Adjusting pinion — VW

(Adjusting output shaft)

The pinion only needs adjusting as described here if the gears themselves have been renewed. If other parts which affect the position of the pinion are to be renewed, the setting must be measured before dismantling and set to this dimension on assembly. See => page
39-35
for table of adjustments

Assemble pinion up to needle bearing for 1st speed gear wheel, tighten needle bearing inner race to 210 Nm.

Install pre-assembled pinion in the gearbox housing without shim "S3". Install retaining ring and tighten to 225 Nm first then back it off and tighten to 225 Nm again.

Finding dimension "e"

Screw adjusting ring into gearbox housing until it is flush with housing.

Adjust setting ring on measuring bar VW 385/1 to dimension 'a".

a = approx. 75 mm.

Assemble bar as shown. Dial gauge extension VW 385/16 = 12.3 mm long.

Place measuring plate VW 385/17 on end of pinion.
Place bar in housing and screw 2nd adjusting ring in until it is also flush with housing. Move the 2nd centering ring outwards with the movable setting ring until the bar can just be turned by hand.

Note:

To screw the 2nd ring in a wrench can be made from a lock plate and a piece of strip metal, as shown in illustration.

Set universal gauge VW 385/30 to Ro = 63.00 mm and place it on the bar. Zero dial gauge (3 mm) with 1 mm preload.

Turn bar until measuring pin touches plate on end of pinion and needle deflects to return point.

The reading is dimension "e"

Example: 0.40 mm.

Finding thickness of shim "S3"

S3 = e+r

e = Measured figure (max. deflection)

r = Deviation (marked on crown wheel in 1/100 mm or found by actual measurement)

Example:
Dial gauge reading "e" · 0.40 mm.
Deviation "r" marked on
crown wheel · +0.25 mm.
Thickness of shim ''S3'' · =0.65 mm.

Shims available as parts

Part No. · Thickness (mm)
001 311 391 · 0.15
001 311 392 · 0.20
001 311 393 · 0.30
001 311 394 · 0.40
001 311 395 · 0.50
001 311 396 · 0.60

The shim tolerances make it possible to select any required thickness for "S3"

Measure shims at several points with a micrometer and check them for burrs and damage. Use only shims which are in good condition

Checking adjustment

Install pinion with measured shift "S3" and check the setting

If the shim has been selected correctly, the dial gauge reading (read anticlockwise, red figures) should now show deviation "r" within a tolerance of ± 0.04 mm.

Arrangement of measuring tools for finding dimension "e"