Output Shaft, Adjusting

Output Shaft, Adjusting

=> [ Determining Shim Thickness ]

(Selecting the correct adjusting shim for the output shaft)

Special tools, testers and auxiliary items required

• Dial Gauge Holder (VW 387)

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

• Thrust Pad (VW 512)

• Replacement Stud (8 mm/10 mm) (3114/2)

• Punch (VW 407)

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

• Dial Gauge

• Kukko Extractor 37-46 mm (21/6)

• Kukko Support (22/2)

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

• Output shaft

• Clutch housing

or

• 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.

Perform the following

- Install the small tapered roller bearing outer race with a 0.65 mm thick shim into the clutch housing to the limit stop. Refer to => [ Installing the Small Outer Race/Tapered Roller Bearing ] Output Shaft.

- Install the output shaft and tighten the bearing support nuts to 25 Nm.

- Rotate the output shaft 20 to 30 times in one direction.

• It must be rotated in one direction so the tapered roller bearing rollers are seated in one direction.

• Therefore, it must be rotated 20 to 30 times in one direction.

• Otherwise the measurements will be incorrect.

- Install the dial gauge (3 mm measuring range) and set to "0" with a 1 mm preload.






- Move the output shaft up and down, read off the play on the dial gauge and make a note of it (example: to 0.20 mm).

Determining Shim Thickness

The specified bearing preload is reached by adding a constant preload figure of 0.10 to 0.15 mm to the reading obtained and the thickness of the installed shim.

Example:






Example:






- Remove the output shaft and then remove the small taper roller bearing outer race. Refer to => [ Remove the Small Outer Race/Tapered Roller Bearing ] Output Shaft.

Adjustment Shim Table






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

- Insert shim with the correct thickness.

• If the previous 0.65 mm adjustment shim will be inserted again, check it for damage.

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

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

- Install the outer race/small tapered roller bearing with the selected adjusting shim (in the example: 1.00 mm).






- Install the output shaft, tighten the bearing support nuts in the clutch housing to 25 Nm + an additional 90° (1/4) turn.