Dismantling and assembly notes Dismantling

1. Press off synchronizer hub for 3rd and 4th gear.

Assembly

1. Insert spring into loose gearwheel, engaging the hooked end into the bore.

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2. Check synchronizing ring for wear, pushing synchronizing ring into the sliding sleeve and measuring gap "a" in three places (A, B and C) using a feeler gauge. Add measured values and divide by 3. The resulting value must not be less than 0.5 mm.

3. Heat synchronizing body to approx. 100°C and press into place, observing correct position. Make sure the oil groove (arrow 1) lines up with the oil bore (arrow 2) in the drive shaft.

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VW412

5. Drive clamping sleeve into the drive shaft, inserting 9 mm dia. drift "A" into the oil bore and driving in clamping sleeve "B" until it rests on the drift stop.

VW519

4. Redetermine thickness of snap ring on the A = Drift, 9 mm dia.

synchronizer hub. B = Clamping sleeve

- Press synchronizer hub up to the stop, observing correct position.

- Determine the thickest snap ring that can just barely be inserted and insert snap ring. Make sure the opening lines up with the oil groove of the synchronizer hub.

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