Pinion Shaft, Adjusting
Procedures, after which the pinion shaft must be adjusted, List of Adjustments
Special tools and equipment
- VW204B installation tool for crankshaft seal
- VW296 removal tool
- VW385 universal gauge
- VW385/1 measuring bar
- VW385/2 centering disc (for transmissions without polygon bearing)
- VW383/3 centering disc (2x)
- VW385/14 measuring rod
- VW385/15 extension pin
- VW385/30 master gauge (adjustable)
- VW385/33 end gauge
- VW387 Dial Gauge Holder
- VW401 thrust plate
- VW407 punch
- VW519sleeve
- VW792 installation arbor
- 3005 thrust pad
- Torque gauge 0-600 Nm
- Dial indicator
- Dial indicator extension 9.3 mm
- Dial indicator extension 6.5 mm
- Dial indicator extension 30 mm
Determining total shim thickness "Stotal" for shims "S3 + S4".
- Adjust preload of tapered roller bearing for pinion shaft.
- Differential removed
- Pressing on double tapered roller bearing inner race, Fig. 4 Pressing on Double Tapered Roller Bearing Inner Race
- Secure lower tapered roller bearing (arrow).
Note: The Illustration shows the pinion shaft without gears.
- Install tapered roller bearing outer race for pinion shaft without shims into transmission housing, Fig. 3 Pressing In Double Tapered Roller Bearing Outer Race
- Install rubber washer (item 40), and pressure plate (item 39 ) into transmission cover. Overview
- Pressure plates with a thickness of 14.8 mm or 15.3 mm can be installed.
- Install tapered roller bearing outer race for pinion shaft with shim S4* (1.0 mm thickness) into transmission cover, Fig. 8 Pressing In Tapered Roller Bearing Outer Race
Note: A shim S4 with a thickness of 1.0 mm is installed for initial measurement. It is referred to in the following text as S4*. After determining measurement "e, " S4* is replaced with the appropriate shim S4.
- Install fully assembled pinion shaft into transmission housing.
- Install transmission cover and tighten to 22 Nm (16 ft. lbs.).
- Turn transmission so that the transmission cover points downward.
- Press down on face of pinion shaft using VW296 removal tool until tapered roller bearing outer race contacts transmission cover.
- While maintaining pressure, turn pinion shaft by hand to seat tapered roller bearing.
- Assemble measuring equipment, use 30mm dial indicator extension.
- Set dial indicator (3 mm measuring range) to O with 1 mm preload.
Note: Make sure dial indicator extension contacts machined surface on face of drive shaft..
- Turn transmission 180° so transmission cover faces upward.
- Turn pinion shaft 5 rotations in each direction to seat the tapered roller bearing.
- Read play on dial indicator and note.
- Dimension in the following example: 0.45 mm
Note: If the measurement has to be repeated, first turn pinion shaft 5 rotations in both directions to seat the tapered roller bearing. Set dial indicator to O with 2mm preload.
Formula:
"Stotal" = "S4*" + measured value + bearing preload
Example:
Installed shim "S4*" 1.00 mm
+ Dimension (example) 0.45 mm
+ Bearing preload (constant) 0.15 mm __________
= Total thickness "S total" for "S3 + S4" 1.60 mm
Determining thickness of shim "S3*"
Formula:
"S3" = "Stotal"-"S4*"
Example:
Total thickness "Stotal" for "S3 + S4" 1.60 mm
- Installed shim "S4*" 1.00 mm __________
= Thickness of shim "S3*" 0.60 mm
- Remove tapered roller bearing outer race, install shim "S3*" into transmission housing and re-install outer race, Fig. 3 Pressing In Double Tapered Roller Bearing Outer Race
.
- Install fully assembled pinion shaft into transmission housing.
- Install transmission cover and tighten to 22 Nm (16 ft. lbs.).
Checking preload for tapered roller bearing for pinion shaft
- Turn pinion shaft 5 rotations in each direction to seat tapered roller bearing.
Notes:
- If the pinion shaft cannot be turned by hand, install a M10 x 20 bolt into face of pinion shaft and turn the pinion shaft at this bolt using tool.
- Remove bolt after fuming pinion shaft..
- Install measuring tools and secure to transmission housing with bolt (arrow).
- Attach dial indicator (3 mm measuring range) to center of transmission cover and set to O with 2 mm preload.
- Loosen transmission cover bolts and turn pinion shaft.
- If correct shims have been selected, dial indicator will now indicate the following value: 0.05-0.15 mm.
- Tighten transmission cover bolts to 22 Nm (16ft.lb).
- Remove measuring tools.
- Turn pinion shaft 5 rotations in each direction to seat tapered roller bearing.
Calculating dimension "e"
Note: Dimension "e" is required to determine the final shim thickness of S3 and S4.
- Set adjustment rings of universal mandrel using VW385/1 measuring bar to the following measurements:
Dimension -a- = 35 mm
Dimension -b- = 75 mm
- Assemble VW385/1 measured bar as illustrated:
- Set dial indicator (3 mm measuring range) to O with 2mm preload.
Note: For transmissions with drive flange without polygon bearing ( Application and ID ) use VW385/2 centering disc instead of VW385/3 centering disc opposite dial indicator..
- Place end gauge on face of pinion shaft.
Note: Make sure gauge contact surface is precisely installed and free of oil.
- Remove master gauge and install measuring mandrel into transmission housing.
- Dial indicator extension -A- = 6.5 mm long must be installed
- VW385/3 centering disc faces cover for final drive
- Install differential cover and tighten 4 bolts to 22 Nm (16 ft. lbs.).
- Using adjustable ring, pull 2nd VW385/3 centering disc out as far as possible, so mandrel can only just be turned by hand.
Note: For transmissions with drive flange without polygon bearing ( Application and ID ) use VW385/2 centering disc instead of VW385/3 centering disc opposite dial indicator.
- Turn mandrel until dial indicator plunger tip touches end gauge on pinion shaft head, measure maximum runout(return point).
- Measurement in following example "e" = 0.26 mm (red scale)
Note: After removing universal mandrel, and with VW385/30 master gauge in place, check dial indicator again to see if it indicates "O" with 2 mm preload, otherwise correct adjustments.
Determining thickness of shim "S3"
Formula:
S3 = S3*+r-e
(-e- in black scale)
or
S3 = S3* - r-e
(-e- in red scale)
Notes:
- The deviation "r" (tolerance) related to the VW385/30 master gauge "Ro" is measured for the final drive sets supplied as replacement parts and marked on the outer circumference of the ring gear.
- If measurements are based on red scale, subtract value "e."
- If measurements are based on black scale, add value "e."
Example:
Shim S3* installed 0.60 mm
+ Deviation r 0.38 mm
- Value measured for "e" ( in red scale) 0.26 mm __________
= Thickness of shim S3 0.72 mm
- Determine shim(s) according to table. Part numbers, Refer to parts supplier.
"S3" Shims Table
Shim Thickness (mm) (1)
0.40 0.55 0.70
0.45 0.60 0.75
0.50 0.65
(1): Using shim tolerances it is possible to find the exact shim thickness required: Insert two shims if necessary.
Determining thickness of shim "S4"
Formula:
S4 = Stotal - S3
Example:
Total shim thickness Stotal for S3 + S4 1.60
- Thickness of shim S3 0.72 mm __________
= Thickness of shim S4 0.88 mm
- Determine shim(s) according to table. Part numbers, Refer to parts supplier.
"S4" Shim Table
Shim Thickness (mm) (1)
0.49 0.69 0.85
0.57 0.73 0.89
0.61 0.77
0.65 0.81
(1) Using shim tolerances it is possible to find the exact shim thickness required: insert two shims if necessary.
Checking measurement
Checking dimension "r"
- Install pinion shaft together with measured shims S3 and S4 and turn 5 rotations in both directions.
- Install universal mandrel Determining dimension "e"; and perform check measurement.
- Read dial indicator 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.
Note: After removing universal mandrel, and with VW385/30 master gauge or VW385/15 extension pin in place, check dial indicator again to see if it indicates O with 2 mm preload. If not, correct adjustments.