Volkswagen Type II Transporter 1200 Series Shop Manual page 108

27-Transmission and Rear Axle
MEASURING PIN
~LEEVE
Tool No VW299 Mounted on Pinion Shaft to Measure
Spacer Sleeve and End-Float.
TO ADJUST CONCAVE WASHER
From Chassis No. 602615 and rear axle No. 2996125
the third gear washer on the drive pinion was replaced by a
concave washer. The length of the spacer sleeve fitted
between the third and fourth gears was reduced. There has
been an alteration in the space from the rear of the drive
pinion head to the shoulder for the fourth gear and the
splines, for the clutch gear and third gear so arranged that
these components have a minimum backlash of .002" on
the pinion.
By varying the thicknesses of the shims the concave
washer can be adjusted to give a spring travel of .007''
±
.0004" and the pressure exerted on the third gear and the
clutch gear for the first and second gear is approximately
220 lb. The self-oscillations of these parts is thus reduced,
thereby improving the silent operation of the rear axle.
TO MEASURE ASSEMBLY
(1) Assemble the drive pinion to the stage which
includes the third gear.
Do not tightly seat the clutch gear for first and second
gear and the third gear on the drive pinion.
(2) Ensure that the clutch gear for the first and second
108
BALLS AND SEPARATOR
~
Drive Pinion Double Row Ball Bearing Components. Later
Models have a Double Row Roller Bearing. (Inner cones are
marked thrust on outer face.)
gears and the third gear are correctly positioned. Recheck
the end play of the first gear .004" to .010" and correct if
necessary.
(3) Slide the sleeve of the adjusting tool onto the drive
pinion to abut the shoulder for the fourth gear and zero the
dial gauge. Replace the gauge plunger pin of the gauge by
an extension piece 1.102" long.
( 4) Slide the drive pinion spacer sleeve on the
measuring pin of the adjusting gauge.
(5) Take off the measuring sleeve from the drive pinion
and slide it on the measuring pin of the adjusting tool,
securing it on the spacer sleeve.
The reading on the dial gauge shows the amount by
which the spacer sleeve is shorter than the distance from
the shoulder on the pinion for the fourth gear to the third
gear.
TO CALCULATE SHIM THICKNESS
With the drive pinion fully assembled, press the fourth
gear on to the pinion as far as the shoulder. Compensate the
dial gauge reading by shims while taking into consideration
the concave washer thickness .041" (constant), and the
prescribed spring travel .007''.
The serviced thicknesses of the shims are 0.15, 0.2,
0.25, 0.3, 0.4, 0.6, 0.8, 1.0 and 1.2 mm. Measure the shims
carefully with a micrometer before use.
The shim thickness is finally checked by positioning
the shims below the spacer sleeve on the measuring pin of
the adjusting tool. Firmly press down the measuring sleeve.
The dial gauge reading must not exceed .048"
±
.0004" the
thickness of the concave washer plus spring travel. The
silent operation of the rear axle will be adversely affected if
the clutch gear and third gear are tightly seated and no
backlash is present due to the concave washer being too
tightly adjusted.
The second gear is likely to jump out if the maximum
spring travel is in excess of the specified amount.
NOTE: The concave washer is only for installation with the
modified drive pinion. In the event of any doubt ·arising
measure the distance from the rear of the drive pinion head
to the shoulder for the fourth gear, with a vernier gauge.