Get Gears,Shafts -> 3.1 Overview - Input Shaft, 5th/6th and Reverse Gears Guide for 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

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

Rep. Gr.35 - Gears, Shafts

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤

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

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤

6-Speed Manual Transmission 02Q - Edition 05.2013

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

Rep. Gr.35 - Gears, Shafts

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤

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

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤

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

Rep. Gr.35 - Gears, Shafts

Gears,Shafts -> 3.1 Overview - Input Shaft, 5th/6th and Reverse Gears for Your Volkswagen Golf 4 Door Fifth Generation (2003-2008)

Related Topics

Popular Owner Manuals

Latest Owner Manuals