Audi Workshop Service and Repair Manuals

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  -1-Internal puller -Kukko 21/6- t  -4-Counter-support -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

–  Press small tapered roller bearing outer race together with a 0.65 mm thick shim fully into clutch housing. –  Insert output shaft and tighten nuts for bearing mounting to 25 Nm.

–  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 0.35 mm). Determining thickness of shim The specified bearing preload is obtained by adding a constant preload figure (0.15 mm) to the measured value obtained (0.35 mm) and the thickness of the shim installed (0.65 mm). Example:

Shim installed	0.65 mm
+ Measured value	0.35 mm
+ Preload (constant value)	0.15 mm
Thickness of shim	1.15 mm

–  Remove output shaft and pull out small taper roller bearing outer race. A -  Internal puller 37 ... 46 mm, e.g. -Kukko 21/6- B -  Counter-support, e.g. -Kukko 22/2- The following shims are available:

Thickness (mm)	Part No.
0.65 0.70	020 311 391 P 020 311 391 Q
0.75 0.80 0.85	020 311 391 020 311 391 A 020 311 391 B
0.90 0.95 1.00	020 311 391 C 020 311 391 D 020 311 391 E
1.05 1.10 1.15	020 311 391 F 020 311 391 G 020 311 391 H
1.20 1.25 1.30	020 311 391 J 020 311 391 K 020 311 391 L
1.35 1.40	020 311 391 M 020 311 391 N

Tolerance variations make it possible to obtain the exact shim thickness required. –  Press in small tapered roller bearing outer race together with the correct shim (in example 1.15 mm) ( → Anchor) and install output shaft. Tighten new nuts for bearing mounting in clutch housing to 25 Nm and then turn 90° further.