volkswagen Workshop Repair Guides

Volkswagen Golf Workshop Service and Repair Manuals

Dismantling and assembling reverse shaft > < From gearbox build date 04 09 0 the synchronisation for 1st gear has been modified
5-speed manual gearbox 02J
Adjusting output shaft
Adjusting output shaft
 
W35-0028

(Determining shim for output shaft)

Special tools and workshop equipment required

  • ◆ VW 387 Universal dial gauge bracket
  • ◆ VW 385/17 End measuring plate
  • ◆ VW 512 Press disk
  • ◆ 3114/2 Straightening tool
  • ◆ VW 407 Press tool
  • ◆ V.A.G 1331 Torque wrench
  • ◆ Dial gauge
 
W00-0633

Special tools and workshop equipment required

  • ◆ 1 - Internal puller Kukko 21/6
  • ◆ 4 - Kukko 22/2 Counter support

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

  • ◆ Final drive
  • ◆ Clutch housing

or

  • ◆ Taper roller bearing

Adjustment overview

  • ‒ Press small taper roller bearing outer race together with a 0.65 mm thick shim fully into clutch housing .
  • ‒ Insert output shaft and tighten nuts for bearing support to 25 Nm, then turn 90° further.
 
V35-1140
  • ‒ → Mount dial gauge (3 mm measuring range) and set to "0" with 1 mm preload.
  • ‒ Move output shaft up and down and note dial gauge reading (example: 0.30 mm).

Determining thickness of shim

The specified bearing preload is obtained by adding
a constant preload figure of (0.20 mm)
to the reading obtained (0.30 mm)
and the thickness of the shim installed (0.65 mm).

Example:

Shim installed

0.65 mm

+ Reading

0.30 mm

+ Preload (constant)

0.20 mm

Thickness of shim

1.15 mm

  • ‒ Remove output shaft and pull out small taper roller bearing outer race => Page 35-36

The following adjustment shims are available:

Size (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

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

  • ‒ Press in small taper roller bearing outer race together with the correct shim (in example 1.15 mm) ( ) and install output shaft. Tighten bearing support nuts in clutch housing to 25 Nm and then turn 90° further.

Dismantling and assembling reverse shaft > < From gearbox build date 04 09 0 the synchronisation for 1st gear has been modified