Adjusting output shaft for 5th, 6th and reverse gears: VW 2.0 (BYD, CDLA, CDLC, CDLF, …)

🧭 Before you start

Fits: platform code 138

• Special tools named: dial gauge

🔧 Engine codes this applies to

📋 Procedure

1. Press tapered roller bearing outer race with 1.70 mm thick shim into gearbox housing to stop. In the process, support gearbox housing using thrust piece2050 directly below bearing support.
2. Set complete 5th, 6th and reverse gear output shaft in clutch housing.
3. Fit gearbox housing in position and tighten bolts (A) as well as (B) alternately and diagonally.
4. Fit measuring tools on clutch housing.
5. Fit washers with a total thickness of 8 mm underneath assembly toolVW 792(arrow).

6. Set dial gauge (3 mm measuring range) to "“0”" with 1 mm preload.
7. Loosen clutch housing/gearbox housing securing bolts diagonally until the bolts release the gearbox housing or output shaft.
8. Read and note value on dial gauge (example: 0.25 mm). [Note: If no value is indicated when clutch housing/gearbox housing securing bolts are loosened:Fit 1.95 mm shim or, if necessary, 2.20 mm shim for the measurement instead of 1.70 mm shim.Allocate shims using Electronic Parts Catalogue.]
9. Determine thickness of shim from table.
10. Remove gearbox housing and pull tapered roller bearing outer race from gearbox housing.
11. Remove inserted shim (1.70 mm thick) from gearbox housing.
12. Part numbers Electronic Parts Catalogue.
13. Press in tapered roller bearing outer race together with correct shim (in example 1.65 mm). In the process, support gearbox housing using thrust piece2050 directly below bearing support.
14. Fit measuring tools onto clutch housing.
15. Fit washers with a total thickness of 8 mm underneath assembly toolVW 792(arrow).
16. Set dial gauge (3 mm measuring range) to "“0”" with 1 mm preload.
17. Loosen clutch housing/gearbox housing securing bolts diagonally until the bolts release the gearbox housing or output shaft.
18. If correct shim has been selected, dial gauge will indicate a value between 0.15 mm to 0.25 mm.

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