Output Shaft For 1st to 4th Gear, Adjusting

Output shaft for 1st to 4th gear, 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 1st to 4th 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 1st to 4th gears into clutch housing.





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





- Insert measuring tools and secure to clutch housing using a bolt - arrow -.
- 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: 0.14 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 (0.14 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: 1.75 mm). Support transmission housing directly beneath bearing mount using pressure plate 2050 while doing so.





Perform check measurement
^ Determined adjustment shim installed.
- Insert measuring tools and secure to transmission housing using a bolt - arrow -.
- 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.

Measurements, checking





- Install universal gauge and dial indicator.
- Turn input shaft, so that the tapered roller bearings set.
- Pull input shaft in direction of dial indicator.
- Bearing play must be min. 0.015...max. 0.100 mm.

Note: If no bearing play can be measured, but the input shaft has noticeable side play and can be turned easily, the adjustment is also OK.