Adjusting Pinion Gear

NOTE:
^ Before adjusting the pinion, adjust the ring gear (total shim thickness, "Stotal, " S1 + S2, determining). Adjusting Ring Gear
^ Adjustment of the pinion is only required if the ring gear and pinion set, the tapered roller bearing for the pinion or the final drive housing has to be replaced. Adjustment Summary
^ Do not additionally treat new tapered roller bearings to measure turning torque. For this purpose, the bearings are already pre-treated with a special oil.





- Pull large outer race for tapered roller bearing into housing without shim.

NOTE: On the pressure piece 3253/4, the inscription "top" faces the nut on the pulling device.





- Press outer race of small tapered roller bearing into housing.

NOTE:
^ Lubricate the bearing outer race well and install using VW 295 and 30-205.
^ The illustration shows the incorrect special tool. Installation ring tool No. 10-9 must be used instead of VW 204b.





- Install pinion without spacer sleeve.
- Heat inner race for tapered roller bearing to 100°C (212°F) and install on pinion.

NOTE:
^ Do not additionally treat new tapered roller bearings to measure turning torque. For this purpose, the bearings are already pre-treated with a special oil.
^ Only install the spacer sleeve during subsequent turning torque adjustment (with shim "S3" already determined).





- Install drive shaft flange and tighten pinion nut until correct turning torque is achieved.
New bearings: 200-250 Ncm (18-22 inch lb)
Used bearings: 30-60 Ncm (3-5 inch lb)





- Measuring turning torque
A -Torque gauge, standard commercial; 0-600 Ncm (0-53 inch lb)
B - Socket, 36 mm





- Set adjusting ring of universal measuring bar VW 385/1 to dimension "a" = 60 mm (2.36 in).
- Set movable adjusting ring to dimension "b" = 55 mm (2.17 inch).





- Assemble universal measuring bar according to illustration.
Gauge extension VW 385/15 = 9.3 mm long
- Set master gauge VW 385/30 to Ro = 57.5 mm.
- Set dial indicator to zero with 2 mm pre-load.

NOTE: Before measuring, turn the pinion at least 5 turns in both directions, so the tapered roller bearing can settle. Otherwise, the measurement will be incorrect





- Place end gauge VW 385/33 on pinion head.
- Remove master gauge VW 385/30 and install measuring bar in housing.
Centering washer for VW 385/3 faces final drive cover.
- Install final drive cover and tighten 4 bolts.
- Using sliding adjusting ring, turn 2nd centering washer far enough outward so that measuring bar can still be just turned by hand.





- Measure dimension "e."
- Turn measuring bar until dial indicator on end gauge on piston head runs out and max. runout (reversing point) is displayed.
Measurement is dimension "e" (red scale range)
Example: 1.60 mm

NOTE: Dimension "e" is necessary for determining the thickness of shim "S3. "

- After removing the universal measuring bar:
Check again to make sure dial indicator is on "0" with 2 mm pre-load, with gauge VW 385/30 installed; repeat measurement if necessary.