Pinion, Adjusting
Note:
- Before adjusting pinion, adjust ring gear (total shim thickness "Stotal " (S 1 + S2).
- A new pinion adjustment is necessary only if the drive gear set, tapered roller bearing for pinion or final drive housing are being replaced.
- When measuring new tapered roller bearings for friction torque, additional oil is not necessary.
- Clamp final drive in vice.
- Install large tapered roller bearing outer race into housing without shim.
Note:
Lettering "Top " points at thrust washer 325314, towards nut of insertion tool.
- Install small tapered roller bearing outer race into housing.
Note:
- Oil bearing outer race and install with VW295 and 30-205.
- Replace VW204B with 10-9 or equivalent
- Install pinion without spacer sleeve.
- Heat tapered roller bearing inner race to approx. 1000C (2120F) and install onto pinion
Note:
- When measuring new tapered roller bearings for friction torque, additional oil is not necessary.
- Install spacer sleeve for friction torque adjustment (with already determined "S3" shim).
- Tighten pinion nut until specified friction torque is achieved.
- A=Torque gauge, commercial, 0 - 600 Ncm
B=Socket, 32 mm
- Set adjusting ring of measuring bar 385/1; dimension -a-= 60 mm.
- Set sliding adjusting ring of measuring bar 385/1; dimension -b- = 55 mm
- Set up universal measuring bar as shown.
- Dial indicator extension VW 385/15 = 9 mm long
- Set up universal master gauge VW 385/30 to RO = 57.5 mm.
- Set dial indicator to zero with preload of 3 mm.
Note:
Before measuring turn pinion at least 5 times in both directions so that tapered roller bearing is set. Failure to turn pinion could result in an inaccurate measurement.
- Place end plate VW 385/33 on pinion head.
- Remove master gauge VW 385/30 and insert measuring bar into housing. The centering plate for VW 385/33 should point to final drive cover.
- Draw second centering discount with sliding ring far enough so that bar can only just be turned by hand.
- Measure dimension "e".
- Turn measuring bar until dial indicator tip touches end plate on pinion head and indicates maximum deflection (reversal point).
The reading obtained is dimension "e" (red figure range)
Example: 1.60 mm
Note:
The dimension "e" is required to determine the thickness of adjustment shim "SX.
- Remove universal measuring bar and recheck that gauge, with master gauge VW 385/30 installed with 3 mm preload, indicates "0". If not, repeat adjustment check.
Determining thickness of shim S3
S3= e - r
e - Reading obtained (max. deflection)
r- Deviation (indicated on ring gear in 1/100 mm or determined by actual measurement)
Example:
Reading -e- indicated on dial gauge 1.60 mm
- Deviation"r" inscribed on ring gear 0.42 mm
____________________________________ _________
= Thickness of shim S3 1.18 mm
See the parts catalog for replacement shims
Note:
The tolerances in nominal shim sizes make it possible to choose a shim with the precise thickness required for S3.
- Remove universal measuring bar.
- Remove pinion and large tapered roller bearing outer race and reinstall with selected shim, spacer and seal.
- Install small tapered roller bearing inner race and tighten nut until specified friction torque is attained.
Note:
- When measuring new tapered roller bearings for friction torque, additional oil is not necessary
- Slowly increase tightening torque and read friction torque value several times.
- If the specified friction torque is exceeded, the spacer sleeve must be replaced and the adjustment repeated!
- A sleeve that has been compressed cannot be reused.
The following friction torques should be set:
Checking measurements
- Check dimension "r".
- Rotate pinion several times in both directions.
- Install measuring bar and perform check measurement.
If shims have been correctly selected, the dial indicator, reading counterclockwise (red gauge scale), should indicate the inscribed value of deviation "r" within a tolerance of :h 0.05 mm.