Final Assembly of Transaxle
- To measure end play between final drive housing and transmission, place straightedge on transmission attaching face of final drive housing. Using depth gauge, measure distance from top surface of straightedge down to edge of pinion shaft oil seal sleeve.
- Measure distance from top surface of straightedge to face of final drive housing. Subtract straightedge-to-face distance from straightedge-to-oil seal sleeve distance. Result is measurement "A". See Fig 1 . Note result for future reference.
- With new gasket on transmission separation plate, position straightedge on transmission case. Measure distance from top surface of straightedge down to gasket surface.
- Measure distance from top surface of straightedge down to shim surface on shoulder of reverse planetary gear set ring gear. Subtract straightedge-to-shoulder measurement from straightedge-to-gasket measurement. Result is measurement "B". See Figure . Note and record measurement "B".
- Subtract measurement "B" (obtained in step 4)) from measurement "A" (obtained in step 2)). Result is end play (without shims) between final drive and transmission.
- Use END PLAY SHIM SELECTION
table to select proper end play shim(s) to use. Use minimum number of shims possible.END PLAY SHIM SELECTION
End Play Correct Shim In. (mm) In. (mm) .009-.003 (.23-.84) None .033-.049 (.85-1.24) .016 (.4) .049-.065 (1.25-1.64) .032 (.8) .065-.080 (1,65-2.04) .048 (1.2) .081-.096 (2.05-2.44) .064 (1.6) .096-.112 (2.45-2.84) .080 (2.0) .112-.128 (2.85-3.24) .096 (2.4) .128-.143 (3.25-3.64) .112 (2.8) .144-.153 (3.65-3.88) .128 (3.2) - Transmission-to-final drive end play adjusting shims are available in 2 thicknesses: .016" (.4 mm) and .047" (1.2 mm). Combine shim thicknesses to obtain total thickness required. Install selected end play adjusting shim(s) on top of pinion shaft oil seal sleeve in final drive case.
- Install "O" ring into groove around final drive housing. Install turbine shaft and pump shaft fully into pinion shaft of final drive. End of turbine shaft with piston rings must be toward transmission with rings inside pinion shaft.
- Turbine shaft used in 087 models is 16.71" (424.5 mm) with 20.2" (513 mm) pump shaft. Turbine shaft used in 089 models is 15.82" (401.7 mm) with 19.32" (490.6 mm) pump shaft.
- Join final drive case to transmission case. Install, and tighten, nuts attaching drive to transmission case. Drive governor needle bearing into final drive case until it bottoms, using Driver (VW 545). Using driver and Collar (VW 545/2), install governor oil seal with lip facing out toward governor. Place new "O" rings onto governor cover and speedometer driven gear assembly.
Transmission-to-final drive end play limits end play of reverse planetary ring gear.
- Install governor, cover, and speedometer driven gear into case. Install transaxle oil cooler. Ensure pump shaft is fully inserted into pump splines before installing converter. Install torque converter onto stator support to complete assembly. Ensure torque converter engages splines on pump shaft.