Pinion Shaft, Adjusting
Pinion shaft, adjusting, 02X, 6-Speed Four-Wheel Drive M/T
(Adjusting pinion shaft with hollow shaft)
Repairs after which the pinion shaft must be adjusted
Special tools, testers and auxiliary items required
^ Removal tool VW 296
^ Holding plate VW 309
^ Transmission support VW 353
^ Universal measuring tool VW385
^ Dial gauge holder VW387
^ Thrust plate VW402
Special tools, testers and auxiliary items required
^ Punch VW407
^ Thrust disc VW 412
^ Installation arbor VW792
^ Thrust plate 2050
^ Thrust pad 3062
^ Press Support-R Wheel Brgs. 3144
Special tools, testers and auxiliary items required
^ Press tool 3345
^ Torque wrench V.A.G 1331
^ Dial gauge
^ Dial gauge extension, 30 mm
^ Hose clip
Determining total shim thickness "S total" for shims "S3" Plus "S4"
(Adjustment of pre-load of tapered roller bearings for pinion shaft with hollow shaft)
^ Differential removed.
- Press double tapered roller bearing inner race - 1 - onto pinion shaft and secure.
- Install large needle bearing - 2 -.
- Install pinion shaft in hollow shaft - 3 -.
^ Reassemble hollow shaft with selector gears and tapered roller bearing inner race.
- Install small needle bearing - 4 -.
- Press double tapered roller bearing outer race for pinion shaft into transmission housing without shims.
- Press in tapered roller bearing outer race for pinion shaft/hollow shaft with shim "S4*" (thickness 1.01 mm) into bearing housing.
Note:
^ For measurement purposes a shim "S4" with a thickness of 1.01 mm is inserted provisionally. This is referred to in the following as "S4*". "S4" is exchanged with the final shim "S4" after determining measured value "e".
- Secure transmission housing onto transmission support VW 353 with bolts - arrows -.
- Install fully assembled pinion shaft with hollow shaft into transmission housing.
- Install bearing housing and transmission cover and tighten bolts to 35 Nm.
- Turn transmission so that the transmission cover points downward.
- Press down on face of pinion shaft with removal tool VW 296 until tapered bearing outer race contacts bearing housing.
- While still maintaining pressure, rotate pinion shaft 5 turns in each direction in relation to the hollow shaft to settle the double tapered roller bearing.
- Rotate pinion shaft together with the hollow shaft 5 turns in each direction to settle the hollow shaft tapered roller bearing.
- Turn transmission so that the transmission cover points upward.
- Turn pinion shaft with hollow shaft five turns in both directions so that the double tapered roller bearing settles. Otherwise the result of the measurement will be incorrect.
- Set up measuring tool.
- Clamp pinion shaft onto hollow shaft with a hose clip - arrow -.
- Set dial gauge (3 mm measuring range) to "0" with 1 mm preload.
- Then move pinion shaft - A - with hollow shaft up and down in direction of - arrow -.
- Read off play on dial gauge and note reading.
^ Measurement in example: 0.46 mm
Note:
^ If the measurement has to be repeated, pinion shaft with hollow shaft must first be rotated another 5 turns in each direction to settle the double tapered roller bearing. Preload dial gauge to 1 mm and set to "0" again.
Formula: "S total" = "S4*" measured value bearing preload
Determining thickness of shim "S3"
Formula: "S3*" = "S total" - "S4*"
- Remove double tapered roller bearing outer race, install shim "S3*" in transmission housing and install outer race again
- Re-install fully assembled pinion shaft with hollow shaft into transmission housing.
- Install bearing housing and transmission cover and tighten bolts to 35 Nm.
- To settle the tapered roller bearings: rotate pinion shaft together with hollow shaft 5 turns in each direction, then rotate pinion shaft separately in relation to hollow shaft 5 turns in each direction.
- Set up measuring tools using dial gauge extension 30 mm - A - place nut M12 between VW 792 and transmission housing when securing bolt - arrow - to transmission housing.
Note:
^ Place dial gauge extension - A - onto web in transmission cover.
- Set dial gauge (3 mm measuring range) to "0" with 1 mm preload.
- Loosen transmission cover bolts and turn pinion shaft several times.
- If correct shims have been selected the dial gauge will now indicate the following value:
^ 0.09 to 0.18 mm
- Tighten transmission cover bolts again to 35 Nm.
- Take down measuring tools.
- To settle tapered roller bearings: rotate pinion shaft together with hollow shaft 5 turns in each direction, then rotate pinion shaft separately in relation to hollow shaft 5 turns in each direction.
Determining dimension "e"
Note:
^ Measurement "e" is required to determine the final shim thickness of "S3" and "S4"
- Set adjustment rings of measuring bar VW385/1 to the following values:
^ Dimension - a - = 45 mm
^ Dimension - b - = 75 mm
- Assemble universal measuring tool VW385/1 as illustrated:
^ Dial gauge extension - VW 385/15 -, 6.5 mm long
^ Master gauge-adjustable VW385/30
- Set master gauge-adjustable VW385/30 to Ro 59.65 mm and install onto measuring tool.
- Set dial gauge (3 mm measuring range) to "0" with 2 mm preload.
- Place end measuring plate on face of pinion shaft.
Note:
^ Make sure plate contact surface fits exactly and is free of oil.
- Remove master gauge and insert measuring tool into housing.
^ Install gauge extension - A - (length 6.5 mm).
^ The dial gauge faces toward final drive cover
- Install cover for final drive and tighten 4 bolts to 20 Nm.
- Using adjustable ring, pull 2nd centering pad VW385/36 out as far as possible so that the measuring tool can still just be turned by hand.
- Turn measuring tool until dial gauge point touches the end measuring plate on pinion shaft head, then measure maximum deflection (return point).
^ Measurement in following example: "e" 0.26 mm (in red scale)
Note:
^ Then (after removing universal measuring tool), check once again that the dial gauge indicates "0" with 2 mm preload when master gauge VW385130 is in place.
Determining thickness of shim "S3"
^ The deviation (tolerance) "r" in relation to the master gauge "Ro" is measured for the final drive sets supplied as replacement parts and marked on the outer circumference of the ring gear.
^ Subtract value "e" if measurement is obtained on red scale.
^ Add value "e" if measurement is obtained on black scale.
Formula:
"S3" = "S3*" + "r" + "e" ("e" on black scale)
"S3" = "S3*" + "r" - "e" ("e" on red scale)
- Determine shim(s) according to table.
Available shims for "S3"
Determining thickness of shim "S4"
Formula: "S4" = "S total" - "S3"
- Determine shim(s) according to table.
Shims available for "S4"
Checking adjustment
Checking deviation (tolerance) "r"
- Install pinion shaft and hollow shaft with determined shims "S3" and "S4"
- Turn hollow shaft against pinion shaft five turns in both directions so that the double tapered roller bearing settles.
- Turn pinion shaft with hollow shaft five turns in both directions so that the tapered roller bearings settle.
- Insert universal measuring tool and check adjustment.
- Read off dial gauge counter-clockwise (red scale).
^ If shims have been correctly selected, the deviation "r" (marked on outer circumference of ring gear) should be indicated within a tolerance of ± 0.04 mm.