Output Shaft, 1ST To 4TH Gears, Adjusting
It is necessary to readjust the output shaft when the following components are replaced:
- Transmission housing
- Clutch housing
- Output Shaft, 1st to 4th Gears
- Tapered roller bearing for output shaft
Adjustment overview, refer to ADJUSTMENT OVERVIEW .
Special tools and workshop equipment required
- Dial Gauge Holder VW 387
- Punch VW 407
- Thrust Pad Con. 8/65 VW 433
- Installation Arbor VW 792
- Holding Fixture VW 801
- Thrust Plate 2050
- Dial gauge VAS 6080
- Kukko 21/7 internal puller
- Kukko 22/2 counter-support
Adjusting
- Attach transmission to assembly stand. Refer to TRANSMISSION, SECURING TO ASSEMBLY STAND .
- Sealing surfaces of clutch- and transmission housing must be cleaned of sealant.
- For the measurement, only install shaft to be measured.
-- Press the tapered roller bearing outer ring with a 1.70 mm adjustment shim into the transmission housing. Support transmission housing directly beneath bearing mount using 2050.
-- Set complete output shaft for 1st to 4th gears into clutch housing.
-- Install transmission housing and tighten bolts -A- as well as -B- to tightening specification in diagonal sequence.
-- Install measuring tools and secure to clutch housing with bolt -arrow-.
-- Set VAS 6080 (3 mm measuring range) to 0 with 1 mm preload.
-- 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).
If no measured value is displayed on the dial gauge when loosening the securing bolts for the clutch housing/transmission housing, install adjustment shim 1.95 mm (part number 084 409 383 AS) or if necessary 2.20 mm (part number 084 409 383 BD) for the measurement.
Determining Shim Thickness
The specified bearing pre-load is reached when determined measured value (0.14 mm) is subtracted from inserted adjustment shim (1.70 mm) and a constant pre-load value (0.20 mm) is added.
Example:
| Installed adjustment shim | 1.70 mm |
| - Measured value | 0.14 mm |
| + Pre-load (constant value) | 0.20 mm |
| Thickness of shim | 1.76 mm |
-- Determine the adjustment shim thickness according to the table; part number.
The following shims are available:
| Thickness of Shims in mm | |||
|---|---|---|---|
| 1.45 | 1.70 | 1.95 | 2.20 |
| 1.50 | 1.75 | 2.00 | 2.25 |
| 1.55 | 1.80 | 2.05 | |
| 1.60 | 1.85 | 2.10 | |
| 1.65 | 1.90 | 2.15 | |
Different shim thicknesses make it possible to select the required thickness precisely.
-- Remove the transmission housing and pull the tapered roller bearing outer ring out of the transmission housing.
A - Support, for example Kukko 22/2
B - Internal puller 46 to 58 mm, for example Kukko 21/7
-- Remove inserted adjustment shim (1.70 mm thick) from transmission housing.
-- Press in the tapered roller bearing outer ring with the determined adjustment shim (1.75 mm as an example). Support transmission housing directly beneath bearing mount using 2050.
Checking Measurement
- Determined adjustment shim installed.
-- Install measuring tools and secure to clutch housing with bolt -arrow-.
-- Set VAS 6080 (3 mm measuring range) to 0 with 1 mm preload.
-- Loosen securing bolts for clutch housing/transmission housing in diagonal sequence until bolts clear transmission housing and output shaft.
- For a correctly selected adjustment shim, the dial gauge must now display a value of 0.15 mm to 0.25 mm.