Input shaft, adjusting up to transmission manufacture date 180503: Notes

WARNING: This page is about a different car, the 2004 Volkswagen R32. However, it is still accessible from the selected car via links, so may be relevant.

(Determining adjustment shim for input shaft)

NOTE:

Adjustment instructions are valid only for transmissions up to transmission manufacture date 180503 (input shaft bearing with tapered roller bearings)
Bearing for input shaft has changed as of transmission manufacture date 190503 → Input shaft, disassembling and assembling as of transmission manufacture date 190503 . Adjustment was then discontinued.

Special tools, testers and auxiliary items required

Fig 1: Identifying Special Tools - Input Shaft, Adjusting Up To Transmission Manufacture Date 180503 (1 Of 2)

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Holding plate VW 309
Engine support adapter VW 353
Magnetic plate VW 385/17
Dial gauge holder VW 387

Punch VW 407
Thrust piece VW 433

Special tools, testers and auxiliary items required

Fig 2: Identifying Special Tools - Input Shaft, Adjusting Up To Transmission Manufacture Date 180503 (2 Of 2)

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Holding plate VW 801
Torque wrench V.A.G 1331/
Internal puller 1- Kukko 21/7
Support 4- Kukko 22/1

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

Transmission housing
Clutch housing
Input shaft

or the

Tapered roller bearing

List of adjustments → Adjustment overview for manual transmission

Conditions

Determined adjustment shims for both output shafts are installed.

Fig 3: Pressing Tapered Roller Bearing Outer Race Into Transmission Housing

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Press tapered roller bearing outer race without adjustment shim into transmission housing up to stop.
Place both output shafts and input shaft in clutch housing and attach transmission housing. Tighten hex bolts to specified torque.

Fig 4: Measuring Appliance And Dial Gauge Mounted In Clutch Housing

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Install measuring device and dial gauge into clutch housing.
Rotate input shaft before measuring procedure so that tapered roller bearing settles. Set dial gauge to "O" with 1 mm pre-load.

NOTE:

This procedure must be repeated after every measuring procedure, otherwise dial gauge is not reset to initial position.

Pull input shaft in direction of dial gauge.
Read play on dial indicator and note (example 1.63).
Determine thickness of adjustment shim from table (example 1.55). Part numbers Electronic Parts Catalog (ETKA)

Fig 5: Pressing Tapered Roller Bearing Outer Race Out Of Transmission Housing

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove transmission housing and pull tapered roller bearing outer race out of transmission housing.

A - Support , e.g. Kukko 22/2

B - Internal puller 46 to 58 mm , e.g. Kukko 21/7

Press tapered roller bearing outer race together with 1.55 adjustment shim (example) into transmission housing.
Install transmission housing and tighten new hex bolts to specified torque.