Pinion, Adjusting

Pinion, Adjusting - 6 Spd. Manual Transmission 0A3 All Wheel Drive

Procedures after which the drive pinion must be adjusted.

There are 2 procedures when adjusting drive pinions.

1. Adjusting gear seats where dimension E is indicated on the outer circumference of ring gear.
2. Adjusting gear seats where dimension e is indicated on outer circumference of ring gear.

Adjusting gear seats where dimension "E" is indicated on outer circumference of ring gear

Special tools, testers and auxiliary items required

^ Universal measuring device VW 385

^ Torque wrench V.A.G 1331
^ Depth gauge, e.g. Digital Depth Gauge VAS 6087
^ Dial gauge

Determine thickness of previous shim "S3" and "S4"

^ Differential removed.
^ Double angular contact ball bearing is pressed onto drive pinion.

Note:
^ For the initial measurement, an adjustment shim "S3" of 1.00 mm is inserted. It is designated as "S3*" in the following. After adjusting dimension "E", "S3*" is replaced by the final shim "S3".

- Secure transmission housing to transmission mounting VW 353. To do so, transmission housing must be vertical.
- Place shim "S3*" in transmission housing.

- Coat outer races - 3 - and - 4 - of double angular contact ball bearing with transmission fluid.
- Carefully slide drive pinion - 1 - with double angular contact ball bearing by hand into transmission housing - 2 - and press onto upper outer race - 3 - at the same time.

Note:
^ Warm transmission housing beforehand with a hot air gun in bearing seat area, if necessary.

Outer races - 3 - and - 4 - must not tilt when inserting, they must remain together. Otherwise, seal - 6 - can be damaged by pinion face - 5 -.

If double angular contact ball bearing seal is damaged, the bearing must be replaced.

Determine previous shim "S4" as follows:

- Using a digital depth gauge (e.g Digital Depth Gauge VAS 6087), measure from outer race/double angular contact ball bearing - 1 - to retaining plate bolting surface - 2 -.

In the example, gap dimension - a - = 1.14 mm. Determine previous shim "S4" according to table.

Note:
^ For the initial measurement, an adjustment shim "S4" of 0.95 mm is inserted. It is designated as "S4*" in the following. After adjusting dimension "E", "S4*" is replaced by the final shim "S4".

- Place previous shim "S4*" (0.95 mm in example) and retaining plate - A - (only fits in one position) on transmission housing bolting surface.
- Clean threads of previous screws - arrows - with a wire brush. Then tighten screws diagonally to 30 Nm.

Dimension "E", adjusting

Note:
^ Dimension "E" must be adjusted at master gauge VW 385/30 to determine final shim thickness of "S3" and "S4".

- Set adjustment rings of universal mandrel VW 385/1 to the following values:

^ Dimension - a - = 45 mm
^ Dimension - b - = 60 mm

- Assemble universal mandrel VW 385/1 as shown in the illustration:

^ Dial gauge extension VW 385/16, 12.3 mm long

- Set master gauge VW 385/30 to dimension "E" in example = 62.50 mm and place on universal mandrel VW 385/1.
- Set gauge (3 mm measuring range) to "0" with 2 mm pre-load.

- Place magnetic plate VW 385/33 onto head of drive pinion.

Note:
^ Make sure magnetic plate VW 385/33 is precisely installed and free of oil.

- Remove master gauge VW 385/30 and insert universal mandrel in transmission housing.

^ A dial gauge extension - A - = 12.3 mm long must be screwed in.
^ Dial gauge faces final drive cover.
^ O-ring is inserted in final drive cover.

- Install final drive cover and tighten 4 bolts to 24 Nm.
- Using adjustable ring, pull 2nd centering disc VW 385/36 out far enough, so that the universal mandrel can only just be turned by hand.

- Turn universal mandrel until dial gauge tip touches magnetic plate on head of pinion and indicates max. runout (return point).

^ Measured value in following example: = 0.15 mm (red number range)

Note:
^ After removing universal mandrel - check again whether dial gauge stands at "0" with 2 mm pre-load when adjustable master gauge VW 385/30 is attached.

Determining thickness of adjustment shim "S3"

^ If measured in red numbered area, measured value must be subtracted.
^ If measured in black numbered area, measured value must be added.

- Determine shim(s) according to table.

Available adjustment shims for "S3"

^ Using shim tolerances it is possible to find the exact shim thickness required, insert two shims if necessary.

- Remove previous shims "S3*" and "S4*".
- Insert determined shim "S3", 0.85 mm in example, in transmission housing.

Determining thickness of adjustment shim "S4"

^ Determined shim "S3" is installed in transmission housing.

- Coat outer races - 3 - and - 4 - of double angular contact ball bearing with transmission fluid.
- Carefully slide drive pinion - 1 - with double angular contact ball bearing by hand into transmission housing - 2 - and press onto upper outer race - 3 - at the same time.

Note:
^ Warm transmission housing beforehand with a hot air gun in bearing seat area, if necessary.

Outer races - 3 - and - 4 - must not tilt when inserting, they must remain together. Otherwise, the seal - 6 - can be damaged by the pinion face - 5 -.

If the double angular contact ball bearing seal is damaged, the bearing must be replaced.

Determine shim "S4" as follows:

Note:
^ Allocate adjustment shims.

- Place determined shim "S4" (0.80 mm in example) and retaining plate - A - (only fits in one position) on transmission housing bolting surface.
- Then tighten bolts - arrows - diagonally to 30 Nm.

Performing measuring check, checking dimension "E"

- Install drive pinion with measured adjustment shims "S3" and "S4".

- Install universal mandrel and perform measurement check.
- Read dial indicator counterclockwise (red numbered area).

^ If adjustment shims were determined correctly, dimension "E" must have a clearance of ±0.04 mm.

Note:
^ After removing universal mandrel - check again whether dial gauge stands at "0" with 2 mm pre-load when adjustable master gauge VW 385/30 is attached.

Adjusting gear seats where dimension "e" is indicated on outer circumference of ring gear

Special tools, testers and auxiliary items required

^ Universal measuring device VW 385

^ Torque wrench V.A.G 1331
^ Depth gauge, e.g. Digital Depth Gauge VAS 6087
^ Dial gauge

Determining thickness of previous shims "S3" and "S4"

^ Differential removed.
^ Double angular contact ball bearing is pressed onto drive pinion.

Note:
^ For the initial measurement, an adjustment shim "S3" of 1.00 mm is inserted. It is designated as "S3*" in the following. After adjusting dimension "e", "S3*" is replaced by the final shim "S3".

- Secure transmission housing to transmission mounting VW 353. To do so, transmission housing must be vertical.
- Place shim "S3*" in transmission housing.

- Coat outer races - 3 - and - 4 - of double angular contact ball bearing with transmission fluid.
- Carefully slide drive pinion - 1 - with double angular contact ball bearing by hand into transmission housing - 2 - and press onto upper outer race - 3 - at the same time.

Note:
^ Warm transmission housing beforehand with a hot air gun in bearing seat area, if necessary.

Outer races - 3 - and - 4 - must not tilt when inserting, they must remain together. Otherwise, the seal - 6 - can be damaged by the pinion face - 5 -.

If the double angular contact ball bearing seal is damaged, the bearing must be replaced.

Determine previous shim "S4" as follows:

- Place previous shim "S4*" (0.95 mm in example) and retaining plate - A - (only fits in one position) on transmission housing bolting surface.
- Clean threads of previous bolts - arrows - with a wire brush. Then tighten bolts diagonally to 30 Nm.

Dimension "e", adjusting

Note:
^ Dimension "e" must be adjusted to determine final shim thickness of "S3" and "S4" for this gear set.

- Set adjustment rings of universal mandrel VW 385/1 to the following values:

^ Dimension - a - = 45 mm
^ Dimension - b - = 60 mm

- Assemble universal mandrel VW 385/1 as shown in illustration:

^ Dial gauge extension VW 385/16, 12.3 mm long

- Set master gauge VW 385/30 to dimension "Eo" = 62.50 mm and place on universal mandrel VW 385/1.
- Set gauge (3 mm measuring range) to "0" with 2 mm pre-load.

- Place magnetic plate VW 385/33 onto head of drive pinion.

Note:
^ Make sure magnetic plate VW 385/33 is precisely installed and free of oil.

- Turn universal mandrel until dial gauge tip touches magnetic plate on head of pinion and indicates max. runout (return point).

^ Measured value in following example: = 0.43 mm (red number range)

Note:
^ After removing universal mandrel - check again whether dial gauge stands at "0" with 2 mm pre-load when adjustable master gauge VW 385/30 is attached.

Determining thickness of adjustment shim "S3"

^ Dimension "e" which is based on the master gauge "Eo" is measured for the final drive sets supplied as replacement parts and marked on outer circumference of ring gear.
^ If measured in red numbered area, measured value must be subtracted.
^ If measured in black numbered area, measured value must be added.

- Determine shim(s) according to table.

Available adjustment shims for "S3"

- Remove previous shims "S3*" and "S4*".
- Insert determined shim "S3", 0.90 mm in example, in transmission housing.

Determining thickness of adjustment shim "S4"

^ Determined shim "S3" is installed in transmission housing.

- Coat outer races - 3 - and - 4 - of double angular contact ball bearing with transmission fluid.
- Carefully slide drive pinion - 1 - with double angular contact ball bearing by hand into transmission housing - 2 - and press onto upper outer race - 3 - at the same time.

Note:
^ Warm transmission housing beforehand with a hot air gun in bearing seat area, if necessary.

Outer races - 3 - and - 4 - must not tilt when inserting, they must remain together. Otherwise, the seal - 6 - can be damaged by the pinion face - 5 -.

If the double angular contact ball bearing seal is damaged, the bearing must be replaced.

Determine shim "S4" as follows:

Note:
^ Allocate adjustment shims

- Place determined shim "S4" (0.85 mm in example) and retaining plate - A - (only fits in one position) on transmission housing bolting surface.
- Then tighten screws - arrows - diagonally to 30 Nm.

Performing measuring check, checking dimension "E"

- Install drive pinion with measured adjustment shims "S3" and "S4".

- Install universal mandrel and perform measurement check.
- Read dial indicator counterclockwise (red numbered area).

^ If shims have been determined correctly, deviation "e" (as marked on outer circumference of ring gear) should be indicated on dial within a tolerance of ±0.04 mm.

Note:
^ After removing universal mandrel - check again whether dial gauge stands at "0" with 2 mm pre-load when adjustable master gauge VW 385/30 is attached.