Volkswagen Workshop Service and Repair Manuals > Polo Mk4 > Clutch and gearbox | 5-speed manual gearbox 02R | Gearbox,mechanics,gears,shafts,internal operation

Output shaft - adjust

(Determining shim for output shaft)

Special tools and workshop equipment required

t	Clock mounting -VW 387-

t	Final measurement plate -VW 385/17-

t	Pressure disc -VW 512-

t	Threaded pin -3114/2-

t	Pressure pin -VW 407-

t	5 - 50 Nm Torquemeter -VAG 1331-

t	Dial gauge

t	Inner puller -Kukko 21/6-

t	Counter-support -KUKKO 22/2-

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

t	Transmission to the shaft

t	Clutch housing

t	Taper roller bearing

Adjustment overview → Chapter.

–	Press small taper roller bearing outer race together with a 0.03in thick shim fully into clutch housing → Fig.

–	Insert output shaft and tighten nuts for bearing support to 25 Nm, then turn 90° further.

–	Mount dial gauge (3 mm measuring range) and set to “0” with 1 mm preload.

–	Move output shaft up and down and note dial gauge reading (example: 0.30 mm).

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