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

or the

• ◆ Taper roller bearings

is renewed.

Adjustment overview

• ‒ → Press taper roller bearing outer race, without shim, into gearbox housing onto stop.
• ‒ Install input shaft in gearbox housing and assemble clutch housing. Tighten hexagon head bolts to 25 Nm.

• ‒ → Fit measuring appliance and D.T.I. (3 mm measuring range).
• ‒ Before taking any measurements, rotate input shaft to allow bearings to settle. Set dial gauge to "O" with 1 mm preload.

Note:

This preparation is to be repeated for each subsequent measurement, otherwise the gauge will not return to the starting position.

• ‒ Press input shaft in direction of D.T.I.
• ‒ 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 35-16 .
• ‒ Remove input shaft and pull taper roller bearing outer race out of clutch housing => Page 35-1 .

• ‒ → Press taper roller bearing outer race together with selected shim (in example 1.20 mm) into clutch housing.
• ‒ Insert input shaft into gearbox housing and assemble clutch housing and tighten hexagon head bolts to 25 Nm.

Table of shims

Carrying out check measurement

• ‒ → Install measuring appliance and D.T.I.
• ‒ Rotate input shaft so that the taper roller bearings settle.
• ‒ Zero D.T.I. with 1 mm of preload.
• ‒ Press input shaft in direction of D.T.I.
• ‒ Bearing play should be min. 0.01 ... max. 0.12 mm.

Note:

If the bearing clearance cannot be measured, but input shaft play is perceptible and the input shaft turns freely, the adjustment is acceptable.

• ‒ Frictional moment max. 20 Ncm.