Volkswagen Workshop Service and Repair Manuals

Adjusting planet carrier

Special tools and workshop equipment required

t	Support plate -VW 309-

t	Support clamp -VW 313-

t	Gearbox support -VW 353-

t	Measuring tool -VW 382-

t	Torque wrench -V.A.G 1331-

t	Dial gauge

Overview - components for adjusting planet carrier

–	Install components for adjusting planet carrier in gearbox housing without shim → Item.

1 -	Input gear

q	Do not remove to adjust planet carrier.

q	Removing and installing input gear or needle thrust bearing for planet carrier → Chapter

2 -	Needle thrust bearing washer

q	Insert smooth side in input gear.

3 -	Needle thrust bearing

4 -	Needle thrust bearing washer

5 -

O-ring

q	Insert into planet carrier ⇒ Assembling planet carrier → Chapter.

q	Always renew

6 -	Planet carrier

7 -	Gearbox housing

q	With input gear and needle thrust bearing

q	Needle thrust bearing remains in input gear

q	If needle thrust bearing is damaged ⇒ Removing and installing input gear → Chapter

8 -

Washer

9 -	Needle thrust bearing

10 -	Large sun gear

11 -

Washer

q	Insert into large sun gear ⇒ Assembling planetary gearbox → Chapter.

12 -	Needle thrust bearing

13 -	Large input shaft

14 -	Needle thrust bearing

15 -	Needle bearing

16 -	Small input shaft

17 -

Shim

q	Do not install when adjusting planet carrier.

18 -

Washer

19 -	Small drive shaft bolt, 30 Nm

Determining shim -A- –  Observe general repair instructions → Chapter. –  Install all components from → Item to → Item to adjust planet carrier into gearbox housing → Item. –  Engage → parking lock.

–  Insert screwdriver through holes of “large sun gear” to loosen and tighten “bolt for small input shaft”. –  If → parking lock cannot be engaged, also block large input shaft with a second screwdriver.

–  Install bolt for small input shaft -1- with washer -2- without shim. Torque setting 30 Nm. –  Remove screwdriver.

–  Set up measuring instrument with dial gauge tip centred of bolt head with 1 mm preload. –  Set dial gauge to “0”. –  Move small input shaft up and down (press up) and read value on dial gauge. Example: Measured value 2 mm –  Ascertain thickness of shim according to table and determine part No. from parts catalogue. Table of shims:

Measured value (mm)	Shims (mm)
1.26 … 1.35 1.36 … 1.45 1.46 … 1.55	1.0 1.1 1.2
1.56 … 1.65 1.66 … 1.75 1.76 … 1.85	1.3 1.4 1.5
1.86 … 1.95 1.96 … 2.05 2.06 … 2.15	1.6 1.7 1.8
2.16 … 2.25 2.26 … 2.35 2.36 … 2.45	1.9 1.0 + 1.0 1.0 + 1.1
2.46 … 2.55 2.56 … 2.65 2.66 … 2.75	1.1 + 1.1 1.1 + 1.2 1.2 + 1.2
2.76 … 2.85 2.86 … 2.95 2.96 … 3.05	1.2 + 1.3 1.3 + 1.3 1.3 + 1.4
3.06 … 3.15 3.16 … 3.25	1.4 + 1.4 1.4 + 1.5

Example: Measured value 2.00 mm = insert 1.7 mm thick shim. –  Remove bolt for small input shaft.

–  Set determined shim -3- on small input shaft -arrow-. –  Tighten bolt for small input shaft -1- with washer -2-. Torque setting 30 Nm. –  Check dimensions of planet carrier. Checking dimensions of planet carrier

–  Insert dial gauge in -VW 382/7- and place tip on bolt of small input shaft. –  Move small input shaft up and down and read play on dial gauge. Play: min. = 0.23 mm max. = 0.37 mm If the planet carrier has been adjusted with reverse gear brake -B1- and freewheel removed, then install reverse gear brake -B1- before installing planet carrier ⇒ Assembling planetary gearbox → Chapter.