Gearbox removal & installation: Determining total shim thickness "Stotal" for shims "S3" + "S4" — VW

🧭 Before you start

Fits: VW Passat B5 (3B)

• Special tools named: dial gauge

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• As a test prerequisite, a shim "S4" of 1.0 mm must be temporarily installed. It is referred to below as "S4*". After value "e" is determined, "S4*" is replaced with final shim "S4".
• Pinion shaft is shown in illustration without gears.
• The dial gauge extension must contact the machined surface on the face of the pinion gear.
• If the measurement has to be repeated, the pinion shaft must first be turned 5 turns in each direction again to settle the tapered roller bearing. Set dial gauge again to "0" with 2 mm preload.

🔩 Torque settings

Values can differ between engine variants — check the code stamped on your block.

ℹ️ Always cross-check the exact figure against your vehicle's factory manual before final tightening — a wrong torque can damage the engine. These values are extracted from workshop data and may not cover every variant or revision.

📋 Procedure

1. Install large tapered roller bearing outer race without shim in gearbox housing.
2. Insert rubber disc and pressure plate in gearbox cover.
3. Press small tapered roller bearing outer race with 1.00 mm thick temporary shim S4 into gearbox cover to stop. [Note: As a test prerequisite, a shim "S4" of 1.0 mm must be temporarily installed. It is referred to below as "S4*". After value "e" is determined, "S4*" is replaced with final shim "S4".]
4. Press on large tapered roller bearing inner race .
5. Secure lower tapered roller bearing (arrow). [Note: Pinion shaft is shown in illustration without gears.]

6. Insert completely assembled pinion shaft in gearbox housing.
7. Fit gearbox cover and tighten bolts to 22 Nm. — 22 Nm (16 lb-ft)
8. Turn gearbox so that gearbox cover is downwards.
9. Press down on face of pinion shaft with gear set removal leverVW 296 until tapered roller bearing outer race contacts gearbox cover.
10. Press further onto pinion gear, rotating pinion shaft 8 turns by hand so that tapered roller bearing settles.
11. Attach dial gauge (3 mm measuring range) and set to "0" with 2 mm preload.
12. Use 30 mm dial gauge extension. [Note: The dial gauge extension must contact the machined surface on the face of the pinion gear.]
13. Turn gearbox 180° so that gearbox cover is upwards.
14. Rotate pinion shaft 5 turns in each direction so that tapered roller bearing settles.
15. Read and note play on dial gauge. [Note: If the measurement has to be repeated, the pinion shaft must first be turned 5 turns in each direction again to settle the tapered roller bearing. Set dial gauge again to "0" with 2 mm preload.]
16. Remove large tapered roller bearing outer race .
17. Fit temporary shim "S3*" in gearbox housing and install outer race again .
18. Insert completely assembled pinion shaft into gearbox housing again.
19. Fit gearbox cover and tighten bolts to 22 Nm. — 22 Nm (16 lb-ft)

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