Volkswagen Golf Variant 2007 Service Manual page 117

– Check whether puller hooks -T10040/2A- can be inserted cor‐
rectly under 5th gear wheel.
Puller hooks -T10040/2A- cannot be inserted correctly.
-A-
Puller hooks -T10040/2A- make
contact too soon with:
♦ gearbox housing wall
♦ ribs in gearbox housing under
5th gear wheel
-B-
Puller hooks -T10040/2A- come
into contact with ribs in gearbox
housing below gear wheel.
Puller hooks -T10040/2A- cannot be inserted correctly.
5th/6th gear can be removed individually
Remove 5th and 6th gears individually
– Remove selector fork for 5th and 6th gears as follows:
– Cover openings with a cloth.
– Engage 5th gear -arrows 1- and -2-.
– Remove selector jaw for 5th and 6th gears -bolt A-.
– Then remove both bolts -B- for pivot pins.
– Pull out pivot pins.
– Remove selector fork for 5th and 6th gears.
– Remove -bolts A- for inner bearing races from input and output
shafts, engaging 5th gear -arrow 1- and 1st gear -arrow 2- and
-arrow 3-.
– Input shaft and output shaft are locked when both gears are
engaged. Both bolts can now be loosened.
Note
If the shafts are to be reused, clean residual locking material out
of threaded holes using a thread chaser.
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
6-speed manual gearbox 02S - Edition 07.2009
Removal of "synchro-hub
5th/6th gear", "6th gear
wheel", " 5th gear wheel"
and "gearbox housing" to‐
gether ⇒ page 115
⇒ page 113
5. Dismantling and assembling gearbox
113