Output Shaft, Adjusting

Output Shaft 1st through 4th Gear, Adjusting

Special tools and workshop equipment required

• Holding Fixture -VW313-
• Transmission Support -VW353-
• Dial Gauge Holder -VW387-
• Press Piece - Rod -VW407-
• Press Piece - Multiple Use -VW433-
• Seal Installer - Stator -VW792-
• Crankshaft Holding Fixture -VW801-
• Holding Plate -VW309A-
• or Holding Plate -VW309A-
• Slide Hammer - Press Plate -2050-
• Torque Wrench 1331 5-50Nm -VAG1331-
• -1-Puller - Kukko Internal - 46-56mm -21/7-
• -4-Puller - Kukko Counterstay -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 for 1st to 4th gears or
• Output shaft tapered roller bearing

Adjustment overview.

Requirements:

• Remove any Sealant remaining on the sealing surfaces on the clutch and transmission housing.
• 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 shim. Support transmission housing directly beneath bearing mount using Slide Hammer - Press 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.

• Position the measuring tools on the clutch housing and secure them with a bolt -arrow-.
• Set the dial gauge (3 mm range) with 1 mm preload to "0".
• Loosen securing bolts for clutch housing/transmission housing in diagonal sequence until bolts clear transmission housing and output shaft.
• Read measured value on dial indicator and note (example: 0.14 mm).

Note

• The measured value will not be displayed when loosening the bolts that connect the clutch housing to the transmission housing.
• Install a 1.95 mm shim or, if necessary, a 2.20 mm shim in place of the 1.70 mm shim for measuring.
• Allocate the correct shim. Refer to the Parts Catalog.

Determining the Shim

The required bearing tension is reached as follows:

The specified bearing pre-load is reached when determined measured value (0.14 mm) is subtracted from inserted adjustment shim (1.70 mm).

A constant figure of (0.20 mm) is added to the reading.

Example:

• Select the correct shim thickness according to the table.
• Remove the transmission housing and remove the tapered roller bearing outer race from the transmission housing.

1. 1
   Counter Support, for example, Puller - Kukko Counterstay -22/2-
2. 2
   Internal Puller 46 to 58 mm, for example, Puller - Kukko Internal - 46-56mm -Kukko 21/7-

• Remove the inserted shim (1.70 mm) from the transmission housing.

Shim Table

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

• Shim part number. Refer to the Parts Catalog.
• Install the outer race/tapered roller bearing with the selected shim (in the example: 1.75 mm) Support transmission housing directly beneath bearing mount using Slide Hammer - Press Plate -2050-.

Checking Measurement

• The selected adjusting shim is installed.
• Position the measuring tools on the clutch housing and secure them with a bolt -arrow-.
• Set the dial gauge (3 mm range) with 1 mm preload to "0".
• Loosen securing bolts for clutch housing/transmission housing in diagonal sequence until bolts clear transmission housing and output shaft.
• For correctly selected shim, the dial gauge must now display a value of 0.15 mm to 0.25 mm.

Tightening Specifications

Transmission housing to clutch housing.

Output Shaft, 5th, 6th and Reverse Gears, Adjusting

Special tools and workshop equipment required

• Holding Fixture -VW313-
• Transmission Support -VW353-
• Dial Gauge Holder -VW387-
• Press Piece - Rod -VW407-
• Press Piece - Multiple Use -VW433-
• Seal Installer - Stator -VW792-
• Crankshaft Holding Fixture -VW801-
• Holding Plate -VW309A-
• or Holding Plate - VW309A-
• Slide Hammer - Press Plate -2050-
• Torque Wrench 1331 5-50Nm -VAG1331-
• -1-Puller - Kukko Internal - 46-56mm -21/7-
• -4-Puller - Kukko Counterstay -22/2-
• Dial Indicator -VAS6080A-

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

• Transmission Housing
• Clutch Housing
• Output Shaft, 5th, 6th and Reverse Gears or
• Output shaft tapered roller bearing

Adjustment Overview.

Requirements:

• Remove any Sealant remaining on the sealing surfaces on the clutch and transmission housing.
• 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 shim. Support transmission housing directly beneath bearing mount using Slide Hammer - Press Plate -2050-.
• Install the output shaft for 5th/6th gears and reverse gear into the clutch housing.

• Install the transmission housing and tighten the bolts -A- and -B- diagonally.

• Attach the measuring tools to the clutch housing.

In the case of protruding housing edges:

• Place washers (total thickness: 8 mm) under the Seal Installer - Stator -VW792--arrow-.
• Set the dial gauge (3 mm range) with 1 mm preload to "0".
• Loosen securing bolts for clutch housing/transmission housing in diagonal sequence until bolts clear transmission housing and output shaft.
• Read measured value on dial indicator and note (example: 0.25 mm).

Note

• The measured value will not be displayed when loosening the bolts that connect the clutch housing to the transmission housing.
• Install a 1.95 mm shim or, if necessary, a 2.20 mm shim in place of the 1.70 mm shim for measuring.
• Allocate the correct shim. Refer to the Parts Catalog.

Determining the Shim

The required bearing tension is reached as follows:

The specified bearing pre-load is reached when determined measured value (0.25 mm) is subtracted from inserted shim (1.70 mm).

A constant figure of (0.20 mm) is added to the reading.

Example:

• Select the correct shim thickness according to the table.
• Remove the transmission housing and remove the tapered roller bearing outer race from the transmission housing.

1. 1
   Counter Support, for example, Puller - Kukko Counterstay -22/2-
2. 2
   Internal Puller 46 to 58 mm, for example, Puller - Kukko Internal - 46-56mm -21/7-

• Remove the inserted shim (1.70 mm) from the transmission housing.

Shim Table

• Part numbers. Refer to the Parts Catalog.

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

• Install the outer race/tapered roller bearing with the selected shim (in the example: 1.65 mm) Support transmission housing directly beneath bearing mount using Slide Hammer - Press Plate -2050-.

Checking Measurement

• The selected adjusting shim is installed.

• Attach the measuring tools to the clutch housing.

In the case of protruding housing edges:

• Place washers (total thickness: 8 mm) under the Seal Installer - Stator -VW792--arrow-.
• Set the dial gauge (3 mm range) with 1 mm preload to "0".
• Loosen securing bolts for clutch housing/transmission housing in diagonal sequence until bolts clear transmission housing and output shaft.
• For correctly selected shim, the dial gauge must now display a value of 0.15 mm to 0.25 mm.

Tightening Specifications

Transmission housing to clutch housing.