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 pad con. (VW433)

• Installation arbor (VW792)

• Holding fixture (VW 801)

• Holding plate (VW 309)

• Thrust plate (2050)

• Torque wrench (V.A.G 1331)

• Internal extractor (Kukko 21/7)

• Support (Kukko 22/2)

A new output shaft adjustment is required when the following components have been replaced:

• Transmission housing

• Clutch housing

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

• Tapered roller bearing for output shaft

List of adjustments --> [ Adjustment Overview ] Adjustment Overview.

Requirements

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

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

- Press tapered roller bearing outer race with a 1.70 mm adjustment shim into transmission housing. Support transmission housing directly beneath bearing mount using thrust piece (2050).

- Set complete output shaft for 5th/6th and reverse gears into 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 bolt - arrow - for installation arbor (VW 792) on clutch housing.

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

- 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 adjustment shim (2.20 mm) for the measurement.

Determining Shim Thickness

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

Example

- Determine thickness of adjustment shim according to table.

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

A Support, e.g. (Kukko 22/2)
B Internal puller 46 to 58 mm, e.g. (Kukko 21/7)

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

Table of Adjustment Shims

Varying tolerances make it possible to measure the required shim thickness exactly.

- Determine part numbers of adjustment shims according to.

- Press in tapered roller bearing outer race with determined shim (1.65 mm in example). Support transmission housing directly beneath bearing mount using thrust piece (2050).

Performing Measurement Check

• Determined adjustment shim installed.

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