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Component Disassembly & Reassembly: MAINSHAFT: Reassembly

  1. Inspect all parts for wear or damage and replace as necessary. Press synchro ring onto gear by hand and check clearance. See Fig 2 .
  2. Specified clearance is .040-.066" (1.0-1.7 mm). If clearance is less than .020" (.5 mm), replace synchro ring and or gear. If synchro assembly was disassembled, reassemble synchro hub to sleeve by meshing the teeth in various positions until a free sliding fit is obtained.
  3. Open ends of springs on opposite sides of assembly must be installed 120 degrees apart with angled ends over the keys.
    Fig 1: Exploded View of Pinion Shaft Assembly
    G95H55779
    Fig 2: Measuring Synchro Ring-to-Gear Clearance
    G95A55780Courtesy of VOLKSWAGEN UNITED STATES, INC.
    NOTE: The 1st-2nd gear synchro ring (2nd-3rd on 5-speed), can be identified by having one groove in blank area on outer edge. Synchronizers for 3rd-4th gears (4th-5th on 5-speed), have 2 grooves in blank area on outer edge of ring.
  4. To complete reassembly of mainshaft, reverse disassembly procedure. Install synchro assembly so that side with groove on sleeve is toward 4th gear (5th gear on 5-speed), and the side of the clutch gear hub having wide chamfer on teeth goes toward 3rd gear (4th gear on 5-speed).
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