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

t  Internal puller -1-Kukko 21/6- t  Counter support -4-Kukko 22/2- t  Puller -2-Kukko 18/0- (threaded spindle)

t  Adapter -VW 771/15- It is necessary to readjust the output shaft when the following components are renewed: t  Output shaft t  Clutch housing or t  Tapered roller bearing Adjustment overview → Chapter Requirement: l  Sealing surfaces of clutch and gearbox housings must be free of sealant. –  Press outer ring of small tapered roller bearing to stop with 0.65 mm shim into clutch housing → Fig.. –  Insert output shaft and tighten nuts for bearing support to 25 Nm, then turn 90° further. –  Turn output shaft 20 to 30 times in one direction.   Note t  The shaft must be turned in one direction so that the rollers of the tapered roller bearing settle in one direction. t  It is necessary to turn the shaft 20 to 30 times to achieve this. t  Otherwise the resulting reading will be incorrect.

–  Set up dial gauge (3 mm measuring range) and set to „0“with 1 mm preload. -A- = threaded spindle from puller -- Kukko 18/0-. –  Move output shaft up and down. Read and note play indicated on dial gauge. Determining thickness of shim The specified bearing preload will be attained if the determined measured value is added to the 0.65 mm shim already installed. Example:

Bearing play = (0.65 mm shim plus determined measured value)	Thickness of shim according to table
0.740 mm	0.900 mm

Table of shims

Bearing play = (0.65 mm shim plus determined measured value)	Shim thickness (mm)
0.650 0.660 … 0.689	0.750 0.800
0.690 … 0.739 0.740 … 0.789 0.790 … 0.839	0.850 0.900 0.950
0.840 … 0.889 0.890 … 0.939 0.940 … 0.989	1.000 1.050 1.100
0.990 … 1.039 1.040 … 1.089 1.090 … 1.139	1.150 1.200 1.250
1.140 … 1.189 1.190 … 1.239 1.240 … 1.289	1.300 1.350 1.400
1.290 … 1.339 1.340 … 1.389 1.390 … 1.429	1.450 1.500 1.550

Note Allocate shims according to → Electronic parts catalogue „ETKA“. –  Remove output shaft and pull out small tapered roller bearing outer race → Fig.. –  Insert shims of determined thickness, thickest shim first. l  If the previously used 0.65 mm shim is to be reinstalled, check it for damage. If the size of shim required is larger than those listed in the table, insert two shims totalling the correct figure. The various thicknesses make it possible to achieve the exact shim thickness required. –  Press in outer race of small tapered roller bearing together with the calculated shim → Fig. and install output shaft. Tighten bearing support nuts in clutch housing to 25 Nm and then turn 90° further.