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Upgrades (non TDI Engine related) The place of handling, lighting and other upgrades that do not relate to the performance or economy of the TDI engine. In other words upgrades to your TDI that don't fit into TDI Fuel Economy & TDI Engine Enhancements.Please note the Performance Disclaimer

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Old May 19th, 2013, 15:16   #1
Join Date: Apr 2006
Location: Cleveland, OH
Default Need help to get selector gear off for 5th gear swap

I am in the process of converting my 03 Golf from an auto to a 5spd (donor was an 01 Beetle) and while I was at it I wanted to go ahead and upgrade 5th gear since it was already drained and was easy to access. I have the bolts off and the selector ring out of the way but I can not get the selector gear loose. I realize that it is pressed on, but I have been heating it and putting a lot of pressure (more that I am really comfortable with) on it with a 2 jaw puller but I have yet to get it to budge. I have also tried tapping on the gear with a wrench while it was hot and with the puller loaded, but still no such luck.

Has anyone who has done a 5th gear swap before had this much trouble getting the selector gear off? Any thoughts (I am concerned about shattering the gear with too much force and I don't want to put too much heat into it with a torch)?

Thanks in advance.
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Old May 19th, 2013, 16:53   #2
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Join Date: Apr 2006
Location: Cambridge
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I use a three jaw puller, with the ends of the jaws ground down so that they slide fully under the gear and selector ring. That and a little heat from a propane torch and the gear will pop off without too much difficulty.

Proudly installing things where they're not supposed to go since 1996!
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