Pinion, Adjusting
Special tools and workshop equipment required
- Measuring Set - Extension Pin - 9.3mm : VW 385/15
- Measuring Set - Adjustable Master Gauge : VW385/30
- Measuring Set - Adjustable Master Gauge :VW 385/30
- Magnetic Plate
- Measuring Set - End Gauge : VW 385/33
- Transmission Holder :T40407
- Hot Air Gun
- Dial Indicator :VAS 6080A
- Universal Mandrel
- Measuring Set - Measuring Bar : VW 385/1
- Universal Mandrels
- Centering Plate :T40337
Pre-work
-- Secure transmission housing to the Gearbox Support :T40207 . The transmission housing be vertical to do so.
-- Remove the differential. Refer to Differential, Removing and Installing .
-- 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 .
Thickness of temporary shims S3 and S4 *, determining
The previous (removed) shims S3 and S4 are temporarily used as the initial measurement. They are designated as S3 * and S4 * in the following. After adjusting the dimension R, these are replaced by the final shim SR , S 4 *.
-- 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).
-- Insert the old shim S 3 * -1- (in the 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.
Determine the temporary shim S4 * -2- as follows:
Formula: S4 * = 2.54 mm - S3 *
| Example: | ||
|---|---|---|
| Constant value | 2.54 mm | |
| - | Thickness of the old shim S3 * | 1.05 mm |
| = | Thickness of the temporary shim S4 | 1.49 mm |
-- Place the temporary shim S4 * -2- on the double angular contact ball bearing.
Conditions
- 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.
Dimension R, adjusting
The dimension R is adjusted to determine the final shim thickness of the S3 and S4 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:
- 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:
- Measuring Set - Extension Pin - 9.3mm 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 drivetrains 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-.
Conditions
- 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.
Conditions
- The dial gauge faces the final drive cover
- The right flange shaft seal is not removed from the final drive cover
- The O-ring is inserted in final drive cover
-- Position the final drive cover -1- and tighten the four bolts -2- to the tightening specification.
-- 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 head of the pinion and indicates the maximum runout (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.
S3 Shim, Determining Thickness
- If measured in red numbered area, measured value must be subtracted.
- If measured in black numbered area, measured value must be added to it.
-- Calculation:
- S3 = S3 * + measured value (measured value in the black numbered area)
- S3 = S3 *- measured value (measured value in the 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 Electronic Parts Information (ETKA) for the part number.
| Available shims (mm) | ||||
|---|---|---|---|---|
| 0.45 | 0.81 | 1.17 | 1.53 | 1.89 |
| 0.49 | 0.85 | 1.21 | 1.57 | 1.93 |
| 0.53 | 0.89 | 1.25 | 1.61 | 1.97 |
| 0.57 | 0.93 | 1.29 | 1.65 | 2.01 |
| 0.61 | 0.97 | 1.33 | 1.69 | 2.05 |
| 0.65 | 1.01 | 1.37 | 1.73 | 2.09 |
| 0.69 | 1.05 | 1.41 | 1.77 | 2.13 |
| 0.73 | 1.09 | 1.45 | 1.81 | |
| 0.77 | 1.13 | 1.49 | 1.85 | |
-- Remove the pinion with the old shims "S 3 *" and "S 4 *". Refer to Pinion, Removing and Installing .
-- Warm the transmission housing with the Hot Air Blower in the area of the bearing seat -arrows- to approximately 100 °C (212 °F).
-- If necessary, slightly cool the double angular contact ball bearing on the pinion for example with commercially available cooling spray.
-- Insert the determined shim S 3 * -1- (in the example 0.97 mm) in the transmission housing.
-- Then insert the pinion -3- quickly without tilting all the way in the transmission housing.
Shim Thickness "S4 ," Selecting
-- Formula: S4 = 2.54 mm - S3
| Example: | ||
|---|---|---|
| Constant value | 2.54 mm | |
| - | Shim thickness S3 | 0.97 mm |
| = | Thickness of the Shim S4 | 1.57 mm |
-- Place the determined shim S 4 -2- (in the example 1.57 mm) on the double angular contact ball bearing.
-- Install the circlip -1- in the transmission housing groove all around.
Conditions
- Installation position of the circlip -1- : the bevel -arrow- points upward and the flat side points to the double angular contact ball bearing.
Performing the measurement check, checking dimension R
-- Install pinion with measured shims S3 and S4 .
-- Install the Universal Mandrel and perform measurement check.
-- Read out the measured value.
- If shims were determined correctly, dimension R must have a clearance of ± 0.05 mm.
-- After removing the universal mandrel, check again whether the dial gauge stands at "0" with 2 mm pre-load when adjustable master gauge is attached.