Audi Workshop Service and Repair Manuals

(Determining input shaft adjustment shim)

Special tools and workshop equipment required

• ◆ VW 309 Holding plate
• ◆ VW 353 Gearbox support
• ◆ VW 385/17 End measuring plate
• ◆ VW 387 Universal dial gauge bracket
• ◆ VW 407 Press tool
• ◆ VW 433 Press piece

Special tools and workshop equipment required

• ◆ VW 457 Support rails
• ◆ VW 801 Holding plate
• ◆ V.A.G 1331 Torque wrench
• ◆ 1 - Kukko 21/7 Internal puller
• ◆ 4 - Kukko 22/1 Counter-support

It is only necessary to readjust the input shaft when the following components are renewed:

• ◆ Gearbox housing
• ◆ Clutch housing

• ◆ Input shaft

or the

• ◆ Taper roller bearings

Adjustment overview

• ● Shims of determined thickness are installed for both output shafts.

• ‒ → Press taper roller bearing outer race without shim into gearbox housing onto stop.

• ‒ Install both output shafts and input shaft in clutch housing and assemble gearbox housing. Tighten hexagon head bolts to 25 Nm and then turn 45° 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 "O" with 1 mm preload.

Note:

This preparation is to be repeated for each subsequent measurement, otherwise the gauge will not return to the starting position.

• ‒ → Pull input shaft in direction of dial gauge.
• ‒ Read off and note clearance indicated on dial gauge (example 1.63).
• ‒ Determine thickness of shim from table => Page 35-18 (example 1.60).

• ‒ → Remove input shaft and pull taper roller bearing outer race out of gearbox housing.

A - Counter support, e.g. Kukko 22/2

B - Internal puller 46...58 mm, e.g. Kukko 21/7

• ‒ Press taper roller bearing outer race together with the 1.60 shim into gearbox housing using VW 510.
• ‒ Assemble gearbox housing and tighten new hexagon head bolts to 25 Nm and then turn 45° further.