Volkswagen Workshop Service and Repair Manuals

• ‒ To adjust clutch play install components without shim (item 37-83.

• Gearbox housing
• Axial needle bearing with washer
• ◆ Axial needle bearing faces towards small input shaft
• ◆ Washer faces towards -K3-
• 3rd and 4th gear clutch -K3- with pump shaft
• ◆ On gearboxes from 01.93 the -K3- clutch operates only 4th gear
• Axial needle bearing washer
• ◆ Lugs face towards axial needle bearing

• Axial needle bearing
• Axial needle bearing washer
• 1st to 3rd gear clutch -K1- with turbine shaft
• Shim
• ◆ Do not install when adjusting clutch play
• ◆ 1 or 2 shims can be installed
• Reverse gear clutch -K2-

→ Determining shim -A-

A - Shim

1 - ATF pump

2 - Reverse gear clutch -K2-

3 - 1st to 3rd gear clutch -K1-

4 - 4th gear clutch -K3-

• On gearboxes from 01.93 the -K3- clutch operates only 4th gear => Page 00-5.

• ‒ Calculating thickness of shim. Determine gap "x" and calculate shim thickness.

Gap x = a - b

Calculating "a":

• ‒ → Place straightedge "A" onto gearbox housing.
• ‒ Press -K1- down in direction of arrow and measure distance into -K1- with depth gauge "B".

Example:

Reading 1 = 88.5 mm

• ‒ → Measure with depth gauge "B" to pump flange on gearbox housing.

Example:

Reading 2 = 34.3 mm

= Size measured from pump flange/gearbox housing into -K1-.

Calculating "b":

• ‒ → Place straightedge -B- onto stator support (arrow) and measure with depth gauge -A- to gasket of pump flange.

Example:

Gap x = a - b

= 54.2 mm - 51.0 mm = 3.2 mm

• ‒ Determine size of shim according to table:

Table of "shims":

• ‒ Ascertain thickness of shims according to table and determine Part No. from parts catalogue.
• ‒ Carry out clutch play check measurement after installing ATF pump.

Check measurement (clutch play)

• ‒ The clutch play cannot be measured until the ATF pump has been installed.

• ‒ Attach dial gauge holder to gearbox housing and place dial gauge on turbine shaft with a preload of 1 mm.
• ‒ → Move turbine shaft up and down and read of play on dial gauge.

• Play:
• min. = 0.5 mm
• max. = 1.2 mm