Pinion Depth

NOTE: Pinion bearing preload must be correctly adjusted before adjusting pinion depth; see DRIVE PINION SHAFT REASSEMBLY.

Pinion depth is checked using Universal Measuring Bar (VW385/1). Screw in right adjusting ring until ring outer surface is flush with transaxle case. Install Magnetic Measuring Plate (VW385/17) on end of pinion gear.
Set dimension "A" to 2.95" (75 mm) by sliding setting ring to correct distance from center of measuring bar. See Fig 1 . Slide 2 Centering Discs (VW385/4) onto measuring bar until they contact setting rings.
Attach measuring Pin (VW385/14) with Extension (VW385/16) to gauge pin hole in center of measuring bar. Attach a dial indicator to end of bar.
Position measuring bar in transaxle case. Install left adjusting ring in case until outer edge is flush with case. Loosen second setting ring and slide out with centering ring until measuring bar can just barely be turned by hand. Tighten screw in setting ring.

Fig 1: Installation of Pinion Depth Checking Tools
Courtesy of VOLKSWAGEN UNITED STATES, INC.
Using setting Block (VW385/1), zero dial indicator. Turn measuring bar by hand until measuring pin extension is against measuring plate on pinion gear. Turn bar back and forth over center. Record maximum reading on dial indicator. Read deviation number stamped on ring gear.
NOTE: Although production gears are no longer marked with deviation "r" in .01 mm readings, replacement gear sets will have this number. Shims (S3) must be installed between pinion bearing shoulder and gear case to correct axial placement of pinion gear for proper meshing with ring gear teeth.
To find correct shim thickness (S3), add dial indicator deflection to "r" number stamped on gear. Shims are available in thicknesses of .15 mm, .20 mm, .30 mm, .40 mm, .50 mm, and .60 mm. Install shim or combination of shims required to obtain correct pinion depth.