Re-Determining Shim "S4" When Replacing Bearing Housing

Re-determining shim "S4" when replacing bearing housing - 6 Spd. Manual Transmission 02X All Wheel Drive

Special tools, testers and auxiliary items required





^ Dial gauge holder VW387





^ Installation arbor VW792
^ Digital depth gauge (e.g. VAS 6087)
^ Dial gauge
^ Dial gauge extension, 30 mm
^ Straightedge

- Clean housing flange.





- Place straightedge (e.g. 19.50 mm wide - 1 - onto housing flange.
- Measure difference between depth - a - on old and new bearing housing with a digital depth gauge (e.g. VAS 6087).

Example:





- If new bearing housing is deeper, install a thicker "S4" shim.
- If previous bearing housing is deeper, install a thinner "S4" shim.

Example:





Shims available.

- Press tapered roller bearing outer race with shim "S4" into bearing housing.
- Re-install fully assembled pinion shaft with hollow shaft into transmission housing.
- Install bearing housing and transmission cover and tighten bolts to 35 Nm.
- To settle tapered roller bearings: rotate pinion shaft together with hollow shaft 5turns in each direction, then rotate pinion shaft separately in relation to hollow shaft 5 turns in each direction.





- Set up measuring tools using dial gauge extension 30 mm - A -; place nut M12 between VW 792 and transmission housing when securing bolt - arrow - to transmission housing.

Note:
^ Place dial gauge extension - A - onto web in transmission cover.

- Set dial gauge (3 mm measuring range) to "0" with 1 mm preload.
- Loosen transmission cover bolts and turn pinion shaft several times.
- If correct shims have been selected the dial gauge will now indicate the following value:

^ 0.09 to 0.18 mm

If this reading is not obtained, the adjustment must be corrected.