Ring Gear, Adjusting
5 SPD. A/T 01L AWD
Ring gear, adjusting
(Adjusting differential)
Procedures to be performed after ring gear is adjusted, Refer to Adjustment overview. Adjustment Overview
Note:
^ 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 "S total".
^ ^Do not grease new tapered roller bearings additionally for friction torque measurement. The bearings are already greased with a special oil from the factory.
Total shim thickness S total for shims SI + 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 bearing outer races for differential and remove adjustment shims.
^ Press left tapered roller bearing outer race for differential (housing side) with adjustment shim "ST into differential housing. Use a shim "S2" with a 1.00 mm thickness for measurement purposes (1 shim with 0.80 and 1 shim with 0.20 mm).
Note: All measurements are performed with shim S2 of 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.
^ Drive in right tapered roller bearing outer race for differential (cover side) without adjustment shims up to stop.
^ 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 onto housing side of differential housing.
^ Rotate cover side of differential housing upward.
^ Turn differential 5 rotations in each direction to seat the tapered roller bearing.
^ Place VVV385/17 magnetic plate onto differential.
^ Install measuring tools.
A - Dial gauge extension approximately 30 mm long
B - Hex bolt M8 x 45
^ Set dial gauge extension onto center of VW385/17 magnetic plate.
^ Set dial indicator (3 mm measuring range) to 0 with 2 mm preload.
^ Lift differential without turning it, read backlash 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:
"S total" = "S2*" + measured value + bearing preload
Example:
Installed shim(s) "S2" 1.00 mm
+ Measurement 0.50 mm
+ Bearing preload (constant) 0.30 mm
= Total shim thickness "Stotal" for shims "S1 + S2" 1.80 mm
Determining thickness of shim "S1"
Note:
^ "S1 "is used for the initial measurement After determining backlash, "S1 "is replaced with final shim "S1".
^ The total shim thickness "S total" remains unchanged.
Formula:
"S1" = "Stotal" minus "S2"
Example:
Total shim thickness "S total" for shims "S1 + S2" 1.80 mm
Installed shim(s) "S2" 1.00 mm
Thickness of shim "S1" 0.80 mm
^ Calculate adjustment shims as accurately as possible according to the table.
Measuring friction torque (check measurement)
^ Drive pinion removed
^ Differential installed with shims "S1" and "S2"
^ Torque gauge 0 to 600 Ncm -A- installed on differential.
^ Read friction torque.
Friction torque specified values:
Note:
^ 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 "S total".
^ Do not grease new tapered roller bearings additionally for friction 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 must now be performed with checks.
Adjusting backlash
(position of ring gear in transmission housing)
^ Drive pinion installed with shim S3
^ Differential installed with shims "S1" and "S2"
^ Insert differential in 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 VVV388 measuring lever to dimension "a" = 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 0 with 1 mm preload.
^ Turn ring gear back until it contacts opposite tooth flank (backlash).
^ Read backlash and note.
^ Turn ring gear 90 " every time 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
=Total of measurements 1.16 mm
^ Result: The average backlash is 1. 16 mm / 4 = 0.29 mm
Determining thickness of shim "S2"
Formula:
"S2" = "S2*" minus 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. For Part numbers; Refer to Part Supplier
Available shims for S2
Determining thickness of shim "SI"
Formula:
"S1" = "S total" minus "S2"
Example:
Total shim thickness "S total" for "S1 + S2" 1.80 mm
-Thickness of shim "S2" 0.86 mm
=Thickness of shim "S1" 0.94 mm
^ Determine shim as closely as possible according to table. For Part numbers =Parts Catalog
Available shims for S1
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
Note:
^ If backlash is outside tolerance, repeat adjustments. Do not change total shim thickness "S,,I" while doing so.
^ The individual measurement values can deviate a maximum of 0.06 mm from each other