Audi Workshop Service and Repair Manuals

Adjusting output shaft for 1st - 4th gear Re-adjustment of the output shaft is required if the following components have been renewed: t  Gearbox housing t  Clutch housing t  Output shaft for 1st - 4th gear t  Tapered roller bearings for output shaft Table of adjustments → Chapter

Special tools and workshop equipment required

t	Universal dial gauge bracket -VW 387-

t	Press tool -VW 407-

t	Press tool -VW 433-

t	Assembly device -VW 792-

t	Support plate -VW 801-

t	Thrust piece -2050-

t  Dial gauge -VAS 6080-

t  -1- Kukko internal puller 21/7 t  -4- Kukko 22/2 counter-support Adjusting l  Mounting gearbox on assembly stand → Chapter l  Sealing surfaces of clutch and gearbox housings must be free of sealant. l  When taking measurements, install only the shaft to be measured.

–  Press tapered roller bearing outer race with shim (thickness 1.70 mm) into gearbox housing. Support gearbox housing with thrust piece -2050- directly below bearing mounting. –  Fit complete 1st to 4th gear output shaft into clutch housing.

–  Fit gearbox housing and tighten bolts -A- and -B- diagonally to correct torque.

–  Set up measuring tools and secure with bolt -arrow- to clutch housing. –  Set dial gauge -VAS 6080- (3 mm measuring range) to “0” with 1 mm preload. –  Loosen clutch housing/gearbox housing securing bolts diagonally until output shaft is free to move in gearbox housing. –  Read off play on gauge and note reading (example: 0.14 mm).   Note If no play is indicated on the dial gauge when the clutch housing/gearbox housing securing bolts are loosened, fit a 1.95 mm shim (part number -084 409 383 AS-), or if necessary a 2.20 mm shim (part number -084 409 383 BD-) for performing the measurement. Determining thickness of shim The specified bearing preload is attained by subtracting the measured value (0.14 mm) from the inserted shim (1.70 mm) and adding a constant value for preload (0.20 mm). Example:

Inserted shim	1.70 mm
– Measured value	0.14 mm
+ Preload (constant value)	0.20 mm
Thickness of shim	1.76 mm

Select a shim of the required thickness from the table. For part numbers refer to → Electronic parts catalogue. The following shims are available:

Thickness of shims in mm
1.45	1.70	1.95	2.20
1.50	1.75	2.00	2.25
1.55	1.80	2.05
1.60	1.85	2.10
1.65	1.90	2.15

The exact shim thickness required can be obtained by combining shims of different thicknesses.

–  Detach gearbox housing and pull tapered 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- –  Remove inserted shim (1.70 mm thick) from gearbox housing.

–  Press in tapered roller bearing outer race together with the correct shim (in example 1.75 mm). Support gearbox housing with thrust piece -2050- directly below bearing mounting.

Checking adjustment l  Required shim installed (thickness as determined above) –  Set up measuring tools and secure with bolt -arrow- to clutch housing. –  Set dial gauge -VAS 6080- (3 mm measuring range) to “0” with 1 mm preload. –  Loosen clutch housing/gearbox housing securing bolts diagonally until output shaft is free to move in gearbox housing. –  If the correct shim has been selected, the dial gauge should now indicate a value between 0.15 and 0.25 mm.