Volkswagen Type II Transporter 1200 Series Shop Manual page 133

VW381/3 with the thrust piece VW381/4 and tighten the
nuts to the prescribed torque.
(6) Using the special setting tool, press in the bearing
outer race until it is possible to just turn the mandrel by
hand in the bearing races.
(7) Positioned the setting pin VW381/6 on the drive
pinion end face and properly seat it.
NOTE: Throughly clean all ·surfaces to obtain accurate
measurements.
(8) Insert a dial indicator with a .6102" range with
extension VW381/12 (3.346" long) in the measuring bar
VW381/2.
(9} Set the dial indicator to zero on the setting pin
without pre-load.
(10) By sliding the measuring bar, bring the dial
indicator pin on the mandrel and locate the highest point.
Note the dial reading.
(11) Read the deviation marked (r) on the pinion and
subtract it from the measured amount. The difference
between the two indicates the thickness of the pinion
positioning shim (S3} which has to be installed.
(12) Take off the left end cover and remove the
mandrel. Take out the pinion, lock the round nut, assemble
aild instal the transmission as already described in the
appropriate section. lristal the shim S3 as measured.
(13) Again instal the mandrel, fit the left end cover and
tighten nuts to prescribed torque.
(14) Once again check the measurements. zero the dial
indicator with the setting pin. .
(15) Move the measuring bar bringing the dial indicator
pin on the mandrel and locate on the highest point. The
reading now obtained should correspond with the deviation
marked on the pinion end face within a tolerance of
±
.0015", if the positioning shims S3 have been correctly
selected.
(16) Remove the differential side covers and lift out
the mandrel. Remove the pinion assembly from the
· transmission case.
NOTE: Keep the pinion position shims S3. intact for
installation after the carrier side bearing pre-load has been
adjusted; .
TO ADJUST CARRIER BEARING PRE-LOAD
(1) With the pinion assembly removed from the
transmission case, instal the differential and ring gear
assembly in the transmission case so that the ring gear will
be to the left hand side.
(2) With the oil seals removed from the side covers and
the bearing outer races pressed fully into position in the
covers, remove the 0-ring seal from each cover.
(3) Place a special measuring shim VW 381/10 in
133
Transmission and Rear Axle--52
Special Tools in Position to Establish Pinion Positioning
Shim Thickness.
position on the left hand side of the transmission case and
instal the left hand side cover, secure with nuts and washers
tighten to a torque of 14 ft/lb.
NOTE: The left hand side cover is adjacent to the ring gear.
(4) Turn the transmission case so that the differential
and ring gear assembly will be vertical with the ring gear
side inner cone and rollers in contact with the outer race in
the left hand side cover.
(5) Instal the right hand side cover, together with
special measuring shim VW 381/10, but do not fit the
securing nuts at this stage.
NUTH: The special measuring shim VW 381/10 installed
with· each side cover has a constant thickness dimension of
1.30mm
· (6) Place special tool VW 381/3 with thrust collar VW
381/4 in position over the right hand side cover and secure
with the six nuts.
NOTE: Instal the tool VW 381/3 so that the clamp sleeve
for the dial indicator in the /klnge of the tool is below the
axis of the differential ca"ier bearings.
(7) Carefully screw the spindle of tool VW 381/3 in
until the thrust collar lightly contacts the back of the outer
bearing race of the right hand side cover.
(8) Insert the dial indicator with 52 mm length plunger
and Jock. in position in the clamp sleeve with the· plunger