Output Shaft For 5th/6th and Reverse Gears, Adjusting

Output shaft for 5th/6th and reverse gears, adjusting, 02M/02Y, 5 & 6 Speed M/T, AWD
(Determine adjustment shim for output shaft)

A new output shaft adjustment is required when the following components have been replaced:
^ Transmission housing
^ Clutch housing
^ Output shaft 5th/6th and reverse gear
^ Tapered roller bearing





Special tools, testers and auxiliary items required
^ Transmission support VW 353
^ Dial gauge holder VW 387
^ Punch VW 407
^ Thrust pad con. 8/65 VW 433
^ Installation arbor VW 792
^ Holding fixture VW 801





Special tools, testers and auxiliary items required
^ Holding plate VW 309
^ Thrust plate 2050
^ Torque wrench V.A.G 1331
^ - 1 - Internal extractor Kukko 21/7
^ - 4 - Support Kukko 22/2

Adjustment requirements
^ Sealing surfaces of clutch and transmission housings must be cleaned of sealant.
^ For the measurement, only install shaft to be measured.





Work procedure
- Press outer race/tapered roller bearing with a 1.70 mm adjustment shim into transmission housing. Support transmission housing directly beneath bearing mount using pressure plate 2050 while doing so.
- Insert complete output shaft for 5th/6th and reverse gears into clutch housing.





- Install transmission housing and tighten bolts - A - as well as - B - to tightening torque in diagonal sequence.





- Install measuring tools. Insert washers with a total thickness of 8 mm at securing bolt - arrow - for Installation arbor VW 792 at clutch housing.
- Set dial gauge (measuring range: 3 mm) to "0" with 1 mm pre-load.
- Loosen securing bolts for clutch housing/transmission housing in diagonal sequence until bolts clear transmission housing and output shaft.
- Read measured value on dial indicator and note (example: 0.27 mm).

Note: If no measured value is displayed on dial gauge when loosening securing bolts for clutch housing/transmission housing, install 1.95 mm adjustment shim or, if necessary, 2.20 mm adjustment shim for the measurement.

Determining adjustment shim
The specified bearing pre-load is reached when determined measured value (0.27 mm) is subtracted from inserted adjustment shim (1.70 mm) and a constant pre-load value (0.20 mm) is added.

Example:





- Determine shim thickness on the basis of the following table:








- Remove transmission housing and pull outer race/tapered roller bearing out of transmission housing.

A - Support Kukko 22/2
B - Internal puller 46 to 58 mm Kukko 21/7

- Remove inserted 1.70 mm adjustment shim from transmission housing.





- Press in outer race/tapered roller bearing together with determined adjustment shim (example: 1.65 mm). Support transmission housing directly beneath bearing mount using pressure plate 2050 while doing so.





Perform check measurement
^ Determined adjustment shim installed.
- Install measuring tools. Insert washers with a total thickness of 8 mm at securing bolt - arrow - for Installation arbor VW 792 at clutch housing.
- Set dial gauge (measuring range: 3 mm) to "0" with 1 mm pre-load.
- Loosen securing bolts for clutch housing/transmission housing in diagonal sequence until bolts clear transmission housing and output shaft.
^ For correctly selected adjustment shim, dial gauge must now display a value of 0.15 mm to 0.25 mm.