5-speed manual gearbox 0A4.pdf

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤
5-speed manual gearbox 0A4 - Edition 04.2010
Checking 5th gear synchro-ring
– Before installing synchromeshed gear and synchro-ring for 5th
gear, press synchro-ring onto cone of synchromeshed gear
and measure gap -a- with a feeler gauge.
Gap -a-
Installation (new) dimension
Wear limit
5th gear 1.1 … 1.7 mm 0.5 mm
– Install 5th gear synchromeshed gear with needle bearing.
– Place 5th gear synchro-ring on synchromeshed gear.
– If synchro-hub and locking collar for 5th gear are dismantled,
assemble before installing ⇒ page 162 .
Installation position 5th gear synchro-hub and locking collar
The pointed teeth of the locking collar -arrow 1- and the high
shoulder of the synchro-hub -arrow 2- face the gearbox housing.
The synchro-hub supports -arrow 3- align with the cast locking
pieces of the 5th gear synchro-ring ( ⇒ page 138 , bottom).
5th gear synchro-ring with cast locking pieces
– Cover all openings in gearbox housing with a cloth to prevent
foreign bodies from entering gearbox.
– Heat 5th gear synchro-hub to about 100 °C with inductive
heater -VAS 6414- before installing.
WARNING
Wear protective gloves!
– Drive on 5th gear synchro-hub.
Note
When driving on, ensure that synchro-ring moves freely.
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in this document. Copyright by Volkswagen AG.
138 Rep. Gr.34 - Controls, housing