Input Shaft, Adjusting

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Fig 1: Identifying Special Tools - Input Shaft, Adjusting (1 Of 2)

Courtesy of VOLKSWAGEN UNITED STATES, INC.

(Determining input shaft adjustment shim)

Special tools and equipment

VW 309 Holding plate
VW 353 Transmission support
VW 385/17 End measuring plate
VW 387 Universal dial gauge bracket
VW 407 Press tool
VW 433 Press piece

Fig 2: Identifying Special Tools - Input Shaft, Adjusting (2 Of 2)

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Special tools and equipment

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

It is only necessary to readjust the input shaft when the following components are replaced:

Transmission housing
Clutch housing
Input shaft

or the

Tapered roller bearings

Adjustment overview. Refer to Adjustment overview

Shims of determined thickness are installed for both output shafts.

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

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Press tapered roller bearing outer race without shim into transmission housing onto stop.
Install both output shafts and input shaft in clutch housing and assemble transmission housing. Tighten hex bolts head. Refer to Transmission housing and selector mechanism, removing and installing item Transmission housing and selector mechanism, removing and installing

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

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Mount measuring appliance and dial gauge in clutch housing.

Fig 5: Measuring Appliance And Dial Gauge Mounted In Clutch Housing

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Install measuring appliance and dial gauge in clutch housing.
Before taking any measurements, rotate input shaft to allow bearings to settle. Set dial gauge to "O" with 1 mm preload.

NOTE: This preparation is to be repeated for each subsequent measurement, otherwise the gauge will not return to the starting position.

Pull input shaft in direction of dial gauge.
Read and note clearance indicated on dial gauge (Example: 1.63).
Determine thickness of shim from table. Refer to Table of adjustment shims (Example: 1.55).

Fig 6: Identifying Counter Support, Internal Puller & VW 801

Courtesy of VOLKSWAGEN UNITED STATES, INC.

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

A - Counter 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 shim into transmission housing.
Assemble transmission housing. Tighten hex bolts head. Refer to Transmission housing and selector mechanism, removing and installing item Transmission housing and selector mechanism, removing and installing