Volkswagen Workshop Service and Repair Manuals

Adjusting input shaft (Determining input shaft shim)

Special tools and workshop equipment required

t	Universal dial gauge bracket -VW 387-

t	End dimension plate -VW 385/17-

t	Thrust pad -VW 510-

t	Thrust pad -VW 447 i-

t	Press tool -VW 407-

t	Torque wrench -V.A.G 1331-

t	Dial gauge

It is necessary to readjust the input shaft only when the following components are renewed: t  Gearbox housing t  Clutch housing t  Input shaft t  Gear wheel for 4th gear or the t  Tapered roller bearing Adjustment overview → Chapter Requirement: l  Sealing surfaces of clutch and gearbox housings must be free of sealant.

–  Press tapered roller bearing outer race into gearbox housing to stop.

–  Press tapered roller bearing outer race without shim into gearbox housing to stop. –  Install input shaft in clutch housing and set gearbox housing in place. Tighten hexagon head bolts to 25 Nm and then turn 90° further.

–  Fit measuring appliance and dial gauge in clutch housing. –  Before taking any measurements, rotate input shaft to allow bearings to settle. Set dial gauge to „0“ with 1 mm preload.   Note This step must be repeated for each subsequent measurement, or the dial gauge will not return to the starting position.

–  Press input shaft in direction of dial gauge -direction of arrow-. –  Read and note play on dial gauge (example: 1.21 mm).   Note Dial gauge does not return to original position. Determining thickness of shim Example:

Bearing play, measured value	Thickness of shim according to table
1.21 mm	1.175 mm

Table of shims

Bearing play	Shim
Measured value (mm)	Thickness (mm)
0.671…0.699 0.700…0.724 0.725…0.749	0.650 0.675 0.700
0.750…0.774 0.775…0.799 0.800…0.824	0.725 0.750 0.775
0.825…0.849 0.850…0.874 0.875…0.899	0.800 0.825 0.850
0.900…0.924 0.925…0.949 0.950…0.974	0.875 0.900 0.925
0.975…0.999 1.000…1.024 1.025…1.049	0.950 0.975 1.000
1.050…1.074 1.075…1.099 1.100…1.124	1.025 1.050 1.075
1.125…1.149 1.150…1.174 1175…1.199	1.100 1.125 1.150
1.200…1.224 1.225…1.249 1.250…1.274	1.175 1.200 1.225
1.275…1.229 1.300…1.324 1.325…1.349	1.250 1.275 1.300
1.350…1.374 1.375…1.399 1.400…1.424	1.325 1.350 1.375
1.425…1.449 1.450…1.474 1.475…1.499	1.400 1.425 1.450
1.500…1.524 1.525…1.549 1.550…1.574	1.475 1.500 1.525
1.575…1.599 1.600…1.624 1.625…1.649	1.550 1.575 1.600
1.650…1.674 1.675…1.699 1.700…1.724	1.625 1.650 1.675

Note Allocate shims using → Electronic Parts Catalogue (ETKA). –  Remove input shaft and press outer race of tapered roller bearing out of gearbox housing using thrust plate -VW 447 i-. –  Insert shims of determined thickness, thickest shim first. If the size of shim required is larger than those listed in the table, insert two shims totalling the correct figure. –  Press outer race of tapered roller bearing together with the shim (1.175 mm in example) into gearbox housing using thrust pad -VW 510-. –  Set gearbox housing in place and tighten hexagon head bolts to 25 Nm and then turn 90° further. Carrying out check measurement

–  Set up measuring appliance and dial gauge. –  Rotate input shaft so that tapered roller bearings settle. –  Press input shaft in -direction of arrow-. –  Bearing play should be min. 0.01 … max. 0.09 mm.   Note If the bearing play cannot be measured, but input shaft play is perceptible and the input shaft turns freely, the adjustment is acceptable.