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REPAIR MAINTENANCE OPERATION OF MOTOR VEHICLES
Volkswagen Passat B3 / B4 (c 1988 and 1996 model year)

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Volkswagen Passat B3 / B4
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Passat B3 / B4
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Removing gearbox
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Dismantling gearbox
Dismantling, check and assemblage of a primary shaft
Output shaft
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The gear change mechanism
Install the input shaft end play
Setting the axial backlash of a secondary shaft
Assembling the gearbox
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Install the input shaft end play



Location specific template and mounting bracket to check the axial play of the primary shaft
Fig. 8.41. Location specific template and mounting bracket to check the axial play of the primary shaft


Location of the template and the mounting bracket to check the axial play of the secondary shaft
Fig. 8.42. Location of the template and the mounting bracket to check the axial play of the secondary shaft


To adjust the axial play of the primary shaft use a special template and mounting brackets (Fig. 8.41, 8.42), or ask for help from experts specialized service stations.
Install the input shaft endplay spend in the following order:
press-fit tapered bearing in the clutch / differential;
set the clutch / differential input shaft;
Set gearbox housing and tighten it to a torque of 25 Nm;
pressing the input shaft to the template micrometer preloaded, check the axial clearance (see. Fig. 8.41);
based on the value of the axial backlash pick the proper gasket to provide the required axial play of the input shaft;
remove the gearbox housing and remove the primary shaft;
Remove the outer ring of the bearing, install the selected pad, then re-install the outer ring;
Install the input shaft;
Set gearbox housing and tighten it to a torque of 25 Nm;
repeatedly rotate the input shaft to ensure accurate setting of bearings;
recheck the endplay. The bearing clearance must be in the range of 0.01 - 0.12 mm.




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Setting the axial backlash of a secondary shaft

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