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)

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

• Transmission housing

• Clutch housing

• Output shaft 5th/6th and reverse gear or

• Tapered roller bearing for output shaft

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

Requirements

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

• For the measurement, only install the output shaft to be measured.

- Press the tapered roller bearing outer race with a 1.70 mm adjustment shim into the transmission housing. Support the transmission housing directly beneath the bearing mount using the (2050).

- Set the complete output shaft for 5th/6th and reverse gears into the clutch housing.

- Install the transmission housing and tighten the bolts - A - as well as - B - to specification in a diagonal sequence.

- Install the measuring tools.

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

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

- 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).

• The measured value will not be displayed when loosening the bolts that connect the clutch housing to the transmission housing.

• Install either the 1.95 mm adjusting shim or the 2.20 mm adjusting shim for the measuring.

Determining Shim Thickness

The required bearing tension is reached as follows:

The specified bearing preload is reached when determined measured value (0.25 mm) is subtracted from inserted adjustment shim (1.70 mm).

A constant figure of (0.40 mm) is added to the reading.

Example:

- Determine thickness of adjustment shim according to table. Refer to => [ Adjustment Shim Table ].

- Remove the transmission housing and pull the tapered roller bearing outer race from the transmission housing.

A Support, for example, (22/2)
B Internal puller 46-58 mm, for example, (21/7)

- Remove the inserted adjustment shim (1.70 mm thick) from the transmission housing.

Adjustment Shim Table

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

- Press in the tapered roller bearing outer race with determined shim (1.65 mm in example). Support the transmission housing directly beneath the bearing mount using the (2050).

Checking Measurement

• Determined adjustment shim installed.

- Install the measuring tools.

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