Adjusting Pinion Shaft With Universal Setting Gage Vw385
Determine adjustment value E from known design value R =66.30 mm by adding deviation "r" which is shown on pinion face.
NOTE:
The collar nut on the pinion shaft must definitely be tightened to specified torque prior to measuring.
Fasten gear housing with 2 nuts. Install free gear of 5th speed together with spider. Block pinion shaft with clamp P 37a. Engage 4th speed and tighten collar nut to specified torque.
2. Make sure that outer races of bevel roller bearings are firmly seated in gear housing and housing side cover.
1 " Deviation "r" in 1/100 mm
2 - Mating number
Example:
The pinion face shows deviation "r" to be N 10
3. Move adjustable collar on setting gage VW 385/1 to dimension "a".
R = Design value r = Deviation
E = Adjustment value
66.40 mm
1. Assemble gear cluster without selector forks or adjustment shims. Tighten preload plate nuts to specified torque.
4. Slide gage blocks VW 385/4 onto the setting gage shaft and screw contact plunger VW
together with the contact extension VW 385/53 (14 mm), into place.
NOTE: Turn adjustable collar back to stop.
5. Place master plate VW 385/52 (R = 66.30 mm) in position and adjust dial indicator (3 mm range) to 0 under a 1 mm preload (small pointer on 1, long pointer on 0).
1 = VW 385/1 Setting gage shaft
3 = VW 385/14 Gage contact plunger
4 = VW 385/53 Gage contact extension
5 = VW 385/52 Master plate
6 = Dial indicator
6. Place setting pad VW 385/17 on the pinion face.
7. Remove master plate and place setting gage in gear housing, making sure that the dial indicator extension is oriented towards the setting pad.
8. Insert housing side cover (without O-ring) and tighten nuts to specified torque.
Caution:
Never use a hammer when installing the housing side cover. This may cause the magnetically attached setting pad to fall off the pinion. Bring side cover into proper place only by evenly tightening the retaining nuts.
If the value indicated on the gage deviates clockwise from the set design value (R= 66 .'30 mm), then the dimension is smaller than 66.30 mm, that is, the amount of deviation from 0 must be subtracted from the value of 66.30 mm.
9. Using the spindle, pull the second gage block so far outwards that the setting gage shaft can still be barely turned.
Example:
The small pointer on the indicator is between 1 and 2, 'and the long pointer shows 0.29 mm.
Adjusted design value (master plate VW 385/52) minus measured value
Distance to pinion shaft face
Adjustment value (as example) Distance to pinion shaft face
Shim thickness
66.01 mm
Carefully turn setting gage until the gage contact extension is positioned perpendicular to the pinion shaft face. In this instance, the indicator shows the highest reading which is to be noted.
This means that the pinion shaft must be moved away from the ring gear center by 0.39 mm. This is accomplished by installing two 0.20 mm thick shims (end values of 3 or more should be rounded off to 5, and from 7 on to 10).
Note the following points when reading the dial indicator:
Recheck adjustment value E (shown as 66.40 mm in the example) upon installation of shims; a deviation of i 0.03 mm is permissible. A tooth contact pattern test need not be performed.
The design value R = 66.30 mm was set by means of the master plate VW 385/52.
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