Output Shaft, 5th, 6th and Reverse Gears, Adjusting

Output Shaft, 5th, 6th and Reverse Gears, Adjusting

Special tools, testers and auxiliary items required

• Transmission Support (VW 353)

• Dial Gauge Holder (VW 387)

• Punch (VW 407)

• Thrust Piece (VW 433)

• Alignment Fixture (VW 792)

• Holding Plate (VW 801)

• Holding Plate (VW 309)

• Thrust Piece (2050)

• Torque Wrench (V.A.G 1331)

• Internal Puller (Kukko 21/7)

• Counter-Support (Kukko 22/2)

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

• Transmission housing

• Clutch housing

• Output shaft 5th/6th gear/reverse gear

• Tapered roller bearing

Adjustment overview. Refer to => [ Adjustment Overview ] Adjustment Overview

Requirements:

• Transmission attached to assembly stand. Refer to => [ Transmission, Securing to Assembly Stand ] Transmission, Securing to Assembly Stand.

• Sealing surfaces of clutch and transmission housing must be cleaned of sealant.

• For the measurement, only install shaft to be measured.

Work sequence:

- Press the tapered roller bearing outer race into the transmission housing with a 1.70 mm thick shim. When doing this, support the transmission housing with the Thrust Plate (2050) directly under the bearing mounting.

- Set the complete output shaft for 5th/6th gear and reverse gear into the clutch housing.

- Install transmission housing and tighten bolts - A - as well as - B - to tightening specification in diagonal sequence.

- Install measuring tools. Install shims with a total thickness of 8 mm at the bolt - arrow - for the Installation Arbor (VW 792) on the clutch housing.

- Set gauge (3 mm measuring range) to "0" with 1 mm pre-load.

- Loosen securing bolts for clutch housing/transmission housing in diagonal sequence until bolts clear transmission housing and output shaft.

- Read measured value on dial indicator and note (example: 0.25 mm).

• If no measured value is displayed on dial gauge when loosening securing bolts for clutch housing/transmission housing, install adjustment shim 1.95 mm or if necessary 2.20 mm for the measurement.

Determining shim thickness:

The specified bearing pre-load is reached when determined measured value (0.25 mm) is subtracted from inserted adjustment shim (1.70 mm) and a constant pre-load value (0.20 mm) is added.

- Determine the shim thickness according to the table; for the part number, refer to the Parts Catalog.

The following shims are available:

* Tolerance variations make it possible to find the exact shim thickness required.

- Remove transmission housing and pull tapered roller bearing outer race out from transmission housing.

A Counter Support (Kukko 22/2)
B Internal Puller 46 to 58 mm (Kukko 21/7)

- Remove the inserted shim (1.70 mm thick) from the transmission housing.

- Press the tapered roller bearing outer race into the transmission housing with the determined shim (for example 1.65 mm). When doing this, support the transmission housing with the Thrust Plate (2050) directly under the bearing mounting.

Checking Measurement

• Determined adjustment shim installed.

- Install measuring tools. Install shims with a total thickness of 8 mm at the bolt - arrow - for the Installation Arbor (VW 792) on the clutch housing.