Input Shaft, Adjusting

WARNING: This page is about a different car, the 2013 Volkswagen Beetle and 2012 Volkswagen Beetle. However, it is still accessible from the selected car via links, so may be relevant.

Choosing the adjusting shim for the input shaft.

Special tools and workshop equipment required

Dial Gauge Holder VW387
Magnetic Plate 50 mm Diameter VW385/17
Thrust Pad VW510
Thrust Pad VW447 i
Punch VW407
Torque Wrench 1331 5-50 Nm VAG 1331
Dial Gauge (commercially available)

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

Transmission housing
Clutch housing
Input shaft
4th gear

or the

Tapered roller bearing

Adjustment overview, refer to ADJUSTMENT OVERVIEW .

Requirement:

Remove any sealant still on the sealing surfaces on the clutch and transmission housings.

Perform the following

-- Press the taper roller bearing outer race into the clutch housing all the way.

Fig 1: Identifying Tapered Roller Bearing Outer Race

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Install the outer race/tapered roller bearing all the way into the transmission housing without the adjusting shim.

Fig 2: Identifying Tapered Roller Bearing Outer Race

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Install the input shaft into the clutch housing and mount the transmission housing. Install the bolts.

-- Install the measuring device and the dial gauge in the clutch housing.

Fig 3: Identifying Special Tools VW387, VW353 & VW385-17

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Rotate the input shaft before measuring so the tapered roller bearing settles. Set the dial gauge with a 1 mm preload to "0".

NOTE:

Repeat this process each time a measurement is taken otherwise the dial gauge will not go back to its start setting.

-- Press the input shaft toward the dial gauge in the -direction of the arrow-.

Fig 4: Identifying Special Tools VW387, VW353 & VW385-17

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Read and make note of the play on the dial gauge (example: 1.21 mm).

NOTE:

The dial gauge does not return to its starting position.

Determining Shim Thickness

Example:

Bearing clearance measured value:	Adjustment shim thickness according to the table:
1.21 mm	1.175 mm

Adjustment Shim Table

Bearing play	Shim
Measured value (mm)	Thickness (mm)
0.671 to 0.699 0.700 to 0.724 0.725 to 0.749	0.650 0.675 0.700
0.750 to 0.774 0.775 to 0.799 0.800 to 0.824	0.725 0.750 0.775
0.825 to 0.849 0.850 to 0.874 0.875 to 0.899	0.800 0.825 0.850
0.900 to 0.924 0.925 to 0.949 0.950 to 0.974	0.875 0.900 0.925
0.975 to 0.999 1.000 to 1.024 1.025 to 1.049	0.950 0.975 1.000
1.050 to 1.074 1.075 to 1.099 1.100 to 1.124	1.025 1.050 1.075
1.125 to 1.149 1.150 to 1.174 1175 to 1.199	1.100 1.125 1.150
1.200 to 1.224 1.225 to 1.249 1.250 to 1.274	1.175 1.200 1.225
1.275 to 1.229 1.300 to 1.324 1.325 to 1.349	1.250 1.275 1.300
1.350 to 1.374 1.375 to 1.399 1.400 to 1.424	1.325 1.350 1.375
1.425 to 1.449 1.450 to 1.474 1.475 to 1.499	1.400 1.425 1.450
1.500 to 1.524 1.525 to 1.549 1.550 to 1.574	1.475 1.500 1.525
1.575 to 1.599 1.600 to 1.624 1.625 to 1.649	1.550 1.575 1.600
1.650 to 1.674 1.675 to 1.699 1.700 to 1.724	1.625 1.650 1.675

-- Remove the input shaft and then remove the outer race/tapered roller bearing from the transmission housing using the thrust pad VW 447 i.

-- Insert the shim with the correct thickness.

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.

-- Press the outer race/tapered roller bearing and the selected shim (1.175 mm in the example) into the transmission housing using the thrust pad VW 510.

-- Assemble the transmission housing and tighten the bolts.

Checking the Measurement

-- Install the measuring device and the dial gauge.

Fig 5: Identifying Special Tools VW387, VW353 & VW385-17

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Turn the input shaft so that the tapered roller bearings settle.

-- Press the input shaft in the -direction of the arrow-.

-- Bearing play should be between 0.01 and 0.09 mm.

NOTE:

The adjustment is OK if it is not possible to measure the bearing play and yet the input shaft still have a noticeable play and it easy to turn.

Tightening Specifications

Transmission housing to clutch housing, refer to TRANSMISSION HOUSING AND SHIFT MECHANISM OVERVIEW .