Determining shim -A- thickness

Fig 1: Measuring Gaps To Determine Shim Thickness

Courtesy of VOLKSWAGEN UNITED STATES, INC.

• For the measuring sequence the transmission housing must be clamped into the assembly stand so that the input gear is facing downward, as illustrated on. Refer to Overview of components to adjust reverse gear brake -B1-  .

Shim thickness is determined by gap "x" and selected from table. Refer to Table of shims  .

x = k + l/2 - m

• A = Shim
• x = Gap
• I = Position of piston in freewheel
• m = Height of plate set including pressure plate

• K = Constant = 26.9 mm

"K" is determined by installed height in transmission housing and is not adjustable.

Calculating "I": 

Fig 2: Identifying Straightedge On Outer Race Of Freewheel & Depth Gauge On Inner Edge Of Piston

Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Press piston in direction of arrow up to stop.
• Place straightedge "A" onto outer race of freewheel.
• Measure to inner edge of piston with depth gauge "B"

Example: 

Calculating "m": 

Fig 3: Identifying Straightedge On Thrust Plate & Depth Gauge On Plate Set

Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Place straightedge "A" on thrust plate.
• Compress set of plates including pressure plate in direction of arrow and measure thickness of plate set with depth gauge "B".

Example: 

x = k + l/2 - m

= 26.9 + 3.6/2 - 25.3 = 3.4 mm

• Determine size of shims according to table: