Adjusting shaft bevel gear: VW Golf IV / Bora

🧭 Before you start

Fits: VW Golf IV / Bora (1J)

• Special tools named: dial gauge

Don't miss

• (A) Screw in hexagon bolt M10 as counterhold.
• Only increase torque setting slowly thereby reading off friction torque regularly; if the prescribed friction torque is exceeded then the soldering wire must be renewed and the adjustment repeated.
• Allocate shims using ETKA (electronic parts catalogue).
• Finally, check again whether dial gauge returns to "“0”" with 3 mm preload with master gaugeVW 385/30 applied. Otherwise repeat measurement.

🔩 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. Press outer race of large tapered roller bearing for shaft bevel gear into pinion housing with press piece2050.
2. Press outer race of small tapered roller bearing for shaft bevel gear into pinion housing with press pieceVW 473.
3. Press large tapered roller bearing inner race onto shaft bevel gear with tubeVW 415 a.
4. (A) Put on soldering wire of 1.5 mm ∅ instead of shim S4.
5. Put on spacer ring (B) with chamfer facing tapered roller bearing inner race.

6. Fit shaft bevel gear.
7. Fit small tapered roller bearing inner race and output flange and fit hexagon nut.
8. (A) Screw in hexagon bolt M10 as counterhold.
9. Tighten hexagon nut to 20 Nm, loosen or completely remove hexagon bolt (A). — 20 Nm (15 lb-ft)
10. Measure friction torque.
11. Increase torque setting if necessary to achieve the prescribed friction torque. [Note: Only increase torque setting slowly thereby reading off friction torque regularly; if the prescribed friction torque is exceeded then the soldering wire must be renewed and the adjustment repeated.]
12. Remove shaft bevel gear and carefully remove crushed soldering wire.
13. Measure thickness of soldering wire at a well crushed together area where there is no lip.
14. Select shim(s) of same thickness. [Note: Allocate shims using electronic parts catalogue.]
15. The various thicknesses make it possible to achieve the exact shim thickness required.
16. Fit shim S4 and install shaft bevel gear.
17. Tighten nut for output flange to specified torque .
18. Install pinion housing with shaft bevel gear and installed shim S4.
19. Do not insert O-ring.
20. Adjust setting ring of universal measuring toolVW 385/1 to dimension a = 75 mm.
21. Set sliding positioning ring to dimension b = 32 mm.
22. Set up universal mandrel according to figure. Measuring gauge extensionVW 385/20 = 3 mm.
23. Set dial gauge to 0 with 3 mm preload.
24. Place end measurement plate on head of shaft bevel gear.
25. Insert universal mandrel.
26. Fit cover and tighten hexagon bolts.
27. Use sliding setting ring to pull centring disc outwards until mandrel can still just be turned by hand.
28. Determine dimension "“e”". Turn test gauge until point of dial gauge makes contact with end measuring plate and indicates max. deflection (return point). The measured value is dimension "“e”" (in red scale). Example: 0.47 mm
29. Remove universal test gauge. [Note: Finally, check again whether dial gauge returns to "“0”" with 3 mm preload with master gaugeVW 385/30 applied. Otherwise repeat measurement.] [Note: Allocate shims using electronic parts catalogue.]
30. The various thicknesses make it possible to achieve the exact shim thickness required.
31. Remove pinion housing with shaft bevel gear.
32. Install determined shim S3.

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