Adjustment principle
The distance between the axis of the differential and the end of the drive gear determines the location of the contact patch in the meshing of the final drive gears. When installing the output shaft in the gearbox, this distance affects the degree of wear and noise of the main gear bone. Therefore, it must be adjusted with great care using a special tool.
The initial length of the adjustment value is the calculated value of the distance between the differential axis and the end face of the drive gear (size «Ro». see diagram), corrected by the amendment «r», determined during the manufacture of the drive gear. The adjustment consists in fitting the adjusting ring S of the required thickness under the outer ring of the rear output shaft bearing in the gearbox housing.
Adjustment and measurement of the distance between the end face of the drive gear of the final drive and the axle of the differential and the side clearance between the teeth of the gears of the main gear: Ro is the estimated distance between the end of the drive gear and the axle of the differential; r is the correction measured or marked on the crown of the driven gear to the estimated distance between the end face of the driven gear of the final drive and the axle of the differential; S3 - adjusting ring for the distance between the end of the drive gear and the axis of the differential: S1 and S2 - adjusting rings for the differential bearing preload
Determination of the correction value «r»
Note. This measurement is made if there is no correction mark on the driven gear of the final drive «r» in hundredths of a millimeter from the nominal position of the drive gear, and also if there has been a replacement of parts that directly affect the position of the drive gear of the final drive: the rear double-row tapered roller bearing of the output shaft, the crankcase or the rear cover of the gearbox, the bearing of the 1st gear gear.
Remove the gearbox rear cover.
Install a special adjusting washer VW 381/11 and fix it strictly at a right angle relative to the output shaft by hand-tightening two M8x50 bolts.
Tighten the bolts to 200 Ncm using» torque wrench.
The drive gear, after tightening the bolts, takes the position that it occupied when the gearbox rear cover was installed. This operation must be carried out very carefully whenever the distance between the end of the pinion gear and the axle of the differential is adjusted.
Remove differential.
Install measuring mandrel VW 385 (calibrated for preload 2 mm) on «zero» using the VW 385-30 indicator.
Determine the estimated size «r», which is a deviation from the size «Ro».
When replacing parts by selecting the thickness of the adjusting ring, achieve the maximum possible accuracy of maintaining the resulting size «r».
Selection of the adjusting ring of the rear bearing of the secondary shaft
If the final drive is to be used again, press the rear bearing outer race together with the old adjusting ring into the gearbox housing. If parts have been replaced, install the bearing outer ring without the adjusting ring.
Install the secondary shaft and press on the second inner ring of the rear bearing, as well as the V gear.
Attach the gearbox housing to the clutch housing with a new gasket.
Tighten the nut of the rear end of the secondary shaft with a torque of 10.0 kgf·m.
Install the special output shaft preload shim VW 381/11 as described in the previous paragraph.
Install also the measuring mandrel VW 385 (calibrated for preload 2 mm) on «zero» using the indicator VW 385-30, measure the value «G» and compare it with the calculated value «r», if the main gear was replaced, or with the value marked on the driven gear, when the main gear was replaced If the obtained value «r» less than the calculated one, then a thicker adjusting ring S3 should be installed, and vice versa Difference between the obtained and calculated values «r» indicates by how much to reduce or increase the thickness of the adjusting ring S3.
Remove the set of measuring instruments and install the selected adjusting ring S3 under the outer ring of the rear output shaft bearing.
Install the output shaft.
Differential bearing preload and gear backlash adjustment
These operations are performed. as described for gearbox type 014 II, see section «Four speed gearbox».
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