Measuring backlash: 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.

Drive pinion housing with shaft bevel gear and S ₃ installed

Head bevel gear / input shaft with S ₁^* is installed on side of large cover, S ₂^* is installed on side of small cover.

Fig 1: Measuring Backlash Using Special Tools

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Assemble measuring tools.

Dimension "a" = 43.5 mm
Screw in adjustable measuring lever VW 388 so that dial gauge extension stands at right angle to measuring surface

Twist head bevel gear/input shaft up to stop. Shaft bevel gear must stand still while doing this. Position dial gauge, turn back head bevel gear/input shaft and read backlash. Note value.
Loosen clamping screw of roll pin and repeat three more times after turning head bevel gear/input shaft an additional 90 °. Add the four measured values and calculate mean backlash.

Calculating mean backlash