Volkswagen Workshop Service and Repair Manuals > Golf Mk5 > Power transmission | 6-speed manual gearbox 02S, four-wheel drive | Gearbox,mechanics,gears,shafts,internal operation | Input shaft

Adjusting input shaft

(Determining input shaft shim)

Special tools and workshop equipment required

t	Universal dial gauge bracket -VW 387-

t	End dimension plate -VW 385/17-

t	Thrust pad -VW 510-

t	Thrust pad -VW 447 i-

t	Press tool -VW 407-

t	Torque wrench -V.A.G 1331-

t	Dial gauge

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

t	Gearbox housing

t	Clutch housing

t	Input shaft

t	Gear wheel for 4th gear

or the

t	Tapered roller bearings

Adjustment overview → Chapter

Requirement:

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

–	Press tapered roller bearing outer race into gearbox housing to stop.

–	Press tapered roller bearing outer race without shim into gearbox housing to stop.

–	Install input shaft in clutch housing and set gearbox housing in place. Tighten hexagon head bolts to 25 Nm and then turn 90° further.

–	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 “0” 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.

–	Press input shaft in direction of dial gauge -direction of arrow-.

–	Read and note play on dial gauge (example: 1.21 mm).

Note

Dial gauge does not return to original position.

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