Output Shaft, Adjusting: Notes

WARNING: This page is about a different car, the 2009 Volkswagen Rabbit, 2008 Volkswagen Rabbit, 2007 Volkswagen Rabbit, and 2006 Volkswagen Rabbit. However, it is still accessible from the selected car via links, so may be relevant.

(Selecting the correct adjusting shim for the output shaft)

Special tools and workshop equipment required

Dial Gauge Holder VW 387
Magnetic Plate 50 mm Dia VW 385/17
Thrust Pad VW 512
Replacement Stud (8 mm/10 mm) 3114/2
Punch VW 407
Torque Wrench (5-50 Nm) V.A.G 1331
Dial Gauge
Kukko Extractor 37-46 mm 21/6
Kukko Support 22/2

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

Output shaft
Clutch housing

Tapered roller bearing

Adjustment overview, refer to ADJUSTMENT OVERVIEW .

Requirement:

Remove any sealant still on the sealing surfaces on the clutch and transmission housings.

Perform the following procedure:

-- Install the small tapered roller bearing outer race with a 0.65 mm thick shim into the clutch housing to the limit stop Installing the Small Outer Race/Tapered Roller Bearing .

-- Install output shaft and tighten the bearing mount nuts to 25 Nm + 90° (1/4) additional turn.

-- Rotate the output shaft 20 to 30 times in one direction.

NOTE:

It must be rotated in one direction so the tapered roller bearing rollers are seated in one direction.

Therefore, it must also be rotated 20 to 30 times in one direction.

Otherwise the measurements will be incorrect.

-- Install dial gauge (3 mm measuring range) and set to "0" with 1 mm preload.

Fig 1: Identifying Special Tools VW385/17, VW387 & 3114/2

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Move the output shaft up and down. Read the play on the dial gauge and note it (example: 0.20 mm).