Output shaft for 1st to 4th gear, adjusting: 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.

Special tools, testers and auxiliary items required

Fig 1: Identifying Special Tools -- Output Shaft For 1st-4th Gears, Adjusting (1 Of 2)

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Engine support adapter VW 353
Dial gauge holder VW 387
Punch VW 407
Thrust piece VW 433

Assembly tool VW 792
Holding plate VW 801

Special tools, testers and auxiliary items required

Fig 2: Identifying Special Tools -- Output Shaft For 1st-4th Gears, Adjusting (2 Of 2)

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Holding plate VW 309
Thrust piece 2050
Torque wrench V.A.G 1331
Internal puller 1- Kukko 21/7

Support 4- Kukko 22/2

(Determining adjustment shim for output shaft)

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

Transmission housing
Clutch housing
Output shaft 1st to 4th gear
Tapered roller bearing for output shaft

List of adjustments → Adjustment overview for manual transmission

Requirements

Sealing surfaces of clutch and transmission housing must be cleaned of sealant.
For the measurement, only install output shaft to be measured.

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

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Press tapered roller bearing outer race with a 1.70 mm adjustment shim into transmission housing. Support transmission housing directly beneath bearing mount using thrust piece 2050.
Set complete output shaft for 1st to 4th gears into clutch housing.

Fig 4: Identifying Transmission Housing Bolts

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Install transmission housing and tighten bolts - A - and - B - to specified torque in diagonal sequence.

Fig 5: Identifying Measuring Tools, Secure With Bolt To Clutch Housing

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Install measuring tools and secure to clutch housing with bolt - arrow -.
Set gauge (3 mm measuring range) to "0" with 1 mm pre-load.
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).

NOTE:

If no measured value is displayed on dial gauge when loosening securing bolts for clutch housing/transmission housing, install adjustment shim of 1.95 mm or if necessary, adjustment shim of 2.20 mm for the measurement.
Allocate adjustment shims via Electronic Parts Catalog (ETKA).