Adjusting

Adjustment Summary
- When servicing the transmission, adjustment of the output shaft (pinion), final drive gear or gear set is necessary only if components that have a direct effect on the adjustment of the final drive unit are replaced. Refer to the table to avoid unnecessary adjustment





Differential Adjusting
- Drive the tapered roller bearing outer race (opposite gear side) along with shim S2 always (1 mm thick), into clutch housing

CAUTION: The inner and outer races of the tapered roller bearings are a matched set and cannot be interchanged.





- Drive the tapered roller bearing outer race (gear side) into the transmission housing without shim
- Install the differential gears in clutch housing.
- Install the transmission housing (with gasket) with only 5 bolts
- Tightening torque: 25 Nm (18 ft lb)





- Set up the dial indicator and zero with 1 mm preload
- Move the differential assembly up and down and record axial play indicated by dial indicator - example: 0.90 mm

CAUTION: Do not rotate the differential during the measurement as this will cause the bearings to settle, which will result in incorrect reading.





Determining thickness of shim S1
- The thickness of shim S1 is determined by adding:
^ Specified bearing preload (a constant, 0.40 mm)
^ The measured axial play (example: 0.90 mm)

Example:
Measured axial play (0.90 mm)
+ Preload (constant) (0.40 mm)
= Thickness of shim S1 -- (1.30 mm)

- Remove the transmission housing and drive out tapered roller bearing outer race
- Install shim or shims S1 of correct thickness (determined above), installing thickest shim (1.0 mm when possible) first


NOTE: Varying tolerances make it possible to select the precise shim thickness required

Available shims:
0.15mm Part no. 020409231
0.30mm Part no. 020 409 231 A
0.60mm Part no. 020 409 231 D
0.70mm Part no. 020 409 231 E
0.80mm Part no. 020 409 231 F
1.00mm Part no. 020409298

CAUTION: Part numbers are listed for reference only. Always check with your Parts department for the latest in formation.

- Drive in outer race again, lubricate bearing with gear oil
- Install transmission housing with gasket and tighten down





Bearing preload, checking
- A = Commercially available torque gauge 0-600 Ncm
- Friction torque: 50-150 Ncm (4-13 in lb) (bearings lubricated with gear oil
- Min. friction torque of used bearings: 30 Ncm (3 in lb)