Ring Gear, Adjusting
5 Speed A/T 01V
Ring gear, adjusting
(Adjusting differential)
Procedures after which the ring gear must be adjusted, Refer to Adjustment overview, Refer to Adjustment Overview
Notes
^ Tapered roller bearings for differential are low friction bearings. Therefore friction torque can only be used for check measurement in a limited way. A correct adjustment is only possible by determining the total thickness "Stotal".
^ Do not grease new tapered roller bearings additionally for Action torque measurement. The bearings are already greased with a special oil from the factory.
Total shim thickness "Stotal" for adjustment shims "S1" + "S2", determining
(adjust preload of tapered roller bearing for differential)
Drive pinion removed or ring gear detached from differential housing
- Pry out drive flange seal using tire iron.
- Remove tapered roller bearings for differential and remove adjustment shims-, Refer to Differential Assembly, Service and Repair
- Press tapered roller bearing outer race for left side of differential housing (housing side) together with shim "S2" into differential housing, Refer to Differential Assembly, Service and Repair. Use a shim "S2*" with a 1.00 mm thickness for measurement purposes (1 shims with 0.80 and 1 with 0.20 mm).
Note: All measurements are performed shim S2 with 1.00 mm thickness. The shim will be indicated by "S2*" in the following procedures. After determining backlash, S2 is replaced by final shim S2.
- Press in tapered roller bearing outer race for right side (cover side) of differential without adjustment shims to stop, Refer to Differential Assembly, Service and Repair, See Fig. 8.
- Insert differential in housing. Ring gear is on the right side (cover side).
- Install cover and tighten bolts to 25 Nm.
- Install VW521/4 locking sleeve and 521/8 sleeve press tool into differential housing on housing side.
- Rotate cover side of differential housing upward.
- Turn differential 5 rotations in each direction to seat the tapered roller bearing.
- Place VW385/17 magnetic plate onto differential.
- Install measuring tools.
A- Dial gauge extension approximately 30 mm long
B - Hex bolt Me x 45
- Set dial gauge extension onto center of VW 385/17 magnetic plate.
- Set dial indicator (3 mm measuring range) to 0 with 2 mm preload.
- Lift the differential without turning it, read play on dial indicator and note.
^ Measured value in the following example: 0.50 mm
Note: If measurement is repeated, differential must first be rotated 5 complete revolutions in both directions again to seat tapered roller bearing.
Formula: "Stotal", Refer to "S2*" ^measured value + bearing preload
Example:
Installed shim(s) "S2*" 1.00 mm
+ Measurement 0.50 mm
+ Bearing preload (constant) 0.30 mm
Refer to Total shim thickness "Stotal" for shims "S1" + "S2" 1.80 mm
Determining thickness of shim "S1*"
Notes
^ "S1*" is used for the initial measurement. After determining backlash, "S1*" is replaced with final shim "S1".
^ The total shim thickness "Stotal" remains unchanged.
Formula:"S1*", Refer to "Stotal" - ''S2*'
Example:
Total shim thickness "Stotal" for shims "S1" + "S2" 1.80 mm
-Installed shim(s) "S2*" 1.00 mm
Refer to Thickness of shim "S1*" 0.80 mm
- Determine adjustment shim(s) as closely as possible according to table, Refer to Ring Gear, Adjusting
Measuring friction torque (check measurement)
Drive pinion removed
-Differential installed with shims "S1*" and "S2*"
- Position torque gauge O to 600 Ncm -A- on differential.
- Read friction torque.
Friction torque specified values:
1) have been run in at least 50 km
Notes
^ Tapered roller bearings for differential are low friction bearings. Therefore Action torque can only be used for check measurement in a limited way. A correct adjustment is only possible by determining the total thickness "Stotal".
^ Do not grease new tapered roller bearings additionally for Action torque measurement. The bearings are already greased with a special oil from the factory.
^ For a new adjustment of the gear set, the drive pinion adjustment should now be checked, Refer to Drive Pinion, Adjusting
Adjusting backlash
(position of ring gear in transmission housing)
Drive pinion installed with shim S3
Differential installed with shims "S1*" and "S2*"
- Insert differential into final drive housing, install cover and tighten all bolts to 25 Nm.
- Turn differential 5 rotations in each direction to seat the tapered roller bearing.
- Install measuring tools.
- Use VW382/10 extension pin, 6 mm.
- Set VW388 measuring lever to dimension "a", Refer to 60 mm.
- Determine backlash between teeth flanks as follows:
- Turn ring gear until it contacts a tooth flank (end of backlash travel).
- Set dial indicator to O with 1 mm preload.
- Turn ring gear back until it contacts opposite tooth flank (backlash).
- Read backlash and note.
- Turn ring gear an additional 90° in each case and repeat measurement 3 times.
Note: If measurements vary more than 0.06 mm from each other, ring gear or gear set is not installed correctly. Check installation, replace gear set if necessary.
Determining average backlash
Example:
1. Measurement 0.28 mm
+ 2. Measurement 0.30 mm
+ 3. Measurement 0.30 mm
+ 4. Measurement 0.28 mm
Refer to Total of measurements 1.16 mm
Result: The average backlash is 1.16 mm /4, Refer to 0.29 mm
Determining thickness of shim "S2"
Formula: "S2", Refer to "S2*" - backlash ^lift
Example:
Installed shim "S2*" 1.00 mm
-Average backlash 0.29 mm
+ Lift (constant) 0.15 mm
= Thickness of shim "S2" 0.86 mm
- Determine shim as closely as possible according to table. Part numbers
Refer to Parts Supplier
Available shims for S2
1) By using shim tolerances, it is possible to determine the exact shim thickness required, insert two shims if necessary
Determining thickness of shim "S1"
Formula: "S1", Refer to "Stotal"-"S2"
Example:
Total shim thickness "Stotal" for "S1" + "S21" 1.80 mm
- Thickness of shim "S2"0.86 mm
Refer to Thickness of shim "S1"0.94 mm
- Determine shim as closely as possible according to table. Part numbers
Refer to Parts Supplier
Available shims for S1
1) By using shim tolerances, it is possible to determine the exact shim thickness required, insert two shims if necessary
Checking measurement
Drive pinion installed with shim S3
Differential installed with shims "S1" and S2
- Turn differential 5 rotations in each direction to seat the tapered roller bearing.
- Measure backlash 4 times on circumference.
^ Specification: 0.12 to 0.22 mm
Notes
^ If backlash is outside tolerance, repeat adjustments. Do not change total shim thickness "Stotal" while doing so.
^ The individual measurement values can deviate a maximum of 0.06 mm from each other