5TH/6TH And Reverse Gear Output Shaft, Adjusting
Special tools and workshop equipment required
- Transmission Support: VW353
- Dial Indicator 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, 6-50Nm: VAG1331A
- -1- Internal Puller: VAS251615 (Kukko 21/7)
- -4- Counter Support: VAS251623 (Kukko 22/2)
- Dial Indicator: VAS6080A
It is necessary to adjust the output shaft if the following components were replaced:
- Transmission Housing
- Clutch Housing
- 5th/6th and Reverse Gear Output Shaft
- 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.
- Only install the output shaft that is going to be measured.
-- Install the outer race/tapered roller bearing with a 1.70 mm shim in the transmission housing. At the same time, support the transmission housing directly under the bearing mount using the : 2050 .
-- Place the entire 5th/6th and reverse gear output shaft in the clutch housing.
-- Install the transmission housing and tighten the bolts -A and B- diagonally.
-- Attach the measuring tools to the clutch housing.
In the case of protruding housing edges:
-- Place washers (total thickness: 8 mm) under the : VW792 -arrow-.
-- Set the dial gauge (3 mm measuring range) with 1 mm pretension to "0".
-- Loosen the clutch housing/transmission housing bolts in a diagonal sequence until the bolts release the transmission housing and output shaft.
-- Read the measured value on the dial gauge and make a note of it (example: 0.25 mm).
The measured value will not be displayed when loosening the clutch housing/transmission housing bolts.
Install a 1.95 mm shim or, if necessary, a 2.20 mm shim in place of the 1.70 mm shim for measuring.
Select the correct shims using the Parts Information.
Shim, Determining
The required bearing pre-load is reached as follows:
The determined measured value (0.25 mm) is subtracted from the inserted shim (1.70 mm).
A constant preload value (0.20 mm) is added to the reading.
Example:
| Inserted shim | 1.70 mm |
| - measured value | 0.25 mm |
| + preload (constant value) | 0.20 mm |
| Shim thickness | 1.65 mm |
-- Select the correct shim thickness according to the table found here. Refer to the Shim Table below.
-- Remove the transmission housing and remove the tapered roller bearing outer race from the transmission housing.
A -
Counter Support: VAS251623 (Kukko 22/2)
B -
Internal Puller: VAS251615 (Kukko 21/7)
-- Remove the inserted shim (1.70 mm) from the transmission housing.
Shim Table
| Thickness (mm) | ||
|---|---|---|
| 1.50 | 1.80 | 2.10 |
| 1.55 | 1.85 | 2.15 |
| 1.60 | 1.90 | 2.20 |
| 1.65 | 1.95 | 2.25 |
| 1.70 | 2.00 | |
| 1.75 | 2.05 | |
-- Part numbers. Refer to the Parts Information.
Tolerance variations make it possible to find the exact shim thickness required.
-- Install the outer race/tapered roller bearing with the selected shim (in the example: 1.65 mm). At the same time, support the transmission housing directly under the bearing mount using the : 2050 .
Checking Measurement
- The selected shim is installed.
-- Attach the measuring tools to the clutch housing.
In the case of protruding housing edges:
-- Place washers (total thickness: 8 mm) under the : VW792 -arrow-.
-- Set the dial gauge (3 mm measuring range) with 1 mm pretension to "0".
-- Loosen the clutch housing/transmission housing bolts in a diagonal sequence until the bolts release the transmission housing and output shaft.
- For correctly selected adjustment shim, dial gauge must now display a value of 0.15 mm to 0.25 mm.
Tightening Specifications