Audi Workshop Service and Repair Manuals

Adjusting input shaft (Determining thickness of shim for input shaft) The input shaft must be re-adjusted when the following components are renewed: t  Gearbox housing t  Clutch housing t  Input shaft t  Tapered roller bearings Table of adjustments → Chapter

Special tools and workshop equipment required

t	Support plate -VW 309-

t	Gearbox support -VW 353-

t	End measuring plate -VW 385/17-

t	Universal dial gauge bracket -VW 387-

t	Press tool -VW 407-

t	Press tool -VW 433-

t  Support plate -VW 801-

t  -1-Internal puller -Kukko 21/7- t  -4-Counter-support -Kukko 22/1- Adjusting l  Shims of determined thickness are installed for both output shafts.

–  Press tapered roller bearing outer race (without shim) into gearbox housing onto stop. –  Install both output shafts and input shaft in clutch housing and fit gearbox housing. Tighten hexagon bolts to 25 Nm + tighten 45° (1/8 turn) further

–  Fit measuring appliance and dial gauge in clutch housing. –  Before measurement, rotate input shaft to allow tapered roller bearings to settle. –  Set dial gauge to “0” with a preload of 1 mm.   Note This procedure must be repeated for each subsequent measurement, as otherwise the dial gauge will not return to its original setting. –  Move input shaft towards dial gauge. –  Read off and note play indicated on dial gauge (in this example: 1.63 mm). –  Determine thickness of shim according to following table (in this example: 1.60).

Bearing clearance Measured value (mm)	Shim (mm) → Note	Bearing clearance Measured value (mm)	Shim (mm) → Note
1.480 … 1.524	1.45	1.925 … 1.974	1.90
1.525 … 1.574	1.50	1.975 … 2.024	1.95
1.575 … 1.624	1.55	2.025 … 2.074	2.00
1.625 … 1.674	1.60	2.075 … 2.124	2.05
1.675 … 1.724	1.65	2.125 … 2.174	2.10
1.725 … 1.774	1.70	2.175 … 2.224	2.15
1.775 … 1.824	1.75	2.225 … 2.274	2.20
1.825 … 1.874	1.80	2.275 … 2.324	2.25
1.875 … 1.924	1.85	2.325 … 2.374	2.30

1)	Part No.; for allocation refer to → Parts catalogue

–  Remove gearbox housing and pull tapered roller bearing outer race out of gearbox housing. A -  Counter-support -Kukko 22/2- B -  Internal puller 46 ... 58 mm -Kukko 21/7- –  Press tapered roller bearing outer race (with shim) into gearbox housing (shim in this example: 1.60 mm). –  Fit gearbox housing and tighten hexagon bolts to 25 Nm + tighten 45° (1/8 turn) further.

Checking adjustment –  Fit measuring appliance and dial gauge. –  Rotate input shaft to allow tapered roller bearings to settle. –  Move input shaft towards dial gauge. l  Bearing clearance min. 0.065 mm. l  Bearing clearance max. 0.150 mm.   Note If the bearing clearance cannot be measured, but input shaft play is perceptible and the input shaft turns freely, the adjustment is acceptable.