Volkswagen Workshop Service and Repair Manuals

1st gear synchronisation changed from gearbox date 04 09 0

Following new components have been added or existing ones changed: t  -A- Inner ring t  -B- Outer ring t  -C- Synchro-ring With additional notches -4- for lugs -1- of inner ring -A-. t  Synchromeshed gear for 1st gear With additional notches -3- for lugs -2- of outer ring -B-.   Note t  The same inner ring, outer ring and synchro-ring is also installed on 2nd gear. t  If components are not to be renewed, ensure that they are matched with their original gears. Installation position of inner ring, outer ring and synchro-ring for 1st gear

–  Place inner ring -A- on synchromeshed gear for 1st gear. Angled lugs -arrows 1- face outer ring -B-. –  Fit outer ring -B-. Lugs -arrows 2- engage in notches -arrows 3- of synchromeshed gear. –  Fit synchro-ring -C-. Notches -arrows 4- engage in lugs -arrows 1- of inner ring -A-.

Check 1st gear inner ring for wear. –  Press inner ring onto cone of synchromeshed gear and measure gap “a” using a feeler gauge.

Gap “a”	Installation (new) dimension	Wear limit
1st gear	0.75 ... 1.25 mm	0.3 mm

Check 1st gear synchro-ring and outer ring for wear. –  Press synchro-ring, outer ring and inner ring onto cone of synchromeshed gear and measure gap “a” using a feeler gauge.

Gap “a”	Installation (new) dimension	Wear limit
1st gear	1.2 ... 1.8 mm	0.5 mm

Assembling locking collar and locking pieces with 1st and 2nd gear synchro-hub 1 -  Spring 2 -  Locking collar 3 -  Synchro-hub 4 -  Locking piece With introduction of modified 1st gear synchronisation, collar is equally wide on both sides of synchro-hub. The collar has a chamfer on one side -arrow B-. Chamfer on collar of synchro-hub and outer teeth of locking collar -arrow A- face in same direction after assembly. Notches -arrow C- in synchro-hub and sliding collar for locking pieces must align.

Installation position of locking collar with synchro-hub for 1st and 2nd gears Teeth of locking collar -arrow- face splines for 3rd and 4th gear synchro-hub -A-. –  Remove and reinstall 1st and 2nd gear synchro-hub as described previously.