Output Shaft, 5th, 6th and Reverse Gears, Adjusting
Output Shaft, 5th, 6th and Reverse Gears, Adjusting
=> [ Shim, Selecting ]
=> [ Adjustment Shim Table ]
=> [ Checking the Measurement ]
Special tools, testers and auxiliary items required
• Transmission Support (VW 353)
• Dial Gauge Holder (VW 387)
• Punch (VW 407)
• Thrust Pad Con. 8/65 (VW 433)
• Installation Arbor (VW 792)
• Holding Fixture (VW 801)
• Holding Plate (VW 309)
• Thrust Plate (2050)
• Torque Wrench (5-50 Nm) (V.A.G 1331)
• Kukko Extractor 46-58 mm (21/7)
• Kukko Support (22/2)
It is necessary to adjust the output shaft if the following components were replaced:
• Transmission housing
• Clutch housing
• Output shaft, 5th, 6th and reverse gears, or
• Output shaft tapered roller bearing
Adjustment overview, refer to => [ Adjustment Overview ] Adjustment Overview.
Requirements
• Remove any sealant still on the sealing surfaces on the clutch and transmission housings.
• Install the output shaft that is going to be measured.
- Install the tapered roller bearing outer race in the transmission housing with a 1.70 mm adjustment shim. Support the transmission housing directly under the bearing mount using the thrust plate (2050).
- Install the output shaft for 5th, 6th and reverse gear into the clutch housing.
- Install the transmission housing and tighten the bolts - A and B - diagonally to specification.
- Install the measuring tools.
- In the case of protruding housing edges: Place several washers on the clutch housing (total thickness: 8 mm) for the bolt - arrow - being used to secure the installation arbor (VW 792).
- Set the dial gauge (3 mm range) with a 1 mm preload to "0".
- Loosen the bolts securing the clutch housing to the transmission housing in a diagonal sequence until the bolts clear the transmission housing and output shaft.
- Read the measured value on the dial gauge and make a note of it (example: to 0.25 mm).
• The measured value will not be displayed when loosening the bolts that connect the clutch housing to the transmission housing.
• Install either the 1.95 mm adjusting shim or the 2.20 mm adjusting shim for the measuring.
• For the correct adjusting shim, refer to the Parts Catalog.
Shim, Selecting
The required bearing tension is reached as follows:
The specified bearing preload is reached when determined measured value (0.25 mm) is subtracted from inserted adjustment shim (1.70 mm).
A constant figure of (0.40 mm) is added to the reading.
Example:
- Select the correct adjusting shim thickness according to the table.
- Remove the transmission housing and remove the tapered roller bearing outer race from the transmission housing.
A Counter support, for example, Kukko support (22/2)
B Internal puller 46 to 58 mm, for example, Kukko extractor 46-58 mm (21/7)
- Remove the adjusting shim (1.70 mm) from the transmission housing.
Adjustment Shim Table
- For the correct part number, refer to the Parts Catalog.
Tolerance variations make it possible to find the exact shim thickness required.
- Install the outer race/tapered roller bearing with the selected adjusting shim (in the example: 1.65 mm) Support the transmission housing directly under the bearing mount using the thrust plate (2050).
Checking the Measurement
• The selected adjusting shim is installed.
- Install the measuring tools.
- In the case of protruding housing edges: Place several washers on the clutch housing (total thickness: 8 mm) for the bolt - arrow - being used to secure the installation arbor (VW 792).
- Set the dial gauge (3 mm range) with a 1 mm preload to "0".
- Loosen the bolts for the clutch housing to transmission housing in a diagonal sequence until the bolts clear the transmission housing and output shaft.
- For a correctly selected adjustment shim, the dial gauge must now display a value of 0.15 to 0.25 mm.