Passat Sedan V6-2792cc 2.8L DOHC (AAA) (1995)
Synchronizer Hub: Service and Repair
Disassembling/Assembling 1st/2nd Operating Sleeve/Gear Hub
Removing 1st/2nd Gear Operating Sleeve With Synchro-hub
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Remove circlip
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Pull off operating sleeve/synchro-hub assembly using bearing support
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A = Separator, 22-115 mm e.g. Kukko 17/2
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B = 17 mm hex-head bolt (M10 x 20)
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Support the separator tool so that the lst/2nd gear operating sleeve stays in position and is NOT pulled off
Assembling 1st/2nd Gear Operating Sleeve And Synchro-hub
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1 Spring
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2 Operating sleeve
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3 Synchro-hub
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4 Locking piece
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Press operating sleeve over synchro-hub
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After assembly, wider shoulder of synchro-hub (arrow A) and outer splines of operating sleeve (arrow B) face in opposite directions
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Recesses for locking pieces, in synchro-hub and in operating sleeve, must be aligned
Assembled View Of 1st/2nd Gear Operating Sleeve And Synchro-hub
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Operating sleeve pressed over synchro-hub
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Insert locking pieces and install springs
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Spring ends must be offset by 120°
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Bent end of spring must engage in locking piece