Output Shaft, Adjusting

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

Special tools and equipment:

(Determining shim for output shaft)

- VW 387 Universal dial gauge bracket
- VW 385/17 End measuring plate
- VW 512 Press disk
- 3114/2 Straightening tool
- VW 407 Press tool
- V.A.G 1331 Torque wrench
- Measuring dial gauge

Special tools and equipment:

- 1 -Kukko 21/6 Internal extractor
- 4 -Kukko 22/2 Retainer
- It is necessary to readjust the output shaft when the following components are replaced:
- Final drive
- Clutch housing or
- Tapered roller bearing
- Adjustment overview
- Press small tapered roller bearing outer race together with a 0.65 mm thick shim into clutch housing.
- Insert output shaft and tighten nuts for bearing support to 25 Nm, then turn 90°.





- Mount dial gauge (3 mm measuring range) and set to "0" with 1 mm preload.
- Move output shaft up and down and note dial gauge 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 (0.30 mm) and the thickness of the shim installed (0.65 mm).
Example:





- Remove output shaft and pull out small tapered roller bearing outer race
- The following adjustment shims are available:





Varying tolerances make it possible to obtain the exact shim thickness required.
- Press in small tapered roller bearing outer race together with correct shim (in example 1.15 mm) and install output shaft. Tighten bearing support nuts in clutch housing to 25 Nm plus an additional 1/4 turn 90°.