Engage 5TH Gear

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Engage 5th gear -arrow 1- and 1st gear -arrows 2- and -3- and remove the bolts -A- for the synchronizer hub and the 5th gear.

Fig 1: Identifying Input Shaft And Output Shaft (Locked As Shown)

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- The input shaft and the output shaft are blocked after both gears are engaged. The synchronizer hub and the gear cannot turn. Both bolts can be loosened now.

NOTE:

Remove any locking compound residue still in the threaded holes using a thread tap if the shafts are not going to be replaced.

Remove the 5th gear synchronizer hub together with locking collar and locking pieces. Use the T10309 for this.

-- Insert the T10309/1 between the 5th gear -A- and the mount for the 5th gear shift fork -B-.

The T10309/1 must be placed under the synchronizer ring.

Fig 2: Identifying Puller T10309/1 Placed Below Synchronizer Ring
Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Press the puller into the end position, if necessary.

-- Rotate the T10309/1 to the opposite side in the -direction of the arrow-.

-- Insert the T10309/3 into the T10309/1

Fig 3: Identifying Puller Inserted Threaded Insert T10309/3

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Install the second T10309/1 and mount the T10309/2 on the tool.

-- Check the synchronizer hub after pulling for damage.

-- Replace the 5th gear synchronizer ring

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

-- Remove the 5th gear drive gear. The illustration shows it on a different transmission.

Fig 4: Identifying Special Puller Tools

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Insert the hook -A-.

B - 40 - 105 or M10 x 20 bolt, 17 mm

NOTE:

When remove the drive gear, make sure the hook does not bend outward. Check the 5th gear for damage.

Warm the gear with the V.A.G 1416.

Installing

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

-- Install the clutch release lever and release bearing. Refer to CLUTCH RELEASE MECHANISM OVERVIEW .

-- Fill the transmission with fluid. Refer to PAY ATTENTION TO THE FOLLOWING LIST FOR THE SUBJECT - "TRANSMISSION FLUID, CHECKING AND FILLING" .