Output Shaft: Adjustments

Identification

NOTE: Vehicles with 2.0 liter, 85kW (115 hp) engine have output shaft with increased diameter for hub splines of 4th gear and an additional circlip toward 3rd gear





- Output shaft for vehicles with 2.0 liter, 85 kW (115 hp) engine with two circlips (arrows) for 4th gear





- Output shaft for all other vehicles with one circlip (arrow) for 4th gear





Adjusting

NOTE:
It is necessary to measure output shaft axial play and determine the proper shim thickness for adjustment of the output shaft when one or more of the following have been replaced:
^ Clutch housing
^ Final drive gear and output shaft (ring and pinion)
^ Tapered roller bearings of output shaft





- Install a 0.65 mm thick adjustment shim and drive outer race of small tapered roller bearing into clutch housing until it bottoms
- Install output shaft and tighten bolts for bearing cover
- Tightening torque: 25 Nm (18 ft lb) plus an additional 1/4 turn (900)





- Set up dial indicator (3 mm range) and zero gauge with 1 mm preload
^ A = Shim, 0.65 mm
- Move output shaft up and down and record dial indicator reading (example: 0.30 mm)

CAUTION: Do not turn the shaft during the measurement as this will cause the bearings to settle, which will result in an incorrect reading.

Available Shims:

Determining thickness of shim S3
- The correct thickness for shim S3 is determined by adding:
^ Specified bearing preload (a constant, 0.20 mm)
^ Measured axial play (example: 0.30 mm)
^ Test shim thickness (0.65 mm)

Example:
Inserted test shim (0.65 mm)
+ Reading from dial indicator (0.30 mm)
+ Preload (constant) (0.20 mm)
= Thickness of shim S3 -- (1.15 mm)

CAUTION: Part numbers are listed for reference only. Always check with your Parts department for the latest information.





- Remove output shaft and extract outer race of small tapered roller bearing
^ A = Internal extractor 37-46 mm, e.g. Kukko 21/6
^ B = Counter support, e.g. Kukko 22/2
- Install selected shim S3 (1.15 mm in example above) and drive tapered roller bearing outer race into clutch housing
- Lubricate tapered roller bearing with gear oil and install output shaft
- Tighten bolts for bearing cover to 25 Nm (18 ft lb) plus an additional quarter turn (90°)





Checking bearing preload
- A = Commercially available torque gauge, 0-600 Ncm

NOTE: Lubricate the bearings before checking with gear oil.

- Friction torque, new bearings: 130-180 Ncm (12-16 in lb)
- Min. friction torque of used bearings: 30 Ncm (3 in lb)