Golf Mk5
| Assembly overview - removing and installing cover for gearbox housing and 5th and 6th gears |
| 1 - | Gearbox housing |
| q | Pull off together with 5th and 6th gears → Chapter. |
| q | Repairing → Chapter. |
| 2 - | Gear wheel for 5th gear |
| q | Pull off individually → Chapter |
| q | Pull off together with gearbox housing → Chapter |
| 3 - | Sleeve |
| 4 - | Gear wheel for 6th gear |
| q | Pull off individually → Chapter |
| q | Pull off together with gearbox housing → Chapter |
| 5 - | Cylindrical roller bearing inner race |
| q | For output shaft |
| q | Mark before removing |
| q | Do not interchange with inner race for cylindrical roller bearing of input shaft |
| q | Larger outer diameter from gearbox date 21 08 6 |
| q | Allocation → Fig. |
| 6 - | Bolt |
| q | For output shaft |
| q | Allocation of bolts → Fig. |
| q | To gearbox date 20 08 6: 40 Nm and 180° further |
| q | From gearbox date 21 08 6: 80 Nm and then turn 90° further |
| q | Self-locking |
| q | Always renew |
| q | Clean residual locking fluid from threaded holes for securing bolts for synchro-hub for 5th and 6th gears and gear wheel for 6th gear with a thread chaser. Otherwise the bolts may shear. |
| 7 - | Gearbox housing cover |
| q | With cylindrical roller bearings for input and output shafts |
| q | Cylindrical roller bearings for input and output shafts from gearbox date 21 08 6 with larger outer diameter → Fig. |
| q | Repairing → Chapter. |
| 8 - | Bolt, 18 Nm |
| q | Qty. 5 |
| q | For gearbox housing cover. |
| 9 - | Bolt |
| q | For input shaft |
| q | Allocation of bolts → Fig. |
| q | To gearbox date 20 08 6: 40 Nm and 180° further |
| q | From gearbox date 21 08 6: 80 Nm and then turn 90° further |
| q | Self-locking |
| q | Always renew |
| q | Clean residual locking fluid from threaded holes for securing bolts for synchro-hub for 5th and 6th gears and gear wheel for 6th gear with a thread chaser. Otherwise the bolts may shear. |
| 10 - | Cylindrical roller bearing inner race |
| q | For input shaft |
| q | Mark before removing |
| q | Do not interchange with cylinder roller bearing inner race of output shaft. |
| q | From gearbox date 21 08 6, combined with thrust washer in one component → Item |
| q | Allocation of inner race for cylindrical roller bearing → Fig. |
| 11 - | Thrust washer |
| q | Through gearbox date 20 08 6 |
| 12 - | Inner race for cylindrical roller bearing with thrust washer |
| q | For input shaft |
| q | From gearbox date 21 08 6 |
| q | Allocation of inner race for cylindrical roller bearing → Fig. |
| 13 - | Sleeve |
| q | For 6th gear needle bearing. |
| q | Renew together with needle bearing |
| q | Larger diameter from gearbox date 21 08 6 |
| q | Allocation of components via → Electronic parts catalogue (ETKA) |
| 14 - | Needle bearing |
| q | For 6th gear |
| q | Renew together with sleeve |
| q | Larger diameter from gearbox date 21 08 6 |
| q | Allocation of components via → Electronic parts catalogue (ETKA) |
| 15 - | Synchromeshed gear for 6th gear |
| q | Adapted to sleeve and needle bearing from gearbox date 21 08 6 |
| q | Allocation of components via → Electronic parts catalogue (ETKA) |
| 16 - | Wave spring washer |
| q | From gearbox date 26 05 8 |
| q | In this case, install only locking piece springs without angled ends. (As shown in → Fig. - item 1-) |
| q | Allocate according to → Electronic parts catalogue „ETKA“ |
| 17 - | Synchro-ring for 6th gear |
| 18 - | Locking collar with synchro-hub for 5th and 6th gears |
| q | Pull off individually → Chapter |
| q | Pull off together with gearbox housing → Chapter |
| q | Dismantling and assembling → Fig. and → Fig. |
| q | From gearbox date 12 06 6, locking collar modified → Fig. |
| q | Adjusting, through gearbox date 11 06 6 → Fig. |
| q | Adjusting, from gearbox date 12 06 6 → Fig. |
| q | Installation of springs with angled ends for locking pieces → Fig. |
| 19 - | Synchro-ring for 5th gear |
| q | Will be damaged during removal of input shaft |
| q | Always renew |
| 20 - | Wave spring washer |
| q | From gearbox date 26 05 8 |
| q | In this case, install only locking piece springs without angled ends. (As shown in → Fig. - item 1-) |
| q | Allocate according to → Electronic parts catalogue „ETKA“ |
| 21 - | Synchromeshed gear for 5th gear |
| 22 - | Needle bearing |
| q | For 5th gear |
| 23 - | Socket head bolt, 25 Nm |
| q | For pivot pin to gearbox housing |
| 24 - | Pivot pin |
| 25 - | 5th/6th gear selector fork |
| 26 - | Selector jaw for 5th and 6th gears |
| 27 - | Bolt, 25 Nm |
|
|
| Gearbox manufacture date | Dim. „a“ mm | Dim. „b“ mm | ||
| Through 20 08 6 | 21 | 31 | ||
| From 21 08 6 | 23.4 | 37
|
|
|
| Gearbox manufacture date | Dim. „a“ mm | Dim. „b“ mm |
| Through 20 08 6 | 21 | 31 |
| From 21 08 6 | 23.4 | 37 |
