Final Drive, Adjusting, When Replacing The Transmission Housing Or Pinion: Notes
Special tools and workshop equipment required
- Seal Installer - Crankshaft: VW 204 B
- Clamping Piece: VW 386A
- Press Piece - Multiple Use: VW 412
- Crown Wheel Adjusting Tool: VW 521
- Press Piece - Multiple Use: 3005
- Bearing Installer - Wheel Bearing: 3345
Special tools and workshop equipment required
- Bearing/Bushing Installer - Multiple Use: VW 295
- Measuring Set - Magnetic Plate - 50mm: VW 385/17
- Dial Indicator Holder: VW 387
- Measuring Lever: VW 388
- Press Plate: VW 402
- Dial Gauge for example Dial Gauge - 0-3mm : VAS 6080
Tip:
- Careful adjustment is important for service life and smoothness of the final drive.
- If only the differential bearing or the differential is replaced, the pinion can remain installed. Then perform the procedure. Refer to FINAL DRIVE, ADJUSTING WHEN REPLACING DIFFERENTIAL OR DIFFERENTIAL BEARING .
- Adjustment Overview. Refer to Adjustment Overview .
- A new adjustment of the final drive is required, if the transmission housing or the pinion was replaced.
- The pinion is removed. Refer to PINION, REMOVING AND INSTALLING .
- The transmission is secured on the assembly stand and the flywheel is removed with the right flange shaft.
Total Shim Thickness "S total " for Shims "S 1 " + "S 2 ", Determining
(Adjust the bearing pre-load for the differential).
-- Remove the flange shaft seals.
-- Remove the bearing outer race for the differential from the transmission housing and the final drive cover and remove the shim. Refer to OVERVIEW - DIFFERENTIAL .
-- Drive in the left outer race/tapered roller bearing together with adjusting washer "S2 " into the transmission housing. To measure a shim "S 2 *" with 0.65 mm thickness is used.
Courtesy of AUDI OF AMERICA, LLCTip:
- A for example 0.65 mm thick adjusting shim "S2 " is used temporarily for the initial measurement. This will be indicated by "S2 *" in the following. After determining the torsional backlash, "S2 *" is replaced by final "S 2 ".
- Available adjusting shims. Refer to Adjusting Shims Available for "S 2 " and the Parts Information for the shim allocation.
-- Install the outer race for the right angular contact ball bearing with the temporary shim "S1 " in the final drive cover. To measure a shim "S 1 *" with 1.05 mm thickness is used.
The larger diameter of the Seal Installer - Crankshaft: VW204B points to the outer race for the angular contact ball bearing.
Tip:
- A 1.05 mm thick adjusting shim "S 1 " is used temporarily for the initial measurement. This will be referred to as "S 1 *" in the following. After determining the torsional backlash, "S 1 *" is replaced by the final "S1 ".
- Available adjusting shims. Refer to Adjusting Shims Available for "S 1 " and the Parts Information for the shim allocation.
-- Insert the differential into the transmission housing. The ring gear is laying on the right side in front of the final drive cover.
- O-ring is inserted in final drive cover.
-- Fasten the final drive cover carefully with four bolts diagonally to 20 Nm.
-- Turn the transmission so that the final drive cover faces upward.
-- Turn each differential five turns in both directions so that the bearings settle.
-- Place the Measuring Set - Magnetic Plate - 50mm: VW 385/17 on the differential.
-- Attach the measuring tools to the transmission housing.
-- Set the dial gauge (3 mm measuring range) -A- to "0" with 2 mm pre-tension.
-- Position the dial gauge test probe on the differential.
-- Lift the differential without turning it, read backlash on dial indicator and note.
Measured value in the following example: 0.22 mm
- To lift the differential, secure the special tools Crown Wheel Adjusting Tool : VW 521/4
and : VW 521/5
left on the differential (housing side).
- At the same time the Crown Wheel Adjusting Tool : VW 521 must not touch the transmission housing -arrow-.
- If measurement is repeated, differential must first be rotated five turns in both directions again to seat the bearing.
Formula: "S total " = "S 1 *" + "S 2 *" + measured value + bearing pre-load
| Example: | ||
|---|---|---|
| Inserted shims "S 1 *" + "S 2 *" | 1.70 mm | |
| + | Measured value | 0.22 mm |
| + | Bearing pre-load (constant value) | 0.30 mm |
| = | Total shim thickness "S total " for "S 1 " + "S 2 " | 2.22 mm |
- The temporary shim "S 1 *" with a thickness of 1.05 mm remains installed in the final drive cover.
Determining the following shim thickness "S 2 *"
- The temporary shim "S 2 *" is replaced by the final shim "S 2 " after the torsional backlash has been determined.
- Total shim thickness "S total " remains unchanged.
Formula: "S 2 *" = "S total " - "S 1 *"
| Example: | ||
|---|---|---|
| Total shim thickness "S total " for "S 1 " + "S 2 " | 2.22 mm | |
| - | Inserted shim "S 1 *" | 1.05 mm |
| = | Shim thickness "S 2 *" | 1.17 mm |
Available adjusting shims. Refer to Adjusting Shims Available for "S 2 " and the Parts Information for the shim allocation.