Pinion, Adjusting
Pinion, Adjusting
Procedures after which the drive pinion must be adjusted, refer to => [ Adjustment Overview ] Adjustment Overview.
There are 2 procedures when adjusting drive pinions.
1. Adjusting gear seats where dimension "E" is indicated on the outer circumference of ring gear.
2. Adjusting gear seats where dimension "e" is indicated on outer circumference of ring gear.
Adjusting gear seats where dimension "E" is indicated on outer circumference of ring gear
Special tools, testers and auxiliary items required
• Universal measuring device (VW 385)
• Torque wrench (VAG 1331)
• Depth gauge, e.g. digital depth gauge (VAS 6087)
• Dial gauge
Determine thickness of previous shim "S3 " and "S4"
• Differential removed.
• Double angular contact ball bearing is pressed onto drive pinion.
• For the initial measurement, an adjustment shim "S3" of 1.00 mm is inserted. It is designated as "S3*" in the following. After adjusting dimension "E", "S 3*" is replaced by the final shim "S3".
- Secure transmission housing to transmission mounting (VW 353). To do so, transmission housing must be vertical.
- Place shim "S3*" in transmission housing.
- Coat outer races - 3 - and - 4 - of double angular contact ball bearing with transmission fluid.
- Carefully slide drive pinion - 1 - with double angular contact ball bearing by hand into transmission housing - 2 - and press onto upper outer race - 3 - at the same time.
• Warm transmission housing beforehand with a hot air gun in bearing seat area, if necessary.
Outer races - 3 - and - 4 - must not tilt when inserting, they must remain together. Otherwise, seal - 6 - can be damaged by pinion face - 5 -.
If double angular contact ball bearing seal is damaged, the bearing must be replaced.
Determine previous shim "S4" as follows:
- Using a digital depth gauge (e.g digital depth gauge (VAS 6087)), measure from outer race/double angular contact ball bearing - 1 - to retaining plate bolting surface - 2 -.
In the example, gap dimension - a - = 1.14 mm. Determine previous shim "S4" according to table,
• For the initial measurement, an adjustment shim "S4" of 0.95 mm is inserted. It is designated as "S4*" in the following. After adjusting dimension "E", "S 4*" is replaced by the final shim "S4".
- Place previous shim "S4*" (0.95 mm in example) and retaining plate - A - (only fits in one position) on transmission housing bolting surface.
- Clean threads of previous screws - arrows - with a wire brush. Then tighten screws diagonally to 30 Nm.
Dimension "E", adjusting
• Dimension "E" must be adjusted at master gauge (VW 385/30) to determine final shim thickness of " S3" and "S4".
- Set adjustment rings of universal mandrel (VW 385/1 ) to the following values:
• Dimension - a - = 45 mm
• Dimension - b - = 60 mm
- Assemble universal mandrel (VW 385/1) as shown in the illustration:
• Dial gauge extension (VW 385/16), 12.3 mm long
- Set master gauge (VW 385/30) to dimension "E" in example = 62.50 mm and place on universal mandrel (VW 385/1).
- Set gauge (3 mm measuring range) to "0" with 2 mm pre-load.
- Place magnetic plate (VW 385/33) onto head of drive pinion.
• Make sure magnetic plate (VW 385/33) is precisely installed and free of oil.
- Remove master gauge (VW 385/30) and insert universal mandrel in transmission housing.
• A dial gauge extension - A - = 12.3 mm long must be screwed in.
• Dial gauge faces final drive cover.
• O-ring is inserted in final drive cover.
- Install transmission cover and tighten 4 bolts to 24 Nm.
- Using adjustable ring, pull 2nd centering disc ( VW 385/36) out far enough, so that the universal mandrel can only just be turned by hand.
- Turn universal mandrel until dial gauge tip touches magnetic plate on head of pinion and indicates max. runout (return point).
• Measured value in following example: = 0.15 mm (red number range)
• After removing universal mandrel - check again whether dial gauge stands at "0" with 2 mm pre-load when adjustable master gauge (VW 385/30) is attached.
Determining thickness of adjustment shim "S 3"
• If measured in red numbered area, measured value must be subtracted.
• If measured in black numbered area, measured value must be added.
- Determine shim(s) according to table. Part numbers.
Available adjustment shims for "S3"
* Using shim tolerances it is possible to find the exact shim thickness required, insert two shims if necessary.
- Remove previous shims "S3*" and " S4*".
- Insert determined shim "S3", 0.85 mm in example, in transmission housing.
Determining thickness of adjustment shim "S 4"
• Determined shim "S3" is installed in transmission housing.
- Coat outer races - 3 - and - 4 - of double angular contact ball bearing with transmission fluid.
- Carefully slide drive pinion - 1 - with double angular contact ball bearing by hand into transmission housing - 2 - and press onto upper outer race - 3 - at the same time.
• Warm transmission housing beforehand with a hot air gun in bearing seat area, if necessary.
Outer races - 3 - and - 4 - must not tilt when inserting, they must remain together. Otherwise, the seal - 6 - can be damaged by the pinion face - 5 -.
If the double angular contact ball bearing seal is damaged, the bearing must be replaced.
Determine shim "S4" as follows:
- Using a digital depth gauge (e.g digital depth gauge (VAS 6087)), measure from outer race/double angular contact ball bearing - 1 - to retaining plate bolting surface - 2 -.
In the example, gap dimension - a - = 0.99 mm. Determine shim "S4" 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.
- Place determined shim "S4" (0.80 mm in example) and retaining plate - A - (only fits in one position) on transmission housing bolting surface.
- Then tighten bolts - arrows - diagonally to 30 Nm.
Performing measuring check, checking dimension " E"
- Install drive pinion with measured adjustment shims "S 3" and "S4".
- Install universal mandrel and perform measurement check.
- Read dial indicator counterclockwise (red numbered area).
• If adjustment shims were determined correctly, dimension "E" must have a clearance of ± 0.04 mm.
• After removing universal mandrel - check again whether dial gauge stands at "0" with 2 mm pre-load when adjustable master gauge (VW 385/30) is attached.
Adjusting gear seats where dimension "e" is indicated on outer circumference of ring gear
Special tools, testers and auxiliary items required
• Universal measuring device (VW 385)
• Torque wrench (VAG 1331)
• Depth gauge, e.g. digital depth gauge (VAS 6087)
• Dial gauge
Determining thickness of previous shims "S 3" and "S4"
• Differential removed.
• Double angular contact ball bearing is pressed onto drive pinion.
• For the initial measurement, an adjustment shim "S3" of 1.00 mm is inserted. It is designated as "S3*" in the following. After adjusting dimension "e", "S 3*" is replaced by the final shim "S3".
- Secure transmission housing to transmission mounting (VW 353). To do so, transmission housing must be vertical.
- Place shim "S3*" in transmission housing.
- Coat outer races - 3 - and - 4 - of double angular contact ball bearing with transmission fluid.
- Carefully slide drive pinion - 1 - with double angular contact ball bearing by hand into transmission housing - 2 - and press onto upper outer race - 3 - at the same time.
• Warm transmission housing beforehand with a hot air gun in bearing seat area, if necessary.
Outer races - 3 - and - 4 - must not tilt when inserting, they must remain together. Otherwise, the seal - 6 - can be damaged by the pinion face - 5 -.
If the double angular contact ball bearing seal is damaged, the bearing must be replaced.
Determine previous shim "S4" as follows:
- Using a digital depth gauge (e.g digital depth gauge (VAS 6087)), measure from outer race/double angular contact ball bearing - 1 - to retaining plate bolting surface - 2 -.
In the example, gap dimension - a - = 1.14 mm. Determine previous shim "S4" according to table,
• For the initial measurement, an adjustment shim "S4" of 0.95 mm is inserted. It is designated as "S4*" in the following. After adjusting dimension "e", "S 4*" is replaced by the final shim "S4".
- Place previous shim "S4*" (0.95 mm in example) and retaining plate - A - (only fits in one position) on transmission housing bolting surface.
- Clean threads of previous bolts - arrows - with a wire brush. Then tighten bolts diagonally to 30 Nm.
Dimension "e", adjusting
• Dimension "e" must be adjusted to determine final shim thickness of "S3" and "S4" for this gear set.
- Set adjustment rings of universal mandrel (VW 385/1 ) to the following values:
• Dimension - a - = 45 mm
• Dimension - b - = 60 mm
- Assemble universal mandrel (VW 385/1) as shown in illustration:
• Dial gauge extension (VW 385/16), 12.3 mm long
- Set master gauge (VW 385/30) to dimension "Eo" = 62.50 mm and place on universal mandrel (VW 385/1).
- Set gauge (3 mm measuring range) to "0" with 2 mm pre-load.
- Place magnetic plate (VW 385/33) onto head of drive pinion.
• Make sure magnetic plate (VW 385/33) is precisely installed and free of oil.
- Remove master gauge (VW 385/30) and insert universal mandrel in transmission housing.
• A dial gauge extension - A - = 12.3 mm long must be screwed in.
• Dial gauge faces final drive cover.
• O-ring is inserted in final drive cover.
- Install transmission cover and tighten 4 bolts to 24 Nm.
- Using adjustable ring, pull 2nd centering disc ( VW 385/36) out far enough, so that the universal mandrel can only just be turned by hand.
- Turn universal mandrel until dial gauge tip touches magnetic plate on head of pinion and indicates max. runout (return point).
• Measured value in following example: = 0.43 mm (red number range)
• After removing universal mandrel - check again whether dial gauge stands at "0" with 2 mm pre-load when adjustable master gauge (VW 385/30) is attached.
Determining thickness of adjustment shim "S 3"
• Dimension "e" which is based on the master gauge " Eo" is measured for the final drive sets supplied as replacement parts and marked on outer circumference of ring gear, refer to => [ Adjustment and marking gear set, dimension indicated ] Gear Sets, Adjustments and Markings.
• If measured in red numbered area, measured value must be subtracted.
• If measured in black numbered area, measured value must be added.
Formula:
"S3" = "S3*" + " e" + "measured value" ("measured value" in black numbered area)
"S3" = "S3*" + " e" - "measured value" ("measured value" in red numbered area)
- Determine shim(s) according to table. Part numbers.
Available adjustment shims for "S3"
* Using shim tolerances it is possible to find the exact shim thickness required, insert two shims if necessary.
- Remove previous shims "S3*" and " S4*".
- Insert determined shim "S3", 0.90 mm in example, in transmission housing.
Determining thickness of adjustment shim "S 4"
• Determined shim "S3" is installed in transmission housing.
- Coat outer races - 3 - and - 4 - of double angular contact ball bearing with transmission fluid.
- Carefully slide drive pinion - 1 - with double angular contact ball bearing by hand into transmission housing - 2 - and press onto upper outer race - 3 - at the same time.
• Warm transmission housing beforehand with a hot air gun in bearing seat area, if necessary.
Outer races - 3 - and - 4 - must not tilt when inserting, they must remain together. Otherwise, the seal - 6 - can be damaged by the pinion face - 5 -.
If the double angular contact ball bearing seal is damaged, the bearing must be replaced.
Determine shim "S4" as follows:
- Using a digital depth gauge (e.g digital depth gauge (VAS 6087)), measure from outer race/double angular contact ball bearing - 1 - to retaining plate bolting surface - 2 -.
In the example, gap dimension - a - = 1.04 mm. Determine shim "S4" 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.
- Place determined shim "S4" (0.85 mm in example) and retaining plate - A - (only fits in one position) on transmission housing bolting surface.
- Then tighten screws - arrows - diagonally to 30 Nm.
Performing measuring check, checking dimension " E"
- Install drive pinion with measured adjustment shims "S 3" and "S4".
- Install universal mandrel and perform measurement check.
- Read dial indicator counterclockwise (red numbered area).
• If shims have been determined correctly, deviation "e" (as marked on outer circumference of ring gear) should be indicated on dial within a tolerance of ± 0.04 mm.
• After removing universal mandrel - check again whether dial gauge stands at "0" with 2 mm pre-load when adjustable master gauge (VW 385/30) is attached.