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Determine the adjusting washer > < Disassembling and assembling output shaft 5th/6th gear and reverse gear

Octavia Mk1

Setting output shaft 5th/6th gear and reverse gear
Setting output shaft 5th/6th gear and reverse gear
(Determine adjusting washer for output shaft)
Special tools and workshop equipment required
t  Pressure spindle -MP3-423 (VW 407)-
t  Universal dial gauge holder -MP3-447 (VW 387)-
t  Washer -MP6-415 (3260)-
t  Retaining plate -T30027 (VW 801)-
t  Thrust piece -T30042 (2050)-
t  Assembly device -T30069 (VW 792)-
t  Interior extractor 46...58 mm, e.g. -Kukko 21/7-
t  Countersupport e.g. -Kukko 22/2-
t  Dial gauge
The output shaft must be re-set when the following components are replaced:
t  Gearbox housing
t  Clutch housing
t  Output shaft 5th/6th gear and reverse gear
or
t  Tapered-roller bearing for output shaft
Setting overview → Chapter
Requirements:
l  Sealing surfaces of clutch and gearbox housing must be removed of sealant residues.
l  During the measurement, only install the output shaft to be measured.
   
–  Press outer ring/tapered-roller bearing with a 1.70 mm thick adjusting washer into the gearbox housing. While doing so, support the gearbox housing with a thrust piece -T30042 (2050)- directly below the bearing support.
–  Insert complete output shaft 5th/6th gear and reverse gear into the clutch housing.
  S35-0198
–  Fit on gearbox housing and tighten screws -A- as well as -B- crosswise with tightening torque.
  S34-0582
–  Mount the measuring tools. Fit washers with a total thickness of 8 mm at the fixing screws -arrow- for assembly device -T30069 (VW 792)- onto the clutch housing.
–  Set dial gauge (3 mm measuring range) to “0” with a 1 mm bias.
–  Slacken fixing screws of clutch housing/gearbox housing crosswise, until the screws release the gearbox housing or the output shaft.
–  Read off measured value on dial gauge and note (in the example: 0.27 mm).
  Note
If no measured value is displayed on the dial gauge when loosening the fixing screws of the clutch housing/gearbox housing, install the adjusting washer 1.95 mm or if necessary the adjusting washer 2.20 mm for the measurement. Part number → Electronic Catalogue of Original Parts.
  S35-0293

Determine the adjusting washer > < Disassembling and assembling output shaft 5th/6th gear and reverse gear