2003-2008 Volkswagen Golf 4 Door Gears,Shafts -> 2.2 Output Shaft, 1st to 4th Gears, Disassembling and Assembling User Manual
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Gears,Shafts -> 2.2 Output Shaft, 1st to 4th Gears, Disassembling and Assembling 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  
2.2  
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  
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 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  

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