5 Speed Manual 02J

5 Speed Manual 02J

Output Shaft Adjusting
(Determining shim for output sahft)

Special tools






- VW 387 Dial gauge holder
- VW End measuring plate
- VW 512 Thrust pad
- 3114, /2 Door alignment device
- VW 407 Punch

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

- Final drive
- Clutch housing
or
- Tapered roller bearing

- Press small tapered roller bearing outer race together with a 0.65 mm thick shim fully into clutch housing.
- Insert output shaft and tighten bearing support.
Tightening torque: 25 Nm (18 ft. lbs.) + 90°





- Mount dial indicator (3 mm measuring range) and zero with 1.0 mm preload.
- Move output shaft up and down and note dial indicator reading (example: 0.30 mm).

Determining thickness of shim

The specified bearing preload is obtained by adding a constant preload figure of (0.20 mm) to the reading obtained (example: 0.30 mm) and the thickness of the shim installed (0.65 mm).






- Remove output shaft and pull out small tapered roller bearing outter race.

The following adjustment shims are available:






Varying tolerances make it possible to find the exact shim thickness required by measuring the shims.
- Press in small tapered roller bearing outer race together with correct shim (in example: 1.15 mm).
- Install output shaft and tighten bearing support nuts in clutch housing.
Tightening torque: 25 Nm (18 ft. lbs.) + 90°