Volkswagen Workshop Service and Repair Manuals

Adjusting output shaft for 5th, 6th and reverse gears

(Determining shim for output shaft)

Special tools and workshop equipment required

t	Gearbox support -VW 353-

t	Universal dial gauge bracket -VW 387-

t	Press tool -VW 407-

t	Thrust piece -VW 433-

t	Assembly tool -VW 792-

t	Support plate -VW 801-

t	Support plate -VW 309-

t	Thrust piece -2050-

t	Torque wrench -V.A.G 1331-

t	-1-Internal puller -Kukko 21/7-

t	-4-Counter support -Kukko 22/2-

It is necessary to readjust the output shaft when the following components are renewed: t  Gearbox housing t  Clutch housing t  Output shaft for 5th, 6th and reverse gears or t  Tapered roller bearing Adjustment overview → Chapter Prerequisites: l  Sealing surfaces of clutch and gearbox housings must be free of sealant. l  When taking measurements, install only the shaft to be measured.

–  Press tapered roller bearing outer race with 1.70 mm thick shim into gearbox housing to stop. In the process, support gearbox housing using thrust piece -2050- directly below bearing support. –  Set complete 5th, 6th and reverse gear output shaft in clutch housing.

–  Set gearbox housing in place and tighten bolts -A- as well as -B- alternately and diagonally to specified torque → Item and → Item.

–  Set up measuring tools. Put washers with a total thickness of 8 mm on bolt for -arrow- securing assembly device -VW 792- to clutch housing. –  Set dial gauge (3 mm measuring range) to „0“ with 1 mm preload. –  Loosen clutch housing/gearbox housing securing bolts diagonally until the bolts release the gearbox housing or output shaft. –  Read and note value on dial gauge (example: 0.27 mm).   Note If dial gauge indicates no value when clutch housing/gearbox housing securing bolts are loosened, install 1.95 mm shim → Electronic parts catalogue (ETKA) or, if necessary, 2.20 mm shim → Electronic Parts Catalogue (ETKA) when taking measurements. Determining thickness of shim. The specified bearing preload will be attained by subtracting the measured value (0.27 mm) from the inserted shim (1.70 mm) and adding a constant value for preload (0.20 mm). Example:

	Installed shim	1.70 mm
-	Measured value	0.27 mm
+	Preload (constant)	0.20 mm
	Shim thickness	1.63 mm

–  Determine thickness of shim from table → Anchor.

–  Remove gearbox housing and pull tapered roller bearing outer race 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 gearbox housing. Table of shims

	Thickness (mm)
1.50	1.80	2.10
1.55	1.85	2.15
1.60	1.90	2.20
1.65	1.95	2.25
1.70	2.00
1.75	2.05

–  Part number → Electronic parts catalogue (ETKA) The various thicknesses make it possible to achieve the exact shim thickness required.

–  Press in tapered roller bearing outer race together with correct shim (in example 1.65 mm). In the process, support gearbox housing using thrust piece -2050- directly below bearing support. Carrying out check measurement l  Determined shim installed.

–  Set up measuring tools. Put washers with a total thickness of 8 mm on bolt for -arrow- securing assembly device -VW 792- to clutch housing. –  Set dial gauge (3 mm measuring range) to „0“ with 1 mm preload. –  Loosen clutch housing/gearbox housing securing bolts diagonally until the bolts release the gearbox housing or output shaft. –  If correct shim has been selected, dial gauge will indicate a value between 0.15 mm to 0.25 mm.