SEAT Workshop Service and Repair Manuals

Adjusting output shaft

Consult the equivalence table for tools and equipment according to applicability among Seat / VW / Audi / Skoda → Chapter.

Special tools and workshop equipment required

t	Torque wrench kit -SAT 8010-, see equivalent → Anchor

t	Socket -T20020-, see equivalent → Anchor

t	Kit (case) -U 40200A-, see equivalent → Anchor

t	Kit (case) -U 40300-, see equivalent → Anchor

Adjust the secondary shaft when one of the following elements has been replaced: l  clutch housing l  Output shaft l  Tapered roller bearings for output shaft To avoid unnecessary adjustment work, consult adjustment chart → Chapter. Conditions: l  Sealing surfaces of clutch and gearbox housings must be free of sealant. –  Remove the outer track of the small roller bearing → Fig..

–  Install outer track of secondary shaft small roller bearing in clutch casing, with a shim of 0.65 mm thickness. –  Place the secondary shaft in its housing in the clutch casing. –  Tighten the housing nuts to tightening torque → Item. –  Turn output shaft 20 to 30 times in one direction.   Note t  The shaft must be turned in one direction so that the rollers of the tapered roller bearing settle in one direction. t  It is necessary to turn the shaft 20 to 30 times to achieve this. t  Otherwise false results will be obtained.

–  Install support -T20020- with a comparator on the clutch housing. Locate the end of the dial gauge on the secondary shaft. –  Mount dial gauge (3 mm measuring range) and set to „0“ with 1 mm preload. –  Move secondary shaft alternately in direction of dial gauge. –  Note the reading on the comparator (e.g. 0.30 mm).   Note While measuring do not turn the secondary shaft. The roller bearings settle and falsify the measurement Determining thickness of shim: Example: The specified bearing preload will be attained if the determined measured value is added to the 0.65 mm shim already installed. –  Determine shim thickness using the table; Spare part number → Electronic spare parts catalogue (ETKA).

Bearing play = (0.65 mm shim plus determined measured value)	Thickness of shim according to table
0.740 mm	0.900 mm

Table of shims

Bearing play = (0.65 mm shim plus determined measured value)	Shim thickness (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 Allocate shims using → Electronic parts catalogue (ETKA). –  Once the necessary shim has been determined, remove the dial gauge. –  Separate the secondary shaft. –  Remove the layshaft small conical bearing outer track from the clutch housing → Fig.. –  Remove the 0.65 mm thick shim from the clutch housing. l  If the previously used 0.65 mm shim is to be reinstalled, check it for damage. –  Install shims of the calculated thickness, thickest shim first. The existence of different tolerances allows the exact calibration of the thickness of the shim needed. –  If the thickness needed is greater than those indicated on the table, two shims can be used that add up to the determined value.

–  Fit the small secondary shaft rear bearing outer track with the calculated shim (0.70 mm in the example) in the clutch housing. –  Lubricate the roller bearings with gearbox oil. –  Place the secondary shaft in its housing in the clutch casing. –  Tighten the bolts on the bearing housing to corresponding torque. → Item