Output Shaft For 1ST-4TH Gears, Adjusting

Output shaft for 1st-4th gears, adjusting, 02M, 5 and 6 Spd. M/T

Special tools and equipment:

(Determining shim for output shaft)

- VW 353 Transmission support
- VW 387 Universal dial gauge bracket
- VW 407 Press tool
- VW 433 Press piece
- VW 792 Installation tool
- VW 801 Holding plate

Special tools and equipment:

- VW 309 Holding plate
- 2050 Thrust piece
- V.A.G 1331 Torque wrench
- 1 - Kukko 21/7 Internal puller
- 4 - Kukko 22/2 Counter support

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

- Transmission housing
- Clutch housing
- Output shaft for 1st-4th gear or
- Tapered roller bearing
- Adjustment overview

Requirements
- Sealing surfaces of clutch and transmission housings must be free of sealant.
- When taking measurements, install only the shaft to be measured.





- Press tapered roller bearing outer race with a 1.70 mm thick shim into transmission housing, supporting transmission housing directly under bearing support with thrust piece 2050.
- Set complete 1st-4th gear output shaft in clutch housing.





- Fit transmission housing and tighten bolts -A- and -B- diagonally to correct torque.





- Fit measuring tools and secure with bolt (arrow) to clutch housing.
- Set dial gauge (3 mm measuring range) to zero with 1 mm preload.
- Loosen clutch housing/transmission housing securing bolts diagonally until bolts release transmission housing or output shaft.
- Read play on gauge and note reading (example: 0.14 mm)

Note: If the dial gauge indicates no value when the clutch housing/transmission housing securing bolts are loosened, install a 1.95 mm shim (Part No. 084 409 383 AS) or, if necessary, a 2.20 mm shim (Part No. 084 409 383 BD).

Determining thickness of shim
The specified bearing pretension will be attained by subtracting the measured value (0.14 mm) from the inserted shim (1.70 mm) and adding a constant for pressing (0.20 mm).

Example:





- Determine thickness of shim from table.





- Remove transmission housing and pull tapered roller bearing outer race out of housing.
- A - Counter support, e.g. Kukko 22/2
- B - Internal puller 46 to 58 mm, e.g. Kukko 21/7
- Remove inserted shim (1.70 mm thick) from clutch housing.

Shim table





Varying tolerances make it possible to obtain the exact shim thickness required.





- Press in tapered roller bearing outer race together with determined shim (in example 1.75 mm) while supporting transmission housing with thrust piece 2050 directly under bearing support.

Perform check measurement





- Determined shim installed.
- Install measuring tools and secure with bolt (arrow) to transmission housing.
- Set dial gauge (3 mm measuring range) to zero with 1 mm preload.
- Loosen clutch housing/transmission housing securing bolts diagonally until output shaft is free to move in transmission housing.
- If correct shim has been selected, dial gauge will indicate a value of 0.15 mm to 0.25 mm.