Volkswagen Type II Transporter 1200 Series Shop Manual page 137

(20) Position each individual shim pack on the
respective side . cover studs and instal the side covers,
tightening the nuts finger tight.
NOTE: Ensure. that each shim pack and side cover is fitted
on the correct side and use new oil seals and 0-rings.
0 '
(21) Instal
th~
bridge piece VW 381/8 on the end face
dowels and tighten the side cover nuts to a torque of 14
ft/lb,
(22) Mark several of the ring gear teeth with a coating
of engineer's blue on the .contact faces.
(23) While restricting rotation of the ring gear, rotate
the pinion in both directions, by engaging 4th gear and
tumingthe main drive shaft so that the pinion will leave a
pattern of tooth contact on both sides of the marked ring
gear teeth.
(24) Check the tooth contact as ih operation (23) at
two or three positions around the ring gear and compare
the contact markings. A satisfactory tooth marking should
Transmission and Rear Axle-56
have the margin above and below the area of contact
approximately equal and the margin of contact running
approximately three quarters of the length of the tooth,
with marking slightly closer to the toe of the ring gear
tooth. Check the pattern of the tooth markings on both
sides of the tooth. ·
(25) When the ring gear and pinion assembly has been
satisfactorily adjusted, slacken the right hand side cover
nuts and lift off the bridge piece VW 381/8.
NOTE: The side cover nuts must be loosened to prevent the
carrier bearing preload from expanding and distorting the
transmission case with the clutch housing removed.
(26) Instal the clutch housing on the open end of the
transmission case and secure with spring washers and nuts.
Tighten the nuts to 14ft/lb.
· (27) Tighten the right side cover securing nuts to 14
ft/lb and the transmission and rear axle assembly is ready
for installation and further assembly of the drive shafts etc.
14. TRANSMISSION "ND FINAL DRIVE MODIFICATIONS
DESCRIPTION
The following modifications were incorporated in the
1969 Transporter models, commencing at chassis No.
219000001. The three retaining plates and studs used to
secure the drive pinion double row roller bearing have been
replaced by a retaining ring nut which screws on the rear
threaded end of the bearing outer race and is locked by a
lock plate attached to the gear case wall by a bolt.
The pinion positioning shim (S3) is located between
the gear case wall and the flange on the forward end of the
bearing outer race.
The differential case carrier bearings are located in the
two threaded adjusting ring nuts screwed into the sides of
the housirtg. ·
The carrier bearing preload and ring gear to pinion
backlash are adjusted by the ring nuts and not by shims as
previously. The r.ing nuts have ah internal multi-hex by
which they may be rotated using special tool VW 381/15.
DOUBLE ROW BEARING
137
These modifications also change the procedure of the
following operations in overhaul.
During removing and installing the transmission in the
transmission case, shims S3, controlling the position of the
pinion in relation to the ring gear axis, must be installed
~n
the bearing outer race between the flange and the
transmission case wall.
The threaded ring nut securing the bearing must be
tightened to a torque of 160 ft/lb initially, then backed off
and finally tightened to a torque of I
OS
ft/lb and. secured
with the small lock plate attached to the gear case wall.
NOTE: Use care when installing the transmission in the case
to ensure that the two flats on the shoulder of the bearing
are correctly engaged with the two flats in the wall of the
housing.
If the shift forks are to be adjusted using special tool
VW 294a, hew spacer studs marked Type 2/69 must be
used together with a special retaining ring nut for the
Crownwheel and Pinion with Double Row Bearing. (Later
type assembly.)