Get Gears,Shafts -> 2.3 Output Shaft 1st through 4th Gear, Adjusting Guide for Volkswagen Golf 4 Door Fifth Generation (2003-2008)

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤

6-Speed Manual Transmission 02Q - Edition 05.2013

Installing the 3rd Gear Wheel with Needle Bearing

•

The synchronizer ring -1- and the tabs -arrow A- are inside the

openings in the synchronizer hub -2-.

The pins -arrows B- in the outer race lock in the recesses

-arrows C- in the gear wheel -3-.

– Install the 3rd gear wheel with the needle bearing.

Note

♦ Pressing on inner race/tapered roller bearing. Refer to

⇒ Fig. ““Installing the Inner Race/Tapered Roller Bearing on

the Side of the Transmission Housing”“ , page 323 .

♦ Selecting the locking ring for the inner race/tapered roller bear‐

ing. Refer to

⇒ Fig. ““Selecting The Locking Ring”“ , page 323 .

2.3

Output Shaft 1st through 4th Gear, Ad‐

justing

⇒ “2.3.1 Determining the Shim”, page 341

⇒ “2.3.2 Shim Table”, page 342

⇒ “2.3.3 Checking Measurement”, page 342

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-

♦ -1- Puller - Kukko Internal - 46-56mm - 21/7-

♦ -4- Puller - Kukko Counterstay - 22/2-

(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 for 1st to 4th gears or

♦ Output shaft tapered roller bearing

Adjustment overview. Refer to

⇒ “4 Overview - Adjustment”, page 393 .

Requirements

•

Remove any sealant remaining on the sealing surfaces on the

clutch and transmission housing.

•

Install the output shaft that is going to be measured.

340

Rep. Gr.35 - Gears, Shafts

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤

6-Speed Manual Transmission 02Q - Edition 05.2013

– 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 Slide Hammer - Press

Plate - 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 to the tightening specification.

– 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 the clear transmission hous‐

ing or the 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.

♦ Allocate the shims. Refer to the Parts Catalog.

2.3.1

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).

2. 1st through 4th Gear Output Shaft

341

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤

6-Speed Manual Transmission 02Q - Edition 05.2013

A constant figure of (0.20 mm) is added to the reading.

Example

Inserted shim

1.70 mm

0.14 mm

0.20 mm

1.76 mm

- Measured value

+ Preload (constant value)

Shim thickness

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

to ⇒ “2.3.2 Shim Table”, page 342 .

– Remove the transmission housing and remove the tapered

roller bearing outer race from the transmission housing.

A - Counter Support , for example, Puller - Kukko Counterstay -

22/2-

B - Internal Puller 46 to 58 mm , for example, Puller - Kukko In‐

ternal - 46-56mm - 21/7-

– Remove the inserted shim (1.70 mm) from the transmission

housing.

2.3.2

Shim Table

Thickness (mm)

1.45

1.50

1.55

1.60

1.65

1.70

1.75

1.80

1.85

1.90

1.95

2.00

2.05

2.10

2.15

2.20

2.25

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

ness required.

– Shim 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 housing

directly beneath bearing mount using Slide Hammer - Press

Plate - 2050- .

2.3.3

Checking Measurement

•

The selected adjusting shim is installed.

342

Rep. Gr.35 - Gears, Shafts

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤

6-Speed Manual Transmission 02Q - Edition 05.2013

– 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 the clear transmission hous‐

ing or the output shaft.

•

For correctly selected adjustment shim, dial gauge must now

display a value of 0.15 mm to 0.25 mm.

2. 1st through 4th Gear Output Shaft

343

Gears,Shafts -> 2.3 Output Shaft 1st through 4th Gear, Adjusting for Your Volkswagen Golf 4 Door Fifth Generation (2003-2008)

Related Topics

Popular Owner Manuals

Latest Owner Manuals