Pinion, Adjusting
Pinion, adjusting, 01V, 5 SPD. A/T (AWD)
Special tools, testers and auxiliary items required:
^ Universal measuring device VW385
^ Holding fixture VW540
^ Friction meter VAS 6222
^ Dial gauge
^ Long socket wrench insert AF36
Drive pinion only has to be adjusted again according to the following instructions if gear set, tapered roller bearings for drive pinion or rear axle housing were replaced.
Adjustment shim S3, determining thickness
(adjust preload of tapered roller bearing for drive pinion).
^ Pull both tapered roller bearing outer races without adjustment shims into housing
^ Insert drive pinion with inner race/large tapered roller bearing without spacer sleeve into housing.
CAUTION: Wear protective gloves!
^ Heat up small tapered roller bearing inner race to approximately 100°C and place on drive pinion.
^ Install flange for propshaft and tighten hex nut for flange
^ Install new tapered roller bearing as supplied and do not use additional oil.
^ Only install spacer sleeve if friction torque has been adjusted (Shim "S3" already determined).
Increase tightening torque gradually, frequently measuring friction torque. If the specified friction torque is surpassed, replace spacer sleeve and repeat adjustment! A spacer sleeve which has been compressed too much cannot be reused.
To measure friction torque, use friction meter VAS 6222 and long socket insert AF36.
Set following frictional torques:
run for at least 50 km (30 miles)
^ Set adjusting ring of measuring bar VW385/1 to dimension "a" = 60 mm.
^ Set adjustable ring to dimension "b" = 55 mm.
^ Assemble measuring bar VW385/1 as shown. extension pin 9.3 mm VW385/15 = 9 mm long. Set master gauge-adjustable VW385/30 to R = 57.50 mm.
^ Set gauge (3 mm measuring range) to zero with 2 mm preload.
^ Turn drive pinion 8 rotations in each direction to seat the tapered roller bearing.
^ Place end gauge on drive pinion face.
^ Remove master gauge and insert measuring mandrel into housing.
^ Attach rear final drive cover and tighten with 4 bolts.
^ Using adjustable ring, pull 2nd centering disc out far enough, so that the mandrel can only just be turned by hand.
^ Measure dimension "e". Turn measuring mandrel until dial indicator extension touches end gauge and measure the maximum runout (return point). Measured value is dimension "e" (red numbered area). Example: 1.60 mm
Adjustment shim "S3", determining thickness
"S3" = e - r
Table of adjustment shims
Allocate adjustment shims via original parts distributor.
^ Remove universal mandrel.
^ Remove drive pinion and large tapered roller bearing outer race and install together with determined adjustment shim "S3" and spacer sleeve.
^ Insert small tapered roller bearing inner race and tighten drive pinion nut until specified friction torque is obtained
Increase tightening torque gradually, frequently measuring friction torque. If the specified friction torque is surpassed, replace spacer sleeve and repeat adjustment! A spacer sleeve which has been compressed too much cannot be reused.
Set following frictional torques:
* run for at least 50 km (30 miles)
Performing measurement check - checking dimension "r"
^ Turn drive pinion 8 rotations in each direction to seat the tapered roller bearing.
Insert measuring bar VW385/1 and measure dimension "r".
If adjustment shims were determined correctly, dial indicator must indicate deviation "r" with a tolerance of + 0.05 mm (reading counterclockwise in red number display).
^ After the nut for drive pinion has been secured, the radial run-out at propshaft flange must be measured and marked.