Output Shaft For 5TH, 6TH And Reverse Gear, Adjusting

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Fig 1: Identifying Special Tools - Output Shaft For 5th, 6th And Reverse Gear, Adjusting (1 Of 2)

Courtesy of VOLKSWAGEN UNITED STATES, INC.

(Determining shim for output shaft)

Special tools and equipment

VW 353 Transmission support
VW 387 Universal dial gauge bracket
VW 407 Press tool
VW 433 Press piece
VW 792 Installation tool
VW 801 Holding plate

Fig 2: Identifying Special Tools - Output Shaft For 5th, 6th And Reverse Gear, Adjusting (1 Of 2)

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Special tools and equipment

VW 309 Holding plate
2050 Thrust piece
VAG 1331 Torque wrench
1 - Kukko 21/7 Internal puller
4 - Kukko 22/2 Counter support

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

Transmission housing
Clutch housing
Output shaft for 5th, 6th and reverse gears

Tapered roller bearing

Adjustment overview. Refer to Adjustment overview

Requirements

Sealing surfaces of clutch and transmission housings must be free of sealant.
When taking measurements, install only the shaft to be measured.

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

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Press tapered roller bearing outer race with a 1.70 mm thick shim into transmission housing, supporting housing directly under bearing support with thrust piece 2050.
Set complete 5th, 6th and reverse gear output shaft in clutch housing.

Fig 4: Identifying Transmission Housing Bolts

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Install transmission housing and tighten bolts -A- and -B- diagonally to correct torque.

Fig 5: Install Measuring Tools To Clutch Housing

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Install measuring tools. Put washers with a total thickness of 8 mm on bolt (arrow) securing installation tool VW 792 to clutch housing.
Set dial gauge (3 mm measuring range) to zero with 1 mm preload.
Loosen clutch housing/transmission housing securing bolts diagonally until output shaft moves freely in transmission housing.
Read play on gauge and note reading (Example: 0.27 mm)

NOTE: If dial gauge indicates no value when clutch housing/transmission housing securing bolts are loosened, install shim 1.95 mm (Part No. 084 409 383 AS) or, if necessary, shim 2.20 mm (Part No. 084 409 383 BD).

Determining thickness of shim

The specified bearing pretension will be attained by subtracting the measured value (0.27 mm) from the inserted shim (1.70 mm) and adding a constant for pressing (0.20 mm).

Example:

Inserted shim	1.70 mm
- Measured value	0.27 mm
+ Preloading (constant)	0.20 mm
Shim thickness	1.63 mm

Determine thickness of shim from table. Refer to Shim table .

Fig 6: Pulling 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 housing.

A - Counter support, e.g. Kukko 22/2

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

Remove inserted shim from clutch housing.

Shim table

Size (mm)	Part No.
1.40 1.45 1.50	084 409 383 AF 084 409 383 AG 084 409 383 AH
1.55 1.60 1.65	084 409 383 AJ 084 409 383 AK 084 409 383 AL
1.70 1.75 1.80	084 409 383 AM 084 409 383 AN 084 409 383 AP
1.85 1.90 1.95 2.00	084 409 383 AQ 084 409 383 AR 084 409 383 AS 084 409 383 AT
2.05 2.10 2.15 2.20 2.25	084 409 383 BA 084 409 383 BB 084 409 383 BC 084 409 383 BD 084 409 383 BE

Varying tolerances make it possible to obtain the exact shim thickness required.

Fig 7: Pressing Tapered Roller Bearing Outer Race Into Transmission Housing

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Press in tapered roller bearing outer race together with determined shim (in Example 1.65 mm) while supporting transmission housing with thrust piece 2050 directly under bearing support.

Perform check measurement

Determined shim installed.

Fig 8: Install Measuring Tools To Clutch Housing

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Install measuring tools. Put washers with a total thickness of 8 mm on bolt (arrow) securing installation tool VW 792 to clutch housing.
Set dial gauge (3 mm measuring range) to zero with 1 mm preload.
Loosen clutch housing/transmission housing securing bolts diagonally until output shaft moves freely in transmission.

If the correct shim has been selected, the dial gauge will indicate a value of 0.15 mm to 0.25 mm.