Output Shaft, 5TH, 6TH And Reverse Gears, Adjusting: Notes

WARNING: This page does not describe the selected car, but rather 7 other vehicles, including the 2010 Volkswagen Jetta, 2009 Volkswagen Jetta, 2009 Volkswagen GLI, 2008 Volkswagen Jetta, and 2008 Volkswagen GLI. However, it is still accessible from the selected car via links, so may be relevant.

Special tools and workshop equipment required

Transmission Support VW 353
Dial Gauge Holder VW 387
Punch VW 407
Thrust Pad Con. 8/65 VW 433
Installation Arbor VW 792
Holding Fixture VW 801
Holding Plate VW 309
Thrust Plate 2050
Torque Wrench (5-50 Nm) V.A.G 1331
Kukko Extractor 46-58 mm 21/7
Kukko Support 22/2

It is necessary to adjust the output shaft if the following components were replaced:

Transmission housing
Clutch housing
Output shaft, 5th, 6th and reverse gears or
Output shaft tapered roller bearing

Adjustment overview, refer to ADJUSTMENT OVERVIEW .

Requirements:

Remove any sealant still on the sealing surfaces on the clutch and transmission housings.
Install the output shaft that is going to be measured.

-- Install the tapered roller bearing outer race in the transmission housing with a 1.70 mm adjustment shim. Support the transmission housing directly under the bearing mount using the thrust plate 2050.

Fig 1: Identifying Outer Race/Tapered Roller Bearing Pressed Into Transmission Housing

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Install the output shaft for 5th/6th gears and reverse gear into the clutch housing.

-- Install the transmission housing and tighten the bolts -A and B- diagonally to the tightening specification.

Fig 2: Identifying Transmission Housing Bolts

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Install the measuring tools.

-- If there are protruding housing edges: place an 8 mm washer on the bolt -arrow- for the installation arbor VW 792 on the clutch housing.

Fig 3: Identifying Washers Inserted At Securing Bolt For Assembly Tool VW 792 At Clutch Housing

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Set the dial gauge (3 mm range) with 1 mm preload to "0".

-- Loosen the bolts for the clutch housing to transmission housing in a diagonal sequence until the bolts clear the transmission housing and output shaft.

-- Read the measured value on the dial indicator and note (example: 0.25 mm).

NOTE:

If the dial gauge will not display a value when the clutch housing/transmission housing bolts are loosened. Then install either the 1.95 mm or the 2.20 mm adjusting shim for the measuring.