Adjusting
Overview of adjustments
1 Input gear
^ Adjusting
2 Drive pinion
^ Adjusting
3 Differential
^ Adjusting
4 Shim for input gear
^ Determine thickness on basis of table,
5 Shim for drive pinion
^ Determine thickness on basis of table
^ Determine part number from parts catalog
6 Shim for differential
7 Taper roller bearings for input gear
^ Always replace together
^ Measure friction torque via pinion shaft. Friction torque of new taper roller bearings must be 180 ... 220 Nm (16 - 20 inch lbs.) greater than friction torque of pinion shaft
8 Taper roller bearings for drive pinion
^ Always replace together
^ Re-determine shim when replacing taper roller bearings
9 Taper roller bearings for differential
^ Always replace together
^ Measure friction Torque via drive pinion. Friction torque of new taper roller bearings Must be 60 ... 80 Nm (5 - 7 inch lbs.) greater than friction torque of drive pinion
Adjustments to be completed after replacing individual components
When working on the transmission the following components only require adjustment if individual components have been replaced that directly affect the final drive adjustment. To eliminate unnecessary adjustments observe following table:
Drive pinion, adjusting
Required special tools and equipment:
^ VW 385/17 End dimension plate
^ VW 387 Universal dial gauge bracket
^ Dial gauge
^ Torque gauge (commercially available) 0 ... 600 Nm (0 - 50 inch lbs.)
Conditions:
^ Support ring for drive pinion bearing is installed and secured.
^ Parking lock mechanism and parking lock gear are installed.
Adjusting:
^ Place two shims (each 1.5 mm thick) -arrow- onto the drive pinion.
^ Place output gear with taper roller bearing onto drive pinion and tighten nut (41 mm socket) to 250 Nm. Engage parking lock when performing this step.
^ Insert dial gauge -A- and zero with a preload of 1 mm. Move drive pinion up and down. Read play at dial gauge and note (example C,.93 mm).
Note:
When measuring, do not turn drive pinion as the bearings will otherwise settle causing the measurement to be incorrect.
Shims, determining
In this example, the specified bearing pre load is achieved if the reading (0.93 mm), the preload of the bearings 0, 12 mm and the amount for compression 0,10 mm are deducted from the 2 x 1.5 mm thick shims.
^ Remove output gear. Determine size of shim on basis of table, and install on drive pinion.
^ Re-install output gear and tighten nut to 250 Nm (184 ft. lbs.) and secure with drift.
Table of shims for drive pinion and input gear
Friction torque, checking
The friction torque can only be checked if taper roller bearings have been replaced.
If taper roller bearings have not been replaced, the friction torque must not be checked. In this case adjust drive pinion as described from.
^ Lubricate bearing with gear oil before measuring torque.
A Torque gauge, commercially available, 0 ... 600 Nm (0 - 50 inch lbs.)
B Socket (41 mm)
The friction torque of new taper roller bearings must be 80 ... 120 Nm (7 - 11 inch lbs.).
Input gear, adjusting
Required special tools and equipment:
^ VW 382 Measuring appliance
^ V.A.G 1332 Torque wrench or equivalent
^ Dial gauge
^ Torque gauge (commercially available) 0 ... 600 Nm (0 -50 inch lbs.)
^ Tighten socket head fastener without dished washer and without shim to 100 Nm (74 ft. lbs.)
-A- Torque wrench
-B- 22 mm socket
The parking lock must be engaged.
^ Remove socket head fastener.
^ Measure distance between input gear and taper roller bearing inner race.
^ Insert dial gauge and zero with a preload of 3 mm. Note reading (example 1.00 mm).
^ The thickness of the dished washer 1.50 mm must be added to the reading of = 2.50 mm.
Shim, determining
In this example, the specified bearing preload is achieved if the bearing preload of 0.18 mm is deducted from the figure obtained from the measurement (dished washer + reading) of 2.50 mm.
^ Determine shim on the basis of the table and install on drive shaft. Table of shims.
^ Insert axial needle bearing and tighten socket head fastener including dished washer to 250 Nm. (184 ft. lbs.)
Note:
Insert axial needle bearing for input shaft before tightening socket head fastener Installation position refer to Input gear, removing and installing.
Friction torque, checking
The friction torque can only be checked if taper roller bearings have been replaced.
If taper roller bearings have not been replaced, the friction torque must not be checked. In this case adjust input gear as described.
The friction torque of new taper roller bearings must be 180 ... 220 Nm (7-11 inch lbs.) greater than at the pinion shaft.
^ Before checking torque, lubricate bearings with ATF
-A- Torque gauge, (commercially available) 0 ... 600 Nm (0 - 50 inch lbs.)
-B- Socket (41 mm)
Differential, adjusting
Required special tools and equipment:
^ 3155 Ring nut wrench
^ V.A.G 1332 Torque wrench or equivalent
^ Torque gauge (commercially available) 0 ... 600 Nm (0 - 50 inch lbs.)
^ Tighten bearing body with 3155 to 150 Nm (111 ft. lbs.) to the stop and secure.
^ Tighten adjusting ring to 50 Nm (37 ft. lbs.) and mark.
Note:
When measuring do not turn differential otherwise the bearings will settle causing the measurement to be incorrect.
^ Turn adjusting ring by five locking lugs -arrow- and secure to achieve the preload of the taper roller bearings.
Friction torque, checking
-A- Torque gauge (commercially available) 0 ... 600 Nm (0-50 inch lbs.)
The friction torque of new tapper roller bearings must be 60 ... 80 Nm (5 - 7 inch lbs.) greater than at the drive pinion.
^ Before checking torque lubricate bearing with gear oil.
Example