Volkswagen Type II Transporter 1200 Series Shop Manual page 113

Special tool VW289d on Adjusting Plate.
To obtain the fitting dimension of the drive pinion
without shims is to add the dial gauge reading to the
nominal dimension of Jhe mandrel with adjusting plate. In
cases where the gear sets have a standard fitting dimension
of 58.70 mm (Gleason and strengthened Klingelnberg gear
sets), the dial gauge reading is subtracted from the nominal
dimension of the mandrel whilst taking the pre-load into
consideration. In other cases of Klingeinberg gear sets
which have neither a P on the outer edge of the ring or a K
on the face of the drive pinion (fitting dimension 59.70
mm) the dial gauge needie will move anti-clockwise. In the
case of these gear sets, the dial gauge reading must be added
to the nominal dimension of the mandrel.
Example:
Nominal dimension of mandrel
with adjustment plate ............... 58.70 inm
Dial gauge reading ( 1.0 mm
pre-load of dial gauge
taken into consideration) . . . . . . . . . . . . . .58 rrtm
Fitting dimension of
pinion without shims ............... 58.12
rt1t:n
The correct fitting dimension of the pinion is based on
the standard fitting dimension R
+
the tolerance
discrepancy. The difference between these two values
denotes the thickness of the shims required.
Example:
Standard fitting dimension •
of pinion R . . . . . . . . . . . . . . . . . . . . . 58.70 mm
±.Tolerance discrepancy . . . . . . . . . . . . . .18 mm
58.88 mm
Fitting dimension of
pinion without shims ............... 58.12 mm
Thickness of shims required . . . . . . . . . . . .76 mm
Carefully measure shims at different points with a
micrometer.
Carefully select · shims as near as possible to the
thickness required. Thickness of shims must not differ more
than
±
.0008" from the calculated thickness.
Shims are available in
thickne~s
from .10 to 1 mm in
113
Transmis,sion and Rectr A.xle-.12
increments of .1 mm plus .1 5 and 1.2 mrt:t. The toleranc6 of
the shims according to thickness is between .01 and .03 mm
(.0004" and .00012"). .
(8) Mount the dial gauge bracket, special tool VW297,
on one of the axle
t~be
retainer studs. Position the dial
gauge on the bracket and set to zero.
(9) Turn the transmission .case 180° andby doing so
the mandrel will slide across against the right final drive
cover bearing. The reading .registered on the dial gauge is
added to the length of the mandrel and the totill sum
represents the depth of the transmission case (distance
between differential carrier bearings) which is required for
adjusting the ring gear.
Example:
Normal length of mandrel . . . . . . . . . 107.88 mm
+
Dial gauge reading . . . . . . . . . . . . . 2.02 mm
Depth of transmission case . . . . . . . . . 109.90 mm
(10) Return the transmissiM case io the horizontal
position and remove the dial gauge bracket. Undo the left
final drive cover securing nu t!l.
(11) Position the spinclle of the special tool VW297 on
the left final drive cover and tighten it.
(12) Press off the_ right final drive cover with the
spindle removing the mandrel from the transmission case.
(13) Remove the left final drive cover and withdraw
the left ball bearing retainer and press the transmission out
of the case ..
(14) Slip the shims into position on the ball bearing.
Using the special gearshift test appliance VW294, adjust the
s~lectoi forks and then instal the transmission in the case.
TO ADJUST RING GEAR
( 1) Into the special tool VW287a insert the dial gauge
with a 28 mm plunger.
On
the polished surface for the
differential case, position the adjusting plate and zero the
dial gauge.
(2) Raise the gauge plunger and insert the differential
and 2.8 mm special gauge ring, VW298, on the ring gear
side of the tool.