheel and the needle bearing.  
Installing the Sleeve -A-  
•
Installed position: wide collar points toward reverse gear se‐  
lector gear.  
– Install the circlip.  
Check the 5th and 6th Gear Synchronizer Ring for Wear  
-A- = Brass Synchronizer Ring  
Gap Dimension Installation Dimen‐  
Wear Limit  
-a-  
sion  
5th and 6th gear  
1.0 to 1.7 mm  
0.5 mm  
-B- = Steel Synchronizer Ring  
Gap Dimension Installation Dimen‐  
Wear Limit  
-a-  
sion  
5th and 6th gear  
1.2 to 2.1 mm  
0.8 mm  
3. 5th, 6th and Reverse Gear Output Shaft  
351  
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6-Speed Manual Transmission 02Q - Edition 05.2013  
– Press synchronizer ring onto taper of the gear wheel and  
measure gap dimension -a- using a feeler gauge.  
Disassembling and Assembling Locking Collar and Synchronizer  
Hub for 5th and 6th Gears  
– To disassemble, remove the springs -1-.  
1 - Spring  
2 - Locking piece  
3 - Locking collar  
4 - Synchronizer hub  
– Slide the locking collar over the synchronizer hub.  
•
Installed position: The narrow locking piece recesses in the  
synchronizer hub align with the recesses in the locking collar.  
Assembling Locking Collar/Synchronizer Hub for 5th and 6th  
Gears  
•
The locking collar is pushed over the synchronizer hub.  
– Install the locking pieces and springs offset by 120°.  
•
The angled end of the spring must engage into the hollow  
locking piece.  
– Install the 6th gear wheel with needle bearing.  
– Install the 6th gear synchronizer ring.  
Warming and Installing the Locking Collar/Synchronizer Hub for  
5th and 6th Gears  
On some locking collars, there is a chamfer on the outer diameter.  
Installation position: the bevel on the outer diameter of the locking  
collar faces toward the 5th gear wheel.  
– Turn the 6th gear synchronizer ring so that the grooves line up  
with the locking pieces.  
– Install the locking ring.  
– Install the 5th gear synchronizer ring.  
– Install 5th gear wheel with needle bearing.  
352  
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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤  
6-Speed Manual Transmission 02Q - Edition 05.2013  
Installing the Inner Race/Tapered Roller Bearing on the Side of  
the Transmission Housing  
– Choose the correct locking ring. Refer to  
⇒ Fig. ““Selecting the Locking Ring”“ , page 353 and install.  
Selecting the Locking Ring  
– Choose and install the thickest locking ring that will fit.  
– Select the locking ring according to the Table. Part number.  
Refer to the Parts Catalog.  
Available Locking Rings  
Thickness (mm)  
1.79  
1.83  
1.86  
1.89  
1.92  
1.95  
1.98  
Installing the Inner Race/Tapered Roller Bearing on the Side of  
the Clutch Housing  
3.3  
Output Shaft, 5th, 6th and Reverse  
Gears, Adjusting  
⇒ “3.3.1 Determining the Shim”, page 355  
⇒ “3.3.2 Shim Table”, page 355  
⇒ “3.3.3 Checking Measurement”, page 356  
Special tools and workshop equipment required  
♦ Transmission Support - VW353-  
♦ Dial Gauge Holder - VW387-  
♦ Press Piece - Rod - VW407-  
♦ Press Piece - Multiple Use - VW433-  
♦ Seal Installer - Stator - VW792-  
♦ Crankshaft Holding Fixture - VW801-  
♦ Holding Plate - VW309A-  
♦ Slide Hammer - Press Plate - 2050-  
♦ Torque Wrench 1331 5-50Nm - VAG1331-  
3. 5th, 6th and Reverse Gear Output Shaft  
353  
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6-Speed Manual Transmission 02Q - Edition 05.2013  
♦ -1- Puller - Kukko Internal - 46-56mm - 21/7-  
♦ -4- Puller - Kukko Counterstay - 22/2-  
It is necessary to adjust the output shaft if the following compo‐  
nents were replaced:  
♦ Transmission Housing  
♦ Clutch Housing  
♦ Output Shaft, 5th, 6th and Reverse Gears or  
♦ Output shaft tapered roller bearing  
Adjustment overview. Refer to  
⇒ “4 Overview - Adjustment”, page 393 .  
Requirements  
•
Remove any sealant remaining on the sealing surfaces on the  
clutch and transmission housing.  
•
Install the output shaft that is going to be measured.  
– Install the tapered roller bearing outer race in the transmission  
housing with a 1.70 mm shim. Support transmission housing  
directly beneath bearing mount using Slide Hammer - Press  
Plate - 2050- .  
– Install the output shaft for 5th/6th gears and reverse gear into  
the clutch housing.  
– Install the transmission housing and tighten the bolts  
-A and B- diagonally to the tightening specification.  
354  
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6-Speed Manual Transmission 02Q - Edition 05.2013  
– Install the measuring tools.  
– Place several washers (total thickness: 8 mm) on the clutch  
housing at the bolt -arrow- being used to secure the Seal In‐  
staller - Stator - VW792- .  
– Set the dial gauge (3 mm range) with 1 mm preload to “0”.  
– Loosen securing bolts for clutch housing/transmission housing  
in diagonal sequence until bolts the clear transmission hous‐  
ing or the output shaft.  
– Read measured value on dial indicator and note (example:  
0.25 mm).  
Note  
♦ The measured value will not be displayed when loosening the  
bolts that connect the clutch housing to the transmission hous‐  
ing.  
♦ Install a 1.95 mm shim or, if necessary, a 2.20 mm shim in  
place of the 1.70 mm shim for measuring.  
♦ Allocate the shims. Refer to the Parts Catalog.  
3.3.1  
Determining the Shim  
The specified bearing preload is obtained by adding a constant  
preload figure of (0.20 mm) to the reading obtained (0.25 mm)  
and the thickness of the shim installed (1.70 mm).  
Example  
Inserted shim  
1.70 mm  
0.25 mm  
0.20 mm  
1.65 mm  
- Measured value  
+ Preload (constant value)  
Shim thickness  
– Select the correct shim thickness according to the table. Refer  
to ⇒ “3.3.2 Shim Table”, page 355 .  
– Remove the transmission housing and remove the tapered  
roller bearing outer race from the transmission housing.  
A - Counter Support , for example, Puller - Kukko Counterstay -  
2/2-  
B - Internal Puller 46 to 58 mm , for example, Puller - Kukko In‐  
ternal - 46-56mm - 21/7-  
– Remove the inserted shim (1.70 mm) from the transmission  
housing.  
3.3.2  
Shim Table  
Thickness (mm)  
1.50  
1.55  
1.60  
1.65  
1.70  
1.80  
1.85  
1.90  
1.95  
2.00  
2.10  
2.15  
2.20  
2.25  
3. 5th, 6th and Reverse Gear Output Shaft  
355  
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤  
6-Speed Manual Transmission 02Q - Edition 05.2013  
Thickness (mm)  
1.75  
2.05  
– Part numbers. Refer to the Parts Catalog.  
Tolerance variations make it possible to find the exact shim thick‐  
ness required.  
– Install the outer race/tapered roller bearing with the selected  
shim (in the example: 1.65 mm) Support transmission housing  
directly beneath bearing mount using Slide Hammer - Press  
Plate - 2050- .  
3.3.3  
Checking Measurement  
•
The selected adjusting shim is installed.  
– Install the measuring tools.  
– Place several washers (total thickness: 8 mm) on the clutch  
housing at the bolt -arrow- being used to secure the Seal In‐  
staller - Stator - VW792- .  
– Set the dial gauge (3 mm range) with 1 mm preload to “0”.  
– Loosen securing bolts for clutch housing/transmission housing  
in diagonal sequence until bolts the clear transmission hous‐  
ing or the output shaft.  
•
For correctly selected adjustment shim, dial gauge must now  
display a value of 0.15 mm to 0.25 mm.  
356  
Rep. Gr.35 - Gears, Shafts  
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤  
6-Speed Manual Transmission 02Q - Edition 05.2013  
4
Special Tools  
Special tools and workshop  
equipment required  
♦ Press Plate - VW401-  
♦ Press Plate - VW402-  
♦ Press Piece - Rod -  
VW407-  
♦ Press Piece - Rod -  
VW408A-  
♦ Press Piece - Rod -  
VW412-  
♦ Press Piece - Multiple Use  
- VW454-  
4. Special Tools  
357  
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤  
6-Speed Manual Transmission 02Q - Edition 05.2013  
♦ Bearing Installer - Multiple  
Use - 40-20-  
♦ Bearing Installer - Differen‐  
tial Bearing - 40-21-  
♦ Slide Hammer - Press Plate  
- 2050-  
♦ Holding Fixture - Spacers -  
VW540/1B-  
♦ Puller - Taper Roller Bear‐  
ing - VAG1582-  
♦ Puller - Taper Roller Bear‐  
ing - Adapter 7 -  
VAG1582/7-  
358  
Rep. Gr.35 - Gears, Shafts  
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤  
6-Speed Manual Transmission 02Q - Edition 05.2013  
Special tools and workshop  
equipment required  
♦ Press Plate - VW401-  
♦ Press Plate - VW402-  
♦ Press Piece - Rod -  
VW407-  
♦ Press Piece - Rod -  
VW408A-  
♦ Press Piece - Multiple Use  
- VW412-  
♦ Press Piece - 60mm -  
VW415A-  
4. Special Tools  
359  
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤  
6-Speed Manual Transmission 02Q - Edition 05.2013  
♦ Holding Plate - VW309A-  
♦ Transmission Support -  
VW353-  
♦ Press Piece - Multiple Use  
- VW433-  
♦ Press Piece - Multiple Use  
- VW454-  
♦ Support Channels -  
VW457-  
♦ Crankshaft Holding Fixture  
- VW801-  
360  
Rep. Gr.35 - Gears, Shafts  
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤  
6-Speed Manual Transmission 02Q - Edition 05.2013  
♦ Holding Plate - VW309A-  
♦ Holding Fixture - VW313-  
♦ Transmission Support -  
VW353-  
♦ Press Piece - Multiple Use  
- VW431-  
♦ Press Piece - Multiple Use  
- VW433-  
♦ Press Piece - Multiple Use  
- VW454-  
4. Special Tools  
361  
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤  
6-Speed Manual Transmission 02Q - Edition 05.2013  
♦ Press Piece - Multiple Use  
- VW512-  
♦ Press Piece - 42mm -  
VW516-  
♦ Press Piece - Multiple Use  
- VW519-  
♦ Slide Hammer Set - Ham‐  
mer - VW771-  
♦ Crankshaft Holding Fixture  
- VW801-  
♦ Press Piece - Multiple Use  
- 40-105-  
362  
Rep. Gr.35 - Gears, Shafts  
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤  
6-Speed Manual Transmission 02Q - Edition 05.2013  
♦ Transmission Support -  
VW353-  
♦ Dial Gauge Holder -  
VW387-  
♦ Press Piece - Rod -  
VW407-  
♦ Press Piece - Multiple Use  
- VW433-  
♦ Seal Installer - Stator -  
VW792-  
♦ Crankshaft Holding Fixture  
- VW801-  
4. Special Tools  
363  
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤  
6-Speed Manual Transmission 02Q - Edition 05.2013  
♦ Press Piece - Multiple Use  
- VW431-  
♦ Press Piece - Multiple Use  
- VW455-  
♦ Press Piece - Multiple Use  
- VW510-  
♦ Press Piece - 42mm -  
VW516-  
♦ Press Piece - Multiple Use  
- VW519-  
♦ Press Piece - Multiple Use  
- 30-11-  
364  
Rep. Gr.35 - Gears, Shafts  
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤  
6-Speed Manual Transmission 02Q - Edition 05.2013  
♦ Holding Plate - VW309A-  
♦ Slide Hammer - Press Plate  
- 2050-  
♦ Torque Wrench 1331  
5-50Nm - VAG1331-  
♦ -1- Puller - Kukko Internal -  
46-56mm - 21/7-  
♦ -4- Puller - Kukko Counter‐  
stay - 22/2-  
4. Special Tools  
365  
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤  
6-Speed Manual Transmission 02Q - Edition 05.2013  
♦ Press Piece - Multiple Use  
- 40-105-  
♦ Bearing Installer - Multiple  
Use - 40-20-  
♦ Slide Hammer - Press Plate  
- 2050-  
♦ Press Piece - Reverse  
Gear Syncro - 3296-  
♦ Puller - Taper Roller Bear‐  
ing - VAG1582-  
♦ Puller - Taper Roller Bear‐  
ing - Adapter 4 -  
VAG1582/4-  
♦ Puller - Taper Roller Bearing - Adapter 7 - VAG1582/7-  
366  
Rep. Gr.35 - Gears, Shafts  
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤  
6-Speed Manual Transmission 02Q - Edition 05.2013  
♦ Inductive Heater - VAS6414-  
♦ Press Piece - Bushing - 50mm Diameter - VW432-  
♦ -1- Puller - Kukko Internal - 46-56mm - 21/7-  
♦ -1- Puller - Kukko Internal - 56-70mm - 21/8-  
♦ -2- Puller - Kukko Puller - 60-200mm Width, 250mm Length -  
18/2-  
♦ -3- Puller - Kukko Quick Action Separating Tool - 22-115mm -  
17/2-  
♦ -4- Puller - Kukko Counterstay - 22/2-  
♦ -1- Puller - Kukko Internal - 28-37mm - 21/5-  
♦ -3- Puller - Kukko Quick Action Separating Tool - 22-115mm -  
17/2-  
♦ -4- Puller - Kukko Counterstay - 22/2-  
4. Special Tools  
367  
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤  
6-Speed Manual Transmission 02Q - Edition 05.2013  
♦ Locking Pin Driver - 30-505-  
♦ Bearing Installer - Multiple Use - 32-111-  
368  
Rep. Gr.35 - Gears, Shafts  

Related Topics

1 Input Shaft 1.1 Overview - Input Shaft 1.2 Input Shaft, Disassembling and Assembling 2 1st through 4th Gear Output Shaft 2.1 Overview - Output Shaft, 1st to 4th Gears 2.2 Output Shaft, 1st to 4th Gears, Disassembling and Assembling 2.3 Output Shaft 1st through 4th Gear, Adjusting 3 5th, 6th and Reverse Gear Output Shaft 3.1 Overview - Input Shaft, 5th/6th and Reverse Gears 3.2 Output Shaft, 5th, 6th and Reverse Gears, Disassembling and Assembling 3.3 Output Shaft, 5th, 6th and Reverse Gears, Adjusting 4 Special Tools

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