Shim " S 6 " for positioning 2nd gear selector gear, redetermining

Fig 1: Positioning Of 2nd Gear Selector Gear And Of Gear Set In Transmission Is Determined With This Shim

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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 

Fig 2: Universal Measuring Device VW 385

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• Universal measuring device VW 385

Fig 3: Straight-Edge T 40100

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

Fig 4: Setting Adjusting Rings Of Measuring Bar VW 385/1

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

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

Fig 5: Assemble Universal Mandrel VW 385/1

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• 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.

Fig 6: Using Digital Depth Gauge, Measuring At Highest Point Of Universal Mandrel VW 385/1

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• 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 " S ₃ " and " S ₄ ".

Fig 7: Measuring From Inner Race/Roller Bearing To Straight Edge Using Digital Depth Gauge

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• 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 " S  ₆  " 

Formula: Measuring range (total dimension) = Dimension -A- + Dimension -B-