volkswagen Workshop Repair Guides

Volkswagen Workshop Service and Repair Manuals

ABOUT US
Table of shims > < Dismantling and assembling input shaft, through gearbox date 18 05 3

Golf Mk4

Adjusting input shaft (through gearbox date 18 05 3)
Adjusting input shaft (through gearbox date 18 05 3)
(Determining input shaft shim)
  Note
t  The adjusting instructions apply only to gearboxes through gearbox date 18 05 3 (input shaft supported with tapered roller bearings).
t  From gearbox date 19 05 3, the input shaft support has been modified → Chapter. Adjustment is no longer required.
   
Special tools and workshop equipment required
t  Support plate -VW 309-
t  Gearbox support -VW 353-
t  End dimension plate -VW 385/17-
t  Universal dial gauge bracket -VW 387-
t  Press tool -VW 407-
t  Thrust piece -VW 433-

   
t  Support plate -VW 801-
t  Torque wrench -V.A.G 1331/-
t  Internal puller -1- Kukko 21/7-
t  Counter support -4- Kukko 22/1-

It is necessary to readjust the input shaft only when the following components are renewed:
t  Gearbox housing
t  Clutch housing
t  Input shaft
or the
t  Tapered roller bearing
Adjustment overview → Chapter
l  Shims of determined thickness are installed for both output shafts.
   
–  Press tapered roller bearing outer race without shim into gearbox housing to stop.
–  Install both output shafts and input shaft in clutch housing and assemble gearbox housing. Tighten hexagon bolts to specified torque → Item.
  N35-0234
–  Fit measuring appliance and dial gauge in clutch housing.
–  Before taking any measurements, rotate input shaft to allow bearings to settle. Set dial gauge to „O“ with 1 mm preload.
  Note
This step must be repeated for each subsequent measurement, or the dial gauge will not return to the starting position.
–  Pull input shaft in direction of dial gauge.
–  Read and note clearance indicated on dial gauge (example 1.63).
–  Determine thickness of shim from table → Chapter (example 1.55). Part numbers → Electronic parts catalogue (ETKA).
  N35-0236
–  Remove gearbox housing and pull tapered roller bearing outer race out of gearbox housing.
A - Counter support, e.g. -Kukko 22/2-
B - Internal puller, 46…58 mm, e.g. -Kukko 21/7-
–  Press tapered roller bearing outer race together with 1.55 shim into gearbox housing.
–  Fit gearbox housing and tighten new hexagon bolts to specified torque → Item.
  N35-0331

Table of shims > < Dismantling and assembling input shaft, through gearbox date 18 05 3