Volkswagen Workshop Service and Repair Manuals

(Determining input shaft adjustment shim)

Special tools and workshop equipment required

• ◆ VW 387 Universal dial gauge bracket
• ◆ VW 385/17 End measuring plate
• ◆ VW 510 Press piece
• ◆ VW 447 i Thrust plate
• ◆ VW 407 Press tool
• ◆ V.A.G 1331 Torque wrench
• ◆ Dial gauge

It is only necessary to readjust the input shaft when the following components are renewed:

• ◆ Gearbox housing
• ◆ Clutch housing
• ◆ Input shaft
• ◆ 4th gear wheel

or the

• ◆ Taper roller bearings

Adjustment overview

• ‒ Press taper roller bearing outer race without shim into gearbox housing onto stop, using VW 510.
• ‒ Install input shaft in clutch housing and assemble gearbox housing. Tighten hexagon head bolts to 25 Nm and then turn 90° further.
• ‒ → Fit measuring appliance and D.T.I. in clutch housing (large taper roller bearing in gearbox housing).
• ‒ Before taking any measurements, rotate input shaft to allow bearings to settle. Set dial gauge to "O" with 1 mm preload.

Note:

This preparation is to be repeated for each subsequent measurement, otherwise the gauge will not return to the starting position.

• ‒ → Press input shaft in direction of D.T.I. (arrow).
• ‒ Read off and note clearance indicated on D.T.I. (example 1.21).

Note:

D.T.I. does not return to original position.

• ‒ Determine thickness of shim from table => Page 35-19 (example 1.175).
• ‒ Remove input shaft and press taper roller bearing outer race out of gearbox housing using VW 447i .
• ‒ Press taper roller bearing outer race together with the 1.175 shim into gearbox housing using VW 510.
• ‒ Assemble gearbox housing and tighten hexagon head bolts to 25 Nm and then turn 90° further.