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Exploded view - dismantling and assembling reverse shaft > < Exploded view - dismantling and assembling output shaft

A1

Adjusting output shaft
Adjusting output shaft
(Determining thickness of output shaft shim)
   
Special tools and workshop equipment required
t  Universal dial gauge bracket -VW 387-
t  End measuring plate -VW 385/17-
t  Thrust pad -VW 512-
t  Straightening tool -3114/2-
t  Press tool -VW 407-
t  Torque wrench -V.A.G 1331-
t  Dial gauge

   
t  Internal puller -1- Kukko 21/6-
t  Counter-support -4 - -Kukko 22/2-
The output shaft must be re-adjusted when the following components are renewed:
t  Final drive gear set
t  Clutch housing or
t  Tapered roller bearings
Table of adjustments → Chapter
Requirement:
l  Sealing surfaces of clutch and gearbox housings must be free of sealant.
–  Press small tapered roller bearing outer race together with a 0.65 mm thick shim fully into clutch housing → Fig..
–  Insert output shaft and tighten bearing mounting nuts to 25 Nm and then turn 90° further.
–  Turn output shaft approx. 20 turns in one direction.
  Note
t  The output shaft has to be turned in one direction to seat the rollers in the tapered roller bearing.
t  This requires 20 turns.
t  If this is neglected, the measurement will not be correct.
  W00-0633
–  Mount dial gauge (3 mm measuring range) and set to „0“ with 1 mm preload.
–  Move output shaft up and down; read off and note play indicated on dial gauge (in this example 0.18 mm).
Determining thickness of shim
The specified bearing preload is obtained by adding the measured value (0.18 mm) to the thickness of the shim installed (0.65 mm).
Example:
  V35-1140
Bearing clearance =
shim (0.65 mm) + measured value (0.18 mm)		Thickness of shim according to table
0.830 mm0.950 mm

The following shims are available:
   
Bearing clearance =
shim (0.65 mm)
+ measured value		Thickness
of shim (mm)
0.650
0.660 … 0.689		0.750
0.800
0.690 … 0.739
0.740 … 0.789
0.790 … 0.839		0.850
0.900
0.950
0.840 … 0.889
0.890 … 0.939
0.940 … 0.989		1.000
1.050
1.100
0.990 … 1.039
1.040 … 1.089
1.090 … 1.139		1.150
1.200
1.250
1.140 … 1.189
1.190 … 1.239
1.240 … 1.289		1.300
1.350
1.400
1.290 … 1.339
1.340 … 1.389
1.390 … 1.429		1.450
1.500
1.550

  Note
t  Select correct shims from → Electronic parts catalogue.
t  Tolerance variations make it possible to obtain the exact shim thickness required.
–  Remove output shaft and pull out small tapered roller bearing outer race → Fig..
–  Insert shim of correct thickness.
If the size of the shim required is larger than those listed in the table, install two shims amounting to the correct value. Install the thicker of the two shims first.
l  If the original shim (0.65 mm) is to be refitted, check the shim for damage.
–  Press in small tapered roller bearing outer race together with the correct shim (in example 0.95 mm) → Fig. and install output shaft. Tighten bearing mounting nuts in clutch housing to 25 Nm and then turn 90° further.
   

Exploded view - dismantling and assembling reverse shaft > < Exploded view - dismantling and assembling output shaft