Input Shaft, Adjusting

Input shaft, adjusting, 02M, 5 and 6 Spd. M/T

Special tools and equipment:

(Determining input shaft adjustment shim)

- VW 309 Holding plate
- VW 353 Transmission support
- VW 385/17 End measuring plate
- VW 387 Universal dial gauge bracket
- VW 407 Press tool
- VW 433 Press piece

Special tools and equipment:

- VW 801 Holding plate
- V.A.G 1331 Torque wrench
- 1 - Kukko 21/7 Internal puller
- 4 - Kukko 22/1 Counter-support

It is only necessary to readjust the input shaft when the following components are replaced:
- Transmission housing
- Clutch housing
- Input shaft
- or the
- Tapered roller bearings
- Adjustment overview
- Shims of determined thickness are installed for both output shafts.





- Press tapered roller bearing outer race without shim into transmission housing onto stop.
- Install both output shafts and input shaft in clutch housing and assemble transmission housing. Tighten hex bolts





- Mount measuring appliance and dial gauge in clutch 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.

- Pull input shaft in direction of dial gauge.
- Read and note clearance indicated on dial gauge (Example: 1.63).
- Determine thickness of shim from table.





- Remove transmission housing and pull tapered roller bearing outer race out of transmission housing.
A - Counter support, e.g. Kukko 22/2
B - Internal puller 46 to 58 mm, e.g. Kukko 21/7
- Press tapered roller bearing outer race together with 1.55 shim into transmission housing using VW 510.
- Assemble transmission housing. Tighten hex bolts head