Volkswagen Golf Variant 2007 Workshop Manual page 207

Installation of synchro-ring outer ring and 1st gear inner ring
– Insert synchro-ring -A- into synchro-hub.
Lugs -1- engage in notches -2- of synchro-hub.
– Insert outer ring -B- into synchro-ring.
Lugs -3- point away from synchro-ring.
– Insert inner ring -C- into outer ring.
Lugs -4- engage in larger notches -5- of synchro-ring -A-.
Installing synchromeshed gear for 1st gear with needle bearing
• Synchro-ring -1- is located with lugs -arrow A- in notches of
synchro-hub -2-.
Pins -arrows B- of outer ring engage in notches -arrows C- of
synchromeshed gear -3-.
– Install thrust washers for 1st and 4th gears
⇒ Item 19 (page 186)
– Install 4th gear synchromeshed gear with needle bearing.
Checking synchro-ring for 4th gear for wear
– Press synchro-ring onto cone of synchromeshed gear and
measure gap -a- using feeler gauge.
Gap -a- Installation dimen‐
4th gear 1.0 ... 1.7 mm
Installation position of locking collar with synchro-hub for 3rd and
4th gears
Wider shoulder of synchro-hub -arrow- faces 3rd gear.
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤
and ⇒ Item 20 (page 186)
Wear limit
sion
0.5 mm
6-speed manual gearbox 02Q - Edition 06.2010
.
2. Output shaft for 1st through 4th gears
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