Input Shaft, Adjusting

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.

(Choosing the adjusting shim for the input shaft)

Special tools and workshop equipment required

Dial Gauge Holder VW 387
Magnetic Plate 50 mm Dia. VW 385/17
Thrust Pad VW 510
Thrust Pad VW 447 i
Punch VW 407
Torque Wrench (5-50 Nm) V.A.G 1331
Dial Gauge

A new input shaft adjustment is required when the following components have been replaced:

Transmission housing
Clutch housing
Input shaft
4th gear

or the

Tapered roller bearing

Adjustment overview. Refer to ADJUSTMENT OVERVIEW .

Requirement:

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

-- Press the tapered roller bearing outer race into the clutch housing all the way.

Fig 1: Pressing In Tapered Roller Bearing Outer Race

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Install the outer race/tapered roller bearing all the way into the transmission housing without the adjusting shim.

Fig 2: Pressing In Tapered Roller Bearing Outer Race

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Install the input shaft into the clutch housing and install the transmission housing. Tighten the bolts to 25 Nm + 90° (1/4) additional turn.

-- Install the measuring device and the dial gauge in the clutch housing.

Fig 3: Identifying Special Tools VW387, VW353 & VW385-17

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Rotate the input shaft before measuring so the tapered roller bearing settles. Set the dial gauge with a 1 mm preload to "0".

NOTE:

Repeat this process each time a measurement is taken otherwise the dial gauge will not go back to its start setting.

-- Press the input shaft toward the dial gauge in the -direction of the arrow-.

Fig 4: Identifying Special Tools VW387, VW353 & VW385-17

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Read and make note of the play on the dial gauge (example: 1.21 mm).

NOTE:

The dial gauge does not return to its starting position.

Determining Shim Thickness

Example:

Bearing Clearance Measured Value	Adjustment Shim Thickness According to the Table
1.21 mm	1.175 mm

Adjustment Shim Table

Bearing Play	Adjusting Shim
Measured Value (mm)	Thickness (mm)
0.671•••0.699 0.700•••0.724 0.725•••0.749	0.650 0.675 0.700
0.750•••0.774 0.775•••0.799 0.800•••0.824	0.725 0.750 0.775
0.825•••0.849 0.850•••0.874 0.875•••0.899	0.800 0.825 0.850
0.900•••0.924 0.925•••0.949 0.950•••0.974	0.875 0.900 0.925
0.975•••0.999 1.000•••1.024 1.025•••1.049	0.950 0.975 1.000
1.050•••1.074 1.075•••1.099 1.100•••1.124	1.025 1.050 1.075
1.125•••1.149 1.150•••1.174 1.175•••1.199	1.100 1.125 1.150
1.200•••1.224 1.225•••1.249 1.250•••1.274	1.175 1.200 1.225
1.275•••1.229 1.300•••1.324 1.325•••1.349	1.250 1.275 1.300
1.350•••1.374 1.375•••1.399 1.400•••1.424	1.325 1.350 1.375
1.425•••1.449 1.450•••1.474 1.475•••1.499	1.400 1.425 1.450
1.500•••1.524 1.525•••1.549 1.550•••1.574	1.475 1.500 1.525
1.575•••1.599 1.600•••1.624 1.625•••1.649	1.550 1.575 1.600
1.650•••1.674 1.675•••1.699 1.700•••1.724	1.625 1.650 1.675

-- Remove the input shaft and then remove the outer race/tapered roller bearing from the transmission housing using the thrust padVW 447 i.

-- Install the shim with the correct thickness, thickest shim first.

If the measured shim thickness is larger than those listed in the table, then install two shims that add up to the necessary thickness.

-- Press the outer race/tapered roller bearing and the selected shim (1.175 mm in the example) into the transmission housing using the thrust padVW 510.

-- Assemble the transmission housing and tighten the bolts to 25 Nm + an additional 90° (1/4) turn.

Checking the Measurement

-- Install the measuring device and the dial gauge.

Fig 5: Identifying Special Tools VW387, VW353 & VW385-17

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Turn the input shaft so that the tapered roller bearings settle.

-- Press the input shaft in the -direction of the arrow-.

-- Bearing play should be between 0.01 and 0.09 mm.

NOTE:

The adjustment is OK if it is not possible to measure the bearing play and yet the input shaft still have a noticeable play and it easy to turn.