Ring Gear, Adjusting
Ring gear, adjusting, 01V, 5 SPD. A/T (AWD)
(Adjusting differential)
Special tools, testers and auxiliary items required:
^ Magnetic plate 50mm dia. VW385/17
^ Dial gauge holder VW387
^ Measuring lever VW388
^ Ring gear adjustment device VW521
^ Torque wrench 550 Nm V.A.G. 1331
^ Dial gauge
^ Hex bolt M8x45
A new ring gear adjustment is necessary if:
Rear axle housing, final drive cover, tapered roller bearing for differential, differential housing or gear set has been replaced.
Adjustment overview.
Total shim thickness "S total" (S1 Plus S2), determining
(adjust preload of tapered roller bearing for differential)
^ Drive pinion is removed!
If only the tapered roller bearing for differential has been replaced, ring gear can be removed from differential housing. Drive pinion then does not need to be removed.
^ Pry out seal for flanged shaft using lever.
^ Remove outer race/tapered roller bearings for differential and remove adjustment shims.
^ Press in outer race/tapered roller bearing with a 1.00 mm thick adjustment shim until stop into housing (S2-side).
^ Insert differential into housing.
Ring gear is on the cover side.
^ Set cover in place and tighten bolts to 25 Nm.
^ Assemble tools on differential housing on the transmission housing side.
^ Turn final drive with cover side upward
^ Turn differential 8 rotations in each direction to seat the tapered roller bearing.
^ Install measuring tools.
^ Place magnetic plate 50mm dia. VW385/17 on differential.
A - dial gauge extension 30 mm
^ Screw in hex bolt M 8 x 45 - B -.
^ Place dial gauge extension on center of magnetic plate 50 mm dia. VW385/17.
^ Set gauge (3 mm measuring range) to zero with 2 mm preload.
^ Move differential up and down - direction of arrow - without turning.
^ Read play on dial gauge.
Example
0.50 mm
"S total" determining (S1 + S2)
"S total" = measurement result + preload
^ If it is desired to repeat the measurement, turn differential 8 rotations in each direction to seat the tapered roller bearing.
The specified bearing preload is obtained by adding a constant preload figure of (0.30 mm) to the reading obtained (0.50 mm) and the thickness of the shim installed (1.00 mm).
Example:
Install the determined total shim thickness (1.80 mm in the example) behind outer race/tapered roller bearing in housing (S2-side).
Allocate adjustment shims via original parts distributor.
Initial shim "S1", determining thickness
(ring gear side)
Initial shim "S1" is replaced with final shim S1 after backlash has been determined.
Allocate adjustment shims S1 and S2 via the original parts distributor.
^ Varying tolerances make it possible to measure the required shim thickness exactly.
Install determined adjustment shims, S1 on ring gear side, S2 opposite ring gear, use 2 adjustment shims if necessary.
Torsional backlash, adjusting
^ Drive pinion with S3 installed.
^ Compensation: "S total" (S1 + S2) installed into transmission housing.
^ Install cover for final drive and tighten bolts to 25 Nm.
^ Turn differential a few times in each direction to seat the tapered roller bearing.
^ Install measuring tools.
^ Use dial gauge extension VW382/10 (6 mm flat).
Set measuring lever VW388 to dimension "a" = 60 mm.
^ Twist ring gear until stop. Set dial gauge to zero with 1 mm preload, turn back ring gear and read off backlash. Note value.
^ After an additional turn of ring gear approximately 90°, repeat measuring procedure three more times. Add the four measured values and calculate mean backlash.
Mean backlash, calculating
Example:
Mean backlash = 1.20 mm : 4 = 0.30 mm.
If the individual - measurements differ by more than 0.06 mm from each other, the installation of the ring gear or the final drive set itself is not correct. Check repair work, replace gear set if necessary.
Shim S2, determining thickness
(opposite ring gear)
Lift = 0.15 mm
Table of adjustment shims
Allocate adjustment shims via original parts distributor.
Shim S1, determining thickness
(ring gear side)
Table of adjustment shims distributor
^ Varying tolerances make it possible to measure the required shim thickness exactly.
^ Initial shim "S1" is replaced with final shim S1 after backlash has been determined.
Install determined adjustment shims, S1 on ring gear side and S2 opposite ring gear, use 2 adjustment shims if necessary.
Perform check measurement.
Measure backlash four times at circumference.
^ It must be 0.12 0.22 mm.
If the individual measurements differ by more than 0.06 mm from each other, the installation of the ring gear or the final drive set itself is not correct. Check repair work, replace gear set if necessary.