Pinion, Adjusting: Notes

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Special tools and workshop equipment required

Measuring Set:VW 385

Fig 1: Universal Measuring Device VW 385
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Transmission Holder:T40407

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Hot Air Blower:V.A.G 1416 or Wiring Harness Repair Set - Hot Air Blower: VAS 1978/14A

Fig 2: Hot Air Blower VAG1416
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Dial Gauge for example Dial Gauge - 0-3mm:VAS 6080

Fig 3: Dial Gauge - 0-3mm VAS6080
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Centering Plate:T40337

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Determining thickness of previous shims "S₃ " and "S₄ "

-- Secure transmission housing to the Gearbox Support:T40207 . The transmission housing be vertical to do so.

The differential is removed.
The double angular contact ball bearing is pressed on the pinion and the preload sleeve with circlip is installed. Refer to DRIVE PINION, DISASSEMBLING AND ASSEMBLING .
Warm the transmission housing, for example with the Hot Air Blower in the area of the bearing seat -arrow- to approximately 100 °C (212 °F).

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A old (removed) adjusting shim -1- "S ₃ " for example 1.05 mm is used temporarily for the initial measurement. It is designated as "S ₃ *" in the following. After adjusting the dimensions "R", "S ₃ *" is replaced with the final shim "S₃ ".

-- Insert the old shim "S ₃ *" -1- for example 1.05 mm in the transmission housing.

-- Then insert the pinion -3- quickly by hand without tilting all the way in the transmission housing.

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Determine the temporary shim "S ₄ " -2- as follows:

Formula: "S ₄ " = 2.54 mm - "S ₃ "

Example:
	Constant value	2.54 mm
-	Thickness of old shim "S ₃ *"	1.05 mm
=	Thickness of temporary shim "S ₄ "	1.49 mm

Insert a 1.49 mm shim "S₄ " temporarily for the initial measurement. It is designated as "S ₄ *" in the following. After adjusting the dimensions "R", "S ₄ *" is replaced with the final shim "S₄ ".

-- Place the temporary shim "S ₄ *" -2- on the double angular contact ball bearing.

Installation position of the circlip -1- : the bevel -arrow- points upward and the flat side points to the double angular contact ball bearing.

-- Install the circlip -1- in the transmission housing groove all around.

Adjust the dimension "R"

The dimension "R" is adjusted to determine the final shim thickness of the "S ₃ " and "S ₄ " for this drivetrain on the Measuring Set - Adjustable Master Gauge:VW 385/30 .

-- Adjust the setting rings of the Measuring Set - Measuring Bar:VW 385/1 -1- to the following value:

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Dimension -a- = 61 mm
Dimension -b- = 35 mm

The dimension -a- is located on the side of the location -arrow- of the Dial Indicator:VAS 6080A .

-- Assemble the Measuring Set - Measuring Bar:VW 385/1 , as shown:

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Measuring Set - Extension Pin - 9.3mm:VW 385/15 , 9.3 mm long.

-- Adjust the Measuring Set - Adjustable Master Gauge:VW 385/30 to the dimension "R" = 60.00 mm and place on the Measuring Set - Measuring Bar:VW 385/1 .

TIP:

The dimension "R" generally is for all dimensions 60.00 mm. There is no individual dimension.

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

-- Place the Measuring Set - End Gauge:VW 385/33 -2- on the pinion head -1-.

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Pay attention that the Measuring Set - End Gauge:VW 385/33 is precisely installed and free of oil.
The Measuring Set - End Gauge :VW 385/33 must be flush on the pinion head -arrow- and may not be tilted in the clutch housing.

-- Remove the Measuring Set - Adjustable Master Gauge:VW 385/30 and insert the Measuring Set - Measuring Bar:VW 385/1 in the transmission housing.

The Measuring Set - Extension Pin - 9.3mm:VW 385/15 must not touch the magnet -arrow- of the Magnetic Plate when turning the Universal Mandrel.

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Dial gauge faces final drive cover.
The right flange shaft seal is not removed from the final drive cover.
O-ring is inserted in final drive cover.

-- Position the final drive cover -1- and tighten the four bolts -2- to the tightening specification.

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-- Using an adjustable ring, pull the Measuring Set - Centering Plate:T40337 out far enough so that the Universal Mandrel can only just be turned by hand.

-- Turn the Universal Mandrel until the dial gauge tip touches the Magnetic Plate on the pinion head and indicates the maximum run-out (return point).

Measured value in the following example: = 0.08 mm (red range)

Check one more time after removing the Universal Mandrel if the dial gauge, with the 2 mm pre-tension, is at "0" with the Measuring Set - Adjustable Master Gauge:VW 385/30 installed.

Determining thickness of the 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 to it.

Formula:

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

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

Example:
	Installed shim "S₃ *"	1.05 mm
-	Determined value (red numbered area)	0.08 mm
=	Shim thickness "S ₃ "	0.97 mm

-- Determine the shim according to the table. Refer to the appropriate Electronic Parts Information for the part number.