Drive Pinion, Adjusting

5 SPD. A/T 01L AWD

Drive pinion, adjusting

Note:
^ Before adjusting drive pinion, adjust ring gear (determine total shim thickness S total S1 + S2).
^ Drive pinion only has to be adjusted if gear set tapered roller bearings for drive pinion of final drive housing was replaced. List of adjustments.
^ 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 assembly fixture.





^ Install double tapered roller bearing outer race without shim into housing.

Note: On 325314 pressure disc, marking "Oben" points toward nut on installation device





^ Pull small tapered roller bearing outer race into housing.
^ Install oiled outer race using VW408A punch and 30-205 thrust pad





^ Install drive pinion without spacer sleeve.
^ Heat tapered roller bearing inner race to 100°C and install on drive pinion.

CAUTION: Wear protective gloves.

Note:
^ 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).





A - Standard torque gauge, 0 to 600 Ncm
B - 36 mm socket insert

Note: If necessary use 314" to 112"reducing piece.





^ Bolt in 3028 retainer using two hex bolts M8 x 30 -A-.
B - 36 mm long socket





^ Tighten drive pinion nut to achieve following friction torque:
When nut is tightened, final drive must be supported (e.g. using VAG 1359/2 universal mount together with VAG 1383A transmission hoist).





^ Install adjustment ring from VW385/1 measuring bar.
^ Dimension a = 60 mm
^ Adjust sliding adjustment ring.
^ Dimension b = 55 mm





^ Complete measuring bar as shown in illustration.
^ VW385/15 extension pin 9 mm
VW385/30 master gauge, adjusting:
^ Ro = 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.





^ Install VW385/33 end gauge at 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 maximum run-out (return point). Measured value is dimension "e" (red numbered area).
^ Measured value in the following example: "e" = 1.60 mm

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

^ After removing universal mandrel, and with VVV385/30 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" = "e" minus "r"
e = determined value
r = deviation (indicated in 1/100 mm on ring gear)

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





Available shims for S3
^ Remove universal mandrel.
^ Remove drive pinion and large tapered roller bearing outer race and install together with determined shim S3 and spacer sleeve from.
^ Insert small tapered roller bearing inner race and tighten drive pinion nut until prescribed friction torque is attained ; Refer to .Fig. 15,.

Note:
^ Do not grease new tapered roller bearings additionally for friction 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:

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





^ Install universal mandrel and perform check measurement.
If shims have been determined correctly, dial indicator must indicate deviation r with a tolerance of � 0.04 mm (reading counterclockwise in red number display).
^ Secure drive pinion nut using mandrel.

Note: Measure radial run-out at drive shaft flange and mark.