Determining thickness of adjustment shim S : Notes

WARNING: This page is about a different car, the 2004 Volkswagen R32. However, it is still accessible from the selected car via links, so may be relevant.

Seal for output flange removed

Press outer race of large tapered roller bearing for shaft bevel gear into drive pinion housing using pressure piece 3253/7 .
Press outer race of small tapered roller bearing for shaft bevel gear into drive pinion housing using pressure piece VW 472/1 .
Place inner race of large tapered roller bearing on shaft bevel gear.

Fig 1: Pressing Inner Race Of Small Tapered Roller Bearing On Output Flange Using Special Tools

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Press inner race of small tapered roller bearing on output flange.
Insert shaft bevel gear.
Insert thickest adjustment shim "S ₄ " = 2.5 mm (allocate according to Electronic Parts Catalog (ETKA) on shaft bevel gear.
Insert output flange with inner race and install hex nut.

Screw in hex bolt - A - M10 as counter bearing.

Socket wrench insert - B -

Fig 2: Identifying Socket Wrench Insert & Hex Bolt

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Protective pads - C -

Tighten hex nut to 50 Nm, screw back or unscrew completely hex bolt - A -.
Press shaft bevel gear in direction of outer race for large tapered roller bearing and turn eight times while doing so.

Fig 3: Moving Shaft Bevel Gear Up And Down

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Install dial gauge and set to "0" with 1 mm pre-load.
Move shaft bevel gear up and down (in direction of - arrow - ).
Check play on dial gauge and determine adjustment shim S ₄ .