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Adjusting the output shaft (transmission G 86)

Readjustment of the output shaft in accordance with the instructions below is necessary only if the drive set is replaced. If other parts which also influence the output shaft position are changed, make the adjustment via the previously determined installation position. See DETERMINING THE INSTALLATION POSITION OF THE OUTPUT SHAFT (ACTUAL MEASUREMENT)  .

  1. Total disc thickness Stot. (S 3 + S 4). 

    Preload of the tapered roller bearings/output shaft

    • Install the outer races for the tapered roller bearings without adjusting shims in the transmission housing or in the transmission case cover. Always use rubber washer and pressure plate for measuring the disc thickness and for measuring the S4 disc. See Figure .
      NOTE: Pressure plates of various thicknesses can be installed.
    • Fit the inner races for the tapered roller bearings. See DISASSEMBLING AND ASSEMBLING THE OUTPUT SHAFT . Secure the lower tapered roller bearing (arrow). See Fig 1 .
      Fig 1: Fitting Inner Races On Output Shaft
      G03102827Courtesy of PORSCHE OF NORTH AMERICA, INC.
    • Place the transmission housing on the workbench.
    • Put the output shaft into the transmission housing.
    • Put on the transmission case cover and tighten the screws with 25 Nm (19 ft.lb.).
    • Turn the gears so that the transmission case cover faces downwards.
    • Using the special tool VW 296, press on the output shaft head until the tapered roller bearing outer race fits closely in the transmission case cover.
      Fig 2: Pressing Output Shaft Head Using Special Tool
      G03102828Courtesy of PORSCHE OF NORTH AMERICA, INC.
    • Turn the output shaft manually until the tapered roller bearing settles.
    • Assemble the measuring tool and set the dial gauge with 1 mm preload to "0".
      Fig 3: Setting Dial Gauge On The Output Shaft Head
      G03102829Courtesy of PORSCHE OF NORTH AMERICA, INC.
    • Turn the transmission through 180° so that the transmission case cover faces upwards.
      Fig 4: Turning Transmission Through 180° So That The Transmission Case Cover Faces Upwards
      G03102830Courtesy of PORSCHE OF NORTH AMERICA, INC.
    • Turn the output shaft manually so that the tapered roller bearing settles.
    • Read off the measurement result on the dial gauge (for example, 1.45 mm).
    • Measure the total disc thickness "Stot." (S 3 + S 4). See Figure .
    THICKNESS MEASUREMENT

    Stot. = Measurement result
      + pressing
    Pressing: (constant value)   0.15 mm
    Measurement result + 1.45 mm
    Stot.   1.60 mm
  2. Checking the preload of the tapered roller bearings for the output shaft. 
    • Install the measured total disc thickness (example 1.60 mm) behind the tapered roller bearing outer race of the transmission case cover (S4 side).
    • Put on the transmission case cover and tighten the fastening screws with 25 Nm (19 ft.lb).
    • Turn the output shaft a few times so that the tapered roller bearings settle.
      NOTE: Screw the screw into the shaft head in order to turn the output shaft.
    • Fit the measuring tools.
      Fig 5: Fitting Measuring Tools To Transmission Housing
      G03102831Courtesy of PORSCHE OF NORTH AMERICA, INC.
    • Set the dial gauge (3 mm measurement range) with 1 mm preload to "0".
    • Undo the screws of the transmission case cover and read off the dial gauge.
      NOTE:
      • The dial gauge may now display a value of 0.08 mm to 0.15 mm with correctly selected adjusting shims.
  3. Determining the dimension "e" 
    • Allow the measured total disc thickness (in the example 1.60 mm) into the tapered roller bearing outer race in the transmission case cover (S4 side).
    • Refit the transmission case cover.
    • Turn the output shaft a few times so that the tapered roller bearings settle.
    • Adjust the setting collar of the special tool VW 385/1 to the dimension "a" = 35 mm."
    • Adjust the movable setting collar to the dimension "b" = 65 mm.
      Fig 6: Adjusting Setting Collar
      G03102832Courtesy of PORSCHE OF NORTH AMERICA, INC.
    • Complete the universal measuring mandrel as shown in the illustration.
      Fig 7: Installing Universal Measuring Mandrel
      G03102833Courtesy of PORSCHE OF NORTH AMERICA, INC.
    • Set the master gauge, special tool 385/30, to the dimension R o = 59.65 mm and place on the measuring mandrel. Set the dial gauge (3 mm measurement range) with 1 mm preload to "0".
    • Place the end plate, special tool VW 385/33, onto the output shaft head.
      Fig 8: Placing End Plate And Special Tool Onto Output Shaft Head
      G03102834Courtesy of PORSCHE OF NORTH AMERICA, INC.
    • Remove the master gauge and insert the measuring mandrel with the dial gauge downwards into the housing.
    • Put on the cover for the final drive and secure it with 4 screws.
    • Pull out the 2nd centring disc via the movable setting collar far enough so that the measuring mandrel can still just be turned manually.
    • Measure dimension "e".

      Turn the measuring mandrel until the dial gauge tip touches the end plate on the output shaft head and displays the max. deflection (reversing point). The measured value is the dimension "e" (black number range).

      Example 0.46 mm

      Fig 9: Turning Measuring Mandrel
      G03102835Courtesy of PORSCHE OF NORTH AMERICA, INC.
    • Arrangement of the measuring tools for determining dimension "e".
    Fig 10: Identifying Measuring Tools Arrangement
    G03102836Courtesy of PORSCHE OF NORTH AMERICA, INC.
  4. Determining the thickness of the adjusting shim "S 3". 
    ADJUSTING SHIM THICKNESS SPECIFICATIONS (S3)

    S3 = e + r
    e = Measured value (max. deflection)
    r = Deviation (given in 1/100 mm on the crown wheel or is determined in the actual measurement)
    ADJUSTING SHIM (S3) THICKNESS CALCULATION - EXAMPLE

    Value "e" read off on the dial gauge   0.46 mm
    Deviation "r" written on the crown wheel + 0.18 mm
    Disc thickness "S3" = 0.64 mm

    Discs of 0.55 mm...1.05 mm thickness are available (0.05 mm increments). Different tolerances allow the required disc thickness to be measured exactly.

  5. Determining the thickness of the adjusting shim "S 4". 

    S4 = Stot. - S3

    Example 

    ADJUSTING SHIM (S4) THICKNESS CALCULATION - EXAMPLE

    Total disc thickness   1.60 mm
    Disc thickness "S3" - 0.64 mm
    Disc thickness "S4" = 0.96 mm
    NOTE:
    • Pressure plates of 14.8 mm or 15.3 mm can be installed.

    Discs of 0.45 mm...1.49 mm thickness are available (0.04 mm increments). Different tolerances allow the required disc thickness to be measured exactly.

  6. Performing a check measurement (checking dimension "r". 
    • Install the output shaft with the measured adjusting shims S3 and S4 and turn several times in both directions.
    • Insert a universal measuring mandrel (special tool) and carry out a check measurement.
      Fig 11: Inserting Universal Measuring Mandrel
      G03102837Courtesy of PORSCHE OF NORTH AMERICA, INC.
    • If the selected adjusting shims are the correct ones, the dial gauge must display the value of the written deviation "r" (in the example 0.18 mm) with a tolerance of +/- 0.04 mm when read off counterclockwise (red number range).
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