Adjusting bevel gear (with stub shaft) — VW

🧭 Before you start

Fit the 1.2 mm trial shim on the S2 side, press in the outer race, fit the bevel gear with stub shaft and the cover without seals or the S1 shim, and seat the bearings by pressing the gear each way while turning it eight times. Measure the play with a dial gauge to find the total shim thickness. Set up the measuring tools, turn the gear to the stop, zero the gauge and read the backlash, repeat 3 more times at 90° intervals and average the four readings. Fit the determined S2 shim, press the outer race in again, fit the determined S1 shim, press the race in, fit the cover and confirm the final value of 0.15 to 0.20 mm.

Fits: VW Golf IV / Bora (1J)

• Special tools named: dial gauge

Don't miss

• Cover goes on for measuring without O-ring, drive flange seal or shim S1.
• Turn the gear eight times while pressing each way so the bearings settle before measuring.
• Dial gauge: 2 mm preload on a 30 mm extension; the play read there gives Stotal.
• Backlash is four readings 90° apart, averaged; a single reading is not a measurement.
• Total shim thickness stays the same when the trial shim S1* is swapped for the final S1.
• Final value to confirm: 0.15 to 0.20 mm.

Written for this job from the workshop steps below · TorqFix editorial.

📋 Procedure

1. Fit 1.2 mm shim in small tapered roller bearing outer race seat (S2 side).
2. Press in outer race .
3. Fit bevel gear with stub shaft with tapered roller bearing.
4. Install cover with large tapered roller bearing outer race but without O-ring, drive flange seal and without shim S1.
5. Press bevel gear with stub shaft in direction of cover while turning eight times.

6. Press bevel gear with stub shaft in direction of outer race of small tapered roller bearing while turning eight times.
7. Set up dial gauge (2 mm preload) (A) dial gauge extension 30 mm.
8. Move bevel gear with stub shaft up and down ((direction of arrow)).
9. Read play from dial gauge and determine Stotal. [Note: After backlash is determined, temporary shim S1* is replaced with final shim S1.The total shim thickness "Stotal" remains unchanged.]
10. Set up measuring tools.
11. Turn bevel gear with stub shaft to stop. Set dial gauge to 0, turn back bevel gear with stub shaft and read backlash. Note reading.
12. Loosen clamping sleeve locking screw and after turning bevel gear with stub shaft a further 90°, repeat complete measuring process 3 more times. Add the four results and calculate the average backlash. [Note: Allocate shims using electronic parts catalogue.]
13. The various thicknesses make it possible to achieve the exact shim thickness required.
14. Install determined shim S2 in place of S2.*.
15. Press outer race in again and fit bevel gear with stub shaft. [Note: Allocate shims using electronic parts catalogue.]
16. Various tolerances make it possible to obtain the exact shim thickness required.
17. Insert determined S1 shim.
18. Press outer race in again.
19. Fit cover.
20. It must be 0.15…0.20 mm.

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