Pinion Gear For 5TH/6TH and Reverse Gear, Adjusting

Pinion gear for 5th/6th and reverse gear, adjusting
(Determine adjustment shim size for pinion shaft).

Special tools and equipment
^ VW353 transmission support
^ VW387 dial gauge holder
^ VW407 punch
^ VW433 thrust pad
^ VW792 installation arbor
^ VW 801 holding fixture

Special tools and equipment
^ 2050 thrust plate
^ 3235 press device
^ VAG 1331 torque wrench
^ 1 Kukko 21/7 extractor
^ 4 Kukko 22/2 support

Re-adjustment of the pinion shaft is essential if the following components are replaced:
^ Transmission housing
^ Clutch housing
^ Pinion shaft for 5th/6th and reverse gear or
^ Tapered roller bearing Adjustment overview, Refer to Differential Assembly, Adjustments

Requirements

^ Sealing surfaces of clutch housing and transmission housing must be free of sealant.
^ Only install shaft to be measured when measuring.
- Press tapered roller bearing outer race into transmission housing using an adjustment shim of 1.70 mm thickness. Support transmission housing with 2050 thrust pad below bearing support.
- Insert complete pinion shaft for 5th/6th and reverse gear into clutch housing.

- Install transmission housing and tighten bolts - A - and - B - diagonally to proper tightening torque.

- Install measuring tools. Insert washers for a total thickness of 8 mm at securing bolt (arrow) for VW792 installation arbor to clutch housing.
- Set dial indicator (3 mm measuring range) to O with 1 mm preload.
- Unscrew bolts for clutch housing/transmission housing diagonally until the bolts release the transmission housing or pinion shaft.
- Read measured value on dial indicator and note example: 0.27 mm).

Notes: If no measuring value is displayed on dial indicator when securing bolts from clutch housing/transmission housing are loosened, install adjustment shim 1.95 mm (part number 084 409 383 AS) or adjustment shim 2.20 mm (part number 084 409 383 BD) for the measurement.

Determine adjustment shim
The specified bearing preload is reached if the determined measurement value (0.27 mm) is subtracted from the adjustment shim (1.70 mm) and a constant value for compression (0.20 mm) is added.

Table of adjustment shims
Different tolerances allow for required adjustment shim thickness to be measured exactly.

- Press in tapered roller bearing outer race with the determined adjustment shim (i.e. 0.06 in). Support transmission housing with 2050 thrust pad below bearing support.

Perform check measurement
^ Determined adjustment shim installed