Output Shaft For 5TH, 6TH and Reverse Gear, Adjusting

Output shaft for 5th, 6th and reverse gear, adjusting
(Determining shim for output shaft)

Special tools and equipment

^ VW353 Transmission support
^ VW387 Universal dial gauge bracket
^ VW407 Press tool
^ VW433 Press piece
^ VW792 Installation tool
^ VW801 Holding plate

Special tools and equipment

^ VW309 Holding plate
^ 2050 Thrust piece
^ VAG1331 Torque wrench
^ 1 - Kukko 21/7 Internal puller
^ 4 - Kukko 22/2 Counter support

It is necessary to readjust the output shaft when the following components are replaced:
^ Transmission housing
^ Clutch housing
^ Output shaft for 5th, 6th and reverse gears

or
^ Tapered roller bearing

Requirements
^ Sealing surfaces of clutch and transmission housings must be free of sealant.
^ When taking measurements, install only the shaft to be measured.

^ Press tapered roller bearing outer race with a 1.70 mm thick shim into transmission housing, supporting housing directly under bearing support with thrust piece 2050.
^ Set complete 5th, 6th and reverse gear output shaft in clutch housing.

^ Install transmission housing and tighten bolts -A- and -B- diagonally to correct torque.

^ Install measuring tools. Put washers with a total thickness of 8 mm on bolt -arrow- securing installation tool VW 792 to clutch housing.
^ Set dial gauge (3 mm measuring range) to zero with 1 mm preload.
^ Loosen clutch housing/transmission housing securing bolts diagonally until output shaft moves freely in transmission housing.
^ Read play on gauge and note reading (Example: 0.27 mm)

Note: If dial gauge indicates no value when clutch housing/transmission housing securing bolts are loosened, install shim 1.95 mm (Part No. 084 409 383 AS) or, if necessary, shim 2.20 mm (Part No. 084 409 383 BD).

Determining thickness of shim
The specified bearing pretension will be attained by subtracting the measured value (0.27 mm) from the inserted shim (1.70 mm) and adding a constant for pressing (0.20 mm).

Example:

^ Determine thickness of shim from table 35-82.

^ Remove transmission housing and pull tapered roller bearing outer race out of housing.
A - Counter support, e. g. Kukko 22/2
B - Internal puller 46 to 58 mm, e.g. Kukko 21/7
^ Remove inserted shim (1.70 mm thick) from clutch housing.

Shim table

Varying tolerances make it possible to obtain the exact shim thickness required.
^ Press in tapered roller bearing outer race together with determined shim (in Example 1.65 mm) while supporting transmission housing with thrust piece 2050 directly under bearing support.

Perform check measurement
^ Determined shim installed.