Volkswagen Workshop Service and Repair Manuals

Adjusting output shaft (Determining shim for output shaft)

Special tools and workshop equipment required

t	Universal dial gauge bracket -VW 387-

t	End dimension plate -VW 385/17-

t	Thrust pad -VW 512-

t	Straightening tool -3114/2-

t	Press tool -VW 407-

t	Torque wrench -V.A.G 1331-

t	Dial gauge

It is necessary to readjust the output shaft when the following components are renewed: t  Final drive gear set t  Clutch housing or t  Tapered roller bearing Adjustment overview → Chapter

–  Press small tapered roller bearing outer race together with a 0.65 mm thick shim into clutch housing to stop. –  Install output shaft and tighten nuts for output shaft bearing support to specified torque → Item.

–  Set up dial gauge (3 mm measuring range) and set to “O”with 1 mm preload. –  Move output shaft up and down and note dial gauge reading (example: 0.30 mm).   Note Do not turn the output shaft whilst measuring or the bearings will settle and a false reading will be obtained. Determining thickness of shim. The specified bearing preload is obtained by adding a constant preload figure (0.20 mm) to the reading obtained (0.30 mm) and the thickness of the shim installed (0.65 mm). Example:

Installed shim	0.65 mm
+ Measured value	0.30 mm
+ Preload (constant)	0.20 mm
Shim thickness	1.15 mm

–  Remove output shaft and pull out small tapered roller bearing outer race → Fig.. The following shims are available:

Thickness (mm)	Part number
0.65 0.70	020 311 391 P 020 311 391 Q
0.75 0.80 0.85	020 311 391 020 311 391 A 020 311 391 B
0.90 0.95 1.00	020 311 391 C 020 311 391 D 020 311 391 E
1.05 1.10 1.15	020 311 391 F 020 311 391 G 020 311 391 H
1.20 1.25 1.30	020 311 391 J 020 311 391 K 020 311 391 L
1.35 1.40	020 311 391 M 020 311 391 N

The various thicknesses make it possible to achieve the exact shim thickness required.

–  Press in small tapered roller bearing outer race together with the correct shim (in example 1.15 mm) and install output shaft. Tighten bearing support nut in clutch housing to prescribed torque → Item.