Input Shaft: Adjustments

5 Speed Manual 02J

Input shaft adjustment shim

Special tools






- VW 387 Dial gauge holder
- VW 385/17 End measuring plate
- VW 510 Thrust pad
- VW 447 i Thrust pad
- VW 407 Punch

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

- Transmission housing
- Clutch housing
- Input shaft
- 4th gear
or:
- Tapered roller bearing

- Using VW 510 press tapered roller bearing outer race (without shim) into transmission housing onto stop.
- Install input shaft in clutch housing and assemble transmission Housing.
Tightening torque: 25 Nm (18 ft. lbs.) + 90°






- Mount holder and dial indicator in clutch housing (for large tapered roller bearing in transmission housing).
- Rotate input shaft to allow bearing to settle.
- Set dial indicator to "0" with 1.0 mm preload.

Note:

This preparation is to be repeated for each measurement, otherwise the dial indicator will not return to the starting position.

- Press input shaft in direction of dial indicator (-arrow)
- Read and record clearance indicated (example: 1.2 1).

Note:

The dial indicator does not return to the original position.

- Determine thickness of shim from table (example 1.175 mm).
- Remove input shaft and press tapered roller bearing outer race out of transmission housing using VW 447i.
- Press tapered roller bearing outer race together with shim (size determined using table), into transmission housing.
- Assemble transmission housing.
Tightening torque: 25 Nm (18 ft. lbs.) + 90°

Table of adjustment shims


















Measurement, checking






- Mount holder and dial indicator in clutch housing.
- Rotate input shaft so that tapered roller bearing settles.
- Press input shaft in direction of arrow.
- Bearing play: min. 0.01 or max. 0.09 mm.

Note:

If the bearing clearance cannot be measured, but input shaft play is perceptible and the input shaft turns freely the adjustment is acceptable.