Volkswagen Workshop Service and Repair Manuals

(Determining thickness of shim for input shaft)

It is only necessary to readjust the input shaft when

• ◆ Gearbox housing
• ◆ Clutch housing
• ◆ Input shaft
• ◆ 4th gear wheel

or the

• ◆ Taper roller bearing

is renewed.

Adjustment overview

• ‒ Press taper roller bearing outer race without shim into gearbox housing onto stop, using VW 510.
• ‒ Install input shaft in clutch housing and assemble gearbox housing. Tighten hexagon head bolts to 25 Nm and then turn 90° further.
• ‒ → Fit measuring appliance and D.T.I. in clutch housing (large taper roller bearing in gearbox housing).
• ‒ Before taking any measurements rotate input shaft to allow bearing to settle. Set D.T.I. to "O" with 1 mm preload.

• ‒ → Press input shaft in direction of D.T.I. (arrow).
• ‒ Read off and note clearance indicated on D.T.I. (example 1.21).

Note:

D.T.I. does not return to original position.

• ‒ Determine thickness of shim from table => Page 35-15 (example 1.175).
• ‒ Remove input shaft and press taper roller bearing outer race out of gearbox housing using VW 447i .
• ‒ Press taper roller bearing outer race together with the 1.175 shim into gearbox housing.
• ‒ Assemble gearbox housing and tighten hexagon head bolts to 25 Nm and then turn 90° further.