volkswagen Workshop Repair Guides

Volkswagen Workshop Service and Repair Manuals

Dismantling and assembling reverse shaft > < Dismantling and assembling output shaft (pinion shaft)
5-Speed manual gearbox 02A
Adjusting output shaft
Adjusting output shaft

(Determining thickness of output shaft shim)

It is necessary to readjust the output shaft when

  • ◆ Final drive
  • ◆ Clutch housing

or

  • ◆ Taper roller bearing

have been changed.

Adjustment overview

  • ‒ Press small taper roller bearing outer race together with a 0.65 mm thick shim fully into clutch housing .
 
V35-1140
  • ‒ Insert output shaft and tighten bearing support to 25 Nm and then turn 90° further.
  • ‒ → Mount D.T.I. (3 mm measuring range) and "O" with 1 mm preload.
  • ‒ Move output shaft up and down and note dial gauge reading (example: 0.30 mm).
Warning!
Do not rotate output shaft during measurement as this will cause the bearings to settle, resulting in incorrect reading.

Determining thickness of shim

The specified bearing preload is obtained by adding
a constant preload figure of (0.20 mm)
to the reading obtained (0.30 mm)
and the thickness of the shim installed (0.65 mm).

Example:

Shim installed

0.65 mm

+ Reading

0.30 mm

+ Preload (constant)

0.20 mm

Thickness of shim

1.15 mm

  • ‒ Remove output shaft and pull out small taper roller bearing outer race => Page 35-29

The following adjustment shims are available:

Size (mm)

Part No.

0.65
0.70

020 311 391 P
020 311 391 Q

0.75
0.80
0.85

020 311 391
020 311 391 A
020 311 391 B

0.90
0.95
1.00

020 311 391 C
020 311 391 D
020 311 391 E

1.05
1.10
1.15

020 311 391 F
020 311 391 G
020 311 391 H

1.20
1.25
1.30

020 311 391 J
020 311 391 K
020 311 391 L

1.35
1.40

020 311 391 M
020 311 391 N

Varying tolerances make it possible by measuring the shims to obtain the exact shim thickness required.

  • ‒ Press in small taper roller bearing outer race together with the correct shim (in example 1.15 mm) ( ) and install output shaft. Tighten bearing support nuts in clutch housing to 25 Nm and then turn 90° further.

Checking friction moment

 
V35-1141

→ A - Commercially available torque gauge 0 ... 600 Ncm

For new taper roller bearings the friction moment must be 130 ... 180 Ncm.

For used taper roller bearings the friction torque must be at least 30 Ncm.

Note:

Lubricate bearings with gearbox oil before checking friction moment.

Dismantling and assembling reverse shaft > < Dismantling and assembling output shaft (pinion shaft)