Manual Transmission/Transaxle: Adjustments

Input Shaft Adjusting

Determining circlips for input shaft ball bearing

It is necessary to readjust input shaft when:

• Transmission housing

or the

• Input shaft

are replaced.

Special tools, testers and auxiliary items required

• Drift sleeve (30 - 100)

• Door hinge alignment tool (M8 and M10) (3114/2)

• Fitting tool (T10246)

• Digital depth gauge e.g. (VAS 6087)

Determining thickness for circlip behind input shaft ball bearing

- Install provisional circlip - arrow - in rear groove on input shaft.





- Push ball bearing onto input shaft.

Installation position:

The sealed side of ball cage faces transmission housing.

- Pressing in ball bearing:





Install pin (M8 and M10) (3114/2) into tapped hole for ball head stud.

Slide thrust plate (T10246/2) onto input shaft.

Position fitting tool (T10246/1) behind splines for clutch plate. Tighten bolts - a - only slightly. The bolts locate in recesses in thrust plate (T10246/2).

Press in ball bearing onto stop by tightening bolts alternately (1/2 turn at a time).

- Install dished spring - 1 -.





Installation position:

The convex side faces guide sleeve - 2 -.

- Install a shrink hose onto input shaft splines.

- Bolt guide sleeve to transmission housing - 2 - with bolts - 3 -.

- Turn transmission housing so joint flange for bearing housing points upward.

• The contact surface must be cleaned to remove sealing paste.

- Place thrust washer - 1 - for 4th and 5th speed selector gears onto input shaft.





- Place a digital depth gauge (e. g. ( VAS 6087)) onto thrust washer and measure distance to contact surface of housing. The measuring point on housing contact surface must be as close to input shaft as possible.

• When measuring, lift the input shaft with e.g. support bridge (30-211A) or the help of a second mechanic until the play in the ball bearing is taken up.

Specification: distance "a" = 164.14 mm

• If the measured value exceeds the specification, use a thinner circlip than the circlip installed so that the specification is attained.

• If the measured value is below the specification, use a thicker circlip than the circlip installed so that the specification is attained.

• Determine the circlip thickness to meet the specification as exactly as possible (164.14 mm).

The following circlips are available:





- Select circlip from table.

Checking adjustment and checking distance "a"





• Determined circlip is installed.

The distance "a" should be 164.14 mm +/- 0.04 mm if the correct circlip has been selected.

Determining thickness for circlip in front of the input shaft ball bearing

- Drive rear circlip (as determined) and ball bearing onto input shaft using drift sleeve (30 - 100).

- Determine thickest circlip which will still fit.





- Refer to table , to determine correct circlip. For part numbers