Volkswagen Golf / Golf GTI / Golf Variant. Manual - part 529

♦ Slide Hammer - Press Plate - 2050-
♦ Torque Wrench 1331 5-50Nm - VAG1331-
♦ Puller - Kukko Internal - 46-56mm - 21/07-
♦ Puller - Kukko Counterstay - 22/2-
♦ Dial Indicator - VAS6080A-
(Selecting the correct adjusting shim for the output shaft)
It is necessary to adjust the output shaft if the following compo‐

nents were replaced:
♦ Transmission Housing
♦ Clutch Housing
♦ Output shaft, 1st to 4th gears or
♦ Output shaft tapered roller bearing
Adjustment overview. Refer to

⇒ “3 Adjustment Overview”, page 221

 .

Requirements:
• Remove any sealant still on the sealing surfaces on the clutch

and transmission housings.

• Install the output shaft that is going to be measured.
– Install the tapered roller bearing outer race in the transmission

housing with a 1.70 mm shim. Support transmission housing

directly beneath bearing mount using -2050- .

– Install the output shaft for 1st through 4th gears into the clutch

housing.

– Install the transmission housing and tighten the bolts

-A and B- diagonally.

– Position the measuring tools on the clutch housing and secure

them with a bolt -arrow-.

– Set the dial gauge (3 mm range) with 1 mm preload to “0”.
– Loosen securing bolts for clutch housing/transmission housing

in diagonal sequence until bolts clear transmission housing

and output shaft.

– Read measured value on dial indicator and note (example:

0.14 mm).

Note

♦

The measured value will not be displayed when loosening the

bolts that connect the clutch housing to the transmission hous‐

ing.

♦

Install a 1.95 mm shim or, if necessary, a 2.20 mm shim in

place of the 1.70 mm shim for measuring.

♦

For the correct adjusting shim. Refer to the Parts Catalog.

Determining the Shim
The required bearing tension is reached as follows:
The specified bearing pre-load is reached when determined

measured value (0.14 mm) is subtracted from inserted adjust‐

ment shim (1.70 mm).
A constant figure of (0.20 mm) is added to the reading.
Example:

Inserted shim

1.70 mm

- Measured value

0.14 mm

+ Preload (constant value)

0.20 mm

= Shim thickness

1.76 mm

– Select the correct shim thickness according to the Table. Refer

to 

⇒ page 189

 .

– Remove the transmission housing and remove the tapered

roller bearing outer race from the transmission housing.

A - Counter Support , for example, -22/2-
B - Internal Puller 46 to 58 mm , for example, -21/7-
– Remove the inserted shim (1.70 mm) from the transmission

housing.

Shim Table

 

Thickness (mm)

 

1.45

1.75

2.05

1.50

1.80

2.10

1.55

1.85

2.15

1.60

1.90

2.20

1.65

1.95

2.25

1.70

2.00

 

Tolerance variations make it possible to find the exact shim thick‐

ness required.
– For the correct part number. Refer to the Parts Catalog.

– Install the outer race/tapered roller bearing with the selected

shim (in the example: 1.75 mm). Support transmission hous‐

ing directly beneath bearing mount using -2050- .

Checking Measurement
• The selected adjusting shim is installed.

– Position the measuring tools on the clutch housing and secure

them with a bolt -arrow-.

– Set the dial gauge (3 mm range) with 1 mm preload to “0”.
– Loosen securing bolts for clutch housing/transmission housing

in diagonal sequence until bolts clear transmission housing

and output shaft.

• For correctly selected adjustment shim, dial gauge must now

display a value of 0.15 mm to 0.25 mm.

Tightening Specifications
♦ Refer to

⇒ “5.3 Overview - Transmission Housing and Selector Mech‐

anism”, page 111

 .

2.3.2

Output Shaft, 5th, 6th and Reverse

Gears, Adjusting

Special tools and workshop equipment required
♦ Transmission Support - VW353-
♦ Dial Gauge Holder - VW387-
♦ Press Piece - Rod - VW407-
♦ Press Piece - Multiple Use - VW433-
♦ Seal Installer - Stator - VW792-
♦ Crankshaft Holding Fixture - VW801-
♦ Holding Plate - VW309A-
♦ Slide Hammer - Press Plate - 2050-
♦ Torque Wrench 1331 5-50Nm - VAG1331-
♦ Puller - Kukko Internal - 46-56mm - 21/07-
♦ Puller - Kukko Counterstay - 22/2-
♦ Dial Indicator - VAS6080A-
It is necessary to adjust the output shaft if the following compo‐

nents were replaced:
♦ Transmission Housing
♦ Clutch Housing
♦ Output shaft, 5th, 6th and Reverse Gears or
♦ Output shaft tapered roller bearing
Adjustment Overview. Refer to

⇒ “3 Adjustment Overview”, page 221

 .

Requirements
• Remove any sealant still on the sealing surfaces on the clutch

and transmission housings.

• Install the output shaft that is going to be measured.
– Install the tapered roller bearing outer race in the transmission

housing with a 1.70 mm shim. Support transmission housing

directly beneath bearing mount using -2050- .

– Install the output shaft for 5th/6th gears and reverse gear into

the clutch housing.

– Install the transmission housing and tighten the bolts

-A and B- diagonally.