Redetermining Shim S6 For Positioning 2nd Gear Selector Gear

Redetermining Shim S6 for Positioning 2nd Gear Selector Gear - 6 Spd. Manual Transmission 0A3 All Wheel Drive





Positioning of 2nd gear selector gear and of gear set in transmission is determined with this shim - A -.

This adjustment is required when the following components are replaced:

^ Transmission housing
^ Gear set
^ Hollow shaft

or

^ Gears on hollow shaft

Special tools, testers and auxiliary items required





^ Universal measuring device VW 385





^ Straight-edge T 40100
^ Digital depth gauge (e.g. VAS 6087)





- Set adjustment rings of universal mandrel VW 385/1 to the following values:

^ Dimension - a - = 45 mm
^ Dimension - b - = 60 mm





- Assemble universal mandrel VW 385/1 as shown in the illustration:

Dimension - A -, determining

^ Outer races/tapered roller bearings for differential mounting are installed in transmission housing and final drive cover.

- Insert universal mandrel VW 385/1 with centering disc VW 385/4 facing toward transmission housing.
- Insert final drive cover with integrated O-ring and tighten 4 screws to 24 Nm.
- Using adjustable ring, pull centering disc outward until universal mandrel can no longer be turned by hand.

^ Round side of universal mandrel must face upward toward depth gauge.





- Place straight edge T 40100 on cleaned transmission housing join surface.
- Using a digital depth gauge - 1 - (e.g. Digital Depth Gauge VAS 6087), measure at highest point of universal mandrel VW 385/1.

In the example, dimension - a - = 143.80 mm

- Subtract height of straight edge T 40100 from this dimension and add half of universal mandrel VW 385/1 diameter to it. This value is 16 mm.





Dimension - B -, determining

^ Drive pinion is installed with shim "S3" and "S4".





^ Retaining plate connecting screws - arrows - are tightened to 30 Nm.

- Install input shaft, hollow shaft with roller bearing pressed on and bearing bracket - 1 -.
- Place straight edge T 40100 on cleaned transmission housing join surface.
- Measure from inner race/roller bearing to straight edge using a digital depth gauge - 2 - (e.g. Digital Depth Gauge VAS 6087).

In the example, dimension - b - = 172.00 mm

- Add height of straight edge T 40100 to this dimension.





Determining thickness of adjustment shim "S6"





Determine shim according to table.





Note:
^ Allocate adjustment shims.

- The thickness of shim "S6" in this example is 4.30 mm.