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Determining thickness of shim > < Assembling 1st to 4th gear output shaft - from gearbox date 02?11?9 onwards

Leon Mk1

Adjusting output shaft for 1st through 4th gears
   
Adjusting output shaft for 1st through 4th 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-

(Determining shim for output shaft)
It is necessary to readjust the output shaft when the following components are renewed:
t  Gearbox housing
t  Clutch housing
t  Output shaft for 1st to 4th gear 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 output shaft for 1st through 4th gears in clutch housing.
  N35-0239
–  Set gearbox housing in position and tighten bolts -A- as well as -B- alternately and diagonally to specified torque.
  N34-0992
–  Set up measuring tools and secure to clutch housing using bolt -arrow-.
–  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: 0.14 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).
  N35-0240

Determining thickness of shim > < Assembling 1st to 4th gear output shaft - from gearbox date 02?11?9 onwards