5 SPD. A/T 01V
Drive pinion and ring gear, adjusting
General notes:
^ Carefully adjust the drive pinion and ring gear for the service life and smooth running of the final drive. For this reason, the drive pinion and ring gear are matched together during manufacturing, and checked to make sure a good mesh pattern and quiet running. The position of quietest running is found by moving the drive pinion in an axial direction and at the same time lifting the ring gear out of the zero play mesh position by maintaining the backlash within the specified tolerance.
^ The deviation r based on master gauge Ro is measured and marked on the outer circumference of the ring gear. Final drive set (drive pinion and ring gear) may only be replaced together!
Gear sets, adjusting and marking
1 - Marking "0937" indicates Oerlikon final drive set with transmission ratio 37:9.
Note: Klingelnberg final drives K937 or Gleasen final drives G937 can be installed.
2 - Gear set pairing number (312).
3 - Deviation (tolerance) "r" is based on the test machine master gauge used in production. The deviation r is always given in 1/100 mm. Example: 25 means r = 0.25 mm
Ro - Length of adjustment master Ro of tester used.
Ro - Ring gear = 57.50 mm
R - Actual dimension between ring gear and face of pinion shaft at point with quietest running for this gear set. R = Ro + r
Vo - Hypoid offset
Position of shims
Note: Adjustment overview when Replacing individual components of transmission.
S1 - Adjustment shim for ring gear in cover for final drive
S2 - Shim for ring gear in final drive housing
S3 - Shim for drive pinion in final drive housing
Adjustment overview
Note: If performing assembly work on the final drive it is only necessary to adjust the drive pinion or final drive set if components have been replaced which have a direct effect on the adjustments of the final drive. To eliminate unnecessary adjustments observe following table:
Final drive readjustment sequence
The following procedure is recommended to save time when the drive pinion and ring gear have to be adjusted:
1.) Determine total shim thickness "Stotal" for "S1" + "S2" for the specified preload for taper roller bearings for differential.
2.) Determine total shim thickness "S3" to reproduce the installation position for the drive pinion determined on the test machine in production.
3.) Distribute total shim thickness "Stotal" for "S1" + "S2" so that the specified backlash exists between ring gear and drive pinion.
Drive pinion, adjusting
Special tools and workshop equipment required
^ VW 385 Universal measuring tool
^ VW 540 Engine and gearbox support
Notes:
^ Before adjusting the drive pinion adjust the ring gear (ascertain total shim thickness "S" for shims "S1" + "S2").
^ Re-adjustment of the drive pinion is only necessary if the final drive set, taper roller bearing for drive pinion or housing for final drive is replaced. Adjustments.
^ Do not additionally oil new taper roller bearings for frictional torque measurement. The bearings have already been treated with special oil by the manufacturer.
Ascertaining shim "S3" thickness
(Setting preload of taper roller bearing for drive pinion)
- Clamp final drive into assembly bracket.
- Insert both outer races for the taper roller bearing without shims into the housing
- Insert drive pinion without spacer sleeve.
- Heat inner race for taper roller bearing to approximately 100°C and install onto drive pinion.
WARNING: Wear protective gloves!
Notes:
^ Only install spacer sleeve for final frictional torque measurement (after determining shim "S3")
^ Install new taper roller bearings in delivery condition and do not oil additionally.
^ Mount flanges for drive shaft and tighten hexagon nut for the flange
A - Torque gauge, commercially available, 0 to 600 Nm
B - Socket, A/F 36
- Tighten drive pinion nut until the following frictional torque is obtained.
200 to 250 Ncm 30 to 60 Ncm
- Set adjustment ring of universal mandrel VW 385/1.
^ Distance a = 60 mm
- Set sliding adjustment ring.
^ Distance b = 55 mm
- Assemble universal mandrel as illustrated.
^ Dial indicator extension VW 385/15 = 9 mm long
- Set universal master gauge VW 385/30.
^ Ro = 57.50 mm
- Set dial indicator (3 mm measuring range) to 0 with 2 mm preload.
- Turn drive pinion 8 turns in both directions so that the taper roller bearings settle.
- Place end measuring plate VW 385/33 onto drive pinion head.
- Remove master gauge and insert measuring mandrel in the housing.
^ The centering disc for VW 385/3 faces towards cover for final drive
- Install cover for final drive and tighten 4 bolts.
- Using the adjustable ring, move 2nd centering disc out as far as possible so that the mandrel can still just be turned by hand.
Determining measurement "e"
- Turn mandrel until the dial indicator point touches the end measuring plate on pinion shaft head, then measure maximum deflection (return point). The measured value is dimension "e" (in red range).
^ Measurement in following example: "e" = 1.60 mm
Note: Dimension "e" is required to determine thickness of shim S3.
- Then, (after removing universal mandrel) check again that the dial indicator, with master gauge VW 385/30 fitted, indicates 0 with 2 mm preload, otherwise repeat the measurement.
Determining shim thickness "S3"
Formula:
"S3" = "e" - "r"
e = determined value
r = deviation (marked on ring gear in 1 /100 mm)
Example:
Determined value "e" 1.60 mm
Deviation "r" 0.42 mm
Thickness of shim "S3" 1.18 mm
- Determine shim(s)) as accurately as possible from table. Part numbers
go to Parts List
The following shims are available for "S3"
^ Remove universal mandrel.
^ Remove drive pinion and outer race for large taper roller bearing and reinstall with calibrated shims SY and spacer sleeves.
^ Insert inner race for small taper roller bearing and tighten drive pinion nut until specified frictional torque is achieved
Notes:
^ Do not additionally oil new taper roller bearings for frictional torque measurement. The bearings have already been treated with special oil by the manufacturer.
^ Only increase tightening torque slowly and read-off frictional torque frequently. If the specified frictional torque is exceeded, the spacer sleeve must be replaced and the adjustment repeated. It is not possible to re-use a spacer sleeve that has been excessively compressed.
^ Set to following frictional torques:
200 to 250 Ncm 30 to 60 Ncm
Performing check measurement
Checking dimension "r"
- Turn drive pinion 8 turns in both directions so that the taper roller bearings settle.
- Insert universal mandrel and perform check measurement.
^ If the shims have been correctly selected, the dial indicator, reading counter clockwise (in red range), will show the deviation "r" within a tolerance of ± 0.05 mm
- Peen drive pinion nut with a punch.
- The radial run-out at flange for drive shaft must always be measured and marked.
Ring gear, adjusting
(Adjusting differential)
Special tools and workshop equipment required
^ VW 385/17 End measuring plate
^ VW 387 Universal dial indicator holder
^ VW 388 Test lever
^ VW 521 Adjustment tool for ring gear
^ V.A.G 1331 Torque wrench
It is necessary to readjust the ring gear when:
Final drive housing, cover for final drive, taper roller bearing for differential, differential housing or drive pinion are replaced.
Adjustment overview
Notes:
^ Differential taper roller bearings are low friction bearings. Therefore the frictional torque only has a limited use as a check. Correct adjustment is only possible by determining the total shim thickness Stotal.
^ Do not additionally oil new taper roller bearings for frictional torque measurement. The bearings have already been treated with special oil by the manufacturer.
Determining total shim thickness "Stotal" for shims "S1" + "S2"
(Setting preload of taper roller bearing for differential)
^ Drive pinion is removed!
Note: If only the taper roller bearings for the differential are being replaced, the ring gear can be removed from the differential housing. The pinion shaft does not then need to be removed.
- Pry out seals for flange shaft using a suitable lever.
- Remove outer races of differential taper roller bearings and remove shims
- Drive outer race/taper roller bearing for left differential (housing side) with shim "S2*" of thickness 1.00 mm into housing.
Note: For measurement purposes a shim "S2" with a thickness of 0.04 in is initially inserted. It is referred to as "S2*" in the following. After determining the backlash "S2*" will be replaced by the correct "S2".
- Drive outer race/taper roller bearing for right differential (cover side) without shim in onto stop.
- Insert differential into housing. The ring gear is positioned on the right side (cover side).
- Install cover and tighten bolts to 25 Nm.
- Install special tools VW 521/4 and 521/8 onto housing side in differential housing.
- Turn cover side of differential housing upwards.
- Turn differential 8 turns in both directions so that the taper roller bearings settle.
- Place measuring plate VW 385/17 onto differential.
- Install measuring tools.
A - Dial indicator extension approximately 30 mm long
B - Hexagon bolt M8 x 45
- Position dial indicator extension in middle of measuring plate VW 385/17.
- Set dial indicator (3 mm measuring range) to 0 with 2 mm preload.
- Lift differential without turning; read off play on dial indicator and note it down.
^ Measurement in following example: 0.50 mm
- If you want to repeat the measurement differential 8 turns in both directions so that the taper roller bearings settle.
Determine "Stotal" (S1 + S2)
Formula:
"Stotal" = "S2*" + measurement + bearing preload
Example:
Inserted shim(s) "S2*" 1.00 mm
+ Measurement 0.50 mm
+ Bearing preload (constant) 0.30 mm
=Total shim thickness "Stotal"
for shims "S1" + "S2: 1.80 mm
Determining thickness of shim "S1"
Notes:
^ The preliminary adjustment shim "S1" will be replaced with the final shim "S1" after determining the backlash.
^ The total shim thickness "Stotal" remains the same.
Formula:
"S1*" = "Stotal" - "S2*"
Example:
Total shim thickness "Stotal"
for shims "S1" + "S2" 1.80 mm
- Inserted shim(s) "S2*" 1.00 mm
= Thickness of shim "S1*" 0.80 mm
- Define shim(s) as precisely as possible based on the table.
Measuring frictional torque (check)
^ Pinion shaft removed
^ Differential installed with shims "S1*" and "S2"
- Install torque gauge 0 to 600 Ncm -A- onto differential.
- Read off friction torque.
Frictional torque specified values:
150 to 300 Ncm 30 to 60 Ncm
Notes:
^ Differential taper roller bearings are low friction bearings. Therefore the frictional torque only has a limited use as a check. Correct adjustment is only possible by determining the total shim thickness "Stotal".
^ Do not additionally oil new taper roller bearings for frictional torque measurement. The bearings have already been treated with special oil by the manufacturer.
^ If the final drive set is being re-adjusted, the adjustment of the pinion shaft should be performed now, and the adjustment should be checked.
Adjusting backlash
- Drive pinion with shim "S3" installed
- Differential with shims "S1*" + "S2" installed
- Insert differential into final housing mount cover and tighten all bolts to 25 Nm.
- Turn differential 5 turns in both directions so that the taper roller bearings settle.
- Install measuring tools.
- Use dial indicator extension VW 382/10 (6 mm flat).
- Set measuring lever VW 388 to dimension a = 60 mm.
- Measure play between teeth flanks (backlash) as follows:
- Turn ring gear until it makes contact with a tooth flank (end of backlash travel).
- Preload dial indicator to 1 mm and set to zero.
- Turn ring gear back until lying against an opposite tooth flank (backlash).
- Read off backlash and note value.
- Turn ring gear through 90° and repeat measurements a further 3 times.
Determining average backlash
Example:
1st Measurement 0.28 mm
+ 2nd Measurement 0.30 mm
+ 3rd Measurement 0.30 mm
+ 4th Measurement 0.28 mm
= Sum of measured values 1.16 mm
Result: The average backlash is 1.16 divided by 4 = 0.29 mm
Note: If the individual measurements differ by more than 0.06 mm from each other, the installation of the ring gear or the final drive set itself is not correct. Check installation; replace final drive set, if necessary.
Determining thickness of shim "S2"
Formula:
"S2" = "S2*" - backlash + lift
Example:
Inserted shim "S2" 1.00 mm
- Average backlash 0.29 mm
+ Lift (constant) 0.15 mm
=Thickness of shim S2 0.86 mm
Determine shim(s) as accurately as possible from table. Part numbers
go to Parts List
The following shims are available for "S2"
Determining thickness of shim "S1"
Formula:
"S1" = "Stotal" - "S2"
Example:
Total shim thickness "Stotal" 1.80 mm
for "S1" + "S2"
- Thickness of shim "S2" 0.86 mm
=Thickness of shim "S1" 0.94 mm
Determine shim(s) as accurately as possible from table. Part numbers
go to Parts List
The following shims are available for "S1"
Check measurement
^ Drive pinion with shim "S3" installed
^ Differential with shims "S1" (cover side)+ "S2"(housing side) installed
- Turn differential 5 turns in both directions so that the taper roller bearings settle.
- Measure backlash four times on circumference.
- Specification: 0.12 to 0.22 mm
Notes:
^ If the backlash is beyond the tolerance, the adjustments must be repeated. The total shim thickness "Stotal" must not be changed.
^ The individual measurements must not differ by more than 0.06 mm from each other.