1ST-4TH Gear Pinion Shaft, Adjusting

1st-4th gear pinion shaft, adjusting
(Determine adjustment shim size for pinion shaft).





Special tools and equipment
^ VW353 transmission support
^ VW387 dial gauge holder
^ VW407 punch
^ VW433 thrust pad
^ VW792 installation arbor
^ VW 801 holding fixture





Special tools and equipment
^ 2050 thrust plate
^ 3235 press device VAG 1331 torque wrench
^ 1 Kukko 21/7 extractor
^ 4 Kukko 22/2 support

A re-adjustment of the pinion shaft is essential if the following components are replaced:
^ Transmission housing
^ Clutch housing
^ Pinion shaft for 1st to 4th gear or
^ Tapered roller bearing
Adjustment overview, Refer to Differential Assembly, Adjustments

Requirements





^ Sealing surfaces of clutch housing and transmission housing must be free of sealant.
^ Only install shaft to be measured when measuring.
- Press tapered roller bearing outer race into transmission housing using an adjustment shim of 1.70 mm thickness. Support transmission housing with 2050 thrust pad below bearing support.
- Set complete pinion shaft 1st to 4th gear into clutch housing.





- Install transmission housing and tighten bolts - A - and - B - diagonally to proper tightening torque.





- Install measuring tools and secure to transmission housing with bolt (arrow).
- Set dial indicator (3 mm measuring range) to O with 1 mm preload.
- Unscrew bolts for clutch housing/transmission housing diagonally until the bolts release the transmission housing or pinion shaft.
- Read measured value on dial indicator and note (example: 0.14 mm).

Notes: If no measuring value is displayed on dial indicator when securing bolts from clutch housing/transmission housing are loosened, install adjustment shim 1.95 mm Apart number 084 409 383 AS) or adjustment shim 2.20 mm (part number 084 409 383 BD) for the measurement.

Determine adjustment shim
The specified bearing preload is reached if the determined measurement value (0.14 mm) is subtracted from the adjustment shim (1.70 mm) and a constant value for compression (0.20 mm) is added.





Example:
- Determine thickness of adjustment shim according to table.





- Remove transmission housing and pull out tapered roller bearings outer race.
A - support, i.e. Kukko 22/2
B - extractor, e.g. Kukko 21/7
- Remove installed adjustment shim (1.70 mm thickness) from transmission housing.





- Press in tapered roller bearing outer race with the determined adjustment shim (i.e. 1.75 mm). Support transmission housing with 2050 thrust pad below bearing support.

Perform check measurement
^ Determined adjustment shim installed





- Install measuring tools and secure to transmission housing with bolt (arrow).
- Set dial indicator (3 mm measuring range) to 0 with 1 mm preload.
- Unscrew bolts for clutch housing/transmission housing diagonally until the bolts release the transmission housing or pinion shaft.
- The dial indicator can now display a value of 0.15 mm to 0.25 mm with a correctly selected adjustment shim.