Shaft Bevel Gear, Adjusting
Shaft bevel gear, adjusting
Special tools, testers and auxiliary items required
^ Holding plate VW 309
^ Universal Measuring Tool VW 385
^ Transmission holder T10108
^ Alignment fixture T10114
^ Torque wrench V.A.G 1332
^ Dial gauge
^ Torque gauge 0 - 600 Ncm, standard
A new shaft bevel gear adjustment is necessary if
^ Drive pinion housing
^ Rear axle housing
^ Tapered roller bearing for shaft bevel gear or the
^ Gear set
are replaced.
Adjusting friction torque
- Install twelve-point nut for shaft bevel gear.
- Tighten twelve-point nut to 120 Nm, then measure friction torque, increase tightening torque until specified friction torque is set, if necessary.
A - Toggle with 3/4 drive
- Use an adapter of 1/2 on 3/4.
Note: Only increase tightening torque slowly and read off friction torque several times while doing this, if specified friction torque is exceeded, spacer sleeve must be replaced and adjustment must be repeated! A spacer sleeve which has been compressed too much cannot be reused.
Set following frictional torques:
- Measure friction torque.
A - Torque gauge, 0 - 600 Ncm, standard
B - Adapter of 1/2 on 3/4 drive
Determining thickness of adjustment shim S 3
- Install complete drive pinion housing with shaft bevel gear and initial adjustment shim S 3 (1.3 mm thick).
Note: For the initial measurement, an adjustment shim S 3 of 1.30 mm is inserted. It is designated as S 3 in the following. After determining the measured value "e", S 3 is replaced by the final adjustment shim S 3.
- Do not insert O-ring.
- Set adjusting ring of universal measuring device VW 385 to dimension a = 38 mm.
- Set adjustable ring to dimension b = 35 mm.
- Install Universal Measuring Device VW 385 according to illustration. Dial Gauge Extension VW 385/16 = 12.3 mm long. Set adjustable master gauge VW 385/30 to R 0 = 42.70 mm.
- Set dial gauge to zero with 2 mm pre-load.
- After removing master gauge, slide on VW 385/39 until stop.
- Place magnetic plate onto head of shaft bevel gear.
- Insert universal mandrel.
- Attach cover and tighten hex bolts.
- Using adjustable ring, pull 2nd centering disc out far enough, so that the mandrel can only be turned by hand.
- Measure dimension "e". Turn measuring mandrel until tip of dial gauge touches magnetic plate and measure the maximum runout (return point). Measured value is dimension "e" (black numbered area). Example: 0.28 mm
- Remove universal measuring device.
Note: Then check again whether dial gauge stands at "0" with 2 mm pre-load when universal adjustable master gauge VW 385/30 is attached, otherwise repeat measurement.
Determining thickness of adjustment shim S 3
S 3 =S 3 + r + e
("e" in black numbered area)
S 3 =S 3 + r - e
("e" in red numbered area)
Note:
^ If measured in red numbered area, measured value "e" must be subtracted.
^ If measured in black numbered area, measured value "e" must be added.
^ Dimension "r" which is based on adjustable master gauge "Ro" must be determined according to the following formula.
Formula: r = R - Ro
R - - Value inscribed on head bevel gear (in the example: 43.14 mm).
- Ro- Length of adjustable master gauge used
r = 43.14 mm - 42.70 mm
r = 0.44 mm
Example:
Available adjustment shims for S 3 0.28 mm
- Remove drive pinion housing complete with shaft bevel gear and adjustment shim 1.3 mm.
- Install determined adjustment shim S 3.
2 shims corresponding to measured value may be installed.
Performing measurement check - checking dimension "r"
Insert universal mandrel and measure dimension "r".
If adjustment shims were determined correctly, dial indicator must indicate determined dimension "r" with a tolerance of + 0.04 mm (reading counterclockwise in red number display).