Settings when renewing certain parts, gearbox type 1 — VW

It must be adjusted:
/ / / Replacement part · Selector forks / / =>page 34-76 · Determine before removing drive wheel "r" / / =>Page 34-141 · "Determine S3" according to "r" / / =>page 34-154 · Determine S1 and S2 / / / =>page 34-148
Gearbox housing · X · X · X · X
Final drive cover · X
Differential · X
Double bearing for input gear · X · X · X
Drive wheel and crown wheel · X · X · X
Roller bearing for final drive cover · X
All works on gearwheel shafts · X

Determine distance "e"

Check radial bearing for differential in final drive covers with the straightening press and VW 401, 441 and 408a for secure seat
Insert right cover for final drive and tighten nuts to 35 Nm (3.5 kgm).

Do not hit on the cover, but only press in its gearbox seat by tightening the hexagon nuts evenly.
Place the measuring plate on the face side of the drive wheel.

A -
VW 385/17

Adjust adjusting ring of the universal measuring device VW 385/1 to dimension "a".

a = approx. 50 mm.

Complete measuring device as shown

1 -
VW 385/1
2 -
VW 385/15
3 -
VW 385/14
4 -
VW 385/9
5 -
VW 385/4

Extension for dial gauge VW 385/15 = 9.3 mm.

Position template VW 385/9 (Ro = 58.70 mm) on the measuring device and calibrate dial gauge (margin: 3 mm) to 0 with 1 mm pretension.

Note:

Pull movable adjusting ring back to limit stop.

Take adjusting template off and place the measuring shaft on the housing.
Insert left cover for final drive and tighten nut to 35 Nm (3.5 kgm).
Slide the second plugwasher outwards on the movable adjusting ring until no axial play is perceptible on the radial bearings.

Turn measuring shaft until the test prod of the dial gauge is slid onto the measuring plate on the front side of the drive wheel and indicates the maximum excursion (vertex).

The measured value is the dimension "e".

Note:

If the crown wheel is to be adjusted, the gearbox width must also be measured. See "Adjusting crown wheel"=> Page.
34-157

Determine shim "S3"

S3 = e + r

e = calculated value (maximum deviation)

r = Distance (on the crown wheel given in hundredth mm).

Example:

e = 0.40 mm.

r = 0.25 mm.

S3 = e + r

S3 = 0.40 mm + 0.25 mm

S3 = 0.65 mm

Shims are available as spare parts

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

Use shims that are in a perfect state only.
Shim tolerances allow to calibrate any thickness for "S3".

Perform check measurement

Install drive wheel together with the determined shim "S3" and perform check measurement.

If the right shim "S3" has been selected, the dial gauge must show the value for the distance "r" with a tolerance of +- 0.04 mm when measuring anti-clockwise (red range of numbers).

1 -
VW 385/17
2 -
VW 385/15
3 -
VW 385/14
4 -
VW 385/1
5 -
VW 385/4

Adjusting crown wheel

Determine thickness "S total" for shims

(adjust pretension for radial bearing)

The crown wheel must be renewed when replacing components which affect the crown wheel adjustment, e.g. hypoid toothing, gearbox, differential housing, differential housing cover, radial bearing and final drive cover.

See "adjustment" =>Page
34-150

General

To adjust the hypoid toothing - drive wheel and crown wheel - observe general notes on =>Page
34-147

Measure gearbox width

The gearbox width can be measured during the drive wheel adjustment. When placing the measuring shaft do not exert pressure on the radial bearings in the bearing caps. To avoid this, use dial gauge when rectifying the axial clearance.

Fit universal dial gauge VW 385/1 with plugwashers VW 385/4. Install cover for final drive and tighten nuts to 35 Nm (3.5 kgm).
Fit dial gauge holder VW 297 to bearing cap and dial gauge extension VW 381/13 (length: 52 mm).

Notes on tools

The universal dial gauge VW 387 can be used instead of the dial gauge (part of VW 297).

Push plugwashers on the spindles until the dial gauge does not show any axial clearance.

1 -
VW 297
2 -
VW 381/13

Adjust only until no axial clearance exists. When doing this do not exert pressure on the radial bearings.
Lock spindle in this position with a locking screw.
After checking the distance "e" to adjust the drive wheel, remove left cover, measuring shaft and and fit to device VW 287 a.

Note:

Both plugwashers must lie against the shims.

Fit the big dial gauge (measuring range: 10 mm) with dial gauge extension VW 382/8 (length: 22 mm) to the measuring device and calibrate with 9 mm pretension to "0".

1 -
VW 382/8
2 -
VW 287a

Determine distance

Take measuring shaft out of the dial gauge, position differential housing and read distance at dial gauge. Example: 6.76 mm
To reach the specified pretension of the bearings there must be added a constant value of 0.14 mm (0.07 mm at each bearing) to the calculated distance value to compensate the pretension.

Determine value "S total"

"S total" = Distance value + compensating value for pretension

Example:

"S total" = Distance value · 6.76 mm
+ compensating value for pretension (constant) · 0.14 mm
"S total"= · 6.90 mm

Adjust face clearance

Manual gearbox is installed.

Tension differential between the two pressure plates of the device. Fit retaining pin from the crown wheel side and tighten nuts.

A -
VW 297

Install right cover of final drive and place differential into the gearbox.
Fit VW 298 or a shim of approx. 2.8 mm (measure exactly and note thickness) to the crown wheel side, fit left cover for final drive and tighten nuts of both covers to 35 Nm (3.5 kgm).
Place spindle to left cover for final drive. Tighten hexagon securing nuts for spindle.

Fit yoke VW 381/11 for drive wheel on the intermediate block.

A -
VW 381/11

Turn gearbox housing for 180° and fit dial gauge holder to measure face clearance of the retaining pin for both pressure plates.

A -
VW 297

Secure dial gauge holder to measure the axial displacement of the differential. Use dial gauges with standard extensions.

A -
VW 298 or shims of exactly 2.80 mm thickness.
1 -
VW 297

Insert differential together with the spindle into the radial bearing of the left cover for final drive onto stop. Release spindle and adjust dial gauge to measure the axial displacement of the differential to 2.8 mm (measuring ring thickness) or to the thickness of the measured shim.

To avoid measuring mistakes, which may be caused by the axial clearance of the radial bearings of the differential, the differential must hang in the gearbox with the crown wheel showing downwards when performing the following measurements. Observe also that the radial bearing is secured in the left cover when adjusting the dial gauge. Tighten spindle again, release and check dial gauge adjustment.
Fit supports so that they are positioned at right angles to each other. Continuously secure yoke VW 381/11 for drive wheel.
Turn crown wheel to limit stop. Calibrate dial gauge to zero, turn crown wheel backwards and read face clearance value.

Move differential with the spindle slowly in direction of drive wheel until a face clearance of 0.20 mm is measured.

When measuring the face clearance the spindle must be released.
Read end position value of the dial gauge (axial displacement of the differential) and note.

Example:

Start position of the dial gauge (thickness of the fitted test record) · 2.80 mm
Axial displacement up to the prescribed face clearance · 0.43 mm
End position of the dial gauge · 3.23 mm

Take dial gauge holder off and drive out left cover for final drive. Place spindle at right cover for final drive and pull differential off the gearbox housing.

Determine thickness of shim S1 (crown wheel side)

S1 = Axial displacement of the differential up to the prescribed face clearance.
+ Average for pretension (for one bearing)

Example:

Axial displacement · 3.23 mm
Average for pretension · 0.07 mm
S1 = · 3.30 mm

Determine thickness of shim S2 (in front of the crown wheel)

S2 = S total - S1

Example:

S2 = Shim thickness S total · 6.90 mm
- S1, crown wheel side · 3.30 mm
S2 = · 3.60 mm

Available shims

ET-No. (Part Number). · Thickness (mm)
113 517 199 / 113 517 201 / 113 517 203 · 2.80 / 2.90 / 3.00
113 517 205 / 113 517 207 / 113 517 209 · 3.10 / 3.20 / 3.30
113 517 211 / 113 517 213 / 113 517 215 · 3.40 / 3.50 / 3.60
113 517 217 / 113 517 219 / 113 517 221 · 3.70 / 3.80 / 3.90
113 517 245 · 0.25

The necessary thickness of the shim can be determined exactly with different tolerances

Install measured shims:
S1 at the crown wheel side; S2 in front of the crown wheel.

Installation position

Chamfer must show to differential housing. Install shim of 0.25 mm between the thicker shim and the radial bearing, if necessary.

Check measurement

Measure face clearance at four positions of the crown wheel; Specification: 0.15 - 0.25 mm

The different measured values must not deviate more than 0.05 mm from one another.