Volkswagen Workshop Service and Repair Manuals

→ The following components have been added or modified:

• ◆ A- Inner ring
• ◆ B- Outer ring
• ◆ C- Synchro-ring

with additional recesses -4- for the lugs -1- of inner ring -A-.

• ◆ 1st gear wheel

with additional recesses -3- for the lugs -2- of outer ring -B-.

Note:

For the 2nd gear the same inner ring, outer ring and synchro ring are installed.

• ‒ If the components are not renewed, ensure they are reallocated to the original gear.

→ Installation position of inner ring, outer ring and synchro-ring 1st gear:

• ‒ Place inner ring -A- on 1st gear wheel.

Angled lugs (arrow 1) point towards outer ring -B-.

• ‒ Fit outer ring -B-.

Lugs (arrow 2) engage in gear wheel recesses (arrow 3).

• ‒ Fit synchro-ring -C-.

The recesses (arrow 4) engage in lugs (arrow 1) of inner ring -A-.

→ Check inner ring 1st gear for wear

• ‒ Press inner ring onto gear wheel cone and measure gap "a" with a feeler gauge.

→ Check synchro-ring 1st gear and outer ring for wear

• ‒ Press synchro-ring, outer-ring and inner-ring onto selector gear cone and measure gap "a" with feeler gauge.

→ Assembling locking collar and locking pieces with 1st and 2nd gear synchro-hub

•      1 -     Circlip
•      2 -     Locking collar
•      3 -     Synchro-hub
•      4 -     Locking piece

With introduction of the modified 1st gear synchronisation the shoulder has the same width on both sides of synchro-hub.

The shoulder has a chamfer on one side (arrow B).

After assembly the shoulder of the synchro-hub and the outer splines of the locking collar (arrow A) face same direction.

Recesses for locking pieces on synchro-hub and locking collar (arrow C) must align.

→ Installation position of locking collar/synchro-hub 1st and 2nd gear

The locking collar splines (arrow) point to splines for 3rd/4th gear synchro-hub -A-.

• ‒ Remove the 1st gear synchro-hub as described and install again.