Pinion Shaft, Adjusting
Pinion shaft, adjusting, 01A, 5 SPD. M/T (AWD)
(Adjusting pinion shaft and hollow shaft)
Procedures after which the pinion shaft must be adjusted.
Special tools, testers and auxiliary items required:
^ Torque wrench V.A.G. 1331
^ Removal tool VW 296
^ Universal measuring device VW 385
^ Dial gauge holder VW 387
^ Pressure plate VW 401
^ Punch VW 407
Special tools, testers and auxiliary items required:
^ Tube VW 519
^ Assembly tool VW 792
^ Thrust pad 3062
^ Push-on contact 3182
Procedures after which pinion shaft must be adjusted.
Determine total shim thickness "S total" for adjustment shims "S3" + "S4"
(adjust preload of tapered roller bearing for drive pinion with hollow shaft)
^ Differential removed
^ Press inner race - 1 - for double tapered roller bearing onto drive pinion and secure.
^ Install needle bearing - 2 -.
^ Install circlip - 3 -onto hollow shaft and press on inner race for tapered roller bearing - 4 -.
^ Insert pinion shaft into hollow shaft.
Note: The illustration depicts the hollow shaft without gear wheels. Drive pinion can be adjusted with and also without gear wheels as well.
^ Insert outer race for double tapered roller bearing for drive pinion without adjustment shims into transmission housing
^ Insert outer race for tapered roller bearing for pinion shaft with adjustment shim "S4" (1.0 mm thick) into transmission cover
Note: For the initial measurement, an adjustment shim "S4" of 1.0 mm is inserted. It is designated as "S4" in the following. After determining the measured value "e" "S4" is replaced by the final adjustment shim "S4".
^ Install fully assembled pinion shaft with hollow shaft into transmission housing.
^ Install transmission cover and tighten bolts to 25 Nm.
^ Turn transmission so that the transmission cover points downward.
^ Press onto pinion shaft face using removal tool VW 296 until outer race of tapered roller bearing makes contact in transmission cover.
^ While maintaining pressure, rotate drive pinion 5 rotations each in both directions in opposite direction of hollow shaft so that double tapered roller bearing settles.
^ Turn pinion shaft with hollow shaft 5 rotations in both directions to settle tapered roller bearing.
^ Assemble measuring tool, use 30 mm dial gauge extension.
^ Set gauge (3 mm measuring range) to "0" with 1 mm preload.
Note:
^ Dial gauge extension must stand on hatched area on pinion shaft face.
^ Turn transmission 180°, so transmission cover faces upward.
^ Turn hollow shaft with driveshaft, 5 rotations in both direction to seat tapered roller bearing. Otherwise, measurement will result in false readings.
^ Read play on dial indicator and note.
^ Measured value in example: 0.45 mm
Note:
^ If measurement is repeated, pinion shaft with hollow shaft must first be rotated 5 complete rotations in both directions again to settle tapered roller beating. Set dial gauge again to "0" with 1 mm preload
Formula: "Stotal" = "S4" + measured value + bearing preload
Determining thickness of adjustment shim "S3*"
Formula: "S3*" = "S total" - "S4*"
Remove outer race for double tapered roller bearing, insert adjustment shim "S3" into transmission housing and reinstall outer race.
^ Install fully assembled drive pinion into transmission housing.
^ Install transmission cover and tighten bolts to 25 Nm.
^ Turn pinion shaft with hollow shaft against hollow shaft 5 rotations in both directions to settle tapered roller bearings.
^ Install measuring tools and secure to transmission housing with bolt - arrow -.
^ Set gauge (3 mm measuring range) to "0" with 2 mm preload.
^ Loosen transmission cover bolts and turn pinion shaft.
^ Dial gauge must now display the following value for correctly selected adjustment shims:
^ 0.05 to 0.15 mm
^ Tighten transmission cover bolts to 25 Nm.
^ Remove measuring tools.
^ Turn drive pinion with hollow shaft against hollow shaft 5 rotations in both directions to settle the tapered roller bearings.
Determining dimension "e"
Note:
^ Dimension "e" is required to determine final shim thickness of "S3" and "S4"
^ Set adjustment rings of universal mandrel VW 385/1 to following values:
Dimension - a - = 35 mm
Dimension - b - = 75 mm
^ Assemble universal mandrel VW 385/1 as shown in the illustration:
Dial gauge extension - A -, 6.5 mm long
Adjustable master gauge VW 385/30
^ Set adjustable master gauge VW 385/30 to Ro = 54.95 mm and attach to mandrel (for ring gear diameter 170 mm).
^ Set gauge (3 mm measuring range) to "0" with 2 mm preload.
^ Place end gauge on pinion shaft face.
Note:
^ Make sure gauge contact surface is precisely installed and free of oil.
^ Remove master gauge and insert measuring mandrel into housing.
^ A dial gauge extension - A - = 6.5 mm long must be screwed in.
Dial gauge faces cover for final drive
^ Install cover for final drive and tighten four bolts to 25 Nm.
^ Using adjustable ring, pull 2nd centering disc VW 385/2 out far enough, so that the mandrel can only be turned by hand.
^ Turn measuring mandrel until dial indicator plunger tip touches end gauge on pinion shaft head and measure maximum runout (return point).
Measured value in following example: "e" = 0.26 mm (red numbered area)
Note: After removing universal measuring bar, check again whether dial gauge stands at "0" with 2 mm preload when adjustable master gauge VW 385130 is attached.
Determining thickness of adjustment shim "S3"
^ The deviation, or tolerance "r" which is based on master gauge "Ro" is measured for final drive sets supplied as replacement parts and marked on outer circumference of ring gear.
^ If measured in red numbered area, measured value "e" must be subtracted.
^ If measured in black numbered area, measured value "e" must be added.
Formula:
"S3" = "S3" + "r" + "e" ("e" in black numbered area)
"S3" = "S3" + "r" - "e" ("e" in red numbered area)
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.
Determining thickness of adjustment shim "S4"
Formula: "S4" = "S total" - "S3"
Determine shim(s) according to table.
Available shims for "S4"
Using shim tolerances it is possible to find the exact shim thickness required, insert two shims if necessary
Perform check measurement
Check dimension "r"
^ Install drive pinion/hollow shaft with measured out adjustment shims "S3" and "S4".
^ Turn hollow shaft against driveshaft, 5 rotations in each direction to seat tapered roller bearing.
^ Turn hollow shaft with driveshaft, 5 rotations in both direction to seat tapered roller bearing.
^ Install universal mandrel and perform check measurement.
^ Read dial indicator counterclockwise (red numbered area).
If shims have been determined correctly, deviation "r" (as marked on outer circumference of ring gear) should be indicated on dial within a tolerance of ± 0.04 mm.