Audi Workshop Service and Repair Manuals

(Determining shim for output shaft)

Special tools and workshop equipment required

• ◆ VW 353 Gearbox support
• ◆ VW 387 Universal dial gauge bracket
• ◆ VW 407 Press tool
• ◆ VW 433 Press piece
• ◆ VW 792 Fitting tool
• ◆ VW 801 Holding plate

Special tools and workshop equipment required

• ◆ 2050 Thrust piece
• ◆ 3235 Press
• ◆ V.A.G 1331 Torque wrench
• ◆ 1 - Kukko 21/7 Internal puller
• ◆ 4 - Kukko 22/2 Counter support

It is necessary to readjust the output shaft when the following components are renewed:

• ◆ Gearbox housing
• ◆ Clutch housing
• ◆ Output shaft for 5th, 6th and reverse gears

or

• ◆ Taper roller bearing

Adjustment overview

Prerequisites

• ● Sealing surfaces of clutch and gearbox housings must be free of sealant.

• ● When taking measurements, install only the shaft to be measured.

• ‒ → Press taper roller bearing outer race with 1.70 mm thick shim into gearbox housing, supporting gearbox housing directly under bearing support with thrust piece 2050.
• ‒ Set complete 5th, 6th and reverse gear output shaft in clutch housing.

• ‒ → Fit gearbox housing and tighten bolts -A- and -B- diagonally to correct torque.

• ‒ → Fit measuring tools. Put washers with a total thickness of 8 mm on bolt -arrow- securing fitting tool VW 792 to clutch housing.
• ‒ Set dial gauge (3 mm measuring range) to zero with 1 mm preload.

• ‒ Loosen clutch housing/gearbox housing securing bolts diagonally until output shaft moves freely in gearbox housing.
• ‒ Read off play on gauge and note reading (example: 0.27 mm)

Note:

If dial gauge indicates no value when clutch housing/gearbox housing securing bolts are loosened, install shim 1.95 mm (part No. 084 409 383 AS) or, if necessary, shim 2.20 mm (part No. 084 409 383 BD).

Determining thickness of shim

The specified bearing pretension will be attained by subtracting the measured value (0.27 mm) from the inserted shim (1.70 mm) and adding a constant for pressing (0.20 mm).

Example:

• ‒ Determine thickness of shim from table => Page 35-81.

• ‒ → Remove gearbox housing and pull taper roller bearing outer race out from gearbox housing.

A - Counter support, e.g. Kukko 22/2

B - Internal puller 46...58 mm, e.g. Kukko 21/7

• ‒ Remove inserted shim (1.70 mm thick) from clutch housing.

Shim table

Varying tolerances make it possible to obtain the exact shim thickness required.

• ‒ → Press in taper roller bearing outer race together with the determined shim (in example 1.65 mm) while supporting gearbox housing with thrust piece 2050 directly under bearing support.

Carry out check measurement

• ● Determined shim installed.

• ‒ → Fit measuring tools. Put washers of a total thickness of 8 mm on bolt -arrow- securing fitting tool VW 792 to clutch housing.
• ‒ Set dial gauge (3 mm measuring range) to zero with 1 mm preload.
• ‒ Loosen clutch housing/gearbox housing securing bolts diagonally until output shaft moves freely in gearbox.
• ‒ If the correct shim has been selected, dial gauge will indicate a value of 0.15 mm to 0.25 mm.