volkswagen Workshop Repair Guides

Volkswagen Workshop Service and Repair Manuals

ABOUT US
Adjusting input gear > < Adjustments to be completed after renewing individual components

Golf Mk4

Adjusting pinion shaft
   
Adjusting pinion shaft
Special tools and workshop equipment required
t  End dimension plate -VW 385/17-
t  Universal dial gauge bracket -VW 387-
t  Torque wrench -V.A.G 1576-

Prerequisites:
l  Support ring for pinion shaft bearing is installed and secured.
l  Parking lock mechanism and parking lock gear are installed.
Adjusting
   
–  Place two shims (each 1.5 mm thick) -arrow- on pinion shaft.
–  With parking lock engaged, place output gear with tapered roller bearing on pinion shaft and tighten hexagon nut (41 mm AF).
Torque setting → Item
  V39-1390
–  Set up dial gauge -A- and set to “0” with 1 mm preload. Move drive shaft up and down. Read and note play on dial gauge (example: 0.93 mm).
When taking measurements, do not turn the drive shaft, or the bearings will settle and a false reading will be obtained.
Determining shims
The specified bearing preload is attained when the reading (0.93 mm), the preload of the bearings 0.12 mm and the allowance for settling 0.10 mm are deducted from the 2 x 1.5 mm thick shims.
Example:
  V39-1404
Shims inserted3.00 mm
- Measured value0.93 mm
- Preload0.12 mm
- Allowance for settling0.10 mm
= Thickness of shim1.85 mm

–  Remove output gear, determine size of shim according to table →  and fit onto pinion shaft.
–  Reinstall output gear, tighten hexagon nut to specified torque → Item and secure with drift.
   
Table of shims for pinion shaft and input gear
Measured thickness (mm)Shim to be fitted (mm)Measured thickness (mm)Shim to be fitted (mm)Measured thickness (mm)Shim to be fitted (mm)
0.975 … 0.9991.0001.550 … 1.5741.5752.125 … 2.1492.150
1.000 … 1.0241.0251.575 … 1.5991.6002.150 … 2.1742.175
1.025 … 1.0491.0501.600 … 1.6241.6252.175 … 2.1992.200
1.050 … 1.0741.0751.625 … 1.6491.6502.200 … 2.2242.225
1.075 … 1.0991.1001.650 … 1.6741.6752.225 … 2.2492.250
1.100 … 1.1241.1251.675 … 1.6991.7002.250 … 2.2742.275
1.125 … 1.1491.1501.700 … 1.7241.7252.275 … 2.2992.300
1.150 … 1.1741.1751.725 … 1.7491.7502.230 … 2.3242.325
1.175 … 1.1991.2001.750 … 1.7741.7752.325 … 2.3492.350
1.200 … 1.2241.2251.775 … 1.7991.8002.350 … 2.3742.375
1.225 … 1.2491.2501.800 … 1.8241.8252.375 … 2.3992.400
1.250 … 1.2741.2751.825 … 1.8491.8502.400 … 2.4242.425
1.275 … 1.2991.3001.850 … 1.8741.8752.425 … 2.4492.450
1.300 … 1.3241.3251.875 … 1.8991.9002.450 … 2.4742.475
1.325 … 1.3491.3501.900 … 1.9241.9252.475 … 2.4992.500
1.350 … 1.3741.3751.925 … 1.9491.9502.500 … 2.5242.525
1.375 … 1.3991.4001.950 … 1.9741.9752.525 … 2.5492.550
1.400 … 1.4241.4251.975 … 1.9992.0002.550 … 2.5742.575
1.425 … 1.4491.4502.000 … 2.0242.0252.575 … 2.5992.600
1.450 … 1.4741.4752.025 … 2.0492.0502.600 … 2.6242.625
1.475 … 1.4991.5002.050 … 2.0742.0752.625 … 2.6492.650
1.500 … 1.5241.5252.075 … 2.0992.1002.650 … 2.6742.675
1.525 … 1.5491.5502.100 … 2.1242.1252.675 … 2.7002.700

Various tolerances make it possible to obtain the exact shim thickness required.
Part number → Electronic parts catalogue “ETKA”
   

Adjusting input gear > < Adjustments to be completed after renewing individual components