Determining total shim thickness "Stotal" for shims "S3" plus "S4"

(Setting preload of tapered roller bearings for pinion shaft)

• Differential removed.

Fig 1: Pressing Tapered Roller Bearing Outer Race For Pinion Shaft Into Transmission Housing Without Shims

Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Press tapered roller bearing outer race for pinion shaft into transmission housing without shims.

Fig 2: Pressing In Tapered Roller Bearing Outer Race For Pinion Shaft With Shim Into Bearing Housing

Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Press in tapered roller bearing outer race for pinion shaft with shim "S₄ *" (thickness 1.01 mm) into bearing housing.

Fig 3: Securing Transmission Housing Onto Transmission Support VW 353 With Bolts

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• Secure transmission housing onto transmission support VW 353 with bolts - arrows  -.

Fig 4: Tapered Roller Bearing Inner Race, Selector Gears And Locking Collar For 1st And 2nd Gears And Tapered Roller Bearing Inner Race

Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Press tapered roller bearing inner race - 1  - onto pinion shaft and secure Pressing on tapered roller bearing inner race .
• Install selector gears and locking collar for 1st and 2nd gears - 2  - → Pinion shaft, disassembling and assembling .
• Press tapered roller bearing inner race - 3  - onto pinion shaft Pressing on tapered roller bearing inner race .
• Insert completely assembled pinion shaft in transmission housing.

• Install bearing housing and transmission cover with 4 dowel sleeves and tighten bolts to 35Nm.
• Turn transmission so that the transmission cover points downward.

Fig 5: Pressing Down On Drive Pinion Head Using Removal Tool VW 296

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• Press down on face of pinion shaft with removal tool VW 296 until tapered bearing outer race contacts bearing housing.
• Maintain pressure and rotate pinion shaft 5 turns in both directions to seat taper roller bearing.

Fig 6: Installing Dial Gauge (3 Mm Range) And Set To "0" With 2 Mm Pre-Load

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• Attach dial gauge (3 mm measuring range) with dial gauge extension to transmission housing.
• Preload dial gauge to 1 mm and set to "0".

The dial gauge extension must contact machined surface on the face of pinion.

Fig 7: Turn Transmission 180 Degrees, Settle Tapered Roller Bearing And Read Play On Dial Gauge

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• Turn transmission so that the transmission cover points upward.
• Rotate pinion shaft 5 turns in each direction so that the tapered roller bearing seats properly. Otherwise the result of the measurement will be incorrect.
• Read off play on dial gauge and note reading.

• Measurement in example: 0.46 mm

Formula: "S_total " = "S₄ *" + measured value + bearing preload

Determining thickness of shim "S₃ *"

Formula: "S₃ *" = "S_total " - "S₄ *"

• Pull tapered roller bearing outer race out of transmission housing Pulling tapered roller bearing outer race out of transmission housing 
• Install shim "S₃ *" in transmission housing and install outer race again.
• Insert completely assembled pinion shaft into transmission housing again.
• Install bearing housing and transmission cover with the 4 dowel sleeves and tighten bolts to 35Nm.

• Turn pinion shaft 5 turns in each direction so that taper roller bearings seat properly.

Fig 8: Identifying Assembly Device VW 792, M12 Nut, VW 387 And Transmission Cover

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• Install assembly device VW 792 on transmission housing; when doing so, insert a M12 nut - A  - between assembly device VW 792 and transmission housing.
• Install universal dial gauge bracket VW 387 with dial gauge and 30 mm extension.
• Apply dial gauge extension exactly at center of intersection of ribs on transmission cover - arrow  -.
• Set dial gauge (3 mm measuring range) to "0" with 1 mm preload.

• Loosen transmission cover bolts and turn pinion shaft several times.
• If correct shims have been selected the dial gauge will now indicate the following value:

• 0.06 to 0.12 mm

• Tighten transmission cover bolts again to 35 Nm.
• Take down measuring tools.
• Turn pinion shaft 5 turns in each direction so that taper roller bearings seat properly.

Determining dimension "e"

Fig 9: Setting Adjusting Rings Of Measuring Bar VW 385/1

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• Set adjustment rings of universal measuring tool VW385/1 to the following values:

• Dimension - a  - = 45 mm
• Dimension - b  - = 75 mm

Fig 10: Universal Measuring Tool VW385/1

Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Assemble universal measuring tool VW385/1 as illustrated:

• Dial gauge extension - VW 385/15  - , 6.5 mm long
• Master gauge VW385/30

• Set master gauge VW385/30 to Ro = 59.65 mm and install onto measuring tool.
• Set dial gauge (3 mm measuring range) to "0" with 2 mm preload.

Fig 11: Measuring Plate End Placed On Face Of Pinion Shaft

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• Place end measuring plate on face of pinion shaft.

Fig 12: Inserting Measuring Mandrel VW 385/1 Into Housing

Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Remove master gauge and insert measuring tool into housing.

• The dial gauge faces toward final drive cover

• Install cover for final drive and tighten 4 bolts to 20 Nm.
• Using adjustable ring, pull 2nd centering pad VW385/36 out as far as possible so that the measuring tool can still just be turned by hand.

Fig 13: Turning Measuring Mandrel Until Dial Gauge Plunger Tip Touches End Gauge On Pinion Shaft Head And Measure Maximum Runout

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• Turn measuring tool until dial gauge point touches the end measuring plate on pinion shaft head, then measure maximum deflection (return point).

• Measurement in following example: "e" = 0.17 mm (in red scale)