Volkswagen Golf Variant / Jetta. Manual - part 195

 

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Volkswagen Golf Variant / Jetta. Manual - part 195

 

 

4th Gears
The bevel -arrow- faces the 4th gear.

Installing the Synchronizer Hub with Locking Collar for 3rd and

4th Gears

Installing the Sleeve for the 4th Gear Needle Bearing

Installing the Sleeve for the Needle Bearing/Output Shaft

2.2

Output Shaft, Adjusting

⇒ “2.2.1 Determining the Shim”, page 244

(Selecting the correct adjusting shim for the output shaft)
Special tools and workshop equipment required
♦ Dial Gauge Holder - VW387-
♦ Measuring Set - Magnetic Plate - 50mm - VW 385/17-

242

nents were replaced:
♦ Output Shaft
♦ Clutch Housing
or
♦ Tapered roller bearing
Adjustment overview. Refer to

⇒ “2 Adjustment Overview”, page 262

 .

Requirement:
• Remove any sealant remaining on the sealing surfaces on the

clutch and transmission housing.

Perform the following procedure:
– Install the small tapered roller bearing outer race with a 0.65

mm thick shim into the clutch housing to the limit stop. Refer

to

⇒ Fig. ““Outer Race/Small Tapered Roller Bearing, Instal‐

ling”“ , page 235

 .

– Install output shaft and tighten the bearing mount nuts to 25

Nm, and then a 90° additional turn.

– Rotate the output shaft 20 to 30 times in one direction.

Note

It must be rotated in one direction so the tapered roller bearing

rollers are seated in one direction.

Therefore, it must also be rotated 20 to 30 times in one direc‐

tion.

Otherwise the measurements will be incorrect.

– Install dial gauge (3 mm measuring range) and set to “0” with

1 mm pre-load.

– Move the output shaft up and down. Read the play on the dial

gauge and note it (example: 0.20 mm).

2. Output Shaft    

243

Determining the Shim

The specified bearing preload is reached by adding a constant

preload figure 0.10 to 0.15 mm to the reading obtained and the

thickness of the installed shim.
Example:

Inserted shim

0.65 mm

+ measured value

0.20 mm

+ Preload (constant value)

0.15 mm

Shim thickness

1.00 mm

Example:

Bearing play =

(adjustment shim 0.65 mm

plus the measured value)

Adjustment shim thickness ac‐

cording to the table

0.850 mm

1.000 mm

– 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‐

ing”“ , page 235

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.

– Install the shim with the correct thickness, thickest shim first.
• If the previous 0.65 mm adjustment shim will be inserted again,

check it 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.

244

(1.00 mm in the example). Refer to

⇒ Fig. ““Outer Race/Small Tapered Roller Bearing, Instal‐

ling”“ , page 235

 and then install the output shaft. Tighten the

bearing mount nuts in the clutch housing to 25 Nm and then

turn 90° further.

2. Output Shaft    

245

 

 

 

 

 

 

 

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