Audi Workshop Service and Repair Manuals

Adjusting output shaft (Determining thickness of output shaft shim)

Special tools and workshop equipment required

t	Drift -VW 295-

t	Thrust pad -VW 512-

t	Universal dial gauge bracket -VW 387-

t	End measuring plate -VW 385/17-

t	Spindle from assembly tool -3066-

t	Dial gauge

t  Installing ring -2003/3-

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 have been 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 hexagon bolts for bearing mounting to 25 Nm.

–  Mount dial gauge (3 mm measuring range) and set to “0” with 1 mm preload. A -  Shim (0.65 mm thick) –  Move output shaft up and down; read off and note play indicated on dial gauge (in this example 0.35 mm).   Note When taking measurements, do not turn the output shaft as the bearings will otherwise settle and falsify the measurement results. 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 tapered roller bearing outer race. A -  Internal puller 37 ... 46 mm, e.g. -Kukko 21/6- B -  Counter-support, e.g. -Kukko 22/2-   Note Position installing ring -2003/3- on the mounting surface for the bearing mounting to prevent the legs of counter-support from damaging the clutch housing. 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. If the size of the shim required is larger than those listed in the table, install two shims amounting to the correct value. –  Press in small tapered roller bearing outer race together with the correct shim (in example 1.15 mm) → Fig. and install output shaft. Tighten hexagon bolts for bearing mounting in clutch housing to specified torque.