Output Shaft, 5th, 6th and Reverse Gears, Adjusting

Output Shaft, 5th, 6th and Reverse 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)

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

• Transmission housing

• Clutch housing

• Output shaft, 5th, 6th and reverse gears or

• Output shaft tapered roller bearing

Adjustment overview, refer to => [ Adjustment Overview ] 02Q 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 with 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 5th/6th gears and reverse gear into the clutch housing.

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






- Install the measuring tools.

- If there are protruding housing edges: place an 8 mm washer on the bolt - arrow - for the installation arbor (VW 792) on the clutch housing.






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

- Loosen the bolts for the clutch housing to transmission housing in a diagonal sequence until the bolts clear the transmission housing and output shaft.

- Read the measured value on the dial indicator and note (example: 0.25 mm).

• If the dial gauge will not display a value when the clutch housing/transmission housing bolts are loosened. Then install either the 1.95 mm or the 2.20 mm adjusting shim for the measuring.

• For the correct shims, refer to the Parts Catalog.

Determining Shim Thickness

The specified bearing preload is obtained by adding a constant preload figure of (0.20 mm) to the reading obtained (0.25 mm) and the thickness of the shim installed (1.70 mm).

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 46 to 58 mm, for example, kukko extractor 46-58 mm (21/7)

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

Adjustment Shim Table






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

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

- Install the outer race/tapered roller bearing with the selected adjusting shim (in the example: 1.65 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.

- If there are protruding housing edges: place an 8 mm washer on the bolt - arrow - for the installation arbor (VW 792) on the clutch housing.






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

- Loosen the bolts for the clutch housing to transmission housing in a diagonal sequence until the bolts clear transmission housing and output shaft.

- For the correctly selected adjustment shim, the dial gauge must now display a value of 0.15 mm to 0.25 mm.