Transmission Housing Shims, Determining: Procedure:

First it is determined how >>high<< the shafts are in the clutch housing.

Then the >>depth<< of the transmission housing is measured.

Both >>heights<< are subtracted from each other.

The bearing pre-load is given for each shaft in the procedure. For this reason follow the following procedures.

Because each shaft has a different pretension, follow the procedures exactly and pay attention to the different pretensions.

In this way the correct shim can be determined.

• Do not insert the differential yet. The output shaft 1, 2 and 3 remain in their bearings.

Follow the instructions:

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-- Measure the height of their Measuring Tool - Measuring Rod :T10425/3  .

-- Zero out the Digital Depth Gauge w/Measuring Hook - 200mm :VAS 6619  on the collar for the bearing shells.

-- Measure the hight of the drift.

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Note the height of the drift to be used. The height is noted in the following calculations. Name the hight of the drift D = ? mm.

Example: "D" = 237.01 mm

It begins with the output shaft 1

-- Position the bearing shell, measuring rod and headpiece.

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-- Turn the outer driveshaft. While turning push the measuring rod by hand downward with force.

This places the output shaft 1 correctly in its bearing seat.

-- Remove the Measuring Tool - Headpiece :T10425/5  from the drift and move to the side.

-- Zero out the Digital Depth Gauge - 300mm :VAS 6594  on the Measuring Tool :T10425  .

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-- Measure the height from the surface of the Measuring Tool :T10425  to the flange surface of the clutch housing.

Always measure near the respective bearing area.

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-- Name this value "a1".

-- Note the value.

Example:

"a1" = 264.97 mm

-- Measure the height from the drift to the Measuring Tool :T10425  .

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-- Name this value "b1".

Example:

"b1" = 170.83 mm

It is calculated:

"a1" + "b1" minus the drift height "D" = output shaft 1 height

Example:

264.97 mm + 170.83 mm - 237.01 mm = 198.79 mm

-- Then record the calculated value for the "height of the output shaft 1".

Example: "output shaft 1 height" = 198.79 mm

This value is needed later.

Continued with the output shaft 2.

-- Position the bearing shell, measuring rod and headpiece to be installed.

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-- Turn the outer driveshaft. While turning push the measuring rod by hand downward with force.

This places the output shaft 2 correctly in its bearing seat.

-- Remove the Measuring Tool - Headpiece :T10425/5  from the drift and move to the side.

-- Zero out the Digital Depth Gauge - 300mm :VAS 6594  on the Measuring Tool :T10425  .

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-- Measure the height from the surface of the Measuring Tool :T10425  to the flange surface of the clutch housing.

Always measure near the respective bearing area.

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-- Name this value "a2".

-- Note the value.

Example:

"a2" = 264.93 mm

-- Measure the height from the drift to the Measuring Tool :T10425  .

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-- Name this value "b2".

Example:

"b2" = 145.97 mm

It is calculated:

"a2" + "b2" minus drift height "D" = output shaft 2 height

Example:

264.93 mm + 145.97 mm - 237.01 mm = 173.89 mm

-- Then record the calculated value for the "height of the output shaft 2".

Example: "output shaft 2 height" = 173.89 mm

This value is needed later.

Continued with the output shaft 3.

-- Position the bearing shell, measuring rod and headpiece to be installed.

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-- Turn the outer driveshaft. While turning push the measuring rod by hand downward with force.

This places the output shaft 3 correctly in its bearing seat.

-- Remove the Measuring Tool - Headpiece :T10425/5  from the drift and move to the side.

-- Zero out the Digital Depth Gauge - 300mm :VAS 6594  on the Measuring Tool :T10425  .

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-- Measure the height from the surface of the Measuring Tool :T10425  to the flange surface of the clutch housing.

Always measure near the respective bearing area.

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-- Name this value "a3".

-- Note the value.

Example:

"a3" = 264.92 mm

-- Measure the height from the drift to the Measuring Tool :T10425  .

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-- Name this value "b3".

-- Note the value.

Example:

"b3" = 92.57 mm

It is calculated:

"a3" + "b3" minus drift height "D" = output shaft 3 height

Example:

264.92 mm + 92.57 mm - 237.01 mm = 120.48 mm

-- Then record the calculated value for the "height of the output shaft 3".

Example: "output shaft 3 height" = 120.48 mm

This value is needed later.

1. Move the Measuring Tool :T10425  to the side.
2. Remove the output shafts 1, 2 and 3.
3. Install the differential.
4. Position the Measuring Tool :T10425  on the clutch housing again.
5. Position the Measuring Tool - Measuring Rod :T10425/3  with Measuring Tool - Adapter :T10425/4  on the Measuring Tool :T10425  .

-- Zero out the Digital Depth Gauge w/Measuring Hook - 200mm :VAS 6619  on the bearing shell collar.

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Check which collar is for the bearing shell.

-- Measure the height of the Measuring Tool - Measuring Rod :T10425/3  with the Measuring Tool - Adapter :T10425/4 

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Note the height of the drift with adapter to be used. The height is noted in the following calculations. Name the hight of the drift E = ? mm.

Example: E= 263.00 mm

Always insert and remove the differential using the Lock Carrier Support Tool :3411  .

-- Position the bearing shell, adapter, measuring rod and headpiece.

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-- Turn the differential. While turning push the measuring rod by hand downward with force.

This places the differential correctly in its bearing seat.

-- Zero out the Digital Depth Gauge - 300mm :VAS 6594  on the Measuring Tool :T10425  .

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-- Measure the height from the surface of the Measuring Tool :T10425  to the flange surface of the clutch housing.

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-- Note the value.

-- Name this value "a4_a ".

To avoid inaccuracy when measuring, measure on two additional locations.

Name these values "a4_b " and "a4_c ".

-- Determine the average from the three measured values.

Formula: a4 + a4 + a43 = a4

Example:

• "a4" = 264.96 mm + 264.98 mm + 264.94 mm3 = 264.96 mm
• Result dimension "a4" = 264.96 mm

-- Measure the height from the drift to the Measuring Tool :T10425  .

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-- Name this value "b4".

-- Note the value.

Example:

"b4" = 13.21 mm

It is calculated:

"a4" + "b4" minus the hight of the drift "E" = hight of the differential

Example:

264.96 mm + 13.21 mm - 263.00 mm = 15.17 mm

-- Note the calculated value for the "differential height".

Example: "differential height" = 15.17 mm

This value is needed later.

This measurement determines how >>high<< the shaft is in the clutch housing.

The >>depth<< of the transmission housing is measured in later procedures.

Please follow the instructions:

• The clutch housing sealing surface is clean, level and not >>destroyed or damaged<<.

-- Secure the transmission housing with the Support Bridge :T10323  in the support bridge.

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-- Install the alignment sleeves in the transmission housing.

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-- Place the measuring tool on the transmission housing.

-- Place the Measuring Tool :T10425  on the alignment sleeves.

Start again with the measurement for the output shaft 1:

The bearing pre-load for this output shaft 1 is: 0.25 mm.

-- Zero out the Digital Depth Gauge - 300mm :VAS 6594  on the flange surface.

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-- Measure the seating of the bearing shell in the transmission housing.

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-- Then record the calculated value for the "output shaft 1 depth".

Example: "output shaft 1 depth" = 199.89 mm

Now the value for the "output shaft 1 height" is required.

-- Perform the following calculation: "output shaft 1 depth" minus the "output shaft 1 height" + bearing pre-load 0.25 mm = determined shim thickness.

Example: "output shaft 1 height" = 198.79 mm

Example: "output shaft 1 depth" = 199.89 mm

199.89 mm minus 198.79 mm + 0.25 mm = 1.35 mm

-- Note the calculated value for the "determined shim thickness".

Example: "determined shim thickness" = 1.35 mm

Determined Shim Thickness In The Output Shaft 1 Transmission Housing		Shim To Be Installed In Millimeter
from	through
0.625	0.674	0.65
0.675	0.724	0.70
0.725	0.774	0.75
0775	0.824	0.80
0.825	0.874	0.85
0.875	0.924	0.90
0.925	0.974	0.95
0.975	1.024	1.00
1.025	1.074	1.05
1.075	1.124	1.10
1.125	1.174	1.15
1.175	1.224	1.20
1.225	1.274	1.25
1.275	1.324	1.30
1.325	1.374	1.35
1.375	1.424	1.40
1.425	1.474	1.45
1.475	1.524	1.50
1.525	1.574	1.55
1.575	1.624	1.60
1.625	1.674	1.65
1.675	1.724	1.70
1.725	1.774	1.75
1.775	1.824	1.80
1.825	1.874	1.85

-- Measure the shim from the delivered washers, which are are needed.

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Additionally with the measurements for the output shaft 2:

The bearing pre-load for this output shaft 2 is: 0.30 mm.

-- Zero out the Digital Depth Gauge - 300mm :VAS 6594  on the flange surface.

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-- Measure the seating of the bearing shell in the transmission housing.

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-- Then record the calculated value for the "depth of the output shaft 2".

Example: "output shaft 2 depth" = 175.18 mm

Now the value for the "output shaft 2 height" is required.

-- Perform the following calculation: "output shaft 2 depth" minus the "output shaft 2 height" + bearing pre-load 0.30 mm = determined shim thickness.

Example: "output shaft 2 height" = 173.89 mm

Example: "output shaft 2 depth" = 175.18 mm

175.18 mm minus 173.89 mm + 0.30 mm= 1.59 mm

-- Note the calculated value for the "determined shim thickness".

Example: "determined shim thickness" = 1.59 mm

Determined Shim Thickness In The Output Shaft 2 Transmission Housing		Shim To Be Installed In Millimeter
from	through
0.625	0.674	0.65
0.675	0.724	0.70
0.725	0.774	0.75
0775	0.824	0.80
0.825	0.874	0.85
0.875	0.924	0.90
0.925	0.974	0.95
0.975	1.024	1.00
1.025	1.074	1.05
1.075	1.124	1.10
1.125	1.174	1.15
1.175	1.224	1.20
1.225	1.274	1.25
1.275	1.324	1.30
1.325	1.374	1.35
1.375	1.424	1.40
1.425	1.474	1.45
1.475	1.524	1.50
1.525	1.574	1.55
1.575	1.624	1.60
1.625	1.674	1.65
1.675	1.724	1.70
1.725	1.774	1.75
1.775	1.824	1.80
1.825	1.874	1.85

-- Measure the shim from the delivered washers, which are are needed.

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Additionally with the measurements for the output shaft 3:

The bearing pre-load for this output shaft 3 is: 0.15 mm.

-- Zero out the Digital Depth Gauge - 300mm :VAS 6594  on the flange surface.

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-- Measure the seating of the bearing shell in the transmission housing.

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-- Then record the calculated value for the "depth of the output shaft 3".

Example: "output shaft 3 depth" = 121.40 mm

Now the value for the "output shaft 3 height" is required.

-- Perform the following calculation: "output shaft 3 depth" minus the "output shaft 3 height" + bearing pre-load 0.15 mm = determined shim thickness.

Example: "output shaft 3 height" = 120.48 mm

Example: "output shaft 3 depth" = 121.40 mm

121.40 mm minus 120.48 mm + 0.15 mm = 1.07 mm

-- Note the calculated value for the "determined shim thickness".

Example: "determined shim thickness" = 1.07 mm

Determined Shim Thickness In The Output Shaft 3 Transmission Housing		Shim To Be Installed In Millimeter
from	through
0.625	0.674	0.65
0.675	0.724	0.70
0.725	0.774	0.75
0775	0.824	0.80
0.825	0.874	0.85
0.875	0.924	0.90
0.925	0.974	0.95
0.975	1.024	1.00
1.025	1.074	1.05
1.075	1.124	1.10
1.125	1.174	1.15
1.175	1.224	1.20
1.225	1.274	1.25
1.275	1.324	1.30
1.325	1.374	1.35
1.375	1.424	1.40
1.425	1.474	1.45
1.475	1.524	1.50
1.525	1.574	1.55
1.575	1.624	1.60
1.625	1.674	1.65
1.675	1.724	1.70

-- Measure the shim from the delivered washers, which are are needed.

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Additionally with the measurements for the differential:

The bearing pre-load for the differential is: 0.20 mm.

Remove the Measuring Tool :T10425 

Determine the depth of the differential:

To calculate the depth of the differential as close as possible, three measuring points are measured on the bearing seat. The measurement results are >>determined<<.

-- Place the second straight edge Ruler (2 pc.) :T40100  on the flange surface.

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-- Zero out the Digital Depth Gauge - 300mm :VAS 6594  on the flange surface.

The measurement is repeated on two additional points -arrows- on the flange surface to increase the measuring exactness.

-- Measure three times on the bearing seat -arrows-.

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Carefully measure.

-- Note the average of these three measurements.

Example: 16.28 mm + 16.27 mm + 16.29 mm3 = 16.28 mm

Example: first measurement result = 16.28 mm

The two measurements follow:

-- Place both straight edges Ruler (2 pc.) :T40100  on the flange surfaces.

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-- Zero out the Digital Depth Gauge - 300mm :VAS 6594  on the flange surface.

-- Measure three times on the bearing seat -arrows-.

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Carefully measure.

-- Note the average of these three measurements.

Example: 16.25 mm + 16.24 mm + 16.27 mm3 = 16.25 mm

Example: second measurement result = 16.25 mm

The three measurements follow:

-- Place both straight edges Ruler (2 pc.) :T40100  on the flange surfaces.

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-- Zero out the Digital Depth Gauge - 300mm :VAS 6594  on the flange surface.

-- Measure three times on the bearing seat -arrows-.

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Carefully measure.

-- Note the average of these three measurements.

Example: 16.24 mm + 16.24 mm + 16.21 mm3 = 16.23 mm

Example: third measurement result = 16.23 mm

Calculate the average from all three measurement results.

Example: 16.28 mm + 16.25 mm + 16.23 mm3 = 16.253 mm

-- Round mathematically correctly: = 16.25

-- Then record the calculated value for the "differential depth".

Example: "differential depth" = 16.25 mm

Now the value for the "differential height" is required.

-- Perform the following calculation: "differential depth" minus the "differential height" + bearing pre-load 0.20 mm = determined shim thickness.

Example: "differential height" = 15.17 mm

Example: "differential depth" = 16.25 mm

16.25 mm minus 15.17 mm + 0.20 mm = 1.28 mm

-- Note the calculated value for the "determined shim thickness".

Example: "determined shim thickness" = 1.28 mm

Determined Shim Thickness Of The Differential		Shim To Be Installed In Millimeter
from	through
0.625	0.674	0.65
0.675	0.724	0.70
0.725	0.774	0.75
0775	0.824	0.80
0.825	0.874	0.85
0.875	0.924	0.90
0.925	0.974	0.95
0.975	1.024	1.00
1.025	1.074	1.05
1.075	1.124	1.10
1.125	1.174	1.15
1.175	1.224	1.20
1.225	1.274	1.25
1.275	1.324	1.30
1.325	1.374	1.35
1.375	1.424	1.40

-- Measure the shim from the delivered washers, which are are needed.

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-- Install the shims and bearing shells from the transmission housing. Refer to TRANSMISSION HOUSING, SERVICING .

-- Assembling the transmission. Refer to TRANSMISSION, ASSEMBLING .