Clutch Housing Shim, Determining

WARNING: This page is about a different variant/trim than selected.

Special Tools And Workshop Equipment Required

Measuring Tool :T10425

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Dial Gauge - 0-10mm :VAS 6079

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Dial Gauge Holder :VW 387

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Not illustrated: Digital Depth Gauge w/Measuring Hook - 200mm :VAS 6619
Digital Depth Gauge - 300mm :VAS 6594

Brief Description:

In this >>step<< it is determined, how thick the shim in the clutch housing must be. There are three shims installed in total. Under each output shaft one shim. The differential does not have a shim.

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It begins with these procedures. The goal is that the output shafts 1 to 3 in align in the clutch housing in the >>intended level<<. This >>intended level<< is specified from the front end of the outer driveshaft.

There are guide plates under the output shaft 2 and 3 which are not shown here. Refer to CLUTCH HOUSING, SERVICING for the installation of shims, guide plates and bearing shells.

A bearing race is placed under the differential bearing shell, which is not shown here but is installed together with the bearing shell.

NOTE:

To determine the shims do not install guide plates or shims. Only install the shaft bearing shells.

Requirement:

The clutch housing sealing surface is clean, level and not >>destroyed or damaged<<.
The outer driveshaft is installed. Refer to CLUTCH HOUSING, SERVICING .

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The bearing shells of all shafts and the differential bearing shells are installed. Refer to CLUTCH HOUSING, SERVICING .
No guide plates and no shims are installed.

NOTE:

Only for adjustment: do not install shims. Do not install guide plates.

-- Place the partially disassembled output shaft 1 and output shaft 2 in the bearing shell.

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How >>far<< the shafts can be assembled: output shaft 1 refer to OUTPUT SHAFT 1, PARTIALLY DISASSEMBLING and output shaft 2 refer to OUTPUT SHAFT 2, ASSEMBLING .

-- Pay attention that the alignment sleeves are inserted in the clutch housing.

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Assemble the Measuring Tool :T10425 for the procedures on the clutch housing.

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Tightening Specification: 15 Nm

-- Place the Measuring Tool :T10425 on the alignment sleeves.

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-- Place the Measuring Tool - Measuring Rod :T10425/3 on the output shaft 1.

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NOTE:

All gears have burrs on the gears. These burrs >>interfere<< with measuring. Here it is shown -where- the gears are measured in the following measurement.

The measuring surfaces begin on the >>feet<< of the teeth.

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They extend up to the >>first shoulder<<. Illustrated "light" in the image.

The teeth themselves can be used to measure. It is important that the depth gauge is not placed on the burr.

It begins with the output shaft 1

-- Place the Digital Depth Gauge w/Measuring Hook - 200mm :VAS 6619 on the outer driveshaft. Here shown as >>green<<. Set the sliding gauge to >>zero<<.

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-- Measure on the 4th gear wheel of the output shaft 1 using the Digital Depth Gauge w/Measuring Hook - 200mm :VAS 6619 . Here shown as >>blue<<.

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-- Note this value.

-- Name this value "A1_a ".

-- It is measured three times. Name the additional vales "A1_b " and "A1_c ".

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-- Before the additional turn mark the driveshaft.

-- Turn the driveshaft 120° in the -direction of the arrow- and measure again. The turn 120° additional turn again and measure again.

NOTE:

The shaft wheels are toothed at an angle. When turning the shafts it can be the case that they are lifted from the bearing.

-- So that the shafts stay in the bearing, while turning push forcefully by hand on the Measuring Tool - Measuring Rod :T10425/3 . Do not forget the Measuring Tool - Headpiece :T10425/5 .

Determine the average from the three measured values "A1_a ", "A1_b " and "A1_c ".

Formula: A1 + A1 + A13 = A1

The 4th gear wheel has axial play on the shaft. Measure this play as follows:

-- Install the Dial Gauge Holder :VW 387 on the sealing surface of the clutch housing.

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-- Place the button from the Dial Gauge - 0-10mm :VAS 6079 on the 4th gear wheel.

-- Adjust the dial gauge pretension to >>0<<.

-- Raise the 4th gear wheel up as far as the stop and note the measurement result.

-- Name this value "B1".

-- This is calculated: "A1" minus "B1" = the determined shim thickness.

Determined Shim Thickness		Shim To Be Installed In Millimeter
from	through	Shim To Be Installed In Millimeter
0.625	0.674	0.65
0.675	0.724	0.70
0.725	0.774	0.75
0775	0.824	0.80
0.825	0.874	0.85
0.875	0.924	0.90
0.925	0.974	0.95
0.975	1.024	1.00
1.025	1.074	1.05
1.075	1.124	1.10
1.125	1.174	1.15
1.175	1.224	1.20
1.225	1.274	1.25
1.275	1.324	1.30
1.325	1.374	1.35
1.375	1.424	1.40
1.425	1.474	1.45
1.475	1.524	1.50
1.525	1.574	1.55
1.575	1.624	1.60
1.625	1.674	1.65
1.675	1.724	1.70
1.725	1.774	1.75

-- Measure the shim from the delivered washers, which are are needed.

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WARNING:

Later only install this one shim. Not two.

Store this shim carefully, do not interchange with other shims inadvertently.

Continued with the output shaft 2.

-- Place the Measuring Tool - Measuring Rod :T10425/3 on the output shaft 2.

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Turn the mark from the outer output shaft >>in alignment<< with the output shaft 2.

NOTE:

The shaft wheels are toothed at an angle. When turning the shafts it can be the case that they are lifted from the bearing.

-- So that the shafts stay in the bearing, while turning push forcefully by hand on the Measuring Tool - Measuring Rod :T10425/3 . Do not forget the Measuring Tool - Headpiece :T10425/5 .

-- Place the Digital Depth Gauge w/Measuring Hook - 200mm :VAS 6619 on the outer driveshaft. Here shown as >>green<<. Set the sliding gauge to >>zero<<.

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-- Measure on the 6th gear wheel of the output shaft 2 using the Digital Depth Gauge w/Measuring Hook - 200mm :VAS 6619 . Here shown as >>red<<.

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-- Note this value.

-- Name this value "A2 _a ".

-- It is measured three times. Name the additional vales "A2 _b " and "A2 _c ".

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Use the mark >>present<< for orientation.

-- Turn the driveshaft 120° in the -direction of the arrow- and measure again. The turn 120° additional turn again and measure again.

NOTE:

The shaft wheels are toothed at an angle. When turning the shafts it can be the case that they are lifted from the bearing.

-- So that the shafts stay in the bearing, while turning push forcefully by hand on the Measuring Tool - Measuring Rod :T10425/3 . Do not forget the Measuring Tool - Headpiece :T10425/5 .

Determine the average from the three measured values "A2 _a ", "A2 _b " and "A2 _c ".

Formula: A2 + A2 + A23 = A2

The 6th gear wheel has axial play on the shaft. Measure this play as follows:

-- Install the Dial Gauge Holder :VW 387 on the sealing surface of the clutch housing.

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-- Place the button from the Dial Gauge - 0-10mm :VAS 6079 on the 6th gear wheel.

-- Adjust the dial gauge pretension to >>0<<.

-- Raise the 6th gear wheel up as far as the stop and note the measurement result.

-- Name the value "B2".

-- This is calculated: "A2" minus "B2" = determined shim thickness.

Determined Shim Thickness		Shim To Be Installed In Millimeter
from	through	Shim To Be Installed In Millimeter
0.625	0.674	0.65
0.675	0.724	0.70
0.725	0.774	0.75
0775	0.824	0.80
0.825	0.874	0.85
0.875	0.924	0.90
0.925	0.974	0.95
0.975	1.024	1.00
1.025	1.074	1.05
1.075	1.124	1.10
1.125	1.174	1.15
1.175	1.224	1.20
1.225	1.274	1.25
1.275	1.324	1.30
1.325	1.374	1.35
1.375	1.424	1.40
1.425	1.474	1.45
1.475	1.524	1.50
1.525	1.574	1.55
1.575	1.624	1.60
1.625	1.674	1.65
1.675	1.724	1.70
1.725	1.774	1.75
1.775	1.824	1.80
1.825	1.874	1.85
1.875	1.924	1.90

-- Measure the shim from the delivered washers, which are are needed.

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WARNING:

Later only install this one shim. Not two.

Store this shim carefully, do not interchange with other shims inadvertently.

-- Remove the output shaft 1 and 2 and assemble.

Output Shaft 1. Refer to OUTPUT SHAFT 1, ASSEMBLING .
Output Shaft 2. Refer to OUTPUT SHAFT 2, ASSEMBLING .
Then adjust the output shaft 3.

-- First measure the thickness of the gear wheel for the reverse gear.

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NOTE:

When measuring pay attention that the burr of the teeth is not measured.

-- Note this value and name the value "B3".

Adjusting output shaft 3.

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The output shaft 3 is correctly adjusted, when the dimension -K- = 19.9 millimeter.

-- Position the output shaft 3 in the bearing.

-- Place the bearing shell to be installed on the shaft.

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-- Place the Measuring Tool - Measuring Rod :T10425/3 on the shaft.

-- Position the Digital Depth Gauge - 300mm : VAS 6594 on the reverse gear wheel to "zero".

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NOTE:

When measuring pay attention that the burr of the teeth is not measured.

-- Measure the distance to the housing flange surface.

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-- Note this value and name the value "A3".

-- For determining the shim to be installed from the value "A3" the >>thickness<< of the reverse gear wheel B3 is "subtracted". Name this value "C".

Formula: "A3" minus "B3" = "C"

Remember: The output shaft 3 is correctly adjusted, when the dimension -K- = 19.9 millimeter.

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-- For this reason measure a shim to come to -K- = 19.9 millimeter.

Using the dimension -K- and the dimension "C" the shim thickness to be installed is determined according to the following calculation.

Formula: 19.9 millimeter minus the value for "C" = determined shim thickness.

Determined Shim Thickness		Shim To Be Installed In Millimeter
from	through	Shim To Be Installed In Millimeter
0.775	0.824	0.80
0.825	0.874	0.85
0.875	0.924	0.90
0.925	0.974	0.95
0.975	1.024	1.00
1.025	1.074	1.05
1.075	1.124	1.10
1.125	1.174	1.15
1.175	1.224	1.20
1.225	1.274	1.25
1.275	1.324	1.30
1.325	1.374	1.35
1.375	1.424	1.40
1.425	1.474	1.45
1.475	1.524	1.50
1.525	1.574	1.55

-- Measure the shim from the delivered washers, which are are needed.

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WARNING:

Later only install this one shim. Not two.

Store this determined shim carefully, do not interchange with other shims inadvertently.
Move the Measuring Tool :T10425 to the side.
Installing the measured shims for the output shaft, bearing shells and guide plate. Refer to CLUTCH HOUSING, SERVICING .
Assembling the output shaft 1. Refer to OUTPUT SHAFT 1, ASSEMBLING .
Assembling the output shaft 2. Refer to OUTPUT SHAFT 2, ASSEMBLING .
Position all output shafts in the clutch housing.
Position the Measuring Tool :T10425 on the clutch housing again.

-- Determine the transmission housing shims. Refer to TRANSMISSION HOUSING SHIMS, DETERMINING .