Transmission Cover, Replacing (Recalculating Shims)

Special tools and equipment
- VW385/3 centering disc (2x)
- VW385/17 magnetic plate
- VW387 dial indicator holder
- VW792 installation arbor
- Dial indicator
- Dial indicator extension
- Depth gauge with minimum 5/100 mm precision

- Clean housing mating surfaces.





- Measure difference in depth -a- on old and new transmission covers.

Example:

Depth "a" (old transmission cover) 257.40 mm
Depth "a" (new transmission cover) 257.55 mm
= Difference 0.15 mm

- Install thicker shim S4 if new transmission cover is deeper
- Install thinner shim S4 if old transmission cover is deeper

Example:

Previous shim S4 0.95 mm
+ Difference 0.15 mm
= New shim S4 1.10 mm

Available shims = table, Refer to total shim thickness stotal for shim S3+S4, determining.

- Press tapered roller bearing outer race with shim S4 into transmission cover, See Fig. 8, Refer to Drive pinion and hollow shaft, disassembling and Assembling.
- Reinsert assembled pinion shaft into transmission housing fully. Install transmission cover and tighten bolts to 22 Nm (16 ft. lbs.).
- To settle tapered roller bearings, rotate pinion shaft together with hollow shaft 5 turns in each direction, then rotate pinion shaft separately in relation to hollow shaft 5 turns in each direction.





- Install measuring tools and secure with bolt (arrow) to transmission housing.
- Set dial indicator (3 mm measuring range) to "O" with 2 mm preload.
- Loosen transmission cover bolts and turn pinion shaft several times.
If correct shims have been selected, dial indicator will now indicate the value: 0.05 - 0.15 mm
If this reading is not obtained the adjustment must be corrected.