Output Shaft, Adjusting

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(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
Kukko Extractor 37-46 mm 21/6
Kukko Support 22/2
Dial Gauge

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 .

Requirements:

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

-- Press the outer race/small tapered roller bearing with the adjustment shim 0.65 mm into the clutch housing as far as the stop. Refer to Figure.

-- Install the output shaft and tighten the bearing support nuts to 25 Nm + an additional 90° (1/4) 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 be rotated 20 to 30 times in one direction.

Otherwise the measurements will be incorrect.

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

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

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Move the input shaft up and down, check the play on the dial gauge and make a note of it.

Determining Shim Thickness

The specified bearing tension is reached when the adjustment shim (0.65 mm) is added to the measured value.

Example:

Bearing Play = (adjustment shim 0.65 mm plus the measured value)	Adjustment Shim Thickness according to the Table
0.740 mm	0.900 mm

Adjustment Shim Table

Bearing Play = (adjustment shim 0.65 mm plus the measured value)	Adjustment Shim Thickness (mm)
0.650 0.660 ••• 0.689	0.750 0.800
0.690 ••• 0.739 0.740 ••• 0.789 0.790 ••• 0.839	0.850 0.900 0.950
0.840 ••• 0.889 0.890 ••• 0.939 0.940 ••• 0.989	1.000 1.050 1.100
0.990 ••• 1.039 1.040 ••• 1.089 1.090 ••• 1.139	1.150 1.200 1.250
1.140 ••• 1.189 1.190 ••• 1.239 1.240 ••• 1.289	1.300 1.350 1.400
1.290 ••• 1.339 1.340 ••• 1.389 1.390 ••• 1.429	1.450 1.500 1.550

-- Remove the output shaft and then remove the small taper roller bearing outer race. Refer to Figure.

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

If the previous 0.65 mm adjustment shim will be inserted again, check it for damage.

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

Tolerance variations make it possible to find the exact shim thickness required.

-- Press in small tapered roller bearing outer race with determined shim (0.70 mm as in example). Refer to Figure and install output shaft. Tighten the bearing support nuts in the clutch housing to 25 Nm + an additional 90° (1/4) turn.