Volkswagen Golf / Golf GTI / Jetta. Manual — part 323

35-80

- Loosen clutch housing/transmission housing

securing bolts diagonally until output shaft
moves freely in transmission housing.

- Read play on gauge and note reading (Example:

0.27 mm)

Note:

If dial gauge indicates no value when clutch

housing/transmission 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 (0.27 mm)
from the inserted shim (1.70 mm) and adding a
constant for pressing (0.20 mm).

Output shaft for 5th, 6th and reverse gear, adjusting

35-81

Example:

Inserted shim

1.70 mm

- Measured value

0.27 mm

+ Preloading (constant) 0.20 mm

Shim thickness

1.63 mm

- Determine thickness of shim from table

35-82

.

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

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

- Remove transmission housing and pull tapered

roller bearing outer race out of housing.

- Remove inserted shim from clutch housing.

Output shaft for 5th, 6th and reverse gear, adjusting

35-82

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

2.00

084 409 383 AQ

084 409 383 AR

084 409 383 AS

084 409 383 AT

2.05

2.10

2.15

2.20

2.25

084 409 383 BA

084 409 383 BB

084 409 383 BC

084 409 383 BD

084 409 383 BE

Varying tolerances make it possible to

obtain the exact shim thickness required.

Output shaft for 5th, 6th and reverse gear, adjusting

35-83

Perform check measurement

- Press in tapered roller bearing

outer race together with
determined shim (in Example
1.65 mm) while supporting
transmission housing with thrust
piece 2050 directly under bearing
support.

Determined shim installed.

If the correct shim has been
selected, the dial gauge will indicate
a value of 0.15 mm to 0.25 mm.

- Install measuring tools. Put

washers with a total thickness of
8 mm on bolt (arrow) securing
installation tool VW 792 to clutch
housing.

- Set dial gauge (3 mm measuring

range) to zero with 1 mm preload.

- Loosen clutch

housing/transmission housing
securing bolts diagonally until
output shaft moves freely in
transmission.

Output shaft for 5th, 6th and reverse gear, adjusting