Volkswagen Workshop Service and Repair Manuals

Calculating shims for clutch housing

This »section« explains how to calculate thickness of shims in clutch housing. 3 shims are installed in total. There is 1 shim under each output shaft. Differential does not have a shim here.

Oil deflectors are inserted under output shafts 2 and 3, which are not shown here. For information about installation of shims, oil deflectors and bearing races, refer to → Chapter.

Do not install any oil deflectors or shims when calculating which shims to use. Only install bearing races of shafts.

l  Outer input shaft is installed → Chapter. l  Bearing races of all shafts and bearing race of differential are installed → Chapter. l  No oil deflector and no shim is installed.   Note For adjustment only: do not install any shims. Do not install any oil deflectors.

–  Place partially dismantled output shaft 1 and output shaft 2 into bearing race. To find out how »far« shafts are allowed to be assembled, refer to → Chapter for output shaft 1, and → Chapter for output shaft 2.

–  Make sure that dowel sleeves are inserted in clutch housing.

Assemble measuring tool -T10425- for work on clutch housing. Torque setting 15 Nm

–  Place measuring tool -T10425- on dowel sleeves.

–  Place mandrel -T10425/3- on output shaft 1.   Note All gears have burrs on their teeth. These burrs »disrupt« measurements. This is intended to show -where- gear wheels are measured in following measurements.

Measuring surfaces start at »roots« of teeth. They extend as far as »first shoulder«. Shown here in „light“ colour in illustration. Teeth themselves can be used for measurement. It is important to make sure that depth gauge does not locate on burrs.

–  Zero depth gauge -VAS 6619- on outer input shaft. Shown here in »green«.

–  Use depth gauge -VAS 6619- to measure on 4th gear wheel of output shaft 1. Shown here in »blue«. –  Make a note of this value. –  Identify value as „A“.

–  Three measurements are taken. Therefore, make a mark on gear of outer input shaft. –  Turn input shaft by 120° further and repeat measurement. Then turn through another 120° and measure again.   Note Gears of shafts have helical gearing. Turning shafts causes them to be raised out of bearing. –  To make sure that shafts remain in their bearing, tap mandrel -T10425/3- lightly whilst turning. Do not forget headpiece -T10425/5-. This gives you 3 measurement values, from which you should calculate the average.

Gear wheel for 4th gear has axial play on shaft. This play is not allowed to »influence« size of subsequent shim. Therefore, axial play is measured. –  Identify value as „B“. –  Make a note of this value. –  Calculation: „A“ minus „B“ = calculated shim thickness.

Calculated shim thickness		Shim to be installed (in millimetres)
from	to
0.625	0.674	0.65
0.675	0.724	0.70
0.725	0.774	0.75
0775	0.824	0.80
0.825	0.874	0.85
0.875	0.024	0.00
0.025	0.074	0.05
0.075	1.024	1.00
1.025	1.074	1.05
1.075	1.124	1.10
1.125	1.174	1.15
1.175	1.224	1.20
1.225	1.274	1.25
1.275	1.324	1.30
1.325	1.374	1.35
1.375	1.424	1.40
1.425	1.474	1.45
1.475	1.524	1.50
1.525	1.574	1.55
1.575	1.624	1.60
1.625	1.674	1.65
1.675	1.724	1.70
1.725	1.774	1.75

–  From the shims that have been supplied, measure shim that you require.   WARNING Later on, only insert this 1 shim. Not 2. Keep this shim carefully, do not mix it up with any other shims.

–  Place mandrel -T10425/3- on output shaft 2. Turn mark on outer input shaft »into alignment« with output shaft 2.   Note Gears of shafts have helical gearing. It is possible for shafts to be raised out of their bearing when they are turned. –  To make sure that shafts remain in their bearing, tap mandrel -T10425/3- lightly whilst turning. Do not forget headpiece -T10425/5-.

–  Zero depth gauge -VAS 6619- on outer input shaft. Shown here in »green«.

–  Use depth gauge -VAS 6619- to measure on 6th gear wheel of output shaft 2. Shown here in »red«. –  Make a note of this value. –  Identify value as „A“.

–  Three measurements are taken. Use »existing« mark for orientation. –  Turn input shaft by 120° further and repeat measurement. Then turn through another 120° and measure again.   Note Gears of shafts have helical gearing. It is possible for shafts to be raised out of their bearing when they are turned. –  To make sure that shafts remain in their bearing, tap mandrel -T10425/3- lightly whilst turning. Do not forget headpiece -T10425/5-. This gives you 3 measurement values, from which you should calculate the average. Gear wheel for 6th gear has axial play on shaft.

This play is not allowed to »influence« size of subsequent shim. Therefore, axial play is measured. –  Identify value as „B“. –  Make a note of this value. –  Calculation: „A“ minus „B“ = calculated shim thickness.

Calculated shim thickness		Shim to be installed (in millimetres)
from	to
0.625	0.674	0.65
0.675	0.724	0.70
0.725	0.774	0.75
0775	0.824	0.80
0.825	0.874	0.85
0.875	0.024	0.00
0.025	0.074	0.05
0.075	1.024	1.00
1.025	1.074	1.05
1.075	1.124	1.10
1.125	1.174	1.15
1.175	1.224	1.20
1.225	1.274	1.25
1.275	1.324	1.30
1.325	1.374	1.35
1.375	1.424	1.40
1.425	1.474	1.45
1.475	1.524	1.50
1.525	1.574	1.55
1.575	1.624	1.60
1.625	1.674	1.65
1.675	1.724	1.70
1.725	1.774	1.75
1.775	1.824	1.80
1.825	1.874	1.85
1.875	1.024	1.00

–  From the shims that have been supplied, measure shim that you require.   WARNING Later on, only insert this 1 shim. Not 2. Keep this shim carefully, do not mix it up with any other shims. –  Remove output shafts 1 and 2 and assemble them. t  Output shaft 1 → Chapter t  Output shaft 2 → Chapter t  Then adjust output shaft 3

–  First measure thickness of synchromeshed gear for reverse gear. –  Make a note of this value and identify value as „B“.

Adjust output shaft 3. Output shaft 3 is set correctly when dimension -K- = 19.9 millimetres. –  Place output shaft 3 into bearing.

–  Take bearing race that is to be installed and place onto shaft. –  Place mandrel -T10425/3- onto shaft.

–  Zero depth gauge -VAS 6594- on synchromeshed gear for reverse gear.

–  Measure distance from housing flange surface. –  Make sure that burrs on teeth are not included in measurement. –  Make a note of this value and identify value as „A“. »Thickness« of synchromeshed gear for reverse gear „B“ must be subtracted from this value.

–  Top edge of gear wheel to housing flange surface „A“ minus thickness of gear wheel „B“ = actual value for „K“. Output shaft 3 is set correctly when dimension -K- = 19.9 millimetres. –  Therefore, now calculate a shim to arrive at -K- = 19.9 millimetres. 19.9 millimetres minus actual value for „K“ = calculated shim thickness.

Calculated shim thickness		Shim to be installed (in millimetres)
from	to
0.775	0.824	0.80
0.825	0.874	0.85
0.875	0.024	0.00
0.025	0.074	0.05
0.075	1.024	1.00
1.025	1.074	1.05
1.075	1.124	1.10
1.125	1.174	1.15
1.175	1.224	1.20
1.225	1.274	1.25
1.275	1.324	1.30
1.325	1.374	1.35
1.375	1.424	1.40
1.425	1.474	1.45
1.475	1.524	1.50
1.525	1.574	1.55

–  From the shims that have been supplied, measure shim that you require.   WARNING Later on, only insert this 1 shim. Not 2. 1 -  Keep this measured shim carefully, do not mix it up with any other shims. 2 -  Place measuring tool -T10425- to one side. 3 -  Install measured shims for output shafts, bearing races and oil deflectors → Chapter. 4 -  Assembling output shaft 1 → Chapter. 5 -  Assembling output shaft 2 → Chapter. 6 -  Insert all output shafts in clutch housing. 7 -  Put measuring tool -T10425- back onto clutch housing. –  Calculating shims for gearbox housing → Chapter.