Input Shaft, Adjusting

Input shaft, adjusting, 02J, 5 Spd. M/T

Special tools and equipment:

(Determining input shaft adjustment shim)

Special tools and equipment
^ VW 387 Universal dial gauge bracket
^ VW 385/17 End measuring plate
^ VW 510 Press piece
^ VW 447 i Thrust plate
^ VW 407 Press tool
^ Dial gauge

It is only necessary to readjust the input shaft when the following components are replaced:
^ Transmission housing
^ Clutch housing
^ Input shaft
^ 4th gear
or the
^ Taper bearings

- Press tapered roller bearing outer race without shim into transmission housing onto stop, using VW 510.





- Install input shaft in clutch housing and assemble transmission housing. Tighten hex head bolts to 25 Nm and then turn 90° further.
- Fit measuring appliance and dial indicator in clutch housing (large tapered roller bearing in transmission housing).
- Before taking any measurements, rotate input shaft to allow bearings to settle.
- Set dial gauge to 0 with 1 mm preload.

Note: This preparation is to be repeated for each subsequent measurement, otherwise the gauge will not return to the starting position.

- Press input shaft in direction of dial indicator (arrow).
- Read off and note clearance indicated on dial indicator (example 1.21).

Note: Dial indicator does not return to original position.





- Determine thickness of shim from table (example 1.175).
- Remove input shaft and press tapered roller bearing outer race out of transmission housing using VW 447i.
- Press tapered roller bearing outer race together with 1.175 shim into transmission housing using VW 510.
- Assemble transmission housing and tighten hex head bolts to 25 Nm and then turn 90° further.