Volkswagen Golf Variant 2007 Workshop Manual page 205

Check outer friction surface of 1st gear outer ring and 2nd gear
outer ring for wear
– Check inner surface of synchro-ring -arrow- for scoring and
radial contact scoring, renew if necessary.
– Place inner ring, outer ring and synchro-ring on cone of inner
ring.
– Press on synchro-ring with outer ring whilst turning at same
time in order to seat them.
– Measure gap size -a- at 3 points offset by 120° using feeler
gauge.
– Make a note of average value.
Gap -a- Installation dimen‐
1st and 2nd gears 1.00 ... 1.80 mm
– Install 2nd gear synchromeshed gear with needle bearing.
Installation of outer ring, inner ring and synchro-ring for 2nd gear
– Place inner ring -A- on synchromeshed gear.
Lugs -1- point away from synchromeshed gear.
– Fit outer ring -B-.
Lugs -2- engage in notches -3- of synchromeshed gear.
– Fit synchro-ring -C-.
Larger notches -4- engage in lugs -1- of inner ring -A-.
Dismantling and assembling locking collars and synchro-hubs of
1st and 2nd gears as well as 3rd and 4th gears
1 - Spring
2 - Locking piece
3 - Locking collar
4 - Synchro-hub
– Slide locking collar over synchro-hub.
In 3rd and 4th gear, wide collar of synchro-hub and, if present,
shoulder on locking collar point in one direction.
Notches for locking pieces in synchro-hub and locking collar must
align.
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤
Wear limit
sion
0.8 mm
6-speed manual gearbox 02Q - Edition 06.2010
2. Output shaft for 1st through 4th gears
201