Audi Workshop Service and Repair Manuals

Adjusting output shaft (Determining thickness of output shaft shim)

Special tools and workshop equipment required

t	Universal dial gauge bracket -VW 387-

t	End measuring plate -VW 385/17-

t	Thrust pad -VW 512-

t	Straightening tool -3114/2-

t	Press tool -VW 407-

t	Torque wrench -V.A.G 1331-

t	Dial gauge

t  -1-Internal puller -Kukko 21/6- t  -4-Counter-support -Kukko 22/2- t  -2-Puller -Kukko 18/0- (threaded spindle)

t  Adapter -VW 771/15- Procedure The output shaft must be re-adjusted when the following components are renewed: t  Output shaft t  Clutch housing or t  Tapered roller bearings for output shaft Table of adjustments → Chapter Requirement: l  Sealing surfaces of clutch and gearbox housings must be free of sealant. –  Press small tapered roller bearing outer race together with 0.65 mm shim onto stop in clutch housing → Fig.. –  Insert output shaft and tighten bearing mounting nuts to 25 Nm and then turn 90° further. –  Turn output shaft approx. 20 to 30 turns in one direction.   Note t  The output shaft has to be turned in one direction to seat the rollers in the tapered roller bearing. t  This requires 20 to 30 turns. t  If this is neglected, the measurement will not be correct.

–  Mount dial gauge (3 mm measuring range) and set to „0“ with 1 mm preload. -A- = (threaded spindle) from puller -Kukko 18/0-. –  Move output shaft up and down; read off and note play indicated on dial gauge (in this example 0.20 mm). Determining thickness of shim The specified bearing preload is obtained by adding a constant preload figure (0.10 … 0.15 mm) to the thickness of the shim installed (0.65 mm) and the measured value obtained (0.20 mm). Example:

Bearing clearance = shim (0.65 mm) + measured value	Thickness of shim according to table
0.850 mm	1.000 mm

–  Remove output shaft and pull out small tapered roller bearing outer race → Fig.. Table of shims

Bearing clearance = shim (0.65 mm) + measured value	Thickness of shim (mm)
0.650 0.660 … 0.689	0.750 0.800
0.690 … 0.739 0.740 … 0.789 0.790 … 0.839	0.850 0.900 0.950
0.840 … 0.889 0.890 … 0.939 0.940 … 0.989	1.000 1.050 1.100
0.990 … 1.039 1.040 … 1.089 1.090 … 1.139	1.150 1.200 1.250
1.140 … 1.189 1.190 … 1.239 1.240 … 1.289	1.300 1.350 1.400
1.290 … 1.339 1.340 … 1.389 1.390 … 1.429	1.450 1.500 1.550

Note t  Select correct shims from → Electronic parts catalogue. t  Tolerance variations make it possible to obtain the exact shim thickness required. –  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. l  If the original shim (0.65 mm) is to be refitted, check the shim for damage. –  Press in small tapered roller bearing outer race together with the correct shim (in example 1.00 mm) → Fig. and install output shaft. –  Tighten bearing mounting nuts in clutch housing to 25 Nm and then turn 90° further.