2003-2008 Volkswagen Golf 4 Door Gears,Shafts -> 2.1 Overview - Output Shaft, 1st to 4th Gears User Manual
MyCarUserManual.com
USER MANUALS FOR EVERY MAKE & MODEL

Gears,Shafts -> 2.1 Overview - Output Shaft, 1st to 4th Gears 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  
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  

Related Topics

Gears,Shafts
1 Input Shaft 1.1 Overview - Input Shaft 1.2 Input Shaft, Disassembling and Assembling 2 1st through 4th Gear Output Shaft 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

Popular Owner Manuals

Audi
Audi
BMW
BMW
Citroen
Citroen
Ford
Ford
Honda
Honda
Peugeot
Peugeot