Volkswagen Type II Transporter 1200 Series Shop Manual page 112

31-Transmission and Rear Axle
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Components of Third arid Fourth Speed Synchro
Assembly.
pinion is essential after replacing the transmission case, the
ring gear and drive pinion set or the drive pinion ball
bearing.
The reason for having to re-adjust the ring gear arid
drive pinion is to maintain silent operation as was originally
set with special appliance by the manufacturers of the
vehicle.
When undertaking adjustment, silent operation can be
obtained by following the following procedure:
The drive pinion must first of all be adjusted by the
installation of shims between the double row bearing and
the contact face at the transmission case, thereby ensuring
that the distance from the ring gear centre line to the drive
pinion face corresponds with the fitting dimension
determined at the factory. The ring gear is then adjusted to
give the proper backlash and the thickness of the shims for
the differential housing determined. It is very important
that both of the final drive covers must be installed with a
pre-load of .005 5". After determining the thickness of the
shims to be installed, a pre-load of .0028" must be taken
into consideration in both sides.
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LATER
MODELS
r
p
EARLY
MODELS
TO ADJUST DRIVE PINION AND MEASURE DEPTH OF
TRANSMISSION CASE BETWEEN DIFFERENTIAL
BALL BEARINGS
(1) Instal the transmission in the case less the shims for
the drive pinion.
(2) Fit the four ball bearing retainer bolts with washers
and tighten the bolts to a torque of 36 ft/lb.
(3) Check and ensure that the bearings are correctly
seated in the final drive covers.
( 4) Instal the left final drive cover with new gasket and
evenly tighten the securing nuts.
NOTE: Until the depth of the transmission case has been
determined, the use of a hammer must not be resorted to
for installing the final drive cover, as the hammer blows can
loosen the bearings in the drive covers. Final drive cover
securing nuts must be evenly tightened for co"ectly seating
the drive covers in the transmission case.
(5) Thoroughly clean the adjusting plate and the
contact face of the mandrel, special tool VW289d, and
position the mandrel in the adjusting plate. Fit a .1181"
plunger to the dial gauge and position
it
in the mandrel and
set the dial gauge to zero with a pre-load of .039".
(6) Position the mandrel in the transmission case, fit a
new gasket and instal the right final drive cover and tighten
the cover nuts.
(7) Check the dial gauge through the hole in the
mandrel and allow the tracer pin of the dial gauge to
carefully come into contact with the face of the pinion.
Rotate the mandrel until
thP.
maximum reading registers on
the dial gauge.
, . _ - R - -
~69
26
R. Standard fitting dimension,
drive p1nion face to centre
line of crownwheel.
r. Variation from R in 100th
millimeter; ,
P. Mating number of gear set.
C. Gear ratio.
G833
P
r
C
Crownwheel and Pinion Markings. Early 1200 Models have Markings on Pinion Head. Later Models have Markings on
Pinion Shaft.
112