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

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.

-- 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 specification.

-- 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.

-- Set the dial gauge (3 mm range) with a 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).