Volkswagen Workshop Service and Repair Manuals

Installing 5th/6th gears l  Ensure that support bridge -30-211A- and support device -T10323- are attached. –  Lock bolt of support bridge -30-211A- with nut -A-.

Installation position, 5th gear wheel The circumferential groove -arrow- faces gearbox housing.

–  Drive on gear wheel for 5th gear.

Checking 5th gear synchro-ring and 6th gear synchro-ring –  Before installing synchromeshed gears and synchro-rings for 5th and 6th gear, press synchro-rings onto cones of synchromeshed gears and measure gap -a- with a feeler gauge.

Gap -a-	Installation dimension	Wear limit
5th and 6th gears	1.1 … 1.7 mm	0.5 mm

–  Install 5th gear synchromeshed gear with needle bearing. From gearbox date 26 05 8: set corrugated spring washer on synchromeshed gear for 5th gear → Item. –  Place 5th gear synchro-ring on synchromeshed gear. –  If synchro-hub and locking collar for 5th and 6th gears are dismantled, assemble before installing → Fig., → Fig. and → Fig.. –  Also observe modifications to locking collar for 5th and 6th gears from gearbox date 12 06 6 → Fig.. These modifications are very important for the later adjustment of the 5th and 6th gears.

Installation position, synchro-hub and locking collar for 5th and 6th gears Shoulder -arrow 1- faces 6th gear. The supports -arrow 2- of the synchro-hub align with the cast locking pieces of the synchro-ring (arrows in figure below).

5th gear and 6th gear synchro-rings with cast locking pieces -arrows- –  Cover all openings in gearbox housing with a cloth to prevent foreign bodies from entering gearbox.

–  Drive on synchro-hub for 5th and 6th gear.   Note When driving on, ensure that synchro-ring moves freely.

–  Heat inner race of cylindrical roller bearing for 6th gear synchromeshed gear to maximum 100° C and drive onto input shaft.   WARNING Wear protective gloves! –  Install synchro-ring for 6th gear. From gearbox date 26 05 8: set corrugated spring washer on synchromeshed gear for 6th gear → Item. –  Install synchromeshed gear for 6th gear with needle bearing. Through gearbox date 20 08 6

–  Set thrust washer -A- in place.   Note Do not interchange inner races of cylindrical roller bearings of input and output shafts. –  Heat cylindrical roller bearing inner race -B- to maximum 100° C and drive onto input shaft.   WARNING Wear protective gloves! From gearbox date 21 08 6

Cylindrical roller bearing inner race -B- and thrust washer -A- are combined in one component. –  Heat cylindrical roller bearing inner race to maximum 100° C and drive onto input shaft.   WARNING Wear protective gloves! Continuation for all –  Set sleeve -A- on gear wheel for 5th gear.

Installation position of 6th gear wheel:

Groove -B- faces away from sleeve -A-. »Or« groove -arrow 1- near shoulder -arrow 2- faces away from sleeve -A- see previous figure).   WARNING Wear protective gloves! –  Heat 6th gear wheel to maximum 100° C and press on. –  Shift locking collar for 5th and 6th gear to freewheel position to enable synchromeshed gear for 6th gear to turn while gear wheel for 6th gear is being pressed on. –  Drive on gear wheel for 6th gear, being careful that teeth of gear wheel and synchromeshed gear for 6th gear mesh.

–  Heat cylindrical roller bearing inner race -A- to maximum 100° C and drive onto output shaft.

–  Loosen support for input shaft.   WARNING Wear protective gloves! Clean residual locking fluid from threaded holes for securing bolts -A- for synchro-hub for 5th and 6th gears and gear wheel for 6th gear with a thread chaser. Otherwise the bolts may shear. Please note allocation of securing bolts → Fig. and → Fig. –  Tighten securing bolts for synchro-hub and gear wheels for 5th and 6th gears to specified torque → Chapter.

–  To tighten securing bolts -A-, engage 2 gears -arrows 1- through -3-. –  Install selector forks for 5th and 6th gears.

Adjusting 5th and 6th gears through gearbox manufacture date 11 06 6 –  Engage 5th gear. –  Loosen bolt -1-. –  Insert two 0.5 mm feeler gauges -A- above both selector segments -arrows- (to 6th gear) into locking collar. –  Then press the selector jaw and the locking collar down -arrows- and tighten bolt -1- to 25 Nm. l  5th gear engaged.

l  Check measurement: it should be possible to insert a 0.5°mm feeler gauge without play between locking collar and each selector segment -arrow- on the side of 6th gear. –  If necessary, repeat adjustment. –  Engage 5th gear and then 6th gear. When 5th or 6th gear is engaged, the selector fork for 5th and 6th gear should have slight clearance in the selector jaw. –  Switch to neutral. l  Locking collar must now be in the neutral position. Synchro-ring must move freely. –  Shift through all gears.

Adjusting 5th and 6th gear from gearbox manufacture date 12 06 6 –  Engage 5th gear. –  Loosen bolt -1-. –  Then press the selector jaw and the locking collar down -arrows- and tighten bolt -1- to 25 Nm. l  5th gear engaged.

l  Check measurement: it should not be possible to insert a 0.2°mm feeler gauge between locking collar and each selector segment -arrow- on the side of 6th gear. –  If necessary, repeat adjustment. –  Engage 5th gear and then 6th gear. When 5th or 6th gear is engaged, the selector fork for 5th and 6th gear should have slight clearance in the selector jaw. –  Switch to neutral. l  Locking collar must now be in the neutral position. Synchro-ring must move freely. –  Shift through all gears. Continuation for all –  Apply sealant -AMV 188 200 03- evenly to sealing surface of gearbox housing cover. –  Install gearbox housing cover → Chapter. –  Fit release bearing guide sleeve → Chapter. –  Fit clutch release lever and release bearing → Chapter. –  Top up gear oil, Golf 2004 ► → Anchor –  Top up gear oil, Golf 2009 ► with 1.4 l engine → Anchor –  Top up gear oil, Golf 2009 ► with 1.8 l engine → Anchor –  Top up gear oil, Golf Plus 2005 ► → Anchor –  Top up gear oil, Golf Plus 2009 ► → Anchor –  Top up gear oil, Eos → Anchor –  Top up gear oil, Passat 2006 ► → Anchor. –  Top up gear oil, Passat 2011 ► → Anchor. –  Top up gear oil, Passat CC and CC → Anchor –  Top up gear oil, Scirocco → Anchor