Skoda Workshop Service and Repair Manuals

Setting shank bevel gear Special tools and workshop equipment required t  Universal measuring device -VW 385- t  Pressure plate -MP3-420 (3124)- t  Pipe section -MP3-450 (VW 415 A)- t  Pressure plate -MP6-418 (VW 442)- t  Gearbox mount -T30012 (3221)- t  Stop plate -T30012/1A (3221/1A)- t  Commercially available torque gauge, 0...600 Ncm t  Dial gauge t  Screw M10 t  Soldering wire Ø 1.5 mm The shank bevel gear must be re-set when the following components were replaced: t  Final drive housing t  Tapered-roller bearing for shank bevel gear t  Drive train or t  Secondary shaft housing Setting overview (angle gearbox) → Chapter. Determining the thickness of adjusting washer S4 –  Press outer ring of large tapered-roller bearing for shank bevel gear with thrust plate -MP3-420- into the secondary shaft housing. –  Press outer ring of small tapered-roller bearing for shank bevel gear with thrust plate -MP6-418- into the secondary shaft housing. –  Press inner ring of large tapered-roller bearing with pipe section -MP3-450- onto the shank bevel gear.

A - Position soldering wire Ø 1.5 mm instead of the adjusting washer S4. B - Fit on spacer ring with chamfer to the shank bevel gear. –  Insert shank bevel gear. –  Insert inner ring of the small tapered-roller bearing and insert the output flange and position nut.

A - Screw in screw M10 as support. B - Socket wrench insert. –  Tighten nut to 20 Nm, turn screw -A- back or release fully.

–  Measure friction torque. A - Torque gauge, commercially available 0...600 Ncm. B - Socket wrench insert. –  If necessary, further increase the tightening torque until the prescribed friction torque is set.   Note Only increase the tightening torques slowly and at the same time, read the friction torque several times; if the prescribed friction torque is exceeded, the soldering wire must be renewed and the adjustment repeated. Following friction torques must be adjusted:

new bearings	used bearings1)
100…240 Ncm	30…50 Ncm

1) In service for at least 50 km. –  Remove shank bevel gear and carefully take off the crimped soldering wire.

–  Measure the thickness of the soldering wire at a point which is well pressed together - without shoulder. –  Select the adjusting washer(s) with the same thickness. The following adjusting washers are available:

Thickness (mm)	Spare part No.
0,65 0,70 0,75	02C 409 280 02C 409 280A 02C 409 280B
0,80 0,85 0,90	02C 409 280C 02C 409 280D 02C 409 280E
0,95 1,00 1,05	02C 409 280F 02C 409 280G 02C 409 280H
1,10 1,15 1,20	02C 409 280J 02C 409 280K 02C 409 280L
1,25 1,30 1,35 1,40	02C 409 280M 02C 409 280N 02C 409 280P 02C 409 280Q

–  Insert adjusting washer S4 and install shank bevel gear.

–  Insert nut with gearbox oil and tighten to 350 Nm. A - Socket wrench insert for 3/4 inch drive" Perform control measurement - check friction torque Friction torques → Anchor. If necessary correct by a thinner (more friction torque) or thicker (less friction torque) adjusting washer S4. Determining the thickness of the adjusting washer S3 –  Install secondary shaft housing with shank bevel gear and fitted with adjusting washer S4. –  Insert O-ring.

–  Set the adjusting ring on the universal measuring rod -VW 385/1- to measurement a = 75 mm. –  Set the movable adjusting ring to measurement b = 32 mm.

–  Assemble universal measuring rod as shown in figure. Dial gauge extension -VW 385/20- = 3 mm. Set universal master setting -VW 385/30- to Ro = 36.20 mm. –  Set the dial gauge to 0 with 3 mm preload.

–  Place the gauge block plate on the head of the shank bevel gear.

–  Insert universal measuring rod. –  Position the cover -B- with the outer ring for the large tapered-roller bearing and tighten the screws. –  Turn the screw -A- in a clockwise direction -arrow-. –  The locating disc is pulled into the cover over the moveable adjusting ring -VW 385/41- ( → Anchor, fig. N39-0086). –  The universal measuring rod must still just be turned by hand.

–  Measure measurement “e”. Turn the measuring rod until the dial gauge indicator points towards the gauge block plate and is at maximum deflection (reversing point). The measured value is the measurement “e”. Example: 0.47 mm –  Remove universal measuring rod.   Note Finally, check again whether the dial gauge with the master setting -VW 385/30- mounted is at “0” with the 3°mm preload, otherwise repeat measurement. Determining the thickness of adjusting washer S3 S3 = e + r

e	-	determined value (maximum deflection)
r	-	Deviation (given on the head bevel gear in 1/100 mm)

Example:

on the dial gauge, value “e” is read off	0.47 mm
deviation recorded on crown wheel “r”	+ 0.33 mm
Thickness of the adjusting washer S3	= 0.80 mm

The following adjusting washers are available:

Thickness (mm)	Spare part No.
0,65 0,70 0,75	02C 409 114L 02C 409 114M 02C 409 114N
0,80 0,85 0,90	02C 409 114P 02C 409 114Q 02C 409 114R
0,95 1,00 1,05	02C 409 114S 02C 409 114T 02C 409 114AA
1,10 1,15 1,20	02C 409 114AB 02C 409 114AC 02C 409 114AD
1,25 1,30 1,35	02C 409 114AE 02C 409 114AF 02C 409 114AG
1,40 1,45 1,50	02C 409 114AH 02C 409 114AJ 02C 409 114AK

–  Remove secondary shaft housing with shank bevel gear. –  Install determined adjusting washer S3. Control measurement - check the value of “R” Insert the universal measuring rod and measure the value of “R”. If the adjusting washers have been chosen correctly, the dial gauge reading anti-clockwise (red number range) should show the written value of the head bevel gear “r” with a tolerance of +0.04°mm.