Gap Dimensions

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Gap dimension -a-	Installation Dimension	Wear limit
1st and 2nd gear	0.75 to 1.25 mm	0.3 mm

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Install the synchronizer ring, outer race and inner race onto taper of selector gear and then measure the gap dimension -a- with a feeler gauge.

Gap dimension -a-	Installation Dimension	Wear limit
1st and 2nd gear	1.2 to 1.8 mm	0.5 mm

Fig 1: Exploded View Of Modified 1st Gear Synchronization Components

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Install the inner race -A- on the 2nd gear wheel.

The angled tabs -arrows 1- face the outer race -B-.

-- Install the outer race -B-.

The tabs -arrows 2- must lock into the retainers -arrows 3- in the gear wheel.

-- Install the synchronizer ring -C-.

The retainers -arrows 4- lock in the tabs -arrows 1- on the inner race -A-.

Fig 2: Exploded View Of Locking Collar And Synchronizer Hub For 1st And 2nd Gears

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Slide the locking collar over the synchronizer hub.

Installed position:

The groove on the front -arrow A- and the higher collar -arrow B- on the synchronizer hub faces the outer splines on the locking collar -arrow C-.

Deeper recesses -arrow D- for locking pieces in synchronizer hub and recesses -arrow E- in locking collar must align.