Gearbox removal & installation: Redetermining shim "“S"6” for positioning 2nd gear synchromeshed gear — VW

🧭 Before you start

Fits: VW Passat B5 (3B)

Don't miss

• In order to apply the digital depth gauge better, the bearing support was not set in installation position in figure.
• Allocate shims according to Electronic parts catalogue "“ETKA”".

🔩 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. Set adjustment rings of universal mandrelVW 385/1 to the following values:
2. Assemble universal mandrelVW 385/1 as illustrated:
3. Insert universal mandrelVW 385/1 with centring ringVW 385/4 facing gearbox housing.
4. Fit final drive cover with O-ring installed and tighten 4 bolts to 24 Nm. — 24 Nm (18 lb-ft)
5. Pull centring ring outwards via movable adjustment ring until universal measuring tool cannot be turned by hand.

6. Lay straightedgeT 40100 on cleaned joint surface of gearbox housing.
7. Using a digital depth gauge (1) (e.g. digital depth gaugeVAS 6320), measure the highest point of the universal mandrelVW 385/1
8. From this dimension, subtract the height of the straightedgeT 40100 and to that, add half of the diameter (∅) of the universal mandrelVW 385/1. This value is 16 mm.
9. Install input shaft, shim "“S"5”, gear wheels for 3rd through 6th gears with roller bearings and bearing mounting (1). [Note: In order to apply the digital depth gauge better, the bearing support was not set in installation position in figure.]
10. Lay straightedgeT 40100 on cleaned joint surface of gearbox housing.
11. Using a digital depth gauge (2) (e.g. digital depth gaugeVAS 6320), measure from roller bearing inner race to straightedge.
12. To this dimension, add the height of the straightedgeT 40100. [Note: Allocate shims according to Electronic parts catalogue.]
13. The thickness of shim "“S"6” in this example is 4.30 mm.

Other VW procedures

• Removing engine · 41 torque figures
• Removing and installing camshaft – VW Golf Cabriolet · 47 torque figures
• Adjusting valve timing – VW Passat B5 · 83 torque figures
• Removing and installing camshafts – VW Passat B6 · 39 torque figures
• Removing and installing coolant pump · 53 torque figures
• Removing and installing seal for drive flange or flange shaft
• 90 A - Bosch version with poly V-belt drive
• Checking the Ignition Transformer – VW 2.3 AGL
• Pressing wheel bearing out and in when the wheel bearing housing is still installed
• Routing diagram for vehicles with petrol engine