Output Shaft, 1st to 4th Gears, Adjusting

Output Shaft, 1st to 4th Gears, Adjusting

=> [ Determining Shim Thickness ]

=> [ Adjustment Shim Table ]

=> [ Checking 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)

Select the correct adjusting shim for the output shaft.

It is necessary to adjust the output shaft if the following components were replaced:

• Transmission housing

• Clutch housing

• Output shaft, 1st to 4th gears, or

• Output shaft tapered roller bearing

Adjustment overview, refer to => [ Adjustment Overview ] Final Drive, Differential (02Q Manual Transmission).

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 using 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 1st through 4th gears into the clutch housing.

- Install the transmission housing and tighten the bolts - A and B - diagonally to specification.

- Install the measuring tools on the clutch housing and secure them with the bolt - arrow -.

- Set the dial gauge (3 mm range) with a 1 mm preload to "0".

- Loosen the bolts for the clutch housing/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 0.14 mm).

• The measured value will not be displayed when loosening the bolts that connect the clutch housing to the transmission housing.

• Install then 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.

Determining Shim Thickness

The required bearing tension is reached as follows:

The specified bearing preload is reached when the determined measured value (0.14 mm) is subtracted from the 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. Refer to=> [ Adjustment Shim 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, for example, Kukko extractor 46-58 mm (21/7)

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

Adjustment Shim Table

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

- For the correct part number, refer to the Parts Catalog.

- Install the outer race/tapered roller bearing with the selected adjusting shim (in the example: 1.75 mm) Support the transmission housing directly under the bearing mount using the thrust plate (2050).

Checking Measurement

• The selected adjusting shim is installed.

- Install the measuring tools on the clutch housing and secure them with the bolt - arrow -.