Volkswagen Golf / Golf GTI / Jetta. Manual — part 314

35-48

It is necessary to readjust the output shaft when
the following components are replaced:

Transmission housing

Clutch housing

Output shaft for 1st-4th gear

or

Tapered roller bearing

Adjustment overview

Page 39-23

Requirements

Sealing surfaces of clutch and transmission

housings must be free of sealant.

When taking measurements, install only the

shaft to be measured.

- Press tapered roller bearing outer race with a

1.70 mm thick shim into transmission housing,
supporting transmission housing directly under
bearing support with thrust piece 2050.

- Set complete 1st-4th gear output shaft in clutch

housing.

Output shaft for 1st-4th gears, adjusting

35-49

- Install transmission housing and

tighten bolts -A- and -B-
diagonally to correct torque.

- Install measuring tools and

secure with bolt (arrow) 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 is free to move in
transmission housing.

Output shaft for 1st-4th gears, adjusting

35-50

- Read play on gauge and note reading (example:

0.14 mm)

Note:

If the dial gauge indicates no value when the

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 (0.14 mm)
from the inserted shim (1.70 mm) and adding a
constant for pressing (0.20 mm).

Example:

Inserted shim

1.70 mm

- Measured value

0.14 mm

+ Preloading (constant) 0.20 mm

Shim thickness

1.76 mm

- Determine thickness of shim from table

Page

35-52

.

Output shaft for 1st-4th gears, adjusting

35-51

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 transmission
housing.

- Remove inserted shim from clutch

housing.

Output shaft for 1st-4th gears, adjusting