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Adjusting output shaft for 5th, 6th and reverse gears > < Output shaft for 1st through 4th gears

Leon Mk1

Adjusting output shaft for 5th, 6th and reverse gears
   
Adjusting output shaft for 5th, 6th and reverse gears
Special tools and workshop equipment required
t  Gearbox support -VW 353-
t  Universal dial gauge bracket -VW 387-
t  Press tool -VW 407-
t  Thrust piece -VW 433-
t  Assembly tool -VW 792-
t  Support plate -VW 801-

   
t  Support plate -VW 309-
t  Thrust piece -2050-
t  Torque wrench -V.A.G 1331-
t  Internal puller - 1 - Kukko 21/7-
t  Counter support -4 - Kukko 22/2-

It is necessary to readjust the output shaft when the following components are renewed:
t  Gearbox housing
t  Clutch housing
t  Output shaft for 5th, 6th and reverse gears or
t  Tapered roller bearing for output shaft
Adjustment overview → Chapter
Prerequisites:
l  Sealing surfaces of clutch and gearbox housings must be free of sealant.
l  When taking measurements, install only the output shaft to be measured.
   
–  Press tapered roller bearing outer race with 1.70 mm thick shim into gearbox housing to stop. In the process, support gearbox housing using thrust piece -2050- directly below bearing support.
–  Set complete 5th, 6th and reverse gear output shaft in clutch housing.
  N35-0255
–  Set gearbox housing in position and tighten bolts -A- as well as -B- alternately and diagonally to specified torque.
–  Set up measuring tools.
  N34-0992
–  If the edges of the housing protrude, put washers with a total thickness of 8 mm on bolt -arrow- for securing assembly device -VW 792-.
–  Set dial gauge (3 mm measuring range) to „0“ with 1 mm preload.
–  Loosen clutch housing/gearbox housing securing bolts diagonally until the bolts release the gearbox housing or output shaft.
–  Read and note value on dial gauge (example: 0.25 mm).
  Note
t  If no value is indicated when clutch housing/gearbox housing securing bolts are loosened:
t  Install 1.95 mm shim or, if necessary, 2.20 mm shim for measurement.
t  Allocate shims using → Electronic parts catalogue (ETKA).
  N35-10008

Adjusting output shaft for 5th, 6th and reverse gears > < Output shaft for 1st through 4th gears