Shim S3

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It is necessary to measure output shaft axial play and determine the proper shim thickness for adjustment of the output shaft when one or more of the following have been replaced:

Clutch housing
Final drive gear and output shaft (ring and pinion)
Tapered roller bearings of output shaft

Adjustment summary, see ADJUSTMENT SUMMARY

Install a 0.65 mm thick adjustment shim and drive outer race of small tapered roller bearing into clutch housing, to stop.

Fig 1: Installing Small Tapered Roller Bearing Into Clutch Housing
Courtesy of VOLKSWAGEN OF AMERICA, INC.
Install output shaft and tighten bolts for bearing cover.
Tightening torque: 25 N.m (18 ft lb) plus an additional 1/4 turn (90°)
Set up dial indicator (3 mm range) and zero gauge with 1 mm preload.
A - Shim, 0.65 mm
Move output shaft up and down and record dial indicator reading (example: 0.30 mm).

Fig 2: Measuring Axial Play Of Output Shaft

Courtesy of VOLKSWAGEN OF AMERICA, INC.

CAUTION: Do not turn the shaft during the measurement as this will cause the bearings to settle, which will result in an incorrect reading.