2. and 4th gear brake -B2- adjustment — VW

Special tools, workshop equipment, testers, measuring instruments and auxiliary items required

VW 309 Retaining plate
VW 313 Support clamp
VW 353 Gearbox support
3459 Adjustment tool
Depth gauge
Straightedge

2. and 4th gear brake adjustment

The -B2- brake play is determined by the thickness of the shim -
11
-.

To adjust, install components without shim (item
11
), without last outer plate (item
10
) and spring caps (item
6
).

Gearbox housing
Circlip
For supporting tube

Supporting tube -B2-
Spare parts are allocated according to gearbox code
Insert so that groove engages in wedge of freewheel

Outer plate -B2-
3 mm thick

Spring cap
Install after installing first outer plate (item
4
)

Spring cap
Do not install when adjusting -B2-
Install before installing last outer plate

Spring
Spare parts are allocated according to gearbox code

Inner plate -B2-
Quantity => from page
00-6
Place new inner plate in ATF for 15 minutes before installing.
Spare parts are allocated according to gearbox code

Outer plate -B2-
Install 2 mm outer plates always
Quantity => from page
00-6

Outer plate -B2-
3 mm thick
Do not install when adjusting -B2-

Shim
Do not install when adjusting -B2-

Retaining ring
Inserted with smooth side facing last inner plate (item
8
) when adjusting -B2-

Calculating thickness of shim(s) -D-.

The thickness of the shim(s) is determined by gap x. For this the formula

Gap x = a - b - 2.65 mm

must be used. The measuring points are shown in the illustration to help understanding the formula. Special tool 3459, which exerts a force -F- onto the plate packet via the retaining ring, is not illustrated.

Determining dimension "a" => page
37-217
.

Determining dimension "b" => page
37-219
.

2.65 mm - The amount for settling is taken into account by force "F".

1 -ATF pump

2 - Retainer ring

3 - Plates for -B2- (without last outer plate)

4 - Supporting tube

The first installed outer plate-arrow- and the last outer plate (not installed when measuring) are always 3 mm thick.

Calculating dimension "a":

Assemble planet gearbox up to last -B2- inner plate, => page
37-154
. The last outer plate and shim are not installed.

Place retaining ring with smooth side onto last inner plate.
Place 3459 onto retaining ring and turn so that the 3 clips align with the 3 holes for the ATF pump.
Bolt 3459 to AFT pump flange with 5 Nm.

The plate packet for -B2- is now pressed together for the measurements.

Measure from gearbox housing pump flange -arrow- to 3459 using a depth gauge.

Dimension a = height of item 3459 in mm - measured value

Example:

Height of 3459 · = · 60.0 mm
- Measured value · = · -32.7 mm
Calculated value a · = · 27.3 mm

Note calculated value.
Remove 3459.
Remove retaining ring.

Calculating dimension "b":

Push piston into ATF pump onto limit stop.
Place a new paper gasket onto ATF pump.

Place a straightedge "B" onto stator support (arrow) and measure with depth gauge "A" to pump flange gasket.

Example:

Reading · = · 39.8 mm
- Straightedge · = · -19.5 mm
Calculated value b · = · 20.3 mm

Note calculated value "b".

Gap x = a - b - 2.65 mm

Gap x = 27.3 - 20.3 - 2.65 mm = 4.35 mm

Ascertain thickness of shim(s) according to table:

Table of "shims":

Gap "x" (mm) · Shims (mm)
3,25 ... 3,50 / 3,51 ... 3,75 / 3,76 ... 4,00 · 1,00 / 1,25 / 1,50
4,01 ... 4,25 / 4,26 ... 4,50 / 4,51 ... 4,75 · 1,75 / 1,00 + 1,00 / 1,00 + 1,25
4,76 ... 5,00 / 5,01 ... 5,25 / 5,26 ... 5,50 · 1,25 + 1,25 / 1,25 + 1,50 / 1,50 + 1,50
5,51 ...5,75 / 5,76 ...6,00 · 1,50 + 1,75 / 1,75 + 1,75

Ascertain thickness of shim(s) according to table and determine part number from parts catalogue.

In this example two shims must be used (each 1.00mm thick).

Insert three spring caps -arrows- onto compression springs.
Insert last outer plate -3 mm thick-.
Install correct shim(s) -a-.
Place retaining ring -b- onto shim(s). Smooth side faces shim.
Further installation instructions are described => from page
37-164
.