Golf Mk5
Dismantling and assembling output shaft for 5th, 6th and reverse gears |
Special tools and workshop equipment required |
t | Thrust plate -VW 401- |
t | Thrust plate -VW 402- |
t | Press tool -VW 407- |
t | Press tool -VW 408A- |
t | Press tool -VW 412- |
t | Tube -VW 415A- |
t | Support plate -VW 309- |
t | Gearbox support -VW 353- |
t | Thrust piece -VW 433- |
t | Thrust piece -VW 454- |
t | Support rail -VW 457- |
t | Support plate -VW 801- |
t | Thrust piece -VW 431- |
t | Installing sleeve -VW 455- |
t | Thrust pad -VW 510- |
t | Tube -VW 516- |
t | Tube -VW 519- |
t | Thrust plate -30-11- |
t | Thrust plate -40-105- |
t | Drift sleeve -40-20- |
t | Thrust piece -2050- |
t | Tube -3296- |
t | Tapered roller bearing puller -V.A.G 1582- |
t | Adapter -V.A.G 1582/4- |
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Note
t | If output shaft or tapered roller bearings have been renewed, adjust output shaft → Chapter. |
t | Always renew both tapered roller bearings together as a set. |
1 - | Clutch housing |
2 - | Washer |
q | Always 0.65 mm thick |
3 - | Tapered roller bearing outer race |
q | Pulling out → Fig. |
q | Pressing in → Fig. |
4 - | Tapered roller bearing inner race |
q | Pulling off → Fig. |
q | Pressing on → Fig. |
5 - | Output shaft |
q | For 5th, 6th and reverse gears |
q | Adjusting → Chapter |
6 - | Reverse gear synchro-hub |
q | Pressing off → Fig. |
q | Installation position → Fig. |
q | Pressing on → Fig. |
7 - | Retaining ring |
8 - | Reverse gear locking collar |
q | With synchro-ring |
9 - | Needle bearing |
q | For reverse gear synchromeshed gear |
10 - | Synchromeshed gear for reverse gear |
11 - | Sleeve |
q | Press off with reverse gear synchromeshed gear → Fig. |
q | Installation position: wide shoulder of sleeve faces reverse gear synchromeshed gear |
q | Pressing on → Fig. |
12 - | Retaining ring |
13 - | Needle bearing |
q | For 6th gear |
14 - | Synchromeshed gear for 6th gear |
15 - | Synchro-ring for 6th gear |
q | Check for wear → Fig. |
16 - | Locking collar with synchro-hub for 5th and 6th gears |
q | After removing retaining ring → Item, press off via synchromeshed gear for 6th gear → Fig. |
q | Dismantling → Fig. |
q | Assembling locking collar and synchro-hub → Fig. and → Fig. |
q | Pressing on → Fig. |
17 - | Retaining ring |
18 - | Needle bearing |
q | For 5th gear |
19 - | Synchro-ring for 5th gear |
q | Check for wear → Fig. |
20 - | Synchromeshed gear for 5th gear |
21 - | Tapered roller bearing inner race |
q | Pulling off → Fig. |
q | Pressing on → Fig. |
22 - | Retaining ring |
q | If tapered roller bearing → Item and output shaft → Item are renewed, redetermine → Fig. |
23 - | Tapered roller bearing outer race |
q | Pulling out → Fig. |
q | Pressing in → Fig. |
24 - | Shim |
q | Determining thickness → Chapter |
25 - | Gearbox housing |
26 - | Spring |
q | Installation position → Fig. |
27 - | Locking collar |
28 - | Synchro-hub |
29 - | Locking pieces (Qty. 3) |
q | Installation position → Fig. |
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Gap -a- | Installation (new) dimension | Wear limit |
5th and 6th gears | 1.0…1.7 mm | 0.5 mm |
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Thickness (mm) | ||
1.79 | 1.89 | 1.98 |
1.83 | 1.92 | |
1.86 | 1.95 |
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