Drive Pinion, Adjusting

5 Speed A/T 01V

Drive pinion, adjusting

Notes
^ Before adjusting drive pinion, adjust ring gear (determine total shim thickness "S" total" for adjustment shims "S1" + "S2"), Refer to Ring Gear, Adjusting.
^ Drive pinion only has to be adjusted again if gear set, tapered roller bearings for drive pinion or final drive housing was replaced. Adjustment overview, Refer to Adjustment Overview.
^ Do not grease new tapered roller bearings additionally for friction torque measurement. The bearings are already greased with a special oil from the factory.

Determining Shim "S3"
(adjust preload of tapered roller bearing for drive pinion
- Clamp final drive into engine and transmission assembly stand.





- Pull large tapered roller bearing outer race into housing.

Note: On 3253/4 pressure disc, marking "Oben" points toward nut on installation device





- Pulling small tapered roller bearing outer race into housing.
- The outer race must be oiled and installed using VW408A punch and 30-205 thrust pad.





- Install drive pinion without spacer sleeve.

WARNING: Wear protective gloves!

- Heat up small tapered roller bearing inner race to approximately 100°C and position on drive pinion.

Notes
^ Do not grease new tapered roller bearings additionally for friction torque measurement. The bearings are already greased with a special oil from the factory.
^ Only install spacer sleeve if friction torque has been adjusted (Shim S3 already determined).





- Install 3304 retainer using two hex bolts M8 x 30.
- When tightening nut, support final drive (e.g. using VAG1359/2 universal mount with VAG1383A transmission hoist).
- Always replace drive pinion nut.
- Tighten nut for drive pinion until no more drive pinion backlash is present.
- Increase tightening torque further until specified friction torque is attained; while tightening measure friction torque multiple times.





A- Standard torque gauge, O to 600 Ncm
B- Extension with 32 mm wrench socket





- Adjust to following friction torque
1) have been run in at least 50 km





- Adjust adjustment ring of VW385/1 measuring bar.
^ Dimension a, Refer to 60 mm
- Adjust sliding adjustment ring.
^ Dimension b, Refer to 55 mm





- Assemble measuring bar as shown in illustration.
^ VW385/15 extension pin 9 mm
- Adjust VW385/30 master gauge-adjustable.
^ Ro, Refer to 57.50 mm
- Set dial indicator (3 mm measuring range) to 0 with 2 mm preload.

Note: Turn differential at least 5 rotations in each direction to seat the tapered roller bearings. Otherwise, measurement will result in false readings.





- Position VW385/33 end gauge on drive pinion head.





- Remove master gauge and insert measuring mandrel into housing.
^ VW385/3 plastic piece faces final drive cover
- Install cover for final drive and tighten four bolts.
- Using adjustable ring, pull 2nd centering disc out far enough, so that the mandrel can only just be turned by hand.





Determining dimension "e"
- Turn measuring mandrel until dial indicator plunger tip touches end gauge on pinion shaft head, and measure the maximum run-out (return point). Measured value is dimension "e" (red numbered area).
^ Measured value in the following example: "e", Refer to 1.60 mm

Note: Dimension "e" is required to determine thickness of S3 shim.

- After removing universal mandrel, and with VW385/30 master gauge in place, check dial indicator again to see if it indicates 0, with 2 mm preload. If not, repeat measurement.

Determining thickness of shim "S3"
Formula: "S3", Refer to "e" - "r"
e, Refer to determined value
r, Refer to deviation (indicated in 1/100 mm on ring gear)

Example:
determined value "e", Refer to 1.60 mm
-Deviation "r", Refer to 0.42 mm
= Thickness of shim "S3" 1.18 mm
- Determine shim as closely as possible according to table. Part numbers
Refer to Parts Supplier





Available shims for S3
1) By using shim tolerances, it is possible to determine the exact shim thickness required, insert two shims if necessary

- Removing universal mandrel.
- Remove drive pinion and large tapered roller bearing outer race and install together with determined adjustment shim "S3" and spacer sleeve, Refer to Differential Assembly, Service and Repair
- Insert small tapered roller bearing inner race and tighten nut for drive pinion until specified friction torque is attained, Refer to Ring Gear, Adjusting, See Fig. 11.

Notes
^ Do not grease new tapered roller bearings additionally for Action torque measurement. The bearings are already greased with a special oil from the factory.
^ Increase torque slowly and measure friction torque multiple times. If the specified friction torque is surpassed, replace spacer sleeve and repeat adjustment! Any spacer sleeve that has been pressed together too far one time must be replaced.





- Adjust friction torque to following values:
1) have been run in at least 50 km

Perform check measurement
Checking dimension "r"
- Rotate drive pinion at least 5 complete revolutions in both directions.





- Insert universal mandrel and perform check measurement.
^ If adjustment shims were determined correctly, dial indicator must indicate deviation "r" with a tolerance of ^0.04 mm (reading counterclockwise in red number display).





- Peen drive pinion nut using mandrel.