Input Shaft, Adjusting

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

Special tools and equipment:

(Determining input shaft adjustment shim)

- 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
- V.A.G 1331 Torque wrench
- Measuring dial gauge
It is necessary to readjust the input shaft when the following components are replaced:
- Transmission housing
- Clutch housing
- Input shaft
- 4th gear wheel or the
- Tapered roller bearings
- Adjustment overview





- 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 an additional 90°.





- Install 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 "O" 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 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 an additional 90°.