Get Gears,Shafts -> 3.2 Output Shaft, 5th, 6th and Reverse Gears, Disassembling and Assembling 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

3.2

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

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

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

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

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

Rep. Gr.35 - Gears, Shafts

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

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

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.

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

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 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

Gears,Shafts -> 3.2 Output Shaft, 5th, 6th and Reverse Gears, Disassembling and Assembling for Your Volkswagen Golf 4 Door Fifth Generation (2003-2008)

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