Output Shaft, 5th, 6th And Reverse Gears, Adjusting: Adjusting

Special Tools And Workshop Equipment Required 

• Transmission Support VW 353
• Dial Gauge Holder VW 387
• Punch VW 407
• Thrust Pad Con. 8/65 VW 433
• Installation Arbor VW 792
• Holding Fixture VW 801
• Holding Plate VW 309
• Thrust Plate 2050
• Torque Wrench (5-50 Nm) Vag 1331
• Kukko Extractor 46-58 mm 21/7
• Kukko Support 22/2

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: 

• Remove any sealant still on the sealing surfaces on the clutch and transmission housings.
• 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 adjustment shim. Support the transmission housing directly under the bearing mount using the thrust plate 2050.

Fig 1: Identifying Outer Race/Tapered Roller Bearing Pressed Into Transmission Housing

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Install the output shaft for 5th/6th and reverse gears into the clutch housing.

-- Install the transmission housing and tighten the bolts -A and B- diagonally to the tightening specification.

Fig 2: Identifying Transmission Housing Bolts

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Install the measuring tools to the clutch housing.

Fig 3: Identifying Inserting Washers At Securing Bolt For Assembly Tool VW 792 At Clutch Housing

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

In the case of protruding housing edges:

-- Place washers (total thickness: 8 mm) under the bolt -arrow- for the installation arbor VW 792 on the clutch housing.

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

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

-- Read the measured value on the dial gauge and make a note of it (example: to 0.25 mm).