Input Shaft, Adjusting

Input Shaft, Adjusting

=> [ Determining Shim Thickness ]

=> [ Checking Measurement ]

(Choosing the adjusting shim for the input shaft)

Special tools, testers and auxiliary items required

• Dial Gauge Holder (VW 387)

• Magnetic Plate 50 mm Dia. (VW 385/17)

• Thrust Pad (VW 510)

• Thrust Pad (VW 447 i)

• Punch (VW 407)

• Torque Wrench (5-50 Nm) (V.A.G 1331)

• Dial Gauge

A new input shaft adjustment is required when the following components have been replaced:

• Transmission housing

• Clutch housing

• Input shaft

• 4th gear

or the

• Tapered roller bearing

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

Requirement:

• Remove any sealant still on the sealing surfaces on the clutch and transmission housings.

- Press the taper roller bearing outer race into the clutch housing all the way.





- Install the outer race/tapered roller bearing all the way into the transmission housing without the adjusting shim.





- Install the input shaft into the clutch housing and install the transmission housing. Tighten the bolts to 25 Nm + an additional 90 degrees turn.

- Install the measuring device and the dial gauge to the clutch housing.





- Rotate the input shaft before measuring so the tapered roller bearing settles. Set the dial gauge with 1 mm preload to "0".

• Repeat this process each time a measurement is taken otherwise the dial gauge will not go back to its start setting.

- Press the input shaft toward the dial gauge in the - direction of the arrow -.





- Read and make note of the play on the dial gauge (example: 1.21 mm).

• The dial gauge does not return to its starting position.

Determining Shim Thickness

Example:






Adjustment Shim Table






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

- Remove the input shaft and then remove the outer race/tapered roller bearing from the transmission housing using thrust pad (VW 447 i).

- Install the shim with the correct thickness, thickest shim first.

If the measured shim thickness is larger than those listed in the table, then install two shims that add up to the necessary thickness.

- Press the outer race/tapered roller bearing and the selected shim (1.175 mm in the example) into the transmission housing using thrust pad (VW 510).

- Assemble the transmission housing and tighten the bolts to 25 Nm + an additional 90 degrees turn.

Checking Measurement

- Install the measuring device and the dial gauge.





- Turn the input shaft so that the tapered roller bearings settle.

- Press the input shaft in - direction of arrow -.

- Bearing play should be between 0.01 and 0.09 mm.

• The adjustment is OK if it is not possible to measure the bearing play and yet the input shaft still have a noticeable play and it easy to turn.