Volkswagen Type II Transporter 1200 Series Shop Manual page 140

59-Transmission and Rear Axle
gear and half housing in position and bolt the two halves of
the housing together.
(3) Using a dial indicator mounted on the end of the
long side gear shaft with the indicator plunger contacting
the end face of the differential housing, zero the indicator
gauge.
(4) Raise the upper side gear and shaft as far as possible
against the gear thrust washer and check the reading on the
indicator gauge. This reading will denote the end float in
the gears with the short spacer sleeve fitted. Record the end
float.
(5) Take out the bolts and remove the upper side gear
and shaft and lift off the spacer sleeve. Measure the length
of the . sleeve, add the measured end float recorded in
operation (4).
(6) Select a sleeve .05 mm less in length than the result
of operation (5) and instal between the two side gears. This
clearance of .05 mm is within the specified end float
tolerance of 0 to .05 mm if the correct spacer sleeve is
selected.
TO ADJUST DRIVE PINION
Adjusting the position of the drive pinion (Shim S3) is
the same as that described f9r the previous model
transmission except for the following modifications.
The pinion double row roller bearing is secured by
\
Differential and Crownwheel Assembly in Position.
140
tightening the threaded retainer ring nut first to a torque of
160 ft/lb, then backed off and finally tightened to a torque
of 108 ft/lb.
Screw in the left side carrier bearing adjuster until it is
1 mm below the surface of the housing, insert the setting
mandrel through the hole for the right hand adjuster ring
and screw in the right hand adjuster ring until the mandrel
can just be turned by hand.
Using the dial indicator and measuring bar, measure
and calculate the thickness of the pinion positioning shim
S3 as described earlier for models with shim adjusted
differential carrier bearings.
Calculating the thickness of the shim is somewhat
different from that for the previous type double row roller
bearing attachment.
This is due to the position of the positioning shim S3
being changed from the rear to the front of the
transmission case wall. Use the special mandrel, gauge and
setting pin as for the earlier type and work to the following
example and formula: S3 = e
+
r.
Example:
Length of setting pin, VW 381/6
Subtract difference between pin
and mandrel measurements (e)
Pinion dimension without shim S3
Manufacturers pinion dimension
(constant)
Add pinion head thickness
variation (r)
Housing dimension
Add half diameter of mandrel cylinder
Nominal pinion dimension
Actual pinion dimension
without shim S3
= 83.00 mm
=
.40mm
= 82.60mm
= 63.00 mm
= .25mm
= 63.25 mm
20.00 mm
= 83.25 mm
= 82.60mm
Thickness of shim S3
=
.65 mm
Since 'e' represents the difference between the
measurement taken on setting pin VW 381/6 and that on
the highest point of the mandrel and 'r' represents pinion
head variation from standard thickness, then:
S3
=
e+r
= .40+ .25 mm
= .65mm
Select shims from the range available for service and
measure the thickness with a micrometer in several places.
With ·the shim S3 installed, recheck the setting, using
the dial indicator, setting pin and mandrel as before. Set the
indicator gauge to zero on the setting pin, move ·the
measuring bar so that the indicator plunger is on the
mandrel at the highest point. The reading obtained will
represent the pinion head thickness variatioR. 'r',. and be
within a tolerance of± .04 mm if the setting is correct.