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)

(Selecting 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 ] 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 1st through 4th gears into the clutch housing.

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

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

- 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: 0.14 mm).

• If the measured value is not be displayed when loosening the bolts that connect the clutch housing to the transmission housing. Then install 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 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

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.

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