Before any of the mentioned adjustment works are carried out, we must once again pay attention to that. that special tools are needed. Never attempt to make adjustments without special tools. The operations described below must only be carried out with special tools.
Output shaft adjustment
Adjusting the output shaft includes determining the thickness of the shim located under the outer ring of the front shaft bearing. It is the smaller of the two tapered roller bearings.
Insert a 0.65 mm wear washer into the bearing shield and press in the outer race of the smaller bearing.
Insert input shaft and tighten bearing cap screws to 40 Nm.
Mount the instruments and, by preloading 1 mm, set the dial gauge to «ABOUT».
Move the shaft up and down and look at the dial indicator; it can be, for example, 0.3 mm. During the measurement itself, the input shaft must not be turned.
Bearing preload according to the instructions will be achieved by adding 0.2 mm to the dial gauge reading. An example of such a measurement is as follows:
Inserted wear washer thickness - 0.65 mm
+ measured value - 0.30 mm
+ preload value - 0.20 mm
The thickness of the compensation washer - 1.15 mm
At the end of the measurement, dismantle the secondary shaft again and remove the outer race of the bearing from the gearbox housing. Insert a compensation washer, the thickness of which is equal to the value obtained. Press in the bearing ring. mount the output shaft and bearing cap. Compensation washers of various thicknesses are available (a total of 16 sizes from 0.65 to 1.40 mm in 0.05 mm increments).
Differential adjustment
Press the differential bearing outer race towards the flat bevel gear by placing a 1mm shim under the race. In the subsequent adjustment, we will designate this washer as S2. Now we will talk about how to find the thickness of the washer S1. located on the other side.
Install the differential bearing outer race into the gearbox housing on the side of the flat bevel gear where the wear washer is missing. Insert the differential box into the bearing housing.
Put on the gearbox housing with a new seal and tighten the five screws to a torque of 20 Nm.
Install the dial indicator together with the holder. Position the VW 385/17 measuring disc on the upper end of the flanged input shaft.
Set the dial indicator to «0» by a preload of 1 mm.
Move the differential up and down and look at the dial indicator; it should be, for example, equal to 0.9 mm. During the measurement itself, do not turn the differential.
To obtain the bearing preload according to the instructions, 0.4 mm must be added to the reading of the dial indicator. An example of the measurement is as follows:
Reading - 0.90 mm + preload - 0.40 mm
Washer thickness S1 - 1.30 mm
Dismantle the gearbox housing again and knock out the bearing working ring. Insert the necessary wear washers and drive in the bearing ring again. Always insert the thickest washer first (possibly a washer 1 mm thick). Washers of various thicknesses are available (only six sizes), so you can make any combination of pucks.
According to the instructions, now you need to measure the torque of the differential. To do this, attach a torque wrench to the shaft and turn the shaft. For new bearings, the key reading should be 50-150 Nm. for used bearings, at least 30 Ncm.
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