Final Drive, Adjusting, When Replacing The Transmission Housing Or Pinion: Notes

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Special tools and workshop equipment required 

• Seal Installer - Crankshaft:VW 204 B 
• Clamping Piece:VW 386A 
• Press Piece - Multiple Use:VW 412 
• Crown Wheel Adjusting Tool:VW 521 
• Press Piece - Multiple Use:3005 
• Bearing Installer - Wheel Bearing:3345 

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Special tools and workshop equipment required 

• Bearing/Bushing Installer - Multiple Use:VW 295 
• Measuring Set - Magnetic Plate - 50mm:VW 385/17 
• Dial Indicator Holder:VW 387 
• Measuring Lever:VW 388 
• Press Plate:VW 402 
• Dial Gauge for example Dial Gauge - 0-3mm:VAS 6080 

TIP:

• Careful adjustment is important for service life and smoothness of the final drive.
• If only the differential bearing or the differential is replaced, the pinion can remain installed. Then perform the procedure. Refer to FINAL DRIVE, ADJUSTING WHEN REPLACING DIFFERENTIAL OR DIFFERENTIAL BEARING .
• Adjustment Overview. Refer to Adjustment Overview .

• A new adjustment of the final drive is required, if the transmission housing or the pinion was replaced.
• The pinion is removed. Refer to PINION, REMOVING AND INSTALLING .
• The transmission is secured on the assembly stand and the flywheel is removed with the right flange shaft.

Total Shim Thickness "S _total " for Shims "S ₁ " + "S ₂ ", Determining

(Adjust the bearing pre-load for the differential).

-- Remove the flange shaft seals.

-- Remove the bearing outer race for the differential from the transmission housing and the final drive cover and remove the shim. Refer to OVERVIEW - DIFFERENTIAL .

-- Drive in the left outer race/tapered roller bearing together with adjusting washer "S₂ " into the transmission housing. To measure a shim "S ₂ *" with 0.65 mm thickness is used.

Fig 1: Driving Outer Race For Tapered Roller Bearing With Shim Into Transmission Housing

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TIP:

• A for example 0.65 mm thick adjusting shim "S₂ " is used temporarily for the initial measurement. This will be indicated by "S₂ *" in the following. After determining the torsional backlash, "S₂ *" is replaced by final "S ₂ ".
• Available adjusting shims. Refer to Adjusting Shims Available for  and the appropriate Electronic Parts Information for the shim allocation.

-- Install the outer race for the right angular contact ball bearing with the temporary shim "S₁ " in the final drive cover. To measure a shim "S ₁ *" with 1.05 mm thickness is used.

Fig 2: Identifying Outer Race Tapered Bearing, Installation

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The larger diameter of the Seal Installer - Crankshaft:VW 204 B  points to the outer race for the angular contact ball bearing.

TIP:

• A 1.05 mm thick adjusting shim "S ₁ " is used temporarily for the initial measurement. This will be referred to as "S ₁ *" in the following. After determining the torsional backlash, "S ₁ *" is replaced by the final "S₁ ".
• Available adjusting shims. Refer to Adjusting Shims Available for  and the appropriate Electronic Parts Information for the shim allocation.

-- Insert the differential into the transmission housing. The ring gear is laying on the right side in front of the final drive cover.

• O-ring is inserted in final drive cover.

-- Fasten the final drive cover carefully with four bolts diagonally to 20 Nm.

-- Turn the transmission so that the final drive cover faces upward.

-- Turn each differential five turns in both directions so that the bearings settle.

-- Place the Measuring Set - Magnetic Plate - 50mm: VW 385/17  on the differential.

-- Attach the measuring tools to the transmission housing.

Fig 3: Installing Magnetic Plate 50MM Dia. VW 385/17 And Dial Gauge

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-- Set the dial gauge (3 mm measuring range) -A- to "0" with 2 mm pre-tension.

-- Position the dial gauge test probe on the differential.

-- Lift the differential without turning it, read backlash on dial indicator and note.

Measured value in the following example: 0.22 mm

• To lift the differential, secure the special tools Ring Gear Locking Sleeve:VW 521/4  and :VW 521/5  left on the differential (housing side).

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• At the same time the Crown Wheel Adjusting Tool :VW 521  must not touch the transmission housing -arrow-.
• If measurement is repeated, differential must first be rotated five turns in both directions again to seat the bearing.

Formula: "S _total " = "S ₁ *" + "S ₂ *" + measured value + bearing pre-load

• The temporary shim "S ₁ *" with a thickness of 1.05 mm remains installed in the final drive cover.

Determining the following shim thickness "S ₂ *"

• The temporary shim "S ₂ *" is replaced by the final shim "S ₂ " after the torsional backlash has been determined.
• Total shim thickness "S _total " remains unchanged.

Formula: "S ₂ *" = "S _total " - "S ₁ *"

Available adjusting shims. Refer to Adjusting Shims Available for  and the appropriate Electronic Parts Information for the shim allocation.