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Adjusting input gear > < Adjustments to be completed after replacing individual components of front final drive

Leon Mk1

Automatic gearbox 099 four-wheel drive
Adjusting front final drive -Overview-
Adjusting drive pinion
 
W39-0012

Special tools and workshop equipment required

  • ◆ VW 385/17 End measuring plate
  • ◆ VW 387 Universal dial gauge bracket
  • ◆ 2004 Gearbox holder
 
V39-1647
  • ‒ → Secure gearbox housing to gearbox holder 2004
  • ‒ Place washers between gearbox housing and gearbox holder 2004 and secure gearbox holder with 8 mm ø bolts.

Conditions:

  • ● Supporting ring for drive pinion bearing is installed and secured.
  • ● Parking lock mechanism and parking lock gear are installed.
 
V39-1390

Adjusting:

  • ‒ → Place two shims (each 1.5 mm thick) -arrow- onto the drive pinion.
  • ‒ Place output gear with taper roller bearing onto drive pinion and tighten hexagon nut (41 mm AF) to 250 Nm; engage parking lock when performing this step.
 
V39-1404
  • ‒ → Insert dial gauge -A- and zero with a preload of 1 mm. Move drive pinion up and down. Read off play at dial gauge and note (example 0.93).

when performing measurement, do not turn drive pinion as the bearings will otherwise settle and falsify the result of the measurement.

Determining shims

The specified bearing preload is achieved if the reading (0.93 mm), the preload of the bearings 0,12 mm and the amount for compression 0,10 mm are deducted from the 2 x 1.5 mm thick shims.

Example:

Shims inserted

3.00 mm

- Reading

0.93 mm

- Preload

0.12 mm

- Amount for settlement

0.10 mm

= Thickness of shim

1.85 mm
  • ‒ Remove output gear. Determine size of shim on basis of table and fit onto drive pinion.
  • ‒ Re-install output gear and tighten hexagon nut to 250 Nm and secure with drift.

Table of "shims" for drive pinion and input gear

Gauged
thickness (mm)

Shim to be
fitted (mm)

Gauged
thickness (mm)

Shim to be
fitted (mm)

Gauged
thickness (mm)

Shim to be
fitted (mm)

0.975 ... 0.999
1.000 ... 1.024
1.025 ... 1.049
1.050 ... 1.074
1.075 ... 1.099
1.100 ... 1.124
1.125 ... 1.149
1.150 ... 1.174
1.175 ... 1.199
1.200 ... 1.224
1.225 ... 1.249
1.250 ... 1.274
1.275 ... 1.299
1.300 ... 1.324
1.325 ... 1.349
1.350 ... 1.374
1.375 ... 1.399
1.400 ... 1.424
1.425 ... 1.449
1.450 ... 1.474
1.475 ... 1.499
1.500 ... 1.524
1.525 ... 1.549

1.000
1.025
1.050
1.075
1.100
1.125
1.150
1.175
1.200
1.225
1.250
1.275
1.300
1.325
1.350
1.375
1.400
1.425
1.450
1.475
1.500
1.525
1.550

1.550 ... 1.574
1.575 ... 1.599
1.600 ... 1.624
1.625 ... 1.649
1.650 ... 1.674
1.675 ... 1.699
1.700 ... 1.724
1.725 ... 1.749
1.750 ... 1.774
1.775 ... 1.799
1.800 ... 1.824
1.825 ... 1.849
1.850 ... 1.874
1.875 ... 1.899
1.900 ... 1.924
1.925 ... 1.949
1.950 ... 1.974
1.975 ... 1.999
2.000 ... 2.024
2.025 ... 2.049
2.050 ... 2.074
2.075 ... 2.099
2.100 ... 2.124

1.575
1.600
1.625
1.650
1.675
1.700
1.725
1.750
1.775
1.800
1.825
1.850
1.875
1.900
1.925
1.950
1.975
2.000
2.025
2.050
2.075
2.100
2.125

2.125 ... 2.149
2.150 ... 1.274
2.175 ... 2.199
2.200 ... 2.224
2.225 ... 2.249
2.250 ... 2.274
2.275 ... 2.299
2.230 ... 2.324
2.325 ... 2.349
2.350 ... 2.374
2.375 ... 2.399
2.400 ... 2.424
2.425 ... 2.449
2.450 ... 2.474
2.475 ... 2.499
2.500 ... 2.524
2.525 ... 2.549
2.550 ... 2.574
2.575 ... 2.599
2.600 ... 2.624
2.625 ... 2.649
2.650 ... 2.674
2.675 ... 2.700

2.150
2.175
2.200
2.225
2.250
2.275
2.300
2.325
2.350
2.375
2.400
2.425
2.450
2.475
2.500
2.525
2.550
2.575
2.600
2.625
2.650
2.675
2.700

Different tolerances enable the required shim thickness to be measured precisely.

Part number:

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Adjusting input gear > < Adjustments to be completed after replacing individual components of front final drive