Volkswagen Type II Transporter 1200 Series Shop Manual page 96

15-Transmission and Rear Axle
TO ADJUST DRIVE PINION
The fundamental adjustment has already been carried
out by the installation of shims between the drive pinion
head bearing and the clutch of the first speed gear, while
assembling the drive pinion.
Using a special mandrel, measure the distance for the
axial adjustment of the drive pinion after measuring the
total depth of the transmission case (J) referred to
previously, for the ring gear adjustment.
(1) Turn the mandrel until the arrow points to the
gearshift housing. Slacken the knurl-headed screw until the
tracer pin comes in contact with the face of the drive
pinion.
(2) Tighten t}le knurl-headed screw and turn the
mandrel 90° to prevent altering the tracer pin position
when the transmission case is being opened.
(3) Remove the mandrel and, using a depth gauge,
measure the length of the tracer pin.
( 4) To the length of the tracer pin, add half the
diameter of the mandrel. The value obtained must
correspond with the distance R (standard 59.35 mm) after
adding or subtracting the tolerance discrepancy, ie, plus or
minus mark on the face of the drive pinion.
Ensure that a minus amount is added to and a plus
amount is subtracted from .the distance R ..
Example mm
(a) Standard dimension of R . 59.35 (2.3366")
Tolerance 4iscrepancy =
OJ 8 mm therefore add . .
+
0.18 (.0071 ")
59 53 (2.3437")'·
Fitting dimension . . . . . . .
Approximately . . . . . . . 59.5 (2.3425")
(b) Radius of mandrel . . . . . 30.00 ( 1.1811 ")
Length of tracer piri 29.6 (1.1653")
Dimension measured 59.6 · (2.3465")
While making comparison between the· measured value
of 59.6 mm and the fitting dimension of 59.5 mm, it will
be seen that the total thickness of the drive pinion shims
must be increased by 0.1 mm or .004".
TO CHECK DIFFERENTIAL ADJUSTMENTS
Ensure that the axial adjustments of the drive pinion
and ring gear are correct by measuring the backlash and
checking the tooth contact.
(1) Position the differential in the left half of the
transmission case, ensuring that the two differential shims
are correctly
fitt~d
to the sides. The shim must be
positioned with the chamfered face towards the differential
housing. In case it is necessary to instal an additional shim
of 0.25 mm, it should be positioned between the ball
bearing and the other shim.
(2) Position the drive pinion ap.d lightly tap it towards
96
the ring gear to remove any existing end play.
(3) Mix some red lead with engine oil and apply a light
coat on the ring gear teeth.
( 4) Position the right half of the transmission case and
secure with bolts.
(5) Attach the gearshift housing to the transmission
case.
(6) Mount a dial gauge in the differential housing so
that the tracer pin of the dial gauge is in contact with one
of the axle tube retainer studs. Secure the gauge in position.
(7) The drive pinion should be prevented from
movement and slightly move the dial gauge to take up the
play in both directions. The deflection of the needle will
indicate the amount of backlash.
{8) The measurement should be done a number of
times but each time the ring gear should be turned 90°. The
difference, while comparing one measurement with
another, should not exceed .002". The backlashmarked on
the ring gear should be compared with the measured value.
Any marked difference between the measured value
and the prescribed backlash should be corrected by
changing the shims S1 and S2 maintaining the total
thickness of the shims. Again check the backlash.
(9) The ring gear and the differential should both be
rotated at the axle shafts.
(10) Again open up the transmission case.
(11) Carefully check the tooth contact of the ring gear
and correct the axial adjustment, if necessary. Check once
again.
· (12) When adjustments have been satisfactorily
completed, finally assemble the transmission case.
Method of Measuring Depth of Half Transmission Case. ·