SEAT Workshop Service and Repair Manuals

Adjustment of the shaft bevel gear is required when

• ◆ Pinion housing
• ◆ Rear axle housing
• ◆ Shaft bevel gear taper roller bearings

or the

• ◆ Gear set

are replaced.

Adjustment overview

Special tools and workshop equipment required

• ◆ VW 353 Gearbox support
• ◆ VW 385 Universal mandrel
• ◆ VW 385/17 End measuring plate
• ◆ VW 387 Universal dial gauge bracket
• ◆ VW 388 Adjustable measuring lever
• ◆ VW 521 Crown wheel adjusting device

• ◆ 3156A Socket spanner

Setting friction torque

• ‒ Fit hexagon nut to shaft bevel gear.

• ‒ → Tighten hexagon nut to 120 Nm, then measure friction torque => Page 39-174, if necessary increase tightening torque further until the correct friction torque is set.

• A - Ring spanner 41 mm AF
• B - Torque wrench - to screw on turn anti-clockwise

Use reducer 3/4 " to 1/2 " if necessary.

• C - Vice clamps

Increase tightening torque slowly and check friction torque at regular intervals. If the prescribed friction torque is exceeded, the spacer sleeve must be renewed and the adjustment repeated. A spacer sleeve which has been compressed too much cannot be reused.

Set friction torque as follows:

    1)    run at least 50 km (30 miles)

• ‒ → Measure friction torque.

• With torque gauge, 0 ... 600 Ncm, commercially available

A - protective jaws

Determining thickness of shim "S3"

• ‒ Install pinion housing complete with shaft bevel gear and 1.3 mm shim (Part No. 02D 525 291 N).
• ‒ Do not fit O-ring.
• ‒ → Set universal mandrel VW 385/1 setting ring to dimension a = 34 mm.
• ‒ Set sliding positioning ring to dimension b = 39 mm.

• ‒ → Assemble universal mandrel as shown in illustration. Measuring gauge extension VW 385/16 = 12.3 mm. Set universal gauge VW 385/30 to
  Ro = 42.70 mm.
• ‒ Preload dial gauge to 2 mm and zero.
• ‒ After removing universal master gauge, slide VW 385/39 onto stop.

• ‒ → Position end-measuring plate on head of shaft bevel gear.

• ‒ → Insert universal mandrel.
• ‒ Fit cover and tighten hexagon bolts (for rear final drive with differential lock, install cover without sliding sleeve).
• ‒ Using sliding setting ring to pull centring disc outwards until mandrel can still just be turned by hand.

• ‒ → Measure dimension "e".
  Turn mandrel until tip of dial gauge makes contact with end measuring plate and indicates max. deflection (return point). The measured value is dimension "e" (red number range). Example: 0.39 mm.
• ‒ Remove universal mandrel.

Finally, check again whether dial gauge returns to "0" with master gauge VW 385/30 of 2 mm preload, otherwise repeat measurement.

Determining shim thickness "S3"

S3 = e + r

Example:

The following adjustment shims are available:

• ‒ Remove pinion housing complete with shaft bevel gear and 1.3 mm shim.
• ‒ Install determined shim S3.

Carry out check measurement - checking dimension "R"

Insert universal mandrel and measure dimension "R".

With correctly selected shims, the dial gauge, reading anti clockwise (red number range), must indicate the value of the noted deviation "r" on the bevel gear or the actual measured value to within a tolerance of + 0.04 mm.