Adjusting output shaft for 1st-4th gears — VW

The 1st to 4th gear output shaft in the New Beetle RSi is fundamentally similar to the Golf/Bora 4motion.

The following description deals with the Golf 1998 ä, Bora 1999 ä. Therefore differences must be considered, if necessary.

(Determining shim for output shaft)

Special tools, workshop equipment, test and measuring appliances and auxiliary items required

VW 353 Gearbox support
VW 387 Universal dial gauge bracket
VW 407 Press tool
VW 433 Press piece
VW 792 Assembly tool
VW 801 Holding plate

Special tools, workshop equipment, test and measuring appliances and auxiliary items required

VW 309 Holding plate
2050 Thrust piece
V.A.G 1331 Torque wrench
1 - Kukko 21/7 Internal puller
4 - Kukko 22/2 Counter support

It is necessary to readjust the output shaft when the following components are renewed:

Gearbox housing
Clutch housing
Output shaft for 1st-4th gear

or

Taper roller bearing

Prerequisites:

Sealing surfaces of clutch and gearbox housings must be free of sealant.

When taking measurements, install only the shaft to be measured.

Press taper roller bearing outer race with 1.70 mm thick shim into gearbox housing, supporting gearbox housing directly under bearing support with thrust piece 2050.
Set complete 1st-4th gear output shaft in clutch housing.

Fit gearbox housing and tighten bolts -A- and -B- to prescribed torque using diagonal sequence =>Page
34-72
, item
13
.

Fit measuring tools and secure with bolt (arrow) to clutch housing.
Set dial gauge (3 mm measuring range) to zero with 1 mm preload.
Loosen clutch housing/gearbox housing securing bolts diagonally until bolts release gearbox housing or output shaft.

Read off play on gauge and note reading (example: 0.14 mm)

Note:

If dial gauge indicates no value when clutch housing/gearbox housing securing bolts are loosened, install shim 1.95 mm (part No. 084 409 383 AS) or, if necessary, shim 2.20 mm (part No. 084 409 383 BD).

Determining thickness of shim

The specified bearing pretension will be attained by subtracting the measured value (0.14 mm) from the inserted shim (1.70 mm) and adding a constant for pressing (0.20 mm).

Example:

Inserted shim · 1.70 mm
- Measured value · 0.14 mm
+ Preloading (constant) · 0.20 mm
Shim thickness · 1.76 mm

Determine thickness of shim from table => Page
35-51
.

Remove gearbox housing and pull taper roller bearing outer race out from gearbox housing.

A - Counter support, e.g. Kukko 22/2

B - Internal puller 46...58 mm, e.g. Kukko 21/7

Remove inserted shim (1.70 mm thick) from clutch housing.

Shim table

Size (mm) · Part No.
1.40 / 1.45 / 1.50 · 084 409 383 AF / 084 409 383 AG / 084 409 383 AH
1.55 / 1.60 / 1.65 · 084 409 383 AJ / 084 409 383 AK / 084 409 383 AL
1.70 / 1.75 / 1.80 · 084 409 383 AM / 084 409 383 AN / 084 409 383 AP
1.85 / 1.90 / 1.95 · 084 409 383 AQ / 084 409 383 AR / 084 409 383 AS
2.00 / 2.05 / 2.10 · 084 409 383 AT / 084 409 383 BA / 084 409 383 BB
2.15 / 2.20 / 2.25 · 084 409 383 BC / 084 409 383 BD / 084 409 383 BE

Varying tolerances make it possible to obtain the exact shim thickness required.

Press in taper roller bearing outer race together with the determined shim (in example 1.75 mm) while supporting gearbox housing with thrust piece 2050 directly under bearing support.

Carry out check measurement

Determined shim installed.

Fit measuring tools and secure with bolt (arrow) to clutch housing.
Set dial gauge (3 mm measuring range) to zero with 1 mm preload.
Loosen clutch housing/gearbox housing securing bolts diagonally until output shaft is free to move in gearbox housing.
If correct shim has been selected, dial gauge will indicate a value of 0.15 mm to 0.25 mm.