Manual Transmission/Transaxle: Adjustments

Output Shaft, Adjusting

(Determine adjustment shim for output shaft)

Special tools, testers and auxiliary items required

• Dial gauge holder (VW 387)

• Magnetic plate (VW 385/17)

• Thrust pad (VW 512)

• Replacement stud (3114/2)

• Punch (VW 407)

• Torque Wrench (V.A.G 1331)

• Dial gauge

• Internal puller (1- Kukko 21/6)

• Counter support (4- Kukko 22/2)

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

• Gear set

• Clutch housing

or

• Tapered roller bearing

Adjustment overview --> [ Adjustment Overview ] Adjustment Overview

Requirements:

• Sealing surfaces of clutch and transmission housing must be cleaned of sealant.

- Press small tapered roller bearing outer race with a 0.65 mm thick shim into the clutch housing to the limit stop --> [ Pressing in small outer race/tapered roller
bearing ] Output Shaft

- Install output shaft and tighten nuts for bearing mount to 25 Nm, then turn 90° further.

- Install dial gauge (3 mm measuring range) and set to "O" with 1 mm pre-load.





- Move output shaft up and down. Read the play on the dial gauge and note it (example: 0.36 mm)

Determining Shim Thickness

The specified bearing preload is obtained by adding a constant preload figure of (0.14 mm) to the reading obtained (0.36 mm) and the thickness of the installed shim (0.65 mm).

Example:





- Remove output shaft and pull out small tapered roller bearing outer race --> [ Pulling off small outer race/tapered roller
bearing ] Output Shaft

If measured washer thickness is greater than that listed in, 2 washers that correspond to the measured value can be installed.

Varying tolerances make it possible to measure the required shim thickness exactly.

- Press in small tapered roller bearing outer race with determined shim (1.15 mm as in example) --> [ Pressing in small outer race/tapered roller
bearing ] Output Shaft and install output shaft. Tighten bearing mount nut in clutch housing to 25 Nm and then turn 90° further.