Pinion Shaft, Adjusting

Pinion shaft, adjusting, 01A, 5 SPD. M/T (AWD)

Special tools, testers and auxiliary items required

Universal measuring device VW 385:

Holding fixture VW 540:

Note:
^ Before adjusting pinion shaft, adjust ring gear (determine total shim thickness "S total" for adjustment shims "S1" + "S2").
^ Pinion shaft only has to be adjusted again if gear set, tapered roller bearings for pinion shaft or final drive housing was replaced. List of adjustments.
^ Do not grease new tapered roller bearings for friction torque measurement The bearings are already greased with a special oil from the factory.

Determine adjustment shim "S3"
(adjust preload of tapered roller bearing for pinion shaft)
^ Clamp final drive in assembly fixture.
^ Pull both tapered roller bearing outer races without adjustment shims into housing and





^ Install pinion shaft without spacer sleeve.
^ Heat tapered roller bearing inner race to 100°C and install on pinion shaft.

CAUTION: Wear protective gloves!

Note:
^ Do not grease new tapered roller bearings for friction torque measurement The bearings are already greased with a special oil from the factory.
^ Only install spacer sleeve if friction torque has been adjusted (Shim "S3" already determined).





^ Install flange for driveshaft and tighten hex nut for flange
A - Standard torque gauge 0 to 600 Ncm
B - 36 mm socket insert

Note:
^ If necessary use 314 to 112 reducing piece.





^ Screw on retainer 3028 with two hex bolts M8x30 - A
B - 36 mm wrench socket insert

^ Tighten pinion shaft nut to achieve following friction torque:





^ When tightening nut, final drive must be supported (e.g. using universal transmission support V.A.G 1359/2 in conjunction with engine/transmission jack V.A.G 1383 A).





^ Adjust adjustment ring of universal measurement bar VW 385/1.

Dimension - a - = 60 mm
^ Adjust slide-able adjustment ring.
^Dimension - b - = 55 mm





^ Complete measuring bar as shown in illustration.
^ Dial gauge extension VW 385/15 = 9 mm long
^ Adjust universal adjustable master gauge VW 385/30.
^ Ro = 57.50 mm
^ Set gauge (3 mm measuring range) to "0" with 2 mm preload.

Note:
^ Turn differential at least 5 rotations in each direction to seat the tapered roller bearings. Otherwise, measurement will result in false readings.





^ Place end gauge VW 385/33 on pinion shaft face.





^ Remove master gauge and insert measuring mandrel into housing.
^ Centering Disc 69 mm Dia. VW385/3 faces cover for final drive
^ Install cover for final drive and tighten four bolts.
^ Using adjustable ring, pull 2nd centering disc out far enough, so that the mandrel can only just be turned by hand.

Determining dimension "e"





^ Turn measuring mandrel until dial indicator plunger tip touches end gauge on pinion shaft head and measure the maximum runout (return point). Measured value is dimension "e" (red numbered area).
^ Measured value in following example: "e" = 1.60 mm

Note:
^ Dimension "e" is required to determine thickness of adjustment shim "S3"

^ Finally, after removing universal measuring bar, check again whether dial gauge stands at "0" with 2 mm preload when adjustable master gauge VW 385/30 is attached, otherwise repeat measurement.

Determining thickness of adjustment shim "S3"

Formula: "S3" = "e" - "r"

e - determined value

r - deviation (indicated in 1/100 mm on ring gear)





Determine shim(s) according to table.

Available shims for "S3"





Using shim tolerances, it is possible to find the exact shim thickness required, insert two shims if necessary
Remove universal mandrel.
^ Remove pinion shaft and large tapered roller bearing outer race and install together with determined adjustment shim "S3" and spacer sleeve.
^ Insert tapered roller bearing inner race and tighten nut for pinion shaft until specified friction torque is attained

Note:
^ Do not grease new tapered roller bearings for friction torque measurement. The bearings are already greased with a special oil from the factory.
^ Increase tightening torque slowly and measure friction torque at regular intervals. If the specified friction torque is exceeded, replace spacer sleeve and repeat adjustment! Any spacer sleeve that has been compressed too far one time must be replaced.

^ Adjust friction torque to following values:





Perform check measurement
Check dimension "r"
^ Rotate pinion shaft at least 8 complete revolutions in both directions.





^ Install universal measuring tool and perform measurement check.
^ If adjustment shims were determined correctly, dial indicator must indicate deviation "r" with a tolerance of ± 0.05 mm (reading counter-clockwise in red number display).
^ Secure pinion shaft nut using punch.
^ After pinion shaft nut has been secured, the radial run-out at driveshaft flange must be measured and marked.