Audi Workshop Service and Repair Manuals

Adjusting output shaft (Determining shim for output shaft)   Note t  Re-adjustment of the output shaft is required if the following components have been renewed: t  Gearbox housing, clutch housing, output shaft or taper roller bearing. t  Table of adjustments → Chapter

Special tools and workshop equipment required

t	Universal dial gauge bracket -VW 387-

t	Measuring device d = 50 mm -VW 385/17- from universal measuring device -VW 385-

t	Thrust pad -VW 512-

t	Press tool -VW 407-

t  Dial gauge -VAS 6080-

t  -1-internal puller-Kukko 21/6- t  -4- Counter-support -4 - Kukko 22/2-

Procedure –  Press home the taper roller bearing outer race with a 0.75 mm thick shim in the clutch housing. –  Insert output shaft in clutch housing and install gearbox housing. Tighten bolts to 25 Nm.

–  Set up the universal dial gauge holder -VW 387- with dial gauge -VAS 6080- (3 mm measuring range). –  Turn the output shaft prior to measurement so that the taper roller bearings settle. –  Preload dial gauge to 1 mm and set to „0“.   Note This procedure is to be repeated for all further measurements, as the dial gauge does not otherwise return to the initial position. –  Pull the output shaft in -direction of arrow-. –  Read off play on dial gauge and note reading. l  Measurement in following example: 0.30 mm. Determining thickness of shim Specified bearing preload = fitted shim + measured value + preload (constant value).

Example:
Inserted shim	0.75 mm
Dial gauge reading (example)	+ 0.30 mm
Preload (constant value)	+ 0.20 mm
Thickness of shim	= 1.25 mm

–  Determine the thickness of the shim on the basis of the following table; for part numbers refer to → Electronic parts catalogue.

Available shims - Thickness of shims in mm 1)
0.70	1.00	1.30
0.75	1.05	1.35
0.80	1.10	1.40
0.85	1.15
0.90	1.20
0.95	1.25
l  1) Different shim thicknesses permit precise setting of the required shim thickness. Fit 2 shims if necessary.

–  Remove output shaft and pull taper roller bearing outer race out of clutch housing. A -  Internal puller 37 … 46 mm -Kukko 21/6- B -  Counter-support -Kukko 22/2- –  Take the shim fitted (0.75 mm thick) out of the clutch housing. –  Press in the taper roller bearing outer race with the shim determined (1.25 mm in the example) and fit the output shaft. –  Mount the gearbox housing and tighten the bolts to 25 Nm.