Volkswagen Workshop Service and Repair Manuals

Adjusting 2nd and 4th gear brake -B2-

These instructions for adjustment apply only to gearboxes in which a shim → Item and a retaining ring → Item are installed in → brake -B2-, version -B-.

In these gearboxes, the play of → brake -B2- is determined by the thickness of the shim.

–	Install components for adjusting without shim → Item, without last outer plate → Item and without spring caps → Item.

1 -	Gearbox housing

2 -	Retaining ring

q	For support tube.

3 -	Support tube -B2-

q	Parts are allocated according to gearbox code letters.

q	Insert so that recess on support tube engages in freewheel retaining wedge.

4 -	Outer plate -B2-

q	3 mm thick.

5 -	Spring cap

q	Install after installing first outer plate → Item.

6 -	Spring cap

q	Do not install when adjusting -B2-.

q	Install before installing last outer plate.

7 -

Spring

q	Parts are allocated according to gearbox code letters.

8 -	Inner plate -B2-

q	Quantity → Chapter.

q	Parts are allocated according to gearbox code letters.

9 -	Outer plate -B2-

q	Always install 2 mm thick outer plates.

q	Quantity → Chapter.

10 -	Outer plate -B2-

q	3 mm thick.

q	Do not install when adjusting -B2-.

11 -

Shim

q	Do not install when adjusting -B2-.

12 -	Retaining ring

q	Insert with smooth side facing last inner plate → Item when adjusting -B2-.

The thickness of the shim(s) depends on gap x. Observe the following formula to do this:

Gap x = a - b - 2.65 mm To help in the understanding of this formula, the measuring points are shown in the figure. Setting tool -3459-, which exerts a force -F- onto the plate set via the retaining ring, is not illustrated. Calculating dimension -a- → Anchor. Calculating dimension -b- → Anchor. 2.65 mm - the allowance for settling is taken into account by force -F-. 1 -  → ATF pump 2 -  Retaining ring 3 -  -B2- plates without last outer plate 4 -  Support tube First outer plate -arrow- and last outer plate (do not install to measure!) are always 3 mm thick. Calculating dimension a: Assemble → planetary gearbox up to the last -B2- inner plate → Chapter. The last outer plate and shim are not to be installed.

–  Set smooth side of retaining ring on last inner plate. –  Place -3459- on retaining ring and turn so that the 3 clips align with the 3 holes for → ATF pump. –  Bolt -3459- to flange for → ATF pump with 5 Nm torque. This presses the plate set for -B2- together for the measurement.

–  Measure from pump flange of gearbox housing -arrow- to -3459- with depth gauge. Dimension -a- = height of -3459- in mm - measured value Example:

Height of -3459-	=	60.0 mm
- Measured value	=	-32.7 mm
Calculated value a	=	27.3 mm

–  Note calculated value a. –  Remove -3459-. –  Remove retaining ring. Calculating dimension b: –  Push piston into → ATF pump to stop. –  Place new paper gasket on → ATF pump.

–  Place straightedge -B- on stator support -arrow- and measure with depth gauge -A- to gasket of pump flange. Example:

Measured value	=	39.8 mm
- Straightedge	=	-19.5 mm
Calculated value b	=	20.3 mm

–  Note calculated value b. Gap x = a - b - 2.65 mm Gap x = 27.3 - 20.3 - 2.65 mm = 4.35 mm –  Determine thickness of shim(s) according to table: Table of shims:

Gap-x- (mm)	Shims (mm)
3.25 … 3.50 3.51 … 3.75 3.76 … 4.00	1.0 1.25 1.50
4.01 … 4.25 4.26 … 4.50 4.51 … 4.75	1.75 1.00 + 1.00 1.00 + 1.25
4.76 … 5.00 5.01 … 5.25 5.26 … 5.50	1.25 + 1.25 1.25 + 1.50 1.50 + 1.50
5.51 …5.75 5.76 …6.00	1.50 + 1.75 1.75 + 1.75

–  Ascertain thickness of shim(s) according to table and determine part No. from parts catalogue. In this example, two shims must be installed (each 1 mm thick). –  Place three spring caps onto compression springs. –  Insert last outer plate, 3 mm thick.

–  Install correct shim(s) -a-. –  Place retaining ring -b- onto shim(s). Smooth side faces shim. –  Further installation instructions are described from → Anchor.