Audi Workshop Service and Repair Manuals

Adjusting input shaft (Determining thickness of shim for input shaft)

Special tools and workshop equipment required

t	Universal dial gauge bracket -VW 387-

t	End measuring plate -VW 385/17-

t	Thrust pad -VW 510-

t	Thrust plate -VW 447 i-

t	Press tool -VW 407-

t	Torque wrench -V.A.G 1331-

t	Dial gauge

The input shaft must be re-adjusted when the following components are renewed: t  Gearbox housing t  Clutch housing t  Input shaft t  4th gear wheel t  Tapered roller bearings for input shaft Table of adjustments → Chapter Requirement: l  Sealing surfaces of clutch and gearbox housings must be free of sealant.

–  Press tapered roller bearing outer race without shim onto stop in gearbox housing. –  Install input shaft in clutch housing and put on gearbox housing. Tighten hexagon bolts to 25 Nm, then turn 90° further.

–  Fit measuring appliance and dial gauge in clutch housing. –  Before measurement, rotate input shaft to allow tapered roller bearings to settle. Set dial gauge to „0“ with 1 mm preload.   Note This procedure must be repeated for each subsequent measurement, as otherwise the dial gauge will not return to its original setting.

–  Push input shaft towards dial gauge in direction of -arrow-. –  Read off and note play indicated on dial gauge (in this example: 1.21 mm).   Note Dial gauge does not return to original setting by itself. Determine thickness of shim. –  Example:

Bearing clearance (measured value)	Thickness of shim according to table
1.21 mm	1.175 mm

Table of shims

Bearing clearance	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 1.175…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 Select correct shims from → Electronic parts catalogue. –  Remove input shaft and press tapered roller bearing outer race out of gearbox housing using thrust plate -VW 447 i-. –  Insert shim of correct thickness. If the size of the shim required is larger than those listed in the table, install two shims amounting to the correct value. Install the thicker of the two shims first. –  Press tapered roller bearing outer race together with the correct shim (1.175 mm in example) into gearbox housing using thrust pad -VW 510-. –  Fit gearbox housing and tighten hexagon head bolts to 25 Nm and then turn 90° further.

Checking adjustment –  Install measuring appliance and dial gauge. –  Rotate input shaft to allow tapered roller bearings to settle. –  Press input shaft in direction of -arrow-. –  Bearing clearance should be min. 0.01 ... max. 0.09 mm.   Note If no bearing clearance is measurable, but the input shaft has perceptible play and turns freely, the adjustment is acceptable. Table of shims