5 SPD. M/T 01A AWD
Pinion and ring gear, adjusting
General:
^ Careful adjustment of the pinion and ring gear is a decisive factor as regards the service life and smooth running of the final drive. Even during production, the pinion and ring gear are checked together to ensure a good seating position and low noise in both directions of rotation. The position which achieves the smoothest running is determined by moving the pinion axially, so that the ring gear is never absolutely tight against the pinion but remains within the specified tolerance for torsional side clearance.
^ The objective of adjustment is to once more achieve the position for smoothest running, which was originally ascertained on the testing machine during production.
^ The dimension "r" referenced to controller "Ro" is written on the circumference of the ring gear. Only replace drive unit components (pinion and ring gear) together.
Drive units, adjusting and marking
1 - Code "0937" stands for Oerlikon drive unit with transmission ratio 37:9.
2 - Pair number (312) of drive set
3 - Dimension "r" referenced to controller of testing machine used in production. Dimension "r" is always stated in 1/100 mm. Example: "25" stands for r = 0.25 mm
Ro - Length of testing machine controller used.
Ro - Ring gear diameter 170 mm = 54.95 mm
R - Actual dimension between ring gear axis and end face of pinion at the point of smoothest running for this one drive set
Vo - Hypoid offset
Position of shims
Note: Adjustment table for replacing individual transmission components.
S1 - Shim for ring gear in final drive cover
S2 - Shim for ring gear in transmission housing
S3 - Shim for pinion in transmission housing
S4 - Shim for pinion in transmission cover
Adjustment table
Note: When performing transmission repair work, the pinion, ring gear or drive unit must only be re-adjusted if you are replacing components which directly influence the setting of the final drive. Refer to the table so as to avoid unnecessary adjustment.
Drive unit, re-adjustment sequence
If the pinion and ring gear require re-adjustment, please follow the sequence described below in the interest of rationalized work procedure:
1.) Define total shim thickness "Stotal" of "S1" + "S2" (adjusting pre-load of tapered roller bearing for differential).
2.) Define total shim thickness "Stotal" of "S3" + "S4" (adjusting pre-load of tapered roller bearing for differential).
3.) Distribute total shim thickness "Stotal" of "S3" + "S4" in such a way that dimension from center of ring gear to end face of pinion corresponds to mounting dimension "R" as defined during production.
4.) Distribute total shim thickness "Stotal" of "S1" + "S2" in such a way that the specified torsional side clearance is present between ring gear and pinion.
Note: List of components and shims.
Pinion, adjusting
(Adjusting pinion and hollow shaft)
Work after which pinion must be adjusted see Table.
Special tools and equipment
^ VAG 1331 Torque wrench
^ VW 296 Extractor lever
^ VW 385 Universal measuring device
^ VW 387 Universal dial indicator holder
^ VW 401 Pressure plate
^ VW 407 Press tool
^ VW 519 Tubular section
^ VW 792 Assembly device
^ 3062 Thrust pad
^ 3182 Insertion sleeve
Defining total shim thickness "Stotal" of shims "S3" + "S4"
(Adjusting pre-load of tapered roller bearing for pinion and hollow shaft)
^ Differential removed
- Press inner race -1- of double tapered roller bearing onto pinion and secure.
- Install needle bearing -2-.
- Position circlip -3- on hollow shaft and press on inner race of tapered roller bearing A-.
- Insert pinion shaft in hollow shaft.
Note: In the illustration the hollow wheel is shown without gears. The pinion can be set either with or without gears.
- Insert outer race of double tapered roller bearing for pinion in transmission housing without shims.
Smaller diameter of pressure plate 3062 faces outer race.
- Insert outer race of pinion tapered roller bearing together with shim "S4" (1.0 mm thick) in transmission cover.
Note:
^ A shim "S4" 1.0 mm thick is used provisionally as a reference value. It is referred to below as "S4*". Once measured value "e" has been determined, "S4*" will be replaced by actual shim "S4".
^ For measurement, always insert rubber washer together with ring for rubber washer.
- Insert fully assembled pinion and hollow shaft in transmission housing.
- Install transmission cover and tighten bolts to 22 Nm.
- Turn transmission so that transmission cover faces downward.
- Press head of pinion with lever VW 296 until outer race of tapered roller bearing makes contact with transmission housing.
- Maintaining the same pressure, rotate pinion in opposite direction to hollow shaft 5 turns in both directions, so that double tapered roller bearing slips into place.
- Next, rotate pinion and hollow shaft together 5 turns in both directions, so that tapered roller bearing slips into place.
- Install dial indicator and set to 0 with 1 mm pre-load.
Note: Dial indicator extension must be situated on ground surface of pinion head.
- Turn transmission 180° so that transmission cover faces upward.
- Rotate pinion and hollow shaft together 5 turns in both directions, so that tapered roller bearing slips into place. Otherwise, measurement results will be incorrect.
- Read off and note down clearance indicated on dial indicator.
- Example measured value: 0.45 mm
Note: If the measurement is repeated, first rotate the pinion and hollow shaft once more 5 turns in each direction. Set dial indicator to 0 with 1 mm pre-load once again.
Formula:
"Stotal" = "S4*" + measured value + bearing pre-load
Example:
Inserted shim "S4*" 1.00 mm
+ measured value (example) 0,45 mm
+ bearing pre-load (constant value) 0.15 mm
=Total shim thickness Stotal
of "S3" + "S4" 1.60 mm
Defining thickness of shim "S3*"
Formula:
"S3*" = "Stotal" - "S4"
Example:
Total shim thickness "Stotal"
of "S3" + "S4" 1.60 mm
- inserted shim S4 1.00 mm
=Thickness of shim S3 0.60 mm
- Remove outer race of tapered roller bearing, insert shim S3 in transmission housing and reinstall outer race.
- Re-insert fully assembled pinion in transmission housing.
- Install transmission cover and tighten bolts to 22 Nm.
- Rotate pinion in same direction and in opposite direction to hollow shaft 5 turns in both directions, so that tapered roller bearings slip into place.
- Install measuring tools and secure with bolt (arrow) to transmission housing.
- Set dial indicator (3 mm measuring range) to 0 with 2 mm pre-load.
- Loosen bolts of transmission cover and turn pinion freely.
- If correct shims were selected, the dial indicator should show the following value:
^ 0.05 to 0.15 mm
- Tighten bolts of transmission cover to 22 Nm.
- Remove measuring tools.
- Rotate pinion in same direction and in opposite direction to hollow shaft 5 turns in both directions, so that tapered roller bearings slip into place.
Defining dimension "e"
Note: Dimension e is required to determine the definitive shim thickness of "S3" and "S4".
- Adjust set rings of multi-purpose measuring mandrel VW 385/1 to following values:
^ Dimension a = 35 mm
^ Dimension b = 75 mm
- Assemble multi-purpose measuring mandrel VW 385/1 as shown in illustration:
^ Dial indicator extension -A-, 6.5 mm long
Adjust controller VW 385/30 to Ro in line with ring gear 0 and place on measuring mandrel.
Ring gear diameter 170 mm = 54.95 mm
- Set dial indicator (3 mm measuring range) to 0 with 2 mm pre-load.
- Place gauge block plate on pinion head.
Note: Make sure plate fits exactly and contact area is oil free.
- Remove controller and insert measuring mandrel in housing.
^ Dial indicator extension -A- = 6.5 mm long must be screwed in
^ Dial indicator faces cover of final drive
- Position cover of final drive and tighten 4 bolts to 22 Nm.
- Pull 2nd centering disc outward using moveable set ring until measuring mandrel can only just be turned by hand.
- Turn measuring mandrel until tip of dial indicator runs into gauge block plate on pinion head and gauge displays maximum deflection (point of return).
- Measured value in following example: "e" = 0.26 mm (red zone)
Note: After removing multi-purpose measuring mandrel, check again whether dial indicator with controller VW 385130 in position is still set to 0 with 2 mm pre-load.
Defining thickness of shim "S3"
^ The dimension "r" referenced to controller "Ro" is measured for the drive units which are delivered as replacement parts and written on the circumference of the ring gear.
^ If measurement is performed in red zone measured value "e" must be deducted.
^ If measurement is performed in black zone measured value "e" must be added on.
Formula:
"S3" = "S3*" + "r" + "e"
("e" in black zone)
"S3" = "S3*" + "r" - "e"
("e" in red zone)
Example:
Inserted shim "S3*" 0.60 mm
+ dimension "r" 0.38 mm
- obtained value "e" (red zone) 0.26 mm
= Thickness of shim "S3" 0.72 mm
- Define shim(s) as accurately as possible using chart. Part numbers
go to Parts catalog
Available shims for "S3"
Defining thickness of shim "S4"
Formula:
"S4" = "Stotal" - "S3"
Example:
Total shim thickness "Stotal"
of "S3" + "S4" 1.60 mm
- thickness of shim SY 0.72 mm
=Thickness of shim S4 0.88 mm
- Define shim(s) as accurately as possible using chart. Part numbers
go to Parts catalog
Available shims for "S4"
Checking measurement
Checking dimension "r"
- Install pinion/hollow shaft with defined shims "S3" and "S4".
- Rotate hollow shaft against pinion 5 turns in both directions, so that tapered roller bearing slips into place.
- Rotate pinion and hollow shaft together 5 turns in both directions, so that tapered roller bearing slips into place.
- Insert multi-purpose measuring mandrel = Defining dimension "e", and check measurement.
- Read off dial indicator counter-clockwise (red zone).
^ If correct shims were selected, dimension "r" (written on circumference of ring gear) must be displayed showing a tolerance of ±0.04 mm
Shim "S4", re-determining when replacing transmission cover
Special tools, testers and other items required
^ 2 x centering disc VW 385/3
^ Measuring plate VW 385/17
^ Universal dial indicator holder VW 387
^ Assembly device VW 792
^ Dial indicator
^ Dial indicator extension
^ Depth caliper gauge with minimum measuring accuracy of 5/100 mm
- Clean joint surfaces of cover.
- Measure difference in depth a on old and new transmission covers.
Example:
Depth "a" of old transmission cover 257.40 mm
Depth "a" of 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:
Old shim "S4" 0.95 mm
+ Difference 0.15 mm
= New shim S4 1.10 mm
- Insert outer race for tapered roller bearing together with shim S4 in transmission cover.
- Re-insert fully assembled pinion in transmission housing.
- Install transmission cover and tighten bolts to 22 Nm.
- Rotate pinion in same direction and in opposite direction to hollow shaft 5 turns in both directions, so that tapered roller bearings slip into place.
- Install measuring tools and secure with bolt (arrow) to transmission cover.
- Set dial indicator (3 mm measuring range) to 0 with 2 mm pre-load.
- Loosen bolts of transmission cover and turn pinion freely.
- If correct shims were selected, the dial indicator should show the following value:
^ 0.05 to 0.15 mm
If this value is not obtained, setting must be corrected.
Ring gear, adjusting
(Adjusting differential)
Special tools and equipment
^ VW 382/10 Dial indicator extension
^ VW 385/17 Gauge block plate
^ VW 386 A Clamp for pinion
^ VW 387 Universal dial indicator holder
^ VW 388 Measuring lever
^ VW 402 Pressure plate
^ VW 408 A Press tool
^ VW 681 Extractor lever
^ 2050 Pressure piece
^ VW 521 Adjusting device for ring gear
^ VAG 1331 Torque wrench
^ Dial indicator
The ring gear must be re-adjusted if:
transmission housing, final drive cover, differential tapered roller bearing, differential housing or drive unit
are replaced.
Adjustment table
Defining total shim thickness "Stotal" of shims "S1" + "S2"
(Adjusting pre-load of differential tapered roller bearing)
^ Pinion removed
^ If only differential tapered roller bearings are replaced, the ring gear can be detached from the differential housing. In this case, the pinion does not have to be removed.
- Pull out oil seals for drive flanges using extractor lever VW 681.
- Remove outer races of differential tapered roller bearings and take out shims.
- Drive outer race of small tapered roller bearing and shim "S2" into transmission housing. For measurement purposes, a shim "S2*" 1.20 mm thick is used (2 shims of 0.60 mm).
Note: A shim "S2" 1.20 mm thick is used provisionally as a reference value. It is referred to below as "S2*". Once torsional side clearance is determined, "S2*" is replaced by the definitive "S2".
- Press outer race of tapered roller bearing into cover of differential without shim S1.
- Insert differential without driving gear for sender of speedometer -G22 in transmission housing.
- Install cover of differential using 4 bolts (25 Nm).
- Position transmission so that cover of differential faces upward.
- Rotate differential 5 turns in both directions, so that tapered roller bearing slips into place.
- Lay measuring plate VW 385/17 on differential.
- Set up measuring tools using a 30 mm dial indicator extension.
- Set dial indicator (3 mm measuring range) -A- to 0 with 2 mm preload.
Note: Measuring tip of dial indicator must be positioned on center of differential.
- Lift differential without turning; read off and note down clearance indicated on dial indicator.
^ Measured value in following example: 0.62 mm
Note:
^ To raise differential, fasten special tools VW 52114 and VW 521112 to right of differential (housing side).
^ If the measurement is repeated, first rotate the pinion and hollow shaft once more 5 turns in each direction, so that the tapered roller bearing slips into place.
Formula:
"Stotal" = "S2*" + measured value + bearing pre-load
Example:
Inserted shim(s) "S2*" 1.20 mm
+ measured value 0.62 mm
+ bearing pre-load (constant value) 0.30 mm
=Total shim thickness Stotal
for "S1" + "S2" 2.12 mm
Defining thickness of shim "S1*"
Note:
^ Provisional shim "S1*" is replaced by definitive "S1" after torsional side clearance has been determined.
^ Total shim thickness "Stotal" remains unchanged.
Formula:
"S1*" = "Stotal" - "S2*"
Example:
Total shim thickness "Stotal"
for "S1" + "S2" 2.12 mm
- inserted shim(s) "S2" 1.20 mm
=Thickness of shim "S1*" 0.92 mm
Assigning shims
go to Parts catalog
Measuring torsional side clearance
^ Pinion installed with shims S3 and S4
- Install differential with ring gear: S1* is installed on cover side, S2* in transmission housing.
- Mount final drive cover and tighten bolts to 25 Nm.
- Insert adjustment tool for ring gear VW 521/4 and VW 521/12.
- Rotate differential 5 turns in both directions, so that tapered roller bearings slip into place.
- Secure dial indicator holder VW 387 to housing. Insert dial indicator together with dial indicator extension VW 382/10 (6 mm plane). Set measuring lever VW 388 to dimension a = 67 mm (for ring gear diameter 170 mm).
- Determine clearance between flanks of teeth as follows:
- Rotate ring gear until it makes contact with one tooth flank (end of clearance).
- Set dial indicator to 0 with 2 mm pre-load.
- Turn ring gear back until it makes contact with opposite tooth flank (torsional side clearance).
- Read off torsional side clearance and note down measured value.
- Turn ring gear additional 90° turn in each direction and repeat measurement 3 times.
Note:
^ If pinion turns when differential is rotated, install VW 386 A to ensure that exact torsional side clearance can be measured.
^ Release clamp for turning ring gear.
Determining mean torsional side clearance
- Add up the 4 measured values and divide the total by 4.
Example:
1st measured value 0.28 mm
+ 2nd measured value 0.30 mm
+ 3rd measured value 0.30 mm
+ 4th measured value 0.28 mm
=Sum total of measured values 1.16 mm
Result: The mean torsional side clearance equals 1.16 mm: 4 = 0.29 mm
Note: If during measurement the individual values differ from one another by more than 0. 06 mm, the ring gear or drive unit itself have not been correctly installed. Check repair work and replace drive unit if necessary.
Defining thickness of shim "S2"
Formula:
"S2" = "S2*" - torsional side clearance + lift
Example:
Inserted shim "S2" 1.20 mm
- mean torsional side clearance 0.29 mm
+ lift (constant value) 0.15 mm
=Thickness of shim "S2" 1.06 mm
Define shim(s) as accurately as possible using chart. Part numbers
go to Parts catalog
Available shims for "S2"
Defining thickness of shim "S1"
Formula:
"S1" = "Stotal" - "S2"4
Example:
Total shim thickness "Stotal" 2.12 mm
for "S1" + "S2"
- thickness of shim "S2" 1.06 mm
=Thickness of shim "S1" 1.06 mm
Define shim(s) as accurately as possible using chart. Part numbers
go to Parts catalog
Available shims for "S1"
Checking measurement
- After shims S1 and ST have been installed, rotate differential 5 turns in each direction so that tapered roller bearings slip into place.
- Measure torsional side clearance 4 times at circumference.
- Specification: 0.12 to 0.22 mm
Note:
^ If torsional side clearance is outside tolerance, repeat adjustments. But do not change total shim thickness Stotal-
^ Individual measured values may only differ from one another by maximum 0.06 mm.