Output Shaft, Adjusting

WARNING: This page is about a different car, the 2013 Volkswagen Beetle. However, it is still accessible from the selected car via links, so may be relevant.

Selecting the correct adjusting shim for the output shaft.

Special tools and workshop equipment required

Dial Gauge HolderVW387
Magnetic Plate 50 mm Dia.VW385/17
Thrust PadVW512
Replacement Stud (8 mm/10 mm) 3114/2
PunchVW407
Torque Wrench 1331 5-50NmVAG1331
Dial Gauge
Kukko Extractor 37-46 mm21/6
Puller - Kukko Counterstay22/2

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 .

Requirement:

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

Procedure

-- Install the small tapered roller bearing outer race with a 0.65 mm thick shim into the clutch housing to the limit stop, refer to Figure.

-- Install the output shaft and tighten the bearing support nuts to the tightening specification.

-- 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 output shaft up and down, read off the play on the dial gauge and make a note of it (example: to 0.20 mm).

Determining Shim Thickness

The specified bearing preload is reached by adding a constant preload figure of 0.10 to 0.15 mm to the reading obtained and the thickness of the installed shim.

Example:

Inserted adjusting shim	0.65 mm
+ Measured value	0.20 mm
+ Preload (constant value)	0.15 mm
= Adjusting shim thickness	1.00 mm

Example:

Bearing play = (adjustment shim 0.65 mm plus the measured value)	Adjustment shim thickness according to the table
0.850 mm	1.000 mm

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

Adjustment Shim Table

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

NOTE:

For the correct shims, refer to the Parts Information.

-- Insert shim with the correct thickness.

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 adjusting shims that add up to the necessary thickness. Insert the thickest adjusting shim first.

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

-- Install the outer race/small tapered roller bearing with the selected adjusting shim (in the example: 1.00 mm).

Fig 2: Identifying Small Outer Race/Tapered Roller Bearing

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Install the output shaft, tighten the bearing support nuts in the clutch housing to 25 Nm + an additional 90° (1/4) turn.

Tightening Specifications

Bearing mount to the clutch housing, refer to INPUT SHAFT, OUTPUT SHAFT, DIFFERENTIAL AND SELECTOR FORKS OVERVIEW .