Drive pinion, adjusting

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Fig 1: Identifying Special Tools - Pinion, Adjusting

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(Adjusting drive pinion and hollow wheel)

Special tools and equipment

VW 385 Universal measuring tool
VW 387 Universal dial gauge holder
VW 402 Thrust plate
VW 407 Thrust tool

VW 771 Multi-purpose tool
3062 Thrust disc

Fig 2: 3114/2 Straightening Tool

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3114/2 Straightening tool

Fig 3: 3116 Spring Pin

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3116 Spring pin
Torque gauge 0 to 600 Ncm
Dial gauge
Dial gauge extension 6.5 mm

Dial gauge extension 30 mm

Re-adjustment of the drive pinion according to the following instructions is only necessary if the final drive set, taper roller bearing for drive pinion and transmission housing are being replaced. Refer to Adjustment overview .

Determine total shim thickness "Stotal"(S3 plus S4)

(Setting preload of taper roller bearing for drive pinion).

Differential is removed.

Fig 4: Preloading Pinion/Hollow Shaft To 10 Nm, While Holding Hollow Shaft

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Clamp drive pinion in vice using vice clamps -A-.
Insert taper rollers with grease, assemble drive pinion and hollow shaft.
Rotate hollow shaft against drive pinion 5 turns in both directions to settle taper roller bearing.
Preload drive pinion/hollow shaft to 10 Nm, hold hollow shaft tight for this step.

Install large taper roller bearing outer race into transmission housing without shim. Refer to Heating transmission housing in order to install outer race for taper roller bearing and Inserting outer race for large taper roller bearing in transmission housing and pressing home

Fig 5: Pressing In/Out Small Outer Race/Tapered Bearing

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Press small taper roller bearing outer race together with a 1.00 mm thick provisional shim S4* fully into bearing plate.

NOTE: For measurement purposes a shim S4 with a thickness of 1.00 mm is inserted provisionally. It is referred to as S4* in the following. After determining measurement "e", S4* is replaced by the final shim S4.

Insert completely assembled pinion shaft in transmission housing.
Install bearing plate with dowel sleeves and tighten bolts to tightening torque.
Rotate drive pinion and hollow shaft 8 turns in both directions prior to each measurement in order to settle taper roller bearing.

Fig 6: Installing Measuring Tools

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Install measuring tools.
Use 30 mm dial gauge extension
Position dial gauge extension in middle of measuring plate VW 385/17.
Set dial gauge (3 mm measuring range) to zero with 2 mm preload.

Move drive pinion upward and downward without turning; read off play on dial gauge and note.

(Example: 0.90 mm)

Before each measuring procedure the drive pinion must be turned together with the hollow shaft in order to avoid obtaining a false reading.

The specified bearing pre-load is obtained by adding a constant pre-load value (0.15 mm) to reading obtained (0.90 mm) and thickness of shim S4* (1.0 mm).

Stotal = S4* + reading obtained + pre-load

Example:

Inserted shim S4*		1.00 mm
Pre-load (constant value)		+0.15 mm
Reading obtained (Example)		+0.90 mm
Stotal		= 2.05 mm

Determining thickness of provisional shim S3*

Provisional shim S3* = Stotal - S4*

Example:

Total shim thickness Stotal (S3 + S4)	2.05 mm
Inserted shim S4*	-1.00 mm
Provisional shim thickness S3*	= 1.05 mm

Removing outer race for large taper roller bearing. Refer to Pulling out large taper roller bearing outer race , Inserting provisional shim S3* into transmission housing and re-installing outer race. Refer to Heating transmission housing in order to install outer race for taper roller bearing and Inserting outer race for large taper roller bearing in transmission housing and pressing home .
Insert completely assembled pinion shaft in transmission housing again.
Install bearing plate with dowel sleeves and tighten to 25 Nm.
Rotate drive pinion and hollow shaft 8 turns in both directions prior to each measurement to settle taper roller bearing.

Determining measurement "e"

Fig 7: Setting Adjusting Rings Of Measuring Bar VW 385/1

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Set universal mandrel VW 385/1 setting ring to dimension a = 65 mm.
Adjust moveable setting ring to measure b = 55 mm.

Fig 8: Assemble Measuring Bar According

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Arrange universal mandrel as illustrated. Dial gauge extension VW 385/15 = 9.3 mm. Set master gauge VW 385/30 to Ro = 59.65 mm and install onto mandrel.
Set dial gauge (3 mm measuring range) to zero with 2 mm preload.
Place end measuring plate VW 385/17 onto drive pinion head.

Fig 9: Insert Measuring Mandrel Into Housing

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Remove master gauge and insert measuring mandrel in the housing. Centering disc VW385/3 faces toward cover for final drive.
Install final drive cover and tighten 4 bolts to 25 Nm.
Using sliding setting ring to pull 2nd centering disc VW 385/2 outward until mandrel can still 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

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Measure dimension "e".

Turn mandrel until the dial gauge extension touches the final measuring plate on pinion shaft head, then measure maximum deflection (return point). The measured value is dimension "e".

Example:

0.16 mm (red scale)

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

Measurement in following example: "e" = 0.16 mm (in red scale on dial)

Determining thickness of shim S3

S3 = S3* + r + e

("e" in black scale)

S3 = S3* + r + e

("e" in red scale)

NOTE:

The deviation "r", which is related to the master gauge "Ro" is measured for the final drive sets supplied as replacement parts and marked on the outer circumference of the ring gear.
If dial gauge reading is in red scale, subtract dimension "e".
If dial gauge reading is in black scale, add dimension "e".

Example:

Inserted shim S3*		1.05 mm
Dimension "r" indicated on ring gear		+0.38 mm
Determined value "e" (red scale)		-0.16 mm
Shim thickness S3		= 1.27 mm

Available shims for S3

Shim thickness (mm)
0.45	0.60	0.75
0.50	0.65	0.80
0.55	0.70	0.85

Different tolerances make it possible to obtain exact shim thickness required.

Determining thickness of shim S4

S4 = Stotal - S3

Example:

Total shim thickness "Stotal"		2.05 mm
Thickness of shim S3		-1.27 mm
Thickness of shim S4		= 0.78 mm

Available shims for S4

Shim thickness (mm)
0.45	0.65	0.85
0.50	0.70	1.25
0.55	0.75
0.60	0.80

Different tolerances make it possible to obtain exact shim thickness required.

Carry out check measurement - checking dimension "r"

Install pinion shaft with measured shims S3 and S4 and turn several times in both directions.

Fig 11: Turning Measuring Mandrel Until Dial Gauge Plunger Tip Touches End Gauge On Pinion Shaft Head And Measure Maximum Runout

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Insert universal mandrel and measure dimension "r".

If the correct shims have been selected the D.T.I. must now indicate the mark dimension "r" (reading anti-clockwise on red scale) within a tolerance of ± 0.04 mm.

Measuring frictional torque (check)

NOTE: Taper roller bearings for drive pinion/hollow shaft are low friction bearings. Therefore the frictional torque only has a limited use as a check. Correct adjustment is only possible by determining the total shim thickness Stotal.

Fig 12: Do Not Use Additional Oil

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Install new taper roller bearings in delivery condition and do not oil additionally.

Fig 13: Identifying Special Tool

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Measuring frictional torque

With torque gauge -A-, 0 to 600 Ncm, standard commercially available

New bearings	Used bearings 1)
80 to 150 Ncm	30 to 60 Ncm

1) with at least 50 km service