5TH Gear, Installing

Fig 1: Support Bridge T10323/Bracket 30-211 A

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• Make sure the bracket 30-211 A and the support bridge T10323 are installed.

-- Secure the bolt on the bracket 30-211 A with the nut -A-.

Fig 2: 5th Gear Circumferential Groove

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The groove all the way around -arrow- faces the transmission housing.

-- Install the 5th gear.

Fig 3: Driving On 5th Gear

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Fig 4: Checking 5Th Gear Synchronizer Ring

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-- Before reinstalling the gear and synchronizer ring for 5th gear, press the synchronizer ring onto the taper of the gear and measure the gap dimension -a- using a feeler gauge.

-- Install the 5th gear selector gear with needle bearing.

-- Place the 5th gear synchronizer ring onto the selector gear.

-- If disassembled, assemble the 5th gear locking collar/synchronizer hub. Refer to Figure.

Fig 5: Assembling 5Th Gear Locking Collar/Synchronizer Hub

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Fig 6: Identifying Locking Collar, Synchro-Hub & Synchro-Hub Mountings

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The pointed teeth on the locking collar -arrow 1- and the high collar on the synchronizer hub -arrow 2- face the transmission housing.

The notches -arrow 3- on the synchronizer hub must line up with the cast locking pieces on the synchronizer ring (see Fig 7).

Fig 7: 5Th Gear Synchronizer Ring With Cast Locking Pieces

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-- Cover all openings with a cloth to prevent foreign objects from getting into the transmission.

-- Install the 5th gear synchronizer hub.

Fig 8: Driving On 5th Gear Synchro-Hub

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-- Loosen the input shaft support.

Fig 9: Support Bridge T10323/Bracket 30-211 A

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-- Clean the synchronizer hub and 5th gear drive gear threaded holes of locking fluid residue with a thread tap.

Otherwise, there is the danger that the bolts could shear off.

-- Install the synchronizer hub and 5th gear bolts.

Fig 10: Installed Position Of Plate Springs For 5Th Gear Synchronizer Hub And Drive Gear Securing Bolts

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The outer diameter -arrows- faces the 5th gear.

-- Tighten the bolts for the synchronizer hub and 5th gear drive gear to the specification. Refer to TRANSMISSION HOUSING COVER AND 5TH GEAR .

-- Engage 5th gear -arrow 1- and 1st gear -arrows 2 and 3- and then tighten the bolts -A- for the synchronizer hub and the 5th gear to specification, see -item 4- in TRANSMISSION HOUSING COVER AND 5TH GEAR .

Fig 11: Locking Input Shaft And Output Shaft (As Shown)

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-- The input and output shafts are blocked after engaging both gears, the synchronizer hub and the toothed gear cannot turn. Both bolts can now be loosened.

-- Install the 5th gear selector fork.

Fig 12: Adjusting 5Th Gear

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-- Shift into gear. Loosen the bolt -1-. Press the locking collar and shift jaw in the -direction of the arrow-, then tighten the bolt -1- to 25 Nm.

• Measurement check: It must not be possible to slide a 0.2 mm feeler gauge between the locking collar and drive gear. Repeat the adjusting procedure if necessary.

-- Install the 5th gear. The locking collar must be in the neutral position. The synchronizer ring must move freely.

-- Move the shift lever through all the gears.

-- Install the transmission housing cover. Refer to TRANSMISSION HOUSING COVER AND 5TH GEAR .

-- Install the guide sleeve for the release bearing. Refer to CLUTCH RELEASE LEVER WITH RELEASE BEARING .

-- Install the clutch release lever with release bearing. refer to CLUTCH RELEASE LEVER WITH RELEASE BEARING .

-- Fill the transmission fluid. Refer to one of the following:

Rabbit for Model Years (MY) 2006-2009, refer to Pay attention to the following list for the subject - "Transmission Fluid, Checking and Filling" .

Golf from MY 2010, refer to .