Volkswagen Workshop Service and Repair Manuals

• ‒ To adjust clutch play, install components without axial needle bearing -item 37-123 .
• ‒ Adjusting clutch play between -K1- and AT pump
• ‒ Adjusting clutch play between -K2- and ATF pump => Page 37-160
• ‒ Perform check measurement (clutch play)

• Gearbox housing
• ◆ Planetary gearbox installed up to small input shaft => assembling planetary gearbox, Page 37-123
• 1st to 3rd gear clutch -K1- with turbine shaft

• Axial needle bearing with washer
• ◆ Observe installation position
• ◆ Do not install when adjusting clutch play
• Reverse gear clutch -K2-
• Shim
• ◆ Do not install when adjusting clutch play
• Gasket
• ◆ For ATF pump
• ATF pump
• Bolt, 20 Nm

Adjusting clutch play between -K1- and ATF pump

→ Calculate thickness for the axial needle bearing -A-

The thickness of the axial needle bearing is determined by the gap "x" and is to be selected from the table, => Page 37-159 .

Gap x = a - b

A - Axial needle bearing (not installed when performing measurement).

D - Gasket

1 - ATF pump

2 - Reverse gear clutch -K2-

3 - 1st to 3rd gear clutch -K1-

4 - Gearbox housing

Calculating "a":

• ‒ → Place straightedge "A" onto gearbox housing.
• ‒ Measure distance to -K1- using a depth gauge "B".

Example:

Reading 1 = 54.8 mm

• ‒ Place gasket "C" on pump flange of the gearbox housing.

• ‒ → Measure with depth gauge "B" to pump flange on gearbox housing.

Example:

Reading 2 = 23.2 mm

Calculating "b":

• ‒ → Place straightedge "B" on pump housing.
• ‒ Measure with depth gauge "A" to pump flange.

Example:

Gap x = a - b

= 31.6 mm - 28.1 mm = 3.5 mm

• ‒ Ascertain thickness of the axial needle bearing according to table and determine Part No. from parts catalogue.

Table of "Axle needle bearings":

Adjusting clutch play between -K2- and ATF pump

→ Calculate thickness of shim -B-

Shim thickness is determined by gap "y" and selected from table, => Page 37-163 .

Gap y = c + d

B - Shim (not installed when performing measurement).

D - Gasket

1 - ATF pump

2 - Reverse gear clutch -K2-

3 - 1st to 3rd gear clutch -K1-

4 - Gearbox housing

Calculating "b":

• ‒ → Place straightedge "A" onto pump housing.
• ‒ Measure with depth gauge "B" to pump housing.

Example:

Reading 1 = 34.0 mm

• ‒ → Measure with depth gauge "A" to pump flange.

Example:

Reading 2 = 33.8 mm

Calculating "d":

• ‒ → Place straightedge "A" onto gearbox housing.
• ‒ Measure to collar of the reverse gear clutch -K2- with depth gauge "B".

Example:

Reading 1 = 88.5 mm

• ‒ Place gasket "C" on pump flange of the gearbox housing.
• ‒ → Measure with depth gauge "B" to pump flange on gearbox housing.

Example:

Reading 2 = 23.2 mm

Gap y = c + d

= 0.2 mm + 1.5 mm = 1.7 mm

• ‒ Ascertain thickness of shims according to table and determine Part No. from parts catalogue.

Table of "Shims":

• ‒ After installing the ATF pump perform a check measurement of the clutch play .

Check measurement (clutch play)

• ‒ The clutch play cannot be measured until the ATF pump has been installed.
• ‒ Attach dial gauge holder to gearbox housing and place dial gauge on turbine shaft with a preload of 1 mm.

• ‒ → Move turbine shaft up and down and read play on dial gauge.

• Play:
• min. = 0.25 mm
• max. = 0.55 mm