Volkswagen Golf Workshop Service and Repair Manuals

Synchronizer hub for 5th gear with retaining ring for locking keys =>page 35-36

Note:

When installing new gears, see Technical Data

• M 17 screw 150 Nm
• ◆ Renew, coat new screw with D 6 locking solution
• Sleeve
• Hub
• Locking key
• Long side towards synchro ring
• Spring
• Wire dia. 1.4 mm.
• M 7 x 24 screw - 15 Nm
• Gearbox housing
• Clamping plate
• ◆ Secures bearing =>fig. 9 .

• 4th speed gear
• Synchro ring for 4th gear
• ◆ Check for wear =>fig. 3 .
• Sleeve
• Hub
• Locking key
• Spring
• Wire dia. 1.4 mm
• Input shaft
• Bush for clutch push rod
• ◆ Position =>fig. 10 .
• ◆ Knocking out =>fig. 12 .
• ◆ Knocking in =>fig. 13 .
• Needle bearing for input shaft
• ◆ Pulling out =>fig. 16 .
• ◆ Knocking in =>fig. 17 .
• Bearing housing

• Seal for clutch push rod
• Can be replaced with gearbox out (not dismantled)
• ◆ Position =>fig. 10 .
• ◆ Knocking out =>fig. 11 .
• ◆ Pressing In =>fig. 14 .
• 3rd speed gear
• Synchronizing for 3rd gear
• ◆ Sprayed with molybdenum check for wear =>fig. 3 .
• Sleeve/hub for 3rd / 4th gear
• ◆ Pressing off =>fig.2
• ◆ Pressing off =>figs.4 - 6 .
• ◆ Pressing on =>fig.7 .
• Circlip
• Fit new, do not over stretch, must seat properly in groove.

• Ball bearing
• ◆ Pressing off =>fig.1 .
• ◆ Pressing into gearbox housing
  =>fig.8 .
• Up to assembly date 31 05 9:
• When renewed, use 020 311 123 G
• ◆ Press inner race off and on separately =>fig.18 and 19 .
• Shim for input shaft
• Thrust washer
• ◆ Position: Chamfer on outer dia.
  towards ball bearing
• 5th speed gear
• Synchro ring for 5th gear
• ◆ Check for wear => fig. 3 .
• Sleeve/hub for 5th gear
• ◆ Assembling => fig. 15 .

→ Fig.1     Pressing ball bearing off

A - Separating appliance 12 - 75 mm - e.g. Kukko 17/1.

→ Fig.2     Pressing off sleeve/hub with 3rd speed gear

→ Fig.3     Checking synchronizer rings

Press synchro ring on to gear cone and measure gap "a" with feelers

→ Fig.4     Assembling sleeve and hub for 3rd/4th gear

Position:

The chamfer on the inner splines of the hub - arrow 1 - goes towards 3rd gear.

Additional identification groove - arrow 2 - goes towards 4th gear.

→ Fig.5     Identification of hub for 3rd/4th gear

Either a groove -withe arrow- on hub (4th gear side) or axial grooves or the splines -black arrow-.

→ Fig.6     Assembling sleeve/hub for 3rd/4th gear

• ‒ Push sleeve over hub. It is no longer necessary to assemble the parts in a particular position.
• ‒ Install keys and fit springs 120° offset. The spring with the angled end must engage in the hollow key.

→ Fig.7     Pressing hub and sleeve on

Fitting direction:
See =>fig. 4 .

Turn synchronizer ring so that grooves align with keys.

→ Fig.8     Pressing ball bearing and shim into the gearbox housing

Fitting direction:
Wide shoulder on inner race towards 4th gear.

Secure with clamping plate =>fig. 9 .

→ Fig.9     Securing clamping plate

→ Fig.10     Position of seal and bush

•      A -     Seal for clutch push rod
•      B -     Bush for clutch push rod

→ Fig.11     Pulling seal for clutch push rod out

Can be removed with gearbox out without dismantling box

→ Fig.12     Knocking out bush for clutch push rod

A = 10 mm rod such as an old pump shaft from automatic gearbox.

→ Fig.13     Drive bush in fully

→ Fig.14     Installing seal

Push seal -A- in with the fitting plug -B- supplied. Take plug out. The seal is then in the correct position. (0.8 - 1.3 mm deep). Oil lips of seal.

→ Fig.15     Assembling hub and sleeve for 5th gear

• ‒ Push sleeve over hub. It is not necessary to assemble the parts in a particular position.
• ‒ Insert keys with long side downwards (towards synchronizer ring).
• ‒ Install both springs from below 120° offset.
• ‒ The spring with the angled end must engage in the hollow key.

→ Fig.16     Pulling needle bearing out of bearing housing

•      A -     Extractor 18.5-23.5 mm e.g. Kukko 21/3
•      B -     Support e.g. Kukko 22/2

→ Fig.17     Knocking needle bearing into bearing housing

→ Fig.18     Pressing off 4th speed gear and ball bearing inner racer

•      A -     Separating tool, 12 - 75 mm e.g. Kukko 17/1.

Only up to assembly date 31 059

→ Fig.19     Pressing on ball bearing inner race

Only up to assembly date 31 05 9.