Output Shaft, 1st to 4th Gears, Adjusting

Output Shaft, 1st to 4th Gears, Adjusting

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

• Transmission housing

• Clutch housing

• Output Shaft, 1st to 4th Gears

• Tapered roller bearing for output shaft

Adjustment overview, refer to => [ Adjustment Overview ] Adjustment Overview.

Special tools, testers and auxiliary items required

• Dial Gauge Holder (VW 387)

• Punch (VW 407)

• Thrust Pad Con. 8/65 (VW 433)

• Installation Arbor (VW 792)

• Holding Fixture (VW 801)

• Thrust Plate (2050)

• Dial gauge (VAS 6080)

• Kukko 21/7 internal puller

• Kukko 22/2 counter-support

Adjusting

• Attach transmission 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.

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

- Set complete output shaft for 1st to 4th gears into clutch housing.

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

- Install measuring tools and secure to clutch housing with bolt - arrow -.

- Set (VAS 6080) (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: 0.14 mm).

• If no measured value is displayed on the dial gauge when loosening the securing bolts for the clutch housing/transmission housing, install adjustment shim 1.95 mm (part number (084 409 383 AS)) or if necessary 2.20 mm (part number (084 409 383 BD)) for the measurement.

Determining Shim Thickness

The specified bearing pre-load is reached when determined measured value (0.14 mm) is subtracted from inserted adjustment shim (1.70 mm) and a constant pre-load value (0.20 mm) is added.

Example:

- Determine the adjustment shim thickness according to the table; part number, refer to the electronic parts catalog ETKA.

The following shims are available:

Different shim thicknesses make it possible to select the required thickness precisely.

- Remove the transmission housing and pull the tapered roller bearing outer ring out of the transmission housing.

A Support, for example (Kukko 22/2)
B Internal puller 46 to 58 mm, for example (Kukko 21/7)

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

- Press in the tapered roller bearing outer ring with the determined adjustment shim (1.75 mm as an example). Support transmission housing directly beneath bearing mount using (2050).

Checking Measurement

• Determined adjustment shim installed.

- Install measuring tools and secure to clutch housing with bolt - arrow -.