Adjusting Output Shaft for 1st-4th Gears | 6-speed Manual Gearbox 02Q

Adjusting output shaft for 1st through 4th gears

Special tools and workshop equipment required

t	Gearbox support -VW 353-

t	Universal dial gauge bracket -VW 387-

t	Press tool -VW 407-

t	Thrust piece -VW 433-

t	Assembly tool -VW 792-

t	Support plate -VW 801-

t	Support plate -VW 309-

t	Thrust piece -2050-

t	Torque wrench -V.A.G 1331-

t	Internal puller -1 - Kukko 21/7-

t	Counter support -4 - Kukko 22/2-

(Determining shim for output shaft)

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

t	Gearbox housing

t	Clutch housing

t	Output shaft for 1st to 4th gear or

t	Tapered roller bearing for output shaft

Adjustment overview → Chapter

Prerequisites:

l	Sealing surfaces of clutch and gearbox housings must be free of sealant.

l	When taking measurements, install only the output shaft to be measured.

–	Press tapered roller bearing outer race with 1.70 mm thick shim into gearbox housing to stop. In the process, support gearbox housing using thrust piece -2050- directly below bearing support.

–	Set complete output shaft for 1st through 4th gears in clutch housing.

–	Set gearbox housing in position and tighten bolts -A- as well as -B- alternately and diagonally to specified torque.

–	Set up measuring tools and secure to clutch housing using bolt -arrow-.

–	Set dial gauge (3 mm measuring range) to „0“ with 1 mm preload.

–	Loosen clutch housing/gearbox housing securing bolts diagonally until the bolts release the gearbox housing or output shaft.

–	Read and note value on dial gauge (example: 0.14 mm).

Note

t	If no value is indicated when clutch housing/gearbox housing securing bolts are loosened:

t	Install 1.95 mm shim or, if necessary, 2.20 mm shim for measurement.

t	Allocate shims using → Electronic parts catalogue (ETKA).

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