Input shaft, adjusting

(Determining thickness of shim for input shaft)

It is necessary to re -adjust the input shaft when any of the following is replaced:

• Transmission housing
• Clutch housing
• Input shaft
• 4th gear (4GR)
• Input shaft tapered roller bearing

Adjustment overview, see Adjustment overview  .

• Press tapered roller bearing outer race, without adjustment shim, into transmission housing to stop.
  • Use thrust pad VW 510
• Install input shaft into clutch housing, then install transmission housing.
  Fig 1: Installing Measuring Fixture And Dial Indicator In Clutch Housing

  Courtesy of VOLKSWAGEN OF AMERICA, INC.
  • Tightening torque: 25 N.m (18 ft lb) plus additional 90° (1/4-turn)
• Install measuring fixture and dial indicator in clutch housing.
  • Large tapered roller bearing in transmission housing
• Before taking measurements, rotate input shaft to seat bearings.
• Adjust dial indicator to zero with 1 mm preload.
  CAUTION: Repeat the procedure for each measurement, otherwise the dial indicator will not return to its original position.
• Press input shaft in direction of dial indicator (-arrow-).
Fig 2: Pressing Input Shaft In Direction Of Dial Indicator
Courtesy of VOLKSWAGEN OF AMERICA, INC.
• Read and record play indicated on dial indicator.
  • Example: 1.21 mm
  NOTE: Dial indicator does not return to its original position.
• Determine required thickness of shim, see INPUT SHAFT ADJUSTMENT SHIMS 
  • Example: 1.175 mm
• Remove input shaft and press tapered roller bearing outer race out of transmission housing.
  • Use tool VW 447i
• Press tapered roller bearing outer race back into transmission housing with 1.175 mm shim (example).
• Install transmission housing.
  • Tightening torque: 25 N.m (18 ft lb) plus additional 90° (1/4-turn)