volkswagen Workshop Repair Guides

Volkswagen Workshop Service and Repair Manuals

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Adjusting shaft bevel gear > < Recommended sequence for adjusting gear set

Golf Mk3

5-Speed manual gearbox 02C four wheel drive
Adjusting shaft bevel gear and bevel gear (gear set)
Determining shim "S4" thickness when replacing output flange

This adjustment is only necessary if the output flange is replaced. Its purpose is to re-establish the shaft bevel gear taper roller bearing preloading.

Note:

Identifying differences between 4-Cyl. engine and 6-Cyl. injection engine output flanges .
 
V39-1076
  • ‒ → Measure length of old and new output flange shafts and determine difference.

Example:

Old output flange

25.80 mm

New output flange

25.60 mm

Difference

0.20 mm

If the new output flange is longer: Install a thinner, by the difference, S4shim.

If the old output flange is longer: Install a thicker, by the difference, S4shim.

The following adjustment shims are available:

Size (mm)

Part No.

0.65
0.70
0.75

02C 409 280
02C 409 280A
02C 409 280B

0.80
0.85
0.90

02C 409 280C
02C 409 280D
02C 409 280E

0.95
1.00
1.05

02C 409 280F
02C 409 280G
02C 409 280H

1.10
1.15
1.20

02C 409 280J
02C 409 280K
02C 409 280L

1.25
1.30
1.35
1.40

02C 409 280M
02C 409 280N
02C 409 280P
02C 409 280Q

Adjusting shaft bevel gear > < Recommended sequence for adjusting gear set