Pinion Gear

PINION, ADJUSTING
Adjustment of the pinion in accordance with the following instructions is only necessary if the ring and pinion gearset or the tapered roller bearing has been replaced. If the pinion bushing, spacer or pinion end cover are replaced, then it is only necessary to measure for shim S4.

Refer to the adjustment table found under General Information (Read First)

Determining Thickness Of Shims S3 And S4 (Stotal)
(Adjusting preload of pinion tapered roller bearing)





- Press on tapered roller bearing inner race with pinion bushing.





- Pull tapered roller bearing outer race with shim S3 (1.50 mm thickness) into transmission housing.





- Press tapered roller bearing outer race into pinion cover.





- Insert pinion, then install parking lock gear, output gear, shim S4 (arrow) and spacer.

S4 = 2.40 mm thickness (2 shims = 1.20 mm)

NOTE: Installation position of parking lock gear, output gear and spacers refer to Pinion Gear. Service and Repair





- Install pinion cover, insert tapered roller bearing inner race and nut (arrow) on pinion.





A in illustration = Torque wrench
B in illustration = Socket (41 mm)
- Tighten 4 bolts for pinion cover.
Tightening torque: 25 Nm (18 ft lb)
- Engage parking lock and temporarily tighten nut.
Tightening torque: 340 Nm (250 ft lb)
- Loosen hex-nut and re-tighten to 240 Nm (177 ft lb).





- Mount dial indicator holder VW387 on pinion cover.
- Place plate VW385/17 on pinion.
- Install and zero dial indicator.
- Move pinion up and down several times without turning, and note dial indicator gauge reading.

CAUTION: Turning the pinion will falsify the reading.

- The measured axial play and the specified bearing preload (0.25 mm, a constant) must be subtracted from the temporarily installed 2.40 mm shim S4.

Example:
Installed shim S4 - Measured play - Specified preload = Shim thickness required
2.40 mm - 0.95 mm - 0.25 mm = 1.20 mm


- Remove pinion cover, nut, and test shims.
- Install shim S4 (1.20 mm thick in example), refer to Ring Gear.
- Install cover again and tighten nut to 340 Nm (251 ft lb).
- Loosen and then tighten nut.
Tighten to: 240 Nm (177 ft lb)

Measuring Turning Torque





A in illustration = Socket, 41 mm
B in illustration = Torque gauge (0-600 Ncm (0-50 in. lb) range)

The turning torque for the new bearings must be 135-265Ncm (12-23 in. lb).

NOTE: With used bearings the turning torque measured before parts were disassembled must be attained.





- Set adjusting ring of measuring bar VW385/1.
Dimension -a- = 70 mm





- Assemble measuring bar as shown.
A in illustration = Dial indicator extension, 385/16, 12 mm
- Set master gauge VW385/30 to Ro = 59.2 mm.
- Zero dial indicator at 1 mm.





- Place universal bar (A in illustration) into housing and install VW385/33 end plate on pinion head.
- Install differential cover.
- With sliding ring, move second centering disc outward enough so that measuring bar has no lateral play but can still be turned by hand.





- Turn measuring bar until extension tip contacts end plate on pinion head and indicates maximum deflection (return point).
- The measured value is dimension e.
Red figures: under 1 mm measuring range
Black figures: over 1 mm measuring range
Example: 0.32 mm (red figure)

NOTE:
^ If the measured value is in the red figure range, dimension e must be added in following formula.
^ If measured value is in black figure range, dimension e must be subtracted.


Determining Thickness Of Shims S3 And S4 (Pinion Depth)

NOTE:
^ If the measured value is in the red figure range, DIMENSION "e" MUST BE ADDED in following formula.
^ If measured value is in black figure range, DIMENSION "e" MUST BE SUBTRACTED.
^ Dimension "e" = Reaing obtained (max. deflection)
^ DDimension "r" = Deviation (indicated on ring gear in 1/100 mm)

Determining Shim S3 Thickness

Example:
S3 = Installed shim + Reading obtained (max. deflection) - Deviation (indicated on ring gear in 1/100 mm)
1.50 mm + 0.32 mm - 0.26 mm = 1.56 mm


Determining Shim S4 Thickness

Example:
S4 = 120 mm + Reading obtained (max. deflection) - Deviation (indicated on ring gear in 1/100 mm)
1.20 mm + 0.32 mm - 0.26 mm = 1.26 mm

NOTE:
^ If a thicker S3 shim is required, S4 shim must also be thicker (by same amount).
^ If the S3 shim is thinner the S4 shim must also be thinner (by same amount).

- Select shims from the following tables.

CAUTION:
^ Part numbers are listed here for reference only.
^ Always check with your Parts supplier for the latest information.

S3 Shim Table:

S4 Shim Table: