Checking synchronizer rings

WARNING: This page does not describe the selected car, but rather 21 other vehicles, including the 2002 Volkswagen Cabrio, 2001 Volkswagen Cabrio, 2000 Volkswagen Cabrio, 1999 Volkswagen Jetta, and 1999 Volkswagen Golf. However, it is still accessible from the selected car via links, so may be relevant.

Press synchronizer rings onto gear cones and measure gap -a- with feeler gauge.

Fig 1: Checking Synchronizer Ring Gap -a-

Courtesy of VOLKSWAGEN OF AMERICA, INC.

SYNCHRONIZER RING GAP -a- DIMENSIONS (OUTPUT SHAFT)

Gap -a-	Dimension (new)	Wear limit
1st gear	1.1-1.7 mm (0.043-0.067 in.)	0.5 mm (0.020 in.)
2nd gear