2003-2008 Volkswagen Golf 4 Door Gears,Shafts -> 2 1st through 4th Gear Output Shaft User Manual
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Gears,Shafts -> 2 1st through 4th Gear Output Shaft 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  
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  
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤  
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  
Rep. Gr.35 - Gears, Shafts  
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤  
6-Speed Manual Transmission 02Q - Edition 05.2013  
2.2.1  
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  
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤  
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  
Rep. Gr.35 - Gears, Shafts  
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤  
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  
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤  
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  
Rep. Gr.35 - Gears, Shafts  
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤  
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  
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤  
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  
Rep. Gr.35 - Gears, Shafts  
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤  
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  
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤  
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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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 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  
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤  
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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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤  
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  
Rep. Gr.35 - Gears, Shafts  
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤  
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  
Rep. Gr.35 - Gears, Shafts  
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤  
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.  
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  
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤  
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  
Rep. Gr.35 - Gears, Shafts  
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤  
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  
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤  
6-Speed Manual Transmission 02Q - Edition 05.2013  
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  
Rep. Gr.35 - Gears, Shafts  
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤  
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  

Related Topics

Gears,Shafts
1 Input Shaft 1.1 Overview - Input Shaft 1.2 Input Shaft, Disassembling and Assembling 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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