Assembling, From Transmission Build Date 25 May 2000

Fig 1: Identifying Check Of Wear To Inner Race -1- And Outer Race -2- Through Gap -a-

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-- Install the inner race -1- on the cone on the gear.

-- Install the outer race -2- on the cone on the inner race. Measure the gap -a- with a feeler gauge at 3 locations at 120°.

-- Note the average value.

Fig 2: Identifying Synchronizer Ring -Arrow- On Inner Running Surface For Grooves And Radial Wear Through Gap -a-

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-- Check the synchronizer ring -arrow- on the inner running surface for grooves and radial wear, and replace if necessary.

-- Install the inner race, the outer race and the synchronizer ring on the cone on the inner race.

-- Press the synchronizer ring onto the outer races while turning it at the same time so that it seats correctly.

-- Measure the gap -a- with a feeler gauge at 3 locations at 120°.

-- Note the average value.

-- Install the 2nd gear with the needle bearing.

Fig 3: Installed Position Of Outer Race, Inner Race And Synchronizer Ring, 2nd Gear

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-- Install the inner race -A- in the gear.

The tabs -1- face away from the gear.

-- Install the outer race -B-.

The tabs -2- engage in grooves -3- on the gear.

-- Install the synchronizer ring -C-.

The larger openings -4- lock in the tabs -1- on the inner race -A-.

Fig 4: Exploded View Of Gear Locking Collar And Synchro-Hub Components

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1. Spring 
2. Locking piece 
3. Locking collar 
4. Synchronizer hub 

-- Slide the locking collar over the synchronizer hub.

In 3rd and 4th gear, the wide collar on the synchronizer hub and the locking collar face in one direction.

The notches for the locking pieces on the synchronizer hub and locking collar must line up with each other.

Fig 5: Identifying 3rd And 4th Gear Locking Collar/Synchro-Hub

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The locking collar is pushed over the synchronizer hub.

-- Install the locking pieces and springs offset by 120°. The angled end of the spring must engage into the hollow locking piece.

Fig 6: Installation Position Of 1st And 2nd Gear Locking Collar/Synchro-Hub

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The identification groove -arrow 1- and the narrow collar -arrow 2- on the synchronizer hub face 1st gear.

Fig 7: Identifying Sequence To Install Locking Collar/Synchronizer Hub For 1st And 2nd Gears

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The pins -A- on the synchronizer ring lock into the recesses -B- in the synchronizer hub.

-- Install the locking ring.

Fig 8: Identifying Sequence To Install Outer Ring Synchronizer Ring And 3rd Gear Inner Ring

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-- Install the synchronizer ring -A- in the synchronizer hub.

The tabs -1- lock in the openings -2- in the synchronizer hub.

-- Install the outer race -B- in the synchronizer ring.

The tabs -3- face away from the synchronizer ring.

-- Install the inner race -C- in the outer race.

The tabs -4- lock in the larger openings -5- in the synchronizer ring -A-.

Fig 9: Identifying Installation Of 1st Gear With Needle Roller Bearing

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• The synchronizer ring -1- and the tabs -arrow A- are inside the openings in the synchronizer hub -2-.

The pins -arrows B- in the outer race lock in the recesses -arrows C- in the gear -3-.

-- Install the thrust washers for 1st and 4th gears, refer to "Thrust Washers" in item  19 and "Washer" in item  20.

-- Install the 4th gear with needle bearing.

Fig 10: Identifying Check Of 4th Gear Synchronizer Ring For Wear

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-- Press the synchronizer ring onto the taper of the gear and measure the gap dimension -a- using a feeler gauge.

Fig 11: Identifying Check Of 4th Gear Synchro-Ring For Wear

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Fig 12: Installation Position 3rd And 4th Gear Locking Collar/Synchro-Hub

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The wider collar on the synchronizer hub -arrow- faces 3rd gear.

-- Place the synchronizer ring for 4th gear on the 4th gear selector gear.

Fig 13: Identifying Tool Assembly To Press On 3rd And 4th Gear Synchro-Hub With Locking Collar

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-- Turn the synchronizer ring so that the grooves line up with the locking pieces.

-- Install the locking ring.

Fig 14: Identifying Sequence To Install Outer Ring Synchronizer Ring And 3rd Gear Inner Ring

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Install the synchronizer ring -A- in the synchronizer hub.

The tabs -1- lock in the openings -2- in the synchronizer hub.

-- Install the outer race -B- in the synchronizer ring.

The tabs -3- face away from the synchronizer ring.

-- Install the inner race -C- in the outer race.

The tabs -4- lock in the larger openings -5- in the synchronizer ring -A-.

Fig 15: Identifying Installation Of 1st Gear With Needle Roller Bearing

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• The synchronizer ring -1- and the tabs -arrow A- are inside the openings in the synchronizer hub -2-.

The pins -arrows B- in the outer race lock in the recesses -arrows C- in the gear -3-.

-- Install the 3rd gear with the needle bearing.