Adjusting Drive Pinion

NOTE: The setting value "E" is indicated on the ring gear.

1. Install complete gear set without "S3" shims and tighten all tensioning plate hexagon head nuts to 23 Nm (17 ft lb).
2. Fit gear housing and locate with three nuts.
3. Install and engage sixth gear.





4. Block input shaft with Special Tool 9253 and tighten drive pinion collar nut to 300 Nm (221 ft lb).





5. Set adjusting ring of measuring mandrel VW 385/1 to dimension "a".
6. Assemble measuring mandrel with centering disks 9109, tapered roller bearing, plunger VW 385 /14 and dial gauge extension VW 385/15.





7. Set measuring mandrel with master gauge 385/30 to the setting value (61.43 mm in the example).
- Set dial gauge (3 mm measuring range) to zero with 1 mm preload.





8. Put gauge block plate 9281 on drive pinion head and insert measuring mandrel into transmission case.
- Dial gauge extension is located in the area of the gauge block plate.
9. Fit lateral transmission cover without O-ring and tighten crosswise with 4 nuts.

NOTE:
- Do not use a hammer when fitting the lateral transmission cover (the gauge block plate held by magnets might fall off).
- Fit cover in installation position only by tightening the nuts uniformly.





10. Pull second centering disk with spindle towards the outside until the measuring mandrel can just be turned by hand.
11. Turn measuring mandrel carefully until the dial gauge extension is vertical to the face of the drive pinion head.
- At this point, the pointer of the dial gauge reaches maximum deflection (reverse point) and the dial gauge must be read.

NOTE: The measured value always deviates from the set dimension clockwise (the smaller pointer on the dial gauge is between 1 and 2), i.e. if the dial gauge is set with a preload of 1 mm, the value deviating from 1 is taken as shim thickness "S3".

Example:
- If the small pointer on the dial gauge is between 1 and 2 and the large pointer indicates 0.37 mm, then 0.37 mm is the shim thickness (with 1 mm gauge preload) to be inserted
- Always round up or down to the nearest 0.05 mm (e.g. 0.37 mm to 0.35 mm).

12. After inserting the necessary shims, check the setting value "E" again.
- A deviation of ± 0.03 mm is permissible.