Volkswagen Golf / Golf GTI / Golf Variant. Manual — part 600
– Install dial gauge (3 mm measuring range) and set to “0” with
1 mm pre-load.
– Move the input shaft up and down, check the play on the dial
gauge and make a note of it.
Determining the Shim
The specified bearing tension is reached when the adjustment
shim (0.65 mm) is added to the measured value.
Example:
Bearing Play =
(Adjustment Shim 0.65 mm
Plus the Measured Value)
Adjustment Shim Thickness
According to the Table
0.740 mm
0.900 mm
Shim Table
Bearing Play =
(Adjustment Shim 0.65 mm
Plus the Measured Value)
Adjustment Shim
Thickness (mm)
0.650
0.660 to 0.689
0.750
0.800
0.690 to 0.739
0.740 to 0.789
0.790 to 0.839
0.850
0.900
0.950
0.840 to 0.889
0.890 to 0.939
0.940 to 0.989
1.000
1.050
1.100
0.990 to 1.039
1.040 to 1.089
1.090 to 1.139
1.150
1.200
1.250
1.140 to 1.189
1.190 to 1.239
1.240 to 1.289
1.300
1.350
1.400
1.290 to 1.339
1.340 to 1.389
1.390 to 1.429
1.450
1.500
1.550
Note
Allocate the shims. Refer to the Parts Catalog.
– Remove the output shaft and then remove the small taper roll‐
er bearing outer race. Refer to
⇒ Fig. ““Remove the Small Outer Race/Tapered Roller Bear‐
– Install the shim with the correct thickness, thickest shim first.
• If the previous 0.65 mm adjustment shim will be inserted again,
it must be checked for damage.
If the measured shim thickness is larger than those listed in the
Table, then install two shims that add up to the necessary thick‐
ness.
Tolerance variations make it possible to find the exact shim thick‐
ness required.
– Press in the outer race/small tapered roller bearing with de‐
termined shim (0.70 mm as in example). Refer to
⇒ Fig. ““Installing the Small Outer Race/Tapered Roller Bear‐
and install output shaft.
– Tighten the nut for the bearing mount in the clutch housing.
Tightening Specifications
♦ Bearing mount to the clutch housing. Refer to
⇒ “5.6 Overview - Input Shaft, Output Shafts, Differential,
.
3
Reverse Shaft
⇒ “3.1 Overview - Reverse Shaft”, page 170
⇒ “3.2 Reverse Shaft, Disassembling and Assembling”,
3.1
Overview - Reverse Shaft
Note
Always replace the needle sleeve after removing it from the clutch housing or from the reverse shaft support.
1 - Clutch Housing
2 - Needle Sleeve
❑ Removing. Refer to
❑ Installing. Refer to
3 - Reverse Drive Gear
4 - Circlip
❑ Replace after removing
5 - Reverse Gear Wheel
❑ Remove before replac‐
ing the locking ring
❑ Collar faces reverse
gear wheel
6 - Reverse Shaft
❑ Removing and instal‐
ling. Refer to
.
7 - Needle Sleeve
❑ Removing. Refer to
❑ Installing. Refer to
Needle Sleeve into the Reverse Shaft Support”“ , page 172
8 - Reverse Shaft Support
❑ Removing and installing. Refer to
⇒ “5.11 Transmission, Disassembling and Assembling”, page 105
.
3.2
Reverse Shaft, Disassembling and As‐
sembling
Special tools and workshop equipment required
♦ Press Piece - Multiple Use - VW454-
♦ Press Piece - Multiple Use - VW447H-
♦ Press Piece - Rod - VW411-
♦ Centering/Press Pin - 12-551-
♦ Press Plate - VW401-
♦ Press Piece - Rod - VW408A-
♦ -1- Puller - Kukko Internal - 14-19mm - 21/2-
♦ -4- Puller - Kukko Counterstay - 22/1-
Caution
This procedure contains mandatory replaceable parts. Refer
to component overview prior to starting procedure.
Mandatory Replacement Parts
♦ Needle Sleeve - Reverse Shaft
Removing the Needle Sleeve from the Clutch Housing
A - Puller - Kukko Counterstayt - 22/1- , for example.
B - Puller - Kukko Internal - 14-19mm - 21/2- , for example.
Note
The needle sleeve will get damaged when it is removed and must
be replaced.
Installing the Needle Sleeve -A- into the Clutch Housing
Removing the Needle Sleeve from the Reverse Shaft Support
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