volkswagen Workshop Repair Guides

Volkswagen Workshop Service and Repair Manuals

Determining thickness of shim > < Dismantling and assembling output shaft for 1st through 4th gears
Adjusting output shaft for 1st through 4th gears
   
Adjusting output shaft for 1st through 4th gears
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  Internal puller -1- Kukko 21/7-
t  Counter support -4- Kukko 22/2-

(Determining shim for output shaft)
It is necessary to readjust the output shaft when the following components are renewed:
t  Gearbox housing
t  Clutch housing
t  Output shaft for 1st to 4th gear or
t  Tapered roller bearing for output shaft
Adjustment overview → Chapter
Prerequisites:
l  Sealing surfaces of clutch and gearbox housings must be free of sealant.
l  When taking measurements, install only the output 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 output shaft for 1st through 4th gears in clutch housing.
  N35-0239
–  Set gearbox housing in position and tighten bolts -A- as well as -B- alternately and diagonally to specified torque.
  N34-0992
–  Set up measuring tools and secure to clutch housing using bolt -arrow-.
–  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: 0.14 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.
  N35-0240

Determining thickness of shim > < Dismantling and assembling output shaft for 1st through 4th gears