Ring Gear, Adjusting
Ring gear, adjusting, 012/01W, 5 SPD. M/T
(Adjusting differential)
Special tools, testers and auxiliary items required:
^ Magnetic Plate 50mm Dia. VW 385/17
^ Dial Gauge Holder VW 387
^ Measuring Lever VW 388
^ Ring gear adjustment device VW 521
^ Clamp 3177
^ Torque Wrench 5-50Nm V.A.G. 1331
Special tools, testers and auxiliary items required:
^ Extension Pin 6mm VW 382/10
^ Thrust Plate VW 402
^ Punch VW 408 A
^ Press appliance VW 459/2
^ Thrust Pad VW 472/1
^ Extractor Lever VW 681
Special tools, testers and auxiliary items required
Thrust Plate 2050:
Total shim thickness "S total" for adjustment shims "S1" + "S2", determining
(adjust preload of tapered roller bearing for differential)
^ Drive pinion removed
^ Remove drive flange seals using Extractor Lever VW 681.
^ Remove tapered roller bearings for differential and remove adjustment shims.
^ Drive in small tapered roller bearing outer race with adjustment shim "S2" into transmission housing. Use a shim "S2*" with a 1.20 mm thickness for measurement purposes (2 shims with 0.60 mm).
Note:
^ For initial measurement, an adjustment shim "S2" with a thickness of 1.20 mm is inserted. It is designated as "S2*" in the following. After determining backlash, "S2*" is replaced by final adjustment shim "S2".
^ Press in tapered roller bearing outer race without shim "S1" into differential cover.
^ Install differential into transmission housing without gear drive for Speedometer Vehicle Speed Sensor (VSS) G22.
^ Install cover for differential and tighten four bolts to 25 Nm.
^ Position transmission so that cover for differential faces upward.
^ Turn differential 5 rotations in each direction to seat the tapered roller bearing.
^ Place Magnetic Plate 50 mm Dia. VW 385/17 on differential.
^ Assemble measuring tool, use 30 mm dial gauge extension.
^ Set gauge (3 mm measuring range) to zero with 2 mm pre-load.
Note:
^ Tip of dial gauge must be positioned on the center of the differential.
^ Lift the differential without turning it, read backlash on dial gauge and note.
^ Measured value in the following example: 0.62 mm
Note:
^ If measurement is repeated, differential must first be rotated 5 complete revolutions in each direction again to seat tapered roller beating.
Formula: "S total" = "S2*" + measured value + bearing pre-load
Determining thickness of adjustment shim "S1*"
Note:
^ Initial shim "S1*" is replaced with final shim "S1" after backlash has been determined.
^ The total shim thickness "S total" remains unchanged.
Formula: "S1*" = "S total" - "S2*"
Allocate adjustment shims via Electronic Parts Catalog (ETKA).
Measuring backlash
^ Drive pinion with shims "S3*" and "S4*" installed.
^ Install differential with ring gear: S1 is on the cover side, S2 is installed in transmission housing.
^ Install cover for final drive and tighten bolts to 25 Nm.
^ Turn differential 5 rotations in each direction to seat the tapered roller bearing.
^ Secure Dial Gauge Holder VW 387 to housing.
^ Insert dial gauge with Extension Pin 6 mm VW 382/10 (6 mm).
^ Set Measuring Lever VW 388 to dimension "a":
Determine backlash between teeth flanks as follows:
^ Turn ring gear until it contacts a tooth flank (end of backlash travel).
^ Set dial gauge to "0" with 2 mm pre-load.
^ Turn ring gear back until it contacts opposite tooth flank (backlash).
^ Read backlash and note.
^ Turn ring gear 90° every time and repeat measurement 3 times.
Note:
^ If drive pinion turns when turning differential, install Clamp 3177 - A - so that an exact backlash measurement can be made.
^ Loosen clamping piece to turn the ring gear further.
^ Differential must be installed with cutout for differential bevel gears facing drive pinion.
^ If Clamp 3177 is installed, install differential 180° to final position and repeat measurements.
Determining average backlash
^ Add the four measured values together and divide total by 4 to determine average.
Result: The average backlash is 1.16 mm / 4 0.29 mm
Note:
^ If measurements vary more than 0.06 mm from each other, ring gear or gear set is not installed correctly. Check installation, replace gear set if necessary.
Thickness of adjustment shim "S2", determining
Formula: "S2" = "S2*" - backlash + lift
Determine shim(s) according to table.
Available adjustment shims for "S2"
Using shim tolerances it is possible to find the exact shim thickness required, insert two shims if necessary
Thickness of adjustment shim "S1", determining
Formula: "S1" = "S total" - "S2"
Determine shim(s) according to table. Part numbers Electronic Parts Catalog (ETKA).
Available adjustment shims for "S1"
Using shim tolerances it is possible to find the exact shim thickness required, insert two shims if necessary
Checking measurement
^ After installing adjustment shims "S1" and "S2" turn differential 5 revolutions in each direction so that tapered roller bearings settle.
^ Measure backlash 4 times on circumference.
^ Specified value: 0.12 to 0.22 mm
Note:
^ If backlash is outside tolerance, repeat adjustments. Do not change total shim thickness "S total" while doing so.
^ The individual measurement values may deviate a maximum of 0.06 mm from each other.