Get Gears,Shafts -> 3 5th, 6th and Reverse Gear Output Shaft 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

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

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

6-Speed Manual Transmission 02Q - Edition 05.2013

♦ -1- Puller - Kukko Internal - 46-56mm - 21/7-

♦ -4- Puller - Kukko Counterstay - 22/2-

It is necessary to adjust the output shaft if the following compo‐

nents were replaced:

♦ Transmission Housing

♦ Clutch Housing

♦ Output Shaft, 5th, 6th and Reverse 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.

– 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 5th/6th gears and reverse gear into

the clutch housing.

– Install the transmission housing and tighten the bolts

-A and B- diagonally to the tightening specification.

354

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 measuring tools.

– Place several washers (total thickness: 8 mm) on the clutch

housing at the bolt -arrow- being used to secure the Seal In‐

staller - Stator - VW792- .

– 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:

0.25 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.

3.3.1

Determining the Shim

The specified bearing preload is obtained by adding a constant

preload figure of (0.20 mm) to the reading obtained (0.25 mm)

and the thickness of the shim installed (1.70 mm).

Example

Inserted shim

1.70 mm

0.25 mm

0.20 mm

1.65 mm

- Measured value

+ Preload (constant value)

Shim thickness

– Select the correct shim thickness according to the table. Refer

to ⇒ “3.3.2 Shim Table”, page 355 .

– Remove the transmission housing and remove the tapered

roller bearing outer race from the transmission housing.

A - Counter Support , for example, Puller - Kukko Counterstay -

2/2-

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.

3.3.2

Shim Table

Thickness (mm)

1.50

1.55

1.60

1.65

1.70

1.80

1.85

1.90

1.95

2.00

2.10

2.15

2.20

2.25

3. 5th, 6th and Reverse Gear Output Shaft

355

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

6-Speed Manual Transmission 02Q - Edition 05.2013

Thickness (mm)

1.75

2.05

– Part numbers. Refer to the Parts Catalog.

Tolerance variations make it possible to find the exact shim thick‐

ness required.

– Install the outer race/tapered roller bearing with the selected

shim (in the example: 1.65 mm) Support transmission housing

directly beneath bearing mount using Slide Hammer - Press

Plate - 2050- .

3.3.3

Checking Measurement

•

The selected adjusting shim is installed.

– Install the measuring tools.

– Place several washers (total thickness: 8 mm) on the clutch

housing at the bolt -arrow- being used to secure the Seal In‐

staller - Stator - VW792- .

– 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.

356

Rep. Gr.35 - Gears, Shafts

Gears,Shafts -> 3 5th, 6th and Reverse Gear Output Shaft for Your Volkswagen Golf 4 Door Fifth Generation (2003-2008)

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