Measuring And Adjusting The Output Shaft (Total Shim Thickness S3)

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Get ready to take measurements.

Fig 1: Identifying Output Shaft Shim Locations
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
1. 1.1. Fit spacer sleeve and fixed gear wheel for 3rd gear on the output shaft. The narrow collar is facing the tensioning plate.
2. 1.2. Insert 4th gear.
3. 1.3. Block the drive shaft using special tool Retaining Device 9253 .
4. 1.4. Fit special tool Assembly Sleeve 9263 -A- and shims (Part No. 950.302.296.03) -B- on the output shaft.
  
  Fig 2: Identifying Assembly Sleeve On Output Shaft
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
5. 1.5. Screw collar nut onto the output shaft. → Tightening torque: 300 Nm (222 ft. lb.)
6. 1.6. Adjust setting ring on special tool Measuring Mandrel VW 385/1 to dimension a (approx. 65 mm).
  
  Fig 3: Identifying Setting Ring Adjustment On Measuring Mandrel
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
7. 1.7. Fit measuring mandrel as shown in the illustration.
  
  Fig 4: Identifying Measuring Mandrel
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Take the measurement.
1. 2.1. Read off installation dimension E from the crown wheel.
  1. Adjustment dimension E
  2. Backlash F
  3. Pairing number
  Example:
  
  E = 70.20 mm
  
  Fig 5: Identifying Crown Wheel Installation Dimension
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
2. 2.2. Set the installation dimension E on special tool Universal Master Gauge VW 385/30 and set the dial gauge to 0 with 2 mm pretension.
3. 2.3. Place special tool Adjusting Shim 9281 on the pinion head of the output shaft.
4. 2.4. Fit measuring mandrel as shown in the illustration.
  
  Fig 6: Identifying Position Of Measuring Mandrel
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
5. 2.5. Fit side transmission cover without an O-ring and pull downwards with four screws. Do not tap down.
  → Tightening torque: 25 Nm (19 ft. lb.)
6. 2.6. Press taper roller bearing over the spindle into the bearing shells using the centering screw. It should still be possible to turn the measuring mandrel with your hand.
7. 2.7. Turn the measuring mandrel carefully back and forth until the return point on the dial gauge is reached. At this point, the dial gauge extension is positioned exactly at a right angle to the front face of the pinion head.
Make adjustments.

Fig 7: Identifying Output Shaft Shim Locations
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
1. 3.1. Read off the deviation from the specified adjustment value -E- . If the deviation is greater than 0.04 mm, an adjustment is required.
  Example:
  
  0.10 mm
2. 3.2. To achieve the required adjustment dimension -E- , the adjusting shim S3 must be adjusted by the measured value.
  Example:
  
  New shim thickness S3 = 0.90 mm
3. 3.3. To adjust the altered shim -S3- , shim -S4- must be altered in the opposite direction by the determined value.
  Example:
  
  S4 = 1.15 mm (increase of 0.10 mm)
4. 3.4. Since the thickness of shim S4 is identical to the thickness of shim S5, shim S5 must be altered by the same value as shim S4.
  Example:
  
  S5 = S4 = 1.15 mm
5. 3.5. When the shims -S3, S4 and S5- have been adjusted as required and inserted, the adjustment dimension -E- must be checked again.