Adjusting gear seats where dimension "E" is indicated on outer circumference of ring gear

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Special tools, testers and auxiliary items required

Fig 1: Universal Measuring Device VW 385

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Universal measuring device VW 385

Fig 2: Identifying Torque Wrench V.A.G. 1331

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Torque wrench V.A.G 1331
Depth gauge, e.g. Digital Depth Gauge VAS 6087
Dial gauge

Determine thickness of previous shim " S ₃ " and " S ₄ "

Differential removed.
Double angular contact ball bearing is pressed onto drive pinion.

NOTE:

For the initial measurement, an adjustment shim " S ₃ " of 1.00 mm is inserted. It is designated as " S ₃ * " in the following. After adjusting dimension "E" , " S ₃ * " is replaced by the final shim " S ₃ ".

Secure transmission housing to transmission mounting VW 353. To do so, transmission housing must be vertical.
Place shim " S ₃ * " in transmission housing.

Fig 3: Removing Drive Pinion From Bore In Transmission Housing

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Coat outer races - 3 - and - 4 - of double angular contact ball bearing with transmission fluid.
Carefully slide drive pinion - 1 - with double angular contact ball bearing by hand into transmission housing - 2 - and press onto upper outer race - 3 - at the same time.

NOTE:

Warm transmission housing beforehand with a hot air gun in bearing seat area, if necessary.

Outer races - 3 - and - 4 - must not tilt when inserting, they must remain together. Otherwise, seal - 6 - can be damaged by pinion face - 5 -.

If double angular contact ball bearing seal is damaged, the bearing must be replaced.

Determine previous shim " S ₄ " as follows:

Fig 4: Using Digital Depth Gauge To Measure From Outer Race/Double Angular Contact Ball Bearing To Retaining Plate Bolting Surface

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Using a digital depth gauge (e.g Digital Depth Gauge VAS 6087), measure from outer race/double angular contact ball bearing - 1 - to retaining plate bolting surface - 2 -.

In the example, gap dimension - a - = 1.14 mm. Determine previous shim " S ₄ " according to → Available adjustment shims for " S 4 " .

NOTE:

For the initial measurement, an adjustment shim " S ₄ " of 0.95 mm is inserted. It is designated as " S ₄ * " in the following. After adjusting dimension "E" , " S ₄ * " is replaced by the final shim " S ₄ ".

Fig 5: Identifying Bolts & Retainer Plate

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Place previous shim " S ₄ * " (0.95 mm in example) and retaining plate - A - (only fits in one position) on transmission housing bolting surface.
Clean threads of previous screws - arrows - with a wire brush. Then tighten screws diagonally to 30 Nm.

Dimension "E" , adjusting

NOTE:

Dimension "E" must be adjusted at master gauge VW 385/30 to determine final shim thickness of " S ₃ " and " S ₄ ".

Fig 6: Setting Adjusting Rings Of Measuring Bar VW 385/1

Courtesy of VOLKSWAGEN UNITED STATES, INC.

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

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

Fig 7: Assembling Universal Mandrel VW 385/1

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Assemble universal mandrel VW 385/1 as shown in the illustration:

Dial gauge extension VW 385/16 , 12.3 mm long

Set master gauge VW 385/30 to dimension "E" in example = 62.50 mm and place on universal mandrel VW 385/1.
Set gauge (3 mm measuring range) to "0" with 2 mm pre-load.

Fig 8: Placing Magnetic Plate VW 385/33 Onto Head Of Drive Pinion

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Place magnetic plate VW 385/33 onto head of drive pinion.

NOTE:

Make sure magnetic plate VW 385/33 is precisely installed and free of oil.

Fig 9: Removing Master Gauge VW 385/30 And Inserting Universal Mandrel In Transmission Housing

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove master gauge VW 385/30 and insert universal mandrel in transmission housing.

A dial gauge extension - A - = 12.3 mm long must be screwed in.
Dial gauge faces final drive cover.
O-ring is inserted in final drive cover.

Install final drive cover and tighten 4 bolts to 24 Nm.
Using adjustable ring, pull 2nd centering disc VW 385/36 out far enough, so that the universal mandrel can only just be turned by hand.

Fig 10: Turning Measuring Mandrel Until Dial Gauge Plunger Tip Touches End Gauge On Pinion Shaft Head And Measure Maximum Runout

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Turn universal mandrel until dial gauge tip touches magnetic plate on head of pinion and indicates max. runout (return point).

Measured value in following example: = 0.15 mm (red number range)

NOTE:

After removing universal mandrel - check again whether dial gauge stands at "0" with 2 mm pre-load when adjustable master gauge VW 385/30 is attached.

Determining thickness of adjustment shim " S ₃ "

If measured in red numbered area, measured value must be subtracted.
If measured in black numbered area, measured value must be added.

Example:
	Inserted shim " S ₃ * "	1.00 mm
-	Value determined (red number range)	0.15 mm
=	Thickness of adjustment shim " S ₃ "	0.85 mm

Available adjustment shims for " S ₃ "

Shim thickness (mm) * See note
0.55	0.75	0.95
0.60	0.80	1.00
0.65	0.85	1.05
0.70	0.90

*Using shim tolerances it is possible to find the exact shim thickness required, insert two shims if necessary.

Remove previous shims " S ₃ * " and " S ₄ * ".
Insert determined shim " S ₃ " , 0.85 mm in example, in transmission housing.

Determining thickness of adjustment shim " S ₄ "

Determined shim " S ₃ " is installed in transmission housing.

Fig 11: Removing Drive Pinion From Bore In Transmission Housing

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Coat outer races - 3 - and - 4 - of double angular contact ball bearing with transmission fluid.
Carefully slide drive pinion - 1 - with double angular contact ball bearing by hand into transmission housing - 2 - and press onto upper outer race - 3 - at the same time.

NOTE:

Warm transmission housing beforehand with a hot air gun in bearing seat area, if necessary.

Outer races - 3 - and - 4 - must not tilt when inserting, they must remain together. Otherwise, the seal - 6 - can be damaged by the pinion face - 5 -.

If the double angular contact ball bearing seal is damaged, the bearing must be replaced.

Determine shim " S ₄ " as follows:

Fig 12: Using Digital Depth Gauge To Measure From Outer Race/Double Angular Contact Ball Bearing To Retaining Plate Bolting Surface

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Using a digital depth gauge (e.g Digital Depth Gauge VAS 6087), measure from outer race/double angular contact ball bearing - 1 - to retaining plate bolting surface - 2 -.

In the example, gap dimension - a - = 0.99 mm. Determine shim " S ₄ " according to → Available adjustment shims for " S 4 " .

Available adjustment shims for " S 4 "

Gap dimension - a -	Adjustment shim " S ₄ " * See note
Measured value (mm)	Thickness (mm)
0.67 to 0.71 0.72 to 0.76 0.77 to 0.81	0.50 0.55 0.60
0.82 to 0.86 0.87 to 0.91 0.92 to 0.96	0.65 0.70 0.75
0.97 to 1.01 1.02 to 1.06 1.07 to 1.11	0.80 0.85 0.90
1.12 to 1.16 1.17 to 1.21 1.22 to 1.26	0.95 1.00 1.05
1.27 to 1.31 1.32 to 1.36 1.37 to 1.41	1.10 1.15 1.20
1.42 to 1.46 1.47 to 1.51 1.52 to 1.56	1.25 1.30 1.35
1.57 to 1.61	1.40

*Using shim tolerances it is possible to find the exact shim thickness required, insert two shims if necessary.

NOTE:

Fig 13: Identifying Bolts & Retainer Plate

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Place determined shim " S ₄ " (0.80 mm in example) and retaining plate - A - (only fits in one position) on transmission housing bolting surface.
Then tighten bolts - arrows - diagonally to 30 Nm.

Performing measuring check, checking dimension "E"

Install drive pinion with measured adjustment shims " S ₃ " and " S ₄ ".

Fig 14: Turning Measuring Mandrel Until Dial Gauge Plunger Tip Touches End Gauge On Pinion Shaft Head And Measure Maximum Runout

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Install universal mandrel and perform measurement check.
Read dial indicator counterclockwise (red numbered area).

If adjustment shims were determined correctly, dimension "E" must have a clearance of ± 0.04 mm.

NOTE:

After removing universal mandrel - check again whether dial gauge stands at "0" with 2 mm pre-load when adjustable master gauge VW 385/30 is attached.

Special tools, testers and auxiliary items required

Fig 1: Universal Measuring Device VW 385

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Universal measuring device VW 385

Fig 2: Identifying Torque Wrench V.A.G. 1331

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Torque wrench V.A.G 1331
Depth gauge, e.g. Digital Depth Gauge VAS 6087
Dial gauge

Determining thickness of previous shims " S ₃ " and " S ₄ "

Differential removed.
Double angular contact ball bearing is pressed onto drive pinion.

NOTE:

For the initial measurement, an adjustment shim " S ₃ " of 1.00 mm is inserted. It is designated as " S ₃ * " in the following. After adjusting dimension "e" , " S ₃ * " is replaced by the final shim " S ₃ ".

Secure transmission housing to transmission mounting VW 353. To do so, transmission housing must be vertical.
Place shim " S ₃ * " in transmission housing.

Fig 3: Removing Drive Pinion From Bore In Transmission Housing

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Coat outer races - 3 - and - 4 - of double angular contact ball bearing with transmission fluid.
Carefully slide drive pinion - 1 - with double angular contact ball bearing by hand into transmission housing - 2 - and press onto upper outer race - 3 - at the same time.

NOTE:

Warm transmission housing beforehand with a hot air gun in bearing seat area, if necessary.

Outer races - 3 - and - 4 - must not tilt when inserting, they must remain together. Otherwise, the seal - 6 - can be damaged by the pinion face - 5 -.

If the double angular contact ball bearing seal is damaged, the bearing must be replaced.

Determine previous shim " S ₄ " as follows:

Fig 4: Using Digital Depth Gauge To Measure From Outer Race/Double Angular Contact Ball Bearing To Retaining Plate Bolting Surface

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Using a digital depth gauge (e.g Digital Depth Gauge VAS 6087), measure from outer race/double angular contact ball bearing - 1 - to retaining plate bolting surface - 2 -.

In the example, gap dimension - a - = 1.14 mm. Determine previous shim " S ₄ " according to → Available adjustment shims for " S 4 " .

NOTE:

For the initial measurement, an adjustment shim " S ₄ " of 0.95 mm is inserted. It is designated as " S ₄ * " in the following. After adjusting dimension "e" , " S ₄ * " is replaced by the final shim " S ₄ ".

Fig 5: Identifying Bolts & Retainer Plate

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Place previous shim " S ₄ * " (0.95 mm in example) and retaining plate - A - (only fits in one position) on transmission housing bolting surface.
Clean threads of previous bolts - arrows - with a wire brush. Then tighten bolts diagonally to 30 Nm.

Dimension "e" , adjusting

NOTE:

Dimension "e" must be adjusted to determine final shim thickness of " S ₃ " and " S ₄ " for this gear set.

Fig 6: Setting Adjusting Rings Of Measuring Bar VW 385/1

Courtesy of VOLKSWAGEN UNITED STATES, INC.

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

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

Fig 7: Assembling Universal Mandrel VW 385/1

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Assemble universal mandrel VW 385/1 as shown in illustration:

Dial gauge extension VW 385/16 , 12.3 mm long

Set master gauge VW 385/30 to dimension "Eo" = 62.50 mm and place on universal mandrel VW 385/1.
Set gauge (3 mm measuring range) to "0" with 2 mm pre-load.

Fig 8: Placing Magnetic Plate VW 385/33 Onto Head Of Drive Pinion

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Place magnetic plate VW 385/33 onto head of drive pinion.

NOTE:

Make sure magnetic plate VW 385/33 is precisely installed and free of oil.

Fig 9: Removing Master Gauge VW 385/30 And Inserting Universal Mandrel In Transmission Housing

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove master gauge VW 385/30 and insert universal mandrel in transmission housing.

A dial gauge extension - A - = 12.3 mm long must be screwed in.
Dial gauge faces final drive cover.
O-ring is inserted in final drive cover.

Install final drive cover and tighten 4 bolts to 24 Nm.
Using adjustable ring, pull 2nd centering disc VW 385/36 out far enough, so that the universal mandrel can only just be turned by hand.

Fig 10: Turning Measuring Mandrel Until Dial Gauge Plunger Tip Touches End Gauge On Pinion Shaft Head And Measure Maximum Runout

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Turn universal mandrel until dial gauge tip touches magnetic plate on head of pinion and indicates max. runout (return point).

Measured value in following example: = 0.43 mm (red number range)

NOTE:

After removing universal mandrel - check again whether dial gauge stands at "0" with 2 mm pre-load when adjustable master gauge VW 385/30 is attached.

Determining thickness of adjustment shim " S ₃ "

Dimension "e" which is based on the master gauge "Eo" is measured for the final drive sets supplied as replacement parts and marked on outer circumference of ring gear.
If measured in red numbered area, measured value must be subtracted.
If measured in black numbered area, measured value must be added.

Formula:

" S ₃ " = " S ₃ * " + "e" + "measured value" ("measured value" in black numbered area)

" S ₃ " = " S ₃ * " + "e" - "measured value" ("measured value" in red numbered area)

Example:
	Inserted shim " S ₃ * "	1.00 mm
+	Dimension "e"	0.33 mm
-	Determined value (red numbered area)	0.43 mm
=	Thickness of adjustment shim " S ₃ "	0.90 mm

Available adjustment shims for " S ₃ "

Shim thickness (mm) * See note
0.55	0.75	0.95
0.60	0.80	1.00
0.65	0.85	1.05
0.70	0.90

*Using shim tolerances it is possible to find the exact shim thickness required, insert two shims if necessary.

Remove previous shims " S ₃ * " and " S ₄ * ".
Insert determined shim " S ₃ " , 0.90 mm in example, in transmission housing.

Determining thickness of adjustment shim " S ₄ "

Determined shim " S ₃ " is installed in transmission housing.

Fig 11: Removing Drive Pinion From Bore In Transmission Housing

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Coat outer races - 3 - and - 4 - of double angular contact ball bearing with transmission fluid.
Carefully slide drive pinion - 1 - with double angular contact ball bearing by hand into transmission housing - 2 - and press onto upper outer race - 3 - at the same time.

NOTE:

Warm transmission housing beforehand with a hot air gun in bearing seat area, if necessary.

Outer races - 3 - and - 4 - must not tilt when inserting, they must remain together. Otherwise, the seal - 6 - can be damaged by the pinion face - 5 -.

If the double angular contact ball bearing seal is damaged, the bearing must be replaced.

Determine shim " S ₄ " as follows:

Fig 12: Using Digital Depth Gauge To Measure From Outer Race/Double Angular Contact Ball Bearing To Retaining Plate Bolting Surface

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Using a digital depth gauge (e.g Digital Depth Gauge VAS 6087), measure from outer race/double angular contact ball bearing - 1 - to retaining plate bolting surface - 2 -.

In the example, gap dimension - a - = 1.04 mm. Determine shim " S ₄ " according to → Available adjustment shims for " S 4 " .

Available adjustment shims for " S 4 "

Gap dimension - a -	Adjustment shim " S ₄ " * See note
Measured value (mm)	Thickness (mm)
0.67 to 0.71 0.72 to 0.76 0.77 0.81	0.50 0.55 0.60
0.82 to 0.86 0.87 to 0.91 0.92 to 0.96	0.65 0.70 0.75
0.97 to 1.01 1.02 to 1.06 1.07 to 1.11	0.80 0.85 0.90
1.12 to 1.16 1.17 to 1.21 1.22 to 1.26	0.95 1.00 1.05
1.27 to 1.31 1.32 to 1.36 1.37 to 1.41	1.10 1.15 1.20
1.42 to 1.46 1.47 to 1.51 1.52 to 1.56	1.25 1.30 1.35
1.57 to 1.61	1.40

*Using shim tolerances it is possible to find the exact shim thickness required, insert two shims if necessary.

NOTE:

Fig 13: Identifying Bolts & Retainer Plate

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Place determined shim " S ₄ " (0.85 mm in example) and retaining plate - A - (only fits in one position) on transmission housing bolting surface.
Then tighten screws - arrows - diagonally to 30 Nm.

Performing measuring check, checking dimension "E"

Install drive pinion with measured adjustment shims " S ₃ " and " S ₄ ".

Fig 14: Turning Measuring Mandrel Until Dial Gauge Plunger Tip Touches End Gauge On Pinion Shaft Head And Measure Maximum Runout

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Install universal mandrel and perform measurement check.
Read dial indicator counterclockwise (red numbered area).

If shims have been determined correctly, deviation "e" (as marked on outer circumference of ring gear) should be indicated on dial within a tolerance of ± 0.04 mm.

NOTE:

After removing universal mandrel - check again whether dial gauge stands at "0" with 2 mm pre-load when adjustable master gauge VW 385/30 is attached.