Volkswagen Type II Transporter 1200 Series Shop Manual page 134

53-Transmission an.d Rear Axle
loaded by approximately 3 mm. Set the indicator dial to
zero.
(9) Turn the transmission case so that the clutch cover
end is up and fit the spacer bridge piece VW 381/8 on the
dowels in the end face of the case.
NOTE: The spacer bridge piece must be fitted to prevent
the case from spreading and distorting when the necessary
preload is applied.
(10) Lubricate each carrier bearing sparingly with the
correct grade of hypoid transmission oil.
(I I) With the tool VW 381/3 with thrust collar set as
in operation (7) and the dial indicator set as in operation
(8), screw the tool spindle in a clockwise direction until all
end float is removed in the differential carrier bearings but
do not apply any preload.
(12) Fit the special clamping sleeve VW 381/5 to the
left hand side differential side gear shaft, with the sleeve
against the ring gear end of the differential case and the
sleeve bolt screwed into the end of the gear shaft. Tighten
the bolt lock nut securely.
(13) Using a suitable preload gauge tool on the
hexagon bolt of the clamping sleeve, rotate differential in
both directions to seat the bearings.
(14) Turn the differential in its normal direction of
rotation, using the preload tool, and screw the spindle of
tool VW 381/3 clockwise until the specified preload is
recorded on the preload gauge.
NOTE: The dimension by which the outer race of the right
hand ca"ier bearing outer race has been moved towards the
left to obtain the requisite preload will be recorded on the
dial indicator gauge, which was set to zero when all end
float was removed from the bearings in operation (8). Do
not preload the bearings in excess of that specified or it will
be necessary to remove the special tool and the right hand
side cover and press the bearing back fully into the cover in
order that the preload may be readjusted.
(I 5) Record the dial indicator reading which should be
within the limits of .50 to L60mm (.020" to .063."). The
bearing preload should be 18 in/lb for new bearings or 2 to
6 in/lb for bearings that have been in use.
(16) Remove the special tool and bridge piece, take off
the side covers and lift the differential assembly from the
transmission case.
NOTE: Mark the side covers so that they can
be
assembled
on the co"ect sides as they must not be interchanged, once
the preload on the ca"ier bearings has been adjusted.
TO ADJUST RING GEAR AND PINION BACKLASH
(I) With the transmission and gear carrier installed and
the pinion positioning shims fitted; instal and secure the
three pinion retainers and nuts.
(2) Instal the differential and ring gear assembly in the
transmission case and fit left hand cover, with special
measuring shims VW 381/10, ensuring that the covers are
fitted to the correct sides as determined during the carrier
bearing preload adjustment. ,
(3) Fit the right hand side cover, with special
measuring shim VW 381/10, plus shims to the equivalent
thickness of the dimension recorded on the dial indicator in
operation (IS) in the differential carrier bearing preload
adjustment.
( 4) Fit the special bridge piece on the clutch cover end
dowels and with the fourth gear selected and rotating the
Special Tool in Position for Adjusting Carrier Bearing Pre-load with Drive Pinion Removed.
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