Intermediate Shaft Radial Clearance

rebuilder · Post by **rebuilder** » Thu Jan 10, 2008 4:26 pm

I am in the process of rebuilding my 1989 1.6l NA Jetta engine #ME 834422 and have noticed some wear on the outboard intermediate shaft bearing. Does anyone know what the allowable wear limit is on this part? Would appreciate this information. Could not find it in Bentley.

82vdub · Post by **82vdub** » Thu Jan 10, 2008 4:29 pm

IMO, I would replace the intermediate bearings, no matter their condition. You probably want 300k miles from your rebuild, replace these parts especially since they are pretty cheap.

rebuilder · Post by **rebuilder** » Thu Jan 10, 2008 4:32 pm

Thanks for the insight. I have already ordered the parts. The first run on this engine was 290,000 miles before the compression dropped to 290 psi, at which point I began the rebuild.

VW Jon · Post by **VW Jon** » Thu Jan 10, 2008 5:00 pm

I've read that the intermediate bearings need reamed after they are installed. Any truth to this??????????????

rallydiesel · Post by **rallydiesel** » Thu Jan 10, 2008 7:27 pm

They may. Most don't. However, if you install the bearings and the intermediate shaft with a light coat of oil, you should be able to turn the the shaft by hand (with the pulley installed). I have the joy of dealing with this problem after I rebuilt my engine and put it back in the car because I did not know some intermediate bearings need to be reamed.

rebuilder · Post by **rebuilder** » Thu Jan 10, 2008 7:51 pm

Gentlemen...The outside diameter of the inner and outer intermediate shaft surfaces is 42.95 mm. It would be difficult to obtain a reamer that size. Even if you could you would have to line up the centerline of the tool with the undersized bearings after they were pressed into the block.

I will let you know the dimensions of the replacement bearings and the tolerance between these and the shaft bearing diameter when they arrive. Clearly care needs to be used when removing and replacing these parts. Likely special tools will be needed for a clean removal especially for the inside bearing since it is only exposed from one side. Expect to finish block cylinder boring/honing tomorrow. New beraings will be received later next week and the lower part of the engine assembled.

82vdub · Post by **82vdub** » Thu Jan 10, 2008 8:38 pm

According to my Durabond catalog, these engines have a bearing housing bore of 1.8115" for bearing #1, and 1.7721 for bearing #2 and the bearings have a max wall thickness of .0590".

That means that the bearings for journal #1 has an ID of 43.00mm, and for journal #2 bearing ID is 42.00mm.

rallydiesel · Post by **rallydiesel** » Thu Jan 10, 2008 8:45 pm

Technically speaking, they would be line-bored, not reamed.

libbybapa · Post by **libbybapa** » Thu Jan 10, 2008 8:48 pm

Pre-sized bearing are available at almost every local auto parts store for cheap. I recently got a couple sets for $12 each off the shelf.

Andrew

nicknack2 · Post by **nicknack2** » Thu Jan 10, 2008 11:02 pm

any body know if the intermediateshaft bearings that Jack sell need to be reamed???

nicknack2 · Post by **nicknack2** » Thu Jan 10, 2008 11:18 pm

check the bottom of this post they have a "home made" tool to install the bearings!
viewtopic.php?t=771&postdays=0&postorde ... s&start=30

Post by **Fatmobile** » Fri Jan 11, 2008 1:16 am

I tried 3 kinds of bearings;
Durabond, clevite and I can't remember the other.
Clevite fit the best for the I-shaft I was using.

tylernt · Post by **tylernt** » Fri Jan 11, 2008 2:08 am

libbybapa wrote:Pre-sized bearing are available at almost every local auto parts store for cheap. I recently got a couple sets for $12 each off the shelf.

Libbybapa, do these include the little oil jet for the vacuum pump gear? Or did you add that yourself? Thanks!

libbybapa · Post by **libbybapa** » Fri Jan 11, 2008 9:42 am

That is machined into each set of pre-sized bearings I have used.

Andrew

Post by **Fatmobile** » Fri Jan 11, 2008 11:41 pm

have noticed some wear on the outboard intermediate shaft bearing. Does anyone know what the allowable wear limit is on this part?

I haven't seen them wear like a normal bearing,... they chip out.
chunks break off the surface.
How did you notice wear,... actually looking at the bearing or feeling slop in the shaft?