Adjusting drive pinion: VW Passat B5

🧭 Before you start

Fits: VW Passat B5 (3B)

• Special tools named: dial gauge

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• As a test prerequisite, a temporary shim S4 of 1.00 mm must be installed. It is referred to below as S4*. After determining value "„e“", replace S4* with final shim S4.Insert completely assembled pinion shaft into gearbox housing.
• Remove universal master gauge and insert universal mandrel in housing. The centring discVW 385/3 must face final drive cover.
• Shim allocation Electronic parts catalogue "„ETKA“"
• Tapered roller bearings for pinion shaft are low-friction bearings. Therefore, the frictional torque has only limited use as a check. Correct adjustment is only possible by determining the total shim thickness Stotal.
• Install new bearings as supplied and do not oil.

🔩 Torque settings

Values can differ between engine variants — check the code stamped on your block.

ℹ️ Always cross-check the exact figure against your vehicle's factory manual before final tightening — a wrong torque can damage the engine. These values are extracted from workshop data and may not cover every variant or revision.

📋 Procedure

1. Install large tapered roller bearing outer race in gearbox housing and .
2. Press small tapered roller bearing outer race with 1.00 mm thick temporary shim S4* into bearing plate to stop. [Note: As a test prerequisite, a temporary shim S4 of 1.00 mm must be installed. It is referred to below as S4*. After determining value "„e“", replace S4* with final shim S4.Insert completely assembled pinion shaft into gearbox housing.]
3. Fit bearing plate with dowel sleeves and tighten bolts to torque.
4. Turn pinion shaft at least 8 turns in both directions before each measurement so that tapered roller bearings settle.
5. Set up measuring tools.

6. Use 30 mm dial gauge extension.
7. Set dial gauge extension on centre of end measuring plateVW 385/17.
8. Set dial gauge (3 mm range) to zero with 2 mm preload.
9. Move pinion shaft up and down without turning it, note play indicated on dial gauge and record it. (Example: 0.90 mm)
10. Remove large tapered roller bearing outer race , insert temporary shim S3* into gearbox housing and insert outer race again and .
11. Insert completely assembled pinion shaft into gearbox housing again.
12. Fit bearing plate with dowel sleeves and tighten to 25 Nm. — 25 Nm (18 lb-ft)
13. Turn pinion shaft at least 8 turns in both directions before each measurement so that tapered roller bearings settle.
14. Adjust setting ring of universal test gaugeVW 385/1 to dimension (a) = 65 mm.
15. Set sliding positioning ring to dimension (b) = 55 mm.
16. Set up universal measuring tool according to figure. Dial gauge extensionVW 385/15 = 9.3 mm. Set universal master gaugeVW 385/30 to Ro = 59.65 mm and set on universal mandrel.
17. Set dial gauge (3 mm range) to zero with 2 mm preload.
18. Place end measuring plateVW 385/17 on face of pinion gear.
19. Remove universal master gauge and insert universal mandrel in housing. The centring discVW 385/3 must face final drive cover.
20. Fit final drive cover and tighten 4 bolts to 25 Nm. — 25 Nm (18 lb-ft)
21. Use sliding setting ring to pull 2nd centring discVW 385/2 outwards until universal mandrel can still just be turned by hand.
22. Determine dimension "„e“". Turn universal mandrel until dial gauge extension contacts end measuring plate and indicates maximum deflection (return point). The measured value is dimension "„e“".
23. Turn universal mandrel until tip of dial gauge extension contacts end measuring plate on pinion gear and indicates maximum deflection (return point). [Note: The allowance "„r“", based on the universal master gauge"„Ro“" is measured for the drive pinion sets supplied as replacement parts and marked on the outer circumference of the crown wheel.If measurement is obtained on red scale, subtract value "„e“".If measurement is obtained on black scale, add value "„e“".] [Note: Shim allocation Electronic parts catalogue
24. The various thicknesses make it possible to achieve the exact shim thickness required. [Note: Shim allocation Electronic parts catalogue
25. The various thicknesses make it possible to achieve the exact shim thickness required.
26. Install pinion shaft with measured shims S3 and S4 and rotate several times in each direction. [Note: Tapered roller bearings for pinion shaft are low-friction bearings. Therefore, the frictional torque has only limited use as a check. Correct adjustment is only possible by determining the total shim thickness Stotal.]
27. Install new bearings as supplied and do not oil.
28. Measure friction torque.

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