DG end float

[Bigjcc55]

I've got my engine out to sort an oil leak, but before it goes back together I've a question about the end float, I have 7 thou, 1.778 mm.
The Haynes recommends 0.1 mm, so it's excessive.
upon inspection of the shims they look worn the big one has a grove worn into it, is this caused by the end float? And is this larger shim available ? I can't find it on the usual places only the smaller two.
I changed all the seals last year when I did water jacket seals and a few other jobs.
So I don't want to be putting it together again for it to spring another leak!
Thanks
jc

[itchyfeet]

The larger diameter one is this...

http://www.vwheritage.com/vw_spares_Shi ... tartPage=1" onclick="window.open(this.href);return false;

It says 81x0.4 the other shims are about 75mm in diameter

Brickwerks are cheaper and i'd say this is the same larger diameter one at 0.4 thick

http://www.brickwerks.co.uk/index.php/e ... 0-4mm.html" onclick="window.open(this.href);return false;

all the other smaller diameter shims from Brickwerks are cheaper also i think

If needed, its ok to have four shims i asked that question before

another thing i gleaned is that you need to measure endfloat in a number of positions of the crank, if it varies your in
trouble

I guess tge damage is from excessive float

[Bigjcc55]

All answered and more good man thanks.
I'll measure it in a few more positions tomorrow if I get a chance, did you lever it in and out? I just pushed it in then forced it back out by hand.

[itchyfeet]

No levering just push and pull
i did it several times and rotated crank 90 degs and repeated for each 90 deg turn
Do you have a dial guage or are you using the feeler guage and bracket method?

i used a dial guage but you will inevitably get some movement of the engine and guage hence do it several times and you get a pretty good idea of play

i assume that 1.7mm is with the shims out otherwise id say you are in trouble
its normal to measure with shims in then measure shims

[bigherb]

I have 7 thou, 1.778 mm.


jc

Are you sure you have got that right?

[Bigjcc55]

It's 0.778mm 0.007 thou, slight typing error.
I'm using a dial gauge this time, I've clamped it to the block and trying carefully to only move the crank, I'm going to put it together tomorrow and take some more measurements at 90 degs, I was a bit peeved after having to take the engine out again![img]http://img.tapatalk.com/d/14/02/25/yreva7u3.jpg[/img]

[itchyfeet]

Thats with the shims in i assume,
what do they measure?
measurement may be a bit inaccurate if they are badly scored

[Bigjcc55]

Yes that's with the shims in, I haven't measured them yet I measured the end float and stripped it that was about it, I think it will be difficult to accurately measure them as the are badly worn and quite out of shape.
I'll give it a go tomorrow night if I get a chance.

[itchyfeet]

Need to measure them or you wont know what to buy to fill the gap

[Bigjcc55]

I've measured up the shims I have one large and two small the large one on the un worn outer edge is 0.30mm the smaller ones are 0.40 and 0.40, but the larger one on brickwerks is 0.40 thick I take it will be just a case of recalculating using that larger one at 0.40 and the two smaller ones thinner to give me the 0.1 I'm looking for?

[itchyfeet]

Sounds odd to me 0.3+0.4+0.4(probably 0.38)= 1.1, your float is 0.778 ( with shims in ) and should be 0.1 so you need a total of 1.778
thats a lot for 3 or even 4 shims of max 0.4mm

i wonder if your measurements are right

[Bigjcc55]

You are prob right with the 0.38, I've got the caliper and shims home with me to double check.
My float with all the shims in is 0.1778, sorry I've just looked at my post again, another typo, fat oily fingers on a phone!!

[Bigjcc55]

I need to add the .778 to the shim thickness I have to get my new total thickness?

[itchyfeet]

I'd buy a new 0.4 large shim as its knackered and a 0.34 or 0.36

Float can be 0.07 -1.3

[Bigjcc55]

Fitted new shims today and checked the float I'm getting 0.08-0.1 checked every 90 deg, and checked again just to be sure, put together with new seals and stretch bolts, there was a tiny groove in the fly wheel so I fitted the seal closer to the fly wheel(not as far in but still under flush)
I checked the breather was clear incase back pressure was part of the problem but all good. I hope this will cure the leak this time as I couldn't see anything else apart from the end float that would be causing the problem.
It's hard to think that the tiny bit of movement it had would leak so bad! Anyway fingers crossed..

Thanks itchyfeet