Drive Pinion, Adjusting
Drive pinion, adjusting, 012/01W, 5 SPD. M/T
Special tools, testers and auxiliary items required:
^ Pulling device for crankshaft oil seal VW 204 B
^ Removal Tool VW 296
^ Universal measuring device VW 385
^ Dial Gauge Holder VW 387
^ Thrust Plate VW 401
^ Punch VW 407
Special tools, testers and auxiliary items required:
^ Sleeve VW 519
^ Installation Arbor VW 792
^ Thrust Pad 3005
^ Bushing Puller 3128
^ Assembly Tool 3301
^ Torque Wrench 5-5ONm V.A.G. 1331
Drive pinion only has to be adjusted again according to the following instructions if gear set, tapered roller bearings for drive pinion or transmission housing were replaced.
The goal of the adjustment is to reproduce the setting for the quietest possible running, as obtained on the test machine during production. Make sure that all installation and measurement procedures are performed with the utmost care and cleanliness to ensure a successful result.
Total shim thickness "Stotal" for adjustment shims "S3" + "S4", determining
(adjust preload of tapered roller bearing for drive pinion)
^ Differential removed
^ Installing outer race/tapered roller bearing without adjustment shims into transmission housing.
^ Insert rubber washer and thrust plate into transmission cover.
^ Thrust plates as well as rubber washes of various thicknesses can be installed:
^ Pressing in small tapered roller bearing/outer race with a 1.00 mm initial shim S4 into transmission housing until stop.
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".
^ Press in large tapered roller bearing inner race.
^ Secure lower tapered roller bearing - arrow -.
Note:
^ The illustration shows the drive pinion without gears.
^ Install fully assembled drive pinion into transmission housing.
^ Install transmission cover and tighten to 22 Nm.
^ Turn transmission so that the transmission cover points downward.
^ Press down on drive pinion head using Removal Tool VW 296 until tapered roller bearing outer race contacts transmission cover.
^ Continue pressing down on drive pinion head and turn drive pinion by hand 8 rotations to settle tapered roller bearing.
^ Install dial gauge (3 mm measuring range) and set to "0" with 2 mm pre-load.
^ Use dial gauge extension 30 mm.
Note:
^ The dial gauge extension must be placed on the beveled surface of the drive pinion head.
^ Turn transmission 180°, so transmission cover faces upward.
^ Turn drive pinion 5 rotations in each direction to settle tapered roller bearing.
^ Read play on dial gauge and note.
^ Measured value in example: 0.45 mm
Note:
^ If measurement is repeated, drive pinion must first be rotated 5 complete revolutions in both directions again to seat tapered roller beating. Set dial gauge again to "0" with 2 mm pre-load.
Formula: "S total" = "S4*" + measured value + bearing pre-load
Determining thickness of adjustment shim "S3"
Formula: "S3*" = "S total" - "S4*"
Large outer race/tapered roller bearing.
Insert initial shim "S3" into transmission housing and replace outer race.
^ Install fully assembled drive pinion into transmission housing.
^ Install transmission cover and tighten to 22 Nm.
Preload for tapered roller bearing for drive pinion, checking
^ Turn drive pinion 5 rotations in each direction to settle tapered roller bearing.
Note:
^ If the drive pinion cannot be turned by hand, install a M10 x 20 bolt into face of drive pinion and turn the drive pinion at this bolt with a tool.
^ Remove bolt.
^ Install measuring tools and secure to transmission housing with bolt - arrow -.
^ Attach dial gauge (3 mm measuring range) to center of transmission cover and set to "0" with 2 mm preload.
^ Loosen transmission cover bolts and turn drive pinion.
^ For correctly selected adjustment shims, dial gauge must now display the following value:
^ 0.05 to 0.15 mm
^ Tighten transmission cover bolts to 22 Nm.
^ Remove measuring tools.
^ Position M10 x 20 bolt on drive pinion head and rotate drive pinion 8 full revolutions so that tapered roller bearing settles.
^ Remove bolt.
Determine dimension "e"
Note:
^ Dimension "e" is needed for determining the final total shim thickness of "S3" and "S4"
^ Set adjusting rings of Measuring Bar VW 385/1 to the following values:
Dimension - a - = 35 mm
Dimension - b - = 75 mm
^ Assemble Measuring Bar VW 385/1 according to figure.
Set Master Gauge-Adjustable VW 385/30 after ring gear diameter to Ro and place upon mandrel.
Ring gear diameter 180 mm Ro = 59.65 mm
Ring gear diameter 170 mm Ro = 54.95 mm
^ Set gauge (3 mm measuring range) to zero with 2 mm pre-load.
^ Place end gauge on drive pinion face.
Note:
^ Make sure gauge contact surface is precisely installed and free of oil.
^ Remove master gauge and insert measuring mandrel into housing.
^ If Ro = 54.95, a dial gauge extension = 6.5 mm must be bolted instead of Extension Pin 9.3mm VW 385/15.
^ Dial gauge points toward final drive cover.
^ Install cover for final drive and tighten four bolts to 22 Nm.
^ Using adjustable ring, pull 2nd centering disc out far enough, so that the mandrel can only just be turned by hand.
^ Turn measuring mandrel until dial gauge plunger tip touches end gauge on pinion shaft head and measure the maximum runout (return point).
^ Measured value in the following example: "e" = 0.26 mm (red scale)
Note:
^ After measuring bar has been removed, check again if dial gauge with Master Gauge-Adjustable VW 385130 in place is set to "0" with 2 mm pre-load.
Thickness of adjustment shim "S3", determining
^ If measured in red numbered area, measured value "e" must be subtracted.
^ If measured in black numbered area, measured value "e" must be added.
^ The deviation "r" which is based on the master gauge "Ro" is measured for the final drive sets supplied as replacement parts and marked on the outer circumference of the ring gear.
Formula:
"S3" = "S3*" + "r" + "e" ("e" in black scale)
"S3" = "S3*" + "r" + "e" ("e" in red scale)
Determine shim as closely as possible according to table.
Available adjustment shims for "S3"
*Using shim tolerances it is possible to find the exact shim thickness required, insert two shims if necessary
Thickness of adjustment shim "S4", determining
Formula: "S4" = "S total" - "S3"
Example
Determine shim as closely as possible according to table.
Available adjustment shims for "S4"
Using shim tolerances it is possible to find the exact shim thickness required, insert two shims if necessary
Perform check measurement
Checking dimension "r":
^ Install drive pinion with determined shims "S3" and "S4" and turn 5 rotations in each direction.
^ Insert universal mandrel and perform check measurement.
^ Read dial gauge counterclockwise (red scale).
^ 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.