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

Special tools and workshop equipment required 

• Transmission Support:VW353 
• Dial Gauge Holder:VW387 
• Press Piece - Rod:VW407 
• Press Piece - Multiple Use:VW433 
• Seal Installer - Stator:VW792 
• Crankshaft Holding Fixture:VW801 
• Holding Plate:VW309A 
• Slide Hammer - Press Plate:2050 
• Torque Wrench 1331 5-50Nm:VAG1331 
• -1- Internal Puller:VAS251615  (21-7)
• -4- Counter Support:VAS251623  (22-2)
• Dial Indicator:VAS6080A 

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: 

• The sealing surfaces of the clutch and transmission housing must be cleaned of sealant.
• 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 shim. Support transmission housing directly beneath bearing mount using :2050  .

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- 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.

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Attach the measuring tools to the clutch housing.

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

In the case of protruding housing edges: 

-- Place washers (total thickness: 8 mm) under the :VW792  -arrow-.

-- Set the dial gauge (3 mm range) with 1 mm preload to "0".

-- Loosen securing bolts for clutch housing/transmission housing in diagonal sequence until bolts clear transmission housing and output shaft.

-- Read measured value on dial indicator and note (example: 0.25 mm).