Volkswagen Workshop Service and Repair Manuals

Installing 5th gear 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 –  Before installing synchromeshed gear and synchro-ring for 5th gear, press synchro-ring onto cone of synchromeshed gear and measure gap -a- with a feeler gauge.

Gap -a-	Installation dimension	Wear limit
5th gear	1.1 … 1.7 mm	0.5 mm

–  Install 5th gear synchromeshed gear with needle bearing. –  Place 5th gear synchro-ring on synchromeshed gear. –  Assemble 5th gear synchro-hub and locking collar before installing → Fig..

Installation position 5th gear synchro-hub and locking collar The pointed teeth of the locking collar -arrow 1- and the high shoulder of the synchro-hub -arrow 2- face the gearbox housing. The supports -arrow 3- for the synchro-hub align with the cast locking pieces of the gear synchro-ring (-arrows- in figure below).

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

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

–  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 gear and 5th gear wheel with a thread chaser. Otherwise the bolts may shear. –  Screw in securing bolts for synchro-hub and gear wheel for 5th gear.

Installation position of dished springs for securing bolts for gear wheel and synchro-hub for 5th gear The outer diameter -arrows- faces 5th gear. –  Tighten securing bolts for synchro-hub and gear wheel for 5th gear to specified torque. → Chapter

–  Tighten bolts -A- for synchro-hub and 5th gear wheel to specified torque → Chapter. To do this, engage 5th gear -arrow 1- and 1st gear -arrows 2- and -3-. –  After both gears are engaged, the input shaft and output shaft are locked. The synchro-hub and gear wheel cannot turn. Now both bolts can be tightened. –  Install 5th gear selector fork.

Adjusting 5th gear –  Engage 5th gear. Loosen bolt -1-. Push locking collar and selector jaw in -direction of arrow- and then tighten bolt -1- to 25 Nm. l  Check measurement: It must not be possible to slide a 0.2 mm feeler gauge between locking collar and gear wheel. If necessary, repeat adjustment. –  Disengage 5th gear. Locking collar must now be in the neutral position. Synchro-ring must move freely. –  Shift through all gears. –  Install gearbox housing cover → Chapter.