Output Shaft

5 Speed Manual 02J

Output Shaft, Adjusting
Determining shim for output shaft





Special Tools
- VW 387 Universal dial gauge bracket
- VW 385/17 End measuring plate
- VW 512 Press disk
- 3114/2 Straightening tool
- VW 407 Press tool
- Dial indicator (not illustrated)

It is necessary to readjust the output shaft when the following components are replaced:
- Final drive
- Clutch housing
- Taper roller bearing
Adjustment overview. Refer to Differential, Manual Transaxle.
- Press small tapered roller bearing outer race together with a 0.65 mm thick shim fully into clutch housing.
- Insert output shaft and tighten nuts for bearing support to 25 Nm, then turn 90°further.





- Mount dial indicator (3 mm measuring range) and set to zero with 1.0 mm preload.
- Move output shaft up and down and note dial indicator reading (example: 0.30 mm).

Determining Thickness Of Shim
The specified bearing preload is obtained by adding a constant preload figure of (0.20 mm) to the reading obtained (0.30 mm) and the thickness of the shim installed (0.65 mm).





Example:





- Remove output shaft and pullout small tapered roller bearing outer race.





Adjustment Shim chart 1 of 2





Adjustment shim chart 2 of 2

The following adjustments shims are available.
Varying tolerances make it possible by measuring the shims to obtain the exact shim thickness required.
- Press in small tapered roller bearing outer race together with the correct shim (in example 1. 15 mm).
- Install output shaft and tighten bearing support nuts in clutch housing to 25 Nm (18 ft. lbs.) plus 90°.