Determining Disc Thickness S3
Determining disc thickness S31. Push fixed wheel for 3rd gear on to the output shaft. The narrow collar faces the tensioning plate.
2. Shift into 4th gear.
3. Block the input shaft with special tool retaining device 9253.
4. Push special tool assembly sleeve 9263 -A- and discs (Part No. 950.302.296.03) -B- on to the output shaft.
5. Screw collar nut on to the output shaft.
Tightening torque: 300 Nm (222 ft. lbs.)
6. Set the setting collar on special tool measuring mandrel VW 385/1 to the dimension a (approximately 65 mm).
7. Complete the measuring mandrel as shown in the illustration.
8. Read off the installation dimension E from the crown wheel.
1 Installation dimension E
2 Backlash F
3 Matching number
Example: E = 70.20 mm
9. Set the installation dimension E on special tool universal master gauge VW 385/30 and set the dial gauge to 0 with 2 mm pretension.
10. Place special tool adjusting shim 9281 on the pinion head of the output shaft.
11. Insert the measuring mandrel as shown in the illustration.
12. Place the side transmission cover in position without an O-ring and pull downwards with 4 screws. Do not knock.
Tightening torque: 25 Nm (19 ft. lbs.)
13. Press tapered roller bearing with the centering screw over the spindle into the bearing shells. It should just be possible to turn the measuring mandrel by hand.
14. Turn the measuring mandrel carefully back and forth until the reversing point on the dial gauge is reached At this point, the dial gauge extension is positioned exactly at right angles to the front face of the pinion head.
15. Read off the deviation from the specified adjusting value E. If the deviation is greater than 0.04 mm, a correction must be carried out.
Example: 0.10 mm
Note:
^ So in the example, the actual value of the adjusting dimension E would not be 70.20 but rather 70.30 mm.
16. In order to achieve the required adjusting dimension E, the adjusting shim S3 must be adjusted by the measured value.
Example: new disc thickness S3 = 0.90 mm
17. In order to correct the altered disc S3, disc S4 must be altered in the opposite direction by the determined value.
Example: S4 = 1.15 mm (increase by 0.10 mm)
18. As the thickness of disc S4 is identical to the thickness of disc S5, disc S5 must be altered by the same value as disc S4.
Example: S5 = S4 = 1.15 mm
19. When the discs S3, S4 and S5 have been corrected appropriately and inserted, the adjusting dimension E should be checked again.